TwoPrimaryTypes

TypesOfRefrigerationSystems
CryogenicSystem

MechanicalSystem

Anopensystemthatusestherefrigerant
onceandthenventsitintothe
atmosphere.
t
h

Asealedsystemthatusesthesame
refrigerantoverandover.

Examples:Afreezingsystemusingliquid
nitrogen(LN2)orcarbondioxide(CO2).

Examples:AsystemthatusesAmmonia
(NH3)orFreonastherefrigerant.
Wellfocusonmechanicalsystemstoday.

HowItWorks
HowDoesMechanicalRefrigerationWork?
1 TTocooltheairorliquid,itmovesthroughaheatexchanger(evaporator),transferringits
1.
l th i
li id it
th
h h t
h
(
t ) t
f i it
heatintotherefrigerant.
2. Therefrigerantinsidetheevaporatormustbemaintainedatalowertemperaturethanthe
airorliquid.Heat(highenergy)movestocold(lowenergy).
i
li id H t (hi h
)
t
ld (l
)
3. Temperatureofrefrigerantiscontrolledbythepressureinsidetheevaporator.
(PressureTemperaturerelationship)
4. Theliquidrefrigerantinsidetheevaporatorabsorbstheheat,changingstatetovapor.
(boiling)

HowItWorks
HowDoesMechanicalRefrigerationWork?

Examples:
At33.5PSIG,Ammoniaboilsat+20F.
At3.6PSIG,itboilsat20F.
AllfluidshaveaPressure TemperatureRelationship.

HowItWorks
Thatmeans
Bymaintainingthedesiredpressure
By
maintaining the desired pressure insidetheevaporatorwegetthe
inside the evaporator we get the
desiredtemperature.
Thetemperatureatthatboilingpointdetermineshowmuchheatis
absorbedintotherefrigerant,changingtheliquidrefrigeranttoavapor.

PrimaryComponents
FourPrimaryComponentsOfAMechanicalSystem

Evaporator:Thisiswheretheheat
f
fromtheproductorspaceis
th
d t
i
transferredintotherefrigerant.
Itsmainfunctionistoremoveheat
fromairorliquid.
Thereareseveraltypesof
evaporators used in food processing
evaporatorsusedinfoodprocessing
industry.

PrimaryComponents
TypesofEvaporators

AirUnits:acommontypeof
evaporatorfoundincoldstorages,
t f
di
ld t
precoolers,andmechanicalfreezers.
Theyareacombinationoffansanda
coil.Airisblownoverthetubes
whichcontainsrefrigerant.
Other names: evaporators coils
Othernames:evaporators,coils

PrimaryComponents
TypesofEvaporators

ShellAndTubeHeatExchangers:
primarily
i
il usedtocoolfluids.Fluid
dt
l fl id Fl id
beingcooledispumpedthroughthe
tubeswhiletheliquidrefrigerantisin
theshell.
Applications:chillglycol,wine,water

PrimaryComponents
TypesofEvaporators

PlateandFrameHeatExchangers:
platesstackedtogethercontaining
l t t k d t th
t i i
refrigerantorproductinalternating
plates.Thesehaveextremelygood
heattransfercharacteristics.
Applications:chillglycol,wine,water

PrimaryComponents
FourPrimaryComponentsOfAMechanicalSystem

Compressor:thelargestelectrical
userinafoodstoragefacilityisthe
i f d t
f ilit i th
compressor.
Itmaintainstheevaporator
refrigerantpressurerequiredtogive
desiredevaporatortemperatureand
tocompresstherefrigerantgasfrom
the evaporator to a higher pressure
theevaporatortoahigherpressure.
Thereareprimarilythreetypesof
compressors

PrimaryComponents
TypesofCompressors

RotaryScrewCompressor:Themost
commontypeused.Theseunitsare
t
d Th
it
typical100HPto1,000HP.
Widerangeofapplicationsandcan
beusedinasinglestagesystemoras
thehighstageorboosterinatwo
stagesystem.

PrimaryComponents
TypesofCompressors

ReciprocatingCompressor: these
unitshavepistonsgoingupand
it h
it
i
d
downcompressinggas,similartoa
carengine.
Typically50HPto200HPandcanbe
usedinasinglestagesystemoras
thehighstageorboosterinatwo
stage system Limited compression
stagesystem.Limitedcompression
ratio.

PrimaryComponents
TypesofCompressors

RotaryBoosterCompressor:These
arenolongermanufacturedbut
l
f t db t
therearestillmanyinoperation.
Theyareusedonlyasboostersin
twostagesystems.

PrimaryComponents
FourPrimaryComponentsOfAnyRefrigerationSystem
Condenser:highpressuregasis
cooledandcondensesbacktoliquid.
Thisiswherealloftheheatfromthe
coldstorageandfromthefood
productistransferredoutofthe
refrigerationsystem.
Fansblowairthroughcoilsaswateris
pumpedoverthem.Thewater
evaporates,absorbingtheheatinthe
refrigerantgas,andtheenergyis
rejectedintotheatmosphere.

PrimaryComponents
FourPrimaryComponentsOfAnyRefrigerationSystem

ExpansionDevice:functionisto
controltheflowofrefrigerantfrom
l h fl
f fi
f
high(condensingpressure)tolow
(evaporatingpressure)andcontrols
theflowofliquidrefrigerantintothe
q
g
evaporator.
SeveralTypes:handexpansionvalve,
motori ed modulating valve thermal
motorizedmodulatingvalve,thermal
expansionvalve,etc.

HandExpansion
p
Valve

MotorizedModulating
g
Valve

ThermalExpansion
p
Valve

RefrigerationSystem

RefrigerationSystem

RefrigerationSystem
CommercialSystem FreonOnly
Ex:supermarkets,conveniencestores,andsmallcoldstorages
p
,
,
g

CondensingUnit:Theoutdoor
condensingunitcontainsboththe
d i
it
t i b th th
compressorandcondenser.

AirUnit:Standardairunitwith
thermal expansion valve and electric
thermalexpansionvalveandelectric
defrost.

Applications
ColdStorage

ColdStorage:Largerooms/buildings,
typically 0FFto20
typically0
to 20FF,forstoring
for storing
frozenfoods.Foundinlarge
processingplantsandasfood
distributioncenters.
Refrigerationsystemscanbeshutoff,
sometimesforhours,without
temperature gain that damages
temperaturegainthatdamages
frozenfood.

Applications
Cooler

Cooler:Typically+32Fto+40Ffor
storing perishable refrigerated food
storingperishable,refrigeratedfood
products.
Becauseproducttemperaturehasa
verytighttolerance,lengthoftime
therefrigerationcanbeoffisvery
limited.

Applications
TypesOfMechanicalFreezers

IQFBeltFreezer:Alongtunneltype
f
freezerwithoneortwobelts.
ith
t b lt
Tofreezemostlysmall,IQFproducts
suchaspeas,cutcorn,Frenchfries,
onions,pizzatopping,shredded
cheese,etc.
Usualretentiontimeisunder20
Usual
retention time is under 20
minutes.

Applications
TypesOfMechanicalFreezers:

SpiralFreezer:spiralwoundbeltwith
manytierstofreezeitemsrequiringa
ti t f
it
ii
longerretentiontimesuchaschicken
parts,fishfillets,hamburgerpatties,
potatocoproducts,entrees,pizzas,
etc.
Usualretentiontimeis3060
minutes.
minutes

Applications
TypesOfMechanicalFreezers:

VariableRetentionFreezer:also
calledacartonfreezer,isalargeunit
ll d
t f
i l
it
withmovingconveyorsortrays.
Forlongretentiontimeproductslike
pies,tubsoficecream,orturkeys
andcartooned(boxed)productslike
chickenparts,turkeyparts,meat.
Retentiontime212hoursor
possiblylonger.

Applications
TypesOfMechanicalFreezers:

BlastFreezer:smallroomwithlarge
coil inside This is a batch operation
coilinside.Thisisabatchoperation
withracks,loadedwithproduct,
manuallyputintoandremovedfrom
thefreezer.
Retentiontimemorethananhour,
sometimesupto20hours.

Applications
TypesOfMechanicalFreezers:

PlateFreezer:verticalorhorizontal
plates Also called contact freezers
plates.Alsocalledcontactfreezers
becausetheproductisindirect
contactwiththeheatexchangeplate
surface.
Productispumpedorplaced
betweenthemovableplatesand
refrigerant is pumped through the
refrigerantispumpedthroughthe
plates.Verticalplatefreezersare
usedtofreezemeat,offal,andfruit
productsinto5060lbblocks.
Usualretentiontimeis24hours.

Horizontal

Vertical

Applications
TypesOfMechanicalFreezers:

FlatProductFreezer:specifictype
f
freezerforquicklyfreezingthin
f
i kl f
i thi
productlikehamburgersandfish
fillets.
DesignedspecificallytoreplaceLN2
freezers.

Applications
FoodFreezingLoadCalculation:

Product:GreenPeas
Quantity:10,000lbs/hr
Temperature:Entering+70F
Exiting: 0F(equilibrated)

Applications
FoodFreezingLoadCalculation:

1) ProductLoad
SpecificHeatabovefreezingis

0.79btu/lbF

39F(+70F +31F)x0.79
Latent Heat (from chart)
LatentHeat(fromchart)

=30.8btu/lb
=106.0btu/lb
106 0 btu/lb

SpecificHeatbelowfreezingis

0.42btu/lbF

+31F(+31F 0F)x.42
TOTAL:

=13.0btu/lb
= 139.8btu/lb

10,000lb/hrx139.8BTU/lb =116.5TR
12,000BTU/TR

Applications
FoodFreezingLoadCalculation:

2)BaseLoad
Motors (116 HP x 3 000 btu/h/HP)
Motors(116HPx3,000btu/h/HP)

= 348 000 btu/h

=348,000btu/h

Enclosure

=60,000btu/h

Other(lights,etc.)

=84,000btu/h
TOTAL:=492,000btu/h
492,000btu/h
12,000btuh/TR

=41.0TR

3) SafetyFactor
5% (water,unevenproductfeed):

=6.0TR

TOTALLOAD

=163.5TR