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1. INTRODUCTION
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Use of Desuperheater in Refrigeration
Condenser
r
CT water
To Evaporator
Compressor
SLHE
TEV
Chilled Water
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Use of Desuperheater in Refrigeration
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Use of Desuperheater in Refrigeration
For example fuel fired (Diesel or Furnace oil) boilers are used to
generate hot water for domestic use, cleaning, or for process need. At the
same time refrigeration is used for process cooling, cold storage and
pasteurisation or ice making. Entire heat rejected by refrigeration is rejected
to atmosphere through air-cooled or water-cooled condensers. Many times
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Use of Desuperheater in Refrigeration
this process of heat rejection and fresh heat generation is done across the
wall in the same plant and seldom noticed for complimenting each other.
While this energy is of low grade variety, it still represents waste energy.
Combining these two, waste heat and fresh heat generation makes clever
sense of energy conservation.
4 .THE CONCEPT:
Desuperheater
Hot
Water
Evapo
From
Condenser
rator
Compressor
SLHE
TEV
Figure 2 Evaporator
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Use of Desuperheater in Refrigeration
exchanger, designed to transfer hot gas energy to domestic hot water use.
Every air conditioning system has available heat energy, which can be
recovered. This heat is comprised of two components; “superheat” and
“condensing” heat energy. The “superheat” typically accounts for 15% of the
total system heat of rejection, whereas the “condensing” energy accounts for
about 85%. The Desuperheater uses hot refrigerant gas “superheat” energy
to heat domestic hot water to 60 deg C.
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Use of Desuperheater in Refrigeration
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Use of Desuperheater in Refrigeration
We have already seen the available heat but all the heat available is
not completely recovered. The amount heat recovered depends upon the heat
exchanger effectiveness. The heat exchanger generally has their
effectiveness between 60-80%.
Once the amount of heat that may be transferred to the water is
determined, it is then appropriate to view this energy recovery in terms of the
energy savings that may be achieved. One ton of heat removal is equivalent
to 12600 kJ/hr. Every liter of water requires 8.75kJ/hr of heat addition to raise
its temperature 1 deg C. Thus we can have hot water per hour free for every
ton. Free is relative since the equipment has some costs attached. Assuming
the alternative was to heat the water electrically (or burning fuel), the heat
recovery unit would provide savings on electricity (or on burning fuel). To get
overall savings, simply multiply hourly savings by the hours/day of operation.
Then consider the number of days/year that cooling is required.
Several other considerations are important:
• Since installation of a heat recovery unit requires the addition of other
components in the refrigerant lines, your warranty or service
agreement may be affected.
• Heat recovery units recover heat only when the chiller is operating.
Therefore, savings will be reduced if the chiller operating hours are
reduced.
• Long runs of refrigerant or water lines can add to the cost, as well as
resulting in additional heat loss in the system.
• If the unit produces hot water faster than it can be used, the excess
capacity may be wasted, thereby reducing potential savings.
• All heat recovery units should be provided with bypass valves that
allow the unit to be isolated from the system in case of leaks or
required maintenance.
• Heating water to temperatures higher than recommended results in
lower output in gallons per hour.
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Use of Desuperheater in Refrigeration
• Heat recovery systems can be adopted for all air conditioning units
from as small as 2 tons up to the largest chillers available
7. ECONOMICS CONSIDERATIONS:
The economics of this heat recovery is attractive. It is important to
ensure recovered hot water displaces prime energy (fuel or electricity) used
by facility. The economics can be adversely affected due to poor operating
hours of compressor. The system evaluation and total integration with facility
hot water system is essential step to ensure favorable economics of project.
Though there are other advantages of heat recovery system, over
empathizing of these benefits can create serious situation. While system is
conceptualized use of hot water should be properly estimated so that
recovered heat is not wasted. Providing metering of hot water flow and
recording the operating temperature will help to monitor and compare post
implementation performance of system. Generally 1litre fuel oil and 1kWh of
electricity delivers 270 & 28 liters of hot water respectively hot water at
55deg C. Thus with large requirement of hot water and refrigeration running
on one side, Desuperheater provides substantial savings in fuel.
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Use of Desuperheater in Refrigeration
8.1.Dairy processing:
Dairy processing plants usually use energy efficiently. Heat
transmitted to milk products during pasteurization is normally rejected to
incoming cold milk in the regenerator. A large percentage of waste energy is
in the heat rejected by the refrigeration condensers. It can be used in
generating hot water for use in cleanup, in preheating boiler feed water, or in
heating culture tanks for some unit operations. Wastewater and exhaust from
spray dryers are other major sources of waste heat. Contaminants in the
wastewater may restrict its use for heat recovery, but dryer exhaust can be
recovered and used to preheat supply air for the dryer.
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Use of Desuperheater in Refrigeration
8.2.Poultry processing:
In poultry processing, large quantities of energy are required for scalding,
cooling and freezing. The scalders and chillers have continuous overflow, and
thus large amounts of energy are lost. However, recovery of heat (or cooling
capacity) from scalders (or from chillers) is feasible, and the energy can be
returned to the scalders (or chillers). Heat can also be recovered from
refrigeration system condensers and used to preheat boiler makeup water or
washwater.
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Use of Desuperheater in Refrigeration
9. CASE STUDIES :
Let us now evaluate how much savings are we seeing at
Case study 1:
Hotel requires overall cooling of building and hot water for domestic use. Hot
water is required in room service as well as kitchen is supplied from hot water
that is maintained between 45 to 50 0C. Hotel has 50TR of refrigeration. The
desuperheater produces hot water and it is piped in existing hot water system.
Thus the required hot water is provided by desuperheater and electricity
/diesel firing makes up the short fall.
The assumed 15%heat recovery for 50ton we get 1575kJ/min
16 hrs operation per day provides 1.5 GJ /day.
Fuel heat gives 2751kJ/kg. (for HSD fuel)
(Assuming Density 0.84, efficiency .84)
Effective heat 1940 kJ/lit
Savings /day/TR /16 hr Operation of refrigeration system = 0.77 lit
Case study 2:
Heat energy is removed from milk during cooling. The heat energy can be
'dumped' from an air-cooled condenser, or all/or part of it can be transferred
to water using a water-cooled condensing mechanism or milk precooler.
Water-cooled condensers and milk precoolers will reduce compressor
running- time. However, the greater energy savings usually come from
displacing water heating energy costs.
On most, dairy farms the milk heat available can preheat more water than the
required for nominal wash-up and sanitizing.
Milk Cooling
To maintain milk quality, milk must be cooled from about 39° C (cow body
temperature) to 3° C for safe storage. Milk is normally cooled by a
refrigeration unit removing heat from milk (source) to air or water (sink).
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Use of Desuperheater in Refrigeration
27℃
Evaporator Air
Hot water
As discussed hot water is required for sanitization and pasteurization. The
temperature of this water is around 70 0C.
Consider a refrigeration capacity of dairy as 30TR(2100kJ/min)
Assuming 15%heat recovery from it gives us 945kJ/min
20 hrs operation per day provides 1.13 GJ /day.
Fuel heat gives 2488kJ/kg. (for furnace oil)
(Assuming Density 0.94, efficiency .80)
Effective heat 1870 kJ/lit
Desuperheater
Savings /day/TR /16 hr Operation of
refrigeration system = 0.60 lit Hot water
65℃
Valve 24℃
Water pass
35℃
Condenser Air
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Use of Desuperheater in Refrigeration
10. CONCLUSION:
Heat recovery from refrigeration is effective and provides reliable source of
heat to fulfill major demand of hot water. System can preheat water up to
600C without affecting refrigeration cycle. Simultaneous generation of chilled
water and usable hot water results in
1. Increased output of heating system
2. Reduced fuel consumption and
3. Enhanced overall system efficiency.
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11.REFERENCE :
1. HEAT CHILLER RECOVERY published by ASHRAE in 1999
2. A COURSE OF REFRIGERATION AND AIR-CONDITIONING by
S.C. Arora and S. Domkundwar
3. Best Energy Systems Inc. acrobat file BRAMPTON case study
4. www.agr.gc.ca
5. Internet.oit.edu
6. Fact sheet EES-26 published by UNIVERSITY OF FLORIDA
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