ASHRAE WILL GIVE

YOU THE WORLD

This ASHRAE Distinguished Lecturer is brought to you by the

Society Chapter Technology Transfer Committee
 Complete the Distinguished Lecturer
Event Summary Critique

CTTC needs your feedback to continue to

improve the DL Program
 Distribute the DL Evaluation Form to all attendees
 Collect at the end of the meeting
 Compile the attendee rating on the Event Summary
Critique
 Send the completed Event Summary Critique to your
CTTC RVC and ASHRAE Headquarters

Forms are available at:

www.ashrae.org/distinguishedlecturers
BECOME A FUTURE LEADER IN ASHRAE – WRITE THE NEXT
CHAPTER IN YOUR CAREER
ASHRAE Members who attend their monthly chapter meetings become
leaders and bring information and technology back to their job.

YOU ARE NEEDED FOR:

 Membership Promotion
 Research Promotion
 Student Activities
 Chapter Technology
Transfer Technical
Committees

Find your Place in ASHRAE! Visit www.ashrae.org

 An Introduction to Ammonia
Refrigeration Systems

Douglas Reindl, Ph.D., P.E.

ASHRAE Fellow
Director, IRC
Professor, University of Wisconsin-Madison
During this presentation, we will
discuss

• Brief background on ammonia and its uses

• Ammonia, the refrigerant
• Ammonia refrigeration, the technology
• How is ammonia different compared to
other refrigerants?

5
 Where is ammonia used?
NH3

Annual ammonia use in U.S.

Annual US consumption in 2012 was 14.4 million metric tons*.

2%**
11%

87%

Agriculture Other Refrigerant

• Source: US Geological Survey (2013).

** Source: ASHRAE Position Document on ammonia (RA 2013) 6
 Anhydrous ammonia as a refrigerant
•Where is ammonia used as a refrigerant?
– Industrial systems: large cold storage and process systems
– Some HVAC systems
(requires a central plant)
– Where no ODP and low/no GWP is desirable/needed
• Distinct characteristics
– Usually a custom engineered
system vs. a packaged
systems for halocarbons

9
Anhydrous ammonia characteristics

• Refrigerant grade
– 99.95% Purity
– 75 PPM H2O (max)
• Vapor tends to be lighter than air
• Liquid specific gravity ~ 0.65
• Alkaline – pH of 11.6
• Pungent odor makes it self-alarming
• Highly soluble in water
• Very corrosive to human tissue upon exposure!
• Toxic at elevated concentrations
10
 Flammability characteristics
• ASHRAE 34 flammability classification: 2L
• DOT classified as non-flammable
• Autoignition temperature: 1204F
• Lower flammability limit (vol.%)1 15-16
• Upper flammability limit (vol. %)1 25-28
• Combustion products: oxides of nitrogen
• Fire hazard: slight

1 IIAR Ammonia Data Book, (2009). 11

12
13
 Materials compatibility for ammonia

• Not permitted
– Copper and copper alloys such as brass are
prohibited (but allowed for bearing materials)
– Zinc (in continuous contact with ammonia)
– Non-metallic materials that degrade upon exposure
• Permitted
– Carbon steel
– Stainless steel
– Aluminum
– Other nonmetallic materials such as PTFE are permitted
(if they will not break down)

14
Anhydrous ammonia

• Why is ammonia widely used in food processing

and storage facilities?
• Because it is a good refrigerant!
– High heat transfer coefficients in equipment
– Efficient compressor operation
– Low refrigerant cost
– No ozone depletion & very low/no global warming
– Sustainable
– Self-alarming
15
Let’s now look at the technology
Ammonia refrigeration technology

• Single stage compression with

evaporators configured as
– direct-expansion
– flooded
– overfeed
• Multi-stage compression systems
• Cascade systems

17
Simple vapor compression system

Saturated liquid, Qcond Superheated vapor,

high pressure
high pressure
Condenser
2
1

Expansion high-side
Device Comp Wcomp

low-side
3

Evaporator 4

liquid+vapor, Saturated vapor,

low pressure low pressure
Qevap 18
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Equalizing line
Protected suction

Solenoid valve Thermostatic

expansion valve

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Equalizing line
Protected suction

25 psig (~11F) Solenoid valve Thermostatic

expansion valve

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

40 psig (~26F)

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Equalizing line
Protected suction

25 psig (~11F) Solenoid valve Thermostatic

expansion valve

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

40 psig (~26F) 60 psig (~41F)

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Equalizing line
Protected suction

25 psig (~11F) Solenoid valve Thermostatic

expansion valve

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

40 psig (~26F) 60 psig (~41F)

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Equalizing line
Protected suction

25 psig (~11F) Solenoid valve Thermostatic

expansion valve

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Compressor, rotary screw

Compressor
Motor

Motor

Oil Separator

24
Oil Separator

Compressor
Motor
Discharge
vapor

Compressor discharge

Oil Separator
Oil

1st Stage Oil Separation 2nd Stage Oil Separation

25
Compressors, reciprocating

26
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Protected suction

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Condensers, evaporative
Moist, hot air out

Eliminators

Spray header

High pressure
vapor refrigerant, in

High pressure
liquid refrigerant, out

Ambient Air
Ambient Air

Remote sump

Makeup water Condenser water

28
Condensers, evaporative

29
Evaporative condenser coil

30
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Protected suction

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Receivers, high pressure

32
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Protected suction

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
King valve

34
Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Protected suction

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Evaporator, air-cooling

Penthouse evaporator in a freezer

Ceiling-hung evaporator in a dock area

36
Evaporator technologies
• Air-cooling
– Very low temperature blast freezing
– Low temperature holding freezers
– Higher temperature storage coolers, production areas,
air-conditioning
• Liquid-cooling (secondary fluids and products)
– Shell-and-tube
– Plate-and-frame
– Falling film
– Scraped surface

Shell-and-tube liquid chiller Plate-and-frame liquid chiller 37

Single stage – Direct-eXpansion (DX)
High pressure gas

Equalizer
Evaporative Evaporative
Condenser
Condenser

line
Condenser
Discharge line

High pressure liquid

King valve DX Evap n
High (automatic)
DX Evap 1
Pressure
Receiver
…

T T

Protected suction

Suction To HPR
Trap

Refrigerant
Transfer
Compressor(s) System
Transfer system

Suction trap

Transfer drums

Oil pot

39
 Gravity flooded recirculation system
High pressure gas

Equalize Hand expansion

line Solenoid valve
valve
Evaporative
Condenser(s
) Flooded evaporator
King valve
Discharge line

Float

High pressure liquid

High
Pressure
Receiver

“Protected” suction

Flooded evap, n
Suction Flooded evap 1
trap

To HPR

Compressor(s) Transfer
Station
 Gravity flooded evaporator

Surge Drum
Evaporator, vapor return

Evaporator, liquid supply

Pumped liquid overfeed
High pressure gas

Equalize
Evaporative Evaporative
Condenser

line
Discharge line

Condenser

3 3

High High pressure liquid

Pressure King valve
2 Receiver
Wet
return

Dry suction 4
1

Pumped
recirculator Overfed
4’ evaporator(s)
4”’
T
Compressor(s)
Liquid overfeed system

Recirculator

Float column

Pumped liquid
line

Liquid refrigerant pumps

Liquid overfeed system components

44
Two-stage compression systems

• Lower evaporator temperatures

– Requires lower evaporator pressures
– Leading to increased compressor compression
ratios
• Limitations of specific compression technologies
• Increased refrigerant discharge superheat

45
Two-stage compression
(two temperature level with two stages of liquid expansion)

Evaporative
Condenser(s) Equalize
line DX Evap

3 King valve

High
Pressure T

Low Receiver
5
temperature
Evaporator(s) Medium
4’ Temperature
4 Recirculator/
Intercooler
6

Intercooler
5’’ 5’ 4’ 2
Low
temperature
1
recirculator 7

Booster High-Stage
Compressor(s) Compressor(s)
 Two-stage compression
(two temperature level with two stages of liquid expansion)

Evaporative
Condenser(s) Equalize
line DX Evap

3 King valve

10.4 psia or 8.8” Hg (~40F) High

T
Pressure
Low Receiver
5
temperature
Evaporator(s) Medium
4’ Temperature
4 Recirculator/
Intercooler
6

Intercooler
5’’ 5’ 4’ 2
Low
temperature
1
recirculator 7

Booster High-Stage
Compressor(s) Compressor(s)
 Two-stage compression
(two temperature level with two stages of liquid expansion)
196 psia or 181 psig (~95F)
Evaporative
Condenser(s) Equalize
line DX Evap

3 King valve

10.4 psia or 8.8” Hg (~40F) High

T
Pressure
Low Receiver
5
temperature
Evaporator(s) Medium
4’ Temperature
4 Recirculator/
Intercooler
6

Intercooler
5’’ 5’ 4’ 2
Low
temperature
1
recirculator 7

Booster High-Stage
Compressor(s) Compressor(s)
 Two-stage compression
(two temperature level with two stages of liquid expansion)
196 psia or 181 psig (~95F)
Evaporative
Condenser(s) Equalize
line DX Evap

3 King valve

10.4 psia or 8.8” Hg (~40F) High

T
Pressure
Low Receiver
5
temperature
Evaporator(s) Medium
4’ Temperature
4 Recirculator/
6 45 psia Intercooler
(~17F)
Intercooler
5’’ 5’ 4’ 2
Low
temperature
1
recirculator 7

Booster High-Stage
Compressor(s) Compressor(s)
 Two-stage compression
(two temperature level with two stages of liquid expansion)
196 psia or 181 psig (~95F)
Evaporative
Condenser(s) Equalize
line DX Evap

3 King valve

10.4 psia or 8.8” Hg (~40F) High

T
Pressure
Low Receiver
5
temperature
Evaporator(s) Medium
4’ Temperature
4 Recirculator/
6 45 psia Intercooler
(~17F)
Intercooler
5’’ 5’ 4’ 2
Low
temperature
1
recirculator 7

45 196
𝐶𝑅𝐵 = = 4.3: 1 𝐶𝑅𝐻𝑆 = = 4.3: 1
10.4 45
Booster High-Stage
Compressor(s) Compressor(s)
 What’s a “typical” system?
High pressure gas

Equalizer
Evaporative Evaporative
Condenser

line
Condenser
DX evaporator

3 3

T
High

High pressure liquid

Pressure
2 Receiver
King valve
(automatic) Flooded
Evaporator

Dry suction To HPR

4 Wet Suction
Trap
return
1 Transfer
Station

Overfed evaporator(s)

4’ T
4”’
Pumped Compressor(s)
Compressor(s)
recirculator
QUESTIONS?

52
What did you learn?
1. Where does the vast majority of ammonia originate from?
2. Which of the following materials is not compatible with
ammonia: carbon steel, stainless steel, copper,
aluminum?
3. Ammonia is considered highly flammable:
True or False?
4. The “suction trap” is needed to prevent compressors from
ingesting liquid refrigerant:
True or False?
5. Which of the following is not an industrial ammonia
system configuration: direct-expansion, liquid underfeed,
gravity flooded, two-stage?
53