COMPRESSOR

The purpose of the compressor in the vapour compression cycle is to compress the low-pressure dry gas from the
evaporator and raise its pressure to that of the condenser. Compressors may be divided into two types, positive
displacement and dynamic. Positive displacement types compress discrete volumes of low-pressure gas by physically
reducing the volumes causing a pressure increase, whereas dynamic types raise the velocity of the low-pressure gas
and subsequently reduce it in a way which causes a pressure increase.

a. Reciprocating Compressor – The working of reciprocating compressor is very similar to the reciprocating
engine used in automotive. The difference is that while the engine generates power, the compressor
consumes power and compresses the refrigerant. The reciprocating compressor is comprised of the piston
and the cylinder arrangement connected by the connecting rod to the motor shaft. When the shaft of the
motor rotates, the piston performs the reciprocating motion inside the cylinder, absorbing and compressing
the refrigerant.
Reciprocating compressors can be used for small as well as large refrigerating and air-conditioning
units. Their power consumption is more compared to rotary compressors, and they also make more noise.
Types of Reciprocating Compressors
i. Open Type
ii. Hermetics – totally sealed and semi-hermetic
The speed of the open compressor can be adjusted as per the capacity requirements. If it is a multi-
cylinder compressor, a certain number of cylinders can be bypassed to adjust the capacity and reduce power
consumption.

b. Rotary Compressor – In rotary compressors the compression of the refrigerant is achieved by the rotary
motion of the rotors instead of the reciprocating motion of the piston.

Types of Rotary Compressors

i. Rolling Piston – a rotor is fixed on the eccentric shaft, which rotates in the cylinder. A vane placed
in the slot inside the cylinder acts as the dividing line between suction and discharge of the
refrigerant.
 ii. Rolling Vane – the rotor is concentric with the shaft and rotates inside the cylinder. The cylinder is
offline with respect to the motor shaft. Depending upon the capacity of the compressor there may be
multiple vanes on the shafts. As the refrigerant enters the compressor in gaseous state it gets
trapped between successive vanes and gets compressed. The back flow of gas is prevented by the
oil film between the surface of the cylinder and vane tip.

c. Scroll (Scroll Pump) – has one fixed scroll which remains stationary and another moving or orbiting scroll
that rotates through the use of swing link. When this happens, the pockets of refrigerant between the two
scrolls are slowly pushed to the center of the two scrolls causing the reduction of the volume of the gas. It is
then discharged through the center port to the condenser.
The advantage of scroll compressor is that it has fewer moving parts and less torque variation
compared to the reciprocating compressor. This advantage is translated to a smooth and quiet operation.

d. Screw – uses a pair of helical rotors where it traps and compresses the gas as the rotors revolve in the
cylinder. In the HVAC, they are usually used in systems with 20-ton capacity and above. The male rotor and
the female rotor are built inside the cylinder. The low-pressure refrigerant enters on end of the compressor
and the resultant high-pressure refrigerant is discharged into the opposite end to the condenser.

e. Centrifugal – is usually used in large capacity refrigerating system. In this compressor, the vapor is moved
in a circular motion known as centrifugal force. An impeller which is a disk with radial blades spins rapidly
inside this housing causing the gas to gain velocity.
A diffuser converts this energy into pressure energy and is then discharged into the condenser. The
pumping efficiency increases with speed; hence this type of compressors is designed to operate at high
speed.
The main advantage of centrifugal compressor is that there are no valves, pistons or cylinders. The
wearing parts that need attention are the main bearings.

CONDENSER

The purpose of the condenser in a vapour compression cycle is to accept the hot, high-pressure gas from the
compressor and cool it to remove fi rst the superheat and then the latent heat, so that the refrigerant will condense
back to a liquid. In addition, the liquid is usually slightly subcooled. In nearly all cases, the cooling medium will be air
or water.

HEAT TO BE REMOVED

The heat to be removed in the condenser is shown in the p–h diagram and, apart from comparatively small heat
losses and gains through the circuit, will be Heat taken in by evaporator heat of compression This latter, again ignoring
small heat gains and losses, will be the power input to the compressor, giving Evaporator load compressor input
power condenser load Condenser load is stated as the rate of heat rejection. Some manufacturers give ratings in
terms of the evaporator load, together with a ‘ de-rating ’ factor, which depends on the evaporating and condensing
temperatures. Evaporator load factor condenser load

The provision of a separate oil cooler will reduce condenser load by the amount of heat lost to the oil and
removed in the oil cooler. This is of special note with oil-injected screw compressors, where a high proportion of the
compressor energy is taken away in the oil. This proportion varies with the exact method of oil cooling, and figures
should be obtained from the compressor manufacturer for a particular application.
TYPES OF CONDENSER

1. AIR-COOLED CONDENSER

The simplest air-cooled condenser consists of a plain tube containing the refrigerant, placed in still air and
relying on natural air circulation. An example is the condenser of the domestic refrigerator, which may also
have some secondary surface in the form of supporting and spacer wires. Above this size, the flow of air over
the condenser surface will be by forced convection, i.e. fans. The high thermal resistance of the boundary
layer on the air side of the heat exchanger leads to the use, in all but the very smallest condensers, of an
extended surface. This takes the form of plate fi ns mechanically bonded onto the refrigerant tubes in most
commercial patterns. The ratio of outside to inside surface will be between 5 : 1 and 10 : 1. Flow of the
liquefied refrigerant will be assisted by gravity, so the inlet will be at the top of the condenser and the outlet
at the bottom. Rising pipes should be avoided in the design, and care is needed in installation to get the pipes
level. The flow of air may be vertically upwards or horizontal, and the configuration of the condenser will
follow. Small cylindrical matrices are also used, the air flowing radially inwards and out through a fan at the
top.

2. WATER-COOLED CONDENSERS

The higher heat capacity and density of water make it an ideal medium for condenser cooling and,
by comparison with the 350 kW plant cited above, the flow is only 9.8 litre/s. Small water-cooled condensers
may comprise two concentric pipes ( ‘ double pipe ’ ), the refrigerant being in either the inner tube or the
annulus. Configurations may be straight, with return bends or headers, or coiled.

The double-pipe condenser is circuited in counterflow (media flowing in opposite directions) to get
the most subcooling, since the coldest water will meet the outgoing liquid refrigerant. Larger sizes of water-
cooled condenser require closer packing of the tubes to minimize the overall size, and the general form is
shell-and-tube, having the water in the tubes. This construction is a very adaptable mechanical design and
is found in all sizes from 100 mm to 1.5 m diameter and in lengths from 600 mm to 6 m, the latter being the
length of commercially available tubing. Materials can be selected for the application and refrigerant, but all
 mild steel is common for fresh water, with cupronickel or aluminum brass tubes for salt water. Some economy
in size can be effected by extended surfaces on the refrigerant side, usually in the form of low integral fi ns
formed on the tubes. On the water side, swirl strips can be fitted to promote turbulence, but these interfere
with.

EVAPORATOR

The purpose of the evaporator is to receive low-pressure, low-temperature fluid from the expansion valve and to bring
it in close thermal contact with the load. The refrigerant takes up its latent heat from the load and leaves the evaporator
as a dry gas. Evaporators are classified according to their refrigerant flow pattern and their function. The flow pattern
can be one of two types. Either the refrigerant flows continuously through the heat exchanger whilst it evaporates and
becomes superheated, or alternatively it resides in a vessel at low pressure whilst it evaporates or from which it is
taken to individual coolers, returning as liquid/vapor mixture. The most common type by far is the continuous flow
type, referred to as a direct expansion evaporator. The function of the evaporator is to cool air or liquid in almost all
cases. The air or liquid then cools the load. For example, in a refrigerated display cabinet, the air is cooled and
circulated to keep the contents at the required temperature; in a water chiller system, the water is circulated to
individual fan-coil units to provide air conditioning. In heat pumps, the function can be described as recovering heat
from air or liquid, but the evaporator construction will be very similar.

1. AIR COOLING EVAPORATORS

Air cooling evaporators for display cases, cold rooms, blast freezers and air-conditioning have finned pipe
coils. In all but very small coolers such as domestic and small retail units there will be fans to blow the air
over the coil.
2. LIQUID COOLING EVAPORATORS

Liquid cooling evaporators may be direct expansion or flooded type. Flooded evaporators have a body of
fluid boiling in a random manner, the vapor leaving at the top. In the case of ammonia, any oil present will fall
to the bottom and be drawn off from the drain pot or oil drain connection.

In the shell-and-tube type, the liquid is usually in the pipes and the shell is some three-quarters full of the
liquid, boiling refrigerant. A number of tubes is omitted at the top of the shell to give space for the suction gas
to escape clear of the surface without entraining liquid. Further features such as multiple outlet headers,
suction trap domes and baffl es will help to avoid liquid droplets entering the main suction pipe. Gas velocities
should not exceed 3 m/s and lower fi gures are used by some designers.

3. PLATE EVAPORATORS FOR FREEZING

The coil usually made up of copper or aluminum is

embedded in the plate so as so to form a flat looking surface.
Externally the plate type of evaporator looks like a single plate, but
inside it there are several turns of the metal tubing through which
the refrigerant flows. The advantage of the plate type of
evaporators is that they are more rigid as the external plate
provides lots of safety. The external plate also helps increasing the
heat transfer from the metal tubing to the substance to be chilled.
Further, the plate type of evaporators is easy to clean and can be
manufactured cheaply.
The plate type heat exchangers can be easily formed into
various shapes as per the requirement. Thus, in the household
refrigerators and the deep freezers, where they are used most
commonly, they can be converted into the box shape to form the
closed enclosure, where various food can be kept in the frozen
state. The plates can also be welded together forming
 the bank of the plate type of evaporators that can be used the larger evaporators of higher capacities.
Plate types of evaporators provide excellent shelves in the freezers and similar applications. They
can be used as the as the partitions in the freezers, frozen food display cases, ice cream cabinets, soda
fountains and others. Due to various advantages and flexibility offered by the plate type of evaporators, they
are used extensively.

4. Finned Evaporators
are the bare tube type of evaporators covered with the fins. When the fluid (air or water) to be chilled
flows over the bare tube evaporator lots of cooling effect from the refrigerant goes wasted since there is less
surface for the transfer of heat from the fluid to the refrigerant. The fluid tends to move between the open
spaces of the tubing and does not come in contact with the surface of the coil, thus the bare tube evaporators
are less effective. The fins on the external surface of the bare tube evaporators increases the contact surface
of the of the metallic tubing with the fluid and increase the heat transfer rate, thus the finned evaporators are
more effective than the bare tube evaporators.
The fins are the external protrusions from the surface of the coil and they extend into the open space.
They help removing the heat from the fluid that otherwise would not have come in contact with the coil.
The finned evaporators are most commonly used in the air conditioners of almost all types like
window, split, packaged and the central air conditioning systems. In these systems the finned evaporator is
popularly known as the cooling coil. The hot room air flows over the finned evaporator or the cooling coil,
gets chilled and enters the room to produce the cooling effect. In window a/c the finned evaporators is located
behind the beautifully looking grill. In the wall mounted split unit it located behind the front grill of the indoor
unit.

5. Shell and Tube Type –

are used in the large refrigeration and central air conditioning systems. The evaporators in these
systems are commonly known as the chillers. The chillers comprise of large number of the tubes that are
inserted inside the drum or the shell. Depending on the direction of the flow of the refrigerant in the shell and
tube type of chillers, they are classified into two types: dry expansion type and flooded type of chillers. In dry
expansion chillers the refrigerant flows along the tube side and the fluid to be chilled flows along the shell
side. The flow of the refrigerant to these chillers is controlled by the expansion valve. In case of the flooded
type of evaporators the refrigerant flows along the shell side and fluid to be chilled flows along the tube. In
these chillers the level of the refrigerant is kept constant by the float valve that acts as the expansion valve
also.

EXPANSION VALVES

The purpose of the expansion valve is to control the flow of refrigerant from the high-pressure condensing side of the
system into the low-pressure evaporator. In most cases, the pressure reduction is achieved through a variable flow
orifice, either modulating or two-position. Expansion valves may be classified according to the method of control.

1. THERMOSTATIC EXPANSION VALVES

Thermostatic expansion valves (TEVs) for such circuits embody a mechanism which will detect the superheat
of this gas leaving the evaporator. Refrigerant boils in the evaporator at 𝑇𝑒 𝑎𝑛𝑑 , 𝑃𝑒 , until it is all vapour,
point A and then superheats to a condition 𝑇𝑠 , 𝑃𝑒 , at which it passes to the suction line, point B. A
 separate container of the same refrigerant at temperature T s would have a pressure 𝑃𝑠 , and the difference
𝑃𝑠 - 𝑃𝑒 represented by C–B in Figure 8.1 is a signal directly related to the amount of superheat.

2. EXTERNAL EQUALIZER
 The simple thermostatic expansion valve relies on the pressure under the diaphragm being approximately
the same as that at the coil outlet, and small coil pressure drops can be accommodated by adjustments to
the spring setting.

Where an evaporator coil is divided into a number of parallel passes, a distribution device with a small
pressure loss is used to ensure equal flow through each pass. Pressure drops of 1–2 bar are common. There
will now be a much larger finite difference between the pressure under the diaphragm and that at the coil
inlet. To correct for this, the body of the valve is modified to accommodate a middle chamber and an
equalizing connection which is taken to the coil outlet, close to the phial position. Most thermostatic expansion
valves have provision for an external equalizer connection

3. ELECTRONIC EXPANSION VALVES

The electronic expansion valve offers a finer degree of control and system protection. The benefits can be
summarized as:
1. Precise flow control over a wide range of capacities.
2. Rapid response to load changes.
3. Better control at low superheats so that less evaporator surface is required for superheat. More surface
for evaporation results in higher evaporating temperature and better efficiency.
4. Electrical connection between components offers greater flexibility in system layout, which is important for
compact systems.
5. The valve can close when the system shuts down, which eliminates the need for an additional shut off
solenoid valve.

OPERATION AND PRINCIPLE OF REFRIGERATION

REFRIGERATION CYCLE
The vapour compression cycle is used for refrigeration in preference to gas cycles; making use of the latent heat
enables a far larger quantity of heat to be extracted for a given refrigerant mass flow rate. This makes the equipment
as compact as possible. A liquid boils and condenses – the change between the liquid and the gaseous states –
at a temperature which depends on its pressure, within the limits of its freezing point and critical temperature. In
boiling it must obtain the latent heat of evaporation and in condensing the latent heat is given up.

Evaporation and condensation of a fluid

Heat is put into the fluid at the lower temperature and pressure thus providing the latent heat to make it
vaporize. The vapour is then mechanically compressed to a higher pressure and a corresponding saturation
temperature at which its latent heat can be rejected so that it changes back to a liquid. The cooling effect is
the heat transferred to the working fluid in the evaporation process, i.e. the change in enthalpy between the
fluid entering and the vapour leaving the evaporator.

a. Receiver or condenser - The refrigerant is under pressure.

b. Expansion It is a device, which controls the rate of flow of refrigerant into the evaporator. Now high
pressure refrigerant enters low pressure zone.

c. Evaporator - It consist of coils, here the refrigerant evaporates by absorbing heat from the space. The
energy required for this process is taken from the surrounding (space which is to be cooled). In this step,
liquid vapourises, but some liquid still remains.

d. Liquid trap - This is used to remove the traces of liquid refrigerant and then returned to receiver
(condenser).

e. Compressor - Saturated vapour is allowed to pass through the compressor. The compression is
adiabatic and it produces supersaturated gas.

f. Condenser - The supersaturated gas (vapour) flows to the condenser where the gas is liquefied.

In the P-h diagram, the saturation curve defines the boundary between vapour and liquid. In the boundary
outside the curve on the left side, labeled as liquid, the fluid is subcooled liquid, SCL. In the region labeled
vapour, the fluid is superheated vapour, SHV. In the saturation curve, on the right side of the curve, the fluid
is saturated vapour, and saturated liquid on the left. The region inside the saturation curve, the fluid is a wet
vapor mixture WVM.

In the first process, compression, the fluid passes through the compressor, from saturated vapor, the
pressure and the temperature starts to rise and the fluid becomes superheated vapour. This process where
the compression raises both the pressure enthalpy is called adiabatic compression. The energy used in this
compression process is converted into heat thus raising both temperature and enthalpy.

Next, the fluid enters the condenser where heat is released at constant pressure. The line passes through
the saturation curve, until it enters the boundary inside the saturation curve until finally reaching the saturation
curve at saturated liquid state. In the third process, the fluid passes through the expansion valve at constant
enthalpy. The fluid expands and becoming a wet vapor mixture.

Lastly, the fluid enters the evaporator where heat is added. The enthalpy rises until it becomes saturated
vapor again before finally entering the compressor thus repeating the cycle. Both the condensation and
evaporation process are constant pressure processes or isobaric processes represented by a horizontal line.