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Energy Efficient Refrigeration
page 1 of 5
Bill Greco 4/9/2009
The use of thermostatic expansion valves, capillary tubes and constant pressureexpansion valves used in todays refrigeration systems all have one thing in common,
they waste the energy used to expand the refrigerant
. A pressure drop throughexpansion devices is required to produce a pressure drop and corresponding refrigerantphase change. By eliminating these devices
and installing in their place a turbineconnected to a generator,a 4% reduction in energy
can be realised.THE BASIC REFRIGERATION CYCLEMechanical refrigeration is achieved by constantly circulating, evaporating, andcondensing a fixed suppy of refrigerant inside a closcd systen.Mechanical refrigeration is made possible thrcugh the proper use of tcmperature, Prcssure,latent hcat of vaporization, and latent heat of condensation.Evaporation occrus at a low pressure and 1ow temperature. Condensation occursat a high temperature and high pressure. Thus, it is possible to transfer lteat ftoman area of 1ow temperatrre to an area of high temperatureIf we begin the rcfrigeration cycle at the evaporator inlet the 1ow-pressure liquid expandsabsorbs heat, and evaporates, changing to a low prcssurc vapor at the ortlet of theevaporator. During the cxpansion process approrimately 20 petcent of the refrigeranttums to flash gas. Flash gas cools the remaining refrigeranlt down to evaporatortemperature.The compressor draws this vapor from the evaporator and increases its pressure. Thehigh prcssure vapor is then dischargcd to the condenser . In the condenser, the heat isremoved from the vapor, causing it to condense and become warm, high-pressure liquid.The next component encountered by the refrigerant as it travels through the system is theliquid line strainer/drier, which prevents plugging of the flow-control device by trappingscale, dirt, and moisture. The flow of refrigerant into the evaporator is controlled by apressure differential across the flow control device.As the warm, high-Pressurc liquid refrigerant cnters the evaporator, it is subjected to amuch lower pressure owing to the combined suction of the comprcssor and the pressrredrop across the flow control device. Thus, thc refrigerant tends to expand and evaporate.In order to evaporate, the liquid mrst absorb heat from the air passing over the evaporator.Eventually, the dcsired temperature is reached inside thc conditioned space and atcmperature control (thermostat) will stop the compressor. As the tempenttre of theconditioned space rises, the temperatue control starts the compressor again. After thecompressor starts, the cycle is continued.A11 compression rcfrigeration systems operate at two deturite pressrre levels. Thedividing line passes through the compressor discharge valve on one end and the orificeof the flow-contrcl device on the other end.The compressor discharge valve and the orifice of the flow control device are thedividing points between the high side and the low sidc of ihe system.
 
Energy Efficient Refrigeration
page 2 of 5
Bill Greco 4/9/2009
The high sidc of the system includes all the components operating at or abovethc condensing pressure. The high side includes the discharge sideof the compressor, the discharge service valve, condenser, liquid receiver, liquidline shutoff valve, drier, liquid line strainer, and the connecting lines ln practice, thecomplete compressor is considered as being on tle high side of the system.The 1ow side of the system includes all components operating at or below theevaporating pressure.The low pressure side includes the outlet side of the flow-control device, evaporator,suction line, suction service valve( for refilling the system), comprcssor crankcase, thepiston or scroll, and suction valves of the compressor. In practice, the flow control deviceis considcred as being on the low side of the system.Although therc are
mary type’s of compression refrigeration systens, the cycle inall of them is the same.We can summaize the compression rcfngeration cycle as follows:1. The refigerant vapor is compressed by the compressor and discharged into thecondenser.2.The comprcssed vapor is cooled and condensed to a liquid in the condensor.3. The liquid refrigerant is passed through the flow-control device to the evaporator or cooling coil.4. Because of the reduccd Pressure in the evaporator. vaporization takes place. Some of lhe refrieerant converts to flash gas. Refigeration results from thc absorption of heat dunngvaporization in the cooling coils.5. The refrigerant vapor is drawn into the compressor and the cycle isrepeated.
 
Energy Efficient Refrigeration
page 3 of 5
Bill Greco 4/9/2009Better Energy Efficiency
See Figure-2 above indicates a simplified Refrigeration Diagram wherethe expnsion valve has been replaced by a turbine to decompress the refrigerant,the pressure drop through the turbine is used to turn a generator which sendspower back to the compressor motor.Mathematical Example of the energy savings:Assume a 9 ton direct expansion system using R-407c with the following characterisitcs:A 10 hp compressor motorA condensing temperature of 123 degrees F.An outdoor ambient temperature of 99 deg F dry bulb and 77 deg. F wet bulb.64 deg F return gas temperature to the compressor15 deg F sub cooling and 20 deg F super heat1,450 pounds of refrigerant flow per hour44 deg F saturated suction temperature at the evaporatorThe refrigerant to be at 305 psia at the condenser and 98 psia after expansionAt 25 deg C. R-407c has a specific gravity of 1.1361 gallon of R-407c = 8.34 x 1.136 = 9.474 poundsThe generator would supply about 4% of the electric power back to the 10 hp compressor.1,450 pounds per hourFlow = 24.167 pounds per minute60 minutes24.167 pounds per minute2.551 gallons per minute Note: 1 psia = 2.31 head feet9.474 pound per gallonRefrigeration Pressure drop
through the turbine = 305 - 98 = 207 psia2.551gpm2.31207 psia P1.136 specific gravity0.437 hp39600.8 expansion efficiency
 Brakehorsepower 
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