Ammonia Refrigeration How It Differs

Of the number of visitors to this website, the most frequently asked question is: "How does
ammonia refrigeration work?" Yes, it is different from refrigeration and air-conditioning
using halocarbon refrigerants. But there are a lot of similarities also. So lets start with
some basics a short review of vapor-compression refrigeration, native to all
refrigerants. Im going to leave out any discussion of ammonia/water absorption (heatdriven) cycles and limit this discussion to cycles involving vapor-compression.
The Bare Bones Basics
Every vapor-compression refrigeration system or unit ever built will have at least one each
of these four components:

compressor

condenser

expansion device

evaporator

Figure 1 illustrates these components and their relative placement with one another.
Figure 1 Basic Vapor-Compression Refrigeration Cycle

The line numbers denote:

1. Hot gas (high pressure, high temperature)
2. Liquid (high pressure, warm temperature)
3. Liquid + vapor (low pressure, cold temperature)
4. Vapor (low pressure, cold temperature + ~10 F superheat)
Note the horizontal dashed line in Figure 1. All portions of the system above this line are
part of the system high side those components operating under a high(er) pressure than

the pressure within the system low side. As the absolute pressure of a gas increases, its
temperature increases, therefore the system high side is usually hot or at least warm to the
touch. Everything residing below the dashed line operates under a low(er) pressure than
the high side. The pressure difference is a function of the temperatures involved in the
process and the refrigerant selected.
Starting at the discharge connection of the compressor, line 1 conveys a high pressure
superheated hot gas where it enters a heat exchanger (the condenser). After entering, the
gas is first desuperheated. Upon reaching its saturation temperature, the vapor then begins
to condense, changing from a vapor state back into a liquid state. If additional heat is
removed from this liquid stream, the process is known as "subcooling"[1].
Line 2 conveys the high pressure refrigerant liquid stream from the condenser into an
expansion device. There are many different types of expansion devices; in the following
short list, Ive divided these into modulating devices and fixed devices.
1. Capillary tubes (fixed)
2. Orifices (fixed, short orifice, Accurator)
3. Electronic expansion valves (modulating, senses refrigerant temperature rise across
evaporator)
4. Thermal expansion valves (modulating, senses refrigerant superheat generated
within evaporator)
5. Hand expansion valves (fixed but manually readjustable)
6. High-side floats (modulating, senses liquid level)
7. Liquid control valves (usually positioned by a remote high side float)
Expansion devices numbered 1 through 4 are commonly applied in halocarbon refrigeration
systems. Devices numbered 4 though 7 are used as throttling devices in industrial
refrigeration systems and practices.
After leaving the expansion device, the refrigerant has now become a mixture of low
pressure cold liquid and vapor as it travels down line 3. In most cases, especially with
halocarbon units, this line is very short maybe an inch or two long. This mixture then
enters an evaporator where the remaining liquid is boiled away while transferring heat
energy across the evaporator tubing (and fins if they exist). If the expansion device
measures refrigerant superheat (or a temperature rise) occurring within the evaporator, the
gaseous refrigerant is then superheated slightly before it leaves the evaporator and enters
line 4.
Line 4 (also known as suction) conveys the now slightly superheated low pressure vapor
back into the compressor where its pressure and temperature are simultaneously raised to a
level where heat can be rejected from the condenser into a heat sink (air, water).
When looking at Figure 1, this energy balance becomes apparent:
(1)
As my learned colleagues at the University of Wisconsin remind me: "Denkmann, the
system has to balance. The sum of the gozoutas minus the sum of the gozintas has to be
equal to zero". All fine and well, Id say. The bloody thing has to balance.
So far, everything Ive presented up until now is generic among all refrigeration systems
and units. This includes ammonia as well. Where things become interesting are the
differences between Commercial Refrigeration as commonly practiced (all DX) and Industrial
Refrigeration and its practices (DX + liquid overfeed + thermosiphon). These two fields of

practice grew up separately, rarely if ever speaking with one another at ASHRAE
meetings. Consider the following Equations 2 and 3. The system energy balance is simple
and straightforward as weve already seen (Eq 1). However, when it comes to mass flows,
things get a little murky.
All refrigeration systems (packaged units as well) can be grouped into either of two
categories described by one of the following:
(2)
describes all direct expansion systems[2], and
(3)
describes all remaining liquid overfeed and gravity-flooded systems.
The three equations presented so far describe every vapor compression refrigeration system
built, and regardless of the refrigerant charged into the system, where m is mass flow.
Now lets look at the ways ammonia (industrial) refrigeration systems differ from their
commercial halocarbon counterparts.
Ammonia Refrigeration Systems Ways They Differ
Probably the number one difference between a typical DX unit and an ammonia refrigeration
system centers on this: oil. In a DX halocarbon unit, oil is continuously returned to the
compressor. Oil is not returned to the compressor in ammonia refrigeration systems but is
instead drained out of the system periodically. Oils used in ammonia refrigeration systems
are essentially insoluble in NH3 (some slight solubility exists at high pressures); oil is
heavier than liquid ammonia, making it easy to drain out. On the other hand, oil solubility
is absolutely essential with the halocarbons in order to facilitate oil return. This makes oil
management in an ammonia system a relative piece of cake. Its easy to manage just
drain it out. We dont have to maintain minimum gas velocities in order to bring it back
through dry suction piping. Paraffinic-based oils are commonly used with ammonia. These
oils do a good job of cleaning out old welding slag and dirt, hence another reason why it
cant be returned to a compressor it is too dirty to reuse. Oil, once drained from the
system, is no longer usable.
The next difference lies in the choice of piping materials. Copper, brass, bronze cannot be
used with ammonia your metal choices are mild steels, stainless steels, nickel, but
absolutely no copper.
The next difference lies in refrigerant management. In nearly all halocarbon packaged units
(air-conditioning, commercial refrigeration), the refrigerant charge is critical. This means
that the system has no alternate place(s) to store refrigerant not in use by the system at
some particular point in time. Stated differently, refrigeration units are built using the
simplest designs no pressure vessels, no solenoid valves. Any excess liquid becomes
stored inside the condenser and any excess liquid decreases system refrigerating
capacity. Generally speaking, a critically-charged unit should be charged within 1-2% of
the listed charge. If it isnt, the unit will fail to produce its stated capacity. Over-charge
also increases the risk of liquid carryover to the compressor. A few systems will have
suction traps (a small vessel) to detain a liquid surge; some traps have an internal heat
exchanger to facilitate liquid boil-off.

Have you ever noticed how a critically-charged system (or unit) behaves when its
compressor initially starts? A critically-charged system takes a few minutes to "get going"
that is, start to produce some cooling effect. During this interval, the compressor is
evacuating refrigerant vapor from the low side and sending this now higher pressure vapor
off to the condenser to be reliquified. Then this liquid must start to back up in the high
pressure liquid line so that it can seal off the opening into the liquid capillary (the expansion
device). Now your unit will start to produce cooling. This time delay isnt acceptable with
most ammonia systems, especially when process cooling or freezing is involved. I know of
only one ammonia refrigeration system designed for critical charging. The owner of this
system wasnt very happy with it either and has probably removed it by now. And for a
good reason the time delay associated with a critical charge just isnt acceptable. Hence,
another difference with ammonia the need for pressure vessels.
Pressure Vessels
Whenever someone familiar with halocarbon DX practices walks into an ammonia
refrigeration engine room, their jaw usually drops open. "You gotta be joking me,
man! What are those huge tanks for? Are those filled up with ammonia?"
Since the time delay associated with critically-charged systems cant be tolerated with
industrial refrigeration, some means of preventing this delay, or at least shortening it
becomes necessary. That means takes the form of pressure vessels a device to store
liquid ammonia. Heres a partial list of the tasks that pressure vessels perform in ammonia
refrigeration systems:
Repository of liquid not in use by the system at any point in time
Liquid operating reserve for mechanical drive refrigerant pumps (often 5 minutes or more)
Separate liquid from vapor (by gravitational forces)
Protect compressors from liquid slugging
Liquid transfer to other vessels within the system
Cool booster discharge vapor (two-stage systems with intercooler)
Collect oil for later removal
In the U.S., most ammonia pressure vessels are stamped for 250 psig service although
youll occasionally see 300 psig vessels in the Desert Southwest for storing high pressure
liquid. The minimum allowable pressure (U.S.) is 150 psig for low-side vessels. All vessels
built in the U.S. must conform to ASME Section VIII requirements.
Water and Refrigeration Systems
Another way ammonia is different from its halocarbon counterparts has to do with a water
inclusion. Just about every field-erected halocarbon refrigeration system Ive ever seen or
designed has at least one filter/dryer. The desiccant used adsorbs water. A high pressure
drop across a dryer core is a sure sign that water has accumulated a liquid sight glass will
probably read yellow (R22), indicating the system has taken on some water. If this goes
uncorrected, water will freeze inside distributor tubing if the evaporating temperature is
<32 F.
Ammonia is very different with its relationship to water. They have this love affair going
ammonia loves water! As the water content in liquid ammonia increases, the evaporating
temperature also increases with the evaporating pressure held constant. But as ammonia
becomes dissolved into water its freezing point temperature drops. This makes freezing

water in an ammonia mixture virtually impossible (at normal temperatures). So distributor

tubing doesnt suffer the same fate with an ammonia/water mixture as it does with the
halocarbons.
However I have also seen evaporators that stopped performing because so much water had
entered (through a failed tube in a water-cooled condenser) and the oil turned to a
sludge. This sludge then coated the inside of each evaporator tube on nearly all
evaporators in the plant so that all that remained was a " hole in a 1" tube certainly not
sufficient for a gravity evaporator. All of them had to be scrapped. The tell-tale sign was
clearly visible only a few U" bends had any frost on them most were warm to the touch.
So the take home on NH3 + H2O comes down to this: some can be tolerated but it
shouldnt be more than 0.4% by weight[3]. A refrigerant remediator (a batch-fed still) can
be used to remove water from ammonia. Dont try using a halocarbon desiccant the bond
between the desiccant and water is weaker than the bond between ammonia and
water. Besides, if you try doing this, you wont like the outcome because the liquid
ammonia will dissolve the desiccant, sending little bitty pieces of it down the liquid line
which plugs up everything. Been there.
Ammonia Remediators & Foul Gas Purgers
One way to remove water from ammonia is to use a batch remediator a tall, skinny vessel
with a couple of float switches and usually one or more belly-band resistance
heaters. "Weak aqua" is then manually drained out. If desired (or required), neutralize the
aqua with a little citric acid before sending it down a sewer. Ok, that takes care of getting
water out. Now how about air?
This is the purpose of a "foul gas" (non-condensable gas) purger remove collected air,
trapped during servicing. These two devices - a remediator and a purger make operating
an ammonia refrigeration system low side below atmospheric pressure feasible. It is not
uncommon to see a blast freezing line run at -60 F suction, which is 18.6 inches Hg
vacuum. This is not possible with any of the HFC halocarbons even minute quantities of
moisture + air + oil forms acids.
Evaporator Liquid Feed Methods
The three methods of supplying refrigerant to an evaporator are:
1. Direct-expansion (DX)
2. Liquid overfeed (via mechanical drive pump or controlled pressure receiver)
3. Gravity flooded recirculation (one surge drum required for each evaporator, gravity
handles all refrigerant circulation also known as "thermosiphons")
All three are commonly applied in industrial refrigeration using ammonia. No one method is
"better" than the other. Each has its best applications. Most systems have a mix of
evaporators "A dog from every town[4]".
Compressors
The major difference between the halocarbon series and ammonia with respect to
compressors has to do with the motor open drive versus hermetic. With only one
exception (Japan), all ammonia compressors are open-drive design due to the
incompatibility of copper and NH3.

The most commonly applied compressor design is twin rotary screw in todays industrial
marketplace. Reciprocating compressors are still applied and have an inherent advantage
of better part-load efficiency over a screw at off-load (slide valve positioned).
With only one exception that I am aware of, centrifugal compressors are not used with
ammonia. The low mol weight of the NH3 molecule (17) makes this particular refrigerant a
poor candidate for turbo compression which relies on a high density gas.
Another factor that distinguishes ammonia systems from their halocarbon counterparts has
to do with compressor capacity unloading. One of the most energy-wasteful practices ever
to come about in refrigeration is using hot gas bypass as a means of unloading a
compressor. When the hot gas bypass solenoid opens, hot gas is sent directly back into the
compressor suction. While effective at reducing system suction cfm, it does little or nothing
for a corresponding reduction in compressor energy use. Fortunately, hot gas bypass
cannot be applied to ammonia systems, unless it is injected into a side-inlet distributor and
then into a DX evaporator. Any attempt at sending compressor discharge vapor directly
back to suction will either shut the machine down on high oil temperature or high discharge
temperature (screw compressors) or blacken the discharge heads of a reciprocating
compressor. You may also coke up your compressor oil as well.
Condensers
Ive seen all three methods of heat rejection (to ambient) applied:
1. Air-cooled
2. Water-cooled
3. Evaporative-cooled
An air-cooled condenser is seldom used with ammonia. One system Im aware of, operating
at 0 psig suction (Tsat = -28 F), requires two stages of compression in order to reject heat
at 110 F condensing temperature. However, this system seldom sees hot days and the
regional water quality is low and difficult to obtain. Other than this system, I know of no
others using air-cooled heat rejection.
Evaporative cooled condensers are by far the most common, followed by water-cooled
condensers (with a cooling tower). Id say the percent ratio is ~1% with water-cooled
condensers (shell & tube design). All others (the vast majority) use evaporative condensers
selected for a 95 F maximum condensing temperature.
The removal of heat from a liquid at its boiling (saturation) temperature. This is no
different than a pan of water on your stove after youve turned the burner off. The only
variations are the temperatures involved. For example, that mug of coffee youre drinking
lets say its measured temperature is 120 F. To find the amount of subcooling your coffee
has, subtract its measured temperature from 212 F (boiling temperature at one standard
atmosphere). Answer: 92 F of liquid subcooling. This subcooling temperature can then be
used to find other data about handling a fluid near its boiling point, usually involving static
lift or pump NPSHA.
[1]

The < character in Eq 2 is necessitated by hot gas bypass as a means of compressor

capacity unloading.
[2]

[3]

IIAR

[4]

Source: Doug Reindl