REFRIGERATION

ENGINEERING
(MEC161)

SHAHANI T. LAGURA
Instructor
Applications of Refrigeration and Air Conditioning

Air Conditioning Refrigeration

Industrial
refrigeration,
Heating, Cooling and
including food
humidifying, dehumidifying
preservation,
and control of operations in
chemical, and
air quality air conditioning
process
industries

Figure 1. Relationship of the refrigeration and air-conditioning fields.

 Applications of Refrigeration and Air Conditioning
Air conditioning of medium-sized and large buildings
Industrial air conditioning
Spot Heating
Spot cooling
Environmental laboratories
Printing
Textiles
Precision parts and clean rooms
Photographic products
Computer rooms
Power plants
Residential air conditioning
Air conditioning of vehicles
Food storage and distribution
Food processing
Dairy products
Beverages
Chemical and process industries
…. And etc.
Thermodynamic Properties:

Temperature
Pressure Thermodynamic processes
Density and specific volume Heat transfer
Specific heat Conduction
specific heat (at constant volume) Cv Convection
specific heat (at constant pressure) Cp Radiation
Cp = 1.0 kJ/kg.K dry air
= 4.19 kJ/kg.K liquid water
= 1.88 kJ/kg.K water vapour
Enthalpy
Entropy

Perfect-gas Law
pv=RT p = absolute pressure, Pa
v = specific volume, m3/kg
R = gas constant
= 287 J/kg.K (for air)
= 462 J/kg.K (for water)
T = absolute temperature, K
 REFRIGERANTS

Halocarbon compounds
Inorganic compounds
Hydrocarbons
Azeotropes
MAIN REFRIGERATION SYSTEMS

The main goal of a refrigeration system which performs the

reverse effect of a heat engine is to remove the heat from a low-
level temperature medium (heat source) and to transfer this heat
to a higher level temperature medium (heat sink). Figure 2 shows
a thermodynamic system acting as a refrigeration machine. The
absolute temperature of the source is TL and the heat transferred
from the source is the refrigeration effect (refrigeration load) QL.
On the other side, the heat rejection to the sink at the
temperature TH is QH . Both effects are accomplished by the
work input W. For continuous operation, the first law of
thermodynamics is applied to the system.

Figure 2. A thermodynamic system acting as a refrigerator.

REFRIGERATION SYSTEM COMPONENTS
Major components of a vapor-compression refrigeration system:
1. Compressor
2. Condenser
3. Evaporator
4. Throttling device

In the selection of any component for a refrigeration system, there are a number of factors that need to be considered
carefully, including:
• maintaining total refrigeration availability while the load varies from 0 to 100%;
• frost control for continuous performance applications;
• variations in the affinity of oil for refrigerant caused by large temperature changes, and oil migration outside
the compressor crankcase;
• selection of cooling medium: (i) direct expansion refrigerant, (ii) gravity or pump recirculated or flooded
refrigerant, or (iii) secondary coolant (brines, e.g., salt and glycol);
• system efficiency and maintainability;
• type of condenser: air, water, or evaporatively cooled;
• compressor design (open, hermetic, semihermetic motor drive, reciprocating, screw, or rotary);
• system type (single stage, single economized, compound or cascade arrangement); and
• selection of refrigerant (note that the type of refrigerant is basically chosen based on operating temperature
and pressures).
REFRIGERATION SYSTEM COMPONENTS
1. COMPRESSORS
- has two main functions within the refrigeration cycle.
1. to pump the refrigerant vapor from the evaporator so that the desired temperature and pressure
can be maintained in the evaporator.
2. to increase the pressure of the refrigerant vapor through the process of compression, and
simultaneously increase the temperature of the refrigerant vapor.

- Also known as the heart of the vapor-compression refrigeration systems.

Figure 3. Compressor types (Heap, 1979).

REFRIGERATION SYSTEM COMPONENTS
Expectations from the compressors
The refrigerant compressors are expected to meet the following requirements:
• high reliability
• long service life
• easy maintenance
• easy capacity control
• quiet operation
• compactness
• cost effectiveness

Compressor selection criteria

In the selection of a proper refrigerant compressor, the following criteria are considered:
• refrigeration capacity
• volumetric flow rate
• compression ratio
• thermal and physical properties of the refrigerant.
REFRIGERATION SYSTEM COMPONENTS

Hermetic Compressors

A hermetic or sealed compressor is one in which both compressor and motor are confined in a single outer welded steel
shell. The motor and compressor are directly coupled on the same shaft, with the motor inside the refrigeration circuit. Thus
the need for a shaft seal with the consequent refrigerant leakage problem was eliminated. All the refrigerant pipeline
connections to the outer steel shell are by welding or brazing. The electrical conductors to the motor are taken out of the
steel shell by sealed terminals made of fused glass. Hermetic compressors are ideal for small refrigeration systems, where
continuous maintenance (replenishing refrigerant and oil charge etc) cannot be ensured. Hence they are widely used in
domestic refrigerators, room air conditioners etc. Since, the motor is in the refrigerant circuit, the efficiency of hermetic
compressor based systems is lower as the heat dissipated by the motor and compressor becomes a part of the system load.
REFRIGERATION SYSTEM COMPONENTS

Semihermetic Compressors

a. b.

Semihermetic reciprocating compressors. (a) Single stage. (b) Two stage (Courtesy of Bitzer K¨uhlmaschinenbau GmbH ).

In larger sizes, refrigeration compressors are often semihermetic, that is, although motor and compressor are
within one casing, this casing may be unbolted, and the refrigerant does not flow over the motor windings. Access for
maintenance is straightforward, but the need for external motor cooling which aids efficiency in cooling applications is no
advantage in refrigeration operations, and the cost is substantially higher than for hermetic units.
These compressors (single or double acting) were developed to avoid the disadvantages of the hermetic
compressors. Semihermetic compressors are identical to the hermetic types, but the motor and compressor are constructed
in a fabricated enclosure with bolted sections or access panels to facilitate servicing. These compressors are manufactured
in small and medium capacities and their motor capacities can reach 300 kW. For this reason they are cheap and another
advantage is that they are compact. Also, they do not have a leakage problem.
REFRIGERATION SYSTEM COMPONENTS

Open Compressors

Open reciprocating compressors with a shaft seal and an external drive motor suitable for a range of prime
movers are also available up to about 2 MW duty (e.g., compressor in the condensing unit). In these
compressors, the crankshafts, which are externally coupled with electric motors, extend through the
compressor housings. Appropriate seals must be used where the shafts come through the compressor
housings to prevent refrigerant gas from leaking out or air from leaking in (when the crankcase pressure is
lower than atmospheric pressure). In order to prevent leakage at the seal, the motor and compressor are
rarely enclosed in the same housing.
REFRIGERATION SYSTEM COMPONENTS

Displacement Compressors
These compressors use the shaft work to increase the refrigerant pressure by reducing the
compression volume in the chamber. The compressors of this group are reciprocating, vane
(rotary), and screw (helical rotary) compressors.

Reciprocating Compressors

(a) Open type reciprocating compressor and (b) air-cooled condensing unit with an open type reciprocating compressor
(Courtesy of Bitzer K¨uhlmaschinenbau GmbH ).
 Energy and Exergy Analyses of Compressors

Conservation of mass principle requires that:

Energy and Exergy Analyses of Compressors
Energy and Exergy Analyses of Compressors
Energy and Exergy Analyses of Compressors

The compression ratio is defined as the ratio of discharge pressure to suction pressure at saturated conditions,
expressed in absolute terms, for example, Pa or kPa.
Energy and Exergy Analyses of Compressors

The performance of a compressor is influenced by numerous parameters including the following:

• compressor speed
• suction pressure and temperature
• discharge pressure and temperature
• type of refrigerant and its flow rate.

The compressor isentropic efficiency:

Energy and Exergy Analyses of Compressors

EXAMPLE
REFRIGERATION SYSTEM COMPONENTS

2. CONDENSERS
- There are several condensers to be considered when making a selection for installation. They are air-cooled,
water-cooled, shell and tube, shell and coil, tube within a tube, and evaporative condensers. Each type of
condenser has its own unique application. Some determining factors include the size and the weight of the unit,
weather conditions, location (city or rural), availability of electricity, and availability of water.

Selection of condenser type depends on the following criteria:

• condenser heat capacity
• condensing temperature and pressure
• the flow rates of refrigerant and coolant
• design temperature for water and/or air
• operation period, and
• climatic conditions.
REFRIGERATION SYSTEM COMPONENTS

Condensers utilized in the refrigeration industry are commonly of three types, as follows:
• water-cooled condensers
• air-cooled condensers, and
• evaporative condensers.

Water-Cooled Condensers

Various water-cooled condensers (Courtesy of Standard Refrigeration Company).

REFRIGERATION SYSTEM COMPONENTS

If a water-cooled condenser is used, the following criteria must be examined:

• requirement of cooling water for heat rejection

• utilization of a cooling tower if inexpensive cooling water is available
• requirement of auxiliary pumps and piping for recirculating cooling water
• requirement of water treatment in water recirculation systems
• space requirements
• maintenance and service situations, and
provision of freeze protection substances and tools for winter operation.

Air-Cooled Condensers
The air-cooled condensers find applications in domestic, commercial, and industrial refrigerating, chilling,
freezing, and air-conditioning systems with a common capacity of 20−120 tons. The centrifugal fan air-cooled
condensers (with a capacity of 3−100 tons) are particularly used for heat recovery and auxiliary ventilation
applications. In fact, they employ outside air as the cooling medium. Fans draw air past the refrigerant coil and the
latent heat of the refrigerant is removed as sensible heat by the air stream.
REFRIGERATION SYSTEM COMPONENTS

The advantages of air-cooled condensers are the following:

• no water requirement
• standard outdoor installation
• elimination of freezing, scaling, and corrosion problems
• elimination of water piping, circulation pumps, and water treatment,
• low installation cost, and
• low maintenance and service requirement.

On the other hand, they have some disadvantages as given below:

• high condensing temperatures

• high refrigerant cost because of long piping runs
• high power requirements per kW of cooling A typical air-cooled condenser (Courtesy of Trane Company).
• high noise intensity, and
• multiple units required for large-capacity systems.
REFRIGERATION SYSTEM COMPONENTS
Evaporative Condensers
- Evaporative condensers are apparently water-cooled
designs and work on the principle of cooling by
evaporating water into a moving air stream. The
effectiveness of this evaporative cooling process
depends upon the wet-bulb temperature of the air
entering the unit, the volume of airflow, and the
efficiency of the air/water interface.

- Evaporative condensers use water sprays and airflow to

condense refrigerant vapors inside the tubes. The
condensed refrigerant drains into a tank called a liquid
receiver. Refrigerant subcooling can be accomplished by
piping the liquid from the receiver back through the water
sump where additional cooling reduces the liquid
temperature even further. (a) An evaporative condenser. (b) A counter-flow cooling tower
(Courtesy of Baltimore Aircoil International).
REFRIGERATION SYSTEM COMPONENTS
The following are some characteristics of these condensers:

• reduced circulating water for a given capacity,

• water treatment is necessary,
• reduced space requirement,
• small piping sizes and short overall lengths,
• small system pumps, and
• availability of large-capacity units and indoor configurations.
 Energy and Exergy Analyses of Condensers

Condensers are used to reject heat from a refrigeration system. In a vapor-compression refrigeration cycle, the
refrigerant is cooled and condensed as it flows in the condenser coils. The conservation of mass principle requires
that:

Referring to Figure (b). Assuming that heat exchanger

is insulated, the energy balance in this case becomes

The schematic of condensers considered for mass and energy analysis.

(a) Air-cooled condenser. (b) Water-cooled condenser.
The rate of heat rejected to water is:
The steady-flow energy balance can be written as (with negligible
kinetic and potential energies):
Energy and Exergy Analyses of Condensers

Referring to figure (a), an entropy balance on the condenser may be written as:
Energy and Exergy Analyses of Condensers
Energy and Exergy Analyses of Condensers

If we consider Figure (b), for the operation of an evaporator, an entropy balance may be written as:

EXAMPLE
REFRIGERATION SYSTEM COMPONENTS

3. EVAPORATORS
Evaporator can be considered as the point of heat capture in a refrigeration system and provides the cooling effect
required for any particular application. There are almost as many different types of evaporators as there are
applications of heat exchangers. However, evaporators are divided into two categories such as:
(i) direct cooler evaporators that cool air that, in turn, cools the product and
(ii) indirect cooler evaporators that cool a liquid such as brine solution that, in turn, cools the product.

In practice, the following evaporators are commonly used for cooling, refrigerating, freezing, and air-conditioning
applications:
• liquid coolers
• air coolers, and/or gas coolers.
REFRIGERATION SYSTEM COMPONENTS

Liquid Coolers

Some example applications in food and

refrigeration industry are:
• chilling of drinkable water
• chilling of water for air-
conditioning coils,
• chilling of milk after
A shell-tube type evaporator (Bejan, 2004).
pasteurization, and
• process cooling operations.
REFRIGERATION SYSTEM COMPONENTS

Air and Gas Coolers

These coolers are generally called direct
expansion coils and consist of a series of
tubes through which refrigerant flows.
- The tubes, which are finned to increase the
heat-transfer rate from the medium to be
cooled (e.g., air) to the boiling point, are
normally arranged into a number of parallel
circuits fed from a single throttling valve. The Air coolers. (a) Room type. (b) Large-scale industrial type (Courtesy of Super
Radiator Coils).
hot refrigerant vapor is accumulated in the
outlet (suction) gas header. These direct
expansion coils are used only in the positive
displacement compressor systems, owing to
quite low-pressure ratios.
Energy and Exergy Analyses of Evaporators

Evaporators are used to absorb heat

from the refrigerated space. In a
vapor-compression refrigeration
cycle, the refrigerant is evaporated as
it flows in the evaporator coils. The
conservation of mass principle
requires that:
The schematic of evaporators considered for mass and energy analysis.
(a) Refrigerant absorbing heat from a space. (b) Refrigerant absorbing
heat from water.

Referring to Figure (a), energy is entering and leaving by the refrigerant stream and heat is absorbed from the cooled
space, (Q˙in or Q˙ L). The steady-flow energy balance can be written as (with negligible kinetic and potential energies)
Energy and Exergy Analyses of Evaporators

Figure (b) shows a heat exchanger operating as an evaporator in which

water is cooled as the refrigerant is evaporated. Assuming that heat
exchanger is insulated, the energy balance in this case becomes:
Energy and Exergy Analyses of Evaporators
Energy and Exergy Analyses of Evaporators
Energy and Exergy Analyses of Evaporators

EXAMPLE
Energy and Exergy Analyses of Evaporators
Energy and Exergy Analyses of Evaporators
REFRIGERATION SYSTEM COMPONENTS

4. THROTTLING DEVICES
In practice, throttling devices, called either expansion valves or throttling valves, are used to reduce the
refrigerant condensing pressure (high pressure) to the evaporating pressure (low pressure) by a throttling
operation and regulate the liquid-refrigerant flow to the evaporator to match the equipment and load
characteristics. These devices are designed to proportion the rate at which the refrigerant enters the cooling
coil to the rate of evaporation of the liquid refrigerant in the coil; the amount depends, of course, on the
amount of heat being removed from the refrigerated space.

The most common throttling devices are:

• thermostatic expansion valves
• constant-pressure expansion valves
• float valves, and
• capillary tubes.

An electronic expansion valve (Courtesy of Danfoss A/S ).

Energy and Exergy Analyses of Throttling Devices

Throttling devices are used to decrease pressure of a fluid. In a vapor-compression refrigeration cycle, the refrigerant
enters the throttling valve as a liquid and leaves as a saturated liquid–vapor mixture. The conservation of mass principle
requires that:

The schematic of a throttling valve considered for mass and energy analysis.

Energy is entering and leaving by the refrigerant stream. Heat transfer with the surroundings is negligible and
there is no work interaction. Then the steady-flow energy balance can be written as (with negligible kinetic and
potential energies)
EXAMPLE
REFRIGERATION SYSTEM COMPONENTS

Auxiliary Devices
Accumulators
Receivers
Oil Separators
Strainers
Driers
Check Valves
Solenoid Valves
Defrost Controllers