DESIGN AND ANALYSIS OF LOW

TEMPERATURE REFRIGERATION
SYSTEM
1

Presented By:
Suman Pathak

Department of Mechanical Engineering, Kathmandu University, Dhulikhel

May, 2022
2 WHY THIS?

Image Source: https://www.who.int/

Figure: Different vaccines with it’s storing temperature
3 OBJECTIVES
 To design and analyze low temperature refrigeration system
 To recommend the best thermofluidic mechanism.
 To design the components of the system
 LOW TEMPERATURE REFRIGERATION
SYSTEM
4  Used to achieve a low temperature(-60°C to -90°C) in evaporator.

 Consist of two refrigeration cycles(high temperature cycle and low

temperature cycle).

 Two cycles are connected by cascade chamber which consist of

evaporator of high temperature cycle and condenser of low temperature
cycle.
 SCOPES

 Pharmaceutical Sector
5  Biological storage
 Metallurgical testing
Image Source: https://www.freon.com/

Fig: A woman taking Fig: Freezer for Fig: Ultra low temperature
vaccine from freezer metallurgical testing freezer for small size
 COMPONENTS
 Compressor
6  Oil Separator
 Condenser
 Receiver Tank
 Filter Drier
 Throttle Valve/ Expansion valve
 Solenoid Valve
 Evaporator
 Cascade chamber
7 WORKING MECHANISM
For low temperature
circuit:
Process (1-2): Low side refrigerant is compressed isoentropically
and increases the temperature and pressure.
Process (2-3): Here, the refrigerant heat is exchanged to the high
side cascade evaporator this reduces the temperature and pressure
remains constant.
Process (3-4): Here, it reduces the pressure as well as the
temperature and then it is passed through evaporator where
refrigeration effect is to be produced
Process (4-1): Heat is added to a evaporator from a cold Fig: Cascade Refrigeration
system
refrigerated space.
Cont…

8
For high temperature circuit:

Image Source: Thermodynamics: An Engineering Approach 8th

Process (5-6): Higher stage refrigerant coming from the
evaporator is compressed isentropically.
Process (6-7): Then it is passed to a condenser where the

Edition by Yunus Cengel, Michael Boles

temperature reduces and pressure remains constant.
Process (7-8): Refrigerant is passed through an expansion valve
where pressure reduces as well as temperature.
Process (8-5): Further it is passed though cascade evaporator
where it absorbs the heat from the cascade condenser and thus
liquid R-134a gets evaporated and ready to be compressed Fig: Cascade Refrigeration
system
 11
T-S DIAGRAM

Fig: TS diagram for cascade refrigeration system

Image Source: Thermodynamics: An Engineering Approach 8th

Edition by Yunus Cengel, Michael Boles
 METHODOLOGY
12

Cooling Space design Cycle design and

Component design
and Refrigeration cooling load
and Selection
selection calculation

Research and Calculation Using the EES software Optimization using Iterative
process
13
SPECIFIC DESIGN FEATURE COOLING
SPACE
Evaporator Section Design

• Cold room with refrigerated space of 8*8*8

ft is designed,
• Polyurethane is used as insulating material,
• Lamination of Pre-Painted galvanized
Iron(PPGI) is used to laminate the room,
• Overlapped(hinged) door is used,
• 1300 Kg of vaccines are considered to be
Fig: Preliminary 3D design of cold room
stored in this section. storing vaccine inside boxes
 14
SELECTION OF REFRIGERANT
Source: Modern refrigeration and air conditioning by Andrew D. Althouse and

 Refrigerants are selected on the basis of properties like flammability, toxicity

and GWP.
Carl H. Turnquist

Table: Some refrigerants with their GWP

15
SELECTED REFRIGERANT
R134a (High temperature circuit)
 Boiling point -26.3oC
 Environment friendly in comparison to R-12
 Market friendly

R508b (Low temperature circuit)

 Boiling point -87.4oC
 Selected over R503 and R23
 Since, the another best alternative Co2 solidifies at temperature below -70oC
which block the flow of refrigerant
16 CYCLE DESIGN
After the calculation in EES software we found following data to proceed cycle design.

Properties Result for HTC Result for LTC

Refrigerant R134A R508B

COP 3.676 1.969

Qin 138.8 KJ/Kg 84.32 KJ/Kg

Qout -176.5 KJ/Kg 127.1 KJ/Kg

37.75 KJ/Kg 42.83 KJ/Kg

W
Table: Expansion Valve properties
17
COOLING LOAD CALCULATION
Cooling load is the rate at which heat must be removed from the evaporator space to
maintain a constant temperature.

 Transmission Load: Heat transfer through 35.72m2 area, insulated with

polyurethane foam and PPGI lamination.
 Product Load: 2 lacs doses of vaccine equivalent to 1300kg .
 Internal Load: Load generated by two people for an hour per day.
Cont…
18
 Lighting Load: Load due to four lighting bulbs of 40W for 3 hours a
day.
 Equipment Load: Heat load from three fans of 200W for 20 hours a day.
 Defrosting: Heat load due to defrosting process.
 Infiltration Load: Load due to warm air entry when doors, window and
walls opens or deforms.

Refrigeration capacity of 6.8 KW was obtained after taking safety

factor in account.
19 COMPONENT DESIGN AND
Component CALCULATION
Description For HTC For LTC
• Low back pressure(LTC)
Compressor • Medium back pressure(HTC) Size= 8.18 KW Size= 6.8KW
• Hermetic compressor
• Copper tubes
Condenser • External diameter =12.7 mm Length= 48.4m Length= 66.3m
• Internal diameter=10.9 mm

• Copper tubes
Overall length Overall length=
Evaporator • External diameter =12.7 mm
= 64.7m 65m
• Internal diameter= 10.9 mm

Table: Calculated data for components

20
CASCADE CHAMBER
 Water is used as a heat transfer medium.
 Anti freezing agent like ethylene glycol is added to water.

THROTTLE/EXPANSION VALVE
 Standard part are selected based on
properties and use.
 Use of external equalizer to transmits the
pressure at the outlet of the evaporator-to
the inside of the bellows of the expansion
valve. Figure: Expansion valve with external equilizer
21
SELECTION OF EXPANSION VALVE

Properties Valve for HTC Valve for LTC

Product Code 068Z3393 (Danfoss) 9761-2/027770
(ZZ Ultra low temp)
Maximum Working 34 bar 31 bar
Pressure
Body and Connection Brass Brass
material
Temperature Range -40°C to -5°C -70°C to -90°C
Inlet Size 3/8 in ½ ODF
Outlet size ½ in 5/8 ODF

Table: Expansion Valve properties

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THANK YOU!!!
An y q u eries ?