REFRIGERATION

DEFINITIONS AND USEFUL INFORMATION

 Refrigeration is a branch of science that deals with the process of reducing and maintaining
the temperature of a space or material below the temperature of the surroundings.
 Refrigeration is used to describe thermal systems that maintain process space or material
at a temperature less than available from ambient conditions.
 Joule-Thomson Effect is expansion of liquid into mixture of liquid and vapor at constant
enthalpy.
 Condensers are high-pressure vapor heat exchangers.
 Evaporators are low-pressure vapor heat exchangers.
 Expansion valves or capillaries are throttling devices that transport refrigerant from high-
pressure condition (condenser) to low-pressure condition (evaporator).
 Compressors are pressure-raising devices.
 Coefficient of Performance (COP) is defined as refrigerant effect divided by network input,
where the refrigerant effect is the absolute value of the heat transferred from the lower
temperature source, and the network input is the absolute value of the heat transferred to
the higher temperature sink minus this refrigerant effect.
 COP is also defined as the ratio calculated by dividing the total heating capacity in Btu/hr
provided by the refrigeration system, including fan heat, but excluding supplementary
resistance, by the total electric input in watts times 3.412. This definition applies primarily to
heat pumps.
 Energy Efficiency Ratio (EER) is a ratio calculated by dividing the cooling capacity in Btu/hr
by the power input in watts and any set of rating conditions, expressed in Btu/Watt-hr. It is
also defined as the amount of heat removed from the cooled space in Btu for one Watt-
hour of electricity consumed.

 EER could be expressed in terms of COP with the following equation:
Useful Re frigerating Effect,Btu / Hr
EER   COP  3.412 
Net Energy Input, W

Where, 1 Watt = 3.412 Btu/hr

 Seasonal Energy Efficiency Ratio (SEER) is the anticipated performance of a refrigerating

device over an average season, used primarily for residential and commercial air
conditioning; it also expressed in Btu/kW-hr.
 Heating Season Performance Factor (HSPF) is the anticipated performance of a heat pump
device during heating season, primarily used for residential and commercial heat pump;
expressed in Btu/kW-hr.
 Reversed Cycle – is a system that receives heat from a colder body and delivers heat to a
hotter body, not in violation of the Second Law of thermodynamics, but by virtue of work
input.
 Refrigeration cycle – is a reversed cycle whose objective is to extract heat from the low
temperature reservoir.

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  Heat pump – is a reversed cycle whose objective is to supply energy to the high
temperature reservoir.
 Standard Rating of a refrigeration machine, using a condensable vapor, is the number of
standard TR it can produce under the following conditions:
 Liquid only enters the expansion valve and vapor only enters the compressor or the
absorber of an absorption system;
 The liquid entering the expansion valve is sub-cooled at 9 oF (5 oC) and the vapor
entering the compressor or absorber is superheated at 9 oF (5 oC), these temperatures
to be measured within 10 ft (3.05 m) of the compressor cylinder or absorber;
 The pressure at the compressor or absorber inlet corresponds to a saturation
temperature of 5 oF (-15 oC);
 The pressure at the compressor or absorber outlet corresponds to a saturation
temperature of 86 oF (30 oC).
 British Unit of Refrigeration – corresponds to a heat absorption rate of 237.6 Btu/min (4.175
kW) with inlet and outlet pressures corresponding to saturation temperature of 23 oF (-5 oC)
and 59 oF (15 oC), respectively.
 KW – the unit to specify refrigeration loads, as standard practice in Europe.
 Frigorie – the unit of refrigeration capacity, occasionally used in Europe. 1 Frigorie = 50
Btu/min = 0.8786 kW; 1 Frigorie = 0.25 x std TR.

METHODS OF REFRIGERATION
1. Ice Refrigeration
 A refrigeration method of lowering and maintaining the temperature of a material or
space by the use of a literal ice (water or other substance, say, dry ice).
2. Mechanical Refrigeration
 A method of refrigeration using mechanical components composing a system known as
vapor-compression refrigeration system.
3. Absorption Refrigeration
 A method of refrigeration through the use of a system or cycle known as Absorption
Refrigeration System or Cycle.
4. Steam Jet or Vacuum Refrigeration
 A method of refrigeration system using water as refrigerant; lowering and maintaining of
system temperature is attained by creation of vacuum condition through the action of
steam jet.
5. Air Cycle Refrigeration
 A method of refrigeration using air as refrigeration; the system is normally called as Air
Cycle Refrigeration system.

APPLICATIONS OF REFRIGERATION
 The following are some of the common applications of refrigeration:
1. Food preservation
2. Ice making
3. Air conditioning for summer comfort
4. Industrial Applications
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 o Examples are: Making “cold rubber”, to improve wearing quality; Oil refinery processes;
Treatment of steel; and Manufacture of chemicals
5. Cryogenics – very low temperature refrigeration
6. Heat pump – heating the building

UNITS AND CONSTANT

o Units of Force
1 kgf = 9.8066 N 1 lbf = 4.4484 N 1 lbf = 0.4536 kgf

o Units of Pressure
1 Pa = 1 N/m2 1 Atm = 101.325 kPa 1 Bar = 100 kPa
1 Atm = 1.033 kgf /cm2 1 psi = 6895 Pa 1 Atm = 14.699 psi

o Units of Energy and Work

1 Joule = 1 N-m 1 Cal. = 4.187 J 1 Btu = 252 Cal = 1055 Joules

o Units of Power
1 Watt = 1 J/s 1 Hp = 0.746 kW = 42,4 Btu/min
o Gas Constant
Air, R = 0.28708 kJ/kg-oK Water, R = 0.4615 kJ/kg-oK

UNIT OF REFRIGERATION CAPACITY

 Ton of Refrigeration (TR) – is the rate of cooling required to freeze one ton of water at 32 oF
into ice at 32 oF in one day or 24 hours.
 1 TR = (2000 lb) (144 Btu/lb) / (24 hr) = 12000 Btu/hr = 200 Btu/min
 1 TR = (12000 Btu/lb) (252 Cal/Btu) = 3024 kCal/Hr = 50.4 kCal/min
 1 TR = (200 Btu/min) (1055 J/Btu) = 211 kJ/min = 3.516 kW

PROPERTIES OF WATER
 Specific heat of liquid water, Cp = 4.187 kJ/kg-oK = 1.0 Btu/lb-oR
 Specific heat of ice water, Cpi = 2.0935 kJ/kg-oK = 0.5 Btu/lb-oR
 Specific heat of water vapor (steam), Cp = 1.88 kJ/kg-K
 Latent heat of evaporation, hfg = 2257 kJ/kg = 970.3 Btu/lb
 Latent heat of fusion of ice, hi = 335 kJ/kg = 144 Btu/lb

STANDARD REFRIGERATION CYCLE

 The following temperatures standard design temperature conditions are applicable for a vapor-
compression refrigeration system
 Evaporation temperature 5 oF = - 15 oC
 Condensing temperature 86 oF = 30 oC

ICE REFRIGERATION
 Diagram below, Figure 1.1, represents the transformation of ice into liquid; to determine the
amount cooling provided by the ice to the material in ice refrigeration.

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Figure 1. Ice Refrigeration
t1 tf = 0 o C t2

Ice Solid Liquid Water

 Amount of Cooling Provided by the ice

q = m c pi (t f - t 1 ) + m h i + m c pw (t 2 - t f )
Where, cpi = specific heat of ice, kJ/kg-oK, Btu/lb-oR cpi = 2.0935 kJ/kg-oK =
o
0.5 Btu/lb- R
cpw = specific heat of liquid water, kJ/kg-oK, Btu/lb-oR cpw = 4.187 kJ/kg-oK = 1.0
Btu/lb-oR
hi = heat of fusion of ice, kJ/kg, Btu/lb hi = 335 kJ/kg = 144 Btu/lb-oR

REVERSED CARNOT CYCLE/ENGINE OR CARNOT REFRIGERATION SYSTEM

 Figure 12 below represents the schematic diagrams, and Figure 1.3 represents the Ts diagram
of reversed Carnot cycle/engine or Carnot Refrigeration System.

Figure 2. Schematic Diagram, Carnot Refrigeration System

QR High-
temperature
Condenser QH
Reservoir, TH
Reversed W

Expander W Carnot Engine

QL
Evaporator Low-
Compresso
4
temperature
QA r
Reservoir, TL
Figure 3. Ts Diagram, Carnot Refrigeration Cycle

T
TH 3 2

TL
4 1

s4 = s 3 s2 = s 1 s

 From Figure 1.3, the processes that composed the Carnot refrigeration cycle are as
follows:
o 1 – 2: Adiabatic or Isentropic Compression Process (S = C)
o 2 – 3: Isothermal Heat Rejection Process (TH = C)
o 3 – 4: Adiabatic or Isentropic Expansion Process (S = C)
o 4 – 1: isothermal Heat Addition Process (TL = C)

VAPOR-COMPRESSION REFRIGERATION SYSTEM

 Figure 4 illustrates the schematic diagram of Vapor-compression Refrigeration Cycle

Figure 4. Vapor-Compression Refrigeration QR

Condenser

Expansion

Valve W

Evaporator
Compresso
QA r

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  Basic Components of Vapor-Compression Refrigeration System
1. Compressor – a component used to compress refrigerant vapor that causes the
refrigerant to flow in the system
2. Condenser – a component that condenses refrigerant vapor while rejecting heat to a
cooling medium (either air or water).
3. Expansion Valve – a component that reduces the pressure of the refrigerant in order to
attain low temperature condition in the evaporator.
4. Evaporator – a component used to evaporate liquid refrigerant while absorbing heat
from the surrounding.

Figure 5. ph & Ts Diagrams of Vapor-compression Refrigeration

2
p T
3 p=C 2
T=C 3

p=C T=C
4 1 4 1
s
h

 Processes
 Process 1-2: Reversible and adiabatic compression from saturated vapor to the
condenser pressure (s = C)
 Process 2-3: Reversible rejection of heat at constant pressure, de-superheating and
condensation of refrigerant.
 Process 3-4: Irreversible expansion at constant enthalpy, from saturated liquid to the
evaporator pressure.
 Process 4-1: Reversible addition of heat at constant pressure in the evaporator to
saturated vapor.

COMPRESSORS
 Compressor is one of the four essential components of the compression refrigeration system;
others components include the condenser, evaporator, and expansion device. The compressor
circulates refrigerant through the system in a continuous cycle.

Basic Types of Compressors

1. Positive Displacement Compressors
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 o These compressors increase the pressure of the refrigerant vapor by reducing the volume.
o Examples: Reciprocating compressors; Rotary compressors (rolling piston, rotary vane,
single-screw, and twin-screw); Scroll compressors; Trochoidal compressors.
2. Dynamic Compressors
o These compressors increase the pressure of refrigerant vapor by a continuous transfer of
angular momentum to the vapor from the rotating member followed by a conversion of this
momentum into a pressure rise.
o Centrifugal compressors are of this type.

Positive-Displacement Compressors Performance

o Compressor performance is the result of design compromises involving physical limitations
of the refrigerant, compressor, and motor, while attempting to provide the following:
 Greatest trouble-free life expectancy
 Most refrigeration effect for the least power input
 Lowest applied cost
 Wide range of operating conditions
 Acceptable vibration and sound level

Ideal Compressor
o The capacity of a compressor at a given operating condition is a function of the mass of
gas compressed per unit time. Ideally, the mass flow is equal to the product of the
compressor displacement per unit time and the gas density.

Actual Compressor Performance

o Actual compressor performance deviates from ideal performance because of various
losses, with a resulting decrease in capacity and an increase in power input.
o Depending on the type of compressor, some or all of the following factors can have a major
effect on compressor performance.
1. Pressure drops within the compressor unit
 Through shutoff valves (suction, discharge, or both)
 Across suction strainer/filter
 Across motor (hermetic compressor)
 In manifolds (suction and discharge)
 Through valves and valve ports (suction and discharge)
 In internal muffler
 Through internal lubricant separator
 Across check valves
2. Heat gain to refrigerant from
 Hermetic motor
 Lubricant pump
 Friction
 Heat of compression; heat exchange within compressor
3. Valve inefficiencies due to imperfect mechanical action
4. Internal gas leakage
5. Oil circulation

6. Re-expansion.

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 The volume of gas remaining in the compression chamber after discharge, which re-
expands into the compression chamber during the suction cycle, and limits the mass
of fresh gas that can be brought into the compression chamber.
7. Deviation from isentropic compression.
 The compression cycle deviates from isentropic compression primarily because of
fluid and mechanical friction and heat transfer within the compression chamber. The
actual compression process and the work of compression must be determined from
measurements.
8. Over- and under-compression.
 In fixed volume ratio rotary, screw, and orbital compressors, over-compression
occurs when pressure in the compression chamber reaches discharge pressure
before reaching the discharge port, and under-compression occurs when the
compression chamber reaches the discharge port prior to achieving discharge
pressure.

Protective Devices
o Compressors are provided with one or more of the following devices for protection against
abnormal conditions and to comply with various codes.
1. High-pressure protection as required by Underwriters Laboratories and per ARI standards
and ANSI/ASHRAE Standard 15, Safety Code for Mechanical Refrigeration. This may
include the following:
a. A high-pressure cutout.
b. A high- to low-side internal relief valve, external relief valve, or rupture member
c. A relief valve assembly on the oil separator of a screw compressor unit.
2. High-temperature control devices to protect against overheating and oil breakdown.
a. Motor over temperature protective devices.
b. To protect against lubricant and refrigerant breakdown, a temperature sensor is
sometimes used to stop the compressor when discharge temperature exceeds safe
values. The switch may be placed internally (near the compression chamber) or
externally (on the discharge line).
c. On larger compressors, cooling with either a heat exchanger or direct liquid injection
controls lubricant temperature, or the compressor may shut down on high lubricant
temperature.
d. Where lubricant sump heaters are used to maintain a minimum lubricant sump
temperature, a thermostat may be used to limit the maximum lubricant temperature.
3. Low-pressure protection may be provided for
a. Suction gas
 Many compressors or systems are limited to a minimum suction pressure by a
protective switch. Motor cooling, freeze-up, or pressure ratio usually determined the
pressure setting.
b. Compressor
 Lubricant pressure protectors are used with forced feed lubrication systems to
prevent the compressor from operating with insufficient lubricant pressure.
4. Time delay, or lockouts with manual resets, prevents damage to both compressor motor
and contactors from repetitive rapid-starting cycles.
5. Low voltage and phase loss or reversal protection is used on some systems.
 Phase reversal protection is used with multi-phase devices to ensure the proper
direction of rotation.

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 6. Suction line strainer
 Most compressors are provided with a strainer at the suction inlet to remove any dirt
that might exist in the suction line piping. A suction line strainer is normally required in
all field-assembled systems.

Types of Refrigeration Compressors

1. Reciprocating Compressor
o It is a compressor that consists of one or more piston and cylinder combinations. The
piston moves in reciprocating motion to draw the suction gas into cylinder on one stroke
and to compress and discharge it to the condenser on the return stroke.
2. Centrifugal Compressor
o It is a compressor that has a single or multi-stage high-speed impeller to set up enough
centrifugal force within a circular casing to raise the pressure of the refrigerant gas to
condensing level.
3. Rotary Sliding-Vane Compressor
o It is a positive displacement compressor that traps a given volume of gas, compresses
it, and ejects from the machine. It usually has a rotor revolving off-center in a cylinder
with sliding vanes forced against the cylinder wall. Refrigerant gas is compressed by the
sliding vanes around the cylinder from suction port to the discharge port.
4. Rotary Screw Compressor
o This compressor is another positive displacement compressor, and was first used for
refrigeration in the late 1950s.
o The compressor basically consists of two mating helically grooved rotors, a male (lobes)
and female (grooves), in a stationary housing with suction and discharge ports.

Types of Halocarbon Reciprocating Compressor

1. Open-type Compressor
 It is a compressor with crankshaft extended through the compressor housing in which
the motor is externally coupled to the shaft.
 Ammonia compressors are manufactured only in the open-type design.
2. Hermetic Compressor
 It is a compressor in which the motor and compressor are contained within the same
pressure vessel with the motor shaft as part of the compressor crankshaft, and with the
motor in contact with the refrigerant.
 Two types of hermetic compressor are as follows:
a) Semi-hermetic, Accessible, or Serviceable Hermetic Compressor
o It is of bolted construction capable of field repair, in which the cylinder head can
be removed for servicing of the valves and pistons
b) Welded-shell (sealed) Hermetic Compressor
o It is the one in which the motor-compressor is mounted inside a steel shell that in
turn is sealed by welding
 An ideal reciprocating compressor is assumed to operate in a reversible adiabatic manner;
pressure losses in the valves, intake, and exhaust manifolds are neglected.

Horizontal Double-Acting Compressor

o This compressor is a single- or two-cylinder reciprocating compressor usually directly
connected to a steam engine or slow-speed synchronous motor. The compressor is a very
ragged type one.
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  The pistons reciprocate in the cylinders in a horizontal plane. Suction and discharge
ports are provided at each end of the cylinder and pumping is done in every stroke of
the piston in each direction.

Vertical Single-Acting Compressor

o Vertical single-acting compressor is a reciprocating machine, most commonly built in two-,
three-, or four-cylinder combinations with medium rotative speeds, from 600 rpm in the
smaller sizes to 300 rpm in the larger sizes.
 The crankshaft converts the rotary motion of the flywheel into a reciprocating motion to
operate the pistons in a vertical plane. The pistons draw the suction gas into the
cylinders on the down stroke and compress it to discharge pressure on the upward
stroke.
V or VW Compressors
o These compressors are types of single-acting reciprocating compressors with cylinders and
pistons arranged in V, W, or VV patterns; and may have as many as 16 cylinders for single
compressors.
o These are high-speed compressors, often direct-connected to the shaft of the driving
motor. Common speed of the compressor is 1750 rpm.

Angle Compressor
o Angle compressor is a compressor using one or more cylinder, usually driven by an internal
combustion engine whose pistons and connecting rods are connected to the same
crankshaft.
 One set of cylinders operates in a horizontal plane and the other in a vertical plane.

ROTARY COMPRESSORS
 In these compressors, the working fluid enters the compressor at low pressure moving into a
set of rotating blades, from which it exits at high velocity, a result of the shaft input to the fluid.
The fluid then passes through a diffuser, in which it is decelerated in a manner that results in a
pressure increase. The fluid then exits the compressor at high pressure.
 These machines are characterized by the circular or rotary motion as opposed to reciprocating
motion.
 The positive displacement compression process is non-reversing and either continuous or
cycloidal, depending on the mechanism employed.
 Most of rotary compressors are direct-drive machines.
 Two common types of rotary compressors, namely: the rolling-piston type; and the rotating-
vane type. These two machines are very similar with respect to size, weight, thermodynamic
performance, field of greatest applications, and range of sizes, durability, and sound level.
 Rotary compressor has high volumetric efficiency because of its small clearance volume and
corresponding low re-expansion loss.
 Rotary-vane compressors have a low weight-to-displacement ratio, which in combination with
their small size makes them suited to transport applications.

Single-Screw Compressors
o These machines consist of a single cylinder main rotor that works with a pair of gate-rotors.
o Single-screw compressors are most often used in the liquid injection mode, where sufficient
liquid cook and seals the compressor.
o The compressors operate with pressure ratios above 20 in single stage.
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 o Single-screw compressors are available in capacities from 20 to 1300 TR.

Double Helical Rotary (Twin-Screw) Compressor

o This compressor belongs to the broad class of positive displacement compressors.
o It was first introduced to the refrigeration industry in the late 1950s.
o The compressor essentially consists of two mating helical grooved rotors, a male (lobes)
and a female (gullies), in a stationary housing with suitable inlet and outlet gas ports.
o The flow of gas in the rotors is both radial and axial.
o The female rotor can be driven by the male rotor.

Orbital Compressors
1. Scroll Compressor
o Scroll compressor is a rotary-motion, positive-displacement compressor that uses two inter-
fitting, spiral-shaped scroll members to compress the refrigerant vapor.
o Capacities of a scroll compressor are ranging from approximately 1 to 15 TR (3.5 to 53
kW).
o Currently used in residential and commercial air-conditioning (including heat pumps) and
automotive applications.
o The advantages of this compressor include low noise as well as high efficiency.
o The disadvantages of this compressor include incompatibility with solid contaminant and
poor performance at low suction pressures.
o It has a critical good lubrication.
2. Trochoidal Compressor
o This machine is small, rotary, orbital, positive-displacement device that can run at speeds
up to 9000 rpm.
o Trochoidal compressors are manufactured in a variety of configurations, including the
Wankel design.
 Wankel soved earlier sealing problems and produced a trochoidal compressor with 3-
sided epitrochoidal piston (motor) and twin-envelope cylinder (casing) in capacities up
to 2 TR (7 kW).

CENTRIFUGAL COMPRESSORS
 These are members of a family of turbo-machines that include fans, propellers, and turbines.
 Centrifugal compressors are characterized by a continuous exchange of angular momentum
between a rotating mechanical element and a steadily flowing fluid.
 These compressors have greater volumetric efficiencies, size for size, than do positive
displacement devices.

 For effective momentum exchange, their rotative speeds must be higher, but little vibration or
wear results because of the steadiness of the motion and the absence of contacting parts.

DIVISIONS OF VAPOR-COMPRESSION SYSTEM

1. Low-pressure Side
 Expansion Valve
 Evaporator
 Suction line
o Pressure is called as low side pressure, evaporator pressure, suction pressure, or
back pressure

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 2. High-pressure Side
 Compressor
 Discharge or the “hot gas” line
 Condenser
 Receiver tank
 Liquid line
o Pressure is called as condensing pressure, discharge pressure, or head pressure.

BASIC COMPONENTS OF VAPOR-COMPRESSOR SYSTEM

 The basic components of the actual vapor-compression refrigeration system are indicated in
Figure 7.

Figure 7. Main Components of Actual Vapor-Compression System

Purger or

Surge Tank
Condenser
Oil Separator
Liquid
Receiver

Expansion
Valve

Evaporator
Compressor
Accumulator

Main Components of Actual Vapor-Compression Refrigeration System

a) Compressor b) Purger
c) Oil separator d) Condenser
e) Liquid receiver f) Expansion Valve
g) Evaporator h) Accumulator

Types of Condensers for Vapor-Compression Refrigeration System

1. Air-cooled type Condenser

a. Bare tube type
b. Finned tube type
2. Water-cooled type Condenser
a. Shell-and-tube type
b. Shell-and-coil type

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EXPANSION VALVE/DEVICES
 Expansion valves/devices are important components in the refrigeration system used to:
o Reduce the pressure in the system between the high value in the condenser and the low
value in the evaporator so that a corresponding low temperature may be obtained in the
evaporator.
o Meter the flow of liquid refrigerant to the evaporator so that the gas leaving it will be slightly
superheated.

Types of Expansion Valves/Devices

1. Thermostatic Expansion Valve
o This valve positions the valve spool to admit the refrigerant as required by evaporator
load.
2. Electric Expansion Valve
o This valve has the same role as the thermostatic expansion valve, but electricity utilized
to assist in part of the control process. The valve may be heat-motor operated,
magnetically modulated, pulse-width modulated, or step-motor driven. The control may
be either digital or analog electronic circuits, which gives flexibility not possible with
thermostatic valves.
3. Capillary tube
o Capillary tube is not a valve, but effectively replaces the expansion valve in many
applications.
o It is a long thin tube placed between the condenser and the evaporator. The small
diameter and long length of the tube produce a large pressure drop.
o The main advantage of the capillary tube is its simplicity and low cost; and it is not
subject to wear.
o The very small bore of the tube is subject to plugging if precautions are not taken to
maintain a clean system. Moisture can also cause plugging due to ice formation.
o With 0.5 mm to 2 mm inside diameter, 1 m to 6 m length, and a capacity up to 10 kW.
4. Short Tube Restrictor
o Short tube restrictor is widely used in place of capillary tube in residential systems.
o It has high reliability, low cost, and easily inspected and replaced.
o Orifice Tube, the very shortest tube restrictor, is most commonly used in automobile air-
conditioning systems.
 It may be stationary or movable, with the movable type having a piston that can
move within the housing, restricting the flow in one direction
 Stationary tubes are used in units that only cool, and the movable types are used in
heat pumps.
5. Evaporator Pressure Regulator
o It is used to maintain a relatively constant minimum pressure in the evaporator.
o The main application f evaporator pressure regulator is to set a minimum evaporator
temperature to permit the use of different evaporators at different pressures on the
same compressor.
6. Suction Pressure Regulator
o Suction pressure regulator is used for limiting the maximum pressure at compressor
suction.

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 o It is a load-limiting device, and functions very much like the evaporator pressure
regulator except that it senses compressor suction pressure.
o It reduces the compressor load during the start-up period, because the valve will remain
closed until suction pressure is reduced to a set pressure.
7. Other Expansion Valves
a. Gate valve
b. Constant pressure expansion valve
c. Thermostatic expansion valve with external equalizer
d. Float valve – used with flooded evaporator

EVAPORATOR

 Evaporator is the component in the refrigeration circuit where heat is removed from the
substance being cooled, air or water in the case of air conditioning.
 Liquid refrigerant within the evaporator absorbs heat from the air or water and, in so doing,
boils.

Types of Evaporator
1) Flooded shell-and-tube evaporator
 This evaporator is used mostly for water chilling.
 It has liquid covering the whole of its heat transfer surfaces.
 This evaporator is cheaper and is in common use for larger duties and for centrifugal
machines.
2) Dry shell-and-tube evaporator
 This evaporator is used for both water chilling and for air conditioning.
 In this type, water flows in the shell outside the tubes, turbulence and consequent good
heat transfer being assisted by baffles, the refrigerant evaporating within the tubes.
 It is preferred, because of its lower cost, for duties below 140 kW.
3) Submerged evaporator
 In this evaporator, the water circuit is open and the water storage vessel constitutes its
own feed and expansion tank. Heat transfer from submerged coil is promoted by
employing water agitator.
4) Baudelot Cooler
 This type is used for water chilling up to the temperature of 2 oC or lower.

Note: Submerged evaporator and Baudelot cooler are expensive and bulky and for this reason
these two types are very seldom used today.

REFRIGERATION CYCLE WITH SUBCOOLING AND/OR SUPERHEATING

 Superheating is increasing the temperature of refrigerant gas leaving the evaporator above the
saturation temperature corresponding to the evaporator temperature; while sub-cooling is
lowering the temperature of the liquid refrigerant leaving the condenser below the saturation
temperature corresponding to the condenser
p 4 pressure. Figure2 1.8 below illustrates the ph
diagram of a refrigeration cycle with superheating3 and sub-cooling.
tc
Figure 8. ph Diagram, Superheating and Sub-cooling

t1
14 1
5 6
h
REFRIGERATION SYSTEM WITH HEAT EXCHANGER
 Refrigeration system with heat exchanger is a vapor-compression refrigeration system with
heat exchanger installed between condenser and expansion valve and installed between
evaporator and compressor. The objectives are two folds, namely: to sub-cool the refrigerant
liquid leaving the condenser and entering the expansion valve; and to superheat the refrigerant
gas leaving the evaporator and entering the compressor.
 The main advantage of this system is the increase of the system refrigerating capacity or
increase of the Coefficient of Performance (COP) of the system. Figure 1.9 below illustrates
the system with heat exchanger for superheating and sub-cooling.

Figure 9. Schematic and pV Diagrams of System with Heat Exchanger

QR
Condenser 2
p 4 2
3
1 3
Heat Exchanger Wc
tc
4 Compressor
Expansion
t1
Valve
6 1
5 Evaporator
5 6
h
Qe

 Functions of Heat Exchanger

 To make sure that no liquid enters the compressor
 To prevent bubbles of vapor refrigerant to the expansion valve

REFRIGERANTS
 Refrigerant is a fluid used for energy exchanges in a refrigerating or heat pump system.
 Refrigerants are the transport fluids that convey the heat energy from the low-temperature
level to the high-temperature level where it can in terms of heat transfer give up its heat.
 Montreal Protocol is an international agreement, that took effect in 1989, and the New
Clean Air Act that was signed in 1990, that limit the production and regulate the use and
disposal of chlofluorocarbon (CFC) refrigerants.
 CFC is the Montreal Protocol designation for Chlorofluorocarbons that cause ozone-layer
depletion.
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  HCFC or HFC is the designation for other refrigerants that are chlofluorocarbons but cause
little or no ozone destruction.
 HCFC stands for Hydrochlorofluorocarbon
 HFC stands for hydrofluorocarbon
 ODP – Ozone Depletion Potential – is the ozone-destroying power of a substance
measured relative to refrigerant 11 (R-11 or CFC-11).
 GWD – Global Warming Potential – is a relative measure of the ability of a substance to
cause an increase in the temperature of the atmosphere by absorbing solar and earth
radiation that is relative to the effect of refrigerant 11.

Desirable Thermal Properties of the Refrigerants

1) Convenient evaporation and condensation pressures b) High critical and low
freezing temperatures
c) High latent heat of evaporation and high vapor specific heat d) Low viscosity and
high film heat conductivity
Desirable Practical Properties
1) Low cost b) Chemical and physical inertness under
operating conditions
c) Non-corrosiveness toward ordinary construction materials d) Low explosive
hazard both alone and mixed with air
Thermodynamic Characteristics
1) High latent enthalpy of evaporation b) Low freezing temperature
c) Relatively high critical temperatures c) Positive evaporating pressure
d) Relatively low condensing pressure
Physical and Chemical characteristics
1) High dielectric strength of vapor 2) Good heat transfer characteristics
3) Satisfactory oil solubility 4) Low water solubility 5)
Inertness and stability
Safety Characteristics
1) Non-flammability 2) Non-toxicity 3) Non-irritability
Effects on the Environment
1) Ozone depletion potential 2) Global warming potential
Other characteristics
1) Low cost 2) Easy to detect in case of leaks

LIST OF SOME SELECTED REFRIGERANTS BASED ON SERIES OR GROUPS

 Methane Series
R-11 Trichlorofluoromethane C Cl3 F R-12
Dichlorodifluorometahne C Cl2 F2
R-13 Chlorotrifluoromethane C Cl F3 R-14 Carbon tetrafluoride C
F4
R-21 Dichlorofluoromethane CH Cl2 F R-22 Chlorodifluoromethane
CH Cl F2
R-23 Trifluoromethane CH F3 R-50 Methane
CH4
 Ethane Series
R-114 1,2-Dichlorotetrafluoroethane, C Cl F2 C Cl F2 R-123 2,2-Dichloro-1,1,1-
trifluoroethane, CH Cl2 C F3

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 R-124 2-Chloro-1,1,1,2-tetrafluoroethane, CH Cl F C F3 R-125
Pentafluoroethane, CH F2 C F3
R-134a 1,1,1,2-Tetrafluoroethane, CH2 FCF3 R-143a 1,1,1-
Trifluoroethane, CH3 CF3
R-152a 1,1-Difluoroethane, CH3 CHF2 R-170 Ethane, CH3
CH3
 Propane Series
R-290 Propane, C3 H8
 Butane Series
R-600 Butane, C4 H10 R-601 Iso-butane, C4 H10
 Inorganic Compounds
R-702 Hydrogen , H2 R-704 Helium, He
R-717 Ammonia NH3 R-718 Water, H2O
R-728 Nitrogen, N2 R-729 Air
R-732 Oxygen, O2 R-744 Carbon dioxide, CO2
R-764 Sulfur dioxide, SO4
 Zeotropes
R-400 R-12/114
 Azeotropes: An azeotropic mixture of two substances is one that cannot be separated into its
components by distillation.
R-502 R-22/115 (48.8 % / 51.2 %) R-400 R-12/114 (must be
specified)
 Hydrocarbon Refrigerants
R-50 Methane CH4 R-170 Ethane C2H6
R-290 Propane C3H8 R-600 Butane C4H10

 CFC Refrigerants: R-11; R-12; R-113; R-114; R-115

 HCFC Refrigerants (less resistant than CFC’s)

 R-22 or HCFC-22 Chloro-difluoromethane CHCLF2
 R-123 or HCFC-123 Dichloro-trifluoroethane CHCL2CF3
 R-124 or HCFC-124 Chloro-tetrafluoroethane CHCLFCF3
 R-141b or HCFC-141b
 R-142b or HCFC-142b

 HFC Refrigerants (least harmful to ozone layer)

 R-125 or HFC-125 Pentafluoroethane CHF2CF3
 R-134a or HFC-134a Tetrafluoroethane CH2FCHF3
 R-152a or HFC-152a Difluoroethane CH3CHF2
 R-32 or HFC-32 Difuoromethane CH2F2
 R-23 or HFC-23 Trifluoromethane CHF3
 R-143a or HFC-143a Trifluoroethane CH3CF3

 Replacement Refrigerant Compounds

Current Replacement
Refrigerants Refrigerants Formula
R-11 (CFC- HCFC-123 CHCl2CF
11)
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 R-12 (CFC- HFC-134a CH2FCF3
12)
R-13 (CFC- HFC-23 CHF3
13)
R-502 R402A, Blend
R404A
R-22 HCFC-22 CHClF2

 Halocarbon Refrigerants – refrigerants that contain one or more of the three halogens
chloride, fluorine, and bromine.
R-11 CCl3F Trichloromonofluoromethane R-12 CCl2F
Dichlorodifluoromethane
R-13 CClF3 Monochlorotrifluoromethane R-22 CHClF2
Monochlorodifluoromethane
R-40 CH3Cl Methyl Chloride R-113 CCl2FCClF2
Trichlorotrifluoroethane R-114 CClF2CClF2 Dichlorotetrafluoroethane

ASHRAE REFRIGERANT DESIGNATION SYSTEM

1. The first digit on the right is the number of fluorine, F, atoms in the compound.
2. The second digit from the right is one more than the number of hydrogen (H) atoms in the
compound.
3. The third digit from the right is one less than the number of carbon, C, atoms in the
compound. When this digit is zero, it is omitted from the number.
4. Blends are designated by their respective refrigerant numbers and weight proportions,
named in the order of increasing normal boiling points of the components, for example R-
22/12 (90/60).
5. Zeotropic blends that have been commercialized are assigned an identifying number in the
400 series accompanied by the weight proportions of the components, for example R-400
(90/10) for mixture of R-12 and R-114.
6. Azeotropes that have been commercialized are assigned and identifying number in the 500
series with no composition shown.
7. Organic refrigerants are assigned serial numbers in the 600 series.
8. Inorganic compounds are designated by adding 700 to their molecular mass
9. The letter C is used before number designations to identify cyclic derivatives. Lower case
letters are appended after numbers to distinguish isomers-refrigerants with the same
chemical composition but with differing molecular structures.

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