Refrigeration: Back to the Basics

Seminar 32 Sponsor: TC10.1, and Refrig. Committee

Economizing for Industrial Refrigeration Screw Compressors

Joseph W. Pillis P.E.
York Refrigeration, (Frick) Waynesboro, PA
All Rights Reserved Copyright 2001 by YORK International Corporation

Disclaimer
THIS INFORMATION WAS PRESENTED AT ASHRAE SEMINAR 32 HELD IN CINCINNATI, OH. THE SEMINAR FORMAT IS TO PRESENT INFORMATION OF CURRENT INTEREST AND TO PROVIDE A VENUE FOR INTERACTION BETWEEN ASHRAE MEMBERS. THESE SEMINARS SHOULD NOT BE CONSIDERED PEER-REVIEWED (OR THE FINAL WORD ON ANY SUBJECT). ASHRAE HAS NOT INVESTIGATED, AND ASHRAE EXPRESSLY DISCLAIMS ANY DUTY TO INVESTIGATE ANY PRODUCT, SERVICE, PROCESS, PROCEDURE, DESIGN, OR THE LIKE WHICH MAY BE DESCRIBED HEREIN. THE APPEARANCE OF ANY TECHNICAL DATA OR EDITORIAL MATERIAL IN THIS PRESENTATION DOES NOT CONSTITUTE ENDORSEMENT, WARRANTY, OR GUARANTY BY ASHRAE OF ANY PRODUCT, SERVICE, PROCESS, PROCEDURE, DESIGN, OR THE LIKE. NEITHER ASHRAE, THE AUTHORS OR THEIR EMPLOYERS WARRANT THAT THE INFORMATION IN THIS PRESENTATION IS FREE OF ERRORS. THE ENTIRE RISK OF THE USE OF ANY INFORMATION IN THIS PRESENTATION IS ASSUMED BY THE USER. BEFORE MAKING ANY DECISION OR TAKING ANY ACTION ON THIS SUBJECT, YOU SHOULD CONSULT A QUALIFIED PROFESSIONAL ADVISOR.

Economizers
This presentation will cover the fundamentals of economizers as used with twin rotary screw compressors.
port location and function characteristics sideloads economizers cycle efficiency refrigerant comparisons

Suction process

Maximum Suction Volume Trapped Vs

Vs

Compression

Continuation of Compression

Beginning of Discharge

Vd

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Primary Suction

Discharge

Primary Suction

Discharge

Primary Suction Econo. Inlet

Discharge

Economizer Port Location

The Economizer Port

A port placed in the rotor housing can locate any pressure between suction and discharge. This port acts as a secondary suction port. The additional flow does not reduce the primary suction gas flow. The gas mixes in the screw threads and is carried on to discharge. Compression efficiency is high as additional frictional power is small. Like a frictionless compressor

Uses of the Econo. Port

This secondary suction port is used in two ways. Sideloads are generally gas flows coming from a secondary, (higher temp.) evaporator. Economizers are used to subcool condenser liquid.

Sideload Evaporators
Condenser

Secondary Evaporator

Comp.

Evaporator

Vapor from a secondary evaporator can be drawn into the compressor economizer port, providing the secondary evaporator is at a pressure higher than the econo. pressure.

-17 F 20 psia Econo. ? psia

96 F 200 psia NH3 Sideload Example What pressure is the port ?

100 % Volume

62% Volume

Sideload port location for refrigeration application 62% volume = volume reduction ratio 1.6 : 1

-17 F 20 psia

20 psia

Econo. ? psia

96 F 200 psia Port pressure ~=(Volume ratio)^k * (P suction) NH3 k ~= 1.29 Port pressure = (1.6^1.29) * 20 psia = 37 psia

-17 F 20 psia 8F 37 psia

96 F 200 psia Port pressure ~=(Volume ratio)^k * (P suction) NH3 k ~= 1.29 Port pressure = (1.6^1.29) * 20 psia = 37 psia

-17 F Evaporator
96 F Condenser Secondary Evaporator 8 F Secondary Evaporator

Comp.

-17 F Evaporator

With a -17 F primary evaporator temp. a secondary evaporator can be used as long as the temperature is above ~ 8 F.

R-717
10000

Absolute Pressure (PSIA)

1000

100

10

1 0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

R-717
10000

Absolute Pressure (PSIA)

1000

100

Sideport
10

Evaporator

1 0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

- 40 F 10 psia -20 F 18 psia

96 F 200 psia Port pressure ~=(Volume ratio)^k * (P suction) NH3 k ~= 1.29 Port pressure = (1.6^1.29) * 10 psia = 18 psia

-40 F Evaporator
96 F Condenser Secondary Evaporator -20 F Secondary Evaporator

Comp.

-40 F Evaporator

With a -40 F primary evaporator temp. a secondary evaporator can be used as long as the temp. is above - 20 F

40 F 73 psia 72 F 133 psia

96 F 200 psia Port pressure ~=(Volume ratio)^k * (P suction) NH3 k ~= 1.29 Port pressure = (1.6^1.29) * 73 psia = 133 psia

40 F Evaporator
96 F Condenser Secondary Evaporator 72 F Secondary Evaporator

Comp.

40 F Evaporator

With a 40 F primary evaporator temp. a secondary evaporator can be used as long as the temp. is above 72 F. Port pressure is too high to be useful !!!!!!!!!!

-17 F 20 psia 8F 37 psia

96 F 200 psia Effect of Lower Condensing Pressure

-17 F 20 psia 8F 37 psia

75 F 140 psia Effect of Lower Condensing Pressure

-17 F 20 psia 8F 37 psia

75 F 140 psia Port pressure ~=(Volume ratio)^k * (P suction) NH3 k ~= 1.29 Port pressure = (1.6^1.29) * 20 psia = 37 psia

-17 F 20 psia 8F 37 psia

75 F 140 psia Econo. Pressure is a function of suction pressure and port location only ! Not discharge pressure !

-17 F 20 psia 8F 37 psia

96 F 200 psia What is the Sideload capacity? on NH3

Liquid from cond

100 lbm/min -17 F 20 psia

Secondary Evaporator 37 psia (8F)

Zero flow P=37 psia

Liquid from cond

100 lbm/min -17 F 20 psia

Secondary Evaporator 38 psia (10F)

16 lbm/min P=37 psia

Liquid from cond

100 lbm/min -17 F 20 psia

Secondary Evaporator 41 psia (13F)

21 lbm/min P=38 psia

Liquid from cond

100 lbm/min -17 F 20 psia

Secondary Evaporator 43 psia (15F)

28 lbm/min P=40 psia Thread packing brings up the pressure in the screw thread

Sideload Capacity
as a % of suction capacity % of Suct. Tons Refr.
400% 300% 200% 100% 0% -40 -20 0

NH3 Refrig.
Sideload Temp.

40F 20F 0F -10F

20

Sat. Suct Temp. F

Sideload Evaporator Piping

Condenser Secondary Evaporator Secondary Evaporator Evaporator

Economizer Piping
Condenser Flash Economizer Evaporator

An Economizer is a special case of a sideload evaporator, where part of the condensed liquid is evaporated to cool the remainder of the condensed liquid. 96F liq Condenser Flash Economizer 17 F liq (45psia) NH3 18 lbm/min Comp. Evaporator -17F (20 psia) 100 lbm/min

R-717 Single stage compression

10000

Absolute Pressure (PSIA)

1000

229 Tons Refrigeration

/m in

100

10

1 0 100 200 300 400 500 600 700 800 900

-17F/96F NH3

Enthalpy (B.T.U. per LB)

10

(hg-hf)=458b/lbm

lb m

R-717 Economizer cycle

10000

Absolute Pressure (PSIA)

1000

19% increase in evaporator tons @273 Tons same evaporator Refrigeration massflow
/m
700

100

19 lbm/min
10

(hg-hf)=458b/lbm (hg-hf)=545b/lbm
1 0 100 200 300 400 500 600

10
800

lb m
900

Enthalpy (B.T.U. per LB)

in

R-717 Economizer cycle

10000

Absolute Pressure (PSIA)

19% More Tons 19% More massflow

Only 9% More Power

/m in

1000

100

10

100 lbm/min

1 0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

11

19 lbm/min

lb m

100 lbm/min -17 F 20 psia

19 lbm/min 45 psia

The economizer vapor is at a lower compression ratio, and adds no additional friction to the compression

119 lbm 96 F 200 psia

NH3 Cycle efficiency

-17 F evaporator 96 F condensing Capacity Power 229 494 273 538 19% 9%

HP/TR 2.16 non-Econ 1.97 Econo. 9.6% improved

R-22 Cycle efficiency

-10 F evaporator 95 F condensing Capacity Power 106 212 136 230 28% 8%

HP/TR 2.0 non-Econ 1.7 Econo. 17% improved

Capacity and Power Non-E

800 700 600

TR & BHP

Power

500 400 300 200 100 0 -60 -40 -20 0 20 40 60

Capacity

NH3 R507 R22 NH3 BHP R507 BHP R22 BHP

Evap Temp (F)

Capacity and Power- Economized

800 700

Power
600

HP and TR

500 400 300

Capacity
200 100 0 -60 -40 -20 0 20 40 60

NH3 Cap R507 Cap R22 Cap NH3 HP R507 HP R22 HP

Evap Temp (F)

BHP/TR (E and non-E)

6 5 4 3 2 1 0 -60 -40 -20 0 20 40 60 NH3 E R507 E R22 E NH3 non R22 non R507 non

Evap Temp (F)

6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 -55 -50 -45 -40 -35 -30 -25 -20 NH3 E R507 E R22 E NH3 non R22 non R507 non

BHP/TR (E and non-E)

Evap Temp (F)

Econo. Flash Gas Flow

500 450 400 350

Lbm/min

300 250 200 150 100 50 0 -60 -40 -20 0 20 40 60 NH3 R507 R22

Evap Temp (F)

TR increase E/Non-E
90.0% 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% -60 -40 -20 0 20 40 60 NH3 Cap R507 Cap R22 Cap

Evap Temp (F)

Efficiency Gain w/ Economizing

50.0% 45.0% 40.0% 35.0% 30.0% 25.0% 20.0% 15.0% 10.0% 5.0% 0.0% -60 -40 -20 0 20 40 60 NH3 R507 R22

Evap Temp (F)

Economizer Piping
Open flash vessel Flash vessel with HX Direct Expansion

Open Flash Vessel . One Compressor

DX - Shell and Tube

Level Controlled Shell and Coil

If load varies widely and econo is used below 90% SV use BPR controlling compressor side