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Design, Construction and Testing of A Cold Store With Water-Cooled Chiller
Design, Construction and Testing of A Cold Store With Water-Cooled Chiller
Design, Construction and Testing of A Cold Store With Water-Cooled Chiller
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Serap Akdemir
Tekirdağ Namık Kemal University Technical Sciences Vocatinal School
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All content following this page was uploaded by Serap Akdemir on 06 September 2022.
S. AKDEMİR
Department of Machine and Metal Technologies. Technical Sciences Vocational School,
Tekirdag Namik Kemal University, Tekirdag, 59030, TURKEY.
sakdemir@nku.edu.tr
Abstract−− Objective of this research was to de- tower fans and condenser water pumps were investigated.
sign, construction and test of a cold store with chiller With regard to an example chiller system, the optimal
unit. Dimensions of the cold store were 5x4x3m. Heat control coupled with variable condenser water flow could
load was calculated and capacity of cooling system reduce the annual system electricity use by 5.3% and op-
was determined. Ambient temperature was set 2oC erating cost by 4.9% relative to the equivalent system us-
and relative humidity 90% for cold store testing. Am- ing constant speed fans and pumps with a fixed set point
bient temperature, relative humidity and air velocity for cooling water temperature control (Yu and Chan,
were measured for 3 different levels and 12 points for 2008). In a study, calculation of cooling load and choos-
each level in the cold store. Total heat load and capac- ing of the cooling system elements as compressor, con-
ity of cooling system were calculated 6264 kcal/h denser, and evaporator were explained for designing of
(7.284 kW). The descriptive statistics were calculated an evaporative cold store (Akdemir, 2008). A manual
for the ambient temperature; mean, 2.82oC, standard was prepared to discuss various piping and control strat-
deviation 0.02oC and CV (%) 0.56, and for the rela- egies commonly used with chilled water systems includ-
tive humidity; mean 88.01%, standard deviation 0.61 ing variable flow pumping systems (Anonymous, 2001).
(%) and CV(%) 0.70 and for the air velocity mean Steady natural convection heat transfer behavior of
0.37m/s, standard deviation 0.22 m/s, CV 33.45 %. nanofluids is investigated numerically inside a square en-
Even the air velocity CV was high, the ambient tem- closure filled with a porous medium. The governing
perature and relative humidity variations were eval- equations were obtained based on the Darcy's law with
uated very good. the nanofluid model. The transformed dimensionless
Keywords−− cold store, chiller, design, heat load governing equations were solved by finite difference ap-
proach (Mansour et al., 2015). A risk-based design pro-
I. INTRODUCTION cedure of ammonia-based refrigeration processes taking
Reducing the losses with various techniques from harvest into account the allocation of the manufacturing plant and
to consumer indirectly increases agricultural production the surrounding environment vulnerability at early stages
and producer income (Eris, 2001). In order to ensure the of process design was presented in paper (Biscotti et al.,
homogeneity of the temperature in large volume cold 2019).
stores, it is necessary to provide it with separate and spe- Chiller cooling systems are becoming more and more
cial air channel systems (Bayboz et al., 2004). It is the common in cold storage. In this type of cold stores, cold
range of change of this temperature in a factor as im- air is conditioned, ventilated from the ceiling and ab-
portant as the storage temperature. Deviations in the cold sorbed through inlets located on the opposite side. The
storage degree should be less than ± 1oC. The biggest dis- purpose of this research was to calculate the heat load for
advantage of high deviations in the storage temperature a cold store with water-cooled chiller system that distrib-
is that it affects the storage humidity. Therefore, this is utes conditioned cold air as homogeneously as possible
very important in cold store with high relative humidity in the cold store. The capacities of the system elements
(Cemeroglu et al., 2001). In the design and operation of were determined according to the cooling load calcula-
cold storage systems, the problems of saving operation tions. Then, the cold store with chiller was constructed
cost and improving global economics of whole systems and the cooling system was tested for ambient factors
are equally important. An approach to calculate and to such as temperature, relative humidity and air velocity.
choose the chiller and cold storage tank for the optimal
scheme was provided in the method. The method was II. METHODS
demonstrated by a case study, in which the optimal A. Cooling load calculations
scheme was compared on economics with other schemes Heat load from the stored products and other heat sources
with chiller priority control or storage priority control. It in the cold store were calculated for determining cooling
can be seen that the payback period of the optimal load. Cooling capacity of the air conditioning and the
scheme was the shortest (Liu and Wang, 2001). The de- cooling unit were calculated in order to provide the de-
sign guide of the chiller cooling systems was presented sired temperature and relative humidity in the cold store.
in a book (Anonymous, 2009). Energy performance of a Transmission heat (𝑞1 ), infiltration heat (𝑞2 ), heat for
chiller and cooling tower systems integrated with varia- cooling of the stored products (𝑞3 ), heat from other
ble condenser water flow and optimal speed control for sources (𝑞4 ) and unknown and unexpected heat load (𝑞5 )
https://doi.org/10.52292/j.laar.2022.635 21
Latin American Applied Research 52(1):21-26 (2022)
for calculated to determine total amount of heat required 𝑡𝑜 = Outdoor temperature (oC)
in the cold store (Ozkol, 1999). Outdoor temperature as 𝑡𝑟 = Indoor temperature (oC)
35oC, storage temperature as 0oC and relative humidity Heat generated by stored product maturation (𝑞3,2 de-
as 90% were taken for the cooling load calculations. fined as also maturation heat was calculated by Eq. 7.
Monthly average air temperature for the hottest month 𝐺 .𝑐
𝑞3,2 = 𝑢 𝑟 (7)
was determined as outside temperature. The transmission 1000 .24
heat load (𝑞1 ) generated by heat transmission from walls, where 𝑐𝑟 = Respiration heat during storage (kCal/ t-24h)
ceiling and floor was calculated by using Eq. (1-3) (Guzel (It was assumed as 200 kCal/t-24h for apple at 0oC cold
et al., 1996). storage).
𝑞1 = ∑𝑛𝑖=1 𝑘𝑖 𝐴𝑖 𝛥𝑡𝑖 (1) Other heat load (𝑞4 ) generated by workers (𝑞4,1 ),
1 lightening (𝑞4,2 ) and unknown and unexpected heat load
𝑘𝑖 = 1 𝑛 𝐿 1 (2)
𝛼𝑜
+ ∑𝑖=1
λ
+
𝛼𝑖
(𝑞4,3 ) were calculated by Eq. (8-10) (Cemeroglu and
𝛥𝑡𝑖 = 𝑡𝑜 − 𝑡𝑟 (3) Acar, 1986; Ozkol, 1999; Erol, 1993).
where 𝑞4 = 𝑞4,1 + 𝑞4,2 + 𝑞4,3 (8)
𝑞1 = Transmission heat load (kCal/h) 𝑞4,1 = 𝑛. 𝑐𝑖 . 𝑡1 (9)
𝑖 = Number of layer (1, 2, ..,n) where
𝑛 = Maximum number of layers 𝑞4,1 = Heat load emitted from workers (kCal/day)
𝑘𝑖 = Total heat transfer coefficient (kCal/m2hoC) 𝑛 = Number of workers
𝐴𝑖 = Total surface area of ceiling, walls, floor (m 2) 𝑐𝑖 =Heat load from a worker (kCal/h-person) (Ozkol,
𝛥𝑡𝑖 = Temperature difference (oC) 1999)
𝛼𝑜 = Coefficient of heat transmission of outside surface 𝑡1 = Daily working time for a worker in the cold store
(kCal/m2hoC) (It was assumed as 18 kCal/m2hoC) (h/day) (assumed as 1 h/day).
𝐿 = Material thickness (m) 𝑞4,2 = 860. 𝑁𝑙𝑖𝑔ℎ𝑡 . 𝑡2 (10)
λ = Thermal conductivity (kCal/mhoC) 𝑞4,2 = Heat load generated by lightening (kCal/day)
𝛼𝑖 = Coefficient of heat transmission of inside surface 860 =Thermal equivalent of work (kCal/kWh)
(kCal/m2hoC) (It was assumed as 18 kCal/m2hoC) 𝑁𝑙𝑖𝑔ℎ𝑡 =Power of the lighting facility (kW) (0.020kW)
𝑡𝑜 = Neighbour volume (outside) temperature (oC) 𝑡2 = Daily working time of the lighting (h /day) (2h/day)
𝑡𝑟 =Room (inside) temperature (oC) In order to include the effect of unknown and unex-
𝑘𝑖 was calculated 0.26 kCal/m2hoC for walls, ceiling pected heat load (𝑞4,3 ) was determined by Eq. 11 (Ozkol,
and floor manufactured from polyurethan. Thickness was 1999).
0.08 m. 𝑞4,3 = 0.1 (𝑞4,1 + 𝑞4,2 ) (11)
Infiltration heat load (𝑞2 ) caused from leakage and where 𝑞4,3 = Unknown and unexpected heat load
exchange air was calculated by the Eq. 4 (Erol, 1993). (kCal/day)
𝑞2 = 𝑧. 𝛾. 𝑉. ℎ𝑜 . ℎ𝑖 (4) It was also assumed that the cooling system works 16
where hours per a day and time factor as 24/16 was reflected to
𝑞2 = Heat load from leakage and exchange air (kcal/h) the calculation of the total heat load (𝑄𝐾 ) (Eq. 12)
𝑧 = Number of air changes in one day (Erol, 1993) (Cemeroglu and Acar, 1986; Ozkol, 1999; Erol, 1993).
𝛾 =Specific gravity of air (kg/m3) (for 35oC) (Savas, 24
𝑄𝐾 = ( ) . (𝑞1 + 𝑞2 + 𝑞3 + 𝑞4 + 𝑞5 ) (12)
1987) 16
𝑉 = Room volume (m3) where 𝑄𝐾 = Total heat load (kCal/h) and 24/16 = Time
ℎ𝑜 = Enthalpy of outdoor air (kcal/kg) factor.
ℎ𝑖 = Enthalpy of indoor air (kcal/kg) B. Determination of Cooling Unit Capacity
Heat load (𝑞3 ) caused by stored products was calcu- Air is cooled by giving its heat to the fluid passing
lated by Eq. (5-7) through the pipes when the air passes through the serpen-
𝑞3 = 𝑞3,1 + 𝑞3,2 (5) tine in the ventilation unit. The air conditioner provides
where the desired temperature and humidity to the air before en-
𝑞3 = Cooling load (q3) from cold stored products (kcal/h) ters the cold store. Calculations of the volumetric flow
𝑞3,1 = Heat generated by cold stored product (kcal/h) rate, mass flow rate and the cooling capacity of the air
𝑞3,2 = Heat generated by stored product maturation conditioning unit were determined by the following for-
(kcal/h) mulas. The amount of cold air was calculated by Eq.13
The heat emitted by reducing the amount of heat re- (Yamankaradeniz et al., 2012).
𝑄𝐾
quired to be taken from the daily loaded products to de- 𝑉𝑎 = (13)
𝜌ℎ .𝐶𝑝ℎ .𝛥𝑡
crease temperature from 𝑡𝑜 to 𝑡𝑟 . where
𝑞3,1 = (𝐺𝑢 . 𝑐𝑢 ). (𝑡𝑜 − 𝑡𝑟 ) (6) 𝑉𝑎 = Volumetric air flow rate (m3/h)
where 𝜌ℎ = Density of air (kg/m3)
𝑞3,1 = Heat produced by cold stored product (kcal/h) 𝐶𝑝ℎ = Specific heat of air at constant pressure (kcal/kg0C)
𝐺𝑢 = Amount of the daily stored products (kg) 𝛥𝑡 = Differences between storage temperature and venti-
𝑐𝑢 = Specific heat of the product (kCal/kgoC) lation temperature (0C)
22
S. AKDEMIR
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Latin American Applied Research 52(1):21-26 (2022)
Table 6. Total heat load per hour and day Table 10. General specifications of the cold store
Heat load Amount (kCal/day) Dimensions (m) 4.0x5.0x3.0m
Transmission 18959 Working temperature (°C) 0°C /+30 °C
Infiltration 10908 Relative humidity 55% – 95%
Stored product 65417 Tolerance for relative humidity (%) ±%5
Unknown and unexpected source 4932 Tolerance for ambient temperature(°C) ± 0,5 °C
Total Daily heat load 100216 Steps for controlling of the ambient tem- 0.1 °C
Total heat load (kCal/h) 6264 kCal/h perature
Total heat load (kW) 7.284 kW
24
S. AKDEMIR
25
Latin American Applied Research 52(1):21-26 (2022)
The operating ranges and capacities of the selected cool- Erol, N. (1993) Basic Methods in Cooling and Air Con-
ing system provided homogeneous distribution of ambi- ditioning, Higher Maritime School Alumni Associ-
ent temperature and the relative humidity in the given ation, Istanbul.
storage conditions. Guzel, E., Ulger, P. and Kayisoglu B. (1996) Product
Processing and Evaluation Technique. Cukurova
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