ME 331

Refrigeration & Air Conditioning

M Asfandyar

Refrigeration & Air Conditioning 1

 Refrigeration System Components

 Functioning and types of compressors, evaporators, condensers and expansion

valves.

 water chiller and water heater

 Air handling unit

 Chilled water and hot water recirculation system, return air supply system, air
dust cleaning and bacteria removal

Refrigeration & Air Conditioning 2

 Rotary, Positive Displacement Type Compressors
Rolling piston (fixed vane) type compressors:

These compressors belong to the class of positive displacement type as compression is

achieved by reducing the volume of the refrigerant.
The mass flow rate of refrigerant through the compressor is given by:

Where
A = Inner diameter of the cylinder
B = Diameter of the roller
L = Length of the cylinder
block N = Rotation speed,
RPM
ηv = Volumetric efficiency
ve = specific volume of
refrigerant at
suction
Rotary compressors have high volumetric efficiencies due to
negligible clearance. Refrigeration & Air Conditioning 3
 Rotary, Positive Displacement Type Compressors

Multiple vane type compressors:

Rotary vane type compressors have

low mass-to-displacement ratio, which
in combination with compact size
makes them ideal for transport
applications.

 The cooling capacity is normally

controlled either by compressor speed
regulation or suction gas throttling.
 Large rotary compressors are used in low-
temperature fields (-90 to -100ºC) with
wide range of refrigerants such as R 22,
ammonia, R 404a etc.
 Available in 10 to 600 hp sizes with 2 to
120 𝑚3/min displacement.

Refrigeration & Air Conditioning 4

 Rotary, Positive Displacement Type Compressors
Rotary, screw compressors:

Twin-screw compressor:
 The twin-screw type compressor consists of two mating helically grooved
rotors, one male and the other female. Generally the male rotor drives the
female rotor. The male rotor has lobes, while the female rotor has flutes
or gullies.
 A four-lobe male rotor will drive a six-gully female rotor at 2/3rd of its
speed.
 At 3600 rpm, the number of compressed gas discharges of a four-lobe rotor
will be 4x3600=14,400 per minute
 Unlike centrifugal compressors, it has no surging problem.

Twin-screw compressor with 4 male lobes and

6 female gullies

Refrigeration & Air Conditioning 5

 Rotary, Positive Displacement Type Compressors
Rotary, screw compressors:
Single-screw compressors:

Single screw compressors consist of a single helical

screw and two planet wheels or gate rotors. The
helical screw is housed in a cylindrical casing with
suction port at one end and discharge port at the other
end.

The gate rotors are normally made of plastic materials.

Very small power is required to rotate the gate rotors
as the frictional losses between the metallic screw and
the plastic gate rotors is very small.

Refrigeration & Air Conditioning 6

 Rotary, Positive Displacement Type Compressors

Scroll compressors:

Scroll compressors are orbital motion, positive

displacement type compressors, in which
suction and compression is obtained by using
two mating, spiral shaped, scroll members, one
fixed and the other orbiting.

Refrigeration & Air Conditioning 7

 Roto-dynamic type compressor
Centrifugal Compressors

 In these compressors the required pressure rise takes

place due to the continuous conversion of angular
momentum imparted to the refrigerant vapour by a
high- speed impeller into static pressure.

 As the refrigerant flows through the blade passages

towards the tip of the impeller, it gains momentum and its
static pressure also increases.

 They are more compact and

provide steady flow of air

Refrigeration & Air Conditioning 8

 Roto-dynamic type compressor
Centrifugal Compressors
In the diffuser, the refrigerant is decelerated and as a result the
dynamic pressure drop is converted into static pressure rise.

1: Refrigerant Inlet (eye)

To accelerate the fluid to the impeller inlet
2: Impeller
To transfer energy to the fluid in the
form of increased
static pressure (enthalpy) and kinetic
3: energy.
Vaneless Diffuser 5
4
To convert the K.E at the impeller outlet
into enthalpy in pressure rise
1
4: Volute Casing 3 2
To collect the fluid and to rise pressure further.

5: Refrigerant Discharge

Refrigeration & Air Conditioning 9

 Roto-dynamic type compressor
Centrifugal Compressors
Application of steady-Flow Energy Equation:
Compression is achieved by centrifugal force as well as by conversion of kinetic energy of the high-
velocity vapors into static enthalpy.
Applying the steady-flow energy equation to processes from the entrance to the discharge as shown on
the h-s diagram.
𝐶 42 𝑝4
ℎ20 = ℎ30 = ℎ40
2 𝑝3
ℎ4
𝐶32 4
2
4𝑖𝑠 𝑝2
ℎ3
3
5
𝐶 22 4
2
h→

∆ℎ0 ℎ2
2 1
3 2
Isentropic

𝑝𝑖
𝑝1
ℎ10 = ℎ𝑖0
ℎ𝑖 𝑖 𝐶 12
ℎ1 2

s→
Refrigeration & Air Conditioning 10
 Roto-dynamic type compressor
Centrifugal Compressors

Flow through Inlet Casing (Process i-1):

Fluid accelerated, but there is no energy transfer. The stagnation enthalpy remains constant but there is a drop in the
static pressure and enthalpy.
𝐶𝑖 2 𝐶12
ℎ𝑖 = ℎ10 ℎ𝑖 + = ℎ1 + ℎ1 < ℎ 𝑖 𝐶𝑖 2 < 𝐶12
𝑜 2 2
Flow through Impeller (Process 1-2):
Work done by the impeller. Energy is transferred to the fluid and the velocity, pressure and enthalpy are
increased.
𝐶22 − 𝐶12
𝑤 = ℎ 2 − ℎ1 + = ℎ20 − ℎ10
2
Flow through Diffuser (Process 2-3):
There is no energy transfer, but kinetic energy is converted
into static enthalpy.
𝐶 22
ℎ20 = ℎ30 ℎ2 + 2 = ℎ3 +
𝐶2
3
Flow through Volute casing (Process2 3-4):
There is no energy transfer, but kinetic energy is converted into
static
enthalpy.
ℎ30 = ℎ 40 2 2
ℎ + 𝐶3 = ℎ + 𝐶 4
3 4
2 2

Refrigeration & Air Conditioning 11

 Roto-dynamic type compressor
Centrifugal Compressors

Combining (Processes from 2 to 4):

ℎ20 = ℎ40 𝐶2 2 𝐶 2
4
ℎ2 + 2= ℎ 4 + 2

Further combination:
ℎ20 = ℎ40
𝐶42 − 𝐶12
𝑤 = ℎ20 − ℎ10 = ℎ40 − ℎ10 = ∆ℎ0 = (ℎ4 − ℎ1) + 2

Refrigeration & Air Conditioning 12

 Roto-dynamic type compressor
Centrifugal Compressors
Application of Momentum Equation:

𝜏 = 𝐶𝑤2𝑟2 − 𝐶𝑤1𝑟1

𝑤 = 𝜔𝜏 = 𝜔(𝐶𝑤2𝑟2 − 𝐶𝑤1𝑟1) 𝑢2
𝐶 𝑤2
𝛽2
𝑤 = 𝐶 𝑤2𝑢 2 − 𝐶 𝑤 1 1 𝛼2
𝑢 𝐶𝑟2 𝐶2
Using the law of triangles:

𝐶 𝑟12 = 𝑢 1 2 + 𝐶12 − 2𝐶𝑤1𝑢1

Whirl velocity
𝐶 𝑟22 = 𝑢 2 2 + 𝐶22 − 2𝐶 𝑤2𝑢2

Substituting for 𝐶 𝑤2𝑢 2 & 𝐶 𝑤1𝑢1

𝐶1 𝐶𝑟1
𝐶𝑓1
2 𝛽1
𝑢 2 − 𝑢 2 𝐶 2
−𝐶 𝐶 −𝐶 2 2 𝛼1
2 1 𝑟1 𝑟2 2 1
𝑤= 2 + 2 + 2 𝑢1
𝐶𝑤 1

Refrigeration & Air Conditioning

Conditioning M.Umer Whirl velocity 13
 Roto-dynamic type compressor
Centrifugal Compressors
Combining Energy and Momentum Equation:

𝐶 2 2 − 𝐶 12
𝑤 = ℎ20 − ℎ10 = ℎ2 − ℎ1 +
2
2
𝑢 2 2 − 𝑢 12 2 2 𝐶2 −
= + 𝐶 𝑟1 − 𝐶 𝑟2 + 𝐶12 𝑢2
𝐶 𝑤2
2 2 2
𝛽2
The static enthalpy increase is given by: 𝛼2
𝐶𝑟2
2 2 Dynamic pressure 𝐶2
𝐶 −𝐶
ℎ2 − ℎ1 = 𝑤 − 2 1 (Increase in K.E)
2

𝑢 2 2 − 𝑢 12 2 2
ℎ 2 − ℎ1 = + 𝐶 𝑟1 − 𝐶 𝑟2
2 2 Whirl velocity

Static head due to Relative head resulted

centrifugal force from change in 𝐶1 𝐶𝑟1
Backward Vanes
cross- sectional area 𝛼1
𝐶𝑓1
𝛽1
𝑢1
𝐶𝑤1

Conditioning
Refrigeration & Air Conditioning M.Umer Whirl velocity 14
 Roto-dynamic type compressor
Centrifugal Compressors
Combining Energy and Momentum Equation:

With selection of an appropriate inlet blade angle 𝛽1

At the design point, the velocity 𝐶𝑤1 can be reduced to
zero 𝑢2
𝛼2
When there is no whirl component at
𝐶2
inlet Also at the outlet the whirl 𝐶𝑟2 𝛽
2

component is
𝐶𝑤2 = 0 & 𝐶𝑤2 = 𝑢2 𝑢2
Radial Vanes
Then
𝑤 = 𝑢 22

𝐶1 𝐶𝑟1
𝛽1
𝛼1
𝑢1
Refrigeration & Air Conditioning 15
 Roto-dynamic type compressor
Centrifugal Compressors

Three different characteristic blade angle

Refrigeration & Air Conditioning 16

 Roto-dynamic type compressor
Centrifugal Compressors
Example: A centrifugal compressor handles 3 kg/s of air, running at 2400 rpm. The
internal and external diameters of the impeller are 120 mm and 240 mm, respectively. The
impeller angle at the exit is 35º. The air enters the impeller radially with 7 m/s. Calculate
(a) power required to drive the compressor
(b) the vane angle at inlet
𝑢2
(c) Relative velocities at inlet and 𝐶𝑤 2
outlet 𝛽2
𝛼2
Solution: 𝜋𝐷 𝑁1 𝐶𝑟2
𝑢1 = = 15 𝑚/𝑠 𝐶2
60
𝜋𝐷2𝑁
𝑢2 = = 30 𝑚/𝑠
60

𝑤 = 𝐶 𝑢2𝑢 2 − 𝐶 𝑢1𝑢1

𝑤 = 600 𝐽/𝑘𝑔 𝐶 𝑤2𝑢 2 = 20 𝑚/𝑠

𝑤 = 1.8 𝐾 𝑊 𝐶1 𝐶𝑟1

𝛼1 𝛽1
𝛽1 = 25°
𝑢1
𝐶𝑟1 = 12.2 𝑚/𝑠 𝐶𝑟2 = 16.55 𝑚/𝑠
Refrigeration & Air Conditioning 17
 Roto-dynamic type compressor
Centrifugal Compressors
Performance characteristic and losses:
 This graph shows the pressure-volume/head-flow characteristics of a
centrifugal compressor running at certain speed with 𝛽2 < 90°.
 In actual compressors losses occur due to eddy formation in the flow passages,
frictional losses and shock losses at the inlet to the impeller.
 The entry losses are due to change of direction of refrigerant at the inlet and also
due to pre-rotation.
 The optimum point at which the losses are minimum is selected as the design point
for the compressor.

Leakage and
𝐇𝐞𝐚𝐝

𝐻𝑒𝑎𝑑
Entrance
Losses

𝐂𝐫𝟐(𝐋𝐨𝐚𝐝/𝐅𝐥𝐨𝐰)
𝐃𝐞𝐥𝐢𝐯𝐞𝐫𝐲 𝐯𝐚𝐥𝐯𝐞 𝐜𝐥𝐨𝐬𝐞𝐝 𝐶𝑟 2 (𝐹𝑙𝑜𝑤)
Refrigeration & Air Conditioning 18
 Roto-dynamic type compressor
Centrifugal Compressors
Non-overloading characteristic:
 For a centrifugal machine, there is a decrease in the power requirement with an increase
in the condensing temperature.
 This is due to rapid drop in refrigerants mass flow rate of centrifugal compressor as the
head
required increases..
 This characteristic implies that there is no overloading of the motor with
increasing condenser temperature.

Refrigeration & Air Conditioning 19

 Roto-dynamic type compressor
Centrifugal Compressors
Flat head-capacity characteristic:

The advantages of the centrifugal compressor over the reciprocating compressor are high
efficiency over a large range of load and a large volume of the suction vapor and hence large
capacity for its size.

Evaporator temperature
 In a typical centrifugal compressor at a
constant condensing temperature of 38ºC
and constant rpm, the variation in the
evaporator temperature is only 2 to 7.5ºC
for a load variation of 100 to 240 TR.
 Whereas it is -11 to 6ºC for the same load
variation for a reciprocating compressor.

Refrigeration & Air Conditioning 20

 Roto-dynamic type compressor
Centrifugal Compressors
The compressor is
Performance map:
undersized

Compressor maps are an integral part

of predicting the performance of a
refrigeration system, both at design
and off-design conditions

The compressor is
oversized

Refrigeration & Air Conditioning 21

 Roto-dynamic type compressor
Centrifugal Compressors
Surging:
 A centrifugal compressor cannot pump the refrigerant when the condensing pressure
exceeds a certain value and/or when the evaporator pressure falls below a certain
point.

 If the resulting pressure difference exceeds the design pressure difference of the
compressor, then refrigerant flow reduces and finally stops. Further increase in
condenser pressure causes a reverse flow of refrigerant.

 As a result the evaporator pressure increases, the pressure difference reduces and the
compressor once again starts pumping the refrigerant in the normal direction.

 Once the refrigerant starts flowing in the normal direction, the pressure
difference increases and again the reversal of flow takes place.

 This oscillation of refrigerant flow and the resulting rapid variation in

pressure difference gives rise to the phenomenon called “surging”.

Refrigeration & Air Conditioning 22

 Roto-dynamic type compressor
Centrifugal Compressors
Comparison of Performance of Reciprocating and Centrifugal Compressors:

Characteristics Reciprocating Centrifugal

Pressure Ratio 4 to 7 2 to 5
Flow of Air: Unsteady Steady
Mechanical Low (75 to 80 %) High (above 90 %)
Efficiency
Size High/Bulky Compact
Air Quality Low Quality High Quality
Speed Low High
Maintenance Higher Lower

Refrigeration & Air Conditioning 23

 Types of compressors

Compressors

Positive displacement
Dynamic

Reciprocating Rotary
Centrifugal Axial

One Rotor Two Rotor

One stage
One stage
Multiple vanes Twin Screw Multi-stage
Multi-stage

Single Screw
Fixed vanes

Lobe type
Spiral

Refrigeration & Air Conditioning 24

Reference:
NPTEL, C.P Arora, Wikipedia…

Refrigeration & Air Conditioning 25