Presentation on

Building a Robust Refrigeration System

By

P. Sudhir KumarFrick India Limited

What is a Cold Store ?

A Cold store is a building or a group of buildings with thermal insulation and a refrigeration system, in which various perishable foodstuffs can be stored for various lengths of times in set conditions of temperature and humidity, thus slowing the deterioration and spoilage that would occur in a natural environment. In some countries cold stores are known as refrigerated warehouses.

TYPE OF COLD STORES : TYPE OF COLD STORES :

PRE-COOLING

COLD ROOMS

LARGE COLD STORAGES

FROZEN STORES

IQF/BLAST FREEZING

PLATE FREEZING

HIGH HUMIDITY CHAMBERS

CONTROLLED ATMOSPHERE COLD STORES

PRE-COOLING

COLD ROOMS

LARGE COLD STORAGES

FROZEN STORES

IQF/BLAST FREEZING

PLATE FREEZING

HIGH HUMIDITY CHAMBERS

CONTROLLED ATMOSPHERE COLD STORES

Planning A Cold Store

SITE

PRODUCTS

STORAGE CONDITIONS

MATERIAL HANDLING

REFRIGERATION SYSTEMS

SELECTION OF SITE

A. FACTORS? Geographical

? Economic Factor

B. CONSIDERATIONS? Proximity to Rail/Roads

? Possibility of later expansions

? Water and Power supply

? Availability of Work Force

MAINTAINAING A COLD STORE FOR FINANCIAL VIABILITY

Multipurpose Cold Stores

Operation round the year

Ordinary Single Product Store

Operation only for part of a year

How a Refrigeration Plant is to be designed ?

Capacity of Plant

Refrigerant

Type of Cooling Direct Secondary

Selection of refrigeration equipment

Choosing the Right refrigerant

Why Ammonia ?

? Less expensive to install? Easy to operate? Highly reliable? Easy to modify or expand? Safe? Self-Alarming

Depletion of Ozone Layer

Environmental issue and natural refrigerantsEnvironmental issue and natural refrigerants

Global Warming

Montreal Protocol (1987)

CFC : Fazed out in 1996

HCFC : Regulation starts in 2004 to be fazed out by 2020

Kyoto Protocol (1997)

Requires : Reduction 6% of green house gases compared to 1990 level (First target annual : 2008~2012)

Regulated gases : 3 gases such as HFC

Recovery and disposal of Fluoro-carbon (Freon) law : Refrigerants CFC, HCFC, HFC

PRTR :Aw (Chemical Control promotion law ) : HCFC22, HCFC123, EG Brine etc.

Utilization of natural refrigerants

Comparision of refrigerant characteristicsComparision of refrigerant characteristics

Tc/Te = 40/00C (Sc = Sh=00C) (Calculated by REFPROP V6.01)COP and Refrigeration capacity ratios are compared with R22Discharge pressure at discharge temperature of 400CSafety group is according to AHRAE standard safety group 34A: Lower Toxicity, B : Higher toxicity 1: Nonflammable, 2: Flame resistant 3: Inflammable

Refrigerant ODP GWP100 years

Safety Group

COPratio

RefrigerationCapacity

DischargePressure MPa

DischargeTemp. 0C

HCFC-R22 .055 1700 A1 1 1 1.53 57.5

HFC-R134a 0 1300 A1 0.99 0.91 1.02 44.5

HFC-R404A 0 3870 A1/A1 0.89 0.68 1.83 44.8

HFC-R407C 0 1650 A1/A1 0.99 0.99 1.64 53.6

HFC-R410A 0 1980 A1/A1 0.93 1.0 2.41 57.2

HFC-R507A 0 3850 A1 0.88 0.65 1.88 44.4

R717(Ammonia) 0 <1 B2 1.04 6.90 1.55 93.3

R290(Propane) 0 3 A3 0.97 1.71 1.37 44.2

R600a(Isobutane) 0 3 A3 1.01 1.66 0.53 40.0

R744(CO2) 0 1 A1 0.63 0.85 9.0 72.0

ODP : Ozone Depletion PotentialGWP : Global Warming Potential

Ammonia is a colourless gas that liquefies under pressure and has a pungent odour.

Ammonia is considered a natural refrigerant because it occurs in nature’s material cycles.

Ammonia is also an ideal refrigerant from a climate protection point of view

It contributes neither to ozone depletion nor to global warming .

Ammonia has no ozone depletion potential (ODP = 0) and no direct greenhouse effect (GWP = 0).

Ammonia is combustible only to a limited degree; its ignition energy is 50 times higher than that of natural gas

Source : eurammom-information No.2/August 2005

Ammonia – A Natural RefrigerantsAmmonia – A Natural Refrigerants

Thermodynamic properties :means that its indirect global warming potential is also very low.

Plants that use ammonia as opposed to other refrigerants have a better TEWI (Total Equivalent Warming Impact).

The TEWI is the sum of the direct global warming impact – caused by the refrigerant lost through leakage and recovery

Source : eurammom-information No.2/August 2005

Ammonia – A Natural RefrigerantsAmmonia – A Natural Refrigerants

COMPRESSORS

CONDENSERS

EVAPORATORS

RECIRCULATION SYSTEMS

AUTOMATION

COMPRESSORS

CONDENSERS

EVAPORATORS

RECIRCULATION SYSTEMS

AUTOMATION

EQUIPMENT FOR THE REFRIGERATION SYSTEM

EQUIPMENT FOR THE REFRIGERATION SYSTEM

Most Popular & Successful Compressors are :

+Rotary Twin Screw Compressor Package

+Reciprocating Compressors

Frick India Limited

Frick India high Speed Reciprocating compressors

Frick India high Speed Reciprocating compressors

Capacity Range : 108.9kW to 864 kWCFM Range : 99.4 to 796

Advantages of High speed Reciprocating Compressors

Advantages of High speed Reciprocating Compressors

Latest advancement in refrigeration compressor technology now manufactured and assembled in India.

Runs at 730 rpm to 1200 rpm.

High efficiency and high performance.

Smooth unloading system for power saving.

Low vibration and noise.

Tolerance measured in light bands rather than thousandths of inches.

Advance filter removes 95% of contaminants as small as 3 micron in size.

Oil pressure is maintained even at very low suction pressure.

Double bellows shaft seal.

Installation can be done almost anywhere, even at top floor.

EVAPORATORS

Horizontal Discharge

Vertical Discharge

CONDENSERS

Evaporative Condenser

Evaporative Condenser

• Less Space, no civil work required.

• Less Connected pump & fan motor.(at least 50%)

• Combination of S/T Condenser & Atmospheric Condenser.

• Run at lower condensing Temp – means BKW / TR of Compressor come down and it will reduce the power cost

Ammonia Re-Circulation Systems

Superb refrigerant distribution

Lower inlet liquid temperature

Cut down capital costs

Low maintenance

Protection of compressors from liquid slugs

Tremendous power saving in operation.

Advantages of using Re-circulation System Advantages of using Re-circulation System

Automation system For Refrigeration Plant

Controlled Parameters

Ease of Operation

Flexible Load

Power Saving

Automation in Refrigeration Plant Operation.

Total Plant Control. centralized temperature recorder and interlocking electric circuit for various process controls can be interlocked to your PC/PLC

Additional advantageous of VFD drive When an induction motor is connected to a full voltage supply, it draws

several times ( up to about 6 times) its rated current. As the load accelerates, the available torque usually drops a little and then rises to a peak while the current remains very high until the motor approaches full speed.

By contrast, when a VFD starts a motor, it initially applies a low frequency and voltage to the motor. The starting frequency is typically 2 Hz or less.

Thus starting at such a low frequency avoids the high inrush current that occurs when a motor is started by simply applying the utility (mains) voltage by turning on a switch.

After the start of the VFD, the applied frequency and voltage are increased at a controlled rate or ramped up to accelerate the load without drawing excessive current. This starting method typically allows a motor to develop 150% of its rated torque while the VFD is drawing less than 50% of its rated current from the mains in the low speed range.

A VFD can be adjusted to produce a steady 150% starting torque from standstill right up to full speed.

FRICK INDIA LIMITEDFRICK INDIA LIMITEDSAFETY IN COLD STORE

FIRE SAFETY Causes of Fire Potential Hazards Fire Prevention in protecting the cold store Fire prevention and fire safety equipment Fire precautions

SAFETY FROM ACCIDENTS General precautions Preventing accidents due to poor design Precaution against getting trapped in a freezing room Precaution against refrigerant leak Water safety measures

THANK YOU

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Please contact : sudhir@frickmail.com