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“Energy Efficient Refrigeration system for Dairy Plant”By

P. SUDHIR KUMAR(PAST PRESIDENT – AAR)

( DIRECTOR MARKETING – FRICK INDIA LTD )sudhir@frickmail.com

+91 9819704968

AAR WEBINAR - 20-05-2020 1

Fresh & Hygienic Milk By Animals

Farms Fresh & Hygiene Milk

Collection Points

Rural Milk Collection CentreCools Milk for Collection and

Processing Milk Processing and Storage Centre; DAIRY PLANT

Process Milk into Milk Products

(Cheese, Butter, Yoghurt,Powder, Sweets etc.)

Retail Centre/ConsumersUtilize the Milk And Milk

Products as Nutritious Food

Farmers Transport Milk by Small Vehicle/

Motorcycle/Walk

Milk CollectorCollects milk

from Cooperative Societies

RefrigeratedTransportation

RefrigeratedTransportationof Milk and Milk

Products to Consumers

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CONTENTS : REFRIGERATION LOAD IN DAIRIES

TYPES OF CHILLED WATER GENERATION SYSTEM

ENERGY EFFICIENT COMBINATION OF CHILLED WATER GENERATION SYSTEM

USE OF PRE CHILLER ( PHE & FALLING FILM CHILLERS)

SELECTION OF EQUIPMENTS

USE OF ENERGY EFFICIENT MOTORS, VFD STARTERS AND AUTOMATION

THE AVERAGE ENERGY CONSUMPTION OF REFRIGERATION SYSTEM IN A DAIRY

PLANT OF SIZE 5 TO 30 LAKHS LTR/DAY IS 60 TO 65 %

THE AVERAGE ENERGY CONSUMPTION OF REFRIGERATION SYSTEM IN A DAIRY

PLANT OF SIZE 5 TO 30 LAKHS LTR/DAY IS 60 TO 65 %

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CHILLED WATER LOADCHILLED WATER LOAD

DIRECT REFRIGERATION LOADDIRECT REFRIGERATION LOAD

MAIN REFRIGERATION LOAD IN DAIRIESMAIN REFRIGERATION LOAD IN DAIRIES

CALCULATION OF REFRIGERATION LOAD IN DAIRIES BASED ON VARIOUS MILK

PROCESSES AND COLD STORAGES PLAYS A KEY ROLE IN SELECTION OF EQUIPMENTS

CALCULATION OF REFRIGERATION LOAD IN DAIRIES BASED ON VARIOUS MILK

PROCESSES AND COLD STORAGES PLAYS A KEY ROLE IN SELECTION OF EQUIPMENTS

TYPES OF LOADSTYPES OF LOADS

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DIRECT REFRIGERATION LOAD

MILK COLD ROOMS (3 TO 4 DEG C) BUTTER ,CHEESE AND ICECREAM COLD ROOMS (-18 TO -22 DEG C)

DAHI BLAST ROOMS ( 2-4 DEG C)DAHI COLD ROOM ( 3-4 DEG C)AAR WEBINAR - 20-05-2020 5

HEAT LOAD

Refrigeration load willbe sum of thefollowing for ColdRoom such asStorage, Blast, DeepFreezer etc.,

Wall heat load Air change load Product load and Supplementary

load or Miscellaneous load

Heat Load Sheet

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COLD ROOMS DESIGN

1. OPTIMUM ROOM HEIGHT OF COLD ROOMS TO REDUCE HEAT LOAD

2. ANTE ROOMS IS A MUST FOR NEGATIVE TEMPERATURE COLD ROOM.

3. SIZING OF ACU WITH DRAIN PAN HEATER AND HEAT TRACING OF DRAIN PIPES.

4. PROPER HOT GAS DEFROSTING CONTROLS

1. OPTIMUM ROOM HEIGHT OF COLD ROOMS TO REDUCE HEAT LOAD

2. ANTE ROOMS IS A MUST FOR NEGATIVE TEMPERATURE COLD ROOM.

3. SIZING OF ACU WITH DRAIN PAN HEATER AND HEAT TRACING OF DRAIN PIPES.

4. PROPER HOT GAS DEFROSTING CONTROLS

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COLD ROOMS DESIGN

AIR CURTAINSSTRIP CURTAINS

SLIDING DOORSPUF PANELS & LED ENERGY SAVING LIGHTING

COLD ROOM SAFETY SYSTEM AAR WEBINAR - 20-05-2020 8

CHILLED WATER LOADCHILLED WATER LOAD

MILK CHILLER

RAW MILK CHILLER :34 Deg C to 4 Deg C

TANKER MILK CHILLER10 Deg C to 4 Deg C

MILK PASTEURIZATION : 14 Deg C to 4 Deg C

BUTTER MILK CHILLER : 45 Deg C to 4 Deg C

AGEING TANKS :8 Deg C to 4 Deg C

MILK CHILLER

RAW MILK CHILLER :34 Deg C to 4 Deg C

TANKER MILK CHILLER10 Deg C to 4 Deg C

MILK PASTEURIZATION : 14 Deg C to 4 Deg C

BUTTER MILK CHILLER : 45 Deg C to 4 Deg C

AGEING TANKS :8 Deg C to 4 Deg C

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CHILLED WATER LOADCHILLED WATER LOAD

Calculation of refrigeration capacity

Plotting a Histogram

Decide a base load for the refrigeration

Design a optimum system

Calculation of refrigeration capacity

Plotting a Histogram

Decide a base load for the refrigeration

Design a optimum system

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CHILLED WATER LOAD- CALCULATION

Time

Tanker Milk Chiller

Butter Milk Chiller

Rinse Milk Chiller

Milk Chilling Cream Chilling

Cream Aging

CBBM jacket spray

Butter w ash w ater

Pow der conveying air de- humidif ication

airconditioning

Total Load

FLOW LPH 40000 2000 5000 20000 2500 50000 1875 20000 17000IN/OUT TEMP ( 12-4 ) ( 18-4) ( 34-4 ) ( 12-4 ) ( 34-4 ) - ( 8-2 ) ( 34-8 ) ( 7-2 )Sp.Gravity 1.03 1.03 1.03 1.03 1.03 1 1 1 1Sp.Heat 0.935 0.935 0.935 0.935 0.935 1 1 1 1DELTA T 8 14 30 8 30 1 6 26 5PER HOUR LOAD 101.91 8.92 47.77 50.96 23.89 16.53 3.72 171.96 28.11 16.00

117.20 10.25 54.94 58.60 27.47 19.01 4.28 197.75 32.32 18.407 to 8 A.M 10.25 58.60 27.47 19.01 4.28 32.32 18.40 170.348 to 9 A.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.549 to 10 A.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.5410 to 11 A.M 117.20 10.25 54.94 58.60 27.47 19.01 4.28 32.32 18.40 342.4711 to 12noon 117.20 10.25 58.60 23.89 19.01 4.28 197.75 32.32 18.40 481.7012 to 1 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.541 to 2 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.542 to 3 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.543 to 4 P.M 117.20 10.25 54.94 58.60 27.47 19.01 4.28 32.32 18.40 342.474 to 5 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.545 to 6 P.M 117.20 10.25 58.60 27.47 19.01 4.28 197.75 32.32 18.40 485.296 to 7 P.M 10.25 58.60 27.47 19.01 4.28 32.32 18.40 170.347 to 8 P.M 10.25 58.60 27.47 19.01 4.28 32.32 18.40 170.348 to 9 P.M 10.25 54.94 58.60 27.47 19.01 4.28 32.32 206.879 to 10 P.M 10.25 4.28 32.32 46.8610 to 11 P.M 32.32 32.3211 to 12MidNight 0.0012 to 1 A.M 58.60 27.47 19.01 105.081 to 2 A.M 58.60 27.47 19.01 105.082 to 3 A.M 54.94 58.60 27.47 19.01 160.023 to 4 A.M 58.60 27.47 19.01 32.32 137.414 to 5 A.M 58.60 27.47 19.01 32.32 137.415 to 6 A.M 58.60 27.47 19.01 197.75 32.32 335.166 to 7 A.M 10.25 58.60 27.47 19.01 4.28 32.32 151.94Daily Load 5306.30Average Load/Hr

Running Hours

10 16 4 21 21 21 16 3 20 12

TOTAL LOAD TR

5291.48 1171.97 164.08 219.74 1230.56 576.83 399.31 68.45 593.25 646.49 220.80

Average Load/Hr264.57

15% safety

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Load distribution

0.00

100.00

200.00

300.00

400.00

500.00

600.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time

Cap

acity

(TR

)

Process load

CHILLED WATER LOAD- GRAPH

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CHILLED WATER LOAD- PLOTTING HISTOGRAM

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

450.00

500.00

CAPA

CITY

( TR

)

7 to 8 A.M 10 to 11A.M

1 to 2 P.M 4 to 5 P.M 7 to 8 P.M 10 to 11P.M

1 to 2 A.M 4 to 5 A.M

TIME

HISTOGRAMairconditioning

Powder conveying airde- humidification

Butter wash water

CBBM jacket spray

Cream Aging

Cream Chilling

Milk Chilling

Rinse Milk Chiller

Butter Milk Chiller

Tanker Milk Chiller

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• Total Load = 5, 292 TR / day

• Average Load / 20 Hrs = 264.6 TR

• Peak load = 483.38 TR

CHILLED WATER LOAD- LOAD SUMMARY

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TYPES OF CHILLED WATER GENERATIONTYPES OF CHILLED WATER GENERATION

IBT SYSTEM : This is conventional system

ICE SILO :

IBT + PRE CHILLER SYSTEM (PHE / FFC)A combination of IBT And Pre Chiller depending upon load

histogram.

PHE Chiller / Falling Film Chiller : i. Chilled Water PHE/ FFCii. Chilled Glycol System for Deep Chilling

IBT SYSTEM : This is conventional system

ICE SILO :

IBT + PRE CHILLER SYSTEM (PHE / FFC)A combination of IBT And Pre Chiller depending upon load

histogram.

PHE Chiller / Falling Film Chiller : i. Chilled Water PHE/ FFCii. Chilled Glycol System for Deep Chilling

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IBT SYSTEM : This is conventional systemIBT SYSTEM : This is conventional system

ADVANTAGES OF IBT SYSTEM :

THERMAL STORAGE OF ENERGY AVAILABLE

REFRIGERATION PLANT CAPACITY SMALLER

LATENT HEAT AVAILABLE

SAFE DURING POWER CUTS/ BREAK DOWNS

DISADVANTAGES

MORE SPACE REQUIRED

LOW SUCTION ( -10 DEG C) INCREASES POWER CONSUMPTION

ADVANTAGES OF IBT SYSTEM :

THERMAL STORAGE OF ENERGY AVAILABLE

REFRIGERATION PLANT CAPACITY SMALLER

LATENT HEAT AVAILABLE

SAFE DURING POWER CUTS/ BREAK DOWNS

DISADVANTAGES

MORE SPACE REQUIRED

LOW SUCTION ( -10 DEG C) INCREASES POWER CONSUMPTION

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PHE / FALLING FILM CHILLER WITH IBT SYSTEM

The concept of Pre (PHE/ FFC) Chiller and IBT combination i.e. return water from process will be pre chilled in the PHE/Falling film chiller and fed into IBT for further chilling. In the above system, power saving will be substantial

IBT ( 2 to 0.5 Deg C)

RETURN FROM PROCESS ( 12 Deg C)

Falling Film Chiller / PHE chiller

( 12 to 2 / 0.5 Deg C)To Milk Process

( 0.5 Deg C)

Chilled Water PumpAAR WEBINAR - 20-05-2020 17

In a 1 Lakhs Ltr/ Day Dairy, 60,000 liters of milk will be processed in 4 Hours in the morning and 40,000 liters of milk will be processed in 2–½ Hours in the evening.For a 15,000 LPH milk process PHE chilled water flow of 30,000 LPH shall be circulated with a temp range of 12 to 0.5 C. 12 Deg C return water shall be pre chilled to 2 Deg C in a PHE chiller and fed into IBT for further chilling down to 0.5 C.

PHE / FALLING FILM CHILLER WITH IBT SYSTEM

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IBT SYSTEM IBT CUM PRE CHILLER

Total handling of milk

No of compressor

Comp. connected motor workingSuction/ Discharge temp.

System Details

Liq. pump system

Condenser Type

Refrigeration Capacity

Screw Comp. BkW/ TR

Recip Comp. BkW/ TR

2.00 Lakhs

2 Nos Screw (1w+1S)

1nos. x 160 kW

-10 0 C / 38 0 C

IBT

Yes

Evaporative Condenser

150 TR

0.93

1.02

2.00 Lakhs

2 Nos Screw ( 1 w + 1 s)

1 no. x 132 Kw

-5 0 C / 38 0 C

Pre chiller with IBT

Yes

Evaporative Condenser

150 TR

0.77

0.86

POWER COMPARISON

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ONLY PHE CHILLERS WITH HOT AND COLD WELL TANK

• The concept of only (PHE) Chiller has also been introduced without ice bank tank but with a hot and cold well or buffer tank

• The compressor size increases • Better for peak loads and chilling centers.

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PHE / FFC Chiller SystemFor the PHE / FFC chilling, heat load works out to 135 TR (approximately), a screwcompressor selected @ –2 C SST & 40 C SDT delivers refrigeration capacity of 137.6 TR which consumes 103.3 BkWBkW / TR = 0.75Power Consumption in a day 137.6 TR x 0.75 BkW/ TR x 6.5 Hrs = 671 Units

Equivalent IBT SystemThe BkW/TR of a SCREW compressor for an IBT application at –10 C SST & 40 C SDT will be 1.00

Total Refrigeration capacity required 137.6 TR x 6.5 Hrs = 894 TR Per Day Considering 20 Hours of Operation 894 TR / 20 Hours = 44.7 TRBkW/ TR @-10 SST and 40 Deg C SDT will be = 1.00Power Consumption 44.7 TR x 20 Hours x 1.0 BkW/TR = 894 Units

From saving of approx. 25 to 30 % with the above , you will notice a unit (power)Pre-Chiller system

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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

Ammonia – A Natural RefrigerantsAmmonia – A Natural Refrigerants

SELECTION OF REFRIGERANTSELECTION OF REFRIGERANT

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HEART OF THE REFRIGERATION SYSTEMCOMPRESSORS

HEART OF THE REFRIGERATION SYSTEMCOMPRESSORS

TYPES OF COMPRESSORS IN AMMONIA

RECIPROCATING OR

SCREW COMPRESSORS

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Reciprocating Comp are selected if the refrigeration capacity is

less than 350 kW (100 TR).

Latest developments for energy optimization in reciprocating

compressors

• High speed compressors

• Direct drive.

• PLC control panel

RECIPROCATING COMPRESSORSRECIPROCATING COMPRESSORS

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SCREW COMPRESSORSSCREW COMPRESSORS

SPECIAL FEATURES OF SCREW COMPRESSOR

• Less Space for big plants (Number of compressors less)• Adapts better for power saving in large plants running at part

load.• Dual capacity control system monitors volume as well as

compression control.• Total installed horsepowerreduces.

• Easy to automate• Very low maintenance.

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Rotors

Shaft seal

Discharge CasingThrust bearing

Rotor casing

Housing

Capacity control Valve

Radial Bearing

Capacity Control Cylinder Inlet casing INLET

DISCHARGE

Parts of Screw Compressor Block

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• Evaporative condenser is a water conservation device and in effect, a condenser and a cooling tower combined into a single unit.

• Most of the refrigeration plants in dairies are having open type atmospheric condensers, which mean indirectly getting affected by power penalty.

• Power penalty by way of running the make-up water pump continuously due to water wastage by splashing, high wind velocity etc.

ADVANTAGES OF EVAPORATIVE CONDENSER OVER OPEN TYPE CONDENSERS

Kw Total KwCondenser water pump 6.00 19.00 114.00Cooling Tower Fan 6.00 7.50 45.00

26.50 159.00

Fan Motor 6.00 9.00 54.00Pump Motor 6.00 3.70 22.20

12.70 76.20

Diff. in Kw 82.80 Considering Motor Efficiency 85% 97.41 Therefore Kw difference 97.41 No. of hrs running 20.00 No. of days 300.00 Unit Rate (Rs.) 8.00 Total Saving/ year 46,75,764.71

FOR 6 NOS. PHE CONDENSER ( 300 TR EACH ) + COOLING TOWER + PUMPS

Apart from above the Compressor will run at 38 Deg C Condensing Temp., so that there will be further power saving in

compressor power.

FOR 6 NOS. EVAPORATIVE CONDENSER

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Difference to run at Low Condensing temp at -10 Deg SST Screw

• If run with 38 = 0.06 x 100 TR x 18 Hr x 365 x Rs 7 = Rs. 2.75 Lakhs

• If run with 40 = 0.12 x 100 TR x 18 Hr x 365 x Rs 7 = Rs. 5.50Lakhs

For 100 TRCondensing Temp Deg C Capacity & BkW BkW/ TR

Difference(BkW/TR)

36 104.1 TR/92.4 BkW 0.88

38 103.1TR/97 BkW 0.94 0.06

40 101.9 TR/ 101.9 BkW 1.00 0.12

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Desuperheater SystemDesuperheater System

• To cool down the superheated discharge gas from the compressor before entry into the condenser

• It is usually used in heat recovery to generate hot water ( 50 to 60 DegC ) which can used in crate washing and floor cleaning.

• Temperature range: 0°C to 150°C

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Ammonia Pumping Re-circulation SystemAmmonia Pumping Re-circulation System

• Superb refrigerant distribution

• Lower inlet liquid temperature

• Cut down capital costs

• High system efficiency

• Reduced operating expenses

• Low maintenance

• Protection of compressors from liquid slugs

• Tremendous power saving in operation.

• Reduce Equipment size

• Eliminate individual accumulator

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Priority Vessel And Thermosiphon Oil Cooler

ADVANTAGES OF THERMOSIPHON OIL COLLING SYSTEM

• There is no possibility of contamination of the cooling water circuit

• The water in the cooling circuit does not require to be diverted to produce free cooling

• The free cooling is produced by evaporation of a relatively small flow of refrigerant. Thus a

• Thermosiphon system might require 80 mm refrigerant piping and valves whereas a free cooling

• system, in which the water to be cooled is circulated directly through an ambient cooler, might require 150mm piping and valves.

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Motor should select based on the efficiency.The efficiency of an electric motor is defined as the ratio of usable

shaft power to electric input power.

Motor efficiency [%] = shaft Power [kW] / electrical input [kW]

Based on the Efficiency level, Motor are classified as Eff1, IE1, IE2,

IE3/ IE4 Motors.

Compressor Motor & its Drives.

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SELECTION OF EQUIPMENTS

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Compressor Motor & its Drives.

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VFD & Vertical in line pump for chilled water circulation

• Installed HP of pump will be reduced

• Speed will vary depending upon load means reduce power cost.

• Increase overall efficiency.

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Soft Starter

Variable frequency drive (VFD)

A variable frequency drive (VFD) is a motor control device

that protects and controls the speed of an AC induction motor.

VFD can control the speed of the motor during the

start and stop cycle, as well as throughout the run cycle.

TYPES OF DRIVES

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

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DATA LOGGING / SCADA DCS SYSTEM

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LATEST TRENDS

• PHE/ Falling Film chiller + IBT• Screw Compressors • Evaporative Condensers• Liquid Ammonia pumping system• Thermosiphon Oil Cooling system• Introduction of VFD for compressors.• Chilled water pump automation with VFD• Energy efficient motors ( IE3)• Automation of the complete plant

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NEW INNOVATIONS/CHALLENGES

• LOW CHARGE AMMONIA REFRIGERATION SYSTEM

• CO2 REFRIGERATION SYSTEMS

• AMMONIA REFRERATION CHILLER SYSTEMS FOR COMMERCIAL AIRONDITIONING.

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THANK YOU

YOU CAN MAIL YOUR QUERIES TOammoniaindia@gmail.com

sudhir@frickmail.com

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