Engineering Tomorrow's Industrial Refrigeration Solutions in...

Materials arranged & presented by Ghaleb Abusaa – Eng. Of Opinion

Email: [email protected] 1 www.Abusaa.com GASO

Engineering Tomorrow's Industrial

Refrigeration Solutions in KSA

Quick Review

• Refrigeration science main concern is to drop the temp of a substance, (solid, liquid or gas state) below the surrounding atmospheric temp in a definite place & time.

Definition

• Before AD in Cafes, during night in open areas, sawdust Fredric Tudor, 1856, Kelvinator 67 & 1918

History

• Market size, nature and need locally and globally

HVAC Vs Refrigeration

mailto:[email protected]






Most known method of refrigeration

1. Refrigeration by Evaporation

2. Refrigeration by Vapor Compression

3. Refrigeration by Vapor Absorption

4. Refrigeration by Thermo-Electric Effect

5. Refrigeration by Expansion of Air

6. Combined cooling & heating by unguided swirl flow

through circular pipes








Refrigeration by Thermo-Electric Effect

This type of refrigeration is utilized when current passes in a circuit having

two different metals where one end gets hot & the other gets cold. The temp.

levels depend on different factors such as metal, Ampere rate, etc.

Very limited applications (My personal Experience)

1- Cooling drinking water only, 10 Liters/Hour, 400 Watts, 35 to 15 oC. Dubai

2- Collecting water from Atmospheric air Dubai (With & W/T available Power)







Most known method of refrigeration Most known method of refrigeration


Others experience from the Net








Refrigeration by Expansion of Air

If air when it is under high pressure is released and expanded, its temp will

go down provided useful mechanical work is utilized from it. This principle

was used commercially around 1880 specially for importing meat &

vegetables to Europe from Australia & North America by utilizing expanded

air from the ship engines. Same principle is now used in air-conditioning of

Airplanes by utilizing part of the expanded air from the Airplane engines.







Compressed Air Supply

Control Valve

Hot Air Vortex Spin Chamber

Cold Air


Combined cooling & heating by unguided swirl flow

through circular pipes (Vortex)

A 1/4 ton of

refrigeration in the

palm of your hand!







Combined cooling & heating by unguided swirl

flow through circular pipes

Applications Cooling electronic controls

Cooling machining operations

Cooling CCTV cameras

Setting hot melts

Cooling soldered parts

Cooling gas samples

Cooling heat seal

Environmental chambers

Temp. range -45 to 120 oC.

How A Vortex Tube Works

• Compressed air, normally 5 to 7 BAR, is ejected

tangentially into the vortex spin chamber

• At up to 1,000,000 RPM, this air stream revolves

toward the hot end where some escapes through the

control valve & the remaining air, still spinning, is

forced back through the center of this outer vortex

• The inner stream gives off kinetic energy as heat to

the outer stream and exits the vortex tube as cold air.

The outer stream exits the opposite end as hot air.

Compressed Air Supply

Control Valve

Hot Air Vortex Spin Chamber

Cold Air







Most Common Refrigeration applications

Industrial refrigeration

As the progress of technology continues, new line called industrial and process

cooling started and is heavily used in film making, electronic components,

plastics, soft drinks, oil & Gas, refrigeration in Chemical Industry etc.








Ice manufacture – Human use, Ice rinks, Ready mix concrete








Fishing industry








Low temperature applications

1. The phrase “low, medium & high temperature” is a relative term

a. In air conditioning applications, SST of Zero oC is considered low

temperature.

b. In refrigeration for food and cold storage, zero oC is considered high

temperature application, while “-10 to -15” oC is considered medium

temperature application and “-30 to -50” oC is considered low

temperature application.

c. Temperatures below that up to absolute zero “-270” oC. are

considered Cryogenics.








Low temperature applications

تطبيقات درجات الحرارة المتدنية

Environmental test facilities

مختبرات البيئة

Cryogenics

علم فيزياء درجات الحرارة المتدنية

Low temperature refrigeration

علم تبريد درجات الحرارة المتدنية

Biomedical applications of

Cryogenic refrigeration

التطبيقات الطبية الحيوية لعلم تبريد درجات الحرارة

المنخفضة








1- Env. test facilities are used to simulate an environment or combination of

environments under lab controlled conditions that duplicate or exaggerate

the effects found in actual service. to assist the researcher in exploring the

effects of equipment on resistance to the many environmental forces.

2- Cryogenics is a term normally associated with low temp. However, the

location on the temp scale at which refrigeration generally ends &

cryogenics begins has never been well defined. Most scientists and

engineers working in this field restrict cryogenics to a temp. below 125 K

because the normal boiling points of most of the permanent gases (e.g.,

helium, hydrogen, neon, nitrogen, argon, oxygen, and air) occur below this

temp.








The food industry uses large amounts of liquid nitrogen to

freeze the more expensive foods like shrimp and to maintain

frozen food during transport.

Liquid nitrogen cooled containers are used to preserve whole

blood, bone marrow, and animal semen for extended

periods.

Cryogenic surgery is performed to cure such involuntary

disorders as Parkinson’s disease.

Medical diagnosis uses magnetic resonance imaging (MRI),

which requires cryogenically cooled superconducting

magnets.







Event main topic Refrigeration for the food industry, (Storage & Processing)

Maximizing system efficiency while saving energy consumption

Most common SSTs used in food industry in GCC countries

1. Dry stores around +2 degrees Celsius

2. Chilled products around (-10 to -15) degrees Celsius

3. Holding freezers and blast freezing applications around (-30 to -40) oC.

Most common SCTs in food industry in GCC countries

1- Air cooled condensers around 55 degrees Celsius

2- Evaporative condensers and water cooled systems around +35 to +40 oC.

3- CO2 requires a condensing temperature not to exceed (15) degrees Celsius

Main Refrigerant properties affecting the technical and financial selection

1- Circulation rate (Weight & volume), latent heat & working pressure at design

conditions

2- Safety , ODP, GWP, TEWI







Most common Refrigerants used in GCC & their ODP, GWP & TEWI Vs

some natural refrigerants







Event main topic

Refrigeration for the food industry, (Storage & Processing)









What refrigerant to use







Building a multi purpose cold store only in GCC & ME Region

Temperature applications at SST around (0 to -50) oC







Case study – Life cycle cost

Project: Multi purpose cold store facility

Location: Kingdom of Saudi Arabia

Size: 10,000 metric tons storage capacity

Refrigeration system type: Centralized, screw compressors, evaporative condensers

Refrigerant: NH3

Compressors on line capacity: 850 KW cooling with 450 KW electric power.

Total system power including condensers, coolers and other accessories = 570 KW

Yearly average loading of refrigeration system: Assumed 80% of rated capacity

from a similar job in Australia due to non- availability of data from the local

owner.

Annual power consumption: 8760X0.8*570 = 3,994,560 KW.

Cost of annual electric bills as of today’s commercial rate 0.3 SAR/KW =

SAR1,198,368

Cost of electric bills for 20 Years with today’s rate: SAR 23,967.360








Project: Multi purpose cold store facility

Location: Kingdom of Saudi Arabia

Size: 10,000 metric tons storage capacity

Make up water for the evaporative condensers at the rate of 2.25 Liter/KWH

Annual make up water Mt3 = 13,403

Annual make up water cost at SAR 6/Mt3 = SAR 80,415

Make up water cost in 20 years = SAR1,608,336

Above utilities cost does not include water treatment, spare parts, O & M

labor and consumable. The expected cost of these items may at least

equal the cost of water and electricity. The total OPEX during life

cycle of 20 years is figured around SAR 50,000,000.

The CAPEX for the refrigeration system is in the range of SAR 22,000,000

Conclusion

OPEX are 250% of the CAPEX. More important than CAPEX.








Recommendations

1. Apply sustainability, green, renewables, energy

conservation, reclaim waste energy, & condensate,

economize and apply all building efficiency measures.

Start from early design stage through out the project mile

stones till putting the project into commercial operation.

2. Experience indicate savings in OPEX to be between 15%

& 30% depending on the particulars of your project.







Event main topic



نشكركم على حضوركم ونتمنى لكم طعاما

شهيا على الدوام

صحة وعافية

Thanks for attending, and wish

you delicious meals for ever

Bon appétit!

Q & A



Engineering Tomorrow's Industrial Refrigeration Solutions in...

Documents

Transcript of Engineering Tomorrow's Industrial Refrigeration Solutions in...