Providing free cooling

from low temperature waste heat

through

By

Dinesh Gupta Past President ASHRAE India chapter

President, Bry-Air Asia

A. THE TECHNOLOGY

Comparing the adsorption cycle with the refrigeration cycle......Something

you are already familiar with … History of Adsorption Chiller More on the working principles of Adsorption Chiller The Adsorber... at the heart of it all Let us compare Adsorption Chiller with Absorption Chiller

Comparing the adsorption cycle with the refrigeration cycle ... Something you are already familiar with …

THE REFRIGERATION CYCLE THE ADSORPTION CHILLER CYCLE

The thermal

compressor

The electric

compressor

1848: Faraday produced cooling using adsorption refrigeration phenomena using silver chloride to adsorb ammonia.

1928 : Albert Einstein and his former student, Hungarian-born American physicist Leo

Szilard first patented the design for Absorption refrigeration in 1928. 1986: The commercialization of Adsorption Chiller happened in Japan using silica gel

and water pair. 2000: CCHP Adsorption machines were used in Germany 2008: PPI developed Eco Max Adsorption Chillers using Silica Gel and water pair. 2015: Bry-Air introduces Adsorption Chillers for the first time in India / Asia.

Brief History of Adsorption Chillers

ADC WHITE BOARD PRESENTATION

How does the Adsorption Chiller Work?

• The principle of adsorption works with the

interaction of gases and solids. With

adsorption chilling, the molecular interaction

between the solid and the gas allow the gas

to be adsorbed into the solid.

• The adsorption chamber of the chiller is

filled with solid material, silica gel,

eliminating the need for moving parts and

eliminating the noise associated with those

moving parts.

• The silica gel creates an extremely low

humidity condition that causes the water

refrigerant to evaporate at a low

temperature.

• As the water evaporates in the evaporator, it

cools the chilled water.

How it Works:

Silica gel

Silica gel

7°C(44:F)

12°C(53:F )

29°C

(85:F )

38°C(100:F)

90°C(182:F)

80 :C(182:F)

Adsorption Chamber 1

Adsorption Chamber 2

Evaporator Chamber

Cold Water

Cool Water Hot Water

“Flapper valves”

Condenser Chamber

External Water Trap Column (breaks pressure differential)

Refrigerant water

Silica gel

Silica gel

7°C(44:F)

12°C(53:F )

30:C(85: F)

38°C(100:F)

90°C(182:F)

80 :C(182:F)

Adsorption Chamber 1

Adsorption Chamber 2

Evaporator Chamber

Cold Water

Cool Water Hot Water

“Flapper valves”

90:C(194: F)

80:C(182:F)

Heat Recovery: Mass Recovery: Normal Cycle:

Components of Adsorption Chiller

Current Range: 35 kW to 1180 kW (10 to 335 tons) Future Range: 10 kW to 35 kW (3 to 10 tons)………the BryChill Range

The External System with BOP (Balance of Plant)

External to the Adsorption Chiller

Components of BOP and their importance

1. Heat source and heating, comprising

• Hot water (through waste heat or solar)

• Hydraulics package comprising the pump, expansion tank, meters, temperature

probes and chemical treatment system (if needed)

• Interconnecting plumbing and valves

• Hot water tank for temperature buffering

2. Heat rejection equipment comprising

• Cooling tower or Dry Cooler with or without evaporative cooling or geo-thermal

• Hydraulics package comprising the pump, expansion tank, meters, temperature

probes and chemical treatment system (if needed)

• Interconnecting plumbing and valves

• Plate frame heat exchanger

3. Chiller water comprising

• Interconnecting piping and valves

• Pump

Adsorption Chiller Works well at low hot water temperatures!

Adsorption Chiller Vs Absorption Chiller R

efr

igera

tion C

apacity

Adsorption

60 70 80 90 100 110 120 130 140

degrees C

Absorption

Complimentary or Competitive?

Absorption may

be a better choice

Adsorption is

your only answer

80-90ᵒC Sweet spot of Adsorption

Adsorption Chiller Vs Absorption Chiller

Limitations of Absorption Chiller

Benefits of Adsorption Chiller

• Long life > 25 years

• Negligible maintenance

• Low noise and vibration

• Wide range of operating temperatures

• Lithium bromide is highly corrosive and toxic

• Crystallization is very high

• High corrosion protection required • Maintenance is very high

B. HOW TO APPLY

1. Importance of: 1.1) Understanding COP 1.2) Waste heat – Types of waste heat including generated heat 1.3) Hot water temperature and its impact 1.4) Cooling water temperature 2. Performance calculator and some working examples 3. BOP 3.1) Heat sources 3.2) Maintenance and lack of maintenance thereof

Understanding COP

Coefficient of performance COP = Cooling Produced Heat Input

COP is only important if heat has been generated though solar, steam, other sources for driving the heat into the chiller. COP is not important if there is abundant supply of waste heat

TYPES OF WASTE HEAT

Examples: • Food processing

• Beverage processing

• Hospitals, Universities

• Chemical processing

• Manufacturing sites

Present installation(PPI): •Fritolay, Charlotte; (potato chip line, 1 chiller)

•Network Appliance, Fresno,CA (3 chillers)

Source 1: Process Waste Heat

Solar

Array

Examples: • Commercial

• Light industrial

• Multi-Family Housing

Present installation(PPI): Mixed use development,Fletcher, NC

by Vanir Energy

(640 collectors & 2 chillers for heating,

hot water, A/C)

Source 2: Solar Heat

Example: Turbine or diesel driven generators for

electric power, heating & A/C

Present installation(PPI): Vineyard 29, St. Helena, CA.

(2 Gas Turbines, 1 Chiller)

Source 3: Tri-Generation

ADsorption

60 70 80 90 100 110 120 130 140

degrees C

ABsorption

Complimentary or Competitive?

ABsorption may

be a better choice

ADsorption is

your only answer

80-90ᵒC Sweet spot of Adsorption

Turbine Exhaust Gas

Engine Jacket Water

Solar – Flat Plate / Evac Tubes

Condensed Water from Food Frying

Process Waste Heat Process Waste Heat

Actual Performance at 52 / 30 / 9.4 C

Cooling Capacity Vs Condenser Water Temperature

U.S. Embassy – Monrovia, Liberia

• U.S. Dept. of State, OBO

(Overseas Building Operations)

• 150TR @ 52°F chilled water

• Tri-generation application

• Shipped 1st Qtr, 2010

U.S. Embassy – Monrovia, Liberia

FACTS

• On-site diesel generator producing 1,000 kW of electricity

• 1,300 kW of waste hot water available at 90 C

• Need 150 tons of cooling at 52 F (11 C)

• Evaporative cooling is available at 30 C

CRITERIA FOR SELECTION

• Heat check: 1,300 kW x 0.55 COP = 715 kW (204 tons) is possible, so more than enough heat is available.

90 C hot water

30 C cooling water

11 C chilled water

120% actual

output vs nominal

U.S. Embassy – Monrovia, Liberia

Which chiller model is required?

• Knowing that 120% of nominal output will be provided at these

conditions…

• 150 tons / 1.2 = 125 ton (nominal) will provide the required cooling

output

• So a model E-125 would be the proper selection, but that is not

available. A model E-120 and E-140 are available. By contacting the

manufacturer, we learn that a model E-125 can easily be produced

and will have the same dimensions as the E-120.

U.S. Embassy – Monrovia, Liberia

Ed W. Clark High School – Las Vegas, NV

• HVAC Modernization Project

• 105TR

• Solar application

Ed W. Clark High School – Las Vegas, NV

Fact

• HVAC Modernization Project

• 105TR

• Solar application

• 500 solar hot water panels expected to produce 2,290,000 BTU/hr (671kW) of hot water at 88°C

• Evaporative cooling available at 28 C

• Chilled water design temperature 7 C

Selection Criteria

Heat check: 671 kW x 0.55 COP = 369 kW (105 tons)

90 C hot water

28 C cooling

water

7 C chilled water

104% actual

output vs

nominal

Ed W. Clark High School – Las Vegas, NV

• 671kW of hot water at 88°C

• Evaporative cooling available at 28°C

• Chilled water design temperature 7°C

• What size chiller is needed?

• 1. Heat check: 671 kW x 0.55 COP = 369 kW (105 tons)

• 2. Size: 369 / 1.04 = 354 kW (100 tons)

• A nominal 100 ton chiller model E-100 can be used.

• For added safety factor, a slightly larger model E-105 was actually used.

Ed W. Clark High School – Las Vegas, NV

Zero Carbon Building – Hong Kong

• New construction – no emissions

• 20 TR

• On-site power generation

Zero Carbon Building – Hong Kong

Facts

• 45% Less Energy Consumption than Standard Design

• Heat source: Biodiesel Generator

• Electric Power Output: 100 kW

• Hot Water Production: 100 kW at 80°C

• 1% Summer Design Conditions: 91 dry bulb / 79 wet bulb (33 / 26°C)

• Dry cooler is required (assume 5°C approach)

• Chiller COP = 0.55

• Required output: 46 kW of cooling at 7°C

Selection criteria

Heat check: 100 kW * 0.55 = 55 kW possible

(enough heat is available)

80 C hot water

38 C cooling water

7 C chilled water

65% actual

output vs nominal

Zero Carbon Building – Hong Kong

• Hot Water Production: 100 kW at 80°C

• Chiller COP = 0.55

• Required output: 46 kW of cooling at 7°C

What size chiller is needed?

• 1. Heat check: 100 kW * 0.55 = 55 kW possible (enough heat is available)

• 2. Size: 46 kW / 0.65 = 70.7 kW nominal size (20 tons)

• The model C-20 will deliver 46 kW of cooling.

Zero Carbon Building – Hong Kong

Heat Sources and heat exchangers thereof

• Onsite power production e.g. Tri-Generation (CHP), DG Sets, Gas engines • Radiator - Jacket water • Exhaust gas heat - Hex required

• Industrial waste heat • Flue gas exhaust heat • Boiler condensate • Boiler blow down • Process waste heat e.g.

• Refineries • Power plants • Food processing, and beverages • Chemicals • Pharmaceuticals • Plastic extrusion • Pulp and paper • Aluminum • Cement • Steel

• Solar thermal

• Evacuated tube collectors • Flat plate collectors • Concentrated parabolic collators, dish and trough

Minimal Maintenance

Items to maintain

• Monthly - Dispose of condensed water from vacuum pump

• Monthly - Visual inspection of Chiller

• Quarterly - Replace vacuum pump oil

• Annually - Inspect butterfly valves seals

– Inspect vacuum bellows, pneumatic actuators,

temperature sensors

Please note: • No chemical additives • No compressors • No fluorocarbon/corrosive/toxic refrigerants

Adding Water is Simple (if ever required)

The Bry-Air Adsorption Chillers

1964 USA 1991 Malaysia

2006 Bry-Air Asia acquired global

business interests including

the Bry-Air brand from Bry-

Air Inc., USA 1999 China 2010 Switzerland 2013 Brazil

Leaders in Dehumidification…Worldwide

1981 India

Partners in innovation

Bry-Air manufactures Adsorption Chillers in India under license from Power Partners Inc., USA (PPI).

Power Partners, Inc., Athens, GA, USA

Facility:

Square footage: 677,400

Products:

Overhead Distribution Transformers

Solar Water Heaters

Adsorption Chillers

Milestones:

52 Years in Operation

7 Years as Power Partners, Inc.

More than 8 million overhead

transformers produced

Question and Answers

Thank you!