Thermax Cooling Products Presentation

Cooling & Heating Solutions Sustainable Solutions in Energy and Environment

Leaders in Energy conservation & Environment preservation

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• 1984 - Started Selling Absorption Chillers made by Sanyo, Japan

• 1989 – Entered into a Collaboration with Sanyo, Japan to Manufacture Steam Fired VAM

• 1994 – In house development of fuel driven VAM (100-1000 TR)

• 1996 – Technical collaboration with Kawasaki, Japan for efficient fuel driven VAM (30-1100 TR)

• 1998 – In house development efficient split evaporator design

• 2001 – Launched ‘Cogenie’ – Small Hot Water Driven VAM Chiller

• 2004 – Launched high COP ‘B4K’ Series VAM & Twin Type Hot Water VAM

• 2005 – Launched Zero Degree VAM

• 2008 – Developed Air Cooled VAM & High COP Next Generation VAM

• 2009 – Built “The World’s Largest Test Facility for VAMs” (VAM testing upto 3500 TR)

• 2009 – Developed & Tested 3200 TR Exhaust gas fired chiller

• 2010 – Developed High efficiency Simultaneous Chiller-Heater

• 2011 – Launched Triple Effect VAM Chillers (World’s Highest Efficiency & COP of 1.7)

• 2012 – Launched the improved Twin type hot water VAM Chillers

• 2013 – Launched the improved Double Effect Series VAM Chillers

• 2014 – Launched Closed Circuit Cooling Towers/ Evaporative Condensers / ACC/ Dry Coolers

The Thermax Journey Te

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Thermax Product Basket

-40 +160

Closed Circuit Cooling Tower /Evaporative Condenser

0 -5 LiBr VAM

35 Hybrid Chiller Heat Pump

(Type I)

Chiller - Heater

Heat Pump (Type II)

90

V-type & H-type Dry Cooler

Air Cooled Condensers

COOLING SOLUTIONS

Single effect (COP: 0.7 – 0.75) Steam: 0 – 3.5 bar.g Hot water: 80 – 150 oC

Double effect Chiller (COP: 1.38 – 1.43) Steam: 3.0 – 10 bar.g Hot water: 150 – 185 oC Exhaust gas: 270 – 600 oC Direct fired (Oil / Gas / LPG)

Triple effect (COP: 1.75 – 1.9) Steam: 10 – 26 bar.g Hot water: 200 – 225 oC Exhaust gas: 400 – 600 oC

Hybrid Chiller (25 – 250 TR) Steam: 0.5 – 10 bar.g Hot water: 90 – 185 oC Exhaust gas: 270 – 600 oC Direct fired (Oil / Gas / LPG)

HEATING SOLUTIONS

Heat Pump Type I [200 kW – 40 MW] Steam: 1 – 10 bar.g Hot water: 130 – 185 oC Exhaust gas: 270 – 600 oC Direct fired (Oil/Gas/LPG)

Heat Pump Type II (Heat Transformer) Generates steam or hot water at high T from low T hot water

Chiller-Heat Pump Simultaneous chilled & hot water NO cooling water required

Chiller-Heater 40% savings on on Heating Can operate in Cooling only, Heating only or Simultaneous cooling and heating modes Requires cooling water

NON-ABSORBTION COOLING

CLOSED CIRCUIT COOLING TOWER Replaces conventional cooling tower and PHE/shell-tube heat exchanger For Process Fluid/Gas Cooling

Evaporative Condenser Replces conventional Atmospheric Condensor/ Cooling Tower for Chillers/ etc.

Dry Coolers V-type Dry Coolers H-type dry coolers

AIR COOLED CONDENSERS For Power Plant Steam Condensation


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What is Refrigeration ?

REFRIGERATION

AIR CONDITIONING

Air Conditioning

Refrigeration Heating Addition /

Removal of Moisture

Air Purity and Noise Control

Air Distribution

» Since heat cannot flow from low temperature reservoir to high temperature reservoir on its own, external work is required to achieve refrigeration.

– Refrigeration: Producing and maintaining a temperature below that of the surrounding atmosphere.

– Air Conditioning: Maintaining temp, humidity, purity, quality and distribution of air in a given space.


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Tons of Refrigeration (USRT or TR)

AIR CONDITIONING

1 US Ton of Water

at 0 oC

1 US Ton of Ice

at 0 oC

Day 1 00:00 Hrs

Day 2 00:00 Hrs

Heat Removal at Constant rate

• Rate at which heat has to be removed from 1 US ton of Water (907 kg) at 0 oC to get 1 US ton of Ice at 0 oC in 24 Hours

• Commonly used unit to express refrigeration capacity

• Unit Conversion:

1 USRT = 3024 kCal/hr

= 3.51628 kW


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Types of Refrigeration Systems

AIR CONDITIONING

Refrigeration Systems

Vapour Compression

Screw Chillers Capacity 25 – 300 TR Temperature no bar

Centrifugal Chillers Capacity > 300 TR

Temperature >0 oC

Reciprocating Chillers

Low Capacity (<100TR)

Temperature no bar

Vapour Absorption

Lithium Bromide Good COP, Standard

Range, Positive Cooling

Ammonia Low COP, Custom Built,

Sub Zero application


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Multi Energy to Multi utility


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COP Improvement Over the Years

0.65

1.2

1.35

1.42

1.7

1.8

0 0.25 0.5 0.75 1 1.25 1.5 1.75 2

1983

1996

2004

2008

2011

2013

COP of Thermax Chillers


Types of Vapour Absorption Machines

Based on its Utility / Application

Chiller Chiller - Heater Heat Pump

(Type I) Heat Pump

(Type II) Chiller - Heat

Pump

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Based on Effect (No of stages of regeneration)

Half Effect COP – 0.4

Single Effect COP – 0.75

Single-Double Effect

COP – 1.05

Double Effect COP – 1.4

Triple Effect

COP – 1.8

Based on Driving Heat Source

Steam Driven Hot Water

Driven Exhaust Gas

Driven Direct Fuel Fired

Multiple Heat Sources


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Comparison- Compression & Absorption Chillers

AIR CONDITIONING

CONDENSER

COMPRESSOR

EVAPORATOR

Electricity

CONDENSER

GENERATOR

EVAPORATOR

Heat

PUMP

ABSORBER


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Comparison Between Engine and Chiller

ENGINE

Power Output ‘O’

Input Energy, ‘I’

CHILLER

Refrigeration Output ‘O’

Input Energy, ‘I’

Heat rejected to Hot water

‘R1’

Heat rejected to Exhaust Gas ‘R2’

Heat Rejected to Cooling Water, ‘R’


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Principle of Operation

• Shell side of evaporator maintained under vacuum

• Chilled water circulated through evaporator tubes

• Saturated Liquid Refrigerant sprayed on the evaporator tubes

• Latent heat of evaporation for refrigerant extracted from chilled water

• Chilled water temperature reduces

• Refrigerant vapour produced

• Pressure inside the shell increases

Higher Pressure = Higher Boiling Point Lower Pressure = Lower Boiling Point


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Higher LiBr Concentration = High Affinity Lower LiBr Temperature = High Affinity

Concentrated LiBr solution sprayed in absorber

Concentrated LiBr solution is hygroscopic in nature (has affinity to water vapour)

Refrigerant vapour absorbed by LiBr solution

Pressure in shell reduces

Absorption process exothermic

Cooling water circulated through absorber tubes remove heat of dilution

Dilute LiBr solution generated



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• Dilute LiBr solution taken to generator by absorbent pump

• LiBr solution heated by heat source to its boiling point

• At boiling point, refrigerant boils out as LiBr has higher boiling point

• Concentration of LiBr solution increases

• Concentrated LiBr solution sprayed again in absorber

• Pressure increases inside the generator due to refrigerant vapour

Higher Pressure = Higher Boiling Point Lower Pressure = Lower Boiling Point



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• Refrigerant Vapour goes into the condenser

• Refrigerant vapour condenses by rejecting heat to cooling water flowing in the condenser tubes

• Liquid refrigerant goes back into the evaporator to continue cooling cycle

• This completes one cycle of absorption cooling

• Cooling is generated as long as heat source and heat sink (cooling water) are available

Lower cooling water inlet temperature = Lower Pressure in the condenser / generator



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High Efficiency Chiller – Heater

• Heat Source • Dry Saturated Steam (3.0 – 10.0 bar.g)

• High temperature hot water (145 – 180 oC)

• Direct Fuel Firing (Gas/Oil/LPG/Propane)

• Exhaust Gas (275 – 600 oC)

• Capacity Range

• Cooling : 100 – 3500 TR

• Heating : 100 kW – 9 MW

• Temperature Range

• Cooling : 0 – 30 oC

• Delta T : 30 oC max

• Heating : 30 – 90 oC

• Delta T : 5 – 50 oC

• 23 % saving in overall heat input

OR 40% saving on heat input for heating


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Double Effect Steam/Hot Water fired VAM

• Heat Source • Dry Saturated Steam (3.0 – 10.0 bar.g)

• High temperature hot water (150 – 180 oC)

• Capacity Range : 50 – 3500 TR

• COP : 1.38 – 1.43


• Water : 1.0 – 35 oC

• Glycol : 0 – 35 oC



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Triple Effect Steam Fired VAM

Capacity Range : 50 – 1000 TR

Heat Source : Dry Saturated Steam (15 – 25 bar.g)

Specific Steam Consumption:

2.8 – 2.9 kg/hr/TR

COP : 1.7 – 1.8


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Single Effect Steam/Hot Water fired VAM

• Heat Source: • Dry Saturated Steam (0.0 – 3.5 bar.g)

• Medium temperature hot water (120 – 150 oC)

• Capacity Range : 100 – 3500 TR

• COP : 0.72 – 0.76


• Water : 1.0 – 35oC

• Glycol : 0 – 35oC

• Delta T : 30oC max


Double Effect Direct Fired VAM

• Heat Sources: • Natural gas / HSD / LPG / Propane

• Bio gas / Coke oven gas / Corex gas

• Capacity Range : 50 - 1350 TR

• COP : 1.3 - 1.35


• Water : 1.0 – 35 oC



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Double Effect Exhaust Fired VAM

• Heat Source: • Flue gases (275 oC - 600 oC)

• Lowest Exhaust Gas outlet : 135oC (for natural gas engine exhaust)

• Capacity Range : 50 - 3500 TR

• COP : 1.38 - 1.43


• Water : 1.0 – 35 oC


• Delta T : 30 oC max 23


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Touch Screen Control Panel

HMI: Siemens TP 700

o 7 inch TFT Touch Screen operator panel

o SD and USB slots available for data logging

o Capacity to log nearly 500 alarms

o Supports nearly 40 languages

o Printer connectivity via USB

o Software downloads using pack and go via ethernet cable


Other Vapour Absorption

& NON VAM -Related Products


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Heat Pump – Type I Heat Source (30 - 60oC):

Cooling tower water

Process condensate / hot water

Geothermal water

Driving Heat Source:

Dry Saturated Steam (1 – 10 bar.g)

High temperature hot water (130 – 180 oC)

Exhaust Gas (275 – 600oC)

Direct Fired (Gas/Oil/Propane/LPG)

Heating Capacity : 0.25 – 40 MW

Heating COP : 1.65 – 1.75

Temperature Range

• Hot Water : 35 – 90oC

• Delta T : 55oC max


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Heat Pump – Type II Heat Source (80 - 120oC):

Process condensate / hot water

Geothermal water

Steam condensate from steam turbine

Heating Output:

Dry Saturated Steam (1.0 – 4.0 bar.g)

Hot water (110 – 155 oC)

Heating Capacity : 0.5 – 10 MW

Heating COP : 0.45 – 0.5


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Sub-Zero Cooling – Hybrid Technology – Electrical

• Runs on Vapour compression

technology

• Higher COP

• Requires clean high grade

energy for operation

• High Power Consumption

– Chemical

• Predominantly Vapour

Absorption type

• Lower COP

• Runs on low grade waste heat

– Hybrid chiller harnesses the

advantages of above

technologies

– Maximizes the benefits from

both cycles


Operational Principle A. Refrigerant /Water is circulated through the coils. B. Heat from refrigerant dissipated through coil tubes. C. Partial heat evaporated sidewise directly by the

downward natural induced air & discharged to atmosphere.

D. Rest of the heat remains to the water cascading downward over the tubes.

E. Simultaneously, air is drawn in also through the air inlet louvers at the base of the condenser and travels through the dehydrator and heat exchange fills at the same direction of the water flow.

F. A small portion of the water is evaporated which removes the heat. The warm moist air is drawn sidewise also by the fan and is discharged to the atmosphere.

G. The remaining water falls to the sump at the bottom of the condenser where it is recirculated by the pump up through the water distribution system and back down over the coils.

What are Evaporative Condensers / Closed Circuit Cooling Towers?

Evaporative Condensers / Closed circuit cooling towers operate in the manner similar to open cooling towers, except that the heat load to be rejected is transferred to the process fluid (refrigerant gas / water / process oil / working fluid being cooled) to the ambient air through a heat exchange coil. The coil serves to isolate the process fluid from the outside air, keeping it clean and contamination free in a closed loop.Thus, hereby, two separate circuits are created

Primary / Internal circuit in which the process fluid / gas circulates inside the coil Secondary / External circuit sprays circulates water over the coil & mixes with outside air


Water Distribution System

Side Air Inlet Screen & Air Deflector

Honeycomb Fills Circuit Pump & Descaling Cleaner /Water Curing Device

Basin with Slope Bottom

Condensing Coil Set

Drift Eliminator Maintenance Room

Axial Propeller Fan

Convenient Repair & Maintenance


Advantages of Evaporative condenser/

Closed Circuit Cooling Tower

• Advanced Technology Condenser/Cooling Tower

• Environmentally Conscious Operation

• Low Energy Consumption

• Lower Annual Operating Costs

• Reliable & Simple Operation and Maintenance

• Completely isolate the process cooling fluid from the atmosphere. avoid contamination

• Occupies upto 30% less space compare to conventional systems

SPLASH FILL FILM FILL Cooling Technology

using the fill method Conventional Cooling Tower /

Atmospheric Condenser THERMAX®

Evaporative Condenser

Effective heat exchange area 30 - 45 m2 /m3 150 m3 Fill height required 5-10 m 1.2-1.5 m

Pumping head required 9-12 m 5-8 m Typical Liquid/Air ratio 1.1-1.5 1.5-2.0 Quantity of air required High Very Low

Comparison of types of fills - Bureau of Energy Efficiency (BEE) India, 2004


Reference Installations

Thank You

Thermax Cooling Products Presentation

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