. AR Ammonia Cie elim clue Licelt and Training Program Basic Ammonia Refrigeration Module 5 - CondensersIIAR Basic Ammonia , Refrigeration Module 5 - Condensers Lesson 1 In previous modules, we discussed some of the major ‘components that make up industrial refigeration systems, ned ceo Most industrial systems have a receiver (Fig. 1) that contains the supply of liquid ammonia | necessary to operate the system when needed upon demand. Liquid ammonia flows from receiver through a king valve and a pressure reduction device, which in this case is an Coad ‘expansion valve, and into a vessel. As it passes through the 7 valve, the pressure and temperature of the ammonia reftigerane are suddenly oe lowered a Porn A pump moves the cold Pune Matecing vale ammonia fiom the vessel, through a metering valve and into an evaporator where the liquid ammonia con- verts to a vapor as it absorbs heat. The compressor, pulls the ammonia vapor from the evaporator and through the vessel, increases the pressure and temperature, and delivers the superheated vapor to the condenser. In the condenser, the ammonia vapor rejects the heat collected by the refi asic passed through the evaporator and compressor. As the hea rejection process ‘occurs, he ammonia refrigerant condenses, returning to aliquid. The liquid ammonia flows out of the condenser, collecting in the high pressure receiver where its held for reuse in the system, In this module we will examine some of the different types of condensers in use in industrial refrigeration systems, ‘The condenser (Fig. 2) is an important part of the ammonia refrigeration system for two primary reasons. First, itis responsible for removing the heat from the ammonia refrigerant thac was absorbed in the gm. cvaporator and added by the mechanical © operation of the compressor. [n addition, the vapor rejects heat, gradually converting into a liquid as it flows from the inlet header to the outlet header. Coed Fig. 1 Fig. 2 Module 5 1‘As we know, the system uses the same ammonia ‘over and over. Since the ammonia must be in liquid form to pick up heat in the evaporator, it must return toa liquid atthe end of the process in order to be reused. The condenser converts ammonia vapor toa liquid, which is the second reason why the condenser isan integral component in the system, ‘One way to think about the condenser i asa companion component of the evaporator. (Fig. 3) Condensers and evaporators have many pats with the same names. However, the tasks they perform ina refrigeration system ate exactly opposite. In an evaporator, ammonia converts from a liquid to a vapor. However, in a condenser, ammonia converts from a vapor toa liquid. Fig. 3 ‘As we learned in a previous module, an evaporator is often located directly within the area to be refrigerated. Ammonia flows into the evaporator coil, absorbing heat at its boiling point. The process that occurs in the condenser is exactly the opposite of this The condenser cools ammonia vapor. As a result, it rejects heat and condenses back to a liquid. Unlike an evaporator, the condenser is always located away from the area to be cooled, In fact, the condenser is generally located outdoors to allow the rejected heat to be released outside of the area that is being refiigerated In previous lessons we learned chat a5 the ammonia enters the condenser it isa supetheated vapor. Before entering the condenser, the ammonia has absorbed heat in both the evaporator and in the compressor. <0 (Once ammonia vapor enters the condense, it interacts with a condensing medium. ‘A condensing medium is the water, ai, or a combination of both that absorbs the heat from the ammonia vapor in the condenser (Fig. 4). Is important to understand that this interaction isnt direct: the ammonia rejects heat to the ng medium through a heat exchange surface such as a coil, tube or pipe. Because heat is always con the move from warmer matter co colder matter, the condensing medium absorbs the heat rejected by the ammonia vapor causing, the temperature of the ammonia vapor to decrease until it reaches the point at which it condenses to aliquid. ‘Afcer dhe ammonia exits the condenser, the liquid ammonia flows into a receiver where itis collected for reuse in the refrigeration sytem Fig. 4 “Thus, where the ammonia absorbs heat in the evaporator, causing it to boil and evaporate, it rejects heat in the condenser, causing it to convert back to a liquid, achieving two imporcant goals: 2 Module 51) unvanted heat has been removed from the area to be cooled. 2) the ammonia has returned to a liquid s0 that it can be used again to pick up and remove more unwanted heat from the arca to be cooled Though the design of condense and method of xpoxng the ammonia 0 2 cooling agent may vary the condensation process remains the same in Condenser You wil real tha boling ammonia an pick up here wou change in temperature. The same is true as ammonia vapor rejects heat. Is temperature decreases until it reaches the point at which ammonia vapor converts back into aliquid with no Further reduction in temperature. This point is called the saturation poine. ‘When we tak about the temperature at which the liquid ammonia converts to 4 vapor—as it does in the evaporator—is called the boiling point. However, ‘when we refer to the temperature at which ammonia vapor converts back to a liquid —as it does in the condenser—it is refered to as the condensing point. 1s at this temperature that the liquid ammonia then flows back into the receiver, where ic stars through the refrigeration circuit once again To Review: AR © Condensers are important co the refrigeration process for two primary . 1) they reject heat collected by ammonia in the evaporator and compressor 2) they convert ammonia vapor to liquid in order for it to be reused in the system. © Condensers are located away from the arca tobe refrigerated © Ammonia absorbs heat in the evaporator and rejects heat in the condenser, © Condensers use air or water or both to absorb heat rejected by the ammonia vapor. © Juse as boiling ammonia can absorb heat without a change in temperature, condensing ammonia can also reject heat without a change in temperature. © Saturation or condensing temperature of ammonia is similar to the boiling temperacure of ammonia, PX Module 34 Lesson 2 =e The condensing process has two distinct stages. The frst stage occurs when the compressed, superheated gas flows into the condenser. At that point the cooling medium: the air and/or water—removes sensible heat from the Ye learned before that sensible heat is the heat that can be measured or “sensed” by a thermometer. As sensible heat is removed, the temperature of| the ammonia vapor decreases until ic eaches the saturation temperature. Fig. 5 Cee eae OAC ee Ree) Due Fig. 5 Cer een eg Oe) Ru ea More efficient To Review: The second stage occurs when the vapor reaches the saturation point, which is the temperature at which the refrigerant begins to condense to a liquid. Ac this point, the condensing medium absorbs the latent heat of the ammonia. The latent heat, we learned previously, is the heat that cannot be measured by a thermometer Even though the vapor continues to convert to a liquid at ths stage. the pressure and temperature of the ammonia does NOT change. ‘Another important fact to remember is that an ammonia refrigeration system works most efficiently when the difference between the low side pressure and the high side pressure is ac che ‘minimum that’ possible. In terms of temperature that means the difference between the condensing temperature and the evaporating temperatures are as close as possible (Fig. 5). We learned in Module 2 that in the evaporator, ammonia has a greater capacity o absorb heat ‘once it has reached its boiling temperature. The same concept applics in the condenser. When ammonia vapor contains excessive superheat, as i does when it leaves the compressor, an additional amount of condensing medium, air and/or water, and heat exchange surface, or coil, are required to lower the temperacure of the ammonia vapor to its saturation point, the temperature ar which che vapor condenses toa liquid. © Condensation is a ewo step process: 1) sensible heat is removed from hot compressed vapor, reducing the em 2) laten co liquid. ature of the ammonia vapor to its saturation point. heat is removed from the ammonia vapor as it converts @ Ammonia reftigeration systems work most efficienely when there is a minimum difference berween the high side and low side pressures, © Ammonia has a greater ability to reject heat once it has reached its saturation temperature Module 5 9 3Lesson 3 Now that we are familiar withthe basic function of the condenser, ler’ take a closer look at its parts and how they work together. As mentioned in the evious lesson, condensers use air, fare, or both 2 cooling mediums to absorb heat from ammonia vapor co ‘The evaporative condenser is the ost widely-used in the ammonia igeration industry and it uses both ait and water. Before we talk about the evaporative condense, les look at ewo other basic kinds of condensers. When a fan is used to circulate air around the coil, its called a forced-air or forced-convection condenser. These condensers are commonly refered to as air-cooled condensers, Air-cooled consensers (Fig. 6) consist of a housing, which contains all the other parts, an inlet header, through which ammonia vapor travels from the compressor into the condenser, a col, in which the hhot compressed ammonia vapor condenses to a liquid, one or more fans, which circulate air over and around the coil that absorbs heat from the ammonia and an outlet header, through which the liquid ammonia flows back into the systems receiver. With air-cooled condensers, it’s very important to keep the parts clean because the air often causes lint, diet, dust and other particles to collect on the heat ‘exchange surface. It’ also important to ensure that the air access route is clea. Otherwise, the air may not circulate adequately, causing unnecessarily high condensing temperatures and pressures. Water cooled condensers are also commonly used in the ammonia refiigeration industry. There are two basic kinds of water-cooled condensers used in ammonia refigeration systems: 1) tube-in-tube condenser 2) shell and tube condenser As ts mame suggests the tbe-in-tube condenser (Fig. 7) is componed of eve layer of tubes, cach of which conta a smaller inside cube-The fmionia vapor i this sytem flowa tzough the ‘ute be while water Howe through the ier tube (Fg 8). In exence, the ammonia vapor Rows ll around the inner tube, rejecting heat through the innee cube walls co the water. As the ammonia reject heat it gadually reaches is saturacon point (a and begins to convert to a liquid. By the ime the Kein ammonia has completed ts um through the outer tubes, this process has gone on long enough cotmplesly comer the sanrooniat a Bad coe Fig. 8 Module5 56 Module 5 The water in PM che cube-in- MIE ube system can flow in either direction in 9 relation to that of the ammonia’ flow. If che water flows in the same direction as the ammonia, the system is called 2 parallel flow system. However, when the water lows in one direction and the ammonia refrigerant flows in the opposite direction, the system is called a counterflow Tomar} ‘The second kind of water-cooled condenser isthe shell-and-tube condenser (Fig. 9). Like the tube-in-tube, the shell-and-rube contains straight tubes through which water flows. These straight water tubes are contained within a cylindrical stel shel. In the shell-and-tube, water flows inside the tubes while the ammonia flows ‘over and around them. As with other water-cooled systems, the water absorbs the heat from the ammonia until the ammonia reaches ies saturation temperature. The water continues to absorb heat asthe ammonia vapor changes state back to a liqui In the next lesson, well ake a close look at the evaporative condenser, the most coouton typeof condenser uscd today To Review: © There are three kinds of condensers: 1) air-cooled condenser 2) water-cooled condenser 3) evaporative condenser. © Air-cooled condensers use only ai circulated by a fan to cool hot ammonia vapor. © Wacer-cooled condensers use only water to cool hot ammonia vapor © Evaporative condensers use both air and water to cool the hot ammonia vapor. 3 © There are two different types of water cooled condensers: 1) tubesin-tube 2) shell-and-tube,i Lesson Gy sense REE OTE EOE The most commonly used condenser in industrial refrigeration systems is the evaporative condenser. This type of condenser uses both air and water as cooling agents. The name, “Craporative condenser” may seein like a contradiction in terms, since the evaporator and the condenser have opposite functions. Bue in fact, the name isa perfect description of what happens—that is, che condensation of ammonia through the evaporation of Fig. 10 This may sound confusing, but it’s really quite simple. Recall that in an evaporator, the capacity of ammonia to absorb heat is greater during the ‘evaporating process. This principle holds true for a liquids, including water. As evaporation occurs, aliquid absorbs a greater amount of heat. The ‘evaporative condenser relies on this principle as its primary method of removing heat from the ammonia vapor The pats of an evaporative condenser are contained in a housing. Like the air-cooled condense, the evaporative condenser contains an inlet header, coil and an outlet header chrough which the ammonia flows fom the compressor to the receiver (Fig, 10). As ammonia flows through the coil, water is sprayed downward from the spray nozales across the col. As this happens, the water absorbs heat from the ammonia vapor inside the coil, causing the the water to evaporate (Fig, 11). At the same time, fans move air into the ‘condenser, circulating it over and around the coil (Fig. 12) The water vapor is carried away from the condensing area by the flow ofa. During this process, the air absorbs some of the heat from the water causing ito become warmer and more moist as it proceeds over and around the coil It's the relative humidity or wet bulb temperature, of the moist air moving over and around the condenser coil that aceally determines the heat transfer rate or capacity of the condenser. The wet bulb temperature is determined by Fig. 11 mother nature and may vaty from day to day. Refrigeration systems uilizing evaporative cooling should accommodate the anticipaced maximum wet bull temperature of a particular location, The lower Module 7 =i8 the wet bulb temperature, the greater the amount of heat that can be rejected by a given condenser ‘As the water continues to evaporate, absorbi ‘more and more heat from the ammonia vapor, the refrigerant converts back toa liquid while a mixture of water vapor and air carries the absorbed heat out of the condenser (Fig. 13). Because the condenser emits hot moist air, it ust be outside the area co be refrigerated. Many times, itis best to have it outside the refrigeration facility entirely. AAs a result of this process, some but not all of the water pumped into the spray system is discharged asa vapor out of the condenset. The water that is NOT evaporated fills into a pan called a sump or a basin at the base of the condenser where it collects and is pumped back into the spray system. Fig. 12 ‘Only water evaporates during this process, leaving behind dissolved minerals or impurities ‘contained in the water which can build up in the condenser sump. Asa result itis necessary to drain or “bleed” some of the remaining water in order to reduce the amount of impurities present. In addition, air pollution, dust, pollen and insects may collect in the condenser spray water loop. Properly bleeding the water circulation system limits the buildup of these imputities. An adequate water supply is maintained by replacing the evaporated and bleed water. Fig. 13 ‘The quality of the sump water supply is very important, because the evaporative condenser is susceptible to mineral build-up which may cause corrosion. Thus, itis importanc to regularly inspect the system for mineral ‘up as well as dire and other foreign particles which may collect in the bul water pan. Since the condenser is usually located outside the facility, itis also important to ensure that the water used with the condenser doesnt freeze. during cold weather Module 5fed . To Review: © Evaporative condensers are the most commonly used condenser in ammonia refrigeration facilites, © In cvaporative condensers, water is sprayed down across the condensers cil while iris blown over and around the coil. © The water absorbs heat from che ammonia and evaporates. © Air moves over and around the coil, mixing with watet vapor, and is blown ‘out of the condenser. © The ammonia vapor cools and converts to aliquid, © cis important to inspect the evaporative condensers water circulation system for a buildup of impurities that can cause corrosion. Module 5 910 Fig. 14 ‘Module 5 Lesson 5 “The evaporative condenser is, in most cases, the most efficient of all the types of condensers we've discussed. A condenser’ efficiency and heat-transfer capability depends on a combination of factors 1) amount of heat transfer surface arca 2) conductive capability of the heat transfer surface 3) difference in temperature between the cooling agent and the ammonia vapor 4) rate and direction of flow of both the ammonia and cooling agent. ‘One of the most important factors i the overall surface area of the pipe, tube, cr coil in which the ammonia vapor condenses to a liquid. A general rule of thumb is thac the more the surface ares, the more heat chat is capable of being rejected For instance, in air-cooled and evaporative condensers, the size and length of the coil or tubes determines the overall surface area. The larger the coil’ surface area, the more exposure it has to the cooling medium and the more exposure to the cooling medium, the more heat chat is capable of being rejected to the cooling medium. Ina different way, surface area is also important in the shell-and-tube and tube-in-tube condensers. Recall that in both of these condensers the water flows inside « tube or pipe while the ammonia flows around the tube on the ‘outside. Even though the flow path of the refrigerant differs in each of these condensers, the surface area of the tubes is equally as important in each condenser, “The conductive capability of the heat transfer surface is also important. Conduction is a measure of the ability of a material to transmit heat. Conduction is affected by the size, thickness, and material of the piping, tubing or coil through which the ammonia vapor rejects heat. If the tubing or coil is constructeil-of non-conductive materials, the heat transfer capability ofthe system is reduced. For the same reason, iti important to ensure that the condenser coil be kept clean. ‘The water used to absorb heat can leave mineral deposits on the outside of the coil (Fig. 14). This can cause an insulating effect on the col, limiting the ability to transfer hedt from the ammonia vapor to the air and/or water. Therefore itis important that inspecting the condenser coil should be a routine maintenance procedure Another factor affecting heat-transfer efficiency isthe difference in temperature Deoween the ammonia vapor and the cooling medium or agent. Generally, che greater the temperature difference, the greater the cap. ‘Since heat moves from hot to cold, the colder the cooling medium, the morea effective it will be ac absorbing heat from hot Fig. 15 ammonia vapor. Just like evaporators, the temperature difference between a condenser's cooling medium and the refrigerant is described as the TD, So, generally speaking, the greater the TD, the greater the heat transfer capacity. Recall that inthe evaporative condenser, the water and air absorb heat fom the ammonia vapor. The air/water mixture moving over and around the coil absorbs heat. Duting this process the water absorbs heat and evaporates. Another important factor affecting capacity isthe rate and direction of flow, both of the ammonia and of the cooling medium. Plow rate is affected by Liquid three Factors: Post 1) the amount of the ammonia or cooling medium. 2) the size and number of tubes or coils in the condenser. 3) the pressure difference between the ‘compressor and the condenser and the condenser and the receiver. ‘As ammonia condenses into aliquid, i collects era) on the wall surfaces ofthe col or pipe through or around which ie is flowing. As ic collects, the heat transfer rate is enhanced. The ripples and drips of ammonia all asise the heat tranafer process. The flow rate of the cooling agent—that isthe air and/or wwater—as it flows over, around or through the condenser also impacts heat- transfer efficiency. ‘As we just leamed, the colder the cooling agent, che greater its ability o absorb hheat from the ammonia vapor. But ifthe cooling agent is flowing too slowly in the condenser, the cooling agent’s temperature. will continue to increase as it absorbs mote and more heat from the ammonia. AAs the cooling agent's remperature increase, the TD between the ammonia and the cooling agent decreases and the condenser’ capacity for heat transfer also decreases. However, if we increase the rate of flow the cooling agent main- tains a relatively cool temperature throughout the time i is interacting with the ammonia, and itis therefore better able to absorb its heat. ‘The direction of the low is also important. When the ammonia and the cooling medium are lowing in the same direction (parallel flow), the rate of| heat transfer is generally slowee than when they are flowing in opposite directions (counter flow) Lets assume chat the two substances are flowing through ther respective pipes at the same rate and in the sume direction (Fig. 15) The greatest TD occurs at the stare of the process. As the water and ammonia flow in the same direction, the ammonia cools asthe supetheat is removed. The ammonia then begins to condense while maintaining a constant temperature. At the same time, the ‘temperature of the water—or condensing medium—increases, As a result the TD diminishes. Module 5 nTo Review: © The capacity of a condenser is affected by: C 1) the amount of heat transfer surface area a 2) the conductivity ofthe heat transfer surface 3) the temperature difference between vapor and cooling agent 4) the rate and direction of the flow of both ammonia and cooling agent. © The size and length of the coil or tubes in air-cooled, shell-and-tube, and ‘evaporative condensers determines the overall heat transfer surface area © Conduction is a measure of a material’ ability co wansmit heat and is affected by the size, thickness, and material of the piping, tubing or coil through which the ammonia vapor rejects heat. © Mineral build up on a col will cause an insulating effect on the coil and the coil’s heac transfer qualities. © When referring to condensers, Temperature Difference, ot TD, in a condenser is the difference in temperature between the ammonia vapor and the cooling medium or agent. © "The flow rate of the ammonia and the cooling medium in a condenser is affected by: 1) the amount of the ammonia or cooling medium 2) the size and number of tubes or coils in the condenser 3) the pressure difference berween the compressor and the condenser and the condenser and the receiver. a © Ina condenser, the heat transfer rate is enhanced: 1) as ammonia condenses into aliquid and collects on the wall surfaces of the coil or pipe through or around which itis flowing, 2) by the ripples and drips of ammonia 3) by the flow rate of the cooling medium. © Asacooling agent's temperature increases, the TD between the ammonia and the cooling agent decreases and the condenser’ capacity for heat transfer decreases. © The heat transfer rate in a condenser with a counter flow is generally faster. © The heat transfer rate in a condenser with a parallel flow is generally slower.Module 5 - Condensers