FST-404 Food Process Engineering Operation of Refrigeration Equipment Lecture No.5

FST-404
Food Process Engineering

Operation of Refrigeration equipment
1
Lecture no.5
Prepared by
Miss Adan Naeem/Miss Sidra-tul-Muntaha
Department: Food Science and Technology
2 Refrigeration
 Removal of unwanted heat from a selected object, substance, or space

and its transfer to another object, substance, or space. Removal of heat
lowers the temperature and may be accomplished by use of ice, snow,
chilled water or mechanical refrigeration
3 Vapor Compression Refrigeration
Cycle
 The Vapor Compression Refrigeration Cycle involves four
components: compressor, condenser, expansion valve/throttle valve and
evaporator
 It is a compression process, whose aim is to raise the refrigerant pressure, as
it flows from an evaporator. The high-pressure refrigerant flows through a
condenser/heat exchanger before attaining the initial low pressure and
going back to the evaporator
4 STEP 1: COMPRESSION
 The refrigerant (for example R-717) enters the compressor at low

temperature and low pressure. It is in a gaseous state. Here, compression
takes place to raise the temperature and refrigerant pressure. The
refrigerant leaves the compressor and enters to the condenser. Since this
process requires work, an electric motor may be used. Compressors
themselves can be scroll, screw, centrifugal or reciprocating types
5 STEP 2: CONDENSATION
 The condenser is essentially a heat exchanger. Heat is transferred from the

refrigerant to a flow of water. This water goes to a cooling tower for cooling
in the case of water-cooled condensation. Note that seawater and air-
cooling methods may also play this role. As the refrigerant flows through the
condenser, it is in a constant pressure.
 One cannot afford to ignore condenser safety and performance.
Specifically, pressure control is paramount for safety and efficiency
reasons.
6 STEP 3: THROTTLING AND EXPANSION
 When the refrigerant enters the throttling valve, it expands and releases
pressure. Consequently, the temperature drops at this stage. Because of
these changes, the refrigerant leaves the throttle valve as a liquid vapor
mixture, typically in proportions of around 75 % and 25 % respectively.
 Throttling valves play two crucial roles in the vapor compression cycle. First,
they maintain a pressure differential between low- and high-pressure sides.
Second, they control the amount of liquid refrigerant entering the
evaporator
7 STEP 4: EVAPORATION
 At this stage of the Vapor Compression Refrigeration Cycle, the refrigerant

is at a lower temperature than its surroundings. Therefore, it evaporates and
absorbs latent heat of vaporization. Heat extraction from the refrigerant
happens at low pressure and temperature. Compressor suction effect helps
maintain the low pressure.
 There are different evaporator versions in the market, but the major
classifications are liquid cooling and air cooling, depending whether they
cool liquid or air respectively
Vapor
Compression
Cycle
8
9 PROBLEMS IN THE VAPOR
COMPRESSION CYCLE
 The Coefficient of Performance (COP) expresses the efficiency of this cycle.
Knowing that the aim of the refrigerator is heat removal and that this
process requires work, the COP of the cycle becomes:
 Where “h” is the enthalpy in the system.
 Some of the Vapor Compression Refrigeration Cycle Problems that may
affect this value are
10 Conti...
 COMPRESSOR LEAKAGE/FAILURE
 The failure of an industrial refrigeration compressor can be expensive affair to
the company and damaging to the manufacturer’s reputation. Often,
manufacturers will tear down returned compressors in search faults. Over years
of studies, some common reasons for compressor failure have been identified to
include lubrication problems, overheating, slugging, flood back and
contamination
 FOULING – EVAPORATOR AND CONDENSER
 Fouling is any insulator hinders transfer between the water and the refrigerant.
 It could result from algae growth, sedimentation, scale formation or slime. As this
problem increases head pressure, it can lead to increased energy use by the
compressor
11 Conti...
 Keep the evaporator surface and condenser tubes clean. Water treatment
practices need to be on point to keep this problem at bay.
 MOTOR COOLING
 The motor is easily the highest energy consumer in the vapor compression
cycle. Most times when efficiency drops in this device, it is because of a
cooling problem. Many issues could lead to this- blocked air filters, dirty air
passages etc. Regular checks of the chiller logs should unearth any
anomaly, specifically the comparison between amperage and voltage
12 Conti...
 LIQUID LINE RESTRICTION

 If you are a refrigeration technician and you encounter low evaporator
pressure, one of the areas to check is the liquid line, specifically for any form of
restriction. Many other symptoms could point to the problem that affects the
system enthalpy as shown by the following examples:
 Abnormally high discharge temperature
 Low current draw
 High superheats
 Low condensing pressures
 Local frost close to the restriction
 Bubbles in sight glass
13 Conti...
 In commercial cooling, liquid line restriction can degrade cooling capacity of

the system by as much as 50%
 Diagnosis of this problem does not to be fancy, as an experienced technician
can tell something is not okay by just checking the system history or checking
visually. If you are not acquainted with the system, you may need to conduct a
few tests to pinpoint the issue
 The first one is temperature drop test, which is done at all points likely to develop
restriction. You could also perform a freeze test if finding the exact point
becomes troublesome. This test comes in handy when you suspect several
components such as evaporator, feeder tubes and metering device
 Thermal imaging has to be the most advanced and reliable method of
identifying liquid line restriction. It gives real time results that help you identify the
problem as shown by temperature changes
14 Reference
 Zeki Berk. 2013, Food Process Engineering and Technology

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FST-404

Food Process Engineering

 Removal of unwanted heat from a selected object, substance, or space

 The refrigerant (for example R-717) enters the compressor at low

 The condenser is essentially a heat exchanger. Heat is transferred from the

 At this stage of the Vapor Compression Refrigeration Cycle, the refrigerant

 LIQUID LINE RESTRICTION

 In commercial cooling, liquid line restriction can degrade cooling capacity of

 Zeki Berk. 2013, Food Process Engineering and Technology

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