22/05/2020 1 “Energy Efficient Refrigeration system for Dairy Plant” By P. SUDHIR KUMAR (PAST PRESIDENT – AAR) ( DIRECTOR MARKETING – FRICK INDIA LTD ) [email protected]+91 9819704968 AAR WEBINAR - 20-05-2020 1 Fresh & Hygienic Milk By Animals Farms Fresh & Hygiene Milk Collection Points Rural Milk Collection Centre Cools Milk for Collection and Processing Milk Processing and Storage Centre; DAIRY PLANT Process Milk into Milk Products (Cheese, Butter, Yoghurt, Powder, Sweets etc.) Retail Centre/Consumers Utilize the Milk And Milk Products as Nutritious Food Farmers Transport Milk by Small Vehicle/ Motorcycle/Walk Milk Collector Collects milk from Cooperative Societies Refrigerated Transportation Refrigerated Transportation of Milk and Milk Products to Consumers AAR WEBINAR - 20-05-2020 2 CONTENTS : REFRIGERATION LOAD IN DAIRIES TYPES OF CHILLED WATER GENERATION SYSTEM ENERGY EFFICIENT COMBINATION OF CHILLED WATER GENERATION SYSTEM USE OF PRE CHILLER ( PHE & FALLING FILM CHILLERS) SELECTION OF EQUIPMENTS USE OF ENERGY EFFICIENT MOTORS, VFD STARTERS AND AUTOMATION THE AVERAGE ENERGY CONSUMPTION OF REFRIGERATION SYSTEM IN A DAIRY PLANT OF SIZE 5 TO 30 LAKHS LTR/DAY IS 60 TO 65 % THE AVERAGE ENERGY CONSUMPTION OF REFRIGERATION SYSTEM IN A DAIRY PLANT OF SIZE 5 TO 30 LAKHS LTR/DAY IS 60 TO 65 % AAR WEBINAR - 20-05-2020 3 CHILLED WATER LOAD CHILLED WATER LOAD DIRECT REFRIGERATION LOAD DIRECT REFRIGERATION LOAD MAIN REFRIGERATION LOAD IN DAIRIES MAIN REFRIGERATION LOAD IN DAIRIES CALCULATION OF REFRIGERATION LOAD IN DAIRIES BASED ON VARIOUS MILK PROCESSES AND COLD STORAGES PLAYS A KEY ROLE IN SELECTION OF EQUIPMENTS CALCULATION OF REFRIGERATION LOAD IN DAIRIES BASED ON VARIOUS MILK PROCESSES AND COLD STORAGES PLAYS A KEY ROLE IN SELECTION OF EQUIPMENTS TYPES OF LOADS TYPES OF LOADS AAR WEBINAR - 20-05-2020 4 DIRECT REFRIGERATION LOAD MILK COLD ROOMS (3 TO 4 DEG C) BUTTER ,CHEESE AND ICECREAM COLD ROOMS (-18 TO -22 DEG C) DAHI BLAST ROOMS ( 2-4 DEG C) DAHI COLD ROOM ( 3-4 DEG C) AAR WEBINAR - 20-05-2020 5 HEAT LOAD Refrigeration load will be sum of the following for Cold Room such as Storage, Blast, Deep Freezer etc., Wall heat load Air change load Product load and Supplementary load or Miscellaneous load Heat Load Sheet AAR WEBINAR - 20-05-2020 6
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Sudhir Kumar -Energy Efficiency in dairy plant- AAR ... · P. SUDHIR KUMAR (PAST PRESIDENT –AAR) ( DIRECTOR MARKETING – FRICK INDIA LTD ) [email protected] +91 9819704968 AAR
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22/05/2020
1
“Energy Efficient Refrigeration system for Dairy Plant”By
TYPES OF CHILLED WATER GENERATIONTYPES OF CHILLED WATER GENERATION
IBT SYSTEM : This is conventional system
ICE SILO :
IBT + PRE CHILLER SYSTEM (PHE / FFC)A combination of IBT And Pre Chiller depending upon load
histogram.
PHE Chiller / Falling Film Chiller : i. Chilled Water PHE/ FFCii. Chilled Glycol System for Deep Chilling
IBT SYSTEM : This is conventional system
ICE SILO :
IBT + PRE CHILLER SYSTEM (PHE / FFC)A combination of IBT And Pre Chiller depending upon load
histogram.
PHE Chiller / Falling Film Chiller : i. Chilled Water PHE/ FFCii. Chilled Glycol System for Deep Chilling
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IBT SYSTEM : This is conventional systemIBT SYSTEM : This is conventional system
ADVANTAGES OF IBT SYSTEM :
THERMAL STORAGE OF ENERGY AVAILABLE
REFRIGERATION PLANT CAPACITY SMALLER
LATENT HEAT AVAILABLE
SAFE DURING POWER CUTS/ BREAK DOWNS
DISADVANTAGES
MORE SPACE REQUIRED
LOW SUCTION ( -10 DEG C) INCREASES POWER CONSUMPTION
ADVANTAGES OF IBT SYSTEM :
THERMAL STORAGE OF ENERGY AVAILABLE
REFRIGERATION PLANT CAPACITY SMALLER
LATENT HEAT AVAILABLE
SAFE DURING POWER CUTS/ BREAK DOWNS
DISADVANTAGES
MORE SPACE REQUIRED
LOW SUCTION ( -10 DEG C) INCREASES POWER CONSUMPTION
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PHE / FALLING FILM CHILLER WITH IBT SYSTEM
The concept of Pre (PHE/ FFC) Chiller and IBT combination i.e. return water from process will be pre chilled in the PHE/Falling film chiller and fed into IBT for further chilling. In the above system, power saving will be substantial
IBT ( 2 to 0.5 Deg C)
RETURN FROM PROCESS ( 12 Deg C)
Falling Film Chiller / PHE chiller
( 12 to 2 / 0.5 Deg C)To Milk Process
( 0.5 Deg C)
Chilled Water PumpAAR WEBINAR - 20-05-2020 17
In a 1 Lakhs Ltr/ Day Dairy, 60,000 liters of milk will be processed in 4 Hours in the morning and 40,000 liters of milk will be processed in 2–½ Hours in the evening.For a 15,000 LPH milk process PHE chilled water flow of 30,000 LPH shall be circulated with a temp range of 12 to 0.5 C. 12 Deg C return water shall be pre chilled to 2 Deg C in a PHE chiller and fed into IBT for further chilling down to 0.5 C.
PHE / FALLING FILM CHILLER WITH IBT SYSTEM
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IBT SYSTEM IBT CUM PRE CHILLER
Total handling of milk
No of compressor
Comp. connected motor workingSuction/ Discharge temp.
System Details
Liq. pump system
Condenser Type
Refrigeration Capacity
Screw Comp. BkW/ TR
Recip Comp. BkW/ TR
2.00 Lakhs
2 Nos Screw (1w+1S)
1nos. x 160 kW
-10 0 C / 38 0 C
IBT
Yes
Evaporative Condenser
150 TR
0.93
1.02
2.00 Lakhs
2 Nos Screw ( 1 w + 1 s)
1 no. x 132 Kw
-5 0 C / 38 0 C
Pre chiller with IBT
Yes
Evaporative Condenser
150 TR
0.77
0.86
POWER COMPARISON
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ONLY PHE CHILLERS WITH HOT AND COLD WELL TANK
• The concept of only (PHE) Chiller has also been introduced without ice bank tank but with a hot and cold well or buffer tank
• The compressor size increases • Better for peak loads and chilling centers.
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PHE / FFC Chiller SystemFor the PHE / FFC chilling, heat load works out to 135 TR (approximately), a screwcompressor selected @ –2 C SST & 40 C SDT delivers refrigeration capacity of 137.6 TR which consumes 103.3 BkWBkW / TR = 0.75Power Consumption in a day 137.6 TR x 0.75 BkW/ TR x 6.5 Hrs = 671 Units
Equivalent IBT SystemThe BkW/TR of a SCREW compressor for an IBT application at –10 C SST & 40 C SDT will be 1.00
Total Refrigeration capacity required 137.6 TR x 6.5 Hrs = 894 TR Per Day Considering 20 Hours of Operation 894 TR / 20 Hours = 44.7 TRBkW/ TR @-10 SST and 40 Deg C SDT will be = 1.00Power Consumption 44.7 TR x 20 Hours x 1.0 BkW/TR = 894 Units
From saving of approx. 25 to 30 % with the above , you will notice a unit (power)Pre-Chiller system
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Ammonia is a colourless gas that liquefies under pressure and has a pungent odour.
Ammonia is considered a natural refrigerant because it occurs in nature’s material cycles.
Ammonia is also an ideal refrigerant from a climate protection point of view
It contributes neither to ozone depletion nor to global warming .
Ammonia has no ozone depletion potential (ODP = 0) and no direct greenhouse effect (GWP = 0).
Ammonia is combustible only to a limited degree; its ignition energy is 50 times higher than that of natural gas
Ammonia – A Natural RefrigerantsAmmonia – A Natural Refrigerants
SELECTION OF REFRIGERANTSELECTION OF REFRIGERANT
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HEART OF THE REFRIGERATION SYSTEMCOMPRESSORS
HEART OF THE REFRIGERATION SYSTEMCOMPRESSORS
TYPES OF COMPRESSORS IN AMMONIA
RECIPROCATING OR
SCREW COMPRESSORS
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Reciprocating Comp are selected if the refrigeration capacity is
less than 350 kW (100 TR).
Latest developments for energy optimization in reciprocating
• Less Space for big plants (Number of compressors less)• Adapts better for power saving in large plants running at part
load.• Dual capacity control system monitors volume as well as
compression control.• Total installed horsepowerreduces.
• Easy to automate• Very low maintenance.
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Rotors
Shaft seal
Discharge CasingThrust bearing
Rotor casing
Housing
Capacity control Valve
Radial Bearing
Capacity Control Cylinder Inlet casing INLET
DISCHARGE
Parts of Screw Compressor Block
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• Evaporative condenser is a water conservation device and in effect, a condenser and a cooling tower combined into a single unit.
• Most of the refrigeration plants in dairies are having open type atmospheric condensers, which mean indirectly getting affected by power penalty.
• Power penalty by way of running the make-up water pump continuously due to water wastage by splashing, high wind velocity etc.
ADVANTAGES OF EVAPORATIVE CONDENSER OVER OPEN TYPE CONDENSERS
Kw Total KwCondenser water pump 6.00 19.00 114.00Cooling Tower Fan 6.00 7.50 45.00
26.50 159.00
Fan Motor 6.00 9.00 54.00Pump Motor 6.00 3.70 22.20
12.70 76.20
Diff. in Kw 82.80 Considering Motor Efficiency 85% 97.41 Therefore Kw difference 97.41 No. of hrs running 20.00 No. of days 300.00 Unit Rate (Rs.) 8.00 Total Saving/ year 46,75,764.71
FOR 6 NOS. PHE CONDENSER ( 300 TR EACH ) + COOLING TOWER + PUMPS
Apart from above the Compressor will run at 38 Deg C Condensing Temp., so that there will be further power saving in
compressor power.
FOR 6 NOS. EVAPORATIVE CONDENSER
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Difference to run at Low Condensing temp at -10 Deg SST Screw
• If run with 38 = 0.06 x 100 TR x 18 Hr x 365 x Rs 7 = Rs. 2.75 Lakhs
• If run with 40 = 0.12 x 100 TR x 18 Hr x 365 x Rs 7 = Rs. 5.50Lakhs
For 100 TRCondensing Temp Deg C Capacity & BkW BkW/ TR
Difference(BkW/TR)
36 104.1 TR/92.4 BkW 0.88
38 103.1TR/97 BkW 0.94 0.06
40 101.9 TR/ 101.9 BkW 1.00 0.12
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Desuperheater SystemDesuperheater System
• To cool down the superheated discharge gas from the compressor before entry into the condenser
• It is usually used in heat recovery to generate hot water ( 50 to 60 DegC ) which can used in crate washing and floor cleaning.
• Temperature range: 0°C to 150°C
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Ammonia Pumping Re-circulation SystemAmmonia Pumping Re-circulation System
• Superb refrigerant distribution
• Lower inlet liquid temperature
• Cut down capital costs
• High system efficiency
• Reduced operating expenses
• Low maintenance
• Protection of compressors from liquid slugs
• Tremendous power saving in operation.
• Reduce Equipment size
• Eliminate individual accumulator
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Priority Vessel And Thermosiphon Oil Cooler
ADVANTAGES OF THERMOSIPHON OIL COLLING SYSTEM
• There is no possibility of contamination of the cooling water circuit
• The water in the cooling circuit does not require to be diverted to produce free cooling
• The free cooling is produced by evaporation of a relatively small flow of refrigerant. Thus a
• Thermosiphon system might require 80 mm refrigerant piping and valves whereas a free cooling
• system, in which the water to be cooled is circulated directly through an ambient cooler, might require 150mm piping and valves.
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Motor should select based on the efficiency.The efficiency of an electric motor is defined as the ratio of usable
shaft power to electric input power.
Motor efficiency [%] = shaft Power [kW] / electrical input [kW]
Based on the Efficiency level, Motor are classified as Eff1, IE1, IE2,
IE3/ IE4 Motors.
Compressor Motor & its Drives.
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SELECTION OF EQUIPMENTS
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Compressor Motor & its Drives.
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VFD & Vertical in line pump for chilled water circulation
• Installed HP of pump will be reduced
• Speed will vary depending upon load means reduce power cost.
• Increase overall efficiency.
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Soft Starter
Variable frequency drive (VFD)
A variable frequency drive (VFD) is a motor control device
that protects and controls the speed of an AC induction motor.
VFD can control the speed of the motor during the
start and stop cycle, as well as throughout the run cycle.
TYPES OF DRIVES
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Total Plant Control. centralized temperature recorder and interlocking electric circuit for various process controls can be interlocked to your PC/PLC
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DATA LOGGING / SCADA DCS SYSTEM
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LATEST TRENDS
• PHE/ Falling Film chiller + IBT• Screw Compressors • Evaporative Condensers• Liquid Ammonia pumping system• Thermosiphon Oil Cooling system• Introduction of VFD for compressors.• Chilled water pump automation with VFD• Energy efficient motors ( IE3)• Automation of the complete plant
AAR WEBINAR - 20-05-2020 39
NEW INNOVATIONS/CHALLENGES
• LOW CHARGE AMMONIA REFRIGERATION SYSTEM
• CO2 REFRIGERATION SYSTEMS
• AMMONIA REFRERATION CHILLER SYSTEMS FOR COMMERCIAL AIRONDITIONING.