IIAR Ammonia ~ Refrigeration Education and Training Program SPR ta Ue: elif Module 5 - Condenserse~ IIAR Basic Ammonia Refrigeration Module 5 - Condensers Lesson 1 In previous modules, we dlscusted some ofthe major components that make up industrial refrigeration systems orn Mose industrial systems have a receiver (Fig, 1) thar contains the supply of liquid ammonia anccesiay to operate the system when needed upon demand. Liquid ammonia flows from the recciver through a king valve and a pressure reduction device, which in this case is an ceed Peer expansion valve, and into a anne: 8 vessel. As itpssss through the valve, the pressure and temperature of the ammonia Po Rg refrigerant are suddenly Novel lope rT ce A pump moves the cold P Mtering valve ammonia from the vessel through a metering valve and into an evaporator where the liquid ammonia con- Fig.1 vers «0 a vapor as it absorbs hear. The compressor, pulls the ammonia vapor from the evaporator and through the vessel, increases the presure and temperature, and delivers the supecheated vapor to the condenser, In the condenser the ammonia vapor rejects the heat collected by the refiigerant a it passed through the cyaporator and compressor. As the heat rejection process wars, the ammonia reftigerant condenses, returning to a liquid. The liquid ammonia flows out of the condenser, collecring in the high pressure receiver where its held for reuse in the system, In this modile-we will examine some of the different types of condensers in use in industrial refrigeration syerems Fig. 2 ‘The condenser (Fig, 2) is an imporant part 2 of the ammonia telrigeration sytem for Wo primary reasons. First, ici esponsble for removing the heat from the ammonia refiigranc that was absorbed in the evaporator and added by the mechanical eperation of the compressor. [a addition, che vapor rejects heat, gradually converting into « liga st ls tom te ner header to the ute: header. Module 5As we know, the system uses the sane ammonia ‘ver and over Since the ammonia must bein liquid oom to pick up hear in the evaporator, it must return (0 liquid a the end of the process in onder to be reused. The condenset converts ammon vapor to a liquid, which is the second reason why the condenser is an integral component in the 3 Che way think bout the condenser ia & comgarioncomponmnt ofc crporice (ig 3) Condes and onporor fave many pts with the ame umes. weve, heck hey perform ination tn cast opp na rapoc Howe's concenacatronis ener ams apo nae Fig. 3 AAs we karned in a previous module, an evaporator is often located directly within the area to be refrigerated. Ammonia flows into che evaporator coil, absorbing heat at its boiling point. The process that occurs in the condenser is exactly the opposite fof this The condenser cools ammonia vapor. Asa result, ie rejects heat and condenses back co aliquid. Unlike an evaporator, the condenser is always located away from the atea to be cooled. In fact, the condenser is generally located outdoors to allow the rejected heat to be released outside of the area chat is being refrigerated. In previous lesons we learned that asthe ammonia enters the condenser it isa superheated vapar. Before entering the condenser the ammonia has absorbed heat in both the evaporacor and in the Compressor. «@ ‘Once ammonia vapor enters the condenser, it interacts with a condensing medium. ‘A-condensing medium is the water, ait, ot a combination of both that absorbs the treat from the ammonia vapor in the condenser (Fig. 4). Ies important ro understand that this interaction isn direc: the ammonia rejects heat to the ‘condensing medium through a heat exchange surface such as a coil, tube or pipe Because heat is always ‘on the move from warmer matter to colder atte, the condensing medium absorbs the hheat rejected by the ammonia vapor causing the temperature of the ammonia vapor t0 decrease uni it reaches the point at which ie condenses to aliquid Alter the ammonia exits the condenser, the liquid ammonia flows into a receiver where itis collected for reuse in the reftigeration system. Fig. 4 “Thus, where the arumonia absorbs heat in the evaporator, causing it co boil and ou evaporate, it rejects heat in the condenser, causing it ro convert back co a liquid, achieving exo imporcant goals: 2 Module 51) unvranted heat has been removed from the arca to be cooled. 2) the a has returned 1o a liquid so that i can be used again to pick up and remove more unwanted heat from the area to be cooled. ‘Though the design of a condenser and method of exposing the ammonis to cooling agent may vary the condensation process remains the same in all condensers. You will recall thac boiling ammonia can pick up heat wichour a change in temperature. The same is teue as ammonia vapor rejects hea. Its temperature decreases unt it reaches the point at which ammonia vapor converts back into aliquid with no further reduction in temperature, This point is called the saturation point, When we talk abour the tompetature at which the liquid ammonia convert to 2 vapor—a it docs 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 ie does in the condenser—itis referred to a the condensing point. Ics at this temperature thatthe liquid ammonia then flows back into the receiver, where it starts through the refrigeration circuit once again, 4 A To Review: © Condensers are importanc to the refrigeration process for two primary 1) they reject heat collected by ammoni and compressor 2) they convert ammonia vapor to liquid ia ord for it to be cused in the system. i the evaporator © Condensers are located away from che area to be refiigeated. © Ammonia absorbs heat in the evaporacor and rejects heat in the condense. © 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 eemperacure. © -Sacuracion or condensing temperature of ammonia is similar to the boiling temperature of ammonia, Module 5 3Lesson 2? =e ‘The condensing process has ovo distinct stiges. The fits sage occurs when the compreied, perhested gas flows inco the condenser Ar cha pone the cooling medi: —the air and/or water—removes sensible heat from the a ‘We learned before chat sensible heat isthe eat chat can be mcasurce ‘or “tensed” by a thermometer. As sensible heat is removed, the temperature of the ammonia vapor decreases unlit reaches the saturation temperacure. Fig. 5 é Co eu Reg een eC a less efficient Fig. 5 Condensing temp 95,F yu) eee pea yeeig Uris The second stage occurs when the vapor reaches the saturation point; which i the cemperacure at which che refrigerant begins ro condense to a liquid, Ae this point, the condensing medium absorbs the latent heat of the ammonia. The latent heat, we learned previously, i the heat that cannot be measured by 2 thermometer. Even though the vapor continues f0 convert to liquid ac this sage, the pressure and temperature of the ammonia does NOT change. ‘Another important fact to remember is that ‘an ammonia refrigeration system works most ffciently when che difference between the low side pressure and the high side pressure is ar the minimum that’s possible, In terms of temperature that means the difference berween the condensing temperature and the evaporating temperatures are as close as possible (Fig. 5). We learned in Module 2 chat in the evaporator, ammonia has a greater capacity co absorb heat ‘once it has reached its boiling temperature. ‘The same concept applies in the condenser. When ammonia vapor contains excessive superheat, as i docs when ic leaves the compressor, an additional amount of condensing medium, ait and/or water, and heat exchange surface, or coil, are required to lower the temperature of the ammonia vapor to its saturation point, the ature at which the vapor condenses 0 a To Review: © Condensation is a swo step process: 1) sensible hea is removed from hot compresied vapor reducing the temperature ofthe ammonia vapor © its saturation point. 2) lant heat is removed from the ammonia vapor as it converts wo liquid @ Ammonia rigeration systerns work most efficiently when there is « minimum diff 3 ence berween the high side and lew side pressures © Ammonia has a greater ability to reject heat once it has reached is saturation temperate 4 Module $Lesson 3 sam Now that we are familiar with the basic 9} function of the condense, ler take @ closer look st its parts and how they ‘work together. As mentioned in the previous lesson, condensers use air, ‘water, or both as cooling mediums to absorb heat fiom ammonia vapor corr} ‘The evaporative condenser is the most widely-used in the ammonia refrigeration industry and it uses both ait and warer, Before we talk about che evaporative condenser, lets look ar two ‘other basic kinds of condensers. “When a fan is used to circulate air around the col, if called a foreed-air or forced-convection condenser. ‘These condensers are commonly rfeced tos air-cooled condensers. Fig. 6 rooled consensers (Fig, 6) consist of a honsing, coher parts, an inlet header, through which ammonia vapor travels from the compressor into the condenses a coil, in which the hot compressec ammonia vapor condenses to a liquid, one or more fans, which circulate air over and around the col that absorbs heac from the nonia and an outlet header, through which che WD ied cmemonia own bac into the semis recive, With air-cooled condensers, its very important to keep the parts clean because the air often causes lint, dirt, dust and other particles ro collect on the heat exchange surface. Irs also important to ensure that the air access route is leas. Ocherwise, the aie may not circulate adequarely, causing unnecessarily high condensing temperatures and pressures, Water-cooled condensers are also commonly used in the ammonia refrigeration industry. There are two basic kinds of water-cooled condensers used in ammonia refrigeration systems: 1) tube in tube condenser 2) shell and tube condenser As its name suggests, the tube-in-tube condenser ig, 7) is compose of several layers of tubes, each (of which contain 2 smaller inside tube. The ‘ammonia vapor in this system flows through the outer tube while water lows through the inner tube Gig. 8) In essence, the ammonia vapor flv all around the inner tube, rejecting heat through che net tube walls to the water, AS dhe ammonia ejects heat, it gradually reaches its saturation point Pee va begins to convert to aliquid. By the ine the 2 oo ‘ammonia has completed its run through the outer tubes, this process has gone on long enough to completely convert the ammonia to a liqu a Fig. 8 Module5 56 Module 5 "The water in the tube-in- tube system can flow in either direction in niostehae @ of the ammonia’ ove the water flows in the same dicection er ocmecm sth ammonia, the system is called 4 parallel flow system. Howeves, when the water flows in one direction and the ammonia reftigerane flows in the opposite direction, the system is called 2 counterflow sytem. “The sccond kind of water-cooled condenser is the shell-and-tube condenser (fig, 9). Like the tube-in-tube, the sell-and-tube contains straight tubes through which water flows. These straight water tubes are contained within cylindrical stel shell. In the shell-and-tube, water flows inside the tubes while the ammonia Hlows cover and around them. AS with other water-cooled systems, the water absorbs the heat from the ammonia until the armmonia reaches its saturation temperature. The water continues to absorb heat 2s the ammonia vapor changes state back to a liquid. In the eat son, well ake « dose look atthe eraportive condenacs the mos: common type of condenser used today. To Review: © There are three kinds of condensers: 1) ir cooled condenser 2) water-cooled condenser 3) evaporative condenses @ Air-cooled condensers use only air circulated by a fan to coo! hot ammonia vapor Water-cooled condensers use only water to cool hot ammonia vepor. © Evaporative condensers wie both air and water to cool the hot ammonia vapor ® © There are nvo different types of water cooled condensers 1) tabe-in-tube 2) shell-and-mbeLesson 4 moe ‘The most commonly used condenser in industrial reltigeration systems is the evaporative condenser. This type of condenser uses both air and wacer as cooling agents. The name, “evaporative condenses.” may seem like a contradiction in term since the evaporator the condenser have opposite functions. Bue in fact, the name isa perfect description of whae hhappens—thae is, the ‘condensation of ammonia through the evaporation of water. pe id co Fig. 10 ‘This may sound confusing, but it really quit simple, Recall cha in an ‘evaporator, the capacity of ammonia to absorb heat is greater during che ‘evaporating process. This principle holds true for all iquids, including water. AAs evaporation occurs, a liquid absorbs a greater amoune of heat. The evaporative condenser relies on this principle a its primary method of removing heat from the ammonia vapor. The parts of an evaporative condenser are contained in a housing. Like che air-enoled condenser, the evzporative condenser contains an inlet header, coil and an outlet header through which the ammonia flows from the compressor to the receiver (Fig. 10). ‘As ammonia flows chrough the coil, water is sprayed downward from the spray nozzles actoss the col. As this happens, the water absorbs heat from the ammonia vapor inside the coil, causing the the warer to evaporate (Fig, 11). ‘Ac the same time, fans meve ar into the condense; circulating it over and around the coil (Fig. 12). The water vapor is caried away fram the condensing area by the How of air. During this process, the air absorbs some of the heat from the water causing it to become warmer and mote moist as it proceeds over and atound the col. Ieis the relative humidity or wee bulb temperature, of che moist air moving over and around che condenser oil that actualy ddecermines the heat transfer rate ot capacity of the condense ‘The wet bulb temperature is determined by Fig.11 smother nature and may vary fom day to day. Refrigeration systems utilizing evaporative cooling should accommedate the anticipated maximum wet bulb temperstute ofa particular location. The lower Module 7the wet bulb cemperature, che greater the annount of beat chat can be rejected by a given condenser As the water continues to evaporate, absorbing ‘more and more heat from the ammonia vapor, 3 the refrigerant converts back to aliquid while a mixture of water vapor and air caries the absorbed heat out of the condenser (Fig. 13). Because the condenser emits hot moist ai, i ‘must be outside the area to be refrigerated. Many cs it fs best to have it outside the viel. refrigeration fac As a resule of this process, some but not all oF the water pumped into the spray system is discharged as a vapor out ofthe condenser. The water that is NOT evaporated falls into a pan called 2 sump or a basin at the base of the condenser where it collects and is pumped back into the spray syste Fig. 12 ‘Only water evaporates during this process, leaving bebind dissolved minerals or impurities contained in the water which can build up in the condenser sump. As a resul it is necessary «© drain or “bleed” some of the remaining water in order to reduce the amount of impurities present In addition, ai pollution, dust, pollen and @ insects may collect in the condenser spray water loop. Properly bleeding the water circulation systean limits the buildup of these impurities. ‘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 che evaporative condenser is suscepuble to mineral build-up which may cause corrosion. Thus, ic is impostant ro regularly inspect ehe system for mineral build-up as well as dirc and ocher foreign particles which may collect in the ‘water pan. Since the condenser is usually located outside the fiilty, it i aso imporeant to ensure thar the warer used with the condenser doesnt fiecze during cold weather, Module 5To Review: © Evaporative condensers are the most commonly used condenser in ammonia reftigeration facilities. © In craporative condensers, water is sprayed down accoss the condenser’s coil while air is blown over and around the coil © The water absorbs heat from the ammonia and evaporates. © Air moves over and around the coil, mixing with water vapor, and is blown ou ofthe condenser © The ammonia vapor cools and converts 04 liquid. © Ieis important to inspect che evaporative condensers water circulation system for a buildup of impurities thar can cause corrosion. Module 5 9Lesson 5 The evaporative condenser is, in most cases, the most efficient ofall he (ypss of condensers we've discussed. A condensers efficiency and heat-ransfer capability depends on a combination of factors 1) amount of heat transfer surface area 2) condactive 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 factots is the overall surface area ofthe pipe, tube, cr coil in which the ammonia vapor condenses to a liquid. A general rule of thumb is chae the mote the surface area, the more heat that 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 atea. The larger the coils surface area, the more exposure it has to the cooling medium and the more exposure to the cooling medium, che more heat that is capable of being rejected to the ‘noling medium. Ina different way, surface area is alo important in the shell-and-nube and tube-in-tube condensers. Recall that in both of these condensers the water flows inside a 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, che surface area of the tubes is equally as important in each condenser. “The conductive capability of the heat teansfer sueface is also imporcane. ‘Conduetion is a eacasure of the ability of a material to transmit heat. Conduction is affecred 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 constructet of non-conductive materials, the heat transfer capability of the system is reduced, For the same reason, itis important to ensure that the condenser coil be kept clean ‘The warer used ta absarh heat can leave mineral deposits on the outside of the coil (Big. 14). This can cause an insulating effecr on the col, limiting the abiliey to transfer hedt fran the araraonia vapor to the air and/or water. Therefore ic is important that inspecting the condenser coil should be a routine maintenance procedure. Fig. 14 Another factor affecting heat-transfer efficiency is the difference in temperature between the ammonia vapor and the cooling medium or agent. Generally, the greater the temperature difference, the greater the capacity. Since heat moves from hot to cold, the colder the cooling medium, the more 10 Module $Fig. 15 cffective it will be at absorbing heat from hot ammonia vapor. Just like evaporators, che Mc Ammonio temperature difference berween a conedenser’s \ Ais cooling medium and the refrigerant is described 2 y the TD. So, generally speaking, the greater the TD, the greater the heat transfer capacity Recall that in the evaporative condenser, the water and air absorb heat from the ammonia vapor. The rwater mixture moving over and around the coil absorbs heat. During this process the water absorbs heae and evaporates. tee Another importane factor affecting capaciey isthe tate and direction of flaw, both of the ammonia and of the cooling medium. Flow rate is affected by ear three Factors eae) / 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 hetween the compressor and the condenser and the condenser and the receiver. ‘As ammonia condenses into a liquid, it collects et) con the wall surfaces of the coil or pipe through or around which its flowing. As i collects, the hea transfer rate is enhanced. The ripples and drips of ammonia all asist the heat tcansfer process. The flow rate of the cooling agent—that isthe air and/or ‘water—as it flowe over, around or through the condenser also impacts heat- transfer efficiency, ‘As we just learned, the colder the cooling agent, the greater its ability co absorb hear from the ammonia vapor. But ifthe cooling agent is flowing too slowly in the condenser, the cooling agent's temperacure.will continue to increase as it absorbs more and more heat from the ammonia As the cooling agent’ cemperature incteases, the TD between the ammonia and the cooling agent decreases and te condenscr’s capacity for heat transfer also decreases. However, if we increase the rate of flow the cooling agent main- relatively cool temperature throughout the time it is interacting with the ammonia, and itis therefore better able to absorb its heat. ‘The direction of the flow is also important. When the ammonia and the cooling medium are flowing in the same direction (parallel flow), the rate of heat transfer is generally slower than when they are flowing in opposite ditections (counter flow). Lec’: assume that the two substances are flowing through their respective pipes a: the same rate and in the same dizection (Fig. 15) The greatest TD occurs the statt of the process, As the water and aanmonia Fow in the same direc the ammonia cools as the superheat is temoved. The ammonia then begins to condense while maintaining a constane temperature. Ar the same time, the temperature of the wate-—or condensing medium—increases. Asa result the TD diminishes. Module 5 u12 ‘Module 5 To Review: © The capacity of a condenser is affected by: 1) the amount of heat transfer surface area 2) the conductivity of the heat transfer surface 3) the temperature difference berween 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 to transmit heat and is affected by the size, thickness, and material of the piping, cubing or coil through which the ammonia vapor rejects heat, © Mineral build up on a coil will cause an insulating effect on the coil and inibic the coils heae transfer qualities © When referring 10 condensers, Temperature Difference, ot TD, in a condenser isthe difference in temperature between the ammonia vapor and the cooling medium or agent. @ The low rate of the ammonia and the cooling medium in a condenser is alfected by: 1) the aniount of the ammonia or cooling medium 2) the size and number of tubes oF coils in the condenser 3) the pressure difference berween the compressor and the condenser and the coadenser and the receiver. © Ina condenser, the heat cransfer rate is enhanced: 1) as ammonia condenses into a liquid and collects on the wall surfaces of the coil or pipe through or around which it is flowing 2) by the ripples and drips of ammonia 3} by the flow rate of the cooling medium. © Asacooling agents temperature increases, the TD beeween 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 cransfer rate in a condenser with a parallel flow is generally slower.Module 5 - Condensers