Refrigeration:

Back to the Basics

Seminar 32
Sponsor: TC10.1, and Refrig.
Committee
 Economizing for
Industrial Refrigeration
Screw Compressors
Joseph W. Pillis P.E.
York Refrigeration, (Frick)
Waynesboro, PA
All Rights Reserved
Copyright 2001 by YORK International Corporation
 Disclaimer
THIS INFORMATION WAS PRESENTED AT ASHRAE SEMINAR 32
HELD IN CINCINNATI, OH. THE SEMINAR FORMAT IS TO PRESENT
INFORMATION OF CURRENT INTEREST AND TO PROVIDE A VENUE
FOR INTERACTION BETWEEN ASHRAE MEMBERS. THESE
SEMINARS SHOULD NOT BE CONSIDERED PEER-REVIEWED (OR
THE FINAL WORD ON ANY SUBJECT). ASHRAE HAS NOT
INVESTIGATED, AND ASHRAE EXPRESSLY DISCLAIMS ANY DUTY
TO INVESTIGATE ANY PRODUCT, SERVICE, PROCESS, PROCEDURE,
DESIGN, OR THE LIKE WHICH MAY BE DESCRIBED HEREIN. THE
APPEARANCE OF ANY TECHNICAL DATA OR EDITORIAL
MATERIAL IN THIS PRESENTATION DOES NOT CONSTITUTE
ENDORSEMENT, WARRANTY, OR GUARANTY BY ASHRAE OF ANY
PRODUCT, SERVICE, PROCESS, PROCEDURE, DESIGN, OR THE
LIKE. NEITHER ASHRAE, THE AUTHORS OR THEIR EMPLOYERS
WARRANT THAT THE INFORMATION IN THIS PRESENTATION IS
FREE OF ERRORS. THE ENTIRE RISK OF THE USE OF ANY
INFORMATION IN THIS PRESENTATION IS ASSUMED BY THE USER.
BEFORE MAKING ANY DECISION OR TAKING ANY ACTION ON THIS
SUBJECT, YOU SHOULD CONSULT A QUALIFIED PROFESSIONAL
ADVISOR.
 Economizers
• This presentation will cover the
fundamentals of economizers as used
with twin rotary screw compressors.
– port location and function
– characteristics
– sideloads
– economizers
– cycle efficiency
– refrigerant comparisons
Suction process
Maximum Suction Volume
Trapped Vs

Vs
Compression
Continuation of
Compression
Beginning of Discharge

Vd
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction
Primary
Suction

Discharge
Primary
Suction

Discharge
Primary
Suction

Econo.
Inlet

Discharge
Economizer Port Location
 The Economizer Port
• A port placed in the rotor housing can
locate any pressure between suction and
discharge.
• This port acts as a secondary suction
port.
• The additional flow does not reduce the
primary suction gas flow.
• The gas mixes in the screw threads and is
carried on to discharge.
• Compression efficiency is high as
additional frictional power is small.
• Like a “frictionless” compressor
Uses of the Econo. Port
• This secondary suction port is used
in two ways.
• Sideloads are generally gas flows
coming from a secondary, (higher
temp.) evaporator.
• Economizers are used to subcool
condenser liquid.
 Sideload Evaporators
Condenser

Secondary Evaporator
Comp.

Evaporator

Vapor from a secondary evaporator can be drawn into

the compressor economizer port, providing the
secondary evaporator is at a pressure higher
than the econo. pressure.
 -17 F
20 psia

Econo.
? psia

96 F
200 psia
NH3 Sideload Example -
What pressure is the port ?
 100 %
Volume

62% Volume

Sideload port location for refrigeration application

62% volume = volume reduction ratio 1.6 : 1

 -17 F
20 psia 20 psia

Econo.
? psia

96 F
200 psia
Port pressure ~=(Volume ratio)^k * (P suction)
NH3 k ~= 1.29
Port pressure = (1.6^1.29) * 20 psia = 37 psia
 -17 F
20 psia

8F
37 psia

96 F
200 psia
Port pressure ~=(Volume ratio)^k * (P suction)
NH3 k ~= 1.29
Port pressure = (1.6^1.29) * 20 psia = 37 psia
 -17 F Evaporator
96 F Condenser

Secondary Evaporator
8 F Secondary Evaporator
Comp.

-17 F Evaporator

With a -17 F primary evaporator temp. a secondary

evaporator can be used as long as the temperature is
above ~ 8 F.
 R-717
10000
Absolute Pressure (PSIA)

1000

100

10

1
0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

 R-717
10000
Absolute Pressure (PSIA)

1000

100

Sideport
10 Evaporator

1
0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

 - 40 F
10 psia

-20 F
18 psia

96 F
200 psia
Port pressure ~=(Volume ratio)^k * (P suction)
NH3 k ~= 1.29
Port pressure = (1.6^1.29) * 10 psia = 18 psia
 -40 F Evaporator
96 F Condenser

Secondary Evaporator
-20 F Secondary Evaporator
Comp.

-40 F Evaporator

With a -40 F primary evaporator temp. a secondary

evaporator can be used as long as the temp. is above - 20 F
 40 F
73 psia

72 F
133 psia

96 F
200 psia
Port pressure ~=(Volume ratio)^k * (P suction)
NH3 k ~= 1.29
Port pressure = (1.6^1.29) * 73 psia = 133 psia
 40 F Evaporator
96 F Condenser

Secondary Evaporator
72 F Secondary Evaporator
Comp.

40 F Evaporator

With a 40 F primary evaporator temp. a secondary

evaporator can be used as long as the temp. is above 72 F.

Port pressure is too high to be useful !!!!!!!!!!

 -17 F
20 psia

8F
37 psia

96 F
200 psia
Effect of Lower
Condensing Pressure
 -17 F
20 psia

8F
37 psia

75 F
140 psia
Effect of Lower
Condensing Pressure
 -17 F
20 psia

8F
37 psia

75 F
140 psia
Port pressure ~=(Volume ratio)^k * (P suction)
NH3 k ~= 1.29
Port pressure = (1.6^1.29) * 20 psia = 37 psia
 -17 F
20 psia

8F
37 psia

75 F
140 psia
Econo. Pressure is a function of suction
pressure and port location only ! Not discharge
pressure !
 -17 F
20 psia

8F
37 psia

96 F
200 psia

What is the Sideload capacity?

on NH3
 Liquid from cond

100 lbm/min Secondary

Evaporator
-17 F 37 psia (8F)
20 psia

Zero flow

P=37 psia
 Liquid from cond

100 lbm/min Secondary

Evaporator
-17 F 38 psia (10F)
20 psia

16 lbm/min

P=37 psia
 Liquid from cond

100 lbm/min Secondary

Evaporator
-17 F 41 psia (13F)
20 psia

21 lbm/min

P=38 psia
 Liquid from cond

100 lbm/min Secondary

Evaporator
-17 F 43 psia (15F)
20 psia

28 lbm/min

P=40 psia
Thread packing brings up the pressure
in the screw thread
 Sideload Capacity NH3 Refrig.
as a % of suction capacity
Sideload Temp.
% of Suct. Tons Refr.

400%
40F
300%
20F
200%
0F
100%
-10F
0%
-40 -20 0 20
Sat. Suct Temp. F
Sideload Evaporator Piping
Condenser

Secondary
SecondaryEvaporator
Evaporator

Evaporator

Economizer Piping
Condenser
Flash
Economizer

Evaporator
 An Economizer is a special case of a sideload
evaporator, where part of the condensed liquid is
evaporated to cool the remainder of the condensed
liquid.

96F liq
Condenser
Flash 18 lbm/min
Economizer Comp.
17 F liq Evaporator -17F
(45psia) 100 lbm/min
(20 psia)

NH3
 R-717
Single stage compression
10000
Absolute Pressure (PSIA)

1000
229 Tons
Refrigeration
100

in
/m
m
10

lb
(hg-hf)=458b/lbm

0
10
1
0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

-17F/96F NH3
 R-717cycle
Economizer
10000
Absolute Pressure (PSIA)

19% increase in
1000 evaporator tons
@273
sameTons
evaporator
Refrigeration
massflow
100

19 lbm/min

in
/m
m
10

lb
(hg-hf)=458b/lbm

0
10
(hg-hf)=545b/lbm
1
0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

 R-717cycle
Economizer
10000
19% More Tons
Only
Absolute Pressure (PSIA)

19% More massflow

9% More Power
1000

in
/m
m
100

lb
19 lbm/min

9
11
10 100 lbm/min

1
0 100 200 300 400 500 600 700 800 900

Enthalpy (B.T.U. per LB)

 100 lbm/min
-17 F
20 psia

19 lbm/min
45 psia

119 lbm
96 F
The economizer vapor is at a lower 200 psia
compression ratio, and adds no
additional friction to the compression
 NH3 Cycle efficiency
-17 F evaporator
96 F condensing
Capacity Power HP/TR
229 494 2.16 non-Econ
273 538 1.97 Econo.
19% 9% 9.6% improved
 R-22 Cycle efficiency
-10 F evaporator
95 F condensing
Capacity Power HP/TR
106 212 2.0 non-Econ
136 230 1.7 Econo.
28% 8% 17% improved
 Capacity and Power Non-E
800

700

600
Power NH3
TR & BHP

500 R507
R22
400
NH3 BHP
300 R507 BHP
Capacity R22 BHP
200

100

0
-60 -40 -20 0 20 40 60

Evap Temp (F)

 Capacity and Power- Economized
800

700
Power
600

500 NH3 Cap

HP and TR

R507 Cap
400 R22 Cap
NH3 HP
R507 HP
300
R22 HP
Capacity
200

100

0
-60 -40 -20 0 20 40 60

Evap Temp (F)

 BHP/TR (E and non-E)
6

4 NH3 E
R507 E
R22 E
3
NH3 non
R22 non
2 R507 non

0
-60 -40 -20 0 20 40 60

Evap Temp (F)

 6

5.5 BHP/TR (E and non-E)

5

4.5

4
NH3 E
3.5
R507 E
3 R22 E
NH3 non
2.5 R22 non
R507 non
2

1.5

1
-55 -50 -45 -40 -35 -30 -25 -20

Evap Temp (F)

 Econo. Flash Gas Flow
500

450

400

350
Lbm/min

300
NH3
250 R507
R22
200

150

100

50

0
-60 -40 -20 0 20 40 60

Evap Temp (F)

 TR increase E/Non-E
90.0%

80.0%

70.0%

60.0%

50.0% NH3 Cap

R507 Cap
40.0% R22 Cap

30.0%

20.0%

10.0%

0.0%
-60 -40 -20 0 20 40 60

Evap Temp (F)

 Efficiency Gain w/ Economizing
50.0%
45.0%
40.0%
35.0%
30.0%
NH3
25.0% R507
R22
20.0%
15.0%
10.0%
5.0%
0.0%
-60 -40 -20 0 20 40 60

Evap Temp (F)

 Economizer Piping
• Open flash vessel
• Flash vessel with HX
• Direct Expansion
Open Flash Vessel -
.
One Compressor
DX - Shell and Tube
Level Controlled Shell and Coil

If load varies widely and

econo is used below 90% SV
use BPR controlling
compressor side