Sunday, July 10, 2016

Working of Refrigerator & Refrigeration Principle

Refrigeration technology is commonly used in domestic and industrial applications. This video gives a detailed and logical introduction to the workings of refrigerators using the vapor compression cycle.

The Basic Principle

The basic principle of refrigeration is simple. You simply pass a colder liquid continuously around the object that is to be cooled. This will take heat from the object. In the example shown, a cold liquid is passed over an apple, which is to be cooled. Due to the temperature difference, the apple loses heat to the refrigerant liquid. The refrigerant in turn is heated due to heat absorption from the apple.

It is clear that, if we can produce cold liquid refrigerant continuously, we can achieve continuous refrigeration. This simple fact forms the core of the refrigeration technology. We will next see how this is achieved.

Components of Refrigerator & Working

An inside view of a refrigerator is shown.

Fig.2 An inside view of a refrigerator
It has 4 main components: compressor, condenser, evaporator, and throttling device. Of these components, the throttling device is the one that is responsible for the production of the cold liquid. So we will first analyze the throttling device in a detailed way and move on to the other components.

Throttling Device

The throttling device obstructs the flow of liquid; cold liquid is produced with the help of this device. In this case, the throttling device is a capillary tube. The capillary tube has an approximate length of 2 m and an inside diameter of around 0.6 mm, so it offers considerable resistance to the flow.

Fig.3 A Capillary tube: This results in sudden drop in pressure and temperature
For effective throttling at the inlet, the refrigerant should be a high-pressure liquid. The throttling device restricts the flow, which causes a tremendous pressure drop. Due to the drop in pressure, the boiling point of the refrigerant is lowered, and it starts to evaporate. The heat required for evaporation comes from the refrigerant itself, so it loses heat, and its temperature drops. If you check the temperature across the throttling device, you will notice this drop.

It is wrong to say that the throttling is a process. We know only the end points of throttling, that is, the states before and after throttling. We don’t know the states in between, since this is a highly irreversible change. So it would be correct to call throttling a phenomenon rather than a process.

Evaporator - Heat Absorption Process

The next phase is simple: this cold liquid is passed over the body that has to be cooled. As a result, the refrigerant absorbs the heat. During the heat absorption process, the refrigerant further evaporates and transforms into pure vapor. A proper heat exchanger is required to carry the cold refrigerant over the body. This heat exchanger is known as an evaporator.

Fig.4 Cold liquid is passed through a heat exchanger know as evaporator for absorbing heat from the refrigerator
So we have produced the required refrigeration effect. If we can return this low-pressure vapor refrigerant to the state before the throttling process (that is the high-pressure liquid state), we will be able to repeat this process. So first step, let’s raise the pressure.

Compressor

A compressor is introduced for this purpose. The compressor will raise the pressure back to its initial level. But since it is compressing gas, along with pressure, temperature will also be increased. This is unavoidable.

Fig.5 A compressor is used to raise pressure of the refrigerant
Now the refrigerant is a high-pressure vapor. To convert it to the liquid state, we must introduce another heat exchanger.

Condenser

This heat exchanger is fitted outside the refrigerator, and the refrigerant temperature is higher than atmospheric temperature. So heat will dissipate to the surroundings. The vapor will be condensed to liquid, and the temperature will return to a normal level.

Fig.6 Condenser heat exchanger is fitted outside the refrigerator so it will reject heat to the surroundings


So the refrigerant is back to its initial state again: a high-pressure liquid. We can repeat this cycle over and over for continuous refrigeration. This cycle is known as the vapor compression cycle. Refrigeration technology based on the vapor compression cycle is the most commonly used one in domestic and industrial applications.

Refrigeration Accessories

You can find more details on refrigerator components here. Evaporators and condensers have fins attached to them. The fins increase the surface area available for convective heat transfer and thus will significantly enhance heat transfer.

Fig.7 Fins attached to the condenser and evaporator
Since the evaporator is cooling the surrounding air, it is common that water will condense on it, forming frost. The frost will act as an insulator between the evaporator heat exchanger and the surrounding air. Thus it will reduce the effectiveness of the heat removal process. Frequent removal of frost is required to enhance the heat transfer. An automatic defrosting mechanism is employed in all modern refrigerators.

More on Compressor

Apart from raising the pressure, the compressor also helps maintain the flow in the refrigerant circuit. Usually, a hermetically sealed reciprocating type compressor is used for this purpose. You might have noticed that, your household refrigerator consumes a lots of electricity compared to the other devices. In a vapor compression cycle, we have to compress the gas; compressing the gas and raising pressure is a highly energy intensive affair. This is the reason why the refrigerator based on the vapor compression refrigeration technology consumes a lot of electricity.

Coefficient of Performance

The heat and power transfer happening in a vapor compression refrigeration circuit is shown below.

Fig.8 Energy interaction happening in a refrigeration system
A simple energy balance of the system yields the following relationship.

It is often required to evaluate performance of a refrigerator or compare between different refrigeration technologies. A term called Coefficient of Performance (C.O.P) helps in doing this. To understand this term completely, we need to know what is the input and output of a refrigeration system. What we need from a refrigerator is the cooling effect. Or QABSORBED is the output of a refrigeration cycle. Input to the refrigerator is the power given to the compressor. So the term C.O.P can easily be defined as output by input and is expressed as follows.






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Air Conditioning Circuit and Cycle Diagram


The component at #1 in this air conditioning circuit and cycle
diagram is the compressor.




The compressor is the heart of the system; it keeps the refrigerant flowing through the system at specific rates of flow, and at specific pressures.

It takes refrigerant vapor in from the low pressure side of the circuit, and discharges it at a much higher pressure into the high side of the circuit.




The rate of flow through the system will depend on the size of the unit,

And the operating pressures will depend on the refrigerant being used and the desired evaporator temperature.




The component at #2 in this air conditioning circuit and cycle diagram is the condenser.




The red dots inside the piping represent discharge vapor.

The solid red color represents high pressure liquid refrigerant.




Most air cooled air conditioning and refrigeration systems are designed so that the refrigerant will condense at a temperature about 25 to 30 degrees above outside ambient air temperature.





When the hot refrigerant vapor discharged from the compressor travels through the condenser, the cool air flowing through the condenser coil absorbs enough heat from the vapor to cause it to condense.




If the outside air temperature is 80 degrees, the system is designed so that the temperature of the refrigerant, right at the point where it first condenses, will be about 105 to 115 degrees.




Why do we want the refrigerant to condense at this relatively high temperature?




So that the air will be very cold relative to the temperature of the discharge vapor,

Which will allow the latent heat energy in the vapor to transfer over to that relatively cold air,

And cause the refrigerant to condense.




This transfer of heat from the vapor to the flowing air is what makes hot air blow out of your air conditioner's condensing unit.




At this stage in the air conditioning circuit and cycle diagram, high pressure liquid refrigerant will flow down the liquid line, through a filter drier that is designed to prevent contaminants from flowing through the system, and on to the metering device.




The metering device, component #3 on this air conditioning circuit and cycle diagram, is the dividing point between the high pressure and low pressure sides of the system,

And is designed to maintain a specific rate of flow of refrigerant into the low side of the system.




If the wrong capacity of metering device is used, or if there is a problem with the metering device,

An incorrect quantity of refrigerant will flow into the evaporator.




When the refrigerant passes through the metering device, it drops from about 225 psi to about 70 psi,

It also drops in temperature from about 110 degrees to about 40 degrees,

It starts evaporating immediately,

And it wouldn't be too inaccurate to imagine it acting like warm soda when you shake the bottle and pop the top off.

It shoots out into the evaporator foaming, bubbling, and boiling,

And remember, it's at a low pressure, so it's only boiling at about 40 degrees F.




And that brings us to the evaporator, component #4 in the air conditioning circuit and cycle diagram.




There will be relatively warm air flowing over the evaporator coil, lets say about 80 degrees.




The air conditiong system is designed so that the refrigerant will evaporate in the evaporator at a temperature of about 40 degrees, so that it will be cold compared to the warm air flowing over it.




The system is designed so that the heat in the warm air flowing over the evaporator will be absorbed by the cold evaporating refrigerant.




This cools the air flowing over the evaporator, and is the reason cold air blows out of your air conditioner.




I hope this air conditioning circuit and cycle diagram has helped you understand air conditioning systems, and once again, feel to copy it and print it out.

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Performance Testing


Compound Gauge (Low Side)
•The compound gauge derives its name from its function. It will register both pressure or vacuum.
•All air conditioning systems can, under certain conditions, drop from a pressure into a vacuum on the low side. It is necessary that a gauge be used that will show either pressure (psi and kPa) or inches of mercury vacuum (Hg.).
•The vacuum side of the gauge must be calibrated to show 0 to 30 inches (0 to 762 mm) Hg. The pressure side of the gauge must be calibrated to register ac­curately from 0 pressure to a minimum of 60 psi (414 kPa).
•The maximum reading of the pressure should not exceed 160 psi (1103 kPa). Practically all readings of the low side of the system will be less than 60 psi (414 kPa) with the system in operation.

High Pressure Gauge (High Side)
•The high pressure gauge is used to determine pressures in the high side of the system.
•The gauge is calibrated to register accurately from zero pressure to a minimum of 300 psi (2070 kPa).
•A few systems operate under high head pressure during normal operation conditions. This is why the high pressure gauge should have a reading of at least 600 psi (4140 kPa).

Gauge Manifold
•The gauge manifold mounts the high and low side gauges and connects the gauges into the high and low sides of the system by means of test hoses.
•The gauges connect to the upper part of the manifold through holes drilled and tapped to a 1/8-inch pipe thread.
•Test hose connectors below the gauges on the lower side of the manifold direct the refrigerant through the manifold to the gauges to obtain pressure readings.
•A center test hose connector on the lower side of the manifold is connected to both pressure gauges and the test hoses by a passage in the manifold.
•Refrigerant flow into the high and low side is controlled by a shutoff hand valve at each end of the manifold.



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Basic Refrigeration Cycle


Theory of Refrigeratiion Cycle

Principles of Refrigeration

•Liquids absorb heat when changed from liquid to gas


•Gases give off heat when changed from gas to liquid.


For an air conditioning system to operate with economy, the refrigerant must be used repeatedly. For this reason, all air conditioners use the same cycle of compression, condensation, expansion, and evaporation in a closed circuit. The same refrigerant is used to move the heat from one area, to cool this area, and to expel this heat in another area.
•The refrigerant comes into the compressor as a low-pressure gas, it is compressed and then moves out of the compressor as a high-pressure gas.
• The gas then flows to the condenser. Here the gas condenses to a liquid, and gives off its heat to the outside air.
•The liquid then moves to the expansion valve under high pressure. This valve restricts the flow of the fluid, and lowers its pressure as it leaves the expansion valve.
•The low-pressure liquid then moves to the evaporator, where heat from the inside air is absorbed and changes it from a liquid to a gas.
•As a hot low-pressure gas, the refrigerant moves to the compressor where the entire cycle is repeated.

Note that the four-part cycle is divided at the center into a high side and a low side This refers to the pressures of the refrigerant in each side of the system


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