HVAC Equipment: MAE 406 Energy Conservation in Industry Stephen Terry

HVAC Equipment
MAE 406 Energy Conservation in Industry Stephen Terry
HVAC Fundamentals
HVAC stands for Heating, Ventilation, and Air Conditioning. Sometimes see written as HVAC-R, which includes Refrigeration HVAC important in residential, commercial, and industrial plants
Focus in this Course

Weve already looked at using boilers to provide steam which is used by many large facilities, including NCSU, for heating. This lecture and the next will focus mostly on space air conditioning and refrigeration.
Method of Providing Cooling

Heat naturally moves from hot to cold, Refrigeration systems must move heat from a cold space to a hot space This is accomplished using a refrigeration cycle manipulating the pressure and temperature of a refrigerant This process also requires energy heat pump
Refrigeration Cycle
From Heating, Ventilating, and Air Conditioning Analysis and Design, McQuiston and Parker, 3rd edition
Cycle Efficiency MAE302

Depends on condenser and evaporator temperatures & compressor isentropic efficiency Usually discuss efficiency as COP or in kW/ton
Efficiency (COP) = Desired Output / Required Input = Qevaporator / Wcompressor = Qevaporator / (Qcondenser Qevaporator)
Note: 1 ton = 12,000 BTU/hr 1 kWh = 3,413 BTU
Typical Operating Temperatures

Evaporator Temperature: between 35-45F Operating colder than this can cause freezing / frost on coils defrost cycle Condenser Temperature:
80-90F for water cooled applications 110-140F for air cooled applications Why?
Compressor isentropic efficiency, ~70%
Types of Refrigeration Units

Air cooled DX unit Uses air-cooled condenser Usually cools air directly by venting return / outside air through ductwork Packaged and split system varieties. Efficiency 1.2-1.4 kW/ton
Advantages / Disadvantages of DX Unit

Advantages Flexible system, can grow with plant or building Self-contained system Relatively low first cost Disadvantages Efficiency is poor Maintenance can be expensive with many units
Types of Refrigeration Units

Central Water Chiller Refrigeration cycle cools water that circulates around building to AHUs Chiller can be water or air-cooled Requires piping and pumps Efficiency 0.6 kW/ton to 1.0 kW/ton
Advantages / Disadvantages of Chiller

Advantages Great energy efficiency Central unit reduces maintenance costs Can provide space conditioning and process cooling Disadvantages Requires cooling tower and pumps / pipes Must operate at lowest temperature required for entire system Must maintain chilled water system and cooling tower water system with chemicals
Refrigerants
R-134a and R-22 are commonly used today Older chillers use R-11/R-12 Ozone depleters Since R-11 not made any more, older chillers must be retrofitted if plants supply of refrigerant runs out. Food manufacturers will often use NH3 in a double stage system.
Double Stage System

Useful for large systems with two zones Ammonia is cheap&efficient, but is toxic! Condenser good for heat recovery to cleaning water.
Cooling Towers
Most often used to provide condenser for chillers. Can also be used to cool process equipment, especially air compressors. Water is sprayed / falls through a media while air is drawn through. Evaporation of water represents most of refrigeration effect Outlet temperature depends on wet-bulb temp.
Cooling Towers
Efficiency: 0.05 kW/ton Typical temperatures:
90 F in / 70-80 F out
Fans usually are 2-50 hp Can use multiple cells Two speed motors / VSDs
Absorption Chillers
Uses low pressure steam to generate chilled water! Chilled water temps: 40-50 F Refrigerant is a Li-Br salt. Steam is used to concentrate salt like a compressor is used to compress vapor Efficiencies: 1-2 Btu cooling / Btu of steam Requires a large cooling tower Systems are 2x the cost of regular chiller, so it is not economical unless steam is free
Air Distribution System Single Zone Rooftop Unit

Most common type of system seen in smaller industrial plants Utilizes an air cooled direct expansion unit to provide cold refrigerant to the cooling coil System may have multiple compressors to stage cooling May have a gas pack or steam coil for heating Often utilizes an economizer with relief venting
Single Zone Roof-top Unit Schematic

filters Economizer damper Heating Coil or Gas Pack Condenser
fan Compressors
Return air from room
Cooling Coil
Supply air to room
Economizers
Compares outdoor air temperature / enthalpy to indoor conditions. Three modes of operation:
Free cooling outside air temperature less than supply air temperature use mixture of outdoor air and return air, deactivate compressors Economizer cooling outdoor air cooler than indoor, but above supply air temperature. Use all outdoor air and cool it to supply temperature No savings outdoor air hot and system uses all return air (except minimum outside air)
Outdoor Air Requirements

Must supply minimum outside air to space to remove CO2 and contaminants, especially in newer buildings. Can utilize some air-to-air heat recovery in cold climates ASHRAE standard is 15 cfm per person Can be varied for classrooms or auditoriums if a CO2 sensor is used to determine fresh air required.
Multiple Zones
Dual Deck System
Utilizes ductwork with hot air and ductwork with cold air, which is mixed in proportion to maintain conditions Energy inefficient since hot and cold air are mixed.
Multiple Zones
Variable air volume (VAV)
Utilizes sensors to vary flow of air and therefore cooling through unit. Can use electric strip heater for heating purposes
Psychrometrics
Used to determine actual cooling / heating requirements, considering both temperature and humidity. Refer to psychrometric chart in thermodynamics book or ASHRAE handbook
Definitions Sensible Heat

Sensible heating heating or cooling that is done to change temperature only, no change in moisture. Example:
Determine sensible heat to raise the temperature of 1,000 lb/hr of air from 70 to 110 F. Sensible Heat = = 1,000 lb/hr x 0.24 BTU/lb- F x (110-70 F) 9,600 BTU/hr
Latent Heat
Latent heat is heat added in the form of moisture. Evaporative cooling is an example water sprayed into dry air causes liquid to evaporate to vapor, removing heat in the process. Moisture content of air specified by dew-point temperature or by specific humidity. Lines of constant dew-point are horizontal on chart Note that relative humidity is not horizontal
Enthalpy
A measure of sensible and latent heat Is a true measure of energy required to change state. Can be used to determine actual cooling loads, including latent heat removal.
Example
Find the heat removed from 10,000 lb/hr (2,222 cfm) of air starting at 95F and 75F dew-point to 55F and saturated.
Solution: h 95/75 h 55/55 Q removed = = = = = 44 BTU/lb 23 BTU/lb 10,000 lb/hr x (44 23 BTU/lb) 210,000 BTU/hr 17.5 tons of cooling
Air Washer Systems

Uses a water spray to spray cold chilled water into an air stream.
Air is first saturated along wet-bulb line (constant h) Once saturation is reached, saturated air is cooled by conduction to exit temperature Air is usually dehumidified in process Direct contact heat exchanger infinite surface area Must make provision for cleaning out dirt and grime from chilled water

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HVAC Equipment: MAE 406 Energy Conservation in Industry Stephen Terry

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HVAC Equipment

MAE 406 Energy Conservation in Industry Stephen Terry

Focus in this Course

Method of Providing Cooling

Cycle Efficiency MAE302

Typical Operating Temperatures

Compressor isentropic efficiency, ~70%

Types of Refrigeration Units

Advantages / Disadvantages of DX Unit

Types of Refrigeration Units

Advantages / Disadvantages of Chiller

Double Stage System

Air Distribution System Single Zone Rooftop Unit

Single Zone Roof-top Unit Schematic

Return air from room

Supply air to room

Outdoor Air Requirements

Definitions Sensible Heat

Air Washer Systems

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