REFRIGERATION

Refrigeration Cycle
Refrigerants & properties

Shipboard Reefer Plant Layout & Operation

Closed (power) Cycle
WORKING
FLUID
ENGINE
W
HEAT HEAT
SOURCE SINK

PUMP H
H

W
Closed (power) Cycle
WORKING
FLUID
ENGINE
HP Vapor LP Vapor
W
HEAT HEAT
SOURCE SINK
HP Liquid LP Liquid
PUMP H
H
LowestTemp:
Highest Temp:
W Sea Water
Combustion Gasses
Refrigeration Cycle WORKING
FLUID
(Refrigerant)
COMPRESSOR

W
HEAT HEAT
SOURCE SINK
EXPANSION
DEVICE
H H
Refrigeration Cycle WORKING
FLUID
(Refrigerant)
COMPRESSOR

Highest Temp:
HP Refrigerant
LP Vapor
W HP Vapor
HEAT HEAT
SOURCE LP Liquid HP Liquid SINK
EXPANSION
DEVICE
H H
Lowest Temp:
LP Refrigerant
 Refrigerant Properties
 Safe: non-toxic, non-flammable, non-explosive,
environmentally friendly
 Chemically Inert: non-corrosive, does not react with
lubricants
 Detectable: so that leaks may be located (i.e., halide
torch)
 Operating Range: saturation conditions on high side
and low side at reasonable temperatures and pressures
 Economical: good pumping characteristics, good
thermodynamic properties for absorbing and rejecting
heat, compatibility with compressor lubricants
 Refrigerant Properties
 Operating Range: saturation conditions on high side
and low side at reasonable temperatures and pressures
Boiling Temp Evap Press at Evap Press at Evap Press at
Refrigerant (at 14.7 psia) 0oF (freeze) 34oF (Chill) 100oF

R-12 -21.6oF 9.17 psig 31.7psig 117 psig

R-12 is a CFC: a group of aliphatic organic compounds containing the

elements carbon and fluorine, and, in many cases, other halogens (especially
chlorine) and hydrogen
Invented in the 1920’s, R-12 was considered a “miracle compound”—colorless,
odorless, non-toxic, non-flammable & non-corrosive, and quickly replaced
earlier, toxic substances (ammonia, methyl chloride, sulfur dioxide) which had
caused many fatalities.
 Refrigerant Properties
 Other CFC compounds, patented by du Pont under the
FREON trademark, offered different operating conditions:
R-114 for Marine Chillers & R-502 for commercial freezers

Boiling Temp Evap Press at Evap Press at Evap Press at

Refrigerant (at 14.7 psia) 0oF (freeze) 34oF (Chill) 100oF

R-12 -21.6oF 9.17 psig 31.7psig 117 psig

R-114 39oF 17.8 “Hg 2.0 “Hg 31.1 psig

R-502 -50.0oF 31.2 psig 71.1psig 214 psig

But …
 Refrigerant Properties
 Ironically, (escaped) CFC’s remain stable as they
migrate to high up in the atmosphere
 There, the chlorine in the CFC’s breaks down the
ozone layer which protects the Earth’s surface
from dangerous UV radiation
 The manufacture of CFC’s was banned in 1996
 Recycled CFC’s may still be used intil 2030, but
as the supply decreases they are becoming
prohibitively expensive
 CFC’s may be replaced temporarily with HCFC’s
and ultimately with HFC’s
 Refrigerant Properties
CFC’s: chloroflourocarbons – manufacture banned 1996
R-12 R-11 R-502
(also R-11, -13, -113, -114, -500: FREON trademark products)

HCFC’s: hydrochloroflourocarbons – breaks down in lower
atmosphere, chlorine does not reach ozone layer; manufacture
phased out by 2030 (65% by 2010, 90% by 2015, 99% by 2020)

R-123 R-22
(also R-401, -402, -403, -408, -409:)

HFC’s: hydroflourocarbons – no chlorine component

R-134a R- ? R-407c
(also HFC-32, -125, -143a, -152a: SUVA trademark products)

 Refrigerant Properties
 CFC  HCFC  HFC replacement requires similar
thermodynamic properties
Boiling Temp Evap Press at Evap Press at Evap Press at
Refrigerant (at 14.7 psia) 0oF (freeze) 34oF (Chill) 100oF

Medium temperature refrigeration, Appliance, Commercial & Automotive

R-12 -21.6oF 9.17 psig 31.7psig 117 psig

R-134a -15oF 6.5 psig 29.5 psig 124 psig

Low temperature commercial freezers

R-22 -41.4oF 24.1 psig 60.5 psig 198 psig

R-407c -32.0oF 18.4 psig 54.0 psig 192 psig

Refrigeration Components
COMPRESSOR 125 psig, 100oF+
superheated vapor

100oF saturated
vapor-liquid mix

CONDENSER Ocean @
85oF

RECEIVER
LP HP 90oF sub-
2 psig, -10oF cooled liquid
15% vapor- EXPANSION
85% liquid DEVICE
  Why is the liquid-vapor mix on the low side of the
expansion device much colder than the high side?

On low pressure
side R-134a Under nigh side
evaporates at pressures
-10oF but each (125+ psig)
lb requires 90- -10 F
o 90oF R-134a is a liquid
100 BTU of at temperatures
latent heat to under 100oF
change phase

 In cooling to -10o each lb can “donate” sensible

heat to the process
 It takes about 6 lbs of R-134a cooling from 90oF to
-10o in order to create 1 lb of vapor (i.e, about
15% evaporates)
 Refrigeration Components
COMPRESSOR 125 psig, 100oF+
superheated vapor

100oF saturated
vapor-liquid mix

CONDENSER Ocean @
EVAPORATOR 85oF

RECEIVER
Broccoli
@ 5oF
LP HP 90oF sub-
2 psig, -10oF cooled liquid
15% vapor- EXPANSION
85% liquid DEVICE
 In the evaporator … 2 psig
(saturation temp: -10oF)
0oF: Superheated Vapor

SENSIBLE HEAT -5oF: Superheated Vapor

-10oF: 100% Saturated Vapor
LATENT HEAT
-10oF: 80% Vapor, 30% liquid

LATENT HEAT -10oF: 50% Vapor, 50% liquid

LATENT HEAT
-10oF: 25% Vapor, 75% liquid

Broccoli
@ 5oF -10oF: 15% Vapor, 85% liquid
 How can anything be superheated at -5oF?
o
F End here: -10 to -5oF (5
to 10o of “superheat”

VAPOR
0o
Start here:
15% vapor
-5o
LIQUID

LATENT HEAT
-10o X
LIQUID/VAPOR mix
Saturated conditions for R-
-15o 123a: 2 psig / -10oF SENSIBLE
HEAT

-20o

HEAT ABSORBED
 How can anything be superheated at -5oF?
Thermometer
“Compound”
Gage
Actual
temp (-
5oF)

Corresp Sat Temp Actual press

(-15oF @ 3.2 psi) (3.2 psi)

10 Fo of
R-12 superheat
Is it liquid or vapor?
Corresp Sat Temp Thermometer
(105oF @ 125 psi)

Actual press
(125 psi) Actual
temp
“Compound” (90oF)
Gage

Liquid: sub-
R-12 cooled 15 Fo
 Refrigeration Components
COMPRESSOR 125 psig, 100oF+
2 psig, superheated vapor
superheated vapor LP HP
100oF saturated
(-5 to 0oF) vapor-liquid mix

CONDENSER Ocean @
EVAPORATOR 85oF

2 psig,-10oF
100% Vapor
2 psig,-10oF
50% Vapor
RECEIVER
Broccoli
@ 5oF
LP HP 90oF sub-
2 psig, -10oF cooled liquid
15% vapor- EXPANSION
85% liquid DEVICE
 Capacity & Performance
COMPRESSOR
HEAT HEAT

WORK
SOURCE Ocean @
SINK
85oF

Broccoli
HEAT
?
@ 5oF
What you want
Coefficient of Performance: BTU/hr 1 “TON” of
COP = HEAT TRANSFERRED refrigeration =
WORK DONE What you pay for 12,000 BTU/hr
Compr kW

COP = TONS of Refrigeration x 3.5

Compressor kW
 Refrigeration controls …
Superheated Vapor

TXV:
Senses refrigerant temp
leaving evaporator
Throttles refrigerant flow
to maintain 5—10o
superheat at evap outlet
Ensures that no liquid
returns to compressor
Thermal
Broccoli
TXV Expansion
Valve
@ 5oF
-10oF: 15% Vapor, 85% liquid
 Refrigeration controls …
Superheated Vapor

SOL V:
Senses BOX temperature
Opens/closes in response
to thermostat high/low
settings
Stop valve action—does
not throttle
T

Broccoli
TXV
@ 5oF
-10oF: 15% Vapor, 85% liquid
SOLENOID
VALVE
 Refrigeration controls …
LP
Superheated Vapor

LP CUT-OUT:
Senses compression suction
pressure & starts/stops
compressor under normal
operating conditions
Starts compressor at 3—5 psi
T Stops compressor at 0.5-1 psi

Broccoli
TXV
@ 5oF
-10oF: 15% Vapor, 85% liquid
SOLENOID
VALVE
 Refrigeration controls …
LP HP
Superheated Vapor

HP CUT-OUT:
Senses compression discharge
pressure & stops compressor
under abnormal operating
conditions
Preventing over-pressurization
T of condenser

Broccoli
TXV
@ 5oF
-10oF: 15% Vapor, 85% liquid
SOLENOID
VALVE
 Evap @
Freeze & Chill boxes
34oF from other BOXES to compressor 0.5 to
(29.5 psig) suction 3.5 psig
BACK=PRESSURE
40oF VALVE

Maintains evap pessure in

“high temp” (chill) boxes

Not required in
34 to 44oF T “low temp” boxes
RECEIVER
where evap press
Evap @ -10oF ≈ compressor
-4oF
(2 psig) suction press

“KING” Valve

-2 to +8oF T
to other BOXES (evaporators)
 Refrigeration controls …
LP HP

Circulating
Water
Regulating
Valve
RECEIVER
to
other
service
S.W. Service Pump
Refrigeration control summary
 On evaporator
 TXV: on inlet. Controls flow to guarantee 5-10o of superheat at
outlet
 Solenoid Valve: admits refrigerant to TXV— opens/closes via
thermostat setting to control box temperature
 Back-Pressure Valve: on evap outlet of high temp boxes
maintains evap pressure above compressor suction pressure
 On compressor
 LP Cut-out: suction pressure activated switch that starts/stops
compressor under normal operating conditions
 HP Cut-out: discharge pressure activated switch that stops
compressor under abnormally high condenser pressures
 On condenser
 Circulating Water Regulating Valve: controls sea water flow
through condenser in response to condenser pressure
 System charging

Gas charging

Liquid charging

RECEIVER
DRIER
R-
CYL