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WELCOME Presentation on “FREE” Hot Water from Refrigeration

WELCOME Presentation on “FREE” Hot Water from Refrigeration. VRAJALAL KANETKAR. REFRECON MAGIC SYSTEMS PVT. LTD. PUNE. TECHNOLOGY SOLUTIONS FOR GREEN EFFECT. Perfected Technology Solution. “FREE” Hot water using “DESUPERHEATER”

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WELCOME Presentation on “FREE” Hot Water from Refrigeration

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  1. WELCOME Presentation on“FREE” Hot Water from Refrigeration VRAJALAL KANETKAR REFRECON MAGIC SYSTEMS PVT. LTD. PUNE TECHNOLOGY SOLUTIONS FOR GREEN EFFECT

  2. Perfected Technology Solution “FREE” Hot water using “DESUPERHEATER” G-2-LHeat Transfer to recover Waste Heat from Refrigeration Compressors

  3. REFRECON MAGIC Offers • Value added product • Innovative concepts and services • Custom built system integration • Implementation on turnkey basis • Product that creates lasting relations

  4. REFRECON SOLUTION • Time tested proven solution • Heat recovery that does not change basic refrigeration cycle, in fact it improves ! • Appropriate technology at affordable cost ! TECHNOLOGY SOLUTIONS FOR GREEN EFFECT

  5. Hot water applications • Pre-heated Boiler feed water • Dairy and Food Processing • Boiler feed water • CIP, • Crate & can washing, • Butter melting • Floor washing • Tanker Washing • Process Heating - Drying

  6. Conventional mode to get hot water • Electrical Resistance Heater • Fuel fired hot water heater • Gas fired (LPG/NG) • HSD/LDO • FO fired boiler – direct steam injection • Heat Pump • Heat Recovery – Free of any energy cost

  7. Heating Cost for 55 deg C, 10,000 liters/day hot water Fuel Energy Cost Rs. /day • Coal 253 • NG 400 • LPG 600 • FO 600 • LDO 950 • HSD 1050 • Electricity • Domestic 1100 • Industrial 1320 • Commercial 1570 • Heat Pump 480 • Heat Recovery “ FREE”

  8. CONCEPT • Heat Rejection Dairy Cooling Heat recovery Cooling Tower Evaporator # Refrigeration compressor # Condenser

  9. Some Basic Essentials of Heat Recovery • Heat Recovery is by-product. • Consistency in base system operation is paramount important. No compromise on operation freedom of base system (i.e. Refrigeration) is acceptable. • Safety of base system remains unchanged • Efficiency & performance is improved. • Add on heat recovery should meet end user requirement

  10. Common FAQs • Is it possible to match heating & refrigeration? Do these capacities and time of use coincide? • Right question ! • The refrigeration compressor rating and hot water generation seldom match in • capacities • time of use. This demands integrated system approach

  11. Common FAQs • What safeties are required? • Cross contamination, • Cleaning of heat transfer media • Pressure Drop • Does air conditioning gets affected? • No. In fact, it enhances condenser performance due to increased condensing area, resulting in improved refrigeration cycle. • Reduces condenser cleaning frequency • Reduces cooling tower thermal load

  12. Common FAQs • How long will it work ? • As long as Refrigeration compressors operate – REFRECON Desuperheater performance is life long • REFRECON service support ? • We are equipped to undertake annual maintenance contract to ensure saving consistency and keep customer confidence alive.

  13. Supporters of the Concept • American Society of Heating Refrigeration & air conditioning Engineers (ASHRAE) • Center for Analysis and Dissemination of Demonstrated Energy Technology (CADDET) • University of Florida and many others

  14. ASHRAE Comments • Heat rejected by air conditioning chillers can be captured and used for heating water. Resulting in benefits such as • increase in total system efficiency • reduced fuel requirement • condenser heat is not rejected to atmosphere

  15. Conceptual Ammonia Refrigeration Cycle R-717 Condenser: Evaporative cooling OR Shell & tube From Evaporator CT water Compressor Receiver Evaporator / IBT Liquid NH3 Chilled Water

  16. Conceptual Ammonia (R 717) Cycle with Desuperheater REFRECON Desuperheater Oil separator From Evaporator CT water Compressor Condenser Receiver Evaporator Liquid NH3 Chilled Water

  17. Freon 22 Refrigeration Cycle with Desuperheater From RMS Desuperheater R-22 Hot Water Condenser Optional Extra CT water From Evaporator Compressor To Evaporator S L H E Evaporator TEV Chilled Water

  18. Refrigeration cycle on Pressure Enthalpy Chart • Pressure – Enthalpy Chart Desuperheater

  19. Refrecon Desuperheater Construction details Gas side tested to 375 psi. • Tube in tube heat exchanger Refrigerant Cleaning End plugs Water Vent -open to atmosphere

  20. Factory tested Desuperheater • Tested to 25 Bar gas side pressure • 10 Bar water side pressure • Seamless Heat Exchanger Tubes • Demo for tube cleaning on installation - Hardly need external service support

  21. Summary of REFRECON Desuperheater construction benefits • Efficient heat exchanger design with negligible loss in gas-side Differential Pressure • Pressure Tested Heat Exchanger & option for Vented Double Wall design provide lifelong andcomplete protection against cross contamination • Quick and easy access for water side tubes cleaning for consistence performance

  22. Waste Heat Recovery Key benefits - Technical • Hot water@ 55 to 70 deg. C “absolutely free” - no operating energy cost • Pre-heated feed water reduces fuel used in boiler or other prime energy used for water heating in plant • Integrated system approach (see next slide) • and no compromise for basic refrigeration cycle / cooling effect

  23. Hot Water Circuit - Typical

  24. Dairy Hot Water Circuit

  25. System Integration • No Big frills • Level of simple automation • Operator friendly • Existing system continue as stand-by support

  26. Water Chemistry Issues • Water changes Properties beyond 50 deg C • SS, TDS, Hardness • Result in poor heat transfer • Poor system performance • Refrigeration Capacity loss • Addressing water issues • Access to water side tube cleaning • Provision of removable plug ends • On-line water pipe cleaning ( without stopping cooling system)

  27. Economics of Desuperheater • 75 TR system has potential heat recovery of 24,000 kcal/hr. (Thermal units of heat measurement) • Translated to money savings, it is Rs. 5,00,000 per annum (Basis: 360 days, 20 hrs/day, Rs. 24/ kg FO as fuel ) • In addition, it results in 3 to 5 % reduction in refrigeration and AC operating cost, reduced condenser cooling load, coupled with prolonged compressor life, Reduced condenser cleaning (Intangible Benefits)

  28. Savings Estimates - Through free hot water generation • 1 TR= 12,000 BTUs/hr or 3024 kcal/hr Cooling Load • Savings = 10 to 12% Heat Recovery = 330 kcal / TR • HRU in 20 hrs operation/day = 6600 kcal /day • Fuel heat =10,400 kcal/kg (FO as fuel) • Density 0.93, efficiency = 84% • Effective heat / lit. = 8200 kcal • Savings /day/TR /18 hr Operation of refrigeration system =0.8 lit/day fuel • Saves emission to atmosphere per year • 900 kg CO2 • 0.4 million kcal Heat

  29. Key benefits - Social & Commercial • A step towards eco-friendly organization image. • Guaranteed recovery of investment - in less than 18 months

  30. ProductCertifications;Appreciation;Approvals • Dairies under KMF (Karnataka Milk Federation) • NDDB • MILMA, North Kerala • Heritage Foods & Dairy Products • Cream line (Jersey Dairy) Hyderabad) • VOLTASLtd. (Business Alliance) • BLUE STARLtd. • Hospitality Industry

  31. 1 Heritage Foods Ltd. Village Yadvanahalli, Banglore. ** 3X30 TR KPC-KC2 Kirloskar Aug 2003 June 2004 2 Heritage Foods Ltd. Narkatpalli, A.P. ** 2X30 TR KPC-KC2 June 2004 3 Kolar Milk Union, Kolar (NDDB) 75 TR KPC–KC4 August 2004 4 Heritage foods, Ltd. Tirupati. TN ** 1X120TR 1X30 TR KPCKC4 KPC-KC2 October 2005 5 Kasargod, Dairy, Kasargod, MILMA, Kerla 40 TR KPC–PC 2 March 2006 6 Hassan Co-op. Milk Union, Hassan.(KMF) 125 TR 4 X Frick Dec 2006 7 MILMA, Calicut, 120 TR Frick March 2007 8 MILMA, Palakkad, 120 TR Frick March 2007 9 MILMA, Kannur 120 TR Frick March 2007 10 Tumkur co-op. Milk Union. Tumkur (KMF) 135 TR Frick March 2008 11 Heritage Foods, Hydrabad 27 Desuperheaters dispatched from 40 on order 12 Kolar Milk Union, Kolar (KMF) 225TR 3XKC4 Oct. 2008 Some Dairy Installations

  32. Some prestigious Installations • Hotel Pride, Pune 50 TR TRANE • Hotel Sagar Plaza, Pune 40 TR Blue Star • Hotel Victor Palace, Kolhapur 2x40 TR Voltas • Hotel Tunga, Mumbai 80 TR Voltas • Hotel Emerald Park, Nasik 2x40 TR Voltas • Hotel Midtown Pritam, Mumbai 2X60 TR Voltas • Hotel Centurion, Pune 80 TR Voltas • Hotel Tunga, Mumbai 2X40 TR Carrier/Voltas • Heritage Group, Banglore & Hyd. 5X30 TR Kirloskar • Taj Varkhala Resort. 30 TR Voltas • Kolar Milk Union, Kolar 75 TR Kirloskar • Hotel marine Plaza, Mumbai 2X80 TR Blue Star • Hotel Regency, Mumbai 40 TR Voltas • Hotel Dolphin, Vishakhapatanum 60 TR Blue Star • Soft-tech Pharma, Mumbai/Daman 120 TR Voltas • Hotel Ascot 2X11 TR Voltas Scroll • MILMA, Kasargod 2X20 TR Kirloskar • MILMA, Calicit/Kannur/Palkkad 3X120 TR Kirloskar

  33. Installations Heritage Foods, Yadavanhalli, Banglore. 30 TR 30 TR

  34. INSTALLATION75 TR 40 TR

  35. MILMA Kasargod Unit at Shop Floor 40 TR

  36. Commissioning at Hassan Dairy

  37. Trial TEST Measurements During Commissioning at Hassan 120 TR

  38. Installation Kasargod Dairy

  39. InstallationMILMA Calicut 120 TR

  40. Commissioning Team at MILMA Palakkad 120 TR

  41. Installation MILMA Kannur 120 TR

  42. Case Study 1 • Refrigeration Capacity – 90 TR • Water temperature – 70 deg C • Water flow – 950 lit /hour • Operating Hours – 20 to 22 hours / day • Furnace oil saved – 1200 lit./month (Reported) • Diesel saved – 800 lit./month (Reported) • Power saved – 75 kWh/day • Total annual Savings – Rs. 612,000/- per Year • Simple pay back – 12 months • Avoided addition of condenser area for 30 TR compressor

  43. Case Study 2 • Refrigeration Capacity – 120 TR • Water temperature – 60 deg C • Water flow – 1400 lit /hour • Operating Hours – 22 hours / day • FO saved – 2400 lit. / month (Reported) • Power Saving – 75 kWh /day • Annual Saving (360 days) – Rs. 815,000 / Yr. • Simple pay back – 14 months • Increased milk processing capacity 45,000 lit/day without additional refrigeration

  44. Case Study 3 • Refrigeration Capacity – 2X80 TR (R22) • Water temperature – 50 deg C • Water flow – 1800 lit /hour • Operating Hours – 14 hours / day • HSD saved – 1400 lit./month (Reported) • Total annual Savings – Rs. 545,000/- per Yr. • Simple pay back – 12 months

  45. Case Study 4 • Refrigeration Capacity – 225 TR • Water temperature – 60 deg C • Water flow – 2500 lit /hour • Operating Hours – 24 hours / day • FO saved – 5,000 lit. / month (Reported) • Power Saving – 40,000 kWh /month • Annual Saving (360 days) – Rs. 32,00,000 / Yr. • Simple pay back – 10 months • Reduced Header pressure and compressor knocking, and increased IBT capacity

  46. TEN GOOD REASONS TO INSTALLREFRECONHEAT RECOVERY AHeat transfer1Consistent due to online maintenance 2Life long cross contamination free BEnergy Conservation3without loss of refrigeration capacity CImprovement4Air conditioning performance 5Standard water heater life, boiler life DReduction6Maintenance for A.C. equipments 7Evaporation loss of water in CT 8CO2 and Heat emissions EInvestment Recovery 9Less than eighteen months F REFRECON10System integration, design assistance, Effectiveness Installation guidance, Flawless commissioning

  47. Cost of delay of not implementing ENRCON project • 75 TR refrigeration plant looses saving opportunity for 1250Rs./day on fuel and 330 Rs./day on power Basis Operating 20 hrs/day using FO as fuel for hot water

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