Danfoss Industrial Refrigerationan - An introduction to the basics

Refrigeration
- an introduction to the basics
Lecture
REFRIGERATION &
AIR CONDITIONING DIVISION
MAKING MODERN LIVING POSSIBLE
Produced by Danfoss AC-DSL, HBS. 11.2007DKRCC.PF.000.F2.02
The Danfoss product range for the
refrigeration and air conditioning industry
Danfoss Refrigeration & Air Conditioning is
a worldwide manufacturer with a leading
position in industrial, commercial and
supermarket refrigeration as well as air
conditioning and climate solutions.
We focus on our core business of making
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that enhance performance and reduce
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heat exchanger

Automatic Controls and Compressors for refrigeration
Automatic controls for
commercial refrigeration
Automatic controls for
Industrial refrigeration
Electronic controls for refrigeration Appliance controls
Compressors for household
and commercial refrigeration
Condensing units

This Danfoss publication must be regarded as a supplement to the comprehensive literature on refrigera-
tion that is available today and which is primarily aimed at readers with a professional relationship to the
refrigeration industry/trade e.g. refrigeration engineers and installers.
The contents of this book are intended to interest those who are not engaged every day with refrigeration
plant but who wish to extend their knowledge on the basic principles of appliances they see every day.
When compiling the material for the booklet a deliberate attempt was made to provide a thorough descrip-
tion of the elementary principles involved together with an explanation in everyday language of the practical
design of the individual components.
For additional training material we refer to:
http://www.danfoss.com/BusinessAreas/RefrigerationAndAirConditioning
Choose“Training & Education”.
Nordborg, 2007
Refrigeration-anintroductiontothebasics
Contents
1. Introduction...........................................................................................................................................................................................3
2. Fundamental terms............................................................................................................................................................................4
2.1 Unit systems..................................................................................................................................................................................................................................4
2.2 Temperature..................................................................................................................................................................................................................................4
2.3 Force and pressure......................................................................................................................................................................................................................5
2.4 Heat, work, energy and power...............................................................................................................................................................................................5
2.5 Substances and phase change...............................................................................................................................................................................................6
2.6 Latent heat.....................................................................................................................................................................................................................................7
2.7 Superheat.......................................................................................................................................................................................................................................7
2.8 Refrigerant diagrams.................................................................................................................................................................................................................8
3. Refrigerant circuit...............................................................................................................................................................................9
3.1 Evaporator......................................................................................................................................................................................................................................9
3.2 Compressor...................................................................................................................................................................................................................................9
3.3 Compressor, method of operation........................................................................................................................................................................................9
3.4 Condenser................................................................................................................................................................................................................................... 10
3.5 Expansion process.................................................................................................................................................................................................................... 10
3.6 High and low pressure sides of the refrigeration plant......................................................................................................................................................10
4. Refrigeration process, pressure/enthalpy diagram........................................................................................................ 11
5. Refrigerants........................................................................................................................................................................................ 12
5.1 General requirements............................................................................................................................................................................................................. 12
5.2 Fluorinated refrigerants......................................................................................................................................................................................................... 12
5.3 Ammonia NH3............................................................................................................................................................................................................................ 12
5.4 Secondary refrigerants........................................................................................................................................................................................................... 12
6. Refrigeration plant main components.................................................................................................................................. 13
6.1 Compressor................................................................................................................................................................................................................................ 13
6.2 Condenser................................................................................................................................................................................................................................... 13
6.3 Expansion valve........................................................................................................................................................................................................................ 15
6.4 Evaporation systems............................................................................................................................................................................................................... 16
7. The practical build-up of a refrigeration plant.................................................................................................................. 17
© Danfoss A/S (AC-DSL / HBS), 07 - 2007 DKRCC.PF.000.F2.02 / 520H0924 1

Lecture Refrigeration - an introduction to the basics
The job of a refrigeration plant is to cool articles
or substances down to, and maintain them at a
temperature lower than the ambient tempera-
ture. Refrigeration can be defined as a process
that removes heat.
The oldest and most well-known among refrige-
rants are ice, water, and air. In the beginning, the
sole purpose was to conserve food. The Chinese
were the first to find out that ice increased the life
and improved the taste of drinks and for centu-
ries Eskimos have conserved food by freezing it.
1. Introduction
Aa0_0003_00_A1
heat heat
Aa0_0002_00_A1
Danfoss
R64-1869.10
At the beginning of the last century, terms like
bacteria, yeast, mould, enzymes etc. were known.
It had been discovered that the growth of micro-
organisms is temperature-dependent, that
growth declines as temperature falls, and that
growth becomes very slow at temperatures be-
low +10 °C.
As a consequence of this knowledge, it was now
possible to use refrigeration to conserve food-
stuffs and natural ice came into use for this pur-
pose.
The first mechanical refrigerators for the produc-
tion of ice appeared around the year 1860. In
1880 the first ammonia compressors and insulat-
ed cold stores were put into use in the USA.
Electricity began to play a part at the beginning
of this century and mechanical refrigeration
plants became common in some fields: e.g. brew-
eries, slaughter-houses, fishery, ice production,
for example.
After the Second World War the development of
small hermetic refrigeration compressors evolved
and refrigerators and freezers began to take their
place in the home. Today, these appliances are re-
garded as normal household necessities.
There are countless applications for refrigeration
plants now. Examples are:
Foodstuff conservation
Process refrigeration
Air conditioning plants
Drying plants
Fresh water installations
Refrigerated containers
Heat pumps
Ice production
Freeze-drying
Transport refrigeration
In fact, it is difficult to imagine life without air
conditioning, refrigeration and freezing - their
impact on our existence is much greater than
most people imagine.
Danfoss
R64-1866.10

4 DKRCC.PF.000.F2.02 / 520H2251 © Danfoss A/S (AC-DSL / HBS), 07 - 2007
2.1 Unit systems
2. Fundamental terms On an international level, agreement has been
reached on the use of the Systeme International
d’Unités - often referred to as the SI-system. For a
number of countries the implementation of the
SI-system is still an on-going process.
In this booklet the SI-system will be the primary
unit system used. However, in many parts of the
refrigeration community it is still practice to use
metric units or other alternative units. Therefore,
the practically used alternative units will be given
in parenthesis where needed.
The table shows the SI-units and the other often
used alternative units for the quantities that are
used in this booklet.
Quantity SI-unit Alternative units
Time s (second) h (hour)
Length m (meter) in (inch)
ft (foot)
Mass kg (kilogram) lb (pound)
Temperature K (Kelvin) °C (Celsius)
°F (Fahrenheit)
Force N (Newton) kp (kilopond)
Pressure Pa (Pascal) = N/m2
bar
atm (atmosphere)
mm Hg (millimeter mercu-
ry column)
psi (pound per square inch)
Energy J (Joule) = Nm kWh (kilowatt hour)
cal (calorie)
Btu (British thermal unit)
Power W (Watt) = J/s calorie/h, Btu/h
Name pico nano micro mili kilo Mega Giga Tera Peta
Prefix p n m m k M G T P
Factor 10-12
10-9
10-6
10-3
103
106
109
1012
1015
2.2 Temperature Temperature is a very central property in refriger-
ation. Almost all refrigeration systems have the
purpose of reducing the temperature of an
object like the air in a room or the objects stored
in that room.
The SI-unit for temperature Kelvin [K] is an abso-
lute temperature because its reference point [0 K]
is the lowest temperature that it in theory would
be able to obtain.
When working with refrigeration systems the
temperature unit degree Celsius [°C] is a more
practical unit to use. Celsius is not an absolute
temperature scale because its reference point
(0 °C) is defined by the freezing point of water
(equal to 273.15 K).
The only difference between Kelvin and Celsius is
the difference in reference point. This means that
a temperature difference of 1 °C is exactly the
same as a temperature difference of 1 K.
In the scientific part of the refrigeration commu-
nity temperature differences are often described
using [K] instead of [°C]. This practice eliminates
the possible mix-up of temperatures and temper-
ature differences.
The choice of prefix is“free”but the best choice
will normally be the one where the value written
will be in the range from 0.1 to 999.9.
Prefixes should not be used for combined SI-units
- except when [kg] is used.
Example:
2000 W/m2
K should be written as 2.000 × 103
W/m2
K and not as 2 kW/m2
K.
The practical use of the SI-units is strongly associ-
ated with the use of the decadic prefixes to avoid
writing either very small or large numbers. A part
of the prefixes used can be seen in the table be-
low.
Example:
The atmospheric air pressure is 101325 Pa. Using
the decadic prefixes from the table below the
best way of writing this would be 101.325 kPa.

Fundamental terms The SI-unit for force is Newton (N) which is actual-
ly a [kg m/s2
].
A man wearing skis can stand in deep snow with-
out sinking very deep - but if he steps out of his
skis his feet will probably sink very deep into the
snow. In the first case the weight of the man is
distributed over a large surface (the skis). In the
second case the same weight is distributed on
the area of his shoe soles - which is a much small-
er area than the area of the skis. The difference
between these two cases is the pressure that the
man exerts on the snow surface.
Pressure is defined as the force exerted on an
area divided by the size of the area. In the exam-
ple with the skier the force (gravity) is the same in
both cases but the areas are different. In the first
case the area is large and so the pressure be-
comes low. In the second case the area is small
and so the pressure becomes high.
2.3 Force and pressure
In refrigeration pressure is mostly associated with
the fluids used as refrigerants. When a substance
in liquid or vapour form is kept within a closed
container the vapour will exert a force on the in-
side of the container walls. The force of the va-
pour on the inner surface divided by its area is
called the absolute pressure.
For practical reasons the value for pressure is
sometimes stated as“pressure above atmospher-
ic pressure”- meaning the atmospheric pressure
(101.325 kPa = 1.013 bar) is subtracted from the
absolute pressure. The pressure above atmos-
pheric pressure is also often referred to as gauge
pressure.
The unit used should reflect the choice of abso-
lute pressure or gauge pressure. An absolute
pressure is indicated by the use of lowercase“a”
and a gauge pressure is indicated by a lower-
case“g”.
Example:
The absolute pressure is 10 bar(a) which convert-
ed to gauge pressure becomes (10 - 1.013) bar(g)
≈ 9 bar(g). The combination of the SI-unit for
pressure [Pa] and the term gauge pressure is not
recommended.
Other units for pressure that are still used today
are mm of mercury column [mmHg], and meter wa-
ter gauge [mwg]. The latter is often used in con-
nection with pumps to indicate the height of the
water column that the pump is able to generate.
Vacuum is defined as an absolute pressure of 0 Pa
- but since it is almost impossible to obtain this
the term“vacuum”is used generally to describe a
pressure much lower than the atmospheric pres-
sure. Example: The absolute pressure is 0.1 bar(a)
which converted to gauge pressure becomes
(0.1 - 1.013) bar(g) ≈ –0.9 bar(g). Vacuum is also
often described in Torr (1 Torr is equal to 10 Pa)
and millibar (a thousandth of a bar).
2.4 Heat, work, energy and
power
Heat and work are both forms of energy that can
be transferred between objects or systems. The
transfer of heat is closely connected to the tem-
perature (or temperature difference) that exists
between two or more objects. By itself heat is al-
ways transferred from an object with high tem-
perature to objects with lower temperatures.
Heating of water in a pot on a stove is a good
everyday example of the transfer of heat. The
stove plate becomes hot and heat is transferred
from the plate through the bottom of the pot and
to the water. The transfer of heat to the water
causes the temperature of the water to rise. In
other words, heating an object is the same as trans-
ferring energy (heat) to the object.
In many practical applications there is a need to
reduce the temperature of an object instead of
increasing it. Following the example above this
can only be done if you have another object with
a lower temperature than that of the object you
wish to cool. Putting these two objects into con-
tact will cause a transfer of heat away from the
object you wish to cool and, consequently, its
temperature will decrease. In other words, cooling
an object is the same as transferring energy (heat)
away from the object.
The transfer of work is typically connected to the
use of mechanical shafts like the one rotating in
an electric motor or in a combustion engine.
Other forms of work transfer are possible but the
use of a rotating shaft is the primary method
used in refrigeration systems.
As mentioned both heat and work are forms of en-
ergy. The methods of transfer between objects are
different but for a process with both heat and work
transfer it is the sum of the heat and work transfer
that determines the outcome of the process.

Fundamental terms The SI-unit Joule [J] is used to quantify energy,
heat and work. The amount of energy needed to
increase the temperature of 1 kg of water from 15
to 16 °C is 4.187 kJ. The 4.178 kJ can be trans-
ferred as heat or as work - but heat would be the
most used practical solution in this case.
There are differences in how much energy is re-
quired to increase the temperature of various
substances by 1 K. For 1 kg of pure iron app.
0.447 kJ is needed whereas for 1 kg of atmos-
pheric air only app. 1.0 kJ is needed. The property
that makes the iron and air different with respect
to the energy needed for causing a temperature
increase is called the“specific heat capacity”. It is
defined as the energy required to cause a tem-
perature increase of 1 K for 1 kg of the substance.
The unit for specific heat capacity is J/kg K.
The rate at which energy is transferred is called
power. The SI-unit for power is Watt (W).
Example:
If 10 J is transferred per second, the rate of energy
transfer is stated as 10 J/s = 10 W. In the SI-system
the choice of unit for power is the same for transfer
of heat and work. In other unit systems the transfer
rates for heat and work could have different units.
All substances can exist in three different phases:
solid, liquid, and vapour. Water is the most natural
example of a substance that we use almost every-
day in all three phases. For water the three phases
have received different names - making it a bit
confusing when using it as a model substance.
The solid form we call ice, the liquid form we just
call water, and the vapour form we call steam.
What is common to these three phases is that the
water molecules remain unchanged, meaning
that ice, water, and steam all have the same
chemical formula: H2O.
When taking a substance in the solid to the liq-
uid phase the transition process is called melting
and when taking it further to the vapour phase
the transition process is called boiling (evapora-
tion). When going in the opposite direction
2.5 Substances and phase
change
taking a substance from the vapour to the liquid
phase the transition process is called condens-
ing and when taking it further to the solid phase
the transition process is called freezing (solidifi-
cation).
2.4 Heat, work, energy and
power (cont.)
At constant pressure the transition processes dis-
play a very significant characteristic. When ice is
heated at 1 bar its temperature starts rising until
it reaches 0 °C - then the ice starts melting.
During the melting process the temperature does
not change - all the energy transferred to the
mixture of ice and water goes into melting the ice
and not into heating the water. Only when the ice
has been melted completely will the further
transfer of energy cause its temperature to rise.
The same type of behaviour can be observed
when water is heated in an open pot. The water
temperature increases until it reaches 100 °C -
then evaporation starts. During the evaporation
process the temperature remains at 100 °C. When
all the liquid water has evaporated the tempera-
ture of the steam left in the pot will start rising.
The temperature and pressure a substance is ex-
posed to determine whether it exists in solid, liq-
uid, or vapour form - or in two or all three forms
at the same time. In our local environment iron
appears in its solid form, water in its liquid and
gas forms, and air in its vapour form.
Danfoss
R64-1850.10
1 kcal
(4,187 kJ)
16 C
o
15 C
o
Danfoss
R64-1851.10

Fundamental terms
Going back to the process of ice melting it is im-
portant to note that the amount of energy that
must be transferred to 1 kg of ice in order to melt
it is much higher than the energy needed to
change the temperature of 1 kg of water by say
1 K. In section 2.4 the specific heat capacity of
water was given as 4.187 kJ/kg K. The energy
needed for melting 1 kg of ice is 335 kJ. The same
amount of energy that can melt 1 kg of ice can
increase the temperature of 1 kg of water by
(335 kJ/4.187 kJ/kg K) = 80 K!
When looking at the boiling process of water the
energy needed for evaporating 1 kg of water is
2501 kJ. The same amount of energy that can
evaporate 1 kg of water can increase the tempe-
rature of not 1 but 6 kg of water by 100 K!
These examples show that energy transfer relat-
ed to the transitional processes between phases
is significant. That is also why ice has been used
for cooling - it takes a lot of energy to melt the
2.6 Latent heat
ice and while the ice melts the temperature stays
at 0 °C.
The refrigerating effect in refrigeration systems is
based on the use and control of the phase transi-
tion processes of evaporation. As the refrigerant
evaporates it absorbs energy (heat) from its sur-
roundings and by placing an object in thermal
contact with the evaporating refrigerant it can be
cooled to low temperature.
Different substances have different melting and
boiling points. Gold for example melts at 1064 °C,
chocolate at 26 °C and most refrigerants melt at
temperatures around -100 °C!
For a substance that is present in two of its phas-
es at the same time - or undergoing a phase
change - pressure and temperature become de-
pendent. If the two phases exist in a closed con-
tainer and the two phases are in thermal equilib-
rium the condition is said to be saturated. If the
temperature of the two-phase mixture is in-
creased the pressure in the container will also in-
crease. The relationship between pressure and
temperature for saturated conditions (liquid and
vapour) is typically called the vapour pressure
curve. Using the vapour pressure curve one can
determine what the pressure will be for an evap-
orating or condensing process.
2.5 Substances and phase
change (cont.)
Superheat is a very important term in the termi-
nology of refrigeration - but it is unfortunately
used in different ways. It can be used to describe
a process where refrigerant vapour is heated
from its saturated condition to a condition at
higher temperature. The term superheat can also
be used to describe - or quantify - the end condi-
tion of the before-mentioned process.
Superheat can be quantified as a temperature dif-
ference - between the temperature measured
with a thermometer and the saturation tempera-
ture of the refrigerant measured with a pressure
gauge. Therefore, superheat can not be deter-
2.7 Superheat mined from a single measurement of tempera-
ture alone - a measurement of pressure or satura-
tion temperature is also needed. When superheat
is quantified it should be quantified as a tempera-
ture difference and, consequently, be associated
with the unit [K]. If quantified in [°C] it can be the
cause of mistakes where the measured tempera-
ture is taken for the superheat or vice versa.
The evaporation process in a refrigeration system
is one of the processes where the term superheat
is used. This will be explained further in the next
chapter.
Danfoss
R64-1852.10
0 C
o
26 C
o
Danfoss
R64-1853.10
335 kj
(80 kcal)

Fundamental terms The characteristics of a refrigerant can be illustrat-
ed in a diagram using the primary properties as
abscissa and ordinate. For refrigeration systems
the primary properties are normally chosen as
energy content and pressure. Energy content is re-
presented by the thermodynamic property of spe-
cific enthalpy - quantifying the change in energy
content per mass unit of the refrigerant as it un-
dergoes processes in a refrigeration system. An ex-
ample of a diagram based on specific enthalpy
(abscissa) and pressure (ordinate) can be seen be-
low. For a refrigerant the typically applicable inter-
val for pressure is large - and therefore diagrams
use a logarithmic scale for pressure.
The diagram is arranged so that it displays the liq-
uid, vapour and mixture regions for the refriger-
ant. Liquid is found to the left (with a low energy
content) - vapour to the right (with a high energy
content). In between you find the mixture region.
The regions are bounded by a curve - called the
saturation curve. The fundamental processes of
evaporation and condensation are illustrated.
The idea of using a refrigerant diagram is that it
makes it possible to represent the processes in the
refrigeration system in such a way that analysis
and evaluation of the process becomes easy.
When using a diagram determining system oper-
ating conditions (temperatures and pressures) sys-
tem refrigerating capacity can be found in a rela-
tively simple and quick manner.
Diagrams are still used as the main tool for analysis
of refrigeration processes. However, a number of
PC programmes that can perform the same analy-
sis faster and with more details have become gen-
erally available.
2.8 Refrigerant diagrams
Liquid
Condensation
Mixture of
Liquid + Vapour
(saturated)
Evaporation Vapour
Specific enthalpy
(energy content)
Pressure

The physical terms for the refrigeration process
have been dealt with previously, even though for
practical reasons water is not used as a refrige-
rant.
3. Refrigerant circuit
3.1 Evaporator
3.2 Compressor
A simple refrigerant circuit is built up as shown in
the sketch below. In what follows, the individual
components are described to clarify a final overall
picture.
A refrigerant in liquid form will absorb heat when
it evaporates and it is this conditional change
that produces cooling in a refrigerating process. If
a refrigerant at the same temperature as ambient
is allowed to expand through a hose with an out-
let to atmospheric pressure, heat will be taken up
from the surrounding air and evaporation will oc-
cur at a temperature corresponding to atmos-
pheric pressure.
If in a certain situation pressure on the outlet side
(atmospheric pressure) is changed, a different
temperature will be obtained since this is analo-
gous to the original temperature - it is pressure-
dependent.
The component where this occurs is the evapora-
tor, whose job it is to remove heat from the sur-
roundings, i.e. to produce refrigeration.
The refrigeration process is, as implied, a closed
circuit. The refrigerant is not allowed to expand to
free air.
When the refrigerant coming from the evapora-
tor is fed to a tank the pressure in the tank will
rise until it equals the pressure in the evaporator.
Therefore, refrigerant flow will cease and the tem-
perature in both tank and evaporator will gradu-
ally rise to ambient.
To maintain a lower pressure, and, with it a lower
temperature it is necessary to remove vapour.
This is done by the compressor, which sucks va-
pour away from the evaporator. In simple terms,
the compressor can be compared to a pump that
conveys vapour in the refrigeration circuit.
In a closed circuit a condition of equilibrium will
always prevail. To illustrate this, if the compressor
sucks vapour away faster than it can be formed in
the evaporator the pressure will fall and with it
the temperature in the evaporator. Conversely, if
the load on the evaporator rises and the refrige-
rant evaporates quicker, the pressure and with it
the temperature in the evaporator will rise.
Refrigerant leaves the evaporator either as satu-
rated or weak superheated vapour and enters the
compressor where it becomes compressed.
Compression is carried out as in a petrol engine,
i.e. by the movement of a piston. The compressor
requires energy and carries out work. This work is
transferred to the refrigerant vapour and is called
the compression input.
Because of the compression input, vapour leaves
the compressor at a different pressure and the extra
energy applied causes strong superheating of the
vapour. Compression input is dependent on plant
pressure and temperature. More work is of course
3.3 Compressor, method of
operation
required to compress 1 kg vapour 10 bar than to
compress the same amount 5 bar.
Evaporator
Evaporating heat
Liquid
refrigerant
Evaporator
Piston
compressor

The refrigerant gives off heat in the condenser,
and this heat is transferred to a medium having a
lower temperature. The amount of heat given off
is the heat absorbed by the refrigerant in the
evaporator plus the heat created by compression
input.
The heat transfer medium can be air or water, the
only requirement being that the temperature is
lower than that which corresponds to the condens-
ing pressure. The process in the condenser can oth-
erwise be compared with the process in the evapo-
rator except that it has the opposite“sign”, i.e. the
conditional change is from vapour to liquid.
3.4 Condenser
3.5 Expansion process Liquid from the condenser runs to a collecting
tank, the receiver. This can be likened to the tank
mentioned under section 3.1 on the evaporator.
Pressure in the receiver is much higher than the
pressure in the evaporator because of the com-
pression (pressure increase) that has occurred in
the compressor. To reduce pressure to the same
level as the evaporating pressure a device must
be inserted to carry out this process, which is
called throttling, or expansion. Such a device is
therefore known either as a throttling device or
an expansion device. As a rule a valve is used - a
throttle or expansion valve.
Ahead of the expansion valve the liquid will be a
little under boiling point. By suddenly reducing
pressure a conditional change will occur; the liq-
uid begins to boil and evaporate. This evapora-
tion takes place in the evaporator and the circuit
is thus complete.
There are many different temperatures in-
volved in the operation of a refrigeration
plant since there are such things as sub-
cooled liquid, saturated liquid, saturated va-
pour and superheated vapour. There are how-
ever, in principle, only two pressures; evapo-
rating pressure and condensing pressure. The
plant then is divided into high pressure and
low pressure sides, as shown in the sketch.
3.6 High and low pressure sides
of the refrigeration plant
Heat
Superheat zone
Condenser
Condensing
Compressor
Saturated liquid
Compressor
Vapour
Liquid/
vapour
Liquid
CondenserEvaporator
Receiver
High pressure sideLow pressure side
Expansion valve
Com-
pressorEvaporator
Liquid tank (receiver)
Expansion (throttle) valve

The condensed refrigerant in the condenser is in
condition A which lies on the line for the boiling
point of the liquid. The liquid has thus a tempera-
ture tc, a pressure pc also called saturated temper-
ature and pressure.
The condensed liquid in the condenser is further
cooled down in the condenser to a lower temper-
ature A1
and now has a temperature tl and an en-
thalpy h0. The liquid is now sub-cooled which
means that it is cooled to a lower temperature
than the saturated temperature.
The condensed liquid in the receiver is in condi-
tion A1
which is sub-cooled liquid. This liquid
temperature can change if the receiver and liquid
is either heated or cooled by the ambient tem-
perature. If the liquid is cooled the sub-cooling
will increase and visa versa.
When the liquid passes through the expansion
valve its condition will change from A1
to B. This
conditional change is brought about by the boil-
ing liquid because of the drop in pressure to p0.
At the same time a lower boiling point is pro-
duced, t0, because of the drop in pressure.
In the expansion valve the enthalpy is constant
h0, as heat is neither applied nor removed.
At the evaporator inlet, point B, there is a mixture
of liquid and vapour while in the evaporator at C
there is saturated vapour. At the evaporator outlet
4. Refrigeration process,
pressure/enthalpy
diagram
point C1
there is super-heated vapour which
means that the suction gas is heated to a higher
temperature than the saturated temperature.
Pressure and temperature are the same at point B
and at outlet point C1
where the gas is super-heat-
ed the evaporator has absorbed heat from the
surroundings and the enthalpy has changed to h1.
When the refrigerant passes through the com-
pressor its condition changes from C1
to D.
Pressure rises to condensing pressure pc. The
temperature rises to thot-gas which is higher than
the condensing temperature tc because the va-
pour has been strongly superheated. More ener-
gy (from the electrical motor) in the form of heat
has also been introduced and the enthalpy there-
fore changes to h2.
At the condenser inlet, point D, the condition is
thus one of superheated vapour at pressure pc.
Heat is given off from the condenser to the sur-
roundings so that the enthalpy again changes to
main point A1
. First in the condenser there occurs
a conditional change from strongly superheated
vapour to saturated vapour (point E), then a con-
densation of the saturated vapour. From point E
to point A the temperature (condensing tempera-
ture) remains the same, in that condensation and
evaporation occurs at constant temperature.
From point A to point A1
in the condenser the
condensed liquid is further cooled down, but the
pressure remains the same and the liquid is now
sub-cooled.
tc = condensing temperature
pc = condensing pressure
tl = liquid temperature
t0 = evaporating temperature
p0 = evaporating pressure
Expansion
valve
Receiver
Pressure
Heat
Condenser
Evaporator
Heat
Compressor
Enthalpy
hot-gas

5. Refrigerants During the examination of the refrigeration process
the question of refrigerants was not discussed since
it was not necessary to do so in connection with the
basic physical principles of the conditional change
of substances. It is well known, however, that in
practice different refrigerants are used according to
the specific application and requirements. The most
important factors are as follows:
The refrigerant ought not to be poisonous.
Where this is impossible, the refrigerant must
have a characteristic smell or must contain a
tracer so that leakage can quickly be observed.
The refrigerant ought not to be flammable
nor explosive. Where this condition cannot
be met the same precautions as in the first
point must be observed and local legisla-
tions must be followed.
The refrigerant ought to have reasonable
pressure, preferably a little higher than at-
mospheric pressure at the temperatures re-
quired to be held in the evaporator.
5.1 General requirements
5.2 Fluorinated refrigerants Fluorinated refrigerants always carry the designa-
tion“R”followed by a number, e.g. R22, R134a,
R404A and R407C. Sometimes they are met bear-
ing their trade names. The fluorinated refrigerants
all have the following features:
Vapour is smell-free and non-irritant.
Extensively non-poisonous. In the presence
of fire the vapour can give off fluoric acid
and phosgene, which are very poisonous.
Non-corrosive.
Non-flammable and non-explosive.
The most common fluorinated refrigerants are:
R134a, which is a substance of the ethane group
with the formula CH2FCF3 and has a normal boiling
point of –26.1 °C. Its thermodynamic properties
make it suitable as a refrigerant for medium temper-
ature applications such as domestic refrigerators.
R22, which is a substance of the methane group
with the formula CHF2CI and has a boiling point of
–40.8 °C. Its thermodynamic properties make it
suitable as a refrigerant for a wide range of applica-
tions in commercial refrigeration and air condition-
ing. R22 is being phased out as refrigerant in many
countries due to its ozone depleting potential.
R404A/R507A (also known as R507), which is a
mixture of the refrigerants R125 (CHF2CF3) and
R143a (CH3CF3) with a boiling point at (–46.7 °C)
which is slightly lower than for R22. Its thermody-
namic properties makes it suitable as a refrigerant
for low and medium temperature applications in
commercial refrigeration (e.g. supermarkets).
R407C, which is a mixture of the refrigerants R32
(CH2F2), R125 (CHF2CF3) and R134a (CH2FCF3) with
a boiling point at (–43.6 °C) which is slightly lower
than for R22. Its thermodynamic properties make
it suitable as a refrigerant for medium and high
temperature applications in residential and com-
mercial air conditioning.
R410A, which is a mixture of the refrigerants R32
(CH2F2) and R125 (CHF2CF3) with a boiling point at
(–51.4 °C) which is lower than for R22. Its thermo-
dynamic properties make it suitable as a refriger-
ant for medium and high temperature applications
in residential and commercial air conditioning.
Apart from these fluorinated refrigerants there is
a long series of others not seen very often today:
R23, R123, R124 and R218.
Except for R22, systems with fluorinated hydro-
carbons are in general lubricated with polyol es-
ter oils (POE). These oil types are much more sen-
sitive to react chemically with water, the so-called
“hydrolysis”reaction. For that reason systems to-
day are kept extremely dry with filter driers.
Ammonia NH3 is used extensively in large indus-
trial refrigeration plants. Its normal boiling point
is –33 °C. Ammonia has a characteristic smell
even in very small concentrations in air. It cannot
5.3 Ammonia NH3 burn, but it is moderately explosive when mixed
with air in a volume percentage of 13 to 28%.
Because of corrosion, copper or copper alloys
must not be used in ammonia plants.
The refrigerants mentioned above are often de-
signated“primary refrigerants”. As an interme-
diate link in heat transmission from the surround-
5.4 Secondary refrigerants ings to the evaporator, the so-called“secondary
refrigerants”can be used, e.g. water, brine, atmos-
pheric air etc.
To avoid heavy refrigerator design the pres-
sure, which corresponds to normal con-
densing pressure, must not be too high.
Relatively high evaporating temperature is
required so that heat transmission can occur
with least possible circulating refrigerant.
Refrigerant vapour ought not to have too
high a specific volume because this is a de-
terminant for compressor stroke at a partic-
ular cold yield.
The refrigerant must be chemically stable at
the temperatures and pressures normal in a
refrigeration plant.
The refrigerant ought not to be corrosive
and must not, either in liquid or vapour
form, attack normal design materials.
The refrigerant must not break down lubri-
cating oil.
The refrigerant must be easy to obtain and
handle.
The refrigerant must not cost too much.

The job of the compressor is to suck vapour from
the evaporator and force it into the condenser.
The most common type is the piston compressor,
but other types have won acceptance, e.g. cen-
trifugal scroll and screw compressors.
The piston compressor covers a very large capac-
ity range, right from small single cylinder modeIs
for household refrigerators up to 8 to 12 cylinder
modeIs with a large swept volume for industrial
applications.
In the smallest applications the hermetic
compressor is used, where compressor and
motor are built together as a complete hermetic
unit.
For medium sized plants one of the most
common compressors is the larger sizes of
hermetic compressors in either piston or scroll
versions. The applications are both air
conditioning, general commercial refrigeration
and chillers.
For larger plants the most common is the semi-
hermetic compressor. The advantage here is that
shaft glands can be avoided; these are very
difficult to replace when they begin to leak.
However, the design cannot be used on ammonia
plants since this refrigerant attacks motor
windings.
Still larger HFC compressors, and all ammonia
compressors, are designed as“open”compres-
sors, i.e. with the motor outside the crankcase.
Power transmission can be direct to the crank-
shaft or through a V-belt drive.
For quite special applications there is the oil-free
compressor. But lubrication of bearings and cylin-
der walls with oil is normally always necessary.
On large refrigeration compressors oil is circulat-
ed by an oil pump.
6. Refrigeration plant
main components
6.1 Compressor
The purpose of the condenser is to remove the
amount of heat that is equal to the sum of the
heat absorbed in the evaporator and the heat
produced by compression. There are many diffe-
rent kinds of condenser.
Shell and tube condenser. This type of condenser is
used in applications where sufficient cooling water
is available. It consists of a horizontal cylinder with
welded-on flat end caps, which support the cool-
ing tubes. End covers are bolted to the end plates.
The refrigerant condensate flows through the
cylinder, the cooling water through the tubes.
The end covers are divided into sections by ribs.
The sections act as reversing chambers for the
6.2 Condenser
water so that it circulates several times through
the condenser. As a rule, the water becomes
heated 5-10 °C when it has passed through a
condenser.

If it is desirable or necessary to cut down on the
amount of water an evaporating condenser can be
used instead. This type of condenser consists of a
housing in which there is a condensing coil, water
distribution tubes, deflection plates and fans.
The warm refrigerant vapour is led to the top of
the condensing coil after which it condenses
and runs from the bottom of the coil as liquid.
Refrigeration plant main
components
6.2 Condenser (cont.)
Water distribution tubes with nozzles are placed
over the condensing coil so that water is spread
over and runs down the coil. The fans direct a
strong flow of air across the condensing coil.
When the falling drops of water meet the up-
ward air flow some of the water will evaporate.
This absorbs the necessary evaporating heat
from the refrigerant vapour and causes it to con-
dense.
1. Fan
2. Deflector plate
3. Outer covering
4. Superheat remover
5. Condenser tubing
6. Air intake
7. Collecting tray
8. Overflow pipe
9. Water distribution pipe
10. Water circulation pump
11. Air intake
1. Fan
2. Deflector plate
3. Outer covering
4. Nozzle
6. Air intake
7. Collecting tray
8. Overflow pipe
9. Cooling water from condenser
10. Air intake
11. Cooling water return to condenser
The principal involving water evaporation is
also used in connection with cooling towers.
These are installed when the most practical is
to place a shell and tube condenser near a
compressor. The water is then circulated in a
circuit between condenser and cooling tower.
In principle, the cooling tower is built up
the same as the evaporating condenser,
but instead of condensing elements there
are deflector plates. Air is heated on its way
through the tower by direct contact with the
trickle of water travelling downwards and
is, therefore, able to absorb an increasing
amount of moisture coming from part-
evaporation. In this way, the cooling water
loses heat. Water loss is made up by supplying
more water.

It is possible to save 90-95% water consumption
by using evaporating condensers or cooling
towers, when compared to the water consump-
tion of shell and tube condensers.
For one reason or another it is not always pos-
sible to use water for the condensing process. In
such cases an air-cooled condenser must be
used. Since air has poor heat transfer characte-
ristics, compared with water, a large surface on
the outside of the condensing tubes is neces-
sary. This is achieved using large ribs or fins and,
in addition, by ensuring generous air circulation
mechanically.
This is the normal condenser for commercial re-
frigeration.
The main purpose of the expansion valve is to en-
sure a sufficient pressure differential between the
high and low pressure sides of the plant. The sim-
plest way of doing this is to use a capillary tube
inserted between the condenser and evaporator.
The capillary tube is, however, only used in
small, simple appliances like refrigerators be-
components
6.2 Condenser (cont.)
6.3 Expansion valve cause it is not capable of regulating the amount
of liquid that is injected into the evaporator. A
regulating valve must be used for this process,
the most usual being the thermostatic expan-
sion valve, which consists of a valve housing,
capillary tube and a bulb. The valve housing is
fitted in the liquid line and the bulb is fitted on
the evaporator outlet.
This figure shows an evaporator fed by a thermo-
static expansion valve. A small amount of liquid is
contained in a part of the bulb. The rest of the
bulb, the capillary tube and the space above the
diaphragm in the valve housing is charged with
saturated vapour at a pressure corresponding to
the temperature at the bulb. The space under the
diaphragm is in connection with the evaporator
and the pressure is therefore equal to the evapo-
rating pressure.
1. Inlet with strainer
2. Cone
3. Outlet
4. Bore
5. Connection for pressure equalizing
6. Spring housing
7. Diaphragm
8. Capillary tube
9. Spindle for setting spring pretension
(opening superheat)
10. Bulb

The degree of opening of the valve is determined
by:
The pressure produced by the bulb temper-
ature acting on the top surface of the dia-
phragm.
The pressure under the diaphragm, which is
equal to the evaporating pressure.
The pressure of the spring acting on the un-
derside of the diaphragm.
During normal operation, evaporation will cease
some distance up in the evaporator.
Then, saturated gas appears which becomes su-
perheated on its way through the last part of the
evaporator. The bulb temperature will thus be
evaporating temperature plus superheat, e.g. at
Finned evaporator
Plain tube evaporator
Ribbed tube evaporator
6.4 Evaporation systems
components
6.3 Expansion valve (cont.)
–10 °C evaporating temperature the bulb tem-
perature could be 0 °C.
If the evaporator receives too little refrigerant the
vapour will be further superheated and the tem-
perature at the outlet pipe will rise. The bulb tem-
perature will then also rise and with it the vapour
pressure in the bulb element since more of the
charge will evaporate. Because of the rise in pres-
sure the diaphragm becomes forced down, the
valve opens and more liquid is supplied to the
evaporator. Correspondingly, the valve will close
more if the bulb temperature becomes lower.
Thermostatic expansion valves are produced in
several versions and of course there are many
variants within each type.
Depending on the application, various require-
ments are imposed on the evaporator. Evapora-
tors are therefore made in a series of different
versions.
Evaporators for natural air circulation are used less
and less because of the relatively poor heat trans-
fer from the air to the cooling tubes. Earlier ver-
sions were fitted with plain tubes, but now it is
common to use ribbed tubes or finned elements.
Evaporator performance is increased significantly
if forced air circulation is used. With an increase of
air velocity the heat transfer from air to tube is
improved so that for a given cold yield a smaller
evaporator surface than for natural circulation
can be used.
As the name implies, a chiller cools down liquid.
The simplest method is to immerse a coil of tube
in an open tank. Closed systems are coming into
use more and more. Here, tube coolers made simi-
lar to shell and tube condensers are employed.

Figure A shows the principle build-up of a refrig-
eration plant for a simple cold store - much like
those that can be seen in butchers’shops and su-
permarkets.
The compressor unit can, for example, be in-
stalled in an adjacent storage room with an outlet
to fresh air. Such a unit consists of a compressor
driven by V-belt and electric motor. Additionally,
the base frame carries an air-cooled condenser
and a receiver. A fan is mounted on the shaft of
the electric motor to force air through the con-
denser and ensure the necessary degree of cool-
ing. The line between compressor and condenser
is known as the discharge line.
Today the majority of compressors used are of
the semi-hermetic and hermetic types.
7. The practical build-up
of a refrigeration plant
From the receiver, an uninsulated line, the liquid
line, is taken out to the cold store where it is con-
nected to the thermostatic expansion valve at
the evaporator inlet. The evaporator is built up
with close-pitch fins attached to tubes. It is also
equipped with a fan for forced air circulation and
a drip tray.
From the outlet side of the evaporator a line,
the suction line, is led back to the compressor.
The diameter of the suction line is somewhat
larger than the liquid line because it carries
vapour. For this reason the suction line is as a
rule insulated.
Thermostatic expansion valve
Fan
Evaporator
Drip tray
Cold store
Liquid line Pressure line
Suction lineCondenser
Compressor
Base frame
Compressor unit
Fig. A

Figure B gives details of momentary temperatures
in a refrigeration plant. At the compressor outlet
the pressure is 7.6 bar and the temperature is 60 °C
because of the presence of superheated gas. The
temperature in the upper part of the condenser
will quickly fall to saturation temperature, which
at the pressure concerned will be 34 °C, because
superheat is removed and condensation begins.
Pressure at the receiver outlet will remain more or
less the same, while subcooling of the liquid be-
gins because the temperature has fallen by 2 °C
to 32 °C.
In the evaporator a pressure of 1 bar and an evap-
orating temperature of –10 °C are indicated. In the
last part of the evaporator the vapour becomes
superheated so the temperature at the thermo-
static expansion valve bulb becomes +2 °C, corre-
sponding to the superheat set on the valve.
As illustrated below, air temperature will vary, in
that the air will take up heat on its way round the
store from products, walls, ceiling, etc. The tem-
perature of the air blown across the condenser
will also vary with the time of year.
A refrigeration plant must then be dimensioned
according to the largest load it will be subjected
to. To be able to accommodate smaller loads, fa-
cilities must exist in the plant for altering yield.
The process of making such alterations is called
regulation and it is precisely regulation that
Danfoss’automatic controls are made for. But that
is a subject, which is outside the scope of this
publication.
The practical build-up of a
refrigeration plant
R134aFig. B

Danfoss Industrial Refrigerationan - An introduction to the basics

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Danfoss Industrial Refrigerationan - An introduction to the basics