Engineering Tomorrow's Industrial Refrigeration Solutions in KSA

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1 Quick Review Definition Refrigeration science main concern is to drop the temp of a substance, (solid, liquid or gas state) below the surrounding atmospheric temp in a definite place & time. History Before AD in Cafes, during night in open areas, sawdust Fredric Tudor, 1856, Kelvinator 67 & 1918 HVAC Vs Refrigeration Market size, nature and need locally and globally ghaleb.abusaa@abusaa.com 1

2 Most known method of refrigeration 1. Refrigeration by Evaporation 2. Refrigeration by Vapor Compression 3. Refrigeration by Vapor Absorption 4. Refrigeration by Thermo-Electric Effect 5. Refrigeration by Expansion of Air 6. Combined cooling & heating by unguided swirl flow through circular pipes 2

3 Most known method of refrigeration Refrigeration by Thermo-Electric Effect This type of refrigeration is utilized when current passes in a circuit having two different metals where one end gets hot & the other gets cold. The temp. levels depend on different factors such as metal, Ampere rate, etc. Very limited applications (My personal Experience) 1- Cooling drinking water only, 10 Liters/Hour, 400 Watts, 35 to 15 o C. Dubai 2- Collecting water from Atmospheric air Dubai (With & W/T available Power) ghaleb.abusaa@abusaa.com 3

4 Most known method of refrigeration Refrigeration by Thermo-Electric Effect 4

5 Most known method of refrigeration Refrigeration Most known by method Thermo-Electric of refrigeration Effect Others experience from the Net 5

6 Most known method of refrigeration Refrigeration by Expansion of Air If air when it is under high pressure is released and expanded, its temp will go down provided useful mechanical work is utilized from it. This principle was used commercially around 1880 specially for importing meat & vegetables to Europe from Australia & North America by utilizing expanded air from the ship engines. Same principle is now used in air-conditioning of Airplanes by utilizing part of the expanded air from the Airplane engines. 6

7 Most known method of refrigeration Combined cooling & heating by unguided swirl flow through circular pipes (Vortex) Cold Air Compressed Air Supply Vortex Spin Chamber Control Valve Hot Air A 1/4 ton of refrigeration in the palm of your hand! ghaleb.abusaa@abusaa.com 7

8 Combined cooling & heating by unguided swirl flow through circular pipes Applications Cooling electronic controls Cooling machining operations Cooling CCTV cameras Setting hot melts Cooling soldered parts Cooling gas samples Cooling heat seal Environmental chambers Temp. range -45 to 120 o C. How A Vortex Tube Works Compressed air, normally 5 to 7 BAR, is ejected tangentially into the vortex spin chamber At up to 1,000,000 RPM, this air stream revolves toward the hot end where some escapes through the control valve & the remaining air, still spinning, is forced back through the center of this outer vortex The inner stream gives off kinetic energy as heat to the outer stream and exits the vortex tube as cold air. The outer stream exits the opposite end as hot air. Cold Air Compressed Air Supply Control Valve Vortex Spin Chamber Hot Air ghaleb.abusaa@abusaa.com 8

9 Most Common Refrigeration applications Industrial refrigeration As the progress of technology continues, new line called industrial and process cooling started and is heavily used in film making, electronic components, plastics, soft drinks, oil & Gas, refrigeration in Chemical Industry etc. 9

10 Most Common Refrigeration applications Ice manufacture Human use, Ice rinks, Ready mix concrete 10

11 Fishing industry Most Common Refrigeration applications 11

12 Most Common Refrigeration applications Low temperature applications 1. The phrase low, medium & high temperature is a relative term a. In air conditioning applications, SST of Zero o C is considered low temperature. b. In refrigeration for food and cold storage, zero o C is considered high temperature application, while -10 to -15 o C is considered medium temperature application and -30 to -50 o C is considered low temperature application. c. Temperatures below that up to absolute zero -270 o C. are considered Cryogenics. ghaleb.abusaa@abusaa.com 12

13 Most Common Refrigeration applications Low temperature applications تطبيقات درجات الحرارة المتدنية Environmental test facilities مختبرات البيئة Cryogenics علم فيزياء درجات الحرارة المتدنية Low temperature refrigeration علم تبريد درجات الحرارة المتدنية Biomedical applications of Cryogenic refrigeration التطبيقات الطبية الحيوية لعلم تبريد درجات الحرارة المنخفضة 13

14 Most Common Refrigeration applications 1- Env. test facilities are used to simulate an environment or combination of environments under lab controlled conditions that duplicate or exaggerate the effects found in actual service. to assist the researcher in exploring the effects of equipment on resistance to the many environmental forces. 2- Cryogenics is a term normally associated with low temp. However, the location on the temp scale at which refrigeration generally ends & cryogenics begins has never been well defined. Most scientists and engineers working in this field restrict cryogenics to a temp. below 125 K because the normal boiling points of most of the permanent gases (e.g., helium, hydrogen, neon, nitrogen, argon, oxygen, and air) occur below this temp. ghaleb.abusaa@abusaa.com 14

15 Most Common Refrigeration applications The food industry uses large amounts of liquid nitrogen to freeze the more expensive foods like shrimp and to maintain frozen food during transport. Liquid nitrogen cooled containers are used to preserve whole blood, bone marrow, and animal semen for extended periods. Cryogenic surgery is performed to cure such involuntary disorders as Parkinson s disease. Medical diagnosis uses magnetic resonance imaging (MRI), which requires cryogenically cooled superconducting magnets. ghaleb.abusaa@abusaa.com 15

16 Event main topic Refrigeration for the food industry, (Storage & Processing) Maximizing system efficiency while saving energy consumption Most common SSTs used in food industry in GCC countries 1. Dry stores around +2 degrees Celsius 2. Chilled products around (-10 to -15) degrees Celsius 3. Holding freezers and blast freezing applications around (-30 to -40) o C. Most common SCTs in food industry in GCC countries 1- Air cooled condensers around 55 degrees Celsius 2- Evaporative condensers and water cooled systems around +35 to +40 o C. 3- CO 2 requires a condensing temperature not to exceed (15) degrees Celsius Main Refrigerant properties affecting the technical and financial selection 1- Circulation rate (Weight & volume), latent heat & working pressure at design conditions 2- Safety, ODP, GWP, TEWI ghaleb.abusaa@abusaa.com 16

17 Most common Refrigerants used in GCC & their ODP, GWP & TEWI Vs some natural refrigerants 17

18 Event main topic Refrigeration for the food industry, (Storage & Processing) Maximizing system efficiency while saving energy consumption 18

19 Refrigeration for the food industry, (Storage & Processing) Maximizing system efficiency while saving energy consumption 19

20 Refrigeration for the food industry, (Storage & Processing) Maximizing system efficiency while saving energy consumption 20

21 Refrigeration for the food industry, (Storage & Processing) Maximizing system efficiency while saving energy consumption 21

22 Refrigeration for the food industry, (Storage & Processing) What refrigerant to use 22

23 Building a multi purpose cold store only in GCC & ME Region Temperature applications at SST around (0 to -50) o C ghaleb.abusaa@abusaa.com 23

24 Case study Life cycle cost Project: Multi purpose cold store facility Location: Kingdom of Saudi Arabia Size: 10,000 metric tons storage capacity Refrigeration system type: Centralized, screw compressors, evaporative condensers Refrigerant: NH3 Compressors on line capacity: 850 KW cooling with 450 KW electric power. Total system power including condensers, coolers and other accessories = 570 KW Yearly average loading of refrigeration system: Assumed 80% of rated capacity from a similar job in Australia due to non- availability of data from the local owner. Annual power consumption: 8760X0.8*570 = 3,994,560 KW. Cost of annual electric bills as of today s commercial rate 0.3 SAR/KW = SAR1,198,368 Cost of electric bills for 20 Years with today s rate: SAR 23, ghaleb.abusaa@abusaa.com 24

25 Case study Life cycle cost Project: Multi purpose cold store facility Location: Kingdom of Saudi Arabia Size: 10,000 metric tons storage capacity Make up water for the evaporative condensers at the rate of 2.25 Liter/KWH Annual make up water Mt 3 = 13,403 Annual make up water cost at SAR 6/Mt 3 = SAR 80,415 Make up water cost in 20 years = SAR1,608,336 Above utilities cost does not include water treatment, spare parts, O & M labor and consumable. The expected cost of these items may at least equal the cost of water and electricity. The total OPEX during life cycle of 20 years is figured around SAR 50,000,000. The CAPEX for the refrigeration system is in the range of SAR 22,000,000 Conclusion OPEX are 250% of the CAPEX. More important than CAPEX. ghaleb.abusaa@abusaa.com 25

26 Case study Life cycle cost Recommendations 1. Apply sustainability, green, renewables, energy conservation, reclaim waste energy, & condensate, economize and apply all building efficiency measures. Start from early design stage through out the project mile stones till putting the project into commercial operation. 2. Experience indicate savings in OPEX to be between 15% & 30% depending on the particulars of your project. 26

27 Event main topic Refrigeration for the food industry, (Storage & Processing) Maximizing system efficiency while saving energy consumption Q & A Thanks for attending, and wish you delicious meals for ever نشكركم على حضوركم ونتمنى لكم طعاما شهيا على الدوام صحة وعافية appétit! Bon ghaleb.abusaa@abusaa.com 27