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Danfoss is one of the world leaders for refrigeration compressors and accessories and Werner Finley a leading brand of manufacturer for all Process Cooling Equipment. With Werner Finley’s core competence in Process Cooling Technology, Danfoss wanted to partner with us on this project.
Danfoss wanted to build an Industrial Chiller which will reduce the impact on environment caused by refrigerants and improve energy efficiency of the system. This is the most relevant issue faced by the industry today. At Werner Finley we are already pro-actively trying to phase out CFCs and are in the process of phasing out HCFC based refrigerants which are hazardous to our environment. So when Danfoss approached us to partner with them on such a project we took it immediately, as the smallest possible contribution for the cause counts. We are grateful for the opportunity.
Micro Channel Heat Exchanger (MCHX) : For heat exchangers, compactness and higher volumetric heat transfer capacity are required. MCHX has a great potential for condensers or evaporators in these respects. Due to a higher air-side heat transfer performance of micro channel heat exchangers, the volume of the heat exchanger can be significantly reduced at the same cooling or heating capacity. With the decrease of the heat exchanger volume, the refrigerant charge amount can be decreased as well. Furthermore, it has a merit for recycling process. For typical fin-and-tube heat exchangers, tubes and fins have different materials. However, fins and tubes of micro channel heat exchangers are both made of the same material, aluminum.
Step motors can run at 200 steps per second and can return to their exact position very quickly. The controller remembers the number of step signals sent by the controller. This makes it possible for the controller to return the valve to any previous position at any time. This gives the valve very accurate control of refrigerant that flows through it. Most of these ETSs have 1,596 steps of control and each step is 0.0000783 inches.
Experimental setup : Figure 1 Shows the Test set up for the industrial Chiller system being used for testing the performance using the test conditions. Data logging was conducted through a precision data logger made by Yokagawa, and the 5000 data has been stored. P&I drawing to be included here by Puttaraju
Highlights and Conclusion:
Conclusion: The performance of an Industrial Chiller system having a MCHX condenser was experimentally evaluated and compared with that having a fin-and-tube condenser. The tested MCHX condenser has the same face area as that of the fin-and-tube condenser, but its internal refrigerant flow volume is 49% smaller than that of the baseline condenser. Due to its smaller internal volume, the optimum refrigerant charge amount of the micro channel condenser system is 60-70% lower than that of the baseline system. The steady state COP of the micro channel condenser system is increased by 3 to 6% as compared with that of the baseline system. This is attributed to the decrease in the compressor power consumption rather than the increase in the cooling capacity. Decrease of the power consumption for the micro channel condenser system is caused by the lower pressure ratio between the condensing and evaporation pressure, which is caused by the increased condenser heat capacity and ETS. In the cyclic operation, the cooling capacity of the micro channel condenser system is higher and its compressor power is lower than those of the baseline system. These benefits in the cycle operation are originated from the increased condenser heat capacity and improved injection of liquid to the evaporator using ETS.
Testimonial from Danfoss: “We at Danfoss take this opportunity to thank the entire Werner Finley team for your valiant support in getting this Project Executed. The commitment and interest shown by you and your team is simply commendable and that’s the reason we have been able to make it a successful one. I wouldn’t be doing justice if i didn’t mention Mr. Nataraj and Mr. Yogesh’s name specifically who had put in their 100% effort and extended the fullest support day in and day out until this project was completed. Also, our sincere appreciation and thanks to your entire production team.”