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NH3 Systems and Practices in MEA Region

Mr. Arun Kumar Bhatia(Founder & Technical head )

T.E.D Consulting services

BOARD Member Association of Ammonia Refrigeration (AAR) India

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• COMPONENTS NH3 system

• REFRIGERATION system

• APPLICATION food

• SPECIALapplication

• CONCLUSION

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Ammonia which is produced by biological processes and naturally decomposes is an efficient and reliable refrigerant.

Ammonia is a natural refrigerant without the threat of global warming, having a low global warming potential rand also having low ozone depletion Potential rating.

• GWP=0• ODP=0• High volumetric capacity• Cheaper than HFCs/HCFCs (Reasonably priced)• High availability (abundance)• Low operating costs of project• Low energy demand for refrigeration• High specific refrigeration capacity• Downsized pipe dimensions• Known for centuries as a refrigerant• Minor Leak can instantly locate thanks to its odour• Question, that ammonia could be phased out in future

WHY NH3 Popular in region

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COMPONENTS

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COMPRESSORS

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COMPRESSORS

Reciprocating Twin Screw Single Screw

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COMPRESSORS

Reciprocating compressor Package

Screw compressor Package

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COMPRESSORS

Single Screw compressor Package

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COMPRESSORS

2 Stage Screw compressor Package

Tandem Screw compressor Package

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COMPRESSOR selections

o Spaceo Pressureo Geographical locationo Screw compressors oil cooling is thermosyphono Water cooled /Refrigerant injection (not very popular)o Natural Refrigerant (NH3) is favorite choice for Refrigeration plants

• Fruits and Vegetable storage• Fruits and Vegetable processing• Meat/Fish/Poultry processing• ICE Cream/Dairy plants• Leisure (Ski Slopes/ICE rinks)

o Condensing temperature : +30 °C to +52 °C o Wet bulb temperature : +22 °C to +32 °Co Capacity : kW /TRo Oil cooling : ?o POWER /Frequency : 3 x 380 V ± 5% or 110 / 220 V 60 Hz,

3 x 400 V ± 5% / 50 Hz ; 3 x 380 V ± 5% / 50 Hzo Motor : IP23 /IP 55 (IE3 ,IE3 ,IE4)

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CONDENSERS

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• MOST Popular is evaporative condensero GRP/FRP Casing o Galv. Steel or SS Casing o Galv. Steel tubes or SS tubeso With or Without Desuperheater

• Combination of S&T (PHE /others) and cooling towers• Air cooled condensers • Combination of AIR cooled and Water cooled • Pressure• Geographical location

CONDENSERS selections

Condensing temperature : +34 °C to +32 °C Wet bulb temperature : +24 °C to +32 °CMax rejection capacity : kW /TRDry bulb temperature : +10 °C to +50 °C

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CONDENSING methods

Evaporative Condenser

• Air• Electricity• Water• Chemical • Wastewater

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CONDENSING methods

Water-Cooled( cooling tower)

• Air• Electricity• Water• Chemical • Wastewater

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CONDENSING methods

Hybrid Condenser• Air• Electricity• Water• Chemical • Wastewater

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CONDENSING methods

Air cooled Condenser• Air• Electricity

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AIR COOLED condenser

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WATER COOLED condenser

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COMPARISON condensing methods

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AIR COOLERS

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AIR COOLERS popular

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AIR COOLERS popular

Processing areas

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FOOD Processing

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Operational Temperatures11 June 2020 26

1.3PL warehouses 2.FRUIT and VEG Cold stores3.Meat Proceeding factories4.DAIRY & Milk Proceeding5.JUICE factories 6.FISH Processing7.DRY stores 8.SLAUGHTERHOUSES 9.FREEZING and CHILLING

F&B Food and Beverages

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PUMP refrigeration system

1. Compressor2. Condenser3. Receiver vessel4. Expansion valve5. Separator (cold) vessel6. Oil drain required7. NH3 pump (cold)8. Valve station for evaporator9. Wet return line (cold)10. Dry suction line (cold)

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PUMP refrigeration system

The ANSI standard has three wall thickness grades for the same outside diameter: Schedule 80, Schedule 40 and Schedule 20.

• Schedule 80 is the heavy wall type, • Schedule 40 the more or less standard version used • Schedule 20 is available only for pipe sizes from 200 mm

The choice of wall thickness is based on mechanical strength and expected corrosion impact. All Schedules are suitable for maximum working pressure of 25 bar for an ammonia plant.

Ammonia ( refrigerant) plants is classified as Class B2 (EN378) and Fluid Group 1 (PED).

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PUMP refrigeration system

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SAFE system

• The internal safety of the mechanical plant itself based on the design rules. For Europe EN378 and PED (Pressure Equipment Directive)

• External safety during repair and maintenance of the plant. Here EN378 ,and it prescribes that only trained and certified fitters are allowed to work.

• Ammonia detection (standard) , this will activate alarms before the irritation level has been reached.

• Pressure • Material• Certification (standards)

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VESSELS skids

I. Manufacturer’s name. II. Serial number. III. Year of manufacture. IV. Maximum allowable working pressure (bar). V. Test Pressure applied (bar).VI. Working temperature (°C).VII. Design Code (ASME or PED)VIII. STEEL (Lt or HT)

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• PU Insulation density will be not less than 35 kg/m3• smaller size pipes (1/2 inch or lower) can insulated using other materials• Piping material for the Ammonia low temp system is ASTM A333 , seamless piping • Piping material for the med/high temp system is ASTM A106, seamless piping• Piping material for the water /glycol system is SS / Steel / Upvc / PE

SAFE system

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SAFE system

• VENTILATION Fans• AIR Purger• NH3 Dryer

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Operational Temperatures

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CHILLERS glycol or water

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CHILLERS glycol or water

Screw Chiller Package

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AIR COOLING special

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AIR COOLING special

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SPIRAL IQF

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OTHERS

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DAIRY plants

TSU Units

Reduces Peak Load = Save Energy +smaller investment

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DAIRY plants

Falling Film ChillerTemperature closer to 0.5°C are possible

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HEAT pumps

Single stage Heat pump

2 stage Heat pump

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o Pasteurization process in the dairy industryo Hot water for scalding activities in slaughterhouseso De-feathering in poultry plantso Hot water for cleaning in food processing areaso Horticulture using green houseso Sport facilities with combined need for heat or cold

HEAT pumps

COP upto 4.9

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SKI slope

Ski Dubai is an indoor ski resort with 22,500 square meters of indoor ski area.85-metre-high indoor mountain (equivalent to a 25-story building) with 5 slopes

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PLANT room

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CONCLUDE stakeholders