Learn how intelligent purging systems work to extract non-condensable gases from an industrial ammonia refrigeration system.
Learn how smart purge systems work to remove non-condensible gases from an ammonia industrial refrigeration system.
Scroll down to see the YouTube tutorial.
Check
out the Danfoss Intelligent Purging System CLICK HERE
With its compact design, easy installation, and automatic
purging functionality, the Danfoss Intelligent Purging System (IPS) helps
improve the operational safety, efficiency, and cost-effectiveness of
industrial refrigeration systems.
🎁 Discover the Danfoss smart purge system CLICK HERE
Industrial Refrigeration System Cycle
If we look at a typical single stage industrial ammonia refrigeration system, we have the compressor pushing high pressure ammonia vapor into the condenser. Any unwanted heat from the cooling space is removed from the refrigerant in the condenser and this heat is then dispersed to the atmosphere.
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| Typical single stage industrial ammonia refrigeration system |
As heat is removed, the ammonia refrigerant condenses and becomes a liquid. This high pressure liquid refrigerant flows into the receiver and expander. The receiver holds a quantity of liquid refrigerant in temporary storage and releases or accumulates refrigerant here to stabilize changes in system cooling demands. There is an equalization line between the reservoir and the compressor discharge line which, as the name suggests, equalizes the pressure between these two points in the system so that the ammonia vapor can escape and therefore the level of liquid refrigerant. may vary.
The expansion valve regulates the pressure and the addition of liquid refrigerant in the evaporator circuit. From the expansion valve, the ammonia flows into the liquid separator. The liquid flows down where a pump would normally draw in the refrigerant and send it to the evaporator to provide refrigeration and collect unwanted heat.
The ammonia picks up unwanted heat from the evaporator, causing it to boil and evaporate. It leaves the evaporator and returns to the liquid separator as a liquid/vapor mixture. The liquid refrigerant falls and repeats the cycle again, but the vapor refrigerant rises and will be drawn into the compressor suction line. This low-pressure vapor refrigerant is compressed and sent throughout the system in a continuous cycle.
Basic industrial refrigeration cycle with ammonia
This is our basic industrial refrigeration cycle with ammonia. We covered this in more detail in our previous article. To check this CLICK HERE
Why do we need to purge?
In this system we will obtain an accumulation of non-condensable gases and air in two main places. At the top of the receiver above the liquid refrigerant and at the top of the dropper at the outlet of the condenser. These gases and air pockets will decrease system efficiency, reducing cooling capacity and increasing energy consumption. It is inevitable that air will enter the system, so we must bleed them to maintain optimum performance.
How do we do this?
What we do is connect the purge unit to the two air and gas collection places and control access to them with solenoid valves. We also have another pipe connected to the liquid line, this will act as a drain and return the ammonia collected during filtration.
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| purge unit connected |
Inside a purge unit
Let's take a look inside the purge unit to see how it works. We've just illustrated this a bit differently to make it easier to see.
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| internal purge unit |
So as you can see inside the purge unit we have another separate and much smaller cooling system. We have a small compressor that pushes a different refrigerant, R452A, around the separate loop. It flows to a small condenser with its own fan that blows ambient air through the heat exchanger, then the refrigerant flows to a receiver, then flows to an expander, to an evaporator and back to the compressor.
The evaporator is connected to the ammonia system. But the two systems are completely separate, ammonia and R452A never meet or mix.
The controller signals one of the solenoid valves to open and vent the mixture of air, ammonia and non-condensable gases to the evaporator inside the purge unit. Only one valve can be opened at any given time because if both open; then the liquid refrigerant will come out and flood the unit.
We have covered in detail how solenoid valves work in a separate article, to check it out CLICK HERE.
So with one of the solenoid valves open, say the receiver tank valve for example, the mixture of air, ammonia vapor and other gases will leak out of the receiver tank and into the tank purge unit evaporator.
These vapors and gases will accumulate in the evaporator. The small refrigeration system circulates R452A refrigerant to the other side of the evaporator and will cool the gas mixture.
The mixture will cool below the ammonia condensation temperature, causing the ammonia to condense into a liquid. Air and gases will remain in gaseous form because their properties are different and their condensation temperature is much lower. Therefore, the air and gases will remain in the evaporator while the ammonia turns to a liquid and will then return by gravity to the system through the drain line. When this happens, it naturally sucks in more air, ammonia vapor, and gas.
This continues until the accumulation of air and gas in the evaporator reaches a certain level. The controller detects that the evaporator temperature and pressure have changed due to buildup. This will open another solenoid in the evaporator vent line to vent air and gas buildup. This allows air and gases to flow into an external water bath to wash out any remaining ammonia that may have been collected. The process is then repeated and we keep the system running at peak performance.
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