Thermax Cooling Products Presentation

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Cooling & Heating Solutions

Sustainable Solutions in Energy and Environment

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• 1984 - Started Selling Absorption Chillers made by Sanyo, Japan

• 1989 – Entered into a Collaboration with Sanyo, Japan to Manufacture Steam Fired VAM

• 1994 – In house development of fuel driven VAM (100-1000 TR)

• 1996 – Technical collaboration with Kawasaki, Japan for efficient fuel driven VAM (30-1100 TR)

• 1998 – In house development efficient split evaporator design

• 2001 – Launched ‘Cogenie’ – Small Hot Water Driven VAM Chiller

• 2004 – Launched high COP ‘B4K’ Series VAM & Twin Type Hot Water VAM

• 2005 – Launched Zero Degree VAM

• 2008 – Developed Air Cooled VAM & High COP Next Generation VAM

• 2009 – Built “The World’s Largest Test Facility for VAMs” (VAM testing upto 3500 TR)

• 2009 – Developed & Tested 3200 TR Exhaust gas fired chiller

• 2010 – Developed High efficiency Simultaneous Chiller-Heater

• 2011 – Launched Triple Effect VAM Chillers (World’s Highest Efficiency & COP of 1.7)

• 2012 – Launched the improved Twin type hot water VAM Chillers

• 2013 – Launched the improved Double Effect Series VAM Chillers

• 2014 – Launched Closed Circuit Cooling Towers/ Evaporative Condensers / ACC/ Dry Coolers

The Thermax Journey

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Thermax Product Basket

-40

+160

Closed Circuit Cooling Tower

/Evaporative Condenser

0 -5

LiBr VAM

35 Hybrid Chiller

Heat Pump

(Type I)

Chiller - Heater

Heat Pump

(Type II)

90 V-type & H-type

Dry Cooler

Air Cooled

Condensers

COOLING SOLUTIONS

Single effect (COP: 0.7 – 0.75)

Steam: 0 – 3.5 bar.g Hot water: 80 – 150 o_C

Double effect Chiller (COP: 1.38 – 1.43)

Steam: 3.0 – 10 bar.g Hot water: 150 – 185 o_C

Exhaust gas: 270 – 600 o_C

Direct fired (Oil / Gas / LPG)

Triple effect (COP: 1.75 – 1.9)

Steam: 10 – 26 bar.g Hot water: 200 – 225 o_C Exhaust gas: 400 – 600 o_C Hybrid Chiller (25 – 250 TR) Steam: 0.5 – 10 bar.g Hot water: 90 – 185 o_C Exhaust gas: 270 – 600 o_C

HEATING SOLUTIONS

Heat Pump Type I [200 kW – 40 MW] Steam: 1 – 10 bar.g

Hot water: 130 – 185 oC Exhaust gas: 270 – 600 oC Direct fired (Oil/Gas/LPG) Heat Pump Type II (Heat Transformer)

Generates steam or hot water at high T from low T hot water Chiller-Heat Pump

Simultaneous chilled & hot water NO cooling water required Chiller-Heater

40% savings on on Heating Can operate in Cooling only, Heating only or Simultaneous cooling and heating modes

Requires cooling water

NON-ABSORBTION COOLING

CLOSED CIRCUIT COOLING TOWER

Replaces conventional cooling tower and PHE/shell-tube heat exchanger

For Process Fluid/Gas Cooling

Evaporative Condenser

Replces conventional Atmospheric Condensor/ Cooling Tower for Chillers/ etc.

Dry Coolers

V-type Dry Coolers H-type dry coolers

AIR COOLED CONDENSERS

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What is Refrigeration ?

REFRIGERATION AIR CONDITIONING

Air Conditioning

Refrigeration

Heating

Addition /

Removal of

Moisture

Air Purity and

Noise Control

Air Distribution

»

Since heat cannot flow from low temperature reservoir to high temperature

reservoir on its own, external work is required to achieve refrigeration.

– Refrigeration:

Producing

and

maintaining a temperature below that

of the surrounding atmosphere.

– Air Conditioning: Maintaining temp,

humidity,

purity,

quality

and

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Tons of Refrigeration (USRT or TR)

AIR CONDITIONING

1 US Ton of Water

at 0

o

_C

1 US Ton of Ice

at 0

o

_C

Day 1

00:00 Hrs

Day 2

00:00 Hrs

Heat Removal at

Constant rate

• Rate at which heat has to

be removed from 1 US

ton of Water (907 kg) at 0

o

_{C to get 1 US ton of Ice}

at 0

o

_{C in 24 Hours}

• Commonly used unit to

express refrigeration

capacity

• Unit Conversion:

1 USRT = 3024 kCal/hr

= 3.51628 kW

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Types of Refrigeration Systems

Refrigeration

Systems

Vapour

Compression

Screw Chillers

Capacity 25 – 300 TR

_{Temperature no bar}

Centrifugal Chillers

Capacity > 300 TR

Temperature >0

o

_C

Reciprocating

Chillers

Low Capacity (<100TR)

Temperature no bar

Vapour Absorption

Lithium Bromide

_{Range, Positive Cooling}

Good COP, Standard

Ammonia

Low COP, Custom Built,

Sub Zero application

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COP Improvement Over the Years

0.65

1.2

1.35

1.42

1.7

1.8

0

0.25

0.5

0.75

1

1.25

1.5

1.75

2 1983

1996

2004

2008

2011

2013

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Types of Vapour Absorption Machines

Based on its Utility / Application

Chiller

Chiller - Heater

Heat Pump

(Type I)

Heat Pump

(Type II)

Chiller - Heat

Pump

Based on Effect (No of stages of regeneration)

Half Effect

COP – 0.4

Single Effect

COP – 0.75

Single-Double

Effect

COP – 1.05

Double Effect

COP – 1.4

Triple Effect

COP – 1.8

Based on Driving Heat Source

Steam Driven

Hot Water

Driven

Exhaust Gas

Driven

Direct Fuel Fired

Multiple Heat

Sources

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Comparison- Compression & Absorption

Chillers

CONDENSER

COMPRESSOR

EVAPORATOR

Electricity

CONDENSER

GENERATOR

EVAPORATOR

Heat

PUMP

ABSORBER

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Comparison Between Engine and Chiller

ENGINE

Power

Output ‘O’

Input Energy, ‘I’

CHILLER

Refrigeration

Output ‘O’

Input Energy, ‘I’

Heat rejected

to Hot water

‘R1’

Heat rejected to

Exhaust Gas ‘R2’

Heat Rejected to

Cooling Water, ‘R’

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Principle of Operation

• Shell side of evaporator maintained

under vacuum

• Chilled water circulated through

evaporator tubes

• Saturated Liquid Refrigerant sprayed

on the evaporator tubes

• Latent heat of evaporation for

refrigerant extracted from chilled

water

• Chilled water temperature reduces

• Refrigerant vapour produced

• Pressure inside the shell increases

Higher Pressure = Higher Boiling Point

Lower Pressure = Lower Boiling Point

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Higher LiBr Concentration = High Affinity

Lower LiBr Temperature = High Affinity



Concentrated LiBr solution sprayed in

absorber



Concentrated LiBr solution is hygroscopic

in nature (has affinity to water vapour)



Refrigerant vapour absorbed by LiBr

solution



Pressure in shell reduces



Absorption process exothermic



Cooling water circulated through absorber

tubes remove heat of dilution



Dilute LiBr solution generated

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• Dilute LiBr solution taken to

generator by absorbent pump

• LiBr solution heated by heat source

to its boiling point

• At boiling point, refrigerant boils out

as LiBr has higher boiling point

• Concentration of LiBr solution

increases

• Concentrated LiBr solution sprayed

again in absorber

• Pressure increases inside the

generator due to refrigerant vapour

Higher Pressure = Higher Boiling Point

Lower Pressure = Lower Boiling Point

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• Refrigerant Vapour goes into the

condenser

• Refrigerant vapour condenses by

rejecting heat to cooling water

flowing in the condenser tubes

• Liquid refrigerant goes back into the

evaporator to continue cooling cycle

• This completes one cycle of

absorption cooling

• Cooling is generated as long as heat

source and heat sink (cooling water)

are available

Lower cooling water inlet temperature =

Lower Pressure in the condenser / generator

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High Efficiency Chiller – Heater

• Heat Source

• Dry Saturated Steam (3.0 – 10.0 bar.g)

• High temperature hot water (145 – 180

o

_C)

• Direct Fuel Firing (Gas/Oil/LPG/Propane)

• Exhaust Gas (275 – 600

o

_C)

• Capacity Range

• Cooling : 100 – 3500 TR

• Heating : 100 kW – 9 MW

• Temperature Range

• Cooling : 0 – 30

o

_C

• Delta T : 30

o

_C

_max

• Heating : 30 – 90 oC

• Delta T : 5 – 50 oC

• 23 % saving in overall heat input

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Double Effect Steam/Hot Water fired VAM

• Heat Source

• Dry Saturated Steam (3.0 – 10.0 bar.g)

• High temperature hot water (150 – 180

o

_C)

• Capacity Range : 50 – 3500 TR

• COP : 1.38 – 1.43

• Temperature Range

• Water : 1.0 – 35

o

_C

• Glycol : 0 – 35

o

C

• Delta T : 30

o

C

max

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Triple Effect Steam Fired VAM



Capacity Range : 50 – 1000 TR



Heat Source : Dry Saturated Steam (15 –

25 bar.g)



Specific Steam Consumption:



2.8 – 2.9 kg/hr/TR

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Single Effect Steam/Hot Water fired VAM

• Heat Source:

• Dry Saturated Steam (0.0 – 3.5 bar.g)

• Medium temperature hot water (120 – 150

o

_C)

• Capacity Range : 100 – 3500 TR

• COP : 0.72 – 0.76

• Temperature Range

• Water : 1.0 – 35

o

_C

• Glycol : 0 – 35

o

C

• Delta T : 30

o

C

max

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Double Effect Direct Fired VAM

• Heat Sources:

• Natural gas / HSD / LPG / Propane

• Bio gas / Coke oven gas / Corex gas

• Capacity Range : 50 - 1350 TR

• COP : 1.3 - 1.35

• Temperature Range

• Water : 1.0 – 35

o

_C

• Glycol : 0 – 35

o

C

• Delta T : 30

o

C

max

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Double Effect Exhaust Fired VAM

• Heat Source:

• Flue gases (275

o

_{C - 600}

o

_C)

• Lowest Exhaust Gas outlet : 135

o

_C

_(for

natural gas engine exhaust)

• Capacity Range : 50 - 3500 TR

• COP : 1.38 - 1.43

• Temperature Range

• Water : 1.0 – 35

o

_C

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Touch Screen Control Panel

HMI: Siemens TP 700

o

7 inch TFT Touch Screen operator panel

o

SD and USB slots available for data logging

o

Capacity to log nearly 500 alarms

o

Supports nearly 40 languages

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Other

Vapour Absorption

&

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Heat Pump – Type I



Heat Source (30 - 60

o

_C):



Cooling tower water



Process condensate / hot water



Geothermal water



Driving Heat Source:



Dry Saturated Steam (1 – 10 bar.g)



High temperature hot water (130 – 180

o

_C)



Exhaust Gas (275 – 600

o

_C)



Direct Fired (Gas/Oil/Propane/LPG)



Heating Capacity : 0.25 – 40 MW



Heating COP : 1.65 – 1.75



Temperature Range

• Hot Water : 35 – 90

o

_C

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Heat Pump – Type II



Heat Source (80 - 120

o

_C):



Process condensate / hot water



Geothermal water



Steam condensate from steam turbine



Heating Output:



Dry Saturated Steam (1.0 – 4.0 bar.g)



Hot water (110 – 155

o

_C)



Heating Capacity : 0.5 – 10 MW

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Sub-Zero Cooling – Hybrid Technology

– Electrical

• Runs on Vapour compression

technology

• Higher COP

• Requires clean high grade

energy for operation

• High Power Consumption

– Chemical

• Predominantly Vapour

Absorption type

• Lower COP

• Runs on low grade waste heat

– Hybrid chiller harnesses the

advantages of above

technologies

– Maximizes the benefits from

both cycles

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Operational Principle

A. Refrigerant /Water is circulated through the coils. B. Heat from refrigerant dissipated through coil tubes. C. Partial heat evaporated sidewise directly by the

downward natural induced air & discharged to atmosphere.

D. Rest of the heat remains to the water cascading downward over the tubes.

E. Simultaneously, air is drawn in also through the air inlet louvers at the base of the condenser and travels through the dehydrator and heat exchange fills at the same direction of the water flow.

F. A small portion of the water is evaporated which removes the heat. The warm moist air is drawn sidewise also by the fan and is discharged to the atmosphere.

G. The remaining water falls to the sump at the bottom of the condenser where it is recirculated by the pump up through the water distribution system and back down over the coils.

What are Evaporative Condensers /

Closed Circuit Cooling Towers?

Evaporative Condensers / Closed circuit cooling towers operate in the manner similar to open cooling towers, except that the heat load to be rejected is transferred to the process fluid (refrigerant gas / water / process oil / working fluid being cooled) to the ambient air through a heat exchange coil. The coil serves to isolate the process fluid from the outside air, keeping it clean and contamination free in a closed loop.Thus, hereby, two separate circuits are created

Primary / Internal circuit in which the process fluid / gas circulates inside the coil

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Water Distribution System

Side Air Inlet Screen & Air Deflector

Honeycomb Fills Circuit Pump & Descaling Cleaner

/Water Curing Device

Basin with Slope Bottom Condensing

Coil Set

Drift Eliminator Maintenance Room

Axial Propeller Fan

Convenient Repair & Maintenance

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Advantages of

Evaporative condenser/

Closed Circuit Cooling Tower

• Advanced Technology Condenser/Cooling Tower

• Environmentally Conscious Operation

• Low Energy Consumption

• Lower Annual Operating Costs

• Reliable & Simple Operation and Maintenance

• Completely isolate the process cooling fluid from the atmosphere. avoid

contamination

• Occupies upto

30%

less space compare to conventional systems

SPLASH FILL

FILM FILL

Cooling Technology using the fill method

Conventional Cooling Tower / Atmospheric Condenser

THERMAX®

Evaporative Condenser

Effective heat exchange area 30 - 45 m2_/m3

_{150 m}

3

Fill height required 5-10 m

1.2-1.5 m

Pumping head required 9-12 m

5-8 m

Typical Liquid/Air ratio 1.1-1.5

1.5-2.0

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