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A COMPUTER PACKAGE FOR DAIRY PLANT REFRIGERATION SYSTEMS. Q. Tuan Pham University of New South Wales. Summary. Software has been developed at UNSW under a DRDC-funded project to simulate refrigeration systems We report test results and potential uses in design, operation and optimisation.

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slide1

A COMPUTER PACKAGE FOR DAIRY PLANT REFRIGERATION SYSTEMS

Q. Tuan Pham

University of New South Wales

slide2

Summary

  • Software has been developed at UNSW under a DRDC-funded project to simulate refrigeration systems
  • We report test results and potential uses in design, operation and optimisation
rationale
Rationale
  • 30 to 50% of electricity in dairy industry is used in refrigeration
  • Staff are more concerned with production than with energy efficiency
  • Most industrial refrigeration systems can improve their energy efficiency by about 10 to 15% with negligible capital spending.
  • Software helps identify possible savings and inefficiencies
a simple refrigeration system
A simple refrigeration system

Generating

cold

Using

cold

slide5

Generating

cold

A dairy plant refrigeration system

Using

cold

energy saving 1 generation of cold
Energy saving 1: Generation of cold
  • Proper selection of compressors, condensers
  • Better operation of engineroom (compressor schedule)
  • Maintenance of equipment, e.g.
    • prevent condenser fouling
    • remove noncondensables (air)
  • Improved control in engineroom, applications
  • Energy recovery
energy saving 2 use of cold
Energy saving 2: Use of cold
  • Improved chilling and freezing methods
  • Better chiller and freezer designs
  • Shifting loads to reduce peak loads
  • Eliminating wastages, e.g.
    • door infiltration
    • excessive fan heat
    • poor insulation
slide10

Example: non-optimal cooling regime

FAST COOLING:

High energy cost

Quality problems

OVER-DESIGN:

Capital cost $$$

Product

heat load

Optimum

UNDER-DESIGN:

Operational problem

SLOW COOLING

Quality/safety problems

Compliance problems

Cooling/freezing time

simulation software
Simulation software
  • General purpose simulation software: Aspen Plus, Hysim...
  • General purpose refrigeration software: RADS
  • Industry-specific refrigeration software: DRDC-UNSW suite
what software can do
What software can do
  • Predicting changes to refrigeration requirements with
    • changes in processing operations
    • changes in product type or throughput
  • Comparing predicted with actual power consumption - identify wastage
  • Suggesting alternative schedules for freezers and chillers to reduce peak power charges
organisation of programs
Organisation of programs

User inputs

Outputs:

Application heat load

Plant heat load

Power consumption

Graphs, reports

validation tests objectives
Validation Tests: Objectives
  • Check that all applications can be modelled
  • Check that accuracy is acceptable
  • Check ease of use and robustness
using the software in optimisation
Using the Software in Optimisation
  • Design of new refrigeration plants
  • Upgrading of plants
    • replacement of old equipment
    • new products
    • changed flowrates
    • new processes
    • changes in schedules
using the software in optimisation cont
Using the Software in Optimisation (cont)
  • Checking performance to pinpoint defects
  • Optimising design and operation
    • Reschedule applications to shift peak load?
    • Turn off fans and refrigerators temporarily?
    • One big compressor or several small ones?
    • One or two stage compression?
acknowledgments
Acknowledgments

Dairy Research & Development Corporation

Dairy Process Engineering Center

Dairy Farmers

to describe an application
To describe an Application...

Clicking on 1 starts APDATA.EXE

Clicking on ”Help" brings up...

Clicking on "Create a Chiller" brings up...

Clicking on ”Page 8" brings up...

to describe a plant
To describe a Plant...

Clicking on 3 starts PLANT.EXE

Double-clicking on a textbox brings up the Application window

Clicking on “Applications” starts the Applications list

Enter name of file created by APPLIC.EXE here

to describe an engineroom
To describe an Engineroom...

Clicking on p.1 brings up the General Layout window

Clicking on 5 starts ENGROOM.EXE

Clicking “Details on level 1” brings up...

to describe an engineroom cont
To describe an Engineroom (cont)...

Clicking on 5 starts ENGROOM.EXE

Clicking on “Compressor models” brings up the Compressors window

Clicking on a textbox to enter models details...

to describe an engineroom cont29
To describe an Engineroom (cont)...

Clicking on 5 starts ENGROOM.EXE

Click on Operating conditions...

Click on a textbox ...

to carry out routine refrigeration calculations
To carry out routine refrigeration calculations ...

Clicking on 8 starts

basic compression cycle

Clicking on 7 starts Basic Refrigeration Calculations

Clicking here gives results

that s it folks

This presentation can be downloaded from

www.ceic.unsw.edu.au/staff/Tuan_Pham/ (go to bottom of page)

That’s it folks!

tuan.pham@unsw.edu.au