An ammonia compressor lies at the heart of industrial refrigeration systems, playing a crucial role in many industries, including food, petrochemicals, and pharmaceuticals. The working principle of an ammonia compressor is to provide a continuous flow of ammonia gas in a closed-loop system.
The process begins with the ammonia being compressed at high pressure until it reaches the second heat exchanger outlet. This compression causes the ammonia gas to heat up. As the ammonia is pressurised, it travels up into the coils at the back of the refrigeration unit, where the heat dissipates. The ammonia is then saturated and discharged, resulting in a cool and stable system.
This efficient and cost-effective system is why ammonia is the most commonly used refrigerant worldwide for large commercial applications.
What is the principle of ammonia compressor?
The fundamental principle of an ammonia compressor operation is based on the vapour-compression refrigeration system. Here’s how it works:
- Compression: The compressor collects ammonia vapours generated in the evaporator and maintains its suction pressure. It increases the ammonia pressure and temperature by reducing its vapour volume through compression. This is where the ammonia gas heats up as the pressure increases.
- Condensation: As the high-pressure gas moves into the condenser, the heat is removed and the ammonia turns from gas into liquid. The pressurised ammonia travels up into the coils at the back of the refrigeration unit, where the heat dissipates.
- Evaporation: The ammonia suction vapour developed in the evaporator is transferred to the condenser.
Why is ammonia compressor used?
Ammonia, also known as NH3, is a popular choice for industrial refrigeration systems due to its unique properties and advantages such as:
- Energy Efficiency: Ammonia is one of the most efficient refrigerants available, with applications ranging from high to low temperatures. A flooded ammonia system is typically 15-20% more efficient than its DX R404A (Pentafluoroethane, 1,1,1-Tetrafluoroethane, 1,1,1,2-Tetrafluoroethane) counterpart.
- Environmental Impact: Ammonia is a natural refrigerant with both Global Warming Potential (GWP) and Ozone Depletion Potential (ODP) equal to zero, thus making it one of the better environmental-friendly choices.
- Cost-Effectiveness: Ammonia is inexpensive and extremely efficient, making it the most commonly used refrigerant worldwide for large commercial applications.
- Safety: Although ammonia is a toxic refrigerant, and it is also flammable at certain concentrations, however, with proper handling and maintenance, it can be safely used in industrial applications.
Where and Why Is Ammonia Compressor Technology Indispensable?
Ammonia compressor technology is indispensable across a variety of industries due to its efficiency, cost-effectiveness, and environmental friendliness. Here are some key sectors where it plays a vital role:
- Food and Beverage Industry: Ammonia compressors are extensively used in the food and beverage industry to chill food and beverages and to produce ice cream and other frozen desserts. They are also used in distribution cold stores, freezing tunnels, and food processing plants such as slaughterhouses and ice cream factories.
- Automotive Industry: The automotive industry also utilises ammonia compressors, although the specific applications can vary.
- Chemical Industry: Ammonia is a byproduct of coal combustion and has a high octane rating, allowing it to be compressed to high ratios without the risk of causing a lot of NOx emissions, thus making it an ideal choice for use in compressors for liquefied gas. Ammonia production plants also use these compressors to produce ammonia as a base chemical.
- Petrochemical and Pharmaceutical Industries: These industries also rely on ammonia compressors for various applications.
Ammonia Compressor Maintenance
Operating and maintaining an ammonia compressor can present several challenges. However, with regular maintenance and a proactive approach, these challenges can be effectively managed.- Wear and Tear: Like any mechanical system, ammonia compressors are subject to wear and tear over time. Routine inspections and maintenance play a crucial role in identifying potential issues before they escalate into more serious problems.
- Improper Maintenance: Neglecting regular maintenance can lead to impaired compressor function, posing serious risks and potentially expensive repairs. The motive power of the compressor should undergo servicing at least once every three months.
- Oil Issues: Low oil pressure can occur if the oil pump is seriously worn and the clearance is extremely large. To troubleshoot it, you can add oil, stop the compressor, and eliminate ammonia liquid. If the fault is serious, you should repair the oil pump or replace it.
- Operating Conditions: It’s important to monitor operating conditions (suction and discharge pressure and temperature, lubrication oil temperature, lubrication oil level, etc.) to ensure a safe start-up. Corrective actions are required if the conditions are outside of allowable limits.
Corken, the World-Class Range of Ammonia Compressor from IDEX
Corken, a unit under IDEX Corporation, presents a diverse portfolio of ammonia compressors catering to various industrial needs. These reciprocating compressors, spanning small horsepowers from 7.5 hp to 75 hp, exemplify quality and performance. Available in both vertical and horizontal designs, featuring double (D-Style) or triple packing (T-Style), these oil-free compressors are suitable for industries such as chemicals, petrochemicals, oil & gas, liquid terminals, and the marine market. Capable of handling a spectrum of gases, including those that are toxic, volatile, hazardous, and corrosive, Corken’s compressors offer versatility and reliability. Corken stands out for its commitment to customisation, offering custom-engineered solutions to meet specific application requirements. Whether utilising standard mountings or creating bespoke solutions from the ground up, Corken ensures a tailored approach to ammonia compression needs.
Conclusion
The ammonia compressor stands as a vital component in diverse industrial sectors, driving the efficiency of refrigeration systems with its robust working principle. Its role in maintaining a continuous flow of ammonia gas within a closed-loop system makes it indispensable for applications ranging from food and beverage to the petrochemical and pharmaceutical industries. The unique properties of ammonia, such as energy efficiency, environmental friendliness, and cost-effectiveness, contribute to its widespread adoption. While ammonia compressors bring numerous advantages, addressing challenges like wear and tear, maintenance lapses, oil-related issues, and monitoring operating conditions is crucial for ensuring safe and optimal performance. As industries continue to grow and evolve, the significance of ammonia compressor technology persists, offering a reliable and efficient solution for various cooling needs.