FACULTY OF ENGINEERING TECHNOLOGY

COURSE CODE & NAME BNL 40303 – PLANT ENERGY EFFICIENCY

TITLE PRACTICAL 7
SUBMISSION DATE 14/11/2019
PROGRAMME 4 BNL
SECTION 1
GROUP MEMBERS NAME MATRIX NO
ARIF BIN NOR AZLAN DN160143
MUHAMMAD RIDZUAN IQBAL BIN DN160030
MOHD RADZI
WAN AHMAD KHUZAIRIL ASYRAF DN160090
BIN WAN YUSOF
AHMAD NADZMI BIN RIZAL DN160176
MOHAMAD AZIRUL BIN MAT NADIR DN160091
MOHD HAKIMIN BIN IBRAHIM DN150306
INSTRUCTOR’S NAME TS. MOHD FAIZAL BIN ESA
DR. RAIS HANIZAM BIN MADON
 CHILLER

1. INTRODUCTION

A chiller is a machine that removes heat from a liquid through a refrigeration

cycle of vapor-compression or absorption. It can be transmitted to a cooling
machine or to another process flow (for example air or process water) via a
thermo-exchanger. Refrigeration, as a necessary by-product, creates waste heat
that must be recovered for heating purposes to be exhausted to the atmosphere or
for greater efficiency. In medium to large commercial, industrial and institutional
facilities, chilled water is used to cool and dehumidify air. Water chillers can be
cooled by water, air-cooled or cooled by evaporation. Water-cooled systems can
provide advantages over air-cooled systems in terms of efficiency and
environmental impact.
An industrial chiller's purpose is to transfer heat from one location (usually
processing equipment or product) to another location (usually outside the
factory). It is very common to use water or a water / glycol solution to transfer
heat from and to the chiller, which may require a tank or pumping system from
the process chiller. Making sure you have enough cooling is essential to
efficiency and cost savings, irrespective of your sector or system. Chiller systems
are vast in size and design and available as portable, located or mobile chiller
units for smaller uses or as large central chillers for whole processes(W Jarvis
Ave, 2015).
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2. OBJECTIVE

The aim of this project is to:

1. To identify the type of chiller in biodiesel plant UTHM.
2. To analyze retail cost of operation for chiller in 8 hours daytime.

3. Analyse the efficiency of the chiller.

3. LEARNING OUTCOMES

At the end of this topic, students had been able to analyze the economic performance
of a plant system and equipment using various theories and techniques, explain the
energy management and efficiency improvement measures of plant components
using appropriate techniques and engineering methods, and manage effectively as a
group member throughout assignments and presentations.

4. PRACTICAL THEORY

Usually the chiller is located either in the basement or on the roof, depending on
what type of chiller is used. Roof top chillers are generally "air-cooled," while
basement chillers are generally "water-cooled," but both have the same function to
produce cool air-conditioning water by eliminating the building's excessive heat. The
only difference is how unwanted heat is discarded by the chiller. Air cooled chillers
may use fans to blow cool ambient air throughout their condenser in order to remove
heat from the process. There are two large cylinders in the water-cooled chiller; the
one is called an evaporator, the other a condenser.
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The chilled evaporator is where the cooled water is generated. The chilled water
exits the evaporator and is forced through the chilled water pump around the
biodiesel pilot plant. The chilled water is flowing up the height of the plant to each
floor in pipes known as "rising" Those same pipes are known as risers, no matter if
the water flows up or down within them. When the chilled water leaves the cooling
coil, it's going to be warm. The warm chilled water then returns to the evaporator via
the return riser, and once it enters the evaporator, the refrigerant absorbs the
unwanted heat and moves it over to the condenser. The chilled water will leave the
building cool again, ready to circulate and gather more unwanted heat (Paul Evans,
2017).

5. PRACTICAL EQUIPMENT

APPARATUS:
5.1. Chiller
ADDITIONAL EQUIPMENT
5.2. Personal Protective Equipment
5.3. Recorder

6. PRACTICAL PROCEDURES

1. The practical instruction is analyzed.

2. Knowledge and theoretical about chiller and energy cost is filled.
3. Strategies plan is made to conduct the chiller project.
4. Personal protective equipment; safety-boots and safety-helmet are wearing.
5. chiller is observed.
6. Identify all mechanism related to chiller.
7. Chiller is observed and analyzed.
8. The type and watt of chiller is found.
9. All equipment data of chiller is gathering and recorded.
10. All the data is then used to find the result.
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11. Analyzing performance data, reviewing operating history, gathering and

calculating operating costs.
12. The result must be the total cost of chiller.
13. The result then is analyzed to examine the energy cost saving.
14. Assessing alternative system and other improvement measures to determine
the best technical and economic options.
15. Examining maintenance and energy cost saving practices.
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7. OBSERVATION
From this practical, we need to observe the chiller installed at the biodiesel pilot
plant. Then we discover the part of the chiller and the operation or work involved
in running this chiller. From the results that we obtained from the calculation, the
estimation of energy consumption for chiller 8 hours per day is 22.29 kWh. The
energy consumption for one month is 490.38kWh. It is clear that the cooler uses
a lot of energy and can increase the cost of electricity. There are a lot of ways we
can use to reduce the cost of energy to the air compressor. Even a small
adjustment can reduce operational stress and energy costs while increasing flow
rates and outputs.

Chiller at Compressor Room

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8. RESULTS

Pout = T × ω
2𝜋
= 16.27(1638 × )
60

= 16.27(171.22)
= 2785.75 W

𝑃𝑜𝑢𝑡
𝜂 = × 100%
𝑃𝑖𝑛
0.0314
𝜂 = × 100%
2.75
= 92.85%

Electrical Energy Cost

Based on Tariff D- Low voltage industrial Tariff from TNB.

Figure 8: Tariff D – Low Voltage Industrial from TNB (Tenaga Nasional Berhad TNB,
2014).
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Total energy usage per day

2785.75(8) = 22286/1000
= 22.29 kWh

Total energy usage per month (22 days)

22.29 x 22 = 490.38 kWh

Rate (sen / kWh) Usage (kWh/Month) Cost (RM/Month)

38.00 200 76.00
44.10 290.38 128.06
Total (RM) 52.06
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9. DISCUSSION

From all the task at chiller, there seem to be significant improvements in efficiency
that could only be cost justified at the time of purchase. If a poor purchase decision is
taken, the operating costs will be high for many years to come. Pay particular
attention to the first section on Purchasing Energy-Efficient Chillers and Equipment
if the chiller is over 10 years old, if the air-cooled chiller is heavily used over 100
tons, if the chiller has inadequate power, if it has frequent problems or if you
consider buying a chiller for expansion or reliability. If the chillier system is less than
10 years old and does not require an immediate upgrade or replacement, the cost may
justify replacing the chiller on the basis of energy efficiency savings alone. In this
case, optimizing existing Chilled Water Systems is designed to evaluate ways to
make existing cooling systems more efficient. Air-cooled systems reduce a need for a
cooling tower that minimizes installation and energy costs.
Oversized chillers are not only more expensive to buy, they also waste time and
energy due to poor minimal-load efficiency. Consider multiple chiller compressor
systems for inefficiency and allow compressors to be assembled. Stage compressors
are sequenced automatically to keep compressors close to full load. Variability speed
centrifugal chillers enabled chillers to operate with improved efficiency at partial
load. If chillers can indeed be staggered, considering just use a centrifugal chiller as a
lead chiller to take care of variable loads and conventional chillers as a support
process at near full load if they occur. Note that savings must also be made in high-
efficiency pumps and engines and in powerful two-speed and variable-speed cooling
towers. Chilled water pumping systems can include primary and secondary loops and
may be very complex.
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10. CONCLUSION

For this experiment, we have selected the building of the biodiesel pilot plant as our
experimental site. We need to get to learn regarding the actual chiller process from
the test we've performed. In general, the different size of the chiller unit can be
installed in different locations. There is an array of chiller system for this building
that we found during this experiment that is located in one room apart from the
compressor unit. After an observation, we could observe the whole refrigeration
process and analyze the data required in the chiller system, such as form and energy
usage. The total cost result shows that the energy used is higher in range. This means
that a few steps need to be taken to save energy. The chiller system should be
regularly checked by scheduled maintenance for further recommendation. The
appropriate system must also install the chiller system in a building, using the
appropriate watt to refer to the space. Overall, we are able to evaluate the chiller
system from this subject matter and determine the total energy cost of the chiller
system in the entire biodiesel pilot plant 8 hours a day. Consequently, the experiment
is successful.
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11. REFERENCES

Paul Evans. (2017). How a Chiller, Cooling Tower and Air Handling Unit work
together. Retrieved from https://theengineeringmindset.com website:
https://theengineeringmindset.com/chiller-cooling-tower-air-handling-unit-
work-together/
Tenaga Nasional Berhad TNB. (2014). ELECTRICITY TARIFF SCHEDULE.
(January), 1–5. Retrieved from https://www.tnb.com.my/commercial-
industrial/pricing-tariffs1/
W Jarvis Ave. (2015). How Does A Chiller Work? Retrieved November 9, 2019,
from https://www.thermalcare.com website: https://www.thermalcare.com/how-
does-a-chiller-work/