Design of Ammonia Refrigeration Systems for Peak Performance and Efficiency

As a refrigerant, ammonia has been in widespread use in the industrial sector for more than a century. With no ozone depletion potential and no global warming potential, it is environmentally friendly as well as an efficient choice for refrigeration. In this course, you will learn how to take advantage of ammonia’s desirable properties to design your refrigeration systems for peak performance. You will also learn from the experts about safety precautions and the latest research from the IRC that you can immediately apply on your next refrigeration system specification or design.

• Design/build contractors 
• Owners, plant operators, supervisors, engineers, and designers who want to better specify systems 
• Project managers responsible for ammonia system design and construction 
• Consulting engineers

This course is part of the Process Safety Management Professional Certificate. Increase your knowledge and effectiveness at managing PSM/RMP programs for your ammonia refrigerated facility, while earning a recognized credential. Course can be taken individually as well.

Attendees participating in this course will be able to earn a digital badge as evidence of the knowledge they obtained during the course. Digital badges are micro-credentials that can be earned by successfully passing a final quiz administered online after completing the course. Find more information on digital badges.

Day 1

Welcome and Introduction

Design Considerations for Energy Efficiency

• Review of systems: single-stage, DX, flooded, overfed, and multi-stage systems
• Energy efficiency considerations for industrial refrigeration systems

Load Calculations and Psychrometrics

• Temperature requirements
• Load types: envelope, product, internal, equipment, infiltration
• Psychrometrics review
• Sensible and latent loads
• Infiltration loads: theory vs. real-world
• Rules-of-thumb

Load Calculation Workshop Load Calculation Workshop (continues) Evaporators

• Types
• Performance characteristics
• Manufacturer's rating methods
• Selection process
• Energy efficiency considerations
• Variable speed drive fans

Assign Homework – Class Design Project

• Preliminary refrigeration system layouts
• Load calculations
• Evaporator selection/layout

Adjourn to Work on Class Project

Day 2

Homework Review Valves and Valve Selection

• Valve types and uses
• Actuating methods (direct-acting, pilot-operated)
• Installation considerations
• Typical valve groups
• Safety considerations
• Energy efficiency considerations

Condensers

• Performance characteristics
• Sizing considerations
• Selection
• Fan alternatives and methods of control
• Energy efficiency considerations

Condenser Selection Workshop

• Types: high-pressure receiver, thermosiphon, low-pressure accumulator, flash intercooler
• Configurations: horizontal or vertical
• Ratings
• Proper practices for system integration
• Knock-out velocity
• Down-comer sizing
• Refrigerant level control (floats, capacitance probes)

Vessel Sizing/Selection Workshop

Assign Homework

• Evaporator valve selection and valve train layout

Adjourn to Work on Class Project

Day 3

Homework Review Liquid Refrigerant Pumps

• Pump types and performance curves
• Net positive suction head: required and available
• Pump selection
• Energy efficiency considerations

Compressors

• Compressor ratings
• Full-load and part-load operation
• Oil cooler heat rejection methods (screw compressors)
• Volume ratio (fixed and variable)
• High stage and booster selection
• Energy efficiency considerations

Compressors (continued)

Class Design Project Assign Homework

• Select compressors
• Select condensers

Adjourn to Work on Class Design Project

Day 4

Homework Review Refrigerant Piping

• Sizing vapor lines (suction, discharge, hot gas)
• Liquid line sizing
• Wet return line sizing
• Piping practices to minimize potential for hydraulic hammer
• Riser pipe sizing practices
• Energy efficiency considerations

Refrigerant Piping Workshop Heat Recovery Opportunities

• Assessing the potential for heat recovery in ammonia systems
• Heat recovery options Design Project

Assign Homework

• Class design project

Adjourn to Work on Class Design Project

Day 5

Homework Review

Finalize Design Project

Design Project Presentations

Question/Answer Session

"I got a great overview and exposure to the details. I will definitely be a smarter customer for both design services and equipment supply. Also, got some energy tips I'll be looking at."

"All was excellent, from the knowledge and skills of the speakers to the facility."

"I have a completely new perspective on design. The course really cleared up a lot of things in my systems and how they operate."

Todd Jekel

Todd Jekel, PhD, PE is the Assistant Director of the Industrial Refrigeration Consortium (IRC) at the University of Wisconsin–Madison, where he leads applied research and technical outreach in industrial refrigeration. His work focuses on system and component modeling, refrigeration load and energy calculations, accumulator design, and safety relief vent systems. Dr. Jekel has contributed to the development and instruction of several web-based and in-person courses for refrigeration professionals, covering topics such as ammonia refrigeration, process safety, and energy efficiency. He holds degrees from Calvin College and the University of Wisconsin–Madison. In addition to his academic and research roles, he is an active member of ASHRAE and the International Institute of Ammonia Refrigeration (IIAR), serving on multiple technical committees. Dr. Jekel is recognized for his expertise in vessel design, oil separation, and dehumidification strategies for cold storage facilities.

Douglas Reindl

Douglas Reindl, PhD, PE is a professor in the Department of Mechanical Engineering and a Program Director at the Office of Interdisciplinary Professional Programs at the University of Wisconsin–Madison. He brings extensive expertise in mechanical systems, with a particular focus on industrial ammonia refrigeration. As the founding director of the Industrial Refrigeration Consortium, Dr. Reindl is dedicated to advancing the safety, efficiency, and reliability of refrigeration infrastructure. He holds a BS in Mechanical Engineering Technology from the Milwaukee School of Engineering, and both MS and PhD degrees in Mechanical Engineering from UW–Madison. A registered professional engineer in Wisconsin, Dr. Reindl is widely recognized for his leadership in refrigeration education and applied research.

Marc Claas

Marc Claas is an Associate Researcher with the Industrial Refrigeration Consortium, specializing in industrial refrigeration since 2009. He focuses on system maintenance, safe operation, troubleshooting, and regulatory compliance, with a growing interest in emerging cooling technologies. Marc has led online operator training programs and brings extensive field experience in Process Safety Management (PSM), including audits and Process Hazard Analyses (PHAs). He also investigates energy efficiency and operational improvements in refrigeration systems. Marc holds a B.S. in Mechanical Engineering from UW-Platteville and an M.S. in Mechanical Engineering with a focus on Thermal Sciences from UW-Madison. He is an active member of the International Institute of Ammonia Refrigeration.

Bent Wiencke

Bent Wiencke has 35 years of experience in the industrial refrigeration industry specializing in the design, optimization, operation, and installation of refrigeration systems. Throughout his international career he has worked for contractors, original equipment manufacturers (OEMs) and end-users. His broad work experience includes the food and beverage industry, marine industry, petrochemical and chemical industry using a wide range of refrigerants, such as: Ammonia, CO2, Hydro-Carbons, CFCs, HCFCs and HFCs. Bent is a longtime International Institute of Ammonia Refrigeration (IIAR) member and has been an active participant in the work of the IIAR Research Committee. In addition, he was a two-term member of the IIAR Board of Directors from 2010 to 2016. Throughout the years he contributed to the industry with numerous papers as well as championed numerous research and safety topics. In 2008 he won the "Andy Ammonia Award" for best paper. He has a MS and BS in Mechanical Engineering.