Air ConditioningContents
Introduction What is meant by Air conditioning? Why do we need Air conditioning? Functions Objectives & importance of Air conditioning.
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Pharmaceutical Application |
Difference between Air conditioner and Air cooler |
Comfort Zone |
Types of Air Conditioner |
Design of an Air Conditioned Room |
Selection Criteria of an Air Conditioner |
Pharmaceutical Needing of Air Conditioner |
Introduction
An air conditioning system is an electrical device that is purposely installed for the removal of heat and moisture from the interior of an occupied space. It is a process that is commonly used to achieve a more comfortable environment, basically for humans and other animals. An air conditioning system is also used to cool and dehumidify rooms that contain heat-producing electronic devices, such as computer servers, and power amplifiers. It is also used in space that contains delicate products like artwork.
Cooling is generally achieved in the air conditioning system through a refrigeration cycle, but sometimes evaporation or free cooling is employed. The system can also be made based on desiccants (chemicals that eliminate moisture from the air). Most AC system stores and rejects heat in pipes called subterranean.
Objectives
To control of temperature and humidity in the production area of pharmaceutical industry.
To avoid degradation of various chemical and biological products.
To facilitate the operation in hospital in order to maintain dust free environment.
Functions of the air conditioning system
Below are the major functions of an air conditioning system in modern houses:
The primary purpose of air conditioning is to create a room climate comfortable.
Some special type of conditioning is used to cool the temperature of electric devices.
Air conditioning system affects the room air to comfort people and their productivity is not impeded.
The condition of the air is characterized by temperature, pressure, and humidity. The air pressure is not changed.
Air conditioning systems can be for heating, dehumidifying, cooling, and humidifying
Applications
Promoting the human comfort
Human body feels comfort when the heat produced by metabolism of human body is balanced by the sum of the heat dissipated to the surroundings and the heat stored in human body. Air purity is of utmost importance. For example, increase in carbon di oxide adds discomfort. The efficiency and the health of workers should be maintained at safe tolerance limit.
Maintenance of proper conditions for the manufacture, processing and preserving of material and equipment: the following areas are identified.
Compression of tablets
In the granulation sector air conditioning is optional, if necessary, the conditions are 45% RH and 22C. in the tableting section, the condition are less than 20% and 22C. in the production of effervescent product, dry syrups, controlling humidity is a vital factor. The relative humidity should not exceed 10 to 15% and temperature is at 22 C.(Kusuma et al., 2018)
Manufacture of soft gelatin capsule
The temperature is usually in the range of 20 C to 22 C and humidity is controlled to a maximum of 40% in the operating areas and between 20 to 30% in the drying areas.(Kusuma et al., 2018)
Manufacture of sterile products in case of parenteral and ophthalmic products, the environmental conditions are much more stringent in filling and sealing rooms. Therefore, the standards of clean air quality are of greater importance. In the production of all biological products air conditioning is essential.
Environmental test cambers
These are designed to carry out stability and self-life testing of drugs. They offer reproducible temperature and humidity conditions. Climatic conditioning is also required for herbal research, pesticide research and zoology.(’Subrahmanyam et al., 2001)
Types of Air Conditioners
MAIN TYPES OF AIR-CONDITIONERS
Window AIR-CONDITIONERS
Split air-conditioners
Centralised air-conditioners
Package air-conditioners
Window A.C.
Window air conditioners are one of the most commonly used and cheapest type of air conditioners. To install one of these units, you need the space to make a slot in the wall, and there should also be some open space behind the wall. Window air-conditioner units are reliable and simple-to-install solution to keep a room cool while avoiding the costly construction of a central air system. Better yet, when the summer heat dies down, these units can be easily removed for storage, and you can use the window sill for other purpose
Part of Window AC
Front Panel:
The front panel is the one that is seen by the user from inside the room where it is installed
The front panel has adjustable horizontal and vertical(some models) louvers where the direction of air flow are adjustable to suit the comfort of the users
The fresh intake of air called VENT (ventilation) is provided at the panel in the event that user would like to have a certain amount of fresh air from the outside.
Indoor Side Components: Cooling Coil Fan Blower Operation Panel Filter Drier
| Outdoor Side Components: Compressor Condenser Coil Propeller Fan Fan Motor
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Construction 
It contains:
WORKING OF WINDOW AIR CONDITIONER
The coils and pipes in an air conditioning unit contain refrigerant gas. The refrigerant gas enters the compressor as warm, low-pressure gas and leaves it as hot, high-pressure gas.
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In the condenser coils, hot, compressed refrigerant gas loses heat to the outdoor air and becomes liquid while it is still warm.
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The warm, liquid refrigerant passes through the tiny opening of the expansion valve, expands, and partly turns to gas at a low temperature.
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In the cooling coils, the refrigerant takes up heat from the indoor air and leaves the coils as warm, low-pressure gas.
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The indoor air gives up heat to the refrigerant in the cooling coils and also loses moisture as it is chilled. The moisture condenses on the coils and trickles down to outside drain holes. Cooled air is blown back into the room.
Advantages of the Window Air Conditioner
Increased comfort level.
In extreme heat, air-conditioning can be a life saver, gives constant temperature.
Most air conditioners also reduce the humidity level, which helps both comfort, and reduces mold growth.
Less noise as the windows will be closed thus also prevents the dust entering.
Easy maintenance & installation.
Disadvantages of the Window Air Conditioner
Split Air-Conditioning System
The split air conditioner comprises of two parts: the outdoor unit and the indoor unit. The outdoor unit, fitted outside the room, houses components like the compressor, condenser and expansion valve. The indoor unit comprises the evaporator or cooling coil and the cooling fan. For this unit you don't have to make any slot in the wall of the room. Further, the present day split units have aesthetic looks and add to the beauty of the room. The split air conditioner can be used to cool one or two rooms.
Construction
There are two main parts of the split air conditioner. These are:
1) Outdoor unit:
This unit houses important components of the air conditioner like the compressor condenser coil and also the expansion coil or capillary tubing.
This unit is installed outside the room or office space which is to be cooled.
The compressor is the maximum noise making part of the air conditioner, and since in the split air conditioner, it is located outside the room, the major source of noise is eliminated.
In the outdoor unit there is a fan that blows air over the condenser thus cooling the compressed Freon gas in it.
This gas passes through the expansion coil and gets converted into low pressure, low temperature partial gas and partial liquid Freon fluid.
2) Indoor unit:
It is the indoor unit that produces the cooling effect inside the room or the office
This is a beautiful looking tall unit usually white in color, though these days a number of stylish models of the indoor unit are being launched.
The indoor unit houses the evaporator coil or the cooling coil, a long blower and the filter.
After passing from the expansion coil, the chilled Freon fluid enters the cooling coil.
The blower sucks the hot, humid and filtered air from the room and it blows it over the cooling coil.
As the air passes over cooling coll its temperature reduces drastically and also loses the excess moisture.
The cool and dry air enters the room and maintains comfortable conditions of around 25-27 degree Celsius as per the requirements.
Major Parts of split air conditioning systems
Working of A Split Air Conditioner
In brief below is the process of how the split-type AC works in general. It involves a lot more technical aspects than what we listed here but we try to keep it simple for everyone to understand the concept.
The evaporator coil will absorb heat in the room and release it to the refrigerant
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The refrigerant will move into the compressor
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The compressor will compress the refrigerant even further until it forms a liquid
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The liquid will be sent to the condenser coil where it will exchange heat with the environment and form a gas again with the motor fan to dissipate the heat
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The hot liquid refrigerant will travel to the expansion valve. Depressure the refrigerant and cool it down
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Low-pressure cold liquid will be flowing into the evaporator coil and will distribute out through the help of the air blower
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The process will repeat and circulate until you turn them off
Advantages of the split air conditioner
Takes up less space for installation with low energy cost.
Can be installed in room with no windows
It has fewer parts that can be easily maintained and fewer things that can go wrong, so the maintenance costs are low too with such an AC system if it is properly maintained.
The noise is also low because the amount of air moved by the fan is small.
Installation process is quick and easy since it does not require ducting.
Disadvantages of the split air conditioner
The highest horsepower of the split type can go up to 3 horsepower only. ((PDF) ENERGY EFFICIENT AIR CONDITIONING FOR PHARMACEUTICAL APPLICATIONS, n.d.)
If you have a very large area that needs to be cooled down, you might need more than one unit.
Centralized Air-Conditioning System
The central air conditioning plants or the systems are used when large buildings, hotels, theaters, airports, shopping malls etc. are to be air conditioned completely. The window and split air conditioners are used for single rooms or small office spaces. If the whole building is to be cooled it is not economically viable to put window or split air conditioner in each and every room. Further, these small units cannot satisfactorily cool the large halls, auditoriums, receptions areas etc.
Construction: The construction of the equipment is shown in the figure.
Components of Central AC
Air handling unit(AHU)
Supplying duct
Return duct
Diffusers/Registers
Compressor
Condenser
Expansion device
Evaporator
Thermostat
Working of central A.C.
Central air conditioners circulates cool air through a system of supply and return ducts.
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Supply ducts and registers (i.e., openings in the walls, floors, or ceilings covered by grills) carry cooled air from the air conditioner to the home.
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This cooled air becomes warmer as it circulates through the home, then it flows back to the central air conditioner through return ducts and registers.
Advantages
Improves indoor air quality.
Level of indoor noise is almost negligible.
Maintains a constant temperature and humidity throughout the conditioned space.
Disadvantages
The size for the AC unit is large.
The cost of installing the system is high.
Packaged Air-Conditioning System
These systems include window mounted or wall bracket conditioners. Most of these units are air cooled, though water-cooled types have also been made. The window and split air conditioners are usually used for the small air conditioning capacities up to 5 tons. The central air conditioning systems are used for where the cooling loads extend beyond 20 tons. The packaged air conditioners are used for the cooling capacities in between these two extremes. The packaged air conditioners are available in the fixed rated capacities of 3,5,7,10 and 15 tons. These units are used commonly in places like restaurants, telephone exchanges, homes, small halls, etc.
Construction: The construction of the equipment is shown in the Figure.
Components
This self contained unit is assembled in a casing where all the air conditioning components are housed. They include:
Compressor
Water cooled or air cooled condenser
Thermosatic expansion valve
Air filter
Front panel
Evaporator fan and housing
Working:
Room air enters the casing at the front panel. It is mixed with part of the outdoor air.
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This mixture is forced over the cooling coils by a centrifugal fan, which is driven electrically.
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Some of the moisture in the air is condensed and disposed off by means of a single ring of the propeller type of condenser.
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The units are hermetically sealed.
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Reciprocating compressors using nontoxic refrigerant and driven by capacitor motors are used.
Advantages of packaged air conditioners
Space efficiency
Energy efficient heating and cooling performance- All package units now offer 13 SEER or higher cooling performance. Gas package units offer 80% AFUE heating performance or better.
Quick installation
Safety- Package units are installed by certified professionals who understand the technical challenges of constructing a gas supply system high voltage wiring, high pressure refrigerant lines and routing critical condensate lines.
A simple installation process
Disadvantages of packaged air conditioning
Difference between air conditioner and air cooler
Air Cooler
| Air Conditioner
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It just cools down the air
| It can cool down as well as heat up the air
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It has only two main parts, a fan and a water pump
| It has four main parts: compressor condenser, expansion valve and evaporator and works on the refrigeration cycle
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It is portable and easy to transfer from one place to another
| It is really big and heavy in size and has to be installed on the wall in a window
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It uses simple water to cool the
| It uses a chemical coolant to cool the air
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It throws out humid air
| It throws out dry air
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It only works in dry areas and does not work in humid areas
| It works in humid areas as well as dry ones
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Comfort Zone
(Psychrometric Chart)
Air outside is at different conditions from our comfort zone condition. In order to bring its condition to within the comfort zone we may need to do one or more of the following:
heat it cool it; dehumidify it: humidify it:
Design of an air conditioned room
Designing an air-conditioned room in the pharmaceutical industry involves careful planning to ensure that the space meets regulatory requirements and maintains the necessary environmental conditions for pharmaceutical manufacturing. Here's a simplified outline of the design process:
1. Determine Cleanroom Classification:
Identify the required cleanroom classification based on the specific pharmaceutical processes to be conducted. Common classifications include ISO Class 5 (most stringent) to ISO Class 9 (least stringent).
2. Room Layout and Size:
Design the layout of the room, considering factors such as the workflow, equipment placement, and personnel movement. The room size should accommodate the intended activities and personnel comfortably.
3. HVAC System Selection:
Choose the appropriate HVAC system based on the cleanroom classification. The HVAC system should provide precise temperature and humidity control, as well as efficient filtration to maintain air quality.
4.Heat Load or Cooling Load
Once the cleanroom requirements are clearly defined, the next step is cooling load calculations.
There are two types of cooling load:
1. Sensible Load
2. Latent Load
Where, Total Load = Sensible Load + Latent Load
A number of factors are accountable for the heat being liberated or transferred from:
These factors cause sensible heat dissipation on a low scale. Therefore, parameters like temperature and relative humidity are maintained to overcome heat loss or gains.
Once the heat calculations are done, the next step is an airflow pattern study.
5. Temperature and Humidity Control:
Set temperature and humidity control parameters within the desired range, typically around 20-25°C and 45-55% relative humidity(Alsmo & Alsmo, 2016). If RH is not maintained per the specifications, it may result in:
Install sensors and controls to monitor and adjust these parameters as needed.
6. Air Filtration:
Include HEPA or ULPA filters in the HVAC system to remove particles and maintain a sterile environment. Filtration efficiency should meet regulatory standards. A common practice in HVAC system design is the installation of HEPA filters of 99.97% retention efficiency for a particle size range of 0.25 to 0.3μ.The percentage of particles crossing through such filters is only 0.03%.ULPA filters have 99.9997% retention efficiency for the particle size of 0.10 to 0.12μ.(Xu, 2014)
7. Airflow Design:
Implement a unidirectional airflow system, if required, to minimize contamination risks. Air should flow from cleaner areas to less clean areas to maintain sterility.
8. Pressure Differentials:
Maintain appropriate positive or negative pressure differentials between rooms to control the movement of contaminants. Positive pressure is used in clean areas, and negative pressure in containment or hazardous material storage areas.
9. Cleanroom Materials and Finishes:
Choose materials and finishes that are easy to clean and disinfect. Wall and ceiling surfaces should be smooth and non-porous.
10. Lighting:
Install cleanroom-compatible lighting that minimizes particle generation and provides adequate illumination for tasks. Lighting fixtures should be sealed to prevent contamination.
11. Monitoring and Validation:
Implement a continuous monitoring system to ensure environmental conditions remain within specified limits. Regular validation and testing of the room and HVAC system are essential for compliance.
12. Regulatory Compliance:
Ensure that the cleanroom design and operation comply with regulatory standards such as Good Manufacturing Practices (GMP), specific pharmacopeial guidelines, and local regulatory requirements.
13. Training and SOPs:
Develop Standard Operating Procedures (SOPs) for cleanroom operation and provide training to personnel on proper gowning and cleanroom practices.
14. Emergency Systems:
Install backup power supplies and emergency systems to ensure uninterrupted operation in case of power outages or equipment failures.
15. Documentation:
Maintain comprehensive documentation of the cleanroom design, equipment specifications, maintenance records, and validation reports.
16. Ongoing Maintenance: Establish a rigorous maintenance schedule to ensure that the HVAC system and cleanroom infrastructure continue to meet regulatory requirements.
Selection of an air conditioner
1. Cost:
It is a common practice to purchase the least expensive AC systems to save up costs. However, the costlier units prove to be more cost-effective in the long run. They consume limited amount of energy and help in lowering electricity bills. They are efficient systems that keep rooms cool. It is recommended to avoid installation of these systems on our own due to potential risks involved. A professional service can quickly install all necessary components in an effective manner. Aside from that, we should also consider our budget while choosing a new AC system.
2. Quality:
Cost factor plays a major role in choosing an AC system for residential or commercial buildings, but we should also take into account the quality. More expensive systems are often of higher quality and can stay in optimal working condition for long. We should focus on the specifications of AC unit to determine the most appropriate option. We can invest in a high quality system to ensure that we do not have to repair or replace our air conditioner frequently.
3. Size:
Make sure that the AC unit has a suitable size and can be easily placed at desired location. A professional air conditioner installation service in Cleveland, TN can guide us on choosing the right AC for our home. The professional workers analyze the available space and ensure that we get AC of right dimensions. If AC is too small, we have to run it continuously that will result in higher consumption of energy. On the other hand, large AC systems quickly cool air and the on and off cycle is extremely fast. Therefore, they are not able to dehumidify air effectively.
4. Efficient Ductwork:
Before installing an AC system, it is necessary to ensure that our ductwork is in good condition. Seal the joints so that cool air stays in the room. Old or inefficient ducts tend to leak up to 20% of cool air in the environment. We can hire the services of a professional company or an AC technician to resolve problems with ducts. They check the systems and fix the issues in an efficient manner. Once the duct system is secured, we can contact a professional for air conditioner installation in Cleveland, TN.
5. Energy Consumption:
Make sure that we purchase an energy efficient AC system to decrease our electricity bill. We must check the energy efficiency rating, also known as EER rating, to identify the most cost-effective solution. The rating ranges from 8 to 11.5. The higher the rating, the more energy efficient is the system. Energy efficient AC units are suitable for environment. They do not emit harmful gases or heat in the environment. Modern systems come equipped with functions such as variable fan speed, sleep settings and digital temperature controls.
Pharmaceuticals needing of air conditioning
1. Temperature Control: Air conditioning helps maintain a stable temperature within pharmaceutical manufacturing and storage areas, ensuring that products are not exposed to extreme temperatures that could affect their stability.
2. Humidity Control: It helps regulate humidity levels, preventing moisture-related issues such as degradation of active ingredients, microbial growth, and changes in product properties.
3. Sterility Maintenance: Air conditioning systems can incorporate HEPA and ULPA filters to maintain sterile environments in cleanrooms and laboratories where aseptic manufacturing takes place.
4. Product Quality Assurance: Temperature and humidity control are essential for preserving the quality, potency, and shelf life of pharmaceutical products.
5. Compliance with Regulations: Many pharmaceutical regulations, such as Good Manufacturing Practices (GMP), require controlled environmental conditions, which air conditioning systems help achieve.
6. Dust and Particle Control: Air conditioning systems can filter out dust and particles to maintain a clean and controlled manufacturing environment, crucial for preventing product contamination.
7. Worker Comfort and Safety: Comfortable working conditions for employees help maintain productivity and reduce the risk of accidents or errors in pharmaceutical production.
8. Energy Efficiency: Modern air conditioning systems are designed to be energy-efficient, reducing operational costs and environmental impact.
9. Process Control: Controlled temperature and humidity levels are essential for the precise execution of pharmaceutical manufacturing processes.
10. Cold Storage: Air conditioning systems are used for cold storage areas, ensuring temperature stability for temperature-sensitive products like vaccines and biologics.
Reference
Alsmo, T., & Alsmo, C. (2016). A Comparison of Relative Humidity between Two Swedish Buildings with Different Ventilation Solutions. Journal of Environmental Protection, 07(06), 855–873. https://doi.org/10.4236/jep.2016.76078
Kusuma, S. A. F., Abdassah, M., & Aritrixso, A. (2018). Simple design of miniaturized cabinet for compounding vitamin c effervescent tablet in laboratory scale. International Journal of Applied Pharmaceutics, 10(3), 157–161. https://doi.org/10.22159/ijap.2018v10i3.25541
ENERGY EFFICIENT AIR CONDITIONING FOR PHARMACEUTICAL APPLICATIONS. (n.d.). Retrieved October 2, 2023, from https://www.researchgate.net/publication/343343971_ENERGY_EFFICIENT_AIR_CONDITIONING_FOR_PHARMACEUTICAL_APPLICATIONS
’Subrahmanyam, C. V. S., ’Setty, J. T., ’Suresh, S., & ’Devi, V. K. (2001). PHARMACEUTICAL ENGINEERING, Unit Operation-I (Second Edition). Vallabh Prakashan.
Tawfeek, S. (n.d.). Design of central air conditioning system for "Safa" pharmaceutically. Retrieved October 2, 2023, from https://www.academia.edu/35175022/Design_of_central_air_conditioning_system_for_Safa_pharmaceutically
Xu, Z. (2014). Characteristics of Air Filters. In Fundamentals of Air Cleaning Technology and Its Application in Cleanrooms. https://doi.org/10.1007/978-3-642-39374-7_4
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