Global Trends in Industrial Refrigeration Systems Anatolii Mikhailov April 2016 Industrial Refrigeration 1 │
Agenda • Introduction • Global Warming • Safety Aspects • Energy Efficiency Considerations • Industrial System Costs • Combined trends and solutions • Case stories 2 │
Agenda • Introduction • Global Warming • Safety Aspects • Energy Efficiency Considerations • Industrial System Costs • Combined trends and solutions • Case stories 3 │
Businesses in Danfoss Cooling Industrial Refrigeration Danfoss Cooling Refrigeration & A/C Controls Commercial Compressors Industry Business Heat Exchaners 4 | Danfoss Industrial Refrigeration
Industrial Refrigeration Industry Drivers 5 Cost 1 Safety • primary growth in products and emerging markets • system design with higher price pressure, TCO awareness Cost Safety 2 Reliability Global Automatic running • Reliability Global warming 4 warming refrigerants focus, • plays along with NH3 and CO2 Energy efficiency Energy efficiency 3 • new and retrofit systems • Industriel heat pumps 7 | Industrial Refrigeration 6 | Danfoss Cooling Segment
Agenda • Introduction • Global Warming • Safety Aspects • Energy Efficiency Considerations • Industrial System Costs • Combined trends and solutions • Case stories 7 │
Cost Safety Global Reliability warming Energy efficiency 8 | Danfoss Cooling Segment
TEWI - quantifying environmental performance What is TEWI? TEWI = T otal E quivalent W arming I mpact = = Direct equivalent (chemical emissions through leakages) + + Indirect (energy use) global warming effects. In stationary applications indirect emissions are larger than direct emissions due to refrigerant leakage (Sources: IPCC report) 9 | Danfoss Cooling Segment
Regulatory – Refrigerant Map Source: UNEP 2010 TOC Refrigeration, A/C and Heat Pumps Assesment Report 100.000 R23 R143A R507A R13 R114 R404A 10.000 R12 R125 R115 R422C Short Term R113 4.000 R11 R417A Global Warming Potential (GWP) R142B R410A R22 R407C 1.000 R134A R124 R32 Pending HFC developments R152A 100 R123 R290 (Propane) CFC HCFC R1270 (Propylene) R600A (Isobutane) HFC 10 Natural HFC-1234ze A1 Non-toxic/non-flammable HFC-1234yf B Toxic 2L Low flammability Medium to 2 or 3 flammable R744 (Carbon Dioxide) Long Term R717 (Ammonia) 0 0,05 0,10 1,00 Ozone Depletion Potential (ODP) 10 | Danfoss Cooling Segment
Environmental Impact: TEWI analysis of alternative systems (Atlanta) Indirect Emissions (1.5 lbs CO 2 /kWh) Recycling -55% (25% EOL) -82% Direct Emissions (20%/year) R404A state of R134a/CO 2 R404A glycol Ammonia Transcitical System type the industry cascade chiller chiller CO 2 booster Medium Temp: R404A DX R134A DX Prop. Glycol Pumped CO 2 CO 2 DX Low Temp: R404A DX CO 2 DX CO 2 DX CO 2 DX CO 2 DX ( TEWI = T otal E quivalent W arming I mpact) 12 | Danfoss Cooling Segment
Agenda • Introduction • Global Warming • Safety Aspects • Energy Efficiency Considerations • Industrial System Costs • Combined trends and solutions • Case stories 15 │
Cost Safety Global Reliability warming Energy efficiency 16 | Danfoss Cooling Segment
Requirements for ammonia systems globally E Management Off site safety Safety distance Management (operation) D Guidelines Instructions / training IIAR Maintenance (IOR) Safety Risk assessment C System design System requirements System design Safety requirements “Foundation” Design Components B Components design / requirements Valves Safety valves Vessels Compressors A Raw materials Castings requirements Welding requirements, Etc. 17 | Danfoss Industrial Refrigeration
Offsite risk mitigation by charge reduction / segmentation 4 MW ammonia system Charge Charge: 5 kg / kW reduction! 20.000 kg A B C D E Increase general Sub-segments Ammonia-DX Ammonia-CO2 Super low-charge safety level of system Ammonia system system. • Install a number of • Ammonia-CO2 • Ammonia DX-system • Documented risk • Design system with a rooftop mounted self- cascade system or reduce the required assessment. number of sub- contained ammonia Ammonia-CO2 brine • Offsite risk liquid charge segments, which can units system assessment. be separated from • Safety quick closing each other in the event section valves. of leakage. • Safety gas detection. • Etc. R717-charge e.g. R717-charge R717-charge e.g. R717-charge e.g. 1 x 20.000 kg R717-charge ~ 2.000 kg 8 x 200 kg 4 x 5.000 kg 2 x 5.000 kg (0,5 kg / kW) (0,4 kg / kW) (5 kg / kW) (5 kg / kW) (2,5 kg / kW) 18 | Danfoss Cooling Segment
Ammonia charge in large industrial refrigeration systems 19 | Danfoss Cooling Segment
1. “Optimized” NH3 systems Example: Cold Store 2300 kW Ammonia Ceiling Coil system Ammonia DX system with Aluminum Air Coolers Ammonia Ammonia Charge charge Type of evaporators charge reduction (kg /kW) (kg) (%) U bend ceiling coil (OD,38mm; ID, 32mm) 59869 26 94% Aluminum DX Air coolers 3680 1.6 Capacity, 50,000 pallets with recirculation system, room temperature, -18 ℃ 20 | Danfoss Cooling Segment
2. DX NH 3 system SAFETY IMPROVED 21 | Danfoss Cooling Segment
3. CO2 cascade systems NH 3 /CO 2 cascade system Ammonia is limited to engine room Reduce charge by 70-90% Reduce potential risk of food pollution Reduce potential risk of food pollution Better performance / energy saving at low temperature- 22 | Danfoss Cooling Segment
CO 2 in Industrial Refrigeration - History CO 2 applications: The Past: 1992 The CO 2 was re-invented (Gustav Lorentzen) 2004 115 CO 2 / ammonia installations operating in Europe. 35% of these installations in Nederland. (Holm Gebhardt, Nestle) Today: Industrial CO 2 installations is today build with “standard” components, and therefore it is difficult to trace the number of installations. More than 500 installations operating in Europe, dominated by Nederland, France and Spain. It is estimated that 10-15 % of all new industrial installations in Europe is build with CO 2 . 23 | Danfoss Cooling Segment
Industrial Ammonia - CO 2 system Fruit storage Holland – H.M. de Jong • NH 3 – CO 2 “brine” systems, fruit storage • CO 2 temp. -8 Deg.C (17 Deg.F) • 20 m (66 feet) high • 12,500 pallets • 15 individual temperature compartments • Total ground surface area: 13.000 m 2 (140.000 ft 2 ) • Hot gas defrost by separate compressors 24 | Danfoss Cooling Segment
CO2 in cold storage US Cold Storage’s distribution warehouse in Pennsylvania, USA (phase 1,2,3) Phase 1,2,3 Capacity: 3.6 MW CO2 Charge: 30 tons Valve size: up to DN 250 Phase 1,2,3 25 | Danfoss Cooling Segment
6. Super low charged ammonia system for cold storages Mitigating risks Though not entirely new, advancements in evaporator design and liquid feed control open the door to NH3 systems offering 1) No need for an engine room Roof-top based design “VLC” very low NH3 charge Claimed to have up to 98% less ammonia than regular systems 2) (lowest charge < 100 g / kW) Fully automated self-contained NH3 system Very fast installation 3) Source: 1) http://www.foodengineeringmag.com/articles/92191-making-ammonia-safer-and-more-efficient-in-refrigeration-applications 2) http://www.ammonia21.com/web/assets/companybrochure/file/533_azanefreezer_uk.pdf 3) http://hvacpproducts.com/2015/03/evapco-introduces-evapcold-packaged-refrigeration-system/ 26 | Danfoss Cooling Segment
Some common root cause for major incidents on ammonia systems Design System not designed acc. “state of the art” Due to lack competence (do not understand the critical requirements) Safety requirements has not been addressed properly Automated systems eliminates human errors Correct sized safety valve ensure “controlled” realize of ammonia Emergency shutoff valves reduce the release ammonia Gas detectors give fast and reliable warning about any leaks Ensure safe and robust design Safe and robust components . All pressure bearing parts need to be manufactured of suitable materials, documented quality welding. Final test, documentation and complete risk assessment Verification by independent authority 27 | Danfoss Cooling Segment
Cost Safety Global Reliability warming Energy efficiency 30 | Danfoss Cooling Segment
Components Performance Direct welding • Low temperature steel • Modular concept • 31 | Danfoss Cooling Segment
Quality Assurance SAFETY IMPROVED 32 | Danfoss Cooling Segment
Agenda • Introduction • Global Warming • Safety Aspects • Energy Efficiency Considerations • Industrial System Costs • Combined trends and solutions • Case stories 33 │
Cost Safety Global Reliability warming Energy efficiency 34 | Danfoss Cooling Segment
Ammonia is an effective refrigerant Energy Cost, kDKK 10~53% Energy Saving First cost of R22 pump +53% system is higher than R717. Compared to R22 DX system, payback years for R717 system are 0.3~ 3.3 year. +10% +52% +10% +47% +11% 300KW 500KW 1000KW Capacity *Calculation based on: -20 ℃ room temperature ， Shanghai climate condition, the pump system has the same piping dimension. 35 | Danfoss Cooling Segment
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