aicarr vicenza 2016 emerson

TECHNOLOGICAL INNOVATIONS FOR

ENERGY SAVINGS IN SUPERMARKETS

Vicenza, 5th February 2016

Evoluzione dei Compressori e dei Sistemi di

Refrigerazione Commerciale in relazione alle

recenti normative energetiche ed ambientali

Bachir Bella

……

Autore - Affiliazione

Titolo relazione


Agenda

• F-Gas impact on Commercial Refrigeration

• System and Compressors Evolution in Relation to

the new F-gas Regulation

• CO2 Compressors Technologies

• R290 Compressors


Titolo relazione


Regulation EU N°517/2014 (F-gas)

24%

Domestic

fridge

GWP >150

Single Split AC

(GWP <750)

Moveable AC

GWP < 150

Refrig/Freezers

For Comm. Use

GWP<2500

Stationary Ref.

And Service Ban

GWP<2500

Jan 2015:

Applicability

Multipack

Refrigeration

GWP <150

(except cascades

with GWP <1500)

Refrig/Freezers

for Comml use

herm sealed

GWP <150

No recycled

/reclaimed

GWP <2500

for servicing

2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030

45%

21%

93%

63%

31%

Service usage of

HFC recycled and

reclaimed is

authorizes till 1st

Jan. 2030

100% corresponds to average 2009-2012 of HFC quantities placed on the

market and declared by refrigerants producers according to 842/2006 CE

100% = 182 Millions Tons of CO2 / 21% = 38 MT CO2


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F-Gas Refrigerants Landscape

R-410A like

R404A

R407A/F

like

R134a

like GWP

< 1500

600

150 - 300

1234yf/ze

R410A

R407C/A/F

0 500 1000 1500 2000

Co

oli

ng

Cap

acit

y/

Pre

ssu

re

R448A/R449A

R32/HFO Blends (DR5, L41, ARM71)

R134a

CO2

R404A

R290

NH3

A1 – Non flammable

A2L – Middly flammable

A3 – flammable

B2L – Toxic, middly flam.

(3922)

R32/HFO Blends (XL20/40, HDR110, L20, ARM20)

R450A,R513A

2500

400-675


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F-Gas Impact on Future Refrigerating System

R-410A like

R404A

R407A/F

like

R134a

like GWP

< 1500

600

150 - 300

HFO

R410A

R407C/A/F

0 500 1000 1500 2000

Co

oli

ng

Cap

acit

y/

Pre

ssu

re

R448A/R449A

R32/HFO

R134a

CO2

R404A

R290

NH3

(3922)

R32/HFO

R450A,R513A

All new systems

2020 2022

Centralized > 40kW

Hermetic

2022

2500

400-675

2030 2024

The system architecture will change with the refrigerant type

The imposed quotas will influence the future decisions

Bans

Avg. GWP

Phase down

Primary circuit

(Centralized > 40 kW)


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Non Hermetic Sealed Hermetic Sealed

Today Tomorrow

Centralized DX

R290

HFO GWP <150 R450A, R513A,

R448A, R449A, R134a, R407A/F

R404A

R407A/F

HFO R290

R450A,R513A

R448A/R449A/R134a

Cascade Booster

Indirect Systms

R744 R744

Sys

tem

s <

40

kW

R450A, R513A

R448A/R449A/R134a

ENTR Lot. 1

For condensing

Units

Global Impact

(LCCP)

Legislations

&

Standards Directions

Commercial Refrigeration

a Rational Choice

Sys

tem

s >

40

kW

HFO GWP <150 ?

Centralized DX LT

HFO GWP <150?

Investment


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Non Hermetic Sealed Hermetic Sealed

Today Tomorrow

Centralized DX

R450A, R513A,

R448A, R449A, R134a, R407A/F

R404A

R407A/F

HFO A2L <300

R290

R450A,R513A

R448A/R449A/R134a

Cascade Booster

Indirect Systms

Sys

tem

s <

40

kW

R450A, R513A

R448A/R449A/R134a

ENTR Lot. 1

For condensing

Units

Commercial Refrigeration

(Compressor Evolution)

Sys

tem

s >

40

kW

Centralized DX

R744

R290

R290


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Diagram Pressure-Enthalpy

CO2 (R744)

Transcritic Cycle

Transcritic Compressor is

designed

to operate either in

Transcritic or in subcritic

mode

Subcritic Cycle

Subcritic Compressor is

designed

to operate only in

subcritical mode


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Criteria How R744 behaves?

Capacity

Cooling

Significantly higher volumetric capacity

4 to 5 times R404A

Efficiency Varies, depending on system type and

ambient temperature

Operating

Conditions

Operating and Standstill pressures

significantly higher

Safety high pressures and associated hazards

present challenges, Low toxicity

Suitability

as a retrofit

Not suitable because of higher pressure

and volumetric cooling capacity

Most Critical Design Parameter for

CO2 is the High Pressure

High Pressure is the most challenging Feature

• Enclosures designed at least for 3 times the max allowed

pressures 270/420 bar for MT and 100/150 bar for LT

application

• Sliding surfaces are highly stressed when used for

transcritical application (reliability)

0

20

40

60

80

100

120

140

-60 -40 -20 0 20 40 60 80 100 120

Ma

x w

ork

ing

Pre

su

res

(b

ar)

Temperature ( C)

R404A

Cycle Optimization

LS

-M

ed

ium

T.

HS

-M

ed

ium

T.

R744

R134a

HS

Lo

w T

.

System Charge

CO2

R404A

R134a

LS

Lo

w T

.

CO2 Require new Compressor Generation


Titolo relazione


0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

-60 -50 -40 -30 -20 -10 0 10

Dis

ch

arg

e P

ress

ure

(b

ar)

Evaporating Temperature ( C)

Recip.Transcritical

Recip.Subcritical

Scroll

16 b

ar

31 b

ar

42 b

ar

CO2 Compessors for MT & LT Application & Performances

Modulation

Scroll Digital 10 to 100%

Reciprocating AC Inverter 25 to 70 Hz

PSS 30 bar

PSS 90 bar

CO2 Operating Envelope

PSS 90 bar

80 %

100 %

120 %

-45 -40 -35 -30 -25

Evap. Temp. in °C

COP Scroll/Recip

Tcond. = -5°C

Tcond. =5°C


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CO2 Booster Simulation Efficiency with Ambient Temperature

0

1

2

3

4

5

0 5 10 15 20 25 30 35 40

Bo

os

ter

CO

P

Ambient Temperature ( C)

R404A R744

< 18 C CO2 Booster Good Efficiency

> 18 C CO2 Booster Less Efficient,

Others Systems:

• Parallel compression

• Ejector

• Cascade System

Simulation & Assumptions

•MT capacity 100 kW

•Evap. temperature -10 C

•LT capacity 25 kW

•Evap. temperature -35 C

•DT condenser 6K for CO2 and

varying from 6 to 10K for R404A

+29%

-21%


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Why Propane (R290)?

Tested Performances on Scroll

78 83 96102 109 130-20

-15

-10

-5

0

5

10

15

20

60

70

80

90

100

110

120

130

140

Dis

ch

arg

e T

em

pe

ratu

re v

s.

R4

04

A

Capacity COP Discharge Temp.

30 C 45 C 60 C

Condensing Temp. ( C)

R2

90

Pe

rfo

rma

nc

es

vs

R-4

04

A (

%)

Evaporating Temp. : -10 CEvaporating Temp. : -10 C

Properties

GWP=3

Higher COP – Up to 30% at High Condensing Temperature

Discharge Temperature slightly higher vs. R404A but manageable

Lower Cooling Capacity vs. R404A (Avg. -15%)

Limitation (Flammability)

Hazardeous

Limited Experiences

Less addressed in the standards

Directives and Refrigerants Standards not harmonized sometimes

Directives and Local Legislations making confusions


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Relevant Regulations & Standards For

Flammable Refrigerants

• EN 378 (Refrigeration Systems)

System Design

&

System

Location

Occupancy

Public

Access

Supervised

Occupancy

Authorize

d

Access

Only

All in Occupied

Space 1.5 2.5 10

Compressor &

Receiver in

unoccupied

space

1.5 2.5 25

All in Open

Space or

Machinery

room

5 10 unlimited

Max. Charge Limit forR290 (kg)

• Risk Assessment

No Special requirement • EN 60335-2-89 (Commercial Ref.

Appliances): max. charge 150g

Sm

all

Sys

tem

L

arg

e

Sys

tem

• ATEX 99/9/EC Compliances

• The compressor is not

located in an area where a

potentially flammable

mixture of refrigerant and

air could accumulate

• ATEX 94/9/CE compliance

and Relevant Standards

EN60079

• Electrical components

Not a source of ignition

• Hot surfaces shall not

exceed auto-ignition

Temperature of the

refrigerant minus 100 K


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R290 Compressors Trend

Fixed Speed

HFC Scroll

Fixed Speed

R290 Scroll

Variable Speed

R290 Scroll

• Compactness

• Weight

Natural Refrigerant

• Energy Efficiency

• Single Compressor To Cover

Multitude System Range

(Self-Contained)

R290 VSS Applications: Self-Contained Cases, Ref Small Chiller And Small Cascade System


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Dedicated R290 Scroll Design Fixed Speed

• PED Shell, fittings, sight glass, Fusite

PED Category I II III

P x V

(bar.liter)

Non flamm. 50 - 200 200 -1000 1000 - 3000

Flammable 25 - 50 50 - 200 200 - 1000

Quality System Internal N.B.

Design Internal Internal N.B.

Welding process Internal N.B. N.B.

Weld Inspection NDT - - N.B.

R290 Comm’l Cmp.

Cost Impact! N.B.: Notified body


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• ATEX Zone 2

0

10

20

30

40

50

60

-5 5 15 25 35 45 55 65 75

Vis

co

sit

y (

cS

t)

Temperature ( C)

Oil Viscosity

R404A 3MAF R290 3MAF R290 HXL 4467

Tevap. -10°C


• PED Shell, fittings, sight glass, Fusite New Material and Processes

• Reliability low viscosity with Std. POE

Electrical components Not a

source of ignition and Hot

surfaces shall not exceed auto-

ignition Temp. minus 100 K

http://www.engineeringtoolbox.com/fuels-ignition-temperatures-d_171.html


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• PED Shell, fittings, sight glass, Fusite New Material and Processes

• Reliability New Developed lubricant

New Lubricant

Special Sliding

Surfaces Coat

New Main

Pressure

Bearing Parts

Suction Baffle

Fully Hermetic

Design

ATEX eBox

• ATEX Zone 2

Electrical components Not a

source of ignition and Hot

surfaces shall not exceed auto-

ignition Temp. minus 100 K


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R290 Variable Speed Scroll Target Applications

• Compressor with DC Brushless Motor

• Frequency Drive (220VAC Single Phase)

Applications

• Self-contained display case applications

• Cascade systems & R290/Water-Gylcol secondary systems

• Condensing units and Monoblocks

0 2 4 6 8 10 12 14

ZPV21

ZPV29

Displacement (m3/h)

990 Watt 4240 Watt

1280 Watt 5900 Watt

-10/45 C

30Hz

30Hz

117Hz

117Hz


Titolo relazione

Autore - Affiliazione Different speed needs map controller

1

1.4

1.8

2.2

2.6

3

0 2000 4000 6000 8000

CO

P

Compressor Speed (rpm)

50 C

35 C

-10 C evaporating

Performance & Operating Limits ZBV Scroll with R290

COP quasi costant at variable speeds

DC Motor for High Efficiency

ZPV21


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Conclusion

• F-gas induces for long term low GWP (< 500?)

• System architecture and the refrigerant choice

will be linked to Investment, Global warming

Impact and Legislations

• Natural Refrigerants Refrigerants like Propane

R290 and Carbon Dioxide (CO2) are Potential

Candidates for a long term

• Carbon Dioxide (CO2) and Propane R290 need

Dedicated compressors design because of the

high pressure, safety and reliability

21

aicarr vicenza 2016 emerson

Technology