expanding the use of ammonia refrigeration
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IRC Forum May 6, 2015
Expanding The Use of Ammonia Refrigeration
John D. Collins, P.E.
Zero Zone, Inc.
John.Collins@Zero-Zone.com
(763) 398-1937
Expanding The Use of Ammonia Refrigeration
NEW TECHNOLOGY, NEW APPLICATIONS, NEW DEMANDS
The potential for ammonia refrigeration to grow in new applications is greater than ever before . . .
I. Why Ammonia Now?
II. Where are the New Ammonia Refrigeration Applications?
III. What Factors Will Bring Ammonia Into New Applications?
Expanding The Use of Ammonia Refrigeration
A. Regulatory Pressure on Current Synthetic
Refrigerants (HFC’s)
B. Uncertainty About New Synthetic Refrigerants
C. Environmental Concerns are Shaping Attitudes
D. Technology is Supporting New Applications
I. Why Consider Ammonia Now?
Expanding The Use of Ammonia Refrigeration
The F-Gas Regulations are Coming to the U.S.
The TEWI Concept
THE REGULATORY LANDSCAPE
Global Warming Impact Refrigerants should be evaluated on life-cycle performance
using TEWI or LCCP
Expanding The Use of Ammonia Refrigeration
What Will be the Next Best Refrigerant?
THE REFRIGERANT GAMBLE
Expanding The Use of Ammonia Refrigeration
Corporate Decisions Do Consider The Environment
Consumer Awareness is Playing a Role
Corporate Leaders are Taking a Proactive Approach
Public Relations Affect the Bottom Line for Retailers
CHANGING ATTITUDES
Expanding The Use of Ammonia Refrigeration
NEW TECHNOLOGY
The potential for ammonia refrigeration to grow in new applications is greater than ever before . . .
Low Charge Systems
Reducing the charge in a system reduces the hazard
A number of strategies are being employed to reduce charge
Ammonia/CO2 Cascade
CO2 cascade technology for low capacity low charge units
Better controls, valves, compressors and heat exchangers
Expanding The Use of Ammonia Refrigeration
NEW TECHNOLOGY
Low Charge Systems:
Micro Channel Heat Exchangers vs. Round Tube
Traditionally 40-50% of system charge in round tube
exchangers
Micro Channel exchangers operate with as little a 10%
of the charge of round tube exchangers
Micro Channel Condensers becoming more common
Expanding The Use of Ammonia Refrigeration
NEW TECHNOLOGY
Low Charge Systems:
DX Ammonia Evaporators vs. Recirculated
More than 75% reduction in NH3 charge
Distributed Unitary Systems vs. Central Systems
Eliminate central plant and piping mains
Expanding The Use of Ammonia Refrigeration
NEW TECHNOLOGY
NH3/CO2 Cascade System:
Recirculated CO2 to
Medium Temperature Loads
DX CO2 to Low Temperature
Loads w/ Booster Compressor
Expanding The Use of Ammonia Refrigeration
Comfort Cooling: Warehouses and Office Buildings
Equipment Cooling: Data Centers and Manufacturing
Building Management: Conference Centers, Hotels
Commercial Supermarkets
II. Where Are The New Ammonia Applications?
Expanding The Use of Ammonia Refrigeration
CHALLENGES
New Applications Come with New Challenges . . .
We Must Find Ways to:
1. Isolate ammonia by separating it from occupied areas.
2. Address unique engineering problems with new design.
3. Make systems as user friendly as possible.
4. Keep cost justifiable in markets accustomed to cheaper
systems using synthetic refrigerants.
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Application: Retail Grocery, Refrigeration
Only project utilizing
NH3 in a supermarket
in the U.S.
Cascade system with
NH3 outside and
CO2 to the retail areas
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Application: Retail Grocery, Refrigeration
Business Case:
Use of sustainable technology key to corporate culture.
Eliminate synthetics entirely to operate with zero ozone depletion, and low TEWI potential.
Address safety concerns by locating ammonia outside on the roof.
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Application: Retail Grocery, Refrigeration
Major Features:
Ammonia / CO2 cascade refrigeration
package
CO2 to the refrigerated
cases in the retail areas
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Challenge: On-site safety
Solution: Limit potential for ammonia exposure
Outdoor, rooftop package
Controlled access to equipment area
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Challenge: On-site safety
Solution: Limit potential for ammonia exposure
Fully enclosed equipment - removable panels
Leak detection with local and remote alarms
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Challenge: No on-site operator
Solution: Incorporate near-total automation
Extra sensors for system monitoring
Automatic Shut-down / Re-start
Remote Monitoring for Trend Logging,
and Troubleshooting
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Challenge: Minimize regular on-site service
Solution: Reduce traditional maintenance functions
Automatic oil recovery and return system
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Challenge: Find efficiencies to improve life cycle cost
Solution: Hybrid Condensing System
Wetted pads for evaporative cooling, minimum water
Elimination of water treatment chemicals
Expanding The Use of Ammonia Refrigeration
CASE STUDY 1: WHOLE FOODS MARKET
Challenge: Find efficiencies to improve life cycle cost
Solution: Capture the compressor heat
Heat recovery for facility hot water and heating
Reduced overall energy bill
Expanding The Use of Ammonia Refrigeration
We Must Find Ways to:
A. Promote good design for cost effective and user
friendly systems
B. Develop resources for industry knowledge and
training
C. Develop products for the light industrial / heavy
commercial market
III. How to Bring Ammonia to New Applications?
Expanding The Use of Ammonia Refrigeration
KNOWLEDGE and RESOURCES
IRC, IIR, ASHRAE, RETA, RSES, IIAR, ……….
IIAR-2 is the First Comprehensive Safety Standard for Ammonia
How ammonia will be used outside of the machine room
Single code for any ammonia refrigeration system
RETA and RSES key groups for operator / service training
Great training/certification programs
Local chapters promote community of ideas
Expanding The Use of Ammonia Refrigeration
PRODUCT DEVELOPMENT
A. More small capacity compressor options needed
B. Semi-hermetic compressors
C. Alternatives to all steel welded piping systems
D. Miscible oils for ammonia
Expanding The Use of Ammonia Refrigeration
CONCLUSION
We’ll see many more of these applications, and new, innovative uses of our technology to solve a wider variety of problems faced by customers who have been traditionally reliant on synthetics.
Opportunities for new applications are growing
To take advantage of new markets, we’ll need to standardize system and equipment design
Expanding The Use of Ammonia Refrigeration
Questions and Discussion
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