expanding the use of ammonia refrigeration

IRC Forum May 6, 2015

Expanding The Use of Ammonia Refrigeration

John D. Collins, P.E.

Zero Zone, Inc.

[email protected]

(763) 398-1937

mailto:[email protected]




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?


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?


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


What Will be the Next Best Refrigerant?

THE REFRIGERANT GAMBLE


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


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


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


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


NEW TECHNOLOGY

NH3/CO2 Cascade System:

Recirculated CO2 to

Medium Temperature Loads

DX CO2 to Low Temperature

Loads w/ Booster Compressor


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?


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.


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




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.




Major Features:

Ammonia / CO2 cascade refrigeration

package

CO2 to the refrigerated

cases in the retail areas



Challenge: On-site safety

Solution: Limit potential for ammonia exposure

Outdoor, rooftop package

Controlled access to equipment area



Challenge: On-site safety

Solution: Limit potential for ammonia exposure

Fully enclosed equipment - removable panels

Leak detection with local and remote alarms



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



Challenge: Minimize regular on-site service

Solution: Reduce traditional maintenance functions

Automatic oil recovery and return system



Challenge: Find efficiencies to improve life cycle cost

Solution: Hybrid Condensing System

Wetted pads for evaporative cooling, minimum water

Elimination of water treatment chemicals



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


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?


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


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


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


Questions and Discussion

expanding the use of ammonia refrigeration

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