innovative and climate-friendly cooling technologies

Institute of Air-handling and Refrigeration (ILK Dresden)

Innovative and climate-friendly cooling technologies

GIZ Proklima side-event at the 29th Meeting of the Parties, Montreal 2017

3

ILK Business: HVAC&R Full Service Provider

3

Research &

Development

Technology Transfer

Measurements and

Analysis

Software

Development

Prototype

Construction

Consulting

Training and

Qualification

Planning

21.11.2017 Energy efficient cooling technologies in industry

Centrifugal chillers with R718

(water as refrigerant)

21.11.2017 Energy efficient cooling technologies in industry 4

Future refrigerant options


0,00

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

0,10

0 1000 2000 3000 4000

OD

P

GWP

Source: EN 378 - 2008

HCFC

HFC

natural

HC

NH3, CO2,

H2O, Air, He

LOW GWP < 150

Water ...

Is environmentally friendly

Is non-toxic

Is non-flammable

Is much cheaper than any other refrigerant

Is everywhere available

Is a very efficient refrigerant

Doesn’t require a refrigerant stock

Causes no hazards

Requires no on-site security facilities

Is very well suited for office / building applications

Can work with heat exchangers with low nominal pressure

Water is one of the refrigerants of the future!

6

R718 = water – the “most natural” refrigerant


Properties of R718 and its consequences

High volume flow rate


R718

R134a

1,E+02

1,E+03

1,E+04

1,E+05

1,E+06

0 200 400 600 800

Vo

lum

e flo

w ra

te [

m³/

h]

Refrigerating capacity [kW]

tE = 4 C

High pressure ratio

R718

R134a

tc = 36 °C

0

2

4

6

8

10

12

14

16

-3 0 3 6 9

Pre

ssu

re ra

tio

pEvaporation temperature tE [°C]

Cycle configurations for R718 chillers

Single and double stage cycle calculations

Single-stage cycle Double-stage cycle with interstage cooling


R134a

single-stage

R1234ze

single-stage

R718

single-stage

R718

double-stage

Pressure ratio 2.5 2.6 6.4 6.4

Discharge temperature t4 46 43 232 126

EER 5.65 5.2 5.5 6.05

Ratio: EER Rxxx / EER R134a 1 0.92 0.98 1.08

Boundary conditions: tE = 5.5 °C; tC = 35.5 °C; superheating: 0.1 K; subcooling: 2 K

qC

h

p

q0wt

1

45

6

qC

h

p

q0

wt_2

wt_1

1

23

45

6

Efficiency considerations

Calculated EER-Values of double-stage vapour compression cycles with

interstage cooling

(boundary conditions: tE = 5.5 °C, tC = 35.5 °C, superheating: 0.1 K, subcooling: 2 K,

first and second stage isentropic efficiency: 0.7)


History of R718 at ILK

20 years ago = First Experiments with new ILK centrifugal compressor for

Vapour compression cycle with water as refrigerant

CFRP wheel, hermetic design


Experimental R718 ciller, 500- 1000 kW, up to 52 m³/s, 9000 min-1

ILK 1997

2 x 1.000 kW VW Dresden 2001 still operating!

4 x 1.000 kW Daimler Düsseldorf 2000 / 2003

1 x 800 kW Uni Essen 2000

1 x 650 kW G.A.E Grevenmacher 2001

1 x 480 kW Cargolux Luxemburg 1999

R718 centrifugal chillers - customer installations

21.11.2017 11Energy efficient cooling technologies in industry

Test and functional demonstration at ILK, 2013

Results:

New compressor achieves

expectations

Proof of concept

Key figures determined

R718 – semi-hermetic chiller technology

12Energy efficient cooling technologies in industry21.11.2017

R718 – Future

Looking for industrial partners

Harvesting „low hanging fruits“ -> applications with high chilled water

temperatures (14…20 °C), e.g. in data centers or some industrial processes

Single-stage design, high efficiency (EER ~ 11)


Worldwide developments in R718 refrigeration

Kawasaki, J

352 kW / 100 tonR

DTI / JCI (Sabroe) /

Kobe Steel

~800 kW

Efficient Energy, D

20…60 kW


Source: Kawasaki

Source: DTI

Source: Efficient Energy

Cold thermal energy storage … why?

Energy efficient cooling technologies in industry 15

Cooling applications need energy

Air conditioning, food processing and storage, industrial processes

Most chillers driven by electricity

Cooling related loads dominate in many regions

(40…60 % of electricity consumption in warmer climates)

Without storage dimensioning of chillers for peak load

21.11.2017

Cold thermal energy storage … why?


High electrical peak power demand especially caused by air-

conditioning

Thermal storage for decoupling of cooling demand and cooling

generation

Cold thermal directly stores final energy

Integration of renewables needs storage

-> “Power-to-Cold”

Efficiency increase of cold generation

at favorable re-cooling/condensation

conditions

(day-night temperature difference)

21.11.2017

© wetterkontor.de

Abu Dhabi

New requirements with higher share of Renewables


Source: www.energieheld.de

Power price and consumption during one day,

German Amprion network, 5.3.2015

Po

wer

co

ns

um

pti

on

in M

WP

ow

er p

rice

in €

/MW

h

Ice generation by direct evaporation


Heat of evaporation (6.1 mbar; 0.01 °C)

hV = 2500 kJ/kg

Heat of fusion

hfus = 333.5 kJ/kg3...6 °C

Water vapour centrifugal compressor

Water vapour condenser

Evaporator

Charging pump

Ice Slurry

Ice generation at water surface

Condensate reflux

Water reflux

Ice slurry

Chilled water from chiller

Chilled water to chiller

8...12 °C

Ice: 882 g / 0.962 l

Water (liquid, 0 °C)

1 000 g

1.0002 l

Water vapour118 g

24 244 l

21.11.2017

Pumpable Ice Slurry generated by vacuum freezing


Integration of vacuum ice cold thermal storage in

chilled water system


21

Installations – Vacuum ice slurry cold storage

Zwickau, Germany

Charging capacity: 50 kW

Storage capacity: 350 kWh

Discharging capacity: 100 kW

Load management at local chilled

water network

Energy efficient cooling technologies in industry21.11.2017

Göttingen, Germany

Charging capacity: 180 kW

Storage capacity: 1 MWh

Discharging capacity: 350 kW

Load management at local chilled

water network

Vacuum ice slurry

7 times higher energy density than chilled water storage

~30 % higher efficiency than block ice storage

Flexible operation; 0…100 % discharging

Cheap storage medium (PCM)

Pumpable storage medium

Applicable for district cooling

Sustainable, using water (R718) as refrigerant

More information: www.ilkdresden.de/iceslurry


http://www.ilkdresden.de/iceslurry

PV driven refrigerated storage - Nigeria


source: presentation Nnaemeka Ikegwuonu

Idea: PV-powered cold room with

natural refrigerant

470 million small farmers loose

25 % of their annual income by

fruit or vegetable spoilage

21.11.2017

Solution: Cold Hubs


Financial and logistic support by GIZ

Contributions of ILK Dresden:

Concept development

Component sizing and test

Manufacturing instructions

Training

source: www.coldhubs.com

21.11.2017

Indonesia


Idea: PV-powered block ice machine with

natural refrigerant, ice harvest irradiation

dependent

Diesel supply of remote ice factories,

High GWP refrigerants

21.11.2017

Solution: Dynamic ice generator


Financial and logistic support by GIZ

Contributions of ILK Dresden:

Concept development

Concept test

Control and monitoring system

Manufacturing instructions

Set-up support

21.11.2017


Container based system solutions by ILK

PV Milk Cooling Centre

• 20ft container with milk storage

• PV generator: 3.4 kWp

• nom. cooling power: 5.1 kW

(-5 C / 50 C)

• milk storage and refrigeration

• capacity: 1000 l

• ice storage with 30 kWh

• milk cooling with ice water

cycle

System for cooling and cold storing of milk

21.11.2017


Container based system solutions by ILK

PV Ice Maker

• 20ft container with ice maker

• PV generator: 5.1 kWp

• nom. cooling power: 5.9 kW

(-10 C / 45 C)

• 250 kg crushed ice per day

• water tank

• UV water disinfection

• ice storage seizing two daily

outputs

Specially developed ice machine with high efficiency

21.11.2017

„SolarSplit“ - Project

Integrating energy storage into Mono-Split Systems

Energy efficient cooling technologies in industry 2921.11.2017

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

0 4 8 12 16 20 24

po

wer

, hea

t fl

ow

rat

e [

kW]

day time [h]

PV Generation

Cooling Demand including bedrooms

Cooling Demand excluding bedrooms

Daily Time Shift between Cooling Demand and

PV Energy Supply in Residential Buildings

Solar radiation and PV electricity generation peak around noon

high electricity feed to grid during the day

People leave home during the day and arrive during afternoon / evening

high grid load during afternoon (cooling down the building) and in times of low

PV electricity generation (evening / night)

Rising number of PV installations on residential buildings do not directly

decrease grid peak loads resulting from air conditioning systems


move cooling production

to electricity generation peak

by integrating an ice storage

21.11.2017

Integrating an Ice Storage in Mono-Split Systems

Starting Point


indoor unit

including evaporator

outdoor unit

direct refrigerant side connection(low pressure liquid and low pressure suction gas tube)

ice storage

21.11.2017

Test Rig


rated cooling capacity 4 kW

rated EER 3.52

rated SEER 6.9 (EN 14825)

ice storage volume 60 l

thermal capacity 5 kWh

electrical heater 3 kW

Thermally driven refrigeration

Absorption and Adsorption chillers

Natural refrigerants water (R718) or ammonia (R717)

Heat Sources

Solar Collectors

Burning of agricultural residues, e.g. rice husks

(Biogas) driven cogeneration units

Industrial waste heat

Engines on vessels


Water/LiBr-developments – High efficiency solar cooling

Double-Effect chiller for

concentrated solar power

• Cooling capacity: 50 kW

• EERth 1,3

© IGS, Braunschweig University


Prototype at test rig

Commercial chiller on vessel

Absorption chillers for vessels

Special operating conditions

Reliable operation even at heavy swell

GL: +/- 22,5° dynamic, 15° static

Operation at comparatively high cooling water

temperatures up to 32 °C of sea water resulting

in 36...38 °C fresh cooling water

Mechanical strength:

+/- 0,8 g accelerating force and vibrations

(dynamic acceleration because of swell)

Coping with permanent vibrations caused by the

propeller, for example


Source: Enercon

Directly air-cooled absorption chiller

Reduction of the auxiliary

energy demand by using

directly air-cooled absorber

and condenser

no cooling water circuit

Less system components

Lower complexity

Lower installation effort

Free cooling at ambient

temperatures < 12 °C


1 Generator 2 Condenser

3 Absorber 4 Evaporator


Directly air-cooled absorption chiller

1 = generator

2 = condenser

3 = absorber

4 = evaporator

5 = fan

5

32

4

1

5 32

4

1

Previous functional model The enhanced chiller

Closed type re-cooler with adiabatic pre-cooling

Low cooling water temperature for high chiller efficiency

Adiabatic (wetted pads) for pre-cooling of air if needed

Low water consumption, precise dosage

No water treatment -> tap water

Swiveling pads for unhindered air flow in dry mode


Source: EAW Source: Thermofin

ILK DresdenMathias Safarik

Department of Applied Energy Engineering

Bertolt-Brecht-Allee 20; 01309 Dresden; Germany

Tel.: +49 351 4081-700

E-Mail: [email protected]

mailto:[email protected]

innovative and climate-friendly cooling technologies

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