making the transition to an effective refrigerant architecture · making the transition to an...
TRANSCRIPT
1
July 30, 2019
Making the Transition to an Effective
Refrigerant Architecture
2
Tom Land
Tom has worked to protect the earth’s ozone layer and fight climate
change for over 20 years in the EPA’s Office of Atmospheric
Programs. He is now running the GreenChill Partnership program
to help the supermarket industry reduce emissions of ozone-
depleting substances and greenhouse gases.
Tom Land
U.S. Environmental Protection Agency
Stratospheric Protection Division
GreenChill Partnership
Phone: 202-343-9185
Email: [email protected]
3
Connecting to Webinar Audio
► Please dial in!— 1-866-299-3188 (706-758-1822 from outside the U.S.)
— Code 202 343 9185#
► Dial-in listeners
— Can more easily participate in the Q & A session
— Have fewer technical complications
► Phones are muted (#6 to unmute)
4
Welcome / Webinar Etiquette
► Webinar is being recorded
► Recording will be available on the
GreenChill website under “Events and
Webinars”
► Request a copy of today’s webinar slides,
email: [email protected]
5
Options for submitting and asking questions:
► Submit your questions using CHAT at anytime
1. Type question into “Chat” box in bottom right corner
2. Send question to host by selecting “Start a Private
Chat,” host will ask question “anonymously” during Q&A
► Raise your hand during Q & A
— Host will prompt you to unmute your line (#6) and ask
your question verbally
Q & A after Presentation
6
Sending Questions via Chat
Tom Land
7
Sending Questions via Chat
8
Sending Questions via Chat
9
Raising Your Hand
10
Today’s speakers…
11
Andre Patenaude
Andre Patenaude, C.E.T.
Director – Food Retail Marketing &
Growth Strategy, Cold Chain
Emerson
Office: 519-717-5282
Email: [email protected]
Andre is responsible for developing the North American
marketing and strategy pertaining to Emerson’s food retail and
chiller market. He was most recently responsible for Emerson’s
global CO2 development. Andre has more than 34 years of
industry experience in sales, marketing, training and business
development of heating ventilation air conditioning and
refrigeration system architectures and applications with
compression and component technologies.
12
John Wallace
John Wallace
Director of Innovation
Emerson
Office: 770-425-2724
Email: [email protected]
John has been active in the design and development of electronic control
systems for more than 20 years and holds several patents related to the
control of HVAC and refrigeration systems. He is a recognized expert in the
field of smart buildings and has testified before the U.S. Senate Energy and
Natural Resources Committee on the impact of smart building technologies
on the nation’s infrastructure. John earned a bachelor’s degree in electrical
engineering from the University of Kentucky and a master’s degree in
electrical engineering from the University of Missouri.
13
July 30, 2019
Making the Transition to an Effective
Refrigerant Architecture
14
Industry Is Dealing With
Extraordinary Dynamics
Refrigerant RegulationsF-Gas + EPA + CARB + ECCC+ DOE
New System ArchitecturesSteep learning curve
IoT and Cloud-based ServicesSimple, sustainable, stable
Technician ShortageComplexity vs. simplification
Energy Costs and IncentivesDemand peak charge, time of use rates
Food Safety, QualityFSMA, blockchain
OSHA RegulationsLow-charge ammonia, light industrial
Harvest Processing Transportation Distribution End Users
End-to-end data,
services and
insights
Operations DrivenCold Chain Challenges
FSMA: Food Safety Modernization Act
FDA: Food and Drug Administration
IoT: Internet of Things
F-Gas: Fluorinated gas
EPA: Environmental Protection Agency
CARB: California Air Resources Board
ECCC: Environment and Climate Change Canada
DOE: Department of Energy
OSHA: Occupational Safety and Health Administration
15
RegulationsECCC (Canada)
►Centralized cond. units
<2,200 GWP
►LT ref., stand-alone
<1,500 GWP
►MT ref., stand-alone
<1,400 GWP
►Chiller <750 GWP
►Dom. ref. <150
GWP
►Mobile ref. <2,200
GWP
F-Gas (Europe)
►Self-contained ref.
<2,500 GWP
►Stationary refrigeration
<2,500 GWP
►Recycled, permitted for
service <2,500 GWP
►Self-contained <150
GWP
►Centralized ref.
>11.3 tons (40 kW)
<150 GWP
►Top-side chiller
<1,500 GWP
CARB (California)
Adopted
EPA SNAP
Rules 20
and 21
Refrigeration
>50 lbs <150 GWP
All new refrigerant
sales <50 lbs <1,500
GWP
New resi.
AC and
comm. AC
RTU
<750 GWP
2019 2020 2021 2022 2023 2025
CARB: Chiller <750 GWP starting 2024 SNAP: Significant New Alternatives Policy
GWP: Global warming potential
AC: Air conditioning
RTU: Roof top unit
MT: Medium temperature
LT: Low temperature
16
CARB 2022 (new)
>50 lbs charge
<150 GWP
CARB 2022 (new)
<50 lbs charge
<1,500 GWP
500 1,000 1,500 2,000
R-134a
Like
R-404A
Like
R-410A
Like
GWP Level
Pressure
R-134a
R-407A R-404A
(3,922)R-449/8A
R-410A
R-513AR-515A1234yf
CO2
NH3
R-290R-444B
R-32
= A1 Non-flammable = A2L Mildly Flammable
= A3 Flammable = B2L Toxic, Mildly Flam.
AC 2023/24
U.S.
Climate
Alliance
may
follow
California’s
lead
R-454C
455A
R-454B
As a result
of EPA
SNAP Rules
20 and 21
CARB Rulemaking #2
CARB Board
Meeting
Scheduled
March 2020CO2: Carbon dioxide
NH3: Ammonia
17
End Users/Operators –
What Do They Want?
18
Simple
Serviceable Secure
Stable
Smart
Sustainable
End Users/Operators –
What Do They Want?
19
NATURAL REFRIGERANT
OPTIONS
FOR COMMERCIAL
REFRIGERATION
Natural Refrigerant Options
for Commercial Refrigeration
20
Natural Refrigerants GWP ODP Considerations Refrigeration System Differences
0 0 ►Potentially toxic
►Mildly flammable
►Very low charge requirements
►Used in the high stage to absorb heat and/or cool R-744 (cascade or used as a secondary fluid)
►Far removed from occupied spaces
1 0
►High pressure
►Low critical temperature
►High triple point
►Very little danger to occupants in the event of small leaks
►Used in medium and low stages
►Pumped into the fixtures used in occupied spaces, rather than R-717
3 0
►Highly flammable
►Exempt from venting prohibitions
►Very low charge requirements (currently 150 grams is the max)
R-744 (CO2)
R-717
(Ammonia)
R-290
(Propane)
Natural Refrigerant Options
ODP: Ozone depletion potential
21
CO2 Booster Transcritical Distributed
Indirect Chiller With Cascade Integral Display Case – Micro Distributed
CO2 A1
CO2 A1
R-290 A3
HFO A2L<150 GWP
NH3 B2L
CO2 A1
HFC/HFO A1
HFO A2L
► Many refrigerant options
► Optimize suction press
► Location flexibility
► Lower charge
► Small footprint
► 0 ODP, 1 GWP, 1 A1
► Higher pressures
► Standing pressures
► Good low ambient perf.
► High ambient strategies
► Niche application
► Commercial/industrial
► Full natural option
► Energy efficient
► Low charge
► AHJ approvals
► R-290 150g limit, future?
► A2L 500g limit, future?
► Water loop for condensing
► Heat pump integration option
► Flexible
► AHJ approvals R-290 A3
HFO A2L <150 GWP
CO2 A1
System Architectures Choices
Centralized De-Centralized
22
Propane (R-290)
23
International U.S.
Europe F-Gas CARB 1CARB 2 (Proposed)
Final Vote March 2020
Commercial
Equipment
• 2,500 GWP Jan. 2020
• 150 GWP Jan. 2022
• EPA SNAP Rules 20
and 21
• 1,500 GWP Jan. 2022
(<50 lbs)
• 150 GWP Jan. 2022
(>50 lbs)
Cold
Rooms/Walk-
Ins
• 2,500 GWP Jan. 2020 • EPA SNAP Rules 20
and 21
• 1,500 GWP Jan. 2022
(<50 lbs)
• 150 GWP Jan. 2022
(>50 lbs)
Supermarket
Racks
• Multi-pack
• 40 kW (140 kBTU/hr)
• 150 GWP Jan. 2022
• EPA SNAP Rules 20
and 21
• 150 GWP Jan. 2022
500g for R-290
1.2kg for A2L
(passed)
IEC 300g for R-290 (timing TBD)
1.2kg for A2L (timing TBD)
UL
Application approval for A2L
(timing TBD)
EPA SNAP
Regulations
kW: Kilowatt
kBTU: Thousands, British thermal units, IEC: International Electrotechnical Commission
24
R-290 Yields 20%+ Better EER Efficiency Over R-404A.
24
R-404A and R-290 EER Comparison
25
ASHRAE/UL Working With Industry on Flammable Research Sub-Cmte.
and Completing Charge Limit Increase and Safety Standards Proposal.
Effectivity of an R-290 Charge Limit Increase Could Be 2019 for Stand-Alone Equipment
R-290: U.S. Approx. 300 gram charge limit in proposal
A2L: U.S. 1.2 kg charge limit in proposal IEC/UL/ASHRAE/ICC:
1/8HP 1/6 1/4 1/3 1/2
Domestic Refrigerators (53g)
Vending Mach.
Bev. Dispensers
UC/Prep
Bottle Coolers
3/4 1
1DS 1DG 2DS 3DS 3DG
X = Applications Not Approved by EPA SNAP Final Rule
X
Ice
Walk-ins (Remote)
Commercial Reach-ins
X2DG
150g Charge Limit Current
Larger Units Achievable With Multiple Systems
300+ g Charge Limit in Proposal
In Proposal
(stand-alone, OK)
U.S. EPA SNAP-Approved End Use
Applications for R-290
IEC: International Electrotechnical Commission
UL: Underwriters Laboratories
ASHRAE: American Society of Heating, Refrigerating, and Air-Conditioning Engineers
ICC: Industrial Cooling Corporation/International Code Council
26
R-290 Stand-Alone
End Use Applications
27
Be Sure to Consult Authority Having Jurisdiction (AHJ)
for Additional Code/Standard Requirements Before Installing.
or
12 ft. case
R-290 (3 GWP) 500g limit
or
12 ft. case
R-290 (3 GWP) 150g limit
R-290 Micro Distributed Applications
28
Carbon Dioxide (R-744)
29
CO2 DX
CO2 DX
CO2 DX
TRANSCRITICAL
BOOSTERCASCADESECONDARY
CO2
Secondary
Fluid
up to 650
psig
R-717,
R-290
HFCR-717,
R-290
HFC
CO2
up to 650
psig
up to 1,600+
psig
CO2 System Architectures
Psig: Pound-force per square inch
30
Refrigerant R-744 (CO2) R-404A R-134a R-407A R-407F
Temperature at
atmospheric pressure
-109.3 °F
(-78.5 °C)
(Temp. of
dry ice)
-50.8 °F
(-46 °C)
(Saturation
temp.)
-14.8 °F
(-26 °C)
(Saturation
temp.)
-41.8 °F
(-41 °C)
(Mid-point
saturation temp.)
-45.5 °F
(-43 °C)
(Mid-point
saturation temp.)
Critical temperature 87.8 °F
(31 °C)
161.6 °F
(72 °C)
213.8 °F
(101 °C)
179.6 °F
(82 °C)
181.4 °F
(83 °C)
Critical pressure 1,056 psig 503 psig 590 psig 641 psig 674 psig
Triple-point pressure 61 psig 0.44 psia 0.734 psia 0.18 psia TBC
Pressure at a saturated
temperature of 20 °C815 psig 144 psig 68 psig 133 psig 139 psig
Global warming potential 1 3,922 1,430 1,990 1,824
Basic Properties of R-744 vs. Commonly
Used Refrigerants
Psia: Pound-force per square inch
31
p. 17
Pressure-Enthalpy Diagram of CO2
Subcritical to Supercritical
32
Medium-
Temperature
R-404A
Low-
Temperature
R-404A
162 °F
Critical Point
R-404A
-20 °F
Low-Temp.
162 °F
Critical Point
R-404A
+25 °F
Med.-Temp.
Products
►Mechanical TXV
►Mechanical EPR
►Mechanical CPR
and differential
valves
►Mechanical
pressure controls
►Typically, on/off
compressor
control
Typical R-404A System
TXV: Thermo expansion valves
EPR: Evaporator pressure regulator
CPR: Crankcase pressure regulator
33
CO2 Refrigeration System Highlights
► Three Main Differences
Between
HFC and R-744 Systems
1. High pressure
2. Low critical point
3. High triple point
► Dealing With Standstill
Pressures
4. Managing power outages
5. Managing pressure reliefs
6. How to mitigate risk
► Peculiarities of R-744
7. Managing superheat
34
Ammonia (R-717)
35
Safety and Environmental Requirements
►OSHA requirements
►Low-charge ammonia systems
►Moving ammonia out of occupied spaces
►Cascade systems using CO2 in the low
stage
►Booster transcritical CO2 architecture for
MT and LT
► Increased use of R-744 (CO2) and a
volatile secondary fluid
Increased Emphasis on Total Cost of
Ownership
►Equipment costs
►Maintenance costs
►Energy costs (improved performance of
CO2 at LT such as -40 °F)
Key Industrial Refrigeration Trends
MT: Medium temperature
LT: Low temperature
TCO: Total cost of ownership
36
►OSHA requirements
► Low-charge ammonia systems
Safety and Environmental Requirements
Modular Refrigeration Unit Low-charge Central Systems
Key Industrial Refrigeration Trends
37
Food safetyHandling
Transportation
Regulatory requirements
Multipleplayers
IntermediariesMany steps
Complexity
Consistent temperature control
Natural Refrigerant Options Span
the Journey From Farm to Fork
38
Controls architecture is
“loosely coupled” to the
systems architecture
Two basic controls
architectures
Centralized
Distributed
System architectures vary
on control requirements
CO2, cascade-
centralized control
Distributed, integral-
distributed control
How Do We Maintain Controls Consistency
Across the Different Architectures?
What Are the Key Considerations
and Tradeoffs From a Controls
Perspective?
39
Control System Review: Layers and
Functions of a Control System
Remote
Supervisory
Control
►Remote user interface
►Site information
►Data feed
►Advanced optimization
Key ElementsArchitecture
Layer
►On-site user interface
►User management
►Data logging
►Alarming
►Cross-system coordination►Device integration
►Control algorithms
►Inputs and outputs
►Sensors and transducers
►Equipment interface
Hardware can be
combined or separated.
Site
40
By Taking Advantage of the Supervisory
Layer’s Ability to Integrate
Different Devices, a Common User
Experience Can Be Created
Remote
Supervisory
Control
Architecture layer
Site
Supervisory
41
Planning for the Future: Newer Systems
Need Flexibility and Advanced Control to
Create Smarter Buildings► “Traditional” control
architecture expanding to
enable more value
► Flexibility provided by add-
on “apps” which facilitate
customized solutions
► Site control provides macro-
level control, coordination of
equipment on a cross-site
basis (i.e., HVACR) and
data aggregation
► Transactive services
provide opportunity to utilize
“smart grid” as well as other
cloud-based services (i.e.,
renewable integration, etc.)
Supervisory
Equipment control
Site control
Transactive
services
Apps
RemoteCloud
services
Transactive
services
Distributed controllers
Advanced supervisory systems
HVACR: Heating, ventilation, air conditioning, and refrigeration
42
1. Global refrigerant regulations are driving trials and adoption of
future-proof natural refrigerant architectures.
2. Propane has regained global popularity as a viable efficient
refrigerant choice with a GWP of only 3. Its high flammability has
kept self-contained equipment designs to 150g charge. IEC
International charge limits have increasing to 500g. UL2-89 still has
limit set at 150g(but AHJ will still have the final say).
- Propane is NOT a retrofit refrigerant — new systems only
3. CO2 has proved very effective in both low- and medium-temperature
applications. Successfully deployed in commercial and industrial
applications in Europe for nearly two decades, it has made inroads
in North America in recent years. Due to its low critical point and
high operating pressures, the designer must account for its unique
characteristics.
- CO2 is NOT a retrofit refrigerant — new systems only
Key Take-Away Messages
43
4. Ammonia’s superior thermodynamic properties make it a logical first
choice for early refrigeration systems. It is often used in industrial,
process cooling, cold storage and ice rink applications. However, its
toxicity demands careful adherence to safe application procedures to
ensure operator safety and customer well-being.
5. Most recently, ammonia has been introduced into commercial
applications via cascade systems that utilize lower refrigerant
charges and keep the ammonia circuit removed from occupied
spaces. Conversely, CO2 has been introduced in the industrial
segment as a natural refrigerant option.
6. Control systems can vary across the various system architectures.
7. Supervisory systems can create a common user interface and
provide familiarity for technicians.
Key Take-Away Messages
44
Thank You!Learn about the environmental regulations impacting HVACR at:
Climate.Emerson.com/JulyGreenChill
45
Contacts and Additional Information
Presenter Contact Information
► Andre Patenaude, Emerson
519.717.5282
► John Wallace, Emerson
770.425.2724
GreenChill Contact Information
► Tom Land, U.S. EPA
202.343.9185
▪ Join our webinar invitation list ▪ Request today’s webinar slides
▪ View past GreenChill webinars45
Upcoming Webinars
Date Topic
Sept 24 Ozone Layer Update from the National Aeronautics and Space Administration
Oct 8 Benefits of Partnering with GreenChill for Small and Independent Grocers
Nov 12 Retrofit Doors