Innovative and climate-friendly cooling technologies

Transcription

1 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

2 ILK Business: HVAC&R Full Service Provider Research & Development Technology Transfer Measurements and Analysis Software Development Prototype Construction Consulting Training and Qualification Planning Energy efficient cooling technologies in industry 3

3 Centrifugal chillers with R718 (water as refrigerant) Energy efficient cooling technologies in industry 4

4 ODP Future refrigerant options Source: EN ,10 0,09 0,08 0,07 0,06 0,05 0,04 0,03 0,02 0,01 0,00 NH 3, CO 2, H 2 O, Air, He LOW GWP < 150 GWP HCFC HFC natural HC Energy efficient cooling technologies in industry 5

5 R718 = water the most natural refrigerant 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! Energy efficient cooling technologies in industry 6

6 Volume flow rate [m³/h] Pressure ratio p Properties of R718 and its consequences High volume flow rate High pressure ratio 1,E+06 t E = 4 C R t c = 36 C 1,E R ,E ,E+03 R134a 6 4 R134a 2 1,E Refrigerating capacity [kw] Evaporation temperature t E [ C] Energy efficient cooling technologies in industry 7

7 Cycle configurations for R718 chillers Single and double stage cycle calculations R134a single-stage R1234ze single-stage R718 single-stage R718 double-stage Pressure ratio Discharge temperature t EER Ratio: EER Rxxx / EER R134a Boundary conditions: t E = 5.5 C; t C = 35.5 C; superheating: 0.1 K; subcooling: 2 K p qc p qc wt_2 q0 wt q0 wt_1 Single-stage cycle h Double-stage cycle with interstage cooling h Energy efficient cooling technologies in industry 8

8 Efficiency considerations Calculated EER-Values of double-stage vapour compression cycles with interstage cooling (boundary conditions: t E = 5.5 C, t C = 35.5 C, superheating: 0.1 K, subcooling: 2 K, first and second stage isentropic efficiency: 0.7) Energy efficient cooling technologies in industry 9

9 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, kw, up to 52 m³/s, 9000 min -1 ILK Energy efficient cooling technologies in industry 10

10 R718 centrifugal chillers - customer installations 2 x kw VW Dresden 2001 still operating! 4 x kw Daimler Düsseldorf 2000 / x 800 kw Uni Essen x 650 kw G.A.E Grevenmacher x 480 kw Cargolux Luxemburg Energy efficient cooling technologies in industry 11

11 R718 semi-hermetic chiller technology Test and functional demonstration at ILK, 2013 Results: New compressor achieves expectations Proof of concept Key figures determined Energy efficient cooling technologies in industry 12

12 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) Energy efficient cooling technologies in industry 13

13 Worldwide developments in R718 refrigeration Kawasaki, J 352 kw / 100 tonr DTI / JCI (Sabroe) / Kobe Steel ~800 kw Source: Kawasaki Efficient Energy, D kw Source: DTI Source: Efficient Energy Energy efficient cooling technologies in industry 14

14 Cold thermal energy storage why? 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 Energy efficient cooling technologies in industry 15

15 Cold thermal energy storage why? High electrical peak power demand especially caused by airconditioning Thermal storage for decoupling of cooling demand and cooling generation Cold thermal directly stores final energy Integration of renewables needs storage -> Power-to-Cold Abu Dhabi Efficiency increase of cold generation at favorable re-cooling/condensation conditions (day-night temperature difference) wetterkontor.de Energy efficient cooling technologies in industry 16

16 Power consumption in MW New requirements with higher share of Renewables Power price and consumption during one day, German Amprion network, Power price in /MWh Source: Energy efficient cooling technologies in industry 17

17 Ice generation by direct evaporation Chilled water from chiller C Condensate reflux Water vapour condenser Evaporator Ice generation at water surface Chilled water to chiller C Water vapour centrifugal compressor Water reflux Heat of evaporation (6.1 mbar; 0.01 C) h V = 2500 kj/kg Heat of fusion h fus = kj/kg Water (liquid, 0 C) g l Water vapour 118 g l Ice slurry Ice: 882 g / l Charging pump Ice Slurry Energy efficient cooling technologies in industry 18

18 Pumpable Ice Slurry generated by vacuum freezing Energy efficient cooling technologies in industry 19

19 Integration of vacuum ice cold thermal storage in chilled water system Energy efficient cooling technologies in industry 20

20 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 Göttingen, Germany Charging capacity: 180 kw Storage capacity: 1 MWh Discharging capacity: 350 kw Load management at local chilled water network Energy efficient cooling technologies in industry 21

21 Vacuum ice slurry 7 times higher energy density than chilled water storage ~30 % higher efficiency than block ice storage Flexible operation; % discharging Cheap storage medium (PCM) Pumpable storage medium Applicable for district cooling Sustainable, using water (R718) as refrigerant More information: Energy efficient cooling technologies in industry 22

22 PV driven refrigerated storage - Nigeria Idea: PV-powered cold room with natural refrigerant source: presentation Nnaemeka Ikegwuonu 470 million small farmers loose 25 % of their annual income by fruit or vegetable spoilage Energy efficient cooling technologies in industry 23

23 Solution: Cold Hubs Financial and logistic support by GIZ Contributions of ILK Dresden: Concept development Component sizing and test Manufacturing instructions Training source: Energy efficient cooling technologies in industry 24

24 Indonesia Idea: PV-powered block ice machine with natural refrigerant, ice harvest irradiation dependent Diesel supply of remote ice factories, High GWP refrigerants Energy efficient cooling technologies in industry 25

25 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 Energy efficient cooling technologies in industry 26

26 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 Energy efficient cooling technologies in industry 27

27 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 Energy efficient cooling technologies in industry 28

28 SolarSplit - Project Integrating energy storage into Mono-Split Systems Energy efficient cooling technologies in industry 29

29 Daily Time Shift between Cooling Demand and PV Energy Supply in Residential Buildings power, heat flow rate [kw] 2,0 1,8 1,6 1,4 PV Generation Cooling Demand including bedrooms Cooling Demand excluding bedrooms 1,2 1,0 0,8 0,6 0,4 0,2 0, day time [h] 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) move cooling production to electricity generation peak by integrating an ice storage Rising number of PV installations on residential buildings do not directly decrease grid peak loads resulting from air conditioning systems Energy efficient cooling technologies in industry 30

30 Integrating an Ice Storage in Mono-Split Systems Starting Point ice storage outdoor unit direct refrigerant side connection (low pressure liquid and low pressure suction gas tube) indoor unit including evaporator Energy efficient cooling technologies in industry 31

31 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 Energy efficient cooling technologies in industry 32

32 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 Energy efficient cooling technologies in industry 33

33 Water/LiBr-developments High efficiency solar cooling Double-Effect chiller for concentrated solar power Cooling capacity: 50 kw EER th 1,3 IGS, Braunschweig University Energy efficient cooling technologies in industry 36

34 Absorption chillers for vessels Prototype at test rig 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 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 Commercial chiller on vessel Source: Enercon Energy efficient cooling technologies in industry 37

35 Directly air-cooled absorption chiller Reduction of the auxiliary energy demand by using directly air-cooled absorber and condenser no cooling water circuit 1 Generator 2 Condenser 3 Absorber 4 Evaporator Less system components Lower complexity Lower installation effort Free cooling at ambient temperatures < 12 C Energy efficient cooling technologies in industry 38

36 Directly air-cooled absorption chiller 1 1 = generator 2 = condenser 3 = absorber = evaporator = fan Previous functional model The enhanced chiller Energy efficient cooling technologies in industry 39

37 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 Energy efficient cooling technologies in industry 40

38 ILK Dresden Mathias Safarik Department of Applied Energy Engineering Bertolt-Brecht-Allee 20; Dresden; Germany Tel.: