CO 2 the natural refrigerant for MT and LT in discounters, super- and hypermarkets 18.08.09 PE4, Bernd Heinbokel
AGENDA 1 Legislation in Europe, trends Comparison of refrigerants Overview on subcritical LT cascade systems Overview on transcritical MT systems Comparison of energy efficiency Comparison of investment costs Evaluation of different refrigerating concepts Conclusion
2 Carrier has the right refrigerant solution for every application, but every application will not have the same refrigerant solution.
LEGISLATION IN EUROPEAN COUNTRIES 3 Norway Tax on GWP e.g. R404A: 60 EUR/kg Denmark Tax on GWP e.g. R404A: 50 EUR/kg Max. 10 kg filling charge HFC per system Germany Incentive directive for reduction of greenhouse gases of commercial refrigeration systems, energy efficiency and natural refrigerants, 15% up to 35% of net invest Netherlands tax incentive for energy efficiency and natural refrigerants Luxembourg Max. 30 kg filling charge HFC per system and max. 100 kw cooling capacity Switzerland Max. allowed cooling capacity for HFC systems: 80 kw Secondary cooling systems over 80 kw cooling capacity Secondary cooling and heat carrier systems over 100 kw cooling capacity and an GWP over 2.000 Austria Max filling charge 100 kg HFC + 1,5 kg/kw All European Countries F-gas regulation (EU 842/2006), regular leakage tests for refrigeration systems over 3 kg filling charge
LEGISLATION IN EUROPEAN COUNTRIES Trends in Germany 4 Chemikalien Klimaschutz Verordnung, EG842/2006 Limits for leakage rates of F-gases, Commissioning after 30.6.08: < 10kg 3% 10kg < x < 100kg 2% > 100kg 1% Incentive directive for commercial refrigeration systems - Energy efficiency - Natural refrigerants - Heat recovery - Financial incentive of 15% up to 35% of net invest
REFRIGERANT OVERVIEW 5 Green house potential: GWP Direct expanding Non toxic LT application Innovative system concepts Intelligent Controls?? Hot gas defrost Heat recovery Subcooled systems Multi Evaporating MT DP1* Deutsche Umwelthilfe tests the flammability of HFO1234yf. (23.10.08) Synthetic???? Fluid H* R134a R404A Natural HC s EU, Mobile air conditioning: 2011: Ban in new car types 2017: Ban in all new cars NH 3 CO 2 excellent fulfilling bad * ) Joint-Venture DuPont/ Honeywell: currently discussed replacements are HFO1234yf / ze
HFO1234yf AND HFO1234ze ARE??? 6 Flammability according EC Directives 67/548/EEC, Safety data sheet: extremly flammable R12, F+ Use only in explosion proof systems and areas Guideline for use and handling, Honeywell: Indicated as mildly flammable, but see General Guidelines, Refrigerant with Air: - Fire or explosion may result, if - Avoid mixing HFO1234yf and air above atmospheric pressure Expected classification according DIN EN 378:2008 due to published data: low flammability, not toxic, safety class A2 - Charge limitation - Use in multi compressor units with direct expansion would not be possible! 12.6.2009: Environment Minister Sigmar Gabriel has raised his voice to warn the German automotive industry against a highly risky economic and technical adventure with an untested, flammable, and toxic refrigerant 1234yf., but rather choose CO 2 now as the most energy-efficient and safe alternative available.
WHY NATURAL REFRIGERANTS? TEWI comparison for the supermarket format 7 TEWI of supermarket refrigeration systems (Qo MT =60kW, Qo LT =20kW, 15 years, 10%, 5%, 1% leakage rate /a) 3000 179% TEWI (leakage) TEWI [t CO2-equivalent] 2500 2000 1500 1000 500 144% 116% 133% 120% 109% TEWI (recycling losses) TEWI (energy consump.) 100% 100% 100% 0 10% 5% 1% 10% 5% 1% 10% 5% 1% MT: R404A / LT: R404A MT: R134a / LT: CO2 MT: CO2 / LT: CO2 Filling charge: R404A: 220kg R134a: 210kg CO 2 : 130kg CO 2 : 25kg Data according German climate conditions
WHY CO 2 AS REFRIGERANT? CO 2 (R744) is... 8 A natural substance A by-product of the air separation process a climate neutral refrigerant No Ozone depletion potential No disposal necessary Classified as non-toxic As carbonic acid contained in many beverages Cost effective and worldwide available
WHY CO 2 AS REFRIGERANT? CO 2 (R744) is... 9 A good heat transfer fluid 4 to 6 times higher volumetric efficiency A future proof refrigerant No taxes on GWP No filling charge limitation No phase-out CO 2 is not subject to the European F-Gas-regulation (EU 842/2006)! Best in class refrigerant for heat reclaim
WHY CO 2 AS REFRIGERANT? Heat reclaim in MT-multi compressor systems Refrigerating capacity 100kW, to=-10 C, CO 2 =-8 C, superheat 8K, sub cooling 5K Desuperheating to 30 C, tap water approx. 25-50 C QWRG Desuperheat capacity tv2 30 C [kw] QWRG / Qc [%] Tv2 Discharge temperature [ C] Water tank targettemperature 60 C 10 Condensing Temperature CO 2 -subcritical: approx. 3 times higher heat reclaim capacity to heat-up tap water compared to R404A or R134a
TIMELINE AND OUTLOOK in the retail business 11 LT Pilot phase Standardised CO 2 -LT-cascade First market installation 2000 2002 2004 2006 2008 2010
SYSTEMS FOR LT Subcritical in cascade to MT or as Booster 12 CO 2 -LT got standard for example in: - Scandinavian countries, Swiss - Several German retailer chains 5.300 kw LT-refrigerating capacity in 160 stores
TIMELINE AND OUTLOOK in the retail business 13 LT Pilot phase Standardised CO 2 -LT-cascade First market installation MT Pilot phase Standardised CO 2 -MT/ LT 2000 2002 2004 2006 2008 2010
DX-SYSTEMS for medium temperature, transcritical Norway 9 Stores 14 Denmark UK Germany Czech Rep. Hungary Luxembourg Austria Switzerland 26 Stores 4 Stores 18 Stores 2 stores 1 Store 1 Store 1 Store 11 Stores 10.000 kw refrigerating capacity in 73 Stores, additional 25 stores ordered
RISKS by high pressure level 15 Pressure multiplied by volume as parameter for risk by overpressure is not higher than in R4040A- or R134a- DX-systems, while having significantly lower filling charges.
CO 2 DIRECT EXPANSION for MT- and LT refrigeration 16 Cascade Booster - Higher energy efficiency - Smaller rack footprint - Lower installation costs
CONTROLS FOR RACKS AND CABINETS CO 2 -MT transcritical 17 Linde controller VS 3010C on CO 2 multi compressor rack with the following additional functions: High pressure control Medium pressure control Controller for water spray Gas Cooler Compressor Rack - high pressure compressor - high pressure control valve - medium pressure control valve Installation - safety devices Heat Reclaim Control Systems - rack - control valves - cold rooms and cabinets It s a energy efficient controller concept! Coldrooms Cabinets
COMPARISON OF ENERGY EFFICIENCY R404A-DX TO CO 2 -DX 18 CO 2 -subcritical > 80% of the year CO 2 -transcritical < 20% of the year Cumulative frequency Ambient temperature in hours Higher COP with CO 2 lower COP with CO 2 Attractive energy savings can be obtained with average annual temperatures up to 15 C. For example: Stockholm 7 C, Berlin 9 C, Paris 12 C, Milan 13 C, Madrid 14 C Ambient temperature in C
RAC AWARDS 2008 19 An awards organized by the British refrigeration and air conditioning magazine rac
MULTI COMPRESSOR RACKS Coop Wettingen, Switzerland 20 MT-Rack LT-Rack MT-Rack Q o : 160 kw Q o : 50 kw Q o : 160 kw With heat reclaim for hot water and space heating With Linde LDS controller system Commissioning 11/2004
SALES AREA MEDIUM TEMPERATURE Coop Wettingen, Schweiz 21
MULTI COMPRESSOR RACK, LT-BOOSTER tegut Lorsch (KK 03-2009) 22 MT Qo: 70 kw LT Qo: 20 kw Frequency controlled compressors Heat reclaim for tap water Linde LDS controllers
SALES AREA MT-PRODUCTS tegut Lorsch (KK 03-2009) 23
MT-RACK WITH LT-BOOSTER RACK EDEKA Center Hövener Wuppertal 24
SALES AREA EDEKA Center Hövener Wuppertal 25
OVERALL COMPARISON OF MT-CONCEPTS Supermarket application 26 R404A direct CO 2 direct R404A indirect with brine NH 3 indirect with brine Total Annual equivalent energy- Investment warming impact consumption costs - 1) + + 2) + + O 1) O - O O O - 1) Potential for improvement + good Increasing due to O satisfactory F-gas regulation - bad EU 842/2006 2)
CONCLUSION DX-systems for MT-/LT-refrigeration 27 TEWI Indirect Emissions Direct Emissions Avoidance of direct emissions by: Use of the natural refrigerant CO 2 with GWP=1 Reduction of indirect emissions by: Energy efficiency gains of CO 2 in direct expansion with average annual temperatures up to 15 C
The sustainable refrigeration concept by Carrier! 28