Advanced Refrigeration Systems - Emerson · PDF fileAdvanced Refrigeration ... •...
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Advanced Refrigeration Systems Mike Saunders
Transcript of Advanced Refrigeration Systems - Emerson · PDF fileAdvanced Refrigeration ... •...
Advanced Refrigeration Systems Mike Saunders
Agenda • Objective
• System Model Assumptions
• Review Results
• Update On Products Used In Analysis
• Conclusions
• Questions
Objective • Evaluate Both Traditional And Newer Refrigeration Systems
From Cooling Performance Only
– Annual And Peak Load Energy Consumption
– Life Cycle Climate Performance (LCCP)
• Analysis To Be Done Using
– Documented Assumptions
– Existing Production Compressors And Technologies
– Five Weather Zones For The United States
• Technical Evaluation Only
– Commercial Considerations Such As First Cost, Maintenance, Etc Not Included
Assumptions • Analysis Looks At System Refrigeration Only
• Store Load
– MT: 900K BTUH, 20 F SST
– LT: 300K BTUH, -25 F SST
• Mid Point Temperatures, Both Evaporator & Condenser
• No Pressure Drop Effect Included
• Heat Transfer Effect Included
• Evaporator Superheat: 10 F
• Minimum Condensing Temperature: 70 F
• CO2 Pump Power
– MT: 1.9% of MT Load
– LT: 1.3% of LT Load
• Glycol Pump Power – MT: 3% of MT Load
• Condenser Fan Power – 10% of Compressor Power For HFC’s
– 9% of Compressor Power For Transcritical CO2
• Electric Generation Factor
– 1.5 lbs CO2 / kWh
• Analysis Based On Compressor Test Data
System Simulation Conditions
System Charge
(lbs)
Leak Rates
(%)
Evaporator Temp (F)
Condenser TD’s (F)
Superheat/ Return Gas (F)
Central DX 3200 15 LT: -25°F MT: 20°F
LT:10°F MT:15°F
LT: 30°F RGT MT: 50°F RGT
Distributed DX 970 10 LT: -23°F MT: 23°F
LT:10°F MT:15°F
LT 20°F SH MT: 20°F SH
Cascade CO2 705 5 LT: -23°F MT: 10°F
LT:8°F MT:15°F
LT: 36°F SH MT 20°F SH
Secondary 540 2 LT: -30°F MT: 10°F
LT:10°F MT:15°F
LT: 20°F SH MT :20°F SH
Transcritical Booster CO2
705 15 LT: -23 F MT: 23°F
MT:10°F LT: 36°F SH MT: 20°F SH
*Heat Exchanger Penalties Accounted For In Temperature Assumptions
Analysis Matrix • Systems
– Centralized DX Rack System
– Distributed DX System
– Cascade CO2 – (Glycol) MT, CO2 DX LT
– Secondary – (Glycol) MT & (CO2) LT
– Transcritical Booster CO2
• Annual Analysis Based On 5 F Temperature Bins
And 8760 hrs
– Weather Data From National Solar Radiation Atlas. Data is averaged over 30 years (1961 – 1990)
• Locations
– Boston (1)
– Columbus (2)
– St Louis (3)
– Atlanta (4)
– Houston (5)
• Refrigerants
– R404A, R134a, R407A, R410A, CO2
Climate Zones
1
2
3
4
5
Sub
coo
ler
MT Cases
Centralized DX Rack Systems
LT Cases
Ro
of
To
p
Reta
il S
pace
M
ach
ine R
oo
m /
Ho
use
Distributed DX Systems
LT Cases MT Cases
Ro
of
To
p
Reta
il S
pace
M
ach
ine R
oo
m
/ H
ou
se
LT Cases MT Cases
Cascade CO2 Systems
Ro
of
To
p
Reta
il S
pace
M
ach
ine R
oo
m /
Ho
use
CO2 Glycol
LT Cases MT Cases
Secondary Systems
Ro
of
To
p
Reta
il S
pace
M
ach
ine R
oo
m /
Ho
use
Glycol CO2
LT Cases MT Cases
Transcritical Booster CO2 Systems
Ro
of
To
p
Reta
il S
pace
M
ach
ine R
oo
m /
Ho
use
CO2 CO2
LTIndirect
MTIndirect
LTDirect
MTDirect
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000
CentralizedDX Racks
DistributedDX
ParallelSecondary
CompactSecondary
CascadeCO2
Estimated Total Equivalent Warming Impact (TEWI), lbs of CO2/yr)
Base
-46%
-50%
-53%
-57%
System Architecture Can Reduce Equivalent CO2 Emissions By 46 – 57%
• Distributed DX Offers Option w/ Low Energy Consumption & Reasonable Environmental Impact
• Compact Secondary Offers Best Environmental Option With Comparable Energy
•Comparison Contains Multiple Assumptions & Should Be Used For General Comparisons. Emerson Recommends Completing
Similar Analysis On Specific Store Cases Before Making Decisions As Results May Change Based On Store Specifics.
•Fixed Load; US Avg 0.65 kg CO2/kWh; Parameters Held Constant Expect For Architecture.
R404A System Comparison - Boston
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000
DX
DX Distr
Cascade
Secondary
Trans Booster
R4
04
AR
40
4A
R4
04
AR
40
4A
CO
2
lbs CO2/yr
Boston
LT Indirect
MT Indirect
LT Direct
MT Direct
-11%/-50%
+18%/-46%
+20%/-47%
+12%/-52% Power / lbs CO2/yr
Baseline
•Distributed DX Least Power Consumption
•System Architecture Can Reduce CO2 Emissions 46-52%
70 Min Condensing
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000
DX
DX Distr
Cascade
Secondary
Trans Booster
R4
04
AR
40
4A
R4
04
AR
40
4A
CO
2
lbs CO2/yr
Boston
LT Indirect
MT Indirect
LT Direct
MT Direct
R404A System Comparison - Boston
-10%/-52%
+22%/-48%
+24%/-49%
+6.1%/-58%
Baseline
•Lower Condensing Improves Overall LCCP & Power
•Increased Power Relative To Baseline, Except Trans Booster
50 Min Condensing
Power / lbs CO2/yr
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000
DX
DX Distr
Cascade
Secondary
Trans Booster
R4
04
AR
40
4A
R4
04
AR
40
4A
CO
2
lbs CO2/yr
Boston
LT Indirect
MT Indirect
LT Direct
MT Direct
R404A System Comparison - Boston
-11%/-50%
+18%/-46%
+20%/-47%
-9.5%/-61%
Baseline
CO2 Becomes Attractive, But Not Equal Comparison
HFC:70 Min Condensing
CO2: 50 Min Condensing
Power / lbs CO2/yr
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000
DX
DX Distr
Cascade
Secondary
Trans Booster
R4
04
AR
40
4A
R4
04
AR
40
4A
CO
2
lbs CO2/yr
Houston
LT Indirect
MT Indirect
LT Direct
MT Direct
R404A System Comparison - Houston
-10%/-48%
+19%/-42%
+21%/-43%
+19%/-45%
Baseline
70 Min Condensing
Distributed DX Least Power Consumption & Lowest LCCP
Power / lbs CO2/yr
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000
DX
DX Distr
Cascade
Secondary
Trans Booster
R4
04
AR
40
4A
R4
04
AR
40
4A
CO
2
lbs CO2/yr
Houston
LT Indirect
MT Indirect
LT Direct
MT Direct
R404A System Comparison - Houston
-6.1%/-45%
+25%/-39%
+27%/-41%
+22%/-44%
Baseline
50 Min Condensing
•Lower Condensing Improves Overall LCCP & Power
•Increased Power Relative To Baseline, Including Trans Booster
Power / lbs CO2/yr
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000
DX
DX Distr
Cascade
Secondary
Trans Booster
R4
04
AR
40
4A
R4
04
AR
40
4A
CO
2
lbs CO2/yr
Houston
LT Indirect
MT Indirect
LT Direct
MT Direct
R404A System Comparison - Houston
-10%/-48%
+19%/-42%
+21%/-43%
+12%/-48%
Baseline
Trans Booster CO2 Improves In Hot Climates, But Not Equal Comparison
HFC:70 Min Condensing
CO2: 50 Min Condensing
Power / lbs CO2/yr
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000
R404A DX
R407A DX
R134a/R407A DX
R134a/R404A DX
R410A DX
R404A DX Distr
R407A DX Distr
R134a/R407A DX Distr
R134a/R404A DX Distr
R410A DX Distr
R404A Cascade
R407A Cascade
R134a/R407A Cascade
R134a/R404A Cascade
R410A Cascade
R404A Secondary
R407A Secondary
R134a/R407A Secondary
R134a/R404A Secondary
R410A Secondary
CO2 Trans Booster
lbs CO2/yr
LT Indirect
MT Indirect
LT Direct
MT Direct
Refrigerant Comparison - Boston
+1.8%/-26%
+5.5%/-32%
+5.3%/-25%
-11%/-50%
-9.7%/-55%
-12%/-57%
-9.7%/-55%
+18%/-46%
+24%/-45%
+26%/-45%
+26%/-45%
+20%/-47%
+16%/-49%
+20%/-48%
+22%/-47%
+12%/-52%
Baseline
-5.0%/-29%
-9.7%/-55%
+17%/-48%
+20%/-48%
Refrigerants Within
Each Technology
Yield Similar
Results
70 Min Condensing
Power / lbs CO2/yr
0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000
R404A DX
R407A DX
R134a/R407A DX
R134a/R404A DX
R410A DX
R404A DX Distr
R407A DX Distr
R134a/R407A DX Distr
R134a/R404A DX Distr
R410A DX Distr
R404A Cascade
R407A Cascade
R134a/R407A Cascade
R134a/R404A Cascade
R410A Cascade
R404A Secondary
R407A Secondary
R134a/R407A Secondary
R134a/R404A Secondary
R410A Secondary
CO2 Trans Booster
lbs CO2/yr
LT Indirect
MT Indirect
LT Direct
MT Direct
Refrigerant Comparison - Houston
-0.7%/-26%
+2.1%/-31%
+2.0%/-25%
-10%/-48%
-14%/-54%
-11%/-54%
-11%/-53%
+19%/-42%
+20%/-43%
+21%/-43%
+21%/-43%
+21%/-43%
+15%/-46%
+22%/-43%
+21%/-43%
+19%/-45%
Baseline
-8.0%/-29%
-12%/-54%
+15%/-45%
+20%/-44%
Distributed DX
Exhibits Best LCCP
& Efficiency
70 Min Condensing
Power / lbs CO2/yr
Temperature Profile
0
200
400
600
800
1000
1200
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Ho
urs
Boston
0
200
400
600
800
1000
1200
1400
1600
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
Ho
urs
Houston
Maximum Temperature
Determines Peak Power
Consumption
0 50 100 150 200 250 300
R404A DX
R404A DX Distr
R404A Cascade
R404A Secondary
CO2 Trans Booster
KWh
LT Peak Power
MT Peak Power
Peak Energy - Boston
-4.5%
+24%
+40%
Baseline
+19%
CO2 Highest
Peak Energy
*Hottest Average Hourly Temperature Used For Analysis
70 Min Condensing
0 50 100 150 200 250 300
R404A DX
R404A DX Distr
R404A Cascade
R404A Secondary
CO2 Trans Booster
KWh
LT Peak Power
MT Peak Power
Peak Energy - Houston
*Hottest Average Hourly Temperature Used For Analysis
Higher Peak
Energy The
Hotter The
Climate
-2.7%
+26%
+45%
Baseline
+18%
70 Min Condensing
Zone
DX DX Dist Cascade Secondary Transcritical Booster CO2
% Diff lbs
CO2/yr
% Diff Power
% Peak Power KWh
% Diff lbs
CO2/yr
% Diff Power
% Peak Power KWh
% Diff lbs CO2/yr
% Diff Power
% Peak Power KWh
% Diff lbs CO2/yr
% Diff Power
% Peak Power KWh
1 -50 -11 -4.5 -46 +18 +19 -47 +20 +24 -52 +12 +40
2 -50 -11 -4.6 -45 +18 +19 -47 +20 +24 -51 +13 +40
3 -49 -10 +0.7 -44 +19 +19 -46 +20 +31 -49 +16 +51
4 -49 -11 -2.3 -44 +19 +19 -45 +20 +27 -49 +15 +46
5 -48 -10 -2.7 -42 +19 +18 -43 +21 +26 -45 +19 +45
R404A Climate Comparison B
aseli
ne
1
2
3
4
5
Differences Across Regions Are Similar, Except Transcritical
70 Min Condensing
Analysis Summary • System Architecture Affects LCCP And Energy Consumption,
More Than Refrigerant Choice
• Secondary, Distributed DX, CO2 Systems All Reduce LCCP By
About 50% Compared To Large DX HFC
• All DX Systems Are Better Than Secondary For Energy Efficiency
• In The US, Compared At Equal Minimum Condensing
Temperatures, CO2 Trans-Critical Is Not Efficient On An Annual
Basis; Peak Power At Best Is 40% More Than DX-HFC
• Distributed DX System Show Several Advantages – Less Charge,
Less Leak Potential, Less Energy – Both Annual & Peak Load
Next Steps • Continue To Fine Tune Assumptions And Analyze
• Add CO2 Cascade System With DX In Medium Temperature
(R134a) – Used In Europe And Australia
• Analyze Effect Of Heat Reclaim On The Different Systems
• Analyze Systems For Canada (Colder Climates), Europe, Asia
And Latin America
Copeland Scroll K5 Refrigeration Compressor 7.5-15HP New Product Launch
Optimized For Annual Energy Efficiency
Improved Design Results In Increased Refrigeration Uptime
CoreSense Technology Onboard For Enhanced Reliability & Troubleshooting
Redesigned Suction Gas Flow Lowers Oil Circulation
Operational Improvements
U.S. Manufacturing Improves Lead Times
Designed to Maximize Refrigeration Uptime & Efficiency
6.9
7.8
6.0
6.5
7.0
7.5
8.0
ZF33K4E ZF34K5E
LT R404A Weighted EER 0.8*(-25/70 EER)+0.2*(-25/105 EER)
+ 13% 13.9
16.1
12.0
13.0
14.0
15.0
16.0
17.0
ZB75KCE ZB76K5E
MT R404A Weighted EER 0.8*(20/70 EER) + 0.2*(20/120 EER)
+16%
– Discharge Temperature Protection
– Advanced Motor Protection
– Current Sensing Diagnostics
– Remote Communications/Reset
– Compressor Status/Fault History
– Compressor Asset Information
EX-4,5,6,7,8
ZO34 to ZOD104
Copeland
CO2 Subcritical Scroll
4MTL
Emerson
E2
Transcritcal Booster CO2 Copeland
Semi-Hermetic CO2
Emerson Can Provide Complete CO2 Compression Solution
*Small Head Standard (Compactness)
No Change in Connection Points
Modulation Digital Blocked Suction
No Oil Cooler Required
Nameplate Location (Ease Of Application)
High Efficiency With Multi-Refrigerants R404A, R134a, R407A/C, R-22 Future (High P) Refrigerant Capable
New Product Range
1 Stretch Model
CoreSense Protection
Same Footprint
*Tall head for Digital, Unloader & Discus with CoreSense Diagnostics (ISD) models
Standard Sump
Global Design – Leveraged Best Practices From US & Europe Engineering
Service Compatibility – Same Capacities
New 4D & 6D Discus Product Features
Product Selection Software (PSS)
•Key Functionality
•Compressor Performance
•Compressor Selection/Sizing
•Annual Energy Analysis
•Other Features
•Refrigerant Properties
•Psychrometric Properties
•AE Bulletins
•Mechanical/Electrical Drawings
•Walk-In Cooler Load Calculator
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Complete Product Selection & Analysis
Thank You!
