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(R)evolutions in refrigeration. Matthew... · Choosing a refrigeration system in a post R22 world....
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(R)evolutions in refrigeration. Can we make things cold without turning up the heat? EMANZ 2016 Matthew Darby
Transcript of (R)evolutions in refrigeration. Matthew... · Choosing a refrigeration system in a post R22 world....
(R)evolutions in refrigeration. Can we make things cold without turning up the heat?
EMANZ 2016 Matthew Darby
(R)Evolutions In Refrigeration
The Past: Evolutions of a Revolution
The Present: Retain, Retrofit or Replace?
Putting in Practice
Practical Steps
The Near Future: The Supermarket of Tomorrow
Today.
The (R)evolution to come.
Matthew Darby
The Past Evolutions of a revolution
3
EcoChill 4
1748 1805
1850- 1870
1914 1920/ 30s
Evolution of Refrigeration
1000 BC
REVOLUTION EVOLUTION
The Present
5
In NZ the phase out of HCFC refrigerant and regulatory pressure is currently the single biggest issue for refrigeration …
EcoChill 6
1987
Montreal Protocol established
1996
NZ implements Ozone Layer Protection Act & Regulations
2010
New HCFC Imports reduced on yearly basis by 63%
2015 NO new HCFC’s imported: R22
Montreal Protocol -impact on synthetic refrigerants.
NOT A USE BAN
When it comes down to it there are 3 real options…
EcoChill 7
Retain
Keep R22 system
Retrofit
Keep plant and replace with a synthetic refrigerant
Replace
Build new plant with synthetic or natural refrigerant
Capital Cost
Low
Strategy
Low
Capital Cost
Med
Strategy
Med - High
Capital Cost
Med -High
Strategy
High
Safety
Performance
Economics
Environment
Retrofit or Replace: Choosing a Refrigerant
EcoChill 8
REFRIGERANT SELECTION
Toxicity, Flammability
Working Pressures
Physical Properties
Energy
Technology Changes
Energy Efficiency
Ozone (ODP)
Climate (GWP/ TEWI)
Retrofit or Replace: Changing Refrigerants
Synthetic
CFC’s (Phased Out)
HCFC (Importation
Ban)
HFC’s
HFO’s
Natural
Ammonia
CO2
HC
Water
Air
EcoChill 9 Secondary Systems
Commercially viable
Retrofit or Replace Refrigerant: Synthetics
Ref. Safety Performance Economics* Environment GWP (100Y)
404A $49 kg 3922
438A $72 kg 2264
407F $30 kg 1824
134A $24 kg 1430
EcoChill 10
Generalized market prices April 2016
Legend 0 = Poor 1 = OK 2= Good 3 = Excellent
Replace Refrigerants: Naturals
Ref. Safety Performance Economics* Environment GWP (100Y)
EcoChill 11
$6.50 kg 1
3
0
$ 82 kg
$14 kg
CO2 (R744)
Ammonia (R717)
HC /mix (e.g.
R290)
Generalized market prices April 2016
Legend 0 = Poor
1 = OK 2= Good
3 = Excellent
Globally synthetic F-Gas
refrigerants are facing
ongoing regulation and
phase down… EcoChill 12
The Move Away from HFC’s
1987
Montreal Protocol
CFCs banned.
2005 Kyoto Protocol
Green house Gas Emissions regulated.
HCFCs banned.
2014 North American Amendment to Montreal Protocol HFCs phase down starts.
2015 EU F- Gas Regulations HFCs phase down starts.
UN FCCC France 2016
Global commitment to
do more to control SGG’s &
scale up activity
Replace Refrigerant: Alternatives – HFO 1234yf
Safety Low toxicity (?),
flammable
Performance
No known cool store sites within
NZ
Economics Not currently
available
Enviro. (GWP 100Y)
4
EcoChill 13
“No known
coolstore
installs.”
HFO 1234yf
Replace Systems: CO2
Advantages
• Uses a single refrigerant.
• Greatly increased energy efficiency.
• Low cost of CO2.
• Safe refrigerant.
• Environmentally good choice.
Disadvantages
• Requires specific knowledge and skill to install and maintain.
• Capital and servicing costs (though gap closing).
EcoChill 14
“Becoming more viable:
situation specific.”
Replace Refrigeration Systems: Standard Secondary
EcoChill Diagram courtesy of water-food.com 15
• Reduce amount of primary stage refrigerant. • Reduce leakage rate of primary stage refrigerant. • Reduced primary system size. • Easier maintenance.
Why? • Smaller primary circuit
compared to DX. • Uses a secondary fluid as
main cooling medium.
What?
Replace Refrigeration Systems: Advanced Secondary
EcoChill Diagram courtesy of water-food.com 16
Features Standard Secondary Advanced Secondary
Expansion Valves Typically Mechanical Electronic
Capacity Control Typically Unloaders VSD
Primary Circuit Size Typically Larger Optimised for Critical
Charge
Primary Refrigerant Quantity
Typically Higher Minimised through design
Replace: Advancements in Secondary Systems
• Reduced refrigerant charge • Increased energy efficiency • Increased system reliability • Reduced operating costs • Reduced stored product risk • Guaranteed system safety and
compliance
EcoChill 17
Operational Trends
EcoChill 18
Safety
Charge minimisation,
user error
Energy Efficiency
System, & operational
Retail efficiencies
Space, versatility,
longevity, food trends.
Electronics & Computing
Remote control & maintenance,
data.
Integration
Turners & Growers: Putting refrigeration to work
19
Problems • Old R22 systems
• Want to reduce running costs
• Looking for added value
EcoChill 20
Solution • Reengineered precooling
• Refurbished R22 coolstores to optimal conditions
• Built new coolstore, same footprint as existing R22
• EcoChill Kiwi using HC/ Glycol Advanced System design.
Kerifresh images courtesy Kerifresh.co.nz
EcoChill 21
Store capacity (Pallets)
Cost to Cool (Per Pallet/
Day
% improvement
R22 840 $0.34 Baseline
EcoChill 864 $0.25 36%
Result:
“36% saving on
energy costs while
cooling more
pallets”
EcoChill 22
948
1,173
1,568
1,119 1,228
R290 R22 R404A / R507
R134A R407f
Tons of CO2 over 15 years
Total Equivalent Warming Impact (TEWI) “225
tonnes of
CO2 saved or the yearly
emissions
from 43
cars.”
EcoChill 23
19%
-34%
5%
-5% R290 R404A / R507 R134A R407f
R290 R404A / R507 R134A R407f
R22
TEWI:
“EcoChill
19%
better
than an
R22
system ”
Total Equivalent Warming Impact versus R22
EcoChill 24
Refrigerant Costs by Comparison
164 490 270 300
3,280
9,800
5,400 6,000
40
200
225
200
0
50
100
150
200
250
$0
$2,000
$4,000
$6,000
$8,000
$10,000
$12,000
R290 R404A / R507 R134A R407f
Annual Leakage Rate 5% Initial System Charge Charge kg
EcoChill 25
Maintaining Optimal Conditions
• Pack
• Precool
• Uniform Temperature
• High Room Humidity
• No Air Temp Variations
• Energy Efficient
• Low Maintenance
• Increased margin
• Higher “vine to table” volumes
“Refrigeration:
providing
competitive
advantage.”
Zespri images courtesy zespri.com
Practical Steps
26
Ass
ess
• Audit - Quantity - Leakage - Age - Loads - Design
• Capture
Ide
nti
fy
• Decision criteria - Performance - Design - Investment - Regulatory - Cost - Competitive advantages
• Limitations
• Budget & timing
Se
lect
• Best option
• Complete
• Verify
Making A Decision
EcoChill 27
Decision Process
Working With Your Refrigeration Partner
EcoChill 28
Expertise Reliability
Safety Licensed
Experience Energy Efficiency Service Offering
Product Offering (Parts) CCCA/ IRHACE / EECA members
R22 – Ask How It’s Disposed.
• Response to public and legislative
concern - refrigerant industry set up
the Refrigerant Recovery Trust.
• Not for profit that collects a levy on
SGG’s purchases - pays for disposal/
ensures not released into the
atmosphere.
• Illegal to knowingly release R22 into
the environment when servicing,
maintaining or disposing of
refrigeration & AC plant and
equipment.
• Fines of up to $100,000.
• More information on obligations:
www.epa.govt.nz
EcoChill 29
www.RefrigerantRecovery.co.nz
The (Near) Future
30
Coop, MIT, Arneg Collaboration – The Supermarket of the Future.
The Future
32
The Next R(evolution) in Refrigeration
Alternatives
Electro-caloric
Magnetic Sonic Hydraulic Optical Cooling
Acoustic
EcoChill 33
EcoChill 34
Electrolux Design Lab - Yuriy Dmitriev
EcoChill 35
Real time monitoring AND servicing. Self service.
First line of site assessments.
Virtual servicing.
System immersion – design and service.
Virtual design – global teams.
EcoChill 36
www.ecochill.kiwi
QUESTIONS?
