HFC-free refrigeration technology for the retail business in the Netherlands

Transcription

1 HFC-free refrigeration technology for the retail business in the Netherlands (Currently a technical revolution is taking place in the refrigeration industry) BRUNEL University Bart van der Wekken 23rd January 2014

2 2 About Fri-Jado-Retail Fri-Jado-Retail is installing per year about 200 turn-key central refrigeration systems in supermarkets (new and re-modelling). Fri-Jado Service is monitoring about 1000 Dutch supermarkets 24 hours per day and 7 days a week (average supermarket 50 LT/MT objects) In 2007 Fri-Jado introduced an environmentally friendly CO 2 -based refrigeration concept: cascade LT/MT refrigeration systems CO 2 /R134a or CO 2 /R410A (e.g. Albert Heijn (Ahold)) transcritical CO 2 booster LT/MT systems (e.g. C1000, Plus, Deen, Jan Linders, Agrimarkt, Hoogvliet, Sligro, Ahold).

3 3 The vision of Fri-Jado HFC-free refrigeration systems should be: Smaller Simpler Lower energy consumption Lower initial costs Lower maintenance costs Lower Carbon footprint No HFC To be installed all over the world Integrated heat recovery system

4 4 New update of European Regulation 842/2006 on F-gases Phase-down HFC s from 100% in 2015 to 21% in Refill ban virgin refrigerant HFC systems with a GWP>2500 (R404A/R507) per Refilling with recycled refrigerant with a GWP>2500 for small HFC systems until 2030 (R404A/R507 charge<10kg). Ban on new HFC systems with a GWP>2500 from Ban on central refrigeration systems for supermarkets with a cooling capacity > 40 kw and a GWP > 150 per Except cascade systems with a GWP< 1500 in the primary system, Practical consequences: Not wise building new installations with R404A/R507 (GWP>2500) Remodeling: consideration R404A/R507 until Intermediate solution and small systems (Qo<40kW) : LT/MT booster R407F (GWP=1850) Future = CO 2 (GWP=1)

5 5 Natural refrigerants Hydro Carbons (HC: e.g. Propane and Iso-butane) Generally excepted in plug-in refrigeration cabinets/refrigerators (charge < 150 gr.) Market is growing for indirect systems; systems located outdoors High flammability Ammonia (NH 3 ) Well known in industrial refrigeration technology High toxicity Carbon Dioxide (CO 2 ) Retail refrigeration technology High pressure

6 Simplified scheme, CO 2 /R410A Cascade (CO 2 subcritical) All cabinets and evaporators CO 2 Only machineroom R410A or R134a Charge 85% CO 2 and 15% HFC Suitable for hot climates Energy saving 10% compared to HFC s TEWI reduction ca 40%

7 Heat recovery Heat recovery

8 8 Simplified scheme, Transcritical Booster CO 2 Charge 100% CO 2 (HFC-free) Suitable for moderate climates Simple system (compared to cascade) For Dutch climate best solution TEWI reduction up to 45% Energy saving 15%

9 H-log p-diagram 9

10 10 Optimum high pressure Temperature and pressure are in depended from each other Source: Bitzer

11 COP Hours/year 11 COP Comparison Refrigerant system COP year everage Booster R404A 4,0 Booster CO 2 4,7 Booster R404A + heat recovery 3,6 Booster CO 2 + heat recovery 4, Ambient temperature ( C) uren Hours per per jaar year Booster CO2/CO2 Booster R404A Cascade R134a/CO2

12 12 Centralised refrigeration systems for supermarkets Transcritical CO 2 Booster, with LT and MT cabinets, is the best solution for northern Europe (North of Paris) More efficiënt Equal Less efficiënt

13 13 CO 2 Booster for high temperature climates CO 2 booster systems are less efficient at higher ambient temperatures Two solutions: 1. Water spraying (reducing ambient temp. with about 5K, T ambient >28 C ) 2. Additional subcooling system (R134a or HC)

14 14 CO 2 emissions per CO 2 kg/year Dutch supermarket; sales area 1200 m 2 TEWI: GWP refrigerant leakage energy consumption 300, , , , ,000 50,000 0 R404A Booster bij 10% lek leakage CO Booster CO2/CO2 2 Booster 10% leakage Indirect (elektriciteitsopwekking) (electricity) Direct (HFK (HFK-leakage) lekkage)

15 15 Transcritical Booster CO 2 with heat recovery (1 HE) Source: Bitzer

16 Heat recovery: heat exchangers connected up in series 16

17 Heat recovery + heat pump: HE connected up in series 17

18 Calculation model: required heating capacity 18

19 Calculation model: LT & MT refrigeration demand 19

20 Calculation model: available desuper heating 20

21 Calculation model: results 21

22 Calculation model: results 22

23 CO 2 Booster + heat pump: experimental results

24 24 Safety issues for CO 2 installations Cold Cel room verdamper evaporator AKV 10-xx met AKV-spoel 220VDC 18W AKV op EKC414A1 S1 Liquid line Vloeistofleiding zuigleiding Suction line Check valve Terugslagklep S2 S3 Alarm unit Alarm unit Sensor CO2 leak sensor in detector cel Leak detector in coldroom and machineroom Alarm at 0,5% (5000ppm) CO 2 MAC value During an alarm the electronic expansion valve (AKV) is closed and only the refrigerant charge of the evaporater is leaking in to the room +/- 30cm

25 Safety issues Discharge safety valves outside 25

26 26 CO 2 Booster CE/PED certified (module H/H1) PS 30Bar PS 45Bar PS 120Bar

27 3-D Model 27

28 CO 2 Booster 28

29 CO 2 Booster 29

30 13 december CO 2 Booster + Heat pump (R134a) + subcooling (R134a) CO 2 Booster + R134a HP

31 CO 2 installations, Fri-Jado 1. Jan Linders, Venlo (Oktober 2009) 2. C1000, Leiderdorp (Mei2010) 3. Plus, Stellendam (Juni 2010) 4. Jan Linders, Deurne (Juli 2010) 5. Coop, Nijmegen (Juli 2010) 6. Plus, Benschop (Augustus 2010) 7. C1000, Spijkenisse (Augustus 2010) 8. Jan Linders, Sint Anthonis (September 2010) 9. Ahoy, Rotterdam (September 2010) 10. Plus, Den Hoorn (Oktober 2010) 11. C1000 van Garderen, Almere-Buiten (Oktober 2010) 12. Agrimarkt, Middelharnis (November 2010) 13. Deen, Wieringerwerf (November 2010) 14. C1000, Hoogezand (December 2010) 15. Jan Linders, Nuenen (Februari 2011) 16. Jan Linders, Herten (Februari 2011) 17. COOP, Ameide (April 2011) 18. Jan Linders, Wijchen (Mei 2011) 19. Dirk van den Broek, Goes (Mei 2011) 20. Bas van der Heijden, Bolnes (Augustus 2011) 21. Plus, Delft (Augustus 2011) 22. C1000, Bergen op Zoom (September 2011) 23. Jan Linders, Klimmen (September 2011) 24. Deen Uithoorn, (Oktober 2011) 25. Plus, Eindhoven (Oktober 2011) 26. Em-Té, Enschede (December 2011) 27. Em-Té, Rijssen (Februari 2012) 28. Dirk van den Broek, Amersfoort (Februari 2012) 29. Hoogvliet, Ede (April 2012) 30. COOP, Eemnes (Juni 2012) 31. Jan Linders, Nijmegen (Mei 2012) 32. Agrimarkt, Oud Beierland (Augustus 2012) 33. Albert Heijn, Amersfoort (Oktober 2012) 34. Deen, Purmerend (Februari 2013) 35. Plus, Margraten (Juni 2013) 36. Jumbo Oegstgeest (Sept. 2013) 37. Jumbo Breukelen (Sept 2013) 38. Hoogvliet Alphen a/d Rijn (Aug 2013) 39. Hoogvliet Bilthoven (Sept 2013) 31

32 32 Conclusions Transcritical CO 2 Booster best solution for HFC-free refrigeration technology in the retail. Up to 15% less energy consumption Up to 45% TEWI reduction Suitable for heat recovery Initial costs higher compared to HFC technology With increasing market share costs of CO 2 components will decrease