4-Bart van der Wekken - HFC-free refrigeration technology in

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
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 CO2-based
refrigeration concept:
2007-2011
–
80 cascade LT/MT refrigeration systems CO2/R134a or CO2/R410A
(e.g. Albert Heijn (Ahold)).
2009-2013
– 50 transcritical CO2 booster LT/MT systems (e.g. C1000, Plus,
Deen, Jan Linders, Agrimarkt, Hoogvliet, Sligro, Ahold).
·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
New update of European Regulation 842/2006 on F-gases
•
Phase-down HFC’s from 100% in 2015 to 21% in 2030.
•
Refill ban virgin refrigerant HFC systems with a GWP>2500 (R404A/R507)
per 1-1-2020.
•
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 1-1-2020
•
Ban on central refrigeration systems for supermarkets with a cooling
capacity > 40 kW and a GWP > 150 per 1-1-2022. 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 2020.
•
Intermediate solution and small systems (Qo<40kW) : LT/MT booster R407F
(GWP=1850)
•
Future = CO2 (GWP=1)
·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 (NH3)
•
Well known in industrial refrigeration technology
•
High toxicity
Carbon Dioxide (CO2)
•
Retail refrigeration technology
•
High pressure
Simplified scheme , CO2/R410A Cascade (CO2 subcritical)
• All cabinets and evaporators CO2
• Only machineroom R410A or R134a
• Charge 85% CO2 and 15% HFC
• Suitable for hot climates
• Energy saving 10% compared to HFC’s
• TEWI reduction ca 40%
Heat recovery
Heat recovery
·8
Simplified scheme, Transcritical Booster CO2
•Charge 100% CO2 (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
· 10
Optimum high pressure
Temperature and pressure are in depended from each other
Source: Bitzer
· 11
COP Comparison
7.5
Refrigerant system
COPyear everage
Booster R404A
4,0
Booster CO2
4,7
Booster R404A + heat recovery
3,6
Booster CO2 + heat recovery
4,0
500
450
6.5
400
350
Hours/year
5.5
COP
300
4.5
250
200
3.5
150
100
2.5
50
1.5
0
Ambient temperature (°C)
uren
perper
jaaryear
Hours
Booster CO2/CO2
Booster R404A
Cascade R134a/CO2
· 12
Centralised refrigeration systems for supermarkets
Transcritical CO2 Booster, with LT and MT cabinets, is
the best solution for northern Europe (North of Paris)
More efficiënt
Equal
Less efficiënt
· 13
CO2 Booster for high temperature climates
CO2 booster systems are less
efficient at higher ambient
temperatures
Two solutions:
1.
Water spraying (reducing
ambient temp. with about 5K,
Tambient>28°C )
2.
Additional subcooling
system (R134a or HC)
· 14
CO2 emissions per CO2 kg/year
Dutch supermarket; sales area 1200 m2
TEWI:
• GWP refrigerant
• leakage
• energy consumption
300,000
250,000
200,000
150,000
100,000
50,000
0
R404ABooster
Booster bij10%
10% lek
R404A
leakage
CO2 BoosterBooster
10% CO2/CO2
leakage
Indirect
(elektriciteitsopwekking)
Indirect
(electricity)
Direct
lekkage)
Direct(HFK
(HFK-leakage)
· 15
Transcritical Booster CO2 with heat recovery (1 HE)
Source: Bitzer
· 16
Heat recovery: heat exchangers connected up in series
· 17
Heat recovery + heat pump: HE connected up in series
· 18
Calculation model: required heating capacity
· 19
Calculation model: LT & MT refrigeration demand
· 20
Calculation model: available desuper heating
· 21
Calculation model: results
· 22
Calculation model: results
· 23
CO2 Booster + heat pump: experimental results 2013
· 24
Safety issues for CO2 installations
AKV 10-xx met AKV-spoel 220VDC
AKV
18W
op EKC414A1
verdamper
Cold Cel
room
evaporator
S1
Vloeistofleiding
Liquid line
zuigleiding
Suction line
Check valve
Terugslagklep
S2
S3
Alarm
unit unit
Alarm
•
•
•
Sensor
leak sensor
CO2
detector
in
de cel
+/- 30cm
Leak detector in coldroom and machineroom
Alarm at 0,5% (5000ppm) CO2 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
Safety issues
Discharge safety valves outside
25
· 26
CO2 Booster CE/PED certified (module H/H1)
PS 30Bar
PS 45Bar
PS 120Bar
· 27
3-D Model
· 28
CO2 Booster
· 29
CO2 Booster
13 december 2012 · 30
CO2 Booster + Heat pump (R134a) + subcooling (R134a)
CO2 Booster + R134a HP
CO2 installations, Fri-Jado
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
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25.
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27.
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29.
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31.
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33.
34.
35.
36.
37.
38.
39.
Jan Linders, Venlo (Oktober 2009)
C1000, Leiderdorp (Mei2010)
Plus, Stellendam (Juni 2010)
Jan Linders, Deurne (Juli 2010)
Coop, Nijmegen (Juli 2010)
Plus, Benschop (Augustus 2010)
C1000, Spijkenisse (Augustus 2010)
Jan Linders, Sint Anthonis (September 2010)
Ahoy, Rotterdam (September 2010)
Plus, Den Hoorn (Oktober 2010)
C1000 van Garderen, Almere-Buiten (Oktober 2010)
Agrimarkt, Middelharnis (November 2010)
Deen, Wieringerwerf (November 2010)
C1000, Hoogezand (December 2010)
Jan Linders, Nuenen (Februari 2011)
Jan Linders, Herten (Februari 2011)
COOP, Ameide (April 2011)
Jan Linders, Wijchen (Mei 2011)
Dirk van den Broek, Goes (Mei 2011)
Bas van der Heijden, Bolnes (Augustus 2011)
Plus, Delft (Augustus 2011)
C1000, Bergen op Zoom (September 2011)
Jan Linders, Klimmen (September 2011)
Deen Uithoorn, (Oktober 2011)
Plus, Eindhoven (Oktober 2011)
Em-Té, Enschede (December 2011)
Em-Té, Rijssen (Februari 2012)
Dirk van den Broek, Amersfoort (Februari 2012)
Hoogvliet, Ede (April 2012)
COOP, Eemnes (Juni 2012)
Jan Linders, Nijmegen (Mei 2012)
Agrimarkt, Oud Beierland (Augustus 2012)
Albert Heijn, Amersfoort (Oktober 2012)
Deen, Purmerend (Februari 2013)
Plus, Margraten (Juni 2013)
Jumbo Oegstgeest (Sept. 2013)
Jumbo Breukelen (Sept 2013)
Hoogvliet Alphen a/d Rijn (Aug 2013)
Hoogvliet Bilthoven (Sept 2013)
31
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Conclusions
Transcritical CO2 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 CO2
components will decrease

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