NH3/CO2 Refrigeration System “NewTon”
- Energy Conservation -
Nov. 2013 (O)
Mayekawa Mfg.Co.,Ltd. “MYCOM”
JAPAN
2
Global Environment Issues
Ozone Depletion Global Warming
Montreal Protocol
CFC :banned in 1996
HCFC:Limited from 2004
To...
3
3
Refrigerant
(Natural Five)
NH3
Ammonia
CO2
Carbon Dioxide
HC
Hydro Carbon
H2O
Water
Air
Notes ・Conventional
system
・Ec...
4
Natural Five Applications
90℃
CO2hot water
NH3 Chiller
7℃
NH3 Brine chiller
NH3+CO2
-5℃
-25℃
-65℃
AIR
Ice bank system
NH...
The construction of giant NH3 refrigeration plants presents various problems.
1. Reduction of skilled engineer to design, ...
Ideal Refrigeration Cycle
Single Stage compression Tow Stage compression Cascade Refrigeration
p-h chart
Flow
diagram
COP
...
Comparison of theoretical COP
0
1
2
3
4
5
6
7
8
-60 -40 -20 0 20
COP(-)
TE (℃)
NH3 Single
NH3 Two Stage
NH3/CO2 Cascade
Evap.
NH3
Cond.
Water CO2
Out door NewTon Cold Storage
Cooler
CT
NH3 Package
・New Screw compressor
・Semi-hermetic IPM moto...
9
NH3 New Screw Compressor
Two stage compound Screw
Semi-hermetic IPM Motor
10
High Efficiency Motor(IPM motor)
- Semi-Hermetic for NH3 -
Conventional
IPM motor 回転子
Benefits of IPM motor
・ 5~10% bet...
11
New rotor profile and
Double economizer system
Booster High stage
Condenser
Evap.
Inter coolerBooster Economizer
Double...
New type of Heat Exchanger
S&T
S&P
NH3液
NH3ガス
CO2液
CO2ガス
NH3液
NH3ガス
CO2ガス
CO2液
S&T S&P Improve
Volume (m3) 0.689 0.269 -39...
Flash tank type Economaizer
【conv. 】 【New 】
コンデンサ
中間 エコノマイザ
CO2液化器
ΔT=3.6 ΔT=3.4
コンデンサ
中間 エコノマイザ
CO2液化器
Pd
Pm
Pe
Ps
Subc...
[Compressor]
Oil Separator
High P&T Gas
and Oil
High Pressure gas
[Condenser]
High P Liquid
Inter Cooler
Economizer
Booste...
Main Installations of NewTon
User tons Newton sets installed
Nissui Logistics kawasaki 14,000 ton 3 2008
Igarashi reizo Hi...
0
500
1,000
1,500
2,000
Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec.
PowerConsumptionx1000(kWH)
Refrigeratio...
Specific Power Consumption in Cold Storage
SPC = PCy/Vc
where:
SPC : Specific Power Consumption (kWH/year/m3)
PCy : Annual...
Specific Power Consumption in Cold Storage
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
180.0
0 50,000 100,000 150,000 ...
Customer
Volume Age
Refrigerant formerly
used
Power
reduction
(m3) (year) Refrig. Comp. (%)
Tokyo Toyomi 45,000 29 HCFC-22...
20
F1610C-8sets
HCFC-22 DX
NewTon 3000-8stes
NH3/CO2
Tokyo Toyomi Reizo (Funabashi) “Renewal”
Storage volume :45,000 m3
(a...
Comparison of Power Consumption in Freezer
FLoFREEZE Existing Compressor NewTon
Dice Potato
HCFC-22
(F2016C)
NewTon Power ...
Energy Efficiency Factor for Freezer
EEF = (LCt/Wa)∙Kca
where:
EEF: Energy Efficiency Factor for Freezer system
LCt: Requi...
Energy Efficiency Factor for Freezer
Dice Potato
Size
(mm)
HCFC-22
(F2016C)
NewTon Ratio
4.8x4.8x4.8 0.415 0.622 1.50
10x1...
Energy Efficiency Factor for Freezer
Salmon
Ref.
System
Inlet
temp.
Outlet
temp.
Ambient
Temp.
Power
consumption
EEF
HCFC-...
Demonstration Site:
PT.ADIB Global Supplies
Energy Efficient Refrigeration Technology
Entity:
Mayekawa Mfg CO. Ltd
Project...
PCAS Server Newton Monitor
Local Office
No.1
No.2
No.3 NTT docomo
FOMA Network
NewTon
Observation
・Data Logging
・Daily Che...
PCAS Server
Trend Data
Current Operating
Conditions
Set point Data
Trend Diagnosis and Management
COP ratio
Comp. Vibration
Approach Temp. of Cond.
Comparison of ph-diagram between actual /...
Mycom Moriya Plant
NTT Docom
Network
PCAS Global Network
Mega NewTon
NewTon R-8000 120kW
NewTon F-800 100kW
Use Model Remarks
Cold
Storage
-25C NewTon R-3000, R-6000, R-8000 RT : -25℃
0 C NewTon C platform
Freezer NewTon F-300, F-...
NewTon Technical Data
Model Capacity
*1)
Power*1)
NH3
Charge
L x W x H Weight Use
R-3000 94.5 43.0 25 2.8 x 2.0 x 2.4 3,30...
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New ton presentation_c

  1. 1. NH3/CO2 Refrigeration System “NewTon” - Energy Conservation - Nov. 2013 (O) Mayekawa Mfg.Co.,Ltd. “MYCOM” JAPAN
  2. 2. 2 Global Environment Issues Ozone Depletion Global Warming Montreal Protocol CFC :banned in 1996 HCFC:Limited from 2004 Totally Banned in 2020 Kyoto Protocol Reduction of global warming gas by 6% from 1990 level in the frist period of 2008 ~2012). HFC are the target Freon Recycling Law: CFC,HCFC,HFC PRTR Law (chemical gas): HCFC22,HCFC123, Ethylene glycol, etc. Introduction of Environment Tax, Freon Tax to industries Demand for use of Natural Refrigerant has increased
  3. 3. 3 3 Refrigerant (Natural Five) NH3 Ammonia CO2 Carbon Dioxide HC Hydro Carbon H2O Water Air Notes ・Conventional system ・Eco-Cute ・Nat’l Proj. ・Butane + Propane ・Nat’l Proj. ・Adsorption ・Heat Recov. ・Nat’l Proj. ・Air-cycle 90℃ 60℃ 10℃ -15℃ -25℃ -40℃ -50℃ -60℃ -100℃ Utility hot water Cold storage, Freezer, Fish boat Specific Refrigeration needs Freezer, Freezed-dry, Super Low temp storage Cryogenics Utility hot water Heating HVAC ChillerChilled water Ice making Utility hot water Heating Chilled water Ice making Heat recovery ・National Projects
  4. 4. 4 Natural Five Applications 90℃ CO2hot water NH3 Chiller 7℃ NH3 Brine chiller NH3+CO2 -5℃ -25℃ -65℃ AIR Ice bank system NH3/Brine chiller Air conditionimg Expo Aichi National Museum Logistic centre Museum NH3 Heat pump゚ 50℃ Golf Club Eco kyuto Air conditioning Heating Cold strage NewTon3000 (NH3/CO2) Tuna warehouse SF class Air cycle
  5. 5. The construction of giant NH3 refrigeration plants presents various problems. 1. Reduction of skilled engineer to design, to construct NH3 plants. 2. Risks of perspective of costs, time, and quality. 3. Large NH3 Charge makes higher risk of accident. 4. Need of many workers and equipments for maintenance. One solution is to use a “prefabricated package.” 1) The NH3 refrigeration cycle is completed at our factory, tested, adjusted before shipping. 2) The package is standardized and built to the same package everywhere. 3) The onsite construction time is shortened because only minimal piping and wiring is required. 4) The amount of NH3 charging is minimized and is completely automatic control. 5) The capacity of compressor is optimized to load of plant, allowing for increased energy savings The Problems and Solutions Facing Giant NH3 Plants
  6. 6. Ideal Refrigeration Cycle Single Stage compression Tow Stage compression Cascade Refrigeration p-h chart Flow diagram COP h 1 2 3 4 h3,h4 p h1 h2 1 2 3 4 h4,h3 h p 5 6 h1 h5 h2 h6 GM GL 1 23 4 h3,h 4 h p 5 6 7 8 h7,h 8 h1 h5 h2 h6 GL GH 41 2 3 Expansion Valve Condenser Evaporator Compressor 41 6 3 Condenser Evaporator Expansion Valve High Stage Compressor Inter Cooler 5 2 Expansion ValveBooster Compressor 1 6 3 Expansion Valve Condenser Evaporator High Side Compressor 8 2 Cascade Condenser 4 7 5 Low Side Compressor Expansion Valve COP 12 41 hh hh COP    )0.1( )56)(()12( )41(     GL hhGMGLhhGL hhGL COP )0.1( )56()12( )41(     GL hHGHhhGL hhGL COP
  7. 7. Comparison of theoretical COP 0 1 2 3 4 5 6 7 8 -60 -40 -20 0 20 COP(-) TE (℃) NH3 Single NH3 Two Stage NH3/CO2 Cascade
  8. 8. Evap. NH3 Cond. Water CO2 Out door NewTon Cold Storage Cooler CT NH3 Package ・New Screw compressor ・Semi-hermetic IPM motor ・Flooded Evaporator ・Double economizer ・Automatic operation CO2 brine ・Safety ・Low pump power ・No trouble by oil ・High heat transfer Water cooled ・Energy saving ・NH3 charge min. ・Free layout ・Easy Maintenance 「Safety」 「Energy saving」 「Easy maintenance」 Basic Concept of NewTon
  9. 9. 9 NH3 New Screw Compressor Two stage compound Screw Semi-hermetic IPM Motor
  10. 10. 10 High Efficiency Motor(IPM motor) - Semi-Hermetic for NH3 - Conventional IPM motor 回転子 Benefits of IPM motor ・ 5~10% better in efficiency ・ 40% smaller in size ・ High speed is possible
  11. 11. 11 New rotor profile and Double economizer system Booster High stage Condenser Evap. Inter coolerBooster Economizer Double Economizer Features ・High efficiency: Less gas leakage ・Quiet: Low noise, low vibration ・High reliability: Use of proven bearings
  12. 12. New type of Heat Exchanger S&T S&P NH3液 NH3ガス CO2液 CO2ガス NH3液 NH3ガス CO2ガス CO2液 S&T S&P Improve Volume (m3) 0.689 0.269 -39% Space (m2) 1.57 0.49 -31% Approach temp.(K) 3.0 1.7 (COP:+4%) Comparison of Evaporator
  13. 13. Flash tank type Economaizer 【conv. 】 【New 】 コンデンサ 中間 エコノマイザ CO2液化器 ΔT=3.6 ΔT=3.4 コンデンサ 中間 エコノマイザ CO2液化器 Pd Pm Pe Ps Subcool :5deg up Refrigeration effect : 2% up
  14. 14. [Compressor] Oil Separator High P&T Gas and Oil High Pressure gas [Condenser] High P Liquid Inter Cooler Economizer Booster [Evaporator] CO2 Liquid CO2 Gas Low P&T Gas Low T Liquid
  15. 15. Main Installations of NewTon User tons Newton sets installed Nissui Logistics kawasaki 14,000 ton 3 2008 Igarashi reizo Hidaka 15,000 ton 4 2008 Toyo suisan Nagoya 32,000 ton 9 2009 Kowa reizou Nagoya 8,500 ton 4 2009 Coop Tosu 50,000 ton 12 2009 Hosui Atsugi 8,000 ton 2 2010 Yokohama reito Osaka 27,000 ton 8 2011 Matsuoka Kawasaki 80,000 ton 11 2013 Nisui Log. /Kawasaki Igarashi/Hidaka LCC Kowa reizo/ Nagoya Yokohama reizo/Osaka COOP/Tosu Log. Toyo suisan /Nagoya Matsuoka/Kawasaki 500 are running
  16. 16. 0 500 1,000 1,500 2,000 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. PowerConsumptionx1000(kWH) Refrigeration Elevator, Light Office Electric Power Usage in Cold Storage Refrigeration:65%, Elevator, Light:30%, Office:5%
  17. 17. Specific Power Consumption in Cold Storage SPC = PCy/Vc where: SPC : Specific Power Consumption (kWH/year/m3) PCy : Annual Power Consumption (kWH/year) Vc : Cold Storage Volume (m3) * PCy is the total power consumption which includes refrigeration system, elevator, light and office. Definition of “SPC”
  18. 18. Specific Power Consumption in Cold Storage 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 0 50,000 100,000 150,000 200,000 250,000 300,000 SpecificPowerConsumption(kWH/m3/year) Storage Volume (m3) HCFC-22 NewTon (NH3/CO2) NH3/Brine
  19. 19. Customer Volume Age Refrigerant formerly used Power reduction (m3) (year) Refrig. Comp. (%) Tokyo Toyomi 45,000 29 HCFC-22 Screw 31.1 Niigata Reizo 10,000 33 HCFC-22 Recip. 41.2 QP “Kewpie” 16,250 27 HCFC-22 Recip. 24.9 Sensui Reizo 6,125 38 HCFC-22 Screw 29.3 Ajinomoto 7,500 25 HCFC-22 Recip. 28.0 Gliko 30,000 30 HCFC-22 Screw 19.8 Showa Reizo 32,500 22 HCFC-22 Recip. 28.0 AMB Funabashi 30,000 25 NH3/Brine Recip. 34.0 Power reduction through renewal with NewTon
  20. 20. 20 F1610C-8sets HCFC-22 DX NewTon 3000-8stes NH3/CO2 Tokyo Toyomi Reizo (Funabashi) “Renewal” Storage volume :45,000 m3 (average reduction -31.1%)
  21. 21. Comparison of Power Consumption in Freezer FLoFREEZE Existing Compressor NewTon Dice Potato HCFC-22 (F2016C) NewTon Power reduction (mm) (kWH/ton) ( - ) 4.8x4.8x4.8 200.0 133.5 0.333 10x10x10 146.2 109.0 0.254 15x15x15 174.9 122.1 0.302
  22. 22. Energy Efficiency Factor for Freezer EEF = (LCt/Wa)∙Kca where: EEF: Energy Efficiency Factor for Freezer system LCt: Required Total Cooling Load LCt = LC1 + LC2 + LC3 LC1 : Cooling down load before freezing LC2 : Freezing load LC3 : Cooling down load after freezing Wa: Actual Power consumption on Compressor Kta: Calibration of ambient temperature Definition of EEF 0.60 0.80 1.00 1.20 1.40 1.60 0 10 20 30 40 50 Kca(-) Ambient temperature (degree C) Kca is “theoretical COP ratio” based ambient temperature 25 degree C.
  23. 23. Energy Efficiency Factor for Freezer Dice Potato Size (mm) HCFC-22 (F2016C) NewTon Ratio 4.8x4.8x4.8 0.415 0.622 1.50 10x10x10 0.568 0.761 1.34 15x15x15 0.475 0.680 1.43 Operating conditions 1) Inlet/Outlet temperature of dice potato : 25/-18 (degree C) 2) Specific heat of potato, before/after freezing : 0.813 / 0.407 (kcal/kgK) 3) Ambient temperature : 25 (dgree C)
  24. 24. Energy Efficiency Factor for Freezer Salmon Ref. System Inlet temp. Outlet temp. Ambient Temp. Power consumption EEF HCFC-22 9.0 -10.0 10.0 85.7 0.577 NewTon 10.0 -8.5 18.5 77.5 0.773 (unit) (degree C) (kWH/ton) ( - ) •NewTon shows 33% higher EEF than HCFC-22 system. * Existing HCFC-22 system is dry expansion type air cooler.
  25. 25. Demonstration Site: PT.ADIB Global Supplies Energy Efficient Refrigeration Technology Entity: Mayekawa Mfg CO. Ltd Project site Energy Consumption reduction 570,000 kwh /year ・MOEJ introduce the Energy Efficient Refrigeration Technology of “NewTon” as Japanese Good Practices. Joint Crediting Mechanism Host Country : Indonesia “NewTon” for ASEAN A cold storage warehouse nearby Jakarta This project was funded by the MOEJ in FY 2013 as the 1st project to Joint Crediting Mechanism . P.T. ADIB JCM Project for Cold Chain Industry in Indonesia with “NewTon” CO2 Coldwater Cealedchiller 100 ton NH3/CO2 Fridge NewTon R-6000 Defrost water tank 10m3 Defrost water Chiller (Cooler) 6 units Thermo shutter 3 units Defrost water (heatup heat exchanger) RefrigeratorA(-25℃) RefrigeratorB(-25℃) RefrigeratorC(-25℃) Machine room Freight handling “1st NewTon system” will be installed to P.T. ADIB Global Food Supplies in Indonesia. NewTon R-6000 Most advanced Japanese energy efficient non-fluorocarbon cooling system http://www.env.go.jp/en/earth/ozone/goodpractice/full.pdf Estimated GHG reductions Without consideration of HFC leakage emissions: 213 (tCO2/year) With consideration of HFC leakage emissions: 902 (tCO2/year)
  26. 26. PCAS Server Newton Monitor Local Office No.1 No.2 No.3 NTT docomo FOMA Network NewTon Observation ・Data Logging ・Daily Checking Out work by mechanics ・Checking ・Precise Diagnosis ・Repair, Recover Remote Monitor ・Operating Data ・Alarm Data ・Mailing of Alarm Diagnosis ・Pre-Diagnosis ・Trend Management ・Trouble Analysis ・Monthly Report Minimize Daily Works Reliable Maintenance Brush-up Further Improvement User LAN NTT FOMA Mycom LAN Moriya Plant User
  27. 27. PCAS Server Trend Data Current Operating Conditions Set point Data
  28. 28. Trend Diagnosis and Management COP ratio Comp. Vibration Approach Temp. of Cond. Comparison of ph-diagram between actual / design conditions
  29. 29. Mycom Moriya Plant NTT Docom Network PCAS Global Network
  30. 30. Mega NewTon NewTon R-8000 120kW NewTon F-800 100kW
  31. 31. Use Model Remarks Cold Storage -25C NewTon R-3000, R-6000, R-8000 RT : -25℃ 0 C NewTon C platform Freezer NewTon F-300, F-600, F-800 RT:-35℃ Skate Rink NewTon S NewTon Lineup NewTon R-3000, NewTon F-300 NewTon C, NewTon S 31
  32. 32. NewTon Technical Data Model Capacity *1) Power*1) NH3 Charge L x W x H Weight Use R-3000 94.5 43.0 25 2.8 x 2.0 x 2.4 3,300 Cold StorageR-6000 189 86.0 50 4.8 x 2.4 x 2.6 6,800 R-8000 270 120 75 4.0 x 2.6 x 2.7 7,600 F-300 70.0 43.0 25 2.8 x 2.0 x 2.4 3,300 FreezerF-600 140 86.0 50 4.8 x 2.4 x 2.6 6,800 F-800 170 100 75 4.0 x 2.6 x 2.7 7,600 C 235 65.0 60 3.4 x 2.2 x 2.7 6,000 Cold Storage (kW) (kg) (m) (kg) *1) Conditions : + Room temperature ; R series / -25 C, F series / -35 C, C series / +2 C + Cooling water inlet temperature / 32 C
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