Aicarr vicenza 2016 emerson

TECHNOLOGICAL INNOVATIONS FOR
ENERGY SAVINGS IN SUPERMARKETS
Vicenza, 5th February 2016

Evoluzione dei Compressori e dei Sistemi di
Refrigerazione Commerciale in relazione alle
recenti normative energetiche ed ambientali
Bachir Bella
……

Autore - Affiliazione
Titolo relazione
Agenda
• F-Gas impact on Commercial Refrigeration
• System and Compressors Evolution in Relation to
the new F-gas Regulation
• CO2 Compressors Technologies
• R290 Compressors

Titolo relazione
Regulation EU N°517/2014 (F-gas)
24%
Domestic
fridge
GWP >150
Single Split AC
(GWP <750)
Moveable AC
GWP < 150
Refrig/Freezers
For Comm. Use
GWP<2500
Stationary Ref.
And Service Ban
GWP<2500
Jan 2015:
Applicability
Multipack
Refrigeration
GWP <150
(except cascades
with GWP <1500)
Refrig/Freezers
for Comml use
herm sealed
GWP <150
No recycled
/reclaimed
GWP <2500
for servicing
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
45%
21%
93%
63%
31%
Service usage of
HFC recycled and
reclaimed is
authorizes till 1st
Jan. 2030
100% corresponds to average 2009-2012 of HFC quantities placed on the
market and declared by refrigerants producers according to 842/2006 CE
100% = 182 Millions Tons of CO2 / 21% = 38 MT CO2

Titolo relazione
F-Gas
Refrigerants Landscape
R-410A like
R404A
R407A/F
like
R134a
like
GWP
< 1500
600
150 - 300
1234yf/ze
R410A
R407C/A/F
0 500 1000 1500 2000
CoolingCapacity/Pressure
R448A/R449A
R32/HFO Blends
(DR5, L41, ARM71)
R134a
CO2
R404A
R290
NH3
A1 – Non flammable
A2L – Middly flammable
A3 – flammable
B2L – Toxic, middly flam.
(3922)
R32/HFO Blends
(XL20/40, HDR110, L20, ARM20)
R450A,R513A
2500
400-675

Titolo relazione
F-Gas
Impact on Future Refrigerating System
R-410A like
R404A
R407A/F
like
R134a
like
GWP
< 1500
600
150 - 300
HFO
R410A
R407C/A/F
0 500 1000 1500 2000
CoolingCapacity/Pressure
R448A/R449A
R32/HFO
R134a
CO2
R404A
R290
NH3
(3922)
R32/HFO
R450A,R513A
All new systems
20202022
Centralized > 40kW
Hermetic
2022
2500
400-675
2030 2024
 The system architecture will change with the refrigerant type
 The imposed quotas will influence the future decisions
Bans
Avg. GWP
Phase down
Primary circuit
(Centralized > 40 kW)

Titolo relazione
Non Hermetic SealedHermetic Sealed
Today Tomorrow
Centralized DX
R290
HFO GWP <150 R450A, R513A,
R448A, R449A, R134a, R407A/F
R404A
R407A/F
HFOR290
R450A,R513A
R448A/R449A/R134a
Cascade Booster
Indirect Systms
R744 R744
Systems<40kW
R450A, R513A
R448A/R449A/R134a
ENTR Lot. 1
For condensing
Units
Global Impact
(LCCP)
Legislations
&
Standards
Directions
Commercial Refrigeration
a Rational Choice
Systems>40kW
HFO GWP <150 ?
Centralized DX LT
HFO GWP <150?
Investment

Titolo relazione
Non Hermetic SealedHermetic Sealed
Today Tomorrow
Centralized DX
R450A, R513A,
R448A, R449A, R134a, R407A/F
R404A
R407A/F
HFO A2L <300
R290
R450A,R513A
R448A/R449A/R134a
Cascade Booster
Indirect Systms
Systems<40kW
R450A, R513A
R448A/R449A/R134a
ENTR Lot. 1
For condensing
Units
Commercial Refrigeration
(Compressor Evolution)
Systems>40kW
Centralized DX
R744
R290
R290

Titolo relazione
Diagram Pressure-Enthalpy
CO2 (R744)
Transcritic Cycle
Transcritic Compressor is
designed
to operate either in
Transcritic or in subcritic
mode
Subcritic Cycle
Subcritic Compressor is
designed
to operate only in
subcritical mode

Titolo relazione
Criteria How R744 behaves?
Capacity
Cooling
Significantly higher volumetric capacity
4 to 5 times R404A
Efficiency Varies, depending on system type and
ambient temperature
Operating
Conditions
Operating and Standstill pressures
significantly higher
Safety high pressures and associated hazards
present challenges, Low toxicity
Suitability
as a retrofit
Not suitable because of higher pressure
and volumetric cooling capacity
Most Critical Design Parameter for
CO2 is the High Pressure
High Pressure is the most challenging Feature
• Enclosures designed at least for 3 times the max allowed
pressures 270/420 bar for MT and 100/150 bar for LT
application
• Sliding surfaces are highly stressed when used for
transcritical application (reliability)
0
20
40
60
80
100
120
140
-60 -40 -20 0 20 40 60 80 100 120
MaxworkingPresures(bar) Temperature ( C)
R404A
Cycle
Optimization
LS-MediumT.
HS-MediumT.
R744
R134a
HSLowT.
System
Charge
CO2
R404A
R134a
LSLowT.
CO2 Require new Compressor Generation

Titolo relazione
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
-60 -50 -40 -30 -20 -10 0 10
DischargePressure(bar)
Evaporating Temperature ( C)
Recip.
Transcritical
Recip.
Subcritical
Scroll
16bar
31bar
42bar
CO2 Compessors for MT & LT
Application & Performances
Modulation
Scroll Digital 10 to 100%
Reciprocating AC Inverter 25 to 70 Hz
PSS 30 bar
PSS 90 bar
CO2 Operating Envelope
PSS 90 bar
80 %
100 %
120 %
-45 -40 -35 -30 -25
Evap. Temp. in °C
COP Scroll/Recip
Tcond. = -5°C
Tcond. =5°C

Titolo relazione
CO2 Booster Simulation
Efficiency with Ambient Temperature
0
1
2
3
4
5
0 5 10 15 20 25 30 35 40
BoosterCOP
Ambient Temperature ( C)
R404A R744
< 18 C CO2 Booster Good Efficiency
> 18 C CO2 Booster Less Efficient,
Others Systems:
• Parallel compression
• Ejector
• Cascade System
Simulation & Assumptions
•MT capacity 100 kW
•Evap. temperature -10 C
•LT capacity 25 kW
•Evap. temperature -35 C
•DT condenser 6K for CO2 and
varying from 6 to 10K for R404A
+29%
-21%

Titolo relazione
Why Propane (R290)?
Tested Performances on Scroll
78 83 96102 109 130
-20
-15
-10
-5
0
5
10
15
20
60
70
80
90
100
110
120
130
140
DischargeTemperaturevs.R404A
Capacity COP Discharge Temp.
30 C 45 C 60 C
Condensing Temp. ( C)
R290PerformancesvsR-404A(%)
Evaporating Temp. : -10 CEvaporating Temp. : -10 C
Properties
 GWP=3
 Higher COP – Up to 30% at High Condensing Temperature
 Discharge Temperature slightly higher vs. R404A but manageable
 Lower Cooling Capacity vs. R404A (Avg. -15%)
Limitation (Flammability)
 Hazardeous
 Limited Experiences
 Less addressed in the standards
 Directives and Refrigerants
Standards not harmonized sometimes
 Directives and Local Legislations
making confusions

Titolo relazione
Relevant Regulations & Standards For
Flammable Refrigerants
• EN 378 (Refrigeration Systems)
System Design
&
System
Location
Occupancy
Public
Access
Supervised
Occupancy
Authorize
d
Access
Only
All in Occupied
Space
1.5 2.5 10
Compressor &
Receiver in
unoccupied
space
1.5 2.5 25
All in Open
Space or
Machinery
room
5 10 unlimited
Max. Charge Limit forR290 (kg)
• Risk Assessment
No Special requirement• EN 60335-2-89 (Commercial Ref.
Appliances): max. charge 150g
Small
System
Large
System
• ATEX 99/9/EC Compliances
• The compressor is not
located in an area where a
potentially flammable
mixture of refrigerant and
air could accumulate
• ATEX 94/9/CE compliance
and Relevant Standards
EN60079
• Electrical components
Not a source of ignition
• Hot surfaces shall not
exceed auto-ignition
Temperature of the
refrigerant minus 100 K

Titolo relazione
R290 Compressors Trend
Fixed Speed
HFC Scroll
Fixed Speed
R290 Scroll
Variable Speed
R290 Scroll
• Compactness
• Weight
Natural Refrigerant
• Energy Efficiency
• Single Compressor To Cover
Multitude System Range
(Self-Contained)



R290 VSS Applications: Self-Contained Cases, Ref Small Chiller And Small Cascade System

Titolo relazione
Dedicated R290 Scroll Design
Fixed Speed
• PED
Shell, fittings, sight glass, Fusite
PED Category I II III
P x V
(bar.liter)
Non flamm. 50 - 200 200 -1000 1000 - 3000
Flammable 25 - 50 50 - 200 200 - 1000
Quality System Internal N.B.
Design Internal Internal N.B.
Welding process Internal N.B. N.B.
Weld Inspection NDT - - N.B.
R290 Comm’l Cmp.
Cost Impact!
N.B.: Notified body

Titolo relazione
• ATEX Zone 2
0
10
20
30
40
50
60
-5 5 15 25 35 45 55 65 75
Viscosity(cSt)
Temperature ( C)
Oil Viscosity
R404A 3MAF R290 3MAF R290 HXL 4467
Tevap. -10°C
Fixed Speed
• PED
New Material and Processes
• Reliability
low viscosity with Std. POE
Electrical components Not a
source of ignition and Hot
surfaces shall not exceed auto-
ignition Temp. minus 100 K

Titolo relazione
Fixed Speed
• PED
New Material and Processes
• Reliability
New Developed lubricant
New Lubricant
Special Sliding
Surfaces Coat
New Main
Pressure
Bearing Parts
Suction Baffle
Fully Hermetic
Design
ATEX eBox
• ATEX Zone 2
Electrical components Not a
source of ignition and Hot
surfaces shall not exceed auto-
ignition Temp. minus 100 K

Titolo relazione
R290 Variable Speed Scroll
Target Applications
• Compressor with DC Brushless Motor
• Frequency Drive (220VAC Single Phase)
Applications
• Self-contained display case applications
• Cascade systems & R290/Water-Gylcol secondary systems
• Condensing units and Monoblocks
0 2 4 6 8 10 12 14
ZPV21
ZPV29
Displacement (m3/h)
990 Watt 4240 Watt
1280 Watt 5900 Watt
-10/45 C
30Hz
30Hz
117Hz
117Hz

Titolo relazione
Different speed needs map controller
1
1.4
1.8
2.2
2.6
3
0 2000 4000 6000 8000
COP
Compressor Speed (rpm)
50 C
35 C
-10 C evaporating
Performance & Operating Limits
ZBV Scroll with R290
COP quasi costant at variable speeds
DC Motor for High Efficiency
ZPV21

Titolo relazione
Conclusion
• F-gas induces for long term low GWP (< 500?)
• System architecture and the refrigerant choice
will be linked to Investment, Global warming
Impact and Legislations
• Natural Refrigerants Refrigerants like Propane
R290 and Carbon Dioxide (CO2) are Potential
Candidates for a long term
• Carbon Dioxide (CO2) and Propane R290 need
Dedicated compressors design because of the
high pressure, safety and reliability
21

Aicarr vicenza 2016 emerson

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