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This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Benefits of integration
between heat pumps and food
refrigeration systems for
commercial applications.
An example of efficient energy recovery for Near Zero
Energy Buildings
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Sergio Maria Capanelli
Carel Industries Spa
16th of May 2017
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Introduction
New solutions for HVAC/R market
Could water loop
technology be
a solution!?
YES!
If each unit is also equipped
with EEV and BLDC variable speed compressor
water loop could be a better solution.
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
BLDC compressor
• Modulate power according to request
• Reduce number of ON-OFF cycles
• Optimize working conditions
Introduction
Electronic expansion valve (EEV)
• Control of evaporation and condensation
• Keep the unit stable and increase efficiency
• Adapt the cabinet to water loop working condition
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Introduction
Compressor: ON-OFF vs BLDC
Features On-Off BLDC
Nominal cooling capacity 2 kW 2 kW
Compressor maximum cooling capacity 2.4 kW 2.4 kW
Actual cooling capacity 1.5 kW 1.5 kW
Air set point 2 °C 2 °C
Ambient temperature 18 °C 18 °C
Evaporation temperature -11.3 °C -5.5 °C
Condensation temperature 28.9 °C 21.2 °C
Estimated
energy saving
rate: 35%
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Plant description
• Built in 2016, North of Germany
• Annual average temp.: 8.8 °C
Condensation average
temperature of cabinet:
25 °C
Type of Cabinet Number
Low temperature (LT) 17
Medium temperature (MT) 23
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Plant description
R-744 Heat pump
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Plant description
Features Value
Cooling Capacity (trans-critical) 90 kW
Cooling Capacity (sub-critical) 72 kW
Evaporation temperature 4 ˚C
Outlet water temperature (heating) 42 ˚C
Inlet water temperature (heating) 25 ˚C
Water tank with evaporator 700 liters
Compressors (Bitzer) 3 ( 1 V.S. + 2 On-Off )
COP (trans-critical) 2.6
COP (sub-critical) 7.8
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Test and results
• First cycle of measurements: Jan.-Feb. 2016
• Second cycle of measurements: Mar. 2016
• Water loop for the cabinet is organized in 9
zones (topology, pipe length optimization)
• Test data from zone 6: here connected on the
loop 5 cabinet dedicated to milky products
• Between the test sessions, the regulation
parameters for R-744 heat pump has been
refined and tuned in a more precise way
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Test and results
Measurements have been acquired for 24 hours
every day, also during closing time on Sunday.
SundayThursday
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Test and results
Effect of PID tuning
on water outlet
temperature
Before PID tuning After PID tuning
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Test and results
Effect of PID tuning on evaporation temperature
• More precise regulation of EEV
• Reduced number of unnecessary switch on and
off of the two On-Off compressors
Before PID tuning After PID tuning
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Test and results
Effect of PID tuning on energy consumption
• Average reduction (2-3%)
• Reduction of peaks
Before PID tuning After PID tuning
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Test and results
Cooling system failure test
Time Description
Water
Temp
10:00 Test starts: the heat-pump
chiller is switched off
17.5 ˚C
11:25 Water temperature reaches the
peak value
41 ˚C
11:30 First cabinet stops for
temperature control alarm
41 ˚C
11:30 The heat pump/chiller is
switched on again
41 ˚C
11:50 Water temperature decrease to
an efficient temperature level
24 ˚C
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Conclusions
• Integration of air conditioning and refrigeration
is possible with benefits to both.
• The tuning phase assures a first level
integration between the heat pump and the
cabinet, thanks to the improvement of the
stability of water loop working conditions.
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden
Conclusions
• Opportunities to get further improvements:
 Integration of supervisory system to
coordinate controls (Plant integration)
 Optimization of heat pump in partial
conditions (System efficiency)
 Cabinet equipped with low GWP refrigerants
(CO2 emission reduction)
This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL
All unauthorized use, reproduction or distribution of this document or the information contained in it,
by anyone other than Carel employees is severely forbidden

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Benefits of integration between heat pumps and food refrigeration systems for commercial applications

  • 1. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Benefits of integration between heat pumps and food refrigeration systems for commercial applications. An example of efficient energy recovery for Near Zero Energy Buildings This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Sergio Maria Capanelli Carel Industries Spa 16th of May 2017
  • 2. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Introduction New solutions for HVAC/R market Could water loop technology be a solution!? YES! If each unit is also equipped with EEV and BLDC variable speed compressor water loop could be a better solution.
  • 3. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden BLDC compressor • Modulate power according to request • Reduce number of ON-OFF cycles • Optimize working conditions Introduction Electronic expansion valve (EEV) • Control of evaporation and condensation • Keep the unit stable and increase efficiency • Adapt the cabinet to water loop working condition
  • 4. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Introduction Compressor: ON-OFF vs BLDC Features On-Off BLDC Nominal cooling capacity 2 kW 2 kW Compressor maximum cooling capacity 2.4 kW 2.4 kW Actual cooling capacity 1.5 kW 1.5 kW Air set point 2 °C 2 °C Ambient temperature 18 °C 18 °C Evaporation temperature -11.3 °C -5.5 °C Condensation temperature 28.9 °C 21.2 °C Estimated energy saving rate: 35%
  • 5. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Plant description • Built in 2016, North of Germany • Annual average temp.: 8.8 °C Condensation average temperature of cabinet: 25 °C Type of Cabinet Number Low temperature (LT) 17 Medium temperature (MT) 23
  • 6. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Plant description R-744 Heat pump
  • 7. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Plant description Features Value Cooling Capacity (trans-critical) 90 kW Cooling Capacity (sub-critical) 72 kW Evaporation temperature 4 ˚C Outlet water temperature (heating) 42 ˚C Inlet water temperature (heating) 25 ˚C Water tank with evaporator 700 liters Compressors (Bitzer) 3 ( 1 V.S. + 2 On-Off ) COP (trans-critical) 2.6 COP (sub-critical) 7.8
  • 8. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Test and results • First cycle of measurements: Jan.-Feb. 2016 • Second cycle of measurements: Mar. 2016 • Water loop for the cabinet is organized in 9 zones (topology, pipe length optimization) • Test data from zone 6: here connected on the loop 5 cabinet dedicated to milky products • Between the test sessions, the regulation parameters for R-744 heat pump has been refined and tuned in a more precise way
  • 9. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Test and results Measurements have been acquired for 24 hours every day, also during closing time on Sunday. SundayThursday
  • 10. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Test and results Effect of PID tuning on water outlet temperature Before PID tuning After PID tuning
  • 11. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Test and results Effect of PID tuning on evaporation temperature • More precise regulation of EEV • Reduced number of unnecessary switch on and off of the two On-Off compressors Before PID tuning After PID tuning
  • 12. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Test and results Effect of PID tuning on energy consumption • Average reduction (2-3%) • Reduction of peaks Before PID tuning After PID tuning
  • 13. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Test and results Cooling system failure test Time Description Water Temp 10:00 Test starts: the heat-pump chiller is switched off 17.5 ˚C 11:25 Water temperature reaches the peak value 41 ˚C 11:30 First cabinet stops for temperature control alarm 41 ˚C 11:30 The heat pump/chiller is switched on again 41 ˚C 11:50 Water temperature decrease to an efficient temperature level 24 ˚C
  • 14. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Conclusions • Integration of air conditioning and refrigeration is possible with benefits to both. • The tuning phase assures a first level integration between the heat pump and the cabinet, thanks to the improvement of the stability of water loop working conditions.
  • 15. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Conclusions • Opportunities to get further improvements:  Integration of supervisory system to coordinate controls (Plant integration)  Optimization of heat pump in partial conditions (System efficiency)  Cabinet equipped with low GWP refrigerants (CO2 emission reduction)
  • 16. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden