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Natural efficiency: available now!
Andreina Figuera
NSM Retail
March, 2017
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
CAREL
 CAREL is a world leader in control solutions for air-conditioning,
refrigeration and heating, and systems for humidification and evaporative
cooling.
 We design our products to bring energy savings and reduce the
environmental impact of machinery and systems.
 Our solutions are used in commercial, industrial and residential
applications.
 Our mission of high efficiency solutions summarises the model that CAREL
has adopted, both the starting point and the final objective that enclose the
entire process, from conception to production and marketing of our
systems.
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
Agenda
1. Most Common supermarket installations.
2. Main drivers on the selection of the type of installations.
3. Natural efficiency available now.
3
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
1. Most common supermarket installations.
The food conservation systems that are normally taken into account are
among the following ones:
1. Traditional MULTIPLEX refrigeration system .
2. CASCADE MULTIPLEX refrigeration system with DX (normally with
R134A) MT cycle and subcritical CO2 LT cycle.
3. BOOSTER MULTIPLEX refrigeration system with CO2 MT & LT cycle.
4. Secondary loop system.
5. Distributed compressor system (aircooled or watercooled).
6. Distributed watercooled self contained inverter driven display case
system.
1. Most common
supermarket
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
A traditional MULTIPLEX refrigeration
systems comprises at least two compression
racks (one for Medium Temperature and one
for Low Temperature applications); each fitted
with multiple compressors in parallel
connected with common piping to the display
cases and cold rooms on one side and to the
remote condensers on the other side.
The multiplicity of compressors (normally
from 3 to 6), working with a common suction
and delivery pressures, allows to get a simple
capacity control by switching and/or
sequencing them.
The wide and complex piping network
contains a massive quantity of refrigerant (in
average approx 2,5 lb/kBtuh) and, being
mostly realized in copper with brazed
junctions and connections, is prone to
frequent leaks (up to 25% per year of the
overall content), difficult to detect for the
presence of necessary insulation material
and costly to repair and to replenish.
• Traditional MULTIPLEX refrigeration system
1. Most common
supermarket
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
This system has an overall architecture similar to a
traditional system (two compressor racks, one for MT
applications, one for LT ones) but with two basic
differences:
1. The refrigerant of the LT circuit is carbon dioxide
(CO2) working in a subcritical cycle;
2. The condensation of LT circuit is achieved in a
special evaporator belonging to the MT circuit low
pressure side; the cooling capacity of the MT
compressor is sized to absorb the heat rejected by
the LT cycle condenser.
The main advantages of this solution are:
• Low environmental impact due to refrigerant GWPs
(1300 for R134A; 1 for CO2);
• High efficiency of R134A working in the MT circuit;
• Low compression ratio in the LT circuit compressor
rack.
Drawbacks:
• Lower efficiency of CO2 subcritical cycle vs. HFC
refrigerants at equal conditions.
• Cascade MULTIPLEX refrigeration system with DX (normally with
R134A) MT cycle and subcritical CO2 LT cycle.
1. Most common
supermarket
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
In this system the high pressure hot gas is delivered by
the compressor rack to the aircooled gas heat
exchanger where it is cooled and, through a pressure
reduction valve, conveyed at an intermediate pressure to
a common receiver partially as a gas (hence sucked by
the MT compressor) and partially as a liquid.
From there the liquid refrigerant is sent through the
piping network and the expansion valves to all display
cases and walk-in coolers (both MT & LT).
The refrigerant sucked from LT evaporators by the LP
rack (at ≈ -25°F ≡ 181 psig) is compressed and delivered
to the HP compressor rack suction side together with the
refrigerant evaporated in the MT display cases (at ≈
14°F ≡ 370 psig).
The overall weight of refrigerant and the annual leakage
rate are of the same order of magnitude of a traditional
system.
To the great advantage of an ultra-low environmental
impact the following negative aspects are associated:
• Low efficiency (decreasing with the average outdoor
temperature increase);
• Higher capital investment;
• High level of competence required.
• Booster MULTIPLEX refrigeration system with CO2 MT &
LT cycle.
1. Most common
supermarket
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
In this system each display case and cold room
has its own compressor (speed controlled with
an inverter in order to adjust its capacity
according to the actual requirement) and a water
cooled condenser.
Water is recirculated by a pump between the
internal units and an outdoor package (drycooler or
/and chiller ).
The advantages of this system are:
• ENVIRONMENT RESPECT:
• Extra low content of refrigerant (≈ 10÷20%
vs that of a multiplexed system).
• LOW LEAKAGE RATE (≈ 2%/year),
including display cases and chiller.
• ENERGY SAVING by:
• Virtually no refrigerant pressure drops.
• Self adjusting evaporating temperature.
• Full recovery of condensing heat to
produce sanitary or heating hot water.
• FOOD QUALITY: Smooth temperature regulation
around the set point since the first start up.
• Distributed watercooled self contained inverter driven display case
system.
1. Most common
supermarket
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
2. Main drivers on the selection of the type of
installations.
Investment cost
Energy Consumption
Environment impact
Food quality
2. Main drivers on the
selection of the type of
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
2. Main drivers on the selection of the type of
installations: Energy Consumption
The most common available technologies that increase the energy efficiency
of the equipment used in all types of installations, and thus help to comply with
the normatives, are:
 Electronic expansion valves (EEV).
 Variable capacity compressors.
 Variable frequency drives (VFD).
 Evaporative cooling.
 Electronic fans and pumps.
 Controllers and supervisory systems with energy-efficiency functionalities.
 High efficiency heat exchangers (e.g. micro-channels, flooded).
10
2. Main drivers on the
selection of the type of
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
2. Main drivers on the selection of the type of
installations: Environment impact.
11
Sector Application GWP limit Year
Plug in Hermetically sealed equipment 150 2022
CDU
Multipack centralized refrigeration systems for
commercial use with a rated capacity of less
than 40 kW is included.
1500 2020
Centralized
system
Multipack centralized refrigeration
systems for commercial use with a rated
capacity of 40 kW or more
150 2022
2. Main drivers on the
selection of the type of
installations
Refrigerant scenario
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
3. Natural efficiency available now
12
1.- Selecting a type of installation..
• Optimize the system
• Standardize the components
• Reduce environmental impact
2.- Creating the solution to offer the complete application control to:
Water loop BLDC:
Centralized systems:
compressor pack or
condensing units.
The latest technological developments, allows to have all types of installations with natural
efficiency; it means: installations that can use refrigerants with a low GWP and at the same time
functioning with energy efficiency.
3. Natural efficiency available
now
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
Hypermarket – Supermarkets Big -
Medium formats
•Compressor racks, mainly CO2 transcritical
booster
•Natural refrigerant CO2 as standard
•Continuous improvement for energy efficiency
mostly in warm climates
•Carbon footprint reduction
Convenience store – Petrol Station
Small – Extra small formats
•Condensing Units
•Natural refrigerant CO2 available
•Partial load energy efficiency
•Carbon footprint reduction
3. Natural efficiency available now:
Condensing units and centralized systems.
3. Natural efficiency available
now
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017 14
3. Natural efficiency available now:
pRack for centralized systems.
The know-how of Carel, on the natural refrigerating applications, allowed
designing specific features inside pRack platform.
Transcritical
3. Natural efficiency available
now
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
3. Natural efficiency available now: pRack for
centralized systems with Co2 trasncritical.
15
Evaporative cooling
Subcooler Parallel compression
Ejectors
3. Natural efficiency available
now
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
3. Natural efficiency available now:
HECU for Condensing units.
16
• Continuous modulation of the
suction pressure set point
• ON-OFF cycles kept to the
minimum
• High efficiency and stability with
CAREL power+
• Continuous modulation of the superheat set point
• Stable product temperature
• High efficiency and stability with CAREL electronic
expansion valve
Real time continuous energy optimization through data communication with refrigerated
unit (MPX PRO).
3. Natural efficiency available
now
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
3. Natural efficiency available now:
HEOS for waterloop BLDC systems.
17
Plug-in refrigerated units equipped with top DC inverter and modulating EEVs technologies.
Water condenser on-board connected with a water loop system for condenser heat management.
High flexibility and Low ambient impact and Energy saving
3. Natural efficiency available
now
Frost-trol & Partners
W o r k s h o p s
EuroShop 5th-9th March 2017
3. Natural efficiency available now:
HEOS for waterloop BLDC systems.
18
Environmental friendly
Flexibility
High Efficiency
Food quality
3. Natural efficiency available
now
Natural efficiency: available now!

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Natural efficiency: available now!

  • 1. Natural efficiency: available now! Andreina Figuera NSM Retail March, 2017
  • 2. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 CAREL  CAREL is a world leader in control solutions for air-conditioning, refrigeration and heating, and systems for humidification and evaporative cooling.  We design our products to bring energy savings and reduce the environmental impact of machinery and systems.  Our solutions are used in commercial, industrial and residential applications.  Our mission of high efficiency solutions summarises the model that CAREL has adopted, both the starting point and the final objective that enclose the entire process, from conception to production and marketing of our systems.
  • 3. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 Agenda 1. Most Common supermarket installations. 2. Main drivers on the selection of the type of installations. 3. Natural efficiency available now. 3
  • 4. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 1. Most common supermarket installations. The food conservation systems that are normally taken into account are among the following ones: 1. Traditional MULTIPLEX refrigeration system . 2. CASCADE MULTIPLEX refrigeration system with DX (normally with R134A) MT cycle and subcritical CO2 LT cycle. 3. BOOSTER MULTIPLEX refrigeration system with CO2 MT & LT cycle. 4. Secondary loop system. 5. Distributed compressor system (aircooled or watercooled). 6. Distributed watercooled self contained inverter driven display case system. 1. Most common supermarket
  • 5. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 A traditional MULTIPLEX refrigeration systems comprises at least two compression racks (one for Medium Temperature and one for Low Temperature applications); each fitted with multiple compressors in parallel connected with common piping to the display cases and cold rooms on one side and to the remote condensers on the other side. The multiplicity of compressors (normally from 3 to 6), working with a common suction and delivery pressures, allows to get a simple capacity control by switching and/or sequencing them. The wide and complex piping network contains a massive quantity of refrigerant (in average approx 2,5 lb/kBtuh) and, being mostly realized in copper with brazed junctions and connections, is prone to frequent leaks (up to 25% per year of the overall content), difficult to detect for the presence of necessary insulation material and costly to repair and to replenish. • Traditional MULTIPLEX refrigeration system 1. Most common supermarket
  • 6. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 This system has an overall architecture similar to a traditional system (two compressor racks, one for MT applications, one for LT ones) but with two basic differences: 1. The refrigerant of the LT circuit is carbon dioxide (CO2) working in a subcritical cycle; 2. The condensation of LT circuit is achieved in a special evaporator belonging to the MT circuit low pressure side; the cooling capacity of the MT compressor is sized to absorb the heat rejected by the LT cycle condenser. The main advantages of this solution are: • Low environmental impact due to refrigerant GWPs (1300 for R134A; 1 for CO2); • High efficiency of R134A working in the MT circuit; • Low compression ratio in the LT circuit compressor rack. Drawbacks: • Lower efficiency of CO2 subcritical cycle vs. HFC refrigerants at equal conditions. • Cascade MULTIPLEX refrigeration system with DX (normally with R134A) MT cycle and subcritical CO2 LT cycle. 1. Most common supermarket
  • 7. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 In this system the high pressure hot gas is delivered by the compressor rack to the aircooled gas heat exchanger where it is cooled and, through a pressure reduction valve, conveyed at an intermediate pressure to a common receiver partially as a gas (hence sucked by the MT compressor) and partially as a liquid. From there the liquid refrigerant is sent through the piping network and the expansion valves to all display cases and walk-in coolers (both MT & LT). The refrigerant sucked from LT evaporators by the LP rack (at ≈ -25°F ≡ 181 psig) is compressed and delivered to the HP compressor rack suction side together with the refrigerant evaporated in the MT display cases (at ≈ 14°F ≡ 370 psig). The overall weight of refrigerant and the annual leakage rate are of the same order of magnitude of a traditional system. To the great advantage of an ultra-low environmental impact the following negative aspects are associated: • Low efficiency (decreasing with the average outdoor temperature increase); • Higher capital investment; • High level of competence required. • Booster MULTIPLEX refrigeration system with CO2 MT & LT cycle. 1. Most common supermarket
  • 8. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 In this system each display case and cold room has its own compressor (speed controlled with an inverter in order to adjust its capacity according to the actual requirement) and a water cooled condenser. Water is recirculated by a pump between the internal units and an outdoor package (drycooler or /and chiller ). The advantages of this system are: • ENVIRONMENT RESPECT: • Extra low content of refrigerant (≈ 10÷20% vs that of a multiplexed system). • LOW LEAKAGE RATE (≈ 2%/year), including display cases and chiller. • ENERGY SAVING by: • Virtually no refrigerant pressure drops. • Self adjusting evaporating temperature. • Full recovery of condensing heat to produce sanitary or heating hot water. • FOOD QUALITY: Smooth temperature regulation around the set point since the first start up. • Distributed watercooled self contained inverter driven display case system. 1. Most common supermarket
  • 9. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 2. Main drivers on the selection of the type of installations. Investment cost Energy Consumption Environment impact Food quality 2. Main drivers on the selection of the type of
  • 10. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 2. Main drivers on the selection of the type of installations: Energy Consumption The most common available technologies that increase the energy efficiency of the equipment used in all types of installations, and thus help to comply with the normatives, are:  Electronic expansion valves (EEV).  Variable capacity compressors.  Variable frequency drives (VFD).  Evaporative cooling.  Electronic fans and pumps.  Controllers and supervisory systems with energy-efficiency functionalities.  High efficiency heat exchangers (e.g. micro-channels, flooded). 10 2. Main drivers on the selection of the type of
  • 11. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 2. Main drivers on the selection of the type of installations: Environment impact. 11 Sector Application GWP limit Year Plug in Hermetically sealed equipment 150 2022 CDU Multipack centralized refrigeration systems for commercial use with a rated capacity of less than 40 kW is included. 1500 2020 Centralized system Multipack centralized refrigeration systems for commercial use with a rated capacity of 40 kW or more 150 2022 2. Main drivers on the selection of the type of installations Refrigerant scenario
  • 12. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 3. Natural efficiency available now 12 1.- Selecting a type of installation.. • Optimize the system • Standardize the components • Reduce environmental impact 2.- Creating the solution to offer the complete application control to: Water loop BLDC: Centralized systems: compressor pack or condensing units. The latest technological developments, allows to have all types of installations with natural efficiency; it means: installations that can use refrigerants with a low GWP and at the same time functioning with energy efficiency. 3. Natural efficiency available now
  • 13. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 Hypermarket – Supermarkets Big - Medium formats •Compressor racks, mainly CO2 transcritical booster •Natural refrigerant CO2 as standard •Continuous improvement for energy efficiency mostly in warm climates •Carbon footprint reduction Convenience store – Petrol Station Small – Extra small formats •Condensing Units •Natural refrigerant CO2 available •Partial load energy efficiency •Carbon footprint reduction 3. Natural efficiency available now: Condensing units and centralized systems. 3. Natural efficiency available now
  • 14. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 14 3. Natural efficiency available now: pRack for centralized systems. The know-how of Carel, on the natural refrigerating applications, allowed designing specific features inside pRack platform. Transcritical 3. Natural efficiency available now
  • 15. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 3. Natural efficiency available now: pRack for centralized systems with Co2 trasncritical. 15 Evaporative cooling Subcooler Parallel compression Ejectors 3. Natural efficiency available now
  • 16. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 3. Natural efficiency available now: HECU for Condensing units. 16 • Continuous modulation of the suction pressure set point • ON-OFF cycles kept to the minimum • High efficiency and stability with CAREL power+ • Continuous modulation of the superheat set point • Stable product temperature • High efficiency and stability with CAREL electronic expansion valve Real time continuous energy optimization through data communication with refrigerated unit (MPX PRO). 3. Natural efficiency available now
  • 17. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 3. Natural efficiency available now: HEOS for waterloop BLDC systems. 17 Plug-in refrigerated units equipped with top DC inverter and modulating EEVs technologies. Water condenser on-board connected with a water loop system for condenser heat management. High flexibility and Low ambient impact and Energy saving 3. Natural efficiency available now
  • 18. Frost-trol & Partners W o r k s h o p s EuroShop 5th-9th March 2017 3. Natural efficiency available now: HEOS for waterloop BLDC systems. 18 Environmental friendly Flexibility High Efficiency Food quality 3. Natural efficiency available now

Editor's Notes

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