Global Trends in Industrial Refrigeration Systems Anatolii - - PowerPoint PPT Presentation

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Global Trends in Industrial Refrigeration Systems Anatolii - - PowerPoint PPT Presentation

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Global Trends in Industrial Refrigeration Systems Anatolii Mikhailov April 2016 Industrial Refrigeration 1 Agenda Introduction Global Warming Safety Aspects Energy Efficiency Considerations Industrial System Costs

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SLIDE 1

Global Trends in Industrial Refrigeration Systems

Anatolii Mikhailov April 2016

Industrial Refrigeration 1│

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SLIDE 2

Agenda

2│

  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories
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SLIDE 3
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

3│

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SLIDE 4

4 | Danfoss Industrial Refrigeration

Businesses in Danfoss Cooling

Danfoss Cooling Industrial Refrigeration

Refrigeration & A/C Controls Commercial Compressors Industry Business Heat Exchaners

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SLIDE 5

Danfoss Cooling Segment 6 |

Safety Reliability Energy efficiency Global warming Cost

Industrial Refrigeration

Industry Drivers

2 Reliability

  • Automatic running

1 Safety

  • products and

system design Energy efficiency

  • new and retrofit

systems

  • Industriel heat pumps

3 Global warming

  • refrigerants focus,

plays along with NH3 and CO2

4 5 Cost

  • primary growth in

emerging markets with higher price pressure, TCO awareness

Industrial Refrigeration 7 |

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SLIDE 6
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

7│

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SLIDE 7

Danfoss Cooling Segment 8 |

Safety Reliability Energy efficiency Global warming Cost

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SLIDE 8

Danfoss Cooling Segment 9 |

TEWI - quantifying environmental performance

What is TEWI?

TEWI = Total Equivalent Warming Impact = = Direct equivalent (chemical emissions through leakages) + + Indirect (energy use) global warming effects.

In stationary applications indirect emissions are larger than direct emissions due to refrigerant leakage

(Sources: IPCC report)

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SLIDE 9

Danfoss Cooling Segment 10 |

100.000 10.000 1.000 100 10 1,00 0,10 R507A R422C R410A R417A R407C R404A HFC-1234ze HFC-1234yf R1270 (Propylene) R744 (Carbon Dioxide) R717 (Ammonia) R600A (Isobutane) R290 (Propane) R152A R143A R134A R125 R32 R23 R142B R124 R123 R22 R115 R114 R113 R13 R12 R11

CFC HCFC HFC Natural A1 Non-toxic/non-flammable B Toxic 2L Low flammability 2 or 3 flammable

4.000 0,05 Global Warming Potential (GWP) Ozone Depletion Potential (ODP)

Source: UNEP 2010 TOC Refrigeration, A/C and Heat Pumps Assesment Report

Pending HFC developments

Regulatory – Refrigerant Map

Short Term Medium to Long Term

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SLIDE 10

Danfoss Cooling Segment 12 |

Environmental Impact:

TEWI analysis of alternative systems (Atlanta)

System type R404A state of the industry R134a/CO2 cascade R404A glycol chiller Ammonia chiller Transcitical CO2 booster Medium Temp: Low Temp: R404A DX R404A DX R134A DX CO2 DX

  • Prop. Glycol

CO2 DX Pumped CO2 CO2 DX CO2 DX CO2 DX

  • 55%
  • 82%

Direct Emissions (20%/year) Indirect Emissions (1.5 lbs CO2/kWh) Recycling (25% EOL)

(TEWI = Total Equivalent Warming Impact)

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SLIDE 11
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

15│

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SLIDE 12

Danfoss Cooling Segment 16 |

Safety Reliability Energy efficiency Global warming Cost

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SLIDE 13

17 | Danfoss Industrial Refrigeration

Requirements for ammonia systems globally

Off site safety

Safety distance

Management (operation)

Instructions / training Maintenance Safety Risk assessment

System design

System requirements System design Safety requirements

Components

Components design / requirements Valves Safety valves Vessels Compressors

Raw materials

Castings requirements Welding requirements, Etc.

E D C B A

Management “Foundation” Design

Guidelines IIAR (IOR)

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SLIDE 14

Danfoss Cooling Segment 18 |

E

Super low-charge Ammonia system

  • Install a number of

rooftop mounted self- contained ammonia units R717-charge e.g. 8 x 200 kg (0,4 kg / kW)

4 MW ammonia system Charge: 5 kg / kW 20.000 kg D

Ammonia-CO2

  • Ammonia-CO2

cascade system or Ammonia-CO2 brine system R717-charge ~2.000 kg (0,5 kg / kW)

A

Increase general safety level of system.

  • Documented risk

assessment.

  • Offsite risk

assessment.

  • Safety quick closing

section valves.

  • Safety gas detection.
  • Etc.

R717-charge 1 x 20.000 kg (5 kg / kW)

B

Sub-segments

  • Design system with a

number of sub- segments, which can be separated from each other in the event

  • f leakage.

R717-charge e.g. 4 x 5.000 kg (5 kg / kW)

C

Ammonia-DX system

  • Ammonia DX-system

reduce the required liquid charge R717-charge e.g. 2 x 5.000 kg (2,5 kg / kW)

Offsite risk mitigation by charge reduction / segmentation

Charge reduction!

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SLIDE 15

Danfoss Cooling Segment 19 |

Ammonia charge in large industrial refrigeration systems

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SLIDE 16

Danfoss Cooling Segment 20 |

  • 1. “Optimized” NH3 systems

Example: Cold Store 2300 kW Ammonia Ceiling Coil system  Ammonia DX system with Aluminum Air Coolers

Capacity, 50,000 pallets with recirculation system, room temperature, -18℃

Type of evaporators Ammonia charge (kg) Ammonia charge (kg /kW) Charge reduction (%) U bend ceiling coil (OD,38mm; ID, 32mm) 59869 26 94% Aluminum DX Air coolers 3680 1.6

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Danfoss Cooling Segment 21 |

SAFETY IMPROVED

  • 2. DX NH3 system
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SLIDE 18

Danfoss Cooling Segment 22 |

  • 3. CO2 cascade systems

NH3/CO2 cascade system  Ammonia is limited to engine room  Reduce charge by 70-90%  Reduce potential risk of food pollution  Reduce potential risk of food pollution  Better performance / energy saving at low temperature-

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Danfoss Cooling Segment 23 |

CO2 in Industrial Refrigeration - History

CO2 applications:

The Past: 1992 The CO2 was re-invented (Gustav Lorentzen) 2004 115 CO2 / ammonia installations operating in

  • Europe. 35% of these installations in
  • Nederland. (Holm Gebhardt, Nestle)

Today: Industrial CO2 installations is today build with “standard” components, and therefore it is difficult to trace the number of installations. More than 500 installations operating in Europe, dominated by Nederland, France and Spain. It is estimated that 10-15 % of all new industrial installations in Europe is build with CO2.

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Danfoss Cooling Segment 24 |

Fruit storage Holland – H.M. de Jong

  • NH3 – CO2 “brine” systems, fruit

storage

  • CO2 temp. -8 Deg.C (17 Deg.F)
  • 20 m (66 feet) high
  • 12,500 pallets
  • 15 individual temperature

compartments

  • Total ground surface area: 13.000

m2 (140.000 ft2)

  • Hot gas defrost by separate

compressors

Industrial Ammonia - CO2 system

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SLIDE 21

Danfoss Cooling Segment 25 |

CO2 in cold storage

US Cold Storage’s distribution warehouse in Pennsylvania, USA (phase 1,2,3)

Phase 1,2,3

Phase 1,2,3 Capacity: 3.6 MW CO2 Charge: 30 tons Valve size: up to DN 250

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SLIDE 22

Danfoss Cooling Segment 26 |

  • 6. Super low charged ammonia system for cold

storages

Mitigating risks

Though not entirely new, advancements in evaporator design and liquid feed control open the door to NH3 systems offering

 No need for an engine room  Roof-top based design  “VLC” very low NH3 charge  Claimed to have up to 98% less ammonia than regular systems (lowest charge < 100 g / kW)  Fully automated self-contained NH3 system  Very fast installation

1) 2) 3)

Source: 1) http://www.foodengineeringmag.com/articles/92191-making-ammonia-safer-and-more-efficient-in-refrigeration-applications 2) http://www.ammonia21.com/web/assets/companybrochure/file/533_azanefreezer_uk.pdf 3) http://hvacpproducts.com/2015/03/evapco-introduces-evapcold-packaged-refrigeration-system/

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Danfoss Cooling Segment 27 |

Some common root cause for major incidents on ammonia systems

Design

 System not designed acc. “state of the art”

  • Due to lack competence (do not understand the critical requirements)
  • Safety requirements has not been addressed properly
  • Automated systems eliminates human errors
  • Correct sized safety valve ensure “controlled” realize of ammonia
  • Emergency shutoff valves reduce the release ammonia
  • Gas detectors give fast and reliable warning about any leaks
  • Ensure safe and robust design
  • Safe and robust components.
  • All pressure bearing parts need to be manufactured of suitable materials,

documented quality welding.

  • Final test, documentation and complete risk assessment
  • Verification by independent authority
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SLIDE 24

Danfoss Cooling Segment 30 |

Safety Reliability Global warming Cost Energy efficiency

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SLIDE 25

Danfoss Cooling Segment 31 |

Components Performance

  • Direct welding
  • Low temperature steel
  • Modular concept
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SLIDE 26

Danfoss Cooling Segment 32 |

Quality Assurance

SAFETY IMPROVED

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SLIDE 27
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

33│

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SLIDE 28

Danfoss Cooling Segment 34 |

Safety Reliability Global warming Cost Energy efficiency

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SLIDE 29

Danfoss Cooling Segment 35 |

Ammonia is an effective refrigerant

+11% 300KW 500KW 1000KW Energy Cost, kDKK +47% +10% +52% +10% +53% *Calculation based on: -20℃ room temperature， Shanghai climate condition, the pump system has the same piping dimension. Capacity 10~53% Energy Saving

First cost of R22 pump system is higher than R717. Compared to R22 DX system, payback years for R717 system are 0.3~ 3.3 year.

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SLIDE 30

Danfoss Cooling Segment 36 |

COP-coefficient of refrigerant system performance

1,75 1,92 1,77 1,86 2,18 1,09 1,38 1,22 1,42 1,78 0,5 1 1,5 2 2,5

Ammonia, single stage Ammonia, two stages R-22, single stage R-22, two stage Ammonia / CO2 cascade system

COP

  • 40 / + 25 Deg.C (-40 / + 77 Deg.F) .
  • 50 / + 25 Deg.C (-58 / + 77 Deg.F) .

Source: IIAR - Albuquerque, New Mexico 2003, P.S Nielsen & T.Lund Introducing a New Ammonia/CO2Cascade Concept for Large Fishing Vessels

Example of CO2/NH3 cascade system COP

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Danfoss Cooling Segment 37 |

System control

  • Compressor
  • Condenser
  • Oil
  • Safety
  • Liquid level
  • Defrost
  • Media temperature

Proper automation secures high efficiency operation of diary refrigeration systems

Control solutions for IR system

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SLIDE 32

Danfoss Cooling Segment 38 |

Dairies Ice Rinks Slaughter- houses Breweries Poultry District Heating

Ammonia Heat pumps

Ammonia – high temperature

  • Pressure: up to 65 bar
  • COP: up to 6 or higher as add-on
  • Temperature range: water up to 95oC
  • Applications: food processing, process technologies and district heating
  • Capacity range: ~200 kW –> 10+ MW
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SLIDE 33
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

41│

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SLIDE 34

Danfoss Cooling Segment 42 |

Safety Reliability Global warming Cost Energy efficiency

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SLIDE 35

Danfoss Cooling Segment 43 |

Industry Drivers in future

(external requirements)

Cost (First cost of installation) Cost is important, but more importantly is “Total cost of

  • wnership” (TCO)

TCO includes cost of all products, equipment and the total cost for all activities required, incl. indirect cost related to the project, from project start to up to the system is

  • perational.

 Product / equipment cost  The cost to select the right components.  The cost to bring the product on site and install and adjust it.  Cost of waiting time (e.g. long delivery time).  Getting the permission to build project  Etc.

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Danfoss Cooling Segment 44 |

Lower TCO leads to higher profitability

  • TCO but not first cost is the most important thing
  • Design
  • Equipment
  • Transportation
  • Installation
  • commissioning
  • Certification
  • Operation
  • Maintenance
  • 。。。。。。

Total cost of ownership

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SLIDE 37

Danfoss Cooling Segment 45 |

Life time costs are typically far greater than first cost

  • CO2 brine systems have at least 15% lower lifetime cost – including

installation, energy and maintenance costs

  • The system is a future proof, as it is efficient and uses no synthetic

refrigerants

10 20 30 40 50 60 70 80 90 100 CO2 G lycol maintance running cost first cost

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SLIDE 38
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

46│

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SLIDE 39

Danfoss Cooling Segment 47 |

Safety Global warming Cost Reliability Energy efficiency

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SLIDE 40

Danfoss Cooling Segment 51 |

Innovation highlights 2004-2014

ICV small and medium sizes

2004 2009 2006

ICV large sizes

2011

AKS 4100 ICF 20-25

2012 2014

SVL Flexline SVL SS Flexline ICLX two-step servo-operated ICF 15

2016

ICF Large

2013

EKE 347

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SLIDE 41

Danfoss Cooling Segment 52 |

Danfoss Flexline™ Commonalities Across ICV , ICF And SVL

  • Platform based concept offering a lot of benefits such as
  • Clever simplicity
  • Advanced flexibility
  • Timesaving efficiency
  • All products are designed for Ammonia
  • Approved up to 52 bar making them suitable for CO2 as well

ICF Flexline TM

  • Complete valve stations

SVL Flexline TM

  • Line components

ICV Flexline TM

  • Control valve
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SLIDE 42

Danfoss Cooling Segment 53 |

Valve Industry has stepped forward with improve solutions

Eliminating flanged stop valves

  • Cast Iron bodies
  • Valve seats more prone to wear
  • Flanges prone to leak
  • Corrosion is a problem
  • Phased out 15-20 years ago

Today’s steel body valves

  • Low temperature steel
  • Direct “Weld-in”
  • Less leak potential (no flange gaskets)
  • Higher Design Working Pressure
  • “Industry Standard”
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SLIDE 43

Danfoss Cooling Segment 54 |

Flanged control valves

  • Ductile iron
  • Flanged
  • Additional gaskets
  • Low pressure

Today’s direct weld control valves

  • Low temperature steel
  • Less gaskets = less leaks, no flange

torque requirements

  • Higher working pressures

Valve Industry has stepped forward with improve solutions

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SLIDE 44

Danfoss Cooling Segment 55 |

Valve Industry has stepped forward with solutions that are widely embraced

  • Minimizing Dynamic

Spindles

  • Control valves of the past with external

actuators

  • Borrowed and adopted from the heating and

process industry

  • Today’s sealed valves
  • Encapsulated spindles
  • Magnetically coupled actuators
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SLIDE 45

Danfoss Cooling Segment 56 |

Valve stations (solutions)

  • Less welding = faster and higher

quality installations

  • Better materials – no ductile iron
  • Less leak potential
  • Higher working pressure
  • Less refrigerant to purge during

service

  • Faster and easier to service
  • Flexible modular construction

Valve Industry has stepped forward with improve solutions

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SLIDE 46

Danfoss Cooling Segment 57 |

NH3 systems 140 130 120 110 100 90 80 70 60 50 40 30 20 10 NH3/CO2 pumped system NH3/CO2 hot gas defrost NH3 Heat Pump CO2 systems at stand still pressure Transcritical CO2 systems

Max Working pressure Pressure [bar]

90 bar (1300 PSI) 140 bar (2050 PSI) 65 bar (940 PSI) 52 bar (750 PSI) 40 bar (580 PSI) 25 bar (360 PSI)

Industrial systems

Need for higher working pressure

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SLIDE 47
  • Introduction
  • Global Warming
  • Safety Aspects
  • Energy Efficiency Considerations
  • Industrial System Costs
  • Combined trends and solutions
  • Case stories

Agenda

59│

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SLIDE 48

Cases Ammonia

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SLIDE 49

Danfoss Cooling Segment 61 |

Meat Industry - ammonia Gran Farm

  • A large contributor to the

Chinese meat industry

  • 50% cost savings on

installation

  • 30% savings on

maintenance

  • 4,000 ICF valve stations

from Danfoss serve the cooling industry in China

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Danfoss Cooling Segment 62 |

Cold Storage: Sabharwal Food Industries

  • Pvt. Ltd. in India
  • The first European standard

cold storage model in India

  • High-quality food safety

from farm to consumer for millions of Indians.

  • Apart from ensuring

extremely high food quality, the European storage model is also the most cost effective and energy efficient solution on the market.

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SLIDE 51

Cases Ammonia Heat pumps

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SLIDE 52

Danfoss Cooling Segment 66 |

Cattle Slaughterhouses Optimization of energy

  • Heating and Electricity
  • 4.500 cattles a week
  • 110 cattles per hour

Technical data

  • 4560kW -10C / +30C
  • R717 pump
  • 100 evaporates
  • 2 screw compressors
  • 1 piston compressor
  • 1000kW Heat Pump +28C /

+ 61C

  • 2 piston compressors
  • 2 evaporate condensers 2400kW
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SLIDE 53

Danfoss Cooling Segment 67 |

Questions

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SLIDE 54

Industrial Refrigeration 10|

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SLIDE 55

69 | Danfoss Industrial Refrigeration

BACK-UP SLIDES

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Danfoss Cooling Segment 70 |

China - Ceiling coils (Bunker coils)

Relative ammonia charge in various system

Conventional Pumped circulation system Optimized Pumped circulation system Advanced Ammonia DX-System CO2-NH3 Cascade System CO2-NH3 Pumped (volatile brine system) Super Low Charge Ammonia systems

Central Systems “Hybrid” Systems Packaged Systems

Relative Ammonia Charge System Type