How to Meet 2017/2020 Energy Regulations

Transcription

1 How to Meet 2017/2020 Energy Regulations U.S. Commercial Foodservice February 18, 2016 Allen Wicher Emerson Climate Technologies

2 % Energy Foodservice Channel and Business Dynamics Balancing Four Basic Variables to Solve Customer Needs DOE Regulations Require New System Designs -35% -17% -37% Now '17 Now '18 Now '20 Reach-In Ice Walk-In % of Top 50 Retailers Testing Refrigerant Alternatives 100% 80% 60% 40% 20% 0% 83% 6% C-Stores Targeting Foodservice for Growth 100% Food 80% and Bev. 60% Other 40% 20% 0% Fuel and Tobacco Sales % Margin % $K Component Electronics Are a Larger Spend HFC Optional Electronics Mechanical CO₂

3 Refrigerant and Minimum Energy Efficiency Regulations Require Industry to Balance the Equation Reduce energy consumption with optimized refrigeration equipment system performance. Ensure EPA compliance and reduce GWP with refrigerant choices that minimize impact to equipment performance. Preserve reliability, serviceability and safety. Understand the toxicity, flammability and pressure implications. Estimate the total cost of ownership and viability of technology changes. Best Solution for End User

4 U.S. Department of Energy Status of U.S. Refrigeration Energy Regulations Energy Product Class Current NOPR Final Effective Energy Level Reduction Closed-Doors Reach-Ins (Self-Contained) 2010 Oct March 2014* (await court decision) March 2017 kwh/day 30% 50% Ice Makers 2010 NODA Sept Jan Jan kwh/100 lbs 5% 15% Display Cases, Including Remote 2012 Oct March 2014* (await court decision) March 2017 kwh/day 30% 50% Walk-In (Foodservice) 2009 Sept Jan. 2016** No change MT; No change panels and doors; LT and multiplex out of cmte. Jan (all enforced) AWEF MT 20% 40%; LT and Multiplex 20 30% (ASRAC Cmte. Proposal) * Lawsuit filed by industry in 7 th Circuit Court; DOE response filed 7/22/15, NAFEM replied 8/19/15, awaiting court decision ** Lawsuit filed by industry in 5 th Circuit Court; settlement reached July 2015 to refer to ASRAC Cmte. with cmte. To make proposal in January 2016, which they met. Awaiting DOE and Court final approvals. Compliance effective dates are nearing.

5 EPA s Final Rule, July 20, 2015, Changed Listing Status of Certain HFCs* Environment Phase-out Refrigerant R-404A/507A Super-market New* Jan. 1, 2017 Supermarket Retrofit *** July 20, 2016 Remote Cond. Unit New Jan. 1, 2018 Remote Cond. Unit Retrofit* ** July 20, 2016 MT <2,200 BTU/hr. and not contain flooded evap. New Stand-alone MT 2,200 BTU/hr. with or without flooded evap. New Jan. 1, 2019 Jan. 1, 2020 R-410A OK - OK - Jan. 1, 2019 Jan. 1, 2020 R-407A/C/F OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 LT New Jan. 1, 2020 LT and MT Retrofit*** July 20, 2016 Jan. 1, HFC-134a OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK Likely Alternatives (Emerson Perspective) R-448A/449A OK OK OK OK Neither SNAPapproved, nor banned Neither SNAP-approved, nor banned R-450A/513A OK OK OK OK OK OK OK OK R OK OK OK - R-744 OK - OK - OK OK OK - Jan. 1, 2020 OK OK OK for LT only R-717 OK (in primary loop of secondary CO 2 sys.) - OK (in primary loop of secondary CO 2 sys.) ** Includes ice machines connected to a supermarket rack refrigeration system. *** EPA uses term retrofit to indicate the use of a refrigerant in an appliance that was designed for and originally operated using a different refrigerant. Term does not apply to upgrades to existing equipment where the refrigerant is not changed. * Abbreviated see EPA final rule for complete listing; Reference: Federal Register / Vol. 80, No. 138 / Monday, July 20, 2015 / Rules and Regulations,

6 Alternatives for Refrigerant Applications Environment Pressure or Capacity R-410A Like CO 2 A1 Non-Flammable A2L Mildly Flammable R446A, R447A, ARM-71a R32/HFO R32 Blends A3 Flammable B2L Toxic, Mildly Flam. Available Now OEMs Testing Qualitative Not to Scale Established R410A R404A & R407/22 Like NH 3 R290 <150 ~300 HDR110 DR3 ARM-20a R444B = L20 L40, DR7 ARM-20b R32/HFO Blends R448A R449A < 1500 R32/HFC/HFO Blends R22 R407A R407C R407F, R452A R404A R507A (3922) R134a Like R123-Like (V.Low Pr.) HFO 1234yf HFO 1234ze ARM-42 DR2, N12, ARC 1 ~600 HFC/HFO Blends R450A R513A R134a ,000 1,500 2,000 GWP Level Many <150 GWP refrigerant alternatives have increased flammable characteristics.

7 Refrigerant Limitations Energy Environment Equipment R-448A/449A Approval for Stand-Alone MT Required R-448A/449A for Reciprocating Hermetic LT Envelope Challenges Due to High Heat of Compression Glide Considerations Capacity Increases From R404A R-450A/513A for Reciprocating Hermetics R-450A Capacity Drops From 134a R-513A Near Drop in Replacement With No Theoretical Capacity Changes Glide Considerations MBP to LBP Performance Drops and Capacity Changes Requiring Complete System Redesign No silver bullet alternative refrigerant

8 % Market % Energy Where We Are: Regulations and Refrigerants Energy Environment Equipment Economics DOE Energy Reach-In Ice Walk-In Supermarket CA Title % -17% -37% -25% 0 Today 2017 EPA Refrigerants Today 2018 Today % 100% Low GWP Blend 100% Low GWP Blend Low GWP Blend R % Low GWP Blend R-290 CO 2 Today 2019 Today Voluntary Today 2018 Today 2017 Redesigns are widespread. Results require system-wide optimization.

9 Compliance Will Not Be Easy EPA Refrig. DOE Energy Energy Environment Equipment Economics Supermarket (Rack) 1/1/17 <2,500 GWP Walk-In (Remote CDU) Cooler Freezer 1/1/18 <2,500 GWP Awaiting Final Court Sign-Off 1/1/ % 20 30% Reach-In (Stand-Alone) Cooler <2,200 BTU >2,200 BTU Freezer 3/27/ % 1/1/19 <600 GWP <600 GWP <1,500 GWP Ice Machine 1/1/ % 1/1/20 Opportunity to comply with one design cycle change

10 DOE Potential Impact to Channel Energy Economics Equipment Equipment Mfg. Wholesalers/ Contractors Design Consultants, Mfg. Reps, Dealers End Users 1. Equip. Cost Adder X X X X 2. Footprint Increase and Space Management X X X X 3. Equipment Architecture Change X X X X 4. System Architecture Change X X X X 5. Inventory and Existing Stock Sell Thru Provision Mgmt. X X X 6. Compliance Approval Mgmt. X 7. Service Training and Equipment Availability (New Equipment Cross-Reference) X X X X 8. Equipment Performance and Product Reposition and Consolidation X X 9. Installation Changes and Retrofit Frequency X X 10. Equipment Operation and User Interface Differences X X X X 11. New Maintenance Training X X X X All channel stakeholders will be impacted.

11 DOE Energy Regulations Impact by Application Ani Jayanth Emerson Climate Technologies

12 DOE Equipment Regulations Survey Commercial Refrigeration Equipment Walk-In Coolers and Freezers (WICF) Automatic Commercial Ice Makers Effective March 2017 on New Equipment CRE Measured in kwh/ 24-Hour Day Each Equipment Class Assigned Equation Variable: Total Display Area (TDA) or Volume Effective January 2020 on New Equipment WICF Measured in Three Major Components AWEF Measured Using AHRI-1250 Testing Standard Each Equipment Class Assigned Equation Variable: Q = System Capacity Effective January 2018 on New Equipment ACIM Measured in kwh/100lbs Ice Each Equipment Class Assigned Equation Variable: H = Harvest Rate in lbs per 24 Hours Industry Reach-In Solid Door Refrigerator Energy Draw From 20% to 50% Energy Reduction Required for Systems, Depending on Class 5% to 25% Energy Reduction Required Source: Department of Energy

13 Commercial Refrigeration Equipment Equipment Classes Equipment Affected Low or Medium Temperature Vertical, Semi- Vertical, Horizontal, or Service Over Counter Self-Contained or Remote Condensing With or Without Solid/Transparent Doors Commercial Refrigerator and Freezer No Energy Conservation Standards and Test Procedures Salad Bars, Prep Tables, Refrigerated Buffet Tables HOWEVER If There Is a Reach-In Under Them, Waiver From DOE Must Be Requested Source: Department of Energy

14 CRE Regulation Exceptions Salad Bars, Chef Bases, Griddle Stands, Frost Tops, Buffet, Prep Top Rail Refrigerated Cold Wall or Forced Air Bottom Storage Refrigerated or Non-Refrigerated Currently No Test Procedures for Certain Styles of Equipment Based on Power Supply and the Sharing/Non-Sharing of Refrigeration System for Both Top and Bottom If Criteria Met, OEMs Can Apply for Waiver Based on Architecture Contact DSN for Answers on Specific OEM-Related Questions on Exceptions

15 CRE Prep and Buffet Table Architectures and Compliance Note Can Be Tested w/doe Test Procedure Can t Be Tested w/doe Test Procedure Top Bottom Certification Required Criteria Rail Storage No Power Supplied or From See Refrigeration Power Supply Single Energy Source Common Supply With Top Requirements Power Supply Power Supply Yes Dual Energy Source With Single-Source Requirement Top Rail Bottom Storage Certification Required Criteria Refrigerated: Cold Wall or Forced Air Dry: Non-Refrigerated No Regular Buffet/Prep Construction: No Classification Refrigerated: Cold Wall or Forced Air With Heat Being Rejected Directly Into Lower Section Refrigerated: Air in Lower Section Coming in Direct Contact With Top Rail, and Single Condensing Unit No Heat From Upper Rail Is Being Absorbed Directly Into Lower Section Refrigeration System With Single Energy Source and Single Refrigeration System Refrigerated: Cold Wall or Forced Air With No Direct Contact With Lower Section Refrigerated: Cold Wall or Forced Air With No Direct Contact With Rail Section, and Single Condensing Unit Yes Heat From Upper Rail Is Not Being Absorbed Directly Into Lower Section Refrigeration System With Single Energy Source and Single Refrigeration System Refrigerated: Cold Wall or Forced Air With Its Own Condensing Unit Refrigerated: Cold Wall or Forced Air With Its Own Condensing Unit Yes Dual Refrigeration System With Single Refrigeration System Requirement, Single or Dual Energy Source

16 Commercial Refrigeration Equipment Design Option vs. Cost System Compressor CDU Component $90 $ OEM Cost Adder $80 $70 Solid-Door Reach-In Refrigerator (DOE/ADL Study) VS VS Compr Comp. kwh/day $60 $50 $40 Better Insulation Better Insulation BPM Compr Mtr BPM Motor 2.0 years Payback Hot-Gas Antisweat Hot Gas Anti-Sweat kwh/day = Comp. Energy Draw + Lighting + Fan + Controls + Others $30 $20 $10 ECM Evap Fan ECM Evaporator / Condenser ECM Fan Fan LED Lighting Higher Eff Compr 1.0 year High Effy. Comp. 0.5 year % Energy Saving $0 0% 5% 10% 15% 20% 25% Total System Measurement Based on Equipment Type CDU Is Treated as Component Source: Department of Energy

17 Walk-In Coolers and Freezers (WICF) Equipment Classes Medium or Low Temp Multiplex Condensing Dedicated Single walk-in feed A packaged dedicated system where the unit cooler and condensing unit are integrated into a single piece of equipment A split dedicated system with separate unit cooler and condensing unit sections Multiplex Unit coolers matched to multiplex condensing rack system Recip. Hermetic, Semi-Hermetic Recip. or Scroll Compression <9K Btu/h or >= 9K Btu/h Indoor or Outdoor Medium or Low Temp Dedicated Condensing Source: Department of Energy

18 DOE WICF Regulation Changes Reach-In Walk-In DOE Final Ruling March 28, 2014 June 3, 2014 Compliance Date March 27, 2017 June 5, 2017 Court Brief Filed March 28, 2015 April 9, 2015 Petitioners Zero Zone/NAFEM Lennox/AHRI Court 7 th Circuit 5 th Circuit Government Reply Due July 8 Late June Petitioner Reply Due July 22 Mid-July Walk-In Pending 5 th Circuit Approval Dedicated/Multiplex Condensing Original Challenge Suggested Compression Compliance Guidance Settlement LT Walk-In Freezer MT Walk-In Cooler June 2017 June 2017 DOE Setting Internally Inconsistent Standards That Were Unachievable Using Economically Feasible Technologies Flowed Cost Benefit Work Failed Analysis of Small Business Impacts DOE Court Order Necessary to Make Changes Liquid Injected Scroll Floating Head Pressure Hermetic Recip Scroll Floating Head Pressure LT Dedicated and Multiplex Systems Vacated and Committee Re-Work Completed Jan Enforced Jan MT Multiplex Systems Vacated and Committee Re-Work Completed Jan MT Dedicated Systems Enforced Jan. 2020

19 Automatic Commercial Ice Makers Overview Affecting Batch Ice Machines Also Known as Cubers Affecting Continuous Ice Machines Also Known as Flakers or Nugget Air or Water Cooled Self- Contained or Remote Condensing Various Harvest Rates Frozen Carbonated Beverage Machines Not Affected

20 Automatic Commercial Ice Makers Design Options Technology Options Batch Continuous Compressor Condenser Improved EER Part Load Operation Increased Surface Area Enhanced Fin Surfaces Increased Air Flow and Water Flow Brazed Plate or Micro Channel Coil ECM Condenser Fan Motors Improved Auger Motor Improved Pump Motor Evaporator Other Reduced Energy Loss From Thermal Cycling Reduced Harvest Time Thicker Insulation Reduced Potable Water Flow Source: Department of Energy

21 Thank You! Questions? Allen Wicher Ani Jayanth Director, Marketing Foodservice Manager, Market Foodservice DISCLAIMER Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated herein or that other measures may not be required.