Small Applications with Ammonia
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1 eurammon Symposium 2017 Small Applications with Ammonia Daniel McDougall Star Refrigeration Ltd. Schaffhausen, 22 nd /23 rd June, 2017
2 Traditional Ammonia Refrigeration Technology Compressor Plantroom Surge Drum Vessel and Liquid Pumps HPR Liquid Storage Vessel Schaffhausen, 22 nd / 23 rd June, 2017 Page 2
3 Ammonia Refrigerant Charge The refrigerant for a well designed pumped recirculation ammonia system is ** 2.6 kg/kw **GCCA White Paper on Low Charge Systems Schaffhausen, 22 nd / 23 rd June, 2017 Page 3
4 So what Is Low Charge? Schaffhausen, 22 nd / 23 rd June, 2017 Page 4
5 Low Charge: A Definition Any ammonia system which requires a specific system charge of less than *1.3kg/kW (10 lb/tr ) of refrigerant. *GCCA White Paper on Low Charge Systems Schaffhausen, 22 nd / 23 rd June, 2017 Page 5
6 Case Study 1 - System Refrigerant Charge Small R22 DX Plant Single DX R22 Refrigeration Plant installed 1991 Single stage plant with 3x Compound Reciprocating Compressors 2x Evaporative condensers 5x DX Evaporators Main Freezer Chamber -22degC 175kW installed room cooler capacity 540kg refrigerant charge 3.1kg/kW specific system charge Schaffhausen, 22 nd / 23 rd June, 2017 Page 6
7 Case Study 2 - System Refrigerant Charge Small R407F DX Plant 4x Modular DX R407F Split Systems installed 2014 Each modular system comprised 1x Air-cooled condensing unit 1x Evaporator 55kg gas charge Main Freezer Chamber -22degC 140kW installed refrigeration capacity 220kg refrigerant charge 1.75kg/kW specific system charge Schaffhausen, 22 nd / 23 rd June, 2017 Page 7
8 Case Study 3 - System Refrigerant Charge Large R717 PC Plant Single R717 Pump Circulation Refrigeration Plant installed 2013 Two stage plant with 2 LT + 3 HT Screw Comps + 2 Evap Condensers LT Freezer Chamber 5 Evaporators MT Chamber 1,656kW 12 Evaporators HT Chamber 492kW 4 Evaporators Approximately 1,000 meters of PL and WR refrigerant pipework 3,085kW installed refrigeration capacity 8,700kg refrigerant charge 2.82kg/kW specific system charge Schaffhausen, 22 nd / 23 rd June, 2017 Page 8
9 Kg/kW Specific System Refrigerant Charge kg/kw Well designed R717 Pump Circ system 2.6 kg/kw Definition of Low Charge R kg/kw Schaffhausen, 22 nd / 23 rd June, 2017 Page 9
10 Low Charge : Alternative Definition The lowest possible charge required for stable operation of the unit over the full range of possible operating conditions while maintaining the system s rated capacity Refrigerant Charge Reduction in Refrigerating Systems IIR Informatory Note Schaffhausen, 22 nd / 23 rd June, 2017 Page 10
11 Where s The Charge? Schaffhausen, 22 nd / 23 rd June, 2017 Page 11
12 Target Areas For Reducing Charge Schaffhausen, 22 nd / 23 rd June, 2017 Page 12
13 Design Criteria For Low Charge Lowest possible charge for safe and reliable operation Schaffhausen, 22 nd / 23 rd June, 2017 Page 13
14 Charge How Low Can You Go? Schaffhausen, 22 nd / 23 rd June, 2017 Page 14
15 Relative Risk Charge How Low Can You Go? Safety Performance System Charge Schaffhausen, 22 nd / 23 rd June, 2017 Page 15
16 Design Criteria For Low Charge Lowest possible charge for safe Maximum Require and reliable the possible lowest operation efficiency possible level Pose Be of reliable zero maintenance (or across close a to range zero) risk of Be operating to employees Be leak-free Not low cost require conditions special permits or reporting Schaffhausen, 22 nd / 23 rd June, 2017 Page 16
17 Design Criteria For Low Charge Lowest possible charge for safe and reliable operation Maximum possible efficiency Require the lowest possible level of maintenance Pose zero (or close to zero) risk to employees Be leak-free Be reliable across a range of operating conditions Be low cost Not require special permits or reporting Schaffhausen, 22 nd / 23 rd June, 2017 Page 17
18 Case Study 4 140kW Low Charge R717 Condensing Unit Freezer Storage facility -22degC Country: Scotland, UK Capacity: circa 140kW Refrigerant: R22 - kg unknown?? Photos taken from Pinneys DX R22 Freezer Plant with Air Cooled Condenser Year of Installation: 1990 Schaffhausen, 22 nd / 23 rd June, 2017 Page 18
19 System Charge - kg Case Study 4 140kW Low Charge R717 Condensing Unit Well designed R717 Pump Circ system Schaffhausen, 22 nd / 23 rd June, 2017 Page 19
20 System Charge - kg Case Study 4 140kW Low Charge R717 Condensing Unit Well designed R717 Pump Circ system Definition of Low Charge R717 Schaffhausen, 22 nd / 23 rd June, 2017 Page 20
21 System Charge - kg Case Study 4 140kW Low Charge R717 Condensing Unit Well designed R717 Pump Circ system Alternative DX R407F Definition of Low Charge R717 Schaffhausen, 22 nd / 23 rd June, 2017 Page 21
22 System Charge - kg Case Study 140kW Low Charge R717 Condensing Unit Well designed R717 Pump Circ system Alternative DX R407F Definition of Low Charge R717 Pinneys Low Charge R717 Condensing Unit Schaffhausen, 22 nd / 23 rd June, 2017 Page 22
23 System Charge - kg Case Study 140kW Low Charge R717 Condensing Unit Well designed R717 Pump Circ system 75% Reduction 63% Reduction Definition of Low Charge R717 50% Reduction Alternative DX R407F Pinneys Low Charge R717 Condensing Unit Schaffhausen, 22 nd / 23 rd June, 2017 Page 23
24 Case Study 4 140kW Low Charge R717 Condensing Unit Freezer facility -22degC 140kW Refrigeration Capacity Low Charge R717 Cond Unit 91kg Charge = 0.65kg/kW Schaffhausen, 22 nd / 23 rd June, 2017 Page 24
25 Low Charge R717 Condensing Units 70kW to 350kW capacities Cold storage applications No plant room Factory assembled and wired Local or remote location Air, evaporative or water cooled Efficient operation Fast installation <0.65kg/kW charge Schaffhausen, 22 nd / 23 rd June, 2017 Page 25
26 Key Component Aluminium Coil Excellent heat transfer Very low charge High efficiency Metal Density kg/m 3 Thermal Conductivity kw/ m 2 C Aluminium Stainless Steel Galvanised Steel Schaffhausen, 22 nd / 23 rd June, 2017 Page 26
27 Key Component 4 Way Valve Single 4 way ball valve Reverse plant operation Electrical actuator Rapid defrost Schaffhausen, 22 nd / 23 rd June, 2017 Page 27
28 Low Charge R717 Condensing Unit Schaffhausen, 22 nd / 23 rd June, 2017 Page 28
29 Packaged Low Charge Ammonia Units Schaffhausen, 22 nd / 23 rd June, 2017 Page 29
30 Case Study 5 Low Charge Packaged Systems Low pressure receiver system Reverse cycle defrosting Pump free design High efficiency, low charge Secondary glycol to loading dock Schaffhausen, 22 nd / 23 rd June, 2017 Page 30
31 Future Development components control systems package design Schaffhausen, 22 nd / 23 rd June, 2017 Page 31
32 Summary Low charge ammonia is Regulation is driving increased already available interest Possible Solutions to reduce from HVAC charge to by New component 75%+ technology Freezers New system development development Improved efficiency Lower life cycle cost Schaffhausen, 22 nd / 23 rd June, 2017 Page 32
33 Summary Low charge ammonia is already available Regulation is driving increased interest Solutions from HVAC to Freezers Possible to reduce charge by 75%+ New component technology development New system development Improved efficiency Lower life cycle cost Schaffhausen, 22 nd / 23 rd June, 2017 Page 33
34 Contact: Star Refrigeration Ltd. Thornliebank Industrial Estate Glasgow Scotland UK +44 (0)
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