Mayekawa Mfg. Co., Ltd. Kuniaki Kawamura 1

Transcription

1 Mayekawa Mfg. Co., Ltd. Kuniaki Kawamura 1

2 Contents 1. Introduction for Mayekawa Mfg 2. Refrigerants comparison 3. Natural refrigeration system update 3.1 NH3/CO2 refrigeration system(newton) 3.2 Air cycle (Pascal-Air) for Future Trend 2

3 Founded: 1924 Location: Tokyo, Japan Turnover: $1.5 Billion Employees: 3,350 (33 countries) 3

4 Belgium England Spain France Switzerland Germany Turkey Dubai India Moscow Beijing Philippines South Korea Canada (Vancouver, Toronto) Shanghai Taiwan USA(LA, etc.) Thailand Viet Nam Singapore Malaysia イIndonesia Australia New Zealand Chile Argentina Mexico Venezuela Costa Rica Colombia Ecuador Peru Brazil Main operations Mayekawa is doing business globally, having 57 domestic offices and 3 plants, and 90 overseas offices including 6 plants. Corporate offices Botan, Koto-ku, Tokyo ,Japan Established in 1924 Capital 1,000,000,000 yen President Tadashi Maekawa Brazil plant Moriya plant Domestic plant: Moriya, Higashi-Hiroshima, Saku Overseas plant: Mexico, Brazil, USA, Belgium, South Korea T

5 2. Refrigerants comparison 5

6 Progress of international regulations and measures over F-gases Protection of Ozone Layer Montreal Protocol Vienna Convention CFC(R11,R12,R502, etc.) HCFC(R22, etc.) Depleting the ozone layer Impact on global warming Prevention of Global Warming Kyoto Protocol United Nations Framework Convention of Climate Change (UNFCCC) Cl F C Cl F CFC HCFC HFC H H N H H NH 3 H F C Cl F F F F C C H F F H C C F H H C HFO F F HFC(R404A,R410A,R134a, R407C, etc.) Lower GWP HFC (HFO,HFO&HFC Blends, etc.) Natural Refrigerant (NH 3,CO 2,Air,H 2 O,HC) Non Depletion of the ozone layer Non Depletion of the ozone layer Impact on global warming Proposed Amendment to the Montreal Protocol F-gas Regulation(EU, since 2015) Act on Rational Use & Proper Management of Fluorocarbons(JPN, since 2015) Non or low Impact on global warming

7 Consumption Level Allowed Progress of international regulations and measures over F-gases Control measures under the Montreal Protocol Table. HCFCs (Annex C_Group Ⅰ )Consumption Reduction Schedule Month/Year *Baseline calculated as 1989 HCFC consumption +2.8 percent of 1989 CFC consumption. Reference: OZONE SECRETARIAT_UNEP

8 Comparison of refrigerants on ideal cycle Refrigerant unit R22 R404A R407C R410A R134a R32 Evaporating Pressure MPaA Condensing Pressure MPaA Brake Shaft Power kw Cooling Capacity kw COP Refrigerant unit NH3 R1270 R290 R1234yf R1234ze(E) Evaporating Pressure MPaA Condensing Pressure MPaA Brake Shaft Power kw Cooling Capacity kw COP Calculated Condition : Te=-15[degC], Tc=+40[degC], SH=+5[K], SC=+0.5[K], Volumetric Efficiency =100[%], Adiabatic Efficiency =100[%] Properties of refrigerant were calculated by REFPROP ver9.0

9 3. Natural refrigeration system update 3.1 NH3/CO2 Refrigeration system(newton) 9

10 Market Requirements High Efficiency: Compressors and IPM Motors Low Charge: * Secondary Refrigerant System(CO2) Less Leakage: Hermetic Motors High reliability: 5 years maintenance free Long term refrigerant supply

11 Industrial Refrigeration with Natural Refrigerants Target Industrial Domestic Commercial

12 The comparison of CFC refrigerants and natural refrigerants The name of refrigerant HCFC HFC NWFS R22 R134a,R410A NH3,CO2,HC R407C,R404A H20,AIR Ozone depletion potential (ODP) Global warming potential (GWP) ~3920 0~3 Leakage Much Much No NH3 is found when leaked Odor/Smell No No NH3:Sharp odor Flammability No No/Lower NH3:Lower flammability HC:Higher flammability Coefficient of performance (COP) ~1.2(NH3) * GWP used here is a 100-year GWP based on the data from Japan Fluorocarbon Manufacturers Association (JFMA). * COP is the comparison value when R22=1.

13 Development Concepts High efficiency Low refrigerant charge Less leakage High reliability

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15 Basic Concept of NewTon Out door NewTon Cold Storage Cooler CT Cond. Evap. Water NH3 CO2 Water cooled Energy saving NH3 charge min. Free layout Easy Maintenance NH3 Package New Screw compressor Semi-hermetic IPM motor Flooded Evaporator Double economizer Automatic operation CO2 brine Safety Low pump power No trouble by oil High heat transfer Safety Energy saving Easy maintenance 15

16 NH3 New Screw Compressor Semi-hermetic IPM Motor Two stage compound Screw 16

17 High Efficiency Motor(IPM motor) - Semi-Hermetic for NH3 - Benefits of IPM motor 5~10% better in efficiency 40% smaller in size High speed is possible Conventional IPM motor 回転子 17

18 New rotor profile and Double economizer system Evap. Booster High stage Condenser Features High efficiency: Less gas leakage Quiet: Low noise, low vibration High reliability: Use of proven bearings Booster Economizer Inter cooler Double Economizer 18

19 High Performance Heat Exchanger NH3 gas Comparison of Evaporator CO2 gas S&P S&T S&P Improve CO2 liquid NH3 liquid NH3 gas S&T Volume (m3) % Space (m2) % Approach temp.(k) (COP:+4% ) CO2 gas NH3 liquid CO2 liquid 19

20 Case 1 Power consumption data (2013) Power consumtion (kwh) Office Light, Lift etc Refrigeration Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Light, Lift etc 26 % Office 7 % Specific Power Consumption (kwh/m3/year) Refrigeration 18.8 Light, Lift etc 7.9 Refrigeration 67 % Office 1.9 Total

21 Main Installations of NewTon Customer Volume (m3) Newton sets installed Nissui Logistics / Kawasaki 35, Toyo Suisan / Nagoya 80, Hosui / Atsugi 20, Yokohama Reito / Osaka 68, Coop / Onomichi 75, Matsuoka / Kawasaki 200, Nichirei Log. / Kawasaki (for one floor) 100, Maruha-Nichiro Log. Net. / Kawasaki 75, are running Nisui Log. /Kawasaki Toyo Suisan / Nagoya Yokohama Reito / Osaka 21 Coop / Onomichi Matsuoka/Kawasaki Nichirei / Kawasaki

22 Specific Power Consumption in Cold Storage 180,0 Specific Power Consumption (kwh/m3/year) 160,0 140,0 120,0 100,0 80,0 60,0 40,0 20,0 0,0 HCFC-22 NewTon (NH3/CO2) NH3/Brine Case Storage Volume (m3) 22

23 Distribution center F1610C Storage capacity :18,000 ton NewTon 3000 Existing Refrigerant :HCFC-22 Machine :F1610C ー 8sets System :Dry Expansion 8sets of NewTon3000 replaced. 4sets in sets in

24 Reduction of Power Consumption 600,000 Renewal Example 50.0 P ower Consunption (kwh) 500, , , , , K WH Reduction (%) 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec (Befor Replacement) 2009(After 4units Rplaced) 2010(After 8units Replaced) Reduction(After 4units Rplaced) Reduction(After 8units Replaced) *Based the bill of Tokyo Power Co. *Total Power consumption, incl carriers, lights, office machines, etc. *Storage capacity : 1 ton = 0.4 m3

25 Power reduction through renewal with NewTon Customer Volume Age Refrigerant formerly used Power reduction (m3) (year) Refrig. Comp. (%) Tokyo Toyomi (Case 2) 45, HCFC-22 Screw 31.1 Niigata Reizo 10, HCFC-22 Recip QP Kewpie 16, HCFC-22 Recip Sensui Reizo 6, HCFC-22 Screw 29.3 Ajinomoto 7, HCFC-22 Recip Gliko 30, HCFC-22 Screw 19.8 Showa Reizo 32, HCFC-22 Recip AMB Funabashi 30, NH3/Brine Recip

26 Temp: +10 Diary Cold Storage Ice Arena Ice Mkaing Maine Temp: -45 Food

27 NewTon for ASEAN 1 st NewTon system will be installed to P.T. ADIB Global Food Supplies in Indonesia. P.T. ADIB A cold storage warehouse nearby Jakarta Joint Crediting Mechanism Host Country : Indonesia JCM Project for Cold Chain Industry in Indonesia with NewTon This project was funded by the MOEJ in FY 2013 as the 1 st project to Joint Crediting Mechanism. Most advanced Japanese energy efficient non-fluorocarbon cooling system NewTon R-6000 Freight handling Cealed chiller 100 ton Refrigerator A(-25 ) Refrigerator B(-25 ) Refrigerator C(-25 ) CO2 Thermo shutter 3 units Machine room NH3/CO2 Fridge NewTon R-6000 Cold water Project site Entity: Mayekawa Mfg CO. Ltd Chiller (Cooler) 6 units Defrost water Defrost water (heatup heat exchanger) Defrost water tank 10m3 Demonstration Site: PT.ADIB Global Supplies Energy Consumption reduction 570,000 kwh /year Estimated GHG reductions Without consideration of HFC leakage emissions: 213 (tco2/year) With consideration of HFC leakage emissions: 902 (tco2/year) Energy Efficient Refrigeration Technology MOEJ introduce the Energy Efficient Refrigeration Technology of NewTon as Japanese Good Practices. 27

28 3.2 Air cycle (Pascal-Air) for

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30 Conventional system *Has an Air cooler + Fan motors *Defrost required Air cooler + Fan motors Air

31 Pascal Air system Air duct Blown-in *No air cooler + Fan motors *No defrost Ducts easily installed Blown-out -60 Warehouse facility Storage capacity : 8000ton. Blown-out

32 Save Energy Safety Low working pressures. Not Toxic or flammable No safety regulations required Nature No environmental load GWP=ODP=0 Environment friendly Air refrigerant system

33 Direct Air circulation The integrated turbo-compressor-expander motor KPa abs Turbo-compressor Turbo-expander Primary cooler KPa abs Cooling Water Cold heat recovery Heat exchanger Warehouse -60 超低温エリア

34 Compressor Motor Expander One shaft for power recovery 34

35 Comparison of Air cycle and the conventional system Item Conventional system Air cycle Heat entering through walls 30% 30% Heat loss through opening refrigerator 5% 5% Product cooling 25% 25% Heat generated by fan motor 20% 0% Thermal resistance due to frost(defrost) 10% 0% Illumination 10% 10% Total 100% 70% 35

36 Installed and other applicable areas (1) Installed areas Ultra-low temperature warehouse for bonito/tuna (17 units already installed -50~-60 ) Food rapid freezing system (3 units- freezers -50 ) Chemical process cooling (2 units pharmaceutical -70~-80 ) (2) Other applicable areas Vacuum Freeze-dry Semiconductor manufacturing Low temperature Milling etc.

37 Pascal Air(Brine cooling) Turbo Compressor and Expander +35 Comp モータ Exp 120K GN2 1st Cooler nd Brine 115 K Heat Recovery Cooler 37

38 4. Future Trend There have been many actual instllations using natural refrigerants in Japan. About 30% of energy saving have been established. Government support (MOE) has started for natural refrigerants system since 2014.(about 50 MUS$) We would like to challenge our continuous development for energy saving and safety using Natural Five. 38

39 Refrigerant (Natural Five) NH 3 R-717 CO 2 R-744 HC Hydrocarbon H 2 O R-718 Air R Utility hot water Utility hot water Heating Chilled water Ice making Chilled water Ice making Cold storage, Freezer, Fish boat Specific Refrigeration needs Utility hot water Heating HVAC Heat recovery Chiller Freezer, Freeze-dry, Super Low temp storage -60 Cryogenics Cryogenics -100 Notes Eco-Cute Nat l Proj. Butane + Propane Nat l Proj. Adsorption Heat recovery Nat l Proj. Air-cycle 39

40 Thank you very much for your Attention. NATURE IS WHAT WE DESIGN FOR 40