LATEST TRENDS IN CHILLER TECHNOLOGIES By: Arif Hussain, National Product Manager
Latest Trends in Chiller Technologies Speed Control Improved Power factor Power electronics operational savings Levitation and magnetic bearings Elimination of oil circuit Elimination of Gears Current scenario Future Scenario Change in refrigerant scenario Advanceme nts in Heat exchanger Technology Falling Film Evaporator Microchannel Condenser
YVAA YORK Variable Speed Air Cooled Screw Chiller All these benefits flow from our key technology elements
VSD application can differ significantly: Screws need constant torque w/speed change
Electrical Benefits Soft Starting There are several benefits (beyond efficiency and sound performance) that come with using a VSD design VSD provides Soft start with no inrush. Starting current never exceeds full load amps. Lowest maximum electricity demand costs Eliminates starting thermal and electrical stress No motor heating at start allows for quicker re-start after power failure Stand by generator size reduced % Full-Load Amps 600 500 400 300 200 100 0 Solid State Starter Star Delta Starter YVAA Chiller 0 10 20 30 40 50 Time (milliseconds) 5
Electrical Benefits Power Factor The VSD in chiller provides 0.95 displacement power factor as standard Power factor is constant at all loads Non VSD systems will have reduced power factor at part load operation j or 99% of the operating hours Many electric rate structures charge consumer based on power factor or offer incentives for high power factor These are based on the average over the billing cycle They will be affected by part load operation Power Factor 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 YVAA Ordinary A/C Screw Chiller 20 30 40 50 60 70 80 90 100 Chiller Load (%)
Electrical Benefits Power Factor How can power factor affect the retrofit market? Power factor influences the total unit current draw (amps) Lower amps = smaller electrical wire sizes More importantly when replacing equipment, the ability to install more cooling capacity without replacing electrical service Electrical service retrofit can be a major contributor to cost 7
Proven Compressor & VSD Compressor & VSD More than 15,000 YORK compressors operating on VSD in air-cooled chiller applications All in YCAV & YCIV models shipped since 2004 We use a dedicated VSD platform Eliminates slide valve and associated inefficiencies, and reduces compressor moving parts by 50% - going to a dedicated VSD design improved reliability Competitor s with add on VSD still must maintain unloading components in their compressor design Our motor is purpose designed for operating in a VSD system, allowing for maximum reliability and efficiency 1 Circuit per compressor, protects compressor from oil and liquid management issues 8
VSD application can differ significantly: Torque varies proportionately to square of speed
Basic Centrifugal Machines Laws Fan Laws CFM ~ RPM Static head ~ RPM 2 HP ~ St Head*CFM HP ~ RPM 3 Major savings driven by application head (p-discharge minus p-suction) reduction Centrifugal Compressor Refri Flow Rate ~ RPM Lift ~ RPM 2 HP ~ Lift * Refri Flow Rate Input Power ~ RPM 3 %RPM %Power 100 100 90 73 80 50 70 34
Head Head Energy Savings Power Speed 1 Power Speed 2 Throttling (riding the curve) VFD (varying the speed)
Full Load Efficiency Evaporator DX Evaporator: Water outside the tubes Refrigerant inside the tubes Water connection at sides Flooded Evaporator: Water inside the tubes Refrigerant outside the tubes Water connection at ends
Efficiency LOW HIGH Full Load Efficiency Falling Film Evaporator. Best elements of DX and Flooded. Hybrid Falling Film Evaporator: Water is inside the tubes; Refrigerant is outside the tubes Two bundles of water tubes Upper bundle is covered in a film of refrigerant Lower bundle is flooded in the refrigerant Falling Film Flooded DX LOW HIGH Refrigerant Qty 1
Full Load Efficiency Falling Film Evaporator. Best elements of DX and Flooded. Hybrid Falling Film Evaporator: Water is inside the tubes; Refrigerant is outside the tubes Two bundles of water tubes Upper bundle is covered in a film of refrigerant Lower bundle is flooded in the refrigerant Patented Falling Film design provides the best combination of performance & refrigerant charge 1
Full Load Efficiency Microchannel Coils. Lightweight, robust and easily cleaned. All Aluminum tubes, fins, and header Higher heat transfer per volume of coil Increased heat transfer without adding chiller length or weight Microchannel Coil Round Tube Plate Fin Coil Tube Cross Section Round Tube Microchannel Images courtesy
Full Load Efficiency Microchannel Coils. Lightweight, robust and easily cleaned. Microchannel maintains the high efficiency of your chiller over time All aluminum construction minimizes the opportunity for galvanic (dissimilar metal corrosion) The fins do not extend past the tubes making it easier to clean with water spray Microchannel coils are less deep, allowing more complete dirt removal when washing 1
Full Load Efficiency Microchannel Coils. Lightweight, robust and easily cleaned. Why microchannel coils? Fins are secured and recessed between channels No galvanic corrosion keeps the fins attached to the channels Microchannel coils with R134a are being used in automobiles for over a decade Photo courtesy of Danfoss 1
Centrifugal Chiller Design Enhancements Aerodynamic Condenser Inlet Diffuser Eliminate Losses at Exit of the Discharge Pipe Uniform Distribution of Refrigerant over Condenser Tubes Better Utilization Condenser Tubes Efficiency Improvement
Centrifugal Chillers Specify Superior Sustainability Hybrid Falling Film Components Evaporator Spray Header Around 100 spray slots Proprietary V-pattern spray design. Spray pattern design was tested down to a minimum system head and lift of 1 psid and still delivered good spray performance. Picture represents spray at minimum pressure (1 psid.) Spray Header Spray Header in Operation
90/10 Copper/ Nickel tubes for Condenser
Heat Exchanger Tube Design Water Flow Tube Sheet Tube Support Tube Actual Tube Thickness Gage Enhanced Section Plain Section (land) 23 0.025" 0.050-0.053" 22 0.028" 0.053-0.056" 20 0.035" 0.059-0.063"
Magnetic Centrifugal Chillers Employ Superior Efficiency Permanent magnet motor with active magnetic bearings Proven aerodynamic designs from our flagship YK product line
Magnetic Centrifugal Chillers Driveline Design -- Permanent Magnet Motor Proven aerodynamics combined with efficient motor technology Permanent Magnet Motor YK Aero Section
Magnetic Centrifugal Chillers Driveline Design -- Permanent Magnet Motor Motor Stator Motor Rotor Motor Stator Radial Bearing Axial Bearing Touchdown Bearing During operation the rotor is suspended (levitated) and there is no mechanical contact between the rotor and the bearings The YMC² s motor rotor is supported on magnetic bearings with touchdown ball bearings for backup
Magnetic Centrifugal Chillers Acquire Superior Attenuation Lowest sound levels on the market. Selections available for all tonnages at 73 dba or less (AHRI 575 Rating) Achieved through the use of: Permanent magnet motor with active magnetic bearings OptiSound Control Conversational speech 60 dba Telephone dial tone 80 dba Chainsaw 110 dba 50 dba Average home 73 dba YMC² 90 dba Most centrifugal chillers 140 dba Jet aircraft
In Paris, parties agreed to hold global temp. rise below 2 C by the end of the century 195 countries agreed in Dec. 2015 to develop plans to mitigate global temperature rise required 5 year review cycle Monitoring, reporting and verification of emissions Submitted plans include reduction of energy use in buildings and HFCs Verification will require energy monitoring of buildings $100B to be used for climate mitigation significant portion will be towards reducing buildings energy consumption Potential for carbon market with 3rd party verified energy efficiency projects
Oct. 2016 agreement in Rwanda to manage reduction of HFCs under the governance of the Montreal Protocol 196 countries agreed to phase-down targets for HFC refrigerants (all equipment, not just chillers) Final goal is 85% global CO2 equivalent reduction from now to 2047 Individual countries and regions to decide on specific plans to meet targets Not a phase-out, no impact to existing equipment, servicing or sales today
Montreal Protocol amendment agreement HFC phase down schedule "Developed Countries" Andorra, Australia, Azerbaijan, Belarus, Canada, European Union with its 28 members, Iceland, Israel, Japan, Kazakhstan, Liechtenstein, Monaco, New Zealand, Norway, Russian Federation, San Marino, Switzerland, Tajikistan, Ukraine, United Kingdom of Great Britain and Northern Ireland, United States of America, Uzbekistan "Developing Countries - Faster Track" China, African Group, GRULAC (Latin American and Caribbean Group*), Thailand, Malaysia, Indonesia, Cambodia, West Asian Countries (except those in Group 2), Turkey, Pacific Islands, Maldives, Sri Lanka Year Total % of Base Line Remaining 2019 90% 2024 60% 2029 30% 2034 20% 2036 15% Year Total % of Base Line Remaining 2024 100% 2029 90% 2035 70% 2040 50% 2045 20% "Developing Countries" GCC (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia, United Arab Emirates), India, Iran, Pakistan, Iraq Year Total % of Base Line Remaining 2028 100% 2032 90% 2037 80% 2042 70% 2047 15%
Beneficial The Impact of different refrigerants Larger Components smaller Components Beneficial
Energy consumption, and the CO2 emissions resulting from power production, accounts for over 95% of a chiller s lifetime carbon footprint. 95% from electricity consumption 5% from refrigerant GWP
Greenhouse gas emissions or carbon footprint can be measured through equipment life-cycle climate performance Energy consumption driven by burning of fossil fuels (indirect impact) Leakage of refrigerant over the life of the equipment (direct impact) + = TOTAL equivalent greenhouse gas emissions Annual kwh used CO2 emissions / kwh generated Leaks Escape during service Refrigerant not recovered at end-of-life >95% <5%
When low-gwp provides the best environmental option GWP is an inadequate measure of impact Most electricity consumed by the chiller is produced by burning fossil fuels Global greenhouse gas emissions (Source: US EPA)
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