2015.5.28 Mayekawa Mfg. Co., Ltd. Kuniaki Kawamura 1
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 -60 4. Future Trend 2
Founded: 1924 Location: Tokyo, Japan Turnover: $1.5 Billion Employees: 3,350 (33 countries) 3
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 3-14-15 Botan, Koto-ku, Tokyo 135-8482,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
2. Refrigerants comparison 5
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
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 http://ozone.unep.org/new_site/en/treaties/treaties_decisions-hb.php?sec_id=12
Comparison of refrigerants on ideal cycle Refrigerant unit R22 R404A R407C R410A R134a R32 Evaporating Pressure MPaA 0.2962 0.3610 0.2632 0.4800 0.1639 0.4881 Condensing Pressure MPaA 1.5336 1.8925 1.7489 2.4256 1.0166 2.4783 Brake Shaft Power kw 58.31 64.61 58.17 91.40 34.22 99.11 Cooling Capacity kw 209.36 200.19 177.23 301.78 121.06 340.20 COP - 3.59 3.10 3.05 3.30 3.54 3.43 Refrigerant unit NH3 R1270 R290 R1234yf R1234ze(E) Evaporating Pressure MPaA 0.2362 0.3630 0.2916 0.1837 0.1200 Condensing Pressure MPaA 1.5554 1.6485 1.3694 1.0184 0.7666 Brake Shaft Power kw 60.11 63.31 51.29 34.68 25.11 Cooling Capacity kw 222.29 220.47 178.89 114.91 87.94 COP - 3.70 3.48 3.49 3.31 3.50 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
3. Natural refrigeration system update 3.1 NH3/CO2 Refrigeration system(newton) 9
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
Industrial Refrigeration with Natural Refrigerants Target Industrial Domestic Commercial
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) 0.055 0 0 Global warming potential (GWP) 1810 1770~3920 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) 1.00 0.90 1.05~1.2(NH3) * GWP used here is a 100-year GWP based on the data from Japan Fluorocarbon Manufacturers Association (JFMA). http://www.jfma.org/database/table.html * COP is the comparison value when R22=1.
Development Concepts High efficiency Low refrigerant charge Less leakage High reliability
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
NH3 New Screw Compressor Semi-hermetic IPM Motor Two stage compound Screw 16
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
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
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) 0.689 0.269-39% Space (m2) 1.57 0.49-31% Approach temp.(k) 3.0 1.7 (COP:+4% ) CO2 gas NH3 liquid CO2 liquid 19
Case 1 Power consumption data (2013) Power consumtion (kwh) 700 000 600 000 500 000 400 000 300 000 200 000 Office Light, Lift etc Refrigeration 100 000 0 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 28.2 20
Main Installations of NewTon Customer Volume (m3) Newton sets installed Nissui Logistics / Kawasaki 35,000 3 2008 Toyo Suisan / Nagoya 80,000 9 2009 Hosui / Atsugi 20,000 2 2010 Yokohama Reito / Osaka 68,000 8 2011 Coop / Onomichi 75,000 8 2012 Matsuoka / Kawasaki 200,000 11 2013 Nichirei Log. / Kawasaki (for one floor) 100,000 1 2013 Maruha-Nichiro Log. Net. / Kawasaki 75,000 6 2014 500 are running Nisui Log. /Kawasaki Toyo Suisan / Nagoya Yokohama Reito / Osaka 21 Coop / Onomichi Matsuoka/Kawasaki Nichirei / Kawasaki
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 1 0 50 000 100 000 150 000 200 000 250 000 300 000 Storage Volume (m3) 22
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 2008 4sets in 2009 23
Reduction of Power Consumption 600,000 Renewal Example 50.0 P ower Consunption (kwh) 500,000 400,000 300,000 200,000 100,000 40.0 30.0 20.0 10.0 0.0 K WH Reduction (%) 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec -10.0 2007(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
Power reduction through renewal with NewTon Customer Volume Age Refrigerant formerly used Power reduction (m3) (year) Refrig. Comp. (%) Tokyo Toyomi (Case 2) 45,000 29 HCFC-22 Screw 31.1 Niigata Reizo 10,000 33 HCFC-22 Recip. 41.2 QP Kewpie 16,250 27 HCFC-22 Recip. 24.9 Sensui Reizo 6,125 38 HCFC-22 Screw 29.3 Ajinomoto 7,500 25 HCFC-22 Recip. 28.0 Gliko 30,000 30 HCFC-22 Screw 19.8 Showa Reizo 32,500 22 HCFC-22 Recip. 28.0 AMB Funabashi 30,000 25 NH3/Brine Recip. 34.0 25
Temp: +10 Diary Cold Storage Ice Arena Ice Mkaing Maine Temp: -45 Food
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. http://www.env.go.jp/en/earth/ozone/goodpractice/full.pdf 27
3.2 Air cycle (Pascal-Air) for -60 28
Conventional system *Has an Air cooler + Fan motors *Defrost required Air cooler + Fan motors Air
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
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
Direct Air circulation The integrated turbo-compressor-expander motor -80 101.3KPa abs Turbo-compressor Turbo-expander Primary cooler -60 101.3KPa abs Cooling Water Cold heat recovery Heat exchanger Warehouse -60 超低温エリア
Compressor Motor Expander One shaft for power recovery 34
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
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.
Pascal Air(Brine cooling) Turbo Compressor and Expander +35 Comp モータ Exp 120K GN2 1st Cooler +93-100 -105 2 nd Brine 115 K +40 +35 Heat Recovery Cooler 37
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
Refrigerant (Natural Five) NH 3 R-717 CO 2 R-744 HC Hydrocarbon H 2 O R-718 Air R-728 90 Utility hot water 60 10-15 -25 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 -40-50 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
Thank you very much for your Attention. NATURE IS WHAT WE DESIGN FOR 40