Top Retailer Trends for Refrigeration, Controls and Facility Optimization E360 Webinar March 6, 2018
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Factors in Evaluating and Selecting Refrigerants Andre Patenaude Director of Food Retail Marketing and Growth Strategy Emerson
Food s Journey: Disconnected and Complex From Farm to Fork Transportation Consistent temperature control Regulatory requirements Handling Multiple players Intermediaries Many steps Complexity 4
Food Retail Is Dealing With Extraordinary Dynamics Consumer Driven Operations Driven Omnichannel Proficiency Seamless Desktop + Mobile + In-Store Experience Home Delivery Last-Mile Channels and Subscriptions Experiential Retail Retail-tainment New Retail Formats Retail/Foodservice Blurs Strategic Locations Urban, Smaller, High-Turnover Products Regulations DOE + EPA + CARB = Complexity Energy Costs and Incentives Demand Peak Charge, Time of Use Rates IoT and Cloud-Based Services Simple, Safe, Sustainable Technician Shortage Complexity vs. Simplification New System Architectures Steep Learning Curve Retailers Are Investing in Better Shopping Experiences and New Formats. 5
Global Innovation Centers The Helix Dayton, Ohio 6
Full Circle for Natural Refrigerants Global Warming Kyoto Protocol, COP21 Kigali Amendment (MP) Natural Refrigerants CO 2, NH 3, Propane Technical Issue Safety Current Drivers: Refrigerant Regulations o Bans o Taxes o Incentives Energy Regulation F-Gas 2006 F-Gas 2014 HFC R-404A, R-507, R-134a, R-410A 2005+ 1930s CFC R-12, R-502 1990s 1980s HCFC R-22 Ozone Depletion Montreal Protocol (1987) Slide design compliments of AHT 7
GWP Weighted CAP (% of Baseline) Kigali Amendment to the Montreal Protocol October 15, 2016 120 100 80 60 40 A2 Countries (U.S., Canada, etc.) F-Gas 2018 2024 Freeze A2 Countries (Belarus, Russian Federation, Kazakhstan, Tajikistan, Uzbekistan) 2028 Freeze A5 Countries Group 1 A5 Countries Group 2 (India, Iran, Pakistan, Iraq, GCC) Baselines A2 countries (U.S., Canada, etc.) Avg. HFC consumption 2011 to 2013 + 15% HCFC baseline A2 countries (Belarus, etc.) Avg. HFC consumption 2011 to 2013 + 25% HCFC baseline A5 countries (Group 1) Avg. HFC consumption 2020 to 2022 + 65% HCFC baseline A5 countries (Group 2) Avg. HFC consumption 2024 to 2026 + 65% HCFC baseline 20 0 2010 2015 2020 2025 2030 2035 2040 2045 2050 2055 Ref: conf.montreal-protocol.org/meeting/mop/mop-28/crps/english/mop-28-crp10.e.docx Global Agreement on HFC Phase-Down Reached by 197 Countries of the World in Kigali, Rwanda, on October 15, 2016 8
Other Refrigerant Regulation Activity F-Gas Europe (EU): effective May 20, 2014 Commercial Application GWP Limit Date Self-contained refrigeration 2,500 2020 Stationary refrigeration 2,500 2020 Self-contained refrigeration 150 2022 Centralized refrigeration 150 2022 Except top side of cascade 1,500 2022 Environmental Canada (EC) Reg. Oct.18, 2017 Effective around April 18, 2018 Commercial Application Refrigeration centralized (was 1,500) systems (MT/LT racks) GWP Limit Date 2,200 2020 Refrigeration condensing units 2,200 2020 Refrigeration LT stand-alone 1,500 2020 Refrigeration MT stand-alone (was 700) 1,400 2020 Mobile refrigeration 2,200 2025 Chillers, refrig. and AC (was 700) 750 2025 Domestic refrigeration 150 2025 9
EPA SNAP Rule: DC Court Rejects Appeal; CARB and Other States Will Likely Act On January 26th, U.S. Court of Appeals for District of Columbia Declined Honeywell, Chemours & NRDC s petitions for a rehearing en banc CARB Rulemaking #1: Adoption of EPA s SNAP Rules 20 and 21 Findings: EPA did not have authority to regulate HFCs as ozone-depleting substances HFCs are no longer delisted Supreme Court Appeal is expected within 90 days of Feb. 5, 2018 California still moving forward with delisting CARB Rulemaking #2: SLCP Strategy to Reduce HFCs Commercial Application All refrigerant sales * All refrigerant sales * Non-residential refrigeration (> 50 lbs) Non-residential refrigeration (20 50 lbs) Chiller (refrig or AC) AC (non-residential and residential) (2 or more lbs) * Sales ban on new and recycled GWP Limit 2,500 1,500 150 1,500 150 Date 2020 2024 2021 2021 2021 750 2021 Recommendation: Continue to Follow the Business Path of Rulemaking 1 10
Refrigeration Application Alternatives Emerson s Approvals in Progress or Complete A1 Non-flammable A2L Mildly flammable A3 Flammable B2L Toxic, mildly flam. Volumetric Capacity / Pressure Naturals Mildly Flammable (A2L) HFO and Blends Lowest GWP Non-Flammable (A1) HFC/HFO Blends Today s Non-Flammable (A1) HFCs Elevated R-744 (CO 2 ) 1 Medium R-404A like R-290 (Propane) 3 R-717 (Ammonia) 0 R-455A (HDR-110) 146 R-454C (XL20) 146 R-457A (ARM-20a) 139 R-449A (XP40) 1,282 R-448A (N40) 1,273 R-449B (ARM-32) 1,296 R-407A 1,923 R-407F 1,674 R-507A 3,985 R-407C 1,624 R-404A 3,943 HFO-1234yf <1 R-513A (XP10) 573 Low R-134a like HFO-1234ze <1 ARM-42 131 R-450A (N13) 547 R-515A 392 R-134a 1,300 GWP 0 5 0 150 350 1,300 1,300 4,000 This List Is Subject to Change. Please Check Publication, Form 93-11 or With Emerson Representatives for Most Current Approvals in Progress. 11
System Architectures Choices CO 2 Booster Transcritical Distributed 0 ODP, 1 GWP 1, A1 Higher Pressures Standing Pressures Good Low Ambient Perf High Ambient Strategies Indirect Chiller with Cascade CO2 A1 Many Refrigerant Options Optimize Suction Press Location Flexibility Lower Charge Small Footprint CO2 HFC/ HFO HFO Integrated Case Micro Distributed A1 A1 A2L Niche Application Commercial /Industrial Full Natural Option Energy Efficient Low Charge AHJ Approvals CO2 R290 HFO NH3 A1 A3 A2L<150 GWP B2L R-290 150g Limit, Future? A2L 500g Limit, Future? Water loop for Condensing Heat Pump Integration Option Flexible AHJ Approvals R290 A3 HFO CO2 A2L<150 GWP A1
What s Driving Trends in Control Selections John Wallace Director of Innovation Emerson
Refrigerant & Architecture Decisions Influence Controls Architecture Store Type & Surface Area (ft²) Trend Architecture & Refrigerant Towards 2020 Controls Considerations Warehouse & Large Supermarkets >40k ft² Medium Size Supermarkets 10k to 40ft ft² Small Supermarkets & Hard Discounts 6k to 10K ft² C-Stores 1.2k to 6k ft² Restaurants <1.2k ft² Centralized Architecture NH 3, Cascade and Booster CO 2 Centralized & Distributed HFO or CO 2 Centralized, Distributed : HFO or CO2 Integrated Display Cases R290 Distributed : HFC, HFO, CO2 Multiple HFO Units Integrated Display Cases R290 Distributed HFC, HFO, Multiple Units, Roof Mount, R290 Display Distributed Mix/Centralized Certain control decisions forced by system architecture Can be mixed, shades of gray depending on preferences Implications beyond Refrigeration system
What makes a building Smart? The Edge: Amsterdam, Netherlands Utilize Sensors, Controls and IoT for occupant comfort, efficient operations and save energy https://www.bloomberg.com/features/2015-the-edge-the-worlds-greenest-building/ Your local supermarket Utilize Sensors, Controls and IoT to create a comfortable shopping experience, help keep food safe and lower energy & maintenance costs Building Controls Architecture Can Drive Value And Enable Future Options 15
Low-GWP Refrigerants Can Impact Controls Architecture CO 2 Transcritical R-290 Higher pressures; Careful processes critical Requires electronic expansion valve control (control at the case) Fast acting; Requires Fast control loops and limited delays for compressor staging Controls must coordinate medium and low temp compressor operation Flammable; Careful processes critical Low charge levels drive distributed architecture Requires Distributed Control that manages all functions (i.e. compressor, temperature, etc.) 16
Systems Evolved From Islands of Control Integrated to Form a Complete Integrated Control System Individual systems tied together Information sharing across systems Supervisory system Emergence of supervisory functions Ref. Lighting Integration/Control maturity similar to auto industry evolution Communication technologies More sensors Smarter control Use data to drive actions HVAC Other Connecting the islands into an integrated control system Controls Evolution 17
Comparison of Control Architectures Centralized/Mix Distributed Centralized control architecture Distributed control architecture Refr. controls Case controls Refr. controls Floorplan Temp Sensors Control elements centralized at refrigeration rack or electrical panel Home runs for sensors I/O boards for control Case controls Control elements at case Communication daisy chain to EMS Complete control at refrigeration case Case electronics for control Additional sensors provide more data 18
Modern Building Automation Systems (BAS) Control a Broad Range of Equipment and Enable Integrated, Cross-Site Optimization 19
Connectivity Across Site Enables Enterprise Visibility and Advanced Services Single Store All Stores Enterprise HVAC Lighting Refrigeration Foodservice Equipment Foodservice Equipment and Other Critical Equipment Site-Level Controls Are Critical, but Connectivity Helps Create Higher Value. 20
Layers and Functions of a Control System Architecture Layer Remote Key Elements Remote user interface Site information Data feed Supervisory On-site user interface User management Data logging Alarming Cross-system coordination Control Control algorithms Inputs and outputs Sensors and transducers Equipment interface Site Distributed Architectures Separate Supervisory and Control, but Both Are Still Required. 21
Planning for the Future: Newer Systems Need Flexibility and Advanced Control to Create Smarter Buildings Remote Cloud services Transactive services Traditional control architecture expanding to enable more value Flexibility provided by add-on apps which facilitate customized solutions Site control provides macro-level control and coordination of equipment on a cross-site basis (i.e., HVAC/R) Supervisory Transactive services Transactive services provide opportunities to utilize smart grid as well as other cloud-based services (i.e., renewable integration, etc.) Apps Site control Advanced supervisory functions Equipment control Distributed controllers 22
How Refrigerant and Control Selections Are Impacting System Design and Engineering Andrew Knight Vice President Henderson Engineers
Considerations for Small Store/Footprint Design As demographics are shifting to higher-density living, consumers still expect convenience and proximity to fresh food. Accommodating smaller-footprint stores in high-rise or mixed-use buildings can be challenging. The ability to offer fresh and convenient offerings of a grocery store is directly related to the systems that support them, such as HVAC and refrigeration systems. Spaces not intended to support grocery operations can be expensive to upgrade. 24
Equipment Considerations for Small Store/Footprint Design Compressor House? Consolidation of rack(s), condenser(s), electrical and centralized controls Service technician friendly But large and heavy 25
Equipment Considerations for Small Store/Footprint Design (cont d.) Machine Room/Equipment Mezzanine (maybe) Consolidation of rack(s), electrical and centralized controls Serviceability Expensive to build Can take up sizable space inside store (possibly reduced sales floor space) Needs leak detection and exhaust 26
Equipment Considerations for Small Store/Footprint Design (cont d.) Distributed System Mounted on top of walk-in coolers Saves space and is quiet Service access isn t ideal What happens if/when walk-in needs replacement? 27
Equipment Considerations for Small Store/Footprint Design (cont d.) Exterior Distributed System Packaged equipment Lighter-weight unit Integral condenser Limited capacities (depending on the ambient) 28
Equipment Considerations for Small Store/Footprint Design (cont d.) Unitized Exterior Distributed System Packaged equipment (mounted to curb) Lighter-weight unit with microchannel condensers All electronic valves Case controls separated from rack controls 29
Considerations for Small Store/Footprint Design Question: When should refrigeration and HVAC system considerations begin? Answer: Ideally, during the site evaluation/selection process. (But it s about location, location, location!) Reason: Shell-building systems (especially in older buildings) were not designed to support the refrigeration and HVAC system demands of a grocery store and the heat they can generate. Example: Currently working on a project where a landlord is unable to provide the means necessary for THR. In order to reduce THR, operator has been forced to reduce refrigerated case footage and cooking appliances theoretically reducing ROI. 30
ANNUAL kwh Refrigerant Energy Comparison (20-30K sq. ft.) 450000 kwh vs. Location 400000 350000 300000 250000 200000 150000 100000 50000 R448A R407A R744 0 Denver, CO Evap. Cond Denver, CO Air Cond. Chicago, IL, Evap. Cond. Chicago, IL Air Cond. Santa Monica, CA Evap Cond. LOCATION Santa Monica, CA Air Cond. Austin, TX Evap. Cond. Austin, TX Air Cond. 31
Trends in Case Control Technology Case-level control along with electronic expansion valves allow for greater flexibility for merchandising. Another advantage of caselevel control is the capability of embedding case parameters locally with the case instead of a centralized system. Cases could soon have selfdiagnostic capabilities (like your car) to communicate issues before problems surface. Advancements in Electronic Valve and Controls Technology Have Helped Case-Level Control Become More Viable. 32
Trends in Case Control Technology (cont d.) Advancements in electronic valve and controls technology have helped case-level control become more viable (cont d). Case controller allows consolidation of 120 V circuits fans/lights/antisweat circuits; leads to pulling fewer conductors. Crystal ball: it won t be too long before we start seeing advancements in defrost technology in refrigerated cases. 33
Cases How many residential refrigerators are on the market without doors? 34
Cases (cont d.) 400000 Lifecycle Energy Cost (20 Years) 350000 300000 250000 Adding doors reduces compressor horsepower up to 83% and energy usage by 75%! 200000 150000 Medium Temp (ft) Load (MBH) Suction Temp ( F) Compressor (HP) Energy (kwh) Annual Energy Cost ($)* Lifecycle Energy Cost (20 years) 100000 Open 448 436 26 66 225,00 0 $18,000 $360,000 50000 Doors 448 118 32 11 56,000 $4,480 89,600 0 Open Doors *Based on $0.08/kWh Open Doors 35
Cases (cont d.) New construction implementation depends on store planning approval. Retrofit New case or retrofit existing multi-deck? Retrofitting existing multi-deck considerations: Control valve sizes Riser and piping sizes Rack considerations 36
Thank You! Questions? 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. 37