Refrigeration System Archtiectures and Compressor Solutions in Light of F-Gas Regulation

1

Exhibition Hall 1

Technical

Programme

Fachprogramm

Refrigeration System Architectures and Compressor Solutions in Light of F-Gas Regulation

Venugopal Kandi

Product Manager Refrigeration Marketing

Emerson Climate Technologies

52076, Aachen

Germany

Emerson Climate Technologies, File Name, xx/yy/zz, Page 3

Overview

F-Gas 517/2014 Overview

Commerical Refrigeration – Simplistic View Of Market Today

F-Gas Impact On Commercial Refrigeration

System Architectures & Compressor Technologies

Summary – Practical Refrigeration Systems & Refrigerant Options


F-Gas 517/2014 – Summary & Timeline

2015 2016-17 2018-20 2021-23 2024-26 2027-29 2030

21% 100% 63% 45% 31% 24% 93%

Domestic

fridge (GWP

150)

2025:

split AC

(GWP 750)

2020:

• Moveable AC (GWP

150)

• Hermetically Sealed

Comm. Refrig (GWP

2500)

• Stat Refrigr (GWP

2500)

2022:

• Hermetically Sealed

Comm Refrig (GWP

150)

• Multipack refr

(GWP 150) – except

primary cascades

(GWP 1500)

01/01/2015:

Applicabilit

y + repeal

842/2006

31/12/2022:

Comprehensive

report on effect

of Regulation

01/07/2020:

Report Annex

III: split AC

31/12/2020:

HFC report

01/01/2017:

• Report national

codes/standards

re. alternatives &

training

01/07/2017:

• Report Annex III:

multipack

• Report PD method

Ph

as

e-d

ow

n

Ba

ns

O

the

r

Re

vie

w/r

ep

ort

s

2017:

Traceability

2020:

Service ban >2500

2030:

No recycled/reclaimed

for servicing >2500

2015:

Reporting


0

50

100

150

200

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30

20

31

20

32

MTo

ns

of

CO

2 E

qu

ival

en

t

100%93%

63%

45%31%

24% 21%

F-Gas 517/2014 Phase Down/Quota

Based on 2009-2012 average consumption

– Exact value to be confirmed end of this year

– Allocated to refrigerant producers & importers & NER (New Entry)

2017: pre-charged equipment imported under quota

Expected average GWP in 2030: ~350 (Emerson)


Se

gm

en

t

Food Service, Convenience Discounter, Small Retail Large Retail

Te

ch

no

log

y

DX Centralized MT/LT

R404A, R134a

Integral LT

R404A, R290


R404A, R134a

Self-Contained Cases

R404A, R134a


R404A, R134a, R744

DX Decentralized MT/LT

R404A, R134a, R744

Eq

uip

me

nt

Condensing Units

Integral Equipment

Condensing units


Small Packs

Large central packs

Distributed packs

Siz

e

Small Medium Large

Commercial Refrigeration – A Simplistic View Of The Market Today


Different Refrigerant Options – Need To Choose A Future Proof Refrigerant

• No Refrigerant Will Satisfy All Metrics Of An Ideal Refrigerant

• HFC < 2500 Are Available Today & Will Play An Important Role In The Transition Phase

• Natural Refrigerants And Low GWP Refrigerants <150 GWP Provide Future-Proof Solution

ASHRAE No. Common

Name GWP

Safety Class

Replacing Ready-to-

use

R404A R404A 3922 A1 - today

R407A/F R407A/F 2107/1825 A1 - today

R134a R134a 1430 A1 - today

R448A N40 1000…150

0 A1 R404A 2015

R449A XP40 1000…150

0 A1 R404A 2015

R450A N13 400…700 A1 R134a 2015

R513A XP10 400…700 A1 R134a 2015

R744 CO2 1 A1 - today

DR7 DR7 150…300 A2

(A2L) R404A > 2016

R1234yf 1234yf 6 A2

(A2L) R134a > 2016

R1234ze 1234ze 4 A2

(A2L) R134a 2015/16

R717 Ammonia 0 B2 - today

R290 Propane 3 A3 - today


F-Gas Regulation Impact - New Equipment Commercial Refrigeration

Refrigerators and freezers for commercial use

(Hermetically sealed systems)

Stationary refrigeration equipment

Exception: Equipment for product temperatures below -50°C

Mulitpack centralized refrigeration systems for commercial

use with a cooling capacity ≥ 40kW Exception: Primary refrigerant circuit of cascade systems, where fluroinated

green house gases with a GWP of less than 1500 may be used

1

2

3

Jan 2020: 2500

Jan 2022: 150

Jan 2020: 2500

Jan 2022: 150


Refrigerators and Freezers for Commercial Use

System Architecture Compressor Technologies Applications

Refrigerant Options

Transitional

(< 2500)

Future-Proof

(< 150)

Small Hermetic Piston Food Service & Convenience

HFC<2500 • R407A/F

• R448A

• R449A

• R450A

• R134a

R290

HFO (<150)

Scroll Technology Food Service & Convenience

Discounter & Small Retail

HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R290

HFO (<150)

1


MT

Integrals LT

System Architectures: Integrals & Self-Contained Cases

• Compact

• Light weight

• Transitional / Future Proof

Scroll HFC Scroll R290

http://www.aht.at/en/products/supermarket/island-merchandisers/


Self-Contained Display Cases For Small Retail Applications

Move From Centralized Pack To Self-Contained Display Cases (Vertical & Horizontal)

Ideal For Discounter And Small Retailer Applications

Several Hundred Stores Are In Operation With Self-Contained Display Cases With Scroll

Remote Display Cabinets Self-Contained Cabinets

Feature Centralized Remote System Self-Contained Display Case

Flexibility Low High – Plug And Chill

Service Complexity High Low

Refrigerant Charge High Charge Low Charge

Speed / Lead Time Long Fast

Onsite Installation Complex, Long Pipe Length Simple, Factory Bulit

1

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Stationary Refrigeration Equipment Systems


Refrigerant Options

Transitional

(< 2500)

Future-Proof

(< 150)

Food Service &

Convenience

Discounter & Retail HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R744

HFO (<150)

R290

Discounter & Small Retail

HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R744

HFO (<150)

Small Compressor Pack

System Architectures : Condensing Units & Small Compressor Packs

Condensing Unit

• Semi Hermetic w/ CoreSense

• Simple & Precise Stream Digital

• Scrolls - Low Sound

• ATEX Certified R290 Compressor


Semi Hermetic & Scroll


Scroll HFC Semi HFC/CO2

• Multi refrigerant Semi HFC

• Semi CO2 for high stand still

• Digital modulation on Semi/Scroll

• Scroll w/ CoreSense Diagnostics


Semi HFC/CO2 Scroll HFC Scroll R290

2


Multipack Centralized Refrigeration System For Commercial Use ≥ 40kW


Refrigerant Options

Transitional

(< 2500)

Future-Proof

(< 150)

Small Retail, Large Retail

HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R744

Semi Hermetic & Scroll Discounter & Small

Retail

HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R744

HFO (<150)

CO2 Booster System

CO2 Cascade System

System Architectures : CO2 Booster & Cascade Systems

• Semi Subcritical With High Standstill

• Scroll suction/discharge 30/52

• Inverter modulation for Semi CO2

• Semi Hermetics w/ Diagnostics

• Semi & Scroll Multi-Refrigerant (MT)

• Simple And Precise Semi Digital

• Compact & Light Weight Scroll


Scroll LT


Semi MT Semi LT

Semi MT Scroll MT Scroll LT

3


Examples Of CO2 Booster System With Semi / Semi & Semi / Scroll Compressors

CO2 Booster Semi/Semi CO2 Booster Semi/Scroll

Stream CO2 Low Temperature

Stream CO2 MediumTemperature

Trialled From Nov 2012 To July 2013 in UK

Medium Temp: 2 x Stream 4MTL With Inverter

Low Temp: ZO21 Scroll + ZOD34 Scroll Digital

40 to 60 Packs Running In Different Locations

Running Since June 2012 – 50K Running Hours

Medium Temp: 5 x Stream 4MTL With Inverter

Low Temp: 2 x Stream 4MSL With inverter

Regular Production For Green & Cool

3


Multipack Centralized Refrigeration System For Commercial Use ≥ 40kW


Refrigerant Options

Transitional

(< 2500)

Future-Proof

(< 150)

Small Retail, Large Retail

HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R290

HFO (<150)

Semi Hermetic & Scroll Discounter & Small

Retail

HFC<2500

• R407A/F

• R448A

• R449A

• R450A

• R134a

R290 (MT)

HFO <150 (MT)

R744 (LT)

Secondary System

Hybrid-Cascade System

System Architectures : Secondary & Hybrid-Cascade Systems

• Semi And Scroll Option For MT

• Full Hermetic Scroll For R290

• Tandem Possibility For R290

• Digital Modulation Semi / Scroll HFC

• Scroll CO2 suction/discharge 30/52

• Scroll MT With HFC And R290

• Semi With CoreSense On Board



Semi HFC

Semi HFC Scroll HFC/R290 Scroll LT

Scroll HFC Scroll R290

3


Different CO2 System Architectures – Advantages & Disadvantages

System Architecture Advantages Disadvantages

CO2 Booster System • One Refrigerant

• One System, Lowest System Costs

• Better Efficiency Than HFC Systems

In Cold Climates

• System Faults In Coupled Systems

Affect MT and LT

• High Operating Pressures

• Lower Efficiency Than HFC Systems In

Warm Climates

CO2 Cascade System • Two Simple Systems

• LT With Low R744, The MT With A

Low GWP HFC Refrigerant

• Standard HFC Components For

Medium And Low Temperature Cycles

• Better Efficiency In Warm Climates

• Two Refrigerants Although R744 Can Be

Used In The High Stage

• Temperature Difference In The Cascade

Heat Exchanger Reduce The Efficiency

For The LT Cycle

• System Faults Affect MT And LT

CO2 Secondary System • Using R744 As A Secondary Fluid

Using The Latent Heat, Very Low Pump

Power Required

• Simple Chiller System For The High-

stage With Avaialble Components

• Chiller Could Use HFOs Or HCs

• Additional Heat Exchange And

Tempeature Difference Slightly Reduce

The Efficiency

• R744 Pumps Required


Se

gm

en

t

Food Service, Convenience Discounter, Small Retail Large Retail

Re

frig

era

tio

n

Sys

tem

1. Condensing Units

2. Self-Contained Cases

MT/LT

1. Small Compressor Pack

2. Condensing Units

3. Self-Contained Cases MT/LT

1. Booster CO2 System

2. Cascade CO2 System

3. Secondary System

Sh

ort

Te

rm

Re

frig

era

nt HFC<2500

• R407A/F

• R448A (N40)

• R449A(XP40)

• R450A (N13)

• R134a

HFC<2500

• R407A/F

• R448A (N40)

• R449A(XP40)

• R450A (N13)

• R134a

HFC<2500

• R407A/F

• R448A (N40)

• R449A(XP40)

• R450A (N13)

• R134a

Fu

ture

-Pro

of

Re

frig

era

nt

1. R744, R290, HFO (<150)

2. R290, HFO (<150)

1. R744, R290, HFO (<150)

2. R744, R290, HFO (<150)

3. R290, HFO (<150)

1. R744 / R744

2. HFO / R744

3. HFO or HC / R744

Summary– Practical Refrigeration System & Refrigerant Options

17

Exhibition Hall 1

Technical

Programme

Fachprogramm

Refrigeration System Archtiectures and Compressor Solutions in Light of F-Gas Regulation

Documents

average gwp

split ac gwp

overview fgas

moveable ac gwp

low gwp refrigerants

multipack refr gwp

r134a integral lt r404a

r290 dx centralized