cascade co2_nh3 refrigeration
TRANSCRIPT
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ASustainableRefrigeratingSystem
forthePRWIndustry
2012Heartland
Chapter
Meeting
Chicago,IL.October34,2012
CascadeCO2
/NH3
Refrigeration
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RefrigerationThen
1924 Ball Horizontal Dual Acting Compressor
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RefrigerationThen
Rotary Blade Booster
Compressors
Reciprocating High Stage
Compressors
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RefrigerationNow
Screw Compressor and Reciprocating Compressor
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ModernRefrigerationEngine
Room
Cascade CO2/NH3 System
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ShouldIChoseCO2
(R744)formyRefrigerating
System? Whattemperaturesdoyouneedtomaintain?
Arethereproductfreezingrequirements?
IsmaintainingareducedAmmoniasystem
chargecritical?
Isno
contaminating
refrigerants
in
the
food
storage,processingandemployeeworkareas
desirableor
needed?
And,isprovidingaGreen
refrigeration
system
important?
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RefrigerationSystem FirstCost
SingleStageEconomizedSystem(Lowest)
CascadeCO2
/NH3
System(Mid
Range)
TwoStageAmmoniaSystem(Highest)
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Independent3rd
PartyStudySystem Efficiency Results
Cascade CO2 vs. Two Stage NH3
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Independent3rd
PartyStudy
2StageNH3
Reference
System[kW/TR]
CO2/NH3
CascadeSystem
[kW/TR]
%Improvement
InEfficiency
20FSuctionGroup 0.8 0.7 12.3
58FSuctionGroup 1.6 1.0 37.3
Combined
20Fand
58F
Suction
Groups 1.2 0.9 28.7
HighTempSuctionGroup 0.7 0.8 8.5
TotalSystemkW/TR(Compressors) 1.7 1.6 8.1
Total
System
kW/TR
(Compressors
and
Condenser) 1.9 1.8 6.8
TotalSystemkW/TR(Compressors,
CondenserandAirUnits) 2.4 2.3 5.8
System Efficiency Results
Cascade CO2 vs. Two Stage NH3
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FieldTestMeasurement/Instrumentation
Flow Meters
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CO2
SystemAdvantagesOperating
0.80
1.00
1.20
1.40
1.60
1.80
2.00
2.20
-70 -65 -60 -55 -50 -45 -40 -35 -30 -25 -20
COP
Evaporating temp [deg F]
COP comparison of CO2/Ammonia withconventionel Ammonia Systems at full load
CO2/AmmoniaDT cascade = 9F
Single stage withopen economizer
Two stage withopen inter-midiate cooler
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CO2
SystemAdvantagesOperating
COP comparison of CO2/Ammonia with
conventionel Ammonia Systems at 50% load
0.40
0.60
0.80
1.00
1.20
1.40
1.60
1.80
2.00
2.20
2.40
-65 -60 -55 -50 -45 -40 -35 -30 -25 -20
Evaporating temp [deg F]
COP
CO2/Ammonia
DT cascade = 6F
Single stage with
open economizer
Two stage with
open inter-
midiate cooler
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CO2
SystemAdvantagesOperating
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CO2
SystemAdvantagesOperating
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CO2
SystemAdvantagesOperating
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RefrigerationSystem
Ammoniacompressor
CO2
compressor
Ammoniacondenser
CO2
/NH3
heatexchanger(cascade
cooler)
CO2
receiver(pump
separator)
CO2
evaporator
CO2
liquidpump
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CO2
Application ColdStorage
NH3 Surge
Drum
NH3 Screw
11 / 95F
Evap. Condenser
CP-Receiver
(Economizer)NH3/CO2 Cascade
Heat Exchangers
CO2
VPR
-55F
CO2
VPR
-30F
Blast FreezerFreezer
NH3 Screw
11 / 95F
CO2 HPR
20FCO2 Recip
-55/ 20F
CO2 Recip-55/ 20F
CO2 Recip
-30/ 20F
CO2 Recip-30/ 20F
Drier
CoolerDock
OilRectifier
OilRectifie
r
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CO2
SystemsBackgroundDrivers
Refrigerantsituation
Ammoniacharge
restrictions
Ammoniasdamagingeffects
Electricity
costs Lowerfirstcost
Refrigerant
cost Lowertemperaturesatreasonablecosts
Lessspacerequired
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CO2
SystemsFactsonCO2
(R744)
CO2
isalreadyintheatmosphere
CO2
isnon
toxic
and
non
flammable
CO2
isusedtoputoutfires
A
major
leak
will
not
damage
products OnlyCO2
snow(DryIce)willfalldownon
products
Dryicesublimatetovaporandwillnotleavea
wetsurface
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CO2
SystemsFactsOnEmissions
CO2CascadeSystemsreduceCO2emission
lb.less
CO2emission
for
each
kWh
saved
1mileinanaveragecarproducesonepound
ofCO2
emission
Cryogenicfreezingtypicallyuses2lbs.ofCO2
foreachpoundofproductfrozen
InaCO2cascadesystemstheCO2
iskept
insidetheclosedloop
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CO2
SystemAdvantagesLowerFirstCost
LowerCosts
Compressors(LTside)
Suctionanddischargepiping,valvesinsulation,etc.
Liquidseparatorvessels(plusinsulation)
Refrigerant HigherCosts
Cascadeheatexchangerinsteadofintermediatecooler
vessel Liquidpiping,valvesinsulation,etc.
Higherpressureratingforsomecomponents
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CO2
SystemAdvantagesLowerFirstCost
0.3
3.0
30
300
-67 -58 -49 -40 -31
Evaporating temperature (o
F)
Capacity(TR)
CO2
NH3
HighPressureCompressor
HPO28
StandardCompressor
CMO28
Condensing temperature at 14oF
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CO2
SystemAdvantagesLowerFirstCost
Liquid, 300ft pipeLiquid, 300ft pipe
Pipe sizePipe size TemperatureTemperaturedropdrop
PressurePressuredropdrop
VelocityVelocity
InchInch FF PSIPSI ft / secft / sec
AmmoniaAmmonia 22"" 1.41.4 1.41.4 3.63.6
CO2CO2 4"4" 0.30.3 1.051.05 3.53.5
Discharge, 100ft pipeDischarge, 100ft pipe
Pipe sizePipe size TemperatureTemperaturedropdrop
PressurePressuredropdrop
VelocityVelocity
InchInch FF PSIPSI ft / secft / sec
AmmoniaAmmonia 6"6" 0.210.21 0.20.2 7979
CO2CO2 4"4" 0.140.14 0.90.9 2929
Wet suction, 300ft pipe, two 90 bends, one stop valveWet suction, 300ft pipe, two 90 bends, one stop valve
Pipe sizePipe size TemperatureTemperaturedropdrop
PressurePressuredropdrop
VelocityVelocity
InchInch FF PSIPSI ft / secft / sec
AmmoniaAmmonia 12"12" 1.011.01 0.310.31 5454
CO2CO2 6"6" 0.960.96 2.852.85 2323
Dry suction, 100ft pipe, two 90 bends, one stop valveDry suction, 100ft pipe, two 90 bends, one stop valve
Pipe sizePipe size TemperatureTemperaturedropdrop
PressurePressuredropdrop
VelocityVelocity
InchInch FF PSIPSI ft / secft / sec
AmmoniaAmmonia 12"12" 0.290.29 0.0890.089 6868
CO2CO2 6"6" 0.330.33 11 3939
Piping example 300TR at -40F
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CO2
SystemAdvantagesCharge/Leaks
Lowammoniacharge
Ammonialimitedtoengineroom
CO2
doesnotdamageproducts
CO2
isnontoxicandnonflammable
However!!
Longtermexposurelimitis1%concentrationofCO2
Shorttermexposurelimitis3%concentrationofCO2
10 20%concentrationofCO2
ishealthandlife
threatening
CO2
detectors
are
required24
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CO2
SystemAdvantages
Service/Maint. Norecoveryunitorwaterbasinsrequiredforopening
systemcomponent
Nosmell
NooildrainageonCO2
side
Alwayspositiveoperatingpressure
However!!
Becarefulwithtrappedliquid.Ifthetemperatureisincreasedby
7F,thepressureincreasestotheyieldlimitofsteelpipes!
Becareful
with
trapped
liquid/gas.
Saturated
liquid/gas
at
room
temperature e.g.68F=812 PSIG
Componentevacuationforair/moisturerequiredafterservice
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CO2
SystemAdvantagesValveGroups
Penthouses,
piping and valvegroups on roof
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CO2
SystemAdvantagesPiping
Condenserand
mainpiping
on
roof
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CO2
RefrigerationSystems
CO2
Compressors
8cyl.206TR
4cyl.103TR
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CO2
RefrigerationSystems
Ammonia
Compressors
Screw222TR
Screw
307
TR
Applications Typ. Cold Storage - Example
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CO2
RefrigerationSystems
NH3
Surge
Acc.CascadeCO2Condenser
HPR&
LPR
Applications Typ. Cold Storage - Example
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CO2
RefrigerationSystems
Economizer(CPR)
Glycolfloorwarming
heatedbyoilcoolers
CO2
HPR
(Highpressure
receiver)
Applications Typ. Cold Storage - Example
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CO2
RefrigerationSystems
Oil Rectifier
Oil reservoir
Oil heater and
Temp. sensor
Oil return
Oil float switch
Applications Typ. Cold Storage - Example
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CO2
RefrigerationSystems
Large PRWs utilizing Cascade
CO2
Refrigerating Systems
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CCCCCCCCCCCCCCCCCCCCRRRRCCC
CCCCCCCCCCCCCCCCCCCLLLLCCCCCCCCCCCCCCCCCCCCCCCCCCCLLLLLL
LUCK
ThankYou
ChuckToogood
M&MRefrigeration,
Inc.
(410)7548005
34
mailto:[email protected]:[email protected]:[email protected]