Coolstore Refrigeration in a Post R22 World

Matthew Darby

Coolstore Refrigeration In A Post R22 WorldForces affecting

choicesRetain, Retrofit or

Replace?Refrigerant

CharacteristicsRefrigeration systems

Case Study

Making a Decision

Disposing of R22www.ecochill.kiwi

Matthew Darby

EcoChill 3

R22 phase out and regulatory pressures are creating change in the refrigeration industry…

1987Montreal Protocol established

1996NZ implements Ozone Layer Protection Act & Regulations

2010New HCFC Imports reduced on yearly basis by 63%

2015NO new HCFC’s imported: R22

Montreal Protocol -impact on synthetic refrigerants.

NOT A USE BAN

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…while market demands are driving system selection…

Refrigeration SystemSelectionBusines

s

Performance Government

Consumer

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Deciding how to manage refrigeration can seem complicated; but when it comes down to it there are 3 real options…

RetainKeep R22 system

RetrofitKeep plant and replace

with a synthetic refrigerant Replace

Build new plant with synthetic or natural

refrigerant

Capital CostLow

Strategy

Low

Capital CostMed

Strategy

Med - High

Capital CostHigh

Strategy

High

EcoChill

Retrofit or Replace: Changing Refrigerants

Synthetic

CFC’s (Phased

Out)

HCFC (Phasing

Out)

HFC’s

HFO’s

Natural

Ammonia

CO2

HC

Water

Air

Alternative

Electro-calroic

Magnetic

Sonic

Hydraulic

Optical Cooling

Acoustic

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Secondary Systems

Commercially

viable

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Safety

Performance

Economics

Environment

Retrofit or Replace: Choosing a Refrigerant

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REFRIGERANT SELECTION

Toxicity, Flammability

Working Pressures

Physical Properties Energy

Technology Changes

Energy Efficiency

Ozone (ODP)

Climate(GWP/ TEWI)

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Retrofit or Replace Refrigerant: Synthetics

Ref. Safety Performance

Economics*

Environment

GWP (100Y)

404A $17 kg 3922

438A $52 kg 2264

407F $23 kg 1824

134A $15 kg 1430

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*R22 currently $32 kg - predictions $50 post December 2014.

Legend0 = Poor1 = OK2= Good3 = Excellent

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Globally synthetic F-Gas refrigerants are facing

ongoing regulation and phase out…

The Move Away from HFC’s

1987Montreal Protocol CFCs banned.

2005Kyoto ProtocolGreen house Gas Emissions regulated. HCFCs banned.

2014North American Amendment to Montreal ProtocolHFCs phase out starts.

2015EU F- Gas RegulationsHFCs phase out starts.

UN FCCCFrance 2015Global

commitment to do more to control SGG’s & scale up activity

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Replace Refrigerants: Naturals

Ref. Safety

Performance

Economics*

Environment

GWP (100Y)

$6.50 kg

1

3

0

$ 82 kg

$14 kg

CO2(R744)

Ammonia (R717)

HC /mix (e.g.

R290)

*R22 currently $32 kg - predictions $50 post December 2014.

Legend0 = Poor

1 = OK2= Good

3 = Excellent

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Replace Refigerant: Alternatives

Safety Low toxicity (?), flammable

PerformanceNo known cool

store sites within NZ

Economics Not currently available

Enviro.(GWP 100Y) 4

“No known coolstore installs.”

HFO 1234yf

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Replace Systems: CO2 for Kiwifruit Coolstores

Advantages• Use single refrigerant.• Increased energy efficiency.• Low cost of CO2.• High humidity. • Safe refrigerant.• Environmentally good

choice.

Disadvantages• Not widely used.• Limited knowledge/

skill.• Capital and servicing

costs (though gap closing).“Becoming more

viable: situation specific.”

EcoChillDiagram courtesy of water-food.com

Replace Refrigeration Systems: Secondary

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• Reduce amount of primary stage refrigerant.

• Reduce leakage rate of primary stage refrigerant.

• Reduced primary system size.• Easier maintenance.

Why?• Smaller primary

circuit compared to DX.

• Uses a secondary fluid as main cooling medium.

What?

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Replace: Advancements in Secondary Systems• Reduced refrigerant charge• Increased energy efficiency• Increased system reliability• Reduced operating costs• Reduced stored product risk• Guaranteed system safety

and compliance

Standard Secondary EcoChill

Expansion Valves Likely Mechanical ElectronicCapacity Control Likely Unloaders VSD

Primary Circuit Size Likely Standard Optimised for Critical Charge

Primary Refrigerant Quantity Likely Standard Minimised through

design14

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Replace Systems: Maintaining Optimal Conditions

• Pack• Precool

• Uniform Temperature

• High Humidity• No Air Temp

Variations• Energy Efficient • Low Maintenance

• Increased margin• Higher “vine to

table” volumes“Refrigeration: providing competitive advantage.”

Zespri images courtesy zespri.com

Case Study

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Problem• Old R22 systems• Reduce running costs• Looking for added value

Solution• Reengineered precooling • Refurbished R22

coolstores to optimal conditions• Built new coolstore same

footprint as R22• EcoChill Kiwi using HC/

Glycol Advanced System design.

Kerifresh images courtesy Kerifresh.co.nz

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Store capacity (Pallets)

Cost to Cool(Per Pallet/

Day

% improveme

nt

R22 840 $0.34 BaselineEcoChill 864 $0.25 36%

“36% saving onenergy costs while

cooling more pallets”

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R290 R22 R404A / R507

R134A R407f

9481,173

1,568

1,119 1,228

Tons of CO2 over 15 years

Total Equivalent Warming Impact “225

tonnes of CO2 savedor the yearly emissions from 43 cars.”

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R290 R404A / R507

R134A R407f

19%

-34%

5%

-5%

Overall System Performance

R22

“TEWI: EcoChill

19% better off

than an R22

system ”

Total Equivalent Warming Impact versus R22

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Refrigerant Costs by Comparison

R290 R404A / R507

R134A R407f$0$500

$1,000$1,500$2,000$2,500$3,000$3,500$4,000$4,500$5,000

3,280 3,400 3,375

4,600

164 170 168.75 230

Initial System ChargeAnnual Leakage Rate 5%

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Refrigeration System Options

Secondary

Direct Exp

CO2 Advanced

Secondary

LowHigh

High

Low

Capital Cost

Operating Cost

Taking Action

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Asse

ss • Audit- Quantity- Leakage- Age- Loads- Design

• Capture

Iden

tify • Decision

criteria - Performance- Design- Investment- Regulatory- Cost - Competitive advantages

• Limitations

• Budget & timing

Sele

ct • Best option

• Complete

• Verify

Making A Decision

Decision Process

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Working With Your Refrigeration Partner

ExpertiseReliability

Safety Licensed Experience

Energy Efficiency Service Offering

Product Offering (Parts)CCCA/ IRHACE members

EcoChill

R22 – Ask How It’s Disposed.

• Response to public and legislative concern - refrigerant industry set up the Refrigerant Recovery Trust.

• Not for profit that collects a levy on SGG’s purchases - pays for disposal/ ensures not released into the atmosphere.

• Illegal to knowingly release R22 into the environment when servicing, maintaining or disposing of refrigeration & AC plant and equipment.

• Fines of up to $100,000.

• More information on obligations: www.epa.govt.nz 2

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www.RefrigerantRecovery.co.nz

www.ecochill.kiwi

QUESTIONS?