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System Design for CO2 Secondary Coolant Based System

Hernan Hidalgo, Danfoss Inc.

www.danfoss.com

Content

Most Common Refrigeration Systems


Considerations for CO2 use
Brine Principle. Volatile vs. Glycol
Pressure Rating Considerations
Energy Consumption Analysis
Control in CO2 High Temp Rooms
Defrost Strategies
Moisture in CO2 systems

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April 2012 | 2

Systems overview
NH3 systems. Low,Medium,High Temp
NH3/Glycol Systems. Medium Temp
NH3/CO2 Cascade systems. Medium/Low Temp
NH3/CO2 Brine systems. Medium / Low Temp

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Indirect Cooling - Considerations

NH3 chargereduction
Largenumberofstaffinprocessareas
InsurancePremiums Riskassessment

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NH3/Glycol Layout

Warm Glycol

NH3

Cold Glycol

Supply Pump

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NH3

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April 2012 | 5

Glycol Systems
Large Footprint
Typically two large expansion tanks required for
pump units
Larger Pipe Sizes / More Insulation
Higher Pumping kW
Glycol Mixture Monitoring

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CO2 Overview

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NH3 CO2pumped
High Side - NH3

Low temperature CO2

NH3 Compresor(s)

Cascade
Heat
Exchanger

CO2 separator
Evaporator
CO2 pump

ICM Motorized valve

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NH3 CO2on PH

CO2

-15 oC
+5

(23 bar)

+86 oF

oF (333 psi)

+30 oC

(171 psi)
(12 bar)

R717
-4 oF (28 psi)
-20 oC (1,9 bar)

Enthalpy

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Enthalpy

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April 2012 | 9

CO2 Wet Suction Pressure drop

Evap Temp.

NH3

CO2

32F

2.3 psig

14.5 psig

-4F

1.2 psig

9 psig

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CO2highdensityprovides
considerableadvantages
inwetordrysuctionlines
Pressuredrop
equivalentto
loweringevaporating
temperature1.8F

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CO2 Pump Systems


HighPressureCascadeHeatExchanger
RefrigerationloadinCO2 asbrinesystembalances
automatically
Oilfreeoperation
LowerPumpingkW
Lowerenergyconsumptioncomparedtoglycol
counterparts

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CO2 Pump System PH Overview

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EnergyEfficiencyCO2 asBrineSystems
High Heat Transfer Coefficient
Higher efficiency is noticeable at the cascade
heat exchanger
TD between NH3/CO2 is considerably lower than
NH3/glycol
Higher suction temp of cascade fluid
Line sizes are significantly reduced
Lower Pump Power

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PipeLineSizeComparison

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Energy Consumption
Low Recirculation rates than ammonia systems
Recirculation varies between 1.1 to 1.5

Volatile brine vs. Glycol sensible heat gain


CO2 pumps consume on average 90% less
energy required compared to water based
brines

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April 2012 | 15

CO2 vs. Glycol Mass Flow Comparison

A system operating at 14F (-10 C)


Mglycol = Q / (C T )
MCO2 = Q / H
Latent heat CO2 at 14F (-10C): 112BTU/lb
(260kJ/kg)

Cglycol = 0.72 BTU/lb-F (3.42) ; T = 7.2F (4K)


typical
Mass flow required to reject 247BTU/s (260kW)
cooling load
MCO2: ~ 2.2 lbs/s (1 kg/s) vs. ME. Glycol: 45.4 lbs/s
(20 kg / s)

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April 2012 | 16

CO2 vs. Glycol Pump Power Comparison


Calculation Example
Capacity: 142TR (500kW)
CO2 recirc. rate : 1.5 to 1
Differential Head: 82 ft (25m)
T glycol inlet/outlet: 7.2F (4K)
CO2 = 75%

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CO2 vs. Glycol Relative Pumping


Power
Power kW

Fluid

14 F (-10C)

.-4 F(-20C)

0.97

0.85

CaCl2

13.34

14.22

Hycool

16.02

16.15

Ethylene Glycol

15.87

18.8

Propylene Glycol

14.03

16.68

CO2

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Total Energy Consumption


SimplifiedAssessment.(Nodefrostandothervariablesconsidered)
Prequired =Pcompr +Ppumps
Pcompr = Qoadjusted /COP
COP:Calculationpurposes1.9for4F airand3.8
for32F
UsingPackCalculationIIandCO2 brinecalculator
v.3.91:fora215TR(750kW)plantandroomair
temperatureof39F(5 C)

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Total Energy Consumption


CO2

Ethylene
Glycol

Units

39

39

Cooling power, Qo

215

215

TR

Circulation rate, n

1.5

Air temperature, tair

Temp. dif. in evap., dtevap

13

7.2

7.2

25

19.5

5%

7%

37.5

50.6

kW

Pump head pressure, Hpump

37

37

psig

Pump power cons., Ppump

1.6

16.6

kW

Adjusted cooling power,


Qo,ad

789.1

815.6

kW

Compr. power cons., Pcomp

170.8

196.2

kW

Total install energy cons.

172.4

212.8

kW

3,112.9

3,930.3

kW*h

Temp. dif. in PHE, dtPHE


Brine temp. dif., tout - tin
Evaporating temp., to
Additional heat gains, kq
Additional heat gains, Qadd

Total daily energy cons.


Energy savings

21%

Table 2. Energy Consumption Comparison


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April 2012 | 20

Results
CO2 offersfasterreactiontime.However:
Savingsalsodependon
LoadPatterns
DefrostType
ControlStrategy
UseofVFD

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April 2012 | 21

Two Sites Comparison


Inanattempttovalidatetheoreticalcalculations,
datafromtwodistributioncentersforfruitslocated
intwodifferentclimateshasbeenanalyzed
Anadjustmenthasbeenmadetooffsetclimate
influence

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April 2012 | 22

Two Sites Comparison


Conditions / Location

North Italy

The Netherlands

Fruit

Fruit

Avera 34F

Aver 32F

8.6 F

13 F

Glycol

CO2

.=17.6 / 25

18.5

Temperature difference in cascade heat exchanger difference,


F

9 to 12

5.5 to 7.2

Cooler temperature difference, F

8 to 12

Lighting, estimated from the total load

10%

5%

Total fans installed, kW

74.1

45.3 (fans are running only


20% of the time)

1.300.000

2.700.000

Total compressors and pumps, kW h (calculated, excluding


lights and excluding fans)

576607

1245025

Region corrected consumption, kW h, by PackCalculation II


software, according to the assumptions above, everything
adjusted to the Netherlands climate

518000

1245025

Average consumption, kW (calculated by PackCalculation II


software to fit the corrected consumption)

188

660

Per unit of cooling consumption kW h/kW cooling (corrected


consumption / average consumption)

2.75

1.88

Storage type
Air temperature
Suction temperature
Brine Type
Media temperature (for glycol in/out) F

Total consumed, kW h (measured figure)

Difference in Energy Consumption

32% Higher

Table 3. Actual Energy Consumption site comparison

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April 2012 | 23

Site Results
Measuredvalue:kW/kWh
Thougha32%differenceissubstantial,large
deviationsoccurduetoothervariables

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April 2012 | 24

NH3 Systems Medium, High Temp

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PWM in high temp CO2

PWM

Raising 15F by means of a pressure


regulator requires a 106 psi increase in
CO2 pump pressure making it impractical

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April 2012 | 26

PWM Control Principle

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CO2 Brine System Control

ICF valve stations feeding penthouse units

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April 2012 | 28

CO2 Brine Pump Package

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April 2012 | 29

Standstill temperature control

PS

CO2 receiver

Dedicated
generator

Auxiliary
Refrigeration
system
(Condensing)

Auxiliary cooling system - in case of power failure


Capacity dependent of system design and ambient temperature
(~ 4kW / 1000 kW)

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April 2012 | 30

Defrost

Common defrost strategy for CO2 brine systems:

Electrical (similar to standard brines)

Brine defrost (additional system)

Water defrost (drain required)

Hot gas defrost. The availability of components rated at 754 psig (52 bar) has
made possible to use one of the most efficient defrost strategies

(requires additional vessel and HE heated by HP stage) There is a system


available patented by Star Refrigeration - UK

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April 2012 | 31

Hot Gas Defrost Control

PWM technology

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Electric Defrost

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Moisture in CO2 Systems

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Water Solubility in vapor phase

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R134a

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Moisture in CO2 vapor phase


20

Safe
Performance

Temperature [ C]

90
ppm

-40
RH = 0%

50
ppm

Free
Water
Ice

Other
Problems!
Chemical
Rection

Functionality Problems
Sensitive:

Solenoid
valves
7
ppm

Piston
equipment
RH = 100%

Other
equipment:
Strainers
Compressor

RH >> 100%

Relative Humidity
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April 2012 | 37

Water content in a CO2 system

Where Moisture comes from ?

Service
Filter driers continuous process
Infiltration
CO2 supplier

Start-up
vacuum

Deep vacuum, extra care


on commissioning and start-up

Note: 1 gram of water in 1000 kg of CO2 1 ppm

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April 2012 | 38

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