Tecnologie ad alta efficienza con refrigeranti alternativi agli HFC
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The recent introduction of international directives on the control of environmental CO2 emissions has had a major impact on the commercial refrigeration sector. Governments around the world are planning to soon approximate into national law directives on the reduction of HFC refrigerants, the so-called F-gases with high environmental impact, and establish regulations to promote the transition to natural refrigerants. “High-efficiency technology using alternative refrigerants to HFCs” is the title of the presentation by Biagio Lamanna, CAREL HVAC/R Knowledge Center Manager, aimed at underlining how it is possible to combine natural refrigerants with energy saving.
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Tecnologie ad alta efficienza con refrigeranti alternativi agli HFC
- 1. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Tecnologie ad alta efficienza con refrigeranti alternativi agli HFC Utilizzo dei gas naturali e altre alternative agli Fgas, con particolare riferimento al settore della refrigerazione, MATTM Biagio Lamanna Roma, 17 Nov 2016 This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden
- 2. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden 1. Carel in a snapshot 2. Refrigerants scenario 3. High efficiency technologies 4. Refrigeration applications: • Convenience stores (small shops) • Supermarkets (mid size shops) • Hypermarkets (large shops) Summary
- 3. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Carel in a snapshot
- 4. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden We are specialists in control technologies for air-conditioning & refrigeration. Our products are designed to bring value to the customer offering energy savings solutions.
- 5. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden 1100+ Employees 19 Subsidiaries 3,700+ Customers 6,200 Part numbers 7 Mln Pcs per year 203 Mln€ Turnover 7 Production facilities CAREL in snapshot
- 6. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden CAREL U.K. London - GB CAREL Ibérica Barcelona – ES Madrid - ES CAREL France Lyon - FR CAREL Deutschland Gelnhausen - DE CAREL Russia St. Petersburg – RU Moscow - RUCAREL Nordic Höganäs - SE CAREL Adriatica Labin - HR CAREL Central & Southern Europe Brugine - IT CAREL Ireland Dublin - IE CAREL SPOL Prague - CZ CAREL Turkey Izmir - TR Subsidiaries Affiliates CAREL Italia Brugine - IT CAREL INDUSTRIES Headquarters Europe & Middle East 668+ Employees
- 7. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden AAPAC CAREL China Suzhou – CN Beijing – CN Guangzhou- CN CAREL South Africa Johannesburg – ZA Cape Town - ZA CAREL HVAC&R Korea Seoul - KR CAREL Australia Sydney – AU Melbourne - AU CAREL Asia Hong Kong – CN Kuala Lumpur - MAL CAREL India Mumbai – IN Delhi - IN CAREL Japan Fukuoka- JP CAREL Thailand Bangkok- TH Subsidiaries Affiliates 267+ Employees
- 8. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Americas CAREL USA Manheim – US Milwaukee – US Los Angeles – US Atalanta – US Baltimore - US CAREL Sud America Valinhos - BR CAREL Mexicana Monterrey - MX Subsidiaries 120+ Employees
- 9. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Our key strategies We offer integrated solutions for vertical applications We innovate to achieve higher energy saving We continuously improve our operating performances and ensure financial solidity We want to be close to the customers for a better understanding of their needs We operate globally with the same world-class manufacturing standards We are specialists in HVAC and Refrigeration
- 10. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Our products range
- 11. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Refrigeration: supermarket, c-store, restaurant chain, refrigerated warehouse… HVAC: residential, commercial, industrial process, data centre Main system applications
- 12. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden A history of innovation 70’s Foundation 80’s Direction 90’s More Europe & Solutions 00’s More International December 1973: CAREL is founded First microprocessor electronic control for HVAC/R First European subsidiaries Geographical worldwide growth Cross market solutions
- 13. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Refrigerants scenario
- 14. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Refrigerants scenario
- 15. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden R-404A is quickly phased out in new commercial refrigeration equipment It is replaced with a range of different low GWP alternatives CO2 HFO blends HFC blends Refrigerants scenario
- 16. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden PROPANE PROS • High efficiency • Flexible for LT and MT applications CONS • Flammability • Missing legislative uniformity at EU and local level • Low cooling capacity due to 150g/circuit current charge limitation • Specific unit design CO2 PROS • Becoming really popular among markets driven by «green consciousness» • Low cost • Sustainable long term solution in many HVAC/R applications CONS • Low efficiency in warm climates • Expensive high pressure components • Still limited compressors capacity range • Specific unit design HFO blends R448A, R449A, R455A, R458A, R513, etc PROS • Retrofit allowed • Designed to be compliant with F-gas regulations worldwide CONS • Not a natural solution • Not clear future compliance with regulations • High current price, future pricing policy still not clear • Lack of LT (high pressure) solutions Refrigerants scenario
- 17. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Refrigerants scenario Effects of the transition between HFCs and their alternatives • Specific unit design may cause initial poor unit design due to lack of competences or time lower efficiency • Compromises natural refrigerants and low GWP HFO blends are not designed to be “good refrigerants” only, they are a compromise between different needs lower efficiency vs HFCs • Increased unit cost propane and CO2 require a specific components and safety devices (what about ROI?) higher efficiency is needed vs HFCs • Increased unit displacement CO2 requires extra components and pipings to work properly wise use of space is needed
- 18. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden High Efficiency Technologies
- 19. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Technologies: DC compressors On-Off cycling is not efficient as the refrigeration circuit needs time to reach the nominal efficiency. Part load conditions (i.e. 25%) won’t allow to reach nominal efficiency. Average efficiency is very low. This area represents the increase of efficiency at part load. It’s bigger with a wider DC compressor capacity range A refrigeration application is working for the largest part of the time at partial load Permanent magnet variable capacity compressors driven by intelligent DC drives (inverters)
- 20. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Technologies: DC compressors INCREASED ENERGY EFFICIENCY: • 10-40% higher part load efficiency VS fixed speed BETTER PERFORMANCES: • The controlled temperature is stable without on-off cycling • Lower noise operation at all most frequent conditions (part load) BETTER RELIABILITY: • Soft start of the compressor with controlled speed ramp • Extremely reduced number of compressor start-stops • Lower pressure ratio and temperature of the compressor REDUCED ENCUMBRANCE: • The compressor is smaller compared to a fixed speed one of the same capacity thanks to its speed range (up to 7800rpm VS 3600rpm)
- 21. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Technologies: Electronic Exp. Valves Electronic Expansion Valves, stepper motor valves driven by intelligent showcase controllers SH set Regulation temp. ADAPTIVE WORKING CONDITION To optimise the use of energy and keep a stable product temperature
- 22. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Technologies: Electronic Exp. Valves INCREASED ENERGY EFFICIENCY: • 10-40% higher efficiency VS mechanical devices (thermostatic valves, cap. tubes) BETTER RELIABILITY: • Can protect the compressor managing suction and discharge pressures, temperatures and superheat values BETTER PERFORMANCES: • Duty temperatures are reached very quickly and kept stable when using EEVs (also in case of refrigerant leakages!) EASIER MAINTENANCE: • No need of periodic checks on superheat regulation. Probes and controllers used to drive EEVs can provide useful feedback on the unit/plant behavior/issues
- 23. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Technologies: CO2 Ejector Carrier CO2 refrigeration expertize met Carel controls expertize to jointly deliver a full RANGE of MODULATING EJECTORS fo CO2 application • Continuous stepper modulation • Easy adaptation to all working condition and part load • Replacement of existing high pressure valve (HPV) • Different sizes to match different compressor rack capacities • Vapour ejectors design for full mass flow • Full advanced control system (rack, cabinets, monitoring) Ejectors provide a energy efficiency increase to all CO2 applications. With Ejectors CO2 systems are efficient even in warm and hot climates
- 24. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Refrigeration Applications
- 25. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Food quality Innovation suitable for all Always connected Small shops (HECU)
- 26. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Small shops (HECU)
- 27. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Any reproduction, modification or distribution of this document, whether in part or entirely and by any means, is expressly prohibited except upon CAREL's express prior written permission. 2016 CAREL all rights reserved Seasonal effect of High Pressure Optimization Night/day effect of Floating suction • LOWEST possible compression ratio fitted efficiently with lower compressor speed • MINIMUM possible refrigerant flow-rate through the heat exchangers increasing efficiency Small shops (HECU)
- 28. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Unique controller board For BLDC compressor management and CO2 valves management, both high pressure and flash gas valves Advanced DC compressor driver For an efficient and variable speed compressor driving and optimal performance at partial load Electronic expansion valves For a calibrated injection and precise regulation of gas cooler and receiver pressure Any reproduction, modification or distribution of this document, whether in part or entirely and by any means, is expressly prohibited except upon CAREL's express prior written permission. 2016 CAREL all rights reserved Fully integrated and compact solution ALL in ONE Small shops (HECU)
- 29. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Highest quality of food preservation combined with high energy efficiency The condensing unit constantly responds to the cooling demand of each connected unit, dynamically adapting to current conditions while the E2V valves on each unit are managing the flow of refrigerant, and the MPXPRO controllers minimize temperature fluctuations Any reproduction, modification or distribution of this document, whether in part or entirely and by any means, is expressly prohibited except upon CAREL's express prior written permission. 2016 CAREL all rights reserved Small shops (HECU)
- 30. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Direct data access and notification With optimized interface for different device and configurable report Any reproduction, modification or distribution of this document, whether in part or entirely and by any means, is expressly prohibited except upon CAREL's express prior written permission. 2016 CAREL all rights reserved GPRS-ETHERNET Simple and deep MAINTENANCE Fully independent access to the refrigeration unit to maximize the maintenance experience Intuitive site navigation With custom maps and graphics Easy optimization and higher service level With site graphs and trend Small shops (HECU)
- 31. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Mid size shops (HEOS) Self contained refrigerated unit with DC inverter compressor and Electronic Expansion Valve on board and with water condensation to recover heat.
- 32. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Flexibility SELF CONTAINED WATERCOOLED UNIT • Possibility to easly move cabinets inside the supermarket: Easy layout change • Easy installation or replacement of new/promotional cabinets Flexible sales area • No more need of compressor rack technical room Wider sales area • Critical components fully contained into the cabinet High investment recovery in case in case of store relocation Mid size shops (HEOS)
- 33. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden The stability in the regulation bring the effect to have the temperature at set point for the whole time Consequently, the Shelf-life of food in particular meat, fish and chicken can be increased. High Efficiency – Food quality Mid size shops (HEOS)
- 34. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Ease of installation & maintenance Installation • Plug & Play cabinets • Only power supply and water connection on field • No welding on fields, only plastic pipe connections • Factory tested and optimized units 40% Commissioning saving Low noise & vibration • Field measumerents demonstrates that noise level of compressors at maximum speed is always lower than environment noise (fan, people, etc…) • Low speed during normal operation and start up Comp. Speed SPL [dB] 0% 67,6 100% 67.1 Mid size shops (HEOS)
- 35. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden TEWI reduction 40% with HFCs! Refrigerant leaks reduction • No welding on the field • Factory tested units with statistical 1-2% leakage rate versus 15-20% of a centralised system Refrigerant charge reduction • No long copper pipes • No compressor rack • No receivers Environmental friendly even with HFCs Mid size shops (HEOS)
- 36. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden INTEGRATION WITH BUILDING AC SYSTEM allows to totally recover the heat of condensation of the refrigeration system • Waterloop as cold source for heat pumps in winter mode • Great overall building efficiency Summer mode Winter mode Mid size shops (HEOS)
- 37. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Heat Reclaim & AC integration Evaporative cooling Subcooler Parallel compression Ejectors Large shops (CO2 racks)
- 38. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Complete management of CO2 transcritical ejector system MT comps gas cooler heat reclaim flash gas valve ejector LT comps P comps • Direct management from main rack controller • MT and Parallel compressors switch • Real time communication with evaporators controllers • Built in features and safeties • Ultracap technology for safe closing in case of power failure • Scalable controllers platform Large shops (CO2 racks)
- 39. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Winter : standard CO2 transcritical system, ejector as replacement of HPV valve, flash gas valve Mid: standard CO2 transcritical system, ejector as replacement of transcritical valve, flash gas valve and parallel compressors synchronization Summer: Ejector mode, medium temp and parallel compressors ALL WORKING AS PARALLEL COMPRESSORS, gas ejectors maintaning ΔP for flooded evaporators Large shops (CO2 racks) Ejectors
- 40. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden Performance analysis: Ejectors grants high energy efficiency for all climates, even when compared to the best available technology with R404A Normalized Energy Consumption (Advanced R404A) Abs % Traditional R404A 108 8% Advanced R404A 100 Cascade R134a/CO2 102 2% Booster 95 -5% Booster + PC 91 -9% Booster + PC + EJ 86 -14% Traditional R404A 109 9% Advanced R404A 100 Cascade R134a/CO2 102 2% Booster 105 5% Booster + PC 97 -3% Booster + PC + EJ 87 -13% Traditional R404A 112 12% Advanced R404A 100 Cascade R134a/CO2 103 3% Booster 109 9% Booster + PC 100 0% Booster + PC + EJ 90 -10% BerlinRomeAthens Large shops (CO2 racks)
- 41. This document and all its contents are for Carel internal use only and strictly CONFIDENTIAL All unauthorized use, reproduction or distribution of this document or the information contained in it, by anyone other than Carel employees is severely forbidden