Documente Academic
Documente Profesional
Documente Cultură
CO2 Compressor
1897
1850
1866
Re-activation of CO2
refrigeration technology
(G. Lorentzen)
1920 ----------1930
Page 2
1960
1992
1993
S. Forbes Pearson,
A pumped CO2 volatile brine
system with NH3 condensing
for a small cold store
Page 3
Future?
2008
1834
ethylether
(R610)
Natural
CO NH methylSO chloride
HCs
1930
1990
HCFC
CFC
1950 NH
CFC
NH CO
HCs
Risto Ciconkov
TJISADANE
Page 4
Introduction
Page 5
CO2 was chosen because NH3 considered too risky with a residence 30 metres
from the plant room. In Transcritical mode CO2 is used to heat process water
and potable water for domestic and cleaning purposes.
Introduction
Page 6
Continued
The original time frame was mid September 2009 end May 2010, but the
project was eight months late for various reasons.
The major equipment suppliers Bitzer Australia and Guentner Australia were
selected as partners, a sound decision.
Description
1
2
3
4a
4b
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
P=
T=
M=
LC =
Page 7
No Off
2
1
3
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
Page 8
NO
OFF
No
DESCRIPTION
10
11
12
22
Page 9
Variable
No of Units
produced daily.
Average
kWh
Average energy
consumption
Wh / Unit
1/7/2009 30/6/2010
Before New Plant (BNP)
9,483
993
104.7
8,877
16,897
940
1,394
105.9
82.5
Increase/Decrease Quantity
% Increase/Decrease
+ 8,020
+ 90.3
+454
+48.3
-23.4
-22.1
8,821
18,832
925
1,349
104.9
71.6
Increase/Decrease Quantity
% Increase/Decrease
+10,011
+113.5
+424
+45.8
-33.3
-31.7
+37,932 (+400%)
+210 (+21.1%)
-79.3 (-75.7%)
Final Target
Page 10
Page 11
1.
The Blast Freezer fans have been running @ 100% speed rather than 80% for
low freezing capacity.
2.
3.
Lower than design Blast Freezing air temperatures because of unfounded fear
of large ice crystal growth during slow freezing.
4.
5.
6.
Some old systems like electrical underfloor heating in the old cold store and
Blast Freezer continued to operate.
7.
Some extra process equipment and pumps not taken into account during
design.
8.
9.
10. People object to work in the new refrigerated packing room. It is too cold and
doors are left open.
11. Significant infiltration into cold store. The general air tightness of the panel
construction -23C cold store and -30C to -35C Blast Freezer is suspect.
12. Notwithstanding the preceding litany of woes in not achieving planned energy
efficiency, a 31.7% reduction in specific energy consumption has been
achieved when increasing production 113.5%, which increased energy
consumption 45.8%. This was considerably more than predicted.
13. Efforts to reduce the energy consumption are continuing by tuning the systems
and more is learned about its peculiarities.
14. The reduction in gas consumption for water heating has not yet been
evaluated.
Page 12
Page 13
Alternative systems like Ammonia, HFCs and HCs were not considered,
either as total systems or as CO2 /NH3, CO2/HFC and CO2/HC cascades.
The new system had to be efficient to avoid having to upgrade the electricity
supply capacity. This provided a significant capital offset of around $300,000.
When the lowest lender of AU$1.3 million was recieved, the client requested
that the project would be project managed, which would save an estimated
AU$350,000.
Estimated cost savings were not achieved and the final project cost exceeded
the originally tendered price plus an 8 month delay.
May, June, July 2010 compared with May, June July 2011
1.
+113.5%
2.
+45.8%
3.
-31.7%
Page 14
The above figures are a long way below the following forecast figures for the
reasons stated previously.
1.
400%
2.
21.1%
3.
60%
4.
75.7%
5.
40%
Page 15
Lessons Learned
Page 16
The oil still on the -5C low pressure receiver/high stage compressor
suction trap/booster discharge desuperheater does not work and is
completely useless. This is likely due to the high miscilility of CO2 and
POE oils.
We did not install a suction heat exchanger in the suction lines to the AC
& high stage compressors. To achieve a high COP we try to work with a
virtual gas cooler exit temperature of +5C.
This gives the disadvantage of low suction super heat on the high stage
and AC compressors, resulting in low discharge temperatures and
difficulty reaching high water temperatures.
Page 17
We had to change cold store and chill store evaporator circuiting on site
and were lucky to find a very skilled welder tradesman who was capable
of doing this.
We will endeavour not to repeat the design errors made in this first
project.
Page 18
Other than the above, designing and building these systems is not a
whole lot different from designing a two stage industrial ammonia plant
with a Low Pressure receiver.
Everything we learned will be taken into account in the next project, i.e.
the good, the bad and the ugly.
Page 19
Difficulties were experienced obtaining parts like high pressure leak proof
valves for the transcritical discharge side.
Initially cost differences were not a concern but when cost overruns
occurred they became, and still are, a concern for management.
Page 20
Future Plans
Page 21
Our office has recently completed the design and documentation for a much
larger project. We were pleased and grateful that, Mr David Rose, the CEO of
EXQUISINE, told our new client that he was pleased with the final system,
notwithstanding the trials and tribulations experienced with the Exquisine plant,
the first of its type in the world.
As for designing a system, one should in general follow the rules and practices of
industrial ammonia refrigeration system design obeying several simple
guidelines.
Ensure that no liquid can enter any of the compressors at any time.
Ensure that the CO2 vapour velocity through the cross section of any vessel
in the suction of any compressors does not exceed
0.2 m/sec. This is because the high density CO2 vapour exerts a much
greater drag force on a small CO2 droplet requiring much lower separation
velocities than is the case with ammonia plants.
Page 22
Do not design piping systems too small in the belief that high pressure drops
can be tolerated. Low piping pressure losses are always beneficial!
Ensure that any evaporator circuit exit velocities do not exceed about 7
m/sec @ T0 = 40C and 10 m/sec @ T0 = 0C to ensure high circuit
pressure drops do not occur with attendant boiling point suppression.
Carry out an analysis of the local climate and estimate the annual
performance.
Similar to NH3 practice collect the oil from the lowest point of a suction trap
in the lowest temperature DX circuit and ensure there is sufficient heat
available to boil any CO2 off distilling only oil.
Locate the Low Pressure Receiver in a Cold Store to ensure no CO2 blow off
during a prolonged stoppage of the plant.
Page 23
Description
Factory cooling
707kW @ T0 = 0C
Page 24
% water
savings
Cooling
only
.1
.2
Office buildings
Existing USA
CO2 retrofit
3.22
5.29
7.95
7.04
5.64
0
19.8
103,338
51,669
0
50.0
13.1
7.7
0
41.2
0
80
0
19.8
.3
8.49
7.23
5.9
16.2
64,793
37.3
8.0
38.9
46
16.3
.4
.5
6.9
8.49
10.6
7.06
3.46
4.05
50.8
42.4
46,865
44,580
54.6
56.6
4.7
5.5
64.1
58.0
80
53
53.4
42.4
No
Description
% Red.
BTU
%
Red.
Emissions(2)
lbs
%
Red.
At
At
build- power
ing
station
(3)
2
.1
Hospitals
Existing USA
3.35
13.8
218,390
26.8
.2
.3
CO2 retrofit
NH3 retrofit (3)
5.37
9.04
7.99
8.18
10.8
11.0
21.7
20.3
117,700
121,379
46.1
44.4
14.7
15.1
45.1
43.6
88
45
21.7
20.0
.4
7.0
10.68
6.5
52.9
77,701
64.4
8.8
67.1
88
55.0
.5
9.04
7.94
8.05
41.6
88,736
59.4
10.9
59.3
52
41.7
(3)
(1)
(2)
(3)
Page 25
Please note much larger reductions in electrical, primary energy and water consumption, and emissions would be possible
with energy recovery from exhaust air, ambient air economizing and pre-cooling cycles, different methods of air
distribution and chilled beams technology for example.
Emissions do not take into account any reduction in direct emissions from Fugitive HFC Refrigerant Gases.
In all ammonia cases a separate compressor is required as a heat pump compressor.
Page 26
Page 27
Page 28
Technology
Page 29
Training
There is a dire need for the development of a nuts and bolts CO2
design manual. Industrial ammonia designers would have little or no
difficulty adapting to this quickly and competently once basic design
parameters are formulated.
Safety
We do not see any major safety issues with NH3 and CO2 with which
we are familiar.
We are not familiar with the requirements of the safe use and handling
of HCs.
Policy, Standards
and Regulations
Page 30
Policy
Policy, Standards
and Regulations
Page 31
Standards
Policy, Standards
and Regulations
Page 32
Regulation
Any barriers against the use of NH3 in the built environment should
be removed consistent with the highest safety standards.
Markets, Costs,
End Users
Page 33
Conclusions
Page 34
Conclusions continued
Page 35
The total integration of all cooling and heating functions into single
and two stage transcritical refrigeration systems holds a lot of
promise to significantly reduce the total energy consumption and
attendant emissions plus the elimination of direct fugitive HFC
emissions.
Conclusions continued
Page 36
Purpose built CO2 systems for building heating and cooling in new
buildings offer even greater opportunities in reducing energy
consumption and attendant emissions particularly if coupled with
other strategies.
Acknowledgements
Mr David Rose, the Managing Director of Exquisine, has the authors undying gratitude for his
courage to try this unproven application of CO2 refrigeration and heating into one working prototype.
He has done society at large a great favour, somewhat at his own expense.
AusIndustrys financial support is gratefully acknowledged. It is unlikely the project would have been
able to proceed without the substantial support.
The help and assistance of the following people are also gratefully acknowledged.
Dr Petter Neksa, Senior Research Scientist, SINTEF, Trondheim, Norway, for supporting the idea of
the first fully integrated CO2 plant in the world.
Mr Sergio Girotto, Managing Director of Enex srl, out of Treviso, Italy, for checking our design and
suggesting modifications.
Dr Andy Pearson, Managing Director of Star Refrigeration out of Glasgow, Scotland, for reviewing
the installation and suggesting modifications.
Mr Ruediger Rudischhauser, Managing Director of Bitzer Australia (BA) for breaking BAs policy by
selling the two compressor racks to the end user direct to assist getting this project off the ground.
Mr Glen Wiles, General Manager, Guenter Australia, also for selling the evaporators and gas cooler to
the end user, direct to facilitate this unique demonstration project getting off the ground.
Mr Murray Carter, Project Manager, who took firm control of the project when it was necessary to create
some order out of the chaos which developed during the installation phase.
Mr Kristian Sorensen out of Denmark for assisting the local refrigeration contractors with the
commissioning between the end of November and mid December last year.
Page 37
Vision
Page 38
There is no likelihood man can ever tap the power of the atom.
ROBERT MILLIKAN, Nobel Prize winner for physics, 1923.
We dont like their sound and guitar music is on the way out.
The record company DECCA, rejecting the Beatles, 1962.