Pack Calculation Pro report

Created by : Dr. Eng. Ion Zabet

Program version : 4,20. Personal license
Personal license - non-commercial use only

Introduction
This report contains results for the simulated yearly energy consumption of the following refrigeration systems:
1) R404A (reference)
System type: One stage:

2) R717
System type: One stage:

3) R744
System type: One stage:

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One year of operation was simulated for each system. The same yearly load profile and weather conditions were
used in all the simulations.

Each simulation was performed on an houly basis by performing one steady state simulation for each hour in the
year. In each hour the load was known from an hourly load profile for the entire year. By stepping through the
compressor capacity stages of the simulated system it was determined which capacity stage(s) that best matched
the average load during the hour.

If no capacity stage was able to match the load exactly, which is usually the case for systems without a speed
controlled compressor, then the results for the hour were calculated by time weighing results for the two closest
mathcing capacity stages.

The simulation used R404A as reference system, and the selected location, which determines the ambient
temperature, was Romania, Bucharest.

Details about the simulated systems and the conditions can be found later in this report.

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Energy consumption graph

The diagram above shows the energy consumption per month of the simulated systems. Each bar equals the sum of the compressor energy consumption and the energy
consumption of additional equipment (condenser and evaporator fans and pumps used in the system).

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Summary

R404A (reference) R717 R744

Load fulfillment
% of time: 99,7 92,6 69,7
% of energy: 100,0 99,1 96,4
COP
Average COP [-]: 3,06 3,52 2,38
Energy consumption
Pumps and fans [kWh]: 21.158 19.115 11.986
Compressor [kWh]: 172.615 148.073 159.400
Total [kWh]: 193.774 167.188 171.385
Savings
Yearly energy savings [kWh]: - 26.586 22.388
Yearly energy savings [%]: - 13,7 11,6
Warnings:
R717
Load is only fulfilled 92,6% of the time

R744
Load is only fulfilled 69,7% of the time
Only 96,4% of the total cooling requirement is fulfilled

Increase compressor capacity or decrease load.

The table above shows the yearly energy consumption of the simulated systems. Savings are compared to the
reference system.

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Energy consumption table

R404A R717 R744

Month Compressor [kWh] Fans and Pumps [kWh] Total [kWh] Compressor [kWh] Fans and Pumps [kWh] Total [kWh] Compressor [kWh] Fans and Pumps [kWh] Total [kWh]
January 13.108,1 850,8 13.958,9 11.170,8 798,3 11.969,1 19.201,3 905,4 20.106,7
February 11.794,0 904,6 12.698,6 10.051,3 846,0 10.897,3 17.276,7 959,8 18.236,5
March 13.170,7 1.266,0 14.436,7 11.267,7 1.166,6 12.434,3 17.516,7 1.128,6 18.645,2
April 13.090,0 1.767,7 14.857,7 11.344,6 1.596,6 12.941,2 11.638,9 960,1 12.599,0
May 15.423,3 2.261,0 17.684,3 13.400,8 2.018,7 15.419,4 9.374,1 931,5 10.305,6
June 16.207,0 2.536,7 18.743,7 14.036,6 2.260,6 16.297,2 6.295,9 762,2 7.058,1
July 18.041,9 2.804,5 20.846,3 15.273,2 2.492,3 17.765,5 8.468,0 986,5 9.454,5
August 17.873,2 2.725,3 20.598,5 15.104,1 2.428,8 17.532,9 9.350,4 1.063,5 10.413,9
September 14.359,2 2.168,2 16.527,4 12.563,0 1.938,4 14.501,4 8.802,2 908,0 9.710,2
October 13.887,1 1.780,3 15.667,4 11.990,1 1.613,7 13.603,8 13.990,3 1.172,9 15.163,2
November 12.672,9 1.159,4 13.832,3 10.805,4 1.080,5 11.886,0 18.465,4 1.215,0 19.680,4
December 12.988,1 933,9 13.922,0 11.065,2 874,8 11.940,0 19.019,9 992,2 20.012,0
Total 172.615,4 21.158,3 193.773,7 148.072,8 19.115,3 167.188,1 159.399,7 11.985,6 171.385,3
Average 14.384,6 1.763,2 16.147,8 12.339,4 1.592,9 13.932,3 13.283,3 998,8 14.282,1

The table above shows the energy consumption per month of the simulated systems. Additional equipment equals condenser and evaporator fans and pumps used in the
system.

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Life cycle cost

R404A R717 R744

Initial cost:
Cost of equipment [Euro] 25.000 35.000 30.000
Cost of installation [Euro] 10.000 15.000 12.500
Annual operating cost:
Energy consumption [kWh] 193773,71 167188,08 (-26.586) 171385,29 (-22.388)
Cost of maintenance [Euro] 5.000 2.000 3.000
Result:
Effective interest rate [%] 1,96 1,96 1,96
Internal rate of return [%] - 45,49 71,11
Total annual cost [Euro] 34.066 27.078 (-6.988) 28.708 (-5.358)
Payback time [years] - 2,1 1,4
Total initial cost [Euro] 35.000 (10%) 50.000 (17%) 42.500 (14%)
Present value of maintenance cost [Euro] 45.005 (13%) 18.002 (6%) 27.003 (9%)
Present value of energy cost [Euro] 261.625 (77%) 225.730 (77%) 231.397 (77%)
Life cycle cost [Euro] 341.630 293.732 (-47.898) 300.900 (-40.730)
Summary of LCC.

LCC diagram.

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LCC plot.

Conditions
Expected average interest rate: 4 %
Expected average inflation rate: 2 %
Expected average energy cost: 0,15 Euro/kWh
Expected lifetime: 10 years

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CO2 Emissions

R404A (R404A) R717 (R717) R744 (R744)

Refrigerant charge [kg] 14,00 6,45 13,40
Recycle rate [%] 0,8 0,8 0,8
Leakage rate[%/year] 8,0 8,0 8,0
Summary of CO2 Emissions.

Leakage [kg CO2] Recycle loss [kg CO2] Indirect [kg CO2] Total [kg CO2]
R404A 43.926 (3,9%) 54.469 (4,8%) 1.027.001 (91,3%) 1.125.396
R717 3 (0,0%) 3 (0,0%) 886.097 (100,0%) 886.103
R744 11 (0,0%) 13 (0,0%) 908.342 (100,0%) 908.366
CO2 Emission results.

CO2 Emissions.

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Plots

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Systems overview

R404A R717 R744

One stage One stage One stage
Configuration Reference system
Refrigerant [-] R404A R717 R744
Design condition [-] Custom, MBP (Te/Tc = -10,0 / 45,0 C) Custom, MBP (Te/Tc = -10,0 / 32,0 C) Custom, MBP (Te/Tc = -10,0 / 25,0 C)
Capacity [-] 99,5 kW / 143,8 kW 100,0 kW / 126,3 kW 99,0 kW / 135,7 kW
Comp 1 [-] 4MK-35X, R404A, 50Hz (CC) Compressor_8642, R717, 50Hz ZOD104KCE-TF5, R744, 50Hz
Comp 2 [-] 4MK-35X, R404A, 50Hz (CC) Compressor_8642, R717, 50Hz ZOD104KCE-TF5, R744, 50Hz
Comp 3 [-] - - ZOD104KCE-TF5, R744, 50Hz
Suction side
Cooling capacity
Profile [-] Supermarket. Day-Night Supermarket. Day-Night Supermarket. Day-Night
Dimensioning capacity [kW] 100,00 100,00 100,00
Tamb at dim [C] 32,0 32,0 32,0
Profile change [-] 1,0 1,0 1,0
Profile const below Tamb [C] 20,0 20,0 20,0
Dry Expansion Evaporators
Total superheat [K] 20,0 0,0 20,0
Non usefull superheat [K] 10,0 0,0 0,0
Evaporation temperature
Evaporation temp profile [-]
Temp for const profile [C] -10,0 -10,0 -10,0
Additional
Internal hx eff. [-] 0,5 0,5 0,5
Discharge side
Condenser type [-] Air cooled Air cooled Air cooled
Cond. cap. ctrl.
Tc profile [-] - - -
Temp for const profile [C] - - -
Const Tc [C] 25,0 25,0 25,0
Tc = A*Tamb+DT [C] - - -
Fan with compressor [-] - - -
Minimum Tc [C] 20,0 20,0 20,0
Subcooling [K] 2,0 0,0 0,0
Speed ctrl. fans [-] False False False
Speed ctrl. pump [-] - - -
Condenser def.
Qc_100 [kW] 143,8 126,3 135,7
W_fan [kW] 4,3 3,8 4,1
W_pump [kW] - - -
DT_0 [K] 12,0 12,0 12,0
Qc_0 [kW] 5,8 5,1 5,4
DT_100 [K] 12,0 12,0 12,0

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