Refrigerating capacity [kW] and COP [-]

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

F O O D R E T A I L F O O D R E T A I L

Designing CO ₂ -Systems

- Danfoss System Solution for CO

based Refrigeration

Jens Christian Callesen

Business Development Manager CO ₂ Applications

Danfoss Food Retail

September 07 / 2 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Refrigeration and Air Conditioning

Household Compressors

Industrial Refrigeration Food / Retail

Commercial

Large Large

Medium Small

System size

CFC - HCFC - HFC

PRS

Process Refrigeration

Systems

Hydro Carbons Ammonia

Segment

Refrigerant

Hydro Carbons

CO

sub

critical

CO

Transcritical

September 07 / 3 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Food Retail

Sub critical CO2 applications

Valves, Controls, Driers and Safety equipment

CO2 Applikationen

Heat Pumps & Bottle Coolers

Transcritical CO2 applications

Compressors, controls and complete cooling cassettes

Industrial

Sub critical CO2 applications

Valves, Controls, Driers and Safety equipment

Food Retail

Transcritical CO2 applications

Controls

September 07 / 4 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

CO

receiver

Low stage – Compressor(s)

High Stage – Compressor(s)

R290, R1270,…

R134a, R404A,…

R717 (NH ₃ ) CO ₂

High Stage – Condenser

Low Stage – Expansion valve

Low stage – Evaporator

High Stage – Expansion valve

Low Stage – Liquid pump

CO ₂ systems (Food & Retail and Industrial)

CO ₂ Transcritical

Low stage High stage

September 07 / 5 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

High pressure components - CO ₂

Danfoss Sub Critical CO

- components

"Commercial" product line ^PS

35 bar

[508 psi]

PS 42bar

[609 psi]

Solenoid Valves EVR 2, EVR 3

EVRH 6 - EVRH 15

Shutoff Valves (Ball Valves) GBC (45 bar)

+

Check Valves ^NRVH

Electrically operated expansion valve AKV 10 - AKV 15

+

Filter drier ^DCRH

DCR

+

DML

+

Moisture indicator ^SGN

+

Pressure controls KP6

+

Pressure transmitters AKS 3000

Controllers for CO2-applications

Case controllers: AKC 114A, AKC 115A, AKC 116A EKC 414A, EKC 414A1

AK2 CC 303

Evaporator controller EKC 315A

Pack controller EKC 331T, EKC 531D1, AK2 PC 311

- - - -

PS 46 bar

[667 psi]

+ + +

-

+

+

+ The product can be used in standard version. All products are CE approved

September 07 / 6 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

High pressure components - CO ₂

"Industrial" product line

DN

Main Valves, Solenoid Valves ICS 1 ICS 3 all 20-65

Motor Valves ^{ICM all 20-65}

Multifunction valve ICF all 20-40

Pilots for ICS Valves ^{CVP (XP)}

EVM

Stop Valves - SVA ST,LT,HS SVA 10-65 10-65

Regulating Valves - REG REG all 15 - 65

Stop Check Valves SCA ^{SCA 15-65 15-65}

Filters FIA ^{FIA 15-65 15-65}

Check Valves CHV all 15- 40

Solenoid Valves ^{EVRS all 10-25}

EVRA all 10-40

Electrically operated expansion valve AKVA all 10-40

SFA 15 -

DSV 1, 2 20-32

POV 40, 50, 80 40-80

Filter drier DCRH High pressure version #

Liquid level transmitter ^{AKS 41 -} -

Gas detectors GD

+ + + + + + + +

Safety Valves and Change Over Valves SFV - DSV

+ +

#

#

#

#

#

#

#

#

PS 40bar

[580 psi]

PS 52 bar

[754 psi]

+ +

+ + + +

+ The product can be used in standard version. All products are CE approved

The product must be manufactured in a special version (higher test pressure, marking and documentation). All products are CE approved

Code no. for these products are description in this application gauide 46 bar

¤

September 07 / 7 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

EU “LIFE” Project

• Objective:

Develop a refrigeration system only using CO ₂ as refrigerant.

• Project:

EU-financed Project (EU-Life Environment programme) with 5 Participants.

– Knudsen Køling , Alu Heat Exchanger, Bock , Danfoss, REMA1000, Danish Technological Institute

• Duration:

October 2005 to October 2007

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

F O O D R E T A I L F O O D R E T A I L

Trans Critical Cycle with double expansion

Gas Cooling

2nd Expansion Liquid

1st Expansion

Compression

2nd Expansion Vapour

Evaporation

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

F O O D R E T A I L F O O D R E T A I L

System layout (preliminary)

GC

EV,MT

EV,LT

1 2

3

4

5 15

6

7

10

11 8

13 14 17 16

12

9

p

p

p

p

CP,HS

CP,LS REC

IHX#1

IHX#2

ICMT ICS+CVP(XP)

AKV

AKV Multiple evaporators

for low and medium temperature.

Scalable system:

Refrigeration

capacities from

20 kW to 400 kW

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

F O O D R E T A I L F O O D R E T A I L

Trans-Critical CO ₂ Booster Plant

Closed intermediate

stage cooler

Gas Cooler

ICS, CVP(XP) ICMT

(Prototype)

AKD

AKD AKD

AKD TX

TX TX

Ambient Temperature

AK2-PC311 Pack Controller

LON Net

EKC 414

EKC 414 AKA 245 Gateway

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

F O O D R E T A I L F O O D R E T A I L

REMA 1000 in Esbjerg (started 01-03-2007) Refrigerating capacities

– Medium temperature: 20 kW

– Low temperature: 8 kW

September 07 / 12 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Optimal High Pressure

Δh _EVAP Δh _COMP COP = 1.90

COP = 2.31 COP = 2.28

75 80 85 90 95 100 105 110 115 120

Gas cooler pressure [bar]

0.00 0.25 0.50 0.75 1.00 1.25 1.50

Refrigerating capacity [kW] and COP [-]

COP

QE

t_E = -10 °C, Δt_SH = 10 K t_GC,OUT = 35 °C

OPERATING CONDITION

September 07 / 13 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Control of gas cooler pressure

•Danfoss components

–ICMT main valve (prototype)

–ICAD actuator

–EKC controller (prototype)

–MBS pressure transducer(s) –AKS temperature sensor

•Purpose

–Control pressure in gas

cooler according to system

optimum relation with gas

cooler exit temperature

September 07 / 14 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Prototype ICMT Gas Valve with Controller for Trans Critical CO2

•Optimum pressure compared to gascooler temperature.

•Automatic change-over to sub-critical operation

when possible

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

New concept valve for Trans-critical CO ₂ applications

Function:

• Pressure control

• Expansion

• ON / OFF

Maximum working pressure: PS 140 bar Capacity: Kv 0,6 – 2,4 and 4,6 [m

/h]

Hermetic sealed coupling Pipe connection:

DN 25/ ø33,7 mm (new versions) Control etc.: See standard ICAD info

ICMT

Code No Description

027H0183 ICMT 20 Manuel

opening device

027H1204 ICAD 600S Actuator :

027H1069 ICMT 20-C, Kv = 4,6:

027H1068 ICMT 20-B, Kv = 2,4:

027H1067

ICMT 20-A, Kv = 0,6:

September 07 / 16 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Control of receiver pressure

• Danfoss components

– ICS main valve

– CVP(XP) pilot valve

• Purpose

– By-pass of flash-gas

from expansion in ICMT

while keeping receiver

pressure constant

September 07 / 17 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Average Yearly COP, NT

- Based on Yearly temperature profile for Denmark

4,87 4,57

4,51 -10/14F

4,50 4,22

4,07 -12/10F

4,17 3,91

3,71 -14/7F

R134 R404

CO2 t _e

*t _sh =5K, t _c =21 C/70F, t _sc =2K, n _is =65%

Real comparison due to better

evaporator efficiency (2 K)

September 07 / 18 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

AK AK - - PC 730 Power Pack Controller PC 730 Power Pack Controller

September 07 / 19 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

AK AK - - PC 730 PC 730 – – Pack Controller Pack Controller

Application Example 1: Two Suction Group Cascade with Dry Cool

September 07 / 20 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Application Example 2: Booster Set

AK AK - - PC 730 PC 730 – – Pack Controller Pack Controller

September 07 / 21 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Application Example 3

AK AK - - PC 730 PC 730 – – Pack Controller Pack Controller

September 07 / 22 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Application Example 4

AK AK - - PC 730 PC 730 – – Pack Controller Pack Controller

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

… a quick way

to change technology

Transcritical CO ₂ system for bottle cooling

”The Black Box”

for cooling…

R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Next Generation CO2 compressor

High pressure security valve

Low noise level 62 dbA

September 07 / 25 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

CO ₂ expansion device

TBR

(Thermal Backpressure Regulator) MBR

(“fixed” Pressure Regulator)

September 07 / 26 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

September 07 / 27 R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Food Retail

Sub critical CO2 applications

Valves, Controls, Driers and Safety equipment

CO2 applications

Heat Pumps & Bottle Coolers

Transcritical CO2 applications

Compressors, controls and complete cooling cassettes

Industrial

Sub critical CO2 applications

Valves, Controls, Driers and Safety equipment

Food Retail

Transcritical CO2 applications

Controls