03_the latest technology for the industrial refrigeration

03_the latest technology for the industrial refrigeration

２０１5．5．28
Mayekawa Mfg. Co., Ltd.
Kuniaki Kawamura
1
Contents
1. Introduction for Mayekawa Mfg
2. Reｆrｉgｅrants comparison
3. Natural refrigeration system update
3.1 NH3/CO2 refrigeration system(Newton)
3.2 Air cycle (Pascal-Air） for -60 ℃
4. Future Trend
2
Founded: 1924
Location:
Tokyo, Japan
Turnover: $1.5 Billion
Employees: 3,350 (33 countries)
3
Belgium
England
Spain
France
Switzerland
Germany
Beijing South Korea Canada (Vancouver, Toronto)
Philippines Shanghai
Moscow
Taiwan
USA(LA, etc.)
Mexico
Turkey
Dubai
Thailand
Viet Nam
India
Singapore
Malaysia
ｲIndonesiaAustralia ﾞNew Zealand Chile
Main operations
Venezuela
Costa Rica
Colombia
Ecuador
Peru
Mayekawa is doing business
globally, having 57 domestic
offices and 3 plants, and 90
overseas offices including 6
plants.
Brazil
・Corporate offices
3-14-15 Botan, Koto-ku,
Tokyo 135-8482,Japan
Established in 1924
Capital 1,000,000,000 yen
President Tadashi Maekawa
Argentina
Domestic plant: Moriya,
Higashi-Hiroshima, Saku
Overseas plant: Mexico,
Brazil, USA, Belgium, South
Korea
Brazil plant
Moriya plant
T
2. Refrigerants comparison
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Progress of international regulations and measures over F-gases
Protection of Ozone Layer
・Montreal Protocol
・Vienna Convention
CFC(R11,R12,R502, etc.)
HCFC(R22, etc.)
Depleting the
ozone layer
Impact
on global
warming
Non Depletion of
the ozone layer
Impact
on global
warming
Prevention of Global Warming
HFC(R404A,R410A,R134a,
・Kyoto Protocol
R407C, etc.)
・United Nations Framework
Convention of Climate Change
・Proposed Amendment to the Montreal Protocol
(UNFCCC)
・F-gas Regulation(EU, since 2015)
Cl
F C
Cl
FC
F
Cl
F
H C
C
F
H
F
HCFC
CFC
H
HN H
H
NH3
・Act on Rational Use & Proper Management of
Fluorocarbons(JPN, since 2015)
F
H
F
HFC
F F
F C
C
H
H
C
HFO
Lower GWP HFC
(HFO,HFO&HFC Blends, etc.)
Natural Refrigerant
F
(NH3,CO2,Air,H2O,HC)
Non Depletion of
the ozone layer
Non or low
Impact on
global warming
Progress of international regulations and measures over F-gases
Consumption Level Allowed
Control measures under the Montreal Protocol
Table. HCFCs (Annex C_Group Ⅰ )Consumption Reduction Schedule
Month/Year
*Baseline calculated as 1989 HCFC consumption +2.8 percent of 1989 CFC consumption.
Reference: OZONE SECRETARIAT_UNEP
http://ozone.unep.org/new_site/en/Treaties/treaties_decisions-hb.php?sec_id=12
Comparison of refrigerants on ideal cycle
Refrigerant
unit
R22
R404A
R407C
R410A
R134a
R32
Evaporating Pressure
MPaA
0.2962
0.3610
0.2632
0.4800
0.1639
0.4881
Condensing Pressure
MPaA
1.5336
1.8925
1.7489
2.4256
1.0166
2.4783
Brake Shaft Power
kW
58.31
64.61
58.17
91.40
34.22
99.11
Cooling Capacity
kW
209.36
200.19
177.23
301.78
121.06
340.20
COP
-
3.59
3.10
3.05
3.30
3.54
3.43
Refrigerant
unit
NH3
R1270
R290
R1234yf
R1234ze(E)
Evaporating Pressure
MPaA
0.2362
0.3630
0.2916
0.1837
0.1200
Condensing Pressure
MPaA
1.5554
1.6485
1.3694
1.0184
0.7666
Brake Shaft Power
kW
60.11
63.31
51.29
34.68
25.11
Cooling Capacity
kW
222.29
220.47
178.89
114.91
87.94
COP
-
3.70
3.48
3.49
3.31
3.50
Calculated Condition : Te=-15[degC], Tc=+40[degC], SH=+5[K], SC=+0.5[K],
Volumetric Efficiency =100[%], Adiabatic Efficiency =100[%]
Properties of refrigerant were calculated by REFPROP ver9.0
3. Natural refrigeration system
update
3.1 NH3/CO2 Refrigeration system(Newton)
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Market Requirements
• High Efficiency: Compressors and
IPM Motors
• Low Charge:
* Secondary Refrigerant System(CO2)
• Less Leakage: Hermetic Motors
• High reliability: 5 years maintenance free
• Long term refrigerant supply
Industrial Refrigeration with Natural Refrigerants
Target
Industrial
Domestic
Commercial
The comparison of CFC refrigerants and natural refrigerants
HCFC
HFC
NWFS
R22
R134a,R410A
R407C,R404A
NH3,CO2,HC
H20,AIR
0.055
0
0
1810
1770～3920
0～3
Leakage
Much
Much
No
Odor/Smell
No
No
NH3：Sharp odor
Flammability
No
No/Lower
NH3:Lower flammability
The name of refrigerant
Ozone depletion
potential (ODP)
Global warming
potential (GWP)
NH3 is found when leaked
HC：Higher flammability
Coefficient of
performance (COP)
1.00
0.90
1.05～1.2(NH3)
* GWP used here is a 100-year GWP based on the data from Japan Fluorocarbon Manufacturers
Association (JFMA). http://www.jfma.org/database/table.html
* COP is the comparison value when R22=1.
Development Concepts
• High efficiency
• Low refrigerant charge
• Less leakage
• High reliability
Basic Concept of NewTon
Out door
Cold Storage
NewTon
Cooler
CT
Cond.
Water
Water cooled
Evap.
NH3
NH3 Package
CO2
CO2 brine
・Energy saving
・New Screw compressor
・Safety
・NH3 charge min.
・Semi-hermetic IPM motor
・Low pump power
・Free layout
・Flooded Evaporator
・No trouble by oil
・Easy Maintenance
・Double economizer
・High heat transfer
・Automatic operation
「Safety」 「Energy saving」 「Easy maintenance」
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NH3 New Screw Compressor
Semi-hermetic IPM Motor
Two stage compound Screw
16
High Efficiency Motor（IPM motor）
- Semi-Hermetic for NH3 -
Benefits of IPM motor
・ ５～１０％ better in efficiency
・ 40% smaller in size
・ High speed is possible
Conventional
IPM motor
回転子
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New rotor profile and Double economizer system
Booster
High stage
Features
・High efficiency: Less gas leakage
・Quiet: Low noise, low vibration
・High reliability: Use of proven bearings
Evap.
Condenser
Booster Economizer
Inter cooler
Double Economizer
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High Performance Heat Exchanger
Comparison of Evaporator
NH3 gas
CO2 gas
S&T
S&P
Improve
Volume (m3)
0.689
0.269
-39%
Space (m2)
1.57
0.49
-31%
Approach temp.(K)
3.0
1.7
(COP:+4%
)
S＆P
CO2
liquid
NH3
liquid
NH3 gas
S＆T
CO2 gas
NH3
liquid
CO2
liquid
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Case 1
Power consumption data (2013)
700 000
Office
600 000
Light, Lift etc
Power consumtion (kWH)
Refrigeration
500 000
400 000
300 000
200 000
100 000
0
Jan
Feb
Mar
Apr
May
Office
7%
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Specific Power Consumption (kWH/m3/year)
Light, Lift
etc
26 %
Refrigeration
67 %
Refrigeration
18.8
Light, Lift etc
7.9
Office
1.9
Total
28.2
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Main Installations of NewTon
Customer
Volume (m3)
Newton sets
installed
Nissui Logistics / Kawasaki
35,000
３
2008
Toyo Suisan / Nagoya
80,000
９
2009
Hosui / Atsugi
20,000
２
2010
Yokohama Reito / Osaka
68,000
８
2011
Coop / Onomichi
75,000
８
2012
Matsuoka / Kawasaki
200,000
１１
2013
Nichirei Log. / Kawasaki (for one floor)
100,000
１
2013
Maruha-Nichiro Log. Net. / Kawasaki
75,000
6
2014
500 are running
Nisui Log. ／Kawasaki
Toyo Suisan / Nagoya
Yokohama Reito / Osaka
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Coop ／ Onomichi
Matsuoka/Kawasaki
Nichirei / Kawasaki
Specific Power Consumption in Cold Storage
Specific Power Consumption (kWH/m3/year)
180,0
160,0
HCFC-22
140,0
NewTon (NH3/CO2)
120,0
NH3/Brine
100,0
80,0
60,0
40,0
20,0
0,0
0
50 000
Case
1
100 000
150 000
200 000
250 000
Storage Volume (m3)
300 000
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Distribution center
F1610C
NewTon 3000
Storage capacity ：18,000 ton
Existing
Refrigerant ：HCFC-22
8sets of NewTon3000
replaced.
Machine ：F1610Cｰ8sets
4sets in 2008
System ：Dry Expansion
4sets in 2009
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Renewal Example
600,000
50.0
500,000
40.0
400,000
30.0
300,000
20.0
200,000
10.0
100,000
0.0
0
-10.0
Jan Feb Mar Apr May Jun
2007(Befor Replacement)
2010（After 8units Replaced)
Reduction（After 8units Replaced）
Jul
Aug Sep Oct Nov Dec
2009（After 4units Rplaced)
Reduction（After 4units Rplaced)
＊Based the bill of Tokyo Power Co.
＊Total Power consumption, incl carriers, lights, office machines, etc.
＊Storage capacity :”1 ton = 0.4 m3”
KWH Reduction （％）
Power Consunption (kWH)
Reduction of Power Consumption
Power reduction through renewal with NewTon
Refrigerant formerly
used
Power
reduction
Volume
Age
(m3)
(year)
Refrig.
Comp.
(%)
45,000
29
HCFC-22
Screw
31.1
Niigata Reizo
10,000
33
HCFC-22
Recip.
41.2
QP “Kewpie”
16,250
27
HCFC-22
Recip.
24.9
Sensui Reizo
6,125
38
HCFC-22
Screw
29.3
Ajinomoto
7,500
25
HCFC-22
Recip.
28.0
Gliko
30,000
30
HCFC-22
Screw
19.8
Showa Reizo
32,500
22
HCFC-22
Recip.
28.0
AMB Funabashi
30,000
25
NH3/Brine
Recip.
34.0
Customer
Tokyo Toyomi
(Case 2)
25
Temp: +10℃
Diary
Cold Storage
Ice Arena
Ice Mkaing
Temp: -45℃
Maine
Food
“NewTon” for ASEAN
P.T. ADIB
A cold storage
warehouse
nearby Jakarta
“1st NewTon system” will be installed to
P.T. ADIB Global Food Supplies in Indonesia.
Joint Crediting Mechanism
Host Country : Indonesia
JCM Project for Cold Chain Industry in Indonesia with “NewTon”
This project was funded by the MOEJ in FY 2013 as the 1st project to Joint Crediting Mechanism .
Most advanced Japanese energy efficient non-fluorocarbon cooling system
NewTon R-6000
Freight
handling
Cealed chiller
100 ton
Thermo shutter
3 units
Refrigerator A（-25℃）
Refrigerator B（-25℃）
Refrigerator C（-25℃）
Cold water
Machine
room
CO２
Entity:
Mayekawa Mfg CO. Ltd
Energy
Consumption
reduction
570,000 kwh
/year
NH3/CO2 Fridge
NewTon R-6000
Project site
Defrost water
Defrost water tank
10m3
Chiller （Cooler）
6 units
Defrost water
(heatup heat exchanger)
Estimated
GHG
reductions
Demonstration Site:
PT.ADIB Global Supplies
Without consideration of HFC leakage
emissions: 213 (tCO2/year)
With consideration of HFC leakage
emissions: 902 (tCO2/year)
Energy Efficient Refrigeration Technology
・MOEJ introduce the Energy Efficient Refrigeration Technology of
“NewTon” as Japanese Good Practices.
http://www.env.go.jp/en/earth/ozone/goodpractice/full.pdf
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3.2 Air cycle (Pascal-Air） for -60 ℃
28
Conventional system
Air cooler +
Fan motors
Air
*Has an Air cooler + Fan motors
*Defrost required
Pascal Air system
Blown-in
Air duct
*No air cooler + Fan motors
*No defrost
Ducts easily installed
Blown-out
-60℃ Warehouse facility
Storage capacity : 8000ton.
Blown-out
Save Energy
Safety
Low working pressures.
Not Toxic or flammable
No safety regulations
required
Air refrigerant system
Nature
No environmental load
GWP=ODP=0
Environment friendly
Direct Air circulation
The integrated turbo-compressor-expander
motor
Turbo-compressor
-80℃
101.3KPa abs
Turbo-expander
Primary cooler
-60℃
101.3KPa abs
Cooling Water
Cold heat
recovery
Heat exchanger
Warehouse
-60℃
超低温エリア
Motor
Compressor
Expander
One shaft for power
recovery
34
Comparison of Air cycle and the conventional system
Item
Conventional system
Air cycle
Heat entering through walls
30%
30%
Heat loss through opening refrigerator
5%
5%
Product cooling
25%
25%
Heat generated by fan motor
20%
0%
Thermal resistance due to frost(defrost)
10%
0%
Illumination
10%
10%
Total
100%
70%
35
Installed and other
applicable areas
(1) Installed areas
 Ultra-low temperature warehouse for bonito/tuna
(17 units already installed -50～-60℃)
 Food rapid freezing system
(3 units- freezers -50℃)
 Chemical process cooling
(2 units –pharmaceutical -70～-80℃)
(2) Other applicable areas
 Vacuum Freeze-dry
 Semiconductor manufacturing
 Low temperature Milling etc.
『Pascal Air(Brine cooling)』
Turbo Compressor and Expander
+35℃
120K
GN2
モータ
Comp
1st Cooler
Exp
+93℃
-100℃
2nd Brine
-105℃
115 K
+40℃
Heat Recovery
Cooler
+35℃
37
4. Future Trend
• There have been many actual instllations
using natural refrigerants in Japan.
• About 30% of energy saving have been
established.
• Government support (MOE) has started
for natural refrigerants system since
2014.(about 50 MUS$)
• We would like to challenge our continuous
development for energy saving and safety
using Natural Five.
38
Refrigerant
(Natural Five)
NH3
R-717
CO2
R-744
HC
Hydrocarbon
H2O
R-718
Air
R-728
90℃
Utility hot water
60℃
Utility hot water
Heating
Chilled water
10℃
-15℃
Ice making
Utility hot
water
Chilled water
Heat recovery
Heating
HVAC
Ice making
Chiller
Cold storage, Freezer, Fish boat
-25℃
Specific Refrigeration needs
-40℃
-50℃
Freezer, Freeze-dry, Super Low temp
storage
-60℃
Cryogenics
Cryogenics
-100℃
Notes
・Eco-Cute
・Nat’l Proj.
・Butane +
Propane
・Nat’l Proj.
・Adsorption
・Heat recovery
・Nat’l Proj.
・Air-cycle
39
Thank you very much for
your Attention.
NATURE IS WHAT WE DESIGN FOR
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