Congres F-gassen 2015. Workshop 8: Scroll CO2, bied veel meer dan alleen een prijsgunstige...

Emerson Compact COEmerson Compact CO22Booster Solution Booster Solution Dr. Gábor Böszörményi

Sales Manager CO2

Jack Quadflieg

Sales Manager Benelux

FF--Gas Directive and its implicationsGas Directive and its implicationsFF--Gas Directive and its implicationsGas Directive and its implications

--7%7%

--37%37%

20152015 20162016 20172017 20182018 20192019 20202020 20212021 20222022 20232023 20242024 20252025 20262026 20272027 20282028 20292029 20302030

--55%55%

--69%69%

--76%76%--79%79%

COCO22 Equivalent Equivalent -- ExampleExampleRefrigerant: R404ARefrigerant: R404AGWP: 3922GWP: 3922Amount: 10 kgAmount: 10 kgCOCO22 equivalent: 39 tonsequivalent: 39 tons

The FThe F--Gas directive already has a major impact on the introduction and Gas directive already has a major impact on the introduction and

promotion promotion of refrigeration of refrigeration technologies based on natural refrigerants or on technologies based on natural refrigerants or on

their combination with HFCs/HFOs.their combination with HFCs/HFOs.

Possible system architecturesPossible system architecturesPossible system architecturesPossible system architecturesSecondarySecondary HybridHybridCOCO22 BoosterBooster

Small Pack /Small Pack /

Condensing UnitCondensing UnitSelfSelf--ContainedContained

Emerson does not believe in oneEmerson does not believe in one--fitsfits--all solution. The optimum solution for a all solution. The optimum solution for a

certain certain application and application and geographic location is always geographic location is always a tradea trade--off off between between

several requirements.several requirements.

Refrigerant Refrigerant

ChargeCharge

SystemSystem

Life CycleLife Cycle

ClimateClimateApplication Application

EnvironmentEnvironment

Service Service

InfrastructureInfrastructure

LegislationLegislation

& Policy& Policy

System System

IntegrationIntegration

ShortShort-- and longand long--term refrigerant strategyterm refrigerant strategyShortShort-- and longand long--term refrigerant strategyterm refrigerant strategy

Architecture Today Retrofit RefurbishNew Site

“Future-proof”

Condensing Units& Small Packs < 40 kW

R404A R404A, R407A/F R407A/F, R134a, R448A, R449A

R744, R290, (R1234yf/ze)R134a R134a R134a, R450A, (R513A),

R407C R407CR407C, R134a,

R448A, R449A, (R444B)

Multi-compressor PacksR404A R404A, R407A/F R407A/F, R448A, R449A

R744, R290, (R1234yf/ze)R134a R134a R134a, R450A, (R513A),R134a R134a R134a, R450A, (R513A),

Cascade Systemsmedium temperature

circuitlow temperature assumed

CO2

R404A R404A, R407A/F R407A/F, R448A, R449A

R744, R290, (R1234yf/ze)R134a R134a R134a, R450A, (513A),

CO2 Booster Systems R744 R744 R744 R744

Self-contained SystemsR404A R404A, R407A/F R407A/F, R448A, R449A

R290, (R1234yf/ze)R134a R134a R134a, R450A, (R513A)

Future proof solutions are based on a combination of natural and minimum GWP Future proof solutions are based on a combination of natural and minimum GWP

synthetic refrigerants. The currently available lowsynthetic refrigerants. The currently available low--GWP refrigerants represent GWP refrigerants represent

a bridge towards future proof solutions.a bridge towards future proof solutions.

50

60

70

80

90

Co

olin

g C

ap

ac

ity

(k

W)

at

-10°C

/90

bar

Stream CO2 Range / Medium Temperature

Stream COStream CO22 With CoreSense Diagnostics With CoreSense Diagnostics Overview Overview -- Medium Medium TemperatureTemperatureStream COStream CO22 With CoreSense Diagnostics With CoreSense Diagnostics Overview Overview -- Medium Medium TemperatureTemperature

> 200 Boosters In Operation> 200 Boosters In Operation

23.3 m23.3 m33/h/h

26.6 m26.6 m33/h/h

33.3 m33.3 m33/h/h

0

10

20

30

40

4MTL-05X 4MTL-07X 4MTL-09X 4MTL-12X 4MTL-15X 4MTL-30X 4MTL-35X 4MTL-40X 4MTL-50X

Sample Oct 2014Launch Jan 2015

Available Sample June 2015Launch Sept 2015

Co

olin

g C

ap

ac

ity

(k

W)

at

4.6 m4.6 m33/h/h6.2 m6.2 m33/h/h

7.4 m7.4 m33/h/h9.5 m9.5 m33/h/h

12.5 m12.5 m33/h/h

17.9 m17.9 m33/h/h

Samples 2015Samples 2015

25

30

35

40

45

Co

olin

g C

ap

ac

ity

(kW

) a

t -3

5°C

/-5°C

Stream CO2 Range / Low Temperature

Stream COStream CO22 With CoreSense Diagnostics With CoreSense Diagnostics Overview Overview -- Low TemperatureLow TemperatureStream COStream CO22 With CoreSense Diagnostics With CoreSense Diagnostics Overview Overview -- Low TemperatureLow Temperature

0

5

10

15

20

25

4MSL-03X 4MSL-04X 4MSL-06X 4MSL-08X 4MSL-12X 4MSL-15X

Sample Dec 2014Release March 2015

Available

Co

olin

g C

ap

ac

ity

(kW

) a

t

4.6 m4.6 m33/h/h 6.1 m6.1 m33/h/h7.4 m7.4 m33/h/h

9.5 m9.5 m33/h/h

12.5 m12.5 m33/h/h

17.9 m17.9 m33/h/h

Samples: Samples: October 2015October 2015Launch:Launch: January 2016January 2016Subcritical Stream compressors represent a high standstill pressure solution for better systemSubcritical Stream compressors represent a high standstill pressure solution for better system

resilience. resilience.

Low

Side PS

High

Side PS

ZO21K5E-TFDN-551 8854405 1,5 2,6 4,8 3,6 22

ZO34K3E-TFDN-551 8830718 2 4,1 7,2 3,6 30

ZO45K3E-TFDN-551 8831266 2,5 5,4 10,2 3,8 31

ZO58K3E-TFDN-551 8831277 3,5 6,9 13,0 3,9 33400/3/50

(TFD)

Fix Scroll

Rated Pressures

30Bar

Technology Model Ident hpDispl.

m³/h

Cooling

Capacity

kW (1)

COP

(1)

Net Weight

kg

Power

Supply

52Bar

Copeland ScrollCopeland ScrollTM TM ZO(D)ZO(D)Overview Overview -- Low TemperatureLow TemperatureCopeland ScrollCopeland ScrollTM TM ZO(D)ZO(D)Overview Overview -- Low TemperatureLow Temperature

ZO88KCE-TFDN-551 8849830 5,5 10,1 19,5 3,9 40

ZO104KCE-TFDN-551 8837388 6 11,7 22,7 4,0 40

ZOD34K3E-TFDN-551 8850721 2 4,1 7,2 3,7 30

ZOD104KCE-TFDN-551 8847287 6 11,7 22,1 3,8 41

(1) LT EN12900: -35°C/-5°C 10K SH

45Bar

(TFD)

Digital Scroll

10…100%

Modulation

Subcritical Scroll compressors offer standstill Subcritical Scroll compressors offer standstill

pressure at market level. As compared to pressure at market level. As compared to

frequency inverters, more compact, simple frequency inverters, more compact, simple

and precise capacity modulation is used.and precise capacity modulation is used.

52 bar

Range Range ZOD*KCE Digital Capacity ModulationZOD*KCE Digital Capacity ModulationHigh Side Standstill PS High Side Standstill PS Increase Increase 52 bar52 barRange Range ZOD*KCE Digital Capacity ModulationZOD*KCE Digital Capacity ModulationHigh Side Standstill PS High Side Standstill PS Increase Increase 52 bar52 bar

As there is no check valve on the Digital Scroll compressors, an As there is no check valve on the Digital Scroll compressors, an

external placement of check valve at the discharge line of the external placement of check valve at the discharge line of the

compressor is necessary. compressor is necessary.

Full SemiFull Semi--Hermetic vs. Full Scroll Hermetic vs. Full Scroll Solution in Hybrid SystemsSolution in Hybrid SystemsFull SemiFull Semi--Hermetic vs. Full Scroll Hermetic vs. Full Scroll Solution in Hybrid SystemsSolution in Hybrid Systems

MT LT MT LT

Compressor ZB76KCE ZO45 4CES 2FSL

Cooling Capacity [kW] 14 11 14 11

COP 2,7 3,2 2,8 3,1

Weight [kg] 61 31 90 53

Sound [dBA] 77 (67) 67 (57) 74 ?

Model (Fix) 3 x ZB76 1 x ZO45 3 x 4CES 1 x 2FSL

Model (Modulation) 1 x ZBD76 1 x ZOD34 1 x 4CES (inv.) 1 x 2FSL (Inv.)

Emerson Scroll Hybrid Bitzer Semi HybridBenchmark SH Cascade

4-cyl. 2-cyl.

3 x 4-cyl. 1 x 2-cyl.

1 x 4-cyl. (inv) 1 x 2-cyl. (inv)

Competitive SH Hybrid

MT LT

4-cyl. 2-cyl.

14 11

2,8 3,1

90 53

74 not available

3 x 4-cyl. 1 x 2-cyl.

1 x 4 cyl. (inv.) 1 x 2 cyl. (inv.)

� Comparable Efficiency

� Lighter (150 kg) & Compact

� Simple & Cost Effective Digital Modulation (10-100 %)

� Sound Shell Option (-10 dBA)

� Lowest Applied Cost (40…50 %< Semi System)

SolutionsSolutions �� Comparable EfficiencyComparable Efficiency

�� Costly InverterCostly Inverter

�� Higher Higher WeightWeight

Model (Modulation) 1 x ZBD76 1 x ZOD34 1 x 4CES (inv.) 1 x 2FSL (Inv.)

Capacity [kW] 56 19 55 23

Weight [kg] 306 466

EfficiencyEfficiencySound Sound ControlControl

ModulationModulation

Cost Cost ControlControl

CompactCompact

ScrollScrollScroll Scroll Digital Digital

Scroll Scroll Sound Sound Shell Shell

MTMT

LTLT

RefrigerantRefrigerantScrollScroll

Scroll Scroll Digital Digital


R134a/CO2 Hybrid:

To NK1 = -2 °C tc = 47 °C; (MT)

toTK = -30 °C; tcTK = +5 °C. (LT)

1 x 4-cyl. (inv) 1 x 2-cyl. (inv)1 x 4 cyl. (inv.) 1 x 2 cyl. (inv.)

55 23

466

MT scroll compressors approved for new

low-GWP refrigerants N13 and XP10.

Complete COComplete CO22 Solution from EmersonSolution from EmersonComplete COComplete CO22 Solution from EmersonSolution from Emerson

ScrollScroll / Semi/ Semi--Hermetic Concept as CostHermetic Concept as Cost--Effective, Effective, Compact and Compact and Efficient Solution in Booster SystemsEfficient Solution in Booster SystemsScrollScroll / Semi/ Semi--Hermetic Concept as CostHermetic Concept as Cost--Effective, Effective, Compact and Compact and Efficient Solution in Booster SystemsEfficient Solution in Booster Systems

Compactness

CO2

The CO2 System Efficiency Level Needs To Be At Least Equivalent Or Better Than Standard HFC Systems

A Move To Natural Refrigerant Shall Be Economically Viable And CO2 Solutions Should Reach As Much Parity As Possible With Systems Using HFC Refrigerants Currently In Place

Cost

Convenience-Stores or Fuel Forecourt Have Limited Space For Refrigeration Systems Due To Their Typical City Centre Location

HFC

Efficiency

Scroll vsScroll vs. Semi. Semi--Hermetic Hermetic Compressor Compressor ComparisonComparisonScroll vsScroll vs. Semi. Semi--Hermetic Hermetic Compressor Compressor ComparisonComparison

Displacement at 50 Hz (m3/h) 6.36 5.37

Cooling capacity * (kW) 11.12 10.24

Power input * (kW) 2.85 2.61

Competitive SH Emerson Scroll

Power input * (kW) 2.85 2.61

COP * (-) 3.90 3.92

Height (mm) 295 403

Footprint (LxW) (cm2) 693 586

Weight (kg) 53 31

Sound pressure at 1 m (dBA) not available 56

Standstill Pressure LS/HS (bar) 30 / 53 30 / 52

* Rated conditions -35 °C / -5 °C / 10 K SH / 0 K SC

Emerson Scroll compressors are typically more compact, lower weight and Emerson Scroll compressors are typically more compact, lower weight and

as efficient as efficient as bestas best--inin--class class semisemi--hermetic compressors. hermetic compressors.

Scroll vs. SemiScroll vs. Semi--Hermetic Hermetic Compressor ComparisonCompressor ComparisonScroll vs. SemiScroll vs. Semi--Hermetic Hermetic Compressor ComparisonCompressor Comparison

4

5

6

7C

om

pre

sso

r C

OP

(-)

2-cyl. SH

ECT Scroll

Pressure ratios crucialfor booster application

Emerson Scroll compressors have comparable or slightly better efficiency as Emerson Scroll compressors have comparable or slightly better efficiency as

standard semistandard semi--hermetic hermetic ones in the pressure ratio range that is crucial from the ones in the pressure ratio range that is crucial from the

booster application point of view.booster application point of view.

2

3

1,5 2 2,5 3 3,5 4

Co

mp

resso

r C

OP

Pressure Ratio (-)

ECT Scroll

Case Study Case Study –– Compact COCompact CO22 Booster PackBooster Packprimarily for Smallprimarily for Small--Size Formats Size Formats

Case Study Case Study –– Compact COCompact CO22 Booster PackBooster Packprimarily for Smallprimarily for Small--Size Formats Size Formats

LT Suction 25 barLT Suction 25 bar

Receiver 60 barReceiver 60 bar

Medium Temperature:Medium Temperature:

Load 47 kW at Load 47 kW at --10 10 °°C / 90 bar C / 90 bar (35 (35 °°C)C)

Compressors: 2 x 4MTLCompressors: 2 x 4MTL--15X15X

Low Temperature:Low Temperature:

Load Load 7kW 7kW at at --35 35 °°C C / / --5 5 °°CC

Compressors: Compressors: 1 1 x x ZOD34 + 1 x ZO21ZOD34 + 1 x ZO21

Convenience Store Typical Load

MT Suction 40 barMT Suction 40 bar

MT Discharge 120 barMT Discharge 120 bar

Case Study Case Study –– SemiSemi--Hermetic/Scroll vs. Full Hermetic/Scroll vs. Full SemiSemi--Hermetic Compressor TechnologyHermetic Compressor TechnologyCase Study Case Study –– SemiSemi--Hermetic/Scroll vs. Full Hermetic/Scroll vs. Full SemiSemi--Hermetic Compressor TechnologyHermetic Compressor Technology

MT LT MT LT

Compressor 4MTL-30X ZO104 4FTC-20 4FSL-7

Cooling Capacity [kW] 43 27 41 27

COP 2,0 4,7 1,9 5,2

Weight 175 40 165 94

Sound [dBA] 86 72 (62) 78 ?

Models 3 x 4MTL-30X 1 x ZO104 3 x 4FTC 1 x 4FSL

Models (Modulation) 1 x 4MTL-30X 1 x ZOD104 1 x 4FTC (inv.) 1 x 4FSL (Inv.)

Emerson Stream / Scroll Hybrid Bitzer Semi Hybrid

4-cyl. 4-cyl.

3 x 4-cyl. 1 x 4-cyl.

1 x 4-cyl. (inv.) 1 x 4-cyl. (inv.)

Best-in-class SH Booster

3 x 4 cyl. 1 x 4 cyl.

1 x 4 cyl. (inv.) 1 x 4 cyl. (inv.)

Emerson Stream / Scroll Hybrid

MT LT

Compressor 4MTL-15X ZO21

Cooling capacity (kW) 25.2 4.8

COP (-) 1.8 3.6

Weight 170 22.2

Sound (dBA) 82 (70) 63 (53)

Models 4MTL-15X ZO21

Models (modulation) 4MTL-15X (inv.) ZOD34

Competitive SH Booster

MT LT

4-cyl. 2-cyl.

23.5 4.3

1.7 3.7

165 47

83 not available

4-cyl. 1 x 2-cyl.

4-cyl. (inv.) 1 x 2-cyl. (inv.)

� Comparable Efficiency

� Simple & Cost Effective Digital Modulation (10-100 %) with one inverter

� CoreSense Diagnostics

SolutionsSolutions �� Comparable Comparable EfficiencyEfficiency

�� Two costly inverters neededTwo costly inverters needed

�� HigherHigher WeightWeightMTMT

LTLT

ScrollScrollScroll Scroll Digital Digital


EfficiencyEfficiencySound Sound ControlControl

ModulationModulation

CostCostControlControl

CompactCompact RefrigerantRefrigerant

CompressorCompressor Monitoring/ DiagnosticsMonitoring/ Diagnostics

Models (Modulation)

Capacity [kW] 171 55 165 54

Weight [kg] 780 848

Stream COStream CO22

(High PS) (High PS)

Stream Stream InverterInverter

CO2-Booster:

To MT = -10 °C; tGcout = 35 °C; 90 bar (MT)

To LT = -35 °C; tcLT = -10 °C (LT)

1 x 4-cyl. (inv.) 1 x 4-cyl. (inv.)1 x 4 cyl. (inv.) 1 x 4 cyl. (inv.)

165 54

848

Models (modulation) 4MTL-15X (inv.) ZOD34

Capacity (kW) 50.3 12.2

Weight (kg) 392

4-cyl. (inv.) 1 x 2-cyl. (inv.)

47 11.6

427

Case Study Case Study –– Compact COCompact CO22 Booster PackBooster Packprimarily for primarily for SmallSmall--Size Formats Size Formats


1 26% Footprint Reduction Through Iterative Design

– Vertical Scroll & Experience w/ Technology

– Pre-bent Pipe Assemblies w/ Minimal Fittings

– One Inverter Less (Digital Scroll)

– Compact Control Panel

– Years Of Experience in Packaged Units Building

– Be Flexible & Listen To The End User

R&D Test Frame - Prototype

Pre-Production Frame

1900 W x 800 L x 1940 H (mm)

Production Frame1400 W x 800 L x 1940 H (mm)

2

3

– Be Flexible & Listen To The End User

– 3D Simulations

Start Finish



� Trialled From Nov 2012 To July 2013 in Pucklechurch, UK

� Several Design Iterations & Improvements

� Production Launched Since Aug 2013

� Several Packs Already Running In Stores In Different Locations

Limited Space

Available

Case Study Case Study –– Achievements thanks to Achievements thanks to Emerson COEmerson CO22 Products and SolutionsProducts and SolutionsCase Study Case Study –– Achievements thanks to Achievements thanks to Emerson COEmerson CO22 Products and SolutionsProducts and Solutions

1. Inverter (Medium

Temperature Only)

2. Scroll Technology

Efficiency3…6 % > HFC

1. Copper K65


Cost50 % > HFC (Pack)

35 % > HFC (Installation)

1. Scroll

2. Pre-Bent Pipes

3. 3D Simulations

4. Design Expertise

5. Manufacturing Experience

Compactness26 % Reduction To 1,4 m

CO2

= New Technologies


3. Digital Modulation

(Low Temperature)


3. Digital Modulation

4. HP Oil Management

5. On-Board Compressor

Electronics

5. Manufacturing Experience

HFC

Continuous Improvements Ongoing:

� Continue Simplifying Oil Circuit

� Optimise Piping Sizing

� Optimise Component Sizing

� Smaller Capacities

� Air Conditioning

� Heat Reclaim

Emerson Contributing

Products OM5 Oil Management (130 bar)

Scroll / Scroll Digital ZO(D)CO2 Low Temperature

Stream With CoreSense DiagnosticsCO2 Medium Temperature

EmersonEmerson Has Proven Field Has Proven Field Booster Experience Booster Experience In EuropeIn EuropeEmersonEmerson Has Proven Field Has Proven Field Booster Experience Booster Experience In EuropeIn Europe

Others

•• CO2 Booster For Express CO2 Booster For Express Stores / Small FootprintStores / Small Footprint

•• Scroll & Digital Technology Scroll & Digital Technology Allow Cost ContainmentAllow Cost Containment

•• 2 x Stream + 2 x Scroll2 x Stream + 2 x Scroll

•• Serial Production With 100 Serial Production With 100 Installed CInstalled C--StoresStores

•• Supermarket Booster & CSupermarket Booster & C--Stores ExpressStores Express

•• Fully Use Of Fully Use Of CoreSenseCoreSense

•• 60 bar 60 bar StandStillStandStill (Use of T/C)(Use of T/C)

•• Now In Serial Production With Now In Serial Production With 40 Installed Stores40 Installed Stores

•• One site Running In USOne site Running In US

•• Started With Emerson Started With Emerson Scroll/SemiScroll/Semi

•• 2 Supermarket Boosters 2 Supermarket Boosters In In LithuaniaLithuania

•• First Will Be Installed In OctFirst Will Be Installed In Oct

•• Expect More Stores In 2015Expect More Stores In 2015

Others: Arctic Circle (UK), Others: Arctic Circle (UK), ArnegArneg (ITA), (ITA), QplanQplan (HUN), Hill Phoenix (US), System LMP (CAN)(HUN), Hill Phoenix (US), System LMP (CAN)

Estimate 200 Systems Running With Emerson COEstimate 200 Systems Running With Emerson CO22 SolutionsSolutions

ConclusionsConclusionsConclusionsConclusions� Close cooperation between compressor and system

manufacturer is essential during system design.

� Mixing scroll and semi-hermetic compressor technology in a booster system does not require any special design change.

� Using Scroll Compressors with proven Digital Technology instead of costly Semi-Hermetic compressors with inverter instead of costly Semi-Hermetic compressors with inverter keeps the investment cost competitive. They are a superior solution also in Hybrid Systems, in which its advantages are multiplied.

� CO2 has been the refrigerant choice also for small format shops where Scroll Technology represents a reliable, cost-effective, energy efficient and compact solution.

� Therefore, combining Scroll and Semi-Hermetic Compressor Technology in a system, convenience store operators can afford to make the transition to CO2.

Stream CO2 With Stream CO2 With CoreSenseCoreSense™ Diagnostics ™ Diagnostics Field ExperienceField ExperienceStream CO2 With Stream CO2 With CoreSenseCoreSense™ Diagnostics ™ Diagnostics Field ExperienceField Experience

Regular Regular OrdersOrders

Packs Packs ProducedProduced By Carrier/By Carrier/ProfroidProfroid

Congres F-gassen 2015. Workshop 8: Scroll CO2, bied veel meer dan alleen een prijsgunstige...

Engineering

Transcript of Congres F-gassen 2015. Workshop 8: Scroll CO2, bied veel meer dan alleen een prijsgunstige...