final aar panel discuss r5 as on 13 june 2020€¦ · 13/06/2020 · refrigerants currently used...

6/13/20

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13 June 2020AAR WEBINAR 1

Moderator Anil D Gulanikar Past President – AARDirector , DAG-TECH SERVICESMobile : 9004099792, Email: [email protected]

Panelist

Haresh Rupchandani, Sr. Gen. Manager – Johnson Controls Mobile : 9923200941, Email [email protected]

Anish SimhaSr. Gen. Manager – Rinac India Ltd.Mobile : 9972344255, Email: [email protected]

Prakash Patil India Cluster Head, GEA RefrigerationMobile : 9765401543, Email: [email protected]

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Introduction of Refrigerants

Evolution of Refrigerants

Ammonia Refrigerant Properties, Characteristics

Phase down of Refrigerants

Why ammonia is Refrigerant of Choice ?

Applications with Ammonia and New Developments

Ammonia in Air-conditioning


• Food is affected by spoilage• Initial application was to minimize the

spoilage of food and later on an extension of it’s shelf life.

Preserve food and extend the shelf life

• Maintain Temeperature in a process• Product manufacturing Process Cooling

• Growth in World population • Urbanization with growing middle class,• Greater food safety and quality.• New Product development

Demand for Refrigeration

} A refrigerant is a substance or mixture, usually a fluid, used in a heat pump and refrigeration cycle. ... Other common refrigerants used in various applications are ammonia, sulfur dioxide, and non-halogenated hydrocarbons such as propane.

} Ammonia as Refrigerant―Anhydrous Ammonia used for heat transfer in a closed-circuit ammonia refrigerating system used the vapour-compression cycle, which absorbs heat at a low temperature and low pressure of the fluid and rejects heat at a higher temperature and higher pressure of the fluid, usually involving change of state of the fluid.


} 1870 -1930: Natural refrigerants only• Ammonia (NH3, R717)

Outstanding thermo-dynamical properties

• Sulfur-dioxide (SO2, R764) Poisonous, corrosive

• Carbon-dioxide (CO2, R744) High pressure

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Global

• 195 countries have signed the Kigali agreement.

• Main objective limit increase in global temperature 2 Deg C and to just 1.5 Deg C if possible.

• Use of natural refrigerant is the ultimate decision.

• As per the agreement India has to prepare and follow Standard on “Natural Refrigerant and design, install, operate and maintain safe and energy efficient refrigeration system”

• Europe shifted to natural refrigerant even for commercial refrigeration like supermarket.

• USA shifting to natural refrigerant

India

• India has signed Kigali agreement

• Ammonia as a refrigerant is popular in India for more than 100 years.

• Very widely used for various industrial refrigeration applications

• Make in India is virtually followed. 100% Indian manufacturing, material / component available.

• Skilled manpower available

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Low Cost Easy Availability Easy to Use Energy

Efficient

Stable Compound

Environment Friendly Sustainable Long Life

Hard to Ignite

Lighter than Air

Dissolves in Water

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• One of oldest refrigerant

• It is less expensive

• Most efficient refrigerant: high heat transfer characteristics

• Has no effect on the "ozone layer" 0 ODP & <1 GWP

• It is thermodynamically stable refrigerant

• Ammonia is not miscible with lubricating oil

• Ammonia system components may be smaller than those in HFC, HCFC systems

• Refrigeration grade ammonia is available everywhere

• No need to write off investment of ammonia plant due to environmental concerns

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Ammonia purity requirement: Ammonia Characteristics

Ammonia Purity Requirement As per AAR standard 1

Ammonia content: 99.95% min.

Non basic gas in vapour phase: 25 PPM max.

Non basic gas in liquid phase: 10 PPM max.

Water : 33 PPMOil : 2 PPMSalt : NonePyridine , hydrogen sulfide , Naphthalene : None

IS 16656/ISO 817 and ASHRAE classify A1,A2,A3, B1,B2,B3 as safety groups.

A category is for Toxicity.

B category is for flammability.

A3 most toxic.

B3 is most flammable.

Ammonia is classified in B2L category by IS 16656/ISO 817 and ASHRAE Std. 34 i.e. it is less flammable than B2 since its burning velocity is less than 10 cm/s.

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Toxicity :Ammonia has a pungent odor and small leak as low as 5 ppm is detectable by smell and serves as early warning

Almost all human beings can detect levels up to 25 ppm and continuous exposure to 50 ppm level is permitted for 8 hours per day per week.

Flammability: Ammonia is extremely hard to ignite ( above 650°C) and breaks down above 450°C

Pure ammonia is considered flammable between the 16% and 27% atmospheric pressure

Ammonia is classified as Class B2L and hence not considered as highly flammablerefrigerant.

Ammonia is less flammable as compared with many hydrocarbons and other fuels which areused in Day to Day life.Its ignition energy is 50 times higher than the natural gas and ammonia cannot burn withoutpresence of supporting flame.Ammonia in vapor state will not sustain a flame.

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Description of Guideline level

10 min

30 min 60 min

4 hr 8hr

AEGL 1 Would not cause discomfort

30 30 30 30 30

AEGL 2 Would not cause disability

220 220 160 110 110

AEGL 3 Would not cause death 2700 1600 1100 550 390

. Source Table 14 page 38 IIF –IIR ammonia as refrigerant AAR WEBINAR 11 13 June 2020AAR WEBINAR 12

Refrigerant ODP GWPHCFC HCFC-22 0.055 1700

HCFC-123 0.02 93

HFC

HFC-32 0 550HFC-23 0 12000HFC-125 0 3400

HFC-134a 0 1300R-404A 0 3780R-407C 0 1650

R-410A 0 1980R-507A 0 3850

NaturalRefrigerants

Ammonia (R717) 0 <1

Propane (R290) 0 3CO2 (R744) 0 1

Propylene (R1270) 0 3Ethane (R170) 0 3

Air (R729) 0 0

Steam (R718) 0 0

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Towards Green Cooling


The Montreal Protocol reduced greenhouse gas emissions globally by 135 billion tonnes CO2-e between 1990–2010.

The Kigali HFC phase-down will avoid 72 billion tonnes of global CO2-e emissions up to 2050.

This is an HFC phase-down, not an HFC phase-out.The importation quota controlling the HFC phase-down is CO2-e based. This means that the lower the global warming potential (GWP) of a refrigerant is, the more kilograms can be imported before the import quota is exhausted.

HOW DOES THE HFC PHASE-DOWN WORK? Refrigerants have a measured property, their GWP. This represents an “equivalent carbon dioxide effect” (CO2-e). High GWP is bad, low GWP is good. Many of the synthetic refrigerants currently used in refrigeration and air conditioning have a high GWP.

What is Global Warming Potential and CO2-eGlobal Warming Potential (GWP) is a measure of the ability of a

substance to trap heat in the atmosphere. Carbon dioxide is used as the baseline with a GWP of 1. Carbon dioxide equivalent (CO2-e) is the measurement of the GWP of a refrigerant.


Kigali Amendment Ratification Schedule

Non-A5 CountriesAustralia, Japan, New Zealand, North Korea, Lao (PDR)

A5 Group 1 CountriesChina, Thailand, Malaysia, Indonesia, Cambodia, Pacific Islands, Maldives, Sri Lanka, and “West Asian

A5 Group 2 CountriesIndia

The Montreal Protocol was agreed in 1987 and has phased-out over 99 per cent of the production and import of nearly 100 ozone-depleting substances.

All 197 UN member countries agreed to use the Montreal Protocol to phase down production and import of hydrofluorocarbon (HFC) refrigerants, through the Kigali Amendment. The higher the GWP, or the more CO2-e a refrigerant has, the more potential it has to increase climate change.

S.N. Item R134a R404a R407c Ammonia1 Classification HFC HFC HFC2 Composition C2H2F4 R125 60% + R2902%

+ R-22 38%R-32 23% + R-12525% + R-134a 52%

NH3

3 GWP 1430 3900 1650 less than 14 ODP 0 0 0 05 Phase out status in Europe 2040 2030. In Europe

already banned2030 No phase out as

natural refrigerant6 COP compressor -4 evap &

52 condensing air cooled2.4 2.1 2.3 3.9

7 Availability of Gas will have scarcity and cost will increase due to phase down

Always Available

8 .+20 evaporation temp fall under operating envelop. (Yes/ No)

Yes No No Yes

9 Gas top up in case of gas leak

Not blend so can be top up.

Saves operating cost

Blend, Can not be top up, We have to remove entire gas in case of small

refrigerant leak.

Top Up Possible

10 Refrigerant cost INR /kg 400 355 330 7011 Operating pressure kg/cm2g

at 52 condensing temp12.79 22.9 19.8 14.8


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Refrigerant

Shaftpower kW@ 40 Deg C cond. (Water cooled)

Diff. in shaft power w.r.t Ammonia

extra energy bill for 15 year s of plant life ( RS)

Shaftpower kW@ 52 Deg C cond. (Air cooled)

Diff. in shaft powerw.r.t Ammonia

extra energy bill for 15 years of plant life ( INR)

R-717 26.5 0 26.5* 0

R-407c 30.92 4.42 15,91,200 43.17 16.67 60,01,200

R-404a 45 6.56 23,61,600 45.11 18.61 66,99,600

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Sr No Description Ammonia Freon R-404a

Capacity TR Power kW Capacity TR Power kW

1 Evap / Cond temp. -3/40 -3/52

2 Reciprocating Compressor 1 x 50 TR 45.71 10 x 5TR( air cooled condensing unit with

9.375 KW power)

93.375

3 Evaporative Condenser ( Ammonia ) / Air cooled

condenser ( Freon )

81 3.74

4 Low Pressure Receiver 50 2 NA

5 Evaporator Units 5TR x 10 6.66 5TR x 10 10

Total, kW 58.11 103.375


Sr No Description Ammonia Freon R-404a

Capacity TR Power kW Capacity TR Power kW

1 Evap / Cond temp. -40/40 -40/52

2 Reciprocating Compressor 1 x 52 108.7 2 x 25.5TR 301

3 Evaporative Condenser ( Ammonia ) /

Air cooled condenser ( Freon )

109 4.08 Integral -

4 Low Pressure Receiver 52 2 NA -

5 Evaporator Units 2 x 26 TR 15.84 2 x 26TR 25

Total, kW 130.6 326

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Holding time : Per day kW consumed for Ammonia /R-134a


Purpose

• Food and beverage preservation,

• Extend shelf life of food and beverages,

• Utility in processing food and beverages,

• Utility in manufacturing of all kind of non food products,

• Air conditioning for human well being,

• Airconditioning for setting proper production environments,

• Leisure (ice skating, ski- and snow domes).

Applications

• Meat Processing • Fish Processing• Fruit & pulp plants and

beverages • Chocolates manufacturing• Breweries• Cold storages: Ultra modern

multi temperature• Egg powder plant• Ice Cream Plant• Edible oil plant• Commercial refrigeration

system

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Air Conditioning of airports internationally.

Low ammonia charge system

Efficient Ammonia /CO2 brine system.

Heat Pumps

Other aspects of the comparison:•Ammonia and R-134a chillers have almost the same efficiency at 100 percent and 75 percent capacity.•The ammonia chiller has a much better part-load efficiency.•The IPLV efficiency is 12 percent higher in an ammonia chiller.•First cost of the ammonia chiller is twice that of an R-134a chiller.•At a cost of electricity of about Rs.7/kWh, the ammonia chiller will be cost competitive over its lifetime.•Ammonia chiller energy efficiency can be improved using an economizer.•The ammonia chiller can be greatly improved with optimized heat exchangers.•There is phase down of R134a while not in case of ammonia.


Standard HVAC Chiller with R134a Ammonia Chiller

A “simple system” with semi-hermetic, suction-gas-cooled compressor motors, shell-and-tube flooded evaporators with enhanced copper tubes, no service valves, an electronic control center & a low height.

It has standard open screw compressors with variable-volume ratio regulation and capacity regulation down to 10 percent; high-efficiency, low-noise motor; semi-welded, plate & frame condenser; liberal use of service valves; and uses a polyalphaolefin or mineral oil.

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1999 An ammonia system for air-conditioning the office rooms at Saab in Linköping, Sweden. Here the system required for efficient supply of refrigeration for the premises covering 5,000 square meters also needed to be easily upgradable to cope with future expansion.

2000 An air-conditioning system using the natural refrigerant R723 (ammonia / dimethyl ether) in its office building. The core element of the refrigerating system that operates with a blend of natural refrigerants is a two-circuit liquid chilling unit. The refrigerating capacity is around 60 kilowatt with an evaporation temperature of 0°C and a condensation temperature of 45°C.

2000 Berlin's Ostbahnh of train station is equipped with a system for the air-conditioning and ventilation of the three- storey building complex. The necessary air-conditioning and ventilation tasks in the buildings entail cooling the secondary refrigerant down from 16 to 10°C. The solution consists of three air-cooled ammonia compact liquid chilling units with a total capacity of 1,250 kilowatt.

2004 Stuttgart airport changes over to an ammonia system for the new Terminal 3, comprising two liquid chilling units with an overall capacity of 2,300 kilowatt.

2005 Ammonia air-conditioning system installed for 22,000 square meters of working areas at Roche's headquarters in Welwyn Garden City near London with two ammonia chiller units 930 kilowatt capacity each on the roof of the building.

2008 Mülligen letter sorting center, which is the largest building in Switzerland, is provided with refrigeration and heat by an ammonia heat pump. The energy needed for heating and chilling is taken from the wastewater of a nearby sewage plant. The heat pump has a refrigerating capacity of 4.3 and a heating capacity of 5.6 megawatt at 62°C outlet temperature. Refrigeration is generated in the first stage by three piston compressors at an evaporation temperature of 5°C and a condensation temperature of 30°C

2010 An integrated refrigeration and air-conditioning concept for the Ozeaneum in Stralsund with a total refrigerating capacity of 900 kilowatt, including around 500 kilowatt for air-conditioning. A single-stage ammonia refrigeration system was installed with flooded evaporation, consisting of two separated Chill-Pac chilling units with 730 kilowatt each and two hybrid evaporative condensers for chilling cold water.

Reference: eurammonAAR WEBINAR 13 June 2020

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} AAR Standard } AAR Ammonia brochure } ASHRAE} Eurammon} IIR document} UNEP} Practical experience of the team


q Why Ammonia is not getting more popular than F gases ?

q Why Cost of Ammonia plant automation is much higher than F gases?

q In my multi room cold storage I can always switch off units if not used, but I have to run complete plant in Ammonia?

q Cost repairs of smaller compressor is much less than ammonia big compressors

q What is standard Available in India for Ammonia plant design?

q What is minimum size of Ammonia plant I can have?

q Why new technologies are not developed in Ammonia refrigeration industry as compared to Air conditioning?


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final aar panel discuss r5 as on 13 june 2020€¦ · 13/06/2020 · refrigerants currently used...

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