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Danfoss CO 2 solutions www.danfoss.com/CO2

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Page 1: Carbon dioxide solutions

Danfoss CO2 solutions

www.danfoss.com/CO2

Page 2: Carbon dioxide solutions

1850 Aleksandar Twining in his British patent suggested CO2 as refrigerant

1867 Thaddeus S.C. Lowe (adviser of Abraham Lincoln) experimented with military balloons and designed first ice making device with CO2. He also constructed device for transport frozen food on ships.

History of using COHistory of using CO22 as refrigerantas refrigerant

2

1920 – 1930 systems with CO2 are at their peak, mostly in marine applications, while NH3 was mostly used on land.

By apearing of “Freon” R12 use of CO2 significantly dropped, mostly because of drop of cooling capacity and high pressure on higher outside temperatures.

1993 New focus on CO2 as natural refrigerant, encouraged by limitations of CFC i HFC as well as demands to limit amount of NH3 in installations.

Page 3: Carbon dioxide solutions

Peak of CO 2 usage

History of using COHistory of using CO22 as refrigerantas refrigerant

CO2 compressorfrom 1900

3

1850 199319601920 ----------1930

Rediscover of CO2 cooling technology (Gustav Lorentzen)

Suggestion to use CO2 as refrigerant (Alexander Twining,British patent)

Page 4: Carbon dioxide solutions

(Carbon dioxide / R744)

Characteristics of COCharacteristics of CO22

• Natural substance ( ODP = 0 ; GWP = 1 )• Refrigerant classified as non toxic and non flammable• Dangerous for humans if concentration exceeds 5000 ppm (0,5% v/v)

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• Dangerous for humans if concentration exceeds 5000 ppm (0,5% v/v)• Odourless• Heavier than air (app 1,5 times)• High volumetric cooling capacity

smaller dimensions of suction pipelinesmaller compression volume in compressor

• Compatible with most of materials (non corrosive)• Less sensitive to pressure drop in pipeline• Low critical point (31°C), high triple point (-56.6° C)

Page 5: Carbon dioxide solutions

(Carbon dioxide / R744)

Characteristics of COCharacteristics of CO22

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• High volumetric cooling capacitysmaller dimensions of suction pipelinesmaller compression volume in compressor

• Low viscosity liquid and gas pipelines (small pressure drop)• High coefficient of heat exchange during evaporation and

condensation• Compatible with most of materials (non corrosive)• Less sensitive to pressure drop in pipeline• Low critical point (31°C), high triple point (-56. 6°C)

Page 6: Carbon dioxide solutions

Drivers of future refrigerantsDrivers of future refrigerants

Charges orsubvention

Initialcosts

EnvironmentalProtection

Tradition ….

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Legislations

“Green”profile

Safety

Sustainabledevelopment

EfficiencyBudućerješenje

Page 7: Carbon dioxide solutions

Global warming potential GWP i Global warming potential GWP i Ozone depletion potential ODPOzone depletion potential ODP

Global WarmingGlobal Warming Potential (GWP)Potential (GWP)100a100a

4.0004.000

20.00020.000

R404AR404A

Kyo

to

pro

toko

l

7

2.0002.000

R404AR404A

Montreal protokol

Page 8: Carbon dioxide solutions

Global warming potential GWP i Global warming potential GWP i Ozone depletion potential ODPOzone depletion potential ODP

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Page 9: Carbon dioxide solutions

Global warming in perspectiveGlobal warming in perspective

30.000 km30.000 km

What is the mileage you canmake with Volkswagen Golf 2.0 TDI in order to emit same amount of CO2 equivalent to leakage of 1kg R404A.

30.000 km30.000 km

Retail store with 500 kg load of R404A and 10% early leakage means 1.500.000 km**

* CO2 emission per km. 129 g/km**GWP of 404a is 3983 according to IPCC AR4

(100 year radiative forcing)

Equatorial Equatorial circumference of circumference of the Earththe Earth40.070 km!40.070 km!

Page 10: Carbon dioxide solutions

COCO22 -- aa naturalnatural choice for refrigerationchoice for refrigeration

• No tax on refrigerant• No charge limitation• Cascade systems applicable in all weather conditions• Green profile • Less energy consumption than indirect systems• One refrigerant ( transcritical)• Simple system (transcritical)

COCO22

Page 11: Carbon dioxide solutions

Refrigerant R134a R404a NH 3 CO2

Natural substance NO NO YES YES

Ozone Depletion Potential (ODP) * 0 0 0 0

Global Warming Potential (GWP) * 1300 3784 - 1

Critical point bar°C

40.7101.2

37.372

113 132.4

73.631.1

COCO22 in comparison with other refrigerantsin comparison with other refrigerants

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°C 101.2 72 132.4 31.1

Triple point bar°C

0.004-103

0.028-100

0.06-77.7

5.18-56.6

Flamable or explosive NO NO (YES) NO

Toxic NO NO YES NO

* prEN 378-1 (2003)

Page 12: Carbon dioxide solutions

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Page 13: Carbon dioxide solutions

0 - 5°C

5 -

Mean Annual Temperatures

•Copenhagen 9%

•Stockholm 10%

•Berlin 3%

Energy savings of transcritical CO2 compared to single stage R404A

•London 4%

Transcritical Energy SavingsTranscritical Energy Savings

5 -10°C

10 -15°C

15 -20°C

•Paris 0%

•Madrid -7%

•Rom -10%

•Vienna 1%

•Istanbul -9%

Page 14: Carbon dioxide solutions

Transcritical vs. SubcriticalTranscritical vs. Subcritical

Transcritical & Subcritical CO2

•Copenhagen 9%Paris 0%•

•Rom -10%Seattle 3%• Sapporo 3%••Buffalo 1%

Subcritical CO2

Transcritical & Subcritical CO2

Subcritical CO2

Energy savings of transcritical CO2 compared to single stage R404A

Melbourne -4%•Cape Town -10%•

Page 15: Carbon dioxide solutions

Principal diagram CO2 cascade system with 2 temperature Principal diagram CO2 cascade system with 2 temperature levels (e.g. supermarket refrigeration)levels (e.g. supermarket refrigeration)

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Pump circulating system / -7°C

Direct expansion / -20°C

Page 16: Carbon dioxide solutions

Characteristics of CO2 cascade systemCharacteristics of CO2 cascade system

• Efficient in all climate areas

• Usage of CO2 lowers the amount of HFC refrigerant (system charge)

• If combined with NH3 or Hydrocarbons on upper side of cascade, 100% ecological solutioncascade, 100% ecological solution

• CO2 is practical when used in low temperature cooling

• Highest pressure in the system is 40 bar, so copper pipelines and standard components can be used

• 70% - 90% lower consumption of el. energy for recirculation, comparing to brine systems

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Page 17: Carbon dioxide solutions

ExperiencesExperiences

• Mostly good experiences, but larges issues can occur with dimensioning of pipes, heat exchangers and problems on HT system

• HC or HFC system on HT side• CO2 on LT and MT (25/40 bar systems)• Typical system:

-30°C evaporation on LT CO2 system

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-30°C evaporation on LT CO2 system-10°C evaporation on MT CO2 system

• CO2 condensation at -10°C• Direct expansion on LT and pump (or natural) recirculation on MT• In large systems, CO2 pump uses app. 10% el. energy

Page 18: Carbon dioxide solutions

Cascade HFC Cascade HFC -- CO2 systemCO2 system

Page 19: Carbon dioxide solutions

CO2 cascade systemCO2 cascade system

Industrial Industrial refrigerationrefrigeration

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refrigerationrefrigeration

Page 20: Carbon dioxide solutions

• Faster reaction time to any temperature change

• Pipelines are much smaller comparing to brine systems

• Energy consumption for recirculation is few percentage

Why COWhy CO22 in industrial applications ?in industrial applications ?

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recirculation is few percentage comparing to classical systems

Page 21: Carbon dioxide solutions

Program for calculating energy savings with CO2 as Program for calculating energy savings with CO2 as secondary refrigerantsecondary refrigerant

www.danfoss.com/COtoo

CO2 calculator helps you estimate energy savings using CO2 as secondary refrigerant comparing traditional systems with water mixtures

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Page 22: Carbon dioxide solutions

Energy efficiency comparison between R404A/CO2 cascade Energy efficiency comparison between R404A/CO2 cascade system and conventional R404A i R22 systems in retail system and conventional R404A i R22 systems in retail storesstores

A. Silva(a) , E. Almeida(b) , E.P. Bandarra Filho(c)(a), (b)Bitzer Compressores Ltda , Brazil.(c)Faculty of Mechanical Engineering – Federal University of Uberlandia, Brazil9th IIR Gustav Lorentzen Conference 2010, Sydney

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Page 23: Carbon dioxide solutions

Energy efficiency comparison between R404A/CO2 cascade Energy efficiency comparison between R404A/CO2 cascade system and conventional R404A i R22 systems in retail system and conventional R404A i R22 systems in retail storesstores

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Page 24: Carbon dioxide solutions

Energy efficiency comparison between R404A/CO2 cascade Energy efficiency comparison between R404A/CO2 cascade system and conventional R404A i R22 systems in retail system and conventional R404A i R22 systems in retail storesstores

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Page 25: Carbon dioxide solutions

COCO22 Transcritical BoosterTranscritical Booster

3

45

6

1 2

79

10

11

12

8

Page 26: Carbon dioxide solutions

COCO22 Transcritical BoosterTranscritical Booster

CO2 Trans-critical Booster

• Efficient in mild climates• One refrigerant• Controls available today

– Gas-cooler controls– Gas-cooler controls– Receiver pressure controls

• Standstill security• Oil management solved• Excellent potential for heat reclaim.

Page 27: Carbon dioxide solutions

COCO22 Transcritical BoosterTranscritical Booster

High pressure High pressure regulatorregulator

Gas “byGas “by--pass”pass”valvevalve MTMT

HT compressorHT compressor

Gas coolerGas cooler

valvevalve

ExpansionExpansion

valvevalve

LTLT

MTMT

Booster / LT compressorBooster / LT compressor

Page 28: Carbon dioxide solutions

Market Drivers for RefrigerantsMarket Drivers for Refrigerants

1. Legislation– Tax on refrigerants– Refrigerant charge – F-gas

2. Operating cost– Energy– Service– Refrigerant cost

3. Green profile- Carbon footprint

Page 29: Carbon dioxide solutions

Subsidies: Japan, Germany, Quebec

North AmericaEurope

Russia

TAX on F-gases: DK, NO, SE, etc.

Legislation, Subsidies, & TaxesLegislation, Subsidies, & Taxes

South America

Europe

Africa

Middle EastAsia

Australia

Japan

Legislation forces the use of natural refrigerants

California?

Charge limitations: Denmark, Austria, ….

Page 30: Carbon dioxide solutions

Taxes on refrigerants in Denmark, Sweden and NorwayTaxes on refrigerants in Denmark, Sweden and Norway

2010 2011 2010 2011

Refrigerant KR / kg KR / kg € / kg € / kg

HFC-23 (R-23) 400 600 54,1 81,1

HFC-134a (R-134a) 130 215 17,6 29,1

http://www.skm.dk/tal_statistik/satser_og_beloeb/184.html

R-404A (HFC-143a/HFC-125/134a) 378 588 51,1 79,5

R-407C (HFC-32/HFC-125/134a) 165 266 22,3 35,9

R-410A (HFC-32/HFC-125) 198 313 26,8 42,3

R-507 (HFC-125/HFC-143a) 385 598 52,0 80,8

Page 31: Carbon dioxide solutions

Taxes on refrigerants in SloveniaTaxes on refrigerants in Slovenia

Tax 1.1.2013

GWP € / kg

Company responsible for keeping record about refrigerants, pays after first installation 5% targeted tax level for 2013.

For refilling of the installation, following taxes apply:

GWP € / kgR404A 3784 93,4 40,5R134a 1300 93,4 13,9

01.01.2009 01.01.2010 01.01.2011 01.01.2011 01.01.201310% 20% 40% 80% 100%

R404A 4,05 8,1 16,2 32,4 40,5R134a 1,39 2,78 5,56 11,12 13,9

Page 32: Carbon dioxide solutions

Market trends COMarket trends CO22 status Nordicstatus Nordic

• Subcritical CO2– Several hundreds of various types of installations– more than 10 years of experience but now in decline because of simpler

transcritical systems and high taxes on HFC refrigerants• Transcritical stores

– 2006 > 5 stores– 2007 > 50 stores– 2007 > 50 stores– 2008 > 150 installations– 2009 > 300– 2010 > 500– 2011 > 700

• Market standard appears to become1. Cascade MT pump CO2 and LT CO2 DX2. Transcritical booster systems� Most ambitious is IKEA saying a carbon footprint of 0% !!!

Page 33: Carbon dioxide solutions

Market trends COMarket trends CO22 status Great Britainstatus Great Britain

The Environmental Investigation Agency releasesChilling Facts III report ; March 2011

HFC-free refrigeration in UK– 2008 > 14– 2009 > 193– 2010 > 239– 2010 > 239

TESCO ; HFC-free, 57 in UK, 23 outside UKMarks & Spencer ; 29 stores by April 2011. Totally HFC-free by 2030Sainbury ; 2 stores in 2009, 71 stores by March 2011Morrisons ; hybrid systems in 23 stores• Tesco, Sainsbury, COOP and many others say reduction of carbon footprint by

20-30 % by 2020

Page 34: Carbon dioxide solutions

Market trends COMarket trends CO22 in Eastern in Eastern EuropeEurope

PolandSince 2008 several industrial cascade NH3/CO2 plants; capacities 300-600 kWOne supermarket application

RussiaIndustrial cascade NH3/CO2 plants ; 2 storage, 2 production, 1 sport facility

Hungary4 years of experienceIn beginning subcritical systems but now transcritical is more attractiveApplications in supermarket and industrial refrigerationAprox. 10 subcritical and 40 transcritical systems

Page 35: Carbon dioxide solutions

Future trendsFuture trends

• Today systems build are between 25 and 300 kW• Future systems will be smaller to cover gas stations and small stores

segment• Bigger systems will also be a more common application taking over

from ammonia in some cases• Transcritical CO will also be used in large AC systems• Transcritical CO2 will also be used in large AC systems

Page 36: Carbon dioxide solutions

Large systemsLarge systems

• Netto Central storage facility vest of Århus (Denmark)

• Total installed capacity approx 1,5 MW

• Transcritical gas by pass system

• Heat reclaim 1,5 MW at 70/40 ºC waterat 70/40 ºC water

• Start up Q2 2009

Page 37: Carbon dioxide solutions

Large systemsLarge systems

� Storage of fruit and vegetables Måkested Norway:

� Booster with gas-by-pass, DX� Capacity: 2 x 400 kW� Evaporation temperature: -10ºC/ -35ºC� Economy: 20 % saving on installation

and approx 20 % saving on energy.Compared to cascade systemsCompared to cascade systems

Page 38: Carbon dioxide solutions

Parken in Copenhagen Parken in Copenhagen –– AC with DX CO2AC with DX CO2

� Gas by-pass system with DX CO2 � 3 x 400 kW installed capacity� Evaporation temperature 7-8 ºC� Economy: 20% saving on

installation and 15% saving on energy compared with high end HFC chillers