eurammon symposium 2016...eurammon symposium 2016 efficient deep freezing under extreme conditions...

eurammon Symposium 2016

Efficient deep freezing under extreme conditions

Güntner insulated unit cooler – THERMOSTORE

Miguel Garrido

Schaffhausen, 23rd/24th June, 2016

Schaffhausen, 23rd / 24th June, 2016

o Ammonia most “natural” refrigerant

o Smart plant design: Efficiency and Safety

o Case Study: “Efficient deep freezing under extreme conditions”

New Generation. Güntner THERMOSTORE with EC technology

AGENDA


Ammonia: most „natural“ refrigerant


PROS:

+ Environment – friendly refrigerant: (ODP= 0, GWP= 0)

+ Wide application range: to= -45°C bis +10°C (boiling point. -33°C)

+ High volumetric efficiency

+ Best thermodynamic properties

+ Energie efficient

+ Cheap

+ Experiences from more than 100 years ! First plant is dated 1876 !)

CONS:

- Toxic

But easy to SMELL!

- Flammable

But ONLY in non-controlled situation ( < 15 Vol-%)

- Explosive

But ONLY in non-monitored plants (15-30 Vol-% - inflamation 630°C)



100%

111%

93%91% 89%

0%

20%

40%

60%

80%

100%

120%

R22 NH3 R134a R507 R404A

100%

111%

93%91% 89%

0%

20%

40%

60%

80%

100%

120%

R22 NH3 R134a R507 R404A

NH3 Proven technology vs HFC systems:

Wide range of compressor small and large caps

Robust design

Energy Efficient:

15-20% better COP in NH3 pump system than R-

404ADx

Life cycle cost and Service life

last 50-75% longer than HFC systems

Accurately control and monitoring technology

Not subject to commercial pressure of refrigerant

manufacturers neither special taxations variations

COP refrigerants at t0= -10 °C, tC= +40 °C







AGENDA


Targets:

- Maximized energy efficiency

- Minimized risk of accidents

- Reduced Life cycle cost

- Monitoring&Control as safety key

factor

- Enviromentally friendly

Smart Design of Ammonia plants


Designed for Safety!

- Low NH3 refrigerant charge compressors units

- Dx systems.

- Nh3/CO2 cascade systems

- Indirect NH3/Secundary loop systems

- Desing pressure 25bar ( VS . CO2 up to 130 bar)

- NH3 sensors and security systems available to monitore the plant

- Contractors and operators well trained



Systems configuration adapted to Customers needs:

NH3 Low charge refrigerant chillers/installations:

• Flooded systems with low pump ratio: 1.2:1

• Dx evaporators

• NH3/Secundary loop systems

Piping and valve sets design:

Minimize piping length

Optimization of piping lines lay outs ( clean design, no vibration, ss

material, corrosion protection, etc..)

Min. valves sets possible, easy to access and monitor.


Facts 1 / 2:


Improved design of evaporators and condensers:

• New Fin patterns – High thermal profile (capacity/m2 ratio)

• Different tube types and tube patterns:

- Reduce diameter reducing internal volume

- SS grooved tubes increases heat transfer

• Optimization of cooling capacities both bottom and top feed evaps

• Dx high efficiency evaps.

• Hybrid and adiabatic condensers with less foot print

New Generation of evaporators

• Insulated coolers

• Pent house coolers


Facts 2 / 2:






AGENDA


Case Study: “Efficient deep freezing under extreme conditions”


Sustainable and environmentally friendly refrigeration engineering and

high economic efficiency was required for this great cold store. This is

why ammonia (R717) is used as refrigerant

Case Study: Al-Shahini Cold Store, Riyad

Motivation


Cold store for foodstuffs

- Low temperature area 3,500 m² (-24 °C)

- Normal temperature rooms 7,950 m² (+4 °C)

- Logistics area approx. 3,000 m² (+6 °C)

Location: Riyad, Saudi Arabia

Operator: Shahini Holding Group

Refrigeration System:

- Consultant: Ing. Büro Brunnenkant, Wiesloch, Germany

- Contractor: Al Salem Johnson Controls, Jeddah

Al-Shahini Cold Store, Riyad

General Information



Rooms, air coolers

37 m 23 m 48 m 49 m

25

m

75

m 2,700 m²

+4 °C

(-24 °C)

1,650 m²

+4 °C

(-24 °C)

3,500 m²

-24 °C

3,600 m²

+4 °C

(-24 °C)

1,300 m²

+4/6 °C

910 m²

+4/6 °C

770 m²

+4/6 °C



Special requirements

Requirements for the store:

- Constant temperature distribution in all cold store

- No “air hot spots” during times of high ambient temperatures (Ambient T°: +50°C)

- State-of-the-art technology

- Silent and draft-free

- All components outside of the cooling rooms (maximize store surface+ increase safety)

Requirements for the evaporators (insulated unit coolers):

- Good defrost characteristics

- Air distribution via ducts

- Low energy consumption

- Low-maintenance

- Service-friendly

Energy saving, Service and Control

- EC fans (No fan belts, less servicing)

- Easy accessibility of fans and components

- Individual control concept

- Proven Product


Insulated unit cooler – THERMOSTORE

New Generation with EC technology

APPLICATION THERMOSTORE

- EC fans

- Arrangement of components

- Inspection & cleaning

- Flap construction

- Service-friendly


Optimal solution for deep-freeze stores

Energy efficient Best defrost performance

Positioning inside or outside the cooling room possible Safety

Accessible for service and repair, at ambient T° Safety+maintenance friendly

Güntner: more than 15 years of experience in building insulated unit coolers

Insulated unit cooler – Güntner THERMOSTORE

General Information



Refrigerating plant

Installed capacity

To -34 °C: 1,560 kW

To -8 °C: 1,250 kW

H2O/glycol 800 kW

∑ 3,610 kW

Refrigerating plant

NH3 pump

2-stage

To low pressure -34 °C

To high pressure -8 °C

H2O/glycol 8/16 °C

Ta.: +45 °C

4x ND Screw

Sabroe, SAB 193L

To -34/Tc -8 °C

1x VFD

3x HD Screw

Sabroe, SAB 233S

To -8/Tc +47 °C

1x VFD

1x Swing Screw

Sabroe, SAB 193L

To -8/Tc +47 °C

To -34/Tc -8 °C



Refrigeration plant

Minimum pressure losses in main

refrigerant lines

Max. refrigeration plant COP

Cortesy of Al Salem Johnson Controls, Jeddah



Equipment Güntner Group

2 x thermowave TL 250 To

-8 °C

H2O/glycol 8/16 °C

2 x Güntner AGVH 090.4A/2x5M

Condenser: Ta≤ 30 °C, 950 kW

Desuperheater: Ta= 43 °C, 180 kW

22 x Güntner

GGHN

H2O/glycol

Energy efficient design:

NH3 air condensers and

desuperheaters for heat recovery

NH3/glycol secundary loop

for loading bays and air

conditioning.



Positioning of the insulated unit coolers

Position of the freezers/coolers THERMOSTORE


Capacity/unit 20-200 kW

Position of the 13 freezers

10 coolers

Criteria:

Max. Storage capacity

Pipes and valves outside

Min. number of coolers

Constant T° in all „corners“


Positioning of the insulated unit coolers – Güntner THERMOSTORE

Air volume 10.000-125.000 m³/h



Evaporators selected

Low temperature rooms -24 °C

4 freezer units

9 freezer/chiller units

Güntner THERMOSTORE

Qo = 120 kW

Surface: 467 m²

Coil: SS/Alu

Panels: 200 mm

Centrifugal fans: -EC motors

-direct driven

Normal temperature rooms +4 °C

10 chiller units

Güntner THERMOSTORE

Qo = 150 kW

Surface: 467 m²

Coil: SS/Alu

Panels: 170 mm

Centrifugal fans -EC motors

-direct driven


All component parts are positioned inside an insulated casing.

Insulation: 100- 200 mm PU foam

Flap at front - open during refrigeration mode

- closed during defrost mode

- 100 % of the defrost heat stays in the casing

Bottom of the casing serves as tray and drain

Casing is accessible for inspection and maintenance

Suitable for forklift or crane transport

Insulated unit cooler – THERMOSTORE

Evaporators-General Information


• Evaporators positioning outside of the cooling room

• Valves sets outside

• Clean pipeline lay-out design

• Accessible for inspection and service




Max. storage space

Constant T° in the coldstore Optimal air distribution (plenum) :

Optimal extern P

Low noise P. level

Low Abs. power on EC fans

High efficient defrost system




Heat exchanger design

Easy to inspect and clean


THERMOSTORE Maintenance, Monitoring and Safety

Schaffhausen, 23rd / 24th June, 2016 Page 31

• Large service flap for each chamber

• Easy to open

• For inspection and cleaning

Service flaps for inspection of heat exchangers




Dismantling of the fans using guide rails

• Fans may be drawn from the casing on rails.

• Fan weight: approx. 200 kg




• Sufficient space for inspection and service

• Even between the individual fans




Monitoring


THERMOSTORE Control and Safety


• All electrical components are wired to control panel outside of the casing

• All important parameters can be displayed on the touch-screen and connected with

Scada central station

• NH3 leaking detectors easy to install and monitor in each unit




Individual control acc. customer

requirements

- Communication with BMS

- Controlling of the cooling process

- Automatic defrost when necessary

- Controlling of the defrost process

- Emergency mode




Summarizing…

Ammonia is a „NATURAL“ Safe solution

To


“Efficient deep freezing under extreme conditions”

Güntner insulated unit cooler – THERMOSTORE

Your contact person:

Miguel Garrido/Martin Beermann

Phone: +49 8141 242-0

E-mails:

[email protected]

[email protected]

Thank you for your attention!

mailto:[email protected]

mailto:[email protected]


Room for QUESTIONS

Contact eurammon:

Dr. Karin Jahn | Managing Director

Lyoner Strasse 18

D-60528 Frankfurt

Germany

Phone: +49 (0)69 6603 1277

E-mail: [email protected]

eurammon symposium 2016...eurammon symposium 2016 efficient deep freezing under extreme conditions...

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