NH3/CO2 Refrigeration System “NewTon”- Energy Conservation -

Nov. 2013 (O)Mayekawa Mfg.Co.,Ltd. “MYCOM”

JAPAN

2

Global Environment Issues

Ozone Depletion Global Warming

Montreal ProtocolCFC ： banned in 1996

HCFC ： Limited from 2004

　　　　 Totally Banned in 2020

Kyoto ProtocolReduction of global warming gas by 6% from 1990 level in the frist period of 2008～ 2012). HFC are the target

Freon Recycling Law: CFC,HCFC,HFC

PRTR Law (chemical gas): HCFC22,HCFC123, Ethylene glycol, etc.

Introduction of Environment Tax, Freon Tax to industries

Demand for use of Natural Refrigerant has increased

33

Refrigerant(Natural Five)

NH3

Ammonia

CO2

Carbon Dioxide

HCHydro Carbon

H2O

Water

Air

Notes ・ Conventional system

・ Eco-Cute ・ Nat’l Proj.

・ Butane + Propane

・ Nat’l Proj.

・ Adsorption

・ Heat Recov.

・ Nat’l Proj.

・ Air-cycle

90℃

60℃

10℃

-15℃

-25℃

-40℃

-50℃

-60℃

-100℃

Utility hot water

Cold storage, Freezer, Fish boat

Specific Refrigeration needs

Freezer, Freezed-dry, Super Low temp storage

Cryogenics

Utility hot water

Heating

HVAC ChillerChilled water

Ice making

Utility hot water Heating

Chilled water

Ice making

Heat recovery

・ National Projects

4

Natural Five Applications

90℃CO2hot water

NH3 Chiller

7℃

NH3 Brine chiller

NH3+CO2

-5℃

-25℃

-65℃

AIR

Ice bank systemNH3/Brine chiller

Air conditionimg

Expo Aichi

National Museum

Logistic centreMuseum

NH3 Heat pump ﾟ

50℃

Golf Club

Eco kyuto

Air conditioningHeating

Cold strageNewTon3000 　 (NH3/CO2 ）

Tuna warehouse

SF classAir cycle

The construction of giant NH3 refrigeration plants presents various problems.

1. Reduction of skilled engineer to design, to construct NH3 plants.2. Risks of perspective of costs, time, and quality.3. Large NH3 Charge makes higher risk of accident.4. Need of many workers and equipments for maintenance.

One solution is to use a “prefabricated package.”

1) The NH3 refrigeration cycle is completed at our factory, tested, adjusted before shipping.

2) The package is standardized and built to the same package everywhere.3) The onsite construction time is shortened because only minimal piping and wiring is required.4) The amount of NH3 charging is minimized and is completely automatic control.5) The capacity of compressor is optimized to load of plant, allowing for increased

energy savings

The Problems and Solutions Facing Giant NH3 Plants

Ideal Refrigeration Cycle

Single Stage compression Tow Stage compression Cascade Refrigeration

p-h chart

Flowdiagram

COP

h

1

23

4

h3,h4

p

h1 h2

1

2

3

4

h4,h3 h

p5

6

h1 h5 h2 h6

GM

GL1

23

4

h3,h4 h

p

5

67

8

h7,h8

h1 h5 h2 h6

GL

GH

41

23

ExpansionValve

Condenser

Evaporator

Compressor

41

63

Condenser

Evaporator

ExpansionValve

High StageCompressor

Inter Cooler

5

2

ExpansionValveBooster

Compressor1

6

3

ExpansionValve

Condenser

Evaporator

High SideCompressor 8

2CascadeCondenser

4

7

5

Low SideCompressor

ExpansionValve

COP

12

41

hh

hhCOP

)0.1(

)56)(()12(

)41(

GL

hhGMGLhhGL

hhGLCOP

)0.1(

)56()12(

)41(

GL

hHGHhhGL

hhGLCOP

Comparison of theoretical COP

-60 -50 -40 -30 -20 -10 0 100

1

2

3

4

5

6

7

8

NH3 SingleNH3 Two StageNH3/CO2 Cascade

TE ( )℃

COP

(-)

Evap.

NH3

Cond.

Water CO2

Out door NewTon Cold StorageCooler

CT

NH3 Package

　・ New Screw compressor

　・ Semi-hermetic IPM motor

　・ Flooded Evaporator

　・ Double economizer

　・ Automatic operation

CO2 brine

　・ Safety

　・ Low pump power

　・ No trouble by oil

　・ High heat transfer

Water cooled

　・ Energy saving

　・ NH3 charge min.

　・ Free layout

　・ Easy Maintenance

「 Safety 」　「 Energy saving 」　「 Easy maintenance 」　

Basic Concept of NewTon

9

NH3 New Screw Compressor

Two stage compound Screw

Semi-hermetic IPM Motor

10

High Efficiency Motor （ IPM motor ）- Semi-Hermetic for NH3 -

Conventional IPM motor 回転子

Benefits of IPM motor

・　５～１０％ better in efficiency

・　 40% smaller in size

・　 High speed is possible

11

New rotor profile and Double economizer system

Booster High stage

CondenserEvap.

Inter coolerBooster Economizer

Double Economizer

Features

・ High efficiency: Less gas leakage

・ Quiet: Low noise, low vibration

・ High reliability: Use of proven bearings

New type of Heat Exchanger

S ＆ T

S ＆ P

NH3 液

NH3 ガス

CO2 液

CO2 ガス

NH3 液

NH3 ガス

CO2 ガス

CO2 液

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%)

Comparison of Evaporator

Flash tank type Economaizer 【 conv. 】 【 New 】

コンデンサ

中間 ｴｺﾉﾏｲｻ ﾞ

CO2液化器

ΔT=3.6

ΔT=3.4

コンデンサ

中間 ｴｺﾉﾏｲｻ ﾞ

CO2液化器

Pd

Pm

Pe

Ps

Subcool :5deg upRefrigeration effect : 2% up

[Compressor]

Oil Separator

High P&T Gas and Oil

High Pressure gas

[Condenser]

High P Liquid

Inter CoolerEconomizerBooster

[Evaporator]

CO2 Liquid

CO2 Gas

Low P&T Gas

Low T Liquid

Main Installations of NewTonUser tons Newton sets installed

Nissui Logistics kawasaki 14,000 ton ３ 2008

Igarashi reizo Hidaka 15,000 ton ４ 2008

Toyo suisan Nagoya 32,000 ton ９ 2009

Kowa reizou Nagoya 8,500 ton ４ 2009

Coop Tosu 50,000 ton １２ 2009

Hosui Atsugi 8,000 ton ２ 2010

Yokohama reito Osaka 27,000 ton ８ 2011

Matsuoka Kawasaki 80,000 ton １１ 2013

　　　 Nisui Log. ／ Kawasaki 　　　　　　　　　　　 Igarashi ／ Hidaka LCC 　　　　　　　　　　　 Kowa reizo/ Nagoya

Yokohama reizo ／ Osaka 　　　　　　　　　　　 COOP ／ Tosu Log. 　　　　　　　　　　 Toyo suisan ／ Nagoya Matsuoka/Kawasaki

500 are running

Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec.0

500

1,000

1,500

2,000

Refrigeration Elevator, Light Office

Pow

er C

onsu

mp

tion

x10

00(k

WH

)Electric Power Usage in Cold Storage

Refrigeration:65%, Elevator, Light:30%, Office:5%

Specific Power Consumption in Cold Storage

SPC = PCy/Vc  where:SPC : Specific Power Consumption (kWH/year/m3)PCy : Annual Power Consumption (kWH/year)Vc : Cold Storage Volume (m3)

* PCy is the total power consumption which includes refrigeration system, elevator, light and office.

Definition of “SPC”

Specific Power Consumption in Cold Storage

0 50,000 100,000 150,000 200,000 250,000 300,0000

20

40

60

80

100

120

140

160

HCFC-22

Logarithmic (HCFC-22)

NewTon (NH3/CO2)

Storage Volume (m3)

Sp

ecif

ic P

ower

Con

sum

pti

on (

kW

H/m

3/ye

ar)

CustomerVolume Age Refrigerant formerly

usedPower

reduction

(m3) (year) Refrig. Comp. (%)

Tokyo Toyomi 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

Power reduction through renewal with NewTon

20

F1610C-8sets

HCFC-22 DX

NewTon 3000-8stes

NH3/CO2

Tokyo Toyomi Reizo (Funabashi) “Renewal”

Storage volume ： 45,000 m3

(average reduction -31.1%)

Comparison of Power Consumption in Freezer

FLoFREEZE Existing Compressor NewTon

Dice PotatoHCFC-22(F2016C) NewTon Power reduction

(mm) (kWH/ton) ( - )

4.8x4.8x4.8 200.0 133.5 0.333

10x10x10 146.2 109.0 0.254

15x15x15 174.9 122.1 0.302

Energy Efficiency Factor for Freezer

EEF = (LCt/Wa)∙Kca  where: EEF: Energy Efficiency Factor for Freezer system LCt: Required Total Cooling Load LCt = LC1 + LC2 + LC3 LC1 : Cooling down load before freezing LC2 : Freezing load LC3 : Cooling down load after freezingWa: Actual Power consumption on Compressor Kta: Calibration of ambient temperature

Definition of EEF

5 10 15 20 25 30 35 40 450.60

0.80

1.00

1.20

1.40

1.60

Ambient temperature (degree C)

Kca

(-)

Kca is “theoretical COP ratio” based ambient temperature 25 degree C.

Energy Efficiency Factor for Freezer

Dice Potato

Size(mm)

HCFC-22(F2016C)

NewTon Ratio

4.8x4.8x4.8 0.415 0.622 1.50

10x10x10 0.568 0.761 1.34

15x15x15 0.475 0.680 1.43

Operating conditions1) Inlet/Outlet temperature of dice potato : 25/-18 (degree C)2) Specific heat of potato, before/after freezing : 0.813 / 0.407 (kcal/kgK) 3) Ambient temperature : 25 (dgree C)

Energy Efficiency Factor for Freezer

Salmon

Ref.System

Inlet temp.

Outlet temp.

Ambient Temp.

Power consumption EEF

HCFC-22 9.0 -10.0 10.0 85.7 0.577

NewTon 10.0 -8.5 18.5 77.5 0.773

(unit) (degree C) (kWH/ton) ( - )

•NewTon shows 33% higher EEF than HCFC-22 system.

* Existing HCFC-22 system is dry expansion type air cooler.

Demonstration Site: PT.ADIB Global Supplies

Energy Efficient Refrigeration Technology

Entity: Mayekawa Mfg CO. Ltd

Project site

Energy Consumptionreduction

570,000 kwh /year

・ MOEJ introduce the Energy Efficient Refrigeration Technology of “NewTon” as Japanese Good Practices.

Joint Crediting Mechanism Host Country : Indonesia

“NewTon” for ASEAN

A cold storage warehouse nearby Jakarta

This project was funded by the MOEJ in FY 2013 as the 1st project to Joint Crediting Mechanism .

P.T. ADIB

JCM Project for Cold Chain Industry in Indonesia with “NewTon”

CO２

Cold water

Cealed chiller100ton

NH3/ CO2FridgeNewTon R- 6000

Defrost water tank10m3

Defrost water

Chiller （Cooler）6units

Thermo shutter3 units

Defrost water (heatup heat exchanger)

Refrigerator A（-25℃） Refrigerator B（-25℃） Refrigerator C（-25℃）

Machine room

Freight handling

“1st NewTon system” will be installed to P.T. ADIB Global Food Supplies in Indonesia.

NewTon R-6000

Most advanced Japanese energy efficient non-fluorocarbon cooling system

http://www.env.go.jp/en/earth/ozone/goodpractice/full.pdf

Estimated GHG reductions

Without consideration of HFC leakage emissions: 213 (tCO2/year)With consideration of HFC leakage emissions: 902 (tCO2/year)

PCAS Server

Newton Monitor

Local Office

No. １

No. ２

No. ３ NTT docomoFOMA Network

NewTon

Observation・ Data Logging ・ Daily Checking

Out work by mechanics 　・ Checking 　　・ Precise Diagnosis 　　・ Repair, Recover

Remote Monitor ・ Operating Data 　・ Alarm Data 　　・ Mailing of Alarm

Diagnosis 　 　 　 ・ Pre-Diagnosis・ Trend Management 　 　 　・ Trouble Analysis 　・ Monthly Report

Minimize Daily Works

Reliable Maintenance Brush-upFurther Improvement

　　　　　　　　　 User LAN　　　　　　　　　 NTT FOMA　　　　　　　　　 Mycom LAN

Moriya Plant

User

NewTon Monitor and Backup Network

PCAS Server

Trend Data

Current Operating Conditions

Set point Data

Trend Diagnosis and Management

COP ratio

Comp. Vibration

Approach Temp. of Cond.

Comparison of ph-diagram between actual / design conditions

Mycom Moriya Plant

NTT DocomNetwork

PCAS Global Network

Mega NewTonNewTon R-8000 120kWNewTon F-800 100kW

Use Model Remarks

Cold Storage

-25C NewTon R-3000, R-6000, R-8000 RT : -25℃

0 C NewTon C platform

Freezer NewTon F-300, F-600, F-800 RT:-35℃

Skate Rink NewTon S

NewTon Lineup

NewTon R-3000, NewTon F-300 NewTon C, NewTon S31

NewTon Technical Data

Model Capacity*1)

Power*1)NH3

Charge L x W x H Weight Use

R-3000 94.5 43.0 25 2.8 x 2.0 x 2.4 3,300

Cold StorageR-6000 189 86.0 50 4.8 x 2.4 x 2.6 6,800

R-8000 270 120 75 4.0 x 2.6 x 2.7 7,600

F-300 70.0 43.0 25 2.8 x 2.0 x 2.4 3,300

FreezerF-600 140 86.0 50 4.8 x 2.4 x 2.6 6,800

F-800 170 100 75 4.0 x 2.6 x 2.7 7,600

C 235 65.0 60 3.4 x 2.2 x 2.7 6,000 Cold Storage

(kW) (kg) (m) (kg)

*1) Conditions : + Room temperature ; R series / -25 C, F series / -35 C, C series / +2 C + Cooling water inlet temperature / 32 C