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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 Page 2
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
Schaffhausen, 23rd / 24th June, 2016 Page 3
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
Schaffhausen, 23rd / 24th June, 2016 Page 4
Ammonia: most „natural“ refrigerant
Schaffhausen, 23rd / 24th June, 2016 Page 5
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)
Ammonia: most „natural“ refrigerant
Schaffhausen, 23rd / 24th June, 2016 Page 6
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
Ammonia: most „natural“ refrigerant
Schaffhausen, 23rd / 24th June, 2016 Page 7
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
Schaffhausen, 23rd / 24th June, 2016 Page 8
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
Schaffhausen, 23rd / 24th June, 2016 Page 9
Smart Design of Ammonia plants
Schaffhausen, 23rd / 24th June, 2016 Page 10
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
Smart Design of Ammonia plants
Schaffhausen, 23rd / 24th June, 2016 Page 11
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.
Smart Design of Ammonia plants
Facts 1 / 2:
Schaffhausen, 23rd / 24th June, 2016 Page 12
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
Smart Design of Ammonia plants
Facts 2 / 2:
Schaffhausen, 23rd / 24th June, 2016 Page 13
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
Schaffhausen, 23rd / 24th June, 2016 Page 14
Case Study: “Efficient deep freezing under extreme conditions”
New Generation. Güntner THERMOSTORE with EC technology
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
Schaffhausen, 23rd / 24th June, 2016 Page 15
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
Schaffhausen, 23rd / 24th June, 2016 Page 16
Al-Shahini Cold Store, Riyad
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
Schaffhausen, 23rd / 24th June, 2016 Page 17
Al-Shahini Cold Store, Riyad
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
Schaffhausen, 23rd / 24th June, 2016 Page 18
Insulated unit cooler – THERMOSTORE
New Generation with EC technology
APPLICATION THERMOSTORE
- EC fans
- Arrangement of components
- Inspection & cleaning
- Flap construction
- Service-friendly
Schaffhausen, 23rd / 24th June, 2016 Page 19
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
Schaffhausen, 23rd / 24th June, 2016 Page 20
Al-Shahini Cold Store, Riyad
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
Schaffhausen, 23rd / 24th June, 2016 Page 21
Al-Shahini Cold Store, Riyad
Refrigeration plant
Minimum pressure losses in main
refrigerant lines
Max. refrigeration plant COP
Cortesy of Al Salem Johnson Controls, Jeddah
Schaffhausen, 23rd / 24th June, 2016 Page 22
Al-Shahini Cold Store, Riyad
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.
Schaffhausen, 23rd / 24th June, 2016 Page 23
Al-Shahini Cold Store, Riyad
Positioning of the insulated unit coolers
Position of the freezers/coolers THERMOSTORE
Schaffhausen, 23rd / 24th June, 2016 Page 24
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“
Al-Shahini Cold Store, Riyad
Positioning of the insulated unit coolers – Güntner THERMOSTORE
Air volume 10.000-125.000 m³/h
Schaffhausen, 23rd / 24th June, 2016 Page 25
Al-Shahini Cold Store, Riyad
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
Schaffhausen, 23rd / 24th June, 2016 Page 26
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
Schaffhausen, 23rd / 24th June, 2016 Page 27
• Evaporators positioning outside of the cooling room
• Valves sets outside
• Clean pipeline lay-out design
• Accessible for inspection and service
Al-Shahini Cold Store, Riyad
Positioning of the insulated unit coolers
Schaffhausen, 23rd / 24th June, 2016 Page 28
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
Al-Shahini Cold Store, Riyad
Positioning of the insulated unit coolers
Schaffhausen, 23rd / 24th June, 2016 Page 29
Heat exchanger design
Easy to inspect and clean
Al-Shahini Cold Store, Riyad
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
Al-Shahini Cold Store, Riyad
THERMOSTORE Maintenance, Monitoring and Safety
Schaffhausen, 23rd / 24th June, 2016 Page 32
Dismantling of the fans using guide rails
• Fans may be drawn from the casing on rails.
• Fan weight: approx. 200 kg
Al-Shahini Cold Store, Riyad
THERMOSTORE Maintenance, Monitoring and Safety
Schaffhausen, 23rd / 24th June, 2016 Page 33
• Sufficient space for inspection and service
• Even between the individual fans
Al-Shahini Cold Store, Riyad
THERMOSTORE Maintenance, Monitoring and Safety
Schaffhausen, 23rd / 24th June, 2016 Page 34
Monitoring
Al-Shahini Cold Store, Riyad
THERMOSTORE Control and Safety
Schaffhausen, 23rd / 24th June, 2016 Page 35
• 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
Al-Shahini Cold Store, Riyad
THERMOSTORE Control and Safety
Schaffhausen, 23rd / 24th June, 2016 Page 36
Individual control acc. customer
requirements
- Communication with BMS
- Controlling of the cooling process
- Automatic defrost when necessary
- Controlling of the defrost process
- Emergency mode
Al-Shahini Cold Store, Riyad
THERMOSTORE Control and Safety
Schaffhausen, 23rd / 24th June, 2016 Page 37
Summarizing…
Ammonia is a „NATURAL“ Safe solution
To
Schaffhausen, 23rd / 24th June, 2016 Page 38
“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:
Thank you for your attention!
Schaffhausen, 23rd / 24th June, 2016 Page 39
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]