The Danfoss CO2 Gas Cooler Solution

Danfoss CO2 Gas Cooler Solution

 Contents
CO2 as a refrigerant: overview Transcritical CO2 systems Gascooler control solutions Components for the gascooler control solutions
ICM ICS ETS ICMTS + ICAD EKC 326A

Danfoss CO2 Gas Cooler Solution

Global warming in perspective How long can you drive a Skoda Octavia 2,0 TDI to emit the amount of CO2 that is an equivalent of 1 kg of R404a? (CO2 emission pr. km. 149 g/km)

26 000 km!
Supermarket with 250 kg charge of R404a and 15% annual leak rate equals 1.000.000 km or 50 cars driving the same year
(typical 20.000 km/year)

Danfoss CO2 Gas Cooler Solution

Facts about CO2

ODP = 0 (Ozone depletion potential) GWP = 1 (Global warming potential) Not flammable Not toxic (EN 378) Low viscousity High volumetric cooling capacity Small compressors Small suction lines High pressures Low critical temperature High tipple point Substance Critical temperature and pressure

CO2 Propane Water Ammonia

31C / 73,8 bar 96,7 C / 42,4 bar 374 C / 22 bar 132 C / 113 bar

Substance CO2 Propane Water Ammonia

Tripple point -56,6C / 5,18 bar -188 C / 0,3 mPa 0 C / 0,006 bar -77,6 C / 0,06 bar

Danfoss CO2 Gas Cooler Solution

Main CO2 drivers

Application Increased efficiency Refrigerant phase out (legislation) (CFC, HCFC, HFC) 3 Charge reduction due to refrigerant cost (tax) (CFC, HCFC, HFC) Charge reduction due to safety (Ammonia) Green image

* Hot water heat pumps (Transcritical; big water temp. increase) Hot water heat pumps (Transcritical; medium water temp. increase) Bottle coolers (Coca Cola) Transcritical Food & Retail in EU Subcritical (CO2 + HFC) Food & Retail in EU Sub + transcritical (CO2) Industrial refrigeration Ammonia (-20 -> -40 oC) Industrial refrigeration Ammonia ( > -20 oC)
* These applications are subsidized in Japan

3 *

3 (3) 3 (3)

3 3 3 3

3 3 3 3

3 3

Danfoss CO2 Gas Cooler Solution

Transcritical VS. Subcritical

Transcritical
P [bar]

Subcritical
10
2

10 -500

0,2

0,4

0,6

0,8

-400

-300

-200

-100

-0

h [kJ/kg]
At temperatures higher than the critical temperature (31 C) CO2 can not condense. At lower temperatures than 31 C the system runs sub critical. Often a cascade system is cooling the CO2 system to keep the pressure down.

Danfoss CO2 Gas Cooler Solution

Optimal High Pressure

1.50

Refrigerating capacity [kW] and COP [-]

COP
1.25

1.00

COP = 1.90 COP = 2.31 COP = 2.28

QE

0.75

0.50

hEVAP
OPERATING CONDITION tE = -10 C, tSH = 10 K tGC,OUT = 35 C

hCOMP

0.25

0.00 75 80 85 90 95 100

Gas cooler pressure [bar]

105

110

115

120

Danfoss CO2 Gas Cooler Solution

Transcritical systems

Low pressure receiver systems

Intermediate pressure receiver

Direct expansion

Floated evaporator

Simple two stage expansion

Gas by pass system

MT MT+LT
Cascade system Booster system Cascade systems Booster systems

Danfoss CO2 Gas Cooler Solution

Gas by-pass system

Description To reduce the pressure in the distribution systems the gas by pass is introduced. After the high pressure expansion the gas and liquid are separated and the gas is bypassed directly to the suction side of the compressor. The liquid is distributed to the evaporators. This makes it possible to use standard 40 bar components.

Applications Supermarkets and other systems that are running continuously. Installers Knudsen Kling, Linde / Carrier, Green and Cool ect.

Danfoss CO2 Gas Cooler Solution

Gas by-pass system 1st generation with mechanical valve

10

-0
-0 ,7 -K

R744

-1

-0

,9

,8

6 0,

/ kJ

kg

P [bar]

10 -400

0,2

0,4

0,6

0,8

-300

-200

-100

100

h [kJ/kg]

Danfoss CO2 Gas Cooler Solution

Gas by-pass system 1st generation with motor valve

10
-0
-0 ,7 -K
2

AKS 2050

R744

-1

-0

,9

AKS 11 EKC 326A EKC 347 Gas cooler P2 MBS 3000

P [bar]
-0 ,6

,8

/ kJ

kg

P1 ICM Compressor ICMTS

10 -400
1

0,2

0,4

0,6

0,8

-300

-200

-100

100

h [kJ/kg]

Danfoss CO2 Gas Cooler Solution

Gas by-pass system 2nd generation

10

-0
-0 ,7 -K

R744

-1

-0

,9

,8

6 0,

/ kJ

kg

P [bar]

10 -400

0,2

0,4

0,6

0,8

-300

-200

-100

100

h [kJ/kg]

Danfoss CO2 Gas Cooler Solution

Danfoss high pressure system for transcritical CO2 applications The system is cost optimized, with only one controller necessary to run both high and medium pressure valves. High pressure valve design has been optimized based on the extensive experience in the field tests. All components are field proven, and have successfully passed harsh tests in Danfoss labs and at our customers facilities. Danfoss engineering and sales teams offer a comprehensive support in system design as well as selecting the optimal components for CO2 systems.

Danfoss CO2 Gas Cooler Solution

References

Over 400 CO2 high pressure systems installed globally More than 4 years of field tests Extensive experience within CO2 system design since 2001 in all areas (controls, valves and compressors)

Danfoss CO2 Gas Cooler Solution

Applications
As a rule, HP system is installed on packs, so the target group is mainly Rack manufacturers

Example: pack from Advansor

Danfoss CO2 Gas Cooler Solution

Intermediate pressure controls and valves

Danfoss CO2 Gas Cooler Solution

ICS with pilot valve CVP-XP

ICV platform based MWP 52 bar (65 bar on request) Regulation range up to 52 bar Both welding and soldering connections are available Low temperature steel housing

Danfoss CO2 Gas Cooler Solution

ICS 30 bar receiver pressure

3000

2500

2000 Cooling capacity [kW]

Data: t_e=-10 C t_gc_out=35 C P_gc=88,6 bar eta_SGHX=0 47 % bypass

1500

1000

500

0 Capacity ref [kW]

ICS 25-5 61,3

ICS 25-10 126,2

ICS 25-15 216,3

ICS 25-20 288,5

ICS 25-25 414,7

ICS 32 613,0

ICS 40 973,6

ICS 50 1586,5

ICS 65 2524,0

Danfoss CO2 Gas Cooler Solution

ICS 35 bar receiver pressure

4500

4000

3500

Data: t_e=-10 C t_gc_out=35 C P_gc=88,6 bar eta_SGHX=0 47 % bypass

3000 Cooling capacity [kW]

2500

2000

1500

1000

500

0 Capacity ref [kW]

ICS 25-5 99,7

ICS 25-10 205,3

ICS 25-15 351,9

ICS 25-20 469,2

ICS 25-25 674,4

ICS 32 997,0

ICS 40 1583,5

ICS 50 2580,5

ICS 65 4105,3

Danfoss CO2 Gas Cooler Solution

ICM
ICV platform based MWP 52 bar (65 bar on request) Regulation range up to 65 bar Both welding and soldering connections are available Low temperature steel housing Driven by ICAD motor with a built-in driver

Danfoss CO2 Gas Cooler Solution

ICM 30 bar receiver pressure

3000

2500

2000 Cooling capacity [kW]

Data: t_e=-10 C t_gc_out=35 C P_gc=88,6 bar eta_SGHX=0 47 % bypass

1500

1000

500

0 Capacity ref [kW]

ICM 20-A 21,6

ICM 20-B 86,5

ICM 20-C 165,9

ICM 25-A 216,3

ICM 25-B 432,7

ICM 32-A 324,5

ICM 32-B 613,0

ICM 40-A 540,9

ICM 40-B 937,5

ICM 50-A 829,3

ICM 50-B 1442,3

ICM 65-B 2524,0

Danfoss CO2 Gas Cooler Solution

ICM 35 bar receiver pressure

4500

4000

3500

Data: t_e=-10 C t_gc_out=35 C P_gc=88,6 bar eta_SGHX=0 47 % bypass

3000 Cooling capacity [kW]

2500

2000

1500

1000

500

0 Capacity ref [kW]

ICM 20-A 35,2

ICM 20-B 140,8

ICM 20-C 269,8

ICM 25-A 351,9

ICM 25-B 703,8

ICM 32-A 527,8

ICM 32-B 997,0

ICM 40-A 879,7

ICM 40-B 1524,8

ICM 50-A 1348,9

ICM 50-B 2345,9

ICM 65-B 4105,3

Danfoss CO2 Gas Cooler Solution

ETS valve
MWP 46 bar MOPD up to 32 bar Soldering connections Brass housing Available for CO2 from June 2009

Danfoss CO2 Gas Cooler Solution

ETS 30 bar receiver pressure

200

45,5 bar (60-80 bar)/ MOPD 33 bar

180

160 Data: t_e=-10 C t_gc_out=35 C P_gc=88,6 bar eta_SGHX=0 47 % bypass

140 Cooling capacity [kW]

120

100

80

60

40

20

0 Capacity ref [kW]

ETS 12,5 26,4

ETS 25 51,2

ETS 50 92,3

ETS 100 186,4

Danfoss CO2 Gas Cooler Solution

ETS 35 bar receiver pressure

400

45,5 bar (60-80 bar) / MOPD 33 bar

350 Data: t_e=-10 C t_gc_out=35 C P_gc=88,6 bar eta_SGHX=0 47 % bypass

300

Cooling capacity [kW]

250

200

150

100

50

0 Capacity ref [kW]

ETS 12,5 42,9

ETS 25 83,3

ETS 50 150,1

ETS 100 303,2

Danfoss CO2 Gas Cooler Solution

Selection
DIRcalc 1.17 or 1.17CO2 (for ICMTS only) CO2 Selector 1.0 (for intermediate pressure valves only)

Danfoss CO2 Gas Cooler Solution

High pressure control valve ICMTS

Danfoss CO2 Gas Cooler Solution

ICMTS technical features

Designed for high pressure CO2 systems. applications for a maximum working pressure of 140 bar / 2030 psig. Applicable to other common refrigerants as well. The ICMTS is not applicable for flammable refrigerants. Direct coupled connections. Connection types are DIN butt weld. Low temperature steel body. Low weight and compact design. Regulating cone ensures optimum regulating accuracy particularly at part load. Manual opening possible via ICAD or Multi-function tool. PTFE seat provides excellent valve tightness. Magnet coupling - real hermetic sealing.

Danfoss CO2 Gas Cooler Solution

ICMTS other features

Refrigerants Applicable to all common refrigerants including R744 (CO2) and non- corrosive gases/liquids. ICMTS valves must not be used with flammable refrigerants. For further information please contact your local Danfoss sales company. Temperature range: Media: 60/+120C (76/+248F). Pressure The valve is designed for: Max. working pressure: 140 bar g (2030 psig) Surface protection ICMTS: The external surface is treated in order to provide good corrosion protection. Max. openening pressure differential (MOPD)ICMTS: 90 bar (1305 psi) Time to move from Closed to Open position or in reverse order with maximum selected speed at ICAD is 3 sec.

Danfoss CO2 Gas Cooler Solution

High pressure controller EKC 326A

Danfoss CO2 Gas Cooler Solution

3rd generation gas cooler controller EKC 326a

New features Optimum COP gas cooler control Control of receiver pressure together with the ETS valve Heat reclaim with 0-10V signal Optimum capacity control via digital signal (approx 5% extra capacity with the same system) Use of radiometric pressure transmitters Supports 60, 100 and 160 bar pressure transmitters type AKS 2050

Danfoss CO2 Gas Cooler Solution

Algorithm

Danfoss CO2 Gas Cooler Solution

Read more about Danfoss CO2 products and solutions visit us at www.danfoss.com/CO2

Danfoss CO2 Gas Cooler Solution