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Efficient Refrigeration System Design CPD Training Seminar

Join us to explore efficient refrigeration system design, refrigerant selection, and sustainable practices to maximize energy savings and meet environmental regulations. Learn how to integrate cooling and heating systems, gain BREEAM points, and improve system efficiency.

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Efficient Refrigeration System Design CPD Training Seminar

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  1. Efficient Refrigeration System Design CPD Training Seminar

  2. The world of refrigeration is changing…. • Revised building standards along with a client’s needs to reduce both their carbon footprint and their energy costs are driving change • It is now becoming commonplace to see a refrigeration system specified that is focused around sustainability and provides compliance with BREEAM or a system that will provide a client with significant energy savings • However there is still a tendency to apply what we know and potentially miss the opportunity to increase efficiency or improve sustainability.…

  3. Where is refrigeration now….? • We have increasing refrigerant & sustainable standards plus a market which is now demanding increased efficiency But in practice we see…. • Efficient systems not generally being applied… • Minimal integration between cooling & heating… • Potential BREEAM credits from refrigeration and associated areas are not taken advantage of…

  4. Where does refrigeration need to be….? • Explore efficient refrigeration system design based on the opportunities & demands of each application • Treat refrigeration design as a priority based on the implication of future 365 day/yr energy consumption • Identify opportunities to maximise efficiency & gain practical BREEAM points for a client • Integrate cooling & hot water systems – why throw free & zero carbon energy away? • Identify if CO2 or Hydrocarbon Refrigerants will provide benefits to the project…

  5. Refrigerants are at the heart of all cooling systems and also some heating/hot water systems…. • First we should consider what is refrigeration? • Whether providing chilled or frozen storage, air conditioning or production cooling, refrigeration is simply the process of transferring heat from one area to another • The refrigerant accomplishes the transfer of heat within the refrigeration system • Why is refrigerant selection such a critical and widely discussed area…

  6. One hundred-eighty years have passed since Jacob Perkins patented the vapour compression cycle • The vapour compression (refrigeration) cycle uses the refrigerant as a medium to transport heat from the cold side to the hot side of a refrigeration system • We use essentially the same thermodynamic (refrigeration) cycle to this day • However refrigerants have changed throughout time • The following illustration shows the development of refrigerants over the last 180 years….

  7. Refrigerant environmental impact is classified by GWP • Global warming potential (GWP) quantifies a refrigerants impact as a factor of carbon dioxide • It compares the amount of heat trapped by a certain mass of the gas to the amount of heat trapped by an equivalent mass of C02….

  8. Refrigeration legislation allows systems to use standard HFC refrigerants plus naturals & hydrocarbons • HCFC R22 gas has been outlawed from Jan 2015 • HFC R404 will be out of circulation in 2020 • Environmental legislation increases year on year • Great focus on refrigerants to minimise the detrimental effects on the environment • However system efficiency can also be influenced by refrigerant selection • Energy efficiency & environmental benefits are linked…

  9. Refrigerant selection is key to ensuring that system efficiency and performance are maintained throughout the life of the installation • Correct selection is application dependent on the type of application and it’s energy & environmental requirements • The following examples illustrate the importance of refrigerant selection when considering differing applications….

  10. A BREEAM centralised refrigeration system with kitchen, cold room and hot water requirement would call for R744 CO2 with PIR panel construction • BREEAM single cold room and integral display unit would call for R290 Hydrocarbonwith PIR construction • Centralised system operating in 55C+ ambient condition would call for R134a HFC with PIR or PU panels • 6 x budget focused cold room system for a UK food service application would call for R407 HFC with PIR or PU panels • Efficiency+sustainability+budget = Design

  11. However energy efficiency & environmental demands are both linked… • Environmental focused designs normally deliver energy savings What is the objective of installing renewables, creating sustainable designs or focusing on low carbon equipment….to use less energy • Where is the first place to look for energy & carbon savings….necessary critical plant & equipment that has to be incorporated within the project • Gain the highest cost effective level of return with efficiency & sustainability…

  12. Cold room/cold store construction & operation also need to be considered…. • Increasing wall, floor and ceiling thickness will reduce heat loss • The PIR panel production process means a PIR panel construction has the potential to achieve fire rating accreditation • Correct operation of the cold storage facility will reduce energy use (GC operation guide) • Low energy lighting reduces energy use • Correct monitoring reduces operational costs and also increases sustainability….

  13. What sustainable standards and requirements are in place within the UK currently… What is BREEAM? • Building Research Establishment’s Environmental Assessment Method How is BREEAM used? • Clients & Developers, Property Agents, Architects, Design Teams, Construction Managers • Combined approach to increase the sustainability levels within a building during the design & construction stages…

  14. BREEAM credits – required for compliance

  15. Areas of BREEAM that can are highly relevant to refrigeration system design….

  16. Necessary refrigeration systems can make a significant contribution to the BREEAM credit total • Potentially over ten credits can be achieved by applying a design to match the demands of the application • A well designed food service refrigeration system can realistically contribute over 15% of a projects total BREEAM excellent credits

  17. BREEAM refrigeration designs generate efficiency & energy cost savings • Efficient refrigeration designs generate sustainability and carbon savings *The cost of achieving BREEAM credits via improving required refrigeration systems can be lower than the cost of gaining credits from other areas…. • Enhanced Capital Allowance (ECA) can also improve BREEAM cost effectiveness with year one write off

  18. Efficiency, budget, space, environment, design, contingency, on-going support…. • These are all areas that relate to a refrigeration system specification • An efficient refrigeration system design undoubtedly represents best value • Capital costs can be justified with a three to four year payback, underwritten by energy savings and importantly not subsidies • Correct refrigeration system design is key.…

  19. What is correct system design? Surely one refrigeration system is similar to another…. • The common theme is that all systems use the vapour compression cycle • Aside of this there are different configurations and methods of installation • Each will provide variations & benefits in terms of efficiency, integration with other systems, capital cost, space requirements and operational costs… The following examples highlight opportunities to increase efficiency and save costs….

  20. Application example – Centralised catering refrigeration…. • Common to see multiple cold rooms with separate refrigeration units (evaporator & condenser) • Common to see integral kitchen & display refrigeration units (evaporator & condenser) How can this type of design be improved? • By designing a centralised refrigeration system which services all cold rooms and kitchen refrigeration • Why is this beneficial, it does the same job as separate or integral units….?

  21. Separate units all have individual condenser units with individual motors, where motor starting load is the biggest consumer of energy…. • Centralised packaged units provide much better load management & reduced running costs by minimising motor starting with centralised efficient compressors Separate units provide vulnerability in the event of failure, there is no contingency for any one item…. • Centralised systems provide greater contingency i.e. a cold room will not be lost if one compressor fails, as is the case with separate units…

  22. Separate units all require space around the condenser unit for airflow and maintenance…. • Centralised packaged systems are significantly more compact and require a smaller footprint, this saves space and also means that any issue around positioning or noise can be managed effectively Separate units all require individual installation and associated ancillary components…. • Centralised packaged units simplify installation and control which increases the efficiency of installation

  23. Application example – Centralised catering refrigeration with optional hot water output….

  24. Application example:Centralised 6 x coldroom & kitchen refrigeration system....

  25. NEW Green Cooling optimised pack.... Green Cooling has brought to market the new GC-ECO (GC-ECO refrigeration pack range), why…? Because existing ‘packs’ from compressor manufacturers are not optimised for Food Service, GC-ECO incorporates… • Dynamic load management as standard • Simultaneous cooling & heating as standard • Compact & flexible design as standard • 50% contingent design as standard • Alternate & single system capability as standard • OEM manufactured in the UK by GC • Food Service application optimised

  26. Centralised systems further benefit from CO2 refrigerant and system selection.… • Further savings from 25% increased efficiency of CO2 centralised refrigerant systems • Where BREEAM projects are concerned greater efficiency levels will increase project viability by achieving additional energy savings • £ per BREEAM credit represents excellent value • CO2 will also allow further development of the application by enabling higher temperature hot water to be produced free of cost and free of carbon…

  27. Application example – CO2 centralised system…. *Boiler efficiency 92% & 3p/kWH, **Electric heating efficiency 97% & 13p/kWH ***Taking into account savings on displaced heating tanks

  28. Application example – CO2 centralised system….Typical Green Cooling-ENEX packaged CO2 refrigeration unit providing simultaneous cooling (chilled 4°C & Freezer -18°C) and hot water generation at 65°C…

  29. The diagram above shows the energy consumption per month of asimulated pack system. Each bar equals the sum of the compressor energy consumption and the energy consumption of additional equipment (condenser and evaporator fans and pumps used in the system).

  30. Application example – ‘Up cycling’ of waste heat…. What do we know? • We know that refrigeration is simply a means of transferring energy from one place to another What do we do? • We transfer valuable energy directly to waste, we do not normally attempt to recycle this high cost waste energy from cooling What can we do? • The GC–Thermal hub system enables waste energy to be ‘upcycled’ and used to produce hot water…

  31. CO2 centralised applications have the ability to provide simultaneous cooling & heating, this provides FREE & ZERO CARBON second time use energy… *Boiler efficiency 92% & 3p/kWH, **Electric heating efficiency 97% & 11p/kWH • Significant savings can be made by utilising waste refrigeration heat energy Integration with mechanical services and early stage design is key….

  32. Correct design creates resilience & reliability…. Redundancy in components within a centralised system provides greater resilience than separate individual units... • One centralised compressor failing is not a system failure • Correct capacity selection prevents a system being ‘over worked’ extending the lifecycle of the system • Monitoring of all components & performance reduces down time and communicates a problem at the earliest opportunity • Automated temperature monitoring, maintenance alarms and energy reporting are easily achieved – GO TM

  33. Summary… Refrigeration design is a technically involved area that is becoming increasingly more energy & environmentally focused…. • Standard refrigerants along with CO2 and hydrocarbon low GWP refrigerants • BREEAM projects require high sustainability levels to meet planning obligations • Projects have increasingly higher efficiency standards and energy cost saving targets • Applications require maximum achievable levels of performance & operational efficiency….

  34. Green Cooling provide… • Food service cooling including high specification & high performing coldrooms and the appropriate highest specification refrigeration system…GC-ECO and GC-ENEX CO2 • Independent CO2 hot water/cooling systems or simultaneous hot water & cooling systems • From10kW to 1,000kW, single to multiple applications, GC-ECO PLUS the GC specifier support service… Design, specification and delivery for any size of project…

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