Freeze For Less Anatoli Naoumov Slides

Thursday, October 5
Freeze for less: energy cost reduction in industrial refrigeration
Anatoli Naoumov, GreenQ Partners
Message to take home
• 30% reduction of energy use
is possible through a low/no capex
whole plant optimization
• No risk to operation, machines or
relations with current refrigeration contractor
• Scientifically solid and
practically proven framework
• $hort payback, incentives apply

GreenQ Partners © 2017 2
What’s In It For Me if I do not own
the plant?
• Proven way to score praise, respect and recognition
• Low risk to you: you stay in charge of changes
• Professional satisfaction: gain more out of
machines
• Massive energy cost savings is a winning topic to
brag about at a next conference or job interview

Plan for the next 40 minutes
WHAT: Plant optimization : Theory and example
HOW: Project framework
Results of completed project
Q&A

Component vs. whole plant
optimization in refrigeration
Component Whole plant
Analysis Component consumption Component and whole plant
measurement consumption measurement
Whole plant consumption
modelling
Solution Improve component Improve whole plant performance
focus performance
Reporting Engineering calculation of Savings are determined from
assumed savings in assumed measurement of actual whole
conditions of separate plant consumption with
components no engineering calculations
Does your CFO understand engineering calculations?
Plant optimization measures
1. Reduce condensing pressure Efficient operation is
the key
2. Optimize suction pressure to savings
3. Optimize hot gas defrosting schedule
4. Add VFDs to motors where needed
(and set them properly!)
Science of industrial refrigeration
efficiency
“Lowering condensing pressure can provide up to 50% of total energy savings“.
Russell U.K. 2005, “The Process of Optimizing and Fine Tuning Refrigeration Systems to
Improve Efficiency and Lower Operating Costs”, IIAR Ammonia Refrigeration Conference
Acapulco, Mexico, IIAR, Arlington

“When suction pressure increases, parasitic (fan) load increases as well. There is
point at which the additional parasitic power consumption exceeds the
compressor power reduction”.
Reindl, D.T., Jekel, T.B., Elleson, J.S., 2005, Industrial Refrigeration Energy Efficiency Guide
book, Industrial Refrigeration Consortium – University of Wisconsin‐Madison. Madison, WI
“Eliminating one unnecessary 20‐min defrosting per day will save 2% of energy use of the
whole refrigeration plant.”
Stoecker, W.F. 1998, Industrial Refrigeration Handbook, McGraw Hill publishers
Papers by Sergei Khoudiachov
Optimization of Refrigeration Plant Operation. Engineering Approach
32nd Annual Meeting International Institute of Ammonia Refrigeration March 14–17, 2010 2010 Industrial
Refrigeration Conference & Exhibition Manchester Grand Hyatt San Diego, California
http://www.iiar.org/IIAR/WCM/IIAR_Publications/IIAR_Technical_Papers/2010_Technical_Pa
pers.aspx
Operating Ammonia Refrigeration Systems At Peak Efficiency
International institute of Refrigeration .Ammonia Refrigeration Technology. International Conference.
Ohrid 2013
http://toc.proceedings.com/18495webtoc.pdf
1. Reduce condensing pressure:
massive opportunity
3 psig reduction 1‐1.5% reduction
of the compressor energy use

50 psig reduction at 400hp compressor
 200MWh per year

Reduction is part of floating
Reduction saves 90‐95% of the floating savings

1. Reduce condensing pressure:
barriers and solutions
Barriers Solutions
Incomplete defrosting Adjust valves, add pressure during defrosting
Insufficient oil cooling of screw Add small liquid pump or electronic valve
compressors
Insufficient liquid supply far from Add ammonia pump or heat exchanger to sub‐
receiver cool ammonia
Increase regulating valve
Oil carry over Install oversized oil separator
2. Optimize suction pressure
1degF increase of
suction pressure Higher suction pressure
 1‐2% decrease  more evaporators = more heat
at compressor use  compressor load increase
Solution: accurate modelling to min total consumption
3. Optimize defrosting schedule
• Defrosting is routinely done on time schedule
• An additional 20‐min defrosting per day
= 2% of refrigeration plant energy use
• Solution: To minimize energy use
defrosting schedule should follow
frost formation, not time.
Economics of measures: example
• Regional food
distribution center
• Compressors ‐ 800 hp
evaporators ‐ 112 hp
condenser ‐ 25 hp
• 3,000MWh per year
($300K at $100/MWh)
Example: energy savings
Total Savings: 20% of use
Energy savings (kWh/yr) Low capex optimization 46% of total
Add
condenser
Add VFD to fan VFD
screw 8%
compressors
15%
Lower
cond.
Optimize pressure
suction form 135
pressure + psig to 95
evaporator psig
fans VFDs 31%
31%
Optimize
hot gas
defrosting
15%
Example: Economics at a glance
Total Savings: 20% of use
Energy savings (kWh/yr) No capex optimization 46% of total
Add
condenser
Add VFD to fan VFD
screw 8%
compressors Simple payback (years)
15%
Lower Add VFD to screw compressors 9.1
cond.
Optimize pressure Optimize suction pressure +
suction form 135 6.3
evaporator fans VFDs
pressure + psig to 95
evaporator psig Optimize hot gas defrosting 0.5
fans VFDs 31%
31% Lower cond. pressure form 135
0.5
Optimize psig to 95 psig
hot gas
Add condenser fan VFD 3.1
defrosting
15%
Example: Economics for CFO
Energy % of total Simple
SIR
Description savings energy payback Investment
(5 years)
(kWh/yr) use (years)
Add condenser fan VFD 48,900 2% 3.1 1.4 $ 15,000
Lower cond. pressure
form 135 psig to 95 psig
185,000 6% 0.5 8.8 $ 9,250
Optimize hot gas
defrosting
90,000 3% 0.5 8.8
$ 4,500
Optimize suction
pressure + evaporator 188,000 6% 6.3 0.7 $ 118,000
fans VFDs
Add screw compressors
87,700 3% 9.1 0.5
VFDs $ 80,000
Total 599,600 20%
Framework steps
1. Assess opportunities through analysis of system
setup and procedures, modeling and measurement
2. Create whole plant consumption baseline “before”
through statistical analysis
3. Implement changes
4. Measure consumption “after” to document savings
as cumulative sum of differences between predicted
and actual consumption
5. (Keep monitoring to ensure results stay)
Measurement is the key to prove
results
Completed project
Process cooling at industrial bakery
Issues:
 Process cooling is a bottleneck
 Struggle to meet demand
 Adding ice affects quality

Baseline:
actual and predicted ‘before’
Predicted
Actual
Savings ‘after’
Implementation (partial)
 180 psig  150 psig
Results
 Reduction 13%
 Bottleneck removed
Predicted
Actual
Cumulative sum of saving
(CUSUM)
Savings
normalized to
production and
weather
Summary
• 30% energy use reduction is possible though optimization
• Metering removes risks of hidden performance
• Current refrigeration contractor stays
• Incentives apply
Contact
Anatoli Naoumov, CMVP, MBA
anaoumov@greenq.ca
416‐728‐7239
www.GreenQ.ca
To receive a copy of this presentation with links to reports, financial details of example, and detailed
explanations on how suggested measures work –

Leave me your card marked ‘slides’
Reduction of condensing pressure
Overcoming barriers
• Not enough pressure for complete hot gas defrosting
Some operators report that hot gas defrosting cannot be completed when condensing pressure is low. This is only
partially true: Often incomplete defrosting issue can be resolved through adjustment of defrosting valves. If incomplete
defrosting still persists, condensing pressure can be slightly elevated for defrosting time and set back when defrosting is
over through PLC.
• Insufficient oil cooling of screw compressors
This is likely the most common barrier to reduction of condensing pressure. Typically, at condensing pressure below 120
psig flow of liquid into the compressor will be limited by the thermal expansion valve. An addition of a small liquid
ammonia pump or of an electronic expansion valve will remove this barrier.
• Insufficient liquid supply of ammonia far from receiver
We sometimes hear from operators that at condensing pressure below 120 psig, pressure difference 80‐90 psig, plants
experience an undersupply of liquid ammonia to evaporators that are far away from receiver. This happens because
liquid ammonia starts to evaporate in the pipe and vapour blocks liquid supply. This issue can be resolved through
additional cooling of liquid ammonia below saturation temperature or by increasing the size of the regulating valve. Sub
cooling can be achieved through installation of heat exchanger or ammonia pump.
• Oil carry over into ammonia through separator
At low condensing pressure gas density decreases and velocity increases. High gas velocity can cause oil carry over into
ammonia system. This barrier can be removed by installation of oversized oil separator or by reducing mass flow of the
refrigerant.
Reduction of condensing pressure
Floating vs. reduced condensing pressure
Floating condensing pressure consists of two steps:
• lowering condensing pressure and
• actual floating.
Typically, lowering condensing pressure can provide 90‐95% of energy savings. Actual floating can give us just 5‐
10% of the savings. Why does it happen? Lower condensing pressure reduces energy use by compressors, while
floating condensing pressure reduces energy use by condensers. Usually, nominal power of condensers is about
10% of compressors’ power.
Additionally, floating can be activated only during short periods of the year. During summer, no floating is
possible, because condensers typically run at full capacity to keep required condensing pressure. During winter,
no floating is possible because refrigeration plants operate at minimum allowable condensing pressure. During
fall and spring, floating can be activated, when condenser capacity exceeds optimum. However, floating will never
be activated if a refrigeration plant has undersized condensers.
Optimize suction pressure
It is a common knowledge, that raising suction pressure, often measured as suction temperature, reduces energy
consumption at compressor. Typically, reduction is 1‐2% per 1 degF increase in suction temperature. Increase of suction
pressure does not come free; therefore, efficiency of the whole refrigeration plant should be considered to determine
the optimum suction pressure. This is not a trivial decision.
Higher suction pressure will reduce temperature difference between suction temperature and air temperature in the
refrigerated room. To keep the required refrigeration capacity more evaporators will be running. Therefore, fans will use
more energy and release more heat in refrigerated room. This will cause a need for additional compressor energy to
compensate this parasitic refrigeration load.
To estimate plant performance at a higher suction pressure, energy saved by compressors should be compared to energy
used by additional evaporator fans. Sometimes, increase of energy use at evaporator fans exceeds saving at compressors.
Power of evaporator fans determines optimum suction pressure.
Optimal value of suction pressure should be determined for each plant through accurate modeling.
Optimize Hot Gas Defrosting frequency
Hot gas defrosting requires temporary heating parts of plant that are cold during the regular work cycle. In our experience, the
procedure is routinely done on time schedule, while from energy use perspective it should be done on as‐needed basis: often in
summer and rarely in winter.
Defrosting is needed to eliminate frost from evaporator coils. Too much frost kills efficiency of evaporators. On the other hand,
defrosting itself costs energy.
Defrosting is a highly inefficient procedure in terms of energy: from every 100 units of heat provided by hot gas, less than 20
units will melt frost, the remaining 80 units will warm up parts of the system. These 80 units must be removed by the
refrigeration plant during the regular operation. After 35 minutes of hot gas defrosting, the evaporator coil, as well as part of
refrigeration plant, will run for the next 1 hour in a cooling mode to remove the heat of defrosting. As a rule of thumb,
eliminating one unnecessary defrosting per day saves 3% of whole refrigeration plant energy use.
Frequency of defrosting should be set to minimize total energy losses from frost and hot gas defrosting procedure. We
recommend accurate plant‐specific modeling to determine this frequency.
Screw compressor VFD
VFDs can be installed for refrigeration compressors. These compressors have constant torque loads. With constant torque
loads, the torque loading is not a function of speed. As the speed changes, the load torque remains constant and energy
use changes linearly with speed. This means that at 50% speed the compressor will use 50% energy. There is no energy
saving benefits of using VFDs for reciprocated compressors, unless you want gradual change capacities of these
compressors.
Typically, screw compressors use slide valves to reduce capacity. Capacity can be changed gradually but energy efficiency
will suffer. This energy efficiency will be reduced gradually (linearly) by unloading screw compressor from 100% to 50%. It
will be reduced exponentially when compressor capacity is below 50%.
How much energy can be saved by compressor VFD?
This depends of average compressor load and operating compression ratio. Compressor VFD helps to recover losses related
to part load operation of this compressor. The losses are greater when compressor operate at low capacity (below 50%)
and at high compression ratio. It means that if compressor operate long time at low capacity and high compression ratio
energy saved by VFD will be good. If compressor operate at high capacity and at low compression ratio energy saved by
VFD will be minimal. Don’t forget that VFD itself use additional 3 – 3.5% of energy.
Fan VFDs
VFDs can be helpful to recover losses related to part load operation (compressors, condensers, evaporators). How great are
the energy losses related to part load operation?
If plant is poorly designed and/or poorly operated, energy losses will be great and a lot of energy can be recovered through
the use of VFDs and they will have a relatively short payback. If plant has a good design and is operated well, energy losses will
be minimal and little energy can be recovered. Payback for an investment in VFDs for this plant will be very long. Plant design
and plant operation are two major factors to determine VFDs’ payback.
Condenser fan VFDs can save up to 8% of a refrigeration plant’s energy use. But typically, the energy savings will be
significantly lower because the operating time at favorable energy saving conditions will be short. During summer operation,
the majority of refrigeration plants run condensers at full capacity. Very little energy can be saved during summer time. During
winter operation, many condensers use little energy. This means that energy losses of part load operation are minimal and
little energy can be recovered. During spring and fall some refrigeration plants can get good energy savings from condenser
fan VFDs, especially plants with centrifugal condenser fans. To get maximum savings from condenser fan VFDs, condensers
should not be undersized.
Evaporator fan VFDs can be useful to save energy, especially for evaporator coils located in penthouses. Electrical motors of
these evaporator fans, typically, are oversized. Many designers are over focused on air throw and little attention is paid to
natural air convection. Typically, penthouses are located in the middle of a cold room and the warmest air located under the
ceiling is pulled evenly from each side of the room. This factor helps prevent hot spots in a refrigerated room with penthouses
and many evaporator fans can operate successfully at a low speed. Ceiling hung evaporator fans should have a good throw to
push warm air from the opposite upper corner of a cold room. Modern cold rooms with penthouses are typically high‐rise
construction. During the cooling mode, the room height will help to natural air convection and the warmest air will always
enter the evaporators.

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Thursday, October 5

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