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7/29/2019 TEWI analysis
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New Compressor TechnologyTrendsFor Residential, Commercial
And Industrial Heat Pumps
Dr Eric WINANDY
Institute of Refrigeration
London, Thursday 6 th December 2012
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Main Trends & Drivers
OEMs
Energy
Environment
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Which Translates in Compressors For Heat
PumpsTrendsz Residential
High Temperature, Envelope Extensions
Refrigerant Choice Modulation
Electronics Integrated Solutions
z Commercial Seasonal Efficiency optimisation (Cooling and Heating)
z Industrial
Increase of Applications Opportunities
High Temperature/High Pressure
Low Pressure Ratio Capability (Double Stage)
OEMs
Energy
Cost
Env.
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Heat Pump Optimised
Scroll Technology
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13 SEER
Copeland Scroll Growth
More than 80M pieces installed today
86 87 90 00 05
EmersonacquiresCopeland
Launch of first residentialscroll The answer to
increase SEER
standards
Expansion > Plant franchise > Product localization
A/C commercial & refrigeration scrollsEurope
Chlorine-free refrigerant, 10 SEEREurope,US
Stepless modulationAsia
Heating ScrollEurope, Asia
2-Step modulationUS
China ScrollAsia
US
AnnualProduction(Million pcs)
0
5
10
08 11
VSSEurope, US
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Summary Application and Compressor
Technology
Heat Source Temperature
WaterTemperature
Floor
Radiator
Ground
Air
20.0
30.0
40.0
50.0
60.0
70.0
-30.0 -20.0 -10.0 0.0 10.0 20.0
Underfloor HeatingRadiator/DWH
Air/Water w/Radiator
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Heat Pump Compressor
How it works
0
10
20
0 0.2 0.4 0.6 0.8 1 1.2
Volumenverhltnis
Druck(bar
Druckverlauf ohne Ventil
Isentrope Drucksteigerung
Druckverlauf mit Ventil
Kltemittel: R404A
t0: -30 C
tc: 45 C
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2
3
4
5
6
7
1 .5 2 .0 2.5 3.0 3.5 4 .0 4 .5 5.0 5.5 6 .0 6.5 7.0 7 .5 8 .0 8.5 9.0 9 .5 10 .0 10 .5 11.0 11.5
COP
Isentr.
Effy
Pressure Ratio
Std Isent ro pic Eff y
Heat. Opt . Isentr opic Eff yStd COPHeat. Opt COP
St andard Copel and Scroll
Heating Opt im ized Copeland
StandardBuilt-in
Pressure Ratio
+10% COP Operating Envelope
Extension
-5% COP
Heating Opt.Built-in
Pressure Ratio
Heat Pump Compressor
Isentropic Efficiency & COP
Heating Optimization:
Improved Heating Efficiency at Higher PR, up to 10% Larger Operating Envelope
Ex
pandedScale
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Summary Application and Compressor
Technology
Heat Source Temperature
WaterTemperature
Floor
Radiator
Ground
Air
20.0
30.0
40.0
50.0
60.0
70.0
-30.0 -20.0 -10.0 0.0 10.0 20.0
Underfloor HeatingRadiator/DWH
Air/Water w/Radiator
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Vapour Injection Circuit Diagram
TEV
HX
Vapour Injection
Scroll
TEV
Solenoid Valve
Condenser
Evaporatorm
im+
i
P
h
m
i
im+
Pi
Better Heating Capacity (+25%)Better COP (+10%)
More Condenser mass flowgives more heating capacity
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SCOP calculationSpace Heatingz Heat load in each ambient bin.
z All heat in lowest bin supplied by back up heater
kWHeatLoad
Heat pump
Back up heater
Hours at each ambient temperature
0 5 10 15C
-15 -10 -5
All heat in lowest bin supplied by back up heater
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Comparison of scroll typesLocation: Frankfurt, constant water temperature 55C
ZR Scroll
SCOP = 2.29
Heat pump - space heat
Back up heater
Heat pump - DHW
SCOP calculation
Space Heating and Domestic Hot Water (58C)
ZH Scroll
SCOP = 2.69
= +17%ZH Scroll Vapour Injection
SCOP = 3.05
= +33%
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Residential HeatPump Compressors
What is Next?1. High temperatures, envelopeextension
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0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
5 0
5 5
6 0
6 5
7 0
7 5
-3 5 -3 0 -25 -2 0 -15 -1 0 -5 0 5 10 1 5 20 2 5 30
CondT
empC
Evap Tem p C
ZHI* P 5K EVI
Wet Injectio n ZHI* P EVI
Envelope ZHI**K1P
Heating w/ EVI
Operat ion
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Wet Vapour Injection Further Extends
Compressor Operating EnvelopeP
h
m
i
im+
Pi2
7
2
P
h
m
i
im+
Pi6 7
Superheat at point 7 Wet vapour at point 7
Wet vapour injection discharge temperature (2)
and envelope
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Residential HeatPump Compressors
What is Next?2. Refrigerant choice
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R410A ?z Higher Heat transfer Coeffcient
Potential to reduce Evap TD in A/W
z
No glide: Defrost benefit in A/W
No counter/parallel flow issue in Reversible A/W HP
No Water Freezing issue for W/W
z Compactness and Cost
No need of an Internal Heat Exchanger for B/W
z Potential to reduce Refrigerant charge
Pushing up the limit kW for 3kg HFC (Service costs)
z Less proliferation for AC customers using R410A
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What about efficiency?
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BUTz Dew Point convention for definition of
evaporating and condensing temperature for
R407Cz R410A compressors have better isentropic
efficiency and this offsets the slight
thermodynamic property disadvantage.z Heat exchanger temperature differences and
subcool conditions for the two heat pumps differbecause of the different fluid properties
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Minimum Condensing Temp R407C
35
30
Water
Bubble Point 33.5
~70
PHX
32
R407C
Dew 38.5C
R407C Cond TD at W35C = 3.5K
[Pinch Point 1]
Zero Press drop
1.5K SubcoolingR407C with liquidreceiver
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Minimum Condensing Temp R410A
35
30
Water
~70
PHX
R410A 36.5C
[Pinch Point 2]
[Pinch Point 1]
Zero Press drop
33.0
3.5K SubcoolingR410A no liquidreceiver
R410A
R410A Cond TD at W35C = 1.5K
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GSHP Performance Characteristics
R410A
EVI
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ASHP Performance Characteristics
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HP Seasonal Performance
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HP Seasonal Performance
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SCOP calculation
SCOP = 3.05
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HP Seasonal Performancez Meteonorm (2009) Strasbourg
z Bivalent point at -2C
z Space Heating + DHW
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2,0
2,5
3,0
3,5
4,0
ZH12K1P ZHI11K1P(EVI)
ZH38K4E ZH13KVE(EVI)
SCOPRadia
tor,Compensat
ed
Heating Only
With 20% DHW
M ax. Water
Out let 56CDHW 56C
R410A R407C
SCOP ResultsStrasbourg, Bivalent -2C
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SCOP Results
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Discussionz Superior SCOP with DHW :
significant running hours are accumulated at high
evaporating temperatures in the warmer conditionsz High evaporating temperatures result in very high
capacity,
In practice it is necessary to ensure that the heat candistributed without short cycling,
Future modulating compressor will be advantageous.
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Source : Papers by Dupont, Honeywell, Daikin,Panasonic, Mitsubishi ElectricNEDO Symposium 2/17/2010 JapanPurdue Refrigeration Conf July 2010
R410A
Lowest-GWP Available By Flammability Class & Capacity
R410-Like
Capacity
R404A-LikeR407-LikeR22-Like
R134-Like
GWP Level
A2L400-675
A2L4-6
A11500 +
A1< 1500
A1
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Residential Heat PumpCompressors
What is Next?3. Moduation-Variable Speed
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Variable Speed ZHW**K1P
Com pressor Com po nent :
z BPM M otor
z Oil pum p
EVI Com pon ent :
z Shell Fitt ingz Dog Bone & O-rings
O-Ring
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Simulated Systems CharacteristicsThree Different R410A Heat Pump Solutions
z
Defrost Included Same De-rating And Scheme For All Three Systems
z Fan Power Consumption Considered
z Water Pump And Other Aux Power Consumption Not Included
System # #1ZH12 #2ZHI11 #3ZHW16
Refrigerant R410A R410A R410A
Heating Optimised Yes Yes Yes
Enhanced Vapour Injection(EVI)
No Yes Yes
Motor Induction InductionPermanent
Magnets
Modulation Fixed Speed Fixed Speed Variable Speed
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Fixed Speed Compressors SimulationAverage Climate (A)
0
2
4
6
8
1 0
1 2
1 4
1 6
1 8
2 0
-1 0 -5 0 5 1 0 1 5
kW
Outdoor Ambient Temperature C
Bivalent
Point
Back-upElectrical
HeaterNeed
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0
2
4
6
8
1 0
1 2
1 4
1 6
-1 0 -5 0 5 1 0 1 5
kW
Outdoor Ambien t Tempera ture C
Variable Speed CompressorAverage Climate (A)
Smaller Electrical HeaterOr
No Need At All
Higher Compressor Efficiency(Permanent Magnet Motor) Better Temperature Control Higher Comfort
Reduced Compressor Cycling
Variable Speed
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3.94.0
4.4
2.8
3.1
3.7
2.0
2.5
3.0
3.5
4.0
4.5
Fixed Speed Fixed Speed EVI Var iable Speed EVI
SCOP
SCOP Sim ulat ion Result sCom p W 35 SCOPCom p W 55 SCOP
Seasonal Performance Calculation
EVI Effect
Variable Speed BringsSubstantial SCOP
Increase To The System
EVI (Enhanced VapourInjection) Effect HigherAt Higher PressureRatio (Higher WaterTemperature)
Variable Speed ScrollOptimised For HigherPressure Ratio(Higher Water Temperature)
High WaterTemperature MandatoryFor Retrofit Application
VS Effect
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Residential Heat PumpCompressors
What is Next?4. Electronics-Integrated Solutions
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Electronic Controlers
Compressor operating map & speedmanagement
Synchronised Superheat control with
auto-tuning PID loop
Vapour and wet injection controlfor economizer cycle (ZHW only)
Smart crank-case heater control
Frequency management to avoidresonances
Modbus serial communication tosystem controller
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Integrated Solutions
z Integrated Solutions in order to reduce to time toMarket, Investment, Complexity while optimisingEfficiency and ensuring highest reliability
Wide Range ofFixed Speed
Scrolls
Variable SpeedScroll & Inverter
Drive
CombinedSolution
IntegratedSolution
Time To Market, Investments, Complexity -Efficiency & Reliability +
Decr easi n g
In cr easi n g
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Commercial Heat Pump
CompressorsSeasonal Efficiency OptimisationCooling and Heating
EN14825 Considers 3 Climate Zones for Heating
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EN14825 Considers 3 Climate Zones for HeatingWarmer, Average, Colder & 1 Zone for Cooling
Meteonorm SW 6.1Temp. profile of 225 CitiesAveraged b-w 96 and 05
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0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
kWh
Outdoor Temp C
80% Energ y
80% Energ y (p rEN14825)
80% Energ y
80% Energ y
Cold er Clim ate
W armer Clim ate
Average Clim ate
CoolingEnergy Consumption Profiles
z Profiles Differ in Terms of Absolute Max Energy Consumption But, Very Similar Temp. Range to Cover the 80% of the Tot En. Consumption
z The prEN14825 Chooses a Single Climatic Profile (grey/black color)
Based on 100kWcooling load @ 35C
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0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
-25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
kWh
Outdoor Temp C
80% Energ y
80% Energy
80% Energ yW arm er Cl im ate
Average Clim ate
Col der Clim ate
HeatingEnergy Consumption Profiles
z For Each Climate the Normative Defines 4 Water Temperatures: LT(35C),MT(45C), HT(55C), VHT(65C)
Based on 100kW heating loadbuilding @ -22C
OEMs Challenge
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OEM s ChallengeMultipleOptimizations
and potentially, for each Heating Climate Optimization, there are 4 different
Water Temperatures: LT(35), MT(45), HT(55), VHT(65)
System CoolingSeason
Heating Season
Cooling Warmer Average Colder
Chiller
Rev. Chiller
Heat Pump
Rev. HeatPump
Primary Optimization
Secondary Optimization
Comfort Applications & Comfort
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Comfort Applications & ComfortOptimized ScrollsZH*P
Energy Needs by Applications 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.4 4.5
Chiller A/W ESEER/EN Fixed Outlet
HP A/W Warmer Clima (LT,MT,HT)
HP A/W Average Clima (LT,MT)
HP A/W Colder Clima (LT)
HP B/W Warmer Clima (LT, MT, HT)
HP B/W Average Clima (LT, MT, HT)
HP B/W Colder Clima (LT)
HP W/W Warmer Clima (LT, MT, HT)
HP W/W Average Clima (LT, MT, HT)
HP W/W Colder Clima (LT, MT, HT)
BIPR
(R410A)
Cooling: Highest Energy Consumption
30% of Total Energy Consumption
80% of Total Energy Consumption
Heating: Highest Energy Consumption
30% of Total Energy Consumption
80% of Total Energy Consumption
IE%
StandardScroll for A/C
Comfort OptimizedScroll ZH*P
Low PR Improvement High PR Improvement
Low PR Medium PR Medium PR High PR
Heating Applications & Heating
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Heating Applications & HeatingOptimized ScrollsZHI*P
Energy Needs by Applications 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.4 4.5 4.6 4.8 5.0 5.2 5.4 5.5 5.6 5.8 7.4 7.5
HP A/W Average Clima (HT)HP A/W Colder Clima (MT,HT)
HP B/W Colder Clima (MT, HT)
BIPR
(R410A)
Cooling: Highest Energy Consumption
30% of Total Energy Consumption
80% of Total Energy Consumption
Heating: Highest Energy Consumption
30% of Total Energy Consumption
80% of Total Energy Consumption
IE%
Heating OptimizedScroll ZHI*P
High PR Stronger Improvement
w/ VaporInjection
StandardScroll for A/C
Medium PR High PR
Comfort and Heating Optimized Scrolls
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R410AHeat ing
Capacity (kW )
M o d e l-7C/ 50C
SH 5K, SC 4K
ZHI26K1P-TFD 26.0
ZHI31K1P-TFD 30.8
ZHI35K1P-TFD 34.8
ZHI39K1P-TFD 39.1
ZHI46K1P-TFD 46.3
ZH22K1P-TFD 21.6
ZH26K1P-TFD 25.3
ZH29K1P-TFD 28.5
ZH32K1P-TFD 32.1
ZH38K1P-TFD 38.0
Heat ing Scrol l
Comf ort Scrol l
Comfort and Heating Optimized ScrollsLineup Overview
Main Features & Benefits
Optimized for Heating Dedicated Apps. High Pressure Ratio Optimization, HighPower Motor & Vapor Injection (EVI)
Improved SCOP +++Standard ESEER Extended Envelope +++
Vapor & Wet Injection HT Water / Sanitary Water Production downto -22C Ambient
Optimized for Comfort Dedicated Apps.Dynamic Volume Ratio Optimization(High & Low PR)
Improved SCOP ++ Improved ESEER ++
Liquid Injection Extended Envelope ++
EVI
Liquid
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Industrial Heat Pumps
Natural Gas and Electrical kWhr Prices
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Converging Increased Interest
Count ries ELEC GAS * * % Savings 1kW h prod uced
per kWh(elec) 2009
per kWh(heat)
COP
3COP
4COP
5COP
6
Finland 0,083 0,110 74,8% 81,1% 84,9% 87,4%
Sweden 0,073 0,048 48,8% 61,6% 69,3% 74,4%
France 0,080 0,039 31,2% 48,4% 58,7% 65,6%
Denmark 0,132 0,063 29,6% 47,2% 57,8% 64,8%
Turkey* 0,078 0,035 25,9% 44,4% 55,5% 62,9%
Croatia* 0,089 0,037 20,4% 40,3% 52,2% 60,2%
Netherlands 0,141 0,059 20,0% 40,0% 52,0% 60,0%
Spain 0,095 0,039 18,3% 38,7% 51,0% 59,1%
Poland 0,090 0,036 17,2% 37,9% 50,3% 58,6%
United Kingdom 0,125 0,049 14,5% 35,9% 48,7% 57,3%
Austria 0,121 0,046 12,8% 34,6% 47,7% 56,4%
Portugal 0,103 0,039 11,4% 33,5% 46,8% 55,7%
Slovenia 0,107 0,039 8,0% 31,0% 44,8% 54,0%
Germany 0,147 0,050 2,0% 26,5% 41,2% 51,0%
Ireland 0,148 0,050 1,3% 26,0% 40,8% 50,7%
Lithuania 0,078 0,026 1,0% 25,7% 40,6% 50,5%
Czech Rep, 0,098 0,029 -13,6% 14,8% 31,8% 43,2%
Latvia 0,077 0,023 -14,1% 14,4% 31,6% 43,0%
Luxembourg 0,118 0,034 -16,5% 12,6% 30,1% 41,7%
Bulgaria 0,070
0,020 -16,7% 12,5% 30,0% 41,7%Estonia 0,071 0,020 -18,3% 11,3% 29,0% 40,8%
Hungary 0,135 0,038 -20,0% 10,0% 28,0% 40,0%
Belgium 0,129 0,035 -22,9% 7,9% 26,3% 38,6%
Romania 0,134 0,033 -37,4% -3,1% 17,5% 31,3%
Italy 0,179 0,043 -40,4% -5,3% 15,8% 29,8%
Slovakia 0,130 0,028 -57,6% -18,2% 5,5% 21,2%
Cyprus 0,142 NO DATA
Greece 0,091 NO DATA
Mal ta 0,105 NO DATA
2,00
2,50
3,00
3,50
4,00
4,50
1998 2000 2002 2004 2006 2008
Ratio Elec/ Gas
Trend
EU 15-EU 27
Data source EUROSTAT* * Corrected valu e based on 80% gas heater ef ficiency
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Industrial Heat Pumps
z High temperature (high pressure) needed
z Low pressure ratio capability (two-stage) needed
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Available Waste Heat
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Vilter Single Screw Advantagesz Balanced Bearing Loading
No Thrust Load
z Suited to High Pressures and Pressure Differences
z Variable Volume Slide 1.2 to 7.0 Ratioz Well suited for high pressure heat pump requirements
No Mid-Rotor Deflection
nt
Ammonia Pressure-Temperature
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pRelationship
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Scavenging Heat Pump System
2-Stage Scavenging Heat
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g g gPump System
NH3 T St H t P
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NH3 Two Stage Heat Pump
3 x 2-stage system
Capacity: 15 MW COP: > 3,0 @ 90 oC
Seawater: + 8/4 oC
Heating: +60 90
oC NH3 charge: < 2000
kg
High efficiency
Capacity controldown to 10%
Low operating and
maintenance cost
Drammen Norway District Heating
Courtesy of Star Refrigeration Ltd. U.K.
ConclusionsC f R id ti l H t P
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Compressors for Residential Heat Pumps
z Heat Pump Optimised Scroll Technology And VapourInjection Allow High Temperature Operation WhileIncreasing The Heat Pump SCOP
z R410A Is Seen To Be The Next Generation Heat PumpsRefrigerant Over Conventional R407C
System Design To Be Adapted
z Variable Speed Technology Substantially Increases TheSCOP Of A/W Heat Pumps
System To Be Designed For Capacity Control
z Electronics/Integrated Solutions bring
ConclusionsC f C i l H t P
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Compressors for Commercial Heat Pumps
z Optimisation of high and low pressure ratio inorder to maximise SEER and SCOP
0
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
-3 0
-2 0
-1 0
0
1 0
2 0
3 0
4 0
5 0
-25 -23 -21 -19 -17 -15 -13 -11 -9 -7 -5 -3 -1 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45
BuildingLoad(kW)
Tevap&Tcond(C)
Outdoor Temp ( C)
Tevaporating
ConclusionsCompressors for Industrial Heat Pumps
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Compressors for Industrial Heat Pumps
z The single screw compressor with its balancedbearing loading and high pressure capabilitybrings the concept of high temperature heat
recovery to reality.
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Thank you for your
attention!Questions?
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