WPs 2.1, 2.2, 2.3, 2.4, 2 - I-Stutei-stute.org/Other files/Progress MC December 2014/MC presentation...Pathway to impact: with Asda, Sainsburys, The Coop and Bond Retail Display and

WPs 2.1, 2.2, 2.3, 2.4, 2.5

Graeme Maidment

i-STUTE cooling based projects

WP2.1. and WP2.2 Supermarket refrigeration

– Judith Evans, Alan Foster and Deborah Andrews

WP2.3 . Data centres

– Gareth Davies

WP2.4. Transport refrigeration

– Christina Francis, Gareth Davies, Judith Evans and Graeme Maidment

WP2.5. Integrated heating and cooling

– Akos Revesz, Issa Chaer and Graeme Maidment

Cost of ownership

Carbon/ energy

Materials, resources & waste

Integration

WP 2.1 Retail chilling and freezing [1st Wave, Graeme Maidment, LSBU]

Rationale: • UK Supermarkets are large energy users /carbon producers

& consume 3% of UK energy and 7.3 MT CO2. • At least 40 % of a energy is used directly for cooling, mainly

refrigerated display cabinets (RDCs), • A further 25% is used for heating, of which 1/3 offsets

cooling losses from RDCs.

Carbon Reduction Potential: 4.8MT CO2 pa UK. Investigations consider cradle to grave, remanufacture/ recycling, reducing embodied carbon impact.

Pathway to impact: with Asda, Sainsburys, The Coop and Bond Retail Display and will consider form and ergonomics, user requirements, readiness, etc.

WP 2.1 Retail chilling and freezing

• WP2.1.1 – Technologies will be initially investigated and sifted

• WP2.1.2 – In parallel with WP2.1 technologies will be investigated experimentally and a physical proof of concept and a prototype will be developed

• WP2.1.3 – Non technical barriers preventing uptake of new technologies, such as customer reaction, implementation, cost-benefit models, end user (supermarket) incentives will be assessed

• WP2.1.4 – The final part of this work package will involve a trial of the prototype in-store with ASDA


• 77 technologies evaluated (some discarded)

• 58 technologies written up

• Currently 108 page report

• Some still being updated

• Some additional new technologies being added (~8)

• Supermarket model developed

• Still need some information from ASDA


• Store modelled

• ASDA Weston-Super-Mare

• Reasonably typical large supermarket

• Used a representative store

• Model can be adapted to different store sizes and configurations


Store general

Size (m2) 6290 (74 x 85 m) (total store)

Store temperature (°C), RH (%) 19-24, no RH control

Store heating Gas

Store cooling Air conditioning, make up air. Store pressurised

Cabinets

Length of chilled cabinets (m) 179.2

Length of frozen cabinets (m) 68.3

Cabinet lighting Fluorescent (T5 and T8), no LED

Controls for cabinet lighting MT/HT fridges lights reduced to 30% (10 pm to 8 am).

LT always on full

Cabinet fan motors EC fans

ASH Only on frozen cabinets, controlled by humidistat (full on when humidity

is > 60%, off when humidity is < 20%, modulates in between)

Shelf risers Standard on chilled – however, not all cabinets have them fitted

Defrosts Freezers 2/day

Chilled (off cycle ) 4/day

Terminate on temp (max and min time)

Monitoring system RDM


Refrigeration plants

Refrigerant plant Mix of packs and condenser units

Condensers Air cooled

Condenser fan motors Replacing SP (30%) with EC motors (70%)

Suction-liquid heat exchange None

Floating head pressure control Head pressure controlled to 10.5 barg (however, head pressure rises

above this in summer)

Water spray used for 1-2 weeks /year when operating above design

conditions

Suction pressure control LT 0.7 barg

HT 3.5 barg

No floating suction control

Liquid pressure amplification None

Pipe insulation Insulated

Pressure drops Minimised in design

Refrigerant R404A (packs), R407A (chilled condensing units)

Refrigerant charge (kg)

Refrigerant leakage (kg/year) 59.4

Causes of leakage Compressor change

Lots of pipework leaks

Leak on condensing unit

Liquid line fracture


Item kW

Compressor 164.72

Condenser fan 15.51

Evaporator fan 9.49

Defrost heater 7.29

Trim heater (not glass) 22.66

Trim heater glass 22.66

Light 4.69

Total 247.01



Cabinet types Total length (m)

LT remote FGD 14.63

HGD/well 53.64

TOTAL 68.28

MT remote Roll-in 48.77

Multi-deck 130.45

TOTAL 179.22

LT integrals HGD 0.91

MT integrals Multi-deck 24.87

FGD 5.00

TOTAL 35.66

Hot food 4.88

TOTAL ALL 283.16

WP 2.1 Retail chilling and freezing Quality of information 5 independent peer review papers in general agreement = 5*

3 independent peer review papers in general agreement =4* General agreement between Independent reports or 1 peer reviewed publication=3* General agreement between Web based and sales literature =2* Personal communication only = 1*

Barriers to staff/customers

H=major barrier M=partial barrier L=no barrier

Availability barriers H=prototype/demonstrator only M=limited availability L=available

Limits to commercial maturity

H=lack of maturity M=intermediate L=mature

Ease of use of installation

H=major issues M=partial L=simple

Technology independence

H=high (i.e., interaction) M=some L=none

Maintainability H=major issue M=some problems L=no issues Legislative concerns H=major (issue now) M=issue in near future L=no impact Energy savings % or actual savings Scope of application Range of applications Direct emissions % emissions from technology

Cost (payback) Cost of technology, ROI (time)


>10% saving in refrigeration energy

WP 2.1 Retail chilling and freezing >10% saving in refrigeration energy






• Need to add direct effects (waiting information from ASDA)

• Leakage estimated at ~20%/year, therefore reduction strategies will have large impact on CO2e emissions

• Add additional technologies

• Some technologies limited information and so attempting to find additional information


• Prototype cabinet – technologies that can be considered:

– Doors

– Night blinds/covers

– Strip curtains

– Fans

– Loading mechanisms

– Air deflectors

– Evaporator design

– Evaporator rifling

– Air flow design (inc. short air curtains)

– Floating head pressure (plant)

• Not all technologies will be acceptable

WP 2.1 Retail chilling and freezing • Several technologies not as beneficial as envisaged (or already applied by

ASDA):

– Lighting (LEDs)

– Lighting controls

– Radiant reflectors

– SLHE

– Risers and weir plates

– Cabinet temperature control

– Store temperature control

– Refrigerants (plant) – may show more benefit when direct emissions included

– Evaporative condensers (plant)

– Inverters (plant)

– Suction pressure control (plant)

– Secondary systems (plant)

Rationale: WP2.1 will be extended into a 2nd Wave project

investigating more fundamental concepts of retail display

and their applicability in the longer term.

Challenge: to challenge the concept of the retail display

cabinet, specifically from a fundamental aesthetic,

ergonomic and energy use perspectives.

Objectives/ Deliverables: To deliver a new concept in RDC

that has 1/10 of the existing energy consumption

Carbon Impact potential: 12 million tonnes of carbon in

energy alone

Pathway to impact: as for WP2.1

WP2.2 Retail chilling and freezing [Potential 2nd Wave project]

30 mm Air flow

Air curtain –1C

Dissemination

• Keynote for ICEF12 (Quebec)

• Abstract for IRC in Yokohama accepted

• Peer reviewed paper on technological options (probably IJR)

WP2.3 - Data Centre Cooling

22

Background • Data centres currently account for approx. 2-3%

of total electricity consumption in the UK

• Typically, approx. 50% of data centre energy is used for cooling and humidification

• Currently, the main method used is to circulate

chilled, humidified air between the server racks. Typically use a raised floor and hot aisle/cold aisle arrangement.

• Limited focus on heat recovery

Deliverables • Roadmap/report on cooling

• Detailed investigation - integrated cooling, heat

recovery and heat transfer.

Project Plan

23

• Phase 1 (July 2013 – Oct 2014) – Development of roadmap – review of data centre cooling technologies. Energy/ carbon saving opportunities

Tasks: (1) Review of cooling methods currently used in data centre industry

(2) Evaluate options for reducing energy used and carbon emissions

(3) Future trends in data centre cooling

(4) Identify technologies for detailed study/development in second

phase of project

(5) Report/Review/Roadmap • Phase 2 (Aug 2014 – Sep 2016) – Detailed study of selected

technologies Proposed project plan to be presented below

24

Potential for Waste Heat Recovery from Data Centres

• Different cooling methods/technologies produce different temperature waste heat output streams with different reuse values

• The higher the temperature of the waste heat, the greater the range of potential reuse applications

• For most applications, it is necessary to boost the temperature of the waste heat using heat pumps

• Waste heat uses include: domestic and industrial space and water heating, district heating, organic Rankine cycle, absorption chiller, desalination, biomass processing, piezoelectrics, thermoelectrics

• Currently, district heating appears to be the most promising reuse option, providing suitable networks are available

Waste heat driven absorption chiller

Carnot efficiency 5% for waste heat at 65°C

District Heat Networks

25

• Currently supply only 2% of heat demand in UK by district heating

• UK government plans to substantially expand district heating networks making use of waste heat sources e.g. data centres

• London plans to build a low temperature heat network – supply temperature 70°C (London Mayor reports, 2012; 2013)

• Data centre waste heat could be upgraded via heat pumps to contribute heat at this temperature. A heat pump COP of above 3.0 is needed for viability

Plan for Phase 2 of Project

26

• Mapping of potential data centre heat sources for district heating network -

quantity of heat for each data centre and temperatures of waste heat streams -

matching of heat sources and heat loads

• Effects of variations in IT load and ambient temperature on quality of waste

heat

• Theoretical analysis of selected heat pump thermodynamic cycles. Both single

stage and multistage combining e.g. compressor + pump; compressor +

thermosyphon stages

• Construct and test laboratory scale heat pump system to verify performance of

optimised cycles

• Develop a model to predict savings in cooling, heating, energy, carbon emissions

and costs for different thermodynamic cycles and waste heat stream profiles

Distribution of Data Centres across UK

27

• Distribution of colocation data centres in UK

• Largest concentration of data centres is in London

Locations and Sizes of Data Centres in London

28

• Approx. 75 colocation data centres identified in Greater London

• Majority are concentrated in central London, along the Thames

• Sizes range from 1 to 28 MW

• (For those shown as zero on the map, their capacity has not yet been determined)

London Heat Map (Heat Use)

29

• Greatest requirement for heat in commercial use and public buildings is in central London. Residential heat requirement is fairly evenly spread across the Greater London area

Numbers and Sizes of Data Centres for London Districts

30

• Number and size distributions differ – some areas have a few large data centres, while others have higher numbers of data centres, but smaller

• Largest concentration of data centres, however, is for Tower Hamlets – mainly in Docklands/Canary Wharf area

Matching of DC Heat Sources with Heat Loads (for whole of London)

31

• Total waste heat from data centres is estimated to be 1.34 TWh per annum

Considerations:

1. Note: above estimate is based on colocation data centres alone. There are also a large number of other data centres including e.g. government (central and local), police, hospitals, universities and private companies, which could provide as much heat again

2. For connection to a district heating network, location is important. Data centres are not evenly spread across London

Existing and Proposed District Heating Networks

32

• Yellow lines indicate existing heat networks, red lines indicate proposed heat networks

Next steps

33

• Effects of variations in IT load and ambient temperature on quality of waste

heat

• Theoretical analysis of selected heat pump thermodynamic cycles. Both

single stage and multistage combining e.g. compressor + pump;

compressor + thermosyphon stages

• Further development and completion of data centre roadmap

• Presentation of paper on data centre waste heat recovery at CIBSE technical

symposium (April 2015)

WP 2.3 Deliverables

• Internal report on cooling of data centres – October 2014

• Report/roadmap of Future technologies with input from Robert Tozer – March 2015

• Dissemination – paper on data centre waste heat recovery to be presented to CIBSE technical symposium April 2015 at UCL

• Initial internal heat recovery report – December 2014 • Detailed heat recovery study commences January

2015

Background • UK primary food distribution by RRT uses 40% more

energy than non-refrigerated vehicles • Environmental Impact

• Indirect emissions - • Transportation - 2 Mtonnes of indirect CO2

emissions from the engine alone. • Refrigeration - ????

• Direct emissions - • RRT units leak up to 30% of their total

refrigerant charge per year – R404A

• System Durability & Reliability • Cost

Deliverables • Development of a model to investigate direct and

indirect emissions • Optimising system performance

WP2.4 refrigerated road transport (RRT)

Research Plan

1. Investigate different types RRT vehicle technologies

2. Analyse maintenance and leakage records to:

a) Identify problematic components/ sources of refrigerant leakage

b) Suggest generic solutions for leak tight systems

3. Develop a model to; a) Estimate direct/ indirect carbon emissions b) Evaluate the effectiveness of various

concepts

4. Measure actual RRT data

5. Validate and optimise model

6. Industry report & PhD thesis

36

Small vans & medium rigid trucks

37

Concerns: 1. Large amount of heat entering during

door openings 2. Refrigeration system stop working

when vehicle stops => system is off when load at its highest 3. Running time between stops may be

short => time insufficient for temp pull-down

Common Solutions: • Rule of thumb - oversize unit to compensate for infiltration by multi- door

openings • Use door protection • Employ a hybrid vapour compression and eutectic refrigeration system

Recommended Solution: Optimum Design • For the average load profile • Typical annual duty cycle-

Proposed Methodology & Design of Experiments for Indirect carbon emissions

38

Evaluate and monitor

• LGVs small vans to medium rigid trucks

• Multi-drop deliveries

• Load profile (size and type)

• Select Optimum Design

• Compare energy intensity of mono-temp chilled/frozen vs. multi-temp

• Match average load profile with annual duty cycle

• But 1st Initiate simple model in MS Excel to determine relative carbon

emissions to determine priority in the main model development

Desired Input Variables may include:

39

MODEL INPUTS/ COMPONENTS

Description

VEHICLE SPECIFICATIONS 1. Fuel/Energy Consumption 2. Engine Speed 3. Year 4. Type 5. Size, Payload

REFRIGERATION SYSTEM

1. Manufacturer Specifications: Compressor, TEV, Condenser, Evaporator, CPR, Reversing Valve 2. Compressor Power/Work 3. Cooling/Heating Capacity 4. Refrigerant Properties

REFRIGERATED BOX SPECIFICATIONS

1.Insulation properties- K Value 2. Thermal bridge factor 3.Air Flow Rate (bulkhead fan, evaporator fan) 4. Inside air temp 5. Infiltration air change rate (door openings)

ENVIRONMENTAL DATA 1. Weather data:

Ambient Temp, Solar radiation, Relative humidity, Wind speed

OPERATION/JOURNEY DETAILS 1. Route 2. No. of door openings 3.Length of time stopped 4. Urban/Rural

PRODUCT DETAILS 1.Types of food 2.Heat characteristics 3. Load size and profile

Activities Completed 4th Qtr 2014

• Literature review internal report

• Comparison of seven (7) existing modelling tools

• Pre-select potential modelling platform for RRT systems

• Address ethical risk and concerns with regards to the anonymity , risk to drivers and methodology for data collection on the refrigerated vehicle

• Initiate model development in MS Excel

41

Project plan flow chart

Prelim Study &

Data Analysis I

Develop

Model Validate &

Optimize

Model

Data

Collection &

Analysis Report for

Transport

Industry

PhD

Thesis

42

Project Schedule

W.P. Activities Duration Milestones

2.4.2 Plan Project Research Nov 2013 - Oct 2014 • LSBU Report – April 2014

2.4.3 Prelim Study & Data Analysis

Jan 2014- Apr 2014 • Brief Industry Report – Feb 2014

2.4.4 Develop Model May 2014 – July 2015 • Interim Report – Jun/July 2014 • LSBU Report – Oct 2014 • Ethical Approval – Mar 2015

2.4.5 Data Collection Aug 2014- Aug 2015 • Report on Findings – Jan & Jun 2015 • LSBU Report – April 2015

2.4.6 Data Analysis Aug 2015- Jan 2016 • LSBU Report – Sept 2015 • Demonstrate Model – Dec 2015

2.4.7 Validate & Optimize Model Jan 2016 – May 2016 • Interim Report – Mar 2016 • Completed Model– May 2016

2.4.8 Compose PhD Thesis Feb 2016 – Nov 2016 • LSBU Report – June 2016 • Viva – Nov 2016

2.4.9 Compose Industry Report Jun 2016- Oct 2016 • Final Industry Report– Oct 2016

WP 2.4 Deliverables

• Internal report on leakage - company A – Feb 2014

• Registration document RES2 – June 2014

• Summer school conference June 2014 Poster

• Ethics application July 2014

• Internal report on leakage - company B – August 2014

• Internal report on modelling platforms- August 2014

• Literature review internal report – Oct 2014

• Draft conference paper for submission for the 24th IIR -ICR 2015

Next immediate steps


• Continue model development in excel

• Acquire and review trial version simulation platform tool

Background

• To investigate the interactions of underground railway tunnels and ground heat exchangers

• To investigate the potential indirect use of waste heat from the tunnels to heat buildings

above ground.

Deliverables

• Development of a model

• Case study materials

INTERACTIONS

2. Project time line with the key milestones

Stage 1 & 2 Stage 3 Stage 4 Stage 6 Stage 7

Currently ongoing

3. Past achievements and ongoing tasks Key Activities Status

Sta

ge

2

• Preliminary studies exploration

Completed • On site familiarization with LU

• Initiated evaluation of simulation software (report)

• LSBU - Summer School Conference

Sta

ge

3

• Assessment of the proposed model details and set the modelling objectives

Completed • Abstract / paper preparation and submission for an International Congress

• Journal paper preparation

Sta

ge

4

• Familiarization with the selected simulation software Completed

• Produce a model development strategy Completed

• 2D models development and validation exercises Ongoing

• Conference paper preparation Ongoing

4. Proposed tasks for the upcoming months

Events Comment

4.1 2D model

development Individual building blocks and the corresponding validation exercises

4.2

Revise and submit the

review paper for

publication

Submission: January 2015

4.4 Prepare and submit

the RES 3 form Submission: February 2015

4.3

Prepare and submit

the IIR Conference

paper

Submission: February 2015

WP 2.5 Deliverables

• Internal reports April July and November 2014

• Summer school conference June 2014 Poster

• Registration document RES2 – September 2014

• Internal report on modelling platforms- November 2014

• Literature review internal report – Oct 2014

• Journal paper submission – January 2015


Questions

Documents

WPs 2.1, 2.2, 2.3, 2.4, 2 - I-Stutei-stute.org/Other files/Progress MC December 2014/MC presentation...Pathway to impact: with Asda, Sainsburys, The Coop and Bond Retail Display and