tewi analysis

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


Heating: Highest 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



Heating: Highest 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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tewi analysis

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