The company installed controls consisting of sensors and computer software, which automatically modulated compressor discharge and suction pressures to improve the coefficient of performance and to better adjust compressor operation to changes in refrigeration system cooling demand. The upgrade led to annual energy savings of 367,000 kWh as well as reduced operations and maintenance costs through more efficient system operation . The reported payback period, which included both electricity bill savings and reduced operations and maintenance costs, was around 2.6 years. Floating head pressure control. Floating head pressure control can be a particularly effective control strategy for reducing compressor energy consumption. Floating head pressure control allows compressor head pressures to move up or down with variations in ambient wet-bulb temperature, saving energy compared to fixed head pressure operation. However, additional energy is required for the condenser fan, which must be balanced with compressor energy savings. It is also important not to allow head pressure to go too low, as certain system demands might require minimum head pressures . Hackett et al. estimate a typical payback period of less than one year for floating head pressure control systems. A U.S. DOE sponsored energy audit at the Odwalla Juice Company’s facility in Dinuva, California, estimated that the use of floating head pressure control on the facility’s seven ammonia compressors would save the company nearly $108,000 per year in energy costs . Total estimated electricity savings were around 1 million kWh per year at a payback period of only six months. Birds Eye Walls, a UK based manufacturer of frozen foods, nft growing system implemented refrigeration controls that allowed for floating head pressure in its Gloucester, England, facility in 1994.
The controls led to a 30% lower head pressure on average, allowing the company to save around £150,000 in refrigeration costs annually . At an initial investment cost of less that £30,000 , the payback period was less than three months. Indirect lubricant cooling. Direct injection of refrigerant is an inefficient method for compressor cooling that can decrease the overall efficiency of screw-type compressors by as much as 5% to 10% . An indirect system is a more efficient option for lubricating and cooling screw-type compressors, in which a heat exchanger is used in conjunction with cooling tower water, a section of an evaporative condenser, or a thermosyphon system to cool compressor lubricant. Raising system suction pressure. In two-stage compressor systems, a simple way to save energy is to raise the suction pressure and temperature of the low-stage compressor when ambient temperatures decrease. It has been estimated that energy savings of about 8% can be realized in two-stage systems when suction temperatures are raised from -30 °F to -20 °F . Adjustable-speed drives on compressor motors. Adjustable-speed drives can be used in conjunction with control systems to better match compressor loads to system cooling requirements. The Industrial Refrigeration Consortium reports that ASDs used on compressors below a part-load ratio of about 95% will deliver performance equal to a fixed speed compressor but with lower electricity requirements. However, at near full load, ASDs are approximately 3% less efficient than fixed speed drives due to electrical power losses associated with the ASD controller. Adjustable-speed drives are thus most beneficial for refrigeration systems with large differences between required and installed condenser capacities . Galitsky et al. have estimated average refrigeration system energy savings of 10% from the use of ASDs on compressors. Naumes, Inc., an Oregon based company specializing in fruit growing, processing, storage, and juice production, recently upgraded their ammonia-based refrigeration system with computer controls and ASD compressors for more efficient matching of cooling demand and system load.
The new system saved the company a reported 741,000 kWh per year, with total annual energy savings of around $37,000 . The simple payback period was estimated at just over two years. As part of a planned expansion for its dairy facility in Portland, Oregon, WestFarm Foods installed a new compressor with a 350 hp ASD, which allowed the remaining system compressors to either be off or working efficiently at 100% load. Other upgrades included new refrigeration system controls and ASDs on the system’s evaporator fans. The totalsystem upgrade reduced annual refrigeration system energy consumption by nearly 40% and annual operating costs by around $75,000 . At an investment cost of $310,000, the payback period was estimated at roughly four years; however, energy efficiency investment incentives from Portland General Electric as well as a 35% tax credit from the Oregon Department of Energy helped reduce the final payback to around one year. In 2003, Oregon Freeze Dry, a manufacturer of freeze-dried fruits, vegetables, and other specialty foods, installed ASDs on its refrigeration system screw compressors at its Albany, Oregon, facility. The company also decided to replace an undersized eight inch suction line with a new 12 inch line. The energy savings of the ASD and suction line installations amounted to nearly 2 million kWh per year , while energy cost savings amounted to $77,700 per year . Compressor heat recovery. Where economically feasible, rejected heat can be recovered from compressors and used in other facility applications, such as space heating or water heating. Further details on this measure are provided in Chapter 10. Dedicating a compressor to defrosting. It has been reported that if one compressor of a large system can be dedicated to running at the pressure needed for the defrost cycle, while the other compressors can be run at lower system pressures, that the resulting energy savings can often justify the cost of the dedicated compressor .
Keeping condensers clean. Condensers should be checked regularly for dirt, ice buildup, or plugged nozzles, which can reduce heat transfer rates and thus raise the condensing temperature. Furthermore, water-cooled and evaporative condensers should be kept free of hard water or bacterial buildup, which can cause fouling, scaling, and clogging that can also lead to increased condensing temperatures. In general, a one degree Celsius increase in condensing temperature will increase operating costs by 2% to 4% . Badly corroded condensers should be replaced as soon as possible. Automatic purging of condensers. Periodic purging of evaporative condensers is needed to remove non-condensable gases , which can reduce refrigeration system efficiency by increasing system head pressure and impeding condenser heat transfer . Automatic purging systems can help refrigeration systems operate efficiently by ensuring purging occurs on a regular basis. Automatic purging systems can also reduce the refrigerant loss and labor costs associated with manual purging. Excel Logistics Ltd., an operator of cold storage facilities in the United Kingdom, installed a five-point automatic refrigeration purging system at their Glasgow, Scotland, facility in 1989. Previously, the company purged its system manually on a weekly basis, which was time consuming and often led to refrigerant loss. The automatic purging system featured computer controls and five different refrigeration system purge points: one at each end of thereceiver, one on each of the two condenser outlets, and one on the hot gas line. The company reported that the automatic purging system led to a 15% reduction in compressor energy use and £8,800 in annual energy savings . The simple payback period, nft hydroponic system including both energy and maintenance cost savings, was 10 months. Reducing condenser fan use. Sometimes condenser fans are operated continuously, even when the refrigeration system’s compressor isn’t running. This practice wastes energy. Wherever possible, the operation of condenser fans should be coupled to the operation of the system’s compressors to ensure that the fans are only run when needed. Reducing condensing pressure. This measure is similar to floating head pressure control for compressors . To reduce the energy required to compress refrigerant, condensing pressures and temperatures should be set as low as possible. Computer controls can be installed on condensing systems to minimize condensing temperatures and pressures based on ambient wet-bulb temperatures, as well as to optimize the use of condenser fans and water . Lowering the condensing temperature can reduce compressor energy use by around 2% to 3% for every degree Celsius of temperature reduction . Use of axial condenser fans. Air-cooled or evaporative condensers generally do not need high-pressure air, and thus axial fans are well suited for this application. Adjustable-speed drives on condenser fans. For refrigeration systems with large differences between installed and operating condensing capacity, the use of ASDs on condenser fans can lead to significant energy savings compared to fixed-speed condenser fans. Prior to installing ASDs, however, it is important to establish the extent to which the condensing pressure can be floated. On systems where floating head operation is stable, ASDs can lower condenser fan energy consumption by up to 40% compared to operating a fixed-speed condenser fan in on/off fashion .
Cycling of evaporator fans in cold storage. It is often possible to maintain adequate temperature in cold storage areas without continuously running evaporator fans. Where feasible, evaporator fans can be turned off or ramped down periodically using timers or variable-speed control systems to save electricity while still maintaining proper cold storage temperatures. The cycling of evaporator fans should be managed carefully, however, to avoid stratification and to ensure that solenoids are cycled properly . In 1996, Stahlbush Island Farms, a grower, canner, and freezer of fruits and vegetables in Corvalis, Oregon, installed timers to cycle the evaporator fans of its cold storage unit. Prior to the installation of the timers, evaporator fans were run close to 24 hours per day. By cycling the evaporator fans, the company was able to save around 133,000 kWh of electricity per year because the fans ran for fewer hours and the fan motors released less heat into the cold storage unit . The annual savings were estimated at $4,500 and, with a one-time implementation cost of $1,000, the simple payback period was around three months. Adjustable-speed drives on evaporator fans. Similar to ASDs on condenser fans, for refrigeration systems with excess evaporator capacity, the installation of ASDs can lead to significant energy savings compared to fixed-speed fans. The cost effectiveness of ASDs, however, depends on the number of hours the evaporator fans can be run under part-load conditions. In an analysis of a -20° Fahrenheit freezer with seven evaporators, the use of ASDs on evaporator fans at a load ratio of 50% required 20% lower power than fixed-speed fans under the same operating conditions . The U.S. DOE has supported the development of a simple evaporator fan controller for medium temperature walk-in refrigeration units, which is capable of varying fan speed is reported to reduce evaporator and compressor energy consumption by 30% to 50% . The controller regulates the speed of evaporator fan motors to better match cooling demands in the refrigeration cycle. The U.S. DOE estimates typical payback periods of one to two years. As of 2000, the controller had been installed in 300 refrigeration units and had led to cumulative energy savings of around $80,000. According to BC Hydro , evaporator fan controllers are not good candidates for freezers that run under 28° Fahrenheit, have compressors that run continuously, have evaporator fans that run on poly-phase power, and have evaporator fans of types other than shaded-pole and permanent-split-capacitor. Demand defrost. Evaporators should be defrosted only when necessary, as opposed to on timed schedules where defrosting occurs regardless of need. Defrosting cycles should ideally be based on coil pressure readings, where an increase in pressure drop indicates that frost is present on the coils and that defrosting is necessary . Water defrosting. Water defrosting is said to be more efficient than hot gas defrosting . In water defrosting, water is sprayed manually over the evaporator coils to remove frost. However, water defrosting must be managed properly to ensure that the water does not freeze on the evaporator coils.Compressed air generally represents one of the most inefficient uses of energy in U.S. industry due to poor system efficiency. Typically, the efficiency of a compressed air system—from compressed air generation to end use—is only around 10% . Because of this inefficiency, if compressed air is used, it should be of minimum quantity for the shortest possible time; it should also be constantly monitored and weighed against potential alternatives. Many opportunities to reduce energy consumption in compressed air systems are not prohibitively expensive; payback periods for some options can be extremely short. Energy savings from compressed air system improvements can range from 20% to 50% of total system electricity consumption .