Many international organisations have begun to discover the advantages of using hydrocarbons such as propane and propene as they are climate-neutral refrigerants, apart from being energy efficient. Eurammon, the European initiative for natural refrigerants, presents case studies to support this view

According to the International Institute of Refrigeration1 20% of the global warming potential of refrigerating and air conditioning systems come from leaks (direct emissions), while 80% results from their energy consumption (indirect emissions). Today’s refrigeration systems consume around 15% of the world’s available electrical energy. This implies that reducing this energy demand would make an important contribution towards reducing the threat to global warming.

In this context, special importance is attributed to natural refrigerants such as ammonia, carbon dioxide and hydrocarbons, which offer high-energy efficiency as well as being climateneutral. Expert opinion recognises ammonia as the most efficient refrigerant. But hydrocarbons such as propane, propene and isobutane also have outstanding thermodynamic properties. Refrigerating and air conditioning systems that run on these refrigerants are particularly energy-efficient. This fact has been recognised by numerous international companies, including Ben & Jerry, Pepsi and Unilever. They use hydrocarbons for refrigeration in both their chilling units and freezers. Various tests in the field have confirmed energy savings between 10 and 30% compared to HFC systems.

In addition, certain hydrocarbons can also be used as a ‘drop-in solution’ for synthetic refrigerants. For example, propane (R290) and propene (R1270) have similar thermodynamic behaviour to the HCFC R22. They use the same technology, which means that many of the existing installed components are compatible. For higher ambient temperatures or higher humidity levels, propane and propene are more efficient than R22.

MAKING AIR CONDITIONING SYSTEMS ENVIRONMENT FRIENDLY

The Chinese air conditioning system manufacturer Gree Electric Appliances is one of the companies using propane to replace R22 and R410A in new systems. The company is one of the world’s largest manufacturers of room air conditioners, with a production output of more than 70 million units a year.

The Chinese use HCFC R22 as a standard refrigerant, but these refrigerants contribute considerably to global warming as well as destroying the ozone layer. Altogether, China’s air-conditioning systems generate annual HCFC emissions amounting to 260 million T of carbon dioxide equivalent, thus constituting one of China’s largest sources of emissions. This is why in late 2009, Gree, assisted by the implementing agency GTZ Proklima, started pilot production of room air conditioning systems based on propane. The quantity of refrigerant ranges from 200 to 350g for rated cooling capacities of 2 to 4 kW, depending upon the model. Significantly, the air conditioners have a higher efficiency than both R22 and R410A models, whilst requiring a smaller mass of system materials. In addition to the reduced charge size, GTZ Proklima with UK-based consultant Daniel Colbourne, assisted with the safe design of the air conditioners. A production line will turn out 180,000 systems per year.

The change-over in refrigerant will save 560,000 T of carbon dioxide equivalents in direct emissions over the entire service life of the air conditioning systems. To this should be added a further 320,000 T of carbon dioxide equivalents in indirect emissions saved by the improved energy efficiency of the systems. For the final consumer, this translates into benefits in terms of lower electricity bills.

The best project practice, which is intended to have a role-model effect for China’s entire air conditioning industry and beyond, is being funded by the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety, within the framework of the International Climate Initiative based on a decision of the German Federal Parliament.

FRUIT STORAGE – DELAYING THE RIPENING

Companies in other industries are also opting for hydrocarbons, such as the British fruit grower Mansfields. The family company stores apples and cherries in a controlled atmosphere so that they will be available in top quality all year round, regardless of when they were picked. State-of-the-art measuring, control and refrigerating systems monitor temperature, humidity, oxygen and carbon dioxide levels, keeping them at the required level to delay the ripening of fruit and vegetables. Mansfields wanted an efficient, HFC-free refrigeration system for the warehouse in Chartham near Canterbury. The refrigeration experts International Controlled Atmosphere Storage and SRS Frigadon designed a propane secondary refrigerant system completed in 2008 with an output of 1,150 kW. Five air-cooled factory-assembled packages charged with altogether 90 kg propene provide refrigerating energy for the secondary circuit at a temperature of -9°C.

The special safe design of these chillers and a detailed safety analysis was provided by Re-phridge. A brine mixture of water and salt is used as the secondary refrigerant. The circuit is filled with 30,000 L and works at an operating pressure of only 1.5 bar to cool the heat transfer fluid down to -3°C. The brine is pumped to the 36 controlled-atmosphere cold storage rooms which are kept at a constant air temperature of -0.5°C and 1.5°C. The secondary refrigerant also cools the preparation and loading areas.

The evaporators in the warehouses are defrosted by off-cycle defrost. This entails interrupting the refrigeration process so that the brine absorbs heat from the ambient air which is used for defrosting. This method prevents the products being cooled from absorbing unnecessary heat and saves energy.

The system design minimises the quantity of refrigerant and guarantees an ESEER (European Seasonal Energy Efficiency Ratio) of more than 4.2, although based on local conditions, the real seasonal cooling COP (coefficient of performance) is around 6.

SUPPORTING BIOTECHNOLOGICAL RESEARCH

One important process in the research and production of biotechnological products is freezing and defrosting substances for transport and storage. At the pharmaceuticals company Roche, this takes place in tanks with a volume of 300 L which are cooled down to -40°C in a clean room atmosphere.

Here, the company wanted an efficient refrigeration system to cope with fast changes in temperature between -50 and 130°C with an accuracy of +/- 1 K, with automatic drainage and refilling of the tank’s cooling jacket.

Furthermore, compliance with the Roche Environment Protection Guidelines restricted the choice of refrigerants to substances that protect the ozone layer and the climate. To meet these requirements, Peter Huber Kältemaschinenbau developed a chiller that works with a small charge of 1.8 kg propene. The core element of the system is a two-stage semi-hermetic reciprocating Bitzer compressor, which is designed for use with propene. After being brought down to a temperature of -60 to -30°C, the propane then cools the silicone oil circulating in the cooling jacket. The output is 12 kW at a secondary refrigerant outlet temperature of 0°C, and 6.5 kW at -40°C. The safety concept of the system comprises separate refrigeration circuits into several sections so that in the event of a burst pipe, any refrigerant leak is limited to the affected section rather than the complete charge. Additional components in the refrigeration system, commissioned in 2006, include a plate heat exchanger acting as evaporator, a water-cooled coaxial condenser and a Modbus-based control unit.

AS SAFE AS REFUELLING STATIONS

“The case studies show that non-halogenated hydrocarbons are suitable for reliable refrigeration in many different branches,” says Monika Witt, Chairwoman of Eurammon, the European initiative for natural refrigerants.

“However, certain requirements have to be met when using these substances. Potential sources of ignition have to be identified and eliminated early during the planning phase. The systems have to be designed so as to avoid leaks: this includes reducing the number of joints and applying permanent corrosion protection. As far as possible, the refrigeration system should be installed on the roof or equipped with a gas detection and ventilation system so that the gas can be exhausted in the event of a leak. Components containing the refrigerant must be clearly marked as such, so that service technicians are informed accordingly and can take corresponding precautions. Good initial and advanced staff training plays a crucial role, as faulty maintenance is one of the greatest risks when operating refrigeration systems with hydrocarbons.”

Having said that, Witt rests her case when she points out: “But even if the flammability of hydrocarbons pose a challenge, these substances can still be handled safely, as demonstrated every day in thousands of refuelling stations all over the world.”

Presentation: “Improving Energy Efficiency in Refrigeration”, Jean- Luc Dupont, Head of the Scientific and Technical Information Department, International Institute of Refrigeration, Asgabat, March 1, 2007.

In view of the non-availability of potable water and the limited availability of treated sewage effluent for district cooling, should we intensify our gaze seawards? If so, what are the inherent challenges… and solutions?

With Government mandated non-availability of potable water for district cooling in Abu Dhabi and Dubai, and with questions being raised about the adequate availability of treated sewage effluent (TSE) and also the costs associated with polishing the water to acceptable standards, many experts have been advocating the use of seawater for a while now.

The question about the availability of TSE is a pertinent one, given that there is a demand for it for agricultural and horticultural uses. And then there is the cost. It is possible to purchase TSE at one-sixth of the cost of potable water, but there is a cost associated with treating it. A third issue involving TSE is drainage, or rather the lack of it, from a blow-down point of view. When viewed against the backdrop of these three factors, seawater is regarded as a strong option. Says Craig Thomas of High Performance Tube company, “Using seawater to reject heat, when feasible, will free up potable water and TSE for other more important uses.” Adds Greg Cox of Mott McDonald, who has had extensive experience with a successful seawater cooling regimen in Hong Kong: “There is a higher demand on TSE for irrigation, so seawater, although having lower cycles of concentration, could be the correct choice, considering that it has the lowest overall energy usage.”

The concept of seawater is not a new one. As Thomas says, while it is new to district cooling, it is not to other applications. Indeed, seawater has been used commonly in refineries and the petrochemical industries, LNG, power generation and thermal desalination. One of the success stories for seawater cooling is Jubail in Saudi Arabia, where the volume of water used equals two-third of the flow of the Tigris and the Euphrates rives combined. And as for the UAE, Fujairah has been using seawater since 1993, George Berbari of DC Pro Engineering, points out. “In Fujairah, we did district cooling with 2,000 TR that used seawater cooled with titanium and fibreglass tubes,” he says. Amar Farjo of JCI backs Berbari’s observation. “We need seawater cooling towers, because they can save 57,600 gallons of potable water per kilo of cooling every day,” Farjo says.

A GAMUT OF ISSUES

While there is a growing favour for seawater cooling in some circles, there are several aspects to consider. The various components – be they cooling towers, chillers, heat exchangers or intake systems – come with their attendant issues and challenges.

Cooling towers, for instance, come with a gamut of sub-issues. Typical questions revolve around the impact of seawater on the sizing of the cooling towers, the materials needed in building the towers and the environment around them.

Seawater impacts thermal performance in three ways, says Kent Martins of SPX Cooling Technologies. If seawater has 70,000 ppm of TDS, it lowers vapour pressure by five per cent, which is a negative impact, Martins says. The same seawater characteristic reduces specific heat (0.92 compared to 1 for freshwater). “The cooling tower,” he says, “must be sized three to seven per cent larger to compensate for the reduced heat transfer characteristics of seawater at 70,000 ppm TDS in circulation.”

When it comes to material selection for cooling towers, corrosion of compounds can occur. Fibreglass, Martins says, is a good material for seawater exposure. Likewise, concrete towers also hold good, he says, but they would require a specialty mix and rebar design. Generally speaking, he recommends premium hardware materials and coatings.

Another sub-issue is the drift from the cooling towers. Circulating water is distributed as droplets or films to maximise surface area. Exit water for cooling towers contains water vapour, drift droplets and condensate droplets. It, therefore, becomes essential to reduce drift, and for this, careful installation is of paramount importance. “It is crucial to reduce drift at the source with the best available drift eliminator,” Martins says. “That way, salt deposition will not be a major concern. Also, drift eliminator data should be specific to the distribution system used. Further, it would help to site the tower downstream from the prevailing wind direction and away from high-rise structures.”

Heat exchangers and chillers also come with a string of challenges, considering the corrosive nature of seawater. Newer plants use titanium to overcome the challenge of the aggressive nature of seawater. Earlier, coppernickel was widely prevalent, Thomas says, but it came to be found that copper is prone to erosion and washing away. Also, ammonia does not go well with any copper alloy, observes Farjo. In that context, he says, titanium is the “gold standard”. Though high on costs, it is immune to erosion and corrosion and has the longest life expectancy. Besides a corrosion point of view, there is also the conductivity point of view. Most other materials simply do not match up to titanium when considering resistance to corrosion and conductivity. For instance, the thermal conductivity of stainless steel is less than that of titanium.

Intake systems also have their attendant sub-issues, ranging from costs of installation and maintenance to environmental acceptability (safety of fish and fry, which are prone to getting sucked into the system). Screens and strainers are integral parts of intake systems. Says Daniel Bewg of GLV-EIMCO Water Technologies, “We put a screen before the cooling water pump and a strainer after it. Bewg says there are several factors to consider, be it to determine the method of filtration or the size of the intake channel. For instance, an important aspect to consider for filtration is the flow rate. A passive screen would work with a low flow rate (less than 0.1 m3/s). In the case of a medium flow rate (0.1 to 5 m3/s) or large flow rate (greater than 10 m3/s), Bewg says, bar filtration, and bar and screen filtration would serve the purpose.

Passive screens are prone to buildup of marine matter, mainly in the form of zebra mussels, because it is not possible to chlorinate the screens. To prevent the occurrence, it becomes necessary to coat them with a copper-nickel material.

The pipework walls are prone to mollusc and crustacean infestation due to the settlement of larvae. If not properly addressed, says Cox, they will dislodge when mature and collect in the condenser tubes.

In view of such factors, maintenance is of critical importance in a seawatercooling regimen, be it for intake systems or condenser tubes. Cox talks of the need for a proper maintenance framework and for involving a girth of experts, be it sustainability advisors, marine biologists, water treatment specialists, operators, manufacturers, cost consultants and legal professionals.

Seawater is the future, agree many in the district cooling fraternity, and is, perhaps, integral to ambitious coastal developments in the region. In view of that, they recommend prudent planning in developments to later accommodate a seawater-cooling regimen. Says Jamie Saunier of TAS: “If district cooling plants are built to accept TSE today, at some point in the future, if the Government implements seawater, then you would be faced with huge capital costs to convert or upgrade to seawater. So we are better off designing to accommodate later.”

Note: This article is based on the Sea Water District Cooling Symposium, on November 14, 2009, at Atlantis, Dubai. Despite extracting information from an event, held a few months ago, the author of this article, after ascertaining from the organiser, IMEC, guarantees that the statements and observations by the participants in the symposium are not outdated.

Story and pictures: B Surendar

For the chiller industry, downturn or not, the drive to produce more efficient and environmentally friendly chillers continues, especially from a green context, writes Jose Franco.

There is no question the demand for chillers is heading towards green territory. It is, therefore, proper and logical for manufacturers to invest in environmentally friendly units of the machine that can implement a variety of refrigerants. Innovative products are a must but not enough, to make a company maintain or increase sales volume, however. Tapping new markets is another great way of doing such.

“The challenges for companies include maintaining sales volume,” says Maged Makar, Head of the Product Engineering Department at Daikin McQuay Middle East. “And you can maintain sales volume by adding new markets.” Saudi Arabia is top on the list, what with its rapid urbanisation, high population and massive investments in various projects in the transport, education and healthcare sectors.

Abu Dhabi and the Northern Emirates and Qatar, Kuwait, Oman and Egypt are also on the list of Makar and other experts in the HVAC and refrigeration (HVAC&R) industry in the Middle East. These Arab states are seen either banking on the projected high oil export receipts and/ or reacting to a growing population and consumer demand by spending more on infrastructure projects and social developments.

Camels on Jumeirah Beach, in Dubai: The hot and humid climate in the Middle East is a challenge to chiller manufacturers to produce innovative products

UAE-based B S Prashanth, Regional Manager-Russian Federation at AHI Carrier, remarks, “Ours is a hot and humid climate, so there’s great requirement for cooling systems, including chillers with wide-ranging applications. Manufacturers need to continue making products that could withstand hot climate.” He mentions in particular the residential and commercial (office complexes) buildings in the Gulf as having the highest demand for chillers.

As early as two years ago, BSRIA, a UK-based construction and building services consultancy, predicted the central plant airconditioning market in Saudi Arabia to nearly triple in value by 2012. “Saudi Arabia and Egypt are promising markets for air conditioning products because of a hot climate and rapidly growing population,” it says in a white paper, titled, ‘Middle Eastern and Indian market for air-conditioning 2008’.

In the UAE, reciprocating chillers (which can serve the smallest loads efficiently) were noted to have continued their presence in the market, although the popularity of this type of compressors has been in decline, owing to increasing demand by district cooling for centrifugal chillers. The same report says the UAE would enjoy the greatest progress of all compressor types with an annual growth rate of 20%.

Centrifugal chillers, which are used to cool large buildings in a centralised air-conditioning system, and absorption chillers that utilise water as the refrigerant are also big business in Egypt, the Arab world’s most-populous nation where district cooling has been gaining popularity.

The global chiller market was valued at $1.9 billion as at 2008, BSRIA noted, with the Middle East and India region having the smallest share. The consultancy firm noted, however, of “significant markets” in India, the UAE and Saudi Arabia. “[O]verall the chiller market is expected to enjoy a slight increase over the next few years, although the growth rate will vary from country to country,” it says in an April 2009 article, published on its website. “Reciprocating compressors continue to disappear from the majority of markets, with the trend leaning towards scroll and screw compressors.”

In the Middle East, where the chiller sector is estimated to reach $500 million this year on a 15-20% increase, Makar says, Saudi Arabia will undoubtedly be the biggest market. He and Prashanth disagree with other experts and entrepreneurs who find it difficult to penetrate the Saudi market due to a number of reasons, including too much bureaucracy. “I don’t think there’s a big problem in Saudi,” Prashanth says. “Just look for a good partner, and you need to know the market and its people.”

Most companies engaged in HVAC&R, in fact, are either raring to enter the Saudi market or planning to expand operations in the Gulf country of over 27 million people. Daikin McQuay signed a new distribution agreement in Saudi after having a presence there for the past 10-15 years, and put up an office in Abu Dhabi this year, which will be launched next month. “We have good sales volume in Qatar, and we are increasing our market share there,” Makar says. “We also have good market share in Saudi, Abu Dhabi and Kuwait.”

All this is part of Daikin McQuay’s move to pursue further expansion and business partnerships across the region. Carrier, on the other hand, will continue to rely on its innovative products to maintain and advance its market share. Innovation is what most manufacturers have in their growth and expansion programme, with Daikin and McQuay recently putting up a $50-million research and development (R&D) centre, to develop and test newly created products, including chillers. It’s the world’s most advanced R&D centre dedicated to the HVAC industry.

In December, Daikin McQuay launched two new products – the air-cooled chiller and the magnetic bearing centrifugal chiller, which both boast highperformance and premium efficiency.

The first company to use magnetic bearing technology in the chiller sector in 2004, McQuay says the oil-free design eliminates the efficiency losses created by traditional compressors. Daikin McQuay is part of Daikin Europe, which operates under the umbrella of Daikin Industries. The global company posted about $13-billion turnover in 2009.

Chiller companies worldwide are seen to continue manufacturing products that could withstand hot climate, owing to the growing importance of the Middle East market, Prashanth says. It’s this same extreme heat across the Middle East, African countries and most parts of India which hampers the sales of moveable air conditioning units, according to BSRIA.

And due to pressure from environmental groups, Prashanth adds, one challenge to manufacturers that stands out among many is to produce chillers that are highly efficient with reduced carbon emission. This will be in line with the provisions found in the Kyoto Protocol, which deals with issues on global warming, and the move against refrigerants being called by the Montreal Protocol. The sector has already begun using environment friendly refrigerants.

After the annus horribilis that was 2009, the German HVACR industry is showing signs of getting on the growth path. Jose Franco reports.

In a scenario where every manufacturer or distributor is driving in search of better opportunities in the HVAC&R industry, it seems that all roads lead to the Arab world, particularly Saudi Arabia. And it seems that most products and technological know-how are coming from the West, especially Europe’s biggest economy, Germany.

It may have been overtaken by China as the world’s largest exporter, but Germany still stands tall among the highly developed nations for its high-quality products and industrial knowledge. So much so that it has tremendous experience and know-how to offer other countries, particularly the Gulf Arab states. This could be on various fields like engineering and solar energy.

Being the world’s top installer of photovoltaics, or the PV cells that help convert solar radiation into direct current electricity, Germany has a feed-in tariff for renewable energy. This tariff is a policy mechanism providing for the adoption of renewable energy sources towards grid parity, wherein electricity is equal to or cheaper than grid power.

This is one sector where the Germans could very well help the Gulf economies and the wider Middle East region, which has a year-round supply of strong sunlight. But there must be strong policy coming from governments. In the UAE, for instance, where electricity is cheaper relative to other economies outside the Gulf, government must lead the way for the development of solar energy projects by offering incentives to actual developers.

“Yes, Germany has a lot to offer when it comes to solar energy technology,” says Dubai-based Tarek Hourani, Technical Sales Manager of Al Sahoo Trading Company, whose business started off with plumbing equipment and has diversified into the HVAC&R industry. “But the UAE government has to dictate the development of the sector by targeting actual developers and offering them incentives, to advance this endeavour.” He has no immediate suggestions on the kind of incentives that could be made available to developers, however. But he says that in Europe, incentives for increased solar power use are in the form of lower taxes.

As stressed by Hourani, the UAE doesn’t have any project, save for the Abu Dhabi National Energy Company, or Masdar, which is devoted to advancing the development and use of solar energy. It’s unlike in other parts of the Middle East, such as Lebanon, Syria and Jordan where the sector is developed, owing perhaps to higher prices of power consumption.

German companies have lots to offer the Middle East market, all right, but they face the challenge of coming up with the same high-quality products with affordable prizes, owing to the slump in global trade. They need to invest more in research and development for traditional products in, say, the HVAC&R industry, but aiming for lower cheaper production.

“We see the trend going towards medium-size quality due to the economic crunch,” says Hourani. “This means a demand for innovative companies to use new technology in doing the same job and products at lower costs.”

Dubai-based Adel Kamel, Managing Director for the Middle East of Güntner, admits that German products are a bit pricey. “[O]ur price is the major challenge for customers to agree with,” he notes. “Yet we are an established and leading brand, not to mention a brand that’s constantly innovating, so customers know that they are getting value for their money.”

Germany has lost to China in world exports, with the latter breaking a 13-month decline in trade as a result of the global downturn. China’s state news agency, Xinhua reported in January that China’s exports rose 17.7% in December, with total exports for 2009 at $1.2 trillion (£749bn), though total foreign trade over the year was down 13.9%.

“It is safe to say now that Chinese exporters have come right through the period of weakness,” Xinhua quoted statistician, Huang Guohua as saying. The slowing decline in Chinese trade may also be a sign that its $586-billion stimulus package is working. As a country in the middle of transforming itself into a more modern and industrialised economy, China needs significant development. And experts say the country is fiscally strong enough to finance its plans for increased spending on infrastructure projects, as it sits on piles of cash.

Industrial production in Germany was also down 2.6% in December, owing partly to weaker production of cars and machinery. While a government’s car-scrapping bonus programme boosted car sales in the country for much of last year, this expired in September. Output in the construction sector was unfavourable as well, dropping by 2.6%. However, the German economy this year will climb by 1.4% – described by economists as a steady but unspectacular growth – as export markets pick up.

Another big challenge facing foreign HVAC&R manufacturers wanting to do business in the Middle East is the region’s climate, which has high temperatures during summer and is hot most of the year. Dust is another major concern for outdoor units as well as well as lowkey maintenance, Kamel says, while the lack of technical know-how on the part of the users is also a challenge that should be addressed through better customer service.

Noting that major refrigeration consultancies in the Middle East are foreignbased, Kamel says the lack of regional expertise hampers optimal and efficient designs. In a region where water is scarce, manufacturers should consider concerns on energy saving, carbon-footprint reduction and overall more eco-friendly systems. “Since water is in scarcity, we are seeing gradual changes in the market with regard to using water as a coolant,” he says. “Regions like Central Saudi Arabia are regulating this trend very effectively, and this is where dry-coolers come into the picture as major roleplayers.”

He, likewise, notes the current trend of refrigerants taking a turn to being less ozone-depleting, paving the way for increased usage of ammonia, which is a natural refrigerant. He also welcomes the fact that most warehouses for industrial refrigeration are increasingly investing in quality engineering to increase the systems’ lifespan, as they are undergoing complete automation.

“[W]e at Güntner believe deeply in continuous innovation,” he opines. “We recently launched our revolutionary condenser series named Microox, which is based on micro-channel head exchanger technology. “Compared to conventional fin and tube condensers, Microox is a whole new game altogether.” The firm’s new microox technology makes its condensers smaller but more efficient heat exchangers that have protection against galvanic corrosion.

Such German innovation is the stuff that the Middle East’s HVAC&R industry could possibly benefit from.

Stating that it intends to meet the demand for a product that combines comfort with tight control and high environmental quality, Trane has introduced active chilled beams with integrated controls to its Europe, Middle East, India and Africa markets.

According to Trane, the chilled beams are ideally suited for office buildings, hospitals, schools and airport terminals.

“Trane active chilled beams are designed to combine high output and low energy input,” said Jo De Clercq, air systems portfolio leader for Trane. “Providing comfort with tighter control, Trane chilled beams offer a tailored terminal solution to help meet specific customer needs and maximise their system performance.”

According to Trane, the units are designed to integrate into ceiling systems, as well as exposed surface mounted units that can incorporate lighting. The latest version, scheduled to be released during the first quarter of 2010, will include electrical heaters. The product also allows for site flexibility. Length and width are variable to adapt to different construction standards. Four widths (300, 600, 625 or 675 mm) and 15 lengths ranging from 1,200 to 3,600mm are available. The units, which can be fitted together to ensure aesthetic consistency, are installed in such a way that they do not hinder any future section-wall removals or additions. Also, they can be used in combination with green technologies such as free cooling, heat recovery and ground source water systems. This technology conforms to district cooling and heating distribution requirements, added Trane.

The active chilled beams incorporate the following features:

Compact ceiling or surface-mounted units with two or four pipe coils providing both heating and cooling.

Unlike passive chilled beams, active chilled beams have an integral constant air-flow supply passing through nozzles, which induce air from the space up through the cooling or heating coil.

The filtered air allows for improved control of temperature and humidity, generating better indoor air quality.

Trane’s ZN523 zone controls are factory- mounted onto the chilled beams units, pre-configured and tested to meet the requirements of their specific application. This minimises time spent coordinating control integration before or during installation.

Energy efficiency is inherent to the chilled beams technology, which requires higher chilled water and lower hot water temperatures than conventional terminal units, allowing for primary airflow temperatures closer to ambient.

In combination with a variable speed pump, additional energy savings can be achieved.

Pointing out that cooling ceilings and other critical areas in HVAC and technical installations, which are operating close to the dewpoint temperature, need an early alarm system against moisture formation, because of potential danger of condensation, E+E Elektronik has introduced the specially designed Condensation Monitor EE46. The product helps early detection of condensation so that immediate countermeasures can be taken, claim the manufacturers, and add that it can be installed in a few seconds on pipelines, walls and ceilings.

According E+E Elektronik, a special coating protects the sensor and electronics against dirt and dust, thus ensuring a long-lasting , stable and maintenance-free operation. It is designed to be powered by 24 V ac/dc, They explain how it works:

• The fast-response E+E humidity sensor is exposed to the temperature of the surface of the object by means of a thermal conducting foil.
• Therefore, the humidity sensor measures the same relative humidity as is present at the surface of the object to be monitored.
• If the preset set point of 90%RH is exceeded, the monitor switches a potential free contact and provides a signal, facilitating taking countermeasures, for example, to increase the temperature of the water in the pipe, to decrease the cooling power or to turn on the heat.
• In addition, a LED on the enclosure indicates the actual status.

Introducing a new line of energy-efficient potable water recirculator pumps, Bell & Gossett say that the use of a revolutionary technology helps achieve significant energy savings while delivering instant hot water to every faucet.

According the manufacturers, featuring ECM (Electronically Commutated Motor) technology and a patented spherical motor design, eliminates the need for a conventional shaft, seal and bearing assembly. The rotor/impeller is the only moving part in the entire pump and it is magnetically balanced on a stationery ceramic bearing inside the pump housing to provide silent, long-lasting operation.

This design allows the ecocirc to use 68% less energy than most standard pumps and can save an average family of four more than 12,000 gallons of water a year by eliminating the need to wait for hot water to reach the plumbing fixture, claim Bell & Gossett. Using only 10 watts of power, the equivalent of a small nightlight, the ecocirc can save a home owner hundreds of dollars in energy costs a year, they add.

Other special features include:

• Maintenance-free, long-lasting operation
• Seal-less and leak-free
• Resistant to scale build-up, ensuring optimal flow
• Only self-realigning bearing in the small pump market
• Self-lubricating and automatically cooled by pump media
• Resin-encompassed stators eliminate corrosion
• Energy savings pay back the cost of the pump within months
• The magnetically centred rotor can tilt to avoid small particles
• Built-in temperature sensor automatically adjusts frequency and voltage
• Built-in 24 hour timer
• Motor is separated from wetted parts by a stainless steel partition
• Superior starting torque
• Easy to install

The recirculator pump is also available with a timer module that adapts to all ecocirc circulators. The plug-in timer design makes it possible to convert the pump to a timer- controlled unit for greater energy savings.

According to Bell & Gossett, it acquired the technology in 2009 when ITT purchased German pump manufacturer Laing GmbH – a producer of energyefficient circulator pumps used in residential and commercial plumbing and HVAC systems.

Driven by government regulations, the European market has more stringent energy standards that require more technologically advanced pumps.

“The ecocirc demonstrates ITT’s ongoing commitment to more energyefficient products for plumbing and HVAC systems,” said Monica Levy, Director of Communications at ITT’s Residential and Commercial business.

“We are excited about expanding this platform of products going forward.”

A fledgling recovery in the US market fuels a healthy attendance at the AHR Expo

2010 AHR Expo

Signs of a recovering economy was a key view from many interviewed as to the main reason for the attendees at the 2010 AHR Expo, from January 25 to 27, at the Orange County Convention Center, Orlando, Florida. According to the organisers, nearly 45,000 attendees and exhibitors filled the aisles during the Expo. They came from 120 different countries to see hundreds innovative products on display from 1,823 exhibiting companies. More than 200 companies were first-time exhibitors at the AHR Expo. According to the organisers, the 28,582 registered visitors, a nearly 8% increase from the 2005 AHR Expo in Orlando, set a new record for Southeast HVAC/R shows.

Clay Stevens, president of International Exposition Company, which produces and manages the AHR Expo, attributed much of the show’s success to an improving economy and the huge amount of valuable information offered at the event. “There is great interest and demand for ‘green’/ sustainable products and technologies,” Stevens said.

“Hundreds of exhibitors were featuring energy-efficient solutions and we offered a variety of educational sessions built around these interests.” The following were the show highlights:

• Several ‘Green’ features and educational sessions

• The International Energy Agency sponsored, for the first time a workshop on Solar Air-Conditioning and Refrigeration

• LEED half-day workshops, presented by the US Green Building Council provided practical knowledge on how to be an essential and knowledgeable part of a LEED team and how to manage a LEED project from the first client meeting to final certification

• Energy Star Your Customer’s Path to Green, Sustainable Buildings, presented by the US EPA’s Energy Star Programme

• PM Live: Hydronic Design for Solar & Geothermal Heat Pump Systems, John Siegenthaler, Hydronics Editor of PM Magazine discussed the essentials of successful solar combisystem design

• The presentation of the AHR Expo Innovation Awards. Nine category-winners received the first place honour, while 32 companies were awarded Honourable Mention. Danfoss won the AHR Expo Product of the Year Award for their Performer VSD, a variable speed compressor for residential use.

• Nearly $11,000 in entry fees from the 2010 AHR Expo Innovation Awards Competition was given to the Jacksonville Police Athletic League (JAXPAL) to help install a new HVAC control system

• Powering the Smart Grid with the LonWorks Technology and RF Wireless Technology, presented by LonMark Americas

• Introduction to Cloud Services for Buildings, presented by Ken Sinclair, Editor/Owner of www. automatedbuildings.com According to the organisers, the 2011 AHR Expo will be held in Las Vegas, from January 31 to February 2, 2011.
What they said:

“We are very happy with the traffic. It was more than we expected, given the current economy. There has been a lot of interest in our new high-efficiency commercial product.”
– April Johnson, Marketing Director, Weil McClain

“We got tonnes of good leads, and the traffic was great. This show has the best ROI of any show we do in this industry.”
– Martin Dingman, Product Manager, Siemens

“Traffic was heavy from the very beginning. The quality was great. We saw a lot of engineers.”
– Mark Adams, Channel Development Manager for Florida Schneider Electric

“A lot of interest in new products, and we saw a lot of manufacturer reps.”
– Tom Petersen, VP Sales & Marketing, Mars Air Systems

“It was absolutely fantastic! We couldn’t have been happier. There was tonnes of interest in our new software.”
– Jackie Catalano, Marketing Communications Manager, Emerson

“It started off with a bang and stayed steady all show long. We’re as happy as can be with the traffic we saw. We introduced a new product and received more leads than we did all of last year – and last year was a good show.”
– Lou Laroche, National Sales Manager, Airtec

“The aisles were flooded. There was a steady flow of people, and we got quality leads.”
– Gene Ziegler, Regional Manager, Daikin AC

“We were impressed! We were a bit pessimistic, but the first-day traffic was steady, and there seems to have been a lot of international visitors.”
Steven Junge, President, – Lattner Boiler Manufacturing Company

“It was a good first day. We saw a good mixture of engineers and contractors. There is a lot of interest in our new energy-efficient products.”
– Mark Handzel, National Sales, ITT R&CW

“We were seeing people from a variety of places and diverse industry sectors. People visiting our booth really liked all our options. They saw what we had and got excited about how to use it in their own business. It’s obvious attendance was much higher at this year’s Expo. We’re busy nonstop, which is just the way we like it!”
– Todd Strem, Sales & Marketing Manager, WoodMaster

“The diversity in attendance at the Show was exceptional, especially the number of international visitors. We saw the buying behaviour improve from a lot of kicking the tyres last year to a much more significant resource commitment here in Orlando, which was critical to the success with the introduction of our new RIGIDconnect online business tool. We were extremely pleased!”
Steve Dyer, Director of Marketing, RIDGID

“The Show was great. We saw a lot more foot traffic in our booth, especially local contractors and applied distributors. Our broad product displays and minivignettes really helped us tell the complete story of LG’s offerings.”
– Kelly Cutchins, VP Commercial Air Conditioning, LG Electronics

“We heard from many attendees in our booth that our variable speed compressors are the “wave of the future”, and that to see the wave of the future you need to attend the AHR Expo. It’s the Show you want to have your products at, if you want to be positioned for meeting the needs of the industry, now and going forward.”
– Steve Hamlin, Sales Group Manager, Panasonic

“As a first-time exhibitor, this was incredible for us. As a new company looking to meet customers, AHR Expo brings the largest and most knowledgeable crowds. This was a perfect fit.”
– Ben Pierce, Customer Service Manager, Clean Alert

“We saw a lot of interest in renewable and comfort systems from all areas, and good engineering contacts, who have an appreciation for quality, and proven, truly sustainable systems. People who came to the booth understand the importance of the ‘whole systems’ approach to sustainable building, and are eager to work with us on making it happen.”
– Bill Johansen, Business Unit Manager, Building Technology, REHAU

“We were very pleased with the show this year. Visitors to our booth were very interested in retrofitting old buildings to enable energy savings. The consumer is searching for low-cost and minimal-disruption solutions, and we heard that over and over. It’s these timely topics and offerings that attendees hear about and see at the AHR Expo.”
– Harry Sim, CEO, Cypress Envirosystems

“We chose AHR to introduce the Premier VS-VH high efficiency heating system because the Expo is recognised as North America’s most significant HVAC/R show. We consider this to be our best show yet!”
– Susan Samson, Marketing Manager with Superior Radiant Products

ASHRAE EFC meeting focuses on sustainability by casting the spotlight on building codes and on CHP systems.

The ASHRAE Emirates Falcon Chapter on February 17 reiterated the importance that sustainability deserves by hosting a presentation on building codes, followed by a presentation on CHP systems. The Chapter meeting took place at the Arjaan Rotana, Dubai.

Matthew Plumbridge

It was Matthew Plumbridge, Consultant (Environmental and Sustainability Planning) from the Department of Municipal Affairs, Abu Dhabi, who spoke on building codes. In his presentation, Plumbridge spoke of the International Energy Conservation Code, be it from the point of view of mechanical systems or in terms of lighting. In the case of mechanical systems, Plumbridge said, it was important to consider such factors as right-sizing the plant and equipment, energy recovery, set point and controls. And in the case of lighting, Plumbridge said, it was important to look at daylighting zones and lighting density for external and internal features.

In view of the fact that local conditions were different, Plumbridge said that the Abu Dhabi body was looking to develop the codes further. “In the local context, for instance,” Plumbridge said, “it is important to consider district cooling demand management.” District cooling, he said, was less efficient, owing to unknown demand. In that context, he spoke of establishing supply water temperature at 4ºC to manage risk and 50 square metres per tonne of refrigeration as a benchmark that could be achieved.

He further said that while with the subject of chilled water, it would be sensible to wonder whether or not we could engage in energy recovery from condensate water. “It is 13ºC water,” Plumbridge said, asking, “Instead of just using the water, why not use energy (chilled), as well?

In his presentation, Plumbridge spoke of a code for improving IAQ and for reducing carbon emissions. While drawing the code, he said, it would be useful to consider such factors as natural ventilation, ventilation rate, outdoor air percentage and TES.

Ainul Abedin, Principal Consultant at Ainul Abedin Consulting, who spoke next, conducted a masterclass on CHP/cogen systems, in the process sharing his decades long experience.

In his presentation, Abedin said that CHP feasibility and design depended on magnitude, duration, and electrical and thermal loads. Matching a CHP plant’s heat/ power ratio with that of building or process load, he said, was required for optimum economic benefit. That, he added, was a major challenge for HVAC engineers.

Getting into the nittygritty, Abedin said that the form and quality of the required thermal energy was important. If more highpressure steam was required, a reciprocating engine was less attractive as a thermal source than a combustion engine.

Ainul Abedin

Saying that CHP/cogen power plants were rated against incremental heat rates (fuel input) by comparing incremental fuel requirements with base case energy needs of a particular site, and that fuel consumption was the greatest contributor to operating costs, Abedin went into an elaborate description of reciprocating engines.

All recip engines, Abedin said, required clean and cool air for optimum performance. In that context, he added, it was crucial to avoid heated air, because power output dropped with a rise in engine temperature.

Quoting from experience, Abedin said that reciprocating engines had special requirements. For instance, he said, installing a separate exhaust for each engine reduced the possibility of condensation in the engine that was not running. Equally important, he said, was to allow for thermal expansion in exhaust piping (about 0.09 inches per foot). Further, he said, it would help to slope the exhaust away from the engine to prevent condensate back flow.

Speaking, then, on combustion turbines, Abedin said that they had been developed for stationary use as prime movers. Advantages of combustion turbine design, he said, included dual-fuel design; ability to meet stringent pollution standards; lack of necessity of cooling water; clean, dry exhaust; and lesser lubricating oil consumption.

On the flip side, a key disadvantage, he said, included a possible lower efficiency. “Also each 18F rise in inlet temperature decreases power output by nine per cent,” he said.

With the stage set, Abedin lapsed into a discussion on combustion turbine inlet air cooling (CTIAC) systems, which he said, increased the capacity and the efficiency of the turbine by increasing air density. Speaking of the importance of a CTIAC system, Abedin said, “When you need maximum power in summer, it derates by 30-40%; CTIAC helps to prevent this.”

Speaking, then, on the economics of CHP, Abedin said it was based on cost of equipment, installation, and operations and maintenance. For a CHP project assessment, Abedin highlighted the importance of a preliminary screening analysis, for simple payback, and a feasibility analysis, which consisted of energy analysis, conceptual development and financial analysis.

Nearly $11,000 entry fee presented to the Jacksonville Police Athletic League (JAXPAL) to help install a new HVAC control system.

Danfoss’ Performer VSD, a variable speed compressor for residential use, was selected as the AHR Expo Product of the Year Award. The award ceremony was held during the 62nd AHR Expo, that took place from January 25 to 27, at the Orange County Convention Center, Orlando, Florida.

The Performer VSD was chosen from among the nine category-winners of the 2010 AHR Expo Innovation Awards – an industry-wide competition designed to promote and encourage product innovation. Danfoss won the award in the Green Building category, and then was selected from among the nine winners to earn the final award. Thirty-two products received honourable mentions.

“We are proud to receive this award because it is welcome proof of the continuing Danfoss commitment to energy efficiency achieved through engineering innovation,” said Stephen Gugliotta, Director of Sales for Danfoss Air Conditioning.

The 2010 AHR Expo Innovation Award entry fees totalling nearly $11,000, was presented to the Jacksonville Police Athletic League (JAXPAL) to help install a new HVAC control system.

Since 2004, more than $45,000 has been donated to vocational schools and humanitarian projects for communities in states where the show is held.

“The AHR Expo Innovation Awards programme provides a unique opportunity to honour companies for their commitment to innovation, while also providing funds to organisations dedicated to helping others,” said Clay Stevens, President of International Exposition Company (IEC), the organiser of the AHR Expo.

The Innovation Awards are jointly sponsored by the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE); the Air- Conditioning, Heating and Refrigeration Institute (AHRI); and IEC.