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1 STEM038 ver.n-1.1, ANSÖKAN OM FORSKNINGSSTÖD Datum Dnr 1 (8) Projektnr Sökande Företag/organisation Organisationsnummer KTH, Kungliga Tekniska Högskolan Institution/avdelning Postgiro/Bankgiro/Bankkonto Energiteknik, Avd. Tillämpad Termodynamik och Kylteknik PG: , BG: Postadress Brinellvägen 68 Postnummer Ort Länskod Kommunkod Land Stockholm Sverige Projektledare (förnamn, efternamn) Samer Sawalha Telefon E-postadress Samer.sawalha@energy.kth.se Eventuell medsökande (ange organisation) Fax Webbplats Projektet Ansökan avser nytt projekt Fortsättning på tidigare projekt, ange projektnummer: Projekttitel (på svenska) Utvärdering av kyl- och värmesystem i livsmedelsbutiker genom fältmätning och modellering Projekttitel (på engelska) A comprehensive evaluation of refrigeration and heating systems in supermarkets based on field measurements and modelling Sammanfattning (på svenska). Sammanfattningen skall omfatta max 250 ord och skall skrivas både på svenska och på engelska. Sammanfattningen skall skrivas så att den i ämnet oinvigde med lätthet förstår projektets innehåll och syfte. Detta projekt behandlar kartläggning, mätning och utvärdering av kyl- och värmesystem i livsmedelsbutiker. Fokus kommer att ligga på transkritiska CO2-system och kaskadlösningar. Tillgängliga lösningar på marknaden kommer att kartläggas, förslag till förbättringar kommer att läggas fram och nya systemlösningar kommer att föreslås. CO2-lösningar kommer att jämföras med andra nya och konventionella alternativ. Projektet kommer att inkludera en utvärdering och analys av möjligheterna att utnyttja kylsystem för uppvärmning, samt modellering av systemens huvudkomponenter. Det kommer också att inkludera en utvärdering av värme- och kylbehov i livsmedelsbutiker baserad på fältmätningar och på simuleringar av representativa fall. Projektet kommer att utnyttja information från den databank som skapats i tidigare fältmätningsprojekt för att genomföra mer detaljerade analyser med fokus på komponentprestanda, parasitisk energiförbrukning, bättre förståelse för systemkontrollen. Inom projektet kommer också att upprättas handledning för hur kylsystem bör instrumenteras och för hur olika analysmetoder ska förstås. Enkla indikatorer för prestanda kommer också att ges. Sekretariatet EFFSYS+ Institutionen för Energiteknik Avdelningen Tillämpad termodynamik och kylteknik Kungliga Tekniska Högskolan Stockholm Besöksadress Brinellvägen 68 Telefax E-post Effsysplus@energy.kth.se

2 Datum 2 (8) I samarbete med de inblandade företagen, inkluderande de stora tillverkarna, grossisterna och användarna på fältet, kommer en state of the art butikskylanläggning med värmeåtervinning att byggas. Forskarna i projektet kommer att vara inblandade i ett tidigt skede av systemutformningen. Systemet kommer att vara välinstrumenterat för att underlätta analysen, och dess prestanda kommer att jämföras med de andra system som utvärderats i tidigare faser av studien. Projektet är en fortsättning på en forskningsaktivitet som pågått inom ramen för olika svenska projekt sen En stor fördel är att samma huvudpersoner funnits med i projektet hela tiden och historien har bevarats. Forskargruppen är den enda i Sverige som bedriver forskning inom detta område, CO2-teknik med inriktning mot butikssystem. Teknikområdet har en mycket snabb utveckling och respresenterar en stor kommersiell potential för tillverkare och installatörer, både nationellt och internationellt. Sammanfattning på engelska enligt ovan (max 250 ord). This project investigates the performance of new vapour compression system solutions for heating and refrigerating needs in supermarkets. Focus will be on CO2 trans-critical and cascade solutions, the available solutions in the market will be investigated, suggestions for system modifications and optimization will be made, and new system solutions will be suggested. The investigations in this project will be done on several levels; it will include general analysis of the vapour compression systems for heating and cooling needs and will investigate the performance of main system components. It will also include evaluation of the heating and cooling demands in supermarkets by surveying field installations and by performing calculations for representative cases. This project will use the data bank created in earlier supermarket field test projects to perform more detailed analysis focusing on components performance, parasites energy consumption, and understand systems control. The project will also provide guidelines on how to instrument refrigeration systems and to explain the different analysis methods. Simple indicators of performance will be also provided. In cooperation with the involved companies which include major manufacturers, suppliers and consumers in the field, a state of the art supermarket refrigeration system with heat recovery will be built. The researchers in this project will be involved at the early stages of system design; the system will be properly instrumented, analyzed and compared to the rest of the systems included in earlier stages of the study. Enskilt projekt Datum för projektstart Forskningsprogram, ange vilket: EFFSYS Totalt sökt belopp kr Tidpunkt då projektet beräknas vara genomfört

3 Datum 3 (8) Motivering; Energi-/miljö-/näringslivsrelevans, max 250 ord. Ange koppling till resultat från tidigare genomfört program eller projekt. The number of supermarket installations is constantly increasing, at the same time the available solutions for refrigerating and heating in supermarkets has also increased in recent years, especially CO2 based solutions. This is mainly due to the regulations on the use of synthetic refrigerants and due to the constant strives for energy saving. This is an extension of the work that that started already back in 2004 as cooperation between KTH and IUC. Vast amounts of experience in systems, components and methods have been gained through out the years. It is unique that a research team has worked together for such a long time in so many different projects. In a Swedish context it has been very valuable that this group as the only one in Sweden has gathered and spread information in this important field. In a previous recent project titled Field Tests of Supermarket Refrigeration Systems, managed by IUC- SEK, a data bank of 11 supermarkets has been created which contains a huge amount of valuable information, for instance, about the components performance, control strategies, and system losses that were not possible to extract during the project period. In an Effsys2 project titled Investigations of Heat Recovery in Different Refrigeration System Solutions in Supermarkets run by KTH, different heat recovery solutions have been investigated with focus on CO2 trans-critical systems. The results in the project showed significant advantages of using CO2 for heat recovery in supermarket applications. However, the work in the project was mostly based on computer simulation modelling due to the practical difficulties of performing field measurements on the heating systems and the difficulties in evaluating the heating loads in the supermarket installations. There are many sources of information about the new solutions for supermarket refrigeration and heat recovery with different, many times contradicting, indication on efficiencies. Supermarket refrigeration and heat recovery solutions are complex systems and there is an essential need for detailed analysis and clear guidelines of how to instrument and compare systems. The work done already and proposed in this project is unique on the international level in this field and will strengthen the competence of Swedish researchers and companies on the international level. Bakgrund; vad har gjorts tidigare?, vad är nytt i detta projekt?, forskargruppens verksamhet?, samarbeten? etc, max 1 A4-sida There is an essential need for detailed analysis of the new system solutions for supermarket refrigeration and heat recovery. This should include investigations of the performance of the systems as a whole, and further looking at the details of the system performance such as the components performance, control strategies and system losses. In close cooperation between IUC-SEK and KTH and co-financing by Energimyndigheten, field measurements in supermarkets project has been running for the last three years. Data of 11 supermarkets have been collected for periods of up to two years. The general performance of the systems has been analyzed. Heat recovery comparison between the systems has not been included in the project; however, in an Effsys2 project ran at KTH heat recovery has been investigated, mostly theoretically, for different system solutions, limited field measurements have been performed due to the difficulty of performing measurements on the heating needs in the supermarkets. In the two projects computer models have been created to simulate the performance of each system in the studies. In the two previous supermarket projects at IUC-SEK and KTH, a data bank has been created for all systems for periods varying between several months and two years. It contains significant amount of

4 Datum 4 (8) information that can be extracted; such as components performance, system/components control, and system losses. A main challenge working with field measurements data bank is to have continuity in the work, interruptions makes it very hard to re-start working with the analysis and handing over the task from one researcher to another is a time consuming process with high risk of making mistakes. Therefore, a long term project with main researcher, PhD student, is the best way to handle such a complex task. The field installations were not specially instrumented for the field measurement project and it has been noticed that the systems have extensive measuring points but in most of the cases key parameters needed for the energetic analysis of the system is missing. This project aims at providing guidelines for how to instrument supermarket installations to facilitate the evaluation of the refrigeration and heat recovery systems. The project will also provide guidelines of the different methods that can be used for the system evaluation. For installations that lack the proper instrumentations, guidelines for simplified indicators to estimate the performance will be provided. The complexity of this task rises from the fact that there are several concepts for refrigeration and heat recovery where each system will have different measurements requirements, analysis method and indicators of performance. Using the collected data from different system solutions, different manufacturers and system requirements, the control strategies applied in the different solutions will be extracted and evaluated. Using the available computer simulation models for a parametric evaluation in the different systems new control strategies will be suggested. The results from the Effsys2 heat recovery project stressed the importance of the good control strategy for CO2 trans-critical system in order to become a good solution for simultaneous heating and cooling in supermarkets. In the heat recovery project a CO2 test have been built and fully instrumented. The test rig have been used for components testing, mainly heat exchangers and compressor. The test rig is a permanent installation at the laboratory of the Energy Technology Department at KTH and will be used for further components testing within the project and for evaluation of different control techniques for heat recovery. For the best use of the experiences and knowledge accumulated in this project, a state-of-the-art supermarket system solution will be built in cooperation with the involved companies. The system will cover the simultaneous heating and cooling needs in the supermarket and will be fully instrumented. The performance of the system will be analyzed and compared to a developed computer simulation model. The Energy Technology Department at KTH has a long experience in working with supermarkets refrigeration. Samer Sawalha produced a PhD thesis titled CO2 in Supermarket Refrigeration and has been working in close cooperation with Jörgen Rogstam who managed the field measurements project and has long experience in testing refrigeration system, especially CO2 related research. A PhD student will have the major task of conducting the research activities in the project.

5 Datum 5 (8) Mål; Ange enkla, tydliga och mätbara mål i exempelvis kwh, max 250 ord. This objective of this project is to investigate and improve the performance of new vapour compression system solutions for combined refrigerating and heating needs in supermarkets. Focus will be on CO2 trans-critical and cascade solutions, the available solutions in the market will be investigated, suggestions for system modifications and optimization will be made. The comparison between the systems in the field measurement projects showed that an advanced conventional system has about 20% higher cooling COP than a comparable trans-critical CO2 system. However, the theoretical analysis of the systems showed that with minor system modifications and better control of the CO2 system the cooling COP of both systems will be on the same level, this has been partly verified by field measurements of new systems. The CO2-systems should benefit from lower parasite losses due to absence of pumps on for the secondary refrigerant and the coolant. Potentially the condensers/gas coolers may use less fan power due to higher temperature difference to the ambient air. These factors should be analysed since they are key drivers to justify the use of CO2 although it may look, from a first glance, like a less efficient solution. When taking the heat recovery into account it was found that with proper control the trans-critical CO2 systems have the lowest energy consumption in providing the required heating and cooling in an average size supermarket. The comparison was made with many refrigeration and heating system alternatives. This was based on computer simulation models calculations where this project aims at verifying the findings experimentally and from the field measurements. A major output of the project is to participate in building and analyzing a state-of-the-art refrigeration system based on the accumulated knowledge in this and previous projects. Significant energy saving are expected in the proposed system which will contribute to minimizing the direct and indirect impact on the environment from the supermarket refrigeration applications. Condensed project deliveries Secure the knowledge gathered in different Swedish project in this field the last 7 years by allowing two senior researchers to be engaged in the project. Produce one PhD within the project. Follow the international development in the CO2-field and report back to the Swedish market. Develop and propose standardised methods for field measurements and evaluation of supermarket refrigeration and heat recovery systems. Identify good and relevant indicators for system and component comparison. Distinguish the energy usage in the CO2 system compared to conventional such as parasites, defrost need, etc. Collect information and experience from systems with different defrost methods i.e. electrical defrost and hot gas defrost. Establish the importance of appropriate (adapted) heat exchangers for CO2-systems. Refine an existing simulation model to allow comparison of supermarket energy systems. Contribute to one state of the art supermarket by close cooperation with the project partners. Bring hard facts from the field measurements into the research. Extend the number of investigated supermarkets from 11 today to 25 in 3 years. Compare control strategies for heat recovery. Produce a basis for developing guidelines in heat recovery system design.

6 Datum 6 (8) Genomförande, max 250 ord. The project activities will be based on several unique resources accumulated from the previous work in supermarket refrigeration. Hence, the plan is to allow Samer Sawalha, Jörgen Rogstam and Jaime Arias to take active part in the project to guarantee the continuity of the collected knowledge in previous projects financed by the Swedish Energy Agency and Kylbranschens Samarbetsstiftelse, KYS. Samer Sawalha will act project manager with Jörgen Rogstam as assisting. Jaime Arias will be a part of the project team contributing with his unique modelling experience. A PhD student will be hired for the job and there is already a good candidate identified. All 4 mentioned key resources represent KTH employees where Sawalha and Arias are post docs and senior researchers and Rogstam and potential PhD student are PhD students. A good network exist after the previous projects mentioned above, implying working routines for the cooperation already exists. This includes the contacts with the partners as well as that they are familiar with the methods and the history. The project will consist of the following main activities: 1. Extensive literature survey will be conducted. Cases and system solutions in several countries will be studied, for example: Denmark, Norway, Germany, Canada, Netherlands, and UK. 2. Survey will be conducted among major suppliers and consumers in order to define the heating and cooling needs in supermarkets. 3. Process the available data from the field measurements projects in order to evaluate the performance of key system components in different system solutions. Evaluate the system losses and understand the system control. 4. Experimentally investigate the performance of selected components and evaluate the different control strategies 5. Produce guidelines for how to instrument and analyze supermarket refrigeration systems. 6. Perform field measurements and build computer simulation models of different refrigeration and heat recovery systems. In this project more instrumentation will be installed to obtain detailed information about the performance of system components that were not possible to evaluate in the earlier projects, such as the power consumption of pumps, dry cooler, gas cooler, defrost, cabinets, etc. 7. Participate in designing, instrument and analyzing a state-of-the-art refrigeration system covering the simultaneous heating and cooling needs in the supermarket. Results of the project will be published in local and international conferences and journals. Periodical reports will be produced and the project will be concluded with producing a PhD thesis.

7 Datum 7 (8) Kostnader Projektets totala kostnad Projektets totala kostnader per år % av heltid KALENDERÅR Lönekostnader Laboratoriekostnad Datorkostnad Utrustning Material Resor Övriga kostnader Ev förvaltningskostnader SUMMA Finansiering inkl. samfinansiärer Andel i kronor och procent av projektets totala kostnader/år FINANSIÄR År År Total (%) Effsys Kylbranschens Samarbetsstiftelse Green & Cool Carrier Ref Huurre ICA Sverige AB Ahlsell Kyl AB Wica Cold AB IWMAC Alfa Laval Cupori SUMMA Detta projekt är i sin helhet i vissa delar lika med ansökan till annan myndighet, ange vilken: Sökt stöd för dyr utrustning (Vetenskapsrådet, Wallenbergsstiftelsen e.d.) Gäller endast högskola. Namn på doktorand Namn på doktorand Namn på doktorand Namn på doktorand Övriga samarbetspartners (ange organisation och namn) Jörgen Rogstam är engagerad som forskarstuderande vid KTH. Även om inte samfinansieringen i skrivande stund är helt låst kommer sannolikt de 4 parterna KYS, Green & Cool, Carrier Ref och Huurre att bidra med kontanta medel upp till kr.

8 Datum 8 (8) Resultatredovisning (ange här om resultatet kommer att redovisas på något ytterligare sätt än det obligatoriska, se information). Bilagor Intyg med underskrifter från samfinansiärer Gantt-schema Övriga bilagor Datum Datum Behörig firmatecknares (prefekt motsv.) underskrift Projektledarens underskrift Namnförtydligande, titel och telefon Björn Palm, Professor, Namnförtydligande och titel Samer Sawalha, Research Assistant

9 Bilaga Gantt, Utvärdering av kyl- och värmesystem i livsmedelsbutiker genom fältmätning och modellering Analys av kyl- och värmesystem i livsmedelsbutiker genom fältmätning och modellering År Aktivitet/Kvartal 1 Litteraturstudier 2 Statistikinsamling 3 Fältmätning/databehandling 4 Utvärdering av fältmätningar 5 Metodutveckling std fältmätning 6 Simuleringsmodell - utveckling 7 Projektering "state of the art" 8 Delrapporter 9 Handledning för värmeåtervinning 10 Slutrapportering Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2

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