German manufacturer GEA Group has reported a 100K (100°C/180°F) temperature lift with a cascade ammonia (R717)/water (R718) industrial heat pump system, significantly reducing CO2e emissions and improving energy efficiency compared to conventional gas heating.
Kenneth Hoffman, Product Manager of GEA, unveiled these findings at the 10th International Institute of Refrigeration (IIR) conference held in Ohrid, North Macedonia, April 27–29.
“Many industrial processes’ energy demand cannot be fulfilled with outlet temperature below 100°C [292°F]; to address high customer demand, temperature lifts above this limit is necessary.” Hoffman stated,
Looking at different refrigerant alternatives, Hoffman found that R718 “seemed to outperform any other refrigerants, performing with an isentropic efficiency exceeding 80%.”
The cascade system uses ammonia in the low-stage and water in the high-stage cycle, which results in a 100°C (180°F) temperature lift (from 40°C/104°F at the lower stage to 140°C/284°F in the outlet temperature of the higher stage). Notably, it can offer a cooling capacity of 1,964kW (558.45TR) and a heating capacity of 2,730kW (776.26TR) at an evaporation temperature of 38°C (100°F) while consuming total power of 1,089kW. This results in a COP of 2.5.
A Pathway to Carbon Neutrality
The new ammonia and water cascade mechanism holds promise for an organization seeking to reduce its carbon footprint. “At present, many customers prioritize maintaining their operational cost and achieving carbon neutrality over immediate payback,” said Hoffman.
This new heat pump could decrease yearly CO2e emissions by 1,531 metric tons compared to natural gas heating. If the heat pump is powered by renewable electricity, it could result in zero CO2e emissions. Moreover, the system’s yearly cost is lower than that of natural gas heating, further solidifying its environmental and economic benefits.
“GEA continues its quest for even higher temperature lifts, indicating the firm’s commitment to leading the industry towards sustainable solutions,” said Hoffman.
Other new products
Hoffman also emphasized GEA’s latest compressors. The new ammonia piston compressor comes equipped with an array of features designed for performance and reliability, he said. These include robust bearings for increased durability, a condensation-prevention system during the standstill period to protect crucial components, an improved oil distribution system to ensure smooth operation and an ammonia droplet catcher before the compressor to enhance efficiency. These enhancements allow the compressor to achieve a temperature of 95°C (203°F).
Meanwhile, GEA’s screw compressor has also advanced with the company’s new GEA GRASS LXHP model. Its key features include variable volume ratio (Vi), Triax bearings, new rotor design, optimized compression ratio and improved efficiency along with an outlet temperature of 95°C.
“At present, many customers prioritize maintaining their operational cost and achieving carbon neutrality over immediate payback”Kenneth Hoffman, Product Manager of GEA