Chiller Management System PRACTICE PAPER 1 SUBMITTED BY: Development Environergy Services Limited AUGUST 2022 © 2022 The World Bank 1818 H Street NW, Washington DC 20433 Telephone: 202-473-1000; Internet: www.worldbank.org Some rights reserved This work is a product of the staff of The World Bank. The findings, interpretations, and conclusions expressed in this work do not necessarily reflect the views of the Executive Directors of The World Bank or the governments they represent. The World Bank does not guarantee the accuracy of the data included in this work. The boundaries, colors, denominations, and other information shown on any map in this work do not imply any judgment on the part of The World Bank concerning the legal status of any territory or the endorsement or acceptance of such boundaries. ABSTRACT To facilitate the adoption of best practices in terms of energy efficiency technologies, refrigerants with low global warming potential (GWP), and promoting cold chains based on low ozone depleting substances (ODS) this practice paper outlines the types of chillers for fish processing plants and decarbonization options for chillers in India. 3 CONTENTS ABBREVIATIONS ........................................................................................................................... 6 INTRODUCTION ............................................................................................................................. 7 CONTEXT OF THE RESOURCE EFFICIENCY MEASURES ....................................................... 8 TYPES OF CHILLERS FOR FISH PROCESSING PLANT ........................................................... 9 Centrifugal compressor ........................................................................................................................11 Rotary screw compressor ....................................................................................................................11 Reciprocating compressor ...................................................................................................................11 ANALYSIS OF DECARBONISATION OPTIONS FOR CHILLERS IN INDIA .............................. 13 Chiller Management System ...............................................................................................................13 6. ROLE OF WOMEN ................................................................................................................ 16 7. CONCLUSION .......................................................................................................................... 16 8. ANNEXURE ........................................................................................................................... 17 4 FIGURES Figure 1: Aims and components of the Fisheries Sector Project ..................................................................... 7 Figure 2: A typical chiller management system ................................................................................................ 8 Figure 3: Common ammonia chiller system ...................................................................................................10 Figure 4: Chiller system elements classification based on type or configuration ..........................................10 Figure 5: Centrifugal compressor (Image courtesy: Havayar) .......................................................................11 Figure 6: Rotary screw compressor (Image courtesy: Wabtec) .....................................................................11 Figure 7: Reciprocating compressor and internal structure (Image courtesy: linquip Technews4) ..............12 TABLES Table 1: Different aspects of existing manual operated chiller systems ........................................................12 Table 2: Parameters of existing chiller systems .............................................................................................13 Table 3: Analysis of specific GHG emissions .................................................................................................14 Table 4: Different aspects of chiller management systems............................................................................14 Table 5: Summary of policy benefits (Central and State)...............................................................................15 Table 6: Breakup of aspects of manual operated chiller systems..................................................................17 Table 7: Breakup of aspects of manual operated chiller systems..................................................................17 5 ABBREVIATIONS ABBREVIATIONS FULL FORM CEA Central Electricity Authority DESL Development Environergy Services Limited DOF Department of Fisheries EE Energy efficiency GWP Global warming potential HGWPR High Global Warming Potential Refrigerant IQF Individual Quick Freezing MSME Micro Small Medium Enterprises ODS Ozone depleting substance SME Small and Medium Enterprises 6 INTRODUCTION The World Bank and the Department of Fisheries (DOF, under the Government of India, Ministry of Fisheries, Animal Husbandry & Dairying) are implementing the “India - Fisheries Sector COVID-19 Response and Recovery Project” to foster improvements in fish value chains with a view to enhance productivity, environmental stewardship, safety, quality of products and expand the range and diversity of attractive market channels. Figure 1: Aims and components of the Fisheries Sector Project The objectives of the engagement are to conduct diagnostic assessments of the value chains of identified products and provide recommendations for improvement, to facilitate the adoption of best practices in terms of energy efficiency technologies, refrigerants with low global warming potential (GWP), and promoting cold chains based on low ozone depleting substances (ODS). Development Environergy Services Ltd. (DESL) has been engaged to undertake part of the study and this practice paper has been developed under the project. 7 CONTEXT OF THE RESOURCE EFFICIENCY MEASURES Most of the processing units in the fishery sector have a significant cooling load requirement to preserve the shrimps/fishes/finfishes/seafood during pre-processing, processing and at the cold storage areas. In a typical fish processing plant, the energy consumption due to cooling load may be around 60% of the total electricity consumption of the plant. Almost all the plants are using an ammonia-based chiller system to meet their cooling requirement at (for sub zero temperature). Thus, it is essential to optimize the chiller operation to save energy and reduce GHG emission in the plant. Air conditioning industries are struggling to identify and resolve the frequently happening problems which affect the chiller operation and leading to poor performance of the chillers. This will not only increase the energy consumption of the chillers but also increase the GHG emission. One of the solutions is chiller management systems, which is an advanced control solution recommended for chiller plant applications with multiple chillers. System components will work in harmony to maximize comfort, compliance, and performance. It can control the other components in the chiller system 1. In a wider context, countries like Bangladesh, the common practice does not include a chiller management system as a part of their chiller system. A typical schematic arrangement of the chiller management system is represented in the below figure. Figure 2: A typical chiller management system 1 Natural Storage Solutions Pvt. Ltd. TYPES OF CHILLERS FOR FISH PROCESSING PLANT Different types of chillers are used in a fish processing unit. In a typical fish processing plant, the cooling is required in the following purposes: ● Raw material storage ● Ice making ● Freezers (IQF and Blast type) ● Finished good storage In most cases, the temperature requirement is below 0 oC may be around -18 oC to - 20 oC, for which ammonia is used as refrigerant in the chiller system. Ammonia is the most suitable refrigerant for sub-zero cooling applications. There are some advantages and disadvantages for the ammonia chillers over the freon based refrigeration chillers, which is given below: Salient advantages of Area Description Ammonia Chillers • High coefficient of performance • Less quantity of refrigerant • Around 40% less power consumption than freon Low power consumption based chillers • Require smaller size of compressors and system components Processing Plant • Less O&M cost • Longer working life Low maintenance and operating (O&M) cost • Less refrigerant requirement Cold Storage (7 to 8 times) than freon based chillers • Ammonia price much less compared to freon Low refrigerant cost • Zero ODP (Ozone Depletion Potential) • Zero Global Warming Potential (GWP) Environment Friendly 9 In fisheries processing units typically, the chiller system comprises the components presented in the diagram below. Figure 3: Common ammonia chiller system The typical elements of an ammonia chiller system which contributes to energy consumption are the compressor, cooling tower pump, cooling tower fan & evaporator fan. The following diagram depicts the configuration/types of compressors, cooling types and Evaporator types. Chiller System Compressor Coolers Evaporator Centrifugal Water Flooded compressor coolers evaporator Direct Rotary screw Evaporative expansion compressor coolers evaporator Reciprocating compressor Type Configuration and type Type Figure 4: Chiller system elements classification based on type or configuration Compressor being the heart of any chiller system, there are many types but most used types of compressors in existence are: 10 Centrifugal compressor These are also commonly known as dynamic compressors. As the name suggests, this compressor imparts kinetic energy to the incoming air stream which increases the air's velocity. The imparted kinetic energy is converted into potential energy by increasing the cross-section area gradually, this causes the increase in pressure of air. Figure 5: Centrifugal compressor (Image courtesy: Havayar2) Rotary screw compressor This type of compressor is a positive type displacement compressor with a rotary type mechanism. The operating principle is as the name suggests compression due to rotary movement. The compressor within has male and female rotors which are made in such a way that they always turn in unison. The male and female rotors have convex lobes and concave cavities. When the air enters from the inlet into the high-speed rotors they get trapped in between and achieve compression. The male rotor has characteristically less lobes than the female making it rotate more and effectively. The compressed air is transferred to the holding tank or the receiver region. The figure below depicts a typical rotary screw compressor. Figure 6: Rotary screw compressor (Image courtesy: Wabtec3) Reciprocating compressor These are generally known as piston compressors and are commonly used for high pressure gas applications. The main component of this type of compressor is the pistons that are present 2 Havayar 3 Wabtec 11 within them. The compressor has a piston which moves in a downward direction to draw in the gas by creating vacuum. As the piston moves in the upward direction, this causes an increase in pressure, forcing the gas out of the cylinder and emptying it to the receiving end. The working is very similar to an automobile engine. The diagram below shows the reciprocating compressor model Figure 7: Reciprocating compressor and internal structure (Image courtesy: linquip Technews44) The chiller systems have either water or evaporative coolers (Figure 4 Common ammonia chiller system indicates water coolers). Typically, evaporative condensers are used for lower capacity but are very cost effective, require lower maintenance and are perfect for smaller buildings/systems. The key difference between the water and evaporative coolers is the number of stages required to achieve cooling. The water-cooled chiller systems utilize cooling tower focuses on two stage heat transfer which are: ● Heat transfer from the pressurised hot ammonia gas to the water through a heat exchanger. ● Heat rejection from water to the atmosphere by evaporative cooling. Unlike the water coolers, the evaporative coolers achieve the same effects by a single heat rejection process involving evaporation of water from the external surface of the pipe carrying pressurized hot ammonia gas. The final component is the evaporator whose working principle is quite opposite to that of a condenser. The refrigerant undergoes phase change due to absorbing heat from the air from the surroundings which is facilitated by the fans present. The evaporator configuration is classified broadly into 2 types: ● Flooded evaporator: In this type the receiver acts as a separator of gaseous and liquid components of the refrigerant. This is done to ensure that feeds contain only liquid refrigerant. Unlike the direct expansion evaporator, the refrigerant is not completely evaporated and at times superheated at the outlet (typically refrigerant at the outlet consists of 50-80% gas5). ● Direct expansion evaporator: In this type, the refrigerant is completely evaporated and at times superheated at the outlet. The various aspects of the current scenario from the field visit have been recorded and tabulated in table 1. Table 1: Different aspects of existing manual operated chiller systems Aspects Parameter Unit Manual operated chiller systems 4 linquip Technews 5 Refrigeration handbook - SWEP 12 Capex Rs/t - Financial Opex Rs/t 3,218 Use water in chiller system is basically in Water usage - the cooling tower or in evaporative condenser Economical Currently the taxes are levied upon the Tax benefit for Govt. - workers as per tax laws Environmental GHG (Grid electricity) kgCO2/k 0.32 g Energy Specific energy kJ/kg 1448 The complete breakup of the table above has been provided in the Annexure. ANALYSIS OF DECARBONISATION OPTIONS FOR CHILLERS IN INDIA According to the energy consumption and GHG emissions analysis of the various target value chains in India, it was observed that in the fish processing units, chillers contribute to around 53.13% of the total GHG emissions by the fish processing plant. During the field study, energy audits were conducted in the fish processing units in Gujarat, Andhra Pradesh, and Tamil Nadu. The objective of the energy audit was to identify major areas of energy efficiency, reduction of HGWPR and ODS. The existing chiller systems in fish processing units have been noticed to be mismanaged. The determination of the required number of chillers required for operation is based on thumb rules rather than accurate control. There was a lack of ensuring the required number of components to meet the system load. The maintenance was infrequent rather than basing it on actual run time. The cooling towers effectiveness has been recorded at around 54.5% which is lower in comparison to the standard values lying in the range of effectiveness 70 to 75%. All these reasons strengthen the cause for optimizing the usage of existing chiller systems through the chiller management system. The other relevant details from the energy audits pertaining to the existing chiller systems have been summarized in the table below: Table 2: Parameters of existing chiller systems Parameter Unit Value Average energy consumption % due to chiller load % 60 Average GHG emissions contribution % due to chiller load % 53 Average specific energy consumption due to chiller system load MWh/t 0.40 Average specific emissions due chiller system tCO2/t 0.32 Average specific power consumption kW/TR 0.8 Introduction of a chiller management system can be viewed as a means of decarbonization or reducing GHG emissions and efficient usage of energy. Chiller systems being the major GHG emission contributor, any EE measures will have a profound impact on the total energy consumption as well as the total GHG emissions of a fisheries processing unit. Certain SME clusters in Gujarat have reported to have 0.76 kW/TR for ammonia- based chiller systems 6. Chiller Management System Chiller management systems were considered due to an advanced control solution which is recommended for chiller plant applications with multiple chillers. The chiller management system intervention to the existing 6 Manual on Energy conservation in Gujarat SME clusters - BEE 13 manually operated chiller systems provide the benefit of lowering the specific power consumption 77 and the scalability feature of it is quite attractive since it can be applied to any pre-existing chiller systems of varied complexity: Success story: Installation of chiller management system A few years ago, a fish processing unit in Goa installed the chiller management system onto their existing chiller units having 9 compressors of 315 kW load each. The objective of the unit was to improve the energy efficiency of their existing chiller system, to minimize the energy usage and to optimize the pre-existing system. The installation has been facilitated by Danfoss Industries. The results of the installations are as follows: ● Successful reduction of energy consumption by chiller system load by 9% ● Capital cost for the chiller management system was 9 Lakh Rs. The success story has proved that the addition of a chiller management system is possible. The estimated emission reduction is as follows: Table 3: Analysis of specific GHG emissions Parameter Unit Value Present specific GHG emissions due to chiller load tCO2/t 0.32 Proposed specific GHG emissions (Chiller management system tCO2/t 0.29 installation) Emission reduction considering the proposed changes % 27.2 The emission reduction of 27.2% has been achieved after the installation of a chiller management system. The other benefits achieved in various aspects have been estimated and summarized in table 4. Table 4: Different aspects of chiller management systems Aspects Parameter Unit Chiller management system Capex Rs/t 162 Financial Opex Rs/t 2,928 7 TRANE 14 Due to use of chiller management Economical system the fan speed is controlled Water usage - according to the requirement and the water losses are drastically reduced8 Tax benefit for The usage of the chiller management Govt. system reduced electricity usage. As a result, the cost of producing a product was lower and the profit margin was higher. As people get better remuneration, the government benefits from the taxes. Environmental GHG (Grid kgCO2/k 0.29 electricity) g Apart from the GHG emission reduction, the chiller management system has an edge of reduced Opex by 9% in comparison to the scenario of no use of the chiller management system. The energy consumption overall is also reduced. The payback period for a typical fish processing unit whose annual production capacity of 5,544 ts (With a grid electricity cost of 8 Rs. /kWh) is around 0.6 years. 5. CURRENT POLICY There is no relevant national policy in this context but there are certain State policies which is in relevance and summarized below: 1. West Bengal Fisheries Investment Policy9 ○ Concerned Department: Department of fisheries, Govt. of West Bengal. ○ Budget: The budget has not been disclosed for the duration of policy 2015-20 ○ Objective of policy: The aim is to provide fiscal incentive for entrepreneurs to establish MSME in the fisheries sector. ○ Incentives: The incentive is a capital subsidy for the setup of a unit of a minimum of 5% (Different subsidy percentage for different areas) and applicable for research development type equipment. ○ Status: The policy validity has been completed. 2. Fisheries Policy of Andhra Pradesh ○ Concerned Department: Department of fisheries, Govt. of Andhra Pradesh10. ○ Budget: The budget has not been disclosed for the duration of policy 2015-20 ○ Objective of policy: The aim is to double the fish production and productivity in the next 5 years during the 5 year 2015-20 by intervention of marine, brackish water, inland fisheries and reservoirs development and ornamental fishery trade. ○ Incentives: An interest subvention of 6% on bank loan subject to 2.5 Cr. Rs. for a 5- year period for aqua processing unit, ice plant and cold storage. ○ Status: The policy validity has been completed. Table 5: Summary of policy benefits (Central and State) Policy 1 2 benefits Capital Subsidy ✔ - Interest Subsidy - ✔ 8 Stakeholder consultation with vendor 9 Department of Fisheries, West Bengal 10 Department of Fisheries, Andhra Pradesh 15 In this context there are 2 policies which provide subsidies in capital and interest wise. The West Bengal Fisheries Development Policy provides a minimum of 5% in capital subsidy involving research and development type equipment but only for entrepreneurs trying to establish a new plant. Whereas the Fisheries Policy of Andhra Pradesh is focused on the existing processing units (aqua processing unit, ice plant and cold storage) and provides an interest subsidy of 6%. There is no policy promoting the chiller management system explicitly. The chiller management system has the potential to save a lot of energy especially in fish processing units whose major energy consuming equipment/system is the chillers. The major issue is the capex and the awareness of the technology. The existing/new policy in this case must take into consideration the advantage provided by the use of a chiller management system instead of manual intervention- b a s e d operation and revise/develop accordingly as a means of decarbonization and promoting energy efficiency 11. 6. ROLE OF WOMEN There is a significant contribution and role of women in the value chain. In a processing unit most of the labor force is represented by the female gender. But in the chiller system management which is generally handled by the maintenance workers who are generally male gender (observed during the energy audits). The improvement in the chiller system could indirectly benefit the women workers in the processing unit due to reduced operational expense for making the product. 7. CONCLUSION The fisheries processing unit has been found to have major portions of their annual energy expended on the chiller systems. The typical specific loads in these industries have 0.8 kW/TR. The fish processing plant's energy consumption due to cooling load may be around 60% of the total electricity consumption of the plant. Almost all the plants are using an ammonia-based chiller system to meet their cooling requirement at (for sub zero temperature). The average specific emissions in the fish processing unit due to chiller load were found to be 0.32 tCO2/t. A review of the success story of implementing the chiller system in a fisheries processing unit showcases the possibility of GHG emission reduction. The proposed chiller management system implementation estimated GHG emission reduction of 27.2%. 11 Stakeholders’ consultation with vendors 16 8. ANNEXURE Table 6: Breakup of aspects of manual operated chiller systems Aspects Parameter Breakup Unit Valu Sourc e e No chiller management Capex A. Capex Rs/t - system case B. Average specific energy Stakeholders’ consumption by MWh/t 0.40 consultation with Financial fish processing unit chillers Opex Stakeholders’ C. Cost of grid Rs. /kWh 8 consultation with electricity fish processing unit Opex {B*C} Rs. /t 3,218 - A. Average specific energy Stakeholders’ consumption by MWh/t 0.40 consultation with chillers fish processing unit GHG (Grid Environment electricity) al B. Electricity kgCO2/kWh 0.8 CEA emission factor Specific emission kgCO2/kg 0.32 - {A*B} Stakeholders’ Energy Specific energy Specific energy kJ/kg 1,448 consultation with fish processing unit Table 7: Breakup of aspects of manual operated chiller systems Aspects Parameter Breakup Unit Valu Sourc e e Stakeholders’ A. Average t/y 5,544 consultation with annual fish processing unit production Capex B. Cost of chiller Stakeholders’ management Lakh Rs. 9 consultation with system Danfoss solution Financial Capex {B/A} Rs/t 162 - A. Average Stakeholders’ specific energy MWh/t 0.40 consultation with consumption by fish processing unit Opex chillers 17 Aspects Parameter Breakup Unit Valu Sourc e e B. % Energy savings by Stakeholders’ % 9 consultation with chiller management Danfoss solution system Stakeholders’ C. Cost of grid Rs. /kWh 8 consultation with electricity fish processing unit Opex {A*(1-B%) *C} Rs. /t 2,928 - A. Average specific energy Stakeholders’ MWh/t 0.40 consultation with consumption by chillers fish processing unit B. % Energy Stakeholders’ Environmenta GHG (Grid savings by electricity) % 9 consultation with l chiller management Danfoss solution system C. Electricity kgCO2/kW 0.8 CEA emission factor h Specific emission kgCO2/kg 0.29 - {A*(1-B%) *C} A. Average specific energy Stakeholders’ MWh/t 0.40 consultation with consumption by chillers fish processing unit Energy Specific energy B. % Energy savings by Stakeholders’ % 9 consultation with chiller management Danfoss solution system Stakeholders’ Specific energy kJ/kg 1,318 consultation with {A*(1-B%)} fish processing unit 19