Energy Savings Potential for Commercial Refrigeration Equipment Final Report Prepared by Arthur D. Little, Inc. For Building Equipment Division Office of Building Technologies U.S. Department of Energy June 1996 Prepared by: Detlef Westphalen Robert A. Zogg Anthony F. Varone Matthew A. Foran DOE Program Managers: Dr. James R. Brodrick Terry DuBois Arthur D. Little, Inc. Acorn Park Cambridge, Massachusetts 02140-2390 Reference 46230-00 Table of Contents 1. Executive Summary...................................................................................................1-1 1.1 Supermarket Refrigeration.......................................................................................1-3 1.2 Beverage Merchandisers..........................................................................................1-6 1.3 Reach-In Freezers.....................................................................................................1-7 1.4 Reach-In Refrigerators.............................................................................................1-8 1.5 Ice Machines.............................................................................................................1-9 1.6 Refrigerated Vending Machines.............................................................................1-10 2. Introduction................................................................................................................2-1 3. Scope of Work............................................................................................................3-1 4. Prototypical Descriptions of Baseline Equipment......................................................4-1 4.1 Supermarket Refrigeration Systems.........................................................................4-2 4.1.1 Equipment Description and Illustrations...............................................................4-2 4.1.2 Energy Consumption: Prototypical Supermarket Refrigeration System..............4-9 4.1.3 Manufacturing, Purchase, and Installation Costs................................................4-16 4.1.4 Life, Reliability, and Maintenance Characteristics.............................................4-16 4.1.5 Major Manufacturers...........................................................................................4-17 4.1.6 Major End-Users.................................................................................................4-19 4.2 Beverage Merchandisers........................................................................................4-20 4.2.1 Equipment Description and Illustration..............................................................4-21 4.2.2 Energy Consumption...........................................................................................4-24 4.2.3 Manufacturing, Purchase, and Installation Costs................................................4-25 4.2.4 Life, Reliability, and Maintenance Characteristics.............................................4-25 4.2.5 Major Manufactures............................................................................................4-25 4.2.6 Major End-Users.................................................................................................4-26 4.3 Reach-In Freezer....................................................................................................4-27 4.3.1 Equipment Description and Illustration..............................................................4-28 4.3.2 Energy Consumption...........................................................................................4-29 4.3.3 Manufacturing, Purchase, and Installation Costs................................................4-31 4.3.4 Life, Reliability, and Maintenance Characteristics.............................................4-31 4.3.5 Major Manufacturers...........................................................................................4-31 4.3.6 Major End-Users.................................................................................................4-31 4.4 Reach-In Refrigerator.............................................................................................4-33 4.4.1 Equipment Description and Illustration..............................................................4-34 4.4.2 Energy Consumption...........................................................................................4-35 4.4.3 Manufacturing, Purchase, and Installation Costs................................................4-36 4.4.4 Life, Reliability, and Maintenance Characteristics.............................................4-36 4.4.5 Major Manufacturers...........................................................................................4-36 i Table of Contents (continued) 4.4.6 Major End-Users.................................................................................................4-37 4.5 Ice Machines...........................................................................................................4-38 4.5.1 Equipment Description and Illustration..............................................................4-39 4.5.2 Energy Consumption...........................................................................................4-42 4.5.2.1 General Characteristics.....................................................................................4-42 4.5.2.2 Estimated Total Energy Consumption.............................................................4-45 4.5.2.3 Energy Consumption Breakdown....................................................................4-45 4.5.3 Manufacturing, Purchase, and Installation Costs................................................4-47 4.5.4 Life, Reliability, and Maintenance Characteristics.............................................4-47 4.5.5 Major Manufacturers...........................................................................................4-48 4.6 Refrigerated Vending Machines.............................................................................4-49 4.6.1 Equipment Description and Illustration..............................................................4-51 4.6.2 Energy Consumption...........................................................................................4-53 4.6.3 Manufacturing, Purchase, and Installation Costs................................................4-54 4.6.4 Life, Reliability, and Maintenance Characteristics.............................................4-54 4.6.5 Major Manufacturers...........................................................................................4-55 4.6.6 Major End-Users.................................................................................................4-55 4.7 Walk-In Coolers and Freezers................................................................................4-56 4.7.1 Equipment Description and Illustration..............................................................4-59 4.7.2 Energy Consumption...........................................................................................4-62 4.7.3 Manufacturing, Purchase, and Installation Costs................................................4-66 4.7.4 Life, Reliability, and Maintenance Characteristics.............................................4-66 4.7.5 Major Manufacturers...........................................................................................4-66 4.7.6 Major End-Users.................................................................................................4-67 5. Energy-Saving Technologies ....................................................................................5-1 5.1 Supermarket Refrigeration.......................................................................................5-1 5.1.1 Energy-Saving Technologies - Supermarket Refrigeration..................................5-1 5.1.2 Economic Analysis - Supermarket Refrigeration................................................5-19 5.1.3 Barriers to Implementation..................................................................................5-25 5.2 Beverage Merchandiser..........................................................................................5-26 5.2.1 Energy-Saving Technologies..............................................................................5-26 5.2.2 Economic Analysis..............................................................................................5-29 5.2.3 Barriers to Implementation..................................................................................5-31 5.3 Reach-In Freezer (Single-door)..............................................................................5-32 5.3.1 Energy Saving Technologies...............................................................................5-32 5.3.2 Economic Analysis..............................................................................................5-33 5.3.3 Barriers to Implementation..................................................................................5-36 ii Table of Contents (continued) 5.4 Reach-In Refrigerator (two-door)...........................................................................5-36 5.4.1 Energy Saving Technologies...............................................................................5-36 5.4.2 Economic Analysis..............................................................................................5-36 5.4.3 Barriers to Implementation..................................................................................5-38 5.5 Ice Machines...........................................................................................................5-38 5.5.1 Energy-Saving Technologies..............................................................................5-38 5.5.2 Economic Analysis..............................................................................................5-41 5.5.3 Barriers to Implementation..................................................................................5-41 5.6 Refrigerated Vending Machine..............................................................................5-42 5.6.1 Energy Saving Technologies...............................................................................5-42 5.6.2 Economic Analysis..............................................................................................5-42 5.6.3 Barriers to Implementation..................................................................................5-44 5.7 Walk-In Coolers and Freezers................................................................................5-44 5.7.1 Energy-Saving Technologies..............................................................................5-44 5.7.2 Economic Analysis..............................................................................................5-49 5.7.3 Barriers to Implementation..................................................................................5-55 6. References..................................................................................................................6-1 iii List of Figures Figure 1-1: Primary Energy Usage in Commercial Refrigeration (trillion Btu)............1-1 Figure 1-2: Commercial Refrigeration Savings Potential (trillion Btu).........................1-1 Figure 2-1: Commercial Sector Primary Energy Usage - 1993.....................................2-1 Figure 4-1: Typical Supermarket Layout (Foster Miller, 1990)....................................4-3 Figure 4-2: Single-Level Wide Aisle Open Display Case.............................................4-5 Figure 4-3: Glass Door Reach-In Display Case.............................................................4-5 Figure 4-4: Multi-Level Open Dairy Case.....................................................................4-6 Figure 4-5: Multi-Level Open Meat Case......................................................................4-6 Figure 4-6: Supermarket Refrigeration System Compressor Rack................................4-7 Figure 4-7: Supermarket Refrigeration System..............................................................4-9 Figure 4-8: Supermarket Electricity Consumption Breakdown (27,000 sq. ft. Supermarket).............................................................................................4-10 Figure 4-9: Installed Cost Breakdown for a 100 Ton Supermarket Refrigeration System.....................................................................................................4-16 Figure 4-10: Estimated Supermarket Refrigeration Sales (1992)................................4-17 Figure: 4-11: Supermarket Refrigeration System Market Share (based on sales values)..............................................................................4-17 Figure 4-12: Supermarket Refrigeration Distribution Chain.......................................4-18 Figure 4-13: Supermarket Refrigeration Compressor Market......................................4-19 Figure 4-14: Beverage Merchandisers - 1994 Equipment Inventory...........................4-21 Figure 4-15: Beverage Merchandiser - Equipment Illustration....................................4-22 Figure 4-16: Typical Self-Contained Refrigeration Circuit.........................................4-23 Figure 4-17: Beverage Merchandisers - Estimated Market Share................................4-26 Figure 4-18: Reach-in Freezers - 1994 Equipment Inventory......................................4-27 Figure 4-19: Reach-In Freezer - Equipment Illustration.............................................4-28 Figure 4-20: Reach-In Refrigerators & Freezers - “Standard-Line” Estimated market Share........................................................................................................4-32 Figure 4-21: Reach-In Refrigerators & Freezers - “Specification-Line” Estimated Market Share...........................................................................................4-32 Figure 4-22: Reach-In Refrigerators - 1994 Equipment Inventory..............................4-33 Figure 4-23: Reach-In Refrigerator - Equipment Illustration.......................................4-34 Figure 4-24: Ice Machine Equipment Illustration........................................................4-39 Figure 4-25: 1994 Ice Machine Energy Consumption Versus Capacity......................4-43 Figure 4-26: 1994 Ice Machine Water consumption Versus Capacity.........................4-44 Figure 4-27: Compressor Freeze Cycle Energy Consumption by Load......................4-46 Figure 4-28: Refrigerated Vending Machines - 1994 Equipment Inventory...............4-49 Figure 4-29: Refrigerated Vending Machines (Canned Beverage) - Owner/Operator Inventory Share.......................................................................................4-50 Figure 4-30: Refrigerated Vending Machines (Canned Beverage) - Weekly Sales Breakdown...............................................................................................4-51 Figure 4-31: Refrigerated Vending Machine (Canned Beverage) - Equipment Illustration.............................................................................4-52 iv List of Figures (continued) Figure 4-32: Refrigerated Vending Machines (Canned Beverage) - Estimated Market Share........................................................................................................4-55 Figure 4-33: Walk-in Coolers and Freezers - 1994 Equipment Inventory...................4-58 Figure 4-34: Walk-in Coolers and Freezers - End Use Applications..........................4-58 Figure 4-35: Walk-in Cooler/Freezer - Equipment Illustration....................................4-60 Figure 4-36: A Walk-in Cooler with Merchandising Doors........................................4-61 Figure 4-37: Components of a Split Refrigeration System Serving a Walk-In............4-61 Figure 5-1: Air-Cooled Condenser...............................................................................5-1 Figure 5-2: Evaporative Condenser..............................................................................5-2 Figure 5-3: Mechanical Subcooling.............................................................................5-4 Figure 5-4: Liquid-Suction Heat Exchanger................................................................5-6 Figure 5-5: Refrigeration System for Ammonia with Secondary Refrigeration Circuit.....................................................................................................5-14 Figure 5-6: Refrigerant COP’s -- M edium Temperature...........................................5-15 Figure 5-7: Refrigerant COP’s -- Low Temperature..................................................5-15 v Table 1-1: Identified Energy Savings Potential.............................................................1-2 Table 1-2: Comparison of Electric and Gas Refrigeration Options...............................1-3 Table 1-3: Supermarket Energy Savings: Machine Room Technologies....................1-4 Table 1-4: Supermarket Energy Savings: Display Case Technologies.........................1-5 Table 1-5: Beverage Merchandiser Energy Savings......................................................1-6 Table 1-6: Reach-In Freezer Energy Savings.................................................................1-7 Table 1-7: Reach-In Refrigerator Energy Savings.........................................................1-8 Table 1-8: Ice Machine Energy Savings........................................................................1-9 Table 1-9: Refrigerated Vending Machine Energy Savings.........................................1-10 Table 4-1: Estimates of Commercial Refrigeration Inventories and Energy Usage......4-1 Table 4-2: Store Numbers and Average Sales in the Food Sales Sector........................4-2 Table 4-3: Supermarket Refrigeration System--Electricity Consumption Summary (prototypical 45,000 sq. ft. supermarket)...................................................4-11 Table 4-4: Compressor Rack Loads.............................................................................4-11 Table 4-5: Refrigeration Load Summary.....................................................................4-13 Table 4-6: Case Load Breakdown................................................................................4-13 Table 4-7: Medium Temperature Cases--Electricity Consumption.............................4-14 Table 4-8: Low Temperature Cases--Electricity Consumption....................................4-14 Table 4-9: Medium Temperature Walk-Ins--Electricity Consumption........................4-15 Table 4-10: Low Temperature Walk-Ins--Electricity Consumption............................4-15 Table 4-11: Top 10 Supermarket Chains.....................................................................4-19 Table 4-12: Commercial Sector Overview - Beverage Merchandiser Consumption...4-21 Table 4-13: Beverage Merchandisers - Refrigerated Cabinet Description...................4-23 Table 4-14: Beverage Merchandiser - Compressor Data.............................................4-24 Table 4-15: Beverage Merchandiser Load Breakdown................................................4-24 Table 4-16: Energy Consumption Breakdown - Beverage Merchandiser (One-Door)4-24 Table 4-17: Beverage Merchandisers - Manufacturer List Prices................................4-25 Table 4-18: Commercial Sector Overview - Reach-in Freezer Consumption.............4-27 Table 4-19: Reach-in Freezers - Refrigerated Cabinet Description.............................4-29 Table 4-20: Reach-in Freezers - Refrigeration Component Description......................4-30 Table 4-21: Reach-In Freezer Load Breakdown..........................................................4-30 Table 4-22: Energy Consumption Breakdown - Reach-in Freezer (one-door)............4-30 Table 4-23: Reach-in Freezers (One-Door) - Manufacturer List Prices.......................4-31 Table 4-24: Commercial Sector Overview - Reach-in Refrigerator Consumption......4-33 Table 4-25: Reach-in Refrigerators - Refrigerated Cabinet Description......................4-34 Table 4-26: Reach-in Refrigerators - Refrigeration Component Description..............4-35 Table 4-27: Reach-In Refrigerator Load Breakdown...................................................4-35 Table 4-28: Energy Consumption Breakdown - Reach-in Refrigerator (two-door)....4-36 Table 4-29: Reach-in Refrigerators (Two-Door) - Manufacturer List Prices..............4-36 Table 4-30: Approximate 1993 Ice Machine Unit Sales..............................................4-38 Table 4-31: Ice Machine Primary Energy Usage.........................................................4-45 Table 4-32: Estimated Annual Energy Consumption by Component..........................4-46 Table 4-33: Major Ice Machine Manufacturers and Approximate Market Share........4-48 1 Table 4-34: Commercial Sector Overview - Refrigerated Vending Machine Consumption.............................................................................................4-51 Table 4-35: Refrigerated Vending Machine (Canned Beverage) - Refrigerated Cabinet Description................................................................................................4-52 Table 4-36: Refrigerated Vending Machine (Canned Beverage) - Refrigeration Component Description............................................................................4-53 Table 4-37: Vending Machine Refrigeration Load Breakdown...................................4-53 Table 4-38: Refrigerated Vending Machine (Canned Beverage) - Energy Consumption Breakdown................................................................................................4-54 Table 4-39: Commercial Sector Overview - Walk-in Coolers and Freezers................4-59 Table 4-40: Characteristics of the Prototypical Freezer and Cooler............................4-63 Table 4-41: Storage-only Walk-in Freezer - Energy Consumption Breakdown..........4-64 Table 4-42: Merchandising Walk-in Cooler - Energy Consumption Breakdown........4-64 Table 4-43: Walk-in Refrigeration Load Breakdown..................................................4-65 Table 4-44: Prototypical Walk-in Heat Exchangers.....................................................4-65 Table 5-1: Lighting Power Consumption by Lighting Configuration - Multi-Deck Display Case.................................................................................................5-7 Table 5-2: Shaded-Pole and High Efficiency Fan Motors.............................................5-8 Table 5-3: Insulation Thickness Increase: 1½” to 21/2”................................................5-9 Table 5-4: Insulation Improvement..............................................................................5-10 Table 5-5: System COP for various Coil Temperature Differences.............................5-11 Table 5-6: Evaporator Coil Improvement....................................................................5-12 Table 5-7: New Supermarket System Refrigerants......................................................5-13 Table 5-8: Comparison of Gas-Fired Refrigeraiton Options........................................5-18 Table 5-9: Utility Rates (Supermarkets)......................................................................5-19 Table 5-10: Economic Analysis - Supermarkets..........................................................5-20 Table 5-11: Energy Savings Potential -- Supermarkets...............................................5-21 Table 5-12: Display Case Lighting Energy Savings (for prototypical 45,000 sq ft supermarket)............................................................................................5-22 Table 5-13: Evaporator Fan Motor Power Requirements (for prototypical 45,000 sq ft supermarket).............................................................................................5-23 Table 5-14: Compressor Load Reductions due to Use of High-Efficiency Evaporator Fan Motors.......................................................................................................5-23 Table 5-15: Antisweat Heater Control Energy Savings (prototypical 45,000 sq ft supermarket).............................................................................................5-24 Table 5-16: Defrost Control (Prototypical 45,000 sq. ft. Supermarket).......................5-25 Table 5-17: Economic Analysis Beverage Merchandiser............................................5-30 Table 5-18: Economic Analysis Reach-In Freezers.....................................................5-34 Table 5-19: Economic Analysis Reach-In Refrigerators..............................................5-37 Table 5-20: Economic Analysis for Ice Machines.......................................................5-41 Table 5-21: Refrigerated Vending Machines...............................................................5-42 Table 5-22: Compressor Electricity Reductions With Economizing Cooling.............5-48 Table 5-23: Economic Analysis- Walk-in Coolers......................................................5-50 2 Table 5-24 : Economic Analysis - Walk-in Freezers...................................................5-52 Table 5-25: Walk-In Energy Savings Potential............................................................5-54 3 1. Executive Summary Primary energy usage in the commercial refrigeration sector is estimated as 990 trillion Btu.1 The contribution to this sum of the different commercial refrigeration sectors is shown in Figure 1-1 below. Walk-Ins 180 Other 80 Beverage Merchandisers 52 Reach-In Freezers Supermarkets 65 326 Reach-In Refrigerators 54 Refrigerated Ice Machines Vending 102 Machines 134 Figure 1-1: Primary Energy Usage in Commercial Refrigeration (trillion Btu) Note: “Others” includes Roll-Ins, Under-counter, non-beverage self-contained merchandisers and display cases, and single-compressor remote systems serving display cases in small grocery applications. The analyses described in this report indicate that there are large opportunities for savings in the commercial refrigeration sector. Primary energy savings of about 266 trillion Btu (29% for the equipment types examined) were identified based on improvements in current technology assuming implementation of the most economically attractive technologies for all equipment in the installed based. The split of these savings amongst the studied equipment types is shown in Figure 1-2 below. Reach-In Refrigerators Refrigerated Reach-In 24 Vending Freezers Machines 28 56 Beverage Merchandizers Ice Machines 29 18 Supermarkets Walk-Ins 53 58 Figure 1-2: Commercial Refrigeration Savings Potential (trillion Btu) 1 Primary energy use is calculated based on a heat rate of 10,867 Btu/kWh, which takes into account power production, distribution, and transmission losses. 1-1