1. NH3/CO2 Refrigeration System “NewTon”
- Energy Conservation -
Nov. 2013 (O)
Mayekawa Mfg.Co.,Ltd. “MYCOM”
JAPAN

2. 2
Global Environment Issues
Ozone Depletion Global Warming
Montreal Protocol
CFC ：banned in 1996
HCFC：Limited from 2004
Totally Banned in 2020
Kyoto Protocol
Reduction of global warming gas by 6%
from 1990 level in the frist period of 2008
～2012). HFC are the target
Freon Recycling Law: CFC,HCFC,HFC
PRTR Law (chemical gas): HCFC22,HCFC123, Ethylene glycol, etc.
Introduction of Environment Tax, Freon Tax to industries
Demand for use of Natural
Refrigerant has increased

3. 3
3
Refrigerant
(Natural Five)
NH3
Ammonia
CO2
Carbon Dioxide
HC
Hydro Carbon
H2O
Water
Air
Notes ・Conventional
system
・Eco-Cute ・Nat’l Proj.
・Butane +
Propane
・Nat’l Proj.
・Adsorption
・Heat Recov.
・Nat’l Proj.
・Air-cycle
90℃
60℃
10℃
-15℃
-25℃
-40℃
-50℃
-60℃
-100℃
Utility hot water
Cold storage, Freezer, Fish boat
Specific Refrigeration needs
Freezer, Freezed-dry, Super Low temp
storage
Cryogenics
Utility hot
water
Heating
HVAC
ChillerChilled water
Ice making
Utility hot water
Heating
Chilled water
Ice making
Heat recovery
・National Projects

4. 4
Natural Five Applications
90℃
CO2hot water
NH3 Chiller
7℃
NH3 Brine chiller
NH3+CO2
-5℃
-25℃
-65℃
AIR
Ice bank system
NH3/Brine chiller
Air conditionimg
Expo Aichi
National Museum
Logistic centre
Museum
NH3 Heat pumpﾟ
50℃
Golf Club
Eco kyuto
Air conditioning
Heating
Cold strage
NewTon3000 (NH3/CO2）
Tuna warehouse
SF class
Air cycle

5. The construction of giant NH3 refrigeration plants presents various problems.
1. Reduction of skilled engineer to design, to construct NH3 plants.
2. Risks of perspective of costs, time, and quality.
3. Large NH3 Charge makes higher risk of accident.
4. Need of many workers and equipments for maintenance.
One solution is to use a “prefabricated package.”
1) The NH3 refrigeration cycle is completed at our factory, tested, adjusted before
shipping.
2) The package is standardized and built to the same package everywhere.
3) The onsite construction time is shortened because only minimal piping and wiring
is required.
4) The amount of NH3 charging is minimized and is completely automatic control.
5) The capacity of compressor is optimized to load of plant, allowing for increased
energy savings
The Problems and Solutions Facing Giant NH3 Plants

6. Ideal Refrigeration Cycle
Single Stage compression Tow Stage compression Cascade Refrigeration
p-h chart
Flow
diagram
COP
h
1
2
3
4
h3,h4
p
h1 h2
1
2
3
4
h4,h3
h
p
5
6
h1 h5 h2 h6
GM
GL
1
23
4
h3,h
4 h
p
5
6
7
8
h7,h
8
h1 h5 h2 h6
GL
GH
41
2
3
Expansion
Valve
Condenser
Evaporator
Compressor
41
6
3
Condenser
Evaporator
Expansion
Valve
High Stage
Compressor
Inter Cooler
5
2
Expansion
ValveBooster
Compressor
1
6
3
Expansion
Valve
Condenser
Evaporator
High Side
Compressor 8
2
Cascade
Condenser
4
7
5
Low Side
Compressor
Expansion
Valve
COP
12
41
hh
hh
COP



)0.1(
)56)(()12(
)41(




GL
hhGMGLhhGL
hhGL
COP
)0.1(
)56()12(
)41(




GL
hHGHhhGL
hhGL
COP

7. Comparison of theoretical COP
0
1
2
3
4
5
6
7
8
-60 -40 -20 0 20
COP(-)
TE (℃)
NH3 Single
NH3 Two Stage
NH3/CO2 Cascade

8. Evap.
NH3
Cond.
Water CO2
Out door NewTon Cold Storage
Cooler
CT
NH3 Package
・New Screw compressor
・Semi-hermetic IPM motor
・Flooded Evaporator
・Double economizer
・Automatic operation
CO2 brine
・Safety
・Low pump power
・No trouble by oil
・High heat transfer
Water cooled
・Energy saving
・NH3 charge min.
・Free layout
・Easy Maintenance
「Safety」 「Energy saving」 「Easy maintenance」
Basic Concept of NewTon

9. 9
NH3 New Screw Compressor
Two stage compound Screw
Semi-hermetic IPM Motor

10. 10
High Efficiency Motor（IPM motor）
- Semi-Hermetic for NH3 -
Conventional
IPM motor 回転子
Benefits of IPM motor
・ ５～１０％ better in efficiency
・ 40% smaller in size
・ High speed is possible

11. 11
New rotor profile and
Double economizer system
Booster High stage
Condenser
Evap.
Inter coolerBooster Economizer
Double Economizer
Features
・High efficiency: Less gas leakage
・Quiet: Low noise, low vibration
・High reliability: Use of proven bearings

12. New type of Heat Exchanger
S＆T
S＆P
NH3液
NH3ガス
CO2液
CO2ガス
NH3液
NH3ガス
CO2ガス
CO2液
S&T S&P Improve
Volume (m3) 0.689 0.269 -39%
Space (m2) 1.57 0.49 -31%
Approach temp.(K) 3.0 1.7 (COP:+4%)
Comparison of Evaporator

13. Flash tank type Economaizer
【conv. 】 【New 】
コンデンサ
中間 ｴｺﾉﾏｲｻﾞ
CO2液化器
ΔT=3.6 ΔT=3.4
コンデンサ
中間 ｴｺﾉﾏｲｻﾞ
CO2液化器
Pd
Pm
Pe
Ps
Subcool :5deg up
Refrigeration effect : 2% up

14. [Compressor]
Oil Separator
High P&T Gas
and Oil
High Pressure gas
[Condenser]
High P Liquid
Inter Cooler
Economizer
Booster
[Evaporator]
CO2 Liquid
CO2 Gas
Low P&T Gas
Low T Liquid

15. Main Installations of NewTon
User tons Newton sets installed
Nissui Logistics kawasaki 14,000 ton ３ 2008
Igarashi reizo Hidaka 15,000 ton ４ 2008
Toyo suisan Nagoya 32,000 ton ９ 2009
Kowa reizou Nagoya 8,500 ton ４ 2009
Coop Tosu 50,000 ton １２ 2009
Hosui Atsugi 8,000 ton ２ 2010
Yokohama reito Osaka 27,000 ton ８ 2011
Matsuoka Kawasaki 80,000 ton １１ 2013
Nisui Log. ／Kawasaki Igarashi／Hidaka LCC Kowa reizo/ Nagoya
Yokohama reizo／Osaka COOP／Tosu Log. Toyo suisan ／Nagoya Matsuoka/Kawasaki
500 are running

16. 0
500
1,000
1,500
2,000
Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec.
PowerConsumptionx1000(kWH)
Refrigeration Elevator, Light Office
Electric Power Usage in Cold Storage
Refrigeration:65%, Elevator, Light:30%, Office:5%

17. Specific Power Consumption in Cold Storage
SPC = PCy/Vc
where:
SPC : Specific Power Consumption (kWH/year/m3)
PCy : Annual Power Consumption (kWH/year)
Vc : Cold Storage Volume (m3)
* PCy is the total power consumption which includes
refrigeration system, elevator, light and office.
Definition of “SPC”

18. Specific Power Consumption in Cold Storage
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
180.0
0 50,000 100,000 150,000 200,000 250,000 300,000
SpecificPowerConsumption(kWH/m3/year)
Storage Volume (m3)
HCFC-22
NewTon (NH3/CO2)
NH3/Brine

19. Customer
Volume Age
Refrigerant formerly
used
Power
reduction
(m3) (year) Refrig. Comp. (%)
Tokyo Toyomi 45,000 29 HCFC-22 Screw 31.1
Niigata Reizo 10,000 33 HCFC-22 Recip. 41.2
QP “Kewpie” 16,250 27 HCFC-22 Recip. 24.9
Sensui Reizo 6,125 38 HCFC-22 Screw 29.3
Ajinomoto 7,500 25 HCFC-22 Recip. 28.0
Gliko 30,000 30 HCFC-22 Screw 19.8
Showa Reizo 32,500 22 HCFC-22 Recip. 28.0
AMB Funabashi 30,000 25 NH3/Brine Recip. 34.0
Power reduction through renewal with NewTon

20. 20
F1610C-8sets
HCFC-22 DX
NewTon 3000-8stes
NH3/CO2
Tokyo Toyomi Reizo (Funabashi) “Renewal”
Storage volume ：45,000 m3
(average reduction -31.1%)

21. Comparison of Power Consumption in Freezer
FLoFREEZE Existing Compressor NewTon
Dice Potato
HCFC-22
(F2016C)
NewTon Power reduction
(mm) (kWH/ton) ( - )
4.8x4.8x4.8 200.0 133.5 0.333
10x10x10 146.2 109.0 0.254
15x15x15 174.9 122.1 0.302

22. Energy Efficiency Factor for Freezer
EEF = (LCt/Wa)∙Kca
where:
EEF: Energy Efficiency Factor for Freezer system
LCt: Required Total Cooling Load
LCt = LC1 + LC2 + LC3
LC1 : Cooling down load before freezing
LC2 : Freezing load
LC3 : Cooling down load after freezing
Wa: Actual Power consumption on Compressor
Kta: Calibration of ambient temperature
Definition of EEF
0.60
0.80
1.00
1.20
1.40
1.60
0 10 20 30 40 50
Kca(-)
Ambient temperature (degree C)
Kca is “theoretical COP ratio”
based ambient temperature 25
degree C.

23. Energy Efficiency Factor for Freezer
Dice Potato
Size
(mm)
HCFC-22
(F2016C)
NewTon Ratio
4.8x4.8x4.8 0.415 0.622 1.50
10x10x10 0.568 0.761 1.34
15x15x15 0.475 0.680 1.43
Operating conditions
1) Inlet/Outlet temperature of dice potato : 25/-18 (degree C)
2) Specific heat of potato,
before/after freezing : 0.813 / 0.407 (kcal/kgK)
3) Ambient temperature : 25 (dgree C)

24. Energy Efficiency Factor for Freezer
Salmon
Ref.
System
Inlet
temp.
Outlet
temp.
Ambient
Temp.
Power
consumption
EEF
HCFC-22 9.0 -10.0 10.0 85.7 0.577
NewTon 10.0 -8.5 18.5 77.5 0.773
(unit) (degree C) (kWH/ton) ( - )
•NewTon shows 33% higher EEF than
HCFC-22 system.
* Existing HCFC-22 system is dry expansion
type air cooler.

25. Demonstration Site:
PT.ADIB Global Supplies
Energy Efficient Refrigeration Technology
Entity:
Mayekawa Mfg CO. Ltd
Project site
Energy
Consumption
reduction
570,000 kwh
/year
・MOEJ introduce the Energy Efficient Refrigeration Technology of
“NewTon” as Japanese Good Practices.
Joint Crediting Mechanism Host Country : Indonesia
“NewTon” for ASEAN
A cold storage
warehouse
nearby Jakarta
This project was funded by the MOEJ in FY 2013 as the 1st project to Joint Crediting Mechanism .
P.T. ADIB
JCM Project for Cold Chain Industry in Indonesia with “NewTon”
CO２
Coldwater
Cealedchiller
100 ton
NH3/CO2 Fridge
NewTon R-6000
Defrost water tank
10m3
Defrost water
Chiller （Cooler）
6 units
Thermo shutter
3 units
Defrost water
(heatup heat exchanger)
RefrigeratorA（-25℃） RefrigeratorB（-25℃） RefrigeratorC（-25℃）
Machine
room
Freight
handling
“1st NewTon system” will be installed to
P.T. ADIB Global Food Supplies in Indonesia.
NewTon R-6000
Most advanced Japanese energy efficient non-fluorocarbon cooling system
http://www.env.go.jp/en/earth/ozone/goodpractice/full.pdf
Estimated
GHG
reductions
Without consideration of HFC leakage
emissions: 213 (tCO2/year)
With consideration of HFC leakage
emissions: 902 (tCO2/year)

26. PCAS Server Newton Monitor
Local Office
No.１
No.２
No.３ NTT docomo
FOMA Network
NewTon
Observation
・Data Logging
・Daily Checking
Out work by mechanics
・Checking
・Precise Diagnosis
・Repair, Recover
Remote Monitor
・Operating Data
・Alarm Data
・Mailing of Alarm
Diagnosis
・Pre-Diagnosis
・Trend Management
・Trouble Analysis
・Monthly Report
Minimize
Daily Works
Reliable Maintenance
Brush-up
Further Improvement
User LAN
NTT FOMA
Mycom LAN
Moriya Plant
User

27. PCAS Server
Trend Data
Current Operating
Conditions
Set point Data

28. Trend Diagnosis and Management
COP ratio
Comp. Vibration
Approach Temp. of Cond.
Comparison of ph-diagram between actual / design conditions

29. Mycom Moriya Plant
NTT Docom
Network
PCAS Global Network

30. Mega NewTon
NewTon R-8000 120kW
NewTon F-800 100kW

31. Use Model Remarks
Cold
Storage
-25C NewTon R-3000, R-6000, R-8000 RT : -25℃
0 C NewTon C platform
Freezer NewTon F-300, F-600, F-800 RT:-35℃
Skate Rink NewTon S
NewTon Lineup
NewTon R-3000, NewTon F-300 NewTon C, NewTon S
31

32. NewTon Technical Data
Model Capacity
*1)
Power*1)
NH3
Charge
L x W x H Weight Use
R-3000 94.5 43.0 25 2.8 x 2.0 x 2.4 3,300
Cold StorageR-6000 189 86.0 50 4.8 x 2.4 x 2.6 6,800
R-8000 270 120 75 4.0 x 2.6 x 2.7 7,600
F-300 70.0 43.0 25 2.8 x 2.0 x 2.4 3,300
FreezerF-600 140 86.0 50 4.8 x 2.4 x 2.6 6,800
F-800 170 100 75 4.0 x 2.6 x 2.7 7,600
C 235 65.0 60 3.4 x 2.2 x 2.7 6,000 Cold Storage
(kW) (kg) (m) (kg)
*1) Conditions :
+ Room temperature ; R series / -25 C, F series / -35 C, C series / +2 C
+ Cooling water inlet temperature / 32 C