Grasso%205hp%20series aug%202014 en final 502425 rt 002 0104 us eu tcm30 18588

GEA Refrigeration Technologies

Reciprocating compressors for:• Freezing applications with refrigerant CO2

• (Add-on) heat pump applications with refrigerant NH3

GEA Grasso 5HP Series

engineering for a better world

Grasso 5HP Series_AUG 2014_EN_FINAL.indd 1 30-10-2014 16:10:18

2

GEA provides cooling and freezing technology tailored to the requirements and wishes of its customers: cost-efficient, long-life, energy-efficient, sustainable and customized. After all, we know your business and your refrigeration needs from experience of more than 100 years. This is why GEA offers the best solutions together with top quality products. Solutions for your processes for greater efficiency and for enhanced climate protection.

GEA is one of the leading manufacturers of reciprocating and screw compressors and packages for industrial refrigeration. The extensive range of high quality, reliable and modern refrigeration compressors can be applied in almost every industrial refrigeration process. Our products find their way to the end-user via contractors, distributors and Original Equipment Manufacturers (OEM).

Our main markets for industrial refrigeration solutions are:• Food processing • Storage and distribution • Industrial processes• Sport and leisure • Heat recovery

GEA covers many different industries. For most industrial cooling and freezing applications, our products offer optimal solutions with high reliability and low energy consumption.

Refrigeration technology is an inherent and essential part of the food processing industry. GEA supplies an excellent range of components which can be used throughout the whole value chain, beginning with the production itself and ending with the product ready for market. GEA supplies components for cold storage on fishing vessels, cooling and freezing solutions for meat, vegetables, beer and beverages – within the production process or for storage. For storage and distribution of food along the trade chain, cooling and freezing is a must.

GEA also increases their focus on the subject: heat recovery. This is a logical next step in supporting industrial processes by turning low-level waste heat into usable heat.

Cooling, freezing & heat recovery evolved from excellence

In touch with your markets and processes


3

Freezing applicationsSince the introduction in 2006, the 50 bar GEA Grasso 5HP compressor, developed for use in CO

2 cascade freezing systems, is a well accepted and reliable appearance in the

industrial refrigeration market. Four single stage models from 3 up to 6 cylinders cover a wide range of capacities. The extremely low volume flow in relation with the cooling capacity makes this series a big performer.

Heat pump applicationsA logic further development of the GEA Grasso 5HP Series is the integration in NH

3 heat

pump systems. The 50 bar design makes it possible to condensate up to 80˚C and results in producing a high level of water temperatures. Heat pump systems are developing very quickly in various segments of industry (dairy, slaughterhouses etc.) and contribute in reducing waste heat as well as CO

2 emissions.

GEA’s drive for sustainable solutions is based on the following statements:• 25% of the primary energy consumed in West European countries is used for cooling and heating applications• Oil and gas reserves are in decline• Electricity prices are rising at a slower rate than gas prices (European trend) • Help to achieve reduction targets for CO

2 and other green house gases (Kyoto protocol)

• Help to achieve EU target: sustainable energy consumption needs to be 20% of the total in 2020 (8,5% in 2008)

The GEA Grasso 5HP Series

Reciprocating compressors: the best choice to reduce your energy costs


4


5

The GEA Grasso 5HP Series was introduced in 2006 for use with the natural refrigerant CO

2 in subcritical freezing applications. The advantage to use CO

2 in low temperature

applications is the high capacity per kg refrigerant. Compared with the natural refrigerant NH

3, the required swept volume is 10 to 12 times smaller and the effi ciency up to 16%

higher compared to the booster section of an NH3 system running on -50˚C. Due to the

higher pressure diff erence in the system, the effi ciency of a reciprocating compressor is roughly 20% higher compared to a screw compressor running on similar conditions.The relative high pressure of CO

2 needs a design of 40 to 50 bar to be able to fi t it in

the low stage side of a cascade system. On high stage side the natural refrigerant NH3

fi ts perfectly.

The GEA Grasso 5HP Series for freezing applications

The small size big performer


6

• Smaller size engine room layout compared with other refrigerants• Smaller size electric motor for the same freezing capacity• Always a (>5.5 bar) positive pressure in the system (less non condensables)• Low cost, natural and environmental friendly refrigerant• In favour of evaporating temperatures between -52 and -40˚C• Food is save in case of a leakage

Reduced maintenanceAs all industrial GEA Grasso reciprocating compressors, also the GEA Grasso 5HP is fitted with long-life composite valve technology. This, in the meantime, well proven valve ring material, reduces the number of service intervals and results in minimizing downtime due to maintenance.

CO2 is present all over the world. Why not use it as a refrigerant?

The advantages in using CO2 as refrigerant


7

Lower freezing temperatures for better product quality

Capacity table for freezing applications with CO2

CO2 Freezing

Models Swept volume*(m3/h)

Cooling cap. (kW)** Dimensions (mm) Weight (kg)CO

2L W H

Single stage -50/0 oC -40/-10

oC

GEA Grasso 35HP 101 88 152 883 861 718 552

GEA Grasso 45HP 135 117 202 883 861 718 552

GEA Grasso 55HP 168 147 252 919 943 768 633

GEA Grasso 65HP 202 176 303 919 943 768 633

* Theoretical swept volume based on max. speed of N = 1.500 min.-1

** Capacity based on: 2K superheat, 0K subcooling

W


8

Features of the GEA Grasso 5HP Series

The robust nodular cast iron compressor housing in combination with the composite valve rings material makes this compressor

an effi cient, silent operating 24h work horse under high pressure. For freezing as well as heat pump applications this compressor

is an excellent performer.

1. Safety fi rst

Counter pressure independent overfl ow valve between suction and

discharge chamber to secure a safe operation.

2. High pressure

The 50 bar(e) housing design allows for a wide range of operation, for

instance:

• hot gas defrost in case of CO2 freezing applications

• hot water supply up to 80˚C in case of NH3 heat pump

application

3. Shaft seal

Special designed gas tight shaft seal assures long trouble-free lifetime

under high pressure.

4. Capacity control

Capacity control steps per cylinder.


9

5. Suitable for speed control

The large speed rage (500 - 1.500 min. -1) makes the compressor

extremely suitable for use in combination with a frequency inverter.

6. Effi ciency & lifetime

Composite valve material in combination with the best possible valve

design guarantees the highest effi ciency in combination with long

service intervals.

7. Axial roller bearing

Long-life heavy duty axial roller bearing construction to withstand the

continuous high crankcase pressure.

8. Noise level

The heavy nodular cast iron housing and the composite valve material

guarantees a very low-noise emission.


10 Subtropical pool uses heat pump for hot water.


11

The heat pump, how does it work?In existing refrigeration plants the heat extracted and rejected at the condensor, is often not recovered and re-used because the temperature level is too low to be usefull. This low-grade ‘waste’ heat ends up in the atmosphere. This low-grade waste heat can however be used as a heat source for the heat pump system that is able to raise this heat to a higher usable temperature level.

The most suitable layout for this purpose is a so called ‘Add on heat pump’, see picture below.

Advantages in fi tting an add on heat pump:• Lower energy costs• Low temperature (waste) heat can be converted to usable heat• Processing plants are often in need of refrigeration as well as heating• Add-on heat pump systems are designed to install on existing refrigeration plants• Lower or no fuel costs with installed boilers• Maintenance is done by a refrigeration contractor only• Condensor load of the existing refrigerating plant reduces while the heat pump is in operation. This results in power savings of the refrigeration plant• Surplus heat can be sold to adjacent users• Reduced CO

2 footprint

The GEA Grasso 5HP for heat pump applications

Usable waste heat

Existing refrigeration

plant

Electricdriving power Pe1

Electricdriving power Pe2

NH3

heat pumpsystem

Q cooling

Heat ofrefrigeration plant

t0 = -10˚C

Q condensor

‘Waste’ heattc = +35˚C

Q heat pump

Useful heattchp = +80˚C


12

A traditional boiler (gas or oil fired) for producing hot water the ratio between the useful and consumed energy is always < 1. For this reason a heat pump system is always more efficient than a traditional boiler if waste heat is available. In fact 3 to 7 times more useful energy becomes available in the form of hot water than the heat pump consumes in electrical power.

The efficiency of the heat pump system is expressed in COP (Coefficient of Performance), see the figure below.

The ratio between the electricity and the gas/oil price is always an important investment criterium in the payback analyses of a heat pump system. The electricity price has been decreasing – in relative terms- compared to the gas/oil price in recent years.

This trend makes the payback analyses of a heat pump more attractive in comparison to traditional gas/oil fired heating systems.

What is the benefit?

The advantages of using NH3 with your heat pump

COPheatpump =Q heatpump

P e2


13

The GEA Grasso 5HP heat pump application

Utilisation of waste heat

Applications• Hot water supply for industrial processes• Hot water supply for cleaning/scalding activities in for instance slaugterhouses• Pasteurisation process in the dairy industry• District heating• Horticulture using green houses• Sport facilities with combined need for heat and cold

Advantages• Recovery of waste heat• High efficiency• Energy cost reduction• Short payback time of investment• Sustainable solution• Reduction of CO

2 emission

SummaryIn applications where heat and cold are required simultaneously, GEA can help to substantially reduce your energy costs. The GEA Grasso 5HP compressor in combination with the natural refrigerant NH

3, is the heart

of the heat pump system, and can be delivered ‘bare’ or packaged. This enables the installer to design an optimum installation for the end user.


14

NH3 Heat pump applications

Models Swept volume*(m3/h)

Heating cap. (kW)** Dimensions (mm) Weight(kg) NH

3L W H

Single stage 35/80 oC 35/70 oC

GEA Grasso 35HP 101 261 278 883 861 718 552

GEA Grasso 45HP 135 348 370 883 861 718 552

GEA Grasso 55HP 168 435 463 919 943 768 633

GEA Grasso 65HP 202 521 555 919 943 768 633

* Theoretical swept volume based on max. speed of N = 1.500 min.-1

** Capacity based on: 2K superheat, 0K subcooling

W

Higher heating temperatures for saving more energy

Capacity table for heat pump applications with NH3


15

GEA After Sales Service

GEA is proud of the quality and reliability of their products. Our objective is to ensure that GEA reciprocating compressors are well designed, properly installed and maintained. We understand that correct preventive maintenance will ensure the highest level of reliability and unexpected break-downs can be minimized. At the same time, the lifetime of compressors will increase.

With this in mind, GEA takes care of its customers by offering the best possible aftersales service in terms of technical consultation, warrantee management field service and training courses. All supported by rapid spare parts supply all over the world.

Spare parts A practical and fast working spare parts organization has been established to supply the required spare parts worldwide. To shorten delivery times, distribution centers have been created at GEA offices throughout the world. GEA has an extensive stock of spare parts covering new and phased out GEA compressors as well.

Laboratory tests and field experience have proven that the use of genuine GEA parts keep compressor performance, reliability and a low Total Cost of Ownership to the optimum level. GEA has created distribution centers at the GEA offices worldwide, to be able to supply you the right parts directly. That is why the genuine GEA parts are the obvious choice.

Training coursesFor GEA is it very important to ensure maximum possible support for end users all over the world. This can only be achieved when the right training programs are available. Local representatives and contractors are able to attend to these training courses. These courses, developed for design- and service engineers, are focused on the correct selection and application of GEA compressors as well as performing the correct service to maintain the highest level of reliability.

These courses take place at the GEA manufacturing site for reciprocating compressors. The courses could also be, on request, performed locally, if this is more convenient for a larger audience. We strongly recommend attending these courses on a regular basis to offer the local market the best possible and up-to-date support.


© G

EA G

roup

AG

. All

right

s re

serv

ed. 0

8/2

014

– RT

-002

-010

4-U

S-EU

. Sub

ject

to m

odifi

catio

n.

GEA Refrigeration Technologies

GEA Refrigeration Netherlands N.V. Technology Center Piston Compressors - GEA Grasso

Parallelweg 27, 5223 AL ‘s-Hertogenbosch, The NetherlandsPhone: +31 (0)73 6203 [email protected], www.gea.com

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity


Documents

Grasso%205hp%20series aug%202014 en final 502425 rt 002 0104 us eu tcm30 18588