Refrigeration in supermarkets

Historic insight

November 2017

Content

• Advansor’s history in brief

• Natural refrigerants- the alternatives

• Historical system designs and why CO2 had to win in the end!

• Developments and improvements on TC CO2

– Parallel compression

– Ejectors

• Conclusions and questions

20062007

20082009

20102011

20122013

20142015

20162017

6

18

40

70

100+

HistoryDKK 250 MTurnover

Torben Hansen and Kim Christensen established Advansor in 2006. It has since progressed rapidly in terms of technology and an over-all growth

Advansor is sold to HillPhoenix, USA in 2011 but remains very ”Danish” with its entrepreneurial roots and values100 x

1834: Perkins mechanical vapour compression refrigeration with ethyl ether

1880s ammonia, sulphuric acid

to carbondioxide and propane1920s …

1930s CFCs (R12)

1950s HCFCs (R22, R502)

1974 Ozone depletion theory (Mario Molina and Sherwood Rowland)

1987 Montreal Protocol (phase-out of CFCs and HCFCs)

1992 UN Framework Convention on Climate Change (FCCC)

1996 Gustav Lorentzen conference in DK

1997 Kyoto Protocol (reduction of emissions of HFC, PFC, CO2, SF6, N20, CH4)

3rd millennium... which refrigerants to use in the long term?

2001 Taxation on HFC’s in DK (and other countries)

2007 10 kg ban introduced in DK

2015 F-gas directive (phase-down + other instruments), HFC prices

The history “Ozone depletion” and

“Green House effect”

The closed refrigerant cycle

Natural refrigerants

NH3, CO2, hydrocarbons

CFCs

R12, R502

HCFCs

R22

HFCs

R404A, R134a,

R507, R407

Technical issues

Local safety

Montreal Protocol

Ozone depletion

Kyoto Protocol

Global warming

?1980s

1930s

1990s

System configurations in supermarkets

R134a

Køl

CO2

Kaskade-anlæg

Frost

CO2 anlægTørkøler

Kaskade

veksler

Kondensator

Kølekom-

pressor

Frostkom

-pressor

CO2-

pumpe

Køl

Frost

CO2

CO2

Kondensator HT-ventil

GBP-ventil

Kølekom-

pressor

Frostkom

-pressor

R404A

Køl

R404A

HFC-anlæg

Frost

Tørkøler

Kondensator

Kølekom-

pressor

Frostkom

-pressorBrine

pumpe

Possible refrigerants• Hydro carbons

– ODP = 0, GWP < 8

– Non-toxic, but flammable

– Compatible, mixable, stabile

– Low density, low discharge temp

– High COP

• Ammonia– ODP = 0, GWP = 0

– Toxic and flammable

– Corrosive, not mixable with oil

– Low density and high discharge temps

– High COP

• “New” refrigerants HFO’s– Flammable (A2L?), toxic?, expensive

28 mm 12

mm22 mm

R404R/Propan CO2

Ammoniak

Sugerør (-30°C)

Væskerør (+30°C)

8 mm 6 mm5 mm

Accidents in a refrigerated warehouse - propane

• Germany 2017• Aarhus, 2008

1. 2. 3.

Propan/

NH3

CO2 (-10°C)

Brine (-10°C)

CO2 (-30°C)

+5°C

-18°C

Propan/

NH3

CO2 (-10°C)

CO2 (-10°C)

CO2 (-30°C)

+5°C

-18°C

CO2 (-10°C)

CO2 (38°C)

-10°C

CO2 (-10°C)

CO2 (-30°C)

+5°C

-18°C

Odense-projektet, 2000

Beder-projektet, 2001

Schou Epa – Roskilde, 1996

F&U-projekt, ENS, 1999

Sjapis-aktiviteter på køl, 2000

F&U-projekt, ENS, 1999

McD/Findan-projektet, 2002

Knudsen Køling-projektet, 2002

Carrier, 2002

Carrier, 2002/2003Costan (2000)

Carrier (2003)

Linde (2004)

Knudsen Køling (2005)

Teknologisk Institut26.10.2005

Køle- og Varmepumpeteknik

9

Supermarkets – 3-step rocket1999-2005

Propane compressor

Brine pumps CO2 compressor

Oil seperator + IHXReceiver

Top: IHX

Left: Brine cooler with ex. valve

Right: Cascade HX with ex. valve

and 4 pcs. stop valves

Ventilation duct

Supermarket rack development

Challenges with CO2• High pressure

– Knowhow and education– Understand the process

• How does it work? – More complex – 2 new valves– Centralized/ remote

• Electronic controls – EEV instead of TEV– Electronic controllers needed

• Warmer climates– New accelerating technologies

• Availability of components– Compressors 10-20 kW

• Price

75 80 85 90 95 100 105 110 115 120

1

1.2

1.4

1.6

1.8

2

2.2

2.4

1

1 .2

1 .4

1 .6

1 .8

2

2 .2

2 .4

Pg,2

[bar]C

OP

[-

]

32°C

CO

P [-

]34°C

36°C

40°C

4 4°C

Challenges with CO2

• CO2 leaks

– Knowhow and education

• High pressure - components

– New accelerating technologies

0,5% CO2 (=5000ppm) is normal gas detector set point

HT LTDon’t do this:

aircooler

Tesco UK/ Migros Switzerland

Euroshop 2011- edge of break through

Advantages of CO2 as refrigerant

• Only one refrigerant – CO2 / DX and copper piping

• Optimized design: cobber, small pipes, hoses , and oil handling

• No brine nor water pipes

• Can be installed anywhere, no limits to the loc. of the condenser

High level of security

Reliable operation

Easy installation

Low installation and

operating costs

Safety valves and switches

Production and assembly approved

CE-labelled in accordance to PED cat. IV

High level of documentation

Well known tested components (compressors, exchanger, control)

Optimal and easy controls and monitoring

Resistant against compressor failure (oil handling, IHX, accu)

Secure handling of stand still pressure

High safety at service (pump-down, easy access)

Low energy consumption

Low cost refrigerant

Easy and quick service

Availability of all components (standard)

200% extra heat recovery

cooling with termosyfon

Stabile temperatures

1

10

100

1000

MT LT AC

Small single weatherproof compressor unit

Retail/Pharmaceutical5 evaporators

Small compact multi-compressor unit

Discount/Convenience

Medium multi-compressor unit

Supermarket/Convenience

Medium + Large multi-compressor unit

Supermarket/Hypermarkets

Large + XL multi-compressor unit

Industrial

CDU XXS1350 x 1000 x 800 mm

MiniBooster XXS800 x 100 x 2100 mm

ValuePack XS2500x1900x800 mm

compSUPER S/L6000x2150x800 mm

compINDUSTRI XL6000x2150x1200 mm

Growth – Pricing and rack efficiency improvement over timeOverall, TC CO2 technology have improved its competitiveness

• Prices per kW have been reduced by more than 30% since 2006

• Energy effciency has been improved by 25% since 2006

Pressure on priceand technology

HP

Gas-by-pass

Oil separator

Gas cooler

MT comp

GBP

EE

V

EE

V

EE

V

MT

EV

AP

OR

AT

OR

S

EE

V

EE

V

EE

V

LT

EV

AP

OR

AT

OR

S

CO2 evolution – Advansor solutions Heat recover HX

False load evaporator

Heat pump function

IHX

Parallel comp

Sub-cooler

Heat recovery

Heat pump

Air conditionAdiabatic

Sub-cooler

Parallel comp

CO2 cassette

Adiabatic

MT load

LT load

Ejector gas

Ejector liquid

LT comp

LT compres

Ejector

AC

Energy and hot climate techParallel compression, adiabatic, sub-cooling, ejector

CO2 Booster solutions

Ejector CO2 Booster solutions

CO2 Booster solutions

Enhanced CO2 Booster solutions

Big growth in the market for CO2

Reference: Shecco

Trends in Supermarkets• Consumer/ shopper do change behavior! • Digitalization: Robots, sensors, amusement• Trends

– Online shopping– Small store locally– Eat out!

• Physical store or on-line?– E-tail/ online shopping– Local collect– Cash & Carry / Drive Thru– Employee free stores