Ian tuena (2) natural refrigerants presentation april 2016
- 2. Presentation Contents ALDI Australia 1. Current Refrigeration – CO2/R134a system performance/analysis 2. Chest Freezer Performance/Analysis 3. ALDI Refrigeration Future – CO2 Transcritical Systems Other Supermarkets around Australia: 1. Woolworths 2. Coles Australia 3. Coles Coburg 4. Coles Coburg - Liquorland New developments across Asia Pacific Possible barriers to CO2 transcritical in Australia Possible commercial applications for natural refrigerants in Australia
- 3. Refrigeration Systems Found in a typical ALDI store ▸ Currently utilise CO2 Cacade/R134a systems. ▸ Used For Chiller, Freezer Rooms and Multideck Cases ▸ Typically 5 kWr on low Temp and 89 kWr on Med Temp ▸ 145 + stores installed since 2014
- 4. Performance & Results ▸ Small efficency improvement ▸ Good refrigeration performance ▸ Elimniated all R404a leaks/emmisions Issues and Learning ▸ Initial cost premium (now eliminated) ▸ Some upskilling of installers required (becoming industry standard) . ALDI CO2 Cacade/R134a systems ▸ Needs high side plant operating – may have relief valve discharge (not a major problem).
- 5. ▸ R290 utilised on both Chest and Top Freezer units ▸ Each has < 150g of Hydrocarbon charge ▸ Each unit has VSD compressor and EC fans on condenser/sub cooler. ALDI Chest Freezers
- 6. Performance & Results ▸ Very reliable ▸ 6.7 kWhrs/24 hrs for 670L net volume ▸ Can have significantly less central plant as low temp load is removed from the central racks Issues and Learning ▸ 6.7 kWhrs/24 hrs for 670L net volume ▸ Need department of mines rego if used in QLD ▸ Service mechanics need extra training ALDI Chest Freezers ▸ Use policy of no major cut ins/major service in store.
- 7. CO2 TRANSCRITICAL Performance & Results ▸ Utilises one low temp booster compressor and 3 medium temp compressors ▸ Single Gas Cooler with adiabatic water sprays and small water chiller running on R290 and high pressure sub cooler ▸ Site has no synthetic refrigerant , so overall TEWI is reduced for the systems life
- 8. CO2 TRANSCRITICAL Issues and Learning ▸ Cost premium for initial installations. ▸ Tests run in February 2016 showed the system would overload if ran without water sprays, resulting in some CO2 release from the LT receiver. Performance and Results ▸ Very good multideck performance ▸ Ran 1 year without any major fault ▸ Reduced energy usage f0r majority of operating conditions below 30 degC ▸ For December, overall the same as similar stores, better for colder months Future ▸ Improve reliability of subcooler ▸ Source OEM units on natural refrigerants ▸ Reduce size of booster ▸ CO2 integral units on water loop ▸ Only enable water sprays at peak ambient ▸ Consider parrallel compression and ejectors for next generation
- 9. Woolworths Australia ▸ Many CO2/R134a installations in the past few years (industry standard). ▸ Two CO2 transcritical plants in New Zealand underway.
- 10. Coles Coburg North Store – System Description ▸ Also serving store airconditioing via chilled water from 3 parallel compression compressors and chilled water heat exchange ▸ Alfa Laval gas cooler with adiabatic water sprays. ▸ High pressure sub cooling via plate heat exchangers to the parallel compresion suction. ▸ System has heat reclaim on discharge. ▸ Has emergency compressor/condenser to maintain pressure in case of fault. ▸ 1 store CO2 transcritical using two large bitzer compressor racks ▸ Serving 6 freezer case stubs and 14 medium temp stubs per rack including BOH freezer and chiller rooms
- 11. Coles Coburg North Store Performance and Results ▸ General concensus is happy with results ▸ Significant energy savings reported (>15%) since commissioning in June. ▸ This store success will be a catalyst for future installations. Issues and Learning ▸ Trial of Hot gas defrost has been reverted back to electric – no significant energy difference reported. ▸ Some oil foaming issues (currently being worked through) ▸ Failure of oil separator (due to internal implosion). ▸ Some learning due to separation of commissioning responsibility from initial installation crew.
- 12. ▸ Condensing via waterloop to dry cooler with adiabatic sprays ▸ Hydrocrabon charges of 650-850g per case (greater than 150g limit) – requires cases to be built in as part of risk/compliance review. ▸ Using OEM (Carter UK) equipment. Coles Coburg Liquor Land – Hydrocarbon R1270 System description ▸ 2 X 3.75m & 1x2.5m Multideck liquor display cases, pre packaged with 2 hermetic compressors on each case.
- 13. Other Installations – New Zealand System Features ▸ CO2 transcritical with air cooled gas coolers ▸ Low Temp and Med Temp And Hot water Reclaim ▸ High standing pressure avoids need for standby power 120 bar high side 60 bar low side ▸ Have multiple stores in Place Issues and Learning ▸ Need to consider implications of specialist controls systems which need overseas assistane for modifications etc. ▸ New Zealand has a form of carbon levy on high GWP refrigerants – this helps make the case for CO2 Transcritical
- 14. Barriers in Australia to Adoption of CO2 Transcritical and natural Refrigeration
- 15. Cost Premium ▸ Higher initial Cost - offset by lower lifecycle cost ▸ HFOs not considered as long term solution and are expensive ▸ Transcritical costs will be reduced as volume of installations increase Expertise ▸ Lack of skills and knowledge arround transcritical and natural refrigerants ▸ This is a ‘chicken and egg’ scenario – as demand increases, switched on companies and mechanics will upskill to meet demand. Barriers in Australia to Adoption of CO2 Transcritical and natural Refrigeration
- 16. Regulatory Barriers ▸ Inconsistent and uninformed OH&S regulators – Better licensing programs are required ▸ Standards (such as AS1677) need replacing (ISO 5149 to be released late 2016?). ▸ Concern on who carries the risk for new applications utilising this technology – What is the definition of a competent person? ▸ Where are our industry bodies? – seem to be taking a passive approach, Missed opportunites. Training Faculties and Courses ▸ Australian TAFE systems facing many hurdles – Demand is needed to pull incentives for course development – A Better licensing system that rewards technicians who has upskilled Barriers in Australia to Adoption of CO2 Transcritical and natural Refrigeration
- 17. ▸ Chilled water from parallel compression supermarket refrigeration (e.g. Coles Coburg North) ▸ Direct Expansion CO2 in multisystem applications (e.g. Equizine in Thornbury) ▸ Chilled water forom high temp stage of ammonia refrigeration system (e.g. Aldi) ▸ Future applications of Air cooled Hydrocarbo water chillers ▸ Small charge Hydrocarbon split systems Natural Refrigerants & HVAC systems in commercial applications