COMMERCIAL REFRIGERATION AT HIGH PERFORMANCE ENERGY APRIL 2016

Presentation Contents ALDI Aust ral ia 1. Current Refrigerat ion – CO2/ R134a system performance/ analysis

2. Chest Freezer Performance/ Analysis

3. ALDI Refrigerat ion Future – CO2 Transcrit ical Systems

Other Supermarkets around Aust ral ia: 1. Woolworths

2. Coles Australia

3. Coles Coburg

4. Coles Coburg - Liquorland

New developments across Asia Paci f ic Possible barriers to CO2 t ranscri t ical in Aust ral ia Possible commercial applicat ions for natural refr igerants in Aust ral ia

Refrigeration Systems Found in a typical ALDI store

▸ Current ly ut ilise CO2 Cacade/ R134a systems. ▸ Us ed For Chiller, Freezer Rooms and Multideck Cas es

▸ Typically 5 kWr on low Temp and 89 kWr on Med Temp

▸ 145 + s tores ins talled s ince 2014

Performance & Results

▸ Small efficency improvement

▸ Good refrigeration performance

▸ Elimniated all R404a leaks /emmis ions

Issues and Learning

▸ Initial cos t premium (now eliminated)

▸ S ome ups killing of ins tallers required (becoming indus try s tandard) .

ALDI CO2 Cacade/R134a systems

▸ Needs high s ide plant

operating – may have relief valve dis charge (not a major problem).

▸ R290 ut ilised on both Ches t and Top Freezer units

▸ Each has < 150g of Hydrocarbon charge

▸ Each unit has VS D compres s or and EC fans on condens er/s ub cooler.

ALDI Chest Freezers

Performance & Results

▸ Very reliable

▸ 6.7 kWhrs/ 24 hrs for 670L net volume

▸ Can have significant ly

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.

CO2 TRANSCRITICAL

Performance & Results ▸ Utilis es one low temp boos ter compres s or and 3 medium

temp compres s ors

▸ S ingle Gas Cooler with adiabatic water s prays and s mall water chiller running on R290 and high pres s ure s ub cooler

▸ S ite has no s ynthetic refrigerant , s o overall TEWI is reduced for the s ys tems life

CO2 TRANSCRITICAL

Issues and Learning

▸ Cos t premium for initial ins tallations .

▸ Tes ts run in February 2016 s howed the s ys tem would overload if ran without water s prays , res ulting in s ome CO2 releas e from the LT receiver.

Performance and Results

▸ Very good multideck performance

▸ Ran 1 year without any major fault

▸ Reduced energy us age f0r majority of operating conditions below 30 degC

▸ For December, overall the s ame as s imilar s tores , better for colder months

Future

▸ Improve reliability of s ubcooler

▸ S ource OEM units on

natural refrigerants

▸ Reduce s ize of boos ter

▸ CO2 integral units on water loop

▸ Only enable water s prays at peak ambient

▸ Cons ider parrallel compres s ion and ejectors for next generation

Woolworths Australia

▸ Many CO2/R134a ins tallations in the pas t few years

(indus try s tandard).

▸ Two CO2 trans critical plants in New Zealand underway.

Coles Coburg North Store – System Description

▸ Als o s erving s tore airconditioing via chilled

water from 3 parallel compres s ion compres s ors and chilled water heat exchange

▸ Alfa Laval gas cooler with adiabatic water s prays .

▸ High pres s ure s ub cooling via plate heat exchangers to the parallel compres ion s uction.

▸ S ys tem has heat reclaim on dis charge.

▸ Has emergency compres s or/condens er to maintain pres s ure in cas e of fault.

▸ 1 s tore CO2 trans critical us ing two large bitzer compres s or racks

▸ S erving 6 freezer cas e s tubs and 14 medium temp s tubs per rack including BOH freezer and chiller rooms

Coles Coburg North Store

Performance and Results ▸ General concensus is happy with

res ults

▸ S ignificant energy s avings reported (>15%) s ince commis s ioning in June.

▸ This s tore s ucces s will be a catalys t for future ins tallations .

Issues and Learning ▸ Trial of Hot gas defros t has been reverted

back to electric – no s ignificant energy difference reported.

▸ S ome oil foaming is s ues (currently being worked through)

▸ Failure of oil s eparator (due to internal implos ion).

▸ S ome learning due to s eparation of commis s ioning res pons ibility from initial ins tallation crew.

▸ Condens ing via waterloop to dry cooler with

adiabatic s prays

▸ Hydrocrabon charges of 650-850g per cas e (greater than 150g limit) – requires cas es to be built in as part of ris k/compliance review.

▸ Us ing OEM (Carter UK) equipment.

Coles Coburg Liquor Land – Hydrocarbon R1270

System description ▸ 2 X 3.75m & 1x2.5m Multideck liquor dis play cas es , pre packaged with 2

hermetic compres s ors on each cas e.

Other Installations – New Zealand

System Features ▸ CO2 transcrit ical with

air cooled gas coolers

▸ Low Temp and Med Temp And Hot water Reclaim

▸ High s tanding pres s ure avoids need for s tandby power 120 bar high s ide 60 bar low s ide

▸ Have multiple s tores in Place

Issues and Learning ▸ Need to cons ider

implications of s pecialis t controls s ys tems which need overs eas as s is tane for modifications etc.

▸ New Zealand has a form of carbon levy on high GWP refrigerants – this helps make the cas e for CO2 Trans critical

Barriers in Australia to Adoption of CO2 Transcritical and natural Refrigeration

Cost Premium ▸ Higher init ial Cost - offs et by lower lifecycle cos t

▸ HFOs not cons idered as long term s olution and are expens ive

▸ Trans critical cos ts will be reduced as volume of ins tallations increas e

Expertise

▸ Lack of s kills and knowledge arround trans critical and natural refrigerants

▸ This is a ‘chicken and egg’ s cenario – as demand increas es , s witched on companies and mechanics will ups kill to meet demand.

Barriers in Australia to Adoption of CO2 Transcritical and natural Refrigeration

Regulatory Barriers ▸ Inconsistent and uninformed OH& S regulators

– Better licens ing programs are required

▸ S tandards (s uch as AS 1677) need replacing (IS O 5149 to be releas ed late 2016?).

▸ Concern on who carries the ris k for new applications utilis ing this technology – What is the definition of a competent pers on?

▸ Where are our indus try bodies ? – s eem to be taking a pas s ive approach, Mis s ed opportunites .

Training Faculties and Courses

▸ Aus tralian TAFE s ys tems facing many hurdles – Demand is needed to pull incentives for cours e development

– A Better licens ing s ys tem that rewards technicians who has ups killed

Barriers in Australia to Adoption of CO2 Transcritical and natural Refrigeration

▸ Chilled water from parallel compres s ion s upermarket refrigeration (e.g. Coles

Coburg North)

▸ Direct Expans ion CO2 in multis ys tem applications (e.g. Equizine in Thornbury)

▸ Chilled water forom high temp s tage of ammonia refrigeration s ys tem (e.g. Aldi)

▸ Future applications of Air cooled Hydrocarbo water chillers

▸ S mall charge Hydrocarbon s plit s ys tems

Natural Refrigerants & HVAC systems in commercial applications