COLD STORES
Refrigerant charge size 80kg (313.8 tonnes equivalent CO2
) Cha llenges:
Humidity control (essential for product quality) Control of Δt across evaporator Defrost
Q R-407A (classification A1 – GWP 2107-AR4) Refrigerant charge Size 18kg (38 tonnes equiv- alent CO2
)
Ben efits: Improved control of Δt across the heat exchanger Improved control of humidity Improved product quality 88% reduction in tonnes equivalent CO2
Q R-454A (Opteon XL40 – classification A2L – GWP 238-AR4) Refrigerant charge Size 17.5kg (four tonnes
equivalent CO2 Ben =efits: Improved control of Δt across heat ex- changer Improved control of humidity Improved product quality
@98% reduction in tonnes equivalent CO2 v’s R-404A
@89% reduction in tonnes equivalent CO2 v’s R-407A 78% reduction in charge size v’s R-404A DX 3% reduction in charge size v’s R4-07A secondary system.
External plant room The plant room was fabricated offsite and installed externally to the cold store and is fully ventilated. The refrigeration system was installed and commissioned in October 2021 and is certified as PED Cat III. Internal volume of the plant room is 18m³. Risk assessments were considered in relation to using an A2L refrigerant. Operating conditions: Evaporator temp = -1°C, condenser temp. = 38°C, Total Superheat = 4 to 6K, Subcool amount = 3 to 4K. Key components (supplied by manufacturer and installer Welvent) Q Refrigerant: Opteon XL40 (R-454A) Q Charge size: 17.5kg Q Compressor: Bitzer GSD60235VLB4-2 inverter driven scroll
Q Condenser: N9 (A2L Approved) CD-STP-2.5- 1900-1050-6R-42-V1
Q Glycol pump: inverter driven Pedrollo F32/160B pump
Q Brazed plate heat exchanger: Swep V120THx70/IP-SC-M heat exchanger
Q Electric expansion valve: Danfoss Colibri EEV ETS 12C. 034G7S0R (A2L)
Q Controller: Danfoss controller EKE 1C superheat controller.
Although no records exist for comparison of power consumption, Kitchen Garden Produce reports that run times between R-407A and R-454A are unchanged and it is possible to run a simulation showing the two fluids properties at the design conditions.
Using R-404A as a datum, we vs
R-404A 76% reduction in charge size vs R-404A DX
can see that like-for-like simulations at design conditions demonstrate improved performance and efficiency when employing Lower GWP refrigerants. The values are based on £0.14/kWhr, 50% running time and a notional 5% leakage rate. Running costs are very similar to R407A but with a notable reduction in TEWI (total environmental warming impact). Key benefits from converting to LGWP A2L Opteon XL40 (R-454A): Q Environmental credentials: Low GWP
90% reduction in tonnes equivalent CO2 3% reduction in charge size
Q Repeatability: Plans proposed for new installations based on this site experience Lessons learnt from this installation being easily transferrable to new projects
Q Improved environmental credentials with supermarket customers (KPI).
With the exception of revisiting the extra points to be considered during the risk assessment, the installation of the system using Opteon XL40 (A2L) was no more problematic than installing a system operating on R-407A (A1). The risk assessment was carried out by Cool Concerns.
New business opportunities Feedback from Kitchen Garden Produce is that this has already led to new business opportunities. Initial concerns regarding ‘glide’ proved unfounded. Correct brazed heat exchanger selection and the use of an electronic expansion valve maintained close control on suction superheat and evaporator capacity. The system has performed as expected since commissioning, without any reported problems and the calculations based on the measured data indicate that the system is performing better than R-407A or R-404A would
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have done if operating at the same system parameters. Opteon XL40 has been proven to be a satisfactory replacement for R-404A / R-407A with improved performance as well as
a circa 98% reduction in tonnes equivalent CO2 compared with R-404A.
Mike Sharp, Joint managing director of the manufacturer and installer Welvent, is clear that as part of Welvent’s commitment to offer clients sustainable technology, the company had been following the F-Gas phase down steps. First, with the move from R-404A to R-407A, and now to
Opteon XL40 (R-454A). With the reduction in CO2 equivalent available for new install and service in the coming years, the very low GWP refrigerant was an excellent solution for the future. The properties of the refrigerant made it much easier to use, even with its low flammability, compared with some other solutions available on the market.
Mr Sharp comments: “The whole project has been a real eye opener into the latest compliance and the new range of technology out there. I believe this project has enabled us to lead the way within the industry. Having the can-do approach is a very important attitude in the industry. Performance-wise from the refrigerant, duties and gas charge are very similar to our standard R-407A systems, with no issues of glide on original design predictions.” Chris Kitchen, partner at Kitchen Garden
Produce, emphasised how important it was that suppliers to the major supermarkets are able to show their environmental credentials and that they are regularly audited to ensure they are reducing their climate impact where possible. The use of a sustainable replacement product with very low GWP for refrigerating his crop was an important element. X
www.opteon.com X
www.welvent.com X
www.kitchengardenproduce.co.uk X
www.coolconcerns.co.uk
www.acr-news.com • July 2022 25
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