CO2 Systems:

Trends, Benefits and ROI

Newark, N.J., August 24, 2016
Derek Gosselin
Technical Sales Manager, Systems Division
Hillphoenix
Impact of Systems Architecture

Refrigerants’ Impact
on the Environment

Different Types of System

Architectures

Energy’s Impact on
System Designs TCO

Investing in New
Technology
Refrigerants’ Impact
on the Environment
Refrigerants’ Impact on the Environment
Alternate Refrigerants Strategy

Refrigerant Other Names/Components ODP GWP

Past
R-22 Freon-22 (HCFC) 0.055 1810
Current R-404A R-125/143a/134a, HP-62 0 3922
systems R-507 R-125/143a, AZ-50 0 3985
R-407A R-32/125/134a 0 2107
New and
R-407F(C) R-32/125/134a 0 1825/1744
retrofit HFC
R-134a Single-component refrigerant 0 1430
New and
retrofit R450A/513A N13-1234ze/R-134a/XP10-1234yf/134a 0 547/631
HFO blends R-448/449A N40 Honeywell, XP40 Chemours 0 1273/1397

Higher-pressure R-410A R-125/32, AZ-20, Puron 0 2088(675)

HFC R-744 CO2 0 1
R-717 Ammonia, NH3 0 <1
Natural R-290 Propane (HC) 0 ≈3-20
fluids R-600a Isobutane (HC) 0 ≈3-20
R-1270 Propylene (HC) 0 ≈3-20
Alternate Refrigerants Strategy
A1 – Non-flammable A3 – Flammable
A2L – Mildly flammable B2L – Toxic, mildly flam.

CO2
Pressure or capacity

400–675
HFO+R-32 R-32 R-410A
blends
R-448A (N40)
NH3 R-449A (DR33)
HFO+R-32 R-404A
150– blends
< 1500
300 R-407C
R-22 like R-407A
R-290
HFO HFO+R32 blends R-407F
R-22
HFO 1234yf R-450A (N13)
HFO 1234ze
?
R-513A (XP10)
HFC
~600
R134a
DP: DR2; HWL: N12
ARK: ARC 1
0 500 1000 1500 2000 2500
4000
GWP Level
Qualitative chart; not to scale
Different Types of System
Architectures
System Architectures to Reduce or Eliminate High-GWP Refrigerants

Distributed Secondary CO2 cascade CO2 booster

100% HFC charge Glycol or CO2 60 to 70% charge reduction 100% natural
Reduced GWP +/-50% charge reduction with ability to use natural refrigerant
w/HFO blends with ability to use natural refrigerant
refrigerant
CO2 Secondary (Pumped) Architecture

Liquid CO2 is circulated to provide refrigeration.

+/- 50% reduction in carbon footprint over traditional DX technology.
Simple system design with on/off solenoid operation for temperature control.
CO2 Secondary (Pumped) Architecture

SNMT2 – MT CO2 secondary

SNLT2 – LT CO2 secondary
CO2 Cascade Architecture

Utilizes DX CO2 on the lower cascade and an HFO blend-based DX system on the upper cascade.
Eliminates all LT HFCs; significantly reduces carbon footprint over traditional DX technology.
CO2 Cascade Architecture

Upper cascade
HFC primary system;
refrigeration located in
machine room

Lower cascade
MT CO2 secondary LT CO2 DX;
refrigeration within the store area
CO2 Cascade Architecture
Change to a GWP HFO blend refrigerant
Upper cascade – primary system

Ammonia (NH3) primary

R-290 propane primary

100% natural refrigerant solution

CO2 Cascade Architecture

SNLTX2 – LT CO2 DX cascade

SNLTX2MT – Combination system
LT CO2 DX cascade with MT CO2 secondary
With HFC primary
CO2 Booster Architecture

Benefits of CO2 booster technology

• HFC-free system, CO2 only
• CO2 is a natural refrigerant; GWP=1
• High-quality heat reclaim opportunities
• Simple oil management system
• Electronic expansion valves in all cases
• Familiar components to traditional DX system
• Low-temp system very similar to cascade system
CO2 Booster Architecture

CO2 booster technology review

GAS COOLER AND

Electronic expansion HEAT RECLAIM LOADS

valves Case controllers

• Case controllers are required

• Used to maintain the
for CO2 booster design
superheat at the outlet of TRANSCRITICAL COMPRESSORS

the case/coil HIGH PRESSURE

EXPANSION VALVE MT cases
MT DISPLAY
CASES

• Can be pulse or stepper FLASH TANK

(INTERCOOLER) FLASH GAS EEV

valves
CONTROL
VALVE

SUBCRITICAL COMPRESSORS
SLHE

LT DISPLAY
CASES

LT cases
EEV
CO2 Booster Architecture

Leading edge field trials,

with some having full adoption
Evolution of CO2 Architecture

CO2 transcritical systems are gaining global traction.

Evolution of CO2 Architecture

200+ Secondary 50+ Cascade 200+ Booster

More than
30 locations
in California
Energy’s Impact on
System Designs TCO
Relationship Between Energy and Global Warming
Continuous Investment in CO2 Booster Technology:
CO2 Warm Climate Technologies

• High-pressure sub-cooler
– Removes additional heat after air-cooled gas cooler
– Requires chilled water; likely HVAC water in urban buildings
(w/ 5–8% overall annual energy benefit), or from combined
heat and power system absorption chiller (w/ 12–15% annual Sub-cooler

energy benefit)
– Market ready
– Enables booster system operation in the highest dry bulb PARALLEL
COMPRESSOR Adiabatic gas cooler
ambient temperatures (as does adiabatic)

• Adiabatic gas cooler

– Peak savings 20–30+%; annual savings 8–12%
– Market ready

• Parallel compression system

– Peak savings 12–20%; annual savings 6–8%
– Currently operational in R&D lab
Continuous Investment in CO2 Booster Technology:
CO2 Warm Climate Technologies

• Ejector
– Works in combination with parallel compression PARALLEL
COMPRESSOR

– Peak savings 15–20%; annual savings 8–10%

– Under development in the R&D lab
– Advansor has delivered a beta system, and it is
operating in Europe EJECTOR

– Ready for U.S. beta site testing in 2016

Parallel compression with ejector

Ejector
CO2 Application in a Warmer Climate

• Elimination of HFCs and reduce the carbon footprint

• Energy comparison with the customer’s traditional R-407A system
• Adiabatic condenser applied to the system for warm climate
CO2 Application in a Warmer Climate
Investing in New Technology
Challenge and Focus on First Cost

$ CO2 system costs are coming down.

Supporting the Purchase of New Technology
Understanding Challenges and Benefits of CO2 Booster Systems

Challenges

Increased Capital Cost

CO2 systems currently cost more
 Driving systems cost reduction to a closer parity with HFC DX systems
 Cases require EEVs and case controllers

Availability of Refrigeration Contractors

The CO2 booster systems are similar to traditional DX systems, but require some additional training for installation, startup and
maintenance that is available through the Hillphoenix Learning Center.

Impact on Energy Performance

With the low critical point of CO2 versus traditional DX systems, ambient conditions impact the performance of the systems.
Adiabatic condensers and parallel compression are recommended in warmer climates.

Tangible Benefits Intangible Benefits

(Things we can calculate) (Things we know but are hard to calculate)

 Savings on startup refrigerant charge  Future cost avoidance of HFC retrofits

 Savings on refrigeration installation  Relief from leak & recordkeeping requirements
 Savings on electrical installation  Savings PM program w/ lower cost refrigerant
 Savings on case performance with EEVs  Better quality product w/ better case controls
 Savings on energy  Impact on social responsibility
Focus on Total Cost of Ownership
Overcoming first cost difference with an ROI
Option A Option B
Sample ROI Difference
Glycol - DX Advansor
Refrigeration system capital cost xxx,xxx xxx,xxx xxx,xxx
Refrigerated display cases capital cost xxx,xxx xxx,xxx xxx,xxx
Equipment capital cost $ 198,060

Estimated start-up refrigerant $ 20,800 $ 2,250 $ (18,550)

Estimated equipment installation $ 398,486 $ 298,000 $ (100,486)
Estimated electrical installation $ 277,388 $ 248,000 $ (29,388)
Estimated installation savings $ 696,674 $ 548,250 $ (148,424)

Annual refrigeration savings (20%) 4160 390 $ (3,770)

Annual energy savings ( .10 kWh rate) 121447 105411 $ (16,036)
Total estimated annual savings 125607 105801 $ (19,806)
Utility rebate or incentive for natural refrigerants that save energy BONUS
Equipment cost - installation savings $ 49,636
ROI with annual savings 2.5 Years
$All ROI’s vary based on baseline design and type of new technology being considered
Focus on Total Cost of Ownership

$
Lessons Learned

“Change is coming, and we need to understand our options

so we can make good business decisions.”

“New lower GWP HFO blend refrigerants provide an

alternative in traditional DX refrigeration.”

“The trend is moving to natural refrigerants globally and can

be a long-term solution.”

“CO2 system costs are decreasing along with rapid

improvement in technology to provide energy efficiency in
warm climates.”
$
Thank You!

Questions?

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Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or
implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for
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herein or that other measures may not be required.

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