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Abstract
The article describes the operation of refrigeration systems in supermarkets that utilize
intermediary fluids, showing its advantages and disadvantages both technical and
economically , in comparison with traditional installations that use the R-22 on direct
expansion cooling systems.
These installations were initially designed with the purpose of reducing the amount of
frigorigenous fluid in the system and also of making possible its substitution by eliminar
means of ammonia or other compatible and environmentally nondangerous fluid. The system
therefore arises as a technical and economical feasible alternative for the substitution of
halogenous fluids utilized in refrigeration systems in supermarkets.
Based on the experience of several operating installations in Brazil, this article points out
the evolution of this type of refrigeration system, which makes possible the elimination of the
defrosting routines in medium temperature circuits. The target of this system design is
maintaining the energy performance in low temperature circuits similar to that achieved in the
direct expansion system.
Introduction
By the end of the 70’s, many scientists were concerned that halogen gases could be
noxious to the troposphere ozone layer within the Earth atmosphere. In 1987, representatives
from various countries gathered in Canada and signed the “Montreal Protocol”. This
international agreement set deadlines for the gradual phasing-out of these gases. The initial
deadline was set around the year 2020.
Since then, social pressure to reduce the use of fluids considered dangerous has increased
progressively, expediting the process of eliminating CFCs and HCFCs besides forcing the
market to adapt itself to this new reality as soon as possible.
In Brazil, because of this new challenge, we have developed plants using secondary fluids
as an alternative to the use of CFCs and HCFCs in refrigeration systems in supermarkets,
during the past ten years. These plants were initially conceived with the purpose of reducing
the quantity of refrigerants in the plant, since it is limited only to the quantity required by the
central plant, and the secondary fluid transports the “cold” from the plant to the consumer’s
point of sale display cases and warehouses. Therefore, it was possible to avoid the utilization
of halogen fluids in the system by using ammonia.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
The system is provided with a liquid chiller that cools down a water solution with an
antifreeze agent, which is able to keep this solution in the liquid state at low temperatures, as
described in the figure 1. The solution flows through a distribution pipework, driven by a
centrifugal pump, from the machine room to the cabinets and cold rooms. The temperature
required to preserve the product is kept by a suitable selection and control of the secondary
fluid temperature and the heat exchange surface temperature of the coils.
Figure 1: System Operation
LEGEND
1 - Liquid chiller
2 - Cooling tower
3 - Secondary fluid pump
4 - Condenser pump
5 - Expansion vessel
6 - Display cases and warehouses
7 - Defrosting valves (just for low temperature system)
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
The solution we designed intends to operate the installation with a smaller difference
between the intermediate fluid temperature, approximately –2ºC, and the product temperature.
Through an adequate trade-off between the selection of the solution flow rate and the heat
transfer surface area of the coils it was possible to keep the temperature required for a good
product preserving. This design alternative eliminates the temperature control and defrosting
routines in cabinets and cold rooms and allows achieving a better global energy efficiency.
2.2. Results
The results achieved as far as they belong to product conservation in these plants, by using
a secondary fluid, are equivalent to the results obtained in a cooling plant with a R-22 direct
expansion conventional system. However, as there are no more interruptions in fluid supply to
the coil, these conditions do not change throughout the day, assuring the perfect preservation
of the products according to the quality standards for merchandise, as shown in the figure 2.
Figure 2: Results Achieved In Cooled Products Systems
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
However, comparing the performance of the system under partial load conditions, using all
the annual average weather conditions, and not only the summer average, a larger increase in
the system COP is noticed. This happens because in direct expansion plants, the thermostatic
valve requires a certain pressure difference to assure the required yield. Considering that in
indirect systems chillers and electronic expansion valves are used, there is no need for a
pressure differential. Therefore, in addition to increasing the evaporation temperature, in these
cases, we also operate with a lower condenser temperature, to achieve a major gain in the
plant yield, as shown in the table 2.
Note: Operating conditions estimated for all the annual average weather conditions in the city of São Paulo -
Brazil (dry-bulb temperature of the air 21ºC and wet-bulb temperature 17,5oC).
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
Inhibited propylene glycol aqueous solutions are also compatible with almost all materials
used in common cooling plants, both equipment and for sealing joints and connections. The
major concern is to avoid contact with:
• Zinc.
• Galvanized steel.
• Gray cast iron.
• Water with excess chlorine.
• Water with excess sulfates.
Regarding toxicity, propylene glycol USP grade is used mainly in the food, cosmetics and
pharmaceutical industries. There are versions of inhibited propylene glycol totally nontoxic
(used in animal food). It complies with all specifications of the Brazilian and American
Pharmacopoeia, and it can also be used as a direct or indirect additive to food.
Regarding its flammability, propylene glycol in solutions with concentrations above 80%
has a flashpoint of 102oC. The product is not flammable under this concentration.
The gain obtained in approximating the temperature differentials is due to the following
factors:
• Greater inside heat transfer coefficient, which results in a greater overall coefficient;
• Utilization of heat exchanger with countercurrent flow;
• Uniform heat transfer throughout the coil;
• Minimization of superheat.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
Other factors should be highlighted in the defrosting procedures, since they also result in
an improvement in the quality of the plants:
• Electrical defrosting acts more effectively in coils with intermediate fluid than in dry
expansion due to the heat diffusion caused by the intermediate fluid throughout the coil
and closings, that also provides shorter periods of defrosting.
• Speed of temperature recovery in display cases and warehouses after defrosting is faster
than in direct expansion system, since there is no limitation on the coil capacity through
the expansion valve.
3.2. Results
The results achieved regarding product preserving in plants operating as described above
assure the conditions required for the storage and display of frozen products in supermarkets,
as shown in the figure 3. Although defrosting routines are still required, it was noticed that the
oscillations in the solution temperature after defrosting are much lower than the variations in
temperature of evaporation during the same periods of time in direct evaporation systems.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
However, when analyzing the plant under partial load condition, again using under all the
annual average weather conditions instead of the summer average only, there is a real gain in
the COP plant. As shown in the table 6.
Note: Operating conditions estimated under all the annual average weather conditions in the city of São Paulo -
Brazil (dry-bulb temperature of the air 21ºC and wet-bulb temperature 17,5oC).
Evaluating the investigated fluids according to the parameters described above, the results
at the table 7 are observed:
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
Regarding corrosion, the table 8 shows comparative data on the effects of corrosion on the
products according to ASTM D1384 standard tests:
The results lead us to the conclusion that potassium acetate, an inhibited organic salt
solution, has more appropriate physical characteristics to operate with intermediate fluid in
low temperature plants.
These solutions are also compatible with almost all materials used in ordinary cooling plants,
both in equipment and sealing joints and connections. The main precautions to be taken are
that they should not be used with:
• Polytetrafluoroethylene (PTFE);
• Silicone mixtures;
• Residues of glycol solution;
• Water with chlorine;
• Galvanized steel.
Regarding toxicity, Potassium acetate is not a dangerous product. Rapid exposures do not
cause any effect on health. Anyhow, it is recommended to use rubber gloves during the
operations according to the general standards for handling chemical substances. The table 9
shows some situations of contact with the product, their consequences and treatment:
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
4. CONTROL SYSTEM
Control system for indirect plants is very simple, particularly when compared to the
traditional refrigeration systems by direct expansion. In plants using intermediate fluid,
controls are restricted to the machine room, being:
• Control loop of the secondary fluid temperature;
• Control loop of the expansion valve.
Both control loops control the system in partial load operation. They are restricted to the
liquid chiller, and are monitored by the chiller microprocessor controller. Thus, it is possible
to maintain the plant stable with fluid temperature variations ranging between +/-1oC. It is
also possible to optimize the cooling cycle range, assuring a superheating up to 4oC.
When completing the control system, there is the automation of the defrosting routines for
frozen product cabinets and cold rooms. Such routines are monitored by dedicated controllers
that act in synchronicity to avoid both equipment from starting their cycle simultaneously. It
also has a temperature sensor that cuts off the cycle when the coil is completely unobstructed,
even though the total operation time has not been reached. Such device prevents the
equipment from superheating and makes it easier to recover the normal operation condition
after defrosting is completed.
All these data are gathered by the communications network and sent to a computer so that
a supervision software may follow up on all operations. This supervision software does not
control or operates the plant, it only transforms the data collected into information that the
operator may easily understand. These data are shown in friendly screens as graphs and
reports or are transmitted to the other remote station enabling a distance monitoring.
5. COSTS
The tables 10 and 11 compare the costs of implementation and operation of a cooling
system in a supermarket in the city of Porto Alegre – Brazil, which sales area totals
approximately 5.000 m2.
Note: The amounts at table 10 are estimated and were supplied directly by equipment and fixtures manufacturers
and do not include transportation, neither overhead costs.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
Note: The operating costs correspond to a plant with the following features:
• Heat load of cooled products: 250.000 kcal/h;
• Heat load of frozen products: 60.000 kcal/h;
• Both plants operating at the average capacity of 70%;
• KWh cost equals US$ 0,10 (sum of the demand, kWh at the peak hour, and out of the peak hour);
• The COP values used are the ones for plants with water condenser;
• Costs with replacement of refrigerant correspond to the amounts used by ASHRAE. For dry-expansion
plants, it indicates that leakage corresponds to 25% the total refrigerant load in the system per year (800
kg);
• The operating costs did not include the reduction in the heat load in the cooled products systems.
Systems with intermediate fluid present the following advantages and disadvantages in
relation to the traditional plants operating with R-22 direct expansion.
6.1. Advantages
• Reduced power consumption;
• Lower thermal load for medium temperature systems;
• Lack of defrosting routine for medium temperature systems;
• Lack of temperature control for cabinet counters and cold rooms;
• More effective heat exchangers;
• Less quantity of refrigerant fluid on the system and much less possibility of leakage;
• Simple installation and consequent lower cost of preventive or corrective maintenance;
• More operating reliability (less maintenance occurrences);
• Simplified control system;
• Feasibility using non-condemned refrigerants required by the “Montreal Protocol”.
6.2. Disadvantages
• Larger physical space at the machine room required for equipment installation;
• Larger areas for heat exchange required at the cooling coils of cold rooms and cabinet
counters in medium temperature systems;
• When using R717 as a refrigerant fluid, a special study of the machine room exhaust
system is needed.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
7. CONCLUSION
The major advantages of the cooling system using secondary fluid are the feasibility of
using an environmentally nondangerous refrigerant fluid, simple operation, a simpler design
of the control loop, required saving of energy, and stability of the plant’s operation. These
features have been be tested in several plants in operation in Brazil for more than ten years,
especially medium temperature systems where defrosting routines were eliminated. The
system remained permanently in a stable operating regimen, varying only according to the
thermal load needs of the store.
For low temperature systems, it was verified that the use of intermediate fluid results in a
better performance of the cooling coils, leading to better results concerning the temperature
maintenance for cold rooms and cabinet counters.
For more than ten years, it has been proved that use of intermediate fluid in refrigeration
plants in supermarkets provide major reliability and stability of operation and represents an
economical feasible alternative to avoid the use of CFCs and HCFCs.
8. EXISTING PLANTS
The table 11 presents a list with supermarkets installations in Brazil, that use scondary
fluid in its refrigeration systems.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001
Refrigeration Systems in Supermarkets with Utilization of Intermediary Fluids
Supermarket City / Brazil Year Area Chiller Cooled Products Frozen Products
m2 Refrig.
Bourbon Assis Brasil Porto Alegre 1990 11.000 R22 Propilene glycol Dry Expansion
Master Sonda Erechim Erechim 1993 4.500 R22 Propilene glycol Dry Expansion
Zaffari Anita Garibaldi Porto Alegre 1993 1.500 R22 Propilene glycol Dry Expansion
Zaffari Marechal Floriano Porto Alegre 1994 2.500 R22 Propilene glycol Dry Expansion
Zaffari Fernandes Vieira Porto Alegre 1995 1.000 R22 Propilene glycol Dry Expansion
Zaffari Fernando Machado Porto Alegre 1996 2.000 R22 Propilene glycol Dry Expansion
Zaffari Higienópolis Porto Alegre 1996 7.000 R717 Propilene glycol Dry Exp. R22
Real Menino Deus Porto Alegre 1996 4.000 R22 Propilene glycol Dry Expansion
Real Rio Grande Rio Grande 1996 4.000 R22 Propilene glycol Dry Expansion
Real Novo Hamburgo Novo Hamburgo 1996 3.000 R22 Propilene glycol Dry Expansion
Big Criciúma Criciúma 1996 5.000 R22 Propilene glycol Dry Expansion
Big Porto Alegre Porto Alegre 1996 16.000 R22 Propilene glycol Dry Expansion
Zaffari Ipiranga Porto Alegre 1997 7.000 R22 Propilene glycol Dry Expansion
Bourbon Canoas Canoas 1997 10.000 R717 Propilene glycol Dry Exp. R22
Zaffari Lima e Silva Porto Alegre 1997 3.500 R22 Propilene glycol Dry Expansion
Master Sonda Centro Erechim 1997 2.000 R22 Propilene glycol Dry Expansion
Big Florianópolis Florianópolis 1997 10.000 R22 Propilene glycol Dry Expansion
Big Joinville Joinville 1997 10.000 R22 Propilene glycol Dry Expansion
Real Iguatemi Porto Alegre 1997 4.500 R22 Propilene glycol Dry Expansion
Real São Leopoldo São Leopoldo 1997 3.000 R22 Propilene glycol Dry Expansion
Real Curitiba Curitiba 1997 1.500 R22 Propilene glycol Dry Expansion
Real Pelotas Pelotas 1997 1.500 R22 Propilene glycol Dry Expansion
Sonda Jaçanã São Paulo 1997 3.000 R22 Propilene glycol Dry Expansion
Zaffari Carazinho Porto Alegre 1998 1.200 R22 Propilene glycol K-Ac.
Sonda Cidade Dutra São Paulo 1998 4.000 R22 Propilene glycol Dry Expansion
Sonda Maria Amália São Paulo 1998 2.500 R22 Propilene glycol Dry Expansion
Bourbon Ipiranga Porto Alegre 1998 10.000 R717 Propilene glycol K-Ac.
Carrefour Pres., Prudente Pres., Prudente 1998 6.000 R22 Propilene glycol Dry Expansion
Carrefour Campo Grande Campo Grande 1998 8.000 R22 Propilene glycol Dry Expansion
Zaffari Cavalhada Porto Alegre 1999 5.500 R22 Propilene glycol K-Ac.
Bourbon Passo Fundo Passo Fundo 1999 9.500 R717 Propilene glycol K-Ac.
Zaffari Cristóvão Colombo Porto Alegre 1999 3.500 R22 Propilene glycol K-Ac.
Zaffari Bordini Porto Alegre 2000 1.600 R22 Propilene glycol K-Ac.
Zaffari Menino Deus Porto Alegre 2000 1.900 R22 Propilene glycol K-Ac.
Carrefour Diadema São Paulo 2000 7.600 R22 Propilene glycol Dry Expansion
Bourbon João Wallig (*) Porto Alegre 2001 10.000 R717 Propilene glycol K-Ac.
Master Sonda F. Caneca São Paulo 2001 2.000 R22 Propilene glycol K-Ac.
Clima 2000/Napoli 2001 World Congress – Napoli (I), 15-18 September 2001