In these times of changing regulations and new technologies affecting refrigerants, everyone is seeing the impact and is turning towards more sustainable alternative solutions.
This could not be more true across the retailing and distribution sector, where R-404A refrigerant is most commonly used. Pascal Tsin, owner of the three Super U stores in Mauritius, is following suit as his supermarket in the centre of Belle Rose undergoes refurbishment.
Covering an area of 2,500 m², the store was in need of renovation, requiring not only new chilled display cabinets and cold rooms, but also systems to replace the ageing refrigeration units loaded with R404A.
Needs analysis for the renovation project
Following a trip to France to meet the various people involved in the project, the condensing unit manufacturer, EPTA, carried out a needs analysis in close collaboration with Action Optimisation Energies, a company specialising in thermal installation control and energy management, and Climalife, the refrigerant specialist.
Giovanni Tourmentin, Super U’s Technical Manager in Mauritius, remembers how important this visit was: “It was essential for us to explore all of the latest technologies available so that we could determine the most appropriate solution for our needs. The aim was to replace all of our refrigeration equipment to give us a reliable system for the next 10 years, but to keep the store open so that our customers wouldn’t be affected.”
Installing the new R-448A system
In June 2017, work began to install the system in a new equipment building in the car park, enabling the upgrade to be performed without closing the store. Super U called upon installation engineer Mauricein Frima to fit the system and the piping, arranging for the majority of the work to be carried out overnight to connect the refrigeration equipment zone by zone. Action Optimisation Energies engineers then worked on site to set up the control and remote monitoring system. The system was configured based on the pressure and temperature settings for R-448A and went into operation without a hitch in September 2017.
Work to replace the cold room panels is almost complete and the cooling system for the delivery bay is scheduled to go into operation to preserve the cold chain. Of particular note, Güntner air-cooled condensers with speed variators fitted on all fans were chosen to reduce noise pollution and prevent any disturbance to local residents. All of the evaporators have also been replaced.
The project is scheduled for completion by mid-April 2018. In Giovanni Tourmentin’s words, “This is fantastic. The system meets all our expectations – all we need to do now is measure our energy usage over the next few months.”
The solution
A centralized R448A system: Giovanni Tourmentin explains why R448A was chosen.
“We examined the C02 option but the location of our equipment room in the car park and the installation of this type of technology would force us to close the store for a while. But R448A was a much more feasible solution and the good thing is that we’ll also be able to use it when we carry out simple retrofits at our other SUPER Us in Grande Baie and Flacq in the coming years. Its low environmental impact is also an advantage.”
Two EPTABERG units, for above-zero and sub-zero refrigeration, were chosen for the project. They will supply the cold storage rooms, the laboratories, all of the new appliances and the chilled display cabinets. These latest generation appliances from manufacturer Bonnet Neve are fitted with LED energy-saving bulbs and have been designed to showcase products in the best way possible and enable easy access for customers. The new centralised system is innovative because it includes a cooling function for the delivery bay without increasing the cooling capacity, and a heat recovery system for the store’s domestic hot water.
Description of the refrigeration system
• Description of the EPTABERG above-zero refrigeration unit:
– Total gross power of connected units: 147,325 W
– Centralised system with five Bitzer 4GE-23Y-40P 400V semi- hermetically sealed compressors (four 50hz compressors + one 60hz compressor) with HP and LP safety pressure switches
– Refrigerant: 350 kg of R448A
– Operating conditions: -11.5°C / +45°C
– Vertical tank cylinder of 200 dm3
– Shock-absorbing fluid cylinder
• Description of the EPTABERG sub-zero refrigeration unit:
– Total gross power of connected units: 42,570 W
– Centralised system with five Bitzer 4GE-23Y-40P 400V semi-hermetically sealed compressors (four 50hz compressors + one 60hz compressor) with HP and LP safety pressure switches
– Refrigerant: 200 kg of R448A
– Operating conditions: -37.5°C / +45°C
– Vertical tank cylinder of 200 dm3
– Shock-absorbing fluid cylinder
• Güntner GVH-type vertical air-cooled condensers
• Güntner evaporators for all cold rooms. Electrical or natural defrosting.
• Action Froid control and monitoring system (electronic expansion for the refrigerated appliances and thermostats for the cold rooms).