40 TH ANNIVERSARY 1979 - 2019
13.03.2025

CO₂ Transcritical Refrigeration at Scale: Advancing Industrial Efficiency in Ecuador

CO₂ Transcritical Refrigeration at Scale: Advancing Industrial Efficiency in Ecuador

 

In the industrial refrigeration landscape, CO₂ transcritical systems are proving to be both a high-efficiency and sustainable alternative to traditional refrigerants. A large-scale shrimp processing facility in Ecuador has adopted this technology, marking a significant step toward reducing environmental impact while maximizing operational performance.

This project integrates a fully CO₂ transcritical refrigeration system with a carefully engineered design to meet the facility’s stringent cooling demands:

  • 46 medium-temperature (MT) transcritical compressors (nominal capacity: 1940 HP)
  • 33 low-temperature (LT) compressors, ME type (nominal capacity: 1060 HP)
  • 6MW of total installed refrigeration capacity, ensuring system stability and redundancy
  • 7 operational refrigeration units, each optimized for specific process requirements
  • 26 industrial evaporators, distributed strategically to maintain uniform cooling
  • 12 gas coolers (each 8x800mm), maximizing heat rejection efficiency
  • 2 LT pump stations, each with 3500L vessels, designed for precise liquid distribution

 

Key Technical Innovations

This CO₂ transcritical system incorporates advanced refrigeration principles that enhance both efficiency and sustainability:

  • Mechanical Subcooling: Improves system efficiency by reducing flash gas formation, increasing cooling capacity without additional energy input.
  • Vapor Ejectors: Enhance energy efficiency by recovering energy lost during pressure reduction from the gas cooler to the liquid line. This innovative approach reduces compressor workload while consistently meeting cooling demands.
  • Hot Gas Defrost: Enhances heat transfer efficiency while minimizing energy consumption and frost buildup within evaporators.
  • Heat Recovery Integration: Captures waste heat from the refrigeration cycle to preheat water, reducing overall energy demand.

 

Performance Metrics

The system is designed to operate at ultra-low and low temperatures, ensuring high thermal stability and energy optimization across different process zones:

  • Ultra-LT Evaporation (-45°C/-42°C): 1620 kW capacity
  • LT Evaporation (-32°C/-25°C): 1530 kW capacity
  • MT Direct Expansion (-5°C/-3°C): 460 kW capacity
  • MPG20% Brine System (+1°C): 640 kW capacity
  • Air Conditioning Water (+6°C): 1000 kW capacity
  • Heat Recovery Water (55°C/65°C): 1300 kW capacity
  • Total Gas Cooler Heat Rejection: 8300 kW

 

 

Impact on Industrial Refrigeration

This facility represents one of the largest fully CO₂ transcritical refrigeration installations in the region, demonstrating the viability of CO₂ as a long-term solution for large-scale food processing. Compared to conventional HFC-based systems, CO₂ transcritical technology offers:

  • Lower Global Warming Potential (GWP = 1), eliminating reliance on high-GWP synthetic refrigerants.
  • Higher Thermodynamic Efficiency, especially in low-temperature applications.
  • Enhanced Energy Recovery Capabilities, reducing auxiliary heating requirements.
  • Improved Safety & Regulatory Compliance, aligning with international F-Gas reduction policies.

 

A New Standard for Industrial Refrigeration

The scale and complexity of this installation highlight the growing shift toward environmentally responsible and high-performance refrigeration solutions. CO₂ transcritical technology is no longer an emerging trend—it is now a proven, scalable solution that aligns with global efforts to reduce carbon footprints in industrial operations.

The adoption of CO₂ refrigeration in large-scale applications like this sets a precedent for the future of industrial cooling—one that balances performance, sustainability, and energy efficiency.

 

 

 

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