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Emerson Highlights Commitment to CO2 at ATMO World Summit 2022

Andre Patenaude | Director – Solutions Strategy

Emerson’s Commercial and Residential Solution’s Business

Emerson recently participated in the ATMO World Summit 2022, a 24-hour event focused on exploring developments in the uses and applications of natural refrigerants. Emily Vilardi, Emerson product marketing manager and I presented a webinar highlighting Emerson’s commitment to CO2 refrigeration via the launch of new products and our expanded research and development (R & R&D) efforts. For those unable to attend the event or our session, ATMO has made it available for free on-demand.

Corporate sustainability objectives and environmental regulations are driving the adoption of refrigerants with lower global warming potential (GWP). As food retailers evaluate emerging solutions and transition to the next generation of refrigeration technologies, CO2 transcritical booster systems offer a proven, natural alternative. Although this innovative system architecture uses CO2 (refrigerant name R-744) for both medium- (MT) and low-temperature (LT) refrigeration loads, it introduces a whole new approach to refrigeration for many end-users and technicians.

Emily and I discussed how Emerson is committed to helping facilitate this transition by simplifying the application of CO2 refrigeration through the seamless integration of system components. We focused on three primary areas: compression and variable frequency drives (VFDs), controls and software, and R&D lab investments.

CO2 compression and VFD technology

For the MT transcritical portion of a CO2 transcritical booster system, Emerson offers the Copeland™ 4MTLS transcritical CO2 semi-hermetic compressor in nine displacements from 40,000 to 300,000 BTUs at 60 Hz. These four-cylinder compressors feature onboard diagnostics and have a capacity range from 17.5 to 354 MBH at 20 °F evaporating, 95 °F gas cooler outlet at 60 Hz. In addition, they can be paired with Copeland VFDs, EVM/EVH Series to enable variable-capacity modulation. EVM/EVH drives offer the security of providing 200 percent maximum overload protection for two seconds.

On the LT side, Emerson offers the Copeland ZO(D) subcritical CO2 scroll compressors: ZO for fixed capacity and ZOD (digital) for variable-capacity modulation or their ability to unload capacity down to 10 percent. For example, the ZOD34 is rated for a 34,000 BTU displacement that can modulate (or unload) its capacity to 3,000 BTUs. These subcritical digital scrolls offer a smaller, lighter-weight footprint and don’t require VFDs for capacity modulation. In addition, Copeland MSLS subcritical semi-hermetic compressors are available in displacements from 60,000 to 180,000 BTUs, have a range of 25 to 70 Hz, and are rated for very high standstill pressures.

Integrated CO2 controls

CO2 transcritical booster systems rely heavily on electronic controls to optimize system installation, integrate with cases and high-pressure valves (HPVs), and manage system pressures. Emily explained Emerson’s integrated approach to CO2 controls that enables seamless communication and enhanced visibility to all aspects of system operation.

The soon-to-be-released Lumity™ supervisory control for CO2 applications will expand upon the legacy E2e control to offer enhanced CO2 capabilities, reduce programming complexities, and simplify system management via:

  • Centralized CO2 suction group control for transcritical booster and parallel compression
  • Advanced compressor superheat management for liquid or hot gas injection
  • Precise load management and automatic recovery from out-of-range conditions
  • Enhanced CO2 system monitoring for system insights
  • Oil management for long compressor life

The Lumity E3-CO2 will also leverage the many benefits of the new E3 platform, including a built-in touchscreen, remote mobile access, and a greatly improved user interface (UI) that brings all critical CO2 system monitoring into one unified view. The control will integrate seamlessly with Emerson’s high-pressure controller and valve driver (XEV20), the soon-to-be-released Lumity CC200 case controller, the XM600 series case controllers, and leak detection devices (RLDS and MRLDS).

Investing in the future of CO2

In the ATMO webinar, I also elaborated on how Emerson is helping our customers to prepare for the future of CO2 refrigeration through continued lab investments and R&D efforts. In addition to the CO2 transcritical booster system that has been installed at The Helix Innovation Center since 2016, we’ve recently dedicated more than 100,000 square feet to a CO2-specific supermarket test lab in our facility in Sidney, Ohio. This new lab will be launched this summer and feature:

  • 18 display cases from five different manufacturers
  • Walk-in cooler and walk-in freezer
  • Dry gas and adiabatic gas coolers on the roof
  • Wide range of high-ambient system strategies
  • Ability to create a 100 percent false load to enable testing at any capacity

These advanced testing capabilities will give Emerson’s application engineers ample opportunities to measure and validate system performance across a full spectrum of application scenarios.

To learn more about how Emerson is helping our customers and the industry to simplify the adoption of CO2 system technologies and optimize refrigeration system performance, please view the ATMO webinar.

 

 

Industry Steps up CO2 Training Efforts

         Don Gillis | Lead Technical Trainer

          Emerson’s Educational Services

The use of commercial CO2 refrigeration technology is expected to increase significantly over the next few years. But in the U.S., very few service technicians have experience installing, commissioning and maintaining CO2 systems. I recently contributed to an article in Contracting Business that discussed how our industry is addressing the urgent need for CO2-specific education, training and certification programs.

Compared to legacy hydrofluorocarbon (HFC) systems, CO2 (refrigerant name R-744) has many unique performance characteristics and system properties. Because CO2 refrigeration is still relatively new to the U.S. market, most HVACR trade schools and technical colleges simply haven’t integrated CO2 topics into their refrigeration training programs. But today, that’s quickly changing.

Stakeholders collaborate to develop CO2 curriculum

Original equipment manufacturers (OEMs) and industry organizations are actively trying to bridge this knowledge gap by developing CO2 training curricula and certification programs. As an industry steward of sustainable refrigeration and a provider of fully integrated CO2 solutions, Emerson is helping industry organizations to accelerate these efforts.

We’re collaborating with the North American Sustainable Refrigeration Council (NASRC), the ESCO Group and other industry stakeholders to spearhead the development of the first CO2 curriculum for community college and trade school HVACR programs in the U.S.

According to Morgan Smith, program and communications director at the NASRC, the goal of this collaboration is to integrate a CO2 curriculum into the commercial refrigeration tracks at technical colleges. The new curriculum will cover a wide range of topics to help familiarize technicians with CO2 refrigeration, including:

  • Basic terms and definitions of CO2 characteristics and systems
  • CO2 safety fundamentals, such as: handling, tools and gauges, relief requirements, leak rates and room sensors
  • Core curricula, including: required experience; understanding CO2 as a refrigerant; operating characteristics; types of CO2 systems; working with non-traditional system components, compressor types, control systems and equipment applications
  • Installation procedures: handling CO2 as a refrigerant; installation fundamentals and piping insulation
  • System commissioning procedures
  • Service and maintenance procedures, such as: system charging and discharging; repairing and replacing components; CO2 oil management; CO2 system recovery; defrost methods and custom systems
  • Troubleshooting

“Because CO2 is so new to the U.S. commercial refrigeration market, technicians and end users have varying degrees of hesitation. We hope these training programs will help remove some of the mystery and concerns about using this efficient and environmentally friendly natural refrigerant,” Smith said.

Emerson CO2 training programs

Emerson continues to expand on our CO2-specific training initiatives through our mobile training units and Educational Services programs. In 2019, we introduced our third-generation CO2 mobile training unit to serve Canada and the continental U.S.; to date, it has trained more than 1,000 industry professionals in North America.

This year, we’ll be launching a second CO2 mobile training unit at Emerson Educational Services’ primary location in Sidney, Ohio. Once there, it will become the centerpiece of a two-day training program designed to give contractors, OEMs, wholesalers and end users a hands-on experience of what it’s like to work on a CO2 transcritical booster refrigeration system. As COVID-related health guidelines permit, we hope to send our CO2 mobile training units back on the road to be featured at industry events and provide training where it is needed most.

In addition, Emerson Educational Services currently offers two virtual and in-person training courses related to CO2:

  • Two-day “CO2 Refrigeration” course specifically designed to train technicians
  • One-day course entitled, “Fit for the Future: Working with Natural Refrigerants, A2Ls, and A1 HFO Blends”

The net goal of all these efforts is to give the entire commercial refrigeration supply chain — from wholesalers and distributors to OEMs, end users and service technicians — a greater familiarity and comfort level with CO2 refrigeration. To learn more about the CO2 training programs at Emerson, visit our course schedule, or contact Emerson Educational Services at Education@Emerson.com.

 

Tracking CO2 Refrigeration Trends in the U.S.

Andre Patenaude | Director – Solutions Strategy

Emerson’s Commercial and Residential Solution’s Business

Until recently, CO2 refrigeration systems in the U.S. have been perceived as exceptions to the rule in commercial refrigeration. But as corporate sustainability initiatives and refrigerant regulations continue to reshape refrigeration decisions, many supermarket retailers are exploring CO2’s long-term potential. I recently contributed an article for Supermarket News in which I examined the regulatory, market and technological trends behind its increased adoption in the U.S. To view the full article, click here.

To date, most CO2 installations in the U.S. have been deployed as proofs-of-concept. Although there are some sustainably-minded retailers that have made it the basis of their refrigeration strategy, CO2 hasn’t yet experienced the industry-wide acceptance we’ve seen in Europe. But that appears to be changing.

Among the environmental strategies identified to combat climate change, the greening of commercial and industrial refrigeration equipment has been recognized as an essential tactic of decarbonization plans and corporate sustainability initiatives. Food retail stakeholders are rethinking their approaches to refrigeration and transitioning away from legacy hydrofluorocarbon (HFC) refrigerants with high global warming potential (GWP). More than ever, retailers are evaluating long-term refrigeration strategies that support:

  • Environmental, social and governance (ESG) efforts
  • Energy efficiency and emissions reductions targets
  • Net-zero goals

Stage is set for wider adoption

With zero ozone depletion potential (ODP) and a GWP of 1, the natural refrigerant CO2 (aka R-744) is a proven alternative to higher-GWP HFC refrigerants. CO2’s inherent energy efficiency in most climates allows it to deliver direct and indirect emissions reductions — a lower total equivalent warming impact (TEWI). For more than a decade, CO2 refrigeration has become a leading sustainability strategy for European retailers. Today, that trend continues with adoption steadily increasing in the U.S. and other countries.

Per recent industry data, nearly 46,500 CO2 transcritical booster systems are currently installed worldwide.

  • 900 in the U.S. (1,400 in North America with the inclusion of Canada)
  • 40k in the E.U.
  • 5k in Japan

If CO2 growth trends continue as they have from 2020–2021, the U.S. commercial refrigeration industry can anticipate CO2 adoption to increase up to 50% by 2025. This trend is expected to follow a similar trajectory throughout the next decade, with the possibility that the U.S. could potentially mirror E.U. levels of adoption.

Regulations drive down GWP levels

Global, federal and state regulations are steering the industry away from HFCs and toward lower-GWP alternatives. Using the Kigali Amendment to the Montreal Protocol as a framework, the next step in the HFC production and consumption phasedown schedule will be a 40% reduction in 2024 (compared to the baseline established in 2011–2013).

The passing of the American Innovation and Manufacturing (AIM) Act in 2020 restored the Environmental Protection Agency’s (EPA) authority to enforce HFC mandates and establish sector-based guidelines. As the EPA follows the Kigali Amendment’s HFC phasedown, decreased supplies will continue to drive up HFC refrigerant prices.

The California Air Resources Board (CARB) continues its progressive efforts to phase down HFCs in the state of California. Under its recently adopted rule, all new refrigeration systems containing more than 50 pounds of refrigerant installed in new facilities must use refrigerants with less than 150 GWP. For existing installations with equipment greater than 50 pounds of refrigerant, retailers can take a fleet approach toward reducing their carbon footprint. CO2 refrigeration is becoming a leading option for achieving these regulatory targets.

Technological improvements and emerging applications

The proliferation of CO2 refrigeration systems around the globe has given equipment manufacturers opportunities to improve compression, controls and valve technologies. Emerson is at the forefront of efforts to simplify system management and help the industry transition from legacy high-GWP HFC systems.

Electronic system controllers

Emerson’s new Lumity™ E3 supervisory control for CO2 systems is designed to manage CO2’s high pressures and system volatilities, greatly simplifying commissioning and system management during standard operation. These improvements minimize system complexities, alleviate the burden from technicians, and provide peace of mind to end users.

Integrated CO2 transcritical booster system components

CO2 transcritical booster systems — where both medium- (MT) and low-temperature (LT) circuits run on R-744 — are the most widely adopted CO2 architectures in medium- to large-format food retail stores. Emerson is helping original equipment manufacturers (OEMs) and operators to ensure the system integration needed to maximize reliability and performance, including: compressors, electronic expansion valves (EEVs), high-pressure valves and an electronic controller.

Warm ambient strategies

CO2 transcritical booster systems are subject to declining efficiencies in warm ambient climates, but manufacturers have developed a variety of strategies to maintain efficiency levels.

  • Adiabatic gas coolers — keep the refrigerant below its critical point for as long as possible to maximize system efficiencies
  • Parallel compression — compresses excess flash gas at higher pressure via a dedicated intermediate- stage compressor, resulting in 8–10% annualized efficiency gains
  • Mechanical sub-cooling — provides increased refrigerant enthalpy
  • Gas ejectors, liquid ejectors — optimize efficiency
  • Low superheat of MT evaporators — delivers year-round efficiency improvements

Increasing our commitment to CO2 innovation

Emerson is expanding CO2 labs, testing facilities and development capabilities to further CO2 adoption and support our OEM and end user partners. As the market for CO2 refrigeration continues to expand, the proliferation of new products is creating economies of scale, which lower the costs and complexities of implementing CO2 technologies. To learn more about improving the efficiency, usability and simplicity of CO2 systems, please visit our CO2 resources hub.

 

 

 

 

 

 

 

[New Webinar] Spotlight on Emerging CO2 Refrigeration Technologies

Andre Patenaude | Director – Solutions Strategy

Emerson’s Commercial and Residential Solution’s Business

Emerson is pleased to announce our participation in the ATMO World Summit 2022 on March 30–31, when industry stakeholders will assemble virtually around the globe to discuss the future of cooling and heating technologies. This free, 24-hour event will feature a webinar at the top of every hour. At 3 p.m. EDT (12 p.m. PST) on March 30, Emerson’s Andre Patenaude, director of solutions strategy, and Emily Vilardi, product marketing manager, will explore how emerging natural refrigerant technologies are poised to deliver the next generation of refrigeration.

Today, corporate sustainability initiatives and refrigerant regulations are driving the increased adoption of natural refrigerants, such as CO2 (R-744), propane (R-290) and ammonia (R-717). Approved for use across a broad range of commercial refrigeration applications, these multipurpose refrigerants are among the lowest-global warming potential (GWP) alternatives available.

For more than a decade, Emerson has been developing natural refrigerant technologies to help support the transition away from high-GWP hydrofluorocarbons (HFCs). Our ATMO World Summit 2022 webinar — “Spotlight on Emerging CO2 Refrigeration Technologies” — will demonstrate how Emerson is simplifying the adoption of CO2 transcritical booster refrigeration via the seamless integration of key system components and technologies.

In addition to hearing the latest trends related to natural refrigerant adoption, attendees will learn about Emerson’s commitment to developing technologies that further CO2 refrigeration in the U.S. via:

  • Introducing electronic controls that simplify CO2 installation and system operation
  • Expanding our CO2 compressor lineup and system components
  • Increasing lab investments to create the next generation of natural refrigerant technologies
  • Releasing our next-generation CO2 mobile training unit to help fill the industry-wide training gapReleasing our next-generation CO2 mobile training unit to help fill the industry-wide training gap

Introducing Lumity™ E3 supervisory control for CO2

Among our many natural refrigerant-related product advancements, we’ll highlight how our new Lumity E3 supervisory control for CO2 reduces system start-up complexities, consolidates multiple functions into one easy-to-use interface, supports mobile connectivity for remote troubleshooting, and integrates with our new Lumity CC200 case controller for full system optimization.

Our webinar on March 30 is just one of 24 sessions that will be presented at the full-day ATMO World Summit 2022. Be sure to check the program’s schedule for other topics that may interest you. Registration for this free online event is now open and will be hosted by the Zoom Events platform.

To learn more about how Emerson is helping the commercial refrigeration industry adopt CO2 system technologies, register for this free webinar.

 

 

 

Beyond Trackers and Loggers: Optimizing the Cold Chain

Juliette Giles | Senior Product Manager, Software & Services

Cold Chain at Emerson

Cold chain monitoring has come a long way in recent years, thanks to devices that provide real-time visibility into perishable shipments. It’s now possible to get key transit information at any time, from a point of origin to final destinations, keeping all stakeholders accountable while minimizing rejected loads.

Now the perishable cold chain is becoming even stronger with the introduction of Oversight cargo services: a robust suite of monitoring, data analytics, and reporting capabilities that delivers detailed information about the real-time and historic performance of your shipments. This cloud-based portal offers many new capabilities — some available at no cost — to help you boost customer loyalty, optimize shipments, preserve your peace of mind, make better-informed cold chain decisions, and protect the integrity of your brand.

Oversight cargo services includes five modules, available individually or in any combination.

Track Your Shipment

If you’re using Emerson’s field-proven line of GO real-time trackers and loggers, you’ve already received a free upgrade with the launch of Oversight cargo services. The Track Your Shipment module — available at no cost with any of these devices — allows you to provide your customers real-time, in-transit shipment and temperature data.

By adding just a few lines of code, you can display a Track Your Shipment box on your website, customized to conform to your brand. Your customers and employees can access shipment data at any time, enhancing the value you provide.

Upgrade the platform with the following paid services:

Reports and Scorecards

Trackers and loggers can provide you with reams of data; but to make the most of it, you need to get the right information to the right people at the right time. Reports and Scorecards give you access to Emerson’s temperature monitoring dashboard, enabling you to identify patterns across multiple shipments and pinpoint the sources of recurring problems — such as whether a carrier, origin or destination is failing to maintain temperature compliance.

Data Integration

High volumes of data can be overwhelming, especially if you need multiple platforms to create new shipments or are constantly being bombarded with alerts. Data Integration allows you to see the information streams that matter most — such as location and temperature alerts — in a consolidated view. This benefits your operation by eliminating duplicate work, minimizing opportunities for error, and reducing your overhead costs. You’ll also have the option to consolidate shipment creation and purchase order (PO) entry processes into one convenient system.

Managed Services

Managed Services extends your in-house resources by outsourcing some (or all) of your monitoring tasks to an experienced team of cold chain specialists. This provides continuous monitoring whenever your shipments are on the road — no matter what time of day or day of the year. You can choose to get alerts when temperature abuse or light alerts happen in transit, and/or empower the Managed Services team to take immediate action in accordance with your preferred operating procedures.

Professional and Consultative Services

Sometimes the best solution to a challenging and complex issue is to get a fresh perspective. Emerson’s Professional and Consultative Services team can perform a comprehensive on-site consultation and analysis to identify gaps in your operation. This team-oriented approach gives you access to experienced cold chain specialists who can help you to identify and solve recurring issues.

Final thoughts

The new suite of Oversight cargo services has been developed by a skilled team of cold chain experts. Several members of the development team have backgrounds in logistics and designed it specifically to address challenges they’ve faced when working for organizations like yours. We’re excited about the portal’s potential to strengthen your perishable cold chain and welcome the opportunity to demonstrate its full value.

For more details, contact us today or download the Oversight cargo services brochure.

Learn More: Oversight Cargo Services at Your Fingertips (emerson.com)

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