Skip to content

Posts tagged ‘Andre Patenaude’

Integrated R-290 Cases Expand Into U.S. Markets

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

I was recently asked to contribute to an Accelerate America article about the increasing use of R-290 in the U.S. commercial refrigeration market. The article featured a variety of perspectives from supermarket operators and equipment manufacturers. Read the full article (pg. 38) and more on Emerson’s perspective below.

Integrated R-290 Cases Expand Into U.S. Markets

A growing number of American retailers — including Target, ALDI US and Whole Foods Market — have been deploying self-contained, R-290 cases as spot merchandisers in hundreds of stores, many of which are mainly served by centralized rack systems. Some retailers regard these units as partial or even full-store alternatives to using a centralized rack-based system.

Obviously, this comes as no surprise to Emerson. Not only have we been partnering with R-290 equipment manufacturers for many years, we also support operators and commercial refrigeration designers alike in their efforts to utilize R-290 — and a variety of other lower-GWP and natural refrigerants — in their systems. As others have stated in the article, this trend reflects a shift in the research and development processes for some manufacturers, in that fewer emerging architectures are being designed to utilize hydrofluorocarbon (HFC) gases.

It’s further evidence that, regardless of the unpredictable state of environmental regulations, R-290 use in commercial refrigeration continues to gain traction. We at Emerson are seeing the use of integrated case architectures — where one or more R-290 compressors is/are housed within a refrigerated case — and the continued use of completely self-contained units as the most likely paths to wider adoption of integrated R-290 in 2019 and beyond.

While R-290 systems may have originally been born out of necessity to address environmental concerns, today they’re perceived in the market as much more than just eco-friendly alternatives. With the expansion of smaller-format stores and increasing retail urbanization, many times there simply isn’t enough space to accommodate a machine room for a traditional central system. In these scenarios, plug-and-play, low-charge, R-290 systems are an ideal fit.

The safe use of R-290, which is classified as an A3, highly flammable refrigerant, is governed globally by the International Electrotechnical Commission (IEC) and nationally by the Underwriters Laboratory (UL). Historically, these standards mandated that R-290 charge limits should be limited to a maximum of 150g. However, the IEC recently updated their standard (IEC 60335-2-89) to allow the use of up to 500g of A3s like R-290. This charge limit increase will enable more application flexibility for European food retailers.

It’s important to note that in the U.S., the UL standard still mandates a maximum of 150g charge limit for A3s. Even with the low charge limit of 150g, R-290 cases have proven viable options for many leading retailers in the U.S. market and abroad.

While the industry adapts to the charge limit increase, there are real-world installations that are also indicative of the safety and reliability of these self-contained, R-290 cases. Since 2013, an HEB grocery store in San Antonio has utilized the R-290 cases installed throughout the entire store as its primary refrigeration source. The designer of that architecture, who was also interviewed in the same article, stated that these cases have proved to be both safe and reliable — and have had no leaks since they’ve been installed.

Today we’re achieving more flexibility using R-290 systems with micro-distributed architectures utilizing integrated cases. They are designed to remove compressor exhaust heat via a shared glycol water loop that’s directed to the roof of the facility for heat removal. These systems typically stay within the 150g limit and enable a greater degree of scalability.

It will be interesting to see how the possibility of increasing the R-290 charge limit, as has been discussed and studied within the industry for years, might impact system design in the future. For now, R-290 seems to have a place — albeit a relatively niche one — in U.S. markets.

Regulatory Uncertainty Impacts Refrigerant Decisions

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

I was recently asked to contribute to an ACHR The NEWS article about the uncertainty surrounding the dynamic regulations governing the use of refrigerants. The article provided perspectives from several industry stakeholders, and I was happy to discuss Emerson’s views on the short- and long-term implications of the situation. Read a summary of the article below and view it here in its entirety.

For the last two years, the commercial refrigeration industry has been in a period of uncertainty regarding the regulations that govern the use of hydrofluorocarbon (HFC) refrigerants with high global warming potential (GWP). Since the U.S. DC Court of Appeals ruled that the Environmental Protection Agency (EPA) did not have the authority to phase down HFCs, the EPA’s role in the national HFC phase-down has been unclear.

R-22 phase-out is still in effect

For the time being, the EPA’s authority covers only the transition from ozone-depleting substances, such as the chlorofluorocarbon (CFC) R-22. So, even though the HFC rules have been vacated, the EPA still has the authority to phase out R-22, which is scheduled to take place on Jan. 1, 2020.

While there’s plenty of discussion about the fate of HFCs, it would be unwise to presume that the 2020 R-22 phase-out won’t have significant impacts. In fact, it may surprise some to learn that there are still many operators with older refrigeration systems currently charged with R-22. But after Jan. 1, they must either retrofit their systems with lower-GWP refrigerants or continue to recover and reuse R-22 until their supplies run out — with the understanding that the latter choice is not a permanent solution.

HFC phase-down continues in California and other states

The absence of a federal mandate to phase down common HFCs is not deterring California from taking its own steps. Per a recent ruling by the California Air Resources Board (CARB), R-404A and R-507A are no longer allowable in many new commercial refrigeration applications.

California’s regulatory stance is a reminder that a retailer’s geographic location is an important factor in the development of their refrigerant strategy. While California is currently taking the lead on U.S. HFC reductions, there are currently

As retailers evaluate their future refrigerant options, state-specific environmental regulations will factor prominently in their decision processes. For example, operators in California are well aware of the efforts to phase down HFCs and most likely have alternative refrigerant plans in place. These operators are either planning for retrofits or trialing new alternative refrigerant architectures.

Strategies for moving forward

Fortunately for operators, component and equipment manufacturers have continued developing solutions that feature a wide range of lower-GWP refrigerant alternatives. These solutions are helping retailers align their sustainability objectives with their refrigeration architectures, and include the following strategies:

  • Retrofit using lower-GWP HFOs — Moving from R-404A to R-448A or R-449A may require adding compressor cooling and other relatively minor system changes but can help operators preserve their existing system investments. Deploying energy optimization best practices will also help them reduce indirect emissions, which lessens their overall carbon footprint.
  • Transition to a new and/or natural refrigerant system — Natural architectures offer maximum carbon footprint reductions and are considered by many as the only true future-proof solutions available today. These systems can be installed in new locations or in parallel with an existing system, allowing the retailer to slowly transition to the natural solution.

Emerson is continuing to develop a variety of alternative refrigerant solutions designed to help operators and equipment manufacturers reduce their carbon footprints. Regardless of the regulations in your specific region, we’re here to support the commercial refrigeration supply chain as it transitions to lower-GWP refrigerant alternatives.

[Webinar Recap] Factoring Energy Management Into Your Refrigeration Retrofits

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

In today’s dynamic food retail climate, many operators are wondering why they should retrofit their aging refrigeration supermarket refrigeration architecture. For most, this is a not an easy decision to make. While you’ll often find some form of a refrigerant regulation accelerating this process, a viable refrigeration retrofit should also include plans for ongoing energy optimization. In our most recent E360 Webinar, I discussed how to merge these two considerations into a sustainable, long-term refrigeration strategy. Read the summary below and/or view the webinar in its entirety.

The transition to more environmentally friendly, future-ready refrigerants is underway, and as a result, many supermarket retailers are evaluating retrofit options on their existing systems. But for large enterprises or individual stores that consume a lot of energy, the rising costs of energy (especially in certain regions with high rates) are moving conversations toward energy management — not only in refrigeration systems, but also entire facility ecosystems and across the enterprise.

Ultimately, the goal of an effective approach to energy optimization is to minimize energy costs in every way possible. Doing so requires an understanding of the various factors that contribute to energy costs, including:

  • Energy consumption profile of key store systems such as refrigeration, HVAC and lighting
  • Peak electric consumption cycles and periods in each store
  • Time of use rates as dictated by the electrical utility, including both on- and off-peak rates
  • Seasonal changes and their impacts on consumption and electricity rates

This is particularly important in certain areas of the country where charges exceed $15 per kW during peak demand periods.

Why the focus on refrigeration?

A typical supermarket uses a centralized direct expansion refrigeration architecture which accounts for more than 50 percent of its total annual energy consumption, with HVAC systems the next largest consumer at 20 percent. At the same time, an average supermarket consumes three times more energy per square foot than other retail facilities. It’s no surprise then that these systems are becoming prime targets for energy optimization in the U.S. and around the globe.

The tendency for refrigerant leaks in traditional centralized systems — most of which are also charged with refrigerants that have a high global warming potential (GWP) — makes these systems ideal candidates for retrofits. Many of them can transition to lower-GWP refrigerants with relatively minimal retrofit requirements.

Six steps along the “Journey to Energy Excellence”

In the webinar, I cited a case study of a supermarket that went through a retrofit process in its centralized refrigeration system. The process followed a methodology that Emerson refers to as the Journey to Energy Excellence. By upgrading only the refrigeration system (i.e., the first three steps below), the supermarket reduced its energy costs by nearly $40 thousand per year.

The six steps along the journey to energy excellence include:

  1. Conduct a baseline energy audit of the existing system.
  2. Recommission the system to its original condition and setpoints.
  3. Make refrigeration technology upgrades, such as: digital compressors, variable frequency drives and floating the head/suction pressures.
  4. Change the lighting and other renewable upgrades such as adding doors, electronic expansion valves and electrically commutated motors on evaporators.
  5. Expand focus to HVAC technology upgrades, including rooftop units and demand control ventilation.
  6. Deploy a condition-based maintenance, internet of things (IoT) infrastructure to accurately monitor asset and system performance.

Each step enables progressive degrees of energy optimization, and as the case study demonstrates, implementing just the first three steps can provide significant financial gains. Collectively, this methodology can help supermarkets develop energy management strategies that consider entire facility ecosystems.

Regardless of where you are in this process, Emerson is providing solutions at every step to help retailers achieve energy excellence in stores and across the enterprise.

GreenChill Hosts Emerson-led Webinar on Natural Refrigerant Architectures

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

My colleague John Wallace, director of innovation, retail solutions, and I recently partnered with the Environmental Protection Agency’s (EPA) GreenChill program to present a webinar about making the transition to an effective refrigerant architecture. In it, we discussed leading natural refrigerant systems, centralized and distributed options, and the controls schemes that support them. What follows are the key takeaways from that discussion, which you can view here in its entirety — last bullet under ‘Webinar Archives’.

Over the past decade, the transition toward natural refrigerants has been driven by a combination of dynamic market trends, which include: global refrigerant and food safety regulations, rapidly changing consumer expectations and corporate sustainability goals. This historic transition has helped accelerate the adoption and investigation of “future-proof” natural refrigerant architectures.

Regulatory drivers of transition to naturals

In the U.S., the California Air Resources Board (CARB) has not only fully implemented the now defunct EPA rules designed to limit the use of hydrofluorocarbon (HFC) refrigerants with high global warming potential (GWP), it is also actively working to enact more aggressive measures that would greatly impact future refrigeration system architectures. One current proposal under review would take effect in 2022 and mandate the following:

  • Systems charged with more than 50 pounds of refrigerant must use an option that is less than 150 GWP
  • New refrigerant sales with less than 50 pounds of refrigerant must use an option that is less than 1,500 GWP

But California is not alone in these initiatives; there are currently 25 states in the U.S. Climate Alliance which have vowed to follow its lead.

Since natural refrigerants are among a very small list of viable options capable of meeting the above criteria, the commercial refrigeration industry is likely to see an increase in system architectures designed to utilize natural options. These include centralized architectures for larger-charge systems and distributed (or micro-distributed) options for smaller-charged system types.

Leading natural refrigerants

When we think of natural refrigerants in commercial refrigeration, we are typically referring to R-744 (CO2 aka carbon dioxide), R-290 (refrigerant-grade propane) and R-744 (ammonia). Let’s look at their unique characteristics and how they can be effectively utilized.

CO2 has proved very effective in both low- and medium-temperature applications and is typically found in centralized systems such as secondary, cascade and transcritical booster. Having been successfully deployed in commercial and industrial applications in Europe for nearly two decades, it has made significant inroads in North America in recent years.

CO2 is not a retrofit refrigerant and is intended for use only in new systems. System designers, operators and technicians need to be aware of CO2’s unique characteristics, particularly its low critical point, high operating pressures and standing pressure (power outage) considerations. It has a GWP of 1, which puts it in an elite class of environmentally friendly options.

Propane continues to experience a global resurgence as a viable, efficient and very low-GWP refrigerant choice. Its high flammability has traditionally limited system charges to 150g, which is why today it’s found primarily in stand-alone systems that operate efficiently with a low refrigerant charge — such as integrated display cases often utilized in micro-distributed applications. In Europe and abroad, the International Electrotechnical Commission (IEC) recently raised its charge limit to 500g; the U.S. conservatively remains at 150g. Also, propane is not a retrofit option and is intended for new systems designed specifically for its use.

With its superior thermodynamic properties, ammonia was a logical first choice for early refrigeration systems. However, its toxicity requires careful adherence to safe application procedures to ensure operator safety and customer well-being. Traditionally, it has been used in industrial, process cooling, cold storage and ice rink applications. Most recently, ammonia has been introduced into commercial applications via cascade systems that utilize lower refrigerant charges and isolate the ammonia circuit away from occupied spaces.

System controls to support natural refrigerant architectures

Because of the unique properties in these emerging natural refrigerant architectures, system controls are even more essential to ensuring efficient operation, troubleshooting and servicing. Generally, the controls are loosely coupled to the refrigeration architecture, often following either a centralized or distributed approach.

However, the expanding variety of natural refrigeration systems can also pose new challenges for operators trying to maintain controls consistency or access a unified view across different systems. Here, a supervisory system — with its ability to integrate different devices into a common user interface — ensures that all stakeholders can quickly and easily evaluate each refrigeration system. 

As regulations continue to evolve and natural refrigerant systems gain more acceptance, Emerson is prepared to help equipment manufacturers, system designers and end users utilize these very low-GWP alternatives in the development of efficient, user-friendly and economically viable refrigeration systems.

 

[New E360 Webinar] Why Retrofit Your Aging Supermarket Refrigeration Architecture?

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

Many supermarket operators face a common dilemma regarding their refrigeration systems: they know they need to make changes or upgrade their legacy systems, but they’re not sure what their retrofit options are — or even where to begin. In our next E360 Webinar, I’ll offer guidance on how supermarket owners/operators can embark on this critical journey.

Join me on Tuesday, Aug. 13 at 2 p.m. EDT/11 a.m. PDT for this informative webinar.

[New E360 Webinar] Why Retrofit Your Aging Supermarket Refrigeration Architecture?

There’s no question that reliable refrigeration is the backbone of any supermarket operation; it accounts for more than 50 percent of the electrical consumption for an average supermarket. That’s why keeping your refrigeration system running at optimal efficiency is essential to maximizing profits and ensuring operational success.

But if you’re like many owners/operators, you’ve been relying on the same centralized refrigeration architecture for decades. During that time, these systems have typically experienced declining performance levels and energy efficiencies — all due to progressive deviations from their original commissioned states. And while these systems are perfect candidates for an upgrade or a retrofit, even newer systems can offer opportunities for improvements, especially within the context of today’s rapidly evolving industry and market dynamics.

Compared to just 10 years ago, the drivers behind refrigeration decisions have changed dramatically, and the days of a one-system-fits-all mentality are quickly becoming a thing of the past. Environmental concerns, energy costs, shifting regulations, shrinking store formats, consumer demands and omnichannel delivery have all irrevocably reshaped the supermarket landscape.

As a result, more supermarket owners/operators are reevaluating their existing (and often aging) systems while looking for any retrofit opportunities that are available to them. Our next E360 Webinar is designed with them in mind. To help you better understand the many factors to consider when evaluating a supermarket refrigeration retrofit, I’ll be discussing the following topics:

  • Industry and market trends driving the need for refrigeration system retrofits
  • How to identify deficiencies and baseline performances in centralized architectures
  • A look at the potential architectures of the future
  • Recommended technologies for retrofits and recommissioning
  • Energy-efficiency strategies for refrigeration, HVAC and the complete building envelope

As always, we will take time after the presentation to answer any of your questions. So, be sure to register now and add this event to your August calendar.

%d bloggers like this: