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European Advances in Supermarket Refrigeration Leak Reduction Christoph Meurer Solvay Fluor GmbH, Germany.

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Presentation on theme: "European Advances in Supermarket Refrigeration Leak Reduction Christoph Meurer Solvay Fluor GmbH, Germany."— Presentation transcript:

1 European Advances in Supermarket Refrigeration Leak Reduction Christoph Meurer Solvay Fluor GmbH, Germany

2 Agenda European Supermarkets Business Specifics Refrigeration Specifics European Legislation and Standards Emission results from the field

3 Market Structure Germany Sales AreaNr. of stores Other Food retail< 4000 ft² Discounter≈ ft² Supermarket ft²9.230 Cons. market ft²1.682 Hypermarket> ft²681 European Supermarkets – Business Specifics

4 European Supermarkets Average Retail Space [m²] European Supermarkets – Business Specifics

5 European Supermarkets Shops are generally smaller Deviations in business structure from country to country Discounters are gaining popularity – especially in GER European Supermarkets – Business Specifics

6 European Supermarkets Conventional MultiplexLow-Charge Multiplex European Supermarkets – Refrigeration Specifics

7 European Supermarkets Accessability of pipework key design criteria for Supermarket chains Leak test methods are being optimised (pressure drop tests overrated / new detectors find leaks < 5g/anno) Nr. of flares reduced Total pipe length reduced European Supermarkets – Refrigeration Specifics

8 European Supermarkets Capacity of refrigeration packages relatively small  typical GER supermarket:75 kW medium / 35 kW low Discounter markets (GER) usually operate with plug-in freezers for low temp and distributed systems for medium temp European Supermarkets – Refrigeration Specifics

9 Design Criteria Pipes shall be joined by welded or brazed joints Flares joints shall not be used Detailed requirements for relief / safety valves (usually blowing to low pressure side not ambient) Systems > 300kg shall be located in machinery rooms (min. compressor racks) …. European Supermarkets – Legislation STEK Regulation (NL)

10 Service Criteria Systems with charge > 3kg shall be inspected annually Systems with charge > 1000kg shall be under constant supervision Logbooks must be kept for all systems > 3kg charge Refill / top up only permitted if leak is identified European Supermarkets – Legislation

11 European Legislation Service / Maintenance regulation framework similar to NL STEK Mandatory service intervalls: charge > 3kg every 6 months charge > 300kg every 3 months Legal Base for that part is „Protection of the environment“  member states may install additional requirements EU F-GAS Regulation (Draft) European Supermarkets – Legislation

12 European Standardisation No flared joints for pipes between 9mm and 19mm Flared joints shall not be used to connect TXVs Operating party must keep logbooks of refrigerant consumption EN European Supermarkets – Standardisation

13 European Supermarkets 96% of the total refrigerant loss was through field assembled joints 15% of the leaks were responsible for 85% of refrigerant loss 21,6% of all detected leaks where flared joints – They are responsible for close to 50% of lost refrigerant Location and Severity of Leaks * * FKT Study – Leak tightness of Refrigeration Systems (1999, ILK Drseden) Emission Results from the field Survey and long term of analysis of 62 supermarket refrigeration systems in two German states. Charge size from 360 kg

14 German Tightness Study* 0,16% of brazed joints had leaks Systems with substantial leaks over long periods had leaks in unaccessible parts of the system * FKT Study – Leak tightness of Refrigeration Systems (1999, ILK Drseden) Emission Results from the field

15 German Tightness Study* * FKT Study – Leak tightness of Refrigeration Systems (1999, ILK Drseden) Emission Results from the field Annual Leakages from Supermarket Systems [%]

16 German Industry Targets* Avg. annual Leaks from stationary Systems [%] FKT Study – Improving Leak tightness of Refrigeration Systems (2003, ILK Drseden)

17 Statistics from NL Overall leakage rate < 4.5% (2000) Leackage rate per sector AC < 1%, Process < 1%, industrial < 5% Fishing industry 80% … 200% Tremendous reduction (50%) of refrigerant market in spite of economical grow Elimination of odd-jobbers/fly-by-nighters Increased fleet efficiency (service)

18 Summary Business Structure in Europe different from US Means for leak reduction are often simple Some areas (NL/GER) have demonstrated that very tight DX systems are possible Target values of 2% leak p.a. are realistic EU legislation will address the issue


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