KrioFrost Creates Russia’s Largest Transcritical CO2 Hypermarket System Using Danfoss Solutions

Monday, May 4, 2020

Driven mainly by the country’s international food retail chains, the Russian refrigeration market is following the same energy efficiency and environmental sustainability trends as the rest of the world.

An increasing number of retailers are following the example of Europe, where environmental regulations for refrigeration are stringent and demand systems that use natural refrigerants such as CO2 for larger projects.

Globus—a growing international chain of hypermarkets with 15 stores in Russia—is one of the brands looking to CO2 as a highly efficient and sustainable alternative to traditional refrigerants.

Danfoss helped KrioFrost—a Moscow-based refrigeration equipment producer and installer—to equip Globus’ huge new store in the Moscow suburb of Salaryevo with the company’s first transcritical CO2 booster refrigeration system.

The result is the largest transcritical CO2-equipped premises in Russia.

Challenge: Deliver huge cooling capacity without a huge price tag

Globus had an ambitious target: to open the new 25,000 square meter hypermarket using transcritical CO2 for its refrigeration and heating.

The retailer chose CO2 for its enhanced reliability, efficiency, and sustainability. The refrigerant has an ultra-low Global Warming Potential (GWP), and its low energy consumption offered the opportunity to reduce operating costs.

Meanwhile, its high volumetric cooling capacity and low purchase price could cut installation costs by reducing the size of system components such as compressors, pipes, and valves—as well as the cost of the refrigerant itself.

With a mix of 191 low, medium, and dual-mode temperature display cabinets on the sales floor, plus 51 low and medium temperature cold rooms, and 29 climate chambers to support a vast range of different food sections, the new store needed a refrigeration solution that could deliver up to 1 MW of cooling and heating capacity. 

Globus hypermarket

Globus selected KrioFrost—a leading refrigeration provider, with experience of large and ambitious projects—to deliver the system. KrioFrost worked with Danfoss, to deliver solutions that would achieve the perfect balance between capacity and efficiency.

“A project like Globus Salaryevo is always the result of close cooperation with our partners,” says Alexander Kotlyar, General Director at KrioFrost. “Working together has allowed us to make the store more energy efficient and cost-effective for the customer. Globus Salaryevo is a project that we can and should be proud of.”

Solution: Transcritical CO2 refrigeration and heat recovery in one system—and on a huge scale

KrioFrost designed, manufactured, and installed two transcritical CO2 refrigeration units to deliver the capacity needed at the new store.

By using the latest CO2-qualified components, KrioFrost was able to take full advantage of the refrigerant’s high energy efficiency to reduce year-round running costs.

The solution uses parallel IT compressors that operate at a lower pressure ratio to reduce energy consumption.

The MT and IT compressors are fitted with two Danfoss VLT frequency converters for each temperature circuit. This boosts performance and efficiency by enabling the system to adapt capacity smoothly, precisely matching the required load with the smallest possible compressor.

The frequency converters further improve efficiency by smoothly controlling the gas coolers’ fan speed.

Each unit has a heat recovery system that uses energy from the discharge line to provide the store’s hot water and heating needs during warmer weather. This eliminates the external water heating systems during warmer weather and reduces energy consumption by least 400 kW.

In colder weather, the store’s system also uses a Danfoss MCX programable controller, which has a free cooling mode to supply climate chambers and fresh produce preparation areas, helping to reduce compressor load and increase energy efficiency.

Despite the system’s wide-ranging capabilities and complex design, KrioFrost prioritized simple monitoring and control. The system uses a single Danfoss controller and extension modules, consolidated into one Danfoss SM720+UNIServer monitoring system.

“At Danfoss, producing energy efficient components and solutions is our key capability”, says Mikhail Shapiro, General Director of Danfoss LLC. “We’re proud that, together with KrioFrost, we helped Globus Salaryevo achieve 1 MW of cooling capacity using a transcritical CO2 system. This technology is becoming increasingly important in Russia.”

“It’s impressive engineering, and much of it—from the heat recovery system that provides hot water and heating, to the variable speed control for compressors and fans—relies on Danfoss components.”

Results: 25% energy savings with transcritical CO2

Overall, the transcritical CO2 booster refrigeration system at Globus Salaryevo is estimated to use 25% less energy than an equivalent traditional design. For a hypermarket of its size, that’s an important saving.

“Refrigeration equipment that operates 24 hours a day makes a significant contribution to hypermarket energy consumption”, says Vitaly Belozertsev, Lead Engineer for Energy Efficiency and Refrigeration Equipment at Globus.

“That’s why reducing energy consumption is one of our top priorities. By using CO2 at our Salaryevo store, we’ve reduced the installed capacity by 15% and achieved very efficient heat recovery. What’s more, CO2 costs 20 times less than traditional refrigerants, it meets all modern environmental standards, and it’s produced in Russia.”

Not only does Globus Salaryevo now boast the largest transcritical CO2 hypermarket solution in Russia, its refrigeration and heat recovery systems are helping Globus to slash its energy costs on a scale that would have been unimaginable using traditional solutions—and it’s helping to reduce the retailer’s impact on the environment, too.

Danfoss HVAC components used at Globus Salaryevo include:

  • Danfoss AK-PC 782A—pack controllers
  • Danfoss AK-CC 550A, AKVH, AKV—EXV controllers
  • Danfoss CCMT—high-pressure electronic expansion valves
  • Danfoss GBC, NRVH, EVR, KP5, KP6, DMT, DCR, DCL—line components and automatic controls
  • Danfoss AQT, VFY, FVF, BVR, NRV EF, VF3—secondary coolant line components
  • Danfoss MCX—hydraulic unit controllers
  • Danfoss Optyma™ Slim Pack—condensing unit
  • Danfoss DGS—gas detectors
  • Danfoss VLT—frequency converters
  • Danfoss SM720+UNIServer—system manager 

Two transcritical booster packs were produced by TehnoFrost.

Refrigeration unit 1

LT compressors: Bitzer 2х2ESL-4K

MT compressors: Bitzer 4FTC-30LK + 5х4FTC-30K

Parallel/HT compressors: Bitzer 4FTC-30LK + 4FTC-30K

Gas cooler:

Güntner GGHV CD 090.2NF/23A-67, 571 kW

LT Gas cooler:

Güntner XGGVC CD 050.1/11-24, 2.8 kW

LT cooling capacity: 33 kW

MT cooling capacity: 345 kW

Maximum capacity of heat recovery system: 315 kW

Refrigeration unit 2

LT compressors: Bitzer 3х4DSL-10K

MT compressors: Bitzer 2x4FTC-30LK + 2х4FTC-30K

Parallel/HT compressors:

Bitzer 2х6FTEU-50LK + 2х6FTE-50K

LT cooling capacity: 122kW

MT cooling capacity: 176 kW

A/C cooling capacity: 258 kW

Max capacity of heat recovery system: 430 kW

Gas cooler:

Güntner GGHV CD 100.2OF/24A-65, 814 kW

Dry cooler:

Güntner GFHV FD 090.2MF/24A-70

Low temperature cabinets: 22

Medium temperature cabinets: 165 LT/MT dual-mode cabinets: 4

Low temperature cold rooms: 16

Medium temperature cold rooms: 41

Climate chambers: 38

Technological equipment: 11

Air coolers: Güntner

Pack controllers: Danfoss AK-PC 782A

EXV controllers: Danfoss AK-CC 550A

EXV: Danfoss AKVH, AKV

High pressure electronic expansion valves: Danfoss CCMT

Line components and automatic controls: Danfoss GBC, NRV H, EVR, KP5, KP6, DMT, DCR, DCL

Line components for secondary coolant line:

Danfoss AQT, VFY, FVF, BVR, NRV EF, VF3

Hydraulic unit controllers: Danfoss MCX

Stand still pressure control: Danfoss Optyma Slim Pack

Gas detectors: Danfoss DGS

Frequency converters: Danfoss VLT

System Manager: Danfoss SM720+UNIServer

Danfoss collaborated with system design, pack testing, and commissioning.

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