Total refrigerating capacity is about 1 Megawatt, which makes the Globus hypermarket one of the largest facility using a transcritical CO2 solution in Russia.
On April 11th a new hypermarket of the Globus international network opened in the shopping center Salaris near the metro station Salarievo. Globus company was founded more than 190 years ago in Germany, and this hypermarket is the 15th one in Russia, and the first one built with the use of transcritical CO2 booster cooling technology.
Total area of the hypermarket is about 26 700 square meters, presenting over 45 000 SKU in the sales area, as well as a number of departments of its own full-cycle production: Meat Shop, Fish Shop, Bakery, Cookery, Sushi and Rolls, as well as a Restaurant and Food-Court.
Cooling system for this hypermarket has been developed, manufactured and assembled by Kriofrost Engineering company. The complex of technical solutions applied in the project fully utilizes the potential of carbon dioxide to improve system efficiency.
Two transcritical booster refrigeration units on carbon dioxide produced by TehnoFrost company are responsible for the cold supply of all consumers in the sales area of the hypermarket, as well as low and medium temperature chambers, processing equipment and workshops. Their total refrigerating capacity is about 1 Megawatt, which makes the Globus hypermarket in Salarievo one of the largest facility using a transcritical CO2 solution in Russia.
The first transcritical carbon dioxide booster unit is based on 10 Bitzer compressors and provides cold to all equipment in the sales area.
The second unit is based on 11 Bitzer compressors, and provides cold to mid and low temperature cameras and technological equipment such as ice makers etc. It cools the shop with the help of the intermediate coolant ХНТ-SNV-40. For the cycle with coolant ХНТ-SNV-40, a 260 kW plate heat exchanger is integrated into the system, which allows cooling the working substance to +2°С using carbon dioxide. In the cold season an air heat exchanger is used to cool the XHT-SNV-40, operating in free-cooling mode.
Еach transcritical carbon dioxide booster refrigeration unit is equipped with a heat recovery system that uses high-grade energy from the discharge line to heat water for the needs of hot water supply and heating, which makes it possible to completely abandon external water heating systems during the warm period of the year and reduce the required heat output by more than 750 kW.
The leading compressor of the low-temperature stage has frequency control, and on medium and parallel compressors there are two frequency converters for each temperature circuit. This solution increases system performance without switching to the next compressor size, reduces power consumption and more smoothly adjusts the cooling capacity, precisely adapting it to the required load.
Guentner gas coolers, which are installed on the roof of the hypermarket, are used to cool the carbon dioxide gas:
GGVC series – to reduce the discharge temperature of carbon dioxide gas of low-temperature compressors to an acceptable value;
GGHV series – for cooling (in the warm period of the year) and condensation (in the cold period) of the total volume of gaseous carbon dioxide of medium-temperature and parallel compressors.
The rotation speed of the fans of gas coolers is also smoothly regulated by the frequency converters, which allows them to be included in the work as efficiently as possible and also reduce energy consumption.
Restaurant area is serviced by a booster freon refrigeration unit produced by TehnoFrost. It is based on 6 Bitzer compressors, and is responsible for cooling the chambers and process equipment in the restaurant area.
Two temperature circuits are combined in one refrigeration unit, using LT load as a "side" for MT installation. This solution shows good savings in relation to the classic solution — reduced costs to manufacture individual units, as well as ensuring the smooth operation of the MT part even in conditions where the compressor of LT circuit operates at a minimum speed.
Another compact freon refrigeration unit is based on 2 Bitzer compressors and is responsible for cooling chambers and processing equipment in the food court area.
Control of all temperature circuits of the units is carried out by means of monitoring based on Danfoss controllers with expansion modules. Monitoring units provide full control of the refrigeration systems, data collection of the main parameters of operation, coordination of evaporator defrost etc. This decision helped to make the system energy efficient, convenient and with low-cost maintenance. Automatic control reduces power consumption of the hypermarket cooling system by 25%.
Heat exchange equipment manufactured by Guentner is installed to maintain the specified temperature conditions in all climatic zones of the hypermarket:
in medium-temperature chambers with operating mode 0/+6°C, cubic air coolers of the GACC RX series equipped with electric defrost heaters are used;
in low-temperature chambers with operating mode -22/-18°C, cubic air coolers of the GHF and GACC RX series are used, also with electric defrost of the heat exchanger, additionally equipped with a double pallet heating with thermal insulation.
in climatic (industrial) premises with temperature regime +8/+15°C dual-flow air coolers of the DHF series with anti-corrosion epoxy coating of lamellas and natural defrost without the use of electric heating elements are used, except for the premises of meat and fish shops, where there is an increased moisture, as well as air coolers are frequently washed using chemistry. In the fish shop dual-flow air coolers of the DHN series with a stainless steel body and anti-corrosion epoxy coating of lamellas are installed, and in the premises of the meat shop, air coolers of the DHN series completely made of stainless steel are installed.
During the realization of the project, the team of KrioFrost Engineering worked closely with equipment manufacturers, carefully working out technical solutions and determining the most effective and profitable for the customer. Well-coordinated work and extensive experience in solving non-standard tasks allowed us to successfully complete all the work in time, and the Globus company to get a modern, eco-friendly and energy-efficient hypermarket.
This hypermarket is a project that you can and should be proud of!