Ecuador Shrimp Facility Implements Large-Scale CO2 Transcritical Refrigeration

A major shrimp processing facility in Ecuador has adopted a fully CO₂ transcritical refrigeration system from SCM Frigo S.p.A., marking a significant step toward sustainable and efficient industrial cooling. The installation demonstrates the potential of CO₂ technology to replace traditional refrigerants while optimizing energy use and reducing environmental impact.

System Overview

The refrigeration system is designed to meet the facility’s stringent cooling demands with a total installed capacity of 6 MW. Key components include:

• 46 medium-temperature (MT) transcritical compressors (1940 HP)
• 33 low-temperature (LT) compressors (1060 HP)
• 7 operational refrigeration units, optimized for process-specific cooling
• 26 industrial evaporators, ensuring uniform temperature distribution
• 12 gas coolers (8x800mm each) for efficient heat rejection
• 2 LT pump stations with 3500L vessels for precise liquid distribution

Key Innovations

The system incorporates advanced refrigeration technologies to enhance efficiency and sustainability:

• Mechanical Subcooling reduces flash gas formation, improving cooling capacity without extra energy consumption.
• Vapor Ejectors recover energy lost during pressure reduction, reducing compressor workload while maintaining stable operation.
• Hot Gas Defrost minimizes frost buildup and energy consumption while improving heat transfer efficiency.
• Heat Recovery Integration captures waste heat from the refrigeration cycle to preheat water, lowering overall energy demand.

Performance Metrics

The installation is designed for ultra-low and low-temperature applications, ensuring thermal stability across different process zones:

• Ultra-LT Evaporation (-45°C/-42°C): 1620 kW
• LT Evaporation (-32°C/-25°C): 1530 kW
• MT Direct Expansion (-5°C/-3°C): 460 kW
• MPG20% Brine System (+1°C): 640 kW
• Air Conditioning Water (+6°C): 1000 kW
• Heat Recovery Water (55°C/65°C): 1300 kW
• Total Gas Cooler Heat Rejection: 8300 kW

Industrial Refrigeration Impact

This installation, featuring a CO₂ transcritical refrigeration system from SCM Frigo S.p.A., is one of the largest of its kind in the region. Compared to conventional HFC-based systems, CO₂ technology offers:

• Lower Global Warming Potential (GWP = 1) by eliminating high-GWP synthetic refrigerants.
• Higher Thermodynamic Efficiency, particularly in low-temperature applications.
• Enhanced Energy Recovery, reducing the need for auxiliary heating.
• Improved Compliance with international F-Gas reduction policies.

The adoption of large-scale CO₂ refrigeration in industrial food processing sets a precedent for balancing performance, sustainability, and energy efficiency, reinforcing CO₂ as a scalable long-term solution for the industry.