Honeywell Refrigerants joined hands with UK-based supermarket chain, Asda to conduct a field test of its new refrigerant blend in one of Asda’s stores. The two organisations claim that the results are encouraging. We bring you the case study.

INTRODUCTION

Supermarkets around the world are coming under intense scrutiny to prove their credentials when it comes to environmental impact and sustainability. Honeywell claims that it has responded by developing a new refrigerant blend – Genetron Performax LT – which, it says delivers positive results across key metrics linked to energy efficiency, carbon footprint reduction and running costs.

In the latest field test – completed with Asda, a supermarket chain in the UK – the new Honeywell refrigerant was assessed against the generally used R-404A and R-407A. According to Honeywell, the results proved Genetron Performax LT to be the best performing refrigerant currently available for supermarket installations. With the case study as proof, the manufacturer says that unlike R407A, Genetron Performax LT can be used in both low-temperature and medium-temperature applications and that the refrigerant delivered favourable results due to its higher capacity and efficiency with a GWP that is nearly 50% lower than R-404A and 15% lower than R-407A.

ASDA’s statement: carbon reduction goals

ASDA states that it has made a public commitment through its Sustainability 2.0 agenda to reduce the environmental impact both of its own operations and those of its supply chain. The ambitious goals for 2015 (compared to 2005 levels) include:

• Reducing energy consumption in existing stores by 35%
• Reducing new store carbon emissions by 60%
• Reducing overall carbon footprint by 10%
• Removing 20 million metric tonnes of CO2 from its global supply chain
• Reducing 60 % of emissions from its transport fleet

A key contributor to these targets for Asda is the identification and application of eco-friendly refrigerants used to preserve meat and dairy products, with particular focus on reducing energy consumption and cost and lowering carbon emissions through improved GWP.

THE CASE STUDY

Following a successful laboratory test of Genetron Performax LT, Asda embarked on a full-scale field test of the Honeywell refrigerant at its new Hunts Cross store in Liverpol, UK.

Aim:

The objective of the full-scale field test was to establish that the new Genetron Performax LT is an efficient, cost-saving and lowest GWP refrigerant for supermarket installations.

Method:

Field test implementation:

Monitoring and assessing data

To ensure the robustness of the project, a dedicated team of professionals was set up to run the trial. In addition to the involvement of Asda’s Head of Refrigeration and Energy Manager, the team included representatives from Honeywell Refrigerants Technical Management, Emerson Climate Technologies (Copeland scroll compressors), AGas, BJA Consulting, CBES Constructive Solutions and City Holdings.

Asda’s Hunts Cross store was chosen because it had two identical MT (medium temperature) systems, which would allow for accurate comparisons of Genetron Performax LT alongside R-404A and R-407A (see Figure 1).

The MT systems comprised:

• Identical connected loads
• Identical pipe-work design and layout
• Eight compressors pack ZB45 (Copeland scroll)

In order to ensure like-for-like comparisons between all three refrigerants, System 1 was converted from R-404A to R-407A and performance and energy consumption measured over a 12-month period. System 2 was, then, converted from R-404A to Genetron Performax LT and operated over an extended period.

Field test results:

A thorough evaluation of the results by the entire project team confirmed the power consumption for the Hunts Cross store shown in Figure 2.

Energy Consumption:

• The R-404A system consumed five per cent more energy as against the R-407A system.
• Genetron Performax LT system consumed 13% less power than the R-407A system and around 20% less than the original R-404A system.

The figures, right, show the energy consumption of the retrofitted pack.

Carbon footprint and operating costs:

The analysis (Figure 3) shows the impact of refrigerants on a standard store similar to the Hunts Cross store carbon footprint and on the system operating costs, based on a 15-year life-cycle assumption and taking account of only the compressor energy consumption. All other energy usage is assumed to be the same for all refrigerants. The results show significant emissions and cost advantages in using Genetron Performax LT over R-404A and R-407A across a range of operating conditions. The cost of retrofitting is not included.

Conclusion:

The Honeywell Genetron Performax LT advantage created for Asda included:

• Up to 15 % saving in system energy bills
• Up to 40 % reduction in system CO2 emissions
• Up to 10 % improvement in system running costs

FEEDBACK: A WIN-WIN RESULT FOR ASDA

Brian Churchyard, Head of Refrigeration, Asda, issued the following statement after the successful conclusion of the field test: “The benefits we are seeing are very much a combination of Asda’s system optimisation and favourable properties of the refrigerant. I feel the most important aspect of this conversion to Performax will be its unparalleled efficiency and lower GWP versus R404A, which will enable us to reduce both direct and indirect emissions. We have killed two birds with one stone. I am impressed by the energy improvement. This will bring us great opportunities when rolling out this conversion also to LT packages and other stores.”

Churchyard added that Asda will extend this programme to the rest of the refrigeration packs (MT and LT) in Hunts Cross and use this experience for the further rollout of conversion to Performax in its other stores in the UK.

SECTOR PERSPECTIVE

Honeywell gives below the implications of rollout the benefits of Performax LT around the world:

The Asda field test confirms the excellent performance and energy efficiency of Genetron Performax LT and the potential for significant energy savings and carbon footprint reductions among supermarket operators. Genetron Performax LT outperforms alternative refrigerants across all ambient conditions – a benefit confirmed by subsequent retro-fit projects in the supermarket sector – creating a potential for extended application into storage and packaging areas. The efficiency of the Honeywell refrigerant also provides potential for enhancing overall profitability when emissions reduction is factored in. Industry-indicative results confirm the Asda experience, with Genetron Performax contributing up to 15% savings in energy bills, a 40% reduction in CO2 emissions and 10% lower running costs.