CO2 TRANSCRITICAL BOOSTER SYSTEMS

William Katz
Sr. Technical Writer
Hillphoenix
2016 Gees Mill Road
Conyers, GA 30013
Tel: 678-613-9364
Email: [email protected]
 CO2 Transcritical Booster Systems

Refrigeration systems for supermarkets and other applications have been evolving
toward the use of environmentally friendly natural refrigerants over the past couple of
decades. In recent years, this advancement has led to the installation of numerous
systems that use carbon dioxide (CO2) as a refrigerant. The first of these systems only
used CO2 as either a secondary coolant or as a direct expansion (DX) gas in the low-
temperature portion of a cascade-type system. Both of these approaches continued
to rely on the use of some synthetic, environmentally harmful hydrofluorocarbon
(HFC) refrigerants in either the primary side of the former systems, or the medium-
temperature portion of the latter. Now a type of DX system that runs entirely off of
CO2 has begun to see increasing use in North America.

CO2 transcritical booster systems

rely on the same vapor-
compression refrigeration cycle as
do traditional DX systems. In fact,
they use the same main
components that traditional
systems do: compressors,
evaporators, condensers and
expansion valves. The operation of
a booster system, consequently,
will seem familiar to anyone who Figure 1 - Booster System Rack

knows how a traditional system works. The difference in how the two types of
systems operate has to do with the nature of the refrigerants they use.

Traditional DX systems that use HFC refrigerants, such as R-410A, typically operate
at pressures of around 400 pounds per square inch (psig). Due to the material
characteristics of CO2 (R-744), systems that use it must be engineered to operate at
higher pressures — as much as 1450 psig depending on ambient conditions. This
means, for instance, that on the high side of the system a type of copper pipe

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 CO2 Transcritical Booster Systems

especially designed for the higher operating pressures of CO2 can be used.1 Other
components specifically designed for the higher operating pressures of R-744 are
also needed for the system. These components are described further on in this
paper.

The energy consumption of the first transcritical CO2 booster systems depended on
the ambient conditions where they are used (see the description of adiabatic
condensers below). As the ambient temperature drops, a CO2 booster system works
in the subcritical range, allowing it to potentially deliver better energy performance
than other types of systems. That, combined with the system’s complete elimination
of HFCs, makes it an effective option for customers looking to achieve sustainability
and lower operating costs. This combination of benefits provides the greatest
rationale for the use of a CO2 booster system.

In addition, the CO2 booster incorporates both medium-temperature and low-

temperature capability in a single,
compact unit. The compressors in the
unit can be sized to accommodate a
wide range of loads. Instead of
separate systems for a store’s
medium- and low-temp loads, only
one system is needed for both. In
about the same amount of space that
would have been needed for just one
portion of a traditional system, a
booster system can meet all of the
store’s refrigeration needs. By
reducing the equipment needed to
run an entire store to a single system,
Figure 2 - Simplified system piping

1
Copper-iron alloy tubing became available in late 2015.

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 CO2 Transcritical Booster Systems

supermarkets can save space and simplify their operation.

How the System Works

Certain aspects of CO2 booster systems will be familiar to anyone who knows how
traditional DX systems work. Like those, booster systems have four main components
that include compressors and evaporators. But in addition to using a condenser and
expansion valves, booster systems also use a high-pressure control valve and a
special type of condenser that works as a gas cooler under higher ambient
conditions.

Another key difference from traditional systems is that booster systems work with the
same refrigerant moving between the low- and medium-temperature compressors.
The low-temperature compressors discharge to the suction of the medium-
temperature compressors. In other words, the low-temperature compressors serve as
a booster to the medium-temperature compressors.

Suction gas from the low-temperature display case and freezer evaporators enters
the low-temperature subcritical compressors at around 200 psig, well below the
critical point for CO2. The low-temperature compressors discharge that gas at about
425 psig then combine it with the medium-temperature suction gas from the
medium-temperature display cases and walk-in cooler evaporators before entering
the medium-temperature transcritical compressors. The medium-temperature
discharge gas leaves the compressors, depending on ambient conditions, anywhere
from 560 psig to as much as 1450 psig, which is above the critical point. Under
warmer conditions in which the pressure rises above 1055 psig, the system operates
in the transcritical range.

Under all conditions, however, the discharge gas from the medium-temperature
compressors feeds to the condenser, where the heat it carries is rejected to the
outside environment. This heat rejection process is standard in any refrigeration
system.

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 CO2 Transcritical Booster Systems

Sizing of the compressors on the low-temperature and medium-temperature stages

of the system is carefully determined to assure optimal capacity control during partial
load operation. The condenser design is optimized for high-performance, even at high
ambient temperatures when the system is operating in the transcritical range.

The CO2 leaving the condenser feeds to a high-pressure control valve that expands
the CO2 into an intermediate pressure receiver called a flash tank. The gas enters the
valve from 560 to 1450 psig, depending on ambient conditions, and exits the valve
at 540 psig. The valve is designed to work somewhat like a hold-back valve in order
to maintain optimum pressure through the gas cooler for the most efficient
operational performance of the system.

The flash tank (or tanks on larger systems) works the same way, in principle, as a
conventional receiver and can usually contain all of the refrigerant charge during
pump-down and shutoff. Some systems, however, utilize capacity in the gas cooler
during pump-down in order to employ a smaller flash tank. The pressure in the tank
is held at a constant level that is sufficient to maintain differential pressure
throughout the system.

From the flash tank, both liquid and gas refrigerant is fed back to the system. Liquid
refrigerant is supplied to the medium- and low-temperature evaporators controlled by
conventional electronic expansion valves. Vapor from the flash tank is fed through a
flash gas bypass valve back to the medium-temperature compressors. The flash gas
bypass valve maintains a constant pressure in the flash tank.

Apart from some of the unique components just described, the system works in a
similar way to other types of DX systems. The main differences are related to the two-
stage design of the system and the fact that all evaporators in the system are
supplied with liquid from the same source. For most experienced technicians, the
system will not seem overly complicated.

Major Components

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 CO2 Transcritical Booster Systems

As previously stated, CO2 booster systems use many components that are common
to other types of DX systems, along with some that are specifically designed for the
CO2 application.

CO 2 Compressors

Like any other type of DX system, compressors are used to move refrigerant through
booster systems. Unlike most other types of DX systems, however, booster systems
use two sets of compressors — one set for the medium-temperature stage and the
other for the low-temperature stage. Semi-hermetic, reciprocating compressors are
typically used for both stages. Scroll compressors can be used for the low-
temperature stage on systems for customers who prefer them. Both types of
compressors are available from a variety of manufacturers.

Compressors operate with either polyolester (POE) or polyalkylene glycol (PAG) oils
specially selected for use in this application, so an oil-management system is
required. The components of the oil-management system are the same as for
conventional DX systems, but they are designed to accommodate the higher
operating pressures associated with CO2 and include oil-level regulators (either
electronic or mechanical), a separator, a reservoir and a filter. CO2 compressors also
require crankcase heaters to warm the oil whenever the compressor is not running.
Some CO2 compressors contain relief valves to ambient. A sight glass on the front of
the compressor allows visual monitoring of the oil system during operation.

When viewed on the pressure-enthalpy diagram (next page), the medium-

temperature compression cycle can be seen starting at around 400 psig where the
gas enters the compressors. From there, depending on ambient conditions, the gas
may reach up to 1385 psig as it discharges from the compressors and enters the
condenser. Of course, for the gas to reach that range, the ambient conditions must
exceed 80°F.

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 CO2 Transcritical Booster Systems

Typically smaller than the medium-temperature compressors (though depending on

application their size may vary), the low-temperature compressors operate well below
the critical point in much the same way as the CO2 compressors on a cascade
system. Like those compressors, the ones on the booster system receive suction gas
from the low-temperature evaporators. On booster systems, suction gas enters the
compressors at 200 psig and discharge gas leaves them at 400 psig. From there, it
is combined with gas from the medium-temperature evaporators to become the
suction gas for the medium-temperature compressors.

Figure 3 - Enthalpy diagram showing how changes in condensing pressure

affect the amount of energy used or released (enthalpy) by the system.

A key feature of the system is the use of a variable frequency drive on the lead
medium-temperature compressor for better capacity control and on the low-
temperature compressors for even greater energy savings.

Oil Separator

Once the medium-temperature discharge gas leaves the medium-temperature

compressors, it passes through an oil separator. Oil separators are a common
component on DX systems. Booster systems, like the lower section of cascade

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 CO2 Transcritical Booster Systems

systems, use synthetic POE oil. Booster systems are equipped with a highly efficient
mechanical oil separator that uses coalescing filters to remove contaminants from
the oil system. The separator can be used with or without an external oil reservoir.

Condenser/Gas Cooler

This component typically works the same way a condenser does in a conventional DX
system. At ambient conditions below 80°F, medium-temperature discharge gas
enters the condenser/gas cooler and rejects heat to the outside air as it passes
through the coils of the unit. The main difference between a booster system
condenser and a conventional condenser is that when the ambient temperature rises
above 80°F, the booster system begins operating in the transcritical range. Then the
discharge gas passing through the system is unable to undergo any further state
change, but remains a supercritical gas, or fluid, as it is otherwise known. This last
point is a key distinction. Under transcritical conditions, the discharge gas enters the
gas cooler as a supercritical fluid and stays that way all the way through the gas
cooler to the high-pressure control valve (below). No subcooling of the gas takes
place as in a regular condenser. Under 80°F, however, the unit then works just like a
condenser in a typical DX system.

In the same way that efficiency gains are made on the compressors through the use
of variable speed drives, so, too, are the fans on the condenser controlled. Also, the
condenser is equipped with a shut-off valve for maintenance or other needs.

In order to extend the efficiencies of the system to warmer climates, an adiabatic

condenser can be used. This type of condenser allows the system to continue
condensing at lower wet-bulb temperature than the ambient dry-bulb temperature.

Adiabatic condensers use the evaporation process to lower the temperature of the
ambient air as it flows through a set of water-moistened pads before reaching the
condenser’s coils. This cooler air then absorbs heat from the dry coils. Customers

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 CO2 Transcritical Booster Systems

have found that in warmer climates this approach actually operates at greater energy
efficiency than air-cooled systems.

High-Pressure Control Valve

Like the condenser, the high-pressure control valve works under two modes of
operation. It usually controls subcooling in the condenser when that unit operates as
a condenser. Under conditions during which the unit is working as a gas cooler
(above 80°F ambient), the valve controls pressure in the unit.

Flash Tank

The expanded gas from the high-pressure control valve flows into the flash tank at
around 540 psig. The flash tank performs the same function as that of a receiver on
a conventional DX system. At 1300 psig it is capable of holding the entire charge of
the system if necessary, such as during pump-down or an outage. Conventional
receivers, however, only return liquid to the evaporators. The flash tank, on the other
hand, is equipped with a flash gas bypass valve that sends vapor from the tank to the
medium-temperature suction lines, where it joins the gas from the medium-
temperature evaporators returning to the medium-temperature compressors.

Other Components

Piping

One of the benefits of CO2, as pointed out earlier, is its high volumetric capacity. This
allows for smaller diameter piping to be used than would otherwise be needed for a
HFC system of similar capacity. In fact, smaller diameters add to the overall
advantages of the system since they decrease the refrigerant charge and handle
higher pressures. In some cases, ¼-inch pipe (6 x 1 mm) is adequate. On systems
with hot gas defrost, however, 3/8-inch (8 x 1 mm) to ½-inch (10 x 1 mm) pipe is
necessary.

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 CO2 Transcritical Booster Systems

Piping and elbows to and from the condenser/gas cooler for installations currently in
the field have used schedule 80 carbon or stainless steel. The piping is welded, and
where damp conditions or exposure to weather might occur, coated with primer and
varnish. Recent developments from suppliers, however, have led to the availability of
a type of copper piping especially designed for use with CO2. Producers of this
material obtained National Science Foundation (NSF) certification at the end of
2015.

Controllers

As with other types of systems, controllers for booster systems are available from a
number of manufacturers. On booster systems, the controller maintains the optimal
pressure in the gas cooler when the system is operating in the transcritical range so
as to maximize the system’s performance. This method of control provides an
optimum coefficient of performance (COP). Heat reclaim with a 0-10 volt signal is
also available through this approach.

The system makes use of compressor capacity control through pack controllers that
can handle up to either four or eight compressors. The pack controllers work on
suction pressure and are a standard means for controlling suction groups in any
refrigeration system. The pack controllers are capable of regulating variable speeds
for two compressors combined with one-step compressors of the same or different
sizes, depending on the choice of coupling pattern.

For most people familiar with the challenges facing commercial refrigeration, the
rationale for moving to environmentally friendly natural refrigerants is well known.
Foremost among the approaches that are available, CO2 booster systems offer the
greatest advantages. The design of these systems allows them to work most of the
time in the same way that traditional DX systems do and makes their installation and
operation fairly straightforward. The complete elimination of HFC refrigerants that
booster systems provide moves users of these systems toward a more sustainable
basis of operation than other alternatives currently available.

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