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INCORPORATING COLD CHAIN |
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at Matador’ s head office in Midrand integrates with the facility’ s control room, provides visibility into system performance and alerts operators to any issues, allowing for quick intervention and minimising downtime.
If any issues arise, a sub-contracted service team is on hand to respond quickly. The use of CO 2 sensors throughout the facility further enhances safety and ensures that any gas leaks are promptly detected and addressed.
The flexibility of the system lies in its automation features. When product types or storage conditions change, the system can be reconfigured without requiring manual intervention. Once the desired temperature settings are determined, operators can remotely initiate the changes, adjusting the system’ s parameters to ensure that the correct temperature is maintained. This level of automation not only enhances operational efficiency but also ensures that the facility operates in a highly responsive manner.
SUSTAINABLE CO 2 REFRIGERATION TECHNOLOGY
“ The decision to implement a CO 2 refrigeration system in the Port Elizabeth cold storage facility aligns with global trends toward sustainability and energy efficiency in industrial refrigeration,” says Duffield. It was a choice made prior to Matador’ s involvement in the project.“ CO 2
, as a natural refrigerant, is non-toxic, non-flammable and has a significantly lower global warming potential( GWP) than traditional refrigerants. This choice reflects the facility’ s commitment to reducing its environmental footprint while maintaining reliable and costeffective
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cooling – as well as meeting the specifications of European export markets.
“ The transcritical CO 2 system, particularly adapted for warm climates, offers improved energy efficiencies when paired with advanced ancillary components and controls. The system’ s performance in high ambient temperatures is optimised by exchangers ensuring the system remains stable and efficient even in extreme conditions.” Vorster adds:“ This installation, which features a mix of medium- and low-temperature compressors, aims to optimise both space and energy use. To achieve this, the system places low-temperature compressors on the top of the rack, while mediumtemperature compressors are positioned below. The use of hot gas defrost – as opposed to traditional electric defrost – minimises energy consumption and lowers operational costs by utilising the discharge gas from the mediumtemperature compressors to defrost the low-temperature coils.”
STATE-OF-THE-ART COMPONENTS
The system incorporates components from top-tier global suppliers, including Danfoss-BOCK for compressors, Swep of Sweden for plate heat exchangers, Colcoil for forced air heat exchangers and locally sourced pressure vessels from Viola. Control panels are assembled in-house, utilising ABB and Schneider components, while the monitoring and control systems are powered by the CAREL control system. This combination of local and international suppliers ensures the system operates at peak efficiency, with reliable performance for years to come.
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Each rack in the facility is equipped with 16 compressors, with three racks in total for a total of 48 compressors. The system also features variable speed drives( VSDs) to help regulate compressor speed and optimise energy consumption.
OVERCOMING CHALLENGES IN INSTALLATION
The installation of the CO 2 transcritical refrigeration system was not without its challenges. The project team faced a range of issues, including shifting specifications, tight working spaces and difficult weather conditions. However, through innovative problem-solving and meticulous planning, each obstacle was effectively addressed.
One of the first hurdles came in the form of a design change that occurred after the order for the compressors had already been placed. Initially, the system was designed to use a certain number of compressors, but the client’ s needs evolved during the project, requiring an additional nine compressors to be added. This late-stage modification meant that the racks had to be reconfigured to accommodate the extra equipment. The team adjusted the design, ensuring that the new system would still meet performance requirements without compromising on space efficiency.
The cold storage plant room posed another significant challenge: limited space. The design required careful consideration of compressor placement, pipe routing and the physical layout of the system components. To maximise the available area, the team made a strategic decision to position low-temperature compressors on the top of the racks, with medium-temperature compressors below.
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This not only saved valuable floor space but also allowed for more efficient use of the entire plant room. The team also had to ensure that each piece of equipment was easily accessible for maintenance and that the plant room remained organised and functional despite the space constraints.
The system’ s installation came with its fair share of logistical hurdles. Heavy machinery, compressor units and evaporators – some weighing over a ton – had to be hoisted into place using mechanical hoists and secured with steel structures spanning the entire facility.
Finally, the weather added another layer of complexity to the project. During the installation phase, heavy rains caused significant delays, with trucks getting stuck in the mud and worksite conditions becoming hazardous. Despite these setbacks, the team remained flexible and adapted to the conditions, using the downtime to focus on other tasks that could be completed indoors or in areas less affected by the weather. By adjusting the work schedule and maintaining clear communication with all stakeholders, the team managed to stay on track and meet the project’ s overall deadline.
Perhaps the most important factor in overcoming these challenges was the seamless collaboration between all parties involved. From manufacturers to subcontractors, the team’ s ability to adapt quickly, communicate effectively and problem-solve on the fly ensured the success of the project. This coordinated approach, combined with a commitment to quality and efficiency, enabled the team to deliver the refrigeration system on time, despite the numerous obstacles that arose during the installation.
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