Project Description

Optimization of Industrial Refrigeration System is a Massive Cost Cutting Opportunity

At an industrial refrigeration plant condensing pressure means energy use: a 2 psig increase of condensing pressure raises energy use by 1-2%.

Historically most plants are set to run at unnecessarily high levels of pressure, which presents an opportunity to cut energy use by 20% with no major investments. Along with condensing pressure reduction energy use can be cut by floating condensing and suction pressures, optimizing hot gas defrosting, optimizing compressors and condensers operating sequences.

Changing refrigeration system settings to cut energy use is never as simple as dimming the lights. Typically, some barriers should be overcome: hot gas defrosting, liquid supply, oil carry-over, oil cooling and so on. Deep understandings of refrigeration technology and design of a particular system as well as diligent implementation are paramount to cutting costs while maintaining a reliable operation.

Real Life Validation

This approach was validated through a real life pilot project conducted for a refrigeration plant at an industrial bakery. Project was performed in adherence with recommendations of IPMVP, including creation of production-normalized consumption baseline and assessment from the data provided by client before and after changes. Project results were approved by CLEAResult.

Similar results can be achieved at most industrial refrigeration plants.

Project results, Sons Bakery, Brampton

Reduction of condensing pressure cut energy consumption of the whole refrigeration plant by 13% while supporting the same load.

Actual reduction exceeded forecast by 3.5%.

Project results were approved by CLEAResult for incentives.

Next steps

In our consideration this refrigeration plant allows for further reduction of condensing pressure below 100psig and some with other energy cost-cutting measures.

Full implementation of these measures will reduce consumption by 38% with payback of 1.25 years prior to incentives. All proposed measures are subject to a 50% incentive in Ontario.