CO₂ Transcritical Refrigeration at Scale: Advancing Industrial Efficiency in Ecuador

In the industrial refrigeration landscape, CO₂ transcritical systems are proving to be both a high-efficiency and sustainable alternative to traditional refrigerants. A large-scale shrimp processing facility in Ecuador has adopted this technology, marking a significant step toward reducing environmental impact while maximizing operational performance.

This project integrates a fully CO₂ transcritical refrigeration system with a carefully engineered design to meet the facility’s stringent cooling demands:

• 46 medium-temperature (MT) transcritical compressors (nominal capacity: 1940 HP)
• 33 low-temperature (LT) compressors, ME type (nominal capacity: 1060 HP)
• 6MW of total installed refrigeration capacity, ensuring system stability and redundancy
• 7 operational refrigeration units, each optimized for specific process requirements
• 26 industrial evaporators, distributed strategically to maintain uniform cooling
• 12 gas coolers (each 8x800mm), maximizing heat rejection efficiency
• 2 LT pump stations, each with 3500L vessels, designed for precise liquid distribution

Key Technical Innovations

This CO₂ transcritical system incorporates advanced refrigeration principles that enhance both efficiency and sustainability:

• Mechanical Subcooling: Improves system efficiency by reducing flash gas formation, increasing cooling capacity without additional energy input.
• Vapor Ejectors: Enhance energy efficiency by recovering energy lost during pressure reduction from the gas cooler to the liquid line. This innovative approach reduces compressor workload while consistently meeting cooling demands.
• Hot Gas Defrost: Enhances heat transfer efficiency while minimizing energy consumption and frost buildup within evaporators.
• Heat Recovery Integration: Captures waste heat from the refrigeration cycle to preheat water, reducing overall energy demand.

Performance Metrics

The system is designed to operate at ultra-low and low temperatures, ensuring high thermal stability and energy optimization across different process zones:

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

Impact on Industrial Refrigeration

This facility represents one of the largest fully CO₂ transcritical refrigeration installations in the region, demonstrating the viability of CO₂ as a long-term solution for large-scale food processing. Compared to conventional HFC-based systems, CO₂ transcritical technology offers:

• Lower Global Warming Potential (GWP = 1), eliminating reliance on high-GWP synthetic refrigerants.
• Higher Thermodynamic Efficiency, especially in low-temperature applications.
• Enhanced Energy Recovery Capabilities, reducing auxiliary heating requirements.
• Improved Safety & Regulatory Compliance, aligning with international F-Gas reduction policies.

A New Standard for Industrial Refrigeration

The scale and complexity of this installation highlight the growing shift toward environmentally responsible and high-performance refrigeration solutions. CO₂ transcritical technology is no longer an emerging trend—it is now a proven, scalable solution that aligns with global efforts to reduce carbon footprints in industrial operations.

The adoption of CO₂ refrigeration in large-scale applications like this sets a precedent for the future of industrial cooling—one that balances performance, sustainability, and energy efficiency.