This issue of the Condenser is all about change. Whether it’s the regulations phasing out HFC’s and the new decisions faced by many in the commercial and industrial world, or the innovations and new technology that are enabling those decisions – one thing is certain, we are moving rapidly into a new era of refrigeration.
Read MoreA growing number of supermarkets are moving to replace hydrofluorocarbons with climate-friendly alternatives, such as propane, ammonia and carbon dioxide, ahead of the planned phase out of R-22 in the United States, but grocers are moving forward cautiously.
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The use of hydrofluorocarbons (HFCs) has recently been at the center of policy deliberations in the United States and globally. Many HFCs used in refrigeration have high global warming potential (GWP) and have become the target for reductions by the U.S. Environmental Protection Agency and the over 170 countries that are parties to the Montreal Protocol.
Read MoreIn this issue, we’re presenting news on one exciting new activity in our industry and our organization – to build and deliver IIAR’s first education program. IIAR is working harder than ever to deliver on its promise to membership: to broaden the reach of our member base by addressing major issues that are occurring in our industry to promote the ongoing growth and health of industrial refrigeration.
Read MoreThe IIAR Academy of Natural Refrigerants certificate program will allow design engineers, installers and responsible parties to show that they have received documented and standardized training. The program will begin with a training course on IIAR-2, the latest IIAR standard to be updated, and will expand to cover additional IIAR standards and other technical courses of study that are necessary for engineers working in the refrigeration industry.
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In June 2016, the Occupational Safety and Health Administration (OSHA) convened a Small Business Advocacy Review (SBAR) Panel to get feedback from small businesses about potential changes to the Process Safety Management (PSM) regulation.
Read MoreThere’s a lot going on at IIAR headquarters these days. We’re growing and expanding with new initiatives, programs and goals for the new membership year. That growth just reflects the expansion of our industry in general.
Read MoreOwners and operators of ammonia refrigeration equipment have a number of regulatorydriven documentation requirements, and the level of understanding regarding those requirements can vary from company to company.
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On March 14, 2016, the Environmental Protection Agency (EPA) published in the Federal Register a proposed rule to modernize the Risk Management Program. The rulemaking comes as a part of the Obama Administration’s efforts to implement Executive Order 13650 – Improving Chemical Facility Safety and Security. The Executive Order was issued in response to an incident at a fertilizer plant in West, Texas in April 2013.
Read MoreThe 2015 – 2016 membership year has been an exciting time for our industry. As regulations and technologies evolve at a rapid pace, we’re seeing new opportunities and applications for refrigeration grow like never before.
Read MoreAs hedrofluorocarbons and hydrochlorofluorocarbons are being increasingly phased out to meet government and regulatory requirements, natural refrigerants are candidates to fill the void, getting a closer look from many types of businesses installing smaller refrigeration systems, such as supermarkets and convenience stores.
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In February 2016, the Occupational Safety and Health Administration (OSHA) announced that it is initiating a Small Business Advocacy Review (SBAR) Panel in order to get feedback on several potential revisions to OSHA’s Process Safety Management Program (PSM) standard.
Read MoreAs you’ve likely noticed, this issue of the Condenser is all about the re-release of IIAR-2, the first comprehensive code standard for the safe, reliable and efficient design of ammonia refrigeration systems. We’re dedicating so much space to IIAR-2 because it is perhaps one of the most important, long reaching projects our association has completed in recent years.
Read MoreWith the completion of IIAR-2, the most comprehensive standard for the safe design of closed-circuit ammonia refrigeration systems, the International Institute of Ammonia Refrigeration has written a single authoritative source document that provides a path forward for the ammonia refrigeration industry.
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On November 9, 2015, the Environmental Protection Agency (EPA) published a Notice of Proposed Rulemaking entitled “Protection of Stratospheric Ozone: Update to the Refrigerant Management Requirements under Section 608 of the Clean Air Act.”
Read MoreIn this issue, we’re presenting news on many exciting activities in our industry and our organization. IIAR is working harder than ever to deliver on its promise to membership: to promote the ongoing growth and health of industrial refrigeration.
Read MoreAgriculture and food processing operations across the American West are scrambling to find new water sources amid a record drought. And although their water problems continue to be seen as a mostly regional issue for many in the industrial refrigeration industry, there’s no mistaking that water scarcity will loom larger in the years to come.
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On August 1, 2013, President Obama signed Executive Order 13650 entitled: Improving Chemical Facility Safety and Security. The action was driven in response to an explosion at a fertilizer facility in West, Texas
Read MoreThroughout this edition of the Condenser, you’ll see a common theme: change. New technologies are opening the door to new types of customers and applications for ammonia and other natural refrigerants.
Read MoreThe move towards lower charge has spurred demand for products like standardized package systems that promise solutions to at least some of the industry’s biggest problems. But exactly how those products will develop, and who will take them to market is yet unclear.
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The November 2014 elections resulted in a significant shift in control of Congress. Republicans gained control of the Senate and widened their majority in the House of Representatives. As a result, efforts to reform the regulatory process are seeing renewed interest this year.
Read MoreThis issue of the Condenser marks the end of the last member year, and the beginning of a new one. It also marks our annual conference, where we come together from all corners of our industry to talk about the trends and technology shaping our business – at IIAR’s Annual Industrial Refrigeration Conference and Exhibition.
Read MoreThe use of CO2 as a refrigerant has grown in recent years, thanks to market demand spurred by a combination of environmental regulatory actions and technology advances in microprocessor controls and valve design.
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In February 2015, the Environmental Protection Agency issued an enforcement alert entitled: “Anhydrous Ammonia at Refrigeration Facilities Under Scrutiny by U.S. EPA.” The EPA’s Office of Civil Enforcement issues alerts such as this periodically to highlight areas where the agency is placing enforcement priority.
Read MoreOne of IIAR’s most important responsibilities is advocating on behalf of our members on state and federal policy. I’m happy to report that in 2014 we stepped up our efforts even more in this realm and we’ve been working closely with government regulatory agencies to provide them with our expertise in a number of different ways.
Read MoreMuch has been made of the so-called manufacturing skills gap in the United States as manufacturers across a wide swath of industries report that the pool of prospective workers with the skill sets and certifications required to perform highly specialized job functions is narrowing, even as U.S. manufacturing continues its steady climb.
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In July 24, 2014, the Environmental Protection Agency published a Request for Information (RFI) regarding the agency’s Risk Management Program (RMP) regulations. The RFI was generated as a part of the Obama Administration’s efforts to implement Executive Order 13650 - Improving Chemical Facility Safety and Security.
Read MoreThroughout this edition of the Condenser, you’ll see a common theme: Progress. I couldn’t be more excited about where IIAR – and the industry as a whole – are heading.
Read MoreThe five-year replacement interval for relief valves isn’t a practice that gets much scrutiny. It’s spelled out in IIAR Bulletin 110, and a provision establishing the need for a common interval appears in the Boiler and Pressure Vessel Code, making it a generally accepted “no-brainer” for much of the industrial refrigeration industry.
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In response to the tragic accident last year in West, Texas, President Obama issued Executive Order (EO) 13650, Improving Chemical Facility Safety and Security. The EO is intended to enhance the safety and security of chemical facilities and reduce risks associated with hazardous chemicals to facility workers and operators, communities, and responders.
Read MoreThere’s a lot going on these days, both in our industry and at IIAR’s headquarters. Regulatory issues have seen an increased focus for our organization while new technologies like low charge systems continue to grow in importance.
Read MoreRefrigeration technologies like synthetic replacements for HFCs, low charge ammonia and CO2 -based systems are growing like never before ahead of a planned phaseout of R-22 in the United States.
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The Obama Administration continues its work under the Executive Order entitled: Improving Chemical Facility Safety and Security that was signed in August 2013.
Read MoreThe beginning of the year has been a busy time at IIAR headquarters as we prepare for our Heavy Equipment show in Nashville. As usual, we’re looking forward to showcasing the best our industry has to offer.
Read MoreAmmonia refrigeration is emerging as a dominant market in many important world economies as governments move to re-energize the Montreal protocol to phase-down greenhouse gasses.
Read MoreThe second half of the year is always a challenging and busy time for the International Institute of Ammonia Refrigeration, and so far, 2013 has followed that precedent. As we wrap up this year’s work on behalf of the industry, the IIAR leadership is pleased to report on several successful initiatives in many different areas.
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On August 1st, President Obama announced the signing of an Executive Order entitled “Improving Chemical Facility Safety and Security.”
Read MoreThe importance of color coding ammonia refrigeration piping is a generally accepted best practice these days, but the debate over which colors to use has been anything but black and white.
Read MoreIn 1974, the International Institute of Ammonia Refrigeration issued IIAR-2, a standard that would uniquely address the design and installation of ammonia refrigeration systems for the first time and establish IIAR as the standards writing body dedicated exclusively to ammonia refrigeration.
Read MoreIn most situations, the correct response to a threat involving ammonia in the first thirty minutes after it is identified will effectively contain most potential hazards, before they have enough time to grow into an unmanageable problem. Preparation can mean the difference between a disorganized response and the ability to shut down a potential incident when time matters the most.
Read MoreThe return of Carbon Dioxide as a refrigerant is probably un-stoppable because it is much more environmentally friendly than most of the non-flammable, non-toxic refrigerants currently in use. However, it is worth considering the reasons why industry departed from it in the 1940s.
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The Adaptive Parabolic Control Algorithm (APCA) is a PID replacement algorithm that performs well with nonlinear level controllers, noisy level indicators, and systems that require a rapid response to load changes but a slower response for unit optimization. The APCA reduced compressor amp standa...
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CO2 has gained significant momentum in the North American refrigeration and heat pump industry in recent years, particularly in transcritical applications. Even though CO2 refrigeration technology is already fully mature in terms of component availability, control strategies, and best practices, ...
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CO2 has become a mainstream solution for numerous applications, including industrial and commercial refrigeration, heat pumps, and winter sport venues. Across all these applications, effective superheat control plays a key role in system efficiency and compressor reliability. Superheat varies sig...
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This study experimentally investigates the use of ejectors in transcritical R-744 water-to-water heat pump systems, focusing on adjustable-nozzle control strategies to enhance energy efficiency and operational stability. Although R-744 systems offer several environmental and thermodynamic benefit...
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The industrial refrigeration and heating industries are increasingly affected by the transition to low–global warming potential (GWP) refrigerants and decarbonization initiatives. Consequently, industrial refrigeration and heating applications now often require high suction pressures due to their...
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This paper examines the growing demand for retrofitting in the food and beverage industry, driven by the introduction of new products to the market, regulatory shifts, sustainability goals, and operational modernization. It identifies the key challenges of retrofitting an active production facili...
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Technological innovations have occurred in the movement of palletized goods into, out of, and within refrigerated facilities. Much recent attention has been on technologies such as AGVs (automated guided vehicles), automated pallet shuttles, high-density vertical storage...
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The food and beverage industry is extremely energy-intensive, and there is significant potential in the waste thermal energy generated by its processes. This energy can be utilized to drive lithium bromide water absorption chillers, capable of producing low-temperature leaving evaporator fluids a...
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The CO2 (R744) Simultaneous Chiller Heat Pump integrates cooling, heating, and domestic hot water production into a single, modular system using CO2, a natural refrigerant with an ozone depletion potential of 0 and a global warming potential of 1. By employing parallel VFD-driven compressors (20–...
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All compressors produce some vibration in the connected pipe and tubing, but how much is too much? Excessive vibration can lead to unexpected leaks that can cause hazardous situations and loss of cooling. In many food applications, loss of cooling results in significant product loss in addition ...
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Carbon dioxide (CO2) has emerged as a leading natural refrigerant in commercial refrigeration applications due to its ultra-low global warming potential (GWP of 1), energy efficiency, and alignment with global regulatory phase-down mandates. However, system reliability, charge preservation due to...
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The selection of materials in finned evaporator construction plays a critical role in determining the performance, durability, and overall efficiency of refrigeration systems. This white paper examines the importance of selecting the appropriate material for the construction of finned heat exchan...
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R744 (CO2) industrial air-source heat pumps (ASHPs) can serve as cost-effective and scalable alternatives to conventional heating and cooling systems. Leveraging the unique thermodynamic properties of CO2, a natural refrigerant, these systems deliver high efficiency and flexibility for certain te...
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Air blast freezing systems are among the most widely used technologies for rapidly freezing both packaged and unpackaged foodstuffs. In many food processing facilities, freezing is a bottleneck in the continuous flow production, and thus techniques to assess and improve their thermal performance ...
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This paper explores the potential of integrating CO2 refrigeration systems with energy savings alternatives to maximize sustainability and energy efficiency in agricultural cold storage facilities. With growing concerns over environmental impact and energy consumption, the adoption of ecofriendly...
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As resources get harder and harder to find, we need to explore other ways to help us be effective and make good decisions. For a single plant or a corporation with multiple plants, having good information available helps us leverage our resources for the most impactful decisions. Having an Auto-P...
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Currently, ANSI/IIAR 2 Standard for Design of Safe Closed-Circuit Ammonia Refrigeration Systems (IIAR 2021) requires machinery room emergency mechanical ventilation systems to provide no less than 30 air changes per hour based on the gross machinery room volume. When this emergency ventilation ra...
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The use of carbon dioxide (CO2), especially in industrial refrigeration systems, has received a lot of attention in the last decades. As for any equipment, a correct lubricant choice and a proper oil management strategy are key for the safe, reliable, and efficient operation of refrigeration syst...
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This presentation will focus on the basic understanding of water treatment and the involvement of industry that is required to extend the life of the equipment. In order to properly protect the asset from a water treatment perspective, industry needs to be more involved and educated. This present...
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You may be familiar with the quote, “Those who do not learn from history are doomed to repeat it.” Learning from others’ mistakes can be a game-changer in the world of ammonia refrigeration. This paper contains a collection of accounts of ammonia releases and interesting details from each inciden...
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Author: Paul Danilewicz, P.E., Santosh Yarlagadda Enerflex Energy Systems, Inc. Houston, Texas
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Large industrial refrigeration systems often suffer from operating instabilities caused by refrigerantliquid feed controls that are poorly engineered or improperly tuned. A strategy that requires more sophisticated controls potentially addresses operating instabilities but may introduce other cha...
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CO2 is an emerging refrigerant in North America, but identifying its suitable applications can still be challenging. In Europe, CO2 has been used in heat pumps for several years. This paper discusses the experience of using CO2 in heat pumps in Europe, giving the basics of its use as a refrigeran...
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Since the advent of process safety, the process hazard analysis (PHA) method of choice across the refrigeration industry has been the what-if/checklist technique. Over the last 20 years, many companies’ and industries’ hazard assessment methods have matured. While the hazard and operability (HAZO...
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The need to decarbonize industrial facilities is greater than ever. One technology that will play a large role in reducing carbon emissions is industrial heat pumps. With hundreds of different combinations of industrial heat pump systems, engineers and designers need to understand which technolog...
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Herein, the application of a rotary gas pressure exchanger (PX) for increasing the efficiency of transcritical CO2 refrigeration systems is examined. The PX uses high-pressure discharge from a condenser/gas cooler as a motive fluid to compress the low-pressure flash gas with minimal external ener...
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This paper describes enhanced and integrated carbon dioxide refrigeration systems that can improve yearly energy figures when compared to traditional flash-gas bypass (FGB) solutions, making CO2 an attractive option for industrial refrigeration in some regions.
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Over the last several years, facilities covered by the Environmental Protection Agency’s Chemical Accident Prevention Provisions, otherwise known as the Risk Management Program, have beenforced to navigate unpredictable and frequent shifts in policy. This paper is intended to familiarize readers ...
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This paper demonstrates how evaporative condensers can be used as low-stage de-superheaters to improve the efficiency of two-stage ammonia refrigeration systems. The high discharge temperatures generated by ammonia compressors can help reject heat to ambient heat sinks, thereby reducing the load ...
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Before companies can report on progress toward sustainability goals, they need to establish a baseline. This paper outlines fundamental best practices for creating a useful energy baseline: defining the metrics upfront, normalizing the data, setting up real-time monitoring, and submetering specif...
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Ammonia refrigeration system managers are looking for more useful information regarding risk mitigation and compliance because they need to determine whether components are fit for service or vulnerable to damage, and when to act. Insulated piping is subject to corrosion under insulation (CUI), b...
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This technical paper addresses potential business risks associated with the Hazardous Waste Operations and Emergency Response (HAZWOPER) standard for ammonia refrigeration contractors when used for repairing leaks in ammonia refrigeration systems. The definitions of an incidental leak and leaks r...
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The requirements for determining the capacity of vapor service pressure-relief devices applied to partially liquid-filled ammonia vessels/equipment and discharging to the atmosphere, as well as liquid service relief devices completely filled with non-volatile liquid (e.g., compressor oil) dischar...
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Reducing the charge in ammonia refrigeration systems is becoming increasingly important. However, reduction must be achieved without compromising the efficiency of the ammonia refrigeration system.
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Intelligent CO2 compressors and ejectors are emerging as highly promising solutions for industrial refrigeration systems. This publication highlights their expanding capacity and scale, demonstrating their suitability for various applications, including cold storage facilities, distribution cente...
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Decarbonization is a crucial process in the effort to mitigate the effects of climate change. Considering this aim, efficient energy utilization is also imperative for sustainable and cost-effective operations in dairy plants. In general, the refrigeration system rejects heat to the atmosphere on...
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This paper provides an overview on the basics of carbon counting and how they may apply to carbon counting within the cold storage industry. It will also cover opportunities to take advantage of newer technologies available to improve the accuracy of carbon reporting data, and the ability to gene...
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Chidambaram Narayanan, External Consultant Joel-Steven Singh, Senior Engineer AFRY Switzerland AG
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The rise of automation brings new cybersecurity threats to heavy industries. Cybersecurity attacks like ransomware, malware, and phishing are becoming commonplace and more sophisticated as they continuously evolve and change. This paper reviews the risks and tactics of the most common classes of ...
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Transcritical CO2 heat pumps are emerging as a viable alternative to synthetic air- or water-source heat pumps, and they present an opportunity for electrification while eliminating the need for refrigerants with high global warming potential. The purpose of this technical paper is to assess the ...
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This paper presents an objective analysis of the Federal Environmental Protection Agency’s (EPA’s) enforcement of ammonia refrigeration facilities across America conducted using hundreds of publicly available independent inspection reports dating from 2006 through 2021...
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Generally, safety standards for refrigeration systems require the placement of at least one overpressureprotection device on all carbon-dioxide (R-744) systems as well as on vessels manufactured in accordance with the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Secti...
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The dominant topics for industrial refrigeration facilities have been climate change and rising energy costs in recent years. A new generation of environmental activists worldwide has pushed this agenda forward to the point where politicians have started to alter their countries’ energy policies....
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Incidents of ammonia releases due to hydraulic shock in the refrigeration pipework have been reported in the past and could occur in the future. Such shock events carry significant commercial risks and are a concern for the health and safety of humans. Two locations where hydraulic shock occurs f...
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The use of a variable frequency drive (VFD) to control the speed of an AC induction motor has numerous benefits, including energy savings, improved reliability, reduced equipment wear and tear, and more precise control of motor speed.
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All too often, energy management projects with good potential will fail for any number of reasons. Most of these failures will be a result of the project not addressing key requirements for success, or not meeting the expectations of all users throughout the organization. This report is intended ...
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Over the last 15 years the market for high-temperature ammonia heat pumps has been growing in Europe and now it is also taking off in North America. That period in Europe has yielded many lessons as higher pressure and temperature present new challenges in refrigerant design. This paper explains ...
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Absorption cycles using the ammonia-water refrigerant pair have a long track record of commercial applications ranging from industrial-size cooling using waste heat as the energy source, to gas-fired residential air-conditioners and small refrigerators for recreational vehicles using propane fuel...
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Carbon dioxide (CO2) has today become the standard refrigerant of choice for many applications, often enabling better coefficient of performance (COP) than the previously adopted technologies based on other refrigerants. This trend is progressively leading to both a lower usage of high global war...
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The goal of any industrial refrigeration system is to remove heat. Therefore, the total heat load is the design engineer’s first calculation, which is then used to size and select the evaporators. Unfortunately, this heat load is often also applied to the sizing of other components in the system,...
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The goal of operators, contractors, and design engineers is to operate a closed loop refrigeration system as close to design intent as possible. The owner wants maximum value from the equipment and personnel employed at the facility. The presence of gases that do not liquify within the operating ...
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The global HFC phase-down and the proposed restrictions on PFAS (per- and polyfluorinated alkyl substances) have accelerated the transition towards natural refrigerants. The requirements of the Paris Agreement, the European CBAM (Carbon Border Adjustment Mechanism) initiative, and ESG (Environmen...
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The ammonia refrigeration industry has a historically good safety record and hence there have been few instances of ammonia release resulting in ignition events. To continue and improve upon safe practice, computational fluid dynamics (CFD) modeling was undertaken...
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The condensation induced hydraulic shock (CIHS) phenomena is a primary safety concern in low temperature ammonia systems. When transient pressure amplitudes become exceedingly high, pipe rupture can occur. Of particular interest to the ammonia industry is the development of a computational fluid ...
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Recognized and generally accepted good engineering practices (RAGAGEP) are written documents intended for use in the design, installation, operation, and maintenance of process equipment. There has been a movement in the ammonia refrigeration industry towards standardization...
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Industrial ammonia refrigeration systems vary widely in their engineering design, size, scope, and technology features. However, they universally experience some level of refrigerant loss throughout their operational life. Refrigerant losses from industrial ammonia refrigeration systems originate...
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The OSHA Process Safety Management (PSM) program and the EPA Risk Management Plan (RMP) rule rely on mechanical integrity to achieve the desired results. In the case of piping and equipment exposed to anhydrous ammonia, the predominate damage mechanism is external corrosion or corrosion under ins...
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Should the hazard and operability (HAZOP) methodology be considered the industry standard for hazard reviews (HRs) and process hazard analyses (PHAs)? The topic is currently the focus of a vigorous debate in the industrial refrigeration industry. While there are advocates for and against employin...
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Considerations around modes of test and operation that place ammonia refrigeration systems in a vacuum are discussed. A literature review of IIAR publications and general industry recommendations regarding design of pressure vessels and systems for evacuation and operation is presented. Results a...
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