Kloosterboer Vlissingen: replacement of old R22 installations

The three terminals with a collective 25 cells are mainly used for the storage and overhaul of juice and concentrate, both frozen and cooled. "Orange, berry, carrot, coconut milk - everything available in juice form is in these cells," indicates technical manager Marco Pijcke. "We also have a blending station where we mix concentrates as commission by our customers."

Three R22-installations, three machine rooms

The terminals were conditioned through three old R22 installations. "The old R22 installations were technically written off," says project manager Richard Garstman, cooling technical administrator of Kloosterboer Vlissingen. "With three machine rooms and ten aged suction compressors they were no longer modern. The cost of keeping their installations going was considerable. The ban on filling up with R22 is also approaching. Something different was needed to safeguard the future of the cooling/ freezing terminals."

One central cooling installation

On central cooling installation with ammonia as a cooling agent was chosen. "One of the best cooling agents as far as energy is concerned, relatively cheap to buy and a GWP value of 0," according to Richard Garstman. At the same time the total capacity was extended to 1.5 MW of cooling/freezing power. The cells are fitted with a total of 50 coolers and can be used for both cooling (+5°C) and freezing (-12°C to -25°C).

Complex task

The new central machine room was constructed in one of the old machine rooms. A complex task, as the existing installation had to continue to run during the conversion. The application of ammonia has had strict demands in the area of detection and safety. "A fire retardant and damp proof shell was built within the room," says Richard Garstman. "After this the ammonia installation was placed, along with a compressor. The first hall was switched to this. Taking out the old compressors was then precision work. After that the other two new compressors could be placed."

Saving energy

Kloosterboer was able to realise a considerable energy saving with the new installation. Because the installation only rarely has to run at full capacity, it is designed so that the compressors also run energy efficiently for a partial load. A stepless speed control through frequency regulators means that the installation runs around 8% more efficiently than through a standard capacity regulator. The fully automatic VI regulator of the screw compressors contributes to an unprecedented high turnover in partial load situations. Through a weather dependent regulator on the condensers the condensation pressure is optimally adjusted to the load and the outside temperature. This means the compressors use around 6% less energy than a set VI setting. The placement of an economiser between the condenser and the divider saves another 13% of energy. For defrosting the air cooler ammonia hot gas is used. Unlike electrical defrosting, available warmth from the freezing installation is used for this. Defrosting the coolers therefore requires no extra energy.

Reusing heat

Part of the heat produced by the installation is used for heating the floors of the frozen storage cells. Any leftover heat is carried away through a dry cooler.

Reusing cold

Part of the cold from the sub flooring is used to cool the separate electrics room. If there is still cold from the sub flooring remaining, it is carried away and heated up with the heat produced by the cooling installation.

EIA-regulation

Due to the design and choice of components, the installation meets the requirements as specified in the EIA regulation 2014 for the energy efficient cooling installations. In a subsidy applicable design the net investment amount is around 14% lower.

Good communication crucial

Richard Garstman is very satisfied with the course of the phased conversion. "Everything went well, thanks to good communication from both sides. Communication is very crucial in a project like this. Especially towards the logistics side, as the storage and overhaul of goods continue. During the realising there are also lifts and dozens of engineers working in the hall. This requires a lot of mutual coordination and understanding."

Opting for Nijssen

Project leader Marco Pijcke: "After setting up a package of demands we invited the most progressive cool technical installers to offer their quotation. The choice was made for the firm Nijssen. They had the best options and listened to what we had exactly envisioned. Nijssen also realised the new building and extension of the Kloosterboer Delta Terminal at the Maasvlakte to satisfaction."

Completion: October 2015

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