Benefits provided by Refra heat pump secure major industry award

Author: Steed Webzell

A highly successful Refra Ignis reversible heat pump installed at a new €20 million flower processing facility in Ireland is the recipient of a prestigious industry award. This advanced Refra propane heat pump with its state-of-the-art technologies has been delivering sustainability and energy efficiency at Keeling’s newly constructed flower processing facility in St Margaret’s, County Dublin, since opening in July 2023.

The level of innovation that the Refra Ignis demonstrates as part of this impressive project led to it winning ‘Heat Pump System of the Year’ at the 2024 IRI (Institute of Refrigeration Ireland) Industry Awards.

Keeling’s, a third-generation family business operating and innovating within the fresh produce industry since 1926, wanted sustainability and resource recovery to be integral parts of its refrigerated warehouse project from the outset. To help ensure this concept became reality, the company turned to local Refra partner Anglo Irish Refrigeration.

Anglo Irish Refrigeration specified a Refra Ignis reversible propane heat pump offering 101.6kW of cooling capacity and 120kW of heating capacity, alongside a Refra chiller with two pump stations and a buffer tank. By providing a variety of products to cover multiple project needs, Anglo Irish Refrigeration became part of the overall sustainability goal at Keeling’s.

The company’s new 8,500m2 facility houses a number of innovative features. For instance, Keeling’s captures and utilizes heat generated from refrigerated rooms to warm other areas, minimizing energy consumption. The company also deploys a rainwater recovery system.

Green light for heat pumps

Regarding heat pump selection criteria for the project at Keeling’s, sustainability was high on the agenda. Heat pumps are already a popular choice for many commercial and industrial refrigeration projects because they use less refrigerants than traditional systems and, by relying on heat transfer principles, generate fewer greenhouse gas emissions than their energy-intensive counterparts. According to market research specialist Global Market Insights (GMI), Europe’s heat pump market was valued at $16.5 billion in 2023 and is estimated to reach $82.1 billion by 2032, delivering an impressive CAGR (compound annual growth rate) of 19.2% from 2024 to 2032.

In light of this demand, technological advancement is critical. Here, Refra leads with heat pumps that use natural cooling technology such as propane. Refra began pioneering the production of refrigeration equipment with natural refrigerants in 2011 and is now celebrating a decade of manufacturing propane-based heat pumps. All of the company’s reversible heat pumps today feature natural R290 (propane), a highly efficient refrigerant with an extremely low GWP (Global Warming Potential).

R290 is an ideal alternative to high-GWP synthetic refrigerants, which are undergoing phase-out under the F-gas regulation. The F-gas regulation is another factor behind the refrigeration industry’s innovation drive, encouraging the development of more environmentally friendly and energy-efficient technologies and refrigerants that can help mitigate climate change.

Some harbour concerns regarding the flammable properties of propane in poorly ventilated spaces. The advice here is to select only propane refrigeration systems which adhere to EN378, a robust industry standard that governs the safety requirements of refrigeration systems and heat pumps. Refra, for example, meticulously incorporates all necessary components mandated by the standard, including pressure relief devices, leak detection systems, safety valves and emergency shutdown mechanisms. Throughout its entire history of producing propane refrigeration systems, Refra has an impeccable safety record with zero reported incidents.

The attraction of magnetic valves

Ensuring the continuous development and evolution of refrigeration technology means that progressive heat pump manufacturers must explore new technologies, particularly those that can influence performance and efficiency.

A good example is a recent collaboration between Siemens and Refra, the outcome of which indicates a clear way to increase heat pump COP (co-efficient of performance) using magnetic expansion valves (MEVs).

Refra tested a Siemens MVL702 MEV on a double-circuit reversible air-to-water heat pump with a total heating capacity of 60kW. The trial took place alongside an identical circuit featuring a conventional electronic expansion valve (EEV). Both circuits used variable-speed drive (VSD) compressors operating continuously at full load, providing outlet water temperatures of 30 to 32°C at an outdoor air temperature of -6°C. COP was in the average range of 3.7 to 4.1.?The parameter settings of each circuit were identical, with testing taking place over several weeks and the heat pump operating non-stop throughout.

21% more heat; 14% less energy

The heat pump featuring the MEV saw COP increase during the heating period alone by 8.3%. When taking the defrost cycle into account, COP doubled to 16.5%. Ultimately, the increase in COP could potentially allow a heat pump to deliver up to 21% more heat while using 14% less energy. MEVs achieve these impressive results through a combination of rapid response and highly accurate positioning in comparison with an EEV driven by a traditional stepper motor.

The outcome of the trial underlines the practical advantages and economic benefits of improving heat pump performance. Refra’s?entire propane heat pump range now features the Siemens MVL702 MEV.