refrigeration energy savings

To achieve maximum refrigeration energy efficiency and ROI, several strategies can be employed:

1. Lowering Compression Ratio: Reducing the overall refrigeration system compression ratio is key. This can be done by maintaining lower condensing pressures and higher suction pressures within the system.
2. Regular Maintenance: Cleaning air filters and coils, ensuring proper refrigerant charge, and regular system checks can prevent efficiency losses.
3. Liquid Pressure Amplification (LPA): Installing LPA liquid refrigerant pumps in the system’s liquid line delivers 100% liquid refrigerant to the expansion valves, eliminating flash gas and enhancing system flow.
4. Floating Head Pressure: Implementing floating head pressure control allows the system to operate at the lowest possible pressure for current ambient conditions, improving efficiency.
5. Flash Gas Suppression: To eliminate liquid line flash gas, an LPA pump can be installed to suppress the flash before it reaches the system expansion valves. Flash gas does not contribute to cooling and thus represents a loss of efficiency.
6. Improved System Design: Designing systems with shorter liquid lines, minimal bends, and proper insulation can prevent flash gas formation or install an LPA pump to overcome liquid line pressure drop.
7. Sub-cooling: Increasing the level of sub-cooling ensures that the refrigerant remains liquid until it reaches the expansion valve, preventing flash gas or install an LPA pump to deliver 100% liquid to the expansion valves regardless of liquid line pressure drop.

By combining these methods, especially the use of HY-SAVE’s LPA technology, significant energy savings can be achieved, leading to a better return on investment. These improvements not only reduce power consumption but also enhance the overall performance of the refrigeration system, providing more cooling with less energy, which is particularly beneficial in the commercial retail industry. For detailed guidance on implementing these strategies, contacting HY-SAVE or a refrigeration efficiency expert is recommended.

What is flash gas?

Case Study

School of Engineering and Design, Brunel University, Uxbridge, Middlesex,

Hadawey, S. A. Tassou*, Y. T. Ge

Case study, dairy farm, northern Ireland, Liquid Pressure Amplification in Refrigeration Systems – Potential for Reducing Energy Consumption in Retrofit Applications

Established since 1984

HY-SAVE is a company that provides liquid refrigerant pumping technologies. They have been at the forefront of developing liquid line refrigerant pumps and other refrigeration applications aimed at enhancing refrigeration efficiency and fluid heat transfer. Their efforts contribute significantly to the reduction of carbon emissions caused by refrigeration systems globally.

Stepping back

1984 Company founded in Portland, Oregon, USA by inventor Bob Hyde.

• Developed and produced liquid line refrigerant pumps (for Freon) to ensure 100% liquid at the liquid metering device, regardless of liquid line vertical height or pressure drop.
• HY-SAVE® technology established to improve refrigeration efficiency.

1986 First patent: “Maximizing Refrigeration Capacity and Performance.”

• Introduced LPA (Liquid Pressure Amplification) pump, establishing it as a slogan, trademark, and brand.
• Began sales and distribution of LPA pumps.

1987 US distributor agreements established.

• Distributors appointed in the USA and Canada.
• New brochure: “Tomorrow’s Refrigeration Technology Today.”

1989 Partnered with US Gov. FEMP to support and document product efficiency and case studies.

• Introduced energy-saving analysis and methods for determining efficiency.
• Improved performance and redesign of model 835 LPA pump.
• Improved model 850 for higher working pressures.
• Launched Stainless Steel Model 875 (Made in America).
• UL pressure strength and fatigue testing of models 809, 815, 820, 833, 860, and 875 recognized.

1990 Tested new efficient TEFC motors for tougher environments.

• Introduced new testing platform, improved quality, and R&D.

1992 HY-SAVE Inc. appointed representation in Florida, Key West, and the Caribbean.

• Began testing liquid injection into compressor cylinder heads for cooling.
• Started de-superheating of compressor cylinders using LPA pumped refrigerant.

1994 Established and patented HY-DRY de-humidification process.

• Automated selection and sizing software projected efficiency established.
• Numerous patents LPA pump performance and operation.
• Established refrigerant two-phase flow heat transfer LPA pumps.
• Expanded the network of regional distributors.
• Increased horsepower of model 850 from 0.5hp to model 860 at 0.6hp.

1996 Developed and patented Plus 2 system for higher efficiency.

• Expanded testing platform to include multi-coupled pressure points.
• Improved facility to provide distributor and customer support.

1998 HY-SAVE IP, patents, designs, and technology acquired by DTE Energy Technologies, Michigan, USA.

• Launched Pump-Pro 1 electronic pump controller measures induced pressure developed by the LPA pump.
• Developed new methods heat transfer system efficiency two-phase cooling mediums.

2000 Established HY-SAVE organization of regional and international distributors and OEMs.

• Energy-efficient refrigeration research and development
• Established PP2 Version 2 to protect LPA® pumps from running dry based on induced liquid differential pressure and quality of liquid entering the pump.

2003 HY-SAVE acquired IP, patents, designs, trademarks, existing agreements, and technology from DTE Energy Technologies, Michigan, USA.

• Terminated underperforming US distributor and reorganized existing channels.
• Continued research and development of LPA technologies, including two-phase non-vapor compression cooling systems.
• Reorganized US manufacturing, introduced new stringent process and quality control for production requirements.
• EU PED Certification for Models 833, 860, and 875 compliance introduced.

2005 Assembly plant transferred to Europe from Portland, Oregon, USA.

• Improved distributor network.
• Enhanced the range of HFC LPA pumps for higher operating pressures.

2006 HY-SAVE USA opened in Tampa, Florida.

• Launched cost-effective remote energy monitoring device with built-in Ethernet and GPRS.
• Continued development of new methods to remove moisture in cold rooms in combination with HY-DRY.

2007 Enhanced UK pressure testing facilities to accommodate natural refrigerant pressures and process control.

2008 Redesigned HFC range of LPA pumps for higher operating pressures.

• Introduced more stringent quality control and specifications.
• Launched 3rd generation pump protection and control.
• Enhanced range of LPA pumps compatible with CO2.

2009 HY-SAVE offices opened in Dandong, China.

• Introduced manufacturing and control process of LPA pumps.

2010 Launched Pump Protection module 3 to include DX free cooling applications and protection.

2011 Launched automated energy monitoring to precisely measure energy consumption.

• Introduced Model 925 LPA pump for HFC and CO2 applications, maximum working pressure 50 bar (725 psi).

2012 Launch of Model 925 for cascade CO2 applications.

• Production of Model 809 range domestic/light commercial CO2 refrigeration applications.
• Engineered solutions -40°F working temperatures.
• Model 975 accommodating single 400 tons refrigeration.
• UL Fatigue and Pressure testing Model 925 awarded.

2014 Official launch of LPA® Model 809-NH3.

• Tested Liquid Injection Screw compressor cooling higher ambients.
• Designed and developed Ammonia fluid LPA® pump for natural refrigerant applications, rated at 540 psi.
• Developed the industries first in-line and auxiliary (TES) Thermal Energy Storage solutions for air conditioning and refrigeration systems.
• Developed new type Propane LPA® pump for greener refrigeration applications.
• Developed Sub-Zero -40°F LPA Model 860 for Arctic environments.

2015 Introduced “Refrigeration on Demand” ™ The Thermal Storage Option.

• Newly developed higher pressure Model 860-SS-080 rated at 80 bar for CO2 DXFC applications.
• Continued development of Model 875-SS-080 high pressure hold capacity LPA® pump for CO2 applications.

2016 Introduced “Compressor cooling.”

• Set up and developed thermal store, latent source thermal storage DX refrigeration storage & solutions, reducing overall power consumption.
• Introduced DX free cooling for split air conditioning units, including wall and ceiling mounted indoor units for intense heat extraction applications.

2017 Developed range of Dual Stage (DS) CO2 Liquid Pressure Amplifiers for solar AC.

• Model 833 rated at 80 bar (1,087 psi) design operating pressure, self-unloading, power 0.5HP.
• Model 820 rated at 80 bar (1,087 psi) design operating pressure, self-unloading, power 0.3HP.
• Developed range of DX Free Cooling split air conditioning units with low power consumption and high efficiency.
• Established DX plate type latent heat thermal storage patent & sub applications.

2018 Awarded patents for Plate Thermal Storage for Air Conditioning used in conjunction with DX Free cooling for low energy thermal cooling for future generations.

• Expanded HY-SAVE’s production area to include R&D, testing, prototyping, environmental testing sector, and quality management.
• Implemented helium leak detection for improved quality control.

2019 Introduced Dual Stage Model 820-DS.

• Performance, measurement, and certification of 820-DS.

2020 Implemented UKCA post-Brexit (United Kingdom).

• Implemented post-Brexit UK equivalent PED HPiVS CE2810 (Directive 2014/68/EU) CE1521UKCA, United Kingdom.

2021 Upgraded refrigerant-based series LPA pumps include CO2 & NH3 80 bar design.

• Approved variant K65 connections higher operating conditions, PS PED/UKCA 80 bar / 200 bar.

2023 R&D new concepts, designs, methods in high ambient geographical territories.

• Including compressor discharge superheat suppression, heat extraction specific to model 820-DS

2024

• ISO certification renewed, improved processes and controls for efficiency including quality, compliance, scalability and sustainability.
• UL certified model 925-SS~ 65 bar awarded, specialty equipment, USA/CA.
• Raised helium leak set point detection rate 5.4 x 10-6 mbar/s to meet with higher industry standards.
•  HARFKO 2024 – HY-SAVE (Asia) exhibits a range of refrigeration equipment including their flagship re-accumulator design for high energy efficient refrigeration performance with lower