In the pursuit of decarbonization and electrification strategies, the grocery industry is turning to innovative technologies to reduce energy consumption and lower operating costs.
One solution gaining traction is CO2 heat recovery, a process that harnesses waste heat from CO2 refrigeration systems to provide heating for stores. Most in the industry refer to this as heat reclaim. CO2 heat reclaim is not new to us, in fact, we pioneered the first CO2 reclaim project 15 years ago and have since done over 1,000 installations. At Flō, we’re taking CO2 reclaim to a whole new level with Boosted Reclaim, which provides approximately three times more heat.
Energy Efficiency and Cost Savings
Traditional heating methods in grocery stores, such as air source heat pumps and electrical resistance heating, rely heavily on synthetic refrigerants and a lot of electricity.
These methods can be costly to operate, especially in colder climates, and can contribute to a store’s overall environmental impact reduction. Boosted CO2 heat recovery offers a dramatic reduction in emissions as a more efficient and cost-effective alternative by maximizing the use of waste heat.
CO2 as a Refrigerant: A Unique Advantage
Carbon dioxide (CO2) has emerged as a preferred refrigerant for heat recovery due to its unique properties.
It has a higher discharge temperature compared to other refrigerants, enabling efficient heat transfer even in low-temperature environments. This makes CO2 an ideal choice for grocery stores located in diverse climates.
A Pilot Test: A Case Study
The effectiveness of boosted CO2 heat recovery was proven by a joint pilot conducted by Flō Energy Solutions and Hillphoenix in Pennsylvania in 2023.
The project involved an existing Flō DOAS+ with Adaptive Multi-Path Technology unit complete with heat reclaim and a CO2 refrigeration system in a small-format store.
By optimizing the reclaim coil and updating the controls integration for boost, the store had nearly all the heat provided by the refrigeration rack almost eliminating the use of natural gas auxiliary heat.
How Boosted CO2 Heat Reclaim Works
The process involves raising the head pressure of the refrigeration rack during winter. This allows for the HVAC system to recover more waste heat for store heating. The system can vary the head pressure based on heating demands, ensuring optimal efficiency.
Boosted CO2 heat reclaim offers significant efficiency and capacity advantages over traditional methods. It boasts 2X the efficiency of air source heat pumps and can provide 3x the heat capacity of standard reclaim. It is also shown to be 6X more efficient than electric heat. This translates to substantial energy savings and a significant reduction in operating costs.
One Important Lesson from the Pilot Test
The pilot test also highlighted the importance of proper insulation in the field piping connecting the refrigeration rack and the HVAC unit. Heat loss through uninsulated piping can significantly impact the system’s efficiency. Therefore, maximizing thermal insulation is crucial for optimal performance.
The Future of Refrigeration, Heating and Cooling for Food Retail
Boosted CO2 heat recovery presents a promising solution for improving the energy efficiency of grocery stores.
By harnessing more waste heat than standard reclaim, stores can decarbonize while still lowering operating costs. Flō Energy Solutions is pushing the boundaries of CO2 heat reclaim technology and changing food retail’s approach to HVAC and refrigeration design.
Flō Energy Solutions’ DOAS+ with Adaptive Multi-Path Technology Units are also able to provide free cooling for food retailers (with dehumidification). The free heating AND cooling present a compelling solution for food retailers to offset the costs associated with moving away from synthetic refrigerants.
As the adoption of CO2 refrigeration accelerates, this technology provides an opportunity for the grocery industry to rethink how their HVAC and refrigeration systems integrate in A Better Way™!
Flō Energy Solutions has worked exclusively in food retail for 25 years, providing innovative HVAC design that enable you to electrify, reduce tonnage, decarbonize, dehumidify and integrate HVAC to your refrigeration creating free heating and cooling. Check out our website to learn more about how we partner with food retailers to create an optimal balance of energy use, moisture control, mechanical systems integration and store comfort.