Scroll compression technology has been around for a long time. It was first patented in 1905. But only in the early 1970s manufacturing processes enabled the industrial use of scroll technology in areas such as air conditioning and refrigeration. Since then, it has become very popular for its efficiency, quietness, and reliability. Experiencing continuous improvements over time, scroll compression technology is now making its next big leap with CO2 transcritical application for refrigeration.
The new Copeland CO2 technology allows to operate scroll compressors in transcritical mode (up to 120 bar) in a very reliable and cost-effective way. This provides an unprecedented alternative to the predominant piston technology which is to date used for 10-40 kW medium temperature compressors. To overcome the high-pressure challenges, our engineers have developed innovative solutions, including many patented technologies. The Result: A very compact design especially when compared to piston technology of the same capacity. And even better: scroll compressors run twice as fast as piston compressors, delivering more cooling capacity per displacement. In addition, our manufacturing engineers have solved all the process questions associated with CO2 high pressures. For instance, by using thicker shells and conducting high-pressure tests.
Equally innovative with Copeland CO2 scroll design is the use of Dynamic Vapor Injection (DVI). It allows CO2 flash gas to be compressed in a very cost-effective way. How? By injecting the flash gas into the intermediate stage of the continuous compression process of the scroll. That way, there is no need for an additional parallel compressor to handle flash gas while efficiency remains unchanged. To prevent the injected gas from flowing back into the flash tank, our engineers devised a solution with an additional check valve. This ultimately simple system architecture, the Copeland CO2 scroll technology, leads to high efficiency in all climates with a single booster design. Less is more!
In addition, our electronic solution engineers have developed dedicated system controller software. With it you can achieve the best system efficiency because it is ensured, that the various parameters are optimized, and that the refrigeration system always operates safely and reliably.
Under standard conditions, refrigeration systems only run at their highest capacity a few hours a year. In winter, they do not have to work as hard as in summer. At night they do not have to cool as much as during the day when customers access the cooling displays. Therefore, it makes sense to design a refrigeration system that can adapt to changing cooling demand.
Our answer to these load fluctuations was to develop dedicated variable speed compressors with specific high efficiency Brushless Permanent Magnet (BPM) motors. The wide speed range enables coverage of a large capacity variation, and the BPM motor ensures high efficiency even at low load, the mode in which the system runs most of the time. By applying these technical solutions, our development team managed to successfully optimize the system’s seasonal efficiency.
When installing new or refurbishing existing refrigeration systems, space and weight constraints are often a challenge. That is why we have worked hard to continuously reduce the footprint and weight of its compressors. The new generation of scroll compressors is much more compact and lighter than most other scroll technology with comparable capacity on the market. This facilitates installations where space is limited. Refurbishments are even possible in tight and difficult environments like urban retail locations in existing structures.
Due to their continuous compression process, Copeland CO2 scroll compressors also run much smoother and quieter than piston compressors, resulting in less vibration (safer for high-pressure systems) and quieter operation. Both are important advantages for installations in environments where low noise emissions are a must – and beneficial in all other environments as well, regardless of the space available.
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