By Eamonn Ryan
Compressors are the heart of any refrigeration or air conditioning system.
Recent advancements in compressor technology have led to more efficient, durable and environmentally friendly systems. These innovations aim to reduce energy consumption, enhance system performance and improve compatibility with natural refrigerants.
Bitzer showcases cutting-edge compressor innovations at chillventa 2024 and beyond
At Chillventa 2024, BITZER revealed its latest advancements in compressor technology, reinforcing its commitment to sustainable refrigeration solutions and energy efficiency. Torsten Steinborn, managing director of BITZER South Africa, highlighted a range of innovations that address the growing demand for efficient and environmentally responsible systems in both industrial and commercial refrigeration markets.
At Chillventa, the company presented innovations from its extensive product portfolio for natural refrigerants. For example, the ECOLINE 8-cylinder reciprocating compressors for subcritical CO2 applications expand the series to include higher capacity ranges with the refrigerant R744 (CO2) – especially for industrial refrigeration. The compressors are designed for high standstill pressures of up to 80 bar. BITZER is also the only manufacturer to include reciprocating, screw and scroll compressors for R290 (propane) in its portfolio. The company showcased these along with the ECOLINE PRO, CS PRO and ORBIT PRO series at Chillventa. Components for R717 (ammonia) will round off the BITZER product portfolio for natural refrigerants.
One of the key developments presented by BITZER at Chillventa 2024 was its enhanced OS A95 ammonia compressor package. “This modular system is designed to meet the substantial refrigeration demands of large-scale industrial applications, such as food processing, cold storage and beverage production. Particularly suited for environments with megawatt-level cooling requirements—such as poultry production, meat processing and large cold storage facilities—these ammonia systems offer both scalability and operational flexibility,” says Steinborn. He emphasises the role of BITZER’s OS A95 screw compressors in this new package.
These compressors are highly adaptable, allowing for the integration of two or three units on a single rack to match different cooling capacities. This modular approach ensures optimal efficiency in part-load operation, reducing energy consumption in variable-demand environments. Furthermore, the inclusion of BITZER’s IQ control module enhances the overall performance by enabling precise monitoring and efficient operation, even in complex industrial setups.
As global environmental regulations continue to tighten, BITZER remains at the forefront of the transition to low-GWP (Global Warming Potential) refrigerants. “Although the South African market has yet to see widespread adoption of these solutions, BITZER is already preparing for a future shift toward more sustainable refrigerants like CO₂ and propane. These refrigerants align with international climate goals and are gaining traction in industries such as food processing and cold storage,” he adds.
Steinborn explains that BITZER’s CO₂ compressors are already being deployed in both subcritical and transcritical systems, offering simplified installations and reduced maintenance requirements. “The new 8 cyl. CO2 compressors, which streamline operations by reducing the number of units needed per rack, are particularly relevant for large-scale refrigeration systems.” Steinborn noted that BITZER’s emphasis on CO₂ technology underscores the company’s commitment to supporting its customers in adopting environmentally responsible solutions.
In line with the growing trend of digitisation within the HVAC industry, BITZER’s IQ module was one of the highlights at Chillventa 2024. This intelligent control module offers remote monitoring capabilities, enabling technicians to access real- time performance data of compressors via Bluetooth on their mobile devices. Compatible with both iOS and Android platforms, the IQ module allows for easy tracking of operational parameters, alarm management, and even communication with plant controllers.
Focusing on energy efficiency, the new generation of the IQ MODULE CM- RC-02 was one of the BITZER product highlights at Chillventa 2024. It has been a standard feature of ECOLINE reciprocating compressors of the C3 series and higher since the beginning of the year and lays the foundation for even higher efficiency in compressor operation and increased availability. In addition, intelligent functions such as monitoring key operating parameters and a user-friendly operating concept simplify compressor installation, commissioning and maintenance. Thanks to extension boards, the IQ MODULE also simplifies connection and operation of VARISTEP capacity control. Steinborn highlights the module’s potential to aid maintenance practices, especially in large-scale industrial and retail environments. “By providing detailed insights into compressor performance, the IQ module allows technicians to detect issues before they escalate into on-site failures, reducing downtime and the need for multiple service visits. Additionally, the module integrates with existing plant monitoring systems via Modbus, allowing for more proactive system management and a seamless connection to centralised monitoring platforms.” Heat pump technology was another major focus for BITZER at Chillventa 2024. With rising energy costs and increasing demand for sustainable solutions, heat pumps are becoming an attractive option for industries seeking to optimise energy usage by repurposing excess heat. BITZER’s heat pump systems, particularly those used in industrial settings, offer substantial energy savings by utilising waste heat for applications such as district heating.
Bitzer’s expanding presence in SA and beyond
BITZER’s innovative compressor technologies are particularly well-suited to the Southern African market, where demand for energy- efficient refrigeration systems is rising. In South Africa and neighbours Namibia and Zimbabwe, BITZER’s solutions are helping industries meet the dual challenges of high energy consumption and environmental responsibility.
Steinborn highlights that BITZER’s ammonia compressor packages have been instrumental in supporting the local food industry, ensuring reliable cooling for cold storage and food processing applications. These systems not only address cooling capacity requirements but also enhance energy efficiency, making them an essential part of the local cold chain infrastructure.
“BITZER is also investing in training and education for our customers in the region. We offer extensive training programmes to help operators understand the new technologies and optimise system performance. These programmes also focus on crucial topics such as refrigerant regulations and environmental responsibility, aligning with BITZER’s commitment to sustainability.”
GEA presented the semi- hermetic screw compressor compax
At Chillventa 2024, GEA presented the semi- hermetic screw compressor CompaX as part of the Grasso X package ideal for seasonal refrigeration applications and flexible capacity requirements. This Grasso X package consists of three CompaX semi-hermetic compressors. “The compact, safe and reliable design, combined with high efficiency, result in reduced risks and a highly sustainable solution. We are pleased to bring over 50 years of experience in the development and production of screw compressors to the market with our semi- hermetic series,” says Robert Brinckmann, product manager packaged components at GEA.
Available as a single compressor package and optionally with two, three or four compressors in parallel, it offers a large capacity range from 395 to 1 900kW (R717 | – 10/+35 °C and redundancy. Together with the large variable speed range up to 6 000rpm, the X-package can be operated in all (partial) load ranges with virtually no loss of efficiency. Based on the semi-hermetic screw compressor models GEA CompaX 350 and 400 without shaft seals, the package is a safe and reliable solution for the use of ammonia, enabling to reach efficiencies to fulfill the Eco Design regulations.
The ultra-compact footprint, another important parameter in the design of the package, facilitates the refurbishment of engine rooms, for example. A future-proof, efficient and safe solution comes with minimal space requirements, maintenance effort and overall risks.
With an ozone depletion potential (ODP) and global warming potential (GWP) of zero, ammonia is a particularly climate-friendly refrigerant and also a particularly efficient one. It has excellent thermodynamic properties, which are reflected in high efficiencies and correspondingly low operating costs. Ammonia has always been used in food processing plants, in the beverage and dairy industry as well as in breweries and cold stores – not least due to the low filling quantities.
Pioneering CO2 hybrid subcritical condenser
The development of advanced condensing technologies directly impacts the performance and efficiency of compressors. A recent breakthrough in CO2 refrigeration, introduced at Chillventa 2024 by Andre van der Merwe, managing director of Evapco South Africa, illustrates how innovations in condensers can significantly benefit compressor operations. The launch of Evapco’s hybrid subcritical condenser marks a major step forward, as it combines air-cooled and wet cooling technologies to condense CO2 at lower temperatures and pressures, reducing the overall load on compressors. This hybrid system is designed to condense CO2 from a gas to a liquid more efficiently than traditional systems, allowing for a reduction in the number or size of compressors required. By integrating a dry cooler that removes much of the high-temperature heat before entering the wet coil, the system enhances the overall efficiency of the refrigeration process, offering a more cost-effective and sustainable solution. For compressors, this means not only improved operational efficiency but also a reduction in energy consumption and maintenance costs, positioning the hybrid condenser as a crucial development for both performance and sustainability in the industry.
“CO2 is increasingly recognised as a refrigerant of the future,” states Van der Merwe, referencing recent discussions about the transition away from ozone- depleting substances. “This hybrid condenser is unique as it can condense CO2 from a gas back to a liquid state, which is a notable departure from traditional gas cooler systems. This is the first official CO2 subcritical condenser that we believe has been launched globally.”
The design allows for a reduction in the number of compressors needed, as an example — four instead of five—resulting in a more cost-effective system overall. Van der Merwe expresses excitement about the potential applications of this new technology, particularly in the South African market. “We are eager to start promoting these innovations back home and will likely showcase the hybrid condenser at FRIGAIR later this year,” he adds.
“This is the first prototype we’ve shown so far,” he remarks, presenting the hybrid condenser. While it may not be the largest model available, its size is sufficient to illustrate the key components: the dry coil and the wet coil.
Van der Merwe explains how the subcritical system operates more efficiently than traditional transcritical systems.
The enthalpy chart he shares highlights how the hybrid system operates at lower temperatures and pressures, ultimately leading to a more cost-effective solution.
With the increasing focus on sustainable refrigerants, particularly CO2, the hybrid subcritical condenser positions Evapco among the more environmentally friendly solutions. “This innovation is highly relevant for South Africa,” he adds.
Dorin innovation unveils new compressor technologies at Chillventa 2024
At Chillventa 2024, Mauro Bonfanti, commercial director of Dorin, outlined the company’s strategic innovations andproducts set to transform the refrigeration landscape. With a focus on sustainability and efficiency, Dorin is transitioning from traditional HFC systems to more environmentally friendly CO2 systems, particularly for supermarkets, while also addressing the growing industrial refrigeration and natural gas heat pump market.
Dorin collaborates with key distributors in South Africa such as Macs Cool, TecsaReco, as well as HC Heat Exchangers, which focuses on commercial and industrial refrigeration. While the company continues to supply mainly HFC compressors, Bonfanti noted a significant trend towards CO2 systems, driven by increasing environmental regulations and a shift in consumer preferences. He emphasises that while this was primarily focused on the supermarket sector, he anticipated growth in industrial transition involving HFC and ammonia systems, indicating broader benefits of CO2 as a natural refrigerant.
A major highlight of Dorin’s R&D efforts is the expansion of its CO2 transcritical compressors. “Currently offering 250kW of cooling capacity for its largest CO2 transcritical compressor, the company is preparing to launch compressors with capacities of 500kW and 1MW in the coming year. This development marks a significant step towards catering to the growing demands of industrial refrigeration in South Africa and rest of the world,” he says.
In addition to CO2 systems, Dorin is innovating in the hydrocarbon sector with the development of ATEX explosion-proof compressors designed for use in hazardous environments. Bonfanti explains the unique challenges of working with hydrocarbons, particularly their miscibility with oil, which can affect compressor performance. “Dorin’s new compressors incorporate special technologies to manage low oil viscosity, ensuring reliable operation under challenging conditions.”
Dorin is also making strides in the heat pump sector, offering high-temperature models that utilise CO2 and hydrocarbons. With maximum discharge temperatures reaching 160°C for both CO2 and hydrocarbon compressors, Dorin is positioning itself to meet the evolving needs of the market. While Bonfanti acknowledges that the heat pump market in South Africa is smaller compared to Europe, he expresses optimism about its growth potential, citing similarities in regulatory trends and market dynamics. “You’re going the same route,” he says.
With a robust focus on CO2 and hydrocarbon technologies, alongside advancements in heat pumps, Dorin is well- equipped to navigate a changing landscape of the refrigeration industry in South Africa as regulations tighten and environmental awareness grows.
