Maersk Container Industry (MCI), a part of A.P. Moeller – Maersk, has announced an “industry first decarbonsiation leap” with its new Star Cool 1.1 triple refrigerant reefer cooling machine.
“After completion of an extensive R&D and verification program we are excited to offer our customers the first reefer solution that offers adaptability to three alternative refrigerants while operating with the highest energy efficiency in the market – thereby delivering a significant advancement in reducing the environmental impact from reefer container operation,’’ said – Søren Leth Johannsen, CEO at MCI. container 10 feet
The three alternative refrigerants are R-134a, R-513A and R-1234yf. The three refrigerants have different Global Warming Potential (GWP) measures. R-134a, the most widely used refrigerant in reefer container today, has a GWP of 1430.
Since 2017 all Star Cool reefer machinery is optimised for R-513A as a drop-in replacement for R-134a. R-513A has a lower GWP of 673, but it is not a “low GWP refrigerant”. With a GWP of 0.5 or 1 R-1234yf is a true or “ultra” low GWP refrigerant.
Reefer machinery manufactures have been preparing for R-1234yf, but MCI is the first to offer a reefer machine that can “operate and switch freely forth and back without any modifications whatsoever between any of the three refrigerants R-134a, R-513A and R-1234yf.”
The new Star Cool 1.1 has a new compressor design. The main construction and components are the same as earlier Star Cool systems, but the piston stroke has been increased to provide higher displacement and lower speed for more efficient operation. A new design of evaporator collects condensate in drain trays and is better protected from cargo operations by thicker profile steel members inside the container.
In terms of energy consumption, MCI says Star Cool 1.1 is 8% more energy efficient than the previous Star Cool machine while offering faster temperature control.
The issue with R-1234yf is that it is an A2 class mildly flammable substance. All other refrigerants used in reefer containers today, including R-1234a, R-404A, R-513A and CO2, are A1non-flammable substances.
This is not and insurmountable obstacle. Other markets, most notably automotive air conditioning, use R-12324yf and in 2015 work started on developing an ISO standard for using flammable substances in refrigeration systems. The resulting ISO 20854 was published in 2019.
As MCI explains, ISO 20854 is “designed to achieve an acceptable level of safety similar to the safety level of reefers using non-flammable refrigerants.” It requires the reefer machinery OEM to carry out an operational mode risk assessment (OMRA), which must cover intended use, reasonably foreseeable misuse and special use during transport in different modes (including loading and unloading), storage in different areas and service and repair. Reasonably foreseeable misuse includes improper repairs and the use of incorrect tools and parts, as well as external events like fire and vibration.
This work needs approval by a classification society. On 24 June MCI received an approval letter from DNV stating that the OMRA it conducted complies with the safety requirements in ISO20854.
OEM certification is one thing, but the standard also puts obligations on reefer operators to evaluate OMRA results from OEMs and conduct their own risk assessment covering the facilities they operate, as well as other obligations. Other reefer machinery OEMs have questioned whether this is something reefer operators want and are willing to do.
Paul Clarke Paul Clarke, Head of Reefer Technology at Maersk, has endorsed Star Cool 1.1.
“The Star Cool 1.1 is a significant innovation in our quest to support the decarbonisation of the shipping industry,” Clarke said.” Its ability to operate efficiently across multiple refrigerant options not only highlights its flexibility but also its readiness to meet both current and future safety and environmental standards. We have thoroughly field tested the upgraded Star Cool system and it is instrumental in our efforts to achieve lower energy consumption and reduced emissions, aligning with our long-term sustainability goals. Star Cool with the SC1.1 set the bar in our industry, that will need to standardise towards its future refrigerant programs for newbuild reefer equipment, along with that of the service networks that will be required to support the reefers of the future,” he concluded.
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