GEA to Provide Ammonia Plant for UK's Top Cold Storage

GEA has been entrusted with the supply of a cutting-edge two-stage ammonia refrigeration system and 32 air coolers for the construction of the United Kingdom's tallest cold storage facility, currently underway in Easton, near Grantham, Lincolnshire. The colossal cold store is set to measure an impressive 150m in length, 100m in width, and reach a height of 47m, boasting a staggering capacity for 101,000 pallets. Positioned adjacent to an existing 44,000-pallet cold store, also owned by Magnavale, the new facility is strategically located on the same site.

The high bay cold store is intricately designed, featuring a 35m long expedition bay equipped with 20 loading docks. Additionally, the facility incorporates two floors dedicated to value-added services. Anticipated for completion in late 2024, this state-of-the-art cold storage facility is characterized by its full automation and a commitment to operate on 100% renewable energy. Primarily intended for the cooling of frozen food products, the facility is engineered to reach temperatures as low as minus -28ºC.

GEA's role in this groundbreaking project involved the development of a customized solution tailored to the specific requirements of the facility. This innovative solution was shaped through the utilization of Computational Fluid Dynamics (CFD) simulations, providing a comprehensive visualization of the air flow and temperature profile within the high bay cold store. The design, rooted in the cold lake principle, ensures optimal efficiency and performance.

The heart of the refrigeration system is the two-stage ammonia plant, meticulously engineered for optimized circulation rates. This sophisticated system incorporates three screw compressors, three reciprocating compressors, and three condensers. In addition, the high-bay cold store is equipped with ten air coolers, while the loading bay area features an additional 22 air coolers.

GEA's choice of screw compressors for the low stage booster compressors, combined with the implementation of GEA Grasso V-series reciprocating compressors, demonstrates a strategic decision to capitalize on the enhanced Coefficient of Performance (COP) exhibited by reciprocating compressors during part load operation. This approach reflects GEA's commitment to delivering a solution that not only meets the current demands of the facility but also optimizes efficiency across various operational scenarios.

The comprehensive refrigeration system is an integral component of the cold storage facility, ensuring precise temperature control and maintaining the quality and integrity of the stored frozen products. By incorporating cutting-edge technology and leveraging GEA's expertise, the facility aims to set new benchmarks in the cold storage industry.

As the project progresses towards its completion in late 2024, the collaborative effort between Magnavale and GEA stands as a testament to the industry's commitment to innovation, sustainability, and operational excellence. The use of renewable energy, coupled with the advanced refrigeration system, positions the facility as a pioneering example of environmentally conscious and technologically advanced cold storage infrastructure.