The project sought to achieve this by implementing multiple CO2 commercial air source heat pumps powered by the existing 2.5 MW solar PV array at the warehouse. This solution would help Amazon UK Services achieve net zero in their operations and adhere to their policy of not using fossil fuels, thereby reducing carbon emissions and promoting environmental sustainability.
Key Project Innovations:
Use of CO2 Commercial Air Source Heat Pumps:
JLM proposed using CO2 (R744) as a refrigerant in commercial air source heat pumps. CO2 is an environmentally friendly refrigerant with a Global Warming Potential (GWP) of 1, making it a highly sustainable choice compared to conventional refrigerants. This is a relatively novel approach, particularly in large-scale industrial applications like warehouses.
Integration with Solar PV Array:
The heating system was designed to be powered entirely by an existing 2.5 MW solar PV array. This integration maximised the use of renewable energy, reducing reliance on external energy sources and moving towards a fully self-sustaining system. Combining solar power with CO2-based heat pumps is an innovative approach to achieving carbon neutrality.
Custom-Built BMS (Building Management System):
The project featured a uniquely designed BMS developed by JLM m&e, tailored specifically for this system. This BMS would provide real-time monitoring, automation, and optimisation of the heating system, ensuring efficient operation by adjusting to factors like occupancy, weather conditions, and solar energy availability. The BMS’s ability to integrate and manage such a system with a focus on maximising energy efficiency and reducing carbon footprint is both novel and highly specialised.
Fossil Fuel Elimination in Operations:
The complete removal of gas-fired burners in favour of a renewable energy-powered heating system is an unconventional approach in warehouse operations, where gas is typically used for heating. This shift demonstrates a strong commitment to sustainability and sets a precedent for other large-scale operations aiming to eliminate fossil fuel use.
Major Challenges Addressed:
Technical Integration of CO2 Heat Pumps:
Implementing CO2-based air source heat pumps on a large scale posed significant technical challenges. CO2 systems operate under different conditions than traditional refrigerants, such as higher pressures and unique thermodynamic properties. Ensuring that the heat pumps could efficiently meet the heating demands of the warehouse, especially in colder weather, required precise engineering and careful system design.
Energy Management with Solar PV Array:
Balancing the heating needs of the warehouse with the energy output from the 2.5 MW solar PV array was a complex challenge. Solar energy production varies with weather conditions and time of day, so the system needs to be highly efficient in storing and managing energy to ensure consistent operation. This included possibly integrating energy storage solutions, which would add to the complexity and cost of the project.
Design and Implementation of the BMS:
Developing a custom Building Management System (BMS) to control and optimise the operation of the CO2 heat pumps and solar PV array was a major challenge. The BMS needed to be sophisticated enough to handle real-time data, automate system adjustments, and provide analytics, all while ensuring reliability and ease of use. Designing such a system from scratch required advanced software and hardware integration skills.
Capital and Operational Costs:
The upfront costs of installing CO2 heat pumps and integrating them with a solar-powered system were likely higher than conventional heating solutions. Additionally, maintaining and operating a high-pressure CO2 system might incur specialised costs. Balancing these costs with long-term savings and environmental benefits required careful financial planning and justification.
Regulatory and Compliance Issues:
Ensuring that the new system met all relevant safety and environmental regulations was critical. CO2 systems operate at high pressures, which could raise safety concerns. Additionally, the project needed to comply with building codes, energy efficiency standards, and environmental regulations, which could vary depending on the location and scale of the installation.
System Reliability and Redundancy:
The transition from gas-fired burners to an entirely new heating technology introduced risks related to system reliability. Ensuring that the CO2 heat pumps would provide consistent and reliable heating, especially during peak demand periods, required robust system design, possibly including redundancy measures to avoid downtime.
Change Management and Training:
Moving from a traditional gas-based heating system to an advanced, renewable energy-powered solution required training for staff and changes in operational procedures. Ensuring that Amazon UK Services personnel could effectively manage and maintain the new system was essential to the project’s success.
Addressing these challenges required careful planning, innovative engineering, and collaboration between multiple stakeholders to ensure the project’s goals were met effectively.
Interested in how JLM Energy is helping Amazon achieve sustainability? Explore our work on another Amazon project at Amazon UK Services to see how we’re driving energy efficiency across multiple locations.