Can CO₂ evaporators be customized?

CO₂ evaporators can be fully customized to match specific refrigeration, heat pump, and industrial process requirements. Because CO₂ (R744) operates at higher pressures and often under transcritical conditions, customization is not only possible but often necessary to ensure safety, efficiency, and reliability.

1. Customization by Application

CO₂ evaporators are designed differently depending on their end use:

• Industrial refrigeration (cold storage, food processing, slaughterhouses)

• Commercial refrigeration (supermarkets, display cases)

• CO₂ heat pumps (space heating, hot water production)

• Process cooling (chemical, pharmaceutical, data centers)

Each application defines the evaporating temperature, load profile, and defrost requirements.

2. Capacity & Thermal Design

Customized parameters include:

• Cooling capacity (kW)

• Evaporating temperature and superheat

• Air or liquid flow rate

• Design approach temperature (ΔT)

• Allowable pressure drop (refrigerant side and air/liquid side)

Advanced thermal calculations ensure optimal heat transfer while minimizing energy consumption.

3. Pressure & Safety Design (Critical for CO₂)

Because CO₂ systems operate at much higher pressures than HFC systems:

• Design pressure: commonly 80–120 bar (or higher, depending on system)

• Tube thickness: increased to meet EN, PED, ASME, or GB standards

• Headers and manifolds: reinforced or forged designs

• Pressure relief provisions: integrated into the evaporator assembly

All customized designs are validated by pressure and fatigue calculations.

4. Geometry & Mechanical Configuration

Customization options include:

• Tube diameter (microchannel, small-diameter steel or stainless tubes)

• Number of tube rows and passes

• Fin type and fin spacing (standard, wide fin, or frost-resistant design)

• Horizontal or vertical airflow arrangement

• Compact or heavy-duty frame construction

These parameters are adjusted to balance footprint, airflow resistance, and serviceability.

5. Materials & Corrosion Protection

Typical customized material choices:

• Tubes: carbon steel, stainless steel, or copper-plated steel (for CO₂ compatibility)

• Fins: aluminum, epoxy-coated aluminum, or hydrophilic fins

• Casing: galvanized steel, stainless steel, or coated carbon steel

Special coatings can be applied for:

• High humidity environments

• Ammonia or salt exposure

• Food-processing hygiene requirements

6. Defrost & Control Options

Customized defrost solutions include:

• Hot gas defrost (CO₂ hot gas)

• Electric defrost

• Water defrost (industrial environments)

Evaporators can also be supplied with:

• Integrated distributors

• Electronic expansion valve compatibility

• Sensor and control mounting provisions

7. Compliance & Certification

Customized CO₂ evaporators can be designed to comply with:

• PED 2014/68/EU

• ASME

• UL

• CE marking

• Customer-specific or regional standards

Documentation such as pressure test reports, material certificates, and drawings can be provided.

8. Summary

CO₂ evaporators are inherently customizable products. From pressure rating and capacity to materials, fin design, and defrost method, every key parameter can be tailored to the application. Proper customization ensures high efficiency, long service life, and safe operation in high-pressure CO₂ systems.