R-32. The next generation refrigerant for air conditioners and heat pumps. Superior energy efficiency and low GWP

Transcription

1 R-32 The next generation refrigerant for air conditioners and heat pumps Superior energy efficiency and low GWP

2 HFC phase-down and the introduction of R32 The European phase-down of HFCs, which will see their use reduced to 21% of average levels between 2009 and 2012 by 2030*, begins in earnest in 2015, with the introduction of the new F-gas regulation. For the HVAC-R industry, the next 15 years will see major changes, with the new legislation restricting and banning the use of refrigerant gases in certain applications. * Based upon CO 2, equivalent refrigerant charge There are a number of options for the next generation refrigerant gas, to meet future legislation and reduce the environmental impact of air conditioning, heat pumps and refrigeration. The choices are generally accepted to be R32 R410A, HFO blends, CO 2, and hydrocarbons, including R290 and R600. R32 in brief R32 is already used in HVAC equipment, as it makes up 50% of R410A. It has a global warming potential (GWP) of 675, which is one third that of R410A (2,088). It s more energy efficient, resulting in a lower refrigerant charge and the potential to manufacture smaller units. As a single component refrigerant, it is also easier to reuse and recycle. Like many low GWP refrigerants, R32 is mildly flammable, requiring some new tools and procedures during installation. It is also easier to handle because it doesn t fractionate. The introduction of R32 will present some challenges for industry but Daikin UK is working hard to help ensure installers are ready, providing clear information on the new refrigerant and offering training in its safe handling. Daikin UK is also providing advice to consultants and end-users to help them make informed choices when designing and selecting HVAC-R systems over the next 10 to 15 years. Daikin s work with R32 Because of its superior energy efficiency and low GWP, R32 is Daikin s preferred next generation refrigerant for air conditioners and heat pumps. Its first domestic air conditioners using R32 were introduced to Japan in 2012 and there have been sales in excess of 2 million systems. In the UK, Daikin is expecting to launch the first Split systems with a cooling capacity under 7kW using R32 in early White paper: The next generation refrigerant for air conditioners and heat pumps

3 Refrigerant gases: timeline 2014: ISO 5149 Refrigerating systems and heat pumps -- Safety and environmental requirements revised. Along with adoption of ISO817 Refrigerants -- Designation system, which recognises A2L class refrigerants, this paves the way for the introduction of new lower Global Warming Potential gases such as R32. BAN 2020: Ban on refrigerants with GWP greater than 2,500 (R404A and R507) used in stationary refrigeration equipment comes into force the beginning of the end for R404A. New equipment will have to be converted to R407A or another blend. GWP limit of 150 will apply to mobile air conditioners. BAN : Ban on single splits using refrigerants with GWP greater than 750, with a charge less than 3kg comes into force. Ban introduced for refrigerants with a GWP greater than 150 in multi-pack centralised refrigeration systems with cooling capacities of more than 40kW, such those in supermarkets, except in the primary circuit of cascade systems, where a GWP limit of 1,500 will apply. A service and maintenance ban of refrigerants with a GWP greater than 2,500 and only applies to refrigeration equipment with a charge size of 40 tonnes of CO2 equivalent or more : EU proposes revision to the F-gas regulation to strengthen phase-down, with further restrictions and a revised timetable for bans on amounts of F-gas being used in certain equipment. BAN 2022: GWP limit of 150 will apply to commercial hermetically sealed refrigerators and freezers. 2015: Phase-down begins: New F-gas regulations come into force. HFC manufacturers and importers receive declining quotas for placing HFC son the market, based on past market share. Complete ban of R22, which means no refrigeration circuits, can be broken into. If they are, the system has to be taken out of service or an alternative refrigerant used. Domestic refrigerators using anything other than hydrocarbons or refrigerants with a GWP less than 150 will be banned, mainly affecting systems running on R134A. 2030: EU phase-down limit on HFCs imposed at 21% of the average level between 2009 and Note R410A, R134A and R407C will not be banned but use will become restricted. White paper: The next generation refrigerant for air conditioners and heat pumps 3

4 The HFC phase-down what it means for the HVAC-R industry The changes will mean the entire industry has to work together so that manufacturers, designers, installers and end-users are well-informed and competent in designing, specifying, installing, maintaining and using these new systems. There is a clear need to choose alternative refrigerant gases that are not only less harmful to the environment but that also meet future legislation, and are both safe and economical in terms of existing system design and installation procedures as well as the cost of the gas itself. Using new refrigerants that completely change system design means some systems installed over the next 5 to 10 years could become obsolete before the end of their working life. Manufacturers are acting now, introducing new products and developing ways of adapting existing systems to use the next generation refrigerants and extend their lifespan. Next-generation refrigerant gases what needs to be considered There are number of factors that need to be considered before choosing the next generation refrigerant: Ozone depletion potential Global warming potential Safety Natural resource efficiency Energy efficiency Affordability. Ozone Depletion Potential and Global Warming Potential Ozone depletion potential must be zero, because of the global Montreal Protocol agreements and EU Ozone depleting regulations, and requires no further justification. But Global Warming Potential (GWP) is slightly more complicated as it must be considered from an entire Life Cycle Climate Performance (LCCP) perspective. This means that the total energy used over the life of one air conditioning or heat pump unit is converted to its global warming equivalent (indirect emissions), then the global warming equivalent of the direct refrigerant emissions is also added to this. This method gives a much more accurate evaluation of the true global warming impact of a unit throughout its life cycle. Only looking to the GWP value is, therefore, not the correct way to assess refrigerant options as a unit with a medium GWP may have a lower total impact than a unit using a low GWP refrigerant. 4 White paper: The next generation refrigerant for air conditioners and heat pumps

5 Safety Safety is paramount when choosing and installing refrigerants. It is important to understand that many factors affect safety, including product type, volume of refrigerant charge, room size and unit location. Natural resources It is as important to be efficient with natural resources as it is to be energy efficient and the environmental and economic parameters to do more with fewer materials should be adhered to. As such, refrigerant options must also be assessed on their potential for reuse. This same rule applies to the assessment of raw materials used to manufacture equipment. So, even when low efficiency refrigerant options could be improved by using more refrigerant in larger systems, this would be detrimental to the total ecodesign balance. Last but not least: Energy efficiency As well as taking all the above factors into consideration, energy efficiency is the key factor in refrigerant choice. Without the highest possible levels of energy efficiency, future systems will require more natural resources to power them and will emit more carbon than is necessary clearly a detrimental step in meeting the UK s tough carbon reduction targets. This includes not only the seasonal efficiency averaged over the cooling or heating season, but also the efficiency in peak load conditions (on very hot or very cold days). The first of these is important in order to reach the energy efficiency goals set by various EU directives (Ecodesign, Energy efficiency directive, EPBD, Renewable Energy Source Directive) whereas the peak load efficiency is important to avoid the requirement for extra power plants. Affordability As it is predicted that 75% of future HFC emissions will originate from developing countries, it is important to find solutions that are affordable on a global scale. White paper: The next generation refrigerant for air conditioners and heat pumps 5

6 Next-generation refrigerant gases the options Which gas will be adopted by the HVAC-R industry as the next-generation refrigerant has been debated for some time. The likely candidates are R32 (which makes up 50% of R410A), HFO blends, CO 2 and hydrocarbons such as Propane and Butane. All have their own advantages and disadvantages and in reality, different refrigerants (and combinations of refrigerants) will be used at different times. The likely candidate for air conditioners and heat pumps is R32. For commercial refrigeration R410A, CO2 and HFO blends. For domestic fridges and freezers Butane. Comparing these alternatives to the common HFCs being used today is a good place to start because the system design and installation costs, as well as energy efficiency and safety, are understood. R32 R32 has a lower GWP than R410A (675 compared with 2,088); offers slightly better energy efficiency; uses similar technology, keeping costs similar and is relatively inexpensive to produce. It is low-toxicity but is mildly flammable, requiring different handling procedures. HFO HFOs such as R1234yf or R1234ze(E) have very low GWP and are possible replacements for R134a due to their similar characteristics. Their pressure and energy efficiency are however not suitable for replacing R410A in air conditioners and heat pumps. They are also mildly flammable. CO 2 CO 2 has a GWP of 1 and is benign. However, system can be high due to operating pressures and temperatures there have also been issues with CO2 being lost from systems when they are switched off. Hydrocarbons Hydrocarbons such as R290 (Propane), R600 (Butane) have low GWPs and are perfect for certain applications, particularly in sealed refrigerator, freezer systems and small mobile air conditioners. While compressor design and cost and energy efficiency are comparable to HFCs, they are highly flammable, which also means system costs are much higher. Current HFCs R32 (HFC) HFO CO 2 Hydrocarbons GWP <10 Compressor design and cost Higher pressure Energy efficiency Safety A1 A2L A2L A1 A3 Refrigerant cost? System cost 6 White paper: The next generation refrigerant for air conditioners and heat pumps

7 R410A R32 High energy efficiency Efficiency: +6% 4.0kW Note used for illustrational purposes Reduced size Volume: Charge: -18% -20% The case for R32 R32 has a GWP of 675 compared with R410A s GWP of 2,088 R32 can be more energy efficient than R410A (6% higher in a 4kW system) Smaller charges means heat exchangers and other components can be smaller, making equipment more compact (18% smaller when compared with a 4kW system using R410A) Like most low GWP HFCs, R32 is rated as A2L, which means there is low risk of accidents due to toxicity (A), and it is mildly flammable (2L) R32 is a single component refrigerant, which means it can be easily reused and recycled; R410A is a blended refrigerant R32 has similar properties to HFO blends, in terms of flammability The boiling temperature of R32 is similar to R410A and slightly higher than R22 White paper: The next generation refrigerant for air conditioners and heat pumps 7

8 The burning issue Both R410A and R22 are rated as A1, which means they lowtoxic and not flammable. However like most low GWP HFCs, R32 is rated as A2L. There are degrees of flammability. R32 has a burning velocity of 6.7cm/s, while Propane s burning velocity is 46cm/s, therefore the thinking on safety of handling both gases varies considerably. Clearly the risks are totally different between an event that causes a person serious injury and one that generates a momentary small flame. Tests carried out by Daikin and Suwa Tokyo University of Science show that even if combustion of R32 occurs (at concentrations of more than 320g/m 3 ), it is not explosive and the possibility of fire spreading is extremely low. With the current guidance for R32 in EN378 are followed and a complete charge were to leak into a confined space it is very unlikely to ignite from a spark created by operating a switch or capacitor. And when performing soldering/brazing work during maintenance, the small flame that occurs from remaining gas in the system is actually caused by the oil. Tests show the behaviour is the same as with R410A systems. Concerns have been raised over the potential for the creation of hydrogen fluoride if R32 is ignited. If exposed to high temperatures (for example an oxy-acetylene flame), R32 will decompose into three substances: carbon monoxide, carbon dioxide and hydrogen fluoride. The latter, when mixed with water, creates hydrofluoric acid, which is highly toxic. However, it must be remembered that all HFC refrigerants will undergo the same process on exposure to high temperatures, including those used today, so while the risks cannot be ignored, they highlight the importance of safe working practices, regardless of the refrigerant being used. Tests carried out by Daikin and Suwa Tokyo University of Science show that even if combustion of R32 occurs (at concentrations of more than 320g/m 3 ), it is not explosive and the possibility of fire spreading is extremely low. Even if all the refrigerant leaked into this room, the low flammable limit (0.306kg/m3) would not be reached kg/m3 1.7 kg 2.5 m 50 m 2 8 White paper: The next generation refrigerant for air conditioners and heat pumps

9 Installation Regardless of the refrigerant gas being used, it is imperative that equipment is installed and charged by competent and well trained people. This means installers should be F-gas certified and trained on the systems they are installing and the refrigerant gases being used. As R32 is already part of R410A, the changes to installation procedures are relatively minor. In essence, installation is the same, the pipework is the same (using flared connections) and pressure testing and leak testing are the same. Of course, different tooling will be needed which is now available such as gauges, manifolds, leak detectors and recovery systems. The key issue is that installers will now be handling a flammable gas, which means a new set of charging and recovery procedures need to be followed but nothing that will present a major challenge. For example, an R32 system must be ventilated during charging and recovery, to prevent a build-up of refrigerant, which could then be ignited by a naked flame. Ordinarily, this is not an issue but if an outdoor unit is being installed inside a building, then a suitably rated fan should be used to ventilate the area. Note that this is already a requirement for installing systems with R410A, as the R32 and R125 gases could separate and, as a result, could be flammable. White paper: The next generation refrigerant for air conditioners and heat pumps 9

10 Daikin and R32 Daikin has decided that R32 is its preferred next generation refrigerant for air conditioners and heat pumps and has started to phase-in this refrigerant. In Japan, the company introduced residential air conditioners using R32 at the end of 2012 and since then over 2 million units have been sold. R32 is expected to be the predominant refrigerant in Daikin s split systems for the future. The timing of its introduction to various ranges will be based upon energy efficiency, the cost of ownership and system quality. Split systems Daikin will introduce the first R32 split systems with capacities less than 7kW in early Those using R410A will still be available for some time to come however, ensuring continuity of supply and aftersales support for existing customers. As split systems have a typical working life of 10 years, customers deciding to stick with R410A should be confident that their system will be unaffected by the HFC phase-down (with regard to maintenance, spares and re-charging of systems). It must be remembered that even after 2030, it will still be possible to use R410A, although it is likely that supplies could become limited. Sky Air range At the moment, Daikin is planning to introduce R32 to its Sky Air light commercial range (with capacities between 7kW and 14kW). As with other split systems, these have a working life of between 10 and 15 years and ranges using R410A will still be available in the medium term, giving customers a huge amount of choice. VRV Plans are also underway to develop Daikin VRV systems using next generation refrigerants, however it is early days and so there are no details or planned launch dates at present, or what refrigerants will be used. However, as previously mentioned, because the 2030 deadline does not represent a total ban on R410A, customers should be confident that a VRV system installed in the next 5 to 10 years will still be compliant and serviceable for the 15-plus years of its working life. It is worth remembering that current VRV systems already meet seasonal efficiency. 10 White paper: The next generation refrigerant for air conditioners and heat pumps

11 Industry support The next 12 months will be crucial for the HVAC-R industry. Daikin will be using the time to help prepare installers, designers and end-users for the introduction of the revised F-gas regulation, the next generation refrigerant gases and new R32 systems. Education will be key. Daikin has begun developing installer training programmes that will cover the properties of the refrigerant and oils, cylinders, service and installation tools, as well as handling procedures, equipment installation and service. Installers need to ensure they are F-gas accredited, are fully aware of the new regulations coming in 2015 and are trained in handling R32 and installing any new systems. They should also keep up-to-date with the latest guidance from industry bodies such as REFCOM, ACRIB, IOR, F-Gas and DEFRA. Summary The phase-down of HFCs will lead to significant change in the HVAC-R industry over the next 15 years. Installers, designers and end-users will have to adapt to using the next generation of refrigerant gases to reduce the environmental impact of air conditioning, heat pumps and refrigeration and to meet increasingly stringent legislation. Daikin s preferred alternative to R410A is R32 and the company will introduce the first systems using this refrigerant in early The introduction of R32 will present a few challenges for industry but Daikin is working hard to help ensure installers are ready, providing clear information on the new refrigerant and offering training in its safe handling. Daikin is also providing advice to consultants and end-users to help them make informed choices when designing and selecting HVAC-R systems over the next 10 to 15 years. White paper: The next generation refrigerant for air conditioners and heat pumps 11

12 For further information, please the Marketing Department at Daikin products are distributed by: FSC Carbon Neutral Daikin units comply with the European regulations that guarantee the safety of the product. Daikin Airconditioning UK Limited The Heights Brooklands Weybridge Surrey KT13 0NY Tel Fax daikin.co.uk UKEPCEN / / DesignHQ. Copyright 2015 Daikin Printed in the UK on FSC certified paper from sustainable sources. Scotland Region Northern Region Midlands Region Western Region North London South London