Next Generation Refrigerants Update. ASHRAE Regional Meeting Montreal January 2014
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1 Next Generation Refrigerants Update ASHRAE Regional Meeting Montreal January 2014
2 Agenda Current Refrigeration and AC refrigerants and emerging trends New Molecule introduction ASHRAE Standard 34 & 15 update Proposed new blends and their possible application Evaluation Results of LGWP Alternatives to R-410A LGWP Alternatives for Chiller Applications LGWP Alternatives for R-404A in Commercial Refrigeration Questions and general discussion 2
3 Refrigerant Selection Decision-Making Criteria vs. Alternatives Safety Environmental Low Global Warming Potential Zero Ozone Depletion Good Life Cycle Climate Performance in All Climates Recycling / Reclamation In Use, Storage, Transport Comprehensive Toxicology Testing Acceptable Flammability Performance High Energy Efficiency Over Complete Operating Range Long-term Durability Cost-To-Serve Low Capital Cost Low Operating Cost Better Cost vs. Alternatives Low System Maintenance Must Meet All Criteria for Acceptance 3
4 Regulatory Requirements Driving Change Montreal Protocol / Ozone Depletion Concerns Kyoto Protocol / Global Warming Concerns CFC Phase-out HCFC Phase-out EU F-Gas Regulation CFCs HCFCs HFCs HFOs Ozone Global warming Ozone Global warming Ozone Global warming Ozone Global warming Simple Chemistry Enhanced Chemistry New Molecule Development Advanced Molecules Development + Complex Chemistry R12 R134a R1234yf 4
5 Required Compliance About Standards and Codes Recommended Practice Industry guidelines and standards are given by professional associations and laboratories like ASHRAE, SAE, UL, National/International Standards typically make reference to the above (ISO, IEC,.). Codes are used by most countries National Regulation Local, State, or Provincial Regulations Required Compliance Compliance with Codes and Standards arise when adopted by a jurisdiction (local, province, national, regional). National & International Codes IBC, IEC, IFC, IMC, UMC National & International Standards ISO, IEC, EN, NFPA, CEN, DIN, GHS, CSA Industry Guidelines & Standards ASHRAE, ASTM, ASME, SAE, UL, ANSI Recommended Practice All alternative refrigerants must comply with applicable codes 5
6 ASHRAE Standard 34 and ISO 817 ASHRAE Std 34 Designation and Classification of Refrigerants: Established a new flammability sub-classification of 2L Assigned A2L classification to two new molecules: R-1234yf and R-1234ze Discussions about new methodologies to measure Burning Velocity are planned. Current standard method uses Dry air conditions The use of standard humidity conditions would be discussed. ISO Std 817 Designation and safety classification of Refrigerants (similar to ASHRAE Std 34). Proposed standard was not approved in Started a list of new work items based on observations by countries that had negative votes. Committee members scheduled to meet Discussions will include new standard methodologies to measure Burning Velocity taking into account humidity effects. 6
7 Three new molecules have been identified 1234yf, 1234ze and 1233zd. HFO s Current Product Non Flammable Mildly Flammable (ASHRAE A2L) Examples of Possible Applications HFC-134a GWP= yf GWP=0 Auto A/C, Vending, Refrigerators 1234 ze GWP=1 Chillers, CO 2 Cascades Refrigerators R-123 GWP= zd GWP = 1 Centrifugal Chillers Note: All GWP values use the latest assessment from the ICCP, AR5 HFO s for Low and Medium Pressure Applications 7
8 Possible Low GWP Refrigerant Blends HFO Blends Current Product N Series Reduced GWP Option Non Flammable (ASHRAE A1) L Series Lowest GWP Option Mildly Flammable (ASHRAE A2L) Examples of Possible Applications HFC-134a GWP=1300 N-13 - GWP=547 Chillers, Med-temp Refrigeration HCFC-22 GWP=1760 N-20 - GWP=891 L-20 - GWP=295 Stationary A/C, Refrigeration R-404A GWP=3943 N-40 - GWP=1273 L-40 - GWP=285 Low-Temp Refrigeration R-410A GWP=1924 L-41 GWP=461 GWP=572 Stationary A/C Applications Note: All GWP values use the latest assessment from the ICCP, AR5 HFO Blends for Medium & High Pressure Applications 8
9 Commercial Status of HFO containing Products 1234 yf In commercial use by auto industry now Sample quantities available today for stationary applications 1234ze Commercially available today Announced world scale plant for zd Commercial plant on stream 2 nd quarter 2014 Sampling for chiller, foam and solvent applications HFO Blends Contains ze and/or yf blended with other products(r32,r125 etc) Recently announced availability of Solstice TM L-41 Currently sampling to OEM s, compressor mfgrs, and AREP Commercialization of HFO s and Blends is underway 9
10 Air Conditioning L41 10
11 AC application analysis L-41: Mini-Split (RAC) System A ductless split system was evaluated at test facility in Shanghai DC inverter heat pump with nominal cooling capacity of 3.6 kw and nominal heating capacity of 5.0 kw Test conditions based on ISO Std as shown below: For L-41, a compressor with slightly larger displacement (11.3 cc vs cc) was used Operating Conditions (Cooling Mode) Test Condition Indoor Ambient Outdoor Ambient Compressor DB (ºC) WB (ºC) DB (ºC) WB (ºC) speed cool-01(t1 rating, moderate climate) rated cool-02(t1 Intermediate) half cool-03(t2 rating, cool climate) rated cool-04(t3 rating, hot climate) rated Operating Conditions (Heating Mode) Test Condition Indoor Ambient Outdoor Ambient Compressor DB (ºC) WB (ºC) DB (ºC) WB (ºC) speed Heat-01 (High Temp. rating) 20 < rated Heat-02 (high Temp. intermediate) 20 < half Heat-03 (Low Temp. rating) 20 < rated Heat-03 ( Extra Low Temp. rating) 20 < rated 11
12 Performance of L41 (% of R410A) Performance of L41 (% of R410A) L-41: Performance-Mini-Split System Performance Results Higher efficiency achieved for both heating and cooling modes relative to R410A 115% 110% 105% 100% 95% 90% Capacity COP 91.1% 104.2% Cooling 100.2% 103.2% Lower capacity with nominal compressor; slightly higher displacement compressor required Capacity and Efficiency results match R410A performance with higher displacement compressor Discharge temperature was slightly higher with L-41 (~11 o C) but well below maximum permissible and below temperatures typically seen with R-32 85% 80% 115% 110% 105% 100% 95% 90% 85% 80% 10.2cc Compressor Capacity 108.9% COP 87.8% 10.2cc Compressor Heating 11.3cc Compressor 102.1% 97.2% 11.3cc Compressor LGWP solutions for R410A based systems developed 12
13 Test Results of Ducted Split Heat Pump Tests were recently conducted with L-41blend refrigerant in a representative ducted split heat pump. With reduced R-32 content, a further reduce discharge temperatures was achieved enabling use of current compressor technology in all climates. Capacity was reduced but a slightly larger displacement compressor (~10%) recovered this capacity without negatively impacting efficiency Ref. Glide Ev (ºC) R410A % 100% % 100% 100% 100% R % 101% % 100% 102% 98% L-41* % 100% % 101% 105% 101% * 11% Larger Displacement Compressor L-41 Performance Summary Capacity (35 C Amb.) Cooling Efficiency (28 C Amb.) Td ( C) 46 C Ambient Heating Rating (+8 C Amb.) Cap. Eff. Heating Low Temp (-8 C Amb.) Cap Eff. 13
14 LCCP for R410A Replacements (Mini-split Heat Pump 3.5 kw) L41 reduces direct emissions substantially as a result of lower GWP (461) Overall, L41 reduces CO 2 emissions by 3% in Southern Europe compared to R410A In countries like France, Germany and Brazil, potential CO2 emissions reduction of 20-30% 14 Blend offers an environment friendly solution for R410A replacement
15 15 LGWP Alternatives for Chiller Applications
16 Low GWP Replacements for Chillers 1234 ze Performance of 1234 ze,1233 zd, N-13 Equal (or better) efficiency compared to R-134a 99.7% reduction in GWP N-13 blend Comparable efficiency to R-134a and is non flammable. Potential for retrofit. ~60% reduction in GWP 1233 zd 16 Higher efficiency than R-123 the current efficiency leader. 94% reduction in GWP HFOs Offer Large GWP Reductions & High Efficiency
17 Star Chiller Installed at Research Center Star Chiller with 1234 ze 1234 ze Shows 7 to 12% Higher COP than R-134a 17
18 18 Commercial Refrigeration
19 Centralized DX System Condenser Machine room Compressors Features Pros Cons Current Future - Compressor rack in machine room far from cases - Long connecting lines -Convenient installation in most buildings in common practice -Very familar to store owners and contractors - Larger refrigerant charge - Higher leak rates R22 R404A R407A R407F N40 19
20 Distributed DX System Condenser Condenser Condenser Features Pros Cons Current Future - Condenser in rooftop and compressor at store level closer to cases - Short connecting lines - Lower refrigerant charge (about 1/2 of centralized systems) - Lower leak rates since condensing units are factory assembled - potentially more efficient than centralized better match of suction groups, shorter lines - Not always feasible in some buidings R404A R407F R407A N40 20
21 Secondary Loop System Machine room Evap Condenser Compressors Heat transfer fluid CO2 or glycol Features Pros Cons Current Future - Secondary fluid (CO2 or glycol) distributed to the cases - Short connecting lines on the refrigerant side - Lower refrigerant charge (about 1/4 of centralized systems) - Very low leak rates - Refrigerant confined in machine room may allow mildly flammable options with very low GWP - Compressor can operate at lower pressures leading to higher energy consumption, also adds pumping power R404A R407F N40 L40 21
22 CO2 Cascade Systems with Secondary Loop CO2 Refrigerant Heat exchanger HFC refrigerant Condenser Machine room Evap Heat transfer fluid (CO2 or glycol) Features Pros Cons Current Future - Secondary fluid (glycol) for medium temp cases - DX CO2 for the low temp cases -Short connecting lines on the refrigerant side - Very low refrigerant charge - Very low leak rates - Refrigerant confined in machine room may allow mildly flammable options with very low GWP - Higher efficiency - Higher initial cost R404A R407F R134a N40 L40 N13 R1234ze 22
23 Lab Evaluations Low Temp -26 C Box 35 C Ambient Performance: N40 and R407F match capacity of R404A with 6% higher efficiency. Both have comparable performance to R22 and have 4% higher efficiency than R407A TXV Adjustment: R404A valve: N40 seems better, needed less adjustment than R407F and R407A R22 valve: N40 and R407F did not require adjustment Discharge Temperature R407F required liquid injection. Not required for N40. At AHRI calorimeter conditions (18 C RGT), R407F is 17 C above liquid injection temp while N40 and R407A are only 5 Key take away N40 allows compressor manufacturer to cover a wider envelope than R407F. Particularly important for retrofit of R404A stores not equipped with liquid injection 23
24 Lab Evaluations Medium Temp 2 C Box 35 C Ambient Performance: N40 and R407F about 3-5% higher efficiency than R404A, 4-6% better than R407A. Both about 3-5% lower efficiency than R22 (expected). TXV Adjustment: R404A valve: Both N40 and R407F required to close about 2 turns. R407A about 3 turns. R22 valve: N40 and R407F did not require adjustment. R407A may require slight adjustment. 24
25 L-40 Relative to R404A Laboratory Evaluations L40 (GWP=283, Mild Flammable) 110% Capacity Efficiency Mass Flow 100% 90% 80% 70% 60% 50% 40% Low Temperature Medium Temperature Designed to be used where mild flammability can be managed: As a chiller of a secondary fluid like CO2 Small to mid size refrigeration systems where new standards (IEC, ISO) will allow enough charge of a 2L Small Self-Contained Refrigeration Systems It Provides over 90% GWP reduction relative to R404A and better efficiency 25
26 Field Trials Centralized DX System With Cases And Food Simulators. Air- Cooled Condensers LT rack equipped with Scroll compressors: ZF25, ZF34, ZFD41 (Digital) MT rack equipped with scroll compressors: ZB95, ZBD76 (Digital) 26
27 Environmental impact of different technologies Assumptions Area of ft 2 (4181 m2) Load distribution of 36% LT and 64% MT Charge of 3200lb (1455 kg) of R404A 15% annual leak rate (DX Systems) The use of N-40 (and even R407F) allows considerable reduction of environmental impact when retrofitting existing systems (~50%). Among current DX technologies, distributed systems using N-40 produce environmental impact similar to more sophisticated technologies (cascade and pumped CO2). 27
28 Summary & Conclusions HFO s and HFO blends should be considered as part of the solution to transition away from High GWP refrigerants. There is no single refrigerant solution, application and selection criteria/market will determine final application of available solutions. Energy efficiency will always be a major factor in determining equipment/refrigerant design choice. System and refrigerant comparisons should be done scientifically using proper experimental protocols. True environmental performance should be considered when making refrigerant/system choices. 28
29 Questions? Genetron Refrigerants Technical Service The information provided herein are believed to be accurate and reliable, but are presented without guarantee or warranty of any kind, express or implied. User assumes all risk and liability for use of the information and results obtained. Statements or suggestions concerning possible use of materials and processes are made without representation or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The user should not assume that all safety measures are indicated herein, or that other measures may not be required. Thank you! 29
30 Back up Back up 30
31 Degree of Superheat Pressure-Temperature Chart R22 AZ-20 (410A) 404A Performax LT (407F) Temp. Pressure Bubble Dew Bubble Dew Bubble Dew Pressure Pressure Pressure Pressure Pressure Pressure ( F) [psig] [psig] [psig] [psig] [psig] [psig] [psig] The refrigerant is in superheated vapor state at the end of the evaporator. To determine superheat, use nearest saturated state (dew point) in your P-T chart Procedure: Use gauges to determine the pressure at the coil outlet, and a thermometer to get the actual temperature at the same point. Get the Dew temperature from the Dew column Superheat = Actual Temperature Dew Temperature Example: Find the superheat on a system which uses Performax LT (407F) when the pressure at the evaporator outlet reads 24 psig and your surface thermometer reads 10 F psig yields ~ 0 F (using dew point) Degree of Superheat = 10 F (0 F) = 10 F 31
32 Degree of Subcooling Pressure-Temperature Chart R22 AZ-20 (410A) 404A Performax LT (407F) Temp. Pressure Bubble Dew Bubble Dew Bubble Dew Pressure Pressure Pressure Pressure Pressure Pressure ( F) [psig] [psig] [psig] [psig] [psig] [psig] [psig] The refrigerant will be in liquid state at the end of the condenser. To determine subcooling, use the nearest saturated state (Bubble point) in your P-T chart Procedure: Use gauges to determine the pressure at the coil outlet, and a thermometer to get the actual temperature at the same point. Use the Bubble column to get the bubble temperature Subcooling = Actual Temperature Bubble Temperature Example: Find the amount of subcooling on a system using Performax LT when the liquid line temperature reads 80 F and the liquid line pressure is 215 psig. 215 psig yields ~ 90 F (using Bubble point) Degree of Subcooling = 90 F - 80 F = 10 F
33 Average condenser coil temperature Pressure-Temperature Chart R22 AZ-20 (410A) 404A Performax LT (407F) Temp. Pressure Bubble Dew Bubble Dew Bubble Dew Pressure Pressure Pressure Pressure Pressure Pressure ( F) [psig] [psig] [psig] [psig] [psig] [psig] [psig] The operating coil temperature for single component refrigerants is the corresponding temperature found in the P-T chart. For blends, however, proceed as follows: Using gauges, determine the pressure at the outlet of your condenser. Inlet pressure may also be used. Find the corresponding Bubble temperature using the Bubble column. Likewise, find the Dew temperature using the dew column. Average Coil Temp. = (Bubble Temp + Dew Temp)/2 Example: Find the average condensing temperature of a system using R407F when the gauge pressure at the condenser outlet reads 215 psig. Find ~215psig in Bubble column: 90 F Find ~215psig in Dew column: 98 F The average coil temp = (90+98)/2 = 94 F 33
34 Average evaporator coil temperature Pressure-Temperature Chart R22 AZ-20 (410A) 404A Performax LT (407F) Temp. Pressure Bubble Dew Bubble Dew Bubble Dew Pressure Pressure Pressure Pressure Pressure Pressure ( F) [psig] [psig] [psig] [psig] [psig] [psig] [psig] Similarly to the condenser coil: Using gauges, determine the pressure at the outlet of your evaporator Find the corresponding Bubble temperature using the Bubble column. Likewise, find the Dew temperature using the dew column. Evaporating Temp. = (Bubble Temp + Dew Temp)/2 Example: Find the average evaporator temperature of a system using R407F as the refrigerant when the gauge pressure at the evaporator outlet reads 10 psig. Find ~10psig in Bubble column: -30 F Find ~10psig in Dew column: -20 F The average coil temp = (-30+(-20))/2 = -25 F A more accurate estimate would account for inlet quality. So instead of average, multiply bubble by 0.35, dew by 0.65 and sum: Find ~10psig in Bubble column: -30 F Find ~10psig in Dew column: -20 F The average coil temp = 0.35*(-30) *(-20)= F 34
35 Temperature TD avg TD dew Condenser Sizing Condenser sizing is typically carried out using TD based on dew point temperature. For a blend, however, design TD should be based on the average coil temperature. (bubble and dew points) Simulation Design Tool Results: TD dew TD avg Condenser Area [ F] [ F] [%] Baseline R404A % R407F drop-in % R407F matching TD dew % Same size condenser! A R407F condenser sized to match the TD-dew of R404A may result in a 20% larger HX R40 4A Outdoo r air Larger condenser! Distance along condenser Experimental Results with R407F retrofit in a R404A 3-Ton walk-in freezer (0 F Box, 95 F Outdoor) TD dew TD avg Capacity [ F] [ F] [%] Baseline R404A % R407F retrofit % Actual data show no need to oversize condenser, since TD-avg is actually lower for R407F While sizing a condenser for a blend, design TD should be based on the average coil temperature (average of bubble and dew points) and not solely on dew point. 35
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