Refrigerant identification and equipment issues in relation to HCFC phase-out. Ole Reinholdt Nielsen

Transcription

1 Refrigerant identification and equipment issues in relation to HCFC phase-out Ole Reinholdt Nielsen Belize, March 3, 2010

2 Outline Brief introduction; Refrigerant identification: Historically; Options for refrigerant identification; Alternative refrigerants - overview Equipment issues for manufacturing sector; and Equipment issues for servicing sector.

3 AGRAMKOW Group Appliance Production Line Solutions Process and test solutions for appliance manufacturing Automotive Production Line Solutions Fluid filling solutions for automotive manufacturing Automotive Maintenance Equipment Maintenance equipment for automotive aftermarket Global Environmental Projects Solutions for reclaim, recovery and recycling

4 AGRAMKOW background 1977 Foundation of AGRAMKOW based on automated charging equipment for Refrigeration and Air-conditioning factories (Appliance Industry) 1979 First reclaim station for reducing emission of R12 (Global Environmental Projects) 1979 First supply of AC filling equipment for automotive factories (Automotive Industry) 1988 AGRAMKOW UK established 1989 First supply of MAC service equipment for R12 (Auto Maintenance Equipment) 1990 RTI, Refrigerant Technologies Inc. established in USA focused on AC service equipment for automotive aftermarket 1999 ISO Certification 2000 Turn-around and name change: AGRAMKOW Fluid Systems A/S 2001 Automotive Maintenance Equipment redefined 2003 GEP Global Environmental Projects established as a new business unit 2004 AGRAMKOW Service Centre India established 2004 AGRAMKOW Sales and Service Centre Shanghai established 2008 Global Pioneer in CO2 technology 1992 Global pioneer in Isobutane technology 1996 ISO 9001 Certification 1996 AGRAMKOW ASIA PACIFIC (Singapore) established 1997 AGRAMKOW Latin America (Brazil) established

5 Refrigerant identification Demand for automotive service early/mid 1990 ies R-12 substituted by R-134a Other applications: Refrigerant recycling / reclaim centers; Tool to prevent illegal trade

6 Refrigerant identificators Historical overview

7 Refrigerant identificators Current

8 Blend ID MAC model RI has built-in in Blend ID software; Can indicate US EPA S N A P Can indicate US EPA S.N.A.P. approved blends for MAC.

9 Blend ID R-406A Substitute (Name Used in the Federal Register) Trade Name GHG, GHG-X3, GHG-12, McCool, Autofrost X3 GHG-X4, R-414A (HCFC Blend Xi) GHG-X4, Autofrost, Chill-it, Autofrost X4 Hot Shot, R-414B (HCFC Blend Omicron) Hot Shot, Kar Kool FRIGC FR-12, (HCFC Blend Beta), R- 416A FRIGC FR-12 Free Zone, (HCFC Blend Delta) Free Zone / RB-276 Freeze 12 Freeze 12 GHG-X5 GHG-X5 GHG-HP (HCFC Blend Lambda) GHG-HP Ikon 12, Ikon A (Blend Zeta) Ikon 12 SP34E SP34E RS-24 RS-24 R-426A RS-24

10 Blend ID

11 Refrigerant identificators Current

12 Refrigerant identificators Technological limitations: Identifies quantitatively: R-12, R-22 and R-134a; and Identifies presence of: Air and Hydrocarbon One manufacturer only

13 Advanced RI DISCONTINUED!!!

14 Refrigerant identification Other options: Temperature / pressure measurements; Gas Chromatography; or Advanced leak detector.

15 Refrigerant identification Temperature / pressure measurements: Single component refrigerants possible; Mixtures difficult; Requires accurate thermometer; Not an on-site operation.

16 Refrigerant identification Gas Chromatography: Costly option; Requires skilled personnel; Not on-site operation.

17 GC Istanbul

18 Refrigerant identification Advanced leak detector: Selective leak detector; Costly option; Not on-site operation.

19 Advanced leak detector

20 Advanced RI NEW PRODUCT Expected to be available spring 2010

21 Advanced RI PRELIMINARY LIST EXPECT UP TO 20 DIFFERENT REFRIGERANT AND BLENDS R22 R134a HC R404A R407C R409A R410A R417A R % 60% R134a 100% 4% 52% 50% R125 44% 25% 50% 46.6% 6% R32 23% 50% R124 25% R142b 10% R143a 52% HC % 3.4% %

22 Viewing the Detail!!!

23 Refrigerant selection industry perspective Price (refrigerant + components) Physical properties: Pressure levels; Volumetric efficiency; Refrigerant charge; Energy efficiency (COP); Safety (flammability, toxicity); Environmental impact. 2

24 Refrigerant Overview Reference: : Bitzer Refrigeration Report 15

25 Alternatives to HCFC s HFC blends (e.g. R-407C or R-410A are today mainly used in: -Room A/C -Commercial A/C -Industrial A/C -Commercial refrigeration (Supermarkets, bottlecooolers etc) -Special refrigeration applications Technically it is possible to substitute the above refr. with R-290 (Propane) or R-1270 (Propylene) R-744 (CO2) Which gas can substitute which refrigerant depends on application and product type 2

26 HFC Blends R-407C Reference: : Bitzer Refrigeration Report 15

27 Retrofit options R-407C Similar to R-12/R-134a retrofit; Requires synthetic oil; Oil change likely required; Temperature glide; Design considerations; Greenhouse gas; Likely best option for retrofit. 2

28 HFC Blends R-410A Reference: : Bitzer Refrigeration Report 15

29 Retrofit options R-410A Design considerations: Pressure; Performance; Insignificant temperature glide; Requires synthetic oil; Oil change likely required; Greenhouse gas; Option for retrofit in special cases only. 2

30 Other HFC blend options R-422D: R-125/R-134a/R-600a; R-417A; R-125/R-134a/R-600; Oil change not required; Temperature glide = design considerations; Greenhouse gases; Cost / availability? 3

31 Other HFC blend options R-427A: R-125/R-134a/R-143a/R-32; Oil change required; Accepts upto 15% MO/POA; Temperature glide = design considerations; Greenhouse gases; Cost / availability? 3

32 Reference: : Bitzer Refrigeration Report 15 HC Options

33 HC Safety regulation EU: ATEX Directive (Atmosphere Explosives) Worldwide accepted and harmonized with US standards; d Many related standards; Hereoff: EN 378: Refrigerant charges <150 g can be handled as normal household equipment (outside the ATEX directive) 3

34 HC retrofit options Flammability / safety: Different approaches tried; No oil change required; Reduced refrigerant charge (app. 50%) Capacity compensation (R-290); HC blends; e.g. Duracool 22a Temperature glide; Potential retrofit option; In particular for small applications 3

35 Reference: : Bitzer Refrigeration Report 15 CO2

36 Efficiency of ideal reversed Rankine System 0,9 0,8 Ca arnot efficien ncy [-] 0,7 0,6 0,5 0,4 03 0,3 R717 R22 R134a R600a R290 R410A R507 R404A R407C R744 CO tc [ C] t evap = -35 C Poor thermodynamic performance of a refrigerant has to be compensated Poor thermodynamic performance of a refrigerant has to be compensated with enhanced component efficiency or system configuration Ref.: Niels P. Vestergaard, Danfoss

37 CO2 drivers: geography Transcritical CO2 systems requires low ambient temperatures to be effective North America Europe Russia California? Africa Middle East Asia Japan South America Australia Ref.: Niels P. Vestergaard, Danfoss

38 CO2 retrofit options Completely new design of refrigerating circuit: Pressures; Condenser/gas cooler; Compressor; Availability / cost of components??? Not a potential candidate for retrofit. 3

39 Ammonia retrofit options Toxicity!!! Incompatibility with copper: Only open-type compressor; Steel piping / components; NH3 / oil not miscible = design considerations; NH3/DME mix being investigated to offset oil issue Not suitable for retrofit. 3

40 Manufacturing sector Large manufacturer: > 10,000 units annually Small manufacturer: < 1,000 units annually; and Medium sized manufacturer: between 1,000 and 10,000 units annually 4

41 Equipment requirements Large manufacturer R-22 baseline Pre-charging leak detection *) Evacuation Charging Refrigerant Post charging supply system leak kdetection ti Other **) HFC s, e.g. R-410 ( ) + + (+) R ( ) + + (+) + R-744 ( ) + n/a (+) = no need for changes; + = changes needed *) Helium **) Welding of charging pipe incl. Safety supervision system

42 History The Worlds First for FORON (1992)

43 Refrigerant Charging stations PRO-MAX (For Large production output) 4

44 Charging stations for R744 (CO2) The technology is called ECOMASTER and it is included in our CO2 charging station range: -ECO 2 PILOT (For small volumes and pilot series) -ECO 2 MAX (For main production lines (Medium/ large) 4

45 Budget pricing overview (1.000 ) R-22 baseline Pre-charging leak kdetection ti *) Evacuation Charging Refrigerant supply system Post charging leakdt detectionti Other **) HFC s, e.g. R-410 n/a n/a n/a R n/a R-744 n/a n/a n/a 5-10 n/a *) Helium leakdetection system (incl recovery) **) Welding of charging pipe and safety supervision system

46 Refrigerant Charging stations for small manufacturer Price level: 1,500 2,000 US$ 4

47 Equipment for medium sized manufacturer????? BUT 4

48 Equipment for medium sized manufacturer EU: F-Gas Directive Restricts the usage of HFC; Automotive industries: All new car models from 2011 can only use refrigerants (for the A/C system) with a GWP less than 150. Initially CO2 was seen as the best solution; Response from chemical industries: New refrigerants!!! 4

49 HFO-1234yf

50 HFO-1234yf

51 HFO-1234yf Other Industrial standards? ds? Charging accuracy?

52 CO2 options Pre-charged CO2 modules 5

53 Impact on Servicing Sector All refrigerants shall be recovered! Except: HC s/co2/nh3; No need to consider oils in compressors for R&R eq. Miscibility not required/wanted; Oil-less compressors not required; Measures to avoid cross contamination: Self purging functions; Evacuation procedure; Filter change may be required. 5

54 Impact on R&R - recovery Larger refrigerant charges: Utilize liquid and/or push-pull recovery; Cylinder overfill protection (scale); Cylinder population; Refrigerant bag limitations (pressure/volume): Less capacity/efficiency; R-410 considerations pressure. 5

55 Refrigerant purification

56 Impact on R&R - recycling Recycling units with automatic purge of NCG s: Needs modification; or Disabling of automatic purge; Pressure limiters; Safety valve; High pressure switch; 5

57 Impact on R&R - recycling Larger charges: On-site recycling; Filter specification important. Cylinder population; 5

58 THX for your attention