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Conversion from HCFC-22 to HC-290 in Residential Air-Conditioners

Update on China and India Experiences

Joint Meeting of the Regional Ozone Networks for Europe & Central Asia (ECA) and South Asia (SA)

Istanbul, Turkey, 26-30 April 2010Markus Wypior, GTZ-Proklima

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PR

OK

LIM

A

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Statement

Hydrocarbon refrigerants are an excellent alternative to HCFCs. Hydrocarbons are used safely in all ways of life from hairspray and cooking gas to fuels for cars and airplanes. Hydrocarbon based technologies have to be designed to operate safely, and they are indeed safe."P

RO

KL

IMA

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window unità 1 – 5 kWà 0.1 -1 kgà small rooms, hotels, homes, offices

through-the-wallà 2 – 10 kWà 0.2 – 1 kgà small rooms, hotels, offices

portableà 2 – 5 kWà 0.2 – 0.5 kgà small rooms, homes, offices

single splità 2 – 10 kWà 0.2 – 1.5 kgà small rooms, hotels, homes, offices

close controlà 10 – 100 kWà 1 - 15 kgmedium rooms, offices, public buildings, IT

Types of room air-conditioning equipment

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Historical and forecast production of RAC equipment in China (for domestic consumption)

10

100

1000

10000

100000

2000 2005 2010 2015 2020 2025

Year

New

pro

duct

s (0

00's

) .

Windows/through thewall

Portables

Single splits

Multisplits

Packaged etc

Chillers

Integral cabinets

Condensing unit systems

Central systems

Increase is nearly exponential !

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Success of Greenfreeze Technology-Diffusion in China

o 1995: Company Quingdao Haier introduced Greenfreeze Technology, supported by GTZ

o 1997: Company Kelon changed its production to Greenfreeze

o 2008: 75% of Chinese production uses Greenfreeze Technology

We did it once. Can we do it again?

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Success of Greenfreeze Technology-Diffusion Worldwide

0

20

40

60

80

100

120

1992 1996 2000 2004 2008

Prod

uctio

n (m

illio

ns o

f uni

ts)

Other

HC600a

HFC134a

CFC12

Now, even in USA, introduction of HCs in some domestics and trials in ice cream freezers and bottle coolers

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Emission Reduction Scenario

o Potential for China (60% of world‘s A/C production)

o Diffusion rate based on experiences with R 600a Greenfreeze technology

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Policy Development

o Over 100 countries will place import quotas to meet 2013/2015 MP obligations

o Europe: reconsidering EN 378 o International: reconsider IEC 60335-2-40?o China: RAC industry safety standardso USA: Clean Air Act / ASHRAEo Safety considerations depend on:

- appropriate industry standards- appropriate service technician education

o Montreal Protocol Example: CFC phase out

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Estimated annual (reported) emissions from China RAC equipment (no R-22)

0

50

100

150

200

250

2004 2006 2008 2010 2012 2014 2016 2018 2020

Reportin

g d

irect

em

issi

ons

(Mt C

O2-e

q) .

no substitution (HCFC and HFC)

7% substitution with NR per year

11% substitution with NR per year

o Additional emissions from each years production, eligible for reporting

o With HFCs only, emissions increase by over 10 times by 2020

o With natural refrigerants, 2007 levels are maintained by 2020

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Policy Development

o Destruction and recycling of CFCs, HCFCs and HFCs

o Most developing countries have no facilities (too expensive, no infrastructure)

o Recovered stocks – ultimate fate is atmosphereo Entire problem can be avoided with HCs

(may be vented)

This policy situation may translate into sooner and higher market demand for natural refrigerant based solutions

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Room Air Conditioner – Present situation

o approx. 1 billion HCFC-22 units worldwideo about 100 million units added annuallyo average HCFC-22 charge about 1.6 kgo approx. 1’600’000 tonnes HCFC-22 contained in

existing equipmento HCFC-22 GWP: 1’810 o 2’896 Mtonnes CO2eq.o Servicing needs: approx. 800’000 tonnes/yro 1’448 Mtonnes CO2eq.

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Market Potential

o Major development in tropical countries:- Energy efficiency, direct emission reductions

o Major countries: China, India, Gulf, ASEAN, Latin America

o LVCs: Island States, Africa o Developing gap between market demand for air

conditioners and availability of HCFC air conditioners due to freeze in 2013 and subsequent reduction steps

o Precondition: Availability of HC refrigerant gas

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ODP and GWP of selected refrigerants

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Substance ODP GWP

CFC-12 1 8,500

HFC-134a 0 1,300

HC 600a (Isobutane)

0 3

HCFC-22 0.055 1,780

HFC-32 0 550

HFC-407C 0 1,610

HFC 410A 0 1,850

HC-290 (Propane)

0 3

Re

frig

erat

ion

Air

-co

nd

itio

nin

g

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Refrigerant LFLa(vol%) UFLa (vol%) Minimum Ignition

Engergy (mJ)

Burning Velocity (cm/s)

Flammability class

HFCF-22 none none - - -

HFC-32 14.4 29.3 30-100 6.7 A2L

HFC-407C none none - - -

HFC-410A none none - - -

HC-290 2.2 10.0 0.25 46 3

Flammability of selected refrigerants

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Demo Projects in China and India

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Target Group: Air-conditioner manufacturer, industry associationstechnical institutes; technical committees of international environmental agreements

Project budget in each country: 2 Mio EUR

Production capacity: approx. 180,000 units p.a. in each project

Expected environmental impact: 900,000 tonnes of CO2e in each project

Project elements: (1)Optimization of technical design(2)Installation of new production equipment(3)Pilot production(4)Training of service technicians

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China Project

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China Project

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China Project

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China Project

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India Project

Split and Window type (China only Split type) 1.0 / 1.5 TR

Simulation was done first for the optimization before carrying out tests

Refrigerant charge reduced to 30% of original HCFC-22 charge (after system optimization)

The performance improved significantly (EER is more than 20% higher )

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Current Status

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Trials and technical optimization: completed (Godrej)

Trials and technical optimization: ongoing (Voltas, Advantec, Lloyds Engg.)

Umbrella agreement: pending

Training concept & manual: completed

Installation of production equipment: end of 2010

Pilot production: end of 2010/beginning of 2011

Commercial production: 1st half of 2011

Trials and technical optimization: completed

Development of safety standards: ongoing

Installation of production equipment: completed

Pilot production: beginning in 1st half of 2010

Commercial production: 2nd half of 2010

China

India

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BEE Energy Efficiency Labeling

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Other Developments

Introduction of micro channel heat exchangersreduces refrigerant charge by 50% and reduce production cost

Propane and micro channel heat exchangers will help Indian AC manufacturers to achieve/maintain high star ratings!

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Other Developments in HC-290 AC

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International Climate Initiative (ICI)

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http://www.bmu-klimaschutzinitiative.de/en/theme

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International Climate Protection Initiative (ICI)

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Complements existing development cooperation activities

Uses the income from the sale of CO2 certificates through the emissions trading system to fund climate protection projects

Priority areas: Increasing energy efficiency  Expanding the use of renewable energies  Reducing climate-damaging fluorocarbons 

Support is provided to both investment projects and capacity-building projects

120 Mio EUR per annum

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Thank you!

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