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Responsible Use of Refrigerants in HVAC

Julian de BulletASHRAE Distinguished Lecturer

Director of Industry Relations

McQuay International

703-395-5054

julian.debullet@mcquay.com

PLEASE MUTE CELL PHONES

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It’s About the World…..

Globally the Issues are the Same……….

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History of Refrigerants

• 1830s - Jacob Perkins - Vapor Compression (ether)• 1851 - John Gorie - Patent for Vapor Compression

Cycle • 1859 R-717 / R-718 (Ammonia / Water)

• 1866 CO2 - Naval Applications

• 1873 - R-717 (Ammonia) Commercial Refrigeration - Karl Linde

• 1875 - R-764 (Sulfur dioxide)• 1920s -R-600a (Isobutane) & R-290 (Propane)• 1922 - Willis Carrier - R-1130 (Dielene)• 1926 - R-30 (Methylene Chloride)

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Fluorocarbons

• CFCs, HCFCs and HFCs

• Limited Combinations

– Adding Chlorine Or

Bromine Increases ODP

– Adding Fluorine Increases

GWP

– Adding Hydrogen Increases

Flammability And Lowers

Atmospheric Lifetime

HYDROGEN

CHLORINE FLUORINE

Flammable

Toxic

Long Atmospheric Lifetime (fully halogenated)

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rowlandmolina.gif

Ozone Depletion was Detected in the 70’s………..

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Refrigerants Circa 1987

• Common HVAC Refrigerants Include CFC-11, CFC-12

(ODP=1.0), HCFC-22 (ODP=0.05)

• Chiller Efficiency 0.70-0.80 kW/ton

• Low Pressure Chillers Lose 25% Of Charge Annually

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Montreal Protocol Corrective Measures

• HFC-134a (ODP=0) Replaces CFC-12 for Chillers and

HCFC-22 for most Commercial HVAC Systems

• HCFC-123 (ODP=0.02) Replaces CFC-11

– These Chillers Tightened Up (High Efficiency Purge,

Portable Refrigerant Vessels, Blankets etc.)

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20 years later….Ozone Depletion Continues…..

2005 ‘Hole” was one of largest and deepest ever….

Latest NASA predictionsdelays recovery until2068…..nearly 20 yearslater than previouslybelieved…..

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1996 2004 2010 2015 2020 2030

0%

20%

40%

60%

80%

100%

65%

25%

10%0.5%

Consumption cap reducedfrom 35% to 25% in 2010

2013 2020 2025 2030 2040

0%

20%

40%

60%

80%

100%

65%

32.5%

2.5%

2015

90% Current: Consumption cap steadilyreduced starting in 2015 Previous: Consumption capped at2015 levels until 2040

Phase Out Schedule – Developed Countries

Phase Out Schedule – Developing Countries

Co

nsu

mp

tio

nC

on

sum

pti

on Freeze

Note: acceleration shown in light blue

2015 Service Tail Review

Montreal Protocol –Changes Made on Friday September 21st, 2007

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AVAILABILITY OF REFRIGERANT(Dupont & ICI Projections)

300

250

200

150

100

50

0

Tons (000)Tons (000)

HCFC22HCFC22

HCFC123HCFC123

HFC134aHFC134a

HFC410AHFC410A

Year

1995 2000 2005 2010 2015 2020 2025 2030

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And Don’t Forget HCFC-22

• HCFC-22 phase-out in 2010 for new equipment and 2020 for service tail production– Consider alternatives for HCFCs now

• Recommended actions – Select high efficiency units that use zero ozone

depleting refrigerants like HFC-410A, HFC-134a and HFC-407C

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HCFC-22 Issues- Clarification

Allow the sale of window air conditioners, packaged terminal air conditioners, and some commercial refrigeration units after Jan. 1, 2010, if they were manufactured before Jan. 1, 2010. Stockpiling of this equipment is allowed under the rule.

• Allow the sale of pre-charged appliance components and parts manufactured (in the traditional sense), such as condensing units, line sets, and expansion valves, used for servicing as long as they were manufactured before Jan. 1, 2010. Stockpiling of this equipment is allowed under the rule.

• Ban the sale and installation on or after Jan. 1, 2010, of pre-charged R-22 air conditioners (such as split systems) and refrigeration appliances that require field charging. Contractors are advised not to stockpile this equipment.

• Permit servicing and repair work that requires the refrigeration loop to be opened and closed. There was a question as to whether this activity would be banned because it could be interpreted as ‘manufacturing’ after the Jan. 1, 2010 deadline.”

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ASHRAE Standard 34

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ASHRAE 34 SAFETY GROUPS

High High FlammabilityFlammability

LowLowFlammabilityFlammability

No FlameNo FlamePropagationPropagation

A3PropaneButane

B3

A2R-142b, 152a

B2Ammonia

A1R-11, 12, 22, 114, 500, 134a

B1R-123, SO2

Lower ToxicityLower Toxicity Higher ToxicityHigher Toxicity

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Refrigerants & Compressors

100101.10

2

4

6

8

10

12

14

16

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WATER COOLED CHILLER DUTY

CFM/TON

DE

LTA

H, (

Btu

/lb)

POSITIVE DISPLACEMENT,ROTARY, SCROLL, RECIP, SCREW

CENTRIFUGAL

113123

11

114

124

134

152a

134a

12

500

22

502125

507

143a

410A

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Application ConsiderationsApplication Considerations

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REFRIGERANT TRANSITION

CFCs HCFCs HFCs

high chlorine

strong ozone depletion

strong global warming

•1974 – Molina-Rowland theory•1987 – Montreal protocol•1990 – CAA amendments•1996 – total phaseout of CFCs

lower chlorine

lower ozone depletion

lower global warming

•2010 - phaseout ofHCFC-22 for new equipment•2020 - total phaseoutof HCFC-22 and New HCFC -123 chillers.

no chlorine

zero ozone depletion

lower global warming

1930s-1990s 1950s-2010s 1990s +

SO2 -NH3

1920s

toxic

flammable

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ASHRAE Standard 15

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ASHRAE Standard 15

What is ASHRAE 15?What is ASHRAE 15?

An industry standard that specifies safe An industry standard that specifies safe design, construction, installation, and design, construction, installation, and operation of refrigerating systemsoperation of refrigerating systems

Establishes safeguards for life, limb, Establishes safeguards for life, limb, health, and property, and prescribes health, and property, and prescribes safety standardssafety standards

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Mechanical Room Safety Check:Mechanical Room Safety Check:

Location of inlet Location of inlet vents in relationvents in relationto exhaust outlets ? to exhaust outlets ?

Location of roof drains ?Location of roof drains ?

Rupture discRupture discoutlet locations ?outlet locations ?

Purge vents Purge vents to outside ?to outside ?

Are safety ruptureAre safety rupture lines the right size ?lines the right size ?

Is access to mechanicalIs access to mechanicalroom restricted ?room restricted ?

Is there a tightIs there a tightseal on doors ?seal on doors ?

Where do theWhere do thefloor drains floor drains empty to ?empty to ?

Are drain valves connectedAre drain valves connectedto evacuation devices ?to evacuation devices ?

Are there anyAre there anypit areas in thepit areas in theroom ?room ?

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Mechanical Room Per ASHRAE 15 Mechanical Room Per ASHRAE 15

Relief discharge shall be located not lessRelief discharge shall be located not lessthan 20 ‘ from ventilation opening andthan 20 ‘ from ventilation opening andnot less than 15’ above ground level (9.7.8)not less than 15’ above ground level (9.7.8)

All indoor machineryAll indoor machinery rooms must be ventedrooms must be vented to the outdoors utilizingto the outdoors utilizingmechanical ventilationmechanical ventilation98.13.3 & 498.13.3 & 4

Access to mechanicalAccess to mechanicalroom shall be restricted.room shall be restricted.Tight fitting doors openingTight fitting doors openingoutward (self closing if theoutward (self closing if theopen into the building)open into the building)adequate in number to adequate in number to ensure freedom of escape.ensure freedom of escape.No other openings that wouldNo other openings that wouldpermit passage of escaping permit passage of escaping refrigerant (8.13)refrigerant (8.13)

Purge systems and relief devicesPurge systems and relief devicesmust be vented to outside (8.16)must be vented to outside (8.16)

Refrigerant sensors are located in areas whereRefrigerant sensors are located in areas whererefrigerant vapor from a leak will be concentratedrefrigerant vapor from a leak will be concentratedso as to provide warning at concentration notso as to provide warning at concentration notexceeding the refrigerant TLV-TWA exceeding the refrigerant TLV-TWA

The total amount ofThe total amount ofrefrigerant stored in arefrigerant stored in amachinery room in allmachinery room in allcontainers not providedcontainers not providedwith relief valves & pipedwith relief valves & pipedin accordance with standardin accordance with standardshall not exceed 330 lb.. (11.5)shall not exceed 330 lb.. (11.5)

Oak Ridge National Laboratory (AFEAS/DOE)

Energy and Global Warming Impacts of HFC Refrigerants and Emerging Technologies Nov 1997

What About GWP and Leakage Rates?

For chillers, (Indirect) global warming gas emissions (CO2) at the power plant account for more than 96% of the Total Equivalent Warming Impact

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Number of Leaks Detected per Unit

Water-Cooled Leaks / Unit Tested

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

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Climate Change & HFC Refrigerants

• GWP=How much a given mass of GHG contributes to global warming• HFC emissions covered under the Kyoto Protocol – Represent less than 2% of all GHG emissions

Global Warming Potential (GWP) of Key Refrigerants

0

2000

4000

6000

8000

10000

12000

R-22 R-12 R-134a R-404A R-407C R-410A R-507A

Refrigerants

GW

P (

Re

lati

ve

to

CO

2)

1 kg R-12 = 10,600 kg CO21 kg R-134a = 1,430 kg CO21 kg R-410A = 2,088 kg CO21 kg R-404A = 3,922 kg CO2

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Climate Initiatives

Waxman/Markey House Bill- Energy Efficiency

• The goal would be for the model building energy codes to be updated every three years to reduce building energy consumption by 30% such target to be increased to 50% incremental reductions in building energy consumption for new code editions released after January 1, 2016, with the ultimate goal being “net-zero-energy” buildings.

• The starting baselines would be the 2004 IECC and ASHRAE Standard 90.1-2004.

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Climate Initiatives

Waxman/ Markey Bill- Climate

– The Draft provides for an HFC regulatory program under the Title VI of the Clean Air Act, and as expected, provides for (1) a cap and reduction schedule, (2) allocations to HFC Producers, Users and Importers (both bulk and products-containing); and several other provisions

– The Draft proves for an initial cap in 2012 that is based on the average of 2004-2006 production (and 100% of HFC and HCFC production).  The number is then to be reduced by 6% in the first year, and then 3% each year until 2028.  EPA is given authority to set this baseline within the bounds of 380 and 280 MMTCO2e

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Total Equivalent Warming Impact (TEWI)

• TEWI - Tool to estimate global warming impact of various technologies

• TEWI estimates CO2 emissions of a given system over its lifetime– Direct: equivalent CO2 emissions caused by direct

leakage or loss of refrigerant

– Indirect: CO2 emissions due to energy consumption by the system

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TEWI – Major Findings

TEWI - Residential Central Air Conditioners

0.00

20.00

40.00

60.00

80.00

1 2

Year

TE

WI

(MT

CO

2/Y

ear)

Direct CO2 emissions A/CMetric Tons

Indirect CO2 emissions A/CMetric Tons

1970 2006

13.9%

86.1%

94%

6%

• New products have half the carbon footprint than products manufactured 35 years ago

• Energy efficiency is key to reducing greenhouse gas emissions from HVACR equipment

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Ohnishi Basis for ICCP/TEAP report

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ARI Standard 550/590

Chiller Certification and IPLV

The Industry ARI Standard Part Load Analysis (IPLV)

% Load % Hrs 100 1 75 42 50 45 25 12

Systems Solution

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Historic Energy Improvements

4

5

6

7

8

9

10

1990 1994 1998 2002

Year

Eff

icie

ncy (

CO

P)

State of the Art IPLV

State of the Art Full Load

Average IPLV

Average Full Load

http://www.unep.org/ozone/Teap-Reports/teap_chiller_report_May2004.pdf

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Full Load Vs. Annual Load

Design Performance

Chiller58%

Tower5%

Fans24%

Pumps13%

Annual Energy Usage

Pumps22%

Tower2%

Chiller33%Fans

43%

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ASHRAE Standard 147 Reducing the Release of Halogenated Refrigerants from HVAC & R Systems

• Replaces Guideline 3

• Includes HFC Refrigerants

New Initiatives

• ARI- Responsible Use Guideline for Minimizing Fluorocarbon Emissions in Manufacturing Facilities

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Other Refrigerants

• R-718 Water

• R-717 Ammonia

• R-744 CO2

• R-290,600,600a (Propane, Butane, Isobutane)

• R-407c

• R-410a

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Natural Refrigerants - Water R-718

• Refrigerant In Absorption Chillers• Safe, Abundant, Environmentally

Friendly• COP = 1 (Centrifugal COP = 6.4)• Current Energy Rates Offer Poor

Life Cycle Analysis In America• Common In Japan

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Natural Refrigerants - Ammonia R-717

• Higher Toxicity And Lower Flammability (B2)

• Environmentally Friendly• Efficient• Special Safety Efforts Required

(Std 15)• Guarded Plants

European Built Ammonia A/C Chiller

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IIAR 2

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Refrigerants

• CO2

• R-245fa• Hydrocarbons• Water

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Flammable Refrigerants

• Propane And Butane

• Major Safety Concerns

• +35% Domestic Market In N. Europe

• 8% Domestic World Market

• Not Popular In North America

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Compression

• Best Performance And Lowest Cost Always Starts With Compression

• Refrigerant Choice Drives Compressor Design

• Examples– Magnetic Bearing

– High Speed Synchronous DC Motors

– DC Rotary And Scroll Compressors (Japanese Technology)

– Inverter Technology

Synchronous brushless DC

motor

Magnetic Brgs

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AHRI CFC Chiller Task Force

• Most recent estimate: 27,000 CFC chillers still in N.A.• Summit of AHRI and Efficiency Advocates- ACEEE,

ASE, Utilities etc• Plan to use Stimulus moneys to replace CFC chillers• Three targets

– Federal Buildings– State and Local Government Buildings– Commercial Buildings

• Plan: – Gain consensus– Develop communication piece– e.g. CFC chillers at 0.9 kw/ton vs 0.56 kw/ton or 90.1- 2010

standards– Write legislative language to finance using Stimulus funds

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Considerations when Replacing or Retrofitting

• Difficulties in Servicing and Maintaining Existing HCFC Equipment.

• Declining Availability of HCFC Refrigerants.

• Adequate Life-Cycle Timeframes for New Equipment using HCFC’s.

• Determining the Remaining Life-Cycle of Existing Equipment.

• Understanding Alternative Equipment, Refrigerant Options and Compatibility of Both Refrigerants and Equipment.

• Containment is Key……………

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Steps we can take today• To have sustainable HVAC solutions

– Need to focus on overall global impact– No one solution works for everyone

• A focus on components alone– Limited by efficiency of individual components– Need to look at the performance of the system

• A focus on refrigerants alone– May increase energy consumed (indirect effect)– HFC’s are a good solution today

• Focus on overall impact of building– Reduce leaks in system– Increase energy efficiency through performance standards

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Innovative Design AwardInnovative Technology Award

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It’s about the NEXT GENERATION…….

THANK YOU………