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Johnson Controls, Inc. —

CHILLERS WITH LOW-GWP REFRIGERANTS

Fortaleza / 30 March 2016 Eric ColinJohnson Controls, Inc.

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Terms & Definitions: RefrigerantsGlobal Warming Potential (GWP)Total energy a gas absorbs over a time period (usually 100 years) compared to carbon dioxide

Low-GWP refrigerantNo uniform definition, but implications of proposed regulations suggest 675-750 GWP range is acceptable based on a number of R-410A alternatives such as R-32. These include natural refrigerants, a number of blends and HFOs.

Hydrofluoro-Olefin (HFO) refrigerantChemical compounds composed of hydrogen, fluorine and carbon ( GWP < 150)

HFO/HFC blends refrigerantBlends of HFOs with HFCs, most commonly R-32 or R-134a, targeted for drop-in and retrofit applications for performance closely matching HFCs, but with reduced GWP < 750.

Natural refrigerantA fluid readily found in nature, but can also be produced with low-GWP. Examples include CO2, ammonia, and hydrocarbons (propane, isobutene, etc.)

Mildly flammableA new class of less flammable refrigerants with a designation of 2L per ASHRAE 34. These are considered difficult to ignite and sustain a flame.

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Terms & Definitions: Types of chiller systems

Air-cooled� Equipment resides outdoors

� Location on the roof, or on a concrete foundation

� Limited to no direct exposure of refrigerant into building air stream

Water-cooled� Equipment resides indoors in equipment room

� Direct exposure to building air stream

- R134a, R-410A, and R-22 most common.

- Flammable and non-flammable Refrigerant options are being proposed.

- Flammability will affect both indoor and outdoor equipment, but more significantly impact water-cooled products.

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100%

90%

65%

33%

3%0% 0%

65%

25%

10%

1% 0%0%

20%

40%

60%

80%

100%

1980 1990 2000 2010 2020 2030 2040 2050

% o

f bas

elin

e

Developing Countries Developed Countries

Eliminate 100%

The mandated HCFC phase-out is proceeding per plan and will prohibit new equipment using R-22 and R-123 globally

Source: U.S. EPA

R-22 phase-out for high ambient applications was a significant challenge for industry and the regions affected. R-410A was not ideal for high ambient and acceptance was limited.

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Support for an HFC phase-down is growing, and there is convergence leading to a possible global agreement.

0%

20%

40%

60%

80%

100%

2015 2020 2025 2030 2035 2040 2045 2050

% o

f bas

elin

eHFC Phase-Down Proposals

India North America Micronesia European Union

Actions already underway targeting mobile AC & commercial refrigeration which account for 65% or more of the total emissions

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Absence of an international agreement is making a transition more complex than in the past

� Asia plays a much greater role in the use and development of key products such as chillers and VRF.

� Regions with hot climates have not generally accepted R-410A, and are holding out with R-22 in the absence of a viable high ambient solution

1987

Developed countries

Developing countries

2014

TIBET

QINGH

AI

Refrigerant manufacturer location

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The optimal refrigerant choice will vary by application

Low

er p

ress

ure

Med

ium

pre

ssur

e

High temp heat pump

High ambient radiated

Air-cooled condenser

Evaporative-cooled

Water-cooled

Data center

Chilled beam

Comfort cooling

Ice thermal storage

Low-temp brine

Air source heat pump

Hig

her

pres

sure

Climate and application driven designs for heat rejection or heat re-use

Type of cooling needed for comfort or process

Ideal application range will vary by refrigerant

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Refrigerant emissions are complicated by a wide variety of end uses across multiple industries.

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Source: U.S. EPA

(i.e. R410A) (i.e. R134a, R1234yf) (i.e. R123, R245fa)

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� Challenges to be addressed:� Energy efficiency� Funding requirements� Safety of substitutes� Availability of technologies� Performance and challenges in high ambient temperatures� Second and third conversions� Capacity building� Nonparty trade provisions� Synergies with the UNFCCC (legal, financial aspects)� Relationship with the HCFC phase out� Ecological effects� Implications for human health� Social implications� National policy implications� Challenges to the production sector� Rates of penetration of new alternatives� Exemptions and ways to address lack of alternatives� Technology transfer

According to the Montreal Protocol working group, many factors need to be addressed for a full transition from HFCs can happen.

Excerpt: 2015 April 22-24, Montreal Protocol, OEWG Meeting, Bangkok, Thailand

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A viable alternative for R-22 is lacking for high ambient applications

Ambient Temperature

°C °F

AHRI 35.0 95.0

Eurovent 35.0 95.0

Hot 52.0 125.6

Extreme 55.0 131.0

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There are multiple alternatives targeted at replacing R-410A, but no perfect solutions…all have some degree of flammability

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There are multiple alternatives targeted at replacing R-134a, but no perfect solutions

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Natural refrigerants sound like a great solution, but also come with challenges or barriers to entry (or limitations) into commercial markets

R-717(Ammonia)

R-290(Propane)

R-718(Water)

� Good efficiency� Toxicity an issue

for widespread adoption

� Good efficiency� Highly flammable

� Great when using waste energy

� Higher cost� Technology stigma

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ODP vs. GWP vs. efficiency vs. safety vs. reliability vs. cost vs. availability vs…..

� Complex choices with no perfect answers

� Trade-offs between low GWP and safety(where flammability is not accepted, applied, or allowed)

� Trade-offs between low GWP and efficiency(unintended consequences of MORE greenhouse gas emissions!)

� Trade-offs between low GWP and product cost(acceptable performance at what cost?)

� A more robust dialog is needed about the real obstacles for low GWP

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� ASHRAE and ISO have added the mildly flammable refrigerant classification define as flammable, but difficult to ignite and sustain a flame.

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Flammable refrigerant classifications have been revised to include a mildly flammable classification 2L.

A3

A2

A1

B3

B2

B1

Higher

Refrigerant safety groups

Higher

Lower

No flame propagation

Lower Higher

Fla

mm

abili

ty

Toxicity

A3

A2

A1

B3

B1

Refrigerant safety groups

A2L

B2

B2L

Higher

Lower

No flame propagation

Difficult to ignite & sustain

Lower Higher

Fla

mm

abili

ty

ToxicityA2L: R32, R1234yf, R1234zeB2L: R717

Historically, refrigerants with level 2 or 3 flammability are not permitted or seldom used (where permitted) in commercial applications.

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Safety implications for product design, operation and service

� Flammability� Flammability has significant implications on cost, product configuration, and risk for the

manufacturer

� Compliance to regional equipment room and product safety codes:

� Adaptation of wiring, electronics, electrical connections, motors and drives

� Ventilation requirements, safeties, and leak detection for the room and/or equipment

� Liability risk for equipment that we may not maintain

� Implication to Service� Training of technicians on safe use flammable refrigerants.

� Cost of additional equipment and compliance with transportation regulations.

� Regional variation in technician capability and requirements

� Pressure:� Pressure vessel code requirements become a cost driver as the design working

pressure of the refrigerant increases.

� Material compatibility� Oils, materials of construction, etc. to reduce risk of flammable or higher toxicity

refrigerant leakage

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Building codes & construction practices must be updated & enforced before flammable refrigerants can be used safely in commercial applications.

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State/Local Gov’t

Local adoption of building codes

LawLocal adoption of

building codes

EnforcementLocal adoption of

building codes

EnforcementLocal adoption of

building codes

UMC, IBCBuilding codes

IBC, GB, CEBuilding codes

ASHRAE 34Refrigerant Safety

Classification

ISO 817GB/T 7778

Refrigerant Safety Classification

ASHRAE 15Safe design, construction, installation &

operation

ISO 5149GB 9237

Design, construction, installation &

operation

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� Energy Efficiency Directive (2012/27/EU)� Driving efficiency, leading to reduce waist energy & retrofit buildings� Major impulse due to 3% of governments buildings be renovated each year.� Requires market / government needs compliant contro ls (i.e. B-AWS).

Key Directives In Europe

Energy and Climate related directives in Europe and their impact

EPBD� Energy Performance of Buildings Directive (2010/31/EU)� nZEB* mandatory by Jan. 2019 (public), Jan. 2021 (others)� Driving Efficiency in Buildings, leading to for exa mple smaller more efficient chillers..� … as well as increasing number of controls (OEM) and with higher complexity.

ECODESIGN� Eco-Design Directive (2009/125/EC)� Ban for products below minimum seasonal energy efficiency levels (non CE mark)� Driving efficiency requirements focus on part load efficiency, requiring better controls

FGAS� F-Gas regulation (517/2014)

� Phase down for HFCs used in HVAC (Chillers). Baseline 2015, -79% by 2030

RES� Renewable Energy Sources Directive (2009/28/EC)� Recognize heat pumps as renewable source, if technology meets minimum efficiency requirements.� Driving growth for Heat Pumps

EED

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� CE marking for Chillers will now include the new Eco-Design Directive (2009/125/EC) that sets out the Minimum Efficiency Performance Standards : MEPS.

� Sets new Minimum standard of Efficiency that must be reached to enable “CE” Certification.

� Units with efficiency below target cannot be sold.

� The building regulations will push for highest possible chiller efficiency, above the MEPS.

� The standards focus off design efficiency replacing ESEER with SCOP (Seasonal coefficient of Performance [H.P.]) - SEPR (Seasonal Efficiency Process Ratio) - SEER. Seasonal Energy Efficiency Ratio).

What is Eco-design

Key Directives In Europe

ECODESIGN

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Agriculture, power production, waste and deforestation are key contributors to global greenhouse gas emissions

Chillers use f-gases

Chillers use energy

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Chillers are a small fraction of the overall greenhouse gas emissions from the mobile & stationary HVAC&R industries

Source: US EPA, Global Mitigation of Non-CO2 Greenhouse gases: 2010-2030. September 2013, EPA-430-R-13-011

Small unitary AC 31%

Large retail food 31%

Motor vehicles 16%

Refrigerated transport 8% Cold storage 6%

Large unitary AC 2%

Medium retail food 2%

Small retail food 1%

Window units & dehumidifiers 1%

PTAC/PTHP <1%

Positive displacement chillers <1%

Centrifugal chillers 1%

Household refrigerators 1%

<2%

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Equipment and technology advancements are needed to optimize chillers for low-GWP alternatives or risk an increa se in net CO2 emissions by consuming more energy

� Sources of greenhouse gas emissions from chillers

� Indirect – from power generated by burning fossil fuels� Inefficient equipment

� Poor maintenance

� Incorrect charge

� Lack of controls and optimization

� Misapplication

� Direct – from emissions of refrigerant� Leaks left unrepaired

� Accidental release during servicing

� Refrigerant not properly reclaimed at end of life

Indirect are as high as 95% over the life

of the equipment

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Refrigerant performance comparison for screw chillers

� R-513A drop-in yields a little extra capacity, but at lower efficiency

� R-1234ze drop-in loses significant capacity. Heat exchangers are oversized and mask efficiency loss.

� Adjusting for equal capacity (all units have same cost basis)

� R-134a provides the best efficiency

Drop-in Adjusted for equal capacity (customer spec)

Capacity Efficiency Capacity Efficiency

R-134a 100 1.00 100 1.00

R-513A 102 0.98 100 0.95

R-1234ze 75 1.00 100 0.91

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Efficiency has a much greater impact on emissions than refrigerant GWP

� Total equivalent warming impact (TEWI) provides a net impact of performance including refrigerant emissions and energy consumption

� Energy efficiency is the most effective means of reducing greenhouse gas emissions from chiller products

� R-134a provides best life cycle climate performance with the lowest greenhouse gas emissions of all four refrigerants due to its high efficiency

Emissions due to GWP <2%

Average 98% emissions

due to energy

Assumptions: Air-cooled screw chiller, 5.15 COP, 0 .4 kg CO2/kWh, 15 year chiller life, 2% leak rate, 90% recla im

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R-134a Low-GWP alternative performance line-up

Larger compressor

Larg

er h

eat

exch

ange

rs

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First cost premium for low-GWP is significant vs. current HFC offering for the same customer specifications

Smaller premium realized when able to stay within a model family size range

Refrigerant drives selection into larger equipment for the same specified performance

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� Many of the new HFO base molecules are being sold in adjacent sectors (foam and automotive).

� Many of the medium and high pressure alternatives are mixtures of existing HFCs with HFOs.

� HFOs will always be some multiple of current HFC prices because they are more complex molecules that require additional production steps to produce.

Low GWP refrigerant options remain expensive compared to today’s refrigerants

Life-cycle cost and environmental performance are essential

� Concerns about climate change are driving creating uncertainty and

confusion in the industry.

� Lacking an international agreement, regional regulations are emerging.

� Higher emitting applications are targeted for some specific bans

(i.e. commercial refrigeration and mobile AC).

� Industry is evaluating potential alternatives to the most common

refrigerants, R22, R404A, R410A and R134a.

� Availability, safety, efficiency, cost and reliability present challenges for

low-GWP refrigerants to become viable solutions.

� Industry must address impact of mildly flammable refrigerants.

� Energy efficiency has the greatest impact on HVAC greenhouse gas

emissions and cost of ownership.