The Changing State of Refrigerants - Refrigeration · PDF file ·...
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The "Changing State" of Refrigerants 3/26/2012
Transcript of The Changing State of Refrigerants - Refrigeration · PDF file ·...
The "Changing State"
of Refrigerants
3/26/2012
3/26/2012
NATE Course # 5397-0001
*** Reclaimed refrigerants not regulated but importing reclaimed R-22 requires EPA pre-approval that includes a detailed history of the recovered refrigerant
Existing Regulations - History • Montreal Protocol A 1987 International Agreement to phase out Ozone Depleting Substance
• US Clean Air Act Was amended in 1990 to adopt the requirements of the Montreal Protocol
• Mandated the rapid phase-out of CFC’s
•Created a detailed phase-out schedule for HCFCs
• Capped production and import rights on HCFCs
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Refrigerant Chemistry •CFC = Chlorofluorocarbon
Rapid phase-out
Stopped U.S. production by 1996
R-11, R-12, R-113, R-114, R-500, R-502
• HCFC = Hydrochlorofluorocarbon Slower, staged phase-out Key dates 2001, 2003, 2010, 2015, 2020, 2030 R-22, R-123, R-124, R-142b R-401a,b R-402a,b, R-408a, R-409a, R-414b, R-416a
• HFC = Hydrofluorocarbon No U.S. phase-out planned R-134a, R-143a, R-152, R-125, R-32, R-404a, R-407a,c,f R-410a, R422a,b,c,d R-427a R-507……..
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0
50%
1999
2001
2003
2005
2007
2009
2011
2013
2015
2017
2019
2021
Year
US HCFC R-22 Phase-Out Plan
R-22 Service Demand
2006 Residential HVAC, the largest user of R-22 adjusts to new efficiency requirements- 30% to 50+% more R-22 is necessary per HVAC unit to meet target.
100%
2015 90% Reduction They Estimate a 60M
pound shortfall based on projected service demand
13 SEER
2010 No New R-
22 Equipment Allowed
2003 US restricts R-22 Imports & Exports.
HCFC R-141b phased out
EFFECTIVE 10-07 2010 Reduction was
amended from 65 to 75%
2020 No R22 Product.
2004 35% Reduction in R-22 production
and import
Effective 1-2011 Annual 10% step-down
thru 2014
Effective 1-2012 EPA Announced a
Immediate 45% cut
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The New Generation “Ozone Friendly“
Refrigerants
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Refrigerant Blend Basics •Most all Refrigerant Blends are a mixture of some or all of the following components
•R-32 HFC •R-125 HFC •R-134a HFC •R-143a HFC •R-200 Series Hydro Carbon (Propane) •R-600 Series Hydro Carbon (Butane)
•The mixture and percentage of each component varies depending on the blend and with (R290/R600) used solely to promote oil return in Mineral Oil systems
•Each manufacture has a vested position in one or more of the components and they Buy or Sell to each other as needed.
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Alphabet Soup HFC Style Refrigerant AKA Manufacture
HFC Fluids Hydrocarbon Fluids R32 R125 R134a R143a R277 R290 R600 R600a R601a
R-134a Multiple 100 R-404A FX70/HP62 Honeywell/Dupont 44 4 52 R-407A KLEA60 Ineos Fluor 20 40 40 R-407B KLEA61 Ineos Fluor 10 70 20 R-407C KLEA 66 SUVA 9000 Ineos Fluor 23 25 52 R-407D 15 15 70 R-407E 25 15 60 R-407F PERFORMAX LT Honeywell 30 30 40 R-410A AZ20 SUVA9100 Honeywell 50 50 R-410B 45 55 R-417A MO59 NU22 Dupont/ICOR 46.6 50 3.4 R-421A RMS of Georgia 58 42 R-422A MO79, One Shot Dupont/ICOR 85.1 11.5 3.4 R-422B NU-22b XAC1 ICOR 55 42 3 R-422C One Shot B XLT1 ICOR 82 15 3 R-422D MO29 Honeywell/Dupont 65.1 31.5 3.4 R-423A 39TC 52.5 47.5 R-424A RS-44 Ref. Services Inc 50.5 47 1.6 0.9 R-426A RS-24 Ref. Services Inc 5.1 93.1 1.3 0.6 R-427A FX100 Arkema 15 25 50 10 R-428A RS-52 Ref. Services Inc 77.5 20 0.6 1.9 R-434A RS-45 Ref. Services Inc 62.3 16 18 2.8 R-438A MO99 Dupont 8.5 45 44.2 1.7 0.6 R-507A AZ-50 Honeywell 50 50
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Low Temperature R22 Replacements
Refrigerant AKA Capacity Relative
to R22
Mass Flow Relative to
R22 Efficency (cop)
rel. to R22 Recommended
Lubricant
IPCC Ver 4 GWP
R-404A FX70/HP62 95% 143% 85% POE 3900 R-407A KLEA60 95% 105% 93% POE 2012 R-407C KLEA 66 SUVA 9000 91% 92% 95% POE 1677 R-407F 22LT 101% 102% 94% POE 1825 R-417A MO59 NU22 72% 99% 90% POE,AB Min 2300 R-421A Choice R-421A 74% 109% 89% POE,AB Min 2600 R-422A MO79, One Shot 89% 160% 82% POE,AB Min 3100 R-422B NU-22b XAC1 75% 108% 88% POE,AB Min 2500 R-422C One Shot B XLT1 87% 152% 83% POE,AB Min 3100 R-422D MO29 79% 123% 86% POE,AB Min 2700 R-424A RS-44 72% 102% 89% POE,AB Min 2400 R-427A FX100 86% 94% 94% POE 2100 R-428A RS-52 97% 170% 81% POE,AB Min 3600 R-434A RS-45 87% 137% 85% POE,AB Min 3200 R-438A MO-99 81% 100% 94% POE,AB Min 2260 R-507 AZ-50 97% 150% 85% POE 3985
NIST Reference Fluid Thermodynamic and Transport Properties-REFPROP Version 8.0 Low Temperature Conditions -20f SST 105f SDT 10f 95f liquid, 30 deg ent Comp 10f SH General Rules:
Mass Flow +/- 30% Requires TXV Modification
POE, AB, Min Products Have Hydrocarbon components that impact performance & efficiency System type, Piping Design and use of Oil Separators will impact the actual performance
http://www.nist.gov/ts/msd/srd/nist23.cfm
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Medium Temperature R22 Replacement
Refrigerant AKA Capacity
Relative to R22
Mass Flow Relative to
R22
Efficiency (cop) rel. to
R22 Recommended
Lubricant IPCC Ver 4
GWP R-404A FX70/HP62 102% 143% 91% POE 3900 R-407A KLEA60 103% 112% 96% POE 2012 R-407C KLEA 66 SUVA 9000 99% 99% 97% POE 1677 R-407F PERFORMAX LT 107% 110% 96% POE 1825 R-417A MO59 NU22 81% 106% 95% POE,AB Min 2300 R-421A 84% 117% 94% POE,AB Min 2600 R-422A MO79, One Shot 98% 163% 89% POE,AB Min 3100 R-422B NU-22b XAC1 85% 116% 94% POE,AB Min 2500 R-422C One Shot B XLT1 97% 157% 90% POE,AB Min 3100 R-422D MO29 89% 129% 92% POE,AB Min 2700 R-424A RS-44 82% 109% 95% POE,AB Min 2400 R-427A FX100 94% 100% 97% POE 2100 R-428A RS-52 104% 170% 88% POE,AB Min 3600 R-434A RS-45 96% 141% 91% POE,AB Min 3200 R-438A MO-99 90% 107% 96% POE,AB Min 2260 R-507 AZ-50 103% 150% 90% POE 3985
NIST Reference Fluid Thermodynamic and Transport Properties-REFPROP Version 8.0 Med Temperature Conditions +20f SST 105f SDT 20f Subcooling and 10f Superheat
General Rules:
Mass Flow +/- 30% Requires TXV Modification
POE, AB, Min Product Contain Hydrocarbon components that impact performance and efficiency System type, Piping Design and use of Oil Separators will impact the actual performance
404A
407A, 407C
407F, 417A
421A,422A,
422B, 422C,
422D,424A,
427A,428A,
434A,438A,
507A
404A, 407A
407C,407F
422A, 422C,
427A, 428A
434A, 438A
507A
90-100% cap match
Commercial Options
407A, 407C
407F,427A
No TXV Change
422A, 422C
428A, 434A
438A
No Oil
Change
R22 Replacements in Med Temp Applications*
422A = 3100
422C = 3100
428A = 2100
434A = 3200
438A = 2260
407A = 2012
407C = 1677
407F =1825
427A = 2100
GWP Values
High Temp - AC R22 Replacement
Performance – It all Depends ……….
80
85
90
95
100
105
110
115
60 80 105 120
% C
apac
ity
Rela
tive
to
R22
Condenser Temperature ~ 20f above Ambient
Refrigeration Capacity +20 Evaporator 10f Superheat & Sub Cooling
R404a
R407a
R422a
R422d
R427a
R438a
Calorimeter Room Tests Typically done a Low Cond
Temps
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R-422B • LT MT AC
•Cap 75% 85% 90%
•Mass FL 108% 116% 119%
• Targeted at Med/AC
• Intended to separate ICOR from R-417a, MO59
• Potential no-oil-change product
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R-422D • LT MT AC
•Cap 79% 89% 94%
•Mass FL 123% 129% 131%
• Targeted at Med/AC
• Used Extensively by WM in 2008
• Potential no-oil Change Product
•AKA MO29
R-407A • LT MT AC
•Cap 95% 103% 110%
•Mass FL 105% 112% 112%
• Targeted at Low/Med
• Requires POE oil
• Currently Most Popular Refrigeration Substitute
• GWP 2012
•Copeland Approved for Retrofit
R-407C • LT MT AC
•Cap 91% 99% 99%
•Mass FL 92% 99% 102%
• Targeted at Med /AC
• Requires POE oil
• Most Popular Full AC Retrofit
• GWP 1677
•OEM Approved New and Retrofit
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R-407F • LT MT AC
•Cap 101% 107% 114%
•Mass FL 102% 110% 110%
• Targeted at Low/Med
• Requires SOME POE oil
• Closest Capacity Match
• GWP 1825 (lowest)
•Copeland Approved for Retrofit
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R-438A • LT MT AC
•Cap 81% 90% 96%
•Mass FL 100% 107% 112%
• Targeted at Low/Med /AC
• May Require POE oil
• GWP 2260
•Copeland Approved for Retrofit
Why all this talk about Oil ? • Proper Oil Return is a critical for any Refrigeration or AC System.
• Miscibility between the refrigerant and the oil ensures the lubricant stays where it belongs ( in the Crankcase). • System design and operating temperature plays a key role • If a system has oil return issues with R22, changing refrigerants will only make it more pronounced. • Generally oils becomes trapped in the receiver, or is logged in the evaporator and low side piping. (Oil is harder to move at low temperature) • Oil logging not only is bad for the compressor but can have a significant impact on the performance of the system. • Oil acts as an insulator and inhibits heat transfer. An oil logged evaporator will act similar to an iced coil
More talk about Oil ? • In the early days Multiple Oil Changes were recommended.
“You must get +99% of the residual oil out”
• Most felt the change was necessary because the oils were not compatible. This was never the case.
• Some refrigerants claim to be no-oil-change solutions, but in most cases, system performance and compressor life are impacted.
• POE Oil is very Hydroscopic so Moisture Management is very important.
• A Vacuum Pump will not pull sufficient moisture from the system, so use a properly sized liquid line drier.
•POE Oil is a very good solvent and can cause issues in older, poorly maintained systems.
•POE can cause damage to new generation roofing materials
•Now it is widely agreed that only percentage of POE is required to ensure proper oil return.
Oil Return Testing
Seals and O-Rings
• Rubber (Elastomers) Seals and O-Rings all absorb refrigerant
• HCFC’s are absorbed more readily - Causing a greater Swell Rate. When the HCFC is removed, the seals contract to near there normal size.
• HFC’s are not absorbed at the same rate so the seals will not swell as much and can cause leaks
• All Elastomer seals and O-Rings must be replaced. •EPR’s (SORIT) •Older Solenoid Valves (Wolverine seals are ok) •Heat Reclaim Valves •Some Open drive shaft seal •Schrader Fittings •Sight Glass Gaskets
•This is true with ALL HFC Refrigerants NO DROP-INS
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Pending Regulations • Now that the wheels in motion to phase out Ozone Depleting Substances, the focus has been turned to Global Warming and the products believed to be the root cause. • GWP is a relative scale which compares the gas in question with carbon dioxide with a GWP of 1. • Refrigerant Gases (CFC’s, HCFC’s and HFC’s) are known to have high Global Warm Potential (GWP) and are under review. • There are a variety of domestic and international policies under consideration that will directly impact this issue and could have a dramatic impact on our industry. •California Refrigerant Management Program IS NOW THE LAW • Auto Makers are scheduled to phase out R-134a in auto AC Europe is underway, GM in 2013. • Proposing a carbon tax on GWP gases – Dead for Now
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New Regulations December 2009: EPA Final Rule - HCFC R-22 Allocation
• Modified the phase out schedule for HCFC’s 2010-2014
Adopted an annual step down of 10% per year
• Formalized Allocation Rights, for manufactures and importers.
No allowance set aside for reclaimers (they were asking for 10%)
•Pre charged New Appliance and Component Rule
What constitutes a new appliance vs a component
What are the limitations.
Company Base Yr Allocation
2010 2011 2012 2013 2014
Arkema 64.9 27.2 24.6 22.1 19.5 16.9 Dupont 85.3 35.7 32.6 29.1 25.6 22.2
Honeywell 77.8 32.6 29.5 26.5 23.4 20.3 Others 34.7 14.6 13.3 11.8 10.4 8.9 Total 263 110.2 100 55 49.5 44.5
Projected Demand
138 126 100 90 80
R22 Allocation Rights By Company (in million-lbs)
They expect the shortfall to be filled by reclaimed or retrofit product
Modified the Phase Out schedule & Allocation Rights for 2010-2014
New Regulations
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New Regulations Pre charged New Appliance and Component Rule
• Appliance Rule
Allows for the sale of factory-charged appliances manufactured prior to 1-1-2010.
Does not prohibit the sale of pre-2010 inventories
No post 1-1-2010 manufactured appliances can be charged with HCFC Refrigerants (Virgin or Reclaimed)
• Component Rule
Allows for the sale of pre-charged components manufactured prior to 1-1-2010. (cond units, coils etc)
Pre-charged components may be used in to service existing equipment, but cannot be assembled to create a new appliance, (unless reclaimed refrigerant is used)
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Nitrogen Charged Units
• Dry units are considered a component and can be charged with R22 in a replacement application. • Some OEM’s are asking EPA plug this loophole in the regs.
• Installing a dry unit with a new Furnace A-coil is prohibited.
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New Regulations January 2011:
California Refrigerant Management Program • Defined a HGWP (High Global Warming Potential) substance as any that has as GWP value greater than 150
• Defined System sizes
Small = 50 to 200 lb charge
Medium = 201 to 1999 lb charge
Large = 2000 lb and greater
• Established Registration and Leak Monitoring requirement based on system size
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GWP of Current Generation Refrigerants
Refrigerant AKA IPCC Ver 4 GWP
R-134a 1430 R-22 1700
R-407C KLEA 66 SUVA 9000 1677 R-407F Proformax LT 1825 R-407A KLEA60 2012 R-410A AZ20 SUVA9100 2100 R-427A FX100 2100 R-438A MO99 2260 R-417A MO59 NU22 2300 R-424A RS-44 2400 R-422B NU-22b XAC1 2500 R-421A 2600 R-422D MO29 2700 R-422A MO79, One Shot 3100 R-422C One Shot B XLT1 3100 R-434A RS-45 3200 R-428A RS-52 3600 R-404A FX70/HP62 3900 R-507A AZ 50 3985
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California Refrigerant Management Program
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California Refrigerant Management Program
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South Coast AQMD Rule 1415-1415.1
•AQMD Governs : LA-OC –SBD-Riverside Counties only
•In Dec-2010 Rule 1415 Modified to cover AC System only. • In Dec-2010 Rule 1415.1 Adopted to match the CARB Refrigerant Management Program.
• AQMD also requires semi-annual inspection of recovery equipment. • All Documentation on the RSD/Refrigerant Suite
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Continuous Leak Monitoring Change – CA Only
• The minimum Alarm threshold is now 100 ppm • Most existing systems are set at 250 ppm
• Instantaneous infrared systems can be reprogrammed (Honeywell Analytics) • Most sample draw systems cannot meet this requirement (CPC)
• 100 ppm Calibration gas will be available soon
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What’s New Secondary Loop Systems
Advantages •Reduces up-front refrigerant costs and minimizes leak potential - Can use a variety of primary refrigerants
•Can use plastic, Vitaulic, or water grade pipe instead of refrigeration grade piping for a 20% to 40% cost savings
•Eliminates TXV’s and EPR’s at the case
• Limits on Effectiveness at Low Temperature
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What’s New CO2 HFC Cascade Refrigeration System
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What’s on the Horizon HFO Refrigerants (Hydro-Fluoro-Olefins)
R-1234yf • The Replacement R-134a in New automotive Model starting in 2011
**Co2 is the other options with several limitations • A Jointly developed by Honeywell and DuPont
• GWP rating = 4
• Very similar performance to R-134a - No Glide • Only a small pilot plant in production now, Currently very expensive
•Commercial production should begin early 2012
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What’s on the Horizon HFO Refrigerant Blends – Cont
• Honeywell’s (Solstice®) refrigerants are now underdevelopment
• Honeywell has already commercialized R-1234ze which is a good LGWP 134a replacement in 1 component foams and aerosol applications. • TEWI* ( Total Equivalent Warming Impact) is the new measure.
*A factor of GWP and energy efficiency • L & N low GWP blends could be available as early as 2013
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What’s on the Horizon HFO Refrigerant Blends
