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Global Refrigerant Shift HCFCs to HFCs
Tony DigmaneseChair of ARI Chiller Product Section
US TAG member & rep to ISO TC86/SC6
Nashville, Oct 9, 2007
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Agenda
BackgroundOzone depletion and global warming
Unitary and light commercial Refrigerants
- HCFC-22 Outlook & Alternatives
- HFC-407C, HFC-410A, HFC-134a,
Large Chiller Refrigerants
- HCFC-123, HFC-134a, HFC-245fa
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Two Environmental Challenges Today
Stratospheric Ozone Depletion
Addressed by the Montreal Protocol, 1987, (191 countries) -Mandatory phase-out of ODS (CFCs & HCFCs for HVAC industry)
Global Climate Change
Addressed by Kyoto Protocol, 1997, (150 countries)
- Limit greenhouse gas emission of developed countries (CO2, CH4, N20, HFC, SF6, PFC)
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Relative Contributions of Greenhouse Gas Emissions (GWP weighted emissions)
Data Source: U.S. Greenhouse Gas Emissions and Sinks: 1990-2002; U.S. EPA
CO2 - 84.5%
CH4 - 8.5%
N2 O - 5.1%F-gases - 2%
( HFCs - 1.7%SF6 - 0.2%PFCs - 0.1%)
2002 U.S. Emissions
CO2 - 81.2%
CH4 - 9.1%
N2 O - 8.4%F-gases - 1.6%
( HFCs - 1.1%SF6 - 0.3%PFCs - 0.2%)
1999 EU (15) Emissions
Data Source:Third Communication from the European Community under the UNFCCC
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Montreal Protocol
In 1990, London Amendment (MOP2) identified HCFCs as transitional substitutes for CFCs
In 1992, Copenhagen Amendment (MOP4) decided phase out schedule for HCFCs, with a cap on consumption
In 2007, Montreal Adjustment (MOP19) decided accelerated phase out schedule for all HCFCs
Eventual phase-out of all HCFCs
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Refrigerant Shift
Shift of Refrigerants in last 15 years
CFCs HCFCs HFCsCFC-11 HCFC-22 HFC-134a
CFC-12 HCFC-123 HFC-407C
HFC-410A
HFC-404A/HFC-507
HFC-245fa
(Phased out) (Transitional) (Long-Term)
(HC CO2 & Ammonia may get into selected niche applications)
DONE ACCELERATED
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Refrigerant Phase-out Schedule
Montreal Protocol Requirements
1996 CFCs
2020 HCFC-22 in new equipmentHCFC-123
2030 HCFC-22 productionHCFC-123
Article 5 countries have a 10-year grace period on above schedule
US has opted to phase out HCFC-22, 10 years earlier (2010)
Most Europe opted to phase out HCFCs in 2001
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In 2007, 9 countries have submitted 6 proposals to phase-out all HCFCs earlier
Montreal Protocol Action on HCFC
HCFCs consumption in developing countries
1989 - 2,300 ODP tons (46,000 tons)
2005 - 20,000 ODP tons (400,000 tons)
DECISION : YES, 10 YEARS EARLIER
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HCFC phase-out Schedule (Non A5 Countries)•20% more reduction overall of HCFCs•10% additional reduction at 2010•05% service tail to be reviewed at 2015
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HCFC phase-out Schedule (A5 countries)•50% more reduction overall of HCFCs•Early baseline, early freeze date, phase-down schedule, service tail
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HCFC phase-out for HVAC Industry
HCFC-22
HCFC-123
Main refrigerants:
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HCFC- 22 Outlook Global R-22 Market
StationaryAftermarket
Stationary OEM
Blowing Agents/Misc.
Polymers
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Market Drivers for Refrigerant ShiftEnergy Efficiency
Application EnvironmentalRegulation
Safety
Refrigerant Market
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R-22 Alternatives Safety and Environment
Safety (non-flammable, low toxicity, Group “A”)
Non ODP = No chlorine atom
Low (similar) GWPHFC-134a = 1300HFC-407C = 1600 HCFC-22 = 1700HFC-410A = 1890
Leak tight design and refrigerant reclaim/recycle programs to reduce direct global warming emission
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R-22 Alternatives Environment (ODP & GWP)
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0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
R-134a Propane R-22 Ammonia R-407C R-410A
Valu
e R
elat
ive
to R
-22
(/)
EfficiencyCapacityPressure
Note:43°F Evaporator Saturation Temperature5°F Evaporator Superheat118°F Condenser Saturation Temperature10°F Subcooling
R-22 Alternatives Performance
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R-22 AlternativesIdentified by Alternative Refrigerant Evaluation Program (AREP)
Industry backed program of major refrigerant suppliers & HVAC manufacturers
HFC-407C
HFC-134aHFC-410A
Major Candidates
Zeotropic BlendHFCs 32(23%)
125(25%),134a(52%)
Near Azeotropic BlendHFCs 32(50%)
125(50%)
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HCFC & HFC global production
HCFC-22 - 650,000 - 700,000 tonsHCFC-123 - 4,000 - 6,000 tonsHFC-134a - 200,000 - 220,000 tonsHFC-400 blends - 40,000 - 60,000 tons
HFC-400s production less than 10% of HCFC-22
Source: UNEP data and refrigerant producers
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Large Chiller RefrigerantsLarge Chiller Refrigerants
HCFC-22
HCFC-123
HFC-134a
HFC-245fa (new)
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Market Drivers for Refrigerant ShiftEnergy Efficiency
Application EnvironmentalRegulation
Safety
Refrigerant Market
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HCFC Environment (ODP & GWP)
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Environmental & safety data for popular refrigerantsRefrigerant Data
Source: ASHRAE and TEAP reports. RCL, refrigerant concentration limit, listed in IMC-2003 and approved by ASHRAE 34 committee & ASHRAE Board. TLV-TWA, threshold limit value – time weighted average, assigned by American Conference of Governmental Industrial Hygienists.
Refrigerant ODP GWP Toxicity RCL (ppm) TLV-TWA (ppm)
HCFC-22 0.05 1700 A1 25,000 1000
HCFC-123 0.02 120 B1 9,100 50
HFC-134a 0 1300 A1 50,000 1000HFC-410A 0 2000 A1 55,000 1000
HFC-407C 0 1700 A1 69,000 1000
HFC-245fa 0 560 B1 34,000 300HFCs are preferred for environment and safety
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Refrigerant SAFETY
High High FlammabilityFlammability
LowLow FlammabilityFlammability
No FlameNo Flame PropagationPropagation
A3Propane ,Butane
B3
A2R-142b, 152a
B2Ammonia
A1R-11, 12, 22, 407C, 410A, 134a
B1R-123, SO2
Lower ToxicityLower Toxicity Higher ToxicityHigher ToxicityA1 Refrigerants are preferred for safety
Source: ASHRAE 34
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HCFC & HFC global production
HCFC-22 - 650,000 - 700,000 tons
HCFC-123 - 4,000 - 6,000 tons
HFC-134a - 200,000 - 220,000 tons
HFC-400 blends - 40,000 - 60,000 tons
HCFC-123 production is 0.5% of total
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New Refrigerant - HFC-245faNew Refrigerant - HFC-245fa
Production started in 2003Main application is to replace HCFC-141b as a foam blowing agent for appliance insulation
Higher capacity alternative to R-123
Higher pressure (~30 psig), between 123 & 134a
Efficiency is close to R-123
EPA approves HFC-245fa as HCFC-123 alternativeAdopted by one international company
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1990(CFC-11)
1995
2000(HCFC-123 & HFC-134a)
2006(HFC-134a)
Centrifugal-Chillers Refrigerant Shift
1995(HCFC-123)
CFCs are gone, HFC-134a now mainstream
Source: YORK marketing data. (Based on global production. 8500-9500 units in 2006.)
2010
134a 245fa (??) 123 (??)CFC11
CFC12
HCFC123
HFC134a
HCFC123HFC134a
HFC134a
HCFC123HCFC22
HCFC22
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How do we compare efficiencies?
Refrigerant efficiency
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Myth of refrigerant efficiency?
Refrigerant efficiency
1. Theoretical refrigerant efficiencies
2. Chiller system design efficiency
3. Real life energy performance efficiency
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Myth of refrigerant efficiency?
Refrigerant efficiency
-Thermal efficiency (HCFC123 has 3.1-3.6% advantage over HFC134a)
-Volumetric efficiency (HCFC123 is 5 times lower, requiring a bigger compressor)
-Heat transfer efficiency (HCFC123 is lower, requiring bigger heat exchangers)
1. Theoretical Refrigerant Efficiencies
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Myth of refrigerant efficiency?
Refrigerant efficiency
2. Chiller System Design Efficiency
- Mechanical efficiency
- Drive efficiency
- Heat transfer efficiency
- Control technologies
- Optimize for FullLoad/FH or PartLoad/PH
(best FL vs best IPLV are not the same unit)
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Myth of refrigerant efficiency?
Refrigerant efficiency
3. Real Life Energy Performance Efficiency
- Full Load and Full Head (Design) (1%)
- Part Load and Part Head (Seasonal) (99%)
- IPLV (ARI Standard) better indicator of annual energy consumption
- Variable Speed Drive (VSD) improves annual energy savings
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Proposal to exempt HCFC123 from early phase-out was not accepted at MOP19
Exemption?
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UNEP IPCC/TEAP 2005 Report on Refrigerants
"HCFCs were successful in meeting the early CFC phase-out goals, but are generally considered undesirable for most new equipment because they do have some ozone-depleting potential; they will eventually be phased out under the Montreal Protocol."
“There can be no trade-offs between saving the ozone layer and minimizing climate change,” said UNEP Executive Director Klaus Toepfer. “This report demonstrates that it is in our power to maintain the Montreal Protocol’s momentum while achieving the Kyoto Protocol’s targets.”
UNEP Position on Refrigerant
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US EPA Position on HCFC Refrigerants
US EPA letter 2006
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WC Screw Chillers
HCFC-22 HFC-134a
AC Screw Chiller
HCFC-22 HFC-134a
AC Scroll Chiller
HCFC-22 HFC-410A
WC & AC Recip Chiller (to screw & scroll)
HCFC-22 HFC-134a, HFC-410A
WC Centrifugal Chiller
HCFC-123 HFC-134a
Chillers Refrigerant ShiftChillers Refrigerant Shift
HFC-407C and natural refrigerants applied in selected European regions
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Thank YouThank You
Acknowledgement to Dupont and Honeywell for supplying some of the information in this presentation