R-22 Alternatives

Stephen V. SpletzerSr. Technical Sales Engineer(610) 878-6980

Learning Outcomes / “Takeaways ”

Legislative / Regulatory Issues

Status of the R -22 Phase-out

Overview of Retrofit Issues

Ability to Make anInformed Retrofit Selection

Legislative / Regulatory Issues

Status of the R -22 Phase-out

NA HFC Submission to the MP

2015 2020 2025 2030 2035 2040 2045 20500

20

40

60

80

100

Year

Cap

(%

Bas

elin

e)

Non-Article 5 Parties

Article 5 Parties

2012 Proposed Allocation Rule

Regulatory Update

Illegal R -22 Importation

●DOJ Activity– HCFC-22 smuggling cases prosecuted

●Catch -22 Compliance Website / Number– http://www.klexserve.com/catch22– (866) 506-6134

●EPA Website– www.epa.gov/compliance/complaints/index.html

R-22 Transition Strategy

Service as usual● Refrigerant price / availability● Leaks

Replacement● Initial equipment costs● Energy savings● Refrigerant recovery

Retrofit● Refrigerant / equipment / labor costs● Refrigerant recovery● Energy costs

Refrigerant Terminology

Replacement Refrigerant : intended for long term use in new equipment

Retrofit Refrigerant : used for

servicing existing systems● Equipment changes● Oil changes

Replacements that are very similar to the original product may be used as retrofits

R-22 Replacement Refrigerants

Air Conditioning Replacements● R-134a● R-410A● R-407C

Refrigeration Replacements● R-404A● R-507A● R-407A

Overview of Retrofit Issues

The Truth About R -22 Retrofits

None work as well as R -22 OVERALL

None are as efficient as R -22 OVERALL

None are “Drop -Ins”

None are miscible with MO or AB

None will work in every R -22 system

Elastomer Changes

R-22 vs. HFCs with elastomers

May need to change seals during retrofit● Schrader valves / caps● Ball valves● Solenoid valves● EPRs● Filter-driers● Sight glasses● Receiver level gages● Etc

Leak check after retrofit

Working with Blends

Blend Identification● 400 or 500 series refrigerants● Azeotropes, Zeotropes, & Near-azeotropes● Charge all blends as liquid

Fractionation: preferential separation of a refrigerant blend’s components that occurs during phase change due to differences in component volatilities, which may affect performance / safety

Glide: a temperature gradient resulting from fractionation (evaporator / condenser) during the phase change process

Blends – Vapor vs. Liquid Charging

= High Volatility= Low Volatility

Blends – Understanding Glide

Evaporator Position

Ref

riger

ant T

empe

ratu

re

T1

T2

T3

T4

T5

1 2 3 4 5

1 2

3

4 5

INLET

OUTLET

= High Volatility= Low Volatility

Blends – Handling Leaks

Blend types● Azeotropes / Near-azeotropes● Zeotropes

Leak types● Liquid vs. Vapor● Running vs. Dormant System

Top–offs

Flooded evaporators

Discharge Temperature Effects

R-22 suffers from high discharge temps● May exceed 300°F,

@ high ambients / low temp

Discharge temps of R -22 retrofits lower● Most typically < 250°F,

even @ high ambients / low temp

Need for liquid injection, desuperheaters, & oil coolers reduced / eliminated

Improved capacity / efficiency for low temp

Ability to Make an Informed Retrofit Selection

R-22 Retrofit Blends

R-404A R-407A R-407C

R-407F R-417A R-417B

R-421A R-421B R-422A

R-422B R-422C R-422D

R-424A R-427A R-428A

R-434A R-438A R-507A

Etc.

R-22

Blend Compositions (weight %)

----------2.7----------18.3-----79.0-----R-417B

-------------------------40.0-----30.030.0R-407F

------------------------------50.050.0-----R-507A-----0.61.7----------44.2-----45.08.5R-438A---------------2.8-----16.018.063.2-----R-434A---------------1.90.6----20.077.5-----R-428A-------------------------50.010.025.015.0R-427A-----0.61.00.9-----47.0-----50.5-----R-424A---------------3.4-----31.5-----65.1-----R-422D---------------3.0-----15.0-----82.0-----R-422C---------------3.0-----42.0-----55.0-----R-422B---------------3.4-----11.5-----85.1-----R-422A

Added--------------------15.0-----85.0-----R-421BAdded--------------------42.0-----58.0-----R-421A

----------3.4----------50.0-----46.6-----R-417A

-------------------------52.0-----25.023.0R-407C-------------------------40.0-----40.020.0R-407A-------------------------4.052.044.0-----R-404A

LubricantR-601aR-600R-600aR-290R-134aR-143aR-125R-32

HFC Component Comparison

1 – Relative to R-22, Standard Cycle @ 105°F Condens er, 25°F Evaporator, 10°F of Superheat & Subcooling2 – From the IPCC AR4

Mass Flow Rate (%) 1

Discharge Temps ( °F) 1

Cond. Pressures (%) 1

Flammability

COP (%) 1

MO / AB Solubility

GWP (100 year) 2

V. R. Capacity (%) 1

- 36

+ 34

+ 62

A2L

- 5

Very Poor

675

+ 60

R-32

+ 84

- 51

+ 31

A1

- 11

Very Poor

3500

+ 7

R-125

+ 25

- 46

+ 19

A2L

- 7

Poor

4470

+ 5

R-143a

+ 8

- 36

- 34

A1

+ 0.6

Very Poor

1430

- 38

R-134a

GWP Comparison

Global WarmingPotential (100 Yr.)

1,700

4,000

2,300

3,200

R-22 G

WP

= 1,810

R-125 / R-143aBased Blends

R-404AR-428AR-434AR-507A

R-125 / R-134aBased Blends

R-417A R-417BR-421A R-421BR-422A R-422BR-422C R-422D

R-424A

R-32 / R-134aBased Blends

R-407AR-407CR-407FR-427AR-438A

High Side Pressure ComparisonBased on Standard Cycle 105°F

Condenser, 25°F Evaporator,10°F Subcooling & 10°F Superheat

0+10-10

-24 +24

-60 +60

R-417A

R-421A

R-424AR-422B

R-438AR-422DR-427A

R-407C

R-407A

R-422C

R-404A

R-421BR-428A

R-422AR-434A

R-507A

(psig)

CondenserPressure ChangeRelative to R-22

Much lower pressure

Lower pressure

Similar pressure

Higher pressure

Much higher pressureR-407F

R-417B

Refrigerant Capacities

Based on Standard Cycle25°F Evaporator,10°F Subcooling

& 10°F Superheat

80 90 100 110 120 13070

75

80

85

90

95

100

105

110 R-404A R-407A R-427A R-422B R-417A

Cap

acity

Rel

ativ

e to

R-2

2 (%

)

Condenser Temperature (°F)

Refrigerant Flow Rate Issues

Most R -22 retrofits require significantly higher refrigerant flow rates than R -22

Flow considerations for retrofit● TXVs● Pistons, orifices, cap tubes● Distributor nozzles● Line sets● Compressor valve plates● Etc.

Mass Flow Rates

R-407FR-407C

R-407A

R-427A

R-404A

R-417AR-417B

R-421AR-421B

R-422AR-422B

R-422CR-422D

R-424A

R-428A

R-438AR-507A

Refrigerant Flow Rates (% Relative to R-22)

R-434A

Based on Standard Cycles65 - 125°F Condenser,

25°F Evaporator,10°F Subcooling,& 10°F Superheat

90 100 110 120 130 140 150 160 170 180 190 200 210

GWP vs. Mass Flow Rate

Refrigerant Flow Rates (% Relative to R-22)

Based on Standard Cycles65 - 105°F Condenser,

25°F Evaporator,10°F Subcooling,& 10°F Superheat

R-404A

R-407A

R-407CR-407F

R-417A

R-417B

R-421A

R-421BR-422A

R-422B

R-422C

R-422D

R-424A

R-427A

R-428AR-434A

R-438A

R-507A

90 100 110 120 130 140 150 160 170 180 190 200 210

Glo

bal W

arm

ing

Pot

entia

l

Oil Miscibility -Use Matrix

YesNoNoHFCs

YesYesYes

(Limited)HCFCs

YesYesYesCFCs

POE (Polyolester)

AB (Alkylbenzene)

MO (Mineral Oil)

All R-22 retrofits are HFC-based refrigerants

All R-22 retrofits are immiscible with MO & AB

Immiscibility Issues - Oil Hold -Up

LIQUID REFRIGERANT

OIL-RICH LAYER

Immiscibility Issues - Oil Logging

21

3

4 5

POE Oil Change Issues

Labor & expense of oil change● Retrofit procedures

Solvency effects● Filter changes● Elastomers

Flushes● Multiple flushes often not required– Oil separators– Dirty installations– Oil concentration / purity

Performance improvement

Oil Change Trade -Offs

R-417A R-417B R-421AR-421B R-422A R-422BR-422C R-422D R-424AR-428A R-434A R-438A

% R-32 & R-143a

0 – 20

Pros

Lower Upfront Cost

Quicker Retrofit

No “POE Issues”

“No Oil Change ”R-404A R-407A

R-407C R-407F

R-427A R-507A

% R-32 & R-143a

20 – 52

Pros

Reduced Oil Logging

Reliable Oil Return

Best Performance

Oil Change to POE

Test Set-Up

1-½ HP R-22 condensing unit / evaporator assembly

Horizontal line-set sloped down from evaporator →→→→ compressor

Optimized refrigerant charge / adjusted TXV superhe at setting

Ran R-422D, R-427A, and R-438A with MO & POE (camer a)

100°F Ambient / 0, 25, & 50 °F Box Temps – “Dry Coil” tests

Condensing UnitEvaporator Unit

Test Data – Oil Return Results

PASSFAILR-438A

PASSFAILR-427A

PASSFAILR-422D

PASSPASSR-22

POEMO

Test Data – MO Runs

0 25 50

4000

6000

8000

10000

12000

14000

16000

R-422D / MO R-427A / MO R-438A / MO

Ref

riger

atin

g C

apac

ity (

Btu

/hr)

Box Temperature (°F)

Test Data – MO vs. POE Runs

0 25 50

4000

6000

8000

10000

12000

14000

16000 R-422D / MO R-427A / MO R-438A / MO R-422D / POE R-427A / POE R-438A / POE

Ref

riger

atin

g C

apac

ity (

Btu

/hr)

Box Temperature (°F)

Testing – Operating Parameters

-25

-20

-15

-10

-5

0

5

10

15

20

25A

vera

ge C

hang

e R

elat

ive

to R

-22

R-422D / MOR-422D / POER-427A / MOR-427A / POER-438A / MOR-438A / POE

SuctionPressure

(psi)

DischargePressure

(psi)

Mass FlowRate(%)

R-22 Retrofit Metrics*

*Standard Cycle 105 °F Condenser, 25 °F Evaporator, 10 °F Subcooling & 10 °F Superheat

Capacity (%)

Capacity (%)

0 0

-5 -5

+5 +5

+15 +15

-15 -15

+25 +25

-25 -25

COP (%)

COP (%)

0 0

-3 -3

+3 +3

+9 +9

-9 -9

+15 +15

-15 -15

MFR (%)

MFR (%)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

Discharge P (psi)

Discharge P (psi)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

Suction P (psi)

Suction P (psi)

0 0

-5 -5

+5 +5

+15 +15

-15 -15

+25 +25

-25 -25

Discharge T (°F)

Discharge T (°F)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

R-427A

Capacity (%)

Capacity (%)

0 0

-5 -5

+5 +5

+15 +15

-15 -15

+25 +25

-25 -25

COP (%)

COP (%)

0 0

-3 -3

+3 +3

+9 +9

-9 -9

+15 +15

-15 -15

MFR (%)

MFR (%)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

Discharge P (psi)

Discharge P (psi)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

Suction P (psi)

Suction P (psi)

0 0

-5 -5

+5 +5

+15 +15

-15 -15

+25 +25

-25 -25

Discharge T (°F)

Discharge T (°F)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

R-404A R-407A

R-407FR-507A

R-407C

R-417A

R-417B

R-421A

R-421BR-422A

R-422B

R-422C

R-422D

R-424A

R-428A

R-434A

R-438A

R-427A

R-404A

R-407A R-407F

R-507A

R-407C

R-417A

R-417B

R-421A

R-421BR-422A

R-422B

R-422C

R-422D

R-424A

R-428A

R-434A

R-438A

R-427A

R-421AR-404A

R-407A

R-407F

R-507A

R-407C

R-417A

R-417B

R-421B R-422A

R-422B

R-422C

R-422D

R-424A

R-428A

R-434A

R-438A

R-427A

R-421A

R-404A

R-407A

R-407F

R-507A

R-407C

R-417A

R-417B

R-421B

R-422A

R-422B

R-422C

R-422D

R-424A

R-428A

R-434A

R-438A

R-427A

R-421A

R-404A

R-407A

R-407F

R-507A

R-407C

R-417A

R-417B

R-421B

R-422A

R-422B

R-422C

R-422D

R-424A

R-428A

R-434A

R-438A

R-427A

R-424AR-421AR-404A

R-407A

R-407F

R-507A

R-407C

R-417AR-417BR-421B

R-422AR-422BR-422CR-428A

R-434AR-422D

R-438A

R-22 Retrofit Metrics*

R-427A

Capacity (%)

Capacity (%)

0 0

-5 -5

+5 +5

+15 +15

-15 -15

+25 +25

-25 -25

COP (%)

COP (%)

0 0

-3 -3

+3 +3

+9 +9

-9 -9

+15 +15

-15 -15

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

Discharge P (psi)

Discharge P (psi)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

Suction P (psi)

Suction P (psi)

0 0

-5 -5

+5 +5

+15 +15

-15 -15

+25 +25

-25 -25

Discharge T (°F)

Discharge T (°F)

0 0

-15 -15

+15 +15

+45 +45

-45 -45

+75 +75

-75 -75

R-407A

R-407C

R-427AR-407A

R-407C

R-427A R-407A

R-407CR-427A

R-407A

R-407C

R-427A

R-407A

R-407C

R-427AR-407AR-407C

Mass Flow (%)

Mass Flow (%)

*Standard Cycle 105 °F Condenser, 25 °F Evaporator, 10 °F Subcooling & 10 °F Superheat

R-22 Retrofit Recommendations

DX Systems OnlyDX Systems OnlyDX Systems OnlyLimitations

POE(MO / AB)*

POEPOEOil

Slight Capacity ↓↓↓↓Moderate Head Pressure ↑↑↑↑

Moderate Head Pressure ↑↑↑↑Cons

Close pressuresNo TXV changes

Lower GWP

Closest MT MatchNo TXV changes

Lower GWP

Closest AC Match No TXV changes

Lowest GWP

Pros

AC, MT, LTMT, LTAC, MTApplication

R-427AR-407AR-407C

* Successfully used with MO and AB with an Oil Sepa rator

Conclusions

Need for R -22 retrofits growing

Many R-22 retrofits● No “drop-ins” / No “1 answer”

Understanding basic HFC components key to differentiating products / advertising claims

HCs help with oil – immiscibility issues remain

R-407C, R-407A, & R-427A are good options