LOW  AND  ULTRA-­‐LOW  GWP  REFRIGERANTS  TO  REPLACE  R-­‐404A  AND  R-­‐134a  IN  COMMERCIAL  

AND  INDUSTRIAL  REFRIGERATION  

Cytef2016©  -­‐  Presenta1on    

A. Marta San Román a, *, B. Nacer Achaichia b

a Honeywell  Refrigerants.  C/Josefa  Valcárcel  24,  28027  Madrid,  Spain b Honeywell  Refrigerants.  Gaston  Geenslaan  14,  3001  Heverlee,  Belgium   *Marta.SanRoman@Honeywell.com

©  

Content

•  Low temperature alternatives –  R-448A –  R-455A

•  Medium temperature alternatives –  R-450A –  R-1243ze –  R-1233zd

•  Conclusiones

HFO molecules - Low and medium pressure applications Nonflammable (A1) Mildly flammable (A2L) Examples of potential app.

R-134a GWP=1300

R-1234yf GWP* < 1

Auto A/C, Vending, Refrigerators

R-1234ze GWP* < 1

Chillers, CO2 Cascades Refrigerators, Heat pumps

R-123 GWP= 79

R-1233zd GWP* =1

Centrifugal Chillers High temperature heat pump

HFO/HFC blends Non Flammable (A1) Mildly Flammable (A2) Examples of

potential app.

R-134a GWP=1300

R-450A GWP* = 547

Sols<ce®  N13az  (R-­‐515A**)  GWP*  =  390

Chillers, Med-temp Refrigeration,

Appliances, Heat pumps

R-404A GWP=3943

R-448A GWP* = 1273

R-455A GWP* = 146

Low-Temp Refrigeration

R-22 GWP=1760

R-444B GWP* = 295

Stationary A/C, Refrigeration

R-410A GWP=1923

R-­‐447A  GWP*  =  572  

R-­‐452B**  GWP*  =  698  

(R-­‐447B**  GWP*  =  740  

Stationary A/C Applications

*IPCC,  AR5  **  Provisional  ASHRAE  number  

Today  

Coming  Soon  

R-­‐515A**  GWP*  =  390  

<1  146  547  1273  GWP  

R-­‐448A   R-­‐450A   R-­‐455A*   R-­‐1234ze  

0

5

10

15

20

25

30

35

15 25 35 45 55 65 75 85 95

Energy  Consumption  [kWh/day]

Ambient  Temperature  Bins  [°F]

R404A N40  (R448A)

Between  5  –  15%  lower  energy  consump<on.  

Auchan  (Paris):  first  Sols<ce  N13  hyper    

•  8000m2    Commissioned  

October  2013  

•  Savings  of  960  tons  CO2eq  /  year  compared  with  using  a  

standard  R-­‐404A  DX  system    

Compressor  test  

•  Extensive  Calorimeter  Tes1ng  

•  Improvevs.          R-­‐404A  

•  A2L  Mildly  Flammable  

U2  supermarket  (Italy)  •  Ze/CO2  cascade  

•  Refrigera1on  MT  &  LT  

•  Hea1ng  

•  Sanitairy  Hot  water  •  Cooling  AC  

The  need  of  GWP  going  down  

R-­‐448A  has  lower  consump1on  in  all  

inves1gated  loca1ons  

LCCP  Analysis  

*Preliminary  ASHRAE  #  

1674  

R-­‐407F  

Asda  (Waltmart),  Hunts  Cross  UK    

•  Up  to  15%  saving  in  

system  energy  bills  

•  Up  to  40%  reduc1on  in  system  CO2  emissions  

•  Up  to  10%  improvement  

in  system  running  costs  

                 

Alterna1ves  for  low  temperature  

 

Selec1on  Criteria  

Environment •  TEWI •  GWP •  Energy consumption •  Fgas

Operating Costs •  Taxes (GWP) •  Energy consumption

Cost of Investment •  €/kg •  New / Retrofit •  Equipment cost (new systems) •  Discharge temperature •  Safety •  References

Alterna1ves  for  low  temperature      

  R-­‐407F R-­‐448A R-­‐455A

Baseline R-­‐404A  (A1,  3922  /  3943) R-­‐404A  (A1,  3922  /  3943) R-­‐404A  (A1,  3922  /  3943) Composi<on 40%/30%/30%  

R-­‐134a/R-­‐125/R-­‐32 26%/26%/21%/7%/20%  

R-­‐32/R-­‐125/R-­‐134a/R-­‐1234ze/R-­‐1234yf 75.5%/21.5%/3%  R-­‐1234yf/R-­‐32/CO2

GWP  4th  /  5th 1824  /  1764 1386  /  1273 148  /  145 Class. A1 A1 A2L

Poten<al  app. MT  and  LT  sta1onary  refrigera1on

MT  and  LT  sta1onary  refrigera1on

Self-­‐contained  Condensing  units

Use New/Retrofit New/Retrofit New Drop-­‐in  (1)  Cap. Similar Similar 4%  lower Drop-­‐in  (1)  Eff. 5%  to  10%  higher 5%  to  10%  higher 3%  to  6  %  higher Compressor  (2) Recip,  Scroll,  Screw Recip,  Scroll,  Screw Recip,  Rotary,  Scroll

Comments No  TXV  change  Higher  Tdis  in  LT

No  TXV  change  Good  compressor  envelope Same  Tdis  in  LT

Status Commercial Commercial Samples  available  Commercial  2016

(1)  Drop-­‐in  test  in  non-­‐op1mized  system  (2)  Suitable  compressor  technology  

R-­‐455A  (Sols1ce®  L40X)  •  Pastorfrigor    

–  Chiller  cabinet  originally  designed  for  R-­‐407F  –  Similar  performance  to  R-­‐407F  

–  First  results  also  show  a  benefit  of  a  lower  discharge  temperature  of  an  average  8°C  

•  Calorimeter  test  Embraco  (AHRI    AREP  program)  –  Compressor  NEK2134GK    –  HDR-­‐110  called  in  that  report  –  Slightly  lower  capacity  and  higher  efficiency  

vs  R-­‐404A  

–  Tests  performed  at  dew  point  temperature  for  suc1on  and  discharge  pressure  condi1ons  (AHRI  Standard  540).  

–  For  high  glide  refrigerants,  actual  systems  operate  closer  to  the  mid-­‐point  condi1on  

–  At  midpoint  condi1ons  capacity  of  R-­‐455A  is  within  5%  of  R-­‐404A  in  typical  design  condi1ons  

Results  for  a  single  compressor  cycle    

Evap.    Temp  

Discharge  Temp  (max)  

Cond.  Temp  

Capacity  Efficiency  

(compressor  only)  

[°C]   [°C]   [°C]   [%]   [%]  

R404A   -­‐34.9   100   33.5   100%   100%  

L40X   -­‐34.4   108   36.1   96%   106%  

R-­‐448A  (Sols1ce®  N40)  

Interes<ng  if    •  Further  GWP  reduc1on  is  desired  

–  -­‐65%  versus  R-­‐404A  –  due  to  environmental  goals  or  taxes  

•  Need  to  improve  discharge  temperature  versus  R-­‐407F  

•  A  close  match  to  R-­‐404A  or  R-­‐22  is  required  

–  direct  retrofit  fluid  

Tips    •  Blend  

–  Systems  must  be  charged  with  liquid  from  the  cylinder  

•  Glide  3K  to  5K,  depending  upon  pressure  –  Use  dew  point  senng  for  superheat  

evalua1on/adjustment  

–  Use  bubble  point  senng  for  subcooling  evalua1on/adjustment  

•  Slightly  larger  charge  size  than  R-­‐404A/R-­‐507  

•  For  expansion  valves  or  op1mized  capillary  tube  systems,  typical  charge  size  rela1ve  to  the  R-­‐404/R-­‐507  being  replaced  is  104%  

•  Trial  supermarket  Asda  (Leeds,  UK)  

•  More  than  2  years  tes1ng  R-­‐448A  compared  to  R-­‐404A  

•  Results:  –  Berer  capacity  and  efficiency  versus  R-­‐404A  –  Easy  retrofit  with  minimum  system  adjustments  

–  Discharge  temperature  close  to  R-­‐404A:  liquid  injec1on    was  not  needed  at  LT  

R-­‐448A  in  Asda  (Walmart)  since  2013  

R-­‐448A  in  a  condensing  unit  •  Performance  test  of  a  condensing  unit  •  Evalua1ons1  of  the  condensing  units  were  carried  out  according  to  std  JIS  B  8623  •  Sols1ce®  N40  showed  4-­‐16%  higher  COP  and  excellent  match  in  capacity  in  standard  

and  high  ambient  temperature  condi1ons  

                         

*Performance  evalua1on  of  condensing  unit  using  low  GWP  refrigerants.  Atsushi  BABA,  Hiroichi  YAMAGUCHI,  Toshiba  Carrier  Corpora1on,  Fuji-­‐shi,  Shizuoka-­‐ken,  416-­‐8521,  Japan  

85%

90%

95%

100%

105%

110%

115%

120%

Tevap  -­‐5%… Tevap  -­‐5%… Tevap  -­‐30%… Tevap  -­‐30%…

%  re

specto  al  R

-­‐440

A

Solstice  N40 CapacidadCOP

‘R-448A is well engineered refrigerant

to meet requirement as an alternative to R-404A”

R-­‐448A  -­‐  Eroski  •  Hypermarket  5000m2    •  Berango,  Bizkaia  

•  Remodeling  

•  Opening  May  2015  

•  2,000kg  of  R-­‐448A  

•  Berer  CoP  than  R-­‐404A  

•  GWP  66%  lower  than  R-­‐404A  

•  Lower  emissions  

•  Lower  taxes  •  Problems-­‐free  retrofit  

•  Safe  

•  Time  savings  

•  Direct  replacement  

•  Performance  adjusted  with  valve  adjustment  

Description •  Original R-404A Hussmann distributed system with LT and MT Scroll Compressors •  Same POE oil used for R-448A. Minor Adjustments of TXVs performed.

Results: Energy data integrated over 3 months and compared at same average ambient temp (∼20°C):

!  R-448A system shows ~14%* lower energy consumption (compressor amps 8% lower)

R-­‐448A:  Hussmann  supermarket  

* Results can vary, and are dependent on many system variables.

Energy    kWh/day  

Compressor    Amps  

Condenser  Amps  

R-­‐448A  –  Simply  (Auchan  group)  •  Hyper  3,500m2  in  Zaragoza  (Spain)  •  Commissioned  December  2014  

•  Berer  refrigera1on  performance  than  R-­‐404A  

•  Monitored  energy  consump1on  shows  a  reduc1on  in  line  with  preliminary  es1ma1ons.  

•  GWP  66%  lower  than  R-­‐404A  

–  Lower  emissions  

–  Lower  CO2e  quota  

•  Retrofinng  of  R-­‐448A  was  problem-­‐free    thanks  to  its  direct  replacement  capability  for  R-­‐404A,  making  it  safe,  easy  and  1me-­‐efficient  for  the  technicians  to  perform  the  work.  

R-­‐448A–  Frío  Vizcaya  (for  LAN  Logís1ca)  Characteristics •  Frozen room for -25ºC •  Total capacity around 6,000m3 •  New installation •  Commissioning: April 2015

System design •  Pack: 5 independent refrigeration packs •  Bitzer semi-hermetic compressors •  Settings:

–  T evap : -33ºC –  T cond : +45ºC

•  Cooling capacity: 155kW •  Hot gas defrost

"R-­‐448A    is  suitable  both  for  new  systems  and  for  cost  effecEve  and  simple  conversión  

of  exsiEng  ones,  and  contributes  to  minimize  impact  of  taxes"  

                 

Alterna1ves  for  medium/high  temperature  

 

•  Similar system operating characteristics as R-134a ➜ easy to use/apply •  Compressors: up to 2bar lower tdis than R-134a ➜ longer life •  Larger operating map ➜ flexibility to apply •  Higher COP at higher ambient temperatures ➜ energy savings •  When capacity allows, it can be used in existing systems with little/no

design change ➜ ease of use •  Maintain A1 Safety Class / Non flammable ➜ ease of use

R-450A (Solstice® N13)

Solstice® N13 (R-450): Auchan hyper

CO2 liquide distribué par pompe à -6°C

Groupe de liquéfaction

Retour du CO2 sous forme gazeuse à -36°C

Retour du CO2 sous forme gazeuse à -6°C

CO2 liquide distribué par pompe à -6°C

Retour du CO2 sous forme gazeuse à -36°C

Retour du CO2 sous forme gazeuse à -6°C Fluide HFO N13b

•  Hypermarket París, 8,000m2, •  1,200kg of R-450A •  Cascade system with CO2 •  Screw compressor •  Commissioned Oct'13 •  Very good performance •  58% GWP reduction •  Similar energy efficiency

to R-134a •  90 tons 90 tons CO2eq/y global

savings compared to glicol system (secundary/ R-134a / CO2)

•  960 tons CO2eq/y savings compared to DX and R404A

Solstice® N13 (R-450A)+CO2: Coviran warehouse

•  Opening October 2014 •  Coslada (Madrid), 12,000m2

•  1,020 kg of R-450A •  58% lower GWP vs R-134a •  Higher CoP

•  3 freezer rooms •  One dual-temperature room •  Large, chilled dispatch area, and

incorporates •  2 evaporative condensers

–  CO2 side of the system –  Mid temperature section

Low  Pressure   Med.  Pressure   High  Pressure  

Evaporator  

Off  

Condenser  

!  Operating pressures are function of refrigerant type used. !  Leaks are pressure dependant. !  Low pressure fluids are key to “leak-tight” chillers.

Operating pressures

Solstice® ze in HP for district heating&cooling •  Rolfbuskta: heating & cooling •  Heat source sea water, indirect •  End user : large Scandinavian energy company •  Operating for 2 years •  World largest combined heating&cooling plant with refrigerant with GWP<1

Heating mode  Heating capacity = 16.4MW   LWT= 78ºC (COP=4.83)   LWT 80ºC possible

Cooling mode  Cooling capacity = 20.1MW  COP=4.83

Solstice® ze in food&service equipment

"We  considered  manufacturing  the  cabinet  using  hydrocarbon  refrigerant,"  says  Jeremy  Hall.  "However,  we  decided  that  the  safety  issues  around  hydrocarbon  outweighed  the  relaEvely  small  advantage  in  terms  of  the  slightly  lower  GWP.  We  think  this  is  the  market's  most  sustainable  blast  chiller.”      

     -­‐  Jeremy  Hall,  sales  director  of  Precision  

Celli: summary of field test results   Solstice ze delivered a 99.5% direct emissions reduction over R134a   Solstice ze exhibited lower discharge pressure (around 40% versus

R-134a), thereby reducing compressor mechanical stresses   Solstice ze proved to be a near drop-in replacement for R134a,

ensuring full optimization of current equipment

Precision Launches Eco Blast Chiller

Comfort a/c with GWP<150: technology projection

50  kW  1  kW   500  kW   2MW  

10    

300    

1400

 

700  

R134a

R410A GWP<150 R455A

GWP=1 R1233zd

20+  MW  

GWP<1 R1234ze

"  

"  "  

MT

REF

RI

A/C

Tevap (°C)Tevap (°C)152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20

Tco

nd

(°C

)

Tevap (°C)

152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20

R

FC + SHW

HF

152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20152025303540455055606570

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20

Tco

nd

(°C

)

Tevap (°C)

HP HIGH TEMP

HP REVERSIBLE + SHW

HEATING FLOORS

LT

REF

RI

CO

OLI

NG

HEATING

R32

R410A

R290

LT R

EFR

I

MT

REF

RI

A/C

HEATING FLOORS

HP REVERSIBLE + SHW

HP RENOVATION 1

HP RENOVATION 2

160155150145140135130125120115110105100

9590858075

Es1mated  L40X  MAP  

Typical  R410A  MAP  

Es1mated  R1234ze  MAP  

Es1mated  R1233zd  MAP  

-­‐35      -­‐30        -­‐25        -­‐20        -­‐15        -­‐10        -­‐5            0              5            10          15          20          25            30          35          40          45          50        55        60          65        70        75        80  

R-­‐1234yf  

R-­‐1234ze  

R-­‐1233zd  

L40X  

Typical  R32  MAP  

T con

d  (°C)  

Tevap  (°C)  

HFOs  MAP  analysis  

Solstice® zd    Sols1ce  zd  is  not  listed  in  either  the  EU  F-­‐Gas  or  the  EU  ODS  regula1ons    Not  considered  to  be  an  ozone  deple1ng  substance    Not  considered  a  fluorinated  GHG    Not  subject  to  use  controls    Not  subject  to  cap  &  phase  down    Not  subject  to  de-­‐lis1ng  by  U.S.  EPA    Not  subject  to  separate  waste  stream  treatment  under  the  EU  WEEE  Direc1ve    Sols1ce  zd  is  not  listed  in  the  RoHS  direc1ve  

Conclusions •  HFOs (hydro-fluoro-olefins) with GWP of up to 99 % lower than currently used alternatives •  Good balance of performance, efficiency, serviceability and safety •  Greener way to reduce carbon footprint. •  Low temperature

– R-448A (A1, GWP=1273) as direct replacement for R-404A – R-455A (A2L, GWP=145), planned to be used in condensing units where R-404A is currently

used. •  Medium temperatures

– R-1234ze, GWP<1, A2L, group PED 2 alternative refrigerant to 134a for new systems with proven records in chillers, heat pumps, district cooling and heating, CO2 cascades systems, etc.

– R-450A, A1 with GWP=547, is a high efficiency alternative with proven records as primary stage of CO2 cascade systems and DX medium temperature refrigeration.

– R-1233zd (A1, GWP=1), with higher capacity, and efficiency similar to R-123, is a good replacement in centrifugal chillers and other low-pressure applications.

•  Pure HFOs are non-ozone-depleting substances, not considered fluorinated greenhouses, not subject to use controls nor to cap & phase down and not subject to de-listing by U.S. EPA.

•  New HFO and HFO blends like R-1234ze, R-1233zd and R-455A allow for an extension of the envelope when compared to typically R-410A or R-32 maps.

http://www.honeywell-refrigerants.com/europe/

DISCLAIMER  Although  all  statements  and  informa<on  contained  herein  are  believed  to  be  accurate  and  reliable,  they  are  presented  without  guarantee  or  warranty  of  any  kind,  expressed  or  implied.  Informa<on  provided  herein  does  not  relieve  the  user  from  the  responsibility  of  carrying  out  its  own  tests  and  experiments,  and  the  user  assumes  all  risks  and  liability  for  use  of  the  informa<on  and  results  obtained.  Statements  or  sugges<ons  concerning  the  use  of  materials  and  processes  are  made  without  representa<on  or  warranty  that  any  such  use  is  free  of  patent  infringement  and  are  not  recommenda<ons  to  infringe  on  any  patents.  The  user  should  not  assume  that  all  toxicity  data  and  safety  measures  are  indicated  herein  or  that  other  measures  may  not  be  required.  

                 

 Backup  

 

Low-Temp System Evaluations – System Description

Commercially available 3/4 HP Reach-in Freezer •  Shelf capacity of 700 liters •  Rated refrigeration capacity of about 560W

Top-mount self-contained refrigeration unit •  354g of R404A charge •  1/2 HP reciprocating compressor •  Round-tube in-fin evaporator and condenser •  Typical suction-line/liquid-line heat exchanger •  Adjustable TXV •  Electric defrost every 4h of compressor running time

 

Evaporator  designed  as  parallel  flow  for  R404A  

Low-Temp System Evaluations – Test Details # ASHRAE 72 standard

! System placed in an environmental chamber at 25°C/14°C (db/wb) ! Cabinet volume filed with glycol/water test simulators and frozen food

#  Instrumentation ! Type-T Thermocouples, pressure and power transducers ! Capacity based on air temperature difference across the evaporator

# R404A baseline tested “as is” at the nominal charge

# Near drop-in test of L40X (R455A) !  TXV was slightly adjusted to provide appropriate superheat !  Same POE oil used !  A typical charge optimization was carried out ! Evaporator position was inverted to get counterflow-like configuration for L40X (R455A)

 

Low-Temp System Evaluations – 24h Performance

Results: •  Box and product temps are a match •  Run time ratio only 4% higher, which indicates close match of R404A capacity •  24-h integrated system energy consumption is 97% of R404A. •  Compressor-only energy consumption is 94% •  Large fan power reduced the improvement in the system (artifact of system design)

Run  Time  Ra<o  

Box  Temp.  

Product  Temp.  

24h  Energy  Consump<on  

(compressor  only)  

24h  Energy  Consump<on  

(system)  

[%  of  R404A]   [°C]   [°C]   [%  of  R404A]   [%  of  R404A]  

R404A   100%   -­‐19.1   -­‐18.3   100%   100%  

Sols<ce  L40X  (R455A)   104%   -­‐19.1   -­‐18.6   94%   97%  

Potential for improvement due to low flow rate and effect of large fan power.