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

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

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)

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

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

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

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

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

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

HCFC phase-out Schedule (A5 countries)•50% more reduction overall of HCFCs•Early baseline, early freeze date, phase-down schedule, service tail

HCFC phase-out for HVAC Industry

HCFC-22

HCFC-123

Main refrigerants:

HCFC- 22 Outlook Global R-22 Market

StationaryAftermarket

Stationary OEM

Blowing Agents/Misc.

Polymers

Market Drivers for Refrigerant ShiftEnergy Efficiency

Application EnvironmentalRegulation

Safety

Refrigerant Market

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

R-22 Alternatives Environment (ODP & GWP)

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

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%)

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

Large Chiller RefrigerantsLarge Chiller Refrigerants

HCFC-22

HCFC-123

HFC-134a

HFC-245fa (new)

Market Drivers for Refrigerant ShiftEnergy Efficiency

Application EnvironmentalRegulation

Safety

Refrigerant Market

HCFC Environment (ODP & GWP)

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

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

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

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

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

How do we compare efficiencies?

Refrigerant efficiency

Myth of refrigerant efficiency?

Refrigerant efficiency

1. Theoretical refrigerant efficiencies

2. Chiller system design efficiency

3. Real life energy performance efficiency

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

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)

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

Proposal to exempt HCFC123 from early phase-out was not accepted at MOP19

Exemption?

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

US EPA Position on HCFC Refrigerants

US EPA letter 2006

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

Thank YouThank You

Acknowledgement to Dupont and Honeywell for supplying some of the information in this presentation