4/19/2013. The Changing State of Refrigerants

Transcription

1 4/19/2013 The Changing State of Refrigerants

2 Refrigerant Chemistry CFC = Chlorofluorocarbon Rapid phase-out Stopped U.S. production in 1996 R-11, R-12, R-113, R-114, R-500, R-502 HCFC = Hydrochlorofluorocarbon Slower, staged phase-out U.S Product/Imports will stop in 2020, (2030 for R123) 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 at this time. 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 /19/2013

3 US HCFC R-22 Phase-Out Plan 2003 US restricts R-22 Imports & Exports. HCFC R-141b phased out % Reduction in R-22 production and import Effective Reduction was amended from 65 to 75% 100% 65% 2010 No New R-22 Equipment Allowed Effective Annual 10% step-down Effective EPA Announced a Immediate 45% cut 35% 25% Effective EPA Rescinded Announced the a Immediate % Cut cut 10% 0 Year % Reduction 2020 No HCFC Product. 4/19/ SEER

4 4/19/2013 RSD Recovery Program

5 4/19/2013 RSD Recovery Program

6 Ozone Friendly HFC Refrigerant Blends 4/19/2013

7 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. 4/19/2013

8 4/19/2013 Your HFC Choices

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10 4/19/2013 Low Temperature R22 Replacements

11 Medium Temperature R22 Replacement 4/19/2013

12 R22 Replacements in Med Temp Applications* Commercial Options 404A 407A, 407C 407F, 417A 421A,422A, 422B, 422C, 422D,424A, 427A,428A, 434A,438A, 507A % cap match 404A, 407A 407C,407F 422A, 422C, 427A, 428A 434A, 438A 507A No Oil Change 422A, 422C 428A, 434A 438A No TXV Change 407A, 407C 407F,427A GWP Values 422A = C = A = A = A = A = C = F = A = 2100

13 High Temp - AC R22 Replacement

14 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

15 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. Now it is widely agreed that only percentage of POE is required to ensure proper oil return.

16 Oil Return Testing

17 4/19/2013 Compressor Oil Level

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19 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 Shaft Seals on Open Drive Compressor Schrader Cores and Seal Caps This is true with ALL HFC Refrigerants NO DROP-INS

20 Schrader Cores and Seal Caps Compressor Shaft Seal 4/19/2013

21 Evaporator Pressure Regulator Heat Reclaim Valve Solenoid Valve 4/19/2013

22 Liquid Receivers and Hydrocarbon Blends Hydrocarbons (Propane-Butane) are used to help with HFC- mineral oil/ab miscibility. The hydrocarbon only assist oil return in the gas or vapor state using velocity to move the oil. In the liquid form it is of no assistance and the oil can get stranded on top of the refrigerant. To ensure proper oil return, you need to use a truly miscible combination HFC-POE

23 Most Popular Refrigeration Solutions Good Better Best Characteristics R422D R407A R407F System Compatibility Lubricant Compatibility Component Compatibility Near Drop-In for systems without a liquid receiver Works with Mineral AB or POE Oil All Elastomer/o-rings should be replaced Close capacity match with some system change required Requires a % of POE Oil All Elastomer/o-rings should be replaced Closest capacity match with some system change required Requires a % of POE Oil All Elastomer/o-rings should be replaced Expansion Device Compatibility Capacity Relative to R22 No TXV change. Fixed orifices should be evaluated No TXV or Fixed orifice change needed 89% at +20 f 103% at +20 f 95% at -20 f No TXV or Fixed orifice change needed 107% at +20 f 101% at -20 f Environmental & Safety Factors 2700 GWP A1/A1 Rated 2012 GWP A1/A1 Rated Lowest 1825 GWP A1/A1 Rated

24 Popular Air Conditioning Solutions Good Better Best Characteristics R422B R422D - R438A R407C System Compatibility Lubricant Compatibility Component Compatibility Near Drop-In for systems without a liquid receiver Works with Mineral AB or POE Oil All Elastomer/o-rings should be replaced Near Drop-In for systems without a liquid receiver Works with Mineral AB or POE Oil All Elastomer/o-rings should be replaced Closest capacity match with some system change required Requires 20 % of POE Oil All Elastomer/o-rings should be replaced Expansion Device Compatibility No TXV change. Fixed orifices should be evaluated No TXV change. Fixed orifices should be evaluated No TXV or Fixed orifice change needed Capacity Relative to R22 90% at +105 f cond. 94% at +105 f cond. 96% at +105 f cond. 99% at +105 f cond. Heat Pump Considerations Lower discharge temperature may impact heating performance Lower discharge temperature may impact heating performance Similar discharge temperature and heating performance

25 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 2107 Copeland Approved for Retrofit

26 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 4/19/2013

27 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

28 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 4/19/2013

29 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 4/19/2013

30 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 4/19/2013

31 AC Retrofit Considerations and Check list Always use proper tools and safety equipment. Identify and correct any system deficiencies. Record baseline system data. Suction and Discharge Pressure Liquid Sub Cooling and Suction Superheat Temps Compressor Amps Disconnect electrical power. Evacuate the system and weigh the R22 Charge. Replace Elastomers Rubber o-rings and seals. Schrader Cores and Seal Caps Shaft Seals on Open Drive Compressor Older Solenoid Valves (Wolverine seals are ok) not typical on AC System.

32 AC Retrofit Considerations - Continued Change to or add POE lubricant if required. Replace liquid line filter driers and suction filters. Perform a system leak check. Charge the system with replacement refrigerant blend. Start at about 95% of the recovered R22 charge. Charge blended refrigerants in a liquid state using a throttling valve. On Expansion Valve systems us the sub cooling method and refrigerant bubble point. On Fixed Orifice systems use the superheat method and the refrigerant dew point. Allow the system to stabilize and adjust the charge as needed. Label the system showing the new refrigerant and oil.

33 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 Proposing a carbon tax on GWP gases Dead for Now 4/19/2013

34 New Regulations 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 4/19/2013

35 GWP of Current Generation Refrigerants 4/19/2013 Refrigerant AKA IPCC Ver 4 GWP R-134a 1430 R R-407C KLEA 66 SUVA R-407F Proformax LT 1825 R-407A KLEA R-410A AZ20 SUVA R-427A FX R-438A MO R-417A MO59 NU R-424A RS R-422B NU-22b XAC R-421A 2600 R-422D MO R-422A MO79, One Shot 3100 R-422C One Shot B XLT R-434A RS R-428A RS R-404A FX70/HP R-507A AZ

36 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 4/19/2013

37 South Coast AQMD Rule AQMD Governs : LA-OC SBD-Riverside Counties only In Dec-2010 Rule 1415 Modified to cover AC System only. In Dec-2010 Rule Adopted to match the CARB Refrigerant Management Program. AQMD also requires semi-annual inspection of recovery equipment. All Documentation on the RSD/Refrigerant Suite 4/19/2013

38 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 Commercial production now underway 4/19/2013

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40 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 /19/2013

41 4/19/2013 What s on the Horizon HFO Refrigerant Blends

42 4/19/2013 For more info go to www/rsd.net/refrigerantsuite or Call ex 00405

43 Thank you! Gary Parker 4/19/2013