The R-404A Challenge. Commercial Opteon Refrigerant Solutions - The New Industry Standard

Transcription

1 Opteon Refrigerants The R-404A Challenge. Commercial Opteon Refrigerant Solutions - The New Industry Standard Mark Hughes Business Development Manager Opteon Refrigerants

2 Agenda Intro Chemours The Chemical Company F Gas Regulations and Market Consequences The size of the problem and possible solutions Opteon solutions - A1 commercial HFO blends Opteon XP40 - Results and market progress Why the Industry standard? March 2,

3 A start-up with more than 200 years of experiences More than 6000 Employees Serving over 5000 customers in 130 countries Excellent portfolio, divided into TiO 2, Fluoroproducts and Chemical Solutions

4 F-Gas regulation and it s market consequences March 2,

5 New Equipment Service Bans HFC Phasedown The Three Pillars Of F-Gas II F-Gas II - (EU) 517/ 2014

6 EU-Regulation(EU) 517/ 2014 Service Ban (Control of use in article 13 (3)) Jan 2020 STOP of HFC and HFC-containing (GWP>2500) above 40t of CO2-e (e.g. >10,2kg R404A); means Supermarkets, industrial Refrigeration, larger food stores, etc. Exceptions: a. Military Equipment b. Applications with product temp <-50 C, e.g. R23/ R508 c. Recycled/ Reclaimed HFCs with GWP>2500 is allowed until end of 2029

7 EU F-Gas II: Drivers for Low GWP Precharge Volume = required CO 2 -equivalents for precharged equipment (ca. 12 %) Precharge Volume Precharge Volume Pre-charge impact Precharge Volume Cap reduction impact Drivers for low GWP 404A replacements: Cap/reduction supply & price pressures on 404A GWP limits ban 404A GWP (AR4) 404A 3922 GWP Limits GWP Limit GWP Limit 407A 2107 New 2500 Service 2500 > 10kg 404A New centralized >40kW 150 New centralized >40kW Primary of cascade F a 1430 XP

8 The potential solutions (1) Not-In-Kind refrigerants Many large end users have a program for new install A lot of noise in the market but what are the facts? Must play a part but the drawbacks limit speed and spread of implementation 8

9 Can 100% of the market go to naturals to meet the cap? Natural refrigerants xx Use constraints CO 2 New systems only. Retrofit not possible (high pressure). Inefficient in high ambient climates. hydrocarbons ammonia Theoretically YES.practically NO! Naturals not possible/practical for retrofit, top-up of installed systems. Naturals have constraints for range of new equipment use safety, cost, codes/standards. Limited industry capacity & skilled contractors for installed base replacement with Natural equipment. New systems only. Very small charge size only; retrofit not allowed (highly flammable; codes/standards). New systems only; retrofit not allowed (flammable, toxicity, codes/standards). Non-public areas. Market Use Good choice for supermarket low T in cascade with HFC for med T use growing in EU. 100% CO2 systems only practical in N.EU. Common choice for hermetically sealed small refrigeration/freezing equipment. Growing use for some low T freezing in discount supermarkets in EU. Common for industrial refrigeration. Lower GWP HFO blends Confidentialrequired to meet the CAP

10 Carbon Dioxide Equivalent Emissions Energy Efficiency will be the major Environmental Concern Loss of 10% in Energy Efficiency=Loss of all benefits of eliminating HFCs 100 If Energy Efficiency Decreases by 10% If Energy Efficiency is Maintained Intended Effect of Phasedown by 2030 Refrigerant Energy Phasedown but with - 10% Energy Efficiency 2030 Source: EPEE Bangkok presentation

11 The potential solutions (2) Lower GWP HFCs 407A/407F are offered for retrofit or new install Large marketing effort has influenced uptake Proven energy savings versus R-404A Lower GWP than R-404A 407F has issues with high discharge temperature GWP level means likely to have to replace in future Only an interim solution

12 How will the market change by 2030? 12

13 Prognosis for Commercial Sector into 2030 HFC/ HFO-Refrigerants in Commercial Refrigeration Mill t kt 15,5kt 11,1 Mill t Vol. [ kt ] CO2-eq [ Mill t CO2-eq ] Criteria: Retail vs. Cond. units is 50%-50%; refrigerant decrease of 0,5%/ year

14 GWP (AR4) Sustainability of F Gases in EU R404A/ R407A/F ISCEON MO29 R410A ~ 2000 GWP R407C 1500 Opteon XP40 R134a 1000 R32 Opteon XP Recycled HFO Others CO 2 Equivalent (Million tonnes)

15 GWP (AR4) Sustainability of F Gases in EU * R407A/F ~ 2000 GWP R407C 1500 R134a Opteon XP Other HFO Opteon XP10 B250 Opteon XL41 R32 0 Recycled CO 2 Equivalent (Million tonnes) * SKM Enviros & DuPont assuming the quantity of refrigerant used remains constant

16 GWP (AR4) Sustainability of F Gases in EU R407A/F ~ 2000 GWP R407C Opteon XP R134a 1000 Opteon XP10 R32-80 % 500 ~ 400 GWP Others HFO Opteon XL40 & Opteon XL20 Opteon XL41 0 Recycled CO 2 Equivalent (Million tonnes)

17 Volume as a percentage of 2015 HFC/HFO Volume Relative Volumes (Tonnes Product) represented as a Percentage of the 2015 HFC/HFO Volume 100% HFC/HFO Reclaim Other 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

18 The Immediate Problem (1) Large banks of installed R-404A/R-507A Equipment still being installed on R-404A R-404A is today still a cheap option and widely used The market does not understand what is coming Inertia from end users and contractors EU wide Confusion in the market - R-???

19 The Immediate Problem (2) Excerpt from EPEE Gapometer project

20 Which new Alternative Refrigerants are already available Today? March 2,

21 Refrigerant Selection Best Balance of Properties for each Application Non-FGas are best sometimes; not always. HFOs are necessary for cost-effective, safe transition. Zero-ODP, Low-GWP, Favorable LCCP Favorable Toxicity No or Low Flammability Safety and Sustainability System Energy Efficiency + Capacity Performance Cost to Use First Cost + Operating = Total Cost to Use ** ** Impacted by maturity of technology Timing of Commercial Availability NOW

22 Low GWP Options - HFOs CFC HCFC HFC HFO Chloro-Fluoro-Carbon Hydro-Chloro-Fluoro-Carbon Hydro-Fluoro-Carbon Hydro-Fluoro-Olefin HFO-1234yf CF 3 CF=CH 2 Unique properties: Stable in operating system Not stable in atmosphere = low GWP Efficient performance

23 A long term solution HFO blends why? GWPs low enough to be maintained under the cap A range of products for different applications Formulated to give best balance of properties Can use in existing equipment Easier to handle than Not-In-Kind refrigerants Opteon Refrigerants The Future is Clear

24 Opteon Refrigerants Refrigerant Opteon XP10 (R-513A) Opteon XP40 (R-449A) GWP* 631 (573) 1397 (1282) Flammability Class (ASHRAE)** Commercially Available 1 YES 1 YES Application Area Refrigeration & AC replacing R134a in DX and flooded systems Medium & Low Temperature Refrigeration Opteon XP44 (R-452A) Opteon YF (R-1234yf) Opteon XL20 (R454C***, DR-3) Opteon XL40 (R-454A, DR-7) Opteon XL41 (R-454B, DR-5A) Opteon XL55 (R-452B***, DR-55) 2141 (1945) 4 (1) 148 (146) 239 (238) 466 (467) 698 (676) 1 YES 2L YES 2L Planned L Planned 2016 Transport Refrigeration and small LT hermetics Automotive AC & Small Charge Refrigeration Small Hermetic Medium and Low Temperature Refrigeration Small non-hermetic Medium and Low Temperature Refrigeration 2L Planned 2016 AC Replacement for R-410A 2L Planned 2016 AC Replacement for R-410A (Preferred R-410A replacement for Trane) *Intergovernmental Panel for Climate Change (IPCC) Assessment Report 4 (AR4) values used for EU F-Gas Legislation. IPCC Assessment Report 5 (AR5) values given in brackets for comparison. **ASHRAE Flammability class 2L must be used in accordance with the current codes and standards e.g. EN-378. *** Preliminary assignment and classification

25 Alternative Refrigerants commercially available today R134a Alternative March 2,

26 Opteon XP10 Replaces R134a ASHRAE #: R-513A HFC/HFO blend: R1234yf / R134a (56% / 44%) ODP: Zero Ozone Depletion Potential GWP: 631 (AR4) ASHRAE safety: A1 non-flammable Glide: 0K (Azeotrope) Can be topped off while servicing (do not mix with R-134a) Compatible with POE lubricants Compressor approvals: Bitzer, Emerson, many others in progress

27 Opteon XP10 Competitive Benchmark Calculations using Bitzer Software (v rev1302) in 4FES-3Y Reciprocating compressor, at 40ºC Condensing Temperature Opteon XP10 R134a R450A Capacity + 23 % C.O.P. 27

28 Opteon XP10 Evaluation in Supermarket Hybrid System Retrofitted from R-134a Medium Temp; CO 2 in Low Temp Running for >three years 28

29 Opteon XP10 Approved by Trane Trane Announced the use of Opteon XP10 for EcoWise Chillers in January 2015

30 Opteon XP10 Approved by York Centrifugal and Screw Chillers 30

31 Alternative Refrigerants commercially available today R404A Alternatives March 2,

32 Opteon XP40 Replaces R404A ASHRAE #: R-449A HFC/HFO blend: R32 / R125 / R1234yf / R134a (24.3%/24.7%/25.3%/25.7%) ODP: Zero Ozone Depletion Potential GWP: 1397 (AR4) ASHRAE safety: A1 non-flammable Glide: ~4-5K Can be topped off while servicing (do not mix with R-404A) Compatible with POE lubricants Compressor approvals: Bitzer, Emerson, Frascold, Dorin

33 Ahold, Marum, Netherlands Retrofit from R407F to Opteon XP40 R-407F Base Data gathered from July to November 2013 Opteon XP40 Data Measured from November 2013 until June 2014 Medium (100 kw) and Low temperature (14 kw) Racks Monitored Copeland Compressors (MT = 1x D4DH % & 2x D4DA-200x, LT = 1x D3DC-100 & 2x D3DA-75X Danfoss ADAP-Kool Controller and electronic expansion valves 3/2/

34 Medium Temperature Power Consumption vs Outside Temperature T outside (ºC) Power consumption of Opteon XP40 vs R407F % % % 34

35 Low Temperature Power Consumption vs Outside Temperature T outside (ºC) Power consumption of Opteon XP40 vs R407F % % % 35

36 LT Maximum Compressor Discharge vs Outside Temperature T outside (ºC) T discharge of Opteon XP40 vs R407F K K K 36

37 Italian Supermarket Medium Temp Cascaded with LT CO 2 Cabinet & Expansion Valve Models Compressor Models (Bitzer Screw) Compressor Model Quantity Range Capacity / W 1 HSK / +45 C HSK /+45 C HSK /+45 C HSK /+45 C HSK /+45 C HSK /+45 C Total Capacity / W Margin relative to requirement / W (11,01%) 37

38 System Measurements Daily Average Temperature of 28ºC 38

39 Energy Comparison Daily Power vs Daily Ambient Temperature -9% 39

40 Belgian Supermarket Retrofit 2 Medium Temperature (MT) Racks each with 2 Bitzer 4J-22.2Y (35kW) compressors. Rack A has an expected maximum load of 46kW and Rack B an expected maximum load of 73kW. The Low Temperature (LT) rack (Rack D) has 3 Bitzer 4NCS-12.2Y (8.63 kw) compressors with cooling fans fitted and an expected maximum load of 24kW. 47 cabinets (35 MT and 12 LT) with 10 cold rooms (8MT, 2LT) operating on the racks. All the cabinets and cold rooms use Danfoss (TE) thermostatic expansion valves. 40

41 Medium Temperature System 19ºC Average Daily Temperature 41

42 Low Temperature System 19ºC Average Daily Temperature 42

43 Daily & Cumulative Power Consumption for Days with Similar Temperatures Click to edit Master title style

44 Working with GEA Refrigeration Industrial applications replacing R-404A and R-507 March 2,

45 New installation CoOp convenience stores Opteon XP40 chosen for new stores in Lincoln CoOp One third the GWP of R-404A Lower GWP than interims such as R-407A/F Chosen as a long term solution for equipment lifetime Finalist Environmental Project of the Year ACR News Awards 2016 March 2,

46 UK Supermarket Retrofits/Refits Watch this space! March 2,

47 Opteon XP40 Approvals Opteon XP40 (R-449A) Approvals, Many More Soon

48 Opteon XP40 - Approvals In both product types Frigolink and Frigoentry the new refrigerant Opteon XP40 (R449A) will be fully supported & included in the near future.

49 Opteon Refrigerants Refrigerant Opteon XP10 (R-513A) Opteon XP40 (R-449A) GWP* 631 (573) 1397 (1282) Flammability Class (ASHRAE)** Commercially Available 1 YES 1 YES Application Area Refrigeration & AC replacing R134a in DX and flooded systems Medium & Low Temperature Refrigeration Opteon XP44 (R-452A) Opteon YF (R-1234yf) Opteon XL20 (R454C***, DR-3) Opteon XL40 (R-454A, DR-7) Opteon XL41 (R-454B, DR-5A) Opteon XL55 (R-452B***, DR-55) 2141 (1945) 4 (1) 148 (146) 239 (238) 466 (467) 698 (676) 1 YES 2L YES 2L Planned L Planned 2016 Transport Refrigeration and small LT hermetics Automotive AC & Small Charge Refrigeration Small Hermetic Medium and Low Temperature Refrigeration Small non-hermetic Medium and Low Temperature Refrigeration 2L Planned 2016 AC Replacement for R-410A 2L Planned 2016 AC Replacement for R-410A (Preferred R-410A replacement for Trane) *Intergovernmental Panel for Climate Change (IPCC) Assessment Report 4 (AR4) values used for EU F-Gas Legislation. IPCC Assessment Report 5 (AR5) values given in brackets for comparison. **ASHRAE Flammability class 2L must be used in accordance with the current codes and standards e.g. EN-378. *** Preliminary assignment and classification

50 Opteon XP44 Replaces R404A/R507A ASHRAE #: R-452A HFC/HFO blend: R32 / R125 / R1234yf (11% / 59% / 30%) ODP: Zero Ozone Depletion Potential GWP: 2140 (AR4) ASHRAE safety: A1 non-flammable Glide: 3-4K Can be topped off while servicing (do not mix with R-404A) Compatible with POE lubricants Compressor approvals: Frascold, many others in progress Applications: High compressor discharge temperature e.g. transport.

51 Opteon XP44 Performance Comparison Capacity, COP and Compressor Discharge temperatures are almost identical to R404A. Ideal for Applications where low compressor discharge temperatures are essential. T cond = 40ºC, Compressor isentropic efficiency = 0.7, evaporator superheat = 5K, total subcooling = 5K, suction line superheat = (T 51 cond -10-T evap )*0.35

52 Transport Refrigeration Opteon XP44 (R452A) March 2,

53 Transport Refrigeration Opteon XP44 (R452A) Carrier Transicold has announced at the CV Show that it will offer R452A as an optional alternative to the existing R404A refrigerant. R452A has the same cooling capacity, fuel efficiency, reliability and refrigerant charge as R404A, but offers a 45 per cent GWP reduction. 53

54 Opteon XP44 Approved by Tecumseh GWP Discharge Temperature

55 Commercial Refrigeration - Opteon XP40 Over 200 supermarkets already Retrofitted in Europe. Germany, Netherlands, Spain, Italy, Belgium, Austria, UK, Greece, Sweden... Different makes of compressors and operating modes and technologies such as MT, LT, cascade systems More than 1000 installations using Opteon XP40 by the end of Minor or no adjustments made and no component or oil changes needed. To date all retrofits to Opteon XP40 have shown an improvement in refrigeration system power consumption compared with R-404A/ R-507A and R- 407F. Many more projects with major supermarkets and other refrigeration applications are in progress.

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57 Help and Support Product Information Case Studies Retrofit Guidelines Technical Data 57

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