Understanding Applications for Alternative Refrigerants E360 Forum Chicago, IL October 5, 2017 Jason Prenger Director of Engineering Emerson
Disclaimer This presentation is intended to highlight changing developments in the law and industry topics. The law is frequently evolving and information and publications in this presentation may not reflect the latest changes in the law or legal interpretations. The statements and information provided in this presentation should not be construed as legal advice or legal opinion regarding any specific facts or circumstances, but is intended for general informational purposes only. The views and statements expressed during this presentation are the personal opinions of the presenter and do not represent those of Emerson Climate Technologies, Inc. or its affiliated companies. You should consult an attorney about your situation and specific facts and you should not act on any of the information in this presentation as the information may not be applicable to your situation. Although all statements and information contained herein are believed to be accurate and reliable, they are presented without warranty of any kind. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. This presentation may not be copied or redistributed without the express written consent of Emerson Climate Technologies, Inc. 2
Is it reliable? Goals for Today s Discussion Brief discussion on industry drivers Communicate differences in applying lower-gwp A1 refrigerants Reliability and performance Discuss which challenges face the different channels OEMs, wholesalers, contractors, end users Update on A2L/A3 refrigerants Industry activity Emerson s readiness and facility investment 3
Refrigerant Options A1 Non-Flammable A2L Mildly Flammable A3 Flammable B2L Toxic, Mildly Flam. Pressure or Capacity R-410A Like CO 2 R-447B R452B R459AR-32/HFO Blends 400 675 R-32 Available now OEMs testing R-410A Qualitative Not to Scale Established R-404A & R-407/22 Like NH 3 R-290 <150 R-455A R-454C R-457A ~300 R-444B R-454A R-448A R-449A R-449B < 1,500 R-32/HFC/HFO Blends R-22 R-407A R-407C R-407F, R-452A R-452C R-404A R-507A (3,922) R-134a Like R-123 Like (V. Low Pr.) HFO 1234yf HFO 1234ze DR2, HFO 1233zd R-515A ~600 R-513A R-450A R-134a 0 500 1,000 1,500 2,000 GWP Level HFC/HFO Blends Lower-GWP Synthetic Refrigerants, Blends and Natural Refrigerants Are Available Options in Various Applications. 4
Summary of EPA s Refrigerant SNAP Approval and Delistings by Application Final Rule 20: July 20, 2015 Final Rule 21: September 26, 2016 Stand-Alone Refrigerant GWP Supermarket (New**) Supermarket (Retrofit***) Remote condensing unit (New) Remote condensing unit (Retrofit***) MT < 2,200 BTU/hr. and not contain flooded evap. (New) MT 2,200 BTU/hr. with or without flooded evap. (New) LT (New) LT and MT (Retrofit***) Refrigerated food processing and dispensing equipment (New) Cold storage warehouses (New) Ice machines (New) Very low-temp refrigeration (New) R-404A/507A 3,943 Jan. 1, 2017 July 20, 2016 Jan. 1, 2018 July 20, 2016 Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 July 20, 2016 Jan. 1, 2021 ^Jan. 1, 2023 OK OK R-452A 2,140 - - OK OK - - - - - - - - R-410A 2,088 OK - OK - Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 - Jan. 1, 2021 ^Jan. 1, 2023 OK OK R-407A R-407C R-407F 1,923 1,624 1,674 OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 OK ^Jan. 1, 2021 R-407A: ^Jan. 1, 2023 R-407C/F OK HFC-134a 1,300 OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK OK OK OK - OK R-407C only R-448A R-449A 1,282 1,296 OK OK OK OK Neither SNAPapproved, nor banned Neither SNAPapproved, nor banned OK OK for LT only - - OK - R-513A R-450A 573 547 OK OK OK OK OK OK OK OK OK OK OK - R-290 3 - - - - OK OK OK - - - OK OK R-744 1 OK - OK - OK OK OK - OK OK - OK R-717 0 OK (in primary loop of secondary system) - OK (In primary loop of secondary system) - OK (in primary loop of secondary system) OK (in primary loop of secondary system) OK (in primary loop of secondary system) OK (in primary loop of secondary system) OK (in primary loop of secondary system) OK OK - ** Includes ice machines connected to a supermarket rack refrigeration system. *** EPA uses term retrofit to indicate the use of a refrigerant in an appliance that was designed for and originally operated using a different refrigerant. Term does not apply to upgrades to existing equipment where the refrigerant is not changed. *Abbreviated; for complete listing, see EPA website. 5
Refrigeration Application Alternatives Emerson s Approvals in Progress or Complete A1 Non-flammable A2L Mildly flammable A3 Flammable B2L Toxic, mildly flam. Volumetric Capacity / Pressure Elevated Medium R-404A like Low R-134a like Naturals R-744 (CO 2 ) 1 R-290 (Propane) 3 R-717 (Ammonia) 0 Mildly Flammable (A2L) HFO and Blends R-455A (HDR-110) 146 R-454C (XL20) 146 R-457A (ARM-20a) 139 HFO-1234yf <1 HFO-1234ze <1 ARM-42 131 Lowest GWP Non-Flammable (A1) HFC/HFO blends R-449A (XP40) 1,282 R-448A (N40) 1,273 R-449B (ARM-32) 1,296 R-513A (XP10) 573 R-450A (N13) 547 R-515A 392 Today s Non-flammable (A1) HFCs R-407A 1,923 R-507A R-407C 3,985 1,624 R-404A R-407F 3,943 1,674 R-134a 1,300 GWP 0 5 0 150 350 1,300 1,300 4,000 This List Is Subject to Change. Please Check Publication, Form 93-11 or With Emerson Representatives for the Most Current Approvals in Progress. 6
Is it reliable? Goals for Today s Meeting Brief discussion on industry drivers Communicate differences in applying lower-gwp A1 refrigerants Reliability and performance Discuss which challenges face the different channels OEMs, wholesalers, contractors, end users Update on A2L/A3 refrigerants Industry activity Emerson s readiness and facility investment 7
What Should a Compressor Manufacturer Do to Qualify a New Refrigerant? A Great Amount of Due Diligence Needs to Be Done by Compressor Manufacturers When Qualifying New Refrigerants for an Application. 8
Theoretical Discharge Temperature (Medium-Pressure) Low-Temperature (-25 F Evaporator) Medium-Temperature (20 F Evaporator) assumes 100% isentropic efficiency Compressor Cooling Will Be Needed for Many R-404A Replacements in Low-Temp Applications. 9
Condensing Temp, F R-404A A1 Low-GWP Alternatives Have Higher Heat of Compression 150 Medium-Temperature Operating Envelope ZSKA 140 130 120 110 100 90 80 70 60 404A 231 F 448A 273 F 404A 199 F 448A 224 F 50 Internal discharge line temperature 6 inches from compressor discharge 40-15 -5 5 15 25 35 45 Evaporating temp, F R-448A and R-449A have similar temperature profiles. Increase in Discharge Temperature Dependent on Condition 10
Condensing temp, F Condensing temp, C R-404A vs. R-448A Operating Envelopes ZS*KA Example Evaporating temp, C -40-34 -29-23 -18-12 -7-1 4 10 160 150 140 130 120 110 100 90 80 70 60 50 40 30-40 -30-20 -10 0 10 20 30 40 50 Evaporating temp, F 71 66 60 54 49 43 38 32 27 21 16 10 4-1 Check Application Engineering Bulletin Before Applying the Same Compressor in an Application With Different Refrigerants. 11
Condensing temp, F Models With Liquid Injection Can Still Run Full Operating Envelope Capabilities 160 ZF**K4E operating envelope R-404A/R-407A/R-448A/R-449A 150 140 130 120 110 100 90 80 70 60 50 40 30-40 -30-20 -10 0 10 20 30 40 50 Evaporating temp, F Compressors Running Higher Heat of Compression Refrigerants Can Run Reliably With Injection; More Power Will Be Consumed. 12
Theoretical Discharge Temperature (Low-Pressure) Low-Temperature (-25 F Evaporator) Medium-Temperature (20 F Evaporator) Discharge Temperature Minimal Concern for Low-Pressure Refrigerants. 13
Condensing Temp, F R-134a A1 Alternatives Have Very Similar Heat of Compression Characteristics 150 Example of extended medium-temperature operating envelope 140 130 120 110 134a 171 F 450A 166 F 513A 174 F 100 90 80 134a 160 F 450A 155 F 513A 144 F 70 60-30 -20-10 0 10 20 30 Evaporating Temp, F Operating Envelopes for R-450A and R-513A Equivalent to R-134a Maps 14
Theoretical Compressor Capacity (Medium-Pressure) Low-Temperature (-25 F Evaporator) Medium-Temperature (20 F Evaporator) assumes 100% volumetric efficiency, dew point condition R-404A Replacements Do Not Deliver as Much Capacity. 15
Mid-Point vs. Dew Point and the Refrigeration Cycle Heat exchangers (condenser and evaporator) operate at mid-point (or bubble/dew) conditions. Compressors see dew point conditions. When there is no glide and assuming little/no pressure drop, the temperature at mid-point = temperature at dew point. Assume negligible pressure drop effects. 16
Mid-Point vs. Dew Point and the Refrigeration Cycle (cont d.) But when there is glide Bubble Dew Per AHRI standards, compressors are rated based on dew point pressure/temperatures. Temperature When there is glide and assuming little/no pressure drop, the temperature at mid-point temperature at dew point. Assume negligible pressure drop effects. 17
Temperature Glide Is Significant for A1 R-404A Replacements Refrigerant Temperature Glide F R-404A ~1 F R-407A ~8 F R-448A ~7 F R-449A ~7 F R-452A ~5 F Significant considerations needed for temperature glide (system component sizing, etc.) 18
Scroll MT Dew Point Capacity R-404A vs. R-407A/R-448A (20/120) 19
Scroll MT Mid/Dew Point Capacity R-404A vs. R-407A/R-448A (20/120) Why is this delta important? 20
Scroll LT Mid/Dew Point Capacity R-404A vs. R-407A/R-448A (-25/105) Compressor sizing should be done off of mid-point. 21
Scroll MT Mid/Dew Point Weighted EER R-404A vs. R-407A/R-448A 22
Scroll LT Mid/Dew Point Weighted EER R-404A vs. R-407A/R-448A 23
Temperature Glide Is Significant for A1 R-404A Replacements, not so for R-134a Refrigerant Temperature Glide F R-404A ~1 F R-407A ~8 F R-448A ~7 F R-449A ~7 F R-452A ~5 F R-134a 0 F (single component) R-450A ~1 F (near azeotrope) R-513A 0 F (azeotrope) Significant considerations needed for temperature glide (system component sizing, etc.) No glide considerations necessary 24
Theoretical Compressor Capacity (Low-Pressure) Low-Temperature (-25 F Evaporator) Medium-Temperature (20 F Evaporator) 25
Capacity (BTU/Hr) Capacity (BTU/Hr) Hermetic LT Capacity R-134a vs. R-450A/R-513A 1600 R-450A/R-513A vs. R-134a Capacity 5/95 40 F RG 3000 R-450A/R-513A vs. R-134a Capacity -10/120 40 F RG 1400 1200 1000 R-134a baseline -14.1% vs. R-134a +4.0% vs. R-134a 2500 2000 R-134a baseline -14.7% vs. R-134a +7.0% vs. R-134a 800 1500 600 1000 400 500 200 0 Compressor: AFE12C4E R-134a R-450A R-513A 0 R-134a R-450A R-513A 26
WEER Hermetic HT Weighted EER R-134a vs. R-450A and R-513A 9.00 R-450A/R-513A vs. R-134a WEER (65 F return gas) 8.00 7.00 6.00 R-134a baseline -0.5% vs. R-134a -1.2% vs. R-134a 5.00 4.00 3.00 2.00 1.00 0.00 Compressor: ARE51C4 R-134a R-450A R-513A Weighted EER Condition = 20% (20 Evap / 120 Cond) + 80% (20 Evap / 70 Cond) 27
Is it reliable? Goals for Today s Meeting Brief discussion on industry drivers Communicate differences in applying lower-gwp A1 refrigerants Reliability and performance Discuss which challenges face the different channels OEMs, wholesalers, contractors, end users Update on A2L/A3 refrigerants Industry activity Emerson s readiness and facility investment 28
Alternate Refrigerants Challenges Through the Channel OEMs Wholesalers Contractors End Users Component selection SKU proliferation Training Regulatory compliance System redesigns Counter-training Retrofit challenges Sustainability goals Engineering resources Inventory planning Energy consumption Testing constraints Short-term vs. long-term change Regulation Uncertainty What Challenges Are You Faced With, Given All the Change in the Industry? 29
Is it reliable? Goals for Today s Meeting Brief discussion on industry drivers Communicate differences in applying lower-gwp A1 refrigerants Reliability and performance Discuss which challenges face the different channels OEMs, wholesalers, contractors, end users Update on A2L/A3 refrigerants Industry activity Emerson s readiness and facility investment 30
Other Refrigerants, Standards, Code-Related Activities Federal acquisition regulation encouraging low-gwp usage in federal buildings Safety standards under revision to include mildly flammable refrigerant (A2L) accommodations U.S.: UL 1995, ASHRAE 15 2018 International: ISO 5149, IEC 60335, EN378 Target late 2017 CARB will start rulemaking process this fall that will affect high-gwp HFCs Section 608 revisions to refrigerant management now include HFCs EPA plans to revisit rule in response to petitions Evaluating revisions on increasing charge limits for flammables U.S. A3 charge limit from 150g to 300g 500g October meeting in Russia for IEC to make a decision on A3 charge limits Building codes for mildly flammable refrigerants being expedited for adoption in 2021 code cycle $5.2M partnership by AHRI, ASHRAE, DOE to study flammable refrigerant behavior in real-world applications Refrigerant-related Changes Are Global in Scope. 31
Emerson Is Investing in A3/A2L Testing Capability to Be Prepared A3/A2L performance stands (10 200K) Life test stands Ambient chamber (0 F 120 F) Functionality Coming Online Throughout 2017 32
Thank You! Questions? DISCLAIMER Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information 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 information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations 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. 33