Gary Parker Refrigerants Product Manager
Refrigerant History Status of the HCFC ( R22) Phase out Ozone Friendly Alternatives Choosing the Best Retrofit Solution Lubricants and how they impact performance Refrigerant Blends and how to apply them Changes in the Legislative Landscape Global Warming US EPA CA Air Resources Board New Generation Alternatives HFO Refrigerants
Fluorine based Refrigerant History CFC = Chlorofluorocarbon (Phased out in 1996) R11, R12, R113, R114 R500, R502 HCFC = HydroChloroFluoroCarbons (Phase out in 2020) R22, R123, R401, R402, R408, R409, R414 HFC = HydroFluoroCarbons (Phase out under consideration) R32, R125, R134a, R143a, R404, R407, R410, R422A,B,C,D R438A, R507 HFO = HydroFluoroOlefins (Phasing in now) R1233ZD, R1234YF, R1234ZD, R1234ZE R444, R445, R446, R447, R448,R449,R450
Ozone Friendly Alternatives Most all Refrigerant Blends are a mixture of some or all of the following components. HFC R-32, R-125, R-134a, R-143a Hydrocarbon R-200 Series(Propane), R-600 Series (Butane) The mixture and percentage of each component varies depending on the target application for the blend. Design Factors include capacity, mass flow and oil miscibility. (R290/R600) used solely to promote oil return in Mineral Oil systems, and impact performance.
Blend composition
Low Temperature R22 Alternatives
Low Temperature R22 Survivors
HT/AC R22 Alternatives
HT/AC R22 Survivors
Lubricant Choice and the Effect on Performance Proper Oil Return is critical for any Refrigeration or AC System. Miscibility between the refrigerant and the oil is essential. Some refrigerants claim to be no-oil-change solutions. In most cases, they have a very narrow application window and lower capacity. With a non-miscible combination oil logging can occur, which impacts compressor life and performance. Have you ever added oil? It is now widely agreed that only percentage of POE is required to ensure proper oil return. System design and operating temperature will play a key role in determining that %. Additives are now being marketed (Super Change) that improve miscibility, limited to basic close coupled systems..
Liquid Receivers & 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, hydrocarbons are 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)
Elastomers Seals and Leaks Myth There is a belief that introducing POE oil into a system causes a breakdown of seal material causing leaks Fact When an HVACR system is charged the rubber elastomers seals absorb refrigerant and swell. When you remove the HCFC refrigerant the elastomers will shrink to near their original size. When you re-charge the system with an HFC, the absence of Chlorine, reduces the absorption rate and the seal will not swell at the same rate. The retrofit process must include replacing all elastomers and o-ring 12
Elastomers Seals and Leaks Schrader Cores and Caps Open Drive Shaft Seals 13
Elastomers Seals and Leaks Evaporator Pressure Regulator Heat Reclaim Valve Solenoid Valve 14
Elastomers Seals and Leaks 15
Refrigerant Blend Characteristics All Blended (R400 Series) Refrigerants have some measure of glide. Glide is the temperature range in which evaporations or condensing occurs.
Refrigerant Blend Characteristics All Blended (R400 Series) Refrigerants have some measure of glide. Glide is the temperature range in which evaporations or condensing occurs. PT Charts reference both Bubble and Dew points Dew is used to measure Superheat Bubble used to measure Subcooling
Refrigerant Blend Characteristics - Superheat To determine superheat, use the Dew point value. Procedure: Use gauges to determine the pressure at the coil outlet. Use a thermometer to get the temperature at the same point. Get the Dew temperature from the Dew column. Superheat = Actual Temperature Dew Temperature. Example: Find the superheat on an R407C system when the pressure at the evaporator outlet reads 80 psig and your surface thermometer reads 60 F. 80 psig yields ~ 50.7 F (Dew point) Degree of Superheat = 60 F - 50.7 F = 9.3 F
Refrigerant Blend Characteristics - Subcooling To determine subcooling, use the Bubble point Value. Procedure: Use gauges to determine the pressure at the coil outlet. Use a thermometer to get the temperature at the same point. Use the Bubble column temperature. Subcooling = Actual Temperature Bubble Temperature. Example: Find the subcooling on a system using R407C when the liquid line temperature reads 110 F and the liquid line pressure is 300 psig. 300 psig yields ~ 120.4 F Bubble point Degree of Subcooling = 120.4 F - 110 F = 10.4 F
Refrigerant Blend Characteristics - Evaporator Looking at the Evaporator at 80 lbs Liquid would enter the Evaporator at Bubble Point 39.9F A combination of liquid and Vapor would exist until it reached the Dew Point of 50.7F Your actual Evaporator Temp will be near the Average 45.3 Always use the Average value for temperature controlled set points, and equipment selections. Assuming you wanted a 55f discharge air, and a standard 10f what would you do?
Refrigerant Blend Characteristics - Condenser Looking at the Condenser at 300 lbs Vapor would enter the Cond. at Dew Point 128.4 F A combination of liquid and Vapor would exist until it reached the Bubble Point of 120.4F Your actual Coil temp will be near of the average 124.4F Always use the Average value for temperature controlled set points, and equipment selection. Assuming you wanted 125f condensing temperature and a standard 20f TD What would you do.?
Legislative Changes Global Warming is now the focus. Carbon containing CFC, HCFC and HFC are categorized as to High Global Warmers. California Refrigerant Management Program took effect in 2012 All Refrigeration systems/circuits 50lb+ now must be registered. Auto Makers and the Aerosols mfg are phasing out of R-134a. F-Gas Regulations are now in place in Europe. EPA is removing SNAP approval from HGWP HFC s most notably R404/R507/R134A. Design target below 150 GWP will have dramatic impact on systems moving forward.
Next Generation Low GWP Alternatives HFO (Hydro-Fluoro-Olefin) Refrigerants look to be the future. HFO refrigerants have zero ozone depletions and have very low global warming potential. Chemical companies around the world are developing both Pure HFO and blended HFO/HFC Refrigerants, for use in a variety of industries and applications. HFO s are mildly flammable, a new A2L safety classification was created. System design, Blend composition and Energy Efficiency will all be balance against the A2L classification and could have a significant affect on the products that are ultimately made commercially available. HFO R1234YF: Is replacing R134A in automotive AC. Full phase out targeted for 2020. GWP.4
Next Generation Low GWP Alternatives R134A Replacements: R444A (Mexichem AC5) similar in capacity and flammability to R1234YF R445A (Mexichem AC6) similar in capacity with a GWP ~ 130 R450A (Honeywell Solstice N13) similar in capacity with a GWP ~ 600 R513A (DuPont Opteon XP10) similar in capacity with a GWP ~ 600 R404A/R507 Replacements: R448A (Honeywell Solstice N40) Similar capacity with a GWP < 1300 R449A (DuPont Opteon XP40 ) Slightly lower capacity with a GWP < 1300 R449B ( Arkema ARM-32) Slightly lower capacity with a GWP < 1400 R410A Replacement: R446A is an R410A replacement with a GWP < 700 R447A is an R410A replacement with a GWP < 700
Next Generation Low GWP Alternatives
Next Generation Low GWP Alternatives
Next Generation Low GWP Alternatives
Next Generation Low GWP Alternatives Emerson Climate Technologies Announced it is prepared to support customers and devote more resources to qualifying lower GWP(600-1500) A1 refrigerant alternatives such as R448A, R449A, R450A and R513A. The EPA has issued SNAP approval for: HFC - R-32 in room Air Conditioners (A2 flammable) HC Ethane, Isobutene and Propane is specific applications below (A3 flammable) System charge sizes are limited <150 gramsco2 Co2 Refrigeration systems are gaining popularity First in cost 60 to 80% higher than traditional designs System effectiveness and energy cost are questionable at +95f ambient. Availability is still an issue.
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