Update On ASHRAE Society Meetings Daniel Dettmers (djdettme@wisc.edu) HVAC&R Center/Industrial Refrigeration Consortium University of Wisconsin www.irc.wisc.edu (866) 635-4721 ASHRAE Technical Committees Section 1.0 Fundamentals and General Section 2.0 Environmental Quality Section 3.0 Materials and Processes Section 4.0 Load Calculations and Energy Requirements Section 5.0 Ventilation and Air Distribution Section 6.0 Heating Equipment, Heating and Cooling Systems and Applications Section 7.0 Building Performance Section 8.0 -- Air-Conditioning and Refrigeration System Components Section 9.0 -- Building Applications Section 10.0 -- Refrigeration Systems ASHRAE Technical Committees What s there to do at ASHRAE? Section 10.0 -- Refrigeration Systems TC 10.1 Custom Engineered Refrigeration Systems TC 10.2 Automatic Icemaking Plants and Skating Rinks TC 10.3 Refrigerant Piping TC 10.4 Ultra-Low Temperature Systems and Cryogenics TC 10.5 Refrigerated Distribution and Storage Facilities TC 10.6 Transport Refrigeration TC 10.7 Commercial Food and Beverage Cooling Display and Storage TC 10.8 Refrigeration Load Calculations TC 10.9 Refrigerated Food and Beverage Applications TC 10.1: Custom Engineered Refrigeration Systems Concerned with one-of-a-kind industrial applications of standard or special equipment to meet specific refrigeration requirements. 1514-WS Thermal Energy Recovery from Industrial Refrigeration Systems 1634-WS Guide for Sustainable Refrigerated Facilities and Refrigeration Systems 1448-RP Ventilation Requirements for Refrigeration Machinery Rooms (TC 4.3) 1472-RP Experimental Validation of Modeling Tools for Mixed Gas Refrigeration Cycles 1602-WS - Thermal-Fluid Behavior of Mixed Refrigerants for Cryogenic Applications ASHRAE Standard 15: Safety Code for Mechanical Refrigeration TC 10.3: Refrigerant Piping Concerned with the design, layout, sizing, specification, insulation, oil carrying characteristics, safety and corrosion of refrigerant piping, excluding secondary refrigerant piping. 1513-WS Liquid/Vapor Separating Velocities for Industrial Refrigeration Systems RP- Methodology to Measure Thermal Performance of Pipe Insulation at Below- Ambient Temperatures (TC1.8) 1
10.5: Refrigerated Distribution and Storage Facilities Concerned with the application of standard and special refrigeration equipment to cold storage warehouse operations... WS 1434 - Refrigerated Facilities Doorway Infiltration Air Energy Reduction RTAR 1433 - The Effect of Loss of Vapor Barrier Integrity on Insulation Performance for Facilities Operating Below 0 F Standards: CA Title 20, 24 New ASHRAE Std: Rating of Walk-ins (10.7) ASHRAE Std 62.1 ventilation requirements for refrigerated spaces? 20 Handbook Chapters Inherited 18 from TC 10.9: Refrigerated Foods and Beverages 10.8: Refrigeration Load Calculations Concerned with the identification and compilation of the factors contributing to, and the development of, procedures for calculating refrigeration load??? MTG: Alternative Lower Global Warming Potential Refrigerants MTG will coordinate TC/TG/TRG technical activities to help transition the HVAC&R industry to sustainable lower Global Warming Potential (GWP) alternative refrigerants. The MTG responsibilities include suggestions for research, development and presentation of technical programs of all types on alternative lower GWP refrigerants, suggestions for Life Cycle Climate Performance (LCCP) systems evaluation for different applications, development of lower GWP solutions for different applications, and a special publication detailing aspects of LCCP applied to the HVAC&R fields. ASHRAE Handbook Committee 12 year commitment to the ASHRAE Handbook Committee Currently serving year 6 as chair of 2014 Refrigeration Handbook Interested in Reviewing? www.ashrae.org > Resources and Publications > Handbook > Comment on the Handbook PAOE points? ASHRAE Position Document What Else is ASRHAE Doing? Served on: Ammonia as a Refrigerant Natural Refrigerants Ozone-Depleting Substances Currently developing: Refrigerants and their Responsible Use Due for a vote at next ASHRAE Board of Directors Meeting 2
Dan s History of Refrigerants Refrigerant Selection Update R-22 s gone, what s next? Daniel Dettmers (djdettme@wisc.edu) HVAC&R Center/Industrial Refrigeration Consortium University of Wisconsin www.irc.wisc.edu (866) 635-4721 1826 Fredric The Ice King Tudor becomes a millionaire by shipping ice from New England across the U.S. and as far as Brazil and India Nathanial The Engineer Wyeth invents various ice plows and other devices to make this possible 1857 1 st canned ice factory constructed Future plants use NH 3 or CO 2 1927 GE Monitor Top refrigerator debuts Used SO 2 (toxic) or Methyl Formate (flammable) Public relations nightmare ensues as refrigerators tend to causes blindness, lesions and death or blow up housewives Dan s History of Refrigerants 1928 Fridgidare asks General Motors lab to come up with a safe refrigerant Cl Cl 3 days later, Thomas Midgley develops R-21 C 1931 - Midgley invents R-11 and R-12 F F 1936 Midgley invents R-22 1938 My father-in-law drowns one of his dad s horses into Long Lake near Madge, WI This ends natural ice harvest in Madge My F-I-L hides for 3 days in the forest 1974 Rowland and Molina publish paper in the journal Nature defining the effects of chlorofluorocarbons on the ozone layer Dan s History of Refrigerants 1985 - UNEP/WMO/ICSU conference concluded that greenhouse gases "are expected" to cause significant warming in the next century 1987 Montreal Protocol CFC s & HCFC s phaseout 1997 Kyoto Protocol HFC s targeted 2006 Al Gore releases An Inconvenient Truth 2009 Copenhagen Summit Copenhagen Accord drafted Where Are We Now? CFC s gone HCFC s going, going HFC s Safe? Not everywhere Kyoto Protocol targets them as a greenhouse gas for reduction/phaseout What do they want? 0 ozone depletion 0 or very low global warming High efficiency Inherently safe Safety & ODP/GWP of Refrigerants Chemical Lifetime ODP GWP Safety Refrigerant Formula Years (R11) (CO 2 ) Classification CFC-11 CCl 3 F 45 1.000 4680 A1 CFC-12 CCL 2 F 2 100 1.000 10720 A1 CFC-113 CCl 2 FCClF 2 85 1.000 6030 A1 CFC-114 CClFCClF 2 300 0.940 9880 A1 CFC-115 CClF 2 CF 2 1700 0.440 7250 A1 HCFC-22 CHClF 2 12 0.050 1780 A1 HCFC-123 CF 3 CHCl 2 1.3 0.020 76 B1 HCFC-124 CHClFCF 3 5.8 0.020 599 A1 HCFC-141b CH 3 CCl 2 F 9.3 0.120 713 HCFC-142b CH 3 CClF 2 17.9 0.070 2270 A2 HFC-32 CH 2 F 2 4.9 0.000 543 A2 HFC-125 CHF 2 CF 3 29 0.000 3450 A1 HFC-134a CF 3 CH 2 F 14 0.000 1320 A1 HFC-143a CH 3 CF 3 52 0.000 4400 A2 HFC-152a CH 3 CHF 2 1.4 0.000 122 A2 R-717 NH 3 0.000 00 B2 R-718 H 2 O 0.000 0 A1 HC-290 C 3 H 8 0.000 0 A3 3
R-22 Outlook Total Projected R-22 Servicing Demand Will there be shortages of: R-22? Replacement parts? EPA has a DRAFT report on HCFC s to see if cap reductions are possible It is a preliminary draft report, not to be cited Source: The U.S. Phaseout of HCFC, U.S. EPA 100 80 60 40 20 HCFC Phaseout Schedule -2007 % Reduction in National Consumption of HCFC s Cap at 1989 ODP- weighted HCFC + 2.8% CFC consumption. 35% reduction of cap 75% reduction of cap (formerly 65%) 2009 EPA step down reduction in R-22 production 90% reduction of cap 99.5% reduction of cap, but 0% allocation to R-22 How Are We Doing? Dupont predicts HUGE shortfalls 2010 virgin allocation not used (recession) 0 2000 2004 2010 2015 2020 2030 0% What About Equipment? 12/23/09 issued 2 statements seeming to ban sale of all R-22 equipment, replacement components and servicing 1/14/10 a Fact Sheet issued to clarify the EPA s position http://www.epa.gov/ozone/title6/phaseout/rulesoverview.html Sale and distribution allowed of: Equipment if manufactured before 1/1/10. Pre-charged appliance components manufactured before 1/1/10 Components manufactured on or after 1/1/10, for the servicing of existing appliances as long as they do not contain a charge of virgin R-22 or a blend with virgin R-22 or R-142b. Not allowed: Field-charging appliances with virgin R-22, -142b or a blend containing either. Source: www.epa.gov/epa-air/2008/december/day-23/a29999.htm, www.epa.gov/epa-air/2008/december/day-23/a29965.htm What Are The Alternatives? Stockpile Purchase large quantities for future use and/or sale Ties up money, incurs storage costs, may not need the stockpile Conversion Replace R-22 with a drop-in alternative refrigerant Replacement Replace with HFC or natural refrigerant 4
Problems with Drop-In Conversion They must have EPA SNAP approval for refrigeration & A/C Significant New Alternatives Policy (SNAP) Program evaluates and regulates substitutes for the ozonedepleting chemicals Other problems: No true drop-ins None are as efficient None are as miscible with Mineral Oil and Alpha Benzene as R-22 None will work in every R-22 System SNAP Retrofits for R-22 n- Isobutanpentane Iso- ASHRAE HFC- HFC- HCF- Propane Trade Name HFC-32 Butane Number 125 134a 143a R-290 R-600 R-600a R-601a R-404A 404A 44 4 52 KLEA 60, 407A 40 40 KLEA 407A 20 KLEA 407C, AC9000 407C 23 25 52 NU-22/ISCEON 59 417A 46.6 50 3.4 Choice R421A 421A 58 42 Choice R421B 421B 85 15 ISCEON 79 422A 85.1 11.5 3.4 ICOR XAC1 422B 55 42 3 ICOR XLT1 422C 45 82 15 3 ISCEON MO29 422D 65.1 31.5 3.4 RS-44 424A 50.5 47.0 1.0 0.9 0.6 Forane 427A 427A 15 25 50 10 RS-52 428A 77.5 20.0 0.6 1.9 RS-45 434A 63.2 18 2.8 16 KDD5, ISCEON MO99 438A 8.5 45.0 44.2 1.7 0.6 R-507A 507A 50 50 Source: Stephen Spletzer, Arkema Inc, 2010 ASHRAE Winter Conference Fairly popular retrofit fluids Source: U.S. EPA: www.epa.gov/ozone/snap/refrigerants/refblend.html Refrigerant Mixtures Zeotropes (Blends or Simple Mixtures) R-400 series Tend to average properties Segregate (Easy to separate) Offer greatest flexibility Azeotropes R-500 series Behave like pure fluid Higher or lower B.P. than components Non segregating (Difficult to separate) Some Zeotropes are very close to Azeotropes (Near-Zeotropes) Why Are Hydrocarbons Used Many of the retrofit blends use hydrocarbons: R-290 (Propane) R-600 (n-butane), R-600a (Iso-butane) R-601a (Iso-pentane) They provide miscibility of the MO/AB with the HFC refrigerant, but not as well as R-22 Problems may occur: Oil-hold up in the receiver (floats on top and isn t pulled out) Oil logging in the evaporator (acts like a frosted evap) Flow problems (screens become plugged) This problem has been documented by multiple manufacturers Be certain compressor manufacturer approves your choice in a retrofit refrigerant and lubricant Source: Stephen Spletzer, Arkema Inc, 2010 ASHRAE Winter Conference GWP of Popular R-22 Retrofits 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 - R-717/-744 R-290/-600 R-134a R-407C R-22 R-410A R-427A R-417A R-422B R-421A R-422D R-428A R-404A/-507A Fairly popular R-22 retrofit fluids What are HFC s Future? Analysis of HFC Production and Consumption Controls Released October 2009 Preliminary analysis of potential benefits for controlling consumption of HFCs No legislation pending Counts on HFO s, natural and low GWP blends to fill the gap 5
Any New Refrigerants? Existing refrigerants being reconsidered R-152a Low atmospheric lifetime, 0 ODP, 122 GWP A2 classification (lower flammability) R-32 Low atmospheric lifetime, 0 ODP, 675 GWP A2 classification (lower flammability) R-245fa Low pressure, B1 classification, 950 GWP Thought to be potential replacement for R-123 Any New Refrigerants? HFO-1234yf A hydrofluoro-olefin refrigerant Development Similar capacity and efficiency to R-134a Joint project of Honeywell and DuPont Targeted at European automotive market as alternative to using R-744 (CO 2 ) in cars No ODP and low GWP (GWP = 4 vs. 1340 for R-134a) Any New Refrigerants? HFO-1234yf, ctd. May eventually have application in stationary equipment or similar HFO Mildly Flammable LEL = 6.2%, UEL = 12.3% A2 classification (lower flammability) Others HFO s under development All manufacturer s are experimenting with different HFO s and HFO blends Most meet at least A2 classification ASHRAE Standard 34-2004 Refrigerant Classification Recently Approved: Flammability classification 2L Refrigerant is still mildly flammable (2) but will have Lower Flammability Rating Lower propagation rate Similar to ISO 817 category 2L Targeted at refrigerants like R 152a Ammonia HFO 1234yf Other HFO s and blends Going Green Natural refrigerants have gained traction in recent years R-717 (Ammonia) R-744 (Carbon Dioxide) 88F critical point R-290 (Propane) Very flammable R-718 (Water) Inefficient/Freezes Air Inefficient They all have 0 ODP, 0 GWP Each has drawbacks that prevent universal application to all refrigeration needs Toxic/Slightly flammable Going Green Multi-national Ctd. Carrier has developed transcritical CO 2 refrigeration systems for: Supermarkets (European) Heat pump water heaters General Electric & Ben & Jerry s (Unilever) Petitioning EPA to allow use of hydrocarbon refrigerants in domestic refrigerator and ice cream cabinets, respectively GE Monogram unit reported to use 2 oz. isobutane Acceptable under UL 471 for Commercial Refrigerators 6
Going Green EPA May 10, 2010 released Proposed Rule to list four hydrocarbon refrigerants as acceptable substitutes, with use conditions, for CFC-12 and HCFC-22 Use of isobutane, propane and HCR-188C and HCR-188C1 in in household refrigerators, freezers, combination refrigerator and freezers and retail food refrigerators and freezers (stand-alone only) HCR-188C blend of propane, isobutane, ethane, and pentane gases 0 ODP and <5 GWP, replaces R-134a Going Green IIAR The Carbon Dioxide Industrial Refrigeration Handbook Published earlier this year to provide guidance to designers of industrial CO 2 refrigeration systems ASHRAE ASHRAE Position Document on Natural Refrigerants Issued Jan. 28, 2009 Supports research and growth of CO2, air, ammonia, hydrocarbons and water Internal tension exists Hydrocarbons (HC) as Refrigerants Propane/Butane/HC as a refrigerant? Technologically yes HC s have 0 GWP and 0 ODP Often have high efficiency R-22 Propane Butane IsoButane COP 4.66 4.5 4.74 4.62 Legality in the U.S? see HC-12a www.epa.gov/ozone/snap/refrigerants/hc-12a.html It has been illegal since July 13, 1995 to replace CFC-12 with the HC-12a formulation that was submitted for SNAP review in any refrigeration or A/C application other than industrial process refrigeration. Pure Hydrocarbon as Refrigerants Be certain they have SNAP approval Beware of another HC drop-in marketed for R-22 systems These do not currently have SNAP approval Sometimes called a HC or Alkane refrigerant Drop-in Propane Hazardous ingredient Alkane Propane is Alkane Lower Flammability Limit (LEL) 2.15% 2.2% Upper Flammability Limit (UEL) 9.6% 9.5% Autoignition temperature 800 F 842 F Boiling Point -44.5 F -43.67 F Source: 2009 ASHRAE Handbook of Fundamentals, Chp 29, Table 9 What s the Danger of HC s? If they are environmentally friendly, efficient and allowed in industrial processes, why won t EPA allow them in A/C processes? Icepak Coolstore in Tamahere, NZ Refrigerated Warehouse that used propane 1 dead, 7 injured Who/What s to blame? Stenching agent no longer present in propane Insufficient warning signs Insufficient flammable gas detection on premises Many other factors mostly related to systemic defects in regulatory environment & communication between agencies In Conclusion Ammonia has been and will continue to be a mainstay refrigerant for industrial applications The phase-out of R-22 creates challenges and opportunities No clear drop in Large number of alternatives = confusion Opportunity to go green (with care) Expect many conflicting messages to come from different sectors of the industry Make certain alternatives have SNAP approval 7