Flammability and the Low GWP Refrigerant Challenge A Presentation to the BSRA Presentation On Guy Fawkes Night 5 th November 2015 Presented by Dewi Garcia MSc, MInstR Technical Manager Harp International Limited
Overview of Harp International Limited
A Brief overview of Harp International Limited Harp International Limited was established in 1991. As of April 2014 Harp are now part of the Gazechim Group of companies MANUFACTURING FACILITIES Site occupies approximately 5000m 2 The main site has approximately 1000 tonnes of bulk storage capacity Formed with the objective of supplying a complete refrigerant service to RAC industry WE OFFER ANALYTICAL SERVICES Refrigerant analysis to AHRI 700 Standard Refrigeration lubricant analysis EXTENSIVE RECLAMATION FACILITIES UK s largest stand alone reclamation plan ROUTE TO MARKET OF HARP REFRIGERANT PRODUCTS Dean & Wood to the contractor sector / Direct to OEMs / End Users
The F-Gas Regulation and the drivers behind the adoption of flammable refrigerants THE F-GAS REGULATION The revised F-Gas Regulation, Regulation (EU) No 517/2014, became effective on the 1 st January 2015 and SHALL be fully complied with in all EU Member States without exception F-Gases, as the name suggests are gases that contain Fluorine The higher the Fluorine content of the gas the higher the direct GWP when released hence the need and introduction of the F-Gas Regulation The lower the Fluorine content of the gas the lower is the direct GWP, BUT...!!!! 1. The Fluorine content affects flammability of the refrigerant 2. The lower the Fluorine content the lower is the direct GWP but the more flammable is the refrigerant!
Refrigerant GWP values So, what GWP do some common and new refrigerants have? Refrigerant GWP value HARP R23 14800 HARP R404A 3922 HARP R410A 2088 HARP R134a 1430 HARP R32 675 R1234ze 6 R1234yf 4 So what are these low and very low GWP value refrigerants? HARP R32 is a HFC that just happens to have a moderate direct GWP R1234ze and R1234yf are the latest 4 th generation range of synthetic refrigerants of the HFO family
So what are HFOs refrigerants? They are the new 4 th generation synthetic products with extremely low direct GWP values R1234yf for instance has a GWP approximately 357 times less than R134a!!! HFOs are in fact un-saturated HFCs that is they have a weak double carbon bond that makes them decompose more readily in the atmosphere It is likely that in the next IPCC Report that current HFOs will be declared to have GWPs less than 1! Less than CO 2. Hydrocarbons have a GWP = 3 Currently R1234yf use in virtually all new models of cars manufactured in the EU and can also be used as a replacement for cabinets, bottle coolers etc. Both R1234yf and R1234ze are used in blends to replace R404A (e.g. OPTEON XP 40 (R449A) Cost is currently prohibitive but they are becoming cheaper
Single component HFOs refrigerants The main 4 th generation synthetic products with extremely low direct GWP values are: REFRIGERANT ASHRAE Classification GWP R1234ze(E) A2L 6 R1234yf A2L 4 R1233zd(E) A1 4.5 The lower the GWP the more flammable the HFO or HFC refrigerant. R1234ze LEL = Not flammable at room temperature, MIE => 61000mJ at 53 C R1234yf LEL = 6.2% vol. in air, MIE >5000mJ at 20 C R1233zd Not flammable Many of the HFOs are classed as lightly flammable and will receive a newly created ASHRAE A2L Classification defined as: Having a burning velocity of less than or equal to 10cm/second at a temperature of 23 C and a pressure of 1.013 bar MIE = Minimum Ignition Energy
ASHRAE Safety Classifications Higher Flammability Lower Flammability No Flame Propagation Safety Group A3 (e.g. R600a) B3 A2 (e.g. R152a) B2 (e.g. R40) A2L (e.g. R1234yf) B2L (e.g. R717) A1 (e.g. R134a) B1 (e.g. R245fa) Lower Toxicity Higher Toxicity
HFOs, the reason for the strange R-numbers HFO R1234yf HFC R134a HFO Describes an organic fluorine compound called a Hydrofluoro oelfin In the 1234yf: 1 Stands for one double bond 2 One less than the number of Carbon atoms 3 One more than the number of Hydrogen atoms (3) 4 Stands number of Fluorine atoms (4) yf Denominates specific isomer (position of Fluorine atoms)
Why the need for HFO based refrigerants EQUIPMENT AND PRODUCT PROHIBITIONS Product(s) / equipment Domestic refrigerators/freezers using HFCs with GWP 150 or more Refrigerators/freezers for commercial use (hermetically sealed systems) Stationary refrigeration equipment using HFCs with a GWP of 2500 or more (except when operating below -50 C) Date of prohibition 1 st January 2015 (ii) (ii) 1 st January 2020 for equipment containing HFCs with a GWP of 2500 or more 1 st January 2022 for equipment containing HFCs with a GWP 150 or more 1 st January 2020
Why the need for HFO based refrigerants EQUIPMENT AND PRODUCT PROHIBITIONS Product(s) / equipment Moveable air conditioning appliances (hermetically sealed) that contain HFCs of GWP 150 or more Multi-pack centralised refrigeration for commercial use with capacity 40kW or more that use F-Gases with GWP of 150 or more. The primary circuit of a cascade will be allowed to use an F-Gas of GWP less than 1500 Single split A/C system containing less than 3kg of an F-Gas of GWP 750 or more Date of prohibition 1 st January 2020 1 st January 2022 1 st January 2025
Why the need for HFO based refrigerants EQUIPMENT SERVICING RESTRICTIONS Re-charging of existing refrigeration equipment with a charge size of 40 tonnes CO 2 equivalent or more and an evaporating temperature of -50 C and above with virgin HFC refrigerant of GWP greater than 2500 will not be permitted from 1 st January 2020. (Not applicable to military equipment) Refrigerant GWP Max. Charge Size (40 tonnes CO 2 equivalent) R404A 3922 10.2 kg R507A 3985 10.0 kg R422A (Isceon 79) 3143 12.7 kg R422D (Isceon 29) 2729 14.6 kg R434A (RS-45) 3245 12.3 kg
The current leading HFO candidates and their application areas Refrigerant Chemical name Chemical formula GWP Applications R1234yf 2,3,3,3- tetrafluoropropene R1234ze (E) & (Z) 1,3,3,3- tetrafluoropropene R1233zd (E) & (Z) 1-chloro,3,3,3- trifluoropropene CF 3 CF=CH 2 4 Automotive A/C, light commercial, domestic refrigeration CF 3 -CH=CHF 7 Chillers (Turbocor), CF 3 -CH=CHCl 4.5 Low pressure centrifugal systems and high temperature heat pumps HARP R32 3,3,3-trifluoropropene CF 3 -CH=CH 2 675 Air conditioning systems
Refrigeration Air conditioning Propellant/blowing agent Solvent -80 C -25 C +50 C R410A R404A R407A R134a R245fa R365mfc R744 (CO 2 ) R-717 (NH 3 ) R-32 Propane Propene R-1234yf R-1234ze(E) R-1243zf R-1234ze(Z) R-1233zd(E) R-1233zd(Z)
So what s available for lower temperature applications? At the moment no extremely low GWP synthetic alternatives are available to replace refrigerants such as R404A. The main contenders are: Hydrocarbons ( R1270) - Extremely flammable Ammonia (R717) Extremely toxic and lightly flammable Carbon dioxide (R744) Extremely high operating pressure At the moment no extremely low GWP pure HFO alternatives are available to replace refrigerants such as R404A. The main contenders are blends of HFOs and HFCs where the HFO portion reduces the overall direct GWP value: The synthetic options available are mid-range GWP value blends of HFCs and HFOs with a GWP value of approximately 50% that of R404A e.g. Opteon XP 40 (R449A) Opteon XP 40 (R449A) R32 / R125 / R134a / R1234yf (24.3 / 24.7 / 25.3 / 26.0 / 25.7) GWP = 1397 this is approximately 65% less than R404A!!! ASHRAE Safety Classification A1 Non-flammable and non-toxic
Safety considerations when using A2L refrigerants during installation, service and maintenance Systems should be assembled, installed and serviced in accordance with EN378. There are issues related specifically to the use of flammable refrigerants that need to be addressed: Design & installation Systems must be designed in accordance with the flammability risk they pose Strict system charge weights will apply Labelling Systems containing an A2L refrigerants shall always be labelled as flammable
Safety considerations when using A2L refrigerants during installation, service and maintenance Tools & Equipment A flammable gas detector should be used to monitor the air in the work area Electronic leak detectors shall be intrinsically safe and sensitive to the flammable refrigerant. Most HFC leak detectors do not need this requirement If an electronic leak detector is used it must be safe and sensitive to the flammable refrigerant. Most HFC leak detectors do not need this requirement All pipework carrying flammable refrigerants shall be protected from mechanical damage
Safety considerations when using A2L refrigerants during installation, service and maintenance Work areas Area must be well ventilated. If necessary forced ventilation should be available There should be no source of ignition within 3 m of the system and the service equipment such as a vacuum pump and recovery machine. Note 3 m is the typical zone required for HC refrigerants. For A2 and A2L (proposed) refrigerants, and where there is good ventilation, the zone may be less. Vacuum pump should be controlled by a switch outside the 3m zone (the vacuum pump s switch should not be used as it is a source of ignition) and the pump should be located in a well-ventilated area
Safety considerations when using A2L refrigerants during installation, service and maintenance Work areas continued When un-brazing joints the A2L refrigerant must be removed from the system, and the system filled with nitrogen Faulty electrical devices and compressors must be replaced with like for like components The charging area must not be below ground level. There must be no below ground areas adjacent to the charging areas where leaking refrigerant could collect Fire extinguishers (dry powder or CO 2 ) should be present in work area
Safety considerations when using A2L refrigerants during installation, service and maintenance Storage The minimum quantity of flammable refrigerant should be inside the charging or work area. All other cylinders should be stored outside in a safe area Training EN378 specifies that anyone working on flammable refrigerants systems should receive training which includes the following: Detailed knowledge of and skill in handling flammable refrigerants, personal protective equipment, refrigerant leakage prevention, handling of cylinders, charging, leak detection, recovery and disposal City and Guilds pathway unit as part of the new City & Guilds 61876 - C & G 6187-21 is a possible suitable qualification
Dewi Garcia Technical Manager Harp International Limited Tel: 07836 671673 Email: dgarcia@harpintl.com Website: www.harpintl.com The End