Natural Refrigerant Alternatives

for the Industrial Marketplace

Newark, N.J., August 24, 2016

Andre Patenaude C.E.T. Antonio De LourdesDirector – CO2 Business Development Senior Project Engineer (R&D)

Emerson Climate Technologies Vilter Manufacturing,

Emerson Climate Technologies

Agenda

Why invest in natural refrigerants?

Ammonia applications

Key industrial refrigeration trends

CO2 system architectures

Strategies for warm ambient operation

Summary

Why Invest in Natural

Refrigerants?

Low-GWP Refrigeration?

Step 1, completed:

Thinning of the ozone layer

caused by CFC and HCFC

(banned)

Step 2, ongoing:

global warming damage

caused by HFC

(phased down / usage bans)

CFC = Chlorofluorocarbon

HCFC = Hydrochlorofluorocarbons

HFC = Hydrofluorocarbons

Step 1: Elimination of ozone-depleting refrigerants (CFC and HCFC)

Step 2: Phase-down of global-warming refrigerants (HFC)

Step 3: Ramp-up of CO2 commercial refrigeration equipment

Step 3, ongoing:

natural refrigerants

CO2, propane, ammonia

(ramping up)

Aggressive European Measures to Reduce and Eliminate HFCs

Global Warming Potential R-404A Equivalent Threshold vs. CO2

8 oz of R-404A =

GWP of 3,922

Global Regulations Confusing Time for End Users

2015 Was Warmest Year Since 1880, – USA Today Article, 1/20/16

• COP21 Meeting in Paris, 12/2015

• Nations agreed to limit global

temperature increase to 2 °C

• Countries to update pollution

reduction pledges by 2020

This means reducing

emissions by 40–70%

by 2050 compared

to 2010!

U.S. Environmental Protection Agency (EPA)

• Slide from Tom Land, U.S.EPA, ATMOsphere America, June 17, 2016

Alternatives for Refrigeration Applications

R-410A

like

capacity

R-404A &

R-407/22

like

R-134a

like

GWP level

400-675

< 1500

~600

~300

HFO 1234yf

HFO 1234ze

ARM-42

R410A

R22

R407A

R407C

R407F, R452A = XP44

ARM-35

0 500 1,000 1,500 2,000

Pressure

or

R32/HFC/HFO

Blends

R-32/HFO

Blends

HFC/HFO

BlendsR134a

CO2

R404A

R507A

DR2, N12, ARC 1

R290

NH3

A1 – Non-flammable

A2L – Mildly flammable

A3 – Flammable

B2L – Toxic, mildly flam.

R-123 like

(v. low pr.)

(3922)

R-32

R32/HFO Blends

R448A

R449A

R449B

R450A = N13

R513A = XP10

R-444B = L20

L40, DR7

ARM-20b

R-455A (HDR110)

DR3

ARM-20a

R-446A, R-447A, ARM-71a

<150

Qualitative; not to scale

R-515A

HFC and/or natural booster / high stage

(no CO2)

System Architecture Landscape

High stage

HFC or natural

(no CO2)CO2

BoosterVolatile brine

CO2-NH3 (or HFC) cascade system

CO2 booster transcritical

CO2 subcritical system CO2 transcritical systemSingle stage

Holistic Facility Approach Can Minimize

“Unintended Consequences”

Equipment

Energy

Economics

Environment

Toxicity, flammability,

working pressures

Heat transfer,

latent heat

Revenue, first cost,

total cost of ownership

CO2 emissions, climate

change

Legal, operations

Energy mgr.,

design eng.

CEO, merchandising, finance

Sustainability officers

Lack of technicians,

performance specs and

service contracts

Utility incentives,

continuous

commissioning,

integrated HVACR

Millennials,

fresh, urban stores

Natural refrigerants,

regulations

Key variables Stakeholders Trends

Refrigerants: Impact Comparison

Refrigerant R-404A R-507A R-22R-290

Propane

R-744

CO2

R-717

Ammonia

Ozone depletion

potential(ODP) 0 0 0.04 0 0 0

Global warming

potential (GWP)

3,700 3,800 1,810 3 1 0

Safety group A1 A1 A1 A3 A1 B2

Reference: ASHRAE Handbook

Ammonia Applications

Ammonia Applications

• Food and beverage processing:

– Dairy, meat processing, breweries, baked goods, frozen foods

• Refrigerated cold storage

• Recreational ice:

– Hockey rinks, curling, ice skating paths

– Olympic speed skating, ski jump, bobsled tracks

• Ground soil freezing, mining HVAC

• HVAC, district heating and cooling, heat pumps

Ammonia Pros

Cost-effective

• Ammonia systems cost ~10–20% less than competitive systems using HCFCs and HFCs

• Less refrigerant required, smaller pipes required due to less mass flow: over nine times more energycontent (Btu/lb) than HFCs

• Up to 25% more efficient in energy usage

• Excellent refrigerant for heat recovery

• Low-cost refrigerant and oils:– Mineral and semi-synthetic oils

• Low-cost refrigerant and oils:– Mineral and semi-synthetic oils

Reference: ASHRAE Handbook

Ammonia: A Natural Refrigerant

Natural refrigerant, environmentally friendly:• One of the most abundant gases in the environment

• Exists all around us (air, water, soil, produced by our kidneys)

• Approx 1.7 times lighter than air

• Breaks down rapidly in the environment

• NH3 (R-717): Nitrogen and hydrogen

• Ozone-depletion potential (ODP) = 0

• Global warming potential (GWP) = 0 N

H

H

HReference: ASHRAE

Handbook

Reference: ASHRAE Handbook

Human production: 198 million tons annually (2012)

• Second-most produced chemical (after petroleum)

• ~80% is produced for fertilizer

• NH3 R-717 refrigerant 99.98% pure ~ 2% of

total production

• Cheap, affordable refrigerant

150 Years of Ammonia Refrigeration

Well known:

• Ammonia used for more than 150 years in refrigeration

• 1850s in France, 1860s in U.S., first patents in 1870s

• Consistently used for large industrial refrigeration for over 100 years

• Most common refrigerant for food and beverage production, cold storage, recreational refrigeration

• Proven safe track record

Key Industrial Trends

Key Industrial Refrigeration Trends

• Safety and environmental requirements

– OSHA requirements

– Low-charge ammonia systems

– Moving ammonia out of occupied spaces

– Cascade systems using CO2 in the low stage

– Booster transcritical CO2 architecture for MT and LT

– Increased use of R-744 (CO2) and a volatile secondary fluid

• Increased emphasis on total cost of ownership

– Equipment cost

– Maintenance costs

– Energy cost (improved performance of CO2 at LT such as -40 °F)

Key Industrial Refrigeration Trends

• Safety and environmental requirements

– OSHA requirements, 10,000-lb threshold

The burden of compliance will continue to be significant, with

OSHA’s National Emphasis Program (NEP) inspections, audits

and regulation changes related to the OSHA 1910.119 PSM

program and the U.S. Environmental Protection Agency’s (EPA)

40 CFR Part 68 Risk Management Plan.

PSM programs (process safety and risk management)

Key Industrial Refrigeration Trends

• Safety and environmental requirements

– OSHA requirements

– Low-charge ammonia systems

Key Industrial Refrigeration Trends

• Safety and environmental requirements

– OSHA requirements

– Low-charge ammonia systems

– Moving ammonia out of occupied spaces

Key Industrial Refrigeration Trends

• Safety and environmental requirements

– OSHA requirements

– Low-charge ammonia systems

– Moving ammonia out of occupied spaces

– Cascade systems using CO2 in the low stage

Key Industrial Refrigeration Trends

• Safety and environmental requirements

– OSHA requirements

– Low-charge ammonia systems

– Moving ammonia out of occupied spaces

– Cascade systems using CO2 in the low stage

– Increased use of R-744 (CO2) and a volatile secondary fluid

Contained in

equip room

Med-temp

Low-temp

Ammonia Evolution: The Future

Ammonia technology trends:

• Lower-charge systems, critically charged systems

– DX ammonia increasingly possible thanks to electronic controls, valves

• Combined ammonia / CO2 cascade

• Ammonia / pumped glycol secondary

• Ammonia / pumped CO2 secondary

• Consistent development of ammonia compressors and equipment …

• Removes ammonia from occupied space

Med-temp

Low-temp

CO2 System

Architectures

CO2 System Architectures — Booster vs. Cascade vs. Secondary

CO2 DX

CO2 DX

CO2 DX

Transcritical

boosterCascadeSecondary

CO2 Secondary System — Schematic

The CO2 would typically be cooled to

-20 °F (200 psig) for the LT load

+20 °F (407 psig) for the MT load

The high-stage system is a simple chiller type system,

typically running on an HFC or HC or ammonia.

-40 °F

+20 °F

CO2 pumped as

volatile brine

CO2 direct

expansion

Metro Distribution Centre, Laval, QC: Ammonia / Secondary CO2 System

Facility• 240,000 square foot cold storage warehouse

• 1000 TR ammonia refrigeration with efficient Emerson / Vilter

single-screw compressors

• Distributed CO2 brine throughout the building

Emerson solution• Vilter compressors delivered superior part-load efficiency

• Expensive VFD drives would have been required with competitor’s

twin-screw compressors

End user benefits• Reduced ammonia charge

• Lower compressor and facility energy costs

• Non-ozone depleting refrigerants with zero global warming potential

• Vilter dual-slide valve technology avoids more than $100,000 of

compressor VFD drives

What About CO2?

R-744 vs. HCFC/HFC

R-744 HFC / HCFC Impact on R-744 Systems

Global warming potential

Ozone-depleting potential

1

0

1,300 to 4,000

0 for HFC / high for HCFC

Future proof

Future proof

Saturation pressures

Operating pressures

Standstill pressures

(Power outages)

Higher

Higher

Higher

Rapid pressure rise

Lower

Lower

Lower

Lower

Additional safety design

Specialized components

Relief valves/tanks, etc.

Pressure relief venting

Inert gas

Flammability

Toxicity

Odor

Yes

A1

No

None

Yes

A1

No

None

Copper may be used

Not flammable

Asphyxiate in high concentrations

Leak detection required

Volumetric mass flow

Heat transfer

High ambient performance

Low ambient performance

Higher

Higher

Lower

Good

Lower

Lower

Higher

Good

Smaller tubes and compressors

Better thermal efficiency

System design to compensate

Subcritical cascade favorable

Cost per pound

Complexity of systems

Adoption

Legislation / regulations

Low

Higher

Low

Low

Higher

Lower

Higher

Higher

Economical

Higher first cost, training and experience

Higher first cost

Long-term viability

R-744 Provides Many Benefits Over HFC Options.

Pressure-Temperature Relationship

Pressure-Enthalpy Diagram, CO2

Liquid and gas density

are the same ONLY at

critical point.

https://www.youtube.com/watch?v=-gCTKteN5Y4

Climatic Impact of CO2 System Architectures

Industrial CO2 Use – New Space

Transcritical

Secondary

CO2 DX

CO2 DX

CO2 DX

Transcritical

boosterCascadeSecondary

Selecting the Best System — Booster vs. Cascade vs. Secondary

Introduction to Cascade — Simple Systems

Simple cascade system comprises:

• Low stage provides the cooling load

It uses CO2 and is always subcritical

• High stage absorbs heat from the

condensing CO2 at the cascade HX

• CO2 condensing temperature is always

below the critical point

• High stage is usually a simple, close-

coupled system

• Typically applied in warm climates

High stage

(HFC or ammonia)

Low stage

CO2

NH3/CO2 Cascade

• Move NH3 out of

occupied space

• Improved efficiency

• Regulatory

compliance

• Natural refrigerant

Primary

stage

NH3

MT

LT

Low-temp

DX — CO2

25 °F = 440 psig

-30 °F = 163 psig

New CO2 Subcritical Open Drive

• Vilter – division of Emerson Climate Technologies

• Founded in 1867 in Wisconsin

• Currently in Cudahy, Wis.

• Products include:

– Recips, single screws, packaged systems for:

• Refrigeration, heat pumps

• Smart vapor management, gas compression for CHP

550 SeriesSingle screwPackage systems SVM unit

552 Test Site: The Helix, Innovation Center

Dayton, Ohio (Startup Sept. 15)

Combined circuit on a common

skid with two cylinder compressors

working in parallel to provide

50 tons at -35 °F SST 25 °F SCT

Ability to test at “real” conditions

Development of the HP Reciprocating Compressor

Vilter 552 Vilter 554 Vilter 556 Vilter 558

1,800 RPM 1,800 RPM 1,800 RPM 1,800 RPM

CFM 56 112 168 224

-30 °F SST/23 °F

SDT

Capacity

(tons)48 97 145 193

BHP 56 112 167 223

-58 °F SST/23 °F

SDT

Capacity

(tons)23 46 69 92

BHP 48 96 145 193

Production statusTesting stage

(Helix)Design stage Design stage

Prototype

stage

CO2 DX CO2 DX

CO2 DX

Transcritical

boosterCascadeSecondary

Selecting the Best System — Booster vs. Cascade vs. Secondary

Transcritical Systems Can “Transition” From Subcritical to Supercritical

CO2 Transcritical Booster Operation

Strategies for Warm

Ambient Operation

Low-GWP

Climatic Impact of CO2 System Architectures

Time Spent in Transcritical

1,020 hrs/yr

w/std. gas cooler

9 hrs/yr

w/adiabatic

gas cooler

202 hrs/yr

w/std. gas cooler

Toronto, ONAtlanta, GA

Five Ways of Improving Efficiencies in Warm Ambient Regions

• Spray nozzles

• Evaporative or adiabatic gas coolers

• Parallel compression

• Sub-cooling

• Ejectors

Supermarket LCCP Analysis

Annual Energy LCCP LT = Low-temperature

MT = Medium-temperature

DX = Direct expansion

LCCP = Life cycle climate performance

Min Cond: 70F

Min Cond: 70F

Min Cond: 70F

Min Cond: 50F

Assumptions

LT load: 384 MBTU

MT load: 1,250 MBU

Leak rate assumptions: 15% for all systems

Note: 15% is probably high for the ammonia systems. Even if we use 0% it will not change the results, as the GWP for ammonia is 0.

Electric generation factor: 1.5 lbs CO2/kWh

Ammonia system was assumed to be single-stage with no subcooling.

Summary of Options

-40 °F

+20 °F

CO2 pumped as

volatile brine

Medium-temp CO2 direct

expansion

Low-temp

CO2 pumped as

volatile brine

Low-temp only

CO2 pumped as

volatile brine

Medium-temp only

Ammonia

Compressor

Ammonia

Compressor

100% ammonia system

Ammonia/CO2 cascade with MT pumped secondary

CO2 transcritical booster system

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.

Thank You!

Andre.Patenaude@Emerson.com

519-717-5282

Antonio.Delourdes@Emerson.com

414-486-2634

For further details, contact