prepare for change low gwp alternatives · the refrigerant composition checked. –any substantial...

PREPARE FOR CHANGE LOW

GWP ALTERNATIVES

November 17

F-GASPHASE DOWN

Where we are now

F-Gas regulation places restrictions on the use of some HFC refrigerants of high GWP.This is indirectly achieved by setting limits on the GWP of products used in specific types of systems.

The aim of the process is to reduce the contribution of refrigerant gases to Global Warming.

R404A has a GWP of 3922 and is amongst a group of refrigerants with GWP > 2500 which will be most affected within a relatively short period of time (2020).The others of concern include R507, R422A, R422D, R428A and R434A.

Key Elements of the F-Gas Regs.

F-Gasregulations

Bans in new equipment

Service ban on HFC with GWP>2500

Training

Reporting, Records

Recovery etc

Leak Checks

Phase down of HFC

Suppliers

Contractor/ End User

F-GAS: CAP & PHASE DOWN OF HFC’S

0%

20%

40%

60%

80%

100%

120%

2015 2016–17 2018–20 2021–23 2024–26 2027–29 2030

% of Baseline (CO2 equivalent)

% of base

2017 picture is uncertain; pre-charged equipment falls under quota (-11% in supply), but all new cars must ship with LGWP refrigerant (effect is uncertain)

Average of 2009-2012

Compliance checklist for EU F-Gas regulation

Purchase of new equipment

- Comply with bans on use of HFC’s in new equipment.

- Take account of service bans when selecting refrigerants

- Take account of HFC phasedown when selecting refrigerants.

Operation of existing equipment

- Mandatory leak checks and repairs.

- Use CO2e* size thresholds for leak check schedule.

- Use CO2e size thresholds for automatic leak detection.

- Keep records of all equipment using F-gas refrigerants .

- Service ban affecting existing high GWP systems.

- Use qualified personnel only.

Recovery / end of life requirements

- High quality recovery of F-gas refrigerants by qualified engineers.

* CO2 equivalent

The upcoming changes under F-Gas

2017All filled units imported into the EU need quota. Approx. 11% reduction in available gas this year

2018Decrease of 37% for available virgin HFC products available to be placed on the market

2020In new stationary systems, ban on refrigerants with GWP>2500. (except below -50°C)

The upcoming changes under F-Gas

2020

Service ban for existing equipment with virgin refrigerants of GWP>2500 where charge size is greater than 40 tonnes of CO2 equivalents.

2022

Ban on the use of virgin refrigerants of GWP>150 in new hermetic and multipack centralized systems. (There are some exceptions such as cascades)

2025Ban on the use of virgin refrigerants of GWP>750 for use in single split air con where charge < 3kg

F-Gas Service bans with existing systems

From 1st Jan 2020, use of virgin HFCs with GWP>2500 to service and maintain commercial refrigeration systems with a charge size>40 tonnes CO2e* shall be prohibited.

Virgin HFC’s below this level can be used to service existing installations (R407F, R407A, R448A,R449A, R134a etc.)

*The charge size threshold is equivalent to 10kg of HFC R404A.

Options:

1 – Replace existing plant with new equipment designed to run with refrigerants of lower GWP, good for plants near to end-of-life.

2 – Retrofit existing plant to replace R404A with lower GWP alternatives such as R407A, R407F, R448A and R449A with an energy efficiency increase of between 4-15% depending on the system.

3 – Reclaim R404A which can be used until 1st Jan 2030. This uses A-gas bespoke technology to return R404A to its initial specification.

F-Gas - The need for labels

You must add a label if you add an F-Gas to refrigeration, fire protection or air conditioning equipment when you’re installing it. The label must state:

• that the equipment contains an F-Gas.

• the industry name for the F-Gas, or the chemical name if there isn’t an accepted industry name.

From 2017 the label must also state the:

• mass of F-Gas in the equipment (in kg)

• carbon dioxide (CO2) equivalent mass of F-Gas in the equipment (in tonnes)

• the global warming potential of the F-Gas

Keeping Records – An F-Gas requirement

The operator of equipment, and the company that services it, must keep the following records about any equipment that has to be checked for leaks (ie any equipment that contains an F-Gas equivalent to more than 5 tonnes of CO2):

• quantity and type of gas in the equipment when it’s installed

• quantity and type of gas added during any maintenance (eg leak repairs)

• details (name, address and certificate number if relevant) of any companies that install, service or decommission the equipment.

• dates and results of all mandatory leak checks.

• measures taken to recover and dispose of gases when disposing of the equipment (egdisposing of it through a registered waste carrier.).

• It must be recorded if the gas used in the equipment has been recycled or reclaimed and if so the:

– details of the recycling or reclamation facility (name, address and certificate number if it has one).

– quantity of any gases recovered.

• Records must be kept for 5 years.

Record Keeping with Gas-Trak Online (GTO)

Acting as the central control point, the Desktop Web Portal enables users to manage their account, customer records, job lists and cylinder fleet.

The CFM enables you to manage your cylinders and control rental costs. Generate cylinder rental status reports and utilise the rental traffic light warning system.

Whether it’s a new installation, a service call or decommissioning, customers can track F-Gas and cylinder usage.

Collect and return cylinders whilst on the move by simply scanning the cylinder barcode. Record any supplier’s cylinders.

The Process for deciding on leak checks

Frequency of leak checks

Fluorinated greenhouse gases (t CO2 eq)

Maximum Frequency of leak checks

No Leakage detection system Leakage detection systems

5 - 50 12 months 24 months

50 - 499 6 months 12 months

500 3 monthly1 6 months

1 Leakage detection systems are mandatory when the equipment containsmore that 500t CO2-eq of refrigerant.

Note: As of January 1st 2017, leak checks are mandatory for all systems >5 t CO2 eq(< 3 kgs for installed systems or < 6kgs for hermetically sealed equipment, These were previously given exemption)

Leak Check Considerations

In General

• The alternatives to HIGH GWP Refrigerants have:-– Considerably higher glide.

– Potentially higher discharge temperatures.

– Changes in mass flow rate.

– Different operational pressures.

• Leakage issues– Dependant upon location small leaks can be “topped up”.

– After repeated “SMALL LEAKS” it would be a good precaution to have the refrigerant composition checked.

– Any substantial leak you should have the composition checked prior to topping up, or carry out a complete recharge.

t CO2/ kg Equivalents

Refrigerant GWP 5 t CO2 eq 10 t CO2 eq 40 t CO2 eq 50 t CO2 eq 500 t CO2 eq

R32 675 7.41 kg 14.81 kg 59.26 kg 74.07 kg 740.74 kg

R134a 1410 3.55 kg 7.09 kg 28.37 kg 35.46 kg 354.61 kg

R404A 3922 1.27 kg 2.55 kg 10.20 kg 12.75 kg 127.49 kg

R407F 1825 2.74 kg 5.48 kg 21.92 kg 27.40 kg 273.97 kg

R410A 2188 2.29 kg 4.57 kg 18.28 kg 22.85 kg 228.52 kg

R448A 1387 3.60 kg 7.21 kg 28.84 kg 36.05 kg 360.49 kg

R449A 1397 3.58 kg 7.16 kg 28.63 kg 35.79 kg 357.91 kg

R452A 2140 2.34 kg 4.67 kg 18.69 kg 23.36 kg 233.64 kg

R454B 466 10.73 kg 21.46 kg 85.84 kg 107.30 kg 1072.96 kg

R455A 148 33.78 kg 67.57 kg 270.27 kg 337.84 kg 3378.38 kg

Leak Checks - additional

• There’s no maximum interval for leak checks on hermetically sealed refrigeration and air conditioning systems unless they contain F-Gas equivalent to 10 tonnes CO2. That’s equal to 2.55kg of R404A or 7kg of R134a.

• There’s no maximum interval for leak checks on refrigeration systems in vehicles, unless the vehicle is a refrigerated truck or trailer.

• The maximum intervals didn’t apply until 2017 for equipment

that contains less than 3 kg of F-Gas. They apply NOW!

When is a ban not a ban?

• The phasedown quota system is written into UK law and generally does not refer to specific gases. It runs parallel to the F-Gas Bans.

• The quota allows for a mix of products as it measures CO2 equivalent Tonnes.

• The phasedown effect on individual high GWP products, such as R404A, is difficult to predict due to this but as the gap between demand and available quota increases, the pressure will be on to reduce the quantity of high GWP products significantly.

• Most of the comments will also apply to other gases with GWP > 2500. These are R507, R422A, R422D, R428A and R434A.

REFRIGERANTS – EU SUPPLY & DEMAND

2000

3000

4000

5000

6000

7000

8000

2015 2016 2017 2018

tonnes UK demand estimate

UK Supply (BAU)

Likely supply crunch

Assumes significant +ve effect on

available quota from MAC directive

Sold in Kg’s

-

50,000

100,000

150,000

200,000

250,000

R404A Performax LT R134a R410A R407A R407C C02

Kg Refrigerant

2016 (kg)

CO2 Equivalent 2016 (tCO2 eq)

-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

900,000

1,000,000


tCO2eq

GWP (tCO2 eq)

COMBINED CHART

-

200,000

400,000

600,000

800,000

1,000,000

1,200,000


Combined CO2 and Refrigerant

GWP (tCO2 eq) 2016 (kg)

Strategies to adopt to the changing regulatory environment

• Existing estate

• Reduce exposure to rising refrigerant prices:

• Retrofit R404A where feasible with lower GPW Products like R407F. R452A can be used in some smaller LT systems.

• Drive down leakage rates to make the reclaimed product last longer.(This is outside the scope of F-Gas quota).

• New equipment

• Stop installing R404A (R407A/F or R448A/R449A will buy time) . Any new system will have to be retrofitted in a few years time.

• Integrals can use hydrocarbons as a long term solution.

• Large multipack systems (>40kw) need to go to naturals, a cascade CO2 system or wait for a LGWP R404A replacement such as R455A (L40X).

DOING NOTHING IS NOT A VIABLE STRATEGY

Items to Consider when Retrofitting

• Due to changes in:-– Mass flow rates.

– Volumetric capacity.

– Operational Pressures.

• It would be prudent to consider:-– Re-calibration / Replacement of the expansion device.

– Investigating an Electronic expansion device, making superheat setting easier.

– System design pressures and PRV’s.

– Re-calibration of the pressure control devices of the system and pressure safety switches to ensure efficient control and reduce nuisance trips due to the change in operational pressures.

Retrofitting Systems

• Medium Temperature Systems– These can generally be retrofitted with the minimum of disruption.

– Considering information already presented.

• Low Temperature Systems– Dependent upon refrigerant choice, there will be an increase in

compressor discharge temperatures resulting in the need for additional compressor cooling.

– R452A has been approved by several manufacturers of hermetic compressors due to a discharge temperature much closer to R404A. However it has a higher GWP than the rest of the alternatives.

– Check with your compressor manufacturer / supplier for suitability and guidance.

What are the Alternatives to high GWP gasses?

Low GWP Options

Refrigerant GWP Flam. Class App. area

R448A 1387 A1 Medium & low temp. refrigeration

R449A 1397 A1 Medium & low temp. refrigeration

R452A 2141 A1 Transport

R454A 239 A2L Small non hermetic med. & low temp

R454C 148 A2L Non hermetic med. & low temp

R455A 148 A2L Hermetically sealed med . & low temp

• Replaces

• ASHRAE #:

• HFC/HFO blend:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

R407F

R32/R125/R134a

Zero Ozone Depletion Potential

1825 (AR4)

A1 non flammable

6.4K

Compatible with POE lubricants

Compressor approvals: Widespread. In >12000 supermarkets

globally, fully qualified by leading OEMs.

R407F – (Performax LT)

R404A

R448A – (N40)

• Replaces

• ASHRAE #:

• HFC/HFO blend:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

•

R448A


1387 (AR4)

A1 non-flammable

~4-5K

Can be topped off while servicing (do not mix with R-404A)


Bitzer, Dorin, Danfoss, Emerson, Frascold.

R32/R125/R1234yf/R134a/R1234ze(E)

Compressor approvals:

R404A

R449A – (XP40)

• Replaces

• ASHRAE #:

• HFC/HFO blend:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

•

R449A

R32 / R125 / R1234yf / R134a


1397 (AR4)

A1 non-flammable

~4-5K



Bitzer, Dorin, Danfoss, Emerson, Frascold &

Tecumseh.


R404A

R452A – (XP44)

• Replaces R404A/R507A

• ASHRAE #: R452A

• HFC/HFO blend: R32 / R125 / R1234yf

•

•

•

•

•

•

•Frascold, Danfoss, Tecumseh, Danfoss.

• Applications: High compressor discharge temperature e.g.

transport, hermetic piston compressors.

ODP:

GWP:


2140 (AR4)

ASHRAE safety: A1 non-flammable

Glide: ~3-4K




R454A – (XL40)

• Replaces R404A, R507A, R407A, R407F

•

•

•

•

•

•

•

R454A

R32 / R1234yf


238 (AR4)

A2L Mildly flammable

~4-5 K

ASHRAE #:

HFC/HFO-blend:

ODP:

GWP:

ASHRAE Safety:

Glide:

Compressor approvals:Danfoss, Frascold, Tecumseh.

• Compatible with POE lubricants

R454C – (XL20)

• Replaces• ASHRAE #:

• HFC/HFO-blend:

• ODP:

• GWP:

• ASHRAE Safety:

• Glide:

•

R22; R407CR454C

R32 / R1234yf


148 (AR4)

A2L Mildly flammable*

~4-6 K

• Compatible with POE lubricants

Compressor approvals:Danfoss, Frascold, Tecumseh.

• Replaces

• ASHRAE #:

• HFC/HFO blend:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

R455A

R32/R1234yf/R744


148 (AR4)

A2L Mildly-flammable

~6-12K



R455A – (L40X)

R404A

Danfoss

• Replaces

• ASHRAE #:

• HFO:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

See below

R1234yf or R1234ze


4,7

A2L or A1

0



Pure HFO

Higher GWP products

Danfoss, Frascold, Tecumseh,

R410A ALTERNATIVES

R410A Alternatives

Product Trade Name GWP Glide Flam. Class

R410 2088 <1K 1

R32 675 0 2L

R454B (XL41) 466 1K 2L

R452B (XL55) 676 <1K 2L

• ASHRAE #:

• HFC:

• GWP:

• ASHRAE safety:

• Glide:

R32

Single Component

675 (AR4)


0K


Compressor approvals: in progress (Already in use with Daikin)

R32

• ASHRAE #:

• HFC/HFO blend:

• GWP:

• ASHRAE safety:

• Glide:

R-545BA

R32/R1234yf

466 (AR4)


1K


Compressor approvals: in progress

R454B – (XL41)

• ASHRAE #:

• HFC/HFO blend:

• GWP:

• ASHRAE safety:

• Glide:

R-452B

R32/R125/R1234yf

676 (AR4)


<1K


Compressor approvals: TRANE Preferred Product

R452B – (XL55)

R134 ALTERNATIVES

R450A – (N13)

• Replaces

• ASHRAE #:

• HFC/HFO blend:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

•

R450A

R134a/ R1234ze


604 (AR4)

A1 non-flammable

~0.4K

MT / HT Refrigeration & Chillers


Bitzer, Danfoss, Dorin, Emerson, Frascold &

Tecumseh.


R134a

R513A – (XP 10)

• Replaces

• ASHRAE #:

• HFC/HFO blend:

• ODP:

• GWP:

• ASHRAE safety:

• Glide:

•

•

•

R513

R134a/ R1234yf


631 (AR4)

A1 non-flammable

0 K

MT / HT Refrigeration & Chillers


Bitzer, Danfoss, Dorin, Emerson, Frascold &

Tecumseh.


R134a

Too many Choices ?

Help is at hand

Help in selecting the right alternative

As you can see, there is no ‘one size fits all’ approach. It depends heavily on the system being installed.

A-Gas offers a system specific comparison of available replacements, allowing the engineer to choose what replacement gas is best for him from a report with over 20 relevant factors.

Simply supply some system specifics.

This can be applied to all the gases affected by the F-Gas GWP limits.

Help in selecting the right alternative

DATA REQUIRED for REFRIGERATION SYSTEM MODELLING

Enquiry from

COMPANY NAME

Contact Email

Contact Phone

What is the system [type] a/c, chiller, cold room, etc.

Existing Refrigerant, [type]

Age of system Years

Evaporating Temperature [°C]

Evaporating Pressure [bar] Evaporator Superheat [°k] Cooling Load [kW] Condensing Temperature [°C] Condensing Pressure [bar] Condenser Sub cooling [°k] Condenser Type [type] Air cooled, Water cooled, Evaporative etc.

Pressure Rating of Pressure Relief Valves [bar] Design Rating for vessels [bar] Type of Expansion device [type] Thermostatic, Capillary tube, float valve etc.

Compressor type [type] OPEN, Semi Hermetic, Hermetic Screw, Centrifugal, Piston, Scroll.

Compression [type] Standard, compound

Is it a flooded system? [yes / no] Can the client accept a loss of cooling

capacity from the system??

Is the equipment in good condition? Use a traffic light method

Green = Good Amber = not bad Red = Poor

https://www.agas.co.uk/refrigerant-suggestions/

High GWP Retrofit Report

Condenser=40ºC, Evaporator=-28ºC, Subcool amount=5K, Total Superheat= 10K

R404A R407F R448A (N40) R449A (XP40) R454A (XL40)

Safety Group A1 A1 A1 A1 A2L

GWP CO2 eq 3922 1825 1387 1397 246

Evaporating Temperature ºc -28.00 -28.01 -28.01 -28.01 -28.02

Evaporating Pressure bar.g 1.20 0.91 0.93 0.89 1.09

Evaporator Super Heat K 5.00 5.00 5.00 5.00 5.00

Suction Line Superheat K 5.00 5.00 5.00 5.00 5.00

Compressor Suction Temperature ºC -17.77 -15.88 -16.01 -16.07 -15.75

Compressor Discharge Temperature ºC 74.19 103.17 94.56 93.38 95.20

Condensing Temperature ºC 40.00 40.00 40.01 40.01 40.02

Condensing Pressure bar.g 17.21 17.19 16.90 16.59 17.19

Condenser Sub Cooling K 5.00 5.00 5.00 5.00 5.00

Liquid Line Subcooling K 0.00 0.00 0.00 0.00 0.00

Liquid Line Temperature ºC 34.83 32.79 32.68 32.69 32.27

Compressor Displacement m3/h 335.47 335.47 335.47 335.47 335.47

Volumetric Efficiency % 0.95 0.95 0.95 0.95 0.95

Isentropic Efficiency % 0.70 0.70 0.70 0.70 0.70

Mass Flow kg/s 0.97 0.69 0.73 0.73 0.74

Evaporator Cooling Capacity kW 100.00 107.19 103.97 101.88 108.38

Compressor Power kW 61.94 61.00 59.91 58.69 62.80

C.O.P. 1.61 1.76 1.74 1.74 1.73

Evaporator Glide K 0.45 4.25 4.02 3.88 4.54

Condenser Glide K 0.34 4.43 4.66 4.63 5.49

Volumetric Capacity kJm3 1129.61 1210.84 1174.41 1150.83 1224.26

Evaporator Inlet Temperature ºC -28.22 -30.14 -30.02 -29.95 -30.29

Condenser Capacity kW 166.08 171.06 166.96 163.62 174.46

Compressor Power Usage to maintain Original Duty Est % 0.92 0.93 0.93 0.94

Estimated power cost P/A £ £36,628.05 £33,649.55 £34,072.79 £34,064.24 £34,262.81

Refrigerant Charge kg 100.00 107.11 104.97 105.10 95.32

BS-EN-378 (2016)

EN 378: Proposed Update in 2016

Final Vote accepted in Q1, 2017

The new EN378 allows for FULL commercialization ofA2L refrigerants!

Trials can be done NOW.

BS-EN-378 (2016)

Example - Max Charge without limitation:

m1= 4m³ x LFL [kg/m³] x Factor

Factor for 2L is 1,5

Refrigerant R290 R152a R1234yf R1234ze R32

Safety class A3 A2 A2L A2L A2L

Charge [kg] 0,15 0,52 1,73 1,82 1,84

EN – 378 introduces some extra criteria in calculating charge size, and an emphasis on leak detection and control. Leak detection schedule based on CO2 equivalent charge and automatic monitoring.

Summary

• Consider not installing New Systems with R404A.

• R407F is the better value option in the short term.

• The new HFO blends help manage the F-Gas phase down requirements

• R448A/R449A improves system energy efficiency (4-15%)

• R448A/R449A are the best overall performing, lowest GWP, A1, R404A alternative currently.

• R455A provides simple, cost effective solutions as the GWP<150 threshold is reached

• AGAS is working with the industry to help meet the requirements for the new standards in refrigeration

THANK YOU FOR LISTENING

prepare for change low gwp alternatives · the refrigerant composition checked. –any substantial...

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