r-22 alternatives 11-16-12 - rses.org · r-32 r-125 r-143a r-134a r-290 r-600a r-600 r-601a...
TRANSCRIPT
R-22 Alternatives75th Annual RSES Conference
November 16, 2012
Stephen V. SpletzerSr. Technical Sales Engineer(610) 878-6980
Learning Outcomes / “Takeaways ”
Legislative / Regulatory Issues
Status of the R -22 Phase-out
Overview of Retrofit Issues
Ability to Make anInformed Retrofit Selection
Legislative / Regulatory Issues
Status of the R -22 Phase-out
NA HFC Submission to the MP
2015 2020 2025 2030 2035 2040 2045 20500
20
40
60
80
100
Year
Cap
(%
Bas
elin
e)
Non-Article 5 Parties
Article 5 Parties
2012 Proposed Allocation Rule
Regulatory Update
Illegal R -22 Importation
●DOJ Activity– HCFC-22 smuggling cases prosecuted
●Catch -22 Compliance Website / Number– http://www.klexserve.com/catch22– (866) 506-6134
●EPA Website– www.epa.gov/compliance/complaints/index.html
R-22 Transition Strategy
Service as usual● Refrigerant price / availability● Leaks
Replacement● Initial equipment costs● Energy savings● Refrigerant recovery
Retrofit● Refrigerant / equipment / labor costs● Refrigerant recovery● Energy costs
Refrigerant Terminology
Replacement Refrigerant : intended for long term use in new equipment
Retrofit Refrigerant : used for
servicing existing systems● Equipment changes● Oil changes
Replacements that are very similar to the original product may be used as retrofits
R-22 Replacement Refrigerants
Air Conditioning
Refrigeration
The Truth About R -22 Retrofits
None work as well as R -22 OVERALL
None are as efficient as R -22 OVERALL
None are “Drop -Ins”
None are miscible with MO or AB
None will work in every R -22 system
Overview of Retrofit Issues
Elastomer Changes
R-22 vs. HFCs with elastomers
May need to change seals during retrofit● Schrader valves / caps● Ball valves● Solenoid valves● EPRs● Filter-driers● Sight glasses● Receiver level gages● Etc
Leak check after retrofit
Working with Blends
Blend Identification● 400 or 500 series refrigerants● Azeotropes, Zeotropes, & Near-azeotropes● Charge all blends as liquid
Fractionation: preferential separation of a refrigerant blend’s components that occurs during phase change due to differences in component volatilities, which may affect performance / safety
Glide: a temperature gradient resulting from fractionation (evaporator / condenser) during the phase change process
Blends – Vapor vs. Liquid Charging
= High Volatility= Low Volatility
Blends – Understanding Glide
Evaporator Position
Ref
riger
ant T
empe
ratu
re
T1
T2
T3
T4
T5
1 2 3 4 5
1 2
3
4 5
INLET
OUTLET
= High Volatility= Low Volatility
Blends – Handling Leaks
Blend types● Azeotropes / Near-azeotropes● Zeotropes
Leak types● Liquid vs. Vapor● Running vs. Dormant System
Top–offs
Flooded evaporators
Discharge Temperature Effects
R-22 suffers from high discharge temps● May exceed 300°F,
@ high ambients / low temp
Discharge temps of R -22 retrofits lower● Most typically < 250°F,
even @ high ambients / low temp
Need for liquid injection, desuperheaters, & oil coolers reduced / eliminated
Improved capacity / efficiency for low temp
Ability to Make an Informed Retrofit Selection
R-22 Retrofit Blends
R-404A R-407A R-407C
R-407F R-417A R-417B
R-421A R-421B R-422A
R-422B R-422C R-422D
R-424A R-427A R-428A
R-434A R-438A R-507A
Etc.
Blend Compositions (weight %)
----------2.7----------18.3-----79.0-----R-417B
-------------------------40.0-----30.030.0R-407F
------------------------------50.050.0-----R-507A-----0.61.7----------44.2-----45.08.5R-438A---------------2.8-----16.018.063.2-----R-434A---------------1.90.6----20.077.5-----R-428A-------------------------50.010.025.015.0R-427A-----0.61.00.9-----47.0-----50.5-----R-424A---------------3.4-----31.5-----65.1-----R-422D---------------3.0-----15.0-----82.0-----R-422C---------------3.0-----42.0-----55.0-----R-422B---------------3.4-----11.5-----85.1-----R-422A
Added--------------------15.0-----85.0-----R-421BAdded--------------------42.0-----58.0-----R-421A
----------3.4----------50.0-----46.6-----R-417A
-------------------------52.0-----25.023.0R-407C-------------------------40.0-----40.020.0R-407A-------------------------4.052.044.0-----R-404A
LubricantR-601aR-600R-600aR-290R-134aR-143aR-125R-32
HFC Component Comparison
1 – Relative to R-22, Standard Cycle @ 105°F Condens er, 25°F Evaporator, 10°F of Superheat & Subcooling2 – From the IPCC AR4
Mass Flow Rate (%) 1
Discharge Temps ( °F) 1
Cond. Pressures (%) 1
Flammability
COP (%) 1
MO / AB Solubility
GWP (100 year) 2
V. R. Capacity (%) 1
- 36
+ 34
+ 62
A2L
- 5
Very Poor
675
+ 60
R-32
+ 84
- 51
+ 31
A1
- 11
Very Poor
3500
+ 7
R-125
+ 25
- 46
+ 19
A2L
- 7
Poor
4470
+ 5
R-143a
+ 8
- 36
- 34
A1
+ 0.6
Very Poor
1430
- 38
R-134a
GWP Comparison
Global WarmingPotential (100 Yr.)
1,700
4,000
2,300
3,200
R-22 G
WP
= 1,810
R-125 / R-143aBased Blends
R-404AR-428AR-434AR-507A
R-125 / R-134aBased Blends
R-417A R-417BR-421A R-421BR-422A R-422BR-422C R-422D
R-424A
R-32 / R-134aBased Blends
R-407AR-407CR-407FR-427AR-438A
High Side Pressure ComparisonBased on Standard Cycle 105°F
Condenser, 25°F Evaporator,10°F Subcooling & 10°F Superheat
0+10-10
-24 +24
-60 +60
R-417A
R-421A
R-424AR-422B
R-438AR-422DR-427A
R-407C
R-407A
R-422C
R-404A
R-421BR-428A
R-422AR-434A
R-507A
(psig)
CondenserPressure ChangeRelative to R-22
Much lower pressure
Lower pressure
Similar pressure
Higher pressure
Much higher pressureR-407F
R-417B
Refrigerant Capacities
Based on Standard Cycle25°F Evaporator,10°F Subcooling
& 10°F Superheat
80 90 100 110 120 13070
75
80
85
90
95
100
105
110 R-404A R-407A R-427A R-422B R-417A
Cap
acity
Rel
ativ
e to
R-2
2 (%
)
Condenser Temperature (°F)
Refrigerant Flow Rate Issues
Most R -22 retrofits require significantly higher refrigerant flow rates than R -22
Flow considerations for retrofit● TXVs● Pistons, orifices, cap tubes● Distributor nozzles● Line sets● Compressor valve plates● Etc.
Mass Flow Rates
R-407FR-407C
R-407A
R-427A
R-404A
R-417AR-417B
R-421AR-421B
R-422AR-422B
R-422CR-422D
R-424A
R-428A
R-438AR-507A
Refrigerant Flow Rates (% Relative to R-22)
R-434A
Based on Standard Cycles65 - 125°F Condenser,
25°F Evaporator,10°F Subcooling,& 10°F Superheat
90 100 110 120 130 140 150 160 170 180 190 200 210
GWP vs. Mass Flow Rate
Refrigerant Flow Rates (% Relative to R-22)
Based on Standard Cycles65 - 105°F Condenser,
25°F Evaporator,10°F Subcooling,& 10°F Superheat
R-404A
R-407A
R-407CR-407F
R-417A
R-417B
R-421A
R-421BR-422A
R-422B
R-422C
R-422D
R-424A
R-427A
R-428AR-434A
R-438A
R-507A
90 100 110 120 130 140 150 160 170 180 190 200 210
Glo
bal W
arm
ing
Pot
entia
l
Oil Miscibility -Use Matrix
YesNoNoHFCs
YesYesYes
(Limited)HCFCs
YesYesYesCFCs
POE (Polyolester)
AB (Alkylbenzene)
MO (Mineral Oil)
All R-22 retrofits are HFC-based refrigerants
All R-22 retrofits are immiscible with MO & AB
Immiscibility Issues - Oil Hold -Up
LIQUID REFRIGERANT
OIL-RICH LAYER
Immiscibility Issues - Oil Logging
21
3
4 5
POE Oil Change Issues
Labor & expense of oil change● Retrofit procedures
Solvency effects● Filter changes● Elastomers
Flushes● Multiple flushes often not required– Oil separators– Dirty installations– Oil concentration / purity
Performance improvement
Oil Change Trade -Offs
R-417A R-417B R-421AR-421B R-422A R-422BR-422C R-422D R-424AR-428A R-434A R-438A
% R-32 & R-143a
0 – 20
Pros
Lower Upfront Cost
Quicker Retrofit
No “POE Issues”
“No Oil Change ”R-404A R-407A
R-407C R-407F
R-427A R-507A
% R-32 & R-143a
20 – 52
Pros
Reduced Oil Logging
Reliable Oil Return
Best Performance
Oil Change to POE
Test Set-Up
1-½ HP R-22 condensing unit / evaporator assembly
Horizontal line-set sloped down from evaporator →→→→ compressor
Optimized refrigerant charge / adjusted TXV superhe at setting
Ran R-422D, R-427A, and R-438A with MO & POE (camer a)
100°F Ambient / 0, 25, & 50 °F Box Temps – “Dry Coil” tests
Condensing UnitEvaporator Unit
Test Data – Oil Return Results
PASSFAILR-438A
PASSFAILR-427A
PASSFAILR-422D
PASSPASSR-22
POEMO
Test Data – MO Runs
0 25 50
4000
6000
8000
10000
12000
14000
16000
R-422D / MO R-427A / MO R-438A / MO
Ref
riger
atin
g C
apac
ity (
Btu
/hr)
Box Temperature (°F)
Test Data – MO vs. POE Runs
0 25 50
4000
6000
8000
10000
12000
14000
16000 R-422D / MO R-427A / MO R-438A / MO R-422D / POE R-427A / POE R-438A / POE
Ref
riger
atin
g C
apac
ity (
Btu
/hr)
Box Temperature (°F)
Testing – Operating Parameters
-25
-20
-15
-10
-5
0
5
10
15
20
25A
vera
ge C
hang
e R
elat
ive
to R
-22
R-422D / MOR-422D / POER-427A / MOR-427A / POER-438A / MOR-438A / POE
SuctionPressure
(psi)
DischargePressure
(psi)
Mass FlowRate(%)
R-22 Retrofit Metrics*
*Standard Cycle 105 °F Condenser, 25 °F Evaporator, 10 °F Subcooling & 10 °F Superheat
Capacity (%)
Capacity (%)
0 0
-5 -5
+5 +5
+15 +15
-15 -15
+25 +25
-25 -25
COP (%)
COP (%)
0 0
-3 -3
+3 +3
+9 +9
-9 -9
+15 +15
-15 -15
MFR (%)
MFR (%)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
Discharge P (psi)
Discharge P (psi)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
Suction P (psi)
Suction P (psi)
0 0
-5 -5
+5 +5
+15 +15
-15 -15
+25 +25
-25 -25
Discharge T (°F)
Discharge T (°F)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
R-427A
Capacity (%)
Capacity (%)
0 0
-5 -5
+5 +5
+15 +15
-15 -15
+25 +25
-25 -25
COP (%)
COP (%)
0 0
-3 -3
+3 +3
+9 +9
-9 -9
+15 +15
-15 -15
MFR (%)
MFR (%)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
Discharge P (psi)
Discharge P (psi)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
Suction P (psi)
Suction P (psi)
0 0
-5 -5
+5 +5
+15 +15
-15 -15
+25 +25
-25 -25
Discharge T (°F)
Discharge T (°F)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
R-404A R-407A
R-407FR-507A
R-407C
R-417A
R-417B
R-421A
R-421BR-422A
R-422B
R-422C
R-422D
R-424A
R-428A
R-434A
R-438A
R-427A
R-404A
R-407A R-407F
R-507A
R-407C
R-417A
R-417B
R-421A
R-421BR-422A
R-422B
R-422C
R-422D
R-424A
R-428A
R-434A
R-438A
R-427A
R-421AR-404A
R-407A
R-407F
R-507A
R-407C
R-417A
R-417B
R-421B R-422A
R-422B
R-422C
R-422D
R-424A
R-428A
R-434A
R-438A
R-427A
R-421A
R-404A
R-407A
R-407F
R-507A
R-407C
R-417A
R-417B
R-421B
R-422A
R-422B
R-422C
R-422D
R-424A
R-428A
R-434A
R-438A
R-427A
R-421A
R-404A
R-407A
R-407F
R-507A
R-407C
R-417A
R-417B
R-421B
R-422A
R-422B
R-422C
R-422D
R-424A
R-428A
R-434A
R-438A
R-427A
R-424AR-421AR-404A
R-407A
R-407F
R-507A
R-407C
R-417AR-417BR-421B
R-422AR-422BR-422CR-428A
R-434AR-422D
R-438A
R-22 Retrofit Metrics*
R-427A
Capacity (%)
Capacity (%)
0 0
-5 -5
+5 +5
+15 +15
-15 -15
+25 +25
-25 -25
COP (%)
COP (%)
0 0
-3 -3
+3 +3
+9 +9
-9 -9
+15 +15
-15 -15
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
Discharge P (psi)
Discharge P (psi)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
Suction P (psi)
Suction P (psi)
0 0
-5 -5
+5 +5
+15 +15
-15 -15
+25 +25
-25 -25
Discharge T (°F)
Discharge T (°F)
0 0
-15 -15
+15 +15
+45 +45
-45 -45
+75 +75
-75 -75
R-407A
R-407C
R-427AR-407A
R-407C
R-427A R-407A
R-407CR-427A
R-407A
R-407C
R-427A
R-407A
R-407C
R-427AR-407AR-407C
Mass Flow (%)
Mass Flow (%)
*Standard Cycle 105 °F Condenser, 25 °F Evaporator, 10 °F Subcooling & 10 °F Superheat
R-22 Retrofit Recommendations
DX Systems OnlyDX Systems OnlyDX Systems OnlyLimitations
POE(MO / AB)*
POEPOEOil
Slight Capacity ↓↓↓↓Moderate Head Pressure ↑↑↑↑
Moderate Head Pressure ↑↑↑↑Cons
Close pressuresNo TXV changes
Lower GWP
Closest MT MatchNo TXV changes
Lower GWP
Closest AC Match No TXV changes
Lowest GWP
Pros
AC, MT, LTMT, LTAC, MTApplication
R-427AR-407AR-407C
* Successfully used with MO and AB with an Oil Sepa rator
Conclusions
Need for R -22 retrofits growing
Many R-22 retrofits● No “drop-ins” / No “1 answer”
Understanding basic HFC components key to differentiating products / advertising claims
HCs help with oil – immiscibility issues remain
R-407C, R-407A, & R-427A are good options