Natural RefrigerantsNatural Refrigerants ‐‐Natural Refrigerants Natural Refrigerants 

Safe Efficient and Reliable UseSafe Efficient and Reliable UseSafe, Efficient and Reliable UseSafe, Efficient and Reliable Useas Alternatives to HFCas Alternatives to HFC

Workshop on High Ambient Temperature, Dubai 31/10/2015Workshop on High Ambient Temperature, Dubai 31/10/2015

Dr. Daniel Colbourne,Dr. Daniel Colbourne,Juergen Usinger Juergen Usinger 

Commissioned by Commissioned by 

GIZ ProklimaGIZ ProklimaGIZ ProklimaGIZ Proklima

Table of Content

Introduction 

Performance of AC at high ambientf f g

Product Safety Assessment

ProductionProduction 

Infrastructure After Sales 

(Examples from other sectors)

INTRODUCTION

Natural refrigerants (NR) such as Ammonia, Hydrocarbons, CO2 are increasingly used to replace substances with high GWP such as R410A R407C R32 because of the improvedGWP such as R410A, R407C, R32, because of the improved performance of NR, specifically with regard to the higher energy efficiency

Key issues in the transition to NR are the development of − design and production capacities of manufacturers− adequate standards that reflect state of the art− reliable infrastructures for quality services and supplies

PERFORMANCE OF AC AT HIGH AMBIENTIN INDIA 

Example: India

At least two enterprises develop ACs using HC‐290 

AC market in IndiaAC market in India‐ 2012 annual AC production about 10.5 m;    

demand now about 4 m/year‐ Annual growth rate ~10%‐ 1/5th for window units, remainder for split ACs‐ 95% of the market is “1TR” (~3.5 kW) and 

“1.5TR” (~5.0 kW)‐ Climate regions range from temperate to veryClimate regions range from temperate to very 

high ambient

Example: Production and Distribution of HC AC in India

Model Cooling capacity COP (EER) 2013 star rating Charge size

Production and Distribution of HC‐AC in India 

GSC 12 FG 7 WMG 3375 W (“1TR”) 3.72 7‐star 0.31 kg

GSC 18 FG 7 WMG 5000 W (“1.5TR”) 3.72 7‐star 0.36 kg

GSC 18 FG 5 WMG 5000 W (“1.5TR”) 3.45 5‐star 0.36 kg

Extensive work carried outpreviously to optimisep y pefficiency and minimiserefrigerant charge;see Devotta/Padalkar et al

RESULTS: RELATIVE CAPACITY, COP, PRESSURE RATIO, DISCHARGE TEMPERATURE

80%

100%

[%]

HC‐290 HCFC‐22

80%

100%

%]

HC‐290 HCFC‐22No performance degradation vsR22

20%

40%

60%Relative capacity 

20%

40%

60%

Relative CO

P [%

0%

20%

48 50 52Ambient temperature  [°C]

R

0%

20%

48 50 52Ambient temperature  [°C]

3

4

5

io [‐]

HC‐290 HCFC‐22

90

110

[°C]

HC‐290 HCFC‐22Improved working conditions vs R22

1

2

3

Compression rat

70

Discharge temp 

0

35 48 50 52Ambient temperature  [deg C]

C

50

35 48 50 52Ambient temperature  [°C]

TEWI Comparison Model Qe EER Ref

Model A 5050 W 3.51 HCFC‐22

Model B 5300 W 3.58 HCFC‐22

Comparison of TEWI and efficiency against 

ode 5300 3 58

Model C 5200 W 3.55 R‐410A

Model D 5275 W 3.60 R‐410A

Model E 5200 W 3.60 HFC‐32

equivalent products

15 power refrigerant

3.70

3.751.5TR '7-star'

10

WI [

tCO

2-eq

]

3.60

3.65

y (E

ER) [

W/W

]Model B

Model DModel E

5TEW

3.45

3.50

3.55Ef

ficie

ncy

Model A

Model B

Model C

01.5TR,5-star

1.5TR,7-star

ModelA

ModelB

ModelC

ModelD

ModelE

3.404 5 6 7 8 9 10

Specific cooling cost [Rs/W]

1.5TR '5-star'

Cycle performance and system efficiency of Split ACCycle performance and system efficiency of Split AC

In many regions performance at high ambient conditions very important:

• Test results for split air conditioner at high outdoor temps

• R290 and R22 performance veryR290 and R22 performance very close, but R410A and R32 drop off 

Source: Chen Zhen Hua, GMCC R&D Centre, China

Several manufacturers in

Other Air conditioners using R290

Several manufacturers in  Europe, China, India, Australia  primarily using R290

Charge sizes up to 1 kg/7 kW  cooling capacity

―Very high efficiency―Very high efficiency

Reversible systems available

Major shift to R290 underway  j yin China

―Availability will improve over  time

R290 production capacity for RAC in China

321,0001,430,000

1,732,000

529,000

329,000360,000

1,507,000

Source: MEP‐

,316,000

61,000Source: MEP

FECO/CHEAA, 2013

Ai di i liAir conditioners – split typeGree products

―Several models developed―Split, window, portable―Reversible and cooling only

―Products have safety system  integrated to reduce leak amount

―Lower cost than equivalent R22,  R410A d lmodels

Capacity  EER   Charge  Max  Dimensions  (mm)(kW) (W/W) (g) noise  

ID/OD  

(dB)2 7 3 55 265 38/52 d 830×284×2052.7 3.55 265 38/52 Indoor  830×284×205

Outdoor 760×257×5413.5 3.52 330 41/52

Air conditioners – split type

Mid dMidea products− Currently two sizes developed− Both reversible− Other products developed− Safety systems under development

Model Indoor  unit (mm)

Outdoor  unit (mm)

Cooling  capacity

EER Heating  capacity

COP R290charge

KFR‐ 850 × 275 780 × 54026GW/N7 Y‐Y(C4)

× 160 × 250 2.6 kW 3.4 2.8 kW 3.6 290 g

KFR‐35GW/N7

900 × 285× 160

780 × 540× 250 3 kW 3 4 3 kW 3 6 3 035GW/N7 

Y‐Y(C4)× 160 × 250 3.5 kW 3.4 3.7 kW 3.6 350 g

Air conditioners – split type

Benson air conditioningSi l li l ibl d h li

p yp

―Single cooling‐only, reversible and heat‐ recovery splits

Safety aspects―Designed to AS/NZS 1677 (similar to EN 378)―Charge size up to 1000 g of R290

Cost of R290 systems less than R410AEfficiency (cooling and heating) better thanEfficiency (cooling and heating) better  than competing R410A and R22 products

Ease of application of natural refrigerants

PRODUCT SAFETY ASSESSMENTPRODUCT SAFETY ASSESSMENTFOR AC WITH HC

Safe design with flammable refrigerats: Safety standardsRelevant standards

EN 378: 2008IEC & EN 60335 2 40IEC & EN 60335‐2‐40IEC & EN 60335‐2‐89

Within the USA, there are ,similar standardsUL471UL484ASHRAE‐15 (comparable in scope to EN 378)scope to EN 378)

Also draft ISO 5149…

Safety with flammability: Other safety features

O S SS SSPRODUCT SAFETY ASSESSMENT

Quantitative risk assessment

Operation: on 12% of time, IDU airflow on 26%; include operating faults

Sources of ignition: In room ~4 arcs/sparks per m2 per 24 h + continuous SOI (candle) for 1 h /24 h; non‐HC outdoor unit (20 arcs per 24 h) and cigarettes;(candle) for 1 h /24 h; non HC outdoor unit (20 arcs per 24 h) and cigarettes; electrical faults inside ODU and IDU; technicians replace faulty protected components with SOIs

Flammable quantities:12 kW unit with additional 

Model 1TR 1 5TR 12 kW

Flammable quantities: volumes, mass, times were modelled for the various leak sizes, into the rooms, 

Scenarios:

safety measures

Model 1TR 1.5TR 12 kW

Load 350 W/m2 170 W/m2 240 W/m2

Piping 15 m 15 m 15 m

IDU, ODU and outside

Leakage: annual leak rate 15%; frequency from 

Charge 0.35 kg 0.42 kg 0.75 kg

Room 10 m2 30 m2 50 m2

Persons 2 6 10

q ysupermarkets; overall 7×10‐4 per year; 

PRODUCT SAFETY ASSESSMENT

Quantitative risk assessment

Safety valve limits amount of gas that can leak into room 

Risk measure 1TR 1.5TR 12 kW

Quantitative risk assessment

Ign freq (room, unit off) (/y) 5.0E‐10 3.4E‐09 6.4E‐10

Ign freq (room, unit on) (/y) 1.3E‐10 1.5E‐10 2.1E‐10

Ign freq (IDU) (/y) 1 5E 16 1 2E 16 8 8E 17

Risk of ignition is >10,000 times lower than 

b k d i kIgn freq (IDU) (/y) 1.5E‐16 1.2E‐16 8.8E‐17

Ign freq (ODU) (/y) 4.3E‐13 6.3E‐13 6.3E‐13

Ign freq (outside) (/y) 1.7E‐10 2.2E‐10 4.5E‐10

background risk

g eq (outs de) (/y) . 0 . 0 .5 0

Total ignition freq (/y) 8.0E‐10 3.8E‐9 1.3E‐9

Freq secondary fire (/y) 8E‐11 4E‐10 2E‐10

Background fire frequency (USA) of ACs: 2×10‐5 y‐1

b k dMax overpressure (kPa) 5.8 6.0 6.7

Can break windows only; requires an instant 3.0 mm leak hole in IDU!

PRODUCTION CONVERSIONPRODUCTION CONVERSIONFOR AC WITH HC

PRODUCTION DESIGN

d /Requirements under Atex/EN 1127

Appropriate equipment used for production

PRODUCTION LINE CONVERSION

Refrigerant storage and feeding system *

Evacuation lines

Strength pressure test and tightness test

Refrigerant charging equipment *

Performance and electrical testPerformance and electrical test equipment

Repair area *

A safety monitoring, alarm and ventilation system *

* Equipment and installation also conform to Atex

INFRASTRUCTURE

Installation/servicing by non‐competent technicians major concern – critical to implement (finance‐based) incentive schemes)Sales and supply in case of AC

— “Mandatory” free installation — Free warrantee (1 – 5 years) is void if 

non‐certified technician interferes— Disposal covered by “E‐waste”

legislation (producer take‐back scheme)

— Sales staff and technicians check installation details (room size, charge size pipe length etc)size, pipe length, etc)

— All details recorded in databaseTechnicians must competent in handling HCs 

— Recruited through an examination,Recruited through an examination, subject to ranking scheme

— Assessment & experience lead to higher ranking 

— High ranking technicians have HC training – those which pass aretraining  those which pass are registered to handle HC

— ~800 qualified to handle HC countrywide

— Issued with appropriate tooling

SERVICE AND MAINTENANCE 

SERVICE AND MAINTENANCE

Summary of risk measures compared against values based for y p g“negligible” limits for worker (from UKG HSE)- For 450 g R290 split AC

Si ifi tl l th i k f i j f l ( fl bl )- Significantly lower than risk of injury from usual (non‐flammable) refrigeration practice

- Nevertheless, highlights importance for training

- No notable variation within the range of charge sizes (250 – 750 g)

Risk measureUntrained/ no competence

Good practiceLimit service workers (HSE)competence workers (HSE)

Total ignition freq (per visit) 1×10‐4 7×10‐6 < 5×10‐4

(per million; begin servicing) 106 7 500

Max overpressure (kPa) ~0 ~0 < 250Max overpressure (kPa) 0 0 < 250 

Max thermal int (s (kW m‐2)4/3) 182 182 < 1000

SERVICE AND MAINTENANCESERVICE AND MAINTENANCEQuantitative risk 

assessment – extensively l t ll l t d

Preparation Opening system

evaluate all related procedures for different Service and Maintenance 

activities

Strength pressure testRemove refrigerant Break into system

Charge refrigerant Close system Leak tightness test

FINAL REMARKS

Summary: Production and Distribution of HC‐AC in IndiaSummary: Production and Distribution of HC‐AC in India So far more than 100,000 HC‐290 split ACs introduced in India, Distribution in other countries has just started (China, Australia, Europe)

S i hi t f db k lit d t b d f t l i i li hi hService history, feedback, quality database and safety analysis implies high success

General, use of HCs− Impose new responsibilities on manufacturers for safe production practices 

Requires additions and changes to the existing production processes− Requires additions and changes to the existing production processes− Products must be designed for safety, capacity and efficiency− Infrastructure must be established to ensure safe environment− Re‐training of  technicians must be concurrent with development processesg p p

Safety issues related to high ambient− Flammability risk is extremely low; >10,000 times below background fire risk− Risk to service and maintenance technicians is a concern but still comparatively 

low to other acceptable risks

Compared to competing products, HC‐290 has lower TEWI, low‐ to medium cost (per kW) and higher efficiency

A ti iti i t d th f d tActivities are ongoing to expand the range of products

Developments include designs for greater integrated safety to further improve intrinsic safety of systems

FINAL REMARKS

Current status of R290 100000 ACs in the field  

Dents, other external

From the quality database, main problems identified

A fault rate of <0.5% per year implies excellent level of safety and general

Compressors (atcommissioning)

,damage

excellent level of safety and general reliability

Cooling complaints

Electrical faults (fanmotors,  circuit

boards)

Leak rate < 0.3% is extremely low (typically 10 – 15% for Article 5 

Leakage

Cooling complaintscountries)

Zero leaks from the IDU or IDU connecting

0 50 100 150 200 250 300 350

Number of faults

IDU or IDU connecting joint

FINAL REMARKSB d SAC d i lBased on new SAC designs – low charge, high efficiency products, 

most applications achievedRefrigerant charge compared to value in obstructive AC standard (under review)

1000

1200

Max charge

Equiv safety /

Higher capacities in larger spaces

800

arge

[g]

Add meas 250 W/m2

200 W/m2

larger spaces resolved through additional

400

600

R290

cha

150 W/m2

100 W/m2

additional measures

200 Cases in the risk assessment

0 0 10 20 30 40 50 60 70

Room area [m2]

assessment

El t f UK lElements of UK proposal

Releasable charge:

600

800

1000

t cha

rge [g]

Releasable charge:

Additional charge permitted, if d t t d it t l k t

0

200

400

Refrigerandemonstrated it cannot leak out

system off system on  sys on;check

temp; shutvalve

sys off;shut valve

sys on; gasdetector;shut valve

leaked not leakedoptional solenoid valve in suction line

indoor unit (e.g., evaporator)

valve in suction line

solenoid valve in liquid line

Measures for ensuring reduced leakage standard

Elements of UK proposal

f g g

Strength pressure test (mandatory)Leak tightness test (mandatory)

M h i l i t t t

standard

⎯ Mechanical impact test⎯ Vibration (transport) test⎯ Resonance test

C li⎯ Cycling test⎯ Drop test (with/out packaging)⎯ Conformity to tightness standard

Improved leak tightness

⎯ Corrosion (salt spray) test⎯ Components & joints to ISO 14903⎯ Additional design/construction 

tightness

features (prevention of frost damage, thermal cycling, etc)

Good Prospects for Natural refrigerantsGood Prospects for Natural refrigerants..... how to proceed

• Build risk awareness in the market and explain the difference betweenperceived and actual risk using a product

• Explain complexities associated with manufacturing and marketing of the• Explain complexities associated with manufacturing and marketing of theproducts of new versus the old refrigerants

• Develop competence of market actors in safe adoption and supply of newtechnologies and products and create competitive environment

• Implement awareness, training and certification to build capacity andcompetence in developing new products and qualified servicesp p g p q

• Develop or adapt the quality of technical standards for products and services

• Adjust or put new incentives and regulation in place, including bans, taxes, t f t d t d d b id li i i th tagreements, safety norms and standards, subsidy policies in the energy sector

03.11.2015 34

Thank you for your attentionThank you for your attention

APPLICATION OF NATURAL REFRIGERANTSAPPLICATION OF NATURAL REFRIGERANTS IN OTHER FIELDS 

Comparison of energy consumptionComparison of energy consumptionSource: Danfoss,2013

Existing chillers with natural refrigerantsExisting chillers with natural refrigerants

Plug‐in chillers and freezers

Many commercial cabinets  with R290, R1270, R600a

Plug‐in chillers and freezers

R290, R1270, R600a―End users report 5 – 15%  lower energy 

use

Numerous manufacturers withinNumerous manufacturers  within Europe, Japan,  Central America, Southern  Africa, China, SE Asia, etc

Two general categoriesTwo general categories―Movable type appliances  with charges up 

to 150 g

―Fixed appliances charges up to 1.5 kgFixed appliances charges up  to 1.5 kg

HC hillSeveral manufacturers using HCsBenson Bright Earthcare Frigadon Futron

HC chillers

―Benson, Bright, Earthcare, Frigadon,  Futron, Klima‐therm, Weatherite,  York/JCI, others…All produce chillers using HC and  other refrigerants (HFC HCFCother refrigerants (HFC, HCFC,  ammonia, etc)Used for both refrigeration as well as  air conditioning applicationsair conditioning applications

HC chillersBensonBenson

―Air‐cooled (scroll, screw)―Water‐cooled (scroll, screw)

Safety aspectsSafety aspects―Designed to AS/NZS 1677―Charge size up to 25 kg of R290 (per circuit)

Cost of R290 systems not more than HFCCost of R290 systems not more than  HFCR290 gives higher efficiency than HFC

HC chillers

Bundgaard KøleteknikAir ooled and ater ooled hillers―Air‐cooled and water‐cooled chillers

Safety aspects―Designed to EN 378; up to 15 kg of R1270

Cost of R1270 systems marginally  more than HFC products

Capacity range: 10 – 600 kW

Ammonia chillersGEA― Air‐cooled and water‐cooled  R717 

Ammonia chillers

Bank 2,400kW

(ammonia) chillers

Safety aspects

― Designed to EN 378

Event hall 5,200 kW

Railway station 1,250 kW

― Possible to install in public areas

Cost more than HFC/HCFCR717 gives higher efficiency than  

Institute 1,050 kW

a ay stat o , 50g g yHFC/HCFC

Shopping mall 1,020 kW

Office complex, 4220 kW

Plug‐in chillers and freezers – efficiencyExamples of data for chiller &  f b

R134a

R744: R600a:

freezer cabinets

Source:  Pedersen,2008 R744:

‐11.7%R600a:‐27,7 %

Source: King et al,2011

Source: van Gerwen et al,2008

Small HC condensing units

DanfossR f R290 d i it

Small HC condensing units

―Range of R290 condensing units―Smaller capacity range

Safety aspects―Designed to EN 378/EN 6035‐2‐ 89

High efficiency

Ducted with HCs

Aicool, Indonesia

Ducted with HCs

―Rooftop ducted and ducted split  systems developed to use R290

Safety aspectsSafety aspects―Designed to EN 378; up to 2.5 kg of  

R290 per refrigerant circuit

C t li htl hi h th R22 t―Cost slightly higher than R22 systems

Gram refrigeration

Plug‐in catering

Gram refrigeration―Commercial stand‐alone cabinets; R290 is standard

Safety aspectsDesigned to EN 60335 2 89―Designed to EN 60335‐2‐89

―Charge size up to 150 g of R290 and R600a

Cost of R290 systems same as HFC productsR290 has lo er energ cons mption than HFC optionsR290 has lower energy consumption than HFC options

Professional food and  drinks preparation

Other appliances

drinks preparation  equipment

―Shake sundae machine―Post‐mix beverage  machine―Juice dispenser

Ice makersCold storage

―Meat freezers and chilled  produce roomsproduce rooms

Viable application in larger coldstoresViable application in larger coldstores

NH3

HCs

CO2CO2

TESTED R22 & R290 SPLIT ACS AT HAT

R22 d lR22 model  R290 model 

Acceptable risk toCriteria Acceptable risk to  public

Risk from AC unit

Frequency of ignition (per year) < 1×10‐5 5×10‐10

Ignition events per million per year 100 0.005

Number of units per ignition event 1 in 100,000 1 in 2,000 million

Frequency of secondary fire (per year) < 1×10‐7 4×10‐12

Overpressure (kPa) < 15 4Overpressure (kPa) < 15 4

Thermal intensity (s(kWm2)4/3) < 250 40

Frequency of fatality (per year) < 1×10‐6 0

Source: Eurammon,2013

Comparison of certain optionsComparison of certain options

COP

PRODUCT SAFETY ASSESSMENT

Regulations/ directives

For flammable gas safety

For pressure safety

For electrical safetysafety safetysafety

Atex LVD PED

Harmonised standards

EN 1127 1 EN 60335 2 24 EN 378EN 1127‐1EN 60079‐EN 13463

EN 60335‐2‐24EN60335‐2‐40EN 60335‐2‐89

EN 378

G ll li bl I t ti l St d d R l ti d G id liGenerally applicable International Standards, Regulations and GuidelinesISO 5149/2014 Part 1-4 Refrigerating systems and heat pumps – Safety and environmental requirements

EN 378/2012 Part 1-4 (Revi) Refrigerating systems and heat pumps safety and environmental requirements ( )

ISO 817 Refrigerants -designation and safety classification

EN 13313:2010 Refrigerating systems and heat pumps competence of personnel

EN 50110 2 100 O ti f l t i l I t ll tiEN 50110-2-100 Operation of electrical Installations

DIN EN ISO 13585:2012 Brazing - Qualification test of brazers and brazing operators

EN ISO/IEC 17024:2012 Conformity assessment - General requirements for bodies operating certification of persons 17024:2012 y q p g p

ADR P200 European Agreement concerning the International Carriage of Dangerous Goods by Road

DOT - 4B, 4BA, 4BW… Department of Transport (US) Welded steel cylinders made of definitely prescribed steels

H h ld & i il l t i l li S f t P t 2 t 24EN60335-2-24:2010 Household & similar electrical appliances – Safety Part 2 to 24: Refrigerating appliances, ice‐ cream appliances & ice makers

EN60335-2-40:2003 Household & similar electrical appliances – Safety Part 2 to 40: Electrical heat pumps, air conditioners and dehumidifiers

Household & similar electrical appliances – Safety Part 2 to 89:EN60335-2-89:2010 Household & similar electrical appliances – Safety Part 2 to 89: Commercial refrigerating appliances, incorporated/remote condensing unit or compressor

Specific Standards and Guidelines for flammable Refrigerants EN6007:2009 Explosive atmospheres – Equipment - general requirementsp p q p g q

EN60079-10-1:2009 Explosive atmospheres - Classification of areas – explosive gas atmospheres

EN60079-14:2008 Explosive atmospheres – Electrical installations design, selection and erection

EN60079-15:2010 Explosive atmospheres - Equipment protection by type of protection “n”

EN 60079-15:2011-02 Equipment protection by type of protection "n“ (Gas detectors for leakage analysis)

EN 60079-0 Explosive atmospheres - Part 0: Equipment - General requirements (Gas detectors)p p q p q ( )

Specific Guidelines for Natural Refrigerants VDMA 24243-1/1:2006 Refrigerating machines and systems - Leak tightness of refrigerating systems and

heat pumps - Leak detection/leak testing Part 1: Basic principles

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PRODUCT SAFETY ASSESSMENTA t f f diff t l k h l i d i t d

1.0E+0

Account for a range of different leak hole sizes and associated leak frequency

1.0E‐1

cy [/y]

1.0E‐3

1.0E‐2

eak frequenc

1.0E‐5

1.0E‐4

Le

0.0 1.0 2.0 3.0 4.0Leak hole size [mm]

Comparative risk assessment – fridge vs. split RAC

HC fridge/freezers excellent safety record― Amongst approx. 700 million HC fridge/freezers, 

ignition frequency about 1×10‐8 per year… lower than “negligible”

vs.― Comparison of risk enables understanding of 

significance of HCs in split AC Risk lower by factor of >100×

1.E‐06

1.E‐04

1/1,000,000

1/10,000

0.02

0.03

0.04

centratio

n (kg/m3)

mean (measurement)

mean (model)

0 10

0.15

0.20

0.25

0.30

entration (kg/

m3)

mean

model

1.E‐081/100,000,000

/ , ,

0.00

0.01

0 100 200 300 400

Time (s)

Floo

r conc

0.00

0.05

0.10

0 50 100 150Time (s)

Conc

e

150 g from refrigerator gives

1.E‐10

public f

ire

fridge/

freeze

r

split RA

C

1/10,000,000,000refrigerator gives 

higher concentration than 400 g from AC