Transcript Retrofit Experience with R-22 Alternatives in Supermarkets

Refrigeration Regulations, Outlook,
Transitions & Alternatives
Charles Allgood, PhD
Senior Technical Service Consultant
DuPont ISCEON® Refrigerants
ASHRAE Meeting
11 November 2008
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WEEKS LEFT
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Agenda
Regulatory – Clean Air Act
Business Outlook – Managing the R22 phase out
Transition – Options and Alternatives
Call to Action – The time to act is now
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R-22 is going away
Millions
Estimated US R22 Supply Demand
for AC & Refrigeration
Important Facts
300
1.
62% Supply Reduction Jan 2010
2.
2010 demand matches supply
Total R22 Consumption
Allocation (lbs)
Quantity (million lbs)
250

AC & Refrigeration
Service Demand
Estimate (lbs)
3.
200
150
100
50
0
2007
11 Nov 2008
2010
2015
.
no room for supply error
2015 demand exceeds supply by
more than 22 Million pounds
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Compliance Requirements of the Clean Air Act
For Systems Containing 50 lb. + Refrigerant Charge Size
A 35% Maximum Leak Rate for Refrigeration, 15% AC
Maintain Accurate Records When Adding Refrigerant
Refrigerant Addition Determines Leak Rate
For Example: Top off a charge with 3% refrigerant, if only 30 days since
last service this equates to a 36% leak rate
Equipment owners legally responsible for
maintenance/records but most look to their service
contractors for assistance
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Penalties for Violating the Clean Air Act
Equipment Owners: (Example: Supermarkets)
Recordkeeping Violation $32,500/day Maximum Fine
Leak Rate Violation $32,500/day Maximum Fine
Up to $65,000/day
Producers and Importers: (Example: DuPont)
Consumption Allocation Violation $32,500/kilogram
$1.8 Million per 125/lb cylinder of R-22
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Clean Air Act: Summary of Impacts
HCFC supply demand imbalance is likely in 2010
Potential implications of doing nothing:
Interruptions to business if R-22 is not available
Uncertainty of R-22 price behavior
Cost / Availability of retrofit labor
Unplanned changes to Maintenance and Remodeling budgets
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Six R’s for Refrigerant Management
Recordkeeping
Repair leaks
Recover / Recycle
Reclaim
Retire old equipment; Specify new equipment with Non Ozone
Depleting refrigerants
Retrofit existing equipment to Non Ozone Depleting
refrigerants
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The Business Case for Switching Out R-22
R-22 is going away
62% Reduction in supply January 1, 2010, R-22 demand is strong
“Advanced” Refrigeration is Expensive per Ton CO2e
i.e. Secondary Loop Technology
Retrofit Refrigerants offer the Lowest Total Cost
Invest precious resources in higher ROI actions
Retrofits provide a low cost supply of R-22
R-22 Prices in the future likely to be volatile
Over 500% price increases in R-22 since January 2003
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R-22 Prices in the future likely to be volatile
HCFC-22 Cylinder Pricing*
*DuPont Sales Price Indexed to Jan 2003
550%
500%
450%
% Price Increase
400%
R22 prices
have increased more
than 500% since
January 2003
350%
300%
250%
200%
150%
Ja
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100%
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Managing the Transition
The Value Delivered by Retrofits
Refrigerant Options and Performance
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How Retrofitting Delivers Value
Supermarket Example:
Replace refrigeration equipment ~ $250,000 / Rack
Retrofit refrigeration equipment ~ $13,000 - $35,000 / Rack
Use reclaimed R-22 to service another store for ~ 5 years
Retrofitting early can help ease potential labor shortage
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Leading Retrofit Refrigerants for R-22
R-422D and R-422A
Refrigerant
Composition
R-422D
HFC-125/HFC-134a/HC-600a (65.1/31.5/3.4)
R-422A
HFC-125/HFC-134a/HC-600a (85.1/11/5/3.4)
•R-422D preferred for R-22 systems (no TXV changes likely; Engineering
Assessment recommended)
•R-422A is preferred for R-502/R-402A/R-408A systems (no TXV changes
likely); also can be used for low temp R-22 systems (TXV change needed)
Advantages:
•Easy to use
• Reliable
• Cost-effective
• Non-ozone-depleting
• Compatible with mineral, alkyl benzene and polyol ester lubricants; hydrocarbon aids oil
return of mineral oil
• Provides similar system performance
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Refrigerant Safety/Environmental Properties
ASHRAE
Refrigerant:
ODP
GWP (SAR 100yr.)
0.055
1500
A1
R-422D
0
2232
A1
R-422A
0
2532
A1
R-404A
0
3260
A1
R-22
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Safety Group
15
Condenser Pressure vs Condenser Temperature
(based on 20°F Evaporator, no subcooling)
450
R22
Condenser Pressure (psia)
R404A
R422A
400
R422D
350
300
250
200
100
105
110
115
120
125
130
135
Average Condenser Temperature (°F)
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140
145
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Evaporator Pressure vs Evaporator Temperature
(based on 105°F Condenser, subcool liquid to 95°F)
120
R-22
Evaporator Pressure (psia)
100
R-404A
R-422A
80
R-422D
60
40
20
0
-30
-20
-10
0
10
20
30
Average Evaporator Temperature (°F)
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40
50
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Summary of Calorimeter Data with 10ºF SC
Cooling Capacity vs R-22
EER vs R-22
Low Temp (–25º/105ºF)
R-404A
+33%
+15%
R-422A
+29%
+13%
R-422D
+8%
+14%
Med. Temp (+20º/120ºF)
R-404A
+7%
-3%
R-422A
Same as R-22
-7%
R-422D
-5%
Same as R-22
*Results with reciprocating compressor. Represents performance based on compressor capacity only; does not include heat
transfer effects, etc. R-22 assumes liquid injection at low temp. No liquid injection for R-404A, R-422A, or R-422D.
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Summary of Retrofit Procedures
1. Establish Baseline Performance with Existing
Refrigerant & repair if necessary
2. Remove Existing Refrigerant from System
3. Replace Filter Dryer, Elastomeric Seals/Gaskets, &
Other Equipment/Components Identified in Preplanning
(Ball Valves, Schrader Cores, TXV’s, etc.)
4. Evacuate System and Check for Leaks
5. Charge with R-422D or R-422A (Remove liquid only
from cylinder)
6. Start up System and optimize performance (adjust
TXVs, refrigerant charge, etc.)
7. Monitor oil levels to maintain desired level in oil
reservoir
8. Label System for R-422D or R-422A
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What to Expect After Retrofit from R-22 to R-422D***
• Discharge pressure (psi)
• +10 - low temperature*
• +12 - medium temperature**
•Discharge temperature (°F)
• -31 - low temperature*
• -66 - medium temperature**
• Estimated cooling capacity (%)
• +8 - low temperature*
• -5 - medium temperature**
• Estimated EER (%)
• +14 - low temperature*
• same - medium temperature**
*low temp: -25°F evaporator; 105°F condenser; 65°F return gas; 10°F subcooling.
**medium temp: -20°F evaporator; 120°F condenser; 65°F return gas; 10°F subcooling
R-22 assumes liquid injection at low temp
***Based on thermocycle model calculations and calorimeter data. Actual results may vary due to system design
and operating conditions.
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R-422D Retrofit from R-22 - Medium Temp Rack (NE US Supermarket)
Energy Consumption
Compressor kWh
Ambient T
800
100
R-22
R-422D
90
700
80
60
50
500
40
400
Comparable Energy
Consumption for MT
Retrofit 8/20-8/21/06
No TXV Change
No Oil Change
300
200
7/2
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7/12
7/22
8/1
8/11
8/21
Date
.
8/31
30
20
10
9/10
9/20
9/30
0
10/10
Temperature (°F)
Compressor kWh/day
70
600
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R-422D Retrofit from R-22 - Medium Temp Rack (NE US Supermarket)
Compressor kWh vs Ambient T
Compressor Energy Consumption (kWh/day)
R-22 kWh
R-422D kWh
Poly. (R-422D kWh)
Poly. (R-22 kWh)
800
700
600
Comparable Energy Consumption
With R-422D
500
400
300
200
100
0
0
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10
20
30
40
50
60
Ambient
Temperature (°F)
.
70
80
90
100
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R-22
R-422D
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Total Energy Consumption R-422D vs R-22
Low and Medium T (SW US Supermarket)
7500
7000
kWh/day
6500
6000
R-22
R-422D
5500
5000
4500
4000
40
45
50
55
60
65
Ambient Temp (ºF)
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70
75
80
85
90
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Retrofit Cost Example
•4 Rack Store with 1.49M Btu/hr load (35% LT/65% MT); 50 TXV/rack
Charge Size = 3000 lb
Assume 20% annual leak rate
Electric Cost = $0.10/kwh
• EER ((BTU/Hr)/Watt) based on Calorimeter Data at 80°F Condensing
R-22
R-404A
R-422D
Low Temp
6.09*
6.28
6.34
(-25°F Evap/70°F Liq/65°F Return)
Med Temp
15.68
15.68
15.52
(20°F Evap/70°F Liq/65°F Return)
*Liquid Injection used to control discharge T of compressor at 230°F
•POE Oil Change for R-404A
•100% TXV change for R-404A; assume 10% TXV change for R-422D
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Retrofit Cost
$45K
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Retrofit Cost
$14K
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R22 Retrofit
Refrigerant Selection
@ 120 F Condensing
2,500
$1,400
2,256
2,000
$1,000
1,625
1,500
$800
1,204
$600
1,000
$400
500
$200
0
$0
R-22
R-404A
Alternative Products
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R-422D
CO2 Equivalents/Year
Total Cost of Ownership
$1,200
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Summary – Supermarket Retrofits
• R-422D is an excellent supermarket retrofit refrigerant option in US
• R-422D has higher capacity and efficiency than R-22 in low temperature applications;
comparable efficiency in medium temperature applications
• No powerhead change needed with R-22 retrofits to R-422D; likely no TXV change, but
need System Analysis to verify post-retrofit TXV loading is adequate
• Lower Retrofit Cost than R-404A (~$30K savings in typical four rack store)
• Smaller Carbon Footprint than R-404A (30% lower in typical four rack store)
•R-422D and R-422A used successfully in supermarket refrigeration
systems
• Low and medium temperature refrigeration
• Multiple rack and case manufacturers
• Multiple compressor manufacturers
• R-22 and R-502 equipment
• Over 1500 retrofitted systems throughout the U.S.
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R-22 Alternatives
(Air Conditioning Equipment)
R-410A
R-407C
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R-410A - General Information
R-410A
Components
R-22
HFC-32/HFC-125
HCFC-22
50/50%
100%
Yes
Yes
R-410A
R-22
Safety Designation
A1
A1
Capacity (Rel to R-22)
1.4
1.0
Efficiency (Rel to R-22)
.95 to 1.05
1.0
New design only
--
Composition (wt%)
UL Recognized
ASHRAE NO.
Application
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Operating Characteristics
R-410A is a “near azeotropic” blend.
Temperature “glide” is less than 1 F (0.5C) and is NOT a
factor.
Leaking R-410A systems can be “topped off” with more
R-410A without removing the charge.
R-410A should be removed from the cylinder as a liquid.
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Saturation Pressure (psig): R-22 vs. R-410A
700
600
500
400
R-22
R-410A
300
200
100
0
0
20
40
60
80
Temperature (F)
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100
120
140
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Cylinder Pressures at 70F of Commonly Used Refrigerants and Industrial Gases
3000
2500
2500
Oxygen
Nitrogen
2500
Pressure (psig)
2000
1500
1000
830
500
136
164
201
R-22
R-404A
R-410A
250
0
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Acetylene
.
CO2
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Suva® 410A Cylinder Design
R-22
R-410A
• DOT #39 (DAC)
• DOT #39 (400)
• Service Pressure 260 psig
• Service Pressure 400 psig
• Test Pressure
325 “
• Test Pressure
• Burst Pressure
650 “
• Burst Pressure 1000 “
• RV
• RV
341 - 520
525 - 800
Do not store ANY refrigerant cylinder above
125ºF.
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500 “
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R-410A in AC/Heat Pumps
Discharge pressure: + 50 to 70%
Capacity: + 40%
Discharge temperature: -10F
12 to 14 SEER meets- DOE guidelines
Wall thickness increased:
• compressor, accumulator, cond. tubes, filter drier,
reversing valves
POE lubricants
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R-410A - Service Equipment
Manifold gauge sets
R/R equipment
• FT FM3600-410A; Promax RG-5410
Recovery cylinders
• DOT 4BA400; 4BW400
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Summary: R-410A
• Safe, non-flammable refrigerant
• Can top off leaks with no noticeable performance
change
• Best performance achieved if removed from cylinder
as a liquid
• High energy efficiency possible
• R-410A: new equipment only
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Conclusions
R22 is going away
The time to act is now
Develop a Refrigerant Management Plan
Survey Equipment, ID units operating on HCFC’s
Know how equipment performs vs. regulatory requirements
Develop plan for change out of HCFC’s
- consider age and history of equipment
- also remodel/shutdown/operation plans
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