1. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 1 Session 1 NEW REFRIGERANTS AND PERSPECTIVE ENERGY SAVING Reversible Air-Conditioners and Heat Pumps Using Carbon Dioxide (CO 2, R744) as Working Fluid A.HAFNER & P.NEKSÅ SINTEF Energy Research 7465 Trondheim Norway www.sintef.no

2. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 2 CONTENTS RAC Air Flow Reversing Units MAC Summary Conclusion

3. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 3 R744 RAC split-type unit R744 RAC Split-type unit Two stage compressor + external oil separator Internal Heat Exchanger with HP bypass Shown in AC-mode

4. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 4 R744 RAC split-type unit The results demonstrate that it is possible for a R744 RAC split-type unit to match the energy efficiency of the best R410A unit on the market in heating mode and in cooling mode in colder climates. RAC System – Calculated SPFHeating ModeCooling Mode AthensOsloAthensOslo R744 prototype – measured data4.32.74.46.7 R410A-unit – manufacturer data4.02.65.36.7 Relative difference in SPF, R744 vs. R410A+7%+4%-17%0% Further development and optimization of the R744 unit, e.g. by utilizing microchannel heat exchangers, applying a compressor with a higher isentropic efficiency and/or using an ejector or expander for expansion work recovery, is required in order to achieve the same or higher energy efficiency in cooling mode in warmer climates.

5. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 5 Reversible R744 systems Refrigerant reversing unit Several valves required Additional cost Heat exchanger mode changes INDOOR OUTDOOR Alternative: Reverse Air flow!

6. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 6 Set-up (heating) INDOOR heating OUTDOOR cooling

7. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 7 Animation

8. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 8 Picture of the R744 turn-table ECU

9. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 9 Results Ambient temperature heating cooling Indoor temperature Indoor temperature [°C]

10. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 10 Temperature bin / Climate / Location

11. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 11 Office hours (8 a.m. – 5 p.m.) 3-3.2 MWh/a Dieselgenerator 2.3-2.5 m.ton/a Coal power p. 2.8-3 m.ton/a China / India 2.25 / 2.7 m.ton/a Energy Demand & CO2 Emissions

12. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 12 Energy Demand & CO 2 Emissions Non-office hours (5pm – 8am) 4.9 - 5.1 MWh/a Dieselgenerator 3.7 - 3.9 m.ton/a Coal power p. 4.6 - 4.8 m.ton/a China / India 3.7 / 4.3 m.ton/a

13. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 13 Summary: Air reversing unit An air reversing, turn-table ECU was designed and experimentally investigated with promising results. The refrigerant circuit can be unchanged, when directing the air through the designated heat exchanger by rotating the entire refrigeration unit. The function of the heat exchanger does not change, i.e. the gascooler can be optimized for a low temperature approaches. No refrigerant charge issues, this can be handled since no ‘dead’ lines are present.

14. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 14 MAC Mobile Air Conditioning Misuse of GreenMACLCCP, when comparing Non-Natural Alternatives with R744 MACs Reduction of fuel consumption of R744 MACs versus NNA’s (= energy saving potential), vehicle measurements by leading TIER 1 and OEM’s

15. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 15 Phase II Simulation results for energy Based on analysis of the accuracy and repeatability of the data, it is estimated that these values are within +/- 6%. February 23-24,2005 Saalfelden, Austria SAE ARCRP II Results

16. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 16 SAE ARCRP II Results, European Scenario

17. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 17 ARCRP II US Scenario

18. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 18 SAE ARCRP II Results -> LCCP ***.xls soon on www.R744.com

19. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 19 Direct Emission Reduction Emission reduction by replacing R134a with R744: Driving distance 15.000km/year times 140gCO 2 /km (NEDC) = 2100 kg CO 2 tailpipe per year w/o AC AC: 100g/y refrigerant leak fugitive over vehicle lifetime (regular and irregular leaks) Direct emission R134a: 100g/y times 1410 GWP = 141 kg of CO2 equivalent emissions Direct emission R744: 100g/y times 1 GWP = 0,1 kg of CO2 equivalent emissions 6% tailpipe equivalent emission reduction

20. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 20 OEM-Result

21. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 21 Indirect Emissions Calculation Annual fuel consumption, 15.000km/year w/o AC.867 l/y R134a FDC or VDC AC ON 60% @NEDC Annual AC fuel consumption117 l/y 12% R134a EVDC AC ON 60% & AC OFF 40%@NEDC Annual AC fuel consumption90 l/y + 6,0 l/y =96 l/y10% R744 EVDC AC ON 60% & AC OFF 40%@NEDC Annual AC fuel consumption63 l/y + 3 l/y =66 l/y 7% 2% reduction ~28€/y 5% reduction ~66€/y

22. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 22 Total Emission Reduction Total tailpipe equivalent emission reduction by implementing R744 MAC: 3-5% due to indirect emissions reduction (reduced fuel consumption) 6% due to direct emission reduction (minimum GWP substance replaces high GWP) 9-11% total tailpipe equivalent emission reduction

23. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 23 Vehicle Test Results – Fuel Consumption NEDC Fuel Consumption Test R134a vs. R744 VW Touran TDI 1,9l; T ambient =20/28/35 °C Additional Fuel Consumption R134aAdditional Fuel Cons. R744 T ambient Additional Fuel Consumption l/100km

24. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 24

25. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 25

26. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 26 Fuel Consumption Test Results Morgenstern, BMW, VDA Wintermeeting 2008 OEM-Result

27. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 27 Schührmanns, BCool, MAC workshop Torino 2007 OEM-Result

28. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 28 Haller, Valeo, MAC workshop Torino 2007

29. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 29 Small European Vehicle Fuel Consumption 1,5l gasoline engine T amb = 35°C, SunLoad = 850W HVAC setting: Outside Air and Blower Position 6 of 8 Fuel consumption

30. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 30 General Conclusion Efficient R744 RAC split-type units are possible. Turn-table residential AC-units, applying R744 as working fluid, are viable option for many global areas, where both heating and cooling is required during a year. R744 MAC systems are the most efficient, sustainable, non-flammable, environ- mental safe and global solutions for cooling and heating of vehicles in the future.

31. SINTEF Energy Research 13th EUROPEAN CONFERENCE; THE LATEST TECHNOLOGIES IN AIR CONDITIONING AND REFRIGERATION INDUSTRY POLITECNICO of MILAN 12th-13th June 2009 31 Thank you for your attention! Questions are welcome!!! Please ask for a copy of the presentation Contact: Armin.Hafner@sintef.no Acknowledgement: Many thanks for financial support of this effort from US-Army, and Modine for the ECU project. Many thanks for the ‘ppt-slides’ support from OE for the MAC chapter of this presentation.