The Current State of R-22 and the Future with New Generation Refrigerants.

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Presentation transcript:

The Current State of R-22 and the Future with New Generation Refrigerants

Freon® The DuPont™ Invented, Workhorse Refrigerant of the last 50 years.

A Low Cost Supply of R-22 Refrigerant Management Plan Recovered R-22 Use recovered R-22 to service other equipment Return to Wholesaler refrigerant reclaim center to get value ($) for R-22 Reclaim Replace Retrofit Recycle System 1 R-22 System 2 System 3 System 4 System 5 System 6 System 7 System 1 MO99™ New System R-410A

R-22 Replacement Refrigerants Mineral Oil Compatible Full change to POE lubricant required Air Conditioning Refrigeration R-438A R-407C R-438AR-407AR-422D

Comparing R-22 “No Oil Change” Products for Air Conditioning Applications ISCEON® MO99™ (R-438A) R-422DR-422BR-421A 1 Capacity (%) COP (%) Components R-32/125/134a/600/601a 8.5/45/44.2/1.7/0.6 R-125/134a/600a 65.1/31.5/3.4 R-125/134a/600a 55/42/3 R-125/134a 58/42 Disch P (psi) Disch T (F) Temp Glide (F) Mass Flow (%) Performance relative to R-22; (+) is increase, (-) is decrease Calorimeter Data at AHRI Standard 540 Air Conditioning Conditions; Performance relative to R F Avg Evap Temp / 115 F Avg Cond Temp / 65 F Return Gas Temp / 15 F Subcool from Avg Cond Temp 1 POE Oil Change typically recommended for ‘HFC Only’ Blends

R-22 to ISCEON® MO99™ (R-438A) Retrofit Procedure* 1.Review retrofit guidelines 2.Obtain Baseline Data on R-22 3.Recover R-22 4.Change filter driers 5.Change critical elastomeric seals 6.Evacuate system & leak check 7.Charge with MO99™ ; Start-up and monitor 8.Leak Check, Label system, and optimize set-points if needed *ISCEON® MO99™ Retrofit Guidelines and ISCEON® MO99™ Retrofit Video –

Summary of Oil Management Considerations MO99™ excels in most Residential A/C, Commercial A/C, and Refrigeration These considerations are true for ANY “No Oil Change” product Use of any 400-series retrofit blend is not recommended in systems with flooded evaporators SystemGuidance More complex systems with potential for challenging oil return Long pipe runs and/or poor line velocity design Liquid receivers but no oil separator present ~20% POE addition Trane™ 3-D™ Scroll / Danfoss Scroll Replace Oil in Compressor Sump with POE Screw compressors Detailed system evaluation recommended

OPTEON® A new generation of low-GWP refrigerants.

Why Do We Need New Refrigerants? Worldwide focus on Global Warming (Climate Change)

ApplicationUseGWP LimitYearLimitation RefrigerationNew All New Centralized >40kW New Centralized >40kW Primary of cascade Service > 40mtCO2 eq (10.2 kg 404A) EU F-Gas II – drivers for low GWP Pre-charge impact Cap reduction impact GWP 404A A F a1430 XP GWP Limits – 404A banned HFC Cap/Reduction DuPont Confidential

Effective Date RefrigerantProposed Unacceptable for:Applications 2021 Model Year R134aMobile AC 1/1/16R404A/R507A Supermarket (Direct/Indirect) Condensing Units Stand Alone Systems Vending Machines New and Retrofit 1/1/16 HFC-227ea, R407B, R421B, R422A, R422C, R422D, R428A, R434A Supermarket (Direct/Indirect) New and Retrofit 1/1/16 R134a and others* Stand Alone Systems Vending Machines New Systems Summary of EPA Proposed Changes to SNAP *R407A, R407C, R407F etc.No proposed limitations on service of existing HFC systems

Creating the Future of Refrigerants HFOs provide a safe, sustainable, cost effective transition Capital Costs + Operation Costs ______________ Total Cost of Ownership Efficiency + Capacity _____________ Performance √  Zero ODP  Low GWP  No or low flammability

HFO-1234yf (CF 3 CF=CH2) Very Similar to HFC-134a but with very low GWP  Same operating conditions as 134a (similar P/T curve)  Thermally stable under extreme use conditions  Capacity and efficiency similar to R-134a  Mildly flammability (A2L) Vapor Pressure Pressure, MPa Temperature, o C R-134aHFO-1234yf FormulaCH 2 FCF 3 CF 3 CF=CH 2 Molecular Weight ODP00 GWP 100 (AR5) T Critical Point102 ºC95ºC Boiling Point-26ºC-29ºC DuPont Confidential

How HFOs Work HFC Hydro fluorocarbon HFC Hydro fluorocarbon HFO Hydro fluoro olefin HFO Hydro fluoro olefin Weaker double bond in HFOs allows for quicker breakdown in the atmosphere, yet stable in systems Weaker double bond in HFOs allows for quicker breakdown in the atmosphere, yet stable in systems

Mobile Air Conditioning Commercialized in 2011  New Car Models  Market Drivers  GWP Regulation in EU, US and Japan  Performance Benefits  Direct 134a replacement  Lower cost per vehicle vs. not-in-kind solutions

DuPont Opteon® Refrigerants NonflammableMildly Flammable CurrentGWPNameGWPNameGWP HFC-134a1430XP10631YF4 DR HFC-404A3902XP401397DR-7246 XP HFC-410A2088DR-5A460 HCFC DR-91988DR-3148 HCFC-12377DR-29 HFO based candidates AR4 GWP Values

Opteon® XP10 R-513A Replacement for 134a  Azeotropic refrigerant  Excellent capacity and efficiency match for 134a  Compatible with existing equipment design/lubricants  Reduction in GWP of 56%  GWP of 631 falls well below EU 1500/1000 lines  Azeotropic refrigerant  Excellent capacity and efficiency match for 134a  Compatible with existing equipment design/lubricants  Reduction in GWP of 56%  GWP of 631 falls well below EU 1500/1000 lines

XP10 Properties R-134aXP10 Chemical FormulaCF 3 CH 2 FAzeotrope 100 yr GWP (AR4) Toxicity/FlammabilityA1 Boiling Point °C (°F)-26 (-15)-29 (-20) Critical Point °C (°F)101 (214)98 (208) Temperature Glide °C (F)0Negligible (Azeotrope) DuPont Confidential

XP10 Calorimeter Testing -- Recip Compressor  2% better energy efficiency  5% higher capacity

XP10 Evaluation in Supermarket - Hybrid System - Retrofitted from R-134a Medium Temp; CO 2 in Low Temp - Running for four years DuPont Confidential

Annual Energy Use and TEWI Comparison TEWI reduced by 48% vs R-404A system DuPont Confidential

Opteon® XP44 R-452A Replacement for 404A/507  Matches discharge temperature of 404A/507  Critical for transport applications  Matches mass flow rate of 404A/507  No TXV adjustments necessary  Compatible with existing equipment design/lubricants  A1 non-flammable  Reduction in GWP of 44%  GWP of 2140  Matches discharge temperature of 404A/507  Critical for transport applications  Matches mass flow rate of 404A/507  No TXV adjustments necessary  Compatible with existing equipment design/lubricants  A1 non-flammable  Reduction in GWP of 44%  GWP of 2140

Opteon® XP40 R-449A Replacement for 404A/507  8-12% more energy efficient than 404A/507  Superior efficiency to CO2  Capacity equivalent to 404A/507  Compatible with existing equipment design/lubricants  A1 non-flammable  TXV adjustment needed similar to 407 series retrofit  Reduction in GWP of 67%  GWP of 1397 falls below EU 1500 line  8-12% more energy efficient than 404A/507  Superior efficiency to CO2  Capacity equivalent to 404A/507  Compatible with existing equipment design/lubricants  A1 non-flammable  TXV adjustment needed similar to 407 series retrofit  Reduction in GWP of 67%  GWP of 1397 falls below EU 1500 line

XP40 Properties R-404AXP yr GWP FlammabilityNone Boiling Point °C (ºF)-47 (-53)-46 (-51) Critical Point °C (ºF)72 (162)82 (180) Vapor Pressure at 25°C in kPa (Psia) 1254 (182)1274 (185) Liquid Density at 25°C in kg/m3 (lb/ft 3 ) 1044 (65.2)1096 (68.4) Vapor Density at 25°C in kg/m3 (lb/ft 3 ) 65.3 (4.08)49.2 (3.07) DuPont Confidential

System Testing – Display Case with External Condensing Unit  2.5 m (8.0 ft) open food display case designed for R-404A, fully loaded with food simulator  Reciprocating compressor with POE 32 oil  Refrigerant charge size ~3.8 kg (8.4 lb), adjusted based on liquid density  Tested per ASHRAE Standard  Tested at two ambient temps: 28ºC (82ºF) and 35ºC (95ºF) in outdoor room, 24ºC (75ºF) in indoor room  Only minor TXV adjustment made (1.6 turns closed)  Tested at low and medium temp conditions Open Display Case in Indoor Room Condensing Unit in Outdoor Room DuPont Confidential

Condensing Unit/Display Case Low Temp Results Energy Cons Rel to R404A Mass Flow Rate kg/hr (lb/hr) Suct Press kPa (Psia) Disch Press kPa (Psia) Comp Ratio Avg Food Temp ºC (ºF) Comp Disch Temp ºC (ºF) Ambient T = 28ºC (82ºF) R-404A100%32 (71)112 (16)1438 (209)13-17 (1.4)78 (172) XP4097%26 (57)104 (15)1407 (204)14-17 (1.4)83 (181) Ambient T = 35ºC (95ºF) R-404A100%33 (73)127 (18)1722 (250)14-16 (3.2)87 (189) XP4096%26 (57)115 (17)1685 (244)15-15 (5.0)92 (198)  ~3% lower energy consumption  Similar pressures and compression ratio  Modest increase in discharge T and slightly lower mass flow rate DuPont Confidential

Condensing Unit/Display Case Med Temp Results Energy Cons Rel to R404A Mass Flow Rate kg/hr (lb/hr) Suct Press kPa (Psia) Disch Press kPa (Psia) Comp Ratio Avg Food Temp ºC (ºF) Comp Disch Temp ºC (ºF) Ambient T = 28ºC (82ºF) R-404A100%38 (83)262 (38)1544 (224) (36)72 (161) XP4092%32 (71)262 (38)1496 (217) (36)75 (167) Ambient T = 35ºC (95ºF) R-404A100%41 (91)248 (36)1827 (265) (36)82 (180) XP4088%34 (74)283 (41)1792 (260) (37)84 (183)  8-12% lower energy consumption  Similar pressures and compression ratio  Less increase in discharge T and slightly lower mass flow rate DuPont Confidential

California Supermarket Conversion from 404A to Opteon® XP40 October 2014

DuPont Confidential Operational Data

DuPont Confidential Energy Data Daily Energy Usage and Average Temperature

DuPont Confidential Comparison Energy Data

DuPont Confidential California Retrofit Summary  Energy benefit of 9% from mid-Oct to year end  Potential for further benefit at higher ambient temps  No changes to equipment, piping, lubricant or seals/gaskets  Adjust TXVs for optimized performance  Meets cooling demand  Stable operation  Energy benefit of 9% from mid-Oct to year end  Potential for further benefit at higher ambient temps  No changes to equipment, piping, lubricant or seals/gaskets  Adjust TXVs for optimized performance  Meets cooling demand  Stable operation

DuPont Confidential 404A/507 Replacement Options Summary 404A/507XP40407A407FCO2 GWP < Energy Efficiency Base+8-12%== =/-* Capacity Base===NEW EQ TXV Adjustment BaseYes NEW EQ Oil POE NEW EQ * Poor at higher ambient conditions

Opteon® XP40 R-449A Replacement for R-22  Eliminates a retrofit to 407 series refrigerants  Capacity equivalent to 404A/507  Minimal TXV adjustment  Reduction in GWP of 22%  GWP of 1397 falls below EU 1500 line  Eliminates a retrofit to 407 series refrigerants  Capacity equivalent to 404A/507  Minimal TXV adjustment  Reduction in GWP of 22%  GWP of 1397 falls below EU 1500 line

DuPont Confidential R-22 Replacement Options Summary R-22XP40407A407F GWP < Eliminates a retrofit ($)? BaseYesNo Energy Efficiency Base=== Capacity Base=== TXV Adjustment BaseNo Oil MOPOE

Projected Timeline 2015 Emerson approval of XP10 and XP40 US Commercialization of XP10, XP44 and XP40 Mar/Apr Jul/Aug