The "Changing State" of Refrigerants

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NATE Course # 5397-0001

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Refrigerant Chemistry •CFC = Chlorofluorocarbon Rapid phase-out Stopped U.S. production in 1996 R-11, R-12, R-113, R-114, R-500, R-502

• HCFC = Hydrochlorofluorocarbon  Slower, staged phase-out

 U.S Product/Imports will stop in 2020, (2030 for R123)  R-22, R-123, R-124, R-142b  R-401a,b R-402a,b, R-408a, R-409a, R-414b, R-416a

• HFC = Hydrofluorocarbon  No U.S. phase-out planned – at this time ….  R-134a, R-143a, R-152, R-125, R-32,

 R-404a, R-407a,c,f R-410a, R422a,b,c,d R-427a R-507…….. 2/15/2013

US HCFC R-22 Phase-Out Plan 2003 US restricts R-22 Imports & Exports. HCFC R-141b phased out

2004 35% Reduction in R-22 production and import

Effective 10-07 2010 Reduction was amended from 65 to 75%

2010 No New R-22 Equipment Allowed

100%

Effective 1-2011 Annual 10% step-down

Effective 1-2012 EPA Announced a Immediate 45% cut

65%

Effective 1-2013 EPA Announced a Immediate 29% cut

35%

25%

2015 90% Reduction

13 SEER

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2021

2019

2017

2015

2013

2011

2009

2007

2005

2003

2001

0 Year

1999

10%

2020 No HCFC Product.

New Regulations Modified the Phase Out schedule & Allocation Rights for 2010-2014

R22 Allocation Rights By Company (in million-lbs) Company

Base Yr Allocation

2010

2011

2012

2013

2014

Arkema

64.9

27.2

24.6

22.1

19.5

16.9

Dupont

85.3

35.7

32.6

29.1

25.6

22.2

Honeywell

77.8

32.6

29.5

26.5

23.4

20.3

Others

34.7

14.6

13.3

11.8

10.4

8.9

Total

263

110.2

100

90 55

81 39.4

??

138

126

100

90

70

Projected Demand

They expect the shortfall to be filled by reclaimed or retrofit product

RSD Recovery Program

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RSD Recovery Program

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“Ozone Friendly“ HFC Refrigerant Blends

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Refrigerant Blend Basics •Most all Refrigerant Blends are a mixture of some or all of the following components •R-32 HFC •R-125 HFC •R-134a HFC •R-143a HFC •R-200 Series Hydro Carbon (Propane) •R-600 Series Hydro Carbon (Butane) •The mixture and percentage of each component varies depending on the blend and with (R290/R600) used solely to promote oil return in Mineral Oil systems •Each manufacture has a vested position in one or more of the components and they Buy or Sell to each other as needed. 2/15/2013

Your HFC Choices

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http://C:\Users\Public\Desktop\Genetron Properties 1.1.lnk/

Low Temperature R22 Replacements

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Medium Temperature R22 Replacement

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R22 Replacements in Med Temp Applications* Commercial Options 404A 407A, 407C 407F, 417A

421A,422A, 422B, 422C, 422D,424A,

427A,428A, 434A,438A, 507A

No Oil

90-100% cap match

Change

404A, 407A

422A, 422C

407C,407F 422A, 422C, 427A, 428A

428A, 434A 438A

434A, 438A

No TXV Change

507A

407A, 407C 407F,427A

GWP Values

422A = 3100 422C = 3100 428A = 2100

434A = 3200 438A = 2260 407A = 2012 407C = 1677 407F =1825 427A = 2100

High Temp - AC R22 Replacement

Why all this talk about Oil ?

• Proper Oil Return is a critical for any Refrigeration or AC System. • Miscibility between the refrigerant and the oil ensures the lubricant stays where it belongs ( in the Crankcase). • System design and operating temperature plays a key role • If a system has oil return issues with R22, changing refrigerants will only make it more pronounced. • Generally oils becomes trapped in the receiver, or is logged in the evaporator and low side piping. (Oil is harder to move at low temperature) • Oil logging not only is bad for the compressor but can have a significant impact on the performance of the system. • Oil acts as an insulator and inhibits heat transfer. An oil logged evaporator will act similar to an iced coil

More talk about Oil ?

• In the early days Multiple Oil Changes were recommended. “You must get +99% of the residual oil out” • Most felt the change was necessary because the oils were not compatible. This was never the case. • Some refrigerants claim to be no-oil-change solutions, but in most cases, system performance and compressor life are impacted.

• POE Oil is very Hydroscopic so Moisture Management is very important. • A Vacuum Pump will not pull sufficient moisture from the system, so use a properly sized liquid line drier. •POE Oil is a very good solvent and can cause issues in older, poorly maintained systems. •Now it is widely agreed that only percentage of POE is required to ensure proper oil return.

Oil Return Testing

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Seals and O-Rings • Rubber (Elastomers) Seals and O-Rings all absorb refrigerant.

• HCFC’s are absorbed more readily - Causing a greater Swell Rate. When the HCFC is removed, the seals contract to near there normal size. • HFC’s are not absorbed at the same rate so the seals will not swell as much and can cause leaks. • All Elastomer seals and O-Rings must be replaced. •EPR’s (SORIT) •Older Solenoid Valves (Wolverine seals are ok) •Heat Reclaim Valves •Shaft Seals on Open Drive Compressor •Schrader Cores and Seal Caps •This is true with ALL HFC Refrigerants NO DROP-INS

Schrader Cores and Seal Caps

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Compressor Shaft Seal

Evaporator Pressure Regulator 2/15/2013

Heat Reclaim Valve

Solenoid Valve

Most Popular Refrigeration Solutions Good R422D

Better R407A

System Compatibility

Near Drop-In for systems without a liquid receiver

Close capacity match with some system change required

Closest capacity match with some system change required

Lubricant Compatibility

Works with Mineral AB or POE Oil

Requires a % of POE Oil

Requires a % of POE Oil

Component Compatibility

All Elastomer/o-rings should be replaced

Expansion Device Compatibility

No TXV change. Fixed orifices should be evaluated

No TXV or Fixed orifice change needed

No TXV or Fixed orifice change needed

Capacity Relative to R22

89% at +20 f

103% at +20 f 95% at -20 f

107% at +20 f 101% at -20 f

Environmental & Safety Factors

2700 GWP A1/A1 Rated

2012 GWP A1/A1 Rated

Lowest 1825 GWP A1/A1 Rated

Characteristics

All Elastomer/o-rings should be replaced

Best R407F

All Elastomer/o-rings should be replaced

Popular Air Conditioning Solutions Good R422B

Better R422D - R438A

Lubricant Compatibility

Near Drop-In for systems without a liquid receiver Works with Mineral AB or POE Oil

Near Drop-In for systems without a liquid receiver Works with Mineral AB or POE Oil

Closest capacity match with some system change required Requires 20 % of POE Oil

Component Compatibility

All Elastomer/o-rings should be replaced

All Elastomer/o-rings should be replaced

All Elastomer/o-rings should be replaced

Characteristics System Compatibility

Expansion Device Compatibility Capacity Relative to R22 Heat Pump Considerations

No TXV change. Fixed orifices should be evaluated 90% at +105 f cond. Lower discharge temperature may impact heating performance

Best R407C

No TXV change. Fixed orifices should be evaluated

No TXV or Fixed orifice change needed

94% at +105 f cond. 96% at +105 f cond.

99% at +105 f cond.

Lower discharge temperature may impact heating performance

Similar discharge temperature and heating performance

R-407A LT •Cap

MT

AC

95% 103% 110%

•Mass FL 105% 112% 112% • Targeted at Low/Med • Requires POE oil • Currently Most Popular Refrigeration Substitute • GWP 2107 •Copeland Approved for Retrofit

R-407F LT

•Cap

MT

AC

101% 107% 114%

•Mass FL 102% 110% 110% • Targeted at Low/Med

• Requires SOME POE oil • Closest Capacity Match • GWP 1825 (lowest) •Copeland Approved for Retrofit

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R-407C LT •Cap

MT

AC

91% 99% 99%

•Mass FL 92% 99% 102% • Targeted at Med /AC • Requires POE oil • Most Popular Full AC Retrofit • GWP 1677 •OEM Approved New and Retrofit

R-422B LT •Cap

MT

AC

75% 85% 90%

•Mass FL 108% 116% 119% • Targeted at Med/AC

• Intended to separate ICOR from R-417a, MO59 • Potential no-oil-change product

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R-422D LT •Cap

MT

AC

79% 89% 94%

•Mass FL 123% 129% 131% • Targeted at Med/AC

• Used Extensively by WM in 2008 • Potential no-oil Change Product •AKA MO29

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R-438A LT

•Cap

MT

AC

81% 90% 96%

•Mass FL 100% 107% 112% • Targeted at Low/Med /AC

• May Require POE oil • GWP 2260 •Copeland Approved for Retrofit

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AC Retrofit Considerations and Check list • Always use proper tools and safety equipment.

• Identify and correct any system deficiencies. • Record baseline system data.

•Suction and Discharge Pressure • Liquid Sub Cooling and Suction Superheat Temps • Compressor Amps

• Disconnect electrical power .

• Evacuate the system and weigh the R22 Charge. •

Replace Elastomers – Rubber o-rings and seals.

•Schrader Cores and Seal Caps •Shaft Seals on Open Drive Compressor •Older Solenoid Valves (Wolverine seals are ok) not typical on AC System.

AC Retrofit Considerations - Continued • Change to or add POE lubricant if required. • Replace liquid line filter driers and suction filters. • Perform a system leak check. • Charge the system with replacement refrigerant blend. • Start at about 95% of the recovered R22 charge.

• Charge blended refrigerants in a liquid state using a throttling valve. • On Expansion Valve systems us the sub cooling method and refrigerant bubble point. • On Fixed Orifice systems use the superheat method and the refrigerant dew point.

• Allow the system to stabilize and adjust the charge as needed. • Label the system showing the new refrigerant and oil.

Pending Regulations

• Now that the wheels in motion to phase out Ozone Depleting Substances, the focus has been turned to Global Warming and the products believed to be the root cause. • GWP is a relative scale which compares the gas in question with carbon dioxide with a GWP of 1. • Refrigerant Gases (CFC’s, HCFC’s and HFC’s) are known to have high Global Warm Potential (GWP) and are under review. • There are a variety of domestic and international policies under consideration that will directly impact this issue and could have a dramatic impact on our industry. •California Refrigerant Management Program IS NOW THE LAW • Auto Makers are scheduled to phase out R-134a in auto AC Europe is underway, GM in 2013. • Proposing a carbon tax on GWP gases – Dead for Now 2/15/2013

New Regulations California Refrigerant Management Program • Defined a HGWP (High Global Warming Potential) substance as any that has as GWP value greater than 150 • Defined System sizes Small = 50 to 200 lb charge Medium = 201 to 1999 lb charge Large = 2000 lb and greater

• Established Registration and Leak Monitoring requirement based on system size

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GWP of Current Generation Refrigerants Refrigerant

AKA

R-134a

1430

R-22

1700

R-407C

KLEA 66 SUVA 9000

1677

R-407F

Proformax LT

1825

R-407A

KLEA60

2107

R-410A

AZ20 SUVA9100

2100

R-427A

FX100

2100

R-438A

MO99

2260

R-417A

MO59 NU22

2300

R-424A

RS-44

2400

R-422B

NU-22b XAC1

2500

R-421A

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IPCC Ver 4 GWP

2600

R-422D

MO29

2700

R-422A

MO79, One Shot

3100

R-422C

One Shot B XLT1

3100

R-434A

RS-45

3200

R-428A

RS-52

3600

R-404A

FX70/HP62

3900

R-507A

AZ 50

3985

Continuous Leak Monitoring Change – CA Only • The minimum Alarm threshold is now 100 ppm

• Most existing systems are set at 250 ppm • Instantaneous infrared systems can be reprogrammed (Honeywell Analytics) • Most sample draw systems cannot meet this requirement (CPC) • 100 ppm Calibration gas will be available soon

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South Coast AQMD Rule 1415-1415.1 •AQMD Governs : LA-OC –SBD-Riverside Counties only •In Dec-2010 Rule 1415 Modified to cover AC System only. • In Dec-2010 Rule 1415.1 Adopted to match the CARB Refrigerant Management Program. • AQMD also requires semi-annual inspection of recovery equipment. • All Documentation on the RSD/Refrigerant Suite

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What’s on the Horizon HFO Refrigerants (Hydro-Fluoro-Olefins) R-1234yf • The Replacement R-134a in New automotive Model starting in 2011 **Co2 is the other options with several limitations • A Jointly developed by Honeywell and DuPont • GWP rating = 4 • Very similar performance to R-134a - No Glide •Commercial production now underway

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What’s on the Horizon HFO Refrigerant Blends – Cont • Honeywell’s (Solstice®) refrigerants are now underdevelopment • Honeywell has already commercialized R-1234ze which is a good LGWP 134a replacement in 1 component foams and aerosol applications. • TEWI* ( Total Equivalent Warming Impact) is the new measure. *A factor of GWP and energy efficiency • L & N low GWP blends could be available as early as 2013

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What’s on the Horizon HFO Refrigerant Blends

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For more info go to www/rsd.net/refrigerantsuite or Call 800-245-8007 ex 00405

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Thank you !

Gary Parker [email protected]

2/15/2013