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R22 Phase-Out in Greece… and what to do?

Joachim GerstelDuPont de Nemours (Deutschland) GmbHNeu-Isenburg/ Germany Feb. 2009

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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REFRIGERANTSISCEON ®

Suva®-

Freon®

FLUOROCHEMICALSPECIALTIES

Zyron Vertrel FormacelDymel

FE

FILMSTedlar®

Teflon®

Nafion®

Fuel Cell

FLUOROPOLYMERSTeflon® PTFETeflon® PFA Teflon® FEP

Teflon®

Finishes

Fluoroproducts Tree:

F-22

Tefzel® ETFE

FluorsparChloroformHF

H2SO4

5

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Dordrecht/ NL

Production & Blending Plant

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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(EC) No 1005/2009 replaces 2037/ 2000

1.Jan. 20101.Jan. 2010Stop of R22Stop of R22--SalesSales

StopStop of R22of R22--ServiceService

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(EC) No 1005/2009 replaces 2037/ 2000by Jan. 1, 2010

http://eur-lex.europa.eu/

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Segmentation R22-Bank

1. Comm. 1. Comm. RefrigRefrig(40-60%)

2. Industrial2. IndustrialRefrigRefrig..

(20-30%)

3. A/C3. A/C(5-15%)

4.Transportcool.4.Transportcool.(1-5%)

EU25-Countries

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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• Keep running existing equipment- change of oil and further technicalmodifications are required:

HFCs of theSuva® range, e.g.R404A or R407C

Four Options

• Maintainoperationusing recycledR-22 = Risk!

• Keep running existing equipment– only moderate modifications arenecessary:

retrofitwith DuPontTM

ISCEON® 9 SeriesRefrigerants

Attention!

• Replace withnew equipmentrunning on:

ammoniahydrocarbonsCO2HFC, e.g. Suva®

R22-Phase-Out -- Options for Retrofit

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The ISCEON® Solutions

Equipment with Serviceable Life• Convert to Cost Effective non-ozone depleting alternatives

R12 / R401A / R409A/ R413A ISCEON® MO49Plus (R437A)

ISCEON® MO29 (R422D) or

R22 ISCEON® MO59 (R417A) orISCEON® MO79 (R422A) or

(Expansion valve change required)

R402A / R403B / R408 / R502 ISCEON® MO79 (R422A)

{

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ISCEON® MO49Plus (R437A)

• ISCEON® MO49 (R413A) Production stopped• MO49Plus (R437A) now in use• Main enquiry is regarding top up• DuPont position:

“ DuPont does not recommend the mixing of refrigerants as this can lead to systems with unpredictable performance and any recovered refrigerant would need to be incinerated”

• However, in practice we do not know of any specific performance or safety related issues should the products become mixed.

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Selection of R22-Replacements

ISCEON® ASHRAE-Nomenclature

Safety-classification

Applications:

MO29 R422D A1 Commercial MT, LT (2-stage, Liquid Inj.), DX-Waterchiller

MO59 R417A A1 Split AC with cab tupe Q0<15kW

MO79 R422A A1 MT, LT especially for R502, R402A, R403B, R408

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Selection of Refrigerants replacing R22

Freon® 22 ISCEON® MO29 ISCEON® MO59 ISCEON® MO79ASHRAE # R22 R422D R417A R422AASHRAE Classification (Safety) A1 A1 A1 A1Molecular mass [g/mol] 86,5 109,94 106,75 113,6ODP 0,055 0 0 0Technical Data

Boiling point at 1 bar [°C] -40,8 -43,5 to -38,6 -39,4 to -34,4 -46,8 to -44,3Discharge Temperature [°C]

at -10°C/ +40°C; t0h=10°C; ηi=0,7 105 75 77 72

Discharge pressure [bar]at -10°C/ +40°C; t0h=10°C; ηi=0,7

15,3 15,9 14,0 18,3

Cooling Capacity (compared to R22) - 0-5% less 5-20% less 10-20% higherComposition [weights %] HCFC-22: 100 HFC-134a: 31,5

HFC-125: 65,1Isobutane: 3,4

HFC-134a: 50 HFC-125: 46,6

Butane: 3,4

HFC-134a: 11,5HFC-125: 85,1Isobutane: 3,4

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Summary of Calorimeter DataCooling Capacity vs R-22 EER vs R-22

Low Temp (liq. Inj.)R-404A +33% +15%

ISCEON® MO79 - +29% +13%

ISCEON® MO29 +8% +14%

Med. TempR-404A +7% -3%

ISCEON® MO79 Same as R-22 -7%

-5% Same as R-22ISCEON® MO29

Actual results may vary due to system design and operating conditions

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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Retrofit Guidelines forISCEON® MO29

8 Steps from establishing baseline performance with existing refrigerant until labelling system showing the refrigerant (and any replacement

lubricant) used. Update system log-book.

www.isceon.com/eu

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Before conversion to an ISCEON® 9 Series Refrigerant

• Check current system performance

• Check Capacity Available vs. Capacity Required

• Ensure system is in good working order• Conversion to an ISCEON® refrigerant will not solve existing

problems.

• Check Product Information Bulletin for suitability

• Refer to Retrofit Guidelines

• Have available product pressure/temperature tables

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During conversion to an ISCEON® 9 Series Refrigerant:Follow the advice given in the product retrofit guidelines

• Majority of problems reported could have been avoided if the guidelines were followed

Follow good refrigeration practice principles• Do not take short cuts

Use pressure-temperature tables for the product being used

• The pressure-temperature relationships are different and it does make a difference

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Summary of Retrofit Procedures1. 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, Magnetic Valves, etc.)

4. Evacuate System and Check for Leaks

5. Charge with ISCEON® MO29 (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 ISCEON® MO29

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ISCEON ® is a technical sale, not a drop in !

• Revamped retrofit guidelines

• Hints and Advice for technically advanced partners

• Technical Bulletin

• Validation of solutions for more system types : pump systems, chillers, process cooling , on-farmmilk cooling

• Work closer with the Contractors

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Retrofit Experience using the ISCEON®Solution

Systems under good conditions => No Issues!

BUT:

• Elastomeric seals (like O-Ring, Terminal board as well Ball- / Schradervalves) exchange

• Oil circulation (Level control at compressor sight glass)Systems without oil separator

Chiller with part load

Old compressors with high oil throw

Cooling Capacity should be calculated by using Software DuPrex 3.0!

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Compatibility with Elastomeric Seals

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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Cost Analysis from the Operator‘s Point of View

COPCOP

Components

Material Time

COPCOP

Components

Material Time

• Refrigerant• Oil

• Refrigerant• Oil

• Filter dryer• TXV• Condenser• Seales/ Gaskets

• Filter dryer• TXV• Condenser• Seales/ Gaskets

• Replacement ofcomponents

• Multipleexchange of oil (POE)

• Replacement ofcomponents

• Multipleexchange of oil (POE)

• Relocation of stored foods

• Relocation of stored foods

• Loss in sales because of partial/temporary close-down

• Loss in sales because of partial/temporary close-down

• Payment of overtime

• Payment of overtime

Operator’sExpenses

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Retrofit Cases

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Milk cooling with ISCEON® MO29

ELAS-partner Werner Bergmann: „The refrigerants experts of DuPont had given us excellent advice in the run-up to the retrofit. Following their suggestion … the mineral oil in the system was replaced by polyolester oil with a similar viscosity. This way we were able to manage the pilot project without disturbing during the daily routine at the farm … The complete retrofit was done smoothly during the milking breaks.”

- ELAS Systems Service GmbH at Elsterwerda -

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Minimal Muenster, Germany - Supermarket- Retrofit from R22 to ISCEON® MO29 on March 20, 2006 -

Medium Temperature1 x 4 meter Sausage cabinet at 4ºC 2 x 3 meter Meat Cabinet at 4,5ºC5 x 2,5 meter Dairy Cabinets at 4ºC4 x 36m3 Chilled food coldstores at 5ºC3x 5 meter refrigerated sales cabinets

Dscf8847.jpg

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Minimal Muenster, Germany - Supermarket

Medium Temperature BBC-Integral Rack3 Copeland compressors – model D3DA3-750 with Shell 22-12Total capacity: 60 kW

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Minimal Münster - Supermarket

R-22 ISCEON® MO29

Evaporation temperature -12°C -13°C

Condensation temperature 30°C 34°C

Refrigerant Charge 75 kg 80 kg

Hot Gas temperature 63,9°C 55,6°C

Compressor Current Ø 11,25 A Ø 11,00 A

Ambient temperature 3°C 9,6°C

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Commercial AC - Chillers

Medium load Low load

R22 ISCEON® MO29 ISCEON® MO29 ISCEON® MO29Discharge Pressure / bar.g 13.5 14.4 13.3 11.9Condensing Temperature / ºC 37.8 37.3 34.3 30.3Liquid Line Temperature / ºC 31.0 35.0 33.1 30.9Sub-Cooling / K 6.8 2.3 1.2 -0.6Condenser outlet temperature / ºC 32.1 - - -Condenser inlet temperature / ºC 28.0 - - -Temperature difference / K 4.1 - - -Suction Temperature / ºC 7.7 12.0 3.1 3.0Suction Pressure / bar.g 4.0 4.0 4.1 4.1Saturated suction temperature / ºC 0.2 1.0 1.6 1.8Superheat / K 7.5 11.0 1.6 1.2Water on temperature / ºC 8.8 14.2 8.5 8.0Water off temperature / ºC 5.2 10.6 5.9 6.1Water T / K 3.593 3.587 2.660 1.936Discharge Temperature / ºC 63.4 63.6 50.4 30.9Cooling Capacity / kW 91.9 91.7 68.0 49.5

100%

France Telecom, Paris, France; December 2007Compressor: Trane L2F5E81NChiller Model: LCG 105F

Initial Poor performance was traced to a faulty TXV

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DX- ChillerAluminium Plant

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Aluminium Norf GmbH• Retrofit done by Johnson Controls Systems & Service GmbH

• Chillers for cooling the production lines

• 2 Systems Aircooled Condensers- 2 Refrigerant Circuits with 1 Piston Compressor- Cooling Capacity 800 kW

• 1 System Water cooled Condensers- Cooling Capacity 400 kW

• Replacement of Filter Dryers

• Performance Control R22 / MO29

• Nearly identical Performance

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Frankfurt’s town hall “Römer”

•Water chiller retrofitted in Sept. 2007

•Part of routine maintenance procedures

•Reals and mineral oil were renewed

•Satisfactory performance since retrofit

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Spanish Navy – AC & Refrigeration

R-22 ISCEON® MO59Condensing Pressure 15.3 bar.g 13.0 bar.gCondensing Temperature 42.5ºC 41.4Evaporating Pressure 4.3 bar.g 3.6 bar.gEvaporating Temperature 1.9ºC 2.0ºCDischarge temp 56.0ºC 45.0ºCSuction Temp 5.2ºC 6.0ºCAir Exit 20.0ºC 19.0ºCAir in 31.0ºC 34.0ºC

Submarine Air ConditioningCompressor: York FS62ANo Change of Oil Type

*

•Mean evaporating Temperature

Water chiller on this frigate also successfully retrofitted

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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SPAR (Edeka) Cold Store Ellhofen- Retrofit from R22 to ISCEON® MO29 on March 29, 2006 -

Key Information

• Cold Store Medium Temperature Application with 36.500 m³• Rack with 4 Copeland DWM Compressors from 1991• Reconstruction: 2 additional Copeland Compressors added• Oil type: Shell 22-12 … one oil change• Cold Store with 20 evaporators (20 TXV)• Contractor Company: Carrier Commercial Germany• R22 charge: 1000 kg• MO29 charge: 930 kg

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SPAR (Edeka) Cold Store Ellhofen- Retrofit from R22 to ISCEON® MO29 on March 29, 2006 -

Key learning• Retrofit took 2 days (change of filter drier, oil Shell 22-12, refrigerant)

• Cooling capacity was equal R22

• Issues around oil return in the beginning• Shell 22-12 created a layer of 3-4 mm on top of the MO29, seen in the receiver sight glass• oil level in the compressors was in the beginning at min• Significant refrigerant leakages occur due to Compressor-”Klemmbrett”-Sealings• Other Leakages due to leaking magnetic valves and ball valves

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SPAR (Edeka) Cold Store Ellhofen- Retrofit from R22 to ISCEON® MO29 on March 29, 2006 -

ÖlreichePhase

Oil Layer

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Pump Circulation Systems with R22

C: Condenser

K: Compressor

HS: Level Control

A: Separator

P: Pump

V: Evaporators

Source Wikipedia

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Pump Circulation System - Retrofits

1. Vessel - Freezing of fresh Fish• Sabroe TSMC 116S Compressor (2-stage with Economizer)

5%longer freezing time; similar power consumption; with MO

2. Cold Store – Low Temperature• 3 Stal Screw Compressors with 2-stage Oil Separation using Alkylbenzene

Lubricant4% higher Current; 1,5 bar higher cond. Pressure; same cooling capacity; with ABIssues with Elastomer Seals

3. Cold Store for Fruits• Bitzer open-type reciprocating compressors, a low pressure surge drum and a Witt

liquid pump5-10% lower capacity; 8% higher power consumption; with POE; change of Elastomer Seals

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Commercial Appl: Comparison R404A vs. ISCEON®MO29 (R422D)

Application and Compressor Technology depended

o Application: Medium- and Low Temperature

o Compressor Technology (only Low Temp)

a) 2-stage with sub cool effect

b) 1-stage with liquid injection

c) 1-stage with head ventilation (e.g. Wake-In-Freezer with single Condensing unit)

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Comparison R404A vs ISCEON®MO29 (R422D)

Medium Temp R404A R422D

rel. zu R22

Cooling Capacity 5% higher 5% lower

Power Consumption (10-15)% higher 5% lower

Condenser Pressure 3bar higher 0,5bar higher

Mass Flow +42% +25%

Expansion valve Exchange No Change

Seals and Gaskets Exchange Exchange

Compressor Oil Multiple ChangeMO (with

Oilseperator)

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Comparison R404A vs ISCEON®MO29 (R422D)Low Temp (2-stage w. SC & 1-stg w. liquid Injection R404A R422D

rel. zu R22

Cooling Capacity 10-20% higher same

Power Consumption 15-20% higher 10% lower

Condenser Pressure 3bar higher 0,5bar higher

Mass Flow +42% +22%

Expansion valve Exchange No Change

Seals and Gaskets Exchange Exchange

Compressor Oil Multiple ChangeMO (with

Oilseperator)

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Comparison R404A vs ISCEON®MO29 (R422D)Tiefkälte (1-stufig mit Kopfventilator) R404A R422D

rel. zu R22

Cooling Capacity same 15-20% lower

Power Consumption 10-15% higher 10-15% lower

Condenser Pressure 3bar higher 0,5bar higher

Mass Flow +42% +22%

Expansion valve Exchange No Change

Seals and Gaskets Exchange Exchange

Compressor Oil Multiple ChangeMO (with

Oilseperator)

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Improvement by using Subcool Effect

R22

ISCEON®MO29

ISCEON®MO79

R404A

0 10 20 30Kälteleistung in %Quelle: Berechnung aus ILK Messdaten

Bitzer 4NCS-20.2Y-40P (56,3m³/h)TK: to = -35°C, tc = +35°C, SH=18K, SC=5K

Additional external subcool Δtcu = 15K

HotGas=145°C

HotGas=85°C

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Cycle with Internal Heat Exchanger

Arial für weitere Texte verwenden

R22 (no internal heat exchanger) and ISCEON®MO29 (R422D)

Improvement of refrigeration capacity & COP !

Improvement of refrigeration capacity & COP !120°C105°C

34°C

39°C

+ 16%

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Table of Contents

1. Introduction2. Basis for the HCFC-Phase-out3. Comparison of Retrofit Solutions4. Retrofit Experience of ISCEON® Solution5. Cost Analysis from the Operator‘s Point of View6. Case Histories7. ISCEON® Solutions for Industrial Application8. Conclusion

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Cost Analysis from the Operator‘s Point of View

COPCOP

Components

Material Time

COPCOP

Components

Material Time

• Refrigerant• Oil

• Refrigerant• Oil

• Filter dryer• TXV• Condenser• Seales/ Gaskets

• Filter dryer• TXV• Condenser• Seales/ Gaskets

• Replacement ofcomponents

• Multipleexchange of oil (POE)

• Replacement ofcomponents

• Multipleexchange of oil (POE)

• Relocation of stored foods

• Relocation of stored foods

• Loss in sales because of partial/temporary close-down

• Loss in sales because of partial/temporary close-down

• Payment of overtime

• Payment of overtime

Operator’sExpenses

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Conclusion on R22-Phase outPotential for business interruption, due to refrigeration system stop

Large user of R22-refrigeration and a/c systems need a phase-out strategy

Several solutions are available, Contractor companies need to learn to use it properly

Operator‘s total costs of the retrofit are the decision factor for the choice of the retrofit solution

With regards to running and retroffiting costs, DuPontTM ISCEON®

MO29 (R422D) is the preferred solution for DX- systems

ISCEON® MO29 (R422D) has shown acceptable performance after retrofits in pump circulation systems

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Time is Running Out

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For more Information on ISCEON® Solution

R-22 Alternative Refrigerants by DuPont: www.isceon.com/eu

Emerson Climate Technologies: www.emersonclimate.com

Carlyle Compressors: www.carlylecompressor.com