R22 Phase-Out iece Feb 2010
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Transcript of R22 Phase-Out iece Feb 2010
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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
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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