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Moldova Slides 1
Moldova Slides 1
Introductions
Background
Montreal Protocol
HCFC Phase out in Moldova
Role of UNDP / NOU
Outline of Workshop
Day one
Session
Introductions
Background - Montreal Protocol and HCFC phase
out it Moldova
Outline of the workshop and Brief Q&A session
Initial Assessment questionnaire
Break
Introduction to Alternative Refrigerants - safety,
efficiency, reliability and good practice
Lunch
System design using alternative refrigerants and
Tewi Analysis
Containment and leak detection of alternative
refrigerants
Break
Maintenance and repair of alternative refrigerant
systems
Retrofitting existing systems with low GWP
alternatives
Finish
Start
9:00
Finish
9:15
9:15
9:30
9:30
10:30
11:00
10:30
11:00
11:15
11:15
13:15
13:15
14:00
14:00
15:00
15:00
16:00
16:00
16:15
16:15
17:15
17:15
17:45
17:45
17:45
Day two
Session
Start
Finish
9:00
9:15
9:15
10:15
10:15
11:15
Break
Measuring the financial and environmental impact
of leakage
Tools and guidance for conducting site surveys
11:15
11:30
11:30
12:00
12:00
12:30
Lunch
12:30
13:30
Introduction to exercise
13:30
13:45
13:45
15:15
Group presentations
15:15
16:45
16:45
17:45
Close
17:45
17:45
Outline of Workshop
Objectives
Informative
Applicable
Replicable
Approach
Flexible
Interactive
For trainers
General
Designs Implications
Standards and
Regulations
Maintenance and
Repair
Introduction
to Alternative
Refrigerants
Guidebook
Worksop and accompanying guide
based on the REAL Alternatives
Europe blended learning programme
for technicians working in the RAC &
heat pump sector with additional
material from industry and
government sources
Designed to improve skills and
knowledge in safety, efficiency,
reliability and containment of
Contents
Introduction
R744 (carbon dioxide, CO2)
R717 (ammonia, NHG3)
R32 (HFC)
R1234ze (HFO)
Contents
Safety
Toxicity and flammability
Pressures
Restrictions on use
Performance and operating conditions
Contents
Environmental impact
Availability
Leakage issues
Relevant standards & legislation
Sources of Material
Sources of Material
Introduction
to Alternative
Refrigerants
Environmental Impact
Refrigeration and Air-Conditioning
causes 10% of all worldwide GHG
emissions
2% through leakage of refrigerant
and 8% through electricity
consumption
HFC/HF
O
A2L
refrigera
nts
Likelihood (5 years)
e
n
E
y
g
r
ef
ci
y
c
en
demand
response
Integrate
d
systems
Emerging
cooling
technolo
gy
impact
low GWP
refrigera
nts
climate
History
2020
EU FGas
HFOs
Regs
2010
Natural 1834
refrigeran
ts
1930
CFCs
HFCs
Kyoto
HCFCs
protocol
1990Montreal
1980
protocol
HFO
EU F-Gas
regulations
will push for
global HFC
phase down
Canada and
Australia
have
introduced
HFC phase
down
In Europe HFC
phase down is
approaching soon
with a big
reduction in 2018
Alternative Refrigerants
A
Sustainable
solutions
Environmen
tal
Safety
Capacity
2015-2020
Centrifugal &
R134a screw
chillers
2020-2025
HFO
R32, HFO Blends
(DR5,DR55 etc)
now
2025-2035
R290
R32
HFO Blends
R290
R32
future
R717
Capacity
R404A
centralised systems
R134a, R744 supermarkets
R407A, R407F
condensing units
R448, R449
R290,
R744
R600a
now
R717 R744
R744 +
R290
R744 HFO & Blends
R290, R744
R600a
future
Main Refrigerants
GW
P
A1 non
flammable
>4,00
0
R425A
A3 highly
flammable
R407A/
F
<1,50
0
R134
a
R450A
<700
R453A
Similar
to:
A2L mildly
flammable
R22
<2,50
0
<150
R404
A
R1233
ZD
R1336mz
zz
R123
R127
0
R600
a
R1234
ze
R134a
R410
A
R449
Old reference
refrigerant
R448
N20
DR7
L40
R444B
DR3
HDR11
0
R290
R404A
R22
R744
R717
R410A
Other
Alternative Refrigerants
Alternative
Global
Warming
Potential
(GWP)
Hydrocarbon
s
3-5
Properties to be
addressed
Commercial
availability
Flammable
Immediate
CO2(R744)
High pressure
Immediate
Ammonia
(NH3, R717)
Toxic
Immediate
675
Mildly flammable
Immediate
HFOs
4-9
Mildly flammable
Immediate
200-400
Mildly flammable
Mid-term
R32-HFO
blends
Alternative Refrigerants
R744, R717 and R290 were among the earliest
refrigerants used for mechanical cooling
systems.
Their use declined when CFCs and HCFCs were
developed and R744 and R290 were rarely
used.
R717 continued to be used in industrial
systems.
When the ozone depleting refrigerants (CFCs
and HCFCs) were phased out R290 and other
hydrocarbons started to be used again
Alternative Refrigerants
Refrigera
nt
R744
R717
R32
R1234ze
R600a
R290
Type
Key facts
GWP1
Sat
temp2
Carbon dioxide,
CO2
High pressures
78C
33C
Industrial
675
52C
Split air
conditioning
19C
12C
42C
Chillers, integrals
Toxic and
Ammonia, NH3
mildly
flammable
Hydrofluorocarb Mildly
on HFC
flammable
Unsaturated
HFC
Mildly
(hydrofluoroolefi flammable
n, HFO)
Isobutane,
C4H10,
Flammable
hydrocarbon
(HC)
Propane, C3H8,
Flammable
hydrocarbon
(HC)
Propene
(propylene),
Typical
applications
Retail refrigeration,
heat pumps,
integrals
Application of alternative
refrigerants
Refrigerant
Central
Plant
VRV,
VRF
Split AC /
Heat
Pumps
Chillers
Remote
Condensi
ng Units
Integral
s
R744
R717
R32
R1234ze
R600a
R290 / R1270
Green these systems are suitable for the refrigerant type indicated, and the charge size is
usually within the limits specified in EN378. Some design changes are required, for
example to electrical devices and / or ventilation.
Amber these systems can and are used with the refrigerant type indicated, but there are
restrictions because of the maximum charge or practical limit specified in EN378 (see note
2 below). Some design changes are required to electrical devices and / or ventilation. In
some cases the volumetric capacity of the refrigerant means it is not ideal for the
application.
Red these systems should not be used with the refrigerant type indicated, usually
because the charge size exceeds the maximum specified in EN3781.
CO2
Pumped secondary where R744 is the secondary fluid cooled by a primary
system.R744 is a volatile secondary which, coupled with the high capacity and
density, reduces the required pump power compared to other secondary fluids
such as glycol.
Cascade where the heat rejected by the condensing R744 is absorbed by the
evaporating refrigerant in a separate high stage system. In these systems the
R744 operates below the critical point and the high side pressure is generally
below 40 bar g. The high stage system can be R744 (see below), or it can be
HFC, HC, HFO or R717.
Transcritical systems where the R744 heat is rejected to ambient air and
at ambient temperatures above approximately 21C the R744 will be above
the critical point (31C) i.e. it will be transcritical. The R744 does not
condense it remains a super critical fluid until its pressure is reduced to
below the critical pressure (72.8 bar g). The high side pressure is typically 90
bar g when transcritical.
CO2
Danfoss
online training CO2
Advantages of CO2
High refrigeration capacity due to high volumetric cooling capacity (e.g., it is approximately up to 5 times that of
R404A). This has a positive impact on compressor displacement and the sizing of heat exchangers and pipe work.
Lower pressure drops in pipe work and heat exchangers.
For example, the impact of long suction and liquid lines is less.
High heat transfer in evaporators and condensers due to the high- pressure and density. This will either allow lower
temperature differences between the refrigerant and the air; therefore improving efficiency, or allow the use of
smaller evaporators and condensers. Tubing wall thickness may need to be increased to handle the higher pressures,
so careful design is required to take advantage of the R744 properties.
The pressure drop across an expansion valve is greater than with other refrigerants, so the minimum setting for head
pressure control can be lower. This improves efficiency.
Lower compression ratios leading to higher compressor isentropic efficiency.
Non-corrosive with most materials. There are very few differences to the materials used in HFC systems.
Good miscibility with compressor lubricants for oil return. Polyolester type lubricants can continue to be used as with
HFCs.
Low toxicity and nonflammable.
Negligible GWP so that, in the event of a leak, the direct impact on climate change is very low.
Inexpensive to produce and widely available, although the purity of the R744 should be 99.99% for use in a
refrigeration system with hermetic and semi-hermetic compressors, i.e., refrigerant grade.
High discharge temperatures due to the high index of compression. This provides good potential for heat reclaim.
The discharge temperature is excessively high in transcritical systems with a large difference between evaporating
and heat rejection temperatures.
Stable molecule leading to a low potential for decomposition within the refrigeration system.
There is no impending legislation phasing down or phasing out R744 so it can be viewed as a long-term refrigerant
Disadvantages of CO2
High operating and standstill pressures are more hazardous and increase the leak potential.
Specially designed components are required.
Special compressors are required because of the higher refrigeration capacity (different motor /
displacement combination).
R744 systems are more complex either cascade or transcritical. This leads to higher costs in
components and installation.
Pipe working on-site potentially includes steel or stainless steel, the need for specially licensed
welders, and different jointing techniques due to higher pressure and different materials.
The greater complexity also increases the probability of poor performance and reliability,
particularly if commissioning is not done well.
For transcritical systems two-stage compression is required for frozen food applications because
of the high discharge temperature of R744.
R744 transcritical systems are not suitable for high
Ambient areas (e.g., Southeast Asia) where the system will always run above the critical point
because of the inefficiency of transcritical operation.
R744 is not controlled by any regulation such as the European Fluorinated Gas Regulation, so its
use is not as carefully monitored as HFCs and leak detection is not as rigorous. However, the
high- pressures make the system leak prone, and performance will suffer if the leak rate is high.
Very sensitive to water contamination and can form unusual compounds when there is a leak in
a cascade heat exchanger.
R717 - Advantages
One of the most energy-efficient refrigerants available for
the temperature range used in the food and beverage
industry is 3-10% more efficient than competitive
refrigerants
Inexpensive
Readily available
Cost effective, with some of the best heat-transfer
characteristics of all refrigerants
Central systems provide central location of plant and easy
facilitation of backup and maintenance
Ammonia refrigeration systems cost 10-20% less to install
than systems using competitive industrial refrigerants.
R717 Disadvantages
Ammonia is flammable in certain concentrations.
Very specific design and operational regulations
Requirement for steel pipe, open drive compressors and oil
rectification, impact on the capital cost of an ammonia
installation.
Central systems require large refrigerant chargeThe vessels in
the machine room have to be sized to carry the system
charge throughout the year, so fairly large surge capacities
must be included.
The distribution network (pipes) that deliver the refrigerant to
the evaporators can be very elaborate, resulting in significant
refrigerant charge.
And all of the control valve stations located throughout the
system have the potential to leak.
R32
R32 is a low flammable HFC. Its performance and operating pressures
are very similar to R410A (R410A is a 50/50 mixture of R125 and R32)
and it is starting to be used in similar applications heat pumps, split
air conditioning systems and chillers. For further information on
suitability of application of this refrigerant you should always contact
your equipment supplier.
Its mild flammability limits the refrigerant charge size, but not to the
same extent as the more flammable hydrocarbons. Electrical devices
on the system will be the non sparking type if a leak can result in a
flammable concentration around the electrical device.
The operating pressures are higher than for most HFCs, but are similar
to R410A. Typically the high side maximum pressure is 35 bar g.
As a single component refrigerant, it is also easier to reuse and
recycle
than a blend such as R410A.
R717
Danfoss online learning
R32
Daikin and other international suppliers are beginning to
replace R410A with R32, and systems have already been
extensively installed in Japan (over 4 million units by 2015)
and they are now available in Europe.
1.6
1.2
0.8
R2
2
R41
0A
R3
2
0.
4
2.5
3.0
Energy Efciency Ratio
3.5
R1234ze
Hydrofluoroolefin (HFO) and Hydrocarbon (HC) refrigerants are referred to
as fourth-generation refrigerants. They are unsaturated HFC refrigerants
and are widely recognized as the next generation of refrigerants because
of their low environmental impact and potential energy efficiency.
HFOs are distinguished from HFCs by being derivatives of olefins rather
than alkanes (paraffins). Olefins have carbon atoms linked by a double
bond where alkanes have single bonds between carbon atoms.
Hydrofluorocarbon (HFC) refrigerants like R-134a, -125, -143a, and -152a,
and HFC-based refrigerant blends like R-507, -407A, -407B, -407C, and
-410A are all composed of hydrogen, fluorine, and carbon connected by
single bonds between the atoms.
Hydrofluoroolefin (HFO) refrigerants are also composed of hydrogen,
fluorine, and carbon atoms, but contain at least one double bond
between the carbon atoms
R1234ze
R1234ze is also a low flammable HFC, marketed as an HFO. This
is a halocarbon containing hydrogen, fluorine, and unsaturated
carbon.
It is in the same family of refrigerants as R1234yf which is now
being used in some car air conditioning systems. It is possible
that it might also be used in stationary systems in the future.
Its mild flammability limits the refrigerant charge size, but not to
the same extent as the more flammable hydrocarbons. Electrical
devices on the system will be the non sparking type if a leak can
result in a flammable concentration around the electrical device.
HFOs are miscible in Polyolester (POE)-type lubricating oils. The
miscibility of HFOs with POE lubricants is comparable to that of R134a. HFOs are not soluble in mineral-oil or alkylbenzene
lubricants.
R1234ze
The saturation temperature at atmospheric pressure is high compared
to other refrigerants so it will operate on a vacuum on the low pressure
side of the system for many applications.
It is therefore most suitable for medium and high temperature
applications such as water chillers.
Its cooling capacity is also low compared to other HFCs which means
that different compressors are required, with a larger displacement
relative to the motor.
R1234ze is not yet widely available, but is being trialled in chillers and
integral units.
Several blends using R1234ze are available for testing. They have lower
saturation temperatures so are suitable for low temperature
applications.
They all have GWPs in excess of 300. Some are non flammable, but
these tend to have significantly higher GWPs.
R-1234ze
An air-cooled, single/dual circuit
R134a/R1234ze high capacity chiller
designed around centrifugal Turbocor
compressor.
FRANCE: Carrier has joined the league
of chiller manufacturers adopting the
new low GWP HFO refrigerant
1234ze(E) with a debut installation in
Geneva.
Two Carrier AquaForce water-cooled
screw chillers using the new
refrigerant have been selected for the
innovative Plan-les-Ouates district
heating project in Geneva,
Switzerland.
R-1234ze
Hydrocarbons
Danfoss online learning
Safety Classifications
Issue
Refrigerant
Mild Flammability
High Flammability
HCs
Low Toxicity
R744 (CO2)
High Toxicity
R717 (Ammonia)
High pressures
(R744).
R744 (CO2)
Safety Classifications
The classifications are defined in ISO817:2009 Refrigerants
Definitions and safety classification. And in EN3781:2008 A2:2012;
Refrigerating systems and heat pumps Safety and environmental
requirements, Part 1 Basic requirements, definitions, classification
and selection criteria. The classifications comprise two parts
Safety
Factor
Degree
Toxicity
A or B
Flammabilit
y
1, 2, 2L or 3
Flammability
Safety
Classification
1
not flammable
2
lower
flammability
2L
*lower
flammability
Lower
Flammabilit
Heat of
y Level
Combust
(LFL) % in
ion J/kg
air by
volume
Flame Propagation
> 3.5
< 19,000
3
3.5
higher
The A2L classification is not yet adopted it is in the current proposed revision of ISO817.
flammability
Toxicity
Class
Toxicity
Safety Classifications
Mixtures
Safety Classifications
LFL, kg/m3
Auto
ignition
temp, C
PL,
kg/m3
ATEL /
ODL
A1
Not
applicable
Not
applicable
0.1
0.07
NH3 R717
B2L*
0.116
630
0.00035
0.00022
HFC R32
A2L*
0.307
648
0.061
0.30
HFO
R1234ze
A2L*
0.303
368
0.061
0.28
HC R600a
A3
0.043
460
0.011
0.06
HC R290
A3
0.038
470
0.008
0.09
HC R1270
A3
0.047
455
0.008
0.002
Safety
group
CO2 R744
Refrigerant
Safety Classification
Notes:
The safety group is as listed in EN3781.
LFL (kg/m3) is the Lower Flammability Limit as listed in EN3781.
PL is the Practical Limit as listed in EN3781. For A1 refrigerants it is the
highest concentration in an occupied space that will not result in escape
impairing effects. For A3 refrigerants it is approximately 20% LFL.
ATEL / ODL is the Acute Toxicity Exposure Limit / Oxygen Deprivation
Limit as listed in EN3781. This is the level above which there is an
adverse effect that results either from a single or multiple exposures in a
short space of time (usually less than 24 hours).
The information for R32 is from the current proposed revision of EN378.
R1234ze is not listed in the current version of EN378. The information is
based on the current proposed revision. R1234ze does not exhibit flame
limits under standard test conditions, but it does at temperatures above
30C. The LFL stated is at 60C.
Safety Classification
Toxicity
R717 is toxic and has a very low practical limited of 0.00035kg/m3
Exposure
Inhalation of any refrigerant vapour in sufficient quantities can lead to asphyxiation, cardiac
sensitisation or an effect on the central nervous system. Theses can lead to dizziness, lethargy or
irregular heartbeat.
Asphyxiation
All refrigerants are asphyxiants because they displace air. This is a hazard if a large amount is
released particularly in an enclosed area, but a small amount leaking into the base of a well type
display case is also a serious hazard. The use of Carbon Dioxide (R744) as a refrigerant is
becoming more common and whilst most are aware of the high pressures involved, there is equal
danger from a leak of refrigerant which could cause an increase in carbon dioxide in the
atmosphere of a plant room for example. Technicians should be very mindful of the disorienting
impact of reduced oxygen and if necessary consider the use of breathing apparatus if a large leak
is suspected.
Products of decomposition
HFC and HFO form toxic products of decomposition when burnt for example during a compressor
burnout. Hydrogen fluoride is produced which forms hydrofluoric acid in contact with moisture. The
effects of inhalation or contact are very severe on human health and require hospital treatment.
Safety Classification
Higher Pressures
Most of the alternative refrigerants operate with lower pressures than
R404A, thus enabling standard tools and equipment to be used
(unless these are inappropriate for other safety reasons such as
flammability or material compatibility such as with ammonia).
However, R32 and R744 operate with higher pressures.
The maximum condensing pressure in R32 systems is typically 35 bar
g;
The maximum high side operating pressure in R744 transcritical
systems is typically 90 bar g. This is not shown in the pressure
temperature chart below because it is above the critical temperature
of 31C.
The maximum condensing pressure in R744 cascade systems is
typically 35 bar g.
Safety Classification
Higher Pressures
Most of the alternative refrigerants operate with lower pressures than
R404A, thus enabling standard tools and equipment to be used
(unless these are inappropriate for other safety reasons such as
flammability or material compatibility such as with ammonia).
However, R32 and R744 operate with higher pressures.
The maximum condensing pressure in R32 systems is typically 35 bar
g;
The maximum high side operating pressure in R744 transcritical
systems is typically 90 bar g. This is not shown in the pressure
temperature chart below because it is above the critical temperature
of 31C.
The maximum condensing pressure in R744 cascade systems is
typically 35 bar g.
Safety Classification
The higher operating pressures have
an effect on:
The rating of the components used;
Pipe thickness;
Tools used to access the system;
Refrigerant recovery equipment.
25.0
20.0
R134A
15.0
R404A
R407F
Pressure, bar g
R290
R600a
10.0
5.0
0.0
-60
-40
-20
20
Saturation Pressure C
40
60
R417A
R404A
40.0
R410A
R290
R717
30.0
R744
20.0
10.0
0.0
-60 -50 -40 -30 -20 -10
10
20
Saturation Pemperature C
30
40
50
60
Design Parameters
Mostly the required components, tools and equipment are now readily available but it is essential that
the appropriate tools, components and equipment are used and are compatible for the refrigerant in use.
Refrigerant
Temperature at
atmospheric
pressure
Critical
temperature
Critical pressure
Triple-point
pressure
Pressure at
saturated
temperature of
20C
Global warming
potential
HFC
R744
R404A
-78.5C
-46C
(Temp. of (Saturation
the dry ice)
temp.)
HCFC
HFO
R134a
R407A
R407F
R22
R1234yf
-26C
(Saturation
temp.)
-41C
(Mid point
saturation
temp.)
-43C
(Mid point
saturation
temp.)
-41C
Saturation
(temp.)
-30C
Saturation
(temp.)
31C
72C
101C
82C
83C
96C
95C
73.8 bar g
35.7 bar g
41.7 bar g
45.2 bar g
47.5 bar g
49.8 bar g
33.8 bar g
5.2 bar
0.03 bar
0.005 bar
0.013 bar
TBC
tbc
57.2 bar g
10.9 bar g
5.7 bar g
10.2 bar g
10.6 bar g
9.1 bar g
5.9 bar g
11
3,9221
1,700
1,430
1,990
1,824
M = 2.5 x LFL1.25 x h x A
Where:
M
max charge in kg
floor area, m2
window, 1.8 -
Location
Example
-46
Required
Displaceme
nt
m3/h
14.84
R744
-78
3.88
1.75
114
3.42
R717
-33
14.3
3.27
152
4.82
R32 b
-52
9.65
3.17
99.5
3.77
R1234ze
-19
34.14
3.28
52
4.54
R600a
-12
47.13
3.26
51
4.40
R290
-42
17.35
3.18
59
3.61
R1270
-48
14.3
3.17
67
3.53
Refrigerant
Saturation
Temp at 0
Bar g C
COP
Discharge
Temp C
Compressi
on Ratio
2.94
57
3.82
Performance
The figures above provide an indication of
comparative performance as it is based on a
theoretical cycle. Actual comparisons depend
on compressor technology, application, ambient
and system type
This is especially so for R744 where expected
COP, for example, would be higher than
indicated below for the type of system and
operating conditions where R744 is typically
deployed.
Performance
Performance