R22 Phase-Out in Israel Feb 2011 Phase-Out in Israel Feb 2011.pdf · Basis for the HCFC-Phase-out...

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

Joachim GerstelDuPont de Nemours Germany

2

Table of Contents

1. Introduction

2. Basis for the HCFC -Phase-out

3. Comparison of Retrofit Solutions

4. Retrofit Experience of ISCEON ® Solution

5. Cost Analysis from the Operator‘s Point of View

6. Case Histories

7. ISCEON® Solutions for Industrial Application

8. Conclusion

3

4

Dordrecht/ NL

Production & Blending Plant

5

(EC) No 1005/2009 replaces 2037/ 2000

2000=> STOP for 2000=> STOP for New SystemsNew Systems1.Jan. 20101.Jan. 2010

Stop of R22Stop of R22 --SalesSalesStopStop of R22of R22 --ServiceService

6

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

7

• 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 DuPont TM

ISCEON® 9 SeriesRefrigerants

Attention!

• Replace withnew equipmentrunning on:� ammonia� hydrocarbons� CO2� HFC, e.g. Suva®

R22-Phase-Out -- Options for Retrofit

8

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)

{

9

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.

10

Selection of R22-Replacements

Split AC with cab tupe Q0<15kWA1R417AMO59MT, LT especially for R502, R402A, R403B, R408

A1R422AMO79

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

A1R422DMO29

Applications:Safety-classification

ASHRAE-Nomenclature

ISCEON®

11

Selection of Refrigerants replacing R22

Freon ® 22 ISCEON® MO29 ISCEON® MO59 ISCEON® MO79

ASHRAE # 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; t 0h=10°C; ηi=0,7 105 75 77 72

Discharge pressure [bar]

at -10°C/ +40°C; t 0h=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

12

Cooling Capacitydiscus compressor

-31.7ºC Evaporator; 5.6 K subcooling

3,0

4,0

5,0

6,0

7,0

8,0

9,0

10,0

25 30 35 40 45 50 55

Condenser Temperature, ºC

Coo

ling

Cap

acity

, kW

R22

R404A

MO79

MO29

MO59

13

C.O.P. discus compressor

-31.7 ºC Evaporator; 5.6 K subcooling

1,0

1,2

1,4

1,6

1,8

2,0

2,2

2,4

25 30 35 40 45 50 55

Condenser Temperature, ºC

C.O

.P.

R22

R404A

MO79

MO29

14

Cooling Capacity discus compressor

-6.7ºC Evaporator;5.6 K subcooling

10

12

14

16

18

20

22

24

26

28

30

25 30 35 40 45 50 55 60

Condenser Temperature, ºC

Coo

ling

Cap

acity

, kW

R22

R404A

MO79

MO29

MO59

15

C.O.P. discus compressor

-6.7ºC Evaporator; 5.6 K subcooling

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

25 30 35 40 45 50 55 60

Condenser Temperature, ºC

C.O

.P.

R22R404AMO79MO29

16

Summary of Calorimeter Data

Cooling Capacity vs R-22 EER vs R-22

Low Temp (liq. Inj.)R-404A/ R507 +33% +15%

ISCEON® MO79 - +29% +13%

ISCEON® MO29 +8% +14%

Med. TempR-404A/ R507 +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

17

Compressor-OEM Endorsement of ISCEON® MO29/ MO79

Pages 19 & 22

18

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

19

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

20

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

21

Summary of Retrofit Procedures

1. Establish Baseline Performance with Existing Refr igerant & repair if necessary

2. Remove Existing Refrigerant from System

3. Replace Filter Dryer, Elastomeric Seals/Gaskets, & Other Equipment/Components Identified in Preplanning (Bal l 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 o il reservoir

8. Label System for ISCEON ® MO29

22

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!

23

Compatibility with Elastomeres

www.refrigerants.dupont.com

24

Elastomers swell at different rates when exposed to R22 versus ISCEON®MO29 and other HFC refrigerants (i.e. R404A)

25

Compatibility with Elastomeric Seals

26

Commercial Appl: ComparisonR404A/ R507 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)

27

Comparison R404A vs ISCEON ®MO29 (R422D)

MO (with Oilseperator) Multiple ChangeCompressor Oil

ExchangeExchangeSeals and Gaskets

No ChangeExchangeExpansion valve

+25%+42%Mass Flow

0,5bar higher3bar higherCondenser Pressure

5% lower(10-15)% higherPower Consumption

5% lower5% higherCooling Capacity

rel. zu R22

R422DR404A/ R507Medium Temp

28

Comparison R404A vs ISCEON ®MO29 (R422D)

MO (with Oilseperator) Multiple ChangeCompressor Oil

ExchangeExchangeSeals and Gaskets

No ChangeExchangeExpansion valve

+22%+42%Mass Flow

0,5bar higher3bar higherCondenser Pressure

10% lower15-20% higherPower Consumption

same10-20% higherCooling Capacity

rel. zu R22

R422DR404A/ R507

Low Temp (2-stage w. SubCool & 1-stage w. liquid Injection)

29

Comparison R404A vs ISCEON ®MO29 (R422D)

MO (with Oilseperator) Multiple ChangeCompressor Oil

ExchangeExchangeSeals and Gaskets

No ChangeExchangeExpansion valve

+22%+42%Mass Flow

0,5bar higher3bar higherCondenser Pressure

10-15% lower10-15% higherPower Consumption

15-20% lowersameCooling Capacity

rel. zu R22

R422DR404A/ R507

Low Temp (1-stage with head ventilation)

30

Improvement by using Subcool Effect

R22

ISCEON®MO29

ISCEON®MO79

R404A

0 10 20 30

Refrigeration Capacity %Quelle: Berechnung aus ILK Messdaten

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

Additional external subcool ∆tcu = 15K

HotGas=145°C

HotGas=85°C

31

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%

Low Temp (2-stage w. SC & 1-stg w. liquid Injection)

32

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

33

Retrofit Cases

34

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 -

35

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

Medium Temperature

1 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

36

Minimal Muenster, Germany - Supermarket

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

37

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

38

Vegetable Grower Cold Store – Almeria, Spain

11.711.9ACompressor amps

6.07.0ºCRoom Temperature

24.929.1KSuperheat

4.43.8KSubcooling

33.533.9ºCLiquid Line

61.178.0ºCDischarge

39.037.7ºCMean Condenser

-18.6-20.2ºCMean Evaporator

ISCEON®MO29R22

Compressor: 2 x Bitzer 4V-10.2Oil: Mineral Oil

Typical Operating Conditions

39

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

40

DuPont - Dordrecht

• Retrofitted Sept 2007

• from R22 to ISCEON ®MO29 (R422D)

• No system changes made

• One oil change to POE

• Satisfactory performance

41

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

42

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

43

Survey R22-Retrofits

�Target group: Service Contractors, Distributors

�Time Frame: Dec. 2009/ Jan. 2010

�Countries: Germany, Italy, Austria, Switzerland

�Results:

o >>2000 plants are retrofitted to R422D

o Lower costs vs. R404A-Retrofit (residual life-time)

o R422D: Similar Cooling Capacity and COP

o R22R: Limited Availability=> Increasing Prices

44

Retrofit Options

45

Reasons to Choose ISCEON ®

46

Sales development of ISCEON ®MO29 (R422D)

0,0 5,0 10,0 15,0 20,0 25,0 30,0Germ

any

France

Italy

Spain

UK

rela

tive

to G

erm

any

2006 2007 2008 2009** Ext polated linear with 9 months

Germany 2006=1

47

Sales development der ISCEON ®MO29 (R422D)

0,0 10,0 20,0 30,0 40,0 50,0 60,0Germ

any

Franc

eIta

lySpa

inUK

rela

tive

to G

erm

any

2006 2007 2008 2009 2010exExtr polated with 10months

Germany 2006=1

48

Industrial Applicationwith R22

49

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 a dded• 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

50

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 S hell 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 a t min

• Significant refrigerant leakages occur due to Compr essor Terminal board

Sealing

• Other Leakages due to leaking magnetic valves and b all valves

51

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

Oil-reachphase

Oil Layer

52

DX- ChillerAluminium Plant

53

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

54

Pump Circulation Systems with R22

C: Condenser

K: Compressor

HS: Level Control

A: Separator

P: Pump

V: Evaporators

Source Wikipedia

55

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

Lubricant

� 4% higher Current; 1,5 bar higher cond. Pressure; same cooling capacity; with AB

� Issues with Elastomer Seals

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

liquid pump

� 5-10% lower capacity; 8% higher power consumption; with POE; change of Elastomer Seals

56

Conclusion on R22 -Phase out� Potential for business interruption, due to R22 sho rtage

� Large user of R22-refrigeration and a/c systems nee d a phase-out strategy

� Several solutions are available, Contractor compani es need to learn to use it properly

� Operator‘s total costs of the retrofit are the deci sion factor for the choice of the retrofit solution

� With regards to running and retroffiting costs, DuPo ntTM ISCEON®

MO29 (R422D) is the preferred solution for DX- syste ms

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

57

Time is Running Out

58

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