Natural Refrigerants in Mobile Air Conditioning:

Suppliers, Research & Timelines

shecco

Overview

MARCH 2013

about shecco

๏ market development company

๏ focus: climate friendly technologies faster to market

๏ expertise: HVAC&R & transport sectors

๏ natural refrigerants: CO2, NH3, HC, H2O, Air

๏ electric vehicles

๏ areas:

๏ industry platforms

๏ ATMOsphere workshops

๏ market research / publications

market: HFC-free in the world

400 million HC fridges

1.2 million HC ice cream freezers (Unilever)

approx. 750,000 HFC-free vending machines

(Coke + Pepsi)the potential for HC chillers alone was

estimated at 4 billion USD

EU: 90% ammonia industrial refrigeration

20 million cars with HC air-

conditioning

EU: 16 CO2 Heat Pump manufacturers

... in transport

CO2 as a refrigerant (2011)

๏ worldwide the use of natural refrigerants increases

๏ example from one leading refrigerant supplier:

๏ 14% increase in volume from 2008-2010

๏ CO2 shows the largest potential: +117% in volume / +88% in revenue increase

source: refrigerant supplier with international operations

5 years ago: ready CO2 MAC suppliers

5 years ago: ready CO2 MAC suppliers

Lubricants & Refrigerant Oils

R744 Charging Stations, Service Stations & Service Kit

CompressorsFlexible Tubing / Hoses

Pressure & Temperature Sensors

Accumulator

Heat Exchangers

Leak Detectors

Compressor Shaft Seals

Pressure Valves

Climate Control Sensors

Charge & Service Valves

Connection Systems

Compressor Test Rigs

Complete MAC system

5 years ago: ready CO2 MAC solutions

Magna Powertrain today

ixetic (Nov 2012 / Feb 2013):

๏ 2005: start of CO2 MAC compressor industrialisation, readiness for

production in 2009

๏ in 2008: contract for serial production of the first CO2 compressor for

MAC worldwide

๏ mid of 2009: belt driven compressor projects stopped due to refrigerant

decision of OEM's

๏ electric compressor development continued

๏ in 2011: presentation of a Heating/Cooling-Unit with R744 for thermal

management of EV's and batteries

Magna Powertrain today

Magna Powertrain today

Magna Powertrain today

Sanden (Feb 2013): “Sanden has completed research development of CO2 for Automotive  AC. However we did not reach commercialization development because of the direction taken / decision made by customers to go for R1234yf. For commercialization, we have to develop together with Automotive manufacturers for performance, durability and other criteria because our parts (...) will be key devices for comfort.  In the future, the alternative refrigerant may change again. Sanden has been developing / supplying CO2 products for the non-automotive area. This technology can be implemented to the products for automotive." 

Sanden today

challenges and timelines for CO2 MAC

Kaco (Feb/Mar 2013): “We had components for R744 ready in 2008. These components have been tested intensively internally and externally in excessive bench an vehicle fleet tests. We are ready to relaunch our project “CO2 compressor shaft seal” at any time. The relaunch of this project very much depends on the requested volumes. Samples we could supply within 3 months after order income. Low volume serial production (50,000 units/year) we could provide in 9 months. High volume production 1.5 years after order income.

Our facilities for testing can be changed back in 3-4 months.”

“We do not see any reason why a CO2 MAC should not fit to any size or type of cars. (...) Difficulties may appear in the service of the cars, especially and regions where you do not have "brand related" dealers.”

challenges and timelines for CO2 MAC

Virtual Vehicle Competence Centre (Oct 2012): “The AC supply industry continued to mature the technology and continued to innovate, i.e. CO2 – air conditioners cooling indirectly via a water-glycol circuit allowing easy adaptability to new models, standardization and reduction of downtimes as well as CO2 –based heat pumps. ...As components and circuit designs have been tested and proven to work during several fleet tests - it is supposed that components and systems could be available within reasonable time.”

University of Braunschweig - Institute for Thermodynamics (March 2013): “Based on a common decision that CO2 will be used as refrigerant in car air conditioning systems I think that we still need about 5 years to commercialize R744 for car AC systems.”

challenges and timelines for CO2 MAC

 

SINTEF (March 2013): “R744 is a long term and sustainable alternative for MAC applications, especially there is a high potential for compact solutions for new vehicle platforms (electric / hybrid) to improve the comfort and increase the mileage of the cars (Heat Pump option). Regarding a timeline for R744: This depends on the contracts and conditions between OEM’s and TIER 1 suppliers. It will take time to reorganize the teams at the TIER 1+2 suppliers, since most of the R744 MAC activity was stopped some years ago. There is a good chance to develop R744 MAC systems until the HFC-134a sunset in 2017.“

challenges and timelines for CO2 MAC

Linde (Feb 2013):

๏ refrigerant business in more than 40 countries in 5 continents

๏ “the constraining issue for R744 MAC will NOT be caused by the

availability of the gas”

๏ is sure that the industrial gases / refrigerant distribution business

can provide however much CO2 refrigerant is needed worldwide

๏ the challenges are in the availability of the MAC technology and

ramping up the equipment for the cars + providing recharging

equipment at the garages

Konvekta (Oct 2012/March 2013): “We appreciate the decision of VW and Daimler to migrate to CO2 as a refrigerant in their vehicles. We believe that it is the right step towards efficiency, protection of our natural environment, and safety. (...) In general, CO2-based MAC-technology is scalable for any type and size of vehicle. (...) According to our knowledge the economies of scale of Daimler and VW alone would already economically justify the shift to CO2. The positive environmental effect would be enormous.

The main remaining issues for the migration to CO2-based air conditioners (...) are economies of scale for the hardware and training of technicians in the value chain – the same challenges like for any other new technology in any industry.

For mass production in cars it realistically will take another 4 years before CO2-based air conditioners will substitute more than 20% of the obsolete technology in the western world. For niche applications the technology will already be available earlier, i.e. buses, e-cars etc.

challenges and timelines for CO2 MAC

Konvekta today: CO2 MAC in buses

๏ first CO2 MAC prototype version introduced in 1996

๏ total number of buses equipped so far: 36 in Germany

๏ won the German Environment Award

๏ higher capital costs are offset by easier and less costly maintenance

๏ all new vehicles are EEV (Environmentally Friendly Vehicle) standard compliant to achieve highest emission reductions

๏ 2012: 12 new MAN buses operated by NIAG group (22 million passengers yearly) use CO2 MAC for local and regional public transport

๏ 2012: Solaris is using Konvekta’s new solution for electric buses using one R744 heat pump cycle to provide compartment heating & cooling + battery temperature control = increases operating range of vehicles by up to 40%

Konvekta today: CO2 MAC in buses

๏ NIAG group (Jan 2013): “The

equipment has proved to be

working so well in practice that

we decided to only invest into

this climate-friendly air

conditioning in new vehicles”

Konvekta today: CO2 MAC in trains

๏ 2012: first hybrid prototype train uses R744 A/C system: Westfrankenbahn by German national train operator Deutsche Bahn

๏ reduction of energy use for A/C = 10%

๏ heating done by heat pump system during winter

๏ will be tested on 37 km long distance with 14 stops to test under frequent acceleration and deceleration conditions

๏ cools and heats both passenger compartment and driver’s side

๏ Deutsche Bahn (Nov 2012):

“This is a big day (...) Deutsche Bahn will fortify its position as an environmentally and climate-friendly transport mode, increasing its head start”

Konvekta today: CO2 MAC in EVs

๏ 2011: Konvekta starts working on conceptual MAC systems especially for EVs to combine cooling and heating

๏ reheat function provides fast dehumidification and clearer front window = increased safety for drivers

๏ unit controls battery temperature to increase driving range by 40% and prolongs life cycle

recent CO2 technology developments

๏ electrically driven compressors for R744

๏ move towards hybrid & full-electric vehicles

๏ use of reversible R744 system for cooling and heating (heat

pump mode)

๏ use of ejectors to improve efficiency - TU Braunschweig (Feb

2013): “We are working on improving energy efficiency of R744

systems, also for mobile applications. Compared to an optimised basic

CO2 refrigeration cycle we measured COP improvements of up to

15-18% due to the employment of an ejector”

main messages

in-house knowledge among CO2 MAC suppliers is still available + products have been tested & technology has been optimised in the meantime

a clear commitment from OEMs is needed to provide investment security

product availability can start now with mass production ready before 2017 for the 2nd phase of the MAC Directive (R134a final phase-out)

HC as a refrigerant for MAC

๏ starting point: automotive industry’s decision to go for a flammable refrigerant - why not use Hydrocarbons instead of HFC-1234yf?

๏ HCs are widespread in domestic, light-commercial applications, with wider adoption in stationary A/C expected

๏ refrigerant benchmark was carried out in 2011, to compare HFC-1234yf, HFC-134a, HFC-152a and different NR solutions

(RE170, R600a, R290, R436B (52% R290 & 48% R600a))

HC as a refrigerant for MAC

HC as a refrigerant for MAC

HC as a refrigerant for MAC

HC as a refrigerant for MAC

HC as a refrigerant for MAC

GUIDEs: published & upcoming

GUIDE Europe

Feb 2012

GUIDEs 2013:

๏ Europe 2nd edition

๏ Japan

๏ China

GUIDE North

America

Mar 2013

ATMOsphere Europe 2012 Report

Content:

๏ market & technology trends

๏ End-User panels

๏ links to presentations, including on CO2 MAC for passenger cars and electric vehicles

๏ EU policy & regulation

๏ http://www.ATMO.org/files/reports/atmo_report_2.pdf

GUIDEs:

http://guide.shecco.com

contact details:

Market Research Teamresearch@shecco.com +32 2 230 3700

shecco - useful links

Industry Platforms:

http://www.R744.com

http://www.hydrocarbons21.com

http://www.ammonia21.com

http://www.R718.com

ATMOsphere 2012 Report / ATMOsphere Europe 2013:

http://www.ATMO.org