UNEP OzonAction Webinar onChallenges for the phase-out of HCFC in the air conditioner sector

17th October 2012

Sukumar DevottaMember, RTOC and World Bank New OORG

Indiasdevotta@gmail.com

Current Status of Room Air-Conditioners with New Alternative Refrigerants

Residential Air-Conditioners

Types of Residential Air-ConditionersSmall Self Contained Air-Conditioners

(SSCA/C)Non-ducted (or duct-free ) Split

Residential A/CsDucted , Split Residential A/Cs

Small Self Contained (SSC) Air-Conditioners

Products Configuration of SSC Air-Conditioners

Packaged Terminal

AC

Window AC Portable AC

Non-ducted Split Air-conditioners

Non-ducted Split A/C Condensing-out door unit One or more indoor units Capacity – about 7 kW Charge quantity- 0.25-

0.30 kg/ kW

Ducted Split Air-conditioners

Ducted Split A/C Condensing -out door unit Air distribution system for multi-

rooms with ducts and outlet and inlet grills

Capacity – 5 kW to 17.5 kW HCFC-22 - Refrigerant prior to 2000 Charge quantity- 0.30-0.35 kg/kW Variable Refrigerant Flow (VRF)

Systems with Scroll compressors; cooling capacity 10 kW to 130 kW have been introduced

HCFC-22 - Preferred Refrigerant for Packaged ACs

HCFC-22 is a single component refrigerant ODP=0.055; GWP=1810 Moderately high pressure with lower and

compact compressor size With a critical temperature of 96.1oC,

suitable even for high ambient conditions Miscible with mineral oils Compatible with commonly used materials

Almost all ACs and heat pumps manufactured prior to 2000 used HCFC-22. Most A5 countries are still predominantly using HCFC-22. Several major producing A5 countries, within Asia, Middle East and South America, are now initiating actions to introduce HCFC-22 alternatives.

Product Category Units Manufactured

2004

Units Manufactured

1999

Increase 2004 vs

1999

Window-mounted and Through-the Wall (Packaged Terminal) Air Conditioners

15.2 million 12.9 million 18%

Non-ducted or Duct-free Split Residential and Commercial Air Conditioners

39.2 million 19.6 million 100%

Ducted, Split Residential Air conditioners

6.9 million 6.0 million 15.0%

Total 61.3 million 38.5 million 57%

Global Growth of Residential ACs

Global AC Market

JARN,2011,No 503

10%

JARN,2011,No 503

Product Category Estimated Population Operating Units

(2004)*

Estimated HCFC-22 Bank

(metric-Tonnes)

Window-mounted and Through-the Wall (Packaged Terminal) ACs

115 million 81000

Non-ducted or Duct-free Split Residential and Commercial ACs

259 million 305000

Ducted, Split Residential Acs and Heat Pumps

83 million 273000

Total 457 million 659000

Estimated Population of Residential ACs & HCFC-22 Banks

In 2012, with about 75% the installed base of ACs using HCFC-22, it represents about 1.5 million Tonnes of HCFC-22 bank. In 2012, the global HFC (mainly R-410A) demand represents approximately 20% of the total refrigerant demand.

Alternatives to HCFCs- Desirable Characteristics

Alternativesto HCFCs

VOC

Flamm-ability?

LowToxicity

Low Cost

ZeroODP

LowGWP

Similar or better

Performance

There is no ideal Refrigerants – Always some compromise

Alternatives to HCFC-22 for ACs

Natural FluidsHFCs (R-410A & HFC-32) Zero ODP

R-410A - High GWPHFC-32 – Low GWP?Low GWP Blends - Cost and Timeline (uncertain)

HC-290 & BlendsZero ODP

Negligible GWPBetter energy efficiencyFlammabilityEmerging Standards?

HCFC-22Montreal Protocol

ODPGWP

CO2/NH3Zero ODP

Negligible GWPMatl Compatibility, Technology, Efficiency,

HCFC-22 Alternatives

Refrigerant

Tb（℃ ) Tc（℃） LFL(kg/m3)

ODP GWP

HCFC-22 -41 96 - 0.055 1780

R-410A -52 72 - 0 2000

HFC-134a -26 101 - 0 1430

R-407C -43 86 - 0 1800

HC-290 -42 97 0.038 0 3

R-744 -78 31 - 0 1

HC-1270 -48 92 0.040 0 3

HFC-1234yf

-29 95 0.293 0 4

HFC-161 -38 102 0.076 0 12

HFC-32 -52 78 0.306 0 675

HCFC Phase out Management Plan (HPMP) - Recommendations to

MLF• HPMPs should also address climate change by using

alternatives with lower GWP taking into account energy efficiencies, equipment, and climate circumstances.

• Conversion policy would consider discouraging the use of HCFC alternatives with high GWP.

• Strategic activities be identified between now and the establishment of the baseline (at the end of 2010). These might include, demonstration projects with no or very low GWP technology and effective energy conservation measures.

• The choice of technologies should also ensure that environmentally-safe substitutes and related technologies are transferred to Article 5 countries under fair and most favourable conditions.

Alternatives (HFC Blends) to HCFC-22

• R-407C (HFC-32/125/134a) : Retrofit candidate with HFCs; Lower energy efficiency and capacity, Lubricant change; Material compatibility; Was used in developed countries for early phase out of HCFC-22 but is decreasing.

• R-410A (HFC-32/125): For new systems (OEMs); Significant design changes (New compressor, HXs, Lubricant, Capillary etc.). Only HFC blend extensively used in many countries, including some A5 countries. China mainly exports R-410A products.

• R-417A (HFC-125/ HFC-134a/ HC-600): Retrofit candidate with HFCs; Material compatibility; Similar capacity; Not seriously considered in developed countries;

• R-422A, B & D (HFC-123/HFC-134a/ HC-600a): Retrofit candidate with HFCs; Material compatibility; Fall in capacity; Not seriously considered in developed countries;

• R-433A (HC-290/HC-1270): Retrofit candidate, Fall in capacity about 5% than HCFC-22, 5-8% more energy efficiency than HCFC-22, Safety considerations, Not seriously considered in developed countries.

Alternatives (Pure Fluids)to HCFC-22

• HC-290: Retrofit possible with similar or slightly lower capacity; New systems have much higher efficiency. Safety considerations; Already in commercial use in many countries including India;

• HFC-161: Low GWP HFC fluid with excellent performance characteristics. Official safety classification is not yet established. There is some interest in China. Thermal stability at high ambient may be an issue?

• HFC-32: Considered as a moderate GWP (675) alternative to HCFC-22. It is not a drop-in substitute. Some adaptations are also necessary due to its flammability. The efficiency is comparable or better than R-410A units. There are plans to manufacture HFC-32 units including A-5 countries.

• HFC-134a: Extensive redesign with substantial cost increase would be required to match HCFC-22 system. No OEM interest.

• HFC-152a: Low GWP but mildly flammable; Extensive redesign with substantial cost increase would be required to match HCFC-22 system. No OEM interest.

China HC-290 AC Project

GIZ, 2012

Indian HC-290 AC

India HC-290 AC Project

Split and Window type (China is only for split type)

Optimization of the model:

Reduction of refrigerant charge

Optimization of capillary length

Enlargement of condenser area but reduction of tube diameter

Energy efficient compressor

Performance improved significantly, with COP > 3.7

Safety Features of HC AC

HC ACs for Exports – Godrej’s Stand

•Godrej is open to the sale of HC-290 ACs in the neighbouring countries, under UNEP coordination. •Ozone officers in countries have to confirm whether their country regulations allow these units to be sold, installed and operated. •Favourable incentives could be provided to promote this green technology.•Proper training of service technicians is an important requirement. This may be done with the assistance of UNEP and/or other implementing agencies.•These units are currently slightly costlier than HCFC-22 units (may be less than R-410A models) in the same energy  star band, because there is a considerable import content such as compressors and refrigerant. In India, they offer free installation for HC-290 ACs, to ensure that ACs are installed by Godrej trained technicians, the cost of which is bundled with the unit price.

• Daikin, METI - Japan and US EPA are promoting HFC-32• Most of the results are on prototype units and open market is yet to be available. Performance is reported to be better than R-410A models.•Daikin has offered free access to its “Basic Patent Essential to Manufacture and Sale of Air Conditioners Using HFC32” for most developing countries .•US, Japan and Korean industries position and market are not yet clear.•Some Chinese manufactures may also use HFC-32. • There is no interest from local manufacturers from India. However, Daikin is reported to start manufacturing HFC-32 units in India•Indonesia plans to use HFC-32 with the support of Japanese METI, Panasonic and Daikin.•Kuwait is reported to be doing a joint evaluation for HFC-32 performance under high ambient temperature condition with Daikin.•Daikin claims that there are more requests and plans from some A5 countries

HFC-32 - Global Trends

Global availability ofHCFC-22 substitutes

• Virtually all alternative refrigerants (r-410A, HFC-32, HCs)are available

• The important F-chemicals are HFC-32, HFC-125 and HFC-134a and their blends

• With limited production capacity, availability of some of the emerging alternatives to HCFC-22 worldwide is doubtful

• Prices may differ considerably depending on the volume and logistics

• HFC-blends may normally have patented composition, which may have some implications on global use

Summary of Refrigerant Options and Challenges

HFC blend mainly R-410A is the most likely near-term refrigerants; this technology is well proven but requires significant design changes.

R-410A Residential ACs with comparable energy efficiency are commercially available including some Article 5 countries

As there is some proposal to consider phase-down of HFCs under Montreal Protocol, there is more interest on low GWP refrigerants

HC refrigerants are applied in low charge residential Air-conditioning and are in commercial use in many countries including India. China is yet to use HC AC in the local market as the local standards are yet to be revised but is exporting HC ACs.

HFC-32 is still under evaluation and yet to be commercially available. It will be soon manufactured in some A5 countries, including Indonesia and India.

HFC-1234yf /ze and their mixtures are under evaluation. There is not much open domain information on cost, performance and reliability.

Use of HFC zeotropic blends will have some challenges for recovery and recycling.