Natural Refrigerants Natural Refrigerants ‐ Natural Refrigerants Natural Refrigerants Safe Efficient and Reliable Use Safe Efficient and Reliable Use Safe, Efficient and Reliable Use Safe, Efficient and Reliable Use as Alternatives to HFC as Alternatives to HFC Workshop on High Ambient Temperature, Dubai 31/10/2015 Workshop on High Ambient Temperature, Dubai 31/10/2015 Dr. Daniel Colbourne, Dr. Daniel Colbourne, Juergen Usinger Juergen Usinger Commissioned by Commissioned by GIZ Proklima GIZ Proklima GIZ Proklima GIZ Proklima
Table of Content Introduction Performance of AC at high ambient f f g Product Safety Assessment Production Production Infrastructure After Sales (Examples from other sectors)
INTRODUCTION Natural refrigerants (NR) such as Ammonia, Hydrocarbons, � CO2 are increasingly used to replace substances with high GWP such as R410A R407C R32 because of the improved GWP such as R410A, R407C, R32, because of the improved performance of NR, specifically with regard to the higher energy efficiency Key issues in the transition to NR are the development of � − design and production capacities of manufacturers − adequate standards that reflect state of the art − reliable infrastructures for quality services and supplies
PERFORMANCE OF AC AT HIGH AMBIENT IN INDIA
Example: India � At least two enterprises develop ACs using HC ‐ 290 � AC market in India � AC market in India ‐ 2012 annual AC production about 10.5 m; demand now about 4 m/year ‐ Annual growth rate ~10% ‐ 1/5 th for window units, remainder for split ACs ‐ 95% of the market is “1TR” (~3.5 kW) and “1.5TR” (~5.0 kW) ‐ Climate regions range from temperate to very Climate regions range from temperate to very high ambient
Example: Production and Distribution of HC AC in India Production and Distribution of HC ‐ AC in India Model Cooling capacity COP (EER) 2013 star rating Charge size GSC 12 FG 7 WMG 3375 W (“1TR”) 3.72 7 ‐ star 0.31 kg GSC 18 FG 7 WMG 5000 W (“1.5TR”) 3.72 7 ‐ star 0.36 kg GSC 18 FG 5 WMG 5000 W (“1.5TR”) 3.45 5 ‐ star 0.36 kg Extensive work carried out previously p y to optimise p efficiency and minimise refrigerant charge; see Devotta/Padalkar et al
RESULTS: RELATIVE CAPACITY, COP, PRESSURE RATIO, DISCHARGE TEMPERATURE 100% 100% No performance HC ‐ 290 HCFC ‐ 22 HC ‐ 290 HCFC ‐ 22 degradation vs 80% 80% R22 [%] %] Relative COP [% Relative capacity 60% 60% 40% 40% 20% 20% 20% 20% R 0% 0% 48 50 52 48 50 52 Ambient temperature [°C] Ambient temperature [°C] 5 Improved working 110 HC ‐ 290 HCFC ‐ 22 HC ‐ 290 HCFC ‐ 22 conditions vs R22 4 io [ ‐ ] [°C] 90 3 3 Discharge temp Compression rat 2 70 1 C 0 50 35 48 50 52 35 48 50 52 Ambient temperature [deg C] Ambient temperature [°C]
TEWI Comparison Model Qe EER Ref Comparison of TEWI Model A 5050 W 3.51 HCFC ‐ 22 and efficiency against Model B ode 5300 5300 W 3 58 3.58 HCFC ‐ 22 equivalent products Model C 5200 W 3.55 R ‐ 410A Model D 5275 W 3.60 R ‐ 410A Model E 5200 W 3.60 HFC ‐ 32 15 power refrigerant 3.75 1.5TR '7-star' 3.70 y (EER) [W/W] WI [tCO2-eq] 10 3.65 Model E Model D 3.60 TEW Model B Model B Efficiency 3.55 5 Model C 3.50 Model A 3.45 1.5TR '5-star' 0 3.40 1.5TR, 1.5TR, Model Model Model Model Model 4 5 6 7 8 9 10 5-star 7-star A B C D E Specific cooling cost [Rs/W]
Cycle performance and system efficiency of Split AC Cycle performance and system efficiency of Split AC In many regions performance at high ambient conditions very important: • Test results for split air conditioner at high outdoor temps • R290 and R22 performance very R290 and R22 performance very close, but R410A and R32 drop off Source: Chen Zhen Hua, GMCC R&D Centre, China
Other Air conditioners using R290 � Several manufacturers in Several manufacturers in Europe, China, India, Australia primarily using R290 � Charge sizes up to 1 kg/7 kW cooling capacity ― Very high efficiency ― Very high efficiency � Reversible systems available � Major shift to R290 underway j y in China ― Availability will improve over time
R290 production capacity for RAC in China 1,430,000 321,000 1,732,000 329,000 360,000 1,507,000 529,000 , 316,000 61,000 Source: MEP ‐ Source: MEP FECO/CHEAA, 2013
Ai Air conditioners – split type di i li � Gree products ― Several models developed ― Split, window, portable ― Reversible and cooling only ― Products have safety system integrated to reduce leak amount ― Lower cost than equivalent R22, R410A models d l Capacity EER Charge Dimensions (mm) Max (kW) (W/W) (g) noise ID/OD (dB) 2.7 2 7 3 55 3.55 265 265 38/52 38/52 Indoor 830 × 284 × 205 830 × 284 × 205 d Outdoor 760 × 257 × 541 3.5 3.52 330 41/52
Air conditioners – split type � Midea products Mid d − Currently two sizes developed − Both reversible − Other products developed − Safety systems under development Model Indoor Outdoor Cooling EER Heating COP R290 unit (mm) unit (mm) capacity capacity charge 850 × 275 780 × 540 KFR ‐ × 160 × 250 26GW/N7 2.6 kW 3.4 2.8 kW 3.6 290 g Y ‐ Y(C4) 900 × 285 780 × 540 KFR ‐ × 160 × 160 × 250 × 250 35GW/N7 35GW/N7 3 3.5 kW kW 3.4 3 4 3 3.7 kW kW 3 6 3.6 3 0 350 g Y ‐ Y(C4)
Air conditioners – split type p yp � Benson air conditioning ― Single cooling ‐ only, reversible and heat ‐ recovery splits Si l li l ibl d h li � Safety aspects ― Designed to AS/NZS 1677 (similar to EN 378) ― Charge size up to 1000 g of R290 � Cost of R290 systems less than R410A � Efficiency (cooling and heating) better than � Efficiency (cooling and heating) better than competing R410A and R22 products
Ease of application of natural refrigerants
PRODUCT SAFETY ASSESSMENT PRODUCT SAFETY ASSESSMENT FOR AC WITH HC
Safe design with flammable refrigerats: Safety standards Relevant standards EN 378: 2008 IEC & EN 60335 2 40 IEC & EN 60335 ‐ 2 ‐ 40 IEC & EN 60335 ‐ 2 ‐ 89 Within the USA, there are , similar standards UL471 UL484 ASHRAE ‐ 15 (comparable in scope to EN 378) scope to EN 378) Also draft ISO 5149…
Safety with flammability: Other safety features
PRODUCT SAFETY ASSESSMENT O S SS SS Quantitative risk assessment � Operation: on 12% of time, IDU airflow on 26%; include operating faults Sources of ignition: In room ~4 arcs/sparks per m 2 per 24 h + continuous SOI � (candle) for 1 h /24 h; non ‐ HC outdoor unit (20 arcs per 24 h) and cigarettes; (candle) for 1 h /24 h; non HC outdoor unit (20 arcs per 24 h) and cigarettes; electrical faults inside ODU and IDU; technicians replace faulty protected components with SOIs 12 kW unit with additional � Flammable quantities: Flammable quantities: safety measures volumes, mass, times were Scenarios: modelled for the various leak sizes, into the rooms, 1TR 1TR Model Model 1 5TR 1.5TR 12 kW 12 kW IDU, ODU and outside 350 W/m 2 170 W/m 2 240 W/m 2 Load � Leakage: annual leak rate Piping 15 m 15 m 15 m 15%; frequency from q y Charge 0.35 kg 0.42 kg 0.75 kg supermarkets; overall 7 × 10 ‐ 4 per year; Room 10 m 2 30 m 2 50 m 2 Persons 2 6 10
PRODUCT SAFETY ASSESSMENT Safety valve limits amount of gas that can leak into room Quantitative risk assessment Quantitative risk assessment Risk measure 1TR 1.5TR 12 kW Ign freq (room, unit off) (/y) 5.0E ‐ 10 3.4E ‐ 09 6.4E ‐ 10 Risk of ignition is >10,000 times Ign freq (room, unit on) (/y) 1.3E ‐ 10 1.5E ‐ 10 2.1E ‐ 10 lower than Ign freq (IDU) (/y) Ign freq (IDU) (/y) 1.5E ‐ 16 1 5E 16 1 2E 16 1.2E ‐ 16 8.8E ‐ 17 8 8E 17 b background risk k d i k Ign freq (ODU) (/y) 4.3E ‐ 13 6.3E ‐ 13 6.3E ‐ 13 Ign freq (outside) (/y) g eq (outs de) (/y) 1.7E ‐ 10 . 0 2.2E ‐ 10 . 0 4.5E ‐ 10 .5 0 Background fire Total ignition freq (/y) 8.0E ‐ 10 3.8E ‐ 9 1.3E ‐ 9 frequency (USA) of ACs: 2 × 10 ‐ 5 y ‐ 1 Freq secondary fire (/y) 8E ‐ 11 4E ‐ 10 2E ‐ 10 Can break windows b k d Max overpressure (kPa) 5.8 6.0 6.7 only; requires an instant 3.0 mm leak hole in IDU!
PRODUCTION CONVERSION PRODUCTION CONVERSION FOR AC WITH HC
PRODUCTION DESIGN Requirements under Atex/EN 1127 d /
PRODUCTION LINE CONVERSION Appropriate equipment used for production � Refrigerant storage and feeding system * � Evacuation lines � Strength pressure test and tightness test � Refrigerant charging equipment * � Performance and electrical test Performance and electrical test equipment � Repair area * � A safety monitoring, alarm and ventilation system * * Equipment and installation also conform to Atex
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