PREPARE FOR CHANGE LOW
GWP ALTERNATIVES
November 17
F-GASPHASE DOWN
Where we are now
F-Gas regulation places restrictions on the use of some HFC refrigerants of high GWP.This is indirectly achieved by setting limits on the GWP of products used in specific types of systems.
The aim of the process is to reduce the contribution of refrigerant gases to Global Warming.
R404A has a GWP of 3922 and is amongst a group of refrigerants with GWP > 2500 which will be most affected within a relatively short period of time (2020).The others of concern include R507, R422A, R422D, R428A and R434A.
Key Elements of the F-Gas Regs.
F-Gasregulations
Bans in new equipment
Service ban on HFC with GWP>2500
Training
Reporting, Records
Recovery etc
Leak Checks
Phase down of HFC
Suppliers
Contractor/ End User
F-GAS: CAP & PHASE DOWN OF HFC’S
0%
20%
40%
60%
80%
100%
120%
2015 2016–17 2018–20 2021–23 2024–26 2027–29 2030
% of Baseline (CO2 equivalent)
% of base
2017 picture is uncertain; pre-charged equipment falls under quota (-11% in supply), but all new cars must ship with LGWP refrigerant (effect is uncertain)
Average of 2009-2012
Compliance checklist for EU F-Gas regulation
Purchase of new equipment
- Comply with bans on use of HFC’s in new equipment.
- Take account of service bans when selecting refrigerants
- Take account of HFC phasedown when selecting refrigerants.
Operation of existing equipment
- Mandatory leak checks and repairs.
- Use CO2e* size thresholds for leak check schedule.
- Use CO2e size thresholds for automatic leak detection.
- Keep records of all equipment using F-gas refrigerants .
- Service ban affecting existing high GWP systems.
- Use qualified personnel only.
Recovery / end of life requirements
- High quality recovery of F-gas refrigerants by qualified engineers.
* CO2 equivalent
The upcoming changes under F-Gas
2017All filled units imported into the EU need quota. Approx. 11% reduction in available gas this year
2018Decrease of 37% for available virgin HFC products available to be placed on the market
2020In new stationary systems, ban on refrigerants with GWP>2500. (except below -50°C)
The upcoming changes under F-Gas
2020
Service ban for existing equipment with virgin refrigerants of GWP>2500 where charge size is greater than 40 tonnes of CO2 equivalents.
2022
Ban on the use of virgin refrigerants of GWP>150 in new hermetic and multipack centralized systems. (There are some exceptions such as cascades)
2025Ban on the use of virgin refrigerants of GWP>750 for use in single split air con where charge < 3kg
F-Gas Service bans with existing systems
From 1st Jan 2020, use of virgin HFCs with GWP>2500 to service and maintain commercial refrigeration systems with a charge size>40 tonnes CO2e* shall be prohibited.
Virgin HFC’s below this level can be used to service existing installations (R407F, R407A, R448A,R449A, R134a etc.)
*The charge size threshold is equivalent to 10kg of HFC R404A.
Options:
1 – Replace existing plant with new equipment designed to run with refrigerants of lower GWP, good for plants near to end-of-life.
2 – Retrofit existing plant to replace R404A with lower GWP alternatives such as R407A, R407F, R448A and R449A with an energy efficiency increase of between 4-15% depending on the system.
3 – Reclaim R404A which can be used until 1st Jan 2030. This uses A-gas bespoke technology to return R404A to its initial specification.
F-Gas - The need for labels
You must add a label if you add an F-Gas to refrigeration, fire protection or air conditioning equipment when you’re installing it. The label must state:
• that the equipment contains an F-Gas.
• the industry name for the F-Gas, or the chemical name if there isn’t an accepted industry name.
From 2017 the label must also state the:
• mass of F-Gas in the equipment (in kg)
• carbon dioxide (CO2) equivalent mass of F-Gas in the equipment (in tonnes)
• the global warming potential of the F-Gas
Keeping Records – An F-Gas requirement
The operator of equipment, and the company that services it, must keep the following records about any equipment that has to be checked for leaks (ie any equipment that contains an F-Gas equivalent to more than 5 tonnes of CO2):
• quantity and type of gas in the equipment when it’s installed
• quantity and type of gas added during any maintenance (eg leak repairs)
• details (name, address and certificate number if relevant) of any companies that install, service or decommission the equipment.
• dates and results of all mandatory leak checks.
• measures taken to recover and dispose of gases when disposing of the equipment (egdisposing of it through a registered waste carrier.).
• It must be recorded if the gas used in the equipment has been recycled or reclaimed and if so the:
– details of the recycling or reclamation facility (name, address and certificate number if it has one).
– quantity of any gases recovered.
• Records must be kept for 5 years.
Record Keeping with Gas-Trak Online (GTO)
Acting as the central control point, the Desktop Web Portal enables users to manage their account, customer records, job lists and cylinder fleet.
The CFM enables you to manage your cylinders and control rental costs. Generate cylinder rental status reports and utilise the rental traffic light warning system.
Whether it’s a new installation, a service call or decommissioning, customers can track F-Gas and cylinder usage.
Collect and return cylinders whilst on the move by simply scanning the cylinder barcode. Record any supplier’s cylinders.
The Process for deciding on leak checks
Frequency of leak checks
Fluorinated greenhouse gases (t CO2 eq)
Maximum Frequency of leak checks
No Leakage detection system Leakage detection systems
5 - 50 12 months 24 months
50 - 499 6 months 12 months
500 3 monthly1 6 months
1 Leakage detection systems are mandatory when the equipment containsmore that 500t CO2-eq of refrigerant.
Note: As of January 1st 2017, leak checks are mandatory for all systems >5 t CO2 eq(< 3 kgs for installed systems or < 6kgs for hermetically sealed equipment, These were previously given exemption)
Leak Check Considerations
In General
• The alternatives to HIGH GWP Refrigerants have:-– Considerably higher glide.
– Potentially higher discharge temperatures.
– Changes in mass flow rate.
– Different operational pressures.
• Leakage issues– Dependant upon location small leaks can be “topped up”.
– After repeated “SMALL LEAKS” it would be a good precaution to have the refrigerant composition checked.
– Any substantial leak you should have the composition checked prior to topping up, or carry out a complete recharge.
t CO2/ kg Equivalents
Refrigerant GWP 5 t CO2 eq 10 t CO2 eq 40 t CO2 eq 50 t CO2 eq 500 t CO2 eq
R32 675 7.41 kg 14.81 kg 59.26 kg 74.07 kg 740.74 kg
R134a 1410 3.55 kg 7.09 kg 28.37 kg 35.46 kg 354.61 kg
R404A 3922 1.27 kg 2.55 kg 10.20 kg 12.75 kg 127.49 kg
R407F 1825 2.74 kg 5.48 kg 21.92 kg 27.40 kg 273.97 kg
R410A 2188 2.29 kg 4.57 kg 18.28 kg 22.85 kg 228.52 kg
R448A 1387 3.60 kg 7.21 kg 28.84 kg 36.05 kg 360.49 kg
R449A 1397 3.58 kg 7.16 kg 28.63 kg 35.79 kg 357.91 kg
R452A 2140 2.34 kg 4.67 kg 18.69 kg 23.36 kg 233.64 kg
R454B 466 10.73 kg 21.46 kg 85.84 kg 107.30 kg 1072.96 kg
R455A 148 33.78 kg 67.57 kg 270.27 kg 337.84 kg 3378.38 kg
Leak Checks - additional
• There’s no maximum interval for leak checks on hermetically sealed refrigeration and air conditioning systems unless they contain F-Gas equivalent to 10 tonnes CO2. That’s equal to 2.55kg of R404A or 7kg of R134a.
• There’s no maximum interval for leak checks on refrigeration systems in vehicles, unless the vehicle is a refrigerated truck or trailer.
• The maximum intervals didn’t apply until 2017 for equipment
that contains less than 3 kg of F-Gas. They apply NOW!
When is a ban not a ban?
• The phasedown quota system is written into UK law and generally does not refer to specific gases. It runs parallel to the F-Gas Bans.
• The quota allows for a mix of products as it measures CO2 equivalent Tonnes.
• The phasedown effect on individual high GWP products, such as R404A, is difficult to predict due to this but as the gap between demand and available quota increases, the pressure will be on to reduce the quantity of high GWP products significantly.
• Most of the comments will also apply to other gases with GWP > 2500. These are R507, R422A, R422D, R428A and R434A.
REFRIGERANTS – EU SUPPLY & DEMAND
2000
3000
4000
5000
6000
7000
8000
2015 2016 2017 2018
tonnes UK demand estimate
UK Supply (BAU)
Likely supply crunch
Assumes significant +ve effect on
available quota from MAC directive
Sold in Kg’s
-
50,000
100,000
150,000
200,000
250,000
R404A Performax LT R134a R410A R407A R407C C02
Kg Refrigerant
2016 (kg)
CO2 Equivalent 2016 (tCO2 eq)
-
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
900,000
1,000,000
R404A Performax LT R134a R410A R407A R407C C02
tCO2eq
GWP (tCO2 eq)
COMBINED CHART
-
200,000
400,000
600,000
800,000
1,000,000
1,200,000
R404A Performax LT R134a R410A R407A R407C C02
Combined CO2 and Refrigerant
GWP (tCO2 eq) 2016 (kg)
Strategies to adopt to the changing regulatory environment
• Existing estate
• Reduce exposure to rising refrigerant prices:
• Retrofit R404A where feasible with lower GPW Products like R407F. R452A can be used in some smaller LT systems.
• Drive down leakage rates to make the reclaimed product last longer.(This is outside the scope of F-Gas quota).
• New equipment
• Stop installing R404A (R407A/F or R448A/R449A will buy time) . Any new system will have to be retrofitted in a few years time.
• Integrals can use hydrocarbons as a long term solution.
• Large multipack systems (>40kw) need to go to naturals, a cascade CO2 system or wait for a LGWP R404A replacement such as R455A (L40X).
DOING NOTHING IS NOT A VIABLE STRATEGY
Items to Consider when Retrofitting
• Due to changes in:-– Mass flow rates.
– Volumetric capacity.
– Operational Pressures.
• It would be prudent to consider:-– Re-calibration / Replacement of the expansion device.
– Investigating an Electronic expansion device, making superheat setting easier.
– System design pressures and PRV’s.
– Re-calibration of the pressure control devices of the system and pressure safety switches to ensure efficient control and reduce nuisance trips due to the change in operational pressures.
Retrofitting Systems
• Medium Temperature Systems– These can generally be retrofitted with the minimum of disruption.
– Considering information already presented.
• Low Temperature Systems– Dependent upon refrigerant choice, there will be an increase in
compressor discharge temperatures resulting in the need for additional compressor cooling.
– R452A has been approved by several manufacturers of hermetic compressors due to a discharge temperature much closer to R404A. However it has a higher GWP than the rest of the alternatives.
– Check with your compressor manufacturer / supplier for suitability and guidance.
What are the Alternatives to high GWP gasses?
Low GWP Options
Refrigerant GWP Flam. Class App. area
R448A 1387 A1 Medium & low temp. refrigeration
R449A 1397 A1 Medium & low temp. refrigeration
R452A 2141 A1 Transport
R454A 239 A2L Small non hermetic med. & low temp
R454C 148 A2L Non hermetic med. & low temp
R455A 148 A2L Hermetically sealed med . & low temp
• Replaces
• ASHRAE #:
• HFC/HFO blend:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
R407F
R32/R125/R134a
Zero Ozone Depletion Potential
1825 (AR4)
A1 non flammable
6.4K
Compatible with POE lubricants
Compressor approvals: Widespread. In >12000 supermarkets
globally, fully qualified by leading OEMs.
R407F – (Performax LT)
R404A
R448A – (N40)
• Replaces
• ASHRAE #:
• HFC/HFO blend:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
•
R448A
Zero Ozone Depletion Potential
1387 (AR4)
A1 non-flammable
~4-5K
Can be topped off while servicing (do not mix with R-404A)
Compatible with POE lubricants
Bitzer, Dorin, Danfoss, Emerson, Frascold.
R32/R125/R1234yf/R134a/R1234ze(E)
Compressor approvals:
R404A
R449A – (XP40)
• Replaces
• ASHRAE #:
• HFC/HFO blend:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
•
R449A
R32 / R125 / R1234yf / R134a
Zero Ozone Depletion Potential
1397 (AR4)
A1 non-flammable
~4-5K
Can be topped off while servicing (do not mix with R-404A)
Compatible with POE lubricants
Bitzer, Dorin, Danfoss, Emerson, Frascold &
Tecumseh.
Compressor approvals:
R404A
R452A – (XP44)
• Replaces R404A/R507A
• ASHRAE #: R452A
• HFC/HFO blend: R32 / R125 / R1234yf
•
•
•
•
•
•
•Frascold, Danfoss, Tecumseh, Danfoss.
• Applications: High compressor discharge temperature e.g.
transport, hermetic piston compressors.
ODP:
GWP:
Zero Ozone Depletion Potential
2140 (AR4)
ASHRAE safety: A1 non-flammable
Glide: ~3-4K
Can be topped off while servicing (do not mix with R-404A)
Compatible with POE lubricants
Compressor approvals:
R454A – (XL40)
• Replaces R404A, R507A, R407A, R407F
•
•
•
•
•
•
•
R454A
R32 / R1234yf
Zero Ozone Depletion Potential
238 (AR4)
A2L Mildly flammable
~4-5 K
ASHRAE #:
HFC/HFO-blend:
ODP:
GWP:
ASHRAE Safety:
Glide:
Compressor approvals:Danfoss, Frascold, Tecumseh.
• Compatible with POE lubricants
R454C – (XL20)
• Replaces• ASHRAE #:
• HFC/HFO-blend:
• ODP:
• GWP:
• ASHRAE Safety:
• Glide:
•
R22; R407CR454C
R32 / R1234yf
Zero Ozone Depletion Potential
148 (AR4)
A2L Mildly flammable*
~4-6 K
• Compatible with POE lubricants
Compressor approvals:Danfoss, Frascold, Tecumseh.
• Replaces
• ASHRAE #:
• HFC/HFO blend:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
R455A
R32/R1234yf/R744
Zero Ozone Depletion Potential
148 (AR4)
A2L Mildly-flammable
~6-12K
Compatible with POE lubricants
Compressor approvals:
R455A – (L40X)
R404A
Danfoss
• Replaces
• ASHRAE #:
• HFO:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
See below
R1234yf or R1234ze
Zero Ozone Depletion Potential
4,7
A2L or A1
0
Compatible with POE lubricants
Compressor approvals:
Pure HFO
Higher GWP products
Danfoss, Frascold, Tecumseh,
R410A ALTERNATIVES
R410A Alternatives
Product Trade Name GWP Glide Flam. Class
R410 2088 <1K 1
R32 675 0 2L
R454B (XL41) 466 1K 2L
R452B (XL55) 676 <1K 2L
• ASHRAE #:
• HFC:
• GWP:
• ASHRAE safety:
• Glide:
R32
Single Component
675 (AR4)
A2L Mildly-flammable
0K
Compatible with POE lubricants
Compressor approvals: in progress (Already in use with Daikin)
R32
• ASHRAE #:
• HFC/HFO blend:
• GWP:
• ASHRAE safety:
• Glide:
R-545BA
R32/R1234yf
466 (AR4)
A2L Mildly-flammable
1K
Compatible with POE lubricants
Compressor approvals: in progress
R454B – (XL41)
• ASHRAE #:
• HFC/HFO blend:
• GWP:
• ASHRAE safety:
• Glide:
R-452B
R32/R125/R1234yf
676 (AR4)
A2L Mildly-flammable
<1K
Compatible with POE lubricants
Compressor approvals: TRANE Preferred Product
R452B – (XL55)
R134 ALTERNATIVES
R450A – (N13)
• Replaces
• ASHRAE #:
• HFC/HFO blend:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
•
R450A
R134a/ R1234ze
Zero Ozone Depletion Potential
604 (AR4)
A1 non-flammable
~0.4K
MT / HT Refrigeration & Chillers
Compatible with POE lubricants
Bitzer, Danfoss, Dorin, Emerson, Frascold &
Tecumseh.
Compressor approvals:
R134a
R513A – (XP 10)
• Replaces
• ASHRAE #:
• HFC/HFO blend:
• ODP:
• GWP:
• ASHRAE safety:
• Glide:
•
•
•
R513
R134a/ R1234yf
Zero Ozone Depletion Potential
631 (AR4)
A1 non-flammable
0 K
MT / HT Refrigeration & Chillers
Compatible with POE lubricants
Bitzer, Danfoss, Dorin, Emerson, Frascold &
Tecumseh.
Compressor approvals:
R134a
Too many Choices ?
Help is at hand
Help in selecting the right alternative
As you can see, there is no ‘one size fits all’ approach. It depends heavily on the system being installed.
A-Gas offers a system specific comparison of available replacements, allowing the engineer to choose what replacement gas is best for him from a report with over 20 relevant factors.
Simply supply some system specifics.
This can be applied to all the gases affected by the F-Gas GWP limits.
Help in selecting the right alternative
DATA REQUIRED for REFRIGERATION SYSTEM MODELLING
Enquiry from
COMPANY NAME
Contact Email
Contact Phone
What is the system [type] a/c, chiller, cold room, etc.
Existing Refrigerant, [type]
Age of system Years
Evaporating Temperature [°C]
Evaporating Pressure [bar] Evaporator Superheat [°k] Cooling Load [kW] Condensing Temperature [°C] Condensing Pressure [bar] Condenser Sub cooling [°k] Condenser Type [type] Air cooled, Water cooled, Evaporative etc.
Pressure Rating of Pressure Relief Valves [bar] Design Rating for vessels [bar] Type of Expansion device [type] Thermostatic, Capillary tube, float valve etc.
Compressor type [type] OPEN, Semi Hermetic, Hermetic Screw, Centrifugal, Piston, Scroll.
Compression [type] Standard, compound
Is it a flooded system? [yes / no] Can the client accept a loss of cooling
capacity from the system??
Is the equipment in good condition? Use a traffic light method
Green = Good Amber = not bad Red = Poor
https://www.agas.co.uk/refrigerant-suggestions/
High GWP Retrofit Report
Condenser=40ºC, Evaporator=-28ºC, Subcool amount=5K, Total Superheat= 10K
R404A R407F R448A (N40) R449A (XP40) R454A (XL40)
Safety Group A1 A1 A1 A1 A2L
GWP CO2 eq 3922 1825 1387 1397 246
Evaporating Temperature ºc -28.00 -28.01 -28.01 -28.01 -28.02
Evaporating Pressure bar.g 1.20 0.91 0.93 0.89 1.09
Evaporator Super Heat K 5.00 5.00 5.00 5.00 5.00
Suction Line Superheat K 5.00 5.00 5.00 5.00 5.00
Compressor Suction Temperature ºC -17.77 -15.88 -16.01 -16.07 -15.75
Compressor Discharge Temperature ºC 74.19 103.17 94.56 93.38 95.20
Condensing Temperature ºC 40.00 40.00 40.01 40.01 40.02
Condensing Pressure bar.g 17.21 17.19 16.90 16.59 17.19
Condenser Sub Cooling K 5.00 5.00 5.00 5.00 5.00
Liquid Line Subcooling K 0.00 0.00 0.00 0.00 0.00
Liquid Line Temperature ºC 34.83 32.79 32.68 32.69 32.27
Compressor Displacement m3/h 335.47 335.47 335.47 335.47 335.47
Volumetric Efficiency % 0.95 0.95 0.95 0.95 0.95
Isentropic Efficiency % 0.70 0.70 0.70 0.70 0.70
Mass Flow kg/s 0.97 0.69 0.73 0.73 0.74
Evaporator Cooling Capacity kW 100.00 107.19 103.97 101.88 108.38
Compressor Power kW 61.94 61.00 59.91 58.69 62.80
C.O.P. 1.61 1.76 1.74 1.74 1.73
Evaporator Glide K 0.45 4.25 4.02 3.88 4.54
Condenser Glide K 0.34 4.43 4.66 4.63 5.49
Volumetric Capacity kJm3 1129.61 1210.84 1174.41 1150.83 1224.26
Evaporator Inlet Temperature ºC -28.22 -30.14 -30.02 -29.95 -30.29
Condenser Capacity kW 166.08 171.06 166.96 163.62 174.46
Compressor Power Usage to maintain Original Duty Est % 0.92 0.93 0.93 0.94
Estimated power cost P/A £ £36,628.05 £33,649.55 £34,072.79 £34,064.24 £34,262.81
Refrigerant Charge kg 100.00 107.11 104.97 105.10 95.32
BS-EN-378 (2016)
EN 378: Proposed Update in 2016
Final Vote accepted in Q1, 2017
The new EN378 allows for FULL commercialization ofA2L refrigerants!
Trials can be done NOW.
BS-EN-378 (2016)
Example - Max Charge without limitation:
m1= 4m³ x LFL [kg/m³] x Factor
Factor for 2L is 1,5
Refrigerant R290 R152a R1234yf R1234ze R32
Safety class A3 A2 A2L A2L A2L
Charge [kg] 0,15 0,52 1,73 1,82 1,84
EN – 378 introduces some extra criteria in calculating charge size, and an emphasis on leak detection and control. Leak detection schedule based on CO2 equivalent charge and automatic monitoring.
Summary
• Consider not installing New Systems with R404A.
• R407F is the better value option in the short term.
• The new HFO blends help manage the F-Gas phase down requirements
• R448A/R449A improves system energy efficiency (4-15%)
• R448A/R449A are the best overall performing, lowest GWP, A1, R404A alternative currently.
• R455A provides simple, cost effective solutions as the GWP<150 threshold is reached
• AGAS is working with the industry to help meet the requirements for the new standards in refrigeration
THANK YOU FOR LISTENING