the case for r-290 in u.s. commercial foodservice
TRANSCRIPT
The Case for R-290 in U.S.
Commercial FoodserviceReviewing the pros and cons for wider adoption
of this low-GWP natural refrigerant alternative
February 18, 2016
Allen Wicher
Mike Saunders Emerson Climate Technologies
Agenda
1. History / Industry Background
2. U.S. Regulations
3. Advantages and Applications
4. Challenges and Misconceptions
5. Flammable Refrigerant Evolution
6. Pros and Cons
Refrigerant and Minimum Energy Efficiency Regulations Require Industry to Balance the Equation
Reduce energy consumption with
optimized refrigeration equipment
system performance.
Ensure EPA compliance and
reduce GWP with refrigerant
choices that minimize impact
to equipment performance.
Preserve reliability, serviceability
and safety. Understand the toxicity,
flammability and pressure implications.
Estimate the total cost of ownership
and viability of technology changes.
Best solution for end users.
Organizations
Montreal Protocol Targets
Ozone Depletion (R-22)
Signed in 1987
North American Proposal
Targets CO2 Emissions
(High Global Warming)
F-Gas RegulationCarbon Tax
HFC Ban & Tax
INTERGOVERNMENTAL PANEL
ON
climate change
Regulations
Refrigerant Change Being Driven
by Regulations and Voluntary Actions Environment
Global regulatory actions to ban high-GWP refrigerants
place renewed emphasis on natural alternatives.
EPA’s Final Rule, July 20, 2015,
Changed Listing Status of Certain HFCs*
Phase-out
Refrigerant
Super-
market
New*
Super-
market
Retrofit***
Remote
Cond. Unit
New
Remote
Cond. Unit
Retrofit***
Stand-alone
MT <2,200 BTU/hr. and
not contain flooded
evap. New
MT ≥2,200 BTU/hr. with or
without flooded evap.
New
LT
New
LT and MT
Retrofit***
R-404A/507AJan. 1,
2017
July 20,
2016
Jan. 1,
2018
July 20,
2016Jan. 1, 2019 Jan. 1, 2020
Jan. 1,
2020
July 20,
2016
R-410A OK - OK - Jan. 1, 2019 Jan. 1, 2020Jan. 1,
2020-
R-407A/C/F OK OK OK OK Jan. 1, 2019 Jan. 1, 2020Jan. 1,
2020OK
HFC-134a OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK
Likely
Alternatives
(Emerson
Perspective)
R-448A/449A OK OK OK OKNeither SNAP-
approved, nor banned
Neither SNAP-approved,
nor bannedOK
OK for LT
only
R-450A/513A OK OK OK OK OK OK OK OK
R-290 - - - - OK OK OK -
R-744 OK - OK - OK OK OK -
R-717
OK(in primary loop
of secondary
CO2 sys.)
-
OK (in primary loop of
secondary CO2
sys.)
- - - - -
* Abbreviated — see EPA final rule for complete listing; Reference: Federal Register / Vol. 80,
No. 138 / Monday, July 20, 2015 / Rules and Regulations, 42870-42959
** Includes ice machines connected to a supermarket rack refrigeration system.
*** EPA uses term “retrofit” to indicate the use of a refrigerant in an appliance that was designed for and originally operated using a different
refrigerant .Term does not apply to upgrades to existing equipment where the refrigerant is not changed.
Environment
R-410A
Like
Capacity
R404A &
R407/22
Like
R134a
Like
GWP Level
400-675
< 1500
~600
~300
HFO 1234yf
HFO 1234ze
ARM-42
R410A
R22
R407A
R407C
R407F, R452A
0 500 1,000 1,500 2,000
Pressure
or
R32/HFC/HFO
Blends
R32/HFO
Blends
HFC/HFO
BlendsR134a
CO2
R404A
R507A
DR2, N12, ARC 1
R290
NH3
A1 – Non-Flammable
A2L – Mildly Flammable
A3 – Flammable
R123-Like
(V.Low Pr.)
(3922)
R32
R32/HFO
Blends
R448A
R449A
R450A
R513A
R444B = L20
L40, DR7
ARM-20b
HDR110
DR3
ARM-20a
R446A, R447A, ARM-71a
<150
B2L – Toxic, Mildly Flam.Qualitative – Not to Scale
EstablishedAvailable NowOEMs Testing
Environment
Alternatives for Refrigerant Applications
Many <150 GWP refrigerant alternatives have
increased flammable characteristics.
Summary for Refrigerant
Changes
You Will Continue to See Refrigerant Changes and a
Movement Toward Low-GWP Refrigerants
No Clear Path to a Single Replacement
Many Lower GWP (<150) Refrigerant Alternatives Carry
an Increase in Flammability
More Flammable Equipment May Mean Increased
Regulation, Training and Specialized Handling for
the Market
Environment
No silver bullet refrigerant alternative.
Redesigns are widespread. Results require system-wide
optimization.
Where We Are: Regulations and Refrigerants
Today 2019
EPA Refrigerants
Low GWP Blend
CO2
Low GWP Blend
R-290
Low GWP BlendR-290
Low GWP Blend
% M
ark
et
100%
40%
100%
50%
Today Voluntary Today 2018 Today 2017
0
20
40
-37%-35%-17%
-25%
Today 2017
SupermarketCA Title 24
Walk-InIceReach-In
DOE Energy
% E
ne
rgy
2012 2013Today 2018 Today 2020
EnergyEnvironment
Economics
Equipment
2016 2017 2018 2019 2020
Supermarket (Rack)
Walk-In (Remote CDU)
Cooler
Freezer
Reach-In (Stand-Alone)
Cooler <2,200 BTU
>2,200 BTU
Freezer
Ice Machine
Compliance Will Not Be Easy
<2,500 GWP
<2,500 GWP
20–40%
<600 GWP
<600 GWP
<1,500 GWP
30–50%
5–15%
EPA Refrig.
DOE Energy
1/1/17
1/1/18
3/27/17
Awaiting Final Court Sign-Off
1/1/18
1/1/20
1/1/19
1/1/20
20–30%
EnergyEnvironment
Economics
Equipment
Opportunity to comply with one
design cycle change
The Industry Is Going Through a Refrigerants Transition Phase
Factors Influencing the Choice of New / Alternative
Refrigerants
Investment Cost
Regulations
Components Availability
Operational Cost
SafetySystem
Architecture
In Natural Refrigerants,– R-744 (CO2) Has Been Gaining Good Market Acceptance and Proven
to Be a Good Alternative
– R-290 (Hydrocarbons) — With Excellent Thermodynamic Properties
Can Be Another Attractive Candidate
EnergyEnvironment
Economics
Equipment
Decreasing alternative refrigerant minimum GWP thresholds
likely to drive market development of naturals.
U.S. R-290 Adoption
EPA SNAP approved, very-low GWP Alternative Refrigerant
Efficiency Benefits
Foodservice Market Leaders Driving OEM’s
http://www.fierceenergy.com/story/mcdonalds-
eyeing-net-zero-energy-restaurants/2015-02-03
Environment
Energy
OEM’s working directly with End Users on integrating
renewable energy solutions like R-290 where applicable.
Other Use Conditions and
Recommendations
– Color-coded hoses and piping: To indicate use of a flammable refrigerant that will help technicians identify the use of a flammable refrigerant
– Labeling: Warning labels featuring letters at least one inch high must be permanently affixed to the equipment until their end of life.
– Unique fittings: Household and retail refrigerators and freezers using HCs must have fittings unique to flammable refrigerants.
– Small containers: To prevent purchase by untrained people, the hydrocarbon refrigerants will not be sold in containers in quantities of less than five pounds (2.8 kg).
– Handling by trained personnel only: EPA recommends that only technicians specificallytrained in handling flammable refrigerants undertake the servicing or disposal of equipment containing hydrocarbon refrigerants.
For New Equipment Only
– Not intended for use as a retrofit
alternative
Safety Standards
– HC Refrigerant (propane) may be
used only in equipment that meets
all requirements in UL Standard
471 9th edition regarding propane
in retail stand-alone equipment.
Refrigerant Charge Size
– Retail food refrigeration in stand-
alone units: 150 grams (5.3 ounces),
in line with the IEC 60335-2-89
standard for commercial appliances
EPA’s ‘SNAP’ Program for Hydrocarbon Refrigerants in Commercial Refrigeration
EnergyEnvironment
Economics
Equipment
Various use conditions to consider.
Results from Emerson’s test labs, comparing the Energy Efficiency Ratio (EER) of R-404A to R-290 in medium and low back pressure (MBP), show a significant improvement when using R-290.
R-404A and R-290 EER Comparison Environment
Energy
R-290 yields 20%+ better EER efficiency over R-404A.
Refrigerant Charge < 150 gm for Retail Stand-Alone Equipment
No Retrofitting of Equipment to R-290 Is Allowed, Only New Equipment
Safety Standards for Equipment Manufacturers
– UL-471
– IEC 60335-2-24: Household refrigerators and freezers
– IEC 60335-2-34: Motor compressors
– IEC 60335-2-89: Commercial refrigerators and freezers
– IEC 60335-2-40: Heat pumps, air conditioners and dehumidifiers
UL 471, SB1 Contains Additional Specifics for Flammable Refrigerants– Fittings Types to Be Used (no quick connect)
– Design Space and Construction Guidelines
– Leaks and Leak Tests to Be Performed
– Ignition Tests to Be Done
– Labels and Markings Required on Equipment
AHJ (Authority Having Jurisdiction)– Local Authorities Such as State, Local as well as Fire Marshals May Have
Other Restrictions
R-290 Codes and StandardsEnvironmentEquipment
Must comply with design and safety standards and be sure to
check AHJ before installing equipment.
Flammable Refrigerants Create Challenges
Refrigerants Approved by the EPA Under
Significant New Alternatives Policy (SNAP)
Limitations
Stand-Alone Units Only
Charge Limit of 150 Grams (5.3 Ounces)
Currently No Formalized Certification
of Service Technicians
No Channel Developed for Service
Replacements for Compressors
Liability ConcernsR-290 (Propane)
R-600a (Isobutane)
R-441A (a blend)
Guideline for technicians
with info on best practices
EnvironmentEquipment
Servicing infrastructure needs development.
Servicing
Specialized Training for R-290 is Not Required, But Highly Recommended
– Refrigeration Service Engineers Society, RSES.org
Flammable Refrigerant Leak Detector Required– Leave on while servicing
Place Safety Placard Advising No Smoking or Open Flames
R-290 May Be Recovered, But Is Not Required. It Can Be Vented to the
Atmosphere.
Brazing Recommendations– Work in well-ventilated, open spaces.
– Eliminate all ignition sources.
– Purge system with dry nitrogen to displace any trapped propane.
– Continue purging during brazing process.
– Tubes should be cut with tubing cutter vs. torch.
– Evacuate to minimum 500 microns.
Charging Procedures Are Same for R-290 as HFC Refrigerants
EnvironmentEquipment
Adherence to servicing procedures a must.
R-290 U.S. Commercial ApplicationsCharge limits/codes/standards evolving
R-290: U.S. 300 gram charge limit in proposal (CE-2020)
A2L: U.S. 500 gram charge limit in proposal (CE-TBD)
1/8HP 1/6 1/4 1/3 1/2
Domestic Refrigerators
Vending Mach.
Bev. Dispensers
UC/Prep
Bottle Coolers
3/4 1
1DS 1DG 2DS 3DS 3DG
X = Applications Not Approved by EPA SNAP Final Rule
X
Ice
Walk-Ins
Commercial Reach-Ins
X2DG
150 g Charge Limit
Larger Units Achievable With Multiple Systems
X
IEC/UL/ASHRAE:
EnergyEnvironment
Economics
Equipment
In U.S, significant headwinds exist to increase charge limits.
Europe: The Usage of Hydrocarbons Has Been Extended to Wider Refrigeration Applications
Self-Contained Cases (MT)
Secondary Systems
Small Cascade Systems
CondensingUnits
Emerging System
Architecture
Low Charge Allows
HC Usage
Discounters,
Supermarkets
Alternative Natural
Ref. Solution
High-Charge HC
Usage
Supermarkets,
Hypermarkets
R-290 / CO2
Solution
Total Natural
Ref. Solution
Cold Rooms,
Convenience
Economical Natural
Ref. Solution
Low Charge Allows
HC Usage
Cold Rooms,
Convenience
Hydrocarbons Already Established in Low-Temperature Cabinets Successfully
R-290 has a wider market acceptance in Europe vs. U.S.
The Case for R-290 in U.S.
Challenges
Classified A3 Flammable Refrigerant
Not a “drop-in” refrigerant, equipment and components designed for R-290
Globally mandated low-charge limits of 150g restrict application range
Difficulty getting approved in fire and building codes
Lack of trained and certified technicians
Market is currently missing a complete product and safety training course
Charge limit, safety and related legislations/regulations are the key areas to address for hydrocarbons
Advantages
Hydrocarbon-based, non-synthetic substance
EPA-approved in commercial refrigeration applications
Very low environmental impacts: GWP=3; ODP=0
High-efficiency, high performance, reliable
LT and MT applications that addresses EPA and DOE compliance challenges
Safe when proper protocols and procedures are followed
Hydrocarbons can be used in multiple applications such as secondary systems, self-contained cases and condensing units
EnergyEnvironment
Economics
Equipment
Charge limit increase in U.S. will likely
bring increased regulations.
Thank You!
DISCLAIMER
Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or
warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its
own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or
suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent
infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures
are indicated herein or that other measures may not be required.
Questions?
Allen Wicher Mike Saunders
Director, Marketing—Foodservice Senior Lead Innovation Technologist
937-493-2496 937-726-4928