Report of the TEAP XXIII/9 Task Force
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Outline
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Introduction
Banks for Refrigeration and Air Conditioning (RAC)
Alternative options and costs for RAC
Alternatives for high ambient temperatures
Foams, quantities, options and costs
Fire protection, quantities, options and costs
Solvents, quantities, options and costs
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Introduction
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Decision XXIII/9 requests a report for consideration by
the OEWG-32, which should contain info on 4 elements
TEAP established a Task Force to prepare the report
consisting of 15 members (FTOC, RTOC, HTOC, CTOC)
Preliminary draft report discussed at the TEAP meeting
in Berlin, 26-30 March 2012
Second draft of Task Force report circulated to TEAP and
some other experts in the course of April 2012
Report posted on Ozone Secretariat website in May 2012
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Refrigerant banks for A5 and Non-A5 Parties
- commercial refrigeration
2015 - Commercial refrigeration sector in non-Article 5 Parties:
• HCFCs have largely disappeared
• The HFC bank will be about 128,000 tonnes
• The non-HFC alternatives bank will be about 14,000 tonnes
2015 - Commercial refrigeration sector in Article 5 Parties:
• HCFCs will still be a dominant bank - about 260,000 tonnes
• The HFC bank will be around 124,000 tonnes
• The total refrigerant bank in Article 5 Parties will be more
than 3 times higher than the one in non-Article 5 Parties
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Refrigerant banks for A5 and Non-A5 Parties
- commercial refrigeration 2000-2015
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Refrigerant banks for A5 and Non-A5 Parties
- commercial refrigeration 2000-2015
A5 Bank: Commercial refrigeration
nA5 Bank: Commercial refrigeration
CFC
HCFC
HFC
CFC
Others
120 000
300 000
100 000
250 000
80 000
200 000
60 000
150 000
40 000
100 000
20 000
50 000
HFC
Others
-
-20 000
HCFC
1995
2000
2005
2010
2015
2020
-50 000
1995
2000
2005
2010
2015
2020
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Refrigerant banks for A5 and Non-A5 Parties
- stationary AC
2015: the stationary AC sector in non-Article 5 Parties:
• HCFCs will constitute 35% of the bank with 340,000 tonnes
• The high GWP HFC bank will be about 550,000 tonnes
• The alternatives bank will be about 25,000 tonnes
2015: the stationary AC sector in Article 5 Parties:
• HCFCs will be the dominant bank (66% of the total) at a
level of 870,000 tonnes
• The high GWP HFC bank will be about 400,000 tonnes
• The alternatives bank will be a bit larger than 20,000 tonnes
• The refrigerant bank in A5 Parties will be 1.4 times larger
than the bank in Non-A5 Parties
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Refrigerant banks for A5 and Non-A5 Parties
- stationary AC 2000-2015
nA5 Bank: Stationary air conditioning
2005
HFC
12.27%
CFC
0.01%
Others
0.00%
HFC
1.37%
CFC
0.00%
Others
0.00%
CFC
CFC
HCFC
HCFC
HFC
HFC
Others
Others
HCFC
87.72%
HCFC
98.63%
nA5 Bank: Stationary air conditioning
2015
Others
5.21%
A5 Bank: Stationary air conditioning
2005
CFC
0,00%
HCFC
35.47%
A5 Bank: Stationary air
conditioning 2015
Others
1%
CFC
HCFC
CFC
0%
HFC
33%
HFC
Others
HFC
59.33%
HCFC
66%
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Refrigerant banks for A5 and Non-A5 Parties
- stationary AC 2000-2015
A5 Bank: Stationary air conditioning
nA5 Bank: Stationary air conditioning
CFC
HCFC
HFC
Others
800 000
1 200 000
700 000
1 000 000
600 000
HCFC
HFC
Others
800 000
500 000
400 000
600 000
300 000
400 000
200 000
200 000
100 000
-
-100 000 1995
CFC
2000
2005
2010
2015
2020
-200 000
1995
2000
2005
2010
2015
2020
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Assessment of the technical, economic and
environmental feasibility of RAC options
The Task Force considered the following aspects:
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Technical feasibility: energy efficiency of the equipment,
and aspects related to toxicity and flammability
Economic feasibility: investment and operating costs
Environmental feasibility: energy efficiency of the
equipment and total greenhouse gas emissions
Assessment of……. (continued) (2)
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Present RAC technology using the vapour compression cycle
will be dominant for the next decades
HCFC replacement are categorised as low GWP and
medium/high GWP alternatives
Low GWP alternatives which are broadly suitable for
replacement of HCFC-22 are: HFC-152a, HFC-161, HC-290,
HC-1270, R-717, R-744, HFC-1234yf, HFC-1234ze
Refrigerants considered to be in the set of medium/high GWP
alternatives are: HFC-134a, R-410A, R-404A and HFC-32; a
variety of other mixtures of HFCs also fall into this category
Assessment of……. (continued) (3)
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Other than vapour-compression refrigeration, technologies
that could be used for HCFC phase-out are: absorption
cycles, desiccant cooling and Stirling systems,
thermoelectric and a number of other thermodynamic cycles
Most of these technologies are not close to commercial
viability for air-cooled air conditioning applications
It is unlikely that they will significantly penetrate these
markets, other than for potential niche applications (such as
absorption cycle), during the next decade
Alternative technologies other than vapour-compression will
therefore have a minimal impact on the HCFC-22 phase-out
Costs – refrigerants
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Considered a variety of different cost elements for different
alternative refrigerants
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Divided into direct product/societal costs and ICC/IOC/”other”
Cost
Refrigerant cost (price) – manufacturing
Refrigerant cost (price) – service/ maintenance
Type
ICC
IOC
Other
×
Direct
×
Societal
System components (materials)
Direct
×
Installation costs
Direct
×
Production line conversion
Direct
×
Technician training
Societal
×
Technician tooling
Societal
×
Service and maintenance costs
Societal
×
Disposal costs
Societal
×
Costs – refrigerants (2)
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Refrigerant price – sourced from UNEP data and intl. suppliers
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System component costs – (compressors, evaporator,
condenser, piping/valves, safety features)
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Wide range for all refrigerants fluids; vary depending upon
whether for service ($1 - $70/kg) or manufacture ($<1 - $60/kg);
must normalise for relative charge size (refrigerant density)
In most costs cases within ±10%
Installation costs – complicated parameter; only qualitative
indicators are estimated
Production line conversion – example costs presented for
medium scale/large systems and large scale/small systems
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Overall cost within ±10% across different refrigerant choices
Costs – refrigerants (3)
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Technician training – requires extra days for handling
flammability, higher pressure, toxicity characteristics
Technician tooling – new tools for handling flammability,
higher pressure, different compatibility
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Typically unique manifold gauge, gas detector, recovery machine
Service and maintenance costs – negligible difference for
alternative refrigerants
Disposal costs – could be negligible difference between
refrigerants, but highly sensitive to local regulations (e.g.,
waste)
Costs – refrigerants (4)
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In general, it is not possible to estimate specific relative
costs for each alternative
Costs generally sensitive to
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Type of product, range of models/capacity of product, design
options adopted for product, charge quantity of existing models
Size of the enterprise, extent of product development, maturity of
the product/option, extent of internal components (heat
exchangers, compressors, etc.)
Existing spread penetration and scale of the technology, status of
patents/licences, region, etc.
The Task Force report provides tabulated relative cost data
from a study on low-GWP alternatives to HFCs
Stationary AC at
high ambient temperatures
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Small packaged equipment in common usage for air
conditioning is mass produced
The refrigerant choice is based on a number of criteria:
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cooling capacity at high outdoor (ambient) temperatures
energy efficiency
input power required
refrigerant GWP
safety
costs
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Stationary AC at
high ambient temperatures
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R-410A, a blend of hydrofluorocarbon (HFC) refrigerants
is less efficient than HCFC-22 for ambient temperatures
higher than about 45°C (higher condenser temperatures)
Refrigerant
HCFC-22
R-410A
Tc (°C)
96.1
71.4
Pcond
(60°C)
(Mpa)
2.42
3.83
Pevap
(10°C)
(MPa)
0.68
1.08
asp
(kg/m3)
Qov
(kJ/m3)
Tdischarge
(°C)
COP
(*)
24.7
35.7
3760
4830
100
96
2.8
2.3
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Stationary AC at
high ambient temperatures
There are many options one can theoretically choose from, dependent on
whether emphasis is on safety, energy efficiency or GWP.
Refrigerant
Tc (°C)
HCFC-22
R-410A
R-407C
HC-290
HFC-32
R-717
HFC-134a
HFC-1234yf
HFC-1234ze
HC-1270
HFC-161
96.1
71.4
86.0
96.7
78.1
132.3
101.1
94.7
109.4
91.1
102.2
Pcond
(60°C)
(Mpa)
2.42
3.83
2.76
2.11
3.92
2.60
1.67
1.63
1.27
2.52
2.17
Pevap
(10°C)
(MPa)
0.68
1.08
0.77
0.63
1.10
0.61
0.41
0.44
0.30
0.77
0.60
asp
(kg/m3)
Qov
(kJ/m3)
Tdischarge
(°C)
COP
(*)
24.7
35.7
23.2
11.9
25.8
4.1
19.6
20.6
13.9
16.3
14.1
3760
4830
3250
2985
5870
4750
2290
2030
1740
3490
3600
100
96
64
79
117
162
80
69
72
87
88
2.8
2.3
2.8
2.6
2.6
3.1
2.7
2.4
2.6
2.6
2.9
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Commercial refrigeration
at high ambient temperatures
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The refrigerant choices for commercial refrigeration are
directly related to the cooling capacity and the evaporation
temperature required
HFC-134a, which has a relatively low volumetric capacity, is
still the preferred refrigerant for small equipment
HCFC-22 or R-404A, both having higher refrigeration
capacities, are used in large commercial systems but also in
small systems with low evaporation temperatures
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Commercial refrigeration at
high ambient temperatures
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High ambient temperatures lead to the choice of “medium
pressure” refrigerants such as HFC-134a (or HFC-1234yf in
near future) for low capacity single stage systems
HC-290 is only applicable in smaller systems due to safety
concerns
Currently there is a lack of low GWP refrigerants with a
large refrigeration capacity to replace R-404A or HCFC-22 in
single stage refrigeration systems
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Commercial refrigeration at high
ambient temperatures
Cascade system
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Cascade systems with CO2 used
at the low evaporation
temperature and refrigerants
(such as HFC-134a, HFC-1234yf
or HC-290) used at the high
condensation temperature
are energy efficient designs for
high ambient temperatures
Med.
temp.
refrigerant
CO2 at low
temperature
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Foams
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Foams
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The main market segments using HCFCs are 1) rigid
polyurethane insulating foam (PUR), including
polyisocyanurate (PIR), and 2) extruded polystyrene (XPS)
foam
Hydrocarbons (HCs), mainly pentanes, are the preferred
choice for HCFC replacement in rigid PU foams in large
enterprises (annual consumption > 50 tonnes)
For very stringent applications in terms of thermal
insulation, such as appliances, HCs are sometimes blended
with saturated HFCs to enhance the foam performance
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Foams (2)
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The incremental capital cost (ICC) for the conversion to
HCs in small and medium enterprises (SMEs) is, in most of
the cases, not cost effective
Saturated HFCs are used in significant amounts in Article 2
Parties for PUR -- mostly in North America
This well proven technology using saturated HFCs has two
drawbacks: high incremental operating cost (IOC) because
of the blowing agent cost and high GWP. This constitutes a
barrier for the conversion away from HCFCs in Article 5
Parties
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Foams (3)
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There are current and emerging options to replace HCFCs
in the different foam market segments that exhibit GWP
values lower than 50: HCs, oxygenated hydrocarbons
(HCOs), CO2 (water) and unsaturated HFCs & HCFCs
(HFOs)
Small quantities of HCOs, specifically methyl formate and
methylal, both low GWP options, are being used in integral
skin foam and some PUR applications where thermal
performance is not critical. Compared to HCFC-141b,
operational costs are higher and thermal efficiency is lower
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Foams (4)
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A new generation of CO2 (all water blown) formulations
have shown an improved dimensional stability relative to
the traditional applied technology but they still provide
foams with higher thermal conductivity than HCFC-141b
Recent evaluations of unsaturated HFCs and HCFCs,
commercially known as HFOs, done in a commercial
household refrigerator/freezer line, showed improved
thermal performance compared to saturated HFCs
It is estimated that HFOs with GWP values lower than 10
will be commercially available in 2014/ 2015. The major
obstacle for their use at SMEs will be the high unit cost
compared to HCFC-141b
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Fire protection
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Fire protection
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HCFCs and their blends were one of several options
marketed as replacements for halon 1301 and halon 1211
in total flood and local/streaming applications respectively
It has been estimated that clean agent alternatives, i.e.
those that leave no residue, comprise approximately 51%
of the former halon market
Of this, HCFCs are used in approximately 1% of the
applications, and therefore the use of HCFCs in fire
protection is very small compared to other alternatives
This is primarily due to tradition, market forces and cost
compared with CO2 and not-in-kind alternatives
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Fire Protection - total flood applications
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Only HCFC Blend A is still produced, and its use today is
primarily for re-charge of exiting systems. Even this is
diminishing because of changes to national regulations in
countries where it has been accepted
Clean agent alternatives to HCFC Blend A include inert
gases and their blends, HFCs, and a fluoroketone (FK)
The inert gases have no environmental impact and the FK
has almost negligible environmental impact
However, the system cost of these alternatives are
approximately one third more than the two closest HFC
alternatives, and the footprint of the cylinders necessary
for the inert gases is three times that of its competitors
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Fire protection –
local/streaming applications
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Only HCFC Blend B is marketed in both non-A5 and A5
Parties, with a market ratio of 4 to 1 respectively. HCFC
Blend E and neat HCFC-123 (the primary agent of the
blends) have limited acceptance in some A5 Parties
Clean agent, HCFC or HFC, based portable extinguishers
are significantly more expensive (3-10 times) than
traditional options (e.g. multi-purpose dry powder, water,
CO2) for the same fire rating (extinguisher performance).
Thus they are only used where cleanliness is a necessity
HCFC Blend B has a very low ODP whereas its main
competitor, HFC-236fa, has an ODP of zero. However, the
climate impact of HFC-236fa is 40 times higher than that
of HCFC Blend B
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Fire protection – future options
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Development and Testing of alternatives to ODS in fire
protection continues, as detailed in the 2010 Assessment
Report of the Halons Technical Options Committee
With the exception or aircraft cargo bays, alternatives to
ODS in the form of zero ODP gases, gas-powder blends,
and other not-in-kind technologies (i.e. non-gaseous), exist
for virtually every total flood application once served by
ODS. However, retrofit of existing ODS based systems may
not be technically or economically feasible
For local/streaming applications, an unsaturated HBFC,
3,3,3-trifluoro-2-bromo-pro-1-pene, is undergoing final
testing for commercialization, and if approved it would be
an effective substitute for HCFC Blend B
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Solvents
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Solvents - ODSs and HCFCs
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1,1,1-Trichloroethane (TCA), carbon tetrachloride and CFC113 were ODSs used in solvent applications
Over 90% of the ODS solvent uses have been reduced
through conservation and substitution by not-in-kind
technologies
Remaining uses are shared by in-kind solvents such as
chlorinated solvents, one brominated solvent, HCFCs, HFCs
and HFEs
Many options are available with various levels of acceptance
to eliminate HCFCs in solvent applications
No single option, however, can replace HCFCs completely
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Solvents - Not-In-Kind alternatives
Aqueous
Semi-aqueous
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Hydrocarbon
Alcoholic
Aqueous and semi-aqueous cleaning can be good
substitutes for metal degreasing or even precision cleaning
when corrosion of the materials is not an issue
The capital investment can be high, but operating cost is
generally inexpensive
Hydrocarbons and alcohols are effective solvents but
flammable. Explosion proof equipment is necessary. Most
of the commonly used hydrocarbons are VOCs
Not-In-Kind alternatives have no ODP and low GWP
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Solvents - In-Kind alternatives
Chlorinated :
Brominated :
nPB
CH2Cl2, CCl2=CCl2, CHCl=CCl2 Fluorinated: HFC, HFE, (HFO)
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Chlorinated solvents and nPB are applicable in a variety of
cleaning applications due to their high solvency.
Retrofitting is available to lower the investment. Operating
costs are also low. Their ODP and GWP are small
Allowable Exposure Limits (AELs) of these chlorinated and
brominated solvents are very low
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Solvents - In-Kind alternatives (2)
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HFC and HFEs are similar to HCFCs except for their
degreasing performance. Due to their mild solvency,
additional ingredients may be necessary
HFCs and HFEs are expensive; they have no ODP but a
middle to high GWP
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Solvents - future options
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Unsaturated HCFCs and HFCs (HFOs) are under
development
They have extremely small GWP values due to their very
short atmospheric lifetimes. They also could be the
candidates to replace the normal HCFCs
They would be as expensive as HFCs and HFEs
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Thank you !
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