MONTREAL PROTOCOL
`
`ON SUBSTANCES THAT DEPLETE
`
`THE OZONE LAYER
`
`2002 REPORT OF THE
`
`REFRIGERATION, AIR CONDITIONING AND HEAT PUMPS
`
`TECHNICAL OPTIONS COMMITTEE
`
`2002 Assessment
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`1 of 209
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`Arkema Exhibit 1115
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`Montreal Protocol
`On Substances that Deplete the Ozone Layer
`
`UNEP
`2002 REPORT OF THE
`REFRIGERATION, AIR CONDITIONING AND HEAT PUMPS
`TECHNICAL OPTIONS COMMITTEE
`
`2002 ASSESSMENT
`
`The text of this report is composed in Times New Roman.
`Refrigeration, Air Conditioning and Heat
`Co-ordination:
`Pumps Technical Options Committee
`
`Composition:
`
`Lambert Kuijpers (Co-chair)
`
`Reproduction:
`
`Date:
`
`UNEP Nairobi, Ozone Secretariat
`
`January 2003
`
`No copyright involved
`Printed in Kenya; 2003.
`
`ISBN 92-807-2288-3
`
`2002 TOC Refrigeration, A/C and Heat Pumps Assessment Report
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`DISCLAIMER
`
`The United Nations Environment Programme (UNEP), the Technology and Economic Assessment
`Panel (TEAP) co-chairs and members, the Technical and Economic Options Committee, chairs, co-
`chairs and members, the TEAP Task Forces co-chairs and members and the companies and
`organisations that employ them do not endorse the performance, worker safety, or environmental
`acceptability of any of the technical options discussed. Every industrial operation requires
`consideration of worker safety and proper disposal of contaminants and waste products. Moreover,
`as work continues - including additional toxicity evaluation - more information on health,
`environmental and safety effects of alternatives and replacements will become available for use in
`selecting among the options discussed in this document.
`
`UNEP, the TEAP co-chairs and members, the Technical and Economic Options Committee, chairs,
`co-chairs and members and the Technology and Economic Assessment Panel Task Forces co-chairs
`and members, in furnishing or distributing this information, do not make any warranty or
`representation, either express or implied, with respect to the accuracy, completeness, or utility; nor
`do they assume any liability of any kind whatsoever resulting from the use or reliance upon any
`information, material, or procedure contained herein, including but not limited to any claims
`regarding health, safety, environmental effect or fate, efficacy, or performance, made by the source
`of information.
`
`Mention of any company, association, or product in this document is for information purposes only
`and does not constitute a recommendation of any such company, association, or product, either
`express or implied by UNEP, the Technology and Economic Assessment Panel co-chairs or
`members, the Technical and Economic Options Committee chairs, co-chairs or members, the TEAP
`Task Forces co-chairs or members or the companies or organisations that employ them.
`
`ACKNOWLEDGEMENT
`
`The UNEP Refrigeration, A/C and Heat Pumps Technical Options Committee acknowledges with
`thanks the outstanding contributions from all of the individuals and organisations who provided
`technical support to committee members. In developing this report, particularly the section chairs and
`co-chairs were instrumental.
`The names, addresses and contact numbers of all section chairs and members of the UNEP TOC
`Refrigeration, A/C and Heat Pumps can be found in Annex III.
`The opinions expressed are those of the Committee and do not necessarily reflect the views of any
`sponsoring or supporting organisations.
`
`Gratitude is expressed to UNEP’s Ozone Secretariat, Nairobi, Kenya for the reproduction of this
`report.
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`UNEP
`2002 REPORT OF THE
`REFRIGERATION, AIR CONDITIONING AND HEAT PUMPS
`TECHNICAL OPTIONS COMMITTEE
`
`2002 ASSESSMENT
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`T a b l e o f C o n t e n t s
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`ABSTRACT EXECUTIVE SUMMARY OF THE 2002 TOC REFRIGERATION, AIR
`CONDITIONING AND HEAT PUMPS ASSESSMENT REPORT ........................................................ 1
`
`1.
`
`EXECUTIVE SUMMARIES OF ALL CHAPTERS ................................................................................. 3
`REFRIGERANTS ............................................................................................................................................ 3
`STATUS OF REFRIGERANT DATA.................................................................................................................. 4
`HEAT TRANSFER FLUIDS (“SECONDARY REFRIGERANTS”) FOR INDIRECT SYSTEMS ................................... 4
`DOMESTIC REFRIGERATION......................................................................................................................... 5
`COMMERCIAL REFRIGERATION.................................................................................................................... 6
`LARGE SIZE REFRIGERATION (INDUSTRIAL, COLD STORAGE AND FOOD PROCESSING)............................... 7
`TRANSPORT REFRIGERATION....................................................................................................................... 8
`AIR CONDITIONING & HEAT PUMPS (REFRIGERANT-TO-AIR)..................................................................... 9
`CHILLERS AND HEAT-PUMP WATER HEATERS .......................................................................................... 10
`VEHICLE AIR CONDITIONING..................................................................................................................... 11
`REFRIGERANT CONSERVATION.................................................................................................................. 11
`INTRODUCTION.............................................................................................................................. 13
`1.1 MONTREAL PROTOCOL DEVELOPMENTS.......................................................................................... 13
`1.2 THE UNEP TECHNOLOGY AND ECONOMIC ASSESSMENT PANEL..................................................... 14
`1.3 THE TECHNICAL OPTIONS COMMITTEE REFRIGERATION, A/C AND HEAT PUMPS............................ 16
`1.4 REFRIGERATION, AIR CONDITIONING AND HEAT PUMPS ................................................................. 19
`1.4.1
`General Remarks ................................................................................................................... 19
`1.4.2
`Long Term Options and Energy Efficiency............................................................................ 20
`1.4.3
`Set Up of the 2002 TOC Refrigeration, A/C and Heat Pumps Report................................... 22
`REFRIGERANTS.............................................................................................................................. 23
`INTRODUCTION ................................................................................................................................ 23
`2.1
`2.2 DATA SUMMARY.............................................................................................................................. 23
`2.2.1
`Ozone Depletion Potentials ................................................................................................... 24
`2.2.2
`ODP and GWP Data for Regulatory Reporting .................................................................... 25
`STATUS AND RESEARCH NEEDS FOR DATA ...................................................................................... 26
`2.3
`2.3.1
`Thermophysical Properties.................................................................................................... 26
`2.3.2
`Heat Transfer and Compatibility Data.................................................................................. 27
`2.3.3
`Safety Data ............................................................................................................................ 28
`STATUS AND RESEARCH NEEDS FOR HEAT TRANSFER FLUIDS (“SECONDARY REFRIGERANTS”) FOR
`2.4
`INDIRECT SYSTEMS.................................................................................................................................... 29
`2.4 REFERENCES .................................................................................................................................... 31
`DOMESTIC REFRIGERATION..................................................................................................... 37
`3.1
`INTRODUCTION ................................................................................................................................ 37
`3.2 NEW EQUIPMENT ALTERNATIVE REFRIGERANTS ............................................................................. 37
`3.3.1
`Compressors:......................................................................................................................... 40
`3.3.2
`Improved Efficiency Evaporator and Condenser Fan Motors: ............................................. 40
`3.3.3 Modified Control Technology and Defrost Algorithms:........................................................ 40
`3.3.4 Modified Refrigeration System Configurations:.................................................................... 40
`3.3.5
`Realisable Efficiency Improvements in Article 5(1) and CEIT Countries:............................ 41
`3.3.6
`Closed Cell Foam Thermal Insulation: ................................................................................. 41
`3.4 EXISTING EQUIPMENT RETROFITS AND FIELD SERVICE.................................................................... 43
`3.4.1
`Refrigeration Sealed System Failure Frequencies ................................................................ 43
`3.4.2
`Service Refrigerant Demand and Availability ....................................................................... 43
`3.4.3
`Special Field Repair Issues ................................................................................................... 44
`3.5 UNIQUE DOMESTIC REFRIGERATION CONSERVATION AND CONTAINMENT CONCERN ..................... 45
`3.5.1
`Refrigerant Recovery During Service and End-Of-Life Disposal ......................................... 45
`3.5.2
`Blowing Agent Recovery During End-Of-Life Disposal........................................................ 45
`SUMMARY COMMENTS..................................................................................................................... 45
`3.6
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`3.7 REFERENCES .................................................................................................................................... 46
`COMMERCIAL REFRIGERATION ............................................................................................. 49
`4.1
`INTRODUCTION ................................................................................................................................ 49
`4.2 DATA ON SYSTEMS AND REFRIGERANT CHARGES............................................................................ 50
`4.3 REFRIGERANT OPTIONS FOR NEW EQUIPMENT................................................................................. 53
`STAND-ALONE EQUIPMENT AND CONDENSING UNIT SYSTEMS........................................................ 53
`4.4
`4.5 CENTRALISED SYSTEMS ................................................................................................................... 54
`4.5.1
`Direct Systems ....................................................................................................................... 54
`Indirect Systems: HFCs, Ammonia, CO2 and HCs................................................................ 54
`4.5.2
`Medium Temperature Applications ................................................................................................................. 55
`Low Temperature Applications ....................................................................................................................... 55
`Refrigerant Choices ......................................................................................................................................... 55
`Energy Consumption ....................................................................................................................................... 56
`Defrosting Issue ............................................................................................................................................... 56
`4.6 OPTIONS FOR EXISTING SYSTEMS .................................................................................................... 56
`4.6.1
`Stand-Alone Equipment and Condensing Units .................................................................... 56
`4.6.2
`Centralised Systems............................................................................................................... 57
`CFC-12 Retrofit ............................................................................................................................................... 57
`R-502 Retrofit.................................................................................................................................................. 57
`HCFC-22 Retrofit ............................................................................................................................................ 57
`4.7 REFRIGERANT CONTAINMENT.......................................................................................................... 57
`4.8 ARTICLE 5(1) COUNTRY ASPECTS ................................................................................................... 58
`4.9 REFERENCES .................................................................................................................................... 59
`LARGE REFRIGERATING SYSTEMS (INDUSTRIAL REFRIGERATION, COLD STORAGE
`5
`AND FOOD PROCESSING)...................................................................................................................... 61
`5.1
`INTRODUCTION ................................................................................................................................ 61
`5.2 APPLICATIONS.................................................................................................................................. 62
`5.2.1
`Cold Storage.......................................................................................................................... 62
`5.2.2
`Food Processing.................................................................................................................... 62
`5.2.3
`Industrial Refrigeration......................................................................................................... 63
`5.2.4
`Liquefaction of Gases ............................................................................................................ 63
`5.2.5
`Industrial Heat Pumps and Heat Recovery ........................................................................... 63
`5.3 CURRENT STATUS AND TRENDS....................................................................................................... 65
`5.3.1
`Developed Countries ............................................................................................................. 66
`5.3.2
`Article 5(1) Countries ............................................................................................................ 66
`5.4 REFRIGERANT OPTIONS FOR NEW EQUIPMENT.................................................................................. 67
`Ammonia (NH3) ..................................................................................................................... 67
`5.4.1
`5.4.2
`HCFC-22 ............................................................................................................................... 68
`5.4.3
`HFCs...................................................................................................................................... 68
`5.4.4
`Hydrocarbons (HC)............................................................................................................... 69
`Carbon Dioxide (CO2/R-744) ................................................................................................ 69
`5.4.5
`5.4.6 Water ..................................................................................................................................... 71
`5.5 NEW TECHNOLOGIES........................................................................................................................ 71
`CO2 in the Transcritical Cycle............................................................................................... 71
`5.5.1
`5.5.2
`Absorption / Compression Cycle ........................................................................................... 71
`5.6 RETROFIT OPTIONS FOR EXISTING SYSTEMS .................................................................................... 71
`SERVICE REQUIREMENTS ................................................................................................................. 72
`5.7
`TECHNICAL REQUIREMENTS FOR HCFC FOR SERVICE............................................................................... 72
`5.8 AVAILABLE DATA ON CONSUMPTION .............................................................................................. 73
`5.8.1
`Refrigerant Consumption....................................................................................................... 73
`5.8.2
`Forecast of Use...................................................................................................................... 74
`5.9 REFERENCES .................................................................................................................................... 74
`TRANSPORT REFRIGERATION.................................................................................................. 77
`6.1
`INTRODUCTION ................................................................................................................................ 77
`6.2 CURRENT STATUS ............................................................................................................................ 77
`6.2.1
`Reefer Ships ........................................................................................................................... 78
`6.2.2
`Refrigeration and Air Conditioning on Merchant Marine, Naval and Fishing Vessels ........ 79
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`Intermodal Refrigerated Containers...................................................................................... 79
`6.2.3
`Road Transport (Trailers, Diesel Trucks and Small Trucks) ................................................ 80
`6.2.4
`Refrigerated Railcars............................................................................................................. 81
`6.2.5
`Air Conditioning in Railcars ................................................................................................. 81
`6.2.6
`6.3 OPTIONS........................................................................................................................................... 82
`6.4 RETROFITS ....................................................................................................................................... 82
`6.5 ENVIRONMENTAL ASPECTS.............................................................................................................. 83
`6.6 CONCLUSION.................................................................................................................................... 83
`6.7 REFERENCES .................................................................................................................................... 84
`AIR CONDITIONING & HEAT PUMPS (REFRIGERANT-TO-AIR) ...................................... 85
`7.1
`INTRODUCTION ................................................................................................................................ 85
`7.2 APPLICATIONS.................................................................................................................................. 85
`7.2.1 Window-mounted and Through-the-Wall Air Conditioners .................................................. 85
`7.2.2
`Non-ducted (or duct-free) Split Air Conditioners.................................................................. 86
`7.2.3
`Ducted Split Residential Air Conditioners............................................................................. 86
`7.2.4
`Ducted Commercial Split and Packaged Air Conditioner..................................................... 86
`7.3 CURRENT USE................................................................................................................................... 87
`7.3.1 Window-mounted and Through-the-Wall Air Conditioners .................................................. 87
`7.3.2
`Non-ducted (or duct-free) Split Air Conditioners.................................................................. 88
`7.3.3
`Ducted Split Residential Air Conditioners............................................................................. 88
`7.3.4
`Ducted Commercial Split and Packaged Air conditioner...................................................... 88
`7.3.5
`Heat Pumps............................................................................................................................ 89
`7.3.6
`Summary of Unit Population and Refrigerant Inventory....................................................... 89
`7.4 ALTERNATIVE REFRIGERANT OPTIONS ............................................................................................ 90
`7.4.1
`Single Component HFC Refrigerants and HFC Blends ........................................................ 91
`7.4.1.1 HFC-134a......................................................................................................................................... 91
`7.4.1.2 HFC-32/125/134a (R-407C) ............................................................................................................ 91
`7.4.1.3 HFC-32/125 (R-410A) ..................................................................................................................... 92
`7.4.1.4 HFC-125/ HFC-134a/ HC-600 (R-417A)........................................................................................ 92
`7.4.2
`Non-Fluorocarbon Refrigerants............................................................................................ 92
`7.4.2.1 Hydrocarbon Refrigerants................................................................................................................ 92
`7.4.2.2 Carbon Dioxide................................................................................................................................ 93
`7.4.3
`Lubricant Requirements......................................................................................................... 94
`7.4.3.1 HFC Refrigerant Lubricants............................................................................................................. 94
`7.4.3.2 Hydrocarbon Refrigerant Lubricants................................................................................................ 94
`7.4.3.3 CO2 Refrigerant Lubricants.............................................................................................................. 94
`7.4.4
`Summary ................................................................................................................................ 95
`7.5 NEW TECHNOLOGY (ALTERNATIVE REFRIGERANT CYCLES) ........................................................... 95
`7.6 RETROFIT......................................................................................................................................... 95
`7.6.1
`Retrofit Issues ........................................................................................................................ 95
`7.6.2
`Potential Candidates ............................................................................................................. 96
`7.6.3
`Anticipated Market Impact of Retrofit Refrigerants .............................................................. 96
`7.6.4
`HC-290 as a Retrofit Refrigerant ..........................................................................................96
`7.7 HCFC USAGE FORECAST................................................................................................................. 96
`7.8 ARTICLE 5(1) COUNTRY CONSIDERATIONS...................................................................................... 99
`7.9 REFERENCES .................................................................................................................................... 99
`ANNEX TO CHAPTER 7......................................................................................................................... 103
`
`8
`
`CHILLERS....................................................................................................................................... 105
`8.1
`INTRODUCTION .............................................................................................................................. 105
`8.1.1
`Role of Water Chillers in Air Conditioning ......................................................................... 105
`8.1.2
`Types of Water Chillers ....................................................................................................... 105
`8.1.3 Measures of Chiller Efficiency ............................................................................................ 105
`8.1.4 World Market Characteristics ............................................................................................. 105
`8.1.4.1
` U.S. Market Characteristics .......................................................................................................... 106
`8.1.4.2 Asian Market Characteristics /JAR00, JAR01, JAR02/ ................................................................. 106
`8.1.4.3
`European Market Characteristics /JAR00, JAR01, JAR02, DKV02/............................................ 107
`8.1.4.4
`India Market Characteristics .......................................................................................................... 108
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`Inventories of Equipment and Refrigerants in Service ........................................................ 108
`8.1.5
`8.1.5.1 United States .................................................................................................................................. 108
`8.1.5.2 Canada /HRAI00/........................................................................................................................... 109
`8.1.5.3
`India /Aga01/ ................................................................................................................................. 109
`INTRODUCTION – HEAT PUMP WATER HEATERS ........................................................................... 110
`8.2
`8.2.1
`Heat Pumps for Water Heating ........................................................................................... 110
`8.2.2
`Types and Volume of Equipment - Residential and Commercial/Institutional Applications110
`8.2.3 Market Characteristics ........................................................................................................ 111
`8.3 REFRIGERANT CHOICES ................................................................................................................. 112
`8.3.1
`Positive Displacement Compressors and Water Chillers.................................................... 112
`8.3.2
`Centrifugal Compressors and Water Chillers ..................................................................... 112
`8.3.3
`Average Refrigerant Charge Levels in Water Chillers........................................................ 112
`8.3.4
`Heat Pumps.......................................................................................................................... 113
`8.4 OPTIONS FOR NEW EQUIPMENT ..................................................................................................... 113
`8.4.1
`Options for New Positive Displacement Compressor Chillers............................................ 114
`8.4.1.1 HCFC-22........................................................................................................................................ 114
`8.4.1.2 HFC-134a....................................................................................................................................... 115
`8.4.1.3 R-407C........................................................................................................................................... 115
`8.4.1.4 Other Refrigerants: R-404A, R-507A, R-410A, Other HFC blends, HFC-32................................ 115
`8.4.1.5 Carbon Dioxide in the Transcritical Cycle..................................................................................... 116
`8.4.1.6 Ammonia........................................................................................................................................ 116
`8.4.1.7 Hydrocarbons................................................................................................................................. 117
`8.4.2
`Options for New Centrifugal Compressor Chillers ............................................................. 118
`8.4.2.1 CFCs and Blends Containing CFCs: CFC-11, CFC-12, CFC-113, CFC-114, and R-500.............. 118
`8.4.2.2 HCFC-22 and HCFC-123............................................................................................................... 118
`8.4.2.3 HFC-134a....................................................................................................................................... 119
`8.4.2.4 HFC-236fa ..................................................................................................................................... 119
`8.4.2.5 HFC-245fa and Other Refrigerants ................................................................................................ 119
`8.4.2.6 Design Issues with Zeotropes, Hydrocarbons, and Ammonia for Centrifugal Chillers.................. 120
`8.4.2.7
`Environmental Evaluation for Retention of HCFC-123 as a Refrigerant for Centrifugal Chillers. 120
`8.4.3
`Options for New Heat Pumps .............................................................................................. 121
`8.4.3.1 HFC-134a....................................................................................................................................... 121
`8.4.3.2 Other Pure HFC and HFE Alternatives.......................................................................................... 122
`8.4.3.3 HFC Blends.................................................................................................................................... 122
`8.4.3.4 Ammonia........................................................................................................................................ 122
`8.4.3.5 Hydrocarbons................................................................................................................................. 123
`8.4.3.6 Carbon Dioxide Used in the Transcritical Process......................................................................... 123
`8.4.4
`Alternative Technologies ..................................................................................................... 124
`8.4.4.1 Absorption Chillers ........................................................................................................................ 124
`8.4.4.2 Absorption Heat Pumps ................................................................................................................. 125
`8.4.4.3 Water as a Refrigerant for Chillers ................................................................................................ 125
`8.5 OPTIONS FOR EXISTING EQUIPMENT (RETROFITS) ......................................................................... 126
`8.5.1
`Positive Displacement Chillers............................................................................................ 126
`8.5.1.1 HFC-134a as a Replacement for CFC-12....................................................................................... 126
`8.5.1.2 R-407C, R-417A, HFC-134a, and Hydrocarbons as Candidate Replacements for HCFC-22........ 127
`8.5.1.3 R-404A or R-507A as Replacements for HCFC-22....................................................................... 127
`8.5.2
`Centrifugal Chillers............................................................................................................. 128
`8.5.2.1 HCFC-123 for CFC-11 in Centrifugal Chillers....................................................................