Making the Transition to an Effective Refrigerant Architecture - July 30, 2019
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Making the Transition to an Effective
Refrigerant Architecture
July 30, 2019
1
Tom Land
Tom Land
U.S. Environmental Protection Agency
Stratospheric Protection Division
GreenChill Partnership
Phone: 202-343-9185
Email: Land.Tom@epa.gov
Tom has worked to protect the earth’s ozone layer and fight climate
change for over 20 years in the EPA’s Office of Atmospheric
Programs. He is now running the GreenChill Partnership program
to help the supermarket industry reduce emissions of ozone-
depleting substances and greenhouse gases.
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Today’s speakers…
10Andre Patenaude
Andre Patenaude, C.E.T.
Director – Food Retail Marketing &
Growth Strategy, Cold Chain
Emerson
Office: 519-717-5282
Email: andre.patenaude@emerson.com
Andre is responsible for developing the North American
marketing and strategy pertaining to Emerson’s food retail and
chiller market. He was most recently responsible for Emerson’s
global CO2 development. Andre has more than 34 years of
industry experience in sales, marketing, training and business
development of heating ventilation air conditioning and
refrigeration system architectures and applications with
compression and component technologies.
11John Wallace
John Wallace
Director of Innovation
Emerson
Office: 770-425-2724
Email: john.wallace@emerson.com
John has been active in the design and development of electronic control
systems for more than 20 years and holds several patents related to the
control of HVAC and refrigeration systems. He is a recognized expert in the
field of smart buildings and has testified before the U.S. Senate Energy and
Natural Resources Committee on the impact of smart building technologies
on the nation’s infrastructure. John earned a bachelor’s degree in electrical
engineering from the University of Kentucky and a master’s degree in
electrical engineering from the University of Missouri.
12Making the Transition to an Effective
Refrigerant Architecture
July 30, 2019
13Industry Is Dealing With
Extraordinary Dynamics
Cold Chain Challenges Operations Driven
Food Safety, Quality
FSMA, blockchain
End-to-end data,
services and Technician Shortage
insights Complexity vs. simplification
IoT and Cloud-based Services
Simple, sustainable, stable
New System Architectures
Harvest Processing Transportation Distribution End Users Steep learning curve
Energy Costs and Incentives
Demand peak charge, time of use rates
Refrigerant Regulations
F-Gas + EPA + CARB + ECCC+ DOE
FSMA: Food Safety Modernization Act
FDA: Food and Drug Administration OSHA Regulations
IoT: Internet of Things Low-charge ammonia, light industrial
F-Gas: Fluorinated gas
EPA: Environmental Protection Agency
CARB: California Air Resources Board
ECCC: Environment and Climate Change Canada
DOE: Department of Energy
OSHA: Occupational Safety and Health Administration 14Regulations
ECCC (Canada)
►Centralized cond. units
►ChillerCARB Rulemaking #2
= A1 Non-flammable = A2L Mildly Flammable
CO2
= A3 Flammable = B2L Toxic, Mildly Flam.
Pressure
AC 2023/24
R-454B R-32 R-410A U.S.
R-410A
Like Climate
R-454C
Alliance
NH3 455A
may
R-404A R-290 R-444B R-449/8A R-407A R-404A follow
(3,922)
Like California’s
lead
1234yf R-515A R-513A R-134a
R-134a
Like
GWP Level
500 1,000 1,500 2,000
CARB 2022 (new) CARB 2022 (new)
>50 lbs chargeEnd Users/Operators –
What Do They Want?
17End Users/Operators –
What Do They Want?
Sustainable Stable
Simple
Serviceable Secure Smart
18Natural Refrigerant Options for Commercial Refrigeration NATURAL REFRIGERANT OPTIONS FOR COMMERCIAL REFRIGERATION 19
Natural Refrigerant Options
Natural Refrigerants GWP ODP Considerations Refrigeration System Differences
► Very low charge requirements
R-717 0 0 ► Potentially toxic ► Used in the high stage to absorb
(Ammonia) ► Mildly heat and/or cool R-744 (cascade or
flammable used as a secondary fluid)
► Far removed from occupied spaces
► Very little danger to occupants in
► High pressure the event of small leaks
1 0 ► Low critical ► Used in medium and low stages
R-744 (CO2) temperature ► Pumped into the fixtures used in
► High triple point occupied spaces, rather than
R-717
► Highly
R-290 flammable
► Very low charge requirements
(Propane) 3 0 ► Exempt from (currently 150 grams is the max)
venting
prohibitions
ODP: Ozone depletion potential 20System Architectures Choices
Centralized De-Centralized
CO2 Booster Transcritical Distributed
► 0 ODP, 1 GWP, 1 A1 ► Many refrigerant options
► Higher pressures ► Optimize suction press
► Standing pressures ► Location flexibility
► Good low ambient perf. ► Lower charge
► High ambient strategies ► Small footprint
CO2 A1
HFC/HFO A1
CO2 A1 HFO A2L
Indirect Chiller With Cascade Integral Display Case – Micro Distributed
► Niche application ► R-290 150g limit, future?
► Commercial/industrial ► A2L 500g limit, future?
► Full natural option ► Water loop for condensing
► Energy efficient ► Heat pump integration option
► Low charge ► Flexible
► AHJ approvals CO2 A1
► AHJ approvals
R-290 A3
R-290 A3
HFO A2LPropane (R-290)
22Regulations
International U.S.
CARB 2 (Proposed)
Europe F-Gas CARB 1
Final Vote March 2020
Commercial • 2,500 GWP Jan. 2020 • EPA SNAP Rules 20 • 1,500 GWP Jan. 2022
Equipment • 150 GWP Jan. 2022 and 21 (50 lbs)
UL
IEC 300g for R-290 (timing TBD)
1.2kg for A2L (timing TBD)
500g for R-290
1.2kg for A2L
(passed)
EPA SNAP
Application approval for A2L
(timing TBD)
Cold • 2,500 GWP Jan. 2020 • EPA SNAP Rules 20 • 1,500 GWP Jan. 2022
Rooms/Walk- and 21 (50 lbs)
Supermarket • Multi-pack • EPA SNAP Rules 20 • 150 GWP Jan. 2022
Racks • 40 kW (140 kBTU/hr) and 21
• 150 GWP Jan. 2022
kW: Kilowatt
kBTU: Thousands, British thermal units, IEC: International Electrotechnical Commission 23R-404A and R-290 EER Comparison
24
R-290 Yields 20%+ Better EER Efficiency Over R-404A.
24U.S. EPA SNAP-Approved End Use
Applications for R-290
X = Applications Not Approved by EPA SNAP Final Rule
Domestic Refrigerators (53g) 150g Charge Limit
Current
UC/Prep
300+ g
X Mach.
Vending In Proposal Charge Limit
Larger Units Achievable in Proposal
Bev. Dispensers With Multiple Systems
Bottle Coolers
Ice
Commercial Reach-ins
1DS 1DG 2DS 2DG 3DS 3DG
Walk-insX
(Remote) (stand-alone, OK)
HP 1/8 1/6 1/4 1/3 1/2 3/4 1
IEC/UL/ASHRAE/ICC: R-290: U.S. Approx. 300 gram charge limit in proposal
A2L: U.S. 1.2 kg charge limit in proposal
IEC: International Electrotechnical Commission ICC: Industrial Cooling Corporation/International Code Council
UL: Underwriters Laboratories
ASHRAE: American Society of Heating, Refrigerating, and Air-Conditioning Engineers
ASHRAE/UL Working With Industry on Flammable Research Sub-Cmte.
and Completing Charge Limit Increase and Safety Standards Proposal.
Effectivity of an R-290 Charge Limit Increase Could Be 2019 for Stand-Alone Equipment25R-290 Stand-Alone
End Use Applications
26R-290 Micro Distributed Applications
or or
12 ft. case 12 ft. case
R-290 (3 GWP) 150g limit R-290 (3 GWP) 500g limit
Be Sure to Consult Authority Having Jurisdiction (AHJ)
for Additional Code/Standard Requirements Before Installing.
27Carbon Dioxide (R-744)
28CO2 System Architectures
SECONDARY CASCADE TRANSCRITICAL
R-717,
BOOSTER
R-717, R-290
CO2
R-290 HFC
HFC
CO2 DX
CO2 DX
CO2
CO2 DX
Secondary
Fluid
up to 650 up to 650 up to 1,600+
psig psig psig
Psig: Pound-force per square inch 29Basic Properties of R-744 vs. Commonly
Used Refrigerants
Refrigerant R-744 (CO2) R-404A R-134a R-407A R-407F
-109.3 °F -50.8 °F -14.8 °F -41.8 °F -45.5 °F
Temperature at (-78.5 °C) (-46 °C) (-26 °C) (-41 °C) (-43 °C)
atmospheric pressure (Temp. of (Saturation (Saturation (Mid-point (Mid-point
dry ice) temp.) temp.) saturation temp.) saturation temp.)
87.8 °F 161.6 °F 213.8 °F 179.6 °F 181.4 °F
Critical temperature
(31 °C) (72 °C) (101 °C) (82 °C) (83 °C)
Critical pressure 1,056 psig 503 psig 590 psig 641 psig 674 psig
Triple-point pressure 61 psig 0.44 psia 0.734 psia 0.18 psia TBC
Pressure at a saturated
815 psig 144 psig 68 psig 133 psig 139 psig
temperature of 20 °C
Global warming potential 1 3,922 1,430 1,990 1,824
Psia: Pound-force per square inch 30Pressure-Enthalpy Diagram of CO2
Subcritical to Supercritical
p. 17
31Typical R-404A System
Products
162 °F Medium-
Critical Point
R-404A
►Mechanical TXV Temperature
R-404A
►Mechanical EPR
►Mechanical CPR
+25 °F and differential
Med.-Temp.
valves
►Mechanical
pressure controls
►Typically, on/off Low-
162 °F Temperature
Critical Point
compressor R-404A
R-404A control
-20 °F
Low-Temp.
TXV: Thermo expansion valves
EPR: Evaporator pressure regulator
32
CPR: Crankcase pressure regulatorCO2 Refrigeration System Highlights
► Three Main Differences
Between
HFC and R-744 Systems
1. High pressure
2. Low critical point
3. High triple point
► Dealing With Standstill
Pressures
4. Managing power outages
5. Managing pressure reliefs
6. How to mitigate risk
► Peculiarities of R-744
7. Managing superheat
33Ammonia (R-717)
34Key Industrial Refrigeration Trends
Safety and Environmental Requirements
► OSHA requirements
► Low-charge ammonia systems
► Moving ammonia out of occupied spaces
► Cascade systems using CO2 in the low
stage
► Booster transcritical CO2 architecture for
MT and LT
► Increased use of R-744 (CO2) and a
volatile secondary fluid
Increased Emphasis on Total Cost of
Ownership
► Equipment costs
► Maintenance costs
► Energy costs (improved performance of
MT: Medium temperature
CO2 at LT such as -40 °F) LT: Low temperature
35
TCO: Total cost of ownershipKey Industrial Refrigeration Trends
Safety and Environmental Requirements
► OSHA requirements
► Low-charge ammonia systems
Modular Refrigeration Unit Low-charge Central Systems
36Natural Refrigerant Options Span
the Journey From Farm to Fork
Transportation Consistent temperature control
Regulatory requirements Handling
Food safety
Intermediaries
Many steps
Complexity
Multiple players
37What Are the Key Considerations
and Tradeoffs From a Controls
Controls architecture is Perspective?
“loosely coupled” to the
systems architecture
Two basic controls
architectures
Centralized
Distributed
System architectures vary
on control requirements
CO2, cascade-
centralized control
Distributed, integral-
distributed control
How Do We Maintain Controls Consistency
Across the Different Architectures?
38Control System Review: Layers and
Functions of a Control System
Key Elements
Architecture
►Remote user interface
Layer ►Site information
Remote ►Data feed
►Advanced optimization
►On-site user interface
Supervisory ►User management
►Data logging
►Alarming
►Cross-system coordination
►Device integration
Control
►Control algorithms
Site
►Inputs and outputs
Hardware can be ►Sensors and transducers
combined or separated.
►Equipment interface
39By Taking Advantage of the Supervisory
Layer’s Ability to Integrate
Different Devices, a Common User
Experience Can Be Created
Architecture layer
Remote
Supervisory
Supervisory
Control
Site
40Planning for the Future: Newer Systems
Need Flexibility and Advanced Control to
Create Smarter Buildings
► “Traditional” control
architecture expanding to
enable more value
► Flexibility provided by add-
on “apps” which facilitate
Cloud Transactive customized solutions
Remote
services services ► Site control provides macro-
level control, coordination of
equipment on a cross-site
basis (i.e., HVACR) and
data aggregation
► Transactive services
provide opportunity to utilize
Transactive “smart grid” as well as other
Supervisory
services cloud-based services (i.e.,
renewable integration, etc.)
Apps Site control Advanced supervisory systems
Equipment control Distributed controllers
41
HVACR: Heating, ventilation, air conditioning, and refrigerationKey Take-Away Messages
1. Global refrigerant regulations are driving trials and adoption of
future-proof natural refrigerant architectures.
2. Propane has regained global popularity as a viable efficient
refrigerant choice with a GWP of only 3. Its high flammability has
kept self-contained equipment designs to 150g charge. IEC
International charge limits have increasing to 500g. UL2-89 still has
limit set at 150g(but AHJ will still have the final say).
- Propane is NOT a retrofit refrigerant — new systems only
3. CO2 has proved very effective in both low- and medium-temperature
applications. Successfully deployed in commercial and industrial
applications in Europe for nearly two decades, it has made inroads
in North America in recent years. Due to its low critical point and
high operating pressures, the designer must account for its unique
characteristics.
- CO2 is NOT a retrofit refrigerant — new systems only
42Key Take-Away Messages
4. Ammonia’s superior thermodynamic properties make it a logical first
choice for early refrigeration systems. It is often used in industrial,
process cooling, cold storage and ice rink applications. However, its
toxicity demands careful adherence to safe application procedures to
ensure operator safety and customer well-being.
5. Most recently, ammonia has been introduced into commercial
applications via cascade systems that utilize lower refrigerant
charges and keep the ammonia circuit removed from occupied
spaces. Conversely, CO2 has been introduced in the industrial
segment as a natural refrigerant option.
6. Control systems can vary across the various system architectures.
7. Supervisory systems can create a common user interface and
provide familiarity for technicians.
43Thank You!
Learn about the environmental regulations impacting HVACR at:
Climate.Emerson.com/JulyGreenChill
44Contacts and Additional Information
Presenter Contact Information GreenChill Contact Information
► Andre Patenaude, Emerson ► Tom Land, U.S. EPA
519.717.5282 202.343.9185
andre.patenaude@emerson.com Land.Tom@epa.gov
► John Wallace, Emerson
770.425.2724
john.wallace@emerson.com
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