The Case for R-290 in U.S.
Commercial Foodservice
Reviewing the advantages and
challenges for wider adoption of this
low-GWP natural refrigerant alternative
Tucson, Ariz. October 12, 2016
Allen Wicher
Mike Saunders
Director, Marketing — Foodservice
Emerson
Senior Lead Innovation Technologist
Emerson
Disclaimer
This presentation is intended to highlight changing developments in the law and industry topics. The
law is frequently evolving and information and publications in this presentation may not reflect the
latest changes in the law or legal interpretations. The statements and information provided in this
presentation should not be construed as legal advice or legal opinion regarding any specific facts or
circumstances, but is intended for general informational purposes only. The views and statements
expressed during this presentation are the personal opinions of the presenter and do not those of
Emerson Climate Technologies, Inc. or its affiliated companies. You should consult an attorney
about your situation and specific facts and you should not act on any of the information in this
presentation as the information may not be applicable to your situation. Although all statements and
information contained herein are believed to be accurate and reliable, they are presented without
warranty of any kind. Information provided herein does not relieve the user from the responsibility of
carrying out its own tests and experiments. 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. This presentation may
not be copied or redistributed without the express written consent of Emerson Climate
Technologies, Inc.
2
Refrigerant Change Being Driven by Regulations and Voluntary Actions
Organizations
Regulations
Montreal Protocol Targets Ozone
Depletion (R-22) Signed in 1987
North American Proposal
Targets CO2 Emissions
(High Global Warming)
INTERGOVERNMENTAL PANEL ON
climate change
HFC Ban & Tax
Carbon Tax
F-Gas Regulation
Global Regulatory Actions to Ban High-GWP Refrigerants Place
Renewed Emphasis on Natural Alternatives.
3
EPA’s Final Rule, July 20, 2015, and September 26, 2016
Changed listing status of certain HFCs*
Final Rule: July 20, 2015
Final Rule: September 26, 2016
Stand-Alone
Phase-out
refrigerant
R-404A/507A
Supermarket
(New**)
Supermarket
(Retrofit***)
Remote
condensing
unit
(New)
Remote
condensing
unit
(Retrofit***)
Jan. 1, 2017 July 20, 2016 Jan. 1, 2018 July 20, 2016
MT < 2,200 BTU/hr.
and not contain
flooded evap.
(New)
MT ≥ 2,200 BTU/hr.
with or without
flooded evap.
(New)
Jan. 1, 2019
Jan. 1, 2020
Jan. 1, 2020 July 20, 2016
LT
(New)
LT and MT
(Retrofit***)
Refrigerated
food processing
and dispensing
equipment
(New)
Cold storage
warehouses
(New)
Ice
machines
(New)
Very lowtemp
refrigeration
(New)
Jan. 1, 2021
^Jan. 1, 2023
OK
OK
R-410A
OK
-
OK
-
Jan. 1, 2019
Jan. 1, 2020
Jan. 1, 2020
-
Jan. 1, 2021
^Jan. 1, 2023
OK
OK
R-407A/C/F
OK
OK
OK
OK
Jan. 1, 2019
Jan. 1, 2020
Jan. 1, 2020
OK
^Jan. 1, 2021
R-407C/F OK
R-407A:
^Jan. 1, 2023
OK
R-407C only
HFC-134a
OK
OK
OK
OK
Jan. 1, 2019
Jan. 1, 2020
OK
OK
OK
OK
OK
-
R-448A/449A
OK
OK
OK
OK
OK
OK for
LT only
-
-
OK
-
R-450A/513A
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
-
R-290
-
-
-
-
OK
OK
OK
-
-
-
OK
OK
R-744
OK
-
OK
-
OK
OK
OK
-
OK
OK
-
OK
-
(In primary loop of
secondary system)
OK
OK
-
Likely alternatives
(Emerson perspective)
R-717
OK
(in primary loop of
secondary system)
OK
-
Neither SNAPNeither SNAPapproved, nor banned approved, nor banned
OK
OK
OK
OK
OK
(in primary loop of
secondary system)
(in primary loop of
secondary system)
(in primary loop of
secondary system)
(in primary loop of
secondary system)
(in primary loop of
secondary system)
** 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.
*Abbreviated – For complete listing, see EPA Final Rule; go to: https://www.gpo.gov/fdsys/pkg/FR-2015-07-20/pdf/2015-17066.pdf
See proposed rule; go to: https://www.gpo.gov/fdsys/pkg/FR-2016-04-18/pdf/2016-08163.pdf
4
Alternatives for Refrigerant Applications
Pressure
or
capacity
Environment
A1 – Non-flammable
A3 – Flammable
A2L – Mildly flammable
B2L – Toxic, mildly flam.
CO2
Qualitative; not to scale
Available now
Established
OEMs testing
R-446A, R-447A, ARM-71a
R-32/HFO
400–675
R-32
blends
R-410A
like
R410A
R-404A &
R-407/22
like
NH3
~300
<150
R290
R-134a
like
HDR110
DR3
ARM-20a
HFO 1234yf
HFO 1234ze
ARM-42
R-123 like
(v. low pr.)
R448A
R449A
R-444B = L20
L40, DR7
ARM-20b
< 1500
R-32/HFO
blends
~600
R404A
R507A
R32/HFC/HFO
Blends
R22
R407A
R407C
R407F, R452A
(3922)
HFC/HFO R450A
Blends R513A
R134a
DR2, N12, ARC 1
0
500
1,000
1,500
2,000
GWP level
Watch: EPA SNAP, AHRI’s A2L Research, Standards and Code Committees,
Equipment Manufacturers’ New Product Launches, CARB Proposal (<150 GWP)
5
Summary for Refrigerant Changes
• Industry workhorse R-404A to be delisted in many applications
• You will continue to see refrigerant changes and a movement toward low-GWP refrigerants
• No clear path to a single replacement
• Natural refrigerants including R-290 gaining an increasing level of evaluation and adoption
• EPA SNAP listing of A2L alternative refrigerants expected by end of 2016
• Many lower-GWP (<150) refrigerant alternatives carry an increase in flammability
• Standards working groups discussing charge limit increases, IEC, UL, ASHRAE, etc. As R-290 limits go
up, so will A2L limits.
• Increased charge limit and end use application adds for A2L and A3 refrigerants will drive a new cycle of
regulation edits (design, servicing, building code, fire code, training and handling requirements)
No Silver Bullet Refrigerant Alternative
6
Where We Are: Energy Regulations and Refrigerants
Reach-in
Ice
Walk-in
Supermarket
CA Title 24
DOE energy
% Energy
40
-35%
20
0
-37%
-25%
-17%
Today
2017
Today
2018
Today
2020
2012
2013
EPA refrigerants
% Market
50%
Low GWP Blend
100%
100%
40%
R-290
Today
2019
Low-GWP blend
Low-GWP blend
R-404A
CO2
R-290
Today
2017
Today
2018
Today
2017
Redesigns Are Widespread. Results Require System-Wide Optimization.
7
Refrigerants and Regulations
2016
2017
2018
2019
2020
<2,500 GWP
Supermarket (Rack)
1/1/17
<2,500 GWP
Walk-In (Remote CDU)
1/1/18
20–40%
Cooler
Freezer
20–30%
1/1/20
30-50%
Reach-In (Stand-Alone)
Cooler
<2,200 BTU
7th Circuit Upholds DOE’s Final Rule
New
3/27/17
<600 GWP
Expecting medium-pressure adds
1/1/19
>2,200 BTU
<600 GWP
Freezer
<1,500 GWP
1/1/20
Ice Machines
New
R-290
approved
5–15%
1/1/18
Next Two Years Are Very Active for the Industry
8
Refrigerant and Minimum Energy Efficiency Regulations
Require Industry to Balance the Equation in U.S.
• 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.
Seek Best Solution for End Users
9
Energy
Environment
Equipment
Refrigerant Properties
Refrigerant
(safety group)
GWP
(AR4)
Critical
temp. (°F)
LEL
(% vol.)
UEL
(% vol.)
Ignition temp.
(°F)
MT theor. cap.
MT theor. EER
Theor. sys. charge
R-404A (A1)
3,922
161.7
Non-flam
Non-flam
Non-flam
100%
100%
100%
R-22 (A1)
1,810
205.1
Non-flam
Non-flam
Non-flam
101%
113%
91%
R-134a (A1)
1,430
213.9
Non-flam
Non-flam
Non-flam
62%
114%
85%
R-290 (A3)
3
206.1
2.1%
9.5%
878
88%
112%
39%
• Refrigerant grade R-290 does not have odorant
• R-290 heavier than air
Increasing flammability
Safety group
Higher flammability
A3
B3
Lower flammability
A2
B2
A2L*
B2L*
A1
B1
Lower toxicity
Higher toxicity
No flame propagation
* Max burning velocity <=10 cm/s
Increasing toxicity
10
Energy
Environment
R-404A and R-290 EER Comparison
+22%
+23%
+13%
+10%
+22%
+21%
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-290 Yields 20%+ Better EER Efficiency Over R-404A.
11
R-290 Codes and Standards
Environment
Equipment
• Refrigerant charge < 150 gm (5.3 ounces) for food retail stand-alone
– In line with the IEC 60335-2-89 standard for commercial appliances
• New equipment only — no retrofitting of equipment to R-290 is allowed
• 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
• AHJ (Authority Having Jurisdiction)
– Local authorities such as state, local as well as fire marshals may have other restrictions
Must Comply With Design and Safety Standards.
Be Sure to Check AHJ Before Installing Equipment.
12
EPA’s ‘SNAP’ Program for Hydrocarbon Refrigerants
in Commercial Refrigeration
Energy
Environment
Equipment
Economics
• UL 471, SB1 contains additional specifics for flammable refrigerants
–
–
–
–
–
–
Fitting types to be used (no quick connect, flare, compressor or packed stem valves)
Design space and construction guidelines
Leaks and leak tests to be performed
Ignition tests to be done
Labels and markings required on equipment
Color-coded processing tubes to indicate use of a flammable refrigerant
• Other use conditions and recommendations
– 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 specifically trained in handling
flammable refrigerants undertake the servicing or disposal of equipment containing hydrocarbon refrigerants.
Various Use Conditions to Consider
13
Environment
Equipment
Servicing
• Specialized training for R-290 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, per EPA regulations.
• 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
Adherence to Servicing Procedures a Must
14
Flammable Refrigerants Create Challenges
Environment
Equipment
Refrigerants approved by the EPA under Significant
New Alternatives Policy (SNAP)
Limitations
• Stand-alone units only
• Equipment size due to limited charge (150 grams or 5.3 ounces)
• Currently no formalized certification of service technicians
• No channel developed for service replacements for compressors
• Liability concerns
Guideline for technicians with info
on best practices
R-290 (Propane)
R-600a (Isobutane)
R-441A (a blend)
Servicing Infrastructure Needs Development.
15
Energy
Environment
Equipment
Relevant EN Standards for Hydrocarbon Usage
Commercial refrigeration
Economics
• EN 60335-2-89 (Commercial Ref. Appliances): max. 150g
• EN 378 (Refrigeration Systems): see below
EN378: Max. Charge Limit for HC (Propane), kg
Occupancy
System Design and
System Location
Public Access
Supervised
Occupancy
Authorized
Access Only
System in occupied space
1.5
2.5
10
Compressor and receiver in
unoccupied space
1.5
2.5
25
All refrigerant in unoccupied
space
5
10
Unlimited
Charge Limits Based on System Design and Location
16
Energy
Environment
Equipment
Hydrocarbons Usage
Implications for OEMs and operators
Application
A3 Refrigerant
< 150g
Economics
OEM
Operator
• Design and safety based on EN 603352-89: Part 2-89
• No special requirements for installation and
operation of the system
• Conformity EN378
• Risk analysis, raised complexity for service,
operation and personnel instructions
R-290, R-1270
A3 Refrigerant
150g … 1.5 kg
R-290, R-1270
A3 Refrigerant
> 1.5 kg
R-290, R-1270
• ATEX 94/9/CE compliance
• Charge limit for vicinity with public:
max 1.5 kg or practical limit x volume*
• Practically, systems can be moved
outside public area
• Same as above
• Outside area, e.g., rooftop, restricted access
• Conformity EN378
• ATEX 94/9/CE compliance
*Example: Practical limit R-290 = 0.008 kg/m3; Room 8 m x 8 m x 3 m => 1.54 kg
OEMs and Operators Need to be Aware of Increasing System Costs as Charge Increases.
17
Energy
Environment
Equipment
Europe: The Usage of Hydrocarbons Has Been
Extended to Wider Refrigeration Applications
Self-contained
cases (MT)
• Emerging system
Secondary
systems
architecture
• Low charge allows HC usage
Economics
• Alternative natural ref. solution
• High-charge HC usage
• Supermarkets, hypermarkets
• Discounters, supermarkets
• R-290 / CO2 solution
• Total natural ref. solution
• Cold rooms, convenience
Small
cascade
systems
• Economical natural ref. solution
• Low charge allows HC usage
Condensing
units
• Cold rooms, convenience
Hydrocarbons already established in low-temperature cabinets successfully
R-290 Has a Wider Market Acceptance in Europe vs. U.S.
18
Energy
Environment
Equipment
Europe R-290 Case Study
Economics
• Self-Contained Cases With R-290 Scrolls for Medium-Temp
-
Fully hermetically sealed refrigeration system
2.5 and 3.75 m self-contained cabinets
4.8 to 7 kW cooling capacity
Refrigerant charge 500 to 700g per cabinet
ATEX components and safety sensors
Water/Glycol
condensing
Benefits Associated With Self-Contained
Feature
Centralized DX Remote System
Self-Contained Display Case
Flexibility
Low
High – Plug and Chill
Service Complexity
High
Low
Refrigerant Charge
High
Low (-85%↓)
System Lead Time
Long
Fast
On-site Installation
Complex, Long Pipe Length
Simple, Factory Built
Refrigerant Leak Rate
High
Minimal
Merchandising Flexibility and Ease of Service Drive Supermarket Adoption.
19
Energy
Environment
Equipment
R-290 U.S. Commercial Applications
Charge limits/codes/standards evolving
Domestic refrigerators
Economics
150g charge
limit
UC/prep
Larger units achievable
with multiple systems
X
Vending mach.
Bev. dispensers
Bottle coolers
Ice (awaiting Federal Register release)
Commercial reach-ins
1DS
1DT
2DS
2DT
3DG
3DS
X
Walk-ins
HP
1/8
1/6
1/4
1/3
1/2
3/4
1
X = Use applications not approved by EPA
IEC/UL/ASHRAE:
R-290: U.S. 300–500-gram charge limit in proposal (CE-2020)
R-290: European proposal to increase to 1 kg (IEC 60335-2-89)
A2L: U.S. 1 kg. charge limit in proposal (CE-TBD)
In U.S, Significant Headwinds Exist to Increase Charge Limits.
20
U.S. R-290 Case Study
Energy
Environment
Equipment
Economics
Name of the Store/Facility: H-E-B at Mueller
Location: Austin, Texas, United States
Type of Facility: supermarket; store area = 7,711 m2
Refrigerant/Product Used: R-290, self-contained
cases
Project Background:
• Develop sustainable design test store
• Reduce energy and potable water consumption 50% vs.
2010 baseline
• Trial the use of climate-friendly refrigerants
Energy Savings, Sustainability and Ease of Service Drive Supermarket Adoption.
21
U.S. R-290 Case Study
Energy
Environment
Equipment
Economics
• New System Installation
– 70 refrigerated cases (cooling capacity 1,013 MBTU’s)
– Majority of cases self-contained R-290 within store connected to water-chilled 134a condenser
– Chiller used for space cooling/heating and refrigeration (25% of load)
• Majority have door or sliding lid; minimizes energy consumption and allows for small refrigerant charge
• Results
– Performance data not available at case study
– 85% carbon footprint reduction vs. baseline store
• 58% due to reduced energy use
• 27% due to direct emissions avoided b/c R-290 use
– Costs higher than baseline store but ROI will be realized
• No refrigeration contractor necessary
• Maintenance low, self-contained simple
• Reduced energy bill
• Challenges/Lessons Learned
– Limited refrigerant charge (150g) meant more compressors than traditional
– Austin Fire Dept. required extra leak detection, alarm systems
22
U.S. R-290 Adoption
Energy
Environment
Equipment
Economics
 EPA SNAP-approved, very
low-GWP alternative refrigerant
 Efficiency benefits
 Foodservice market leaders
driving OEMs
http://www.fierceenergy.com/story/mcdonaldseyeing-net-zero-energy-restaurants/2015-02-03
OEMs Working Directly With End Users on Integrating
Renewable Energy Solutions Like R-290 Where Applicable.
23
Energy
Environment
Equipment
The Case for R-290 in U.S.
Economics
Advantages
Challenges
• Hydrocarbon-based, non-synthetic
substance
• Classified A3 flammable refrigerant
• EPA-approved in commercial
refrigeration applications
• Very low environmental impacts:
GWP = 3; ODP = 0
• High-efficiency, high-performance,
reliable
• LT and MT applications that address
EPA and DOE compliance challenges
• 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
• Safe when proper protocols and
procedures are followed
• Market is currently missing a
complete product and safety training
course
• Hydrocarbons can be used in multiple
applications such as secondary
systems, self-contained cases and
condensing units
• Charge limit, safety and related
legislations/regulations are the key
areas to address for hydrocarbons
Charge Limit Increase in U.S. Will Bring a Revision Iteration of All Regulations Impacted.
24
Thank You!
Questions?
Allen Wicher
Director, Marketing — Foodservice
937-493-2496
[email protected]
Mike Saunders
Senior Lead Innovation Technologist
937-726-4928
[email protected]
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.
25