TRANSITIONING TO LOW-GWP ALTERNATIVES IN COMMERCIAL REFRIGERATION Figure 1: Distribution of Global Commercial Refrigerant Stock by System Type (2006) Background This fact sheet provides current information on low Global Warming Potential (GWP) alternatives in newly manufactured commercial refrigeration equipment relevant to the Montreal Protocol on Substances that Deplete the Ozone Layer.] Commercial refrigeration includes refrigerated equipment found in supermarkets, convenience stores, restaurants, and other food service establishments. In 2006, there were an estimated 530,000 supermarkets worldwide, containing roughly 546,000 metric tons of refrigerant. Due to their large charge sizes, the multiplex rack systems typically used in these supermarkets account for the greatest percentage (60%) of refrigerant installed in the commercial refrigeration sector. HCFCs account for the majority of refrigerant (55%). Figure 1 and Figure 2 graphically present the distribution of the global commercial refrigeration stock by system and refrigerant type in 2006. Equipment in this sector typically last approximately 15-20 years. Equipment can be broadly categorized as either self-contained or remote refrigeration systems, as explained further below: Self-Contained or Stand-Alone Refrigeration Systems Integrates all refrigerating components within its structure Low charge size (-150 grams) Most often contains HCFC-22, HFC-134a, or R-404A (a blend of MFCs) Estimated 32 million stand-alone units in use worldwide with an additional 20.5 million vending machines Remote Refrigeration Systems Condensing Unit Systems Comprised of one or two compressors, one condenser, and one receiver assembled into the condensing unit system; linked to one or more display case(s) in the sales area through a piping network Dominantly contains R-134a, R-22, or R-404A R-407C, R-507, other HFC blends, and HCFC blends are also used Refrigerant charges vary in size from 0.5-20 kg Approximately 34 million systems are in use worldwide Multiplex Rack Systems Remote refrigeration systems consisting of racks of multiple compressors contained typically in a machinery room; linked to multiple display cases in the sales area through extensive piping. Condensers are usually remotely located, such as on the roof above the machinery room. Various designs exist: direct (also called direct expansion) is most common, and circulates refrigerant from a central machinery room to the sales area; indirect (also called secondary loop) systems chill an intermediate fluid which is circulated from the refrigerant-containing equipment to the display cases. R-22 is the most widely used refrigerant in multiplex rack systems CFC-12, R-502, R-404A, R-507A, R-407A, and several HCFC- and HFC-based blends designed for retrofit of existing CFC or HCFC installations are also used Charge size ranges from 300-3,000 kg, depending on the size of the supermarket and on design (e.g., pipe layout and operating characteristics) Currently, the commercial refrigeration sector accounts for approximately 32% of global HFC consumption, or 40% of HFC consumption in the refrigeration/AC sector. Developing countries account for an estimated 131 million metric tons of carbon dioxide equivalent (MMTC02eq.) or 38% of the global HFC consumption in this end-use today. Figure 2: Distribution of Global Commercial Refrigerant Stock by Refrigerant Type (2006) 2010 HFC Consumption (Estimates Presented in MMTCO eq.) Fire Extinguishing (4%) Aerosols Commercial Ref - Developed Countries (25%) Commercial Ref - Developing Countries(15%) (5%) Foams (11%) Global HFC Consumption Total: 1,087 MMTC02eq. Global HFC Consumption Commercial Ref: 346 MMTC02eq. Global Ref/AC Total: 858 MMTC02eq. Global Ref/AC Sector Commercial: 346 MMTC02eq. ------- Alternatives and Market Trends Many design strategies exist today to reduce the amount of refrigerant needed while at the same time reducing the likelihood of leaks and mitigating risks if using a flammable or toxic refrigerant. Although most of these advanced refrigeration systems still rely on HFC refrigerants, they have great potential for drastically reducing HFC consumption in multiplex rack commercial refrigeration systems. In addition, a number of climate- friendly alternatives to CFC/HCFC/HFC refrigerants are, or will become, available for use in commercial refrigeration applications. Alternatives available today include hydrocarbons-isobutane (R-600a), propane (R- 290), and propylene (R-1270)-ammonia (R-717), and carbon dioxide (R- 744). Other alternatives, such as new HFCs/HFOs, are also likely to enter the market in the coming years. Advanced Refrigeration System Designs Distributed systems2 and indirect systems3 have been available for more than 20 years o Distributed systems can lower refrigerant charge by 30-50% 3 Indirect systems can lower refrigerant charge by 50-80% Distributed secondary loop,4 compact chiller,5 and cascade6 designs were introduced recently Systems often use HFC refrigerants but can also use natural refrigerants (e.g., hydrocarbons, ammonia) In the European Union, indirect systems are now the norm; in the U.S., distributed systems account for 40% of new installations and indirect systems are gaining significant market shares Hydrocarbons Primarily used in many northern European countries including Denmark, Sweden, Germany, and the United Kingdom R-290 and R-1270 are used in condensing unit systems produced in northern Europe, as well as in indirect multiplex rack systems as a primary refrigerant A growing proportion of self-contained (stand-alone) equipment now uses propane (R-290) instead of R-134a Several large scale beverage companies have begun producing beverage dispensing fountains with isobutane (R-600a) R-717 Introduced as a primary refrigerant in indirect systems in northern European countries and Africa R-744 Many companies producing larger vending machines use R-744 in lieu of R-134a (e.g., Sanyo) Used as refrigerant in condensing unit systems and multiplex rack systems, mainly in Europe Used as the heat transfer (i.e., secondary) fluid in indirect systems in some countries such as the United States Used in the low temperature loop in cascade systems (often with small amounts of R-134a in the high temperature loop) New HFCs/HFOs New refrigerants (e.g., HFC-32 and HFO blends) are being developed and may become available in multiplex rack refrigeration systems in the next few years Refrigerant R-1 2 R-502 R-507A R-404A R-407A R-22 R-407C R-134a R-32 R-290 R-600a R-1 270 R-744 R-71 7 GWP 10,900 4,657 3,985 3,922 2,107 1,810 1,774 1,430 675 3.3 3 1.8 1 0 ODPa 1 0.334 0 0 0 0.055 0 0 0 0 0 0 0 0 aODP= ozone depletion potential ------- Refrigerant Transition in the Commercial Refrigeration End-Use* Stand-Alone Equipment R-12 - -R-404A -I ğR-134a - R-744 Condensing Unit Systems R-404A - -R-600a R-22 R-290 -R-507A - -R-407C - Multiplex Rack Systems > R-717 R"12B~| * R.502 _T R-22 System Design Transition in Multiplex Rack Systems *Solid arrow represents alternatives already available in the market for these systems; dashed arrows indicate those likely to be available in the future. Direct Expansion [-^Distributed Secondary _ Loop Compact Chiller Ğ Cascad' i Distributed 'secondary Loop Challenges and Potential Solutions Several challenges have limited the transition to climate-friendly alternatives in this end-use. The following table summarizes the challenges associated with the various alternatives as well as potential solutions to overcoming them. Alternative Challenges Potential Solutions Advanced Refrigeration System Designs Technician and Operator Experience Energy Efficiency Concerns Training and Education Standards and Service Procedures Case Studies and Operational Guidelines Hydrocarbons Highly Flammable Safety Code Restrictions Liability Concerns Safety Devices Standards and Service Procedures Training and Education R-717 Toxic and Slightly Flammable Building and Fire Code Restrictions Engineering Design Standards and Safety Regulations Revisions to Existing Codes R-744 Safety Risks High Operating Pressure Engineering Design Training and Education NewHFCs/HFOs Market Availability Research and Development Future Outlook Taken together, the suite of known alternative chemicals, new technologies, and better process and handling practices can significantly reduce HFC consumption in both the near and long term, while simultaneously completing the HCFC phaseout. Although there is much work to do to fully implement these chemicals, technologies and practices, and some unknowns still remain, the industries currently using HCFCs and MFCs have proven through the ODS phaseout that they can move quickly to protect the environment. ------- References Center for Sustainable Production and Consumption (C-SPAC). 2005. "Ecofridge: Make the Right Choice Now." Consumer Unity & Trust Society (CUTS). Retrieved August 19,2010 from: http://www.cuts-international.org/sc98-1.htm GTZ-Proklima International. 2010. "Conversion of Supermarket Refrigeration Systems from F-Gases to Natural Refrigerants." Funded by Federal Ministry for Environment, Natural Conservation, and Nuclear Energy. ICF International. 2009. "2009 Marginal Abatement Cost Curve Analysis for Reduction of MFCs in Traditional Ozone Depleting Substance (ODS) End-Use Applications: Draft Report." Prepared for the U.S. Environmental Protection Agency. October 30,2009. International Panel on Climate Change (IPCC). 2007. "Climate Change 2007:The Physical Science Basis." Contribution of Working Group I to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change. Solomon, S., D. Qin, M. Manning, Z. Chen, M. Marquis, K.B. Averyt, M. Tignor, and H.L. Miller (Eds.). Cambridge University Press, Cambridge, United Kingdom and New York, NY, USA. Available online at: http://www.ipcc. ch/publications_and_data/ar4/wg1/en/contents.html Kauffeld, Michael. 2008. "Trends and Perspectives in Supermarket Refrigeration." Available online at: http://www.ammonia21.com/files/papers/trends-perspectives-supermarket-refrigeration.pdf Mahone, D. and Roberts, J. 2008. "White Paper on Approaches to Reducing Leakage and Improving the Performance of Supermarket Refrigeration Systems." Prepared by Heschong Mahone Group, Inc. and CTG Energetics, Inc. for the California Energy Commission. Technology and Economic Assessment Panel (TEAP). 2009. "Task Force Decision XX/8 Report. Assessment of Alternatives to HCFCs and MFCs and Update of the TEAP 2005 Supplement Report Data." May 2009. Available online at: http://www.unep.ch/ozone/Assessment_Panels/TEAP/Reports/TEAP_Reports/teap-may-2009-decisionXX-8-task-force-report.pdf U.S. Environmental Protection Agency (EPA). 2010. "Overview on Commercial Refrigerants: where are we headed?" Presented by Jeremy Arling, U.S. EPA; Dave Godwin, U.S. EPA; Ron Vogl, Honeywell; Stephen Speltzer, Arkema; Nick Strickland, DuPont; Scott Koerper, Mexichem Flour; and David Callendar, ICOR International; at the GreenChill April Webinar. April 29,2010. Available online at: http://www.epa.gov/greenchill/events.html U.S. Environmental Protection Agency (EPA). 2006. "Global Mitigation of Non-C02 Greenhouse Gases." June 2006. Available online at: http://www.epa.gov/climatechange/economics/downloads/GlobalMitigationFullReport.pdf 'The four factsheets in this series covering domestic refrigeration, commercial refrigeration, MVACs, and unitary AC represent 85% of HFC consumption in the refrigeration/AC sector. The remaining HFC consumption in the refrigeration/AC sector is from chillers, cold storage, industrial process refrigeration, and refrigerated transport. Any service-related consumption is attributed to the specific end-use. 2 Distributed systems use an array of separate compressor racks located near the refrigerated cases rather than having a central compressor system. 3 Indirect systems use a chiller to cool a secondary fluid that is then circulated throughout the store to the cases and coolers. 4 Distributed secondary systems combine secondary loops with the typical distributed design. 5 Compact chiller versions of an indirect system rely on a line-up of 10-20 units, each using approximately 4-7 kg of refrigerant. 6 Cascade systems use a compressor to raise the low temperature coolant (often C02)from low temperature conditions up to an intermediate temperature while a separate refrigerating system uses a different refrigerant to condense the coolant. U.S. Environmental Protection Agency EPA-430-F-1 0-043 www.epa.gov September 2010 Printed on 100% recycled/recyclable paper with a minimum 50% post-consumer waste using vegetable-based inks ------- |