TRANSITIONING TO LOW-GWP ALTERNATIVES in Residential and Commercial Air Conditioning and Chillers Background This fact sheet provides current information on low global warming potential (GWP)1 alternative refrigerants to high-GWP hydrofluorocarbons (HFCs)for use in residential and commercial air conditioning (AC) equipment, including chillers. Ill Cs are powerful greenhouse gases (GHGs) with GWPs hundreds to thousands of times more potent per pound than carbon dioxide (C02); however, more low GWP alternatives are becoming available. Globally, approximately 80% of HFCs are emitted in the refrigeration, AC, and motor vehicle AC (MVAC) sectors, with the remainder accounted for by the foam-blowing, aerosols, fire suppression, and solvents sectors. While developed nations have historically accounted for the majority of global HFC emissions, total HFC emissions in developing nations are projected to quadruple by 2030. This rapidly increasing rate of HFC emissions is largely driven by the increased demand for refrigeration and AC, particularly in the tropical climates of much of the developing world, and the transition away from ozone depleting substances (ODS). HFC refrigerant emissions from AC applications are released to the atmosphere throughout the lifecycle of equipment—i.e. during equipment manufacture, installation, operation, maintenance, and at end ol lile. Figure 1. Global HFC Emissions in 2020 by Sector MVAC / 13% Aerosols, Solvents, Foams, and Fire Ext 21% Other Ref 12% Commercial Ref 26% Global HFC Emissions: 1,084 MMT C02 Eq. Global HFC Emissions in AC: 306 MMT C02 Eq. Source: Estimates based on U.S. EPA (2013). AC Equipment Residential and commercial AC equipment used iri households and commercial buildings contain one or more factory-made assemblies that normally include an evaporator or cooling coil(s), compressor(s), and condenser(s). These include small AC systems (self-contained AC and split AC), large AC systems (single split and multi-split, variable refrigerant flow, and ducted and packaged rooftop units), as well as chillers. Descriptions of each of these AC equipment categories are provided below, followed by Table II, which lists the typical capacity, refrigerant charge, and annual operational leak rate for each equipment type. i 1 GWP is a measure of a substance's climate warming impact compared to COn. ------- Small AC Systems Source: U.S. EPA (2015d) Small Self-Contained AC • Small hermetically sealed AC units are used for cooling small rooms in residential and commercial buildings • The compressor, evaporator, and condenser are all housed within a single unit • Includes portable units, window-mounted units, through-the- wall units, and packaged terminal air conditioning (PTAC) units • Portable units utilize flexible ductwork to supply outside air to the condenser and return heated air to outside of the room • PTAC units are often used in the hospitality industry (e.g., inside hotel rooms) • Packaged terminal heat pumps (PTITI's) are similar to PI AOs and also provide treating Small Split AC • Small split AC units are used for cooling single rooms in residential and commercial buildings • Systems contain two factory- built units interconnected by a Source: UNEP (2015c) refrigerant line; the indoor unit includes the evaporator, installed inside conditioned room ori the wall, ceiling, or floor; the outdoor unit includes a compressor and a condenser Some systems can operate in reverse and provide heating in cold weather Large AC Systems Large Single Split and Multi-Split AC • Larger versions of the small split system described above • Multi-split systems have several indoor units connected to a single outdoor unit • Some models are designed to provide both heating and cooling Variable Refrigerant Flow (VRF) Systems • More complex multi-split systems • One or more air source outdoor compressor units serving multiple indoor fan coil refrigerant evaporator units Source: UNEP (2015d) Source: Pacific Northwest National Laboratory (2012) • Heated or cooled refrigerant moves throughout building in small diameter pipes and passes through coils in each conditioned room • Systems can deliver heating and/or cooling to different rooms of the same building simultaneously through various units Ducted and Packaged Rooftop Systems • In ducted systems, the evaporator is located in an air handling unit to cool air • In packaged rooftop systems, the compressor, evaporator, and condenser are all housed within a single unit • Air is circulated throughout the building via a ducted air ventilation system Source: U.S. EPA (2015d) ------- Chillers Comfort Cooling • Large buildings are often cooled by a central chiller that pumps chilled water to heat exchangers in air handling or fan-coil units that deliver conditioned air • Often located in a machinery room (large buildings) or outdoors (small buildings) • Small and medium-sized chillers typically use a vapor compression cycle with positive displacement compressors (i.e., reciprocating, rotary, scroll, or screw), while large chillers typically use screw or centrifugal compressors Source: UNEP (2015e) Source: AEC Online (2007) District Cooling • Uses a centralized cooling plant to deliver chilled water via underground insulated pipes to several buildings using a single system • Provides AC to multiple buildings in a central location (e.g., hospitals, universities, shopping malls, airports) • Chillers using vapor compression technology and centrifugal compressors often used in cooling plant • Increasing in popularity; commonly used in the Middle East; some installations in China, the United States, Northern Europe, and coastal sites such as Hawaii, Malaysia, and Mauritius, with sufficient deep water resources Table 1. Typical AC Equipment Characteristics Equipment Type Capacity (kW) Refrigerant Charge (kg) Annual Operational Leak Rate" (%) Small Sell Contained AC 2-7 0.2-2 <1 Small Split AC 2-12 0.5-3 1-4 Single Split and Multi-Split (Large) 10-40 3-10 1-4 VRF Systems (Large) 12-150 5-100 1-5 Ducted Systems (Large) 12-750 5-200 2-6 Small/Medium Chillersb 50-750 40-500 2-4 Large Chillers0 750-21,000 500-36,000 2-4 Sources: UNEP (2015a - e) and Johnson Controls (2014). 8 Typical annual operational leak rate does not include additional refrigerant ieaks that can occur during equipment installation, maintenance, servicing, and disposal B Typically use positive displacement compressors (i.e., reciprocating, rotary, scroll, or screw). • Typically use screw or centrifugal compressors. HFC Alternatives and Market Trends Many residential and commercial AC systems in use contain ozone-depleting refrigerants CFC-11, CFC-12, and HCFC-22, which are being phased out globally under the Montreal Protocol. Many new units sold today contain HFCs, or HFC blends, namely R-410A and R-407C, with GWP values of 2,088 and 1,774, respectively. A number of lower GWP alternative refrigerants are available and currently in use or under development for use in residential and commercial AC systems—including hydrocarbons, carbon dioxide, ammonia, water, as well as HFC and III O blends. These alternatives and their potential applications are described on the next page and summarized in Table 2. * HFOs (hydrofluoroolefins) are unsaturated HFCs (i.e., containing a carbon-carbon double bond). ------- TRANSITIONING TO LOW-GWP ALTERNATIVES in Residential and Commercial Air Conditioning and Chillers R-290 (Propane) and Hydrocarbon Blends (e.g., R-441A) • Successfully used in some regions including China and India in small AC units that utilize less than 1 kilogram of refrigerant • Used in small self-contained AC and small split AC in Europe, Far East, Japan, and India • Used in small capacities and outdoor applications in air-cooled chillers in Indonesia, Malaysia, the Philippines, Europe, and New Zealand • R-290 and R-441A are listed acceptable substitutes (subject to use conditions) in room AC units by the U.S. EPA Significant New Alternatives Policy (SNAP) program • Efficiency and performance expected to be equal to or better than R-410A, particularly in regions with warmer climates • Safety concerns for flammable refrigerants require technician training and can increase installation costs Carbon Dioxide (C02, R-744) • Can be used in large AC equipment, typically in ducted systems • Air-cooled chillers using R-744 have been introduced in northern Europe Ammonia (R-717) • Suitable in chillers for numerous building AC applications and district cooling • Used in medium and large chillers with screw or reciprocating compressors • Central comfort cooling chiller plant installations exist in the Middle East, China, Europe, and the United States • Ammonia is listed as an acceptable substitute by the U.S. EPA SNAP program in vapor compression chillers (with a secondary loop) • Ammonia is also used in absorption systems, which are listed as acceptable by the U.S. EPA SNAP program for chillers and in residential and light commercial AC equipment • Safety concerns in comfort cooling applications can increase installation costs and require technician training; restrictions often apply in some countries due to certain building codes or regulations Water (R-718) • Developmental chillers demonstrated in the Middle East, South Africa, and Europe • Requires large space and use of complex compressor technology HFC-32 • Small self-contained and split AC systems produced with HFC-32 are commercially available in 30 countries, including Japan, India, Indonesia, Australia, and soon in China and the United States • HFC-32 is listed as an acceptable substitute (subject to use conditions) in room AC units by the U.S. EPA SNAP program • Efficiency and performance expected to be equal to or better than R-410A Low-GWP Fluorinated Compounds • HFO-1234yf and HFO-1234ze(E) have similar properties to HFC-134a and are under development for ducted and rooftop unit systems • Use of HFO-1234ze(E) is currently under development in large centrifugal chillers and large AC equipment and commercially available in small and medium-sized positive displacement chillers • Chillers using HFO-1234ze(E) are available in the European market • HFO-1234ze(E) is listed as an acceptable substitute in centrifugal, reciprocating, and screw chillers by the U.S. EPA SNAP program • Solstice™ 1233zd(E) is currently used in centrifugal chillers in Europe, the Middle East, and Japan • Solstice™ 1233zd(E) is listed as an acceptable substitute in centrifugal chillers by the U.S. EPA SNAP program • HFO-1336mzz(Z) is under development for use in low pressure centrifugal chillers • HFO-1336mzz(Z) is listed as an acceptable substitute in centrifugal and positive displacement chillers by the U.S. EPA SNAP program HFC/HFO Blends • Various blends of HFCs and HFOs (i.e., unsaturated HFCs) are being developed for all types of AC equipment • R-450A and R-513A are listed as acceptable substitutes in centrifugal, reciprocating, and screw chillers by the U.S. EPA SNAP program • Testing and trials using blends of R-444B, R-446A, and R-447A, in both small and large AC systems, are ongoing, with manufacturers in Japan, Korea, China, and New Zealand developing prototypes • Safety regulations may be required for lower flammability blends (e.g., R-444B, R-446A and R-447A), especially in larger AC equipment ------- TRANSITIONING TO LOW-GWP ALTERNATIVES in Residential and Commercial Air Conditioning and Chillers Table 2. Lower-GWP Alternatives for Residential and Commercial ACa Refrigerant GWP" Small Self-Contained ACC Small Split ACC Single & Multi- Split AC (Large)0 VRF (Large)0 Ducted Systems (Large)0 Chillers0 HFC-32 675 ~+ ~ ~ ~ ~ ~ R-513A 630 ~+ R-450A 601 ~+ HFO-1336mzz(Z) 9 ~+ HFO-1234ze(E) 6 ~ ~+ R-441A <5 ~+ Solstice™ 1233zd(E) 4.7-7 ~+d HFO-1234yf 4 ~ R-290 3 ~+ ~ ~ R-744 (C02) 1 ~ ~ R-717 (ammonia) 0 ~+ Note: R-444B, R-446A, R-447A, and R-718 are currently under development for use in various residential and commercial AC applications. 3 ~ = Available now; ~ = Under Development; + = U.S. EPA SNAP-approved b GWP values are from IPCC Fourth Assessment Report (2007) and U.S. EPA (2015c). i: UNEP (2015a-e). d U.S. EPA SNAP-approved for centrifugal chillers only. Reducing Emissions from Servicing and Disposal Refrigerant emissions from AC equipment occur during various events, including manufacture, operation (i.e., leaks from fittings, joints, shaft seals, etc.), servicing (i.e., due to loss of refrigerant from fugitive emissions), and end-of-life (i.e., equipment disposal). When leaks are fixed during servicing, refrigerant recovery is necessary for certain applications. During servicing events and end-of-life, the refrigerant losses depend on various factors including the existence of or compliance with refrigerant recovery laws, the technical efficiency of refrigerant recovery equipment, and the technical performance of technicians. Improvements in the technologies and practices associated with the use of these gases by manufacturers and technicians, the introduction of alternative gases and technologies, implementation of refrigerant recovery laws and standards, and market/policy drivers that provide financial incentives for recovery may help to offset most HFC refrigerant emissions from residential and commercial AC equipment. Case Study: Hydrocarbon Refrigerants in China With support from the United Nations Industrial Development Organization (UNIDO) and approval for funding by the Executive Committee of the Multilateral Fund for the Implementation of the Montreal Protocol in July 2010, two manufacturers in China—Guangdong Meizhi Co. Ltd and Guangdong Midea Refrigeration Equipment Co. Ltd—conducted a demonstration project to convert R-22 compressors and split AC units to R-290. The Meizhi production line, which has an annual production capacity of 1.83 million rotary compressors for split AC systems, was converted to produce R-290 compressors. The Midea production line was converted to an advanced mechanized line producing 200,000 R-290 split units annually. After 30 months of factory conversion the project was completed by the end of 2013 and two types of compressors (fixed and variable speed) and two types of AC units (split and portable) became available for mass production by these manufacturers. The R-290 AC units also meet both national and international performance standard requirements. In converting the plants, engineering controls and safety measures were implemented into the production lines to address the flammability of R-290, including modified products, tools, parts, equipment, installation procedures, leak detection and containment, staff training, and technology dissemination. The success of this project and advancement of hydrocarbon-based AC technologies has already influenced other Chinese manufacturers to invest in conversion activities. For example, in 2015, nine AC manufacturers in China were designated by the Chinese Ministry of Environmental Protection to receive subsidies to convert to R-290. These advancements are expected to encourage other manufacturers in other developing countries to invest in alternative AC technologies. ------- TRANSITIONING TO LOW-GWP ALTERNATIVES in Residential and Commercial Air Conditioning and Chillers Future Outlook Together, the suite of known alternative chemicals, new technologies, as well as better process and handling practices, can significantly reduce HFC use in both the near and long term. Many countries are transitioning to lower-GWP alternatives in AC applications while satisfying the various international energy efficiency, safety, and environmental standards. 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