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R22 Phase-Out in Greece


… and what to do?

Joachim Gerstel
DuPont de Nemours (Deutschland) GmbH
Neu-Isenburg/ Germany Feb. 2009
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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
4

Fluoroproducts Tree:

Nafion
®
FLUOROCHEMICAL FILMS
SPECIALTIES Tedlar® Fuel Cell
Zyron Vertrel Formacel Teflon®
FLUOROPOLYMERS
Dymel
Teflon® PTFE
FE
Teflon® PFA
Teflon® FEP
REFRIGERANTS
ISCEON ® Teflon®
Suva®- Finishes
Tefzel® ETFE
Freon®

F-22
H2SO4 Chloroform
Fluorspar HF
5
6

Production & Blending Plant

Dordrecht/ NL
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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
8

(EC) No 1005/2009 replaces 2037/ 2000

1.Jan. 2010
Stop of R22-Sales
Stop of R22-Service
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(EC) No 1005/2009 replaces 2037/ 2000


by Jan. 1, 2010
http://eur-lex.europa.eu/
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Segmentation R22-Bank
EU25-Countries

2. Industrial
1. Comm. Refrig
(40-60%) Refrig.
(20-30%)

3. A/C 4.Transportcool.
(5-15%) (1-5%)
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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
12

R22-Phase-Out -- Options for Retrofit


Four Options

• Maintain • Replace with • Keep running • Keep running


operation new equipment existing equipment existing equipment
using recycled running on: - change of oil and – only moderate
R-22 = Risk! ƒ ammonia further technical modifications are
ƒ hydrocarbons
modifications are necessary:
ƒ CO2
ƒ HFC, e.g. Suva® required: ƒ retrofit
ƒ HFCs of the with DuPontTM
Suva® range, e.g. ISCEON® 9 Series

!
R404A or R407C Refrigerants

Attention
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The ISCEON® Solutions


Equipment with Serviceable Life
• Convert to Cost Effective non-ozone depleting alternatives

R12 / R401A / R409A/ R413A Î ISCEON® MO49Plus (R437A)

{
ISCEON® MO29 (R422D) or
R22 Î ISCEON® MO59 (R417A) or
ISCEON® MO79 (R422A) or
(Expansion valve change required)

R402A / R403B / R408 / R502 Î ISCEON® MO79 (R422A)


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ISCEON® MO49Plus (R437A)

• ISCEON® MO49 (R413A) Production stopped


• MO49Plus (R437A) now in use
• Main enquiry is regarding top up
• DuPont position:
“ DuPont does not recommend the mixing of refrigerants as this
can lead to systems with unpredictable performance and any
recovered refrigerant would need to be incinerated”
• However, in practice we do not know of any specific
performance or safety related issues should the products
become mixed.
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Selection of R22-Replacements

ISCEON® ASHRAE- Safety- Applications:


Nomenclature classification
R422D A1 Commercial MT, LT (2-stage,
MO29 Liquid Inj.), DX-Waterchiller

R417A A1 Split AC with cab tupe Q0<15kW


MO59
R422A A1 MT, LT especially for R502,
MO79 R402A, R403B, R408
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Selection of Refrigerants replacing R22


Freon® 22 ISCEON® MO29 ISCEON® MO59 ISCEON® MO79
ASHRAE # R22 R422D R417A R422A
ASHRAE Classification (Safety) A1 A1 A1 A1
Molecular mass [g/mol] 86,5 109,94 106,75 113,6
ODP 0,055 0 0 0
Technical Data
Boiling point at 1 bar [°C] -40,8 -43,5 to -38,6 -39,4 to -34,4 -46,8 to -44,3
Discharge Temperature [°C] 105 75 77 72
at -10°C/ +40°C; t0h=10°C; ηi=0,7
Discharge pressure [bar] 15,3 15,9 14,0 18,3
at -10°C/ +40°C; t0h=10°C; ηi=0,7
Cooling Capacity (compared to R22) - 0-5% less 5-20% less 10-20% higher
Composition [weights %] HCFC-22: 100 HFC-134a: 31,5 HFC-134a: 50 HFC-134a: 11,5
HFC-125: 65,1 HFC-125: 46,6 HFC-125: 85,1
Isobutane: 3,4 Butane: 3,4 Isobutane: 3,4
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Summary of Calorimeter Data


Cooling Capacity vs R-22 EER vs R-22

Low Temp (liq. Inj.)


R-404A +33% +15%
ISCEON
- ® MO79 +29% +13%
ISCEON® MO29 +8% +14%

Med. Temp
R-404A +7% -3%
ISCEON® MO79 Same as R-22 -7%
ISCEON® MO29 -5% Same as R-22

Actual results may vary due to system


design and operating conditions
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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
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Retrofit Guidelines for


ISCEON® MO29

8 Steps from establishing baseline performance


with existing refrigerant until labelling system
showing the refrigerant (and any replacement
lubricant) used. Update system log-book.

www.isceon.com/eu
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Before conversion to an ISCEON® 9 Series


Refrigerant

• Check current system performance


• Check Capacity Available vs. Capacity Required
• Ensure system is in good working order
• Conversion to an ISCEON® refrigerant will not solve existing
problems.
• Check Product Information Bulletin for suitability
• Refer to Retrofit Guidelines
• Have available product pressure/temperature tables
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During conversion to an ISCEON® 9 Series


Refrigerant:
Follow the advice given in the product retrofit
guidelines
• Majority of problems reported could have been avoided if
the guidelines were followed
Follow good refrigeration practice principles
• Do not take short cuts
Use pressure-temperature tables for the product
being used
• The pressure-temperature relationships are different and
it does make a difference
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Summary of Retrofit Procedures


1. Establish Baseline Performance with Existing Refrigerant & repair
if necessary
2. Remove Existing Refrigerant from System
3. Replace Filter Dryer, Elastomeric Seals/Gaskets, & Other
Equipment/Components Identified in Preplanning (Ball Valves,
Schrader Cores, Magnetic Valves, etc.)
4. Evacuate System and Check for Leaks
5. Charge with ISCEON® MO29 (Remove liquid only from cylinder)
6. Start up System and optimize performance (adjust TXVs,
refrigerant charge, etc.)
7. Monitor oil levels to maintain desired level in oil reservoir
8. Label System for ISCEON® MO29
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ISCEON ® is a technical sale, not a drop in !

• Revamped retrofit guidelines


• Hints and Advice for technically advanced partners
• Technical Bulletin
• Validation of solutions for more system types :
pump systems, chillers, process cooling , on-farm
milk cooling
• Work closer with the Contractors
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Retrofit Experience using the ISCEON®Solution

Systems under good conditions => No Issues!


BUT:
• Elastomeric seals (like O-Ring, Terminal board as well Ball- /
Schradervalves) exchange
• Oil circulation (Level control at compressor sight glass)
ƒ Systems without oil separator
ƒ Chiller with part load
ƒ Old compressors with high oil throw

Cooling Capacity should be calculated by using


Software DuPrex 3.0!
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Compatibility with Elastomeric Seals


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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
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Cost Analysis from the Operator‘s Point of View


•• Replacement
Replacementofof
•• Refrigerant
Refrigerant Operator’s components
•• Oil Expenses components
Oil •• Multiple
Multiple
exchange
exchangeof
ofoil
oil
(POE)
(POE)
Tim
r ial e
ate
M
COP •• Loss
Lossininsales
sales
COP because
•• Relocation
Relocationof
of becauseof of
stored foods partial/temporary
partial/temporary
stored foods
Components close-down
close-down

•• Payment
Paymentofof
overtime
overtime
•• Filter
Filterdryer
dryer
•• TXV
TXV
•• Condenser
Condenser
•• Seales/
Seales/Gaskets
Gaskets
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Retrofit Cases
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Milk cooling with ISCEON® MO29


- ELAS Systems Service GmbH at Elsterwerda -

ELAS-partner Werner Bergmann:


„The refrigerants experts of DuPont
had given us excellent advice in
the run-up to the retrofit. Following
their suggestion … the mineral oil
in the system was replaced by
polyolester oil with a similar
viscosity. This way we were able to
manage the pilot project without
disturbing during the daily routine
at the farm … The complete retrofit
was done smoothly during the
milking breaks.”
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Minimal Muenster, Germany - Supermarket


- Retrofit from R22 to ISCEON® MO29 on March 20, 2006 -

Medium Temperature
1 x 4 meter Sausage cabinet at 4ºC
2 x 3 meter Meat Cabinet at 4,5ºC
Dscf8847.jpg 5 x 2,5 meter Dairy Cabinets at 4ºC
4 x 36m3 Chilled food cold
stores at 5ºC
3x 5 meter refrigerated sales
cabinets
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Minimal Muenster, Germany - Supermarket

Medium Temperature BBC-Integral Rack


3 Copeland compressors – model D3DA3-750 with Shell 22-12
Total capacity: 60 kW
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Minimal Münster - Supermarket

R-22 ISCEON® MO29


Evaporation temperature -12°C -13°C

Condensation temperature 30°C 34°C

Refrigerant Charge 75 kg 80 kg

Hot Gas temperature 63,9°C 55,6°C

Compressor Current Ø 11,25 A Ø 11,00 A

Ambient temperature 3°C 9,6°C


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Commercial AC - Chillers
France Telecom, Paris, France; December 2007
Compressor: Trane L2F5E81N
Chiller Model: LCG 105F

Initial Poor performance was traced to a faulty TXV

100% Medium load Low load

R22 ISCEON® MO29 ISCEON® MO29 ISCEON® MO29


Discharge Pressure / bar.g 13.5 14.4 13.3 11.9
Condensing Temperature / ºC 37.8 37.3 34.3 30.3
Liquid Line Temperature / ºC 31.0 35.0 33.1 30.9
Sub-Cooling / K 6.8 2.3 1.2 -0.6
Condenser outlet temperature / ºC 32.1 - - -
Condenser inlet temperature / ºC 28.0 - - -
Temperature difference / K 4.1 - - -
Suction Temperature / ºC 7.7 12.0 3.1 3.0
Suction Pressure / bar.g 4.0 4.0 4.1 4.1
Saturated suction temperature / ºC 0.2 1.0 1.6 1.8
Superheat / K 7.5 11.0 1.6 1.2
Water on temperature / ºC 8.8 14.2 8.5 8.0
Water off temperature / ºC 5.2 10.6 5.9 6.1
Water T / K 3.593 3.587 2.660 1.936
Discharge Temperature / ºC 63.4 63.6 50.4 30.9
Cooling Capacity / kW 91.9 91.7 68.0 49.5
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DX- Chiller
Aluminium Plant
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Aluminium Norf GmbH


• Retrofit done by Johnson Controls Systems & Service GmbH
• Chillers for cooling the production lines
• 2 Systems Aircooled Condensers
- 2 Refrigerant Circuits with 1 Piston Compressor
- Cooling Capacity 800 kW
• 1 System Water cooled Condensers
- Cooling Capacity 400 kW
• Replacement of Filter Dryers
• Performance Control R22 / MO29
• Nearly identical Performance
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Frankfurt’s town hall “Römer”

•Water chiller retrofitted in


Sept. 2007
•Part of routine maintenance
procedures
•Reals and mineral oil were
renewed
•Satisfactory performance
since retrofit
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Spanish Navy – AC & Refrigeration


Submarine Air Conditioning
Compressor: York FS62A
No Change of Oil Type
®
R-22 ISCEON MO59
Condensing Pressure 15.3 bar.g 13.0 bar.g
Condensing Temperature 42.5ºC 41.4
Evaporating Pressure 4.3 bar.g 3.6 bar.g
Evaporating Temperature 1.9ºC 2.0ºC *
Discharge temp 56.0ºC 45.0ºC
Suction Temp 5.2ºC 6.0ºC
Air Exit 20.0ºC 19.0ºC
Air in 31.0ºC 34.0ºC
•Mean evaporating
Temperature
Water chiller on this
frigate also
successfully retrofitted
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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
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SPAR (Edeka) Cold Store Ellhofen


- Retrofit from R22 to ISCEON® MO29 on March 29, 2006 -

Key Information
• Cold Store Medium Temperature Application with 36.500 m³
• Rack with 4 Copeland DWM Compressors from 1991
• Reconstruction: 2 additional Copeland Compressors added
• Oil type: Shell 22-12 … one oil change
• Cold Store with 20 evaporators (20 TXV)
• Contractor Company: Carrier Commercial Germany
• R22 charge: 1000 kg
• MO29 charge: 930 kg
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SPAR (Edeka) Cold Store Ellhofen


- Retrofit from R22 to ISCEON® MO29 on March 29, 2006 -

Key learning
• Retrofit took 2 days (change of filter drier, oil Shell 22-12, refrigerant)
• Cooling capacity was equal R22
• Issues around oil return in the beginning
• Shell 22-12 created a layer of 3-4 mm on top of the MO29, seen in the
receiver sight glass
• oil level in the compressors was in the beginning at min
• Significant refrigerant leakages occur due to Compressor-”Klemmbrett”-
Sealings
• Other Leakages due to leaking magnetic valves and ball valves
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SPAR (Edeka) Cold Store Ellhofen


- Retrofit from R22 to ISCEON® MO29 on March 29, 2006 -

Oil Layer

Ölreiche
Phase
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Pump Circulation Systems with R22

C: Condenser
K: Compressor
HS: Level Control
A: Separator
P: Pump
V: Evaporators

Source Wikipedia
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Pump Circulation System - Retrofits


1. Vessel - Freezing of fresh Fish
• Sabroe TSMC 116S Compressor (2-stage with Economizer)
¾ 5%longer freezing time; similar power consumption; with MO
2. Cold Store – Low Temperature
• 3 Stal Screw Compressors with 2-stage Oil Separation using Alkylbenzene
Lubricant
¾ 4% higher Current; 1,5 bar higher cond. Pressure; same cooling capacity; with AB
¾ Issues with Elastomer Seals
3. Cold Store for Fruits
• Bitzer open-type reciprocating compressors, a low pressure surge drum and a Witt
liquid pump
¾ 5-10% lower capacity; 8% higher power consumption; with POE; change of
Elastomer Seals
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Commercial Appl: Comparison R404A


vs. ISCEON®MO29 (R422D)
Application and Compressor Technology
depended
o Application: Medium- and Low Temperature
o Compressor Technology (only Low Temp)
a) 2-stage with sub cool effect
b) 1-stage with liquid injection
c) 1-stage with head ventilation (e.g. Wake-In-Freezer with
single Condensing unit)
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Comparison R404A vs ISCEON®MO29 (R422D)

Medium Temp R404A R422D


rel. zu R22

Cooling Capacity 5% higher 5% lower

Power Consumption (10-15)% higher 5% lower

Condenser Pressure 3bar higher 0,5bar higher

Mass Flow +42% +25%

Expansion valve Exchange No Change

Seals and Gaskets Exchange Exchange


MO (with
Compressor Oil Multiple Change Oilseperator)
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Comparison R404A vs ISCEON®MO29 (R422D)


Low Temp (2-
stage w. SC & 1-stg
w. liquid Injection R404A R422D
rel. zu R22

Cooling Capacity 10-20% higher same

Power Consumption 15-20% higher 10% lower

Condenser Pressure 3bar higher 0,5bar higher

Mass Flow +42% +22%

Expansion valve Exchange No Change

Seals and Gaskets Exchange Exchange


MO (with
Compressor Oil Multiple Change Oilseperator)
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Comparison R404A vs ISCEON®MO29 (R422D)


Tiefkälte (1-stufig
mit Kopfventilator) R404A R422D
rel. zu R22

Cooling Capacity same 15-20% lower

Power Consumption 10-15% higher 10-15% lower

Condenser Pressure 3bar higher 0,5bar higher

Mass Flow +42% +22%

Expansion valve Exchange No Change

Seals and Gaskets Exchange Exchange


MO (with
Compressor Oil Multiple Change Oilseperator)
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Improvement by using Subcool Effect


Bitzer 4NCS-20.2Y-40P (56,3m³/h)
TK: to = -35°C, tc = +35°C, SH=18K, SC=5K
Additional external subcool Δtcu = 15K

R404A

ISCEON®MO79

ISCEON®MO29 HotGas=85°C

R22 HotGas=145°C

0 10 20 30
Quelle: Berechnung aus ILK Messdaten Kälteleistung in %
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Cycle with Internal Heat Exchanger


R22 (no internal heat exchanger) and ISCEON®MO29 (R422D)

39°C 105°C 120°C


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Table of Contents

1. Introduction
2. Basis for the HCFC-Phase-out
3. Comparison of Retrofit Solutions
4. Retrofit Experience of ISCEON® Solution
5. Cost Analysis from the Operator‘s Point of View
6. Case Histories
7. ISCEON® Solutions for Industrial Application
8. Conclusion
51

Cost Analysis from the Operator‘s Point of View


•• Replacement
Replacementofof
•• Refrigerant
Refrigerant Operator’s components
•• Oil Expenses components
Oil •• Multiple
Multiple
exchange
exchangeof
ofoil
oil
(POE)
(POE)
Tim
r ial e
ate
M
COP •• Loss
Lossininsales
sales
COP because
•• Relocation
Relocationof
of becauseof of
stored foods partial/temporary
partial/temporary
stored foods
Components close-down
close-down

•• Payment
Paymentofof
overtime
overtime
•• Filter
Filterdryer
dryer
•• TXV
TXV
•• Condenser
Condenser
•• Seales/
Seales/Gaskets
Gaskets
52

Conclusion on R22-Phase out


¾ Potential for business interruption, due to refrigeration system stop

¾ Large user of R22-refrigeration and a/c systems need a phase-out


strategy

¾ Several solutions are available, Contractor companies need to learn to


use it properly

¾ Operator‘s total costs of the retrofit are the decision factor for the
choice of the retrofit solution

¾ With regards to running and retroffiting costs, DuPontTM ISCEON®


MO29 (R422D) is the preferred solution for DX- systems

¾ ISCEON® MO29 (R422D) has shown acceptable performance after


retrofits in pump circulation systems
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Time is Running Out


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For more Information on ISCEON® Solution

R-22 Alternative Refrigerants by DuPont:


www.isceon.com/eu

Emerson Climate Technologies:


www.emersonclimate.com

Carlyle Compressors:
www.carlylecompressor.com