HVAC Business Embraces Decrease-GWP Refrigerants

The HVAC business is within the midst of one more refrigerant transition, transferring away from high-GWP choices like R-410A in lots of varieties of consolation cooling tools, in direction of lower-GWP options similar to R-32 and R-454B, that are mildly flammable (A2L) refrigerants. This transition is a part of the AIM Act, which tasked the Environmental Safety Company (EPA) with lowering the manufacturing/import and utilization of HFCs by 85% by 2036. To achieve that purpose, an extra 30% discount in HFC manufacturing went into impact on January 1, 2024 (on high of the ten% discount in 2022), and a 700 GWP restrict might be required for a lot of varieties of new residential and lightweight business air-con tools, beginning January 1, 2026.

On the forefront of this transition are the refrigerant and tools producers, which have been strategizing and making ready for this transformative change for years. On the AHR Expo, these producers shared the methods during which their corporations are navigating the challenges posed by the refrigerant transition within the consolation cooling sector, in addition to the impacts this can have on the HVAC business as an entire.

System Redesign

In preparation for the HFC phasedown, Daikin is redesigning methods that used higher-GWP R-410A and R-134a to make use of lower-GWP refrigerants together with R-32 (675 GWP), mentioned Phil Johnston, environmental enterprise improvement chief at Daikin Utilized Americas.

“We all know that single part R-32 has better latent warmth capability than R-410A, which implies that R-32 can obtain the identical capability at a decrease refrigerant circulate fee. And, at a decrease circulate fee, much less power is required to provide refrigerant circulate, leading to larger efficiencies for R-32. Full- and part-load effectivity will be improved by as much as 12% utilizing R-32 as an alternative of R-410A,” mentioned Johnston.

As well as, R-32 is a pure, single-component refrigerant with glorious thermodynamic efficiency traits, he famous, and Daikin’s evaluation signifies that an R-32 system will be engineered to have 40% much less cost than an identical R-410A system.

“This implies you could possibly scale back the quantity of refrigerant within the system, which might probably scale back the quantity of refrigerant leaking to the setting, in addition to permit HVAC engineers the chance to design smaller compressors and coils,” he mentioned.

On the business facet, Daikin highlighted a number of low-GWP merchandise on the AHR Expo, together with the Trailblazer scroll chiller AGZ-F with R-32; Insurgent warmth pump with R-32; Insurgent Utilized with R-32; SmartSource compact horizontal water-source warmth pump with R-32; and Magnitude WMT magnetic bearing chiller with R-1233zd.

Daikin can be reengineering all of its residential ducted, ductless, and packaged merchandise, from 5 tons and under, to make use of R-32 by the top of 2024, mentioned David Palazzolo, director of residential product advertising and marketing at Daikin.

NEW SYSTEM: Connie Schroder reveals off Daikin’s new OTERRA single-zone ductless system. (Workers picture)

A number of the R-32 residential merchandise displayed on the sales space included the Atmosphera single-zone ductless system, which affords efficiencies as much as 27.4 SEER2 and 11.2 HSPF2; the brand new Oterra single-zone ductless system, which options efficiencies as much as 21 SEER2 and 10.2 HSPF2; and the Altherma air-to-water warmth pump system, which supplies heating and cooling for the house in addition to home sizzling water.

“Daikin has been utilizing R-32 refrigerant in merchandise globally since 2012, which makes the transition right here in North America simpler from a refrigerant standpoint, since we’re utilizing a confirmed refrigerant with 12 years of utilization in over 230 million methods manufactured by Daikin and different producers,” mentioned Palazzolo.

Sustainable Technique

Arkema is responding to the HFC phasedown by increasing manufacturing of R-32 as a way to meet the wants of the business for lower-GWP HFCs. This 12 months, the corporate additionally plans to open the brand new Forane 1233zd line at its Calvert Metropolis, Kentucky plant.

MEETING DEMAND: Glenn Haun (left) and Scot Swan talk about how Arkema is increasing manufacturing of R-32 to satisfy demand for lower-GWP HFCs. (Workers picture)

“The numerous funding will embrace the retrofit of the R-134a manufacturing line and helps Arkema’s local weather plan to cut back greenhouse gasoline emissions by 46% in 2030 versus 2019 on the complete worth chain,” mentioned Glenn Haun, common supervisor of fluorochemicals at Arkema. “R-1233zd is a part of the brand new era of fluorospecialties with no or minimal emissive impression, aligned with Arkema’s sustainable improvement technique to handle world wants. Forane 1233zd has an ultra-low-GWP of 1 and can be low strain, non-ozone depleting, and exempt from VOC laws.”

R-1233zd HTS can be utilized in centrifugal chillers the place R-11 or R-123 have been historically used, and it has already been adopted by a variety of world OEMs for his or her next-generation chillers, mentioned Haun. R-1233zd can be being examined in some high-temperature warmth pump functions.

Arkema additionally highlighted the R-410A alternative, R-32, which is designed to be used in new air-con and warmth pump functions. Haun famous that R-32 exceeds the power effectivity and capability of the refrigerants it replaces and that the transition to this lower-GWP refrigerant will begin in earnest this 12 months.

“We hope that the technicians putting in the brand new tools containing these refrigerants might be in control by the second half of 2024 when most of the new methods begin rolling out,” mentioned Haun. “Technicians can nonetheless get skilled with the assistance of their OEM companions, or organizations similar to ACCA or NATE.”

Spring Manufacturing

In mild of the HFC phasedown, Johnson Controls is redesigning all of its residential and lightweight business ducted tools to make the most of R-454B (466 GWP) throughout all its ducted product traces and R-32 for its ductless choices, mentioned Chris Forth, vice chairman of regulatory, codes and environmental affairs at Johnson Controls. He added that the corporate is already transitioning its factories from R-410A to R-454B (ducted) and R-32 (ductless) tools, with the primary manufacturing starting this spring.

FACTORY TRANSITION: Chris Forth famous that Johnson Controls is already transitioning its factories from R-410A to R-454B and R-32 tools. (Workers picture)

“There are various advantages to new A2L refrigerants,” he mentioned. “Use of R-454B, for example, supplies a 78% discount in GWP whereas bettering HVAC system effectivity and sustaining comparable working traits to R-410A. R-454B additionally requires much less cost than R-410A when totally optimized, whereas its pressures and temperatures are similar to R-410A.”

Forth added that Johnson Controls can be including product options that make working with the brand new A2L refrigerants even safer.

“On the AHR Expo, we showcased our new refrigerant detection methods (RDS) that detects refrigerant leaks for residential and business tools that function utilizing R-454B (ducted) or R-32 (ductless),” mentioned Forth. “The RDS might be required by code in sure functions and non-compulsory in others. Johnson Controls has developed an revolutionary RDS Calculator device that helps prospects perceive when it’s required by code. This device might be accessible each in its product choice instruments and within the Ducted Techniques Options app.”

Along with the RDS methods designed for residential and business tools, Johnson Controls has developed new warmth exchanger applied sciences designed to attenuate refrigerant cost volumes, in addition to enhance effectivity and value, mentioned Forth. He famous that the brand new warmth exchangers, in addition to the compressor, are particularly optimized to be used with R-454B (ducted) and R-32 (ductless).

Not surprisingly, contractors have quite a lot of questions on A2Ls, and a clean refrigerant transition requires complete schooling and preparation throughout your entire channel, mentioned Forth. As such, contractors ought to prioritize three key objectives for a profitable shift: recovering and reclaiming R-410A, understanding low-GWP options, and guaranteeing A2L refrigerant security.

“With proactive preparation and schooling — which incorporates our on-site refrigerant coaching programs at Ducted Techniques Academy and our free on-line assets — contractors can transfer via the transition with restricted disruption and achieve a aggressive benefit, however they should act now to be ready,” mentioned Forth.

Exceeding Efficiency

Chemours has ready for the 40% minimize in HFC manufacturing in 2024 by growing refrigerants with as much as 96% decrease GWP than heritage HFC refrigerants, mentioned Andrew Pansulla, senior technical service engineer of refrigerants at Chemours.

BEST BALANCE: Andrew Pansulla mentioned that Chemours’ Opteon XL41 (R-454B) affords the perfect stability of properties, together with first value, power value, and GWP. (Courtesy of Chemours)

“These lower-GWP refrigerants help with assembly the cuts prescribed by the phasedown, whereas sustaining or exceeding incumbent refrigerant efficiency,” he mentioned. “Nearly all of North American air-con OEMs have specified Opteon XL41 (R-454B) as a result of it affords the perfect stability of properties together with first value, power value, and GWP. For instance, R-454B has a COP enhance of two.3% over R-410A.”

Shifting to A2L refrigerants similar to R-454B does include some challenges, although, mentioned Nick Strickland, Americas advertising and marketing supervisor of refrigerants at Chemours.

“One of many challenges we see is drawing a transparent distinction between the flammability of A1, A2L, and A3 refrigerants. There appears to be confusion about this distinction, and we’re working to share scientific assessments that clearly present the variations between these traits,” he mentioned. “One other problem is that below the EPA’s Know-how Transition closing rule, sure segments like air-con appear to be on a great path relating to the lower-GWP limits; nevertheless, the perpetual servicing with larger GWP refrigerants has raised some questions.”

On the brilliant facet, lowering refrigerant leak charges has all the time been a precedence for the HVAC business. Strickland mentioned that the brand new security requirements for A2L methods will probably proceed to mitigate the difficulty of leak charges.

“As a result of A2L refrigerants require leak detection, we consider conventional leak charges for A2Ls versus HFCs might be a lot decrease,” he mentioned. “We’re excited that this expertise will dramatically decrease the Scope 1 emissions for our prospects.”

Optimized Elements

Copeland has ready for the HVAC refrigerant transition by optimizing compressors, condensing models, digital controls, and leak detection and related elements to be used with lower-GWP A2L options, mentioned Stephen Hueckel, market supervisor at Copeland. He added that lately, the corporate has expanded its portfolio of A2L-optimized options to incorporate business, mild business, and residential air conditioners, chiller, and warmth pump functions.

VARIABLE SPEED: Josh Souders confirmed off a few of the variable-speed, lower-GWP warmth pump options supplied by Copeland. (Workers picture)

“To assist meet the growing demand for lower-GWP options, Copeland has made important investments in its world laboratory and home manufacturing services to assist A2L product improvement,” he mentioned.

For residential OEMs that face potential redesigns in each their air-con and warmth pump methods, Copeland has expanded its portfolio of next-generation compression applied sciences, optimized for HVAC functions to make use of the A2L refrigerants R-454B and R-32. Hueckel mentioned that Copeland’s single- and two-stage compressors might be optimized for each refrigerant choices, and their variable-speed compressors might be supplied in R-454B.

On the business facet, Copeland’s oil-free centrifugal compressor makes use of Aero-lift bearing expertise to take away the complexities of oil administration in air- or water-cooled chillers — with out the prices, challenges, and limitations of magnetic levitation bearings, mentioned Hueckel.

“Aero-lift bearing expertise eliminates the necessity for complicated electronics, sensors, and redundant backup bearings, enabling speedy restarting and clean coasting to close down throughout energy disruptions. Our new oil-free centrifugal expertise can be optimized to be used with lower-GWP refrigerants similar to R-513A, R-515B, and R-1234ze,” he mentioned. “Copeland has additionally developed a full vary of A2L-optimized options in our fixed-speed, two-stage, digital, and variable-speed platforms that ship dependable efficiency and power effectivity in a wide range of business HVAC functions.”

With the 700 GWP restrict on new stationary residential and lightweight business air conditioners and warmth pumps proper across the nook, contractors who are usually not ready to work with A2L refrigerants ought to make schooling and coaching their high priorities this 12 months, mentioned Hueckel.

“Though contractors’ considerations are comprehensible, most A2L servicing and dealing with duties are primarily based on current refrigerant administration greatest practices,” he mentioned. “But it surely’s essential for them to grasp that A2L refrigerants can not merely be added to current R-410A methods. Additional, working with mildly flammable refrigerants would require A2L-optimized leak detection and a devoted set of instruments and gauges. Contractors ought to hunt down coaching from one of many many business organizations and make efforts to coach themselves on servicing greatest practices.”

Minimizing Value

EPA’s Know-how Transition rule units the stage for a major shift in present HFC utilization within the HVACR sector by imposing GWP limits on refrigerants utilized in new tools, mentioned Michael Mukai, world director of enterprise improvement at Koura. Consequently, he mentioned that OEMs might want to rapidly put together for this shift by securing provides of lower-GWP options for use in new methods and tools.

“Largely, these new lower-GWP options will come within the type of A2Ls, as they are usually characterised by general decrease GWPs, low toxicity, and delicate flammability,” he mentioned. “An instance of Koura’s providing on this space contains R-454B, a high-performing alternative for R-410A use in chillers and the HVAC sector.”

Mukai famous that Koura’s strategy to assembly decreased HFC manufacturing relies on mix elements utilized in different industries and functions.

“Our purpose has been to attenuate system improvement value and validation timing,” he mentioned. “These are two core rules of our refrigerant improvement. And since the event technique is to attenuate variation with incumbent refrigerant, every low-GWP refrigerant performs close to its legacy counterpart, and infrequently higher.”

For instance, R-456A (687 GWP) is an A1, direct alternative in R-134a methods that matches R-134a efficiency and effectivity with minimal system modifications wanted. Equally, R-444A (93 GWP) is an A2L, zero-TFA (trifluoroacetic acid) direct alternative in R-1234yf methods and supplies parity cooling efficiency at 10% larger effectivity. These choices are perfect for home equipment like warmth pump water heaters and cellular air-con, mentioned Mukai.

With the extra 30% minimize in HFC manufacturing this 12 months, adoption of lower-GWP refrigerants in HVAC tools will come rapidly, because of the supply-demand stability, mentioned Adam Kimmel, senior supervisor of enterprise improvement at Koura.

“Bigger market segments might require extra CO₂e till they transition to lower-GWP options,” he mentioned. “For consolation cooling, merchandise like Koura 454B can meet intermediate-term GWP discount targets to increase CO₂e allowances to permit larger refrigerant quantities. However with one other 30% minimize in HFC manufacturing set to hit in January 2029, Koura is already effectively into improvement of next-generation, zero-TFA, low-GWP refrigerants like R-R-444A, and the zero-PFAS R-485A, an enhanced CO₂ mix providing higher high-ambient efficiency and effectivity than legacy R-744 (CO₂ refrigerant).”