New Refrigerants Evaluation Results

Transcription

1 New Refrigerants Evaluation Results JAMA-JAPIA Consortium Tohru Ikegami(TOYOTA), Masahiro Iguchi(HONDA), Kenta Aoki(NISSAN), Kenji Iijima(VALEO THERMAL SYSTEM) 008 SAE Alternative Refrigerant Systems Symposium Phoenix, Arizona USA, 10-1 June 008 Contents 134yf Evaluation Procedure Framework Evaluation Schedule Test Vehicle / System Specifications Test Conditions Test Results (DuPont & Honeywell 134yf) Flammability Risk Assessment Summary LCCP Study Comparison of R134a, 134yf and R744

2 The Purpose of 134yf Evaluation Procedure 3 STEP-1: 1. Is a simple Drop-in* possible? - Cooling Performance, System Efficiency and Fuel Consumption - Material Compatibility - Flammability Risk Assessment - Toxicity * Drop-in Only Charge and Expansion Valve were changed to optimize system performance.. If not possible, evaluate the influence. STEP-: 1. Confirmation of Durability and Reliability.. Confirmation of a vehicle marketability. Framework of 134yf Evaluation 4 Items DuPont / Honeywell Suppliers (JAPIA) OEM s (JAMA) STEP-1 STEP- The Feasibility of the Refrigerant Thermal Stability Toxicity Flammability Cost System Bench Test Materials Compatibility Cooling Capacity COP System Durability and Reliability Vehicle Test Cooling Performance A/C Power Consumption Fuel Consumption Vehicle Durability Cooling Capability NV Main Support Refrigerant Suppliers : DuPont & Honeywell JAPIA : 7 Tier1 suppliers (Calsonic, Denso, Japan Climate System, Keihin, Mitsubishi Heavy Industries, Sanden, Valeo) JAMA : 1 OEM s (Daihatsu, Hino, Honda, Isuzu, Mazda, Mitsubishi, Mitsubishi Fuso, Nissan, Nissan Diesel, Subaru, Suzuki, Toyota)

3 Evaluation Schedule (STEP-1) 5 HFO-134yf Oct 007 Nov Dec Jan Feb 008 Mar Apr May Jun Jul Aug Sep EVENT nd European W/S MAC conference JSAE VDA Winter mtg ARSS System Bench Test Vehicle Test Cooling Performance Fuel Consumption Stability Test w/poe w/pag Material Test Elastomer Compatibility Hose Permeability Flammability Risk Assessment Toxicity Test Vehicles 6 Vehicles Engine Type Transmission Toyota GS L SEDAN A/T Mazda Axela L H/B M/T Nissan Sylphy L SEDAN A/T Mitsubishi Outlander.4L SUV CVT Nissan Tiida L H/B A/T Honda Zest 0.6L K-Car A/T Suzuki Every 0.6L K-Car A/T

4 A/C system Specifications 7 Vehicles GS430 Axela Sylphy Outlander Tiida Zest Every Compressor TYPE Capacity (cm 3 ) Variable piston 160 Fixed rotary 10 Variable piston 105 Fixed scroll 90 Fixed rotary 80 Fixed scroll 53.9 Fixed rotary 63.4 Condenser Size (WxHxD mm 660x 363.8x x 38.3x x 343x16 63x x407x16 607x 340.8x16 405x 356.9x16 40x 30x16 Fin pitch 3.55mm.8mm.8mm 3.196mm.8mm.6mm.8mm Evaporator Size (WxHxD mm 11x 93.1x38 30x 185x55 198x 19x40 54x 05x x 5x x 1x x 00x38 Fin pitch 3.0mm 3.4mm 3.1mm.6mm 3.1mm 3.mm 3.0mm Expansion Valve Capacity 1.5ton (Modified) 1.5ton (Modified).0ton (Serial) 1.5ton (Modified) 1.0ton (Modified).0ton (Modified) 1.0ton (Modified) Refrigerant Charge 134yf (R134a) 40g (450g) 480g (500g) 450g (500g) 560g (500g) 450g (450g) 400g (400g) 30g (340g) System bench test condition (GAR common spec) 8 45 o C Evaporator entry is few cases. Besides, this condition is severe for some bench facilities. 60 o C Condenser entry is severe at some bench facilities. Omit this test condition. 35 o C /5% humidity is severe at some bench. Use 40% instead of 5%. Set point 10 adapts only external variable compressor. Internal type is impossible. Fixtypeusesvariablethermoswitchbutit s not major. And it seems not crucial to compare different refrigerants for fix type compressor. 9kg/min is large for air volume of a small car. Max air volume uses test data. Medium air flow depends on each ratio

5 System bench test result (134yf) Cooling Capacity Test Condenser 45ºC Evaporator 35ºC/40% Comparison of 134yf and R134a (134yf / R134a) Cooling Capacity [%] Average 95.0% Max-Min cut (93.8%) On-off 9 60 Comp. speed 900rpm 1800rpm 500rpm 4000rpm 1800rpm Eva. air volume Max Max Max Max 56% GS Axela Sylphy Outlander Tiida Zest Every System bench test result (134yf) System Efficiency (COP) Test Condenser 45ºC Evaporator 35ºC/40% Comparison of 134yf and R134a (134yf / R134a) COP [%] Average 95.9% Max-Min cut (95.4%) On-off 60 Comp. speed 900rpm 1800rpm 500rpm 4000rpm 1800rpm Eva. air volume Max Max Max Max 56% GS Axela Sylphy Outlander Tiida Zest Every

6 Vehicle Test Conditions (GAR Common Spec) 11 < Cooling Performance > Test Condition Chamber temperature : 40ºC Relative humidity : 40% Solar load : 1,000 W/m² Driving cycle Blower Setting and Air Distribution: Automatic and Manual HVAC Control: Cooling : max Blower : max Grill outlet : face level open Recirculation : 100% ON OFF ON OFF ON OFF PorN 3rd PorN nd or EQUV ON OFF (REC,MAX COOL,FACE,FAN MAX) OPEN CLOSE OPEN CLOSE Based on Common Spec Book for evaluating Global Alternative Refrigerants (GAR) V.0 Vehicle test results (134yf Cooling Performance) Vent / Relative Temperature to R134a T[ºC] Pull Down(3km/h) Idle 64km/h Time [min] GS430 Axela Sylphy Outlander Tiida Zest Every Worse Better Time (min) GS430 Axela Sylphy Outlander Tiida Zest Every Average T[ºC] Head / Relative Temperature to R134a T[ºC] Pull Down(3km/h) Idle 64km/h GS430 Axela Sylphy Outlander Tiida Zest Every Worse Time (min) GS430 Axela Sylphy Outlander Tiida T[ºC] Time [min] Better Zest Every Average

7 Vehicle Test Conditions (GAR Common Spec) 13 < Fuel Consumption Performance > Test Condition Chamber temperature [ºC] Relative humidity [%] Enthalpy [kj/kg] Solar load No No No Blower Setting and Air Distribution: Automatic and Manual HVAC Control: Chamber temp Evaporator setting [ºC] Fan voltage [%] Grill outlet Outside Air 5 5 Face 100% 5 8 Face 100% Face 100% Driving cycle (New European Driving Cycle) Based on Common Spec Book for evaluating Global Alternative Refrigerants (GAR) V3.0 Vehicle test results (134yf Fuel Consumption) Consumption ratio (%) NEDC (CITY) Worse Better Cooling Performance ºC 5ºC 35ºC T Worse Better Consumption ratio (%) T NEDC (HIGHWAY) Worse Better Cooling Performance ºC 5ºC 35ºC 14 Worse Better <Definition> Consumption ratio (%) = 134yf F.C. (L/100km) / R134a F.C. (L/100km) (F.C.fuelconsumption) T = 134yf V.T. R134a V.T. (V.T. vent temperature) Consumption ratio (%) T NEDC (OVERALL) Worse Better Cooling Performance ºC 5ºC 35ºC Worse Better Axela Outlander Tiida Zest Average Note: Only vehicle s data are available at 15C due to the facility limit. Negligible influence on fuel consumption when 134yf is applied

8 Material Test Conditions Thermal Stability Test Procedure : ANSI/ASHRAE Sealed Glass Tube Method to Test the Chemical Stability of Materials for Use Within Refrigerant Systems Test condition 15 Temperature ºC 175, 00 * Oil : The kind of the evaluated oil Moisture Test period *Oil * Refrigetant Oil:Ref. (Rate ) Catalyst PPM <10, 1000, (10000) week PAG, POE R134a, 134yf 1:1 Al, Cu, Fe PAG PAG1:Serial PAG for MACs PAG:PAG (without extreme pressure additive,oiliness additive) POE POE1:Serial POE for HV AC POE:Serial POE for Stationary AC Permeation Test Procedure: * JRAIA standard JRA01 Test condition : Temp. : 80ºC, Ref. charge amount: 0.6g/mL * JRAIA : THE JAPAN REFRIGERATION AND AIR CONDITIONING INDUSTRY ASSOCIATION (Permeation was calculated with the difference between the residual mass of 4hour point and that of 96 hour point.) Samples: Yokohama (use types of discharge/suction lines) Material Evaluation Results (134yf) Thermal Stability Test Ref. Oil Condition Low Moisture Total Acid Number Low Moisture Total Acid Number High Moisture Total Acid Number Condition Low Moisture Total Acid Number Low Moisture Total Acid Number High Moisture Total Acid Number ANSI/ASHRAE ppm mgkoh/g ppm mgkoh/g ppm mgkoh/g ppm mgkoh/g ppm mgkoh/g ppm mgkoh/g PAG PAG PAG1:Serial PAG for MACs PAG:PAG (without extreme pressure additive,oiliness additive) POE POE1:Serial POE for HV AC POE:Serial POE for Stationary AC PAG R134a POE POE 175ºC/14days ºC/14days < < PAG PAG Proposed Spec <3.3 POE POE

9 Material Evaluation Results (134yf) 17 Elastomer Compatibility Test Oil:PAG1 (Serial PAG for MACs) Type of elastomers NBR IIR EPDM 1 EPDM Test specification: JIS K651, JIS K653 Material: for AC system sealing 1 Satisfies JAMA own criteria fully Does not satisfy but slightly Test condition PAG1(Serial PAG for MACs) + 134yf Gas at 150ºC 336hours Hardness change (Duro-A) Tensile strength change Elongation change Test condition PAG1(Serial PAG for MACs) + 134yf Liquid and Gas at 40ºC 4hours Hardness change (Duro-A) Tensile strength change Elongation change Need to improve slightly but no fatal results were found Material Evaluation Results (134yf) 18 Elastomer Compatibility Test Type of elastomers Oil:POE1 (Serial POE for HV AC) NBR IIR EPDM 1 EPDM Test specification: JIS K651, JIS K653 Material: for AC system sealing 1 Satisfies JAMA own criteria fully Does not satisfy but slightly Test condition POE1(Serial PAG for HV AC) + 134yf Gas at 150ºC 336hours Hardness change (Duro-A) Tensile strength change Elongation change Test condition POE1(Serial PAG for HV AC) + 134yf Liquid and Gas at 40ºC 4hours Hardness change (Duro-A) Tensile strength change Elongation change Need to improve slightly but no fatal results were found

10 Material Evaluation Result (134yf) 19 Permeation Test Result Permeation HOSE L=400mm JRAIA standard JRA01 Discharge Inner coating(1) Discharge Inner coating() [g/year] Suction Inner coating HFC134a 134yf Inner coat : 6-Nylon Inner coat : 6-Nylon Innerrubber:IIR Innerrubber:IIR Outerrubber:Cl-IIR Outerrubber:EPDM Inner diameter Discharge inner coating (1) (ACH 77 11) 11.mm Discharge inner coating () (ANESIS 11) 11.mm Suction inner coating (ACH 87 15) 15.mm Inner coat : 6-Nylon Innerrubber:IIR Outerrubber:Cl-IIR (at 80 ºC) Annual Leakage will be 0.3g/year under actual condition (estimated by SAE-J77 rev#4 method) Outline of Flammability Risk Assessment Total probability of fire caused by refrigerant leakage in vehicle 0 134yf Risk Fault Tree was divided intothreeareainvehicle OR Potential risk of fire in Engine Room <Refrigerant Leakage> Condenser, piping, <Ignition Source> Exhaust manifold, Potential risk of fire in Passenger Cabin <Refrigerant Leakage> Evaporator, <Ignition Source> Smoking lighter, Potential risk of fire in Trunk Room <Refrigerant Leakage> Rear cooler, <Ignition Source> Lighting bulb, AND AND Detail is described In next slide Leakage Leakage Ignition Source AND Leakage Ignition Source 134yf Risk Assessment was conducted by Member: DNV,JAMA,JAPIA,DuPont, Honeywell

11 Outline of Flammability Risk Assessment 1 Potential risk of fire in Engine Room AND 134yf ignition condition - Flammable limit : % - Auto ignition temp. : 405 ºC - Minimum ignition energy: > 1000mJ 1 Probability of Refrigerant Leak (Probability of the leakage caused by AC cycle parts failure or Accident) Parts failure causes slow leak mainly and Accident causes large leak mainly Probability of 3 Probability of 4 Probability of the Ignition Source Refrigerant Reach Fire Starts when occurrence ignition source condition meets (Hot surface / spark generated area) Normal, Parts failure and Accident case are also considered (Velocity of diffusion, distance of leak point and ignition source) (Quantify the property of low flammability) 1 & : Data collected from JAMA / JAPIA 3&4:QuantifytheriskfromHAZOP(hazardous operation), FMEA (Failure Mode and Effect Analysis) Result of Risk Assessment for Ignition source Result of risky parts Exhaust manifold 600ºC In case of accident, refrigerant may reach. Surface of light bulbs 680ºC Refrigerant may not reach due to its lens / hood. Combustion heater 400ºC In case of accident, refrigerant may reach Normal case Parts Temp...Freq. Exhaust Manifold Light Bulb Combustion Heater Parts failure case Mode, Temp., Freq. Accident case Pick out some risky parts as ignition source. (ex. Exhaust Manifold, ) Confirm whether fire occurs or not by 134yf splash test to hot plate by DuPont / Honeywell Mode, Temp., Freq.

12 Result of Flammability Risk Assessment 3 Estimated Risk Case Result of Risk Assessment In case of Normal / Parts failure Probability In case of Accident Ignition Test Probability (after Ignition Test) Engine Room Passenger Cabin Trunk Room Could be ignited at exhaust manifold Could be ignited by smoking lighter Few ignition source ppm 0.01ppm Insignificant 84ppm Insignificant Insignificant No Ignite (splash test to hot plate) No Ignite (butane lighter) E-06 ppm 1.0E-0 ppm 6.7E-1 ppm Total 106ppm 1.0E-0 ppm The estimated total risk of adoption of 134yf was 1.0E-0ppm. Confirmed that no ignite will occur even at high risk parts. So that, the risk increase by 134yf can be neglected. Summary 134yf Evaluation Results Under high load condition and with the same AC system specs with modified TXV, 4 Cooling Performance Slightly less but quite similar Fuel Consumption Almost equal to R134a (Negligible influence) Material Compatibility No fatal result is found at this time Flammability Risk Assessment No fatal result is found at this time Toxicity Evaluation Only long term toxicity is now under investigation 134yf has potential to be alternative to R134a < Next Step > System reliability and Vehicle suitability in the market

13 5 LCCP Result from JAMA Tohru Ikegami Kiwamu Inui Kenta Aoki TOYOTA TOYOTA NISSAN 008 SAE Alternative Refrigerant Systems Symposium Phoenix, Arizona USA, 10-1 June Content 1. Explanation of modifications on LCCP model. JAMA s LCCP test conditions & Specifications 3. LCCP result 4. Summary of LCCP result

14 7 1. Explanation of Modifications on LCCP model Main points End Of Life Direct Emission Incremental Engine Efficiency Global weighted LCCP 1. Explanation of Modifications on LCCP model End Of Life Direct Emission End of Life Direct Emission Ratio has been modified based on USA & JAPAN market investigation. 100% Original 10% (SAE recovery target) NEW Version 64% 64% (Assumed the same as US) 19% 8 Residue refrigerant when disposed All regions Release Recover USA Other regions JPN USA Market *40% of Vehicles: 90% Recovered *60% of Vehicles: Totally Released Japan Market Official record according to Recycle Law EOL Leak Rate = { (Original charge Annual leak*lifetime)*10% }*40% +{(Original charge Annual leak*lifetime)} *60%

15 1. Explanation of Modifications on LCCP model Incremental Engine Efficiency Engine efficiency is still under discussion. This time, JAMA uses agreed value (on April/16th/ 08). 9 Efficiency Efficiency 50% 40% 30% 0% 10% 0% 31% Original Information 45% 30-40% 30% Several Proposal JAMA s test result shows about 30% is appropriate New Version 35% Agreed Value (on April/16/ 08) Example: Ambient Temp 5 / IDLE & City & Highway combination Around 30% in average MiniA MiniB CompactA MidsizeA MidsizeB LuxuryA 1. Explanation of Modifications on LCCP model Global weighted LCCP Validate the global warming up affect from global point of view as well as One Model s sandonecity s s Life Cycle validation Original PerCityandPerVehicle New Version Total emission of All Vehicles All Over World 30 Vehicle with R134a system Vehicle with Alternative Refrigerant system 57% x CO eq/yr per Vehicle with R134a 43% + x CO eq/yr per vehicle with Alternative Refrigerant = Total emission result

16 31. JAMA s LCCP test conditions & Specifications. JAMA s LCCP test condition&specifications 3 Vehicle Test condition JAMA uses Vehicle Test Result to calculate CO emission due to AC system operation. Agreed TEST Condition between JAMA&SAE Ambient RH% Solar [W/m ] 850* Target temperature setting+ For manual AC: Agreed proposal: vehicle FC 1/ of heater controller 3/4 of heater controller Air Intake REC OSA OSA Fan Speed High nd 1st Drive Schedule Fixed speed Idle / 40km/hr / 100km/hr Air Output VENT VENT VENT From these test results, we take into account Driving Schedule Ambient Condition AC Operation Time for each Cities (i.e. Phoenix, Frankfurt, Tokyo, etc)

17 . JAMA s LCCP test condition & Specifications Vehicle specifications and AC component specifications 134yf has same component as R134a system. CO (R744) system has higher specification. <Car Specification> Model: NISSAN TIIDA/VERSA Engine:1.5L L4 Petrol Engine <Component Specification> R134a Compressor spec Fix Volume Rotary type 134yf Same part as R134a CO (R744) External Control Variable Displacement type 33 Evaporator size 01W x 198H x 36D Same part as R134a Same size as R134a Condenser or Gas cooler size 618W x 337H x 16D Same part as R134a Same size as R134a Cooling Fan 10W x 1 Same part as R134a Same size as R134a Internal Heat Exchanger None None Equipped LCCP result

18 3. LCCP results Total emission over the world If we apply 134yf, CO eq.. emission will be about 1% less than R134a / CO in COeq.[10kg/Year] Global weighted LCCP (in 017) Emission from R134a system Direct by R134a Indirect by R134a Direct by AR (Very Small) Indirect by AR 50 0 R134a 57%: HFO134yf R134a 57%: CO R134a 43%:134yf 43%:CO(R744) 100%: R134a Emission from AR system Assumption : 43% vehicles in the world have alternative refrigerant system in LCCP results Emissions per vehicle, Compact Car yf LCCP result is 0%-30% less than R134a / CO. CO-eq [kg] Phoenix Direct Emission Indirect Emission Tokyo Plant Assem and Others EOL Service irre./life Direct reg. /life AC weight Low load Indirect Mid load High load 0 134a 134yf CO 134a 134yf CO

19 37 4. Summary of LCCP result 4. Summary of LCCP result 38 HFO134yf is the least global warming up impact within 3 refrigerants (R134a, 134yf, CO(R744)). If we apply higher technology such as IHX and ECV, then there is another potential to improve LCCP result on 134yf system.

20 Conclusion 39 Based on our investigations, we conclude as follows, STEP-1 Evaluation: We found no fatal concern at this time including Environmental impact (over fuel consumption), Flammability and Toxicity 134yf has the potential to be a Global solution STEP- Evaluation: System durability and reliability will be evaluated by individual JAMA members 40 Toward the global solution!! Thank you for your attention. END