R32 in air conditioners

& heat pumps

Life Cycle Aspects

Hilde Dhont, Daikin Europe N.V.

Environment Research Center
Chillventa 2012
Copyright Daikin

Daikin press release 27 Sept 2012

launch of worlds first R32 air
conditioner on the Japanese market
Daikin considers that R32 is suitable for
split air conditioners and heat pumps
From fall 2012, Daikin will start to adopt
R32 to all successive models of
residential air conditioners in Japan
Daikin aims to expand use of R32 to
commercial air conditioning equipment
in the future

Why R32 for air conditioners & heat pumps?

R32 IS THE MOST BALANCED SOLUTION

Not depleting the ozone layer
Smaller Global Warming Impact (LCCP) compared to R410A & R22
Higher Energy Efficiency compared to R410A & R22
Reduced refrigerant charge possible
More compact design possible
Acceptably safe because only slightly Flammable (Class A2L)

Refrigerant Production capacity is available

(R32 is a component of R410A)

Easy to recycle and reuse (single component refrigerant)

Affordable for developing countries

R410A is non flammable

R32 is flammable but how flammable ?

On the Safety Data Sheet

& on refrigerant cylinders,
R32 refrigerant is
classified as
extremely flammable,
similar to the classification
of Hydrocarbon
refrigerants (R290)
4

Flammability classification of R32 = 2L

Class 1

Class 2L

Class 2

Class 3

Not flammable

Slightly
flammable

Low flammable

Highly
flammable

R152a

R290

burning velocity
10 cm/s
R744 (CO2)

R1234yf / ze

R410A

R32
R717
(Ammonia)

In reality, flammability of R32 refrigerant is very low.

The burning velocity ( 10 cm/s) is too slow to cause horizontal
flame propagation or explosion.
Classification according to ASHRAE34 & draft ISO817.
5

Safety is a must during

the whole life cycle !
7. Installation
work
1. Production of
refrigerant

4. Production of
equipment
8. Use

2. Transport of
refrigerant

5. Transport of
equipment

3. Storage of
refrigerant

6. Storage of
equipment

9. Service &
Recovery

10. End of life

treatment

International, EU, National & Local regulations & standards play a role.
Avoid Overspecification : the risks of Class 2L refrigerants are much
lower compared to Class 3 refrigerants !

Installation, Service and Use

conditions

Conditions for Refrigerant Ignition

A fire accident triggered by a flammable refrigerant occurs
if 3 conditions are met.
Adequate measures must be taken to prevent the likelihood that such
situation occurs
Characteristics
of Flammable
Refrigerant

Occurrence
of Refrigerant Leakage

Contact
with Ignition Source

Each condition needs evaluation

1. Assess Flammability
Flammable Gas

2. Formulate Refrigerant Charge Limit

Maintenance & Service training

Safety class (ASHRAE)A3 A2 A2L

LFL Low flammable Limit
UFL Upper flammable limit
Auto Ignition temperature
MIE Minimum ignition energy
BV Burning Velocity
Heat of Combustion

3. Investigate ignition
source impact
Ignition
Source

Refrigerant
Leakage
Internal Factor
Poor manufacturing quality
Leakage from piping, joint, Heat exchanger
joint piping
External Factor
Poor installation quality
Poor maintenance & service

Internal Factor
Electric Circuit Board
Magnet Conductor
External Factor
Cigarette
Hot water Supply Boiler
Fire accident

1. Assessment of
Flammability characteristics

10

Ignition Test
Slowly leak the test gas into 1m cubic box:

Density (kg/m3)

1m
Critical point
LFL(Low Flammable Limit)

1m
Ignition
source

Ignition
source

1m

Charge Amount (kg)

11

9/10/2012

Example flammability behaviour

of Class 3 refrigerant (R290)

30 gram R290 / 1m
Ignited by spark
Explosion

12

Example flammability behaviour

of Class 2L refrigerant (R32)

300 gram R32 / 1m

Ignited by flame
No fire

13

Example flammability behaviour

of Class 2L refrigerant (R32)

320 gram R32 / 1m

Ignited by flame
Slow vertical flame
but no explosion

14

2. Refrigerant charge limits

Maintenance/service training

15

Related Safety standards

Revision of international & European standards is ongoing

Field

International

Europe

US

Refrigerant
Classification

ISO817
Under revision

-NA(based on ISO)

ASHRAE 34
UL 2182

ISO5149
Under revision

EN378
Under revision

ASHRAE 15

EN60335-2-40
Based on IEC

UL 207
UL 250
UL 471
UL 474
UL 484
UL 984
UL 1995
UL 60335-2-40

Usage
Restriction for
Safety

IEC60335-2-40
Under revision

16

R32 charge limitations

Refrigerant Charge limit for R32 in ISO & IEC drafts
IEC
60335
2-40

ISO 5149
Draft

A2, A3

4 x LFL

26 x LFL

130 x LFL

A2L
Proposal

6x
LFL=(1.8kg)

52 x
LFL=(16kg)

260 x
LFL=(80kg)

A2, A3

4 x LFL

26 x LFL

130 x LFL

A2L (R32)

6 x LFL=(1.8
kg)

39 x LFL=(12
kg)

195 x LFL=(60
kg)

< 1.8 kg
No restriction

1.8 ~12 (16) kg

According to formula
Mmax=2,5 x (LFL)(5/4) x ho x (A)1/2

Category I
Small charge amount

12 (16) ~ 60 (80) kg
With additional
ventilation

> 60 or 80 kg
National legislation

Category II
Large charge amount

17

R32 charge limitations

in NON ventilated areas
Example from Draft ISO5149

20.00
Floor location
Wall mounted
Window mounted
mounted
Windor
Ceiling mounted

Max.Refrigerant Charge (kg)

18.00
16.00
14.00
12.00
10.00
8.00
6.00
4.00
2.00
0.00
20

40

60

80 100 120 140 160 180 200 220 240 260 280 300

Floor Area (m2)

18

R32 charge limitations

in ventilated areas
Example from Draft ISO5149

Max.Refrigerant Charge (kg)

70,00

With additional ventilation

60,00
50,00
40,00

With minimum ventilation

30,00
QLMV

20,00
QLAV

10,00
0,00
0

20

40

60

80

100

120

140

160

180

200

220

240

260

280

300

Floor Area (m2)

19

Daikin R32 field

tests & training
in India

35units

Supported by Japanese Ministry

for Economy, Trade & Industry

20units
10units

7units

Installation & service in Europe

Technically, installation of R32 unit is similar to R410A
Tooling may be slightly different (under investigation for EU)
Tooling

R410A

R32

Manifold

Normal

R32 values
must be on the scale

Scale

Normal

Normal

Vacuum pump

Normal

Normal

Leak detector

Normal

Under investigation

Recovery unit

Normal

Under investigation

Recovery
bottle

40 bar, right
thread

48 bar, left thread

3. Evaluation of ignition sources

22

Simulation R32 leak no explosion occurs

0g

400g

800g

Simulation R32 rapid leak from liquid line

During brazing work
No explosion occurs. Same result as R410A
(due to oil)
R32+ETHER OIL (5%)

R410A+ETHER OIL (5%)

Worldwide research & risk analyses

on flammable refrigerants

USA

China

Japan

25

Publication of Japanese test results

at JRAIA Symposium in Kobe,
8 & 9 November 2012

26

Conclusion
Safety is a must during the whole life cycle

The safety data sheet is not sufficient to

evaluate the risk in an optimal way, as it leads
to overspecification for the slightly flammable
(2L) refrigerants
Regulations and standards need revision in
order to avoid such overspecification

27

Thank you !