Remplacement du R22 dans les installations existantes

Résumé et principaux résultats

Le règlement européen 2037/2000 régissant l'utilisation des fluides frigorigènes de type HCFC (dont fait partie le R22) prévoit l'arrêt de la production et de l'utilisation de ces fluides en 2015. Toutefois, une pénurie de ces fluides se profile dès 2009 en raison de la planification de leur interdiction et il est indispensable de prévoir la conversion des installations dès à présent. Ce rapport, destiné à toute la chaîne d'intervenants (fabricants, installateurs, gérants et exploitants), compare les différentes options pour le remplacement du R22 dans divers types d'installations. Ce travail exhaustif couvre tous les aspects de la conversion : réglementation, notions élémentaires, propriétés des mélanges, méthodes de conversion, coûts et incidences sur les performances des installations, impacts sur l'environnement et planning de conversion pour un parc d'installations. Enfin, des pistes sont données pour le renouvellement des installations, en particulier avec des options de remplacement utilisant des fluides dits "naturels". Afin d'illustrer les conséquences de la conversion des installations sur leur consommation énergétique et sur leur capacité frigorifique, on a développé un logiciel de calcul spécifique. Lorsque cela était possible, des résultats d'essais de laboratoires indépendants ont été rapportés. En général, ces résultats ont confirmé les résultats de calcul du CETIAT. Parmi les fluides de remplacement passés en revue, la solution proposée par Arkéma (R427A, dénommé "FX-100") semble être la plus "universelle" sur le domaine de températures d'utilisation examiné (applications de réfrigération négative et positive et climatisation). Si, comme l'annonce Arkema, ce fluide permet un fonctionnement avec un taux résiduel d'huile minérale élevé (15%?) après conversion, il semble constituer un bon compromis car il permet un relatif maintien de la puissance moyennant une légère diminution du rendement énergétique, avec des performances quasiment égales à celles du R407C. Les fluides de la série Isceon (R417A, R422A et R422D) présentent l'avantage de la conversion la moins onéreuse car, selon leur fabricant, ils seraient compatibles avec l'huile d'origine utilisée avec le R22. Toutefois, le R417A ne devrait être appliqué que si l'on dispose d'une réserve de puissance frigorifique supérieure à environ 20%. Les installations équipées d'un évaporateur noyé doivent éviter l'utilisation d'un mélange zéotrope à glissement de température important et privilégier le R40A ou le R507A.

Title: R22 substitution in existing installations
Abstract : European regulations prohibit the use of ozone depleting substances like R22 (part of the HCFC fluid family) as of 2015. However, there will likely be a shortage of these fluids from 2009 due to their progressive ban. It is therefore important to plan and implement the retrofit of the installations using HCFCs as early as possible. This report, targeting all the refrigeration chain stakeholders (manufacturers, installers, managers and owners), compares the different options for R22 substitution in various types of (existing) installations. This exhaustive work covers all the aspects of plant retrofit, including regulations, refrigeration basics, properties of refrigerant mixtures, drop-in and retrofit methods, costs and consequences on plant performance, environmental impacts, corporate retrofit planning. Options are also suggested for longer-term solutions like whole plant replacement with the so-called "natural" fluids. In order to quantify the effects of plant retrofit on energy efficiency and capacity, a specific simulation program was developed at CETIAT that enable the comparison of different refrigerants. Whenever it was possible, tests results from independent Laboratories were reported. In general, the results from these Laboratories confirmed the simulation results. Among the available alternatives for R22 replacement in existing installations, the Arkema refrigerant (R427A, aka "FX-100"), seems to be the most "universal" option, spanning the largest refrigeration temperature domain (applicable to negative and positive temperature as well as air conditioning). If, as claimed by Arkema, R427A is compatible with a high mineral (or alkybenzene) lubricant content (15% ?), this refrigerant will offer a good compromise, yielding a very slight decrease in refrigeration/air conditioning capacity and a small energy efficiency penalty. Overall, R427A will offer the same performance as R407C provided oil return is adequate. Refrigerants from the Isceon series (R417A, R422A and R422D) enable the least costly drop-in option because, as claimed by its manufacturer, they are supposed to be compatible with the existing lubricants. However, care should be taken when using R417A because this refrigerant often results in a decrease in refrigerating capacity (circa 20%). This refrigerant should therefore be used only in installations known to be oversized. Plants with flooded-type evaporators should avoid (large gliding) zeotropic mixtures. In this case, R404A or R507A are the best options.

Title: Substitution of R22 in various types of existing installations
Abstract: European regulations prohibit the use of ozone depleting substances like R22 (part of the HCFC fluid family) as of 2015. However, there will likely be a shortage of these fluids from 2009 due to their progressive ban. It is therefore important to plan and implement the retrofit of the installations using HCFCs as early as possible. This report, targeting all the refrigeration chain stakeholders (manufacturers, installers, managers and owners), compares the different options for R22 substitution in various types of (existing) installations. This exhaustive work covers all the aspects of plant retrofit, including regulations, refrigeration basics, properties of refrigerant mixtures, drop-in and retrofit methods, costs and consequences on plant performance, environmental impacts, corporate retrofit planning. Options are also suggested for longer-term solutions like whole plant replacement with the socalled "natural" fluids. In order to quantify the effects of plant retrofit on energy efficiency and capacity, a specific simulation program was developed at CETIAT that enable the comparison of different refrigerants. Whenever it was possible, tests results from independent Laboratories were reported. In general, the results from these Laboratories confirmed the simulation results.
Among the available alternatives for R22 replacement in existing installations, the Arkema refrigerant (R427A, aka "FX-100"), seems to be the most "universal" option, spanning the largest refrigeration temperature domain (applicable to negative and positive temperature as well as air conditioning). If, as claimed by Arkema, R427A is compatible with a high mineral (or alkybenzene) lubricant content (15% ?), this refrigerant will offer a good compromise, yielding a very slight decrease in refrigeration/air conditioning capacity and a small energy
efficiency penalty. Overall, R427A will offer the same performance as R407C provided oil return is adequate. Refrigerants from the Isceon series (R417A, R422A and R422D) enable the least costly dropin option because, as claimed by its manufacturer, they are supposed to be compatible with the existing lubricants. However, care should be taken when using R417A because this
refrigerant often results in a decrease in refrigerating capacity (circa 20%). This refrigerant should therefore be used only in installations known to be oversized. Plants with flooded-type evaporators should avoid (large gliding) zeotropic mixtures. In this case, R404A or R507A are the best options.

Commissions

MFCE - Matériel Frigorifique; Conditionnement d'air; Echangeurs

Thème

Réfrigération et cycles thermodynamiques

Mots-clés

Climatiseurs, Composants frigorifiques, Compresseurs frigorifiques, Conditionnement d'air, Fluides frigorigènes, Pompes à chaleur, Réfrigération

Auteurs

BENSAFI Ahmed