RAISE Train-the-Trainer Workshop Modules - English

TRAIN-THE-TRAINER WORKSHOP

PARTICIPANT’S MANUAL

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IMPLEMENTING PARTNERS

Implementing Partners

DEG, a member of the KFW banking group, finances investments of private companies in developing and transition countries. As one of Europe's largest development finance institutions, it promotes private business structures to contribute to sustainable economic growth and improved living conditions.

Holcim Indonesia is a leading fully integrated producer of cement, ready mixed concrete and aggregates with a unique and expanding retail franchise offering the most complete end-to-end solution to home building, from building materials supply to design and speedy, safe construction.

Geocycle, as a business unit of Holcim, provides environment friendly solutions for industrial and commercial waste. It manages waste with the confidence of knowing responsible and environmentally-sound practices.

ASSIST is a non-stock, non-profit international capacity building organization with its headquarters in the Philippines. It aims to achieve and witness meaningful change to and for our planet and the people living on it. Since 2003, ASSIST has implemented over 20 projects funded by multi-lateral donors such as European Union, USAID, UNEP, UNIDO, DEG, GIZ, etc.

FOREWORD

The Indonesian government has committed to voluntary CO2 emission reduction targets under international climate negotiations within the UNFCCC, amounting to 26% of the 2005 baseline, to be achieved by 2020. This 26% reduction is through local effort, targeted to reach as much as 41% through international cooperation. This is a tremendous challenge for Indonesia! It is estimated that without proper refrigerant management, HFC emissions will dramatically outstrip all other GHGs and by 2050, will reach 5.5–8.8 Gt CO2 equivalent per year. The technology used in air-conditioners and refrigerators has a significant climate impact both through direct emissions (leakages and servicing) and indirect (energy use). Thus, there is significant potential to generate GHG emission reduction not just from energy efficiency but also from management of refrigerants. RAISE Indonesia focuses on commercial buildings, industrial refrigerant service sector and large retail and industry sectors, which are significant users of air-conditioning and refrigeration. Target stakeholders will be relevant government agencies, professionals and practitioners, local chambers of commerce, industry associations and academic institutions. The objective is to contribute to sustainable industrial development in Indonesia by developing human capital in the field of refrigerant and energy management. Refrigerant Management Awareness in Industrial and Commercial Application for Sustainable Energy Conservation (RAISE Indonesia) is a Public – Private Partnership project jointly funded and implemented by DEG and Holcim Indonesia and co-implemented by ASSIST. This Participant’s Manual is prepared for the Train-the-Trainer Workshop to capacitate local trainers on proper refrigerant management.

TABLE OF CONTENTS

Module 1: Training Methodology for Trainer – Trainer’s Guide ……………… 1 Module 2: Global Environmental Issues, Ozone Depletion

and Climate Change ……………………………………………………. 12 Module 3: International and National Response for Ozone

Protection and Reducing Green House Gases …………………… 40 Module 4: Refrigeration and Air Conditioning Technology,

ODS and the Alternative Refrigerants ………………………………. 67 Module 5: Energy Efficiency in Refrigeration and Air Conditioning ……….. 91 Module 6: Refrigerant Management Methods ………………………………….. 131

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Module 1: Training Methodology for Trainers – Trainer’s Guide

Instructions

This trainer’s guide is designed to enable its users understand the RAISE (Refrigerant Management Awareness in Industrial and Commercial Application for Sustainable Energy Conservation) training approach and methodology as well as to enable the trainer to prepare and facilitate RAISE training workshops. It provides information and instructions to deliver the training modules in a professional way in the classroom. Concept and Meaning of Training of Trainers (ToT)

Training of trainers is a form of training imparted to an individual with a view to preparing him/her for his/her future role as a trainer. This is a process which aims to develop his/her capabilities and capacities of imparting training to others as a skilled professional in the field of Refrigerant and Energy management especially to reduce Green House Gas emissions and to contribute to sustainable industrial development. ToT also aims to help organizations to build their own cadre of trainers. The focus of ToT is not only to build a cadre of trainers, but also to develop necessary orientation, awareness and abilities to perform a catalytic role as facilitators to future trainers for refrigerant management program

Principles for Training Adults

It is commonly understood today that adults learn most of what they know by their own experience. They also know what they want to learn and need space to contribute their experiences and opinions. Providing these opportunities will increase their motivation, ensure relevance and encourage active participation.

Tests have shown that people remember:

20% of what they hear

40% of what they see and hear

80% of what they discover for themselves

People remember best the things they themselves have said, so facilitators should try not to speak too much. Remember, adults are MATURE learners:

Motivated - Adults have chosen to participate in SCORE training because they believe it will

bring them benefits

Active - Adults learn and remember better when they are actively involved in the learning

process

Time conscious - Adults, and especially managers and workers, are busy people. Their time

is precious and they will only learn when information is relevant to them.

Utilitarian - Adults want to achieve concrete results. They will be more motivated when

information is useful and directly applicable to their business.

Responsive-Adults can assess their own strengths and weaknesses and react to them.

Constructive feedback encourages them to take action to improve their situation

Experienced - Adults bring a wealth of personal and business experiences to the training.

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Making Learning Fun

All learners learn much better if they are enjoying the process. Main concepts and key messages are easier to absorb and remember if they are connected to a happy memory. Moreover, when people are enjoying themselves they tend to be open to new ideas and are more motivated to challenge their own comfort zones. Many of the methodologies provided below help you to create an environment where learning is fun.

Training Methods

The following training methods are recommended for alternate use by trainers and pending situational needs:

Lecture

Brainstorming

Discussion

Individual exercise

Group discussions

Case study

Who is this Trainer Guide for?

This Trainer Guide is for new and experienced trainers who have attended a RAISE Training of Trainers (TOT) workshop. The guide will help trainers to create opportunities for participants to actively engage with the subject material and the specific tools that will help participants to take their learning from the classroom.

How to Use this Guide

Trainers can use the session plans, step by step instructions and handout provided in this guide to prepare and conduct RAISE training.

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TOT Modules

These modules will encourage trainers to adopt the concept of Refrigerant Management and Sustainable Energy Conservation. From International perspective to national perspective the effective practise of ODS reduction program to properly maintaining R and AC equipment, adopting a strategy of avoiding or reducing refrigerant emissions.

The RAISE training programme contains six modules: Module 1: Training Methodology for Trainer –Trainers Guide Module 2: Global Environmental Issues, Ozone Depletion and Climate Change Module 3: International and National Response for Ozone Protection and Reducing

Green House Gases Module 4: Refrigeration and Air Conditioning Technology, ODS and the Alternative

Refrigerants Module 5: Energy Efficiency in Refrigeration and Air Conditioning and Refrigeration

System Module 6: Refrigerant Management Methods

The Role of the Trainer

Your role as a trainer in this TOT Module is to facilitate the module content and show participants concrete examples for reducing ODS and meeting the national Ozone objectives. After the workshop, you will be able to train the technicians.

The stakeholders’ involvement is a pre-requisite to the success of this programme and to any improvement effort. You will need to reinforce this message in all activities and presentations. Twelve sessions have been developed for this module. It is recommended that these sessions be delivered in a 3-day workshop. Depending on the availability of participants and other relevant factors, the trainer could make certain adjustments to ensure that flexibility is exercised.

Please keep in mind that these workshops should be practical and participatory, allowing participants to share experiences and knowledge.

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1. Objectives

The purpose of this training of trainer’s workshop is to build or strengthen the capacity of the

participants and their respective institutions in the domain of Refrigerant Management Awareness

in Industrial and Commercial Application for Sustainable Energy Conservation.

By the End of this Worksop, Participants will be Able to:

Describe RAISE objectives, themes and approach

Explain Ozone layer depletion, Global warming and climatic change and why they are important to the people, country and enterprise in R&AC

International and National Response for Ozone Protection and Reducing

Green House Gases and Phasing out ODS under Montreal Protocol

Refrigeration and Air Conditioning Technology, ODS and Alternative Refrigerants

Energy efficiency in Refrigeration and Air-conditioning system

Refrigerant Management Methods

Specifically ToT aims at the following:

To use training as a tool for developing skilled trainer in refrigerant management and

Energy efficiency in Air conditioning system.

To prepare the participants as trainers for field level technical training activities for servicing and technicians in R and AC.

To help organisations/agencies in their efforts of refrigerant management for accelerating

the national action plan at the local level.

To provide an understanding of the principles and practices of the training process.

The project contributes to the climate change initiatives of the country and the government’s goal of local Green House Gas emission reductions through refrigerant management.

2. Workshop Programme

The 3-day workshop is split up into four sessions on each day. This format allows for compact sessions with clear objectives. Each session contains exercises that help participants to reach the session objectives and that fit into the action plan which is finalized in the last session.

Time Day 1 Day 2 Day 3

09:00 – 10:30

Session 1:

Introduction

Global Environmental Issues, Ozone Depletion

Session 5: Refrigeration and Air Conditioning Technology

Session 9:


10:30 - 10:45 Tea break Tea break Tea break

10:45 – 12:15

Session 2:

Global warming and Climate Change

Session 6: ODS and the Alternative Refrigerants

Session 10:

Refrigerant Management Methods (Cont’d)

12:15 -13:15 Lunch Lunch Lunch

13:15 – 14:45

Session 3:

International Response for Ozone Protection and Reducing Green House Gases

Session 7:

Energy Efficiency in Air Conditioning System

Session 11:

Examination

14:45 – 15:00 Tea break Tea break Tea break

15:00 – 16:30

Session 4:

National Response to Montreal Protocol and Regional perspective/ Activity

Session 8: :

Energy Efficiency in Refrigeration System

Session 12:

Evaluation and Feedback

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3. LESSON PLANNING AND PREPARATION

Each session is designed so that at the end of the session, participants should have acquired the concepts introduced, had time to digest the topics, and completed exercises which contribute to the action plan to be developed in the last session.

For all sessions, you will need instructional methods such as:

Flip chart

Marker pens

Digital projector

PP slides

Training Manual

Additional resources and hand-outs are provided in this trainer guide. The session plans show where these are used.

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Session Plan

Day 1, Icebreaker: Module 1

Faculty introduction

Ask each participant to collect a brief about their neighbor and introduce them with details such as date of birth, qualifications, work area, experience, hobbies etc.

Time 10 minutes

Objective: Understand each other in the group and create a relaxed learning environment

Day 1, Session 1: Module 2

Global Environmental Issues: Global warming and Climate Change

Lecture Time 60 mins

Objective: Understand what is ozone and ozone layer depletion

Learn about effects of Ozone layer depletion on the Environment

Understanding about the ODP AND GWP

Activity Activity 1

Time 20 mins


Global Environmental Issues: Global warming and Climate Change


Objective: Understand Green house gas effects and global warming

Identify the main man made Green house gases and climatic change effects

Understanding Benefits of the Montreal protocol

Activity Activity 2

Time 20 mins


International and National Response for Ozone Protection and Reducing Green House Gases


Objective: Understand how Montreal Protocol enforces countries

Understand Phase-out Mandates of the Montreal Protocol

Understand Amendments & Adjustments

Activity Activity 3

Time 20 mins

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International and National Response for Ozone Protection and Reducing Green House Gases


Objective: National Response to Montreal Protocol

Regional perspective

Activity Activity 4

Time 20 mins




Objective: Refrigeration System

Air Conditioning System and Types

Activity Activity 5

Time 20 mins




Objective: Refrigerant and its impacts?

Safety Group Classifications

Natural Refrigerants and alternative Refrigerants

Activity Activity 6

Time 20 mins


Energy Efficiency in Refrigeration and Air Conditioning


Objective: HVAC System Equipment and Energy Efficiency in AHUs

Heat Load

Assessment of Air Conditioning & Refrigeration

Energy Efficient Chillers Energy Efficiency in Air-conditioning systems

Activity Activity 7

Time 20 mins

9


Energy Efficiency in Refrigeration and Air Conditioning


Objective: Energy Efficiency in Refrigeration Systems

Cooling Towers

Variable Flow Pumping

Energy Conservation in Buildings

Thermal Energy Storage System

Activity Activity 8

Time 20 mins




Objective: Fundamental components of a refrigerant management program

Good practices in Refrigeration

Preventative Maintenance Program

4 R of Refrigerant Management Plan

Refrigerant Handling


Refrigerant Management Methods (Cont’d)

Time 30 mins

Objective: HCFC Phase-out Management Plans (HPMPs)

Country specific responses

Activity Activity 9 & 10

Time 20 mins

Day 3, Session 11:

Examination

Time 60 mins

Objective: To reinforce learning and test the efficacy of training

Activity

Time

Day 3, Session 12:

Evaluation and Feedback

Time 60 mins

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Handout for Workshop Evaluation

Please let us know what you think. If you are unable to answer any question, please leave it blank, otherwise, circle the most appropriate number for each statement.

During the evaluation process, participants are encouraged to make recommendations for future sessions.

Strongly agree

Agree Neither agree nor

disagree

Disagree Strongly disagree

1. The subject matter was adequately covered.

5 4 3 2 1

2. The content was suitable for my background and experience.

5 4 3 2 1

3. The workshop was well paced.

5 4 3 2 1

4. The handouts and tools were relevant.

5 4 3 2 1

5. Participants were encouraged to take an active part in the event.

5 4 3 2 1

6. The activities helped me understand the content.

5 4 3 2 1

7. The facilitator helped me to understand.

5 4 3 2 1

8. The facilitator answered questions appropriately.

5 4 3 2 1

9. Overall, the training organization, administration and scheduling were handled well.

5 4 3 2 1

10. The workshop venue and facilities were suitable to my needs.

5 4 3 2 1

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SCORE WORKSHOP EVALUATION continued…

11. Was the workshop length: Just right? Too short? Too long?

12. What was your level of interest before the workshop?

Excellent Very good Good Fair Poor

13. Your level of interest after the workshop?


14. Do you have any suggestions that you feel could improve this workshop?

15. What is your overall rating of this workshop?


16. Do you have any other comments on the workshop?

Module 2: Global Environmental Issues: Ozone Depletion and Climate Change

1. Ozone Depletion

2. Global Warming

3. Climate Change

1.What is ozone? (O3)

2.What is the ozone layer

3.Ozone Creation and Destruction

4.Ozone depletion

5.Effects of Ozone layer depletion on the Environment

6.Increasing awareness of Ozone depletion issues

7.ODP AND GWP

8.Global warming

9.What is Climate Change?

10.Climatic Benefits of the Montreal protocol

11.HFCs and Climate Change

Coverage

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Ozone is a stable molecule composed of three oxygen atoms

Blue colored and has a strong pungent odor

Ozone is a gas that is naturally present in the atmosphere Ozone (O3) is found in Earth’s upper and lower atmosphere

Occurs naturally as a layer in the stratosphere

1.What is ozone? (O3)

O

O

O

Ozone Layer

Stratosphere: Contains a lot of ozone (ozone layer):

Our atmosphere and Ozone

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The large amount of ozone in the part of the upper atmosphere known as the stratosphere is often referred to as the “ozone layer”

• The ozone layer, situated in the stratosphere about 15 to 30 km above the earth's surface.

• Ozone protects living organisms by absorbing harmful ultraviolet radiation (UV-B) from the sun.

• The ozone layer is being destroyed by CFCs and other substances.

• Levels of ozone are measured in Dobson units (DU), where 100 DU is equivalent to a 1 millimeter thick layer of pure ozone

• ~ 260 DU near the Tropics

2.What is the ozone layer

Good up high!

Bad nearby!

The ozone layer is in the stratosphere

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• UV-A, the least dangerous form of UV radiation, with a wavelength range between 315nm to 400nm,• UV-B with a wavelength range between 280nm to 315nm, and UV-C which is the most dangerous

between 100nm to 280nm. • UV-C is unable to reach Earth’s surface due to stratospheric ozone’s ability to absorb it.

3.Ozone Creation and Destruction

Stratospheric Ozone and Ultraviolet Radiation (UVR)

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1. Chemicals that potentially deplete the ozone layer

2. Contain chlorine or bromine atoms

3. Have long atmospheric life

Examples:• Chlorofluorocarbons (CFCs) e.g. CFC-12 (aka R-12 or F-12) • Halons (Bromochlorofluorocarbons) e.g. Halon 1301• Carbon tetrachloride• Methyl chloroform• Hydrochlorofluorocarbons (HCFCs) e.g. HCFC-22 (R-22 or F-22)• Hydrobromofluorocarbons (HBFCs)• Bromochloromethane• Methyl bromide

What are Ozone Depleting Substances (ODS)

Refrigerators/freezers

Compressors

Vehicles (mobile air-conditioning systems)

Insulating boards/pipe covers

Metered-dose inhalers (medical inhalers)

Refrigerants (gases)

Fire extinguishers

Fumigants, pesticides

Foam-blowing agents

Cleaning solvents

Aerosol propellants

Air-conditioning systems

Main uses of ODS

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Chlorofluorocarbons (CFCs). CFC-11 (chlorofluoromethane) and CFC-12

(dichlorofluoromethane) are the most widely used as coolants for refrigerators and air conditioners

CFCs were welcomed by industries:– Low toxicity– Chemical stability– Cheap

Usage:– As refrigerants– As blowing agents– For making flexible foam– As cleaning agents– As propellants

What is CFCs?

CFCs were used as refrigerants

CFCs are used in aerosol sprays

4. Ozone Depletion Process

Chemistry of Ozone Depletion Process

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• The pollutants that most adversely affect the ozone layer are fluorocarbons, particularly those that contain chloride and bromide.

• Most of the depletion of the ozone layer has been attributed to pollutants containing chloride (chlorofluorocarbons or CFCs). CFCs were used in refrigeration and air conditioning systems and as propellants in spray cans.

• These chemicals serve as a catalyst in a chemical reaction that converts ozone to oxygen. The presence of ice crystals accelerates the process.

• CFCs are not consumed in the reaction but remain in the stratosphere to continue the destruction of the ozone.

Causes of Ozone Depletion

5. Effects of Ozone Layer Depletion on the Environment

• Harmful to the environment and human health

– Ozone (Layer) depletion

– Climate Change

– Global Warming

– Economic impact

• International agreement for their complete phase out

• National legal obligation for their phase out

• Personal obligation to protect and care for our natural environment

– Our generation

– Our future generation

Why control Ozone Depleting Substances?

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A combination of low temperatures and elevated chlorine and bromine concentrations are responsible for the destruction of ozone in the upper stratosphere

thus forming a “hole”. (Kerr, 1987)

• Over exposure may:– Increase risk of non-melanoma and

malignant melanoma skin cancer – Higher risks of malignant melanoma from

severe sunburns – especially in childhood– Risk of malignant melanoma has increased

10% – Risk of nonmalignant melanoma has

increased 26%

UV-B Effects on Humans

– Suppress immune system– Accelerate aging of skin due high exposure– Cause an outbreak of rash in fair skinned

people due to photo allergy – can be severe

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UV light and skin cancers

Melanoma

Linked to skin cancer – a deadly cancer

• Increases the risk of cataracts– Induces type of protein that provokes

cleaving (splitting) in the lens

– Leading cause of blindness

– The prevalence of cataract after age 30 is doubling each decade

• Causes pterygium– A wedge-shaped growth over the

central cornea

Over Exposure to UV-B

Cataracts

Pterygium

Linked to cataracts on the lens of the eye causing blindness

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• Experimental exposure of seedlings, young plants to enhanced UV-B negatively impacts rates of photosynthesis and growth

• Disruption of plant cycles and food chains

• May limit plant growth and change plant form, how nutrients are distributed

• Increased UV-B is a threat to terrestrial vegetation:

• High UV-B exposure does induce some inhibition of photosynthesis

Plants

UV-B penetrates water columns to depths of 30m

Increased UV-B exposure

• Reduces productivity by interfering with processes of photosynthesis

• Damages DNA • Alters nitrogen metabolism

Phytoplankton

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Oceanic Phytoplankton

• Evidence is clearer that enhanced UV-B negatively affects marine phytoplankton

• Reduced photosynthesis rates, reduced productivity

Lowers levels of surface phytoplankton in the oceandamages the base of the ocean food chain

Synthetic polymers, naturally occurring biopolymers, as well assome other materials of commercial interest are adverselyaffected by solar UV radiation. Today's materials are somewhatprotected from UVB by special additives. Therefore, any increasein solar UVB levels will therefore accelerate their breakdown,limiting the length of time for which they are useful outdoors.

Effects on Materials

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6.Increasing awareness of Ozone Depletion Issues

• Limiting the use of CFC’s is difficult

• Ban the production and use of CFC’s

• Use CFC substitutes such as HCFC’s and HFC’s

• Recycling refrigerants

• Alternatives to gas-blown plastics

• Alternative propellants

• Alternatives to methyl bromide, a fungicide

The Importance of Awareness Raising

• The ozone layer is being depleted, endangering all life on earth.

• All country and governments have committed itself to combating ozone depletion by ratifying the Montreal Protocol on Substances that Deplete the Ozone Layer.

• However, governments alone cannot solve the problems posed by ozone depletion.

• Industry, non-governmental organizations (NGOs) and the public all have roles to play in protecting the ozone layer.

• Awareness is a precondition to successful ODS phase out.

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• Industry must stop all production and consumption of ozone depleting substances (ODS) phased out under the Montreal Protocol.

• Under amended Protocol, industry in developing countries must stop manufacturing ODS or purchasing newly produced CFCs, halons and carbon tetrachloride by 2010, and methyl chloroform by 2015.

• Export of newly produced ODS to developed countries has to stop immediately, except for essential uses, because these countries have agreed to stop importing from the end of 1995.

• Meeting your country’s commitments under the Montreal Protocol will require the adoption of ‘good practices’ to avoid unnecessary emissions from equipment containing ODS.

Awareness to stakeholders

For the most part, the public is not aware that ozone layer depletion is an issue.

Awareness activities should be planned for the following three groups, each with separate objectives

To reduce by 50 per cent consumer purchases of CFC aerosols by raising consumer awareness.

To reduce venting through increasing awareness of the refrigeration service sector of its economic and environmental impacts.

To increase awareness among school children

Public awareness on ozone layer depletion issue

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7. ODP AND GWP

Refrigerant Areas of Application ODPCFC 11(R11)

CFC 12 ( R 12 )

CFC 13 (R 13)

CFC113 ( R113 )

CFC114 ( R114 )Blend of R22and R115(R502)

Air-conditioning Systems ranging from 200 to 2000tons in capacity. It is used where low freezing pointand non-corrosive properties are important.It is used for most of the applications. Air-conditioning plants, refrigerators, freezers, ice-cream cabinets, water coolers, window air-conditioners, automobile air conditioners.For low temp refrigeration up to – 90 C in cascadesystem

Small to medium air-conditioning system andindustrial cooling

In household refrigerators and in large industrialcoolingFrozen food ice-cream display cases and warehousesand food freezing plants. An excellent general lowtemp refrigerant

1.0

1.0

1.0

1.07

0.80.34

Freon Group Refrigerants Application and ODP Values

Global Warming Potential(GWP)

1 ppm = 1g in 1000 kg, 1 ppb = 1 g in 1000 tonnes, 1 ppt = 1 g in 1000 000 tonnes

Greenhouse gas BaselineCurrent level

GWPLifetime in atmosphere (years)

Carbon dioxide (CO2) 280 ppm 370 ppm 1 5-200Methane (CH4) 700 ppb 1720 ppb 23 12Nitrous oxide (N2O) 275 ppb 314 ppb 310 114Ozone - - - Days/weeksChloroflurocarbons(CFC) and related chemicals

0 ppt levels 4000-8000 5-100

Perfluromethane, one of the Perfluorcarbons(PFC)

40 ppt 80 ppt 5700 50000

Sulphur hexafluoride (SF6)

0.01 ppt 3 ppt 22000 3200

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Survey Of Refrigerants

Refrigerant Group Atmospheric life

ODP GWP

R11 CFC 130 1 4000R12 CFC 130 1 8500R22 HCFC 15 .05 1500R134a HFC 16 0 1300R404a HFC 16 0 3260R410a HFC 16 0 1720R507 HFC 130 1 3300R717 NH3 - 0 0R744 CO2 - 0 1R290 HC < 1 0 8R600a HC < 1 0 8

• The Montreal Protocol on Substances that Deplete the Ozone Layer was signed in 1987.

• The ozone treaties have been ratified by 197 states.

• The Montreal Protocol on Substances that Deplete the Ozone Layer is an international treaty designed to protect the ozone layer by phasing out the production of numerous substances believed to be responsible for ozone depletion.

• It is believed that if the international agreement is adhered to, the ozone layer is expected to recover by 2050.

Ozone layer and the Montreal Protocol

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Substance Baseline 2010 2015 2020 2030

CFCs, Halons 1986 100%

Other CFCs,

Carbon tetrachloride,

Methyl chloroform

1989 100%

HCFCs 1989* 75% 90% 99.5% 100%

HBFC None 100%

BCM None 100%

Methyl Bromide 1991 100%

Non-Article 5 Party Control Measures 2010-2030

(Consumption)

* 1989 HCFC Consumption + 2.8 CFC Consumption

• Emerging evidence of start of ozone layer recovery

• Full recovery around 2050• Polar regions 10-25 years later

Recovery can be affected by:• Future production of CFCs, HCFCs• Production of methyl bromide• Emissions from existing equipment• Interaction with climate change

Benefits of Montreal Protocol

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The “greenhouse effect” & global warming are not the same thing

8.Global warming

• Greenhouse effect is natural“natural” greenhouse effect

enables life on earth– average temperature is 15°C.

• Natural greenhouse gases are:– Oxygen– Ozone– Carbon dioxide– Water vapourEffective global insulators

Natural Greenhouse Effect

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Source IPCC 2007

36

Greenhouse Gases

The greenhouse gases responsible for global

warming are:

Carbon dioxide (CO2)

Methane (CH4)

Nitrous oxide (N2O)

Hydrofluorocarbons (HFCs)

Perfluorocarbons (PFCs)

Sulphur hexafluoride (SF6)

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Man-made sources Fossil fuel combustion Transport

Natural sources Volcanoes Forest fires Evaporation from sea water

• Deforestation

• CO2 has the largest impact on the greenhouse effect

Carbon dioxide (CO2)

Methane (CH4)

Methane is formed when organic matter decomposes in the absence of oxygen:

wetlands

wet rice cultivation

decay from landfills

cattle & sheep ranching,

livestock farming

bio-wastes

domestic sewage

landfill

biomass burning

mining and extraction of fossil fuels

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Use of fertilizer

Animal waste in soil

Burning of agricultural residues

Manure

Transport

Nitrous oxide (N2O)

Leakage from refrigeration equipment and end of life destruction

Use of HFC-containing aerosols, air conditioners and metered dose inhalers

HFCs have fairly long atmospheric lifetimes (tens to hundreds of years)

Hydrofluorocarbons (HFCs)

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Generated during aluminum production

Semi-conductor industry

Leakage from refrigeration equipment and end of life destruction

SF6 (sulfur hexafluoride) is used in electrical equipment (switchgear and

devices) and in arc furnaces, window insulation, car tires and sport shoes!

Magnesium smelting process, from semi-conductor manufacture

Perfluorocarbons (PFCs)

Sulphurhexafluoride (SF6)

Climate is the average weather at a given point and time of year, over a long period (typically 30 years).

We expect the weather to change a lot from day to day, but we expect the climate to remain relatively constant.

If the climate doesn’t remain constant, we call it climate change.

9.What is Climate Change?

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• Climate change occurs when the patterns change in time (e.g., winter months get warmer) and space (e.g., monsoon rains occur further south).

• Suppose winter in Pennsylvania began to look like winter in Florida?

What is Climate Change?

Global surface temperature 1855-2010

• Increased occurrence of dramatic weather such as hurricanes

• Melting polar caps, glaciers• Shifts in weather patterns

Rising temperatures results in changing weather patterns

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Evidence of Climate Change: Glacier retreat

Rise in global ocean heat content 1955-2005

Some ups and downs, but clear overall increaseLevitus et al., 2005, GRL

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Sea-level from satellites: 4 cm rise in last 10 years

Rising Sea Levels Threaten Low-lying Islands

•Areas of Florida, U.S., to Flood If Average Sea Level Rises by One Meter Low-Lying Island Nation: Maldives in the Indian Ocean

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Agriculture:Decrease in crop yields

Irrigation demands,Productivity

Forests:Change in Ecologies,

Geographic range of species, and

Health and productivity

Coastal Areas:Erosion and flooding

InundationChange in wetlands

Water Resources:Changes in water supply

and water qualityCompetition/Water conflicts

Human Health:Greater disease risk Infectious disease

Air quality - respiratory illness

Industry and Energy:Changes in Energy

demandProduct demand &

Supply

GHG and Environmental Impacts - Future

Changes in temperature, weather patterns and sea level rise

Increasing Ocean Temperature and Rising Sea Levels

Snow and Arctic Ice Melting

Altered Rainfall Patterns & Extreme Weather Events

More Severe Heat Waves

Loss of Biodiversity

Increased Diseases & Threats to Human Health

Dwindling Freshwater Supply

Drought, Decreased Food Production & Food Shortages

Harmful Effects ofGlobal Warming

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US Geological Survey

Climate change affect people

Everywhere:

●Increase in intensity of hurricanes

●Increase in droughts in some places

●Increase in intense rain in some places

Increased Temperature

10.Climatic Benefits of the Montreal protocol

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Montreal Protocol provided dual protection:to Ozone layer and to Climate change

• Montreal 2007 adjustment:– Emissions reduced by 12‐15 GtCO2‐eq (depends on replacements)

Climate benefits already achieved larger than Kyoto Protocol targets for 2008‐2012.

Potential for additional climate benefits significant compared to Kyoto

Reason: CFCs, HCFCs are greenhouse gases Large GWPs:‐ CO2 : 1

‐ CFCs: 4,000 – 11,000‐ HCFCs: 700 – 2,300

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• 1974: Molina and Rowland: CFCs affect the ozone layer

‐ Public concern drop production

‐ ~1980: Increase in production:

‐ New applications

‐ Growth in Asia and Europe

‐ 1987: Montreal Protocol:

‐ Restricting prod/use CFCs, halons

‐ 2010: Global production stop CFC

Decrease in production of CFCs

Effects on Climate

World avoided by the Montreal Protocol

Reduction Montreal Protocol of ~11 GtCO2‐eq/yr

5‐6 times Kyoto target

(incl. offsets: HFCs, ozone depl.)

CO2 emissions

Velders et al., PNAS, 2007

38

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Offsetting the climate benefits

• About 80% of ozone depleting-substances replaced by non-fluorocarbons

• Substitute gases for CFCs– HFCs and HCFCs– HFC emissions: 0.9 GtCO2-eq/yr by 2010 (IPCC)

• Negative radiative forcing of ozone depletion– IPCC estimate of -0.05 +/- 0.05 W/m2 for 1979-2005

• Total offsets about 30% of direct forcing

• The use of Chlorofluorocarbons (CFCs), leads to ozone layer depletion.

• HFCs do not affect ozone but are a potent family of greenhouse gases with a warming effect that can be several thousand times greater than CO2.

• Gradual phasedown of Hydrofluorocarbons (HFCs) could cut greenhouse gas emissions by 100 billion tonnes of CO2 equivalent by 2050.

• Action on HFCs taken through the Montreal Protocol could lead to a massive boost for the environment

11.HFCs and ClimateChange

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11. HFCs and ClimateChange

• The Montreal Protocol successfully phased out CFCs, an ozone depleting gas and is considered one of the most successful piece of environmental legislation ever.

• HFC was one of the replacement gases.

• HFCs are used as a refrigerant and coolant and can be found in foam and fire extinguishers. The growth in the developing country is expanding rapidly.

• HFCs are an important solution in addressing ozone depletion and are currently responsible for less than one percent of global greenhouse gas emissions..

Module 3: International and National Response for Ozone Protection and

Reducing Greenhouse Gases

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1. Introduction

2. International Response to GHG and ODS

3. International Commitments

4. Effects of Ozone Layer Depletion

5. Phase-out Mandates of the Montreal Protocol

6. Amendments & Adjustments to the Montreal Protocol

7. Exemptions for Use & Production of ODS

8. National Response to Montreal Protocol

9. Regional Perspective

Coverage

1.Introduction

Global response to

Stratospheric Ozone Depletion- ODS

Global warming -GHG

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Relationship between ODS and other

Greenhouse Gases

Carbon Metric TonsConversion of CO2

Refrigerant Factor Equivalent

R-11 1.79 1,000 lbs.=1,790 R-12 4.35 1,000 lbs.=4,350R-114 3.18 1,000 lbs.=3,180R-115 2.33 1,000 lbs.=2,330

ODS’s also have very high Global Warming Potential (GWP)

Global Warming Potential Of Ozone

Depleting Substances

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October 1999Historically, the Antarctic ozone hole is largest during October.

September 2001Satellite data show the area of the 2001 Antarctic ozone hole peaked at a size roughly equal to that of recent years about the same area as North America.

(NASA -Aug 2013) False-color view of total ozone over the Antarctic pole. The purple and blue colorsare where there is the least ozone, and the yellows and reds are where there is more ozone.

Stratospheric Ozonelayer depletion

If greenhouse gases increase in concentration more IR is trapped rise in global temperatures

Greenhouse Effect and Global Warming

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Global warming

International Response toGHG

• U.N. Framework Convention on Climate Change (UNFCCC) was an agreement reached at the 1992 Rio Summit that dealt with global warming and other air quality issues– Called for nations to implement national strategies to limit GHG emissions

• In 1997, a Conference of the Parties (COP) was held in Kyoto, Japan – Goal was to reach an agreement, or protocol, that would address the issue of GHG

emissions beyond 2000

• In July 2001, 178 nations reached an agreement, known as the Kyoto Protocol – Before the 2001 conference, President Bush had taken the United States out of the

agreement

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Kyoto ProtocolAgreement reached in 2001

• 38 industrialized nations must cut GHG emissions to 5.2% below 1990 levels by 2012; no requirements for developing nations

• Emissions targets would be achieved using several market-based instruments, known as flexible mechanisms, including…

– GHG allowance trading system for participating developed nations.

– Credits available for carbon-absorbing forestry practices and for implementing emissions-reducing projects in other nations

• Protocol entered into force in 2005 after being ratified by developed nations representing at least 55% of carbon emissions

International Response to ODS

Montreal ProtocolThe Montreal Protocol on Substances that Deplete the Ozone Layer was designed to reduce the production and consumption of ozone depleting substances in order to reduce their abundance in the atmosphere, and thereby protect the earth’s fragile ozone Layer.

The original Montreal Protocol was agreed on 16 September 1987 and entered into force on 1 January 1989.

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• Representatives from 24 nations, meeting in Montreal on September 1987, signed the "Montreal Protocol on Substances that Deplete the Ozone Layer," an international agreement designed to reduce the worldwide production and use of chlorofluorocarbons (CFCs).

• This protocol is the result of years of negotiation fostered by the United Nations Environment Programme (UNEP) among the major CFC producing countries. Its formulation was a response to a growing international consensus on the need to protect stratospheric ozone from depletion by CFCs.

• The Montreal Protocol is a landmark agreement in that it is the first international treaty for mitigating a global atmospheric problem before serious environmental impacts have been conclusively detected.

The Evolution of the Montreal Protocol

3. International Commitments

1928: CFCs invented;

1950-70s: Consumption and use of CFCs rises rapidly during the 50s-70s

period. Used in Aerosols, Refrigeration, Air Conditioning and

Manufacturing of Foams.

1985: Vienna Convention for the Protection of the Ozone Layer calls for voluntary measures to reduce emissions of ozone-depleting substances (ODS).

1987: Montreal Protocol on Substances that Deplete the Ozone Layer establishes a schedule to reduce the production and consumption of CFCs and Halons.

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Montreal Protocol on Substances that Deplete the Ozone Layer (ODS)

Adopted 16 September 1987; 196 Parties – Universal Ratification

Contains mandatory timetables for the phase out of ODS - Original Protocol: 5 CFCs & 3 halons; - Current: 96 ODS

Amended 4 times (1990, 1992, 1997, 1999)

Adjusted 6 times (1990, 1992, 1995, 1997, 1999, 2007)

As Parties ratify the various Amendments they assume new data reporting responsibilities

Achievements

• Global Production of CFCs and Halons fell by over one million tonnes (by 92%) between 1986 and 2002.

• Global Consumption fell in the same period by the same margin (92%)

• Atmospheric Concentration of Chlorine peaked in 1994 and is now declining.

• Millions of cases of Eye Cataracts and Skin Cancer averted

• Recovery of the Ozone Layer expected by the year 2050, if the Protocol is fully implemented by all Parties.

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World CFC Production 1950 - 2002

• Harmful to the environment and human health

– Ozone (Layer) depletion

– Climate Change

– Global Warming

– Economic impact

– Others?

• International agreement for their complete phase out

• National legal obligation for their phase out

• Personal obligation to protect and care for our natural environment ,Our generation and Our children’s generation

Why control Ozone Depleting Substances?

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4. Effects of Ozone Layer Depletion

Human HealthDamages DNA which suppresses immune system resulting in increase of infectious diseases e.g. Skin Cancer, Eye Cataracts

Plants & TreesReduces crop production, damage to seedsReduces quality of crops

Aquatic OrganismsDamage to plankton, aquatic plants, fish larvae, shrimp, crabsAffects marine food chain

MaterialsDegrades paints, rubber, wood, & plastics, especially in tropical regions

Ground Level Smog Increase in the formation of Ground level ozone as a pollutant

High economic cost Damages could be in billions of US dollars

Ozone Depleting SubstanceList (Montreal Protocol)

• The Montreal Protocol divides ozone depleting substances into a variety of lists of chemicals that are subject to different control requirements. Countries that sign the treaty commit to

1) stop consumption or production of chemicals on Group 1 of Annex A after January 1, 1996 (CFC 11, CFC 12, CFC 113, CFC 114, and CFC 115)

2) stop consumption or production of chemicals on Group 2 of Annex A after January 1, 1994 (Halon1211, Halon 1301, and Halon 2402)

3) stop consumption or production of chemicals on Groups 1, 2 and 3 of Annex B after January 1, 1996 (CFC 13, CFC 111, CFC 112, CFC 211, CFC 212, CFC 213, CFC 214, CFC 215, CFC 216, CFC 217, carbon tetrachloride, and 1,1,1-trichloroethane)

4) reduce consumption or production of hydrochlorofluorocarbons listed in Group 1 of Annex C to 1989 levels

5) reduce consumption or production of methyl bromide to 75% of 1991 levels beginning in 1999.

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Ozone depleting Substance Consumption = Imports + production – Exports

developed Country (Article 2 Parties) (this schedule will be applicable for USA CANADA

Article 5 Parties developing Country (Mexico)

CFCs 100% phase out Jan. 1st, 1996

Base level: 1995-97Freeze in Consumption: Jan 1st, 199950% Cut-200585% Cut-2007Phase out: Jan. 1st 2010

Halons 100% phase out Jan. 1st, 1994

Base level: 1995-97Freeze in Consumption: Jan 1st, 199950% Cut-2005Phase out: Jan. 1st 2010

Methyl Bromide Phase out 2005 Base level: 1995-98Freeze in Consumption: Jan 1st, 2001

20% Cut-2005

Phase out: Jan. 1st 2015

5. Phase-out Mandates of the Montreal Protocol

Schedule Year

CAP .. Base line 1989

30% 2004

75% 2010

90% by 2015

Phase out by 2020

Allowing 0.5% for servicing

2020-2030 and thereafter, consumption restricted to the servicing of Refrigeration and Air-conditioning equipment existing at that date.

The HCFC schedule for Article 2 (Developed Countries)

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The HCFC schedule for Article 5 (Developing Countries)

ScheduleYear

Baseline1989 HCFC Consumption +2.8 percent of 1989 CFC Consumption

Average of 2009 and 2010

Freeze 2013

reduction of 10%) 2015

reduction of 35% 2020

reduction of 67.5% 2025

Annual average of 0.5% 2030 to 2040

reduction of 100 % 2040

Substance Baseline 2010 2015 2020 2030

CFCs, Halons 1986 100%

Other CFCs,

Carbon tetrachloride,

Methyl chloroform

1989 100%

HCFCs 1989* 75% 90% 99.5% 100%

HBFC None 100%

BCM None 100%

Methyl Bromide 1991 100%

Non-Article 5 Party Control Measures 2010-2030

(Consumption)

* 1989 HCFC Consumption + 2.8 CFC Consumption

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• Adjustments

– May modify the phase-out schedules of already controlled substances as well as ODP values of controlled substances based on new research results.

– Automatically binding for all countries that have ratified the Protocol, or the relevant amendment, which introduced the controlled substance.

• Amendments

– May introduce control measures or new ODS

– Countries, which have not ratified a certain amendment are considered a non-Party with regard to a new ODS introduced by that amendment.

6.Amendments & Adjustments to the Montreal Protocol

• Under the original Montreal Protocol agreement (1987), developed countries were required to begin phasing out CFCs in 1993 and achieve a 50% reduction relative to 1986 consumption levels by 1998. Under this agreement, CFCs were the only ODSs addressed.

• The London Amendment (1990) changed the ODS emission schedule by requiring the complete phaseout of CFCs, halons, and carbon tetrachloride by 2000 in developed countries, and by 2010 in developing countries. Methyl chloroform was also added to the list of controlled ODSs, with phaseout in developed countries targeted in 2005, and in 2015 for developing countries.

• The Copenhagen Amendment (1992) significantly accelerated the phaseout of ODSs and incorporated an HCFC phaseout for developed countries, beginning in 2004. Under this agreement, CFCs, halons, carbon tetrachloride, and methyl chloroform were targeted for complete phaseout in 1996 in developed countries. In addition, methyl bromide consumption was capped at 1991 levels.

Amendments to the Montreal Protocol

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Amendments to the Montreal Protocol

• The Montreal Amendment (1997) included the phaseout of HCFCs in developing countries, as well as the phaseout of methyl bromide in developed and developing countries in 2005 and 2015, respectively.

• The Beijing Amendment (1999) included tightened controls on the production and trade of HCFCs. Bromochloromethane was also added to the list of controlled substances with phaseout targeted for 2004.

• Montreal 2007 adjustment: Parties agreed to phase out HCFCs in both developed and developing countries

• Developed countries: Phase-out from 2030 2020 (+ intermediate reductions targets)

• Developing countries: Freeze in 2012– Phase-out from 2040 2030 (+ intermediate reductions targets)– Base level from 2015 average 2009-2010

• For the first time, the United States and China will work together and with other countries to use the expertise and institutions of the Montreal Protocol to phase down the consumption and production of hydrofluorocarbons .

• The agreement between the United States and China reads as follows:

- HFCs are potent greenhouse gases used in refrigerators, air conditioners, but they do not deplete the ozone layer, many are highly potent greenhouse gases. Their use is growing rapidly as replacements for ozone-depleting substances that are being phased out

- Every country in the world is a party to the Protocol, and it has successfully phased out several key classes of chemicals (CFCs), (HCFCs), and halons. The transitions out of CFCs and HCFCs provide major ozone layer protection benefits, but the unintended consequence is the rapid current and projected future growth of climate-damaging HFCs.

- The amendment includes a financial assistance component for countries that can already access the Protocol’s Multilateral Fund, and leaves unchanged the reporting and accounting provisions of the UN Framework Convention on Climate Change and Kyoto Protocol on HFC emissions.

Recent International Developments Underthe Montreal Protocol

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• Essential use: An exemption from the total phase-out of controlled substances can be granted for certain essential uses upon application, if approved by the Meetings of the Parties on a case-by-case basis (exempted category)

• Feedstock: Controlled substances that are used in the manufacture of other chemicals and that are completely transformed in the process.

• Process agents: Some ODS are used in the production of other chemicals e.g. as a catalyst or an inhibitor of a chemical reaction without being consumed. Only those uses of controlled substances approved by the Montreal Protocol are allowed.

• Production to satisfy basic domestic needs: Article 5 countries are allowed a grace period compared with non-Article 5 countries to phase-out the use and production of controlled substances in order to meet their domestic needs.

7.Exemptions for use & production of ODS

Allowable ODS Exemptions

ODS Exempted Use ProcessCFC-11, CFC-12, CFC-114

Propellants in metered dose inhalers (MDIs) used in the treatment of asthma and chronic obstructive pulmonary disease (COPD)

Companies have to apply for the exemption, and if approved, receive a specific quantity associated with this exemption for the calendar year.

Class I ODS Laboratory Uses Companies or individuals do not have to apply for the exemption, and there is no quantity associated with this exemption. Currently in effect through December 31, 2011.

Methyl Bromide Quarantine and Preshipment (QPS) uses

Companies or individuals do not have to apply for the exemption, and there is no quantity associated with this exemption.

Methyl Bromide Critical pre-plant and post-harvest uses

Individuals or associations have to apply for the exemption, and if approved, receive a specific quantity associated with this exemption for the calendar year.

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8.National Response to Montreal Protocol

• Control Measures: phase out schedulesCommon but differentiated approach: Developing countries given 10 years’ grace period

• Regulatory measures: - Establishment of Licensing systems- Trade controls

• Data Reporting - Imports, Exports, Production, Destruction of ODS, Trade with non-Parties

- Exempted uses (if relevant): Feedstocks, Essential uses, Critical and Emergency uses

Main responsibilities of the NOU

• Country Programme & Institutional Strengthening Programme Implementation

• RMP implementation often including recovery & recycling programmes and training programmes for refrigeration technicians and customs officers

– Replacement of CFCs

– Replacement of CFC equipment

– Import restrictions

– Local co-ordinators

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Stakeholders Support

In different sectors:• The manufacturing sector• The servicing sector• The end-user sector, for example through end-user conversion projects• The informal sector

Involving different stakeholders:• Local training institutes• Industry associations• Importers and wholesalers• Non-governmental organisations• The civil society.

National Regulations and Programs

Regulations and trade controls

Economic incentives and disincentives

Training programme on good practices in refrigeration for service technicians

Training programme for customs officers on control and monitoring of ODS

Establishing recovery & recycling programmes for CFC refrigerants

Public awareness

Strengthening of the institutional framework

Suitable policy and regulatory support framework

Improved system for collection of data and control and monitoring of ODS consumption

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An Import / Export Licensing System for ODS controlled by Montreal Protocol is necessary to:

Facilitate control of ODS supply

Increase the monitoring / collecting of information

Identify end users

prevent illegal imports

Measures – Supporting RMP implementation

Enforcement Measures

Enforcing import license regime

Applying penalties to discourage illegal imports /exports

Executing seizures of ODS products and equipment

Introducing quotas and prohibitions

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Monitoring

Most developing countries do not produce ODS and are completely dependent on ODS imports (e.g. Philippines, Sri Lanka)

Consequently, monitoring the legal trade and preventing the illegal trade of these chemical is crucial to achieving the gradual phase-out of ODS and conversion to non-ODS alternatives.

Without the Montreal Protocol by 2050

• Ozone depletion would have reached to at least 50 % in the northern hemisphere’s mid latitudes

• 70% in the southern mid latitudes

• Doubling on the UV-B radiation reaching earth’s surface

• Estimated increases of

– 19 million more cases of non-melanoma cancer

– 1.5 million more cases of melanoma cancer

– 130 million more eye cataracts

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We are here

9. Regional perspective

• USA

• Philippines

• India

• Indonesia

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The United States commitments to Phase out ODS

Implementation of Montreal Protocol In the Philippines

• The Philippines became a signatory in 1991. The DENR, through the Philippine Ozone Desk (POD) of the Environmental Management Bureau (EMB), is the national coordinator for the implementation of the Montreal Protocol in the Philippines.

• Through the Multilateral Fund (MLF) and other implementing agencies, the Philippines has been a beneficiary of over US$36 million in investment and non-investment projects in the country since 1991. About 81 per cent of the funding for investment projects was used to purchase consumable equipment and tools that were distributed to manufacturing companies, training, and service institutions, particularly those involved in refrigeration and air conditioning systems. Other industries involve aerosols, fire extinguishers, rigid and flexible foam, and cigarettes.

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Philippines to cutimports of ozone-depleting

substances by 2013• The import ban on HCFC is part of the country's compliance to the Montreal Protocol on

Substances that Deplete the Ozone Layer, to which the Philippines is a signatory in 1986

• Under the plan, the government will put a cap on the importation of HCFC to 2,644 metric tons (MT) in 2013 since this is the country’s average import of HCFC from 2009 to 2010.

• From the base level of 2,644 MT, HCFC imports will be gradually reduced by 10 percent, to 2,379.6 MT by 2015; 35 percent to 1,718.6 MT by 2020; then 67.5 percent, to 859.3 MT in 2025.

• From 2030 to 2039, however, Environment Secretary Mr. Ramon Paje said the Department of Environment and Natural Resources (DENR) will allow the import of the substance to only 66.1 MT annually, representing 2.5 percent of the base level, for the continued use of the servicing sector.

• The ban will initially cover the foam sector, particularly the polyurethane rigid foam in appliances, panels, and sprays.

India’s Commitment to the Montreal Protocol

17th September 1992 : India became a Party to the Montreal Protocol and ratified the London Amendment.

3rd March 2003 : India ratified Copenhagen Amendment (1992), Montreal

Amendment (1997) and Beijing Amendment (1999).

November 1993 : India’s Country Programme was prepared. January 2006 : India’s Country Programme was updated.

Ozone Cell is established under the Ministry of Environment & Forests for undertaking activities relating to implementation of Vienna Convention and Montreal Protocol.

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ODS Phase out - India’s Achievements

As of January 1, 2010, the production and consumption of CFCs, CTC and Halonswere phased out completely as per the Montreal Protocol time schedule, except theuse of CFCs in Metered Dose Inhalers (MDIs) under the Essential Use Nominations(EUN).

CFC Phase out Freeze of CFC Production and Consumption in July 1999 at 22588 ODP tonnes and

6681 ODP tonnes respectively 50% reduction of CFC Production and Consumption in 2005. Accelerated Phase out of CFCs from 1.8.2008, 17 months prior to the Montreal

Protocol Schedule, except use of pharma grade CFCs for manufacture of MDIs in2008 and 2009.

CTC Phase out Freeze of CTC Production and Consumption at 11553 ODP tonnes and 11505 ODP

tonnes respectively in 2005. 85% reduction of CTC Production and Consumption by the end of year 2005. 100%

reduction as on 1.1.2010.

Halons Freeze of Halon production and consumption on 1.1.2002. Total phase out of Production and Consumption of Halons and Methyl Chloroform

Production and Consumption w.e.f 1.1.2003.So far India has successfully met all the obligations of the Montreal Protocol.

ODS Phase out - India’s Achievements

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Indonesia’s Participation

Global Agreement

Vienna Convention

Montreal Protocol

London Amendment

Copenhagen Amendment

Montreal Amandment

Beijing AmandmentNational Ratifications

Presidential Decision No. 23/1992

Presidential Decision No. 92/1998

Presidential Regulation No.33/2005

Presidential Regulation No. 46/2005

Assistance

Recive Funds from MLF to carry out Control on ODS for Article‐5 Countries

Responsbilities

Meet with ODS freezing and phasing‐out schedules

Conduct ODS Vigilant

Report ODS Data on Production and COnsumption

Stakeholders in Indonesia

Protection of Ozone Layer

Government

Central/Province

Industries

Public

(Consumers)

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Government Roles

1

• Controling Import

• Prohibition of Manufacture BPO

2• Perform research to find alternatives to ODS

3

• Encourage industries to adopt non‐ODS technology gradually, if process productions use ODS

4• Monitor the circulation of ODS

5

• Disseminating programs and activities on ozone layer protection to all stakeholders and the public

Rules and Regulations

Industries Roles

1•Gradual technology shifts, if process productions use ODS

2•Perform research to find alternatives to ODS

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Public (Consumers) Roles

1• Buy products that do not contain ODS

2• To watch‐dog the industrial sectors and services that use ODS

Government Actions

Rules & Regulations

Prohibition of producing and using ODS goods since 1998

Restrictions on the use of ethyl bromide only to pre‐shipment and quarantine activities since 2005

Import ban on Halon and TCA (Methyl Chloroform) since 2006

ODS import regulations (Limited Importer and Manufacturer Imprters) since 2006

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Government Actions

Rules & Regulations

Ban on the import / phase‐out of CFCs since 2008

Set of national competency standards for the company / workshop and service technician refrigeration system

Prevention of the release of ODS into the atmosphere through reclaim and recycle refrigerant

Use of logo differentiating goods that do not use CFC and Halon

Government Actions

Encourage automotive workshops and air-conditioning services to not release ODS to the atmosphere through a grant 3R and 2R ODS machineries

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Government Actions

Non-ODS production machineries grants for industries

Module 4: Refrigeration and Air Conditioning Technology, ODS and

Alternative Refrigerants

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1. Refrigeration System

2. Air Conditioning System and Types

3. What is a Refrigerant?

4. Environmental Impact

5. Health & Safety of Refrigerants

6. Dealing with Ozone Depletion

7. Reducing the impact on Global Warming

8. Safety Group Classifications

9. Fluorinated Refrigerants

10. Natural Refrigerants

11. Alternative Refrigerants

Coverage

What is Refrigeration?

• Refrigeration is the process of removing heat from one substance and transferring it to another substance.

• It also includes the process of reducing heat & maintaining the temp. of a body below the general temp. of its surroundings.

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High Temperature Reservoir

Low Temperature Reservoir

R Work Input

Heat Absorbed

Heat Rejected

How does it work?

Refrigeration cycle

Vapour Compression Refrigeration

Condenser

Evaporator

High Pressure Side

Low Pressure Side

Compressor

Expansion Device

12

3

4

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Low pressure liquid refrigerant in evaporator absorbs heat and changes to a gas

Condenser

Evaporator

High Pressure Side

Low Pressure

Side

CompressorExpansion Device

1 2

3

4

Refrigeration cycle

Refrigeration cycle

The superheated vapour enters the compressor where its pressure is raised

Condenser

Evaporator

High Pressure Side

Low Pressure Side

Compressor

Expansion Device

12

3

4

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The high pressure superheated gas is cooled in several stages in the condenser

Condenser

Evaporator

High Pressure Side

Low Pressure Side


12

3

4

Refrigeration cycle

Liquid passes through expansion device, which reduces its pressure and controls the flow into the evaporator

Condenser

Evaporator

High Pressure Side

Low Pressure Side


12

3

4

Refrigeration cycle

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Refrigeration system

Principles of Refrigeration

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Thermodynamic representation

Evaporator / Chiller

• Located in space to be refrigerated

• Cooling coil acts as an indirect heat exchanger

• Absorbs heat from surroundings and vaporizes

• Latent Heat of Vaporization

• Sensible Heat of Surroundings

• Slightly superheated to ensure no liquid carryover into

compressor

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Compressor

• Superheated Vapor:

• Enters as low press, low temp vapor

• Exits as high press, high temp vapor

• Temp: creates differential (T) promotes heat transfer

• Press: Tsat allows for condensation at warmer temps

Increase in energy provides the driving force to circulate

refrigerant through the system

• Refrigerant rejects latent heat to cooling medium

• Latent heat of condensation (LHC)

• Indirect heat exchanger: seawater absorbs the heat and discharges it overboard.

Condenser

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• Temporary storage space & surge volume for the sub-cooled refrigerant

• Serves as a vapor seal to prevent vapor from entering the expansion valve

Receiver

Expansion Device

• Thermostatic Expansion Valve (TXV)

• Liquid Freon enters the expansion valve at high pressure and leaves as a low pressure wet vapor (vapor forms as refrigerant enters saturation region)

• Controls:• Pressure reduction• Amount of refrigerant entering evaporator controls

capacity

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Refrigeration capacity

• Refrigeration capacity is normally referred in terms of Tonnes of refrigeration (TR).

• American Society of Heating, Refrigerating and Airconditioning Engineers (ASHRAE) defines 1 TR as equivalent to a refrigeration capacity of 3516.85 W or 3023.95 kcal/h.

• Tons of Refrigeration or simply Tons is often used as a general term to indicate the capacity or size of the refrigeration plant.

• Thus 1 TR air conditioner has a refrigeration capacity of 3516.85 W at the prescribed temperatures.

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I ton of ice to water in 24 hours

1 TR

• Air conditioning (often referred to as aircon, AC or A/C) is the process of altering the properties of air.

• Primarily temperature and humidity, to more favorable conditions.

• More generally, air conditioning can refer to any form of technological cooling, heating, ventilation, or disinfection that modifies the condition of air.[

What is Air Conditioning ?

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• Self-Contained System

– Add-on to ships that originally did not have AC plants

– Not located in ventilation system (window unit)

• Refrigerant Circulating System

– Hot air passed over refrigerant cooling coils directly

• Chilled Water Circulating System

– Refrigerant cools chill water

– Hot air passes over chill water cooling coils

AC System Types

Refrigerating machine: Types

• Select right type of equipment for specific application window (room air conditioners) split air conditioners floor mounted package air conditioners rooftop liquid chillers (air cooled) chilled water plants absorption chillers

• Select right type of compressors reciprocating rotary scroll screw

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How Air-conditioning works ?

Types of Air conditioners (window)

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Types of Air conditioners (Split)

Thermal energy moves from left to right through five loops of heat transfer:

1)

Indoor air loop

2)

Chilled water loop

3)

Refrigerant loop

4)

Condenser water loop

5)

Cooling water loop

Centralized Air-conditioning system

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Basic AC System

Evaporative Cooling

• Air in contact with water to cool it close to ‘wet bulb temperature’

• Advantage: efficient cooling at low cost

• Disadvantage: air is rich in moisture

Cold AirHot Air

Sprinkling Water

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3.What are refrigerants ?

• A heat carrier must be use to move heat from the interior of a cabinet or room to the outside.

• Thus in refrigerating system fluids which absorb heat inside the cabinet and release it outside are called refrigerants.

• The ideal refrigerant would be one that could liberate all the heat that it is capable of absorbing.

• The refrigerant changes from liquid to vapor during the process of absorbing heat and condenses again to liquid while liberating heat in most of the refrigerating systems.

Popular refrigerants

NOTE:The most common refrigerants used in mechanical refrigeration systems today are Refrigerant-123 (or R-123), R-134a, and R-22. Ammonia (R-717) and, under certain operating pressures, even water (R-718) and carbon dioxide (R-744) can be used as refrigerants.

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• it should be nonpoisonous.

• it should be non explosive

• it should be non corrosive

• it must be nonflammable

• leaks should be easy to detect.

• leaks should be easy to locate.

• it should operate under low pressure.

• part moving in the fluid should be easy to lubricate

• it should be nontoxic (not harmful if inhaled or if spilled on skin)

• it should be a stable gas

PROPERTIES OF A GOOD REFRIGERANT

Ozone Depletion Potential of Refrigerants (Fluorocarbons)

• The ozone depletion potential (ODP) is the ratio of the potential impact on ozone of a chemical compared to the impact of the same mass of CFC-12, with the latter having an impact of 1.

CFCsSince CFCs contain no hydrogen in molecules, they are stable in the atmosphere. This means they cannot be easily broken down until they reach the stratosphere and thus have a high ODP.

HCFCsSince they contain hydrogen in molecules, HCFCs can be broken down relatively easily in the atmosphere and thus have a low ODP.

HFCsSince they contain no chlorine or bromine, HFCs have an ODP of zero.

83

Global warming potential of refrigerants

Global warming substances

Atmospheric lifeGWP (global warming

potential)100‐year value

PFC14 50,000 6,500

SF6 3,200 23,900

HFC23 264 11,700

CFC12 102 8,100

HFC125 32.6 2,800

HFC134a 14.6 1,300

CH4(Methane) 12.2 21

HCFC22 12.1 1,500

HFC32 5.6 650

Promising Future Refrigerants

• HFC32: A type of HFC, HFC32 has the potential to significantly reduce global warming: it has a global warming potential approximately one-third of HFC410A, and it is more efficient. It can be adapted for use in air conditioners in a relatively short time, and it is an economical way to contribute to reducing global warming impact. It is slightly flammable.

• HFO1234yf: Hydrofluoroolefin. A refrigerant newly developed for use in car engines. Because it has about the same effect on global warming as natural refrigerants, it is slated for use as a next-generation car engine air conditioner. Research is underway to solve several issues that prevent HFO1234yf from being used in general air conditioners; it still contributes to global warming due to its low efficiency and its high power consumption. It is slightly flammable.

• Carbon dioxide (CO2): CO2 has a lower toxicity rating and is not flammable. Because it has similar performance as conventional refrigerants for applications like water heaters, Daikin uses CO2 as a refrigerant for heat pump water heaters. However, because it has a low COP, air conditioners using it require more electricity, thus, there are doubts whether it will lessen the total global warming impact.

• Propane: Propane has equivalent performance to R22, and isobutane, a substance similar to propane, is used as a refrigerant in refrigerators. However, there are still many issues in using propane as a refrigerant in air conditioners. It is highly combustible and thus susceptible to explosion in the event of leakage into the air. To use as an air conditioner refrigerant, the volume of propane must be dramatically reduced to ensure that it is safe. As well, the pipe work for air conditioners must be done on-site. Current technology cannot guarantee the safety of propane air conditioners.

84

In the Standard 34, the refrigerants have been classified into safety groups in the following ways:

The safety classifications consist of two alphanumeric characters (e.g. A2 or B1).

In which the capital letter indicates the toxicity and the Arabic numeral denotes the flammability.

Safety group classification

(1) Toxicity Classification

Refrigerants are assigned to one of two classes: A or B based on the following exposure:

Class A signifies refrigerants for which toxicity has not been identified at concentrations less than or equal to 400 ppm, based on data used to determine Threshold Limit Value-Time-Weighted Average (TLV-TWA) or consistent indices.

Class B signifies refrigerants for which there is evidence of toxicity at concentrations below 400 ppm, based on data used to determine TLV-TWA or concentration indices.

85

(2) Flammability Classification

Refrigerants are assigned to one of three classes: 1, 2 or 3 based on flammability.

Class 1 indicates refrigerants that do not show flame propagation when tested in air at 101kpa and 21 .

Class 2 signifies refrigerants having a lower flammability limit (LFL) concentration of above 0.10 kg/m3 in air at 21 and 101 kpa and a heat of combustion below 19,000 kJ/kg.

Class 3 indicates refrigerants that are highly flammable, as identified by an LFL concentration less than or equal to 0.10 kg/m3 at 21 and 101 kPa, or a heat of combustion greater than or equal to 19,000 kJ/kg.

• By combining toxicity and flammability criteria, a matrix is obtained which classifies a refrigerant into class A1, A2, A3, B1, B2, or B3 as shown in Tab.7-4.

86

A refrigerant must be chemically stable in the temperature range it is exposed to.

Chemical stability means that the refrigerant should not dissociate at the temperatures encountered in

the refrigerator.

Decomposition can result in the production of contaminants such as acids, sludge, or non-

condensable gases.

Chemical stability also means that the refrigerant should not decompose at the catalytic conditions by

the presence of oil, water, metallic impurities.

Chemical Stability

• Refrigerants can be divided in two main groups:

– synthetic (basically halocarbon fluids: CFCs, HCFCs and HFCs)

– non-synthetic (hydrocarbons, carbon dioxide, ammonia, water, air – so-called natural refrigerants)

Types of Refrigerants

87

Synthetic refrigerants

• Most CFCs and HCFCs tend to be colourless, odourless, non-flammable, non-corrosive substances. Because CFCs and HCFCs have low toxicity, their useeliminated the danger posed by refrigerator leaks. In just a few years,compressor refrigerators using CFCs became the standard for almost all homekitchens.

• With the advent of the Montreal Protocol, HFC refrigerants were developedduring the 1980s and 1990s as alternative refrigerants to CFCs and HCFCs.

Natural refrigerants

• Natural refrigerants- They have zero ODP and zero or negligible GWP

• Role in the future in many applications

88

Alternatives to HCFCs-Desirable Characteristics

Alternativesto HCFCs

VOC

Flamm-ability?

LowToxicity

Low Cost

ZeroODP

LowGWP

Similar or better

Performance

There is no ideal Refrigerants – Always some compromise

Alternatives to HCFC-22 for ACs

Natural Fluids

HFCs (R-410A & HFC-32)

Zero ODP

R-410A - High GWP

HFC-32 – Low GWP?Low GWP Blends - Cost and Timeline (uncertain)

HC-290 & Blends

Zero ODP

Negligible GWP

Better energy efficiencyFlammabilityEmerging Standards?

HCFC-22

Montreal Protocol

ODP

GWP

CO2/NH3

Zero ODP

Negligible GWP

Matl Compatibility, Technology, Efficiency,

89

HCFC-22 Alternatives

Refrigerant Tb（ ) Tc（）LFL

(kg/m3)ODP GWP

HCFC-22 -41 96 - 0.055 1780

R-410A -52 72 - 0 2000

HFC-134a -26 101 - 0 1430

R-407C -43 86 - 0 1800

HC-290 -42 97 0.038 0 3

R-744 -78 31 - 0 1

HC-1270 -48 92 0.040 0 3

HFC-1234yf -29 95 0.293 0 4

HFC-161 -38 102 0.076 0 12

HFC-32 -52 78 0.306 0 675

Application of New Eco-friendly Refrigerants

Refrigerant Application HFCs used Possible Eco-friendly

• Domestic refrigeration R134a,R152a HC600a and blends

• Commercial refrigeration R134a,R404A,R407C HC blends,NH3 ,CO2 **

• Cold storage ,food processing

and industrial refrigeration R134a,R404A,R507A NH3 ,HCs,CO2 **

• Unitary air conditioners R410A,R407C CO2 , HC s

• Centralized AC (chillers) R134a,R410A,R407C NH3 ,HCs,CO2, water **

• Transport refrigeration R134a,R404A CO2,

• Mobile air conditioner R134a CO2, HCs

• Heat pumps R134a,R152a,R404A NH3 , HCs, CO2,, water **

R407C,R410A

90

Summary of Refrigerant Options and Challenges

HFC blend mainly R-410A is the most likely near-term refrigerants; this technology is well proven but requires significant design changes.

R-410A Residential ACs with comparable energy efficiency are commercially available including some Article 5 countries.

As there is some proposal to consider phase-down of HFCs under Montreal Protocol, there is more interest on low GWP refrigerants.

HC refrigerants are applied in low charge residential Air-conditioning and are in commercial use in many countries including India. China is yet to use HC AC in the local market as the local standards are yet to be revised but is exporting HC ACs.

HFC-32 is still under evaluation and yet to be commercially available. It will be soon manufactured in some A5 countries, including Indonesia and India.

HFC-1234yf /ze and their mixtures are under evaluation. There is not much open domain information on cost, performance and reliability.

Use of HFC zeotropic blends will have some challenges for recovery and recycling.

Module 5 - Energy Efficiency in Refrigeration and Air-Conditioning

91

Coverage

ENERGY EFFICIENCY IN HVAC

• HVAC System Equipment and Energy Efficiency in AHUs

• Heat Load

• Assessment of Air Conditioning & Refrigeration

• Energy Efficient Chillers

• Energy Efficiency in Air-conditioning systems

• Energy Efficiency in Refrigeration Systems

• Cooling Towers

• Variable Flow Pumping

• Energy Conservation in Buildings

• Thermal Energy Storage System

ENERGY EFFICIENCY IN REFRIGERATION

HVAC

• Heating

– maintain indoor temperature within comfort threshold

– ASHRAE 55-1992: 68-75°F winter, 73-79°F summer

• Ventilation

– replacing air in a space to control temperature or remove CO2, contaminants, moisture, odors, smoke, heat, dust and airborne bacteria

– ASHRAE 62-1999: 20 CFM per person in work environment

• Air Conditioning

– provides cooling, ventilation and humidity control

92

Comfort Zone

HVAC Equipment

• Fans / Blowers

• Filters

• Compressor

• Condensing Units

• Evaporator (cooling coil)

• Control System

• Air Distribution System

• Ducts, dampers, …

93

Supply Air Fan Exhaust Air Fan

Return Air Vent

Air Vent

Zone

Building HVAC: Ventilation

Building HVAC: AHU


Air Handling

Unit

Return Air Vent

Air Vent

Zone

94


Air Handling

Unit

Chilled Water Pump

Return Air Vent

Air Vent

Zone

Building HVAC: Chilled Water


Air Handling

Unit

Chilled Water Pump

Refrigerant

Chiller

CompressorExpansion Valve

Condenser

Evaporator

Return Air Vent

Air Vent

Zone

Building HVAC: Chiller

95

Building HVAC: Cooling


Air Handling

Unit

Chilled Water Pump

Refrigerant

Chiller

Water

Condenser Pump

CompressorExpansion

Valve

Condenser

Evaporator

Cooling Tower

Return Air Vent

Air Vent

Zone

Air Conditioner

Major Eqmt

Air

Building HVAC: Zone Control

Damper

Reheater

96

Building HVAC: Major Equipment


Air Handling

Unit

Chilled Water Pump

Refrigerant

Chiller

Water

Condenser Pump

CompressorExpansion Valve

Condenser

Evaporator

Cooling Tower

Return Air Vent

Air Vent

Damper

Zone

Reheater

Air Conditioner

Major Eqmt

Air

Heat Load in Air Conditioning space

Two type of heat loads : External loads and Internal loads

97

Basic Concepts

Convective and Radiative heat in a conditioned space

Basic Concepts –Building Survey

• People (number or density, duration of occupancy, nature of activity)

• Lighting (W/m2, type)

• Appliances (wattage, location, usage)

• Ventilation (criteria, requirements)

• Thermal storage (if any)

• Continuous or intermittent operation

• Orientation of the building• Use of spaces• Physical dimensions of spaces• Ceiling height• Columns and beams• Construction materials• Surrounding conditions• Windows, doors, stairways

98

Envelope Design Basics

• From an energy efficiency point of view, the envelope design must takeinto consideration both the external and internal heat loads, as well as daylighting benefits.

• One of the goals of the envelope design should be to introduce daylighting into the interior space of the building through windows andskylights, thereby reducing the need for electric lighting.

• Secondly, to maintain thermal comfort and minimize internal cooling/heating loads, the building envelope needs to regulate and optimize heattransfer through roof, walls, windows, doors and other openings.

• Basic design parameters: (for thermal comfort)– Air temp. & air movement

• Typical: summer 24-26 oC; winter 21-23 oC• Air velocity: summer < 0.25 m/s; winter < 0.15 m/s

– Relative humidity• Summer: 40-50% (preferred), 30-65 (tolerable)• Winter: 25-30% (with humidifier); not specified (w/o humidifier)

• Indoor air quality:• Air contaminants : e.g. particulates, VOC, radon, bio effluents• Outdoor ventilation rate provided• Air cleanliness

• Other design parameters:• Sound level• Pressure differential between the space & surroundings

(e.g. +ve to prevent infiltration)

Indoor Design CriteriaIndoor Design Criteria

99

Reduce Heat LoadBy Architect

Reduce Heat LoadBy Architect

1. Using Barriers

1. Shades

2. Blinds

3. Coatings

4. Glass

5. Walls

2. Wall design

1. Cladding

2. Radiant Barriers

3. Phase Change materials

4. High emissivity paint

3. Structure as heat sink.

1. Slowing down interior temperature rise.

2. Direct cooling by natural or mechanical means.

4. Water body as heat drain.

1. A water body in contact with the structure will cool it by evaporation.

2. Used to be pools, fountains and rivers.

3. Today it is cooling towers.

Reduce Heat LoadBy Users

Reduce Heat LoadBy Users

1. Lighting

1. Use day lighting

2. Use automatic dim light switch

3. Use CFL lamps

2. Equipment

1. Go for most energy efficient devices

2. Switch off when done

3. Cooling System.

1. Set to highest comfortable temperature.

2. Install CO2 Monitors to control ventilation rate.

3. Adopt point-of-use air outlets with individual control.

4. Choose multi temperature design.

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HVAC ControlHVAC Control

• Building is designed for max cool/heat load

• Operates at partial load

• Varies with weather, activity, building configuration

• HVAC control affects this “partial load service”

• Within operational constraints

– Zonal temps

– Adequate airflow

– Air pressure

– Flow and pressure throughout the system

– Energy efficiency

– Maintenance efficiency

Why ControlWhy Control

1) Maintain thermal comfort conditions

2) Maintain optimum indoor air quality

3) Reduce energy use

4) Safe plant operation

5) To reduce manpower costs

6) Identify maintenance problems

7) Efficient plant operation to match the load

8) Monitoring system performance

101

• Cooling effect: Tons of Refrigeration

• TR is assessed as:

1 TR = 3024 kCal/hr heat rejected

TR = Q xCp x (Ti – To) / 3024

Q = mass flow rate of coolant in kg/hr Cp = is coolant specific heat in kCal /kg o C Ti = inlet, temperature of coolant to evaporator (chiller) in 0C To = outlet temperature of coolant from evaporator (chiller) in 0C

Assessment of Refrigeration

Specific Power Consumption (kW/TR

• Indicator of refrigeration system’s performance

• kW/TR of centralized chilled water system is sum of

• Compressor kW/TR

• Chilled water pump kW/TR

• Condenser water pump kW/TR

• Cooling tower fan kW/TR

102

Calculating the operating load of a chiller plant-

Example

Refrigerationplant

Hot well12OC

Cold well8OC

Process

Chilled water flow – 100 m3/hr

Refrigeration TR -100,000 kg/hr x 1 x 4

3000

- 133.33 TR

Efficiency -

Power drawn by compressor, kW

TR

M Cp

120

133.33

- = 0.9

• Standard measure of refrigeration efficiency

• Depends on evaporator temperature Te and condensing temperature Tc:

• COP in industry calculated for type of compressor:

COPCarnot = Te / (Tc - Te)

Cooling effect (kW)COP =

Power input to compressor (kW)

Coefficient of Performance

103

185

Measure

• Airflow Q (m3/s) at Fan Coil Units (FCU) or Air Handling Units (AHU): anemometer

• Air density (kg/m3)

• Dry bulb and wet bulb temperature: psychrometer

• Enthalpy (kCal/kg) of inlet air (hin) and outlet air (Hout): psychrometric charts

Calculate TR

3024

h h ρ Q TR outin

Assessment of Air Conditioning

186


Indicative TR load profile

• Small office cabins: 0.1 TR/m2

• Medium size office (10 – 30 people occupancy) with central A/C: 0.06 TR/m2

• Large multistoried office complexes with central A/C: 0.04 TR/m2

104

187


• Accuracy of measurements

• Inlet/outlet temp of chilled and condenser water

• Flow of chilled and condenser water

• Integrated Part Load Value (IPLV)

• kW/TR for 100% load but most equipment operate between 50-75% of full load

• IPLV calculates kW/TR with partial loads

• Four points in cycle: 100%, 75%, 50%, 25%

Window Air-conditioning unit

105

Common Refrigerants and Properties

Properties of Commonly used Refrigerants

RefrigerantBoiling Point **

(oC)

Freezing Point (oC)

Vapor Pressure *

(kPa)

Vapor Volume * (m3 / kg)

Enthalpy *Liquid (kJ /

kg)Vapor (kJ /

kg)R - 11 -23.82 -111.0 25.73 0.61170 191.40 385.43R - 12 -29.79 -158.0 219.28 0.07702 190.72 347.96R - 22 -40.76 -160.0 354.74 0.06513 188.55 400.83R - 502 -45.40 --- 414.30 0.04234 188.87 342.31

R - 7 (Ammonia) -33.30 -77.7 289.93 0.41949 808.71 487.76*At -10 oC **At Standard Atmospheric Pressure (101.325 kPa)

Performance of Commonly used Refrigerants

RefrigerantEvaporating Press (kPa)

Condensing Press (kPa)

Pressure Ratio

Vapor Enthalpy (kJ / kg)

COP**carnot

R - 11 20.4 125.5 6.15 155.4 5.03

R - 12 182.7 744.6 4.08 116.3 4.70

R - 22 295.8 1192.1 4.03 162.8 4.66

R - 502 349.6 1308.6 3.74 106.2 4.37

R - 717 236.5 1166.5 4.93 103.4 4.78

* At -15 oC Evaporator Temperature, and 30 oC Condenser Temperature** COP carnot = Coefficient of Performance = Temp.Evap. / (Temp.Cond. -TempEvap.)

Performance Assessment of window, split and package air conditioning units – Example

• Package air conditioner capacity - 10 TR

• Air Velocity -2.27 m/s (across suction side filter)

• Cross Sectional Area -0.58 m2

• Air Flow Rate -1.32 m3/sec - 4751 m3/hr

Inlet Air Condition

DBT -20 oC

WBT -14 oC

Sp.Vol -0.8405 m3/kg

Enthalpy -9.37 kCal/kg

Outlet Air Condition

DBT -12.7 oC

WBT -11.3 oC

Enthalpy -7.45 kCal/kg

Cooling Effect Delivered -3.6 TR = 12.7 kW

106

Energy Efficiency Measures

Energy Efficiency Concepts

Reduce the time of use

Improve equipment/process efficiency

Energy Efficiency

Reduce energy loads (heating and cooling)

Three broad measures can be used to improve the energy efficiency of an organization:

107

Energy Efficiency Opportunities in

Refrigeration Systems1. Optimize process heat exchange

2. Maintain heat exchanger surfaces

3. Multi-staging systems

4. Matching capacity to system load

5. Capacity control of compressors

6. Multi-level refrigeration for plant needs

7. Chilled water storage

8. System design features

Energy Efficiency Opportunities

High compressor safety margins: energy loss

1. Proper sizing heat transfer areas of heat exchangers and evaporators

• Heat transfer coefficient on refrigerant side: 1400 – 2800 Watt/m2K

• Heat transfer area refrigerant side: >0.5 m2/TR

2. Optimum driving force (difference Te and Tc): 1oC raise in Te = 3% power savings

1. Optimize Process Heat Exchange

108


EvaporatorTemperature (0C)

Refrigeration Capacity*(tons)

Specific Power Consumption (kW/TR)

Increase kW/TR (%)

5.0 67.58 0.81 -

0.0 56.07 0.94 16.0

-5.0 45.98 1.08 33.0

-10.0 37.20 1.25 54.0

-20.0 23.12 1.67 106.0

(National Productivity Council)Condenser temperature 40◦C


CondensingTemperature (0C)

Refrigeration Capacity (tons)

Specific Power Consumption (kW /TR)

Increase kW/TR (%)

26.7 31.5 1.17 -

35.0 21.4 1.27 8.5

40.0 20.0 1.41 20.5

*Reciprocating compressor using R-22 refrigerant. Evaporator temperature.-10◦ C



3. Selection of condensers

• Options:

• Air cooled condensers

• Air-cooled with water spray condensers

• Shell & tube condensers with water-cooling

• Water-cooled shell & tube condenser

• Lower discharge pressure

• Higher TR

• Lower power consumption

109

Thermodynamic mountain

Temperature lift: For comfort-cooling, reducing the entering condenser-water temperature leads to lower energy consumption.

110

Temperature lift: For process cooling, raising the leaving chilled-water temperature leads to reduced energy consumption.

Effect of evaporator and condensing temperatures

111

• Poor maintenance = increased power consumption

• Maintain condensers and evaporators

• Separation of lubricating oil and refrigerant

• Timely defrosting of coils

• Increased velocity of secondary coolant

• Maintain cooling towers

• 0.55◦C reduction in returning water from cooling tower = 3.0 % reduced power

2. Maintain Heat Exchanger Surfaces


2. Maintain Heat Exchanger Surfaces


ConditionTe

(0C)Tc

(0C)Refrigeration Capacity* (TR)

Specific Power

Consumption (kW/TR)

Increase kW/TR

(%)

Normal 7.2 40.5 17.0 0.69 -

Dirty condenser 7.2 46.1 15.6 0.84 20.4

Dirty evaporator 1.7 40.5 13.8 0.82 18.3

Dirty condenser and evaporator

1.7 46.1 12.7 0.96 38.7

Effect of poor maintenance on compressor power consumption

112

3. Multi Staging Systems


• Suited for

• Low temp applications with high compression

• Wide temperature range

• Two types for all compressor types

• Compound

• Cascade

3. Multi Staging Systems


a. Compound

• Two low compression ratios = 1 high

• First stage compressor meets cooling load

• Second stage compressor meets load evaporator and flash gas

• Single refrigerant

b. Cascade

• Preferred for -46 oC to -101 oC

• Two systems with different refrigerants

113

4. Matching Capacity to Load System


• Most applications have varying loads

• Consequence of part-load operation

• COP increases

• but lower efficiency

• Match refrigeration capacity to load requires knowledge of

• Compressor performance

• Variations in ambient conditions

• Cooling load

114

• Cylinder unloading, vanes, valves

• Reciprocating compressors: step-by-step through cylinder unloading:

• Centrifugal compressors: continuous modulation through vane control

• Screw compressors: sliding valves

• Speed control

• Reciprocating compressors: ensure lubrication system is not affected

• Centrifugal compressors: >50% of capacity

5. Capacity Control of Compressors


115

5. Capacity Control of Compressors


• Temperature monitoring

• Reciprocating compressors: return water (if varying loads), water leaving chiller (constant loads)

• Centrifugal compressors: outgoing water temperature

• Screw compressors: outgoing water temperature

• Part load applications: screw compressors more efficient

6. Multilevel Refrigeration


Bank of compressors at central plant

• Monitor cooling and chiller load: 1 chiller full load more efficient than 2 chillers at part-load

• Distribution system: individual chillers feed all branch lines; Isolation valves; Valves to isolate sections

• Load individual compressors to full capacity before operating second compressor

• Provide smaller capacity chiller to meet peak demands

116

6. Multilevel Refrigeration


Packaged units (instead of central plant)

• Diverse applications with wide temp range and long distance

• Benefits: economical, flexible and reliable

• Disadvantage: central plants use less power

Flow control

• Reduced flow

• Operation at normal flow with shut-off periods

7. Chilled Water Storage


• Chilled water storage facility with insulation

• Suited only if temp variations are acceptable

• Economical because

• Chillers operate during low peak demand hours: reduced peak demand charges

• Chillers operate at night time: reduced tariffs and improved COP

117

8. System Design Features


• FRP impellers, film fills, PVC drift eliminators

• Softened water for condensers

• Economic insulation thickness

• Roof coatings and false ceilings

• Energy efficient heat recovery devices

• Variable air volume systems

• Sun film application for heat reflection

• Optimizing lighting loads

Equipment Scheduling and Operating Practices

• Distribute the cooling load among chillers in the manner that minimizes totalplant operating cost.

• In plants with multiple water chillers, minimize the operation of chilled water pumps and isolate idle evaporators.

• Limit the operation of the chiller plant based on the temperature or enthalpy of the outside air.

118

Energy Efficiency Measures in Air‐conditioning systems

Heat gains in buildings

119

Points to be considered:• Orientation• Double Glass Panels• Insulation on Roof• No Leakage from Windows/Doors/Ceiling/Return Air• Long side should be having minimum heat gain.• Minimum heat gain from NORTH

EASTSOUTH &WEST

Building Orientation/ Architectural Features

• Plant Room and AHU locations should be such that ducting/ piping are minimum.

• Sufficient Fresh Air Intake to avoid “Sick Building Syndrome”

• Sun Shades over glass area with proper inclination to avoid direct sunrays.

• Partitions and closure of air grills of unutilized conditioned space.

Building Orientation/ Architectural Features

120

Points to be considered

Space Temperature (23-26°C) - Task & Non-Task, Eqpt. Room etc.

(against earlier 20-26°C)

Space Humidity 30-70% (against earlier 40-60%)

Usage Time Schedule - Working Hours, Holidays etc.

Establishing Baseline Performance Indices

Establishing Baseline Performance Indices

Total tons at worst conditions - At Machine End- At User End

Tons / Sq. Meter

KW / Ton

KWH / Day

KWH / Year

121

Induction of fresh air into building is necessary to reduce “Sick Building Syndrome”

ASHRAE 62-99 specifies 20 cfm of outdoor air per person

Creates additional load on A/C system

Desiccant cooling helps in reducing the additional load due to fresh air (applicable for areas with 80-90% humidity throughout year)

Heat Recovery Wheel/ Desiccant Cooling


The wheel is positioned typically in the duct system so that return air is drawn through its one half and outdoor air is drawn through its other half in a counter flow pattern.

The wheel is rotated at 2 to 20 rpm.

Sensible heat is transferred as the metallic substrate picks up and store heat from the hot air steam and gives it up to the cold one.

Latent heat is transferred as the desiccant on the wheel absorbs moisture from the higher humidity air stream and releases the same into the air stream that has a lower humidity ratio.

122


Free Cooling or Coolingby Total Air Displacement

123

Free Cooling or Coolingby total Air Displacement

Whenever ambient dry bulb temperature is between 16 to 20 °C, cooling of inside space can be achieved by total displacement of inside air with the fresh air.

When the temperature is between 11 to 16 °C, a mixture of return air and ambient air can give the required inside conditions.

In both cases, the ambient air needs to be 100% filtered.

Variable speed drives for pumps and fans

124

• Ice Bank System is a proven technology that has been utilized for decades.

• Thermal energy storage takes advantage of low cost, off-peak electricity, produced more efficiently throughout the night, to create and store cooling energy for use when electricity tariffs are higher, typically during the day.

• The essential element for either full- or partial- storage configurations are thermal-energy storage tanks.

How Ice Bank Works? During off-peak night time hours, the chiller charges the ICEBANK tanks for use during the

next day’s cooling.

The lowest possible average load is obtained by extending the chiller hours of operation.

Ice Bank Systems

Cooling Tower

125

Cooling Tower Performance

Corrosive Factors in Cooling Tower Systems

ScaleFoulingMicrobiological growthCorrosion

Problems due to inadequate treatment

126

Solution to the Problems

• ON line / OFF line Chemical Cleaning

• Preventive Treatment

• Corrosion/Scale Inhibitors

• Dispersants (For Deposit Formation)

• Side Stream Filter

• Bio Dispersants and Biocides

• Chlorination

a) Water Side Problems

• Usually the typical problems that any (Open) cooling system meets with are:

– Corrosion and/or Scale formation

– Biological/Micro‐biological fouling

b) Energy Losses:

• Regardless of the type of system, be it open or closed, if it meets with any of the above problems, either the cooling tower nozzles are blocked resulting in reduced Delta ‘T’ and/or the deposits/scales are formed on the heat transfer surfaces.

Problems in Cooling water system and the corrective measures

1. Operate pumps near best efficiency point.

2. Modify pumping system/pumps losses to minimize throttling.

3. Adapt to wide load variation with variable speed drives.

4. Stop running multiple pumps - add an auto-start for an on-line spare or add a booster pump in the problem area.

5. Conduct water balance to minimise water consumption.

6. Replace old pumps by energy efficient pumps.

Energy Conservation Opportunities in Pumping Systems

127

Pump Selection & Operation

HeadMeters

Pump Efficiency 77%

82%

Pump Curve at Const. Speed

Partially closed valve

Full open valve

System Curves

Flow (m3/hr)

Operating Points

A

B

500 m3/hr300 m3/hr

50 m

70 m

Static Head

C42 m

Selection of Pump

28.6 kW

14.8 kW

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As shown in the drawing, we should be using impeller "E" to do this, but we have an oversized pump so we are using the larger impeller "A" with the pump discharge valve throttled back to 68 cubic meters per hour, giving us an actual head of 76 meters.

•Hence, additional power drawn by A over E is 31 –16.1 = 14.9 kW.

•Extra energy used ‐ 8760 hrs/yr x 14.9 = 1,30,524 kw.

= Rs. 5,22,096/annum

In this example, the extra cost of the electricity is more than the cost of purchasing a new pump.

Using oversized pump!

Symptoms that Indicate Potential for Energy Savings

Symptom Likely Reason Best Solutions

Throttle valve‐controlled systems

Oversized pump Trim impeller, smaller impeller, variable speed drive, two speed drive, lower rpm

Bypass line (partially or completely) open

Oversized pump Trim impeller, smaller impeller, variable speed drive, two speed drive, lower rpm

Multiple parallel pump system with the same number of pumps always operating

Pump use not monitored or controlled

Install controls

Constant pump operation in a batch environment

Wrong system design On‐off controls

High maintenance cost (seals, bearings)

Pump operated far away from BEP

Match pump capacity with system requirement

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• The mandatory requirement for the following elements of the HVAC system:– Natural ventilation: maximum possible use of wind-induced natural ventilation

– Equipment efficiency: minimum equipment efficiencies are required to be met for all theHVAC equipments

– Controls: the code specifies the use of time clocks, temperature controls/thermostats, andtwo-speed or VSD’s

– Pipe and duct work: the code specifies that piping of heating and cooling systems(including the storage tanks) must be insulated

– Economisers: each individual cooling fans system that has the design supply capacityover 1200 lit/s (2500 cfm) and a total mechanical cooling capacity over 22 kW (6.3Tonnes) shall include an economizer

– Hydronic systems: type of equipments to reduce pump energy such as variable fluidflow, automatic isolation valves

Energy Conservation in Buildings

Guidelines on Heating Ventilation and Air conditioning

Energy EfficiencyMeasures in Buildings

Air-Conditioning System:

• Weather stripping of Windows and Doors to avoid air infiltration• Temperature and Humidity Setting: 230-250C & 55%-65% RH• Chilled Water Leaving Temperature ≥ 70C

(every 1o C ↑ of chilled water leaving temperature ≈ ŋcentrifugal chiller ↑ by about 2¼ %)• Chilled Water Pipes and Air Ducts: properly insulated• Chiller Condenser Tubes: cleaned and scales removed • Cooling Towers: ensure water returning to the condenser is less than or equal to the

ambient temperature• Air-handling Unit Fan Speed: install frequency converters• Air Filter Condition: to be maintained clean

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Building Envelope Sealing

• The following areas of the enclosed building envelope shall be sealed,caulked, placed with gasket, or weather-stripped to minimize air leakage:

– Joints around fenestration and door frames– Openings between walls and foundations and between walls and

roof and wall panels– Openings at penetrations of utility services through, roofs, walls,

and floors– Site-built fenestration and doors– Building assemblies used as ducts or plenums– All other openings in the building envelope.

Module 6 - Refrigerant Management Methods

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Contents

Objectives of Refrigeration Management Program (RMP)

RMP Elements

Involving different stakeholders

Fundamental components of a refrigerant management program

Good practices in Refrigeration

Preventative Maintenance Program


Retrofit Best Practice Guidelines


Benefits of using Best Management Practices

HCFC Phase-out Management Plans (HPMPs)

UNDP’s country assistance

Country specific responses

• The RMP is a comprehensive strategy to phase out the use of ozone depleting refrigerants in the refrigeration and air-conditioning servicing sector.

• The concept of Refrigerant Management Plans (RMP) is the response to that need.

The goal of the RMP will be to minimize refrigerant emissions throughout their life-cycle (production, use in systems, recovery at the end of system life, and final destruction)

Objectives of Refrigeration Management Program (RMP)

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• reduce emissions of high-GWP GHG refrigerants from leaky stationary, non-residential refrigeration equipment

• reduce emissions from the installation and servicing of refrigeration and air-conditioning appliances using high-GWP refrigerants

• the strategy of the regulation includes: – registration; refrigerant leak detection and monitoring; leak repair;

reporting and recordkeeping; system retrofit or retirement planning; required service practices; and refrigerant distributor, wholesaler, and reclaimer prohibitions, recordkeeping, and reporting.

Refrigerant management program is designed to:

• Regulations and trade controls

• Economic incentives and disincentives

• Training programme on good practices in refrigeration for service technicians

• Training programme for customs officers on control and monitoring of ODS

• Establishing recovery & recycling programme for CFC refrigerants

• Public awareness

• Strengthening of the institutional framework

• Suitable policy and regulatory support framework

• Improved system for collection of data and control and monitoring of ODS consumption

The successful implementation of RMPs requires the coordination of activities:

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• Policies and Regulations

• Licensing Systems

• Stakeholder Involvement

• Code of Good Practice

• Public Awareness

• Refrigeration Training

• Customs Training

• Recovery and Recycling Program

• Data Collection and Reporting

• Monitoring

• End-user conversion

RMP Elements

• Local training institutes

• Industry associations

• Importers and wholesalers

• Non-governmental organizations

• The civil society

Consultation and co-ordination with stakeholders and organization of stakeholder meetings as necessary


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Anyone servicing Anyone maintaining Anyone repairing Anyone disposing Refrigerant reclaimers Technician certifying programs Appliance owners & operators

Manufacturers

Equipment testing organizations

Selling or purchasing Class I or II

What Types of Facilities Should Consider Implementing Refrigerant Best Management Practices?

Facilities with refrigeration and air-conditioning systems using Chlorofluorocarbon (CFC), Hydrofluorocarbon (HFC), or Hydrochlorofluorocarbon (HCFC) refrigerant including:

Supermarkets Convenience stores Food processing and wholesale Refrigerated warehouses Pharmacies Hospitals Manufacturing Office buildings Institutions

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1. Establish a baseline inventory for equipment: What refrigerant type is contained in the air conditioning and refrigeration systems at your facility? Is it a CFC, HCFC, or HFC refrigerant? How much is in each system or independent circuit? An important factor to take into consideration is the system condition. This will have an impact on system retrofits or retirement plans for systems once leaks develop.

2. Establish a baseline inventory for refrigerants: Weigh each refrigerant cylinder and drum to the ounce. Classify them by condition – new, recovered, recycled, reclaimed, contaminated, fractionated, mixed, etc.

Fundamental components of a refrigerant management program

3. Standardize a method for documentation of refrigerant-related events:– New installations– Service and repair of leaks– Addition and recovery of refrigerants– Disposal of systems, refrigerants and related wastes/oils– Contractor and in-house technician certification verification

4. Develop and implement a record keeping and reporting tool: Paper method or electronic? Spreadsheet or software? Standalone or Web-enabled?

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5. Institute refrigerant management guidelines for your organization to include:

– Policy statements for your facility and specific operations

– Chain-of-command and assigned compliance responsibilities for all affected personnel – management, technicians, contractors

– Specific work instructions and processes to aid consistency

– Communication and training of all affected personnel

– Self-audit checklists and third-party assessments

– Records routing, review and retention instructions

Objective: The training programmes on good practices in refrigeration aim to reduce the emissions of ozone depleting refrigerants during

– servicing, – maintenance, – installation, commissioning or – decommissioning of R &AC systems.

• Service technicians: A training programme for service technicians is a key element to achieve a reduction of the ODS consumption due to poor servicing and maintenance practices of ODS-containing equipment, without major capital investment.

• Servicing professionals: Training on good practices in refrigeration provides servicing professionals with the skills to reduce the emissions of ODS. Skills includes: – recovery & recycling of ozone-depleting refrigerants– retrofitting to alternative refrigerants and – the introduction of new technologies.

Good Practices in Refrigeration

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• Gathering data/information on the equipment in your facility

- take an inventory of your equipment, the inventory list should include:

• make and model of all equipment• equipment age (if known)• location of equipment • refrigerant charge• capacity • service history

First step in refrigerant management planning

Example

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Example

• Check Monthly for Refrigerant Leaks–Display Cases–Walk-Ins–Roof Condensers–Compressor Room–Pits, Risers & Remote Manifolds

• Record and Track Receiver Levels

• Identify and Correct Potential Leaks–Vibration–Condenser Fan Blades –Metal-to-Metal Rub Points

• Keep Compressor Room & Racks Clean

• Leak deduction, Refrigerant tracking, PM program, Training

Preventative MaintenanceProgram

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• Conduct leak inspections, i.e., monthly, quarterly, or annually based on the refrigeration system's full charge capacity, unless automatic leak detection devices are installed

• Repair any refrigerant leak within 14 days of initial leak detection

• Keep on site records of all leak inspections, leak repair work and other servicing of the refrigeration system, including receipts of refrigerant purchases

• Submit an Annual Report , when required.

• Rule also requirements for any person who installs, repairs, maintains, services, relocates, or disposes of any refrigeration system, and for any person who recycles, recovers, reclaims, distributes or sells high GWP refrigerants

Owner / operator is required to

Equipment owners are mostly unaware of the HCFC phase-out and its implications. The lifecycle of HCFC R&AC equipment varies from 10 -30 years depending on the type of equipment.

Typical life span Residential air conditioning - 10 and 15 yearsSupermarket refrigeration equipment - 15 years Large air conditioning units (chillers) - 30 years

Equipment owners need to start considering the potential impact of the HCFC phase-out when considering new equipment and retrofits of existing equipment with their service contractor or equipment specifier.

Equipment Owners (including Homeowners)

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Contractors and equipment specifiers need to fully understand issues surrounding the HCFC phase-out schedule and ensure these issues are explained to their customers when equipment decisions concerning HCFC equipment are being made.

Contractors and Equipment Specifiers

• To service contractor customer needs, wholesaler staff should be aware of and understand the HCFC phase-out schedule, current alternatives and options for replacement of HCFC refrigerants and equipment, and keep up-to-date on the changing situation concerning HCFC alternatives.

• This information should be available both verbally from sales and counter staff, and through communications pieces (brochures, posters, etc.) available at wholesaler counters

Wholesalers

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• A refrigerant management plan includes:– Repair equipment leaks– Retrofit your equipment to alternative refrigerants – Replace older equipment– Recover and reclaim used refrigerant

• Refrigerant management planning is the responsible thing for equipment owners to do.


Retrofit Best Practice Guidelines

Global warming potential & ozone depleting potential

Lubricant

Glide

Standard Performance Capacity & Efficiency

Mass Flow

Evaporator pressure & temperature

Degree of Subcooling at TXV Inlet

Superheat at Evaporator Outlet

Compressor Isentropic & Volumetric Efficiency

Compressor Suction Gas Temperature

Condenser Temperature

Discharge temperature without demand cooling

Added Subcooling Capacity & Efficiency

Performance Data on Retrofit Refrigerants vs. R-22

Range of Retrofit Options New Refrigerant Retrofit Retrofitting with New Mechanicals and New Refrigerant Leak Tightness Improvements during Retrofits

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• Always be thoroughly familiar with surroundings.

• Wear personal protection equipment (PPE) including safety glasses, gloves, and protective clothing.

• Recovered refrigerant may be acidic. BE CAREFUL.

• Do not inhale refrigerant vapors.


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• When possible, work in well-ventilated areas.

• Refrigerant containers should never be filled to more than 80% capacity.

• Always secure cylinders before transporting.

• Properly label all refrigerant cylinders.

• Store tanks in a cool, dry place.

• Always maintain equipment and tools including recovery equipment, gauges, hoses, and refrigerant cylinders.

• Dedicate hoses for use with specific refrigerants to reduce cross-contamination.

• Change oil and filters regularly on recovery equipment.

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What are the benefits of using Best Management Practices? – Save $ annually on refrigerant – Save energy – Help comply with the law

How do Best Management Practices save money?

Examples of savings from reaching a 10% annual leak rate with best management practices include:

– A store with four refrigeration systems with a total charge of 1,000 pounds of refrigerant that leaked 30% per year could save $2,200 on refrigerant.

HCFC PROGRAM

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In 2007, the Parties to the Montreal Protocol agreed to accelerate the phase-out of HCFCs (initially targeted for 2040) largely because of the substantive climate benefits this would bring about. Parties operating under the Montreal Protocol’s Article 5(1) (mostly developing countries) may receive financial assistance from the Multilateral Fund for the implementation of the Montreal Protocol (MLF) to formulate their overarching strategy and prepare HCFC Phase-out Management Plans (HPMPs).

The control steps under the adjusted Montreal Protocol for these parties are:i) “freeze” of HCFC production and consumption by 2013 (the baseline being the average of

2009 and 2010); ii) reduction of 10% by 1 January 2015;iii) 35% reduction by 2020;iv) 67.5% reduction in 2025; v) 97.5 reduction by 2030; and vi) 100% phase-out by 2040.

HCFC Phase-out Management Plans (HPMPs)

Chemicals controlled by the Montreal Protocol

• Protocol requires the control of nearly 100 chemicals

• CFCs: The most commonly used of the chemicals controlled by the Protocol were chlorofluorocarbons. These chemicals were widely used in a large variety of activities and products including refrigeration, foams and metals cleaning. By 2010, CFCs have been virtually phased out worldwide

• HCFCs. HCFCs constitute the largest group of chemicals and represent the largest remaining use of ozone depleting substances. These chemicals have, since 1990,been viewed as transitional substances and needed to be phased-out. the Parties originally agreed to an extended phase-out period with a total phase-out in developed countries by 2030 and a final phase-out in developing countries by 2040. However, the Parties agreed in 2007 to adjust the Protocol’s HCFC control schedule to achieve a faster phase-out.

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Refrigerant Name Equipment Use

HCFC‐22 (R‐22)•Residential air conditioning (central and window)•Commercial rooftop air conditioning, residential and commercial heat pumps•Large air conditioning equipment (chillers)•Commercial refrigeration equipment for supermarkets, food storage, beverage coolers, etc.

HCFC‐123 (R‐123) •Large air conditioning equipment (chillers)

HCFC Blends (R‐401 A and B, 402A and B, 405A, 406A, 408A, 409A, 411 A and B, 414 A and B and 416A)

•Commercial refrigeration equipment (e.g. supermarkets, food processing, storage and distribution)•Beverage and large commercial coolers•Ice machines•Ice rinks

HCFC – Types and Usage

Comparing ODP and GWP

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UNDP is supporting 30 developing countries for their HCFC Phase-Out Management Plans (HPMPs). Combined, these countries represent 77% of the global consumption of HCFCs.

• Institution Capacity Development• Assessment and Demonstration of HCFC Alternative Technologies• Technical Assistance and Technology Transfer• Maximizing Climate Benefits in the Refrigeration and Air Conditioning• Policy and Regulatory Interventions• Increased Access to Funding

UNDP’s country assistance contains the following main elements:

Taking Early Action

Developing countries are close to a very important step in the new accelerated HCFC phase-out; the 2013 freeze. Taking early action that would facilitate compliance, specifically the establishment of policies and legislation, is therefore critical to a successful and smooth phase down – as illustrated below.

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• Canada

• Philippines

• India

• Indonesia

Country Specific Responses

Jan. 1, 1996: Baseline annual allowable amount of HCFCs based on Montreal Protocol

Jan. 1, 2004: Annual allowable amount of HCFCs reduced by 35%


Jan. 1, 2010: No new R‐22 equipment manufactured or imported


Jan. 1, 2020: Annual allowable amount of HCFCs reduced by 99.5% except HCFC‐123, which can be imported or manufactured until 2030 to service large air conditioning units (chillers) under the remaining .5% allowance. No new HCFC equipment to be manufactured or imported

Jan. 1, 2030: HCFCs no longer permitted to be imported or manufactured

HCFC Phase-out Schedule for Canada

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Philippines to cut imports of ozone-depleting substances by 2013

• The import ban on HCFC is part of the country's compliance to the Montreal Protocol on Substances that Deplete the Ozone Layer, to which the Philippines is a signatory in 1986 .

• The ban will initially cover the foam sector, particularly the polyurethane rigid foam in appliances, panels, and sprays.

Philippines secure Montreal Protocol’s assistance in the phase out of HCFC in the Foam Sector

• The Foam Sector Plan is an ongoing Philippines HCFC Phase-out Management Plan (HPMP).

• HCFC-141b is used in the Philippines in the solvent sector, foam sector and other sectors

• Under the Philippines HPMP, the project Foam Sector Plan aims to phase out HCFC-141b used will be phased out by the end of 2012.

• The present HCFC-141b technology utilized for the production of flexible foams will be converted to water technology which is not only ozone-friendly have a very low Global Warming Potential.

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HCFC Phase out Management Plan of India

The 19th MOP took a decision to accelerate the phase‐out of HCFC production and consumption for developed and developing countries. The new phase‐out schedule for Article 5 parties as per the decision taken at the 19th MOP is as follows:Base‐level for production & consumption :the average of 2009 and 2010Freeze= 2013 at the base‐level10% reduction in 201535% reduction in 202067.5% reduction in 2025100% reduction in 2030

OZONE CELLMINISTRY OF ENVIRONMENT & FORESTS

Government of India

Alternative Technologies

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Indonesia’s Plan to Phase-Out HCFC

Why HCFC?

• Indonesia as a country that ratified the Montreal Protocol supports the decision of the international community to accelerate the elimination of HCFCs

• HCFCs still have the potentials to cause Ozone Layer Depletion and Global Warming

Accelerated HCFC Phase-Out Scenario

For Article 5 Countries (Developing Countries)

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Indonesia’s HCFC Phase-OutSchedule

• Baseline determination: 402.2 ODP tons (average of 2009-2010 consumption)

• Freeze at baseline level in 2013

• 10% reduction in 2015

• 35% reduction in 2020

• 67.5% reduction in 2025

• 97.5% reduction in 2030

Strategy to Reduce Consumption in Indonesia

• Control of HCFC import quota to prevent the growth of consumption of HCFCs which would complicate the achievement to freeze in 2013 and decreased by 10% in 2015.

• Development of the regulations governing the import of HCFCs and HCFC use in new products.

• Giving Incentive and Disincentive

• Increased capacity of all stakeholders (industry, government and public)

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Provincial Governments’ Roles

Provincial governments play key role in:

• Supporting Central Government’s efforts to accelerate the elimination of HCFCs, particularly in providing assistance and supervision to industries in the use of HCFCs.

• Management of other types of ODS that are still stored in the equipment as well as old stock are common challenges in the effort to control emissions of ODS into the atmosphere.

Criteria for Alternative Refrigerants

• Zero Ozone Depletion Potential (ODP)

• Low Global Warming Potential (GWP)

• High Energy Efficiency

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Alternative Refrigerants for HCFC

Sector ODS Alternative(s)

Air Conditioning HCFC‐22 HFC‐32, HFC‐245fa

Refrigeration HCFC‐123 HC, HFC‐32

Foam HCFC‐141b HC, HFC‐245fa

Note: HFC is not ODS but still classified as Greenhouse Gas (having high GWP)GHG according to Kyoto Protocol: CO2, CH4, N20, HFC, PFC, SF4

Currently Possible HCFC Alternatives

ODS Destruction in HolcimIndonesia

• Workshop (KLH & MOE Japan) to invite collaboration on ODS pilot facility in 2005.

• No ODS destruction facility at that moment in Indonesia/ South East Asia. No solution was available except to destruct overseas (e.g. Australia ) High insurance, destruction cost & transportation cost.

• To set up of dedicated ODS destruction facility in Indonesia (such as Argon Plasma Arch Technology) was not financially attractive high investment cost and uncertainty of business.

• Using Cement Kiln for ODS destruction facility have been widely used in Japan and this technology is also one of the recommended technology based on TEAP Report.

• Indonesia Environment Ministry, Japan Environment Ministry and PT Holcim Indonesia worked together to set up ODS destruction facility in Indonesia, using cement kiln technology.

ODS Destruction Facility Project Background

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UNEP / TEAP statement on cement kiln as ODS Destruction Facility

Existing cement kilns, when properly operated, can destroy most organic compounds including PCBs because the temperature in the burning zone is over 1500ºC and residence times are up to 10 seconds. The alkaline nature of the material being processed in the kiln neutralizes the acid gases formed by the destruction of CFC. In general, most cement kilns could tolerate the controlled addition of ODS, but this would have to be evaluated on a case-by-case basis.

Cement Kiln For CFC Destruction

• Cement Kiln is a destruction technology in which CFC gas decomposes completely in a few seconds at high temperatures, thus generating hydrochloric and hydrofluoric acids which we are then reacted with alkaline calcium and fixed to form non-toxic and harmless clinker material

• CFC thermal Destruction in cement kiln:– (1) CF2Cl2 + 2H2O 2HCl + 2HF + CO2

– (2) CaCO3 CaO + CO2

– (3) CaO + 2HCl CaCl2 + H2O– (4) CaO + 2HF CaF2 + H2O

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Project Milestones

• May 2006 : MOU sign between MOE Indonesia, MOE Japan and HolcimIndonesia

• Sept 2006 : Visit to Sumitomo Osaka Cement Japan for ODS Destruction Facility Benchmark

• Oct 2006 : Engineering work on facility• Feb 2007 : ODS facility completed, MOE Indonesia release trial permit.• April / July : Several emission test was conducted • Jun 2007 : Technical Expert visit from Sumitomo Osaka Cement • August 2007 : MOE Indonesia release permanent permit / Ministerial Decree for

ODS Destruction facility

ODS Destruction Process in the Cement Kiln

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ODS Destruction Operation at Holcim Indonesia

Feedings Station for CFC gases

Flow Meter in feeding system

ODS Destruction Facility at Holcim Indonesia

ODS Feedings Station Feedings Station for CFC Liquid in drum Feedings Station for CFC gases

Flow Meter, Shut Off Valve ODS Injection in Burner ODS Injection in Burner System‐Primary Air

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Flame in Cement Kiln

Flame Temperature > 2000 oC

Main Burner

Organic Waste will be completely destroyed

Air Emission during ODS destruction

Dioxin measurement

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The only one permitted ODS destruction Facility in Indonesia

Achievement of Indonesian Republic

Ozone Depleting Substance destruction facility developed in partnership with the MoE of Japan, KLH and Holcim Indonesia. This facility is a first of its kind in South East Asia using a safe and proven technology from Japan and approved by the Montreal Protocol. These gases (CFC, HCFC) do not only damage the Ozone layer but also have global warming potential higher compared to CO2.

The Facility has been operated well since May 2007 and also mentioned in Indonesia MDG (Millennium Development Goal) report 2007 as one of the country achievement.

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Indonesia Ozone Awards 2011

• Appreciation from Government (MoE) for participation in the HCFC phase-out program.

• Contribution to Ozone Layer protection

Thank you

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Documents

RAISE Train-the-Trainer Workshop Modules - English