DuPont Suva

REFRIGERANTS

Technical Information Author: Barbara H. Minor, DuPont Fluoroproducts

R410A and R407C Design and Performance A Literature Review

Abstract
In response to concerns about ozone depletion, refrigerant HCFC-22 is being phased-out under the Montreal Protocol. R410A and R407C have emerged as the leading HFC alternatives to replace HCFC-22 in many applications. R407C was designed to have similar pressure and operating performance to HCFC-22, and is therefore intended for use in new equipment without signicant design changes, or as a service refrigerant for existing equipment. R410A was designed to operate at higher pressure and to provide the opportunity for reduced equipment size and increased energy efciency and capacity. The purpose of this paper is to summarize industry experience using these refrigerants in air conditioning applications from both a design and performance standpoint to better understand issues and opportunities for using R410A and R407C.

Introduction
Hydrouorocarbon (HFC) compounds have been essential substitutes for ozone-depleting substances, an important factor in the on-schedule implementation of the Montreal Protocol. Two mixtures have been identied, extensively studied, and determined to be viable alternatives to HCFC22, the current predominant refrigerant in air conditioning applications. R-407C is a blend of HFC-32, HFC-125 and HFC-134a (23/25/52 wt%) and was specically designed to closely match HCFC-22 performance with minimal design changes. R410A is a blend of HFC-32 and HFC-125 (50/50 wt%) specically designed for new equipment which could take advantage of higher pressure and improved transport properties to increase energy efciency.

In this paper, a literature review has been undertaken to investigate and summarize performance data and design improvements that have been realized for R407C and R410A systems. Performance comparisons were primarily made versus HCFC-22 at equal capacity. Performance data includes both system testing and rigorous modeling work. The goal is to help designers and equipment speciers assess performance and to offer ideas to improve and optimize system designs. Though this paper will not present exhaustive detail of each test or design improvement, further information can be found in the references.

1.

R410A Design

R410A was designed to provide benet in energy efciency, capacity and system size by increasing system pressure and taking advantage of thermodynamic and transport properties. Since R410A is a 50/50 weight percent blend of HFC-32 and HFC-125, this near-azeotropic mixture is about 5060% higher pressure than R22. This blend offers several advantages which have been exploited to improve system designs lower viscosity, lower pressure drop, excellent heat transfer, and the opportunity to design smaller equipment due to higher pressure. Following are summaries of design improvements made with R410A. Design improvements in general focused on the compressor, heat exchangers and fan systems. Burns et al (1997) designed unitary R410A air conditioners in 7.014.0 kW capacity range. Several design changes were implemented for 13 SEER (Seasonal Energy Efciency Ratio) systems. To achieve standardization in manufacturing, the evaporator design was not changed from R22. However, due to the higher capacity and improved heat transfer of R410A, the condenser size was reduced 1750%. Because R410A was operating at higher pressure, noise level was expected to be higher, but actual measurements determined noise level to be about 2 dBa lower. This was attributed to lower compressor displacement volume and increased shell thickness. To achieve similar superheating and subcooling as R22, the R410A short tube orice diameter was reduced 13% for a 13 SEER unit. It was also noted that cyclic losses and sensible heat factors were very similar for R410A and R22.

Suzuki et al (1998) redesigned room air conditioners (ductfree splits) using R410A to achieve higher energy efciency than R22. The compressor was modied by redesigning the scroll structure and discharge, achieving 50% efciency improvement. A new inverter was developed with better dc voltage control. More detailed scroll design information is provided in a paper by Ukai, Ito and Toda (1998). The indoor heat exchanger had several modications including new external ns and improvements to the air blowing system which increased capacity about 15%. The outdoor unit was improved by decreasing the diameter of the heat exchangers from 9.52 mm to 8 mm. A new fan was developed with larger diameter blades as well as fewer blades to reduce fan power and pressure loss. The layout of the heat exchanger was improved by minimizing number of bends. Overall system COP for the R410A system achieved was 5% higher than R22. Zheng et al (1998) used a model to optimize R410A design at different SEER ratings and compared system cost with R22. By reducing heat exchanger size and increasing compressor efciency, equipment savings of $13/unit for 11 SEER to $50/unit for 14 SEER could be realized for a typical 3 ton a/c system. Furuhama et al (1999) described design changes made to residential duct-free split systems for R410A. First, the internal volume for a 2-cylinder rotary compressor was reduced by 30% and compressor dimensions optimized. Re-expansion loss was minimized by reducing the top clearance volume by 50%. Overall compressor efciency improved by 6% versus R22. Indoor heat exchanger size was also optimized for R410A and tube diameter was reduced 6.35 mm to 55.5 mm. Heat exchanger modication resulted in another 45% efciency improvement. Combined system efciency improvements of 56% were demonstrated versus R22. Keller (1999) discussed design changes and eld trials for R410A air-to-air heat pumps. Several modications were required to operate R410A at higher pressure and meet minimum burst pressure requirements. These included increased thickness of the compressor shell, accumulator, condenser tubing, reversing valve and lter drier. Also addressed was an issue of stratication of lubricant in the accumulator which could result in excessive lubricant entrapment. This can occur due to the miscibility and foaming characteristics of R410A with polyol ester lubricants versus R22 with mineral oil or alkyl benzene lubricants. The problem was solved with a destratication device designed to ensure good oil return.

Nonaka et al (2002) made several improvements to their R410A room air conditioner design to increase energy efciency. These include development of a gas injection cycle using a gas-liquid separator. This reduced the amount of vapor entering the evaporator thereby increasing enthalpy difference and also the amount of total refrigerant being circulated on the low side which reduced compressor work. Heat exchanger performance was also improved by redesigning internal spiral grooved tubes, including reducing external pressure loss by lowering n height. The scroll compressor design was modied to an asymmetrical scroll shape which allows compression to start earlier than conventional designs. Oil ow was also increased to improve sealability of the compression chamber. Indoor and outdoor fan designs and grills were also improved to optimize air ow. Over a two year period, R410A system COP was increased 5% while system weight was decreased 6%. Hattori et al (2002) described changes to commercial air conditioning systems in the range of 22 to 28 kW. Designing at 28 kW was more challenging due to higher R410A pressure, but the problem was solved with a twin inverter rotary compressor design. The two rotary compressors also weighed 50% less than an equivalent scroll compressor. Using two inverter driven compressors eliminated the on/off losses associated with xed speed compressors. To stabilize oil ow to the twin compressors, they were designed to operate at similar speeds to each other regardless of load. Other system improvements to fans, heat exchangers and blowers contributed to a net overall COP improvement of 3040% versus their R22 design, half of which was attributable to the compressor modications.

Bivens and Denison (1996) tested R410A versus R22 in two residential split 8.0 kW heat pumps. One heat pump was equipped with a reciprocating compressor, the other a scroll compressor both with 33% less displacement than the R22 compressor. Average energy efciency ratios for R410A were 14% higher for cooling and 23% lower for heating versus R22. Modeling was then used to investigate energy improvement potential by recircuiting the heat exchangers. It was found that recircuiting the evaporator from 4 to 3 circuits and the condenser from 5 to 3 circuits could increase energy efciency another 2%. Pande, Hwang and Rademacher (1996) tested a 7.0 kW split heat pump with a reciprocating compressor comparing R410A and R22 and determining SEER and HSPF (Heating Seasonal Performance Factor). Compressor displacement was adjusted to give comparable capacities, though in reality the resized compressors still demonstrated 46% higher capacity for R410A versus R22. Overall, R410A SEER was 2.6% higher than R22 and HSPF was 12% lower. Triebe et al (1999) evaluated R410A performance using a test rig with a variable speed reciprocating compressor to match R22 capacity. The heat source inlet temperature in the evaporator was varied from 0C to 15C. The heat sink was set at 28C. The evaporator was divided and instrumented in four sections. In testing, R410A required a compressor speed 38% lower than R22 due to its larger capacity. COP for R410A varied from 6.8% to 13.5% higher than R22 depending on test conditions. The lower compressor speed for R410A helped increase capacity due to reduced frictional losses. R410A also showed 17% higher heat transfer coefcient in the rst section of the evaporator and 12% higher in the second section. Chin and Spatz (1999) modeled a 12 kW split system air conditioner which incorporated improved heat transfer coefcients for R410A (+55% evaporating and +15% condensing). The number of heat transfer units (NTU) and effectiveness of the heat exchangers for R410A and R22 were calculated assuming cross-ow heat conguration. At the design condition of 35C ambient temperature, energy efciency of R410A was 2% higher than R22. At average operating condition of 28C, energy efciency was 5% higher.

2.

R410A Performance

Since R410A has about 50% higher capacity than R22, references were selected where the performance comparison was on an equal capacity basis to R22. References consistently show equivalent or better energy efciency of R410A systems versus R22 systems. Linton et al (1996) tested R410A in a 10.5 kW residential central heat pump using a scroll compressor versus R22 with a reciprocating compressor. Since the R410A compressor displacement was 66% of the reciprocating compressor, a correction factor was used to compare on an equal capacity basis. Over a range of conditions, the cooling COP of R410A was 17% higher than R22 and the heating COP 07% higher.

3.

R407C Design

4.

R407C Performance

Since R407C was specically designed to match R22 pressure characteristics and performance, there were fewer references citing design changes implemented for R407C. References primarily focused on use of brazed plate heat exchangers and other investigations of counter-ow circuitry to take advantage of R407C temperature glide. Chitti and Bivens (1998) evaluated brazed plate heat exchangers with R407C. Brazed plate designs facilitate implementation of counter-ow congurations. A 12.4 kW capacity industrial chiller with brazed plate heat exchangers and scroll compressor was evaluated under many test conditions. R407C had an average of 5.6% higher cooling capacity and 0.3% higher energy efciency compared with R22. Since R407C is not an azeotropic mixture, circulating composition was also evaluated, but did not change signicantly (25.1/25.9/49.0 wt% R32/R125/R134a versus nominal 23/25/52 wt%). Suzuki et al (1998) designed packaged central air conditioners with R407C. A new scroll compressor was developed with higher efciency and low noise by optimizing the variable turning mechanism radius of the turning scroll. The outdoor heat exchanger heat transfer area and the fan diameter were increased. For condensation, the air ow was directed opposite to the refrigerant to take advantage of R407C temperature glide. Performance tests indicated R407C energy efciency was 6% higher than R22 in cooling mode and equivalent in heating mode. Marques and Domanski (1998) used a computer model to evaluate the benet of using counter-ow heat exchangers to take advantage of R407C temperature glide and achieve glide matching. They studied several different counter-ow and cross counter-ow congurations for the condenser and evaporator. Counter-ow provided the most benet. The predicted COP improvement was 7.1% in cooling mode and 3.6% in heating mode versus R407C using cross-ow conguration. Bailly and Jurkowski (1999) studied chillers tted with brazed plate heat exchangers versus tubular heat exchangers. The system used R407C and a polyol ester oil. The cooling capacity was 710% higher with brazed plate heat exchangers, the rejected heat from the condenser was up to 5% higher and the power consumption was 7% lower. Overall, the energy efciency (EER) was up to 16% higher than R407C using a tubular design.

R407C was designed to match as closely as possible R22 pressure and performance to allow a smooth transition with minimal designed changes and retrots of existing equipment. References below show these parameters have been met with performance within about 5% of R22. Bivens and Denison (1996) tested R407C versus R22 in two residential split 8.0 kW heat pumps. One heat pump was equipped with a reciprocating compressor. The other heat pump used a scroll compressor and an accumulator. The energy efciency ratio during cooling and heating was 35% lower for R407C versus R22. A computer model was then used to investigate the impact of using counterow heat exchangers to take advantage of R407C temperature glide. Improvements of 57% in energy efciency were predicted. Using a liquid-suction heat exchanger (LSHX) could provide an additional 2% improvement. Linton et al (1996) tested R407C in a 10.5 kW residential central heat pump using a reciprocating compressor. To approximate cross counter-ow, the evaporator was inverted. The relative cooling capacity and COP in the original evaporator conguration ranged from 46% lower than R22. When the evaporator was inverted, the cooling capacity was 4% lower to 1% higher and the COP was 14% lower than R22. However, inverting the evaporator resulted in a heating performance penalty of 38% capacity and 79% efciency. Biancardi et al (1997) evaluated effect of fractionation of R407C in an 8.6 kW heat pump with a scroll compressor. During the tests, 25% of the refrigerant charge was leaked then relled, repeating three times. A total of two cooling mode and four heating mode tests were conducted. System leaks were performed when the heat pump was operating and also when idle. Results showed the circulating refrigerant composition stayed close to the initial composition in each test. The worst case composition change occurred during vapor side leaks when the system was idle, but the impact on capacity and energy efciency was determined to be small. Wei, Lin and Wang (1997) conducted a drop-in test of R407C in a 3.5 kW duct-free split air conditioner. The unit was equipped with a rotary compressor and capillary tube. It was tested at standard, overload and low temperature conditions. Overall the cooling capacity was 3% lower for R407C versus R22 and the COP 4% lower.

Vaisman (1998) conducted a computational comparison using a model equipped with condenser and evaporator units and a rotary compressor. At 95F ambient, R407C cooling capacity was 3.8% higher and COP 1.6% lower. At 104F, capacity was 2.8% higher and COP 10.7% lower. Triebe et al (1999) evaluated R407C performance using a test rig with a variable speed reciprocating compressor to match R22 capacity. The heat source inlet temperature in the evaporator was varied from 0C to 15C. The heat sink was set at 28C. The evaporator was divided and instrumented in four sections. In testing, R407C required a compressor speed 17% greater than R22. COP for R407C varied from 3.8% to 6.8% lower than R22 depending on test conditions. In the rst evaporator section, heat transfer coefcients were similar for R407C and R22. In the second section, R407C was 7% lower and 6% lower in the third section. Gopalnarayanan et al (2000) conducted R407C drop-in tests using a 12.3 kW, 12 SEER R22 heat pump equipped with a reciprocating compressor and TXVs for both cooling and heating. The indoor heat exchanger was parallel cross ow in cooling mode and counter cross ow in heating mode. The outdoor unit was cross ow at all times. The only change during the drop-in test was to replace the mineral oil lubricant with polyol ester and refrigerant charge size optimization. The R407C charge was 6% lower than R22. Several conditions were measured to allow an SEER and HSPF (heating seasonal performance factor) value to be determined. R407C had equivalent cooling mode SEER compared with R22 and about 3% lower HSPF. Figure 1. LCCP Analysis Atlanta

Kim, Shin and Kim (2001) studied a residential window air conditioner with a rotary compressor and investigated the effect of using a liquid suction heat exchanger. In the baseline case, the cooling capacity of R407C was 15% lower than R22 and the energy efciency 5% lower. They attributed this to a lower average evaporating temperature and higher compression ratio. When a liquid suction heat exchanger was used, R22 energy efciency increased 2% and R407C increased 13%. Rakesh et al (2003) conducted an exergy analysis using a 0.5 kW heat pump water chiller test stand. A semi-hermitic reciprocating compressor designed for R22 was used. The exergy efciency of the refrigerant cycle was 46% lower for R407C than R22. The exergy efciency of the compressor was about 57% lower. They concluded new R407C heat pump chiller systems could be designed to achieve higher energy efciency than R22 provided the compressor was redesigned. In summary, R407C energy efciency and capacity in drop-in tests is on average 5% lower than R22. With design improvements such as counter-ow heat exchange, performance can be equivalent or better than R22. Impact of R407C fractionation has minimal impact on performance even after leaking and recharging several times.

5.

LCCP Analysis

Results of this literature review have been used to update an LCCP (Life Cycle Climate Performance) analysis by A. D. Little (2002). A baseline 12 SEER R22 air conditioning system in the Atlanta area was chosen to do this analysis. A. D. Little assumptions of a 2%/yr refrigerant leak rate, end-of-life loss of 15% and average electrical generation rate of 0.65 kg CO2 / kWh were used. However, A. D. Little assumed electrical consumption of R22, R407C, R410A and CO2 were equal. Brown, Kim and Domanski (2002) report energy efciency losses for CO2 in stationary could be 40% or more compared to R22. Therefore, energy use compared to R22 was adjusted for the analysis as follows: equivalent usage for R407C equipment, 2% less energy use for R410A, and a 40% increase in energy use for CO2. Results in Figure 1 show comparable LCCP for R22 versus R410A and R407C and signicant environmental benet for these HFC alternatives versus CO2 systems.

Conclusions
R410A and R407C have been extensively studied by the HVAC&R industry in many regions of the world and found to be effective and efcient alternatives to HCFC-22 in air conditioning and heating systems. Designers have been able to take advantage of excellent R410A performance characteristics to design high efciency systems which demonstrate reduced environmental impact. And R407C has proved to be a good match for current HCFC-22 designs which is facilitating the transition away from HCFCs.

Burns, L., Hoffmann, L., Schuster, D., 1997. R410A Experiences in Unitary Air Conditioner Systems, Refrigeration, Vol 72, No. 834, p. 369374. Chin, L., Spatz, M., 1999. Issues Relating to the Adoption of R410A in Air Conditioning Systems, Int. Cong. Of Refrigeration: Refrigeration into the Third Millennium, 20th, Sydney, Australia, Vol 2., Paper 179. Chitti, M. Bivens, D., 1998. Performance of R-407C and HCFC-22 in Chillers with Brazed Plate Heat Exchangers, Proc. of International Refrigeration Conference at Purdue, West Lafayette, p.1318. Furuhama, K., Motohashi, H., Hayano, S., Sano, T., 1999. Alternative Refrigerants in Air-Conditioners for Residential and Commercial Use, Proc. Of Sixth International Energy Agency Heat Pump Conference, Berlin. Gopalnarayanan, S., Blanc, J., Rolotti, G., 2000. Performance of R-407C as a Drop In Replacement for R-22 in Unitary Air Conditioners and Heat Pumps, Proceedings of CIBSE/ ASHRAE Joint Conference, Dublin. Hattori, H., Yamamoto, M., Ishizama, M., Yamashita, T., Chuma, Y., Ueno, K., 2002. Development of Retail Facility and Ofce Air Conditioners with R410A, Proceedings of The International Symposium on HCFC Alternative Refrigerants and Environmental Technology, Kobe, p. 510. Keller, F., 1999. R410A Heat Pump Design and Field Experiences in the North American Market, Proc. Of Sixth International Energy Agency Heat Pump Conference, Berlin. Kim, M., Shin, J., Kim, K., 2001. The Performance of R-407C and R410B in a Residential Window Air Conditioner with a Liquid-Suction Heat Exchanger, ASME International Mechanical Engineering Congress and Exposition, New York, Vol. 41, p. 173178.

Acknowledgements
I would like to acknowledge Don Bivens and Dave Bateman for their assistance compiling literature references for this review.

References
A. D. Little, 2002. Global Comparative Analysis of HFC Alternative Technologies for Refrigeration, Air Conditioning, Foam, solvent, Aerosol Propellant, and Fire Protection Applications, Final Report to the Alliance For Atmospheric Policy. Bailly, A., Jurkowski, R., 1999. Comparison of the Performances of a CIAT Chiller Operating with R 22 and R 407C Fitted with Exel Plate and Tubular CIAT Exchangers, Int. Cong. Of Refrigeration: Refrigeration into the Third Millennium, 20th, Sydney, Australia, Vol 3., Paper 603. Biancardi, F, Pandy, D., 1997. Modeling and Testing of Fractionation Effect with Refrigerant Blends in an Actual Residential Heat Pump System, ASHRAE Transactions, Vol. 103, PH-97-9-5. Bivens, D., Denison, G., 1996. Energy Efciency Potential of HCFC-22 Alternatives, Proceedings of International Energy Agency Heat Pump Conference, p. 303313. Brown, S., Kim Y., Domanski, P., 2002. Evaluation of Carbon Dioxide as R-22 Substitute for Residential Air Conditioning, ASHRAE Transactions, Vol.108 (2).

Linton, J., Snelson, W., Hearty, P, Triebe, A., 1996. Comparison of R-407Cand R-410A with R-22 in a 10.5 kW (3.0 TR) Residential Central Heat Pump, Proc. of International Refrigeration Conference at Purdue, West Lafayette, p.16. Marques, M., Domanski, P., 1998. Potential Coefcient of Performance Improvements Due to Glide Matching with R407C, Proc. of International Refrigeration Conference at Purdue, West Lafayette, p.101107. Nonaka, M., Koyama, M., Morimoto, M., Nakamura, H., Takada, Y., Sasaki, S., 2002. Development of Room Air Conditioner with R410A, Proceedings of The International Symposium on HCFC Alternative Refrigerants and Environmental Technology, Kobe, p. 1520. Pande, M., Hwang, Y., Judge, J., Rademacher, R., 1996. An Experimental Evaluation of Flammable and Nonammable High Pressure HFC Replacements for R-22, Proc. of International Refrigeration Conference at Purdue, West Lafayette, p.2126. Rakesh, B., Venkatarathnam, G., Srinivasa, S., 2003. Experimental Studies on a Heat Pump Operating With R22, R407C, and R407A: Comparison from an Exergy Point of View, Journal of Energy Resources Technology, Vol. 125 (2), p. 101112.

Suzuki, K., Isosumi, S., Ukai, T., Ozeki, S., Ito, T., 1998. Development of HCFC-22 Alternative Refrigerant Air Conditioners, Mitsubishi Juko Giho, V.35 (2), p. 8287. Triebe, A., Linton, J., Snelson, W., Hearty, P., 1999. Cooling Performance of R-407C and R-410A Compared to R-22 on a Constant Capacity Basis, Int. Cong. Of Refrigeration: Refrigeration into the Third Millennium, 20th, Sydney, Australia, Vol. 2., Paper 053. Ukai, T., Ito, T., Toda, T., 1998. Development of Scroll Compressor for Alternative Refrigerant in Room Air Conditioners, Mitsubishi Juko Giho, V.35 (2), p. 8891. Vaisman, I., 1998. Computational Comparison of R22 and R407C Air Conditioners with Rotary Vane Compressors, Proc. of International Refrigeration Conference at Purdue, West Lafayette, p.1924. Wei, C., Lin, S., Wang, C., 1997. System Performance of a Split-Type Unit Having R-22 and R-407C as Working Fluids, ASHRAE Transactions, Vol. 103 (1), p. 797802. Zheng, J., Hughes, M., Spatz, M., Zyhowski, G., 1998. Optimization Strategies for Unitary Air Conditioners Using R410A, Proc. of International Refrigeration Conference at Purdue, West Lafayette, p.6974.

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