1. THIRD ANNUAL CO3OL WORKSHOP
Session 3: Cold Chain
Understanding the cold chain:
equipment, common refrigerants and alternative technologies
presentation by Ray Gluckman
Washington DC
December 5th 2016
THIRD ANNUAL CO3OL WORKSHOP

2. Presentation Contents
sectors of the food chain
sector contributions to energy and refrigerant related greenhouse gas (GHG) emissions
types of refrigeration equipment used in different sectors
refrigerants and foam blowing agents
2nd, 3rd and 4th generation
in A5 and non-A5 countries
summary of the potential to reduce GHG emissions

3. over 35 years of experience in the refrigeration field
My Background
over 35 years of experience in the refrigeration field
two main specialisations:
energy efficiency
alternative refrigerants
numerous private sector food chain clients and projects
also many projects for public sector e.g:
UK Government, European Commission, UNEP, World bank

4. The 6 Food Chain Refrigeration Market Sectors
3. Storage
2. Processing
1. Agriculture
4. Retail
5. Food Service
6. Refrigerated Transport

5. Types of Refrigeration GHG Emission
Direct emissions
created by leakage of refrigerants that have a high global warming potential (GWP)
HCFCs and HFCs
GWPs 1000 to 4000 times higher than CO2
Indirect emissions
energy used to operate the refrigeration systems
almost all is CO2 from electricity generation

6. Food Chain GHG Emissions in Perspective
the following data is based on a detailed analysis of UK food chain refrigeration
carried out for UK Government in 2012
study entitled:
“Reducing Greenhouse Gas Emissions from Refrigeration in the Food Chain”
the data is representative of most geographic regions
it clearly shows the GHG emission “hot-spots”

7. Direct Emissions from refrigerants used

8. Indirect Emissions from energy used
Food service emissions more dominant – low leakage but large energy use
Transport also higher – due to use of less efficient “on-board” power generation

9. Total GHG Emissions (direct + indirect)

10. Direct emissions: split between HFCs and HCFCs

11. Total emissions: split between direct and indirect

12. Factors affecting choice of refrigerant
choice of refrigerant based on many factors
equipment requirements:
size; temperature level
equipment type:
sealed system; split system; chiller with secondary fluid
location:
public access; authorised access; special machinery room
energy efficiency
from 1987: impact on ozone depletion
more recently: impact on global warming

13. 4th Generation: 2015 onwards
4 Generations of Fluorocarbon Refrigerants (dates apply in non-A5 countries)
1st Generation: 1940 to 1990
CFCs were dominant
CFCs developed in the 1930s
Well suited to RAC
Non-toxic, non-flammable, very high GWP
2nd Generation: 1990 to 2005
HCFC use grew
Much lower ODP than CFCs
Interim use in some CFC applications
Non-toxic, non-flammable, high GWP
3rd Generation: 1995 to 2020
HFCs become dominant
Zero ODP: good solution to ozone issue
Non-toxic, non-flammable
High / very high GWP
4th Generation: 2015 onwards
HFOs introduced
Zero ODP and ultra-low GWP
Used as pure fluids or in blends with HFCs
Most have “lower flammability”

14. Timeline for non-fluorocarbon refrigerants
Ammonia
1st Generation: 1940 to 1990
CFCs were dominant
2nd Generation: 1990 to 2005
HCFC use grew
3rd Generation: 1995 to 2020
HFCs become dominant
4th Generation: 2015 onwards
HFOs introduced
Hydrocarbons
CO2

15. Currently used / future refrigerants in new equipment
the 6 food chain market sectors are not homogeneous groups, in terms of equipment types / refrigerant selection
the refrigerant choice depends on the market sub-sector
this has a major impact on options for low GWP alternatives to HFCs
currently used refrigerants in new equipment:
depend on ODS phase-out status
e.g. in whole of EU no new HCFC systems since 2000
hence HFCs are dominant in whole food chain
in A5 countries, widespread use of HCFCs, especially HCFC-22
future refrigerants in new equipment:
some already in widespread use, especially in Europe
some just reaching the market
note: refrigerant lists on following slides give examples
not intended to be an exhaustive list!

16. Food Retail Sealed integral Large centralised pack Condensing unit
Typical charge:
0.1 to 0.5 kg to 10 kg to 200 kg
Typical annual leakage rate:
<1% % to 20% % to 30%
Commonly used 2nd and 3rd generation refrigerants (GWP):
R-404A (3922), HFC-134a (1430), HCFC-22 (1810)

17. 4th generation and non-fluorocarbon options (GWP):
Food Retail
Sealed integral
Large centralised pack
Condensing unit
Typical charge:
0.1 to 0.5 kg to 10 kg to 200 kg
4th generation and non-fluorocarbon options (GWP):
R-290, propane (3)
R-744, CO2 (1)
HFO-1234yf (5)
R-448A, R-449A (1400)
R450A, R-513A (600)
? R-454C, R-455A (146)
? R-744, CO2 (1)
? HFO-1234yf (5)
R-744, CO2 (1) transcritical or cascade
R-290 (3) integrals, water cooled
R-448A, R-449A (1400)
? R-454C, R-455A (146)

18. Food Service Sealed integral Condensing unit Typical charge:
0.1 to 0.5 kg to 10 kg
Typical annual leakage rate:
<1% % to 20%
Commonly used 2nd and 3rd generation refrigerants (GWP):
HFC-134a (1430), HCFC-22 (1810), R-404A (3922)

19. 4th generation and non-fluorocarbon options (GWP):
Food Service
Sealed integral
Condensing unit
Typical charge:
0.1 to 0.5 kg to 10 kg
4th generation and non-fluorocarbon options (GWP):
R-290, propane (3)
R-744, CO2 (1)
HFO-1234yf (5)
R-448A, R-449A (1400)
R450A, R-513A (600)
? R-454C, R-455A (146)
? R-744, CO2 (1)
? HFO-1234yf (5)

20. Food and Drink Manufacture and Cold Stores
Large pumped system
Small / medium DX
Chiller + secondary fluid
Typical charge:
250 to 5000 kg to 100 kg to 2000 kg
Typical annual leakage rate:
4% to 8% % to 10% % to 5%
Commonly used 2nd and 3rd generation refrigerants (GWP):
Ammonia
HCFC-22
HFC-404A, HFC-134a
Ammonia, HFC-134a
HCFC-22, HCFC-123

21. Food and Drink Manufacture and Cold Stores
Large pumped system
Small / medium DX
Chiller + secondary fluid
Typical charge:
250 to 5000 kg to 100 kg to 2000 kg
4th generation and non-fluorocarbon options (GWP):
R-717, ammonia (0)
R-744, CO2 (1)
R-448A, R-449A (1400)
R450A, R-513A (600)
? R-454C, R-455A (146)
? R-744, CO2 (1)
R-717, ammonia (0)
HFO-1234ze (7)
HFO-1233zd (4)
R-514A (9)

22. Food Transport Road vehicles Intermodal containers Typical charge:
1 to 8 kg to 8 kg
Typical annual leakage rate:
8% to 20% % to 12%
Commonly used 2nd and 3rd generation refrigerants (GWP):
R-404A (3922), HFC-134a (1430), HCFC-22 (1810)

23. 4th generation and non-fluorocarbon options (GWP):
Food Transport
Road vehicles
Intermodal containers
Typical charge:
1 to 8 kg to 8 kg
4th generation and non-fluorocarbon options (GWP):
R-452A, (2140)
R-744, CO2 (1)
? R-454C, R-455A (146)

24. Flammability
1st to 3rd generation refrigerants: most are non-flammable
low GWP needs molecules with short atmospheric life
a less stable molecule – with some degree of flammability
refrigeration codes (e.g. ISO 5149) recognise “flammability spectrum”
flammability categories: 1, 2L, 2, 3
3: “higher flammability” e.g. propane
2L: “lower flammability” e.g. HFO-1234yf
very difficult to ignite; burn with very low flame velocity
ammonia is a 2L refrigerant
2L refrigerants likely to be widely used in the future
work needed on building codes / product standards to enable widespread use

25. Retrofitting Existing Refrigeration Equipment
some exisiting equipment well suited to retrofit
especially larger R-404A systems
e.g. large supermarket or medium sized industrial
must use a non-flammable refrigerant
flammable refrigerants should only be used in new equipment
“moderate” GWP options available for simple retrofits
can make significant and quick contribution to HFC phase-down
e.g. replacements for R-404A (GWP 3922)
R-407F (1825), R-407A (2107)
R-448A (1387), R-449A (1397), R449B (1412)

26. Use of Insulation Foam in Food Chain
retail displays, bottle coolers etc.
polyurethane (PU) foam providing case insulation
cold stores
steel faced PU foam panels for walls and roof
PU or extruded polystyrene (XPS) board for floors
trucks and containers
steel faced PU panels for vehicle body
pipes and pressure vessels
PU block foam

27. Options for foam blowing agents
PU foam blowing agents (GWP)
2nd generation: HCFC-141b (725)
3rd generation: HFC-245fa (1030), HFC-365mfc (794)
4th generation: HFO-1234ze (7)
non-fluorocarbon: pentane (5)
XPS foam blowing agents
2nd generation: HCFC-142b (2310), HCFC-22 (1810)
3rd generation: HFC-134a (1430), HFC-152a (124)
4th generation: HFO-1233zd (5), HFO1336mzz (9)
non-fluorocarbon: CO2

28. Overall potential to reduce food chain GHG emissions
excellent potential to reduce GHG emissions from food chain refrigeration systems
indirect (energy related) emissions (any refrigerant)
much greater potential than most energy using systems
existing equipment: 15% to 25%
new equipment: 30% to 50%
direct emissions (from HFC or HCFC based equipment)
existing equipment: up to 70% (leak reduction / retrofit)
new equipment: up to 100% (low GWP refrigerants)

29. Concluding Comments food chain has 6 main market sectors
important to also consider sub-sectors to select appropriate refrigerants
food retail and food service are dominant
around 65% of total GHG emissions
2 types of GHG emission (direct / indirect)
indirect energy related emissions represent around 70% of total
excellent potential to reduce direct impact
many low GWP refrigerants available and others being developed
also excellent potential to reduce energy use
switch to low GWP refrigerants must have equal or better efficiency!

30. Ray Gluckman Gluckman Consulting Tel: 01932 866344 Contact Details
Tel:
Information Sheets about EU F-Gas Regulation:
Fact Sheets about low GWP alternatives to HFCs: