Programa Brasileiro de Eliminao de HCFCs PBH

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Programa Brasileiro de Eliminação de HCFCs
PBH HPMP IN BRAZIL Componentes propostos para
implementação por GTZ-Proklima Components
proposed for implementation by GTZ-ProklimaFlávi
a Gabriela Oyo Franca,Proklima - Deutsche
Gesellschaft fuer Technische Zusammenarbeit Bras
ília, 05 de Maio de 2009
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OverviewGTZs MLF-Business Plan for Brazil -
Status
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HCFC s and CFCs consumption in A5 C to be phased
out in the refrigeration sector (GHG, ODP Impact
and Mass)
Consumption baseline, phase out by 2010
Projected HCFC Baseline
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Outlook Brazil HPMP HCFC RefrigerationServici
ng sectorBackground
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More than 12,000 T of HCFC 22 (53 of total
HCFC consumption) were used for Servicing in
2007 667 ODP T 21,8 Mio CO2T
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Challenges and obstacles
With 53 per cent per annum of all HCFCs
currently being used just for the service and
maintenance of existing plants, leakage is a real
cause of excessive emissions and has to be
addressed first. Therefore, both operator and
service providers will need to work closely
together to ensure low emission refrigerant
containment. Although, the operator is very
much responsible for the refrigeration equipment,
the majority of the work required to comply with
leak regimes will be carried out by a service and
maintenance contractor.
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Servicing Sector Needs

• The most important applications for HCFC in
  refrigeration
• and air conditioning (RAC)
• - Small room air conditioning equipment
• - Water chillers from 100 kW refrigeration
  capacity up to large centrifugal chillers
• - Commercial refrigeration equipment and smaller
  chillers for various purposes
• - Industrial refrigeration equipment
• Commercial refrigeration, such as small,
  plug-in units as well as systems installed on
  site in smaller shops as well as super- and
  hypermarkets
• Transport air conditioning equipment
  ships, refrigerated trucks, containers, railcars,
  trains,

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Strategic elements

• Increase servicing sector awareness
• Reducing demand for virgin HCFCs through
• Utilisation of best practices
• Hermetization of installations
• Reuse of HCFCs
• Drop-in, Retrofit, Replacement where
  environmentally sound
• Registration and certification of use and
  services
• Improve documentation and monitoring
• Advice on regulatory and legal framework
  standards norms

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Problems in replacing R22 in the servicing
sector

• Existing drop in and retrofit options are based
  on HFC blends with higher GWP
• Components of blends behave differently in leaks
  (demixing). Blends cannot be recycled, reused or
  reclaimed with existing technology
• Change of refrigerant mixture due to leakage
  leads to performance drops
• Blends are very expensive in comparison to R22
• Blends and their mixtures are hard to identify
• Recovery of HFC blends requires large storage
  facilities in the absence of professional
  industrial distillation/fractionizing).

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Main consumption and emissions - Use of HCFC 22
in the commercial sector
4 Major Supermarket Owners 80 HCFC 22 use in
supermarkets - Carrefour - Grupo Pão de Açúcar
(CmpreBem, Extra, Sendas) - Lojas Americanas -
Wal-Mart (Bompreço, Sam's Club)
According to DuPont there are more than 73,000
supermarkets in Brazil . Sector consumes (and
emits) an estimated 7,500 T R-22 in 2007
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Major replacements used for HCFC-22 and their
environmental impact
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Source ARI (Air-Conditioning and Refrigeration
Institute )
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Source ARI
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Source ARI
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Source ARI
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Relationship between GHG emissions and leak rate
and range of leakage in the commercial sector
Brazil (source UNDP)
EU
According to UNDP Brazilian Supermarkets leak
upto 100 of charge per year Energy emissions
calculated at 0,6 kgCO2/kwH (actual value 0,5 )
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New challenges and obstacles

• Modification of existing systems to improve
  tightness
• Design or re-design of existing or new
  refrigeration systems
• Installation practices
• Use of new tools
• Identification of HCFCs and of HCFC replacements
  in form of HFC mixtures in various forms.
• Safety matters using natural refrigerants as
  direct HCFC replacement
• Best practices for low emission service,
  maintenance, containment of HCFC and
  alternatives

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Example Elements for control of refrigerant
emissions in the commercial sector

• secure refrigerant containment,
• documented leak inspection regimes,
• record keeping,
• auditable refrigerant recovery,
• skills training and safe refrigerant handling
• certification of the service and maintenance
  company and its employees.

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Registration and Certification of servicing
enterprises

• Registered as carriers of hazardous waste
• Possess recognized certification competency to
  handle refrigerants
• Conform with all current legal requirements
• Operate auditable procedures for the proper
  control of refrigerants
• Use purpose designed refrigerant recovery
  equipment
• Can account for all refrigerant used and
  recovered
• Are environmentally aware and perform refrigerant
  transactions with minimum emissions .

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ConclusionReduce HCFC demand in the servicing
sector step by step

• Start with training and certification in best
  practice and leak safe containment
• Establish necessary framework for registration,
  certification and regulatory control
• Investigate pilot activities for drop in,
  retrofit and replacement
• Adapt extension based on these experiences and
  provide advise for investors

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Outlook Brazil HPMP Overall Arching
StrategyComponents and Activities
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Key Aspects in the preparation of an overarching
strategy

• Assess Need and develop educational and training
  concepts and contents for the servicing sector
  for HCFC conserving practices during
  installation, maintenance, RR
• containment, transport and operation (best
  practice).
• - Identification of strategic partnerships for
  technician training and awareness building,
  targeting independent and company employed
  service mechanics.
• - Study and develop capacity building activities
  for facility management, business guidance and
  roll out strategies for better cold chain
  management throughout the commercial sector, look
  into possibilities for end user incentives

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• - Identify technical options and demonstrate
  alternatives and retrofit activities and best
  practice among stakeholders in the commercial and
  industrial sector Establish capacities and supply
  structures for drop in and retrofit technologies
  and methods
• Study needs to enhance and facilitate sector
  cooperation among stakeholders in order to
  implement certification, quality assurance and
  regulatory processes
• - Develop strategies to realize cost effective
  cross sectoral benefits such as energy efficiency
  gains and the application of related financial or
  trade mechanisms.

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Partners and Outreach

• Continue to include nationally leading
  institutions
• Vocational training
• SME promotion
• Association
• Industry
• Certification/ Quality assurance provider
• others
• Apply decentral approach
• Use mobile training units and on-site/inhouse
  opportunities
• Adapt to business clusters

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• Materials to be developed
• Posters Safety, Recovery, Gases, Leakage Testing
• Handbook on Best Practice emphasizing on
  commercial equipment (Abrava, Senai)
• Handout on Safety issues
• Amend RR handouts available in Brazil
• Develop label for certified servicing

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Kit Didático
O Kit didático é patrimônio do SENAI Departamento
Nacional.
É construído em MDF, revestido com laminado
plástico, perfis de alumínio, rodízios, bancada
de trabalho e equipamentos.
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OutlookHPMP HCFC 142b useSector Background
Strategy Preparation
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Example XPS Production

• XPS is produced by means of extruder in single
  (small output) or Tandem configuration, whereby
• A primary extruder provides the mixing of the
  GPPS with the BLA (single or twin screw)
• A secondary extruder cools down the melt before
  release through the Die (single screw)

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Preparational Activities

• - Inventories of existing enterprises, their
  production lines and practices in 142b
  consumption.
• - Development of educational activities in the
  XPS Sector for using Non-HCFC blowing agents.
• - Development of concepts for retrofit and
  replacement of HCFC using foaming equipment at
  various level use.
• - Demonstrate possible new formulations on
  Non-HCFC blowing agents and prioritizing the use
  of low GWP blowing agents.
• Establish national expert network and capacities
  for retrofit and available technologies and
  methods.
• - Further enhance sector cooperation among
  stakeholders for standardization and regulatory
  processes.

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XPS (blowing agents)

• For the production of XPS a blowing agent is
  required in order to produce a polystyrene foam
  with typical density range 30-35 kg/m3 or
  vacuum technology is used (high investment)
• During the foaming process often gt 90 of the
  blowing agent is emitted into the environment
  lost!

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XPS (blowing agents)

• Typical blowing agents used are
• Common used Art.5 Used in Europe/US
• (HCFC banned since 2002 HFC 2010 ?)
• HCFCs
• HCFC 22
• HCFC 142 b
• HCFC 22/142 b
• HFCs
• HFC 134 a

• HFCs
• HFC 134 a / 152a blends
• HFC 152a aceton
• HCs (flammable)
• Isobutane
• GPL (mixture of isobutenePropaneisobutene)
• CO2
• CO2 organic solvents e.g. ethanol, DME
• 100 CO2 (Patented)
• Other
• Vacuum technology (Patented)
• HBA-1 (still experimental)

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Choice of a blowing agent

• The choice of a blowing agent is a question of
  costs and GWP
• Changes to the nucleant and process aids can be
  applicable as well as GPPS grade but the impact
  is far less as they compose the final product
• HCFC will be phased out but there is direct
  alternative
• HFCs are expensive and when converting existing
  equipment investments are required
• CO2 is the cheapest and most environmental
  friendly alternative but higher equipement
  investments are needed
• Based on a 500 kg/hr machine the following table
  shows the blowing agent consumption per year

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Input required for Trade-off

• Description of the machinery used for
  consideration of changes required
• Production data, total production and split
  according to panel thickness
• BL used at the moment , according to thicknes
  and costs per kg
• Formulation
• Factory layout
• Costs on the local market of the different
  blowing agents

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Remarks

• Machinery life time is often 10 years or more but
  raw material costs are a direct cost borne every
  day.
• Keep in mind that the phase out of GWP substances
  goes faster then anyone expected so chosing HFC
  could mean an additional conversion shortly.

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Obrigada por sua Atenção Thank you for your
attention
GTZ-Proklima Dag-Hammarskjöld-Weg 1-5 P.O.Box
5180 65760 Eschborn, Germany Tel
49-6196-791968 Fax[phone] Email
proklima_at_gtz.de http//www.gtz.de/proklima