Novel HFO Refrigerant Blend R-474A for GWP <1

Automotive Heatpump Application

(266)
Ivan Rydkin, Tsubasa Nakaue, Alvaro Leon

[email protected]

15-18 May 2023, Chicago, Illinois 1

Introduction
• Electric cars are expected to represent 30% to 50+% of new car sales by 2030 in the US, China and Japan
• Wide adoption increases vehicle demands across all climate zones.
• Lack of “Free” engine heat currently requires vehicles to utilize electric resistive heaters (COP 1)
• Winter range decrease of 25+% is observed
• Fast charging increases heating and cooling load on the vehicle

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Introduction
Development Needs:
• GWP
• EPA SNAP & EU MAC Directive requires GWP <150
• Phasedown modeling and demand in other refrigerant consuming markets indicates a real maximum GWP of
<80 and preferred GWP of <1 for any future refrigerant
• Operation temperature
• -20°F (-29°C) at full capacity and COP >1.5
• -30°F (-34°C) for operation and COP >1
• Safety
• A2L for ‘drop-in’ for existing direct expansion systems
• A2 + risk assessment + cabin concentration limit for direct expansion per SNAP
• A2/A3 + Risk Assessment for secondary loop
• Operation Pressure
• Similar range (+/- 20%) required to operate with existing approved component supply chain

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 Introduction
HFO-1132(E)
1,2-Difluoroethene
HFO-1132(E)
Temperature vs. Pressure
Molecular formula CHF=CHF 600.00
Molecular weight g/mol 64.0 R-744 R-1132(E)
500.00
Critical temperature ℃ 75.7 1)
Critical pressure MPa 5.17 1) 400.00
R-474A

Pressure (psig)
Boiling point (101.3kPa) ℃ -52.5 1)

300.00
Vapor pressure at 25 ℃ kPa 1,666 1) R-290
Vapor density at 25℃ kg/m3 56.4
200.00
Liquid density at 25℃ kg/m3 938 R-1234yf
Latent heat at 25℃ kJ/kg 213.7 100.00 R-134a
Lower flammability limit vol% 4.4
0.00
Burning velocity cm/s 30.2 -40 -30 -20 -10 0 10 20 30 40 50 60
GWP 0.0036 2) Temperature °C

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 Introduction
Performance Safety
Glide Condensing Evaporating Boiling Critical
Candidate GWP COP Capacity Disch. Temp. Safety LFL Burning Velocity
Eva/Cond Pressure Pressure Point Temp.
R1234yf=100 R1234yf=100 [K] [degC] [MPaA] [MPaA] [degC] [degC] ASHRAE Class [vol%] [cm/s]
R-474A* <1 99 140 3.6/5.0 80 2.29 0.52 -43 87 A2L 5.5 2.9
R-1234yf 1 100 100 0/0 70 1.64 0.37 -29 95 A2L 6.2 1.5
R-290 3 105 146 0/0 81 2.12 0.55 -42 97 A3 2.1 43
R-152a 124 114 110 0/0 96 1.50 0.31 -24 113 A2 4.8 23

Condition: Te=5[degC], Tc=60[degC], SH=5[K], SC=5[K], Comp Efficiency=70[%] * R-1132(E)/R-1234yf = 23/77% 

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Laboratory Tests

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 Compressor Calorimtery
Air Conditioning points Heat Pump points
Test condition R1234yf R-474A R744 Test condition R1234yf R-474A R744
Discharge pressure [MPaA] 1.5 2.0 10.5 Discharge pressure [MPaA] 1.5 2.0 10.5
Suction pressure [MPaA] 0.3 0.405 3.5 Suction pressure [MPaA] 0.2 0.27 0.264
to=-1.5°C / tc=56.0°C / 25K Superheat / 5K Subcooling to=-12.8°C / tc=56.0°C / 10K Superheat / 5K Subcooling

Specs and condition

Compressor - Brose
Displacement [cc] 34
Oil  - PAG
Super heat [K] 25
Sub cool [K] 10

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Compressor Calorimetry

Compressor RPM Compressor RPM

1500 3000 5000 7000 8500 1500 3000 5000 7000 8500
1234yf COP 1.75 2.12 2.14 2.05 1.91 1234yf COP 0.92 1.01 1.02 0.98
R474A COP 1.82 2.2 2.24 2.15 2.024 R474A COP 0.76 0.97 1.08 1.09 1.05
R134a COP 1.9 2.2 2.3 2.2 2.1 R134a COP 2.2 3.7 5.2 6.2
Cooling Point 1

Cooling Point 2
R744 COP 1.57 1.78 1.74 1.7 R744 COP 0.91 0.91 0.91

1234yf Capacity 1.19 2.54 4.45 6.23 7.41 1234yf Capacity 1.62 2.87 4.02 4.8
R474A Capacity 1.71 3.63 6.24 8.72 10.41 R474A Capacity 1.35 2.39 4.17 5.86 7.03
R134a Capacity 1.39 2.96 5.10 7.15 8.53 R134a Capacity 2.15 3.73 5.21 6.22
R744 Capacity 0.00 2.57 4.76 6.88 8.49 R744 Capacity 3.01 4.41 5.52

Compressor RPM Compressor RPM

1500 3000 5000 7000 8500 1500 3000 5000 7000 8500
1234yf COP 1.02 0.97 0.92 1234yf COP 0.57 0.55 0.52
R474A COP 1.14 1.1 1.05 R474A COP 0.67 0.66 0.637
Heating Point 1

Heating Point 2
R744 COP 1.2 1.2 1.2 R744 COP 1 0.98 0.97

1234yf Capacity 1.85 2.57 3.03 1234yf Capacity 1.07 1.55 1.83
R474A Capacity 2.57 3.58 4.28 R474A Capacity 1.72 2.42 2.88
R744 Capacity 3.42 4.91 6.13 R744 Capacity 2.64 3.82 4.76

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Bench Test

R1234yf system R744 system

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Bench Test

Charge Determination R-474A vs. R-1234yf

30

25

20
Subcooling (K)

15 R-474A
R-1234yf

10

0
300 350 400 450 500 550 600 650 700

Refrigerant Charge (g)

Optimal charge for R474A at drop-in is around 91% of R1234yf for this system

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Bench Test

Evaporator Coolant
Test Condenser Air Condenser Air Evaporator Air Evaporator Air Mass Chiller Inlet Flow Rate Air Temperature Coolant
Temp (°C) Flow (m/s) Temp (°C) Humidity (%) Temperature (°C) Target (°C) ΔT (K)
Flow (kg/h) (l/min)

I60 60 1.5 35 25 300 40 10 3 10

I45 45 1.5 35 25 300 40 10 3 10
M45 45 3 35 25 300 40 10 3 10
H45a 45 4 35 25 300 40 10 3 10
I50a 50 1.5 35 40 300 30 6.7 3 10
I35a 35 1.5 35 40 300 30 6.7 3 10
L35a 35 2 35 40 300 30 6.7 3 10
H35a 35 4 35 40 300 30 6.7 3 10
I40a 40 1.5 25 80 210 25 2.0 3 5
I25a 25 1.5 25 80 210 25 2.0 3 5
H25a 25 4 25 80 210 25 2.0 3 5
I40c 40 1.5 25 50 210 25 2.0 3 5
I25c 25 1.5 25 50 210 25 2 3 5
I30 30 1.5 15 80 210 Off Off 3 Off
I15 15 1.5 15 80 210 Off Off 3 Off

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 Inside temperature and humidity : 35°C and 40 RH%

Results – Max Capacity

Air mass flow : 300 kg/h
Air temp. after evap. : 3°C
Coolant inlet : 30°C
Coolant flow rate : 6.7 L/min
Delta T coolant : 10 K

Comp. speed
= 7782[rpm]

Target temp
 Inside temperature and humidity : 35°C and 25 RH%

Results – Max Capacity

Air mass flow : 300 kg/h
Air temp. after evap. : 3°C
Coolant inlet : 40°C
Coolant flow rate : 6.7 L/min
Delta T coolant : 10 K

Comp. speed
= 5505[rpm]

Target temp
 Results – Fixed Capacity
Inside temperature and humidity : 25°C and 80 RH%
Air mass flow : 210 kg/h
Air temp. after evap. : 3°C
Coolant flow rate : 2.0 L/min
Delta T coolant : 5 K

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 Results – Fixed Capacity
Inside temperature and humidity : 25°C and 50 RH%
Air mass flow : 210 kg/h
Air temp. after evap. : 3°C
Coolant flow rate : 2.0 L/min
Delta T coolant : 5 K

15-18 May 2023, Chicago, Illinois 15

Conclusion
•Based on the bench test results observed, R-474A is capable of extending the heating range of a traditional R-
1234yf heatpump system beyond 0°C to -10°C and with this trend extending likely a significant amount of heat
being available at -20°C. This indicates that a reduction in the quantity and use of PTC heaters Is possible as a
potential weight and cost savings.

•Additionally at mild cooling conditions when matching capacity, there is a significant improvement in COP,
indicating that for a typical automotive drive cycle, there is opportunity to reduce total HVAC energy
consumption and thus improve cruising range.

•Furthermore, charge determination experiment indicates that the total refrigerant charge for an R-474A
system when dropped into an existing commercial system can be as much as 10%.

•Lastly, the significant observed improvement in capacity is shown at many of the test points. This can be
utilized to either improve HVAC system noise vibration and harshness (NVH) characteristics by reducing RPM,
which is significantly more important in generally quieter electric vehicles, or to down size the compressor.

15-18 May 2023, Chicago, Illinois 16