Mobile Air-conditioning Actions for Global Warming Reduction
Toshio Hirata
DENSO CORPORATION
JICOP 「フロン対策の現状と展望」 1/34 虎ノ門パストラル 平成20年3月11日
JICOP 「フロン対策の現状と展望」 2/34 虎ノ門パストラル 平成20年3月11日
1. Mobile Air Conditioning and Global Warming2. Refrigerant Emission Reduction3. Energy Efficiency Improvement
JICOP 「フロン対策の現状と展望」 4/34 虎ノ門パストラル 平成20年3月11日
Compressor
CondenserExpansion Valve
MAC’s Refrigeration Cycle
cool air
Refrigeration Cycle
High press. & high temp. gas
Low press. & low temp. gas
Evaporator
JICOP 「フロン対策の現状と展望」 5/34 虎ノ門パストラル 平成20年3月11日
GHG Effects on Global Warming (Japan)
Methane1.5%
Dinitrogen Monoxide2.7%
PFC0.7%
SF60.4%
Total Amount of
CO2Emission in
20021,330.8
[Mt CO2eq.]
HFC1.0%
CO293.7%
Industry37.2%
Energy Conversion6.4%
Waste Disposal2.0%Limestone
Consumption4.2%
Transport22.0%
Others0.0%
Residential12.7%
Business Use 15.5%
Breakdown of CO2 Emissionby Sectors
JICOP 「フロン対策の現状と展望」 6/34 虎ノ門パストラル 平成20年3月11日
Influence of A/C on Fuel Consumption
A/C Off A/C on(yearly)
Fuel
Con
sum
ptio
n (k
m/L
)
5
10
15
25℃(50%RH)、No Solar Radiation
10Evaporator Outlet AirTemperature ( oC)
LowBlower Speed
FreshFresh / Recirculated Air
0Sun Load (W/m2)
50Humidity (%)
25Temperature ( oC)
Yearly
9 % Actual Running Mode: Compact Car LA4: Stop Ratio 17%
JICOP 「フロン対策の現状と展望」 7/34 虎ノ門パストラル 平成20年3月11日
Example of TEWI Calculation (JAMA)
0
500
1000
1500
2000
2500
3000Emission into atmosphere at scrapping(future level)
Leakage in use, leakage ataccident and repair
Contribution by air-conditioner weight
Contribution for driving alternator
Contribution for driving compressor
TEW
I(kgC
O2)
FF2L S/D
3500Emission into atmosphere at scrapping(present level)
Direct(refrigerant)
In-direct(compressor power)
JICOP 「フロン対策の現状と展望」 8/34 虎ノ門パストラル 平成20年3月11日
Refrigerant Emission Reduction(JAMA’s Action)
JAMA: Japan Automobile Manufactures Association
JICOP 「フロン対策の現状と展望」 9/34 虎ノ門パストラル 平成20年3月11日
Reduction of refrigerant emission from HFC-134a A/C1.Recommend to use small refrigerant charge components;
• Target is 20% reduction from 1995 to 2010.• In 2004, the average of charge has been reached to 21% of
1995’s charge (1995:700gram , 2004:553gram)2.Recovery and destruction of Refrigerant:
• Fluorocarbons Recovery and Destruction Law enforced from October, 2002.
• Reported recovery rate of scrapped vehicles is approx. 40%.• This law was incorporated into Automobile recycling law
from January, 2005.3.Recommend to use lower refrigerant leakage components;
• According to self-assessment of OEM, leakage in operation has been reduced from 15g/yr• Field survey test was done from 2004 to 2005 to seek actual value.
JAMA’s Action Plan
JICOP 「フロン対策の現状と展望」 10/34 虎ノ門パストラル 平成20年3月11日
Refrigerant Charge Reduction from 1995 to 2006
700
600
500
400
300
200
100
01995 1999
700650
2000 2001 2002 2003 2004
615 603588
553582
Ave
rage
cha
rge
(g)*
*Average refrigerant charge = Total charging amount at vehicle production
The number of produced vehicles
Reduced by 23%
2005 2006
548 536
JICOP 「フロン対策の現状と展望」 11/34 虎ノ門パストラル 平成20年3月11日
741,516(+12.8%)
657,2722,375,493(+16.2%)
2,045,135Total
496,971372,0891,500,8281,083,231HFC-134a
244,545285,183874,665961,904CFC-12
2006200520062005
Recovered amount (kg)Refrigerant recovered vehicle numbers
The Refrigerant Recovery Data when scrapping in Japan
JICOP 「フロン対策の現状と展望」 12/34 虎ノ門パストラル 平成20年3月11日
0
5
10
15
20
25
30
35
40
45
CFC-12 HFC-134a (1992) HFC-134a (2004)
Ref
riger
ant L
eaka
ge(g
ram
/yr)
Comp.
Hoses
Fittings
Others
Reduction in Refrigerant Leakage in Operation
JICOP 「フロン対策の現状と展望」 13/34 虎ノ門パストラル 平成20年3月11日
Refrigerant Leakage Field Test(From April, 2004 to December, 2005)
LocationTokyo, Nagoya (average temperature 16C)
Number of test vehicles78 vehicles (seven auto makers)
A/C systemSingle AC (16 type vehicles) Dual AC (6 type vehicles)
Charge amountSingle: Average: 516gram Max: 760gram Min:409gramDual: Average: 804gram Max: 1141gram Min:663gram
Driving distanceSingle: Average: 17,402km Max: 38,381km Min:1,952kmDual: Average: 20,590km Max: 40,983km Min:4,803km
Compressor running timeSingle: Average: 211.3hrs Max: 938.0hrs Min:24.4hrsDual: Average: 248.9hrs Max: 758.9hrs Min:51.5hrs
Compressor cycling numberSingle Average: 32,544 Max: 97,627 Min:253Dual Average: 36,302 Max: 98,777 Min:2178
JICOP 「フロン対策の現状と展望」 14/34 虎ノ門パストラル 平成20年3月11日
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Region: Tokyo & Nagoya (Normal load), average temp.: 16C
Leakage (g/yr)
Average leakage:Single: 8.6g/yrDual: 13.3g/yr
Dual (22 vehicles)
Single (56 vehicles)
Annual Refrigerant Leakage
JICOP 「フロン対策の現状と展望」 15/34 虎ノ門パストラル 平成20年3月11日
Emission duringusage 899.3t/yr
Emission whenMAC broken
628.3t/yr
Emission whenvehicle is totally
lost 98.6t/yr
Emission at theend of life134.7t/yr
Emission whenmanufacturing
33.2t/yr
Total emission: 1794.1 ton/year
• 2.33 M CO2-ton/yr• 0.2% of baseline (1237 M CO2-ton/Yr)
Estimated Breakdown of Refrigerant Leakage from MAC in Japan
Reported to METI (Ministry of Economy, Trade and Industry)
JICOP 「フロン対策の現状と展望」 16/34 虎ノ門パストラル 平成20年3月11日
Energy Efficiency Improvement
90% 10%
Driving Air-conditioning
MAC power saving
・Engine efficiency improvement ・Light weight of vehicle・Thermal management
Fuel Consumption
DrivingDriving
JICOP 「フロン対策の現状と展望」 17/34 虎ノ門パストラル 平成20年3月11日
Trend of MAC Power Saving
201020092008200720062005200420032002200120001999199819971996199519941993
50
60
70
80
90
100
MA
C P
ower
Con
sum
ptio
n (%)
MFSTEP Ⅰ
MFSTEP Ⅱ
Sub-Cool condenser(MFSTEP Ⅲ)
SCS(oil separator)SC10S
E/G cooperationControl
MFSTEP Ⅳ
Humidity Control
SCX (intl. Heat exchanger)
40% reduction (compared to 1992)
More 25% reduction (compared to 2004)
JICOP 「フロン対策の現状と展望」 18/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Compressor
Suction Gas
When Suctioning
Suction
Starts Compressing
When Compressing
Rotary Valve
JICOP 「フロン対策の現状と展望」 19/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Compressor
Fig.7 Comparison of Suction Form
One Body Shell and Fixed Scroll
Suction Refrigerant Gas Flow(Peripheral Suction)
Suction Port set up Shell
Oil Separator
JICOP 「フロン対策の現状と展望」 20/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Sub-Condenser
JICOP 「フロン対策の現状と展望」 21/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Condenser
1980 1985 1990 1995 200040
60
80
100
120
140
160P
erfo
rman
ce Q
/F
2005Serpentine
Multi-Flow
JICOP 「フロン対策の現状と展望」 22/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement:Compact Evaporator
Conventional Type Enhanced type
3858
JICOP 「フロン対策の現状と展望」 23/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Engine-A/C Cooperation Control
Acceleration Signal 1
Output of Compressor Driving Capacity
ON
OFF
Large
SmallTime (Second)
Acceleration Signal 1
Output of Compressor Driving Capacity
ON
OFF
Large
Small
Time (Second)
Cooperation Signal 1
Output of Compressor Driving Capacity
ON
OFF
Large
Small
Time (Second)
ON
ON
OFF
OFF
Slow
Fast
Cooperation Signal 2
Driving Speed
Fuel Cut
Passing Acceleration Control
Start-up Acceleration Control
Acceleration Control Deceleration Control
JICOP 「フロン対策の現状と展望」 24/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: System with Humidity Sensor
Tin20deg.
12deg.15deg.Te
Tout
Tem
p.
Tin
Evap.
Te
H/C
Tout
Power saving Control(External Variable Compressor)
Ambient temperature (℃)Ev
apou
t air
tem
p. (℃
)
DemistHumidity Comfort
Zone
Windshield humidity target: 90%
Cabin humidity Target: 60%
No Reheat
0 5 15 25 35
12
0
Minimum
dehumidificatio
n
w/o Humidity control
With Humidity control
Demist Line
Effect
Power Consumption Ratio
-20%
Conditions: 25°C-50% Blower: M1
With Humidity Control
w/o Humidity Control
0 1
JICOP 「フロン対策の現状と展望」 25/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Internal Heat Exchanger
Double-pipe internal heat exchanger
Evaporator
Compressor
CondenserOuter tuber
Inner tube
JICOP 「フロン対策の現状と展望」 26/34 虎ノ門パストラル 平成20年3月11日
Cooling Performance Improvements
3.33.88
1.611.64
0
1
2
3
4
5
6
IHE
Coo
ling
Per
form
ance
(kW
)
Rear A/C
FrontA/C
+12% Bench Test
Conventionalsystem
Conditions: Large car, idling, ambient temperature 45° CVehicle test
Front20.3 Front
18.1
0
5
10
15
20
25
Fron
t and
Rea
r Pan
el O
utle
t (℃)
-2.2℃
IHEConventionalsystem
Rear22.6
-2.0℃
Rear20.6
JICOP 「フロン対策の現状と展望」 27/34 虎ノ門パストラル 平成20年3月11日
Fuel Consumption Improvement
Vehicle Speed
395 L(-5liter
or -1.3%)
(219.76 L with A/C ON)
400 L
(224.78 L with A/C ON)
Total Annual Fuel
Consumption
8.118.725.010.72.9ON
12.929.140.117.15.4ON
5. 613.918.78.92.8ON
8.018.625.310.73.0ON7.617.623.29.92.6OFF100
km/h
12.728.940.217.45.5ON11.325.033.313.73.8OFF40
km/h
ON 5.53.3
15° C
OFF
OFF
OFF
OFF
A/C
14.523.3
100km/h
40km/h
0km/h
0km/h 10.03.2
7. 610.24.71.4
Same as conventional system
Same as conventional system
Same as conventional system
35° C
Ambient Temperature & Fuel consumption (liter)
20° C25° C30° C
Con
vent
iona
lsy
stem
IHEConditions: Compact car, TEWI * evaluation in Tokyo, Japan
* TEWI: Total Equivalent Warming Impact
JICOP 「フロン対策の現状と展望」 28/34 虎ノ門パストラル 平成20年3月11日
Example of Energy Efficiency Improvement: Recovery of Expansion Energy
■Ejector cycle
■Ejector
separatorejector
Driving flow
Suction flow
condenser
evaporator
compressor
Driving flow
Suction flow
nozzle Mixing region diffuser
JICOP 「フロン対策の現状と展望」 29/34 虎ノ門パストラル 平成20年3月11日
Development of World First Ejector Cycle Refrigerator : EJECS
50% of Energy Efficiency Improvement!!
エジェクタサイクル, Ejector Cycle and EJECS are registered trademarks of DENSO corporation
Truck transport refrigeration unit using ejector
JICOP 「フロン対策の現状と展望」 30/34 虎ノ門パストラル 平成20年3月11日
Truck Transport Refrigeration Unit using Ejector Cycle (EJECS)
Condenser
EvaporatorInsulation Panel
-Cross view of the structure-Front Back
Refrigerator compartment
Purpose: Compressor power saving and Fuel economy improvement
Purpose: Compressor power saving and Fuel economy improvement
CompressorEngine
COP (*1)
+50%COP (*1)
+50%Weight▲40%
Weight▲40%
-Over view of EJECOR -Adopt World First Ejector CycleAdopt World First Ejector Cycle
JICOP 「フロン対策の現状と展望」 31/34 虎ノ門パストラル 平成20年3月11日
Result of Vehicle Monitor Test
Average 55845 (l)Average 63875 (l)Average 70750 (l)Annual fuel consumption (liter)
From 2003 December to2006 NovemberFuel consumption measurement: Fill up method
Period & Method
6107# of vehicles
Weight 186 kgWeight 234 kg Weight 560kg
Ejector Cycle Refrigerator(direct coupling)
Company A Refrigerator(direct coupling)
Company A Refrigerator(Sub engine system)
Refrigeration unit
Kyusyu-Kansai (611 km) long-distance transporter for highwayLoad: frozen and refrigerated food
Driving pattern
Load capacity: 10 tonClassificationExample: Large truck transportation refrigeration unit
▲22% ▲12%
Succeed to decrease fuel consumption by 12% to 22% compared to conventional refrigerators (sub-engine and direct coupling)
JICOP 「フロン対策の現状と展望」 32/34 虎ノ門パストラル 平成20年3月11日
Large
Middle
Small
0
200
400
600
800
1000
1200
1400
Conventional Ejector
▲450,000CO2ton
▲320,000CO2ton
▲230,000 CO2tonThe number of servicing
(300,000 vehicles)
About 70,000 vehicles
About 30,000 vehicles
▲8.1%(▲1 million CO2 tons)
Large
Middle
SmallAbout 200,000 vehicles
CO2 Emission Reduction Effects based on All Refrigerated Vehicle in Japan
Effects of CO2 emission reduction by ▲1 million CO2 tons thanks to the ejector refrigerator
Effects of CO2 emission reduction by ▲1 million CO2 tons thanks to the ejector refrigerator
CO
2em
issi
on (
ten
thou
sand
s to
n)
JICOP 「フロン対策の現状と展望」 33/34 虎ノ門パストラル 平成20年3月11日
Trend of MAC Power Saving
201020092008200720062005200420032002200120001999199819971996199519941993
50
60
70
80
90
100
MA
C P
ower
Con
sum
ptio
n (%)
MFSTEP Ⅰ
MFSTEP Ⅱ
Sub-Cool condenser(MFSTEP Ⅲ)
SCS(oil separator)SC10S
E/G cooperationControl
MFSTEP Ⅳ
Humidity Control
SCX (intl. Heat exchanger)
More 25% reduction (compared to 2004)
JICOP 「フロン対策の現状と展望」 34/34 虎ノ門パストラル 平成20年3月11日
Current Situation for alternative refrigerant
MAC directive2008~ Directive 2006/40/EC (Emission of R134a)2011~ Banning the use of R134a for new type of vehicle2017~ Banning the use of R134a for new vehicle
EuropeVDA 2008/07 : decided to use CO2Other Not decided yet(French, Italy, US, Japan)↓Under evaluation of Low GWP refrigerant. We arediscussing about not only direct effect but energy efficiency (fuel consumption) by refrigerant. The point is LCCP estimate.