India policy workshop on the status of MAC replacement technologies by S.H. Kapoor

1. Mobile Air Conditioner (MAC) and Environment
India policy workshop on the status of MAC replacement technologies
New Delhi, India, 7-8 June 2010
India Mobile Air Conditioning Assessment
S H Kapoor
Technical Chief, Climate Control
TATA Motors Limited, India
Email: sh_kapoor@tatamotors.com
1
©Copyright TATA Motors Ltd

2. MAC System : Impact on Environment
Direct GHG
Direct GHG is Leakage of Refrigerant to the Atmosphere (GWP)
(Refrigerant Leakage through AC Hoses / Joints / Servicing)
Atmospheric degradation products
COF
HCOF
TFA
HF
+
R134a (HFC)
AC System
Indirect GHG AC System
Indirect GHG is CO2 From Fuel Used for operating HVAC
(Exhaust gases)
The leaking refrigerant molecule breaks down into GHG in the atmosphere
2
©Copyright TATA Motors Ltd

3. MAC Refrigerant: Impact on Environment
1960 - 1987 1996- 2001 2005 2010 - > 2011
Kyoto Forced Europe Europe
World Summit
The Montreal Earth Summit Kyoto Protocol (2005) Regulation Regulation
on Sustainable
Protocol Rio De Janeiro Conceived UN Climate Change (2006/40/EC) (2006/40/EC)
Development
(1989) (1992) (1997) Conference Bali (Leakage rate) (F-Gas)
(2002)
(2007) (2011) (2011)
8100 Re
du
cti
on
Global Warming Potential
in
Di r
ec
tG
HG
e mi
ss
ion
1410 s
ISSUE: ISSUE:
4 OZONE DEPLETION GLOBAL WARMING
ODP: 1 (Max) ODP: 0 ODP: 0
CFC-12 [CCl2F2] HFC-134a [C2H2F4] HFO-1234yf [CF3CF=CH2]
(Chloro Fluoro Carbon) (Hydro Fluoro Carbon) (Hydro Fluoro Olefin)
3
©Copyright TATA Motors Ltd

4. MAC initiatives: Environment Sustainability
Reduction of Direct Emission Reduction of In-direct Emission
1. Refrigerant Charge Optimization 1. Heat Load Reduction
• Compact and High efficiency heat • Effective sealing and insulation
exchanger
• Tinted glasses
• Introduction of IRDC condenser
2. Energy Efficiency
• Introduction of MF and flat tube
evaporators • New Generation compressor
• 30% less refrigerant from above • Improved control strategies
initiatives • Customer awareness
2. Refrigerant Leakage Reduction 3. Weight Reduction
• Target all new systems to meet 2009 • Compact and High efficiency heat
and 2011 European norms exchanger
• Improving refrigerant circuit joinery • Light weight and compact
• Dealer level awareness regarding compressors
servicing of HVAC • Compact HVAC unit design
© Copyright TATA Motors Limited 2008 4

5. MAC System: Impact on Energy Consumption
Energy Consumption Ratio (%)
3
9
11
39 Compressor
Blower
Idle Up
Cooling fan
Clutch
38
During operation, power absorbed by
the Compressor accounts for approx.
40% of total energy requirement.
Other major energy losses are from the
blower and the need to increase idle
speed to provide adequate cooling
5
©Copyright TATA Motors Ltd

6. MAC : Current Technology Status
Energy
Environment
Sr. Efficiency
MAC System Parameter Technology Type Indicator
No. Indicator
(Impact)
(Impact)
Refrigeration Cycle & • Vapour Compression Cycle High
1 (GWP: 1410) Medium
Working Fluid • Refrigerant HFC R-134a (ODP: 0)
• Single AC Medium Low
MAC System
2
Architecture
• Dual AC Medium Medium
• Compressors : Fixed/Variable
Displacement Internally Controlled Medium High
(Reciprocating/ Scroll/ Rotary)
3 System Aggregates
• Compact HVAC units / Blowers
• Heat Exchangers Low Medium
(Multiflow Evap/ IRD Condenser)
• Manual Bowden Cable Type
4 Controls • Manual Electric w/ Actuators Low Low
• FATC
• Wire Mesh Type Filters
5 Air Purifiers Low Low
• Pollen (Paper) Type Filters
6
©Copyright TATA Motors Ltd

7. MAC : Future Technology Trends
Energy
MAC System Parameter Technology Type Environment
Sr. Efficiency
Indicator
No. Indicator
(Impact)
(Impact)
Refrigeration Cycle & • Vapour Compression Low High
1 (GWP: 4)
Working Fluid • HFO-1234yf (European Union) (ODP: 0)
(potential to )
• Thermoelectric devices (localised
2 System Architecture cooling/Heating)
Low Low
• Compressors – Variable Displacement
Externally Controlled Low Medium
(Reciprocating), Dual Drive Hybrid
3 System Aggregates • Heat Exchangers
(Mechanical Multi-Exchanger)
• Internal heat Exchange (IHX)
Low Low
• Analogue Pressure Transducers
• ECON Function in Manual & FATC
4 Controls Controls Low Low
• PWM Blower Controllers
• Charcoal Anti-Bacterial Filters
5 Air Purifiers Low Low
• Plasma Ion Generators
7
©Copyright TATA Motors Ltd

8. Growth of MAC Vendors
Source: Internet
The participation and involvement of MAC suppliers in the process to reduce the
environmental impact (on direct and indirect GHG) needs to be speeded up
8
©Copyright TATA Motors Ltd

9. Concluding Remarks
1. INDIAN MAC SECTOR
• The Indian automotive market is growing significantly
• The prime drivers for the automotive market in India are Cost and Fuel Economy
• The Indian market demands high performance MAC systems to meet passenger comfort requirements
• The use of MAC systems in Indian vehicles is increasing - particularly in the commercial vehicle sector and as a
standard OE fitment for passenger cars
• To meet this growing market and passenger comfort requirements there is a demand for higher technology at
competitive prices from MAC system suppliers
• The participation and involvement of MAC suppliers in the process to reduce the environmental impact needs to
be speeded up in the above scenario
2. ENVIRONMENT SUSTAINABILITY
• OEMs and MAC suppliers should be committed to environment sustainability
• There is a need to:
a) adapt new technologies to reduce refrigerant charge, weight and MAC power consumption
b) assess the impact of alternate refrigerants on MAC system designs to ensure an optimal
balance between meeting comfort requirements and reducing impact on environment
• Since significant efforts and resources are required for these assessments and future developments, funding by
National/World bodies will be required
• All MAC systems for export to Europe to be designed to meet EEC refrigerant leakage and future F – Gas
legislation
3. LEGISLATION
• There are no immediate plans for MAC legislation in India
9
©Copyright TATA Motors Ltd

10. Compact and High Efficient Heat Exchanger
10
©Copyright TATA Motors Ltd

11. Compact HVAC units
11
©Copyright TATA Motors Ltd

12. AC Compressors: Energy Efficiency
Rotary
Variable Displacement
(internally controlled)
12
©Copyright TATA Motors Ltd

13. Refrigerant Molecule
< 1997 1997 – 2010 > 2011
We Are Here
R-12 (CFC) R-134a (HFC) HFO-1234yf
CCl2F2 C2H2F4 CF3CF=CH2
• Dichlorodifluoromethane 1, 1, 1, 2 – Tetrafluoroethane (HFC-134a)
H
• Freon – 12
H
F
C
C F
F
C F
CH2F– CF3
• No Chlorine atom (ODP = 0) • Double bond b/w carbon atoms
Mechanism of ozone hole
formation • Strong single bond b/w • Weaker double bond allows it
CCl2F2 + UV Light ==> CClF2 + Cl carbon atoms to break down much more
O3 {ozone} + UV Light ==> O2 + [O] quickly in the atmosphere than
• Atmospheric lifetime 13.6 R-134a
Cl + O3 ==> ClO + O2
ClO + [O] ==> Cl + O2
years (GWP = 1410)
• Atmospheric lifetime is 11 days
Net: [O] + O3 ==> 2O2 (GWP = 4)
13
©Copyright TATA Motors Ltd

14. BUDGETORY COST ESTIMATES
(PROVING AN ALTERNATE MAC-REFRIGERANT)
S No Description % Contribution
Material
Refrigerant
a. Bench validation @30kgs
1 b. Vehicle validation @35kgs 7.0
Compatible HVAC proto parts @ 25sets
(Compresor,Oil,Condenser,IHX,TXV,Evaporator,
Hoses,controls)
Material testing
2 Laboratory Tests 1.0
Vehicle (e.g. flammability tests)
Facility & Equipment
Bench
3 Hot Chamber 30.0
Refrigerant Recovery and Re-cycle machine
Data acquisition system (road trials)
Road Trials (Performance and Durability)
4 Vehicles* @12nos. 60.0
Fuel @12vehs.
Manpower
Bench level (Supervisor,Operator) @60days
5 Vehicle level (Engineer,Supervisor) @60days 2.0
Confirmatory road trials (test engineer, drivers, @90days
support staff)
Total Budget Approx. 6.5 Cr.
* Single AC & Dual AC version / Petrol & Diesel engine version / 2 HVAC suppliers
14
©Copyright TATA Motors Ltd

15. Dual AC System
15
©Copyright TATA Motors Ltd

16. Heat Exchanger and Electrical Sensor
(to lower energy consumption)
Mechanical
Multi-Exchanger Internal Heat Exchanger
Analogue Pressure
Transducer
16
©Copyright TATA Motors Ltd

17. Controls
ECON Function PWM based speed control
Fully Automatic (ECON mode)
Saving electrical power
Air Con Duty Reduction
17
©Copyright TATA Motors Ltd

18. Controls
Manual Control Panel Electric Control Panel FATC control panel
HVACunit
HVAC unit
HVAC unit
PWMPWM blower control
Blower Control
3 Actuator
3 Actuator AirAir quality
Quality
motors
motors Sensor
sensor
3 Actuator
motors
Evaporator
Evaporator
sensor
Sensor Evaporator
Evaporator
sensor
Sensor
Evaporator
18
©Copyright TATA Motors Ltd

19. AC Compressors
Variable Displacement Compressor (belt drive) Dual Drive Compressor (hybrid vehicle)
(externally controlled)
19
©Copyright TATA Motors Ltd

20. Air Purifiers
Wire-mesh Filter
Pollen Filter
Plastic Wire
Steel Wire
20
©Copyright TATA Motors Ltd

21. Air Purifiers
Air purifier for vehicles: Ion Generators
* Run switching action for 15mins
Interval mode
over each mode
* Purify air by coming out negative and
Plasma cluster ion mode
positive ions at the same rate
* Adjust ion balance by increasing
Negative ion mode
the rate of negative ion
Stop * Stop running
21
©Copyright TATA Motors Ltd

22. Thermoelectric Devices
Climate Control Seats (CCS)
Application
CCS System has the Potential to Increase Comfort & Reduce CO2 Emissions When Combined with
Traditional HVAC Systems of Reduced Capacity
22
©Copyright TATA Motors Ltd