Mobile Air-conditioning Actions for
Global Warming Reduction

Toshio Hirata
DENSO CORPORATIONJICOP 「ﾌﾛﾝ対策の現状と展望」

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1. Mobile Air Conditioning and Global Warming
2. Refrigerant Emission Reduction
3. Energy Efficiency Improvement

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Mobile Air-conditioning
and Global Warming

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

MAC’s Refrigeration Cycle
Compressor

Evaporator

Refrigeration Cycle

cool airHigh press.
& high temp. gas
Low press.
& low temp. gas
Condenser
Expansion ValveJICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

GHG Effects on Global Warming (Japan)
HFC
1.0%

PFC
0.7%
SF60.4%

Dinitrogen Monoxide
2.7%

Breakdown of CO2 Emission
by Sectors

CO293.7%

Methane
1.5%
Total
Amount ofCO2Emission in2002
1,330.8[Mt CO2eq.]

Others0.0%

Waste Disposal
2.0%
Limestone
Consumption
4.2%

Energy Conversion
6.4%

Transport
22.0%
Industry
37.2%
Residential
12.7%
Business Use
15.5%

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Influence of A/C on Fuel Consumption

Fuel Consumption (km/L)

25℃(50%RH)、No Solar Radiation

15

Actual Running Mode:
Compact Car LA4: Stop Ratio 17%

9%Yearlyo10

5Temperature ( C)25

Humidity (%)

50

Sun Load (W/m2)

0Fresh / Recirculated Air

Fresh

Blower Speed

Low

Evaporator Outlet Air
oTemperature ( C)10

A/C Off A/C on(yearly)
JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of TEWI Calculation (JAMA)
3500
3000

TEWI(kgCO2)

2500
2000

Emission into atmosphere at scrapping(present level)
Emission into atmosphere at scrapping(future level)

Direct(refrigerant)

Leakage in use, leakage at
accident and repair
Contribution by air-conditioner weight

1500

Contribution for driving alternator

1000
Contribution for driving compressor

500

In-direct(compressorpower)

FF2L S/D
0
JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 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」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

JAMA’s Action Plan
Reduction of refrigerant emission from HFC-134a A/C
1.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 fromOctober, 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.

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Refrigerant Charge Reduction from 1995 to 2006
Reduced by 23%

Average charge (g)*

700

700
650

600

615

603

500

588

582

553548536

2004

2005

2006

400
300
200
1000

1995

1999

2000

2001

2002

*Average refrigerant charge =2003

Total charging amount at vehicle production
The number of produced vehicles

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

The Refrigerant Recovery Data when scrapping in Japan

Refrigerant recovered vehicle
numbers

Recovered amount (kg)

2005

2006

2005

2006

CFC-12

961,904

874,665

285,183

244,545

HFC-134a1,083,231

1,500,828

372,089

496,971

Total

2,045,135

2,375,493(+16.2%)657,272

741,516(+12.8%)JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Reduction in Refrigerant Leakage in Operation
45

Refrigerant Leakage(gram/yr)

40

Others35
30

Fittings
25
20

Hoses
15
10Comp.
50
CFC-12JICOP 「ﾌﾛﾝ対策の現状と展望」

HFC-134a (1992)

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HFC-134a (2004)

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Refrigerant Leakage Field Test
(From April, 2004 to December, 2005)

9Location
Tokyo, Nagoya (average temperature 16C)
9Number of test vehicles
78 vehicles (seven auto makers)
9A/C system
Single AC (16 type vehicles)

Dual AC (6 type vehicles)

9Charge amountSingle:Dual:

Average: 516gram
Average: 804gram

Max: 760gram
Max: 1141gram

Min:409gram
Min:663gram

9Driving distanceSingle:Dual:

Average: 17,402km
Average: 20,590km

Max: 38,381km
Max: 40,983km

Min:1,952km
Min:4,803km

9Compressor running timeSingle:Average: 211.3hrs
Dual:
Average: 248.9hrs

Max: 938.0hrs
Max: 758.9hrs

Min:24.4hrs
Min:51.5hrs

9Compressor cycling number
SingleAverage: 32,544
Dual
Average: 36,302

Max: 97,627
Max: 98,777

Min:253
Min:2178

JICOP 「ﾌﾛﾝ対策の現状と展望」

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Annual Refrigerant Leakage
Region: Tokyo & Nagoya (Normal load), average temp.: 16C
12Dual (22 vehicles)
10Single (56 vehicles)
Average leakage：Single: 8.6g/yr
Dual: 13.3g/yr

86420
123456789

10

11

12

13

14

15

16

1718

1920

21

Leakage (g/yr)

JICOP 「ﾌﾛﾝ対策の現状と展望」

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Estimated Breakdown of Refrigerant Leakage
from MAC in Japan
Reported to METI (Ministry of Economy, Trade and Industry)Emission whenvehicle is totally
lost 98.6t/yr

Emission at theEmission whenend of life
manufacturing
134.7t/yr
33.2t/yr

Emission during
usage 899.3t/yr

Emission when
MAC broken
628.3t/yr

Total emission: 1794.1 ton/year• 2.33 M CO2-ton/yr• 0.2% of baseline (1237 M CO2-ton/Yr)

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Energy Efficiency Improvement
Fuel Consumption
90%

10%Air-conditioning

Driving

MAC power saving

Driving
Driving・Engine efficiency improvement
・Light weight of vehicle・Thermal management

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Trend of MAC Power Saving
100

MFSTEP Ⅰ

MAC Power Consumption （％）

MFSTEP Ⅱ
90
Sub-Cool condenser（MFSTEP Ⅲ）

40% reduction(compared to 1992)

SCS（oil separator）
SC10S

80

E/G cooperation
Control
70
MFSTEP Ⅳ

SCX(intl. Heat exchanger)

Humidity
Control

60

50

More 25% reduction(compared to 2004)
1993

1994

1995

1996

1997

1998

JICOP 「ﾌﾛﾝ対策の現状と展望」

1999

2000

2001

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2002

2003

2004

2005

2006

2007

2008

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

2009

2010

Example of Energy Efficiency Improvement:Compressor

Rotary Valve
SuctionSuction
Gas

StartsCompressing
WhenCompressing

JICOP 「ﾌﾛﾝ対策の現状と展望」

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WhenSuctioning

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of Energy Efficiency Improvement:
Compressor
Suction Port set up Shell

Suction Refrigerant Gas Flow(Peripheral Suction)

Fig.7 Comparison of Suction Form

One Body Shell and Fixed Scroll

JICOP 「ﾌﾛﾝ対策の現状と展望」

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Oil Separator

虎ノ門ﾊﾟｽﾄﾗﾙ 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」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of Energy Efficiency Improvement:
Condenser
160

Performance Q/F

14012010080Multi-Flow

60
40
1980

Serpentine
1985

JICOP 「ﾌﾛﾝ対策の現状と展望」

1990

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1995

2000

2005

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of Energy Efficiency Improvement:
Compact Evaporator
Conventional TypeEnhanced type58
JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of Energy Efficiency Improvement:
Engine-A/C Cooperation Control
Start-up Acceleration Control
Acceleration
Signal 1

FastON

Driving Speed

OFF
Large

Slow

Output ofCompressor
Driving
Capacity

Cooperation
Signal 1

OFF
Small

Cooperation
Signal 2

Time (Second)

ONOFF

Passing Acceleration Control
Acceleration
Signal 1

ONOutput ofLarge
Compressor
Driving
Small
Capacity

ONOFF
Large

Output ofCompressor
Driving
Capacity

OFF

Fuel Cut

ON

Small

Time (Second)

Time (Second)

Acceleration Control
JICOP 「ﾌﾛﾝ対策の現状と展望」

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Deceleration Control
虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of Energy Efficiency Improvement:
System with Humidity Sensor
Power saving Control(External Variable Compressor)

Evap.

H/C

Demist Line

Temp.

TeTout15deg.

Evap out air temp. (℃)

Tin

Te12deg.

num atiom cni difii12
M mihuedWith
Humidity
controlw/oHumidity
control

051525

Ambient temperature (℃)

Blower: M1

w/o Humidity Control-20%With Humidity Control
0

JICOP 「ﾌﾛﾝ対策の現状と展望」

Power Consumption Ratio

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NoReheat0Conditions: 25°C-50%

EffectHumidity Comfort
Zone

DemistTout

Tin
20deg.

Cabin humidity
Target: 60%

Windshield humidity
target: 90%

1

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

35

Example of Energy Efficiency Improvement:Internal Heat Exchanger
Evaporator

Compressor

Condenser

Double-pipe
internal heatexchanger
Outer tuber
Inner tube

JICOP 「ﾌﾛﾝ対策の現状と展望」

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Cooling Performance Improvements
Conditions: Large car, idling, ambient temperature 45° C

Cooling Performance (kW)6+12%

54Rear
1.61 A/C

1.64

323.3

Front
A/C

3.88

10

Conventional
systemJICOP 「ﾌﾛﾝ対策の現状と展望」

Front and Rear Panel Outlet （℃）

Bench Test

IHE

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25Vehicle test
-2.0℃

20-2.2℃

1510

Front
20.3

Rear
22.6

50

Conventional
systemFront
18.1 Rear
20.6

IHE

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Fuel Consumption Improvement

IHE

Conventional
systemConditions: Compact car, TEWI * evaluation in Tokyo, Japan
Vehicle
Speed

A/C

0km/h

Ambient Temperature& Fuel consumption (liter)
35° C30° C25° C

20° C

15° C

OFF

1.4

4.7

10.2

7. 6

3.3

ON

3.2

10.0

23.3

14.5

5.5

40km/h

OFF

3.8

13.7

33.3

25.0

11.3

ON

5.5

17.4

40.2

28.9

12.7

100km/h

OFF

2.6

9.9

23.2

17.6

7.6

ON

3.0

10.7

25.3

18.6

8.0

0km/h

OFF40km/h

OFF100km/hOFFONONON

Same as conventional system
2.8

8.9

18.7

13.9

5. 6

Same as conventional system
5.4

17.1

40.1

29.1

10.7

25.0

18.7

400 L
(224.78 L withA/C ON)

395 L(-5literor -1.3%)

12.9

Same as conventional system2.9

Total Annual
FuelConsumption

8.1(219.76 L withA/C ON)* TEWI: Total Equivalent Warming Impact
JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Example of Energy Efficiency Improvement:
Recovery of Expansion Energy
condenser■Ejector cycle

compressor
Driving flow

separator

ejector

Suction flow

evaporator■EjectornozzleMixing region diffuser

Driving flow

Suction flow

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Development of World First Ejector
Cycle Refrigerator : EJECS
50% of Energy Efficiency Improvement!!

Truck transport refrigeration unit using ejector
エジェクタサイクル, Ejector Cycle and EJECS are registered trademarks of DENSO corporation

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Truck Transport Refrigeration Unit using
Ejector Cycle (EJECS)
Purpose:
Purpose:Compressor
Compressorpower
powersavingsavingandandFuel
Fueleconomy
economyimprovement
improvement−Cross view of the structure−
Front
BackCondenser

(*1)
COP
COP (*1)+50％+50％WeightWeight▲40％▲40％

Refrigerator
compartment

Evaporator
Insulation Panel

Adopt
World FirstCycle
Adopt
FirstEjector
EjectorCycle−Over Worldview of EJECOR−EngineCompressorJICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Result of Vehicle Monitor Test
Example: Large truck transportation refrigeration unit
Classification

Load capacity: 10 ton

Driving pattern

Kyusyu-Kansai (611 km) long-distance transporter for highway
Load: frozen and refrigerated food

Period & Method

From 2003 December to2006 November
Fuel consumption measurement: Fill up method

Refrigeration unit

Company A Refrigerator(Sub engine system)

Company A Refrigerator(direct coupling)

Ejector Cycle Refrigerator(direct coupling)

Weight 560kg

Weight 234 kg

Weight 186 kg# of vehicles

7106Annual fuelconsumption(liter)Average 70750 (l)Average 63875 (l)Average 55845 (l)

▲22%

▲12%

Succeed to decrease fuel consumption by 12% to 22% compared toconventional refrigerators (sub-engine and direct coupling)

JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

CO2 Emission Reduction Effects
based on All Refrigerated Vehicle in Japan
▲8.1％（▲1 million CO2 tons）

CO2 emission ( ten thousands ton)

1400
1200

Small
The number of servicing(300,000 vehicles)

1000
800

Middle400

Middle▲320,000CO2tonLarge▲450,000CO2ton

About 30,000vehicles

Large

2000

▲230,000 CO2ton

About 200,000 vehicles
About 70,000vehicles

600

Small

Conventional

EjectorEffects
Effectsof
ofCO2
CO2emission
emissionreduction
reductionby
by▲1▲1million
millionCO2
CO2tons
tons
thanksthanksto
tothe
theejector
ejectorrefrigerator
refrigerator
JICOP 「ﾌﾛﾝ対策の現状と展望」

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虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

Trend of MAC Power Saving
100

MFSTEP Ⅰ
MFSTEP Ⅱ90

MAC Power Consumption （％）

Sub-Cool condenser（MFSTEP Ⅲ）
SCS（oil separator）
SC10S

80

E/G cooperation
Control

70
MFSTEP ⅣSCX
(intl. Heat exchanger)

HumidityControl

60

50More 25% reduction(compared to 2004)
1993

1994

1995

1996

1997

1998

JICOP 「ﾌﾛﾝ対策の現状と展望」

1999

2000

2001

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2002

2003

2004

2005

2006

2007

2008

虎ノ門ﾊﾟｽﾄﾗﾙ 平成20年3月11日

2009

2010

Current Situation for alternative refrigerant
MAC directive
2008〜 Directive 2006/40/EC (Emission of R134a)
2011〜 Banning the use of R134a for new type of vehicle
2017〜 Banning the use of R134a for new vehicle
EuropeVDA
2008/07 : decided to use CO2
Other
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.
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