Miljøprojekt, 1045 – Udvikling af nye generationer fyldestationer, der muliggør påfyldning af CO2 i automobil- og køleindustrien

Udvikling af nye generationer fyldestationer, der muliggør påfyldning af CO₂ i automobil- og køleindustrien

4 Summary and conclusions

All over the world, R&D departments focus intensively on alternative refrigerants for Mobile Air Conditioning (MAC). One of the alternatives, CO₂, seems to fulfil many of the demands made on the successor of R134a. However, the use of CO₂ involves big challenges because of the very different thermal properties resulting in a considerably higher working pressure and a trans-critical point around 31 °C.

CO₂ is considered an attractive alternative not only for MAC applications. Within commercial refrigeration (CR) intensive development work is done to incorporate CO₂. The use of CO₂ will not only influence the refrigeration circuit but will also make heavy demands on production equipment, including filling stations.

In connection with the conversion to new refrigerants, AGRAMKOW Fluid Systems A/S has always been at the forefront when it comes to developing industrial / service equipment for the handling of new refrigerants and processes - and here CO₂ is no exception.

The process

When at the beginning of 2002, AGRAMKOW Fluid Systems A/S started developing filling equipment for CO₂ in earnest, it soon became evident that the former competencies, know-how and network did not provide the adequate technological base. The process and technology involved were insufficiently clarified and they differed so markedly from the technology already known that we had to start from scratch.

At Agramkow we also had to realise that 25 years' knowledge of refrigerants and industrial processes did not suffice for ensuring R&D success on CO₂. To a wider extent than usually, establishing knowledge networks and entering into cooperation agreements were required. However, learning and the right competencies were not achieved until an internal organisational change was completed that made us well prepared to face competition both where competencies and product programme are concerned. Therefore both AGRAMKOW and participating cooperation partners benefited from the process during which among other things our customers had the opportunity to gain experience with the production parameters for CO₂ refrigeration circuits.

The product

To characterise project results as a paradigm shift within filling would be incorrect based on technical argumentation alone but correct when it comes to the conventional conception of how such equipment works/must work. Only through the experiences and results of countless onsite experiments and tests have we been able to change the customer and market attitude to CO₂.

One of the key challenges within our area of activity is that CO₂ cannot remain liquid at temperatures above 31.06 °C. This is problematic when the equipment is required to function optimally up to 50 °C. The other "uncontrollable" factor is that throughout the temperature range CO₂ is far more sensitive to temperatures / thermal conditions than conventional refrigerants. This is also the reason why the present and well-known technology is not applicable in connection with the development of a CO₂ unit. This is strongly stressed by the fact that it has been particularly difficult to achieve sufficient filling accuracy.

As a result of development work, AGRAMKOW Fluid Systems A/S has been able to apply for a patent on the new technologies. In this connection, the novelty analysis showed that the "developed" technology is unique and patentable.

The market

The market is becoming more outspoken especially where the range and component availability are concerned. At the same time the market within CR and MAC is increasing which is expected to result in considerable sales options within the next 1 to 5 years.

The market for and the attitudes to CO₂ have been very complex and fluctuating throughout the process as reflected in the project. It was difficult to clarify whether and to which extent the MAC or CR sectors would change their production or within which time frames. The technology involved was indistinct, thus conveying some uncertainty during the start-up of this project. This was the reason why prioritation was changed as the project went along so that the MAC sector became our main focus.

We set out developing a CO₂ station designed for volume production at the OEM car factories. This station now stands at the Danish company Nilan A/S filling heat pipes and has done so since January 2005. Subsequently a drastically increasing need for servicing equipment was realised - again with the MAC sector as the primary target group. Since April 2005 this station has been subject to field tests at an OEM car producer.

At the same time, our focus on production equipment for CO₂ handling has resulted in the first order for sale to an OEM CR manufacturer.

All things considered, this staking on CO₂ as an alternative cooling agent appears to be a great success. Through this project we have incorporated new competencies in our company and established new contacts and knowledge networks. In addition, we have succeeded in developing two new filling stations for the CO₂ market thus contributing to influencing the customer segment and changing former attitudes and eliminating "ghosts". Concurrently, we have applied for a patent in respect of the filling concept in use today.

AGRAMKOW is therefore expecting much from the CO₂ staking and is pleased with the order for sale already realised and the good experiences gained from the project.