R-22 Being Phased Out, Not Eliminated

Changes are coming to building HVAC and refrigeration systems. As a

result of new environmental regulations, manufacturers are ceasing
production of refrigerant R-22 for use in new HVAC and refrigeration
equipment. Manufacturers will be able to produce a restricted amount of
the refrigerant for use in existing units, but they will not produce R-22
refrigerant for new systems.

What does this mean for maintenance and engineering managers? Many
chillers screw, scroll, piston, and large centrifugal in commercial,
institutional, and industrial facilities still use R-22, and it is one of the most
commonly used refrigerants in large and small HVAC and refrigeration
systems. What happens to these units after Jan. 1, 2010?

R-22 Sticking Around

The first thing to consider is R-22 will be available long after Jan. 1. The
regulations are phasing out R-22, not eliminating it. Manufacturers will limit
production levels to 25 percent of the 1989 level.

Additional restrictions in 2020 will end the production and importing of R22. Managers still will be able to find supplies of recovered and recycled R22, but no new additions to the stock will be available.

Also, as organizations take chillers that use R-22 out of service, the
refrigerant will be reclaimed and recycled. It is uncertain how much
refrigerant will be available, but it is likely this combination of limited
production and recycling will be adequate to smooth the transition from R22 to alternative refrigerants. By some estimates, the supply of R-22 will be
sufficient to meet demands for 20 years.

The price of the refrigerant probably will increase, but the adequate supply
should keep those increases well within an acceptable range. In time,
managers most likely will see additional price increases, particularly as
new restrictions on its production go into effect and the supply dwindles.

One option managers have when considering the impact the R-22
phaseout will have on facilities is system replacement. Most systems now
being manufactured run on refrigerants that do not contain
chlorofluorocarbons (CFCs). Replacing existing R-22 systems would solve
managers refrigerant supply issues.

Managers should not enter the process of buying a new system lightly.
Small systems only cost several thousand dollars, but the replacement
process can be very disruptive and potentially costly. Large systems can
cost more than several hundred thousand dollars. With large systems, the
disruption related to replacement is even greater.

Managers must determine whether it is worthwhile to replace existing R-22

systems, particularly if those systems are operating efficiently. While no set
answer exists, managers must consider several issues regarding
replacement options.

One of the biggest issues is the units operating efficiency. Todays highefficiency systems typically require 10-20 percent less energy than
systems manufactured even as recently as 10 years ago. Upgrading to a
new, high-efficiency, non-CFC system will cut operating costs and
eliminate the problem of maintaining systems using R-22. One strategy is
to run a comparison of the cost of a new system in terms of energy use
against the current systems energy consumption. Doing so will help
determine the amount of time it would take to recover the investment cost.

Another issue to consider is the systems age. Small systems have a

typical service life of 20 years, while large systems can perform well for 30
years. As these systems approach the end of their expected service lives,
maintenance costs will increase, and reliability and performance will
decline. Also, the availability of replacement parts for older systems will
decline.

Equally important is the operating condition of the existing system. To

determine the existing units condition, managers need to review its
maintenance records and talk with technicians responsible for keeping it
running. If maintenance and reliability have been issues, the existing
system also is likely a candidate for replacement, regardless of its age.

If managers decide to replace an existing chiller, they should work closely

with system manufacturers to ensure the new unit has been designed for
and uses one of the alternative refrigerants on the market. Systems that
manufacturers have specifically designed for use with a particular
refrigerant do not suffer from the loss in capacity or operating efficiency
that sometimes occurs when organizations retrofit an existing design to
Even if a managers goal is to move away from R-22 and other chlorinecontaining refrigerants, not all facilities will be able to replace their systems
immediately, nor should they. While its availability will decline and certainly
its price will increase as supplies dwindle, managers still have time. And
during this time, the process of attrition will take care of many of the
systems using R-22.

Managers can start the process by identifying the systems that use R-22,
rating their condition, and identifying the best candidates for replacement
based on age and operating condition. Eliminating problem systems will
reduce the facilitys demand for R-22. They also need to review
maintenance and purchasing records to identify the amount of R-22 used

each year servicing the systems. This process will provide a baseline of
refrigerant requirements.

The key for successfully managing the transition from R-22 is to minimize
its demand. Managers can improve maintenance practices to reduce the
demand for replacement refrigerant to a minimum. They also can track
refrigerant use to identify systems where problems are developing and
keep accurate records of refrigerant use to satisfy new regulatory
requirements and to identify systems that need overhauling or
replacement.

Amazing Ammonia
The most common approved, environmentally safe refrigerant is ammonia. There are
some systems that use CO2 or hydrocarbons, but the majority of systems in the marine
industry not using HCFCs or HFCs run on ammonia. Since it is a naturally occurring
substance, it does not harm the ozone layer or contribute to global warming if
accidentally released. For this reason, the chance of it being banned in the future is
virtually zero. If you use an ammonia-based refrigeration system you won't have to go
through this again years from now.
Ammonia is an excellent refrigerant. Beyond being in compliance with the law and being
environmentally sound, ammonia has several other advantages. It is much less
expensive than other refrigerants, and the oil used is also less expensive than for
systems using HFCs. All other things being equal, ammonia is more efficient than most
other refrigerants. That means it will drop the temperature of your product faster.
Its pungent smell makes it immediately obvious if a leak has occurred. It is lighter than
air, easily detected, and easily disbursed with ventilation. Ammonia systems are in use
all over the world, and above it too: the International Space Station uses ammonia!
Convert or Replace?
Every installation is unique. Each application has different needs, equipment, and goals
to achieve. It is only possible to speak in general terms about what is involved in each
scenario. To know exactly what is needed you should consult with a reputable
refrigeration company- they will come to your site, speak with you, and do a thorough
evaluation. That is the only way to know with certainty what solution is best for you.
Each option has its pluses and minuses. A conversion, if possible, costs less but you
still have an older system with limited, if any, warranty or tech support. A new system

costs more but it has a longer life than the one you removed, as well as the
accompanying technical support and warranty.
"Conversion" can be misleading. You cannot simply recover your R22 and put in an
HFC such as R404A. The oil has to be changed, along with valves, fittings, and other
components. However, HFCs will be prohibited eventually so you should consider if this
is a good long-term solution. Another negative of a conversion is that the cooling
capacity and efficiency might be reduced. You also can't do this with all systems, and
there may be reliability issues. Ammonia cannot be used in an R22 system at all
because ammonia corrodes brass and copper. So many components have to be
replaced that it doesn't make economic sense to "convert" an RSW system to ammonia.
However, plate freezers can be retro-fit to use ammonia economically. All the coils and
freezer components are typically aluminum. The compressors, chillers, condensers, and
some of the pipes would need replacing but the freezers themselves could stay.
Removing the old system entirely and installing a new, ammonia-based unit is the other
option. This gives you a new warranty, higher efficiency, and more modern controls.
Many factors determine the cost of a system, including tonnage, existing electrical
system, type of controls, desired product temperature, water temperature, and so on.
What Do I Do Now?
Locate everything on your boat or shore plant that uses HCFCs, including cold storage,
ice makers, air conditioners, etc. Make a list of the important information for each
system: age, cooling load, history of maintenance (especially how much refrigerant has
been used to top it up, since this indicates how sound it is), along with any records you
may have. Is the system efficient? Is it cooling adequately or does it struggle to keep
up? All this can help you plan your approach.
If your current system is 15 years old or older, you probably want to replace it. Likewise
if it doesn't handle your cooling needs. If you are using an HCFC blend then it was
probably converted from a long-banned CFC refrigerant, because these blends were
designed specifically for CFC replacement. One conversion is enough. Finally, if you
want to avoid HFCs by using ammonia, you must do a partial or full replacement.
If you want to change over to an HFC refrigerant you can use a pure HFC fluid such as
R134a or an HFC blend for new systems such as R407C. But your best option is
probably a HFC "Service blend" that is designed to be used with an existing R22
system. A significant issue is that most R22 units operate with mineral lubricating oil but
many HFC refrigerants require polyol ester oil. Because it is so time-consuming to
change the oil in an existing system, using a service blend can help minimize this
problem.
What Are My Options?

This issue will not go away. It's the law, and the potential fines could kill your profit or
even put you out of business.
R22 is very expensive and getting more so every year. Every dollar you spend on
refrigerant or maintaining your R22 system is a dollar that could go to converting it or
buying a new one. And, as with everything else, the cost of retrofitting or replacing your
system will only go up over time.

While R22 equipment cannot run on ammonia, ammonia-based equipment can run
R22, so you can replace your components, like this chiller, one at a time.
One thing worth noting: While R22 equipment cannot run on ammonia, ammonia-based
equipment CAN run R22. So you can replace your components one at a time using
pieces that will work with your current R22 system, and later switch to the less
expensive and regulation-compliant ammonia. For example, first replace the chiller.
Then next year swap out the compressor, then later do the condenser. When you're
done, swap out the refrigerant and oil. This way you break up the expense over several
years, but you end up with a new, ammonia-based system.
Talk to a reputable refrigeration company to get a price for modifying or replacing your
existing equipment. Whichever method you choose, you will end up with a refrigeration
system that will keep your catch cold and make sure you get the best price for your fish
at the market. Isn't that what it's all about?