Many laboratories still rely on the refrigerant R22 for essential air conditioning and refrigeration. Harp International, which specialises in the reclamation and management of refrigerants, urges those companies to act now.
One of the most common refrigerants used in laboratory air conditioning and refrigeration is being phased out under European legislation.* The clamp-down covers so-called HCFC compounds, which are harmful to the ozone layer when released to the environment.
One of the most important refrigerants affected is R22, used widely in laboratories and cleanrooms across the UK and Europe. The regulation also affects HCFC-containing refrigerant blends such as R401A, R402A, R403B, R408A and R409A.
“Despite the long-anticipated ban, there is a vast amount of equipment out there still running on R22,” says Dr John Davey, of refrigerant specialist Harp International. It is estimated that up to a third of the cooling systems in the UK depend on it. For many buildings, it is critical to their operation.”
A recent survey of 350 companies, carried out by the Carbon Trust, showed that 70% have at least one air conditioning or refrigeration system using R22. It concludes: “In most cases, these plants are of strategic importance, as they provide crucial cooling.”
The law covering the phase-out of R22 across Europe is the EU Ozone Depleting Substances Regulation 2037/2000. Under this, the use of R22 in new plant has already been banned. The next stage is a ban on the use of “virgin” or new R22 for topping up existing systems – this comes into effect from the end of 2009. From the beginning of 2010, only recycled R22 may be used to top up plant. After the end of 2014, top-up with any R22 will become illegal. There are suggestions that this date may be brought forward, perhaps by up to three years, but so far the European Commission has not put forward concrete proposals.
As a result of the phase-out, the cost of R22 is expected to rise significantly over the coming year. As manufacturers wind down production in line with required supply quotas, supplies will get short and prices are expected to escalate rapidly. For example, in the restricted market in the US the cost of R22 has risen by a factor of five and is still increasing.
It might not be such a problem if refrigerant remained within plant. However, cooling systems are notoriously leaky. A UK Government study carried out a few years ago showed that as much as 75% of all refrigerant sold went to top-up leaky plant. Since then, leakage rates have been reduced; however, experts estimate that annual loss from some plants is still between 25 and 50%.
Those companies whose air conditioning and refrigeration equipment depends on R22-based cooling plant have three main options. The first is to replace R22 plant with a new system. This is the most expensive and radical option, as it entails replacing what might be a perfectly good plant – possibly with several more years’ working life left. Depending on how efficient the old system is, it is possible that some of the capital cost could be offset by reduced energy consumption. Having said that, R22 is known to be a highly efficient fluid, and the efficiency gains of a new system may not be that significant.
Alternative blends
The second option is retrofitting. This entails removing R22 from plant, and replacing it with a refrigerant not subject to legislative controls. There are a number of alternative blends on the market, designed to mirror the characteristics of R22. However, they can be expensive – but then so will R22 become as supplies decrease. The viability of this option may depend on the size and life expectancy of the plant, and the replacement refrigerant chosen.
The benefit of retrofitting is that it enables existing plant to be kept running, ensuring business continuity. Replacement can therefore be delayed until perhaps many years in the future, and planned and budgeted for.
The third option is to take a managed approach. Under this, existing plant is retained and kept running on R22. After 2010, it is topped-up with recycled R22. The law allows this until the beginning of 2015. This approach extends the use of plant for several years, avoiding the up-front cost associated with replacement or retrofitting.
The right option for each situation depends on the following factors: • The remaining life expectancy of existing R22 plant • Possible efficiency gains (or losses) as a result of replacing or retrofitting • The comparative cost of retrofitting • The availability and cost of recycled R22 for top-up, under a managed approach
There is therefore much to consider. It is important, however, to begin this process now. Dr Davey says: “Many people who delay could find that, come the deadline, there simply won’t be the capacity in the refrigeration industry to cater for the surge in demand.
“Simply assuming there will be sufficient recycled R22 to go round is extremely risky. The view from the industry is that demand will significantly exceed available supplies.” Harp International is offering a new service to help companies manage the phase-out of R22 and ensure the continuity of their businesses. This includes management support and technical back-up to ensure that those with R22-based cooling plant make cost-effective decisions for the future.
Cost-effective option
“From our experience helping major clients through this minefield, we know how important and pressing decisions on plant are for businesses that rely on R22,” says Dr Davey. “It is vital to address the problem now, while there is time to weigh up the options and plan ahead. The first thing people should do is check which refrigerants their systems use. If they don’t know, we can help them identify this.
“The second stage is to decide which option will be most cost-effective to ensure continuity of the business. This requires quite specialised knowledge. Again, we can help with technical support to evaluate the options and help people plan ahead with confidence.”
A key benefit is ensuring continuity of refrigerant supplies at a pre-agreed price. This safeguards businesses against uncontrolled escalation in costs. In addition, the company can help those with plant dependent on R22 to manage recovered refrigerant and keep systems running for several years after the ban on the use of new R22 comes into effect. “The cash-flow advantages, of not having to rip out existing plant before the end of its working life or invest in retrofitting, are obvious,” says Dr Davey.
“The key thing is to address the problem now, determine the best solution and have a plan in place. Those who do this can rest easy, knowing their business is safe. Those who bury their heads in the sand will pay a high price, and, in some cases, it could prove disastrous.”
Contact Harp International Limited Gellihirion Industrial Estate Pontypridd Rhondda Cynon Taff CF37 5SX UK T +44 1443 842255 F +44 1443 841805 .(JavaScript must be enabled to view this email address) www.harpintl.com