F-Gas Regulations – What you Need to Know

Plan for the future

Businesses need to start preparing for the future now – remember implementing change as soon as possible is likely to save you money in the future. There are a number of options available for users of HFC refrigeration systems: keep what you have got, gas retrofit, secondary conversion or a replacement plant using synthetic or natural refrigerants. Each has its benefits but also its challenges:

Option 1 – Keep what you’ve got and see what happens in the future

This is by far the lowest cost option but also the riskiest. Even if existing equipment is retained, steps should be taken to address ‘leaky’ components. Thought should also be given to whether low cost options are available to reduce refrigerant charge without affecting performance. Checks should be made to ensure the necessary leak detection measures are in place. At some point in the future, a drop in alternative refrigerant may be available for the equipment, but this is not guaranteed. This gas change may require costly modifications which result in loss of capacity and/or efficiency.

Option 2 – Gas Retrofit

For relatively recent plant installations, a gas retrofit provides a medium term solution and avoids investment in an entirely new system. Alternative HFC and HFC/HFO refrigerant blends are available or being field tested for retrofit to existing system. These have GWPs that aren’t subject to the 2020 service ban and therefore provide some degree of certainty in the future. Depending on the style of system and the current/retrofit gases, there may be cost implications as well as changes in efficiency and capacity. As with Option 1, attempts should be made to reduce refrigerant charge, particularly as the new refrigerant is likely to be many times more expensive per kg. When considering this option, a detailed plant survey should be carried out to determine the suitability of available gases and what measures need to be taken with the existing equipment.

Option 3 – Secondary Fluid Conversion

One option often overlooked is the possible conversion of the existing, direct refrigeration system to cool a secondary fluid that can then be circulated out to the point of cooling. The secondary fluid could be water or glycol, but consideration should also be given to the use of a volatile fluid such as CO2. In most cases, the existing pipework and heat exchangers at the point of cooling will need to be replaced, resulting in a significant cost but without the need to replace the compressor(s) and condenser(s). The resulting system will have 80% to 80% less primary refrigerant and could mean that a service ban is avoided from 2020. The lower primary refrigerant suction temperature and need to pump a secondary fluid will typically increase power consumption and reduce capacity. As with Option 2, a detailed survey is recommended to review the suitability of the system to conversion and what works will be necessary.

Option 4 – Replacement Equipment

This final option is recommended where the existing plant isn’t in a suitable condition for Options 1 to 3. In this case, transition refrigerants such as R407F are available, but consideration should also be given to natural refrigerants such as ammonia and carbon dioxide. Ammonia has zero GWP and CO2 a GWP of one, meaning that they aren’t affected by the F-Gas regulation. This means that both can offer a long term solution and are available over a range of applications and capacities.

Replacement equipment options by refrigerant

When it comes to replacement equipment options, synthetic refrigerants perform well but can slightly increase running costs.

• R134a lowest GWP for chill
• R407A/F lower GWP options for freezers
• Possible use of R32 at low temperature
• Slightly higher capital cost vs R404A/R507
• Look at small, low charge systems
• Consider EC fans, EEVs and inverter motors

Natural gases such as ammonia have been successfully used as refrigerants for over 100 years. Ammonia has no global warming effect and offers high efficiency, long term availability and low cost per Kg. The use of carbon dioxide as a refrigerant is also growing in popularity due to its relatively low global warming potential. Here’s what you need to know:

Natural refrigerants – Ammonia

• Suited for systems > 100kW
• Chill, freezer and two stage options
• Secondary chillers
• Established technology
• Higher efficiency than HFCs
• Zero GWP
• Higher capital cost
• Flammable and toxic

Natural refrigerants – CO₂

• Suited for systems < 200kW
• Chill, freezer and two stage options
• Similar performance to HFCs
• Higher operating pressure
• Higher capital cost
• GWP = 1
• High grade heat recovery available

Natural refrigerants are a long term solution for companies affected by the F-Gas regulations. The initial capital cost of a plant that operates on a natural refrigerant may be higher, but the lifecycle cost of running the system is key. Those who continue to operate cooling systems with HFCs are facing the risk of escalating running costs in the short to medium term.

For more information and support in selecting the way forward for your refrigeration system, contact Rob Lamb at rlamb@star-ref.co.uk.

This article has been certified for Continuing Professional Development (CPD) by CIBSE and The CPD Certification Service. To get your CPD Certificate please email your request to CPDCertificate@star-ref.co.uk