Many buildings still depend on the refrigerant R22 for essential air conditioning. However, the substance is being phased out under EU legislation, creating a major potential problem for those affected

One of the most common refrigerants used in air conditioning large buildings 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 across the UK and Europe. The regulation also affects HCFC containing refrigerant blends such as R401A, R402A, R403B, R408A and R409A.

Dr John Davey, of leading refrigerant specialist Harp International, says: “Despite the long-anticipated ban, there is a vast amount of equipment out there still running on R22. 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 per cent 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 – which 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 next 18 months. 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 USA 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 Government study carried out a few years ago showed that as much as 75 per cent 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 to 50 per cent.

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 - with a new system.

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.

The second option is retrofitting. This entails removing the R22 from plant, and replacing it with an alternative refrigerant not subject to legislative controls. There are a number of alternative refrigerant 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 any given situation depends on a number of factors. These include:
• 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 a lot to consider. It is important, however, to begin this process now. Dr John 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.”

Recognising the problem, Harp International has introduced a new service to help companies manage the phase-out of R22, and ensure the continuity of their businesses. The Total R22 Solution provides expert advice, management support and technical back-up to ensure that those with R22-based cooling plant make the right, cost-effective decisions for the future.

Dr Davey says: “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.

“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.”

The package offered by Harp International includes the following elements:
• Refrigerant management service for R22 users;
• Analytical services for assessing refrigerant type and composition;
• Advice on the best option for a given plant or application;
• Removal of R22, to enable retrofit or replacement; attractive financial credits on the recovered R22
• Reclaiming of R22 to “as new” specification for later re-use in service top-up;
• Supply of reclaimed R22 for topping up plant to the end of 2014, in line with legislation;
• Advice on the suitability of alternative replacement refrigerant for particular applications;
• Supply of alternative replacement refrigerants (R404A, R407A, R507, and ISCEON series);
• Engineering support, including refrigerant recovery machines and cylinders, drums and tanker for holding and transporting refrigerant;
• Guaranteed supply of virgin R22 until the end of 2009.

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.

Dr Davey says: “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.”

“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.”

To arrange a free, no obligation consultation with a Harp representative call 0800 134 404 or email sales@harpintl.com

• web: www.harpintl.com


//PANEL 1//

Who is Harp International?

Established in 1991, the company are leaders in the supply, reclamation and management of refrigerants.

They operate a “complete service” approach, and cater for the needs of major clients in both the UK and overseas markets.

Clients include leading food and drink producers and chemical manufacturers, who rely on Harp International for expert support and technical solutions.

The ISO-accredited company is based in Pontypridd in South Wales. Its 50,000 sq ft plant is equipped with state-of-the-art analytical, reclamation and packaging facilities.

The company has won several Welsh quality and environmental awards. Bulk storage and management of refrigerant on behalf of clients is an important and growing part of service.

• The company can be contacted on 01443 842255.


//PANEL 2//

The phase-out - what the EU Regulations mean

• The phase-out of R22 is being implemented under the EU Ozone Depleting Substances Regulation 2037/2000.
• The use of R22 in new plant has already been banned under the regulations.
• The use of new R22 for topping up existing systems will be banned from the end of 2009.
• From the beginning of 2010, only recycled R22 may be used to top up plant.
• From 2015, the use of all R22 for topping up will become illegal. * R22 contained in plant may continue to be used, but no top up will be allowed.
 

Email: sales@harpintl.com