Global warming and refrigerants

News

Global warming is an urgent problem threatening all of humanity. The fact that the climate is warming is indisputable and has been confirmed by numerous studies, including those conducted by the Intergovernmental Panel on Climate Change (IPCC), an organization representing the position of scientists from dozens of countries. The continuous rise in Earth’s temperature causes catastrophic environmental effects, including the loss of ice cover, rising sea levels, the disappearance of natural habitats, and the extinction of many animal and plant species. Further consequences include severe social problems such as crop losses, migration, limited access to drinking water, material damage, and a direct threat to human life as a result of extreme weather events. The IPCC position is also confirmed by the Polish Academy of Sciences. In a statement issued on 10 December 2018, it stated that human activity is the dominant cause of contemporary global warming, and that science provides indisputable evidence for this.

Polish scientists summarize the current state of knowledge on climate change:

  • The Earth is warming rapidly; the current average temperature is about 1°C higher compared to the period before the rapid development of industry.
  • Greenhouse gas emissions resulting from human activity are the main driver of climate change.
  • Many of the resulting changes already have a negative impact on society today and may further exacerbate social problems.
  • There is still a chance to avoid a total climate crisis, but it is rapidly diminishing over time.

According to the IPCC report, humanity has until 2030 to reduce carbon dioxide emissions by 45% (compared to 2010 levels) in order to prevent catastrophic climate impacts. Otherwise, continued melting of the ice sheets may trigger the release of methane from permafrost—a greenhouse gas that is 25 times “stronger” than CO₂. There is also a real risk of destabilisation of subsea methane hydrates. Uncontrolled release of such large quantities of greenhouse gases could irreversibly accelerate the climate crisis and its consequences. Scientists are clear that human activity is the cause of current climate threats. However, it should be noted that not only gases from fossil fuel combustion are responsible for the enhanced greenhouse effect. Currently used refrigerants from the HFC group are also greenhouse gases with a very high Global Warming Potential (GWP). They are also the only greenhouse gases covered by the Kyoto Protocol that do not occur naturally but are produced by humans. One kilogram of commonly used refrigerants such as R-404A or R-507A has over 3,900 times greater impact on the climate than an equivalent amount of carbon dioxide. Therefore, it is crucial to handle fluorinated gases (F-gases) responsibly, ensure they are used only by qualified personnel, prevent leaks, and properly manage refrigerants recovered from equipment.

Implementing stringent F-gas regulations is often not easy in practice; however, it enables a significant reduction in HFC emissions into the atmosphere, which in turn is one of the key actions we can take to limit climate change on Earth. For nearly 25 years, PROZON Foundation for Climate Protection has been supporting service companies and equipment operators by providing specialist training, offering refrigerant recovery and reclamation services, as well as comprehensive laboratory testing.

Lifecycle of refrigerants

The most commonly used refrigerants today belong to the group of hydrofluorocarbons (HFCs), which are fluorinated greenhouse gases (F-gases) with a high global warming potential (GWP). In addition to HFCs, F-gases also include perfluorocarbons (PFCs) and sulfur hexafluoride (SF₆). The negative environmental impact of these substances requires their recovery from equipment and the implementation of a circular economy approach. This means reusing the gas as much as possible. This is achievable under specific conditions, which will be discussed in the following part of the manual.

Legal regulations

Due to the significant impact of F-gases on climate change, their handling has been regulated by international agreements and legal provisions. The basic legal act in force in the European Union in this area is Regulation (EU) No 517/2014 of the European Parliament and of the Council of 16 April 2014 on fluorinated greenhouse gases and repealing Regulation (EC) No 842/2006. At the national level in Poland, the act specifying the provisions of the above Regulation is the Act of 15 May 2015 on substances that deplete the ozone layer and certain fluorinated greenhouse gases (Journal of Laws 2018, item 2221, as amended). In areas not regulated by law, reference should be made to standards defining best available practices and to scientific publications.

Refrigerant recovery

Recovery means the collection and storage of F-gases from products, including containers and equipment, during maintenance or servicing, or prior to the disposal of products or equipment, in accordance with the definition set out in EU Regulation No 517/2014 (Article 2(14)) [1]. Pursuant to Article 8 of the above-mentioned Regulation [1], the equipment operator is obliged to ensure the recovery of refrigerants for a specific purpose—namely recycling, reclamation, or destruction. Therefore, after recovery, one of these three operations must be carried out. Direct reuse of a refrigerant in an installation is not compliant with the above regulations.

According to Article 3(1)(6) of the Waste Act [3], waste is defined as any substance or object which the holder discards, intends to discard, or is required to discard. However, in the case of equipment decommissioning or replacement of a refrigerant with another one (so-called retrofit), regardless of the owner’s intention to discard it, the recovered refrigerant becomes hazardous waste classified under code 14 06 01*. This results from the fact that in both cases there is a permanent functional separation between the refrigerant and the equipment [5]. If the agreement between the equipment operator and the service company does not state otherwise, under Article 3(1)(32) of the Waste Act [3], the waste producer in the form of recovered refrigerant is the service company performing the service.

The entity holding the waste is obliged to manage it in accordance with the regulations on waste management. In this case, specific legal requirements regarding the storage, transport, and treatment of hazardous waste must be fulfilled [3].

Transport

If the waste producer in the form of recovered refrigerant is the service company, it may transport the waste it has generated to a treatment facility without a permit. However, it should be noted that above 1 tonne, the waste must be transported in accordance with ADR requirements. In situations where the operator is the waste producer and transfers it to a service company, the company must hold a permit for collecting this type of waste and be registered in the Waste Database (BDO) with respect to waste transport.

Recovery authorization

The equipment operator must ensure that the recovery of these gases is carried out by individuals holding appropriate F-gas certificates. [1]

Penalties

Failure to ensure recovery or proper recovery in accordance with the above provision is subject to an administrative penalty ranging from PLN 4,000 to PLN 15,000 (Article 48(13), (14), and (15) of the F-gas Act) [2].

Proper recovery

✔ is carried out using a recovery unit

✔ into a cylinder with a two-valve (two-way valve) system

Zeotropic mixtures

Recovery of zeotropic mixtures (all mixtures whose designation starts with the number 4, e.g. R-404A, R-407C, R-410A) involves their fractionation, which significantly affects their composition and operating parameters. Therefore, it is necessary to subject such recovered refrigerant to chromatographic analysis, and in the event of a change in composition, to a reclamation process.

Refrigerant recycling

“Recycling” means the reuse of a recovered fluorinated greenhouse gas after a basic cleaning process, in accordance with the definition set out in EU Regulation No 517/2014 (Article 2(15)) [1]. The Regulation does not specify what constitutes basic cleaning of a refrigerant. Therefore, reference should be made to standards that define the appropriate methods of handling in this regard.

ISO 11650 [6] provides a detailed description of the requirements for equipment used in the recovery and recycling process. Such equipment must meet specified requirements and perform defined processes. According to this standard, recycling means reducing the level of contamination in a used refrigerant by separating oil, removing non-condensable gases, and using equipment such as filters to reduce moisture, acidity, and the content of solid impurities.

Reuse of a refrigerant in the same installation

EU regulations [1] permit the use of recovered refrigerant in the same installation; however, it should be noted that ensuring proper operation of equipment requires testing the quality of the refrigerant being reintroduced into the system. According to standard PN-EN 378-4 [7], which specifies safety and environmental requirements for refrigeration systems, the decision to reuse refrigerant in the same system should be based on the result of a prior acidity test. The standard also indicates that the applicable method for measuring acidity is a titration test.

Heavily contaminated refrigerant

The standard also specifies that if a refrigeration system has been taken out of service due to heavy contamination of the refrigerant or compressor motor burnout, the refrigerant from such equipment should be subjected to reclamation or destruction. Recycling is not an approved process in this case.

Zeotropic mixtures

In the case of zeotropic mixtures (e.g. R404A, R410A), recycling is an insufficient process to restore proper operating parameters due to changes in the composition of the mixture.

These mixtures exhibit temperature glide, meaning that they consist of substances with different boiling points. As a result, since the refrigerant exists in the system in two phases simultaneously—gas and liquid—leakage can lead to changes in the mixture’s composition.

Therefore, in the event of a leak, after repairing the equipment, the correct procedure is to perform a composition analysis of the mixture. This analysis determines whether the refrigerant requires reclamation or whether, after recycling, it can be reused in the system without further processing.

Any methods aimed at restoring zeotropic mixtures to their original state by topping up losses with a new mixture or more volatile components are incorrect from a regulatory perspective.

Such improper handling may lead to a complete change in the composition of the mixture, resulting in an entirely different refrigerant with different operating parameters. Further attempts at such corrective actions lead to mixing two different refrigerants, which—according to manufacturers’ recommendations for refrigeration system components, especially compressors—is an incorrect practice that may result in damage to the refrigeration system and voiding of the warranty [8].

Impact of refrigerant composition changes on equipment operating parameters

Expert studies clearly indicate the impact of changes in the composition of the working fluid on the operating parameters of refrigeration equipment. When refrigerant fractionation occurs, the following effects are observed [11]:

  • a decrease in cooling capacity,
  • an increase in compressor wear rate,
  • deterioration of refrigerant flow conditions inside heat exchangers due to increased liquid viscosity,
  • changes in temperature glide, resulting in changes in expansion valve control,
  • increased energy consumption.

Service company responsibility

Ultimately, it is the service company that is responsible for the safety, energy efficiency, and reliable operation of the equipment. Therefore, it is also responsible for using a refrigerant with the correct parameters and for being aware of the consequences of using refrigerants whose quality does not comply with the requirements of the standard.

Proper labelling of refrigerants after the recycling process

Reclaimed or recycled fluorinated greenhouse gases must be labelled to indicate that the substance has been reclaimed or originates from recycling, including information on the batch number and the name and address of the facility where the reclamation or recycling was carried out. [1]

 

How to avoid poor refrigerant quality

✔ purchase refrigerant from known and legal sources

✔ check the quality of the purchased refrigerant before first use

✔ check the quality of the refrigerant in the system before carrying out repairs

 

Refrigerant reclamation

According to the definition set out in EU Regulation 517/2014 (Article 2(16)) [1], reclamation means the reprocessing of a recovered fluorinated greenhouse gas in order to restore performance characteristics equivalent to those of the original substance, taking into account its intended use.

Reclamation is the full restoration of the original quality of the refrigerant.

✔ Oil removal
✔ Removal of non-condensable gases
✔ Removal of acids, water, chlorides, and solid particles from the refrigerant
✔ Mixture composition replenishment
✔ Testing and certification
✔ Safe storage. Testing and composition replenishment are essential for restoring the properties of the original refrigerant!

 

High quality refrigerant

✔ Efficient cooling
✔ Lower energy consumption
✔ Longer equipment lifespan
✔ Avoiding costly breakdowns
✔ Safety
✔ Environment

 

Refrigerant quality after reclamation

The refrigerant after the reclamation process has quality parameters corresponding to virgin refrigerants, compliant with the AHRI 700 quality standard [9]. This is confirmed by a certificate issued on the basis of specialized laboratory tests.

 

Use of refrigerants with unknown or improper parameters

Only certainty regarding the composition of the refrigerant guarantees avoiding problems that result from the use of refrigerants of inadequate quality, i.e. increased energy consumption, reduced cooling efficiency, reduced compressor lifespan, serious equipment failures, and emissions. As indicated in the technical literature, the absence of non-condensable gases, moisture, oxides, solid particles and acids in the equipment ensures its long service life. The appearance of these contaminants is the cause of most failures, both those occurring immediately and those appearing after a longer period of equipment operation [10].

Loss of waste status

A very important fact is that the reclamation process causes the recovered refrigerant to lose its waste status, which means that, in accordance with national waste regulations [3], it can be reused in a different piece of equipment than the one it came from.

Service ban from January 1, 2020

In accordance with Article 11(3) of Regulation 517/2014 [1], from January 1, 2020, the use of fluorinated greenhouse gases with a GWP of 2500 or more for the servicing or maintenance of refrigeration equipment with a charge size of 40 tonnes of CO2 equivalent or more is prohibited. For refrigerants R-404A and R-507A, this means a charge of 10.4 kg or more.

Exceptions to the above prohibition include applications in military equipment or devices designed to cool products to temperatures of -50°C.

Furthermore, until January 1, 2030, this prohibition does not apply to the following categories of fluorinated greenhouse gases:

  • reclaimed gases with a GWP ≥ 2500, used for the maintenance or servicing of existing refrigeration equipment, provided they are labelled in accordance with Article 12(6) of Regulation 517/2014 [1]
  • recycled gases with a GWP ≥ 2500, used for the maintenance or servicing of existing refrigeration equipment, provided they have been recovered from such equipment. Such recycled gases may only be used by the undertaking that carried out their recovery during maintenance or servicing, or the undertaking for which the recovery was carried out during maintenance or servicing.

Equipment decommissioning

In the case of equipment decommissioning, the recovered refrigerant must be disposed of [1], which should mean getting rid of it [5] by handing it over to a waste management unit with waste code 14 06 01*. Depending on the results of the testing of the waste refrigerant parameters, it is either subjected to reclamation or thermal disposal. The operator of the decommissioned equipment is obliged to provide information on the measures taken to dispose of the recovered refrigerant in the Equipment Log (applicable to equipment with a charge of ≥ 5 tonnes of CO2 equivalent) in the Central Operator Register in accordance with Article 6 of Regulation 517/2014 [1].

Summary

Recovery is only possible for the purpose of recycling, reclamation, or destruction. Determining the appropriate method of handling the recovered refrigerant requires an assessment of its quality parameters. Reintroducing the recovered refrigerant into the system without conducting quality and composition tests poses a risk to the proper functioning of the equipment. Reclamation is the process that guarantees the restoration of the proper composition and working parameters of the recovered refrigerant.

References:

[1] Regulation (EU) No 517/2014 of the European Parliament and of the Council of 16 April 2014 on fluorinated greenhouse gases and repealing Regulation (EC) No 842/2006
[2] Act of 15 May 2015 on substances that deplete the ozone layer and on certain fluorinated greenhouse gases (Journal of Laws of 2018, item 2221, as amended)
[3] Act of 14 December 2012 on waste (Journal of Laws of 2018, item 992, as amended)
[4] Regulation of the Minister of the Environment of 12 December 2014 on the templates of documents used for waste records (Journal of Laws, item 1973)
[5] Legal opinion for the PROZON Foundation – Law Office of Legal Counsel Urszula Jones – Urszula Owczarska KATENA S.C.
[6] ISO 11650:1999 Performance of refrigerant recovery and/or recycling equipment
[7] PN-EN 378-4 Refrigerating systems and heat pumps – Safety and environmental requirements – Part 4: Operation, maintenance, repair and recovery
[8] Zeotropic mixtures in compression refrigeration systems / Michał Pysz, Artur Bieniek, Łukasz MIKA // Chłodnictwo; ISSN 0009-4919. — 2018, Vol. 53, No. 2, pp. 30–35
[9] AHRI Standard 700: Specifications for Refrigerants
[10] Vademecum of Refrigerant Recovery – Denis Clodic, Frédérique Sauer
[11] Assessment of the impact of R404A refrigerant composition on the operating parameters of the refrigeration cycle – DSc Eng. Jacek Kasperski, Prof. at Wrocław University of Technology, PhD Eng. Bartosz Gil (December 2017)

Collective work edited by

Renata Łukaszewicz