With so many systems still running on R22 and with phase-out rapidly approaching, plant operators need to take some tough decisions as a matter of some urgency. Peter Dinnage, business development manager at IDS Refrigeration, suggests an energy-saving alternative to plant replacement
As is well documented, virgin R22 is to be phased out on the last day of 2009, but it will not be easily available from much earlier as refrigerant manufacturers switch production and are limited by reducing production quotas. Whereas it will remain legal to use recycled/reclaimed R22 to top up existing systems, there is insufficient returned product for reclaim and, more critically, limited capacity for reclamation, so product availability will definitely be a problem from the second half of 2008 onwards. Equally, poor quality reclaimed R22 could have an adverse effect on equipment and increase energy consumption.
Those R22 users such as supermarkets and others in the food supply chain have a choice. They can either rip out existing installations and put in completely new plant, or they can convert R22 applications using a proven direct replacement refrigerant such as DuPont’s Isceon 9 series. On an average supermarket site, the former solution might cost around £300,000 and the latter perhaps £30,000. The direct replacement refrigerant solution is not only far less costly, but causes less on-site disruption, an important factor for any operator where downtime costs them lost sales. Unless the system is on its last legs, the choice is a no brainer.
The Isceon 9 series delivers energy savings from its improved COP in the equipment and by the reduced discharge temperatures observed which can also help reduce compressor wear. Depending on several factors, including the type and age of the equipment, typical energy savings of between 5 and 10% have been reported by many satisfied users, but up to 15% has been achieved in particular instances.
Isceon series refrigerants can be 5-10% more efficient than R22
The Isceon 9 series is a family of replacement refrigerants. They are easy to use, non-ozone depleting retrofit refrigerants for CFC and HCFC equipment. They are non-toxic and non-flammable. There are three which are ideal for R22 and other HCFC applications. They include Isceon MO29 (R422D) for water chillers; Isceon MO59 (R417A) for many medium temperature refrigeration and air conditioning applications; and Isceon MO79 (R422A) for lower temperature applications.
With the R22 phase-out date now looming large, the major problem will be product availability, but the other issue will be price. As manufacturers reduce production it is absolutely inevitable that prices will rise significantly. Our sector has experienced this before with the programmed phasing out CFCs in the nineties. It is the natural law of supply and demand.
However, it is the limited practical timescale of not much more than two years which is the really critical factor. Some are already well advanced with replacing R22 but many others are not. We believe there are approaching 10,000 processes or supply critical refrigeration and air conditioning units still to be dealt with, which is 100 a week over the next two years or so. Understandably, supermarkets and factories have limited time windows when they can allow on-site activity, so factor that into the equation and the size of the problem becomes apparent and quite daunting.
This will place a significant demand on the refrigeration and air conditioning contracting sector’s ability to cope. Contractors familiar with doing conversions will be in big demand and those who leave it late in the day may find their regular contractor busy doing conversions for others. After all, there is only a finite number of suitably trained refrigeration engineers and only a finite capacity within the refrigeration contracting industry.
The phase out regulations make it quite clear that virgin R22 cannot be used after 1 January 2010, so stockpiling in 2009 as a fallback option does not exist. Its use will not be permitted.
So here is the message to those with R22 applications needing replacement:
Do not dilly dally any longer, assess the situation as a matter of urgency, and make some decisions.
Remember, the Isceon 9 series replacement option is a major energy saver, and judged against alternatives, a major capital cost saver as well.
IDS Refrigeration Ltd
0117 980 2520