Replacing Chlorofluorocarbon Refrigerants - US …

1 1 United StatesDepartment ofAgricultureForest ServiceTechnology &DevelopmentProgram7100 EngineeringSeptember 19989871-2835-MTDCR eplacingChlorofluorocarbonRefrigerantsJa sen NeeseSteve Oravetz7E72L56 Refrigeration StudyProject LeaderProgram LeaderSeptember 19982 The United States Department of Agriculture (USDA), prohibits discrimination in all its programs and activities on the basis of race, color, national origin, gender, religion, age, disability, political beliefs,sexual orientation, and marital or family status. (Not all prohibited bases apply to all programs.) Persons with disabilities who require alternative means for communication of program information (Braille,large print, audiotape, and so forth) should phone USDA s TARGET Center at (202) 720-2600 (voice and TDD).To file a complaint of discrimination, write: USDA, Director, Office of Civil Rights, Room 326-W, Whitten Building, 14th and Independence Avenue SW, Washington, DC 20250-9410, or call (202) 720-5964 (voice or TDD).

2 USDA is an equal opportunity provider and _____ 3 Environmental Background _____ 3 Refrigerants Background _____ 4 The Current Situation _____ 5 Procurement Laws _____ 5 Environmental and Servicing Laws _____ 6 The Significant New Alternatives Policy List _____ 6 Decisions Decisions Decisions _____ 7 Mobile Systems _____ 8 Vehicle Options _____ 8 Leave As Is _____ 8 Repair and Recharge _____ 8 Retrofit to HFC- 134a _____ 8 Retrofit to a Blend refrigerant _____ 8 Custom Vehicles _____ 9 Appliances _____ 9 Small Appliances _____ 9 Larger Appliances _____ 9 Comfort Cooling Applications _____ 10 Window Units _____ 10 Central Air-Conditioning _____ 10 Repair _____ 10 Retrofitting _____ 10 Replacement _____ 10 Chillers _____ 10 About the Authors _____ 11 Appendix A Glossary _____ 11 Appendix B Contract Clauses _____ 12 Appendix C Life-Cycle Cost Analyses _____ 13 Appendix D Sources of Additional Information _____ 16 Contents3 IntroductionThe Forest Service has many applications that use chloro-fluorocarbons (CFC s) and hydrochlorofluorocarbons(HCFC s).

3 This report provides guidance for updating thesesystems. These substances are thought to contribute todepletion of the earth s protective ozone layer. As the ForestService repairs or replaces units using these Refrigerants ,it can choose alternatives that are more energy efficientand less harmful to the ozone layer. Because this topic usesspecialized technical terms, a glossary has been included(Appendix A).Environmental BackgroundThe Montreal Protocol Treaty set limits on the productionand use of various ozone-depleting chemicals. Title VI ofthe Clean Air Act Amendments of 1990 addresses theUnited States requirements for handling ozone-depletingsubstances and for phasing them BackgroundCFC s and HCFC s (Figure 1) are chemicals typically usedin refrigeration processes, air-conditioning, and other appli-cations. The Clean Air Act classifies CFC s as Class Iozone-depleting substances (the most harmful) and HCFC sas Class II substances.

4 The production of CFC s essentiallyended in 1996. Class II substances have phaseout datesscheduled in the future. Table 1 summarizes the commonrefrigerants used by the Forest Service and their scheduledDate ofCommonfor phaseoutphaseoutForest Service usesCFC-1101/01/96 ChillersCFC-1201/01/96 ChillersCFC-12"AutomobilesCFC-12"Small appliancesHCFC-12301/01/30 ChillersHCFC-2201/01/20 ChillersHCFC-22"Window air-conditionersHCFC-22"Central air-conditionersRefrigerant Phaseout DatesTable 1 Ozone-depleting substances and their phaseout 1 Cylinder of CFC-12, a widely used Current SituationThe tremendous demand for CFC s with no new CFC sbeing produced is creating a shortage. CFC-12, the mostcommonly used CFC, may become unavailable by the endof 1999. If that happens, all equipment needing to berecharged with CFC-12 would be unusable. A Service-widephaseout of these chemicals can minimize the effects ofthe expected shortage on Forest Service LawsIn addition to environmental and market pressures to phaseout the use of CFC s, Federal agencies are required tominimize their use and procurement of ozone-depletingsubstances (Executive Order No.)

5 12843 and Title 48 of theCode of Federal Regulations, Chapter 1, Part 23, ). In addition, contract clauses (Appendix B) must be in-serted into solicitations or contracts for supplies that may con-tain ozone-depleting substances, including Servicing LawsThe Environmental Protection Agency (EPA) administersrefrigerant regulations. The following rules of thumb sum-marize EPA regulations, but do not replace them. AppendixD lists sources of additional information. Have leaking refrigerant systems fixed. Only EPA-certified technicians using EPA-certifiedrecovery equipment can work on a refrigeration circuit. Under no circumstances, are you allowed to vent refrig-erants into the atmosphere. Have the refrigerant removed before disposing of a unitcontaining Significant NewAlternatives Policy ListThe Significant New Alternatives Policy (SNAP) programwas created by the EPA to evaluate alternatives to ozone-depleting substances.

6 Lists containing all acceptable andunacceptable Refrigerants are available from the EPA. Table2 contains a shortened list of acceptable replacementrefrigerants. Many more applications and alternatives arelisted in the updated SNAP catalog. Any refrigerant usedas a replacement must be evaluated under the SNAP pro-gram. Check the SNAP lists if you want more informationon replacement ForestOzone-depleting ManufacturersService usessubstanceAlternativesTrade namesor distributors**ChillersR-11 HCFC-123 suva -123 DuPontGentron 123 Allied SignalForane 123 Elf AtochemR-123othersR-12 HFC-134aSUVA-134aDuPontGentron 134aAllied SignalForane 134aElf AtochemKLEA 134aICI AmericasR-134aothersAppliancesR-12 HFC-134aSUVA-134aDuPontGentron 134aAllied SignalForane 134aElf AtochemKLEA 134aICI AmericasR-134aothersFreezersR-12R-401 BSUVA MP-66 DuPontRefrigeratorsR-12 BlendsCool EZ RB-276 Quaker StateReach-in coolersR-12R-401 ASUVA MP-39 DuPontWindow air-conditioningR-22 HCFC-22R-22othersCentral air-conditioningR-22 HCFC-22R-22othersR-22R-407 CSUVA 9000 DuPontAutomobilesR-12 HFC-134aSUVA-134aDuPontGentron 134aAllied SignalForane 134aElf AtochemKLEA 134aICI AmericasR-134aothersR-12 BlendsFRIGC FR-12

7 PennzoilCool EZ RB-276 Quaker State * See SNAP list for more selections. ** Phone numbers available in Appendix 2 Forest Service applications and some common replacement alternative Refrigerants .*Replacement Refrigerants for Ozone-Depleting Substances7 Figure 2 Vehicle air-conditioning costssystemcontainsless thanunderCFC-12$50-$75 and to HFC- 134a ,change to a blend, or to and Vehicle Air-ConditioningFigure 4 Comfort cooling adepletingthanor morewatersubstance 10 yearsrefrigerant1chillerSolutionYesNoYes YesRefer to cycle cost to cycle cost with Energy Star2or certified cycle cost with Energy Star2or certified If Yes and the unit is leaking at a rate of 15% or more of the total charge,and over a 12-month period, the unit must be repaired within 30 See Appendix D, See Appendix Cooling DecisionsContainsozone-Olderdepletingtha nsubstance15 yearsSolutionYesYesReplace with Energy Star1 or original refrigerant is not available, replaceor retrofit with SNAP original refrigerant is available.

8 Fix with Energy Star1 or and See Appendix Replacement DecisionsFigure 3 Appliance Decisions DecisionsYou have three basic choices when deciding whether torepair or replace equipment containing Refrigerants . Thefirst option is to fix the equipment, recharging it with theoriginal refrigerant , if it is available. Retrofitting should beconsidered if the original refrigerant has been phased out(CFC-12). Many types of equipment can be retrofitted to usean alternative refrigerant . Retrofitted equipment typicallyhas lower efficiency and less capacity than new third choice is to replace the unit. This option has thehighest initial cost, but in many cases may be the cheapestover the lifetime of the equipment. Over the past 15 years,cooling equipment has become far more energy between the options can be difficult. Economicand environmental factors play an important part in anydecision.

9 A life-cycle cost analysis can help you select aneconomically feasible option. The life-cycle cost analysesin Appendix C are most useful when the unit s age or energy-efficiency rating lies just above or below standards. Also,use a life-cycle cost analysis when the decision matrixes(Figures 2, 3, and 4) do not present a clear-cut equipment is more energy efficient and uses lessharmful Refrigerants . Managers should consider the risk ofcontinuing to use equipment containing CFC s into the nextcentury. CFC s may soon be unavailable. A CFC unit maybecome worthless if it loses its charge of SystemsCFC-12 was the dominant refrigerant in vehicle air-condi-tioning systems. In 1994 all vehicle manufacturers switchedto HFC- 134a , a refrigerant that does not deplete the ozonelayer. A label under the vehicle s hood indicates the typeof refrigerant it contains (Figure 5). The Forest Servicecontinually replaces its vehicles.

10 Most vehicles still usingCFC-12 will be eliminated from the fleet as they are remaining vehicles many different options are 2 contains a decision matrix. The EPA s SNAP listidentifies replacement Refrigerants and sources. Managersshould look over the SNAP list before making any 5 A label indicating that the air-conditioning system hasbeen retrofitted to work with As IsLeaving a vehicle without air-conditioning may be a viableoption. Consider the climate and the vehicle s type of and RechargeThis is probably the best option while CFC-12 is still avail-able at a reasonable price. Many shops are equipped tohandle the procedure. The cost of a simple recharge withCFC-12 was about $100 to $200 in 1998. However, if theair-conditioning system needs to be recharged again, CFC-12 may be unavailable or exceedingly to HFC-134aRetrofitting to HFC- 134a is the preferred alternative if CFC-12 is unavailable or prohibitively expensive.