Eco-friendly

Refrigerants
History Of Refrigeration
Refrigeration relates to the cooling of air or liquids, thus
providing lower temperature to preserve food, cool
beverages, make ice and for many other .
Most evidence indicate that the Chinese were the first
to store natural ice and snow to cool wine and other
delicacies.
Ancient people of India and Egypt cooled liquids in
porous earthen jars.
In 1834, Jacob Perkins, an American, developed a
closed refrigeration system using liquid expansion and
then compression to produce cooling. He used Ether as
refrigerant, in a hand- operated compressor, a water-
cooled condenser and an evaporator in liquid cooler.
Refrigerantion Principle
Modern refrigeration and air-
conditioning equipment is dominated
by vapour compression refrigeration
technology built upon the
thermodynamic principles of the
reverse Carnot cycle.
Refrigerant Changes phases during
cooling and used again and again.
 What is a Refrigerant
Refrigerants are used as working substances in a
Refrigeration systems.
Fluids suitable for refrigeration purposes can be classified
into primary and secondary refrigerants.
Primary refrigerants are those fluids, which are used
directly as working fluids, for example in vapour
compression and vapour absorption refrigeration systems.
These fluids provide refrigeration by undergoing a phase
change process in the evaporator.
Secondary refrigerants are those liquids, which are used
for transporting thermal energy from one location to
other. Secondary refrigerants are also known under the
name brines or antifreezes
 What is
ChloroFloroCarcons
Todays refrigerants are predominantly
from a group of compounds called
halocarbons (halogenated hydrocarbons)
or specifically fluorocarbons.
Chlorofluorocarbons were first developed
by General Motors researchers in the
1920s and commercialized by Dupont as
Freons.
 Halocarbon
Refrigerants
Halocarbon Refrigerant are all
synthetically produced and were
developed as the Freon family of
refrigerants.

Examples :
CFCs : R11, R12, R113, R114, R115
 Freon Group Refrigerants Application and ODP
Values
Refrigerant Areas of Application ODP
CFC 11(R11) Air-conditioning Systems ranging from 200 to 1.0
2000 tons in capacity. It is used where low
freezing point and non-corrosive properties
CFC 12 ( R are important.
12 ) It is used for most of the applications. Air- 1.0
conditioning plants, refrigerators, freezers,
ice-cream cabinets, water coolers, window air-
conditioners, automobile air conditioners.
CFC 13 (R 13) For low temp refrigeration up to 90 C in 1.0
cascade system

CFC113 Small to medium air-conditioning system and 1.07

( R113 ) industrial cooling
0.8
CFC114 In household refrigerators and in large 0.34
( R114 ) industrial cooling
Blend of R22 Frozen food ice-cream display cases and
and R115 warehouses and food freezing plants. An
(R502) excellent general low temp refrigerant
 What is Ozone Layer
Ozone is an isotope of oxygen with three atoms
instead of normal two. It is naturally occurring
gas which is created by high energy radiation
from the Sun.
The greatest concentration of ozone are found
from 12 km to 50 km above the earth forming a
layer in the stratosphere which is called the
ozone layer.
This layer, which forms a semi-permeable
blanket, protects the earth by reducing the
intensity of harmful ultra-violet (UV) radiation
from the sun.
 Ozone Layer Depletion
In the early70s,scientists Sherwood Roland and
Mario Molina at the University of California at
Irvine were the first to discover the loss of ozone
in stratosphere while investigating the ozone
layer from highflying aircraft and spacecraft.
They postulated the theory that exceptionally
stable chlorine containing fluorocarbons could,
overtime, migrate to the upper reaches of the
atmosphere and be broken by the intense
radiation and release chlorine atoms responsible
for catalytic ozone depletion.
OZONE LAYER DEPLETION
N0RMAL REACTION
O2 = O + O
O2 + O = O 3

But CFC refrigerants leaked during the manufacturing and normal

operation or at the time of servicing or repair, mix with
surrounding air and rise to troposphere and then into
stratosphere due to normal wind or storm. The Ultraviolet rays act
on CFC releasing Cl atom, which retards the normal reaction:

RETARDED REACTION
O3 = O2 + O
CCL2F2 = CCLF2 + CL
O3 + CL = CLO + O2
O + CLO = CL + O2
 Harmful consequences of
ozone depletion
For Humans Increase in
skin cancer
snow blindness
cataracts
Less immunity to
infectious diseases
malaria
herpes
For plants
smaller size
lower yield
increased toxicity
altered form

For marine life

Reduced
plankton
juvenile fish
larval crabs and shrimps
MONTREAL PROTOCOL
SIGNED IN 1987 UNDER THE UNEP, AFTER MUCH
DISCUSSIONS

MORE THAN 170 COUNTRIES HAVE RATIFIED

INDIA RATIFIED ON SEPT 17,1992

ONE OF MOST SUCCESSFUL EXAMPLE OF

INTERNATIONAL COOPERATION IN UN HISTORY
 Montreal protocol- Control
Schedule
Montral Protocol- Control Schedule
ozone depleting developed countries developing countries
substance

CFCs phased out end of total phase out by

1995 2010

halons phased out end of total phase out by

1993 2010

HCFCs total phase out by total phase out by

2020 2040
 CFC Phase-out in India
What is to be phased out?
CFC-11, CFC-12 &CFC-113a.
How much and when?

Year1999 22,588 MT
2005 11,294 MT
2010 o MT
How to achieve the target?
Production is controlled through a production quota allocated to each
producer every year. The Ozone Cell conducts audits twice a year to
monitor the production.
How much has been Phaseout?CFC has been completely phased out as
on1st August, 2008
 Vapor compression
refrigeration System
In 1834 an American inventor named Jacob
Perkins obtained the first patent for a vapor-
compression refrigeration system, it used ether
in a vapor compression cycle.
Joule-Thomson (Kelvin) expansion
Low pressure (1.5atm) low temperature (-10 to
+15) inside
High pressure (7.5atm) high temperature (+15
to +40) outside
 Components
Refrigerant
Evaporator/Chiller
Compressor
Condenser
Receiver
Thermostatic
expansion valve
(TXV)
 Circulation of
Refrigerant
Compressor
cold vapor from the evaporator is compressed, raising it temperature and boiling point
adiabatic compression
T, b.p. ~ P
work done on the gas
Condenser
hot vapor from the compressor condenses outside the cold box, releasing latent heat
isothermal, isobaric condensation (horizontal line on PV diagram)
high temperature
T (hot)
latent heat of vaporization Q(hot)
Expansionvalve (throttling valve)
hot liquid from the condenser is depressurized, lowering its temperature and boiling point
adiabatic, isochoric expansion (vertical line on PV diagram)
T, b.p. ~ P
no work done W=0
Evaporator
cold liquid from the expansion valve boils inside the cold box, absorbing latent heat
isothermal, isobaric boiling (horizontal line on PV diagram)
low temperature
T (cold)
latent heat of vaporization Q(cold)
 Importance of
Refrigerant
The thermodynamic efficiency of a refrigeration system
depends mainly on its operating temperatures.
However, important practical issues such as the system
design, size, initial and operating costs, safety,
reliability, and serviceability etc. depend very much on
the type of refrigerant selected for a given application.
Due to several environmental issues such as ozone
layer depletion and global warming and their relation to
the various refrigerants used, the selection of suitable
refrigerant has become one of the most important
issues in recent times.
 Refrigerant selection
criteria
Selection of refrigerant for a particular
application is based on the following
requirements:
i. Thermodynamic and thermo-physical
properties

ii. Environmental and safety properties

Iii. Economics
 Thermodynamic and
thermo-physical
properties
The requirements are:
a) Suction pressure: At a given evaporator temperature, the
saturation pressure should be above atmospheric for
prevention of air or moisture ingress into the system and
ease of leak detection. Higher suction pressure is better as
it leads to smaller compressor displacement
b) Discharge pressure: At a given condenser temperature,
the discharge pressure should be as small as possible to
allow light-weight construction of compressor, condenser
etc.
c) Pressure ratio: Should be as small as possible for high
volumetric efficiency and low power consumption
d) Latent heat of vaporization: Should be as large as
possible so that the required mass flow rate per unit cooling
capacity will be small
 Thermodynamic and
thermo-physical
properties
In addition to the above properties; the following properties are also
important:
e) Isentropic index of compression: Should be as small as possible so
that the temperature rise during compression will be small
f) Liquid specific heat: Should be small so that degree of subcooling
will be large leading to smaller amount of flash gas at evaporator
inlet
g) Vapour specific heat: Should be large so that the degree of
superheating will be small
h) Thermal conductivity: Thermal conductivity in both liquid as well
as vapour phase should be high for higher heat transfer coefficients
i) Viscosity: Viscosity should be small in both liquid and vapour
phases for smaller frictional pressure drops
The thermodynamic properties are interrelated and mainly depend
on normal boiling point, critical temperature, molecular weight and
structure.
 Environmental and
safety properties
At present the environment friendliness of the
refrigerant is a major factor in deciding the usefulness
of a particular refrigerant. The important environmental
and safety properties are:
a) Ozone Depletion Potential (ODP): According to the
Montreal protocol, the ODP of refrigerants should be
zero, i.e., they should be non-ozone depleting
substances. Refrigerants having non-zero ODP have
either already been phased-out (e.g. R 11, R 12) or will
be phased-out in near-future(e.g. R22). Since ODP
depends mainly on the presence of chlorine or bromine
in the molecules, refrigerants having either chlorine
(i.e., CFCs and HCFCs) or bromine cannot be used under
the new regulations
Environmental Effects of
Refrigerants
Global warming :
Refrigerants directly contributing to global
warming when released to the atmosphere

Indirect contribution based on the energy

consumption of among others the
compressors ( CO2 produced by power
stations )
 Environmental and
safety properties
b) Global Warming Potential (GWP): Refrigerants
should have as low a GWP value as possible to
minimize the problem of global warming.
Refrigerants with zero ODP but a high value of GWP
(e.g. R134a) are likely to be regulated in future.
c) Total Equivalent Warming Index (TEWI): The factor
TEWI considers both direct (due to release into
atmosphere) and indirect (through energy
consumption) contributions of refrigerants to global
warming. Naturally, refrigerants with as a low a value
of TEWI are preferable from global warming point of
view.
 Environmental and
safety properties
d) Toxicity: Ideally, refrigerants used in a refrigeration system should be
non-toxic. Toxicity is a relative term, which becomes meaningful only when
the degree of concentration and time of exposure required to produce
harmful effects are specified. Some fluids are toxic even in small
concentrations. Some fluids are mildly toxic, i.e., they are dangerous only
when the concentration is large and duration of exposure is long. In general
the degree of hazard depends on:

- Amount of refrigerant used vs total space

- Type of occupancy

- Presence of open flames

- Odor of refrigerant, and

- Maintenance condition
 Environmental and
safety properties
e) Flammability: The refrigerants should preferably be
non-flammable and non-explosive. For flammable
refrigerants special precautions should be taken to
avoid accidents.
f) Chemical stability: The refrigerants should be
chemically stable as long as they are inside the
refrigeration system.
g) Compatibility with common materials of construction
(both metals and non-metals)
h) Miscibility with lubricating oils: Oil separators have
to be used if the refrigerant is not miscible with
lubricating oil (e.g. ammonia). Refrigerants that are
completely miscible with oils are easier to handle(R12).
 Environmental and
safety properties
Ease of leak detection: In the event of
leakage of refrigerant from the system,
it should be easy to detect the leaks.
Economic properties:
The refrigerant used should preferably
be inexpensive and easily available.
ECO-FRIENDLY REFRIGERANTS

C FC
A L T E R N A T IV E S .

H C FC H FC N A T U R A L R E F R IG E R A N T
R 2 2 ,R 1 2 4 R 1 3 4 a ,R 1 5 2 a N H 3, H C 'S
 Halocarbon
Refrigerants
Halocarbon Refrigerant are all
synthetically produced and were
developed as the Freon family of
refrigerants.

Examples :
CFCs : R11, R12, R113, R114, R115
HCFCs : R22, R123
HFCs : R134a, R404a, R407C, R410a
 HFCs
Remain a popular choice
especially for R22 phase out
Good efforts at improving leakage
performance
e.g. Real Zero project
Interest in R407A to replace R404A
50% reduction in GWP

F Gas Stakeholder Group, 14th October 2009 Slide 30

 Inorganic Refrigerants
Carbon Dioxide
Water
Ammonia
Air
Sulphur dioxide
 HCFC
Transitional compounds with low
ODP
Partially halogenated compounds of
hydrocarbon
Remaining hydrogen atom allows
Hydrolysis and can be absorbed.
R22, R123
 HCFC
Production frozen at 1996 level
35% cut by 2005,65% by 2010
90% by 2015,100 % by 2030
10 year grace period for
developing countries.
 R22
ODP-0.05, GWP-1700
R22 has 40% more refrigerating capacity
Higher pressure and discharge temp and
not suitable for low temp application
Extensively used in commercial air-
conditioning and frozen food storage and
display cases
 R123
ODP-0.02,GWP-90
As a replacement for R11 as
similar thermodynamic properties.
Very short atmospheric life but
classified as carcinogen
Retrofit alternative to R11
 HFC
Zero ODP as no chlorine atom contains
only Hydrogen and Flurodine
Very small GWP values
No phase out date in Montreal Protocol
R134a and R152 a Very popular
refrigerants
HFC refrigerants are costly refrigerants
 R134a
ODP-0, GWP-1300
Used as a substitute for R12 and
to a limited range for R22
Good performance in medium and
high temp application
Toxicity is very low
Not miscible with mineral oil
 R152a
ODP-0,GWP-140
R152a is another attractive HFC with
similar properties to R12.
GWP is one order less than HFC134a
but it is slightly flammable.
Also it has lower energy consumption.
Hence the Environmental Protection
Agency of Europe prefers HFC152a to
HFC134a
 Hydrocarbon
Very promising non-halogenated organic
compounds
With no ODP and very small GWP values
Their efficiency is slightly better than other
leading alternative refrigerants
They are fully compatible with lubricating
oils conventionally used with CFC12.
 Hydrocarbon
Refrigerants
Extraordinary reliability- The most convincing argument
is the reliability of the hydrocarbon system because of
fewer compressor failures.
But most of the hydrocarbons are highly flammable and
require additional safety precaution during its use as
refrigerants.
Virtually no refrigerant losses
Hydrocarbons have been used since the beginning of
the century and now being considered as long term
solutions to environmental problems,
 Hydrocarbons

Dominant in domestic market like

household refrigerators and freezers
Growing use in very small commercial
systems like car air-conditioning system

Examples: R170, Ethane, C2H6

R290 , Propane C3H3
R600, Butane, C4H10
R600a, Isobutane, C4H10
Blends of the above Gases
F Gas Stakeholder Group, 14th October 2009 Slide 42
 R290
ODP-0,GWP-3
Compatible with copper.Miscible with mineral
oil
Highest latent heat and largest vapour density
A third of original charge only is required when
replacing halocarbons refrigerant in existing
equipment
Energy saving : up to 20% due to lower
molecular mass and vapour pressure
 R 600a
ODP-0,GWP-3
Higher boiling point hence lower
evaporator pressure
Discharge temp is lowest
Very good compatibility with
mineral oil
 Flammability
Approximate auto ignition temperatures
R22 630 C
R12 750 C
R134a 740 C
R290 465 C
R600a 470 C

 Modifications of
Electrical Equipment

Replaced with solid state equivalents

Sealed to ensure that any sparks do
not come into contact with leaking gas
Relocated to a position where the
component would not come into
contact with leaking gas
 Modifications of
Electrical Equipment
Faulty components.
Poor, corroded, loose, or dirty
electrical connections.
Missing or broken insulation which
could cause arcing/sparks.
Friction sparks, like a metal fan
blade hitting a metal enclosure.
 Blends & Mixtures
Limited no of pure refrigerants
with low ODP & GWP values
To try a mixture of pure
refrigerants to meet specific
requirement
Azeotropic Refrigerants
A stable mixture of two or several
refrigerants whose vapour and liquid
phases retain identical compositions
over a wide range of temperatures.

Examples : R-500 : 73.8% R12 and 26.2% R152

R-502 : 8.8% R22 and 51.2% R115
R-503 : 40.1% R23 and 59.9% R13
 Zeotropic Refrigerants
A zeotropic mixture is one whose
composition in liquid phase differs to that in
vapour phase. Zeotropic refrigerants
therefore do not boil at constant
temperatures unlike azeotropic refrigerants.
Examples :R404a : R125/143a/134a (44%,52%,4%)
R407c : R32/125/134a (23%, 25%, 52%)
R410a : R32/125 (50%, 50%)
R413a : R600a/218/134a (3%, 9%, 88%)
 Inorganic Refrigerants
Carbon Dioxide
Water
Ammonia
Air
Sulphur dioxide
 Carbon Dioxide
Zero ODP & GWP
Non Flammable, Non toxic
Inexpensive and widely available
Its high operating pressure provides potential
for system size and weight reducing
potential.
Drawbacks:
Operating pressure (high side) : 80 bars
Low efficiency
 Ammonia A Natural Refrigerant
Ammonia is produced in a natural way by
human beings and animals; 17 grams/day for
humans.

Natural production 3000 million tons/year

Production in factories 120 million tons/year

Used in refrigeration 6 million tons/year

 Ammonia as Refrigerant
ODP = 0
GWP = 0
Excellent thermodynamic characteristics: small
molecular mass, large latent heat, large vapour
density and excellent heat transfer characteristics
High critical temperature (132C) : highly efficient
cycles at high condensing temperatures
Its smell causes leaks to be detected and fixed
before reaching dangerous concentration
Relatively Low price
 Some Drawbacks of
Ammonia as Refrigerant
Toxic
Flammable ( 16 28% concentration
)
Not compatible with copper
Temperature on discharge side of
compressor is higher compared to
other refrigerants
 Water
Zero ODP & GWP
Water as refrigerant is used in
absorption system .New developing
technology has created space for it for
use in compression cycles also.
But higher than normal working pressure
in the system can be a factor in
restricted use of water as refrigerant
 Application of New Eco-friendly
Refrigerants
Application HFCs used Possible Eco-
friendly refrigerant

Domestic refrigeration R134a,R152a HC600a and blends
Commercial refrigeration R134a,R404A,R407C HC blends,NH 3 ,CO2 **
Cold storage ,food processing
And industrial refrigeration R134a,R404A,R507A NH 3 ,HCs,CO2 **
Unitary air conditioners R410A,R407C CO 2 , HC s
Centralized AC (chillers) R134a,R410A,R407C NH 3 ,HCs,CO2, water **
Transport refrigeration R134a,R404A CO 2,
Mobile air conditioner R134a CO 2 ,HCs
Heat pumps R134a,R152a,R404A NH 3 ,HCs,CO2, water **
R407C,R410A
 Table 3 -Performance Results of R12 and New Proposed Refrigerants using the same compressor as with R12 in Milk Chilling Unit

Refrigerants
Mass flow rate
kg / min
Refrigerating capacity
kW
Compressor power
kW
COP
Volumetric Refrigeration Capacity(kj/ m 3)
Discharge
Temp
C

R 32
R 290
R 22
R 12
R 134a
R 152a
R 124
R 600a
R 142b
R 600


8.81
4.45
7.45
6.99
4.83
3.00
3.34
3.70
2.23
.825

33.04
18.27
18.09
12.31
10.59
11.25
5.87
6.40
5.80
3.66

8.75
5.01
4.72
3.26
2.86
2.82
1.46
1.73
5.76
.938


3.87
3.64
3.88
3.83
3.70
3.95
4.01
3.70
3.97
3.90

2870.54
1547.29
1550.56
1044.50
897.92
945.60
337.68
495.29
490.26
508.98

72
48.95
64.96
50.6
49.4
59.8
43
43
48.6
43

General Safety measures for
refrigerating plants

Reduction of refrigerant contents:

Components with reduced contents
Indirect systems with secondary refrigerant: distinction
between generation and transport of cold

Scheduled maintenance and leak testing

Governmental surveillance Refrigerant Audits for

systems operating with HFCs. Recovery, Stock of used
refrigerants, Recycling of refrigerants.

For the Netherlands, the combined measures resulted in a leak

rate reduction of 35% (1995) to 8% (2001) for R22-systems
 Survey Of Refrigerants
Refrigerant Group Atmospheri ODP GWP
c life
R11 CFC 130 1 4000
R12 CFC 130 1 8500
R22 HCFC 15 .05 1500
R134a HFC 16 0 1300
R404a HFC 16 0 3260
R410a HFC 16 0 1720
R507 HFC 130 1 3300
R717 NH3 - 0 0
R744 CO2 - 0 1
R290 HC <1 0 8
R600a HC <1 0 8
 Conclusions
In the aftermath of the Montreal protocole HFCs
have predominantly replaced CFCs and HCFCs in
RAC equipment.
Due to their high GWP, HFCs are not a good
replacement solution.
The solution are the natural refrigerants :
Ammonia, Hydrocarbons and Carbon dioxide
System need to have low TEWI factor
High efficiency with ammonia and lower power
consumption with hydrocarbons
 Thank

You
Environmental Effects of
Refrigerants
Global warming :
Refrigerants directly contributing to global
warming when released to the atmosphere

Indirect contribution based on the energy

consumption of among others the
compressors ( CO2 produced by power
stations )