BITZER recommendations for future-proof systems in Europe

Dr Heinz Jürgensen: The updated draft of the F-Gas Regulation calls for a full phase out of fluorinated greenhouse gases in the EU by 2050. For some applications like heat pumps and compact air conditioning systems up to 12 kW, the phase out is already planned for the period between 2032 and 2035. With the range of banned refrigeration applications expanding and growing more stringent, Europe is heading for a future with virtually no fluorinated refrigerants. As a result of the accelerated phase down of F-gases, the refrigeration, air conditioning and heat pump industry needs to prepare for severe restrictions in the use of the corresponding substances in new and existing systems. This will affect hundreds of thousands of systems throughout the EU.

Dr Heinz Jürgensen: Only refrigerants with minimal environmental impact will be available over the long term. Based on today’s standards, that could mean: ozone depletion potential (ODP) equal to 0, global warming potential (GWP) less than ten, high energy efficiency, little to no environmentally harmful degradation products, and minimal production costs and waste. Depending on the application, a range of naturally occurring substances such as R744 (carbon dioxide), R717 (ammonia), R290 (propane), R729 (air) and R718 (water) fulfil these criteria. Natural refrigerants will therefore play an increasingly important role.

Dr Heinz Jürgensen: Whenever possible, new systems should be designed and built to work with refrigerants that will continue to be available over the long term. If that’s not possible due to local regulations, we definitely recommend choosing a refrigerant with GWP below ten such as R1234yf. And if that’s not possible either, GWP below 150 would also be an option. But you need to be careful: This value could potentially be too high for new systems if the recommended phase down values after 2030 are considered.

We see a clear trend towards natural refrigerants for new systems. If absolutely necessary, refrigerants with a higher greenhouse effect should only be used to maintain existing systems. (Cf. image 1.)

Dr Heinz Jürgensen: According to our information, it will only be possible to operate and maintain existing systems with F-gases for around 10 to 15 years. However, there will be limits to permissible GWP values and the quantity of HFCs available. We expect prices to increase from 2024 and cannot rule out refrigerant shortages from 2027. At that point, significant price increases for refrigerants with GWP above 150 will be inevitable. It’s quite possible that even functioning systems will need to be replaced with new ones if the refrigerant or level of efficiency no longer fulfils legal requirements. BITZER therefore strongly recommends converting or retrofitting existing systems with high maintenance costs or refrigerant loss to the lowest GWP values that are technically and economically possible. In this context, we offer our customers and partners support in the form of training courses, manuals and special designs.

Dr Heinz Jürgensen: Natural refrigerants usually require special training to ensure safe use. Hydrocarbons like R290 propane and R600a isobutane, for example, are highly flammable, whilst R744 CO₂ requires high pressure in the system. It’s important to develop an in-depth understanding of the refrigerants of the future. We provide support in the form of information – for example, in the Refrigerant Report – and practical training courses at the SCHAUFLER Academy. (Info box, see below.) The system components themselves need to be designed for the corresponding refrigerant, too. BITZER has many years of experience in the use of natural refrigerants in its products and continues to develop its portfolio in that direction. One example is our new 8-cylinder reciprocating compressor for CO₂ as a refrigerant, which is up to ten per cent more energy-efficient than conventional 6-cylinder compressors on the market. Generally speaking, switching to alternative refrigerants with new compressors and components can offer a high degree of energy efficiency and potential for savings. (Cf. image 2.)

Dr Heinz Jürgensen: If we’re required to significantly reduce the greenhouse effect of our refrigerants in accordance with the F-Gas Regulation, unsaturated partially fluorinated F-gases (HFOs) will be one of our most important tools. Many low-GWP refrigerants that were once used to fulfil the emission quotas of the F-Gas Regulation could be affected by a potential PFAS ban. It would then be more difficult to achieve emission targets. At this moment, we believe that a PFAS ban is all but certain. But it’s difficult to predict exactly which substances will be affected, which is why we so strongly recommend using natural refrigerants in as many systems as possible.

Dr Heinz Jürgensen: Well-founded opinions were accepted during the input phase from March to September 2023. BITZER was also involved in the process. The European chemical agency received more than 6,000 entries from all over the world covering a wide range of applications involving different PFAS, from fluorinated gases, solvents and textile finishes to fluoroplastics for gaskets and slide bearings. It’s important to highlight the relationship between environmental protection and technical and economic feasibility. The entrees will then be processed by the European Parliament, the European Commission and the European Council. Countries have influence again during this phase. We’re also in contact with the German Environment Agency. We don’t expect a decision before 2025.

Dr Heinz Jürgensen: The rest of the world is closely watching current developments in European regulations. The Kigali Amendment also calls for a gradual reduction in F-gas emissions globally, but with a delayed time frame and country group-specific targets. Traditional developed countries are required to reduce their consumption and production emissions by 40 per cent by 2024 compared to the base years of 2011 to 2013. Other countries have more time. For example, so-called Article 5 countries don’t have to begin restricting their emissions until 2024. Like the EU with its F-Gas Regulation, many countries around the world, including Australia, Japan and Norway, are aiming for an even bigger reduction than prescribed by the Kigali Amendment. Individual countries can choose to accelerate reduction, with financial support provided by the Multilateral Fund. If all members agree, the prescribed time frames can also be shortened as a whole. But that’s not likely to happen before 2028. (Cf. image 3.)

Dr Heinz Jürgensen: It’s true that the defined quotas do not take into account the growing demand for refrigerants associated with heat pumps. Whilst small systems for residential buildings are often imported into Europe prefilled, the importing company must demonstrate compliance with the quota in Europe. But thankfully for them, there’s a share of the quotas reserved for so-called new market participants. This share is reduced at a lower rate than the share for manufacturers inside Europe.

Dr Heinz Jürgensen: Water is an interesting refrigerant for special applications such as high temperature heat pumps over 140°C. For more conventional applications, there will be new hydrocarbon blends and blends with CO₂ on the market. The temperature glide of blends like these can be used to increase condenser and evaporator efficiency. Hydrocarbons can be mixed together in different compositions to achieve the same pressure level as another refrigerant. Non-flammable blends can be produced with carbon dioxide. Conversely, hydrocarbons can be added to CO₂ to raise the critical point, which enables condensation at higher temperatures than with pure CO₂ and, in turn, expands the application range. And on the low pressure side, these blends allow condensation at lower temperatures, as hydrocarbons maintain their liquid form at lower temperatures than CO₂. Blends also enable lower pressure levels than pure CO₂, which increases efficiency.