Replacing R22: the pros and cons of drop-in and retrofitting refrigerants

By Michael Labacher – head of environmental services: A-Gas

Across the world, developed countries have already phased out hydrochlorofluorocarbons (HCFCs) and are now focusing on recovering and destroying the last of their installed base.

Meanwhile, Article 5 countries like South Africa are rapidly approaching their phaseout milestones. By 2025, South Africa will be permitted to import only 35% of its 2009/10 baseline HCFC levels. In 2026, this will drop to just 2.5%. The market will increasingly rely on reclaimed refrigerants, which are recovered and processed to help meet demand.

With this in mind, the industry is actively seeking alternatives to R22 and, as discussed in previous articles, one option is to retrofit existing R22 systems with drop- in replacements. However, before making this decision, it is essential to consider the underlying motivations. Is the choice driven by cost, environmental concerns or the availability of refrigerants?

While drop-in replacements have their advantages, they also come with challenges. For example, if the system leaks more than 10% of the gas inside, the rest must be recovered and the system recharged with fresh refrigerant. This could lead to higher costs than simply continuing to use R22, especially in systems that require frequent maintenance.

If the shift is motivated by the desire to reduce the use of products with ozone depletion potential (ODP), it is crucial to choose a replacement carefully. Many hydrofluorocarbon (HFC) alternatives have a higher global warming potential (GWP) than R22, which may counteract the environmental benefits.

For those considering refrigerant availability, A-Gas has been actively recovering refrigerants from the market for decades and has a well-established stockpile that can support customers beyond 2026. However, this stock will come at a price and its availability is uncertain.

We emphasise the importance that the market avoid venting. A-Gas offers various recovery solutions to assist the market in responsible recovery and if necessary, disposal. A-Gas’ also offers a refrigerant buy-back recovery programme. Through responsible refrigerant recovery, we can all contribute to reducing the environmental impact and securing the refrigerants necessary for the future.

Below is a general overview of the pros and cons of using drop-in replacements for R22, and highlighting next generation blends in general.

 

Pros

1. Environmental benefits:

• Drop-in replacements and next- generation refrigerants are non-ozone- depleting
• Many alternatives have a lower GWP than R22, contributing to reduced potential greenhouse gas (GHG) emissions. Examples include R448A and R449A

 

 

2. Regulatory compliance:

• Using drop-in replacements helps businesses comply with international agreements like the Montreal Protocol and local regulations in Article 5 countries
• It helps businesses avoid penalties and restrictions associated with the continued use of R22

3. Cost savings in equipment replacement:

• Retrofitting allows continued use of existing R22 systems with minimal modifications, saving costs compared to purchasing entirely new equipment

4. Wider availability:

• R22 production and imports are being phased out in South Africa, whereas alternatives like R407C, R417A, R448A, R449A and R438A are readily available

5. Improved energy efficiency:

• Some alternatives, such as R449A and R448A, offer better energy efficiency in specific applications (e.g. medium/low- temperature refrigeration)

6. Reduced long-term costs:

• Transitioning early mitigates future price spikes in R22 due to dwindling supply and increasing demand

 

Cons

1. Performance impact:

• Many alternatives have lower cooling capacity and higher energy consumption compared to R22, especially in regions with high ambient temperatures
• Temperature glide in blends like R407C, R417A, R438A, R448A and R449A can affect heat exchanger performance and complicate system tuning

2. Retrofit costs:

• Retrofitting requires an oil change to polyol ester (POE) lubricant, which can be costly and time consuming
• System adjustments (such as expansion valve tuning, filter-drier replacement) may be necessary
• Pricing on low-GWP refrigerants like R448A and R449A is significantly higher than R22 and some of the higher-GWP alternatives

3. Training and expertise:

• Technicians may require additional training to handle and optimise systems with high-glide refrigerants or new blends

 

4. Compatibility issues:

• Some system components, such as seals, gaskets and compressors, may need to be upgraded to ensure compatibility with the new refrigerant

5. Leak management challenges:

• Refrigerant blends with high glide require complete recovery and recharging in case of significant leaks, increasing maintenance complexity and costs

6. Economic viability:

• For older equipment nearing the end of its lifespan, retrofitting may not be economically justifiable compared to replacing the system with modern equipment designed for lower-GWP HFCs or hydrofluoroolefins (HFOs) or blends thereof

7. Pressure differences:

• Many alternatives have higher operating pressures than R22, which may strain older system components

8. Environmental trade-offs:

• While alternatives have a lower ODP, some still have a moderately high GWP (e.g. R438A, R422D, R424A, R427A, R417A, R407A, R407F), which does not fully align with long-term environmental goals. The Kigali Amendment to the Montreal Protocol looks at phasing down high-GWP HFCs from 2029 onwards in Article 5 countries

 

Conclusion

In summary, transitioning from R22 to drop-in and retrofit refrigerants offers several advantages, including environmental benefits, regulatory compliance and potential cost savings in equipment replacement. However, the process also comes with its challenges, such as performance impacts, retrofit costs and the need for specialised training and expertise.

Manufacturers should consider their long- term environmental goals and the viability of retrofitting their existing systems, especially when factoring in the increasing demand for low-GWP refrigerants under global agreements like the Kigali Amendment.

As the market moves away from R22, the recovery and responsible disposal of refrigerants will become increasingly crucial. A-Gas’ refrigerant buy-back recovery programme offers a valuable solution to ensure that refrigerants are returned to the supply chain for reclamation or destruction, mitigating environmental impact.

By collaborating with customers and clients across multiple industries, A-Gas can support its customers in embracing circular economy principles. The industry must focus on adopting environmentally conscious practices, embracing lower-GWP refrigerants and responsibly managing refrigerants now and in the future.

Note: Before introducing any alternative replacement refrigerant into an existing R22 system, please consult the compressor manufacturer to ensure the equipment is capable of handling these products.

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