Evolution of new refrigerants and applications

on 05/08/2024

INTRODUCTION: The purpose of this technical article is to understand the importance of new available refrigerants, and applications. In this paper, the low or ultra-low GWP refrigerants like hydro-fluoro-olefins HFO / HFO blends, HC, and Natural Refrigerants are considered as environmentally friendly next-generation refrigerants.
Early invention – inorganic compounds, today these are still used in many refrigeration, Air conditioning, and heat pump applications as refrigerants such as ammonia (NH3), water (H2O), carbon dioxide (CO2), and sulfur dioxide (SO2). Synthetic refrigerants have been used in refrigeration systems since the creation of CFCs and HCFCs in 1929.
Refrigeration and air conditioning play a vital role in domestic, commercial, and industrial applications. They have a great impact on our day-to-day life. They have also contributed to the world’s major environmental issues like global warming and climate change. The development of the refrigerants used in them, from the days when refrigeration was not known to the present day is very interesting. The development of different refrigerants over time took place based on safety, durability and environmental impact issues. Now, there has been a lot of talk about climate change and global warming.
The first regulation concerning the depletion of the ozone layer was the Montreal Protocol adopted on 16th Sep 1987. The result was that the scientific assessment of ozone depletion in 2014 confirms that the ozone layer is healing, thanks to actions taken by Parties under the Montreal Protocol. It means the Ozone Depletion Potential matter is resolved but the Global Warming potential is highlighted due to increase of global temperature and climate change.
Then, the Kigali Amendment, adopted in 2016, aims to phase down hydrofluorocarbons (HFCs), potent greenhouse gases that contribute to global warming. As of 1st July 2024, 160 countries have ratified the Kigali amendment. Under the Amendment, all countries will gradually phase down HFCs by more than 80 per cent over the next 30 years and replace them with more planet-friendly alternatives.
The scientists and engineers carried out the research and development to establish the next generation refrigerants including the safety that is the most important factor. The recent Scientific Assessment Report estimates that Kigali will reduce future global average warming in 2100 due to HFCs from a baseline of 0.3 °C – 0.5 °C to less than 0.1 °C.
Hydrocarbons are naturally occurring and made only from hydrogen and carbon. Let’s see the current availability of new refrigerants compared to existing HFC refrigerants for low, medium, and high-pressure applications of compressors. We need to choose the new refrigerants based on the environmental effect (GWP), safety, performance (COP), availability, and serviceability.
The three main flammability classifications are class 1 – for refrigerants that do not propagate a flame when tested as per the standard; class 2 – for refrigerants of lower flammability; and class 3 – for highly flammable refrigerants.
The classification of refrigerants are as follows:
The demand of Natural Refrigerants like Ammonia and Carbon dioxide as well as HCs are increasing. A2L refrigerants are slightly flammable than A2 and A3 is highly flammable. B1 & B2 represents toxicity. Mostly, new refrigerants belong to A2L, we should have a serious look at the design and installation of any indoor/outdoor unit, piping, valves, and mechanical room to avoid any accident, as it pertains to the limit of refrigerant charge, sensors, and exhaust according to available standards and local codes.
Ammonia is widely used in the food processing, cold storage, and pharmaceutical industries. However, local permitting authorities may restrict the use of ammonia due to its toxicity and flammability. It has pungent smell. System design for the best system COP may result in high cost, particularly when considering necessary items to ensure safety. Ammonia belongs to B2 category makes it suitable only for indirect chiller systems.
Carbon Dioxide belongs to the AI group, a greenhouse gas, and is very energy efficient but operates at very high pressure. CO2 and its high energy content, which continues to scale at greater temperatures, can be reclaimed, increasing overall system efficiency. From an environmental perspective, CO2 is a very attractive refrigerant with zero ODP and a GWP of 1 Carbon dioxide sees extensive use in large-scale refrigeration systems like marine refrigeration systems.
Hydrocarbons (HC) HC refrigerants have an Ozone depletion potential (ODP) of 0 and a global warming potential (GWP) is 3. Typical hydrocarbon refrigerants for Line refrigerators and freezers are Propane (R-290) or Isobutane (R-600a) but highly flammable belongs to the A3 category. It requires additional safety measures.
However, there’s been a push in recent years to explore other uses for R-290, and ASHRAE has proposed increasing its charge limit to either 300 grams or 500 grams, depending on the application.
ASHRAE Standard 34 shows that Application for Human Comfort stipulates that Group A2, A3, B1, B2, and B3 refrigerants shall not be used in high-probability systems for human comfort. Higher Flammability Refrigerants states that Group A3 refrigerants shall not be used except where approved by the authority having local jurisdiction.
Refrigerants listed as A2L in ASHRAE 34 are listed as Class 2 in the International Mechanical Code.
When we go deep then we see category A2 is divided into A2L and A2 groups. The A2L subgroup, as categorized by ASHRAE Standard 34, are a class of refrigerants that have lower flammability (flame propagation speed is less than 10 cm/s) compared to A2.
HFO refers to the chemical composition of the refrigerant. HydroFluoroOlefin indicates that the refrigerant is comprised of Hydrogen, Fluorine, and Carbon and that there is at least one unsaturated double bond between two carbons (olefin structure). A blend of an HFO with another type of refrigerant is typically combined with a slash HFO blend i.e. next-generation refrigerants compared to existing HFC refrigerants (R-134a, R-407c, and R-410a) i.e., high GWP:
R-1234yf
R1234yf is more environmentally friendly. It has 4 GWP compared to R-134 a 1300 GWP. R1234yf can be used as a long-term environmentally friendly solution in mobile air-conditioning systems. The safety kit is also available to detect the leakage. Technicians need to take the relevant safety measures for the correct transport, storage, and handling of flammable gas.
R-32
The GWP of R32 is 675 while R-410 has 2,088 GWP. EPA based on the Kigali amendment bans CFCs with GWP above 700; this stops new production or importation of R-410a Units by Jan 01, 2025. Besides, the EPA based on the Montreal Protocol stopped production and importation in 1996 for R12 machines and 2010 for R22 machines.
R32 only has one molecule in its formation, its saturated liquid and vapor temperatures are the same. R-32 is a colorless and odorless, mildly flammable gas (A2L). However, there is a slight chance of the smallest fully enclosed premises with total leakage in the evaporator unit.
R-32 is more efficient than R-410a. R-32 is available and requires less quantity than R-410a. R-32 pressure is high compared to R-410a and manufacturers mainly use it in Split Units or VRF. The outdoor unit should be installed in a shaded area especially at high ambient countries. Flush with Nitrogen and proper vacuum requires, and no air should be inside the pipe.
There is a chance of any damage the indoor unit installed in at confined space with a small amount of room volume. But it requires oxygen and constant sources to ignite like hot wire, open flames, etc.
R-32 is heavier than air, it goes down to the floor and may accumulate as well as have lower velocity at ground level then it may favor the formation of the fire but requires a constant high-power source is still required.
R-452B / R-454B
R452B is a mixture of HFC and HFO, with a glide temperature of 1.2 K. Its GWP is 676. Further, R452B has a safety classification of A2L and lower saturation pressure than R410A and R32.
R454B has 466 GWP compared to R-410 has 2,088 GWP. R-454B is mildly flammable gas (A2L) and colorless. Many manufacturers are using R454B refrigerant. It provides easy conversion with minimal changes from the R-410a design. Like R-410A, R-454B is a near azeotrope and so has minimal glide.
Manufacturers use R454B in Residential Light Commercial, Chillers and Heat Pumps. R454B extends cooling and heating capabilities at low ambient temperatures producing higher leaving hot water temperatures. R454B has wider operating maps and compressors, i.e. more reliable. R454B, to comply with future regulations and reduce their carbon footprint.
R-513A
R513A is a medium-pressure, non-flammable. The GWP of R-514A is 573. They have been assigned an A1 safety classification under ASHRAE 34. It may be an alternative to R-410a for new medium and high-temperature systems. It may use in screw and centrifugal chillers.
It is a direct drop-in replacement for R-134a in existing commercial and industrial medium and high-temperature refrigeration equipment that uses positive displacement compressors and direct expansion systems. It is compatible with POE synthetic oils. It is compatible with the equipment, components, lubricant, and joints of an existing R-134a system.
R-514A
ASHRAE 34 class R514A as a B1 category refrigerant, meaning that it is not flammable. It has a low pressure, non-ozone depleting, low global warming potential (GWP) hydrofluoroolefin (HFO) based replacement for R-123. It is suitable for new and retrofit systems, offering an optimal balance of properties, including high energy efficiency and environmental sustainability.
An Azeotrope with zero glides is a low GWP HFO-based refrigerant developed to replace R-123 in low-pressure centrifugal chillers for commercial and industrial applications. The application may be screw and centrifugal chillers.
R-1234ze
R-1234ze is known as a “next-gen” refrigerant & classified as HFO. It has category is A2L and not designed for retrofit projects. While the fact R1234ze has an ultra-low value GWP value is 1 vs 1300 of the R134a, it also results in very efficient chiller operations. This is pure fluid and having zero glide. The lubricant oil is POE Oil. It replaces mainly R134a refrigerant.
The application is air-cooled and water-cooled screw chillers as well as water-cooled centrifugal chillers. Besides, it can be used in medium-temperature commercial refrigeration and heat pumps. This refrigerant has a future choice within a stringent environmental regulation.
R-1233zd
R-1233zd is known as a “next-gen” refrigerant & classified as HFO. It has ultra-low value GWP value is 1. R1233zd is ideal for low-pressure centrifugal chillers which are common in cooling systems for large buildings. Besides, it has no temperature glide.
Refrigerant R1233zd(E) is classified as a fully safe refrigerant (ASHRAE Class A1). The composition of this refrigerant is a single component. R-1233zd is a new and widely accepted refrigerant for high-capacity mainly centrifugal chillers for its attractive properties and mainly to replace R123 refrigerant.
The initial cost of new refrigerants is typically high, but the cost tends to decrease with time due to production process improvements and economies of scale. The total Life Cycle Cost of a system has become increasingly important in recent years as the cost of the system to acquire, install, operational cost, and maintain gained focus.
CONCLUSION: HFCs have high global warming potential (GWP) and trap heat in our atmosphere which contribute to global warming. Thus, they are ultimately bad for the environment. Ultimately, the Kigali amendment timeline must be followed for respective countries. In addition, we need to follow the new design standards (especially A2L & A3), take safety precautions, select high-efficiency equipment, and follow ASHRAE Standards as well as local codes.

EU funded the CBHE CATCH_VR Project Progress Meeting 1st Training Workshop at University of Oradea

on 05/08/2024

The meeting began with a warm welcome note from Prof Radu Tarca, Principal Coordinator of the CATCH_VR project at the University of Oradea, Romania. An address by Prof Sanda Monica Filip, Pro-Rector of Research at the University of Oradea followed this. In his appreciating note, Prof Dr. Bhawani Shankar Chowdhry, Project Coordinator, thanked the University of Oradea for hosting the four-day event and highlighted the significance of the CATCH_VR project and the agenda for the project progress meeting. The aim of the “CApacity building in TeaCHing of AR/VR (CATCH_VR)” project is to enhance the capacity of higher education institutions through Augmented Reality (AR) and Virtual Reality (VR) using Digital Twining with a consortium of several educational institutions from Europe and Asia focusing on Graduate Engineering Education. The project involves a participatory learning approach, with a strong emphasis on practical demonstrations and hands-on experience with physical equipment and digital twins, which promises to be an exciting and engaging part of the project. The meeting also reviewed working on various committees for the work packages and user requirement analysis and finalizing the deliverables D1.1, D6.7, and D6.9. There has been a detailed discussion on Curriculum Development. The training workshop focused on the latest trends in AR/VR technologies, leading towards Digital Twin.
All partner universities from Pakistan, including MUET, QUEST, GIKI, and UET Peshawar, participated physically. Associate partners Rastek Technologies and Engineering Review participated online. European partner universities, including the University of Limerick, Ireland, University College Cork, Ireland, and the University of Oradea, Romania, participated physically, and Technical University Sophia, Bulgaria, participated online.

Green Dreams for a Better Tomorrow: KU CSD Organizes Climate-Action Ideathon

on 05/08/2024

The Department of Computer Science at the University of Karachi organized a two-day event titled the “Climate-Action Ideathon.” Forty teams from ten different universities presented various ideas to combat climate change. Judges selected winners who received cash prizes for first, second, and third place.
The closing ceremony was attended by prominent figures including Dr. Khalid Mahmood Iraqi, Vice Chancellor of the University of Karachi; Engr. Wasim Nazir, Managing Director of MMP; Dr. M. Ali Shaikh, former VC of SMIU; Dr. Tariq Rahim Soomro, Chair of IEEE Karachi Section; Abu Bakar Madni, Special Secretary to DG Local Government; Imdad Hussain Siddiqui, Director of Operations at Sindh Disaster Management Authority; and Dr. Musarrat Jahan Yousuf, Dean of the Faculty of Science at KU. Dr. Sadiq Ali Khan, Chairman of the Department of Computer Science and Chair of IEEE Education Society Karachi Section, hosted the event.
In his speech, Dr. Khalid Mahmood Iraqi emphasized that climate change, a global crisis, is one of the most defining challenges of our time, demanding urgent and innovative solutions. He stressed the importance of reaffirming commitment to sustainable development goals to tackle issues such as global warming, droughts, floods, and natural disasters exacerbated by climate change worldwide.
Dr. Iraqi highlighted the need for practical measures to minimize climate change, urging all relevant authorities worldwide to design effective preventive strategies to mitigate further damage. He underscored that addressing climate change requires a multidisciplinary approach involving experts from fields like engineering, economics, sociology, and computer science.
The event’s Chief Guest, Engr. Wasim Nazir, Managing Director of MMP, stated that climate change is no longer a distant concern but an urgent reality demanding collective action. He emphasized the critical role of oceans, covering over 70% of the planet’s surface, in ecosystems, climate regulation, and human livelihoods, stressing the need for effective irrigation and water management systems to address contamination.
Dr. M. Ali Shaikh, President of the Citizen Educational and Empowerment Society and former VC of SMIU, highlighted the pivotal role of education and technology in shaping a sustainable future. He emphasized the importance of developing solutions to mitigate climate change impacts and promote a greener, more sustainable planet.
Dr. Tariq Rahim Soomro, Chair of IEEE Karachi Section, emphasized that climate change transcends borders and disciplines, requiring a collaborative effort. He praised Dr. Sadiq Ali Khan for organizing the Ideathon and highlighted the crucial role of computer science and information technology in enhancing our response to environmental challenges.
Abu Bakar Madni, Special Secretary to DG Local Government, stressed that climate change is a global problem requiring local action and global cooperation. He encouraged participants to recognize the potential of their ideas, however small, to create significant positive change in the global effort against climate change.
Imdad Hussain Siddiqui, Director of Operations at Sindh Disaster Management Authority, shared firsthand experiences of the devastating impacts of climate change in the province, from floods to droughts. He emphasized the urgent need for innovative solutions, noting that climate change affects ecosystems, economies, and communities.
Dr. Musarrat Jahan Yousuf, Dean of the Faculty of Science, highlighted that climate action is not just an environmental issue but a global challenge impacting every aspect of life. She stressed the importance of prioritizing climate action to ensure a sustainable future for future generations.
Dr. Sadiq Ali Khan concluded by warning of dire consequences if immediate global action is not taken. He emphasized the Ideathon’s role in addressing today’s environmental challenges and urged young minds to lead in resolving these issues.

2nd Pakistan Plumbing and Firefighting Expo 2024: A Remarkable Event for Industry Advancement

on 05/08/2024

The 2nd Pakistan Plumbing and Firefighting Expo (PPFE 2024) successfully concluded on 3-4 July 2024 at the Karachi Expo Center, marking a significant milestone in promoting the importance of plumbing and firefighting systems in building sustainability and safety.
Industry Showcase and Participation PPFE 2024 witnessed the participation of 53 companies, showcasing top-quality solutions and products for plumbing and fire protection. Over 70 percent of the products displayed were made in Pakistan, reinforcing the event’s focus on local innovation and manufacturing. The expo emerged as the largest showcase of PVC pipes and fittings, with companies also presenting high-quality fire and protection systems.
Educational and Networking Opportunities The two-day event was a hub for immersive learning, networking, and professional growth. It featured two international-class conferences on Modern Plumbing and Fire and Safety, drawing participation from leading MEP consultants, engineers, and experts, including:
• Engr. Syed Amir Ali, CEO, SEMS Engineers
• Farhan Mehboob, CEO, SMC Consultants
• Fahmin I. Siddiqui, CEO, FND Consult
• Fahad Hasan, Director, YH Associates
• Pankaj Dhakar, Presidential Member, Fire & Security Association of India
Inauguration and Keynote Addresses Engr. Najeeb Haroon, Chairman of the Pakistan Engineering Council inaugurated the event and appreciated the concept and objectives of PPFE. Engr. Farooq Mehboob, Presidential Member of ASHRAE, delivered the keynote address, emphasizing the critical issues and importance of plumbing and safety in buildings, and their value for human lives, investment, and sustainable built environments. Notable speakers also included Engr. Sohail Bashir, Chairman, IEP, Prof. Dr. Sarosh Hashmat Lodi, Vice Chancellor, NED University, and Engr. Yousuf Hasan, CEO, YH Associates spoke about the standards and challenges in plumbing and fire safety.
Special Session and Panel Discussions Moreover, A special session on “Updates on International Accord,” that was chaired by Mr. George Faller, Chief Safety Officer at Accord Pakistan highlighted safety and fire protection standards in the textile and garment factories in Pakistan.
Tariq Moen, Director of the Fire Protection Association of Pakistan, delivered an insightful speech on fire and protection in Pakistan.
Two engaging panel discussions were also held:
Challenges in Plumbing Systems for High-Rise Buildings: Innovations, Solutions, and Best Practices
Lessons Learned from Major Fire Incidents: Improving Safety and Prevention Strategies
Training and Community Engagement PPFE 2024 turned into a comprehensive business and training platform, training 975 individuals over two days. In collaboration with Sindh Emergency Rescue Services (Rescue 1122), more than 500 participants from various sectors were trained as Emergency First Responders, and about 475 people attended a Masterclass Training on Fire and Safety, consisting of eight sessions over two days.
Visitor Turnout and Coverage The event drew an impressive 5,347 visitors and covered a total area of 36,000 square feet.
The organizer of the Pakistan Plumbing and Firefighting Expo has announced plans to return next year with even more value addition and industry advancements. The next edition promises to feature:
• Increased participation from more companies, both from Pakistan and abroad, showcasing the latest innovations and products.
• A greater number of expert speakers and presenters, providing cutting-edge insights and knowledge.
• Expanded learning opportunities through additional conferences, workshops, and training sessions.
• A futuristic approach to addressing industry challenges and trends, making the expo a truly international platform with unparalleled significance.
BRG Events is committed to building on the success of PPFE 2024, ensuring the event continues to set new benchmarks in the industry and provide unmatched value to all participants.

Fast Cables: Aiming to empower communities through sustainable development. Govt should facilitate, provide a level playing field to local companies: Kamal Mian

on 05/08/2024

We are very serious about focusing on our core business and its quality. We manufacture PVC, copper, and aluminum rods, and also engage in related business activities. However, our primary commitment lies in elevating the standards of our current operations. Our tagline, ‘Taroon Se Sitaroon Tak,’ reflects our dedication to achieving excellence in our vision,” says Kamal Mian, Managing Director of Fast.
He shared his insights with Engineering Review during an interview in Lahore. “Our decision to list on the Pakistan Stock Exchange aims to empower communities through sustainable development,” he explained. “To achieve this, we must ensure our own sustainability and undertake comprehensive planning to position ourselves for the future. This move will transform people into future stakeholders and enable us to raise funds for future expansions.
Relation between Economic Crisis and a Positive Approach
Instead of dwelling on negatives that drain your energy, we should focus on the positives, as positivity can yield results. We have always considered what we can do positively. For instance, during the balance of payments crisis, our cable and conductor industry, which imports metals and uses net dollars, began thinking about how to contribute to resolving this national issue. As a result, we shifted our focus to tripling our exports. This contribution to the national economy also benefited us; we were able to export goods worth over a billion rupees. Our positive approach led us to develop a medium voltage cable (33 KV cable), a product not typically made in Pakistan, and we exported over 400 kilometers of this cable to Saudi Arabia. I believe our national situation is not as dire as perceived.
Made in Pakistan and Our Governments
We often rely too heavily on the government. We must move away from this culture. What is the government? It collects taxes, fulfills macro-level responsibilities, and governs the country. I do not agree that we can only succeed if the government acts. Instead, we expect the government to facilitate and provide a level playing field, rather than offering subsidies, etc. What we need are policy interventions that ensure fairness, not policies like those seen in CPEC, where companies were granted tax and duty exemptions, putting local companies at a significant disadvantage. We oppose policies that harm the interests of local companies. By establishing a level playing field, local companies can thrive. During the Covid-19 pandemic and the balance of payments crisis, when imports were difficult, Fast Cables undertook an important project: The Thar-Matyari transmission line, where imports were not feasible. For the first time, we produced a 500 KV conductor for this transmission line. This demonstrated that local companies can better serve the country if they are trusted.
Innovation and Standard of Fresh Engineers
Of course, there is a gap, and we have introduced a Management Training Program in our company to bridge it. I think universities should link undergraduates with industrial experience by introducing various linkage programs so that they are ready before joining the industry. These programs should be introduced even at pre-university levels in the country, as we focus more on the theoretical and learning side rather than the practical side. Also, graduates require soft skills which are essential before specialization in their subjects.
Imports vs Exports
We have focused 10 percent of our business on exports. The balance of payments is not solely a government-specific issue; it’s a national issue since we import more than we export. All sectors, including the service industry, power, and agriculture, need to make efforts to increase exports. It will affect our economic growth because lower growth rates are not an option for us. We have to provide employment for a large number of young people, for whom growth is essential.
Fast and Lights
We launched the light project two years ago after thorough research. In this field, there are no national standards. Now we are educating people on why they should opt for quality lights; it is a challenge. Substandard lighting can affect vision and be detrimental to health. We have received a good response as our consumers are well aware. Price is, of course, an issue, but in terms of returns, people appreciate it. I think the Pakistan Engineering Council (PEC) and other bodies should work on standards for lights so that quality standards are maintained in the country.