REFRIGERANT RECOVERY SYSTEM

INTRODUCTION

Substances such as chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons

(HCFCs), since they contain chlorine, react with the ozone molecule, producing a
photochemical chain consequence, which ends up breaking down the ozone molecule.

This damage generated largely by CFCs and HCFCs is due to the bad practices carried
out by technicians and professionals who for years and even currently release
refrigerant gases into the atmosphere because they do not know what to do with it.

But these bad practices not only continue to be implemented with these chlorinated
gases, but also with gases considered new generation such as R-410A, created to
replace CFCs and HCFCs, thanks to their Ozone Depletion Potential (ODP). ) is zero,
since it does not contain chlorine and therefore it is maintained that they are definitive
refrigerants. However, it has Global Warming Potential (GWP) values, which implies an
influence on the greenhouse effect.

There are also so-called ecological refrigerants such as hydrocarbons (HC), which are
hydrocarbons, as well as Carbon Dioxide (CO 2 ) and others.
Although the latter are called natural refrigerants because they remain in the
atmosphere for a short time, their use is not yet widespread due to the technical and
safety implications that it entails in systems based on these types of refrigerants.

GOALS

 GENERAL OBJECTIVE
Know the components of a recuperator

 SPECIFIC GOAL
Know the different steps to handle a recoverer
Know the types of refrigerants that damage the ozone layer

THEORETICAL FRAMEWORK

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 1) Recover: It means removing the refrigerant gas, in any condition, from a system
and storing it in an external container, without analyzing or processing it.

2) Recycle: It is cleaning the refrigerant gas to use it again, removing the oil or
passing it through multiple devices, such as filter dehydrators, which reduce
humidity, acidity and the presence of solids. This term usually applies to
procedures that can be implemented at ONE site or in the service shop.

3) Regenerate (Reclaim): It is the process of cleaning the refrigerant gas until it

reaches the specifications of a new gas. This process uses distillation. A
chemical analysis of the gas is required to determine that it has met
specifications. Regenerating involves the use of processes and procedures that
can only be executed on reprocessing equipment or in the manufacturer's plant.
All persons engaged in any activity in the HVAC&R industry have the obligation to
protect the environment from emissions of gases containing chlorine.

Considerations of the definition of regenerate or reclaim

Chemical analysis is a key procedure when regenerating gas. The phrase new gas
specifications means performing a chemical analysis to ensure that purity specifications
in accordance with ARI Standard 700 have been met. Despite having reached the purity
levels, after having reprocessed the gas, it can be said that the refrigerant was NOT
regenerated, unless chemical analysis was performed.

4) Recovery and Destruction: When a refrigerant recovered from refrigeration and

air conditioning equipment is contaminated or mixed with other refrigerants, its
recycling or regeneration is not feasible and therefore it cannot be used again.
The best option for a contaminated or mixed refrigerant is to send it to a process
for final disposal and destruction.
Currently there are many technologies for the destruction of CFCs and HCFCs
refrigerants; These technologies were evaluated and approved by the Technical
and Economic Assessment Panel (TEAP) of the Montreal Protocol.
(Table 1)

Table 1. Technologies evaluated and approved by TEAP for the destruction of

CFCs and HCFCs

CFC and HCFC refrigerant destruction technology TEAP evaluation opinion

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 Destruction and Elimination Efficiency (DEE)** 99.99%
cement kilns Approved
Liquid injection incineration Approved
Oxidation of gases/fumes Approved
Reactor cracking Approved
Rotary kiln incineration Approved
Argon plasma arc Approved
Inductively coupled radiofrequency plasma Approved
microwave plasma Approved
Nitrogen arc Approved
Gas phase catalytic dehalogenation Approved
Superheated steam reactor Approved

The above processes are based on the treatment that must be given to CFCs and
HCFCs, the most harmful refrigerants, which have already been discontinued thanks to
the fact that their manufacture was ceased, however, there are millions of pieces of
equipment in the world that still use them. this technology since entering into the use of
R-410A implies the complete renewal of the refrigeration or air conditioning unit and
therefore a significant cost for those who own this equipment.
(Table 2)

Table 2. Refrigerant gases used to replace CFCs

transient refrigerants Refrigerant Replaces Lubricant Comment
CFC R-12 AB or MIN
HFC R-22 AB or MIN
CFC+HCFC AB or MIN
R-502
HCFC R- R-12 AB Easy change

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 410A
HCFC R- R-12 AB Easy change
401B
HCFC R- R-502 AB Easy change
402A
HCFC R- R-502 AB Only apply in ice cube
402B machines. Easy change

HCFC R- R-502 AB Easy change

408A
HCFC R- R-12 AB Easy change
409A
chlorine-free HFC R-134a R-12 POE Difficult change Not
refrigerants recommended in hermetic
compressor system
HFC R-404A R-502 POE Difficult change Not
recommended in hermetic
compressor system
HFC R-507 R-502 POE Difficult change Not
recommended in hermetic
compressor system
HFC R-407C R-22 Difficult change Not
recommended in hermetic
compressor system
HFC R-410A R-22 POE It should not be done, because
it works with a higher pressure
than R-22.
MIN: Mineral Oil; AB: Alkylbenzene Oil; POE: Polyolester Oil
Recovery technologies

Since a recovery unit will remove more fluorocarbon-based refrigerant from a system
than any other method that can be used, its use should be considered the norm rather
than the exception.
Contractors, technicians and equipment owners must ensure in advance that they will
have the necessary recovery equipment. Their availability, refinement, variety and
demand are increasing and this results in them being used more widely.

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As with vacuum pumps, recovery units will operate most efficiently if the length of the
connecting hoses is as short as possible and their diameter as wide as possible. A 3/8”
diameter hose should be the minimum size, but preferably 1/2”.

In any case, it should not be used as an excuse not to use a recovery unit simply
because it cannot be placed close to the system. If longer hoses have to be used, all
that will happen is that the recovery operation will take longer. There is no acceptable
reason or excuse for letting fluorocarbon-based refrigerants escape into the
environment.
Methodology to recover gases

Refrigerant gas recovery is the initial phase of repairing or servicing HVAC&R

equipment. This means transferring the refrigerant gas from the refrigeration system to a
recovery cylinder. When the recovered refrigerant is not contaminated (despite a
hermetic or semi-hermetic compressor burnout, or other cause), it can be charged back
into the system once the system repair is completed. If the recovered gas has impurities,
before being recharged into the system it must go through an on-site recycling process.

To recover refrigerant gas there are the following ways:

1. Recover the refrigerant in liquid phase.

2. Recover the refrigerant in the gas phase.
3. Recover liquid and vapor, without separating the oil from the refrigerant (this
goes to the recovery cylinder as it is removed from the system).
4. Recover liquid and vapor, separating the oil from the refrigerant.
These ways of carrying out recovery have their benefits and virtues:
The liquid refrigerant recovery method is fairly quick to do, but it leaves vapor in the
system. In steam-only form, the recuperator removes all of the refrigerant, but is
considerably slower. Reclaimers that separate oil from refrigeration or air conditioning
systems are not necessarily better than those that do not.
Some types of recovery equipment require a prior vacuum process before each use,
especially when the refrigerant gas is to be changed, for example, if R-12 is recovered
from a system, and R-22 is to be recovered. of other. Another recovery tank must be
used for R-22, which must have a prior vacuum of at least 1000 microns. You must also
create a vacuum of 1000 microns prior to the recovery machine.

Gas recovery procedure

Pouring coolant into recovery tanks is a risky procedure. It should be done using the
method described by the coolant manufacturer.

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You have to be very careful to:

• Do not overfill the cylinder.

• Do not mix refrigerants of different grades or put refrigerant of one type in a
cylinder whose label is marked for another type.
• Only use clean cylinders, free of all contamination from oil, acids, humidity, etc.
• Visually check each cylinder before use and ensure that all cylinders are
regularly pressure checked.
• That the recovery cylinder has a specific indication depending on the country so
as not to confuse it with a container of virgin refrigerant.
• That the cylinders have separate valves for liquid and gas, and are equipped
with a pressure relief device.

To make gas recovery faster, the recovery tank must be kept cold throughout the
process. This can be achieved by placing it in a bucket of ice. The colder the tank, the
pressure of the gas decreases, but if the equipment from which the gas is being
recovered is at room temperature, then the recovery process is slower.

As a procedure prior to gas recovery, the position of all valves must be checked and, if
applicable, the oil level of the recovery compressor must be verified. It is advisable to
recover the liquid refrigerant in a receiving tank. The liquid must be recovered first and
then the vapor. Recovering the refrigerant in the gas phase leaves oil in the system,
minimizing oil loss.
When the compressor of the system under maintenance does not work, the compressor
crankcase must be warmed. This helps release coolant trapped in the oil.

Recovery in liquid phase

The liquid refrigerant can be recovered by decantation, separation or “push/pull”

techniques (suction and feedback), with the consequent drag of oil.
Push/pull operations are performed using steam from the cylinder to push liquid
refrigerant out of the system.

A hose is connected from the liquid port of the unit, whose refrigerant is required to be
removed, to the liquid valve on the recovery tank. Another hose is connected from the
steam valve of the recovery tank to the suction inlet of the recovery machine and, finally,
a third hose is connected from the outlet or discharge of the recovery machine to the
steam port of the equipment.

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The recovery tank will suck the liquid refrigerant (pull motion) from the HVAC&R unit,
when the recovery machine decreases the cylinder pressure. The steam sucked from
the recovery tank by the recovery unit will then be pushed back (push motion), that is,
compressed towards the side that corresponds to the steam in the deactivated HVAC&R
unit.

When the majority of the refrigerant has been charged from the system to the recovery
tank, the recovery tank will begin to cycle, controlled by its low suction pressure switch,
removing the rest of the refrigerant in the form of vapor. When the recovery unit no
longer continues cycling and stops completely, all possible refrigerant will have been
recovered.

Push/Pull recovery

Gas phase recovery

The refrigerant charge can also be recovered in the form of gas. In large refrigeration
systems this will require more time than when transferring liquid, this is because the
refrigerant gas flow is lower in the gas phase.
The connecting hoses between the recovery units, systems and recovery cylinders must
be of the minimum possible length as well as the maximum possible diameter, in order
to increase the performance of the process.
The refrigerant, in the vapor phase, is normally sucked in by the suction of the recovery
machine and, once condensed, is sent to the recovery tank.

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Liquid and vapor recovery

It is important to know the type and quantity of refrigerant to be recovered. Whenever

possible, pivot valves or Schrader valves must first be removed from the service ports. It
is good refrigeration practice to use hoses with integrated ball valves. It is always best to
try to remove the liquid from the system first and then follow with the remaining vapor.
This action will make it possible to accelerate the speed of gas recovery.
Recovery in liquid and vapor connection

recommendations

With large amounts of refrigerant, it is better to use the push/pull method, as it is three
times faster than doing it directly. When possible, it is advisable to recover gas from the
high pressure side and the low pressure side of the system and use short hoses for
service. Long hoses increase process time.

If when you begin to remove liquid from the system, the compressor sounds, you should
know that this damages it, significantly reducing its useful life. It is unusual for this to
happen, and should not occur under normal procedure.

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Recovery should always be done on the vapor side in the recovery tank, this reduces
the possibility of the presence of liquid refrigerant remaining in the lines. Doing so
guarantees a cleaner process. During gas recovery, when removing the hoses, a line of
liquid refrigerant may come out at the end.

Using a filter drier in all the processes described is a protection for the recuperator. This
recommendation becomes relevant, in particular, when recovering refrigerant gas from a
system in which a compressor has burned out.

Recycling technologies

Recycling has always been part of refrigeration service practices. The various methods
vary from pumping the refrigerant into a container, with minimal loss, to cleaning the
burned refrigerant using filter driers. There are two types of equipment on the market:
the first is called single-pass and the other is multi-pass.

a) Single-pass recycling machines: These devices process the refrigerant

through filter driers and/or through distillation. In many cases distillation is not
appropriate and separation would be better. In this method, the recycling process
is passed to the machine and from it to the deposit cylinder.
b) Multi-pass machines: These recirculate the recovered refrigerant many times
through filter driers. After a certain time or number of cycles, the refrigerant is
transferred to a storage cylinder. Time is not a reliable measure of how well the
refrigerant has been reconditioned, because the moisture content can vary.
Single Step Recycling

Multi-Step Recycling

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Safe handling of recovered refrigerant

Becoming familiar with the recovery equipment, reading the manufacturer's manual, and
applying all prescribed methods and instructions each time the equipment is used are
the primary measures to ensure a safe gas treatment process.
The correct recommendations are:

• Liquid refrigerants can cause frostbite. Avoid the possibility of contact by

wearing appropriate gloves and long-sleeved clothing or shirts.

• The refrigerant being recovered may come from a heavily contaminated system.
Acid is one of the decomposition products; There can be both hydrochloric and
hydrofluoric acid (hydrofluoric acid is the only one that can attack glass). Extreme
care must be taken that oil spilled from refrigerant vapors does not come into
contact with skin or clothing surfaces when servicing contaminated equipment.

• Always wear protective clothing and implements such as safety glasses,

protective footwear, gloves, protective helmet, long pants and long-sleeved shirts.
• Refrigerant gases can be harmful if inhaled. Direct absorption should be avoided
and ventilation should always be at a low level.

• Make sure that all power is disconnected and that the equipment on which the
recovery will be carried out does not have anything running. Disconnect and shut
off power with an approved shut-off device.

• Never exceed the safe cylinder fluid weight level which is based on net weight.
The maximum capacity of all cylinder at 80% of the maximum gross weight.

• When moving a cylinder, use appropriate equipment fitted with wheels. Make
sure the cylinder is securely fastened with straps when the equipment is a small

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 handcart. Never roll the cylinder on its base or lying down from one place to
another.

• Use superior quality hoses. Make sure they are attached correctly and firmly.
Inspect all hose joints tightly.

• Hoses and electrical extension cords present a tripping hazard. Prevent such an
accident by placing appropriate barriers and signs. Locate hoses where the risk is
minimal.

• A cylinder should never be heated with an open flame torch.

• Place labels on the cylinder or container/container in accordance with what the

regulations specify.

• If this is a regeneration job, contact the preferred regeneration plant to make

transportation arrangements.

• Ensure that all cylinders are in safe condition, capped appropriately and with
proper identification.

QUESTIONNAIRE

How does the overfill sensor work?

How does the overfill sensor on the recuperator and cylinder work?

How do we charge refrigerant?

How do we create a vacuum?

How do we install and recover refrigerants?

How do we perform the purge?

How do we know that we should purge and how is it done?

How do we separate condensable and non-condensable fluids?

Where is it and what activates solenoids S2 and S22?

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Where is it and what activates solenoids S13 and S22?

Where is it and what activates solenoids S14 and S10?

Where is the cut filter and what function does it serve?

Where is it and what is the function of the non-return valves and the overfill sensor?

Indicate the recovery cylinder protection systems?

Explain everything about recovery cylinder?

What is it for and where are the low and high pressure switches?

What is the purpose of the purge valve, what do we purge?

Where is the cut filter and what function does it serve?

Who is it and how does the spotter work?

CONCLUSIONS

RECOMMENDATIONS

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