10

Refrigerant
recovery,
recycling and
cylinders
Training Material Reference

Refrigerant recovery, recycling and cylinders - 2012.ppt

Target Group

Trainers and Technicians

Duration of the Session

30 minutes

Purpose of the Session

Participants are informed of the necessity for recovery of refrigerants, the refrigerants that are to

be recovered, active and passive methods of recovery, a simple recovery machine, single pass

recovery & recycling unit.

Terminal Performance Objectives

At the end of the session, participants should know

a) Reasons to recover various refrigerants, not only HCFCs (HCFC-22) but also HFCs (HFC-

134a, HFC blends)

b) Difference between terminologies - recovery, recycling and reclamation

c) Principles of different types of recovery operation, and their major components and circuit

diagrams

d) How to assemble a simple recovery machine (do it yourself)

e) The design and operation of single pass R&R machine developed.

Key Message being delivered through this Session

Recovery of refrigerants is a good practice needs to be adopted by the service technicians for the

environmental protection as well as economic reasons. Various types of recovery and recycling

machines are available in the market for different requirements. However, it is also possible to make

a simple recovery machine, with used components available at the service shop. This can be an

attractive option provided the components are in good conditions.

Tools & Equipments (if any) required for the session

It will be preferable to have a recovery machine close by.

10 Refrigerant Recovery, Recycling & cylinders
Aspects Covered in this session are:
Recovery of Refrigerants such as HCFCs and HFCs will reduce
the emissions to the environment. We will discuss the following
Refrigerant recovery, recycling and cylinders

issues:

• What is the necessity for refrigerant recovery?

• What are the principles of recovery methods? The terminologies
used.
• Passive and active procedures of recovery?
• Recovery machine technician can make themselves.
• What are the different type of cylinders?

Refrigerant Recovery - Reasons?

HCFCs (e.g. HCFC-22) have to be recovered. If released into the atmosphere, it can
cause ozone depletion as well as considerable global warming.

From the environment point of view , is it enough if one does not release HCFCs only?

No. HFCs, such as HFC-134a, R-401A also have to be recovered and should not be
released to the atmosphere as they too have a moderately high GWP, although they do
not damage the ozone layer.

There are also economic reasons. The prices of HCFCs are bound to have a dramatic
rise in the next few years due to the phase out regulations.
Recovery, Recycling, Reclamation

Some of the definitions of these processes as per ISO 11650 are given below:

Recovered Refrigerant: Refrigerant that has been removed from a refrigeration system for
the purpose of storage, recycling, reclamation or transportation.

Recovery: The process of removing a refrigerant in any condition from a refrigeration system
and storing it in an external container without testing or processing in any manner.
Avoid reuse of the recovered refrigerant removed from the burnt-out compressor system or
from a damaged or long neglected appliance. This is usually tested by seeing the blackish
color or by the acidic smell of the refrigerant gas/oil. The lubricant also will have similar acidic
odour. If the recovered refrigerant’s condition is good, it can be reused, e.g. while repairing for
leak or to replace a valve. If the contaminants level is excessive, the refrigerant is generally
sent for destruction in developed countries. Test kits to verify the quality of the recovered
refrigerant are available in some countries.
Recycling: This is the process of reducing the contaminants in used refrigerant by
oil separation; non-condensable removal and core filter driers which reduce moisture,
acidity and particulate matter.
There are single pass recycling machines, which reduce the contaminants level, are
not expensive and are not very effective. Multiple pass machines are more effective but
expensive as well. Filter systems in recycling equipment need to be changed or cleaned
regularly to properly maintain the recycling equipment. In most recycling situations the
recycled refrigerant is returned to the same system it was removed from or charged into
compatible equipment at the same site owned by the same owner.
Reclamation: This is to process used refrigerant to new product specification, by means
which may include distillation. Chemical analysis of the refrigerant will be required to
determine that appropriate product specifications are met. Mini reclamation centres are
available in the market for reclamation of refrigerants.

Disposal: In several countries licensed disposal firms (destruction which might include
incineration) are available to destroy refrigerants that cannot be recycled or reclaimed.
Such destruction facilities are not yet available in many of countries.
It is important to clearly understand and explain the three different processes.
10 Methods of Recovery
Refrigerant recovery, recycling and cylinders

There are two methods of recovery. The first is passive wherein the recovery of the
refrigerant is performed without the assistance of any external equipment.

There are two techniques of passive recovery, both of which do not require any external
recovery machine. These are:

1. Charge migration method

2. Use of system compressor to accelerate the process of recovery
The other is active in which an external recovery machine is used.
In both the methods, the refrigerant is recovered along with the oil that is contained in it.

Charge Migration Method - Passive

In this technique the refrigerant flows from the system to the recovery cylinder essentially
due to the pressure difference between the two. The greater the differential between
both, the faster and larger quantity of refrigerant that will be recovered. Therefore, the
process can be speeded up by creating a greater pressure differential by:

a) Evacuating recovery cylinder,

b) Placing recovery cylinder in ice bath or a combination of these. Basically this technique
allows only a small percentage of charge to be recovered.
Charge Migration Method - Passive

This slide shows the schematic of the recovery arrangement.

Accelerated Passive Recovery using System

Compressor

In this case, the system’s own compressor is used to create the pressure differential and
accelerate the pumping of the refrigerant into the recovery cylinder. The salient aspects as
noted on the slides are:

1. System compressor can pump out refrigerant as vapour (if service valve used) or as
liquid from condenser exit
2. System compressor should not run below “0” PSIG
3. Higher percentage of recovery possible
Still, significant percentage of refrigerant will be left in the system for which external recovery
machine is needed.
Slide illustrates the schematic of the recovery process along with the legend of different
components.
10 Active Methods of Recovery
Refrigerant recovery, recycling and cylinders

Active methods use external recovery machine.

One option is a simple system, which will recover the refrigerant using a compressor,
which then liquefies the vapour in the condenser before it enters into the recovery
cylinder. However, this method does not separate the oil contained in the refrigerant.
This comes in various models and is very compact to carry anywhere.

A more advanced method provides the possibility to separate the system oil from
the refrigerant during the recovery process. Likewise, it also separates the recovery
machine compressor oil and returns it back to the compressor. Now a day lot of recovery
machines are oil less and there is no oil to be returned back to the compressor.

Same recovery machine can be used to recover different refrigerant, after vacuumizing
the recovery machine upto 500 microns or below.
Recovery Unit

This slide explains the principle of recovery with oil separation.

Here, the refrigerant is recovered (as vapour) from the system and passed through the
first oil separator to separate the oil of the system contained in the refrigerant.

In the process of recovery, the refrigerant also carries oil from the compressor of the
recovery machine. This oil is separated in the second oil separator and returned to the
compressor. If this were not done, the compressor will starve of oil and burn out.

The refrigerant is then liquefied in the condenser and collected in the recovery cylinder.

The schematic diagram of the indigenous (means every technician can make it) single
pass recovery and recycling machine is shown in the slide. Such a unit can be used
for the recovery of HCFC as the first step of HCFC servicing. A similar machine can be
used to recover HCFC when servicing /retrofitting HCFC appliance.

The principle is very similar to the one illustrated earlier, with additions of a few more
components such as heat exchangers in the distillator for more efficient oil and refrigerant
separation, pressure gauges to observe the inlet and outlet pressures, low and high
pressure cut-offs and a sight glass with moisture indication.
10 Recovery Unit
Refrigerant recovery, recycling and cylinders

This slide shows the schematic connection with the machine and cylinder.

Recovery in Vapour mode

The refrigerant charge can be recovered in vapour recovery mode as shown in this
diagram. On larger refrigeration systems this will take appreciably longer time than if
liquid is transferred. It must be ensured that the compressor does not suck in liquid
refrigerant as this will cause serious damage. The connection hoses between recovery
units, systems and recovery cylinders should be kept as short as possible and with as
large a diameter as practicable.
Recovery in Liquid Mode (Push and Pull)

There is another method for liquid recovery called the “push and pull” method. If you have
access to a recovery cylinder, the procedure will be successful if you connect the recovery
cylinder to the recovery units vapour valve, and the recovery cylinder liquid valve to the
liquid side on the disabled unit as shown in the diagram. The recovery unit will pull the liquid
refrigerant from the disabled unit when decreasing the pressure in the recovery cylinder.
Vapour pulled from the recovery cylinder by the recovery unit will than be pushed back to the
disabled unit’s vapour side.
10 Suggested guidelines for refrigerant recovery
Refrigerant recovery, recycling and cylinders

Trainer must recommend Recovery of Refrigerants from air-conditioning systems in the

Training and also recommends the use of ‘Recovery cum single Pass Recycling Machine’
they can develop in the workshop. However, in the absence of clear guidelines, Trainers
are unable to answer questions like how to discriminate between recovered refrigerants
that can be reused and those that cannot be and also what is to be done with the
refrigerant that has been recovered. At least for project purposes and not for providing
any National Guidelines or standards, the following guidelines are recommended:

1. Do not vent any refrigerant other than HCs.

2. Use passive or active Recovery methods for recovering the refrigerant from the
appliance.
3. If the air-conditioning system has suffered a compressor motor burn-out, such
refrigerant should be recovered and kept in a cylinder and should not be reused, as it
will have to go for Reclamation.
4. Refrigerants recovered from systems can be reused after subjecting the oil
extracted from the recovery machine to a test for acidity using an ‘Acid test Kit’ and
moisture using a ‘Moisture Test Kit’. Here the acceptable limit for acidity is 0.2 TAN and
that for moisture is100 ppm. Readings obtained using this kit, that are above these
limits will have to be stored separately. For e.g. refrigerant from Burnt out Compressors.
5. If the acid test indicates acid and moisture limits within the above mentioned
limits, the refrigerant can be reused.
The above guidelines do not provide 100% solution in the absence of a national policy
or framework on reclamation, recycling or destruction; but using these, it is possible
to at least discriminate between useable and unusable refrigerants. This is a half way
house for the present.
Recycling Machine

In a single series of operations, the machine permits recovering and recycling refrigerant
with no risk of release into the environment, and also permits purging the A/C system of
humidity and deposits contained in the oil. The machine is equipped with a built-in evaporator/
separator that removes oil and other impurities from the refrigerant recovered from the A/C
system and collects them in a container for that purpose. The fluid is then filtered, recycled
and returned to the tank installed in the machine. The machine also permits running certain
operational and leak tests on the A/C system.

Recycling filter must be installed within the recycling system to absorb and remove the acid,
moisture, and particular matter from refrigerant. Recycling filter must be regularly changed
according to manufacturers’ recommendation and refrigerant contamination state.

Some of these units are assessed for quality and performance as per Air-conditioning and
Refrigeration Institute (AHRI) standard 740.
10 Recycling Machine Filter/Drier
Refrigerant recovery, recycling and cylinders

The drier shown in the slide is able to absorb acid, moisture and particulate matter from
the refrigerant t be purified. But care must be taken for this drier that one must replace
the same as per manufacturer’s recommendation.

Safe Refrigerant capacity

Technician must take care during recovery that he must use the specified recoverable
cylinders and label it properly after recovery that what kind of refrigerant he has stored
in it. For getting the exact capacity of the cylinder it can contain the refrigerant , the
formula is given below:

Water contents x 0.8 = safe refrigerant capacity

Knowing the recommended HCFC charge size for the system is helpful. If it is not
known, weigh the entire amount of refrigerant removed. This amount can be used as
a guide for the initial quantity of replacement refrigerant to be charged into the system.
Type of Refrigerant Cylinders

Refrigerants are packed in both disposable and returnable (refillable) shipping containers,
commonly called “cylinders”. They are considered pressure vessels, and in most countries
therefore are subject to national regulations. Cylinders are designed for pressurized and
liquefied gases, and are labeled accordingly. There are two types of refrigerant cylinders are
available in the market:

a) Disposable / non-refillable cylinders and cans are also available in different quantity.
b) recovery / refillable cylinders
10 Disposable / non-refillable cylinders
Refrigerant recovery, recycling and cylinders

Available in the market are a type of cylinder called “non-refillable” or “disposable”

cylinders. These are sometimes used where the supply infrastructure is less
comprehensive, and it is less costly for refrigerant suppliers who may expect their
cylinders to become lost. From both an environmental and safety perspective, the
use of disposable cylinders is considered to be very bad practice. These containers
are generally discharged after use, resulting in a lot of refrigerant being released to
the atmosphere. Furthermore, there are often attempts to re-use these cylinders (for
example, through brazing new valves onto them to enable re-filling with refrigerant),
despite such practices being forbidden. Also, they tend to be manufactured from thinner
metal than the conventional, re-usable cylinders, rendering them more susceptible to
rusting and mechanical damage over time. As such, their use is not recommended
under any circumstances.

If a disposable cylinder has been used, before disposing of it, it should be properly
emptied. This requires the remaining refrigerant to be recovered until the pressure has
been reduced to pressure of approximately 0.3 bar (absolute). The container’s valve
must be closed at this time and the container marked as empty. The container is then
ready for disposal. It is recommended that the cylinder valve should then be opened
to allow air to enter, and the cylinder should be rendered useless (with the valve still
open) by breaking off the valve or puncturing the container. This will avoid misuse of
the container by untrained individuals. Used cylinders can be recycled with other scrap
metal. Never leave used cylinders with residual refrigerant outdoors where the cylinder
can rust. An abandoned cylinder will eventually deteriorate and could potentially explode.
Recovery / refillable cylinders

Recovery cylinders are specifically intended for refrigerant that have been removed from
refrigeration systems. The recovered refrigerant can then be re-used or sent for reclamation
or disposal. The cylinder valve has the refrigerant filling port enabled, so that refrigerant can
be easily fed into the cylinder, and the second being the external marking.

It is important to ensure that the recovery cylinder is only ever used for one type of refrigerant.
This rule should be followed for two reasons: first, if different refrigerants are mixed, it may not
be possible to separate them again for re-used, and secondly, mixing two or more refrigerants
can result in a pressure that exceeds the pressure of either of the refrigerants added into the
cylinder. Refillable cylinders are available in every country starting from smaller capacity to
larger one. They are being used to carry the new refrigerant for transferring to the smaller unit
like commercial machines, MAC and others.

• Use only clean cylinders, free from contamination by oil, acid and moisture etc. It is also
advised that only certified cylinders should be used, and they should be checked visually
before using.
• Do not exceed 80% of the rated capacity of the cylinder by volume.
• Never mix different refrigerants or recover one refrigerant into a cylinder meant for some
other refrigerant.
• It is always good to label the recovery cylinder putting the refrigerant number, name and
the weight of the cylinder and the total weight with date.
•
Use only approved cylinders that are exclusively reserved for recovery.
10 Cylinder Inspections and Re-testing
Refrigerant recovery, recycling and cylinders

Both the cylinder itself and the valve are usually subject to national regulations for their
design, fabrication, and testing. The use of the various refrigerants in cylinders that are
exposed to the environment is reason for concern, as previously discussed. Although
the interior of these cylinders must be void of moisture, the exterior cannot avoid it.
Thus, corrosion can and does occur, as well as mechanical damage due to mishandling.
These are but a few of the reasons why the cylinders must be inspected and re-tested at
particular intervals. The intervals differ by country, but the date for the next inspection or
testing is usually indicated on the cylinder. It should then be returned to the refrigerant
supplier. Similarly, the valves should be periodically examined, especially the relief
valve. Check to be sure that nothing is obstructing the relief valve and that no visual
deterioration or damage has occurred. If any damage is visible, empty the cylinder and
have the tank repaired. Never use a cylinder with a faulty pressure-relief valve or with
obvious structural impairments.
Evaluation Questions
1. Is it necessary to recover HFC refrigerants for environmental reasons?

2. Is it necessary to recover HC refrigerants for environmental reasons?

3. Can you make a recovery unit without a condenser?

4. What are basic issues for recovery cylinders?

5. What are the basic components required to make a most simple recovery unit?

6. What is the maximum capacity of the cylinder to fill a recovered refrigerant?

7. What is the difference between recovery, recycling and reclamation?

8. Can the same recovery machine be used for different refrigerants?