The Future of Refrigerants: What to Expect in 2025 and Beyond

The Evolution of Refrigerants: Safety, Efficiency, and Environmental Impact

Clint Rabe, P.E.

Clint‘s background designing both mechanical and electrical systems allows him to bring a unique perspective to the design and construction process while helping him to identify potential project opportunities and pitfalls. Clint’s collaborative approach to the construction process is evident as he works to bring all parties to the table in developing the right project solutions. His conscientious and hardworking approach reinforces his personal commitment to making each project a success.

Refrigerants have played a critical role in cooling buildings and preserving food throughout history. Over time, three key factors have influenced the selection of refrigerants: safety, efficiency, and environmental impact.

If you’ve been in the industry long enough, you might recall when R-22 was the go-to refrigerant. However, its ozone depletion potential led to its phase-out, paving the way for R-410A. Today, the industry is shifting focus again, driven by the Kigali Amendment to the Montreal Protocol, which aims to reduce global warming potential (GWP).

The Transition from R-410A: What Comes Next?

The next major refrigerant transition is already underway. Manufacturers are shifting towards R-32 and R-454B as replacements for R-410A, particularly in light commercial rooftop units and heat pumps. By 2025, adoption of these new refrigerants will increase, particularly in the Midwest.

That being said, R-410A won’t disappear overnight. Its production will gradually decrease due to phased regulatory limits, and prices will likely rise over time, making alternative refrigerants more attractive.

R-32 vs. R-454B: Can They Replace R-410A?

Can R-32 or R-454B be used as a one-for-one replacement for R-410A? It depends on the equipment and performance requirements.

Interestingly, R-410A is a blend that already contains R-32, making R-32 a logical successor. However, manufacturers dictate whether a direct switch is possible, and some systems may require modifications or full equipment replacement. Newer systems tend to be significantly more efficient, making an upgrade a worthwhile investment.

Considerations for Existing HVAC Systems and Line Sets

A critical question in HVAC retrofits is whether existing line sets can be reused. The answer depends on several factors:

  • Velocity Differences: R-32 has lower velocity than R-410A, making larger line sets preferable.
  • Line Set Size: If an existing system has a 3/8” liquid line instead of 5/16”, it may be more suitable for reuse.
  • Cleaning Requirements: Before reuse, line sets must be purged with a detergent like R-11.
  • Manufacturer Guidelines: Some manufacturers may not allow line set reuse, especially if the previous system had issues.

What About Chillers and Ice Rinks? The R-134a to R-513A Transition

Beyond HVAC, refrigerants used in chillers and ice rinks are also evolving. R-134a is being replaced by R-513A, which reduces GWP by over 50%. While some R-134a chillers may be retrofitted to use R-513A, modifications such as oil changes, impeller adjustments, and gear modifications may be necessary. In many cases, full equipment replacement is the most practical long-term solution.

Are These New Refrigerants Flammable?

One common concern with newer refrigerants is flammability. While R-32 and R-454B are slightly flammable, their risks are minimal compared to substances like propane. However, building codes may change to require enhanced protection for refrigerant lines, particularly at wall penetrations and interior runs.

Preparing for the Future of Refrigerants

As the HVAC industry moves toward lower-GWP refrigerants, contractors, engineers, and building owners must stay informed. Key takeaways include:

  • R-32 and R-454B are replacing R-410A, with widespread adoption starting in 2025.
  • R-410A will still be available for now, but production will decrease, and costs will rise.
  • Line set reuse is possible in some cases but requires careful evaluation.
  • Chillers are transitioning from R-134a to R-513A, though retrofits may be complex.
  • Mild flammability risks may lead to changes in building codes.

With technological advancements and regulatory shifts, the refrigerant landscape is evolving rapidly. Now is the time to plan for the transition, ensuring efficiency and compliance in the years ahead.

Whether you’re designing new systems or navigating retrofits, staying ahead of these changes is key. Our team at Resource Consulting Engineers is ready to discuss how you can prepare for the future of refrigerants today – let’s talk.

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