Recycled Zeotropic Refrigerant Composition for Low-GWP R-134a Replacement
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Solution Overview
Problem
The need for environmentally friendly refrigerants with low global warming potential (GWP) to replace high-GWP refrigerants like R-134a, which are being phased out due to their contribution to climate change and ozone depletion, while also addressing the challenge of recycling and reusing legacy refrigerants to reduce waste and emissions.
Innovation Solution
A refrigerant composition comprising R-125, R-32, R-134a, and R-1234ze(E) with a GWP of less than 1, formulated from reclaimed refrigerants, which can be used as a drop-in replacement for R-134a in existing systems, utilizing a distillation process to achieve high purity and minimal impurities, and optionally including lubricants and additives for compatibility and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If R-134a is used as a refrigerant, then refrigeration and air conditioning performance is maintained, but global warming potential increases significantly
Solution Approach 1:
The patent changes the chemical composition parameters by blending R-134a with R-125 and R-1234ze(E) to create a new refrigerant mixture with reduced GWP while maintaining the required refrigeration performance parameters through optimized composition ratios
Solution Approach 2:
The patent creates a composite refrigerant mixture combining multiple refrigerant components (R-134a, R-125, R-1234ze(E)) to achieve both environmental benefits (lower GWP) and operational reliability (maintained cooling performance) that cannot be obtained with single-component refrigerants
2Object-affected harmful factors
If high-GWP refrigerants like R-134a are phased out, then environmental impact is reduced, but compatibility with existing systems becomes problematic
Solution Approach 1:
The patent adjusts the compositional parameters of the refrigerant mixture to match the operational characteristics of existing R-134a systems, enabling drop-in replacement without system modifications while achieving reduced environmental impact
Solution Approach 2:
The patent develops a universal refrigerant composition that can serve multiple functions: it replaces R-134a in existing systems, meets new environmental regulations, and maintains compatibility with various system types (automotive AC, commercial refrigeration) through its balanced composition
3Quantity of substance
If virgin refrigerants are produced to replace phased-out refrigerants, then supply demand is met, but carbon emissions and environmental harm increase
Solution Approach 1:
The patent recovers and reuses R-134a from retired refrigeration systems through distillation and purification processes, converting what would be waste or emission sources into usable refrigerant supply, thereby reducing the need for virgin refrigerant production and associated carbon emissions
Solution Approach 2:
The patent creates a self-sustaining refrigerant supply system where retired R-134a is recovered, purified, and blended with supplemental refrigerants to produce replacement refrigerant, reducing dependence on external virgin refrigerant production and its associated environmental harm
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a safe, effective, and cost-effective refrigerant with near-zero GWP, reducing greenhouse gas emissions and avoiding the need for new refrigerant production, while maintaining performance and compatibility with existing equipment, thus contributing to the decarbonization of refrigeration and air conditioning systems.
Implementation Method 1
utilizing a distillation process to achieve high purity and minimal impurities
Data Source
AI summary
A refrigerant composition includes about 56-60 wt % 1,1,1,2-tetrafluoroethane; about 0.1-1 wt % pentafluoroethane; about 3-7 wt % difluoromethane; and about 35-38 wt % 1,3,3,3-tetrafluoropropene, where the composition is zeotropic. The composition has a 91:9 wt % ratio of difluoromethane to pentaflouromethane, which are recycled materials having a net gwp of 0. The 1,3,3,3-tetrafluoropropene also has gwp of about 0. A method of preparing the 91:9 wt % refrigerant mixture includes injecting a mixture of recovered refrigerants into the center of a distillation column, the mixture of injected refrigerants being difluoromethane, pentafluoroethane and chlorodifluoromethane, removing from the top of the distillation column a refrigerant composition of about 90-92 wt % difluoromethane and about 8-10 wt % pentafluoroethane, and removing chlorodifluoromethane from a bottom of the distillation column.