As far back as we can remember man has used ammonia for one reason or another. It is in fact the oldest known refrigerant. It is successfully utilized in many industries including food, petrochemical and pharmaceutical. So why is it so misunderstood?

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In this article, we will attempt to clear up and demystify anhydrous ammonia, which is a formulation void of water, as it relates to refrigeration. We will discuss the benefits and drawbacks of this ammonia refrigerant as well as review leak detection and safe handling procedures.

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Why do we use anhydrous ammonia instead of halocarbons in industrial applications? Ammonia is cheap and extremely efficient. Ammonia is the most commonly used refrigerant worldwide for large commercial applications. The main use of ammonia is agricultural (fertilizer). More than 80 percent of the ammonia produced is utilized in this fashion due to its high nitrogen content. Since ammonia is plentiful, the cost is low. The cost for refrigerant-grade anhydrous ammonia typically is less than 50 cents a pound, compared to about $7 a pound for R4O4A and $15 a pound for R-502.

There are two primary grades of ammonia commonly available in the marketplace. There is an agricultural or commercial-grade ammonia that must contain a minimum water content of at least 2,000 ppm water (0.2 percent) with a maximum water content of 5,000 ppm (0.5 percent). The minimum water content prevents stress corrosion cracking of the metals used in equipment for the agricultural industry.

Industrial-grade anhydrous ammonia, commonly called metallurgical or refrigeration grade, has very little water contamination. Metallurgical-grade has a maximum of about 33 ppm water (0. percent) and refrigeration-grade has a maximum of about 150 ppm water (0.015 percent). For optimum efficiency and effectiveness in your industrial refrigeration system, the ammonia supplied to you for your system should meet or exceed these specifications.

In addition to the price the most compelling reason to utilize anhydrous ammonia is the fact that it has such a high latent capability per pound. Its latent capability at 5° F evaporator temperature is 565 Btu per pound. When compared with R-22, which is approximately 69 Btu per pound at the same temperature, its obvious that it takes less ammonia to do the work because it is more efficient. This means less kwh used and lower operating costs.

Because the smell of ammonia is readily perceptible, you will know it if there's even a tiny leak. With halocarbons a technician&#;s chances of smelling a leak are low, unless it contains a lot of oil and you are near the source.

Ammonia vapor is lighter than air and in a confined area il displaces oxygen from the ceiling downward. Halocarbons are heavier than air and will displace the oxygen from the floor upward. Either situation can be fatal.

Ammonia is flammable and has a lower explosive limit (LEL) of 15 percent (150,000 ppm) and an upper explosive limit (UEL) of 28 percent (280,000 ppm). When the ammonia vapor is mixed with a mistable oil, the LEL can be as low as 8 percent (80,000 ppm).

Ammonia also will undergo what is called hazardous decomposition at temperatures above 850° F. This means it will break down into nitrogen and hydrogen gases. Hydrogen gas has a flammability range of 4 to 75 percent.

Ammonia systems generally are built around an understanding of the characteristics of anhydrous ammonia and its dangers and benefits. As with any system, the first line
of defense is the safety engineering designed into it.

Industry safety standards continue to be the main reason ammonia systems are much safer than most people are aware. Each system must meet strict safety codes, which include materials of construction as well as appropriate relief valves, ventilation, safety switches and other safety engineering concerns.

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As in any other industry, the training of operators and technicians is important. Fully trained operators and technicians are much less likely to cause a situation resulting in death or injury.

Both OSHA and U.S. EPA address training for larger ammonia refrigeration systems. If the ammonia refrigeration system has a charge of 10,000 pounds or more, you must implement or take operational and maintenance training. Many companies follow this regardless of the charge level.

Training must include standard operating procedures for every task that will be performed, as well as safe work practices, including proper line-break procedures. Line-break procedures are what a technician does each time the ammonia refrigeration system is opened for maintenance. Additionally, operating personnel must receive refresher training at least every three years.

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Ammonia As a Refrigerant: Pros and Cons

In March , a -pound ammonia leak occurred at a Boston-area seafood warehouse that killed one worker and forced a shelter-in-place order from Boston Police.  Problematic procedures may be to blame. So as you read the pros and cons of Ammonia as a refrigerant below, remember these key takeaways: ongoing, scheduled evaluations and preemptive maintenance are critical for any ammonia storage solution &#; lax procedures place workers and residents in danger.

Why is Ammonia growing in popularity given this risk? As fewer and fewer CFCs and HCFCs are available for use as refrigerants, companies are looking to ammonia as a more effective replacement. According to ASHRAE and the International Institute of Ammonia Refrigeration (IIAR), ammonia is a cost-effective, efficient alternative to CFCs and HCFCs that is also safe for the environment.

Ammonia (chemical formula NH3) is a gas comprised of two other gases &#; nitrogen and hydrogen. Whether found in nature or made by man, ammonia is colorless but has a sharp, pungent odor. Ammonia, frequently used commercially in large freezing and refrigeration plants is also called &#;anhydrous ammonia&#; because it contains almost no water (it is 99.98% pure). Household ammonia, by comparison, is only about 10% ammonia by weight mixed with water.

As a refrigerant, ammonia has four major advantages over CFCs and HCFCs:

• An ammonia-based refrigeration system costs 10-20% less to build than one that uses CFCs because narrower-diameter piping can be used.
• Ammonia is a 3-10% more efficient refrigerant than CFCs, so an ammonia-based system requires less electricity, resulting in lower operating costs.
• Ammonia is safe for the environment, with an Ozone Depletion Potential (ODP) rating of 0 and a Global Warming Potential (GWP) rating of 0.
• Ammonia is substantially less expensive than CFCs or HCFCs

There are two key disadvantages to using ammonia as a refrigerant:

• It is not compatible with copper, so it cannot be used in any system with copper pipes.
• Ammonia is poisonous in high concentrations. Two factors, however, mitigate this risk: ammonia&#;s distinctive smell is detectable at concentrations well below those considered to be dangerous, and ammonia is lighter than air, so if any does leak, it will rise and dissipate in the atmosphere.

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