Experimental investigation on convective heat transfer mechanism in a scroll compressor

This paper describes an experimental study on the convective heat transfer inside the scroll compressor. An experimental refrigeration system is composed with extensive instrumentations in the compressor that is operated at variable speeds. The 13 thermocouples installed inside the compressor monitor the temperatures of the scroll wrap during compression process of refrigerant. The temperature and the pressure of refrigerant at suction, and the pressure at discharge ports are measured, and applied to the numerical simulation as the operating condition parameters. The temperature measured at the discharge port is used to verify the simulation result with relevant heat transfer coefficient. This paper describes the effect of motion of the orbiting scroll on the convective heat transfer in the scroll wraps. Separate experiments are performed to investigate the heat transfer in such a peculiar physical condition. With this experimental result, the effect of the oscillation of the wall on the heat transfer is quantitatively analyzed and applied to the simulation of compression process in scroll compressor. The whole consecutive compression processes in the scroll compressor is simulated in detail by solving equations of mass and energy balance for the refrigerant. The modified heat transfer coefficient correlation considering the effect of motion of the orbiting scroll predicts the discharge temperature better than other typical heat transfer coefficients.     

Influence of liquid refrigerant injection on the performance of an inverter-driven scroll compressor

The operation of a scroll compressor at high compression ratios can cause excessively high discharge temperatures, which can be detrimental to the reliability and efficiency of the compressor. In the present study, the performance of an inverter-driven scroll compressor with liquid refrigerant injection was measured with a variation of compressor frequency, injection pressure, and injection location. The influence of the liquid injection on the performance is presented as a function of operating parameters and injection location by comparing the results with those for the non-injection case. It was found that liquid injection under high frequency was very effective at attaining higher performance and reliability of the compressor, but injection under low frequency showed some disadvantages. For high frequency at a given injection ratio, the injection at α=180°, for an injection angle at an injection port, yielded slightly better performance of the compressor as compared to that at α=90°.     

Optimization of refrigeration system with gas-injected scroll compressor

Gas refrigerant injection has been proven as an effective method to improve the performance of the scroll compressor and its refrigeration system under high compression ratio working conditions. Much research on the injected scroll compressor and its system has been conducted, but the universal control and design method is still lacking. A model of the refrigeration system with a gas-injected scroll compressor is developed in this paper. With this model, the effects of gas injection on the system and component parameters are investigated. Based on the identified evaporator characteristics and thermodynamic analysis, a set of general principles for the design and operation of the refrigeration or heat pump system with a gas-injected scroll compressor is proposed.     

An investigation of the performance of a scroll compressor under liquid refrigerant injection

In this study, fundamental and practical influence of liquid refrigerant injection on the performance of a refrigerant scroll compressor has been investigated experimentally and theoretically. In the theoretical analysis, a compression model of vapor/liquid mixture is developed by taking account of heat transfer from the cylinder wall to suction, compression and injection refrigerant. An experiment has been done under the condition of keeping the oil temperature constant in order to investigate the fundamental influence of the liquid refrigerant injection on the compressor performance, and the results were compared with the theoretical ones. It was found that the injection basically increases the compression power and decreases the compressor efficiency, though the situation depends on the condition of the heat transfer to the injection refrigerant. And furthermore, the performance of the liquid refrigerant injection compressor under practical operating condition without controlling the oil temperature has been investigated. Under this condition, the compressor showed recovery and slight improvement of performance due to the decrease of the oil and cylinder temperatures by the injection. In addition, influence of the refrigerant injection on the oil viscosity and refrigerant solubility in the oil, which relate mechanical loss and reliability of the compressor, have been discussed.     

Mathematical modeling of scroll compressors — part II: overall scroll compressor modeling

This paper presents the development of a comprehensive simulation model of a horizontal scroll compressor, which combines a detailed compression process model (Chen Y., Halm N., Groll E., Braun J. Mathematical modelling of scroll compressors — part I: compression process modeling, International Journal of Refrigeration 2002;25(6):731–750) and an overall compressor model. In the overall model, compressor components are analyzed in terms of nine different elements. Steady state energy balance equations are established applying the lumped capacitance method. In combination with the detailed compression process model, these equations were implemented into computer code and solved recursively. In this way, the temperature and pressure of the refrigerant in different compressor chambers, the temperature distributions in the scroll wraps, and the temperatures of the other compressor elements can be obtained. Thereafter, power consumption and efficiency of the compressor can be calculated. Tests were used to verify the overall model on a macroscopic basis. Using the simulation program based on the overall compressor model, a parametric study of the scroll compressor was performed, and the effects of internal leakage and heat transfer losses were investigated and some preliminary results were obtained. These results indicate that the comprehensive scroll compressor model is capable of predicting real compressor behavior and useful to the design and optimization of scroll compressors.     

Effects of liquid refrigerant injection on the performance of a refrigeration system with an accumulator heat exchanger

Liquid refrigerant injection technique can be a very effective method for controlling subcooling and the compressor discharge temperature of a refrigeration system at high ambient temperatures. In this study, the effects of liquid refrigerant injection on the performance of a refrigeration system with an accumulator heat exchanger were investigated by varying the liquid injection rate at the conditions of constant expansion valve opening in the evaporator and constant total flow rate. During the tests, the ambient temperature was maintained at 43 °C. With the increase of the liquid injection rate, the subcooling at the inner heat exchanger outlet increased and the superheat at the accumulator outlet decreased. However, unacceptable results such as the increase of the compressor discharge pressure and decrease of the system performance were also observed depending on the control method applied. To obtain high system performance and reliability, optimum control methods for liquid injection in the accumulator heat exchanger are suggested. The liquid injection technique for the refrigeration system with an accumulator heat exchanger was found to be an effective method for controlling adequate subcooling and the compressor discharge temperature of the refrigeration system at high ambient temperatures.     

Efficiency of the indicated process of CO2-compressors

The compressor of a refrigerant compression process is the component with the major influence on the efficiency and reliability of the entire system. Due to the fluid properties of carbon dioxide (CO₂), the pressure ratio of the refrigeration process with CO₂ as the working fluid is, in relation to common refrigeration processes, rather low while the pressure difference is extremely high. From experimental and theoretical considerations it becomes obvious that at these conditions a high volumetric and energetic efficiency of the compressor may be achieved if its design is appropriate. In this paper, the effects on the efficiency of the indicated compression process of a CO₂-compressor are discussed and evaluated and a promising design concept for an efficient CO₂-compressor is derived.     

Performance limit for economized cycles with continuous refrigerant injection

While economizing can improve the performance of vapor compression cycles, the cost of multi-stage compressors has limited its implementation to large-scale applications. However, the development of compressors with injection ports presents new opportunities for economizing in smaller-scale applications. In addition to eliminating the need for a costly multi-stage compressor, multiple injection ports can be added at relatively low cost to further improve cycle performance. In the current study, a model was developed to study the effect of the number of injection ports on performance and determine the limit to performance with injection. The model predicts that continuous injection, in which economized refrigerant is injected at an infinite number of ports to maintain saturated vapor in the compressor, provides very significant performance improvements for air-conditioning and refrigeration applications. At standard operating conditions, the COP increases between 18% and 51% depending on the application, with higher temperature lift cycles benefiting most significantly.     

Scroll compressors using gas and liquid injection: experimental analysis and modelling

The first part of this paper presents an experimental analysis of different hermetic scroll compressors using different methods of injection: the first one is without injection, the second one uses vapor injection and the third one liquid injection. The analysis reveals the influence of these methods on the compressor behavior. A simplified model of the scroll compressor is then proposed that takes into account not only the different internal processes but also the refrigerant injection. It assumes that the refrigerant mass flow rate is affected by a heating-up due to a uniform wall temperature. This fictitious wall is supposed to gain heat from the electromechanical losses and from the discharged gas and to loose heat to the suction and to the ambient. The compression step is considered isentropic up to the adapted pressure and then at constant volume until the discharge pressure. The model is able to compute variables of first importance like the mass flow rate, the electric power and the discharge temperature, as well as secondary variables as suction heating-up, discharge cooling-down, and ambient losses. The validation based on 45 experimental results shows excellent results.     

R32涡旋压缩机两相喷射制冷系统的设计与控制

R32涡旋压缩机存在排气温度过高的问题,利用两相制冷剂喷射可降低排气温度同时提升性能。基于经济器系统,提出了R32涡旋压缩机的两相喷射制冷系统,利用模拟仿真对其设计和控制方法进行了研究。从压缩机的角度,分析了喷射口等效直径对两相喷射压缩机性能的影响,并指出了两相喷射时喷射压力和喷射干度的优化方向。通过对两相喷射系统的模拟分析,在系统层面上对中间换热器的换热能力进行了优化配置和对中间喷射压力进行了优化控制,并提出根据排气温度来确定最优中间压力的方法,即将排气温度控制为135℃对应的中间压力为最优中间压力。经过优化后的两相喷射系统,不仅解决了排气温度过高的问题,而且能够提升制冷量7.1%~11.4%,提升COP 2.6%~6.2%。     

Unsteady state analysis of the compression cycle of a hermetic reciprocating compressor

In this work, an unsteady state analysis of the compression cycle of a small hermetic reciprocating compressor for domestic refrigeration was carried out. A specific one-dimensional model of the valves was developed and the mass and energy balances were applied to the refrigerant inside the cylinder to determine the mass, pressure and temperature behaviour and the heat and work transfer through the compression process. This analysis was inserted into a traditional steady state model of the compressor to evaluate the efficiency of the compression cycle and the performance of the compressor unit. The whole simulation code was validated against the experimental measurements carried out on a R134a commercial unit in a wide range of operative conditions: a fair agreement was found between predicted and measured performances. The simulation code can be a useful tool for the analysis, the design and the development of small hermetic reciprocating compressors for domestic refrigeration.     

电动汽车空调热泵型涡旋压缩机结构分析

为了解决电动汽车空调系统冬季采暖问题,针对冬季空调工况下压缩机单级压比增大的运行特性,以涡旋压缩机制热性能系数为热力学优化目标函数,确定了制冷剂循环系统中的最佳补气压力,优化了涡旋压缩机静涡旋盘上的中间补气口的几何位置和形状,使其具备了准双级压缩功能。将研发的热泵型电动涡旋压缩机安装于电动汽车空调系统,利用空气焓差法对系统进行了制热、制冷性能实验。实验结果表明,静涡旋盘结构优化后的热泵型电动涡旋压缩机,其制热和制冷能力可以满足5人座电动汽车司乘人员的冬季和夏季舒适性要求,并且具有较高的制热和制冷性能系数,从而提升了汽车空调系统热泵循环和制冷循环的热经济性,达到了节能的目的。     

Approaching the performance limit for economized cycles using simplified cycles

Modifications such as economization aim to improve the efficiency of vapor compression equipment by cooling the refrigerant during the compression process. A previous study (Mathison et al., 2010) explored the theoretical limit to cycle performance with economizing, which was defined as the performance when a saturated vapor state was maintained in the compressor by continuously injecting a two-phase mixture. However, achieving continuous injection and controlling the quality of the injected refrigerant poses a substantial challenge. Therefore, the current paper investigates the ability of an economized cycle with saturated vapor injection through a finite number of ports to approach the limiting cycle performance. For an air-conditioner using R-410A with an evaporation temperature of 5 °C and a condensing temperature of 40 °C, the model predicts that injecting saturated vapor through three ports will improve the COP by 12%, which is approximately 67% of the maximum benefit provided by economizing in the limiting case.     

The effect of scroll wraps on the performance of scroll compressors

A number of geometrical curves have been used to form the wraps of scroll compressors. When the suction pressure, pressure ratio, scroll wrap height and thickness, and suction volume are constant, the effect of the involute curves of a cricle, square and line segment on the performances of the scroll compressor, such as geometrical parameters, leakage line length and various gas forces acting on the orbiting scroll are analysed in this paper. The effects of these scroll wraps on the performance of the scroll compressor vary as the suction volume changes. The results in this paper should be considered in scroll compressor design.     

Characteristics of Voorhees refrigerating machine with hermetic piston compressor producing refrigeration at one or two temperature levels

Research on the operation of the refrigerating machine working on the Voorhees cycle which permits two-stage compression in a single-cylinder compressor has been carried out. The purpose of this research was to study the possibilities of using the Voorhees machine in a domestic refrigerator for production of refrigeration at one or two temperature levels. The experiments were carried out on the basis of a small hermetic lubricated compressor with a low refrigerating capacity operating on a commonly used R12 and natural refrigerant isobutane R600a. The improved refrigerating capacity in the Voorhees cycle with isobutane makes the latter an alternative substitute for conventional refrigerants. Some peculiarities in the operation of a hermetic piston compressor as part of the Voorhees refrigerating machine have been revealed. They require the use of a compressor developed specially for the Voorhees cycle. The method of optimizing the cycle parameters for a one temperature refrigerating system is suggested in this paper. The research carried out proved that the optimum intermediate pressures of the Voorhees refrigerating machine producing refrigeration either at one or two temperature levels are different.     

Refrigerant injection for heat pumping/air conditioning systems: Literature review and challenges discussions

This paper reviews the major research on refrigerant injection techniques in detail. Liquid and vapor refrigerant injection techniques are discussed and compared. The current research on refrigerant injection techniques falls into two categories: system level research and component level research. The system level research is focused on low ambient temperature heating, heat pump water heating, high ambient temperature cooling, cycle comparison, and control strategy development. Internal heat exchanger and flash tank cycles are the two typical cycles for refrigerant injection. These two cycles are discussed and compared in detail. The component level research is focused on employing different types of compressors, variable speed compressors, the injection process, and the flash tank. Different types of compressors employing refrigerant injection are presented. Based on the literature study, the potential future research directions are presented and discussed. The flash tank cycle control strategy and refrigerant charge management strategy are worth further research efforts. Compressor design can be improved in order to optimize the performance with refrigerant injection. The appropriate design of flash tanks plays a vital role in achieving appropriate two-phase flow patterns in the flash tank. Computational Fluid Dynamics (CFD) modeling can be a useful tool to facilitate the design of the flash tank.     

Thermodynamic analysis on the performance of a variable speed scroll compressor with refrigerant injection

A thermodynamic model for a variable speed scroll compressor with refrigerant injection was developed using continuity, energy conservation and real gas equation. The model included energy balance in the low-pressure shell compressor, suction gas heating, motor efficiency, and volumetric efficiency considering gas leakages as a function of compressor frequency. The developed model was verified by comparing the predicted results for the no injection condition with the experimental data. The deviations of the predicted from the measured values were within 10% for approximately 90% of the experimental data. Based on the model, mass flow rate, suction gas heating, cooling capacity and power consumption of the compressor were estimated and analyzed as a function of frequency. The effects of refrigerant injection on the performance of the compressor were also discussed as a function of frequency, injection conditions, and injection geometry.

Résumé

A thermodynamic model for a variable speed scroll compressor with refrigerant injection was developed using continuity, energy conservation and real gas equation. The model included energy balance in the low-pressure shell compressor, suction gas heating, motor efficiency, and volumetric efficiency considering gas leakages as a function of compressor frequency. The developed model was verified by comparing the predicted results for the no injection condition with the experimental data. The deviations of the predicted from the measured values were within 10% for approximately 90% of the experimental data. Based on the model, mass flow rate, suction gas heating, cooling capacity and power consumption of the compressor were estimated and analyzed as a function of frequency. The effects of refrigerant injection on the performance of the compressor were also discussed as a function of frequency, injection conditions, and injection geometry.     

Comparative study of the impact of the dummy port in a scroll compressor

A dummy port plays an important role in the porting process and the improvement of the performance of a scroll compressor. This paper documents an investigation on the working mechanism of the dummy port in a scroll compressor. To characterize the dummy port effects on the different parts of the scroll compressor, two scroll compressors, one with and the other without a dummy port, are studied comparatively. The flow through the dummy port is examined in the background of an integrated compressor working process. The assembly of the compressor under investigation includes the upper bearing housing, scrolls, check valve, and discharge plenum. The Navier–Stokes equations with a k– turbulence model are solved at the standard operating conditions of a scroll compressor. Refrigerant-22 is used as the working fluid. The thermodynamic and transport properties of the refrigerant gas are modeled by the Martin–Hou equation of state and power laws, respectively. Global flow physics is investigated first to lay a foundation to understand the working mechanisms that control the porting process before averaging techniques are applied. The behavior of the gas pockets in the porting process is characterized in both geometric and dynamic nature. The time-dependent variation of volume, mass, energy, and volume-averaged field quantities inside the gas pockets are studied throughout the porting process. The impact of the dummy port on the compressor performance is defined.     

Transient modeling of a flash tank vapor injection heat pump system – Part I: Model development

This two-part article explores the dynamic behavior of a flash tank vapor injection heat pump system from a numerical simulation perspective. Part I provides a first-principles model describing the transient heat transfer and flow phenomena of the system with detailed modeling techniques for each component. The vapor injection scroll compressor is analyzed with the internal heat transfer between the refrigerant and metallic parts taken into account. Lumped-parameter models are developed for the flash tank and expansion devices. Heat exchangers are modeled using a finite volume approach and accounting for the complex tube circuitry. The separated flow model without interfacial exchange is utilized for two-phase flows in order to incorporate an appropriate void fraction model so that a more accurate prediction for refrigerant mass distribution can be achieved. The modular nature of the component models allows flexibility in the system configuration. Transient simulations are carried out for start-up and shut-down operations. A detailed comparison of model predictions against experimental data is presented in the companion paper.