Study of capillary tubes in a transcritical CO2 refrigeration system

Capillary tubes have been used in refrigeration systems for many years, but not with a transcritical CO₂ system. In this article, the effects of capillary tubes in a transcritical CO₂ refrigeration system have been investigated experimentally and theoretically. Different types of capillary tubes with different lengths (0.5–4 m) and diameters (1–2 mm) have been tested. The result of this work is a static model, which is used in the further work to make a simulation model (static) of a complete refrigeration system. The model is based on Friedel's and Colebrook's pressure drop correlations.

The behaviour of an adiabatic capillary tube in a refrigeration cycle has been investigated theoretically. The conclusion is that the COP of a system with capillary tubes generally is better than when a fixed high pressure is used, but not as good as when variable optimal high pressure is used. Capillary tubes are especially interesting in applications where the evaporation pressure is constant and the temperature out of the gas cooler varies no more than ±10 K from the design condition. The reduction in COP is more significant at low temperatures out of the gas cooler.     

Basic study on new cryogenic refrigeration using CO2 solid–gas two phase flow

In this paper, a cryogenic refrigeration method is described, which utilizes CO₂ solid–gas two phase flow and the dry ice. The CO₂ solid–gas two phase flow is achieved by expanding liquid CO₂ and thus refrigeration process less than CO₂ triple point −56.6 °C can be available. The experimental work is divided into two parts and two experimental set-ups were designed, constructed and tested. The interest of the first experiment test is the feasibility of expanding liquid CO₂ into CO₂ solid–gas flow in a horizontal circular tube by expansion valve. The second experiment focuses on the feasibility of the refrigeration of liquid CO₂ expanding into solid–gas two phase flows used in a prototype CO₂ heat pump system. The results show that solid–gas two phase flows can be achieved by expanding liquid CO₂ by expansion valve in a closed CO₂ heat pump system loop and low temperature refrigeration below −56.6 °C is achieved in the experiments, which give greater possibility to create a cryogenic refrigeration process below −56.6 °C for food industries, bio-medical engineering, etc.     

Residential CO2 heat pump system for combined space heating and hot water heating

A theoretical and experimental study has been carried out for a residential brine-to-water CO₂ heat pump system for combined space heating and hot water heating. A 6.5 kW prototype heat pump unit was constructed and extensively tested in order to document the performance and to study component and system behaviour over a wide range of operating conditions. The CO₂ heat pump was equipped with a unique counter-flow tripartite gas cooler for preheating of domestic hot water (DHW), low-temperature space heating and reheating of DHW.

The CO₂ heat pump was tested in three different modes: space heating only, DHW heating only and simultaneous space heating and DHW heating. The heat pump unit gave off heat to a floor heating system at supply/return temperatures of 33/28, 35/30 or 40/35 °C, and the set-point temperature for the DHW was 60, 70 or 80 °C. Most tests were carried out at an evaporation temperature of −5 °C, and the average city water temperature was 6.5 °C. The experimental results proved that a brine-to-water CO₂ heat pump system may achieve the same or higher seasonal performance factor (SPF) than the most energy efficient state-of-the-art brine-to-water heat pump systems as long as: (1) the heating demand for hot water production constitutes at least 25% of the total annual heating demand of the residence, (2) the return temperature in the space heating system is about 30 °C or lower, (3) the city water temperature is about 10 °C or lower and (4) the exergy losses in the DHW tank are small.     

Fan-less heat exchanger concept for CO2 heat pump systems

A novel system for space heating has been developed taking advantage of the favourable characteristics of the transcritical CO₂ cycle, where heat is rejected by cooling of supercritical gas at gliding temperature. By a proper design of a counter flow heat exchanger it is possible to heat air to high temperatures and thereby giving the driving force for circulation of air through the heat exchanger, in consequence without using a fan. A concept without a fan, here called a fan-less concept, would give several advantages; no noise, no power consumption for the fan and increased comfort with reduced air draft in the room. The concept may also be used for heat rejection in systems for light commercial applications or other applications where fan assisted heat rejection concepts are used today.

An experimental study of a CO₂ to air heat exchanger has been performed. The heat exchanger was made of a vertically finned aluminium profile. Tubes for CO₂ were mounted in the base of the profile. CO₂ at supercritical pressure flowing downwards through the profile was heating air flowing in the channels formed by the fins of the profile. In this way a perfect counter flow heat exchange was obtained. The prototype heat exchanger was 2000 mm high and 190 mm wide, with 45 mm deep fins.

A simulation model was developed and verified to give good accordance with the experimental data. The model was then used to study how different design parameters influence the efficiency of the heat exchanger. By altering the number of fins and the fin thickness of the tested profile, the heat output at a given condition could be increased to almost double, meaning that the initial design was relatively far from optimal.

With the original heat exchanger profile design concept a heat exchanger with height, width and depth of, respectively 2000, 750 and 200 mm, would be required in order to achieve a heat output of 2500 W if the constraints for assumed acceptable efficiency was applied. If a heat exchanger with less height is preferred, the width will have to be increased in order to maintain about the same front area, width times height. Ideas have also been introduced for how to improve both the compactness and efficiency of the heat exchanger by introducing a compact counter flow heat exchanger in the lower part of the air flow channel. It is concluded that the new concept looks promising for use as the indoor heat exchanger in an air-to-air heat pump or as a gascooler for heat rejection in small commercial equipment, when using CO₂ as refrigerant.     

Flow pattern and heat transfer characteristics during flow boiling of CO2 in a horizontal micro fin tube and comparison with smooth tube data

Flow pattern observations and measurements of the heat transfer in a helical grooved micro fin tube are presented and compared with results for a smooth tube. The micro fin tube used (OD of 9.52 mm) was a Wieland Cuprofin EDX tube with 60 fins (height 0.25 mm) and a helix angle of 18°. The flow pattern observations at 39.7 bar (T_s=+5 °C, p_r=0.54) and 26.4 bar (T_s=−10 °C, p_r=0.36) show a wide range of the annular flow region. The transition from slug to annular flow does not occur, as expected, at constant vapour quality for all mass fluxes but there is an interdependence between transition vapour quality and mass flux. For the heat transfer in the micro fin tube, measurements at 39.7 bar are presented for heat fluxes up to 120 kW m⁻², mass fluxes between 75 and 250 kg m⁻² s⁻¹ and vapour qualities between 0.1 and 0.9.     

Boiling heat transfer of R-22, R-134a, and CO2 in horizontal smooth minichannels

This study examined convective boiling heat transfer in horizontal minichannels using R-22, R-134a, and CO₂. The local heat transfer coefficients were obtained for heat fluxes ranging from 10 to 40 kW m⁻², mass fluxes ranging from 200 to 600 kg m⁻² s⁻¹, a saturation temperature of 10 °C, and quality up to 1.0. The test section was made of stainless steel tubes with inner diameters of 1.5 mm and 3.0 mm, and a length of 2000 mm. The section was heated uniformly by applying an electric current to the tubes directly. Nucleate boiling heat transfer was the main contribution, particularly at the low quality region. An increasing and decreasing heat transfer coefficient occurred at the lower vapor quality with increasing heat flux and mass flux. The mean heat transfer coefficient ratio of R-22:R-134a:CO₂ was approximately 1.0:0.8:2.0. Laminar flow was observed in the minichannels. A new boiling heat transfer coefficient correlation based on the superposition model for refrigerants in minichannels was developed with a mean deviation of 11.21%.     

Optimisation of the throttling system in a CO2 refrigerating machine

This paper is an answer to the need of finding the optimal solution for the throttling system in refrigerating machines using CO₂ as working fluid; such a solution must combine reliability, low installation cost and high energy efficiency. To this purpose, different expansion systems are compared by means of a simulation programme, including a new one, operating with a differential valve, a liquid receiver and a thermostatic valve. The typical compression refrigerating cycle performed by CO₂ involves transcritical operations and therefore the upper pressure needs to be adjusted to the optimal value, that, unlike the traditional cycle, is not determined by heat transfer. The innovative system here proposed shows an intrinsic self-adjusting capability that leads to COP values quite close to the maximum ones when a fixed suitable value of the differential pressure is chosen, even if the temperature of the secondary fluid varies to a large extent.     

Numerical simulation and experimental validation of vapour compression refrigeration systems. Special emphasis on CO2 trans-critical cycles

A numerical and experimental comparative study of a carbon dioxide trans-critical refrigerating system and a conventional sub-critical refrigerating cycle is presented. Attention is focussed not only on the whole refrigeration cycle, but also on the behaviour of the hermetic reciprocating compressors used in these systems. The comparative cases presented have been specially designed for small cooling capacity units with an evaporation temperature around 0 °C. A detailed numerical simulation model for hermetic reciprocating compressors performance, widely validated under conventional fluid refrigerants, has been extended to numerically obtain the CO₂ compressor prototypes behaviour. Two CO₂ compressor prototypes working with CO₂ have been experimentally tested in a specific unit, specially designed and built to analyse high-pressure single stage vapour compression trans-critical refrigerating equipments. This set-up has allowed validating a detailed numerical simulation code for the thermal and fluid-dynamic behaviour of single stage vapour compression refrigeration system working with CO₂ as fluid refrigerant. The numerical results and the experimental data obtained to validate compressors, heat exchangers and whole cycle behaviour have shown a really good agreement. Finally, the numerical and experimental comparison between the carbon dioxide system and the sub-critical conventional cycle has shown the possibility of CO₂ as fluid refrigerant under the studied working conditions.     

The optimum high pressure for CO2 transcritical refrigeration systems with internal heat exchangers

The system performance of a CO₂ refrigeration system is greatly affected by the compressor discharge pressure. An internal heat exchanger (IHX) with high effectiveness is an important factor to achieve high system performance. The expression traditionally used to describe the heat exchange effectiveness is not suitable for CO₂ systems. As a result a practical effectiveness expression for IHX, based on enthalpy difference, has been derived and is reported in this paper. Detailed analysis on the relationship between the optimum high pressure P_k,opt and other systematic parameters was performed. Evaporating temperature has little influence on P_k,opt; and IHX can minimize the sensitivity of the system to the refrigerant quality x at the evaporator outlet. Based on simulation data, a correlation of P_k,opt was developed that predicts the simulation values with a deviation of less than 3.6% in the whole range and 0.94% when the evaporating temperature t₁=5.3 °C. The results reported in this paper can be used in optimum control and performance evaluation of the whole system.     

State-of-the-art of two-phase flow and flow boiling heat transfer and pressure drop of CO2 in macro- and micro-channels

A comprehensive review of flow boiling heat transfer and two-phase flow of CO₂ is presented that covers both macro-channel tests (diameters greater than about 3 mm) and micro-channel investigations (diameters less than about 3 mm). The review addresses flow boiling heat transfer experimental studies, macro- and micro-scale heat transfer prediction methods for CO₂ and comparisons of these methods to the experimental database, highlighting the various limitations of current approaches and the divergence of some data sets from others. In addition, two-phase flow pattern results available in the literature are summarized and compared to some of the leading flow pattern maps, showing significant deviations for CO₂ from the maps prepared for other fluids at lower pressures. Available two-phase pressure drop data for CO₂ are also compared to leading prediction methods.     

跨临界CO_2制冷(热泵)系统中毛细管研究进展

毛细管应用于CO2跨临界循环时,其内部流动不同于普通CFCs和HCFCs,针对毛细管作为跨临界CO2制冷(热泵)系统节流机构的研究进行了回顾。主要从CO2毛细管模型、实验研究、临界流以及毛细管对系统的影响4个方面详细介绍了国内外的研究进展。阐述了目前研究存在的几个问题,并探讨了这一领域内研究的发展方向。     

Theoretical evaluation of trans-critical CO2 systems in supermarket refrigeration. Part II: System modifications and comparisons of different solutions

The performance of CO₂ refrigeration systems strongly depends on the operating conditions. The specific characteristics of low critical temperature and high operating pressure limit its applications and imply the implementation of different control strategies. This study compares the performance of different CO₂ system solutions for supermarket refrigeration with R404A system. Some possible modifications and improvements on the CO₂ system have been investigated. The COP of the investigated CO₂ system solution can be improved by about 3–7% along the ambient temperature range of 10–40 °C. The annual energy consumption calculations in three different climates; cold, moderate and hot, show that the centralized trans-critical CO₂ system is good solution for cold climates whereas the NH₃–CO₂ cascade system has the lowest energy consumption in hot climates. Both systems proved to be good alternatives to R404A DX system for supermarket refrigeration.     

Effects of refrigerant charge amount on the performance of a transcritical CO2 heat pump

A typical transcritical CO₂ system shows lower performance than conventional air conditioners in cooling mode operation. In addition, the CO₂ system shows a large variation of the performance according to refrigerant charge whereas the conventional systems do not show large variation. In this study, the performance of the CO₂ heat pump was measured and analyzed by varying the refrigerant charge amount at standard cooling condition. In addition, the performance sensitivity of the CO₂ system as a function of refrigerant charge was compared to those for the R22, R410A, and R407C systems. The cooling COP of the CO₂ system was reduced more significantly at undercharged conditions than at overcharged conditions as the deviation from the optimal charge increased. The expansion loss was the dominant factor affecting system performance at undercharged conditions, while the gascooler loss became the major parameter at overcharged conditions. Among the systems investigated and compared in this study, the CO₂ system showed the most reduction in performance at undercharged conditions.     

Simulated performance and cofluid dependence of a CO2-cofluid refrigeration cycle with wet compression

Recent experiments demonstrate the viability of a low-pressure CO₂-cofluid compression refrigeration cycle in which CO₂ and a non-volatile cofluid are circulated in tandem and co-compressed in a compliant scroll compressor. This work explores the theoretical performance limitations of such a cycle operating under environmental conditions representative of automotive air conditioning and studies the dependence of this performance on the properties of the CO₂-cofluid mixture. The vapor–liquid equilibrium and thermodynamic properties of the mixture are described using a previously reported activity-coefficient model. A coupled system of physically based equations that allows for consideration of both ideal and real hardware components is used to represent the system hardware and its interaction with the environment. The system efficiency is analyzed in terms of entropy generation rates in the various hardware components; entropy generation in the internal heat exchanger—a component required to achieve sufficiently low cooling temperatures—strongly influences overall system efficiency. The vapor pressure of the CO₂-cofluid mixture and the heat of solution of CO₂ in cofluid have large and somewhat independent contributions to the system performance: lower saturation pressure lowers the optimal operating pressures at fixed CO₂ loading, while increasingly negative heat of solution contributes to higher specific refrigeration capacity and efficiency.

Résumé

Recent experiments demonstrate the viability of a low-pressure CO₂-cofluid compression refrigeration cycle in which CO₂ and a non-volatile cofluid are circulated in tandem and co-compressed in a compliant scroll compressor. This work explores the theoretical performance limitations of such a cycle operating under environmental conditions representative of automotive air conditioning and studies the dependence of this performance on the properties of the CO₂-cofluid mixture. The vapor–liquid equilibrium and thermodynamic properties of the mixture are described using a previously reported activity-coefficient model. A coupled system of physically based equations that allows for consideration of both ideal and real hardware components is used to represent the system hardware and its interaction with the environment. The system efficiency is analyzed in terms of entropy generation rates in the various hardware components; entropy generation in the internal heat exchanger—a component required to achieve sufficiently low cooling temperatures—strongly influences overall system efficiency. The vapor pressure of the CO₂-cofluid mixture and the heat of solution of CO₂ in cofluid have large and somewhat independent contributions to the system performance: lower saturation pressure lowers the optimal operating pressures at fixed CO₂ loading, while increasingly negative heat of solution contributes to higher specific refrigeration capacity and efficiency.     

Naturally circulating probes and collectors for ground-coupled heat pumps

Both vertically and horizontally installed heat source systems for ground-coupled heat pumps based on the thermosyphon principle using CO₂ as the working fluid have been investigated theoretically as well as experimentally.

The investigation of the vertical type (CO₂ probe) has started in 1997. During the last years various design and operational parameters have been analyzed in depth, e.g. optimum number of parallel earth probes, probe length, CO₂ charge required etc. In Austria up to now more than 100 systems have been installed, and the experience confirms that a heat pump system consisting of heat pump, probe head, and CO₂ probe is a reliable, highly efficient as well as environmentally friendly alternative to commonly used ground-coupled systems.

The great success with the CO₂ probe initiated further research activities on a horizontal type (CO₂ collector). The first experimental results carried out with a test rig in the laboratory confirm that CO₂ can be used as heat carrier in collectors.     

Experimental study on automotive cooling and heating air conditioning system using CO2 as a refrigerant

Recently, as one of the countermeasures against the global warming and energy conservation problems, natural refrigerants such as CO₂ are now paid attention as substitutes for HFCs in automotive air conditioning systems. Also, in recent years because the heat release from the eco-car's engine decreases, there is a problem that the present automotive heating air conditioning system cannot provide sufficient heating capacity.

As an alternative approach, we focused on a solution utilizing a CO₂-based heat pump, whereby the waste heat from the heat pump cycle during dehumidification of the incoming air (referred to as the dehumidifying condition) is recovered and used as an auxiliary heat source instead of an electric heater. Based on this concept, we aimed to develop an effective automotive cooling and heating air conditioning system using CO₂ as a refrigerant.

As the result, a prototype CO₂ automotive cooling and heating air conditioning system for medium-sized cars was successfully developed. With this system, performance superior to that of the present HFC134a system can be achieved.     

Integration of a three-stage expander into a CO2 refrigeration system

The inclusion of an expander with work recovery provides two advantages for transcritical CO₂ refrigeration cycles: the COP is improved and the exhaust pressure of the main compressor is lowered. Several designs of expanders have been proposed for this application and some prototypes have been tested already. In our laboratory a three-stage expander has been developed, which replaces the throttle valve of the normal refrigeration cycle and expands into the two-phase region. For optimum integration into the overall system it is proposed to install a vapour-liquid separator between the second and third stage of expansion. The vapour is guided back to the third expander stage whereas the liquid is supplied to the cooling stations via thermostatic or electronic expansion valves.     

Thermodynamic optimization of ejector actuated refrigerating cycles

A cold generation system featuring a Rankine cycle powered refrigeration cycle actuated by a supersonic ejector was theoretically investigated in view of the thermo-fluid-dynamic optimization of the working fluid characteristics.

The ejector model was validated against well established performance charts relating to water. A reference system was considered in which a Rankine cycle at moderate top temperature delivers its expansion power by means of an ideal turbine to an ideal compressor of a refrigeration cycle. Two main optimizing variables were ascertained: the fluid critical temperature and the complexity of the fluid molecule. The best performance of such reference cycle is around 80% of that of an ideal fully reversible, Carnot cycle based, system (COP of 2.0 for t_E,PC = 150 °C, t_E,RC = 5 °C, and t_C = 35 °C). As easily predictable the ejector compression introduces severe losses mainly due to the normal shock and the mixing of the motive and of the driven fluid. Overall COP for the above quoted temperatures decreases from 2.0 (reference cycle) to 0.4–0.7. The optimization of the working fluid showed that comparatively low critical temperatures are favoured and that a fluid complexity similar to that of CH₅N or CH₂Cl₂ gives the best performance. A detailed losses analysis explains this behaviour. In particular at low reduced temperatures the theoretical gain related to the better shape in the T–S plane of both the power and the refrigeration cycle is more than offset by the higher ejector losses due to the stronger normal shock needed to cope with an increased pressure ratio.

Notwithstanding an extensive fluid screening we did not succeed in finding a fluid that could be considered optimum from all points of view including ambient and safety issues. However, a number of traditional (non-zero ODP) chloro-fluoro-carbons and of new (zero ODP) refrigerants were found that yield, on the whole, a satisfactory performance.

Provided calculated COP will be confirmed by experimental testing, ejector powered refrigerators could compete with absorption systems in many applications.     

Investigation of R-744 Voorhees transcritical heat pump system

Using economizer in R-744 heat pump cycle is an effective way to improve the heating capacity in cold climates. In this paper, a modification construction of reciprocating compressor with economizer port, a Voorhees compressor was introduced and the heat pump cycle with Voorhees economizer was compared with the traditional screw or scroll economizer cycles. Both the R-744 transcritical heat pumps with and without Voorhees economizer were tested at the same conditions with different air mass flow rates and different evaporating temperatures. The results show that the heating capacity of the heat pump with Voorhees economizer can be two times higher than the transcritical heat pump without economizer at low evaporating temperature conditions. At the same capacity operation conditions, the efficiency of the heat pump with Voorhees economizer is higher at high refrigerant mass flow rate conditions. The optimum discharge pressure of the heat pump with Voorhees economizer is found to be higher than the heat pump without economizer at the same ambient conditions. For mobile heat pump application, CO₂ transcritical heat pump with Voorhees economizer demonstrates better performance comparing to the conventional transcritical CO₂ heat pump without economizer when the evaporating temperature is lower than −20 °C, or when the mobile is idling with low compressor RPM.     

Experimental investigation of a CO2 automotive air conditioner

In this study, a CO₂ automotive air conditioner prototype was designed and constructed. The compressor was of swash plate design; the gas cooler and evaporator were made of fin-tubes; a manual expansion valve and an internal heat exchanger accumulator were used. The lubricant, the CO₂ charge, the evaporator outlet pressure, the compressor speed, the air inlet temperature and flow rate of the gas cooler and the air flow rate of the evaporator were varied and the performance of the prototype was experimentally investigated in detail. The cooling capacity, compressor power consumption, CO₂ mass flow rate, and COP value were analyzed. The experimental results showed that the CO₂ system performance was greatly affected by different lubricants; the CO₂ system performance was sensitive to the mass charge; the high side pressure affected the system performance greatly and a high side pressure controller was needed.