A steady‐state model for the design and optimization of a centralized cooling system

A simplified steady‐state model has been developed to describe thermodynamically the operation of a centralized cooling system. This model resolves the mass and energy equations simultaneously and uses inputs that are readily available to the design engineer. The model utilizes an empirical relationship for the compressor power as a function of cooling load and key temperatures. The outputs include the chiller coefficient of performance (COP) and the compressor actual power. The model simulation results are validated with a manufacturer performance data and compared with the experimental data collected at Hewlett‐Packard Laboratories site for two chillers: a variable speed and a constant speed chiller. The results of the model are found to closely match the current experimental data with less than 5% average deviation for chiller load over 10% and with a maximum deviation of 18% at 95% chiller load. For the constant speed chiller, the chiller efficiency increases with increasing load and peaks at full load. For the variable speed chiller, the chiller efficiency peaks at part loading between 40 and 80% of the chiller full load depending on the condenser water temperature. This indicates that for variable speed chillers, the chiller design has been optimized for loading less than 100% depending on the ambient conditions, customer specifications and size of the chiller. Copyright © 2010 John Wiley & Sons, Ltd.     

Modelling of a condenser-fan control for an air-cooled centrifugal chiller

There is a lack of detailed experimental and simulation studies on air-cooled centrifugal chillers. This paper investigates how to optimize the control of condenser fans within the chillers to maximize their coefficients of performance (COPs). A thermodynamic model for the chillers was developed and used to analyse the steady-state COP under various load and ambient conditions. An algorithm is introduced to compute the number of staged condenser fans based on settings of the condensing pressure and outdoor temperature. The model was validated using the experimental data and performance data of an existing chiller running under various operating conditions. It is found that the best strategy for switching condenser fans is to vary their rotating speed by the use of a set point of the condensing temperature, which is adjusted in response to the chiller load and condenser air-inlet temperature. The results of this paper provide an important insight into how to increase the COPs of air-cooled chillers.     

Trigeneration in food retail: An energetic,economic and environmental evaluation for a supermarket application

This paper presents results on the evaluation of energy utilisation efficiency and economic and environmental performance of a micro-gas turbine (MGT) based trigeneration system for supermarket applications. A spreadsheet energy model has been developed for the analysis of trigeneration systems and a 2800 m² sales area supermarket was selected for the feasibility study. Historical energy demand data were used for the analysis, which considered factors such as the fraction of the heat output used to drive the absorption chillers, the chiller COP and the difference between electricity and gas prices. The results showed that energy and environmental benefits can be obtained from the application of trigeneration systems to supermarkets compared to conventional systems. The payback period of natural gas driven trigeneration systems and greenhouse gas emissions savings will depend on the relative gas and electricity prices and the COP of the vapour compression and absorption systems. It was also shown that operation at full electrical output gives a better performance than a heat load-following strategy due to the reduction of the electrical generation efficiency of the MGT unit at part load conditions.     

Steady-state simulation of screw liquid chillers

In order to predict the performance of screw liquid chillers in a wide range of configuration parameters and operating conditions, a steady-state simulation model is presented, which is suitable for non-economized and economized chillers. The model includes sub-models for key components, such as non-economized compressor, economized compressor, shell-and-tube condenser, expansion valve, and flooded evaporator. Sequential modular method and successive substitution methods are combined together to carry out the simulation of the chillers. The convergence properties of this simulation technique are also analyzed. The present model can predict the performance within ±10% for large scale of cooling capacity including four specifications of non-economized chillers and three specifications of economized chillers. With the validated model, a sensitivity analysis on the economizer system is made. It is found that the cooling capacity of screw liquid chiller can be increased apparently by adding the economizer, but only when the volumetric ratio of the first stage internal compression is greater than a certain value, the economized screw liquid chiller can gain a higher COP than that of the non-economized one at the same time.     

A simplified method to evaluate the energy performance of CO2 heat pump units

The prediction of the performances of CO₂ transcritical heat pumps demands accurate calculation methods, where a particular effort is devoted to the gas cooler modelling, as the correlation between high pressure and gas cooler outlet temperature strongly affects the cycle performance. The above-mentioned methods require a large amount of input data and calculation power. As a consequence they are often useless for the full characterisation of heat pumps which are sold on the market.A simplified numerical method for the performance prediction of vapour compression heat pumps working in a transcritical cycle is presented, based only on performance data at the nominal rating conditions. The proposed procedure was validated against experimental data of two different tap water heat pumps. For the considered units, simulation results are in good agreement with the experimental ones. The deviations range from −6.4% to +1.7% and from −3.8% to +5.8% for the COP_H of the air/water heat pump and the water/water heat pump, respectively. The heating capacity deviations stayed within −5.5% and +1.7% range and within −5.0% and +7.9% range for the same units.The proposed mathematical model appears to be a reliable tool to be used by the refrigeration industry or to be implemented into dynamic building-plant energy simulation codes. Finally, it represents a useful instrument for the definition of tailored approximated optimal high pressure curve considering the operating characteristics of the specific CO₂ transcritical unit. It could also be implemented on board of a real unit control system where it could be used as model coupled to computational intelligence algorithms for pressure optimisation.     

Experimental determination of the energy efficiency of an air-cooled chiller under part load conditions

In cities located in a subtropical climate, air-cooled chillers are commonly used to provide cooling to the indoor environment. This accounts for the increasing electricity demand of buildings over the decades. This paper investigates how the condensing temperature serves to accurately determine the energy efficiency, or coefficient of performance (COP), of air-cooled chillers under part load conditions. An experiment on an air-cooled reciprocating chiller showed that for any given operating condition, the COP of the chiller varies, depending on how the condensing temperature is controlled. A sensitivity analysis is implemented to investigate to what extent COP is responding to changes in operating variables and confirms that the condensing temperature is an adequate variable to gauge COP under various operating conditions. The specifications of the upper limit for the condensing temperature in order to improve the energy efficiency of air-cooled chillers are discussed. The results of this work will give designers and researchers a good idea about how to model chiller energy performance curves in the thermal and energy computation exercises.     

Solar-assisted single-double-effect absorption chiller for use in Asian tropical climates

Solar energy is accessible throughout the year in tropical regions. The latest development of absorption chillers has demonstrated that these systems are suitable for effective use of solar energy. The utilisation of solar energy for heat-driven cooling systems has significant advantages. Without a doubt, solar energy represents a clean energy source that is available without any additional fuel cost, and that can be proportionally accessible when the cooling load increases during the middle hours of the day. This study focuses on a single-double-effect absorption chiller machine that was installed in Indonesia. The system is driven by a dual-heat source that combines gas and solar energy. This system is characterised by simulating its performance in various conditions in terms of the cooling water (28–34 °C) and the hot water (75–90 °C) inlet temperatures. The reference operating condition of this system is 239 kW of cooling capacity. The mathematical model is validated and shows a good agreement with experimental data. In the operative range considered, simulation results yield a coefficient of performance between 1.4 and 3.3, and a gas reduction ratio from 7 to 58% when compared to a double-effect absorption chiller driven by gas. Based on the simulation results, this system is expected to have a good potential for widespread use in tropical Asia regions.     

Industrial heat recovery by absorption/compression heat pump using TFE–H2O–TEGDME working mixture

The thermodynamic performance of a single-stage absorption/compression heat pump using the ternary working fluid Trifluoroethanol–Water–Tetraethylenglycol dimethylether (TFE–H₂O–TEGDME) for upgrading waste heat has been studied. A simulation program has been developed using a mathematical model based on mass and energy balances in all components of the cycle and thermodynamic equilibrium considerations. In order to establish the optimum operating conditions of the cycle for various thermal conditions, sensitivity studies of the coefficient of performance (COP), the flow rate of the weak solution and the compressor volumetric displacement, both per unit of upgraded energy, were carried out versus of water content in the vapour phase.The results obtained show that the operation of the cycle with this ternary system is still more advantageous than the TFE–TEGDME binary working pair. So, it is possible to upgrade thermal waste heat from 80 to 120°C, with a COP of about 6.4, with a compression pressure ratio of 4 at a low pressure of 100 kPa, the water mole fraction in the vapour being 42%. At these operating conditions, the necessary weak solution mass flow rate is about three times lower than the corresponding binary one. The performance comparison of such a cycle with other absorption cycles like the heat transformer or the single-effect heat pump, both of them using the ternary system, shows its interest and potential.     

European perspective on absorption cooling in a combined heat and power system – A case study of energy utility and industries in Sweden

Mankind is facing an escalating threat of global warming and there is increasing evidence that this is due to human activity and increased emissions of carbon dioxide. Converting from vapour compression chillers to absorption chillers in a combined heat and power (CHP) system is a measure towards sustainability as electricity consumption is replaced with electricity generation. This electricity produced in Swedish CHP-system will substitute marginally produced electricity and as result lower global emissions of carbon dioxide. The use of absorption chillers is limited in Sweden but the conditions are in fact most favourable. Rising demand of cooling and increasing electricity prices in combination with a surplus of heat during the summer in CHP system makes heat driven cooling extremely interesting in Sweden. In this paper we analyse the most cost-effective technology for cooling by comparing vapour compression chillers with heat driven absorption cooling for a local energy utility with a district cooling network and for industries in a Swedish municipality with CHP. Whilst this case is necessarily local in scope, the results have global relevance showing that when considering higher European electricity prices, and when natural gas is introduced, absorption cooling is the most cost-effective solution for both industries and for the energy supplier. This will result in a resource effective energy system with a possibility to reduce global emissions of CO₂ with 80%, a 300% lower system cost, and a 170% reduction of the cost of producing cooling due to revenues from electricity production. The results also show that, with these prerequisites, a decrease in COP of the absorption chillers will not have a negative impact on the cost-effectiveness of the system, due to increased electricity production.     

Performance analysis of the vapour compression cycle using ejector as an expander

The purpose of incorporating an ejector into vapour compression cycle is to improve the COP by reducing the throttling loss associated with the expansion device. A computer simulation of the improved cycle is carried out using a one-dimensional model based on mass, momentum and energy balances. Refrigerant characteristics were evaluated using NIST subroutines for equations of state solutions. According to the results of simulation of the improved cycle, it has been shown that the geometric parameters of the ejector design have considerable effects on the system's performance. The maximum COP is obtained for Φ_opt whose value is around 10. Several refrigerants are considered; it has been observed, at Φ_opt and for given operating conditions, that the best performances are obtained with R141b. Compared with the standard cycle the COP of the improved cycle shows an increase of about 22%. Copyright © 2006 John Wiley & Sons, Ltd.     

Improved energy performance of air cooled centrifugal chillers with variable chilled water flow

This paper considers how to apply optimum condensing temperature control and variable chilled water flow to increase the coefficient of performance (COP) of air cooled centrifugal chillers. A thermodynamic model for the chillers was developed and validated using a wide range of operating data and specifications. The model considers real process phenomena, including capacity control by the inlet guide vanes of the compressor and an algorithm to determine the number and speed of condenser fans staged based on a set point of condensing temperature. Based on the validated model, it was found that optimizing the control of condensing temperature and varying the evaporator’s chilled water flow rate enable the COP to increase by 0.8–191.7%, depending on the load and ambient conditions. A cooling load profile of an office building in a subtropical climate was considered to assess the potential electricity savings resulting from the increased chiller COP and optimum staging of chillers and pumps. There is 16.3–21.0% reduction in the annual electricity consumption of the building’s chiller plant. The results of this paper provide useful information on how to implement a low energy chiller plant.     

Optimization of energy plants including water/lithium bromide absorption chillers

In this paper a methodology for the optimal integration of water/lithium bromide absorption chillers in combined heat and power plants is proposed. This method is based on the economic optimization of an energy plant that interacts with a refrigeration cycle, by using a successive linear programming technique (SLP). The aim of this paper is to study the viability of the integration of already technologically available absorption chillers in CHP plants. The results of this alternative are compared with the results obtained using the conventional way of producing chilled water, that is, using mechanical vapour compression chillers in order to select the best refrigeration cycle alternative for a given refrigeration demand. This approach is implemented in the computer program XV, and tested using the data obtained in the water/LiBr absorption chiller of Bayer in Tarragona (Catalonia, Spain). The results clearly show that absorption chillers are not only a good option when low‐cost process heat is available, but also when a cogeneration system is present. In this latter case, the absorption chiller acts as a bottoming cycle by using steam generated in the heat recovery boiler. In this way, the cogeneration size can be increased producing higher benefits than those obtained with the use of compression chillers. Copyright © 2000 John Wiley & Sons, Ltd.     

Application of a lumped model for predicting energy performance of a variable-speed vapour compression system

This work presents a model for a variable-speed vapour compression system that is able to predict accurately the system performance using data easily obtained from an industrial facility. The model uses information on the secondary fluids input conditions and the compressor speed to predict the secondary fluids output temperatures, the operating pressures, the compressor power consumption and the system overall energy performance. This model has been validated experimentally with steady state tests, presenting a prediction error lower than 10%. Finally, an application of the model to evaluate the influence of the operating variables on the energy performance of a chiller is presented.     

Thermodynamic analysis of a Proton Exchange Membrane fuel cell

In this study, energy and exergy analyses of a 1 kW Horizon H-1000 XP Proton Exchange Membrane (PEM) Fuel Cell has been investigated. A testing apparatus has been established to analyze the system efficiencies based on the first and second laws of thermodynamics. In this mechanism pure hydrogen has been directly used as a fuel in compressed gas formation. Purity of hydrogen was above 99.99%. The system performance was investigated through experimental studies on energy and parametric studies on exergy by changing the operating pressure and operation temperature. The results showed that the energy efficiency of PEM fuel cell is 45.58% for experimental study and 41.27% for parametric study at full load. Also, 2.25% and 4.2% performance improvements were obtained by changing the operating temperature ratio (T/T₀) from 1 to 1.2 and operating pressure ratio (P/P₀) from 1 to 2, respectively.     

Chillers energy consumption, energy savings and emission analysis in an institutional buildings

Chillers consume more than 40% of the total energy used in the commercial and industrial buildings for space conditioning. In this paper, energy consumption by chillers and chilled water pumps, condenser pumps and fan motors has been estimated using data collected by a walkthrough energy audit for the 16 faculties of the University of Malaya. It has been estimated that chillers and motors and pumps used in chillers consume 10,737 MWh (i.e. 51% of total energy consumption) of electric energy for different percentage of loadings. As chillers are major energy users, variable speed drives are applied in chillers to reduce their energy consumption. It has been estimated that about 8368 MWh annual energy can be saved by using efficient chillers at different loadings. It has also been found that about 23,532 MWh annual energy can be saved for chilled water supply pumps, condenser pumps and cooling tower fan motors by matching required speeds using variable speed drives for 60% of speed reduction. About 1,274,692 kg of CO₂ emission could be avoided for using energy efficient chillers at 50% load. It has been also found that about 2,426,769 kg CO₂ emission can be reduced by using variable speed drives for 60% speed reductions. Payback periods found to be only few months for using variable speed drives in chilled water pumps, condensers and fan motors.     

Thermodynamic-behaviour model for air-cooled screw chillers with a variable set-point condensing temperature

This paper presents a thermodynamic model to evaluate the coefficient of performance (COP) of an air-cooled screw chiller under various operating conditions. The model accounts for the real process phenomena, including the capacity control of screw compressors and variations in the heat-transfer coefficients of an evaporator and a condenser at part load. It also contains an algorithm to determine how the condenser fans are staged in response to a set-point condensing temperature. The model parameters are identified, based on the performance data of chiller specifications. The chiller model is validated using a wide range of operating data of an air-cooled screw chiller. The difference between the measured and modelled COPs is within ±10% for 86% of the data points. The chiller’s COP can increase by up to 115% when the set-point condensing temperature is adjusted, based on any given outdoor temperature. Having identified the variation in the chiller’s COP, a suitable strategy is proposed for air-cooled screw chillers to operate at maximum efficiency as much as possible when they have to satisfy a building’s cooling-load.     

Increase of COP for heat transformer in water purification systems. Part I – Increasing heat source temperature

The integration of a water purification system in a heat transformer allows a fraction of heat obtained by the heat transformer to be recycled, increasing the heat source temperature. Consequently, the evaporator and generator temperatures are also increased. For any operating conditions, keeping the condenser and absorber temperatures and also the heat load to the evaporator and generator, a higher value of COP is obtained when only the evaporator and generator temperatures are increased. Simulation with proven software compares the performance of the modeling of an absorption heat transformer for water purification (AHTWP) operating with water/lithium bromide, as the working fluid–absorbent pair. Plots of enthalpy-based coefficients of performance (COP_ET) and the increase in the coefficient of performance (COP) are shown against absorber temperature for several thermodynamic operating conditions. The results showed that proposed (AHTWP) system is capable of increasing the original value of COP_ET more than 120%, by recycling part of the energy from a water purification system. The proposed system allows to increase COP values from any experimental data for water purification or any other distillation system integrated to a heat transformer, regardless of the actual COP value and any working fluid–absorbent pair.     

Modelling of improved energy performance of air-cooled chillers with mist pre-cooling

Air-cooled chillers are widely used to provide cooling energy and yet pragmatic and simple energy efficient measures for them are still lacking. This paper considers how their coefficient of performance (COP) can be improved by using mist to pre-cool ambient air entering the condensers. The benefit of this application rests on the decrease of compressor power resulting from the reduced condenser air temperature with insignificant consumption of water and pump power associated with the mist generation. Based on a simulation analysis of an air-cooled screw chiller operating under head pressure control, applying such mist pre-cooling enables the COP to increase by up to 7.7%. Precise control of mist generation rate and integration with floating condensing temperature control are the major challenges of using a mist system to maximize electricity savings. The results of this study will prompt low-energy operation of existing air-cooled chillers working for various climatic conditions.     

Control strategy of a fuel-cell power module for electric forklift

Fuel cell-battery hybrid systems for the powertrain, which have the advantage of emission-free power generation and adapt to material transport and emission reduction, are investigated. Based on the characteristics of the fuel cell system and the characteristics of the electric forklift truck powertrain system, this work defines the design principle of the control strategy to improve overall performance and economy. A simulation platform for fuel cell and electric vehicles has been established. The optimal performance of the fuel cell stack and the battery capacity were defined for the specific application. An energy control strategy was defined for different operating cycles and operating conditions. Model validation involved comparing simulation results with experimental data obtained during VDI60 test protocol. The main parameters that influence the forklift performance were defined and evaluated, such as energy loss, fuel cell operating conditions and different battery charging cycles. The optimal size of the fuel cell stack of 11 kW and the battery of 10 Ah was determined for the specific load profile with the proposed control strategy. The results obtained in this work forms the basis for an in-depth study of the energy management of fuel cell battery drive trains for forklift trucks.     

Multi-pressure absorption cycles in solar refrigeration:: A technical and economical study

A technical and economical study of regenerative absorption chillers with multi-pressure cycle has been undertaken as solar operated refrigeration systems. Referred to as advanced absorption chillers they represent one of the new technology options that are under development. Advanced absorption cooling technology offers the possibility of chillers with thermal COPs of 1.5 or greater at driving temperatures of 140°C, which reduces the collector area and the heat rejection requirements compared to current absorption cooling technology. Two different absorption systems have been considered. The first is an advanced, double-effect regenerative absorption cooling system, driven at 140°C, whose efficiency is about 55% of the Carnot efficiency. The second is an ideal, single-effect regenerative absorption system that achieves 70% of the Carnot efficiency driven at 140°C or 200°C. To evaluate the solar performance of a thermally driven chiller requires a separate analysis of the solar availability for a given location compared to the required monthly average solar input. In this analysis different systems, including the vapour compression chillers, have been compared in terms of the thermal and electrical energy input. An effective electrical COP may be computed assuming that the ratio of electrical energy cost to thermal energy cost is four, which is typical of today’s fossil fuel costs. The effective electrical COPs of different technical options can then be compared. Those systems with higher electrical COPs will have lower energy costs. If solar is to be competitive, then the cost of delivered solar thermal energy should be less than the cost of delivered fossil thermal energy.