Optimization of Water Consumption in Hybrid Evaporative Cooling Air Conditioning Systems for Data Center Cooling Applications

In the light of its potential to reduce energy consumption when coupled to the condenser of existing vapor compression systems, evaporative cooling technology still faces questions relating to its water consumption pattern and the effect of water quality on its performance. This paper presents an experimental investigation of the water consumption characteristics in a split air-conditioning system employing evaporative precooling of air flowing over the condenser coils. The effect of the cooling pad thickness on the coefficient of performance of the system is investigated by varying the pad thickness from 5 to 15 cm in step size of 5 cm. Condition of the exit air from the pad shows that evaporative cooling can be employed as a standalone method for cooling of data centers, with adequate humidity control systems in place. Results obtained on water consumption shows that the volume of water consumed does not increase proportionally with time, rather it increases by a factor of 1.8, 2.5, and 3.2, for 2, 3, and 4 hours of operation respectively, relative to 1hour of operation. Two parameters; salinity and turbidity were used to study the effect of water quality on the evaporative cooling process. Additionally, a method of optimizing the pump operation is introduced in this paper. Running the pump intermittently could cut the energy consumed by the water pump in such a hybrid system by up to 20%.     

Experimental and theoretical investigation of an innovative evaporative condenser for residential refrigerator

In this study, an innovative, evaporative condenser for residential refrigerator was introduced. A vapor compression cycle incorporating the proposed evaporative condenser was tested to evaluate the cycle performance. To allow for evaporative cooling, sheets of cloth were wrapped around condenser to suck the water from a water basin by capillary effect. The thermal properties at the different points of the refrigeration cycle were measured for typical operating conditions. The experimental results showed that the condenser temperature increases 0.45 °C for each degree increase in evaporator temperature when the air velocity is 2.5 m/s, and the ambient condition is 29 °C and the relative humidity is 37.5%. Meanwhile, the condenser temperature increase is 0.88 °C in the case of air velocity 1.1 m/s and ambient conditions of 31 °C and relative humidity of 47.1%. A theoretical model for the evaporative condenser was developed, and validated by experimental results. The theoretical model showed that the evaporative condenser can operate at a condensing temperature of 20 C lower than that of the air-cooled condenser for heat flux of 150 W/m², and at air velocity 3 m/s. The effect of the different parameters on the condenser temperature was studied too.     

Conservation of energy estimated by second law analysis of a power-consuming process

A refrigeration system removing heat from a cold storage is analyzed to determine exergetic losses of the thermodynamic cycle and the power needed for the flows of the refrigerant and the media transferring heat at a specified temperature. How much the overall power consumption of the system can be decreased by lowering the condensing temperature, by either increasing the external heat transfer at the condenser or by lowering the inlet temperature of the heat exchanging media, is investigated. The latter depends on the relative humidity of the air. The performance of air, water and evaporative-cooled condensers are evaluated as a function of relative humidity of the ambient air. It is shown that the evaporative condenser operates at the lowest condensing temperature and, therefore, the least power consumption of the total system is achieved. Wetting the condenser with water requires only 1% of the overall power consumption but reduces the consumption by 30% as compared with the air-cooled condenser. Precooling the air by a water spray before it enters an air-cooled condenser is of benefit only at relative humidities of 65% or less. At other state conditions of the air, a higher power consumption will result. Lowering the temperature of the surroundings lowers P_rev and the second law efficiency must be properly defined so that, for cases of lowest power consumption, highest values of the efficiency will be obtained. Means for the design of least power-consuming air-conditioners are briefly stated, as well as the advantages of evaporative condensers for fog-free operation.     

Effect of pre‐cooling of inlet air to condensers of air‐conditioning units

Energy conservation and increase in performance of air‐conditioning systems could be achieved by pre‐cooling the air intake of the condensers. This paper experiments three different methods of pre‐cooling the condenser air; the cooling pad (CP) setup, the cooling mesh (CM) setup and the shading setup. The CP and CM setups are two different methods of evaporatively cooling the air. The three methods have been applied to three identical, 2.8 tons, split air‐conditioning units during the peak summer time period in Kuwait, under ambient temperatures ranging from 39 to 45°C. The results yielded a drop in the power consumption ranging from 8.1 to 20.5% and an increase in the cooling load ranging from 6.4 to 7.8% by using the CP and CM setups, which, in turn, resulted in an increase in the coefficient of performance (COP) of the units by 36–59%. The shading setup has resulted in an increase of power consumption due to air trapped below the shaded area, which resulted in heat being generated. Copyright © 2005 John Wiley & Sons, Ltd.     

Improved condenser design and condenser-fan operation for air-cooled chillers

Air-cooled chillers traditionally operate under head pressure control via staging constant-speed condenser fans. This causes a significant drop in their coefficient of performance (COP) at part load or low outdoor temperatures. This paper describes how the COP of these chillers can be improved by a new condenser design, using evaporative pre-coolers and variable-speed fans. A thermodynamic model for an air-cooled screw-chiller was developed, within which the condenser component considers empirical equations showing the effectiveness of an evaporative pre-cooler in lowering the outdoor temperature in the heat-rejection process. The condenser component also contains an algorithm to determine the number and speed of the condenser fans staged at any given set point of condensing temperature. It is found that the chiller’s COP can be maximized by adjusting the set point based on any given chiller load and wet-bulb temperature of the outdoor air. A 5.6–113.4% increase in chiller COP can be achieved from the new condenser design and condenser fan operation. This provides important insights into how to develop more energy-efficient air-cooled chillers.     

System optimization and experimental research on air source heat pump water heater

This paper deals with the system optimization of air source heat pump water heater (ASHPWH), including calculating and testing. The ASHPWH system consists of a heat pump, a water tank and connecting pipes. Air energy is absorbed at the evaporator and pumped to storage tank via a Rankine cycle. The coil pipe/condenser releases condensing heat of the refrigerant to the water side. An ASHPWH using a rotary compressor heated the water from initial temperature to the set temperature (55 °C). The capillary tube length, the filling quantity of refrigerant, the condenser coil tube length and system matching are discussed accordingly. From the testing results, it could be seen that the system performance COP could be improved obviously.     

Field study using the ground as a heat sink for the condensing unit of an air conditioner in Thailand

This paper reports on an investigation of the feasibility of using earth to absorb the heat normally rejected into the atmosphere by the condensing unit of a conventional air conditioner. To this end, a copper tube of about 67 m in length was buried at a depth of 1 m underground, where the temperature was constant at about 27°C year round. The copper coil of an air type condenser is about 22 m long. For the buried condenser, the R-22 refrigerant requirement was 5.8 kg as compared with 1.2 kg for the air condenser system. It was found that with this modified condensing unit, the coefficient of performance (COP) was much higher than that of a conventional one: it varied between 7.1 (daytime) and 8.1 (nighttime), compared to 2.8 and 3.1, respectively. The ground temperature near the buried copper coil did not increase, thus demonstrating the ability of the soil to dissipate the absorbed heat into the ground. Consequently, there is a high potential for contributing to environmental protection by using the ground as a heat sink. The elimination of the condensing fan is an additional advantage of the buried condenser system.     

Numerical Simulation of the Performance of a Capillary Thermal Driven Ejector Refrigerator

A capillary driven ejector refrigerator is a new refrigeration system that can use solar energy and other low-grade heat sources. In this paper, the performance of the refrigeration system is simulated numerically by use of an iteration algorithm and block exchanging technology for all unit models. The flow and heat transfer characteristics in a solar collector, generator, ejector, condenser, and evaporator are analyzed and calculated. The results show that when the generating temperature is higher than 75–80°C and the environmental temperature is lower than 35°C, the system can work normally; the coefficient of performance of this refrigeration system is in the range of 0.05–0.15 by use of water as a refrigerant. The cooling capacity and COP increase with an increasing generative temperature and decreasing condensing pressure.     

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.     

汽车空调性能试验台总成——主机及风洞系统的研制与试验分析

针对微通道换热器用作汽车空调冷凝器的特点,研制了一套冷凝器单体性能测试试验台,即主机及风洞试验台.该试验台主测风洞系统的换热量采用空气焓差法测试,辅测主机系统的换热量采用制冷剂流量计法测试,并选取两款微通道冷凝器对其进行冷凝换热试验,以验证该试验台的稳定性和准确性.结果表明,该试验台空气侧和制冷剂侧所测得的换热量偏差均在5%以内,满足冷凝器测控要求.根据实验数据得到了冷凝器迎面风速对换热量、空气压降和制冷剂压降的影响规律,为微通道换热器的优化设计及企业的相关研究提供参考.     

Performance enhancement of gas turbines by inlet air‐cooling in hot and humid climates

In this paper, a model to study the effect of inlet air‐cooling on gas turbines power and efficiency is developed for two different cooling techniques, direct mechanical refrigeration and an evaporative water spray cooler. Energy analysis is used to present the performance improvement in terms of power gain ratio and thermal efficiency change factors. Relationships are derived for an open gas turbine cycle with irreversible compression and expansion processes coupled to air‐cooling systems. The obtained results show that the power and efficiency improvements are functions of the ambient conditions and the gas turbine pressure ratio. The performance improvement is calculated for, ambient temperatures from 30 to 50°C, the whole range of humidity ratio (10–100%) and pressure ratio from 8 to 12. For direct mechanical refrigeration air‐cooling, the power improvement is associated with appreciable drop in the thermal efficiency. The maximum power gain can be obtained if the air temperature is reduced to its lowest limit that is the refrigerant evaporation temperature plus the evaporator design temperature difference. Water spray cooling process is sensitive to the ambient relative humidity and is suitable for dry air conditions. The power gain and efficiency enhancement are limited by the wet bulb temperature. The performance of spray evaporative cooler is presented in a dimensionless working graph. The daily performance of the cooling methods is examined for an ABB‐11D5 gas turbine operating under the hot humid conditions of Jeddah, Saudi Arabia. The results indicate that the direct mechanical refrigeration increased the daily power output by 6.77% versus 2.57% for the spray air‐cooling. Copyright © 2005 John Wiley & Sons, Ltd.     

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.     

Investigation of water droplet carryover phenomena in industrial evaporative air-conditioning systems

Water droplet carryover phenomena and pressure drop characteristics in drip-type direct evaporative coolers have been experimentally investigated. Ten different evaporative cooling pads were tested for different air frontal velocities, and the onset of carryover has been determined. The onset of water carryover has been found to be at air velocities between 3.5 and 4.2 m/s. Also, the effect of flute height and pad thickness on pressure drop characteristics of cooling pads has been examined. In addition, it has been determined that for the steady-state operation of drip-type direct evaporative coolers, water temperature in the reservoir approaches the wet bulb temperature and can be taken as constant for long term steady-state operations in practice.     

Study on a twin‐bed adsorption refrigeration system using R134a‐activated carbon pair

A low capacity twin‐bed adsorption refrigeration system has been built with R134a as a refrigerant and activated carbon as the adsorbent. Simple tube‐in‐tube heat exchangers have been fabricated and have been used as the adsorber beds. Activated carbon (granular type) has been filled in the annular space of the inner tube and outer tube. A plate heat exchanger has been used as the condenser and the temperature of cooling water has been maintained between 25°C and 30°C, also the evaporator has been custom designed as per requirements. A mathematical model has also been developed and the results obtained have been found to be comparable. While operating the system in the single‐bed mode a cooling power of 250.4 W has been obtained with a coefficient of performance (COP) of 0.38 with an average evaporator temperature of 18.4°C against a predicted value of 263.7 W with a COP of 0.41. While operating in the twin‐bed mode a cooling power of 281.3 W with a COP of 0.47 with an average evaporator temperature of 17.6°C has been obtained against a predicted value of 294.5 W with a COP of 0.52.     

Experimental performance of a silica gel–water adsorption chiller

A newly developed adsorption water chiller is described and tested. In this adsorption refrigeration cycle system, there is no refrigerant valve. Thus, the problem of mass transfer resistance occurring in the conventional systems when methanol or water is used as refrigerant and resulting in pressure drop during the flow of refrigerant inside the tubing is eliminated. To make the utilization of low heat source with temperature ranging from 70 to 95 °C possible, silica gel–water was selected as working pair. The experimental results proved that it is able to produce a cooling power of 6.3 kW with a COP of about 0.4. The test results demonstrate that, through the heat recovery, the COP can be increased by 34.4% while mass recovery has the effect of increasing the cooling power by 13.7% and the COP by 18.3%. The performances of the system were analyzed for varied condensation temperature and for varied evaporation temperature. Based on the first prototype, the second prototype is designed and manufactured to improve the performance. Primary test results demonstrate that the performance is highly improved. It has a COP of about 0.5 and cooling power 9 kW for 13 °C evaporation temperature.     

Suggested solution concentration for an energy-efficient refrigeration system combined with condensation heat-driven liquid desiccant cycle

This paper presents a hybrid energy-efficient refrigeration system enhanced by liquid desiccant evaporative cooling technology for subcooling the refrigerant, where the liquid desiccant cycle is driven by the exhausted heat from the condenser and three commonly used liquid desiccants: LiCl, LiBr and CaCl₂ aqueous solutions are considered here. The solution concentration for the proposed hybrid energy-efficient refrigeration system should be determined and optimized carefully for better performance. Sensitive study of solution concentration involved in the hybrid system is conducted at different condensation temperature. The results indicates that under standard working condition (i.e., condensing temperature is 50 °C), the optimum solution concentration is 0.31 for LiCl aqueous solution, 0.45 for LiBr aqueous solution and 0.42 for CaCl₂ aqueous solution, while the maximum COPs are nearly same. When the condensing temperature is 45 °C, the optimum solution concentration should be set at 0.27 for LiCl aqueous solution, and 0.41 for LiBr aqueous solution and 0.37 for CaCl₂ aqueous solution, while condensing temperature is 55 °C, it is 0.35 for LiCl aqueous solution, 0.49 for LiBr aqueous solution and 0.45 for CaCl₂ aqueous solution. The simple fitting formulas are obtained, and performance improvement potential is discussed.     

Evaluation of adding flash tank to solar combined ejector–absorption refrigeration system

Performance of the absorption cooling system is still a challenge due to the coefficient of performance (COP) that is generally poor when compared with the conventional vapor compression cycle. High solar radiation in hot climates is usually associated with high ambient temperature and consequently peak cooling demand. Absorption cooling cycles can be powered by solar but the performance is limited by heat source temperature (solar collector) and high ambient temperature that can affect the condensation process. Efficiency enhancement of the system components is essential to increase the COP of the system. A modification in the combined absorption–ejector cooling system is adopted. Adding a removable flash tank between the condenser and evaporator could improve entrainment ratio of the ejector, along with improving the cooling effect inside the evaporator. A computer simulation program is developed to evaluate the performance of the modified combined cycle using aqua-ammonia (NH₃–H₂O) refrigerant. The performance of the proposed combined cooling cycle is compared with basic absorption, and combined absorption–ejector cooling cycles. Results showed a significant improvement in the COP of the modified cycle at different operating conditions. Cooling effect and capacity of the evaporator is enhanced due to the reduction of flash gas delivered to the evaporator. Furthermore, the flash tank optimized the ejector entertainment ratio and consequently increasing the condenser pressure. This optimization will enable the system to perform well in hot climates where the condenser efficiency is limited by ambient temperature.     

Performance enhancement of a split air conditioner using porous material inside the evaporator pipes

In this experimental study, a porous material is used inside the pipes of the evaporator as the main heat exchanging device in the air conditioning cycle. The used porous material consists of stainless steel balls of different diameters. As a case study, refrigerant R454B, which is a drop-in replacement to refrigerant R410A, is used as a working fluid in the air conditioner thermodynamic cycle. Four different porosities were used during the experimental tests; 100% (empty tube), 46%, 40%, and 33%. This study investigated the influence of variation of porosity as well as outside air temperature and refrigerant evaporation temperature on the cycle coefficient of performance, evaporation capacity, pressure drop, and power consumption during the compression process. Measured evaporation temperatures and indoor temperatures during tests were in the range of 1.5–12°C and 18–25°C, respectively. The use of porous material in the evaporation heat exchanger resulted in a considerable increase in the cycle evaporation capacity and coefficient of performance. Varying porosity from 100% to 33% resulted in an average percent increase of cycle evaporation capacity and coefficient of performance by 48.8% and 84.3%, respectively. Also, decreasing porosity from 100% to 33% resulted in an average percent increase in power consumption during the compression process by about 27%. An average percent increase of power consumption of compressor by about 25.9% is also reported, when evaporation temperature increased from 1.5°C to 12°C. Increasing outside air temperature from 27.1°C to 39.5°C resulted in decreasing evaporation capacity and coefficient of performance by 35.2% and 34.5%, respectively, and in increasing compressor power consumption by about 14.3%. A considerable pressure drop was recorded during the evaporation process when using porous material. The volumetric evaporation capacity, as well as compressor discharge temperature, are increased by increasing evaporating temperature and by decreasing evaporator porosity. The increase in air ambient temperature resulted in a considerable increase in refrigerant mass flow rate.     

Numerical analysis of an air condenser working with the refrigerant fluid R407C

As CFC (clorofluorocarbon) and HCFC (hydrochlorofluorocarbon) refrigerants which have been used as refrigerants in a vapour compression refrigeration system were know to provide a principal cause to ozone depletion and global warming, production and use of these refrigerants have been restricted. Therefore, new alternative refrigerants should be searched for, which fit to the requirements in an air conditioner or a heat pump, and refrigerant mixtures which are composed of HFC (hydrofluorocarbon) refrigerants having zero ODP (ozone depletion potential) are now being suggested as drop-in or mid-term replacement. However also these refrigerants, as the CFC and HCFC refrigerants, present a greenhouse effect.The zeotropic mixture designated as R407C (R32/R125/R134a 23/25/52% in mass) represents a substitute of the HCFC22 for high evaporation temperature applications as the air-conditioning.Aim of the paper is a numerical–experimental analysis for an air condenser working with the non azeotropic mixture R407C in steady-state conditions. A homogeneous model for the condensing refrigerant is considered to forecast the performances of the condenser; this model is capable of predicting the distributions of the refrigerant temperature, the velocity, the void fraction, the tube wall temperature and the air temperature along the test condenser. Obviously in the refrigerant de-superheating phase the numerical analysis becomes very simple. A comparison with the measurements on an air condenser mounted in an air channel linked to a vapour compression plant is discussed. The results show that the simplified model provides a reasonable estimation of the steady-state response and that this model is useful to design purposes.