Design and analysis of multiple parallel-pass condensers

This paper describes and analyzes a novel design of multiple parallel-pass (MPP) microchannel tube condenser and its applications to automotive A/C systems. A flow distributor concept is introduced in MPP condenser in order to enable parallel flow arrangement in adjacent flow paths. Throughout analysis of two-phase flow and heat transfer processes in MPP condenser, a two-phase zone enlargement technique is developed to enhance condensation heat transfer and reduce pressure drop. Visual observation indicates a more uniform refrigerant quality entering the next cooling pass can be achieved in MPP condenser because superheated vapor through a pass-through hole on flow distributor directly injects into the separated liquid–vapor zone in a header tube. Performance test results show MPP condenser is able to improve heat transfer rate as high as 9.5% while its refrigerant mass flow increases 13.34% when comparing to a benchmark PF condenser.     

Energy-efficient flat-tube heat exchangers for indirectly cooled display cabinets

Different designs of flat-tube heat exchangers with plain fins have been evaluated theoretically in a parameter study in order to evaluate their performance potential in indirectly cooled display cabinets. Two different types of flat-tube heat exchangers were considered; one with serpentine fins and one with continuous plate fins. Both flat-tube heat exchanger types were adapted to the laminar flow regime on the liquid as well as on the air side. The performance of the two heat exchanger types had previously been verified experimentally under dehumidifying conditions. The results from this parameter study show that considerable savings in the required electric drive power to compressors, pumps and fans can be obtained in comparison with the traditional cooling coil. The savings may be up to 15%. In addition, the required temperature difference for the flat-tube heat exchangers is so small that frost-free operation is possible, which would result in even larger savings.     

An elemental NTU- model for vapour-compression liquid chillers

This paper presents a steady-state model for predicting the performance of vapour-compression liquid chillers over a wide range of operating conditions. The model overcomes the idealisations of previous models with regard to modelling the heat exchangers. In particular, it employs an elemental NTU- methodology to model both the shell-and-tube condenser and evaporator. The approach allows the change in heat transfer coefficients throughout the heat exchangers to be accounted for, thereby improving both physical realism and the accuracy of the simulation model. The model requires only those inputs that are readily available to the user (e.g. condenser inlet water temperature and evaporator water outlet temperature). The outputs of the model include system performance variables such as the compressor electrical work input and the coefficient of performance (COP) as well as states of the refrigerant throughout the refrigeration cycle. The methodology employed within the model also allows the performance of chillers using refrigerant mixtures to be modelled. The model is validated with data from one single screw chiller and one twin-screw chiller where the agreement is found to be within ±10%.     

Performance assessment of HC-290 as a drop-in substitute to HCFC-22 in a window air conditioner

As per the Montreal Protocol, CFCs and HCFCs are being phased out. HCFC-22 is used in window air conditioners. This paper presents the experimental performance study of a window air conditioner with propane (HC-290), a natural refrigerant, as a drop-in substitute to HCFC-22. Experimental results showed that HC-290 had 6.6% lower cooling capacity for the lower operating conditions and 9.7% lower for the higher operating conditions with respect to HCFC-22. The coefficient of performance for HC-290 was 7.9% higher for the lower operating conditions and 2.8% higher for the higher operating conditions. The energy consumption of the unit with HC-290 was lower in the range 12.4–13.5% than HCFC-22. The discharge pressures for HC-290 were lower in the range 13.7–18.2% than HCFC-22. For HC-290, the pressure drop was lower than HCFC-22 in both heat exchangers.This paper also presents simulation results for the heat exchangers of an HCFC-22 window air conditioner with HC-290 as a drop-in substitute. The simulation has been carried out using EVAP-COND, a heat exchanger model developed by NIST [National Institute of Standards and Technology. EVAP-COND: simulation models for finned-tube heat exchangers, Maryland, USA (2003). http://www2.bfrl.nist.gov/software/evap-cond/ [18]]. The simulated evaporator capacities are within ±4% of the experimentally measured cooling capacities for both refrigerants. Simulation results for HC-290 and HCFC-22 are compared. The exit temperatures of HC-290 are lower by 0.3–1.2 °C in the condenser and are higher by 2.1–2.4 °C in the evaporator than HCFC-22. Evaporating pressures of HC-290 are lower by 2.1–3.3% as compared to HCFC-22. The pressure drops of HC-290 are lower in both the evaporator and the condenser as compared to HCFC-22. The outlet temperatures of air for HCFC-22 and HC-290 in both heat exchangers are nearly the same.     

Frost, defrost, and refrost and its impact on the air-side thermal-hydraulic performance of louvered-fin, flat-tube heat exchangers

The thermal-hydraulic performance under conditions of an initial frost growth on the air-side surface, and for subsequent ‘refrosting’ after a defrost period is experimentally studied for folded-louvered-fin, microchannel heat exchangers. In total, five heat exchangers are considered; the thermal performances during one frost-growth cycle for four different fin geometries are compared in terms of overall heat transfer coefficient, pressure drop, and j and f factors; the defrost and refrost characteristics of two heat exchangers are compared to explore geometry effects. Typically, the performance under refrosting conditions becomes periodic and repeatable after the third or fourth refrosting cycle. The allowable frost growth period (before a defrost is required), the defrost requirement, and the thermal-hydraulic performance depend on heat exchanger geometry for the specimens used in this study.     

Experimental and numerical study on microchannel and round-tube condensers in a R410A residential air-conditioning system

The effect of different type of condensers on the performance of R410A residential air-conditioning systems was investigated in this study. Two R410A residential air-conditioning systems, one with a microchannel condenser and the other with a round-tube condenser, were examined experimentally, while the other components of the two systems were identical except the condensers. Two condensers had almost same package volumes. The two systems were operated in separate environmental chambers and their performance was measured in ARI A, B, and C conditions. Both the COP and cooling capacity of the system with the microchannel condenser were higher than those for the round-tube condenser in all test conditions. The refrigerant charge amount and the refrigerant pressure drop were measured; the results showed a reduction of charge and pressure drop in the microchannel condenser. A numerical model for the microchannel condenser was developed and its results were compared with the experiments. The model simulated the condenser with consideration given to the non-uniform air distribution at the face of the condenser and refrigerant distribution in the headers. The results showed that the effect of the air and refrigerant distribution was not a significant parameter in predicting the capacity of the microchannel condenser experimentally examined in this study. Temperature contours, generated from the measured air exit temperatures, showed the refrigerant distribution in the microchannel condenser indirectly. The temperature contours developed from the model results showed a relatively good agreement with the contours for measured air exit temperatures of the microchannel condenser.     

A novel special distributed method for dynamic refrigeration system simulation

A novel dynamic mathematical model based on spatially distributed approach has been developed and validated in this paper. This model gives good agreement in predicting the system COP and other parameters. The validated model has been used to enhance the prediction of the micro variations of superheat and sub-cooling. The novel spatial distributed model for the condenser and evaporator in refrigeration system, calculates the two-phase region in gas and liquid field separately since the gas and liquid in the two-phase region have different velocities. Previous researchers have used a pre-defined function of the void fraction in their spatially distributed model, based on experimental results. This approach results in the separate solution of the mass and energy equations, and less calculation is required. However, it is recognized that the mass and energy equations should be coupled during solving for more accurate solution. Based on the energy and mass balance, the spatial distribution model constructed here solves the velocity, pressure, refrigerant temperature, and wall temperature functions in heat exchangers simultaneously. A novel iteration method is developed and reduces the intensive calculations required. Furthermore, the condenser and evaporator models have shown a parametric distribution along the heat exchanger surface, therefore, the spatial distribution parameters in the two heat exchangers can be visualised numerically with a two-phase moving interface clearly shown.     

Thermodynamic performance limit considerations for dual-evaporator, non-azeotropic refrigerant mixture-based domestic refrigerator-freezer systems

Non-azeotropic refrigerant mixtures (NARMs) are investigated for a two-temperature level heat exchange process found in a domestic refrigerator-freezer. Ideal (constant air temperature) heat exchange processes are assumed. The results allow the effects of intercooling between the evaporator refrigerant stream and the condenser outlet stream to be examined in a systematic manner. For the conditions studied, an idealized NARM system will have a limiting coefficient of performance (COP) that is less than that of the best performing pure refrigerant component. However, for non-ideal heat exchange processes (gliding air temperature), the NARM-based system can have a higher limiting COP than a system running on either pure NARM component. Intercooling significantly affects the COP of NARM-based systems; however, depending on the location of ‘pinch points’ in the heat exchangers, only one intercooling heat exchanger may be needed to obtain a NARM's maximum refrigerator COP. The results are presented for mixtures of R22–R142b, R22–R123 and R32–R142b.     

Numerical optimisation of a two-stage ejector refrigeration plant

Jet-refrigeration cycles seem to provide an interesting solution to the increasing interest in environment protection and the need for energy saving due to their low plant costs, reliability and possibility to use water as operating fluid. A steam/steam ejector cycle refrigerator is investigated introducing a two-stage ejector with annular primary at the second stage. The steady_state refrigerator, exchanging heat with the water streams at inlet fixed temperatures at the three shell and tube heat exchangers, evaporator, condenser and generator, is considered as an open system. Heat transfer irreversibilities in the heat exchangers and external friction losses in the water streams are considered, ignoring the internal pressure drop of the vapor. A simulation program numerically searches the maximum COP at given external inlet fluid temperatures as a function of mass flows, dimensions and temperature differences in the heat exchangers. The code gives the ejector and heat exchangers design parameters.     

Modelling of the heat exchangers of a small capacity, hot water driven, air-cooled H2O–LiBr absorption cooling machine

General models for the design of the heat exchangers (absorber, generator, condenser and evaporator) of a prototype of an air-cooled absorption chiller of 2 kW for air-conditioning using the pair H₂O–LiBr have been developed. An absorption machine of such characteristics has been constructed to be used as a test facility for validating the results obtained from the mathematical models developed. The discrepancies considering the heat exchanged between numerical results and experimental data are under 15% in most cases for all these components except the condenser, where the discrepancies are higher. The conclusions reported will lead to: (i) future improvements of the mathematical simulation models and (ii) improvements in the experimental infrastructure.     

An NTU- model for alternative refrigerants

This paper presents a steady state simulation model to predict the performance of alternative refrigerants in vapour compression refrigeration/heat pump systems. The model is based on the NTU- method in analysing the heat exchangers following an elemental approach. The model extends its applicability to new refrigerants including hydrocarbons and uses a large database of REFPROP package for refrigerant properties. The main inputs to the model include the physical details of the heat exchangers, compressor efficiency, mass flow rates of heat transfer fluids and their inlet temperatures to the evaporator and the condenser, the pressure drops across the heat exchangers and the capacity of either the evaporator or condenser (in kW). The model results are validated with a wide range of experimental data of HCFC22 and propane (HC290) on a heat pump test facility for a number of parameters, e.g. coefficient of performance, condenser capacity, mass flow rate of the refrigerant and compressor discharge temperature. Although the model is currently tested for pure refrigerants using compact brazed plate (counter flow type) heat exchangers, it can also be applied to mixture of refrigerants as well as to other types of heat exchangers.

Résumé

Dans cet article, on présente un modèle de simulation de régime permanent pour prédire la performance des frigorigènes de remplacement dans les systèmes frigorifiques ou les pompes à chaleur à compression de vapeur. Fondé sur la méthode NTU- utilisée pour analyser les échangeurs de chaleur, ce modèle emploie une approche élémentaire. Ce modèle étend la méthode aux nouveaux frigorigènes, y compris deees hydrocarbures, et utilise une base de données étendue, celle de REFPROP, pour les propriétés des frigorigènes. Les principaux paramètres du modèle comprennent des détails physiques sur les échangeurs de chaleur, le rendement des compresseurs, et les débits massiques des fluides de transfert de chaleur et leurs températures à l'entrée de l'évaporateur ou du condenseur, la chute de pression à travers les échangeurs de chaleur et la puissance soit de l'évaporateur, soit du condenseur (exprimés en kW). Les résultats obtensus en utilisant ce modèle sont validés pour une large gamme de données expérimentales obtenus avec le HCFC22 et avec le propane (le HC290) sur un banc d'essai de pompe à chaleur et pour un certain nombre de paramètres, par exemple le coefficient de performance, la puissance du compresseur, le débit massique du frigorigène et la température du frigorigène à la sortie du compresseur. En ce moment, le comportement des frigorigènes purs utilisés dans des échangeurs de chaleur compacts à plaques brasées (de type contre-courant) est en train d'être étudié; le modèle peut également être appliqué aux mélanges de frigorigènes et à d'autres types d'échangeurs de chaleur.     

微通道换热器两相分配特性对空调系统性能的影响

微通道换热器作为新一代换热器逐渐被使用在家电领域,其结霜、除尘、排水、分液等都是目前亟待解决的问题。通过R22家用空调系统的标准性能实验台,对三种流程数不同的微通道换热器用作冷凝器和蒸发器时,温度分布均匀性和其对系统性能的影响进行实验,研究发现,微通道换热器在用作冷凝器和蒸发器时,温度分布不均对系统性能的影响分别达到7.3%和3.5%,并且流程数对于温度分布均匀性的影响在作为冷凝器和蒸发器时是不同的。     

Cycling losses in domestic appliances: an experimental and theoretical analysis

The on/off mode is the method of control usually applied in domestic refrigeration equipment. Owing to this method of operation, cycling losses occur which depend on the on/off cycle length, the dimensions of the heat exchangers, etc. It is the aim of this study to analyse these cycling losses in detail, both numerically and experimentally. Two operation modes for cycling are selected: the condenser closed during the off-period and the condenser open during the off-period. Both cycling operation modes are compared with a continuously running system.     

Liquid–gas heat exchanger for household refrigerator

This paper considers the influence of heat exchangers to the efficiency of a household refrigerating system. A steady state mathematical model is used to compare three most commonly used heat exchanger designs. For each design, an optimal inner diameter of the heat exchanger, subject to the compressor's capacity and the heat exchanger's length is found. The influence of operating conditions, such as condensation and evaporation temperatures, superheat in the evaporator and sub-cooling in the condenser, to optimal dimensions of the heat exchanger is also analyzed in the paper. Presented guidelines and recommendations can be used for design and modernization of household refrigerators and freezers.     

CFD simulation on inlet configuration of plate-fin heat exchangers

A computational fluid dynamics (CFD) program FLUENT has been used to predict the fluid flow distribution in plate-fin heat exchangers. It is found that the flow maldistribution is very serious in the y direction of header for the conventional header used in industry. The results of flow maldistribution are presented for a plate-fin heat exchanger, which is simulated according to the configuration of the plate-fin heat exchanger currently used in industry. The numerical prediction shows a good agreement with experimental measurement. By the investigation, two modified headers with a two-stage-distributing structure are proposed and simulated in this paper. The numerical investigation of the effects of the inlet equivalent diameters for the two-stage structures has been conducted and also compared with experimental measurement. It is verified that the fluid flow distribution in plate-fin heat exchangers is more uniform if the ratios of outlet and inlet equivalent diameters for both headers are equal.     

Assessment of condensation heat transfer correlations in the modelling of fin and tube heat exchangers

This is the second paper of a series that assesses the performance of a refrigeration system model by means of cycle parameters. In this case, the condensation temperature is the parameter to study and it is focused on fin and tube condensers. It also studies the influence of the heat transfer models on the estimation of this refrigeration cycle parameter and different correlations for the heat transfer coefficients have been implemented in order to characterise the heat transfer in the heat exchangers. The flow inside the heat exchangers is considered one-dimensional as in previous works. In the cycle definition, other submodels for all the cycle component have been taken into account to complete the system of equations that characterises the behaviour of the refrigeration cycle. This global system is solved by means of a Newton–Raphson algorithm and a known technique called SEWTLE is used to model the heat exchangers. Some experimental results are employed to compare the condensation temperatures provided by the numerical procedure and to evaluate the performance of each heat transfer coefficient. These experimental results correspond to an air-to-water heat pump and are obtained by using R-22 and R-290 as refrigerants.     

Refrigerant distribution in the vertical header of the microchannel heat exchanger – Measurement and visualization of R410A flow

This paper presents the R410A adiabatic upward flow in three vertical headers of microchannel heat exchangers. All microchannel tubes are inserted into the half depth. The objectives are to explore what affects R410A distribution and attempt to predict the distribution. R410A is circulated into the header through the (5 or 10) tubes in the bottom pass and exits through the (5 or 10) tubes in the top pass. It represents the flow in the outdoor heat exchanger (usually used as the condenser) when it is used as the evaporator in the heat pump mode of reversible systems. The quality was typically varied from 0.2 to 0.8 and the mass flow rate from 1.5 to 4.5 kg h^?1 per tube. The best distribution was observed at high mass flux and low quality. The experiment and visualization reveals the flow pattern effects in terms of homogeneity and momentum. The churn flow had better distribution since the two-phase mixture was more homogenous and the distribution was better at high mass flux in the header because the higher momentum liquid was able to reach the top exit tube.     

A minichannel aluminium tube heat exchanger – Part III: Condenser performance with propane

This paper reports heat transfer results obtained during condensation of refrigerant propane inside a minichannel aluminium heat exchanger vertically mounted in an experimental setup simulating a water-to-water heat pump. The condenser was constructed of multiport minichannel aluminium tubes assembled as a shell-and-tube heat exchanger. Propane vapour entered the condenser tubes via the top end and exited sub-cooled from the bottom. Coolant water flowed upward on the shell-side. The heat transfer areas of the tube-side and the shell-side of the condenser were 0.941 m² and 0.985 m², respectively. The heat transfer rate between the two fluids was controlled by varying the evaporation temperature while the condensation temperature was fixed. The applied heat transfer rate was within 3900–9500 W for all tests. Experiments were performed at constant condensing temperatures of 30 °C, 40 °C and 50 °C, respectively. The cooling water flow rate was maintained at 11.90 l min⁻¹ for all tests. De-superheating length, two-phase length, sub-cooling length, local heat transfer coefficients and average heat transfer coefficients of the condenser were calculated. The experimental heat transfer coefficients were compared with predictions from correlations found in the literature. The experimental heat transfer coefficients in the different regions were higher than those predicted by the available correlations.     

Heat transfer characteristics of flat plate finned-tube heat exchangers with large fin pitch

The objective of this study is to provide experimental data that can be used in the optimal design of flat plate finned-tube heat exchangers with large fin pitch. In this study, 22 heat exchangers were tested with a variation of fin pitch, number of tube row, and tube alignment. The air-side heat transfer coefficient decreased with a reduction of the fin pitch and an increase of the number of tube row. The reduction in the heat transfer coefficient of the four-row heat exchanger coil was approximately 10% as the fin pitch decreased from 15.0 to 7.5 mm over the Reynolds number range of 500–900 that was calculated based on the tube diameter. For all fin pitches, the heat transfer coefficient decreased as the number of tube row increased from 1 to 4. The staggered tube alignment improved heat transfer performance more than 10% compared to the inline tube alignment. A heat transfer correlation was developed from the measured data for flat plate finned-tubes with large fin pitch. The correlation yielded good predictions of the measured data with mean deviations of 3.8 and 6.2% for the inline and staggered tube alignment, respectively.     

Compact heat exchangers, enhancement and heat pumps

In order to achieve widespread use of heat pumps across the full spectrum of potential applications, it is critical that the first cost of the units is acceptable. There are many factors influencing this cost, including the number of units manufactured, the ease of installation, the complexity of the control requirements, and the cost of the working fluid(s). A common feature of all heat pump cycles is the presence of at least one heat exchanger, indeed some heat-driven cycles are composed almost entirely of heat exchangers, each having a different but critical role to play. There are several important aspects of heat exchangers that can help to reduce first cost of these components and the system, (in addition to the possible positive impact on coefficient of performance). Two of these are discussed here — compact heat exchangers (CHEs) and heat transfer enhancement. The latter may be directly associated with CHEs but can be equally beneficial in reducing approach temperature differences in 'conventional' shell and tube heat exchangers. Both are essential features of many intensified processes, which the author argues need compatible heat pumps if the market for the latter is to flourish. In this paper, the most recent types of CHE are described, with emphasis on the benefits they can bring to heat pump first cost and performance. Heat transfer enhancement in heat pumps is also reviewed.