Control optimisation of CO2 cycles for medium temperature retail food refrigeration systems

This paper describes a detailed procedure into the investigation of optimised control strategies for CO₂ cycles in medium temperature retail food refrigeration systems. To achieve this objective, an integrated model was developed composing of a detailed condenser/gas cooler model, a simplified compressor model, an isenthalpic expansion process and constant evaporating temperature and superheating. The CO₂ system can operate subcritically or transcritically depending on the ambient temperature. For a transcritical operation, a prediction can be made for optimised refrigerant discharge pressures from thermodynamic cycle calculations. When the system operates in the subcritical cycle, a floating discharge pressure control strategy is employed and the effect of different transitional ambient temperatures separating subcritical and transcritical cycles on system performance is investigated. The control strategy assumes variable compressor speed and adjustable air flow for the gas cooler/condenser to be modulated to achieve the constant cooling load requirement at different ambient conditions.     

Optimization of finned-tube condensers using an intelligent system

The refrigerant circuitry influences a heat exchanger's attainable capacity. Typically, a design engineer specifies a circuitry and validates it using a simulation model or laboratory test. The circuitry optimization process can be improved by using intelligent search techniques. This paper presents experiments with a novel intelligent optimization module, ISHED (Intelligent System for Heat Exchanger Design), applied to maximize capacity through circuitry design of finned-tube condensers. The module operates in a semi-Darwinian mode and seeks refrigerant circuitry designs that maximize the condenser capacity for specified operating conditions and condenser slab design constraints. Examples of optimization runs for six different refrigerants are included. ISHED demonstrated the ability to generate circuitry architectures with capacities equal to or superior to those prepared manually, particularly for cases involving non-uniform air distribution.     

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.     

Optimal shape of the multi-passage branching system in a single-phase parallel-flow heat exchanger

A numerical simulation is performed to examine the heat and fluid flow characteristics of the branching system in a single-phase parallel-flow heat exchanger (PFHE) and to obtain its optimal shape. The relative importance of the design parameters [injection angle of the working fluid (Θ), inlet shape and location (Y_c), and height of the protruding flat tube (Y_b)] is determined to decide the optimization sequence. The optimal geometric parameters are obtained as follows: Θ=−21°, Type A, Y_c=0 and Y_b=0. The heat transfer rate of the optimum model compared to that of the reference model is increased by about 55%. The optimal values of the parameters can be applicable to the Reynolds number ranging from 5000 to 20,000.     

Development of an ejector cooling system with thermal pumping effect

This paper presents a feasibility study of an ejector cooling system (ECS) that utilizes a multi-function generator (MFG) to eliminate the mechanical pump. The MFG serves as both a pump and a vapor generator. The MFG is designed based on the pressure equilibration between high and low pressures through heating and cooling process. In this design, an ECS that contains no moving components and is entirely powered by heat can be practicable. A prototype using refrigerant R141b as working fluid was constructed and tested in the present study. The experimental results showed that the system coefficient of performance (COP_o) was 0.218 and the cooling capacity was 0.786 kW at generating temperature (T_G) 90 °C, condensing temperature (T_C) 32.4 °C and evaporating temperature (T_E) 8.2 °C. While taking into account the extra heat needed for the MFG operation, the total coefficient of performance (COP_t) is 0.185. It is shown that a continuous operation for the generation of cooling effect in an ECS with MFG can be achieved. This cooling machine can be very reliable since there is no moving part.     

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 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%.     

Experimental and numerical research on condenser performance for R-22 and R-407C refrigerants

An experimental study of a fin and tube condenser was performed using two different configurations of condenser paths (U and Z type) and two kinds of refrigerants (R-22 and R-407C) as working fluids. An integral test facility was constructed to evaluate the heat transfer capacity of the air and refrigerant sides of the condenser. An uncertainty study was also performed. A numerical code was developed, using a section-by-section analysis scheme in which mal-distribution on the air side and temperature gliding on the refrigerant side could be considered along the tube-length direction. Different condenser capacities were obtained from both the experimental and numerical results, depending on the paths and refrigerants used. R-22 performed better than R-407C for the Z-type path configuration, but no significant difference was found between results using either refrigerant in the U-type path configuration. On average, the numerical results obtained with R-22 were 10.1% greater than experiment data; using R-407C, results were 10.7% less than experiment data. The numerical code can be used as a design tool to develop better condenser paths.     

Study on adsorption refrigeration cycle utilizing activated carbon fibers. Part 1. Adsorption characteristics

Thermal heat driven adsorption systems using natural refrigerants have been focused on the recent energy utilization trend. However, the drawbacks of these adsorption systems are their poor performance in terms of system cooling capacity and coefficient of performance (COP). The objective of this paper is to improve the performance of thermally powered adsorption cooling system by selecting new adsorbent–refrigerant pair. Adsorption capacity of adsorbent–refrigerant pair depends on the thermophysical properties (pore size, pore volume and pore diameter) of adsorbent and isothermal characteristics of the pair. In this paper, the thermophysical properties of two PAN types of activated carbon fibers (FX-400 and KF-1000) are determined from the nitrogen adsorption isotherms. The standard nitrogen gas adsorption/desorption measurements on various adsorbents at liquid nitrogen of temperature 77.3 K were performed. Surface area of each adsorbent was determined by the Brunauer, Emmett and Teller (BET) plot of nitrogen adsorption data. Pore size distribution was measured by the Horvath and Kawazoe (HK) method. As of the adsorption/desorption isotherms, FX-400 shows very small hysteresis when the value of P/P_o exceeds 0.4, while KF-1000 has no hysteresis in the whole range of P/P_o. The adsorption capacity of FX-400 is about 30% higher than that of KF-1000. The adsorption equilibrium data of activated carbon fiber (ACF)-methanol are presented and correlated with simple equations. The adsorption equilibrium data of ACF (KF-1000)-water also presented in order to facilitate comparison with those of ACFs-methanol pair. The results will contribute significantly in designing the adsorber/desorber heat exchanger for thermally driven adsorption cooling system.     

Azeotropy in the natural and synthetic refrigerant mixtures

A novel approach for the prediction of azeotrope formation in a mixture that does not require vapour–liquid equilibrium calculations is developed. The method employs neural networks and global phase diagram methodologies to correlate azeotropic data for binary mixtures based only on critical properties and acentric factor of the individual components in refrigerant mixtures. Analytical expressions to predict azeotropy and double azeotropy phenomena in terms of critical parameters of pure components and interaction parameters k₁₂, are derived using global phase diagram conception. Modeling of thermodynamic and phase behavior has been carried out on the base of the Redlich–Kwong–Soave and the Peng–Robinson equations of state (EoS). Local mapping method is introduced to describe thermodynamically consistently an accurate saturation curve of refrigerants by three parameters EoS. Optimized neural network was chosen to achieve a complete coincidence of predicted and experimentally observable azeotropic states for training, validation, and test sets simultaneously. All possible cases of azeotropy appearance/absence in the more than 1500 industrially significant binary mixtures of natural and synthetic refrigerants are presented.     

A year-round dynamic simulation of a solar-driven ejector refrigeration system with iso-butane as a refrigerant

In this paper, the performance of the solar-driven ejector refrigeration system with iso-butane (R600a) as the refrigerant is studied. The effects that both the operating conditions and the solar collector types have on the system's performance are also examined by dynamic simulation. The TRNSYS and EES simulation tools are used to model and analyze the performance of a solar-driven ejector refrigeration system. The whole system is modelled under the TRNSYS environment, but the model of the ejector refrigeration subsystem is developed in the Engineering Equations Solver (EES) program. A solar fraction of 75% is obtained when using the evacuated tube solar collector. In the very hot environment, the system requires relatively high generator temperature, thus a flat plate solar collector is not economically competitive because the high amount of auxiliary heat needed to boost up the generator temperature. The results from the simulation indicate that an efficient ejector system can only work in a region with decent solar radiation and where a sufficiently low condenser temperature can be kept. The average yearly system thermal ratio (STR) is about 0.22, the COP of the cooling subsystem is about 0.48, and the solar collector efficiency is about 0.47 at T_e 15 °C, T_c 5 °C above the ambient temperature, evacuated collector area 50 m² and hot storage tank volume 2 m³.     

A comprehensive design and rating study of evaporative coolers and condensers. Part II. Sensitivity analysis

Sensitivity analysis can be used to identify important model parameters, in particular, normalized sensitivity coefficients; by allowing a one-on-one comparison. Regarding design of evaporative coolers, the sensitivity analysis shows that all sensitivities are unaffected by varying the mass flow ratio and that outlet process fluid temperature is the most important factor. In rating evaporative coolers, effectiveness is found to be most sensitive to the process fluid flow rate. Also, the process fluid outlet temperature is most sensitive to the process fluid inlet temperature. For evaporative condensers, the normalized sensitivity coefficient values indicate that the condensing temperature is the most sensitive parameter and that these are not affected by the value of the mass flow ratio. For evaporative condenser design, it was seen that, for a 53% increase in the inlet relative humidity, the normalized sensitivity of the surface area increased 1.8 times in value and, for a 15 °C increase in the condenser temperature, the sensitivity increased by 3.5 times. The performance study of evaporative condensers show that, for a 72% increase in the inlet relative humidity, the normalized sensitivity coefficient for effectiveness increased 2.4 times and, for a 15 °C increase in the condenser temperature, it doubled in value.     

Selective water sorbent for solid sorption chiller: experimental results and modelling

In this paper the experimental results of a lab-scale chilling module working with the composite sorbent SWS-1L (mesoporous silica gel impregnated with CaCl₂) are presented. The interesting sorption properties of this material yield a high COP=0.6 that gives a promising alternative to the common zeolite or silica gel for application in solid sorption units driven by low temperature heat (T 100 °C). The measured low specific power of the device is a result of not optimised geometry of the adsorber and of the pelletised shape of the adsorbent. Heat transfer optimisation is currently under progress to increase the specific power. The experimental results are compared with those of a mathematic model able to describe the dynamic behaviour of the system. The model is used to study the influence of the main operating parameters on the system performance.     

Microchannel heat exchangers for charge minimization in air-cooled ammonia condensers and chillers

This paper presents experimental results from a prototype ammonia chiller with an air-cooled condenser and a plate evaporator. The main objectives were charge reduction and compactness of the system. The charge is reduced to 20 g/kW (2.5 oz/Ton). This is lower than any currently available air-cooled ammonia chiller on the market. The major contribution comes from use of microchannel aluminum tubes. Two aluminum condensers were evaluated in the chiller: one with a parallel tube arrangement between headers and “microchannel” tubes (hydraulic diameter D_h = 0.7 mm), and the other with a single serpentine “macrochannel” tube (D_h = 4.06 mm). The performances of the chiller and condensers are compared based on various criteria to other available ammonia chillers. This prototype was made and examined in the Air Conditioning and Refrigeration Center in 1998, at the University of Illinois at Urbana-Champaign.     

Zeolite heat pump — adsorption of methanol in synthetic zeolites 13X, 4A and 5A

The adsorption isotherms for methanol adsorption in synthetic zeolites 13X, 4A and 5A were measured gravimetrically at various temperatures. The model of Langmuir and the potential theory were used for correlating the equilibrium data. The monolayer capacity was calculated using these two models. A small deviation at elevated temperatures was observed. The differential heat of adsorption was measured calorimetrically for all three zeolites. The isosteric heat of adsorption was calculated for zeolite 13X using measured equilibrium data. The log p, 1/T equilibrium diagram for zeolite 13X was computed using the Langmuir equation.     

Two-phase flow regimes in round, square and rectangular tubes during condensation of refrigerant R134a

An experimental investigation of two-phase flow mechanisms during condensation of refrigerant R134a in six small diameter round (4.91 mm), square (D_h=4 mm, α=1), and rectangular (4×6 and 6×4 mm: D_h=4.8 mm, α=0.67 and 1.5; 2×4 and 4×2 mm: D_h=2.67 mm, α =0.5 and 2) was conducted. Unique experimental techniques and test sections were developed to enable the documentation of the flow mechanisms during phase change. For each tube under consideration, flow mechanisms were recorded over the entire range of qualities for five different refrigerant mass fluxes between 150 and 750 kg m⁻² s⁻¹. The flow mechanisms were categorized into four different flow regimes: intermittent flow, wavy flow, annular flow, and dispersed flow. In addition, the large amount of data enabled the delineation of several different flow patterns within each flow regime, which provides a clearer understanding of the different modes of two-phase flow. Transition lines between the respective flow patterns and regimes on these maps were established based on the experimental data. It was found that for similar hydraulic diameters, flow regime transitions are not very strongly dependent on tube shape or aspect ratio. These maps and the transition lines can be used to predict the particular flow pattern or regime that will be established for a given mass flux, quality and tube geometry.     

An experimental investigation and modelling of the viscosity refrigerant/oil solutions

This paper presents experimental data for the viscosity of solutions of refrigerant R600a (isobutane) with mineral compressor oils Azmol, Reniso WF 15A, and R245fa (1,1,1,3,3-pentafluoropropane) with polyolester compressor oil Planetelf ACD 100 FY on the saturation line. The experimental data were obtained for solution of R600a with mineral compressor oil Azmol in the temperature range from 294.7 to 338.1 K and the concentration range 0.04399 ≤ w_R ≤ 0.3651, the solution of R600a with mineral compressor oil Reniso WF 15A at the temperatures from 285.8 to 348.4 K and the concentration range 0.03364 ≤ w_R ≤ 0.2911, the solution of R245fa with polyolester compressor oil Planetelf ACD 100 FY at the temperatures from 309 to 348.2 and the concentration range 0.06390 ≤ w_R ≤ 0.3845. The viscosity was measured using a rolling ball method. The method for prediction of the dynamic viscosity for refrigerant/oil solutions is reported.     

Transport et distribution de produits alimentaires: situation actuelle et tendances futuresTransport and distribution of foods: today''s situation and future trends

International regulations formerly focused on consumer safety. Now, attention is shifted towards the preservation of the global quality of goods. New control methods (HACCP) can increase the quality of the whole chain. A correct approach to weight losses is a primary goal in the cold chain. Direct fuel consumption (with respect to each mass unit transported) is reduced when the transported weight per vehicle is increased; indirect consumption is optimised when the efficiency of the refrigerating unit is increased and when the overall heat transfer coefficient of the insulated body is minimised. Ageing of the vehicles must be minimised. A voluntary energy labelling program of vehicles provides an excellent opportunity to reduce energy consumption. New insulating products can theoretically worsen the energy budget. Every effort should be made to improve the basic thermal characteristics of new insulating materials and new vehicle design should be studied. Energy and environmental benefits can be obtained by the optimisation of the logistic chain. Multi-temperature vehicles and mini-containers can solve certain specific problems.     

Experimental correlation of falling film condensation on enhanced tubes with HFC134a; low-fin and Turbo-C tubes

The objectives of this paper are to develop experimental correlations of heat transfer for enhanced tubes used in a falling film condenser, and to provide a guideline for optimum design of the falling film condenser with a high condensing temperature of 59.8 °C. Tests are performed for four different enhanced tubes; a low-fin and three Turbo-C tubes. The working fluid is HFC134a, and the system pressure is 16.0 bar. The results show that the heat transfer enhancement of low-fin tube, Turbo-C (1), Turbo-C (2) and Turbo-C (3) ranges 2.8–3.4 times, 3.5–3.8 times, 3.8–4.0 times and 3.6–3.9 times, respectively, compared with the theoretical Nusselt correlation. It was found that the condensation heat transfer coefficient decreased with increasing the falling film Reynolds number and the wall subcooling temperature. It was also found that the enhanced tubes became more effective in the high wall subcooling temperature region than in the low wall subcooling temperature region. This study developed an experimental correlation of the falling film condensation with an error band of ±5%.     

A new thermoeconomic approach and parametric study of an irreversible regenerative Brayton refrigeration cycle

The detailed parametric study of an irreversible regenerative Brayton refrigerator cycle using the new thermoeconomic approach is presented in this paper. The external irreversibility is due to finite temperature difference between the cycle and the external reservoirs while the internal irreversibilities are due to the nonisentropic compression and expansion processes and the regenerative loss. The thermoeconomic objective function defined as the cooling load per unit cost is optimized with respect to the state point temperatures for a typical set of operating conditions. The power input and cooling load are found to be decreasing functions of the expansion outlet temperature (T₁), while it is the reverse in the case of COP. On the other hand, there are optimal values of the temperature T₁, cooling load, power input and COP at which the cycle attains the maximum objective function for a typical set of operating parameters. Again, the objective function, COP and cooling load further enhance, while the power input goes down, as the various values of the effectiveness or efficiency components are increased.