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

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

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

CO2 heat pump systems

After the CFCs and the HCFCs were deemed unfit as working fluids in refrigeration, air conditioning, and heat pump applications, there has been a renaissance for carbon dioxide technology. Heat pumps is one of the application areas where theoretical and experimental investigations are now performed by an increasing number of research institutions and manufacturers. This paper gives an overview of some of the current activities in the CO₂ heat pump field. Discussed are the important characteristics of the transcritical CO₂ process applied to heat pumps, and also discussed are theoretical and experimental results from several heat pump applications. Provided that calculations and system designs are performed on the premises of the working fluid, and that test plants are constructed and operated to fully exploit the specific characteristics of both the fluid and the transcritical process, the results show that CO₂ is an attractive alternative to the synthetic fluids. Competitive products may be launched in the near future.     

Fan-less heat exchanger concept for CO2 heat pump systems

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

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

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

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

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

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

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

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

Experimental investigation of a CO2 automotive air conditioner

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

Study of capillary tubes in a transcritical CO2 refrigeration system

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

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

Modelling the performance of a transcritical CO2 heat pump for high temperature heating

A prototype transcritical CO₂ heat pump was constructed for heating water to temperatures greater than 65°C while providing refrigeration at less than 2°C. The heating capacity was 115 kW at an evaporation temperature of +0.3°C and a hot water temperature of 77.5°C, with a heating coefficient of performance (COP) of 3.4. Performance data is presented for each of the compressor, the gas cooler, and the recuperator as well as for the overall heat pump system. Equipment performance data was incorporated into a computer model to enable parametric investigations of heat pump performance. Model predictions showed that the hot water temperature could be increased from 65 to 120°C with a relatively small reduction in heating capacity and heating COP of 33 and 21%, respectively. Model predictions also highlight the potential for significant capacity improvements by eliminating the recuperator in favour of a larger gas cooler.     

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

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

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

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

Optimized transcritical CO2 heat pumps: Performance comparison of capillary tubes against expansion valves

A capillary tube based CO₂ heat pump is unique because of the transcritical nature of the system. The transcritical cycle has two independent parameters, pressure and temperature, unlike the subcritical cycle. In the present study, a steady state simulation model has been developed to evaluate the performance of a capillary tube based transcritical CO₂ heat pump system for simultaneous heating and cooling at 73 °C and 4 °C, respectively against optimized expansion valve systems. Capillary tubes of various configurations having diameters of 1.4, 1.5 and 1.6 mm along with internal surface roughness of 0.001–0.003 mm have been tested to obtain the optimum design and operating conditions. Subcritical and supercritical thermodynamic and transport properties of CO₂ are calculated employing a precision in-house property code.

It is observed that the capillary tube system is quite flexible in response to changes in ambient temperature, almost behaving to offer an optimal pressure control. System performance is marginally better with a capillary tube at higher gas cooler exit temperature. Capillary tube length turns out to be the critical parameter that influences system optimum conditions. A novel nomogram has been developed that can be employed as a guideline to select the optimum capillary tube.     

The performance of a transcritical CO2 cycle with an internal heat exchanger for hot water heating

The main purpose of this study is to investigate the performance of a transcritical CO₂ cycle with an internal heat exchanger for hot water heating. Performance test and simulation have been carried out for a transcritical CO₂ cycle by varying secondary heat transfer fluid temperatures at evaporator and gas-cooler inlets as well as the discharge pressure. Variations of mass flow rate of refrigerant, compressor power, heating capacity, and co-efficient of performance (COP) with respect to the length of an internal heat exchanger are presented at various operating conditions. Good quantitative agreement between model predictions and experimental results has been found; most parameters have absolute average deviations of less than 4%. As the length of the internal heat exchanger increases, COP is enhanced but heating capacity tends to decrease due to the trade-offs between the effectiveness and pressure drop in the internal heat exchanger.     

Propane heat pump with low refrigerant charge: design and laboratory tests

Independently of the choice of refrigerant, environmental and or safety issues can be minimised by reducing the amount of refrigerant charge per heat pump or refrigeration system. In the investigation reported here, a laboratory test rig was built, simulating a water-to-water heat pump with a heating capacity of 5 kW. The system was designed to minimize the charge of refrigerant mainly by use of mini-channel aluminium heat exchangers. It was shown that the system could be run with 200 g of propane at typical Swedish operating conditions without reduction of the COP compared to a traditional design. Additional charge reduction is possible by selecting proper compressor lubrication oils or by using a compressor with less lubrication oil.     

Performance evaluation of a CO2 heat pump system for fuel cell vehicles considering the heat exchanger arrangements

A novel CO₂ heat pump system was provided for use in fuel cell vehicles, when considering the heat exchanger arrangements. This cycle which had an inverter-controlled, electricity-driven compressor was applied to the automotive heat pump system for both cooling and heating. The cooling and heating loops consisted of a semi-hermetic compressor, supercritical pressure microchannel heat exchangers (a gas cooler and a cabin heater), a microchannel evaporator, an internal heat exchanger, an expansion valve and an accumulator. The performance characteristics of the CO₂ heat pump system for fuel cell vehicles were analyzed by experiments. Results for steady and transient state performance were provided for various operating conditions. Furthermore, experiments to examine the arrangements of a radiator and an outdoor heat exchanger were carried out by changing their positions for both cooling and heating conditions. The arrangements of the radiator and the outdoor heat exchanger were tested to quantify cooling/heating effectiveness and mutual interference. The improvement of heating capacity and coefficient of performance (COP) of the CO₂ heat pump system was up to 54% and 22%, respectively, when using preheated air through the radiator instead of cold ambient air. However, the cooling capacity quite decreased by 40–60% and the COP fairly decreased by 43–65%, for the new radiator-front arrangement.     

Thermodynamic analysis and experimental investigation of a CO2 household heat pump dryer

Carbon dioxide is regarded as an optimal working fluid for heat pump dryers. The transcritical cycle well fits the closed-loop drying process which requires dehumidification and re-heating according to high temperature lift of the air stream.In this paper, the transcritical CO₂ cycle is compared with a sub-critical R134a cycle. The theoretical analysis is based on fixed temperature approach values at the heat exchangers. The study considers optimal high pressure for the transcritical cycle and optimal refrigerant subcooling for the sub-critical cycle. The theoretical analysis investigates the energy performance of the thermodynamic cycle as a function of the temperature and mass flow rate of the drying air. The optimisation of the operating conditions for CO₂ involves lower air temperature than in the case of R134a; this conditions can be satisfied by a suitable design of the appliance, whose thermal balance is achieved when the dissipated heat corresponds to the work spent by the compressor and the fan; the air temperature is a floating variable that adjusts its value to comply with the thermal balance. Experimental results, conducted on a prototype, give a positive assessment for CO₂ as working fluid for heat pump dryers: a negligible decrease in the electric power consumption, with a limited (+9%) increase in the cycle time, is shown in comparison with the reference R134a heat pump dryer.     

Heating performance enhancement of a CO2 heat pump system recovering stack exhaust thermal energy in fuel cell vehicles

A CO₂ heat pump system using recovered heat from the stack coolant was provided for use in fuel cell vehicles, where the high temperature heat source like in internal combustion engine vehicles is not available. The refrigerant loop consists of an electric drive compressor, a cabin heater, an outdoor evaporator, an internal heat exchanger, an expansion valve and an accumulator. The performance characteristics of the heat pump system were investigated and analyzed by experiments. The results of heating experiments were discussed for the purpose of the development and efficiency improvement of a CO₂ heat pump system, when recovering stack exhaust heat in fuel cell vehicles. A heater core using stack coolant was placed upstream of a cabin heater to preheat incoming air to the cabin heater. The performance of the heat pump system with heater core was compared with that of the conventional heating system with heater core and that of the heat pump system without heater core, and the heat pump system with heater core showed the best performance of the selected heating systems. Furthermore, the coolant to air heat pump system with heater core showed a significantly better performance than the air to air heat pump system with heater core.     

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

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

Circulation concentration of CO2/propane mixtures and the effect of their charge on the cooling performance in an air-conditioning system

CO₂ and propane mixtures are considered as alternative refrigerants due to their negligible direct global warming potentials and favorable thermodynamic properties. To properly evaluate the system performance using zeotropic mixtures, the circulation concentration was measured and the cause for its shift from the charged concentration was discussed. The circulation concentration of CO₂/propane mixtures has increased CO₂ fraction than its charged concentration. In addition, the effect of refrigerant charge on the cooling performance was tested for the transcritical cycle of CO₂ and the subcritical cycle of CO₂/propane mixtures of 75/25 and 60/40 by the charged mass percentage. It is shown that CO₂ refrigeration system could operate without a significant impact on its COP over a relatively wider range from the optimum charge.     

Two-stage transcritical carbon dioxide cycle optimisation: A theoretical and experimental analysis

The aim of this paper is to investigate, both experimentally and theoretically, the potential of improving the cycle efficiency through two stage compression with intermediate cooling, at operating conditions typical of air conditioning. The experimental set-up consists of two closed loop air circuits acting as heat sink and heat source for gas-cooler and evaporator, respectively. The tested refrigerating circuit includes two tube-and-fin heat exchangers as gas-cooler and evaporator, a back-pressure valve as throttling device and a double-stage semi-hermetic compound, two-piston, reciprocating compressor equipped with oil separator and intercooler. A full set of thermocouples, pressure transducers and flow-meters allows measurement of all the main parameters of the CO₂ cycle, enabling to perform heat balance both air and refrigerant side. Tests were run at fixed evaporation pressure, evaporator outlet superheating and gas-cooler outlet temperature, varying the gas-cooler outlet pressure in the range 8–11 MPa. The optimal gas-cooler pressure for this application as well as the effect of the intercooler efficiency on the cycle performance were investigated.

A FORTRAN code for the simulation of an improved two-stage cycle was validated against the experimental results; a theoretical analysis performed with this code is proposed for optimisation and energy performance evaluation of such a cycle.     

Optimization of a CO2–C3H8 cascade system for refrigeration and heating

Conventional working fluids (refrigerants) are being phased out worldwide to combat with the twin menace of ozone layer depletion and global warming and natural refrigerants are fast gaining favour lately. Single stage and multi stage refrigeration systems fail to widen the gap between heat source and heat sink temperatures required in many industrial applications requiring simultaneous heating and cooling and cascaded systems appear to be the best alternative. Modest research has been done in cascaded systems based on natural refrigerants thereby offering good potential for research. In this paper, a cascaded system for simultaneous heating and cooling (refrigeration and heat pump system) with a carbon dioxide based HT cycle and propane based LT cycle for simultaneous refrigeration and heating applications has been analyzed. To facilitate prediction of optimum performance parameters, performance trends with variation in the design parameters and operating variables have been presented in this article. Relevant expressions have been developed to serve as guidelines to the user for selecting appropriate design parameters like intermediate temperature so that the system yields optimum performance. Independently developed property codes have been employed for both carbon dioxide and propane for higher accuracy.     

Experimental study of the gravity effect on the distribution of refrigerant flow in a multi-pass condenser

Gravity in multi-pass condensers affects the refrigerant flow rate distribution, owing to the gravitational pressure drop that occurs mainly in the U-bend tubes in fin and tube condensers with horizontal tubes. This effect was studied using an experimental approach. A condenser with two ‘nU’ circuits was selected, and the temperature variation of the refrigerant side was measured and compared along each circuit. The critical air velocity, which indicated the initiation of the gravity effect, was found for a given refrigerant flow rate. As the air velocity increased beyond the critical air velocity, the gravity effect (or mal-distribution of the refrigerant flow) developed further. Similarly, the critical refrigerant flow rate was also determined for a given air velocity. As the refrigerant flow rate decreased below the critical refrigerant flow rate, the gravity effect also developed further. The gravity-affected region was shown in the table with rows of air velocities and columns of refrigerant flow rates, and expressed using a single parameter for a given refrigerant flow circuit.