An experimental and theoretical investigation of refrigerant charge on a secondary loop air‐conditioning heat pump system in electric vehicles

Automotive air‐conditioning heat pump systems are particular interest worldwide in energy conservation and emission reduction for electric vehicles, hybrid electric vehicles, and fuel cell electric vehicles. Refrigerant charge amount is a key factor for the air‐conditioning heat pump system optimization affecting the condensing pressure and subcooling in both heating and cooling modes. In this paper, the influence of the refrigerant charge on system performances was investigated using the experiment method on a secondary loop air‐conditioning heat pump system. The typical heat transfer and flow parameters were recorded, and both cooling and heating performances of the system were investigated and illustrated by pressure‐enthalpy diagrams. The critical refrigerant charges were determined in both heating and cooling modes. Three typical void fraction correlation models were also applied for the refrigerant charge determination modeling as a system off‐design method. Results show that the Hughmark void fraction correlation method has the best prediction of the critical refrigerant charge in both cooling and heating modes.     

Performance of a single‐duct portable propane air conditioning system under different refrigerant charge levels

The effects of the refrigerant charge on the performance of a portable propane air conditioning system have been evaluated and compared to nonportable systems in which the surrounding temperatures of the evaporator and condenser are not equal. This study aims to determine the similarities and differences in the performance of the two types of propane air conditioners under different charge levels, and to serve as a source of reference for future designs of portable air conditioners. The refrigerant charge was changed from ?12.3% to +30% of its normal charge at several room temperatures ranging from 20 °C to 35 °C. The performance parameters include the refrigerant temperature, mass flow rate, maximum velocity of refrigerant, maximum pressure, cooling capacity, compressor work, specific cooling capacity, and coefficient of performance of the system. It has been found that an increase in charge level was found to increase the cooling capacity, coefficient of performance, and maximum velocity of refrigerant in the system while decreasing specific cooling capacity. The increase in the charge caused a relatively insignificant rise in the maximum pressure of the system and useful work of the compressor.     

分液热泵空调系统的制热性能研究

随着热泵空调的普及,热泵空调的能耗占比不断增大,其节能问题成为了关注焦点。换热器对系统性能有着重要的影响,如何通过改进换热器来提升系统性能则成为了研究的热点。其中分液冷凝器作为一种新型的换热设备,能对系统制冷性能产生积极影响。但热泵空调系统在制热工况下,分液冷凝器变成气液分离式蒸发器,其系统制热性能尚未可知。通过实验研究,调整毛细管长度和制冷剂充注量,发现在国家标准工况下分液热泵空调系统的最大制热量比原系统高4.50%,C OP比原系统高7.93%,所对应的毛细管长度为700 mm,制冷剂充注量为700 g。且制冷剂过充注的情况下,分液热泵空调系统的制热性能比较稳定。     

Investigation on the Influence of Refrigerant Charge Amount on the Cooling Performance of Air Conditioning Heat Pump System for Electric Vehicles

The application of air conditioning heat pump(ACHP) in electric vehicles could lead to significant electrical power saving effect. As for an air conditioning heat pump system for electric vehicles, the influence of refrigerant charge amount should be investigated during the design phase. In this study, experimental method was employed to investigate the influence of the refrigerant charge amount on the performance of the ACHP system. The results showed that the refrigerant charge amount had different influence on the refrigerant properties at various locations within the system. The coefficient of performance and pressure-enthalpy diagram were calculated, and showed a close relationship with refrigerant charge amount under different compressor speeds. The degree of subcooling and the degree of superheating were recorded and the critical charge amount was determined by a typical practical test method. In addition, the critical refrigerant charge amount determined by the experimental method was also compared with two typical void fraction correlation models, and the model with consideration of two phase stream reaction of the refrigerant showed a good estimation accuracy on the critical charge amount.     

Performance prediction of a refrigerating machine using R‐407C: the effect of the circulating composition on system performance

This article presents a steady‐state model of a vapour compression refrigerating machine using a ternary refrigerant mixture R‐407C. When using a zeotropic mixture in a refrigerant cycle, the circulating composition does not agree with the composition of the original charged mixture. It is mainly due to the temperature glide and the vapour–liquid slip ratio. As a result of the composition shift and its magnitude, the system performance changes depending on the system design, especially the presence of liquid receiving vessels. In this paper, a method that predicts the circulating composition has been associated to a refrigerating machine model. The results obtained with this model show an enrichment in the most volatile components of about 1% for the circulating composition, which is sufficient to decrease the system performance by about 3%. Factors affecting the overall performance have been investigated. The results show a very strong performance dependence on the refrigerant charge. The COP can decrease by 25% when the refrigerant charge is insufficient. An initial charged composition variation of 2% involves variations of the cooling capacity of about 5%. Furthermore, our model was employed to compare the performance for both R‐22 and R‐407C. The cooling capacity for R‐22 is slightly greater in comparison to R‐407C and the COP is almost constant. Copyright © 2002 John Wiley & Sons, Ltd.     

On the steady‐state modelling of a two‐stage evaporator system

We develop and validate against experimental measurements a steady‐state two‐stage flooded refrigerant evaporator model for a heat pump drying system. A prototype two‐stage heat pump dryer test facility was designed, built and instrumented to provide the required measurements for the validation of the model. Repeatability and data quality tests were conducted to evaluate the accuracy of measurements. Experimental data could be reproduced to within ±6.5 per cent of replicated air and refrigerant side measurements for the same evaporator's air inlet conditions while the discrepancy of energy balance at the air‐side and refrigerant‐side was observed to be within ±8.9 per cent. The two‐stage evaporator model predicted the air‐side total heat and latent heat transfer of the two‐stage evaporator to within (?6.3 per cent, 7.6 per cent) and (?11.5 per cent, 9.5 per cent), respectively. On the refrigerant‐side, the model enabled the calculation of the degree of superheat to within (?10.6 per cent, 1.7 per cent). The model has shown that there is significant improvement in the heat recovered from a two‐stage evaporator system compared to a single evaporator system. In addition, the model demonstrated that the improvement in total heat recovery could be as high as 40 per cent over its base‐value when the latent to total load at the two‐stage evaporator is increased. Copyright © 2001 John Wiley & Sons, Ltd.     

Simulated and experimental performance of split packaged air conditioner using refrigerant HC-290 as a substitute for HCFC-22

This paper discusses the use of propane (HC-290) as a safe and energy efficient alternative to HCFC-22 in a typical split air conditioner with nominal cooling capacities up to 5.1 kW. Initially split air conditioner performance is simulated for cooling capacity, energy efficiency ratio (EER), and refrigerant charge. Tests were conducted for different test cases in a psychrometric test chamber with HCFC-22 and HC-290. The test conditions considered are as per Indian Standards, IS 1391 (1992) Part I. The various parameters considered were based on simulated performance with the objective to achieve maximum EER for the desired cooling capacity. As the flammability is an issue for HC-290, the reduction of HC-290 charge was another objective. Two different types of condensers, first with smaller size tubing and another parallel flow condenser (PFC) or minichannel condenser were used in order to reduce HC-290 charge. For HC-290, the highest EER achieved was 3.7 for cooling capacity 4.90 kW for a refrigerant charge of 360 g.The important safety aspects of using HC-290 in air conditioner are discussed. The refrigerant charge as per EN 378 for different cooling capacities and room sizes is also considered.     

Boiling refrigerant‐type panel cooler (refrigerant circulation and cooling performance)

We have developed a new compact boiling refrigerant type panel cooler. It is a closed two‐phase loop thermosiphon constructed with heat exchanger cores for an automobile air conditioning system. We confirmed higher performance of the natural refrigerant circulation type and tried to optimize the size of the refrigerant path in the boiling core by observing the internal refrigerant flow and successfully achieved much higher cooling performance. © 2004 Wiley Periodicals, Inc. Heat Trans Asian Res, 33(2): 94–105, 2004; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20003     

变流量制冷系统循环性能稳定性的实验研究

针对变制冷剂流量(Variable Refrigerant Flow,VRF)空调系统中过热度、制冷量及性能系数(Coefficient of Performance,COP)等参数的不稳定现象,利用R32变流量制冷循环实验台,研究过热度振荡对系统参数稳定性的影响。结果表明:随着系统内制冷剂流量的增加,蒸发器内制冷剂流型迅速变化,引起换热方式的交替,过热度进入最小稳定过热度线(Minimal Stable Superheat,MSS)的不稳定区间,从而产生了过热度振荡;当过热度处于不同运行频率下的最小稳定点时,系统性能达到最佳,控制难度得到优化;系统定压比运行下,频率的增大对压缩机耗功有更直接的影响,因而导致COP与频率成反比。     

Performance characteristics of mobile heat pump for a large passenger electric vehicle

In this study, the performance of a mobile heat pump for an electric bus, which uses the wasted heat of electric devices for a heating and air source for a cooling, was evaluated. Both cooling and heating performances of the mobile heat pump were tested under various experimental conditions, and then optimized by varying the refrigerant charge and the compressor frequency. The cooling capacity at all compressor frequencies was over 23.0 kW, which is sufficient for the cooling loads of an electric bus. The heating COP decreased but the heating capacity increased with the rise of outdoor temperature and the compressor frequency. The heating COP was 2.4 at an outdoor temperature of 10.0 °C. The observed heating and cooling performance characteristics of the mobile heat pump means it could be used for cabin heating and air conditioning of an electric vehicle with a short driving range.     

Performance evaluation of ecofriendly R1234ze(E) refrigerant in an automotive air conditioning system

A mathematical model for an air conditioning system used in five-seater cars is developed with R1234ze(E) and R134a refrigerants, consisting of real system geometry like an evaporator, compressor, condenser, and thermostatic expansion valve. The mathematical model includes refrigerant properties, heat transfer, and pressure loss correlations for two-phase and single-phase regions. The performance parameters of a system like evaporator cooling duty, condenser heat loss, compressor power, refrigerant flow rate, and compressor volumetric efficiency obtained from a mathematical model are validated with the results of an experimental facility developed with R134a. The uncertainty analysis performed for the testing facility showed below 11% deviation. The simulation and experimental results showed an overall 10%–15% difference. It is found that the experimental cooling capacity with R134a and numerical cooling capacity with R134a show a 4%–12% variation, experimental cooling capacity with R134a and numerical cooling capacity with R1234ze(E) show a 7%–20% variation, and numerical cooling capacity with R134a and numerical cooling capacity with R1234ze(E) show a 5%–15% variation for the given range of compressor speed (500–1500 rpm), and condensing temperature (26–45°C). The study concluded that R1234ze(E) could potentially replace R134a because it has similar thermophysical properties and an average performance difference of up to 10% with R134a. Due to the limitations of the electric motor used to drive the compressor, tests in the current study were conducted at modest compressor speeds (500–1500 rpm). Future research will focus on experiments with high compressor speed (in the range of 1500–4000 rpm) and R1234yf and R1234ze(E) refrigerants for performance evaluation of automobile air conditioning systems.     

Analyses of an integrated thermal management system for electric vehicles

Electric vehicle thermal management system (EVTMS) is a promising method to solve cabin thermal comfort and electronics waste heat. In this paper, an integrated EVTMS combining heat pump, battery cooling, and motor waste heat recovery was proposed. EVTMS performance tests were firstly carried out in the environment chamber with variations of refrigerant charge, electronic expansion valve (EXV) opening, compressor speed, environmental temperature, and waste heat amount. Moreover, the comprehensive energy, exergy, and thermo‐economy analyses for EVTMS were performed based on the experimental results. The results demonstrate that the optimum refrigerant charge for baseline EVTMS is 810 g, and the optimum EXV opening is in the range of 70% to 90%. Accordingly, the percentage of cooling capacity reduction (PCCR) and the percentage of waste heat recovery (PWHR) are in the range of 26.3% to 32.1% and 18.73% to 45.17%, respectively. The exergy destruction ratio of the scroll compressor and external heat exchanger is more than 80%. With the utilization of the proposed EVTMS, the operation cost per hundred kilometers for heating mode is decreased 20.83% compared with that of positive temperature coefficient heaters.     

Effects of operating parameters on the performance of a CO2 air conditioning system for vehicles

This paper deals with the effects of the operating parameters on the cooling performance that can be applied for a transcritical CO₂ automotive air conditioning system. The experimental conditions of the performance tests for a CO₂ system and components such as a gas cooler and an evaporator were suggested to compare with the performance of each at the standardized test conditions. This research presents experimental results for the performance characteristics of a CO₂ automotive air conditioning system with various operating conditions such as different gas cooler inlet pressures, compressor speeds and frontal air temperatures/flow rates passing through the evaporator and the gas cooler. Experimental results show that the cooling capacity was more than 4.9 kW and coefficient of performance (COP) was more than 2.4, at each optimum pressure of gas cooler inlet during idling condition. Also, the cooling capacity was about 7.5 kW and COP was about 1.7 at the optimum pressure of gas cooler inlet during driving condition when air inlet temperatures of gas cooler and evaporator were 45 °C and 35 °C, respectively. Therefore, we concluded that the automotive air conditioning system using CO₂ refrigerant has good performance. This paper also deals with the development of optimum high pressure control algorithm for the transcritical CO₂ cycle to achieve the maximum COP.     

Thermoeconomic analysis and optimization of residential split-type air conditioners

A simulation-based optimization methodology for designing unitary residential air conditioners with focus on both energy performance enhancement and cost savings is presented. A steady-state system simulation model was put forward for a 2.5-ton nominal cooling capacity split-type air conditioning unit operating with R-410A as the working fluid. The model predictions for cooling capacity, sensible heat ratio (SHR) and coefficient of performance (COP) were compared with experimental data, when it was found that the model is able to predict the experimental trends within a ±6% error band. The model was then used to find out the condenser and evaporator geometries (face area, heat transfer area) that enhance the system COP for a fixed cost. On one hand, it was observed that the COP can be increased by 7% if the cost is held fixed. On the other hand, cost savings of 33% were achieved when the system COP was held constant.     

夏季工况条件下空调/冷柜一体机性能实验研究

空调冷柜一体机系统是通过中间冷却器将空调与冷柜耦合,可以将空调系统中的部分制冷剂节流至中间冷却器对冷柜系统中的制冷剂进行过冷以提升其系统性能。实验研究了夏季工况条件下冷柜温度、室外环境温度及质量流量比对一体机系统制冷量及COP的影响。实验结果表明:在夏季工况条件下,冷柜系统的制冷量和COP随质量流量比的增大而增大,但质量流量比大于12%后其增速放缓;空调系统制冷量随质量流量比的增大而减小,而其COP随质量流量比的增大而略有增大。综合分析认为夏季工况条件下,质量流量比控制在8%～12%时可以提高空调及冷柜系统COP,同时空调器制冷量衰减也较小。     

A review on recent developments in new refrigerant mixtures for vapour compression‐based refrigeration,air‐conditioning and heat pump units

In the present paper, an attempt has been made to review the performance of new refrigerant mixtures employed in vapour compression‐based refrigeration, air‐conditioning and heat pump units. The studies reported with refrigerant mixtures are categorized into six groups as follows: (i) hydrocarbon (HC), (ii) hydroflurocarbons (HFC), (iii) HFC/HC, (iv) hydrochloroflurocarbons (HCFC), (v) carbon dioxide (R744) and (vi) ammonia (R717). This paper explores the studies reported with new refrigerant mixtures in domestic refrigerators, commercial refrigeration systems, air conditioners, heat pumps, chillers and in automobile air conditioners. In addition, the technical difficulties faced with new refrigerant mixtures, further research needs in this field and future refrigerant options for new upcoming systems have been discussed in detail. This paper concludes that HC based refrigerant mixtures are identified as a long‐term alternative to phase out the existing halogenated refrigerants in the vapour compression‐based systems. Copyright © 2010 John Wiley & Sons, Ltd.     

Collector selection for solar ejector cooling system

The performance of a solar ejector cooling system is simulated using three different collectors: a conventional flat plate collector, a high efficiency flat plate collector and a vacuum-tube collector. It is shown that with the proper selection of the generating temperature an optimum COP can be achieved. The solar ejector cooling system using the single-glazed solar collector with selective surface and an enhanced air insulating layer can be most economical when operated at the optimum generating temperature of the ejector cooling machine. In this case, the solar system cost is around 1 USD per watt of cooling capacity for air conditioning applications.     

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.     

过冷却技术提高制冷效率的节能效果浅析

介绍了制冷剂过冷技术应用于普通空气调节系统,可提高制冷效率,挖掘节能潜力。应用过冷却技术提高制冷效率,即通过增加外部过冷却装置,在直接膨胀式蒸汽压缩空气调节装置中,具有显著的节能效果。对该技术原理和应用状况进行分析,为我国同类型中央空调系统的节能运行及改造提供一种新的思路和方案,对建筑节能改造具有积极的推进作用。