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.     

Experimental investigation of oil retention in air conditioning systems

In air conditioning and refrigeration systems a small amount of oil is carried with the refrigerant and is retained in the system components. Oil retention characteristics in the condenser, evaporator, liquid and suction lines were measured and are presented and discussed here. Refrigerants R22, R410A, and R134a with miscible and non-miscible lubricants were considered to investigate oil retention physics in the widest possible range of transport properties. A parametric analysis in the suction line showed that oil retention depends on the oil mass fraction, vapor refrigerant mass flux, mixture viscosity ratio and orientation of the pipe. In the suction line, an increase in mixture viscosity of about 55% caused a rise in oil retention in the range of 50%, depending on the oil mass fraction. Oil retention in the upward vertical suction line is about 50% higher than in the horizontal line at similar conditions.     

Experimental investigation and numerical simulation on the hysteresis zone of a variable displacement wobble plate compressor

A test system with the variable displacement compressor (VDC) for automotive air conditioning system is built to study the changing rule of piston stroke length (PSL). It is found from our experiments that the critical suction pressure where the PSL starts to decrease is less than that where the PSL starts to increase for the same PSL; between the two critical lines, a hysteresis zone is formed, within which all the steady-state points fall and there is a multiple-valued relationship between VDC parameters; and the PSL is kept invariable when the VDC parameters change within the hysteresis zone. In order to find out the reason causing the hysteresis zone and to analyze the influence of the compressor parameters on the hysteresis zone, a steady-state mathematical model of VDC is developed and verified by our experimental data. The theoretical analysis indicates that the hysteresis zone is caused by the frictional forces among the moving components of VDC, and the greater the frictional forces, the broader the hysteresis zone and the larger the changing range of suction pressure. The influence of the discharge pressure and rotary speed on the hysteresis zone is that the hysteresis zone moves in the direction of the suction pressure decreasing along with the increase of the discharge pressure or rotary speed.     

Modeling and experimental evaluation of an automotive air conditioning system with a variable capacity compressor

A steady state computer simulation model has been developed for refrigeration circuits of automobile air conditioning systems. The simulation model includes a variable capacity compressor and a thermostatic expansion valve in addition to the evaporator and micro channel parallel flow condenser. An experimental bench made up of original components from the air conditioning system of a compact passenger vehicle has been developed in order to check results from the model. The refrigeration circuit was equipped with a variable capacity compressor run by an electric motor controlled by a frequency converter. Effects on system performance of such operational parameters as compressor speed, return air in the evaporator and condensing air temperatures have been experimentally evaluated and simulated by means of developed model. Model results deviate from the experimentally obtained within a 20% range though most of them are within a 10% range. Effects of the refrigerant inventory have also been experimentally evaluated with results showing no effects on system performance over a wide range of refrigerant charges.     

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.     

An experimental investigation and modelling of the thermodynamic properties of isobutane–compressor oil solutions: Some aspects of experimental methodology

This paper presents experimental data for the solubility, density and capillary constant for solutions of natural refrigerant isobutane with commercial mineral compressor oil Azmol over a wide range of temperatures and concentrations. Based on information for the capillary constant, the surface tension of the solutions isobutane/Azmol is determined. The experimental data were obtained in the temperature range from 303 K to 363 K and at pressures up to 1.7 MPa using static methods. The experimental data obtained for the solutions of the natural refrigerant isobutane with the commercial mineral compressor oil Azmol are sufficiently described with the help of correlations based on the theory of thermodynamic similarity. The paper reports variation of the vapor pressure, density, capillary constant and surface tension as a function of concentration for the isobutane/Azmol solutions. The enthalpy of liquid phase of the isobutane/Azmol solutions is calculated. The analysis of the behaviour of the excess thermodynamic functions is carried out. The paper examines experimental and methodical uncertainties in the investigation of thermodynamic properties of the refrigerant/oil solutions (ROS). The influence of the time taken to establish thermodynamic equilibrium in the experimental cell on the uncertainty of the experimental data for gas-saturated mixtures such as ROS is discussed. Information about the changing concentration of refrigerant in the liquid phase of the ROS and in the surface layer of the liquid phase of the ROS at increasing temperature is presented. In addition, the experimental data for the density, surface tension and refractive index of the mineral compressor oil Azmol are reported.     

Influences of miscible and immiscible oils on flow characteristics through capillary tube—part I: experimental study

A capillary tube is widely used as an expansion device for small refrigeration cycles. In a practical refrigeration cycle, some amount of refrigeration oil is discharged from a compressor and refrigerant/oil mixture flows through the capillary tube. This study investigated experimentally the influence of mixing of the refrigeration oil with the refrigerant on the flow through the capillary tube. The experiments are carried out with not only a miscible combination of refrigerant and oil but also an immiscible combination. In both cases, the mass flow rate through the capillary tube and temperature and pressure distributions along the tube are measured under several conditions of subcooled degree and oil concentration. In the case of miscible combination, the mass flow rate of refrigerant decreases with increasing the oil concentration because the viscosity of liquid phase increases by the mixing of viscous oil. Even in the case of the immiscible combination, the oil droplet is so small that it mixes homogeneously in the liquid phase in the capillary tube and the refrigerant mass flow rate decreases by the mixing of immiscible oil. There is no significant influence of the oil concentration on the underpressure, which means pressure difference between saturation pressure and flash inception pressure, in both miscible and immiscible combinations.     

Modeling absorption of pure refrigerants and refrigerant mixtures in lubricant oil

This paper addresses the problem of absorption of refrigerant vapor in a stagnant layer of lubricant oil. The bulk motion of the solute is described in terms of apparent diffusion coefficients that encompass both molecular diffusion and possible macroscopic motion induced by liquid density instability and surface tension. In absorption of refrigerant mixtures, diffusion in the vapor and liquid phases are coupled with a thermodynamic model for interfacial equilibrium. Results are compared with experimental data available in the literature for absorption of several refrigerants in polyol ester oil (POE68). The adequacy of the formulation is assessed in the light of its basic assumptions and performance of the model.     

Pressure-viscosity coefficient of a refrigerant-oil mixture: Coefficient pression-viscositéd'un mélange frigorigène-huile

A coaxial cylinder viscosimeter has been used to determine the pressure-viscosity coefficient of a pure refrigeration oil and of a mixture of refrigerant and oil at gauge pressures up to 15 MPa. The test fluid, Gargoyle Arctic oil 300, is a naphthenic-base oil. The refrigerant was R22, chlorodifluoromethane, which is a commercially important refrigerant. In a gap apparatus the refrigerant-oil mixture has been visually inspected at different pressures. Two different mechanisms are involved in the refrigerant-oil mixture: the change in solubility with pressure and the change in viscosity with refrigerant concentration. If the mixture is pressurized with excess refrigerant available then the concentration of refrigerant will increase with increasing pressure and therefore the viscosity will decrease. If the concentration is kept at a constant level then the viscosity will increase with pressure. The results from the cylinder viscosimeter showed that the viscosity increase with pressure for the mixture was almost the same as for the pure oil.     

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.     

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.     

Cooling performance of several CO2/propane mixtures and glide matching with secondary heat transfer fluid

This paper presents the cooling performance of several CO₂/propane mixtures measured in air-conditioning test rig at several conditions. The discharge pressure of CO₂/propane mixtures is reduced with increasing mole fraction of propane and their reduced values coincide approximately with the circulation concentrations of propane. Since propane is the refrigerant having a higher refrigerating effect and a much lower vapor density than CO₂, adding propane to CO₂ improves the system efficiency and reduces the cooling capacity. The temperature glide effect of CO₂/propane mixtures on the cooling performance was analyzed based on the experimental data. To utilize the temperature glide effect successfully, a sufficient heat exchange area is required, and the temperature gradient of refrigerant must be similar to that of secondary heat transfer fluid. It is better the temperature change of refrigerant can prevent pinching with that of the secondary heat transfer fluid.     

Flash gas bypass for improving the performance of transcritical R744 systems that use microchannel evaporators

The performance of transcritical R744 systems with direct expansion (DX) can be significantly improved by implementing a Flash Gas Bypass (FGB). The idea behind the concept is to bypass refrigerant vapor, created during the isenthalpic expansion process, around the evaporator. By feeding the evaporator with liquid refrigerant, pressure drop is reduced and refrigerant distribution is improved. With R744 as the working fluid, increased refrigerant-side heat transfer coefficients are expected as well. In addition, the FGB concept proves to be beneficial in terms of system design, in particular for combined air-conditioning and heat pumping applications. An experimental comparison to a conventional DX-system reveals that FGB increases the cooling capacity and COP at the same time by up to 9 and 7%, respectively. Even larger improvements are possible in case a variable speed compressor is utilized to match the performance of the conventional DX-system. A simulation model helps to separate the individual improvement mechanisms. It was found that the reduction of refrigerant-side pressure drop is the dominant improvement mechanism of FGB.     

Performance investigation of a variable speed vapor compression system for fault detection and diagnosis

An experimental study has been performed to investigate the effect of four artificial faults on the performance of a variable speed vapor compression system. Experimental setup to test several artificial faults was made by modifying the conventional vapor compression test rig. Four major faults of compressor fault, condenser fault, evaporator fault, and refrigerant leakage, were implemented by observing the variation of cooling capacity. Two different rule-based modules for constant and variable speed operations were organized for an easy diagnosis of system faults. These two modules were applied differently as the cooling capacity satisfies the necessary air conditioning load. As a result, COP degradation due to the fault in a variable speed system is severer than that in a constant speed system.     

An investigation of the performance of a scroll compressor under liquid refrigerant injection

In this study, fundamental and practical influence of liquid refrigerant injection on the performance of a refrigerant scroll compressor has been investigated experimentally and theoretically. In the theoretical analysis, a compression model of vapor/liquid mixture is developed by taking account of heat transfer from the cylinder wall to suction, compression and injection refrigerant. An experiment has been done under the condition of keeping the oil temperature constant in order to investigate the fundamental influence of the liquid refrigerant injection on the compressor performance, and the results were compared with the theoretical ones. It was found that the injection basically increases the compression power and decreases the compressor efficiency, though the situation depends on the condition of the heat transfer to the injection refrigerant. And furthermore, the performance of the liquid refrigerant injection compressor under practical operating condition without controlling the oil temperature has been investigated. Under this condition, the compressor showed recovery and slight improvement of performance due to the decrease of the oil and cylinder temperatures by the injection. In addition, influence of the refrigerant injection on the oil viscosity and refrigerant solubility in the oil, which relate mechanical loss and reliability of the compressor, have been discussed.     

Experimental results for a hydraulic refrigeration system using n-butane

The hydraulic refrigeration system (HRS) is a vapor-compression system that accomplishes the compression and condensation of the refrigerant in a unique manner, by entraining refrigerant vapor in a down-flowing stream of water and utilizing the pressure head of the water to compress and condense the refrigerant. A multi-stage HRS was designed, fabricated, and tested using n-butane as the refrigerant. In general, both the refrigeration rate and the coefficient of performance (COP) increased with a corresponding decrease in the compression fluid temperature of the third and final stage. The refrigeration rate and COP were also found to increase with a corresponding increase in evaporator temperature. The predictions of an enhanced model incorporating two-phase hydraulic losses show excellent agreement with the experimental data with a maximum error of ±20%. The results of the experimental investigation indicate that the HRS offers an attractive and feasible alternative to conventional vapor-compression systems, especially in applications where direct-contact heat exchange in the evaporator is desirable.     

Reducing running costs in air conditioningRéduire les coûts de fonctionnement en conditionnement d'air

Previous studies using wide-boiling refrigerant mixtures were reported in the literature as a method of reducing power consumption in air conditioning. A novel air conditioning test unit incorporating this concept was tested at the Department of Chemical Engineering at Leeds University. Experimental tests with a refrigerant mixture, R407C, produced COPs in excess of 4. Also, a simulation program was used to model the behaviour of other mixtures. It yielded a COP of about 5 for mixture R32/R134a. A financial study was made to calculate the total annual costs of a unit using R32/R134a. It showed that annual savings of up to 41 per cent were possible compared to a unit using R134a.     

Performance analysis and simulation of automobile air conditioning systemAnalyse de la performance et simulation d'un système de conditionnement d'air automobile

Performance analyses of separate components of an automobile air conditioning system have been carried out under various operating conditions. The air conditioning system consists of a laminated type evaporator, a swash plate type compressor, a parallel flow type condenser, a receiver drier and an externally equalized thermostatic expansion valve. A computer program for performance analysis of the laminated type evaporator has been developed on the basis of the overall heat transfer coefficient and pressure drop which were obtained experimentally. A computer program for performance analysis of the parallel flow type condenser, using an empirical equation for the heat transfer coefficient, has been developed, which demonstrates that the predicted condensing capacity agrees very well with the experimental data. Then, a model for combining the performance analysis programs of separate components of an automobile air conditioning system is proposed, which simulates very well the performance of the integrated automobile air conditioning system. Further, the effects of condenser size and refrigerant charge on the performance of the integrated automobile air conditioning system are discussed.     

多联式空调制冷系统动态仿真研究

为了研究多联机制冷系统的动态性能,建立了基于简化气液两相流体网络的多联式空调制冷系统动态仿真模型.其中,压缩机和电子膨胀阀采用稳态模型,蒸发器和冷凝器采用移动边界动态仿真模型,气液分离器采用动态模型.采用Matlab和Simulink为仿真工具,对多联机动态仿真模型进行求解,并通过一套具有四台室内蒸发器的多联机系统的实验结果进行验证和改进.结果表明,该动态仿真模型能够准确预测多联机动态过程的变化趋势,并保持很高的计算精度,蒸发温度、冷凝温度和过热度的误差都在1.0℃左右,排气温度误差小于3.0℃,可以用于多联机动态性能分析,并可作为开发和优化多联机控制策略和控制算法的有效工具.     

Equipment design and installation features to disperse refrigerant releases in rooms—part II: determination of procedures

There is always a risk of leakage of refrigerant into a room that refrigeration and air conditioning equipment occupies. Mitigation of build-up of flammable concentrations from leakage through appropriate equipment construction and installation criteria minimises the potential for ignition. This paper is the first part of an investigation into design and installation measures to disperse leaked flammable refrigerant. It mainly describes the experiments and provides an analysis of the data. The paper describes a purpose built test facility, which was used to carry out experiments to study the dispersion of carbon dioxide to simulate leaked refrigerant. By measuring carbon dioxide concentrations and making flow visualisation, the effects of parameters such as equipment airflow and installation height were observed. The observed trends provide guidance for designing refrigeration and air conditioning equipment, which helps to ensure rapid dispersion of flammable concentrations in the event of a leak of flammable refrigerant. A second paper (Part II) discussed the development of numerical correlations, which are used in the resulting design procedure.