Engineering topics

Shen, Bo

Publications and source records attributed to Shen, Bo.

At least 91 records · Page 5

DOE OSTI2021

Optimization of Refrigerant Compositions for Low-GWP Refrigerant Mixtures Using Segment-by-segment Heat Exchanger and Detailed System Models

The recently introduced hydrofluoroolefin (HFO) refrigerants, including R1234yf and R1234ze(E), have significantly lower global warming potentials (GWPs) than traditional hydrofluorocarbon (HFC) refrigerants like R410A. However, prior tests show that direct drop-in of pure R1234yf or R1234ze(E) into equipment designed for R410A results in a decrease in heat exchanger capacity and the system coefficient of performance. The primary reason is the lower in-tube heat transfer performance of R1234yf and R1234ze(E) compared with that of R410A. To address this issue, previous studies have mixed the mildly flammable HFC R32 with HFOs to improve system performance, with HFC R125 also added to suppress flammability. Previous studies selected compositions based on simple cycle analyses and did not consider modifications of the heat exchanger circuitry configuration to adapt to the new refrigerants. This study presents a novel multi-objective optimization approach to design a refrigerant composition that maximizes energy efficiency within flammability and GWP limits. The approach in this work simultaneously optimizes mixture composition and heat exchanger circuitry configuration. A case study on a rooftop unit indicates that, compared with mixture-only optimization, simultaneous optimization of mixture and heat exchanger circuitry yields a 5.9% improvement in cycle efficiency and a 48.6% reduction in refrigerant flammability with a GWP of 268. Circuitry optimization using refrigerants with different temperature glides shows that the larger the temperature glide is, the larger EER improvement is obtained. The results show that zeotropic blends with a large temperature glide are more sensitive to the refrigerant circuitry than pure refrigerants and may suffer significant performance degradation with subpar heat exchanger circuitry design. The proposed optimization approach is generally applicable to mixtures with any number of components. Using this approach to design a HVAC system can yield higher system efficiency within flammability and GWP constraints.

Li, Zhenning↗

DOE OSTI2021

Suitable low Global Warming Potential (GWP) refrigerants for two-speed Heat Pumps for residential applications based on speed Heat Pumps for residential applications based on simulated performance simulated performance

Cold climate Heat Pumps (CCHPs) using single-speed compressors in tandem have been successfully built and tested to reach its performance metrics with outdoor temperatures as low as -25°C. CCHPs must be designed to alleviate the problems of too high discharge temperatures, low suction pressure and high-pressure ratio at low ambient conditions and insufficient heating capacity relative to the heating capacity at 8.3°C. In this paper we recognize those concerns. Low-GWP refrigerants are screened based on the shape of their T-S saturation boundary. Simulations of the performance of low-GWP refrigerants (R32, R454B, R466A, and R452B) relative to R410A is done using the DOE/ORNL Heat Pump Design Model at the component level. Systemic inefficiency, the root cause of lost work, is addressed by component-level exergy analysis to refine design options. CCHPs using low-GWP refrigerants addresses issues of reducing energy consumption, lowering carbon footprint, and enabling environmentally sustainability. The CCHP was designed to meet a HSPF > 11.0 and SEER > 15.0 having adequate heat pump heating capacity down to -25°C. It is estimated that at least 2.6 million U.S homes using electric furnaces and heat pumps in cold or very old climates with an annual energy consumption of 0.17EJ would benefit by CCHPs.

Ally, Moonis↗

DOE OSTI2021

Residential Split Heat Pump Using Low GWP Refrigerants

Conventional refrigerants, e.g. R-410A have high global warming potentials (GWP) > 1800. They are being phased out to protect the environment. The candidates to replace R-410A include R-32, R-452B, R-454B and R-466A for heat pump applications. These candidates are intended for drop-in replacement, i.e. having minimum modifications on existing systems. The paper investigates the low GWP refrigerants drop-in application via system simulations using a well-regarded, hardware-based heat pump model. A baseline heat pump having all fin-and-tube heat exchangers and a two-speed compressor was used. Cross-comparisons were made under rated conditions of ambient temperatures, compressor speeds, indoor air flow rates, respectively for cooling and heating operations. The seasonal performance indices, i.e. SEER and HSPF are presented.

Shen, Bo↗

DOE OSTI2021

Model-based Design Optimization to Achieve the Performance Goals (16.0 SEER/9.5 HSPF), Developing Heat Pump by Using Low-GWP Refrigerants and 5 mm Diameter Tubes

Usage of low-GWP refrigerants can reduce the Green House Gas (GHG) emission of HVAC systems. Our research in previous milestone report has shown that using heat exchangers with 5 mm diameter tubes instead of 9 mm diameter tubes is a promising solution to meet the performance goals of heat pump using low-GWP refrigerants. In addition, the 5mm tube heat exchangers can lead to lower system refrigerant charge and as a result, reduce environmental impact further. However, shifting to small tube diameters requires in-depth heat exchanger design optimization to adapt to the transition to low-GWP refrigerants. In the 2nd quarter of FY21, we conducted multi-objective optimizations using Particle Swarm Optimization algorithm on a residential 5-ton air source heat pump to investigate the potential system performance improvements and material savings. 4 low-GWP refrigerants, ARM20A, ARM20B, R454A and R454C are investigated in this study. The objectives of the optimization are to minimize the heat pump material cost and to maximize the system performance simultaneously. As a result, the HXs material cost is reduced by up to 77% according to the copper and aluminum material price in current market. Under heating mode operation, the smart 4-way valve guarantees that the optimal low-GWP systems maintain or outperform the heating performance of the R410A baseline system. The model-based design optimization yields 18.3-18.9 SEER and 10.6-11.9 HSPF for optimal systems using different low-GWP refrigerants. The initial performance goals (16.0 SEER/9.5 HSPF) are achieved. Furthermore, up to 50% system refrigerant charge reduction is possible in the optimized low-GWP heat pump system using ARM20B. And 91%-95% predicted life-time direct CO 2 emission reduction is achieved by using the optimal 5mm tube low-GWP heat pumps. The significant material saving, charge reduction and direct CO 2 emission reduction help in reducing the environmental impacts of heat pump systems. The optimal heat exchangers resulting from this research can fit into the original baseline indoor and outdoor fan-coil unit. This can reduce the retrofitting effort by minimizing the change in manufacturing and installation of the heat pumps and guarantee the compatibility with end-users’ house structure. Finally, the new products can be easily accepted by manufacturers and end-users.

42 ENGINEERING↗

DOE OSTI2021

Perform Life Cycle Energy and GHG Emission Analysis, Select Candidate Refrigerant(s), Developing Heat Pump by Using Low-GWP Refrigerants and 5 mm Diameter Tubes

Reducing environmental impacts from the energy conversion systems has been an important research topic due to recent severe global climate changes. In residential buildings, the space heating and cooling are main energy consumers, which are relying on vapor compression based heat pumps. To mitigate the environmental impacts of residential systems, the heat pumps using low-GWP refrigerants and 5mm-tube heat exchangers are proposed to replace the conventional 9 mm or 7 mm tube heat exchangers. This research uses a simulation-based design method to optimize the refrigerant circuitries of a 5-ton low-GWP refrigerant heat pumps whose indoor and outdoor heat exchangers adopt 5 mm tubes. Heat pump systems using four commercially available low-GWP refrigerants (R454A, R454C, ARM20A and ARM20B) are optimized and compared with the baseline R410A system. The results indicate that directly replacing 9 mm tubes into 5mm tubes in the baseline systems induces heat pump performance degradation; by optimizing the 5 mm tube heat pumps with added tube rows, the system refrigerant charge is reduced up to 33% compared with the baseline; the optimized low-GWP 5 mm tube heat pumps offer the same or higher performance under both cooling and heating mode; that under cooling mode, the EER improvement is up to 10.7% and under heating mode the COP improvement is up to 3.4%; and a smart flow control device to maintain counter-flow circuitry pattern on both operating modes can improve the heating performance of 5 mm tube optimized system by up to 3.0%. In an effort to better understand the environmental impacts of these systems, life cycle climate performance (LCCP) evaluation method is used to assess the baseline and optimized systems. LCCP considers the direct and indirect emissions of the system over the course of its lifetime from manufacturing to disposal. Our analyses indicate that the optimized systems using 5mm tubes and low-GWP refrigerants can reduce life-cycle CO 2 emission significantly. And improving system efficiency is the most effective way to reduce the emission of low-GWP refrigerant systems. This report shows that using 5 mm diameter tubes in heat exchangers is a feasible approach to develop heat pumps with low-GWP refrigerants. Using the proposed design approach can yield higher system efficiency with lower environmental impact.

42 ENGINEERING↗

DOE OSTI2021

Multi-objective optimization of low-GWP mixture composition and heat exchanger circuitry configuration for improved system performance and reduced refrigerant flammability

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Energy and Exergy Analysis of Low-Global Warming Potential Refrigerants as Replacement for R410A in Two-Speed Heat Pumps for Cold Climates

Heat pumps (HPs) are being developed with a new emphasis on cold climates. To lower the environmental impact of greenhouse gas (GHG) emissions, alternate low global warming potential (GWP) refrigerants must also replace the exclusive use of the refrigerant R410A, preferably without re-engineering the mechanical hardware. In this paper, we analyze the performance of four low-GWP alternative refrigerants (R32, R452B, R454B, and R466A) relative to the conventional R410A and draw conclusions on the relative performances for providing heating in cold climates based on the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) 210/240 standard for two-speed heat pumps. The simulations are carried using the Department of Energy, Oak Ridge National Laboratory (DOE/ORNL) Heat Pump Design Model (HPDM), a well-known heating, ventilation, and air conditioning (HVAC) modeling and design tool in the public domain and the HVAC research and development community. The results of the simulation are further scrutinized using exergy analysis to identify sources of systemic inefficiency, the root cause of lost work. This rigorous approach provides an exhaustive analysis of alternate low-GWP refrigerants to replace R410A using available compressors and system components, without compromising performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Hydrodynamic behavior of wrapped coil water heater tank

In this work, a numerical investigation using computational fluid dynamics (CFD) has been carried out to analyze the thermal behavior of a water tank integrated to a heat pump water heating system (HPWH). The heat pump condenser is a long coil wrapped around the water tank and insulated from outside from which heat is transferred from the heat pump cycle into the water stored inside the tank. The simulated water tank has a capacity of about 170 L with the charging inlet located at the bottom segment of the tank and the discharging outlet located at the top segment of the tank like commercially available water heaters. The tank was simulated during charging/discharging process with isothermal boundary condition at the tank wall to represent the majority of the process for refrigerant condensation inside the heat pump condenser (excluding superheated and sub-cooled section). Three flow rates were selected to represent low, medium and high flow pattern. Both mean and turbulent flow properties were calculated and analyzed. Heat transfer mechanisms inside the tank are quantified by calculating Richardson and Péclet numbers to show the relative contribution of driving forces. The calculations show that advection is dominant over diffusion. Mixing factor is calculated and presented. It is found that the rate of increase of mixing is nonlinear with the increase in flow rate. Mixing increased by a factor of four when the flow rate increased by a factor of two.

stratification↗

DOE OSTI2020

Virtual Pressure Sensor for Electronic Expansion Valve Control in a Vapor Compression Refrigeration System

Virtual sensor technology, which uses simulation models/algorithms to calculate a value to represent an unmeasured variable or replace a directly measured reading, has attracted many studies in the heating, ventilation, air conditioning and refrigeration (HVAC&R) industry. However, most virtual sensor technologies are developed for fault detection and diagnostics (FDD) purposes, which generally compare the virtual sensor values with actual measured values to detect if any fault occurred and identify the causes that led to the fault. It is rare to see studies focus on control performance of virtual sensors after substituting an actual sensor. This is particularly important for the system with no redundant sensor since a virtual sensor is the most effective way to operate the system in the desirable region when any sensor failure occurs. To address this gap, this paper develops a new virtual pressure sensor technology to substitute the actual pressure measurement for electronic expansion valve (EXV) control in a vapor compression refrigeration system by integrating compressor and valve characteristics. The control performance of this proposed virtual pressure sensor technology under various operating conditions is validated with experimental data. Closed loop EXV control simulations with the proposed virtual pressure sensor are conducted, and the results are analyzed.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Measurement and analysis of clothes dryer air leakage

Each year clothes dryer appliances are sold globally in the tens of millions. Both vented and ventless types are common and are heated by combustion, electric resistance, or electric heat pumps. In the dyer air path, segments can be defined between components such as the drum, blower, filter, screens or grills, and heat exchangers (where applicable). In this work, a technique was developed to experimentally measure air leakage into and from the segments of a clothes dryer. Detailed leakage measurements were taken on two vented and one ventless residential clothes dryer. The measurements were quantified as a leakage flow coefficient for each segment. For two dryers (one vented and one ventless), these flow coefficients were combined with in situ operating pressure measurements to determine leakage flow rates for each segment. For these two units under normal operation with air pressures within 0.5 kPa (50 mm water column) of ambient pressure, volumetric system air leakage was found to be about 20–60% of the blower airflow. Furthermore, a quasi–steady state psychrometric analysis was conducted on vented dryers with negatively pressurized drums. The analysis revealed that leakage quantity, location, and direction are essential to achieving an acceptable energy balance and accurate modeling results for a vented heat pump clothes dryer but are of limited significance for vented electric resistance clothes dryers.

42 ENGINEERING↗

DOE OSTI2020

Wearable Sensors Measure Ankle Joint Changes of Patients with Parkinson’s Disease before and after Acute Levodopa Challenge

Background . Previous studies found levodopa could improve the activity of the ankle joints of patients with Parkinson’s disease (PD). But ankle joint movement is composed of four motion ranges. The specific changes of four motion ranges in PD remain unknown. Objective . The purpose of this study was to decompose the complex ankle joint movement, measure ankle joint changes before and after the acute levodopa challenge test (ALCT), and investigate the effects of these parameters on gait performance. Methods . 29 PD patients and 30 healthy control subjects (HC) completed the Instrumented Stand and Walk (ISAW) test and gait parameters were collected by the JiBuEn gait analysis system. The percentage of improvement of gait data and the UPDRS III in the on-drug condition (ON) were determined with respect to the off-drug condition (OFF). Results . We observed a reduction in the heel strike angle (HS), 3-plantarflexion (3-PF) angle, and 4-dorsiflexion (4-DF) angle of ankle joints. We did not find significant difference in the toe-off angle (TO), 1-plantarflexion (1-PF) angle, and 2-dorsiflexion (2-DF) angle among three groups. Stride length improvement rate was significantly correlated with HS ( r s = 0.616, P < 0.001 ) and 3-PF ( r s = 0.639, P < 0.001 ) improvement rates. The improvement in the sum of rigidity items (UPDRS motor subsection item 22) was also correlated with HS ( r s = 0.389, P = 0.037 ) and 3-PF ( r s = 0.373, P = 0.046 ) improvement rates. Conclusions . Exogenous levodopa supplementation can significantly reduce the rigidity of patients with PD, improve their 3-PF and 4-DF of ankle joint kinematic parameters, and ultimately enhance their gait.

Wu, Zhuang↗

DOE OSTI2020

Method and device for controlling heat pump

A method for controlling a heat pump is provided. A working mode of the heat pump is determined. Based on a determination that the working mode of the heat pump is a heating mode, an ambient temperature of the heat pump is determined. Based on a determination that the ambient temperature of the heat pump is higher than a first predetermined temperature, a first compressor of the heat pump is operated. Based on a determination that the ambient temperature of the heat pump is lower than the first predetermined temperature, both the first compressor and a second compressor of the heat pump are enabled to operate, in response to a two-stage thermostat. The first compressor and the second compressor are coupled in parallel. The method allows the heat pump to be suitable for a cold climate.

42 ENGINEERING↗

DOE OSTI2019

Development of high efficiency window air conditioner using propane under limited charge

The residential air conditioner market has a significant portion of window air conditioners (WAC). Due to the compact size and small refrigerant charge, WACs are most tolerant of flammable refrigerants. Hydrocarbon (HC) refrigerants are natural substances and have significantly better environmental impacts and lower costs than conventional refrigerants like R-410A and R-22. The paper aimed to develop a WAC prototype using propane (R-290) and verify the performance metrics in the laboratory. The key of developing the WAC using a flammable refrigerant is to control the refrigerant charge under the limit of building safety regulation with the performance meeting the Energy Star standard. To minimize the charge, compact heat exchangers were utilized. To achieve the target efficiency, we collaborated with a leading rotary compressor manufacturer to develop a compressor prototype specifically optimized for R-290, able to achieve superior energy efficiency. In addition, we conducted model-based investigations to identify further charge reduction potential. Finally, with using microchannel heat exchangers to replace the fin-and-tube condenser and evaporator, the system charge can be decreased to 150 g.

42 ENGINEERING↗

DOE OSTI2019

Chemical Synthesis of Magnetic Nanoparticles for Permanent Magnet Applications

Abstract Permanent magnets are a class of critical materials for information storage, energy storage, and other magneto‐electronic applications. Compared with conventional bulk magnets, magnetic nanoparticles (MNPs) show unique size‐dependent magnetic properties, which make it possible to control and optimize their magnetic performance for specific applications. The synthesis of MNPs has been intensively explored in recent years. Among different methods developed thus far, chemical synthesis based on solution‐phase reactions has attracted much attention owing to its potential to achieve the desired size, morphology, structure, and magnetic controls. This Minireview focuses on the recent chemical syntheses of strongly ferromagnetic MNPs ( H c >10 kOe) of rare‐earth metals and FePt intermetallic alloys. It further discusses the potential of enhancing the magnetic performance of MNP composites by assembly of hard and soft MNPs into exchange‐coupled nanocomposites. High‐performance nanocomposites are key to fabricating super‐strong permanent magnets for magnetic, electronic, and energy applications.

Shen, Bo↗

DOE OSTI2019

Extending ORNL HPDM Capabilities for Design and Optimization of New Refrigerant Blends – FY19 2nd Quarterly Milestone Report: Literature Review of Heat Transfer and Pressure Drop Correlations for HFO Blends in Water Heating Application

Based on a comprehensive literature review, the two-phase heat transfer and pressure drop correlations, best suitable for modelling the next generation HFO blends in brazed plate heat exchangers and fluted tube-in-tube heat exchangers, were identified. The selected correlations have been incorporated to the segment-to-segment (finite volume) heat exchanger models in the HPDM library. Details are described below.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Novel PCM Integration with Electrical Heat Pump for Demand Response

In this paper, we examine the potential for using phase change material (PCM) as a thermal storage medium for improving the efficiency as well as enabling grid-responsive control of heat pump (HP) systems. Previous research in PCM integration in buildings has primarily been focused on integration with building envelopes. An objective of our research is to design a novel and practical PCM integration with existing HP systems. High-fidelity models for building, HP and PCM are developed to facilitate the model-based predictive control (MPC) design. To optimize the operation of HP and PCM, we introduce an optimization problem considering various constraints for both comfort and hardware constraints. We include experimental results in which a house fleet are optimized to minimize their power consumption or electricity cost. We numerically demonstrate the designs potential for reducing power consumption or electricity cost by 13% or 19%, respectively.

Dong, Jin↗

DOE OSTI2019

A hardware-based heat pump water heater design model for quasi-steady-state simulation

A storage heat pump water heater (HPWH) comprises a vapor compression system and a hot water tank. It can lead to more than 70% energy saving, compared to electric resistance heating. HPWH usually uses a wrapped-tank coil as the water heater. The wrapped coil has a strong interaction with the water tank and impose a new challenge for the engineering design and simulation study. Based on the US DOE/ORNL Heat Pump Design Model (HPDM), a component-based thermal system modelling platform, a segment-to-segment wrapped-tank coil model and a one-dimensional stratified water tank model were developed, which facilitates modeling and design HPWHs having various configurations and components. In the paper, the new HPWH system design model was used to investigate effects of compressor size, refrigerant charge, water draw pattern, and refrigerant type, etc., for predicting 24-hour energy factors and first-hour rating. The HPWH system model was proved to be an effective equipment design tool.

Shen, Bo↗

DOE OSTI2019

Hydrocarbons as natural refrigerants for heat pump water heating applications

Growing awareness of the potential environmental impacts of conventional refrigerants (CFCs and HFCs) has led to efforts to identify suitable refrigerants for various heat pump applications with minimum environmental impact. This study is focused on the performance evaluation of pure propane and isobutane as drop-in-replacement for R134a for heat pump water heating (HPWH). A component-based model is used to predict the performance. Key performance parameters such as unified energy factor, first hour rating and thermal stratification in the water tank are investigated. Appropriate experiments are conducted to validate the finding from model. Simulation and experimental findings suggest that both alternative refrigerants could provide comparable system performance to that of the baseline system containing R134a. System refrigerant charge and the condenser discharge temperature are established to investigate the potential of hydrocarbon refrigerants to substitute R134a without significant system modifications.

Nawaz, Kashif↗