Miniaturized Air-to-Refrigerant Heat Exchangers
Air-to-refrigerant Heat eXchangers (HX) are an essential component of Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems, serving as the main heat transfer component. The major limiting factor to HX performance is the large airside thermal resistance. Recent literature aims at improving heat transfer performance by utilizing enhancement methods such as fins and small tube diameters; this has lead to almost exhaustive research on the microchannel HX (MCHX). The objective of this project is to develop a miniaturized air-to-refrigerant HX with at least 20% reduction in volume, material volume, and approach temperature compared to current state-of-the-art multiport flat tube designs and also be capable of production within five years. Moreover, the proposed HX’s are expected to have good water drainage and should succeed in both evaporator and condenser applications. The project leveraged Parallel-Parametrized Computational Fluid Dynamics (PPCFD) and Approximation-Assisted Optimization (AAO) techniques to perform multi-scale analysis and shape optimization with the intent of developing novel HX designs whose thermal-hydraulic performance exceeds that of state-of-the-art MCHX. Nine heat exchanger geometries were initially chosen for detailed analysis, selected from 35+ geometries which were identified in previous work at the University of Maryland, College Park. The newly developed optimization framework was exercised for three design optimization problems: (DP I) 1.0kW radiator, (DP II) 10kW radiator and (DP III) 10kW two-phase HX. DP I consisted of the design and optimization of 1.0kW air-to-water HX’s which exceeded the project requirements of 20% volume/material reduction and 20% better performance. Two prototypes for the 1.0kW HX were prototyped, tested and validated using newly-designed airside and refrigerant side test facilities. DP II, a scaled version DP I for 10kW air-to-water HX applications, also yielded optimized HX designs which met project requirements. Attempts to prototype a 10kW have presented unique manufacturing challenges, especially regarding tube blockages and structural stability. DP III comprised optimizing two-phase HX’s for a 3.0Ton capacity in a heat pump / air-conditioning unit for cooling mode application using R410A as the working fluid. The HX’s theoretically address the project requirements. System-level analysis showed the HX’s achieved up to 15% improvement in COP while also reducing overall unit charge by 30-40%. The project methodology was capable of developing HX’s which can outperform current state-of-the-art MCHX by at least 20% reduction in volume, material volume, and approach temperature. Additionally, the capability for optimization using refrigerant charge as an objective function was developed. The five-year manufacturing feasibility of the proposed HX’s was shown to have a good outlook. Successful prototyping through both conventional manufacturing methods and next generation methods such as additive manufacturing was achieved.