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All sources NASA NTRS DOE OSTI

DOE OSTI2026

Experimental Evaluation of a Microchannel Condenser for R600a Domestic Refrigerators

Domestic refrigerators are among the most common household appliances, accounting for approximately 4% of total household energy consumption, which is higher than that of clothes dryers, lighting, or cooking appliances. With nearly 13 million new domestic refrigerators sold annually, even marginal improvements in their energy performance can yield significant reductions in overall energy demand and cost. This study focuses on enhancing the performance of domestic refrigerators using R600a as the refrigerant. Most domestic refrigerators currently employ wire-and-tube condensers, which are bulky and require a larger refrigerant charge. Given that R600a is classified as an A3 flammable refrigerant under ASHRAE standards, minimizing the system charge while maintaining or improving performance is critical. To address this, a compact and light weight single-pass serpentine microchannel heat exchanger (made of aluminum) was adopted as a condenser, replacing the conventional wire-and-tube configuration. The modified system was experimentally tested according to AHAM test standards, and charge optimization was performed. The results demonstrated that the refrigerator equipped with the microchannel condenser achieved a 5.3% reduction in energy consumption compared to the baseline configuration with wire-and-tube condenser.

Murugan, Muneeshwaran [ORNL] (ORCID:00000003340352↗

DOE OSTI2025

Innovative approach to counterfeit and noncompliant refrigerant detection: A cost-effective, portable solution

The increasing prevalence of counterfeit and incompatible refrigerants presents significant risks to Heating, Ventilation, Air Conditioning, and Refrigeration (HVAC&R) systems, including compromised equipment performance, safety hazards, and non-compliance. This article details the development of a novel, cost-effective, and portable detection device designed to accurately verify refrigerants. The device utilizes a controlled gas sampling and analysis system within a sealed chamber, ensuring precise measurements while maintaining safety through a purging mechanism. The system features a high-sensitivity sensor integrated with an onboard control module that analyzes gas composition in real-time, providing feedback within a 2-minute duration. Laboratory validation demonstrated the device’s high accuracy (>95 % based on correct identification of compliant vs. non-compliant blends) in detecting unauthorized refrigerant blends. The projected cost of the product stands at ∼ $150, based on the retail pricing of individual components. Laboratory validation demonstrated the device’s high accuracy (>95 % for composition identification, 100 % rejection of tested counterfeit/incorrect blends) in detecting unauthorized refrigerant blends with a response time <2 min. The device correctly identified authentic R-454A/B/C blends and reliably rejected R-407F and closely related counterfeit mixtures. Key advantages include affordability, ease of use, rapid response time, and compatibility with a wide range of refrigerants. This solution supports compliance with regulatory frameworks, enhances safety in HVAC&R operations, and mitigates the risks associated with counterfeit refrigerants.

Counterfeit refrigerants↗

DOE OSTI2014

Investigation of pressure drop in capillary tube for mixed refrigerant Joule-Thomson cryocooler

A capillary tube is commonly used in small capacity refrigeration and air-conditioning systems. It is also a preferred expansion device in mixed refrigerant Joule-Thomson (MR J-T) cryocoolers, since it is inexpensive and simple in configuration. However, the flow inside a capillary tube is complex, since flashing process that occurs in case of refrigeration and air-conditioning systems is metastable. A mixture of refrigerants such as nitrogen, methane, ethane, propane and iso-butane expands below its inversion temperature in the capillary tube of MR J-T cryocooler and reaches cryogenic temperature. The mass flow rate of refrigerant mixture circulating through capillary tube depends on the pressure difference across it. There are many empirical correlations which predict pressure drop across the capillary tube. However, they have not been tested for refrigerant mixtures and for operating conditions of the cryocooler. The present paper assesses the existing empirical correlations for predicting overall pressure drop across the capillary tube for the MR J-T cryocooler. The empirical correlations refer to homogeneous as well as separated flow models. Experiments are carried out to measure the overall pressure drop across the capillary tube for the cooler. Three different compositions of refrigerant mixture are used to study the pressure drop variations. The predicted overall pressure drop across the capillary tube is compared with the experimentally obtained value. The predictions obtained using homogeneous model show better match with the experimental results compared to separated flow models.

42 ENGINEERING↗

DOE OSTI2019

Options for low-global-warming-potential and natural refrigerants part I: Constrains of the shape of the P–T and T–S saturation phase boundaries

Current research focus is migrating toward low-global-warming-potential (GWP) and natural refrigerants to address the human impact on climate change. In this paper, we examine 13 refrigerants from the perspective of the characteristic shape of their respective temperature–entropy (T–S) and the logarithm of the pressure versus inverse absolute temperature (log P vs. T –1 ) saturated phase boundary. Such analyses explain why certain refrigerants possess a re-entrant characteristic while others do not. The re-entrant region is due to skewness of the saturation boundary. The cause of skewness is investigated for its importance in heat pump performance, design, and configuration. Re-entrant behavior contributes to premature mechanical wear of compressor components. Knowledge of the properties of the phase boundary on either side of the critical point, is useful for a better perspective on discriminating refrigerants, as hydrochlorofluorocarbons are phased out and replacement refrigerants must be found. Here, we conclude by identifying a candidate low-GWP refrigerant for heat pumps. In Part II, we evaluate all 13 refrigerants in thermodynamic cycles based on exergy analysis to identify sources of irreversibility, the root cause of systemic inefficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Refrigerated Warehouse Demand Response Strategy Guide

This guide summarizes demand response measures that can be implemented in refrigerated warehouses. In an appendix, it also addresses related energy efficiency opportunities. Reducing overall grid demand during peak periods and energy consumption has benefits for facility operators, grid operators, utility companies, and society. State wide demand response potential for the refrigerated warehouse sector in California is estimated to be over 22.1 Megawatts. Two categories of demand response strategies are described in this guide: load shifting and load shedding. Load shifting can be accomplished via pre-cooling, capacity limiting, and battery charger load management. Load shedding can be achieved by lighting reduction, demand defrost and defrost termination, infiltration reduction, and shutting down miscellaneous equipment. Estimation of the costs and benefits of demand response participation yields simple payback periods of 2-4 years. To improve demand response performance, it’s suggested to install air curtains and another form of infiltration barrier, such as a rollup door, for the passageways. Further modifications to increase efficiency of the refrigeration unit are also analyzed. A larger condenser can maintain the minimum saturated condensing temperature (SCT) for more hours of the day. Lowering the SCT reduces the compressor lift, which results in an overall increase in refrigeration system capacity and energy efficiency. Another way of saving energy in refrigerated warehouses is eliminating the use of under-floor resistance heaters. A more energy efficient alternative to resistance heaters is to utilize the heat that is being rejected from the condenser through a heat exchanger. These energy efficiency measures improve efficiency either by reducing the required electric energy input for the refrigeration system, by helping to curtail the refrigeration load on the system, or by reducing both the load and required energy input.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Analysis of Refrigeration Units in Off Grid PV/Wind Hybrid Systems on Tribal Land

This paper looks at the performance of residential refrigeration units in off-grid photovoltaic and small wind hybrid (PV/wind) systems with battery storage. Off grid hybrid power systems, dispatched by Navajo Tribal Utility Authority (NTUA), allow Navajo Nation residents in rural areas to have the benefits of electricity. On the Navajo Nation, the rural and rugged nature of the land results in a high capital cost to connecting a house to the grid. In this case, a hybrid PV/wind power generation system may be used at a much lower cost to the customer. In providing affordable power systems to customers, the systems are designed to provide adequate power for use. This requires a constant conservative use of electricity. For systems with refrigerators which are large alternating current (AC) loads, there are performance issues that arise. NTUA reports that new energy star rated refrigerators have performance issues in working with these off grid systems. This paper looks at ways to improve the performance of these systems with the use of a refrigeration unit. This involves looking at conventional refrigerators with its operation. This paper also looks at alternative methods of refrigeration. Also, the power system is looked at to increase the performance in maintaining a proper balance of the system. Lastly, solutions will be recommended to solve the refrigeration issues faced by NTUA.

14 SOLAR ENERGY↗

DOE OSTI2018

Low-GWP Refrigerant Evaluation in AC Systems for High Ambient Temperature Applications – Acquire Nortek Residential AC/HP Units for Evaluation and Model the Units Using HPDM

For the upcoming refrigerant transition from HFCs to minorly flammable HFO refrigerants (A2L), refrigerant charge reduction is important to mitigate the fire hazard. Microchannel heat exchangers (MHXs) are a mature technology, which is effective in reducing system charge while maintaining similar heat transfer performance. MHXs will be applied more widely when the new refrigerants are used. Prior studies of the A2L HFO blends were mostly focused on fin-and-tube coils (FTC). An in-depth study for an air conditioner (AC)/heat pump (HP) system using all microchannel heat exchangers is still lacking. In FY19, a side-to-side comparison will be conducted between two residential split heat pumps, one using all FTCs and the other using all MHXs for drop-in investigation, to identify potential issues for future design. The two heat pumps have similar rated capacity, SEER, HSPF levels, similar fan, blower and compressor, but differ in heat exchangers. Both the HPs use two-stage compressors to facilitate investigating different refrigerant flow rates. We will drop-in HFO refrigerants (replacements for R-410A, e.g. R452B, R447B, R32, etc.). The experiments will reveal the potential of MHXs for charge reduction, and how the two systems using A2L refrigerants operate under standard SEER and HSPF rating conditions. The two units were donated by our partner, i.e. Nortek Global HVAC, an industry leader in making heat pumps using all MHXs as well as FTCs. The units were shipped to ORNL this week, and the product design data were also shared for modeling the two units using HPDM.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

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↗

NASA NTRS1989

Two stage sorption type cryogenic refrigerator including heat regeneration system

A lower stage chemisorption refrigeration system physically and functionally coupled to an upper stage physical adsorption refrigeration system is disclosed. Waste heat generated by the lower stage cycle is regenerated to fuel the upper stage cycle thereby greatly improving the energy efficiency of a two-stage sorption refrigerator. The two stages are joined by disposing a first pressurization chamber providing a high pressure flow of a first refrigerant for the lower stage refrigeration cycle within a second pressurization chamber providing a high pressure flow of a second refrigerant for the upper stage refrigeration cycle. The first pressurization chamber is separated from the second pressurization chamber by a gas-gap thermal switch which at times is filled with a thermoconductive fluid to allow conduction of heat from the first pressurization chamber to the second pressurization chamber.

Jones, Jack A.↗

NASA NTRS1993

COP improvement of refrigerator/freezers, air-conditioners, and heat pumps using nonazeotropic refrigerant mixtures

With the February, 1992 announcement by President Bush to move the deadline for outlawing CFC (chloro-fluoro-carbon) refrigerants from the year 2000 to the year 1996, the refrigeration and air-conditioning industries have been accelerating their efforts to find alternative refrigerants. Many of the alternative refrigerants being evaluated require synthetic lubricants, are less efficient, and have toxicity problems. One option to developing new, alternative refrigerants is to combine existing non-CFC refrigerants to form a nonazeotropic mixture, with the concentration optimized for the given application so that system COP (Coefficient Of Performance) may be maintained or even improved. This paper will discuss the dilemma that industry is facing regarding CFC phase-out and the problems associated with CFC alternatives presently under development. A definition of nonazeotropic mixtures will be provided, and the characteristics and COP benefits of nonazeotropic refrigerant mixtures will be explained using thermodynamic principles. Limitations and disadvantages of nonazeotropic mixtures will be discussed, and example systems using such mixtures will be reviewed.

Westra, Douglas G.↗

NASA NTRS2001

Continuous Magnetic Refrigerators for Cooling in the 0.05 to 10 K Range

Low temperature refrigeration is an increasingly vital technology for NASA's Space Science program since most detectors being developed for x-ray, IR and sub-millimeter missions must be cooled to below 100 mK in order to meet the requirements for energy and spatial resolution. For space applications, magnetic refrigeration has an inherent advantage over alternative techniques because it does not depend on gravity. Adiabatic demagnetization refrigerators, or ADRs, are relatively simple, solid state devices. The basic elements are a magnetocaloric refrigerant (usually an encapsulated paramagnetic salt) located in the bore of a superconducting magnet, and a heat switch linking the salt to a heat sink. The alignment of magnetic spins with the magnetic field causes the refrigerant to warm as the magnetic field increases and cool as the field decreases. Thus the simple process of magnetizing the refrigerant to high field with the heat switch closed, then demagnetizing it with the heat switch open allows one to obtain temperatures well below 100 mK using a heat sink as warm as 4.2 K. The refrigerant can maintain a low temperature for a length of time depending on the applied and parasitic heat loads, its mass, and the initial magnetic field strength. Typically ADRs are designed for 12-24 hours of hold time, after which they must be warmed up and recycled.

Shirron, Peter↗

NASA NTRS2003

Keeping Cool With Solar-Powered Refrigeration

In the midst of developing battery-free, solar-powered refrigeration and air conditioning systems for habitats in space, David Bergeron, the team leader for NASA's Advanced Refrigerator Technology Team at Johnson Space Center, acknowledged the need for a comparable solar refrigerator that could operate in conjunction with the simple lighting systems already in place on Earth. Bergeron, a 20-year veteran in the aerospace industry, founded the company Solus Refrigeration, Inc., in 1999 to take the patented advanced refrigeration technology he co-developed with his teammate, Johnson engineer Michael Ewert, to commercial markets. Now known as SunDanzer Refrigeration, Inc., Bergeron's company is producing battery-free, photovoltaic (PV) refrigeration systems under license to NASA, and selling them globally.

Source record↗

NASA NTRS1989

Two-statge sorption type cryogenic refrigerator including heat regeneration system

A lower stage chemisorption refrigeration system physically and functionally coupled to an upper stage physical adsorption refrigeration system. Waste heat generated by the lower stage cycle is regenerated to fuel the upper stage cycle thereby greatly improving the energy efficiency of a two-stage sorption refrigerator. The two stages are joined by disposing a first pressurization chamber providing a high pressure flow of a first refrigerant for the lower stage refrigeration cycle within a second pressurization chamber providing a high pressure flow of a second refrigerant for the upper stage refrigeration cycle. The first pressurization chamber is separated from the second pressurization chamber by a gas-gap thermal switch which at times is filled with a thermoconductive fluid to allow conduction of heat from the first pressurization chamber to the second pressurization chamber.

Jones, Jack A.↗

NASA NTRS2005

Gifford-McMahon/Joule-Thomson Refrigerator Cools to 2.5 K

A compact refrigerator designed specifically for cooling a microwave maser low-noise amplifier is capable of removing heat at a continuous rate of 180 mW at a temperature of 2.5 K. This refrigerator is a combination of (1) a commercial Gifford-McMahon (GM) refrigerator nominally rated for cooling to 4 K and (2) a Joule-Thomson (J-T) circuit. The GM refrigerator pre-cools the J-T circuit, which provides the final stage of cooling. The refrigerator is compact and capable of operating in any orientation. Moreover, in comparison with a typical refrigerator heretofore used to cool a maser to 4.5 K, this refrigerator is simpler and can be built at less than half the cost.

Britcliffe, Michael↗

DOE OSTI2017

Performance Optimization of Alternative Lower Global Warming Potential Refrigerants in Mini-Split Room Air Conditioners

Oak Ridge National laboratory (ORNL) recently conducted extensive laboratory, drop-in investigations for lower Global Warming Potential (GWP) refrigerants to replace R-22 and R-410A. ORNL studied propane, DR-3, ARM-20B, N-20B and R-444B as lower GWP refrigerant replacement for R-22 in a mini-split room air conditioner (RAC) originally designed for R-22; and, R-32, DR-55, ARM-71A, and L41-2, in a mini-split RAC designed for R-410A. We obtained laboratory testing results with very good energy balance and nominal measurement uncertainty. Drop-in studies are not enough to judge the overall performance of the alternative refrigerants since their thermodynamic and transport properties might favor different heat exchanger configurations, e.g. cross-flow, counter flow, etc. This study compares optimized performances of individual refrigerants using a physics-based system model tools. The DOE/ORNL Heat Pump Design Model (HPDM) was used to model the mini-split RACs by inputting detailed heat exchangers geometries, compressor displacement and efficiencies as well as other relevant system components. The RAC models were calibrated against the lab data for each individual refrigerant. The calibrated models were then used to conduct a design optimization for the cooling performance by varying the compressor displacement to match the required capacity, and changing the number of circuits, refrigerant flow direction, tube diameters, air flow rates in the condenser and evaporator at 100% and 50% cooling capacities. This paper compares the optimized performance results for all alternative refrigerants and highlights best candidates for R-22 and R-410A replacement.

GWP↗

DOE OSTI2019

Analysis of the P-T and T-S phase boundary in discriminating suitable low global warming potential and low flammability refrigerants

Although several alternative low GWP refrigerants including natural have been proposed, the HVAC industry consensus on how to deal with the attendant issues is still evolving. This paper provides invaluable qualitative and quantitative insight into the peculiar phase boundary shapes of refrigerants, essential for understanding their application, and in evaluating existing and future refrigerants. The methodology is firmly grounded in the thermodynamics of phase equilibria and the criteria of positive-definiteness, a direct consequence of the Second Law and the existence of intermolecular forces (IMF). The formal methodology is strikingly easy to implement in practice and explains clearly why certain refrigerants display re-entrant behavior while others do not, and how one can choose the proper refrigerant for a given refrigeration or heat pump application. The paper shows how an evidence-based selection can be made among the 40 refrigerants analyzed in this study.

Ally, Moonis↗

DOE OSTI2019

Options for low–global-warming-potential and natural refrigerants- Performance for heat pump application and analysis of systemic irreversibilities

There is growing interest in substituting existing refrigerants with low global warming potential (GWP) refrigerants, including naturally occurring fluids, to reduce the impact of human activities on climate change. In this study we have evaluated prospective low-GWP refrigerants in four distinct heat pump cycles using the First and Second laws of thermodynamics. The essence of the study is to establish the performance of the low-GWP refrigerants when deployed in a heat pump system. Exergy analysis provides a true measure of lost work, or systemic inefficiencies, vividly quantifying areas of improvement and identifying the preferred cycle for a refrigerant. The combined knowledge of the properties of the phase boundary on either side of the critical point (DOI:10.1.18462/iir.icr.2019.442), and exergy analysis of prospective cycles is necessary for a better perspective on discriminating among refrigerants as hydrochlorofluorocarbons are phased out and replacement refrigerants must be found.

Nawaz, Kashif↗

DOE OSTI2022

A Universal Refrigerant Charge Fault Detection and Diagnostics Method Based on Pump Down Operation

The performance of the heat pump system varies greatly depending on the refrigerant charge amount. Improving the refrigerant charge fault detection and diagnostics (FDD) method of vapor compression systems have the potential for increasing energy efficiency and reducing service cost. Previous studies to predict refrigerant charge amount are mostly empirical methods which require significant amount of experimental data for high accuracy. The primary goal of this research is to develop a universal charge fault detection method which requires only a few experimental data with high prediction accuracy.Currently, pump down operations are typical practices by HVAC technicians when they need to open the refrigerant circuit to make a repairment. In addition, compressors have a built-in low-pressure cut-off protection function, and the compressor performance maps are commonly available from manufacturers. The proposed method innovatively utilizes the typical pump down operation, the compressor low-pressure cut-off protection, and the compressor performance map. It does not require any geometry information of heat exchangers, refrigerant lines, or charge buffers.The new charge prediction method is firstly formulated through theoretical analysis, then verified and calibrated by a quasi-steady-state simulation of the pump down process for a residential heat pump system. The quasi steady-state simulation uses an HVAC system simulation framework driven by DOE/ORNL Heat Pump Design Model (HPDM). Preliminary experiment validations with heat pump refrigerant leakage tests demonstrate the deviation of the proposed charge prediction method compared with measurement is within 8%. This technology makes refrigerant charge amount available at the technician’s fingertips and leads to shorter maintenance time and fewer site visits.

Li, Zhenning↗