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A NUMERICAL STUDY OF REFRIGERANT LEAKAGE FROM A PROPANE-BASED REFRIGERATION SYSTEM
Low Global Warming Potential (GWP) refrigerants, e.g. Propane (R290) (GWP = 3) and R1234yf (GWP = 4), are becoming a popular choice among refrigeration and HVAC systems, such as vending machines and air conditioning. However, most of Low GWP refrigerants are flammable (ASHRAE class A2 or A3), so safety is a very important consideration when designing and deploying low GWP refrigerants-based equipment in buildings. In the event of a refrigerant leak, the flammability of low GWP refrigerants depends on the local concentration of the refrigerant within the vicinity of the leak. In addition, the low GWP refrigerants concentration is affected by the indoor air environment, such as air flow rate and temperature. In the present study, a computational fluid dynamics (CFD) model is developed to model the flow and temperature of air surrounding a propane-based refrigeration system, as well as the concentration of leaked low GWP refrigerants surrounding the refrigeration system. The model results reveal the concentration distribution of low GWP refrigerants within the building, and as a result, the flammable regions within the building can be identified. Moreover, different ventilation layouts will be tested using the model to improve the design of ventilation. The numerical model can assist in the design of ventilation systems to minimize flammable regions within buildings due to leakage of flammable refrigerants.
A Modeling-Based Flammable Risk Treatment of Refrigerant Leakage from a Commercial R-290 Refrigeration Machine
Because of serious concerns about global warming, manufacturers have started phasing out high global warming potential (GWP) refrigerants in commercial refrigeration equipment (e.g., R-134a). As a potential replacement, propane (R-290) is an environmentally friendly refrigerant for commercial refrigeration equipment because its GWP is only three. However, propane is flammable and is therefore classified as a Class A3 refrigerant per ASHRAE Standards, so safety is a very important consideration when propane-based equipment is designed and deployed in buildings. In the event of a refrigerant leak, flammability of the refrigerant depends on the refrigerant’s local concentration, which is highly affected by the indoor air environment, including temperature and air flow. In this study, a ventilation system attached to a commercial R-290 refrigeration device was designed to eliminate the flammability risk. Moreover, a computational fluid dynamics (CFD) model was developed to investigate the refrigerant leak, thereby evaluating effects of the ventilation system. The CFD model can visualize the flammable zones owing to the leak.
Thermoeconomic Evaluation and Optimization of Using Different Environmentally Friendly Refrigerant Pairs for a Dual-Evaporator Cascade Refrigeration System
Applications of dual-evaporator refrigeration systems have recently gained much attention both in academia and industry due to their multiple benefits. In this study, a comprehensive thermodynamic and economic analysis is conducted to evaluate the potential of using several environmentally friendly refrigerant couples and identifies the most suitable one yielding the best economic results. To achieve this goal, a detailed parametric study is conducted, and an optimization process is performed using a particle swarm optimization (PSO) approach to minimize the unit production cost of cooling (UPCC) of the cascade refrigeration system. The results showed that among all selected 18 refrigerant pairs and for all ranges of examined operating parameters, the R170-R161 pair and R1150-R1234yf pair are identified as the best and worst pairs, respectively, from both thermodynamic and economic viewpoints. The results also confirm that R170-R161 pair has an improvement over R717-R744, used as a typical refrigerant pair of cascade refrigeration cycles. For a base case analysis, the COP of R170-R161 and R1150-R1234yf pairs is determined as 1.727 and 1.552, respectively, while their UPCC is found to be $0.395/ton-hr and $0.419/ton-hr, respectively, showing the influence of proper selection of refrigerant pairs on the cascade cycle’s performance. Overall, this study offers a useful thermodynamic and economic insight regarding the selection of proper refrigerant pairs for a dual-evaporator cascade vapor compression refrigeration system.
Options for low-global-warming-potential and natural refrigerants Part 2: Performance of refrigerants and 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 the Part I of the study, we examined 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 ) phase boundary. In Part 2, we are evaluating 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. Here, the combined knowledge of the properties of the phase boundary on either side of the critical point, 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.
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.
Influence of commercial refrigeration system design and refrigerant options on life cycle climate performance
Ongoing efforts to reduce direct and indirect emissions of commercial refrigeration systems include using leak reduction measures, refrigerant charge minimization, low global warming potential (GWP) refrigerants and energy efficiency measures. In this paper, Life Cycle Climate Performance (LCCP) analysis is used to estimate the lifetime carbon dioxide equivalent emissions of commercial refrigeration system designs and refrigerant options. Commercial refrigeration systems investigated in this study include the centralized direct expansion (DX) system with hydrofluorocarbon (HFC) and hydrofluoroolefin (HFO) refrigerant blends, the transcritical R-744 booster system, and self-contained systems using R-290. The results of the LCCP analysis are presented for a variety of cities around the world, and recommended systems and refrigerant options are provided based on direct and indirect carbon emissions.
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.
Ensemble-Based Support Vector Regression with Gravitational Search Algorithm Optimization for Estimating Magnetic Relative Cooling Power of Manganite Refrigerant in Magnetic Refrigeration Application
Magnetic refrigeration technology (MRT) is considered an energy-efficient and environmental-friendly system of refrigeration that has a considerable potential of replacing the classical gas-compression expansion method of refrigeration. Inclusion of manganite-based material (MBM) in MRT as a magnetic refrigerant has attracted significant attention recently due to cost effectiveness of the refrigerant as well as better resistance to oxidation and corrosion as compared to the commonly used metal gadolinium refrigerant. Relative cooling power (RCP) is one of the most important parameters to be considered while assessing the usefulness of MBM. Its value can be altered through doping with external materials and accurate estimation of the dopant influence is required to achieve the right amount of RCP. This present research work proposes support vector regression (SVR) ensemble models with gravitational search algorithm (GSA) hyper-parameters optimization, for estimating RCP of MBM and to determine the influence of dopants on RCP using ionic radii and dopant concentrations as descriptors. GSA-SVR ensemble model (GSE) is developed by employing the outputs of five different SVR models as descriptors while GSA-SVR ensemble model with averaging (GSEA) uses the average of the five different SVR models as its descriptor. The novel ensemble models outperform other SVR models, specifically; GSE performs better than GSA-SVR model and the conventional SVR model with performance improvement of 269.14% and 283.61%, respectively on the basis of root mean square error (RMSE). Furthermore, GSEA outperforms GSE, GSA-SVR model and conventional SVR with performance improvement of 27.51%, 370.70%, and 389.14%, respectively on the basis of RMSE. The developed GSE and GSEA also perform better than the existing RCP model in the literature with performance improvement of 11.53% and 42.21%, respectively. The results of this research work will not only serve to circumvent the experimental challenges of RCP measurement without loss of experimental precision but also further promotes environment-friendly system of refrigeration.
Low global warming potential (GWP) refrigerant supermarket refrigeration system modeling and its application
As an environmentally friendly low global warming potential (GWP) refrigerant, Carbon dioxide (CO 2 ) has continuously gained popularity and research attention as alternative refrigerant for supermarket refrigeration system. In this paper, to fulfill the increasing need of accurate Low-GWP supermarket refrigeration models for development of supervisory level control and optimization strategies, a high fidelity model is developed for CO 2 transcritical supermarket refrigeration system which includes compressor rack of low temperature (LT) compressors and medium temperature (MT) compressors, air-cooled gas cooler, evaporator, expansion valves and other auxiliary equipment. A resistance-capacity model structure is proposed to simulate the display cases. Semi-thermodynamic models are proposed to estimate reciprocating compressors volumetric efficiency and power consumption. Furthermore the zone modeling approach is used for evaporator simulation, and air-cooled gas cooler is modeled with distributed modeling method. The expansion valve simulation is based on orifice flow model. To calibrate these models, both manufacture performance data and experimental data are used. The experiments are conducted with a full instrumental CO 2 supermarket refrigeration system installed in Oak Ridge National Lab Flexible Research Platform (FRP). The simulation model can predict the system performance, including power consumption, cooling capacity, mass flow rate, temperature, and pressure, with high accuracy (within ±4%) compared to experimental data. In addition, this developed model has been used to create the system optimum high side pressure for high side expansion valve control, and to generate wide operating range simulation data for developing the batter-equivalent commercial refrigeration system model which can be used in grid interactive control development.
Dataset of low global warming potential refrigerant refrigeration system for fault detection and diagnostics
Abstract HVAC and refrigeration system fault detection and diagnostics (FDD) has attracted extensive studies for decades; however, FDD of supermarket refrigeration systems has not gained significant attention. Supermarkets consume around 50 kWh/ft 2 of electricity annually. The biggest consumer of energy in a supermarket is its refrigeration system, which accounts for 40%–60% of its total electricity usage and is equivalent to about 2%–3% of the total energy consumed by commercial buildings in the United States. Also, the supermarket refrigeration system is one of the biggest consumers of refrigerants. Reducing refrigerant usage or using environmentally friendly alternatives can result in significant climate benefits. A challenge is the lack of publicly available data sets to benchmark the system performance and record the faulted performance. This paper identifies common faults of supermarket refrigeration systems and conducts an experimental study to collect the faulted performance data and analyze these faults. This work provides a foundation for future research on the development of FDD methods and field automated FDD implementation.
Performance Assessment of High-Efficiency Refrigerated Display Cases with Low-GWP Refrigerants: Preprint
As California policy makers enforce new regulations such as SB 1383 to achieve state greenhouse gas (GHG) reduction goals, it will be critical to understand the energy efficiency implications of low global warming potential (GWP) refrigerants in commercial refrigeration applications. The goal of this research project, funded by Commonwealth Edison was to assess the energy performance of two high efficiency medium-temperature, self-contained, reach-in display cases that utilized natural refrigerant propane (R-290), and hydrofluorocarbon (HFC) drop-in hydrofluoroolefin R-513a, respectively. Performance of these display cases were compared to a baseline fixture using HFC (R-134a) under equal conditions in a controlled environment chamber. These display cases were selected due to their widespread use in convenience stores, and small supermarkets. The high efficiency cases were equipped with energy efficient lighting, improved panel insulation, high efficiency evaporator and condenser fan motors, and high effectiveness heat exchangers. The test method used in this project was foundationally inspired by the ANSI/ASHRAE 72-2018 standard method to evaluate each case under equivalent conditions. However, minor modifications to this methodology were implemented to better represent more realistic operation of the units. While maintaining target product temperature, the energy efficient fixtures containing R-290 and R-513a consumed 61.8% to 32.6% less energy, respectively, than a baseline case using R-134a refrigerant. The daily energy consumption of the R-290, R-513a, and baseline display cases at the upper limit of environmental conditions was 4.30, 7.59, and 11.26 kWh/day, respectively.
Performance Assessment of High-Efficiency Refrigerated Display Cases With Low Global Warming Potential Refrigerants
As California policy makers enforce new regulations such as SB 1383 to achieve state greenhouse gas reduction goals, it will be critical to understand the energy efficiency implications of low global warming potential (GWP) refrigerants in commercial refrigeration applications. The goal of this research project, funded by Commonwealth Edison, was to assess the energy performance of two high-efficiency medium-temperature, self-contained, reach-in display cases that utilized natural refrigerant propane (R-290, GWP = 3), and hydrofluorocarbon (HFC) drop-in hydrofluoroolefin R-513A (GWP = 573). Performance of these display cases was compared to a baseline fixture using HFC (R-134A, GWP = 1301) under equal conditions in a controlled environment chamber. These display cases were selected due to their widespread use in convenience stores and small supermarkets. The high-efficiency cases were equipped with energy-efficient lighting, improved panel insulation, high-efficiency evaporator and condenser fan motors, and high-effectiveness heat exchangers. The test method used in this project was foundationally inspired by the ANSI/ASHRAE 72-2018 standard method to evaluate each case under equivalent conditions (ASHRAE 2018). However, minor modifications to this methodology were implemented to better represent more realistic operation of the units. While maintaining equivalent target product temperature, the energy-efficient fixtures A (containing R-290, improved insulation, heat exchangers with a higher overall heat transfer coefficient (higher UA), and more efficient lighting and fan motors) and B (containing R-513A, improved fans, and higher UA-heat exchangers, and more efficient lighting and fan motors) consumed 61.8% to 32.6% less energy, respectively, than a baseline case using R-134A refrigerant. The daily energy consumption of the R-290, R-513A, and baseline display cases at the upper limit of environmental conditions was 4.30, 7.59, and 11.26 kWh/day, respectively.
Reliability of Copper Inverse Opal Surfaces for Extreme-Heat-Flux Micro-Coolers in Low-Global-Warming-Potential Refrigerant R-1233zd Pool Boiling Experiments
This presentation provides a brief snapshot of the InterPACK paper InterPACK2023-113781. The paper explores copper inverse opal (CIO) surface reliability in pool boiling experiments in water and a new, low-global-warming-potential (GWP = 1) hydrofluoroolefin (HFO) refrigerant R-1233zd. The CIO-based structure is intended to develop enhanced two-phase heat transfer surfaces for extreme-heat-flux (approximately 1 kW/cm2) micro-coolers. In this study, a limited number of pool boiling experiments were performed using water and HFO-1233zd fluid, and the reliability of the CIO-based surfaces was evaluated. Critical heat flux (CHF) values in HFO-1233zd at 40 Degrees Celsius to 45 Degrees Celsius saturation temperatures and the corresponding saturation pressures were also measured. The CHF values with the refrigerant are significantly lower compared to those with water, but the refrigerant allows for a wider usable temperature range in the end application of the micro-coolers and is not limited to data centers with controlled ambient conditions. Reliability experiments with CIO surface samples - involving pool boiling with water on the CIO surfaces for approximately 48 hours and with HFO-1233zd for 144 hours - showed no structural degradation of the enhanced surface or any significant performance drop in heat transfer coefficients. The CIO surface samples in water were oxidized, most likely due to the presence of air in water and in the experimental vessel.
Virtual Refrigerant Charge Sensing Method for Next-Generation Refrigerant in Residential Heat Pumps
The charge level of refrigerant in heat pump systems significantly affects their operational performance. Virtual refrigerant charge (VRC) sensing technology has been well-established for traditional refrigerants (HFCs and HCFCs) for its low cost compared to physical sensors. However, other than traditional refrigerants, HFOs are increasingly used in next-generation heat pumps; whether these conventional VRC sensing methods remain applicable for heat pump systems utilizing next-generation refrigerants requires further investigation. To address these issues, this study develops a low-cost VRC sensing method for next-generation refrigerant heat pumps used in residential buildings. The developed algorithm is evaluated by using simulation models to evaluate the accuracy, considering an R454B heat pump with a nominal heating capacity of 51K Btu/hr (14.95 kW) as an example, and compared with those of the two reference VRC sensing algorithms. Though the developed VRC sensing algorithm and the two reference methods can accurately predict the charge level for the R454B heat pump system (with mean absolute percentage error for various cooling and heating conditions less than 7%), the developed VRC sensing algorithm uses fewer sensors and improves the overall accuracy for heating conditions by 7.1%, and the accuracy for undercharge cooling conditions 14.2%, compared with a mainstream algorithm. This technology will complement physical leakage detectors, and promote the adoption of next-generation heat pump systems, along with reducing wasted energy and maintenance costs.
Vapor and Liquid ( p –ρ– T–x ) Measurements of Binary Refrigerant Blends Containing R-32, R-152a, R-227ea, R-1234yf, and R-1234ze(E)
In this article, The pressure–density–temperature–composition (p–ρ–T–x) data of binary refrigerant mixtures containing R-32 (difluoromethane), R-152a (1,1,-difluoroethane), R-227ea (1,1,1,2,3,3,3-heptafluoropropane), R-1234yf (2,3,3,3-tetrafluoropropene), and R-1234ze(E) (trans-1,3,3,3-tetrafluoropropene) were measured in both the vapor and liquid phases using a two-sinker, magnetic suspension densimeter. The specific samples in this study comprised two compositions of approximately (0.3/0.7) and (0.7/0.3) mole fraction for each of the following four binary refrigerant blends: R-32 + R-1234yf, R-32 + R-1234ze(E), R-1234yf + R-152a, and R-1234ze(E) + R-227ea. Single-phase vapor densities were measured over a temperature range of approximately 253 to 293 K and pressures from 0.05 to 0.98 MPa. Single-phase liquid and supercritical densities were measured over a temperature range of approximately 230 to 400 K and pressures up to 22 MPa; for refrigerant blends containing R-1234yf, the maximum pressure was limited to 14 MPa. Overall relative combined, expanded (k = 2) uncertainties in density ranged from 0.025 to 0.191%, with an average uncertainty of approximately 0.05%. Here, we present measurement results, along with comparisons to available literature data and to default equations of state and mixture models included in REFPROP.