Experimental Thermal and Fluid Science 35 (2011) 978–985
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Experimental Thermal and Fluid Science
journal homepage: www.elsevier.com/locate/etfs
The effect of vapour super-heating on hydrocarbon refrigerant condensation inside a brazed plate heat exchanger ⇑ Giovanni A. Longo
University of Padova, Department of Management and Engineering, Str.lla S. Nicola 3, I-36100 Vicenza, Italy article info abstract
Article history: This paper investigates the effect of vapour super-heating on hydrocarbon refrigerant 600a (Isobutane), Received 4 November 2010 290 (Propane) and 1270 (Propylene) condensation inside a brazed plate heat exchanger. Received in revised form 30 January 2011 Vapour super-heating increases heat transfer coefficient with respect to saturated vapour, whereas no Accepted 30 January 2011 effect was observed on pressure drop. Available online 4 February 2011 The super-heated vapour condensation data shows the same trend vs. refrigerant mass flux as the sat- urated vapour condensation data, but with higher absolute values. A transition point between gravity Keywords: controlled and forced convection condensation has been found for a refrigerant mass flux around 15– Condensation 18 kg m 2 s 1 depending on refrigerant type. The super-heated vapour heat transfer coefficients are from Super-heating Refrigerant 5% to 10% higher than those of saturated vapour under the same refrigerant mass flux. Heat transfer The experimental heat transfer coefficients have been compared against Webb (1998) model for forced Pressure drop convection condensation of super-heated vapour: the mean absolute percentage deviation between the experimental and calculated data is ±18.3%. HC-1270 shows super-heated vapour heat transfer coefficient 5% higher than HC-600a and 10–15% higher than HC-290 together with total pressure drops 20–25% lower than HC-290 and 50–66% lower than HC-600a under the same mass flux. Ó 2011 Elsevier Inc. All rights reserved.
1. Introduction provided also analytical solutions accounting for super-heating ef- fect on condensate film thickness and heat transfer coefficient. In the inverse cycle machines the refrigerant vapour coming With specific reference to refrigerant super-heated vapour con- from the compressor at the inlet of the condenser exhibits some densation Goto et al. [5] measured the heat transfer coefficient degrees of super-heating, normally from 10 °Cto50°C, depending during CFC-113 film condensation on a horizontal tube and they on the isoentropic characteristics of the refrigerant and the pres- found a 5% of heat transfer coefficient enhancement with respect sure ratio. Therefore it is interesting, under a technical point of to saturated vapour condensation for 40 °C of super-heating. Hueb- view, to evaluate the performance of the condenser not only in sat- esch and Pate [6] experimentally investigated HFC-236ea and CFC- urated vapour condensation as it is usual, but also in the real oper- 114 condensation on plain and integral fin tubes and they found a ating conditions in chiller and heat pump considering the effect of 3–5% enhancement with 3–5 °C of super-heating. Longo [7,8] mea- vapour super-heating. sured the heat transfer coefficients of HFC-134a and HFC-410A sat- Minkowycz and Sparrow [1,2] analytically investigated the ef- urated and super-heated vapour (10 °C) inside a brazed plate heat fect of vapour super-heating both in laminar film and forced con- exchanger. The super-heated vapour heat transfer coefficients are vection condensation by integrating the energy and momentum 8–10% higher than those of saturated vapour under the same equation in the boundary layer. For steam condensation they com- refrigerant mass flux both for HFC-134a and HFC-410A. puted a maximum heat transfer coefficient increase of 3%. The present paper investigates the effect of vapour super-heat- Mitrovic [3] for laminar film condensation and Webb [4] for ing on hydrocarbon refrigerant 600a (Isobutane), 290 (Propane) forced convection condensation shown that the condensate film and 1270 (Propylene) condensation inside a brazed plate heat is thinner and therefore the heat transfer coefficient is larger for exchanger. super-heated vapour than for saturated vapour condensation. They 2. Experimental set-up and procedures
⇑ Tel.: +39 0444 998726; fax: +39 0444 998888. The experimental facility, as shown in Fig. 1, consists of a E-mail address: [email protected] refrigerant loop, a water-glycol loop and two water loops. In
0894-1777/$ - see front matter Ó 2011 Elsevier Inc. All rights reserved. doi:10.1016/j.expthermflusci.2011.01.018 G.A. Longo / Experimental Thermal and Fluid Science 35 (2011) 978–985 979
Nomenclature
A nominal area of a plate, m2 Greek symbols b height of the corrugation, m b inclination angle of the corrugation 1 1 cp specific heat capacity, J kg K D difference 1 dh hydraulic diameter, dh =2b,m DJLG latent heat of condensation (vaporisation), J kg F factor in Eq. (12) / enlargement factor f.s. full scale k thermal conductivity, W m 1 K 1 g gravity acceleration, m s 2 l viscosity, kg m 1 s 1 2 1 3 G mass flux, G = m/(nchWb), kg m s q density, kg m h heat transfer coefficient, W m 2 K 1 1 J specific enthalpy, J kg Subscripts k coverage factor ave average L flow length of the plate, m AKERS Akers et al. [18] 1 m mass flow rate, kg s e evaporator N number of plates effective in heat transfer eq equivalent nch number of channels fc forced convection p pressure, Pa G vapour phase P corrugation pitch, m in inlet Pr Prandtl number, Pr = lcp/k L liquid phase 2 q heat flux, q = Q/S,Wm LG liquid gas phase change Q heat flow rate, W lat latent Ra arithmetic mean roughness (ISO 4271/1), lm ln logarithmic Re Reynolds number, Re = Gdh/l m average value Reeq equivalent Reynolds number, Reeq = G[(1 – X)+ 1/2 out outlet X(qL/qG) ]dh/lL p plate Rp roughness (DIN 4762/1), lm r refrigerant s plate wall thickness, m 2 t total S nominal heat transfer area, m sat saturation T temperature, K sup super-heating 2 1 U overall heat transfer coefficient, W m K w water v specific volume, m3 kg 1 3 wall tube or plate wall V volume, m wi water inlet W width of the plate, m wo water outlet X vapour quality, X =(J – JL)/DJLG
the first loop the refrigerant is pumped from the sub-cooler into erant pressure drop through the condenser is measured by a the evaporator where it is evaporated and eventually super-heated strain-gage differential pressure transducer (uncertainty (k =2) to achieve the set vapour quality or vapour super-heating at the within 0.075% f.s.). The refrigerant mass flow rate is measured by condenser inlet. The refrigerant goes through the condenser where means of a Coriolis effect mass flow meter (uncertainty (k =2)of it is condensed and eventually sub-cooled and then it comes back 0.1% of the measured value); the water flow rates through the con- to the post-condenser and the sub-cooler. A variable speed volu- denser and the evaporator are measured by means of magnetic metric pump varies the refrigerant flow rate and a bladder accu- flow meters (uncertainty (k = 2) of 0.15% of the f.s.). All the mea- mulator, connected to a nitrogen bottle and a pressure regulator, surements are scanned and recorded by a data logger linked to a controls the operating pressure in the refrigerant loop. The second PC: Table 2 outlines the main features of the different measuring loop is able to supply a water-glycol flow at a constant tempera- devices in the experimental rig. ture in the range of 10 to 60 °C with stability within ±0.1 K used Before starting each test the refrigerant is re-circulated through to feed the sub-cooler and the post-condenser. The third and the the circuit, the post-condenser and the sub-cooler are fed with a fourth loops supply two water flows at a constant temperature water-glycol flow rate at a constant temperature and the con- in the range of 3–60 °C with stability within ±0.1 K used to feed denser and the evaporator are fed with water flow rates at constant the evaporator and the condenser respectively. temperatures. The refrigerant pressure and the vapour quality or The condenser tested is a BPHE consisting of 10 plates, 72 mm super-heating at the condenser inlet and outlet are controlled by in width and 310 mm in length, which present a macro-scale her- adjusting the bladder accumulator, the volumetric pump, the flow ringbone corrugation with an inclination angle of 65° and a corru- rate and the temperature of the water glycol and the water flows. gation amplitude of 2 mm. Fig. 2 and Table 1 give the main Once temperature, pressure, flow rate and vapour quality steady geometrical characteristics of the BPHE tested. state conditions are achieved at the condenser inlet and outlet both The temperatures of refrigerant and water at the inlet and out- on refrigerant and water sides all the readings are recorded for a let of the condenser and the evaporator are measured by T-type set time and the average value during this time is computed for thermocouples (uncertainty (k = 2) within ±0.1 K); the water each parameter recorded. temperature variations through the condenser and the evaporator Super-heated vapour condensation is a complex phenomenon, are measured by T-type thermopiles (uncertainty (k = 2) within particularly inside BPHE, due to the complicated geometry and ±0.05 K). The refrigerant pressures at the inlet of the condenser the inaccessibility of the heat transfer surface. Therefore the exper- and the evaporator are measured by two absolute strain-gage pres- imental results are reported in terms of average heat transfer coef- sure transducers (uncertainty (k = 2) within 0.075% f.s.); the refrig- ficient and total pressure drop on the refrigerant side. 980 G.A. Longo / Experimental Thermal and Fluid Science 35 (2011) 978–985
Fig. 1. Schematic view of the experimental test rig.
Table 1 Geometrical characteristics of the condenser.
Fluid flow plate length L (mm) 278.0 Plate width W (mm) 72.0 Area of the plate A (m2) 0.02 Enlargement factor U 1.24 Corrugation type Herringbone Angle of the corrugation b (°)65 Corrugation amplitude b (mm) 2.0 Corrugation pitch P (mm) 8.0
Plate roughness Ra (lm) 0.4
Plate roughness Rp (lm) 1.0 Number of plates 10 Number of plates effective in heat transfer N 8
Number of channels on refrigerant side nch.r 4
Number of channels on water side nch.w 5
U ¼ Q=ðSDTlnÞð1Þ The heat flow rate is derived from a thermal balance on the waterside of the condenser:
Q ¼ mwcpwjDTwjð2Þ Fig. 2. Schematic view of the plate. where mw is the water flow rate, cpw the water specific heat capacity and |DTw| the absolute value of the temperature variation on the waterside of the condenser. It includes both the desuper-heating The overall heat transfer coefficient in the condenser U is and the phase change contributions. The nominal heat transfer area equal to the ratio between the heat flow rate Q, the nominal of the condenser heat transfer area S and the logarithmic mean temperature dif- S NA 3 ference DTln ¼ ð Þ G.A. Longo / Experimental Thermal and Fluid Science 35 (2011) 978–985 981
Table 2 The refrigerant vapour quality at the condenser inlet and outlet Specification of the different measuring devices. Xin and Xout are computed starting from the refrigerant tempera- Devices Type Uncertainty Range ture Te.in and pressure pe.in at the inlet of the evaporator (sub- (k =2) cooled liquid condition) considering the heat flow rate exchanged
Thermometers T-type 0.1 K 20/80 °C in the evaporator and in the condenser Qe and Q and the pressure thermocouples at the inlet and outlet pin and pout of the condenser as follows: Diff. thermometers T-type thermopiles 0.05 K 20/80 °C Abs.pressure Strain-gage 0.075% f.s. 0/2.5 MPa Xin ¼ f ðJin; pinÞð7Þ transd. Diff. pressure Strain-gage 0.075% f.s. 0/0.3 MPa Xout ¼ f ðJout; poutÞð8Þ transd. Refrigerant flow Coriolis effect 0.1% 0/300 kg h 1 meter Jin ¼ Je:inðTe:in; pe:inÞþQ e=mr ð9Þ Water flow meters Magnetic 0.15% f.s. 100/1200 l h 1 Jout ¼ Jin þ Q=mr ð10Þ
Q e ¼ me:wcpwjDTe:wjð11Þ is equal to the nominal projected area A = L W of the single plate where J is the specific enthalpy of the refrigerant, mr the refrigerant multiplied by the number N of the effective elements in heat trans- mass flow rate, me.w the water flow rate and |DTe.w| the absolute va- fer. The use of the projected area instead of the actual area allows lue of the temperature variation on the waterside of the evaporator. comparing different plate patterns on an equal volume basis, as The refrigerant properties are evaluated by Refprop 7.0 (NIST [14]). suggested by Shah and Focke [9]. Moreover, due to the brazing material deposition, the actual heat transfer area of a BPHE is differ- 3. Analysis of the results ent from that of the plates and generally unknown. The logarithmic mean temperature difference is equal to: Three different sets of super-heated vapour condensation tests with refrigerant down-flow and water up-flow are carried out at DTln ¼ðTwo TwiÞ=ln½ðTsat TwiÞ=ðTsat TwoÞ ð4Þ four different saturation temperatures: 25, 30, 35 and 40 °C. The where Tsat is the average saturation temperature of the refrigerant condenser outlet condition is slightly sub-cooled condensate. The derived from the average pressure measured on refrigerant side first set includes 37 runs with HC-600a, the second 39 runs with and Twi and Two the water temperatures at the inlet and the outlet HC-290, the third 36 runs with HC-1270. Table 3 indicates the of the condenser. The logarithmic mean temperature difference is operating conditions in the condenser under experimental tests: computed with reference to the average saturation temperature refrigerant saturation temperature Tsat and pressure psat, inlet va- on the refrigerant side as recommended by Bell [10,11] for a proper pour super-heating DTsup and outlet condensate sub-cooling DTsub, design in super-heated vapour condensation whenever the temper- mass flux on refrigerant side Gr and water side Gw, heat flux q. The ature of the heat transfer surface is below the saturation tempera- water and refrigerant mass flux and the heat flux tested cover the ture. In fact, if the temperature of the heat transfer surface is real operating conditions of BPHE condensers in chiller and heat below the saturation temperature, the super-heated vapour con- pump applications [15]. denses directly with a heat transfer coefficient near to that of satu- A detailed error analysis performed in accordance with Kline rated vapour condensation and there is no desuper-heating area at and McClintock [16] indicates an overall uncertainty (k = 2) within the inlet of the condenser working only with gas single-phase heat ±12% for the refrigerant heat transfer coefficient measurement and transfer coefficient. Similarly the condensate film along the whole within ±23% for the refrigerant total pressure drop measurement. heat transfer surface is sub-cooled and there is no sub-cooling area Table 4 shows a summary of the uncertainty analysis. at the outlet of the condenser working only with liquid single-phase Figs. 3–5 show the average heat transfer coefficients on the heat transfer coefficient. In this case, for Bell [10,11], it is both sim- refrigerant side vs. refrigerant mass flux at different saturation pler and more conservative to assume that condensation will occur temperatures (25, 30, 35 and 40 °C) for refrigerant HC-600a, HC- directly from the super-heated vapour using the saturation temper- 290 and HC-1270 respectively. For comparison the figures show ature as the temperature driving force and the average condensa- also the experimental data relative to saturated vapour condensa- tion heat transfer coefficient along the whole heat transfer tion inside the same BPHE under the same operating conditions surface, of course including the desuper-heating sensible heat in previously obtained by the same author [17]. the total heat load. The heat transfer coefficients show weak sensitivity to satura- The average heat transfer coefficient on the refrigerant side of tion temperature (pressure) for all the refrigerants tested. the condenser hr.ave is derived from the global heat transfer coeffi- The saturated vapour data and the super-heated vapour data cient U assuming no fouling resistances: show the same trend vs. refrigerant mass flux for all the refriger- ants tested. At low refrigerant mass flux (G < 15–18 kg m 2 s 1) h ¼ð1=U s=k 1=h Þ 1 ð5Þ r r:ave p w the heat transfer coefficients are not dependent on mass flux and by computing the waterside heat transfer coefficient hw using a probably condensation is controlled by gravity. For higher refriger- 2 1 modified Wilson plot technique. A specific set of experimental ant mass flux (Gr > 15–18 kg m s ) the heat transfer coefficients water-to-water tests is carried out on the condenser to determine depend on mass flux and forced convection condensation occurs. In the calibration correlation for heat transfer on the waterside, in the forced convection condensation region the heat transfer coeffi- accordance with Muley and Manglik [12]; the detailed description cients show a 35–40% enhancement for a 60% increase of the of this procedure is reported in [13]. refrigerant mass flux. The behaviour of the heat transfer coefficient The calibration correlation for waterside heat transfer coeffi- vs. the refrigerant mass flux might be explained by considering the cient obtained results: combined effect of gravity and vapour shear on condensate drain- 2 1 age. At low refrigerant mass flux (Gr < 15–18 kg m s ) the va- 0:766 0:333 hw ¼ 0:277ðkw=dhÞRew Prw ð6Þ pour shear has a weak effect on the condensate flow which is governed mainly by gravity. For higher refrigerant mass flux 5 < Pr < 10 200 < Re < 1200 2 1 w w (Gr > 15–18 kg m s ) the vapour shear reduces the thickness of 982 G.A. Longo / Experimental Thermal and Fluid Science 35 (2011) 978–985
Table 3 Operating conditions during experimental tests.