Purdue University Purdue e-Pubs International Refrigeration and Air Conditioning School of Mechanical Engineering Conference 2012 Effect of Condenser Subcooling of the Performance of Vapor Compression Systems: Experimental and Numerical Investigation Gustavo Pottker [email protected] Predrag S. Hrnjak Follow this and additional works at: http://docs.lib.purdue.edu/iracc Pottker, Gustavo and Hrnjak, Predrag S., "Effect of Condenser Subcooling of the Performance of Vapor Compression Systems: Experimental and Numerical Investigation" (2012). International Refrigeration and Air Conditioning Conference. Paper 1328. http://docs.lib.purdue.edu/iracc/1328 This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact [email protected] for additional information. Complete proceedings may be acquired in print and on CD-ROM directly from the Ray W. Herrick Laboratories at https://engineering.purdue.edu/ Herrick/Events/orderlit.html 2512, Page 1 Effect of Condenser Subcooling of the Performance of Vapor Compression Systems: Experimental and Numerical Investigation Gustavo POTTKER, Pega HRNJAK* Department of Mechanical Science and Engineering University of Illinois at Urbana-Champaign 1206 West Green Street, Urbana, IL 61801, USA * Corresponding Author: [email protected] ABSTRACT This paper presents a theoretical and experimental analysis of the effect of condenser subcooling on the performance of vapor-compression systems. It is shown that, as condenser subcooling increases, the COP reaches a maximum as a result of a trade-off between increasing refrigerating effect and specific compression work. The thermodynamic properties associated with the relative increase in refrigerating effect, i.e. liquid specific heat and latent heat of vaporization, are dominant to determine the maximum COP improvement with condenser subcooling. Refrigerants with large latent heat of vaporization tend to benefit less from condenser subcooling. For a typical AC system, numerical results indicate that the R1234yf would benefit the most from condenser subcooling in comparison to R410A, R134a and R717 due to its smaller latent heat of vaporization. On the other hand, the value of COP maximizing subcooling does not seem to be a strong function of thermodynamic properties. Experimental results comparing R1234yf and R134a confirmed the trends observed during the numerical study. For a given operating condition, the system COP increased up to 18% for R1234yf and only 9% for R134a. 1. INTRODUCTION The state of the refrigerant entering the expansion device of conventional vapor compression cycles is usually assumed to be saturated liquid. However, liquid cooling below saturation reduces the throttling losses and potentially increases COP. Subcooled liquid prior to expansion process can be obtained by adding extra components such as internal heat exchangers in single-stage cycles (Domanski and Didion, 1994) and in two-stage cycles. Subcooling can also be achieved by an auxiliary cooling system such as a thermoelectric device (Radermacher et. al., 2007), a secondary vapor compression system – also known as mechanical subcooling (Couvillion et. al., 1988) or using available coolant supplies, such as condensate water from evaporator (Peterson, 1997). An additional heat-sink cooled heat exchanger, usually denominated subcooler, can also be used to obtain subcooling. Typically, a high-side pressure receiver is installed between the condenser and the subcooler in order to separate liquid from vapor before liquid runs through the subcooler. One can think of the subcooler not only as separate heat exchanger but as part of a then larger condenser which has some of its surface allocated to subcool liquid. In fact, the most conventional way to obtain subcooling in systems without a liquid receiver is by utilizing part of condenser heat transfer area to cool down the liquid below the saturation temperature. Rather than in a high- side pressure receiver, the liquid-vapor interface is eliminated inside the tubes of the condensers, as liquid refrigerant accumulates towards the exit of the heat exchanger. The so-called condenser subcooling is typically obtained during a refrigerant charging procedure. The question raised by Gosney (1982) is whether one would be better off using the subcooling heat transfer surface, either within the condenser or in a separate subcooler, to reduce the condensing pressure and consequently the compression work. Linton et al. (1992) experimentally investigated the effect of condenser liquid subcooling on a refrigeration system performance. Results showed that the cooling COP and refrigeration capacity of all three refrigerants benefited from subcooling increase (from 6°C to 18°C): R134a (12.5%), R12 (10.5%) and R152a (10%), while condensing temperature was kept artificially constant. Subcooling has also been subject of publications related to automotive air conditioners. These systems are usually equipped with either a high-side liquid receiver or a low-side accumulator in order to absorb fluctuations in refrigerant charge. Yamanaka et al. (1997) presented a concept of a sub-cool system in which the liquid receiver is installed before the last pass of a parallel flow microchannel condenser rather than at the exit of the condenser. COP would benefit from subcooling due to an increase in enthalpy difference across International Refrigeration and Air Conditioning Conference at Purdue, July 16-19, 2012 2512, Page 2 evaporator. Condensers with integrated receiver and subcooler pass have become standard in state-of-the-art automotive air conditioning systems. Pomme (1999) also presented a similar study in which subcooling was generated by a pre-expansion valve between the condenser exit and the liquid receiver. A few publications that examined the influence of the refrigerant charge on the COP indirectly explored the relationship between subcooling and COP. Corberan et al. (2008) maximized COP by varying the refrigerant charge in an R290 heat pump equipped with a thermostatic expansion valve. They explained that the system responded to increasing charge by rising the condenser subcooling since no receiver was installed. The COP maximizing charge was related to a COP maximizing subcooling. Primal and Lundqvist (2005) had also optimized the charge of a R290 domestic water heat pump and found the corresponding subcooling to be 4-5°C. Although condenser subcooling is a practical issue in the everyday of refrigeration and air conditioning systems, to the best of authors’ knowledge, this topic has not been the subject of a systematic study in the open literature so far. This study is an attempt to start filling up this gap. First, this paper will theoretically explore the performance trade- off associated with condenser subcooling using cycle analysis. Then, important thermodynamic properties related to this trade-off will be identified and a sensitivity analysis will be presented for different refrigerants. Second, a comprehensive simulation model of an air conditioner will be used estimate potential for COP improvement with condenser subcooling for different refrigerants. Finally, the effect of subcooling on the performance of an actual vehicular air conditioning system will experimentally investigated for two refrigerants (R134a and R1234yf) under the same operating conditions. 2. CYCLE ANALYSIS Fig. 1 illustrates a schematic of a water-cooled tube-in-tube condenser with and without subcooling and Fig. 2 outlines the respective cycles on a T-h diagram. A prime (‘) denotes the cycle with subcooling. Due to the presence of subcooled liquid (Fig 1b), the two-phase heat transfer area would be reduced relative to a condition without subcooling (Fig 1a). As a result, the saturation temperature would rise in the condenser (∆Tc,sat, Fig. 2) which would subsequently increase the specific compression work (∆w, Fig. 2). On the other hand, the refrigerant temperature at the condenser outlet would decrease (∆Tc,out, Fig. 2), increasing subsequently the refrigerant enthalpy difference through the evaporator (∆q, Fig. 2). This logic can be expressed by Eq. (1) and suggests that COP may undergo a maximum, resulting from a trade-off between increasing specific refrigerating effect (by ∆q) and compression work (by ∆w). As illustrated in Fig. 2, strictly speaking, the subcooling (∆Tc,sub) can be a result of both a decrease in refrigerant condenser exit and an increase in condensing temperature. Water Cycle with 2’ subcooling From H TP compressor S 2 ] b u C s DTc,sat Water , ° c [ T DTc,out 3 e D r u 3’ (a) . t t . s . a t t Cycle without n r s s o n n c e subcooling Water o o = p c c s = = m From H TP SC h h e S compressor T Water 1 4’ 4 1’ (b) Dq q w Dw Enthalpy [kJ/kg] Figure 1: Schematic of a water-cooled condenser with (a) and Figure 2: Schematic of cycles with and without subcooling in without (b) subcooling. a T-h diagram. Dq Dw COP ' COP 1 (1) q w q COP (2) w The relative increase in refrigerating effect (∆q/q) can be approximated by Eq. (3) which shows that the relative change in refrigerating effect due to the variation of the refrigerant outlet temperature to the condenser depends on the ratio of liquid specific heat to latent heat of vaporization and on the temperature lift, (Tc - Te)sat. It suggests that reducing the temperature of the refrigerant at the condenser exit would be more welcome for refrigerants with large International Refrigeration and Air Conditioning Conference at Purdue, July 16-19, 2012 2512, Page 3 liquid specific heat and smaller latent heat of vaporization and for operating conditions with high temperature lifts. A similar approach is taken for the relative increase in specific isentropic compression work (∆w/w), given by Eq. (4). Dq DT c,out q h fg,e (3) Tc Te sat c pl Dw h h 2' 2 (4) w h h 2 1 is Table 1 shows calculated numerical values of ∆q/q and Table 1: Effect of refrigerant properties on the relative ∆w/w for several refrigerants, with fixed ∆Tc,out = 5°C and increase in refrigerating effect and specific isentropic compression work ∆Tc,sat = 1°C.