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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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36 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Experimental study of R452B and R454B as drop-in replacement for R410A in split heat pumps having tube-fin and microchannel heat exchangers

The objective of this study is to experimentally evaluate two residential split heat pumps using low-GWP refrigerants, i.e., R452B and R454B, and compare the results against R410A. In this work, each heat pump used the same model of two-speed scroll compressor, the same indoor blower and outdoor fan. However, they were distinguished by the indoor and outdoor heat exchanger types: tube-fin heat exchangers (TFHXs) in one case, and microchannel heat exchangers (MCHXs) in the other. The two heat pumps were extensively evaluated following the test conditions for two-speed SEER (cooling seasonal energy efficiency rating)/HSPF (heating seasonal performance factor) ratings.In general, these results show that R452B and R454B are good replacement candidates for R410A for heat pump using tube-fin heat exchangers and microchannel heat exchangers. R452B and R454B led to lower capacities. In the TFHX heat pump, on average, compared to the performance of R410A, the cooling capacity of R452B is 96%; the heating capacity of R452B is 91%; the cooling capacity of R454B is 95%, the heat capacity of R454B is 89%. In the MCHX heat pump, the cooling capacity of R452B is 97%; the heating capacity of R452B is 97%; the cooling capacity of R454B is 98%, the heat capacity of R454B is 97%. With respect to cooling and heating seasonal performances, in the TFHX heat pump, the SEERs of R452B and R454B are 1.5% lower than R410A. HSPFs of the three refrigerants are identical. In the MCHX heat pump, R454B has 7% higher SEER, and R452B has 2% higher SEER than R410A; in heating mode, R454B has the same HSPF as R410A, while R452B is 4% more efficient. The compressor lubricant overheating issue of R452B and R454B, at low ambient heating condition, high stage, should be noticed.

42 ENGINEERING↗
DOE OSTI2023

Condensation heat transfer and pressure drop of low-global warming potential refrigerants in smooth aluminum tubes

In this work we report condensation heat transfer coefficient and pressure drop data for R-454B, R-32, and R-454C. These refrigerants are low Global Warming Potential (GWP) replacements for R-410A. We obtained these data in a smooth 7.2 mm outer diameter (5.94 mm inner diameter) aluminum tube. In these experiments, the key variables were condensation temperature (35 °C ≤ T cond ≤ 50 °C) and refrigerant mass flux (151.1 ≤ G ≤ 347.3 kg m –2 s –1 ). In general, for similar nominal operating conditions, we measured the highest heat transfer coefficients for R-32 and the lowest for R-454C. Among the correlations we used to predict the heat transfer data for all three refrigerants, the one developed by Thome et al. (2003) predicted the data with the greatest accuracy. Deviations between experimental data and predictions of this correlation were 21.7% for R-454B (with SBG correction), 22.0% for R-32, and 18.8% for R-454C (with SBG correction). Experimental pressure gradient data were predicted by the Friedel correlation Friedel (1979) with deviations of 13.8% for R-454B, 9.8% for R-32, and 10.2% for R-454C. In this work, we also compare the predictions of the Cavallini et al. correlation Cavallini et al. (2006) for R-454B and R-32 in smooth copper versus smooth aluminum tubes. To improve this correlation’s predictive capability for aluminum tubes, we have proposed some modifications. After incorporating these modifications, the deviations between the correlation’s predictions and our data were 10% for R-454B (with SBG correction), 8.1% for R-32, and 5.2% for R-454C (with SBG correction). Furthermore, these data and findings will assist the HVAC and refrigeration industry to implement low-GWP refrigerants in condensers using smooth aluminum tubes.

Aluminum tube↗
DOE OSTI2021

Trends in best-in-class energy-efficient technologies for room air conditioners

Improving the efficiency of room air conditioners (RACs) could provide significant energy and associated emissions savings, particularly in emerging economies with hot climates where the cooling demand is expected to increase dramatically. To help accelerate efficiency improvements, this study identifies “best-in-class” high-efficiency RAC components and products. The findings show that manufacturers tend to minimize manufacturing costs by using RAC designs that are readily available or standardized to their production, and they share components across various models. High-efficiency RAC models use advanced compressor technologies optimized at a low frequency, large heat exchangers with thermodynamically effective materials and designs, highly efficient direct current fan motors, advanced metering devices, and smart sensors for temperature and humidity control. Recently RAC manufacturers have been improving seasonal efficiency – better reflecting part-load operation – especially via variable-speed (inverter) drives for compressor motors. Recent highest-efficiency RAC models use low global warming potential (GWP) refrigerants, having transitioned from conventional high-GWP refrigerants, in regions where RACs that use these low-GWP refrigerants are commercially available. Recently demonstrated innovative technologies show trends toward smart hybrid designs, evaporative cooling, and solid-state materials beyond the conventional vapor-compression technology. This information could help policymakers improve their RAC market-transformation programs to align with the most-efficient global technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

On falling film evaporator – A review of mechanisms and critical assessment of correlation on a horizontal tube bundle with updated development

Optimization of the energy efficiency and reduction of the greenhouse gas emission for the heat pump system is imperative to meet the net-zero goals at 2050. Chillers with falling film evaporator design not only possess better system performance but also contain less refrigerant inventory. Hence, accurate prediction of the evaporator performance is pivotal especially when charged with low-GWP refrigerant. Here, the study reviews the correlations for falling film evaporator with a horizontal tube bundle configuration. The major efforts of this study include four tasks: (a) literature review of the experimental studies and available empirical correlations; (b) comprehensive discussion of the falling film evaporation heat transfer mechanism; (c) development of a new rationally based correlation based on available literature; and (d) comparison of different correlations based on the existing data. The collected data includes 4114 data points from 8 sources, 6 refrigerants (R-600a, R-290, R-245fa, R-134a, R-1234ze(E), R-123), 5 types of the tubes (Plain, Turbo-GII-HP, GEWA-B, Low-fin, High-Flux), liquid Weber number from 2.2 × 10 –6 to 0.7, imposed vapor Weber number from 0 to 37.2, heat flux from 2.5 to 151.5 kW/m 2 , and film Reynolds number from 1 to 3159.8. The new correlation gives a MAD of 28.3%, and an R 2 of 0.86. Yet, the developed correlation considers various heat transfer mechanisms, including the transition point from falling film evaporation to the nucleate boiling, local evaporation, dry-out, mist flow, imposed flow, and enhanced tube effects.

42 ENGINEERING↗
DOE OSTI2021

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.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Elucidating the challenges in extracting ultra-slow flame speeds in a closed vessel - A CH 2 F 2 microgravity case study using optical and pressure-rise data

Refrigerants with a low global warming potential (GWP) possess mild flammability. Hence, a fundamental understanding of their combustion characteristics is required to assess their fire-hazardous potential. The laminar burning velocity is one fundamental property to describe these under safety evaluation aspects. However, measuring laminar burning velocities for slow-burning components, such as low-GWP alternatives, is challenging. This is due to influencing effects such as buoyant flame deformation, stretch, radiation, and confinement, especially at the flammability limits. Here, in the present study, we investigated near-limit flames of the representative refrigerant difluoromethane (CH 2 F 2 ) with nitrogen-enriched oxidizer mixtures to elucidate the potentials and limitations at ultra-slow flame speeds of two widely used flame speed measurement methods in the closed vessel configuration: the optical flame speed measurement in the early quasi-isobaric regime and the flame speed determination from the pressure-rise during the later phase of the isochoric combustion process. Experiments were performed under terrestrial- and microgravity, conducted in a specially designed setup suitable for drop tower applications, using both methods in parallel. Recommendations for the extraction of flame speed data are derived from the non-buoyant reference investigations under microgravity and transferred to ultra-slow flames at terrestrial gravity. Near-limit flames under microgravity were found to be significantly affected by stretch effects for the optical method so that flame speed extrapolations to unstretched conditions are prone to errors. Stretch also affects the pressure method’s lower evaluation limit, and errors can be estimated by combining flame speed data from the pressure method and Markstein lengths from optical experiments.

42 ENGINEERING↗
DOE OSTI2026

Interface and Thermophysical Properties of R 32 Refrigerant

Driven by the urgent demand for efficient cooling in microelectronics and advanced thermal management systems, difluoromethane (R32/CH 2 F 2 ) has emerged as a promising candidate owing to its favorable thermophysical properties, including high heat transfer efficiency and low viscosity. While bulk properties such as density, viscosity, and thermal conductivity have been widely studied, interfacial properties, including surface tension and interfacial thickness, remain comparatively underexplored, despite their importance in phase-transition dynamics. Here, we perform molecular dynamics (MD) simulations from 180 to 300 K using an optimized transferable force field for fluoropropenes with enhanced electrostatics to assess both bulk and interfacial behavior of R32. Simulations reproduced density within ±2.1%, viscosity within 3.05%, and thermal conductivity within 7.41% of NIST reference data. Heat capacities (C p and C v ) were predicted within 5%. For interfacial properties, surface tension trends were reproduced within 13.58% deviation, and the vapor–liquid coexistence curve closely matched reference data, yielding a critical temperature of 345.7 K (1.6% deviation) and a critical density of 0.397 g/cm 3 (6.4% deviation). Importantly, the vapor–liquid interface exhibited pronounced temperature-dependent broadening across the 180–290 K range. This behavior correlates with increasing molecular kinetic energy, reduction in intermolecular cohesive interactions, and a progressive loss of preferential dipole alignment, which collectively enhance thermal fluctuation amplitudes at elevated temperatures. These validated results provide predictive molecular-level insights, particularly for interfacial properties that remain less characterized. By reducing property prediction errors in key parameters such as critical temperature, this work provides reliable inputs for heat-exchanger and system models. Such correlations can support optimized component sizing, improved performance, and reduced refrigerant charge. Beyond R32, the methodology offers a transferable framework for blended and next-generation low-GWP refrigerants, contributing to sustainable thermal management aligned with the 2027 EU F-Gas regulation and 2030 Kigali Amendment.

Fluids↗
DOE OSTI2024

ANALYSIS OF SUITABLE METHODOLOGIES FOR COMPRESSOR MASS FLOW RATE CORRECTION TO OTHER SUPERHEAT LEVELS AND REFRIGERANTS

This paper investigates the impact of suction conditions and refrigerant on scroll compressor mass flow rate by using calorimeter tests from AHRI-11 and AHRI-21 reports, published by AHRI's Low-GWP Alternative Refrigerants Evaluation program. Two Copeland scroll compressors (20 and 51 cm3) have been analyzed including different suction conditions (SH = 11K, SH = 22K, Ti = 18ºC) and several refrigerants (R134a, R32, R410A, R404A, etc.). Previous studies have explored response surfaces for energy consumption and mass flow rate variables. This study aims to expand the analysis by identifying the optimal approach to extrapolate mass flow rate from specific suction conditions to others SH or suction temperature levels and refrigerants. The current compressor characterization standard relies on the 1981 Dabiri correlation to correct compressor mass flow rate with suction conditions. Thus, this study aims to assess the adequacy of this correction and explore alternative correction methods for improved results.

Marchante Avellaneda, Javier↗
DOE OSTI2024

Mitigation of Safety and Environmental Challenges Posed by Low and Ultra-low GWP Refrigerants

The abatement of safety and environmental burden associated with low and ultra-low Global Warming Potential (GWP) refrigerants is a critical undertaking. As the industry shifts towards more environmentally friendly alternatives, mitigating the potential risks and ensuring safety standards becomes paramount. The adoption of low GWP and ultra-low GWP refrigerants contributes significantly to minimizing the greenhouse gas impact on the environment, aligning with global climate and sustainability goals. However, it is essential to address safety concerns and potential environmental implications associated with the end use of these refrigerants.A method to mitigate the safety risk in a flammable refrigerant based HVACR system is the primary focus of this paper. Advent of A2L and A3 refrigerants as replacements to high GWP refrigerants requires careful handling of leak episodes to lower or eliminate the risk associated with creating flammable mixtures capable of fire/explosion hazard. Solid materials tailored to target the molecule of interest (i.e., refrigerant.) by engineering the microporous structure as well as chemically functionalizing the surface to attract and hold on to the chemical compound being removed from the gas stream was realized. Additionally, a chromatic transformation technique is investigated for rapid on-site analysis of refrigerant blends. Preliminary results demonstrating the feasibility of both of these methods for successful deployment of low-GWP refrigerants are presented.

Cheekatamarla, Praveen↗
DOE OSTI2020

Refrigerants: Market Trends and Supply Chain Assessment

The National Renewable Energy Laboratory (NREL), in partnership with ORNL, under the Clean Energy Manufacturing Analysis Center (CEMAC www.manufacturingcleanenergy.org) umbrella, assessed the current state of existing and low-GWP refrigerants for major end-use applications, including HVAC and those outside of the HVAC industry. The project incorporated a market overview, and supply chain assessment to determine the production, distribution, consumption, costs, and potential operating efficiency impacts of new and alternative refrigerants entering the market. Market trends and ongoing research are also documented. This work supplements other DOE efforts to support research activities on refrigerants and their applications including a refrigerant R&D roadmap and outlook into global air conditioning markets (Goetzler et al. 2014, 2016).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

International review of market trends, technologies and policies for commercial refrigeration equipment and implications for China

This report reviews the latest global and China-specific market trends as well as latest technology and policy trends related to commercial refrigeration equipment, with emphasis on refrigerated display cabinets. Section 2 reviews the global and China market trends for commercial refrigeration equipment. Section 3 presents the latest technology options for improving energy performance and compares global Best Available Technologies (BAT) to regional and China-specific baselines, and discusses low-GWP refrigerant options for commercial refrigeration equipment. Section 4 reviews global energy efficiency standards and labeling programs, and compares international efficiency standard requirements with China’s proposed and existing standard requirements. Section 5 ends with a review of key findings and conclusions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Heat Transfer, Refrigeration and Heat Pumps

The Special Issue entitled “Heat Transfer, Refrigeration and heat Pumps” accepted papers covering a wide range of topics related to heat pumps, thermal energy storage, and low-Global Warming Potential (GWP) alternative refrigerants. Heat pumps play a vital role in providing space conditioning and water heating while utilizing the energy of the environment. Since heat pumps use renewable thermal energy from the environs to provide the desired utility, they contribute to the portfolio of technologies that mitigate carbon footprint. The heat pump may be considered a truly renewable technology if the electricity it uses comes entirely from a renewable source. More accurately, a heat pump is a “low carbon technology”. These perspectives make heat pumps an indispensable option for the future in order to reduce the nocuous human impact on the environment. More efficient heat pumping technologies are being developed for the residential, commercial, and industrial sectors of the economy. Another R&D thrust is heat pumps for cold climates. Hardware components, use of low-GWP refrigerants, and identification of systemic inefficiencies are active research areas. This article is a synopsis of the papers submitted to the Special Issue.

42 ENGINEERING↗
DOE OSTI2023

Reduced Order Model to Predict Dispersion of Flammable Refrigerant into a Space

As the HVAC&R industry mobilizes to deploy more low-GWP refrigerants, relevant standards are being continually reviewed and updated. Those include the general safety standards ISO 5149 and ASHRAE 15, and the equipment standards IEC and UL. The standards systematically set the allowable maximum amount of refrigerant that should be used in different equipment types and different applications. To do so, they rely on predictions of how a leaked refrigerant mass will disperse into a space. Dispersion characteristics, such as total flammable volume and its residence time, determine the risk associated with the presence of the flammable refrigerant. The standards have included provisions for the use of flammable refrigerants for approximately two decades. They relied on limited analytical analyses and test cases in their development. Dispersion of a refrigerant into a space is complex. Computational fluid dynamics (CFD) are the most accurate in predicting a given problem. However, CFD is computationally expensive and requires specialized expertise and resources and is not suitable for use by standards development working group as prediction tool. This paper presents the development of a reduced order model (ROM) that predicts the key dispersion characteristics relevant to the dispersion of a leaked refrigerant into a space for any combination of input variables. The inputs are the refrigerant release height, the total released refrigerant mass and its release flow rate, the refrigerant molecular weight, the ventilation flow rate, the floor area and height of the space, recirculation air flow rate, and the tightness of the space. The outputs are histograms of volume fraction of the room in prescribed concentration bins and the total mass of the refrigerant in each bin normalized by the total refrigerant charge at 13 prescribed simulation time stamps between 1 and 900 seconds. The ROM is constructed from a set of CFD simulations with carefully chosen combinations of input parameters. The selection if done using a multidimensional sparse grid which is a generalization of the classical tensor approach but offers additional flexibility and thus can be more carefully tuned towards a specific model. The tuning is done to improve the accuracy, measured in the difference between the output values of the ROM and the CFD model, while minimizing the computational cost, measured in number of CFD simulations which is orders of magnitude more expensive than the processing the training data.

Edwards, Dean↗
DOE OSTI2024

Thermal-hydraulic Performance of Emerging Low GWP Refrigerant Mixture under Flow Boiling in Brazed Plate Heat Exchangers

The hydrofluorocarbon (HFC) refrigerants used in the current refrigeration systems are facing a phase-down due to their higher greenhouse effect resulting in global warming, and thus HVAC&R industry has undergone a transition to low Global Warming Potential (GWP) refrigerants. Refrigerant mixtures are attractive alternatives since their composition can be tailored to comply with environmental regulations while preserving favorable thermophysical properties. However, the new low-GWP zeotropic mixture refrigerants have two or more components with different saturation temperatures at the same pressure level, known as temperature glide, which can cause the degradation of the overall heat transfer performance. The brazed plate heat exchangers (BPHX) provide excellent heat transfer performance due to a compact design and are used in several air-conditioning and refrigeration applications. In this study, flow boiling heat transfer and the associated pressure drop of the refrigerant mixture in a vertical BPHX were experimentally investigated. The single-phase water-to-water experiments were conducted in the tested heat exchanger with a counter-flow configuration. The flow boiling experiments charged with R-134a and R-454C were then performed in a pumped refrigerant loop to evaluate its thermal-hydraulic performance. Furthermore, parametric studies of various heat fluxes, mass fluxes, vapor qualities, and saturation temperatures were also conducted.

Yang, Cheng-Min↗
DOE OSTI2024

Optimization of R290 variable geometry heat exchangers

Air-to-refrigerant heat exchangers (HX) are vital components in Heating, Ventilating and Air Conditioning and Refrigeration (HVAC&R) equipment. Recent literature has proposed utilizing shape-optimized, non-round tubes to reduce component size and refrigerant charge, thus enabling the adoption of low-GWP natural refrigerants like R290. However, most designs are restricted to fixed tube configurations, limiting the overall performance potential. In this work, multi-objective optimization is used in a staged approach to develop variable geometry multi-pass air-to-R290 HXs with minimal volume and airside pressure drop. Non-round tubes are used throughout the domain and each pass may have different tube arrangements to maximize HX performance. Compared to conventional fin-tube HXs, the optimized designs demonstrate more than 60% reductions in envelope volume, 30% reductions in face area, and up to 24% reduction in airside pressure drop. Additionally, the refrigerant charge reduction was up to 64%, thus enabling safe use of flammable and mildly-flammable refrigerants.

42 ENGINEERING↗
DOE OSTI2024

District heating utilizing waste heat of a data center: High-temperature heat pumps

Data centers are energy-intensive facilities with substantial low-grade waste heat. High-temperature heat pumps can be critical in boosting the data center’s waste heat for district heating, improving the system-level energy efficiency of data centers, and reducing CO 2 emissions in district heating. This study built thermodynamic models to assess high-temperature heat pumps with six configurations using low global warming potential refrigerants to supply heat up to 120 °C. The heat pump configurations include single-stage or two-stage cycles with advanced components, such as internal heat exchanger, economizer, flash tank, or parallel compressor. The refrigerants include R1234ze(Z), R1233ed(E), R1224yd(Z), R600, and R600a, and R245fa is used as a reference. A case study was carried out to recover the waste heat from the Frontier high-performance computing data center and provide hot water for district heating at the US Department of Energy’s Oak Ridge National Laboratory campus. The optimized performance of high-temperature heat pumps is characterized with various effectiveness of internal heat exchangers, and the operating parameters of economizer or flash tank, as well as their combination. The results show that the configurations of two-stage cycles with internal heat exchanger + flash tank and internal heat exchanger + economizer/parallel-compressor provide the highest coefficient of performance under scenarios of the maximum allowable value and a fixed value (0.3) of the internal heat exchangers’ effectiveness, respectively. R1234ze(Z) and R600a are the most promising refrigerants, considering trade-offs between the coefficient of performance and the volumetric heating capacity. The single-stage cycle with internal heat exchanger + economizer/parallel-compressor using R1234ze(Z) is recommended for utilizing Fronter’s waste heat in district heating. A one mega-watt high-temperature heat pump will reduce 33,100–33,200 metric tons of CO2 emission annually, corresponding to 85.4 %–85.6 % of equivalent CO2 emissions from natural gas boilers. Here, this study provides good guidelines for designing and deploying high-temperature heat pumps to support sustainable data centers and decarbonize district heating in the US.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Automated fault detection and diagnosis deployment Internet of Things solution for building energy system

The building sector is the highest energy consumer and ranks first in terms of carbon emissions among all sectors. To address these issues, decarbonization and electrification in the building energy sector are two critical missions of the new US administration. For decarbonization, the new administration has set a target to reduce greenhouse gas emissions by 50–52% by 2030 and targeting a carbon-neutral economy by 2050. For electrification, the goal is to achieve 100% clean electricity by 2035. Such decarbonization and electrification in the building sector require that energy consumption in buildings be reduced significantly. Therefore, the building sector must continuously adopt new technologies to achieve its energy and carbon emission goals. One of the most fundamental technologies is the Internet of Things (IoT). IoT has proven to be an effective solution for the building domain, including building information/energy modeling, smart buildings, etc. Although much progress has been made in the development of IoT-based building energy systems, there is still a lack of reliable, scalable, and affordable IoT-based automated fault and degradation diagnostic (AFDD) solutions. Such solutions would enable deployment of advanced algorithms into real systems to archive the projected energy benefits. Here, this study reviews existing IoT solutions developed for building energy–related application and developed a simple but effective AFDD IoT deployment solution, including developing a suitable IoT architecture and conducting easy and scalable deployment by leveraging a common cloud-based IoT service.

42 ENGINEERING↗
DOE OSTI2021

Decarbonizing HVAC and Water Heating in Commercial Buildings

This report is intended to provide building owners and facilities engineers with heating electrification options and design considerations, as well as additional resources on key topics. The document focuses on the electrification of space heating and water heating loads using electric heat pump systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗