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Refrigeration Playbook: Natural Refrigerants; Selecting and Designing Energy-Efficient Commercial Refrigeration Systems That Use Low Global Warming Potential Refrigerants
This report provides guidance for selecting and designing energy efficient commercial refrigeration systems using low global warming potential refrigerants. Refrigeration systems are generally the largest energy end use in a supermarket type building, often accounting for more than half of a building's energy consumption.
Low Global Warming Potential Refrigerants for Commercial Refrigeration Systems
Supermarket refrigeration systems account for approximately 50% of supermarket energy use, placing this class of equipment among the highest energy consumers in the commercial building domain. In addition, the commonly used refrigeration system in supermarket applications is the multiplex direct expansion (DX) system, which is prone to refrigerant leaks due to its long lengths of refrigerant piping. This leakage reduces the efficiency of the system and increases the impact of the system on the environment. The high Global Warming Potential (GWP) of the hydrofluorocarbon (HFC) refrigerants commonly used in these systems, coupled with the large refrigerant charge and the high refrigerant leakage rates leads to significant direct emissions of greenhouse gases into the atmosphere. Environmental concerns are driving regulations for the heating, ventilating, air-conditioning and refrigeration (HVAC&R) industry towards lower GWP alternatives to HFC refrigerants. Existing lower GWP refrigerant alternatives include hydrocarbons, such as propane (R-290) and isobutane (R-600a), as well as carbon dioxide (R-744), ammonia (R-717), and R-32. In addition, new lower GWP refrigerant alternatives are currently being developed by refrigerant manufacturers, including hydrofluoro-olefin (HFO) and unsaturated hydrochlorofluorocarbon (HCFO) refrigerants. The selection of an appropriate refrigerant for a given refrigeration application should be based on several factors, including the GWP of the refrigerant, the energy consumption of the refrigeration system over its operating lifetime, and leakage of refrigerant over the system lifetime. For example, focusing on energy efficiency alone may overlook the significant environmental impact of refrigerant leakage; while focusing on GWP alone might result in lower efficiency systems that result in higher indirect impact over the equipment lifetime. Thus, the objective of this Collaborative Research and Development Agreement (CRADA) between Honeywell and the Oak Ridge National Laboratory (ORNL) is to develop a Life Cycle Climate Performance (LCCP) modeling tool for optimally designing HVAC&R equipment with lower life cycle greenhouse gas emissions, and the selection of alternative working fluids that reduce the greenhouse gas emissions of HVAC&R equipment. In addition, an experimental evaluation program is used to measure the coefficient of performance (COP) and refrigerating capacity of various refrigerant candidates, which have differing GWP values, in commercial refrigeration equipment. Through a cooperative effort between industry and government, alternative working fluids will be chosen based on maximum reduction in greenhouse gases at minimal cost impact to the consumer. This project will ultimately result in advancing the goals of reducing greenhouse gas emissions through the use of low GWP working fluids and technologies for HVAC&R and appliance equipment, resulting in cost-competitive products and systems.
Development of Low Global Warming Potential Refrigerant Solutions for Commercial Refrigeration Systems using a Life Cycle Climate Performance Design Tool
Commercial refrigeration systems are known to be prone to high leak rates and to consume large amounts of electricity. As such, direct emissions related to refrigerant leakage and indirect emissions resulting from primary energy consumption contribute greatly to their Life Cycle Climate Performance (LCCP). In this paper, an LCCP design tool is used to evaluate the performance of a typical commercial refrigeration system with alternative refrigerants and minor system modifications to provide lower Global Warming Potential (GWP) refrigerant solutions with improved LCCP compared to baseline systems. The LCCP design tool accounts for system performance, ambient temperature, and system load; system performance is evaluated using a validated vapor compression system simulation tool while ambient temperature and system load are devised from a widely used building energy modeling tool (EnergyPlus). The LCCP design tool also accounts for the change in hourly electricity emission rate to yield an accurate prediction of indirect emissions. The analysis shows that conventional commercial refrigeration system life cycle emissions are largely due to direct emissions associated with refrigerant leaks and that system efficiency plays a smaller role in the LCCP. However, as a transition occurs to low GWP refrigerants, the indirect emissions become more relevant. Low GWP refrigerants may not be suitable for drop-in replacements in conventional commercial refrigeration systems; however some mixtures may be introduced as transitional drop-in replacements. These transitional refrigerants have a significantly lower GWP than baseline refrigerants and as such, improved LCCP. The paper concludes with a brief discussion on the tradeoffs between refrigerant GWP, efficiency and capacity.
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.
Status of not-in-kind refrigeration technologies for household space conditioning, water heating and food refrigeration
This paper presents a review of the next generation not-in-kind technologies to replace conventional vapor compression refrigeration technology for household applications. Such technologies are sought to provide energy savings or other environmental benefits for space conditioning, water heating and refrigeration for domestic use. These alternative technologies include: thermoacoustic refrigeration, thermoelectric refrigeration, thermotunneling, magnetic refrigeration, Stirling cycle refrigeration, pulse tube refrigeration, Malone cycle refrigeration, absorption refrigeration, adsorption refrigeration, and compressor driven metal hydride heat pumps. Furthermore, heat pump water heating and integrated heat pump systems are also discussed due to their significant energy saving potential for water heating and space conditioning in households. The paper provides a snapshot of the future R&D needs for each of the technologies along with the associated barriers. Both thermoelectric and magnetic technologies look relatively attractive due to recent developments in the materials and prototypes being manufactured.
An Evaluation of the Environmental Impact of Different Commercial Supermarket Refrigeration Systems Using Low Global Warming Potential Refrigerants
Commercial refrigeration systems consumed 1.21 Quads of primary energy in 2010 and are known to be a major source for refrigerant charge leakage into the environment. Thus, it is important to study the environmental impact of commercial supermarket refrigeration systems and improve their design to minimize any adverse impacts. The system s Life Cycle Climate Performance (LCCP) was presented as a comprehensive metric with the aim of calculating the equivalent mass of carbon dioxide released into the atmosphere throughout its lifetime, from construction to operation and destruction. In this paper, an open source tool for the evaluation of the LCCP of different air-conditioning and refrigeration systems is presented and used to compare the environmental impact of a typical multiplex direct expansion (DX) supermarket refrigeration systems based on three different refrigerants as follows: two hydrofluorocarbon (HFC) refrigerants (R-404A, and R-407F), and a low global warming potential (GWP) refrigerant (N-40). The comparison is performed in 8 US cities representing different climates. The hourly energy consumption of the refrigeration system, required for the calculation of the indirect emissions, is calculated using a widely used building energy modeling tool (EnergyPlus). A sensitivity analysis is performed to determine the impact of system charge and power plant emission factor on the LCCP results. Finally, we performed an uncertainty analysis to determine the uncertainty in total emissions for both R-404A and N-40 operated systems. We found that using low GWP refrigerants causes a considerable drop in the impact of uncertainty in the inputs related to direct emissions on the uncertainty of the total emissions of the system.
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.
Comprehensive Compressor Calorimeter Testing of Lower-GWP Alternative Refrigerants for Heat Pump and Medium Temperature Refrigeration Applications
In response to environmental concerns raised by the use of refrigerants with high Global Warming Potential (GWP), the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) has launched an industry-wide cooperative research program, referred to as the Low-GWP Alternative Refrigerants Evaluation Program (AREP), to identify and evaluate promising alternative refrigerants for major product categories. This paper reports one of the Oak Ridge National Laboratory (ORNL) contributions to AREP. It compares performance of alternative refrigerants to that of R-410A and R-404A for heat pump and medium temperature applications, respectively. The alternatives reported in this paper are: R-32, DR-5, and L-41a for R-410A and ARM-31a, D2Y-65, L-40, and a mixture of R-32 and R-134a for R-404A. All performance comparison tests were conducted using scroll compressors of ~1.85 tons (6.5 kW) cooling capacity. Tests were conducted over a range of combinations of saturation suction and saturation discharge temperatures for both compressors. The tests showed that, in general, energy efficiency ratio (EER) and cooling capacity of R-410A alternative refrigerants were slightly lower than that of the baseline refrigerant with a moderate increases in discharge temperature. On the other hand, R-404A alternative refrigerants showed relative performance dependence on saturation suction and saturation discharge temperatures and larger increases in discharge temperature than for the R-410A alternatives. This paper summarizes the relative performance of all alternative refrigerants compared to their respective baseline.
Portable refrigerant charge meter and method for determining the actual refrigerant charge in HVAC systems
A refrigerant charge meter and a method for determining the actual refrigerant charge in HVAC systems are described. The meter includes means for determining an optimum refrigerant charge from system subcooling and system component parameters. The meter also includes means for determining the ratio of the actual refrigerant charge to the optimum refrigerant charge. Finally, the meter includes means for determining the actual refrigerant charge from the optimum refrigerant charge and the ratio of the actual refrigerant charge to the optimum refrigerant charge.
Energy Efficient Commercial Refrigeration with Carbon Dioxide Refrigerant and Scroll Expanders
Current supermarket refrigeration systems are built around conventional fluorocarbon refrigerants – HFC-134a and the HFC blends R-507 and R404A, which replaced the CFC refrigerants, R-12 and R-502, respectively, used prior to the Montreal Protocol phase out of ozone depleting substances. While the HFC refrigerants are non-ozone depleting, they are strong greenhouse gases, so there has been continued interest in replacing them, particularly in applications with above average refrigerant leakage. Large supermarket refrigeration systems have proven to be particularly difficult to maintain in a leak-tight condition. Refrigerant charge losses of 15% of total charge per year are the norm, making the global warming impact of refrigerant emissions comparable to that associated with the energy consumption of these systems.
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.
Reducing the Carbon Footprint of Commercial Refrigeration Systems Using Life Cycle Climate Performance Analysis: From System Design to Refrigerant Options
In this paper, Life Cycle Climate Performance (LCCP) analysis is used to estimate lifetime direct and indirect carbon dioxide equivalent gas emissions of various refrigerant options and commercial refrigeration system designs, including the multiplex DX system with various hydrofluorocarbon (HFC) refrigerants, the HFC/R744 cascade system incorporating a medium-temperature R744 secondary loop, and the transcritical R744 booster system. The results of the LCCP analysis are presented, including the direct and indirect carbon dioxide equivalent emissions for each refrigeration system and refrigerant option. Based on the results of the LCCP analysis, recommendations are given for the selection of low GWP replacement refrigerants for use in existing commercial refrigeration systems, as well as for the selection of commercial refrigeration system designs with low carbon dioxide equivalent emissions, suitable for new installations.
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.