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At least 19 records

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.

Zhang, Mingkan↗

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.

42 ENGINEERING↗

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.

alternative refrigerants↗

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.

critical heat flux↗

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.

Liang, Chenjiyu↗

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.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Refrigerants for a Sustainable Future

Worldwide use of high global warming potential (GWP) hydrofluorocarbon (HFC) refrigerants for space conditioning and food storage results in significant equivalent greenhouse gas (GHG) emissions. This is further exacerbated in developed countries by the current transition from hydrochlorofluorocarbon (HCFC) refrigerants to HFC refrigerants. Under the Kigali amendment to the Montreal Protocol, the proposed phase-out of currently used HFC and HCFC refrigerants has initiated a re-evaluation of some pre-existing refrigerants as well as the development and evaluation of new refrigerants. Making the ideal refrigerant selections for heating, ventilation, air-conditioning, and refrigeration (HVAC&R) applications is thereby difficult in an already overabundant refrigerants market. In this paper, a study of key parameters required of a good refrigerant is conducted, followed by the analysis of refrigerants desired and refrigerants used in two major sectors of the HVAC&R industry, namely commercial refrigeration and residential air-conditioning and heat pumps. Finally, keeping in consideration the global environmental regulations and safety standards, a recommendation of the most suitable refrigerants in both sectors has been made.

54 ENVIRONMENTAL SCIENCES↗

Understanding airflow pattern and temperature distribution in domestic refrigerators – A review analyzing recent developments and bridging knowledge gaps

Refrigerators have become an essential appliance in every household, and they consume approximately 30% of total electricity among other domestic appliances such as clothes washers, dryers, and air conditioners. With the refrigerator’s comparatively high energy consumption compared with other appliances, existing research has mainly focused on improving the energy efficiency of refrigerators by changing the design of the compressor, heat exchanger, refrigerant, and insulation. However, previous studies have paid very little attention to the research and development of the temperature distribution in the refrigerator, which is a key parameter in determining energy consumption and food safety. Therefore, this review aims to present an overview of recent design developments to improve the temperature distribution and air circulation in domestic refrigerators, including static refrigerators and no-frost refrigerators. Herein, this review article discusses the various operation and design factors that can affect the air circulation and temperature uniformity of the refrigerator, including shelf arrangement, the compressor on/off cycle, thermostat settings, evaporator design, ambient conditions, door opening frequency, and product loading temperatures. Additionally, this review provides a summary of the advanced vapor compression cycle based refrigerators that are expected to provide better energy efficiency and independent temperature control in freezer and refrigerator compartments. This review elaborates on the significance of improving the performance of the domestic refrigerator in terms of temperature distribution and air circulation.

42 ENGINEERING↗

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↗

Integration of a grey-box refrigerated case model in EnergyPlus via Python plugin

Commercial buildings, in particular grocery stores (due mainly to their large refrigeration load), provide opportunities for energy cost reductions. Grocery stores could offer substantial load flexibility to the power grid through participation in demand response programs because of their usage patterns and relatively high energy intensity. This load flexibility could come from modifying the control of heating, ventilation, and air conditioning (HVAC) systems, refrigeration systems, or both. Although estimation of the HVAC system’s load flexibility potential is relatively targeted in the literature, estimating load flexibility of refrigeration systems is nascent and has been a challenge, in part because of the lack of proper simulation tools that capture the dynamics in the refrigeration cases. The existing refrigerated case model within EnergyPlus, a whole building energy simulation program, assumes a constant case temperature throughout the simulation period and does not explicitly model the cycling of the compressor serving the refrigerated case. In addition, it does not encompass modeling of temperatures of the product inside the refrigerated case. This difference between modeled and actual operation can be a barrier to the development of demand control algorithm and accurate analysis of load flexibility potential. In this paper, we present a grey-box model for modeling refrigerated cases in grocery stores, which include medium temperature and low temperature. Four cases are modeled; two are low-temperature closed cases and two are medium-temperature cases with one closed and one open. Data from an experimental facility are used to train and test the models. Results demonstrate the efficacy of the grey-box models in predicting the temperatures. This model is integrated into EnergyPlus to capture the dynamic effects of case temperature on the environment and enhance the calculation of sensible and latent heat exchange with the environment (case credits). These enhancements can be leveraged more broadly to model advanced refrigeration controls such as defrost, develop and test unique algorithms that could affect refrigeration interactions with HVAC, and refine store design for any commercial building with refrigeration.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Energy performance augmentation of domestic refrigerators with microchannel condensers

Refrigerators are one of the most extensively used household appliances, accounting for approximately 4% of total household electricity consumption. Enhancing their energy performance can significantly reduce residential energy demand. As a result, this study focuses on reducing the energy consumption of a French-door, bottom-mount refrigerator using isobutane (R600a) as the working fluid. Here, the performance improvement of the refrigerators has been obtained mainly through improving the vapor compression refrigeration cycle, with a particular emphasis on condenser design. This study explores the impact of three-pass serpentine microchannel condenser on energy performance, along with the effects of two distinct fan combinations. Charge optimization experiments were conducted to identify the optimal refrigerant mass for the refrigerator unit with microchannel condenser. Additionally, a comprehensive numerical model was developed to analyze the behavior of vapor compression cycle under various refrigerant charges. The experimental findings revealed that the refrigerator unit with the three-pass microchannel condenser reduces the energy consumption of isobutane-based domestic refrigerators up to 16% while reducing the refrigerant charge by 11% in comparison to the refrigerator unit with conventional wire-and-tube condenser.

Charge optimization↗

Critical Literature Review of Low Global Warming Potential (GWP) Refrigerants and their Environmental Impact

Refrigeration and air conditioning currently account for ~20% of the total electricity consumption in buildings around the world. Over the next three decades as global temperatures are projected to increase, urbanization and economic growth will lead to an increased demand for refrigeration and cooling. Most commonly used refrigerants belong to the five following classes: (i) chlorofluorocarbons, (ii) hydrochlorofluorocarbons, (iii) hydrofluorocarbons (HFCs), (iv) hydrofluoroolefins (HFOs), and (v) natural refrigerants. Over the past century, there have been shifts in which compounds were used for refrigeration to improve safety and durability, allow for ozone protection, and, most recently, to reduce global warming potential (GWP). Although technological advances have led to increased cooling capacity and safer refrigerants, emissions from refrigeration systems can affect the environment by contributing to greenhouse gas emissions or by depleting the ozone layer, depending on the gas emitted. The focus is increasingly on adopting compounds that are both efficient at cooling and effective for reducing emissions and other adverse environmental impacts. Because of policy and regulatory changes to avert ozone depletion and global climate change, much discussion has centered on the environmental impacts of next-generation refrigerants. Of particular interest are the fluorinated refrigerants, HFCs and HFOs, most of which are defined as per- and polyfluoroalkyl substances (PFAS) and their breakdown products (especially trifluoroacetic acid). The US Environmental Protection Agency in 2021 drafted a Strategic Roadmap for PFAS, which has already resulted in an increase in investment in research on these compounds and has restricted the release of PFAS into the environment through the implementation of monitoring and reporting requirements. A critical evaluation of fluorinated refrigerants and their breakdown products with respect to persistence, biodegradation and toxicity, and global warming potential is needed to guide environmental regulations. This document aims to perform a critical review of the relevant scientific data on the most common refrigerants currently used, their degradation products, and their alternatives. Where available, estimates of precursor production quantities and existing environmental regulatory information are reviewed. Key data of interest for the evaluation include physicochemical properties, environmental fate parameters, ecological or human health toxicity/risk information, and GWP for compounds of interest.

54 ENVIRONMENTAL SCIENCES↗

Critical Literature Review of Low Global Warming Potential (GWP) Refrigerants and their Environmental Impact

Refrigeration and air conditioning currently account for ~20% of the total electricity consumption in buildings around the world. Over the next three decades as global temperatures are projected to increase, urbanization and economic growth will lead to an increased demand for refrigeration and cooling. Most commonly used refrigerants belong to the five following classes: (i) chlorofluorocarbons, (ii) hydrochlorofluorocarbons, (iii) hydrofluorocarbons (HFCs), (iv) hydrofluoroolefins (HFOs), and (v) natural refrigerants. Over the past century, there have been shifts in which compounds were used for refrigeration to improve safety and durability, allow for ozone protection, and, most recently, to reduce global warming potential (GWP). Although technological advances have led to increased cooling capacity and safer refrigerants, emissions from refrigeration systems can affect the environment by contributing to greenhouse gas emissions or by depleting the ozone layer, depending on the gas emitted. The focus is increasingly on adopting compounds that are both efficient at cooling and effective for reducing emissions and other adverse environmental impacts. Because of policy and regulatory changes to avert ozone depletion and global climate change, much discussion has centered on the environmental impacts of next-generation refrigerants. Of particular interest are the fluorinated refrigerants, HFCs and HFOs, most of which are defined as per- and polyfluoroalkyl substances (PFAS) and their breakdown products (especially trifluoroacetic acid). The US Environmental Protection Agency in 2021 drafted a Strategic Roadmap for PFAS, which has already resulted in an increase in investment in research on these compounds and has restricted the release of PFAS into the environment through the implementation of monitoring and reporting requirements. A critical evaluation of fluorinated refrigerants and their breakdown products with respect to persistence, biodegradation and toxicity, and global warming potential is needed to guide environmental regulations. This document aims to perform a critical review of the relevant scientific data on the most common refrigerants currently used, their degradation products, and their alternatives. Where available, estimates of precursor production quantities and existing environmental regulatory information are reviewed. Key data of interest for the evaluation include physicochemical properties, environmental fate parameters, ecological or human health toxicity/risk information, and GWP for compounds of interest.

54 ENVIRONMENTAL SCIENCES↗

Portable and Cost-Effective Device for Reliable Detection of Counterfeit and Non-compliant Refrigerants in Diverse Applications

Counterfeit refrigerants pose significant challenges to safety, system reliability, and operational effectiveness due to their harmful contaminants or incompatible chemical compositions. Utilizing these noncompliant products can lead to reduced efficiency, equipment failures, and expensive repairs. Additionally, heightened demand for alternative refrigerants during the industry's transition has created supply gaps, enabling counterfeit products to proliferate. Accurate detection and analysis tools are therefore essential to verify refrigerant authenticity and ensure system integrity in diverse applications. This paper presents the development of a portable device designed for reliable identification and detailed analysis of refrigerant composition. By integrating precision gas sampling, controlled pressure regulation, and automated sensor technology, the device not only detects deviations from standard refrigerant properties but also provides a comprehensive composition breakdown. Pre-calibrated sensors measure the refrigerant gas to identify specific concentrations and contaminants, with an intuitive LED-based indicator system ensuring quick interpretation of results. The user-friendly interface enables operators to select refrigerant types for targeted testing, further enhancing accuracy and usability for field technicians. Comprehensive testing was conducted on mildly flammable A2L refrigerants, showcasing the device’s robustness and adaptability in analyzing composition and detecting discrepancies. The device demonstrated consistent accuracy across a range of refrigerant samples, affirming its reliability in diverse operational environments. Its design minimizes contamination risks during sampling and provides detailed composition results within 90 seconds, ensuring efficient and precise analysis. With a projected price point under $150, the proposed solution delivers affordability alongside its lightweight portability and straightforward operation. Unlike complex and costly alternatives, such as gas chromatography systems, this device provides an accessible option for technicians, customs personnel, and industry operators in need of quick and effective refrigerant verification. Compatible with both current formulations and emerging refrigerant technologies, the device addresses critical counterfeit detection needs across a range of applications. By delivering accurate composition analysis and counterfeit identification, this innovation enhances system performance, safety, and operational reliability in crucial industries.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗

Mitigation of safety and environmental challenges posed by 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 mildly and highly flammable 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 heating, ventilation, air-conditioning, and refrigeration (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. Quantitative analysis reveals the adsorbent's effectiveness in reducing leak potential in the range of 40 %–100 % for various refrigerants. Strategic placement and active leak management with negative pressure offer promising avenues for capturing leaked refrigerants, enhancing overall safety.

42 ENGINEERING↗

Thermal-Hydraulic Performance of a Zeotropic Refrigerant in a Brazed Plate Evaporator

In this work we report the results of a preliminary investigation focused on evaluating the thermal-hydraulic performance of R455A (CO2, R32, R1234yf – 3/21.5/75.5) in a commercial brazed plate heat exchanger. Three key parameters were measured which were refrigerant flow maldistribution, overall refrigerant side heat transfer coefficient, and total refrigerant side pressure drop. These same parameters were also measured for R134a which served as a base-line refrigerant for comparison. The experimental test matrix was set up to investigate the influence of refrigerant mass flux (3 ≤ Gref ≤ 5 kg m-2 s-1), refrigerant inlet vapor quality (0.1 ≤ xin ≤ 0.4), and refrigerant exit superheat (5 ≤ Tsh ≤ 10 K) on the above mentioned thermal-hydraulic parameters. For these experimental conditions, on average, the overall refrigerant side heat transfer coefficients for R455A were 45.2% lower than those of R134a. Refrigerant flow maldistribution for R455A, on average, was observed to be 62.6 % higher than that measured for R134a, and the total pressure drop across the heat exchanger (minor and frictional losses) for R455A was on average 26.5% higher than that measured for R134a. These initial results set the stage for a comprehensive investigation focused on further investigating the thermal-hydraulic performance of zeotropic refrigerants in brazed plate heat exchangers.

Jajja, Saad [ORNL]↗