Search Results (53)

The large-scale utilization of hydrogen energy is currently hindered by challenges in low-cost production, storage, and transportation. This study focused on investigating the impact of the diaphragm cavity profile on the movement behavior and stress distribution of a dual-stage diaphragm compressor. Firstly, an experimental platform was established to test the gas mass flowrate and fluid pressures under various preset conditions. Secondly, a simulation path integrating the finite element method simulation, theoretical stress model, and movement model was developed and experimentally validated to analyze the diaphragm stress distribution and deformation characteristics. Finally, comparative optimization analyses were conducted on different types of diaphragm cavity profiles. The results indicated that the driving pressure differences at the top dead center position reached 85.58 kPa for the first-stage diaphragm and 75.49 kPa for the second-stage diaphragm. Under experimental conditions of 1.6 MPa suction pressure, 8 MPa second-stage discharge pressure, and 200 rpm rotational speed, the first-stage and second-stage diaphragms reached the maximum center deflections of 4.14 mm and 2.53 mm, respectively, at the bottom dead center position. Moreover, the cavity profile optimization analysis indicated that the double-arc profile (DAP) achieved better cavity volume and diaphragm stress characteristics. The first-stage diaphragm within the optimized DAP-type cavity exhibited 173.95 MPa maximum principal stress with a swept volume of 0.001129 m³, whereas the second-stage optimized configuration reached 172.57 MPa stress with a swept volume of 0.0003835 m³. This research offers valuable insights for enhancing the reliability and performance of diaphragm compressors. Full article

Water regeneration in PVC production is a key issue to consider, given the high freshwater consumption rate of the process. This research evaluates the inherent safety of poly(vinyl chloride) (PVC) production via suspension polymerization by implementing mass and energy integration strategies in combination with wastewater regeneration under a zero-liquid-discharge (ZLD) approach. The impact of these integrations on process safety was examined by considering the risks associated with the handling of hazardous materials and critical operations, as well as the reduction in waste generation. To this end, the Inherent Safety Index (ISI) methodology was employed, which quantifies hazards based on factors such as toxicity and flammability, enabling the identification of risks arising from system condition changes due to the implementation of sustainable water treatment technologies. Although the ISI methodology has been applied to various chemical processes, there are few documented cases of its specific application in PVC plants that adopt circular production strategies and water resource sustainability. Therefore, in this study, ISI was used to thoroughly evaluate each stage of the process, providing a comprehensive picture of the safety risks associated with the use of sustainable technologies. The assessment was carried out using simulation software, computer-aided process engineering (CAPE) methodologies, and information obtained from safety repositories and expert publications. Specifically, the Chemical Safety Index score was 22 points, with the highest risk associated with flammability, which scored 4 points, followed by toxicity (5 points), explosiveness (2 points), and chemical interactions, with 4 points attributed to vinyl chloride monomer (VCM). In the toxicity sub-index, both VCM and PVC received 5 points, while substances such as sodium hydroxide (NaOH) and sodium chloride (NaCl) scored 4 points. In the heat of reaction sub-index, the main reaction scored 3 points due to its high heat of reaction (−1600 kJ/kg), while the secondary reactions from PVA biodegradation scored 0 points for the anoxic reaction (−156.5 kJ/kg) and 3 points for the aerobic reaction (−2304 kJ/kg), significantly increasing the total index. The Process Safety Index scored 15 points, with the highest risk found in the inventory of hazardous substances within the inside battery limits (ISBL) of the plant, where a flow rate of 3241.75 t/h was reported (5 points). The safe equipment sub-index received 4 points due to the presence of boilers, burners, compressors, and reactors. The process structure scored 3 points, temperature 2, and pressure 1, reflecting the criticality of certain operating conditions. Despite sustainability improvements, the process still presented significant chemical and operational risks. However, the implementation of control strategies and safety measures could optimize the process, balancing sustainability and safety without compromising system viability. Full article

To investigate the pneumatic characteristics of a piston-type air compressor during the rapid transient processes of intake and compression, this study establishes a computational model incorporating the tank, valves, cylinder, intake and discharge pipe, etc. Utilizing the dynamic mesh method combined with user-defined functions, numerical calculations were performed to analyze the compression process, focusing on pressure variation patterns at various positions inside the cylinder and their impact on compressor performance. The purpose is to enhance understanding of these dynamics. Key findings reveal that during the intake phase, pressure at all monitored points rapidly decreases, with the most significant pressure changes occurring directly below the intake valve. Pressure variations on the surfaces of the intake and discharge valves exhibit high consistency. However, during compression, negative pressure changes become more pronounced. The pressures on the top, side walls, and bottom of the cylinder rapidly decrease as the compression ends. Furthermore, as air flows into the storage tank, its pressure decreases but remains mostly stable until equilibrium is reached, causing the tank pressure to rise. Finally, significant low-pressure areas were observed in small corners below the pipe, while higher pressure values were found in larger corners above the side, demonstrating flow characteristics and energy loss under different geometric conditions. Full article

To investigate the performance of high-speed miniaturized screw refrigeration compressors, this study designed rotors with identical theoretical displacement but varying rated speeds. A normalized analysis established quantitative evaluation criteria for geometric performance, while an exergy analysis model assessed leakage exergy losses. Thermodynamic modeling evaluated the impact of different clearances and rated speeds on performance. Computational fluid dynamics (CFD) simulations analyzed the gas forces and torque acting on the rotors. The rate of efficiency improvement with increasing speed follows a non-linear relationship, demonstrating diminishing returns at ultra-high speeds, where further speed elevation provides negligible efficiency gains. This study reveals that, while tip-housing leakage represents the largest volumetric leakage in screw compressors, interlobe leakage contributes the most significantly to power losses. When the rated speed increases from 3000 rpm to 15,000 rpm, interlobe leakage remains the dominant source of power loss, with its relative contribution showing a marked increase. For compressors with identical cylinder dimensions, reducing the number of lobes decreases the discharge pressure fluctuations and power consumption. Larger wrap angles increase the contact line length and discharge port area, reducing the volumetric efficiency while creating a trade-off between leakage and discharge losses, resulting in an optimal wrap angle that maximizes the adiabatic efficiency. Full article

This paper establishes a simulation model for the performance of an R290 variable frequency compressor in automotive air conditioning and sets up a compressor performance testing system. It investigates the effects of different evaporation temperatures, condensation temperatures, compressor speeds, and pressure ratios on the oil circulation rate (OCR), as well as the impact of various oil circulation rates on the performance of the R290 compressor. As the comparison between simulation and experimental data shows, compressor performance predictions from the simulation model align with experimental results when the OCR is not taken into consideration. Experimental results indicate that the OCR increases with a rising evaporation temperature, decreases with a lowering condensation temperature, and increases with higher compressor speeds. The simulation model shows a minor deviation when predicting volumetric efficiency, while errors are larger when predicting isentropic efficiency and the discharge temperature. Isentropic efficiency and the discharge temperature show a notable impact from the OCR. Additionally, for system cooling capacity, power, and COP predictions, when the OCR is within the range of 2~10%, the accuracy of the simulation model proves satisfactory, with deviations within 5%. Full article

This study investigates the implementation of a cryogenic chiller utilizing a mixed-refrigerant cascade refrigeration cycle (MRCRC). In this setup, R-404A is employed in the high-temperature circuit (HTC), while a mixture of refrigerants is utilized in the low-temperature circuit (LTC). Unlike a conventional MRCRC that operates without a receiver to maintain the composition ratio, this research explores the impact of receiver installation on system performance. Experiments were conducted with and without a receiver to assess performance improvements and device behavior. With a fixed refrigerant charge of 4 kg, the suction and discharge pressures of the LTC compressor remained low and stable after the receiver’s installation. The addition of a receiver significantly reduced the cooling time, with further reductions observed as the refrigerant charge increased. The system achieved evaporative heat capacities of 0.59, 1.76, and 2 kW for refrigerant charges of 4, 7, and 9 kg, respectively. Notably, at the maximum refrigerant charge of 11 kg, the evaporative heat capacity peaked at 3.3 kW. These findings indicate that incorporating a receiver is crucial for enhancing the cooling performance of cryogenic coolers using mixed refrigerants and stabilizing device operation. This contrasts with previous studies that omitted receivers due to concerns over potential alterations in the composition ratio of the mixed refrigerant. Full article

In response to the global pursuit of net-zero carbon emissions, the electrification of agricultural machinery is becoming a significant research and development trend. This study introduces the overall design of a 4 kW air compressor aimed at achieving a green vision for agricultural machinery. The design focuses on providing continuous and stable power and air output using a lithium-ion battery. Durability and cost-effectiveness are prioritized, with a particular emphasis on the Arduino system for integrating battery and motor systems to withstand harsh conditions and ensure ease of maintenance. A permanent magnet brushless motor was selected as the power source, paired with an optimized pulley to supply the proper torque to the air compressor. The system employs an Arduino-based feedback control sensor for air pressure regulation, ensuring energy efficiency. The primary energy source is a 48 V lithium iron phosphate battery, known for its high energy density and safety. The battery design focuses on system integration, addressing specific environmental discharge requirements. The embedded battery management system provides thermal and lifecycle parameter estimation, guaranteeing long-duration power supply and safe operation under various conditions. Unlike traditional fuel-driven systems, lithium iron phosphate batteries do not emit harmful gases, aligning with environmental standards. System integration testing demonstrated that the air pressure feedback control effectively meets the energy-saving requirements by digitally reducing power output as air accumulates in the chamber. Bench testing confirmed that the system performs as designed, achieving the desired results and advancing the goal of sustainable agricultural machinery. Full article

As an advanced energy storage technology, the compressed CO₂ energy storage system (CCES) has been widely studied for its advantages of high efficiency and low investment cost. However, the current literature has been mainly focused on the TC-CCES and SC-CCES, which operate in high-pressure conditions, increasing investment costs and bringing operation risks. Meanwhile, some studies based on the phase-change CO₂ energy storage system also have had the disadvantages of low efficiency and the extra necessity of heat or cooling sources. To overcome the above problems, this paper proposes an innovative compressed CO₂ phase-change energy storage system. During the energy charge process, molten salt and water are used to store heat with a smaller temperature difference in heat exchangers, and high-pressure CO₂ is reserved in liquid form. During the energy discharge process, throttle expansion is applied to realize the evaporation at room temperature, and CO₂ absorbs the reserved heat to improve the power capacity in the turbine and the system energy storage efficiency. The thermodynamic and exergoeconomic studies are performed firstly by using MATLAB. Then, the parametric study based on energy storage efficiency, system unit product cost, and exergy destruction is analyzed. The results show that energy storage efficiency can be improved by lifting liquid CO₂ pressure as well as compressor and turbine isentropic efficiencies, and CO₂ evaporation pressure has the optimal pressure point. The system unit product cost can be reduced by decreasing liquid CO₂ pressure and compressor isentropic efficiency, while CO₂ evaporation pressure and turbine isentropic efficiency both have optimal points. Finally, the optimization of two performances is performed by NSGA-II, and they can reach 75.30% and 41.17 $/GJ, respectively. Moreover, the optimal energy storage efficiency is obviously higher than that of other energy storage technologies, indicating the great advantage of the proposed system. This study provides an innovative research method for a new type of large-scale energy storage system. Full article

The exhaust back pressure of diesel engines is becoming increasingly higher nowadays. In order to keep discharging exhaust unhindered and operating smoothly under high exhaust back pressure, a large reduction in engine maximum brake output is often observed, as well as increased fuel consumption and lower combustion efficiency with heavy exhaust smokes. In our previous study, “Applicability of Reducing Valve Timing Overlap for Diesel Engines under High Exhaust Back Pressure”, a reduced valve timing overlap of 12 °CA partially improves the brake output and BSFC for a fixed-geometry turbocharged diesel engine under high exhaust back pressures. A potential solution for restoring the brake output under high exhaust back pressures could be the use of variable-geometry turbochargers. In this study, a variable-geometry turbocharger is applied to a diesel engine to study the engine performance characteristics and applicability, especially the further improvement of brake output and the brake-specific fuel consumption of the engine. Continuing with the results of our previous research, a basic setting of 12 °CA for the valve timing overlap is set up for the subsequent engine performance simulations in this study (using GT-Power SW). Via simulation, exhaust back pressures of 25 kPa, 45 kPa, and 65 kPa gauge are studied for a turbocharged diesel engine. The results for the engine parameters, including brake output, brake-specific fuel consumption, compressor outlet temperature, turbine inlet temperature, intake air mass flow rate, and exhaust mass flow rate are analyzed. The results of the variable-geometry turbocharger, including turbocharger speed, pressure ratios and efficiencies of compressor and turbine are also analyzed. The results indicate that the brake output and brake-specific fuel consumption are effectively improved under full-load operation with an adequate variable-geometry turbocharger rack position. Operable ranges of rack position are also set up for different back pressures. Full article

Due to the impact of global warming and climate change, more and more people are starting to have a clearer understanding and vigilance about greenhouse gases. To prevent further deterioration of the global environment, this study examines the coefficients of performance of 21 currently available refrigerants with very low global-warming potential and zero ozone-depleting potential under evaporation temperatures of 10, −20, −40, and −60 °C and condensation temperatures of 30, 40, and 50 °C, respectively. It is found that the use of pure refrigerant in a two-stage refrigeration system to replace the single-stage refrigeration system, in addition to mixing it into an appropriate mixture, can effectively improve the performance coefficient of the refrigeration system. For single-stage vapor compression refrigeration systems, R1234ze(Z), R601, and R1233zd(E) have the best refrigeration performances among the environmentally friendly refrigerants studied, while R441A performs the worst for T_eva = 10 °C and −20 °C. Moreover, RE170 has the highest COP of the refrigeration system for T_eva = −40 °C and −60 °C. However, R1234yf performs worse in COP when the evaporation temperature is lower, and it ranks last for T_eva = −60 °C. When a double-stage vapor compression refrigeration system is employed instead, the percentage increase in the COP of the system using R1234yf becomes the largest for T_eva = −40 °C and −60 °C. However, the growth rate of R717 ranks last for T_eva = −60 °C. For an R717/R1234yf mixture at an optimum mass fraction of 0.25, the COP of the refrigeration system can be increased up to 25.8% despite an increase of 15.2% in operating pressure compared to R1234yf. The discharge temperature may rise; however, there will be no overheating problem for the compressor. Full article

Several theoretical studies have predicted that refrigerant mixtures with glides of more than 20 K can yield COP improvements in heat pumps for operating conditions where the temperature difference between the heat source and heat sink is large, but experimental validations and quantifications are scarce. The application of high-glide mixtures (>20 K) in industrial heat pumps in the field is, therefore, still hampered by concerns about the behavior and handling of the mixtures. This study experimentally investigates hydrocarbon (HC) mixtures R-290/600 (propane/butane) and R-290/601 (propane/pentane) and compares them to previously tested mixtures of synthetic refrigerants. Comprehensive evaluations are presented regarding COP, compressor performance, pressure drop, heat transfer, and the possibility of inline composition determination. The mixtures were tested over a range of compositions at a source inlet temperature of 60 °C and a sink outlet temperature of 100 °C, with the heat sink and heat source temperature differences controlled to 35 K. R-290/601 at a mass composition of 70%/30% was found as the best mixture with a COP improvement of 19% over R-600 as the best pure fluid. The overall isentropic compressor efficiency was similar for HC and synthetic refrigerants, given equal suction and discharge pressures. Pressure drops in heat exchangers and connecting lines were equal for synthetic and HC mixtures at equal mass flow rates. This allows higher heating capacities of HC mixtures at a given pressure drop (mass flow rate) due to their wider vapor dome. A previously developed evaporator heat transfer correlation for synthetic refrigerant mixtures was applicable to the HC mixtures. A condenser heat transfer correlation previously fitted for synthetic refrigerants performed significantly worse for HC mixtures. Composition determination during operation and without sampling was possible with a deviation of at most 0.05 mass fraction using simple temperature and pressure measurements and REFPROP for thermodynamic property calculations. Overall, high-glide HC mixtures, just like mixtures of synthetic refrigerants, showed significant COP improvements for specific operating conditions despite a decreased heat transfer coefficient. Potential problems like composition shift or poor compressor performance were not encountered. As a next step, testing high-glide mixtures in pilot-plant installations is recommended. Full article

An experimental validation of a steady-state model for water-to-water heat pumps is conducted on a 10 kW test bench. The objective of the model is to predict the capacity and the required compressor power, based on the inlet conditions of the secondary fluids in the evaporator and condenser. Detailed manufacturer performance maps based on the AHRI 540-2020 standard are utilized to model the fixed-speed scroll compressor. A new semi-empirical model for the thermostatic expansion valve incorporates condensing temperature effects on superheating prediction. Sub-models for individual components, including detailed representations of the evaporator and condenser, are integrated into a global model, resulting in a set nonlinear equation solved using an equation solver with appropriate guess values. The validation of the model is conducted in an experimental test facility equipped with two precisely controlled secondary fluid loops. The heat pump is instrumented to measure condensation and evaporation pressures, the compressor discharge temperature, compressor power, superheating, and sub-cooling. The results are divided into three sub-sections: the first validates the complete heat pump model by comparing its power consumption and COPs in heating and cooling; the second compares the predicted and measured operational conditions; finally, it is shown how the model can be used to predict the non-operational conditions of the heat pump for specific scenarios. Full article

Due to the lack of oil injection cooling, it is usually necessary for dry twin-screw compressors to design cooling jackets to carry away the heat generated during operation. In order to investigate to what extent a cooling jacket can improve the performance of screw compressors, this study set up an experimental platform for a dry twin-screw compressor applied in fuel cell vehicles and used water as the working liquid in the cooling jacket. Then, the performance parameters of the screw compressor under different rotating speeds, discharge pressures, and cooling water flow rates were measured. It can be considered that the existence of a water cooling jacket is of great significance for improving the performance of dry screw compressors and improving extreme operating conditions. The research results may provide a reference for the development and improvement of dry twin-screw compressors in the future. Full article

In order to develop a highly efficient and stable high-temperature heat pump to realize high-efficient electrification in the industrial sector, performance of high-temperature heat pumps with a flash tank vapor injection and sub-cooler vapor injection are compared under different evaporation temperatures, condensation temperatures, compressor suction superheat degrees, subcooling degrees and compressor isentropic efficiencies. The results show that the COP, injection mass flow ratio and VHC of the FTVC are higher than those of the SVIC-0, SVIC-5, SVIC-10 and SVIC-20 under the same working conditions, while the discharge temperature of the FTVC is approximately equal to that of the SVIC-0 and lower than those of the SVIC-5, SVIC-10 and SVIC-20. When the evaporation temperature, the condensation temperature and injection pressure are 55 °C, 125 °C and 921.4 kPa, respectively, the system COP of the FTVC is 4.49, which is approximately 6.7%, 7.3%, 7.8% and 8.9% higher than those of the SVIC-0, SVIC-5, SVIC-10, and SVIC-20, respectively. Full article

This study focusses on the energy efficiency of compressed air storage tanks (CASTs), which are used as small-scale compressed air energy storage (CAES) and renewable energy sources (RES). The objectives of this study are to develop a mathematical model of the CAST system and its original numerical solutions using experimental parameters that consider polytropic charging and discharging processes, changes in the time of the temperature, flow parameters of the inlet and outlet valves under choked and subsonic conditions, and the characteristics of the air motor. This model is used to select CAST as an energy storage system for compressed air generated by compressors and recycling, as well as an energy source to drive DC generators and a pneumatic propulsion system (PPS). A measuring test rig is built to verify the polytropic pressure and temperature variations during CAST charging and discharging obtained from numerical solutions. The topic of discussion is the functional model of a high-pressure air system (HPAS) that contains a CAST connected to an air motor coupled to a mechanical drive for a DC generator or PPS. Such a system is used in small-scale CASTs, which currently respond to socio-economic demands. The presented CAST energy efficiency indicators are used to justify the storage of compressed air energy on a small scale. Small-scale compressed air storage in CASTs is currently important and relevant due to the balance between peak electricity demand and the development of wind energy, photovoltaics, and other renewable energy sources. Full article