Search Results (21)

High-temperature heat pump systems are essential for industrial processes that usually require high-temperature and high-pressure steam. An efficient design of these systems is critical for minimizing fossil fuel consumption, thereby contributing to a significant reduction in carbon emissions. One of the key components of these systems is the horizontal falling film evaporator, which is commonly employed due to its high thermal efficiency and low refrigerant charge. This study presents a preliminary design of a falling film evaporator to meet the target of the heat duty value of 2.2 MW. The phase-change dynamics inherent to the falling film evaporation process were critically analyzed using ANSYS Fluent (2024 R2). The low-global warming potential refrigerant R1336mzz(Z) was incorporated as a refrigerant on the shell side, while hot water was used in the tubes. The study identified key regions of film flow to maximize vapor production and design optimizations. The discussed performance parameters and operational mechanisms of the evaporator are prevailing features, particularly with the adoption of environmental regulations. Overall, the simulation results offer valuable insights into heat transfer mechanisms and evaporator effectiveness for advancing heat pump technologies in industrial applications. Full article

Heat pump water heaters (HPWHs) are a proven technology for water heating that has been commercialized. The adoption of HPWHs for domestic and commercial water heating is growing rapidly because of their superior performance compared with alternative water heating methods. Whereas most existing systems use R-134a as a working refrigerant, R290 has gained major attention owing to its superior thermodynamic properties. The goal of the current study is to assess the performance of residential HPWH with R290 as a direct refrigerant replacement for R134a. Two units of a 50 gal HPWH were used in this experimental study. A baseline unit contained R134a refrigerant, and a prototype unit contained R290 refrigerant. The prototype unit was developed through the modification of a commercially available HPWH unit to achieve a low charge of R290 refrigerant. Another major modification was the replacement of the baseline compressor with a compressor designed for R290. Tests were conducted in a field environment (a research and demonstration house) using programmed drawn profiles daily. The prototype that reduced the charge by 43–47% provided displayed performance comparable to the baseline unit regarding first-hour rating (FHR) and the uniform energy factor (UEF). Full article

Heat pumps are widely regarded as a key technology for sustainable heating, offering a pathway to significantly reduce fossil fuel dependency and combat the climate crisis. However, replacing individual gas boilers with heat pumps in multi-unit residential buildings remains a substantial challenge despite its immense potential to lower urban greenhouse gas emissions. To address this, the following paper describes the development of a compact, modular heat pump system designed to replace conventional gas boilers, focusing on the building and testing of a prototype for such a modular heat pump system. The prototype supports multiple functionalities, including space heating, cooling, and domestic hot water production. The performance advantages of two different compressor technologies were exploited to optimize the efficiency of the complete system and the pressure lifts associated with applications for heating and domestic hot water production. Thus, measurements were conducted across a range of operating points, comparing different heat pump module types. In the case of the piston compressor module, the Carnot efficiency was in the range of 47.2% to 50.4%. The total isentropic efficiency for floor heating and domestic hot water production was above 0.45 for both piston and rotary compressors. Full article

A prototype of a mobile electric charging station was developed to simulate the energy supply to a rural medical post. A 20 m² medical post module was built, divided into two rooms (medical staff room and patient room) and a heater, a freezer, a refrigerator, lights and a personal computer were added inside. The mobile electric charging station was made up of an array of 2.88 kW flexible photovoltaic panels, a 48 V and 19.2 kW·h LiFePO₄ battery bank, a charger inverter with a total capacity of 5 kW and a 4 kW electric generator. All of this equipment was placed in an all-terrain pickup truck. Temperature sensors and electrical sensors were installed to evaluate the performance of the prototype in charging and discharging scenarios. Results were obtained according to the operation over 10 months in the city of Arequipa, Peru. The results indicate an indefinite autonomy on clear days, the autonomy varying between 7 and 10 days for a climate with medium cloudiness, and with very cloudy conditions (i.e., with rain), the autonomy is 2 to 3 days. In circumstances of low solar irradiance, the generator had to supply the energy, thereby improving energy autonomy. Full article

Recently, battery electric vehicles (BEVs) have faced various technical challenges, such as reduced driving range due to ambient temperature, slow charging speeds, fire risks, and environmental regulations. This numerical study proposes an integrated thermal management system (ITMS) utilizing R290 refrigerant and a 14-way valve to address these issues, proactively meeting future environmental regulations, simplifying the system, and improving efficiency. The performance evaluation was conducted under high-load operating conditions, including driving and fast charging in various environmental conditions of 35 °C and −10 °C. As a result, the driving efficiency was 4.82 km/kWh in high-temperature conditions (35 °C) and 4.69 km/kWh in low-temperature conditions (−10 °C), which demonstrated higher efficiency than the Octovalve-ITMS applied to the Tesla Model Y. Furthermore, in fast charging tests, the high voltage battery was charged from a 10% to a 90% state of charge in 26 min at 35 °C and in 31 min at −10 °C, outperforming the Octovalve-ITMS-equipped Tesla Model Y’s fast charging time of 27 min under moderate ambient conditions. This result highlights the superior fast-charging performance of the 14-way valve-based ITMS, even under high cooling load conditions. Full article

Vapor compression heat pump technology is a widely utilized method for energy conversion. Lubricating oil plays a crucial role in the heat pump system cycle by effectively reducing wear on the compressor’s moving parts and preventing refrigerant leakage. However, it can also create an oil film in the heat exchange equipment, which increases thermal resistance and diminishes heat transfer efficiency. This study utilizes a vapor compression heat pump system test bench to investigate factors influencing the system’s oil circulation rate, the two-phase flow patterns of refrigerant and lubricating oil, and the impact of oil circulation on system performance. The findings reveal that as the compressor speed increases, the oil circulation rate initially decreases before increasing again. Additionally, a decrease in the evaporator’s heat load leads to a reduction in oil circulation at high temperatures, while it increases at low temperatures. Furthermore, increasing the opening of the electronic expansion valve results in a gradual decrease in the oil circulation rate, whereas an increase in the refrigerant charge correlates with a rise in the oil circulation rate. The oil return flow pattern can primarily be categorized into three states: slow oil return, oil film flow, and high-speed oil return. These patterns are closely related to the degree of superheat, with lower superheat levels intensifying oil return. 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

The R744/R404A cascade refrigeration system (CRS) has been widely used in supermarkets and hypermarkets, but due to the refrigerant regulation of R404A, research on alternative refrigerants is necessary. In addition, although there have been quite a few studies on R448A and R449A, which are well-known alternatives to R404A, few studies have analyzed the performance coefficients of the three refrigerants, and the studies that have analyzed them are not based on enough variables. Therefore, we aimed to understand the performance characteristics of CRS combined with an internal heat exchanger (IHX) by applying R744 for the low-temperature cycle (LTC) and R404A, R448A, and R449A for the high-temperature cycle (HTC). The analysis method was to analyze the coefficient of performance (COP) and mass flow rate (MFR) of the three refrigerants according to the degree of subcooling (DSC) and degree of superheating (DSH), IHX efficiency, temperature difference in the cascade heat exchanger (CHX), condensation temperature (CT), evaporation temperature (ET), and cascade evaporation temperature (CET). The purpose of this study is to compare R448A and R449A, alternative refrigerants to R404A, in an R744/R404A CRS, with R404A to provide sufficient data for optimal CRS design. The comparison results are as follows: (1) Compared with R404A, the MFR of R448A and R449A are 67.27–77.6% and 70.05–80.80%, respectively, under the same conditions. Therefore, R448A and R449A are economically favorable because they have less refrigerant charge than R404A, and R448A is more favorable than R449A. (2) The R744/R448A CRS is stable and performs better than the R744/R449A CRS in places with large changes in the surrounding environment. Full article

In this study, the performance characteristics of an R404A indirect refrigeration system (IRS) applied to an internal heat exchanger (IHX) is evaluated for supermarkets and hypermarkets. In a direct expansion system, R404A is the primary refrigerant and R744, a brine, is the secondary fluid. While there are abundant studies analyzing the theoretical performance of IRS, experimental research on IRS is lacking, and there are no papers that address the results of changes in the IHX in detail. In this study, the results achieved by modifying various parameters are experimentally evaluated to provide fundamental data for designing the optimal IRS. In the main results, looking at the trend of the increase in IHX efficiency, the change is very minimal when the efficiency is above 50%, so it is ideal to apply an IHX efficiency of about 50% considering economics and COP, etc. Applying the results in this study enables the operation and maintenance of IRSs as an eco-friendly system by achieving energy efficiency through optimizing the system coefficient of performance and securing economic feasibility by minimizing the R404A charging amount of the refrigeration cycle. To serve supermarkets and hypermarkets, R744 as a secondary fluid may help to realize an ecologically friendly, compact IRS system with a high heat transfer coefficient that can operate at low temperatures (−35 to 5 °C). Full article

Ice plates, widely used in food cold chain refrigeration transportation, involve challenges such as long cold storage time and low efficiency in use. This study establishes a mathematical model for ice plate cold storage and release. It analyzes the influence of fin setting position, distribution, and size on the cold storage and release characteristics of non-uniform fins having diverse sizes and spacing on the inner and outer surfaces of the ice plate. Results show that compared to finless ice plates, plates with inner or outer fins can reduce the cold storage and release time, accelerate the charging and discharging efficiency of the cold storage equipment, and potentially save time. Cold storage and release time savings of up to 17.5% and 19.6%, respectively, were attained using outer fins. Driven by natural convection inside the finned ice plate, cold storage proceeds from top to bottom, while cold release proceeds from bottom to top. For inner fins, the distribution has a higher impact on the cold storage and release speed than the size. For outer fins, both the distribution and size equally affect the cold storage and release speed. The smaller the reference spacing between the outer fins, the faster the cooling storage, but the slower the cold release. The larger the reference area, the faster the cooling storage, but the slower the cold release. Thus, when designing ice plate products, the distribution and the size of fins should be selected based on prior consideration of storage or release speed. This study provides a theoretical basis and design guidance for the design of ice plate products, especially for refrigerated transportation applications. Full article

Preservation of perishable food produce is a major concern in the cold chain supply system. Development of an energy-efficient on-farm cold storage facility, hence, becomes essential. Integration of thermal storage into a vapor compression refrigeration (VCR)-driven cold room is a promising technology that can reduce power consumption and act as a thermal backup. However, designing a latent heat energy storage heat exchanger encounters challenges, such as low thermal conductivity of phase change materials (PCMs) and poor heat exchanger efficiencies, leading to ineffective charging–discharging cycles. The current study investigates the effect of the integration of a Phase Change Material (PCM) in terms of the selection of the PCM, the optimal positioning of the PCM heat exchanger, and the selection of heat exchanger encapsulation material. Numerical analysis was undertaken using 3D Experience software (version: 2024x.D31.R426rel.202403212040) by creating a 3D model of a 3.4 m³ micro-cold storage unit to understand the inner temperature distribution profile. Further, the experimental setup was developed, and tests were conducted, during which the energy consumption of 1.1 kWh was recorded for the total compressor run time of 1 h. Results indicated that an improved cooling effect was achieved by positioning the PCM trays on the wall opposite the evaporator. It is seen that a temperature difference in the range of 5 to 7 °C exists between the phase change temperature of PCM and the optimal storage temperature depending on the encapsulation material. Hence, PCM selection for thermal storage applications would have an important bearing on the material and configuration of the PCM encapsulation. Full article

To gain a sustained competitive advantage, organizations such as UPS, Fedex, Amazon, etc., began to seek for industry 5.0 innovative autonomous delivery options for the last mile. Autonomous unmanned aerial vehicles are a promising alternative for the logistics industry. The fact that drones are propelled by green renewable energy source fits the companies’ need to become sustainable, replacing their fuel truck fleets, especially for traveling to remote rural locations to deliver small packages, but a major obstacle is the necessity for charging stations which is well documented in the literature. Therefore, the current research embarks on devising a novel yet practical piece of technology adopting the simplicity approach of direct flights to destinations. The analysis showcases the application for a network of warehouses and hospitals in Israel while controlling costs. Given the products in the case study are medical, direct flight has the potential to save lives when every moment counts. Hydrogen cell technology allows long-range flying without refueling, and it is both vibration-free which is essential for sensitive medical equipment and environmentally friendly in terms of air pollution and silence in urban areas. Importantly, hydrogen cells are lighter, with higher energy density than batteries, which makes them ideal for drone usage to reduce weight, maintain a longer life, and enable faster charging, all of which minimize downtime. Also, hydrogen sourcing is low-cost and unlimited compared to lithium-ion material which needs to be mined. The case study investigates an Israeli entrepreneurial company, Gadfin, which builds a vertical takeoff-and-landing-type of drone with folded wings that enable higher speed for the delivery of refrigerated medical cargo, blood, organs for transplant, and more to hospitals in partnership with the Israeli medical logistic conglomerate, SAREL. An analysis of shipping optimization (concerning the number and type of drone) is conducted using a mixed-integer linear programming technique based on various types of constraints such as traveling distance, parcel weight, the amount of flight controllers and daily number of flights allowed in order to not overcrowd the airspace. Importantly, the discussion assesses the ecosystem’s variety of risks and commensurate safety mechanisms for advancing a newly shaped landscape of drones in an Israeli tight airspace to establish a network of national routes for drone traffic. The conclusion of this research cautions limitations to overcome as the utilization of drones expand and offers future research avenues. Full article

This study proposes the experimental evaluation of alternative refrigerants with low global warming potentials (GWPs) such as R1234ze(E), R513A, and the mixture R516A as a drop-in replacement for R134a in a domestic refrigerator with a volumetric capacity of 513 L. Initially, the optimal charge for each refrigerant was defined based on the minimum energy consumption of the refrigerator, then the thermal and energy performance of the refrigerator was evaluated. Finally, a total equivalent warming impact analysis (TEWI) was performed. The main results indicated that the optimal charge of the alternative refrigerants was below that corresponding to R134a (105 g), of which R516A (86 g) presented the greatest charge reduction. Regarding the average temperature of the refrigerator compartments, very adequate thermal conditions were observed; thus, the alternative refrigerants showed very similar conditions to R134a. For the coefficient of performance (COP) and considering R134a as a reference, it was observed that R513A presented the greatest reduction of around 28%, while R1234ze(E) showed an increase of 13% in relation to R134a. Finally, the TEWI analysis showed R1234ze(E) as the refrigerant with the least impact. Full article

This work addresses the energy management of a combined system consisting of a refrigeration cycle and a thermal energy storage tank based on phase change materials. The storage tank is used as a cold-energy buffer, thus decoupling cooling demand and production, which leads to cost reduction and satisfaction of peak demand that would be infeasible for the original cycle. A layered scheduling and control strategy is proposed, where a non-linear predictive scheduler computes the references of the main powers involved (storage tank charging/discharging powers and direct cooling production), while a low-level controller ensures that the requested powers are actually achieved. A simplified model retaining the dominant dynamics is proposed as the prediction model for the scheduler. Economic, efficiency, and feasibility criteria are considered, seeking operating cost reduction while ensuring demand satisfaction. The performance of the proposed strategy for the system with energy storage is compared in simulation with that of a cycle without energy storage, where the former is shown to satisfy challenging demands while reducing the operating cost by up to 28%. The proposed approach also shows suitable robustness when significant uncertainty in the prediction model is considered. Full article

Due to increasing sales figures, the energy consumption of battery-electric vehicles is moving further into focus. In addition to efficient driving, it is also important that the energy losses during AC charging are as low as possible for a sustainable operation. In many situations it is not possible or necessary to charge the vehicle with the maximum charging power e.g., in apartment buildings. The influence of the charging mode (number of phases used, in-cable-control-box or used wallbox, charging current) on the charging efficiency is often unknown. In this work, the energy consumption of two electric vehicles in the Worldwide Harmonized Light-Duty Vehicles Test Cycle is presented. In-house developed measurement technology and vehicle CAN data are used. A detailed breakdown of charging losses, drivetrain efficiency, and overall energy consumption for one of the vehicles is provided. Finally, the results are discussed with reference to avoidable CO${}_2$ emissions. The charging losses of the tested vehicles range from 12.79 to 20.42%. Maximum charging power with three phases and 16 A charging current delivers the best efficiencies. Single-phase charging was considered down to 10 A, where the losses are greatest. The drivetrain efficiency while driving is 63.88% on average for the WLTC, 77.12% in the “extra high” section and 23.12% in the “low” section. The resulting energy consumption for both vehicles is higher than the OEM data given (21.6 to 44.9%). Possible origins for the surplus on energy consumption are detailed. Over 100,000 km, unfavorable charging results in additional CO${}_2$ emissions of 1.24 t. The emissions for an assumed annual mileage of 20,000 km are three times larger than for a class A+ refrigerator. A classification of charging modes and chargers thus appears to make sense. In the following work, efficiency improvements in the charger as well as DC charging will be proposed. Full article