Zeotropic mixtures are widely discussed as alternative refrigerants for vapor‐compression cooling appliances and heat pumps. Mixtures can increase efficiency due to their nonisothermal phase change. In theoretical studies, zeotropic mixtures show significant benefits for efficiency if the temperature glide of the mixture matches the temperature change in the heat transfer fluids. Such large benefits have never been observed in experiments. First, this article clarifies the gap between simulations and experiments. Second, it is shown how zeotropic mixtures could increase efficiency in real plants. The analysis is based on experimental results from a heat pump with three zeotropic mixtures and on theoretical studies that also include a physical compressor model. The compressor performance is shown to depend strongly on composition. Therefore, the compressor efficiency is the key parameter for large benefits of zeotropic mixtures beyond well‐matching temperature glides. Based on these findings, a fluid database is screened for fluids with well‐matching temperature glides and high compressor efficiencies, utilizing a physical compressor model. As a result of the screening, the zeotropic mixture R152a/R32 is identified. The corresponding simulations show that zeotropic mixtures can achieve large benefits in heat pump efficiency if the pure components have similar and high compressor efficiencies.
The global warming potential of many working fluids used nowadays for vapor compression refrigeration systems and heat pumps is very high. Many of such fluids, which are used in currently operating refrigerators and heat pumps, will have to be replaced. In order to avoid a redesign of the system, it would be very helpful if efficient and ecological alternative working fluids for a given plant could be found. With modern process simulation tools such a selection procedure seems possible. However, it remains unclear how detailed such a model of a concrete plant design has to be to obtain a reliable working fluid ranking. A vapor compression heat pump test-rig is used as an example and simulated by thermodynamic models with different levels of complexity to investigate this question. Experimental results for numerous working fluids are compared with models of different complexity. Simple cycle calculations, as often used in the literature, lead to incorrect results regarding the efficiency and are not recommended to find replacement fluids for existing plants. Adding a compressor model improves the simulations significantly and leads to reliable fluid rankings but this is not sufficient to judge the adequacy of the heat exchanger sizes and whether a given cooling or heating task can be fulfilled with a certain fluid. With a model of highest complexity, including an extensive model for the heat exchangers, this question can also be answered.
This work presents an approach to the contextual integration of fluid selection and compressor design for the cycle design of efficient industrial heat pumps. The vapor-compression cycle of an air-water heat pump operated at 42 °C source and 82 °C target temperature is investigated as a theoretical case study. An optimization study is performed, which includes the assessment of suitable refrigerants. Besides well-known single-component refrigerants, various binary mixtures are considered. The cycle optimization aims at simultaneously providing high cycle coefficient of performance and volumetric heating capacity. Cycle operation with the mixtures R-41/Trans-2-Butene (10, 90) mol % and CO2/R-161 (40, 60) mol % yields the highest values of these parameters, respectively. For further evaluation, centrifugal compressors operated with each of the two promising mixtures are designed with an in-house meanline program. In addition, the compressor design for the hydrofluoro-olefin refrigerant R-1234ze(Z) is considered as a reference. All designs are reviewed with respect to cycle as well as compressor design criteria and the applied methodology will assist designers in identifying key decision variables. The comprehensive design assessment suggests that CO2/R-161 (40, 60) mol % provides the best overall solution for an efficient cycle with a compact compressor design.
ZusammenfassungDas Arbeitsmittel in Wärmepumpen unterliegt einer Vielzahl von Anforderungen, welche für einen effizienten und sicheren Betrieb eingehalten werden müssen. Weiterhin steigt die Anzahl markterhältlicher Arbeitsmittel durch die Entwicklung neuer Gemische kontinuierlich an, wodurch deren Auswahl erschwert wird. Aus diesem Grund wird im Rahmen dieses Beitrags eine Marktanalyse alternativer Arbeitsmittel durchgeführt und die selektierten Arbeitsmittel hinsichtlich ihres Potentials für Wärmepumpen bewertet. Die Marktanalyse beinhaltet eine Einordnung der Arbeitsmittel durch politische Vorgaben (kein Ozonabbaupotential, geringes Treibhauspotential), sicherheitstechnischer Aspekte (Toxizität, Brennbarkeit) sowie technischer Anforderungen (unterkritischer Betrieb, maximale Prozesstemperaturen). Hierbei werden 32 Fluide identifiziert, welche die gestellten Anforderungen einhalten. Diese sind alle brennbar und größtenteils entweder Kohlenwasserstoffe (KW) oder Hydrofluorolefine (HFO). Anschließend wird die Effizienz im einfachen Kältekreislauf nach DIN EN 14825 bestimmt. Um die Fluidabhhängigkeit detailliert und realitätsnah abschätzen zu können, wird ein semi-physikalisches Verdichtermodell eingesetzt, welches fluid- und betriebspunktabhängige Verdichterwirkungsgrade liefert. Innerhalb der Kreislaufberechnung zeigen die Fluide RC270 und R161 die höchsten Effizienzen und führen zu einer Verbesserung der saisonalen Arbeitszahl im Vergleich zu R410A von bis zu 15 %. Diese führen aber zu hohen Temperaturen am Verdichteraustritt und sind daher ungeeignet. Weiterhin zeigen KW höhere Effizienzen als HFO. Bei der Wahl des Arbeitsmittels müssen allerdings weitere Aspekte, wie der Umwelteinfluss sowie Füllmengenbeschränkungen aufgrund der Brennbarkeit des Fluids betrachtet werden. Insgesamt weisen die Arbeitsmittel Propan und Propen das höchste Anwendungspotential auf. Für Anwendungen, in denen füllmengenbeschränkte Wärmepumpen erforderlich sind, bieten die HFO R454C, R457A und R516A effiziente Alternativen, deren Potenzial durch die Integration eines internen Wärmeübertragers in den Kältekreislauf gesteigert werden kann.
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