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Received 7 August 2001; received in revised form 15 November 2001; accepted 30 November 2001
Abstract
The main purpose of this study is to investigate the performance of an autocascade refrigeration system using zeo-
tropic refrigerant mixtures of R744/134a and R744/290. One of the advantages of this system is the possibility of
keeping the highest pressure of the system within a limit by selecting the composition of a refrigerant mixture as com-
pared to that in the vapor compression system using pure carbon dioxide. Performance test and simulation have been
carried out for an autocascade refrigeration system by varying secondary fluid temperatures at evaporator and con-
denser inlets. Variations of mass flow rate of refrigerant, compressor power, refrigeration capacity, and coefficient of
performance (COP) with respect to the mass fraction of R744 in R744/134a and R744/290 mixtures are presented at
different operating conditions. Experimental results show similar trends with those from the simulation. As the com-
position of R744 in the refrigerant mixture increases, cooling capacity is enhanced, but COP tends to decrease while the
system pressure rises. # 2002 Elsevier Science Ltd and IIR. All rights reserved.
Keywords: Refrigeration system; Compression system; Refrigerant; Carbon dioxide; R134a; Propane; Mixture; Refrigerating circuit;
Cascade system; Design; Performance; Measurement; Modelling
Mots cle´s : Système frigorifique ; Système à compression ; Frigorigéne ; Dioxyde de carbone ; R134a ; Propane ; Mélange ; Circuit
frigorifique ; Systéme en cascade ; Conception ; Performance ; Mesure ; modélisation
0140-7007/02/$20.00 # 2002 Elsevier Science Ltd and IIR. All rights reserved.
PII: S0140-7007(01)00110-4
1094 S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101
Nomenclature Subscripts
1 Inlet of compressor
DP Differential pressure (kPa) 2 Outlet of compressor
h Enthalpy (kWkg1) 2nd Secondary heat transfer fluid
m Clearance volume ratio c Condenser
:
mr Mass flow rate of refrigerant (kgs1) dew Dew point
P: Pressure (kPa) e Evaporator
Q Heat capacity (kW) i Inlet
DT Logarithmic mean temperature difference o Outlet
( C) sup Superheated region
v: Specific volume (m3 kg1) tp Two phase region
V: comp Compressor displacement rate
W Compressor power (kW)
Greek letters
v Volumetric efficiency
This paper investigates the performance variations of in Fig. 2. Point 1 represents the inlet of the compressor
an autocascade refrigeration system using refrigerant and the P-h diagram with the point 1 is for the mixture’s
mixtures of R744 (carbon dioxide) with R134a or R290 composition of initial charge. After compression to
(propane). The choice of R134a seems not purely ‘nat- point 2, the refrigerant mixture is cooled down in the
ural’, but it is aimed at finding a possible solution for condenser, but only partially condensed to point 3 by
the transient period of probable reduction in production the heat sink whose temperature is near the ambient
of HFCs in the future before shifting to natural working temperature, as the bubble point of the mixture is much
fluid systems. So far, little work except one of the lower than the ambient temperature. In the phase
authors’ previous work [12] has been performed for an separator, liquid phase at point 4 will have a different
autocascade refrigeration system using CO2. In this composition from the vapor phase at point 7, and each
work, as a continuation of our study, experiment and phase will flow through different passages. The mass
simulation have been carried out to provide perfor- flow rate of each passage is strongly dependent on the
mance characteristics of an autocascade refrigeration quality in the phase separator, which means that low
system for various mass fractions of R744 in the R744/ quality refrigerant at the exit of condenser will force a
134a and R744/290 mixtures and for several operating greater mass flow rate of liquid phase in the evaporative
conditions. condenser. Therefore, the quality at the condenser outlet
should be well determined to maintain a proper heat
balance in the evaporative condenser. In addition to
2. Operation of the autocascade refrigeration system this, the temperature difference should be moderate to
transfer the necessary heat to condense the vapor phase
The autocascade refrigeration system is shown in by evaporating the low temperature refrigerant in the
Fig. 1 and the pressure-enthalpy (P-h) diagram is shown evaporative condenser. Since the vapor phase and liquid
1096 S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101
phase refrigerants have different compositions, two dif- The exit pressures of evaporative condenser and the
ferent P-h diagrams which correspond to the overall evaporator should be equalized very quickly, however, the
composition of each phase describe each heat transfer temperature of two streams will not always be the same.
process. Liquid phase has lower mass fraction of carbon
dioxide, therefore the front P-h diagram shown in Fig. 2
is applied, while the rear P-h diagram is applied to the 3. Experiments
flow of the vapor phase from the phase separator. The
liquid phase is then expanded from point 4 to a lower 3.1. Description of experimental setup
temperature at point 5 entering the evaporative con-
denser to cool the vapor phase in the phase separator. Experimental setup for the performance test of an
This stream flows through one side of the evaporative autocascade refrigeration system consisted of a com-
condenser, vaporizing and leaving slightly superheated pressor, a condenser, two expansion valves, an eva-
at point 6. The vapor phase is condensed from point 7 porator, an evaporative condenser, a phase separator,
to point 8 in the internal heat exchanger. Then, the two and a vapor line to suction line heat exchanger (internal
phase of carbon dioxide rich mixture condenses on the heat exchanger) as shown in Fig. 1. The compressor in
other side of the evaporative condenser, leaving as this study was of an open, reciprocating type with two
saturated liquid or as slightly subcooled liquid at point cylinders each of which had the diameter of 32 mm and
9. This fraction of the refrigerant mixture is then the stroke of 28 mm. Refrigeration oil used for the
expanded to a state with lower pressure and temperature compressor was mineral oil of ISOVG32. The condenser
(point 10). It becomes a superheated vapor (point 11) in and the evaporator were counterflow-type heat
the evaporator by absorbing heat from the secondary exchangers with concentric dual tubes. Metering valves,
fluid and is mixed with the refrigerant coming from eva- which could finely regulate the flow rate, were used as
porative condenser (point 6). Eventually, the state is expansion valves. The rotating speed of the compressor
indicated by point 12 after mixing. The temperature of was also kept constant, and torque transducer was
the mixed refrigerant rises to point 1 through a heat installed between the driving motor and the compressor.
exchange with the vapor refrigerant coming from the Water was used as a secondary fluid in the condenser,
separator. The compressor receives the low pressure and ethylene glycol and water mixture (40:60 by mass)
refrigerant from the internal heat exchanger, and it was used in the evaporator as a secondary heat transfer
forms a complete cycle. fluid.
S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101 1097
3.2. Test conditions and test method tained near 0.5 by controlling the flow rate of the second-
ary fluid while keeping the inlet temperature and the
The performance test during cooling conditions was overall temperature difference of the secondary fluid in the
carried out for the refrigerant mixtures of R744/134a condenser. Table 1 shows the inlet and outlet temperatures
and R744/290. As for composition of the refrigerant and pressures of the refrigerant mixture at the condenser
mixtures, the mass fraction of R744 was selected 0.21– and evaporator together with the calculated dew point
0.36 for R744/134a and 0.13–0.31 for R744/290, so that temperatures, which are estimated from the measured
the maximum operating pressure was below 3 MPa. pressures at the inlet of the condenser and evaporator.
The temperature differences of the secondary heat The cooling capacity was measured by the heat loss or
transfer fluids between the inlet and outlet at condenser gain of the secondary heat transfer fluid in the eva-
and evaporator were set to 8 and 7 C, respectively. In porator and condenser, and the work input to the com-
order to cover the operating ranges for outdoor tem- pressor was calculated from the torque and rotating
perature change during room cooling, the condenser speed measurement. Rotating speed of the compressor
inlet temperature of the secondary heat transfer fluid was kept 1500 rpm.
was varied from 27.8 to 40.0 C for the designated sec- When the variation of temperature measurement was
ondary fluid inlet temperature at the evaporator of within 0.3 C, that of the pressure measurement
26.7 C. The quality at the condenser outlet was main- within 5 kPa, and the change of the mass flow rate of
Table 1
The inlet and outlet temperature levels, pressures and the estimated dew point temperatures at the condenser and evaporator
R744/134a
xCO2 T2nd,ci ( C) Pci (kPa) Pei (kPa) Tci ( C) Tco ( C) Tei ( C) Teo ( C) Tdew,c ( C) Tdew,e ( C)
0.21 27.8 1560.6 519.9 76.4 28.6 23.8 26.9 37.9 3.4
0.21 31.0 1745.1 541.9 85.1 31.8 23.0 26.9 42.0 2.9
0.21 35.0 1954.6 544.6 91.9 35.7 20.8 27.2 46.2 2.9
0.21 40.0 2193.8 543.8 99.8 40.7 17.1 27.1 50.5 2.3
0.26 27.8 1813.7 536.6 79.1 28.5 29.8 26.7 39.4 6.7
0.26 31.0 2012.4 553.2 89.3 31.4 29.1 26.7 43.2 6.5
0.26 35.0 2267.3 543.8 97.2 35.5 27.1 26.6 47.6 7.0
0.26 40.0 2502.8 531.3 103.9 40.5 25.2 26.7 51.3 6.6
0.30 27.8 2000.9 632.9 84.3 28.3 27.2 26.8 40.2 5.1
0.30 31.0 2198.3 636.8 91.4 31.6 26.1 26.8 43.6 4.9
0.30 35.0 2409.3 623.6 98.2 35.5 24.5 26.8 46.9 5.0
0.30 40.0 2671.8 596.9 106.7 40.5 21.5 26.7 50.8 5.2
0.36 27.8 2363.2 760.9 86.7 28.2 27.7 26.8 41.4 4.8
0.36 31.0 2574.5 767.0 97.1 31.4 26.8 26.7 44.5 4.5
0.36 35.0 2831.6 762.2 103.9 35.5 24.8 26.9 47.9 4.0
0.36 40.0 3131.4 723.6 113.1 40.4 22.0 26.8 51.6 4.4
R744/290
xCO2 T2nd,ci ( C) Pci (kPa) Pei (kPa) Tci ( C) Tco ( C) Tei ( C) Teo ( C) Tdew,c ( C) Tdew,e ( C)
0.13 27.8 1534.9 714.5 69.1 29.7 10.3 26.9 36.9 3.6
0.13 31.0 1648.4 638.6 77.1 32.9 10.4 26.7 39.9 0.0
0.13 35.0 1794.3 635.7 82.6 36.5 8.5 26.9 43.4 0.1
0.13 40.0 2009.4 633.3 89.5 41.5 5.5 26.9 48.3 0.0
0.22 27.8 1821.3 785.4 71.5 29.1 14.6 26.6 38.8 0.9
0.22 31.0 1955.9 754.8 79.6 32.2 13.9 26.7 41.7 0.3
0.22 35.0 2235.7 719.3 88.7 35.9 14.1 26.6 47.3 3.0
0.22 40.0 2418.7 702.6 95.4 40.9 12.6 26.9 50.7 2.5
0.31 27.8 2365.2 976.3 78.7 28.3 17.2 26.6 43.2 0.9
0.31 31.0 2519.2 968.9 83.9 31.5 16.1 26.6 45.8 0.5
0.31 35.0 2727.1 911.8 92.0 35.8 12.8 26.7 49.0 1.5
0.31 40.0 2937.2 912.7 98.2 40.5 10.2 26.5 52.1 0.1
1098 S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101
refrigerant was within 0.2 g/s, the system was assumed It is assumed that pressure drop and heat loss in heat
steady and data were collected. exchangers are negligible.
Combined standard uncertainty in measuring the Evaporative condenser is used to condense the vapor
heat capacity in condenser and evaporator is 3.4% of phase of refrigerant in the phase separator that has
the measured heat transfer rate, and that in calculating higher fraction of carbon dioxide by the evaporating
COP (coefficient of performance) is 3.5%. The repeat- refrigerant of low temperature which has relatively
ability of the measurement is within the range of 3.0%. higher fraction of R134a or R290. Evaporative con-
denser is also a counterflow heat exchanger that is
assumed to have negligible pressure drop and heat loss.
4. Autocascade cycle simulation It is idealized to have heat exchanger effectiveness of 1.
Expansion device is modeled to be isenthalpic.
4.1. Modeling of autocascade cycle The refrigerant from the condenser outlet should pass
through the phase separator. In the phase separator, the
Compression process is described by a simple way refrigerant mixture’s vapor and liquid phases are coex-
using the concept of a constant isentropic efficiency. The isting and its composition of liquid phase is different
mass flow rate of refrigerant is calculated considering from that of vapor phase for zeotropic mixtures in this
the compressor displacement rate, volumetric efficiency, study. In this case the mass fraction of carbon dioxide
and specific volume of gas entering the compressor as (R744) is higher in vapor phase, and the liquid phase is
shown in Eqs. (1) and (2). richer in R134a or R290. Even though the phase
separation is not perfect in this flowing situation com-
1
v ¼ 1 mð 1Þ ð1Þ pared with the case of phase equilibrium, it is quite a
2 unique way to assume the liquid and vapor phase have
: the compositions that can be obtained for the phase
: Vcomp
mr ¼ ð2Þ equilibrium state. Once the compositions are determined
1 from the equilibrium relation, it is idealized that the
liquid and vapor phases are flowing independently in
Here, m represents a clearance volume ratio to have the separate passages.
value of 0.04.
Both the evaporator and condenser are modeled as 4.2. Simulation conditions
counterflow heat exchangers as shown in the experi-
ment. Even though the local heat transfer coefficients In the autocascade refrigeration system, evaporating
vary as a function of refrigerant flow rate, heat flux, temperature, condensing temperature, the ratio of mass
mass quality, etc., average temperature difference flow rate at each branch circuit, and the mass fraction of
between the refrigerant and the secondary heat transfer the charged refrigerant are important variables. In order
fluid is designated in the simulation, which is taken as to investigate the effects of the variation of these vari-
an average of test data sets obtained from the experi- ables on the system performance, quality at condenser
ment. The average temperature difference between two outlet, degree of superheat and isentropic efficiency are
fluids is defined as in Eqs. (3) and (4), which is propor- held constant.
tional to the heat transfer rate of each phase of refrig- In order to compare the experimental results with the
erant in the heat exchanger considering the logarithmic simulation results, simulation conditions are made
mean temperature difference of each subsection [13]. The similar to experimental conditions. The selection of the
separation of two phase flow region and the superheated composition of the mixture is limited by the capability
region of refrigerant mixture is necessary, and this is of the thermodynamic property calculation using
quite straightforward since we know pressure and tem- REFPROP [14] near the critical point of the mixture.
perature at each point of heat exchangers. Correspond-
ing secondary fluid temperatures and transferred heat
can be easily obtained from the energy balance based on 5. Results and discussion
mass flow rate of refrigerant and the enthalpies at each
point of heat exchangers. 5.1. Performance at cooling conditions
: :
1 Qsup;c Qtp;c The variations of cooling capacities with respect to
¼ : þ : ð3Þ
Tc Qc Tsup;c Qc Ttp;c the mass fraction of R744 are displayed in Fig. 3.
Cooling capacity is calculated by multiplying three fac-
: : tors of mass flow rate of secondary heat transfer fluid,
1 Qtp;e Qsup;e
¼ : þ : ð4Þ specific heat, and the temperature difference between the
Te Qe Ttp;e Qe Tsup;e
inlet and outlet including the heat gain from the ambient
S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101 1099
air. As the mass fraction of R744 increases, refrigerant the pressure ratio of the compressor increases, which
mass flow rate increases owing to the smaller vapor results in the increase in the compressor power. The
specific volume of R744 than that of R134a and R290 compressor power of R744/290 is greater than that of
for the same temperature and pressure conditions. Since R744/134a at the same composition of R744, which is
cooling capacities are very much dependent on the mass because the saturation pressure of R290 is greater than
flow rate of refrigerant, increased mass flow rate of that of R134a.
refrigerant under constant compressor speed condition The coefficient of performance (COP) is defined as
is expected. The cooling capacity of R744/290 is about the refrigeration capacity divided by the work per unit
twice greater than that of R744/134a, because the time required by the compressor. The variation of COP
refrigeration effect of R290 is greater than that of R134a. with the change of the mass fraction of R744 and the
When the inlet temperature of the secondary heat trans- secondary fluid temperature at the condenser inlet are
fer fluid to the condenser increases, the cooling capacity represented in Fig. 5. As the mass fraction of R744 in
decreases mainly because mass flow rate of refrigerant the mixture increases, COP decreases. Fig. 5 also pre-
decreases due to the increased compressor discharge sents COP variation for several condenser temperature
pressure. Since the specific volume of refrigerant is levels, which indicates it decreases with an increase in
reduced at the discharge line of compressor with ele- the condensing temperature.
vated discharge pressure, compressor volumetric effi- The variations of condensing pressure with respect to
ciency will decrease, and accordingly the mass flow rate mass fraction of R744 are shown in Fig. 6. As the tem-
of refrigerant decreases, as indicated in Eqs. (1) and (2). perature of secondary heat transfer fluid at condenser
Fig. 4 presents the trend of compressor power inlet is elevated and the mass fraction of R744 in the
requirement which is measured by the torque transducer mixture increases, condenser pressure increases. This
and tachometer. The figure shows the compressor power figure shows the limit of the mass fraction of R744 in
increases when the mass fraction of R744 increases, the mixture which should be kept in order for the max-
which is due to the increased mass flow rate and the imum pressure not to exceed a certain limit. For exam-
higher pressure of refrigerant mixture. The specific ple, if the condenser maximum pressure should be kept
volume at the compressor suction remains constant and not to exceed 3 MPa when the condenser inlet tempera-
the specific volume at the compressor discharge decrea- ture of the secondary fluid is 40 C, the mass fraction of
ses as the condensing temperature increases, so that the R744 in R744/290 mixture should be less than about
volumetric efficiency of the compressor decreases. Hence 0.31. Therefore, this figure presents the condenser pres-
sure of the system that can be kept within a certain
Fig. 3. Variations of cooling capacity with respect to mass Fig. 4. Variations of compressor power with respect to mass
fraction of R744 at cooling condition. fraction of R744 at cooling condition.
1100 S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101
Fig. 6. Variations of inlet pressure of condenser with respect to Fig. 7. Performance with respect to condenser exit quality for
mass fraction of R744 at cooling condition. R744/290 and R744/134a mixture.
S.G. Kim, M.S. Kim / International Journal of Refrigeration 25 (2002) 1093–1101 1101
for lower quality. Therefore, the maximum COP was [2] Nekså P, Rekstad H, Zakeri GR, Schiefloe PA. CO2-heat
obtained for the quality of about 0.4 for R744/134a pump water heater: characteristics, system design and
(30/70 wt.%) and 0.5 for R744/290 (30/70 wt.%), experimental results. Int J Refrig 1998;21(3):172–9.
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and R744/290 has been investigated. It is aimed that the ditioning Systems, 13–14 May 1997; Trondheim, Norway.
system using carbon dioxide is devised while keeping the 1997, p. 177–91.
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The performance test and simulation showed that as ceeings of the IIR-Gustav Lorentzen Conference, 2–5 June
inlet temperature of the secondary heat transfer fluid to 1998; Oslo, Norway 1998. p. 341–50.
condenser increased, the refrigeration capacity and COP [7] Aarlien R, Pettersen J, Skaugen G, Nekså P. Residential
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Acknowledgements
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This study is supported by Korea Science and Engine- ural Working Fluids’98, Proceeings of the IIR-Gustav
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