Development of DOE/ORNL Heat Pump Design Model Mark 7 Version

Keith Rice, Zhiming Gao, Bill Jackson Oak Ridge National Lab February 2006

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Mark 7 Model Improvement and Testing Through ASHRAE 1173-TRP ORNL & Purdue Public Models
To Be Improved/Tested/Validated

Objective
Wide-Range Testing of Public AC Models
Mild to Extreme Ambients
Low to High Indoor Humidity

Low to High Charge Low to High Airflow

For HFC R-22 Alternatives With Best Available HT and PD Models

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Refrigerant Property Upgrade - Mark 7

Replaced Legacy Refrigerant Thermo Props Fast running but no longer being updated New Thermodynamic Properties Converted to NIST REFPROP 7.1 Pseudo-pure representations for leading 4 HFC mixtures Reasonably fast operation for cycle analysis codes Implemented in model and tested successfully Transport Properties Pseudo-pure representations not available for mixtures Used alternative formulation (Geller 2000) For R-410A, R-407C, R-507, and R-404A Accurate to very near the critical point Use latest Mark VI transport properties for rest

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Upgrade of HT and PD Correlations

Air-side Correlations Confirmed to be State-of-the-Art Major Upgrade of Refrigerant-Side Heat Transfer and Pressure Drop Correlations Based on TRP-1173 Literature Review Flow-Regime Based Heat Transfer Based Models Recent work of Thome/Cavallini for HT NIST work of Kedzierski and Choi for pressure drop All New Smooth-Tube Correlations Added Rifled-Tube Geometry Input and Correlations Added Previously only constant multipliers available for HT and PD

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Evaporation HT Coefs for Three Refrigerants Smooth (Thome 2002) vs Microfin (Cavallini/ Del Col, 1999) Tubes 12 Heat Transfer Coefficient (kW/M 2K) 10 8 6 4 2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 Vapor Quality (%) 0.7 0.8 0.9 1
R410A, microfin R22, microfin R407C, microfin R410A, smooth R22, smooth R407, smooth
T_dew = 10C Mass flux_sm = 280 kg/m2s Q_flux = 12kW/m2 Smooth tube diam. = 9.3 mm Fin tip diameter = 8.9 mm

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Evaporation HT Multipliers, Microfin vs Smooth Tubes for Three Refrigerants Microfin (Cavallini/ Del Col, 1999) / Smooth (Thome 2002) 5.0 Microfin Heat Transfer Multiplier 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0 0.2 0.4 0.6 0.8 1 Vapor Quality
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R410A R22 R407C Mark 6 Default

T_dew = 10C Mass flux_sm = 280 kg/m2s Q_flux = 12kW/m2 Smooth tube diam. = 9.3 mm Fin tip diameter = 8.9 mm Fin height = 0.2 mm Apex angle = 50 Spiral angle = 18 Groove number = 60

Condensation HT Coefs for Three Refrigerants, SmoothTubes (Hajal/Thome/Cavallini, 2003) vs Microfin (Cavallini/ Del Col, 1999) 16 Heat Transfer Coefficient (kW/M 2K) 14 12 10 8 6 4 2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 Vapor Quality (%) 0.7 0.8 0.9 1
R410A, microfin R22, microfin R407C, microfin R410A, smooth R22, smooth R407C, smooth
T_dew = 40C Mass flux_sm = 404 kg/m2s Smooth tube diam. = 8 mm Fin tip diameter = 7.6 mm

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Condensation HT Multipliers, Microfin vs Smooth Tubes for Three Refrigerants

Microfin (Cavallini/ Del Col, 1999) / Smooth (Hajal/Thome/Cavallini, 2003)

4.5 R410A Condensation Heat Transfer Multiplier 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0 0.1 0.2 0.3 0.4 0.5 0.6 Vapor Quality 0.7 0.8 0.9 1
T_dew = 40C Mass flux_sm = 404 kg/m2s Smooth tube diam. = 8 mm Fin tip diameter = 7.6 mm Fin height = 0.2 mm Apex angle = 50 Spiral angle = 18 Groove number = 60

R407C R22 Mark 6 Default

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Evaporator Local Pressure Drop Predictions Kedzierski and Choi (2001)

8 Evaporation Pressure Drop (kPa/m), dP/dL 7 6 5 4 3 2 1 0 0 0.1 0.2 0.3 0.4 0.5 Vapor Quality 0.6 0.7 0.8 0.9 1
R407C_MICRO_EVAP R22_MICRO_EVAP R410A_MICRO_EVAP R407C_SMOOTH_EVAP R22_SMOOTH_EVAP R410A_SMOOTH_EVAP

T_dew = 10C Mass flux_sm = 280 kg/m2s Q_flux = 12kW/m2 DT = 1.59K Smooth tube diam. = 9.3 mm Fin tip diameter = 8.9 mm Fin height = 0.2 mm Apex angle = 50 Spiral angle = 18 Groove number = 60

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Local Microfin Pressure Drop Multipliers -- Evaporation Kedzierski and Choi (2001)
1.8 1.7 Pressure Drop Multiplier 1.6 1.5 1.4 1.3 1.2 1.1 1.0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Vapor Quality
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T_dew = 10C Mass flux_sm = 280 kg/m2s Smooth tube diam. = 9.3 mm Fin tip diameter = 8.9 mm Fin height = 0.2 mm Apex angle = 50 Spiral angle = 18 Groove number = 60

R410A R407C R22 Mark 6 Default

Condenser Local Pressure Drop Predictions Kedzierski and Choi (2001) 8 Condensation Pressure Drop, DP/DL (kPa/m) 7 6 5 4 3 2 1 0 1 0.8 0.6 0.4 0.2 0 Vapor Quality
T_dew = 40C Mass flux_sm = 404 kg/m2s Smooth tube diam. = 8 mm Fin tip diameter = 7.6 mm Fin height = 0.2 mm Apex angle = 50 Spiral angle = 18 Groove number = 60

R22_MICRO_COND R22_SMOOTH_COND R407C_MICRO_COND R407C_SMOOTH_COND R410A_MICRO_COND R410A_SMOOTH_COND

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Local Microfin Pressure Drop Multipliers -- Condensation Kedzierski and Choi (2001)
5.0 4.5 Pressure Drop Multiplier 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Vapor Quality
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T_dew = 40C Mass flux_sm = 404 kg/m2s Smooth tube diam. = 8 mm Fin tip diameter = 7.6 mm Fin height = 0.2 mm Apex angle = 50 Spiral angle = 18 Groove number = 60

R22 R407C R410A Mark 6 Default

Summary
Constant Rifled Tube HT Multipliers used in Mark 6
Predict close to ave. evap. HT mult. for R22 & R410A Overpredict rifled tube evap. HT effects for R407C By > 20% Underpredict ave. cond. HT mult. for R22 & R410A New HT mult is >50% higher for R410A About 10% more for R22 Approx. predict the ave. cond. HT effects for R407C Underpredict rifled tube PD effects for all refrigs New cumulative PD multiplier effects are about 17% higher for evaporators about 43% higher for condensers

Constant Rifled Tube PD Multipliers used in Mark 6

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Further Mark 7 HPDM Modifications

Provisions Made for Gliding Mixture Systems (like R-407C)
HX revisions to better handle mixture glide effects Dew-point or ARTI mid-point map options provided R-407C compressors added to Web model Adapted from approach developed in TRP-1173 Uses tests at two charge levels to calibrate HX subcooled fraction change Tested and validated as part of TRP-1173 Improves performance calculations For off-design ambient and charge conditions When two-phase refrigerant enters compressor shell Per TRP-1173

Charge Inventory Model Calibration Algorithms

Modified Compressor Superheat Corrections

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Example System Comparisons

Made Sample System Comparisons Between Refrigerants
12+ SEER System, Smooth Evap. Tubes, Rifled Cond. Tubes Same tube sizes for all refrigerants R-22 vs R-410A vs R-407C

Also Looked at Performance Trends vs Ambient

R-22 vs R-410A vs R-407C

Performance Trends/Rankings As Expected

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Results from Mark 7 HPDM Similar Rated Compressor Capacities

Refrigerant,
Compressor Model

Compressor Isentropic Efficiency 70.0% 69.9% 71.5% 70.6%

EER@95F

Capacity (Btu/hr) 35405 35180 37215 34920

R-22
ZR34K3-PFV

11.03 10.47 10.91 11.04

R-407C
ZR34K3E-PFV

R-410A
ZR34K5-PFV

R-410A
ZR32K3-PFV

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EER Trends of 3-Ton Residential Unit Predicted By ORNL Mark 7 HPDM

14 13 R-410A 12 11 EER 10 Implicit TXV Flow Control 9 8 7 6 65 80 95 110 125 140 Ambient Temperature (F) R-22 R-407C

Equal Capacity at 95F, ARI Indoor Conditions

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Hx Results from Mark 7 HPDM

Refrigerant,
Compressor Model

Compr. Inlet Sat. Temp T_e / T_c, F 45.1 / 116.2 48.4 / 121.8 47.1 / 114.6

HX Pressure Drop Ratio evap / cond 1.0 / 1.0 1.01 / 1.08 0.61 / 0.84

HX Heat Transfer Ratio (evap / cond) 1.0 / 1.0 0.90 / 0.90 1.23 / 1.22

R-22
ZR34K3-PFV

R-407C
ZR34K3E-PFV

R-410A
ZR32K3-PFV

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Results
TRP-1173 Project Completed Successfully
Concluded that the Purdue and ORNL Models Perform near equally as well compared to R-410A and R-407C test data New charge calibration approach greatly improves off-design predictions for range of ambients and charges

Mark 7 Web version ready for use online

www.ornl.gov/~wlj/hpdm/MarkVII.shtml Industry-Standard Refrigerant Properties SOA HT and PD Correlations Improved Off-Design Prediction Capability Includes the Four Leading HFC Mixtures

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