Next Generation Heat Pumps Using Natural Fluids

Lorenzo Fanetti
OFFICINE MARIO DORIN S.p.A.

NxtHPG project
Next Generation of Heat This project has received funding from
Pumps working with Natural the European Unions Seventh
Programme for research, technological
fluids development and demonstration under
grant agreement No [307169].
Latest Technologies in Refrigeration and Air Conditioning - XVI European Conference Milano, 12th - 13th June 2015
Consortium structure & organization
HC CO2
prototypes prototypes
MOTIVATIONS OBJECTIVES
Development of electrical Identification of the cases
heat pump (HP) for reduction Concentrating on the
of energy consumption for development on a few
heating/cooling applications selected applications
Low environmental impact Development of a set of HP,
working with HC and CO2
NATURAL FLUIDS
n5 HP prototypes for
Hydrocarbons (HC) most interesting
CO2 applications
Ammonia
Keep the cost very similar or

Increase HP efficiency only a bit higher
Reduce the costs
Expected results
Case Fluid Source Tamb(C) Sink T(C) Application (kW)
Heating water
40 to 50
HC production
1 Air -10 to 35 Water 40
(Propane) Low demand
(outdoor air) 60
of Domestic hot water
Heating water
40 to 50
HC Water Production
2 -5 to15 Water 60
(Propane) (brine) Low demand
60
of Domestic hot water
10 to 15 (Sewage
Water
HC water) or Domestic
3 (Neutral Water 60 50
(Propane) 25 to 30 hot water production
loop)
(Condensation loop)
-10 to 10 (winter)
Domestic
4 CO2 Air 20 to 35 (summer) Water 60 to 80 30
hot water production
(outdoor air)
80
-10 to 35 Heating & domestic hot
5 CO2 Air Water (return water 50
(outdoor air) water production
40)
Test layout
Layout of CASE
4: air to water
heat pump for
Domestic Hot
Water
Production
Heating
capacity ~ 30
kW
Installed
compressor: 2
cylinders model
CD1000H
Test results
Operating conditions of the compressor are very variable
Unlike the refrigeration applications, which work in conditions

fairly stable throughout the year, in heat pumps, the evaporation
pressure can vary from -25C up to +15C
Following results will show:
operating conditions of compressor measured in Enea
the main issues related to the operation of compressor
CD compressors adopted design solutions
Test results Tamb = 7C; Tin_water = 1040C; Tout-water = 6080C
Tambient=7C
161
2014_07_14_Ti n9_Tout65_Tcc7_ma trix
141 2014_07_14_Ti n9_Tout65_Tcc7_pgc105

2014_07_08_Ti n10_Tout55_Tcc7_ma tri x
121 2014_07_10_Ti n10_Tout55_Tcc7_ma tri x
101
T_out_CP [C]

2014_07_01_Ti n20_Tout60_Tcc7_pgc105
61
1. High discharge temperature 2014_07_04_Ti n30_Tout60_Tcc7_ma tri x
2014_07_04_Ti n30_Tout60_Tcc7_pgc82
41
2014_07_04_Ti n30_Tout60_Tcc7_pgc105
2014_07_07_Ti n40_Tout60_Tcc7_pgc105
1
75 80 85 90 95 100 105 110
p_out_CP [bar]
CD compressors design solutions
1. High discharge Separation of suction and discharge side
temperature
HP / LP thermal
insulation
Lower discharge
temperature
Better lubrication
Lower pressure
pulsations
HIGHER RELIABILITY
HIGHER EFFICIENCY
Iron pistons Ambient Discharge
Suction side side
air
Test results Tamb = 12C; Tin_water = 1540C; Tout_water = 6080C
142,3
Tambient=12C
122,3
2014_07_02_Ti n15_Tout60_Tcc12_matri x
102,3
2014_07_02_Ti n15_Tout60_Tcc12_pgc96
T_out_CP [C]
2014_07_02_Ti n15_Tout60_Tcc12_pgc86
82,3
62,3 2014_07_04_Ti n30_Tout60_Tcc12_matri x

2014_07_04_Ti n30_Tout60_Tcc12_pgc95
2. High specific load combined
42,3
with high termal level 2014_07_04_Ti n30_Tout60_Tcc12_pgc105
22,3
2014_07_07_Ti n40_Tout60_Tcc12_pgc105
2,3
85 90 95 100 105 110
p_out_CP [bar]
2. High specific load combined with high termal level
Nominal p Piston Piston Specific load

Refrigerant Range Bore
HP motor (design) pin load (piston pin)
2
[bar] [mm] [mm] [kg] [kg/mm ]
H2 3,8 28 59 18 780 2,2

HFC
H5 30 28 72 20 1160 2,4
CD200 3,8 120 28 12 750 5,9

CO2
CD400 30 120 42 18 1700 4,5
Lubrication
2. High specific load combined with high termal level
port
CD solution
HFC solution
HFC solution
CD solution
51,2
Tambient=15C
46,2
41,2
36,2
2014_07_01_Ti n20_Tout60_Tcc15_pgc105
31,2
T_in_CP [C]

3. High diluition of CO2 in the oil 2014_07_16_Ti n50_Tout60_Tcc15_pgc100
16,2
2014_07_16_Ti n50_Tout60_Tcc15_pgc105
11,2
2014_07_16_Ti n55_Tout65_Tcc15_pgc105
6,2
1,2
20 25 30 35 40 45 50
p_in_CP [bar]
3. High diluition of CO2 in the oil
Approx. 9 %
3. High diluition of
CO2 in the oil
Approx.
14 cst
3. High diluition of CO2 in the oil
% diluition
Residual Max moisture
Refrigerant Oil type (refrigerant in
viscosity water content
the oil)
R134a POE 32 6% 13 cst 50 ppm
POE 85 10% 9 cst 50 ppm

CO2
PAG 68 9% 14 cst 500 ppm
For this reasons, PAG is the best choise

for CO2 heat pump applications
51,2
Tambient=15C
46,2
41,2
36,2
2014_07_01_Ti n20_Tout60_Tcc15_pgc105
31,2
T_in_CP [C]

4. High suction temp. critical 2014_07_16_Ti n50_Tout60_Tcc15_pgc100
16,2
cooling of the motor 2014_07_16_Ti n50_Tout60_Tcc15_pgc105
11,2
2014_07_16_Ti n55_Tout65_Tcc15_pgc105
6,2
1,2
20 25 30 35 40 45 50
p_in_CP [bar]
4. High suction temp. critical cooling of the motor
- 100% mass of
refrigerant
acrosses the
motor
- Inner and outer
gas channels
- Oil discharge
ducts at cylinder
side only
- Low oil carry
over
50
Tambient=2C
45
40
2014_07_10_Ti n10_Tout55_Tccm7_ma tri x
35 2014_07_08_Ti n10_Tout55_Tcc2_ma trix

P_in_CP [bar]

30
25 2014_07_01_Ti n20_Tout60_Tcc15_ma trix
5. Extreme variability 2014_07_02_Ti n17_Tout65_Tcc16_ma trix
20
in the operating
15 conditions
10 2014_07_16_Ti n50_Tout60_Tcc20_pgc105
80 85 90 95 100 105 110
p_out_CP [bar]
CD compressors
design solutions
5. Extreme
variability in
the operating
conditions
Thanks to adopted
design features, of
CD-H compressors
have a wide
operating envelope.
All the operating
conditions tested in
Enea are well inside
the envelope
CD-H compressor range
The widest CO2 compressor range available in the market
Design pressure: LP side 100 bar, HP side 150 bar
Displacements @ 50 Hz from 1.1 m3/h to 30.5 m3/h
Heating capacity (Tair=7C; Tin_w=10C) from 6 kW to 140 kW
Displacement @ Heating
Range Cylinder
50Hz capacity
[m3/h] [kW]
CD200 2 1,12 3,00 6 16
CD300 2 4,34 11,62 23 65
CD400 4 9,48 26,57 50 140
2015 INCOMING FURTHER
IMPROVEMENT
NEW RANGE CD500
6 cylinders compressor
Displacement from 39,8 to 59,5 m3/h
Nominal power from 50 to 80 HP
Heating capacity (Tair=7C; Tin_w=10C) up to 250 kW
External discharge manifold (oil temperature reduction, compressor efficiency
increase)
Design pressure: 100 bar (LP) e 150 bar (HP)
Safety valve on both low and high pressure sides
THANK YOU FOR YOUR KIND ATTENTION

Next Generation Heat Pumps Using Natural Fluids

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Lorenzo Fanetti

OFFICINE MARIO DORIN S.p.A.

Keep the cost very similar or

Unlike the refrigeration applications, which work in conditions

Following results will show:

operating conditions of compressor measured in Enea

the main issues related to the operation of compressor

CD compressors adopted design solutions

141 2014_07_14_Ti n9_Tout65_Tcc7_pgc105

2014_07_10_Ti n10_Tout60_Tcc7_ma tri x

81 2014_07_01_Ti n20_Tout60_Tcc7_ma tri x

62,3 2014_07_04_Ti n30_Tout60_Tcc12_matri x

2. High specific load combined with high termal level

Nominal p Piston Piston Specific load

H2 3,8 28 59 18 780 2,2

CD200 3,8 120 28 12 750 5,9

26,2 2014_07_01_Ti n30_Tout60_Tcc15_matri x

21,2 2014_06_30_Ti n40_Tout60_Tcc15_matri x

R134a POE 32 6% 13 cst 50 ppm

POE 85 10% 9 cst 50 ppm

For this reasons, PAG is the best choise

26,2 2014_07_01_Ti n30_Tout60_Tcc15_matri x

21,2 2014_06_30_Ti n40_Tout60_Tcc15_matri x

35 2014_07_08_Ti n10_Tout55_Tcc2_ma trix

2014_07_14_Ti n9_Tout65_Tcc7_ma tri x

CD200 2 1,12 3,00 6 16

CD300 2 4,34 11,62 23 65

CD400 4 9,48 26,57 50 140

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