Validation of a Charge-Sensitive Vapor-Injected Compression Cycle Model with Economization

In recent years, research on economized vapor injected (EVI) compression systems showed potential improvements to both cooling capacity and coefficient of performance (COP). In addition, the operating range of compressors can be extended by reducing the discharge temperature. However, the optimum operation of such systems is directly related to the amount of refrigerant charge, which often is not optimized. Therefore, an accurate charge estimation methodology is required to further improve the operation of EVI compression systems. In this paper, a detailed cycle model has been developed for the economized vapor injected (EVI) compression system. The model aims to predict the performance of EVI systems by imposing the amount of required refrigerant charge as an input. In the cycle model, the EVI compressor was mapped based on the correlation of Tello-Oquendo et al. (2017), whereas evaporator, condenser and economizer heat exchanger models were constructed based on the available ACHP models (Bell, 2010). With respect to charge inventory, the 2-point regression model from Shen et al. (2009) was used to account for inaccurate estimation of refrigerant volumes, ambiguity in slip flow model, solubility of refrigerant in the lubricating oil, among others. The cycle model has been validated with experimental performance data taken with a 5-ton Environmental Control Unit (ECU) that utilizes EVI technology. The developed cycle model showed very good agreement with the data with a MAE in COP of less than 4%. Furthermore, the estimated charge inventory has been compared to the one-point regression model. Results showed that the former method allowed to predict the charge inventory with an MAE of less than 0.5%

Numerical Analysis of Active Flow Boiling Regime Management Using a Vapor-Compression Cycle Applied to Electronic Processor Cooling

As computing power continues to grow at a rapid rate, the thermal load generated from electronic devices follows. Furthermore, reduced size requirements for electronic devices have driven engineers to produce this increased computing power in smaller packaging than ever before. The combination of these two trends results in high heat flux processors that require innovative cooling techniques. Industry and academia alike have anticipated this trend and have developed several general families of solutions to cooling high-heat flux processors. This work proposes the use of flow boiling in a vapor compression cycle and a spreader to distribute the heat from a high-heat flux source to the evaporator. Specifically, the balance between cycle performance and achievable heat flux is assessed, and operating conditions where the ability of the cycle to control evaporator heat flux and simultaneously achieve a high cycle efficiency are identified. A numerical flow boiling correlation is applied and a microchannel evaporator design model is proposed. Geometric parameters and performance limitations of this technique are analyzed and both quantitative and qualitative results along with future work are presented

Development and Validation of a Mechanistic Vapor-Compression Cycle Model

Detailed models are crucial tools for engineers in designing and optimizing systems. In particular, mechanistic modeling of vapor compression systems for accurate performance predictions at both full- and part-load conditions have been improved significantly in the past decades. Yet, fully deterministic models present still challenges in estimating charge inventory in order to optimize the performance. In this work, a generalized framework for simulating vapor compression cycles (VCC) has been develvoped with emphasis on a charge-sensitive model. In order to illustrate the capabilities of the tool, a direct–expansion (DX) cycle has been considered. In the cycle model, the compressor was mapped by employing the ANSI/AHRI 540 10-coefficient correlation, the evaporator and the condenser were constructed based on the ACHP models (Bell, 2010). Furthermore, a TXV model was implemented based on Li and Braun (2008) formulation. With respect to the charge inventory estimation, the two-point regression model proposed by Shen et al. (2009) was used to account for inaccurate estimation of refrigerant volumes, ambiguous flow patterns for two-phase flow, and amount of refrigerant dissolved in the oil. The solution scheme required manufacturer input data for each component as well as the amount of refrigerant charge. Hence, the degree of superheating at the evaporator outlet, the subcooling at the condenser outlet and the perfromance parameters of the VCC system can be predicted. The model was validated with available experimental and numerical data available in literature. The simulation results demonstrated that the proposed model is more accurate and more generic than other methods presented in the literature

Full 3D numerical analysis of a twin screw compressor by employing open-source software

The push for having more reliable and efficient positive displacement machines (both compressors and expanders) for vapor compression and power generation (e.g., ORCs) applications has moved researchers to an always more spread employment of computational fluid dynamics (CFD). In particular, twin screw compressors, because of their high efficiency compared to other compressor types, have received interest over the last years. The numerical analysis of such machines is challenging: the deforming working chambers are very difficult to be correctly replicated. The relative motion of the rotors and the variation of the gaps during machine operation are few of the major difficulties in implementing reliable CFD models. A custom mesh generation algorithm is therefore often required for sumulating the machine operation. In this work, SCORG-V5.2.2 was used to generate the meshes of the deforming domain around rotating parts of the machines. The open-source software OpenFOAM-v1606+ is then employed to compute the flow field associated with the operation of the twin screw. The coupling of the two tools has been carried out in this work, applying the methodology to a twin screw machine

CFD Simulations of Single- and Twin-Screw Machines with OpenFOAM

Over the last decade, Computational Fluid Dynamics (CFD) has been increasingly applied for the design and analysis of positive displacement machines employed in vapor compression and power generation applications. Particularly, single-screw and twin-screw machines have received attention from the researchers, leading to the development and application of increasingly efficient techniques for their numerical simulation. Modeling the operation of such machines including the dynamics of the compression (or expansion) process and the deforming working chambers is particularly challenging. The relative motion of the rotors and the variation of the gaps during machine operation are a few of the major numerical challenges towards the implementation of reliable CFD models. Moreover, evaluating the thermophysical properties of real gases represents an additional challenge to be addressed. Special care must be given to defining equation of states or generating tables and computing the thermodynamic properties. Among several CFD suite available, the open-source OpenFOAM tool OpenFOAM, is regarded as a reliable and accurate software for carrying out CFD analyses. In this paper, the dynamic meshing techniques available within the software as well as new libraries implemented for expanding the functionalities of the software are presented. The simulation of both a single-screw and a twin-screw machine is described and results are discussed. Specifically, for the single-screw expander case, the geometry will be released as open-access for the entire community. Besides, the real gas modeling possibilities implemented in the software will be described and the CoolProp thermophysical library integration will be presented