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    Dynamic simulation of natural convection bypass

    two-circuit cycle refrigeratorfreezer and its application

    Part I: Component models

    Guoliang Ding *, Chunlu Zhang, Zhili Lu

    Department of Power and Energy Engineering, Institute of Refrigeration and Cryogenics Engineering,Shanghai Jiaotong University, No. 1954 Huashan Road, Shanghai 200030, China

    Received 21 May 2003; accepted 14 December 2003

    Available online 23 January 2004

    Abstract

    In order to reduce the greenhouse gas emissions, efficient household refrigerator/freezers (RFs) are

    required. Bypass two-circuit cycle RFs with one compressor are proved to be more efficient than two-

    evaporator in series cycle RFs. In order to study the characteristics and improve the design of bypass two-

    circuit cycle RFs, a dynamic model is developed in this paper. In part I, the mathematic models of allcomponents are presented, considering not only the accuracy of the models but also the computation

    stability and speed to solve the models. An efficiency model that requires a single calorimeter data point at

    the standard test condition is employed for compressor. A multi-zone model is employed for condenser and

    for evaporator, with its wall thermal capacity considered by effective metal method. The approximate

    integral analytic model is employed for adiabatic capillary tube, and the effective inlet enthalpy method is

    used to transfer the non-adiabatic capillary tube to adiabatic capillary tube. The z-transfer function model

    is employed for cabinet load calculation.

    2004 Elsevier Ltd. All rights reserved.

    Keywords: Dynamic simulation; Refrigerator/freezers; Two-circuit; Natural convection; Component model

    1. Introduction

    The two-evaporator in series natural convection refrigeratorfreezers (RFs) charged with purerefrigerants, such as R-600a and R134a, are widely used because of the simple design and low

    * Corresponding author. Tel.: +86-21-62932110; fax: +86-21-62932601.

    E-mail address: [email protected](G. Ding).

    1359-4311/$ - see front matter

    2004 Elsevier Ltd. All rights reserved.doi:10.1016/j.applthermaleng.2003.12.009

    Applied Thermal Engineering 24 (2004) 15131524

    www.elsevier.com/locate/apthermeng

    http://mail%20to:%[email protected]/http://mail%20to:%[email protected]/
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    Nomenclature

    C specific heat (J kg1

    K1

    )d, D diameter (m)F area (m2)h enthalpy (J kg1)K heat transfer coefficient (W m2 K1)l, L length or thickness (m)m mass flow rate (kg s1)_m average mass flow rate (kg s1)M refrigerant mass (kg)n compressor speed (r.p.s)P pressure (Pa)

    Q heat transfer rate (W)t time (s)T temperature (C or K)T average temperature (C or K)v specific volume (m3 kg1)W work (W or J s1)x vapor quality

    Greek symbols

    a heat transfer coefficient (W m2 K1)k coefficient of compressor capacity

    g electrical efficiency of compressorh excess temperature (C or K)q refrigerant density (kg m3)q average density of refrigerant (kg m3)p circumference ratiow polytropic exponentd thickness of control volume (m)l dynamic viscosity (Pa s)s time variable (s)Ds time step (s)

    Subscriptsamb ambient

    c, con condensercap capillarycom compressor

    cmpt compartmente, eva evaporator

    g vapor phase

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    costs. For this kind of products, it is difficult to control the temperatures of both compartments in

    the required values in the same time. The inherent problem is that temperature can be specified inonly one compartment. The temperature in either the freezer compartment (FZC) or the fresh

    food compartment (FFC) controls the operation of the compressor and, ultimately, the amount ofheat extracted from both evaporators. Thus, the evaporator that does not control the compressoroften receives more or less cooling than it requires. Also, since the evaporating temperature in

    FFC is the same as the evaporating temperature in FZC, the thermodynamic irreversible loss islarge in FFC. For this cycle, extra electric heating is often necessary when the food compartment

    temperature is specified and ambient temperature is very low.One method termed dual-loop system has been suggested to overcome challenge of the

    unique two-temperature application of RFs [14]. The dual-loop cycle RFs had independentcycles for FFC and FZC. Every cycle has itself compressor, condenser, capillary tube, and

    evaporator. One shortcoming for dual-loop cycle is that the initial cost is high since two com-pressors are used.

    Another method termed bypass two-circuit cycle has been used to overcome the short-comings of two-evaporator in series RFs. Bypass two-circuit cycle is achieved by adding an

    additional path in the two-evaporator in series cycle, which can bypass the former evaporator ofin series cycle. The schematic diagrams of bypass two-circuit cycle are shown in Fig. 1(a) and (b).Obviously, the initial cost for this cycle is low since only single compressor is employed. For this

    cycle, since an additional path is added, the design and the characteristics are more complicatedthan two-evaporator in series cycle and dual-loop system, researches on this two-circuit cycle arenecessary and urgent.

    Computer simulation is widely used in refrigerators and other refrigeration system [512],which is a cheap and time-saved means to study characteristics of refrigeration system and im-prove or optimize refrigeration units. For refrigerators simulation, it includes steady-state sim-

    ulation [57] and dynamic simulation [810]. For steady-state simulation, the thermal capacity offoam insulation is neglected. For dynamic simulation, not only the refrigeration system, but also

    the cabinet is considered to be dynamic, so the simulation is complicated. Furthermore, since

    f liquid phasefg liquidvapor phase

    sat saturation, saturatedsc subcoolingsh superheat

    suc suctiontp two phasew wall

    unit unit length

    Superscripts

    i inleto outlet

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    bypass two-circuit cycle RF is complicated, computation stability of dynamic simulation is dif-

    ficult to keep, thus reliable and stable models and its solutions are necessary.Many works on refrigeration simulation were done in our research team, such as RFs, air-

    conditioners, and liquid chillers [912]. Compared with air-conditioners and liquid chillers, the

    dynamic cabinet load model is necessary in dynamic simulation of RFs, it is more difficult to buildand solve the models for dynamic simulation of refrigerator. In this paper, dynamic simulation ofbypass two-circuit cycle RFs is presented as a further research on the early simulation of two-

    evaporator in series cycle RFs [10]. In Part I, only the component models, including the com-pressor model, condenser and evaporator model, capillary tube model, and cabinet load model,are presented in details.

    2. Bypass two-circuit cycle RF

    As shown in Fig. 1(a) and (b), there are two types of bypass two-circuit cycle RFs. The cyclesystem of Fig. 1(a) can bypass the freezer evaporator, and the cycle system of Fig. 1(b) can bypassthe food evaporator. In bypass two-circuit cycle RFs, the three-way solenoid valves only control

    the refrigerant flow direction. The operation of compressor and three-way solenoid valve iscontrolled not only by FFC temperature, but also by FZC temperature. In the example shown inFig. 1(a), FZC controls loop A, and FFC controls loop B. So independent compartment tem-

    perature control can be maintained. The detailed control ways for Fig. 1(a) are as follows:Initially, FZC and FFC temperatures are equal to ambient temperature that is larger than the

    up-limit values of FZC and FFC. The compressor starts up and the solenoid valve switches for the

    refrigerant flowing through loop A. Then the RF works according to the following modes.

    (a) Refrigerant is flowing through the loop A. The compressor runs at first until the FZC temper-ature reaches its low-limit value, then the FFC temperature is compared with its middle-limit

    Condenser

    Compressor

    Capillary Tube-Suction

    Line Heat Exchanger

    Suction Line

    Capillary

    Tube A

    Freezer

    Evaporator

    FoodEvaporator

    Three-Way

    Solenoid Valve

    A B

    Capillary

    Tube B

    FoodEvaporator

    Freezer

    Evaporator

    Capillary Tube-Suction

    Line Heat Exchanger

    Capillary

    Tube B

    Condenser

    Suction Line

    Three-Way

    Solenoid Valve

    Capillary

    Tube A

    A B

    Compressor

    (a) (b)

    Fig. 1. Bypass two-circuit cycle RF.

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    value in order to determine the working mode of the RF. If the FFC temperature is lower

    than the middle-limit value, then the compressor stops and the RF works according to themode (c); otherwise the solenoid valve switches for the refrigerant flowing through loop B

    and the RF works according to the mode (b).(b) Refrigerant is flowing through the loop B. In this case, only the FFC is cooled, and the FZC

    temperature goes up. If FZC temperature gets to its up-limit value before the FFC gets its low-limit value, the solenoid valve switches for the refrigerant flowing through loop A, and the RF

    changes its working mode to mode (a); otherwise, the compressor runs until the FFC temper-ature is below its low-limit value, and the RF changes its working mode to mode (c).

    (c) Compressor stops. In order to protect the motor, off time must be longer than 3 min. After 3

    min, if FZC temperature gets to its up-limit value before FFC temperature gets to its up-limitvalue, the compressor starts up, the solenoid valve switches for the refrigerant flowing through

    loop A, the RF works according to mode (a); if FZC temperature gets to its up-limit value afterFFC temperature does, the RF works according to mode (b); if FZC temperature and FFC

    temperature gets to their up-limit values at the same time, the RF works according to mode (a).

    3. Mathematical models

    3.1. Compressor

    The compressor used in the RF is hermetic reciprocating one. It is composed of two parts:cylinder and shell.

    The mass flow rate and input work are calculated by

    m0com kVth=vsuc 1

    W0com kVthpevaw

    w1

    pcon

    peva

    w1w1

    " #,g 2

    VthpD2Ln i=4 3

    where,m0com is the mass flow rate of compressor; k is the coefficient of compressor capacity; Vth isthe theoretical piston displacement of compressor; vsuc is the specific volume of suction vapor;W0com is the input work of compressor; w is the polytropic exponent; g is electrical efficiency of

    compressor; D is the diameter of the cylinder; L is the length of stroke; n is revolutions of thecrankshaft per second; i is the number of cylinders.

    In order to improve the prediction accuracy by Eqs. (1) and (2), the correction coefficients ofmass flow rate and input work cm; cw are introduced here. They are given by

    cm mcom=m

    0com 4

    cWWcom=W

    0com 5

    wheremcomandWcomare measured mass flow rate and input work respectively at a single point of

    ASHRAE standard test condition. m0com and W0com are computed by Eqs. (1) and (2).

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    The final mass flow rate and work input to compressor are computed by

    mcomm0com cm 6

    WcomW0com cW 7

    The mass conservation equation for compressor is given by

    dMcom=ds moevamcom 8

    The energy conservation equation for compressor shell is given by

    cqVcomdTcom

    ds Wcomm

    icomh

    icomm

    ocomh

    ocomacomFcomTcomTamb 9

    whereacomis the convection heat transfer coefficient of outside surface of compressor shell; Fcomis

    the outside heat transfer area of compressor shell. moeva is the mass flow rate of evaporator outlet.

    3.2. Heat exchangers

    Heat exchangers in RFs include condenser and evaporator. Heat exchanger model can be di-vided into three types: lumped-parameter model, distributed-parameter model and multi-zone

    model. Lumped-parameter model cannot reflect the different heat transfer at different phase state,so its error is great. Theoretically, the precision of distributed-parameter model is best, but theprecision of the heat exchanger model is related with the heat transfer coefficients, and at present,

    the local heat transfer coefficients of heat exchangers are severely limited to use, therefore, as thematter of fact, the precision of distributed-parameter model cannot be assured. At the mean time,

    the convergence of distributed-parameter model is poor and it would cost much time to solve sucha model. As the precision, the convergence, and computation speed are all taken into consider-

    ation, multi-zone model is reasonable in this work.As condensation and evaporation are very complicated, the following assumptions are pro-

    posed to simplify the mathematical models: (1) refrigerant flowing in the tube is one-dimensional;(2) in any cross-section of the evaporator and the condenser, the refrigerant is homogeneous and,

    hence, values of any parameter are identical in any cross-section of the ducts; and (3) heat transferalong the tube axis, pressure drop along the flowing direction, flowing force, and gravity force are

    all neglected.Thermal capacity of wall metals has effects on the dynamic characteristics of heat exchanger. In

    order to take the thermal capacity of the wall metals into account and simplify the heat exchangermodel, the effective metal method is used. Because the convective heat transfer on the refrigerant

    side is greater than that on the airside, the wall temperature is very close to the refrigeranttemperature. Assume that the wall temperature is equal to the refrigerant temperature. Actually,not all of the heat exchanger metal would be the same temperature with the refrigerant, and the

    metal at the same temperature with the refrigerant is termed the effective metal. The effective metalcoefficient, kw is evaluated by

    kwmeff=mw 10

    where meff is mass of effective metal of heat exchanger; mw is total mass of heat exchanger.

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    For whole heat exchanger, mass conservation equation is given by

    dMshMtpMsc

    ds mo mi 0 11

    For each zone of heat exchanger, mass and energy conservation equations are given by

    Mshlsh Aunitqsh 12

    MtpltpAunitqtp 13

    Msc lsc Aunitqsc 14

    lcon lshltp lsc 15

    dMshhsh

    ds kwqwCwAwdlshTsh

    ds moshh

    oshm

    i

    hi

    FunitlshKshTairTsh 16

    dMtphtp

    ds kwqwCwAwdltpTtp

    ds motph

    otpm

    itph

    itp FunitltpKtpTairTtp 17

    dMschsc

    ds kwqwCwAwdlscTsc

    ds moho misch

    iscFunitlscKscTairTsc 18

    In Eqs. (10)(18), the refrigerant mass flow rate (mi) and enthalpy (hi) at the inlet of heat ex-

    changer are known, which are equal to ones at the outlet of compressor for condenser or ofcapillary tube for evaporator, and the refrigerant mass flow rate (mo) at outlet of heat exchanger is

    known too, which is equal to the mass flow rate of capillary tube for condenser or of compressorfor evaporator. The qualitative temperature and average mass flow rate of refrigerant at any zoneare given by arithmetic mean temperature of its inlet and outlet values respectively.

    Eqs. (10)(18) constitute a set of eight equations with eight unknownsMsh;Mtp;Msc; lsh; ltp; lsc;Ttp; Tsc, hence the above equations of heat exchanger can be solved to get a unique group ofsolution.

    The mass in any single-phase zone is calculated by

    Ms-pqs-pFunitls-p 19

    where Ms-p and qs-p are the mass and the average density of refrigerant in single-phase zone

    respectively;ls-p is the length of single-phase zone.The mass in two-phase zone is calculated by [13]

    Mtp baqg 1aqfcFunitltp 20

    a 1 1

    1

    x

    1

    qg

    qf

    21

    where Mtp is the refrigerant mass in two-phase zone; a is the void fraction in two-phase zone; qgand qfare the saturated density of vapor and liquid in two-phase zone respectively;x is averagemass quality of refrigerant in two-phase zone.

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    3.3. Capillary tube

    The capillary tube used in RF has following characteristics:

    (1) The capillary tube used in household RF is always non-adiabatic, which has a heat exchangewith the suction line. (2) During the startup and shutdown processes, the inlet conditions ofcapillary tube change greatly. Not only the subcooling state, but also the superheat state and two-phase state occur.

    Since the outlet states of capillary tube responds very fast to its inlet states because of the highflow velocity in the small diameter capillary tube [14], steady-state model is employed for capillarytube.

    Since the throttling process of non-adiabatic capillary tube is very complicated, generally thenon-adiabatic capillary tube is transferred to adiabatic capillary tube by certain equivalent

    method, such as effective subcooling level method. In this paper, the steady-state model of adi-abatic capillary tube is established first, then, the effective inlet enthalpy method is presented to

    transfer non-adiabatic capillary tube to adiabatic capillary tube.The flow in adiabatic capillary tube is generally considered to be one-dimensional and

    homogeneous and thermal equilibrium. Consequently, the governing equations are as follows:

    dG 0 22

    d h 12G2v2

    dL

    0 23

    dp G2 dv1

    2

    f

    DvG2dL 24

    where p, h, v, G are refrigerant pressure, specific enthalpy, specific volume, and mass fluxrespectively;fis the friction factor, DandLare the inner diameter and length of the capillary tuberespectively.

    From the viewpoint of system simulation, the stable and fast approach is better. Theapproximate integral analytic method to solve Eqs. (22)(24) is presented in [15] when the inletcondition of the capillary tube is subcooled, and in [16] when the inlet condition of the capillary

    tube is superheated or two-phase.The solution to Eqs. (22)(24) cannot be used directly for non-adiabatic capillary tube. In order

    to predict the mass flow rate in non-adiabatic capillary tube, the effective subcooling level method

    was presented at 1988 ASHRAE Equipment Handbook [17]. Such method was evaluated in paper[18]. The accuracy of this method is very well when the inlet condition is subcooled. The effective

    subcooling level method is suitable only when the inlet condition of capillary tube is subcooled.When the inlet condition is superheated or two-phase, the effective subcooling level method is not

    suitable. Herein, effective inlet enthalpy method is presented.Heat exchange between capillary tube and suction line can be equivalent to the effective en-

    thalpy drop by

    Dheffmsuch

    osuch

    isuc

    mcap25

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    where Dheffis the effective enthalpy drop; msucis mass flow rate in the suction line;hisucand h

    osucare

    the inlet and outlet enthalpy of suction line heat exchanger, respectively. mcapis the mass flow rate

    in the capillary tube.

    The effective inlet enthalpy can be equivalent by

    hicap;effhicap Dheff 26

    where hicap;effis the effective inlet enthalpy; hicap is the inlet enthalpy.

    The effective inlet enthalpy method of modeling the non-adiabatic capillary tube first requiresadding the calculated effective enthalpy drop to the actual inlet enthalpy. This results in an adi-abatic equivalent inlet enthalpy. Then the problem to predict the mass flow rate of a non-adiabatic

    capillary tube is changed to do the mass flow rate of a adiabatic capillary tube at the equivalentinlet enthalpy.

    When the inlet condition of capillary tube is subcooled, the effective inlet enthalpy method is

    actually the same as the effective subcooling level method, so the effective inlet enthalpy method isthe extension of the effective subcooling level method.

    3.4. Cabinet

    The performance of RFs is not only concerned with the refrigeration cycle, but also with thecabinet load. Because the thermal properties of foam insulation and convective heat transfer

    coefficients of inner and outer surfaces of insulation walls vary very small under the workingcondition of RFs, they are assumed to be constants. Therefore, the thermal insulation wall is a

    linear system, and the thermal response factor method or conduction transfer function method

    [1921] can be used to calculate the heat transfer through the wall.For RFs, the output parameters are the compartment temperatures. The inputs are heat

    transfer in the surface of inner side and outside of the thermal insulation wall. The output andinputs can be formulated by

    hcmptz1 Wz1Iz1 27

    where hcmptz1is compartment temperature. All temperatures mentioned in this section are the

    excess temperatures to the ambient temperature.Wz1is transfer function of cabinet load;Iz1is total cabinet load; zdenotes the zoperator.

    The method to get the transfer function Wz1 is shown as follows:Take all air in the compartment as the control volume. According to energy conservation law

    and superposition principle of linear system, the governing equation on the control volume isgiven by

    Ccmptdhcmpts

    ds Qambs Qcmpts Qcoms Qothercmpts Qhots Qcolds Qleaks

    28

    where Ccmpt is the thermal capacity of the control volume; Qambs is the heat transfer into thecontrol volume through the foam insulation by the ambient temperature pulse; Qcmptsis the heattransfer into the control volume through the foam insulation by the compartment temperature

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    pulse; Qcoms is the heat transfer into the control volume through the foam insulation by thecompressor chamber temperature pulse; Qhots is the heat transfer into the control volumethrough the foam insulation by the hot-wall condenser heat flux pulse; Qothercmpts is the heat

    transfer into the control volume through the foam insulation by the other compartment tem-perature pulse;Qcoldsis the heat transfer into the control volume through the foam insulation bythe cold-wall evaporator heat flux pulse; Qleaks is the heat transfer into the control volumethrough the door and other gaskets.

    The heat transfer through the gaskets could be calculated by

    Qleaks bLTambTcmpts bLhcmpts 29

    Backward finite-difference and z-transformation is used for Eq. (28), we can get

    Ccmpt

    Ds 1z1hcmptz Qambz

    1 Qcmptz1 Qcomz

    1 Qothercmptz1

    Qhotz1

    Qcoldz1

    Qleakz1

    30where

    Qambz1 Wambz

    1hcmptz1 31a

    Qcmptz1 Wcmptz

    1hcmptz1 31b

    Qcomz1 Wcomz

    1hcomz1 31c

    Qothercmptz1 Wothercmptz

    1hothercmptz1 31d

    Qhotz1

    Whotz1

    qconz1

    31e

    Qcoldz1 Wcoldz

    1qevaz1 31f

    Qleakz1 bLhcmptz

    1 31g

    Qambz1, Qcmptz

    1, Qcomz1, Qothercmptz

    1, Qhotz1, Qcoldz

    1 are heat flux at the inner sur-face of cabinet wall.Wambz

    1,Wcmptz1,Wcomz

    1,Wothercmptz1,Whotz

    1,Wcoldz1are theirz-

    transfer functions. These z-transfer functions can be obtained by the method described in [21].Substituting Eqs. (31ag) into Eq. (30) and rearranging the equation, we can get

    hcmptCcmpt

    Ds

    1 z1 WambWcomprWothercmpt bLWcomprhcomprz Wothercmpthother cmptWhotqconWevaqeva 32

    Compare Eqs. (32) and (27), we have

    Wz 1 Ccmpt

    Ds 1

    z1 WambWcomprWother cmpt bL

    33a

    Iz Wcomprhcomprz Wothercmpthother cmptWhotqconWevaqeva 33b

    So far, the cabinet model has been solved.

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    4. Conclusions

    The component models for natural convection bypass two-circuit cycle RFs are presented here.

    In order to make the simulation program run fast and its accuracy acceptable, the efficiency modelthat required a single calorimeter data point at the standard test condition is adopted for thecompressor; the multi-zone models are employed for condenser and evaporator, with its wallthermal capacity considered by effective metal method; the approximate integral analytic model is

    employed for adiabatic capillary tube, and the effective inlet enthalpy method is used to transferthe non-adiabatic capillary tube to adiabatic capillary tube; the z-transfer function model is usedfor the cabinet load calculation.

    Acknowledgements

    The research is supported by the State Key Fundamental Research Program of China under thecontract No. 2000026309. Part of the research was financed by Refrigerator/Freezer Ltd Com-pany (R/FLC), Haier Group, China. Helps of Mr. Dongning Wang and Mr. Linfei Xu in R/FLC,

    Haier Group are greatly appreciated.

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