A Comprehensive Study on the Effects of Surface Roughness on Power Consumption and Heat Transfer Performance in Novel In-Tube Condensation r123yf Refrigerant Systems

Abstract

This study investigates the impact of surface roughness on the condensation Heat Transfer Coefficient (HTC) of R123yf refrigerant in a uniquely designed test rig with pre-condenser and post-condenser for quality regulation. In mining industries, the mining equipment consumes more amount to power for the Air Conditioning system. To reduce the power consumption of copper metal inside the surface morphology needs to be changed. Experiments were conducted in a 750 mm long, 8.4 mm internal diameter copper tube, with regard to mass flux varying from 150 kg.m-2.s-1 to 300 kg.m-2.s-1, refrigerant quality varying from 0.3 to 0.8, and saturated temperature from 35°C to 45°C. The impact of varying surface roughness (1.5 μm, 2.5μm, 3.4 μm, and 6.7 μm) on HTC was examined. The plane tube condensation experimental results agreed with M M Shah's heat transfer coefficient correlations, with a 20% absolute mean deviation. It was observed that increasing surface roughness enhanced the HTC. The optimal surface roughness was determined to be 3.4 μm, as it resulted in a significant increase in HTC (26.25%) with a moderate rise in power consumption (15.40%). Higher surface roughness led to a drastic increase in power consumption, making it less desirable for practical applications. Through a systematic analysis of the experimental data, this study identifies the critical trade-off between surface roughness and power consumption, providing guidance for the design of energy-efficient condensation heat transfer systems using R123yf refrigerant. By pinpointing an optimal surface roughness for copper tubes used in refrigeration, this study offers a pragmatic solution for enhancing the efficiency of air conditioning systems in mining equipment, a sector notorious for high energy expenditures. The findings indicate a direct application in mining operations where equipment cooling demands contribute significantly to energy consumption. Implementing the recommended surface modifications can lead to substantial energy savings, thereby reducing operational costs and improving the sustainability of mining activities. Furthermore, the adaptation of R123yf refrigerant systems with optimized surface roughness could serve as a model for energy conservation measures across various facets of the mining industry..