Magnetic Refrigeration Technology for High Efficiency Air Conditioning

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Magnetic refrigeration was investigated as an efficient, environmentally friendly, flexible alternative to conventional residential vapor compression central air conditioning systems. Finite element analysis (FEA) models of advanced geometry active magnetic regenerator (AMR) beds were developed to minimize bed size and thus magnet mass by optimizing geometry for fluid flow and heat transfer and other losses. Conventional and magnetocaloric material (MCM) regenerator fabrication and assembly techniques were developed and advanced geometry passive regenerators were built and tested. A subscale engineering prototype (SEP) magnetic air conditioner was designed, constructed and tested. A model of the AMR cycle, combined with knowledge from passive regenerator experiments and FEA results, was used to design the regenerator beds. A 1.5 Tesla permanent magnet assembly was designed using FEA and the bed structure and plenum design was extensively optimized using FEA. The SEP is a flexible magnetic refrigeration platform, with individually instrumented beds and high flow rate and high frequency capability, although the current advanced regenerator geometry beds do not meet performance expectations, probably due to manufacturing and assembly tolerances. A model of the AMR cycle was used to optimize the design of a 3 ton capacity magnetic air conditioner, and the system design was iterated to minimize external parasitic losses such as heat exchanger pressure drop and fan power. The manufacturing cost for the entire air conditioning system was estimated, and while the estimated SEER efficiency is high, the magnetic air conditioning system is not cost competitive as currently configured. The 3 ton study results indicate that there are other applications where magnetic refrigeration is anticipated to have cost advantages over conventional systems, especially applications where magnetic refrigeration, through the use of its aqueous heat transfer fluid, could eliminate intermediate heat exchangers or oil distribution issues found in traditional vapor compression systems.