Optimization study of the circuitry for 5 mm small-diameter finned-tube heat exchanger in air-source heat pumps

Abstract

Finned-tube heat exchangers (FTHXs) are currently extensively utilized in residential air-source heat pumps (ASHPs), but their escalating costs pose an urgent issue needing resolution. This study investigated the feasibility of replacing the 7 mm diameter FTHX in the outdoor unit of an ASHP with a 5 mm small-diameter FTHX, aiming to reduce material consumption without compromising performance. Based on the Intelligent System for Heat Exchanger Design (ISHED), a 6–3-1 circuitry (6 circuitries merging into 3 then 1) optimization scheme tailored for the 5 mm diameter FTHX was proposed under non-uniform airflow distribution. The performance differences between this circuitry and the baseline were then analyzed through numerical simulations. Finally, comparative tests were performed between the original FTHX and the modified 5 mm diameter FTHX. Overall, even with a 5.10 % reduction in total heat exchange area, its heat exchange capacity and efficiency still meet the performance standards for the initial ASHP. Notably, the proposed 5 mm diameter FTHX reduces the material costs and refrigerant charge by 19.76 % and 12.28 %, respectively. This phenomenon illustrates the considerable economic benefits of reducing the volume of FTHX. Additionally, it holds significant practical value in promoting the use of natural refrigerants including hydrocarbons according to the new international legislative framework.