Seasonal performance assessment and experimental investigation of R32 drop-in and BPHX size in an R410A chiller when using two compressor modulation strategies

Abstract

The decrease in fossil fuel reserves and high energy consumption by HVAC&R equipment require the use of compressors with better efficiencies and capacity modulation strategies. Usually, seasonal performance studies focus on compressor capacity modulation methods, however the current study explores the idea of improving the seasonal performance of two compressor modulation techniques: a two-stage and a variable speed compressor with different capacity modulation ranges by using larger condensers in an R410A water ethylene glycol chiller system. The analysis shows that oversizing the heat exchangers has larger benefits with the compressor modulation strategy with lower range. Additionally, the seasonal performance estimated according to AHRI 551/591 (2020) of a two-stage compressor with oversized condenser is higher than a basic single speed compressor with a better motor indicating that oversizing brazed plate heat exchanger (BPHX) might yield higher performance than improving the compressor motor efficiency. Due to the high global warming potential (GWP) of R410A, there is a focus on replacing it with low GWP refrigerants such as R32 to reduce CO2 emissions. This study would also compare the performance when using R32 as a drop-in refrigerant in the two different R410A compressor capacity modulation strategies with comparable cooling capacity. When the refrigerant was changed from R410A to R32, the integrated part load value (IPLV.SI), an efficiency metric for variable speed compressor remains relatively constant at 5.5 while it increases from 3.9 to 4.4 for the two-stage compressor. It is hypothesized that low refrigerant mass flow rate (m˙ref) provided by the variable speed compressor when matching the load at the lower part load conditions leads to refrigerant maldistribution in BPHX and reduced IPLV.SI.