Refrigeration Compressor Research Articles

ANALYSIS OF SURFACE ROUGHNESS OF REFRIGERATIONCOMPRESSOR FRICTION NODES DUE TO INSUFFICIENTLUBRICATION

The article presents an attempt to evaluate the roughness profiles of the components of the friction nodes inrefrigeration compressors due to insufficient lubrication. The damaging impact on the compressor operationunder various unfavorable operating conditions, including with little or no lubricant at all, was analyzed for areal refrigeration system using a dedicated test stand.The Embraco Aspera NE9213GK refrigeration compressor used was originally filled in by the manufacturerwith a polyester lubricant; for the purpose of the study, the R407C lubricant was applied. An accelerateddamage-controlled procedure was carried out on the compressor by reducing the amount of lubricant insubsequent operating cycles of the system. The amount of oil was adjusted by removing lubricant duringshutdown periods using a dedicated spigot in the body of the semi-hermetic compressor casing. The testingcontinued until the refrigeration compressor seized up.The test stand was used to analyze electrical power measurements at the time of intentional damage tothe compressor caused as a result of forced absence of lubrication. Additionally, the authors analyzed surfaceroughness profiles of the compressor sliding elements prone to wear, including crankshaft journals, pistonsurface, and a cylinder surface.

Evaluation of Wear Resistance in Tungsten-Doped Diamond-like Carbon Coatings (WC/C) on Coated and Uncoated Surfaces Under Starved Oil Lubrication with R452A Refrigerant

This article assesses the potential of using a diamond-like carbon coating doped with tungsten, a-C:H:W (WC/C), on the sliding pairs of refrigeration compressors. The ability of WC/C coating to provide low wear and a low coefficient of friction was experimentally verified in a specific refrigeration compressor operating environment (lubrication with oil diluted with refrigerant) and under extreme operating conditions (starved lubrication with a small amount of oil). Conditions of starved lubrication with a substance of reduced lubricity promote a temperature increase and high mechanical (friction) stresses on the surface of the sliding pairs. These situations can hinder the effective operation of WC/C coatings. Comparative wear tests were carried out for S235JR steel samples with and without WC/C coating. It was found that the samples with the WC/C coating had the lowest wear values and the lowest friction coefficients (approximately 0.06). A low coefficient of friction suggests that even a small amount of oil (one drop) is likely sufficient to achieve mixed lubrication conditions between the tested sliding surfaces and reduce material loss. The tested WC/C coating can protect sliding friction pairs in refrigeration compressors under extreme operating conditions caused by a lack of oil. Less friction reduces the need for energy to drive the refrigeration compressor. Additionally, the significance of this research is highlighted by the fact that the wear tests were conducted using R452A, a novel, eco-friendly refrigerant.

Active noise control of refrigerator based on cascaded notch feedback algorithm

Refrigerators bring convenience to people, but the noise they produce can also affect people’s lives. Refrigerator noise is dominated by low-frequency noise, and the active noise control method is more effective for this kind of noise. However, the existing active noise control methods for refrigerators do not take into account factors such as the limited space and complex structure of the refrigerator compressor room, and external interference signals will be introduced to affect the noise reduction performance during the error signal collection. Given that, this paper proposes the cascade notch feedback algorithm, which can well reduce the influence of external interference signals to better achieve the refrigerator noise reduction. The algorithm consists of the cascaded notch filtering algorithm and the feedback algorithm. The cascade notch filtering algorithm is formed by cascading the adaptive notch filtering algorithm, which is used to deal with the main frequency and harmonic noise generated by the refrigerator. The feedback algorithm consists of a robust algorithm for dealing with external interference signals introduced during error signal collection. The simulation experiment proves that the algorithm has advantages in terms of noise reduction and computational cost compared with the adaptive notch filtering algorithm and the improved algorithm. The experimental test platform is set up to carry out the actual refrigerator noise reduction experiments under different conditions. The algorithm has the effect of noise reduction under different robust algorithms.

Sound quality characteristics of reciprocating hermetic refrigeration compressors

In recent years, sound quality (SQ) has become an increasingly important factor in the home appliance industry, enhancing the customer experience and comfort. Manufacturers that prioritize SQ in their designs can gain a competitive advantage in the market and increase customer satisfaction. The compressor is one of the main sources of noise in a refrigerator. While manufacturers typically provide refrigerator sound quality and noise labels, research that specifically evaluates the compressor sound quality metrics at a component level is not common. Therefore, this study aims to isolate the compressor from the refrigerator to investigate SQ metrics for hermetic refrigeration compressors. To achieve this, compressors with different capacities are operated and recorded at different working speeds for different thermal conditions. Objective parameters are calculated and tested using time domain signals and analyzed with spectral analysis methods. In addition to the objective parameters, subjective results are obtained through jury tests consisting of 75 people of different genders and age ranges. By considering objective parameters of sound quality as input and sound quality evaluation values as output, a regression model is established. It is found that Loudness, Sharpness, and Degree of Modulation play an important role in compressor sound quality evaluations consider.

Evaporating temperature estimation of refrigeration systems based on vibration data-driven soft sensors

The evaluation of the operating conditions of refrigeration compressors once installed in household appliances is challenging due to the need to install pressure transducers, a process which requires system evacuation and refrigerant reintroduction. In addition, changes in the piping modify the characteristics of the original product. This paper proposes a soft-sensing technique based on vibration measurements of the compressor surface to predict the evaporating temperature. Different machine learning (ML) techniques are evaluated as data-driven prediction models, namely multilayer perceptron (MLP) neural networks, least squares boosting, generalized additive model, random forest, extreme learning machine, and random vector functional link neural networks. These techniques were applied to data obtained from a test rig designed to emulate compressor operation in a refrigeration system, with an operating envelope from -30°C to -10°C for the evaporating temperature and from 34°C to 54°C for the condensing temperature. The results showed that, with a single vibration measurement point, it was possible to use an MLP technique to estimate the evaporating temperature with a root mean squared error of 1.74°C in a non-intrusive way. For the other prediction techniques, the errors were a bit higher than for the MLP, but the maximum error value was about 2.5°C in all cases.

Experimental study on system characteristics of vapor compression refrigeration system using small-scale, gas-bearing, oil-free centrifugal compressor

Small-scale refrigeration centrifugal compressors hold the potential for superior efficiency compared to currently used positive displacement compressors. However, traditionally, centrifugal compressors have been employed in large refrigeration systems with cooling capacity of several hundred kilowatts or more. Conversely, the application of small-scale centrifugal compressors in smaller refrigeration systems, with cooling capacity in the tens of kilowatts, has largely remained theoretical, lacking practical experimental studies. For a better understanding of the operational characteristics of such systems, this study constructed a 45 kW R245fa refrigeration system test bench based on the small-scale oil-free centrifugal compressor utilizing gas foil bearings. The experimental investigation analyzed the impact of refrigerant charge amount, compressor speed, and coolant flow rate on system performance. Results indicate that the system achieves its peak cooling capacity of 49.73 kW with a system COP of 3.64 at 65,000 rpm. Moreover, at 50,000 rpm, the system demonstrates its highest system COP of 4.23 with a cooling capacity of 26.07 kW. In comparison to traditional positive displacement compressor refrigeration systems, it exhibits higher energy efficiency. Additional simulation studies were conducted to evaluate the effects of substituting R1233zd(E) for R245fa on the system performance and to assess the feasibility of such a substitution.

Simulation Analysis and Image Processing of the Exhaust Silencing Chamber and Coil

The compressor is the most core component of refrigeration products, and its performance directly affects the overall performance of the product. The exhaust silencing chamber and coil are key components of a refrigeration compressor, and their working stability and lifespan determine the reliability and economy of the refrigeration compressor. This paper obtains reference data for the fluid domain of the exhaust silencing chamber through simulation analysis and image processing of the existing exhaust silencing chamber structure and inner diameter size of the coil. Then, the optimal model of the prioritized exhaust chamber is obtained through pattern recognition method. Based on the image processing method, the internal flow field of the exhaust chamber are obtained, providing a strong reference for the optimal structural design of the exhaust silencing chamber and coil of the refrigeration compression body.

Experimental study on the measurement criteria for measuring surface tension in oil/refrigerant mixtures by maximum bubble pressure method

Refrigeration oil used in refrigeration compressors is usually compatible with refrigerant. The properties of the mixture are changed when refrigeration oil and refrigerant are mixed in the oil sump of the compressor because the refrigerant dissolves in the oil. Surface tension is one of the properties of the oil/refrigerant mixture that changes during the dissolving process. This change in property has an impact on foaming and the production of oil mist in compressors. In addition, surface tension can be utilized as an indicator of refrigerant concentration in oil. Hence, it is essential to determine the surface tension of the oil/refrigerant mixture. This study employed the maximum bubble pressure method (MBPM) to measure the surface tensions of the refrigeration oil and refrigerant mixtures. The oil was polyvinyl ether (PVE), while the refrigerants were difluoromethane (R32) and R410A, which was a blend of R32 and pentafluoroethane (R125). Since the viscosity of refrigeration oil changed dramatically with the dissolution of refrigerant, the measurement criterion of the MBPM applicable to a wide range of viscosities was clarified using silicone oil with various viscosities. Based on the findings of the surface tension of the PVE/R410A and PVE/R32 mixtures, a predictive formula was presented to estimate the mixture’s surface tension as a function of temperature and refrigerant concentration in oil. Relationships between the refrigerant concentration and normalized surface tension were also proposed.

Semi-empirical model of the twin-screw refrigeration compressor with capacity control devices

Adopting twin-screw refrigeration compressors with capacity control devices has become the dominant trend to meet varying cooling demands. To analyze the compressor performance with different capacity control methods and further explore the potential, a semi-empirical model with 16 characteristic parameters is proposed. Detailed working processes under the part-load condition (PC) are considered and the corresponding calculations, including pressure loss, power loss, and leakage are innovatively refined. Subsequently, a prototype experiment was carried out for parameters identification and model validation. A good agreement between the experimental and simulated values is attained, with average relative errors of 3.46 % and 1.15 % for shaft power and mass flow rate under the variable frequency condition (VFC) and 3.18 % and 4.63 % under the PC. Thermodynamic simulation results indicate that both shaft power and mass flow rate are linearly correlated with frequency and the efficiencies are nearly stable over the whole interval. However, as the load decreases, the performance decays significantly and the most remarkable change occurs at a position of between 0.9 and 1. The volumetric and adiabatic efficiencies of the VFC are 3.65 and 2.26 times higher than that of the PC when the mass flow rate reaches the lower limit.

Reducing Energy Consumption of Refrigerator Compressor using Aluminum Oxide Nanoparticles

Reducing Energy Consumption of Refrigerator Compressor using Aluminum Oxide Nanoparticles

Maximizing Workshop Efficiency Reusing Old Compressors Globally

This study investigates the feasibility of repurposing old refrigerator compressors to construct an air compressor for workshop use. Conducted at the Laboratory of Mechanical Engineering, Muhammadiyah University of Sidoarjo, the research assesses performance factors such as compressor tube filling time and injection settings. Results indicate that using one compressor motor takes 12 minutes and 57 seconds to fill the tube, while two motors reduce this to 8 minutes and 12 seconds, reaching a maximum pressure of 75 psi. Higher spray gun settings result in faster air depletion. Although pressure output is weaker compared to conventional compressors, the cost-effectiveness of using reused materials is evident, highlighting potential economic and environmental benefits. Highlight: Repurposing old compressors for workshop air supply. Assessing performance: filling time, injection settings. Cost-effective, eco-friendly solution for workshop equipment. Keyword: Repurposing, Refrigerator Compressors, Workshop Equipment, Performance Assessment, Cost-effectiveness

Design and performance comparison of large-scale hydrogen liquefaction processes based on mixed refrigerant cycle

Liquid hydrogen (LH2) is an efficient carrier for storage and transportation of hydrogen energy. To investigate the effect of mixed refrigerant cycle (MRC) on the performance of large-scale hydrogen liquefiers, three processes with a capacity of 50 TPD LH2 are designed in a relatively achievable way. Process I utilizes a dual-pressure hydrogen Claude cycle with nitrogen precooling as a reference. Process II incorporates a five-component mixed refrigerant cycle in place of the nitrogen cycle. Process III advances further by replacing the hydrogen cycle in Process II with an additional MRC composed of Ne, He and H2. Sensitivity analysis is applied to optimize the parameters of the three processes prior to the comparison of their heat exchangers performance and the energy and exergy analyses. Due to the synergistic effect of smaller temperature difference and higher refrigeration temperature, the employment of MRC for precooling yields a SEC of 1.350 kWh/kg LH2, 57.1% and 66.3% lower than those of nitrogen cycle and liquid nitrogen, respectively. The sensible heat of the Ne/He/H2 mixture shows a better temperature matching than the latent heat of the refrigerant hydrogen when cooling the product hydrogen, reducing energy consumption by 28.4%. The utilization of MRC for precooling generates more exergy loss in the separators, mixers and throttle valves, but the absence of nitrogen expanders and much lower flow rate of refrigerant save more exergy in total. The essential reason for the progressiveness of Process III is that the integrated heat exchanger in the cryostat achieves the logarithmic mean temperature difference (LMTD) of 2.11 K, effectively reducing the exergy loss of the refrigerant compressors, thereby diminishing the thermodynamic irreversibility.

Emissions reduction in LNG production facilities through emerging post-combustion carbon capture and storage technologies

The liquefied natural gas (LNG) sector relies extensively on gas turbines for on-site power generation and to drive refrigeration compressors. They provide an efficient and reliable energy source for LNG operations in remote locations. With upcoming changes to the Safeguard Mechanism in Australia, there is an increased focus on Scope 1 emissions, so management and targeted reduction are a priority to reduce liabilities. Despite technology advancements, gas turbines remain one of the largest sources of carbon dioxide (CO2) emissions in LNG production facilities. Also, in Australia, many facilities are not grid-connected, meaning that displacement of Scope 1 emissions through renewable electricity sourcing is a challenge. To develop deeper cuts in Scope 1 emissions, one solution is to deploy post-combustion carbon capture and storage (CCS) on existing gas turbines, with the potential to reduce associated emissions by over 90%. Globally, a number of LNG facilities are already deploying CCS to permanently store reservoir CO2 from the LNG processing trains. Several Australian LNG facilities are located in close proximity to potential CO2 storage reservoirs, meaning that a coordinated approach to both reservoir and post-combustion CO2 should be considered when sizing pipelines, shipping systems and storage wells to optimise and leverage the required investment. This paper outlines the technological, economic and policy aspects of integrating both reservoir post-combustion CCS on LNG facilities, including barriers and opportunities for deployment. It will discuss new developments and enablers for CCS to be more widely deployed at LNG production sites.

High-pressure liquid refrigerant injection for reciprocating compressors

Isentropic (adiabatic) compression of superheated vapor in vapor compression refrigeration cycles usually results in some discharge superheat, i.e. the discharge temperature exceeding the condensing temperature. Large discharge superheat reduces both operating range and compression efficiency. Sub-isentropic compression with heat rejection to the heat sink is therefore superior to adiabatic compression, as it results in lower discharge superheat and improved efficiency. However, significant temperature reduction by heat transfer through the working chamber walls is difficult to facilitate in common refrigeration compressors, particularly reciprocating compressors. Refrigerant and oil injection is a well-established method for reducing temperatures and increasing efficiency in screw and scroll compressors, as well as multi-stage systems. In comparison, effective methods for temperature reduction in single-stage reciprocating compressors are fairly limited. Therefore, a concept for high-pressure liquid injection is proposed. By means of a pump and injection valve, high-pressure liquid refrigerant is injected into the working chamber and atomized. The compressed gas is cooled through the evaporation of the injected liquid. The injection valve allows for control over the injection timing and quantity, enabling adjustment of the temperature profile, which is a major distinction from existing refrigerant injection methods. The coupled compression-injection process is evaluated for various refrigerants using an energetic chamber model. The injection is found to be particularly suitable for refrigerants with a large evaporation heat and a shallow dew line slope. For the example of ammonia, a theoretical reduction in compression work of 8.9% at an evaporation temperature of −10 °C and a condensing temperature of 45 °C is found.

Performance evaluation and optimization of the cascade refrigeration system based on the digital twin model

Cascade refrigeration systems (CRSs) have become the priority choice in low-temperature applications, causing severe energy waste due to the lack of practical control strategies. Currently, refrigeration simulations are mainly based on the simplified thermodynamic or Artificial Intelligence (AI) model. However, the former is insufficiently accurate, while the latter is of unclear thermodynamic significance. By connecting the physical and digital space, the digital twin technology provides exciting opportunities for combining thermodynamic and AI methods. In this paper, an integrated digital twin model for the CRS is innovatively proposed based on the modified semi-empirical model of the twin-screw refrigeration compressor. As a major update, the identification and update method of characteristic parameters is developed based on real-time operating data to ensure performance consistency between digital and physical twins. By comparing with the simplified model, results show that the digital twin model can improve prediction accuracy by 7.42%–23.62%. Founded on the proposed model, the thermodynamic performance of the CRS is evaluated. To facilitate on-site applications, the definition of flat intermediate temperature is given, which is fitted to a control correlation with several easily observed variables as the inputs. Taking a food factory as a case study, simulation results reveal that the optimum intermediate temperature should be significantly lower than the original, and the coefficient of performance (COP) has an average improvement potential of 9.1%. By deploying the optimum strategy under the on-site condition, a superior energy-saving rate of up to 13.1% is attained according to test reports.

Evaluation of three suction pretreatment systems for the air compressor

Air compressor, as the power source of pneumatic tools, suffers the problems of low efficiency and high failure rate in summer. In this paper, three suction air pretreatment systems are presented, which are characterized by the cold sources: a vapor compression refrigeration unit, a water chilling unit and a combination of water chilling unit with cooling tower. Models for the thermodynamic and economic performance evaluation of the three systems are established and solved. The moisture diffusion coefficient is applied to consider the influence of the moisture condensation and the Marshall and Swift coefficients is introduced to consider the capital change over time. Formula to calculate the efficiency of refrigeration compressor is adopted. Besides, the system total efficiency, percentage of power saving (PPS) and payback period (PBP) are defined as performance indexes. A comparative study with typical meteorological data of hot-dry regions and hot-humid regions is conducted to analyze the superiority of each system under the operation conditions of varied suction air temperature and volume flow. According to the results, optimal spray water flowrate exists for each operation condition and an air–water ratio of 0.8 is recommended. When the suction air temperature decreases, the PBP of each system increases and a sharp increase occurs when the temperature is lower than the air dew point temperature. A suction air temperature of 26 ℃ is suggested. Direct air cooling with an evaporator is preferred when the suction air volume flowrate is smaller than 60 m3/min for hot-humidity regions. The combined system is significantly superior in hot-dry regions. The PBP of the three systems is all longer than 10 months. How to guarantee the usage rate is the key for enterprises to consider the use of suction air pretreatment systems.

Theoretical comparison analysis of R134a, R1234yf, R452A and R454C refrigerants used in automobile, trailer and commercial and industrial cooling systems

The increasing environmental disasters in recent years are caused by the release of artificial substances into the environment. The majority of artificial-containing emissions originate from petrochemical products. It also contributes to artificially containing refrigerants used in cooling systems. Artificial refrigerants have contributed greatly to the depletion of the ozone layer and subsequently to global warming. Research on new refrigerants as an alternative to refrigerants that contribute to every environmental disaster is of great importance. In this study, theoretical performance comparisons were made between R1234yf, which is an alternative to R134a refrigerant used in automobile air conditioning systems, and R452A, R454C refrigerants, which are used as alternative refrigerants in industrial, commercial and trailer cooling systems. Performance analyses were carried out according to different condenser and evaporator temperatures. Analysis results are given depending on condenser/evaporator pressure ratio, mass flow rate, compressor power, cooling effect coefficient (COP) and compressor outlet temperature. According to the study results, it was observed that the COP value increased with the increase in evaporator temperature, while the compressor inlet-outlet pressure ratio, refrigerant flow rate, compressor power and refrigerant compressor outlet temperature decreased. It was observed that the refrigerant with the highest compressor power and mass flow rate was R452A, followed by R1234yf, R454C and R134a, respectively. R134a was found to have an average of approximately 5.4%, 8.6% and 0.6% higher COP than R1234yf, R452A and R454C, respectively.

Second law efficiency of air-cooled refrigeration compressors

Isentropic efficiency is a common performance measure for compressors and is useful for modelling the behaviour of real compressors in relation to discharge temperature or required mechanical power input. However, it has a weakness in that a basic assumption in the calculation is that the real compressor is adiabatic. If significant heat transfer from the compressor to the outside environment occurs, then the adiabatic assumption is invalid, but the negative effects of internal entropy generation are reduced, and in principle it is possible to have a measured isentropic ‘efficiency’ greater than 100%, which, while counterintuitive, is highly desirable. We practically demonstrate this effect with an air-cooled swashplate compressor and propose that for cases of intentional compressor cooling, the simple definition for isentropic efficiency is retained as a performance measure but renamed to isentropic performance coefficient (IPC).

Experimental Characterization and Numerical Simulation of a Low-Scale Personal Cooling System with Integrated PCM

Phase Change Materials (PCMs), among the existing thermal storage technologies, are characterized by higher storage densities than conventional storage systems, and absorb and release thermal energy at nearly constant temperatures. In recent years, the potential advantages that can be obtained by the integration of these materials into refrigeration machines have attracted the attention of specialized literature. Indeed, PCMs can allow a more efficient operation through an appropriate increase in thermal inertia, for applications relative to air conditioning in both internal residential environments and inside vehicles for the transport of people, and also in the case of machines used in the field of food refrigeration. Furthermore, in recent years, innovative solutions with integrated PCM have also been analyzed, aiming at enhancing the usability and transportability of refrigeration systems, as well as increasing the energy efficiency and reducing environmental impact. In this context, the present work focuses on the experimental characterization and numerical simulation of a cooling system with integrated PCM. In particular, the cooling system, designed for a personal cooling application, is experimentally analyzed by varying the configuration of the PCM-based condenser, while the numerical simulations have been realized to validate a simulation tool that could be used for the design and optimization of the PCM condenser configuration. The results allow us to identify the main characteristics of the analyzed personal cooling system, namely, the cooling capacity and operating autonomy, and to point out the utility and the limits of the developed simulation tool. Among the various configurations analyzed, the best one in terms of refrigeration power and autonomy is the one characterized by the highest heat transfer surface of the heat exchanger, with the refrigerant compressor at 50% power.

AKGNN-PC: An assembly knowledge graph neural network model with predictive value calibration module for refrigeration compressor performance prediction with assembly error propagation and data imbalance scenarios

Performance prediction plays a key role in product quality control and quality optimization. However, due to the error transmission in the refrigeration compressor assembly process and the imbalance of data collected during the refrigeration compressor assembly process, existing performance prediction methods cannot accurately extract key features of the assembly process resulting in low prediction accuracy. In this paper, a knowledge graph neural network (AKGNN) model with predictive value calibration is proposed for refrigeration compressor performance prediction in two stages. First, a sequence graph attention feature extraction module is designed to extract key features of the assembly process data to cope with the assembly error propagation. Second, to deal with the imbalanced distribution of compressor data, a predictive value calibration (PC) module is designed to calibrate the output of the first stage. Experimental results demonstrate the proposed method outperformed all compared cutting-edge methods in four evaluated indicators.