Dynamic simulation of natural convection bypass

two-circuit cycle refrigeratorfreezer and its application

Part I: Component models
Guoliang Ding
*
, Chunlu Zhang, Zhili Lu
Department of Power and Energy Engineering, Institute of Refrigeration and Cryogenics Engineering,
Shanghai Jiaotong University, No. 1954 Huashan Road, Shanghai 200030, China
Received 21 May 2003; accepted 14 December 2003
Available online 23 January 2004
Abstract
In order to reduce the greenhouse gas emissions, ecient household refrigerator/freezers (RFs) are
required. Bypass two-circuit cycle RFs with one compressor are proved to be more ecient than two-
evaporator in series cycle RFs. In order to study the characteristics and improve the design of bypass two-
circuit cycle RFs, a dynamic model is developed in this paper. In part I, the mathematic models of all
components are presented, considering not only the accuracy of the models but also the computation
stability and speed to solve the models. An eciency model that requires a single calorimeter data point at
the standard test condition is employed for compressor. A multi-zone model is employed for condenser and
for evaporator, with its wall thermal capacity considered by eective metal method. The approximate
integral analytic model is employed for adiabatic capillary tube, and the eective inlet enthalpy method is
used to transfer the non-adiabatic capillary tube to adiabatic capillary tube. The z-transfer function model
is employed for cabinet load calculation.
2004 Elsevier Ltd. All rights reserved.
Keywords: Dynamic simulation; Refrigerator/freezers; Two-circuit; Natural convection; Component model
1. Introduction
The two-evaporator in series natural convection refrigeratorfreezers (RFs) charged with pure
refrigerants, such as R-600a and R134a, are widely used because of the simple design and low
*
Corresponding author. Tel.: +86-21-62932110; fax: +86-21-62932601.
E-mail address: glding@mail.sjtu.edu.cn (G. Ding).
1359-4311/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2003.12.009
Applied Thermal Engineering 24 (2004) 15131524
www.elsevier.com/locate/apthermeng
Nomenclature
C specic heat (J kg
1
K
1
)
d, D diameter (m)
F area (m
2
)
h enthalpy (J kg
1
)
K heat transfer coecient (Wm
2
K
1
)
l, L length or thickness (m)
m mass ow rate (kg s
1
)
_ m average mass ow rate (kg s
1
)
M refrigerant mass (kg)
n compressor speed (r.p.s)
P pressure (Pa)
Q heat transfer rate (W)
t time (s)
T temperature (C or K)
T average temperature (C or K)
v specic volume (m
3
kg
1
)
W work (W or J s
1
)
x vapor quality
Greek symbols
a heat transfer coecient (Wm
2
K
1
)
k coecient of compressor capacity
g electrical eciency of compressor
h excess temperature (C or K)
q refrigerant density (kg m
3
)
q average density of refrigerant (kg m
3
)
p circumference ratio
w polytropic exponent
d thickness of control volume (m)
l dynamic viscosity (Pa s)
s time variable (s)
Ds time step (s)
Subscripts
amb ambient
c, con condenser
cap capillary
com compressor
cmpt compartment
e, eva evaporator
g vapor phase
1514 G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524
costs. For this kind of products, it is dicult to control the temperatures of both compartments in
the required values in the same time. The inherent problem is that temperature can be specied in
only one compartment. The temperature in either the freezer compartment (FZC) or the fresh
food compartment (FFC) controls the operation of the compressor and, ultimately, the amount of
heat extracted from both evaporators. Thus, the evaporator that does not control the compressor
often receives more or less cooling than it requires. Also, since the evaporating temperature in
FFC is the same as the evaporating temperature in FZC, the thermodynamic irreversible loss is
large in FFC. For this cycle, extra electric heating is often necessary when the food compartment
temperature is specied and ambient temperature is very low.
One method termed dual-loop system has been suggested to overcome challenge of the
unique two-temperature application of RFs [14]. The dual-loop cycle RFs had independent
cycles for FFC and FZC. Every cycle has itself compressor, condenser, capillary tube, and
evaporator. One shortcoming for dual-loop cycle is that the initial cost is high since two com-
pressors are used.
Another method termed bypass two-circuit cycle has been used to overcome the short-
comings of two-evaporator in series RFs. Bypass two-circuit cycle is achieved by adding an
additional path in the two-evaporator in series cycle, which can bypass the former evaporator of
in series cycle. The schematic diagrams of bypass two-circuit cycle are shown in Fig. 1(a) and (b).
Obviously, the initial cost for this cycle is low since only single compressor is employed. For this
cycle, since an additional path is added, the design and the characteristics are more complicated
than two-evaporator in series cycle and dual-loop system, researches on this two-circuit cycle are
necessary and urgent.
Computer simulation is widely used in refrigerators and other refrigeration system [512],
which is a cheap and time-saved means to study characteristics of refrigeration system and im-
prove or optimize refrigeration units. For refrigerators simulation, it includes steady-state sim-
ulation [57] and dynamic simulation [810]. For steady-state simulation, the thermal capacity of
foam insulation is neglected. For dynamic simulation, not only the refrigeration system, but also
the cabinet is considered to be dynamic, so the simulation is complicated. Furthermore, since
f liquid phase
fg liquidvapor phase
sat saturation, saturated
sc subcooling
sh superheat
suc suction
tp two phase
w wall
unit unit length
Superscripts
i inlet
o outlet
G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524 1515
bypass two-circuit cycle RF is complicated, computation stability of dynamic simulation is dif-
cult to keep, thus reliable and stable models and its solutions are necessary.
Many works on refrigeration simulation were done in our research team, such as RFs, air-
conditioners, and liquid chillers [912]. Compared with air-conditioners and liquid chillers, the
dynamic cabinet load model is necessary in dynamic simulation of RFs, it is more dicult to build
and solve the models for dynamic simulation of refrigerator. In this paper, dynamic simulation of
bypass two-circuit cycle RFs is presented as a further research on the early simulation of two-
evaporator in series cycle RFs [10]. In Part I, only the component models, including the com-
pressor model, condenser and evaporator model, capillary tube model, and cabinet load model,
are presented in details.
2. Bypass two-circuit cycle RF
As shown in Fig. 1(a) and (b), there are two types of bypass two-circuit cycle RFs. The cycle
system of Fig. 1(a) can bypass the freezer evaporator, and the cycle system of Fig. 1(b) can bypass
the food evaporator. In bypass two-circuit cycle RFs, the three-way solenoid valves only control
the refrigerant ow direction. The operation of compressor and three-way solenoid valve is
controlled not only by FFC temperature, but also by FZC temperature. In the example shown in
Fig. 1(a), FZC controls loop A, and FFC controls loop B. So independent compartment tem-
perature control can be maintained. The detailed control ways for Fig. 1(a) are as follows:
Initially, FZC and FFC temperatures are equal to ambient temperature that is larger than the
up-limit values of FZC and FFC. The compressor starts up and the solenoid valve switches for the
refrigerant owing through loop A. Then the RF works according to the following modes.
(a) Refrigerant is owing through the loop A. The compressor runs at rst until the FZC temper-
ature reaches its low-limit value, then the FFC temperature is compared with its middle-limit
Condenser
Compressor
Capillary Tube-Suction
Line Heat Exchanger
Suction Line
Capillary
Tube A
Freezer
Evaporator
Food
Evaporator
Three-Way
Solenoid Valve
A B
Capillary
Tube B
Food
Evaporator
Freezer
Evaporator
Capillary Tube-Suction
Line Heat Exchanger
Capillary
Tube B
Condenser
Suction Line
Three-Way
Solenoid Valve
Capillary
Tube A
A B
Compressor

(a) (b)
Fig. 1. Bypass two-circuit cycle RF.
1516 G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524
value in order to determine the working mode of the RF. If the FFC temperature is lower
than the middle-limit value, then the compressor stops and the RF works according to the
mode (c); otherwise the solenoid valve switches for the refrigerant owing through loop B
and the RF works according to the mode (b).
(b) Refrigerant is owing through the loop B. In this case, only the FFC is cooled, and the FZC
temperature goes up. If FZC temperature gets to its up-limit value before the FFC gets its low-
limit value, the solenoid valve switches for the refrigerant owing through loop A, and the RF
changes its working mode to mode (a); otherwise, the compressor runs until the FFC temper-
ature is below its low-limit value, and the RF changes its working mode to mode (c).
(c) Compressor stops. In order to protect the motor, o time must be longer than 3 min. After 3
min, if FZC temperature gets to its up-limit value before FFC temperature gets to its up-limit
value, the compressor starts up, the solenoid valve switches for the refrigerant owing through
loop A, the RF works according to mode (a); if FZC temperature gets to its up-limit value after
FFC temperature does, the RF works according to mode (b); if FZC temperature and FFC
temperature gets to their up-limit values at the same time, the RF works according to mode (a).
3. Mathematical models
3.1. Compressor
The compressor used in the RF is hermetic reciprocating one. It is composed of two parts:
cylinder and shell.
The mass ow rate and input work are calculated by
m
0
com
kV
th
=v
suc
1
W
0
com
kV
th
p
eva
w
w 1
p
con
p
eva
_ _
w1
w1
_ __
g 2
V
th
pD
2
Lni=4 3
where, m
0
com
is the mass ow rate of compressor; k is the coecient of compressor capacity; V
th
is
the theoretical piston displacement of compressor; v
suc
is the specic volume of suction vapor;
W
0
com
is the input work of compressor; w is the polytropic exponent; g is electrical eciency of
compressor; D is the diameter of the cylinder; L is the length of stroke; n is revolutions of the
crankshaft per second; i is the number of cylinders.
In order to improve the prediction accuracy by Eqs. (1) and (2), the correction coecients of
mass ow rate and input work c
m
; c
w
are introduced here. They are given by
c
m
m

com
=m
0
com
4
c
W
W

com
=W
0
com
5
where m

com
and W

com
are measured mass ow rate and input work respectively at a single point of
ASHRAE standard test condition. m
0
com
and W
0
com
are computed by Eqs. (1) and (2).
G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524 1517
The nal mass ow rate and work input to compressor are computed by
m
com
m
0
com
c
m
6
W
com
W
0
com
c
W
7
The mass conservation equation for compressor is given by
dM
com
=ds m
o
eva
m
com
8
The energy conservation equation for compressor shell is given by
cqV
com
dT
com
ds
W
com
m
i
com
h
i
com
m
o
com
h
o
com
a
com
F
com
T
com
T
amb
9
where a
com
is the convection heat transfer coecient of outside surface of compressor shell; F
com
is
the outside heat transfer area of compressor shell. m
o
eva
is the mass ow rate of evaporator outlet.
3.2. Heat exchangers
Heat exchangers in RFs include condenser and evaporator. Heat exchanger model can be di-
vided into three types: lumped-parameter model, distributed-parameter model and multi-zone
model. Lumped-parameter model cannot reect the dierent heat transfer at dierent phase state,
so its error is great. Theoretically, the precision of distributed-parameter model is best, but the
precision of the heat exchanger model is related with the heat transfer coecients, and at present,
the local heat transfer coecients of heat exchangers are severely limited to use, therefore, as the
matter of fact, the precision of distributed-parameter model cannot be assured. At the mean time,
the convergence of distributed-parameter model is poor and it would cost much time to solve such
a model. As the precision, the convergence, and computation speed are all taken into consider-
ation, multi-zone model is reasonable in this work.
As condensation and evaporation are very complicated, the following assumptions are pro-
posed to simplify the mathematical models: (1) refrigerant owing in the tube is one-dimensional;
(2) in any cross-section of the evaporator and the condenser, the refrigerant is homogeneous and,
hence, values of any parameter are identical in any cross-section of the ducts; and (3) heat transfer
along the tube axis, pressure drop along the owing direction, owing force, and gravity force are
all neglected.
Thermal capacity of wall metals has eects on the dynamic characteristics of heat exchanger. In
order to take the thermal capacity of the wall metals into account and simplify the heat exchanger
model, the eective metal method is used. Because the convective heat transfer on the refrigerant
side is greater than that on the airside, the wall temperature is very close to the refrigerant
temperature. Assume that the wall temperature is equal to the refrigerant temperature. Actually,
not all of the heat exchanger metal would be the same temperature with the refrigerant, and the
metal at the same temperature with the refrigerant is termed the eective metal. The eective metal
coecient, k
w
is evaluated by
k
w
m
eff
=m
w
10
where m
eff
is mass of eective metal of heat exchanger; m
w
is total mass of heat exchanger.
1518 G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524
For whole heat exchanger, mass conservation equation is given by
dM
sh
M
tp
M
sc

ds
m
o
m
i
0 11
For each zone of heat exchanger, mass and energy conservation equations are given by
M
sh
l
sh
A
unit
q
sh
12
M
tp
l
tp
A
unit
q
tp
13
M
sc
l
sc
A
unit
q
sc
14
l
con
l
sh
l
tp
l
sc
15
dM
sh
h
sh

ds

k
w
q
w
C
w
A
w
dl
sh
T
sh

ds
m
o
sh
h
o
sh
m
i
h
i
F
unit
l
sh
K
sh
T
air
T
sh
16
dM
tp
h
tp

ds

k
w
q
w
C
w
A
w
dl
tp
T
tp

ds
m
o
tp
h
o
tp
m
i
tp
h
i
tp
F
unit
l
tp
K
tp
T
air
T
tp
17
dM
sc
h
sc

ds

k
w
q
w
C
w
A
w
dl
sc
T
sc

ds
m
o
h
o
m
i
sc
h
i
sc
F
unit
l
sc
K
sc
T
air
T
sc
18
In Eqs. (10)(18), the refrigerant mass ow rate (m
i
) and enthalpy (h
i
) at the inlet of heat ex-
changer are known, which are equal to ones at the outlet of compressor for condenser or of
capillary tube for evaporator, and the refrigerant mass ow rate (m
o
) at outlet of heat exchanger is
known too, which is equal to the mass ow rate of capillary tube for condenser or of compressor
for evaporator. The qualitative temperature and average mass ow rate of refrigerant at any zone
are given by arithmetic mean temperature of its inlet and outlet values respectively.
Eqs. (10)(18) constitute a set of eight equations with eight unknowns M
sh
; M
tp
; M
sc
; l
sh
; l
tp
; l
sc
;
T
tp
; T
sc
, hence the above equations of heat exchanger can be solved to get a unique group of
solution.
The mass in any single-phase zone is calculated by
M
s-p
q
s-p
F
unit
l
s-p
19
where M
s-p
and q
s-p
are the mass and the average density of refrigerant in single-phase zone
respectively; l
s-p
is the length of single-phase zone.
The mass in two-phase zone is calculated by [13]
M
tp
baq
g
1 aq
f
cF
unit
l
tp
20
a 1 1
_ _

1
x
_
1
_
q
g
q
f
_
21
where M
tp
is the refrigerant mass in two-phase zone; a is the void fraction in two-phase zone; q
g
and q
f
are the saturated density of vapor and liquid in two-phase zone respectively; x is average
mass quality of refrigerant in two-phase zone.
G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524 1519
3.3. Capillary tube
The capillary tube used in RF has following characteristics:
(1) The capillary tube used in household RF is always non-adiabatic, which has a heat exchange
with the suction line. (2) During the startup and shutdown processes, the inlet conditions of
capillary tube change greatly. Not only the subcooling state, but also the superheat state and two-
phase state occur.
Since the outlet states of capillary tube responds very fast to its inlet states because of the high
ow velocity in the small diameter capillary tube [14], steady-state model is employed for capillary
tube.
Since the throttling process of non-adiabatic capillary tube is very complicated, generally the
non-adiabatic capillary tube is transferred to adiabatic capillary tube by certain equivalent
method, such as eective subcooling level method. In this paper, the steady-state model of adi-
abatic capillary tube is established rst, then, the eective inlet enthalpy method is presented to
transfer non-adiabatic capillary tube to adiabatic capillary tube.
The ow in adiabatic capillary tube is generally considered to be one-dimensional and
homogeneous and thermal equilibrium. Consequently, the governing equations are as follows:
dG 0 22
d h
1
2
G
2
v
2
_ _
dL
0 23
dp G
2
dv
1
2
f
D
vG
2
dL 24
where p, h, v, G are refrigerant pressure, specic enthalpy, specic volume, and mass ux
respectively; f is the friction factor, D and L are the inner diameter and length of the capillary tube
respectively.
From the viewpoint of system simulation, the stable and fast approach is better. The
approximate integral analytic method to solve Eqs. (22)(24) is presented in [15] when the inlet
condition of the capillary tube is subcooled, and in [16] when the inlet condition of the capillary
tube is superheated or two-phase.
The solution to Eqs. (22)(24) cannot be used directly for non-adiabatic capillary tube. In order
to predict the mass ow rate in non-adiabatic capillary tube, the eective subcooling level method
was presented at 1988 ASHRAE Equipment Handbook [17]. Such method was evaluated in paper
[18]. The accuracy of this method is very well when the inlet condition is subcooled. The eective
subcooling level method is suitable only when the inlet condition of capillary tube is subcooled.
When the inlet condition is superheated or two-phase, the eective subcooling level method is not
suitable. Herein, eective inlet enthalpy method is presented.
Heat exchange between capillary tube and suction line can be equivalent to the eective en-
thalpy drop by
Dh
eff

m
suc
h
o
suc
h
i
suc

m
cap
25
1520 G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524
where Dh
eff
is the eective enthalpy drop; m
suc
is mass ow rate in the suction line; h
i
suc
and h
o
suc
are
the inlet and outlet enthalpy of suction line heat exchanger, respectively. m
cap
is the mass ow rate
in the capillary tube.
The eective inlet enthalpy can be equivalent by
h
i
cap;eff
h
i
cap
Dh
eff
26
where h
i
cap;eff
is the eective inlet enthalpy; h
i
cap
is the inlet enthalpy.
The eective inlet enthalpy method of modeling the non-adiabatic capillary tube rst requires
adding the calculated eective enthalpy drop to the actual inlet enthalpy. This results in an adi-
abatic equivalent inlet enthalpy. Then the problem to predict the mass ow rate of a non-adiabatic
capillary tube is changed to do the mass ow rate of a adiabatic capillary tube at the equivalent
inlet enthalpy.
When the inlet condition of capillary tube is subcooled, the eective inlet enthalpy method is
actually the same as the eective subcooling level method, so the eective inlet enthalpy method is
the extension of the eective subcooling level method.
3.4. Cabinet
The performance of RFs is not only concerned with the refrigeration cycle, but also with the
cabinet load. Because the thermal properties of foam insulation and convective heat transfer
coecients of inner and outer surfaces of insulation walls vary very small under the working
condition of RFs, they are assumed to be constants. Therefore, the thermal insulation wall is a
linear system, and the thermal response factor method or conduction transfer function method
[1921] can be used to calculate the heat transfer through the wall.
For RFs, the output parameters are the compartment temperatures. The inputs are heat
transfer in the surface of inner side and outside of the thermal insulation wall. The output and
inputs can be formulated by
h
cmpt
z
1
W z
1
Iz
1
27
where h
cmpt
z
1
is compartment temperature. All temperatures mentioned in this section are the
excess temperatures to the ambient temperature. W z
1
is transfer function of cabinet load; Iz
1

is total cabinet load; z denotes the z operator.

The method to get the transfer function W z
1
is shown as follows:
Take all air in the compartment as the control volume. According to energy conservation law
and superposition principle of linear system, the governing equation on the control volume is
given by
C
cmpt
dh
cmpt
s
ds
Q
amb
s Q
cmpt
s Q
com
s Q
other cmpt
s Q
hot
s Q
cold
s Q
leak
s
28
where C
cmpt
is the thermal capacity of the control volume; Q
amb
s is the heat transfer into the
control volume through the foam insulation by the ambient temperature pulse; Q
cmpt
s is the heat
transfer into the control volume through the foam insulation by the compartment temperature
G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524 1521
pulse; Q
com
s is the heat transfer into the control volume through the foam insulation by the
compressor chamber temperature pulse; Q
hot
s is the heat transfer into the control volume
through the foam insulation by the hot-wall condenser heat ux pulse; Q
other cmpt
s is the heat
transfer into the control volume through the foam insulation by the other compartment tem-
perature pulse; Q
cold
s is the heat transfer into the control volume through the foam insulation by
the cold-wall evaporator heat ux pulse; Q
leak
s is the heat transfer into the control volume
through the door and other gaskets.
The heat transfer through the gaskets could be calculated by
Q
leak
s bLT
amb
T
cmpt
s bLh
cmpt
s 29
Backward nite-dierence and z-transformation is used for Eq. (28), we can get
C
cmpt
Ds
1 z
1
h
cmpt
z Q
amb
z
1
Q
cmpt
z
1
Q
com
z
1
Q
other cmpt
z
1

Q
hot
z
1
Q
cold
z
1
Q
leak
z
1
30
where
Q
amb
z
1
W
amb
z
1
h
cmpt
z
1
31a
Q
cmpt
z
1
W
cmpt
z
1
h
cmpt
z
1
31b
Q
com
z
1
W
com
z
1
h
com
z
1
31c
Q
other cmpt
z
1
W
other cmpt
z
1
h
other cmpt
z
1
31d
Q
hot
z
1
W
hot
z
1
q
con
z
1
31e
Q
cold
z
1
W
cold
z
1
q
eva
z
1
31f
Q
leak
z
1
bLh
cmpt
z
1
31g
Q
amb
z
1
, Q
cmpt
z
1
, Q
com
z
1
, Q
other cmpt
z
1
, Q
hot
z
1
, Q
cold
z
1
are heat ux at the inner sur-
face of cabinet wall. W
amb
z
1
, W
cmpt
z
1
, W
com
z
1
, W
other cmpt
z
1
, W
hot
z
1
, W
cold
z
1
are their z-
transfer functions. These z-transfer functions can be obtained by the method described in [21].
Substituting Eqs. (31ag) into Eq. (30) and rearranging the equation, we can get
h
cmpt
C
cmpt
Ds
1
_
z
1
W
amb
W
compr
W
other cmpt
bL
_
W
compr
h
compr
z W
other cmpt
h
other cmpt
W
hot
q
con
W
eva
q
eva
32
Compare Eqs. (32) and (27), we have
W z 1
C
cmpt
Ds
1
_ _
z
1
W
amb
W
compr
W
other cmpt
bL
_
33a
Iz W
compr
h
compr
z W
other cmpt
h
other cmpt
W
hot
q
con
W
eva
q
eva
33b
So far, the cabinet model has been solved.
1522 G. Ding et al. / Applied Thermal Engineering 24 (2004) 15131524
4. Conclusions
The component models for natural convection bypass two-circuit cycle RFs are presented here.
In order to make the simulation program run fast and its accuracy acceptable, the eciency model
that required a single calorimeter data point at the standard test condition is adopted for the
compressor; the multi-zone models are employed for condenser and evaporator, with its wall
thermal capacity considered by eective metal method; the approximate integral analytic model is
employed for adiabatic capillary tube, and the eective inlet enthalpy method is used to transfer
the non-adiabatic capillary tube to adiabatic capillary tube; the z-transfer function model is used
for the cabinet load calculation.
Acknowledgements
The research is supported by the State Key Fundamental Research Program of China under the
contract No. 2000026309. Part of the research was nanced by Refrigerator/Freezer Ltd Com-
pany (R/FLC), Haier Group, China. Helps of Mr. Dongning Wang and Mr. Linfei Xu in R/FLC,
Haier Group are greatly appreciated.
References
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