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Performance Analysis of R12 Refrigerator Using Hydrocarbon Refrigerant

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 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514
Performance Analysis of R12 Refrigerator Using
Hydrocarbon Refrigerant
S.K. Kalla
Department of Mechanical Engineering
IMS Engineering College Ghaziabad, India
Email: skkalla@yahoo.com
ABSTRACT
This study used hydrocarbon (HC) refrigerant in a
R12 refrigerator to evaluate the refrigeration
performance and feasibility of using this alternative
refrigerant by conducting the no-load pull-down test.
The mixed mass ratio of the HC refrigerants, R290 and
R600a, was 50% and 50% respectively.
The charged ratios were 30%, 40%, 50%, and 60%
based on the charged mass of R12 for HC refrigerant.
The results of the no-load pull-down test revealed that
the optimal charged mass for the HC refrigerant was
50% of that of R12.The results of this experimental
study showed that freezer temperatures below -10º C
were achieved when the HC refrigerant was used, and
that the HC refrigerant could be used in the R12
refrigerator without changing any component.
Keywords — coefficient of performance (COP);
hydrocarbon refrigerant; no-load pull-down test
Introduction
Because of ozone depleting concerns, the use of materials
with ozone depleting effects have been banned. Such a
material is R12, a chlorofluorocarbon (CFC) that is used as
a refrigerant in old small- and medium-sized refrigerators.
R12 is a banned substance under the Kyoto Protocol, and
must not be used. In India older refrigerators still have this
refrigerant as the working substance.
Therefore, R12 should be replaced with the other
refrigerants because this is the most efficient way to stop
the emission of this refrigerant. Ideally, R12 must be
replaced with a refrigerant that has no ozone depletion
potential (ODP), low global warming potential (GWP),
low toxicity, a low price, high chemical stability, and
excellent thermodynamic properties. Some long-neglected
natural refrigerants, such as ammonia, hydrocarbons
(HCs), CO2, water, and air, may be alternatives to
chlorofluorocarbons (CFC).
Many researchers have studied HC refrigerants as
alternatives to traditional refrigerants in a variety of
equipment [1-12]; however, these studies were focused on
medium and small-scale refrigerators or air-conditioners
due to consideration of flammable property and safety.
Previous studies on using HC drop-in refrigerants have
consisted of theoretical analyses and experimental
Subhash Mishra
Department of Mechanical Engineering
Inderprastha Engineering College Ghaziabad, India
research. To conduct theoretical analyses, theoretical
calculations and simulation analyses were used to assess
the use of HCs as alternative refrigerants in refrigerators
[13-16].
The related experimental research concerning refrigerators
retrofitted with HC refrigerants involve studies in which
adjusting the components in the refrigeration system was
necessary, and those in which it was not. In 1998, Alsaad
and Hammad [17] used liquated petroleum gas (LPG) with
24.4% propane (R290), 56.4% butane (R600), and 17.2%
is obutane (R600a)in 320 L of the domestic refrigerant
R12.Experimental results showed that the evaporation
temperature reached -15 º C with a coefficient of
performance (COP) value of 3.4 at a condensation
temperature of 27 º C and an ambient temperature of 20 º
C. LPG was successfully used as an alternative for R12 in
a domestic refrigerator; the refrigerator functioned
normally, and adjusting the refrigeration system was not
required. In 2005, Wong wises and Chimres [18] used the
HC refrigerants R290, R600, and R600a to replace R134a
in a domestic refrigerator with a gross capacity of 239 L.
The refrigerant mixtures used were divided into three
groups: a mixture of the three HCs, a mixture of two HCs,
and a mixture of two HCs and R134a. The experiments
were conducted with the refrigerants under the same no-
load condition at a surrounding temperature of 25 º C.
The results showed that the mixture of R290 and R600
(60% and 40% according to mass, respectively) was the
most appropriate alternative. Compared with using R134a,
using this HC mixture reduced the refrigerator’s energy
consumption by 86%. The refrigerant charge of the HC
mixture system was approximately 50% of that of the
R134a system (120 g).In 2008, Mani and Selladurai [19]
conducted an experimental study on a vapor compression
refrigeration system (VCRS) using an HC mixture of
R290 and R600a (68% and 32% according to mass,
respectively) as a drop-in replacement for R12 and R134a.
The experimental results showed that the HC mixture had
a 19.9% -50.1% higher refrigeration capacity than R12 did
and a 28.6% - 87.2% higher refrigeration capacity than
R134a did. The refrigerant R134a exhibited a slightly
lower refrigeration capacity than R12 did. The HC mixture
consumed 6.8%-17.4% more energy than R12 did. The
refrigerant R12 consumed slightly more energy than
R134a did at high evaporation temperatures. The COP of
53
 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514

the HC mixture increased from 3.9% to 25.1% higher than [25-28]. These HC refrigerants were mixtures of R290 and
that of the R12 at lower evaporation temperatures and R600a in various proportions by mass: 100% R290 and
from 11.8% to 17.6% at high evaporation temperatures. 0% R600a; 50% R290 and 50% R600a; and 0% R290 and
The R12 exhibited a slightly higher COP than the R134a 100% R600a (Table I).
did. The discharge temperature and discharge pressure of The HC refrigerants are superior to R12 because they have
the HC mixture was close to those of the R12. Therefore, extremely low GWP and excellent thermodynamic
the HC mixture can be considered a drop-in replacement properties. Furthermore, the viscosities of the HC
refrigerant for R12 and R134a. refrigerants are lower than that of R12, and the power
In 2009, Mohan raj et al. [9] conducted an experimental consumption for refrigerant circulation can be relatively
investigation using an HC mixture of R290 and R600a low. However, the densities of the HCs are lower than that
(45.2% and 54.8% according to mass, respectively) as an of R12; therefore, the mass flow rate is relatively low
alternative to R134a in a 200-L single-evaporator domestic when the compressor is set at a fixed volumetric flow rate.
refrigerator. Continuous running tests were performed in The safety of the HC refrigerants used in this study is
various ambient temperatures (24, 28, 32, 38, and 43 ºC), classified as A3 class according to ASHRAE Standard 34
whereas cycling running (on and off) tests were [29], which means that they are nontoxic refrigerants that
implemented only at an ambient temperature of 32 C. The are highly flammable.
results showed that the HC mixture exhibited The leakage concentration of these HC refrigerants should
approximately 11.1% lower energy consumption, an not exceed a lower flammable limit concentration (LFL) of
11.6% lower pull-down time, a 13.2% lower on-time ratio, 20% according to ASHRAE Standard 15, BS 4434, and
and a 3.25% - 3.6% higher COP than R134a did. The BS EN 378-1 [30-32], but the leakage concentration must
discharge temperature of the HC mixture was determined not exceed an LFL of 25%
to be 8.5 - 13.4 K lower than that of R134a. Jwo et al. [20]
used an HC mixture of R290 and R600a (50% and 50%
according to mass) as an alternative to R134a in a TABLE I. ALTERNATIVE REFRIGERANTS TO
domestic refrigerator with 150 g of charged R134a. The CFC-12 FOR DOMESTIC REFRIGERATION
results showed that the HC mixture exhibited 4.4% lower APPLIANCES.
energy consumption, a 17.4% lower running time, and a Refrigerant CFC- HFC- HC- HC-600a HC-290
40% lower charging mass of the refrigerant than R134a 12 134a 290 / Isobutene Propane
did. 600a
In 2012, Rasti et al. [21] used R436A, a mixture of R290 Formula CF2Cl2 CH2FCF3 C3H8- C4H10 C3H8
and R600a (56% and 44% according to mass, respectively) C4H10
as an alternative to R134a in a 238-L single-evaporator
domestic refrigerator without any modifications in the Molecular 120.93 102.03 51.12 58.13 44.1
refrigeration cycle. The refrigerator was charged with Weight
various masses of R436A, and in addition to the Critical 112.0 101.1 96.0 135.0 96.8
refrigerator’s power consumption during operation, the temperature
tem-peratures in different sections of the refrigerator were Boil point – –26.16°C –30°C –11.73°C –42.1°C
measured according to the Iranian National Standard No. (100 kPa) 29.8°C
4853-2.
The results showed that, compared with the basic Density
refrigerator functioning with R134a, using R436A reduced (kg/m3;–
the on-time ratio and the daily energy consumption by 25°C) sat 7.57 5.50 3.14 1.66 2.42
13% and 5.3%, respectively. The refrigerant charge of the vapour 1472.0 1371.0 584.4 608.3 580.7
R436A system was approximately 52% of that of the sat liquid
R134a system (105 g).
Flammable None None 1.8-9.0 1.4-8.4 2.2-9.5
In this experimental study, the mixed mass ratio of the HC
limits
refrigerants, R290 and R600a, was 50% and 50%
(%in air),
respectively.
20°C, 100
REFRIGERANT PROPERTIES AND CALCULATION OF A kPa
VCRS ODP 1.0 0 0 0 0
A. Properties and Safety of Refrigerants GWP 10600 1300 3 3 3
Table 1 shows a comparison of the thermodynamic,
environmental, and safety properties of the refrigerants
according to DIN 7003 [33].Regarding the charging
54
 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514

masses of the HC refrigerants in a variety of equipment,
we referred to the relevant provisions of IEC 60335-2-24,
IEC 60335-2-89, and ISO 5149 [34-36]. Fig. 1 shows that
the curves of the saturation temperature in relation to
cabinet eight year old refrigerator. The experimental
setup is shown in Fig. 3 and specifications of the R12
refrigerator are shown in Table II. The schematic
diagram of the experimental setup is shown in Fig. 4.
The experimental measurements were conducted in an
environment with controllable temperature .To improve
the safety of the experiment, a contactless-type
compressor starter was used, the other electrical parts
were sealed, and the insulation was reinforced using
insulating materials to reduce the risk of combustion
and explosion. For temperature measurements, digital
temperature sensor was used and for pressure
measurements, low and high pressure gauges were
used.

saturation pressure of R12, HC blend exhibited similar

trends, but that the saturation pressure of R600a was lower
than that of R12 at the same saturation temperature [27]. Fig. 2. System diagram of VCRS
B. Analysis and calculation of VCRS
Fig. 2 is the system diagram of a VCRS. The most
popular index used for evaluating the efficiency of VCRSs is
the COP. The COP of a VCRS is the ratio of the refrigeration
capacity and compression power, and a high COP indicates
an efficient VCRS. The refrigeration capacity ( ) of a
VCRS can be expressed as

(1)
The motive power of compressor ( of a VCRS can be
expressed as

(2)
The COP of a VCRS can be expressed as
COP = / = / (3) Fig. 3. Experimental setup

where heaping and hevao,out are the enthalpies at the inlet
and outlet of the evaporator, respectively, and hcomp, in
and hcomp, out are the enthalpies at the inlet and outlet of
the compressor, respectively.
II. EXPERIMENTAL DESIGN AND PROCEDURE
A. Experimental apparatuses
The R12 refrigerator used in this study was a single-
The digital temperature sensor was used to measure
temperature with an accuracy of ±0.5º C. Three
measurement points were used i.e. for measuring the
inlet and outlet temperatures of compressor and freezer
temperature. Two pressure gauges were used for
measuring the high-pressure range of 0 to 35 kgf/cm 2
and the low pressure range of -76cm Hg to 17.5
kgf/cm2 at an accuracy of ±0.5%.
55
 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514

B. Experimental procedures The no-load pull-down test was conducted on the R12
refrigerator for 4 h in different environmental
Items Style and structure Specifications and conditions, and the data were recorded involving the
dimensions HC refrigerant. To maintain the continuous operation
of the refrigerator during this experiment, the
Freezer  Inside and  External temperature controller was disabled. The
outside wall: dimensions measurements for the no-load pull-down test were
304 stainless (W x L x H, taken at 16.5, 20 and 26º C ± 0.5º C ambient
steel cm): 37.6 x temperature. The charging masses of the HC
 Insulation 35 x 14.1 refrigerant were approximately 40%-52% of that of R12,
materials: PU  Internal and were determined based on relevant studies [19,
foam dimensions 20, 21, 24].Therefore, the HC refrigerant was charged
 Natural (W X L X at different masses, 40 g (30%), 54 g (40%), 68 g
convection H, cm): (50%), and 81 g (60%), and the charge ratios were
flat evaporator 37.16 x based on the charge mass of the R12 system (135 g).
34.78 x Since the type and charged mass of refrigerant
13.88 will affect the operation.
 Effective
internal of the capillary tube in the refrigeration system, so this
volume (L): experiment was only to evaluate the feasibility that R12
18.15 refrigeration system retrofitted with HC refrigerant
 Hermetic  1/8 HP/AC without replacing any components. The test results of the
Compresso reciprocating 230 V HC refrigerant were used to evaluate the feasibility of
r compressor  Oil type: using this alternative refrigerant and optimal charging
(ML-633, Mineral Oil mass of the HC refrigerant without replacing any
Whirlpool)  Oil charge components.
(cm3): 400 C. Data analysis
Capillary  Seamless  I.D (mm): The vapor compression in the refrigeration cycle,
tube copper tube 0.49 refrigerant temperatures, operating pressures, operating
 Length (m): temperatures and COPs were analyzed. The related
2.05 functions of the refrigeration cycle, including the CRs
 Natural  Tube and COPs were also examined. The thermodynamic
Condenser convection diameter properties of the refrigerant were calculated using
condenser (mm):4.5 REFPROP 9.0 program developed by the NIST. The
 Outline COP can be calculated using Eq. (3), and the CRs were
dimensions calculated as follows:
(W x L x
H, cm): The CR of a VCRS is
42.7 x 57.5 CR = PH,abs / PL,abs
x 0.48 (4)

Refrigeran  R12
t  Charging
mass (g): RESULTS AND DISCUSSION
135 Table III shows the average freezer temperature of the HC
Refrigerant during the final 10 min of the no-load pull-
Compresso down test. The freezer temperatures were obtained by
r starter  Contactless  PTC measuring the air temperature using a temperature sensor
 Connector in the geometric center of the freezer. When using an HC
Filter dimensions refrigerant, the freezer temperature should be close to that
 Molecular (cm): 0.65 maintained when using R12; therefore the optimal
sieves  Outline charging mass of HC blend should be 50% of that of
dimensions R12.
(φ x L,
cm): 7 x
15.8 56
 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514

Amount Voltage Current Discharge Suction Freezer Suction Discharge

of Charge (V) (A) Pressure Pressure Temperature Temperatur Temperature
(gm) (Kg/cm²) (Kg/cm²) (°c) e (°c) (°c)

40 244 1.09 11 0.9 -19.9 13.6 47.2

50 225 1.00 10 0.6 -18.7 31 53

60 225 1.01 10.25 0.6 -19-9 24 55.5

70 225 1.01 10.01 0.6 -20.5 24.7 58.9

80 225 1.01 12 0.98 -16.1 21 58

TABLE IV.
MEASUREMENTS AT DIFFERENT MASS
CHARGES OF HYDROCARBON REFRIGERANT

Fig.5. Effect of ambient temperature on freezer

temperature

Fig. 5 shows the final average freezer temperature of the

Fig.4. Schematic diagram of experimental setup.
no-load pull-down test for the HC refrigerant with a
charging mass of 40% at different ambient temperatures.
As shown in the figure, when the ambient temperature
increased, the final average freezer temperature increased.
The different measurements which were obtained for
different mass charges of hydrocarbon refrigerant are
tabulated in Table IV.
Fig.6 shows the variation of COP with the amount of charge

57
 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514

of hydrocarbon refrigerant. It can be seen from the figure

that at 70 g charge of HC refrigerant the COP obtained was
maximum. Hence it is in agreement with the standard
freezer temperature requirement of -15°c. Also the
maximum COP of R-12 refrigerant was 2.85 at 135 g charge
as noted from the literature [37].Hence we observe that
greater COP is obtained at lesser charge (70g) for HC
refrigerant as compared to R-12 refrigerant with the help of
the data from the literature.
Fig.7 shows below the variation of freezer temperature with
the amount of charge of HC refrigerant. It can be observed
from the figure that the minimum freezer temperature is
obtained for 70 g amount of charge of the HC refrigerant.
Hence it can be concluded that 70 g charge is the optimal
amount of charge on which we are getting lowest freezer
temperature.

TABLE III FINAL AVERAGE FREEZER

TEMPERATURE AT DIFFERENT AMBIENT
TEMPERATURES
Fig. 7 Effect of charge on freezer temperature
Ambient temperature Final average freezer
(ºC) temperature (ºC)
16.5 -23.1
20 -22.2
26 -19.7

Fig.8 shows below the variation of discharge temperature

with the amount of charge of hydrocarbon refrigerant. It is
evident from the figure that the maximum discharge
temperature is obtained at a charge of 70 g of HC
refrigerant. This result is in exact agreement with the one
reported in the literature[37].
Based on these results, it was determined that the HC
refrigerant was suitable in this R12 refrigerator without
replacing parts or making appropriate adjustments.
However, there are also some researchers who
demonstrated replacements and adjustments are necessary
when using HC refrigerants in R12 refrigerators [13,22- Fig.8. Effect of charge on discharge temperature
24]. The differences with the results of these studies are mainly caused by
differences in compressor characteristics. The vapor
densities of HC refrigerants are much lower than that of
R12; therefore, the different volumetric efficiencies of the
compressor greatly affected the mass flow rate of the HC
refrigerants, causing the pressure to drop in the capillary
tube, which influenced the evaporation temperature of the
refrigerator. Furthermore, HC refrigerants that have low
viscosity also affect the function of a compressor.

III. CONCLUSION
This study analyzed the use of R600a and R290 HC
refrigerants with 50%mixed mass ratio of each and
Fig.6. Effect of charge on COP different charging masses in a small R12 refrigerator to

58
 ADVANCED CONCEPTS IN MECHANICAL ENGINEERING (ACME-2018)
AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD
ISSN 0975 9514
evaluate the refrigeration performance and the feasibility
of using this alternative refrigerant. The results of the no-
load pull-down test indicated that there was no need of
replacing any of the components for operating the
refrigerator normally using the HC refrigerant.
Considering the final average freezer temperature, the
charging mass of the HC refrigerant was determined to be
50% of that of R12.The results indicated that replacing
R12 with HC refrigerant is feasible without modifying the
original system.
ACKNOWLEDGMENT
The authors would like to thank IMS Engineering College,
Ghaziabad for providing the experimental setup for this
research.
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