Experimental investigation of electrical domestic heat pumps equipped with a twin-stage oil-free radial compressor

The world energy consumption has dramatically increased since the end of the World War II. The main share of this energy comes from fossil fuel combustion. The worldwide domestic sector consumes about 30% of the global energy supply and the biggest share of that is dedicated to space and water heating. In this context where sustainable energy consumption is required to limit our impact on the environment and the climate, energy efficiency is a key factor to successfully transition to energy sobriety. Electrically-driven heat pumps are known to be a key technology to increase our energy efficiency. More efficient, more compact, more silent heat pumps, built with less raw material, and using lower refrigerant charges are needed. In electrically-driven heat pumps, the compression process is responsible for most of the energy losses. However, for decades now, the heat pump performance has been stagnating, mainly because of the compression process efficiency which has not been increasing significantly. Consequently, the improvement of the compression process is indeed needed. A new single-stage compression unit design has been developed, built, and tested in a previous thesis work. This current thesis work uses a twin-stage successor of the initial single-stage compression unit and tests it into two oil-free domestic heat pump prototypes. This work aims at studying the integration of the radial compression units in domestic heat pumps and at demonstrating their feasibility and potential. The tested prototypes are a twin-stage Air/Water domestic heat pump and a twin-stage Brine/Water domestic heat pump. Both of them are equipped with a twin-stage oil-free radial compression unit rotating on gas bearings. By which, the maximum rotor speed of the compression units is 180 krpm. Six stable operating points have been documented with the Air/Water heat pump prototype. More notably so, the operating point A-7/W35 has been reached and demonstrates a coefficient of performance of 2.36 for a heating power of 10.7 kW. The Brine/Water heat pump prototype has been used to perform partial tests of circuit improvements, in order to solve some of the issues observed on the Air/Water prototype. The analysis of the experimental results uses a mass and energy balance modeling approach to improve the level of understanding of the internal and non measurable flows in the heat pump circuits. This model also propagates the uncertainties of the measurements through the equations. New improvements and innovative circuit layouts, notably at the level of the economizer, a key-component of the two-stage heat pump circuit, are offered to integrate further the compression unit in the heat pump circuits, and to make the whole system more efficient, more compact, more silent, less demanding in raw materials and reducing the refrigerant charge needed for the heat pump cycle.

Theoretical and Experimental Study of a Thermally Driven Heat Pump Based on a Double Organic Rankine Cycle

Jonathan Demierre

Nowadays, one of the main alternatives for a more rational use of energy in heating applications is the heat pumping technologies. The market is dominated by two kinds of heat pump systems: the electrically driven vapor compression heat pumps (EHP), which are the most widely used in residential heating applications and the thermally driven heat pumps (TDHP), that are usually based on a sorption process. In this thesis, theoretical and experimental investigations of a concept of thermally driven heat pump, based on the coupling of a vapor compression heat pump cycle and an organic Rankine cycle, are presented. The system is named here as ORC-ORC. The studied concept uses a single stage centrifugal compressor directly coupled to a single stage radial inflow turbine. The shaft is rotating on gas bearings, which allows the system to be oil-free. Like most of the other TDHP's, this system has the advantage to work with a variety of fuels or heat sources like wood pellets, natural gas, solar heat, geothermal heat or waste heat. The concept studied in this work is a gas red system for space heating and domestic hot water production in small residential buildings. A systematic approach has been used to evaluate, in term of energy efficiency, the potential of ORC-ORC systems and to propose optimal design specifications at different levels of the design process. The method is based on the optimization which allows to identify the best configurations at each design step with respect to the designer choices. This approach is divided in three steps. In the first step, a model of the complete system has been developed based on a process integration approach. This step allows to quickly determine whether the system is potentially attractive or not, for given conditions, before going deeper in the design process. The results show that, in general, it is advantageous for the ORC evaporation to be supercritical. In the second step, based on the process integration results and heuristic rules, a suitable system heat exchanger network has been generated and modeled. The predicted values of the coefficient of performance (COP) at design conditions, for the different situations, are in the range 1.30 and 2.19. In a last step, the off-design characteristics of the compressor-turbine unit are considered, in order to evaluate the COP as well as the heating capacity range that can be covered with a specific compressor-turbine unit design. For this purpose, a model of the compressor-turbine unit has been developed. Experimental investigations have been carried out with R134a as working fluid. A first simple test rig has been developed to test the selected ORC evaporator in supercritical conditions. The measurements have allowed to calibrate and to validate an in-house supercritical evaporator simulation tool. An ORC-ORC prototype has been developed and built. Commercially available equipment has been used, except for the compressor-turbine unit that has been designed especially for this application. The targeted operating point, with an HP evaporation temperature of 0 °C and a condensing temperature of 35 °C, has not been reached, because of experimental difficulties which caused some delay. A maximum temperature difference of 20 °C between the HP evaporation and the condensation has been achieved, which corresponds to a compressor pressure ratio of 1.9. Measurements have been performed with compressor-turbine unit rotational speeds up to 171 krpm. The theoretical investigations shows that the proposed ORC-ORC concept is an interesting alternative of thermally actuated heating device for small residential buildings. Concerning the experimental investigations, although a number of problems have been encountered during the tests, it has been demonstrated that the proposed concept is feasible with today's technology.

EPFL2012

Modeling and Experimental Investigation of an Oil-Free Microcompressor-Turbine Unit for an Organic Rankine Cycle Driven Heat Pump

Jonathan Demierre, Antonio Rubino, Jürg Alexander Schiffmann

Domestic heating and cooling will more and more have to rely on heat pumps (HPs) in order to support a more rational use of primary energy consumption. The HP market is mainly dominated by electrically driven vapor compression cycles and by thermally driven sorption processes. The drawback of electrically driven vapor compression cycle is their dependence on an electrical grid and the fact that they increase the winter or summer electricity peak demands. Hence, a thermally driven vapor compression cycle would offer substantial advantages and flexibility to the end user for heating and cooling applications. This paper presents the investigation of an oil-free compressor-turbine unit (CTU) used for a thermally driven HP (TDHP) based on the combination of a HP compression cycle and an organic Rankine cycle (ORC). The CTU consists of a radial inflow turbine and a centrifugal compressor of the order of 2 kW each, directly coupled through a shaft supported on gas lubricated bearings. The CTU has been tested at rotor speeds in excess of 200 krpm, reaching compressor and turbine pressure ratios up to 2.8 and 4.4, respectively, and isentropic efficiencies around 70%. Comparisons between the experimental data and predictions of models, that are briefly described here, have been carried out. A sensitivity analysis based on the experimentally validated models shows that tip clearance, for both compressor and turbine, and surface roughness of the compressor are key parameters for further improving performance.

American Society of Mechanical Engineers2015

Potential of refrigerant based district heating and cooling networks

Samuel Henchoz

Urban areas represent an ever increasing challenge in terms of energy use and environmental impact associated with it. Projections from the United Nation expect this number to reach 66% by 2050. In Europe 40% of the final energy consumption and 36% of the emissions of greenhouse gases are caused by buildings. The building sector is also one of the area where there is a great potential of reduction of the greenhouse gases emissions and of the dependence on fossil fuels. Among the measures that can help realise this potential, efficient energy conversion technologies supplying thermal energy services could play an important role. The present thesis aims at demonstrating the potential of a new type of district network, capable of delivering indistinctly cooling and heating services using a two-pipe network and in which the transfer of energy across the network is done by exploiting the evaporation/condensation of a refrigerant. The main research question is: "Is it possible to build and operate safe, reliable, energy efficient and economically profitable district heating and cooling networks that use a refrigerant as a transfer fluid?" The demonstration followsthree axes, the first being a thermoeconomic analysis. Thisanalysis focuses on a test case area in Genevaâs city centre where 5 variants of refrigerant based district heating and cooling networks, one cold water network and the mix of conversion technologies currently in use are compared on the basis of their energy and exergy performances and on the economic profitability. Considerations on economic uncertainty, safety and technical issues are also included in the analysis. The key findings are: â¢ All the variants of network can potentially reduce the final energy consumption of over 80% as compared to the current situation. â¢ All the variants of network have rather similar exergy efficiencies comprised between 39.5% and 45%. â¢ The most profitable variant uses CO2 as a transfer fluid and an open cycle CO2 heat pump at the central plant. It costs initially between 27 and 35 mio â¬ , reaches break-even in 4 to 6 years and the net present value after 40 years is comprised between 40 and 80 mio â¬. â¢ A cold water network is the second best option, although more expensive initially and thus less profitable, it has several advantages in terms of safety and availability of components. â¢ The CO2 variants exhibit a much better compactness than the cold water network. The second axis is the design, construction and testing of a lab scale refrigerant network. First a description of the design process and of the test facility is provided. It is followed by a presentation of the results of the test campaign. The tests aimed at demonstrating the practical feasibility of the concept, mostly by assessing the controllability of the network. Overall the good behaviour of the test facility and its ability to be smoothly and automatically controlled could be demonstrated, which further improved confidence in the practicality of the concept. The third axis is the development of dynamic models of simulation. These models are described in the present manuscript. They include, heat exchangers, pipes, pumps and valves. A short comparison between experimental and simulation results is also provided. The comparison between experiment and simulation showed that at their current stage of development the models cannot simulate accurately enough a refrigerant based network.