Parametric Evaluation of the Flow Boiling Heat Transfer Properties of R22 and R407c inside Horizontal Microfin Tube

Deb, Sandipan; Vidhyarthi, Neeraj Kumar; Pal, Sagnik; Das, Ajoy Kumar; Barik, Debabrata

doi:https://doi.org/10.1155/2023/8882662

International Journal of Energy Research

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Abstract Introduction Results and Discussion Conclusion Abbreviations Data Availability Conflicts of Interest Acknowledgments References Copyright Related Articles

Research Article | Open Access

Volume 2023 | Article ID 8882662 | https://doi.org/10.1155/2023/8882662

Parametric Evaluation of the Flow Boiling Heat Transfer Properties of R22 and R407c inside Horizontal Microfin Tube

Sandipan Deb,¹Neeraj Kumar Vidhyarthi,¹Sagnik Pal,¹Ajoy Kumar Das,¹and Debabrata Barik²

Academic Editor: Nagaraj Nandihalli

Received13 Apr 2023

Revised08 Jun 2023

Accepted13 Jun 2023

Published21 Jun 2023

Abstract

The flow boiling heat transfer performance of R22 and R407c, in a microfin tube with a helix angle of 22° and an apex angle of 48°, was evaluated in a study. The study is aimed at investigating the impact of heat flux, mass flux, saturation temperature, and vapor quality on the heat transfer coefficient during flow boiling. Two different saturation temperatures, 293.15 K and 313.15 K, were used in the experiments, with heat fluxes ranging from 25 to 85 kW.m^-2 and mass fluxes ranging from 150 to 350 kg.m^-2.s^-1. To validate the experimental data, the results were compared with existing correlations for microfin tubes. The calculated error margin among all correlations with the experimental dataset, which ±15% and ±30%, was also matched by 85% and 95% of the datasets, respectively. Findings reveal that at lower saturation temperatures, the average heat transfer coefficients augmented with increasing mass flux. The study also found that R22 has a higher heat transfer coefficient than R407c at low saturation temperatures due to its stronger thermal conductivity and lower viscosity.

1. Introduction

Any refrigeration or air conditioning system is not complete without refrigerant as an essential component. The qualities of the refrigerant that is being utilized are a critical factor in determining how efficient the refrigeration process or cooling impact will be [1–3]. Before employing any kind of refrigerant, it is necessary to have a solid understanding of its qualities, which include thermophysical properties, environmental properties, and safety considerations. Several studies addressed refrigerant effectiveness characteristics [1–3] [4–6]. One of the pure refrigerants, chlorodifluoromethane (R22), is still utilized in many industrial systems. R407c, as a replacement refrigerant, has gained popularity due to its efficiency and environmental friendliness [7]. Due to its outstanding refrigeration qualities, R22 was launched in the 1930s and widely utilized. Nowadays, R22 has bad environmental impacts. It depletes the ozone layer, which shields the earth from damaging UV radiation, as a class I ozone-depleting chemical [8]. The Montreal Protocol, which seeks to eliminate ozone-depleting compounds, restricts R22 use in several nations due to environmental concerns [9]. R407c and other ozone-safe refrigerants are in demand. R407c is a greener alternative to R22 since it does not damage the ozone layer or cause low global warming [10]. R407c has comparable efficiency to R22, nevertheless with minor changes [11]. R407c can be employed in lower-temperature systems since its critical temperature is somewhat lower. Microfin tubes are commonly used in heat exchangers for improved heat transfer efficiency [12]. Heating, ventilation, and air-conditioning (HVAC) systems often employ microfin tubes in evaporators and condensers to optimize heat transfer and improve system performance [13]. Microfin tubes are utilized in automotive radiators to enhance cooling performance. In the aerospace industry, microfin tubes are employed in heat exchangers for applications such as aircraft engine cooling and cabin temperature control. Microfin tubes can be utilized in power plant heat exchangers, including condensers and boilers, to enhance heat transfer efficiency and optimize power generation processes. The microfin tube technique is applied in electronic cooling systems to dissipate heat generated by electronic components. Microfin tubes can be employed in solar thermal systems, such as solar water heaters, to enhance the absorption and transfer of solar energy. Various process industries, including chemical, pharmaceutical, and food processing, can benefit from the microfin tube technique [14].

Numerous investigations were conducted on the heat transfer coefficients (HTC) of R22 and R407c. In one study, Shaik and Babu [15] analyzed the effect of heat flux (HF) as well as saturation temperature mostly on heat transfer coefficients (HTCs) of R22 and R407c in a straight plain tube. Kumar et al. [16] investigated the effect of tube diameter and helix angle on flow boiling heat transfer (FBHT) of R407c inside a horizontally enhanced tube. In accordance with the research, the HTC of R407c increased as the tube diameter and helix angle decreased. Deb et al. [17] investigated the influence of HF and mass flux (MF) on the FBHT of R407c in a horizontally enhanced tube. According to their study, the HTC increased with increasing HF and MF, but the effect of HF was greater than that of MF. In a comparable investigation, Jige and Inoue [18] investigated their FBHT parameters for R32 in a horizontal microfin tube. The experiment was conducted at a saturation temperature of 15°C, MF of 50 to 400 kg.m^-2 s^-1, HF of 2.5, 5, 10, and 20 kW.m^-2, ID of 2.1, 2.6, and 3.1 mm, and vapor quality of 10% to 90%. The study revealed that the HTC increased with HF and MF at low vapor quality. However, as the quality of the vapor improved, the effects of HF and MF on HTC were less significant. Sun et al. [19] studied the FBHT properties of horizontal smooth, microfin, and 3D-improved R410a tubes. The experimental conditions were , , and . The study discovered that HTC increased with an increase in MF and a significant form of action. Furthermore, the HTC of a microfin was consistently superior to those of any other type of tube, including those with extremely large external diameters. Wu et al. [20] conducted FBHT studies using R1234ze(E)/R152a in a horizontal microfin tube with a 9.52 mm d_o. With raising HF and saturation temperature, under fixed working circumstances, their study discovered that HTCs increased. The saturation temperature had less of an impact on the HTCs than HF did, and the HTCs rose thereafter and reduced with rising MF. Li et al. [21] investigated the effect of tube width and HF on the FBHT of R410a within a horizontal microfin tube. The research found that the HTC increases as the HF and tube diameter increase. Sharar and Bar-Cohen [22] provided an overview of a physics-based model for the HTC. The flow regime data were collected using dynamic total internal reflection measurements, whereas the HTC data were collected using infrared thermography. The aforementioned information pertains to an analysis conducted on HFE-7100 flow in internally enhanced tubes having ID of 8.84 mm, where the MF ranged from 25 to 300 kg.m^-2 s^-1, HF ranged from 0 to 56 kW.m^-2, and the vapor quality was almost 100%. In a separate study, Diani and Rossetto [23] examined R134a in a microfin tube, with experimental conditions consisting of , to 940 kg.m^-2 s^-1, to 50 kW.m^-2, to 99%, and . The results showed that at low vapor quality, the HTC increases with HF and MF. However, as the vapor quality improves, the impact of HF and MF on HTC becomes less significant. At kg.m^-2 s^-1, they also discovered that the HTC with a high vapor quality value was three times more than the HTC with a poor vapor quality value. Kim [24] explored the FBHT characteristics of R410A in a horizontally enhanced and smooth tube. According to the investigation, the R410A HTC in the redesigned tube performed better than the smooth tube. Boosted heat transfer (HT) is the result of an increase in surface area and the generation of turbulence. He et al. [12] investigated the HT efficacy of R290 and R32 throughout plain and microfin tubes. The experimental conditions were , 9, and 11°C, to 260 kg.m^-2 s^-1, to 30 kW.m^-2, mm (microfin tube), and mm (smooth tube). They discovered a mixture with a very high HTC for practical uses, which rose with rising saturation temperatures and was 14% to 69% higher than R410a. Zhang et al. [25] analyzed the FBHT of R417A through a tube with a helical screw insert. According to the study, the helical screw attachment increased the HTC of the R417A by 52% compared to the plain tube. Kedzierski and Park [26] evaluated local convective boiling for R134a, R1234yf/R134a (56/44% mass), and R1234ze(E). R134a’s HT performance was superior to that of low-GWP refrigerants due to its superior thermal conductivity. For levels less than 30%, the HTC for R1234yf/R134a was within 5% of that of R134a, making them essentially equivalent. With qualities of more than 30%, R1234ze(E) has an HTC of approximately 700 kW.m^-2 K^-1 lower than R134a. In a study conducted by Onan et al. [27], they investigated the FBHT characteristics of R404A within a horizontally oriented tube that had internal ribbing. The study compared the performance of evaporators that utilized grooved tubes versus those that used smooth tubes. The results showed that the evaporators with internally grooved tubes had a 30% higher capacity than the smooth tube evaporators. Even so, amidst the larger capacity, the HTC of the finned tubes was lower, most likely because the finned tube’s internal surface area was 68% higher compared to a plain tube. Overall, the study demonstrated the potential benefits of using internally grooved tubes in evaporator systems. Kuo and Wang [28] and Jung et al. [29] used microfin tubes to study HTC and pressure loss for R22 and R407c. To heat the refrigerant, a network of hot water-carrying pipes was used. R407c HTC and pressure decrease were both less than R22. Lallemand et al. [30] studied the HT during the evaporation of R22 and R407c. The results demonstrated that the HTC of R407c inside smooth and microfin tubes was 15 to 35% lower than R22, respectively, and that the most effective augmentation was achieved at low HF and MF. Local R407c and R410A HTC and pressure loss were studied by Wellsandt and Vamling [31]. The effect of HF on HTC was negligible at low vapor quality levels but grew considerably at vapor quality levels of over 60%. Passos et al. investigated R407c convective boiling and fluctuating pressure drop [32]. Comparing the plane tube to microfin tube revealed that dry out occurred at a greater vapor quality in the plane tube. Rollmann and Spindler [33] discovered a novel relationship between the Nusselt number and R407c flow boiling in a horizontal microfin tube. Because oil becomes immiscible, convective boiling is enhanced as a result of increased vapor quality. Targanski and Cieslinski [34] evaluated single R407c and mixed R407c with oil in long horizontal smooth, microfin, and conjugated tube configurations. HT was decreased by heating R407c in a smooth tube that has the same MF hysteresis as a microfin or corrugated tube.

The performance of a microfin tube is investigated in this study, with different refrigerants and design parameters being analyzed. The microfin tube, which has a helix angle of 22° and an apex angle of 48°, is used with two refrigerants, R407c and R22. The impact on the tube’s performance such as HTC is measured by varying the HF, MF, saturation temperature, and vapor quality. Table 1 includes the thermophysical properties and environmental considerations of R22 and R407c being used in the present investigation. REFPROP 10.0 [35] has been used for determining the thermophysical property of refrigerants.

The remaining part of the whole paper is structured as follows: in Section 2, the experimental setup and procedures are introduced; in Section 3, the data processing and uncertainties are elaborated; in Section 4, the results and the discussion are explained; and, finally, a brief conclusion is summarised in Section 5.

2. Experimental Setup and Procedures

A setup was arranged to investigate the HT phenomena occurring within a horizontally oriented microfin tube with a trapezoidal structure during the flow boiling of R22 and R407c, as shown in Figure 1. Deb et al. [37] describe the experimental methodology and procedures in detail.

(a)

(b)

The refrigerant’s vapor quality was kept constant during the performance test. By keeping a constant rate of water flow and input temperature, the refrigerant’s vapor quality was calculated. The temperature of the heating water and temperatures at various locations along the microfin tube’s length are measured using the measuring devices. The cross-sectional view of the testing tube and the main geometrical dimensions of the microfin tube, including the ID and ODs, length of the tube, apex and helix angle, and fin height, are shown in Figure 2. The 1000 mm-long evaporator test section is composed of copper and has an enhanced microfin tube with an OD of 9.52 mm and an ID of 8.52 mm. The various technical requirements for the upgraded evaporator testing are summarized in Table 2. The temperature of the refrigerant is estimated using T-type thermocouples at each of the 10 locations on the specimen, as well as at the inlet and output. Testing input parameters ranges are provided in Table 3.

3. Data Reduction and Uncertainties

The data reduction techniques used in the present investigation were extensively discussed by Deb et al. [37]. Equation (1) can be used to calculate the local HTC at each measurement section. where

By extrapolating the measured inlet and exit temperatures of R407c, is calculated in Equation (1) and is provided in

Equation (4) was used to obtain the average HTCs from all of the local HTCs. For each measurement portion, is the local HTC, and is the total number of measured sections.

The involved experimental uncertainty can be calculated by utilizing Schultz and Cole’s [38] equation as given

The experimental uncertainties involved with quantitative variables and estimated variables are provided in Table 4.

4. Results and Discussion

In this section, we present the empirical findings on the HTC obtained from flow boiling of refrigerants R22 and R407c in a horizontally oriented microfin tube. The experiments were conducted at different inlet saturation temperatures (293.15 and 313.15 K) and with varying MF ranging from 150 to 350 kg.m^-2.s^-1 and HF ranging from 25 to 85 kW.m^-2. Refrigerants are required for the proper functioning of HVACR systems. The increasing environmental consciousness led to a shift towards the adoption of environmentally sustainable refrigerants. R22 was a widely utilized refrigerant in the past; however, due to its detrimental impact on the environment, it was discontinued. R407c serves as a substitute for R22. The HTC is an essential factor that characterizes the effectiveness of HT between a refrigerant and a heat exchanger. The influence of mass flow on the HTC is a critical aspect to consider when designing efficient heat exchangers for refrigeration applications.

The comparison of the R22 and R407c based on HTC and MF is an intriguing study topic. Figures 3 and 4 depict the effect of MF and HF on the HTC for various HFs and saturation temperatures. R22 has a higher HTC than R407c, as shown by the figures comparing the HTC at various MF and HF levels. When the temperature differential between the refrigerant and the HT surface increases, the HTCs rise, resulting in a more effective HT. In the case of R22 and R407c, a study of HTCs at various saturation temperatures reveals that R22 has greater HTCs than R407c, particularly at low saturation temperatures. The aforementioned result can be reached through an assessment of the physical and thermodynamic properties of the two refrigerants, as outlined in Table 1. In addition, R22 has a greater HTC at low saturation temperatures compared to R407c. Because of its higher thermal conductivity and lower viscosity, R22 has a higher HTC at lower temperatures than R407c. At low saturation temperatures, R407c tends to create a thin coating on the test evaporator surface, hence lowering its HTC [28–30]. R22 is more thermally conductive and less viscous than R407c. The thermal conductivity of refrigerant measures its capacity to transfer heat, and the lower its viscosity, the more easily it flows through the heat exchanger tubes. R22 can transfer heat via the heat exchanger more efficiently than R407c, and its lower viscosity allows it to flow through the tubes more readily due to these characteristics. In addition, R22 has a greater boiling point than R407c. The temperature at which a refrigerant transforms from a liquid to a gas is known as its boiling point [14–17, 31, 34].

(a)

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(a)

(b)

(c)

(d)

(e)

(f)

Figure 5 illustrates the effect of increasing vapor quality on the HTC for various MFs and saturation temperatures. Depending on the flow pattern, the HTC is affected differentially by the vapor quality. Stratified flow and annular flow are two frequent flow patterns seen in heat exchangers. When a clear separation exists between the liquid and vapor phases and the liquid moves along the channel’s lower section while the vapor moves along the upper section, the resulting flow is called stratified. Conversely, in annular flow, a thin film of liquid forms on the inner wall of the channel, and the vapor flows through the central region of the channel. In stratified flow, the HTC rises with increasing vapor quality, up to a point. This is because the vapor phase transfers heat more efficiently than the liquid phase. Nevertheless, above a certain level of vapor quality, the HTC begins to decline because the liquid phase becomes too thin, and the HT area is diminished [28–32]. Further, in annular flow, the HTC initially increases as the vapor quality rises, as the thin coating of liquid on the wall is heated by the hot vapor circulating in the center, hence enhancing HT. Unfortunately, beyond a certain level of vapor quality, the liquid coating becomes too thin and the HTC begins to decline due to drying out. Dry-out is the process that happens when the liquid layer on a wall entirely evaporates, leaving behind just vapor and reducing the HT area. Specifically, the maximum enhancement of HTC compared to a saturation temperature of 313.15 K is about 15% more at a saturation temperature of 293.15 K with refrigerant R407c and 17% more with R22. Additionally, R407c has 17% less HTC value than R22. R407c is still an effective refrigerant that can deliver appropriate cooling performance in a broad range of applications [33, 37, 39, 40].

(a)

(b)

(c)

(d)

(e)

(f)

Figure 6 illustrates a comparison between experimental results and established correlations for flow boiling in microfin tubes. These tubes are widely used in the HVACR and automotive industries for heat exchangers and are in high demand globally. It is essential to consider the flow boiling HTC as a critical leading parameter when constructing an evaporator. To accomplish the same objective, it is necessary to compare the experimental dataset for microfin tubes to widely recognized correlations, such as Shah [41] and Kew and Cornwell [42]. A better agreement may be provided by the correlation of Kew and Cornwell [42]. The calculated error margin among all correlations with the experimental dataset, which ±15% and ±30%, was also matched by 85% and 95% of the datasets, respectively.

(a)

(b)

(c)

(d)

The ratio of HTCs between theoretical results and experimental data is depicted in Figures 6(b) and 6(d), respectively, and is shown to be a function of the quality of the vapor. This particular sort of graph gives us the ability to understand the results across the entire spectrum of vapor quality. The section of the base model with the lowest vapor quality rating is the one that most clearly demonstrates an improvement brought about by the improved model. Shah [41] developed a model that significantly underestimated the data from this region, whereas Kew and Cornwell [42] developed a model where the ratio tends to be closer to one.

5. Conclusion

(i)To assess the FBHT characteristics of R22c and R407 inside a horizontal microfin tube, experiments were carried out to ascertain the characteristics. The total investigations were carried out at a saturation temperature of 293.15 and 313.15 K, heat flux of 25, 45, 65, and 85 kW.m^-2, and 15 to 250 kg.m^-2.s^-1 of MF(ii)To validate the experimental dataset, a comparison was made between the estimated values of a wide range of previously known correlations for microfin tubes. The calculated error margin of 15% and 30% for all correlations with the experimental dataset was also matched by 85% and 95% of the dataset, respectively(iii)Despite the significant difference in flow boiling average HTCs between 293.15 K and 313.15 K under similar boiling conditions, the former still outperforms the latter. The observed phenomenon can be attributed to the combined effects of lower wall shear stress and gas-liquid interfacial tension. As the MF increases, the average HTCs also show an upward trend. To enhance the average HTCs further, one approach is to incorporate micropores and microgrooves into the evaporator test tube, which can create additional nucleation sites and promote interactions between liquid thin films. This can potentially result in significant improvements in heat transfer performance(iv)This is the case because the micropores and microgroves are embedded within the surface of the evaporator test tube. This causes an increase in the surface area that is available for HT while simultaneously optimizing the turbulence that occurs at the interface between the two fluids. An investigation of the HTCs of R22 and R407c at a range of saturation temperatures finds that R22 has higher HTCs than R407c, particularly at low saturation temperatures. This is the case regardless of the saturation temperature(v)This result was reached after analyzing the physical and thermodynamic properties of the two refrigerants listed in Table 1. In addition to this, in comparison to R407c, R22 possesses a higher HTC at lower saturation temperatures. R22 has a better HTC at lower temperatures than R407c does because of its stronger thermal conductivity and lower viscosity(vi)The maximum enhancement of HTC compared to a saturation temperature of 313.15 K is about 15% more at a saturation temperature of 293.15 K with refrigerant R407c and 17% more with R22. Additionally, R407c has 17% less HTC value than R22

Abbreviations

ASHRAE:	American Society of Heating, Refrigerating and Air-Conditioning Engineers
FBHT:	Flow boiling heat transfer
GWP:	Global warming potential
HF:	Heat flux
HTC:	Heat transfer coefficient
HT:	Heat transfer
ID:	Inner diameter
MF:	Mass flux
OD:	Outer diameter
ODP:	Ozone depletion potential.

Nomenclature

:	Specific heat at constant pressure (kJ.kg^-1.K^-1)
:	Diameter (mm)
:	Mass flux (kg.m^-2 s^-1)
:	Heat transfer coefficient (kW.m^-2 K^-1)
:	Fin height (mm)
:	Latent heat of vaporization (kJ.kg^-1)
:	Thermal conductivity (kW.m^-1 K^-1)
:	Length (mm)
:	Molecular mass (kg.kmol^-1)
:	Fin number
:	Pressure (kPa)
:	Heat flux (kW.m^-2)
:	Temperature (K)
:	Vapor quality.

Greek Letters

:	Apex angle (^o)
:	Helix angle (^o)
:	Dynamic viscosity (μPa.s^-1)
:	Density (kg.m^-3)
:	Surface tension (mN.m^-1).

Subscripts

avg:	Average
crit:	Critical
i:	Inner
l:	Liquid
_o:	Outer
sat:	Saturation.

Data Availability

The data is available in the manuscript.

Conflicts of Interest

The authors declare that they have no conflict of interest.

Acknowledgments

The authors sincerely thank Karpagam Academy of Higher Education (KAHE), Coimbatore, India, and National Institute of Technology, Agartala, Barjala, Jirania, Tripura, India, for providing the necessary facilities to carry out the research.

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Copyright © 2023 Sandipan Deb et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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