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Energy Procedia 109 (2017) 102 – 112

International Conference on Recent Advancement in Air conditioning and Refrigeration

RAAR 2016

Performance of CO2 Trans-Critical Refrigeration System with Work

Recovery Turbine in Indian Context
Dileep Kumar Guptaa*, Mani Shankar Dasguptab
a
Institute of Infrastructure Technology Research And Management, Ahmedabad, India
b
Birla Institute of Technology and Science Pilani, India

Abstract

Carbon Dioxide (CO2) refrigeration system in trans-critical cycle, requires modification to improve the overall performance.
This modification become more prominent when it will be used in tropical regions like India. There are many modifications in the
basic cycles are possible to improve the performance and to adopt the conditions as per requirements and applications. In this
paper, a simulation based study has been carried out to analyze the performance of modified CO2 trans-critical refrigeration
system with work recovery turbine. The paper emphasizes upon design and operating parameters based on local environmental
conditions for the best possible performance.

© 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
© 2016 The Authors. Published by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review by the
Peer-reviewunder scientific conference
responsibility committee
of the organizing of RAAR-2016.
committee of RAAR 2016.

Keywords: work recovery turbine; trans-critical cycle, trans-critical CO2 refrigeration system; modeling and simulation; gas cooler; finned tube
gas cooler

1. Introduction

The harmful environmental effects of normally used refrigerants have produced worldwide concern which have
ensued in to their phase-out in recent years. The ozone depletion effect of refrigerants holding chemicals such as
bromine and chlorine, and their contribution to global warming factors has led to international accords, Montreal
Protocol and Kyoto Protocol, to stop production of refrigerants having harmful effects. Policymakers and

1876-6102 © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of RAAR 2016.
doi:10.1016/j.egypro.2017.03.062
 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112 103

environmentalists inked the Montreal Protocol (1987) and subsequently the London and Copenhagen amendments
(1990, 1992) to abandon the production of CFC (chlorofluorocarbon) by the end of 1995 and HCFC (hydro-
8chlorofluorocarbon) by 2030 due to higher ozone depletion potential (ODP). The HFC (hydro-fluorocarbon)
refrigerants, once considered the most promising long term substitute of CFCs and HCFCs, have also proven to be
harmful due to their high; global warming potential (GWP). Therefore, nowadays the focus of the research shifted
toward the natural refrigerants. It is already established that CO2 is one of the most suitable and viable options as
natural refrigerant. CO2 has favorable thermo physical properties and ecologically safe.

Nomenclature
H Enthalpy (kJ kg-1) Subscript

M Mass flow rate (kg s-1) a Air
P Pressure (Pa) c Compressor

ΔP Pressure Drop i Inner

RE Refrigerating effect (kW or kJ kg-1) r Refrigerant

T Temperature ci compressor inlet

Kisen Isentropic efficiency co compressor outlet

K fan Gas cooler fan efficiency ei evaporator inlet

eo evaporator outlet
gci gas cooler inlet
gco gas cooler outlet

The working of CO2 cycle is different from other conventional refrigerant based subcritical cycles due to its low
critical temperature (31.2 0C) with relatively higher critical pressure (73.8 bar). Subsequently, at normal operating
temperature range, the system needs to operate at high pressure, typically 5-10 times higher than that of
conventional refrigerants. The difficulties concerned with lower critical temperature of CO2 can be successfully
overcome by operating the system in the trans-critical mode, first time introduced by Lorentzen [1- 3] where single-
phase heat rejection occurs above the critical temperature in the gas cooler instead of the condenser as in
conventional systems, and where pressure and temperature can be controlled independently to obtain optimum
performance.

The gas cooler pressure is a persuasive parameter where an increase in gas cooler pressure does not always lower
the COP in a trans-critical cycle unlike in conventional subcritical systems [4]. This can be attributed to the unique
behavioral pattern of CO2 properties around the critical point and beyond, where the slope of the isotherms is quite
uncertain for a specific pressure range; at pressure above and below this range, the isotherms become much steeper
as shown in Figure 1. Increasing the high side pressure increases the COP initially and then starts decreasing
because beyond a certain pressure, increase in compressor work overtakes the gain in refrigeration capacity due to
steep isotherms. Therefore, it is important to operate the system at an optimum pressure, which yields a maximum
COP.
It has also been observed by many researchers [5,6], that the performance of the system becomes more sensitive,
when it is operated in high temperature climatic conditions, and the COP yields drastically decreases with increasing
the operating environmental temperature. Therefore, the design of the gas cooler becomes more crucial to achieve
the best possible performance.
The challenges of using this system in high temperature environment, gas cooler design and optimization of those
design and operating parameter has been reported elsewhere [6, 7]. These works were completely focused on high
environmental temperature (Typical Indian Conditions), the performance of the system is analyzed to find the
optimum design of the gas cooler and operating conditions for a best possible COP of the system. The conservation
equations of heat transfer in gas cooler have been discretized using the finite difference scheme and code is
104 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112

developed in MATLAB® to solve these equations. These code is validated through the published experimental
results [8]. Subsequently these code is extended to solve the complete system and simulation results at different
temperature zones in India conditions are discussed. The detail of the temperature zones and its environmental
temperature ranges are shown in Table 1.
Table 1: Temperature zones and its range of temperature, Gupta et al 2010 [6]

No. of major
Temperature Zones Design Temperature
cities
Zone I 3 <=29.4oC
Zone II 19 > 29.4oC<= 40oC
Zone III 41 > 40oC<= 45oC

There are many changes have taken place towards the development of CO2 trans-critical system. Now researchers
are trying to bring new and more efficient breed of trans-critical CO2 systems by blending old concepts with state of
the art technology. Many modifications are feasible in the basic trans-critical CO2 cycle to improve the performance
and to adopt the conditions as per requirements and applications. A few studies that have reviewed multiple
suggested modifications to improve system performance are [2, 5, 9].
A comparative study on the performance improvement with possible modifications i.e. multi-staging,
internal heat exchanger, expansion turbine, ejector and vortex tube in the system is made by Sarkar (2010) [9]. The
detail improvement in COP and reduction of high side pressures is summarized in Table 2.

Table 2. Improvement in COP and Reduction in optimum operating pressure with modification [9]

Modification COP improvement Reduction in optimum

(%) pressure (%)
IHX 7 2
Work Recovery Turbine 36 6
Two Stage 24 6.5
Ejector 16 3.5
Vortex 9.5 3.2

It was determined that the highest improvement of the trans-critical CO2 vapor compression cycle can be achieved
with a work recovery expansion machine or using multi-staging. It is also reported that the optimum high side
pressure in case of using work recovery turbine or multi-staging is lower compared to that of other modifications.
These are a cost intensive improvement compared to others and more effective at the higher temperature
environment.

In this work, the mathematical model and validated code of the gas cooler for simple system [7] is used and
extended the same for the modified cycle. An extensive study has been made and the best possible combinations of
design and operating parameter have been suggested for the modified system in typical Indian climatic conditions.

2. Mathematical Model

The mathematical model for gas cooler design are published elsewhere by Gupta and Dasgupta [7], have been
extended and solved using the MATLAB® code. The modified schematic P-h diagram of the system is shown in
Fig.1. The mathematical model of gas cooler for a simple system was developed and validated. The same model has
been extended for the performance of the overall system, including fan power consumption and utilized in exploring
the application of work recovery turbine.
 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112 105

Fig. 1. (a) Schematic Diagram (b) P-h Diagram [10]

Using the updated model, the refrigeration capacity in kW, compressor work in kW, and COP of the overall system
is computed. The model is represented mathematically in Eq. (1) to Eq. (5). Fan power consumption is calculated
assuming 90% fan efficiency using Eq. (3). The following assumptions are made during modelling of gas cooler;
a) Flow and heat transfer are one dimensional steady state
b) Heat conduction along pipe axis and within fin are negligible
c) Homogeneous distribution of air
d) Contact resistance at the joint of the fin and pipe wall are negligible
e) Refrigerant is in thermal equilibrium at each point.
Subsequently, it is assumed for overall system modelling that, All processes are steady state, and Heat loss or gain
between the pipelines of two components are neglected, i.e. compressor outlet is entrance of gas cooler, similarly for
work recovery turbine and compressor.
The net compressor work in modified system is calculated as the difference of compressor and turbine work. The set
equations are;
ሼୌ౨ౙ౥ ሺ୔ౙ౥ ǡ୘ౙ౥ ሻିୌ౨ౙ౟ ሽ
ୡ୭୫୮ ൌ  (1)
஗౟౩౛౤

ܴ‫ ܧ‬ൌ  ሼ‫ܪ‬௥௘௢ െ ‫ܪ‬௥௘௜ ሺܲ௘௜ ǡ ܶ௘௜ ሻሽ (2)

ொೡሶ ௱௉ೌ೔ೝ
ܹ௙௔௡ ൌ  (3)
ఎ೑ೌ೙

்ܹ௨௥௕௜௡௘ ൌ  ሼ‫ܪ‬௥௖௢ ሺܲ௖௢ ǡ ܶ௖௢ ሻ െ  ‫ܪ‬௥௘௜ ሺܲ௘௜ ǡ ܶ௘௜ ሻሽߟ௜௦௘௡ǡ் (4)

൛ୌ౨౛౥ Ǧୌ౨౛౟ ሺ୔౛౟ ǡ୘౛౟ ሻൟ
 ൌ ൛ౄ౨ౙ౥ሺౌౙ౥ ǡ౐ౙ౥ ሻǦౄ ሶ (5)
౨ౙ౟ ൟା్౬ ౴ౌ౗౟౨ Ǧ൛ୌ
ಏ౟౩౛౤ ಏ౜౗౤ ౨ౙ౥ ሺ୔ౙ౥ ǡ୘ౙ౥ ሻǦୌ౨౛౟ ሺ୔౛౟ ǡ୘౛౟ ሻൟ஗౟౩౛౤ǡ౐

Where, H is function of P and T, and enthalpy at gas cooler outlet is equal to the enthalpy at evaporator inlet. Using
the above steady state model, performances of the system is analyzed for different operating and geometric
conditions for different temperature zones and selected combinations of the model input parameters.

3. Input Parameters (Geometric and Operating Parameters)

In modified cycle the expansion device of the conventional trans-critical cycle has been replaced by the work
recovery turbine. The power generated by the turbine will be utilize to reduce the power consumption in
compressor. The modified cycle and the possible component schematic diagram is shown in figure.
106 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112

Table 3. Modified operating conditions and simulation parameters for optimization

Operating Air
3 pass
Parameters Pressure Velocities
(Tubes)
(MPa) (ms-1)
7.5
1 54
8
Zone I 1.5 45
8.5
2
9
9.5 1
10 1.5 54
Zone II
10.5 2 45
11
11
1 54
11.5
Zone III 1.5 45
12
2
12.5

1 12 1 11
13 10
11 2 12
2 14 9
10 13
3 15 3 8
CO2 9 14
4 16 CO2 4 7
Inlet 8 Inlet 15
17 5 6
5
7 18
6 CO2
Air
Outlet
12 Inlet
13 1 11
1 10
11 14 12
2 2 9
10 15 13
Air 3 9 Air 3 8
Outlet
16 Outlet 14
4 8 4 7
17 Air 15
5 7 18
Inlet 5 6
6
CO2
1 13 11
Outlet
12 1
14 10
2 11 2 12
15 9
3 10 13
3 8
16 14
4 9 4
17 7
8 15
5 18 5 6
6 7

3-Circuit
3-Circuit
Three Pass (48 Tubes)
Three Pass (54 Tubes)
(b)
(a)

Fig. 2. Gas cooler circuit arrangement diagram

As gas cooler is the most crucial component of the cycle the study is more focused on the combination of design and
operating parameters of gas cooler, further it is extended to complete cycle for finding the max yield of the COP
with optimum conditions.
 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112 107

The design and geometric arrangement of the gas cooler selected for the modified system as shown in and the
study is extended for one step lower operating pressure than the optimum condition obtained for the simple
cycle [7] to accommodate the use of work recovery turbine as expansion device. This due to the fact that the
operating pressure reduces when the system is used to work recovery turbine [9]. Circuit design of gas coolers
is shown in Fig.2, and refined combinations of design and operating parameters for each temperature zones are
summarized in Table 3. Which is taken from the published work elsewhere by Gupta and Dasgupta [7], it is
completely based on the ranges found during the simulation with higher COP. Pressure drop between
compressor discharge and gas cooler inlet is neglected, evaporator pressure is taken as constant for maintaining 0 oC
evaporator temperature and mass flow rate of refrigerant is taken as 0.045 kg s -1, which is within the validated range.

4. Results and Discussion

The performance of the system is now studied using a validated model and modified extended model. The various
combinations of input parameters are as given in Table 3. The results are shown and discussed subsequently for all
three temperature zones in Indian climatic conditions (assuming isentropic efficiency of 0.6 for compressor and
turbine).
Fig. 3 to Fig. 5 shows the performance of the modified system at temperature zone I, zone II and zone III
respectively. The variation of refrigeration capacity, compressor and COP of the overall system are analyzed at
different operating and gas cooler design conditions. Finally, the percentage improvement of the COP with work
recovery turbine is compared to that without turbine.

4.1. Temperature zone I

Fig. 3 depicts the simulation results at temperature zone I, at variation in air velocity, for different operating
conditions and gas cooler design. Fig. 3 (a) shows the variation of refrigeration capacity, the conditions
where approach temperature is lowest. It has upward trend with air velocity, however, these variations are
insignificant at higher operating pressure. Refrigeration capacity va riations are found to be dependent more
on pressure instead of gas cooler size at each air velocity, further effect of pressure also reduce at higher
operating pressure.

Fig. 3 (b) shows the variation of compressor work, it is observed that compressor wor k mainly depends upon
operating pressure and inadequately depends on air velocities. The work increases with increase in operating
pressure and air velocities. It was discussed [8] that for simple system, compressor work is independent of air
velocity, however in modified system with work recovery turbine, small variation with air velocity is observed.
It is due to the fact that air velocity affects the gas cooler exit conditions which in term affect the turbine
performance.

Fig. 3 (b) shows the variation of compressor work, it is observed that compressor work mainly depends upon
operating pressure and inadequately depends on air velocities. The work increases with increase in operating
pressure and air velocities. It was discussed [8] that for simple system, compressor work is independent of air
velocity, however in modified system with work recovery turbine, small variation with air velocity is observed.
It is due to the fact that air velocity affects the gas cooler exit conditions which in term affect the turbine
performance.
108 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112

Compressor Efficiency = 0.6 Turbine Efficiency = 0.6 Evaporator Temperature = 273.15K

7.5 3.2
Refrigeration Capacity

Compressor Work (kW)

7
3
6.5
6 2.8
(kW)

5.5 2.6
5
4.5 2.4
4 2.2
3.5
2
0.5 1 1.5 2
Air Velocity (ms-1) 0.5 1 1.5 2
Air Velocity (ms-1)
(a) (b)
3.5 COP Improvement (%) 40

3 30
COP

2.5 20

2 10
0.5 1 1.5 2
0.5 1 1.5 2
Air Velocity (ms-1) Air Velocity (ms-1)
(c) (d)

Fig. 3. Performance of gas cooler and overall system with expander expansion at zone I

The collective effect of the above results are plotted as COP of the modified system and its variation is shown in
Fig. 3 (c). It is observed that the COP has significant variation with operating pressure and gas cooler designs
whereas insignificant variation with air velocities. The optimum condition for the best COP at zone I is found to
be with 8MPa operating pressure, 2 ms-1 air velocity and 54 tubes in gas cooler. Further, the percentage
improvement of COP using work recovery turbine for expansion is plotted in Fig 3 (d). The highest improvement
is found to be 37.78% at lower air velocity (1 ms-1) and lower operating pressures (7.5MPa), however the
maximum COP is not achieved at that condition. It is due to the fact that work produced by the turbine also
depends on operating pressure. Therefore, while selecting the operating condition and design of gas cooler, the
maximum COP condition will be preferred where the improvement is 17.8%.

4.2. Temperature zone II

Fig. (4), Shows the simulation results at temperature zone II (i.e. ambient temperature 40oC) with air velocity for
different operating conditions and gas cooler design. Fig. 4 (a) and Fig. 4 (b) show the variation of refrigeration
capacity and net compressor work with air velocities and operating condition with various gas cooler design. Trends
of these parameter variations are similar to zone I, however in zone II refrigeration capacity values are lower and net
compressor work are higher, at the respective simulation conditions.
Fig. 4 (c) shows the variation of the COP with air velocities and operating condition with various gas cooler designs.
It is observed that there are substantial variation of COP with air velocity and slightly rutted trends are observed
with different operating and design conditions of gas cooler. The maximum yield of COP is found at operating
pressure 10.5MPa, air velocity 1.5 ms-1 and gas cooler with 54 tubes.
 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112 109

Compressor Efficiency = 0.6 Turbine Efficiency = 0.6 Evaporator Temperature = 273.15K

3.5
6.5

Compresssor Work (kW)

Refrigeration Capacity

6
3
(kW)

5.5

2.5
5

4.5
0.5 1 1.5 2
2
Air Velocity (ms-1) 0.5 1 1.5 2
Air Velocity (ms-1)
(a) (b)
2 40

COP Improvment (%)

1.95
30
COP

1.9
20
1.85

10
1.8 0.5 1 1.5 2
0.5 1 1.5 2
Air Velocity (ms-1)
Air Velocity (ms-1)
(c) (d)
Fig. 4. Performance of gas cooler and overall system with expander expansion at zone II

Further the COP improvements using work recovery turbine are plotted in Fig. 4(d), it is found that the maximum
COP improvement achieved (i.e. 32.95%) at lower pressure 9.5MPa and velocity 1 ms-1 with 54 tubes of gas cooler,
however maximum COP condition is different where the improvement is 25.26%. Therefore for maximum COP
condition is to be adopted even improvement rate is slightly lower than maximum.
Comparing with results from zone I and zone II, it is observed that the maximum improvement at zone I is higher
than zone II. However, the improvement rate with optimum condition is more in zone II. Hence use of work
recovery turbine as expansion device will be more effective at higher temperature zone.

4.3. Temperature zone III

Fig. (5) Shows the simulation results at temperature zone III (i.e. ambient temperature 45oC) with air velocity for
different operating conditions and gas cooler design. Fig. 5(a) and Fig. 5(b) shows the similar variation in trends,
for, refrigeration capacity, and the net compressor work respectively. The cumulative effect of these parameters are
plotted in Fig. 5(c) as variation of overall COP system at zone III. It is observed that the COP has comparatively less
variations with different conditions and maximum COP is achieved at operating pressure 11.5MPa, air velocity
1 ms-1 with 54 tubes in gas cooler.
110 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112

Compressor Efficiency = 0.6 Turbine Efficiency = 0.6 Evaporator Temperature = 273.15K

6
3.6
Refrigeration Capacity (kW)

Compressor Work (kW)

5.8
3.4
5.6
3.2
5.4
3
5.2
2.8
5
0.5 1 1.5 2
0.5 1 1.5 2
Air Velocity (ms-1)
Air Velocity (ms-1)
(a) (b)
1.75
35

1.7 COP Improvement 30

COP

(%)

1.65 25

20
1.6
0.5 1 1.5 2
0.5 1 1.5 2
Air Velocity (ms-1)
Air Velocity (ms-1)
(c) (d)

Fig. 5. Performance of gas cooler and overall system with expander expansion at zone III

Fig. 5 (d) shows the variation in COP improvement, it is found that maximum COP improvement (i.e. 31.10%) occurs at
lower pressure and velocity conditions. However, at the optimum condition the COP improvement is 28.13%, therefore
the optimum condition should be adopted as maximum COP achieved on this condition. The percentage improvement in
COP achieved in this zone is higher as compared to zone I and zone II.

From the above discussion of simulation results, it is established that by using work recovery turbine, the COP of
the system improves significantly. The maximum improvement among all temperature zones are found to be for a
combination of lower operating pressure and lower temperature zone. However, with optimum operating conditions,
COP improvement is higher at higher temperature zones. These modifications of the system, reduce the optimum
operating pressure, which is more prominent at higher temperature zones.

5. Conclusions:

A summary of the results for modified system is shown in Fig. (6), it was found that the system using work recovery
device shows significant improvement as compared to the system without turbine. It is observed that the rate of
improvements is more significant at zone III compared to lower zones I & II.
 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112 111

3.5 30

3 25

COP Improvemnet %
2.5
20
2

COP
15
1.5
Without Expander 10
1
With Expander
0.5 5
COP Improvement
0 0
Zone I Zone II Zone III
Temperature Zones

Fig. 6. Performance of overall system at different zones

3.5

45
Zone I

20 25 30 35 40
Zone II
3 COP Improvement (%) Zone III
Zone I
2.5 Zone II
Zone III
2
COP

1.5
15

1 0.55 0.6 0.65 0.7 0.75 0.8

No. 0.6 0.7 0.8
Expander Expander isentropic Efficiency
Expander Isentropic Efficiency

Fig. 7. Comparison of COP with modified System Fig. 8. COP Improvement with modified System

It is also observed that the optimum operating pressure was slightly lower, especially at zone II and III, as compare
to the system without modification. It is also concluded the use of highly efficient expander may further increase the
performance of the system. The COP and its improvement are plotted with different value of isentropic efficiency of
the expander, shown in Fig. (7) and Fig. (8). from the study that using work recovery turbine; significant
improvements are attainable (18-35% in zone I, 25-36% in zone II, and 28-39% in zone III) as compared to the
system without turbine. The rate of improvements is more significant at temperature zone II and zone III as
compared to zone I, it is due to fact that higher operating pressure leads to have more opportunity of work recovery.

Acknowledgements

Authors will like to acknowledge partial financial support received from the BITS Pilani, India and Government of
India under research grant No. DST/TSG/NTS/2012/19-G.
112 Dileep Kumar Gupta and Mani Shankar Dasgupta / Energy Procedia 109 (2017) 102 – 112

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