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Applied Thermal Engineering 67 (2014) 335e340

Contents lists available at ScienceDirect

Applied Thermal Engineering


journal homepage: www.elsevier.com/locate/apthermeng

The effect of selecting proper refrigeration cycle components on


optimizing energy consumption of the household refrigerators
Fatemeh Ghadiri*, Mehdi Rasti
Entekhab Industrial Group, Iran

h i g h l i g h t s

 23.6% energy consumption reduction of refrigerator by hot-wall condenser removal.


 19.3% R134a refrigerant charge amount reduction of refrigerator cycle.
 Reduction of the production cost by eliminating of nearly 10 m of pipe.

a r t i c l e i n f o a b s t r a c t

Article history: This paper presents experimental results of hot-wall condenser removal, condenser air cooling incre-
Received 21 September 2013 ment, capillary tube diameter effect, compressor cooling capacity effect, changes of R134a charge amount
Accepted 12 March 2014 and ambient temperature effect on a commercial bottom mounted freezer to decrease energy con-
Available online 26 March 2014
sumption and production cost. Experiments were carried out on a 418 L dual evaporator domestic
bottom mounted freezer using 155 g R134a as the refrigerant. As a result, the improvement of refrig-
Keywords:
erator energy consumption was studied experimentally. Investigations made under controlled conditions
Domestic Refrigerator
have shown that the more the heat removed from the condenser, the higher the efficiency can be. Data
Hot-wall condenser
Energy efficiency
were provided under the standard conditions for evaluating energy consumption and efficiency of re-
Capillary tube diameter frigerators. Results showed that by hot-wall condenser removal, condenser air cooling increment and
Compressor cooling capacity decreasing compressor cooling capacity, energy consumption and refrigerant charge amount reduced by
23.6% and 19.3%, respectively.
Ó 2014 Elsevier Ltd. All rights reserved.

1. Introduction impact on the future of electricity consumption [4]. Recently,


several researchers focused on different operating factors such as
Refrigerator-freezer is a major household appliance designed for ambient temperature, refrigerant type ant etc. which influence the
preserving foods through refrigerating and freezing. The mechan- energy consumption of domestic refrigerators [5e7].
ical system used for this aim is a vapor compression refrigeration One of the critical zones of domestic refrigerators is located
system, which usually consists of a compressor, a condenser, an around the compressor section, which has relatively high temper-
evaporator, and an expansion device. With increasing market de- atures, due to running compressor and rejecting heat of condenser.
mand for saving energy in household appliances, research and This means more energy consumption. One way to decrease this
development of an energy-efficient refrigeration system has temperature is to ventilate that section of the refrigerator with a
attracted many investigators [1,2]. Refrigerator-freezers contribute small fan [8]. Many domestic refrigerators use wire-and-tube
to approximately 7.2% of the average U.S. household energy con- condensers as a heat exchanger to give off the heat absorbed by
sumption [3]. Therefore, reducing their energy consumption is very the refrigerant in the evaporator and the heat of compression
important. Domestic refrigerator-freezers consumed electricity conveyed from the compressor to the surrounding [9]. A well-
energy for about 26.3% in a single household. So, improving effi- designed condenser should improve the energy efficiency, reduce
ciency of domestic refrigerator-freezers will have a significant the space and material for a specific cooling capacity in a domestic
refrigerator [10]. A usual refrigerator uses a wire-and-tube
condenser [11], which is attached to the back of the refrigerator.
* Corresponding author.
However, this condenser is lying face down to be injured and dirt
E-mail addresses: f.ghadiri@entekhabgroup.ir, ghadiri_fa@yahoo.com tends to gather and form a scale layer on the hot surface. This in-
(F. Ghadiri), m.rasti@entekhabgroup.ir (M. Rasti). creases the fouling resistance and reduces the heat transferred

http://dx.doi.org/10.1016/j.applthermaleng.2014.03.024
1359-4311/Ó 2014 Elsevier Ltd. All rights reserved.
336 F. Ghadiri, M. Rasti / Applied Thermal Engineering 67 (2014) 335e340

from the condenser extensively. According to these factors, another


condenser design, called the ‘‘hot-wall condenser’’ [12] was intro-
duced in the newer generation of domestic refrigerators to replace
the wire-and tube condenser. The hot-wall condenser is placed
inside the refrigerator casing and stuck in good thermal contact to
the refrigerator plate. Hot-wall condenser is a single tube wounded
all around the refrigerator casing [13]. So, two types of condensers
are commonly used in domestic refrigerators [14].
The hot-wall condenser, also known as wrapper type condenser,
consists of steel tubing (coated with copper), which is installed by
direct contact on the inner surface of the outer iron plate of side
walls of the refrigerator as shown in Fig. 1. The adhesive aluminum
foil holds the tube in place and acts as a guard to prevent heat
transfer into the refrigerating compartment. Since the condenser
tubing is installed in the refrigerator wall, which is usually hot, it is
called ‘‘hot-wall condenser’’. There are four panels namely the left,
right, back, and base panel, each with distinct tube configurations
as shown in Fig. 1a.
Generally, the large amount of heat will be dissipated to the
surroundings through the outer plate by means of natural con-
vection and radiation [15], while a small amount will end up
infiltrating into the refrigeration compartment. Beside the advan-
tages of this newer type of condenser, the quality of the adhesive
aluminum foil and the workman skillfulness play the main roles in
the efficiency of these types of condensers. The newest generation
of the condensers is the cubic condenser whose shape is similar to
the wire-and-tube but is packed like a cube. This type of condenser
is cooled with forced convection and the fan makes a forced air flow
over the condenser. By this type of heat removal, according to the
increment of heat transfer coefficient, the area can be reduced
extensively; as a result, the condenser not only takes a little space,
but also eliminates the disadvantages of hot wall type in production
line. The use of compact heat exchanger for domestic refrigerators
causes a reduction in material costs and energy consumption [16].
For wire-and-tube and compact condensers, insufficient or block-
ing surrounding air passage will reduce the performance of both
types of condensers and thus the domestic refrigerator [17].
Poggi et al. reported that one option for refrigerant charge
reduction in domestic refrigerators is to reduce the internal volume
of all the components (exchangers, receivers, liquid line) [18].
Experimental investigations in the field of finding optimum
refrigerant charge are reported in Refs. [19e21].
Most refrigerator-freezers employ constant speed, hermetic,
reciprocating compressors to meet the maximum load re-
quirements. These compressors usually operate at approximately
50% of their maximum design loads which result in reduced per-
formance due to cycling losses [22]. Further, a household refriger-
ator is periodically ON/OFF controlled and the heat capacity of the
evaporator as well as the thermal resistance influences the per-
formance of the system.
There are many parameters that have an effect on domestic
refrigerator-freezers energy consumption. Saiduret et al. investi-
gated the effect of ambient temperature, door opening and ther-
mostat setting position on domestic refrigerator-freezer energy
consumption. The results showed that room temperature had the
higher effect on energy consumption in comparison to door
opening and thermostat setting position [23]. The load and ambient
temperature had a greater impact on energy consumption of do-
mestic refrigerator-freezer than the fresh food, fresh water, and
thermostat settings [24]. Also, Analysis of variance on the domestic
refrigerator by Geppert and Stamminger showed that the most

Fig. 1. Hot-wall condenser; (a) configuration and setup of tubing for a hot-wall
condenser, (b) cross section of a hot-wall condenser on refrigerator’s wall, (c) cubic
condenser sketch.
F. Ghadiri, M. Rasti / Applied Thermal Engineering 67 (2014) 335e340 337

important factor on the energy consumption is ambient tempera- Table 1


ture [25]. Specifications of domestic refrigerator test unit.

To achieve a substantial improvement in the overall thermal Freezer capacity 130 L


efficiency of the system, the performance of the components Fresh food capacity 288.1 L
constituting the refrigeration system should all be improved Current rating 0.85 A
Compressor power consumption 165 W
simultaneously: in addition to higher compressor efficiency; Heater power consumption 450 W
reduction of thermal resistances of both evaporator and condenser, Voltage 220 V
improving characteristic of the expansion device and getting Climate class T
insulation of the enclosure better are the first steps toward the Frequency 50 Hz
No of doors 2
eventual goal. The present study is experimentally investigate the
Refrigerant type R134a
performance of the condenser, hot-wall condenser removal, Defrost system Auto defrost
condenser air cooling increment, compressor cooling capacity Charged mass 155 g
decreasing, R134a refrigerant charge amount decreasing and do- Capillary tube length 280 cm
mestic refrigerator at tropical conditions testing. Capillary tube inner diameter 0.78 mm

2. Materials and methods


0.1  C. The ambient relative humidity range was 50  3% and the
2.1. Experimental procedure
ambient temperature range was 32  0.5  C.
A domestic refrigerator which was designed for working with
155 g R134a as refrigerant had been employed. The most important 3. Results and discussion
specifications of this refrigerator are summarized in Table 1. The
base fan diameter was 12 cm and the alternative fan diameter was The effect of hot-wall condenser removal, condenser air cooling
14 cm. Also, R134a refrigerant was purchased from the T. S Enter- increment, compressor cooling capacity decreasing, R134a charge
prise CO., China. amount decreasing and domestic refrigerator at tropical conditions
The experimental procedure consisted of measuring the energy testing on the energy and power consumption of the refrigerator
consumption for several states such as side condenser removal, are discussed as bellow:
increment of condenser air cooling with bigger fan, reduction of
compressor cooling capacity, reduction of capillary tube diameter 3.1. Side condenser removal and condenser air cooling increment
and obtain optimum refrigerant charge amount at the ambient
relative humidity of 50  3% and the ambient temperature of In order to reduce the energy consumption of the fridge, the idea
32  0.5  C. Also, the case study refrigerator tested in the tropical of side condenser removal is proposed. Fig. 2 shows the condenser
condition (ambient relative humidity of 50  3% and the ambient inlet temperature versus time for these cases (base design and base
temperature of 43  0.5  C) because it was designed for working in design without side condenser). As it is obvious in Fig. 2, side
the tropical region. The experiments compared together when the condenser removal reduces the heat rejection from the cycle and
fresh food cabin average temperature and the hottest temperature causes the compressor over heat. Thus, a third case is proposed in
of freezer cabin achieved to 5  C and 18  C, respectively. which side condenser is removed and at the same time a bigger fan
is used to cool the condenser coils. In this third case, the
compressor outlet temperature is nearly the same as the base case.
2.2. Experimental setup
Results were plotted for one ON-cycle of the compressor.
Fig. 3 shows the time history of condenser outlet temperature
The case study refrigerator had been located in a chamber as a
for three cases. Third case has the lowest temperature and naturally
test room and the ambient conditions (the surrounding tempera-
the best condenser performance. It means that the condenser with
ture and relative humidity) were automatically adjusted with
lower heat rejection area and higher air flow rate over the
heater, cooler, and humidifier. Temperatures in the 16 arbitrary
condenser is not only more efficient in heat removal, but also
points of the refrigerator were monitored and recorded continu-
efficient in space saving.
ously. In addition, voltage and consumed current, active power,
reactive power, power factor, ambient temperature and relative
humidity, were gathered continuously for a cycle through a data
acquisition system. By analyzing the data, ON time ratio1 [26], en-
ergy consumption and working time were calculated. The refrig-
erator was tested under loaded conditions and load characteristics
are defined in standard ISO 8187 [27].
According to ISO 8187, temperature sensors were located in the
refrigerator cabins and loaded freezer cabin to record temperatures.
In addition, temperatures at evaporator input and output of
refrigerator and freezer cabins, compressor, condenser and dryer
were recorded.
The accuracy of the existing sensors in the test room was as
follows: temperature, 0.1  C; voltage stabilizer, 0.1 V; weighing
balance, 0.1 g; relative humidity, 0.1% and ambient temperature,

1
ON time ratio is the operating time of the compressor in one cycle divided into
the total cycle time. Fig. 2. Condenser inlet temperature for one ONeOFF cycle.
338 F. Ghadiri, M. Rasti / Applied Thermal Engineering 67 (2014) 335e340

Fig. 5. Refrigerator power consumption for one ONeOFF cycle.


Fig. 3. Condenser outlet temperature for one ONeOFF cycle.

OFF-time will make the best case. Commonly, the thermal energy
The evaporator temperature over a period of time is measured consumption for fridges is calculated. The results of annual energy
and the results are sketched in Fig. 4. Side condenser removal will consumption are plotted in Fig. 6. According to this figure, annual
cause the lowest condensation and will naturally reduce the cool- energy consumption of domestic refrigerator in states of side
ing capacity of the cycle. Therefore, the second case will have the condenser removal and increment of condenser air cooling
highest evaporator temperature. The third case has the same decreased by 1.2% and 10.8% respectively in comparison of base
evaporator temperature as the base case. The most important factor refrigerator. In each case, annual energy consumption of the
in fridge design is the electrical energy consumption. The electricity refrigerator was calculated for the 24 h test of the refrigerator under
demand of the three cases is measured over time. The results of this the standard test conditions of ISO 8187 and multiplying the results
factor for a cycle of the compressor are reported in Fig. 5. by 365 day in a year.
The base case has the highest energy consumption level. The Efficiency index for the refrigerators was defined below:
side condenser results in a pressure drop and, as a result, the
compressor needs more power to make the pressure difference in Annual energy consumption
Efficiency index ¼
the cycle. Interestingly, the energy level of cases two and three are Standard annual energy consumption
not the same. The third case has a very low electricity consumption (1)
comparing other two cases. By removing the side condenser, the
pressure drop is reduced and by using a bigger fan, the sub-cooling Standard energy consumption was calculated according to
of the refrigerant is guaranteed. These two factors will increase the standard ISIRI 4853-2. According to this standard, the standard
COP of the cycle. For a standard refrigeration load, a higher COP annual energy consumption for the experimental setup was
leads to a lower compressor work and electricity. In Fig. 5, the 835 KW h/year. This standard value was calculated with each
energy is the total energy of the fridge including compressors and compartment volume and average temperature during the ON/OFF
all fans. Although in the third case the condenser fan is bigger and cycle of the appliance.
gets more energy, the total energy consumption of the cycle is
lower than two other cases. 3.2. Compressor cooling capacity
The energy consumptions in Fig. 5 are plotted for a compressor
cycle. In addition to the compressor energy, the compressor work The effect of compressor cooling capacity was experimentally
time is important. The lowest energy consumption and longest investigated. Cooling capacity of the base and the new compressors
were 235 and 200 W, respectively. The power consumptions for a
compressor ON/OFF cycle are plotted in Fig. 7. Experiments were

Fig. 4. Evaporator outlet temperature for one ONeOFF cycle. Fig. 6. Annual energy consumption of the domestic refrigerator.
F. Ghadiri, M. Rasti / Applied Thermal Engineering 67 (2014) 335e340 339

Fig. 9. Comparison of refrigerator power consumption based on R134a charge amount


Fig. 7. Comparison of refrigerator power consumption for one ONeOFF cycle.
for one ONeOFF cycle.

done at 32  C ambient temperature and 50% relative humidity.


inner diameter, following changes were done in the domestic
According to Fig. 7, ON time ratio of compressors with 235 and
refrigerator-freezer: hot-wall condenser removal, condenser air
200 W cooling capacity were 44% and 48%, respectively. Although
cooling increment, compressor cooling capacity decreasing and
ON time ratio of the new compressor increased about 4%, its power
capillary tube with 0.031 in. inner diameter. Afterwards, to obtain
consumption decreased about 22%. As a result, cooling capacity of
optimum refrigerant charge, experiments were carried out for 130,
the base compressor was over designed for the case study domestic
125 and 115 g of R134a as refrigerant. The refrigerator and freezer
refrigerator-freezer.
cabins temperature settings were constant and experiments were
conducted at 32  C ambient temperature and 50% relative humid-
3.3. Capillary tube diameter
ity. The power consumption of one ON/OFF cycle for the three
R134a charge are shown in Fig. 9. According to this figure, although
Fig. 8 shows the effect of capillary tube diameter on power
115 g R134a had the lowest power consumption, its ON time ratio is
consumption and ON time ratio. The results showed that the power
more than 125 and 130 g R134a charges. Therefore, 115 g refrigerant
consumption of the capillary tube with inside diameter of 0.031 in.
charge was not the optimum charge. Energy consumption of 125 g
is lower than the capillary tube with inside diameter of 0.028 in.
R134a in one day was less than 130 g R134a charge. As a result, at
The ON time ratio and the time of 1 ON/OFF cycle for the capillary
energy consumption point of view, the optimum refrigerant charge
tube with inside diameter of 0.031 in. are equal to 46.5% and
was 125 g R134a.Therefore, with mentioned changes, refrigerant
58 min, respectively and the ON time ratio and the time of 1 ON/OFF
charge amount decreased about 19.3%.
cycle of the capillary tube with inside diameter of 0.028 in. are
equal to 48.5% and 68 min, respectively. The results showed that
3.5. Tropical test
energy consumption of domestic refrigerator which used the
capillary tube with inside diameter of 0.031 in. is about 6% less than
The case study domestic refrigerator was originally designed for
the other one.
tropical class. Thus, after hot-wall condenser removal, condenser
air cooling increment, compressor cooling capacity decreasing,
3.4. Refrigerant charge effect
using capillary tube with 0.031 in. inner diameter and R134a charge
amount decreasing, the domestic refrigerator was assessed at 43  C
After experimental assessment of hot-wall condenser,
ambient temperature and 50% relative humidity. The power con-
condenser air flow, compressor cooling capacity and capillary tube
sumption and ON time ratio are shown in Fig. 10. According to this
figure, ON time ratio was 73.4% for fresh food cabin average

Fig. 8. Comparison of refrigerator power consumption based on capillary tube diam-


eter for one ONeOFF cycle. Fig. 10. Power consumption of refrigerator in tropical class test for one ONeOFF cycle.
340 F. Ghadiri, M. Rasti / Applied Thermal Engineering 67 (2014) 335e340

Table 2
Comparison the results of changes on operating parameters of case study domestic refrigerator.

Parameter Base Side Increment of Reduction Reduction capillary Optimum Tropical


refrigerator condenser condenser air compressor tube diameter charge class
removal cooling cooling capacity

R134a charge amount, g 155 155 125 125 125 125 125
Cooling capacity, W 235 235 235 200 200 200 200
Capillary tube inner diameter, in. 0.031 0.031 0.031 0.031 0.028 0.031 0.031
Suction temperature,  C 38.3 46.8 35.7 35 31.3 35 43.8
Discharge temperature,  C 62 84 68 62.3 61 63 76.5
Condenser outlet temperature,  C 46 53 42 40 40.5 40 49.5
Energy consumption, kW h/day 2.221 2.214 1.98 1.722 1.820 1.679 2.480

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