Energetic and Exergetic Analysis

of an Ejector-Based Green Refrigeration

System Employing Evaporative Cooling
in the Gas Cooler

Biswajit Gorai and Satyabrata Sahoo

Nomenclature

cp Sp. heat at cont. pressure (kJ/kg-K)

DBT Dry bulb temperature (°C)
GC Gas Cooler
h Enthalpy (kJ/kg)
İ Exergy destruction (kW)
ṁ Mass flow rate (kg/s)
P Pressure (kPa)
Q̇ Heat transfer rate (kW)
RH Relative humidity (dimensionless)
s Entropy (kJ/kg-K)
T Temperature (°C)
u Velocity (m/s)
Ẇ Power Input (kW)
WBT Wet bulb temperature (°C)

Greek Symbols

ψ̇ Exergy (kW)
η Efficiency (dimensionless)
μ Entrainment ratio (dimensionless)
 Difference
v Specific volume (m3 /kg)

B. Gorai (B) · S. Sahoo

Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines),
Dhanbad, Jharkhand 826004, India

© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022 99
P. Mahanta et al. (eds.), Advances in Thermofluids and Renewable Energy, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-16-3497-0_8
100 B. Gorai and S. Sahoo

Subscripts

AC Air cooled
amb Ambient
comp Compressor
cond Condenser
diff Diffuser
EVC Evaporative cooling
evp Evaporator
in Inflow
out Outflow
p Primary
ref Refrigerant
s Secondary

1 Introduction

Considerable exergy consumption in CO2 refrigeration systems is a major concern

for its high operating pressure in gas cooler. Nowadays, researchers are showing
their keen interest in using CO2 in various refrigeration systems especially in dual
systems where both cooling and heating are required, mobile air conditioning as
well as in supermarkets. CO2 is an environment friendly (ODP = 0 & GWP = 1),
non-toxic and less expensive refrigerant. So, the application of CO2 as refrigerant
is both economical as well as environmental benign. In addition to that CO2 is non-
flammable, having excellent potential for charge reduction and has better transport
properties. Moreover, unlike NH3 , it has no compatibility issue with copper and
other alloys mainly used as the tubing material in refrigeration units. Considering
the above factors, CO2 can be considered as a suitable refrigerant for dairy and auto-
motive air conditioning applications. On the other hand, the major issues with CO2
as a refrigerant, such as low critical temperature (31.4 °C) and high critical pressure
(73.84 bar) are coming in the way of its large-scale commercial use. Because of these
adverse critical properties in most cases, the heat rejection takes place in the super-
critical zone based on the availability of heat sink temperature. Because of its high
critical pressure, the operating pressure of these systems is quite high resulting in
increased power consumption as well as more robust design. Hence, the initial as well
as running cost of these systems are quite high. In order to address these issues and
make these systems commercially viable, many researchers have suggested various
system modifications as well finding simultaneous cooling and heating applications,
where these systems can best fit. Liu et al. [1] did a comparative study on NH3 and
CO2 heat pump systems for both heating and cooling applications. The annual cost
shaving for different food processes and for different locations is estimated. Omer
et al. [2] have explained the best use of heat pump for milk pasteurisation system.
Energetic and Exergetic Analysis of an Ejector … 101

Robinson and Groll [3] have established for a given gas cooler exit temperature the
COP of the transcritical CO2 system is a strong function of the gas cooler pressure,
and the maximum COP is achieved at the optimum gas cooler pressure. The study
also demonstrated that the maximum irreversibility associated with expansion valve
resulted in lower 2nd law efficiency. Ahammed et al. [4] have analysed a conven-
tional transcritical CO2 system for simultaneous cooling and heating application for
a dairy plant. The performance of four different configurations with and without
ejectors employing multiple gas coolers and an internal heat exchanger is compared.
The result clearly demonstrates that the position of the IHX plays a vital role, and the
best performance was realised when the IHX was placed between the gas coolers.
Deng et al. [5] described the usefulness of ejectors in CO2 -based transcritical refrig-
eration systems by showing 25% improvement in cooling COP. Experimental study
carried out by Hajidavalloo, Eghtedari [6], established the usefulness of evaporative
condenser over air cooled condenser in air conditioning applications. The exper-
imental study has demonstrated up to 20% reduction in power consumption and
50% improvement in COP by replacing the air cooled condenser by an evaporative
condenser. Additionally, in hot and dry weather conditions, the application of evapo-
rative condenser is commercially recommended. From the survey, it is observed that
not much study on evaporative cooling-based transcritical CO2 systems is available
in open literature. Moreover, the exergetic analysis especially systems incorporating
evaporative cooling system which handles the air water vapour mixture is scarce in
open literature. Hence, a comprehensive thermodynamic comparison both 1st and
2nd law is the prime focus of the present investigation.

2 CO2 Refrigeration System with Air Cooled

and Evaporative Gas Coolers

2.1 Component Modelling

As shown in Fig. 1a, transcritical CO2 -based vapour compression refrigeration

system deploying an ejector in place of the expansion valve and an air cooled gas
cooler as the heat rejecting unit has been considered for the present analysis. It has
been observed from the literature that in the case of CO2 system, gas cooler rejects
heat in the transcritical zone. So the operating pressure of the gas cooler, hence the
pressure ratio of the compressor is a strong function of gas cooler exit temperature
which mainly depends on the type of cooling medium and the design of the gas
cooler. In order to overcome this problem, an attempt has been made to study a
modified system in which the air cooled gas cooler is replaced by an evaporative
cooling-based gas cooler as shown in Fig. 1b. The refrigerant coming from the gas is
accelerated through the primary nozzle, thus creating a suction which sucks the refrig-
erant vapour from the evaporator through the secondary nozzle (i.e. process 6–10).
Both the streams undergo a constant pressure mixing process while passing through
102 B. Gorai and S. Sahoo

Fig. 1 a Schematic of an ejector-based CO2 refrigeration system with air cooled gas cooler.
b Schematic of an ejector-based CO2 refrigeration system with evaporative gas cooler. c T-s plot of
CO2 refrigeration cycle with ejector
Energetic and Exergetic Analysis of an Ejector … 103

the mixing zone (i.e. process 8–9). After the mixing zone, the refrigerant passes
through a diffusing section to recover the pressure. The phase separator installed at
the exit of the diffuser separates the vapour part from that of the liquid part. The
liquid part enters into the evaporator to take care of the cooling load, and the gaseous
part is compressed by the compressor and then cooled in the gas cooler, completing
the cycle. The compressed gas rejects the heat to the cooling medium while passing
through the gas cooler, thus completing the cycle.
The analysis is based on the following simplifying assumptions:
• The heat loss from different components to ambient is negligible.
• The pressure drop in various components is negligible.
• Refrigerant flow is steady state and steady flow condition.
• The kinetic energy at the entry of the nozzle and at the exit of the diffuser is
negligible
• Energy inputs to the air circulation fan and water pump in the heat rejecting unit
are negligible.
The steady-state thermodynamic analyses of both the systems are carried out
applying 1st and 2nd law to each individual component. The thermodynamic cycle
is pictorially presented on T −s plot as given in Fig. 1c.

2.2 Mathematical Equations

Evaporator
Applying steady flow energy equation and exergy balance to the evaporator, the
refrigeration capacity and rate of exergy destruction can be expressed as given in
Eqs. 1 and 2, respectively. Here ṁref_s is mass flow rate of refrigerant passing through
the secondary nozzle and also through the evaporator.

Q̇ ref = ṁ ref_s (h 6 − h 5 ) (1)

where enthalpy of state point 5 and 6 is the functions of evaporator temperature and
dryness fraction at the inlet and exit of the evaporator.

I˙evp =ṁ evp_s ((h 5 − h 6 ) − Tamb (s5 − s6 ))

 
Tamb
+ Q̇ ref 1 − (2)
Tspace

where T space is the refrigerated space temperature.

Compressor
The compression process is assumed to be non-isentropic by including the isentropic
efficiency, which is given as a function of pressure ratio Robinson et al. [3]
104 B. Gorai and S. Sahoo
   2  3
P2 P2 P2
ηcomp = 0.815 + 0.022 − 0.0041 + 0.0001 (3)
P1 P1 P1

The power input to the compressor is given by:

ṁ ref_p (h 2s − h 1 )
Ẇcomp = ṁ ref_p (h 2 − h 1 ) = (4)
ηcom

Exergy destruction of the compressor is given by:

I˙comp = ṁ ref_p ((h 1 − h 2 ) − Tamb (s1 − s2 )) + Ẇcomp (5)

Ejector
Based on the simplifying assumption mentioned earlier, the ejector part which
comprises the primary, secondary nozzle, mixing chamber and diffuser is simulated
using governing mass, energy and exergy balance equations given below. The ratio
of secondary to primary mass flow rate of the refrigerant in secondary and primary
nozzles, respectively, is termed as entrainment ratio and is expressed as:

μejec = ṁ ref_s /ṁ ref_p (6)

Primary Nozzle
 
h3 − h7
ηejec_np = (7)
h 3 − h 7s

h 7s = f (s3 , P10 ) (8)

u 27
h3 = h7 + (9)
2

I˙nozzle_p = ṁ ref_p Tamb (s3 − s7 ) (10)

Secondary Nozzle
 
h 6 − h 10
ηejec_ns = (11)
h 6 − h 10s

h 10s = f (s6 , P10 ) (12)

u 210
h 6 = h 10 + (13)
2
Energetic and Exergetic Analysis of an Ejector … 105

I˙nozzle_s = ṁ ref_s Tamb (s6 − s10 ) (14)

Constant pressure mixing zone

   
u 28 u 27
ṁ ref_total h 8 + = ṁ ref_ p h 7 +
2 2
 2  (15)
u
+ṁ ref_s h 10 + 10
2
     
I˙mix = ṁ ref_total Tamb s8 − ṁ ref_p Tamb s7 − ṁ ref_s Tamb s10 (16)

Diffuser

u 28
h9 = h8 + (17)
2
 
h 9s − h 8
ηejec_d = (18)
h9 − h8

I˙dif = ṁ ref_total Tamb (s9 − s8 ) (19)

Total exergy destruction of the ejector is given by:

I˙eje = I˙dif + I˙mix + I˙nozzle_p + I˙nozzle_s (20)

Phase separator
It separates the saturated liquid and vapour from the vapour and liquid mixture. The
isothermal separation is expressed as:

ṁ total h 9 = ṁ p h 1 + ṁ s h 11 (21)

Exergy destruction in phase separator is calculated as follows:

ψ̇in_1 = ṁ ref_total ((h 9 − h amb ) − Tamb (s9 − samb )) (22)

ψ̇out,1 = ṁ ref_s ((h 11 − h amb ) − Tamb (s11 − samb )) (23)

ψ̇out_2 = ṁ ref_ p ((h 1 − h amb ) − Tamb (s1 − samb )) (24)

I˙phs = ψ̇in_1 − ψ̇out_1 − ψ̇out_2 (25)

106 B. Gorai and S. Sahoo

Air cooled gas cooler

The heat rejected by the refrigerant is taken by atmospheric air. A constant flow rate
of air in the heat exchanger is maintained by installing a fan of required capacity.
The refrigerant exit temperature of the gas cooler is fixed by assuming a minimum
temperature difference of 15 °C [7] between the coolant (air) and refrigerant. From
the energy balance:

Q̇ gc_AC = ṁ ref_p (h 2 − h 3 ) = ṁ air .cp_air .Tair (26)

where (mair ) mass flow of water through gas cooler and Tair is temperature rise of
air in the gas cooler.
Exergy destruction on the gas cooler is calculated using following equations:
   
ψ̇ref_in = ṁ ref_p h 2 − h amb_ref − Tamb s2 − samb_ref (27)

   
ψ̇ref_out = ṁ ref_p h 3 − h amb_ref − Tamb s3 − samb_ref (28)

ψ̇air_in = 0 (29)
  
h air_out − h air_amb −
ψ̇air_out_AC = ṁ air   (30)
Tamb sair_out − sair_amb

I˙gc_AC = ψ̇ref_in + ψ̇air_in − ψ̇ref_out − ψ̇air_out_AC (31)

Evaporative cooling-based gas cooler

In the evaporative cooler, water is sprayed with the help of a small pump and water
sprinkler. A centrifugal fan maintains the air flow inside the evaporative gas cooler.
Dry atmospheric air enters into the evaporative gas cooler and becomes cooler by
absorbing water particles. This humid air absorbs heat from the refrigerant passing
through the gas cooler tubing. Both latent and sensible heat transfer results in
improved system performance by maintaining lower gas cooler exit temperature.
Based on the data reported in the existing literature, the present analysis assumes
that the refrigerant can be cooled up to 11–13 °C above WBT of the incoming
air. The following mathematical formulation is used to simulate the evaporative
cooling-based gas cooler part.

Psat,in = f (Tin ) (32)

Psat,out = f (Tout ) (33)

Energetic and Exergetic Analysis of an Ejector … 107

Pv,in = Psat,in .R Hin (34)

Pv,out = Psat,out .R Hout (35)

 
h water,in = f Twater,in (36)

 
v = f Twater,in (37)
 
Pv,in
ωin = 0.622 (38)
Patm − Pv,in
 
Pv,out
ωout = 0.622 (39)
Patm − Pv,out
 
ṁ w_makeup
ṁ air = (40)
ωout − ωin

Applying the steady flow energy equation to the evaporative cooling-based gas
cooler.

Q̇ gc_EVC = ṁ ref_p (h 2 − h 3 )
  (41)
= ṁ air h air_out − h air_in − h water_ in .ṁ w_makeup

The expressions for flow exergy associated with refrigerant in, out and air in are
the same as given in Eqs. 27, 28 and 29, respectively.

⎡ ψ̇air_out_EVC = ṁ air  ⎤
  T Tair_output
c p_air + ωout cp_water . Tair_input Tair_output − 1 − ln +
⎢ ⎡ air_input Tair_input ⎤ ⎥
⎢ (1+1.608.ωin ) ⎥ (42)
⎢   (1 + 1.608.ωout ). ln (1+1.608.ωout ) + ⎥
⎣ 0.287. Tair_input .⎣ ⎦ ⎦
ωout
1.608.ωin . ln ωin

ψ̇water_in = ṁ w_makeup
⎡ ⎤
(h water_in − h water_atm ) − Tatm .(swater_in − swater_atm )+
⎢   ⎥ (43)
⎣ 8314  ⎦
( patm − psat_in ).vwater − .Tair_input . ln Rh input
18

I˙gc_EVC = ψ̇ref_in − ψ̇ref_out + ψ̇water_in

  (44)
+ ψ̇air_in − ψ̇air_out_EVC
108 B. Gorai and S. Sahoo

Expansion valve
In an ejector-based system, the expansion valve is installed at the exit port of phase
separator. While flowing through the expansion valve, no change in enthalpy is
observed. However, exergy destruction takes place due to irreversible pressure drop
by frictional dissipation and is estimated using the expression given in Eq. 44.

I˙ev = Tamb ṁ ref_s (s5 − s11 ) (45)

The total exergy destruction is given by:

I˙t = I˙evp + I˙comp + I˙eje + I˙gc_AC / I˙gc_EVC + I˙phs + I˙ev (46)

System COP is calculated considering the cooling effect of the refrigeration

system:

Q̇ evp
C O Psystem = (47)
Ẇcomp

3 Result and Discussion

All the simulations are carried out for the input parameters included in Table 1. If
nothing is mentioned, the RH is assumed to be 40%.

Table 1 Input parameters for

Range
simulation [7–9]
Cooling load 37 kW
Evaporator temperature −3 °C
Volume flow rate of air for air cooled gas cooler 169.1 cm
Volume flow rate of air for EVC-based gas cooler 74.5 cm
Air temperature at the inlet gas cooler 30–40 °C
Relative humidity at the inlet to the EVC-based gas 30–60%
cooler
Relative humidity at the exit of the EVC-based gas 85%
cooler
Nozzle efficiency (both primary and secondary) 85%
Diffuser efficiency 80%
Pressure drop of secondary nozzle 0.3 bar
Pressure drop in gas cooler 1 bar
Water inlet temperature to the evaporative cooler 20 °C
Energetic and Exergetic Analysis of an Ejector … 109

Fig. 2 Effects of ambient temp on system COP and the total irreversibility

Figure 2 presents the effect of ambient temperature on COP and total irreversibility
for both the systems. The figure clearly demonstrates a significant improvement in
COP and reduction in total irreversibility for EVC-based gas coolers compared that of
the air cooled system, and this may be attributed to lower gas cooler exit temperature
in the earlier case which results in lower operating pressure. It has been observed that
for a given gas cooler exit temperature, there exists an optimum gas cooler pressure
at which the transcritical system gives its best performance. Hence, for the present
comparison, the operating pressures for both the air cooled and EVC-based gas
coolers are fixed at their optimum values corresponding to the respective gas cooler
exit temperatures. Because of the reduced operating pressure of the EVC-based gas
cooler system, the power input to the compressor decreases resulting in improved
COP. However, the difference decreases with increase in the ambient temperature. In
case of air cooled systems because of the large temperature difference between the
refrigerant and the air and higher heat rejection rate due to high operating pressure
significantly increases the system irreversibility.
Figure 3 is a pictorial representation of exergy destruction or irreversibility present
in various components. The figure clearly depicts that in case of air cooled systems,
the maximum irreversibility is recorded in the ejector; however, in EVC-based
systems, the gas cooler overtakes the ejector in terms of exergy destruction. It is note-
worthy to mention here that in all the components except the evaporator, the exergy
destruction is higher in case of air cooled systems compared to that of EVC-based
systems. One of the major reasons behind this large difference in the irreversibility
associated with all the components is the high operating gas cooler pressure in case
of air cooled systems. High operating gas cooler pressure results in higher work of
compression, increased compressor inefficiency, higher heat rejection rate in the gas
110 B. Gorai and S. Sahoo

Fig. 3 Component-wise exergy destruction

cooler with larger temperature difference and consequently higher exergy destruc-
tion. Similarly for the expansion valve the exergy destruction is higher for systems
with air cooled gas coolers due to its higher operating pressure ratio.
Figure 4 indicates the effects of relative humidity on the system COP as well as
the makeup water requirement for different ambient conditions. It has been observed
that for dry atmosphere, the COP of the EVC-based system is significantly higher
compared to the air cooled system. This is due to lower WBT of ambient air which
decides the refrigerant exit temperature in case of EVC-based gas coolers. As RH
of the ambient air increases, the COP of the EVC systems approaches that of the air

Fig. 4 Variation of system COP and makeup requirement with the relative humidity of the ambient
air
Energetic and Exergetic Analysis of an Ejector … 111

cooled system. This is more pronounced at lower DBT of the air. The makeup water
requirement reduces with increase in RH and increases with DBT.

4 Conclusion

In the present investigation, a steady-state simulation is carried out to compare the

performance of two ejector-based transcritical CO2 systems: one with air cooled gas
cooler and other one with EVC-based gas cooler. The subject work clearly demon-
strates a significant improvement in the case of EVC-based systems both from 1st
and 2nd law viewpoints. From the parametric study, it is observed that the percentage
improvement in COP decreases with increase in ambient temperature and relative
humidity. One of the important highlights of the present investigation is the estima-
tion of the component-wise exergy destruction with a special focus on an EVC-based
system which deals with binary mixture subjected to both heat and mass transfer.
From the analysis, it is observed that the maximum irreversibility is associated with
the ejector in case of air cooled system and with the gas cooler for the EVC-based
system. Based on this simplified thermodynamic analysis, the study recommends the
use of EVC-based gas coolers in CO2 systems. However, the design and other oper-
ating issues can be realised only after a detailed dynamic analysis with experimental
validation.

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