Modeling and experimental evaluation of

parallel flow micro channel condensers

MODELING AND EXPERIMENTAL EVALUATION OF
PARALLEL FLOW MICRO CHANNEL CONDENSERS

ABSTRACT :
This paper reports results obtained in a theoretical and experimental study
involving micro channel/louvered fin condensers for automotive applications. A
simulation model has been developed based upon three zones related to the
thermodynamic states of the refrigerant in the condenser. Experiments with condensers
have been performed in a set up developed for thermal performance evaluations of
automotive air conditioning systems. Comparisons between simulation model and
experimental results for refrigerant HFC-134a have been performed with respect to three
important condenser parameters: heat rejection rate, refrigerant pressure drop and overall
heat transfer coefficient. It has been shown that model results for the particular tested
condenser compare very well with the experimental data, with deviations being within an
acceptable range.
Keywords: Parallel flow condenser, micro channels, automotive, air conditioning
systems
 Modeling and experimental evaluation of
parallel flow micro channel condensers
INTRODUCTION :
Tight limitations in space and weight of automobile air conditioning condensers,
in addition to high thermal performance requirements has led manufacturers to develop
new and ingenious geometries. One of such geometries, which is prevailing in present
days, is made of blades of extruded aluminum micro channels (typical dimension of the
order of 1 mm), with the space between blades being filled with louvered fins. Blades are
brazing soldered to vertical headers where the refrigerant is distributed to the micro
channels, as shown in Fig. 1. A schematic representation of a louvered surface of the kind
considered in this study is shown in Fig. 2 along with the main geometric parameters.

The basic procedure consists in dividing the coil into three regions: the
superheated vapor, the change of phase, and the subcooled liquid regions. One such
study has been conducted by Rahman Ali (1995), who developed a mathematical model
for a parallel flow micro channel condenser as part of a comprehensive research
involving the simulation of an automobile air conditioning system. Lee and Yoo (2000)
 Modeling and experimental evaluation of
parallel flow micro channel condensers
followed a similar approach modeling a parallel flow micro channel condenser as part of
a simulation program of an automobile air conditioning refrigeration circuit.
Present paper reports the development of a computer simulation program of a parallel
flow micro channel condenser and its validation through results from an experimental set
up. The experimental bench has been developed from actual parts and components of an
automobile air conditioning system and has been operated under typical field conditions.
Nomenclature
A = Area (m2) Lf = Fin corrected length (m)
Acs = Fin cross section area in mf (m2) Lp = Louver pitch (m)
C = Heat capacity, m cp (W/K) L1 = Louver length (m)
Cf = Friction factor m = Mass flow rate (kg/s)
C* = Cmin/Cmax mf = Fin effectiveness parameter given
cp = Specific heat (J/kg.K) by [haAcs/(kff)]0.5
D = Diameter, (m) NTU = Number of Transfer Units
Fp = Fin pitch (m) p = Pressure (Pa)
G = Mass velocity (kg/m2s) Pr = Prandt Number
h = Heat transfer coefficient (W/m2K) Qc = Condenser heat rejection rate (kW)
haverage = Condensing average heat Re = Reynolds number
transfer coefficient (W/m2K) T = Temperature (K)
Hc = Dimension as in Fig.1 (m) TEV = Thermostatic expansion valve
hf = Fin length (m) U = Overall heat transfer coefficient
hm = Tube height (m) (kW/m2K)
i = Enthalpy (J/kg) Va = Face velocity of the air (m/s)
j = Colburn factor, Nu/(RePr1/3) wm = Tube depth (m)
k = Thermal conductivity (W/mK) x = Quality
L = Length (m) Xtt = Martinelli Parameter
Lc = Dimension as in Fig.1 (m)
 Modeling and experimental evaluation of
parallel flow micro channel condensers
CONDENSER MODEL:
The condenser simulation model assumes that the heat transfer surface is divided
into three regions associated to the state of the refrigerant: superheated vapor, condensing
and subcooled liquid. Refrigerant and air total flow rates, and the entrance conditions of
the refrigerant and air are assumed to be known. Each region is considered as an
independent heat exchanger with the total air flow being distributed for each region
according to the procedure described below. The state of the refrigerant at the exit of one
region corresponds to the inlet of the succeeding one, as shown in Fig. 4.

The overall heat transfer coefficient for each region is determined by assuming
negligibly small the combined thermal resistance due to fouling, heat conduction in tube
wall, and metal contact. The following equation can then be written:

where  is the overall effectiveness of the finned surface, given by

 = 1 – (Af/Ae)(1-f)
The internal value for  is one, since the surface of the micro channels is
assumed to be smooth, with no fins on it. The louvered air side fins are assumed as plane
with rectangular profile whose effectiveness is given by the following equation:
f = tanh(mf Lf)/(mf Lf)
 Modeling and experimental evaluation of
parallel flow micro channel condensers
Heat Transfer Correlations
(a) Refrigerant Side
(b) The refrigerant side involves three distinct regions characterized by the
thermodynamic state: superheated, condensing and subcooled. Two remarks
must be made at this point regarding the refrigerant side:
(1) Mixed oil effects have been disregarded in the present approach. Oil was certainly
mixed with the refrigerant in all the experiments since no oil separator was used in the
discharge of the compressor, as it is usual in automobile air conditioning systems. The oil
mass concentration in all the experiments was limited to a maximum of 2.5 %,
determined from the density of the refrigerant in the liquid line. This figure was
considered low enough to cause any significant effect in the condenser performance.
(2) Correlations for the heat transfer coefficient are strongly dependent upon the mass
velocity. Contrary to what happens in standard coil condensers, the refrigerant flow area
might vary between passes in the parallel flow micro channel ones, affecting the value of
the mass velocity, and, as a result, the heat transfer coefficient. This variation must be
introduced in the simulation program in such a way that the heat transfer correlations are
adequately adjusted. In the condenser simulated herein, the refrigerant flow area remains
essentially constant and so does the mass velocity, G.
Regarding the single-phase heat transfer coefficient, Mamani and Saiz Jabardo
(2000) have found that correlations for standard size tubes are equally applicable with
acceptable results to a micro channel geometry like the one considered in the present
study. The well-known Dittus and Boelter (1930) correlation, Eq. (2), was used in the
present version of the simulation program due to its simplicity and accuracy though
others such as the one by Gnielinski (1976) have been tested with satisfactory results.

It must be noted that the single-phase regions occur in an area of limited extent in
the condenser. This is not so with the condensing region which occurs in most of the heat
transfer area. As a result some care must be exercised when dealing with this region.
Several correlations developed for standard tube size have been considered such as the
ones by Akers et al (1959), Shah (1979), and others. The obtained results were
 Modeling and experimental evaluation of
parallel flow micro channel condensers
surprisingly satisfactory considering the doubts raised recently by several authors about
their adequacy to condensation in micro channels. Correlations developed for the
condensation of refrigerants in micro channels have also been tested using the simulation
program. One of such correlations is that proposed by Yang and Webb (1996a), with
satisfactory results when used along with the present simulation model. However,
considering that experimental data for refrigerant R-134a were available involving a
similar channel geometry, a correlation for the local heat transfer coefficient was
obtained by curve fitting these data, Mamani (2001). Curve fitting was performed in
terms of a dimensionless heat transfer coefficient and a modified version of the Martinelli
parameter, evaluated from a Blasius type of correlation for the friction coefficient. The
resulting correlation is as follows:

where
Xtt =  [(1-x)/x]0.875
and
 = ( g/l)0.5 ( l/g)0.125
hl is the single-phase heat transfer coefficient corresponding to the liquid of the
mixture flowing in the micro channel. The condensing heat transfer coefficient in Eq. (3)
depends upon the quality (local correlation), requiring the evaluation of an average
coefficient extensive to the condensing region. This has been accomplished by assuming
a constant heat flux along this region, what allows for the shifting of the dependent
variable from length to quality in the integral of the local heat transfer coefficient. The
resulting equation for the condensing average heat transfer coefficient is as follows:

where
C = 0.555+0.528/0.976

(b) Air side

 Modeling and experimental evaluation of
parallel flow micro channel condensers
The air side thermal resistance is generally the dominant one in the overall
condenser resistance given by Eq. (1). This requires an accurate evaluation of the air side
heat transfer coefficient in order to obtain a satisfactory performance of the simulation
program. In the past fifty years a significant number of publications have addressed the
heat transfer problem related to the flow of gases through compact heat exchangers
channels, including some textbooks such as the one by Kays and London (1984) and,
more recently, the one by Webb (1994). The complexity of the air passageway between
fins in air cooled condensers makes the development of a generalized correlation for heat
transfer a rather cumbersome problem. Chang and Wang (1997) have recently tried to
develop such correlation for different fin geometries, including those considered in this
study. The proposed correlation for the air side heat transfer coefficient is given in terms
of the typical Colburn factor, j, and includes a complex product of dimensionless
geometric factors besides the Reynolds number, assuming the following form:

In contrast with the relative complexity of the Chang and Wang correlation, the
one proposed by Rahman Ali (1995) for the air side heat transfer coefficient is strikingly
simple:

It must be noted that this correlation has been empirically obtained for the air side
geometry considered in this study, i. e. louvered fins brazed on flat blades. Figure 5
presents the variation of the Colburn factor with the air face velocity according to both
correlations, Eqs. (5) and (6). Face velocity has been used in this plot instead of the
Reynolds number since in each correlation this number is based upon different
characteristic dimension. Figure 4 clearly displays minor differences between results
from both correlations, with deviations being in the range between 8 and 10%. In addition
to directly comparing the correlations, comparisons have been performed through the
simulation program run for different operating conditions, the results showing negligibly
small deviations. As a result, the Rahman Ali correlation for the air side heat transfer
 Modeling and experimental evaluation of
parallel flow micro channel condensers
coefficient has been chosen, since, besides its simple form, it is reasonably accurate.

Heat Exchanger Overall Analysis

Each of the three regions of the condenser has been considered as an independent
heat exchanger, and the ( , NTU) procedure has been used for thermal performance
analysis. According to this procedure, the heat exchanger effectiveness is defined as

The Number of Transfer Units, NTU, is defined as the ratio between the product
(UA) and the minimum of the thermal capacities of both fluids. The following (, NTU)
correlations have been adopted in the condenser model:
(a) single phase regions, cross flow with both fluids unmixed
arrangement,

(b) condensing region, the refrigerant temperature is assumed constant

and equal to the saturation temperature at the average pressure in the
region,
 Modeling and experimental evaluation of
parallel flow micro channel condensers
In this case, NTU is evaluated in terms of the thermal capacity of the air,
Ca.Overall energy balances must complement (, NTU) correlations in each region. The
following equations are considered for that purpose in the model:
(a) Air side

(b) Refrigerant side

(b1) Single phase regions

(b2) Condensing region

(c) Overall condenser

Numerical Procedure
The set of equations that constitute the condenser mathematical model has been
solved through the software Engineering Equation Solver, EES, from F-Chart, USA. In
addition to providing solutions for systems of algebraic (and differential) equations, the
software incorporates transport properties of several substances including a number of
halocarbon refrigerants.
The numerical solution proceeds as shown in the block diagram of Fig. 6. Further
details of the adopted procedure can be found in Mamani (1997), a summary of it is as
follows:
(1) Reading input parameters: Condenser geometry, inlet air and refrigerant
temperatures and pressures, mass flow rate of refrigerant and face velocity of the air.
(2) Thermal evaluation of the superheated region:
(a) Determination of the overall heat transfer coefficient and pressure drop
 Modeling and experimental evaluation of
parallel flow micro channel condensers
(b) Determination of the other parameters through an iterative procedure. Initially, the
mass flow rate of air corresponding to this region is assumed to be equal to 10% of the
overall air mass flow rate.
(c) Evaluation of the refrigerant pressure drop.
(d) Evaluation of the air capacity, Ca, along with Cmin , , and the NTU for the region. It
must be noted that the actual heat transfer rate for the region is known, since the inlet and
outlet temperatures of the refrigerant are available.
(e) Evaluation of the product (UA) and area of the region from NTU.
(f) With the external heat transfer area, the mass flow rate of air for that region can be
determined as

(g) The obtained mass flow rate is compared to the initially assumed value, step (b). If the
deviation is within 1% or less, the program proceeds to step (3), otherwise to step (b) to
start the calculation over again.
(3) Thermal evaluation of the condensing region: Once the superheated region has
been solved, the condensing one is started following a similar procedure. The initial
assumption for the air mass flow rate for this region is 80% of the overall mass flow rate.
(4) Thermal evaluation of the subcooled region: The procedure for the subcooled
region is simpler since the mass flow rate of air can easily be determined as the difference
between the overall mass flow rate and the combined flow rate of previous regions.
(5) Closure: The exit average air temperature is evaluated by adiabatically mixing the
exit air from the three regions along with the total refrigerant pressure drop and the
condenser heat transfer. The overall heat transfer coefficient extensive to the full
condenser will be discussed in connection with the experimental results.
 Modeling and experimental evaluation of
parallel flow micro channel condensers

Discussion of Results
Results from the proposed model have been compared with those obtained from
an actual condenser tested in the experimental set up described herein. The particular
condenser of this study is that of the type described in Figs. 1 and 2, with micro channels
of square cross section. The geometry of the condenser is detailed in Tables 1 and 2,
where the micro channels and fins along with the overall dimensions are presented.

A face velocity of the cooling air of 3 m/s was maintained throughout the tests,
corresponding to the flow rate provided by the twin fan system, as mentioned before.
 Modeling and experimental evaluation of
parallel flow micro channel condensers
Results have been compared in terms of three important physical parameters of the
condenser: heat rejection rate, refrigerant pressure drop, and heat transfer coefficient.
Figures 7 (a) and (b) present the comparison between experimental and simulated results
of the first two parameters.. It must be stressed that results involve a relatively wide range
of input parameters, what makes them yet more significant. Regarding the pressure drop,
neglecting effects of headers, and inlet and exit of the micro channels has not
significantly affected simulation model results since they compare well with the
experimental ones. In fact, data dispersion in Fig. 7 (b) is in the range between –3% and +
6%, which is a clear indication that the effect of the neglected parameters over the
simulation model is of limited extent.

According to the simulation procedure, the product of the overall heat transfer
coefficient by the heat transfer area is determined for each of the three condenser regions.
The overall (UA)c product, extensive to the full condenser, is determined by assuming
that the refrigerant is at the average condensing temperature (saturation temperature at the
average condenser pressure) and the exit temperature of the air is uniform. It must be
noted that these are the conditions assumed in the experimental (UA)c product evaluation,
as suggested in succeeding paragraphs. As a result, for each operating condition, the
(UA)c product can be determined according to the following equation:
 Modeling and experimental evaluation of
parallel flow micro channel condensers
For the range of operating conditions, summarized in the caption of Fig. 8, the calculated
(UA)c product varies from a minimum of 728.6 W/K to a maximum of 844.6 W/K,
corresponding to a variation of 15.9%, as shown in the plot of Fig. 8. The average value
of (UA)c, corresponding to the set of operating conditions of Fig. 8, is equal to 784.9
W/K.

In the condenser industry the heat rejection rate is usually correlated in terms of
the difference between the average condensing temperature, corresponding to the average
refrigerant pressure in the condenser, and the inlet air temperature, also known as
"approaching temperature difference". Figure 9 displays this type of plot involving
superimposed experimental and simulation model results. It can be noted that both sets of
data points are aligned over straight lines passing through the origin with slopes as
indicated in the figure. The deviation of the simulated slope with respect to the
experimental one is of the order of 1.79%. Neglecting the effects of the superheated
vapor and subcooled liquid regions, as if the refrigerant underwent solely a condensing
process, it can be shown, Stoecker and Saiz Jabardo (2002), that the slope of the straight
line, R, is given by the following correlation:
 Modeling and experimental evaluation of
parallel flow micro channel condensers

Thus, given that the mass flow rate of air is known and constant, the product (UA)
can be determined from Eq. (21). This U value corresponds to the average overall heat
transfer coefficient extensive to the range of input parameters. Values of (UA)c from
experimental and simulated results are respectively equal to 789.0 W/K and 823.6 W/K.
The simulated value of (UA) deviates 4.39% from the experimental, a rather low figure
considering that the simulation model includes independently obtained heat transfer and
pressure drop correlations and does not present any empirically adjusted coefficient.
Finally, it is interesting to note that the simulated average value of (UA)c determined
from the procedure of Fig. 9 is 4.93% higher than that obtained from straight application
of Eq. (20). This is a predictable result since, in this case, effects of single-phase regions
are taken into account, diminishing the overall heat transfer coefficient. On the other
hand, the simulated average (UA)c from Eq. (20) is within 0.52% of the experimental
(UA) from Fig. 9. A minor deviation suggesting that a higher precision can be obtained
by directly applying Eq. (20) in the determination of the average value of (UA)c.
 Modeling and experimental evaluation of
parallel flow micro channel condensers

CONCLUSIONS :

The proposed simulation model for parallel flow micro-channel condensers for
automobile air conditioning applications has produced physically sound results.
Quantitatively, results from the model in terms of overall parameters, namely heat
rejection rate, refrigerant pressure drop and overall heat transfer coefficient, compare
very well with the experimental ones. Deviations are rather low, mostly in the range from
1 to 6%. Noteworthy is the fact that heat transfer and pressure drop correlations have
been independently obtained from the open literature and the model does not include any
adjusted parameter.

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1. 1959, Condensation heat transfer within horizontal tubes, Chemical Engineering
Progress Symposium series, Vol. .55, No..29, pp.171-176.
2. Chang, Y.J., Wang, C.C., 1997, A generalized heat transfer correlation for louver
fin geometry, International Journal of Heat and Mass Transfer, Vol. 40, n.3, pp.
533-544.
3. Thermal Engineering – By R.K. Rajput (P.P – 506-520)
4. A first course in power plant engineering. – Domkundwar
5. Power plant magazine
6. www. Scielo.br