R744 (CO2) Refrigerant Cooling Systems, the Finned Tube

R744 (CO2) Evaporator and Gas Cooler

Design Principles
Fatih KASAP
Mechanical Engineer
R&D Engineer

Hasan ACL
Mechanical Engineer
R&D Manager

Hatice CANBAZ
Mechanical Engineer
R&D Engineer

Selim ERBL
Mechanical Engineer

ABSTRACT
R744 (CO2) was used in the early stages of the refrigeration industry, but it lost the competition with
halocarbon refrigerants because of its high operating pressure and the loss of capacity and coefficient of
performance when rejecting heat near or above the critical point. Because the negative effect of
halocarbon refrigerants on environment, that R744 (CO 2) started to used recently. New heat exchanger
technology and system components allow R744 (CO 2) to reach competitive efficiency levels for transcritic
cycle especially in northern countries and for sub-critic cascade cycle in southern countries.
Recently, CO2 has been increasingly studied for application as the primary refrigerant in transcritical
mobile air conditioners, vending machines, supermarkets, cold rooms, food production and process
industry, industrial ice cream machineries and heat pumps.
This article is prepared to give general technical information on R744 (CO 2) cooling systems, CO2
evaporators and gas coolers.
Keywords : CO2, R744, Transcritic CO2 Cycle, Subcritic CO2 Cycle, Gas Cooler, Natural Refrigerant

1. INTRODUCTION
Throughout the 20th century, economic operations occurring within the triangle of industrialisation-growthdevelopment, led by developed countries have resulted in a pollution that the environment, the habitat of
man cannot endure. Soil, water, and air are faced with a level of pollution that threatens human life.
Countries that have begun to grasp the magnitude of the problem have commenced seeking permanent
solutions [1]. New standards and norms are being developed and implemented each year in this field. To
be able to adapt to the developments, companies that are associated with the process are forced to
develop technologies, products and manufacturing (process) methods conforming to the new laws and
standards.
Like many branches of industry, the air conditioning sector is affected by these developments. Efforts are
underway to develop environmentally friendly refrigerants for cooling systems to replace
chlorofluorocarbons (CFC) and hydrochlorofluorocarbons (HCFC) which accelerate global warming, harm
the ozone layer, and have a negative influence on the environment. Hydrofluorocarbons (HFC) are
synthesized from natural gases such as ethane and methane that do not contain chlorine, replacing
chlorine with hydrogen, and are consequently described as relatively more environment friendly [2,3]. In
addition to CO2, natural refrigerants such as isobutane and propane cannot be used in large batch

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systems due to their flammable and explosive nature. The R717 (NH3, Ammonia) gas on the other hand
have such disadvantages as their effects on copper alloys, and the risk of toxicity in large scale systems.
Natural refrigerants that do not have an effect on global warming and do not harm the ozone layer are
without a doubt the most significant alternatives in this process. The CO2 gas presents itself as an
effective solution at this point. CO2 has been widely used in the developing stages of the cooling industry.
However, it has been replaced by halocarbon refrigerants due to the drop in coefficient of performance
that emerge due to heat transfer around and above the critical point, as well as high operating pressures
[4]. The harmful effects of halocarbon refrigerants on the environment have in turn led to a return to CO 2
as an alternative, natural refrigerant. The current machine and exchanger technology, and system control
elements have enabled CO2 to reach competitive levels in terms of efficiency particularly in northern
countries through the transcritical cycle, and in the southern countries through the subcritical cascade
cycle. Due to its low critical temperature of 31.06C and high critical pressure of 73.8 bars, R744 (CO 2)
has some additional technical requirements to other conventional refrigerants.

2. R744 (CO2) AS REFRIGERANT

The use of R744 (CO2) as refrigerant was first suggested in 1850 by the Alexander Twining of Britain. Yet
the first CO2 refrigerated system was built toward the end of the 1860s by the American Thaddeus S.C.
Lowe. It was widely used in ships and industry until the 1920s due to its clean and reliable nature. With
the advent of CFCs in 1928, and due to the reasons mentioned above CO 2 was gradually pushed out of
the market, and was no longer used in the 1950s. The increasing restrictions on CFCs toward the end of
th
the 20 century have led to new pursuits, causing old natural refrigerants such as CO 2 and NH3 to be
revisited. Proffesor Gustav Lorentzens patenting of the transcritical CO2 cycle in 1990 was a milestone in
this subject [5].

2.1

ENVIRONMENTAL PROPERTIES OF CO2

There are two basic concepts regarding the environmental properties of refrigerants.
1. ODP (the Ozone Depletion Potential): Denotes the damage that a gas can have on the ozone
layer. It is expressed as a relative figure [6].
2. GWP (the Global Warming Potential): It is a measure of the impact of a greenhouse gas on the
environment over a specific time interval in relation to CO 2 , taking the GWP of CO2 as 1 [6].
CO2 has an ozone depletion potential of zero (ODP=0) and has very low direct impact on global warming
(GWP=1). Table 1 shows the environmental properties of common refrigerants.

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Table 1. Enviromental Properties of Various Widely Known Refrigerants [6]

Refrigerant

Refrigerant Classification

ODP

GWP

R 11

CFC

4600

R 12

CFC

0,82

10600

R 22

HCFC

0,034

1700

R 134a

HFC

1300

R 410a

HFC

1980

R 404a

HFC

3780

R 407c

HFC

1650

R 507a

HFC

3850

R744 (CO2)

Naturel Refrigerant

R 717 (NH3)

Naturel Refrigerant

<1

ODP: (R11=1 admitted) GWP: (CO2=1 admitted)

Another concept exists in the literature in addition to ODP and GWP: the Total Equivalent Warming Impact
(TEWI). The Total Equivalent Warming Impact (TEWI) denotes the direct or indirect global warming impact
of the refrigerant and the system of which it is part. The impact that the refrigerant has on the environment
is the direct impact. The CO2 emission that occurs during the supply of energy to the cooling system of
which it is a part is the indirect impact. The sum of the two impacts is defined as the Total Equivalent
Warming Impact (TEWI). CO2 as a refrigerant is effective in reducing total equivalent warming impact in
cooling systems [7].
2.2

CO2 SAFETY

Refrigerants are collected in 2 groups with respect to toxicity. Class A rating indicates no evidence of
toxicity below 400 ppm. Class B rating indicates evidence of toxicity below 400 ppm. CO2 is included in
Class A, which indicates no toxicity at concentrations below 400 ppm [8].
Refrigerants are divided in 3 classes in terms of flammability. Class 1 indicates a refrigerant which will not
burn in the flammability test under conditions of 21C and 101 kPa pressure. Class 2 indicates refrigerants
that is mildly flammable and produces a combustion heat of less than 19 kJ/kg under conditions of 21C
and 101 kPa pressure. Class 3 indicates refrigerants that is highly flammable and produces a combustion
heat of more than 19 kJ/kg under conditions of 21C and 101 kPa pressure. CO2 is rated as Class 1, as
inflammable [8].
Although CO2 has been described as non-toxic, it has some physical effects on people depending on its
concentration in the air. When the volume concentration of CO2 in the air is between 2 and 3%, rapid
breathing and mild headache may be experienced. The Immediately Dangerous to Life or Health (IDLH)
concentration has been fixed at 4% and the lethal concentration has been declared as 10%. In practice
the %5 limit for CO2 volume in the air is a quite reasonable figure [9]. Consequently designs should be
based on these limits, and the damage on living things in case of an accident or leak should be minimised.
Table 2 shows the safety classification of common refrigerants.

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Tablo 2. Safety Classification of Various Widely Known Refrigerants [8]

Refrigerant

R 11

R 12

R 22

R 134a

R 410a

R 404a

R 407c

R 507a

R744
(CO2)

R 717
(NH3)

Toxicity

Flammable

2.3

THERMOPHYSICAL PROPERTIES OF CO2

The properties of the refrigerant are very important in designing a refrigeration system. CO2 is known to
have different properties than other conventional refrigerants. In comparison, the most remarkable
property of CO2 is its low critical temperature (31.06C) and high critical temperature (73.8 bar). Another
limiting factor in the application of CO2 is its high triple point that occurs at -56.6C and 5.1 bar pressure.
Also in comparison with conventional refrigerants (CFC, HCFC, HFC, HC), it has a fairly high steam
3
pressure and volumetric heat transfer capacity (22545 kJ/m at 0C) [9].
As can be seen from the CO2 phase diagram, there are three conditions where two phases are in
equilibrium: Solid-Gas, Solid-Liquid, and Liquid-Gas equilibrium states. CO2 can only exist as a solid or
gas under atmospheric pressure. The liquid phase is not possible at this pressure. Above this
temperature, CO2 sublimates, transitioning to the gaseous phase. 5.2 bar and -56.6C are the conditions
where all states of CO2 are in equilibrium. The three states of the substance are in equilibrium under these
conditions. CO2 reaches the critical point at 31.1C. At this point, the densities of the liquid and gas phases
are equal and the difference between the two phases disappears. A new phase emerges as a result. This
phase of matter is called the supercritical phase. Figure 1 shows the CO2 Phase Diagram, while Figure 2
shows the CO2 In P-h Diagram.

ekil 2. CO2 lnP h Diagram [10]

Figure 1. CO2 Phase Diagram [10]

As shown in Table 3, CO2 has desirable thermophysical properties and lower viscosity, higher volumetric
capacity, higher thermal conductivity, and higher steam density than similar halocarbon refrigerants.

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Table 3. Thermophysical Properties of Various Widely Used Refrigerants [11]

Gas Phase
Density
(kg/m3)
[b]

Specific
Heat
Capacity
cp,
(kJ/kg)
[a]

Volumetric
Capacity
(kJ/m3)
[a]

Thermal
Conductivity
k, (W/m.K)
[a]

Dynamic
Viscosity
,
(mPa.s)
[a]

Tcrit, (C)

Pcrit,
(bar)

Liquid
Phase
Density f,
(kg/m3) [a]

R 11

198

44,1

1536,9

2,36

0,85

450,76

0,09

0,5

R 12

112

42,2

1400,1

17,185

0,93

2636,52

0,62

0,25

R 22

96,2

49,9

1285,7

20,41

1,16

4205,28

0,09

0,22

R 134a

101,1

40,6

1298,9

13,9

1,3

2773,75

0,09

0,27

R 410a

72,13

49,3

1175

28,82

1,5

6566,35

0,1

0,16

R 404a

72

37,3

1154,8

29,91

1,3

4953,99

0,07

0,18

R 407c

86,74

46,2

1240,8

18,86

1,4

3973,24

0,01

0,21

R 507a

70,6

37,05

1161,1

30,98

1,37

5055,32

0,072

0,18

R744 (CO2)

31

73,7

934,26

94,148

2,5

22089,00

0,11

0,101

R 717 (NH3)

132,3

113,3

640,28

3,31

4,41

4192,51

0,56

0,172

Refrigerant

Aklamalar: [a] For saturated liquid at -1,1C; [b] For saturated vapor at -1,1C

2.4

COST OF THE CO2 REFRIGERANT

Table 4 shows a comparison of the prices of common refrigerants. It is seen that CO2 as a natural
refrigerant has a much lower cost than conventional refrigerants.
Table 4. Cost Comparison of Widely Known Refrigerants [12]
R134a

R404a

R407c

R410a

R507

9,38 /kg

8,85 /kg

10,68 /kg

9,58 /kg

19,53 /kg

R744 (CO2)
0,52 /kg

R717 (NH3)
1,3 /kg

3. CO2 BASIC REFRIGERATION CYCLES

CO2 refrigeration systems have two types of basic cycles: Subcritical and Transcritical. In the cycle known
as Subcritical, the pressure is below the critical point throughout the cycle. In the Transcritical cycle, heat
transfer to the environment occurs above the critical point.

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3.1

SUBCRITICAL CYCLE

3.1.1 Direct Expansion CO2 Subcritical Cycle

The subcritical cycle is the most commonly used system in the refrigeration industry. All temperatures and
pressures are below the critical point, and above the triple point. The single stage subcritical CO2 cycle is
a fairly simple system. However, it has some disadvantages such as a limited temperature range and high
pressure. The low condensation temperature makes heat transfer to the environment more difficult. The
operating pressure is around 60 bar [13].

Figure 3. Direct Expansion CO2 Subcritical Cycle

[14]

Figure 4. Direct Expansion CO2 Subcritical Cycle

ln P h Diagram [10]

3.1.2 CO2 Subcritical Cascade Cycle

The CO2 cascade system is a refrigeration cycle which consists of two separate refrigerants that do not
intermingle. One of the two cycles is usually the compression cycle and the cycle where heat transfer to
the outside occurs. In these systems, the most widely used refrigerant is R717 (NH3, ammonia), which if
followed by R404A and other suitable HFC refrigerants [15]. The operating pressure in this type of system
is about 40-45 bar [16]

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1-2 Isentropic compression in the CO2 compressor

2-3 Isobaric condensation of CO2 in the Cascade
Condenser (shell and tube)
3-4 Expansion of liquid CO2 in the Expansion Valve
4-1 Isobaric evaporation in the Subcritical Evaporator
5-6 Isentropic compression in the
R717/R404A/R134A etc. Compressor
6-7 Isobaric condensation in the R717/R404A/R134A
etc. Condenser
7-8 Isenthalpic expansion in the R717/R404A/R134A
etc. Expansion Valve
8-5 Isobaric evaporation of NH3 in the Cascade
Condenser (shell and tube)
Figure 5. Subcritical CO2 - R717/R404A/R134A
Cascade Cycle Diagram [15]

Figure 6. Subcritical CO2 - R717/R404A/R134A,

Cascade Cycle In P - h Diagram [17]

A different feature of cascade systems is that while CO 2 condenses in the heat exchanger known as the
cascade condenser, the refrigerant on the high temperature side evaporates. This type of heat exchanger
can be plate type or shell and tube type [16]

3.2

CO2 TRANSCRITICAL CYCLE

3.2.1 CO2 Transcritical Cycle

CO2 has a low critical temperature of 31.06 C and a high critical temperature of 73.8 bar. As is the case
in conventional steam compression cycles, it is not possible for the refrigerant to reject heat to the
atmosphere by condensing in the condenser. Heat transfer to the environment in the supercritical area, as
the temperature of gaseous CO2 drops without condensation. Cycles that occur in this way are called
transcritical CO2 cycles [6]. Hence, the gas cooler replaces the condenser in the system. In the
Transcritical CO2 cycle, the compressed CO2 in the compressor rejects its heat to the atmosphere in the
gas cooler [18].

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Figure 8. CO2 Transcritical Cycle ln P h

Diagram[10]

Figure 7. CO2 Transcritical Cycle [19]

3.2.1.1 Simple One Stage Transcritical Cycle with Internal Heat Exchanger
An internal heat exchanger is used to increase efficiency in transcritical systems. To increase the EER of
the exchanger system, this lowers the gas cooler outlet temperature while serving as an accumulator to
prevent liquid leaking to the compressor, ensuring that there is gas at the evaporator outlet.

Figure 9. One Stage Transcritical Cycle with Internal Heat Exchanger

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1-2 Isentropic compression compressor

2-3 Isobaric heat transfer in the Gas Cooler
3-4 Refrigeration in the Internal Heat Exchanger
4-5 Isenthalpic expansion in the Expansion Valve
5-6 Isobaric evaporation in the Transcritical
Evaporator
6-1 Superheating in the Internal Heat Exchanger
Figure 10. One Stage Transcritical Cycle with Internal Heat Exchanger [20]

Figure 11. CO2 Transcritical Cycle with Internal

Heat Exchanger ln P h Diagram [21]

Figure 12. CO2 Transcritical Cycle with Internal

Heat Exchanger T-S Diagram [21]

3.2.1.2 Simple Gas Bypass Transcritical Cycle with Internal Heat Exchanger
Gas bypasses are also included in designs to increase the efficiency of transcritical systems. Unlike
conventional systems, a second expansion valve is added to the system. While the first expansion occurs
from the gas cooler to the liquid tank, the liquid and gas states occur here. Afterwards, the liquid is once
again brought to the desired evaporation temperature. In these systems, the dryness at the evaporator
inlet is decreased due to the second expansion, thus increasing the EER of the system, while the
connection of the system with the outside environment is reduced since a liquid tank is used in the
intermediate pressure stage. The system also includes a balancing valve. Since this valve regulates the
pressure level in the liquid tank, the temperature before the expansion valve, and therefore the inlet
enthalpy of the evaporator are regulated.

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1-2 Isentropic compression compressor

2-3 Isobaric heat transfer to the environment in the
Gas Cooler
3-4 Refrigeration in the Internal Heat Exchanger
4-5 Isenthalpic expansion in the Expansion Valve
5- Separation of the liquid and gaseous phases in
the Receiver
6-7 Isenthalpic expansion of liquid in the Expansion
Valve
7-8 Isobaric evaporation in the Transcritical
Evaporator
9-10 Isenthalpic expansion in the Expansion Valve
11-1 Superheating in the Internal Heat Exchanger
Figure 13. CO2 Gas Bypass CO2 Transcritical Cycle with Internal Heat Exchanger [20]

Figure 14. Gas Bypass CO2 Transcritical Cycle with

Internal Heat Exchanger ln P h Diagram [27]

Figure 15. Gas Bypass CO 2 Transcritical Cycle with

Internal Heat Exchanger T-S Diagram [27]

4. COMPARISON OF CO2 REFRIGERANT SYSTEMS WITH OTHER GASEOUS SYSTEMS AND

SYSTEM EFFICIENCY
Studies conducted in recent years on CO2 Transcritical Refrigeration systems indicate that this cycle is
more profitable particularly in temperate and cold climates. The reason that stresses this opinion is the
fact that the system EER is higher in regions with lower outdoor ambient temperatures. The TESCO
supermarket chain in the UK and the FAKTA supermarket chain in Denmark are leaders in Europe in
terms of CO2 Transcritical Refrigeration applications. Even in periods where summers are warm, the
energy expended in CO2 Transcritical refrigeration systems in these countries have been observed to be
close to conventional systems. The energy saving comparisons of the R404A single stage system and the
CO2 Transcritical system in major European cities based on average annual temperatures are shown
below on the geographic map of Europe. [22]

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Figure 16. Comparison of the R744 (CO2) Transcritical Refrigeration System Efficiency with the R404A
gas in the European region [22]
R744 refrigeration systems have been shown to be more efficient in temperate and cold climates with
medium and low temperatures. The use of cascade systems is recommended in regions with very warm
climates [23, 27].
Efforts to achieve higher efficiency coefficients and increases in efficiency in supermarket systems that
combine deep-freezing with normal refrigeration are in progress. Furthermore, it is predicted that efforts to
increase efficiencies through evaporative condenser systems in warm climates will intensify in the years to
come [27].

5. BASIC ELEMENTS OF CO2 REFRIGERANT REFRIGERATION SYSTEMS

5.1

CO2 COMPRESSORS

Today, the advances in the technology of refrigeration with CO 2 have led many firms to offer compressors
to the market. Compressors that are suited for both subcritical and transcritical are available in rotor,
hermetic, semi-hermetic, spiral, spiral lobe, and centrifugal types. Transcritical compressors can be
selected as single stage or double stage depending on the application. These compressors are also
available with economizer equipment [24].

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Figure 17. Comparison of operating pressures [25]

The advantages and disadvantages of compressors used in R744 refrigeration systems are as follows:
Table 5. Advantages and Disadvantages of R744 Compressors [24]
Advantages

Disadvantages

Low compression ratio and

high volumetric efficiency
Low piston displacement

5.2

Discharge line temperature increases too much in very low

temperature applications.
Substantial reinforcement is required for the outer shell and
other components, due to high operating pressures.

CO2 COMPATIBLE LUBRICANTS

Two types of synthetic lubricants are used in CO2 transcritical refrigerant systems: miscible and nonmiscible. Poly-alpha-olefin (PAO) is a non-miscible lubricant and generally flows on liquid CO2. Polyester
(POE) lubricants are used as miscible lubricants, but since these lubricants are highly sensitive to water,
they should be stabilized in oil. Detailed information has been provided in the following table [10].
Table 6. Comparison of Lubricants [10]
Lubricant Type
Solubility

PAO
Low

POE
High

Hydrolysis

Low

High sensitivity to water

Oil Separator

High degree of filtration required (Active

carbon and multi stage)

Simple as in HFC/ HCFC systems

Oil Feed

Required for oil drainage from low

temperature drip pan

Simple as in HFC/ HCFC systems

Disadvantages

Special requirements in oil separator and

feed

Stabilization in oil and sensitivity to

water

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5.3

CO2 EXPANSION VALVES

The expansion process is definitely used in the gas cooler outlet of the system in order to convey the CO 2
gas to the evaporator at fixed enthalpy. The vanes that implement this process are as follows: [26]
Capillary Tube or Orifice
Automatic Expansion Valve
Thermostatic Expansion Valve
Electronic Expansion Valve
You can find the advantages and disadvantages of valves in Table 10.
Table 7. Comparison of Expansion Valves [10]
Capillary Tube /
Orifice

Mechanic Expansion
Valve

Thermostatic
Expansion Valve

Advantage

Very simple and

cheap.

Reaction depends on
varying capacity.

Reaction depends on
the varying outside
temperature.

Disadvant
age

Operates optimally
only under specified
conditions.

Has only one set value;

does not react
sufficiently to variations
in outside temperature.

Does not optimize

according to varying
capacity.

Electronic
Expansion
Valve
Provides full
control and
optimization to
the system.
Costly and
complex
systems.

Figure 18. R744 Electronic Expansion Valves [26]

5.4

FINNED TUBE CO2 HEAT EXCHANGERS

Studies were conducted by the Friterm A.. R&D Department within the scope of a scientific study
supported by TBTAK, under the main heading of environmentally friendly technologies on designs for
evaporators and gas coolers to be used in CO2 subcritical and transcritical refrigeration systems. Within
the scope of this study, software was developed for the design of CO 2 heat exchangers and a test
laboratory was set up for the same purpose. During the course of the study, software data were compared
to test laboratory data and the compatibility of software results to test results was achieved. The following
information involves a general discussion of the data obtained in the course of this study. [27]

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5.4.1 CO2 EVAPORATORS

Finned lock CO2 evaporators can be used in both subcritical and transcritical cycles.
for design are discussed in three basic sections:

The data required

1. Air side design data

2. CO2 side design data
3. Heat exchanger design data

Figure 19. FRTCOILS CO2 Evaporator Module Interface [27]

5.4.1.1 Air Side Design Data
1. Atmospheric pressure: Atmospheric pressure must be known to determine the air pressure
dependent physical properties of air. Here the Altitude values can also be defined instead of
atmospheric pressure.
2. Air flow: The air flow that can accommodate the required capacity must be known. Air speed and
mass flow values can also be defined.

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3. Inlet temperature: The ambient air inlet temperature where the refrigerant will operate must be
known.
4. Relative Humidity: The relative humidity of the ambient air inlet temperature where the
refrigerant will operate must be known. Wet bulb temperature can also be defined instead of
relative humidity in this section.

5.4.1.2 CO2 Side Design Data

1. Refrigerant Flow: If the refrigerant flow is known, the outlet conditions of the evaporator can
easily be calculated. In this case the superheating degree can be determined according to the
flow. If it is not known, the superheating degree must be specified in addition to the other data
listed below, that need to be defined.
2. Evaporation temperature: The evaporation temperature that will make up for the difference
between the ambient air temperature that is specified according to the products and refrigerant
usage requirements and the evaporation temperature must be known.
3. Dryness Fraction:
In the transcritical R744 (CO2) Refrigeration Cycle, The dryness fraction of the refrigerant must be
known in order to determine the properties of the refrigerant entering the evaporator. This value
depends on the operating pressure and outlet temperature of the gas cooler that serves the
function of heat rejection in the cycle.

Figure 20. Determination of Dryness Fraction in the Transcritical

Cycle [20]

In the Subcritical R744 (CO2) Refrigeration Cycle, the design Condensation temperature of the
system and the supercooling degree must be known.

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Figure 21. Determination of Dryness Fraction in the Subcritical Cycle

[20]
4. Superheating Degree: The superheating degree must be specified for the outlet conditions of the
evaporator to be known.
5. Supercooling Degree: It is the difference between the condensation temperature defined in the
subcritical CO2 refrigeration cycle and the temperature before the expansion valve.
5.4.1.3 Heat Exchanger Design Data

Finned tube heat exchanger design data are given below:

Coil geometry that determines tube diameter and arrangements as well as distance between
tubes and rows
Fin arranged length
Tube number
Row number
Pass number or circuit number
Fin pitch
Fin material
Fin thickness
Collector diameter (If known)
Distributor tubes diameter and dimension
Tube material
Tube thickness
The data defined above under three main headings allow the design and computation of the finned tube
CO2 heat exchanger.

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Figure 22. Appearance of copper tubes and curves [27]

There are some important factors that require attention in the design of the CO 2 heat exchanger. For
instance, the operating pressures in CO2 evaporators are higher than operating pressures of evaporators
operating in conventional refrigeration systems. For this reason, the thicknesses of copper tubes used
must be increased.
Another point is that CO2 has higher specific heat, higher transfer coefficient and lower viscosity than
gases such as R404A, R410A, R134A, etc. This means that the CO2 gas causes lower pressure loss at
the same mass flow for both gases. Another issue that is observed in the design of the CO 2 heat
exchanger is that tube diameters can also be made smaller due to high volumetric efficiency.
CO2 evaporator prototypes designed within this framework and according to data specified above have
been tested in the balanced ambient calorimeter laboratory.

Figure 23. CO2 Evaporator Product Test in the Laboratory [27]

Figure 24. CO2 refrigerant preparation unit [27]

The conditions specified for testing CO2 evaporators are presented in Table 11.

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Table 8. Evaporator test conditions [27]

193,11

Air Inlet
Temperature
o
( C)
12,02

Air Relative
Humidity
(%)
45,17

1,25

164,068

10

48,79

-7,08

122,829

-0,01

50,20

Test

Tested Products

CO2 Evaporation
o
Temperature ( C)

CO2 Mass Flow

(kg/h)

Prototype 1

1,58

Prototype 2

3
4

Prototype 3

-12,39

76,492

-0,01

41,50

Prototype 4

-2,74

110,705

15,03

27,70

Test results obtained for evaporator designs were analysed in the FRTCOILS CO2 software that had been
developed. The experimental results that were obtained can be seen in Table 12.
Table 9. CO2 Evaporator test results [27]
Test

Tested Products

Experimental Results
Capacity (kW)

Prototype 1

11,503

2
3

9,667

Prototype 2

7,684

Prototype 3

4,665

Prototype 4

6,989

Compatibility between the obtained test results and the software that was developed was achieved.
5.4.2 CO2 GAS COOLERS
Finned tube CO2 gas coolers are used in the transcritical cycle. The data required for design is grouped
under three basic sections as in the evaporators: air side, CO 2 side, and heat exchanger design data.

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Figure 25. FRTCOILS CO2 Gas Cooler Module Interface [27]

5.4.2.1 Air Side Design Data

1. Atmospheric pressure: Atmospheric pressure must be known to determine the air pressure
2.
3.
4.

dependent physical properties of air. Here the Altitude values can also be defined instead of
atmospheric pressure.
Air flow: The air flow that can accommodate the required capacity must be known. Air speed and
mass flow values can also be defined.
Inlet temperature: The ambient air inlet temperature where the gas cooler will operate must be
known.
Relative Humidity: Although the humidity of outside air is not an influential parameter, it must be
known.

5.4.2.2 CO2 Side Design Data

1. Refrigerant Inlet temperature: The refrigerant inlet temperature must be specified in relation to
operating pressures and compressor efficiency.

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Figure 26. Determination of the Refrigerant Inlet Temperature

[20]

2. Refrigerant Flow: If the refrigerant flow is known, the outlet conditions of the gas cooler can be
3.
4.

calculated. If it is not known, the CO2 gas cooler outlet temperature must be specified in addition
to the other data listed below, that need to be defined.
Refrigerant Outlet Temperature: In cases where the refrigerant flow is not known, the outlet
temperature of the gas cooler must definitely be specified. The desired air inlet temperature in
designs is within 3-5 K of the CO2 outlet temperature.
CO2 Pressure: Operating pressure must be specified in relation to ambient temperature and
compressor data in gas cooler designs. Furthermore, the EER of the system is influenced not only
by the compressor discharge line pressure but also by other parameters such as ambient and gas
cooler outlet temperature. Therefore an optimization study should be conducted in the system
design phase.

5.4.2.3 Heat Exchanger Design Data

The design data for the finned tube heat exchanger have been presented below.
Coil geometry that determines tube diameter and arrangements as well as distance between
tubes and rows
Fin arranged length
Tube number
Row number
Pass number or circuit number
Fin pitch
Fin material
Fin thickness
Collector diameter (If known)
Distributor tubes diameter and dimension
Tube material
Tube thickness

The data defined above under three main headings allow the design and computation of the finned tube
CO2 heat exchanger.
CO2 gas cooler prototypes designed within this framework and according to data specified above have
been tested in the balanced ambient calorimeter laboratory.

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Figure 27. CO2 Gas Cooler Product [27]

The gas cooler that was designed was tested at the Friterm A.. R&D Test laboratory. Test conditions are
presented in Table 13.

Test

CO2 Inlet
Pressure (Mpa)

7,647

9,2

Table 10. Gas Cooler Test Conditions [27]

CO2 Inlet
Air Inlet
CO2 Mass Flow
Temperature
Temperature
(kg/h)
o
o
( C)
( C)
64,78
281,879
25,03
84,92

227,47

25

Air Mass Flow

3
(m /h)
6840
6840

Gas cooler test results were analysed in the FRTCOILS CO2 software that had been developed. The
experimental results that were obtained can be seen below.
Tablo 11. CO2 Gas Cooler Test Results [27]
Test

Experimental Results
Capacity (kW)

13,215

14,535

The prototype tests conducted in the laboratory supported software studies. Compatibility between the
results obtained from the software that had been developed and experimental data was achieved.
Consequently, the software that allows the design of finned tube CO2 evaporator and gas cooler was
created.

CONCLUSION
For along time, CFC and HCFC refrigerants have been widely used in refrigerant systems that are an
absolute necessity in all areas of life, from the past to the future. Since these chemical gases cause a
greenhouse effect, they exacerbate the problem of global warming. For this reason, a search has begun
for new alternatives in refrigerants. Among natural refrigerants that are in the limelight, CO 2 applications
are becoming more widespread. The ozone depletion factor of the R744 gas is zero, and its global

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warming potential is one. Aside from being very cheap, it is also easy to procure. Its most significant
properties are its high volumetric cooling capacity and its thermal properties. This facilitates a reduction in
the intake and discharge lines of the tubing installation as well as in tube diameters of the finned tube heat
exchangers that are used. Apart from all of these significant advantages, R744 (CO 2) has some additional
technical requirements to other conventional refrigerants due to its low critical temperature of 31.06C and
high critical pressure of 73.8 bars.
To make sure that the very high critical pressure as compared to other gases does not create problems
particularly in terms of safety, the mechanical strength of the system equipment used should be increased.
The low critical temperature makes operation of the systems discharge line difficult particularly in
countries with temperate and warm climates. This is eliminated by cascade system applications and
optimization of gas cooler applications above the critical temperature.
As can be seen from the studies above, the selection of the system that is compatible with design
conditions becomes important. Particularly in more temperate and colder climates, subcritical and
transcritical systems operate with higher efficiency. In warm climates on the other hand, CO2 cascade
applications are more efficient.
Software development efforts required for the design of evaporators and gas coolers among the most
important components of the system- were conducted. Software studies were supported by prototype
tests conducted in the laboratory. The results obtained from the software that had been developed were
observed to be compatible with the experimental data. In consequence, the software that allows the
design of finned tube CO2 evaporator and gas cooler was created.

REFERENCES
[1] YALIN A. Z., Kresel evre Politikalarnn Kresel Kamusal Mallar Perspektifinden
Deerlendirilmesi, Balkesir niversitesi Sosyal Bilimler Enstits Dergisi, Cilt 12, Say 21, ss.288309, Haziran 2009
[2] BULGURCU, H., KON, O., LTEN, N., Soutucu Akkanlarn evresel Etkileri le lgili Yeni Yasal
Dzenlemeler Ve Hedefler , VIII. Ulusal Tesisat Mhendislii Kongresi, 2007
[3] ZKOL, N.; Uygulamal Soutma Teknii, TMMOB Makine Mhendisleri Odas Yayn No: 115,
Nisan 1999, Ankara.
[4] 2006 Ashrae handbook-refrigeration (SI)
[5] PEARSON A., Carbon dioxidenew uses for an old refrigerant, 2005
[6] Thermophysical Properties R744, International Institute of Refrigeration, 2003
[7] IIR 15th Informatory Note on Refrigerants, February 2000
[8] Classification of Refrigerants, International Institute of Refrigeration, 2001
[9] KIM M.H., PETTERSEN, J. ve BULLARD C.W., Fundamental process and system design issues in
CO2 vapour compression systems, Progress in Energy and Combustion Science 30, 119174, 2004
[10] Danfoss Refrigeration and Air Conditioning Division, Food Retail CO 2 Refrigeration Systems,
Danfoss A/S (RA Marketing/MWA), DKRCE.PA.R1.A1.02 / 520H3371, February 2009
[11] LEMMON, E. W., HUBER, M. L., MCLINDEN, M. O., NIST Standard Reference Database 23, Version
8.0, Physical and Chemical Properties Division, 2007
[12] DuPont - Canta A ve Gne Gaz Ltd. ti. Mays 2010
[13] EVANS C. L., BOHN Group-Product Management, CO2 Unit Coolers for Supermarket Refrigeration
Systems, September 2009
[14] http://www.cartage.org.Ib/en/themes/sciences/physics/thermodynamics/basicthermodynamics/
Refrigeration/Refrigeration.htm
[15] Danfoss Refrigeration and Air Conditioning Division, CO 2 Refrigerant for Industrial Refrigeration,
Danfoss A/S (RA Marketing/MWA), DKRCI.PZ.000.C1.02 / 520H2242, September 2007

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[16] ONBAIOLU H., An Overview of Vapour Compression System Using Natural Refrigerant CO 2,
SKD ACV&R Journal of Turkey, Vol:2, pp: 48-64, 2010
[17] http://www.swep.net
[18] SARKAR, J., BHATTACHARYYA, S., RAMGOPAL, M., Optimization of a Transcritical CO 2 Heat
Pump Cycle for Simultaneous Cooling and Heating Applications, International Journal of Refrigeration,
27, 2004.
[19] BAYRAKI, H.C., ZGR, A.E., AKDA, A.E., Ayni soutma Yk iin CO 2li s pompalarnn enerji
sarfiyatlarnn karlatrlmas, IX.Ulusal Tesisat Mhendislii Kongresi
[20] http://simple-one-stage-co2-cycle.software.informer.com
[21] FARTAJ, A., TING, D.S.K., YANG, W.W, Second law analysis of the transcritical CO 2 refrigeration
cycle, Energy Conversion and Management Vol:45, 2004
[22] Danfoss Teknik Dkmanlar
[23] CECCHINATO, L., CORRADI, M., Transcritical carbon dioxide small commercial cooling applications
analysis, International Journal of Refrigeration, Vol: 34, 2011.
[24] ZIMMERMANN, A., Carbon Dioxide as the Refrigerant in Supermarket, CO 2 Compressors, 10th
Short Course in Supermarket Refrigeration, 2010
[25] Bock Kompresr Teknik Dkmanlar
[26] The Danfoss CO2 Gas Cooler Solution
[27] Friterm A.. Teknik Dkmanlar

YAZAR ZGEM:
Fatih KASAP was born in Karabk in 1986. He graduated from the Mechanical Engineering Department of
the Istanbul Technical University in 2009. He is currently pursuing his postgraduate studies in the
department of Thermal Fluids of the same University. He completed his Undergraduate and Post
Graduate theses within the Friterm A.. R&D department. He is currently employed as a Test Laboratory
and Product Development Engineer at the R&D department of Friterm A...

YAZAR ZGEM:
Hasan ACL was born in Ayvalk in 1976. He graduated from the Mechanical Engineering Department of
the Yldz Technical University in 1999. He received his masters degree at the Department of Science and
Technology Strategies of the Gebze Institute of Technology. Before and after completing his Mechanical
Engineering education, he worked as an engineer and administrator in field office, sales, production and
R&D departments of various firms operating in the Heating, Cooling and Air Conditioning sectors. He is
currently employed as the R&D Department Director at Friterm A.., where he has worked since 2003. In
addition to this office, he is in charge of and an instructor at the Friterm Academy. HAsan Acl has the
Tbitak/Tsside R&D Specialist Certificate. Hasan Acl who is also a member of the executive board of
the Kartal District Office of the Istanbul Branch of the Chamber of Mechanical Engineers, is a member of
the International Product Development and Management Association (PDMA), the Istanbul project
Management Association, and the Association of Ship Modelers. He is married, and has a daughter.
YAZAR ZGEM:
Hatice CANBAZ was born in Kocaeli in 1985. She graduated from the Mechanical Engineering
Department of the Yldz Technical University in 2008. She is currently pursuing her postgraduate studies
in the department of Thermal Process of the same University. She has worked as a R&D engineer at
Friterm A.. where she began working after receiving her graduate degree for nearly two years, and has
the Tbitak/Tsside Product Development Specialist Certificate.

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YAZAR ZGEM:
Selim ERBL was born in Ankara in 1986. He graduated from the Mechanical Engineering Department of
the Yldz Technical University in 2010. He is pursing his postgraduate studies at the Istanbul Technical
University Energy Institute. He completed his Undergraduate dissertation within the Friterm A.. R&D
department. He is currently employed by a firm operating in the automotive industry, as a product
development and design engineer.

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