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A comprehensive thermodynamic approach for modeling mixtures of refrigerants and lubricating oils is
presented. The new approach includes generalized methods for predicting the following thermodynamic
properties of refrigerant-oil mixtures: bubble point temperatures, local oil concentrations, liquid specific
heats and enthalpy changes during evaporation. Using this comprehensive method, heat release (enthalpy)
curves are easily generated and also the effect of oil on the LMTD (log mean temperature difference) of
evaporators can be modeled. Importantly, the definition of the boiling heat-transfer coefficient based on
the bubble point temperature is included in the method. This new approach provides the basis for advances
to be made in two-phase refrigeration heat-transfer research and design.
INTRODUCTION
Buildup of lubricating oil in refrigeration, air-conditioning and heat pump systems is perhaps the oldest
unresolved problem vexing industry. It represents a serious roadblock to accurately modeling these systems
under actual operating conditions, i.e. with anywhere from negligible oil up to as much as 5% (by mass) oil
in the refrigerant charge. Oil also creates considerable uncertainty in the integrity of test results by
adversely affecting energy balances, local saturation temperatures implied from pressure measurements,
two-phase pressure drops, and also heat-transfer coefficients and equipment performance data derived from
these tests. To respond to this problem, a new comprehensive method for modeling refrigerant-oil mixtures
has been developed, namely the “Thermodynamic approach,” which can be used as an alternative to the
traditional “Oil contamination approach” in dealing with these mixtures. The new approach not only allows
one to analyze a particular oil's effect on system design and operation but it also provides an improved ther-
modynamic method for giving more accuracy when reducing raw experimental test data to heat-transfer
coefficients or other design parameters. Hence, this new thermodynamic approach is recommended for use
in all new refrigerant-oil heat-transfer studies, and can also be used to reevaluate old test data for improved
results.
Oil adversely affects the optimal performance of various system components: evaporator, condenser,
compressor, expansion device and control valve. The largest effect of oil is on evaporator performance,
where it can significantly alter boiling heat-transfer coefficients and reduce the LMTD, lowering the effec-
tive refrigeration capacity of the system. Local oil concentrations can become as high as 70 to 80% (by
mass) oil in the unevaporated liquid leaving an evaporator, but normally will not exceed 50% (by mass) oil
except in a very small portion of the evaporator.
John Thome is a visiting professor at the Laboratory for Industrial Energetics (LENI), Swiss Federal Institute of Technology, Lausanne,
Switzerland.
110
VOLUME 1, NUMBER 2, APRIL 1995 111
cient and LMTD, where Tsat is determined from the vapor pressure curve of the pure refrigerant at the local
pressure.
This simple approach is not thermodynamically correct; it ignores the effects of oil on boiling point tem-
peratures, specific heats, enthalpies, etc. that, in turn, alter the calculations for energy balances, local boil-
ing temperature differences and vapor qualities, log-mean temperature differences, etc. in the data
reduction process that is used (1) to determine heat-transfer coefficients and two-phase pressure drops and
(2) for the thermal design of evaporators and condensers. In addition, the oil contamination approach pre-
cludes introducing the type of oil and its physical properties in the calculations.
or kilograms divided by the total mass of the mixture in pounds or kilograms, respectively, in a particular
phase (liquid or vapor).
Figure 1(b) depicts an approximate phase diagram for R-134a mixed with an ester-type lubricating oil at
343 kPa (49.7 psia). In this case, the horizontal axis shows the oil concentration in % (by mass) oil. At the
left axis of the diagram the saturation temperature of pure R-134a is 4.4°C (40°F) while at the right axis the
dew and bubble point temperatures rise rapidly towards the saturation temperature of the pure oil (not
shown), which is in the neighborhood of 350°C (662°F). The bubble point curve is quite flat at low oil con-
centrations and starts to rise rapidly at values above 70% (by mass) oil. The dew point curve, which repre-
sents the oil concentration in the vapor phase, is not well-known for refrigerant-oil mixtures and was drawn
assuming negligible amounts of oil enter the vapor phase at liquid oil concentrations below 70% (by mass).
Above this value its concentration is represented by proration towards the pure oil value.
Generalized Method
Takaishi and Oguchi (1987) presented an empirical equation for the vapor pressure curve of R-22 mixed
with synthetic alkyl benzene oil over the concentration range from 0 to 70% (by mass) oil (0 to 0.70 mass
fraction oil) and a temperature span from 10 to 60°C (50 to 140°F). Their empirical vapor pressure equa-
tion for predicting the bubble point temperature for a given saturation pressure and oil concentration was
presented as:
A (woil )
T bub = --------------------------------------------
- (1)
ln ( Psat ) – B ( woil )
where Psat is the saturation pressure in MPa and Tbub is the bubble point temperature in K. The oil concen-
tration in the liquid is given by woil , which is in mass fraction. A(woil ) and B(woil ) were given by the follow-
ing expressions:
Of course, by statistically fitting new constants to Equations (2) and (3) for each specific set of solubility
test data, more accuracy can be achieved; however, such a specific approach cannot be used as a general
application method for any refrigerant and oil combination.
Another important point is that regardless of the inlet oil concentration before the expansion device (nor-
mally in range from 0 to 5% (by mass) oil), 90% or more of the evaporator will always have local concen-
trations less than 50% (by mass) oil [this is evident from evaluation of Equation (5) presented in the next
section for the complete range of local vapor qualities]. Consequently, the method given by Equations (1),
(2), and (3) is proposed for general use in research and industry.
where
x = local vapor quality
hLV = latent heat of vaporization of the refrigerant
(cp )L = specific heat of the liquid refrigerant-oil mixture
(cp )V = specific heat of the pure refrigerant vapor
The values of (cp )L and (cp )V are a function of the local oil concentration and bubble point temperature
VOLUME 1, NUMBER 2, APRIL 1995 115
while hLV is a function of only the bubble point temperature. Equation (4) reduces to the latent heat for a
pure refrigerant.
A heat release curve is not actually determined as a curve, but instead as a series of points at a set inter-
val of temperature or vapor quality indicating the amount of heat absorbed by the fluid per unit mass. In
other words, dH is in J/kg or Btu/lb, relative to its inlet state together with the bubble point temperature and
vapor qualities that correspond to these points. At the inlet no heat has yet been added so the heat absorbed
is zero. Figure 2, adapted from Collier and Thome (1994), graphically depicts a heat release curve for an
evaporating zeotropic mixture. Temperature is plotted on the y-axis while the heat absorbed is plotted on
the x-axis. The vapor quality is shown at intervals along the curve. The bubble point temperatures corre-
sponding to points on the curve are read off the y-axis.
For a pure refrigerant without any oil, wlocal is always equal to zero. Because the oil is essentially non-
volatile, the maximum exit vapor quality that can be achieved in refrigeration, air-conditioning and heat
pump systems is (1−winlet ). This is an important limiting point because in designing a system with, for
example, 3% (by mass) oil, the exit vapor quality from the evaporator has to be less than 0.97. Equation (5)
is based on complete flow of the mixture through the system, i.e. no local oil holdup in the heat-transfer
tubes.
where the liquid specific heat [(cp )L ]oil is in kJ/(kg·K), the temperature of the oil T is in °C (valid for −18°C
< T < 204°C) and s is the specific gravity of the liquid at 15.6°C (valid for 0.75 < s < 1.05). The expression
is an adaptation of the equation for crude oil cuts in Smith, Block, and Hickman (1973) to lubricating oils.
Manufacturers usually provide the density or specific gravity of lubricating oils at 60°F (15.6°C), which
facilitates the use of Equation (6). This correlation compares well with the tabular values for engine oil
cited in Incropera and DeWitt (1981) which have maximum deviations of −2% to +7%, which is sufficient
for present purposes because the sensible heat contribution is small (but not negligible) compared to the
latent heat term in Equation (4).
at each local vapor quality as a function of oil concentration wlocal and bubble point temperature Tbub.
Working in the units of kJ/(kg·K) (Btu/lb·°F), a linear mixing law based on mass fractions of oil gives the
liquid specific heats of these mixtures as:
The above equation is evaluated with the refrigerant and oil properties at the local bubble point temper-
ature of the mixture. Because heats of mixing data are not available and because the values for the oil and
refrigerant are often within 10 to 30% of one another while the value for the oil is accurate to about ±10%,
the linear mixing law approach is appropriate here.
h = q ⁄ ( Tw – Tsat ) (8)
118 HVAC&R RESEARCH
where
q = heat flux (Q/A)
Tw = heated wall temperature
Tsat = saturation temperature of the pure liquid
Q = heat flowing through the heated area A
For flow boiling this definition refers to the local heat-transfer coefficient at a specific local vapor qual-
ity, local heat flux, local wall temperature and local saturation temperature. Experimentally, Tsat is nor-
mally determined from the vapor pressure curve of the pure fluid and the measured pressure.
For refrigerant-oil mixtures, the pool boiling heat-transfer coefficient h is defined as:
h = q ⁄ ( Tw – Tbub ) (9)
where
q = heat flux (Q/A)
Tw = heated wall temperature
Tbub = bubble point temperature of the bulk liquid
Q = heat flowing through the heated area A
In flow boiling, Equation (9) refers to the local heat-transfer coefficient at a specific local vapor quality,
local heat flux, local wall temperature, and local bubble point temperature.
use and improvements for design of refrigeration system evaporators are discussed in the following sec-
tions.
Q j = ( Uo )j ( Ao )j Fj ( LMTD )j (10)
where the subscript j refers to the particular zone, Q j is the heat duty of that zone in W (or Btu/h), (Uo )j is
the overall heat-transfer coefficient for the zone in W/(m2 ·K) (or Btu/h·ft2 ·°F), (Ao )j is the heat-transfer
surface area required for the zone in m2 (ft2 ), Fj is the crossflow correction factor to the log-mean tempera-
ture difference (Fj = 1.0 for pure counterflow or pure cocurrent flow or when one fluid is isothermal), and
(LMTD)j is the log-mean temperature difference for the zone in K (or °F) determined from its standard
equation with the four terminal temperatures of the zone.
As an example of how the thermal design process proceeds, refer to Table 2, where each heat-transfer
zone will be defined by one step in vapor quality. Thus consider here the first zone ( j = 1) with a vapor
quality change from 0.15 to 0.23. The bubble point temperatures at the inlet and outlet of the zone are
4.509°C and 4.516°C. The heat absorbed by the refrigerant-oil mixture is 15.64 kJ/kg in this zone. The
thermal heat duty of this zone Q1 is then determined by multiplying 15.640 kJ/kg by the mass flow rate of
the refrigerant-oil mixture in kg/s to obtain the duty in watts. The design outlet temperature of the chilled
water is normally 45°F (7.2°C) for ARI standard conditions. Thus, the water's outlet temperature in this
zone is assumed to be 7.2°C for counter-current flow. Using the flow rate of the chilled water and its spe-
cific heat together with the zone's heat duty Q1, the inlet temperature of the chilled water in this zone is cal-
culated. Now the four terminal temperatures of the zone are known and (LMTD)1 can be calculated (and
the crossflow correction factor F1 too). Fixing the number of tubes and assuming a length for the zone such
that (Ao )1 is obtained, the heat flux is determined for the zone. The chilled water heat-transfer coefficient is
calculated based on the bundle geometry and water flow rate. The boiling-side heat-transfer coefficient is
then determined for the zone; it is normally determined at both the inlet and outlet vapor qualities of the
zone, 0.15 and 0.23 for the present example, and then the average coefficient is determined from these two
values. Now (Uo )1 for the zone can be calculated. The calculation iterates with assumption of a new value
of (Ao )1 until the heat duty predicted by the right-hand side of Equation (10) matches the heat duty of the
zone Q1.
The thermal design process then passes onto the next zone ( j = 2) and the procedure is repeated. The heat
absorbed in the second zone is (31.28 − 15.64) = 15.64 kJ/kg, the inlet and outlet vapor qualities are 0.23
and 0.31, and the inlet and outlet bubble point temperatures are 4.516°C and 4.525°C, respectively. After
analyzing all the individual zones, the size of the evaporator is known from summation of the tube lengths
for each zone.
Physical Properties
Besides the heat release curve, the thermodynamic and physical properties of a refrigerant-oil mixture
are required for thermal design. These properties are determined at the vapor quality values corresponding
to the heat release curve. The liquid phase properties must be estimated for each local vapor quality using
the local oil concentration and the local bubble point temperature. The liquid phase properties required are
density, viscosity, specific heat, thermal conductivity and surface tension. The vapor phase properties are
for the pure refrigerant since no oil is present in the vapor. The vapor physical properties usually required
are density, viscosity, specific heat, thermal conductivity and latent heat. These are evaluated at the local
bubble point temperature at each vapor quality.
During thermal design of an evaporator the effect of two-phase pressure drop on the local boiling point
temperature should be taken into account to increase the accuracy of the calculations. Thus, one has several
options: (1) calculate the heat release curve values stepwise with the local pressure, the latter obtained from
a stepwise calculation of the two-phase pressure drop, (2) prepare two heat release curves, one at the inlet
pressure and another at or near the outlet pressure, and interpolate between them using the calculated local
pressure from a stepwise calculation of the two-phase pressure drop, or (3) prepare only one heat release
curve at the mean pressure between the inlet and outlet of the evaporator.
Exit Conditions
Within an evaporator it is not thermodynamically correct to refer to superheating of the refrigerant when
oil is present because the rise is that of the local bubble point temperature along the equilibrium bubble
point curve, not superheating of the fluid. The word superheat implies that all of the liquid has been evapo-
rated and become superheated vapor.
The temperature difference between the chilled water and the refrigerant at the exit of the evaporator is
normally small; for chilled water entering at 12.8°C (55°F) and refrigerant evaporating at 4.4°C (40°F), the
temperature difference is only 8.3 K (15°F) at the exit. Thus the rise in the bubble point temperature
severely limits the fraction of refrigerant that can actually be evaporated.
tests.
the exhaust bubble point temperature tends to rise further. This causes the thermostatic valve to errone-
ously “think” that the exit superheat has increased, such that the increased temperature difference acts on
the needle in the expansion valve to increase refrigerant flow and thermal capacity.
In simple terms, existing controllers have a problem telling the difference between (1) a change in the
requested refrigeration duty of the system indicated by a temperature change of the setpoint thermistor and
(2) a change in oil concentration in the refrigerant charge. Thus, new improved control schemes require
measurement of a parameter related to the oil concentration, together with new control logic that appropri-
ately models the oil's effect on refrigeration capacity.
CONCLUSIONS
A new, comprehensive thermodynamic approach for modeling mixtures of refrigerants and lubricating
oils has been presented. The model includes generalized methods for predicting the following thermody-
namic properties of refrigerant-oil mixtures: bubble point temperatures, local oil concentrations, liquid spe-
cific heats and enthalpy changes during evaporation. Using this method, heat release (enthalpy) curves are
easily generated, and the effect of oil on the LMTD of evaporators can be modeled. The boiling heat-trans-
fer coefficient has been redefined for refrigerant-oil mixtures, based on the bubble point temperature rather
than on the saturation temperature of the pure refrigerant. The thermodynamic approach enables advances
to be made in two-phase refrigeration heat-transfer research and design by including in the analysis the
type of oil and the effects of its physical properties.
NOMENCLATURE
A empirical constant
A surface area
(Ao )j outside surface area of zone j
a0 (a1, a2 , a3, a4) empirical constants
B empirical constant
b0 (b1 , b2, b3, b4) empirical constants
(cp )L specific heat of liquid
(cp )V specific heat of vapor
Fj cross-flow correction factor of zone j
h heat-transfer coefficient
hLV latent heat of vaporization
H enthalpy
(LMTD)jlog-mean temperature difference of zone j
Psat saturation pressure
Q heat duty
q heat flux
s specific gravity of liquid
T temperature
Tbub bubble point temperature
Tsat saturation temperature
Tw wall temperature
(Uo )j outside overall heat-transfer coefficient of zone j
X liquid concentration
x vapor quality
winlet oil inlet concentration
wlocal local oil concentration
woil oil concentration
Y vapor concentration
ACKNOWLEDGEMENTS
The present study is part of ASHRAE Research Project 800-RP titled, “Heat-Transfer And Pressure
Drop In The Dryout Region Of Intube Evaporation With Refrigerant/Lubricant Mixtures,” sponsored by
the technical committee TC 1.3. The Swiss Federal Office of Energy (OFEN) has also provided key fund-
ing for this study.
VOLUME 1, NUMBER 2, APRIL 1995 123
REFERENCES
Collier, J.G., and J.R. Thome. 1994. Convective boiling and condensation, 3rd Ed. Oxford, England: Oxford University
Press.
Hesse, U., and H. Kruse. 1988. Prediction of the behavior of oil refrigerant mixtures. In Status of CFCs—Refrigeration
Systems and Refrigerant Properties, IIR, Commissions B1, B2, E1 and E2, Purdue University 2: 101-109.
Incropera, F.P., and D.P. DeWitt. 1981. Fundamentals of heat transfer, p. 780. New York: John Wiley.
Jensen, M.K. 1987. Rensselaer Polytechnic Institute, Troy, New York (Private communication).
Liley, P.E., and W.R. Gambill. 1973. Physical and chemical data. In Chemical Engineering Handbook, 5th ed. Chapter
3, pp. 3-226 - 3-250. Perry and Chilton, eds. New York: McGraw-Hill.
Shao, W., H. Kraft, and E. Granryd. 1992. A simple experimental investigation of saturated vapor pressure for HFC-
134a-oil mixtures. Int. J. Refrig. 16 (6): 357-361.
Smith, B.D., B. Block, and C.D. Hickman. 1973. Distillation. In Chemical Engineers’ Handbook, pp. 13-4 to 13-14.
New York: McGraw-Hill.
Smith, J.M., and H.C.Van Ness. 1987. Introduction to chemical engineering thermodynamics, 4th Edition. New York:
McGraw-Hill.
Takaishi, Y., and K. Oguchi. 1987. Measurements of vapor pressures of R-22/oil solutions. In Proceedings of the XVII-
Ith International Congress of Refrigeration, Vienna, Volume B: 217-222.
Thome, J.R. 1992a. Prediction of vapor pressures of refrigerant-oil mixtures. Internal Report, LENI Laboratory, Swiss
Federal Institute of Technology, Lausanne, Switzerland (Dec. 16).
Thome, J.R. 1992b. Thermodynamic and Transport Properties of Lubricating Oils. EPFL, Lausanne, LENI Report
(December 21). Lausanne, Switzerland: LENI (Laboratory for Industrial Energetics), Swiss Federal Institute of
Technology.
APPENDIX
Numerous comparisons were made of Equations (1), (2), and (3) to measured vapor pressure/tempera-
ture data for refrigerant-oil mixtures (and also with Equation (1) rearranged to predict Psat for a given Tbub
when data were presented at isotherms). A selection of these are shown in Tables 3 through 6, which dem-
onstrate that the accuracy of the present method for oil concentrations of woil < 0.50 is very good, similar to
that of predictions of independent vapor pressure data for pure refrigerants with a general type of vapor
pressure equation. The level of accuracy is less from 0.50 < woil < 0.70, while for woil > 0.70 the accuracy
is poor as the type of oil becomes more important.
Hesse and Kruse (1988) measured vapor pressure curves for R-22, R-114 and their binary mixtures
together with an unspecified synthetic alkyl benzene lubricating oil. Tables 3 and 4 show a comparison
with some of their R-22/oil and R-114/oil data, respectively, at the temperature of 60°C. The values of a0
and b0 for R-114 were determined by fitting Equation (1) to the pure refrigerant vapor pressures at 0 and
60°C (so that a0 = −2849.839 and b0 = 7.99403). For oil mass concentrations up to 0.50, the generalized
method works well. those predicted using a0 = −3384.388 and b0 =
Jensen (1987) measured saturation temperatures 8.251246 obtained from fitting Equation (1) to val-
and pressures of R-113 and 4 different types of ues of the vapor pressure for pure R-113. The aver-
lubricating oils (identified as 3GS, 4GS, 5GS and age error for the pure R-113 values is 0.33°C while
RCO-2) at ambient atmospheric pressure. Oil con- for the R-113/oil mixtures the average error is
centrations of 0, 0.02, 0.05 and 0.10 were tested. As slightly larger, 0.37 K.
shown in Table 5, his data compare very well with
Table 3. Predicted Vapor Pressures of R-114/Oil Mixtures
Measured by Hesse and Kruse (1988)
woil (by mass) (Psat )exp (MPa) (Psat)calc (MPa) % error
0.10 0.5765 0.561 −2.7
0.30 0.551 0.5424 −1.6
0.50 0.498 0.5075 +2.0