Experimental analysis of energy-saving and eco-friendly refrigeration system design with condensate water management

Abstract

In this study, a low-cost plug-in refrigeration system was developed for commercial-scale production. The design includes an innovative condensation pan, a humidification unit, and utilizes airflow techniques. The system operates with environmentally friendly R290 refrigerant and features a specially developed control system that ensures seamless coordination among its components. In this study, designs based on original defrost water removal methodologies were developed. Thus, it was aimed to enhance energy efficiency and sustainability by efficiently removing defrost water without overflow. For these purposes, the system was tested for four days in two modes (Mode-1: defrost water is removed by electrical resistance (PTC) and condenser waste heat, and Mode-2: PTC is not used, defrost water is transferred to the ultrasonic humidifier by water pump). For both modes, the cold room was kept at two different relative humidity ranges (90-95 % and 100 %). Carbon emission reductions of up to 337.66 kg CO2/m2 and energy savings of up to 29.52 % were obtained in the system to reduce the PTC running time with Mode 2. The refrigeration process has been achieved for high performance, and a sustainable design was presented. The highest coefficient of performance (COP) and second law values of the system were calculated as 3.10 and 56.24 % on Day-3. The refrigeration process was realized with high performance, and a sustainable system with rational long-term results was created. Furthermore, this innovative design is feasible and has commercially preferable payback periods.