Optimization of a Residential Air Source Heat Pump using Heat Exchangers with Small Diameter Tubes

Heat exchangers play significant role in refrigeration and air conditioning systems. Ongoing research aims to improve, or at least maintain, the system performance while reducing the size, weight and cost of the heat exchangers. This in turn leads to lower system refrigerant charge and reduced environmental impact. Using heat exchangers with small tube diameters (less than 5 mm) instead of large tube diameters has been shown to be a promising solution to meet the aforementioned goals. However, shifting towards small tube diameters requires in-depth analysis and optimization of several heat exchanger design parameters. This paper presents a multi-objective optimization of a residential air source heat pump system using genetic algorithms with a particular focus on the use of small diameter tubes in the heat exchangers. The objectives are to minimize the heat exchangers’ cost and maximize the system performance. The goal of this study is to determine the potential material savings and cost reduction when using tube diameters between 3 mm and 5 mm in the heat exchangers. In addition to the tube diameters, multiple fin types, tube spacing and fin densities are also investigated. The optimization is carried out for R-410A, and a lower-GWP alternative, R-32. The system utilizing the improved heat exchanger designs has a cost reduction of 60% in comparison to the baseline system. Also, the improvements in the system’s COP and the system charge reduction are around 20% and 35%, respectively.