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Small Diameter Copper Tube Application

and Development
2 | Presentation title and date

Contents

MicrogrooveTM advantages
MicrogrooveTM coil development
MicrogrooveTM coil application
Challenges for air conditioner industry

Energy New Cost


efficiency refrigerant competition
MicrogrooveTM

is small diameter innergrooved copper tube.


is 5mm, 4mm, even 3mm innergrooved copper tube.
is an practical, economical and eco-friendly coil
solution for HVAC industry.
MicrogrooveTM Advantages

Advantages

Cost reduction

Higher energy efficiency

Less refrigerant

Small size

High durability

Less investment
MicrogrooveTM Advantages

Downsize Reduce High Efficiency Cost saving


refrigerant
15% 10% 20%
20%

Similar
processing
technology

*Comparing with 7mm above heat exchanger.


*Data based on ICA projects in US, China and India.
MicrogrooveTM Advantages
Less refrigerant

Brand Kelon Midea Haier

Type 5K BTU Window Type 2600W Split Unit 2600W Split Unit

Refrigerant R22 R410A R290


7mm Evaporator 7mm Evaporator +7mm 7mm Evaporator +7mm
HX of Original Model
+7mm Condenser Condenser Condenser
Refrigerant Charge of Original
349.8 920.0 360.0
Model (g)
5mm Evaporator 7mm Evaporator +5mm 7mm Evaporator +5mm
HX of Improved Model
+5mm Condenser Condenser Condenser
Refrigerant Charge of
243.8 730.0 275.0
Improved Model (g)
Charge Decrease
30.30% 20.65% 23.61%
Percent (%)
*Data based on ICA projects in China.
MicrogrooveTM Advantages
Cost reduction

Tube circuitry of designed indoor unit Tube circuitry of designed outdoor unit
2 rows 7mm to 2 rows 5mm, 2 rows 7mm to 2.5 rows 5mm
1.5mm fin pitch to 1.3mm fin pitch 1.4mm to 1.2mm fin pitch

Design of
Grees
1.3 mm fin pitch
2.6KW type 1.2 mm fin pitch

Result of system simulation

Cooling Heating
EER COP Cost-RMB
capacity, W capacity, W
Prototype AC 2711 3.33 2914 3.49 262.67

Designed AC 2712 3.34 2917 3.50 203.08

Deviation +0.04% +0.30% +0.10% +0.28% -22.68%


*Copper tube price RMB 50,000, Al fin price, RMB 20,000.
*Data based on ICA projects in China.
Test Carried Out in India
Use of smaller diameter copper tube heat
exchangers

Tests conducted on
RACs using 5 mm
copper tube heat
exchangers by ICA
India on R22 , R32 and
R290
Test results of 5 mm copper tube using R 22
in India

Condenser 7 mm 5 mm
type copper copper
tube tube

EER 2.95 3.22

Capacity 5233 W 5275 W

Refrigerant 960 g 870 g

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Test results of 5 mm copper tube using R 32
in India

Condenser 7 mm 5 mm
type copper copper
tube tube

EER 3.10 3.28

Capacity 5000 W 5537 W

Refrigerant 875 g 700 g

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Test results of 5 mm copper tube using R 290
in India

Condenser 7 mm 5 mm
type copper copper
tube tube

EER 3.57

Capacity 5000 W

Refrigerant 480 g 375 g

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Cost saving by using 5 mm copper tube
Condenser for 1.5 TR RAC

Condenser type 7 mm copper tube 5 mm copper tube %age


saving
Copper Weight 1.328 Kg 1.050 Kg 20.9%
Aluminium Weight 2.136 Kg 1.168 Kg 45.3%
Refrigerant R 22 960 g 870 g 9.3%
Refrigerant R 32 875 g 700 g 20.0%

Refrigerant R 290 480 g 375 g 21.8%

Refrigerant R 410A 915 g 836 g 8.6%

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16 | Presentation title and date

Contents

MicrogrooveTM advantages
MicrogrooveTM coil development
MicrogrooveTM coil application
MicrogrooveTM coil development-Process

R&D Platform Establish project team


Establish ICAs expert image in room air-con industry and build
Establishment the technology platform to guide the industrial development

Develop high efficient 5mm diameter copper tube


5mm R&D Develop fin for 5mm diameter copper tube system
Optimize 5mm diameter copper tube system

Commercial Assure commercial availability of high quality equipment for


mechanical tube expansion of 5mm/4mm inner-grooved copper
Popularization tubes

Simulation Software Develop and validate software for heat exchanger and system
Development design with 5mm/4mm inner-grooved copper tubes

Smaller tube HX Develop smaller tube HX technology


R&D, 4mm/3mm
MicrogrooveTM coil development-R&D Team

Institutes Government

Air-con Manufacturers

Supplier

ICA Members

. . .
18
MicrogrooveTM coil development-R&D meetings

Meeting Date Venue


1st project
2007-04-03 Zhuhai
meeting
2nd project
2007-08-23 Xi'an
meeting
3rd project
2008-10-23 Beijing
meeting
4th project
2009-08-28 Guangzhou
meeting
5th project
2010-12-03 Shenzhen
meeting
6th project
2011-11-11 Foshan
meeting
7th project
2012-11-01 Zhongshan
meeting
8th project
2013-11 Zhuhai
meeting
9th project
2014-10 Shenzhen
meeting
MicrogrooveTM coil development
- Optimization Design of Fin
MicrogrooveTM coil development
- Optimization Design of Fin
MicrogrooveTM coil development
- Development of CFD software
MicrogrooveTM coil development
- Optimization of RAC System

2 rows 7mm indoor heat exchanger 2 rows 5mm indoor heat exchanger

2 rows 9.52mm outdoor heat exchanger 2.5 rows 5mm outdoor heat exchanger
MicrogrooveTM coil development
- Non-shrinkage tension tube expansion

As the tube diameter in RTPF heat exchangers goes below 7mm, axial
tube shrinkage becomes more significant, and control of post-expansion
tube length becomes important for quality control. Expansion tool buckling
can also be a problem. ICA supported the development of cost-effective
tube expansion technology that controls tube shrinkage and maintains
tension on the expansion tools for high manufacturing yields and long tool
life.

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MicrogrooveTM further development
Better long term performance

According to laboratory
test and in field test,
Microgroove coil has better
long term efficiency
performance.
dust choking test

Louver fin in slit fin in finned tube


MCHE HE
MicrogrooveTM further development
All Copper Heat Exchanger

Antimicrobial benefits

Improve indoor air quality


MicrogrooveTM Promotion
- 2013 & 2014 China Refrigeration Expo

Large Island Booth (48 sq.


m)

MicroGroove Branding
Throughout

Backlit Posters and


Literature in English &
Chinese
MicrogrooveTM Promotion
- 2013 AHR Expo Seminar and Booth
ASHRAE Advertorial (Dec 2012)
MicrogrooveTM Promotion
- Official Website

www.microgroove.net
MicrogrooveTM Promotion
- MicroGroove Update eNews

Volume 3, Issue 1 Volume 3, Issue 2


Jan 2013 June 2013
32 | Presentation title and date

Contents

MicrogrooveTM advantages
MicrogrooveTM coil development
MicrogrooveTM coil application
Microgroove application

The total production of room air-cons with 5mm copper tubes in


China was 18.83 million units in 2013, had grown by 35% over that of
2012, and occupied 17% of the total annual output.

Room air-cons with 5mm copper tube in China (k Units)

Data from Fbetters survey report


MicrogrooveTM Advantages
Market Application

More OEMs from India

Data from Fbetters survey report


Microgroove application

China Main RAC manufacturers 5mm copper


tube application July, 2013
Condenser of cooling Evaporator of cooling Evaporator of heat Condenser of heat
OEM
only RAC only RAC pump RAC pump RAC
A
B
C
D
E
F
G
H
*Source: Market survey in 2013 by Shanghai Fbetter Consulting
Microgroove application

The 5mm copper tube has been widely applied in air conditioner
industrial, but also has barriers for further development.

Barriers for Microgroove coil application

1. Heat exchanger making process


2. Optimized design capacity
Barriers for 5mm copper
tube application 3. Heating capacity
4. Competition from aluminum micro-channel
Microgroove application

International copper association could provide support


to overcome these barriers.

Technology
communication Design guidance CFD software
platform
Think innovation, think copper.

Copper is the best metal for HVAC


applications.

Convert into your


competitive advantages, and win the market!
Thank you
For more information please contact
shankar.sapaliga@copperalliance.asia

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