The high ozone depletion and global warming potentials of fluorocarbon refrigerants have resulted in prohibitions and restrictions in many markets. Hydrocarbon refrigerants have low environmental impacts and are successfully used in domestic refrigerators and car air conditioners but replacing fluorocarbons in centrifugal chillers for air conditioning applications is unknown. Hydrocarbon replacements need a heat transfer correlation for refrigerant in flooded evaporators and predictions for operating conditions, capacity and performance. Safety precautions for large quantities of hydrocarbon refrigerants are needed and control of overpressure in plantrooms requires accurate prediction.Reliable correlations exist for forced convection in a single phase flow, condensation outside tubes and evaporation off sprayed tubes. For flooded evaporators this thesis proposes a new correlation for forced convection boiling of any refrigerant. An enhancement factor is combined with a modified Chen coefficient using recent pool boiling and forced convection correlations outside tubes. This correlates within typically a factor of two to known boiling literature measurements for CFC-113, CFC-11, HCFC-123, HFC-134a and HC-601.The operating conditions, capacity and performance of replacement hydrocarbons in centrifugal chillers were predicted using fluorocarbon performance as a model. With the new heat transfer correlation hydrocarbon predictions for flooded evaporators were made. For any fluorocarbon refrigerant there exists a replacement mixture of hydrocarbons which with a rotor speed increase about 40% gives the same cooling capacity in the same centrifugal chiller under the same operating conditions. For example replacing HCFC-123 in a flooded evaporator with HC-601/602 [90.4/9.6] and increasing the rotor speed by 43% will increase the coefficient of performance by 4.5% at the same cooling capacity.The maximum plantroom overpressure considered was from leakage and ignition of a uniform air/refrigerant mixture with maximum laminar burning velocity. Flow was modelled using a turbulence viscosity due to Launder and Spalding and turbulent deflagration using a reaction progress variable after Zimont. These partial differential equations were solved approximately for two and three dimensional geometries using finite volume methods from the Fluent program suite. Simple overpressure predictions from maximum flame area approximations agreed with Fluent results within 13.7% promising safe plantroom design without months of computer calculation.
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