Electric vehicle heat pump system operated with R290, and R1234yf: Thermodynamic and driving range analyses for electric vehicle application under diverse climatic conditions

In electric vehicles, the performance of heat pumps under extreme weather conditions is critical for energy efficacy, cabin comfort, and vehicle driving range (VDR), especially when supplemented with positive temperature coefficient (PTC) heaters. In this work, a comparative thermodynamic analysis of indirect heat pumps and PTC systems using R290 and R1234yf refrigerants in severe climates (-35 °C–45 °C) was conducted using one-dimensional GT-SUITE simulation. The performance metrics, namely coefficient of performance (COP), heat pump capacity (Q HP ), compressor work input (W HP ), component-wise exergy destruction, and VDR, have been considered during comparative analysis. Mass flow rate, Q HP , and W HP of the simulation were validated experimentally and demonstrated variations within 5 %, confirming the accuracy and reliability of the simulation model. Compared to R1234yf, R290 exhibits a steady increase in performance across the temperature range of −35 °C to 40 °C, with a COP increase of 7.45 % and a Q HP increase of 68 %. Exergy analysis further indicates lower irreversibility losses in R290 systems, especially in the compressor (29.8 %), expansion valve (36.7 %), and pump (56.9 %) compared to the R1234yf system. R290 sustained heating more effectively than R1234yf, delivering on average 56.7 % higher heating capacity relative to the cabin load at sub-zero temperatures, thereby significantly reducing the need for PTC heaters. VDR improved by up to 5 % across the full temperature range. The outcomes of this work provide valuable guidance for designing and developing optimal heat pump systems integrated with PTC for the future with improved VDR. • Propane-based heat pumps improve heating and cooling performance in electric vehicles. • Energy loss is reduced in the compressor, pump, and expansion valve with propane. • 1D simulation matches experimental results within 5 % error across all temperatures. • R290 improved efficiency and heat output over R1234yf from −35 °C to 0 °C. • Driving range of vehicles increases by up to 5 percent in cold environments.