US20010019120A1 - Method of improving performance of refrigerant systems - Google Patents

Method of improving performance of refrigerant systems Download PDF

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Publication number
US20010019120A1
US20010019120A1 US09/328,858 US32885899A US2001019120A1 US 20010019120 A1 US20010019120 A1 US 20010019120A1 US 32885899 A US32885899 A US 32885899A US 2001019120 A1 US2001019120 A1 US 2001019120A1
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United States
Prior art keywords
heat transfer
acid
lubricant
ester
transfer fluid
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Abandoned
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US09/328,858
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English (en)
Inventor
Nicolas E. Schnur
Bruce J. Beimesch
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Cognis Corp
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Cognis Corp
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Publication date
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Priority to US09/328,858 priority Critical patent/US20010019120A1/en
Priority to CNB008086117A priority patent/CN1276960C/zh
Priority to PCT/US2000/015756 priority patent/WO2000075258A1/en
Priority to SK1710-2001A priority patent/SK287084B6/sk
Priority to CZ20014360A priority patent/CZ20014360A3/cs
Priority to TR2001/03544T priority patent/TR200103544T2/xx
Priority to CA002375742A priority patent/CA2375742C/en
Priority to KR1020017015835A priority patent/KR100672118B1/ko
Priority to JP2001502529A priority patent/JP2003501614A/ja
Priority to BRPI0011375-1A priority patent/BR0011375B1/pt
Priority to EP00938224A priority patent/EP1198535B1/en
Priority to AU53296/00A priority patent/AU5329600A/en
Priority to NZ515610A priority patent/NZ515610A/xx
Priority to SI200020027A priority patent/SI20748B/sl
Priority to MXPA01012160A priority patent/MXPA01012160A/es
Priority to EP10194924.6A priority patent/EP2290032B1/en
Priority to AT00938224T priority patent/ATE517961T1/de
Publication of US20010019120A1 publication Critical patent/US20010019120A1/en
Assigned to COGNIS CORPORATION reassignment COGNIS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HENKEL CORPORATION
Priority to US10/151,458 priority patent/US7018558B2/en
Assigned to HENKEL CORPORATION (HENKEL CORP.) reassignment HENKEL CORPORATION (HENKEL CORP.) ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEIMESCH, BRUCE J., SCHNUR, NICHOLAS E.
Priority to HK02104570.8A priority patent/HK1043146B/zh
Assigned to COGNIS CORPORATION reassignment COGNIS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HENKEL CORPORATION
Abandoned legal-status Critical Current

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    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K5/00Heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants; Materials for the production of heat or cold by chemical reactions other than by combustion
    • C09K5/02Materials undergoing a change of physical state when used
    • C09K5/04Materials undergoing a change of physical state when used the change of state being from liquid to vapour or vice versa
    • C09K5/041Materials undergoing a change of physical state when used the change of state being from liquid to vapour or vice versa for compression-type refrigeration systems
    • C09K5/044Materials undergoing a change of physical state when used the change of state being from liquid to vapour or vice versa for compression-type refrigeration systems comprising halogenated compounds
    • C09K5/045Materials undergoing a change of physical state when used the change of state being from liquid to vapour or vice versa for compression-type refrigeration systems comprising halogenated compounds containing only fluorine as halogen
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M105/00Lubricating compositions characterised by the base-material being a non-macromolecular organic compound
    • C10M105/08Lubricating compositions characterised by the base-material being a non-macromolecular organic compound containing oxygen
    • C10M105/32Esters
    • C10M105/38Esters of polyhydroxy compounds
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M171/00Lubricating compositions characterised by purely physical criteria, e.g. containing as base-material, thickener or additive, ingredients which are characterised exclusively by their numerically specified physical properties, i.e. containing ingredients which are physically well-defined but for which the chemical nature is either unspecified or only very vaguely indicated
    • C10M171/008Lubricant compositions compatible with refrigerants
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    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K2205/00Aspects relating to compounds used in compression type refrigeration systems
    • C09K2205/24Only one single fluoro component present
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2207/00Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/28Esters
    • C10M2207/281Esters of (cyclo)aliphatic monocarboxylic acids
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2207/00Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/28Esters
    • C10M2207/282Esters of (cyclo)aliphatic oolycarboxylic acids
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2207/00Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/28Esters
    • C10M2207/283Esters of polyhydroxy compounds
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2207/00Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
    • C10M2207/28Esters
    • C10M2207/286Esters of polymerised unsaturated acids
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2209/00Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
    • C10M2209/10Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2209/103Polyethers, i.e. containing di- or higher polyoxyalkylene groups
    • C10M2209/109Polyethers, i.e. containing di- or higher polyoxyalkylene groups esterified
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2211/00Organic non-macromolecular compounds containing halogen as ingredients in lubricant compositions
    • C10M2211/02Organic non-macromolecular compounds containing halogen as ingredients in lubricant compositions containing carbon, hydrogen and halogen only
    • C10M2211/022Organic non-macromolecular compounds containing halogen as ingredients in lubricant compositions containing carbon, hydrogen and halogen only aliphatic
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    • C10MLUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2211/00Organic non-macromolecular compounds containing halogen as ingredients in lubricant compositions
    • C10M2211/06Perfluorinated compounds
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10NINDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00Specified use or application for which the lubricating composition is intended
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/30Refrigerators lubricants or compressors lubricants
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10NINDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/32Wires, ropes or cables lubricants
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/34Lubricating-sealants
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/36Release agents or mold release agents
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    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/38Conveyors or chain belts
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/40Generators or electric motors in oil or gas winning field
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/42Flashing oils or marking oils
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/44Super vacuum or supercritical use
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/50Medical uses

Definitions

  • This invention relates to a method or process of improving performance of refrigerant systems such as refrigerators and air conditioners that utilizes a working fluid.
  • the working fluid consists essentially of a chlorine-free fluoro-group containing heat transfer fluid and a lubricant that is miscible and is otherwise compatible with the heat transfer fluid over the operating temperature of the system.
  • the heat transfer fluid is preferably a hydrofluorocarbon.
  • the lubricant preferably comprises an ester formed from an alcohol containing at least two —OH groups and a carboxylic acid that is substantially or exclusively monovalent.
  • Refrigerant systems such as refrigerators and air conditioners collectively consume enormous amounts of energy. Energy consumption of refrigerant systems is likely to increase as a result of the replacement of chlorine-containing heat transfer fluids with chlorine-free organic heat transfer fluids for the purpose of protecting the ozone layer.
  • R-22 difluoromonochloromethane
  • a chlorine-free hydrofluorocarbon heat transfer fluid illustrates this problem.
  • R-22 has very good thermodynamic properties resulting in a lower volume replacement per ton of refrigeration than other commercial heat transfer fluids. Accordingly, refrigerant systems utilizing R-22 require less energy than systems utilizing other heat transfer fluids including expected replacement heat transfer fluids for R-22.
  • This finding applies to working fluids consisting essentially of chlorine-free organic heat transfer fluids, preferably hydrofluorocarbons, and lubricants comprising ester base stocks or compounded esters.
  • the ester lubricants are formed from alcohols containing at least two —OH groups and a carboxylic acid that is substantially or completely monovalent. At least part of the acid constituent is preferably formed from straight chain acids of three to six carbon atoms or acids of three to nine carbon atoms with at least one carbon bonded to three other carbon atoms.
  • the esters are preferably formed from mixtures of alcohols and acids to utilize feedstocks of such mixtures.
  • the lubricant may also comprise mixtures of esters.
  • the lubricant can be formed from only the ester or an ester compounded with one or more additives.
  • FIG. 1 shows a schematic of the refrigeration system used in the test program.
  • FIG. 2 is a graph showing coefficient of performances of a smooth tube coil type refrigerant apparatus using a miscible working fluid of Example 1 compared with coefficient of performance for the same apparatus using an immiscible working fluid of Example A.
  • FIG. 3 is a graph showing the percentage difference in coefficient of performances of a smooth tube type refrigerant apparatus using the miscible working fluid of Example 1 compared with coefficient of performance for the same apparatus using immiscible working fluid of Example A.
  • FIG. 4 is a graph showing coefficient of performances of a microfin tube type refrigerant apparatus using a miscible working fluid of Example 1 compared with coefficient of performance for the same apparatus using immiscible working fluid of Example A.
  • FIG. 5 is a graph showing the percentage difference of coefficient of performance of a microfin tube type refrigerant apparatus using a miscible working fluid of Example 1 compared with coefficient of performance for the same apparatus using immiscible working fluid of Example A.
  • FIG. 6 is a graph showing coefficient of performance of a microfin tube type refrigerant apparatus using miscible working fluids of Example 1 and 2.
  • FIG. 7 is a graph showing the percentage differences of coefficient of performance of a microfin tube type refrigerant apparatus using miscible working fluids of Examples 1 and 2 compared with coefficient of performance for the same apparatus using immiscible working fluid of Example A.
  • FIG. 1 A typical refrigeration system to which this invention applies is illustrated by the schematic set forth in FIG. 1. Such systems would include air conditioners, refrigerators, freezers, soda fountain dispensers as well as other cooling devices.
  • the schematic of the refrigeration system illustrates a typical operation cycle of a refrigeration apparatus 10 which includes the steps of compression, condensation, expansion and evaporation of a heat transfer fluid.
  • compressed heat transfer fluid carrying some lubricant is discharged through a tube 12 to a condenser 14 .
  • the condensed heat transfer fluid and lubricant then pass to an expansion valve 16 and there to an evaporator 18 .
  • the evaporator 18 substantially vaporizes the heat transfer fluid and the vapor and liquid phases of the heat transfer fluid and the lubricant are conveyed through tube 12 to a compressor 20 .
  • the compressor 20 the vapor is compressed and discharged through tube 12 for recirculation through the refrigeration apparatus 10 .
  • the schematic also indicates the presence of thermocouple probes (T) 22 used to calculate evaporator energy transfer, pressure transducers (P) 24 to measure the absolute pressure (P) and changes in pressure ( ⁇ P) at the condenser 14 and evaporator 18 , a mass flow meter 26 to measure refrigerant flow rate and a sight glass 28 .
  • T thermocouple probes
  • P pressure transducers
  • ⁇ P changes in pressure
  • the invention is believed to pertain to a substantial variety of heat transfer fluids including both chlorine-free and chlorine-containing organic compounds.
  • chlorine-free fluoro-group containing organic compounds especially hydrofluorocarbons.
  • hydrofluorocarbons are difluoromethane, pentafluoroethane, 1,1-difluoroethane, 1,1,1-trifluoroethane, 1,1,1,2-tetrafluoroethane, and mixtures thereof.
  • the invention relates to lubricants that are miscible and compatible with a heat transfer fluid at all operating temperatures of a refrigerant system.
  • lubricants that comprise or consist essentially of ester base stocks or esters compounded with additives.
  • the esters suitable for this invention are esters of alcohols that contain at least 2, or more preferably at least 3, —OH groups in unesterified form.
  • % of the alcohol moieties in the ester(s) contain at least one carbon atom bonded to four other carbon atoms by single bonds, or in other words, a “neo” carbon atom. Independently and preferably with increasing preference, at least 62, 81, 90 or 98 no.
  • % of the alcohol moieties for the esters are those derived from pentaerythritol, with the formula C—(CH 2 OH) 4 , from dipentaerythritol, with the formula (HOCH 2 ) 3 CCH 2 OCH 2 C(CH 2 OH) 3 and from 2,2-dimethyl-1,3-propanediol (more commonly known as neopentyl glycol) with the formula (H 3 C) 2 C(CH 2 OH) 2 and from 2,2-dimethylol-1-butanol (more commonly known as “1,1,1-trimethylolpropane” or “TMP”).
  • pentaerythritol with the formula C—(CH 2 OH) 4 , from dipentaerythritol, with the formula (HOCH 2 ) 3 CCH 2 OCH 2 C(CH 2 OH) 3 and from 2,2-dimethyl-1,3-propanediol (more commonly known as neopentyl
  • At least 81, 90 or 98% of the alcohol moieties are derived from pentaerythritol or dipentaerythritol.
  • higher viscosity ester lubricants it is preferred with increasing preference that at least 22, 33, 48 and 68 no. % of the alcohol moieties are derived from dipentaerythritol.
  • Unsaturated as well as saturated alcohols may be used for esters according to this invention. Saturated alcohols are preferred. Also, substituted alcohols as well as unsubstituted alcohols may be used, but it is preferred that the alcohols used have no substituents other than alkoxy groups, fluoro groups, and/or chloro groups. As with the acids or acyl groups to be used for esters according to this invention, generally unsubstituted alcohols are more economical and are most preferred for that reason.
  • the carboxylic acids used to make the ester preferably contain a sufficient fraction of acyl groups that satisfy at least one of the following two criteria.
  • the acyl groups must either contain nine carbon atoms or less and include at least one carbon atom bonded to three other carbon atoms by single bonds and/or be straight chain with three to six carbon atoms.
  • the no. % of acyl groups meeting one or both of these criteria would be at least 33, 42, 50, 67, 86, or, for low viscosity lubricants, 92.
  • the no. % of acyl groups containing at least nine carbon atoms will not be greater than 81, or with increasing preference not greater than 67, 56, 45 or 33. It is also preferred that at least 90 no. % of the acyl groups in all the esters used according to the invention have no more than twenty carbon atoms each.
  • esters Either pure esters or mixtures of esters meeting the above criteria may be effectively used in many embodiments of the invention. Generally, mixtures of esters are more economical, because they may be prepared from commercially available starting materials without costly purification as a prerequisite. In one embodiment of the invention, mixtures of esters are preferred for performance reasons as well as economy. Where moderate to high viscosity lubricants are needed, it is preferred with increasing preference that at least 12, 16, 21, 29, 33 or 40 no. % of the acyl groups in the esters to be used for the invention contain at least 7, more preferably at least 8 and most preferably 9 carbon atoms each. The preferred acid with 8 carbons is 2-ethylhexanoic acid and with 9 carbon atoms is 3,5,5-trimethylhexanoic acid.
  • a highly desirable constituent is the tetraester of pentaerythritol with an acid mixture of about 57 weight percent iso- or i-pentanoic acid, which for purposes of the specification is defined as a mixture of n-pentanoic acid, 2-methylbutanoic acid, and 3-methylbutanoic acid with about 43 weight percent 3,5,5-trimethylhexanoic acid. Additionally and independently, iso- or i-pentanoic acid may with increasing preference make up at least 3, 5, 7, 11 or 14 no. % as needed to improve the miscibility of the ester lubricant with the heat transfer fluid.
  • acids having 5, 7 and 9 carbon atoms. It is preferred with increasing preference that at least 60, 68, 75, 81, 92 and 98 no. % of the acyl groups have 5, 6, 7, 8, 9, 10, or more preferably 5, 7, or 9 carbon atoms and even more preferably have 5 or 9.
  • substantially all of the acyl groups in the esters are preferably monovalent ones.
  • some divalent acyl groups are preferred, as it is believed that esters containing two or more alcohol moieties joined by such divalent acyl groups, with all the other hydroxyl positions on the alcohols corresponding to those esterified by monoacyl groups, are particularly advantageous types of esters for use according to this invention.
  • Alcohol moiety in any ester is defined herein as a connected part of the ester that would remain if all acyl groups were removed from the ester.
  • esters may be denoted herein as an “acid moiety” in an ester). If one or more of the acyl groups in an ester is divalent, the ester is denoted herein as a “complex ester”; such esters preferably include two alcohol moieties, which may be the same or different, but are both of the type already described below. Esters according to the invention with only one alcohol moiety and with all monovalent acyl groups may be denoted herein as “single polyol esters”.
  • At least 55, 67, 81, or 92 no. % of the divalent acyl groups in esters used according to this invention have from 4 to 12, or more preferably from 6-9 carbon atoms, and it is independently preferred, with increasing preference in the order given, that at least 55, 67, 81, or 92% of the monovalent acyl groups in the esters contain no more than 18, more preferably no more than 9, still more preferably no more than 7, carbon atoms.
  • the ratio of the no. % of acyl groups in the ester(s) that contain 8 or more carbon atoms and are unbranched to the no. % of acyl groups in the ester(s) that are both branched and contain not more than six, preferably not more than five, carbon atoms will not be greater than 1.56, more preferably not greater than 1.21, or still more preferably not greater than 1.00.
  • Saturated and unsaturated acyl groups may both be used, but saturated ones are preferred. Also, substituted as well as unsubstituted acyl groups may be used in esters according to the invention, but it is preferred that the acyl groups have no substituents other than alkoxy, fluoro and/or chloro groups. Generally unsubstituted acyl groups are most economical and are most preferred for that reason.
  • esters which form the lubricant composition of the invention it is possible to obtain the same esters by reacting acid derivatives such as acid anhydrides, acyl chlorides, and esters of the acids instead of reacting the acids themselves.
  • acid derivatives such as acid anhydrides, acyl chlorides, and esters of the acids.
  • the acids are generally preferred for economy and are exemplified herein, but it is to be understood that the esters defined herein by their reactive components with acids can be equally well obtained by reaction of alcohols with the corresponding acid derivatives.
  • “commercial isopentanoic acid” normally contains about 65 weight % n-pentanoic acid and about 35 weight % of isopentanoic acids selected from the group consisting of 2-methylbutanoic acid and 3-methylbutanoic acid.
  • reaction between the alcohol(s) and the acid(s) reactants of the respective esters proceeds more effectively if the quantity of acid charged to the reaction mixture initially is enough to provide an excess of 10-25% of equivalents of acid over the equivalents of alcohol reacted with the acid.
  • an equivalent of acid is defined for the purposes of this description as the amount containing one gram equivalent weight of carboxyl groups, whereas an equivalent of alcohol is the amount containing one gram equivalent weight of hydroxyl groups.
  • the composition of the mixture of acids and alcohols that have actually reacted can be determined by analysis of the ester product for its acyl group content.
  • the acid reacted will be lower boiling than the alcohol(s) reacted and the product ester(s).
  • the product is often ready for use as a lubricant blending stock according to this invention.
  • the content of free acid in the product after the first vacuum distillation may be further reduced by treatment with epoxy esters, as taught in U.S. Pat. No. 3,485,754 or by neutralization with any suitable alkaline material such as lime, alkali metal hydroxides, or alkali metal carbonates.
  • the ester base stock described herein will function satisfactorily as a complete lubricant. It is generally preferable, however, for a complete lubricant to contain other materials generally known in the art as additives, such as oxidation resistance and thermal stability improvers, corrosion inhibitors, metal deactivators, lubricity additives, viscosity index improvers, pour and/or floc point depressants, detergents, dispersants, foam promoting agents, antifoaming agents, anti-wear and extreme pressure resistance additives and acid scavangers. Many additives may impart both anti-wear and extreme pressure resistance properties, or function both as a metal deactivator and a corrosion inhibitor. Cumulatively, all additives preferably do not exceed 8% by weight, or more preferably do not exceed 5% by weight, of the total compounded lubricant formulation.
  • An effective amount of the foregoing additive types is generally in the range of 0.01 to 5% for the antioxidant compound, 0.01 to 5% for the corrosion inhibitor component, from 0.001 to 5% for the metal deactivator component, from 0.5 to 5% for the lubricity additives, from 0.01 to 2% for each of the viscosity index improvers and pour and/or floc point depressants, from 0.1 to 5% for each of the detergents and dispersants, from 0.001 to 0.1% for foam promoting agents or anti-foam agents, and from 0.1-2% for the anti-wear and extreme pressure resistance components, and 0.05 to 2% for the acid scavenger.
  • Suitable oxidation resistance and thermal stability improvers are diphenyl-, dinaphthyl- and phenyl-naphtyl-amines, in which the phenyl and naphthyl groups can be substituted, e.g., N,N′-diphenyl phenylenediamine, p-octyldiphenylamine, p,p-dioctyldiphenylamine, N-phenyl-1-naphthyl amine, N-phenyl-2-naphthyl amine, N-(p-dodecyl)-phenyl-2-napthyl amine, di-1-naphthylamine, and di-2-naphthylamine; phenothiazines such as N-alkylphenothiazines, imino(-bisbenzyl); and hindered phenols such as 6-(t-butyl
  • cuprous metal deactivators examples include imidazole, benzamidazole, 2-mercaptobenzothiazole, 2,5-dimercaptothiadizaole, salicylidine-propylenediamine, pyrazole, benzotriazole, tolutriazole, 2-methylbenzamidazole, 3,5-dimethyl pyrazole, and methylene bis-benzotriazole. Benzotriazole derivatives are preferred.
  • more general metal deactivators and/or corrosion inhibitors include organic acids and their esters, metal salts, and anhydrides, such as n-oleyl-sarcosine, sorbitan monooleate, lead naphthenate, dodecenyl-succinic acid and its partial esters and amides, and 4-nonylphenoxy acetic acid; primary, secondary, and tertiary aliphatic and cyloaliphatic amines and amine salts of organic and inorganic acids, such as oil-soluble alkylammonium carboxylates; heterocyclic nitrogen containing compounds, such as thiadiazoles, substituted imidazolines, and oxazolines; quinolines, quinones, and anthraquinones; propyl gallate; barium dinonyl naphthalene sulfonate; ester and amide derivatives and alkenyl succinic anhydrides or acids, dithiocarbamates, dithioc
  • Suitable lubricity additives include siloxane polymers, polyoxyalkene polymers, polyalkyleneglycol and long chain derviative of fatty acids and natural oils, such as esters, amines, amides, imidazolines, and borates.
  • Suitable viscosity index improvers include polymethacrylates, polybutenes, styrene-acrylate copolymers and ethylene-propylene copolymers.
  • pour point and/or floc point depressants include polymethacrylates such as methacrylate-ethylene-vinyl acetate terpolymers; alkylated naphthalene derivatives, and products of Friedel-Crafts catalyzed condensation of urea with naphthalene or phenols.
  • Suitable detergents and/or dispersants include polybutenylsuccinic acid amides; polybutenyl phosphonic acid derivatives; long chain alkyl substituted aromatic sulfonic acids and their salts; and methyl salts of alkyl sulfides, of alkyl phenols, and of condensation products of alkyl phenols and aldehydes.
  • Suitable anti-foam agents include silicone polymers, siloxane polymers and polyoxyalkene polymers and some acrylates.
  • foam promoters include silicone polymers with a different molecular structure than the silicone polymers used as anti-foam agents, siloxane polymers and polyoxyalkene polymers.
  • Suitable anti-wear and extreme pressure resistance agents include sulfurized fatty acids and fatty acid esters, such as sulfurized octyl tallate; sulfurized terpenes; sulfurized olefins; organopolysulfides; organo phosphorus derivatives including amine phosphates, alkyl acid phosphates, dialkyl phosphates, aminedithiophosphates, trialkyl and triaryl phosphorothionates, trialkyl and triaryl phosphines, and dialkylphosphites, such as amine salts of phosphoric acid monohexyl ester, amine salts of dinonylnaphthalene sulfonate, triphenyl phosphate, trinaphthyl phosphate, diphenyl cresyl and dicresyl phenyl phosphates, naphthyl diphenyl phosphate, triphenylphosphorothionate; di
  • suitable acid scavengers are epoxy compounds having at least one epoxy compound in its molecule.
  • Preferred acid scavengers are compounds having at least one glycidyl ester group including aliphatic glycidyl ethers such as propylene glycol, diglycidyl ether, neopentyl glycol diglycidyl ether, 1,4-butanediol diglycidyl ether and 1-propanol diglycidyl ether; aromatic glycidyl ethers such as phenyl glycidyl ether, cresyl glycidyl ether and glycidyl ether of bisphenol A - alkylene oxide adduct and polyalkylene glycol diglycidyl ether.
  • preferable constitutive alkylene groups are ethylene, propylene, butylene, etc. and the preferable molecular weight thereof is 1000 or less.
  • the lubricant base stocks and lubricant be substantially free of such polyether polyols.
  • substantially free it is meant that the compositions contain no more than about 10% by weight, preferably no more than about 2.6% by weight and more preferably no more than about 1.2% by weight of the materials noted.
  • the selected heat transfer fluid and the lubricant components of the working fluid should have chemical characteristics and be present in such a proportion to each other that the lubricant remains miscible with the heat transfer fluid over the entire range of working temperatures to which the working fluid is exposed during operation of a refrigeration system in which the working fluid is used.
  • Such systems vary enormously in terms of their operating conditions. Accordingly, it is often adequate if the working fluid remains miscible up to +30° C., although it is increasingly more preferable if the working fluid remains miscible up to 45°, 60°, 71° and at least 100° C.
  • the working fluid remain miscible when chilled to 0° C., although it is increasingly more preferable if the working fluid remain miscible down to ⁇ 15°, ⁇ 27°, ⁇ 42°, ⁇ 50°, ⁇ 57° and ⁇ 60° C.
  • Miscible working fluids consisting essentially of chlorine-free fluoro-group containing heat transfer fluids and blended ester lubricants can be obtained as described above. Miscibility over a temperature range for working fluids containing up to 1, 2, 4, 10 and 15% by weight of lubricant is successively more preferable.
  • working fluids consisting essentially of a refrigerant heat transfer fluid and lubricant base stock or compounded lubricant is used in a process of operating refrigerant systems in such a manner that the working fluid improves performance of the refrigerant system.
  • lubricant compositions according to this invention are generally the same as established in the art for lubricants to be used in refrigeration systems together with a heat transfer fluid, particularly for a fluorocarbon and/or chlorofluorocarbon heat transfer fluid.
  • lubricants according to this invention have International Organization for Standardization (“ISO”) viscosity grade numbers between 15 and 320.
  • ISO International Organization for Standardization
  • the viscosity ranges for some of the ISO viscosity grade numbers are given in Table 1. TABLE 1 Viscosity Range in Centistokes at 40° C.
  • ester lubricant base stocks of the invention is described in further detail in the following examples.
  • reaction mixture was heated to a temperature between about 220 and 230° C., and water from the resulting reaction was collected in the trap while refluxing acids were returned to the reaction mixture. Partial vacuum was maintained above the reaction mixture as necessary to achieve a reflux.
  • reaction mixture was sampled occasionally for determination of hydroxyl number, and after the hydroxyl number had fallen below 5.0 mg of KOH per gram of mixture, the majority of the excess acid was removed by distillation after applying the highest vacuum obtainable with the apparatus used, while lowering the temperature to about 190° C.
  • the reaction mixture was then cooled, and any residual acidity was removed, if desired, by treatment with lime, sodium hydroxide, or epoxy esters.
  • the resulting lubricant or lubricant base stock was dried and filtered before blending and phase compatibility testing.
  • Example A Two refrigerant working fluids were tested in a vapor compression refrigeration system similar to that described in FIG. 1.
  • One of these fluids (Example A) comprises a heat transfer fluid and a mineral oil lubricant known to be immiscible with the heat transfer fluid.
  • the mineral oil is an Iso 32 naphthentic refrigeration oil.
  • the second working fluid (Example 1) comprises a lubricant comprising a polyol ester which is known to be miscible with the heat transfer fluid.
  • the heat transfer fluid used in both Examples A and 1 is 1,1,1,2-tetrafluoroethane (R134a).
  • the polyol ester of Example 1 is formed from pentaerythritol and a mixture of 37 weight percent n-pentanoic acid, 20 weight percent of a mixture of 2-methylbutanoic acid and 3-methylbutanoic acid and 43 weight percent 3,5,5-trimethylhexanoic acid.
  • the evaporator is a cross-flow refrigerant coil.
  • the refrigerant flows through copper tubes, with air flowing across the tubes. Air-side heat transfer is enhanced with aluminum fins mounted on the copper tubes.
  • the refrigeration system had a coil in which inside of the copper tubes is smooth tube (smooth-tube coil) and the tests were conducted on this coil. Later tests were performed on an evaporator coil with microfin tubes (microfin-tube coil). Both coils have the same design capacity of 10.5 kW (3 tons), but they differ in physical characteristics as the microfin-tube coil is smaller than the smooth-tube coil.
  • the smooth tube coil has 5 ⁇ 8 inch nominal outer diameter copper tubes with twelve fins per inch (12 fpi), while the microfin-tube coil has 3 ⁇ 8 inch copper tubes with 15 fpi.
  • the microfin tube coil has around 25 percent smaller cross-sectional area than the smooth-tube coil cross-sectional area. Also, the volume of the microfin-tube coil on the refrigerant side is about 70 percent smaller than the same volume for the smooth-tube coil.
  • the compressor is a hermetically-sealed constant-speed reciprocating type, designed to operate with HFC-134a refrigerant.
  • the compressor has accessible plugs for charging and draining lubricant so that oil changes can be performed while the compressor is still installed.
  • thermo-expansion valve has a slow response time
  • the needle valve is the preferred device for flow rate control as described in Crown, S. W., H W Shapiro and M. B. Pate. 1992.
  • a comparison study of the thermal performance of R -12 and R -134 a “International Refrigeration Conference—Energy Efficiency and the New Refrigerants” (1): 187-196 (hereafter the “Crown et al article”).
  • the needle valve can be directly controlled by the data acquisition system.
  • Measuring devices used to quantitatively evaluate refrigeration system performance are also shown in FIG. 1.
  • the sensors installed are thermocouple probes, pressure transducers, flow sensors, and a watt transducer. A detailed description of each of those sensors is provided below.
  • thermocouple probes are of the T type, and they are located before and after each of the components of the refrigeration system. All of the thermocouples were calibrated, and the uncertainty of their reading is ⁇ 0.21° C. (0.5° F.).
  • thermocouple grids before and after the evaporator on the air flow side.
  • Each grid consists of 18 thermocouples equally spaced across the heat exchanger cross-sectional area. The purpose of these grids is to accurately calculate evaporator energy transfer on the air side. Dry and wet bulb thermocouples are installed before and after the evaporator for the purpose of measuring the amount of moisture in the air stream.
  • the refrigerant flow rate is measured with a mass flowmeter that was precalibrated by the manufacturer. For accurate flow rate measurements, it is required that refrigerant be in a liquid state at the outlet of the condenser, which is where the flowmeter is located. If the liquid phase requirement is met, the flowmeter can read actual flow rate with an uncertainty of ⁇ 0.0075 kg/min (0.0034 lbm/min).
  • the air flow rate is measured with a Pitot-tube measuring station which uses a calibrated pressure transducer to measure dynamic pressure.
  • the flow rate of the water flowing through the condenser is measured by a calibrated turbine flowmeter.
  • the flowmeter can measure the water flow rate with an uncertainty of ⁇ 0.05 kg/min (0.0225 lbm/min).
  • a watt transducer precalibrated by the manufacturer is used to measure compressor power consumption with a listed uncertainty of ⁇ 0.05 kW (4 Btu/min).
  • the data acquisition system consists of a computer, an IEEE-488 GPIB (General Purpose Interface Bus) controller card, a computer addressable digital voltmeter, and two scanners.
  • the GPIB controller card allowed for computer control of the scanners and the voltmeter. All of the instruments were connected to the data acquisition system, allowing constant updating of the system operating parameters and storing of the information in the computer memory.
  • Condenser water flow rate was kept constant at a maximum value, which corresponds to approximately 80 kg/min (175 lbm/min) of water mass flow rate.
  • the condenser performance becomes independent of the water flow rate magnitude due to a negligible thermal resistance between the water and the tube wall as described in Incorpera F. P. and D. P. De Witt, 1990 Fundamentals of heat mass transfer, third edition, New York: John Wiley & Sons.
  • the water flow rate was removed as a variable during system testing and analysis, and as a result, the condenser performance becomes only a function of water inlet temperature, refrigerant flow rate, and refrigerant temperatures as described in the Crown et al article.
  • Air volumetric flow rate was kept constant at approximately 1.3 m 3 /sec (2400 CFM). This flow rate magnitude is close to the maximum achievable air flow rate in the test facility and is kept constant so that it is not a variable in this study.
  • the system is first charged with refrigerant to an optimum amount.
  • the condenser water was circulated at a constant volume flow rate by operating a pump at its maximum capacity.
  • the air flow rate was set by adjusting the fan motor speed to achieve a constant air stream dynamic pressure.
  • the condenser water temperature is controlled by mixing the chilled water with the condenser return water.
  • the air inlet temperature was kept at a desired value by reheating the air leaving the evaporator by using a combination of a steam coil and an electric heater.
  • the electric heater is used to accurately control the air temperature while the steam coil was used to produce the bulk of the cooling load.
  • a needle valve was used to control the refrigerant flow rate through the system which in turn adjusts the amount of superheat at the compressor exit.
  • the lubricant oil change was performed in accordance with the triple-flush procedure outlined in Byrne J. J., M Shows and M. W. Abel. Investigation of flushing and cleanout methods for refrigeration equipment to ensure system compatibility. Final report. ARTI MLLR Project Number 660-52502.
  • the triple-flush is a method for the removal of the mineral oil from an installation containing R-12 when it is retrofitted with HFC-134a. The same procedure was used in this project to replace the polyolester refrigerant lubricant with the mineral oil. The method requires three lubricant changes to remove any traces of residual mineral oil which reduces the residual oil to less than 1 percent by volume.
  • COP coefficient of performance
  • useful energy transfer i.e., evaporator capacity
  • the coefficient of performance was measured for working fluids of Examples 1 and A for air inlet temperatures of 13° C., 18° C. and 24° C. and for condenser water inlet temperatures of 18.5° C., 24° C., 32° C. and 40.5° C.
  • Table 2 the working fluid of Example 1 is identified as “POE lubricant” and the working fluid of Example A is identified as “Mineral Oil”.
  • FIG. 2 also indicates that COP can vary greatly due to varying air and water temperatures. These differences are illustrated by establishing a reference point corresponding to an air temperature of 13° C. and a water temperature of 18.5° C. It can then be observed that an increase in air temperature from the reference point of 13° C. to 24° C., while keeping the same condenser water temperature, results in approximately a 25 percent COP increase. If the water temperature is increased from 18.5° C. to 40° C. then the COP decreases around 40 percent. Although changes in air and water inlet temperatures have a considerable effect on COP, at the temperature conditions tested, the COP for the refrigerant system was with only one exception higher with the miscible working fluid of Example 1.
  • the results plotted in FIG. 2 can also be presented as a percent difference as shown in FIG. 3.
  • the percent COP difference, COP dif is defined as the difference between the COPs for the miscible working fluid with the POE lubricant and the immiscible working fluid with the mineral oil divided by the COP for the miscible working fluid. The value is expressed as a percentage.
  • COP dif ⁇ [ % ] COP POE - COP m ⁇ ⁇ oil COP m ⁇ ⁇ oil ⁇ 100 ( 1 )
  • the results plotted in FIG. 3 also show that the system operating with the miscible working fluid (POE lubricant) has a larger COP than the system operating with the immiscible working fluid (Mineral oil).
  • the percent differences are as high as 2.5 percent. It appears from FIG. 3 that the largest percent differences correspond to the points with the highest evaporator temperature of 24° C. (75° F.) with the COP percent difference diminishing to a fraction of a percent as the evaporator air entering temperature decreases.
  • the system operates more efficiently with the miscible working fluid (POE) lubricant then with the immiscible working fluid (MO) with the microfin-tube coil.
  • POE miscible working fluid
  • MO immiscible working fluid
  • FIG. 4 also reveals substantial differences in COP due to variations in water and air temperatures. For instance the COP decreases for 25 percent if the water temperature is increased from 24° C. to 40° C., and it also decreases for around 20 percent if the air temperature is reduced from 24° C. to 13° C. Only for a condenser water temperature of 40° C. (105 F.) are there no distinguishable difference among COP percent differences for different air temperatures. Yet, the COP for the refrigerant system was higher for the miscible working fluid of Example 1 for all test conditions.
  • the percent COP difference, COP dif defined earlier, in formula (1) is obtained from the COP results set forth in FIG. 4.
  • the COP dif results expressed in percentage are set forth in FIG. 5.
  • the results demonstrate that the system operating with the miscible working fluid (POE lubricant) has a larger COP than the system operating with the immiscible working fluid (Mineral oil).
  • the COP percent differences are as high as about 4.5 percent, and the largest percent differences correspond to the points with the highest evaporator temperature 24° C. (75° F.) and the lowest condenser water temperature 24° C. (75° F.).
  • the COP percent difference appears to decrease with an increase in water temperature and a decrease in air temperature.
  • the coefficient of performance was measured for the refrigeration apparatus described hereabove using a second miscible working fluid comprising 1,1,1,2-tetrafluoroethane heat transfer fluid and a second polyol ester lubricant (POE #2).
  • the second polyol ester is formed from an alcohol mixture of 65 weight percent pentaerythritol and 35 weight percent dipentaerythritol and a mixture of straight chain acids of 5 to 10 carbon atoms present in the following ranges (53-63 no. % nC 5 ; 5-15 no. % nC 6 ; 7-17 no. % nC 7 ; 7-17 no. % nC 8 ; 0-10 no. % nC 9 and 0-10 no.
  • Example 2 working fluid The conditions under which the coefficient of performance was measured for this Example 2 working fluid were the same as those for the working fluids of Examples 1 and A.
  • the comparative results for COP for the miscible working fluids of Examples 1 and 2 (expressed as POE #1 and #2) are shown in FIG. 6.
  • the coefficient of performance results of the working fluids of Examples 1 and 2 are defined relative to the immiscible working fluid of Example A in terms of a percent difference in FIG. 7 by calculating these differences according to formula (1).
  • the COP percent differences for working fluids of Examples 1 and 2 i.e., POE #1 and POE #2
  • FIG. 7 The COP percent differences data indicate that the miscible working fluid of Example 2 improves the COP of a refrigerant system relative to the immiscible working fluid of Example A.
  • the COP percent improvement for the miscible working fluid of Example 2 over the immiscible working fluid of Example A varied from 0.1 to 5.2%.

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US09/328,858 US20010019120A1 (en) 1999-06-09 1999-06-09 Method of improving performance of refrigerant systems
SK1710-2001A SK287084B6 (sk) 1999-06-09 2000-06-08 Spôsob zlepšenia koeficientu účinnosti chladiaceho systému
EP00938224A EP1198535B1 (en) 1999-06-09 2000-06-08 Method of improving performance of refrigerant systems
AU53296/00A AU5329600A (en) 1999-06-09 2000-06-08 Method of improving performance of refrigerant systems
CZ20014360A CZ20014360A3 (cs) 1999-06-09 2000-06-08 Způsob zlepąení účinnosti chladicích soustav
TR2001/03544T TR200103544T2 (tr) 1999-06-09 2000-06-08 Soğutma sistemlerinin performansının arttırılması için bir yöntem
CA002375742A CA2375742C (en) 1999-06-09 2000-06-08 Method of improving performance of refrigerant systems
KR1020017015835A KR100672118B1 (ko) 1999-06-09 2000-06-08 냉각 시스템의 성능 개선방법
JP2001502529A JP2003501614A (ja) 1999-06-09 2000-06-08 冷媒システムの性能を向上させる方法
BRPI0011375-1A BR0011375B1 (pt) 1999-06-09 2000-06-08 processos para melhorar o desempenho de um sistema refrigerante.
SI200020027A SI20748B (sl) 1999-06-09 2000-06-08 Metoda izboljšanja karakteristike hladilnih sistemov
CNB008086117A CN1276960C (zh) 1999-06-09 2000-06-08 改善制冷系统性能的方法
NZ515610A NZ515610A (en) 1999-06-09 2000-06-08 Method of improving performance of refrigerant systems
PCT/US2000/015756 WO2000075258A1 (en) 1999-06-09 2000-06-08 Method of improving performance of refrigerant systems
MXPA01012160A MXPA01012160A (es) 1999-06-09 2000-06-08 Metodo para mejorar el rendimiento de sistemas refrigerantes.
EP10194924.6A EP2290032B1 (en) 1999-06-09 2000-06-08 Method of improving performance of refrigerant systems
AT00938224T ATE517961T1 (de) 1999-06-09 2000-06-08 Verfahren zur verbesserung der leistungsfähigkeit von kühlsystemen
US10/151,458 US7018558B2 (en) 1999-06-09 2002-05-20 Method of improving performance of refrigerant systems
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