US20080256975A1 - Vapor Compression System With Condensate Intercooling Between Compression Stages - Google Patents

Vapor Compression System With Condensate Intercooling Between Compression Stages Download PDF

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Publication number
US20080256975A1
US20080256975A1 US12/088,767 US8876706A US2008256975A1 US 20080256975 A1 US20080256975 A1 US 20080256975A1 US 8876706 A US8876706 A US 8876706A US 2008256975 A1 US2008256975 A1 US 2008256975A1
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Prior art keywords
refrigerant
condensate
compressor
heat
recited
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Abandoned
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US12/088,767
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English (en)
Inventor
Alexander Lifson
Michael F. Taras
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Carrier Corp
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Carrier Corp
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Assigned to CARRIER CORPORATION reassignment CARRIER CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LIFSON, ALEXANDER, TARAS, MICHAEL F.
Publication of US20080256975A1 publication Critical patent/US20080256975A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B1/00—Compression machines, plants or systems with non-reversible cycle
    • F25B1/10—Compression machines, plants or systems with non-reversible cycle with multi-stage compression
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B31/00—Compressor arrangements
    • F25B31/006—Cooling of compressor or motor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2400/00—General features or devices for refrigeration machines, plants or systems, combined heating and refrigeration systems or heat-pump systems, i.e. not limited to a particular subgroup of F25B
    • F25B2400/07—Details of compressors or related parts
    • F25B2400/072—Intercoolers therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D21/00—Defrosting; Preventing frosting; Removing condensed or defrost water
    • F25D21/14—Collecting or removing condensed and defrost water; Drip trays

Definitions

  • This invention relates generally to vapor compression systems having multiple compression stages and, more particularly, to the cooling of refrigerant vapor passing between an upstream compression stage and a downstream compression stage in a refrigerant vapor compression system.
  • Refrigerant vapor compression systems are well known in the art and commonly used for conditioning secondary fluid such as air to be supplied to a climate controlled comfort zone within a residence, office building, hospital, school, restaurant or other facility.
  • Refrigerant vapor compression systems are also commonly used in transport and stationary refrigeration applications for refrigerating air supplied to a temperature controlled space of a truck, trailer, container, display case or the like for preserving perishable items.
  • most of these refrigerant vapor compression systems operate at subcritical refrigerant pressures and typically include a compressor, a condenser, an evaporator, and an expansion device. Commonly, an expansion device is disposed upstream, with respect to refrigerant flow, of the evaporator and downstream of the condenser.
  • refrigerant system components are interconnected by refrigerant lines in a closed refrigerant circuit, arranged in accord with known refrigerant vapor compression cycles, and operated in the subcritical pressure range for the particular refrigerant in use.
  • Refrigerant vapor compression systems operating in the subcritical range are commonly charged with fluorocarbon refrigerants such as, but not limited to, hydrochlorofluorocarbons (HCFCs), such as R 22 , and more commonly hydrofluorocarbons (HFCs), such as R134a, R410A and R407C.
  • fluorocarbon refrigerants such as, but not limited to, hydrochlorofluorocarbons (HCFCs), such as R 22 , and more commonly hydrofluorocarbons (HFCs), such as R134a, R410A and R407C.
  • HFC refrigerants are more environmentally friendly than the chlorine containing HCFC refrigerants that they replaced, “natural” refrigerants, such as carbon dioxide, are being turned to for use in air conditioning and refrigeration systems instead of HFC refrigerants.
  • carbon dioxide has a low critical point
  • refrigerant vapor compression systems charged with carbon dioxide as the refrigerant are designed for operation in the transcritical cycle.
  • the heat rejection heat exchanger operates at refrigerant pressures above the critical point, while the evaporator operates at refrigerant pressures in the subcritical range.
  • refrigerant vapor compression systems utilizing a low critical point refrigerant, such as carbon dioxide frequently employ a multi-stage compression system, either multiple compressors disposed in series flow arrangement with respect to refrigerant flow or a single compressor having at least two compression stages.
  • the pressure of the refrigerant vapor discharging from the final stage of the compression system commonly referred to as the discharge pressure or the high-side pressure, is high enough that the refrigerant vapor does not condense as it traverses the heat rejection heat exchanger. Consequently, with respect to systems operating in a transcritical cycle, the heat rejection heat exchanger is commonly referred to as, and functions as, a gas cooler, not a condenser.
  • the cooling medium is generally a secondary cooling fluid external to the system, such as chilled water or ambient air, or a portion of the cold system refrigerant diverted from elsewhere within the refrigerant circuit.
  • U.S. Pat. No. 6,658,888 discloses a multi-stage compression refrigerant vapor compression system charged with carbon dioxide refrigerant and having an intercooler between stages of a multi-stage compressor.
  • the refrigerant vapor passing between compression stages traverses the intercooler wherein it rejects heat to the same cooling fluid medium having previously passed through the gas cooler accepting heat from the refrigerant vapor discharged from the compressor.
  • the heated cooling fluid medium exits the system.
  • the cooling fluid medium may be room air, tap water or recirculated water, depending upon the application.
  • U.S. Pat. No. 6,698,234 also discloses a multi-stage compression refrigerant vapor compression system charged with carbon dioxide refrigerant and having an intercooler between stages of a multi-stage compression system.
  • a portion of the cold refrigerant downstream of the gas cooler bypasses the system evaporator and is diverted to pass through the intercooler in heat exchange relationship with the refrigerant vapor flowing between compression stages.
  • the diverted refrigerant is expanded to a lower pressure and temperature prior to passing through the intercooler.
  • the diverted refrigerant stream is heated and the refrigerant vapor flowing between compression stages is cooled.
  • the heated diverted refrigerant is returned to the suction side of the refrigerant circuit downstream of the system evaporator.
  • the refrigerant vapor compression system of the invention includes a first compression device to compress a refrigerant to a first pressure, a second compression device to further compress the refrigerant from the first pressure to a second pressure, a heat accepting heat exchanger (e.g. evaporator) for passing the refrigerant in heat exchange relationship with a moisture bearing gas (e.g. air) whereby the heat is transferred from the gas to the refrigerant and at least some amount of moisture in the moisture bearing gas is condensed to form a condensate (water), and an intercooler wherein the condensate exchanges heat with and accepts heat from the refrigerant passing from said first compression device to the second compression device.
  • a heat accepting heat exchanger e.g. evaporator
  • a moisture bearing gas e.g. air
  • the first compression device is a first compressor and the second compression device is a second compressor with the discharge outlet of the first compressor connected by a refrigerant line in refrigerant flow communication to the suction inlet of the second compressor.
  • the refrigerant line connecting the discharge outlet of the first compressor to the suction inlet of the second compressor traverses the intercooler.
  • the first compression device is a first compression stage of a compressor and the second compression device is a second compression stage of the same compressor. The refrigerant being compressed in the compressor traverses the intercooler as it passes from the first compression stage to the second compression stage.
  • the intercooler includes a refrigerant conveying passage having an exterior heat exchange surface, which can be enhanced for better heat transfer by one of the techniques known in the art, and at least one spray nozzle to spray the condensate condensed from the moisture bearing gas onto the exterior heat exchange surface of the refrigerant conveying passage.
  • a heat exchanger construction may be provided for the intercooler, preferably having moisture and refrigerant flows arranged in a counterflow configuration.
  • a condensate collector may be provided in operative association with the heat accepting heat exchanger for collecting the condensate condensed from the moisture bearing gas.
  • Condensate may be gravity-fed from the condensate collector to the spray nozzle or nozzles if the condensate collector is disposed at a higher elevation than the intercooler.
  • a pump may be provided to supply the condensate from the condensate collector to the intercooler.
  • a method for increasing the capacity of a refrigerant vapor compression system by cooling the refrigerant between a first compression stage and a second compression stage via heat exchange with the condensate.
  • the method of the invention includes the steps of: compressing the refrigerant to a first pressure in a first compression stage and to a second pressure in a second compression stage, passing the refrigerant in heat exchange relationship with a moisture bearing gas whereby the refrigerant accepts heat from the gas and at least a portion of the moisture condenses from the gas to form a condensate, and cooling the refrigerant between the first compression stage and the second compression stage via heat exchange with the condensate.
  • the step of cooling the refrigerant passing between the first compression stage and the second compression stage via heat exchange with the condensate may comprise cooling the refrigerant between the first compression stage and the second compression stage via evaporating at least a portion of the condensate.
  • the method may include the steps of passing the refrigerant flowing between the first compression stage and the second compression stage through a refrigerant conveying passage that may or may not have internal and external enhanced heat transfer surfaces and spraying the condensate onto the refrigerant conveying passage.
  • Condensate delivery may be accomplished with assistance of gravity or mechanical means such as a condensate pump.
  • a refrigerant vapor compression system includes a first compressor to compress a refrigerant to a first pressure, a second compressor to further compress the refrigerant to a second pressure, a refrigerant circuit including a first refrigerant line (or lines) passing through other refrigerant system components and connecting the discharge outlet of the second compressor in refrigerant flow communication with the suction inlet of the first compressor and a second refrigerant line connecting the discharge outlet of the first compressor with the suction inlet of the second compressor, a heat rejecting heat exchanger disposed in the first refrigerant line downstream with respect to refrigerant flow of the discharge outlet of said second compressor, a heat accepting heat exchanger disposed in the first refrigerant line downstream with respect to refrigerant flow of the heat rejecting heat exchanger for passing the refrigerant in heat exchange relationship with a moisture bearing gas whereby the refrigerant accepts heat from the gas and moisture in the gas is at least partially condensed to form a
  • FIG. 1 is a schematic diagram illustrating a first exemplary embodiment of a refrigerant vapor compression system in accord with the invention
  • FIG. 2 is a schematic diagram illustrating a second exemplary embodiment of a refrigerant vapor compression system in accord with the invention
  • FIG. 3 is a schematic diagram illustrating a third exemplary embodiment of a refrigerant vapor compression system in accord with the invention.
  • FIG. 4 is a schematic diagram illustrating a fourth exemplary embodiment of a refrigerant vapor compression system in accord with the invention.
  • the refrigerant vapor compression system 10 includes a compression device 30 , a refrigerant heat rejecting heat exchanger 40 , also referred to herein as a gas cooler or a condenser (depending on an application), a refrigerant heat absorbing heat exchanger 50 , also referred to herein as an evaporator, an expansion device 55 , illustrated as an expansion valve, operatively associated with the evaporator 50 , and various refrigerant lines 60 A, 60 B, 60 C and 60 D connecting the aforementioned components in a conventional refrigerant circuit.
  • the compression device 30 functions to compress and circulate refrigerant throughout the refrigerant circuit as will be discussed in further detail hereinafter.
  • the compression device 30 may be a scroll compressor, a screw compressor, a reciprocating compressor, a rotary compressor, a centrifugal compressor or any other type of compressor or a plurality of any such compressors.
  • the compression device 30 as depicted in FIGS. 1-4 , has a first compression stage 30 - 1 and a second compression stage 30 - 2 .
  • the compression device 30 may be a pair of compressors 30 - 1 and 30 - 2 , for example a pair of scroll compressors, screw compressors, reciprocating compressors or rotary compressors connected in series, having a refrigerant line 60 D connecting the discharge outlet port of the first compressor 30 - 1 , which constitutes the first compression stage, in refrigerant flow communication with the suction inlet port of the second compressor 30 - 2 , which constitutes the second compression stage.
  • the compression device 30 may be a single refrigerant compressor having a first compression stage and a second compression stage, for example a scroll compressor or a screw compressor having at least a pair of staged compression pockets 30 - 1 , 30 - 2 , or a reciprocating compressor having a first bank 30 - 1 and a second bank 30 - 2 of cylinders.
  • a single refrigerant compressor having a first compression stage and a second compression stage
  • a scroll compressor or a screw compressor having at least a pair of staged compression pockets 30 - 1 , 30 - 2 , or a reciprocating compressor having a first bank 30 - 1 and a second bank 30 - 2 of cylinders.
  • a reciprocating compressor having a first bank 30 - 1 and a second bank 30 - 2 of cylinders.
  • one or more compression stage may consist of two or more compressors disposed in a so-called tandem arrangement, that is compressors operating in parallel and having at least one common manifold.
  • the refrigerant vapor compression system of the invention may be operated in either a subcritical cycle or a transcritical cycle.
  • the refrigerant heat rejecting heat exchanger 40 constitutes a refrigerant condensing heat exchanger through which hot, high pressure refrigerant vapor discharged from the compression device 30 - 2 passes in heat exchange relationship with a secondary cooling medium, most commonly ambient air in air conditioning systems or refrigeration systems.
  • the refrigerant heat rejecting heat exchanger 40 constitutes a gas cooler heat exchanger through which supercritical refrigerant vapor discharged from the compression device 30 - 2 passes in heat exchange relationship with a secondary cooling medium, again most commonly ambient air in air conditioning systems or refrigeration systems.
  • a secondary cooling medium typically ambient air passed over the refrigerant conveying passages 44 by an air mover, such as one or more fans 42 operatively associated with the heat exchanger 40 .
  • the refrigerant leaving the heat rejecting heat exchanger 40 passes through refrigerant line 60 B to the evaporator 50 .
  • the refrigerant traverses the expansion device 55 and expands to a lower pressure whereby the refrigerant typically enters the evaporator 50 as a lower temperature, lower pressure mixture of liquid and vapor.
  • the evaporator 50 constitutes a refrigerant evaporating heat exchanger through which the liquid refrigerant passes in heat exchange relationship with a heating fluid whereby the liquid refrigerant is evaporated and typically superheated.
  • the heating fluid (or the fluid to be cooled) passed in heat exchange relationship with the refrigerant in the evaporator 50 may be air passed over the evaporator external surfaces by an air mover, such as one or more fans 52 , and thereafter supplied to a climate controlled environment such as a comfort zone associated with an air conditioning system or a perishable product storage zone associated with a refrigeration unit.
  • an air mover such as one or more fans 52
  • a climate controlled environment such as a comfort zone associated with an air conditioning system or a perishable product storage zone associated with a refrigeration unit.
  • condensate 16 As the air passes over the refrigerant conveying passages 54 and other heat transfer enhancement elements (not shown) associated with the passages 54 of the evaporator 50 , at least a portion of moisture contained in the air condenses out onto the exterior surfaces of the evaporator and the condensed moisture, referred to as condensate 16 , then drains into a condensate collection device 20 , for example a drain pan.
  • the expansion device 55 may be a conventional thermostatic expansion valve (TXV) or electronic expansion valve (EXV) or a fixed restriction device such as an orifice, an accurator, a capillary tube, or the like.
  • a sophisticated expansion device receives a signal indicative of the refrigerant temperature sensed by the temperature sensing element (not shown) associated with the outlet of the evaporator 50 , which may be a conventional temperature sensing element, such as a bulb for a TXV and a thermistor or a thermocouple, frequently coupled with a pressure sensor, for an EXV, and meters the refrigerant flow through the refrigerant line 60 C to maintain a desired level of superheat of the refrigerant vapor leaving the evaporator 50 .
  • the temperature sensing element such as a bulb for a TXV and a thermistor or a thermocouple
  • a suction accumulator (not shown) may be disposed in refrigerant line 60 C downstream with respect to refrigerant flow of the evaporator 50 and upstream with respect to refrigerant flow of the compression device 30 - 1 to remove and store any liquid refrigerant passing through refrigerant line 60 C, thereby ensuring that liquid refrigerant does not pass to the suction port of the compression device 30 - 1 .
  • suction accumulators are typically used in heat pump applications and employed in conjunction with fixed restriction expansion devices.
  • the refrigerant vapor compression system 10 includes an intercooler 24 disposed in the refrigerant circuit between the first compression device 30 - 1 and the second compression device 30 - 2 .
  • Refrigerant vapor passing from the evaporator 50 through refrigerant line 60 C enters the suction inlet of the first compression device 30 - 1 , wherein the refrigerant vapor is compressed to a higher intermediate pressure.
  • the refrigerant vapor then passes from the discharge outlet of the first compression device 30 - 1 through refrigerant line 60 D to enter the suction inlet of the second compression device 30 - 2 wherein the refrigerant vapor is compressed to a still higher discharge pressure before passing from the discharge outlet of the second compression device 30 - 2 into refrigerant line 60 A.
  • the refrigerant vapor passes through refrigerant line 60 D, the refrigerant vapor traverses the intercooler 24 wherein the refrigerant vapor passing through the intercooler 24 is cooled via rejecting heat to the evaporator condensate 16 .
  • a pump 22 draws condensate 16 collecting in the evaporator drain pan 20 therefrom and passes the condensate 16 through condensate line 21 to a bank of spray nozzles 26 .
  • the spray nozzles 26 are arrayed in operative association with a refrigerant conveying tube coil or passage 25 forming the intercooler 24 to spray condensate 16 received through condensate line 16 onto the exterior surfaces of the tubes of the coil 25 .
  • the exterior surfaces of the tube coil or passage 25 can be extended and enhanced for better heat transfer.
  • the refrigerant vapor traversing through the coil 25 as it passes through refrigerant line 60 D from the first compression device 30 - 1 to the second compression device 30 - 2 is cooled as it rejects heat to heat and evaporate at least a portion of the condensate 16 sprayed onto the exterior of the coil 25 .
  • the spray nozzles may comprise atomizers, such as atomizing nozzles or rotary atomizers, which produce a mist of relatively small size droplets of condensate onto the exterior of the coil 25 .
  • the pump 22 withdraws condensate 16 collecting in the evaporator drain pan 20 and passes the condensate 16 through condensate line 21 to and through the intercooler 24 in heat exchange relationship with the refrigerant passing through the intercooler 24 .
  • the refrigerant vapor traverses the intercooler 24 , the refrigerant vapor is cooled as it rejects heat to the condensate 16 .
  • the intercooler 24 may comprise a plate-type heat exchanger, a tube-in-tube heat exchanger, an immersed coil heat exchanger or any other type of heat exchanger wherein the refrigerant vapor is passed in isolation from but in heat exchange relationship with the evaporator condensate. As the condensate passes in heat exchange relationship with the refrigerant vapor, the condensate 16 is heated and/or evaporated. As noted before, as known in the art, the exterior and interior surfaces of the intercooler 24 can be enhanced to provide better heat transfer characteristics. It has to be also noted that, in this case, the intercooler coil 25 can be integrated into the construction of the drain pan 20 , if desired.
  • the system is simplified by removing the pump 22 and disposing the evaporator 50 and its associated condensate drain pan 20 at a higher elevation than the intercooler 24 .
  • Condensate 16 collecting in the evaporator drain pan 20 drains therefrom under the force of gravity through condensate line 21 to a plurality of spray nozzles 26 .
  • the spray nozzles 26 are again arrayed in operative association with a refrigerant conveying tube coil or passage 25 forming the intercooler 24 to spray condensate 16 received through condensate line 21 onto the exterior surface of the tubes of the coil 25 .
  • the refrigerant vapor traversing through the coil 25 as it passes through refrigerant line 60 D from the first compression device 30 - 1 to the second compression device 30 - 2 is cooled as it rejects heat to heat and at least partially evaporate the condensate 16 sprayed onto the exterior of the coil 25 .
  • the spray nozzles may comprise atomizers, such as atomizing nozzles or rotary atomizers, which produce a mist of relatively small size droplets of condensate onto the exterior of the coil 25 .
  • the intercooler 24 is a refrigerant conveying tube coil or passage 25 immersed in the condensate 16 collecting in the condensate pan 20 .
  • the exterior surfaces of tube coils or passages 25 forming the intercooler 24 can be extended and enhanced for better heat transfer.
  • the refrigerant vapor flowing through the intercooler 24 as it passes through refrigerant line 60 D from the first compression device 30 - 1 to the second compression device 30 - 2 is cooled as it rejects heat to heat and evaporate at least a portion of the condensate 16 collected in the condensate pan 20 .
  • the evaporated condensate must be vented to the ambient environment to ensure that the evaporated condensate does not re-enter the conditioned air stream leaving the evaporator 50 .

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Vaporization, Distillation, Condensation, Sublimation, And Cold Traps (AREA)
  • Other Air-Conditioning Systems (AREA)
US12/088,767 2006-08-21 2006-08-21 Vapor Compression System With Condensate Intercooling Between Compression Stages Abandoned US20080256975A1 (en)

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PCT/US2006/032547 WO2008024102A1 (en) 2006-08-21 2006-08-21 Vapor compression system with condensate intercooling between compression stages

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CN (1) CN101292127B (zh)
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WO2008024102A1 (en) 2008-02-28
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