US20110041535A1 - Heat exchange system - Google Patents

Heat exchange system Download PDF

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Publication number
US20110041535A1
US20110041535A1 US12/543,268 US54326809A US2011041535A1 US 20110041535 A1 US20110041535 A1 US 20110041535A1 US 54326809 A US54326809 A US 54326809A US 2011041535 A1 US2011041535 A1 US 2011041535A1
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Prior art keywords
heat exchange
heat
exchange system
refrigerant
fluid
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US12/543,268
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James O'Brien
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TRIEA SYSTEMS LLC
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TRIEA SYSTEMS Inc
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Priority to US12/543,268 priority Critical patent/US20110041535A1/en
Priority to US12/752,585 priority patent/US9027359B2/en
Priority to US12/829,060 priority patent/US20110154838A1/en
Assigned to TRIEA SYSTEMS, INC. reassignment TRIEA SYSTEMS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GINALICK, JR., MATTHEW, O'BRIEN, JAMES
Publication of US20110041535A1 publication Critical patent/US20110041535A1/en
Assigned to TRIEA SYSTEMS, L.L.C. reassignment TRIEA SYSTEMS, L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TRIEA SYSTEMS, INC.
Abandoned legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25BREFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B39/00Evaporators; Condensers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25BREFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B30/00Heat pumps
    • F25B30/02Heat pumps of the compression type

Definitions

  • aspects of the present invention relate to a portable and scalable heat exchange system. More particularly, aspects of the invention relate to a high-efficiency water-to-water heat exchange system for providing an efficient, portable, and/or scalable heating and/or cooling source.
  • FIG. 1 shows an exemplary vapor-compression refrigeration cycle 2 used in many heat exchange systems, in which a refrigerant is circulated through a closed-loop compression and expansion cycle.
  • the refrigerant begins as a vapor at point A.
  • the refrigerant vapor is compressed and circulated by a compressor 10 , resulting in a high-pressure, high-temperature refrigerant vapor.
  • the electro-mechanical energy of the compressor 10 is also converted into heat energy carried by the refrigerant vapor, which exits the compressor 10 as a superheated vapor.
  • Phase 2 of the cycle the superheated vapor passes through a condenser 20 where a heat exchange process pulls heat energy from the superheated vapor, causing the refrigerant to condense into a high-pressure liquid.
  • the hot liquid refrigerant is then directed through a thermal expansion valve 30 , which meters the flow of refrigerant to the evaporator 40 and usually results in a flash lowering of the pressure and temperature of the condensed hot liquid refrigerant.
  • the low-pressure, low-temperature liquid or saturated liquid/vapor refrigerant enters the evaporator 40 during Phase 4 of the cycle, wherein a second heat exchange process draws heat energy from a heat source, such as water or air, to the refrigerant, causing the refrigerant to reach a saturation temperature and returning the refrigerant to the vapor state at point A.
  • a heat source such as water or air
  • the heat exchanging condenser 20 extracts heat energy from the superheated refrigerant vapor during Phase 2 of the cycle by using a blower 50 to direct cool air across condenser coils carrying the hot vapor (see FIG. 1 ).
  • the cool air conducts heat energy from the coils and the heated air is supplied by the blower through ducting, for example, to directly heat the home or residence.
  • the evaporator typically relies on the air temperature outside the home for drawing heat into the refrigerant during Phase 4 of the cycle.
  • the blower 50 may instead be used to direct hot air across evaporator coils carrying the cooler fluid refrigerant during Phase 4 of the cycle 2 .
  • the cooler fluid refrigerant conducts heat energy from the hot air, and the resulting cooler air may be supplied to the home.
  • the condenser 20 relies on the outside air to cool the superheated vapor during Phase 2 of the vapor-compression cycle 2
  • the heat pump may be designed with a reversible valve and specialized heat exchangers, for example, allowing the vapor-compression cycle 2 to operate in either direction, with each heat exchanger serving as either a condenser or an evaporator.
  • the cycle of the heat pump can thus be reversed, so that, depending on the desired climate, a single blower may be used to direct hot or cool air across coils, for example, carrying the cooler refrigerant fluid or the superheated refrigerant vapor, respectively.
  • a typical air-source heat pump works harder to transfer heat from a cooler place to a warmer place as the temperature difference increases between the cooler and warmer places. Accordingly, the performance of an air-source heat pump deteriorates significantly, for example, during the winter months in a very cold climate, as the temperature difference between the air outside a home becomes significantly less than the desired temperature inside the home.
  • a ground source heat pump system which typically extracts heat from the ground, or a body of water, may be used to counteract the effect of significant temperature gradients between the heat source and the heat sink. This is because the ground below a certain depth, and water below a certain level, maintains a fairly constant temperature year round, leading to generally lower temperature differentials throughout significant periods of the year, allowing for increased performance of the heat pump.
  • the vapor-compression cycle 2 described in FIG. 1 may be coupled with a ground source loop 3 that carries a heat exchange fluid, such as water, for example.
  • the heat exchange fluid conducts heat while flowing through conduits 4 buried in the ground or sunk under a body of water 5 .
  • a portion of the heat carried by the heat exchange fluid in the conduits 4 is transferred to the cooler liquid refrigerant by conduction through a heat exchange process performed by the evaporator 40 during Phase 4 of the vapor-compression cycle 2 .
  • the refrigerant is vaporized, and the refrigerant vapor is then compressed during Phase 1 of the vapor-compression cycle.
  • a blower 50 may be used to direct cool air across condenser coils while carrying the hot vapor during Phase 2 of the vapor-compression cycle 2 in order to provide heat to the interior of a structure.
  • a heat sink loop 6 may be coupled with the condenser 20 to capture heat transferred from the heat exchange fluid during Phase 4 of the vapor-compression cycle 2 , along with heat that is added through the electro-mechanical energy input by the compressor 10 during Phase 1 of the vapor-compression cycle 2 , into a heat sink 60 , which could be a tank of hot water, for example.
  • the condensed refrigerant exiting the condenser 20 is then expanded during Phase 3 of the vapor-compression cycle 2 and the cooler refrigerant liquid enters the evaporator 40 once again to draw more heat from the heat exchange fluid flowing through the ground source loop 3 .
  • a typical ground source system such as the ground source loop 3 described above, is expensive to construct and can be extremely disruptive to install because thousands of feet of piping may need to be placed in horizontally dug trenches or wells dug vertically deep into the ground, to effectively tap into the thermal energy contained therein. And although the thermal conductivity of water is greater than that of the ground, generally allowing for less piping to be placed into a body of water, access to a body of water close enough to the home for the purpose of creating a ground source system is often unfeasible.
  • aspects of the present invention provide for a heat exchange system that combines a thermally conductive fluid and a specially tuned vapor-compression cycle in an extremely efficient, modular, portable, and scalable system for providing superior heat exchange capabilities for heating and/or cooling in almost any environment.
  • the heat exchange system in accordance with aspects of the present invention may be disassembled and assembled with ease and without causing damage to the structural components of the system to permit convenient installation in residential, commercial and industrial settings.
  • aspects of the present invention include operation of the system using a portable generator, allowing deployment in remote locations, such as forward operating military outposts, or to provide heating, cooling, hot water and chilled water to people in need around the world, such as victims in disaster relief centers and in refugee camps.
  • aspects of the invention and, in particular, the increased performance of the efficiently designed heat exchange system, permit enhanced heating and cooling while creating a significantly reduced footprint on the environment over conventional heating and cooling systems that rely on fossil fuels to function.
  • FIG. 1 shows an exemplary vapor-compression cycle as typically used in heat exchange systems
  • FIG. 2 shows an exemplary ground source heat pump system as is known in the prior art
  • FIG. 3 shows a system flow diagram of a heat exchange system, in accordance with aspects of the present invention
  • FIG. 4 shows a perspective view of an exemplary heat exchange system, in accordance with aspects of the present invention
  • FIG. 5 shows an enlarged view of various components of the exemplary heat exchange unit, in accordance with aspects of the present invention.
  • FIG. 6 shows a cutaway view of an exemplary heat sink, in accordance with aspects of the present invention.
  • FIG. 3 is an exemplary flow diagram in accordance with aspects of the present invention.
  • the heat exchange system 100 comprises a vapor-compression refrigeration cycle having a compressor 110 , a condenser 120 , an expansion valve 130 , and an evaporator 140 .
  • the refrigerant R- 410 A a mixture of difluoromethane and pentafluoroethane, is preferred for its thermodynamic properties and because R- 410 A does not contribute to ozone depletion.
  • R- 410 A typically operates at higher pressures than most refrigerants, requiring increased strength in certain components of the system.
  • a heat source 200 such as a tank of water, may be provided to work in tandem with the heat exchange system 100 to supply heat energy during Phase 4 of the vapor-compression cycle 2 .
  • the heat source 200 may alternatively be a nearby lake or stream, for example.
  • the heat source 200 may be connected to the heat exchange system 100 through a circulation system 210 , which may be a closed-loop or open-loop system for circulating a heat exchange fluid, such as water.
  • the circulation system 210 may include a pump 215 , for example, for circulating the heat exchange fluid from the heat source 200 , through the evaporator 140 and back to the heat source 200 .
  • Fluid flow valves 216 may be installed on either side of the pump 215 , to allow for fluid flow to the pump 215 to be shut off during assembly, or during repair and/or replacement of the pump 215 .
  • Fluid flow conduits 217 for carrying the heat exchange fluid 205 through the circulation system 210 may include rigid and/or flexible tubing made of a thermally conductive material, such as copper or a modified polyethylene, for example. As shown in FIG. 4 , the fluid flow conduits 217 may include flexible tubing exterior to the heat exchange system 100 , copper or brass tubing, for example, inside of the heat exchange system 100 , and hard plastic tubing, for example, to form a coiled section of the evaporator 140 .
  • the heat exchange fluid 205 is forced by the pump 215 to flow through the stacked coil section 142 of the evaporator 140 in a specified direction.
  • the heat exchange function of the evaporator 140 is accomplished by concurrently running a cold refrigerant conduit 132 , which exits the expansion valve 130 , through the stacked coil section 142 of the evaporator 140 .
  • the cold refrigerant conduit 132 enters the evaporator 140 at an evaporator entrance junction 134 and exits the evaporator at an evaporator exit junction 136 .
  • the cold refrigerant conduit 132 follows, and is contained within, the stacked coil section 142 of the evaporator 140 .
  • the cold refrigerant conduit 132 is ideally situated to permit the entire outer surface area of the cold refrigerant conduit 132 to be in direct contact with the warmer heat exchange fluid 205 flowing through the stacked coil section 142 . Accordingly, increased thermal conduction from the heat exchange fluid during Phase 4 of the vapor-compression cycle 2 is provided by the afore-mentioned arrangement of the structural components.
  • the refrigerant flow entering the evaporator 140 has just completed Phase 3 of the vapor-compression cycle, in which the hot refrigerant fluid has passed through the expansion valve 130 and experienced a rapid decrease in pressure and temperature.
  • the cooler refrigerant fluid flows through the cold refrigerant conduit 132 in the same direction as the warmer heat exchange fluid flows through the stacked coil section 142 of the evaporator 140 .
  • the concurrent tubular flow creates a variable temperature gradient over the length of the stacked coil section 142 , in which the refrigerant absorbs the heat energy of the heat exchange fluid at a greater rate nearer the evaporator entrance junction 134 than towards the evaporator exit junction 136 .
  • the cold refrigerant conduit 132 follows, and is contained within, the stacked coil section 142 of the evaporator 140 .
  • the refrigerant and the heat exchange fluid both approach an equilibrium temperature as the fluids flow in parallel through the respective conduits in the evaporator 140 .
  • the refrigerant has thus completed Phase 4 of the vapor-compression cycle, and, as a vapor, is now ready to enter the compressor 110 .
  • the compressor 110 which may be a reciprocating or scroll compressor, for example, supplies the electro-mechanical energy to compress the vapor into a superheated vapor during Phase 1 of the vapor-compression cycle 2 .
  • a heat sink 300 such as a tank of water, may be provided to work in tandem with the heat exchange system 100 to store the amplified heat energy extracted from the heat exchange fluid during Phase 4 of the vapor-compression cycle 2 .
  • the heat sink 300 may be connected to the heat exchange system 100 through a heat sink circulation system 310 , which may be a closed-loop or open-loop system for circulating a heat absorption fluid 305 , such as water.
  • the heat sink circulation system 310 may include a pump 315 , for example, for circulating the heat absorption fluid from the heat sink 300 , through the condenser 120 and back to the heat sink 300 .
  • Fluid flow valves 316 such as ball or butterfly valves, may be installed on either side of the pump 315 , to allow for fluid flow to be shut off to the pump 315 during assembly, or during repair and/or replacement of the pump 315 .
  • Fluid flow conduits 317 for carrying the heat absorption fluid through the heat sink circulation system 310 may include rigid and/or flexible tubing made of a thermally conductive material, such as copper or a modified polyethylene, for example. As shown in FIG. 4 , the fluid flow conduits 317 may include rigid copper tubing, for example, insulated to protect heat loss during circulation of the heat absorption fluid through the heat sink circulation system 310 .
  • the heat absorption fluid is forced by the pump 315 to flow through the stacked coil section 122 of the condenser 120 in a specified or predetermined direction.
  • the heat exchange function of the evaporator 120 is accomplished by concurrently running a hot refrigerant conduit 112 , which exits the compressor 110 , through the stacked coil section 122 of the condenser 120 .
  • the hot refrigerant conduit 112 enters the condenser 120 at a condenser entrance junction 114 and exits the condenser at a condenser exit junction 116 .
  • the hot refrigerant conduit 112 follows, and is contained within, the stacked coil section 122 of the condenser 120 .
  • the hot refrigerant conduit 112 is ideally situated to permit the entire outer surface area of the hot refrigerant conduit 112 to be in direct contact with the cooler heat absorption fluid flowing through the stacked coil section 122 of the condenser 120 . This enables increased thermal conduction from the superheated refrigerant vapor during Phase 2 of the vapor-compression cycle 2 .
  • the refrigerant flow entering the condenser 120 has just completed Phase 1 of the vapor-compression cycle, in which the refrigerant vapor was compressed by the compressor 110 and experienced a rapid increase in temperature.
  • the superheated refrigerant vapor flows through the hot refrigerant conduit 112 in an opposite direction relative to the cooler heat absorption fluid flowing through the stacked coil section 122 of the condenser 120 .
  • the countercurrent tubular flow maintains a nearly constant temperature gradient over the length of the stacked coil section 122 , in which heat is conducted from the superheated refrigerant vapor into the cooler heat absorption fluid at nearly the same rate near the condenser entrance junction 114 as at the condenser exit junction 116 .
  • the countercurrent flow in the condenser 120 allows efficient transfer of a substantial portion of the heat energy drawn from the heat exchange fluid, as well as the work energy input from the compressor 110 , into the heat sink 300 .
  • the heat exchange system of the present invention draws on the thermal energy contained in the heat source 200 , which may be a tank of water at ambient temperature, for example, and by way of the vapor-compression cycle 2 , deposits the withdrawn thermal energy efficiently into the heat sink 300 , which may be another tank of water, for example.
  • the heat sink 300 may thus reach temperatures of more than 150° F.
  • the hot water in the heat sink 300 may be drawn and pumped through pipes 400 to a radiant heating system, for example, or a hydronic coil and blower arrangement that is connected to a ducting system, in order to provide a constant and efficient source of heat for the interior of a structure.
  • a domestic hot water storage tank 500 may be connected to the heat sink 300 to heat exchange thermal energy into the hot water storage tank 500 for potable water use.
  • FIG. 6 shows an enlarged cutaway view of an exemplary heat sink 300 in accordance with aspects of the present invention.
  • the fluid flow conduits 317 which may be wrapped in insulating material to prevent the escape of thermal energy to the environment, may run from the heat sink 300 to the heat exchange system 100 and back to complete a closed loop, for example.
  • a heat exchange coil 318 comprised of copper, or any other suitable material having high thermal conductivity, may be provided inside the heat sink 300 to facilitate heat exchange from the hot water in the fluid flow conduits 317 into the heat sink 300 .
  • the hot water may then be drawn into the pipes 400 to supply a radiant heating system, for example.
  • the domestic hot water storage tank 500 may connect to the heat sink 300 by pipes 502 , which may be insulated, to conduct heat from the hot water in the heat sink 300 by way of heat exchange coils 504 , also placed in the heat sink 300 .
  • the domestic hot water system may be completely separate from the heat sink circulation system 310 , the efficient heat exchange system thus providing the thermal energy for potable hot water use in a safe and cost-effective manner.
  • an electronic control unit (ECU) 540 may be provided to control operation of the compressor 110 and the circulation pumps 215 and 315 .
  • the ECU 540 may operate with one or more thermostats, for example, to maintain the system in an efficient operating range. For instance, the ECU may set the compressor 110 and the circulation pumps 215 and 315 to run if the temperature of the water in the heat sink 300 drops below a certain temperature.
  • the heat exchange system 100 may be fitted with an electronic pressure control unit 550 .
  • the electronic pressure control unit 550 may be set up to monitor the sensed pressure at any point in the system, including the intake (suction) pressure and the discharge (head) pressure of the compressor 110 . Accordingly, measurement of the evaporator pressure and/or the condenser pressure can provide valuable insight into the efficiency of the system and whether the refrigerant charge is too low or excessive, for example.
  • a sight glass 135 may also be used to aid in the inspection of the refrigerant charge level, as bubbles in the line generally indicate an undercharge.
  • the refrigerant charge in the vapor-compression cycle 2 may be precisely determined in accordance with a length of the refrigerant run (i.e., the length of the and the desired characteristics of a well-balanced heat exchange system.
  • the R- 410 A refrigerant charge may be intentionally set to a level that allows the system to continue to operate at maximum efficiency, while increasing the discharge temperature of the superheated vapor discharged from the compressor 110 .
  • the unexpected results of the present invention call for a substantially lower refrigerant charge than normal to achieve the desired results of an efficient heat transfer between the heat source 200 and the heat sink 300 .
  • R- 410 A enhances the ability to increase the temperature on the discharge side of the compressor 110 , but requires much higher pressures to operate compared to previously used refrigerants. For example, to achieve a condensing temperature value of 140°, an R- 410 high-side pressure must approach 550 psi. In other words, for the heat absorption fluid running through the condenser coil section 122 , which is generally maintained at a temperature of 140° or higher, to condense the superheated vapor of the refrigerant in the conduit 116 , the pressure on the condenser side of the heat exchanger must approach 550 psi or higher.
  • the heat exchange system 100 can handle the higher pressures required to produce the higher compressor discharge temperatures necessary to ensure heat exchange occurs in the condenser at temperatures above 140° F.
  • the temperature of the heat source 200 lowers. Depending on the heat load demand, and the size of the body of water, for example, that is serving as the heat source 200 , the temperature of the heat source 200 may drop significantly. Due to the parallel, concurrent tubular flow design of the evaporator 140 , and the ability to generally maintain the heat source 200 in an ambient environment, the liquid refrigerant is ensured of drawing enough latent heat to effectively boil the liquid refrigerant and deliver vapor with enough pressure to the compressor 110 to function highly efficiently.
  • a slight lowering of the refrigerant charge so that the intake side pressure is slightly lowered, while still preventing liquid refrigerant from being delivered to the compressor 110 may slightly elevate the compression ratio of the compressor 110 .
  • the higher compression ratio in turn may transfer more compression energy to the refrigerant during compression resulting in an even higher discharge temperature so that the heat absorption fluid can be heated to even higher temperatures.
  • the colder heat source may also be used as a cooling medium for chilling water or providing cool air by employing the same water-to-water or water-to-air heat transfer means discussed above with respect to the hot water side.
  • hydronic coils which draw upon the cold water created in the heat source 200 , may be used in combination with a fan to blow hot air across the hydronic coils to produce cooler air for the air conditioning of a particular structure.
  • a separate cold water heat exchange system and storage tank for example, can provide chilled water for a variety of uses.
  • the heat exchange system may be sized appropriately to achieve a symbiotic balance between the thermal mass of the heat sink 300 , and any associated hot side heat exchange systems, and the thermal mass of the heat source 200 , and any associated cold side heat exchange systems. For example, by maintaining the heat source 200 in an ambient air environment, such as interior to the same structure receiving thermal energy from the heat sink 300 , the heat source 200 may continually recapture a portion of the thermal energy in the air provided from the heat sink 300 , rather than that energy simply being lost to the environment.
  • a housing unit 600 may have multiple shelves 601 and 602 for vertically stacking and/or creating compartments for the storage and mounting of the various components of the heat exchange system 100 .
  • Various quick install features may be included to enable the easy installation and/or disassembly of the heat source 200 and/or the heat sink 300 , including hose bibs (not shown), for example, for quickly connecting/disconnecting the fluid flow conduits 217 and 317 to the heat exchange system 100 .
  • Mounting brackets may be provided to allow for quick and efficient mounting of the various components, such as the compressor 110 , the condenser 120 , the evaporator 140 and the circulation pumps 215 and 315 .
  • Rubber padding, insulation, panels, doors and/or a cover may be provided that permit easy assembly/disassembly and access to the interior components for maintenance, while reducing the vibration, sound and heat loss that may be generated during operation of the heat exchange system 100 .
  • the unit 100 may be transported to and employed easily in remote locations.
  • a generator may be used for producing the electricity needed by the compressor 110 and the circulation pumps 215 and 315 , and access to a water source may provide both a heat source 200 and a heat sink 300 for heating and cooling purposes.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat-Pump Type And Storage Water Heaters (AREA)

Abstract

A modular heat exchange system having a refrigerant system for cycling a refrigerant through a compressor, a condenser, an expansion valve, and an evaporator, a heat source circulation system which circulates a heat exchange fluid, and a heat sink circulation system which circulates a heat absorption fluid, wherein the refrigerant cycles through the evaporator in a direction parallel relative to a direction of circulation of the heat exchange fluid flowing concurrently through the evaporator, and wherein the refrigerant flows through the condenser in a direction opposite relative to the circulation direction of the heat absorption fluid flowing concurrently through the condenser. In another aspect, the heat source circulation system includes a heat source and a fluid flow conduit connecting the heat source to the evaporator. In another aspect, the heat sink circulation system includes a heat sink and a hot fluid flow conduit connecting the heat sink to the condenser.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention
  • Aspects of the present invention relate to a portable and scalable heat exchange system. More particularly, aspects of the invention relate to a high-efficiency water-to-water heat exchange system for providing an efficient, portable, and/or scalable heating and/or cooling source.
  • 2. Background of the Technology
  • FIG. 1 shows an exemplary vapor-compression refrigeration cycle 2 used in many heat exchange systems, in which a refrigerant is circulated through a closed-loop compression and expansion cycle. As shown in FIG. 1, the refrigerant begins as a vapor at point A. During Phase 1 of the cycle, the refrigerant vapor is compressed and circulated by a compressor 10, resulting in a high-pressure, high-temperature refrigerant vapor. The electro-mechanical energy of the compressor 10 is also converted into heat energy carried by the refrigerant vapor, which exits the compressor 10 as a superheated vapor. During Phase 2 of the cycle, the superheated vapor passes through a condenser 20 where a heat exchange process pulls heat energy from the superheated vapor, causing the refrigerant to condense into a high-pressure liquid. As shown at Phase 3 of the cycle, the hot liquid refrigerant is then directed through a thermal expansion valve 30, which meters the flow of refrigerant to the evaporator 40 and usually results in a flash lowering of the pressure and temperature of the condensed hot liquid refrigerant. As a result, the low-pressure, low-temperature liquid or saturated liquid/vapor refrigerant enters the evaporator 40 during Phase 4 of the cycle, wherein a second heat exchange process draws heat energy from a heat source, such as water or air, to the refrigerant, causing the refrigerant to reach a saturation temperature and returning the refrigerant to the vapor state at point A. The cycle is repeated.
  • In many conventional residential heat pump systems, for example, for supplying heat, the heat exchanging condenser 20 extracts heat energy from the superheated refrigerant vapor during Phase 2 of the cycle by using a blower 50 to direct cool air across condenser coils carrying the hot vapor (see FIG. 1). The cool air conducts heat energy from the coils and the heated air is supplied by the blower through ducting, for example, to directly heat the home or residence. The evaporator, on the other hand, typically relies on the air temperature outside the home for drawing heat into the refrigerant during Phase 4 of the cycle.
  • For supplying cool air, the blower 50 may instead be used to direct hot air across evaporator coils carrying the cooler fluid refrigerant during Phase 4 of the cycle 2. The cooler fluid refrigerant conducts heat energy from the hot air, and the resulting cooler air may be supplied to the home. Under such circumstances, the condenser 20 relies on the outside air to cool the superheated vapor during Phase 2 of the vapor-compression cycle 2
  • In some conventional systems, the heat pump may be designed with a reversible valve and specialized heat exchangers, for example, allowing the vapor-compression cycle 2 to operate in either direction, with each heat exchanger serving as either a condenser or an evaporator. The cycle of the heat pump can thus be reversed, so that, depending on the desired climate, a single blower may be used to direct hot or cool air across coils, for example, carrying the cooler refrigerant fluid or the superheated refrigerant vapor, respectively.
  • A typical air-source heat pump, as described above, works harder to transfer heat from a cooler place to a warmer place as the temperature difference increases between the cooler and warmer places. Accordingly, the performance of an air-source heat pump deteriorates significantly, for example, during the winter months in a very cold climate, as the temperature difference between the air outside a home becomes significantly less than the desired temperature inside the home.
  • A ground source heat pump system, which typically extracts heat from the ground, or a body of water, may be used to counteract the effect of significant temperature gradients between the heat source and the heat sink. This is because the ground below a certain depth, and water below a certain level, maintains a fairly constant temperature year round, leading to generally lower temperature differentials throughout significant periods of the year, allowing for increased performance of the heat pump. As shown in FIG. 2, the vapor-compression cycle 2 described in FIG. 1 may be coupled with a ground source loop 3 that carries a heat exchange fluid, such as water, for example. The heat exchange fluid conducts heat while flowing through conduits 4 buried in the ground or sunk under a body of water 5. A portion of the heat carried by the heat exchange fluid in the conduits 4 is transferred to the cooler liquid refrigerant by conduction through a heat exchange process performed by the evaporator 40 during Phase 4 of the vapor-compression cycle 2. The refrigerant is vaporized, and the refrigerant vapor is then compressed during Phase 1 of the vapor-compression cycle. As described previously, a blower 50 may be used to direct cool air across condenser coils while carrying the hot vapor during Phase 2 of the vapor-compression cycle 2 in order to provide heat to the interior of a structure. Additionally, a heat sink loop 6 may be coupled with the condenser 20 to capture heat transferred from the heat exchange fluid during Phase 4 of the vapor-compression cycle 2, along with heat that is added through the electro-mechanical energy input by the compressor 10 during Phase 1 of the vapor-compression cycle 2, into a heat sink 60, which could be a tank of hot water, for example. The condensed refrigerant exiting the condenser 20 is then expanded during Phase 3 of the vapor-compression cycle 2 and the cooler refrigerant liquid enters the evaporator 40 once again to draw more heat from the heat exchange fluid flowing through the ground source loop 3.
  • A typical ground source system, such as the ground source loop 3 described above, is expensive to construct and can be extremely disruptive to install because thousands of feet of piping may need to be placed in horizontally dug trenches or wells dug vertically deep into the ground, to effectively tap into the thermal energy contained therein. And although the thermal conductivity of water is greater than that of the ground, generally allowing for less piping to be placed into a body of water, access to a body of water close enough to the home for the purpose of creating a ground source system is often unfeasible.
  • There exists a need for a heat exchange system which combines the efficiencies of the thermal conductivity of a fluid, such as water and a specially tuned vapor-compression cycle to produce an efficient, portable, and scalable heat exchange system for simultaneously providing heating and/or cooling.
  • SUMMARY OF THE INVENTION
  • Aspects of the present invention provide for a heat exchange system that combines a thermally conductive fluid and a specially tuned vapor-compression cycle in an extremely efficient, modular, portable, and scalable system for providing superior heat exchange capabilities for heating and/or cooling in almost any environment. As a result, the heat exchange system in accordance with aspects of the present invention may be disassembled and assembled with ease and without causing damage to the structural components of the system to permit convenient installation in residential, commercial and industrial settings. Aspects of the present invention include operation of the system using a portable generator, allowing deployment in remote locations, such as forward operating military outposts, or to provide heating, cooling, hot water and chilled water to people in need around the world, such as victims in disaster relief centers and in refugee camps.
  • Aspects of the invention, and, in particular, the increased performance of the efficiently designed heat exchange system, permit enhanced heating and cooling while creating a significantly reduced footprint on the environment over conventional heating and cooling systems that rely on fossil fuels to function.
  • Additional advantages and novel features of aspects of the invention will be set forth in part in the description that follows, and in part will become more apparent to those skilled in the art upon examination of the following or upon learning by practice of the invention.
  • BRIEF DESCRIPTION OF THE FIGURES
  • FIG. 1 shows an exemplary vapor-compression cycle as typically used in heat exchange systems;
  • FIG. 2 shows an exemplary ground source heat pump system as is known in the prior art;
  • FIG. 3 shows a system flow diagram of a heat exchange system, in accordance with aspects of the present invention;
  • FIG. 4 shows a perspective view of an exemplary heat exchange system, in accordance with aspects of the present invention;
  • FIG. 5 shows an enlarged view of various components of the exemplary heat exchange unit, in accordance with aspects of the present invention; and
  • FIG. 6 shows a cutaway view of an exemplary heat sink, in accordance with aspects of the present invention.
  • DETAILED DESCRIPTION
  • FIG. 3 is an exemplary flow diagram in accordance with aspects of the present invention. The heat exchange system 100 comprises a vapor-compression refrigeration cycle having a compressor 110, a condenser 120, an expansion valve 130, and an evaporator 140. Although many different refrigerants may be used, the refrigerant R-410A, a mixture of difluoromethane and pentafluoroethane, is preferred for its thermodynamic properties and because R-410A does not contribute to ozone depletion. As will be described in further detail, R-410A typically operates at higher pressures than most refrigerants, requiring increased strength in certain components of the system.
  • As shown in FIGS. 3 and 4, a heat source 200, such as a tank of water, may be provided to work in tandem with the heat exchange system 100 to supply heat energy during Phase 4 of the vapor-compression cycle 2. The heat source 200 may alternatively be a nearby lake or stream, for example. The heat source 200 may be connected to the heat exchange system 100 through a circulation system 210, which may be a closed-loop or open-loop system for circulating a heat exchange fluid, such as water. The circulation system 210 may include a pump 215, for example, for circulating the heat exchange fluid from the heat source 200, through the evaporator 140 and back to the heat source 200. Fluid flow valves 216, such as ball or butterfly valves, may be installed on either side of the pump 215, to allow for fluid flow to the pump 215 to be shut off during assembly, or during repair and/or replacement of the pump 215. Fluid flow conduits 217 for carrying the heat exchange fluid 205 through the circulation system 210 may include rigid and/or flexible tubing made of a thermally conductive material, such as copper or a modified polyethylene, for example. As shown in FIG. 4, the fluid flow conduits 217 may include flexible tubing exterior to the heat exchange system 100, copper or brass tubing, for example, inside of the heat exchange system 100, and hard plastic tubing, for example, to form a coiled section of the evaporator 140.
  • As indicated by the longer arrows in the enlarged view of FIG. 5, the heat exchange fluid 205 is forced by the pump 215 to flow through the stacked coil section 142 of the evaporator 140 in a specified direction. The heat exchange function of the evaporator 140 is accomplished by concurrently running a cold refrigerant conduit 132, which exits the expansion valve 130, through the stacked coil section 142 of the evaporator 140. The cold refrigerant conduit 132 enters the evaporator 140 at an evaporator entrance junction 134 and exits the evaporator at an evaporator exit junction 136. The cold refrigerant conduit 132 follows, and is contained within, the stacked coil section 142 of the evaporator 140. The cold refrigerant conduit 132 is ideally situated to permit the entire outer surface area of the cold refrigerant conduit 132 to be in direct contact with the warmer heat exchange fluid 205 flowing through the stacked coil section 142. Accordingly, increased thermal conduction from the heat exchange fluid during Phase 4 of the vapor-compression cycle 2 is provided by the afore-mentioned arrangement of the structural components.
  • As shown in FIG. 5, the refrigerant flow entering the evaporator 140 has just completed Phase 3 of the vapor-compression cycle, in which the hot refrigerant fluid has passed through the expansion valve 130 and experienced a rapid decrease in pressure and temperature. As shown with the smaller arrows in FIG. 5, the cooler refrigerant fluid flows through the cold refrigerant conduit 132 in the same direction as the warmer heat exchange fluid flows through the stacked coil section 142 of the evaporator 140. The concurrent tubular flow creates a variable temperature gradient over the length of the stacked coil section 142, in which the refrigerant absorbs the heat energy of the heat exchange fluid at a greater rate nearer the evaporator entrance junction 134 than towards the evaporator exit junction 136. The cold refrigerant conduit 132 follows, and is contained within, the stacked coil section 142 of the evaporator 140. The refrigerant and the heat exchange fluid both approach an equilibrium temperature as the fluids flow in parallel through the respective conduits in the evaporator 140. The refrigerant has thus completed Phase 4 of the vapor-compression cycle, and, as a vapor, is now ready to enter the compressor 110.
  • As shown in FIGS. 3 and 4, the compressor 110, which may be a reciprocating or scroll compressor, for example, supplies the electro-mechanical energy to compress the vapor into a superheated vapor during Phase 1 of the vapor-compression cycle 2. A heat sink 300, such as a tank of water, may be provided to work in tandem with the heat exchange system 100 to store the amplified heat energy extracted from the heat exchange fluid during Phase 4 of the vapor-compression cycle 2. The heat sink 300 may be connected to the heat exchange system 100 through a heat sink circulation system 310, which may be a closed-loop or open-loop system for circulating a heat absorption fluid 305, such as water. The heat sink circulation system 310 may include a pump 315, for example, for circulating the heat absorption fluid from the heat sink 300, through the condenser 120 and back to the heat sink 300. Fluid flow valves 316, such as ball or butterfly valves, may be installed on either side of the pump 315, to allow for fluid flow to be shut off to the pump 315 during assembly, or during repair and/or replacement of the pump 315. Fluid flow conduits 317 for carrying the heat absorption fluid through the heat sink circulation system 310 may include rigid and/or flexible tubing made of a thermally conductive material, such as copper or a modified polyethylene, for example. As shown in FIG. 4, the fluid flow conduits 317 may include rigid copper tubing, for example, insulated to protect heat loss during circulation of the heat absorption fluid through the heat sink circulation system 310.
  • As indicated by the longer arrows in the enlarged view of FIG. 5, the heat absorption fluid is forced by the pump 315 to flow through the stacked coil section 122 of the condenser 120 in a specified or predetermined direction. The heat exchange function of the evaporator 120 is accomplished by concurrently running a hot refrigerant conduit 112, which exits the compressor 110, through the stacked coil section 122 of the condenser 120. The hot refrigerant conduit 112 enters the condenser 120 at a condenser entrance junction 114 and exits the condenser at a condenser exit junction 116. The hot refrigerant conduit 112 follows, and is contained within, the stacked coil section 122 of the condenser 120. The hot refrigerant conduit 112 is ideally situated to permit the entire outer surface area of the hot refrigerant conduit 112 to be in direct contact with the cooler heat absorption fluid flowing through the stacked coil section 122 of the condenser 120. This enables increased thermal conduction from the superheated refrigerant vapor during Phase 2 of the vapor-compression cycle 2.
  • As shown in FIG. 5, the refrigerant flow entering the condenser 120 has just completed Phase 1 of the vapor-compression cycle, in which the refrigerant vapor was compressed by the compressor 110 and experienced a rapid increase in temperature. As shown with the smaller arrows in FIG. 5, the superheated refrigerant vapor flows through the hot refrigerant conduit 112 in an opposite direction relative to the cooler heat absorption fluid flowing through the stacked coil section 122 of the condenser 120. The countercurrent tubular flow maintains a nearly constant temperature gradient over the length of the stacked coil section 122, in which heat is conducted from the superheated refrigerant vapor into the cooler heat absorption fluid at nearly the same rate near the condenser entrance junction 114 as at the condenser exit junction 116. Particularly with the use of water as the heat absorption fluid, for example, which has a relatively high thermal conductivity, the countercurrent flow in the condenser 120 allows efficient transfer of a substantial portion of the heat energy drawn from the heat exchange fluid, as well as the work energy input from the compressor 110, into the heat sink 300.
  • The heat exchange system of the present invention draws on the thermal energy contained in the heat source 200, which may be a tank of water at ambient temperature, for example, and by way of the vapor-compression cycle 2, deposits the withdrawn thermal energy efficiently into the heat sink 300, which may be another tank of water, for example. The heat sink 300 may thus reach temperatures of more than 150° F. As shown in FIG. 4, the hot water in the heat sink 300 may be drawn and pumped through pipes 400 to a radiant heating system, for example, or a hydronic coil and blower arrangement that is connected to a ducting system, in order to provide a constant and efficient source of heat for the interior of a structure. In addition, a domestic hot water storage tank 500 may be connected to the heat sink 300 to heat exchange thermal energy into the hot water storage tank 500 for potable water use.
  • FIG. 6 shows an enlarged cutaway view of an exemplary heat sink 300 in accordance with aspects of the present invention. The fluid flow conduits 317, which may be wrapped in insulating material to prevent the escape of thermal energy to the environment, may run from the heat sink 300 to the heat exchange system 100 and back to complete a closed loop, for example. Additionally, a heat exchange coil 318, comprised of copper, or any other suitable material having high thermal conductivity, may be provided inside the heat sink 300 to facilitate heat exchange from the hot water in the fluid flow conduits 317 into the heat sink 300. The hot water may then be drawn into the pipes 400 to supply a radiant heating system, for example.
  • As shown in FIG. 6, the domestic hot water storage tank 500 may connect to the heat sink 300 by pipes 502, which may be insulated, to conduct heat from the hot water in the heat sink 300 by way of heat exchange coils 504, also placed in the heat sink 300. As such, the domestic hot water system may be completely separate from the heat sink circulation system 310, the efficient heat exchange system thus providing the thermal energy for potable hot water use in a safe and cost-effective manner.
  • As shown in FIGS. 3 and 4, in accordance with aspects of the present invention, an electronic control unit (ECU) 540 may be provided to control operation of the compressor 110 and the circulation pumps 215 and 315. The ECU 540 may operate with one or more thermostats, for example, to maintain the system in an efficient operating range. For instance, the ECU may set the compressor 110 and the circulation pumps 215 and 315 to run if the temperature of the water in the heat sink 300 drops below a certain temperature.
  • As shown in FIG. 4, in accordance with aspects of the present invention, the heat exchange system 100 may be fitted with an electronic pressure control unit 550. In combination with one or more pressure transducers 552, the electronic pressure control unit 550 may be set up to monitor the sensed pressure at any point in the system, including the intake (suction) pressure and the discharge (head) pressure of the compressor 110. Accordingly, measurement of the evaporator pressure and/or the condenser pressure can provide valuable insight into the efficiency of the system and whether the refrigerant charge is too low or excessive, for example. As shown in FIG. 5, a sight glass 135 may also be used to aid in the inspection of the refrigerant charge level, as bubbles in the line generally indicate an undercharge.
  • According to aspects of the present invention, the refrigerant charge in the vapor-compression cycle 2 may be precisely determined in accordance with a length of the refrigerant run (i.e., the length of the and the desired characteristics of a well-balanced heat exchange system. The R-410A refrigerant charge may be intentionally set to a level that allows the system to continue to operate at maximum efficiency, while increasing the discharge temperature of the superheated vapor discharged from the compressor 110. The unexpected results of the present invention call for a substantially lower refrigerant charge than normal to achieve the desired results of an efficient heat transfer between the heat source 200 and the heat sink 300.
  • The use of R-410A enhances the ability to increase the temperature on the discharge side of the compressor 110, but requires much higher pressures to operate compared to previously used refrigerants. For example, to achieve a condensing temperature value of 140°, an R-410 high-side pressure must approach 550 psi. In other words, for the heat absorption fluid running through the condenser coil section 122, which is generally maintained at a temperature of 140° or higher, to condense the superheated vapor of the refrigerant in the conduit 116, the pressure on the condenser side of the heat exchanger must approach 550 psi or higher. By using a scroll compressor 110 rated to handle 650 psi before disengaging, and using tubes and fittings rated to withstand the elevated temperatures and pressures of an R-410A charged system, the heat exchange system 100 can handle the higher pressures required to produce the higher compressor discharge temperatures necessary to ensure heat exchange occurs in the condenser at temperatures above 140° F.
  • As heat energy is transferred from the heat source 200 to the heat sink 300, the temperature of the heat source 200 lowers. Depending on the heat load demand, and the size of the body of water, for example, that is serving as the heat source 200, the temperature of the heat source 200 may drop significantly. Due to the parallel, concurrent tubular flow design of the evaporator 140, and the ability to generally maintain the heat source 200 in an ambient environment, the liquid refrigerant is ensured of drawing enough latent heat to effectively boil the liquid refrigerant and deliver vapor with enough pressure to the compressor 110 to function highly efficiently. In fact, a slight lowering of the refrigerant charge so that the intake side pressure is slightly lowered, while still preventing liquid refrigerant from being delivered to the compressor 110, may slightly elevate the compression ratio of the compressor 110. The higher compression ratio in turn may transfer more compression energy to the refrigerant during compression resulting in an even higher discharge temperature so that the heat absorption fluid can be heated to even higher temperatures.
  • The colder heat source may also be used as a cooling medium for chilling water or providing cool air by employing the same water-to-water or water-to-air heat transfer means discussed above with respect to the hot water side. For example, hydronic coils, which draw upon the cold water created in the heat source 200, may be used in combination with a fan to blow hot air across the hydronic coils to produce cooler air for the air conditioning of a particular structure. Similarly, as in the case of a domestic hot water tank, a separate cold water heat exchange system and storage tank, for example, can provide chilled water for a variety of uses. The heat exchange system may be sized appropriately to achieve a symbiotic balance between the thermal mass of the heat sink 300, and any associated hot side heat exchange systems, and the thermal mass of the heat source 200, and any associated cold side heat exchange systems. For example, by maintaining the heat source 200 in an ambient air environment, such as interior to the same structure receiving thermal energy from the heat sink 300, the heat source 200 may continually recapture a portion of the thermal energy in the air provided from the heat sink 300, rather than that energy simply being lost to the environment.
  • Features in accordance with aspects of the present invention include configuring the components of the heat exchange system 100 to be compact, modular and/or portable, for example. As shown in FIG. 4, a housing unit 600 may have multiple shelves 601 and 602 for vertically stacking and/or creating compartments for the storage and mounting of the various components of the heat exchange system 100. Various quick install features may be included to enable the easy installation and/or disassembly of the heat source 200 and/or the heat sink 300, including hose bibs (not shown), for example, for quickly connecting/disconnecting the fluid flow conduits 217 and 317 to the heat exchange system 100. Mounting brackets may be provided to allow for quick and efficient mounting of the various components, such as the compressor 110, the condenser 120, the evaporator 140 and the circulation pumps 215 and 315. Rubber padding, insulation, panels, doors and/or a cover may be provided that permit easy assembly/disassembly and access to the interior components for maintenance, while reducing the vibration, sound and heat loss that may be generated during operation of the heat exchange system 100.
  • By maintaining the modularity and portability of the heat exchange system 100, the unit 100 may be transported to and employed easily in remote locations. A generator may be used for producing the electricity needed by the compressor 110 and the circulation pumps 215 and 315, and access to a water source may provide both a heat source 200 and a heat sink 300 for heating and cooling purposes.
  • While this invention has been described in conjunction with the exemplary aspects outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary aspects of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention, including increasing the size of various components, including the heat source and heat sink, to scale the system appropriately for different applications. Therefore, the invention is intended to embrace all known or later-developed alternatives, modifications, variations, improvements, and/or substantial equivalents.

Claims (20)

1. A modular heat exchange system comprising:
a refrigerant system which cycles a refrigerant through a compressor, a condenser, an expansion valve, and an evaporator;
a heat source circulation system which circulates a heat exchange fluid; and
a heat sink circulation system which circulates a heat absorption fluid,
wherein the refrigerant cycles through the evaporator in a direction that is parallel relative to a direction of circulation of the heat exchange fluid flowing concurrently through the evaporator, and
wherein the refrigerant flows through the condenser in an a direction opposite relative to a circulation direction of the heat absorption fluid flowing concurrently through the condenser.
2. The modular heat exchange system of claim 1, wherein the refrigerant is R-410A.
3. The modular heat exchange system of claim 1, wherein the heat exchange fluid is water.
4. The modular heat exchange system of claim 1, wherein the heat absorption fluid is water.
5. The modular heat exchange system of claim 1, further comprising a high pressure conduit connecting the compressor to the expansion valve, wherein the condenser comprises a coiled tubular section, and the high pressure conduit passes through an interior of the coiled tubular section of the condenser.
6. The modular heat exchange system of claim 1, further comprising a low pressure conduit connecting the expansion valve to the compressor, wherein the evaporator comprises a coiled tubular section, and the low pressure conduit passes through an interior of the coiled tubular section of the evaporator.
7. The modular heat exchange system of claim 1, wherein the heat source circulation system further comprises a heat source and a fluid flow conduit connecting the heat source to the evaporator.
8. The modular heat exchange system of claim 7, wherein the heat source is a body of water.
9. The modular heat exchange system of claim 8, wherein the body of water is contained in a heat source storage tank.
10. The modular heat exchange system of claim 1, further comprising a first circulation pump which circulates the heat exchange fluid.
11. The modular heat exchange system of claim 1, wherein the heat sink circulation system further comprises a heat sink and a hot fluid flow conduit connecting the heat sink to the condenser.
12. The modular heat exchange system of claim 11, wherein the heat sink is a body of water.
13. The modular heat exchange system of claim 12, wherein the body of water is contained in a heat sink storage tank.
14. The modular heat exchange system of claim 1, further comprising a second circulation pump which circulates the heat absorption fluid.
15. The modular heat exchange system of claim 1, further comprising a storage tank connected to the heat sink by a closed-loop circulation system, wherein a fluid in the storage tank receives thermal energy from the heat sink through a heat exchange process.
16. The modular heat exchange system of claim 15, wherein the fluid in the storage tank is water.
17. The modular heat exchange system of claim 1, wherein a refrigerant charge in the refrigerant system is reduced to increase a discharge temperature of the refrigerant leaving the compressor.
18. The modular heat exchange system of claim 1, further comprising an electronic control unit controlling operation of the compressor.
19. The modular heat exchange system of claim 1, further comprising a pressure control device and a pressure transducer, wherein the pressure transducer senses a pressure at a specific point of the refrigerant flow and the pressure control device controls the compressor based on the pressure sensed.
20. The modular heat exchange system of claim 1, further comprising a generator, wherein the generator supplies power to the compressor and at least one circulation pump to operate the heat exchange system.
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