US3768273A - Self-balancing low temperature refrigeration system - Google Patents

Self-balancing low temperature refrigeration system Download PDF

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US3768273A
US3768273A US00299049A US3768273DA US3768273A US 3768273 A US3768273 A US 3768273A US 00299049 A US00299049 A US 00299049A US 3768273D A US3768273D A US 3768273DA US 3768273 A US3768273 A US 3768273A
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mixture
compressed
refrigerant
throttled
condensate
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D Missimer
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Wickes Manufacturing Co
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Gulf and Western Industries Inc
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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
    • F25B9/00—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point
    • F25B9/002—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point characterised by the refrigerant
    • F25B9/006—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point characterised by the refrigerant the refrigerant containing more than one component

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  • the system relies upon a series of intermediate cooling stages in which each stage includes the steps of withdrawing a portion of the liquid condensate from a compressed vapor-liquid refrigerant mixture which enters that stage, throttling the withdrawn condensate to a lower pressure, mixing the throttled condensate with refrigerant being recycled to the compressor from the final evaporator and evaporating the throttled condensate to absorb heat from and at least partially condense the compressed unconcensed vapor in the compressed mixture.
  • Relatively low refrigeration temperatures have been achieved by employing two or more complete refrigeration circuits in cascade connection.
  • the evaporator of one stage forms a heat exchanger with the condenser of the next lower stage.
  • Such systems have the disadvantage of both size and expense in that each stage of the cascade includes all of the components of a complete refrigeration system.
  • such systems have not been effective in producing practical systems due to freezing problems caused by circulation of compressor lubricating oils within the system unless the lower stage included the use of high pressure hazardous hydrocarbon refrigerants, special lubricants, a highly efficient oil separation system or other components of a conventional cryogenic system.
  • a further method of achieving low refrigeration temperatures involves the use of a mixture of refrigerants in a single refrigeration circuit.
  • publications and plublications describing such refrigeration techniques, in both opened and closed circuit systems include U.S. Pat. No. 3,203,194, issued Aug. 31, 1965 to A. Fuederer; U.S. Pat. No. 3,218,816, issued Nov., 1965 to Grenier; U.S. Pat. No. 2,041,725 issued May, 1936 to Podbielniak; U.S. Pat. No. 3,487,653, issued Jan., 1970 to Myre; U.S. Pat. No. 2,952,139, issued Sept. 13, 1960 to Kennedy, et al. and AP.
  • the lowest system temperature is reached at one of the intermediate cascade condensers rather than at the final evaporator, because liquid condensate formed up stream at a partial condensation step when throttled and evaporated reduces the discharge pressure to a level so low that an inadequate amount of liquid condensate is formed in the final step and thus, an insufficient amount of liquid condensate is available for feeding the throttling device which in turn feeds the final evaporator.
  • this situation. can be corrected by the addition of more of the lowest boiling point refrigerant the addition of such additional refrigerant will upset the balance required both for start-up and for final operating design temperatures.
  • a further object of the invention is to provide a novel refrigeration system capable of achieving extremely low temperatures at relatively low discharge pressures and compression ratios such that conventional massproduced air conditioning type compressors may be employed.
  • a further object of the invention is to provide a sealed self-balancing compression refrigeration system employing multiple refrigerants and intermediate cooling stages containing a full refrigerant charge which is capable of rapidly achieving low temperatures without the use of control systems, expansion tanks or other devices designed to alleviate problems associated with high start-up pressures and compression ratios.
  • a novel, single cycle compression refrigeration system which employs a mixture of nonflammable, non-explosive and relatively non-toxic refrigerants having different boiling points and which includes at least one, but preferably more than one, intermediate cooling stage in which a compressed mixture of the refrigerants is at least partially condensed to form a mixture consisting of compressed vapors and compressed liquid condensate, a portion of the liquid condensate is withdrawn to feed a throttling device and the remainder of the liquid condensate is permitted to flow downstream with the uncondensed vapor.
  • each intermediate cooling stage Further cooling and at least partial further condensation is accomplished in each intermediate cooling stage by evaporating the throttled liquid condensate to absorb heat from and at least partially condensed the remaining vapor in the mixture of compressed refrigerant which includes both vapor and the liquid condensate which was not fed through the throttling device at that stage.
  • This novel system may also include sub-cooling and oil separation apparatus as will be more fully described herein.
  • the novel refrigeration system of the invention is not limited to use with particular refrigerant combinations and a wide variety of refrigerant combinations may be employed to achieve operation over a wide temperature range, e.g. 40F. to 300F.
  • the refrigerants in any particular system will range from high boiling point refrigerants of the type normally employed in conventional centrifugal type air conditioning systems to extremely low boiling point refrigerants such as nitrogen, argon, neon, helium and the like.
  • the higher boiling refrigerants will be selected from the group consisting of well-known halogenated hydrocarbons and their azeotropic mixtures. Hydrocarbon refrigerants may also be used provided adequate safety precautions are employed.
  • each refrigerant in the mixture will differ in boiling point from the next closest boiling refrigerant by 50F. to 180F.
  • the differences in boiling point between adjacent refrigerants may vary widely within these ranges but, in general, may be smaller in those instances where a large number of intermediate cooling stages are employed.
  • each refrigerant in the system is not critical and ordinarily sufficient amounts of each refrigerant will be present to insure an adequate flow of liquid at each stage of the process when the system is in full operation.
  • the consid erations as to the type and amount of refrigerant charged to the system are the design-operating temperature and pressures of the system; the nature of the condensing media; the size of various heat exchangers and throttling devices in the system; the compressor displacement and the nature of the refrigerants being employed.
  • the optimum weight ratio of refrigerants in any particular system will also depend upon their respective molecular weights which influence their individual partial pressures; their liquid densities; and the amount of liquid required at each intermediate cooling stage. In general, the amount of lowest boiling refrigerant will be maintained at the minimum necessary to achieve the required refrigeration effect of the system since higher amounts of the lower boiling refrigerants tend to increase the discharge pressures of the system.
  • FIG. 1 is a schematic representation of a refrigeration system having three intermediate cooling stages
  • FIG. 2 is a schematic representation of a refrigeration system similar to that shown in FIG. 1 modified to include apparatus for additional sub-cooling prior to the final evaporator;
  • FIG. 3 is a schematic representation of a refrigeration system similar to that shown in FIG. 1 modified to include apparatus and a technique for removing compressor lubricating oils from the system.
  • a mixture of two or more refrigerants having different boiling points is charged into a single closed refrigeration circuit generally identified as through a service valve 12 or other conventional charging means such as a tube, pipe or the like, which will be sealed after the charging step.
  • the amount of each refrigerant charged to the system may be predetermined by volume or weight or, in the case of lower boiling point refrigerants, by allowing each refrigerant gas to circulate through the system until a predetermined partial pressure and a predetermined total pressure for the system are reached.
  • the vapors are aspirated by a compressor 14 and passed through conduit 16 to condenser 18 where partial condensation occurs.
  • Condensation occurs by heat exchange with ambient air forced over condenser pipes 20 by a fan 22 or, alternatively, condensation may be carried out using a readily available source of water.
  • the partially condensed refrigerant mixture flows through conduit 24.to an auxiliary condenser 26 where, after the system is in operation, further condensation may occur by heat exchange with the cooler vapors returning to compressor 14 from the final evaporator 28 through conduit 30.
  • Utilization of an auxiliary condenser is not critical to the refrigeration system but such additional heat exchange at this point serves to improve the thermodynamic efficiency of the system.
  • FIG. 1 illustrates a refrigeration system including three intermediate cooling stages each consisting of a cascade condenser 34, 36 or 38, a throttling device 40, 54 or 64 and associated conduits.
  • the number of intermediate cooling stages in any system is not critical, provided at least one such stage is present, and the selection of the ultimate number of stages, for example two to six stages, may be readily determined by those persons of ordinary skill inthe art depending upon the operating load and other conditions for which the system is designed;
  • throttling device 40 A portion of the compressed liquid condensate in conduit 32 is throttled in throttling device 40.
  • throttling devices are well known in the art and may consist of a capillary tube, a thermal expansion valve, a float valve or a similar device which permits the pres sure on the liquid flowing therethrough to be dropped from the discharge pressure of the system to the suction pressure of the system. Since the mass flow of liquid through a throttling device is, inter alia, a function of the inlet pressure to the throttling device, it will be apparent to those skilled in the art that throttling.
  • throttling device 40 as well as the other throttling devices in the refrigeration system 10 will not be capable of handling the full flow of liquid condensate under all of the variety of operating conditions which may be encountered during operation of the refrigeration system. Accordingly, throttling device 40 is not designed to permit the flow of all of the liquid condensate in conduit 32 therethrough. A portion of the compressed condensate, as well as the compressed vapors formed in auxiliary condenser 26 flows through conduit 42 to cascade condenser 34. The throttled low pressure liquid leaving throttling device .40 passes through conduit 44 and is intermixed at point 46 with the cold vapors in conduit 30 which are returning. to compressor 14 from final evaporator 28.
  • this low pressure mixture flows through the portion of conduit 30 which is disposed in cascade condenser 34 where the throttled liquid is at least partially evaporated and absorbs heat from the compressed mixture of liquid condensate and vapor which entered cascade condenser 34 through conduit 42 thereby at least partially further condensing the same.
  • a portion of the liquid condensate flowing in conduit 32 may be split off from conduit 32 through a suitable throttling device 48 and a conduit 50 and evaporated in evaporator 51 to obtain an independent refrigeration effect.
  • portion of the throttled liquid which is evaporated would by-pass cascade condenser 34 and be returned to conduit 30 at a point located between cascade condenser 34 and auxiliary condenser 26.
  • a tri-axial or three stream type heat exchanger may be used in place of cascade condenser 34 and evaporator 51.
  • valve 48 and conduit 50 would be eliminated and throttling device 40 would be selected so that the evaporating refrigerant flowing in the low pressure side of the new heat exchanger would be ata rate sufficiently great to absorb heat from both the partially condensing high pressure stream and from the external load.
  • the at least further partially condensed compressed mixture obtained from heat exchange in cascade condenser 34 passes to the. second intermediate cooling stage through conduit 52. Thereafter, the cycle described in connection with the first intermediate cooling stage is repeated, i.e. a portion of the compressed liquid condensate is withdrawn and throttled through throttling device 54 and passes through conduit 56 to point 58 of conduit 30 where the throttled liquid is mixed with recycling vapors.
  • a portion of the compressed liquid condensate as well as the compressed uncondensed vapors flowing in conduit 52 are withdrawn through conduit 60 and enter into cascade condenser 36 where further at least partial condensation occurs by heat exchange with the throttled liquid passing through the portion conduit 30 disposed within cascade condenser 36.
  • the compressed further condensed vapor-liquid mixture from cascade condenser 36 passes to the next successive intermediate cooling stage: through conduit 62 and a portion of the liquid condensate is throttled in throttling device 64, passed through conduit 66 to point 68 where it is mixed with cold vapors being recycled from the final evaporator 28 through conduit 30.
  • the compressed uncondensed vapors and a portion of the compressed liquid condensate in conduit 62 is withdrawn through concuit 70 and passed to cascade condenser 38 where further condensation occurs as a result of the at least partial evaporation of the liquid throttled in throttling device 64.
  • the further condensed compressed mixture in cascade condenser 38 is withdrawn through conduit 72 and passes through final throttling device 74 to the evaporator inlet 76 which is at the coldest system temperature and essentially at the suction pressure.
  • the liquid condensate is partially or completely evaporated in evaporator 28 to achieve the final refrigeration temperature of the system.
  • the refrigeration circuit is closed by returning the vapors and any residual liquid from evaporator 28 through conduit 30 back to compressor 14, the vapor being mixed with additional throttled liquid portions prior to its passage through each of the cascade condensers associated with each of the intermediate cooling stages as previously described.
  • FIG. 2 illustrates a modification of the refrigeration system described in FIG. 1 wherein the condensate emanating from the final intermediate cooling stage through conduit 72 is subcooled prior to the final evaporation stage.
  • the operation of the compressor 14, condenser 22, auxiliary condenser 26 and the intermediate cooling stages is identical to that previously de scribed in connection with FIG. 1.
  • Sub-cooling is accomplished by dividing the compressed condensate flowing in conduit 72 into two streams and utilizing the first stream to sub cool the second stream. More particularly, a conduit 78 is provided for drawing off a said first stream and the first stream is thereafter passed to throttling device 80 where the condensate is throttled to the suction pressure of the system.
  • the throttled liquid which flows into conduit 82 is colder than the compressed condensate flowing into conduit 72.
  • Conduit 82 discharges into said sub-cooler 84 and the throttled liquid is employed to further cool the compressed condensate flowing-in line 72.
  • the throttled and at least partially evaporated liquid leaves sub-cooler 84 through conduit 86 and is mixed at point 88 with cold vapor from evaporator 28 being recycled to the compressor through line 30.
  • the sub-cooled compressor condensate in line 72 (except for that portion withdrawn through line 78) is passed to final throttling device 74 and then to the final evaporator 28, all as previously described with respect to FIG. 1.
  • FIG. 3 is illustrative of a refrigeration system similar to that described in FIGS. 1 and 2 in which the system has been modified to provide for the use of a compressor lubricating oil admixed with the refrigerant and for the removal of that lubricating oil at a point in the system which is well in advance of the lowest temperatures which the system is capable of producing. While the circulation of lubricating oil is acceptable in compression refrigeration systems operating at relatively high final evaporator temperatures, it cannot be tolerated in systems operating at low temperature since good lubricants have relatively high pour points and will not flow thereby coating heat transfer surfaces, clogging conduits throughout the circuit and possibly resulting in inadequate compressor lubrication.
  • a technique for removing the lubricating oil from the refrigerant mixture which technique includes the steps of adding a relatively high boiling separation fluid to the refrigerant mixture.
  • the separation fluid has a boiling point which is about 35F. to l l5F., preferably 40 to F. higher than the highest boiling refrigerant in the refrigerant mixture and has a high degree of miscibility or solubility with the lubricating oil being employed.
  • the first condensation step in the refrigeration system depicted in FIG. 1 will result in condensation of substantially all of the separation fluid which, due to its high miscibility and solubility will entrain substantially all of the lubricating oil.
  • the compressed liquid condensate including the separation fluid and the lubricating oil may be separated from the compressed vapors, throttled to essentially the suction pressure and recycled to the compressor along with the vapors being recycled to the compressor from the final evaporator.
  • a wide variety of relatively high boiling, oil miscible separation fluids may be employed in the oil separation method and the choice of a particular fluid will depend on a number of factors including the boiling point of the fluid; the boiling point of the highest boiling refrigerant and the nature of the lubricating oil.
  • the preferred separation fluids are halocarbons since these materials are relatively non-toxic, non-flammable and non-explosive.
  • Typical halocarbons are those which are normally employed as a refrigerant in high temperature refrigeration systems and include such materials as trichlorotrifluoroethane, methylene chloride, trichlorofluoromethane, dichlorofluoromethane, dichlorotetrafluoroethane, or combinations of these materials, Ordinarily, the lubricating oil employed for lubrication of the compressor will be a hydrocarbon.
  • FIG. 3 which illustrates the refrigeration system of the present invention including an oil separation step
  • a mixture of refrigerants, separation fluid and compressor lubricating oil as above described is charged into the closed refrigeration circuit generally identified as through a service valve or other conventional charging means as previously described.
  • the vapors are aspirated by compressor 102 and passed through conduit 104 to condenser 108 where partial condensation occurs by heat exchange with ambient air forced over c'ondenser pipes 110 by a fan 112 or alternate condenser means as described in connection with FIG. 1.
  • the partially condensed refrigerant mixture may flow through conduit 114 to auxiliary condenser 116 where, when the system is in operation, further condensation may occur by heat exchange with the cooler vapors returning to compressor 102 from the final evaporator 1 18 through conduit 120.
  • the partially condensed refrigerant mixture leaves auxiliary condenser 116 through conduit 122 and passes to a vaporliquid separator 124.
  • the liquid at this point is rich in the separation fluid and compressor lubricating oil as well as the higher boiling refrigerants while the vapor is rich in the lower boiling refrigerant or refrigerants of the mixture.
  • the liquid separated in separator 124 passes through an optional dryer-strainer 126 where particulate matter is filtered from the stream and residual moisture is removed and then through conduit 128 to throttling device 130 which throttles the liquid, i.e. the pressure of the liquid drops from the discharge pressure to the suction pressure of the system.
  • the throttled liquid next passes through conduit 132 to point 134 of conduit 120 where the throttled liquid is mixed with vapors being recycled from the final vaporator to the compressor. Thereafter this mixture flows in conduit 120 through heat exchanger 136 where it is evaporated and used to absorb heat from and further partially condense the separated vapors from separator 124 which enter heat exchange 136 through conduit 138. Following the heat exchange the vapor in conduit 120, which includesthe separation fluid and the lubricant, are recycled to the compressor through auxiliary condenser 116.
  • FIG. 3 depicts two intermediate cooling stages 142 and 144. In each of these intermediate cooling stages a portion of the compressed condensate is throttled and used to cool and further condense a mixture consisting of the remainder of the compressed condensate and the compressed vapors all as previouslydescribed in connection with the system illustrated in FIG. 1.
  • the compressed condensate leaving the final intermediate cooling stage 144 flows through conduit 146 to final throttling device 148, with or without sub-cooling as described in FIG. 2, and the throttled liquidfrom the final throttling device is partially or fully evaporated in final evaporator 118 to achieve the final refrigeration temperature of the system.
  • the condenser may be divided into two sections with a heat exchanger and the vapor-liquid separator installed between the sections.
  • the vapors are aspirated by the compressor, passed through a conduit to the first condenser section where they are desuperheated and partially condensed by heat exchange with ambient air (or alternately by water).
  • the vapor and partially condensed mixture is then passed through the heat exchanger for further cooling and partial condensation and then to the liquid-vapor separator.
  • the condensed liquid at this point is very rich in the separation fluid and contains almost all of the lubricating oils pumped by the compressor along with the aspirated vapors.
  • the liquid separated in the separator passes through a conduit to a throttling device where the pressure is reduced to essentially the suction pressure.
  • This low pressure mixture of separation fluid and lubricating oil is then passed back through the heat exchanger and the separation fluid is evaporated by counter-current heat exchange with the high pressure stream feeding the vapoi-liquid separator.
  • the lubricating oil and evaporated fluid is then recycled to the compressor suction connection.
  • the vapor mixture exiting from the separator is passed through a conduit to the second condenser section where additional heat is removed by further partial condensation and the condensed mixture is then fed to the intermediate cooling stages as previously described.
  • throttling devices, heat exchangers and other apparatus employed in the system is not critical and will, of course, depend upon the operating conditions for which a particular system is designed. For example, in determining the appropriate size of throttling devices such as capillary tubes in which flow capacity is dependent upon the pressure and quality of entering condensate, the total weight of refrigeratant to be circulated in the system is calculated and this amount is divided between the various throttling devices in the system. Ordinarily, the throttling device feeding the final evaporator will be designed to handle about 30 to 50 percent of the total mass flow, the remainder being divided equally among the throttling devices feeding associated with each intermediate cooling stage. The optimum size of each throttling device is, of course, an empirical determination.
  • the optimum design for system heat exchangers is also an empirical determination based on well known principles of heat and mass transfer. It has been found however that ordinarily the intermediate heat exchangers should be designed to handle about twice the evaporator load for systems having a final operating temper ature of about F. and four or more times the load .parts of the system.
  • the start-up pressures were 24 p.s.i.g. suction pressure and 365 p.s.i.g. discharge pressure (compression ratio 9.75/1). Cooling commenced promptly and continued at a good rate until-178 F, the ultimate low temperature of the system, was reached in just over two hours. Subsequently, the system was shut down and then re-started. No difficulty was encountered in again achieving the operating characteristics set forth in Table I.
  • a comparison of Tables I and II indicates that the rate of cooling was much more rapid without the separators. For example, less than 0.75 hours was required to reach 25F. without the use of separators (Table I) while the same temperature was not achieved for almost 2.00 hours using separators. Indeed, after 2.00 hours, the rate of cooling in the system employing separators was so low as indicated by the extremely low suction pressure that it became obvious that a larger amount of a lower boiling refrigerant was required for proper operation of the system.
  • a third system employing vapor-liquid separators between each cascade condenser and additionally employing an auxiliary discharge vapor tank similar to that described at column 5, lines 31-19 of Fuderer U.S. Pat. No. 3,203,194 was employed.
  • the discharge tank was connected to the system across the compressor so that excess high pressure vapors could be stored during start-up (with the low pressure connection closed and the high pressure connection open).
  • the system employed the same refrigerant mixture at the same balanced at rest pressure as employed with the system of FIG. 3. The results of this run are set forth in Table III.
  • step (b) subjecting the compressed mixture from step (b) to at least one intermediate, cooling stage, each said intermediate cooling stage including the steps of throttling a portion of said compressed condensate to a lower pressure, mixing said throttled condenate with the mixture of refrigerants being recycled to the compressing step from the final evaporator, evaporating said throttled condensate to absorb heat from and at least partially condense the compressed vapor in the remaining mixture of the compressed condensate and compressed vapor, returning the mixture of evaporated, throttled condensate and recycled refrigerant mixture to step (a), and passing said at least partially condensed compressed mixture to the next successive intermediate cooling stage;
  • step (d) at least partially evaporating the throttled condensate produced in step (d) to produce the final refrigerating temperature and recycling the at least partially evaporated mixture of refrigerants to said compressing step.
  • said refrigerant mixture includes at least two halocarbon refrigerants
  • said refrigerant mixture includes at least two halocarbon refrigerants and at least one inert gas selected from the group consisting of argon, nitrogen and neon.
  • said refrigerant mixture further includes a compressor lubricating oil and a separation fluid, said separation fluid having a boiling point which is 35 to F. higher than the highest boiling refrigerant in said. refrigerant mixture and being soluble in said lubricating oil, separating the compressed mixture obtained in step (b) into liquid and vapor phases whereby said lubricating oil and a substantial portion of the separation fluid remains in said liquid phase, throttling said separated oil-laden separation fluid to a lower pressure, mixing said throttled oil-laden separation fluid with refrigerant being recycled to the compressor from the final evaporator and passing said compressed vapor phase to the first intermediate cooling stage.

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US9528780B2 (en) 2010-06-15 2016-12-27 Biofilm Ip, Llc Methods, devices and systems for extraction of thermal energy from a heat conducting metal conduit
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CN101893343B (zh) * 2010-06-24 2012-08-15 中国科学院理化技术研究所 一种制冷剂与润滑油深度分离的多元混合工质节流制冷机
US9546647B2 (en) 2011-07-06 2017-01-17 Sumitomo (Shi) Cryogenics Of America Inc. Gas balanced brayton cycle cold water vapor cryopump
CN102255003B (zh) * 2011-08-12 2013-08-07 保定维特瑞光电能源科技有限公司 一种太阳能光伏组件封闭自循环传导散热液及其制备方法
CN102255003A (zh) * 2011-08-12 2011-11-23 保定维特瑞光电能源科技有限公司 一种太阳能光伏组件封闭自循环传导散热液及其制备方法
US9677714B2 (en) 2011-12-16 2017-06-13 Biofilm Ip, Llc Cryogenic injection compositions, systems and methods for cryogenically modulating flow in a conduit
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JPS552374Y2 (enrdf_load_stackoverflow) 1980-01-22
JPS54135762U (enrdf_load_stackoverflow) 1979-09-20
FR2203962B1 (enrdf_load_stackoverflow) 1977-08-12
JPS4995249A (enrdf_load_stackoverflow) 1974-09-10
FR2203962A1 (enrdf_load_stackoverflow) 1974-05-17
CA984167A (en) 1976-02-24

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