U.S. patent application number 12/527758 was filed with the patent office on 2010-02-11 for refrigerant system with variable capacity expander.
Invention is credited to Alexander Lifson, Michael F. Taras.
Application Number | 20100031677 12/527758 |
Document ID | / |
Family ID | 39766190 |
Filed Date | 2010-02-11 |
United States Patent
Application |
20100031677 |
Kind Code |
A1 |
Lifson; Alexander ; et
al. |
February 11, 2010 |
REFRIGERANT SYSTEM WITH VARIABLE CAPACITY EXPANDER
Abstract
A refrigerant system incorporates a variable capacity expander.
A bypass line selectively bypasses at least a portion of the
refrigerant approaching the expander to the intermediate expansion
point within the expander. In this manner, the refrigerant
expansion process is controlled more efficiently than in the prior
art.
Inventors: |
Lifson; Alexander; (MANLIUS,
NY) ; Taras; Michael F.; (Fayetteville, NY) |
Correspondence
Address: |
CARLSON, GASKEY & OLDS, P.C.
400 WEST MAPLE ROAD, SUITE 350
BIRMINGHAM
MI
48009
US
|
Family ID: |
39766190 |
Appl. No.: |
12/527758 |
Filed: |
March 16, 2007 |
PCT Filed: |
March 16, 2007 |
PCT NO: |
PCT/US07/64117 |
371 Date: |
August 19, 2009 |
Current U.S.
Class: |
62/113 ; 62/498;
62/525 |
Current CPC
Class: |
F25B 9/008 20130101;
F25B 2400/14 20130101; F25B 9/06 20130101; F25B 2309/061 20130101;
F25B 2600/2501 20130101; F25B 1/10 20130101 |
Class at
Publication: |
62/113 ; 62/498;
62/525 |
International
Class: |
F25B 41/00 20060101
F25B041/00; F25B 1/00 20060101 F25B001/00; F25B 39/02 20060101
F25B039/02 |
Claims
1. A refrigerant system comprising: a compressor, said compressor
compressing a refrigerant and delivering this refrigerant to a
downstream heat rejection heat exchanger, refrigerant from the heat
rejection heat exchanger passing through an expander, said expander
being operable to recover at least a portion of work from the
refrigerant expansion process, and a bypass line for selectively
bypassing at least a portion of refrigerant from a point upstream
of said expander to an intermediate pressure point in said
expander.
2. The refrigerant system as set forth in claim 1, wherein said
bypass line has a refrigerant flow restriction.
3. The refrigerant system as set forth in claim 2, wherein said
refrigerant flow restriction is a valve.
4. The refrigerant system as set forth in claim 3, wherein the
valve is an on/off valve.
5. The refrigerant system as set forth in claim 4, wherein said
on/off valve has capability to rapidly cycle between on and off
positions.
6. The refrigerant system as set forth in claim 5, wherein said
cycle rate of said valve is between 1 second and 60 seconds.
7. The refrigerant system as set forth in claim 2, wherein said
refrigerant flow restriction has a variable restriction area.
8. The refrigerant system as set forth in claim 1, wherein said
recovered portion of work from the refrigerant expansion process is
utilized to assist in driving at least one of refrigerant system
components.
9. The refrigerant system as set forth in claim 8, wherein said
system component is said compressor.
10. The refrigerant system as set forth in claim 1, wherein said
expander consists of multiple expansion stages.
11. The refrigerant system as set forth in claim 10, wherein at
least one of said expansion stages is an independent expander.
12. The refrigerant system as set forth in claim 10, wherein said
bypass line bypasses the refrigerant from an upstream location of
one of said expansion stages to an upstream location of a
downstream one of said expansion stages.
13. The refrigerant system as set forth in claim 10, wherein there
are multiple bypass lines between said expansion stages.
14. The refrigerant system as set forth in claim 1, wherein said
refrigerant is CO.sub.2.
15. The refrigerant system as set forth in claim 1, wherein the
recovered work is utilized to power another component by providing
at least one of rotational energy and electrical power.
16. A method of operating a refrigerant system including the steps
of: (1) compressing a refrigerant and delivering this refrigerant
to a downstream heat rejection heat exchanger, refrigerant from the
heat rejection heat exchanger passing through an expander, said
expander being operable to recover at least a portion of work from
the refrigerant expansion process; and (2) selectively bypassing at
least a portion of refrigerant from a point upstream of said
expander to an intermediate pressure point in said expander.
17. The method as set forth in claim 16, wherein a valve
controlling the selective bypassing is rapidly cycled between on
and off positions.
18. The method as set forth in claim 17, wherein a cycle rate of
said valve is between 1 second and 60 seconds.
19. The method as set forth in claim 16, wherein said recovered
portion of work from the refrigerant expansion process is utilized
to assist in driving at least one of refrigerant system
components.
20. The method as set forth in claim 18, wherein said bypass line
bypasses the refrigerant from an upstream location of one of said
expansion stages to an upstream location of a downstream one of
said expansion stages.
Description
BACKGROUND OF THE INVENTION
[0001] This application relates to refrigerant systems, wherein the
expansion process is provided by an expander. The capacity of the
expander can be varied by controlling the amount of refrigerant
that is diverted to an intermediate expansion point in the
expander. By controlling the amount of diverted refrigerant, the
overall refrigerant system can be more efficiently controlled and
operated, as will be explained below.
[0002] Refrigerant systems are known in the air conditioning and
refrigeration art, and are utilized to condition a secondary fluid,
such as air, water or glycol solution, that is delivered to a
climate-controlled zone or space. In a basic refrigerant system, a
compressor compresses a refrigerant and delivers it downstream to a
first heat exchanger, where heat is rejected, directly or
indirectly, from the refrigerant to an ambient environment. From
this first heat exchanger, the refrigerant passes through an
expansion process, where it is expanded to a lower pressure and
temperature, and then through a second heat exchanger, where heat
is accepted by the refrigerant from a secondary fluid to cool this
secondary fluid to be delivered to an indoor environment. The first
heat exchanger is normally called a condenser, for system operation
below the refrigerant critical point, or so-called subcritical
operation, and is called a gas cooler, for system operation above
the refrigerant critical point, or so-called supercritical
operation. The second heat exchanger typically operates in a
subcritical two-phase region and is called an evaporator.
[0003] One performance enhancement option that is utilized in known
refrigerant systems is the use of an expander. As compared to
restriction type expansion devices, whether of fixed or adjustable
type, the expander offers advantages of a more efficient isentropic
expansion process, resulting in a higher refrigerant cooling
potential in the evaporator, as compared to an isenthalpic process
for restriction type expansion devices. Also, some expansion work
can be recovered to assist in driving at least one of refrigerant
system components. Both expansion work recovery and additional
refrigerant cooling potential realized in the evaporator are
beneficial to the refrigerant system operation, since they augment
refrigerant system capacity and efficiency.
[0004] The use of the expanders for CO.sub.2 refrigerant
applications is especially important, as on a relative basis, the
expanders provide much larger thermodynamic cycle improvements for
CO.sub.2 refrigerant than for the traditional refrigerants. It is
also important to use expanders within the CO.sub.2 systems, as
these systems are not as thermodynamically efficient, on an
absolute scale, as the systems with conventional refrigerants, such
as R22, R410A, R404A, R407C, R134a, etc.
[0005] One problem in using the expanders is related to a
difficulty of controlling the amount of refrigerant passing through
the expander. Further, because of their transcritical nature of the
CO.sub.2 cycle, these systems are more sensitive to the refrigerant
charge management than systems with conventional refrigerants.
[0006] The prior art systems relied on the refrigerant bypass
around the expander (from its inlet to its outlet) to adjust the
refrigerant flow throughout the system. In other words, a portion
of the refrigerant flow was short-circuited to pass directly from
the heat rejection heat exchanger outlet into the evaporator inlet.
The use of this bypass proved to be inefficient, as the bypassed
refrigerant represents a direct "leakage" from the expander inlet
to the expander outlet, does not participate in the work recovery
and is known to be one of the major contributors to the expander
inefficiency.
SUMMARY OF THE INVENTION
[0007] In a disclosed embodiment of this invention, an expander
capacity is adjusted by providing an intermediate pressure port in
the expander. If it is desirable to pass more refrigerant through
the expander, then a portion of the refrigerant flow from an
expander inlet is diverted to the intermediate expansion port. The
amount of refrigerant passing through the expander is controlled by
appropriate sizing and/or adequate restriction placed in the bypass
line. Preferably, the flow of refrigerant in the bypass line is
controlled by a flow control device such as a valve. For instance,
this valve can be of an ON/OFF type, such as a solenoid valve. The
valve can also be of an adjustable restriction (modulation) type or
of a pulsation type, for even more precise control of the
refrigerant flow through the bypass line. A similar technique can
be used if an expander consists of multiple expansion stages or
expanders that are installed in series with each other. In this
case, some of the refrigerant is diverted from the inlet of the
upstream expansion stage into the inlet of the expansion stage
located downstream. In other words, in this case, the refrigerant
is injected between the expansion stages.
[0008] In this invention, the efficiency of the expansion process
is improved by eliminating the direct "leak" path from a high
pressure heat rejection heat exchanger to a low pressure
evaporator, while maintaining the ability to provide precise
control over the amount of refrigerant passing through the
expander. Furthermore, due to additional work recovery obtained
from the bypassed refrigerant and more efficient isentropic
process, the refrigerant system's operational performance is
improved.
[0009] These and other features of the present invention can be
best understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 schematically shows a prior art refrigerant
system.
[0011] FIG. 2 shows an inventive refrigerant system.
[0012] FIG. 3 shows another schematic of an inventive refrigerant
system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] A prior art refrigerant system 20 is illustrated in FIG. 1.
As known, a compressor 22 compresses a refrigerant and delivers it
to a heat rejection heat exchanger 24, which is a condenser, for
subcritical applications, and a gas cooler, for transcritical
applications. From the heat rejection heat exchanger 24, the
refrigerant, expanding to a lower pressure and temperature, drives
an expander 26. The expander 26 is shown schematically and includes
a moving member that is driven by the expanding fluid. The
expansion work recovered by the expander may be utilized (directly
or indirectly) to assist in driving at least one of refrigerant
system components. In other words, the expander can be connected to
other system components, such as a compressor, a fan, or a pump,
either directly through a coupling, a clutch, a gearbox, etc., or
can be used to drive a generator to produce electric energy.
[0014] In order to control the expansion process through an
expander, the prior art refrigerant systems have utilized a bypass
line 28 that routed at least a portion of the refrigerant from the
outlet of the heat rejection heat exchanger 24 to the inlet of the
evaporator 36, at operating conditions when the expander could not
handle all of the expanding refrigerant flow. In cases when the
expander could not handle all of the expanding refrigerant flow,
the refrigerant system performance would have become sub-optimized,
with the refrigerant pressure in the heat rejection heat exchanger
rising above a desired level and evaporator superheat also
potentially increasing above the desired value. An inlet 32 to the
bypass line 28 extends to an outlet point 33. When a bypass valve
34 is opened, the refrigerant could flow through the bypass line
28, and thus the amount of refrigerant moving through the circuit
can be increased. However, the use of this bypass is ineffective as
it essentially creates a high-to-low refrigerant "leak" bypassing
the expander 26. In other words, as more refrigerant is bypassed
around the expander 26, less useful work can be recovered by the
expander. Furthermore, a portion of the refrigerant that flows
through the bypass valve 34 undergoes isenthalpic expansion, which
is less thermodynamically efficient than an isentropic expansion
process in the expander 26.
[0015] The present invention is shown in FIG. 2 as a refrigerant
system 50. Here, the bypass inlet 32 leads to a bypass line 52. A
restriction 54 can be positioned on the bypass line 52, and the
point 56 terminates the bypass line 52 at an intermediate expansion
point in the expander 26. The restriction 54 may be an ON/OFF,
modulation or pulsation valve. In this invention, when at least a
portion of the refrigerant bypasses through the valve 54, the
entire refrigerant still moves through and exits the expander 26. A
portion of the refrigerant that bypasses through the valve 54
continues to undergo an expansion process from the intermediate
expansion point 56 to the expander exit point 58. In this manner,
part of the expansion work from the refrigerant passing through the
bypass line 52 is still recovered in the expander 26, as well as,
at least partially, this bypassed portion of the refrigerant will
be expanded isentropically. At the same time, pressure upstream of
the expander 26 can be controlled by the same valve 54 to optimize
the operation of the refrigerant system 50.
[0016] The present invention increases the efficiency and capacity
of a refrigerant system by including a variable capacity expander,
while at the same time, controlling the system operation to be in
the optimum domain. The present invention can be extended to an
expander consisting of several expansion stages, as for example,
can be a case for a multi-stage turbine. It can also be extended to
a system configuration of expanders installed in series with each
other. In this case, as shown in FIG. 3 for an embodiment 70, an
intermediate expansion point 156 is located between the expansion
stages (or independent expanders) 26A and 26B. Of course, more than
two expanders can be installed in series with the bypass line
routed into the point between any stages. Further, more than one
bypass line can be installed when more than two expansion stages
are connected serially.
[0017] Also, if needed, there can be multiple bypass lines 52. As
shown in FIG. 3 embodiment, one bypass line 52 extends through the
flow control valve 54 from a point 200 upstream of the first
expansion stage 26A to an intermediate expansion point 202 within
the same expansion stage 26A, while another bypass line 52, also
incorporating the flow control valve 54, extends from a point 32
upstream of the first expansion stage 26A to a point 156
intermediate of two expansion stages 26A and 26B. Obviously,
upstream points 32 and 200 can be combined into a single point.
[0018] As mentioned above, the bypass valve 54 can be of a variable
area type to provide condition dependant control of how much
refrigerant is routed into the bypass line 52. The bypass valve 54
can also operate in a pulse width modulated manner, such that it is
rapidly cycling between ON and OFF positions.
[0019] The present invention is particularly well suited for use in
refrigerant systems incorporating CO.sub.2 as a refrigerant, where
the benefits of using an expander are the most pronounced.
[0020] It should be pointed out that many different expander and
compressor types could be used in this invention. For example,
scroll, screw, rotary or reciprocating expanders and compressors
can be employed.
[0021] The refrigerant systems that utilize this invention can be
used in many different applications, including, but not limited to,
air conditioning systems, heat pump systems, marine container
units, refrigeration truck-trailer units, and supermarket
refrigeration systems.
[0022] Although a preferred embodiment of this invention has been
disclosed, a worker of ordinary skill in this art would recognize
that certain modifications would come within the scope of this
invention. For that reason, the following claims should be studied
to determine the true scope and content of this invention.
* * * * *