Thermal fluid regeneration systems and processes

Abstract

The thermal fluid regeneration process includes a step of combining at least two recovered thermal fluids, each containing at least two refrigerant compounds, to form an integrated thermal fluid. The integrated thermal fluid is a blend of at least two refrigerant compounds having an integrated composition different from the recovered composition of at least one of the at least two recovered thermal fluids. The process also includes a step of testing the integrated thermal fluid to verify that it has an organic purity of more than 99.5% by weight. The process further includes a step of adding at least one unused or spent thermal fluid to the integrated thermal fluid to form a reconstituted thermal fluid. The process further includes a step of analyzing and purifying the reconstituted thermal fluid to form a regenerated thermal fluid. The regenerated thermal fluid has a predetermined regenerated thermal fluid composition different from the integrated thermal fluid composition of the integrated thermal fluid.

Description

Technical Field

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[0001] (Cross - Reference to Related Applications) This application claims priority to U.S. Patent Provisional Application No. 63 / 457,606, filed Apr. 6, 2023, the entire disclosure of which is incorporated herein by reference.

[0002] (Field of the Invention) This disclosure relates to systems and processes for thermal fluid regeneration. More specifically, this disclosure relates to systems and processes for converting used thermal fluid into a regenerated multi - compound thermal fluid.

Background Art

[0003] The regeneration of thermal fluids or refrigerants has long received significant attention due to increasing regulatory requirements and importance for recyclability, emissions reduction, and resource efficiency. Thermal fluids typically contain at least one halogenated compound that can potentially have an adverse impact on the environment. An efficient and effective regeneration process benefits both the environment and the global economy. Historically, the reuse of refrigerants has been essentially limited to single - compound fluids such as chlorodifluoromethane (CHClF2, HCFC - 22) or 1,1,1,2 - tetrafluoroethane (CF3 - CH2F, HFC - 134a), or an azeotropic fluid such as R - 507 (50 wt% pentafluoroethane (C2HF5, R - 125) and 50 wt% 1,1,1 - trifluoroethane (CF3CH3, R - 143a)).

[0004] The efficient and effective regeneration of multi - component (including azeotropic, near - azeotropic, and non - azeotropic) thermal fluids further benefits both the environment and the global economy.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

[0006] In exemplary embodiments, the thermal fluid regeneration process includes the step of combining at least two recovered thermal fluids, each containing at least two refrigerant compounds, to form an integrated thermal fluid. The integrated thermal fluid is a blend of at least two refrigerant compounds having an integrated composition different from the recovered composition of at least one of the at least two recovered thermal fluids. The process also includes the step of testing the integrated thermal fluid to verify that it has an organic purity greater than 99.5% by weight. The process further includes the step of adding at least one unused or spent thermal fluid to the integrated thermal fluid to form a reconstituted thermal fluid. The process further includes the step of analyzing and purifying the reconstituted thermal fluid to form a regenerated thermal fluid. The regenerated thermal fluid has a predetermined regenerated thermal fluid composition different from the integrated thermal fluid composition of the integrated thermal fluid.

[0007] Other features and advantages of this disclosure will become apparent from the following more detailed description, which is made in conjunction with the accompanying drawings illustrating the principles of the present invention as an example. [Brief explanation of the drawing]

[0008] [Figure 1] One embodiment of the present disclosure schematically illustrates a system for regenerating four different thermal fluid compositions from four different recovered thermal fluids. [Figure 2] A schematic diagram of a system for regenerating thermal fluid from three different recovered thermal fluids in one embodiment of the present disclosure is shown. [Figure 3] One embodiment of the present disclosure schematically illustrates a system for regenerating four different thermal fluid compositions from four different recovered thermal fluids. [Figure 4] One embodiment of the present disclosure schematically illustrates a system for regenerating five different thermal fluid compositions from five different recovered thermal fluids.

[0009] Wherever possible, the same reference number should be used throughout the drawing to represent the same part. [Modes for carrying out the invention]

[0010] In exemplary embodiments, integrated business and engineering processes effectively and efficiently recover multiple spent single-component thermal fluids and / or multi-component thermal fluid blends, and modify the recovered product flows to produce new product flows that reduce the need for both the production of unused thermal fluids and the destruction of out-of-specification (unrecoverable) post-spent thermal fluids.

[0011] As used herein, “refrigerant compound” means any hydrofluorocarbon (HFC), hydrochlorofluorocarbon (HCFC), chlorofluorocarbon (CFC), hydrochlorofluoroolefin (HCFO), hydrochloroolefin (HCO), chlorofluoroolefin (CFO), or hydrofluoroolefin (HFO) that can be used as a thermal fluid, either alone or in blends with other refrigerant compounds.

[0012] As used herein, “thermal fluid” refers to any fluid used for heat transfer in a closed-loop system.

[0013] As used herein, “unused thermal fluid” refers to a thermal fluid composition having an organic purity of at least 99.5% by weight, or at least 99.6% by weight, or at least 99.7% by weight, or at least 99.8% by weight, or at least 99.9% by weight, and which has not yet been used in a thermal fluid application.

[0014] As used herein, “used thermal fluid” refers to a thermal fluid composition that has already been used as a thermal fluid and has an organic purity of at least 95% by weight, or at least 96% by weight, or at least 97% by weight, or preferably at least 98% by weight, or at least 99% by weight, or preferably at least 99.5% by weight.

[0015] As used herein, "used hot fluid" refers to a hot fluid composition that has an organic purity of less than 99.5 wt%, or less than 99 wt%, or preferably less than 98 wt%, or less than 97 wt%, or less than 96 wt%, or preferably less than 95 wt% and has already been used as a hot fluid.

[0016] As used herein, "recovered hot fluid" refers to used hot fluid or spent hot fluid that has been discharged from or otherwise removed from a thermal management device, apparatus, or system, such as a refrigerator or air conditioner.

[0017] As used herein, "integrated hot fluid composition" refers to a blend formed by combining two or more different recovered hot fluids.

[0018] As used herein, "reconstituted hot fluid" refers to a hot fluid formed by adding one or more hot fluids, such as unused hot fluid, spent hot fluid, or regenerated hot fluid, to an integrated hot fluid to adjust the relative amount of the refrigerant component in the integrated hot fluid relative to a conventional hot fluid blend.

[0019] As used herein, "regenerated hot fluid" refers to a reconstituted hot fluid that has an organic purity of at least 99.5 wt%, or at least 99.6 wt%, or at least 99.7 wt%, or at least 99.8 wt%, or at least 99.9 wt% and meets the conventional specifications for commercial use or sale as a hot fluid.

[0020] As used herein, "organic purity" refers to the degree to which a fluid or fluid composition does not contain contaminants such as oil and inorganic materials, such as water, acids, non-absorbable gas (NAG), particulates / solids, etc.

[0021] In exemplary embodiments, a thermal fluid regeneration system and process combines at least two recovered thermal fluids, each containing at least two refrigerant compounds, to form an integrated thermal fluid. The integrated thermal fluid is a blend of at least two refrigerant compounds having an integrated composition different from the recovered composition of at least one of the at least two recovered thermal fluids. The system and process tests the integrated thermal fluid to verify that it has an organic purity greater than 99.5% by weight. The system and process adds at least one unused or spent thermal fluid to the integrated thermal fluid to form a reconstituted thermal fluid. The system and process further includes the step of analyzing and purifying the reconstituted thermal fluid to form a regenerated thermal fluid. The regenerated thermal fluid has a predetermined regenerated thermal fluid composition different from the integrated thermal fluid composition of the integrated thermal fluid.

[0022] Figure 1 shows a system for regenerating four different thermal fluid compositions from four different recovered thermal fluids. Four different types of recovered thermal fluid blends are held in recovery tanks 10, 12, 14, and 16 and can be supplied to an integration tank 18 as needed, where they can be combined and mixed to form an integrated thermal fluid. The recovered thermal fluid blends have the same refrigerant compound in different proportions. The recovered thermal blends may be individually tested and verified for organic purity, and / or the integrated thermal fluid may be tested and verified for organic purity. Testing may include determining the composition and amount of organic purity. Verification may include a step of removing one or more impurities and confirming that the thermal fluid has an organic purity of more than 99.5% by weight.

[0023] The tested and verified integrated heat fluid is then supplied, one by one for each desired regenerated heat fluid composition, to the four reconfiguration tanks 20, 22, 24, 26 as needed. The composition can be adjusted within each reconfiguration tank 20, 22, 24, 26 by supplying one or more heat fluids from one or more conditioning tanks 30, 32, 34, 36 to each reconfiguration tank 20, 22, 24, 26 to form four different reconfigured heat fluids. The heat fluids in the conditioning tanks 30, 32, 34, 36 can be unused heat fluid, used heat fluid, or regenerated heat fluid. Each conditioning tank 30, 32, 34, 36 may hold a single refrigerant compound or a blend of two or more refrigerant compounds.

[0024] The reconfigured heat fluids can each be individually subjected to final purification and analysis to confirm that they are of commercial grade and then supplied, as needed, to their respective regenerated heat fluid containers 40, 42, 44, 46 for use or commercial sale. The final purification and analysis can, as needed, include analyzing and purifying for water content, non-absorbable gas (NAG) content, other impurity content, and / or organic purity.

[0025] The system can operate on a continuous basis, a batch basis, or a semi-batch basis. In an exemplary embodiment, the various flows are selected to reduce or minimize the amount of heat fluid from the conditioning tanks 30, 32, 34, 36 in the regenerated heat fluid relative to the amount of integrated heat fluid.

[0026] Figure 2 shows a system for regenerating a thermal fluid from three different recovered thermal fluids. Three different types of recovered thermal fluids are held in recovery tanks 10, 12, and 14 and can be supplied to an integration tank 18 as needed, where they can be combined and mixed to form an integrated thermal fluid. The first recovered thermal fluid contains a single refrigerant compound. The second recovered thermal fluid is a blend of two refrigerant compounds, one of which is the same as the refrigerant compound in the first recovered thermal fluid. The third recovered thermal fluid is a blend of three refrigerant compounds, two of which are the same as the refrigerant compound in the second recovered thermal fluid. The recovered thermal fluids may be individually tested and verified for organic purity, and / or the integrated thermal fluid may be tested and verified for organic purity. Testing may include determining the composition and amount of organic purity. Verification may include the step of removing one or more impurities and confirming that the thermal fluid has an organic purity of more than 99.5% by weight.

[0027] The tested and validated integrated thermal fluid is then supplied to the reconstitution tank 20 as needed. The composition can be adjusted within the reconstitution tank 20 by supplying one or more thermal fluids from one or more adjustment tanks 30, 32, 34 to the reconstitution tank 20 to form the reconstituted thermal fluid. The reconstituted thermal fluid may be of the same type as the third recovered thermal fluid or of a different type. The thermal fluids in the adjustment tanks 30, 32, 34 may be unused thermal fluid, spent thermal fluid, or regenerated thermal fluid. Each adjustment tank 30, 32, 34 may hold a single refrigerant compound or a blend of two or more refrigerant compounds.

[0028] The reconstituted thermal fluids may be subjected to final purification and analysis to confirm that they are of commercial grade, and then supplied to the reconstituted thermal fluid container 40 for use or commercial sale, as required. Final purification and analysis may include analysis and purification for water content, non-absorbent gas (NAG) content, other impurity content, and / or organic purity, as required.

[0029] The system can operate on a continuous, batch, or semi-batch basis. In an exemplary embodiment, various flows are selected to reduce or minimize the amount of thermal fluid from the conditioning tanks 30, 32, and 34 in the regenerated thermal fluid relative to the amount of integrated thermal fluid.

[0030] Figure 3 shows a system for regenerating four different thermal fluid compositions from four different recovered thermal fluids. Four different types of recovered thermal fluids are held in recovery tanks 10, 12, 14, and 16 and, if necessary, can be supplied to an integration tank 18 where they can be combined and mixed to form an integrated thermal fluid. The first recovered thermal fluid contains a single refrigerant compound. The second recovered thermal fluid is a blend of two refrigerant compounds, one of which is the same as the refrigerant compound in the first recovered thermal fluid. The third recovered thermal fluid is a blend of three refrigerant compounds, two of which are the same as the refrigerant compound in the second recovered thermal fluid. The fourth recovered thermal fluid is a blend of four refrigerant compounds, three of which are the same as the refrigerant compound in the third recovered thermal fluid. The recovered thermal fluids may be individually tested and verified for organic purity, and / or the integrated thermal fluid may be tested and verified for organic purity. The testing may include determining the composition and the amount of organic purity. The verification may include a step of removing one or more impurities and confirming that the thermal fluid has an organic purity of more than 99.5% by weight.

[0031] The tested and validated integrated thermal fluid is then supplied to the reconstitution tank 20 as needed. The composition can be adjusted within the reconstitution tank 20 by supplying one or more thermal fluids from one or more adjustment tanks 30, 32, 34, 36 to the reconstitution tank 20 to form the reconstituted thermal fluid. The thermal fluids in the adjustment tanks 30, 32, 34, 36 may be unused thermal fluids, spent thermal fluids, or regenerated thermal fluids. Each adjustment tank 30, 32, 34, 36 may hold a single refrigerant compound or a blend of two or more refrigerant compounds.

[0032] The reconstituted thermal fluids may be subjected to final purification and analysis to confirm that they are of commercial grade, and then supplied to the reconstituted thermal fluid container 40 for use or commercial sale, as required. Final purification and analysis may include analysis and purification for water content, non-absorbent gas (NAG) content, other impurity content, and / or organic purity, as required.

[0033] The first, second, and third recovered thermal fluids can be individually tested and verified for organic purity, subjected to final purification and analysis to confirm that they are of commercial grade, and then supplied to their respective regenerated thermal fluid containers 42, 44, and 46 for use or commercial sale as needed, thereby directly regenerating them into their respective regenerated thermal fluids.

[0034] The system can operate on a continuous, batch, or semi-batch basis. In an exemplary embodiment, various flows are selected to reduce or minimize the amount of thermal fluid from the regulating tanks 30, 32, 34, and 36 in the regenerated thermal fluid relative to the amount of integrated thermal fluid.

[0035] Figure 4 shows a system for regenerating five different thermal fluid compositions from five different recovered thermal fluids. Five different types of recovered thermal fluids are held in recovery tanks 10, 12, 14, 50, and 16, and can be supplied to an integration tank 18 as needed, where they can be combined and mixed to form an integrated thermal fluid. The first recovered thermal fluid contains a single refrigerant compound. The second recovered thermal fluid is a blend of two refrigerant compounds, one of which is the same as the refrigerant compound in the first recovered thermal fluid. The third recovered thermal fluid is a blend of three refrigerant compounds, two of which are the same as the refrigerant compound in the second recovered thermal fluid. The fourth recovered thermal fluid is a blend of four refrigerant compounds, three of which are the same as the refrigerant compound in the third recovered thermal fluid. The fifth recovered thermal fluid is a blend of five refrigerant compounds, four of which are the same as the refrigerant compound in the fourth recovered thermal fluid. The recovered thermal fluids may be individually tested and verified for organic purity, and / or the integrated thermal fluid may be tested and verified for organic purity. The test may include determining the composition and the amount of organic purity. Verification may include removing one or more impurities and confirming that the thermal fluid has an organic purity of more than 99.5% by weight.

[0036] The tested and validated integrated thermal fluid is then supplied to the reconstitution tank 20 as needed. The composition can be adjusted within the reconstitution tank 20 by supplying one or more thermal fluids from one or more adjustment tanks 30, 32, 34, 36, 38 to the reconstitution tank 20 to form the reconstituted thermal fluid. The thermal fluids in the adjustment tanks 30, 32, 34, 36, 38 may be unused thermal fluids, used thermal fluids, or regenerated thermal fluids. Each adjustment tank 30, 32, 34, 36, 38 may hold a single refrigerant compound or a blend of two or more refrigerant compounds.

[0037] The reconstituted thermal fluids may be subjected to final purification and analysis to confirm that they are of commercial grade, and then supplied to the reconstituted thermal fluid container 40 for use or commercial sale, as required. Final purification and analysis may include analysis and purification for water content, non-absorbent gas (NAG) content, other impurity content, and / or organic purity, as required.

[0038] The first, second, third, and fourth recovered thermal fluids can be individually tested and verified for organic purity, subjected to final purification and analysis to confirm that they are of commercial grade, and then supplied to their respective regenerated thermal fluid containers 42, 44, 46, and 48 for use or commercial sale as needed, thereby directly regenerating them into their respective regenerated thermal fluids.

[0039] The system can operate on a continuous, batch, or semi-batch basis. In an exemplary embodiment, various flows are selected to reduce or minimize the amount of thermal fluid from the conditioning tanks 30, 32, 34, 36, and 38 in the regenerated thermal fluid relative to the amount of integrated thermal fluid.

[0040] Although the embodiments described above have been explained in relation to a specific number of thermal fluids and tanks, it will be understood by those skilled in the art that the processes of these embodiments are not so limited and are equally applicable to fewer or more numbers of thermal fluids and tanks.

[0041] Other systems may be designed and constructed to include other numbers and combinations of different recovered thermal fluids and to generate other numbers of different regenerated thermal fluids. The types of regenerated thermal fluids may be the same as or different from the types of recovered fluids.

[0042] In some embodiments, an integration tank receives at least a portion of each type of recovered heat fluid to contain some or all of the refrigerant compounds present in the system. Some systems may have two or more integration tanks, each additional integration tank receiving two or more but not all types of recovered heat fluid and containing two or more but not all of the refrigerant compounds present in the system. In an exemplary embodiment, each integration tank contains at least two refrigerant compounds. The types of recovered heat fluids fed into the integration tanks may be selected based on the refrigerant compounds they contain and the refrigerant compounds in the regenerated heat fluid formed from the integration heat fluids.

[0043] In exemplary embodiments, if the regenerated thermal fluid contains at least one HFO refrigerant compound, the regeneration process includes adding a stabilizer package to the reconstituted thermal fluid. In exemplary embodiments, the stabilizer package contains an effective amount of at least one inhibitor, and as a result, the thermal fluid remains substantially free of oligomeric products, homopolymer products, or other polymer products derived from the thermal fluid. In some embodiments, the at least one inhibitor is selected from hydrocarbons containing at least one cyclic monoterpene, lipophilic organic compounds containing tocopherols such as α-tocopherol, or aromatic organic compounds having at least one chemical moiety -C6H4(OH), including phenol and benzene-1,4-diol. Specific examples of inhibitor compounds include at least one component selected from the group consisting of limonene, α-terpinene, α-tocopherol, butylated hydroxytoluene (BHT), 4-methoxyphenol, and benzene-1,4-diol. In one embodiment, the inhibitor composition includes a liquid at temperatures of about -80°C to about 180°C, about -70°C to about 170°C, and optionally about -60°C to about 160°C. "Stabilized" is intended to mean that the composition contains an effective amount of at least one inhibitor compound that inhibits, if not eliminates, the interaction of fluoroethylene with another compound to form dimers, oligomers, homopolymers, or polymer products.

[0044] In some embodiments, the analyzer determines the composition and purity of one or more of the thermal fluids of the system and process. In some embodiments, the analyzer determines the type and purity of the recovered thermal fluid during recovery from the thermal control unit. Alternatively, the analyzer may determine the type and purity of the integrated thermal fluid, reconstituted thermal fluid, and / or regenerated thermal fluid. If the analyzed thermal fluid is determined by the analyzer to be organically pure (>99.5 wt%) and of a single type, the thermal fluid may be transferred to a suitable recovery tank. However, if the analyzer finds impurities such as oil, water, fouling, and / or acid in the analyzed thermal fluid (or its organic purity is less than 99.5 wt%), the analyzed thermal fluid may be sent to a regenerator for reprocessing.

[0045] In some embodiments, the regenerator purifies the recovered thermal fluid, integrated thermal fluid, reconstituted thermal fluid, and / or regenerated thermal fluid to meet the purity specifications of AHRI Standard 700. The regenerator may include at least a compressor, separator, and filter dryer, and may further include a distiller, diluent, or reformer. In some embodiments, the compressor is driven to circulate the thermal fluid in a refrigerant circuit and apply a voltage to reduce or remove oil, such as refrigerant oil, from the thermal fluid. In some embodiments, the separator may be a type of oil separator. In some embodiments, the filter dryer reduces or removes water and acids contained in the thermal fluid. The regenerator may also determine the suitability of the oil, water, and acids contained in the regenerated thermal fluid and compile information such as the thermal fluid composition and weight.

[0046] In some embodiments, the purification process purifies the recovered thermal fluid, integrated thermal fluid, reconstituted thermal fluid, and / or regenerated thermal fluid to meet the purity specifications of AHRI Standard 700. The purification process includes at least one of the following steps: decanting of total water content by decanter, distillation by distillation column, adsorption by adsorption bed, drying by adsorption bed or column, NAG adjustment by non-condensable purging unit, and neutralization by neutralizer.

[0047] In exemplary embodiments, the regenerative thermal fluid is selected from and conforms to the Standard for Specifications for Refrigerants (AHRI 700) of the American Refrigeration and Air Conditioning Industry Association, which is incorporated herein by reference in its entirety. AHRI 700 specifies appropriate contaminant levels (purity requirements) for fluorocarbon refrigerants, hydrocarbon refrigerants, and carbon dioxide refrigerants, regardless of their source, and lists acceptable test methods. These refrigerants are as referenced in ANSI / ASHRAE Standard 34 and its appendices, which are incorporated herein by reference in their entirety.

[0048] Suitable fluorocarbon refrigerant compounds for the systems and methods of this disclosure include R-11, R-12, R-13, R-22, R-23, R-32, CF3I, R-113, R-114, R-115, R-116, R-123, R-124, R-125, R-134a, R-141b, R-142b, R-143a, R-152a, R-218, R-227ea, and R-236f. Examples include, but are not limited to, R-245fa, R-1233zd(E), R-1233zd(Z), R-1234yf, R-1234ze(E), R-1234ze(Z), R-1224yd(E), R-1224yd(Z), R-1132(E), R-1132(Z), R-1132a, R-1336mzz(E), and R-1336mzz(Z).

[0049] Suitable hydrocarbon refrigerant compounds for the systems and methods of this disclosure include, but are not limited to, R-50, R-170, R-E170, R-290, R-600, R-600a, R-601, R-601a, R-610, R-1150, and R-1270.

[0050] Suitable carbon dioxide refrigerant compounds for the systems and methods of this disclosure may include, but are not limited to, R-744.

[0051] Suitable non-azeotropic blended thermal fluids for the systems and methods of this disclosure include R-401A, R-401B, R-402A, R-402B, R-403A, R-403B, R-404A, R-405A, R-406A, R-407A, R-407B, R-407C, R-407D, R-407E, R-407F, R-407G, R407H, R-408A, R-409A, R-409B, R-410A, R-410B, R-411A, R-411B, and R-412 A, R-413A, R-414A, R-414B, R-415A, R-415B, R-416A, R-417A, R-417B, R-417C, R-418A, R-419A, R-419B, R-420A, R-421A, R- 421B, R-422A, R-422B, R-422C, R-422D, R-422E, R-423A, R-424A, R-425A, R-426A, R-427A, R-428A, R-429A, R-430A, R-431A, R-434A, R-435A, R-437A, R-438A, R-439A, R-440A, R-442A, R-444A, R-444B, R-445A, R-446A, R-447A, R-447B, R-448A, R-44 9A, R-449B, R-449C, R-450A, R-451A, R-451B, R-452A, R-452B, R-452C, R-453A, R-454A, R-454B, R-454C, R-455A, R-456A, R- Possible examples include 457A, R-457B, R-457C, R-458A, R-459A, R-459B, R-460A, R-460B, R-461A, R-462A, R-463A, R-464A, R-465A, R-466A, R-467A, R-468A, R-468B, R-468A, R-469A, R-470A, R-470B, 471A, 472A, 472B, 473A, 474A, 475A, 476A, and 479A, but these are all linear.

[0052] Suitable non-azeotropic hydrocarbon blend thermal fluids for the systems and methods of this disclosure include, but are not limited to, R-432A, R-433A, R-433B, R-433C, R-436A, R-436B, R-441A, and R-443A.

[0053] Suitable azeotropic blend thermal fluids for the systems and methods of this disclosure include, but are not limited to, R-500, R-502, R-503, R-507A, R-508A, R-508B, R-509A, R-510A, R-511A, R-512A, R-513A, R-513B, R-514A, R-515A, R-515B, and R-516A. [Examples]

[0054] The present invention will be described in more detail by specific examples. The following examples are provided for illustrative purposes only and are not intended to limit the invention in any way. Those skilled in the art will readily recognize various non-essential parameters that can be changed or modified to obtain essentially the same results.

[0055] (Example 1) Two or more different used or post-use thermal fluids from Table 1 are collected, tested, verified, and then combined to form an integrated thermal fluid composition. The integrated thermal fluid composition contains difluoromethane (CH2F2, R-32), pentafluoroethane (C2HF5, R-125), and / or 1,1,1,2-tetrafluoroethane (CF3CH2F, R-134a). If the impurity level exceeds 0.5%, the composition can be purified to reduce the impurity level to less than 0.5%.

[0056] Next, by adding one or more unused or used thermal fluids, the composition of all or any part of the integrated thermal fluid composition is adjusted to a composition for forming a reconstituted thermal fluid from among the R-407 series thermal fluids listed in Table 1.

[0057] [Table 1]

[0058] Next, the reconstituted thermal fluid can be further analyzed and purified to form a regenerated thermal fluid.

[0059] (Example 2) Two or more different used or post-use thermal fluids from Table 2 are collected, tested, verified, and then combined to form an integrated thermal fluid composition. The integrated thermal fluid composition contains R-125, 1,1,1-trifluoroethane (CF3CH3, R-143a), and / or R-134a. If the impurity level exceeds 0.5%, the composition can be purified to reduce the impurity level to less than 0.5%.

[0060] Next, the composition of all or any part of the integrated thermal fluid composition is adjusted by adding one or more unused or used thermal fluids to a composition for forming a reconstituted thermal fluid of R-507 or R-404A.

[0061] [Table 2]

[0062] Next, the reconstituted thermal fluid can be further analyzed and purified to form a regenerated thermal fluid.

[0063] (Example 3) Collect, test, and verify two or more different used or post-use thermal fluids from Table 3. Combine all or part of the used or post-use thermal fluids to form an integrated thermal fluid composition. The integrated thermal fluid composition contains R-32, R-125, R-134a, and / or 2,3,3,3-tetrafluoropropene (CF3CF=CH2, R-1234yf). If the impurity level exceeds 0.5% by weight, the composition can be purified to reduce the impurity level to less than 0.5% by weight.

[0064] Next, by adding one or more unused or used thermal fluids, the composition of all or any part of the integrated thermal fluid composition is adjusted to a composition for forming a reconstituted thermal fluid of the R-410A, R-407 series, or R-449 thermal fluids.

[0065] [Table 3]

[0066] Next, the reconstituted thermal fluid can be further analyzed and purified to form a regenerated thermal fluid.

[0067] Any or any portion of the recovered fluids may be further analyzed and purified to form a regenerated thermal fluid from their original thermal fluid compositions, rather than being combined to form an integrated thermal fluid composition.

[0068] For blends containing HFO, a stabilizer package may be added to the reconstituted or regenerated thermal fluid to stabilize the HFO in the thermal fluid.

[0069] (Example 4) Collect, test, and verify two or more different used or post-use thermal fluids from Table 4. Combine all or part of the used or post-use thermal fluids to form an integrated thermal fluid composition. The integrated thermal fluid composition contains R-32, R-125, R-134a, R-1234yf, and / or 1,3,3,3-tetrafluoropropene (CF3CH=CHF, R-1234ze(E)). If the impurity level exceeds 0.5%, the composition can be purified to reduce the impurity level to less than 0.5%.

[0070] Next, the composition of all or any part of the integrated thermal fluid composition is adjusted by adding one or more unused or used thermal fluids to a composition for forming a reconstituted thermal fluid of R-410A, R-407 series, R-449, or R-448.

[0071] [Table 4]

[0072] Next, the reconstituted thermal fluid can be further analyzed and purified to form a regenerated thermal fluid.

[0073] Any or any portion of the recovered fluids may be further analyzed and purified to form a regenerated thermal fluid from their original thermal fluid compositions, rather than being combined to form an integrated thermal fluid composition.

[0074] For blends containing one or more HFOs, a stabilizer package may be added to the reconstituted or regenerated thermal fluid to stabilize the HFOs in the thermal fluid.

[0075] (Example 5) Two or more different used or post-use thermal fluids from Table 5 are collected, tested, verified, and then combined to form an integrated thermal fluid composition. The integrated thermal fluid composition contains 1,3,3,3-tetrafluoropropene (CF3CH=CHF, R-1234ze(E)) and 1,1,1,2,3,3,3-heptafluoropropane (227ea). If the impurity level exceeds 0.5%, the composition can be purified to reduce the impurity level to less than 0.5%.

[0076] Next, by adding one or more unused or used thermal fluids, the composition of all or any part of the integrated thermal fluid composition is adjusted to a composition for forming one of the R-515 series thermal fluids listed in Table 5.

[0077] [Table 5]

[0078] Next, the reconstituted thermal fluid can be further analyzed and purified to form a regenerated thermal fluid.

[0079] Other Embodiments Embodiment 1: A thermal fluid regeneration process comprising: a step of combining at least two recovered thermal fluids containing at least two refrigerant compounds to form an integrated thermal fluid, wherein the integrated thermal fluid is a blend of at least two refrigerant compounds having an integrated composition different from the recovered composition of at least one of the at least two recovered thermal fluids; a step of testing the integrated thermal fluid and verifying that the integrated thermal fluid has an organic purity of more than 99.5% by weight; a step of adding at least one unused or used thermal fluid to the integrated thermal fluid to form a reconstituted thermal fluid; and a step of analyzing and purifying the reconstituted thermal fluid to form a regenerated thermal fluid, wherein the regenerated thermal fluid has a predetermined regenerated thermal fluid composition different from the integrated thermal fluid composition of the integrated thermal fluid.

[0080] Embodiment 2: The process according to Embodiment 1, further comprising the step of recovering at least one used thermal fluid as at least one of at least two recovered thermal fluids.

[0081] Embodiment 3: The process according to Embodiment 1 or 2, wherein at least one of the at least two recovered thermal fluids is a single-component thermal fluid.

[0082] Embodiment 4: The process according to any one of Embodiments 1 to 3, wherein at least one of the at least two recovered thermal fluids is a multi-component thermal fluid blend.

[0083] Embodiment 5: The process according to any one of Embodiments 1 to 4, wherein the step to be verified includes removing one or more impurities from the integrated thermal fluid so that the integrated thermal fluid has an organic purity of more than 99.5% by weight.

[0084] Embodiment 6: The process according to Embodiment 5, wherein one or more impurities include oil.

[0085] Embodiment 7: The process according to any one of Embodiments 1 to 6, wherein at least two refrigerant compounds are three refrigerant compounds.

[0086] Embodiment 8: The process according to Embodiment 7, wherein the three refrigerant compounds are difluoromethane, pentafluoroethane, and 1,1,1,2-tetrafluoroethane.

[0087] Embodiment 9: The process according to Embodiment 7 or 8, wherein the regenerative thermal fluid is selected from the group consisting of R-407A, R-407B, R-407C, R-407D, R-407E, R-407F, and R-407H.

[0088] Embodiment 10: The process according to Embodiment 7, wherein the three refrigerant compounds are 1,1,1-trifluoroethane, pentafluoroethane, and 1,1,1,2-tetrafluoroethane.

[0089] Embodiment 11: The process according to Embodiment 7 or 10, wherein the regenerative thermal fluid is R-404A.

[0090] Embodiment 12: The process according to any one of Embodiments 1 to 6, wherein at least two refrigerant compounds are four refrigerant compounds.

[0091] Embodiment 13: The process according to Embodiment 12, wherein the four refrigerant compounds are difluoromethane, pentafluoroethane, 1,1,1,2-tetrafluoroethane, and 2,3,3,3-tetrafluoropropene.

[0092] Embodiment 14: The process according to Embodiment 12 or 13, wherein the regenerative thermal fluid is R-449A.

[0093] Embodiment 15: The process according to any one of Embodiments 1 to 6, wherein at least two refrigerant compounds are five refrigerant compounds.

[0094] Embodiment 16: The process according to Embodiment 15, wherein the five refrigerant compounds are difluoromethane, pentafluoroethane, 1,1,1,2-tetrafluoroethane, 2,3,3,3-tetrafluoropropene, and 1,3,3,3-tetrafluoropropene.

[0095] Embodiment 17: The process according to Embodiment 15 or 16, wherein the regenerative thermal fluid is R-448A.

[0096] Embodiment 18: The process according to Embodiment 1, further comprising the step of adding a stabilizer package to a reconstituted thermal fluid or a regenerated thermal fluid.

[0097] Embodiment 19: A regenerative thermal fluid formed by the process described in any one of Embodiments 1 to 18.

[0098] Embodiment 20: The process according to Embodiment 7, wherein the three refrigerant compounds are difluoromethane, 1,1-difluoroethane, and trans-1,3,3,3-tetrafluoropropene.

[0099] Embodiment 21: The process according to Embodiment 7 or 20, wherein the regenerative thermal fluid is R-444A.

[0100] This specification includes details of many specific implementations, but these should not be interpreted as limitations on the scope of any invention or claim, but rather as descriptions of features specific to a particular implementation of a particular invention. Specific features described herein in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation may also be implemented separately or in any suitable subcombination in multiple implementations. Furthermore, features are described above as acting in a particular combination, and may even be initially claimed as such; however, one or more features from a claimed combination may, in some cases, be removed from the combination, and the claimed combination may cover a subcombination or a variation of a subcombination.

[0101] Similarly, although the operations are shown in a specific order in the drawings, this should not be understood as requiring that such operations be performed in a specific or sequential order, or that all shown operations be performed, in order to achieve the desired result. In certain circumstances, parallel work and parallel processing may be advantageous. Furthermore, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

[0102] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as those generally understood by those skilled in the art to the extent of the exemplary embodiments. Terms as defined in commonly used dictionaries should be interpreted as having the meaning consistent with their meaning in the context of the relevant art, and it will be further understood that they should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0103] While this disclosure has been described with reference to preferred embodiments, those skilled in the art will understand that various modifications can be made without departing from the scope of the invention, and that equivalents can be used in place of certain elements. In addition, many modifications can be made without departing from the essential scope of this disclosure to adapt the teachings of the invention to specific situations or materials. Various aspects and embodiments are disclosed herein, but other aspects and embodiments will be obvious to those skilled in the art. The various aspects and embodiments disclosed herein are for illustrative purposes only and are not intended to limit, and the true scope and spirit are indicated by the following claims.

Claims

1. It is a thermal fluid regeneration process, A step of forming an integrated thermal fluid by combining at least two recovered thermal fluids containing at least two refrigerant compounds, wherein the integrated thermal fluid is a blend of the at least two refrigerant compounds having an integrated composition different from the recovered composition of at least one of the at least two recovered thermal fluids, A step of testing the integrated thermal fluid and verifying that the integrated thermal fluid has an organic purity of more than 95% by weight, preferably more than 98% by weight, A step of adding at least one unused or used thermal fluid to the integrated thermal fluid to form a reconstituted thermal fluid, A step of analyzing and purifying the reconstituted thermal fluid to form a regenerated thermal fluid, wherein the regenerated thermal fluid has a predetermined regenerated thermal fluid composition that is different from the integrated thermal fluid composition of the integrated thermal fluid. A process that includes this.

2. The process according to claim 1, further comprising the step of recovering at least one used thermal fluid as at least one of the at least two recovered thermal fluids.

3. The process according to claim 1 or 2, wherein at least one of the at least two recovered thermal fluids is a single-component thermal fluid.

4. The process according to any one of claims 1 to 3, wherein at least one of the at least two recovered thermal fluids is a multi-component thermal fluid blend such as R-444A.

5. The process according to any one of claims 1 to 4, wherein the verification step includes removing one or more impurities from the integrated thermal fluid so that the integrated thermal fluid has an organic purity of more than 95% by weight, preferably more than 98% by weight.

6. The process according to claim 5, wherein the one or more impurities include oil.

7. The process according to any one of claims 1 to 6, wherein the at least two refrigerant compounds are three refrigerant compounds.

8. The process according to claim 7, wherein the three refrigerant compounds are difluoromethane, pentafluoroethane, and 1,1,1,2-tetrafluoroethane.

9. The process according to claim 7 or 8, wherein the regenerative thermal fluid is selected from the group consisting of R-407A, R-407B, R-407C, R-407D, R-407E, R-407F, and R-407H.

10. The process according to claim 7, wherein the three refrigerant compounds are 1,1,1-trifluoroethane, pentafluoroethane, and 1,1,1,2-tetrafluoroethane.

11. The process according to claim 7 or 10, wherein the regenerating thermal fluid is R-404A.

12. The process according to any one of claims 1 to 6, wherein the at least two refrigerant compounds are four refrigerant compounds.

13. The process according to claim 12, wherein the four refrigerant compounds are difluoromethane, pentafluoroethane, 1,1,1,2-tetrafluoroethane, and 2,3,3,3-tetrafluoropropene.

14. The process according to claim 12 or 13, wherein the regenerating thermal fluid is R-449A.

15. The process according to any one of claims 1 to 6, wherein the at least two refrigerant compounds are five refrigerant compounds.

16. The process according to claim 15, wherein the five refrigerant compounds are difluoromethane, pentafluoroethane, 1,1,1,2-tetrafluoroethane, 2,3,3,3-tetrafluoropropene, and 1,3,3,3-tetrafluoropropene (E).

17. The process according to claim 15 or 16, wherein the regenerating thermal fluid is R-448A.

18. The process according to claim 1, further comprising the step of adding a stabilizer package to the reconstituted thermal fluid or the regenerated thermal fluid.

19. A regenerative thermal fluid formed by the process described in any one of claims 1 to 18.

20. The process according to claim 7, wherein the three refrigerant compounds are difluoromethane, 1,1-difluoroethane, and trans-1,3,3,3-tetrafluoropropene.

21. The process according to claim 7 or 20, wherein the regenerating thermal fluid is R-444A.

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