Chiller system
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Solution Overview
Problem
Chiller systems face inefficiencies due to low pressure differential between the refrigerant pressure in the cooling line and suction pressure, leading to reduced cooling efficiency and the need for additional pumps, which increase costs and reduce energy efficiency.
Innovation Solution
A chiller system design incorporating an auxiliary cooling branch with an auxiliary condenser that bypasses the main condenser, expansion valve, and evaporator, co-located with the main condenser for heat exchange, to provide additional cooling to components without requiring additional pumps, by maintaining a higher pressure differential and efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If subcooled refrigerant is directed along a cooling line to the compressor, then cooling of compressor components is improved, but the pressure differential between cooling line refrigerant and suction pressure becomes insufficient, reducing cooling efficiency
Solution Approach 1:
The refrigeration system is divided into two separate loops: a main refrigeration loop and an auxiliary cooling loop. The auxiliary cooling branch includes its own condenser (auxiliary condenser) that receives refrigerant directly from the compressor discharge, bypassing the main condenser. This segmentation allows the auxiliary loop to maintain high pressure differential for effective cooling while the main loop handles the refrigeration cycle independently.
Solution Approach 2:
The auxiliary condenser acts as an intermediary device that receives high-pressure refrigerant from the compressor and condenses it before directing it to the cooling line. This intermediary allows the cooling line to receive refrigerant at a pressure closer to compressor discharge pressure, maintaining sufficient pressure differential for effective cooling without requiring additional pumps.
2Productivity
If an additional pump is provided to increase pumping head in the cooling line, then refrigerant flow and cooling efficiency are improved, but system cost and energy consumption increase
Solution Approach 1:
The auxiliary cooling branch is designed to be self-sufficient by including its own condenser that directly receives refrigerant from the compressor discharge. This self-service design allows the auxiliary cooling loop to maintain adequate refrigerant flow and pressure differential without requiring an additional pump, thereby avoiding increased energy consumption and system costs while still achieving effective cooling.
3Device complexity
If the main condenser is used for all refrigerant condensation, then system simplicity is maintained, but insufficient cooling capacity is available for compressor components
Solution Approach 1:
The condensation function is segmented between the main condenser and the auxiliary condenser. The main condenser handles the primary refrigeration cycle, while the auxiliary condenser is dedicated to providing cooling capacity for compressor components. This segmentation increases cooling capacity without significantly increasing overall system complexity, as the auxiliary condenser integrates into the existing refrigeration circuit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances cooling efficiency by maintaining a sufficient pressure differential and reducing energy consumption, while allowing for effective cooling of components without additional pumping forces, thus improving overall system performance and energy efficiency.
Implementation Method 1
the main condenser and auxiliary condenser are co-located for heat exchange with a common flow of an external heat exchange medium
Implementation Method 2
Refrigerant vapour is compressed by the compressor and condensed into liquid refrigerant in the condenser
Implementation Method 3
heat is transferred from the process fluid to the refrigerant, chilling the process fluid and vaporising the two-phase refrigerant
Implementation Method 4
vaporising the two-phase refrigerant
Implementation Method 5
Refrigerant vapour is compressed by the compressor
Implementation Method 6
The expansion valve expands the liquid refrigerant to increase its volume and reduce its pressure
Data Source
AI summary
The present disclosure relates to a chiller system comprising: a refrigeration circuit comprising, in flow order, a compressor, a main condenser, an expansion valve and an evaporator; an auxiliary cooling branch configured to receive an auxiliary refrigerant flow from the refrigerant circuit downstream of the compressor, the auxiliary cooling branch bypassing the main condenser, expansion valve and evaporator, the auxiliary branch comprising an auxiliary condenser configured to discharge refrigerant to a cooling line for cooling one or more components of the chiller system; wherein the cooling line is configured to return the portion of refrigerant flow to the refrigeration circuit at or upstream of the compressor; wherein the main condenser and auxiliary condenser are co-located for heat exchange with a common flow of an external heat exchange medium.