Dual Compressor Chiller Pressure Equalization for Series-Flow Efficiency
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Solution Overview
Problem
Traditional single chiller systems are less efficient compared to series flow chillers, which require additional components and space, making them costly and impractical for many facilities, thus necessitating a method to achieve series flow efficiency with a single chiller.
Innovation Solution
A refrigeration system with a divided evaporator and condenser, utilizing pressure equalization valves and configurations like two-pass flow, allows each chamber to operate at different pressures, mimicking the efficiency benefits of series flow chillers without the need for multiple units, and includes features like baffles and subcoolers to manage pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If series flow chiller configuration is used, then system efficiency is improved, but device complexity and cost increase due to additional evaporators, condensers and conduits
Solution Approach 1:
The patent divides a single chiller into two separate chambers (first chamber and second chamber), each with its own evaporator and condenser sections. This segmentation allows the single chiller to operate with two different refrigerant circuits that can function in series flow configuration, thereby achieving improved system efficiency without requiring multiple complete chiller units. The division creates distinct high-pressure and low-pressure zones within the same device.
Solution Approach 2:
The patent combines multiple functional elements into a single integrated chiller unit. Specifically, it merges two evaporators, two condensers, and two refrigerant circuits into one chiller housing with shared components such as the compressor and control systems. This merging achieves the efficiency benefits of series flow configuration while reducing device complexity and cost compared to using separate chiller units.
2Loss of energy
If series flow chiller configuration is used, then system efficiency is improved, but space requirements increase making it impractical for facilities with limited space
Solution Approach 1:
By segmenting the chiller into two chambers within a single unit, the patent achieves series flow efficiency without the space requirements of multiple separate chillers. The compact integration of high-pressure and low-pressure zones in one housing reduces the footprint while maintaining the functional benefits of staged refrigeration.
Solution Approach 2:
The patent employs a nested arrangement where the second refrigerant circuit is integrated within the same chiller housing as the first circuit. The chambers are arranged concentrically or adjacently within the single unit, allowing one system to be nested within or alongside another, thereby achieving series flow configuration in a compact space that would not accommodate two complete chiller units.
3Loss of energy
If pressure differences between chambers are increased, then compressor head is reduced improving efficiency, but structural integrity may be compromised
Solution Approach 1:
The patent optimizes the pressure differential parameter to achieve the optimal balance between efficiency and structural integrity. By carefully controlling the pressure difference between the high-pressure and low-pressure chambers, the system maximizes compressor head reduction for improved efficiency while maintaining pressure levels that do not compromise the structural strength of the chiller housing and internal components.
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 configuration reduces compressor capacity and enhances system efficiency by maintaining pressure differentials within structural limits, allowing for reduced power consumption and operational flexibility while maintaining the efficiency of series flow systems.
Implementation Method 1
a pressure equalization valve in fluid communication with both the high-pressure side and the low-pressure side of the chiller system to equalize the pressure between the high-pressure side and the low-pressure side
Implementation Method 2
the process fluid is cooled by an evaporator which absorbs heat from the process fluid through evaporating refrigerant
Implementation Method 3
an evaporator which absorbs heat from the process fluid through evaporating refrigerant
Implementation Method 4
The refrigerant may then be compressed in a compressor and transferred to a condenser
Implementation Method 5
In a liquid cooled condenser, the refrigerant is generally cooled by a second process fluid, causing the refrigerant to condense into a liquid
Implementation Method 6
the refrigerant is generally cooled by a second process fluid, causing the refrigerant to condense into a liquid
Implementation Method 7
The liquid refrigerant may then be transferred back to the evaporator, to begin another refrigeration cycle
Data Source
Figure 1
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Figure 5~10
AI summary
Systems for limiting pressure differences in dual compressor chillers are provided. To achieve the efficiency benefits of series flow chillers within a single unit, an evaporator (22) and/or a condenser (24) may be partitioned into separate chambers by a baffle (36, 38). Process fluid may then flow through one chamber of the evaporator and/or condenser prior to entering the other. This configuration creates a pressure differential between chambers which may reduce compressor head and result in greater chiller efficiency. However, to maintain the structural integrity of the evaporator and/or condenser baffle, a system for limiting this pressure differential may be employed. This system may include an evaporator pressure equalization valve (40), a common liquid line (32), or an equalizing line (46) between separate liquid lines. Methods of operating dual compressor chillers using these systems are also provided.