Evaporator Separator Distributor Reducing Refrigerant Charge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Falling film evaporators in HVAC&R systems face challenges with significant refrigerant charge holdup due to separation volumes and liquid-filled distribution manifolds, leading to increased costs and greenhouse gas emissions.
Innovation Solution
A separator and distributor assembly with refrigerant gutters and sparge channels that extend along the length of the evaporator housing, allowing for efficient separation and distribution of liquid refrigerant, reducing refrigerant charge by up to 15% and maintaining effective evaporator performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separation volumes and liquid-filled distribution manifolds are used to meter liquid refrigerant, then reliable metering is achieved, but refrigerant charge holdup increases significantly
Solution Approach 1:
The distribution manifold is segmented into multiple sparge channels with sparge openings distributed along the length of the evaporator. This segmentation allows liquid refrigerant to be introduced at multiple locations rather than requiring a large centralized liquid-filled manifold, reducing overall refrigerant charge holdup while maintaining reliable metering through the distributed sparge openings.
Solution Approach 2:
The invention transitions from a traditional three-dimensional liquid-filled manifold volume to a more distributed, elongated sparge channel structure that extends along the length of the evaporator. This dimensional redistribution reduces the vertical height requirement and concentrates liquid refrigerant delivery along the longitudinal axis, reducing charge holdup while maintaining metering reliability.
2Ease of operation
If traditional distribution manifolds are used, then liquid refrigerant distribution is achieved, but refrigerant charge is increased leading to higher costs and emissions
Solution Approach 1:
The invention extracts the essential function of liquid refrigerant distribution from the traditional large-volume manifold and implements it through streamlined sparge channels with sparge openings. This extraction removes unnecessary liquid-filled volume while preserving the core distribution function, reducing refrigerant charge by up to 15% compared to conventional manifolds.
Solution Approach 2:
The invention changes the geometric parameters of the distribution system by reducing the cross-sectional area and volume of the liquid-carrying passages while extending the length of distribution points along the evaporator. This parameter optimization maintains distribution effectiveness while minimizing refrigerant charge holdup in the distribution system.
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
The solution provides superior liquid distribution to evaporator tubes across a wide range of operating conditions, reducing refrigerant charge and minimizing greenhouse gas emissions while maintaining near-ideal evaporator performance.
Implementation Method 1
a separator and distributor assembly with refrigerant gutters and sparge channels that extend along the length of the evaporator housing, allowing for efficient separation and distribution of liquid refrigerant
Implementation Method 2
The sparge channel includes one or more sparge openings at a top of the sparge channel vertically below the gutter inlet. The one or more sparge openings are configured to flow liquid refrigerant therefrom.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A separator and distributor assembly (30) for a falling film evaporator (12) housed within the evaporator shell includes a housing (80) defining a separation volume (34), a refrigerant inlet (50) configured to admit a liquid and vapor refrigerant flow (24) into the separation volume (34) and one or more refrigerant gutters (36) extending along a lengthwise axis (38) of the housing (80). The refrigerant gutter (36) has a gutter inlet (42) at a bottom (56) of the separation volume (34), and the one or more refrigerant gutters (36) are configured to receive separated liquid refrigerant (32) from the separation volume (34). One or more sparge channels (44) are in fluid communication with the refrigerant gutters (36). The sparge channel (44) includes one or more sparge openings (46) at a top of the sparge channel (44) vertically below the gutter inlet (42) . The one or more sparge openings (46) are configured to flow liquid refrigerant (32) therefrom.