Integrated separator and distributor
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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 holdup by up to 15% compared to current systems.
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 distribution channels with individual metering structures (spargers) along their length. This segmentation allows liquid refrigerant to be metered at multiple locations simultaneously, reducing the need for large liquid holdup volumes while maintaining reliable metering throughout the evaporator tube bundle.
Solution Approach 2:
The invention transitions from a traditional two-dimensional distribution manifold to a three-dimensional network of distribution channels with spargers extending along the length of the evaporator. This dimensional expansion allows liquid refrigerant to be distributed more uniformly across the evaporator surface, reducing charge holdup while improving metering reliability.
2Reliability
If larger separation volumes are used, then liquid refrigerant separation is improved, but refrigerant charge holdup increases
Solution Approach 1:
The separation volume is positioned to perform liquid-vapor separation before the refrigerant enters the distribution channels. By completing the separation action upstream, the system avoids needing large separation volumes within the distribution manifold itself, thereby reducing overall refrigerant charge holdup while maintaining effective separation.
Solution Approach 2:
The liquid separation function is extracted from the distribution manifold and placed in a dedicated separation volume upstream. This extraction allows the distribution manifold to be minimized in size, reducing refrigerant charge holdup while the separated liquid is efficiently delivered through the distribution channels to the evaporator tubes.
3Ease of operation
If traditional distribution manifolds are used, then liquid refrigerant distribution is achieved, but device complexity and refrigerant charge increase
Solution Approach 1:
The distribution manifold structure is merged with the evaporator tube bundle, with distribution channels and spargers integrated directly into the manifold walls. This merging eliminates the need for separate, complex manifold components while maintaining effective liquid distribution capability across the evaporator surface.
Solution Approach 2:
The distribution manifold serves multiple functions simultaneously: it acts as a structural support for the evaporator tubes, provides liquid-vapor separation, meters liquid refrigerant through integrated spargers, and distributes liquid uniformly across the evaporator surface. This multi-functionality reduces device complexity while maintaining distribution effectiveness.
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 effective liquid refrigerant distribution to evaporator tubes with reduced refrigerant charge, maintaining optimal performance and efficiency across a wider range of operating conditions.
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
One or more sparge channels are in fluid communication with the refrigerant gutters. 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
AI summary
A separator and distributor assembly for a falling film evaporator housed within the evaporator shell includes a housing defining a separation volume, a refrigerant inlet configured to admit a liquid and vapor refrigerant flow into the separation volume and one or more refrigerant gutters extending along a lengthwise axis of the housing. The refrigerant gutter has a gutter inlet at a bottom of the separation volume, and the one or more refrigerant gutters are configured to receive separated liquid refrigerant from the separation volume. One or more sparge channels are in fluid communication with the refrigerant gutters. 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.