Integrated Separator and Distributor for Reduced 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
The design incorporates a separator and distributor assembly with refrigerant gutters and sparge channels that receive separated liquid refrigerant, allowing it to flow through sparge openings and into a distribution manifold, optimizing refrigerant distribution and reducing the refrigerant charge 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 patent extracts the liquid refrigerant metering function from the traditional liquid-filled distribution manifold and relocates it to a separate separator assembly. The separator extracts and meters liquid refrigerant before it enters the distribution manifold, allowing the manifold to be smaller and hold less refrigerant while maintaining reliable metering through the separator's controlled discharge.
Solution Approach 2:
The patent introduces a separator as an intermediary component between the refrigerant inlet and the distribution manifold. This separator acts as a mediator that performs the liquid metering function, enabling the distribution manifold to be minimized in size and refrigerant charge while ensuring consistent liquid supply to the evaporator tubes.
2Quantity of substance
If distribution manifold size is reduced to minimize refrigerant charge, then greenhouse gas emissions decrease, but liquid refrigerant distribution uniformity may be compromised
Solution Approach 1:
The patent performs preliminary liquid refrigerant separation and metering in the separator assembly before the refrigerant enters the distribution manifold. By pre-metering the liquid refrigerant and controlling its discharge rate, the system ensures uniform distribution to the evaporator tubes even with a minimized distribution manifold size, maintaining distribution stability while reducing total refrigerant charge.
3Quantity of substance
If spray-based distribution systems are used, then refrigerant charge is reduced, but distribution performance across wider operating conditions deteriorates
Solution Approach 1:
The patent employs hydraulic principles through the separator and sparge channel design to control liquid refrigerant flow. The sparge channels use hydrostatic pressure and controlled flow paths to meter liquid refrigerant, providing adaptability across wider operating conditions while maintaining reduced refrigerant charge levels, outperforming spray-based systems in terms of operating range versatility.
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 ensures effective liquid refrigerant distribution across evaporator tubes with reduced refrigerant charge, maintaining near-ideal performance and tube wetting while minimizing the size of the distribution manifold, and provides superior distribution across a wider range of operating conditions compared to spray-based systems.
Implementation Method 1
separating a liquid refrigerant from the liquid and vapor refrigerant at the separation volume
Implementation Method 2
separating a liquid refrigerant from the liquid and vapor refrigerant
Implementation Method 3
The liquid refrigerant is urged out of one or more sparge openings at a top of the sparge channel via refrigerant pressure in the separation volume
Data Source
Figure 1
Figure 2
Figure 3
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.