Packaged Low-Charge Refrigeration with Cyclonic Separation
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Solution Overview
Problem
Existing industrial refrigeration systems, particularly ammonia-based ones, are highly compartmentalized and require large refrigerant charges, leading to regulatory challenges and safety concerns due to the toxicity of ammonia, necessitating reduced refrigerant quantities to minimize risks and compliance burdens.
Innovation Solution
A packaged, pumped liquid, recirculating refrigeration system with a pre-packaged modular machine room housing the compressor and condenser, utilizing internal enhancements in evaporator and condenser coils, and replacing large receiver vessels with liquid-vapor separation structures, such as cyclonic separators, to achieve a low charge system with less than 10 lbs of refrigerant per ton of refrigeration capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional compartmentalized refrigeration systems are used, then system reliability and separation of functions are improved, but refrigerant charge quantity increases and safety risks worsen
Solution Approach 1:
The patent combines the machine room and penthouse into a single integrated packaged unit. The compressor, condenser, and evaporator are housed together in one modular structure, eliminating the need for separate mechanical rooms and roof penthouses. This merging reduces the total refrigerant charge while maintaining functional separation through internal design, directly resolving the contradiction between system reliability and refrigerant quantity.
Solution Approach 2:
The packaged unit is designed as a modular, pre-fabricated structure that can be segmented into standard shipping containers. This segmentation allows the system to be transported and installed as complete modules, reducing on-site assembly requirements and enabling standardized low-charge designs to be replicated across different installations.
2Quantity of substance
If large receiver vessels are used, then refrigerant storage capacity is improved, but system complexity and space requirements worsen
Solution Approach 1:
The patent extracts and eliminates the traditional large receiver vessels from the system. Instead of using separate storage tanks, the design relies on the integrated heat exchange components and smaller internal reservoirs within the packaged unit, significantly reducing system complexity and space requirements while maintaining adequate refrigerant charge.
Solution Approach 2:
The system employs nested heat exchange configurations where the evaporator and condenser coils are arranged in compact, space-efficient configurations within the packaged unit. This nesting allows maximum heat transfer surface area within minimal volume, eliminating the need for large external receiver vessels.
3Productivity
If ammonia-based refrigeration systems are used, then refrigeration efficiency is improved, but safety risks and regulatory compliance burdens worsen
Solution Approach 1:
The patent changes the system architecture from distributed compartmentalized design to a compact packaged unit with controlled internal pressure and temperature zones. This parameter control, combined with the reduced total ammonia charge, significantly lowers safety risks while maintaining refrigeration efficiency through optimized heat transfer surfaces and refrigerant flow paths.
4Ease of operation
If compartmentalized systems with separate mechanical rooms are used, then maintenance access and operational control are improved, but installation complexity and space requirements worsen
Solution Approach 1:
The patent merges all operational components into a single packaged unit with integrated access points. Maintenance personnel can service the compressor, condenser, and evaporator through designated access doors on the packaged unit, eliminating the need to navigate between separate mechanical rooms and penthouses, thus simplifying installation while maintaining ease of operation.
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 system operates efficiently with significantly reduced refrigerant amounts, requiring less than six pounds per ton, thereby minimizing safety risks and regulatory compliance issues, allowing for safe discharge of the entire refrigerant quantity without harm to humans or the environment.
Implementation Method 1
the standard economizer vessel (which collects liquid coming off the condenser) can also optionally be replaced with a single or dual phase cyclonic separator
Implementation Method 2
liquid-vapor separation structure/device which is housed in the pre-packaged modular machine room
Implementation Method 3
a refrigerant condenser connected to an outlet of the refrigerant compressor via refrigerant line and configured to condense refrigerant vapor produced in the compressor to refrigerant liquid
Implementation Method 4
a refrigerant evaporator coil...configured to vaporize a portion of the liquid refrigerant received from the vapor/liquid separation structure
Data Source
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AI summary
A packaged, pumped liquid, recirculating refrigeration system with charges of 10 lbs or less of refrigerant per ton of refrigeration capacity. The compressor and related components are situated in a pre-packaged modular machine room, and in which the condenser is mounted on the machine room and the evaporator is close coupled to the pre-packaged modular machine room. Prior art large receiver vessels may be replaced with a single or dual phase cyclonic separator also housed in the pre-packaged modular machine room.