Low charge packaged refrigeration system
Find Innovative SolutionsGenerate Solutions
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 ammonia toxicity and potential leaks.
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 refrigerant charge of less than 10 lbs per ton of refrigeration capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional compartmentalized refrigeration systems are used with large receiver vessels, then refrigerant storage capacity is sufficient, but refrigerant charge quantity becomes excessively large (15-25 lbs per ton)
Solution Approach 1:
The patent merges the compressor, condenser, and evaporator into a single integrated packaged unit, eliminating the need for separate mechanical rooms and reducing refrigerant charge to less than 10 lbs per ton. This consolidation removes multiple connection points and potential leak sources while maintaining adequate refrigerant storage within the compact design.
Solution Approach 2:
The patent extracts and eliminates large receiver vessels from the traditional system configuration. By using a compact integrated design with internal refrigerant circulation, the system achieves sufficient refrigerant storage without requiring external receiver tanks, thereby reducing overall refrigerant charge quantity.
2Productivity
If ammonia-based refrigeration systems are used for industrial applications, then refrigeration capacity is sufficient, but safety risks and regulatory burdens increase due to ammonia toxicity
Solution Approach 1:
By integrating all refrigeration components into a single sealed packaged unit, the patent minimizes the amount of ammonia required (less than 10 lbs per ton), thereby reducing toxicity risks and regulatory burdens while maintaining adequate refrigeration capacity for industrial applications.
Solution Approach 2:
The patent changes the system configuration from distributed compartmentalized design to a compact integrated design, which fundamentally alters the refrigerant charge parameters and reduces ammonia quantity to levels below certain regulatory thresholds, thereby mitigating safety and regulatory concerns.
3Quantity of substance
If large receiver vessels are used for vapor-liquid separation, then refrigerant storage is adequate, but system footprint and installation space requirements increase
Solution Approach 1:
The patent combines vapor-liquid separation functionality directly within the packaged unit's internal circulation system, eliminating the need for separate large receiver vessels. This integration maintains adequate refrigerant storage capacity while dramatically reducing the installation footprint to a compact skid-mounted configuration.
Solution Approach 2:
The patent nests the refrigerant circulation and separation functions within the compact packaged unit structure, where internal components are arranged to perform multiple functions including vapor-liquid separation without requiring external receiver tanks, thereby reducing installation space requirements.
4Adaptability or versatility
If multiple separate components are used in refrigeration systems, then system functionality is complete, but potential leak points and maintenance complexity increase
Solution Approach 1:
The patent merges all refrigeration components (compressor, condenser, evaporator, expansion devices) into a single packaged unit with factory-precharged refrigerant, reducing the number of field installation connections and potential leak points while maintaining complete system functionality. This integration simplifies maintenance as the unit operates as a self-contained 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
This configuration reduces ammonia usage to less than six pounds per ton, minimizing regulatory burdens and safety risks, as the system can operate efficiently with less than two pounds per ton, compared to prior art systems which require 15-25 pounds per ton, thereby reducing potential harm in case of a leak.
Implementation Method 1
liquid-vapor separation structure/device which is housed in the pre-packaged modular machine room. According to one embodiment, the liquid-vapor separation structure/device may be a single or dual phase cyclonic separator
Implementation Method 2
the condenser may be constructed of coil tubes preferably formed with internal enhancements that improve the flow of the refrigerant vapor through the tubes, enhance heat exchange and reduce refrigerant
Implementation Method 3
evaporator coil tubes are preferably formed with internal enhancements that improve the flow of the refrigerant liquid through the tubes, enhance heat exchange and reduce refrigerant charge
Data Source
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.