The present invention generally relates to a centrifugal compressor. More specifically, the present invention relates to a centrifugal compressor with liquid injection.
A chiller system is a refrigerating machine or apparatus that removes heat from a medium. Commonly, a liquid, such as water, is used as the medium and the chiller system operates in a vapor-compression refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool air or equipment as required. As a necessary byproduct, refrigeration creates waste heat that must be exhausted to ambient or, for greater efficiency, recovered for heating purposes. A conventional chiller system often utilizes a centrifugal compressor, which is often referred to as a turbo compressor. Thus, such chiller systems can be referred to as turbo chillers. Alternatively, other types of compressors, e.g. a screw compressor, can be utilized.
In a conventional (turbo) chiller, refrigerant is compressed in the centrifugal compressor and sent to a heat exchanger in which heat exchange occurs between the refrigerant and a heat exchange medium (liquid). This heat exchanger is referred to as a condenser because the refrigerant condenses in this heat exchanger. As a result, heat is transferred to the medium (liquid) so that the medium is heated. Refrigerant exiting the condenser is expanded by an expansion valve and sent to another heat exchanger in which heat exchange occurs between the refrigerant and a heat exchange medium (liquid). This heat exchanger is referred to as an evaporator because refrigerant is heated (evaporated) in this heat exchanger. As a result, heat is transferred from the medium (liquid) to the refrigerant, and the liquid is chilled. The refrigerant from the evaporator is then returned to the centrifugal compressor and the cycle is repeated. The liquid utilized is often water.
A conventional centrifugal compressor basically includes a casing, an inlet guide vane, an impeller, a diffuser, a motor, various sensors and a controller. Refrigerant flows in order through the inlet guide vane, the impeller and the diffuser. Thus, the inlet guide vane is coupled to a gas intake port of the centrifugal compressor while the diffuser is coupled to a gas outlet port of the impeller. The inlet guide vane controls the flow rate of refrigerant gas into the impeller. The impeller increases the velocity of refrigerant gas. The diffuser works to transform the velocity of refrigerant gas (dynamic pressure), given by the impeller, into (static) pressure. The motor rotates the impeller. The controller controls the motor, the inlet guide vane and the expansion valve. In this manner, the refrigerant is compressed in a conventional centrifugal compressor. The inlet guide vane is typically adjustable and the motor speed is typically adjustable to adjust the capacity of the system. In addition, the diffuser may be adjustable to further adjust the capacity of the system. The controller controls the motor, the inlet guide vane and the expansion valve. The controller can further control any additional controllable elements.
Flow separation and pressure waves generated at a trailing edge of the impeller in a conventional centrifugal compressor can cause compression noise. An isolation cover or a micro girth liquid film have been used to suppress compression noise.
An object of the present invention is to suppress noise in a centrifugal compressor.
In view of the state of the known technology, one aspect of the present disclosure is to provide a centrifugal compressor adapted to be used in a chiller. The centrifugal compressor includes an impeller, a motor and a diffuser. The impeller is attached to a shaft rotatable about a rotation axis. The motor is arranged and configured to rotate the shaft in order to rotate the impeller. The diffuser is disposed downstream from the impeller. At least one injection port is located within the diffuser. The at least one injection port is configured and arranged to supply liquid refrigerant into the diffuser from a condenser or an economizer of the chiller.
Another aspect of the present invention is to provide a two-stage chiller. The two-stage chiller includes a first centrifugal compressor and a second centrifugal compressor. The first centrifugal compressor includes a first impeller and a first diffuser. The first impeller is rotatable about a first rotation axis. The first diffuser is disposed downstream from the first impeller. The second centrifugal compressor includes a second impeller and a diffuser. The second impeller is rotatable about a second rotation axis. The second diffuser is disposed downstream from the second impeller. At least one motor is arranged and configured to rotate the first impeller and the second impeller. A return channel flow path connects the first diffuser to the second impeller. The two-stage chiller further includes a condenser and an economizer. An evaporator is connected in series with the first stage centrifugal compressor, the second stage centrifugal compressor, the condenser, and the economizer. At least one injection port is located within at least one of the first diffuser, the return channel flow path, and the second diffuser. At least one injection passage is connected to the at least one injection port. The at least one injection passage is arranged and configured to deliver liquid refrigerant from at least one of the condenser and the economizer.
Another aspect of the present invention is to provide a two-stage compressor adapted to be used in a chiller. The two-stage compressor includes a first stage centrifugal compressor, a second stage centrifugal compressor, at least one motor, and a plurality of injection ports. The first stage centrifugal compressor includes a first impeller and a first diffuser. The first impeller is rotatable about a first rotation axis. The first diffuser is disposed downstream from the first impeller. The first diffuser has a first upstream edge and a first downstream edge. The second stage centrifugal compressor includes a second impeller and a second diffuser. The second impeller is rotatable about a second rotation axis. The second diffuser is disposed downstream from the second impeller. The second diffuser has a second upstream edge and a second downstream edge. The at least one motor is arranged and configured to rotate the first impeller and the second impeller. The plurality of injection ports are located within the second diffuser downstream of the second upstream edge of the second diffuser to deliver liquid refrigerant to the second diffuser.
These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments.
Referring now to the attached drawings which form a part of this original disclosure:
Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
Referring initially to
The chiller system 10 basically includes a chiller controller 14, a compressor 16, a condenser 18, an economizer 20, expansion valves 22 and 24, and an evaporator 26 connected together in series to form a loop refrigeration cycle. In addition, various sensors S and T may be disposed throughout the circuit of the chiller system 10. The chiller system 10 may include orifices instead of the expansion valves 22 and 24.
Referring to
The chiller controller 14 receives signals from the various sensors and controls the inlet guide vanes 32 and 36, the compressor motor 40, and the magnetic bearing assembly 42, as explained in more detail below. Refrigerant flows in order through the first stage inlet guide vane 32, the first stage impeller 28, the first diffuser, 34, the return channel 48, the second stage inlet guide vane 36, the second stage impeller 30, and the second diffuser 38. The inlet guide vanes 32 and 36 control the flow rate of refrigerant gas into the impellers 28 and 30, respectively. The impellers 28 and 30 increase the velocity of refrigerant gas, generally without changing pressure. The motor speed determines the amount of increase of the velocity of refrigerant gas. The diffusers/volutes 34 and 38 increase the refrigerant pressure. The diffusers/volutes 34 and 38 are non-movably fixed relative to a compressor casing 44. The compressor motor 40 rotates the impellers 28 and 30 via a shaft 46. Alternatively, a first motor can drive the first impeller 28 and a second motor 30 can drive the second impeller 30. The magnetic bearing assembly 42 magnetically supports the shaft 46. Alternatively, the bearing system may include a roller element, a hydrodynamic bearing, a hydrostatic bearing, an oil bearing, and/or a magnetic bearing, or any combination of these. In this manner, the refrigerant is compressed in the centrifugal compressor 16.
In operation of the chiller system 10, the first stage impeller 28 and the second stage impeller 30 of the compressor 16 are rotated, and the refrigerant of low pressure in the chiller system 10 is drawn by the first stage impeller 28. The flow rate of the refrigerant is adjusted by the inlet guide vane 32. The refrigerant drawn by the first stage impeller 28 is compressed to intermediate pressure, the refrigerant pressure is increased by the first diffuser/volute 34, and the refrigerant is then introduced to the second stage impeller 30. The flow rate of the refrigerant is adjusted by the inlet guide vane 36. The second stage impeller 30 accelerates and compresses the refrigerant, and the refrigerant pressure is increased from an intermediate pressure to a high pressure by the second diffuser/volute 38. The high-pressure gas refrigerant is then discharged to the chiller system 10.
Referring to
The economizer 20 includes an inlet port 20a, a liquid outlet port 20b, and a gas outlet port 20c. The inlet port 20a is provided to introduce the two-phase refrigerant from the condenser 18 into the economizer 20. The liquid outlet port 20b is provided to discharge the liquid refrigerant separated from the two-phase refrigerant to the evaporator 26. The gas outlet port 20c is provided to discharge the gas refrigerant separated from the two-phase refrigerant provided to the economizer 20. The flow rate of the refrigerant flowing into the inlet port 20a is controlled by the expansion valve 22 which is disposed between the condenser 18 and the economizer 20.
In operation, the refrigerant cooled to condense in the condenser 18 is decompressed to an intermediate pressure by the expansion valve 22, and is then introduced into the economizer 20. The two-phase refrigerant introduced from the inlet port 20a into the economizer 20 is separated into gas refrigerant and liquid refrigerant by the economizer 20. Under some conditions, the gas refrigerant is injected from the gas outlet port 20c of the economizer 20 into the return channel 48 of the compressor 16 via a pipe. Under some conditions, the liquid refrigerant is guided from the liquid outlet port 20b to the evaporator 26, or can be stored in a liquid storage portion of the economizer 20, or can be injected into the return channel 48 of the compressor 16 via a pipe.
The gas refrigerant injected into the return channel 48 of the compressor 16 is then mixed with the refrigerant of intermediate pressure compressed by the first stage impeller 28 of the compressor 16. The mixed refrigerant flows to the second stage impeller 30 to be further compressed.
In some embodiments, the casing 44 includes a first casing 50 and a second casing 52, as shown in
The compressor 16 includes at least one injection port 54 configured and arranged to supply liquid refrigerant to the compressor 16 from a source, such as the condenser 18 or the economizer 20. As shown in
As shown in
The injection port 54 is preferably located proximal the trailing edge of the first stage impeller 28, but downstream of the joint between the first impeller 28 and the first diffuser 34. Flow separation occurs within the rotating first stage impeller 28. Injecting the higher pressure liquid refrigerant into the low pressure vapor refrigerant from the impeller substantially prevents the flow separation occurring in the first stage impeller 28 from propagating to the first diffuser 34. The closer the injection port 54 is to the trailing edge of the first stage impeller 28, the higher the velocity of the emitted refrigerant vapor and the lower the pressure.
The refrigerant vapor entering the first diffuser 34 has a high velocity jet flow down the middle of the flow path and a slower velocity separated flow near the walls of the flow path of the first diffuser 34. The separated flow creates eddies in the flow path. Injecting the liquid refrigerant into the first diffuser 34 adds energy to the flow and breaks up the distinction between the jet flow and the separated flow. The injected liquid refrigerant substantially suppresses the flow separation. The injected liquid refrigerant goes through a phase change, from a liquid to a vapor, and slows the flow of the refrigerant vapor.
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An injection passage 58 is connected to the at least one injection port 54 to supply liquid refrigerant thereto. As shown in
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In another embodiment, for example, liquid refrigerant from the economizer 20 is injected in the first diffuser 34, and liquid refrigerant from the condenser 18 is injected in the second diffuser 38. The economizer pressure is lower than the condenser pressure. The first diffuser pressure is lower than the second diffuser pressure. Injecting liquid refrigerant from the condenser 18 into the second diffuser 38 and from the economizer 20 into the first diffuser 34 maintains pressure differentials at the respective injection ports 54.
In some embodiments, each injection passage 58 includes a valve 60 that is controllable to control the flow of liquid refrigerant to the injection port 54, as shown in
In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts.
The term “detect” as used herein to describe an operation or function carried out by a component, a section, a device or the like includes a component, a section, a device or the like that does not require physical detection, but rather includes determining, measuring, modeling, predicting or computing or the like to carry out the operation or function.
The term “configured” as used herein to describe a component, section or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function.
The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.
While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.