Patent Grant
10539350
Field of the Invention
The present invention generally relates to an economizer used in a chiller system.
Background Information
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.
In order to improve the efficiency of the chiller system, an economizer has been used. See for example U.S. Patent Application Publication No. 2010/0251750 and U.S. Pat. No. 4,903,497. The economizer separates refrigerant gas from two-phase (gas-liquid) refrigerant, and the refrigerant gas is introduced to an intermediate pressure portion of the compressor. As a conventional type of economizer, a flash tank economizer is well known in the art. See for example U.S. Patent Application Publication No. 2010/0326130.
In a conventional flash tank economizer, a tank is provided for gas-liquid separation by gravity, and a floating valve is disposed inside the tank. In the conventional flash tank economizer, the refrigerant flow in the outlet of the tank is reduced by the valve disc of the floating valve so as to reduce the pressure of the refrigerant by the floating valve. While this technique works relatively well, this system requires a large tank to ensure dryness of the released gas and to avoid carryover by the refrigerant gas in droplet form, which results in increased costs. Also, the floating valve is often unstable, which makes the economizer system unreliable.
Also, in a conventional flash tank economizer, it is difficult to control the intermediate pressure of the compressor, and thus, a high coefficient of performance (COP) cannot be easily achieved. In addition, a conventional technique requires an economizer of a large diameter.
Therefore, one object of the present invention is to provide an economizer which is stable by using a separation wheel for gas-liquid separation without increased costs.
Another object of the present invention is to provide an economizer which achieves a high coefficient of performance (COP) by actively controlling the intermediate pressure of the compressor.
Yet another object of the present invention is to provide an economizer in which downsizing of the economizer diameter is achieved.
Yet another object of the present invention is to provide a chiller system which uses the economizer in accordance with the present invention.
One or more of the above objects can basically be attained by providing an economizer adapted to be used in a chiller system including a compressor, an evaporator and a condenser, the economizer including a separation wheel arranged and configured to separate refrigerant into gas refrigerant and liquid refrigerant, the separation wheel being attached to a shaft rotatable about a rotation axis, a motor arranged and configured to rotate the shaft in order to rotate the separation wheel, and a liquid storage portion arranged and configured to store the liquid refrigerant.
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 20, a compressor 22, a condenser 24, an economizer 26, expansion valves 25, 27, and an evaporator 28 connected together in series to form a loop refrigeration cycle. In addition, various sensors (not shown) are disposed throughout the circuit of the chiller system 10. The chiller system 10 may include orifices instead of the expansion valves 25, 27.
Referring to
The chiller controller 20 receives signals from the various sensors and controls the inlet guide vanes 32a and 32b, the compressor motor 38, and the magnetic bearing assembly 40 in a conventional manner, as explained in more detail below. Refrigerant flows in order through the first stage inlet guide vane 32a, the first stage impeller 34a, the second stage inlet guide vane 32b, and the second stage impeller 34b. The inlet guide vanes 32a and 32b control the flow rate of refrigerant gas into the impellers 34a and 34b, respectively, in a conventional manner. The impellers 34a and 34b 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 36a and 36b increase the refrigerant pressure. The diffusers/volutes 36a and 36b are non-movably fixed relative to a compressor casing 30. The compressor motor 38 rotates the impellers 34a and 34b via a shaft 42. The magnetic bearing assembly 40 magnetically supports the shaft 42. Alternatively, the bearing system may include a roller element, a hydrodynamic bearing, a hydrostatic bearing, and/or a magnetic bearing, or any combination of these. In this manner, the refrigerant is compressed in the centrifugal compressor 22.
In operation of the chiller system 10, the first stage impeller 34a and the second stage impeller 34b of the compressor 22 are rotated, and the refrigerant of low pressure in the chiller system 10 is sucked by the first stage impeller 34a. The flow rate of the refrigerant is adjusted by the inlet guide vane 32a. The refrigerant sucked by the first stage impeller 34a is compressed to intermediate pressure, the refrigerant pressure is increased by the first diffuser/volute 36a, and the refrigerant is then introduced to the second stage impeller 34b. The flow rate of the refrigerant is adjusted by the inlet guide vane 32b. The second stage impeller 34b compresses the refrigerant of intermediate pressure to high pressure, and the refrigerant pressure is increased by the second diffuser/volute 36b. The high pressure gas refrigerant is then discharged to the chiller system 10.
Referring to
The thrust disk 45 extends radially from the shaft 42 in a direction perpendicular to the rotational axis X, and is fixed relative to the shaft 42. A position of the shaft 42 along rotational axis X (an axial position) is controlled by an axial position of the thrust disk 45. The first and second radial magnetic bearings 44 and 46 are disposed on opposite axial ends of the compressor motor 38. Various sensors detect radial and axial positions of the shaft 42 relative to the magnetic bearings 44, 46 and 48, and send signals to the chiller controller 20 in a conventional manner. The chiller controller 20 then controls the electrical current sent to the magnetic bearings 44, 46 and 48 in a conventional manner to maintain the shaft 42 in the correct position.
The magnetic bearing assembly 40 is preferably a combination of active magnetic bearings 44, 46, and 48, which utilizes gap sensors 54, 56 and 58 to monitor shaft position and send signals indicative of shaft position to the chiller controller 20. Thus, each of the magnetic bearings 44, 46 and 48 are preferably active magnetic bearings. A magnetic bearing control section 71 uses this information to adjust the required current to a magnetic actuator to maintain proper rotor position both radially and axially.
As mentioned above, the chiller system 10 has the economizer 26 in accordance with the present invention. The economizer 26 is connected to an intermediate stage of the compressor 22 to inject gas refrigerant into the intermediate stage of the compressor 22, as explained in more detail below. In the chiller system 10, the economizer 26 is disposed between the evaporator 28 and the condenser 24.
The economizer 26 includes a separation wheel 62, an economizer motor 64, and a liquid storage portion 66 as shown in
The economizer 26 further includes an inlet port 61a, a liquid outlet port 61b, and a gas outlet port 61c. The inlet port 61a is provided to introduce the two-phase refrigerant from the condenser 24 into the economizer 26. The liquid outlet port 61b is provided to discharge the liquid refrigerant separated from the two-phase refrigerant to the evaporator 28. The gas outlet port 61c is provided to discharge the gas refrigerant separated from the two-phase refrigerant to the economizer 26. The flow rate of the refrigerant flowing into the inlet port 61a is controlled by the expansion valve 25 which is disposed between the condenser 24 and the economizer 26. In accordance with the present invention, the expansion valve 25 is disposed away from the economizer 26. This provides more accurately established pressures to monitor for maintaining the liquid height. Also, subcooled liquid remains as liquid all the way to the expansion valve 25, which reduces the pipe size, and more sub cooling is provided by the pressure increase.
In the embodiment illustrated in
In operation, the refrigerant cooled to condense in the condenser 24 is decompressed to an intermediate pressure by the expansion valve 25, and is then introduced into the economizer 26. The two-phase refrigerant introduced from the inlet port 61a into the economizer 26 is separated into gas refrigerant and liquid refrigerant in the separation wheel 62 by dynamic force. The gas refrigerant is injected from the gas outlet port 61c of the economizer 26 into the intermediate stage of the compressor 22 via a pipe. The liquid refrigerant is guided from the liquid outlet port 61b to the evaporator 28, or is stored in the liquid storage portion 66.
The gas refrigerant injected into the intermediate stage of the compressor 22 is then mixed with the refrigerant of intermediate pressure compressed by the first stage impeller 34a of the compressor 22. The mixed refrigerant flows to the second stage impeller 34b to be further compressed.
The compressor 22 can be a screw compressor as shown in
Referring to
In the illustrated embodiment, the control sections are sections of the chiller controller 20 programmed to execute the control of the parts described herein. The magnetic bearing control section 71, the compressor variable frequency drive 72, the compressor motor control section 73, the inlet guide vane control section 74, the expansion valve control section 75, and the economizer control section 76 are coupled to each other, and form parts of a centrifugal compressor control portion that is electrically coupled to an 1/O interface of the compressor 22. However, it will be apparent to those skilled in the art from this disclosure that the precise number, location and/or structure of the control sections, portions and/or chiller controller 20 can be changed without departing from the present invention so long as the one or more controllers are programmed to execute control of the parts of the chiller system 10 as explained herein.
The economizer control section 76 is connected to the economizer variable frequency drive 67 of the economizer 26 and communicates with various sections of the chiller controller 20. In this manner, the economizer control section 76 can receive signals from the sensors of the compressor 22, perform calculations, and transmit control signals to the economizer variable frequency drive 67 of the economizer 26.
The chiller controller 20 is conventional, and thus, includes at least one microprocessor or CPU, an Input/output (I/O) interface, Random Access Memory (RAM), Read Only Memory (ROM), a storage device (either temporary or permanent) forming a computer readable medium programmed to execute one or more control programs to control the chiller system 10. The chiller controller 20 may optionally include an input interface such as a keypad to receive inputs from a user and a display device used to display various parameters to a user. The parts and programming are conventional, except as related to controlling the economizer 26, and thus, will not be discussed in detail herein, except as needed to understand the embodiment(s).
Referring to
As shown in
As shown in
Referring to
As mentioned above, the economizer 26 is provided in the chiller system 10 to inject gas refrigerant into the intermediate stage of the compressor 22. In the illustrated embodiment, the compressor 22 is a two-stage centrifugal compressor. The compressor variable frequency drive 72 of the chiller controller 20 is programmed to control the compressor 22 (S101). The compressor variable frequency drive 72 is programmed to control the compressor 22 in a conventional manner such as disclosed in U.S. Patent Application Publication No. 2014/0260385 and U.S. Patent Application Publication No. 2014/0260388.
In S102, the economizer control section 76 calculates the isentropic efficiency of the first stage of the compressor 22 and the isentropic efficiency of the second stage of the compressor 22 from the current operation status. Next, in S103, the economizer control section 76 calculates an optimum ratio of the first stage compression ratio and the second stage compression ratio of the compressor 22. As discussed above, the peak of the coefficient of performance (COP) of the compressor 22 will be achieved when the ratio of the first stage compression ratio and the second stage compression ratio is optimum.
Next, in S104, the economizer control section 76 calculates a target intermediate pressure of the compressor 22 based on the optimum ratio of the first stage compression ratio and the second stage compression ratio.
In S105, the economizer control section 76 determines whether or not the current intermediate pressure of the compressor 22 is the most efficient, i.e., the current intermediate pressure of the compressor 22 is the target intermediate pressure of the compressor 22 which is calculated in S104. When the economizer control section 76 determines that the current intermediate pressure of the compressor 22 is the most efficient (Yes in S105), the controlling method will be finished. When the economizer control section 76 determines that the current intermediate pressure of the compressor 22 is not the most efficient (No in S105), the economizer control section 76 will proceed to S106.
In S106, the economizer control section 76 determines the opening degree of the expansion valve 25 and the speed of the economizer variable frequency drive 67 to achieve the target intermediate pressure of the compressor 22. In S107, the economizer control section 76 adjusts the opening degree of the expansion valve 25 and the speed of the economizer variable frequency drive 67 to achieve the target intermediate pressure of the compressor 22. In this manner, the flow rate of the refrigerant flowing into the inlet port 61a is controlled by the expansion valve 25 and the rotational speed of the separation wheel 62 of the economizer 26 is controlled by the economizer variable frequency drive 67 so as to achieve the target intermediate pressure of the compressor 22.
In S108, the economizer control section 76 determines whether or not the current intermediate pressure of the compressor 22 is the most efficient, i.e., the current intermediate pressure of the compressor 22 is the target intermediate pressure of the compressor 22. When the economizer control section 76 determines that the current intermediate pressure of the compressor 22 is the most efficient (Yes in S108), the controlling method will be finished. When the economizer control section 76 determines that the current intermediate pressure of the compressor 22 is not the most efficient (No in S108), the economizer control section 76 will go back to S102, and the controlling method will be repeated. For example, the above-mentioned processes can be repeated when at least one of the followings occurs: the speed of the compressor variable frequency drive 72 varies with 10% per minute or more, the discharge pressure of the compressor 22 varies with 10% per minute or more, and the suction pressure of the compressor 22 varies with 10% per minute or more.
Referring to
In a case in which the ratio of the first stage compression ratio and the second stage compression ratio is controlled to be 0.65, the conventional flash tank economizer requires a diameter of 1.77 m because the flow rate to be processed increases. On the other hand, the diameter of the economizer 26 can be maintained at 0.33 m by increasing the speed of the separation wheel 62. Accordingly, downsizing to an approximate 19% diameter can be achieved. See case (2) of
In a case in which the ratio of the first stage compression ratio and the second stage compression ratio is controlled to be 1.35, the conventional flash tank economizer requires a diameter of 0.54 m. On the other hand, the diameter of the economizer 26 can be maintained at 0.33 m. Accordingly, downsizing to an approximate 61% diameter can be achieved. See case (3) of
In terms of global environment protection, use of new low GWP (Global Warming Potential) refrigerants such like R1233zd, R1234ze are considered for chiller systems. One example of the low global warming potential refrigerant is low pressure refrigerant in which the evaporation pressure is equal to or less than the atmospheric pressure. For example, low pressure refrigerant R1233zd is a candidate for centrifugal chiller applications because it is non-flammable, non-toxic, low cost, and has a high COP compared to other candidates such like R1234ze, which are current major refrigerant R134a alternatives. Especially in a case of using low pressure refrigerant, the economizer in accordance with the present invention has advantages because the economizer in accordance with the present invention achieves downsizing of the diameter thereof. Also, various kinds of low pressure refrigerants can be used for the economizer in accordance with the present invention for gas-liquid separation.
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.
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