The present embodiments relate to apparatus for transferring potential energy of a high pressure, high energy cryogenic fluid into mechanical energy for increasing the amount of refrigeration by decreasing the enthalpy of the fluid for use with, for example cryogenic food freezers.
Powering a fan in a refrigeration apparatus which utilizes a refrigerant fluid discharged directly into the refrigeration chamber requires use of electricity to operate an electric motor for the fan, the motor being mounted. either internally or externally to the refrigeration chamber. Motors consume electrical energy and can add heat to the refrigeration apparatus if they are mounted to or within the refrigeration chamber. Further, internal injection headers required to distribute the refrigerant fluid into the refrigeration chamber consume electricity and produce additional unwanted heat within the chamber.
Such refrigeration apparatus may also have ancillary systems which require electrical energy, such systems to include, but are not limited to, conveying apparatus, thermostat devices, control systems, circulating fans and exhaust fans.
Cryogen for known refrigeration apparatus include carbon dioxide (CO2) and nitrogen (N2) stored at high pressures in liquid bulk storage tanks. For example, CO2 is usually stored at from 280 to 300 psig. The CO2 is stored as a cryogenic fluid under high pressure and at a high energy state in this storage condition. In known cryogenic applications, for example in food freezing applications, the CO2 is injected into a process for cooling the cryogenic atmosphere of the freezer, with the fluid traveling from the pressure vessel where the CO2 is at a high energy state in liquid form through a vacuum insulated pipeline to the point of use which is in the cryogenic food freezer. At the point of use the pipeline terminates in at least one and for many applications a plurality of nozzles in which to distribute the cryogen to the freezer atmosphere. The saturated liquid CO2 experiences a pressure drop across the nozzle as it expands into the ambient environment of the freezer chamber. Depending upon the enthalpy of the CO2 before it expands across the nozzle (subcooled, saturated or super-heated state), a particular ratio of the solid CO2 to gas is created to use, for example in the food freezing application.
Therefore, what is needed is a fan and/or an injection device for refrigeration apparatus which is capable of converting the potential energy of the refrigerant liquid into electrical energy, mechanical energy, or any other method of performing work with the high pressure liquid refrigerant prior to injection, at a lower energy state (subcooled). The captured energy from this process can be used to power various ancillary systems or for other purposes.
There is therefore provided an apparatus for transfer of such energy through a fan, turbine or any other rotating device which can be powered by a high pressure, high energy state, cryogenic fluid, such as CO2 or N2. Work can be accomplished with the CO2 before it is passed through the nozzles so that the energy state (enthalpy) of the CO2 liquid will be reduced. This results in the liquid effectively being subcooled before it passes across the nozzle or nozzles and before it is injected into the freezing chamber of the freezing apparatus. The CO2 liquid at a lower energy state produces more CO2 snow and less gas which translates into an increase in refrigeration for the freezing chamber. Energy of the CO2 liquid is transferred from the high pressure liquid by performing mechanical work, thereby resulting in a liquid at a lower enthalpy which yields an increase in refrigeration for the process while using the same mass of liquid CO2.
There is therefore provided an energy conversion apparatus for a freezer, which includes a housing having a first region therein for receiving liquid CO2 at a first pressure and at a first energy state for providing potential energy; a movable member rotatably mounted to the housing and having a second region in fluid communication with the first region, the second region constructed to receive the liquid CO2 for changing to a second pressure less than the first pressure, and a second energy state less than the first energy state for providing kinetic energy from which mechanical work is provided to rotate the movable member; and a discharge member connected to the movable member and haying a third region in fluid communication with the second region, the third region continuing the mechanical work when exhausting the liquid CO2 at a third pressure less than the second pressure, and at a third energy state less than the second energy state such that the liquid CO2 is changed to a CO2 snow. Another embodiment of the apparatus has the movable member disposed external to the freezing chamber.
There is also provided a method of energy conversion for a freezer, which includes providing liquid CO2 at a first pressure and at a first energy state to a first region for providing potential energy; expanding the liquid CO2 to a second pressure less than the first pressure, and to a second energy state less than the first energy state in a second region in fluid communication with the first region for providing kinetic energy for performing mechanical work in the second region; and exhausting the liquid CO2 as a CO2 snow at a third pressure less than the second pressure, and at a third energy state less than the second energy state from a third region in fluid communication with the second region. Another embodiment of the method calls for the providing the kinetic energy and the expanding the liquid CO2 to occur external to the freezer.
For a more complete understanding of the present embodiments, reference may be made to the following detailed description and particular embodiments thereof, taken in conjunction with the following drawings, of which:
The present refrigeration apparatus utilizes internal fans with snow injection devices and/or externally mounted turbines which are capable of reducing the energy state (enthalpy) of the cryogen and generating electrical energy.
The fan and snow injection device described herein are operable via energy provided by the refrigerant fluid. No motors are necessary to operate the fan or snow injection device. Energy may be removed from the refrigerant fluid by the fan or snow injection device, and that energy may be used to power other parts of the refrigeration apparatus. Since the refrigerant fluid provides energy to power the fan or snow injection device (performs work), the fluid is delivered into the refrigeration apparatus with less energy, which results in a subcooled fluid, which in turn results in a greater cooling capacity per pound of refrigerant fluid supplied to the refrigeration apparatus. That is, the transfer of energy from the refrigerant fluid ultimately into electrical energy results in a lower energy state refrigerant fluid which increases the refrigerant capacity of the refrigerant fluid. Accordingly, a 15-20% improvement in refrigeration efficiency is realized by the present .
Provided is a fan for refrigerant fluid, comprising at least one blade having an internal space therein through which a refrigerant fluid passes; at least one nozzle in fluid communication with the internal space of the at least one blade, wherein the at least one nozzle discharges the refrigerant fluid from the at least one blade at a velocity sufficient to rotate the at least one blade; and an electrical generator operationally connected to the at least one blade (alternately a mechanical breaking device can be substituted for an electrical generator. Work is performed on this device which generates heat external to the freezing chamber). Alternatively, the fan may comprise a plurality of blades. The refrigerant fluid may be flashed into a mixture of solid and gaseous refrigerant as it is discharged from the at least one blade.
Also provided is a snow injection device for a carbon dioxide (CO2) refrigerant fluid comprising a disk having an internal space therein through which a CO2 refrigerant fluid passes; at least one nozzle in communication with the internal space within the disk which discharges the CO2 refrigerant fluid from the disk at a velocity sufficient to rotate the disk, the at least one nozzle being, adapted to flash the CO2 refrigerant fluid into gas and solid phases; and an electrical generator (or mechanical break) operationally connected to the disk. Alternatively, the snow injection device may comprise a plurality of nozzles in communication with the internal space in the disk. The snow injection device may further comprise a shroud operatively associated with the snow injection device for causing the solid phase of the flashed CO2 refrigerant fluid to fall at a reduced velocity out of the device, and into the refrigeration chamber.
The fan and/or snow injection device may further comprise means for storing electricity which are in direct or indirect electrical communication with the electrical generator. The above described nozzles may be high-velocity nozzles, and particularly may be supersonic nozzles. The fan or similar device may also be connected to a mechanical break which releases energy to the environment in the form of heat, thereby removing energy from the cryogenic fluid.
Referring now to FIGS, 1 and 2, an embodiment of the fan shown generally at 10 includes a supply of refrigerant fluid 12, which enters a rotary union 14, proceeds through an internal space 16 of at least one blade 18 and is discharged through nozzle 20. The refrigerant fluid, which may be a cryogen fluid such as liquid carbon dioxide (CO2), is delivered from a remote source (not shown) through a pipe 11 or conduit into the rotary union 14, the pipe 11 or conduit being in communication with the internal space 16 such that there is a flow of refrigerant fluid from the remote source through the pipe 11 or conduit and rotary union 14 into the internal space 16 of blade 18 or blades.
The blades 18 are engaged with the rotary union 14 such that the rotary union 14 remains stationary as the blades 18 rotate. The internal space 16 may operate as a conduit for the refrigerant fluid 12, or the internal space 16 may be sized and shaped to receive a conduit extending along the fan blade as shown. Such a conduit would be in fluid communication with the pipe 11. The nozzle 20 may be mounted to a tip of the blade 18 and is in fluid communication with the internal space 16 or conduit therein. The nozzle 20 may be a supersonic nozzle and may have its discharge orifice at a right angle with respect to the blade 18. Discharge speeds from the supersonic nozzle may be up to about Mach 3.
As the refrigerant fluid 12 enters the blade 18, it expands and performs work as it moves toward the nozzle 20, forcing the blade 18 to rotate. The nozzle 20 also increases the velocity of the exiting refrigerant fluid and further serves to increase the efficiency of the refrigerator. The refrigerant fluid 12, which may be CO2, can be either a liquid or a gas as it passes through the blade 18, but upon discharge from the nozzle 20 it flashes into a solid and a gas. In certain embodiments, the fan for refrigerant fluid may additionally comprise one or more blades which do not have the internal spaces 16 therein.
The blades 18 may be operationally connected to or engaged with an electrical generator (not shown) which will function as a mechanical break and will convert the kinetic energy of the rotating blades into electrical energy. Potential energy of the cryogenic fluid at high pressure is converted into kinetic energy upon expansion of the fluid for rotation or movement of the blades 18. The kinetic energy of the moving blades 18 is transferred out of the apparatus or process. As a result, the cryogenic fluid becomes subcooled. Mechanical work is done by the fluid, thereby reducing it's energy state. The blades, as part of a rotor assembly, may be connected to the electrical generator, via a shaft and gear box. In certain embodiments, the shaft may be a low speed shaft that turns a gear which is adapted to turn a second gear connected to a high-speed shaft at a much faster speed than the low-speed shaft turns. The high-speed shaft turns a generator which is housed within a structure which provides a magnetic field. As the generator turns, the magnetic field is altered, thereby generating electricity.
Referring still to
Accordingly, electrical energy extracted from the rotating blades 18 by the electrical generator can be used directly or can be stored in energy storage devices such as capacitors or batteries to provide electrical energy to the ancillary systems of the refrigeration apparatus or for other purposes. Under testing and load conditions, a single fan 10 has been shown to generate in excess of 1.5 horsepower. As a result, while the fans do not require electrical energy in order to function, they can provide electrical energy for other components of the refrigeration apparatus which is converted from the potential energy of the refrigerant fluid. Thus, a refrigeration apparatus which is powered only by the refrigerant fluid may be provided.
For example, but without limitation, the electrical energy generated by the electrical generator may be used to power exhaust fans, conveyor motors, control panels, or other devices associated with the refrigeration apparatus. The electrical energy may be used to power devices or apparatus which are not part of the refrigeration apparatus, or such energy may be sent to the local electrical power grid.
Referring now to
As the CO2 refrigerant fluid 32 enters the disk 38, it expands and performs work as it moves toward the nozzles 40. The nozzles 40 may increase the velocity of the exiting refrigerant fluid and further serve to increase the efficiency of the refrigeration. apparatus. The CO2 refrigerant fluid 32 can be either a liquid or a gas as it passes through the disk 38, but upon discharge from the nozzles 40 it flashes into a solid and a gas. As the CO2 refrigerant fluid is discharged from the nozzles 40 at a substantially tangential angle, the disk 38 is caused to rotate. At least one of the nozzles 40 is used to rotate the disk 38. The regions A-C show similar energy transfer as that discussed above with respect to FIGS. l-2. Work is performed in region B to rotate the disk 38, such that the CO2 is exhausted from the region C at its lowest pressure and lowest energy state.
An electrical generator (not shown) may be disposed between the rotary union 34 and the disk 38, actuated by the rotation of the disk 38 as a rotor for the generator. The disk 38 may be operationally connected to or engaged with an electrical generator (not shown) which will function as a mechanical brake and will convert the kinetic energy of the rotating disk 38 into electrical energy. The disk 38, as part of a rotor assembly, may be connected to the electrical generator, in a manner as discussed with respect to the blades 18 in the embodiments of
Referring now to
The nozzle(s) of the rotating element 58 also increase the velocity of the exiting refrigerant fluid and further serve to increase the efficiency of the refrigerator. The CO2 refrigerant fluid 52 can be either a liquid or a gas as it passes through the rotating element 58, but upon discharge from the rotating element 58 it flashes into a solid and a gas. As the CO2 refrigerant fluid is discharged 62 from the rotating element 58 at a substantially tangential angle with respect to the, body of the rotating nozzle 59, the rotating element 58 is caused to rotate. The regions A-C show similar energy transfer as that discussed above with respect to
An electrical generator may be disposed between the rotary union 54 and the rotating element 58, actuated by the rotation of the rotating element 58 as a rotor for the generator. The rotating element 58 may be operationally connected to or engaged with an electrical generator (not shown) which will function as a mechanical brake and will convert the kinetic energy of the rotating element 58 into electrical energy. The rotating element 58, as part of a rotor assembly, may be connected to the electrical generator, as discussed with respect to the embodiments of
The tunnel freezer 100 includes a housing 101 in which a freezing chamber 122 is provided and through which a conveyor 114 powered by a conveyor motor 116 moves to transfer products such as food products through the freezing chamber 122 of the tunnel freezer 100. At least one fan 106 is mounted in the freezing chamber 122, Each of the rotary unions 104 for a respective fan 106 is in fluid communication with a refrigerant conduit 124 which carries the refrigerant fluid 102, such as liquid CO2 from a remote source (not shown). Each of the rotary couplings 104 is in mechanical communication with an electrical generator 108 which harvests the kinetic energy of the rotating fan 106 and converts it into electrical energy. The electrical generators 108 are in electrical communication with an electrical conduit 110 which may transfer the electrical energy, shown generally by arrows 111, generated by the electrical generators 108 to an electricity storage means 112, such as a battery. The electrical energy stored in the storage means 112 may be used to provide electrical energy, shown generally by arrows 113, to an exhaust fan 120, the conveyor motor 116 as shown generally by arrow 115, and/or a control panel 118 as shown generally by arrows 117. The control panel 118 may monitor the operation of the tunnel freezer 100, including the electricity generated by the fan/ generator assemblies and the electrical load stored by the storage means 112.
Another apparatus for converting the high energy state of the liquid cryogen (CO2) to a lower energy state for refrigeration is shown in
The turbine apparatus 200 includes a housing 210 having an internal space 212 therein arid in Which is mounted an impeller 214 for rotational movement within the space. The impeller 214 includes at least one and for most applications a plurality of vanes 216, with the impeller 214 rotating about a shaft 218 disposed in and extending through the housing 210. Bearings 224 support the shaft 218 for its rotational movement and transfer of such action to the impeller 214.
The housing 210 includes an inlet 220 in communication with the internal space 212, and an outlet 222 also in communication with the internal space.
Referring in particular to
An inlet pipe 233 is in fluid communication with a source (not shown) of liquid CO2 and the inlet 220 of the apparatus 200, while an outlet pipe 234 is in fluid communication with the outlet 222 of the apparatus. The outlet pipe 234 extends through the freezer roof 226 into a freezer chamber 238. The outlet pipe 234 is in fluid communication with a manifold 236 which has at least one or a plurality of nozzles 240 to provide a cryogen spray or CO2 snow.
In operation, liquid cryogen, such as CO2, is introduced into the turbine apparatus 200. The liquid CO2 enters the turbine region “A” at a high energy state. As it engages the blades of the turbine it enters the region “B”, and in this region work is done by the refrigerant and energy is transferred out of the device. Referring again to the embodiment at
As mentioned above, a single fan 10 has been shown to generate in excess of 1.5 horsepower (HP). The 1.5 HP is equivalent to 3818 BTU/hr. With a flow rate of 166 lbs. of CO2 per hour being passed through the apparatus during the test, CO2 liquid at this flow rate will normally result in a 166 lbs./hr—121 BTU/lbs=20,086 BTU/hr. The amount of energy removed in the process to power the fan is 3818 BTU/hr (1.5 horsepower (HP)=3818 btu/hr). This energy is removed from the cryogenic fluid (CO2), thereby now producing 23,904 BTU/hr of refrigeration versus the 20,086 BTU/hr without the fan for a total increase of 19 percent in refrigeration, with the added benefit of no electricity required to power the fan.
For all the inventive embodiments of
in effect, the present inventive embodiments provide an energy conversion apparatus (for example, fan, turbine) for an intermittent step of doing mechanical work with high pressure cryogen before same is injected into a freezer chamber 238. The power generated from the generator 230 can be used to power ancillary equipment or other equipment of the freezer. The high energy state of the liquid cryogen is reduced prior to it being introduced into the freezing chamber 238 at which point the liquid cryogen now produces an increased amount of CO2 snow which is in a phase that provides a higher heat transfer rate for any product, such as food products, when the snow comes in contact with. in the freezer. The turbine apparatus 200 may be used with or substituted for the rotary unions 104, fans 106 and generator 108 of the tunnel freezer 100 in
The refrigerant fluid referred to in the above tunnel freezer and fan embodiments may be CO2 which may be either in liquid or gas form, or a mixture thereof.
When liquid CO2 is used as the refrigerant fluid, the fan and disk embodiments discussed above may subcool the liquid CO2 before it is discharged from the fan. This subcooling results in a reduction in the energy state of the CO2, which increases the solid to gas proportion of the CO2 when it is discharged from the nozzle(s) of the fan or disk.
It has been shown that the solid proportion of CO2 discharged from the present fan embodiments may be from about 52% to about 57%, whereas traditional, stationary injection devices typically realize a solid proportion of from about 47% to about 48%. Without wishing to be limited by theory, it is believed that when using traditional, stationary injection devices, much of the potential energy contained in the liquid CO2 is converted into heat, which provides 47-48% solid CO2 upon flashing into a lower pressure volume. When utilizing the present Jim embodiments, energy is removed from the liquid CO2 in order to perform work to rotate the devices. This results in subcooling, of the liquid CO2 which is accompanied by a decrease in temperature. Because the temperature of tie liquid CO2 is lower, about 52-57% solid CO2 is produced upon flashing. Additionally, the energy produced by the rotation of the present fans may be utilized for other purposes. An increased proportion of solid created by the present fans increases the efficiency of a refrigeration system in which the fans are used, because the solid CO2 provides better heat transfer than does the gaseous CO2.
Therefore, a self powered refrigeration apparatus is provided, comprising a refrigeration chamber and at least one fan, comprising at least one blade having an internal space therein through which a refrigerant fluid passes; at least one nozzle in fluid communication with the internal space within each of the at least one blade, wherein the at least one nozzle discharges the refrigerant fluid into the refrigeration chamber at a velocity sufficient to rotate the at least one blade; and an electrical generator operationally connected to the plurality of blades. Alternatively, the fan may comprise a plurality of blades.
Also provided is a self-powered refrigeration apparatus, comprising a refrigeration chamber and at least one snow injection device, comprising a disk having an internal space therein through which a CO2 refrigerant fluid passes; at least one nozzle in communication with the internal space within the disk which discharges the CO2 refrigerant fluid from the disk at a velocity sufficient to rotate the disk, the at least one nozzle being adapted to flash the CO2 refrigerant fluid into gas and solid phases and eject the gas and solid phases into the refrigeration chamber; and an electrical generator operationally connected to the disk. Alternatively, the snow injection device may comprise a plurality of nozzles.
It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention. All such variations and modifications are intended to be included within the present embodiments as described and claimed herein. It should be understood that the embodiments described above are not only in the alternative, but may be combined.
Number | Date | Country | |
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Parent | 12617156 | Nov 2009 | US |
Child | 14107263 | US |