VERY LOW TEMPERATURE REFRIGERATION SYSTEM WITH FAST OPERATION CYCLE

Abstract

Methods for shortening the cycle time in each of the defrost, standby and cool modes of operation of a very low temperature refrigeration system. These methods can be used alone or in combination with one or more of each of the other techniques, including, for example, in a single very low temperature refrigeration system, to provide a fast total cycle of one, two or all three of the defrost, standby and cool modes.

Description

BACKGROUND

Very low temperature refrigeration systems are used for a variety of different purposes, including removing water vapor and creating high vacuum environments for the coating industry. Such systems typically operate in three different modes: standby mode, in which the unit is recovering or is in readiness; cool mode, in which the system is cooling to serve the process or application need; and defrost mode, in which the system is regenerating the cryocoil. For a typical batch coating process, the system runs in cycles of these three modes. However, different applications have different constraints on how much time can be spent in each mode. Some applications require short time in the defrost mode, and can tolerate a long time in the standby mode after the defrost mode completes. Some applications require a fast cool down to a target supply temperature (for example, −110° C. or −120° C.), so that the coating process can start earlier. Some applications require a fast total cycle of defrost/standby/cool, which can put demands on shortening all three operating modes.

The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background.

SUMMARY

Methods for shortening the cycle time in each of the defrost, standby and cool modes of operation of a very low temperature refrigeration system are taught herein. These methods can be used alone or in combination with one or more of each of the other techniques, including, for example, in a single very low temperature refrigeration system, to provide a fast total cycle of one, two or all three of the defrost, standby and cool modes.

A method of limiting peak operating pressure during startup of a very low temperature refrigeration system having a compressor, a plurality of heat exchangers, an expander and an evaporator comprises, during startup of the compressor, opening a defrost valve in a hot gas defrost circuit to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and the expander and to an evaporator inlet from which the refrigerant flows to the evaporator, thereby accommodating a volume of the refrigerant in the evaporator, to limit an initial increase in pressure of the refrigerant during the startup of the compressor. Subsequently the defrost valve is closed so that flow of the refrigerant proceeds through the high pressure side of the plurality of heat exchangers and the expander to the evaporator.

The refrigerant may be charged into the system at a refrigerant pressure that would create a peak pressure of the refrigerant that would exceed a design pressure of the very low temperature refrigeration system during startup of the compressor absent the opening of the defrost valve. The refrigerant flow volume of the evaporator may be greater than about 10 percent of a refrigerant system volume of the very low temperature refrigeration system. The refrigerant may comprise a mixture of a plurality of different refrigerant components. The mixture may comprise argon, R-14, R-23, R-125 and R-245fa. The refrigerant may be charged into the system such that the system has a balance pressure of between about 230 psig and about 300 psig. Subsequently closing the defrost valve may be performed after at least about 3 seconds from the startup of the compressor; and may be performed before at least about 6 seconds from the startup of the compressor. The method may comprise entering a standby mode of the system upon the subsequently closing the defrost valve, the standby mode comprising closing a cool valve to prevent flow of refrigerant from the high pressure side of the plurality of heat exchangers to the evaporator, while permitting flow of refrigerant through the high pressure side of the plurality of heat exchangers and a low pressure side of the plurality of heat exchangers. During the bypass flow of the refrigerant, a temperature of the refrigerant may be greater than about 25° C. The hot gas defrost circuit may bypass the refrigerant from a high pressure supply line of the compressor to the evaporator inlet from which the refrigerant flows to an evaporator.

A method of reducing time spent in a defrost mode of operation of a very low temperature refrigeration system comprises, in a defrost mode of operation of the system, (i) opening a defrost valve in a hot gas defrost circuit to bypass flow of a refrigerant around a high pressure side of a plurality of heat exchangers and to an evaporator inlet from which the refrigerant flows to an evaporator, to effect warming of the evaporator, and (ii) while opening the defrost valve, closing a cool valve so that the refrigerant does not flow from the high pressure side to the evaporator. Based on an input control signal, a value of a stored defrost completion set point temperature of a return temperature sensor on a low pressure side of the evaporator is set. During the warming of the evaporator, upon the return temperature sensor on the low pressure side of the evaporator reaching the stored defrost completion set point temperature of the return temperature sensor, the defrost valve is closed to prevent the refrigerant flowing to the evaporator.

The stored defrost completion set point temperature of the return temperature sensor may be about 0° C. or lower, depending on the application. The return temperature sensor may comprise a thermocouple on the low pressure side of the evaporator. The method may comprise closing the defrost valve when a controller receives a temperature control signal from the return temperature sensor that is at least as warm as the stored defrost completion set point temperature of the return temperature sensor, the stored defrost completion set point temperature being stored in a memory of the controller.

A method of reducing recovery time after defrost of a very low temperature refrigeration system comprises, based on an input control signal, setting a value of a stored bypass control set point temperature of a return temperature sensor on a low pressure side of the evaporator. Upon a return temperature sensor on a low pressure side of the evaporator warming to be at or above the stored bypass control set point temperature of the return temperature sensor, the method comprises (i) closing a return valve to prevent refrigerant flow through a low pressure side of a plurality of heat exchangers, and (ii) opening a bypass valve to bypass flow of the refrigerant around the low pressure side of the plurality of heat exchangers and to a suction line that enters a low pressure side of a compressor; and warming the bypassed flow of the refrigerant in the suction line before it enters the low pressure side of a compressor.

Warming the bypassed flow of the refrigerant in the suction line may comprise warming the bypassed flow using a heat exchanger that exchanges heat between the suction line and a high pressure side of the plurality of heat exchangers. Warming the bypassed flow of the refrigerant in the suction line may comprise using a heater to heat the suction line. The stored bypass control set point temperature of the return temperature sensor may be less than the compressor's rated input flow temperature, for example, less than about −40° C. For example, the stored bypass control set point temperature of the return temperature sensor may be between about −40° C. and about −70° C.

A method of reducing a cool down time of a very low temperature refrigeration system comprises, during a cooling mode of operation of the system, flowing refrigerant through a high pressure side of a plurality of heat exchangers, through a flow metering device and a cool valve with which the flow metering device is in a series flow connection to an inlet of an evaporator, through the evaporator and through a low pressure side of the plurality of heat exchangers. Upon a discharge pressure of a compressor of the system being at least as high as a stored set point of a maximum discharge pressure during the cooling mode of operation, an unload valve is opened that permits refrigerant flow to bypass around the flow metering device and to the cool valve, until the discharge pressure reduces to be less than the stored set point of the maximum discharge pressure.

An inlet of the evaporator or an outlet of the evaporator may be at a temperature of less than about −110° C. The stored set point of the maximum discharge pressure may be less than an activation pressure of a buffer solenoid valve of the system.

A very low temperature refrigeration system comprises a compressor, a plurality of heat exchangers, an expander, and a controller comprising a processor and a memory. The controller is configured to, (i) during startup of the compressor, control a defrost valve in a hot gas defrost circuit to open to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and the expander and to an evaporator inlet from which the refrigerant flows to an evaporator, thereby accommodating a volume of the refrigerant in the evaporator to limit an initial increase in pressure of the refrigerant during the startup of the compressor; and (ii) to subsequently control the defrost valve to close so that flow of the refrigerant proceeds through the high pressure side of the plurality of heat exchangers and the expander to the evaporator.

Another very low temperature refrigeration system comprises a compressor, a plurality of heat exchangers, an expander; and a controller comprising a processor and a memory. The controller is configured to, in a defrost mode of operation of the system, (i) control a defrost valve in a hot gas defrost circuit to open to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and to an evaporator inlet from which the refrigerant flows to an evaporator, to effect warming of the evaporator, and (ii) while controlling the defrost valve to open, control a cool valve to close so that the refrigerant does not flow from the high pressure side to the evaporator. The controller is further configured to, (i) based on an input control signal, set a value of a stored defrost completion set point temperature of a return temperature sensor on a low pressure side of the evaporator; and (ii) during the warming of the evaporator, upon the return temperature sensor on the low pressure side of the evaporator reaching the stored defrost completion set point temperature of the return temperature sensor, control the defrost valve to close to prevent the refrigerant flowing to the evaporator.

Another very low temperature system comprises a compressor, a plurality of heat exchangers, an expander, and a controller comprising a processor and a memory. The controller is configured to, based on an input control signal, set a value of a stored bypass control set point temperature of a return temperature sensor on a low pressure side of an evaporator. The controller is further configured to, upon a return temperature sensor on a low pressure side of the evaporator warming to be at or above the stored bypass control set point temperature of the return temperature sensor, (i) control a return valve to close to prevent refrigerant flow through a low pressure side of the plurality of heat exchangers, and (ii) control a bypass valve to open to bypass flow of the refrigerant around the low pressure side of the plurality of heat exchangers and to a suction line that enters a low pressure side of the compressor. The system is configured to warm the bypassed flow of the refrigerant in the suction line before it enters the low pressure side of the compressor.

The system may comprise a heat exchanger that exchanges heat between the suction line and a high pressure side of the plurality of heat exchangers. The system may comprise a heater to heat the suction line.

Another very low temperature refrigeration system comprises a compressor, a plurality of heat exchangers, an expander, a flow metering device and a cool valve with which the flow metering device is in a series flow connection to an inlet of an evaporator, and a controller comprising a processor and a memory. The controller is configured to, upon a discharge pressure of a compressor of the system being at least as high as a stored set point of a maximum discharge pressure during the cooling mode of operation, control an unload valve to open to permits refrigerant flow to bypass around the flow metering device and to the cool valve, until the discharge pressure reduces to be less than the stored set point of the maximum discharge pressure.

Systems may be configured to implement any or all of the methods taught herein.

The summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particular description of example embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments.

FIG. 1 is a schematic diagram of a very low temperature refrigeration system.

FIG. 2 is a graph showing defrost time for a system with increased flow through capillary tubes.

FIG. 3 is a graph of test data showing the reduction of defrost time with an increased refrigerant charge, using a technique of limiting the peak operating pressure during startup.

FIG. 4 is a graph showing improved recovery time of a very low temperature refrigeration system using different return valve set points.

FIG. 5 is a simplified schematic block diagram of a controller.

DETAILED DESCRIPTION

A description of example embodiments follows.

Methods for shortening the cycle time in each of the defrost, standby and cool modes of operation of a very low temperature refrigeration system are taught herein. As used herein, “very low temperature” means the temperature range from 90 K to 203 K. The methods can be used alone or in combination with one or more of each of the other techniques, including, for example, in a single very low temperature refrigeration system, to provide a fast total cycle of one, two or all three of the defrost, standby and cool modes.

FIG. 1 is a schematic diagram of a very low temperature refrigeration system. The system can, for example, be an auto-cascade refrigeration system 100. Such systems use a mixture of two or more refrigerants in which the difference between the normal boiling points from the warmest boiling component to the coldest boiling component is at least 50 K or 100 K or 150 K or 200 K. Such systems can include a refrigeration compressor 101, a condenser 102 or desuperheater heat exchanger for rejecting heat, a series of two or more heat exchangers 103 (also referred to herein as a “heat exchanger array” or “refrigeration process”), one or more expanders 104, such as a throttle or flow metering device 104, and an evaporator 105 for heat removal from an application process. In addition, such systems can include phase separators 106, 107 which are positioned on the discharge side between heat exchangers and remove liquid phase refrigerant for use in an internal recycle loop. Such systems can have the ability to operate in different operating modes, including cool mode in which the evaporator 105 is cooled, defrost mode in which hot gas from the compressor 101 is supplied to the evaporator 105, and standby mode in which neither cold refrigerant nor hot refrigerant is delivered to the evaporator 105. Flow through various flow loops within the system can be controlled via a series of capillary tubes 108, 109, 110 and 111 which restrict flow and allow for expansion and thus cooling of refrigerant, and/or via on/off solenoid valves, such as cool solenoid valve 112, bypass solenoid valve 113, return solenoid valve 114, buffer solenoid valve 116, defrost solenoid valve 123, and unload solenoid valve 130. In the embodiment shown in FIG. 1, capillary tubes 108, 109, 110 and 111 are not associated with any solenoid valves, while capillary tube 104 is in parallel with unload solenoid valve 130 and in series with cool solenoid valve 112. Other arrangements of capillary tubes and solenoid valves can be used. The capillary tubes and/or the solenoid valves can be replaced with a proportional valve such as a thermal expansion valve, or a pressure actuated or stepper motor actuated valve. Such systems can also contain an expansion tank 115 which is used to manage high evaporation and expansion of the liquefied refrigerants once the system is turned off and warmed to room temperature. Further, such systems with expansion tanks 115 can also have a buffer solenoid valve 116 which allows high pressure gas to be directed to the expansion tank 115. Such a buffer solenoid valve 116 allows the amount of refrigerant gas in circulation to be reduced, which in turn reduces compressor discharge and suction pressures. For example, any of the methods can be used that are disclosed in U.S. Pat. No. 6,574,978 B2 of Flynn et al., the entire disclosure of which is hereby incorporated herein by reference. Systems as described in this patent enable additional operating modes such as controlled cool down and warm up processes, and extended operation in a hot gas flow mode, or bakeout mode, in which a portion of the hot gas exiting the compressor is continuously circulated from the compressor to the evaporator coil and then back to the compressor, while another portion of the refrigerant exiting the compressor continuously flows through the condenser and then the heat exchanger array and then returns to the compressor.

The buffer solenoid valve 116 is a connection between the discharge (or high pressure) side of the unit and one or more expansion tanks 115. When a high pressure condition exists the controller opens this buffer solenoid valve 116 and allows a portion of the refrigerant to be stored in the expansion tanks 115, thereby reducing the discharge pressure. This can prevent an excessive discharge pressure fault condition.

A hot gas defrost system 121 of the very low temperature system can be used to achieve warming of the evaporator 105. The hot gas defrost system 121 includes a defrost hand shut-off valve 122 and a defrost solenoid valve 123, and directs hot gas from a high pressure supply line 192 of the compressor 101 to the evaporator inlet 124 of the evaporator feed line which sequentially flows through the feed line, the evaporator 105 (also known as cryocoil or cryosurface), the return line 125 and then through the low pressure side of the heat exchanger array 103. There is an oil separator 138 in the high pressure supply line 192 downstream of compressor 101 for separating oil from the flow and returning it to the compressor 101.

The possibility of freezeout of refrigerant that is discharged from the compressor, or another warmer point in the system, and that is being directed to a colder point in the system, can be addressed. Such refrigerant that is being discharged from the compressor may have a higher risk of freezeout because it has not yet passed through the phase separators in the system, and therefore has a different composition than later in the refrigeration process, and thus may have a warmer freezing point and be more likely to freezeout when directed to a colder point in the system. To prevent such freezeout, a freezeout prevention circuit or temperature control circuit can be used, which uses a controlled bypass flow to warm the lowest temperature refrigerant in the system, to warm the stack sufficiently that the refrigerant discharged from the compressor (or another warmer point) does not freezeout when redirected to a colder point in the system. For example, any of the freezeout prevention circuits or temperature control circuits can be used that are disclosed in U.S. Pat. No. 7,478,540 B2 of Flynn et al., the entire disclosure of which is hereby incorporated herein by reference. In the example in FIG. 1, a freezeout prevention valve 131 directs refrigerant that is exiting phase separator 107 to the low pressure inlet 117 of the subcooler 118, which is positioned closer to the evaporator than the next-coldest heat exchanger 119 in the heat exchanger array 103.

The refrigeration system can include a series of internal return paths 108, 109, 110 from the high pressure side of the system to the low pressure side in addition to the return path via the evaporator 105. Typically, the internal return paths 108, 109, 110 are throttle devices. Example throttle devices are capillary tubes and thermal expansion valves. In other scenarios, turbo expanders or other means to reduce the pressure of the refrigerant are used. In a typical defrost warming process the internal throttle devices 108, 109, 110 are allowed to have flow. In other scenarios their flow rate is stopped or controlled. In one example, capillary tubes can be used for the internal throttle devices 108, 109, 110 with no upstream valves. As a result, these throttle devices continue to permit flow during the defrost warming process.

In addition, in the embodiment of FIG. 1, there is also a low pressure side bypass circuit, which includes a bypass solenoid valve 113. This bypasses refrigerant around the low pressure side of the heat exchanger array 103 when the temperature of refrigerant returning from the evaporator 105 is at or above a stored temperature that can be set based on an input control signal. Such a temperature of returning refrigerant can be measured at the location indicated by Tc in FIG. 1, at the low pressure side of the evaporator 105, and can be detected by a temperature sensor, such as, for example, a thermocouple in that location. A sensed temperature signal from the thermocouple can, for example, be provided to a controller, which can compare the sensed temperature signal with the stored temperature based on the input control signal. When the sensed return temperature is at or above the stored temperature based on the input control signal, a return solenoid valve 114 can be shut off by the controller, while the bypass solenoid valve 113 is opened. This permits refrigerant to be bypassed around the low pressure side of the array of heat exchangers 103, in order to prevent overloading the heat exchanger array 103 with returning refrigerant that is too warm.

The system of the embodiment of FIG. 1 also includes a suction line heat exchanger 132, the operation of which will be described further, below. It is connected with its high pressure side in series fluid connection with the outlet 120 of the condenser 102, and with its low pressure side in series fluid connection with the low pressure side of the heat exchanger array 103.

The system of FIG. 1 also includes a control module or controller 180, which is described further, below, with reference to FIG. 5.

In one embodiment, a defrost mode of operation of the system 100 is made faster by increasing the flow through capillary tubes in the system, such as 108, 109, 110 and 104, by using larger diameter and/or shorter length capillary tubes than would otherwise be used, and keeping approximately the same flow ratio for any two of the capillary tubes. For example, an existing set of capillary tubes can be duplicated and connected in parallel. This decreases the system's flow resistance, and increases the maximum suction pressure from a range of about 40-50 psig to a range of about 50-70 psig during the defrost mode of operation. FIG. 2 is a graph showing defrost time for a system with increase flow through capillary tubes, here, by having duplicated capillary tubes. Defrost time was reduced by more than 15%, although with the tradeoff of reducing cooling capacity somewhat. In an alternative embodiment, capillary tubes such as 108, 109, 110 and 104 can be adjustable flow metering devices (such as proportional valves or stepper motor expansion valves) instead of capillary tubes, and flow increase can be achieved by adjusting the valve opening.

In another embodiment, a method is provided of limiting the peak operating pressure during startup of the very low temperature system. One method of increasing the speed of defrost of the system is to increase the quantity of refrigerant charged to the system. However, with more charge mass, the system will have a higher balance pressure (for example, between about 230 and about 300 psig), and the compressor may have difficulty starting because the peak pressure will exceed the design pressure limit, which results in the system shutting off automatically. In order to avoid this, a method is used that limits the peak operating pressure during startup. In this method, the system is started in defrost mode, so that the defrost refrigerant line and evaporator 105 can be used as an additional volume to expand the gas and reduce the peak pressure during startup. This peak pressure during startup typically lasts between about 3 seconds and about 5 seconds. Once the system overcomes the peak pressure, the system can switch back to the standby mode of operation. FIG. 3 is a graph of test data showing the reduction of defrost time with an increased refrigerant charge, using such a technique of limiting the peak operating pressure during startup. Here, the defrost time was reduced by more than 20%. When the increased refrigerant charge is used, a freezeout prevention circuit (as described above) can be used to prevent freezeout.

As used herein the “balance pressure” means a pressure achieved when the high pressure and low pressure of the system are equal, or approximately equal, for example when the stack is warmed such that the average heat exchanger array temperature is at least as warm as a temperature from the group consisting of −5° C., 0° C., 5° C., 10° C., 15° C., 20° C., 25° C., 30° C., 35° C., 40° C.; or for example when the heat exchanger array is warmed such that the range of temperatures in the stack is from at least −5° C. up to 40° C., or is a smaller range within the range of −5° C. to 40° C.

With reference to FIG. 1, by way of illustration, in one embodiment, a method of limiting peak operating pressure during startup of a very low temperature refrigeration system 100 comprises, during startup of a compressor 101, opening a defrost valve 123 in a hot gas defrost circuit 121 to bypass flow of a refrigerant around a refrigerant circuit of a high pressure side of a plurality of heat exchangers 103 and to an evaporator inlet 124 from which the refrigerant flows to an evaporator 105, thereby accommodating a volume of the refrigerant in the evaporator 105, to limit an initial increase in pressure of the refrigerant during the startup of the compressor 101. Subsequently the defrost valve 123 is closed so that flow of the refrigerant proceeds through the refrigerant circuit of the high pressure side of the plurality of heat exchangers 103. The refrigerant can be charged into the system 100 at a refrigerant pressure that would cause peak pressure to exceed a design pressure of the very low temperature refrigeration system during startup of the compressor absent the opening of the defrost valve; for example, the refrigerant can be charged to reach a pressure of about 230 to about 300 psig, which would normally create peak pressures higher than the system's design pressure during startup. The refrigerant flow volume of the evaporator 105 can, for example, be greater than about 10 percent of a refrigerant system volume of the entire very low temperature refrigeration system 100, or even greater than about 15 percent. The volume increase will depend on the size of the evaporator 105 in the system. The refrigerant can be a mixture of a plurality of different refrigerant components, and can, for example, consist of argon, R-14, R-23, R-125 and R-245fa.

The refrigerant can be charged into the system such that the system has a balance pressure of between about 230 psig and about 300 psig. Subsequently closing the defrost valve 123 can be performed after at least about 3 seconds from the startup of the compressor 101; and can be performed before at least about 6 seconds from the startup of the compressor. The method can comprise entering a standby mode of the system upon the subsequently closing the defrost valve 123. The standby mode comprises closing the cool valve 112 that permits flow of refrigerant from the refrigerant circuit of the high pressure side of the plurality of heat exchangers 103 to the evaporator 105, while permitting flow of refrigerant through the high pressure side of the plurality of heat exchangers and a low pressure side of the plurality of heat exchangers. During the bypass flow of the refrigerant, a temperature of the refrigerant can, for example, be greater than about 25° C. The hot gas defrost circuit can, for example, bypass the refrigerant from a high pressure supply line 192 of the compressor 101 to the evaporator inlet 124 from which the refrigerant flows to the evaporator 105.

A defrost completion set point can be set to 0° C. or lower, which differs from a conventional fixed setting of 20° C. This provides not only a fast defrost, but also a fast recovery, because less heat is absorbed in the refrigerant supply line and the application cryocoil. In applications where the chamber containing the cryocoil is evacuated during defrost, the chamber pressure can stay below the triple point of water. If so, the ice on the cryocoil may sublime to vapor directly at a lower temperature, hence negating the need for a higher defrost temperature setting.

By way of illustration, with reference to FIG. 1, an embodiment of a method of reducing time spent in a defrost mode of operation of a very low temperature refrigeration system 100 comprises, in a defrost mode of operation of the system, (i) opening a defrost valve 123 in a hot gas defrost circuit 121 to bypass flow of a refrigerant around a refrigerant circuit of a high pressure side of a plurality of heat exchangers 103 and to the evaporator inlet 124 from which the refrigerant flows to an evaporator 105, to effect warming of the evaporator 105, and (ii) while opening the defrost valve 123, closing a cool valve 112 so that the refrigerant does not flow from the refrigerant circuit of the high pressure side to the evaporator 105. A value of a stored defrost completion set point temperature of a return temperature sensor 133 on a low pressure side of the evaporator 105 is set based on an input control signal. During the warming of the evaporator 105, upon the return temperature sensor 133 on the low pressure side of the evaporator 105 reaching the stored defrost completion set point temperature of the return temperature sensor 133, the defrost valve 123 is closed to prevent the refrigerant flowing to the evaporator 105. The stored defrost completion set point temperature of the return temperature sensor 133 can be about 0° C. or lower. The return temperature sensor 133 can be, for example, a thermocouple on the low pressure side of the evaporator 105. The method can include closing the defrost valve 123 when a controller receives a temperature control signal from the return temperature sensor 133 that is at least as warm as the stored defrost completion set point temperature of the return temperature sensor 133, the stored defrost completion set point temperature being stored in a memory of the controller.

A return solenoid valve 114 is used to control flow through a return side of the heat exchanger array 103. There is a return hand shut off valve 136 in the return side line to the heat exchanger array 103 and a bypass hand shut off valve 137 in the low pressure bypass line. The return valve 114 and low pressure bypass valve 113 are controlled by a control scheme that is based on the temperature Tc in the return location. Only one of the valves 114 and 113 is activated, depending on how the temperature Tc compares with the set point temperature stored in the controller. For example, when the temperature Tc is at or higher than the set point temperature, the bypass valve 113 is opened and the return valve 114 is closed, so that flow is bypassed through the low pressure bypass around the low pressure side of the heat exchanger array 103; but when the temperature Tc is lower than the set point temperature, then the return valve 114 is opened and the bypass valve 113 is closed, so that flow proceeds through the low pressure side of the heat exchanger array 103. In addition, the set point range of the control temperature for the return valve 114 and bypass valve 113 can be set lower than a previous conventional limit of −40° C., which was previously used because it represents the lower operating limit of compressor 101. FIG. 4 is a graph showing improved recovery time of a very low temperature refrigeration system using different return valve set points. To be able to set the return valve set point lower than −40° C., a suction line heat exchanger 132 is added between the discharge (high pressure) and suction (low pressure) refrigerant lines in the heat exchanger array 103. The suction line heat exchanger 132 uses refrigerant at the liquid line temperature (for example, between about 14° C. and about 40° C.) to warm up the suction temperature to protect the compressor, so that the setpoint can be set lower than −40° C. At the same time, it lowers the liquid line temperature and helps the system to recover to be colder in the standby mode of operation. It also improves the overall system efficiency due to the use of internal heat transfer. In another embodiment, the function of the suction line heat exchanger 132 can be performed using, or supplemented with, a heater, such as an electrical resistance heater. Using a heater such as an electrical resistance heater can, for example, permit enhanced control of the temperature of flow to the compressor.

By way of illustration, with reference to FIG. 1, an embodiment of a method of reducing recovery time after defrost of a very low temperature refrigeration system 100 comprises, upon a return temperature sensor 133 on a low pressure side of the evaporator 105 warming to be at or above a stored bypass control set point temperature of the return temperature sensor 133, (i) closing a return valve 114 to prevent refrigerant flow through a refrigerant circuit on a low pressure side of a plurality of heat exchangers 103, and (ii) opening a bypass valve 113 to bypass flow of the refrigerant around the refrigerant circuit on the low pressure side of the plurality of heat exchangers 103 and to a suction line 134 that enters a low pressure side of a compressor 101; and warming the bypassed flow of the refrigerant in the suction line 134 before it enters the low pressure side of the compressor 101. The bypassed flow of the refrigerant in the suction line 134 can be warmed using a heat exchanger 132 that exchanges heat between the suction line 134 and a refrigerant circuit on a high pressure side of the plurality of heat exchangers. Alternatively, a heater can be used to heat the suction line. The stored bypass control set point temperature of the return temperature sensor 133 can be less than about −40° C. For example, the stored bypass control set point temperature of the return temperature sensor 133 can be between about −40° C. and about −50° C., between about −50° and about −60° C., or between about −60° about −70° C.

A cool down time of a very low temperature system can be reduced. Typically, a coating application requires a certain target temperature, such as from about −110° C. to about −120° C. at the evaporator in (124) or evaporator out, based on the maximum water vapor pressure permissible. The time required to achieve this target process temperature is an important factor in the throughput of the coating process. During cool down, it is often observed that the buffer solenoid valve 116 is triggered due to high discharge pressure. When this valve opens, some of the high pressure gas is diverted to an expansion tank 115, and this flow diversion, however temporary, can result in a delay in the cool down time, due to a decrease in refrigerant flow to the cryocoil. In order to reduce the cool down time, activation of the buffer solenoid valve 116 is reduced or eliminated by removing the occurrence of high pressure faults during cooling. An unloader solenoid valve 130 is placed in parallel with flow metering device 104 in the cooling path to the evaporator 105. There is also a cool hand shutoff valve 135 and a cool solenoid valve 112 in the cooling path to the evaporator 105. During cool down, when the discharge pressure exceeds a setpoint, for example 415 psig, this unloader solenoid valve 130 will open so as to allow refrigerant to bypass the flow meter device 104 for a few seconds. This allows the system pressure to be reduced below the limit, without diverting any flow away from the application cryocoil.

By way of illustration, with reference to FIG. 1, an embodiment of a method of reducing a cool down time of a very low temperature refrigeration system 100 comprises, during a cooling mode of operation of the system, flowing refrigerant through a high pressure side of a plurality of heat exchangers 103, through a flow metering device 104, a cool hand shutoff valve 135 and a cool valve 112 with which the flow metering device 104 is in a series flow connection, to an inlet of an evaporator 105, through the evaporator 105 and through a low pressure side of the plurality of heat exchangers 103. Upon a discharge pressure of a compressor 101 of the system being at least as high as a stored set point of a maximum discharge pressure during the cooling mode of operation, an unload valve 130 is opened that permits refrigerant flow to bypass around the flow metering device 104 and to the cool valve 112, until the discharge pressure reduces to be less than the stored set point of the maximum discharge pressure. An inlet 124 of the evaporator 105 or an outlet (at 133) of the evaporator 105 can be at a temperature of less than about −110° C. The stored set point of the maximum discharge pressure can be less than an activation pressure of a buffer solenoid valve 116 of the system.

One or more sensors, such as 133, can be used to provide sensed temperature signals that can be provided to a controller, to be compared with one or more stored temperature setpoints, which can be stored in the memory of the controller. The sensors can, for example, be thermocouples brazed onto one or more locations (such as 133) in the system. For example, the discharge inlet to or discharge outlet from one or more heat exchangers, or the suction inlet to or suction outlet from one or more heat exchangers, can be used as locations for temperature sensors. Also, temperatures at any of the solenoid valves can be used, or inlets or outlets to solenoid valves. In one example, a temperature Tc at the low pressure side of the evaporator, and at the inlet of the return solenoid valve 114, at 133, is sensed. In another example, other temperature sensors can be used in place of, or in addition to, thermocouples, such as silicon diodes or other similar devices.

Various techniques set forth herein are implemented using a controller, and can include computer implemented components.

FIG. 5 is a simplified schematic block diagram of a controller that can be used, for example, as the controller 180 of FIG. 1. Control techniques discussed herein can be implemented using hardware, such as a controller 580 that includes one or more processors 581, which can for example include one or more Application Specific Integrated Circuits (ASICs) 582, 583; application software running on one or more processors 581 of the controller 580; sensor lines 584, 585 delivering electronic signals from sensors that are coupled to systems set forth herein (such as sensor lines from temperature sensor 133 and any pressure sensors) to the controller 580; and actuator lines 586-588 delivering electronic signals to actuated components within systems set forth herein (such as actuator lines delivering electronic signals to actuated valves or other controlled components). The controller 580 can also include user input module 589, which can include components (such as a keyboard, touch pad, and associated electronics in connection with the processor 581 and memory 590) to receive user input to provide set point temperatures, such as control signals that set the stored defrost completion set point temperature, the stored bypass control set point temperature or the stored set point of the maximum discharge pressure. The controller 580 can also include a memory 590 to store such set point temperatures, and to implement procedures under control of computer hardware and software. It will be appreciated that other control hardware may be used, including control hardware that is at least in part pneumatic.

Portions of the above-described methods and systems can be implemented using one or more computer systems, for example to permit automated implementation of control techniques for refrigeration systems and related components discussed herein. For example, techniques can be implemented using hardware, software or a combination thereof. When implemented in software, the software code can be executed on any suitable processor or collection of processors, whether provided in a single computer or distributed among multiple computers.

The teachings of all patents, published applications and references cited herein are incorporated by reference in their entirety.

While example embodiments have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the embodiments encompassed by the appended claims.

Although elements have been shown or described as separate embodiments above, portions of each embodiment may be combined with all or part of other embodiments described above.

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are described as example forms of implementing the claims.

Claims

1. A very low temperature refrigeration system, the system comprising: a compressor;a plurality of heat exchangers;an expander;a defrost valve anda controller comprising a processor and a memory, the controller being configured to:(i) during startup of the compressor, control said defrost valve in a hot gas defrost circuit to open to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and the expander and to an evaporator inlet from which the refrigerant flows to an evaporator, thereby accommodating a volume of the refrigerant in the evaporator to limit an initial increase in pressure of the refrigerant during the startup of the compressor; and(ii) to subsequently control the defrost valve to close so that flow of the refrigerant proceeds through the high pressure side of the plurality of heat exchangers and the expander to the evaporator.

2. The very low temperature refrigeration system according to claim 1, wherein the refrigerant comprises a mixture of a plurality of different refrigerant components, the mixture comprising: argon, R-14, R-23, R-125 and R-245fa.

3. (canceled)

4. The very low temperature refrigeration system according to claim 1, wherein the controller is configured to subsequently control the defrost valve to close after at least about 3 seconds from the startup of the compressor and before at least about 6 seconds from the startup of the compressor.

5. (canceled)

6. The very low temperature refrigeration system according to claim 1, the controller being configured to control the system to enter a standby mode upon the subsequently closing of the defrost valve, the standby mode comprising the controller controlling a cool valve to close to prevent flow of refrigerant from the high pressure side of the plurality of heat exchangers to the evaporator, while permitting flow of refrigerant through the high pressure side of the plurality of heat exchangers and a low pressure side of the plurality of heat exchangers.

7. The very low temperature refrigeration system according to claim 1, wherein the hot gas defrost circuit is configured to flow the refrigerant from a high pressure supply line of the compressor to the evaporator inlet from which the refrigerant flows to an evaporator.

8. A method of limiting peak operating pressure during startup of a very low temperature refrigeration system having a compressor, a plurality of heat exchangers, an expander and an evaporator, the method comprising: during startup of the compressor, opening a defrost valve in a hot gas defrost circuit to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and the expander and to an evaporator inlet from which the refrigerant flows to the evaporator, thereby accommodating a volume of the refrigerant in the evaporator to limit an initial increase in pressure of the refrigerant during the startup of the compressor; andsubsequently closing the defrost valve so that flow of the refrigerant proceeds through the high pressure side of the plurality of heat exchangers and the expander to the evaporator.

9. The method according to claim 8, wherein the refrigerant is charged into the system at a refrigerant pressure that would create a peak pressure of the refrigerant that would exceed a design pressure of the very low temperature refrigeration system during startup of the compressor absent the opening of the defrost valve; and/or wherein a refrigerant flow volume of the evaporator comprises greater than about 10 percent of a refrigerant system volume of the very low temperature refrigeration system; and/orwherein the refrigerant is charged into the system such that the system has a balance pressure of between about 230 psig and about 300 psig; and/orwherein, during the bypass flow of the refrigerant, a temperature of the refrigerant is greater than about 25° C.

10-12. (canceled)

13. A very low temperature refrigeration system, the system comprising: a compressor;a plurality of heat exchangers;an expander;a defrost valve anda controller comprising a processor and a memory, the controller being configured to, in a defrost mode of operation of the system,(i) control said defrost valve in a hot gas defrost circuit to open to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and to an evaporator inlet from which the refrigerant flows to an evaporator, to effect warming of the evaporator, and(ii) while controlling the defrost valve to open, control a cool valve to close so that the refrigerant does not flow from the high pressure side to the evaporator;the controller being further configured to, (i) based on an input control signal, set a value of a stored defrost completion set point temperature of a return temperature sensor on a low pressure side of the evaporator; and (ii) during the warming of the evaporator, upon the return temperature sensor on the low pressure side of the evaporator reaching the stored defrost completion set point temperature of the return temperature sensor, control the defrost valve to close to prevent the refrigerant flowing to the evaporator.

14. The very low temperature refrigeration system of claim 13, wherein the stored defrost completion set point temperature of the return temperature sensor is about 0° C. or lower; and/or wherein the return temperature sensor comprises a thermocouple on the low pressure side of the evaporator; and/orsaid controller being configured to close the defrost valve in response to receiving a temperature control signal from the return temperature sensor that is at least as warm as the stored defrost completion set point temperature of the return temperature sensor, the controller comprising a memory for storing a defrost completion set point temperature.

15-16. (canceled)

17. A method of reducing time spent in a defrost mode of operation of a very low temperature refrigeration system, the method comprising: in a defrost mode of operation of the system, (i) opening a defrost valve in a hot gas defrost circuit to bypass flow of a refrigerant around a high pressure side of a plurality of heat exchangers and to an evaporator inlet from which the refrigerant flows to an evaporator, to effect warming of the evaporator, and (ii) while opening the defrost valve, closing a cool valve so that the refrigerant does not flow from the high pressure side to the evaporator;based on an input control signal, setting a value of a stored defrost completion set point temperature of a return temperature sensor on a low pressure side of the evaporator; andduring the warming of the evaporator, upon the return temperature sensor on the low pressure side of the evaporator reaching the stored defrost completion set point temperature of the return temperature sensor, closing the defrost valve to prevent the refrigerant flowing to the evaporator.

18. A very low temperature refrigeration system, the system comprising: a compressor;a plurality of heat exchangers;an expander;a temperature sensor;a plurality of valves; anda controller comprising a processor and a memory, the controller being configured to, based on an input control signal, set a value of a stored bypass control set point temperature of a return temperature sensor on a low pressure side of an evaporator;the controller being further configured to, upon a return temperature sensor on a low pressure side of the evaporator warming to be at or above the stored bypass control set point temperature of the return temperature sensor,(i) control a return valve to close to prevent refrigerant flow through a low pressure side of the plurality of heat exchangers, and(ii) control a bypass valve to open to bypass flow of the refrigerant around the low pressure side of the plurality of heat exchangers and to a suction line that enters a low pressure side of the compressor; andthe system being configured to warm the bypassed flow of the refrigerant in the suction line before it enters the low pressure side of the compressor,wherein at least one of the plurality of heat exchangers is configured to exchange heat between the suction line and a high pressure side of the plurality of heat exchangers to warm the bypassed flow of the refrigerant in the suction line; orwherein the refrigeration system comprises a heater for warming the bypassed flow of the refrigerant in the suction line.

19-20. (canceled)

21. The very low temperature refrigeration system of claim 18, wherein the stored bypass control set point temperature of the return temperature sensor is less than a rated input flow temperature of the compressor, wherein the stored bypass control set point temperature of the return temperature sensor is between about −40° C. and about −70° C.

22. (canceled)

23. A method of reducing recovery time after defrost of a very low temperature refrigeration system, the method comprising: based on an input control signal, setting a value of a stored bypass control set point temperature of a return temperature sensor on a low pressure side of the evaporator;upon a return temperature sensor on a low pressure side of the evaporator warming to be at or above the stored bypass control set point temperature of the return temperature sensor, (i) closing a return valve to prevent refrigerant flow through a low pressure side of a plurality of heat exchangers, and (ii) opening a bypass valve to bypass flow of the refrigerant around the low pressure side of the plurality of heat exchangers and to a suction line that enters a low pressure side of a compressor; andwarming the bypassed flow of the refrigerant in the suction line before it enters the low pressure side of a compressor.)

24. A very low temperature refrigeration system, the system comprising: a compressor;a plurality of heat exchangers;an expander;a flow metering device and a cool valve with which the flow metering device is in a series flow connection to an inlet of an evaporator; anda controller comprising a processor and a memory, the controller being configured to, upon a discharge pressure of a compressor of the system being at least as high as a stored set point of a maximum discharge pressure during the cooling mode of operation, control an unload valve to open to permit refrigerant flow to bypass around the flow metering device and to the cool valve, until the discharge pressure reduces to be less than the stored set point of the maximum discharge pressure,wherein said controller is further configured to: during startup of the compressor to (i) control a defrost valve in a hot gas defrost circuit to open to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and the expander and to an evaporator inlet from which the refrigerant flows to an evaporator, thereby accommodating a volume of the refrigerant in the evaporator to limit an initial increase in pressure of the refrigerant during the startup of the compressor;(ii) to subsequently control the defrost valve to close so that flow of the refrigerant proceeds through the high pressure side of the plurality of heat exchangers and the expander to the evaporator; andduring defrost to (i) control a defrost valve in a hot gas defrost circuit to open to bypass flow of a refrigerant around a high pressure side of the plurality of heat exchangers and to an evaporator inlet from which the refrigerant flows to an evaporator, to effect warming of the evaporator, and(ii) while controlling the defrost valve to open, control a cool valve to close so that the refrigerant does not flow from the high pressure side to the evaporator;the controller being further configured to, (i) based on an input control signal, set a value of a stored defrost completion set point temperature of a return temperature sensor on a low pressure side of the evaporator; and (ii) during the warming of the evaporator, upon the return temperature sensor on the low pressure side of the evaporator reaching the stored defrost completion set point temperature of the return temperature sensor, control the defrost valve to close to prevent the refrigerant flowing to the evaporator; andfollowing defrost upon a return temperature sensor on a low pressure side of the evaporator warming to be at or above the stored bypass control set point temperature of the return temperature sensor,(i) control a return valve to close to prevent refrigerant flow through a low pressure side of the plurality of heat exchangers, and(ii) control a bypass valve to open to bypass flow of the refrigerant around the low pressure side of the plurality of heat exchangers and to a suction line that enters a low pressure side of the compressor; andthe system being configured to warm the bypassed flow of the refrigerant in the suction line before it enters the low pressure side of the compressor.

25. (canceled)

26. A method of reducing a cool down time of a very low temperature refrigeration system, the method comprising: during a cooling mode of operation of the system, flowing refrigerant through a high pressure side of a plurality of heat exchangers, through a flow metering device and a cool valve with which the flow metering device is in a series flow connection to an inlet of an evaporator, through the evaporator and through a low pressure side of the plurality of heat exchangers; andupon a discharge pressure of a compressor of the system being at least as high as a stored set point of a maximum discharge pressure during the cooling mode of operation, opening an unload valve that permits refrigerant flow to bypass around the flow metering device and to the cool valve, until the discharge pressure reduces to be less than the stored set point of the maximum discharge pressurewherein an inlet of the evaporator or an outlet of the evaporator is at a temperature of less than about −110° C., and/orwherein the stored set point of the maximum discharge pressure is less than an activation pressure of a buffer solenoid valve of the system.

27-28. (canceled)