WO2019175616A1

WO2019175616A1 - Condenser architecture with multiple segments

Info

Publication number: WO2019175616A1
Application number: PCT/IB2018/000565
Authority: WO
Inventors: Jérémy WALLET-LAÏLY; Charbel RAHHAL
Original assignee: Carrier Corporation
Priority date: 2018-03-13
Filing date: 2018-03-13
Publication date: 2019-09-19
Also published as: EP3765800A1

Abstract

A heat exchanger system is provided. The heat exchanger system includes a vapor-compression circuit. The vapor compression circuit includes a compressor (11), an expansion valve (12), a condenser (13) fluidly interposed between the compressor and the expansion valve and an evaporator (14) fluidly interposed between the expansion valve and the compressor. The condenser includes a de-superheating segment (20) and a condensing segment (30). The condensing segment is receptive of a first liquid downstream from the de-superheating segment. The condensing and de-superheating segments are receptive of a second liquid in parallel. Flows of the second liquid into the de-superheating segment are controllable by a control valve (70) based on the temperature of flows of the second liquid exiting the de-superheating segment measured by a temperature sensor (60).

Description

CONDENSER ARCHITECTURE WITH MULTIPLE SEGMENTS

BACKGROUND

[0001] The following description relates to condensers and, more specifically, to a condenser architecture with one or more condensers or one or more heat exchangers and multiple segments for each of the one or more condenser or each of the one or more heat exchangers for improved efficiency due to flow control between the multiple segments.

[0002] In heat transfer systems, a condenser is a device used to condense a substance from its gaseous to its liquid state through a cooling process. In so doing, the latent heat that is given up by the substance is transferred through the condenser to a surrounding environment. Condensers can be made according to numerous designs, and come in many sizes ranging from rather small (hand-held) to very large (industrial- scale units used in plant processes).

[0003] In some cases, a condensing process employed by a condenser can be divided into two segments. The two segments are circuited in series on a refrigerant stream and in parallel on a secondary fluid stream. The first segment is used to decrease refrigerant temperatures down to a saturated temperature level. The second segment is used to condense and sub-cool the refrigerant.

BRIEF DESCRIPTION

[0004] According to an aspect of the disclosure, a heat exchanger system is provided. The heat exchanger system includes a vapor-compression circuit. The vapor compression circuit includes a compressor, an expansion valve, a condenser fluidly interposed between the compressor and the expansion valve and an evaporator fluidly interposed between the expansion valve and the compressor. The condenser includes a de superheating segment and a condensing segment. The condensing segment is receptive of a first liquid downstream from the de-superheating segment. The condensing and de superheating segments are receptive of a second liquid in parallel. Flows of the second liquid into the de-superheating segment are controllable based on characteristics of flows of the second liquid exiting the de-superheating segment. [0005] In accordance with additional or alternative embodiments, the first liquid includes refrigerant and the second liquid includes water.

[0006] In accordance with additional or alternative embodiments, a flow splitter for the second liquid is disposed upstream from the de-superheating and condensing segments and a flow mixer for the second liquid is disposed downstream from the de-superheating and condensing segments.

[0007] In accordance with additional or alternative embodiments, a sensor is interposed between the de-superheating segment and the flow mixer to measure the characteristics of the flows of the second liquid and a controllable valve is interposed between the flow splitter and the de-superheating segment. The controllable valve is controllable to adjust an amount of the second liquid entering the de-superheating segment based on readings of the sensor.

[0008] In accordance with additional or alternative embodiments, the controllable valve includes at least controllable bi-directional valve.

[0009] In accordance with additional or alternative embodiments, first sensors are interposed between the de-superheating and condensing segments and the flow mixer, respectively, to measure the characteristics of the flows of the second liquid, a second sensor is upstream from the de-superheating segment to measure characteristics of flows of the first liquid and a controllable valve is interposed between the flow splitter and the de superheating and condensing segments. The controllable valve is controllable to adjust an amount of the second liquid entering the de-superheating and condensing segments based on readings of the first sensors and the second sensor.

[0010] According to another aspect of the disclosure, a heat exchanger is provided and includes first and second circuits in which a first liquid is directed through first and second segments in series and a second liquid is directed through the first and second segments in parallel, respectively. The second circuit includes first and second inlets and outlets whereby the second liquid enters and exits the first and second segments, respectively, a flow splitter upstream from the first and second inlets, a flow mixer downstream from the first and second outlets, a sensor to measure characteristics of flows of the second liquid exiting the first segment and a controllable valve. The controllable valve is operable to control flows of the second liquid entering the first segment based on readings of the sensor of the characteristics of the flows of the second liquid exiting the first segment.

[0011] In accordance with additional or alternative embodiments, the heat exchanger includes a condenser.

[0012] In accordance with additional or alternative embodiments, the first circuit includes a first pass of the first liquid through the first segment and a second pass, which is in series with the first pass, of the first liquid through the second segment, and the second circuit includes a first pass of the second liquid through the first segment and a second pass, which is parallel with the first pass, of the second liquid through the second segment.

[0013] In accordance with additional or alternative embodiments, the first liquid includes refrigerant and the second liquid includes water.

[0014] In accordance with additional or alternative embodiments, the first segment includes a de-superheating segment and the second segment includes a condensing segment.

[0015] In accordance with additional or alternative embodiments, the sensor is downstream from the de-superheating segment to measure the characteristics of the flows of the second liquid and the controllable valve is controllable to adjust an amount of the second liquid entering the de-superheating segment based on readings of the sensor.

[0016] In accordance with additional or alternative embodiments, the controllable valve includes at least controllable bi-directional valve.

[0017] In accordance with additional or alternative embodiments, the sensor includes first sensors downstream from the de-superheating and condensing segments, respectively, to measure the characteristics of the flows of the second liquid and a second sensor upstream of the de-superheating segment to measure characteristics of flows of the first liquid. The controllable valve is controllable to adjust an amount of the second liquid entering the de-superheating and condenser segments based on readings of the first sensors and the second sensor. [0018] In accordance with additional or alternative embodiments, the controllable valve includes a controllable multi-directional valve.

[0019] According to yet another aspect of the disclosure, a method of operating a heat exchanger is provided. The method includes directing a first liquid through first and second segments in series, directing a second liquid through the first and second segments in parallel, respectively, measuring characteristics of flows of the second liquid exiting the first segment and controlling an amount of the second liquid permitted to enter the first segment based on readings derived from the measuring.

[0020] In accordance with additional or alternative embodiments, the controlling includes opening and closing a bi-directional valve upstream from the first segment.

[0021] In accordance with additional or alternative embodiments, the measuring includes measuring characteristics of flows of the first and second liquids exiting the first and second segments, respectively, and measuring characteristics of flows of the first liquid entering the first segment. The controlling includes opening and closing a multi directional valve upstream from the first and second segments.

[0022] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The subject matter, which is regarded as the disclosure, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0024] FIG. 1 is a schematic illustration of a heat exchanger system in accordance with embodiments; [0025] FIG. 2 is a schematic illustration of circuiting of a condenser of the heat exchanger system of FIG. 1;

[0026] FIG. 3 is a schematic illustration of circuiting of a condenser of the heat exchanger system of FIG. 1;

[0027] FIG. 4 is a schematic illustration of a heat exchanger system in accordance with further embodiments;

[0028] FIG. 5 is a schematic diagram of a controller of the heat exchanger systems of FIGS. 1 and 4; and

[0029] FIG. 6 is a flow diagram illustrating a method of operating a heat exchanger system in accordance with embodiments.

[0030] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

DETAILED DESCRIPTION

[0031] As will be described below, a secondary fluid stream flow of a condenser is divided to feed a first segment and a second segment with a calculated and controlled split ratio. The split ratio can be set to optimize heat transfer efficiency and output water temperatures. The first and second segments are parts of a single heat exchanger with a circuiting architecture or two separate heat exchangers. In both cases, de-superheating and condensing processes are separated and thus make better use of heat transfer surfaces.

[0032] With reference to FIG. 1, a heat exchanger system 10 is provided. The heat exchanger system 10 includes a compressor 11, an expansion valve 12, a condenser 13 fluidly interposed between the compressor 11 and the expansion valve 12 and an evaporator 14 fluidly interposed between the expansion valve 12 and the compressor 11. The compressor 11 is operable to compress a saturated vapor therein and to output a high- pressure and high-temperature superheated vapor toward the condenser 13. The condenser 13 causes the superheated vapor received from the compressor 11 to condense through thermal transfer with water, for example. The condenser 13 outputs the resulting condensed liquid toward the expansion valve 12 as a saturated liquid. The expansion valve 12 abruptly reduced a pressure of the saturated liquid and produces a relatively cold mixture. The liquid of this cold mixture is then evaporated in the evaporator 14 and the resulting saturated vapor is returned to the compressor 11.

[0033] With continued reference to FIG. 1 and with additional reference to FIGS. 2 and 3, the condenser 13 may include a first or de-superheating segment 20 and a second or condensing segment 30. The de-superheating segment 20 and the condensing segment 30 are separate from one another. During operations of the condenser 13, the condensing segment 30 receives a first liquid, such as refrigerant being passed or cycled through the heat exchanger system 10, downstream from the de-superheating segment 20. As such, the de-superheating segment 20 and the condensing segment 30 are disposed in series with respect to the first liquid. While the operations proceed, the de-superheating segment 20 and the condensing segment 30 are also receptive of a second liquid, such as water, in parallel. At least the flows of the second liquid into the de-superheating segment 20 are controllable based on characteristics of flows of the second liquid exiting the de superheating segment 20.

[0034] As shown in FIGS. 2 and 3 the condenser 13 may also include a first circuit 130 (see FIG. 2) that traverses the de-superheating segment 20 and the condensing segment 30 with a serial arrangement as well as a second circuit 131 (see FIG. 3) that traverses the de-superheating segment 20 and the condensing segment 30 with a parallel arrangement.

[0035] As shown in FIGS. 1 and 2, the first circuit 130 is formed of a first header 201, which includes a first inlet 2010 and a first outlet 2011, a second header 202, a separation plate 203 and first and second passes 204 and 205 fluidly connecting the first header 201 and the second header 202. The first inlet 2010 is receptive of the first liquid from the compressor 11 and the outlet 2011 is disposed to permit the first liquid to exit toward the expansion valve 12. The separation plate 203 is disposed in the first header 201 proximate to the first inlet 2010 and defines the first passes 204 as the de-superheating segment 20 and the second passes 205 as the condensing segment 30. That is, the first liquid enters the first header 201 of the condenser 13 via the first inlet 2010 and is forced to flow through the first passes 204 toward the second header 202 by the separation plate 203. The first liquid then flows from the second header 202, through the second passes 205 and back toward the first header 201 whereupon the first liquid exits the condenser 13 via the first outlet 2011.

[0036] As shown in FIGS. 1 and 3, the second circuit 131 is formed of a first header 301, which includes a first inlet 3010 and a second inlet 3011, a second header 302, which includes a first outlet 3020 and a second outlet 3021 (the first and second outlets 3020 and 3021 may be superimposed on another or separate from one another), a separation plate 303 and first and second passes 304 and 305 fluidly connecting the first header 301 and the second header 302. The first and second inlets 3010 and 3011 are receptive of the second liquid in parallel and the second liquid exits through the first and second outlets 3020 and 3021 in parallel. The separation plate 303 is disposed at least in the first header 301 proximate to the first inlet 3010 and defines the first passes 304 as the de-superheating segment 20 and the second passes 305 as the condensing segment 30. That is, the second liquid enters the first header 301 of the condenser 13 via the first and second inlets 3010 and 3011 and is forced to flow through the first and second passes 304 and 305 in parallel toward the second header 302 by the separation plate 303. The second liquid then flows out of the second header 302 via the first and second outlets 3020 and 3021.

[0037] As shown in FIG. 1, the heat exchanger system 10 further includes a flow splitter 40, a flow mixer 50, a sensor 60 and a controllable valve 70.

[0038] The flow splitter 40 is disposed upstream from the de-superheating segment 20 and the condensing segment 30 and is disposed and configured to split a flow of the second liquid into first and second parallel flows of the second liquid 41 and 42 for respective entry the de-superheating segment 20 and the condensing segment 30 in parallel. The flow mixer 50 is disposed downstream from the de-superheating segment 20 and the condensing segment 30 and is disposed and configured to mix third and fourth parallel flows of the second liquid 51 and 52 respectively exiting the de-superheating segment 20 and the condensing segment 30 in parallel.

[0039] The sensor 60 may be provided as a single sensor 61 that is interposed between the de-superheating segment 20 and the flow mixer 50 such that the single sensor 61 is disposed to measure the characteristics of the third flow of the second liquid 51 exiting the de-superheating segment 20. In accordance with embodiments, the single sensor 61 may include or be provided as a temperature sensor. The controllable valve 70 is interposed between the flow splitter 40 and the de-superheating segment 20 and is controllable to adjust an amount of the first flow of the second liquid 41 entering the de superheating segment 20 based on readings (e.g., temperature readings of the flows of the third flow of the second liquid 51 exiting the de-superheating segment 20) of the sensor 60. The controllable valve 70 may include or be provided at least as a controllable bi directional valve or a two-way valve controllable 71.

[0040] With reference to FIG. 4 and in accordance with alternative embodiments, the sensor 60 may be provided as first sensors 62 and 63 and as a second sensor 64. The first sensors 62 and 63 are interposed between the flow mixer 50 and each of the de superheating segment 20 and the condensing segment 30 such that the first sensors 62 and 63 are disposed to measure the characteristics of the third and fourth flows of the second liquid 51 and 52 exiting the de-superheating segment 20 and the condensing segment 30, respectively. The second sensor 63 is disposed upstream of the de-superheating segment 20 such that the second sensor 64 is disposed to measure characteristics of flows of the first liquid entering the de-superheating segment 20 on the first circuit 130. In accordance with embodiments, the first sensors 62 and 63 and the second sensor 64 may each include or be provided as temperature sensors. The controllable valve 70 is interposed between the flow splitter 40 and each of the de-superheating segment 20 and the condensing segment 30 and is controllable to adjust an amount of the first and second flows of the second liquid 41 and 42 entering the de-superheating segment 20 and the condensing segment 30 based on readings (e.g., temperature readings of the flows of the third and fourth flows of the second liquid 51 and 52 exiting the de-superheating segment 20 and the condensing segment 30 and temperature readings of the flows of the first liquid into the de-superheating segment 20) of the first sensors 62 and 63 and of the second sensor 64. The controllable valve 70 may include or be provided at least as a controllable multi-directional valve or as a three- way controllable valve 72.

[0041] With reference to FIG. 5, the heat exchanger system 10 of FIGS. 1 and 4 may also include a controller 501. As shown in FIG. 5, the controller 501 includes a processing unit 502, a memory unit 503, a networking unit 504 and a servo control unit 505. The processing unit 502 is receptive of readings from the single sensor 61 (see FIG. 1) or from the first sensors 62 and 63 and the second sensor 64 (see FIG. 4) by way of the networking unit 504. The processing unit 502 also controls operations of the bi-directional or two-way controllable valve 71 (see FIG. 1) or the multi-directional or three-way controllable valve 72 (see FIG. 4) by way of the servo control unit 505. The memory unit 503 has executable instructions stored thereon, which are readable and executable by the processing unit 502. When the executable instructions are read and executed by the processing unit 502, the executable instructions cause the processing unit 502 to analyze the readings received by way of the networking unit 504 and to control the operations of the bi-directional or two-way controllable valve 71 or the multi-directional or three-way controllable valve 72 based on results of that analysis.

[0042] For example, for the heat exchanger system 10 of FIG. 1, in an event that the temperature of the third flow of the second liquid 51 is deemed too low or too high by the processing unit 502, the processing unit 502 could instruct the servo control unit 505 to open or close the bi-directional or two-way controllable valve 71 to increase or decrease a magnitude of the first flow of the second liquid 41.

[0043] As another example, for the heat exchanger system 10 of FIG. 4, in an event that the temperatures of the third and fourth flows of the second liquid 51 and 52 are deemed too low/high or too high/low by the processing unit 502, the processing unit 502 could instruct the servo control unit 505 to operate the multi-directional or three-way controllable valve 72 to increase or decrease (or vice versa) relative magnitudes of the first and second flows of the second liquid 41 and 42.

[0044] With reference to FIG. 6, a method of operating a heat exchanger, such as the condenser 13 described above, is provided. As shown in FIG. 6, the method includes directing a first liquid through first and second segments in series (block 601), directing a second liquid through the first and second segments in parallel, respectively (block 602), measuring characteristics of at least flows of the second liquid exiting the first segment (block 603) and controlling at least an amount of the second liquid permitted to enter the first segment based on readings derived from the measuring (block 604).

[0045] Benefits of the features described herein are the sub-dividing of de superheating and sub-cooling to increase maximum water temperatures for output water that a system can provide (e.g., about 1.5K to 3K or about equivalent to 3% to 5% energy savings). The division of the condensing process also allows for specific sizing and design of a heat exchanger which can then be dedicated toward achieving a specific heat transfer mode. Optimized control also the system to operate with improved performance regardless of ambient conditions and protects against water vapor generation.

[0046] While the disclosure is provided in detail in connection with only a limited number of embodiments, it should be readily understood that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the disclosure. Additionally, while various embodiments of the disclosure have been described, it is to be understood that the exemplary embodiment(s) may include only some of the described exemplary aspects. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims

CLAIMS What is claimed is:

1. A heat exchanger system, comprising: a vapor-compression circuit comprising a compressor, an expansion valve, a condenser fluidly interposed between the compressor and the expansion valve and an evaporator fluidly interposed between the expansion valve and the compressor, the condenser comprising a de-superheating segment and a condensing segment, the condensing segment being receptive of a first liquid downstream from the de superheating segment, the condensing and de-superheating segments being receptive of a second liquid in parallel, and flows of the second liquid into the de-superheating segment being controllable based on characteristics of flows of the second liquid exiting the de-superheating segment.

2. The heat exchanger system according to claim 1, wherein the first liquid comprises refrigerant and the second liquid comprises water.

3. The heat exchanger system according to claim 1 or 2, further comprising: a flow splitter for the second liquid disposed upstream from the de-superheating and condensing segments; a flow mixer for the second liquid disposed downstream from the de-superheating and condensing segments.

4. The heat exchanger system according to claim 3, further comprising: a sensor interposed between the de-superheating segment and the flow mixer to measure the characteristics of the flows of the second liquid; and a controllable valve interposed between the flow splitter and the de-superheating segment, the controllable valve being controllable to adjust an amount of the second liquid entering the de-superheating segment based on readings of the sensor.

5. The heat exchanger system according to claim 4, wherein the controllable valve comprises at least a controllable bi-directional valve.

6. The heat exchanger system according to claim 3, further comprising: first sensors interposed between the de-superheating and condensing segments and the flow mixer, respectively, to measure the characteristics of the flows of the second liquid; a second sensor to measure characteristics of flows of the first liquid upstream of the de-superheating segment; and a controllable valve interposed between the flow splitter and the de-superheating and condensing segments, the controllable valve being controllable to adjust an amount of the second liquid entering the de-superheating and condensing segments based on readings of the first sensors and the second sensor.

7. The heat exchanger system according to claim 4, wherein the controllable valve comprises a controllable multi-directional valve.

8. The heat exchanger system according to any one of claims 1 to 7, further comprising a controller configured to control operations of the controllable valve.

9. A heat exchanger, comprising: first and second circuits in which a first liquid is directed through first and second segments in series and a second liquid is directed through the first and second segments in parallel, respectively, the second circuit comprising: first and second inlets and outlets whereby the second liquid enters and exits the first and second segments, respectively; a sensor to measure characteristics of flows of the second liquid exiting the first segment; and a controllable valve operable to control flows of the second liquid entering the first segment based on readings of the sensor of the characteristics of the flows of the second liquid exiting the first segment.

10. The heat exchanger according to claim 9, wherein the heat exchanger comprises a condenser.

11. The heat exchanger according to claim 9 or 10, wherein: the first circuit comprises a first pass of the first liquid through the first segment and a second pass, which is in series with the first pass, of the first liquid through the second segment, and the second circuit comprises a first pass of the second liquid through the first segment and a second pass, which is parallel with the first pass, of the second liquid through the second segment.

12. The heat exchanger according to any one of claims 9 to 11, wherein the first liquid comprises refrigerant and the second liquid comprises water.

13. The heat exchanger according to claim 12, wherein the first segment comprises a de-superheating segment and the second segment comprises a condensing segment.

14. The heat exchanger according to claim 13, wherein: the sensor is interposed between the de-superheating segment and the flow mixer to measure the characteristics of the flows of the second liquid, and the controllable valve is controllable to adjust an amount of the second liquid entering the de-superheating segment based on readings of the sensor.

15. The heat exchanger according to claim 14, wherein the controllable valve comprises at least controllable bi-directional valve.

16. The heat exchanger according to claim 13, wherein: the sensor comprises: first sensors downstream from the de-superheating and condensing segments, respectively, to measure the characteristics of the flows of the second liquid; a second sensor to measure characteristics of flows of the first liquid upstream of the de-superheating segment, and the controllable valve is controllable to adjust an amount of the second liquid entering the de-superheating and condensing segments based on readings of the first sensors and the second sensor.

17. The heat exchanger according to claim 16, wherein the controllable valve comprises a controllable multi-directional valve.

18. A method of operating a heat exchanger, the method comprising: directing a first liquid through first and second segments in series; directing a second liquid through the first and second segments in parallel, respectively, measuring characteristics of flows of the second liquid exiting the first segment; and controlling an amount of the second liquid permitted to enter the first segment based on readings derived from the measuring.

19. The method according to claim 18, wherein the controlling comprises opening and closing a bi-directional valve upstream from the first segment.

20. The method according to claim 18, wherein: the measuring comprises: measuring characteristics of flows of the first and second liquids exiting the first and second segments, respectively; and measuring characteristics of flows of the first liquid entering the first segment, and the controlling comprises opening and closing a multi-directional valve upstream from the first and second segments.