Reverse cycle machine provided with a turbine

Abstract

A reverse compression cycle machine includes an evaporator, a compressor and a condenser arranged in series along a path of a working fluid in the machine, further including a boundary layer turbine placed between the condenser and the evaporator. The turbine includes a set of power disks mounted on a shaft which rotates inside a volume of a rotor casing, an inlet opening for introducing a working fluid in a stator volume, a stator nozzle, which accelerates the flow in a direction that is tangential to the power disks, and a discharge of a working fluid. The rotor casing includes a drain of a liquid fraction of the working fluid from the peripheral part of the power disks in order to avoid its concentration in the peripheral part of the volume of the rotor casing.

Claims

1. A reverse compression cycle machine comprising: an evaporator, a compressor and a condenser arranged in series each other along a path of a working fluid in the machine, further comprising a boundary layer turbine, placed between the condenser and the evaporator, said turbine comprising a set of power disks mounted on a rotating shaft which rotates inside a volume of a wheel chamber, an inlet opening for introducing a working fluid in a stator volume, an internal ring forming externally the stator volume with an external enclosure of the turbine and delimiting internally the wheel chamber, a stator nozzle provided in the internal ring, which accelerates the flow in a direction that is tangential to the power disks, a discharge passage of a working fluid provided in the external enclosure of the turbine, the wheel chamber being further delimited laterally by two sealing stator elements, and comprising at least one drain of a liquid fraction at least of said working fluid from the peripheral part of the power disks in order to avoid its concentration in a peripheral part of the volume of said wheel chamber, wherein said at least one drain is arranged in the sealing stator elements and provided on a wall of the wheel chamber.

2. The reverse compression cycle machine according to claim 1, further comprising a bypass circuit arranged in parallel to said turbine.

3. The reverse compression cycle machine according to claim 1, further comprising a first throttling valve and a second throttling valve which are placed, respectively, upstream and downstream of said turbine in a flow direction of a working fluid in said reverse compression cycle machine.

4. The reverse compression cycle according to claim 1, further comprising a generator for generating electrical power, which is coupled to said turbine.

5. The reverse compression cycle according to claim 1, wherein said at least one drain is throttled by a valve, in order to adjust its discharged flow rate.

6. The reverse compression cycle according to claim 1, wherein said turbine comprises a rotating sealing disk provided at at least one face of said set of power disks and coupled with said rotating shaft, said set of power disks being provided with rotor axial discharge holes, said rotating sealing disk being provided with sealing disk axial discharge holes aligned with said rotor axial discharge holes, one of said two sealing stator elements surrounding at least a portion of said rotating sealing disk, said rotating sealing disk being concentric with respect to said set of power disks and having an outside diameter that is smaller than the outside diameter of said set of power disks and being provided with an annular lip engaging a corresponding seat of said one of said two sealing stator elements, a discharge ring provided between said one of said two sealing stator elements and a plug, said discharge ring being provided with radial discharge ring holes, said sealing disk axial discharge holes being in fluid communication with said radial discharge ring holes, said radial discharge ring holes being in fluid communication with said discharge passage of said external enclosure of said turbine a turbine enclosure.

7. A method for adjusting the reverse compression cycle machine according to claim 1, comprising the provision, in said turbine, of a complete outflow of a liquid fraction at least of said working fluid through said at least one drain of said wheel chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The disclosure is described hereinafter with reference to nonlimiting examples, provided with a nonlimiting explanatory purpose in the accompanying drawings. These drawings illustrate different aspects and embodiments of the disclosure and, where appropriate, reference numerals that illustrate structures, components, materials; elements that are similar in different figures are designated by similar reference numerals.

(2) In the accompanying figures:

(3) FIG. 1 is a view of a reverse cycle with at least one compressor, one evaporator and one condenser, in which the expansion of the working fluid from the high-pressure part of the system (condenser) to the low-pressure part of the system (evaporator) occurs, even partially, by means of a boundary layer turbine;

(4) FIGS. 2a and 2b show, respectively, the temperature(T)-entropy(S) and pressure(P)-enthalpy(H) thermodynamic reference charts for the reverse cycle; the charts plot both the traditional cycle (points ABCD) and the one with an ideal turbine, i.e. providing an isoentropic adiabatic expansion of the whole working fluid flow rate (points ABCD.sub.is);

(5) FIG. 3 plots the speed of a boundary layer turbine shaft inserted in a prototype reverse cycle, for refrigeration applications, during a transient from the startup to the shutdown of the entire reverse cycle;

(6) FIG. 4 is an exploded view of an example of a boundary layer turbine for application to reverse cycles; the turbine is drawn, by way of example, symmetrical with respect to the centerline; and

(7) FIG. 5 is a cutout view of the assembly of the boundary layer turbine of FIG. 4.

DETAILED DESCRIPTION OF THE DRAWINGS

(8) While the disclosure is susceptible of various modifications and alternative constructions, some preferred embodiments are shown in the drawings and are described hereinafter in detail.

(9) It is to be understood in any case that there is no intention to limit the disclosure to the specific illustrated embodiment, but, on the contrary, it intends to cover all the modifications, alternative constructions, and equivalents that fall within the scope of the disclosure as defined in the appended claims.

(10) The use of “for example”, “etc.”, “or” indicates nonexclusive alternatives without limitation unless otherwise specified.

(11) The use of “includes” means “includes, but is not limited to” unless otherwise specified.

(12) Indications such as “vertical” and “horizontal”, “upper” and “lower” (in the absence of other indications) are to be read with reference to the assembly (or operating) conditions and with reference to the normal terminology in use in everyday language, where “vertical” indicates a direction that is substantially parallel to the direction of the vector of the force of gravity “g” and “horizontal” indicates a direction that is perpendicular thereto.

(13) With reference to the reverse cycle shown in FIG. 1, which uses a working fluid, for nonlimiting example, of the R134a or R22 type, the compressor (1), driven by a motor (2) for example of electrical type, sends the working fluid from the low-pressure region, in which the evaporator (9) is present, to the high-pressure region, in which the condenser (3) is present. From said condenser, the working fluid traditionally passes through an expansion element (throttling valve or capillary tube) to enter the evaporator. In the present disclosure, the working fluid passes, even partially, through a boundary layer turbine (7) in order to produce useful work.

(14) Said turbine (7) can be connected to an electrical generator (8) for the generation of electric power. Said useful work or electrical power partially compensates the consumption of work or electrical power of the compressor, thus reducing the overall energy consumption and increasing the COP. Said boundary layer turbine (7) works with a multiphase fluid, optionally two phase in the simplest case. With reference to FIG. 2a, 2b and to traditional reverse cycles, the fluid performs the A-B transformation in the compressor and then performs the B-C transformation in the condenser and then performs the isoenthalpic transformation C-D in the throttling element, to then close the cycle with the D-A transformation in the evaporator.

(15) In the case of the present disclosure, the fluid in output from the condenser is sent to the boundary layer turbine (7). Ideally, this turbine might perform an isoentropic reversible transformation, represented between the points C-D.sub.is. However, the actual expansion transformation will be characterized by an isoentropic adiabatic efficiency lower than 100% (that is the case of an ideal transformation), and therefore the actual transformation will be comprised between the ideal one C-D.sub.is and the fully dissipative one of the isoenthalpic type C-D. This brings the following two advantages: the recovery of useful energy, which can be used to reduce the energy consumption of the compressor; the increase of the enthalpy difference available at the evaporator, with a consequent increase in refrigerating or heat pumping capacity. Both advantages entail an increase of COP with respect to the initial reverse cycle without the boundary layer turbine: the energy recovery in fact allows the reduction of the denominator of the COP, compensating the work spent for compression, while the enthalpy difference increase at the evaporator allows an increase of equal amount of the numerator of the COP.

(16) Following the path of the working fluid inside the boundary layer turbine, the working fluid is fed at high pressure through apt inlet openings (70) in the stator volume. Said stator volume is represented by a volume that is defined by the external enclosure of the turbine (75) and an internal ring (50), in which an appropriate slot for the passage of the pressurized fluid has been provided. In FIG. 4, as a nonlimiting example, said stator volume (51) coincides with the volume of said slot. Said ring (50) therefore forms externally the stator volume (51) and internally the rotor casing or wheel chamber (53). Inside the rotor casing there is the moving element of the turbine, which is capable of extracting useful work from the fluid. Said moving element is represented by a rotating shaft (33) on which power disks (30) are rigidly mounted and are mutually spaced (interstitial space) along the shaft axis: the number of the power disks is at least equal to two. The working fluid passes from the stator volume to the wheel chamber by passing through appropriate stator nozzles (52), which accelerate the flow in a direction that is approximately tangential to the power disks (30).

(17) Stator nozzles (52) are provided in the ring (50) as through holes connecting the stator volume (51) with the rotor casing (53) itself.

(18) The acceleration of the fluid occurs at the expense of the pressure energy, which is reduced from the stator volume to the wheel chamber. Due to said pressure reduction, the fluid increases its vapor fraction and decreases the liquid fraction: the liquid fraction can include also the lubricating oil that circulates in the reverse cycle. The vapor fraction is forced to pass through the interstitial space between the power disks, until discharge occurs through apt axial holes in the disks (35); rotor axial discharge holes (35) are provided in each power disk (30) close to the central part of the disk itself, near the rotating shaft (33).

(19) The fluid exchanges useful work with the power disks (30) thanks to the tangential friction forces and is therefore slowed tangentially by said disks, until it exits through said rotor axial discharge holes (35).

(20) Said rotor axial discharge holes (35) are aligned with the sealing disk axial discharge holes (32). Such sealing disks, placed on the opposite sides of the set of power disks, are pressed against the set of power disks, with no interstitial space: the fluid is therefore discharged first through the rotor axial discharge holes (35), then through the sealing disk axial discharge holes (32) provided in the sealing disk (31), and finally through the discharge ring radial holes (59) provided in the fixed discharge ring (57), to be finally collected and sent externally the enclosure (75) through the radial discharge passages (73, 74) provided in the enclosure (75) itself.

(21) In said rotor axial discharge holes and sealing disk axial discharge holes (35, 32) the pressure is lower than the pressure at the power disk periphery and, except for small pressure losses, equal to the final discharge pressure of the turbine (at the discharge passages 73, 74). Therefore, on the two power disk surfaces facing the two opposite sealing stator elements (54), at both sides of the set of the power disks, it is important to limit the leakage losses of the working fluid from the periphery of the power disks to the rotor axial discharge holes (35) and sealing disk axial discharge holes (32).

(22) This sealing effect is provided by the sealing disk (31), which is characterised by appropriate axial-symmetrical slots (34A) in order to hinder the leakage of the working fluid; preferably the sealing disk (31) is provided at least with an annular lip (34) that is engaged in a corresponding seat (54A) of the surrounding sealing stator element (54).

(23) Said sealing disk (31) can be provided by a monolithic part, or by means of the assembly of multiple disks having a definite thickness: in both cases, the sealing disk (31) is characterized by outside diameters of every part of the sealing disk (31) that are smaller than the corresponding inside diameter of the respective part of the sealing stator element (54) within which it rotates, preferably smaller than 0.3%, and smaller than the diameter of the power disks (30), in order to minimize the aforementioned leakage losses.

(24) In other words, the radial distance between the sealing disk (31) and the sealing stator element (54) is preferably smaller than 0.3% of the corresponding diameter.

(25) Like the power disks (30), said sealing disk (31) is mounted rigidly on the rotating shaft (33).

(26) The liquid fraction that is still present after expansion through the stator nozzles (52), instead, follows two alternative paths: to a minimal extent, it is entrained by the vapor fraction to the discharge of the turbine, and for the most part it is confined in the rotor casing, at the power disk periphery, due to the centrifugal force.

(27) In order to evacuate said liquid fraction from the rotor casing, discharge drains (71, 72) are provided on the wall of the wheel chamber in order to collect the liquid fraction and convey it outside the enclosure of the turbine.

(28) Particularly, said drains (71,72) are drains provided in the peripheral portion of the rotor casing (53); more in detail, the drain passage comprises a first drain portion (71A,72A) provided as a duct in the peripheral portion of said sealing stator element (54), in fluid communication with a second drain portion (71B,72B) provided in the sealing stator element (54) as a circumferential or annular channel that, in use, faces the internal wall of the housing (75) and that is on its turn in fluid communication with the hole in the housing (75).

(29) By way of example, said drains (71,72) can convey the liquid fraction toward the general discharge of the turbine (73) or, in other embodiments, directly toward the evaporator (9) of the reverse cycle.

(30) Discharge drain (71, 72) are preferably throttled by respective valves (not shown).

(31) This allows to avoid the flooding of the peripheral part of the power disks, with consequent losses due to the viscous effect.

(32) Finally, the enclosure of the turbine (75) can be closed by plugs (60) at the ends, which can accommodate apt bearings to allow the rotation of the rotating shaft (33).

(33) It is possible to mechanically connect the compressor (1) of the reverse cycle to said rotating shaft, in order to reduce its energy consumption.

(34) In another preferred configuration, a generator (8) for the generation of electrical power is connected to said rotating shaft.

(35) Summarizing, the turbine (7), as shown in FIGS. 4 and 5 in a preferred embodiment, comprises preferably a symmetrical structure in which are provided at least: a turbine enclosure (75) defining an interior volume two mutually facing and opposed plugs (60), for closing the interior volume of the turbine enclosure (75) at opposite sides a rotating shaft (33) passing in the interior volume and projecting outside the plugs (60),
said turbine enclosure (75) being provided with: a radial inlet (70) for a pressurized fluid drains (71,72), discharge passages (73, 74);
inside said interior volume of the turbine enclosure (75) being provided at least: an internal ring (50), with an external annular slot for the passage of the pressurized fluid, defining an internal wall of the turbine enclosure (75), a stator volume (51), said ring (50) defining internally a rotor casing (53); said internal ring (50) being provided with stator nozzles (52) connecting the stator volume (51) with the rotor casing (53), a set of power disks (30) housed in said rotor casing (53) and coupled to said rotating shaft (33), a first and a second rotating sealing disks (31) provided at opposite faces of said set of power disks (30) and coupled with said rotating shaft (33), said power disks (30) being provided with rotor axial discharge holes (35), said sealing disks (31) being provided with axial discharge holes (32) aligned with said rotor axial discharge holes (35), a first and a second fixed (non rotating) sealing stator element (54) surrounding at least a portion of respectively said first and second sealing disk (31),
said rotating sealing disk (31) being concentric with respect to the power disks (30) and having an outside diameter that is smaller than the outside diameter of said power disks (30) and being provided with an annular lip (34) engaging a corresponding seat of the sealing stator element (54), a first and a second discharge ring (57) provided between said first and second sealing stator element (54) and said plugs (60), said first and second discharge ring (57) being provided with radial discharge ring holes (59), said sealing disk axial discharge holes (32) being in fluid communication with said radial discharge ring holes (59), said radial discharge ring holes (59) being in fluid communication with said discharge passages (73, 74) of the turbine enclosure (75).

(36) In this embodiment, said drains (71,72) are drains provided in the peripheral portion of the rotor casing (53) as above described.

(37) In another embodiment (that can be seen as a basic embodiment), the turbine (7) does not show a symmetrical structure, and the turbine (7) comprises: a turbine enclosure (75) defining an interior volume two mutually facing and opposed plugs (60), for closing the interior volume of the turbine enclosure (75) at opposite sides a rotating shaft (33) passing in the interior volume and projecting outside the plugs (60),
said turbine enclosure (75) being provided with: a radial inlet (70) for a pressurized fluid drains (71), discharge passages (73);
inside said interior volume of the turbine enclosure (75) being provided at least: an internal ring (50), with an external annular slot for the passage of the pressurized fluid, defining, with an internal wall of the turbine enclosure (75), a stator volume (51), said ring (50) defining internally a rotor casing (53); said internal ring (50) being provided with stator nozzles (52) connecting the stator volume (51) with the rotor casing (53), a set of power disks (30) housed in said rotor casing (53) and coupled to said rotating shaft (33), a rotating sealing disk (31) provided at one face of said set of power disks (30) and coupled with said rotating shaft (33),
said power disks (30) being provided with rotor axial discharge holes (35), said sealing disk (31) being provided with sealing disk axial discharge holes (32) aligned with said rotor axial discharge holes (35), a sealing stator element (54) surrounding at least a portion of said rotating sealing disk (31),
said rotating sealing disk (31) being concentric with respect to the power disks (30) and having an outside diameter that is smaller than the outside diameter of said power disks (30) and being provided with an annular lip (34) engaging a corresponding seat of the sealing stator element (54), a discharge ring (57) provided between said sealing stator element (54) and said plug (60), said discharge ring (57) being provided with radial discharge ring holes (59),
said sealing disk axial discharge holes (32) being in fluid communication with said radial discharge ring holes (59), said radial discharge ring holes (59) being in fluid communication with said discharge passage (73) of the turbine enclosure (75).

(38) In this embodiment, said drain (71) is a drain provided in the peripheral portion of the rotor casing (53) as above described.

(39) Consider a reverse cycle, which utilizes R134a as working fluid and operates between the conditions at the evaporator (9) of 4 bar and 8.9° C. and the conditions at the condenser (3) of 16 bar and 57.9° C.; adopt the typical convention of thermodynamics, for which the positive sign is associated with the heat provided to the cycle (or absorbed by the cycle) and to the work produced by the cycle; let the coefficient of performance (COP) be the ratio between the heat absorbed by the evaporator and the absolute value of the work that is required in total by the cycle. In the case of a traditional reverse cycle, i.e. with a dissipative expansion device such as a throttling valve, assuming an isentropic adiabatic efficiency in compression equal to 80%, a COP equal to 1.98 is obtained. If the flow rate of working fluid is equal to 2 kg/s, the power absorbed by the compressor (1) is −119.3 kW. If the boundary layer turbine (7) according to the present disclosure is installed in place of the throttling valve, the power consumed in total to the reverse cycle is reduced and the COP increases, as shown in the table below, as the isoentropic adiabatic efficiency of the turbine varies.

(40) TABLE-US-00001 Turbine Turbine Turbine Throttling with ηis = with ηis = with ηis = valve 100% 70% 40% Pcompr [kW] −119.3 −119.3 −119.3 −119.3 Pturb [kW] 0.0 13.4 9.4 5.4 Pabsorbed [kW] −119.3 −105.8 −109.9 −113.9 Qcond [kW] −355.9 −355.9 −355.9 −355.9 Qeva [kW] 236.6 250.0 246.0 242.0 COP 1.98 2.36 2.24 2.13 COP variation — +19% +13% 7.00%

(41) The use of the boundary layer turbine instead of the throttling valve, together with the possibility of energy recovery has been demonstrated experimentally by means of a prototype: FIG. 3 shows the detected rotational speed of the boundary layer turbine during a power-on and power-off test of the prototype reverse cycle.

(42) The aim and objectives listed above are thus achieved.

(43) Numerous variations to what has been described so far are obviously possible.

(44) For example, with reference to FIG. 1, the working fluid that arrives from the condenser of the reverse cycle and is directed to the turbine can be diverted partially or fully through the adjustment bypass valve (4), in order to optimize the performance of the turbine as the operating conditions of the reverse cycle vary. Also, for example, the turbine might perform a partial expansion of the working fluid. Also, for example, the working fluid can be throttled upstream or downstream of the turbine by means of appropriate adjustment throttling valves (5, 6). These valves (4, 5, 6) can be present individually or in pairs or all three simultaneously. The use of these adjustment valves, as the operating conditions of the reverse cycle vary, allows the correct outflow of the liquid fraction of the working fluid from the wheel chamber to the outlet of the turbine through the discharge drains (71, 72), avoiding both the flooding of the peripheral part of the power disks (30) with consequent viscous losses and the maximization of the vapor fraction in the working fluid portion flowing through the rotor, which vapor fraction otherwise might partially leak through said discharge drains (71, 72). Moreover, for example, the flooding of the wheel chamber or the passage of a part of the vapor fraction through the discharge drains (71, 72) can be avoided by adjusting properly the passage section of said discharge drains (71, 72), in order to adjust the mass flow rate of working fluid drained from the wheel chamber (53).

(45) As a further example, with reference to FIG. 4, the outside diameter of the wheel chamber (53) can be any one greater than the outside diameter of the power disks (30), without necessarily causing the wheel chamber to contain as precisely as possible said power disks, i.e., with minimal radial gap between the wheel chamber and the power disks.

(46) As a further example, with reference to FIG. 5, the sealing disk (31) can have both radial-symmetrical slots and axial-symmetrical slots, or only one of the two options, in order to hinder the passage of working fluid from the periphery of the power disks to the discharge holes (35, 32, 59).

(47) As a further example, with reference to FIG. 5, the sealing disk (31) has an outside diameter that is smaller than the inside diameter of the sealing rotor element (54) within which it rotates.

(48) As a further example, with reference to FIG. 1, the boundary layer turbines might be more than one, arranged in series or in parallel from the point of view of the working fluid. Said turbines might process all or a fraction of the flow rate of the working fluid. Likewise, all or only some of the adjustment valves (4, 5, 6), as well as the adjustment of the cross-section of the discharge drains (71, 72), might be repeated for each turbine. Furthermore, the compression of the working fluid might occur in more than one compressor (1), arranged in a series or parallel configuration from the point of view of the working fluid.

(49) The disclosures in Italian Patent Application No. 102016000132467 (UA2016A009642) from which this application claims priority are incorporated herein by reference.