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refrigerant system is provided with a multi-stage compression system. An intercooler is positioned
between at least two compression stages to cool a refrigerant, by heat transfer interaction with a
secondary fluid, after it has been compressed in the lower compression stages to some intermediate
pressure. The intercooler enhances refrigerant system performance, improves compressor reliability,
and extends operational envelope. Further, at least one economizer circuit is incorporated into the
refrigerant system that returns the economized refrigerant flow at the location between at least two
compression stages.

1. A refrigerant system comprising: at least two compression stages connected in series with respect
to a refrigerant flow, a condenser positioned downstream of said at least two compression stages,
an expansion device positioned downstream of said condenser and an evaporator positioned
downstream of said expansion device, refrigerant passing through said at least two compression
stages, to said condenser, to said main expansion device, to said evaporator, and then returning to a
lower compression stage of said at least two compression stages; and an economizer circuit
incorporated into the refrigerant system, said economizer circuit including an economizer heat
exchanger for receiving a portion of refrigerant tapped from a liquid line in the main circuit, and
expanded to an intermediate pressure, said tapped expanded refrigerant cooling a refrigerant
flowing in said liquid line through said economizer heat exchanger, and said tapped refrigerant then
being returned to an injection point intermediate said at least two compression stages, and an
intercooler heat exchanger positioned between said at least two compression stages.

2. The refrigerant system as set forth in claim 1, wherein at least two compression stages are
represented by separate compressor units.

3. The refrigerant system as set forth in claim 1, wherein at least two compression stages are
represented by compression members within the same compressor.

4. The refrigerant system as set forth in claim 1, wherein there are at least three of said compression
stages, and said injection point for said tapped refrigerant and said intercooler are positioned
between different compression stages.

5. The refrigerant system as set forth in claim 4, wherein said intercooler is positioned between
higher compression stages and said injection point is positioned between lower compression stages
with respect to refrigerant flow.

6. The refrigerant system as set forth in claim 4, wherein said intercooler is positioned between lower
compression stages and said injection point is positioned between higher compression stages with
respect to refrigerant flow.

7. The refrigerant system as set forth in claim 1, wherein said injection point for said tapped
refrigerant and said intercooler are positioned between the same compression stages.

8. The refrigerant system as set forth in claim 7, wherein said intercooler is positioned downstream
of said injection point with respect to refrigerant flow.

9. The refrigerant system as set forth in claim 7, wherein said intercooler is positioned upstream of
said injection point with respect to refrigerant flow.

10. The refrigerant system as set forth in claim 1, wherein said tapped refrigerant is tapped from a
location upstream of said economizer heat exchanger.

11. The refrigerant system as set forth in claim 1, wherein said tapped refrigerant is tapped from a
point downstream of said economizer heat exchanger.

12. The refrigerant system as set forth in claim 1, wherein said refrigerant system operates for at
least for a portion of the time in the transcritical cycle.

13. The refrigerant system as set forth in claim 1, wherein said refrigerant system operates for at
least for a portion of the time in the subcritical cycle.

14. The refrigerant system as set forth in claim 1, wherein said refrigerant system utilizes CO2 as a
refrigerant.

15. The refrigerant system as set forth in claim 1, wherein a relative position of said intercooler and
said injection point with respect to refrigerant flow is at least partially defined based on at least one
of a temperature of a source for a secondary fluid supplied to the intercooler and relative importance
of capacity and efficiency provided by the economizer circuit.

16. The refrigerant system as set forth in claim 1, wherein an absolute position of said intercooler
and said injection point with respect to compression stages is at least partially defined based on at
least one of discharge temperature, environmental conditions, required refrigerant system efficiency,
required refrigerant system capacity, required unloading options and a temperature of a source for a
secondary fluid supplied to the intercooler.

17. A method of operating a refrigerant system comprising the steps of: (1) providing at least two
compression stages connected in series with respect to a refrigerant flow, a condenser positioned
downstream of said at least two compression stages, an expansion device positioned downstream of
said condenser and an evaporator positioned downstream of said expansion device, refrigerant
passing through said at least two compression stages, to said condenser, to said main expansion
device, to said evaporator, and then returning to a lower compression stage of said at least two
compression stages; and (2) providing an economizer circuit incorporated into the refrigerant
system, said economizer circuit including an economizer heat exchanger for receiving a portion of
refrigerant tapped from a liquid line in the main circuit, and expanded to an intermediate pressure,
using said tapped expanded refrigerant to cool a refrigerant flowing in said liquid line through said
economizer heat exchanger, and said tapped refrigerant then being returned to an injection point
intermediate said at least two compression stages, and positioning an intercooler heat exchanger
between said at least two compression stages.

18. The method as set forth in claim 17, wherein there are at least three of said compression stages,
and said injection point for said tapped refrigerant and said intercooler are positioned between
different compression stages.

19. The method as set forth in claim 18, wherein said intercooler is positioned between higher
compression stages and said injection point is positioned between lower compression stages with
respect to refrigerant flow.

20. The method as set forth in claim 18, wherein said intercooler is positioned between lower
compression stages and said injection point is positioned between higher compression stages with
respect to refrigerant flow.
21. The method as set forth in claim 17, wherein said injection point for said tapped refrigerant and
said intercooler are positioned between the same compression stages.

22. The method as set forth in claim 21, wherein said intercooler is positioned downstream of said
injection point with respect to refrigerant flow.

23. The method as set forth in claim 21, wherein said intercooler is positioned upstream of said
injection point with respect to refrigerant flow.

24. The method as set forth in claim 17, wherein said tapped refrigerant is tapped from a location
upstream of said economizer heat exchanger.

25. The method as set forth in claim 17, wherein said tapped refrigerant is tapped from a point
downstream of said economizer heat exchanger.

26. The method as set forth in claim 17, wherein said refrigerant system operates at least for a
portion of the time in the transcritical cycle.

27. The method as set forth in claim 17, wherein said refrigerant system operates at least for a
portion of the time in the subcritical cycle.

28. The method as set forth in claim 17, wherein said refrigerant system utilizes CO2 as a
refrigerant.

29. The method as set forth in claim 17, wherein a relative position of said intercooler and said
injection point with respect to refrigerant flow is at least partially defined based on at least one of a
temperature of a source for a secondary fluid supplied to the intercooler and relative importance of
capacity and efficiency provided by the economizer circuit.

30. The method as set forth in claim 17, wherein an absolute position of said intercooler and said
injection point with respect to compression stages is at least partially defined based on at least one
of discharge temperature, environmental conditions, required refrigerant system efficiency, required
refrigerant system capacity, required unloading options and a temperature of a source for a
secondary fluid supplied to the intercooler.



Î
 
  

This application relates to a refrigerant system with a multi-stage compressor that combines the
benefits of an intercooler heat exchanger and an economizer cycle. In particular, this application
relates to a refrigerant system operating, at least for a portion of the time, in a transcritical cycle.

Refrigerant systems are known, and are utilized to condition a secondary fluid. As an example, an
air conditioning system cools and dehumidifies air being delivered into a climate controlled
environment.

A basic refrigerant system includes a compressor compressing refrigerant and delivering that
refrigerant through a discharge line downstream to a first heat exchanger, a so-called condenser for
subcritical applications or a gas cooler for transcritical applications. In the first heat exchanger, the
heat is removed from the refrigerant by a secondary media, such as ambient air. From the first heat
exchanger, refrigerant passes through an expansion device, where it is expanded to a lower
pressure and temperature, and then through a second heat exchanger or so-called evaporator,
where the heat is transferred to the refrigerant from other secondary fluid, such as indoor air, to be
conditioned and delivered to a climate controlled environment. The refrigerant is then returned to the
compressor to repeat the cycle.

To obtain additional capacity, enhance system efficiency and achieve higher compression ratios, it is
often the case that a multi-stage compressor is provided in a refrigerant system. With a multi-stage
compressor, several separate compression members or several separate compressor units are
disposed in series in a refrigerant system. Specifically, for instance, in the case of a two-stage
reciprocating compressor, two separate compression members may be represented by different
banks of cylinders connected in series. Refrigerant compressed by a lower stage to an intermediate
pressure is delivered from a discharge outlet of this lower compression stage to the suction inlet of
the higher compression stage. For a multi-stage compression system, this process is repeated. If the
compression ratio for the compressor system is high (which is typically the case for multi-stage
compression systems) and/or refrigerant suction temperature is high (which is often the case for a
refrigerant system equipped with a liquid-suction heat exchanger), then refrigerant discharge
temperature can also become extremely high, and may exceed the limit defined by safety or
reliability considerations.

Thus, it is known in the art to provide an intercooler heat exchanger (or a so-called intercooler)
between the high and low compression stages to extend the operational envelope and/or improve
system reliability. In the intercooler, refrigerant flowing between the two compression stages is
typically cooled by a secondary fluid. Quite often, additional components and circuitry are required to
provide cooling of the refrigerant in the intercooler. As an example, a fan or pump is supplied to
move a secondary cooling fluid from a cold temperature source to cool the refrigerant in the
intercooler.

Another option that is known in the refrigerant art is the use of an economizer cycle. An economizer
cycle taps a portion of refrigerant from a liquid refrigerant line and expands the tapped refrigerant to
some intermediate (between suction and discharge) pressure. The partially expanded tapped
refrigerant is then passed through a heat exchanger in heat exchange relationship with the liquid
refrigerant flow circulating through the main refrigerant circuit and prior to entering main expansion
device. In this manner, the main refrigerant flow in the liquid line is cooled, while the tapped portion
of refrigerant flow is evaporated and typically superheated. The tapped refrigerant is then returned to
an intermediate pressure point in a compression system. As also known, a flash tank separating
vapor and liquid phases of refrigerant may be used as the economizer heat exchanger and
essentially provide similar benefits to the refrigerant system performance and operation.

The combination of the intercooler heat exchanger and the economizer cycle has not been fully
realized for multi-stage compression systems and would be especially beneficial in modern
refrigerant systems that are operating, at least for portion of the time, in transcritical cycle and
utilizing natural refrigerants such as carbon dioxide (also known as CO2 or R744).

In particular, with the CO 2 refrigerant systems, the intercooler heat exchanger and the economizer
cycle become even more important, as these systems tend to operate at high discharge
temperatures due to high operating pressure ratios, and, in general, by the transcritical nature of the
CO 2 cycle, as well as a high value of the polytropic compression exponent for the CO 2 refrigerant.
However, the additional cost and complexity of the circuitry and components associated with the
intercooler and economizer, makes the provision of the intercooler less feasible. However, it become
desirable to provide proper intercooler and economizer configurations for multi-stage compressor
refrigerant systems, and particularly for CO 2 refrigerant systems, for the reasons described above.
V  
  

In a disclosed embodiment of this invention, a refrigerant system is provided with at least two
compression stages connected in series. The refrigerant is progressively compressed to a higher
pressure while flowing from a lower compression stage to a higher compression stage. At least one
intercooler is placed between at least the two compression stages to cool the refrigerant after it exits
the lower stage and before it enters the higher stage. In addition, the refrigerant system incorporates
at least one economizer cycle, with the tapped portion of refrigerant returned from the economizer
branch to an intermediate compression point between the higher and lower compression stages. In
one embodiment, there are at least three compression stages connected in series, and the tapped
portion of refrigerant is returned to a point in the compression cycle between the two compression
stages that are different from the compression stages between which the intercooler is located. In
this embodiment, the intercooler is preferably positioned downstream of the return point of the
tapped economized refrigerant. In another embodiment, the intercooler and the economizer branch
tapped refrigerant return point are positioned between the same two compression stages, with the
economized refrigerant return point being preferably located downstream of the intercooler heat
exchanger.

Preferably, the intercooler heat exchanger is positioned between the higher compression stages of
the multi-stage compression system (with more than two compression stages), where refrigerant
temperatures have reached higher values, allowing for larger temperature differentials between the
refrigerant and a secondary fluid, enhancing heat rejection capability, and improving performance of
the refrigerant system. This is especially beneficial when ambient air is utilized directly or indirectly
(e.g., through auxiliary loops with an intermediate fluid, such as city water) as a secondary fluid, in
particular, at high ambient temperatures. The locations for the intercooler and the economizer circuit
can be interchanged, with the intercooler positioned between the lower compression stages and the
economizer circuit positioned between the higher compression stages, depending on the
temperature of the secondary fluid utilized in the intercooler and capacity vs. efficiency tradeoff for
the economizer circuit.

On the other hand, strategically positioning the economizer circuit between the lower compression
stages allows for larger temperature differentials in the economizer heat exchanger and thus for
higher refrigerant cooling potential in the evaporator and the refrigerant system performance
(capacity and/or efficiency) enhancement. Also, the colder refrigerant injected between the
compression stages further reduces discharge temperature, improves reliability of the entire
compression system, extends an operational envelope for the refrigerant system and enhances
evaporator dehumidification capability. Lastly, positioning the economizer circuit between lower
compression stages allows for a larger step in refrigerant system unloading strategy, which is
desired in most of the applications.

This is especially important in case of transcritical operation, where the high side temperature and
pressure are independent from each other. In the transcritical operation, the discharge pressure is
not limited by the discharge temperature anymore and can be adjusted to the value providing an
optimum performance level. Thus, in such circumstances, the refrigerant system efficiency and
capacity can be enhanced even further by optimizing the discharge pressure.

In another embodiment, both intercooler and economizer circuit are positioned between the same
compression stages. Once again, the relative position of the intercooler and the economizer circuit,
with respect to refrigerant flow primarily depends on the temperature of the secondary fluid utilized in
the intercooler and capacity-efficiency tradeoff for the economizer circuit.
These and other features of the present invention can be best understood from the following
specification and drawings, the following of which is a brief description.

Î
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  V

FIG. 1 shows a first schematic view of a refrigerant system incorporating the present invention.

FIG. 2 shows a second schematic view of a refrigerant system incorporating the present invention.

     V
 
 
  Î V

A refrigerant system  is illustrated in FIG. 1. Three stages of compression 
, , and are
positioned in series within the refrigerant system  to progressively compress refrigerant from
suction to discharge pressure. Although a multi-stage compressor system is represented by
separate compressor units that are disposed in series, as shown in FIG. 1, separate compression
members can be utilized instead of some or all of the compressor units. Specifically, for instance, in
the case of a three-stage reciprocating compressor, the three separate compression members may
represent different banks of cylinders connected in series. Refrigerant, compressed by the first stage
from a suction pressure to a first intermediate pressure, is delivered from a discharge outlet of this
first stage to the suction inlet of the second stage. Refrigerant vapor is compressed by the second
stage to a second intermediate pressure and delivered from a discharge outlet of this second stage
to the suction inlet of the third stage. Lastly, refrigerant, compressed by the third stage to a
discharge pressure, is delivered from a discharge outlet of this third stage to a discharge line of a
refrigerant system. An intercooler heat exchanger is positioned between the second and third
compression stages and . Secondary fluid, such as air blown by a fan , passes over the
intercooler to cool the refrigerant.

Cooling refrigerant in the intercooler increases system capacity and efficiency, since the
compressor discharge temperature is reduced and the first or outdoor heat exchanger
(a
condenser in the subcritical cycle and a gas cooler in the transcritical cycle) will be capable of
cooling refrigerant to a lower temperature, eventually providing a higher cooling potential for the
refrigerant entering the evaporator ! . Compressor power is also reduced, as heat removed from
the compression process decreases the operating pressure of the outdoor heat exchanger
.
Additionally, if the refrigerant system  operates in a transcritical cycle, where the high side
temperature and pressure are independent from each other, the discharge pressure is not limited by
a discharge temperature anymore and can be adjusted to a value corresponding to an optimum
performance level. Moreover, in both subcritical and transcritical cycles, the temperature of the
refrigerant discharged from the highest, third compression stage is reduced, improving overall
reliability of the compression system. Thus, performance (efficiency and capacity) of the refrigerant
system  is increased and compressor reliability is improved.

The present invention is particularly useful in refrigerant systems that utilize CO 2 as a refrigerant,
since CO 2 refrigerant has a high value of a polytropic compression exponent, and the discharge
operating pressures and pressure ratios of such systems can be very high, promoting higher than
normal discharge temperatures. Still, the invention would extend to refrigerant systems utilizing other
refrigerants.

Preferably, the intercooler heat exchanger is positioned between the higher compression stages,
such as the compression stages and in FIG. 1, where refrigerant temperature have reached
the higher values, allowing for the larger temperature differentials between the refrigerant and
secondary fluid, enhanced heat rejection capability, and superior performance of the refrigerant
system  . This is especially beneficial when ambient air is utilized directly or indirectly (e.g.,
through auxiliary loops with an intermediate fluid, such as city water) as a secondary fluid, in
particular, at high ambient temperatures.

From the third compression stage , the refrigerant passes through the outdoor heat
exchanger
, and then to an economizer heat exchanger . As known, a tapped portion of
refrigerant in a tap line is tapped from a liquid line
. The tapped refrigerant in the tap
line passes through an economizer expansion device
, where it is expanded to some
intermediate (between suction and discharge) pressure. During the expansion process in the
economizer expansion device
, the temperature of the tapped portion of refrigerant is reduced as
well. Therefore, the tapped expanded refrigerant flowing through the economizer heat
exchanger is able to cool refrigerant in the liquid line
. Although, for illustration simplicity, the
two refrigerant streams are shown flowing in the same direction, in this embodiment, in practice, it is
desirable to arrange the two flows in the counterflow configuration. The tapped portion of refrigerant
is evaporated and typically superheated, during heat transfer interaction with the liquid refrigerant in
the liquid line
in the economizer heat exchanger , and is returned through a vapor injection
refrigerant line

to an intermediate point
between the first and second compression
stages 
and .

Downstream of the economizer heat exchanger , refrigerant in the liquid line
, having been
cooled to a lower temperature in the economizer heat exchanger and therefore having higher
cooling potential, passes through a main expansion device
, where it is expanded to a pressure
approximated the suction pressure, and then through an evaporator ! , where it conditions a
secondary fluid supplied to a climate controlled environment, while the refrigerant is evaporated and
typically superheated prior to entering the compression system. From the evaporator ! , the
refrigerant is returned to the first compressor stage 
to repeat the cycle.

As known, in a majority of the cases, the economizer cycle allows for enhanced performance
(capacity and/or efficiency), reduced discharge temperature, improved reliability, more flexible
unloading strategy and better dehumidification capability. Strategically positioning the economizer
circuit return line

between the lower compression stages, such as the compressor
stages 
and in FIG. 1, allows expansion of the tapped portion of refrigerant in the economizer
expansion device
to a lower intermediate pressure, and thus obtaining larger temperature
differentials in the economizer heat exchanger between the refrigerant in the liquid line
to be
cooled and the tapped portion of refrigerant. These higher temperature differentials in turn allow for
lower temperatures of the refrigerant in the liquid line
and higher cooling potential in the
evaporator ! . Therefore, the system performance (capacity and/or efficiency), as well as its
dehumidification capability, can be increased significantly, by locating the vapor injection line

of
the economizer cycle between lower compression stages. Also, the colder refrigerant injected
between the compression stages 
and further reduces discharge temperature, improves
reliability of the entire compression system and extends the operational envelope for the refrigerant
system  . Once again, this is especially important in case of transcritical operation, where the high
side temperature and pressure are not directly related to each other, i.e. the discharge pressure is
not limited by the discharge temperature anymore and can be adjusted to the value providing an
optimum performance level. Thus, in such circumstances, refrigerant system efficiency and capacity
can be enhanced even further by optimizing the discharge pressure. Additionally, it is beneficial in
situations where the intercooler heat exchanger alone is not capable of performing the desired
function and assuring efficient and reliable operation of the refrigerant system  . Lastly, positioning
the vapor injection line

between the lower compression stages 
and allows for a large step
in refrigerant system unloading, which is desired in most of the applications.

By incorporating the intercooler heat exchanger and the economizer cycle, and utilizing strategic
locations for both enhancement option, the present invention provides maximum benefits in
performance (capacity and/or efficiency), reliability, operational envelope extension, unloading
capability, dehumidification flexibility and ability to achieve precise control over the temperature and
humidity in the conditioned environment

Although only three compression stages are shown in FIG. 1, refrigerant systems having more than
three compression stages, with the economizer circuit preferably positioned between the lower
compression stages and the intercooler heat exchanger positioned between the higher compression
stages, can equally benefit and are within the scope of the present invention. Further, depending on
the temperature of the fluid utilized to cool refrigerant in the intercooler (to obtain an overall
counterflow configuration) and a tradeoff between refrigerant system capacity and efficiency related
to the economizer circuit, the locations of the intercooler and the return point of the vapor injection
line

can be interchanged, with the intercooler being positioned between the lower compression
stages and the economizer circuit positioned between higher compression stages.

FIG. 2 shows another embodiment  , wherein the refrigerant system incorporates a higher stage
and a lower stage of compression and 
respectively, with the intercooler heat
exchanger and the return point for the vapor injection line

of the economizer branch both
being positioned intermediate the two compression stages. As shown in this embodiment, the return
point of the vapor injection line

is located downstream of the intercooler , with respect to
refrigerant flow. Further, in this embodiment, the tap line " for tapping the portion of refrigerant to
pass through the economizer heat exchanger is positioned downstream of the economizer heat
exchanger . The economizer circuit and economizer expansion device "operate as in the FIG. 1
embodiment. Also, rather than utilizing the fan of FIG. 1, a fluid conduit  is used to cool the
refrigerant in the intercooler heat exchanger . The fluid in the conduit  can be supplied, for
instance, by a pump (not shown). Although the refrigerant system  shown in FIG. 2 has less
flexibility and potential for operation enhancement, in comparison to the FIG. 1 embodiment, the
benefits obtained from the combination of the intercooler and economizer circuit are still
significant. Obviously, the location of the return point of the vapor injection line

can also be
upstream of the intercooler heat exchanger , with respect to refrigerant flow, and depends on the
temperature of cooling fluid in the conduit  , in order to provide most efficient overall conterflow
configuration. Refrigerant systems with more than two compression stages can equally benefit from
this embodiment, where the intercooler heat exchanger and the economizer circuit positioned
between the same compression stages.

It should be pointed out that many different compressor types could be used in this invention. For
example, scroll, screw, rotary, or reciprocating compressors can be employed. The use of a lower
and upper compression stage can be combined within a single compressor, where the vapor
injection would take place at the intermediate location in the compression cycle for this compressor.
Alternatively, the upper and lower compression stages can be represented by a separate
compression elements, with the vapor injection or intercooling taking place between the stages. The
compression elements can be separate compressor units or the compression elements can be a
part of a single compressor, as it is the case for a reciprocating compressor where each
compression element can be represented by a single bank of cylinders for this reciprocating
compressor. The refrigerant systems that utilize this invention can be applied in many different
applications, including, but not limited to, air conditioning systems, heat pump systems, marine
container units, refrigerated truck-trailer systems, and supermarket refrigeration applications.

Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in
this art would recognize that certain modifications would come within the scope of this invention. For
that reason, the following claims should be studied to determine the true scope and content of this
invention.
 #$ (US), or # (UK/international), are mechanical devices
intended to reduce energy consumption, or to perform another useful function like
preheating a fluid. The term economizer is used for other purposes as well. Boiler,
powerplant, and heating, ventilating, and air-conditioning (HVAC) uses are discussed in this
article. In simple terms, an economizer is a heat exchanger.

à
  

   

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%
There are several kinds of compressors--reciprocating, screw, centrifugal. We'll use a reciprocating
compressor in this example. It's got a piston moving back and forth in a cylinder to compress the air.
(It's like a car engine, and you can get a kit to turn an old Volkswagen engine into a compressor.)
This assembly is called a stage.
The cheapest compressors are single-stage units--they have one piston and cylinder. The air from
the atmosphere is sucked into the assembly, compressed then sent to the tank.
Next come two-stage compressors, which have a low-pressure stage and a high-pressure stage.
The air from the first stage is compressed again by the second stage, which gives more pressure
with less stress on the unit. It's easier on the compressor to take air from 2 atmospheres to 4 than it
is to go from 1 atmosphere to 4.
A three-stage compressor takes this doubly compressed air and compresses it again, and a four-
stage compressor has a fourth compression step.
Most of the people who buy three-stage compressors fill diving tanks with them--you need to be able
to make 5000 psi to fill a diving tank, and three-stage compressors are good for that.
?