CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/397,801, filed August 12, 2022 and U.S. Provisional Patent Application No. 63/435,045, filed December 23, 2022, both of which are incorporated by reference herein their entireties. In addition, this application claims the benefit of and priority to U.S. Patent Application No.

18/204,861, filed June 1, 2023 and U.S. Patent Application No. 17/959,165, filed October 3, 2022, both of which are incorporated by reference herein in their entireties.

BACKGROUND

[0002] In order to protect the global ozone layer, only zero ozone depletion potential (0 ODP) refrigerants are utilized globally in new commercial refrigeration systems. Due to global warming concerns, there is a global goal to set a top end threshold of 500 Global Warming Potential (GWP) for refrigerants utilized in mechanical cooling. Mechanical cooling applications are often categorized as high temperature, or air conditioning, and low temperature, or refrigeration. Some blend refrigerants are now available with GWP under the 500 threshold, but they have flammability or toxicity issues. These low GWP flammable refrigerants are not generally suitable for use in indoor refrigeration systems.

[0003] The natural refrigerants such as R717 (ammonia), R744 (CO2), and R290 (propane) are all below the 500 GWP line. These refrigerants all have technical issues that must be addressed for normal use in commercial refrigeration.

SAFETY GROUP

F I L N A C M R M E A A B S I I L N I G T

Y

INCREASING TOXICITY

[0004] As commercial refrigeration solutions are sought in order to reach the sub 500 GWP refrigeration system goal, one can omit systems with refrigerant larger refrigerant charges, perhaps more than 10 lbs, for indoor use due to the code, or end user, mandated maximum indoor charge of A2 and A3 refrigerants. In low temperature refrigeration systems operating below - 30 °F, cascade refrigeration systems have been employed in order to meet the low temperature requirements. These cascade refrigeration systems utilize one refrigerant for a low stage refrigeration system. The -30 °F low stage refrigeration system rejects the high side heat, condenser heat, to the condenser side of a heat exchanger. The high stage refrigeration system removes the condenser heat through the evaporator side of the cascade heat exchanger. This design allows the refrigeration systems to have higher, efficiency, less horsepower, lower pressures and lower discharge temperatures.

[0005] In order to operate sub 500 GWP Al refrigeration systems with indoor components the natural refrigerant R744 (CO2) appears to be a suitable choice. However, R744 based refrigeration systems have issues with high discharge pressures and operating envelopes above the critical point of the refrigerant. Operation of refrigeration systems in the supercritical domain adds significant complexity requiring added controls, valving, and high-pressure components. This complexity leads to a tripling or quadrupling of the cost of a low temperature refrigeration system. Additionally, if an R744 refrigeration system loses power, the refrigerant in the system gradually warms up. At a temperature of 85 °F, R744 will be at a pressure 1,108 psi above the atmosphere. This pressure exceeds the operating pressure of most refrigeration system tanks, so the refrigerant charge has to be released to atmosphere through a pressure relief device if the power outage is long enough for the R744 refrigerant to warm up to 85 °F anywhere within the system. Thus, as described herein, certain improvements are provided to a cascade refrigeration system in order to provide for the use a sub 500 GWP Al refrigerant.

SUMMARY

[0006] Using a cascade refrigeration system it is possible to achieve sub 500 GWP using the Al natural refrigerant R744 on all indoor components of the system. In order to minimize pressures, and therefore component cost, the R744 refrigeration cycle is limited to a saturated condensing temperature of 80 °F, or less. This low condensing temperature is achieved by employing a cascade refrigeration design. Certain sub 500 GWP refrigerants are A2U flammable refrigerants. The high stage refrigeration system that employs a sub 500 GWP refrigerant that has a flammability rating of A2U is installed outdoors (i.e., outside an enclosed structure, contained facility or building) due to the flammability issues of A2L refrigerants. The high stage system can utilize certain newly developed sub 500 GWP A2L such as R454C and R455A in order to provide a suitable high stage solution in a cascade refrigeration system. The high stage system may utilize R454A, R1234YFA or R471A as alternative refrigerants

[0007] The majority of the commercial refrigeration market is made up of refrigeration systems with air cooled condensing units (ACCUs), 2 hp to 500 hp, with refrigerant charge from 10 lb to 300 lb, that operate stand alone with the exception of occasional contractor visits for preventative maintenance or repairs.

[0008] As described herein, an improved sub 500 GWP cascade refrigeration system utilizing air cooled condensing units (ACCU) for the commercial refrigeration market with sub 500 GWP A2L refrigerants may be employed. The preferred refrigeration system includes positioning the entire A2L refrigerant charge contained outdoors, in the high stage cycle, and positioning the R744 natural refrigerant indoors on the low stage for fluid connection to evaporators. In this design, the 500 GWP A2L refrigerant stays inside the outdoor ACCU cabinet, cooling a cascade heat exchanger through evaporation, compression, condensation and expansion. The low stage natural refrigerant R744 liquid flows out of the ACCU through an expansion device, to the evaporator to pick up a heat load, and then return back to the ACCU through a suction line for compression and condensation at lower temperature and pressures than a single stage ACCU.

[0009] Thermal energy storage may be employed in a cascade refrigeration system. When a cascade refrigeration system is installed with a thermal energy storage reservoir surrounding cascade heat exchanger (CHX), then there is a passive buffer available to more evenly maintain condensing temperature for R744 (CO2) or R717 (ammonia) between 65 and 85 °F without the addition active valving or controls. In addition, in the event of a power outage, the thermal energy storage reservoir will maintain an R744 (CO2) system saturation temperature below 85 °F for a longer time, up to one week, during a power outage, preventing a release of the system refrigeration charge due to pressure increase.

[0010] Another cascade refrigeration system can be installed with a thermal energy storage reservoir surrounding cascade refrigerant receiver, or flash tank, for the benefit that in the event of a power outage, the thermal energy storage reservoir will maintain an R744 (CO2) system saturation temperature below 85 °F for a longer time, up to one week, during a power outage, preventing a release of the system refrigeration charge due to pressure increase. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The features, aspects, and advantages of the disclosed deliver system will become apparent from the following description, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

[0012] Figure l is a simplified diagram of a cascade refrigeration system.

[0013] Figure 2 is a pressure enthalpy diagram of a refrigeration cycle for the high stage circuit refrigerant of the cascade refrigeration system.

[0014] Figure 3 is a pressure enthalpy diagram of a refrigeration cycle for the low stage circuit refrigerant of the cascade refrigeration system.

[0015] Figure 4 is a pressure enthalpy diagram of a refrigeration cycle for R454C as a high stage refrigerant of the cascade refrigeration system.

[0016] Figure 5 is a pressure enthalpy diagram of R744 as a low stage refrigerant of the cascade refrigeration system.

[0017] Figure 6 is a simplified diagram of a cascade refrigeration system that includes a desuperheating stage for the low stage refrigeration side.

[0018] Figure 7 is a simplified diagram of anther exemplary embodiment of a cascade refrigeration system that includes a desuperheating stage for the low stage refrigeration side.

[0019] Figure 8 is a pressure enthalpy diagram of a refigeration cycle including R744 as a low stage refrigerant of the cascade refrigeration system for the embodiment shown in Figure 6.

DESCRIPTION

[0020] An exemplary embodiment of a refrigeration system for an enclosed structure capable of sheltering personnel is disclosed herein. The refrigeration system includes a high stage refrigeration circuit including a high stage compressor, a condenser, a high stage expansion device, wherein the high stage refrigeration circuit circulates a high stage refrigerant having a GWP less than 500. The system further includes a low stage refrigeration circuit including a low stage compressor, a low stage expansion device, and an evaporator, wherein the low stage refrigeration circuit is configured to circulate a low stage refrigerant comprising R744. The evaporator is configured to be located within the enclosed structure and the condenser is configured to be located outside the structure. The system further includes a heat exchanger configured to transfer heat from the low stage refrigerant to the high stage refrigerant.

[0021] According to another embodiment, a refrigeration system for a building is disclosed. The refrigeration system includes a high stage refrigeration circuit including a high stage compressor, a condenser upstream of the high stage compressor, a high stage refrigerant receiver downstream of the condenser, a high stage expansion device downstream of the high stage refrigerant receiver. The high stage refrigeration circuit circulates a high stage refrigerant having a GWP less than 500 and a flammability classification of A2 or A2L. The system further includes a low stage refrigeration circuit including a low stage compressor, an evaporator upstream of the low stage compressor, a low stage expansion device upstream of the evaporator, and a low stage refrigerant receiver upstream of the low stage expansion device, wherein the low stage refrigeration circuit is configured to circulate a low stage refrigerant comprising R744. The evaporator is configured to be located within the building and the condenser is configured to be located outside the building. The system further includes a heat exchanger downstream of the low stage compressor and upstream of the high stage compressor configured to transfer heat from the low stage refrigerant to the high stage refrigerant.

[0022] Referring to Figure 1, there is a low stage refrigeration system 11 that utilizes R744 (CO2) to cool a stationary cold room or cold cabinet by the effect of evaporator 70. Compressor 10 compresses R744 refrigerant to a hot, high-pressure gas through discharge pipe 12 that leads to Cascade Heat Exchanger (CHX) 30. CHX 30 discharges waste heat and causes the hot R744 refrigerant gas to cool down and become warm R744 refrigerant liquid at 85°F or cooler. The warm refrigerant liquid passes through pipe 31 to receiver 50. Then the R744 liquid refrigerant passes to pipe 51 to expansion device 52, then through pipe 53 to evaporator 70. In Evaporator 70 the refrigerant absorbs heat and passes through pipe 9 to the R744 refrigeration low stage compressor 10. For a cold storage application, the evaporator 70 would be in a walk-in refrigerator or a refrigerated warehouse. For a supermarket, evaporator 9 could be in a refrigerated merchandiser. There may be a multiple of evaporators 70 piped in a parallel arrangement.

[0023] The CHX 30 may be surrounded by optional thermal energy storage reservoir 35. The reservoir may be included in order to extend the time until refrigerant will be vented through the pressure relief device during a power outage.

[0024] Figure 3 is a low stage refrigeration system pressure enthalpy diagram. Compressor 10 compresses R744 refrigerant to a hot, high-pressure gas through discharge pipe 12 that leads to Cascade Heat Exchanger (CHX) 30. CHX 30 lowers the refrigerant enthalpy, causing the hot R744 refrigerant gas to condense and become warm R744 refrigerant liquid at 85°F or cooler. The warm refrigerant liquid passes through pipe 31 to receiver 50. Then the R744 refrigerant passes on to expansion device 52, then through pipe 53 to evaporator 70. The expansion device lowers the pressure of the low stage refrigerant gas. In evaporator 70, the refrigerant absorbs heat and passes through the pipe 9 to the R744 refrigeration low stage compressor. The cooling effect of the refrigeration unit at the low stage is due to this heat absorption by the evaporator and thus causes an increase in enthalpy from H53 to H9 in the low stage refrigeration circuit upstream of the compressor 10.

[0025] Referring to Figure 1, there is high stage refrigeration system 21 that utilizes a sub 500 GWP A2L refrigerant to cool Cascade Heat Exchanger (CHX) 30. CHX 30 acts as a low stage R744 condenser. Refrigeration system 21 absorbs heat due to the refrigeration effect in CHX 30. Compressor 20 compresses the sub 500 GWP A2L refrigerant to a hot, high-pressure gas through discharge pipe 22 that leads to air cooled condenser 40. Air cooled condenser 40 discharges waste heat to ambient and causes the hot sub 500 GWP A2L refrigerant gas to cool down and become warm sub 500 GWP A2L refrigerant liquid at 129°F or cooler. The warm refrigerant liquid passes through pipe 41 to receiver 60. Then the sub 500 GWP A2L refrigerant passes through pipe 61 to expansion device 62, then through pipe 63 to the cold side of the CHX 30 for evaporation. In CHX 30, the expanding refrigerant absorbs heat and passes through pipe 19 to the sub 500 GWP A2L refrigerant high stage compressor. [0026] Referring to Figure 2, there is a high stage refrigeration system pressure enthalpy diagram. Compressor 20 compresses sub 500 GWP A2L refrigerant to a hot, high-pressure gas through discharge pipe 22 that leads to air cooled condenser 40. The air cooled condenser 40 lowers the refrigerant enthalpy, causing the hot sub 500 GWP A2L gas to condense and become warm sub 500 GWP A2L liquid at 129 °F or cooler. The warm refrigerant liquid passes through pipe 41 to receiver 60. Next, the sub 500 GWP A2L passes on to expansion device 62, then through pipe 63 to CHX 30. In CHX 30, the high stage refrigerant absorbs heat from the low stage refrigerant and passes through pipe 19 to the high stage compressor 20. The heat absorption from CHX 30 causes enthalpy to increase from He3 to H19 in the high stage refrigeration circuit upstream of the compressor 20.

[0027] Referring to Figure 5, there is cascade refrigeration system represented with a low stage R744 pressure enthalpy diagram and a high stage R452C pressure enthalpy diagram. Low stage evaporation is happening at 25 °F saturated suction temperature with the refrigerant enthalpy rising from H53 of 55 btu/lb to H9 142 btu/lb for cooling a 35 °F cold storage warehouse. Low stage condensation is happening at 70 °F saturated discharge temperature. The refrigeration effect of this low stage system equals the low stage compressor mass flow ( tiow ) in btu/min. times a change in enthalpy of 142 - 55 x Mow x 60 = 5,220Mow btu/hr . The heat of rejection of this low stage system equals the compressor mass flow (M) in btu/min. times a change in enthalpy as H ₁₂ of 182 - FL, of 55 x Mow x 60 = 7,620Mow btu/hr.

[0028] Referring to Figure 4, the same cascade refrigeration system is represented with a high stage R452C enthalpy diagram. High stage evaporation is happening at 45°F saturated suction temperature with the refrigerant enthalpy rising from H of 45 btu/lb to H ₁₉ of 113 btu/lb for cooling CHX 30. High stage condensation is happening in the air-cooled condenser at 1 15 °F saturated discharge temperature. The refrigeration effect of this high stage system equals the low stage compressor mass flow ( thigh ) in btu/min. times a change in enthalpy of 113 - 45 x Jlhig x 60 = 4,080 lt igh btu/hr .

[0029] Since energy is conserved, this low stage heat of rejection is equal to the evaporation effect of the high stage refrigeration system. For Figure 4, 7,620 liow btu/hr = 4,080 Ttiigh btu/hr. Usually, the low stage refrigeration system is selected to match the mass flow required of the of the cold room cooling load. Then the high stage refrigeration system is then selected to match the mass flow required of the cascade heat exchanger CHX 30 cooling load coming from the low stage heat of rejection. In summary in this example thigh = 7,620 4,080 = 1.868 ltlow.

[0030] Disclosed herein is an air-cooled condensing unit with a stationary cascade refrigeration system that operates on natural refrigerants that have a global warming potential (GWP) under 500. The low stage refrigeration cycle operates partially indoors preferably utilizing a natural refrigerant R744 (CO2) with an Al non-flammable and non-toxic safety rating. Although R744 is preferred, other non-flammable low GWP refrigerants may be employed in the low stage cycle. The high stage outdoor refrigeration cycle operates on a sub 500 GWP refrigerant blend with a flammability of Al, A2, or A2L.

[0031] The stationary refrigeration system may use R454C, GWP 148 as the high stage refrigerant. Alternatively, the stationary refrigeration system may use R455A, GWP 146 as the high stage refrigerant. In another embodiment, the stationary refrigeration system may use R- 471 A, GWP <150 as the high stage refrigerant. The stationary refrigeration system may include a configuration wherein the high stage refrigerant is R1234YF, GWP 4. In another embodiment, the stationary refrigeration system may use R290, GWP 4 as the high stage refrigerant. In still another embodiment, the stationary refrigeration system may use a blend of R-32 and R-1234yf with a GWP less than or equal to 500, but with a flammability of Al or A2L as the high stage refrigerant. Alternatively, the stationary refrigeration system may use a blend of some or all of R-32, CO2, R277, R-1234zeE and R-1234yf with a GWP less than or equal to 500, but with a flammability of Al or A2L as the high stage refrigerant.

[0032] In one embodiment, the stationary refrigeration system may use R744 (CO2) as the low stage refrigerant and include a thermal energy storage reservoir surrounding the refrigerant receiver or flash tank to extend the time until refrigerant will be vented through the pressure relief device during a power outage. This embodiment utilizes coconut oil in the reservoir. The oil has a melting point of 76 to 79 °F and may be employed as a thermal energy storage medium with an intention of extending the time until the refrigerant in the powerless system rises above 85 F.

[0033] In another embodiment, the stationary refrigeration system may use R744 (CO2) as the low stage refrigerant and include a thermal energy storage reservoir surrounding the refrigerant receiver or flash tank to extend the time until refrigerant will be vented through the pressure relief device during a power outage. This embodiment utilizes a blend of fats or oils with a melting point of 65 to 79 °F as a thermal energy storage medium in the reservoir with an intention of extending the time until the refrigerant in the powerless system rises above 85 F.

[0034] In yet another embodiment, the stationary refrigeration system may use R744 (CO2) as the low stage refrigerant and include a thermal energy storage reservoir surrounding the cascade heat exchanger (CHX) to extend the time until refrigerant will be vented through the pressure relief device during a power outage. This embodiment utilizes coconut oil with a melting point of 76 to 79 °F as the a thermal energy storage medium with an intention of extending the time until the refrigerant in the powerless system rises above 85 °F.

[0035] Alternatively, the stationary refrigeration system may use R744 (CO2) low stage refrigerant and include a thermal energy storage reservoir surrounding the cascade heat exchanger (CHX) to extend the time until refrigerant will be vented through the pressure relief device during a power outage. This embodiment utilizes a blend of fats or oils with a melting point of 65 to 79 °F as the a thermal energy storage medium with an intention of extending the time until the refrigerant in the powerless system rises above 85 °F.

[0036] There exists an opportunity to reduce power consumption of the system and reduce thermal stress on the interstage heat exchanger of the cascade refrigeration system. An alternative embodiment of a cascade refrigeration system is shown in Fig. 6. The system includes a supplemental heat exchanger for the low stage refrigerant. In a preferred embodiment, the system includes an extended discharge pipe 12 to that carries the hot R744 discharge gas from compressor 10 to an R471A air cooled condenser assembly 40. The R471A air cooled condenser assembly may include a separated secondary circuit of tubing that will use the main condenser fan to cool the hot R744 in discharge pipe 12 from a temperature between 180 F and 220 F down to a temperature between 80 F and 110 F. As the R744 hot gas passes through condenser 40, the gas tends to desuperheat, but does not condense since the condensing occurs in the Heat Exchanger (CHX) 30 which condenses the refrigerant to a much lower temperature of 40F. As the R744 refrigerant exits condenser 40 the refrigerant is carried by the discharge pipe 12 to the Cascade Heat Exchanger (CHX) 30 for condensing. The cooling provided by the condenser reduces thermal stress on Cascade Heat Exchanger (CHX) 30 since the refrigerant is cooled by roughly 100 degrees F as the refrigerant passes through condenser 40.

[0037] Although Fig. 6 shows the additional cooling stage occurring in the piping and a separated portion of the high side or high stage condenser, the additional cooling may occur in a separate heat exchanger not integrated with the high stage. Also, the refrigerant used on the high stage is preferably R471A, but may include any suitable low GWP (preferably also having a low flammability).

[0038] The configuration shown in Fig. 6 also provides further energy savings due to the cooling that may occur due to the temperature difference between ambient air and the refrigerant contained in the discharged pipe 12. In particular, there may be energy savings that results from desuperheating that occurs within discharge pipe 12 as the R744 passes through condenser 40. As a result of the additional cooling step provided by the system shown in Fig. 6, when the ambient air lowers the temperature of the hot R744 gas entering Cascade Heat Exchanger (CHX) 30 for condensing, less heat is low stage heat is transferred into CHX30 (see Fig. 8). The configuration shown in Fig. 6 also reduces the work for the high stage compressor 20. The reduction in compressor work provides a direct increase in system efficiency.

[0039] Figure 7 shows an alternative embodiment where both the high stage 21 and the low stage 11 include parallel compressors 20a/20b and lOa/lOb, respectively. The parallel compressor configuration may provide benefits over the single compressor, such as increased efficiency due to the distribution of the workload and providing redundancy in the event of failure of one compressor. The parallel compressor configuration may be utilized for the high side or low side or both. In addition, the parallel compressor configuration may be utilized with the desuperheating configuration or with the configurat shown in Fig. 1.

[0040] It should be noted that the term “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0041] It is important to note that refrigeration system shown in the various exemplary embodiments is illustrative only. Although several embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that other embodiments are possible and are contained within the scope of the invention. For example, modifications are possible (e g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or resequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.