Method and apparatus for optimizing refrigeration systems

• US 9,423,165 B2
• Filed: 06/10/2013
• Issued: 08/23/2016
• Est. Priority Date: 12/09/2002
• Status: Active Grant

• Current Assignee: Hudson Technologies, Inc.
• Original Assignee: Hudson Technologies, Inc.
• Inventors: Zugibe, Kevin, Papar, Riyaz
• Primary Examiner(s): VON BUHR, MARIA N
• Application Number:
  US13/913,664
• Publication Number:
  US 20130269376A1
• Time in Patent Office: 1,170 Days
• Field of Search: 700 28- 31, 700/275, 700/281, 700/282, 62207-209, 622/14, 622/15, 62226-230, 712/233, 712/241
• US Class Current: 1/1
• CPC Class Codes: F25B 2500/16 Lubrication
• CPC Class Codes: F25B 2500/19 Calculation of parameters
• CPC Class Codes: F25B 2600/05 Refrigerant levels
• CPC Class Codes: F25B 43/02 for separating lubricants from the refrigerant
• CPC Class Codes: F25B 45/00 Arrangements for charging or discharging refrigerant
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems
• CPC Class Codes: G01N 25/18 by investigating thermal conductivity by calorimetry G01N25/20; by measuring change of resistance of an electrically-heated body G01N27/18
• CPC Class Codes: G06F 2119/18 Manufacturability analysis or optimisation for manufacturability
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30
• CPC Class Codes: G06F 30/27 using machine learning, e.g. artificial intelligence, neural networks, support vector machines [SVM] or training a model
• CPC Class Codes: G06F 30/39 Circuit design at the physical level physical level design for reconfigurable circuits G06F30/347
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A control system for controlling a refrigeration system having an operating point, comprising: a memory configured to store a relationship of at least an evaporator efficiency, an evaporator heat load, a refrigerant amount in the evaporator, and a variable dependent on a non-volatile liquid mixed with refrigerant in the evaporator an input port configured to receive a signal corresponding to at least a measured evaporator heat load during operation; an output port configured to present an output to selectively alter an operating point of the evaporator, by altering the refrigerant amount in the evaporator and thereby changing the variable; and a processor, configured to receive the signal, access the memory; and generate the output to selectively move toward an optimum operating point. A corresponding method and refrigeration system are provided.

Claims

1. An apparatus, comprising:

an input configured to receive physical parameters useful for a thermodynamic analysis of refrigeration system performance and defining a current operating state of the refrigeration system;

at least one automated processor configured to;

perform a thermodynamic analysis of the refrigeration system based on at least the received physical parameters;

determine a consistency of the refrigeration system according to the thermodynamic analysis with a previously determined thermodynamic model of the refrigeration system with respect to the current operating state of the refrigeration system; and

estimate a deviance of the refrigeration system from an optimal refrigeration system at the current operating state of the refrigeration system, based on the thermodynamic analysis and the determined consistency to generate an estimate of deviance; and

an output for presenting the estimate of deviance.

2. The apparatus according to claim 1, wherein the at least one automated processor is further configured to:

estimate a refrigeration efficiency of the refrigeration system in an operational state to absorb a heat load;

alter a process variable of the refrigeration system during efficiency measurement; and

calculate a process variable level which achieves an optimum efficiency of the refrigeration system while absorbing the heat load.

3. The apparatus according to claim 1, further comprising a control configured to alter physical parameters of the refrigeration system by altering at least one of an oil concentration in an evaporator and a refrigerant charge of the refrigeration system.

4. A method for determining a deviance of a refrigeration system from an optimum refrigeration system, comprising:

obtaining physical parameters at an operating state of the refrigeration stem sufficient to perform a thermodynamic analysis of performance of the refrigeration system;

defining a model of the refrigeration system;

performing the thermodynamic analysis of the refrigeration system at the operating state based on at least the obtained physical parameters;

determining inconsistencies of the thermodynamic analysis of the refrigeration system at the operating state with the defined model of the refrigeration system evaluated at the operating state; and

estimating a deviance of the refrigeration system at the operating state, from the optimum refrigeration system having a corresponding configuration to the refrigeration system and being optimized at the operating state, to determine an estimate of deviance based on the determined inconsistencies; and

outputting the estimate of deviance.

5. The method according to claim 4, further comprising automatically determining a need for servicing of the refrigeration system based on at least the estimate of deviance.

6. The method according to claim 4, further comprising automatically estimating a refrigeration system capacity based on at least the estimate of deviance.

7. The method according to claim 4, further comprising monitoring a performance of the refrigeration system in real time over a range of operating conditions to determine a sensitivity of refrigeration system performance to physical parameters.

8. The method according to claim 4,

wherein said thermodynamic analysis comprises estimating an efficiency of the refrigeration system;

further comprising;

altering a process control variable of the refrigeration system to thereby alter the operating state of the refrigeration system;

calculating a refrigeration system characteristic based on an analysis of obtained physical parameters after said alteration; and

optimizing a level of the process control variable in accordance with the calculated refrigeration system characteristic.

9. The method according to claim 8, wherein the refrigeration system comprises a compressor having a compressor oil as a lubricant, a condenser, an evaporator, and a refrigerant which circulates through the compressor, the condenser, and the evaporator, and the process control variable is an amount of compressor oil dissolved in the refrigerant in the evaporator.

10. The method according to claim 8, wherein the process variable is refrigerant charge condition.

11. The method according to claim 8, further comprising maintaining the refrigeration system at the operating state by a closed loop control, based on at least the determined optimum efficiency process control variable level.

12. The method according to claim 8, wherein the refrigeration system comprises a compressor having a compressor oil as a lubricant, a condenser, an evaporator, and a refrigerant which circulates through the compressor, the condenser, and the evaporator, and the process control variable is an amount of compressor oil dissolved in the refrigerant in the evaporator, and wherein the process control variable is altered by separating the compressor oil from refrigerant in the refrigeration system.

13. The method according to claim 4, further comprising predicting a cost-benefit resulting from a proposed service operation on said refrigeration system to correct at least a portion of the deviance of the refrigeration system at the operating state from the optimum refrigeration system, based on at least a cost of the proposed service operation, and a benefit predicted to be obtained by remediation of the at least a portion of the deviance from the optimum refrigeration system.

14. The method according to claim 4, further comprising:

determining a sensitivity of the refrigeration system to perturbations of at least one operational parameter which comprises the operating state;

defining an efficient operating regime for the refrigeration system based on at least the determined sensitivity;

determining a cost of a servicing of the refrigeration system to alter the at least one operational parameter; and

performing a servicing of the refrigeration system to bring the at least one operational parameter within the efficient operating regime when;

the refrigeration system is operating outside the defined efficient operating regime; and

a correction of the at least one operational parameter by the servicing of the refrigeration system is predicted to be cost-efficient.

15. The method according to claim 14, wherein the efficient operating regime has a non-trivial double ended range of values, and continued operation of the refrigeration system over time after the servicing follows a consistent trend in change in operating point from a beginning of cycle operating point to an end of cycle operating point, wherein the servicing alters the at least one operational parameter to within a boundary of the non-trivial double ended range of values near the beginning of cycle operating point.

16. The method according to claim 14, wherein the refrigeration system comprises a compressor having a compressor oil as a lubricant, a condenser, an evaporator, and a refrigerant which circulates through the compressor, the condenser, and the evaporator, and the servicing comprises a purification of the refrigerant.

17. The method according to claim 4, further comprising:

predicting a refrigeration capacity of the refrigeration system;

predicting a load on the refrigeration system;

determining a margin of safety; and

servicing the refrigeration system when the predicted refrigeration capacity of the refrigeration system is insufficient to maintain the determined margin of safety with respect to the predicted load on the refrigeration system.

18. The method according to claim 4, further comprising:

defining cost parameters of operation of the refrigeration system;

determining economic usage parameters of the refrigeration system;

predicting an effect on thermodynamic efficiency of the refrigeration system of a service procedure;

estimating a cost of the service procedure; and

conducting a cost benefit analysis for conducting the service procedure based on at least the operation cost parameters, economic usage parameters, predicted effect on thermodynamic efficiency, and estimated cost of the service procedure.

19. A method, comprising:

thermodynamically modeling a refrigeration system having a compressor which consumes a compressor power, a condenser, an evaporator, a superheat level in a headspace of the evaporator, and a refrigerant having a refrigerant purity, to provide a predictive model for the refrigeration system at an operating state, with respect to at least the refrigerant purity, the compressor power, and the superheat level;

predicting a thermodynamic effect of an alteration of the refrigerant purity and compressor power on the superheat level and the predictive model, at the operating state;

altering at least one of the refrigerant purity and the compressor power to achieve a predicted optimum condition for operation of the refrigeration system at the operating state, feedback controlled based on at least the superheat level.

20. The method according to claim 19, wherein the compressor power of the refrigeration system is modulated by an automated feedback controller which receives at least a signal corresponding to the superheat level, by at least one of speed control, duty cycle control, compression ratio, and refrigerant flow restriction.