003 001 Brasz 2003

Short Course on
Throttle Loss Power Recovery

in Refrigeration and Cryogenics
Joost J. Brasz
Carrier Corporation
Syracuse, New York 13221
21th IIR International Conference of Refrigeration

Washington DC, August 17-22, 2003
Course Overview
• Section 1. Thermodynamics of Refrigeration and
Cryogenic Cycles with Emphasis on Throttle Loss
Power Recovery
• Section 2. Example of a Commercialized Throttle Loss

Power Recovery System: Two-Phase-Flow Turbo-
Expanders in Water-Cooled Chillers
• Section 3. Example of Throttle Loss Power Recovery

R&D: The Expressor as Throttle Valve Replacement
SECTION 1
Thermodynamics of Refrigeration and Cryogenic Cycles
with Emphasis on Throttle Loss Power Recovery
Literature:
1. Hays, L.G., History and Overview of Two-Phase Flow Turbines, Proceedings of the IMechE International Conference on
Compressors and their Systems, London, England, pp. 159-170. Sept 13-15, 1999.
2. Smith, I.K., Review of the Development of Two_phase Screw Expanders, Proceedings of the IMechE International
Conference on Compressors and their Systems, London, England, pp. 95-104. Sept 13-15, 1999.
3. Granryd, E.G.U, Method of Improving Refrigeration Capacitry and Coefficient of Performance in a Refrigerating
System, and a Refrigerating System for Carrying Out Said Method, US Patents 4,014,182, March 29, 1977
4. Zoughaib, A. and Clodic, D., A Turbo Expander Development for Domestic Refrigeration Appliances, 21th International
Congress of Refrigeraytion 2003, Washington DC.
5. Heyl P. and Quack, H. Free Piston Expander-Compressor for CO2-Design, Applications and Results, Proceedings of
the20th International Conference of Refrigeration, Sydney, Australia, 1999.
6. Bond, T., Replacement of Joule Thompson Valves by Two-Phase Flow Turbines in Industrial Refrigeration Applications,
Proceedings of the IMechE International Conference on Compressors and their Systems, London, England, pp. 361-374.
Sept 13-15, 1999.
The basic vapor compression cycle
The basic vapor compression cycle used in the refrigeration industry

consists of the following four processes:
1. Compression
2. Condensation
3. Throttling
4. Evaporation
Vapor Compression Cycle
Heat Out to Ambient
Condenser
Throttle Valve Compressor Motor
Power In
Evaporator/Cooler
Heat In from air conditioned space

Thermodynamically, the vapor compression cycle is represented by a

pressure enthalpy (PH) and/or a temperature entropy (TS) diagram.
PH diagram of the ideal vapor compression cycle TS diagram of ideal vapor compression cycle
Isobaric heat rejection
Liquid
Isobaric heat rejection
S atura
isenthalpic Liquid
Temperature, T
r e pi c
n
io
expansion Two-phase
te d va
mp tr o
ss
Pressure, P
uid
isenthalpic isentropic
co sen
liq
expansion compression
por
i
d
Two-phase
ate
tur
Sa
Vapor
Isobaric heat addition Vapor
Isobaric heat addition
∆ hevap ∆ h comp
Enthalpy, h
Entropy, S
The ideal vapor compression cycle has two inherent cycle losses
(thermodynamic irreversibilities): Throttling and desuperheating
TS diagram of ideal vapor compression cycle

indicating its two inherent irreversibilities
Isobaric heat extraction
Satura
Superheat loss
Liquid
Temperature, T
ted vap
id
isentropic
isenthalpic
iqu
compression
expansion
dl
or
Two-phase
ate
tur
Sa

Vapor
Throttling loss
Entropy, S
Throttle Loss (area B) is equal to area A on TS diagram
Area A depends on slope of saturated liquid line and
increases when approaching the top of the dome
Satura
Superheat loss
Liquid
Temperature, T
te d v a
uid
isentropic
isenthalpic compression
liq
expansion
por
ed
Two-phase
A
at
tur
Sa
Vapor
Throttling loss
B
Entropy, S
2 2 3 3
h2 − h1 = ∫ Tds + ∫ Vdp h3 − h1 = ∫ Tds + ∫ Vdp
1 1 1 1
Along isobar:∫ Vdp = 0 Also h2=h3 => Area12561=Area13461
=> Area127=Area3457
2 Isobaric heat extraction
Satura
Superheat loss
Liquid
Temperature, T
te d v a
uid
isentropic
liq
expansion
por
ed
Two-phase
at
tur
Sa
Vapor
1 7 3 Isobaric heat addition
Throttling loss
6 5 4
Entropy, S
Throttle Loss Reduction Methods
1. Subcooling
2. Multistaging with economizers
3. Two-Phase Turbines
4. Granryd Cycle
CYCLE IMPROVEMENT FROM SENSIBLE
SUBCOOLING
D
C
E
por
. Va
id
Pressure
S at
Liqu
rig.
at.
R ef
.S
frig
Re
A B
A
Enthalpy
∆hevap,simple
∆hevap,sens. subc.
with sensible subcooling
Conclusion: less throttling loss with subcooling
subcooling
Satura
Superheat loss
Liquid
Temperature, T
te d v a
uid
isentropic
liq
expansion
por
ed
Two-phase
at
tur
Sa
Vapor
Throttling loss
Entropy, S
CYCLE IMPROVEMENT FROM “FLASH”
SUBCOOLING
D C
F E
r po
Pressure
id
. Va
u
Liq
Sat
at.
.S
r i g.
frig
Ref
Re
A A B
Enthalpy
∆hevap,simple
∆hevap,flash subc.
with flash subcooling
Conclusion: less throttling loss with sensible subcooling
flash
subcooling
Satura
Superheat loss
Liquid
Temperature, T
te d v a
uid
isentropic
liq
expansion
por
ed
Two-phase
at
tur
Sa
Vapor
Throttling loss
Entropy, S
CYCLE IMPROVEMENT FROM ECONOMIZING
D
C
or
ap
id
V
Pressure
iqu
at.
F E
L
.S
at.
frig
.S
Re
frig
Re
A B
A
Enthalpy
∆hevap,simple
∆hevap,economized
TS diagram of the two-stage economized
ideal vapor compression cycle
Conclusion: Throttling loss is half of that of simple cycle
Satura
Superheat loss
Liquid
Temperature, T
isenthalpic
expansion
te d v a
uid
isentropic
compression
liq
por
ed
at
isenthalpic Two-phase
tur
expansion
Sa

Vapor
Throttling losses
Entropy, S
Improvement of COP with increased number of
stages and economizers
9.2
9
Coefficient of Performance
8.8
8.6
8.4
8.2
R134a
8
R11
7.8
R22
7.6 Carnot
7.4
0 1 2 3 4 5
Number of stages
COP of ideal R134a system with and without subcooling
and actual system with 80% efficient compressor
Tevap = 5 0C, Tcond=36 0C
9.0
8.5
8.0
7.5
7.0
6.5
no subcooling
6.0 4 K subcooling
4 K subcooling and Effcomp=.8
5.5
0 1 2 3 4 5
Number of stages
Area A depends
Throttle on slope
loss (area of TS
B on saturated liquid
diagram) line and
= area A
Isobaric heat ex tracti on
S atur a
Liquid Superheat loss
Temperature, T
te d va
isentro pic
uid
isenthalpic com pression

liq
expansi on
por
d
Two-phase
ate
A
tur
Sa
Isobaric heat a ddi tio n

Vapor
B Throttling loss
Entropy, S
Conclusion: Cycle Efficiency less for higher operating T

Ideal vapor compression cycle COP of R11 and R134a for
different evaporation temperatures at constant Carnot
efficiency (Tevap/(Tcond-Tevap)=8.973
9.5
9.0
8.5
8.0
7.5
7.0
R11
R134a
Carnot
6.5
6.0
200 250 300 350 400
Evaporation tem perature, K
R11 and R134a vapor compression cycle effectiveness:
COPvapor com pression cycle /COPCarnot cycle for different evaporation
temperatures at (Tevap/(Tcond-Tevap)=8.973
1.0
Vapor compression cycle effectiveness
0.9
0.9
R11
0.8
R134a
0.8
0.7
200 220 240 260 280 300 320 340 360 380 400
Evaporation temperature, K
Conclusion: Cycle efficiency higher than component efficiencies

Area A depends
Throttle on slope
loss (area of TS
B on saturated liquid
diagram) line and
= area A
Tcr
Isobaric heat ex tracti on
S atur a
Temperature, T
te d va
isentro pic
uid
isenthalpic com pression

liq
expansi on
por
d
Two-phase
ate
A
tur
Sa
Isobaric heat a ddi tio n

Vapor
B Throttling loss
Entropy, S
Conclusion: Cycle Efficiency less for refrigerants with lower Tcr

Coefficient of Performance of Ideal Simple Cycle with 4K
Subcooling of Different Refrigerants plotted against
Critical Temperature
8.5
8.4 R11 R141b
8.3 R123 R113
8.2
R245fa
COP
8.1
R12 R114
8
0
Tevap = 5 C
R134a R236fa 0
7.9 Tcond = 36 C
0
R22 Tsubc = 32 C
7.8
0
Tsup = 5 C
7.7
350 375 400 425 450 475 500
Critical Temperature, K
Vapor Compression Cycle
with Throttle Loss Power Recovery
Heat Out to Ambient
Condenser
Bi-phase
turbine
Generator Compressor Motor
Power Out
Power In
Evaporator/Cooler

CYCLE IMPROVEMENT FROM THROTTLE LOSS
POWER RECOVERY (TLPR)
D
C
por
Expansion
. Va
id
Pressure
iqu
S at
Throttling
L
.
frig
at.
.S
Re
frig
Re
A B
A
Enthalpy
∆hevap,simple
∆hevap,throttle loss power recovery
∆h expander
with throttle loss power recovery
Satura
Superheat loss
Liquid
Temperature, T
te d v a
uid
isentropic
Isentropic compression
liq
expansion
por
d
Two-phase
ate
tur
Sa
Vapor
Entropy, S
Conclusion: All refrigerants have same efficiency with perfect throttle loss recovery
TS diagram of the Granryd cycle
Satura
Superheat loss
Temperature, T
ted va
idu
Two-phase
liq
por
ted
Liquid
a
tur
Sa
Vapor
Entropy, S
Alternative method of throttle loss power recovery:
Granryd Refrigeration Cycle
Heat Out to Ambient
Condenser
Compressor Motor
Power In
Evaporator/Cooler

Replacing the Joule-Thompson throttling valves in cryogenic
equipment will lead to substantial energy savings and yield increases
Conclusions
Two-phase flow throttle loss recovery in air-conditioning and

refrigeration equipment has the potential of improving system
overall efficiency by 5-7 percent.
The potential of this technology for cryogenics seems to be

higher in terms of yield increase and energy savings.
SECTION 2
Example of commercialized throttle loss power recovery:
Two-Phase-Flow Turbo-Expanders
in Water-Cooled Chillers
Literature:
1. Brasz, J.J, , 1995, Improving the Refrigeration Cycle with Turbo Expanders, Proceedings of the 19th International
Conference of Refrigeration, Volume IIIa, pp 246-253, 1995.
2. Hays, L.G and Brasz, J.J., Two-Phase Turbines as Stand-Alone Throttle Replacement Units in Large 2000- 5000 Ton
Centrifugal Chiller Installations, Proceedings of the 1998 International Compressor Engineering Conference at Purdue,
Vol II, pp. 797-802, 1998.
3. Brasz, J.J. Performance Characteristics of Two-Phase Flow Turbo-Expanders used in Water-Cooled Chillers,
Proceedings of the IMechE International Conference on Compressors and their Systems, London, England, pp. 171-180.
Sept 13-15, 1999.
4. Brasz, J.J. Two-Phase Flow Turbine, US patent 5,467,613, November 21, 1995
•Introduction
•Description of cycle modification
•Description of turbine hardware
•Control for off-design conditions
•Performance at off-design conditions
•Conclusions
•Introduction
•Conclusions
Introduction
CFC11, the most efficient refrigerant CFC11, was banned in 1995
The second best refrigerant, HCFC123, will be banned in the near future
HFC134a suffers 5.5% cycle efficiency penalty relative to CFC11 and a

4.5% penalty relative to HCFC123
The bi-phase turbine was introduced to overcome the cycle disadvantages

of chlorine-free refrigerants
The bi-phase turbine is currently a standard option on HFC134a chillers
The focus of this paper is bi-phase turbine performance at off-design

conditions
•Introduction
•Conclusions
Satura
Superheat loss
Liquid
Temperature, T
ted va
id
isentropic
isenthalpic
u
compression
liq
expansion
por
ted
Two-phase
a
tur
Sa

Vapor
Throttling loss
Entropy, S
with throttle loss recovery
Superheat loss
Temperature, T
Liquid
isentropic
isentropic compression
expansion
Two-phase
Vapor
Entropy, S
PH diagram of vapor compression cycle
with and without throttle loss recovery
Liquid
Expansion Two-phase
Throttling
Pressure, P
Vapor
∆hevap,simple ∆hcomp
− ∆hturbine
∆hevap,throttle loss power recovery
∆hturbine
Enthalpy, h
•Introduction
•Conclusions
CONVENTIONAL COMPRESSOR
TURBO-ASSISTED COMPRESSOR
TURBINE CONVENTIONAL COMPRESSOR

Nozzle with inlet flow divider
Nozzle Block
TURBINE WHEEL
Cut-away view of the integrated two-phase-flow turbine
used on centrifugal chillers in the
1000 to 2000 kW cooling capacity range
Turbo-assisted Centrifugal Chiller
•Introduction
•Conclusions
TURBINE COMPRESSOR
No Variable
Geometry Rotating Inlet Guide Vanes for Capacity Control
Inlet guide vane capacity control as function of head and flow
1.2
e Design point
pr essor surg
m
caused by co
t
1. ion limi
Operat
Head Fraction
.8
IGV=90 degrees
.6
IGV=70 degrees
IGV=50 degree
IGV=30 degree
IGV=20 degrees
IGV=10 deg
.4
s
.2
rees
.0
.0 .25 .50 .75 1.0 1.25
Flow Fraction
CROSS-SECTION OF A TWO-PHASE-FLOW NOZZLE
PH diagram comparing
throttling valve (isenthalpic expansion) to
power recovery turbine (isentropic expansion)
l ine
n
a tio
r
a tu
Subcooled liquid ds
u i
region
Liq
Pressure, P
Power Throttling
(H=constant)
recovery
(S=constant)
Two-phase
region
Enthalpy, h
PH diagram comparing Observations:
throttling valve (isenthalpic expansion) to
power recovery turbine (isentropic expansion)
1. No difference between isentropic
lin
e and isenthalpic expansion in
ion
rat
Subcooled liquid sa
t u
subcooled liquid area
region u id
Liq
Pressure, P
2. Not much difference between

Power recovery Throttling
(S=constant) (H=constant) isentropic and isenthalpic expansion
during initial expansion in two-phase
Two-phase
region
region
Enthalpy, h
Trajectory of nozzle expansion process in
pressure-enthalpy diagram
1
V1 = 0
Subcooled liquid
region
2 2(P1 − P2 )
V2 =
ρliq.
Pressure, P
ine
nl
Two-phase
ti o
region
a
tur
sa
uid
Liq
3 V3 = 2( h1 − h3 )
Enthalpy, h
CROSS-SECTION OF A TWO-PHASE-FLOW NOZZLE
1 2
3
Nozzle capacity controlled by Nozzle kinetic energy controlled

liquid velocity at throat: by exit velocity:
2( P1 − P2 )
V2,sat.liq. = V3,spouting = 2( h1 − h3 )
ρliq.
Trajectory of nozzle expansion process in
pressure-enthalpy diagram
1 Capacity is controlled by
amount of subcooling
Subcooled liquid
region 2( P1 − P2 )
2 V2,sat.liq. =
ρliq.
Pressure, P
Spouting velocity is
ine
controlled by enthalpy drop

nl
Two-phase
ti o
region
V3,spouting = 2( h1 − h3 )
a
tur
sa
uid
These two relationships

Liq
3 are virtually uncoupled

since enthalpy does not
change during throttling
of saturated liquid.
Enthalpy, h
•Introduction
•Conclusions
Problem statement
Design point
rge
ssor su
compre
sed b y
Turbine operation limit caused by compressor choke

1. mit cau
opera tion li
Head Fraction
Turbine
.8
.6
How does turbine efficiency change with conditions ?
.4
.2
.0
.0 .25 .50 .75 1.0
Flow Fraction
η/η
Relative efficiencies (η ηmax) of a centrifugal compressor with
inlet guide vane capacity control as function of head and flow
Design point
or surge
1. b y c ompress
sed
imit cau
Head Fraction
ion l
Operat 100%
90%
Operation limit caused by compressor choke

.8
80 %
70%
60%
.6
50%
40%
.4 30 %
20 %
.2 10%
.0
.0 .25 .50 .75 1.0
Flow Fraction
Relative turbine efficiency as a function of speed ratio
for different levels of inlet subcooling
1.05
1.00
ηmax
0.95
5K subcooling
Relative efficiency, η/η
0.90
0.85
1K subcooling
0.80
0.75
2K subcooling
0.70
0.65
0.60
1.0 1.5 2.0 2.5 3.0 3.5
Ratio of spouting velocity and rotor speed, Vspouting/Urotor

RELATIVE TURBINE EFFICIENCY AS A FUNCTION OF
SPEED RATIO AND INLET SUBCOOLING
Comparison between test data and proposed correlation:
Vis
ηturbine = 0.5ηmax [1 + sin(122.5 − 1.296 * ( 8.33 − ∆Tsubc )2 − 175)]
U rotor
1.05
1.00
ηmax
0.95
5K subcooling
0.90
0.85
0.80
0.75 1K subcooling
2K subcooling
0.70
0.65
0.60
1 1.5 2 2.5 3 3.5
Ratio of spouting velocity and rotor speed, Vspouting/Urotor

TURBINE EFFICIENCY AS A FUNCTION OF
ENTERING REFRIGERANT QUALITY
0.175 − x
ηturbine ( x ) = ηturbine ( x = 0 )
0.175
1.2
ηmax
1
0.8
0.6
test data
0.4
correlation
0.2
0
0 0.03 0.06 0.09 0.12 0.15
Turbine inlet quality x=(hin-hliq)/(hvap-hliq)

Mass flow rate correlation for
subcooled liquid entering the turbine
Mass flow rate was found to be substantially larger than corresponds

to maximum pure liquid velocity in nozzle throat:
mturb = Athroat 2 ρliquid ( Tturb ,in ) * [ Pturb ,in − Psat ( Tturb ,in )]
An accurate mass flow rate prediction (within 5%) was possible by

assuming a delay of vaporization of 2.2 K:
mturbine = Athroat 2 ρliquid ( Tturbine ,in ) *[ Pturbine ,in − Psat ( Tturbine ,in − 2.2 )]
TURBINE FLOW RATE AS A FUNCTION OF
ENTERING REFRIGERANT QUALITY
mturbine ( x ) = (16 x 2 − 5.2 x + 1) * mturbine ( x = 0 )

1
Fractional mass flow rate, m(x)/m(x=0)
0.9
0.8
0.7
test data
0.6 correlation
0.5
0 0.03 0.06 0.09 0.12 0.15
Turbine inlet quality x=(hin-hliq)/(hvap-hliq)

Using these four correlations
Vis
ηturbine = 0.5ηmax [1 + sin(122.5 − 1.296 * ( 8.33 − ∆Tsubc )2 − 175)]
U rotor
0.175 − x
ηturbine ( x ) = ηturbine ( x = 0 )
0.175
mturbine = Athroat 2 ρliquid ( Tturbine ,in ) *[ Pturbine ,in − Psat ( Tturbine ,in − 2.2 )]
mturbine ( x ) = (16 x 2 − 5.2 x + 1) * mturbine ( x = 0 )
a turbine performance map could be developed

η/η
Relative efficiencies (η ηmax) of two-phase flow turbine
with inlet throttle capacity control as function of head and flow
Design point
rge
ssor su
compre
sed b y
Turbine operation limit caused by compressor choke

1. mit cau
opera tion li
Head Fraction
Turbine
100%
.8
90%
80 %
.6
70%
60%
50%
.4 40%
20% 30%
0% 10%
.2
Spouting velocity < rotor speed
.0
.0 .25 .50 .75 1.0
Flow Fraction
η/η
Relative efficiencies (η ηmax) of a centrifugal compressor with
inlet guide vane capacity control as function of head and flow
Design point
or surge
1. b y c ompress
sed
imit cau
Head Fraction
ion l
Operat 100%
90%
.8
80 %
70%
60%
.6
IGV=90 degrees
50%
IGV=70 degrees
IGV=50 degre
40%
IGV=30 degre
30 % IGV=20 de
IGV=10 deg
.4
20 %
es
grees
10%
es
.2
s ree
.0
.0 .25 .50 .75 1.0
Flow Fraction
Comparison of turbine and compressor relative efficiencies
η/η
(η ηmax) as function of head and flow
Design point
or surge
1. b y c ompress
sed
imit cau
Head Fraction
ion l 100%
Operat
100%
Operation limit caused by compressor choke

.8
80%
80%
.6
60% 60%
.4 40%
40%
.2
.0
.0 .25 .50 .75 1.0
Flow Fraction
•Introduction
•Conclusions
Conclusions
Two-phase-flow turbines applied to water-ccoled chillers are efficiently

controlled by a float valve at the inlet of the turbine.
Turbine efficiency does not deteriorate with reduced mass flow rates as
long as the input head stays constant and the fluid entering the turbine
remains in the liquid phase.
A reduction in input head by 75% is required to reduce the spouting

velocity to the rotor speed at which point the turbine becomes ineffective.
Those conditions are unlikely to occur in practice.
The relative part-load efficiency of the bi-phase turbine is better than that
of a centrifugal compressor with variable inlet guide vanes.
SECTION 3
Example of throttle loss power recovery R&D:
The expressor as throttle valve replacement
Literature:
1. Brasz, J.J, Smith, I.K. and Stosic, N., Development of a twin screw expressor as a throttle valve replacement
for water-cooled chillers, Proceedings of the 2000 International Compressor Engineering Conference at
Purdue, Volume II, pp.979-986, Purdue University, West Lafayette, IN
2. Brasz, J.J., Single rotor pair expressor as two-phase flow throttle valve replacement, US patent 6,185,956
B1, February 13, 2001.
3. Brasz, J.J. Screw-expressor testing on an R-134a chiller: efficiency, liquid carry-over and chiller benefit,
IMechE Conference Compressors and their Systems, London, England, September 2003.
Technology Overview
Why are we pursuing this technology?
S at ura
Temperature, T
te d va
uid isentropic
isenthalpic
compression
liq
expansion
por
d
Two-phase
ate
t ur
Sa

Vapor
Throttling loss
Entropy, S
• Throttling loss is the only major fundamental loss of the vapor

compression cycle when using fluorocarbon refrigerants
• Difference in cycle efficiency between refrigerants is due to
difference in throttling loss
Technology Overview
with throttle loss recovery
Superheat loss
Temperature, T
Liquid
isentropic
isentropic compression
expansion
Two-phase
Vapor
Entropy, S
The vapor compression cycle with throttle loss recovery

approaches the maximum obtainable efficiency Carnot cycle
Technology Overview
Cycle efficiency comparison different refrigerants

(Assumptions: single stage compressor at following conditions:
42/96/0/7, η com p=82%)
7.3 7.24
7.2 7.13
7.1 7.04
7 6.92
6.9
COP
6.8
6.72
6.7
6.6
6.5
6.4
Throttle loss recovery is the only
CFC11 wayHFC245fa
HCFC123 to overcome the HFC134a
HFC134a thermodynamic
+ cycle
70% eff Exp
disadvantage of R-134 versus R-123 and R-245fa
Existing Throttle Loss Recovery:
19XRT
Turbo-assisted Centrifugal Chiller
TURBINE CONVENTIONAL COMPRESSOR

Two-phase flow turbine issues
• Turbine application is expensive. It requires
– low-loss sensible subcooler
– two throttle valves (upstream and bypass)
– low-loss large piping from bottom condenser to compressor and back to
bottom evaporator
– low-loss refrigerant distribution piping inside cooler
• Turbine-assisted concept with turbine attached to
compressor drive limits its capacity range and prevents
usage for other compressor concepts
• Turbine peak efficiency 52%
• Result: turbine only viable as a option on a

limited number of chillers, not as a standard
feature
Alternative two-phase flow expansion
technology:
screw expanders
ADVANTAGES:
• Expansion efficiencies up to 70% reported
• Easier to apply to larger and smaller compressors
(not limited by the head/capacity/speed
relationship of a turbo-machine)
Cross-section of two-phase flow screw
expander
PH diagram of the screw expressor test facility
Liquid
n
i ti o
dd
Two-phase
Throttling
ta
n
a
sio
he
ric
Pressure, P
Expan
ba
I so
Adiabatic
pressure rise
condensation
∆hexpansion
Enthalpy, h
R113 two-phase flow expander test
facility
Photograph of two-phase-flow R113
screw expander at test facility
Online terminal display of test results
Screw expander efficiency as a function of speed
100
90
80
Adiabatic efficiency
70
60
50
40
30
20
10
0
0 1000 2000 3000 4000 5000
Male rotor speed, rpm
COST PROBLEMS OF SCREW
EXPANDERS
• If applied like the turbine (attached to the

extension of the motor of the main compressor )
the applied screw expander cost looks even worse
than applied turbine cost
• If recovered power is fed to a separate generator

the efficiency advantage of the screw disappears
due to electrical power conversion losses and the
applied cost increases again
Possible solution to the cost problem of
throttle loss power recovery: the
EXPRESSOR
Condenser
Vapor compressed by expressor
Main
Expre ssor Drive comp-
Motor ressor
Evaporator
Dimensions of the expressor for a 500 ton chiller
6.7 inches
169 mm
m m
465 e s
280 i nc h
11. 0
mm 18.3
inche
s
Single rotor pair expressor
PH diagram of the expressor test facility
Liquid
sion ion
dit
Two-phase
ad
n
Throttlin g
s io
t
ea
Thrott ling
res
ch
Pressure, P
Exp an
ri
mp
ba
Iso
Co
Adiabatic
pressure rise
condensation
Vapor
∆hexpansion ∆hcompression
Enthalpy, h
mexp and ∆hexp and = mcomp∆hcomp

Two-phase flow R113 expander/expressor test facility
How to determine expressor efficiency?
Definition of expressor efficiency:
η Expressor = η Expand .η Comp
Where mComp .∆ hisent comp
η Comp =
mComp .∆ hComp
m Expand .∆ h Expand
η Expand =
m Expand .∆ hisent expand
Substitution gives
mComp .∆ hisent comp m Expand .∆ h Expand
η Expressor = *
mComp .∆ hComp m Expand .∆ hisent expand
Therefore:
mComp ∆ hisent comp
η Express = .
m Expand ∆ hisent expand
Two-phase flow expander/expressor test facility
mcompressor
mexpander
Measured expressor overall efficiencies
using
mComp ∆ hisent comp
η Express = .
mExpand ∆ hisent expand
Expressor overal efficiency from the flow measurement
100
90
80
70
60
First mach. Vc=1.308
eta [%]
50 First mach. Vc=1.081

New mach., Vc=1.186
40
30
20
10
0
0 2 4 6 8 10 12 14
Pressure p1 [bar]
Problem with experimental expressor
efficiency determination
• Mass flow rate of vapor being compressed can not
be measured when liquid carry-over takes place
Solution
• Assume a volumetric efficiency and determine mass flow
rate from vapor density at compression inlet and voluyme
flow rate as determined by the swept volume corrected
with the volumetric efficiency:
mcomp = ρvapor ⋅ηvolumetric ⋅V&displacement

Expressor efficiencies as measured at
R113 test rig facility
Schematic of prototype expressor test set-up
as throttle valve replacement at an R134a
chiller
P=887 kPa
high pressure liquid high pressure vapor
P1=872 kPa
Condenser
T1=33.7 0C
Vapor compressed Main

Expre ssor by expressor Drive comp-
P5=826,862,886,937 kPa Motor
Throttle
ressor
valve
P3=412 kPa
Evaporator
low pressure liquid/vapor low pressure vapor
P=362 kPa
R134a expressor testing at a chiller
Chiller with prototype expressor under
construction
Expressor
High pressure liquid High pressure vapor
1 Expander compressor 5
x4
x2
x3
3
Low pressure
two-phase flow
Liquid carry-over into vapor compressor
section of expressor
Expressor compressor inlet quality x4 versus
expander exit quality x2
30%
Quality at compression inlet
25% x4
20%
port
15%
10%
x2
5%
0%
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
expressor rpm
Liquid carry-over into vapor compressor
section of expressor
Expressor separation effectiveness of four
test points close to design conditions
10%
Separation effectiveness,
9%
8% 4
7% 1 3
(x4-x2)/(1-x2)
6%
5%
4% 2
3%
2%
1%
0%
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
expressor rpm
PH diagram of the expressor as intended
Liquid
Two-phase
n
s io
sion
res
Pressure, P
Exp an
mp
Co
Adiabatic
pressure rise
Vapor
∆hexpansion ∆hcompression
Enthalpy, h

PH diagram of the expressor with
major liquid carry over
Liquid
n
ressio
sion Two-phase
Comp
Pressure, P
Exp an
Adiabatic
pressure rise
∆hcompression
Vapor
∆hexpansion
Enthalpy, h
1 − x3
System _ Benefit =
1 − xthrottle
Liquid
Two-phase
n
sio
sion
res
x3
Pressure, P
Expan
mp
xthrottle
Co
Adiabatic
pressure rise
Vapor
y
x2
qualit
due to n of vapor
∆hexpansion
ssor
∆hcompression
expre
Enthalpy, h
ti o
reduc
Prevention of liquid carry-over
Physical separation of expansion

and compression section
Picture of prototype gate rotors

with slot to accommodate
physical separation of expansion
and compression section
Compressor inlet quality x4 and expander exit quality
x2 of original and baffled expressor
50%
45%
40% x4 baffled expressor
35%
30%
Quality
x4 original expressor
25%
20%
15%
10% x2 baffled and original expressor
5%
0%
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
expressor rpm
Expressor separation effectiveness of test points close to
design conditions
50%
45%
Separation effectiveness,
40% baffled expressor

35%
(x 4-x 2)/(1-x 2)
30%
25%
20%
15%
original expressor
10%
5%
0%
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
expressor rpm
Expressor system benefit as a function of its separation effectiveness
100%
90%
Loss in expressor benefit due to
80%
70% original expressor

liquid carry-over
60%
50%
40%
30%
20% baffled expressor

10%
0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Separation effectiveness
Conclusions
The expressor concept has the potential of being a low cost throttle valve
replacement
System benefit depends on the reduction in the two-phase flow quality

entering the evaporator of the refrigeration system
Early prototypes suffered from liquid carry-over into the compressor

section of the expressor
Liquid carry-over can be reduced by inserting a separation baffle plate

inside the rotor

003 001 Brasz 2003

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Short Course on

Throttle Loss Power Recovery

21th IIR International Conference of Refrigeration

• Section 2. Example of a Commercialized Throttle Loss

• Section 3. Example of Throttle Loss Power Recovery

The basic vapor compression cycle used in the refrigeration industry

Throttle Valve Compressor Motor

Heat In from air conditioned space

Thermodynamically, the vapor compression cycle is represented by a

Isobaric heat rejection

TS diagram of ideal vapor compression cycle

Isobaric heat extraction

Isobaric heat addition

Isobaric heat extraction

Isobaric heat extraction

Isobaric heat addition

Isobaric heat ex tracti on

isenthalpic com pression

Isobaric heat a ddi tio n

Conclusion: Cycle Efficiency less for higher operating T

Conclusion: Cycle efficiency higher than component efficiencies

Isobaric heat ex tracti on

isenthalpic com pression

Isobaric heat a ddi tio n

Conclusion: Cycle Efficiency less for refrigerants with lower Tcr

8.4 R11 R141b

8.3 R123 R113

Heat In from air conditioned space

Isobaric heat extraction

Heat In from air conditioned space

Two-phase flow throttle loss recovery in air-conditioning and

The potential of this technology for cryogenics seems to be

CFC11, the most efficient refrigerant CFC11, was banned in 1995

HFC134a suffers 5.5% cycle efficiency penalty relative to CFC11 and a

The bi-phase turbine was introduced to overcome the cycle disadvantages

The bi-phase turbine is currently a standard option on HFC134a chillers

The focus of this paper is bi-phase turbine performance at off-design

Isobaric heat extraction

Isobaric heat addition

Isobaric heat extraction

TURBINE CONVENTIONAL COMPRESSOR

2. Not much difference between

Nozzle capacity controlled by Nozzle kinetic energy controlled

controlled by enthalpy drop

These two relationships

3 are virtually uncoupled

Turbine operation limit caused by compressor choke

Operation limit caused by compressor choke

Ratio of spouting velocity and rotor speed, Vspouting/Urotor

Ratio of spouting velocity and rotor speed, Vspouting/Urotor

Turbine inlet quality x=(hin-hliq)/(hvap-hliq)

Mass flow rate was found to be substantially larger than corresponds

An accurate mass flow rate prediction (within 5%) was possible by

mturbine ( x ) = (16 x 2 − 5.2 x + 1) * mturbine ( x = 0 )

Turbine inlet quality x=(hin-hliq)/(hvap-hliq)

mturbine ( x ) = (16 x 2 − 5.2 x + 1) * mturbine ( x = 0 )

a turbine performance map could be developed

Turbine operation limit caused by compressor choke

Operation limit caused by compressor choke

Two-phase-flow turbines applied to water-ccoled chillers are efficiently

A reduction in input head by 75% is required to reduce the spouting

Isobaric heat extraction