Custom Refrigeration Oil Separator Manufacturers

How to optimize the internal structure design of the refrigeration oil separator to improve the separation efficiency?

The efficient operation of the refrigeration system is inseparable from the reliable operation of the refrigeration oil separator, and the rationality of its internal structure design directly affects the separation efficiency. From the perspective of structural optimization, we can start from the flow channel design, separation element selection, internal component layout and other aspects, combining the principles of fluid mechanics with actual application needs to achieve the improvement of separation efficiency.
Fluid mechanics optimization of flow channel structure
Flow channel design is the basis for the optimization of the internal structure of the refrigeration oil separator, and the two-phase flow characteristics of refrigerant vapor and lubricating oil must be fully considered. In the inlet section, a gradually expanding pipeline design can be adopted to reduce the steam flow rate by expanding the flow cross-sectional area, creating conditions for oil droplet separation. For example, controlling the ratio of the inlet pipe diameter to the separator body diameter between 1:1.5 and 1:2 can reduce the steam flow rate from 20-30m/s to below 10m/s, and use gravity to initially separate larger oil droplets. As a comprehensive refrigeration equipment manufacturer, Zhejiang Jinhao Refrigeration Equipment Co. Ltd also pays attention to the impact of flow channel design on performance in its product development. This flow rate control concept has been applied in its series of unit products.
The steering design of the internal flow channel is also critical. When setting the baffle inside the separator, the eddy current loss caused by the right-angle steering should be avoided. The arc transition (the radius of curvature is 1-1.5 times the diameter of the pipe) or the 45° oblique baffle should be used to generate centrifugal force when the steam flow direction changes, pushing the oil droplets to gather on the wall. Studies have shown that a reasonable baffle angle can increase the separation efficiency by 15%-20%. At the same time, the roughness of the inner wall of the flow channel should be controlled below Ra1.6 to reduce the adhesion resistance of the oil droplets and ensure that the separated lubricating oil flows smoothly into the oil collecting chamber.
Selection and structural improvement of separation elements
Different types of separation elements are suitable for different working conditions and need to be optimized according to the type of refrigeration system. For Freon refrigeration systems, packing separation elements are effective. Stainless steel mesh or ceramic packing can be used. The specific surface area should be controlled at 200-300m²/m³, and the porosity should be maintained at 80%-85%. This can not only ensure the flow of steam, but also capture tiny oil droplets (particle size ≥1μm) through adsorption on the surface of the packing. Zhejiang Jinhao Refrigeration Equipment Co. Ltd has accumulated experience in heat exchange element design in products such as fin heat exchangers. This ability to control the pore structure of materials can be transferred to the selection of refrigeration oil separator packing.
The optimization focus of centrifugal separation elements is on the blade structure. The use of backward-inclined blades (inclination angle 30°-45°) combined with a tapered flow channel can enhance the strength of the centrifugal field. For example, in a separator with a diameter of 500mm, the blade height is designed to be 100-150mm, and the number of blades is controlled at 8-12 pieces, which can make the steam rotation linear speed reach 15-20m/s, effectively separating 5-10μm oil droplets. For the washing separator commonly used in ammonia refrigeration systems, multiple layers of sieve plates (aperture 2-3mm, opening rate 30%-40%) can be set inside to improve the separation accuracy through the washing effect of the refrigerant liquid. The spacing between the sieve plates is preferably 200-300mm to ensure that the steam and the washing liquid are fully in contact.
Collaborative layout design of internal components
The layout of the oil collecting chamber and the oil return pipeline directly affects the sustainability of the separation efficiency. The volume of the oil collecting chamber should be determined according to the oil filling amount of the refrigeration system. It is usually designed to be 1.5-2 times the maximum oil filling amount of the system. A conical funnel structure (cone angle 60°-90°) is set at the bottom to facilitate the accumulation of lubricating oil. The diameter of the oil return pipeline needs to match the system flow rate, which is generally 10-16mm, and the flow rate in the pipe is controlled at 0.5-1m/s to avoid oil return with gas due to excessive flow rate. When providing design solutions to customers, Zhejiang Jinhao Refrigeration Equipment Co. Ltd will match parameters in combination with the actual working conditions of the system. This systematic design thinking is also applicable to the internal layout of the oil separator.
The spatial allocation of the gas-liquid separation area is also crucial. In the upper gas space of the separator, sufficient height (1-1.2 times the diameter of the separator) should be reserved as a secondary separation buffer to allow the tiny oil droplets that are not completely separated to continue to settle under the action of gravity. At the same time, a guide plate is set at the outlet section to guide the steam to flow out evenly to avoid the local flow rate being too high and carrying away the oil droplets. The angle between the guide plate and the wall is preferably 30°, and the bottom height from the liquid level of the oil collecting chamber is not less than 0.5 times the diameter of the separator.
Application of new structures and technologies
The introduction of cyclone separation technology can further improve the separation efficiency. A cyclone generator is set inside the separator to generate a strong cyclone field (tangential velocity ≥ 25m/s) through the rotation of the blades, so that the oil droplets migrate to the wall under the action of centrifugal force. Experimental data show that the separation efficiency of the cyclone separator for oil droplets below 1μm can reach more than 90%, which is 30% higher than the traditional structure. Zhejiang Jinhao Refrigeration Equipment Co. Ltd focuses on continuous technological updates. Such new separation technologies can be incorporated into its product research and development system to provide customers with more efficient solutions.
The use of a multi-stage separation combined structure is also an optimization direction. The centrifugal separation section, the packing separation section and the gravity separation section are arranged in series to grade oil droplets of different particle sizes: the centrifugal section separates oil droplets above 5μm, the packing section captures oil droplets of 1-5μm, and the gravity section settles oil droplets below 1μm. This combined structure can achieve an overall separation efficiency of more than 99%, which is suitable for large refrigeration equipment. At the same time, a removable filter element (filtration accuracy 0.5μm) is set at the key position to facilitate maintenance and replacement, ensuring the stability of the separation performance.