REFRIGERATION SYSTEM

Module 3. Actual Vapor Compression

Refrigeration System
The actual vapor compression cycle includes several deviations from the ideal cycle
due to real-world inefficiencies and non-ideal component behaviors.

These deviations can be categorized into several aspects:

1. Non-Isentropic Compression
In an ideal vapor compression cycle, the compression process is isentropic, meaning
it occurs without any increase in entropy. However, in an actual cycle:

Mechanical Inefficiencies: Due to friction and other mechanical losses within

the compressor, the process is not perfectly isentropic.

Heat Transfer: Some heat may be transferred from the refrigerant to the
surroundings or vice versa during compression, further deviating from the ideal
isentropic process.

2. Pressure Drops
In the actual cycle, there are pressure drops in the evaporator, condenser, and
connecting pipes due to friction and other factors.

Evaporator and Condenser: Pressure drops in these heat exchangers reduce

the effective pressure difference the compressor needs to overcome, leading
to reduced system efficiency.

Piping: Pressure losses occur in the refrigerant piping connecting different

components due to friction and bends.

3. Non-Ideal Heat Transfer

Heat transfer processes in the evaporator and condenser are not perfect, leading to:

Temperature Differences: There is always a temperature difference between

the refrigerant and the medium (air or water) with which it is exchanging heat,
resulting in less efficient heat transfer.

Superheating: The refrigerant is often superheated at the end of the

evaporation process to ensure complete vaporization, which helps protect the
compressor but reduces overall efficiency.

Subcooling: The refrigerant may be subcooled after condensation to ensure it

enters the expansion valve as a fully liquid state, improving system
performance but also representing a deviation from the ideal cycle.

4. Expansion Process
In the ideal cycle, the expansion process is isenthalpic (constant enthalpy). However,
in the actual cycle:
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Irreversibilities: The throttling process in the expansion valve or capillary tube

is irreversible, causing entropy to increase.

Pressure and Temperature Variations: The expansion process might not

achieve a perfect pressure drop, and there may be slight variations in
temperature and pressure.

5. Superheating and Subcooling

Superheating: Ensures that no liquid refrigerant enters the compressor, which

could cause damage. This adds extra heat to the refrigerant before it enters the
compressor, reducing the net refrigeration effect.

Subcooling: Increases the refrigeration effect by reducing the amount of flash

gas formed during expansion, but this also introduces inefficiencies as the
refrigerant is cooled below its condensation temperature.

6. Real Refrigerant Properties

Non-Ideal Gas Behavior: Real refrigerants do not behave as ideal gases,

especially at high pressures and temperatures. The specific properties of the
refrigerant, such as specific heat capacity and latent heat of vaporization,
influence the cycle performance.

Diagrams

P-h Diagram (Pressure-Enthalpy): The actual cycle can be represented on a P-h

diagram, showing the deviations from the ideal cycle. The curves for compression,
condensation, expansion, and evaporation are not perfectly vertical or horizontal,
indicating the inefficiencies and non-ideal behaviors.

The actual vapor compression cycle may have some or all of the items of departure
from the simple saturation cycle as shown on the p-h diagram in above figure.
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1. Superheating of the vapor in the evaporator, 10-11.

2. Heat gain in the suction line, 11-12.
3. Pressure drop in the suction line, 12-13.
4. Pressure drop due to wire drawing at the compressor suction valve, 13-1.
5. Polytropic compression with friction and heat transfer, 1-2.
6. Pressure drop at the compressor discharge valve, 2-3.
7. Pressure drop in the delivery line, 3-4.
8. Heat loss in the delivery line, 4-5.
9. Pressure drop in the condenser, 4-6.
10. Subcooling of the liquid in the condenser or subcooler, 6-7.
11. Heat gain in the liquid line. 7-8.
12. Pressure drop in the evaporator, 9-10.

The pressure drop in the evaporator is large and that in the condenser is small. Due
to various pressure drops, the capacity of the plant is decreased and the power
consumption per unit of refrigeration is increased.

The Coefficient of Performance (COP) of an actual vapor compression cycle is

always lower than that of an ideal vapor compression cycle due to several factors that
introduce inefficiencies and deviations from the ideal assumptions.
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Sample Problems 1 (Refrigeration by Hipolito Santa Maria)

The following data were taken from a test on a twin cylinder, single-acting 15 cm x 20
cm, 320 rpm compressor ammonia refrigeration plant.

Temperatures of refrigerant:
After expansion valve -25°C
Entering brine cooler -25°C
Leaving brine cooler -18°C
Entering compressor -8°C
Leaving compressor 120°C
Entering condenser 110°C
Leaving condenser 30°C
Entering expansion valve 32°C
Pressures of refrigerant:
Compressor discharge and condenser 1352 kPa
Compressor suction 132 kPa
Brine circulation 102kg/min
Temperature drop of brine in cooler 7C
Specific heat of brine 3.14kJ/kg-K
Input to motor 18.8 kW
Motor efficiency at this load 92 %
Compressor jacket cooling water 5 kg/min
Temperature rise of jacket water 8.9C.

Show the thermodynamic states at various points on p-h diagram and calculate:

a. Refrigerating capacity in TR assuming 2 percent loss of useful refrigeration by

heat gain from room in brine cooler
b. Rate of flow of ammonia
c. Compressor IHP and mechanical efficiency
d. Compressor volumetric efficiency
e. COP of the cycle
f. Make a system heat balance.

Solution (ACTUAL VAPOR COMPRESSION CYCLE)

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h1 = h at 132 kPa and − 8C = 1470 kJ/kg

v1 = v at 32 kPa and − 8C = 0.95 m3/kg
h2 = h at 1352 kPa and 120C = 1725 kJ/kg
h3 = h at 1352 kPa and 110C = 1700 kJ/kg
h4= hf at 30C = 341.77 kJ/kg
h5= h6= hf at 32C = 351.50 kJ/kg
h7 = h at 132 kPa and − 18C = 1445 kJ/kg

(a) Refrigerating capacity (from brine)

Qe= (1.02)(mb)(cb)(tb)
Qe = (1.02)(102)(3.14)(7)
Qe = 2286.7992 kJ/min x (1 TOR/ 211 kJ/min )
Qe = 10.8379 TOR

(b) Refrigerating capacity (from refrigeration)

Q𝑒= mref(ℎ7− ℎ6)
2086.7992 = mref (1445 − 351.5)
mref = 2.0913 𝑘𝑔/min
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(c) Energy balance about compressor

(m)(h1) + W = (m)(h2) + QJ
W = (m)(h2− h1) + QJ
W = H + QJ

Change of enthalpy,
H = (m)(h2− h1) = (2.0913)(1725 − 1470) = 533.2728 kJ/min

Heat of jacket water,

QJ= (mc)(cw)(t w) = (5)(4.187)(8.9) = 186.3215 kJ/min

W = H + QJ = 533.2728 kJ/min + 186.3215 kJ/min = 719.5943 kJ/min

Windicated = 719.5943 kJ/min x 1 min / 60 sec x 1 kJ/sec / 0.746 Hp = 16.0767 Hp

Wbrake = Motoroutput
Motoroutput = Motor input x Motor efficiency
Motoroutput =18.8 kW x 0.92 = 17.296 kW x 1 kJ/sec / 0.746 Hp = 23.1850 Hp

Mechanical efficiency = W indicated / W brake

Mechanical efficiency = 16.0767 Hp / 23.1850 Hp
Mechanical efficiency = 0.6934 (69.34%)

(d) Compressor volumetric efficiency = V1 / VD

V1 = m v1 = 2.0913 𝑘𝑔/min x 0.95 m3/kg = 1.9867 m3/min
VD = πD2LNC/ 4 = (π (0.15 m)2 (0.20 m) (320 rev/min) (2 x 1) = 2.2619 m3/min

Compressor volumetric efficiency = 1.9867 m3/min / 2.2619 m3/min

Compressor volumetric efficiency = 0.8783 (87.83%)

(e) COP = Qe / W = 2286.7992 kJ/min / 719.5943 kJ/min = 3.1779

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(f) System Heat Balance

Heat Entering
Compressor, W 719.5943 kJ/min
Evaporator, Qe 2286.7992 kJ/min
Pipe 7 to 1,
Q7-1 = mref (h1 - h7) 52.2750 kJ/min
Q7-1 = 2.0913 (1470 kJ/kg - 1445 kJ/kg)
Pipe 4 to 5,
Q4-5 = mref (h4 – h5)
20.3483 kJ/min
Q4-5 = 2.0913(351.50 kJ/kg -341.77
kJ/kg)
Total Heat Entering 3079.0168 kJ/min

Heat Leaving
Jacket Cooling Water, QJ 186.3215 kJ/min
Pipe 2 to 3,
Q2-3 = mref (h2 – h3) 52.2825 kJ/min
Q2-3 = 2.0913 (1725 kJ/kg – 1700 kJ/kg)
Condenser, QR
Q3-4 = mref (h3 – h4) 2840.4663 kJ/min
Q3-4 = 2.0913 (1700 kJ/kg - 341.77 kJ/kg)
Total Heat Leaving 3079.0703 kJ/min
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Name: __________________________________ Course/Year/Section: ________

Date Submitted: ______________________

ACTIVITY NO. 5 (ACTUAL VAPOR COMPRESSION CYCLE)

Instruction. Show your solution.

A Refrigerant 50 compression plant is to be designed for a capacity of 35 TOR. The

cooling water temperature requires a condenser pressure of 800 kPa and the brine
temperature a pressure of 100 kPa in the brine cooler. The following temperatures will
exist at the points designated:

Compressor Suction -40oC

Entering condenser 90oC
Leaving condenser 32oC
Leaving evaporator -50oC

Wire drawing through compressor valves

Suction 20 kPa
Discharge 200 kPa

A two-cylinder, vertical compressor is to be used at 200 m/min piston speed

Mechanical efficiency 85%
Adiabatic compression efficiency 80%
Volumetric efficiency 70%
Stroke-to-bore ratio 1.3

Determine:
(a) the rate of circulation of Refrigerant 50,
(b) the BHP of the compressor,
(c) the heat rejected at the condenser,
(d) the bore, stroke, and rpm of the compressor, and
(e) the COP

"Success is the sum of small efforts, repeated day in and day out."

- Robert Collier -