Ch-3: Multi-pressure Systems

Books:
▪ Refrigeration & Air-Conditioning by Wilbert F. Stoecker / Jerold W. Jones (Ch-16)
▪ PRINCIPLES of REFRIGERATION by ROY J. DOSSAT.
▪ HEATING AND COOLING OF BUILDINGS Design for Efficiency, by JAN F. KREIDER,
PETER S. CURTISS, ARI RABL
▪ Refrigeration Systems and Applications, 3rd Ed. By Ibrahim Dincer

Mechanical Engineering Dept. UoB 1

 Multi-Pressure System

▪ A Refrigeration System that has two or more low side pressures (i.e. 2 or more evaporators)

▪ Low side pressure is the pressure of the refrigerant between the expansion valve and intake of the
compressor.

Why to use Multi Pressure Systems

▪ Single Pressure systems are adequate as long as the temperature

difference between evaporator and condenser (Temperature Lift ) is small

▪ Temperature lift can become large either due to the requirement of very low evaporator
temperatures and/or due to the requirement of very high condensing temperatures.

▪ in
frozen food industries, required evaporator temperature can be as low as – 40 oC, while in
chemical industries temperatures as low as – 150 oC may be required for liquefaction of gases

Mechanical Engineering Dept. UoB 2

 Multi-Pressure System

Why to use Multi Pressure Systems---contd--

▪ Asthe evaporator temperature becomes very low and/or when the condenser temperature becomes
high, Multi-stage Systems are used in practice

▪ In many refrigeration systems different temperatures are required at various points

o E.g. Dairy where one evaporator operates at -35 oC to harden the ice while another operates at 2
oC to cool the milk

o Another typical application might be in a process industry where a two- or three-stage

compression arrangement serves an evaporator operating at a low temperature of -20 °C or lower

Mechanical Engineering Dept. UoB 3

 Multi-Pressure System

Why to use Multi Pressure Systems---contd--

▪ Throttling losses increase

▪ Superheat losses increase → Due to these drawbacks, single
▪ Compressor discharge temperature increases stage systems are not recommended
▪ Quality of the vapor at the inlet to the evaporator increases
▪ Specific volume at the inlet to the compressor increases
Mechanical Engineering Dept. UoB 4
 Multi-Pressure System

Removal of Flash Gas

Flash Gas

▪ Mass of Vaporized Refrigerant per kg of refrigerant that is just

leaving the throttling or expansion valve
▪ One of the problems with high temperature lift applications is the
high quality of vapor at the inlet to the evaporator

▪ it does not contribute to the refrigeration effect as it is already in

the form of vapor
▪ It is possible to improve the COP of the system if the flash gas is
removed as soon as it is formed and recompressed to condenser
pressure

▪ continuousremoval of flash gas as soon as it is formed and

recompressing it immediately is difficult in practice
▪ Removal of the flash gas is usually done at an intermediate pressure using a flash tank
Mechanical Engineering Dept. UoB 5
 Multi-Pressure System

Removal of Flash Gas

▪ FlashTank is a pressure vessel, wherein the refrigerant liquid and vapor are separated at an
intermediate pressure
▪ Refrigerant from condenser is first expanded to an intermediate pressure corresponding to the pressure
of flash tank, using a low side. Float Valve, which also maintains a constant liquid level in the flash tank

6
To
Compressor
P
1
Flash Tank

4 3 6 1 3

4
5
5 2 7 To
Evaporator
Expansion
h Valve
Mechanical Engineering Dept. UoB 6
 Multi-Pressure System

Removal of Flash Gas

▪ End point of the expansion 2 could have been achieved by interrupting the expansion at 3 and separating
the liquid and vapor phase, which are 4 and 6, respectively
▪ Expanding the liquid at 4 and the vapor at 6 to the final pressure, giving state point 5 and 7 respectively

6
To
P Compressor
1
Flash Tank
4 3 6 1 3

4
5 2 7 5
To
Evaporator
Expansion
h Valve
Mechanical Engineering Dept. UoB 7
 Multi-Pressure System

Removal of Flash Gas

▪ Separation in Flash Tank occurs when the upward velocity of the vapor is low enough for the liquid
particles to drop back into the tank → velocities less than 1 m/s will provide adequate separation

▪ No practical means has yet been developed to separate the vapor continuously as it forms and to
recompress it immediately
6
To
Compressor
P
1
Flash Tank

4 3 6 1 3

4
5
5 2 7 To
Evaporator
Expansion
h Valve
Mechanical Engineering Dept. UoB 8
 Multi-Pressure System

Intercooling
▪ Intercooling between two stages of compression reduces the work of compression per kg of vapor

P
(kPa)
3 Condensation
2
P1 and P2 : inlet and exit pressures of the compressor

Expansion
v1 : specific volume of the refrigerant vapor at the inlet to the
compressor
n : polytropic exponent Evaporation
⇒ Specific work input reduces as specific volume v1 is reduced 4
1
o At a given pressure, the specific volume can be reduced by
reducing the temperature
o This is the principle behind intercooling in multi-stage h, kJ/kg
compression.
▪ Intercooling also reduces the compressor discharge temperature leading to better lubrication and longer
compressor life

Mechanical Engineering Dept. UoB 9

 Multi-Pressure System

Intercooling

Intercooling with water cooled heat exchanger

▪ Water cooled intercooling is suitable only for two-

stage air compression, but for refrigerant
compression the water is usually not cold enough Intercooler

5 2
4

High Stage Low Stage

Compressor Compressor 1

Mechanical Engineering Dept. UoB 10

 Multi-Pressure System

Intercooling
7
Evaporator
Intercooling with Liquid Refrigerant

m1
Flash Tank
P 2
1
5 4 6
2/
5 m2 - m1

Condenser
6 m2 Low-Stage
Pi 3 2 Intercooler Compressor

4
m1 3
7 1 m2

High-Stage
Compressor
h
Mechanical Engineering Dept. UoB 11
 Multi-Pressure System

Intercooling
Intercooling with Liquid Refrigerant---Contd--
▪ Vapors are taken up to bottom of flash chamber and thus allowed
bubble through the liquid in flash chamber → cooling of vapor up to
saturation temperature corresponding to intermediate pressure, i.e, Pi
at state point 3, existing in flash chamber
▪ PV-Diagram → Saving in compressor work equivalent to shaded
area 2342/ P
P
5 4 2/ Pc: Condenser Pressure 5 4
Pc 2/
Pi: Intermediate Pressure m3
2
Pe: Evaporator Pressure 6
Pi
6 3
Pi 3 2
m1
Pe 1
7 7 1

Vc Vs V h
Mechanical Engineering Dept. UoB 12
 Multi-Pressure System

Intercooling
Intercooling with liquid refrigerant---Contd--
▪ Pv-Diagram → Saving in compressor work equivalent to shaded area
2342/
▪ lines 1-2-2/ and 3-4 represent isentropes → slope of isentropes on P-h
diagram reduces (lines become flatter) as they move away from the
saturated vapor line
(h4 - h3) < (h2/ - h2) => (h2 - h1)+(h4 - h3) < (h2/ - h1) P
P 5
5 4 Pc: Condenser Pressure 4 2/
Pc 2/
Pi: Intermediate Pressure m3
Pe: Evaporator Pressure 6
Pi 2 Pi 3 2
6 3
m1
Pe 1 7
7 1

Vc Vs V h
Mechanical Engineering Dept. UoB 13
 Multi-Pressure System

Intercooling
Intercooling with liquid refrigerant---Contd--
▪ Intercooling using liquid refrigerant from condenser in the flash tank
may or may not reduce the power input to the system, depending
upon the nature of the refrigerant
▪ heatrejected by the refrigerant during intercooling generates additional
vapor in the flash tank, which has to be compressed by the high-stage
compressor
=> m3 > m1 P
Ammonia as a Refrigerant
5 4
2/
▪ Amount of liquid evaporated from flash intercooling is m3
extremely small, due to its high latent heat of vaporization → Pi 6
3 2
power required to drive the system decreases
m1
▪ Discharge temperature from the high stage compressor is also 7 1
reduced from about 146 oC at point 2/ to 77 oC → Beneficial for
Compressor’s life h
Mechanical Engineering Dept. UoB 14
 Multi-Pressure System

Intercooling
Intercoolinag with liquid refrigerant---Contd--
R-12 or R-22 as a Refrigerant
▪ Latent heat of vaporization is small and largest amount of
refrigerant will be vaporized resulting in an increased quantity
of mass flow P

5 4
▪ Savingin specific work in the case of R-22 system, by 2/
working an isentropic close to saturated vapor curves does m3
not compensate for increased mass flow which must be
6
pumped by the. high stage compressor Pi 3 2

m2
Flash gas removal is always desirable, and Flash 7 1
Intercooling is suitable in the case of some refrigerants only

h
Mechanical Engineering Dept. UoB 15
 Multi-Pressure System

Example
Calculate the power required to compress 1.2 kg/s of ammonia from saturated vapor at 80 kPa to
1000 kPa:
(a) By single stage compression.
(b) By two stage compression with intercooling by liquid refrigerant at 300 kPa.

Mechanical Engineering Dept. UoB 16

 Multi-Pressure System

Example

Mechanical Engineering Dept. UoB 17

 Multi-Pressure System

Example

Mechanical Engineering Dept. UoB 18

 Multi-Pressure System

Example

Mechanical Engineering Dept. UoB 19

 Multi-Pressure System
Example – contd--

Mechanical Engineering Dept. UoB 20

 Multi-Pressure System

Example – contd--

Mechanical Engineering Dept. UoB 21

 Multi-Pressure System

One Evaporator and One Compressor

▪ Pressure reducing valve throttles the flash gas from the intermediate pressure to the evaporator
pressure

▪ Throttling
is necessary as there is no
Condenser
Pressure
Reducing
compressor available with a high-suction Valve
pressure

▪ Calculations wouldshow that the flash tank Compressor

does not improve the system’s performance. Flash Tank

▪ The only reason for using the flash tank

would be to keep the flash gas in the machine
room rather than sending it to the evaporator.

▪ The flash gas in the evaporator tubes and

Evaporator
long suction line does not refrigeration but
increases the pressure drop. Machine Room

Mechanical Engineering Dept. UoB 22

 Multi-Pressure System

Two Evaporator and One Compressor

▪ One compressor serves two evaporators having

different temperature requirements

▪ Difficulties may arise when an evaporator operates

at an Unnecessarily Low Temperature

▪ Evaporator at -10 oC which cools air for air-conditioning

may collect frost which blocks the flow of air

Mechanical Engineering Dept. UoB 23

 Multi-Pressure System

Two Evaporator and One Compressor--contd--

▪ PressureReducing Valve installed after the high
temperature evaporator regulates the pressure and
maintains a temperature in the air-conditioning
evaporator at 5 oC
▪ RefrigeratingEffect in the high temperature
evaporator is greater than it is in the previous
system

▪ Compression in this system occurs further out in the

Super Heated Region than in the previous system
⇒ This system demands more work per kg of refrigerant

Mechanical Engineering Dept. UoB 24

 Multi-Pressure System

Two compressors and one Evaporators

▪ Two Stage Compression with Intercooling and Removal of Flash Gas is often the ideal way to serve one
low temperature evaporator
▪ Requires less power than with a Single Compressor, and often the saving in power will justify the cost
of extra equipment
5 4
Condenser

3
P
4 High-Stage
5 Compressor

6 2
7
3 2
Flash Tank

6
8 1
1 Low-Stage
Intercooler Compressor

7 8
h Evaporator

Mechanical Engineering Dept. UoB 25

 Multi-Pressure System

Two Compressors and One Evaporators

Mechanical Engineering Dept. UoB 26

 Multi-Pressure System

Two compressors and two Evaporators

▪ Evaporators at two different temperatures can be handled efficiently by a two-stage system which
employs Intercooling and removal of Flash Gas 4
5
Condenser

6 Evaporator
3
P 5 oC, 250 kW
High-Stage
4 Compressor
5

6 2
7
3 2 Flash Tank

6
Low-Stage
1
8 Intercooler
Compressor
1

7 8 Evaporator
-30 oC, 180 kW
h
Mechanical Engineering Dept. UoB 27
 Multi-Pressure System

Example

In an ammonia system one evaporator is to

provide 180 kW of refrigeration at -30 oC and
another evaporator is to provide 200 kW at 5
oC. The system uses two-stage compression

with intercooling and is arranged as in Fig. The

condensing temperature is 40 oC.

• Calculate the power required by the

compressor.

• Also calculate the compressor power if

separate compressor serves each evaporator
in single stage compression.

Mechanical Engineering Dept. UoB 28

 Multi-Pressure System

Example

Mechanical Engineering Dept. UoB 29

 Multi-Pressure System

Example

Simplest way to calculate the mass rate of flow handled by the

high-stage compressor is to make a heat and mass balance about
both the High-temperature Evaporator and the Intercooler

ṁ ṁ ṁ ṁ

ṁ ṁ ṁ ṁ
and
⇒ ṁ3 + ṁ3 +

⇒ ṁ3

Mechanical Engineering Dept. UoB 30

 Multi-Pressure System

Example

Mechanical Engineering Dept. UoB 31

 Multi-Pressure System

Example
If one compressor served each evaporator in single-stage compression:

⇒ ṁ1 =

For h𝟐: P2 = P3 = Psat @ 40 oC = 1557 kPa, s1 = s2 = sg @ - 30 oC = 6.06 kj/kg K

Fig. A1:
h𝟐 = 𝟏𝟖𝟏𝟓 𝒌𝑱/𝒌𝒈

Mechanical Engineering Dept. UoB 32

 Multi-Pressure System

Example

Mechanical Engineering Dept. UoB 33

Multi-Pressure System

Mechanical Engineering Dept. UoB 34

Multi-Pressure System

Mechanical Engineering Dept. UoB 35

 Multi-pressure Vapor Compression Refrigeration

Limitations of Multi-stage Systems

▪ Since only one refrigerant is used throughout the system, the refrigerant used should have high critical
temperature and low freezing point
▪ Operating pressures with a single refrigerant may become too high or too low
▪ Only R12, R22 and NH3 systems have been used in multi-stage systems as other conventional working
fluids may operate in vacuum at very low evaporator temperatures

o Operation in vacuum leads to leakages into the system and large compressor displacement due to
high specific volume

▪ Possibility of migration of lubricating oil from one compressor to other leading to compressor break-down
Above limitations can be overcome by using Cascade Systems

Mechanical Engineering Dept. CEME NUST 36

 Multi-pressure Vapor Compression Refrigeration

Cascade Refrigeration System

▪ How can we make the cold space even colder (reduce Te) and reject heat at an even higher
temperature (increase Tc) without dramatically increasing the cost to build the refrigeration system

▪ Two refrigeration cycles that use two different refrigerants are linked by a heat exchanger
▪ Lower cycle is colder and it absorbs heat from the refrigerated space
▪ upper cycle absorbs heat from the lower
cycle through the heat exchanger

▪ upper cycle is hotter and can reject heat to a very hot

reservoir
▪ So, In a Cascade System a series of refrigerants
with progressively lower boiling points are used in a
series of single stage units

Mechanical Engineering Dept. CEME NUST 37

 Multi-pressure Vapor Compression Refrigeration

Cascade Refrigeration System

▪ component where heat of condensation of lower stage refrigerant is supplied for vaporization of next level
refrigerant is called as Cascade Condenser
▪ Refrigerants selected should have suitable pressure-temperature characteristics
o E.g. Refrigerant combination is the use of Carbon Dioxide (NBP = -78.4oC, Tcr = 31.06oC) in low
temperature cascade and Ammonia (NBP = -33.33oC, Tcr = 132.25oC) in high temperature cascade

Decrease in Qc

Mechanical Engineering Dept. CEME Increase

NUST in Qe 38
 Simple and Multi-pressure Vapor Compression Refrigeration

Cascade Refrigeration System

Three-Stage Cascade Systems:
▪ Cascade refrigeration cycles are commonly used in the liquefaction of natural
gas
▪ Refrigeration down to that temperature can be provided by a ternary cascade
refrigeration cycle using propane, ethane, and methane, whose boiling points
at standard atmospheric pressure are -42, -88, and -161.4 oC, respectively

PH-Diagram

TS-Diagram
Mechanical Engineering Dept. CEME NUST 39
 Simple and Multi-pressure Vapor Compression Refrigeration

Cascade Refrigeration System

▪ compressed Methane vapor is first cooled by heat exchange with the
propane in the propane evaporator before being condensed by heat
exchange with the ethane in the ethane evaporator

▪ Because of the high temperature after compression, the gas leaving

each compressor passes first through a water-cooled intercooler.

Mechanical Eng Dept. HITEC University 40

 Multi-pressure Vapor Compression Refrigeration

Practice Problems:
Book: Stoecker and Jones 5th Ed., Chapter 16
▪Examples: 16.1 to 16.4
▪Problems: 16.1 to 10.4
Book: Refrigeration Systems and Applications, 3rd Ed. By Ibrahim Dincer
▪Example: 1.5, 1.6
Book: Thermodynamics: An Engineering Approach by Yunus A. Cengel, Michael A. Boles 8th Ed.
▪Problems: 11-54, 11-56, 11-57, 11-59, 11-60, 11-61 E, 11-62E

▪All other problems which are included in notes and solved in the class

Mechanical Engineering Dept. UoB 41