Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

Lecturer: -Dr. Esam Mejbil Abid Babylon University

Subject: Air Conditioning and Refrigeration College of Engineering
Year: Fourth B.Sc. Department of Mechanical Engineering

LECTURE-17

Multi-Stage Vapour Compression Refrigeration

Systems

1. Introduction
A single stage vapour compression refrigeration system has one low side
pressure (evaporator pressure) and one high side pressure (condenser pressure). The
performance of single stage systems shows that these systems are adequate as long as
the temperature difference between evaporator and condenser (temperature lift) is
small. However, there are many applications where the temperature lift can be quite
high. The 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. For example, in frozen food industries the required evaporator can be as
o o
low as –40 C, while in chemical industries temperatures as low as –150 C may be
required for liquefaction of gases. On the high temperature side the required
condensing temperatures can be very high if the refrigeration system is used as a heat
pump for heating applications such as process heating, drying etc. However, as the
temperature lift increases the single stage systems become inefficient and
impractical. For example, Figure1 shows the effect of decreasing evaporator
temperatures on T-s and P-h diagrams. It can be seen from the T-s diagrams that for a
given condenser temperature, as evaporator temperature decreases:
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

i. Throttling losses increase

ii. Superheat losses increase
iii. Compressor discharge temperature increases
iv. Quality of the vapour at the inlet to the evaporator increases
v. Specific volume at the inlet to the compressor increases

Figure (1-a): Effect of evaporator temperature on cycle performance (T-s diagram)

Figure (1-b): Effect of evaporator temperature on cycle performance (P-h diagram)

Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

A multi-stage system is a refrigeration system with two or more low-side

pressures. Multi-stage systems can be classified into:

a) Multi-compression systems
b) Multi-evaporator systems
c) Cascade systems, etc.

Two concepts which are normally integral to multi-pressure systems are,

i) flash gas removal, and
ii) intercooling.

2. Flash gas removal using flash tank

It is mentioned above that one of the problems with high temperature lift
applications is the high quality of vapour at the inlet to the evaporator. This vapour
called as flash gas develops during the throttling process. The flash gas has to be
compressed to condenser pressure, it does not contribute to the refrigeration effect as it
is already in the form of vapour, and it increases the pressure drop in the evaporator. 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. However, continuous removal of flash
gas as soon as it is formed and recompressing it immediately is difficult in practice.
One way of improving the performance of the system is to remove the flash gas at an
intermediate pressure using a flash tank. Figure 2 shows the schematic of a flash tank
and Figure 3 shows the expansion process employing flash tank.
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

Figure (2-a): working principle of flase tank

3. Intercooling in multi-stage compression

The specific work input, w in reversible, polytropic compression of refrigerant

vapour is given by:

………………………………(1)

where P 1and P 2are the inlet and exit pressures of the compressor, v1 is the

specific volume of the refrigerant vapour at the inlet to the compressor and n is the
polytropic exponent. From the above expression, it can be seen that specific work input
reduces as specific volume, v1 is reduced. At a given pressure, the specific volume can

be reduced by reducing the temperature. This is the principle behind intercooling in

multi-stage compression. Figures 4 (a) and (b) show the process of intercooling in two-
stage compression on Pressure-specific volume (P-v) and P-h diagrams.
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

Figure (3): Expansion process using a flase tank on p-h diagram

Figure 4(a) & (b): Intercooling in two-stage compression

As shown in the figures, instead of compressing the vapour in a single stage from
state 1 to state 2’, if the refrigerant is compressed from state 1 to an intermediate
pressure, state 2, intercooled from 2 to 3 and then compressed to the required pressure
(state 4), reduction in work input results. If the processes are reversible, then the
savings in specific work is given by the shaded area 2-3-4-2’ on P-v diagram. The
savings in work input can also be verified from the P-h diagram. On P-h diagram, lines
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

1-2-2’ and 3-4 represent isentropic. Since the slope of isentropic on P-h diagram
reduces (lines become flatter) as they move away from the saturated vapour line,

(h4-h3) < (h2’-h2) ⇒ (h2-h1)+(h4-h3) < (h2’-h1) …………………..(2)

Intercooling of the vapour may be achieved by using either a water-cooled heat

exchanger or by the refrigerant in the flash tank. Figures 5(a) and (b) show these two
systems. Intercooling may not be always possible using water-cooled heat exchangers
as it depends on the availability of sufficiently cold water to which the refrigerant from
low stage compressor can reject heat. Moreover, with water cooling the refrigerant at
the inlet to the high stage compressor may not be saturated. Water cooling is commonly
used in air compressors. Intercooling not only reduces the work input but also reduces
the compressor discharge temperature leading to better lubrication and longer
compressor life.

Figure 5 (a): Intercooling using liquid refrigerant in flash tank

Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

Figure 5(b): Intercooling using external water cooled heat exchanger

One of the design issues in multi-stage compression is the selection of suitable

intermediate pressure. For air compressors with intercooling to the initial temperature,
the theoretical work input to the system will be minimum when the pressure ratios are
equal for all stages. This also results in equal compressor discharge temperatures for all
compressors. Thus for a two-stage air compressor with intercooling, the optimum
intermediate pressure, Pi,opt is:

…………………..(2)

where Plow and Phigh are the inlet pressure to the low-stage compressor and exit

pressure from the high-stage compressor, respectively. The above relation is found to
hold good for ideal gases. For refrigerants, correction factors to the above equation are
suggested, for example one such relation for refrigerants is given by:
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

…………………(3)

where P and P are the evaporator and condenser pressures, and T and T are
e c c e

condenser and evaporator temperatures (in K).

4. Multi-stage system with flash gas removal and intercooling

Figures 6(a) and (b) show a two-stage vapour compression refrigeration system
with flash gas removal using a flash tank, and intercooling of refrigerant vapour by a
water-cooled heat exchanger and flash tank. The superheated vapour from the water
cooled heat exchanger bubbles through the refrigerant liquid in the flash tank. It is
assumed that in this process the superheated refrigerant vapour gets completely de-
superheated and emerges out as a saturated vapour at state 4. However, in practice
complete de-superheating may not be possible. As mentioned the use of combination of
water cooling with flash tank for intercooling reduces the vapour generated in the flash
tank. The performance of this system can be obtained easily by applying mass and
energy balance equations to the individual components. It is assumed that the flash tank
is perfectly insulated and the potential and kinetic energy changes of refrigerant across
each component are negligible.
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

Figure 6(a) Two stage vapour compression refrigeration system with flash
gas removal using a flash tank and intercooling
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

Figure 6(a) Two stage vapour compression refrigeration system with flash
gas removal using a flash tank and intercooling-P-h diagram

From mass and energy balance of the flash tank:

…………………(4)

From mass and energy balance across expansion valve,

…………………(5)
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

From mass and energy balance across evaporator:

…………………(6)

From mass and energy balance across low-stage compressor, Compressor-I:

…………………(7)

where is the mass flow rate of refrigerant through Compressor-I. I.m

From mass and energy balance across water-cooled intercooler:

…………………(8)

where QI is the heat transferred by the refrigerant to the cooling water in the

intercooler.
From mass and energy balance across high-stage compressor, Compressor-II:

…………………(9)

where is the mass flow rate of refrigerant through Compressor-II. II.m

Finally, from mass and energy balance across condenser:
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

…………………(10)

Finally, from mass and energy balance across the float valve:

…………………(11)

From the above set of equations, it can be easily shown that for the flash tank:

…………………(12)

It can be seen from the above expression that the refrigerant flow through the
high-stage compression can be reduced by reducing the enthalpy of refrigerant vapour
entering into the flash tank, hII.m 3 from the water-cooled intercooler.

The amount of additional vapour generated due to de-superheating of the

refrigerant vapour from the water-cooled intercooler is given by:

…………………(13)

Thus the vapour generated will be zero, if the refrigerant vapour is completely
de-superheated in the water-cooled intercooler itself. However, this may not be possible
in practice. gen.m
Multi-Stage Vapour Compression Refrigeration Systems DEPARTMEN OF MECHANICAL ENGINEERIN

For the above system, the COP is given by:

…………………(14)

The above system offers several advantages,

a) Quality of refrigerant entering the evaporator reduces thus giving rise to
higher refrigerating effect, lower pressure drop and better heat transfer
in the evaporator.
b) Throttling losses are reduced as vapour generated during throttling from
P to P is separated in the flash tank and recompressed by Compressor-
c i

II.
c) Volumetric efficiency of compressors will be high due to reduced
pressure ratios.
d) Compressor discharge temperature is reduced considerably.