MERE-423 Refrigeration Engineering Lecture 04

MULTISTAGE VAPOR COMPRESSION SYSTEMS or MULTIPRESSURE SYSTEMS

A multistage vapor compression system uses more than one single-stage compression process or more than one low-
pressure side, and usually include a high-stage compressor and a low-stage compressor. It can also be a combination of two
separate refrigeration systems

COMPOUND SYSTEMS
Multistage vapor compression systems are classified as: compound systems or cascade systems. A compound system
consists of two or more compression stages connected in series. Each compression stage usually requires a separate
compressor. However, two or more stages may be internally compounded by means of impellers connected in series.

FLASH GAS REMOVAL (FLASH TANK OR FLASH CHAMBER)

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, and it increases the pressure drop in the evaporator. One way of improving the
performance of the system is to remove the flash gas at an intermediate pressure using a flash tank.

A flash tank is a pressure vessel, wherein the refrigerant liquid and vapor are separated at an intermediate pressure. The
refrigerant from condenser is first expanded to an intermediate pressure corresponding to the pressure of flash tank. The
refrigerant liquid and vapor are separated. The saturated liquid is fed to the evaporator after throttling using an expansion
valve. The saturated vapor is either compressed to the condenser pressure or throttled to the evaporator pressure.

Illustration:

5 To compressor

Flash Tank

From condenser
1 2

To evaporator
3 4
Expansion
Valve
Pressure

Enthalpy

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

LIQUID SUBCOOLING (LIQUID SUBCOOLER)

Another method of obtaining the same result as that of flash gas removal is to employ the flash tank as a liquid subcooler.
Flash coolers are used to subcool liquid refrigerant to the saturated temperature corresponding to the interstage pressure
by vaporizing part of the liquid refrigerant.

A portion of the liquid refrigerant is flashed into vapor going directly to the second-stage suction inlet, so less refrigerant is
compressed in the first-stage impeller. The remaining liquid refrigerant is cooled to the saturated temperature
corresponding to the interstage pressure, which is far lower than the subcooled liquid temperature in a single-stage system.

Illustration:

From condenser 5 To compressor

Flash Tank

1 2

To evaporator
3 4
Expansion
Valve
Pressure

Enthalpy

INTERCOOLING (WATER-COOLED CONDENSER OR FLASH TANK)

In vapor compression systems, the specific work input decreases as the specific volume is reduced. At a given pressure, the
specific volume can be reduced by reducing the temperature. If the refrigerant is compressed in stages with intercooling
instead of compressing in a single stage, reduction in work input results. Intercooling not only reduces the work input but
also reduces the compressor discharge temperature leading to better lubrication and longer compressor life.

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

Intercooling of the vapor may be achieved by using either a water-cooled heat exchanger or by the refrigerant in the flash
tank. Intercooling may not be always possible using water-cooled heat exchangers as it depends on the availability of
sufficiently cold water. Water cooling is commonly used in air compressors.

Intercooling using liquid refrigerant from condenser in the flash tank may or may not reduce the power input to the system,
as it depends upon the nature of the refrigerant. For ammonia, the power input usually decreases with intercooling by
liquid refrigerant. For refrigerants such as R12 and R22, the power input marginally increases.

Illustration:

Water-cooled Intercooler

To condenser

From evaporator

- High-stage Low-stage -
Compressor Compressor

4
To condenser

High-stage
3 - Compressor

2
Flash Tank

From evaporator
1 Low-stage
- Compressor
Pressure

Enthalpy

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

TWO-STAGE COMPOUND SYSTEM with FLASH TANK and INTERCOOLER

1. Vapor refrigerant at state 1 enters the low-stage compressor at the dry saturated state.
2. It is compressed to the interstage pressure at state 2 and becomes superheated. The superheated refrigerant mixes with
the saturated liquid-vapor mixture in the flash tank. The vapor refrigerant leaves the flash tank as saturated vapor.
3. The saturated vapor refrigerant then enters the high-stage compressor at state 3.
4. It is discharged to the condenser in which the vapor refrigerant is condensed and often subcooled at state 5.
5. After the condensing process, the saturated or subcooled liquid refrigerant flows through a throttling device such as a
float valve at the high-pressure side.
6. Inside the flash tank, the refrigerant exists as mixture of vapor and liquid at state 6. The mixture then mixes with the
supplied superheated refrigerant from the low-stage compressor.
7. Liquid refrigerant then flows through another throttling device and is flashed to state 8, and the liquid-vapor mixture
enters the evaporator.
8. The remaining liquid refrigerant is vaporized at point 1 in the evaporator. The vapor then flows to the inlet of the low-
stage compressor and completes the cycle.

Condenser
5 4

High-stage
3 - Compressor

6
Flash Tank 2

7 Low-stage
Expansion -
1 Compressor
Valve
8 Evaporator
Pressure

Enthalpy

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

VARIOUS COMPRESSOR-EVAPORATOR COMBINATIONS

Two evaporators and One Compressor

Illustration:

Condenser
3

Expansion Pressure
Valve Reducing Valve
6 Evaporator
4 5 6 1
-

Compressor

Expansion
Valve
Evaporator
7 8
Pressure

Enthalpy

Energy and Mass Balance:

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

One evaporator and Two Compressors

Illustration:

Condenser
5 4

High-stage
3 - Compressor

6
Flash Tank 2

7 Low-stage
Expansion -
1 Compressor
Valve
8 Evaporator
Pressure

Enthalpy

Energy and Mass Balance:

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

Two evaporators and Two Compressors

Illustration:

Condenser
5 4
Expansion Valve
Evaporator
6 3
-

High-stage
Compressor

6
2
Flash Tank

7
-
Expansion Valve 1
Low-stage
Evaporator Compressor
8
Pressure

Enthalpy

Energy and Mass Balance:

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

THREE-STAGE COMPOUND SYSTEM

Condenser
7 6

High-stage
5 - Compressor

8
4

9 Flash Tank

3 Middle-stage
-
Compressor

10
2

11 Flash Tank

Expansion Low-stage
1 -
Valve Compressor
12
Evaporator
Pressure

Enthalpy

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME

MERE-423 Refrigeration Engineering Lecture 04

SAMPLE PROBLEMS:
1. Calculate the power required and the COP of a system of one compressor serving two evaporators. One evaporator
carries a load of 35 kW at 10°C and the other a load of 70 kW at –5°C. A back-pressure valve reduces the pressure in the
10°C evaporator to that of the –5°C evaporator. The condensing temperature is 37°C. The refrigerant is ammonia.

2. Calculate the power required in an ammonia system which serves a 210-kW evaporator at –20°C. The system uses two-
stage compression with intercooling and removal of flash gas. The condensing temperature is 32°C.

3. In an ammonia system, one evaporator is to provide 200 kW of refrigeration at –30°C and another at evaporator is to
provide 220 kW at 5°C. The system uses two-stage compression with intercooling and flash gas removal. The condensing
temperature is 40°C. Calculate the power required by the compressors and the COP of the system.

4. An ammonia refrigeration system has a capacity of 210 kW at an evaporating temperature of –20°C when the condensing
pressure is 1431 kPa. Compute the total power required by the two compressors and the COP of the system where there is
no intercooling and but there is flash gas removal.

5. A 500-ton multi-stage centrifugal vapor compression system with flash gas removal and intercooling uses R-22 as
refrigerant. Vapor refrigerant enters the low-stage compressor at a dry saturated state, and the subcooled liquid refrigerant
leaves the condenser at a temperature of 32.2°C. Both compression processes at the low-stage compressor and the high-
stage compressor are assumed to be isentropic. Evaporating pressure is 525kPa, and the condensing pressure is 1355 kPa.
Calculate: the fraction of liquid refrigerant vaporized in the flash tank, the mass flow rate of refrigerant flowing through the
condenser, the total work input to the compressor, and the COP of this refrigerating system.

Department of Mechanical Engineering Engr. Dan William C. Martinez, MSME