Ii. Iii. Iv.: Cascade Systems

Cascade Systems
In a cascade system a series of refrigerants with progressively lower

boiling points are used in a series of single stage units. The condenser of lower
stage system is coupled to the evaporator of the next higher stage system and so
on. The component where heat of condensation of lower stage refrigerant is
supplied for vaporization of next level refrigerant is called as cascade condenser.
Figures.1(a) and (b) show the schematic and P-h diagrams of a two-stage cascade
refrigeration system. As shown, this system employs two different refrigerants
operating in two individual cycles. They are thermally coupled in the cascade
condenser. The refrigerants selected should have suitable pressure-temperature
characteristics. An example of refrigerant combination is the use of carbon dioxide
(NBP = -78.4o o C, Tcr = 31.06 C) in low temperature cascade and ammonia (NBP
= -33.33o o C, Tcr = 132.25 C) in high temperature cascade. It is possible to use
more than two cascade stages, and it is also possible to combine multi-stage
systems with cascade systems.
Applications of cascade systems:
i. Liquefaction of petroleum vapours
ii. ii. Liquefaction of industrial gases
iii. iii. Manufacturing of dry ice
iv. iv. Deep freezing etc.
Advantages of cascade systems:
i. Since each cascade uses a different refrigerant, it is possible to select a

refrigerant that is best suited for that particular temperature range.
Very high or very low pressures can be avoided
ii. ii. Migration of lubricating oil from one compressor to the other is
prevented
In practice, matching of loads in the cascade condenser is difficult,

especially during the system pull-down. Hence the cascade condensers are
normally oversized. In addition, in actual systems a temperature difference
between the condensing and evaporating refrigerants has to be provided in the
cascade condenser, which leads to loss of efficiency. In addition, it is found that at
low temperatures, superheating (useful or useless) is detrimental from volumetric
refrigeration effect point-of-view, hence in cascade systems, the superheat should
be just enough to prevent the entry of liquid into compressor, and no more for all
refrigerants.
Optimum cascade temperature:

For a two-stage cascade system working on Carnot cycle, the optimum cascade
temperature at which the COP will be maximum, Tcc,opt is given by:
T ec ,opt = √T e . T c
where Te and
Tc are the
evaporator temperature of low temperature cascade and condenser temperature of

high temperature cascade, respectively.
Fig.1(a) & (b): A two-stage cascade refrigeration system
For cascade
systems employing
vapour
compression refrigeration cycle, the optimum cascade temperature assuming equal

pressure ratios between the stages is given by:
b
Where b1 and b2 are the constants in Clausius-Clayperon equation: P=a− T for low
and high temperature refrigerants, respectively.
Auto-cascade systems:
An auto-cascade system may be considered as a variation of cascade
system, in which a single compressor is used. The concept of auto-cascade system
was first proposed by Ruhemann in 1946. Figure 13.7(a) shows the schematic of a
two-stage auto-cascade cycle and Fig.137(b) shows the vapour pressure curves of
the two
Fig.2(a): Schematic
of a two-stage auto-cascade system
refrigerants used in the cycle on D”hring plot.

In a two-stage auto-cascade system two different working fluids; a low boiling
point (low temperature) refrigerant and a high boiling point (high temperature)
refrigerant are used. The vapour mixture consisting of both these refrigerants is
compressed in the compressor to a discharge pressure (Pdischarge). When this high
pressure mixture flows
through the partial
condenser, the high
temperature refrigerant
Fig.13.7(b): Schematic illustrating principle of two-stage auto cascade system on D˘hring plot
can condense by rejecting heat (Q c,out) to the external heat sink, if its partial
pressure in the mixture is such that the saturation temperature corresponding to the
partial pressure is higher than the external heat sink temperature. Since the
saturation temperature of the low temperature refrigerant is much lower than the
external heat sink temperature at its partial pressure, it cannot condense in the
partial condenser, hence, remains as vapour. Thus it is possible theoretically to
separate the high temperature refrigerant in liquid form from the partial condenser.
Next this high temperature, high pressure liquid is expanded through the expansion
valve into the condenser operating at a pressure Psuction. Due to the expansion of the
high temperature refrigerant liquid from Pdischarge to Psuction, its temperature drops to a
sufficiently low value (Te,h) so that when the low temperature, high pressure
refrigerant vapour comes in contact with the high temperature, low pressure
refrigerant in the condenser it can condense at a temperature T c,l. This condensed,
high pressure, low temperature refrigerant is then throttled to the suction pressure
and is then made to flow through the evaporator, where it can provide the required
refrigeration effect at a very low temperature Te. Both the high temperature
refrigerant from condenser and low temperature refrigerant vapour from evaporator
can be mixed as they are at the same pressure. This mixture is then compressed in
the compressor to complete the cycle. Thus using a single compressor, it is
possible to obtain refrigeration at very low temperatures using the auto-cascade
system. In practice, more than two stages with more than two refrigerants can be
used to achieve very high temperature lifts. However, in actual systems, it is not
possible to separate pure refrigerants in the partial condenser as some amount of
low temperature refrigerant condenses in the partial condenser and some amount of
high temperature refrigerant leaves the partial condenser in vapour form. Thus
everywhere in the system, one encounters refrigerant mixtures of varying
composition. These systems are widely used in the liquefaction of natural gas.

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Ii. Iii. Iv.: Cascade Systems

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Cascade Systems

In a cascade system a series of refrigerants with progressively lower

Advantages of cascade systems:

i. Since each cascade uses a different refrigerant, it is possible to select a

In practice, matching of loads in the cascade condenser is difficult,

Optimum cascade temperature:

evaporator temperature of low temperature cascade and condenser temperature of

compression refrigeration cycle, the optimum cascade temperature assuming equal

refrigerants used in the cycle on D”hring plot.

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