Example 3.

1
Calculate the power needed to compress 1.2 kg/s of ammonia from saturated vapour at 80
kPa to 1000 kPa by (a) single-stage compression and (b) two-stage compression with
intercooling by liquid refrigerant at 300 kPa.

Solution 3.1
Table 3.1 shows a summary of the calculations with the subscripts referring to state points in
figure 3.3.

Table 3.1 Comparison of ammonia compression with and without intercooling.

Without intercooling, With intercooling, processes

processes 1–2 and 2–3 1–2, 2–4 and 4–5
h2–h1, kJ/kg 1588–1410 1588–1410
h3–h2, kJ/kg 1800–1588
h5–h4, kJ/kg …………… 1628–1450
Flow rate, kg/s, 1 to 2 1.2 1.2
2 to 3 1.2
4 to 5 ……………. 1.346
Power required, kW, 1 to 2 213.6 213.6
2 to 3 254.4
4 to 5 …………….. 239.6
Total power, kW 468.0 453.2

The high-stage compressor in the intercooled system must compress1.2 kg/s plus the flow
rate of refrigerant that evaporates to de-superheat the gas at point 2. The flow rate of
ammonia compressed in the high stage can be calculated by making a heat and a mass
balance about the intercooler, as shown in figure 3.5.

Figure 3.5 Heat and mass balance around intercooler

Heat balance:

Mass balance:

Solving gives
 .

Intercooling the ammonia with liquid refrigerant reduces the power required from 468 to
453.2 kW.

Further benefit of intercooling the ammonia:

Discharge temperature will be reduced from 146 °C to 77 °C. A lower discharge temperature
allows for better lubrication of the compressor, which results in its longer life.

Example 3.2
Compare a compression of 3.5 kg/s of refrigerant 22 (with that of ammonia) from saturated
vapour at 100 kPa to a condensing pressure of 1000 kPa by (a) single-stage compression and
(b) two-stage compression with intercooling by liquid refrigerant at 300 kPa.

Solution 3.2
Table 3.2 shows a summary of the calculations with the subscripts referring to state points in
figure 3.3.

Table 3.2 Comparison of refrigerant 22 compression with and without intercooling.

Without intercooling, With intercooling, processes

processes 1–2 and 2–3 1–2, 2-4 and 4–5
h2–h1, kJ/kg 416–387 416–387
h3–h2, kJ/kg 449–416
h5–h4, kJ/kg …………… 430–399
Flow rate, kg/s, 1 to 2 3.5 3.5
2 to 3 3.5
4 to 5 ……………. 3.74
Power required, kW, 1 to 2 101.5 101.5
2 to 3 115.5
4 to 5 …………….. 115.9
Total power, kW 217.0 217.4

For refrigerant 22, intercooling with liquid refrigerant midway during the compression is
ineffective. In an ammonia system, there is an optimum pressure at which the intercooling
should take place. In the compression of air by cooling water or by rejecting heat to ambient,
the intermediate pressure for minimum total power is

where

is the intercooler pressure, kPa,

is the suction pressure of low-stage compressor, kPa, and
is the discharge pressure of the high-stage compressor, kPa.

The development of the equation provides an approximate guideline for the optimal
intermediate pressure.
3.1 One evaporator and one compressor

With one compressor and one evaporator, the flash chamber may function as shown in
figure 3.6.

Figure 3.6 System with one compressor and one evaporator using a flash tank

A pressure-reducing valve throttles the flash gas from the intermediate pressure to the
evaporator pressure because there is high suction pressure compressor available.

Question 3.3
Briefly explain why the system shown in figure 3.6 is not frequently used.

3.2 Two-stage compression with liquid intercooler

Figure 3.7 shows the schematic arrangement of the different components of a two-stage
compression with liquid intercooler, along with p-h diagram showing the processes involved.
The main components of the system are an evaporator, a low-pressure compressor, a liquid
intercooler, a high-pressure compressor, a condenser and an expansion valve.

7
Figure 3.7 Two-stage compression with liquid intercooler

Question 3.4
Describe in your own words the sequence of operation (1–2; 2–3; 3–4; 4–5; 5–6–1) for the
system shown in figure 3.7.

3.3 Two evaporators and one compressor

The system which has two evaporators operating at different temperatures is common in
refrigeration. Low-temperature refrigeration may be required for a process and another may
be used to provide air conditioning for some offices. A dairy cooling milk and manufacturing
ice cream is another example of such a system. A frozen-food plant may require one
evaporator at –40 °C to quick-freeze the food and the other at –25 °C to hold the food after it
is frozen. One method of arrangement of this type of system is shown in figure 3.8 (a). Figure
3.8(b) shows the corresponding p-h diagram.

Figure 3.8
(a) One compressor and two evaporators with the air conditioning evaporator at –10 °C
(b) Pressure-enthalpy diagram for system of (a)

8
Question 3.5
What are the drawbacks of the system in figure 3.8(a)?

To overcome the drawbacks of the system in figure 3.8(a), a revision may be made as
shown in figure 3.9(a). Figure 3.9(b) shows the corresponding p-h diagram. A pressure-
reducing valve installed after the high-temperature evaporator regulates the pressure and
maintains the temperature in the air conditioning evaporator.

Figure 3.9
(a) One compressor and two evaporators with a pressure-reducing valve to maintain a high temperature in the air
conditioning evaporator
(b) Pressure-enthalpy diagram for a system of (a)

The refrigerating effect in the high-temperature evaporator in figure 3.9(a) is greater

than it is in the system in figure 3.8(a). However, the system of figure 3.9(a) demands more
work per kilogram of refrigerant, but for the proper operation of the high-temperature
evaporator the system is nevertheless preferred.

3.4 Two compressors and one evaporator with intercooler and flash tank

This system is often the ideal way to serve one low-temperature evaporator. It requires less
power than a system with a single compressor.
Problem 1
Calculate the power required by the two compressors in an ammonia system that serves a
250kW evaporator at –25 °C. The system uses two-stage compression with intercooling and
removal of flash gas. The condensing temperature is 35 °C.

Solution:

The intermediate pressure for minimum work:

P2= √ P1 P 4
Where:

P1= saturation pressure at –25 °C = 152 kPa, and

P4 = saturation pressure at 35 °C = 1352 kPa.
P2= √ 152 ( 1352 )=453 kPa

h1 =h g at –25 °C = 1430 kJ/kg

h2 = h at 453 kPa after isentropic compression = 1573
h3 = h g at 453 kPa = 1463
h 4 = h at 1352 kPa after isentropic compression = 1620
h5 = h f at 35 °C = 366 h6 = h5 = 366
h7 = h f at 453 = 202 h 8 = h7 = 202

The mass flow rates through evaporator, m1

Refrigerating Load
m 1=
h1−h 8

250 kW
m 1= =0.204 kg /s
1430−202

m1=m2=m7=m8=0.204 kg /s
(a) Two compressors and one evaporator in example 3
(b) Pressure-enthalpy diagram for system in (a)

m2=m7
m3=m6

Heat and mass balance in intercooler:

m2=m7

m3=m6

m2 h2+ m6 h 6=m7 h7 +m3 h 3

( 0.204 ) (1573 )+ m3 (366)=0.204 (202)+ m3 (1463)

m3=0.255 kg/ s

Low-stage power:

W low satge =m1 (h2−h 1)

(
W low satg e = 0.204
kg
s )
( 1573−1430 )=29.2 kW

High - stage power:

W high satge =m3 (h4 −h3 )

(
W high satge = 0.255
kg
s )
( 1620−1463 ) =40 kW

Total power:

W total =W low satge +W high satge

W total =29.2+ 40=69.2 kW

This power requirement can be compared with that of a single-compressor system

developing 250 kW of refrigeration at –25 °C with a condensing temperature of 35 °C. The
pressure-enthalpy diagram is shown in figure 3.11. The enthalpies are as follows:
 Power =

The two-stage compressor system requires 12% less power than the single-
compressor system.

Figure 3.11 Pressure-enthalpy diagram for single-compressor system for conditions in example 3

Example 3.4
In an ammonia system, one evaporator is to provide 180 kW of refrigeration at –30 °C and
another evaporator is to provide 200 kW at 5 °C. The system uses two-stage compression
with intercooling and is arranged as in figure 3.16(a). The condensing temperature is 40 °C.
Calculate the power required for the compressors.

Figure 3.16
(a) Two compressors and two evaporators operating with intercooling and flash gas removal
(b) The pressure-enthalpy diagram corresponding to the system in (a)

Solution 3.4
Sketch the pressure-enthalpy diagram of the cycle in figure 3.16(b). The discharge pressure of
the low-stage compressor and the suction pressure of the high-stage compressor are the same
as the pressure in the 5 °C evaporator.
Next, determine the enthalpies at the state points.

h1 = hg at –30 °C = 1423 kJ/kg

h2 = h at 517 kPa after isentropic compression = 1630
h3 = hg at 5 °C = 1467
h4 = h at 1557 kPa after isentropic compression = 1625
h5 = hf at 40 °C = 390.6 h6 = h5 = 390.6
h7 = hf at 5 °C = 223 h8 = h7 = 223

Mass rates of flow:

The 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, as shown in figure 3.17.

18
Figure 3.17 Heat and mass balance about high-temperature evaporator and intercooler in example 4

Heat balance:

Mass balance:

Therefore

Combining gives

Solving leads to

The power required by the compressors can now be

calculated: Low-stage power: 0.150(1630 – 1423) =
31.1 kW
High-stage power: 0.382(1625 – 1467) = 60.4
Total = 91.5 kW

19
 If one compressor served each evaporator in a single-stage compression, the power
requirement of the compressors would have been as follows:
Flow through low-temperature evaporator:

Flow through high-temperature evaporator:

Power for low-temperature system: 0.174(1815 – 1423) = 68.2 kW

Power for high-temperature system: 0.186(1625 – 1467) = 29.4
Total = 97.6 kW

The combined power for the compressors serving the evaporators individually is greater than
for the combined system shown in figure 3.16. All of the saving is attributable to the flash gas
removal and intercooling of refrigerant serving the low-temperature evaporator.

Example 3.1
Calculate the power needed to compress 1.2 kg/s of ammonia from saturated vapour at 80 kPa
to 1000 kPa by (a) single-stage compression and (b) two-stage compression with intercooling
by liquid refrigerant at 300 kPa.

Solution 3.1
Table 3.1 shows a summary of the calculations with the subscripts referring to state points in
figure 3.3.

Table 3.1 Comparison of ammonia compression with and without intercooling.

Without intercooling, With intercooling, processes

processes 1–2 and 2–3 1–2, 2–4 and 4–5
h2–h1, kJ/kg 1588–1410 1588–1410
h3–h2, kJ/kg 1800–1588
h5–h4, kJ/kg …………… 1628–1450
Flow rate, kg/s, 1 to 2 1.2 1.2
2 to 3 1.2
4 to 5 ……………. 1.346
Power required, kW, 1 to 213.6 213.6
2
2 to 3 254.4
4 to 5 …………….. 239.6
Total power, kW 468.0 453.2

The high-stage compressor in the intercooled system must compress1.2 kg/s plus the flow rate
of refrigerant that evaporates to de-superheat the gas at point 2. The flow rate of ammonia
compressed in the high stage can be calculated by making a heat and a mass balance about the
intercooler, as shown in figure 3.5.

Figure 3.5 Heat and mass balance around intercooler

Heat balance:

Mass balance:

Solving gives
.

Intercooling the ammonia with liquid refrigerant reduces the power required from 468 to
453.2 kW.

Further benefit of intercooling the ammonia:

Discharge temperature will be reduced from 146 °C to 77 °C. A lower discharge temperature
allows for better lubrication of the compressor, which results in its longer life.

3.5 Compound compressors

In the systems where there are two stages of compression, the flow diagrams have shown two
separate compressors. However, there are single compressors available that accept both high
and low suction pressures; these can be used in place of the two compressors shown in figure
3.16.

3.6 Liquid-recirculation systems

A schematic diagram of a liquid-recirculation system is shown in figure 3.18. Liquid

recirculation systems usually achieve good feeding of the evaporators and provide high heat-
transfer coefficients on the refrigerant side. It is not a requirement that a liquid-recirculation
system be served by a multistage compression system.
20
Figure 3.18 A liquid-recirculation system

3.7 Summary

 The removal of and recompression of flash gas before complete expansion decreases
the power requirement by the compressor in multipressure systems.
 Intercooling decreases the power requirement when ammonia is the refrigerant.
 Intercooling decreases the discharge temperature of the refrigerant from the high-
stage compressor.
 A decision to use multiple-stage systems should essentially be based on an economic
analysis.
 The savings in the use of energy must be compared with the cost of additional
equipment.
 Other factors, such as type of refrigerant, the type of compressor and the system’s
size, also have an influence.

3.8 Design project: identification of the refrigeration cycle

3.16.1Temperature limitation

21
The temperature limitation or the system operation temperatures (evaporating temperature
and condensing temperature) are identified based on the application requirement and local
weather conditions.

3.16.2Selection of the cycle

For the selection of the cycle, the efficiency, economics, complexity and safety of the system
should be considered.

Project 1: Cold room Project 2: Freezer

Location Pretoria Pretoria
Product Fruit or vegetable Meat or fish: a particular kind
of meat or fish
Capacity 1000 kg full load 500 kg/day
Temperature 2–5 °C From 30 °C to –18 °C in 24
hours

PHASE 1: Identify the refrigeration cycle for the project (cycle and working conditions).

3.9 Problems

In the following problems, liquid leaves the condensers saturated, vapour leaves the
evaporators saturated and compressions are isentropic.

3.1 A liquid subcooler receives liquid ammonia at 30 °C and subcools 0.6 kg/s to 5 °C.
Saturated vapour leaves the subcooler for the high-stage compressor at –1 °C. Calculate the
flow rate of ammonia that evaporates to cool the liquid.
Answer: 0.0575 kg/s

3.2 In a refrigerant 22 refrigeration system, the capacity is 180 kW at a temperature of –

30 °C. The vapour from the evaporator is pumped by one compressor to the condensing
pressure of 1500 kPa. Later the system is revised to a two-stage compression operating on the
cycle shown in figure 3.19 with intercooling but no removal of flash gas at 600 kPa.
Calculate:
(a) the power required by the single compressor in the original system
(b) the power required by the two compressors in the revised system
Answer: 70.9 kW

22
Figure 3.19 Intercooling system in problem 2

3.3 A refrigerant 22 system has a capacity of 180 kW at an evaporating temperature of –

30 °C when the condensing pressure is 1500 kPa.
Compute:

(a) the power requirement by the system with a single compressor

(b) the total power required by the two compressors in the system shown in figure 3.20,
where there is no intercooling, but there is flash gas removal at 600 kPa
Answer: 60.7 kW

23
Figure 3.20 Flash gas removal system in problem 3

3.4 A two-stage ammonia system using flash gas removal and intercooling operates on
the cycle shown in figure 3.16(a). The condensing temperature is 35 °C. The saturation
temperature of the intermediate-temperature evaporator is 0 °C and its capacity is 150 kW.
The saturation temperature of the low-temperature evaporator is –40 °C and its capacity is
250 kW. What is the rate of refrigerant compressed by the high-stage compressor?
Answer: 0.411 kg/s

3.5 A two-stage refrigerant 22 system that uses flash gas removal and intercooling serves
a single low-temperature evaporator as shown in figure 3.10(a). The evaporating temperature
is –40 °C and the condensing temperature is 30 °C. The pumping capacity of the high- and
low- stage compressors is shown in figure 3.21. What is
(a) the refrigerating capacity of the system?
(b) the intermediate pressure?
Answers: (a) 318 kW; (b) 390 kPa

24
Figure 3.21 Pumping capacity of low- and high-stage compressors of the system in problem 3.5
(The suction pressure of the low-stage compressor is 105 kPa [–40 °C] and the discharge pressure of the high-
stage compressor is 1192 kPa [30 °C].)

3.6 The following data refer to a compound refrigeration system employing water and
flash intercoolers. The system has a load of 20 tons of refrigeration in the evaporator and uses
ammonia as refrigerant. The saturation temperatures in the evaporator and condenser are –
40 °C and 32 °C respectively, and the intercooler pressure is adjusted for minimum power
consumption. Assuminge no superheating, no subcooling, isentropic compression and 75%
volumetric efficiency at each stage of compression.
Calculate:
(a) mass circulation of ammonia through the condenser
(b) piston displacements for each cylinder
(c) power required to drive the unit
(d) coefficient of performance of the system
Answers: 0.74 kg/s; 9.52 and 4.25 m3/min; 28.2 kW; 2.48

3.7 A vapour-compression system with ammonia as refrigerant works between pressure

limits of 3 bar (evaporator) and 12 bar (condenser). The system is fitted with water and flash
intercooling and subcooling. The flash intercooling pressure is 6 bar; saturated vapour enters
both compressors; and the limiting temperature for water intercooling and subcooling is 20
°C. For a refrigerating load of 15 ton, determine:
(a) The power required to drive the two compressors.
(b) The coefficient of performance of the plant.
(c) The swept volume of each compressor if each has a volumetric efficiency of 80%. Draw
the schematic arrangement of the system and use a p-h chart to obtain your solution.
Answers: 8.631 kW, 6.15, 0.0224 m3/s; 0.01278 m3/s

25