c Indian Academy of Sciences

Sadhana Vol. 40, Part 2, April 2015, pp. 437454. 

Numerical optimization of a transcritical CO2 /propylene

cascaded refrigeration-heat pump system with economizer
in HT cycle

ALOK MANAS DUBEY1, , SURESH KUMAR2 and

GHANSHYAM DAS AGRAWAL1
1 Department of Mechanical Engineering, Malviya National Institute of Technology,
Jaipur 302 017, India
2 Department of Mechanical Engineering, University of Petroleum & Energy Studies,

Dehradun 248 007, India

e-mail: [email protected]

MS received 12 May 2014; revised 7 September 2014; accepted 6 November 2014

Abstract. Use of organic refrigerants such as Hydrochlorofluorocarbons and Chlo-

rofluorocarbons have been criticized for their adverse impact on the Earths protective
ozone layer and for their significant global warming potential (GWP). CO2 has
been receiving great concern as an alternative refrigerant. Cascade refrigeration sys-
tems employing CO2 are used for low temperature applications. Being a low critical
temperature fluid CO2 transcritical cascade systems offer low COP for a given
application. Parallel compression economization is one of the promising cycle mod-
ifications to improve the COP of transcritical CO2 cascaded systems. In this paper,
transcritical CO2 /propylene cascade system with parallel compression economization
in the HT cycle has been analysed for cooling/heating applications. An enhancement
in COP of 9% has been predicted. Thermodynamic analysis on R744-R1270 cascade
refrigeration system has been performed to determine the optimal value of the vari-
ous design parameters of the system. The design parameters included are: gas cooler
outlet temperature and intermediate temperature in the high temperature circuit and
evaporator temperature and temperature difference in the cascade condenser in the
low temperature circuit.

Keywords. Propylene/CO2 ; transcritical; cascade refrigeration system; parallel

compression economization.

1. Introduction

Low temperature multi-stage vapor compression refrigeration systems are not suitable for
numerous engineering applications such as cryogenic separation in petrochemical industries,

For correspondence

437
438 Alok Manas Dubey et al

liquefaction of petroleum vapors and natural gas, manufacturing of dry ice, precipitation hard-
ening of special alloy steel and storage of food, blood, etc. This is due to exceedingly large
specific volumes, low solidification temperature, low operating pressure of the refrigerants and
problems faced during operation of compressors. These difficulties can be surmounted by using
a cascade refrigeration system. The cascade refrigeration cycle has two V-C cycles connected in
series. The lower cycle cools the refrigerated space and the upper cycle cools the lower cycle.
This is accomplished with a cascade heat exchanger. This heat exchanger acts like a condenser
for the lower cycle and like an evaporator for the upper cycle. Many engineering applications
require cooling and heating at the same time which cannot be achieved simultaneously and effi-
ciently by a single stage or multistage vapor compression system as a single refrigerant may not
provide the required temperature lift. A cascade system is the most excellent option for these
applications. A layout of the trancritical cascade system is shown in figure 1. Figures 2 and 3,
show the thermodynamic processes for CO2 -propylene transcritical cascade system on P-h and
T-s diagrams. It can be seen from the T-s diagram in figure 3 that the compressor work decreases
and the amount of heat absorbed from the refrigerated space increases as a result of cascading.
For this reason, the coefficients of performance (COP) values of cascade systems are higher than
those of the ideal vapor compression system, as in the literature. It should be noted however

Figure 1. Equipment layout of a transcritical cascade system with economizer.

 Transcritical CO2 cascaded system with economizer 439

2x10 4 2x104
Carbon dioxide
10 4 3 8 9 2 Propylene 10 4
5
7
4 1
Pressure [kPa] 6

10 3 11 10 3
13
12

10 2 14
15 10 10 2

5x101 5x101
110 220 330 440 550
Enthalpy [kJ/kg]

Figure 2. Thermodynamic cycle on P-h plane.

that the initial cost of the cascade system is about double, when compared to a simple vapor
compression system.
Use of hydrocarbons such as propylene, propane, butane, isobutane, ethane as refrigerant
in subcritical cascade high temperature, HT, circuit may be a serious concern due to its high
flammability at a temperature of about 60 C. Because as per the ASHRAE Standard 34 safety

150 150
Carbon dioxide
Propylene
11
100 100

2
Temperature[C]

9
8
50 3
50

5 7
12 4

6 10
0 1 0

13

-50 14 15 -50

0.0 0.5 1.0 1.5 2.0

Entropy[kJ/kg-K]

Figure 3. Thermodynamic cycle on T-s plane.

440 Alok Manas Dubey et al

rating of all the above hydrocarbons is A3, which shows higher flammability if LFL or ETFL60
100 g/m3 or heat of combustion (HOC) 19 MJ/kg at 60 C. The use of propylene as a refriger-
ant in the low temperature, LT circuit of the transcritical cascade system will prevent the ignition
due to lower operating temperature. Use of CO2 in the LT circuit of subcritical cycle limits the
evaporator temperature to the triple point of CO2 (i.e. 56.6 C). The applications requiring cool-
ing temperature below 56.6 C are not possible with the subcritical cascade system. This issue
can also be resolved by using transcritical system with CO2 in HT circuit and propylene (triple
point temperature of 185.2 C) in LT circuit. Propylene has excellent thermodynamic proper-
ties, quite similar to those of ammonia. The molar mass of 42 is ideal for turbo compressors
and is only about one third of its halocarbon competitors. Propylene is cheaply and universally
available. Physical properties of some of the refrigerants are presented in table 1.
The following lines are quoted from Rivera et al (2011) to justify the use of CO2 instead of
ammonia or hydrocarbons in the HT cycle for heating applications. As can be deduced from the
literature review, CO2 in the low cycle and NH3 in the high cycle have been successfully used
in cascade systems for cooling where temperatures as low as 323 K are required. However,
as shown by Dopazo et al (2009) for specific conditions, the COP decreases to about 50% with
the increment of the condenser temperature (from 298 to 323 K). Following that tendency, it
is clear that the COP can be reduced even more at higher condenser temperatures. Another
disadvantage of using ammonia in the high cycle for heating (high condenser temperatures) is
the high operating pressure (e.g., P = 26.1 bar at 333 K). On the other hand, flammability is an
important aspect to consider if hydrocarbons are used in cascade systems. Safety assessments
and appropriate operation range are always recommended. This particular disadvantage can be
controlled if the hydrocarbons are applied in the LT cycle of a cascade cycle.
The conventional fluid pairs used in subcritical cascade systems, employing CO2 in the LT
side and ammonia, propylene, propane, ethanol and butane in the HT side are not suitable for
high temperature heating applications. In the transcritical cascade cycle, gas cooler (HT heat

Table 1. Physical properties of refrigerants (http://en.wikipedia.org/wiki/Refrigerant).

Carbon dioxide Ammonia Propane Propylene

(R-744) (R-717) (R-290) (R-1270)
Environmental classification HC HO
Molecular weight 44 17 44 42
Normal boiling point ( C) 78.4 33.3 42.1 47.7
Critical pressure (bars) 73.72 112.97 42.56 46
Critical temperature ( C) 31.1 133 96.8 94.4
Triple point ( C) 56.6 77.66 187.67 185.2
Liquid density (kg/m3 ) 770 681.9 613.9
Critical density (kg/m3 ) 467.6 225 218.5 223.39
Vapor density (kg/m3 ) 1.977 0.73 2.01 1.81
Heat of vaporization (kJ/mol) 15.326 23.35 15.7 10.427
Specific heat liquid J/(mol K) 80.8 98.36
Specific heat vapour J/(mol K) 36.33 35.06 73.6 62
Ozone depletion potential (ODP) 0 0 0 0
Global warming potential (GWP) 1 0 3 >0 (smog)
ASHRAE Std 34 safety rating A1 B2L A3 A3

(Refrigerant Reference Guide, Fourth Edition, National Refrigerants, Inc.).

 Transcritical CO2 cascaded system with economizer 441

exchanger) pressure and temperature are independent of each other unlike the subcritical two-
phase region. The high CO2 vapor pressure in the gas cooler leads not only to a lower pressure
ratio in compressor but also improves compressor efficiency, along with high heat-transfer coef-
ficients and lower relative pressure losses. This also results in higher gas cooler temperatures
with reasonable compressor power consumption. Therefore, the application of CO2 in transcrit-
ical heat pumps for water heating up to 90 C can be an excellent option. Despite lower COP of
the CO2 transcritical system, it may still compete with other vapor compression systems (sin-
gle stage, multistage and sub critical cascade) using other refrigerants. Sarkar et al (2004) have
proposed NH3 CO2 cascade system with CO2 in the HT side for simultaneous cooling and heat-
ing applications. In 2000, a new refrigeration technology to build cascade systems with carbon
dioxide and propane as refrigerants was implemented in a small supermarket in Denmark. In the
present work, carbon dioxide-propylene cascade system with CO2 in the HT side and C3 H6 in
the LT side has been studied. This system can offer a much larger temperature lift.
A suitable selection of refrigerants in HT and LT cycles of the transcritical cascade system
can provide a large temperature lift with better system efficiency. The low temperature circuit of
a transcritical cascade refrigerant system can normally be charged with N2 O, propane (R290),
butane (R600), R134a, ammonia, carbon dioxide and propylene (R1270) for cooling whereas,
carbon dioxide (R744) is used in the high temperature circuit for heating applications. A compar-
ison of cascade system COP using subcritical or transcritical cycle with different combinations
of refrigerants under different operating conditions as reported by the researchers in the literature
with the transcritical cascade system using CO2 -propylene is presented in table 2. It is observed
that COPmax in transcritical cycle with CO2 -propylene operating under the same conditions is
higher than other cascade cycles due to the superior fluid properties. Even if the heating effect is
not considered, the cooling COP is higher compared to the refrigeration systems mentioned in
the literature.

Table 2. Comparison of COPsys using CO2 -propylene with COP of other cascade systems.

References Present study

Cooling
Cascade TC TE T Topt Topt
References system Refrigerants ( C) ( C) ( C) ( C) COPmax ( C) COPmax
Dopazo et al (2009) Subcritical CO2 /NH3 29.72 50 3.48 20.96 0.92 9.551 1.473
Lee et al (2006) Subcritical CO2 /NH3 30 50 3 20 1.21 9.082 1.473
Getu & Bansal (2008) Subcritical CO2 /NH3 40 50 5 18 1.4 1.327 1.096
Bingming et al (2009) Subcritical CO2 /NH3 40 50 5 23 1.41 1.327 1.096
Kruse & Russmann (2006) Transcritical CO2 / N2 O 35 50 25 5 0.8 7.673 2.009
Kruse & Russmann (2006) Transcritical N2 O / N2 O 35 50 25 5 0.95 7.673 2.009
Cogeneration
Bhattacharya et al (2005) Transcritical CO2 / Propane 45 40 5 5 3.31 2.143 3.245
Bhattacharya et al (2009) Transcritical CO2 / N2 O 45 70 5 12 2 7.755 2.442
Yari & Mahmoudi (2011) Transcritical CO2 / CO2 45 25 5 0.0248 1.484 5.714 1.402
Rivera et al (2011) Transcritical CO2 /R717, 35 32 5 5 3.94 22.27 4.364
R290, R600 ,
R134a

*cooling COPmax
**Cascade system using butane (R600) gives maximum COP
442 Alok Manas Dubey et al

The main drawback of carbon dioxide as a refrigerant is its inherent high working pres-
sure, which is much higher than that of other natural and synthetic refrigerants. Since carbon
dioxide offers a much higher volumetric capacity, the problem of higher working pressure can
be overcome by using optimal design involving compact and stronger components.
Dopazo et al (2009) performed a theoretical analysis of a CO2 /NH3 cascade refrigeration
system for cooling applications at low temperatures. Lee et al (2006) performed a thermody-
namic analysis of optimal condensing temperature of cascade-condenser in CO2 /NH3 subcritical
cascade refrigeration systems. Getu & Bansal (2008) have analysed carbon dioxide-ammonia
subcritical cascade system thermodynamically to find out the optimum condensing temperature
of CO2 using different refrigerants such as NH3 , propane, propylene and ethanol in the high
temperature circuits. Bingming et al (2009) designed and developed an experimental CO2 /NH3
subcritical cascade refrigeration system using screw compressor. Ma et al (2005) measured the
performance of a subcritical cascade CO2 NH3 cycle using an expander as a replacement for
the expansion valve. Dopazo & Seara (2011) experimentally investigated a subcritical cascade
refrigeration system with CO2 /NH3 . Yu et al (2014) presented a CO2 /NH3 cascade refrigeration
system, in which a falling film evaporatorcondenser was used as the cascade heat exchanger.
The thermodynamic analysis results of the proposed system show an improvement in the coef-
ficient of performance (COP) due to the smaller temperature difference provided by this type of
cascade heat exchanger.
Kruse & Russmann (2006) performed a thermodynamic analysis of cascade refrigerating sys-
tems using N2 O as refrigerant for LT stage and compared it with an R23R134a LTHT cycle,
and concluded that the transcritical carbon dioxide HT cycle with nitrous oxide LT cycle cascade
system had a lower COP. A carbon dioxide-propane transcritical cascade system was analysed
by Bhattacharyya et al (2005), to determine an optimum cascade evaporating temperature of
CO2 in the high temperature circuit for simultaneous heating and cooling applications. Another
transcritical cascade system was investigated by Bhattacharyya et al (2009) using N2 O for the
low temperature cascaded stage and carbon dioxide for the high temperature stage, to determine
an optimum cascade evaporating temperature of CO2 in the HT circuit for cooling applications.
Yari & Mahmoudi (2011) presented two new and high performance configurations for ejector-
expansion TRCC cascade cycles and their performances were discussed theoretically based on
first and second laws of thermodynamics.
Subcritical cascade cycle is useful for cooling applications only because HT condenser tem-
perature ranges between 30 C and 40 C, which is unsuitable for heating purposes. Thus,
subcritical cycle has lower COP and temperature lift, hence lower energy efficiency.
Wang et al (2013b) conducted an experimental research on a prototype air-source transcrit-
ical CO2 heat pump water heater, in a range of ambient temperatures (15 to 35 C) and water
outlet temperatures (55 to 80 C) and illustrated the effect of water outlet temperatures, ambient
temperatures and evaporating temperatures on the optimal discharge pressure and system COP.
Cecchinato & Corradi (2011) developed an R744 commercial single door bottle cooler that was
cost affective and matched with the performance of typical cost optimized R404A and R134a
systems. Zhang et al (2010) conducted experimental and simulation researches to investigate
the relationships between optimum heat rejection pressure and other related operating parame-
ters for a transcritical CO2 heat pump system with two throttle valves. Wang et al (2013a)
investigated the effect of geometrical parameters of gas coolers on system performance and
the optimal discharge pressure with a developed and experimentally validated numerical model
of an air-source transcritical CO2 heat pump water heater system. Gu & Chen (2005) per-
formed a detailed analysis on the relationship between the optimum high pressure and other
 Transcritical CO2 cascaded system with economizer 443

systematic parameters for a CO2 transcritical refrigeration system with internal heat exchang-
ers. Sarkar (2009) designed and developed a working prototype of a transcritical CO2 heat pump
system for simultaneous cooling and heating of water based on numerical simulation studies.
Carolina (2012) designed and built a transcritical CO2 heat pump system that combined a water-to-
water CO2 heat pump with both hot and cold thermal storages known as Thermal Battery (TB).
Different researchers adopted various techniques to enhance the performance of simple tran-
scritical CO2 cycle. Kim & Kim (2002) carried out simulation and experimental studies on the
performance of an autocascade refrigeration system using carbon dioxide as a refrigerant. Cho
et al (2005) studied the effect of refrigerant charge amount on the performance of a transcriti-
cal CO2 heat pump and compared it with that of other refrigerant systems. Li & Groll (2005)
predicted that the COP of a transcritical CO2 refrigeration cycle could be enhanced by 16% by
means of an ejector expansion device. Baek et al (2005) investigated the performance impro-
vement of a transcritical CO2 cycle by using pistoncylinder work producing expansion device.
Groll et al (2002) studied the effect of pressure ratios across compressors on the performance
of the transcritical CO2 cycle with two-stage compression and intercooling. Robinson & Groll
(1998) evaluated and compared the efficiencies of transcritical CO2 cycles with and without an
expansion turbine. Kim et al (2004) presented various methods for performance enhancement in
a transcritical CO2 cycle and its applications.
A fluid such as CO2 with a lower critical temperature of 31.1 C will tend to have a higher
volumetric capacity and a lower COP in the high temperature cycle of the transcritical cascade
system due to high levels of irreversibility involved. Parallel compression offers the possibil-
ity to increase cooling capacities and efficiencies of medium temperature systems during peak
load operation and high ambient temperatures. Parallel compression economization is one of
the promising cycle modifications where refrigerant vapor is compressed to a super critical dis-
charge pressure in two separate non-mixing streams, one coming from the economizer and the
other coming from the cascade heat exchanger to improve the performance of the transcritical
CO2 refrigeration cycle. Use of parallel compression reduces gas cooler outlet temperature and
discharge pressure along with the amount of flash gas inside the receiver. This leads to a lower
medium pressure in the system resulting in higher enthalpy differences in evaporator side and
increased refrigeration capacities. Increased cooling demand can be catered with the use of this
technique through capacity regulation. Consequently, parallel compression is redundant with
lower ambient conditions.
Very few attempts have been made to improve the performance of the transcritical cascade
system. In this present paper, an attempt has been made to carry out the thermodynamic anal-
ysis of propylenecarbon dioxide transcritical cascade system employing parallel compression
economization in the HT circuit in order to improve the system performance.

2. System description

A schematic diagram of the transcritical cascade system is shown in figure 1. The cascade refrig-
eration system is constituted by two single stage systems connected by a cascade heat exchanger,
where propylene is used in LT cycle for cooling and CO2 is used in HT cycle to condense propy-
lene. The waste heat of HT cycle can be used for heating purposes in order to improve the system
performance. Propylene evaporator absorbs the heat QL from the cooling space at tempera-
ture TE . Propylene is then compressed in propylene compressor and condensed in the cascade
heat exchanger at temperature T12 before it enters into the evaporator after passing through the
expansion valve in order to complete the cycle.
444 Alok Manas Dubey et al

In the HT circuit heat QH is removed from CO2 gas cooler at gliding temperature varying from
T9 to Tc by an external cooling medium. The liquid and vapour are separated in the economizer
after the expansion of transcritical fluid from states 3 to 4 in primary expansion valve. The liquid
from the separator is further expanded in another expansion valve to provide cooling effect in the
cascade heat exchanger. The saturated vapor from the evaporator and economizer is compressed
in the compressor simultaneously to state 2 and 8 respectively. The mixed stream of state 9 enters
the gas cooler for heat rejection. Figures 2 and 3 show the thermodynamic processes for CO2 -
propylene transcritical cascade system on P-h and T-s diagrams along with their saturation lines.

3. Thermodynamic modelling

The cycle is modelled detailing each individual process of the cycle. Steady flow energy equa-
tion and mass balance equation has been employed. A parametric study at various gas cooler exit
temperatures (32 C, 35 C, 38 C, 41 C and 44 C), evaporating temperatures (35 C, 40 C,
45 C, 50 C and 55 C) and for various temperature differences (3 C, 4 C, 5 C, 6 C, and
7 C) across the cascade heat exchanger is conducted to determine the optimum condensing tem-
perature of a cascade heat exchanger in CO2 -propylene cascade refrigeration system. An opti-
mum temperature of 20 C was selected at the economizer inlet as it resulted in maximum COP.
The thermodynamic analysis of the two-stage cascade refrigeration system was performed
based on the following general assumptions.
(i) Adiabatic and irreversible compression with an isentropic efficiency of 0.8 for both high
and low temperature compressors.
(ii) Refrigerants at the cascade heat exchanger and economizer outlet for HT cycle and
evaporator for LT cycle outlet are saturated.
(iii) All the heat released by the low-temperature circuit condenser is rejected to the high-
temperature circuit evaporator.
(iv) Negligible pressure and heat losses in the pipe networks or system components.
(v) Heat transfer processes in cascade heat exchanger, evaporator, economizer and gas cooler
are isobaric.
(vi) Heat transfer in cascade heat exchanger, evaporator, economizer and gas cooler with the
ambient is negligible.
Compressor power consumption for HT cycle can be formulated as

WHT = mb (h2 h1 ) + ma (h8 h7 ) . (1)

Mass balance in the mixer is:

mc = mb + ma . (2)
Energy balance in the mixer is:
mc h9 = ma h8 + mb h2 . (3)
The rate of heat transfer from the HT gas cooler is expressed as:

QH = mc (h9 h3 ) . (4)

Mass balance in the economizer is:

mc = mb + ma . (5)
 Transcritical CO2 cascaded system with economizer 445

Energy balance in the economizer is given as:

mc h4 = ma h7 + mb h5 . (6)

The mass flow ratio can be derived from energy balance at the cascade condenser:

mb (h1 h6 ) = mp (h11 h12 ) . (7)

The isentropic efficiency of the HT CO2 compressor can be represented as:

(h2s h1 )
c = . (8)
(h2 h1 )
The isentropic efficiency of the LT CO2 compressor can be represented as:
(h8s h7 )
c = . (9)
(h8 h7 )
Compressor power consumption for LT cycle can be formulated as:

WLT = mp (h1 h10 ) . (10)

The rate of heat absorbed by the LT evaporator is defined by:

QL = mc (h15 h14 ) . (11)

Energy balance in the LT internal heat exchanger can be formulated as:

(h10 h15 ) = (h12 h13 ) . (12)

The isentropic efficiency of the LT compressor can be formulated as:

(h11s h10 )
c = . (13)
(h11 h10 )
The expression for effectiveness of the LT internal heat exchanger is represented by:
(T10 T15 )
= . (14)
(T12 T15 )
The COP of heating and that of cooling can be defined as:

QL Qh
COPLTcooling = ; COPHTheating = . (15)
WLT WHT
Equation for the overall COP of the system is expressed as

QL + QH
COPsys = . (16)
WLT + WHT
446 Alok Manas Dubey et al

4. Results

Engineering equation solver version 6.883 has been used for performing calculations, plotting
graphs and regression analysis. COPmax is the maximum coefficient of performance of the sys-
tem at intermediate temperature for given TC , TE and T and that intermediate temperature
is called Topt (for maximum COP). The parameters that have been assumed constant for the
computation of results are mentioned below.

a) Low temperature cycle condensing temperature, T5 = 7 C.

b) Low temperature cycle evaporating temperature, TE = 45 C.
c) Effectiveness of cascade heat exchanger, evaporator and condenser = 1.
d) The economizer inlet temperature, T4 = 20 C.
e) High temperature cycle gas cooler outlet temperature, TC = 45 C.
f) Temperature difference in cascade condenser, T = 3 C.

The parameters which have been varied for the the calculation of results are given below.

a) The cascade condenser temperature difference T = 0 to 20 C.

b) The low temperature cycle condenser temperature is varied from T5 = 3 to 15 C.
c) The economizer inlet temperature is varied from T4 = 0 to 30 C.
d) The low temperature cycle evaporator temperature is varied from TE = 55 C to 25 C.
e) The high temperature cycle gas cooler outlet temperature is varied from TC = 30 C to 45 C.
f) The effectiveness of the LT internal heat exchanger is varied from = 0.5 to 1.
g) Mass flow rate of refrigerant for HT cycle is assumed as 1 kg/sec.

Figure 4 shows the effect of the condensing temperature Tc on COPsys , COPHT and COPLT .
The figure shows that increasing Tc reduces COPsys and COPHT while COPLT remains con-
stant. Rise in condenser temperature increases compressor work of HT circuit due to increase in

7 3
COPsys TE=-450C
0
COPHT DT=3 C
0
T6=7 C
6 COP LT
2.7
COPsys, COPHT

COPLT

5
2.4

2.1
3
30 34 38 42 46
Gas cooler outlet temperature [0C]

Figure 4. Influence of TC on COP of system.

 Transcritical CO2 cascaded system with economizer 447

pressure ratio across HT circuit and hence total work done by system increases while COP
decreases. Theoretically there is no effect of Tc on refrigerating effect of system. Figure 5 rep-
resents the effect of the evaporating temperature TE on COPsys , COPHT and COPLT . The figure
shows that increasing TE increases COPsys and COPLT while COPHT remains constant. There
is a decrease in pressure ratio across low temperature circuit with and increase in evaporator
temperature. This results in reduced total compressor work by system and increased system
refrigerating effect.
Figure 6 shows the effect of gas cooler outlet temperature Tc on COPmax and Topt . The opti-
mal intermediate condensing temperature Topt ensures the maximum system COP under the
given conditions. In the case of the maximum system COP, the overall system configuration
is dependent on the relation between the mass flow rate in HTC and mass flow rate in LTC.
The figure shows that increasing Tc decreases both COPmax and Topt. figure 7 shows the effect
of the intermediate temperature T6 on COPsys , COPHT and COPLT . As T6 rises, temperature
lift for the LT propylene cycle increases whereas that for the HT carbon dioxide cycle lowers
leading to reduction in COPLT and improvement in COPHT . These two opposing phenomena
cause a marginal initial increase and then a reduction in COPsys with an optimum value of COP.
Figure 8 represents the effect LT internal heat exchanger effectiveness on COPsys . Increase in
IHX effectiveness () causes more efficient heat exchange between the cold and hot fluid lead-
ing to reduction in both refrigeration capacity and LT compressor power input resulting in a
marginal increase in COPsys and COPLT while COPHT remains constant.
Figure 9 represents the effect of temperature differences in the cascade condenser T on
COPsys , COPHT and COPLT . Increasing T reduces COPsys and COPLT while COPHT remains
constant. This is intuitive as increase in temperature difference causes heat transfer to occur
through finite temperature difference resulting in external irreversibility in the system thereby
decreasing the system performance. Theoretically, there is no effect of T on refrigerating effect
of system but work of compressor increases with increase in T. The figure 10 shows that with

6
COPLT TC= 350C
COPsys COPHT
T=30C
T6=70C
5
COPsys, COPHT, COPLT

2
-60 -50 -40 -30
Evaporatoring temperature [0C]
Figure 5. Influence of TE on COP of system.
448 Alok Manas Dubey et al

5
COPmax TE= -350C
Topt
T=30C
9

Intermediate opt temp [C]

COPmax 4.5

3.5

33 36 39 42 45
0
Gas cooler outlet temperature [ C]
Figure 6. Influence of TC on COPmax and Topt .

increasing T4 , COPsys first increase attains an optimum value (at 20 C) and then decreases.
The changes in the mass flow ratio of R1270 to that of R744 (see figure 11) were investigated
at identical temperatures. The mass flow ratio of R1270 to that of R744 mass ratio decreased

7 3.8
COPsys
COPHT
6 COPLT
TE= -450C 3.78
TC= 350C
COPHT, COPLT

5 T=30C
COPsys

4 3.76

3
3.74

2
-8 0 8 16
Intermediate temperature [C]
Figure 7. Influence of T5 on COP of system.
Transcritical CO2 cascaded system with economizer 449

TE=-450C
TC=350C
T=30C
3.8
T6=70C
COPsys

3.79
0.5 0.6 0.7 0.8 0.9 1
Internal HEX effectiveness
Figure 8. Variation of system COP with .

6
COPsys COPHT COPLT

5 TE= -450C
COPsys, COPHT, COPLT

TC= 350C
4 T6=70C

1
0 4 8 12 16 20
Overlap Temperature [0C]
Figure 9. Variation of system COP with T.
450 Alok Manas Dubey et al

3.85
TE=-450C
TC=350C
3.76
T=30C
T6=70C

3.67
COPsys

3.58

3.49

3.4
0 5 10 15 20 25 30
Economizer inlet temperature [C]
Figure 10. Influence of T4 on COP of system.

0.23

T=30C
0.22
T6=70C
TE=-450C
0.21
Mass flow ratio

0.2

0.19

0.18

31 33 35 37 39 41 43 45
Gas cooler outlet temperature [0C]
Figure 11. Influence of TC on Mass flow ratio.
 Transcritical CO2 cascaded system with economizer 451

with a rise in condensing temperature, cascade evaporating temperature (T5 ) and temperature
difference in cascade condenser (T) of the system. However, it increased with an increase in
evaporating temperature of R1270 (TE ).
If propylene is replaced by propane in the above transcritical cascade system the COPsys is
3.262. This value of COP is in agreement with the value calculated by Bhattacharyya et al
(2009). A slightly higher value (3.31) of COPsys was a result of the use of a better optimization
technique. The values of other parameters and the trends obtained in the graphs are almost the
same. This fact validates the present model.

5. Optimization

Analysis has been carried out to study the effects of TC , TE , and T on COP and performance
parameters of carbon dioxidepropylene cascade system. In the analysis, five evaporator tem-
peratures (TE = 35 C, 40 C, 45 C, 50 C and 55 C), five gas cooler exit temperatures
(32 to 44 C at an interval of 3 each) and five cascade heat exchanger temperatures (T = 3 C,
4 C, 5 C, 6 C, 7 C) were considered and total 125 data points were obtained. The results of
analysis for T of 3 C are presented in table 3.These input data are used to develop mathemat-
ical equations for optimum performance parameters with multi linear regression method inbuilt
in engineering equation solver (EES commercial version 6.883).
Performance parameters of cascade transcritical system, optimum evaporating temperature of
the HT CO2 circuit (Topt ), the optimum mass flow ratio of R1270 to that of R744 ((mL /mH )opt )
and the maximum coefficient of performance (COPmax ) were regressed as a function of input
operating parameters such as evaporating temperature (TE ), gas cooler outlet temperature (Tc )
and temperature differences in cascade heat exchanger (T). Regression equations for optimum
cascade evaporating temperatures, maximum COP and the optimum mass flow ratio mL /mH opt
for R744-R1270 combination are presented as follows.

Topt = ao + a1 Tc + a2 TE + a3 T (17)

COPmax = ao + a1 Tc + a2 TE + a3 T (18)
 
mL
= ao + a1 Tc + a2 TE + a3 T. (19)
mH opt

Table 3. COP under various design parameters (T = 3 ).

Data
Point No. 1 2 3 4 5 1 2 3 4 5 1 2 3
TE ( C) 55 55 55 55 55 50 50 50 50 50 45 45 45
TC ( C) 32 35 38 41 44 32 35 38 41 44 32 35 38
Topt ( C) 3.878 1.02 1.837 3.878 5.102 5.102 2.245 1.429 1.837 3.469 6.327 3.878 1.837
COP 3.546 3.354 3.182 3.028 2.889 3.787 3.565 3.369 3.193 3.036 4.055 3.798 3.572
mL /mH 0.1972 0.1923 0.1863 0.2258 0.2129 0.2041 0.1964 0.1899 0.2286 0.2166 0.2085 0.2013 0.1956

Data
Point No. 4 5 1 2 3 4 5 1 2 3 4 5
TE ( C) 45 45 40 40 40 40 40 35 35 35 35 35
Tc ( C) 41 44 32 35 38 41 44 32 35 38 41 44
Topt ( C) 0.6122 -0.612 9.184 6.327 3.878 2.245 0.3061 10.1 8.061 6.02 3.571 1.531
COP 3.373 3.195 4.357 4.057 3.796 3.568 3.366 4.696 4.345 4.043 3.781 3.551
mL /mH 0.2349 0.2213 0.2125 0.2066 0.2009 0.1972 0.1923 0.1863 0.2258 0.2129 0.2041 0.1964
452 Alok Manas Dubey et al

Table 4. Statistical information for Eqs. (17)(19).

Linear regression Linear regression coefficients for Linear regression

coefficients for Topt (mL /mH )opt coefficients for COPmax
Standard Standard Standard
Value error Value error Value error
a0 43.60742 0.9004335 0.3584827 0.002377847 8.293449 0.06815297
a1 0.6778426 0.01843947 0.002787539 0.00004869458 0.06983775 0.001395666
a2 0.3321077 0.01106368 0.001018498 0.00002921675 0.04255282 0.0008373998
a3 0.1336481 0.05531841 0.0004375918 0.0001460838 0.03546358 0.004186999
Number of points (n)=125 Number of points (n)=125 Number of points (n)=125
rms = 0.86734 rms = 0.0022905 rms = 0.065648
R2 = 94.95% R2 = 97.4% R2 = 97.73%

The linear regression coefficients a0 , a1 , a2 and a3 along with other statistical indicators such as
standard error, root mean square error and correlation coefficient (R2 ) are given in table 4.
It is important to mention that the compressor discharge pressure P2 (in kPa) has been
optimized to yield maximum COP as given by Sarkar & Agrawal (2010):

P2opt = 3687.7 + 38.23Tc 0.004 T6 + 2.7667 T2c . (20)

6. Conclusions

Thermodynamic analysis of a CO2 propylene based transcritical cascade system has been car-
ried out in the present study using Engineering equation solver commercial version 6.883. In
this study, variation of three important design parameters i.e., gas cooler outlet temperature
TC , evaporating temperature TE and overlap temperature in cascade heat exchanger are consid-
ered in order to determine system COP, optimum temperature in cascade heat exchanger and
optimum mass flow ratio of LT and HT cycles. The following inferences are drawn from the
study.

(i) An improvement in COP of 9% has been estimated by the use of economizer.

(ii) When the intermediate temperature is higher, it is difficult to get the desired evaporator
temperature TE . The results of the analysis suggest keeping the intermediate temperature
lower for getting optimum performance of the system. This is done by decreasing gas
cooler outlet temperature.
(iii) The overall increase in system COP due to a more effective internal heat exchanger is
marginal, hence the use of internal heat exchanger is not recommended.
(iv) The optimum discharge pressure is lowered significantly by the use of economizer in the
HT cycle. There is a considerable effect of the gas cooler exit temperature on optimum
discharge pressure.
(v) COP of the system improves considerably by the use of economizer at lower evaporator
temperature.
(vi) The maximum COP increases with increase in TE , but decreases as Tc or T increases.
(vii) Regression equations have been developed for Topt , COPmax and optimum mass flow ratio
to help thermal engineers to design an optimized transcritical cascade system.
 Transcritical CO2 cascaded system with economizer 453

Nomenclature

h specific enthalpy (kJ kg1 ) Q heat transfer rate (kW)

mH mass flow rate of CO2 (kg s1 ) COP coefficient of performance

WHT HT compressor power (kW) mL mass flow rate of propylene (kg s1 )
T temperature (K) WLT LT compressor power (kW)
effectiveness of internal heat exchanger c compressor isentropic efficiency
IT Intermediate temperature s entropy
1-6 points of refrigerant (HT side) 7-15 points of refrigerant (LT side)
C Carbon dioxide T overlap temperature
P pressure H Heating
L cooling LT low temperature cycle
HT high temperature cycle max Maximum
opt optimum prop Propylene

References

Baek J S, Groll E A and Lawless P B 2005 Pistoncylinder work producing expansion device in a carbon
dioxide cycle. Part II: Theoretical investigation. Int. J. Refrig. 28: 15264
Bhattacharyya S, Garai A and Sarkar J 2009 Thermodynamic analysis and optimization of a novel N2 O
CO2 cascade system for refrigeration and heating. Int. J. Refrig. 32: 107784
Bhattacharyya S, Mukhopadhyay S, Kumar A, Khurana R K and Sarkar J 2005 Optimization of a CO2
C3 H8 cascade system for refrigeration and heating. Int. J. Refrig. 28: 128492
Bingming W, Huagen W, Jianfeng L and Ziwen X 2009 Experimental investigation on the performance of
NH3 /CO2 cascade refrigeration system with twin-screw compressor. Int. J. Refrig. 32(135865)
Carolina C 2012 Energy Optimization for Transcritical CO2 Heat Pumps for Combined Heating and Cool-
ing and Thermal Storage Applications, International Refrigeration and Air Conditioning Conference,
Paper 1168, Purdue, USA
Cecchinato L and Corradi M 2011 Transcritical carbon dioxide small commercial cooling applications
analysis. Int. J. Refrigeration 34(1): 5062
Cho H, Ryu C, Kim Y and Kim H Y 2005 Effects of refrigerant charge amount on the performance of a
transcritical CO2 heat pump. Int. J. Refrig. 28: 126673
Dopazo J A and Seara J F 2011 Experimental evaluation of a cascade refrigeration system prototype with
CO2 and NH3 for freezing process applications. Int. J. Refrig. 34: 257267
Dopazo J A, Seara J F, Sieres J and Uha F J 2009 Theoretical analysis of a CO2 NH3 cascade refrigeration
system for cooling applications at low temperatures. Appl. Therm. Eng. 29: 157783
Getu H M and Bansal P K 2008 Thermodynamic analysis of an R744R717 cascade refrigeration system.
Int. J. Refrig. 31: 4554
Groll E A, Baek J S and Lawless P B 2002 Effect of pressure ratios across compressors on the performance
of the transcritical CO2 cycle with two-stage compression and intercooling. Proceedings of compressor
engineering conference, Purdue, USA, 117
Gu J and Chen Y 2005 The optimum high pressure for CO2 transcritical refrigeration systems with internal
heat exchangers. Int. J. Refrigeration 28: 12381249
Kim M, Pettersen J and Bullard C W 2004 Fundamental process and system design issues in CO2 vapor
compression systems. Prog. Energy Combust. Sci. 30: 11974
Kim S G and Kim M S 2002 Experiment and simulation on the performance of an autocascade refrigeration
system using carbon dioxide as a refrigerant. Int. J. Refrig. 25: 1093101
Kruse H and Russmann H 2006 The natural fluid nitrous oxide an option as substitute for low temperature
synthetic refrigerants. Int. J. Refrig. 29(5): 799806
454 Alok Manas Dubey et al

Lee T S, Liu C H and Chen T W 2006 Thermodynamic analysis of optimal condensing temperature of
cascade-condenser in CO2 /NH3 cascade refrigeration systems. Int. J. Refrig. 29: 11001108
Li D and Groll E A 2005 Transcritical CO2 refrigeration cycle with ejector-expansion device. Int. J. Refrig.
28: 76673
Ma Y T, Ning J H, Chen Q and Ma L R 2005 Study on replacement and energy-saving of natural refrigerant
CO2 /NH3 cascade refrigeration cycle. Proceedings of the International Conference on Compressor and
Refrigeration, Dalian, China
Refrigerant Reference Guide, Fourth Edition, National Refrigerants, Inc.
Rivera W, Colorado D and Hernndez J A 2011 Comparative study of a cascade cycle for simultaneous
refrigeration and heating operating with ammonia, R134a, butane, propane, and CO2 as working fluids.
Int. J. Sustainable Energy 31(6): 365381
Robinson D M and Groll E A 1998 Efficiencies of transcritical CO2 cycles with and without an expansion
turbine. Int. J. Refrig. 21(7): 57789
Sarkar J, Bhattacharyya S and Ramgopal M 2004 Carbon dioxide based cascade systems for simultaneous
refrigeration and heating applications. Proceedings of 6th IIR-Gustav Lorentzen natural working fluid
conference, Galsgow 2004
Sarkar J and Agrawal N 2010 Performance optimization of transcritical CO2 cycle with parallel compres-
sion economization. Int. J. Thermal Sci. 49: 838843
Sarkar J 2009 A transcritical CO2 heat pump for simultaneous water cooling and heating: Test results and
model validation. Int. J. Energy Research 33(1): 100109
Wang S, He Y, Tuo H, Cao F and Xing Z 2013a Effect of heat transfer area and refrigerant mass flux
in a gas cooler on heating performance of air-source transcritical CO2 heat pump water heater system.
Energy and Buildings 67: 110
Wang S, Tuo H, Cao F and Xing Z 2013b Experimental investigation on air-source transcritical CO2 heat
pump water heater system at a fixed water inlet temperature. Int. J. Refrigeration 36(3): 701716
Yari M and Mahmoudi S M S 2011 Thermodynamic analysis and optimization of novel ejector-expansion
TRCC (transcritical CO2 ) cascade refrigeration cycles (Novel transcritical CO2 cycle). Energy 36(12):
68396850
Yu J, Ma M, Yu J and Wang X 2014 Performance evaluation and optimal configuration analysis of a
CO2 /NH3 cascade refrigeration system with falling film evaporatorcondenser. Energy Conversion and
Management 79: 224231
Zhang X P, Fan X W, Wang F K and Shen H G 2010 Theoretical and experimental studies on optimum
heat rejection pressure for a CO2 heat pump system. Appl. Thermal Eng. 30(16): 25372544