Refrigeration Systems Technical college/ Baghdad

Theoretical hours: 2 4th Year

Practical hours: 2
Units: 6 Week No. :- 26-27
Multistage Systems and Cascade Systems:
First 10 minutes: review the last lecture.
Then explain the new lecture, solve an example.
Last 10 minutes review the lecture and ask if there are any questions.

The specific objectives of this lecture are to:

1. Classify multi-stage systems.
2. Discuss the concept of flash gas removal using flash tank.
3. Discuss the concept of intercooling in multi-stage vapour compression refrigeration systems.
4. Analysis of the intercooling process.
5. Discuss Standard two-stage system with one evaporating temperature.
6. Describe briefly cascade systems.
7. Describe briefly the working principle of auto-cascade cycle
1. Introduction:
A significant fraction of industrial refrigeration plants operate with a large difference between
evaporating and condensing temperatures-perhaps 50° to 80° C (100° to 150°F). This large
temperature lift imposes both problems and opportunities for the system. An opportunity is to use
multistage systems.
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. Hence these concepts will be discussed first.
Flash gas removal using flash tank:
Suitable equipment to partially expand the refrigerant and then remove the flash gas is shown
schematically in Figure below Liquid refrigerant from the condenser or high-pressure receiver passes
through a level-control valve. The liquid, being more dense than the vapor, separates and flows on to
the expansion valve of the evaporator. A flash-gas compressor draws off the vapor from the
separating vessel or flash tank and compresses it to the condensing pressure where it joins the vapor
from the main compressor.
Because the level-control valve in Figure (a) is important to realize that it performs the function of
an expansion valve. In controlling the level of liquid in the vessel, the valve opens wider if the liquid
level begins to drop. Similarly, if the liquid level begins to rise, the valve closes more. The pressure in
the flash tank is controlled by the pumping capacity of the flash gas compressor in relation to the flow
rate of liquid passing on to the evaporator. For a given flow rate of liquid leaving the vessel, a low
pumping capacity of the flash-gas compressor results in a high intermediate pressure. This is true,
because at steady-state operation the flow rate of vapor that forms due to flashing must equal the
rate of removal by the compressor. If this pumping rate is low, the process adjusts by generating only
a low flow rate of vapor, which is associated with a small drop in pressure through the valve. The
pressure enthalpy diagram displaying the state points of the refrigerant in the equipment of Figure (a)
is shown in Figure (b).

a) A two-stage compression system b) Pressure-enthalpy diagram of flash-gas

with flash-gas removal. removal process in Figure (a).

Example:
An ammonia system operating with an evaporating temperature of - 30°C (-22°F) and a condensing
temperature of 35°C (95°F) separates flash gas at a temperature of -2°C (28.4°F) and delivers it to the
condenser through a separate compressor. If the refrigerating capacity is 200 kW (56.9 tons of refrigeration),
what are the power requirements if the system operates (a) single stage, and (b) with flash-gas removal?

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 The magnitude of saving from flash-gas removal depends on the thermodynamic properties of the
refrigerant and the magnitude of the temperature lift from the evaporator to the condenser.
Intercooling in multi-stage compression:
The two principal advantages of interstage desuperheating, or intercooling, are the saving in
compressor power and the reduction in discharge temperature from the low-stage compressor.
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 below (a) and (b) show the process
of intercooling in two-stage compression on Pressure-specific volume (P-v) and P-h diagrams.

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 Fig.(a) & (b): Intercooling in two-stage compression

As shown in the figures, in stead 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 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,

Intercooling of the vapour 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 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.

Analysis of the intercooling process:

Just as flash-gas removal was analyzed separately, the intercooling process will also be explored
independently. The flow diagram of a two-stage system using only intercooling is shown in Figure (a)
and the corresponding pressure enthalpy diagram in Figure (b).
Intercooling is often used in two-stage air compression, and in this application water from a cooling
tower or the tap is the cooling medium. The cooling water is assumed to be free-of-charge, so all of
the reduction in power in the high-stage compressor represents a net saving in power. When
intercooling refrigerant, however, the cooling water that is normally available is not cold enough to
desuperheat the refrigerant to the saturation temperature. The vaporization of some refrigerant, which
must then be compressed by the high stage compressor, is an expenditure of power that must be
deducted from the reduction in power attributable to the lower inlet temperature.

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 (a) Two-stage system with intercooling only. (b) the corresponding pressure-enthalpy diagram.
Example:
The intercooling system shown in Figure (a) operates with ammonia at the following saturation
temperatures: evaporating, -35°C (-31°F); intermediate, 0°C (32°F); and condensing, 35°C (95°F).
What is the saving in power of the intercooled cycle, expressed in percent, compared to single-stage
operation?

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Standard two-stage system with one evaporating temperature:

The two features made available by two stages of compression-flash- gas removal and
intercooling—have been analyzed separately. A system4 with two stages of compression and one
level of evaporating temperature usually incorporates both processes, as shown in Figure 3.15. The
corresponding pressure-enthalpy diagram is shown in Figure below. The flash-gas removal may be
achieved either by direct flashing of liquid at the interstage pressure or with a liquid subcooler as
maintained before.

Example:

An R-507 two-stage system with flash-gas removal and intercooling provides 200 kW of refrigeration at an
evaporating temperature of -40°C (-40°F) when operating with a condensing temperature of 35°C (95°F). The
intermediate temperature is -5°C (23°F).

(a) What are the enthalpies of the refrigerant at all points in the system?

(b) Compute the flow rates through each compressor.

(c) What are the power requirements of the compressors?
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(d) What would be the power required in a single-stage R-507 system with these evaporating and condensing
temperatures, and the percentage saving in power through the use of a two-stage system?

A standard two-stage system with flash-gas Pressure-enthalpy diagram for the

removal and intercooling. standard two-stage system.
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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 below (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.

Applications of cascade systems:

- Liquefaction of petroleum vapours.

- Liquefaction of industrial gases.
- Manufacturing of dry ice.
- Deep freezing etc.

Advantages of cascade systems:

1. 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

2. 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
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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.

(a) & (b): A two-stage cascade refrigeration system