Multi-Stage Vapour

Compression
Refrigeration Systems

1
The objectives of this lesson are to:

1. Discuss limitations of single stage vapour compression refrigeration systems

2. Classify multi-stage systems
3. Discuss the concept of flash gas removal using flash tank
4. Discuss the concept of intercooling in multi-stage vapour compression refrigeration
systems
5. Discuss multi-stage vapour compression refrigeration systems with flash gas removal
and intercooling
6. Discuss the use of flash tank for flash gas removal only
7. Discuss the use of flash tank for intercooling only

At the end of the lesson, the student should be able to:

1. Justify the selection of single or multi-stage systems based on operating temperature

range
2. Classify multi-stage systems
3. Applying mass and energy balance equations, evaluate the performance of multi-stage
vapour compression refrigeration systems with:
a) Flash gas removal
b) Intercooling
c) Flash gas removal using flash tank and intercooling using flash tank and/or
external intercooler
d) Flash tank for flash gas removal only
e) Flash tank for intercooling only, and
f) A combination of any of the above

1. Introduction
A single stage vapour compression refrigeration system has one low side pressure
(evaporator pressure) and one high side pressure (condenser pressure). The performance of
single stage systems shows that these systems are adequate as long as the temperature
difference between evaporator and condenser (temperature lift) is small. However, there are
many applications where the temperature lift can be quite high. The temperature lift can
become large either due to the requirement of very low evaporator temperatures and/or due to
the requirement of very high condensing temperatures. For example, in frozen food industries
the required evaporator can be as low as –40oC, while in chemical industries temperatures as
low as –150oC may be required for liquefaction of gases. On the high temperature side the
required condensing temperatures can be very high if the refrigeration system is used as a
heat pump for heating applications such as process heating, drying etc. However, as the
temperature lift increases the single stage systems become inefficient and impractical. For
example, Fig. 1 shows the effect of decreasing evaporator temperatures on T s and P h
diagrams. It can be seen from the T s diagrams that for a given condenser temperature, as
evaporator temperature decreases:

2
 i. Throttling losses increase
ii. Superheat losses increase
iii. Compressor discharge temperature increases
iv. Quality of the vapour at the inlet to the evaporator increases
v. Specific volume at the inlet to the compressor increases

As a result of this, the refrigeration effect decreases and work of compression increases as
shown in the P h diagram. The volumic refrigeration effect also decreases rapidly as the
specific volume increases with decreasing evaporator temperature. Similar effects will occur,
though not in the same proportion when the condenser temperature increases for a given
evaporator temperature. Due to these drawbacks, single stage systems are not recommended
when the evaporator temperature becomes very low and/or when the condenser temperature
becomes high. In such cases multi-stage systems are used in practice. Generally, for
fluorocarbon and ammonia based refrigeration systems a single stage system is used upto an
evaporator temperature of –30oC. A two-stage system is used upto –60oC and a three-stage
system is used for temperatures below –60oC.

Apart from high temperature lift applications, multi-stage systems are also used in
applications requiring refrigeration at different temperatures. For example, in a dairy plant
refrigeration may be required at –30oC for making ice cream and at 2oC for chilling milk. In
such cases it may be advantageous to use a multi-evaporator system with the low temperature
evaporator operating at –30oC and the high temperature evaporator operating at 2oC

3
 T
2’’
2’
2

4
1
4’
1’
4’’
1’’

Ss

Fig.1(a): Effect of evaporator temperature on cycle performance (T-s diagram)

3 2 2’ 2’’

4 1

4’ 1’
1’’
4’’

Fig.1(b): Effect of evaporator temperature on cycle performance (P-h diagram)

4
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.

2. Flash gas removal using flash tank

It is mentioned above that one of the problems with high temperature lift applications
is the high quality of vapour at the inlet to the evaporator. This vapour called as 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 as it is already in the form of
vapour, and it increases the pressure drop in the evaporator. It is possible to improve the COP
of the system if the flash gas is removed as soon as it is formed and recompressed to
condenser pressure. However, continuous removal of flash gas as soon as it is formed and
recompressing it immediately is difficult in practice. One way of improving the performance
of the system is to remove the flash gas at an intermediate pressure using a flash tank. Figure
2.2 shows the schematic of a flash tank and Fig.2.3 shows the expansion process employing
flash tank. A flash tank is a pressure vessel, wherein the refrigerant liquid and vapour are
separated at an intermediate pressure. The refrigerant from condenser is first expanded to an
intermediate pressure corresponding to the pressure of flash tank, Pi using a low side float
valve (process 6-7). The float valve also maintains a constant liquid level in the flash tank. In
the flash tank, the refrigerant liquid and vapour are separated. The saturated liquid at point 8
is fed to the evaporator after throttling it to the required evaporator pressure, Pe (point 9)
using an expansion valve. Depending upon the type of the system, the saturated vapour in
the flash tank (point 3) is either compressed to the condenser pressure or throttled to the
evaporator pressure. In the absence of flash tank, the refrigerant condition at the inlet to the
evaporator would have been point 9’, which has a considerably high vapour quality
compared to point 9. As mentioned, the refrigerant liquid and vapour must get separated in
the flash tank. This is possible when the upward velocity of the refrigerant vapour in the flash
tank is low enough ( < 1 m/s) for the refrigerant liquid droplets to fall back into the flash tank
due to gravity. Thus the surface area of liquid in the flash tank can be obtained from the
volumetric flow rate of refrigerant vapour and the required low refrigerant velocity.

5
 3
6 From To compressor
condenser
Flash tank

8
9
To evaporator
Expansion valve

Fig.2.2(a): Working principle of a flash tank

Pc
6
Pi 8 3
7
Pe
9 9’

Fig.2.3: Expansion process using a flash tank on P-h diagram

3. Intercooling in multi-stage compression

The specific work input, w in reversible, polytropic compression of refrigerant vapour
is given by:

2
æ n ö é æ P ö (n-1) / n ù
w = -ò v.dP =ç ÷P1v1 ê1- ç 2 ÷ ú (2.1)
1 è n - 1ø êë è P1 ø úû

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 where P1 and P2 are the inlet and exit pressures of the compressor, v1 is the specific volume
of the refrigerant vapour at the inlet to the compressor and n is the polytropic exponent. From
the above expression, it can be seen that specific work input reduces as specific volume, v1 is
reduced. 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
2.4 (a) and (b) show the process of intercooling in two-stage compression on Pressure-
specific volume (P-v) and P-h diagrams.

P
4 2’
Savings in
sp. work 4
2’
P 2
3 3
2

1
1

h
v

Fig.2.4(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 isentropes. Since the
slope of isentropes on P-h diagram reduces (lines become flatter) as they move away from the
saturated vapour line,

(h4-h3) < (h2’-h2) Þ (h2-h1)+(h4-h3) < (h2’-h1) (2.2)

Intercooling of the vapour may be achieved by using either a water-cooled heat

exchanger or by the refrigerant in the flash tank. Figures 2.5(a) and (b) show these two
systems. 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.

7
 4

Refrigerant
liquid from 3
condenser
2 High-stage
compressor

Flash
tank Low-stage
compressor

Fig.2.5(a): Intercooling using liquid refrigerant in flash tank

4
Water out Water in

High-stage
2 Compressor
Water-cooled
heat exchanger

1
Low-stage
Compressor

Fig.2.5(b): Intercooling using external water cooled heat exchanger

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. This is
due to the fact that the heat rejected by the refrigerant during intercooling generates
additional vapour in the flash tank, which has to be compressed by the high stage compressor.
Thus the mass flow rate of refrigerant through the high stage compressor will be more than
that of the low stage compressor. Whether total power input to the system decreases or not
depends on whether the increased power consumption due to higher mass flow rate is

8
compensated by reduction in specific work of compression or not. For ammonia, the power
input usually decreases with intercooling by liquid refrigerant, however, for refrigerants such
as R12, R22, the power input marginally increases. Thus intercooling using liquid refrigerant
is not effective for R12 and R22. However, as mentioned one benefit of intercooling is the
reduction in compressor discharge temperature, which leads to better compressor lubrication
and its longer life.

It is also possible to intercool the refrigerant vapour by a combination of water-cooled

heat exchanger and the refrigerant liquid in the flash tank. As a result of using both water-
cooling and flash-tank, the amount of refrigerant vapour handled by the high-stage
compressor reduces leading to lower power consumption. However, the possibility of this
again depends on the availability of cooling water at required temperature.

One of the design issues in multi-stage compression is the selection of suitable

intermediate pressure. For air compressors with intercooling to the initial temperature, the
theoretical work input to the system will be minimum when the pressure ratios are equal for
all stages. This also results in equal compressor discharge temperatures for all compressors.
Thus for a two-stage air compressor with intercooling, the optimum intermediate pressure,
Pi,opt is:

P i,opt = P low .Phigh (2.3)

where Plow and Phigh are the inlet pressure to the low-stage compressor and exit pressure from
the high-stage compressor, respectively. The above relation is found to hold good for ideal
gases. For refrigerants, correction factors to the above equation are suggested, for example
one such relation for refrigerants is given by:

Tc
Pi,opt = Pe.P c (2.4)
Te
where Pe and Pc are the evaporator and condenser pressures, and Tc and Te are condenser and
evaporator temperatures (in K).

Several combinations of multi-stage systems are used in practice. Some of them are
discussed below.

2.4. Multi-stage system with flash gas removal and intercooling

Figures 2.6(a) and (b) show a two-stage vapour compression refrigeration system
with flash gas removal using a flash tank, and intercooling of refrigerant vapour by a water-
cooled heat exchanger and flash tank. The superheated vapour from the water cooled heat
exchanger bubbles through the refrigerant liquid in the flash tank. It is assumed that in this
process the superheated refrigerant vapour gets completely de-superheated and emerges out
as a saturated vapour at state 4. However, in practice complete de-superheating may not be
possible. As mentioned the use of combination of water cooling with flash tank for
intercooling reduces the vapour generated in the flash tank. The performance of this system
can be obtained easily by applying mass and energy balance equations to the individual
components. It is assumed that the flash tank is perfectly insulated and the potential and
kinetic energy changes of refrigerant across each component are negligible.

9
 Qc B B

Condenser
5
6
4 Compressor - II

3 WII
7
Flash
chamber Water intercooler

Qi
2
8
1 Compressor - I
9
Evaporator WI

Qe

Fig.2.6(a): Two-stage vapour compression refrigeration system with flash gas removal using a
flash tank and intercooling

Pc 6
5

8 7 4 3
Pi
2

Pe
9 1

h
Fig.2.6(b): Two-stage vapour compression refrigeration system with flash gas removal using a
flash tank and intercooling – P-h diagram

From mass and energy balance of the flash tank:

. . . .
m7 + m3 = m8+ m4 (12.5)
. . . .
m7 h 7 + m3 h 3 = m8 h 8 + m 4 h 4 (12.6)

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From mass and energy balance across expansion valve,
. .
m8 = m9 (2.7)
h8 = h9 (2.8)
From mass and energy balance across evaporator:
. .
m 9 = m1 (2.9)
.
Q e = m 1 (h 1 - h 9 ) (2.10)

From mass and energy balance across low-stage compressor, Compressor-I:

. . .
m 9 = m1 = m I (2.11)
.
W I = m I (h 2 - h 1 ) (2.12)
.
where m I is the mass flow rate of refrigerant through Compressor-I.

From mass and energy balance across water-cooled intercooler:

. . .
m2 = m3 = mI (2.13)
.
Q I = m I (h 2 - h 3 ) (2.14)

where QI is the heat transferred by the refrigerant to the cooling water in the intercooler.

From mass and energy balance across high-stage compressor, Compressor-II:

. . .
m 4 = m 5 = m II (2.15)
.
WII = m II (h 5 - h 4 ) (2.16)
.
where m II is the mass flow rate of refrigerant through Compressor-II.

Finally, from mass and energy balance across condenser:

. . .
m 5 = m 6 = m II (2.17)
.
Q c = m II (h 5 - h 6 ) (2.18)
Finally, from mass and energy balance across the float valve:
. . .
m 6 = m 7 = m II (2.19)
h6 = h7 (2.20)

From the above set of equations, it can be easily shown that for the flash tank:
. . .
m 7 = m 4 = m II (2.21)
. . .
m3 = m8 = mI (2.22)
. . éh - h ù
3 8
m II = m I ê ú (2.23)
ëh4 - h7 û

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 It can be seen from the above expression that the refrigerant flow through the high-
.
stage compression mII can be reduced by reducing the enthalpy of refrigerant vapour entering
into the flash tank, h3 from the water-cooled intercooler.

The amount of additional vapour generated due to de-superheating of the refrigerant

vapour from the water-cooled intercooler is given by:

. . éh - h ù
m gen = m I ê 3 4
ú (2.24)
ëh4 - h8 û

.
Thus the vapour generated m gen will be zero, if the refrigerant vapour is completely de-
superheated in the water-cooled intercooler itself. However, this may not be possible in
practice.

For the above system, the COP is given by:

.
Qe m I (h 1 - h 9 )
COP = = . .
(2.25)
WI + WII
m I (h 2 - h 1 ) + m II (h 5 - h 4 )

The above system offers several advantages,

a) Quality of refrigerant entering the evaporator reduces thus giving rise to higher
refrigerating effect, lower pressure drop and better heat transfer in the evaporator
b) Throttling losses are reduced as vapour generated during throttling from Pc to Pi is
separated in the flash tank and recompressed by Compressor-II.
c) Volumetric efficiency of compressors will be high due to reduced pressure ratios
d) Compressor discharge temperature is reduced considerably.

However, one disadvantage of the above system is that since refrigerant liquid in the flash
tank is saturated, there is a possibility of liquid flashing ahead of the expansion valve due to
pressure drop or heat transfer in the pipelines connecting the flash tank to the expansion
device. Sometimes this problem is tackled by using a system with a liquid subcooler. As
shown in Fig.2.7, in a liquid subcooler the refrigerant liquid from the condenser is
subcooled by exchanging heat with the refrigerant liquid in the flash tank. As a result, a small
amount of refrigerant vapour is generated in the flash tank, which needs to be compressed in
the high-stage compressor. Compared to the earlier system, the temperature of refrigerant
liquid from the subcooler will be higher than the saturated refrigerant temperature in the flash
tank due to indirect contact heat transfer. However, since the refrigerant at the inlet to the
expansion valve is at high pressure and is subcooled, there is less chance of flashing of liquid
ahead of expansion valve.

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 From
6 condenser To high-stage
3 compressor

Liquid
subcooler
8 To
Expansion evaporator
valve
Fig.2.7: Refrigeration system with liquid subcooler

2.5. Use of flash tank for flash gas removal

Intercooling of refrigerant vapour using water-cooled heat exchangers is possible in
ammonia systems due to high discharge temperature of ammonia. However, this is generally
not possible in systems using refrigerants such as R 12 or R 134a due to their low discharge
temperatures. In these systems, in stead of passing the refrigerant vapour from the low-stage
compressor through the flash tank, vapour from the flash tank is mixed with the vapour
coming from the low-stage compressor. As a result, the inlet condition to the high-stage
compressor will be slightly superheated. A two-stage compression system with flash tank for
flash gas removal for refrigerants such as R 134a is shown in Fig. 2.8 (a). Figure 2.8 (b)
shows the corresponding P-h diagram.

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 Condenser
6 5

3 4 Compressor - II

7 Flash
chamber

8 1 Compressor - I
9
Evaporator

6
5

8 7 3
4 2

9 1

Fig.2.8: A two-stage compression system with flash tank for flash gas removal only
(a) System schematic; (b) Cycle on P-h diagram

2.6. Use of flash tank for intercooling only

Sometimes the flash tank is used for intercooling of the refrigerant vapour between
the low and high-stage compressors. It is not used for flash gas removal. Figures 2.9 (a) and
(b) show the system schematic and P-h diagram of a two-stage compression system where the
flash tank is used for intercooling only.

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 Condenser
5 4
3 Compressor - II

6
Flash
chamber

1 Compressor - I
7
Evaporator

5
4 2'

6 3
2

7 1

Fig.2.9: A two-stage compression system with the flash tank used for intercooling only
(a) System schematic (b) Cycle on P-h diagram

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Questions:
1. When the temperature lift of a single stage vapour compression refrigeration system
increases:

a) Refrigeration effect increases

b) Work of compression increases
c) Compressor discharge temperature decreases
d) Volumetric efficiency of compressor increases

Ans.: b)

2. Multi-stage vapour compression refrigeration systems are used when:

a) Required temperature lift increases

b) Required temperature lift decreases
c) Refrigeration is required at different temperatures
d) Required refrigeration capacity is large

Ans.: a) and c)

3. Using a flash tank:

a) Flash gas formed during expansion can be removed at an intermediate pressure

b) Quality of refrigerant at the evaporator inlet can be increased
c) Temperature of refrigerant vapour at the inlet to higher stage compressor can be reduced
d) Pressure drop in evaporator can be reduced

Ans.: a) , c) and d)

4. Using intercooling in multi-stage compression systems:

a) Refrigeration effect can be increased

b) Work of compression in higher stage compressor can be reduced
c) Maximum cycle temperature can be increased
d) All of the above

Ans.: b)

5. External intercooling of refrigerant vapour:

a) Is feasible for ammonia based systems

b) Commonly used in air compressors
c) Commonly used for halocarbon refrigerants
d) Depends on availability of cold external water

Ans.: a) and b)

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6. Assuming the refrigerant vapour to behave as an ideal gas and with perfect intercooling,
the optimum intermediate pressure of a refrigeration system that operates between 4 bar and
16 bar is equal to:

a) 10 bar
b) 8 bar
c) 6 bar
d) 12 bar

Ans.: b)

7. Refrigeration system with liquid subcooler is used to:

a) Prevent the entry of liquid into compressor

b) Prevent flashing of refrigerant liquid ahead of low stage expansion device
c) Reduce work of compression
d) All of the above

Ans. b)

8. In two-stage compression system with flash gas removal:

a) Refrigerant mass flow rates in both low and high stage compressors are equal
b)Refrigerant mass flow rates in high stage compressors is greater than that in low stage
compressor
c)Refrigerant mass flow rates in high stage compressors is smaller than that in low stage
compressor
d)Mass flow rates in low and high stage compressors are equal if the pressure ratios are
equal

Ans.: b)

9. Use of flash tank for intercooling:

a) Always improves system COP

b) COP increases or decreases depends on the refrigerant used
c) Maximum compressor discharge temperature always decreases
d) Power input to the system always decreases

Ans.: b) and c)

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 10. The required refrigeration capacity of a vapour compression refrigeration system (with R-
22 as refrigerant) is 100 kW at –30oC evaporator temperature. Initially the system was single-
stage with a single compressor compressing the refrigerant vapour from evaporator to a
condenser operating at 1500 kPa pressure. Later the system was modified to a two-stage
system operating on the cycle shown below. At the intermediate pressure of 600 kPa there is
intercooling but no removal of flash gas. Find a) Power requirement of the original single-
stage system; b) Total power requirement of the two compressors in the revised two-stage
system. Assume that the state of refrigerant at the exit of evaporator, condenser and
intercooler is saturated, and the compression processes are isentropic.
condenser

1500 kPa

600 kPa 2nd stage

compressor

intercooler

-18oC
1st1stage
st
stage
evaporator compressor
compressor
(100 kW)

Ans.:

From refrigerant property data, the following values are obtained for R 22:

Point Dryness Enthalpy, Entropy,

Temp.,oC Pressure,kPa Density,kg/m3
fraction kJ/kg kJ/kg.K

1 -30 163.9 1.0 7.379 392.7 1.802

3 39.1 1500 0.0 - 248.4 -

2 76.93 1500 - - 449.9 1.802

2’” 53.55 1500 - - 429.6 1.742

2” 5.86 600 1.0 - 407.2 1.742

2’ 28.94 600 - - 424.4 1.802

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a) Single stage system:

3 2

4 1

Required refrigerant mass flow rate, mr is given by:

mr = Qe/(h1 - h4) = 100/(392.7 - 248.4) = 0.693 kg/s
Power input to compressor, Wc is given by:
Wc = mr(h2 - h1) = 0.693(449.9 - 392.7) = 39.64 kW
COP of the single stage system is given by:
COP = Qe/Wc = 100/39.64 = 2.523
Compressor discharge temperature = 76.93 oC (from property data)

Two-stage system with flash tank for intercooling only:

3 2’” 2

4’ 2’
2”

4 1

h
Required refrigerant mass flow rate through evaporator and 1st stage compressor
(mr,1) is same as that of single stage system, i.e.,

mr,1 = 0.693 kg/s

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Power input to 1st stage compressor, Wc,1 is given by:
Wc,1 = mr,1(h2’ - h1) = 0.693(424.4 - 392.7) = 21.97 kW
The mass flow rate of refrigerant vapour through 2nd stage compressor (mr,2) is
obtained from energy balance across intercooler:

mr,2.h2” = mr,1.h2’ + (mr,2 - mr,1).h4’

Substituting the values of enthalpy and mass flow rate through 1st stage compressor:
mr,2 = 0.768 kg/s
Power input to 2nd stage compressor, Wc,2 is given by:
Wc,2 = mr,2(h2’” - h2”) = 0.768(429.6 - 407.2) = 17.2 kW
Therefore, total power input, Wc is given by:
Wc = Wc,1+Wc,2 = 21.97+17.2 = 39.17 kW

COP of the two-stage system is given by:

COP = Qe/(Wc,1+Wc,2) = 100/39.17 = 2.553

From property data, the discharge temperatures at the exit of 1st and 2nd stage
compressors are given, respectively by:

T2’ = 28.94oC
T2’” = 53.55oC

Comments:
It is observed from the above example that for the given input data, though
the use of a two-stage system with intercooling in place of a single stage system
does not increase the COP significantly (» 1.2 %), there is a significant reduction in
the maximum compressor discharge temperature (» 24oC). The results would be
different if the operating conditions and/or the refrigerant used is different.

20