Version 1 ME, IIT Kharagpur 1

Lesson
13
Multi-Evaporator And
Cascade Systems Version 1 ME,
IIT Kharagpur 2
The objectives of this lesson are to:
1. Discuss the advantages and applications of multi-evaporator systems compared to
single stage systems (Section 13.1)
2. Describe multi-evaporator systems using single compressor and a pressure reducing
valve with:
a) Individual expansion valves (Section 13.2.1)
b) Multiple expansion valves (Section 13.2.2)
3. Describe multi-evaporator systems with multi-compression, intercooling and flash
gas removal (Section 13.3)
4. Describe multi-evaporator systems with individual compressors and multiple
expansion valves (Section 13.4)
5. Discuss limitations of multi-stage systems (Section 13.5)
6. Describe briefly cascade systems (Section 13.6)
7. Describe briefly the working principle of auto-cascade cycle (Section 13.7)
At the end of the lecture, the student should be able to:
1. Explain the need for multi-evaporator systems
2. Evaluate the performance of:
a) Multi-evaporator systems with single compressor and individual expansion valves
b) Multi-evaporator systems with single compressor and multiple expansion valves
3. Evaluate the performance of multi-evaporator systems with multi-compression,
intercooling and flash gas removal
4. Evaluate the performance of multi-evaporator systems with individual compressors
and multiple or individual expansion valves
5. Evaluate the performance of cascade systems
6. Describe the working principle of auto-cascade systems
13.1. Introduction
As mentioned in Chapter 12, there are many applications where refrigeration is
required at different temperatures. For example, in a typical food processing plant, cold
o o
air may be required at –30 C for freezing and at +7 C for cooling of food products or
space cooling. One simple alternative is to use different refrigeration systems to cater
to these different loads. However, this may not be economically viable due to the high
total initial cost. Another alternative is to use a single refrigeration system with one
o
compressor and two evaporators both operating at −30 C. The schematic of such a
system and corresponding operating cycle on P-h diagram are shown in Figs. 13.1(a)
and (b). As shown in the figure the system consists of a single compressor and a single
condenser but two evaporators. Both evaporators-I and II operate at same evaporator
o
temperature (-30 C) one evaporator (say Evaporator-I) caters to freezing while the
o
other (Evaporator-II) caters to product cooling/space conditioning at 7 C. It can be seen
o o
that operating the evaporator at –30 C when refrigeration is required at +7 C is
thermodynamically inefficient as the system irreversibilities increase with increasing
temperature difference for heat transfer.
The COP of this simple system is given by:
)hh()hh(WQQCOP1241cII,eI,e−−=+= (13.1)
In addition to this there will also be other difficulties such as: evaporator catering to
o
space cooling (7 C) may collect frost leading to blockage of air-flow passages, if a
liquid is to chilled then it may freeze on the evaporator and the moisture content of air
may become too low leading to water losses in the food products. In such cases multi-
stage systems with multiple evaporators can be used. Several multi-evaporator
combinations are possible in practice. Some of the most common ones are discussed
below.
13.2. Individual evaporators and a single compressor with a
pressure-reducing valve
13.2.1. Individual expansion valves:
Figures 13.2 (a) and (b) show system schematic and P-h diagram of a multi-evaporator
system that uses two evaporators at two different temperatures and a single
compressor. This system also uses individual expansion valves and a pressure
regulating valve (PRV) for reducing the pressure from that corresponding to the high
temperature evaporator to the compressor suction pressure. The PRV also maintains
the required pressure in high temperature evaporator (Evaporator-II). Compared to the
earlier system, this system offers the advantage of higher refrigeration effect at the high
temperature evaporator [(h -h ) against (h -h )]. However, this advantage is
6 4 7 5
counterbalanced by higher specific work input due to the operation of compressor in
Version 1 ME, IIT Kharagpur 3 1141342Condenser Evaporator-I(-
30oC)CompressorRefrigeration at –30oC Refrigeration at +7oC Heat jtiEvaporator-
II at –30oC 4h1P32-30oCFig.13.1(a) & (b): A single stage system with two evaporators
Version 1 ME, IIT Kharagpur 4Version 1 ME, IIT Kharagpur 5
superheated region. Thus ultimately there may not be any improvement in system COP
due to this arrangement. It is easy to see that this modification does not result in
significant improvement in performance due to the fact that the refrigerant vapour at
the intermediate pressure is reduced first using the PRV and again increased using
compressor. Obviously this is inefficient. However, this system is still preferred to the
earlier system due to proper operation of high temperature evaporator. Evaporator -
II618Evaporator - I57Compressor - I34Condenser2+7oC-
30oCPRVRefrigeration at +7oC Refrigeration at -30oC Heat rejection
645h718P32+7oC-30oCFig.13.2(a) & (b): Multi-evaporator system with single
compressor and individual expansion valves
Version 1 ME, IIT Kharagpur 6
The COP of the above system is given by:
)hh)(mm()hh(m)hh([Link],eI,e−+−+−=+= (13.2)
where are the refrigerant mass flow rates through evaporator I and II respectively. They
are given by: [Link]
)hh(Qm57I,eI.−= (13.3)
)hh(Qm46II,eII.−= (13.4)
Enthalpy at point 2 (inlet to compressor) is obtained by applying mass and energy
balance to the mixing of two refrigerant streams, i.e.,
II.I.8II.7I.2mmhmhmh++= (13.5)
If the expansion across PRV is isenthalpic, then specific enthalpy h will be equal to h .
8 6
13.2.2. Multiple expansion valves:
Figures 13.3 (a) and (b) show system schematic and P-h diagram of a multi-evaporator
with a single compressor and multiple expansion valves. It can be seen from the P-h
diagram that the advantage of this system compared to the system with individual
expansion valves is that the refrigeration effect of the low temperature evaporator
increases as saturated liquid enters the low stage expansion valve. Since the flash gas is
removed at state 4, the low temperature evaporator operates more efficiently.
The COP of this system is given by:
)hh)(mm()hh(m)hh([Link],eI,e−+−+−=+= (13.6)
where are the refrigerant mass flow rates through evaporator I and II respectively. They
are given by: [Link]
)hh(Qm68I,eI.−= (13.7)
)hh(Qm47II,eII.−= (13.8)
Version 1 ME, IIT Kharagpur 7Version 1 ME, IIT Kharagpur 8
Enthalpy at point 2 (inlet to compressor) is obtained by applying mass and energy
balance to the mixing of two refrigerant streams, i.e.,
II.I.9II.8I.2mmhmhmh++= (13.9)
If the expansion across PRV is isenthalpic, then specific enthalpy h will be equal to h .
7 9
COP obtained using the above multi-evaporator systems is not much higher compared
to single stage system as refrigerant vapour at intermediate pressure is first
Evaporator - II7195Evaporator - I68Compressor - I43
2PRV9618hP54372+7oC-30oCFig.13.3(a) & (b): Multi-evaporator system with
single compressor and multiple expansion valves
Version 1 ME, IIT Kharagpur 9
throttled then compressed, and compressor inlet is in superheated region. Performance
can be improved significantly if multiple compressors are used in place of a single
compressor.
13.3. Multi-evaporator system with multi-compression,
intercooling and flash gas removal
Figures 13.4(a) and (b) show the schematic and P-h diagram of a multi-evaporator
system which employs multiple compressors, a flash tank for flash gas removal and
intercooling. This system is good for low temperature lift applications with different
o
refrigeration loads. For example one evaporator operating at say –40 C for quick
o
freezing of food products and other evaporator operating at –25 C for storage of frozen
food. As shown in the system schematic, the pressure in the high temperature
evaporator (Evaporator-II) is same as that of flash tank. Superheated vapour from the
low-stage compressor is cooled to the saturation temperature in the flash tank. The low
temperature evaporator operates efficiently as flash gas is removed in the flash tank. In
addition the high-stage compressor (Compressor-II) operates efficiently as the suction
vapour is saturated. Even though the high stage compressor has to handle higher mass
flow rate due to de-superheating of refrigerant in the flash tank, still the total power
input to the system can be reduced substantially, especially with refrigerants such as
ammonia.
The COP of this system is given by:
)hh(m)hh(m)hh(m)hh(mWWQQCOP34II.12I.63II,[Link],cI,cII,eI,e−+−−+−=++= (13.10)
where are the refrigerant mass flow rates through evaporator I and II respectively. They
are given by: II,[Link]
)hh(Qm68I,eI.−= (13.11)
)hh(Qm63II,eII,e.−= (13.12)
[Link] the mass flow rate of refrigerant through the high-stage compressor which can be
obtained by taking a control volume which includes the flash tank and high
temperature evaporator (as shown by dashed line in the schematic) and applying mass
and energy balance:
mass balance:
[Link]&mmm;mmmm====+=+ (13.13)
energy balance:
Version 1 ME, IIT Kharagpur 10
3377II,[Link]+=++ (13.14)
from known operating temperatures and evaporator loads (Q and Q ) one can get the
e,I e,II
mass flow rate through the high stage compressor and system COP from the above
equations. 81hP765432Evaporator - I87Compressor - I12Evaporator -
II3a6Condenser65Compressor - IIFlash chamber3b34Control volume for finding mass flow
rate through Compressor-II Qe,IQe,IIFig.13.4(a) & (b): Multi-evaporator system with
multiple compressors and a flash tank for flash gas removal and intercooling
Version 1 ME, IIT Kharagpur 11
13.4. Multi-evaporator system with individual compressors
and multiple expansion valves
Figures 13.5(a) and (b) show the schematic and P-h diagram of a multi-evaporator
system which employs individual compressors and multiple expansion valves.
The COP of this combined system is given by:
)hh(m)hh(m)hh(m)hh([Link],cI,cII,eI,e−+−−+−=++= (13.15)
where are the refrigerant mass flow rates through evaporator I and II respectively. They
are given by: [Link]
)hh(Qm93I,eI.−= (13.16)
)hh(Qm71II,eII.−= (13.17)
The inlet to the condenser (state 5) is obtained by applying mass and energy balance to
the process of mixing of refrigerant vapours from Compressors I and II.
13.5. Limitations of multi-stage systems
Though multi-stage systems have been very successful, they have certain limitations.
These are:
a) Since only one refrigerant is used throughout the system, the refrigerant used should
have high critical temperature and low freezing point.
b) The operating pressures with a single refrigerant may become too high or too low.
Generally only R12, R22 and NH systems have been used in multi-stage systems as
3
other conventional working fluids may operate in vacuum at very low evaporator
temperatures. Operation in vacuum leads to leakages into the system and large
compressor displacement due to high specific volume.
c) Possibility of migration of lubricating oil from one compressor to other leading to
compressor break-down.
The above limitations can be overcome by using cascade systems.
Version 1 ME, IIT Kharagpur 121Evaporator - IIEvaporator -
I98Compressor - ICompressor - II3Condenser762
4Qe,IIQe,IWc,IWc,II93hP8765124Fig.13.5(a) & (b): Multi-evaporator system with
individual compressors and multiple expansion valves
13.6. 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 13.6(a) and (b) show the schematic
and P-h diagrams of a two-stage cascade refrigeration system. As shown, this system
employs two different refrigerants operating in two individual cycles. They are
thermally coupled in the cascade condenser. The refrigerants selected should have
suitable pressure-temperature characteristics. An example of refrigerant combination is
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the use of carbon dioxide (NBP = -78.4 C, T = 31.06 C) in low temperature cascade
cr
o o
and ammonia (NBP = -33.33 C, T = 132.25 C) in high temperature cascade. It is
cr
possible to use more than two cascade stages, and it is also possible to combine multi-
stage systems with cascade systems.
Applications of cascade systems:
i. Liquefaction of petroleum vapours
ii. Liquefaction of industrial gases
iii. Manufacturing of dry ice
iv. Deep freezing etc.
Advantages of cascade systems:
i. Since each cascade uses a different refrigerant, it is possible to select a refrigerant
that is best suited for that particular temperature range. Very high or very low pressures
can be avoided
ii. Migration of lubricating oil from one compressor to the other is prevented
In practice, matching of loads in the cascade condenser is difficult, especially during
the system pull-down. Hence the cascade condensers are normally oversized. In
addition, in actual systems a temperature difference between the condensing and
evaporating refrigerants has to be provided in the cascade condenser, which leads to
loss of efficiency. In addition, it is found that at low temperatures, superheating (useful
or useless) is detrimental from volumetric refrigeration effect point-of-view, hence in
cascade systems, the superheat should be just enough to prevent the entry of liquid into
compressor, and no more for all refrigerants.
Optimum cascade temperature:
For a two-stage cascade system working on Carnot cycle, the optimum cascade
temperature at which the COP will be maximum, T is given by:
cc,opt
ceopt,[Link]=
(13.18)
where T and T are the evaporator temperature of low temperature cascade and
e c
condenser temperature of high temperature cascade, respectively. Version 1 ME, IIT
Kharagpur 14
For cascade systems employing vapour compression refrigeration cycle, the optimum
cascade temperature assuming equal pressure ratios between the stages is given by:
⎟⎟⎟⎟⎟⎠⎞⎜⎜⎜⎜⎜⎝⎛++=e1c221opt,ccTbTbbbT (13.19)
where b and b are the constants in Clausius-Clayperon equation: TbaPln−=for low
1 2
and high temperature refrigerants, respectively. Version 1 ME, IIT Kharagpur 15
13.7. Auto-cascade systems Ph1 2 3 4 1’2’3’4’Fig.13.6(a) & (b): A two-
stage cascade refrigeration system Evaporator Compressor - ICompressor - II 123 41’
Cascade condenser High temperature cascadeLow temperature cascade2’3’4’
Evaporator High temp. compressor Low temp. compressor
Qc,out Pdischarge suction c e,h
P T T

An auto-cascade system may be considered as a variation of cascade system, in which

a single compressor is used. The concept of auto-cascade system was first proposed by
Ruhemann in 1946. Figure 13.7(a) shows the schematic of a two-stage auto-cascade
cycle and Fig.137(b) shows the vapour pressure curves of the two refrigerants used in
the cycle on D˘hring plot.
In a two-stage auto-cascade system two different working fluids; a low boiling point
(low temperature) refrigerant and a high boiling point (high temperature) refrigerant
are used. The vapour mixture consisting of both these refrigerants is compressed in the
compressor to a discharge pressure (P ). When this high pressure mixture flows
discharge
through the partial condenser, the high temperature refrigerant Partial condenser
Evaporator Condenser Compressor Version 1 ME, IIT Kharagpur Version 1
ME, IIT Kharagpur 17
can condense by rejecting heat (Q ) to the external heat sink, if its partial pressure in
c,out
the mixture is such that the saturation temperature corresponding to the partial pressure
is higher than the external heat sink temperature. Since the saturation temperature of
the low temperature refrigerant is much lower than the external heat sink temperature
at its partial pressure, it cannot condense in the partial condenser, hence, remains as
vapour. Thus it is possible theoretically to separate the high temperature refrigerant in
liquid form from the partial condenser. Next this high temperature, high pressure liquid
is expanded through the expansion valve into the condenser operating at a pressure
P . Due to the expansion of the high temperature refrigerant liquid from P to
suction discharge
P , its temperature drops to a sufficiently low value (T ) so that when the low
suction e,h
temperature, high pressure refrigerant vapour comes in contact with the high
temperature, low pressure refrigerant in the condenser it can condense at a temperature
T . This condensed, high pressure, low temperature refrigerant is then throttled to the
c,l
suction pressure and is then made to flow through the evaporator, where it can provide
the required refrigeration effect at a very low temperature T . Both the high
e
temperature refrigerant from condenser and low temperature refrigerant vapour from
evaporator can be mixed as they are at the same pressure. This mixture is then
compressed in the compressor to complete the cycle. Thus using a single compressor, it
is possible to obtain refrigeration at very low temperatures using the auto-cascade
system. In practice, more than two stages with more than two refrigerants can be used
to achieve very high temperature lifts. However, in actual systems, it is not possible to
separate pure refrigerants in the partial condenser as some amount of low temperature
refrigerant condenses in the partial condenser and some amount of high temperature
refrigerant leaves the partial condenser in vapour form. Thus everywhere in the system,
one encounters refrigerant mixtures of varying composition. These systems are widely
used in the liquefaction of natural gas.
Questions:
1. Multi-evaporator systems are:
a) Widely used when refrigeration is required at different temperatures
b) When humidity control in the refrigerated space is required
c) When the required temperature lift is small
d) All of the above
Ans.: a) and b)
2. Multi-evaporator systems with a single compressor and a pressure reducing valve:
a) Yield very high COPs compared to multi-evaporator, single stage systems
b) Yield lower compressor discharge temperature compared to single stage systems
c) Yield slightly higher refrigeration effect in the low temperature evaporator compared
to single stage systems
d) Yield slightly higher refrigeration effect in the high temperature evaporator
compared to single stage systems
Ans.: d) Version 1 ME, IIT Kharagpur 18
3. Compared to individual expansion valves, multiple expansion valves:
a) Yield higher refrigeration effect in the low temperature evaporator
b) Yield higher refrigeration effect in the high temperature evaporator
c) Yield lower compressor discharge temperature
d) Decrease the quality of refrigerant at the inlet to low temperature evaporator
Ans.: a) and d)
4. Compared to multi-evaporator and single compressor systems, multi-evaporator
systems with multiple compressors:
a) Yield higher COP
b) Decrease maximum cycle temperature
c) Yield higher refrigeration effect
d) All of the above
Ans.: a) and b)
5. In multi-stage systems:
a) The refrigerant used should have high critical temperature and high freezing point
b) The refrigerant used should have high critical temperature and low freezing point
c) There is a possibility of migration of lubricating oil from one compressor to other
d) Operating pressures can be too high or too low
Ans.: b), c) and d)
6. In cascade systems:
a) Different refrigerants are used in individual cascade cycles
b) There is no mixing of refrigerants and no migration of lubricating oil
c) Higher COPs compared to multi-stage systems can be obtained
d) Operating pressures need not be too high or too low
Ans.: a), b) and d)
7. Cascade systems are widely used for:
a) Large refrigeration capacity systems
b) Applications requiring large temperature lifts
c) Applications requiring very high efficiencies
d) All of the above
Ans.: b)
8. For a two-stage cascade system working on Carnot cycle and between low and high
o o
temperatures of –90 C and 50 C, the optimum cascade temperature at which the COP
will be maximum is given by:
o
a) –20 C
o
b) –30 C Version 1 ME, IIT Kharagpur 19
 o
c) –67 C
o
d) 0 C
Ans.: b)
9. In a two stage, auto-cascade system:
a) Two compressors and two refrigerants are used
b) A single compressor and a single refrigerant are used
c) A single compressor and two refrigerants are used
d) Two compressors and a single refrigerant are used
Ans.: c)
10. In a two stage, auto-cascade system:
a) Compressor compresses refrigerant mixture
b) Refrigerants are separated in partial condenser
c) Condensing temperature of low temperature refrigerant at discharge pressure is
higher than the boiling temperature of high temperature refrigerant at suction pressure
d) Condensing temperature of low temperature refrigerant at discharge pressure is
lower than the boiling temperature of high temperature refrigerant at suction pressure
Ans.: a), b) and c)
11. The figure given below shows a multi-evaporator, vapour compression
refrigeration system working with ammonia. The refrigeration capacity of the high
o
temperature evaporator operating at –6.7 C is 5 TR, while it is 10 TR for the low
o
temperature evaporator operating at –34.4 C. The condenser pressure is 10.8 bar.
Assuming saturated conditions at the exit of evaporators and condenser, ammonia
vapour to behave as an ideal gas with a gas constant of 0.4882 kJ/kg.K and isentropic
index (c /c ) of 1.29, and isentropic compression:
p v
a) Find the required power input to compressor in kW
b) Find the required power input if instead of using a single compressor, individual
compressors are used for low and high temperature evaporators.
Use the data given in the table:
 o
T, C
P sat (kPa)
h (kJ/kg)
f
([Link])
hg( kJ/kg)
sat. vapour
-34.4
95.98
44.0
1417
-6.7
331.8
169.1
1455
27.7
1080.0
330.4
1485
Data for Problem 11 -
34.4oC -6.7oC 10.8 bar 5 TR 10
TR Version 1 ME, IIT
Kharagpur 20
Ans.:
a) Single compressor: The P-
h diagram for the above
system is shown below:
The required mass flow rate
through the low temperature
evaporator (m ) is given by:
r,l
m = Q /(h − h ) = (10 X
r,l e,l 7 5
3.517)/(1417 − 330.4) =
0.03237 kg/s
The required mass flow rate through the high temperature evaporator (m ) is given by:
r,h
m =Q /(h − h ) = (5 X 3.517)/(1455 − 330.4) = 0.01564 kg/s Version 1 ME, IIT Kharagpur 21
r,h e,h 6 4
Assuming the refrigerant vapour to behave as an ideal gas, and assuming the variation in specific
heat of the vapour to be negligible, the temperature of the refrigerant after mixing, i.e., at point 1 is
given by:
T = (m .T + m .T )/(m + m ) = 247.6 K
1 r,l 7 r,h 6 r,l r,h
Assuming isentropic compression and ideal gas behaviour, the power input to the compressor,W is
c
given by:
⎥⎥⎥⎦⎤⎢⎢⎢⎣⎡−⎟⎟⎠⎞⎜⎜⎝⎛⎟⎠⎞⎜⎝⎛−=−1PP1kkT.R.mWk1kec1rc
where m is the refrigerant flow rate through the compressor (m = m + m ), R is the gas constant
r r r,l r,h
(0.4882 kJ/kg.K), P and P are the discharge and suction pressures and k is the isentropic index of
c e
compression ( = 1.29).
Substituting these values, the power input to the compressor is found to be: 645h718P32-6.7oC-
34.4oC645h718P32-34.4oC
W = 18.67 kW (Ans.)
c
Since the refrigerant vapour is assumed to behave as an ideal gas with constant specific heat, and the
compression process is assumed to be isentropic, the discharge temperature T can be obtained using
2
the equation:
W = m .C (T – T ) = 18.67 kW Version 1 ME, IIT Kharagpur 22
c r p 2 1
Substituting the values of m , C (=2.1716 kJ/kg.K) and T , the discharge temperature is found to be:
r p 1
o
T = 427.67 K = 153.5 C
2
b) Individual compressors:
The P-h diagram with individual compressors is shown below:
The mass flow rates through evaporators will be same as before.
The power input to low temperature compressor (process 3 to 4), W is given by:
c,l
⎥⎥⎥⎦⎤⎢⎢⎢⎣⎡−⎟⎟⎠⎞⎜⎜⎝⎛⎟⎠⎞⎜⎝⎛−=−1PP1kkT.R.mWk1kec3l,rl,c
substituting the values, we obtain:
W = 12.13 kW
c,l
Similarly, for the high temperature compressor (process 1-2), the power input W is given by:
c,h
3hP7651248
⎥⎥⎥⎥⎦⎤⎢⎢⎢⎢⎣⎡−⎟⎟⎠⎞⎜⎜⎝⎛⎟⎠⎞⎜⎝⎛−=−1PP1kkT.R.mWk1kh,ec1h,rh,c= 2.75 kW
Therefore total power input is given by:
W = W + W = 12.13 + 2.75 = 14.88 kW (Ans.) Version 1 ME, IIT Kharagpur 23
c c,l c,h
The compressor discharge temperatures for the low temperature and high temperature compressor are
found to be:
o
T = 411.16 K = 138.0 C
4
o
T = 347.27 K = 74.10 C
2
Comments:
1. Using individual compressors in place of a single compressor, the power input to the system could
be reduced considerably (≈ 20.3%).
o
2. In addition, the maximum compressor discharge temperature also could be reduced by about 15 C.
3. In addition to this, the high temperature compressor operates at much lower compression ratio,
leading to low discharge temperatures and high volumetric efficiency.
These are the advantages one could get by using individual compressors, instead of a pressure
regulating valve and a single compressor. However, in actual systems these benefits will be
somewhat reduced since smaller individual compressors generally have lower isentropic and
volumetric efficiencies.
4. A cascade refrigeration system shown in the figure given below uses CO as refrigerant for the low-
2
stage and NH3 as the refrigerant for the high-stage. The system has to provide a refrigeration capacity of
o o
10 TR and maintain the refrigerated space at –36 C, when the ambient temperature (heat sink) is at 43 C.
A temperature difference of 7 K is required for heat transfer in the evaporator, condenser and the cascade
condenser. Assume the temperature lift (Tcond-Tevap) to be same for both CO2 and NH3 cycles and find a)
Total power input to the system; b) Power input if the cascade system is replaced with a single stage NH
3
system operating between same refrigerated space and heat sink.
The actual COP of the vapour compression system (COP ) can be estimated using
act
the equation:
Ans.: Since a temperature difference of & K is required for heat transfer, the CO evaporator and NH
2
condenser temperatures are given by:
3
o
T = −36 −7 = -43 C = 230 K
e,CO2
o
T = 43 + 7 = 50 C = 323 K
c,NH3
In the cascade condenser,
T =T +7
c,CO2 e,NH3
Since the temperature lifts of CO2 and NH3 cycles are same,
(T −T ) = (T −T )
c,CO2 e,CO2 c,NH3 e,NH3
From the above 4 equations, we obtain:
T = 280 K
c,CO2
T = 273 K
e,NH3
Substituting the values of temperatures in the expression for actual COP, we obtain:
COP = 3.17, and
CO2
COP = 3.77
NH3
The power input to CO compressor is given by,
2
W =Q /COP = 10 X 3.517 /3.17 = 11.1 kW
c,CO2 e,CO2 CO2
Since the heat rejected by the condenser of CO2 system is the refrigeration load for the evaporator of
NH3 system, the required refrigeration capacity of NH3 system is given by:
Q =Q =Q +W = 46.27 kW
e,NH3 c,CO2 e,CO2 c,CO2
Hence power input to NH3 compressor is given by:
W =Q /COP = 46.27 /3.77 = 12.27 kW
c,NH3 e,NH3 NH3
Therefore, the total power input to the system is given by:
W =W +W = 23.37 kW (Ans.)
[Link] c,CO2 c,NH3
b) If instead of a cascade system, a single stage NH3 is used then, the actual COP of the system is:
⎥⎦⎤⎢⎣⎡−−=265TT1COP85.0COPecCarnotact
where
COPCarnot = Carnot COP
T =Condensing Temp.,
c
Te= Evaporator Temp. Version 1 ME, IIT Kharagpur 24 Version 1 ME, IIT Kharagpur 25
COP = 1.363
NH3,1st
Power input to single stage ammonia system is given by:
W = Q / COP = 35.17/1.363 = 25.8 kW (Ans.)
c,NH3,1st e NH3,1st

Comments:
1) Using a cascade system the power consumption could be reduced by about 9.5 %.
2) More importantly, in actual systems, the compared to the single stage system, the compressors of
cascade systems will be operating at much smaller pressure ratios, yielding high volumetric and
isentropic efficiencies and lower discharge temperatures. Thus cascade systems are obviously
beneficial compared to single stage systems for large temperature lift applications.
3. The performance of the cascade system can be improved by reducing the temperature difference
for heat transfer in the evaporator, condenser and cascade condenser, compared to larger
compressors.