MULTI-STAGE REFRIGERATION SYSTEM
Learning Outcomes:
By the end of the lecture, students should be able to:
1. Explain the need for multi-stage refrigeration systems.
2. Differentiate between two-stage and cascade systems.
3. Describe the components and working principles.
4. Perform performance calculations (COP, power, mass flow).
5. Solve design-related problems on multi-stage refrigeration.
1. Introduction
A multi-stage refrigeration system is used when a very low evaporator temperature is required, and a
single-stage system becomes inefficient or impractical. By dividing the compression process into
multiple stages, we can:
Reduce compressor work
Improve COP (Coefficient of Performance)
Prevent excessively high discharge temperatures
Manage pressure ratios effectively
Applications:
Cryogenic cooling
Food freezing
Air separation
Chemical processing
Liquefied gases (ammonia, CO₂, etc.)
2. Types of Multi-Stage Systems
(A) Two-Stage Compression with Flash Gas Removal (Intercooling)
Components:
o LP Compressor (Low-Pressure Stage)
o HP Compressor (High-Pressure Stage)
o Flash Intercooler (Removes flash gas between stages)
o Expansion Valves (Throttling devices)
o Evaporator & Condenser
Process Flow:
1. Refrigerant enters LP Compressor (C₁) and is compressed to an intermediate pressure.
2. Discharge from C₁ enters the Flash Intercooler (FIC), where it mixes with expanded
refrigerant.
3. Saturated vapor from FIC goes to HP Compressor (C₂) for final compression.
4. Liquid refrigerant from FIC expands into the evaporator.
Note: The refrigerant is compressed in two stages:
1. From evaporator pressure to an intermediate pressure.
2. From intermediate to condenser pressure.
3. Intercooler reduces temperature between stages → increases efficiency.
where
Pe = evaporator pressure,
Pc = condenser pressure.
Intercooling is beneficial because it reduces compressor work, decreases discharge
temperature, and increases COP.
(B) Two-Stage Compression with Liquid Subcooler
Uses a subcooler instead of a flash intercooler.
More efficient but requires an additional heat exchanger.
(C) Cascade Refrigeration System
Uses two separate refrigerant cycles (high & low temp).
Connected via a heat exchanger (cascade condenser).
Used for very low temperatures (below -60°C).
Each stage uses a different refrigerant suited to its temperature range.
High-temperature circuit (HTC) → e.g. R-134a
Low-temperature circuit (LTC) → e.g. R-23 or CO₂
Heat exchanger (cascade condenser/evaporator) connects the two stages.
3. Key Variables & Equations
(A) Pressure & Temperature Definitions
P₁ = Evaporator Pressure (Lowest)
P₂ = Intermediate Pressure (Flash Intercooler Pressure)
P₃ = Condenser Pressure (Highest)
T₁ = Evaporator Temperature
T₂ = Intermediate Temperature
T₃ = Condenser Temperature
(B) Mass Flow Rates
ṁ₁ = Mass flow rate in LP stage (kg/s)
ṁ₂ = Mass flow rate in HP stage (kg/s)
ṁ₃ = Mass flow rate through evaporator (kg/s)
(C) Work & Heat Transfer
W₁ = Work done by LP Compressor (kW)
W₂ = Work done by HP Compressor (kW)
Qₑ = Refrigeration Effect (kW)
Qc = Heat Rejected in Condenser (kW)
(D) Coefficient of Performance (COP)
COP = Qe / Wtotal = Qe / W1+W2
4. Sample Problem: Two-Stage Compression with Flash Intercooler
Problem Statement:
A two-stage refrigeration system uses R-134a with a flash intercooler.
Evaporator Temp (T₁) = -30°C
Condenser Temp (T₃) = 40°C
Refrigeration Capacity (Qₑ) = 50 kW
Flash Intercooler Pressure (P₂) = Intermediate Pressure (P₂ = √(P₁ × P₃))
Find:
1. Intermediate Pressure (P₂)
2. Mass flow rates (ṁ₁, ṁ₂, ṁ₃)
3. Total Compressor Work (W₁ + W₂)
4. COP
Solution Steps:
(1) Find Pressures (P₁, P₂, P₃)
From R-134a tables:
o At T₁ = -30°C, P₁ (Evaporator) = 84.37 kPa
o At T₃ = 40°C, P₃ (Condenser) = 1016.3 kPa
Intermediate Pressure (P₂) = √(P₁ × P₃) = √(84.37 × 1016.3) ≈ 292.5 kPa
(2) Determine Enthalpies
After Evaporator (Point 1):
o h₁ (saturated vapor at -30°C) = 236.53 kJ/kg
After LP Compressor (Point 2):
o Isentropic compression to P₂ = 292.5 kPa → h₂ ≈ 270 kJ/kg
Flash Intercooler Exit (Point 3):
o Saturated liquid at P₂ → h₃ = 94.02 kJ/kg
o Saturated vapor at P₂ → h₃' = 251.88 kJ/kg
After HP Compressor (Point 4):
o Isentropic compression to P₃ = 1016.3 kPa → h₄ ≈ 290 kJ/kg
After Condenser (Point 5):
o h₅ (saturated liquid at 40°C) = 108.26 kJ/kg
(3) Mass Flow Rate Calculations
ṁ₃ (Evaporator flow) = Qₑ / (h₁ - h₅) = 50 / (236.53 - 108.26) ≈ 0.39 kg/s
ṁ₂ (HP Compressor flow) = ṁ₃ × (h₃' - h₅) / (h₃' - h₃) ≈ 0.39 × (251.88 - 108.26) / (251.88 - 94.02)
≈ 0.45 kg/s
ṁ₁ (LP Compressor flow) = ṁ₂ ≈ 0.45 kg/s
(4) Compressor Work
W₁ (LP Compressor) = ṁ₁ × (h₂ - h₁) = 0.45 × (270 - 236.53) ≈ 15.06 kW
W₂ (HP Compressor) = ṁ₂ × (h₄ - h₃') = 0.45 × (290 - 251.88) ≈ 17.15 kW
Total Work = W₁ + W₂ ≈ 32.21 kW
(5) COP Calculation
COP = Qe/Wtotal = 50 kW/32.21kW ≈ 1.55
5. Advantages of Multi-Stage Systems
✔ Lower compressor discharge temperatures (prevents oil breakdown)
✔ Higher COP compared to single-stage at very low temps
✔ Better pressure ratio management (avoids excessive compression ratios)
✔ Flexibility in refrigerant selection (e.g., cascade systems)
6. Conclusion
Multi-stage refrigeration systems are essential for low-temperature applications (e.g., industrial
freezing, cryogenics). By using intercooling or cascade systems, we achieve higher efficiency and better
temperature control.
Further Practice Problems:
1. Repeat the above problem using R-404A.
2. Compare COP of single-stage vs. two-stage at -50°C evaporator temperature.
3. If compressor 1 discharges 8 bar and compressor 2 discharges 12 bar, find intermediate pressure
if evaporator = 4 bar.
4. R-22 system operates between −20°C (evaporator) and 40°C (condenser). Assume two-stage
compression with intercooling. Determine the ideal COP if work per stage is equal.
