Course code: 20MEXX73

Course Name: Refrigeration & Air Conditioning

Course Category: PEC
L-T-P: 3-0-0
Credits: 3
Unit III Contact Hours:
8
Vapour compression refrigeration: Working principle, essential components of plant,
simple vapor compression refrigeration cycle, Multi pressure systems – multistage
compression, multi evaporator system, Cascade system, use of p – h charts, problems.
System components: Compressors- general classification, comparison, advantages and
disadvantages, Condensers - classification, working, Evaporators - classification,
working, Expansion devices - types, working.

Dr. B. Konda Reddy

Assistant Professor,
Department of Mechanical Engineering,
IIIT RK Valley, RGUKT-AP,
Vempalli, YSR District, Andhra Pradesh-516330.
Vapour Compression Refrigeration:
1. Working Principle:
Vapour compression refrigeration operates based on the phase change of a refrigerant, typically
a fluid with a low boiling point. It utilizes the principles of thermodynamics to transfer heat from
a low-temperature environment to a higher temperature one. The refrigerant undergoes a cyclic
process of compression, condensation, expansion, and evaporation to achieve cooling.
2. Essential Components of a Vapour Compression Refrigeration Plant:
Compressor: It compresses the low-pressure refrigerant vapor into a high-pressure, high-
temperature gas.
Condenser: This component removes heat from the compressed refrigerant, causing it to
condense into a high-pressure liquid.
Expansion Valve or Device: It controls the flow of the liquid refrigerant into the evaporator and
reduces its pressure, leading to a temperature drop.
Evaporator: The low-pressure liquid refrigerant enters the evaporator where it absorbs heat
from the surroundings, causing it to evaporate into a low-pressure vapor.
3. Simple Vapour Compression Refrigeration Cycle:
Compression: The compressor draws in low-pressure refrigerant vapor and compresses it,
increasing its pressure and temperature.
Condensation: The high-pressure, high-temperature refrigerant vapor is then condensed into a
liquid state in the condenser, releasing heat to the surroundings.
Expansion: The high-pressure liquid refrigerant passes through the expansion valve or device,
where its pressure is reduced, causing it to expand and drop in temperature.
Evaporation: The low-pressure, low-temperature refrigerant liquid enters the evaporator and
absorbs heat from the surroundings, turning into a low-pressure vapor, thus completing the
cycle.

Understanding these fundamental components and processes is essential for designing,

operating, and troubleshooting vapour compression refrigeration systems.
Use of P-h Charts:
Pressure-enthalpy (P-h) charts are graphical representations used to analyze and visualize
the thermodynamic properties of refrigerants at different pressures and temperatures. P-h
charts are valuable tools for designing and analyzing refrigeration cycles, aiding in the
selection of appropriate refrigerants, determining cycle performance, and optimizing
system efficiency. They help engineers and technicians understand the state of the
refrigerant at different points in the cycle, facilitating troubleshooting and system
optimization.
Types of Vapour Compression Cycles:

Theoretical Vapour Compression Cycle with dry saturated vapour after compression

Re frigeratin g effect in evaporator h1  h4 h1  h f 3

COP   
Work input to compressor h2  h1 h2  h1
Theoretical vapour compression cycle with wet vapour after compression

Re frigeratin g effect in evaporator h1  h4 h1  h f 3

COP   
Work input to compressor h2  h1 h2  h1
Theoretical vapour compression cycle with superheated vapour after compression:
Theoretical vapour compression cycle with superheated vapour before compression:

Theoretical vapour compression cycle with under-cooling or sub-cooling of the refrigerant:

Actual Vapour Compression Cycle:

The main deviations between theoretical cycle and actual cycle are,
1. The vapour refrigerant leaving the evaporator is in superheated state
2. The compression of refrigerant is neither isentropic nor polytropic
3. The liquid refrigerant before entering the expansion valve is sub-cooled in the condenser
4. The pressure drops in the evaporator and condenser
Effect of Suction Pressure:

Effect of Discharge Pressure:

Improvements in simple saturation cycle:

Simple saturation cycle with flash chamber:

Simple saturation cycle with accumulator or pre-cooler:
Simple saturation cycle with sub-cooling of liquid refrigerant by vapour refrigerant:
Simple saturation cycle with sub-cooling of liquid refrigerant by liquid refrigerant:
Multi-Pressure Systems in Vapour Compression Refrigeration:
Multistage Compression:
In multistage compression systems, the compression of refrigerant occurs in multiple stages
to achieve higher pressures efficiently. Each stage of compression involves a compressor,
where the refrigerant is partially compressed before entering the next stage. Intermediate
cooling between stages may be employed to reduce the work required for compression and
to mitigate temperature rise issues.
Multi-Evaporator System:
A multi-evaporator system consists of a single refrigeration system with multiple
evaporators serving different cooling loads. Each evaporator is connected to the same
compressor and condenser but operates at different temperatures and pressures to suit
various cooling requirements. This system is often used in air conditioning systems with
different zones or in commercial refrigeration applications with multiple display cases.
Cascade System:
A cascade refrigeration system consists of two separate refrigeration cycles operating with
different refrigerants connected through a heat exchanger. The high-temperature
refrigerant cycle (primary loop) condenses at a temperature above the boiling point of the
low-temperature refrigerant used in the secondary loop. Heat exchange in the cascade
condenser transfers heat from the primary loop to the secondary loop, allowing for cooling
at temperatures below the freezing point of the primary refrigerant.
Types of compound vapour compression with intercooler:

1) Two stage compression with liquid intercooler:

2) Two stage compression with water intercooler and liquid sub cooler
3) Two stage compression with water intercooler, liquid sub-cooler and liquid flash chamber
4) Two stage compression with water intercooler, liquid sub cooler and flash intercooler:
5) Three stage compression with water inter coolers
6) Three stage compression with flash chambers:
7) Three stage compression with flash intercoolers:
8) Three stage compression with multiple expansion valves and flash intercoolers:
Types of multiple evaporator and compressor systems:
1) Multiple evaporators at the same temperature with single compressor and expansion valve
2) Multiple Evaporators at Different Temperatures with Single Compressor, Individual
Expansion Valves and Back Pressure Valves
3) Multiple Evaporators at Different Temperatures with Single Compressor, Multiple Expansion
Valves and Back Pressure Valves
4) Multiple Evaporators at Different Temperatures with Individual Compressors and Individual
Expansion Valves
5) Multiple Evaporators at Different Temperatures with Individual Compressors and Multiple
Expansion Valves
6) Multiple Evaporators at Different Temperatures with Compound Compression and
Individual Expansion Valves
7) Multiple Evaporators at Different Temperatures with Compound Compression, Individual
Expansion Valves and Flash Intercoolers
8) Multiple Evaporators at Different Temperatures with Compound Compression, Multiple
Expansion Valves and Flash Intercoolers
Problems:
Complexity: Multi-pressure systems can be more complex in design and operation
compared to single-pressure systems, requiring careful engineering and maintenance.
Energy Consumption: Multistage compression systems may require more energy to
operate due to increased compression stages and associated equipment.
Heat Transfer Issues: In cascade systems, heat transfer across the cascade condenser must
be carefully managed to ensure efficient operation.
Refrigerant Compatibility: The selection of refrigerants for cascade systems must consider
compatibility between the primary and secondary refrigerants to avoid system
inefficiencies or damage.
System Integration: Integrating multiple evaporators or compressors in a multi-evaporator
system requires proper coordination to ensure balanced operation and optimal
performance across all components.

Understanding the intricacies of multi-pressure systems, including multistage compression,

multi-evaporator systems, and cascade systems, is essential for designing and operating efficient
and reliable refrigeration systems across various applications.
System Components: Compressors
1. General Classification:
Reciprocating Compressors: These compressors use a piston-cylinder mechanism to compress
the refrigerant gas. They are suitable for small to medium-sized applications and are commonly
used in household refrigerators and air conditioning systems.
Rotary Compressors: Rotary compressors utilize rotary motion to compress the refrigerant.
Types include rotary vane, scroll, and rotary screw compressors. They are often used in both
residential and commercial air conditioning and refrigeration systems.
Centrifugal Compressors: These compressors use centrifugal force to compress the refrigerant
gas. They are typically used in large-scale industrial applications such as HVAC systems for large
buildings, process cooling, and refrigeration plants.
2. Comparison:
Efficiency: Centrifugal compressors generally offer higher efficiency compared to reciprocating
and rotary compressors, especially at high capacities. Rotary compressors are typically more
efficient than reciprocating compressors.
Size and Footprint: Reciprocating compressors are usually larger and heavier compared to rotary
and centrifugal compressors. Centrifugal compressors tend to have a smaller footprint but
require more space vertically due to their design.
Cost: Reciprocating compressors are often more affordable upfront compared to rotary and
centrifugal compressors. However, operating and maintenance costs may vary depending on
factors such as efficiency and lifespan.
Noise and Vibration: Reciprocating compressors can produce more noise and vibration
compared to rotary and centrifugal compressors, which tend to operate more quietly and
smoothly.
Capacity and Modulation: Centrifugal compressors offer better capacity modulation capabilities
compared to reciprocating and rotary compressors, making them suitable for applications with
varying load requirements.
3. Advantages and Disadvantages:
Reciprocating Compressors:
Advantages: Simple design, cost-effective for small to medium-sized applications, suitable
for high-pressure applications.
Disadvantages: Higher noise and vibration levels, limited capacity modulation, lower
efficiency compared to rotary and centrifugal compressors.
Rotary Compressors:
Advantages: Compact size, lightweight, smoother operation, better efficiency than
reciprocating compressors, suitable for medium-sized applications.
Disadvantages: Limited capacity modulation compared to centrifugal compressors, higher
initial cost than reciprocating compressors.
Centrifugal Compressors:
Advantages: High efficiency at high capacities, lower noise and vibration levels, better
capacity modulation, suitable for large-scale industrial applications.
Disadvantages: Higher initial cost, larger footprint, requires skilled maintenance and
operation, less suitable for low-pressure applications.

Understanding the characteristics, advantages, and disadvantages of different compressor types

is essential for selecting the most suitable option for specific refrigeration and air conditioning
applications, taking into account factors such as capacity requirements, space limitations,
efficiency goals, and budget constraints.
Reciprocating Compressors
Work Done by a Single-Stage, Single Acting Reciprocating Compressor without Clearance Volume
Work done during isothermal compression

Work done by the v1 v

compressor per cycle W  p1v1 ln  2.3 p1v1 log 1  2.3mRT1 log r
v2 v2
Work done during polytropic compression ( pv" = Constant)
 n 1

Work done by the n   p  n
 n T 
W p1v1   2   1  mRT1  2  1
compressor per cycle n 1   p1   n 1  T1 
 
Work done during isentropic compression
  1

Work done by the    p2    
W p1v1     1  mRT2  T1   mc p T2  T1 
compressor per cycle  1   p1    1
 
Power Required to Drive a Single-Stage Reciprocating Compressor
The power required to drive the compressor P W  N, Watts
Where, N=n for single acting compressor and N=2n for double acting compressor
Work Done by Reciprocating Compressor with Clearance Volume

work done by the compressor

 n 1
  n 1

n   p2  n
 n   p2  n 
W p1 v1  v4     1  mRT1     1
n 1   p1   n 1   p1  
   
Volumetric Efficiency of a Reciprocating Compressor

v s v1  v4
v  
v p v1  vc

1/ n
 p2  vc
 v  1  C  C   where , C  clearancefactor 
 p1  v1  vc
Multi-stage Compression

Two-Stage Reciprocating Compressor with Intercooler

Incomplete or imperfect intercooling

Complete or perfect intercooling

Work Done by a Two-Stage Reciprocating Compressor with Intercooler

When the intercooling is incomplete

Total work done per cycle  n 1

  n 1

n   p2  n
 n   p3  n 
W p1v1     1  p2 v2     1
n 1   p1   n 1   p2  
   
 n 1
  n 1

n   p2  n
 n   p3  n 
W mRT1     1  mRT3     1
n 1   p1   n 1   p2  
   
When the intercooling is complete
 n 1 n 1

n   p2  n
 p3  n 
W p1v1        2 
n 1   p1   p2  
 
 n 1 n 1

n   p 2  n  p3  n 
W mRT1        2 
n 1   p1   p2  
 
Minimum Work Required for a Two-Stage Reciprocating Compressor
 n 1 n 1

n   p2  n
 p3  n 
W mR T1    T3    T1  T3 
n  1   p1   p2  
 
When the temperature at the end of cooling in intercooler is fixed
dW n

 T  n 1
0 p2  p1 p3  3 
dp2  T1 
 n 1 n 1

n   p3  2n
 p3  2 n 
W mR T1T3    T1T3    T1  T3 
n 1   p1   p1  
 
For complete or perfect intercooling, T3 = T1 p 2  p1 p3
 n 1

n  p3  2 n
W 2 mRT1    1

n 1  p1  
 
 Hermetic Sealed Compressors
When the compressor and motor operate on the same shaft and are
enclosed in a common
g, they are known as hermetic sealed compressors. These types of
compressors eliminate the
of crankshaft seal which is necessary in ordinary compressors in order
to prevent leakage of
gerant. These compressors may operate on either reciprocating or
rotary principle and may be
ted with the shaft in either the vertical or horizontal position. The
hermetic units are widely
for small capacity refrigerating systems such as in domestic
refrigerators, home freezers and
· w air conditioners. The hermetic sealed compressors have the
following advantages and disadvantages :
The leakage of refrigerant is completely
prevented.
2. It is less noisy.
3. It requires small space because of
compactness.
4. The lubrication is simple as the motor and
compressor operate in a sealed
lubricating oil
Condensers:
Condensers are crucial components in refrigeration and air conditioning systems that facilitate
the transfer of heat from the refrigerant to the surroundings, causing the refrigerant vapor to
condense into a liquid state. Here are the classifications and working principles of condensers:
1. Classification:
Air-Cooled Condensers: Air-cooled condensers transfer heat from the refrigerant to the ambient
air. They typically consist of coils or tubes through which the refrigerant flows, surrounded by
fins to increase surface area for heat exchange. Air-cooled condensers are commonly used in
residential and small commercial air conditioning systems and refrigeration units.
Water-Cooled Condensers: Water-cooled condensers use water as the cooling medium to
remove heat from the refrigerant. They typically consist of a series of tubes or plates through
which the refrigerant flows, surrounded by a shell through which water circulates. Water-cooled
condensers are often used in larger commercial and industrial refrigeration systems where water
is readily available for cooling.
Evaporative Condensers: Evaporative condensers combine the functions of condensation and
cooling in a single unit. They use the evaporation of water to cool the refrigerant and condense
it into a liquid. Evaporative condensers are efficient in hot climates and are commonly used in
large-scale industrial refrigeration and air conditioning systems.
2. Working:
The working principle of a condenser involves the transfer of heat from the refrigerant vapor to
the surroundings, causing the vapor to condense into a liquid state. This process occurs in
several stages:
Refrigerant Entry: The high-pressure, high-temperature refrigerant vapor enters the condenser
from the compressor.
Heat Transfer: As the refrigerant flows through the condenser coils or tubes, heat is transferred
from the refrigerant to the surrounding medium, whether it's air or water.
Condensation: The transfer of heat causes the refrigerant vapor to lose energy and transition to
a liquid state. This process of condensation releases latent heat, which is absorbed by the
surrounding medium.
Liquid Refrigerant Exit: The condensed liquid refrigerant exits the condenser and passes through
the expansion device to the evaporator, where it undergoes further cooling and evaporation.
Cooling Effect: The heat absorbed by the surrounding medium results in a cooling effect, which
helps maintain the desired temperature within the refrigeration or air conditioning system.

By understanding the classifications and working principles of condensers, engineers and

technicians can select the most suitable type of condenser for specific applications, ensuring
efficient heat transfer and optimal performance of the refrigeration or air conditioning system.
Evaporators:
Evaporators play a crucial role in the refrigeration cycle, where they absorb heat from the space
or substance to be cooled, causing the refrigerant liquid to evaporate. Here are the
classifications and working principles of evaporators:
1. Classification:
Bare-Tube Evaporators: Bare-tube evaporators consist of a network of bare tubes through which
the refrigerant flows. Heat exchange occurs between the refrigerant and the surroundings
directly through the tubes. They are simple in design and commonly used in commercial
refrigeration systems.
Finned Evaporators: Finned evaporators enhance heat transfer efficiency by increasing the
surface area available for heat exchange. Thin metal fins are attached to the evaporator tubes,
providing a larger contact area with the surrounding air or substance to be cooled. Finned
evaporators are widely used in air conditioning systems and refrigeration applications where
efficient heat transfer is critical.
Plate Evaporators: Plate evaporators feature a series of plates with refrigerant channels formed
between them. Heat exchange occurs as the refrigerant flows through these channels and
comes into contact with the plates. Plate evaporators are compact and lightweight, making them
suitable for applications with space constraints, such as in refrigerators and small appliances.
Shell and Tube Evaporators: Shell and tube evaporators consist of a bundle of tubes enclosed
within a shell. The refrigerant flows through the tubes while the substance to be cooled
circulates around the shell. This design allows for efficient heat transfer and is commonly used in
industrial refrigeration systems and process cooling applications.
2. Working:
The working principle of an evaporator involves the absorption of heat from the surroundings,
causing the liquid refrigerant to evaporate into a vapor. This process occurs in several stages:
Refrigerant Entry: The high-pressure liquid refrigerant enters the evaporator from the expansion
valve or device.
Heat Absorption: As the refrigerant flows through the evaporator coils or plates, it absorbs heat
from the surroundings, whether it's air, water, or a product to be cooled. This heat transfer
causes the refrigerant to evaporate, lowering its temperature.
Vaporization: The absorbed heat causes the liquid refrigerant to boil and vaporize, transforming
into a low-pressure vapor.
Vapor Exit: The low-pressure vapor exits the evaporator and returns to the compressor to
complete the refrigeration cycle.
Cooling Effect: The heat absorbed by the refrigerant results in a cooling effect in the evaporator
surroundings, such as air or water, effectively lowering the temperature of the desired space or
substance.

By understanding the classification and working principles of evaporators, engineers and

technicians can select the appropriate type of evaporator for specific refrigeration applications,
ensuring efficient heat transfer and optimal performance within the system.
Expansion Devices:
Expansion devices play a critical role in the refrigeration cycle by controlling the flow of
refrigerant from the high-pressure side of the system to the low-pressure side. They create a
pressure drop in the refrigerant, allowing it to undergo a phase change from a high-pressure
liquid to a low-pressure liquid or vapor. Here are the common types and working principles of
expansion devices:
1. Types:
Capillary Tubes: Capillary tubes are simple, inexpensive devices consisting of a long, narrow
tube with a small diameter. They are often made of copper or another suitable material. The
capillary tube is installed between the condenser and the evaporator and acts as a restriction to
the flow of refrigerant. The length and diameter of the capillary tube determine the rate of
refrigerant flow and the pressure drop across the device.
Thermostatic Expansion Valves (TXV): TXVs are widely used expansion devices in refrigeration
and air conditioning systems. They consist of a valve body, a diaphragm or bellows, and an
adjustable superheat spring. The TXV senses the temperature of the refrigerant leaving the
evaporator and adjusts the valve opening accordingly to maintain a desired level of superheat.
This ensures optimal refrigerant flow and prevents liquid refrigerant from entering the
compressor.
Automatic Expansion Valves (AEV): AEVs are similar to TXVs but do not have an external sensing
bulb. Instead, they rely on internal mechanisms to regulate the flow of refrigerant based on
pressure differentials within the valve. AEVs are often used in applications where precise
superheat control is not critical, such as in some commercial refrigeration systems.
2. Working:
Capillary Tubes: The high-pressure liquid refrigerant enters the capillary tube from the
condenser. As it passes through the narrow tube, there is a significant pressure drop, causing the
refrigerant to expand and undergo a phase change to a low-pressure liquid/vapor mixture. The
refrigerant then enters the evaporator at a lower pressure, where it absorbs heat and completes
the refrigeration cycle.
Thermostatic Expansion Valves (TXV): The TXV senses the temperature of the refrigerant
leaving the evaporator coil. When the refrigerant temperature rises above the set superheat
value, the diaphragm or bellows within the TXV expands, opening the valve to allow more
refrigerant flow. Conversely, when the refrigerant temperature decreases, the valve closes to
reduce the flow rate, maintaining the desired level of superheat.
Automatic Expansion Valves (AEV): AEVs regulate the flow of refrigerant based on pressure
differences across the valve. As the pressure in the evaporator decreases due to increased load
or lower ambient temperatures, the valve opens to allow more refrigerant flow. Conversely,
when the pressure in the evaporator increases, the valve closes to reduce the flow rate. AEVs
provide automatic adjustment of refrigerant flow without the need for external sensors.

Understanding the types and working principles of expansion devices is essential for selecting
the appropriate device for a refrigeration or air conditioning system, ensuring efficient operation
and optimal performance throughout the refrigeration cycle.
Thank You