Lesson 3
Lesson 3
INSTITUTE OF TECHNOLOGY
HAWASSA UNIVERSITY
Part 1 – Refrigeration
1.3. Vapor compression refrigeration cycles
1
Refrigeration cycle
• A refrigeration system is a combination of components, equipment,
and piping, connected in a sequential order to produce the
refrigeration effect. Refrigeration systems that provide cooling for
air conditioning are classified mainly into the following categories:
A. Vapor compression systems. In these systems, refrigeration is carried out
through compression of refrigerant by a compressor(s). Vapor compression
is often called mechanical refrigeration, that is, refrigeration by
mechanical compression.
B. Absorption systems. In an absorption system, the refrigeration effect is
produced by means of thermal energy input.
C. Gas expansion systems. In an air or other gas expansion system, air or
gas is compressed to a high pressure by compressors. It is then cooled by
surface water or atmospheric air and expanded to a low pressure. Because
the temperature of air or gas decreases during expansion, a refrigeration
effect is produced.
2
REFRIGERATORS AND
HEAT PUMPS
The transfer of heat from a low-temperature
region to a high-temperature one requires special
devices called refrigerators.
Refrigerators and heat pumps are essentially the
same devices; they differ in their objectives only.
The objective of a refrigerator is to remove heat (QL) from the cold medium;
The objective of a heat pump is to supply heat (QH) to a warm medium.
3
1.3. Vapor Compression
Refrigeration System
(VCRS)
• Vapor compression refrigeration systems are the most
commonly used among all refrigeration systems.
• In a vapor compression refrigeration system, refrigeration is
obtained as the refrigerant evaporates at low temperatures.
• Before the actual cycle is discussed and analyzed, it is
essential to find the upper limit of performance of vapor
compression cycles.
• This limit is set by a completely reversible cycle.
4
The Carnot refrigeration cycle
• Carnot refrigeration cycle is a completely reversible cycle.
• Hence is used as a model of perfection for a refrigeration cycle
operating between a constant temperature heat source and sink.
• It is used as reference against which the real cycles are
compared.
• As shown in Fig. the basic Carnot refrigeration system for pure
vapor consists of four components: compressor, condenser,
turbine and evaporator.
• Refrigeration effect (q4-1 = qe) is obtained at the evaporator.
5.
Figure. Schematic of a Carnot refrigerator and T-s diagram
of the reversed Carnot cycle.
6
• The low temperature, low pressure vapor is compressed isentropically in the
compressor to the temperature Tc.
• The refrigerant pressure increases from Pe to Pc during the compression
process (process 1-2) and the exit vapor is saturated.
• Next the high pressure, high temperature saturated refrigerant undergoes the
process of condensation in the condenser (process 2-3).
• The high pressure saturated liquid then flows through the turbine
and undergoes isentropic expansion (process 3-4).
• During this process, the pressure and temperature fall from Pc,Tc to Pe, Te.
• This low temperature and low pressure liquid-vapor mixture then enters the
evaporator completing the cycle.
7
• Thus as shown in Fig. the cycle involves two isothermal heat
transfer processes (processes 4-1 and 2-3) and two isentropic work
transfer processes (processes 1-2 and 3-4).
• All the processes are both internally as well as externally reversible,
i.e., net entropy generation for the system and environment is zero.
• Applying first and second laws of thermodynamics to the Carnot
refrigeration cycle,
8
now for the reversible, isothermal heat transfer processes 2-3 and 4-
1, we can write:
9
Fig. Carnot refrigeration cycle represented in T-s plane
• It can be seen from the above expression that the COP of a Carnot refrigeration
system increases as the evaporator temperature increases and condenser
temperature decreases.
• This can be explained very easily with the help of the T-s diagram
10
• The reversed Carnot cycle is the most efficient refrigeration cycle operating between TL
and TH.
• However, it is not a suitable model for refrigeration cycles since processes 2-3 and 4-1
are not practical because
• Process 2-3 involves the compression of a liquid–vapor mixture, which requires a
compressor that will handle two phases, and process 4-1 involves the expansion of
high-moisture-content refrigerant in a turbine.
• Using a turbine and extracting work from the system during the isentropic expansion
of liquid refrigerant is not economically feasible.
Fig. Schematic of a
Carnot refrigerator
and T-s diagram of
the reversed Carnot
cycle.
11
• One way of achieving dry compression in Carnot refrigeration
cycle is to have two compressors –one isentropic and one
isothermal as shown in Fig. below.
14
THE IDEAL VAPOR-COMPRESSION REFRIGERATION CYCLE
The vapor-compression refrigeration cycle is the ideal model for refrigeration systems.
Unlike the reversed Carnot cycle, the refrigerant is vaporized completely before it is
compressed and the turbine is replaced with a throttling device.
17
• The heat extraction (evaporation) process is reversible for both
the Carnot cycle and VCRS cycle.
•Hence the refrigeration effect is given by:
For Carnot refrigeration cycle (1-2’’-3-4’):
20
• Since the heat rejection increases and refrigeration effect
reduces when the Carnot cycle is modified to standard VCRS
cycle, the net work input to the VCRS increases compared to
Carnot cycle.
The net work input in case of Carnot and VCRS cycles are given
by:
21
22
The ideal vapor-compression refrigeration cycle involves an irreversible
(throttling) process to make it a more realistic model for the actual systems.
Replacing the expansion valve by a turbine is not practical since the added benefits cannot
justify the added cost and complexity.
Steady-flow
energy balance
An
ordinary
household The P-h diagram of an ideal vapor-
refrigerator. compression refrigeration
cycle.
23
Analysis of standard vapor compression refrigeration
system
• A simple analysis of standard vapor compression refrigeration
system can be carried out by assuming a) Steady flow; b)
negligible kinetic and potential energy changes across each
component, and c) no heat transfer in connecting pipe lines.
The steady flow energy equation is applied to each of the four
components.
Evaporator: Heat transfer rate at evaporator or refrigeration
capacity Qe is given by
24
25
• At any point in the cycle, the mass flow rate of refrigerant mr
can be written in terms of volumetric flow rate and specific
volume at that point, i.e.,
26
Use of Pressure-enthalpy (P-h) charts:
27
Actual Vapor-compression Refrigeration Cycle
An actual vapor-compression refrigeration cycle differs from the ideal one in
several ways, owing mostly to the irreversibility that occur in various
components, mainly due to fluid friction (causes pressure drops) and heat
transfer to or from the surroundings.
The COP decreases as a result of irreversibility. DIFFERENCES
-Non-isentropic
compression
-Superheated vapor at
evaporator exit
-Sub cooled liquid at
condenser exit
-Pressure drops in
condenser and
evaporator
31
• As a result, an optimum evaporator temperature exists at
which the volumetric work of compression reaches a maximum.
32
Modifications of the cycle
Subcooling and superheating
• It is possible to cool the refrigerant liquid in the condenser to a
few degrees lower than the condensing temperature by adding
extra area for heat transfer.
• In such a case, the exit condition of the condenser will be in
the subcooled liquid region. Hence this process is known as
subcooling.
Table Advantage and limitations of subcooling
33
• On the other hand, if the superheating of refrigerant takes
place due to heat transfer with the refrigerated space (low
temperature heat source) then it is called as useful
superheating.
• On the contrary, if the refrigerant vapor to become superheated
by exchanging heat with the surroundings as it flows through
the connecting pipelines. It is called as useless superheating.
Table Advantage and Limitations of super heating
34
Figure Modifications by Subcooling and superheating
Use of liquid-suction heat exchanger
• Some refrigeration systems use a liquid-to-suction heat
exchanger, LSHX, a counter flow heat exchanger which
subcools the liquid from the condenser with suction vapor
coming from the evaporator.
35
• Saturated liquid at point 3 coming from the condenser is
cooled to point 4 by means of vapor at point 6 being heated to
point 1. from heat balance,
36
Actual VCRS systems
• The cycles considered so far are internally reversible and no
change of refrigerant state takes place in the connecting
pipelines. However, in actual VCRS several irreversibilities
exist. These are due to:
– Pressure drops in evaporator, and condenser
– Pressure drop across suction and discharge valves of the compressor
– Heat transfer in compressor
– Pressure drop and heat transfer in connecting pipe lines
37
Fig. Actual VCRS cycle on P-h and T-s diagrams
38
• From performance point of view, the pressure drop in the
evaporator, in the suction line and across the suction valve has a
significant effect on system performance.
• This is due to the reason that as suction side pressure drop
– Increases the specific volume at suction,
– Increases the compression ratio
– Discharge temperature increase.
• All these effects lead to reduction in system capacity, increase in
power input and also affect the life of the compressor due to higher
discharge temperature.
• Hence this pressure drop should be as small as possible for good
performance.
• The pressure drop depends on
– The refrigerant velocity
– Length of refrigerant tubing and layout (bends, joints etc.).
39
40
41
Multi-Stage Vapor Compression Refrigeration
Systems
42
• For example, in frozen food industries the required evaporator
can be as low as –40oC.
• 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. below shows the effect of decreasing
evaporator temperatures on T-s and P-h diagrams.
43
• It can be seen from the T-s diagrams that for a given condenser
temperature, as evaporator temperature decreases:
44
Fig. (a): Effect of evaporator temperature on cycle
performance (T-s diagram)
45
Fig.1 (b): Effect of evaporator temperature on
cycle performance (P-h diagram)
46
• 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 up to an evaporator
temperature of –30oC.
• A two-stage system is used up to –60oC and a three-stage
system is used for temperatures below –60oC.
47
• Apart from high temperature lift applications, multi-stage
systems are also used in applications requiring refrigeration at
different temperatures.
48
• 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.
49
Flash gas removal using flash tank
55
Multi-stage system with flash gas removal and
•intercooling
Figures below a two-stage vapor compression
show refrigeration
system with
Flash gas removal using a flash tank, and
Intercooling of refrigerant vapor a water-cooled
by exchanger and flash tank. heat
The performance of this system can be obtained easily by
applying mass and energy balance equations to the individual
components.
56
57
58
From mass and energy balance of the flash tank:
59
From mass and energy balance across low-stage compressor,
Compressor-I:
61
From mass and energy balance across condenser:
From the above set of equations, it can be easily shown that for
the
flash tank:
62
The above system offers several advantages,
63
Multi-Evaporator And Cascade Systems
•As mentioned above, there are many applications where
refrigeration is required at different temperatures.
•For example, in a typical food processing plant, cold air may
be required at –30oC for freezing and at +7oC for cooling of
food products or space cooling.
•Several multi-evaporator combinations are possible in
practice. Some of the most common ones are discussed below.
1. Individual evaporators and a single compressor with a
pressure-reducing valve
1. Individual expansion valves:
Figures below show system schematic and P-h diagram of a
multi-evaporator system that uses two evaporators at two
different temperatures and a single compressor.
64
65
Multi-evaporator system with single compressor and
individual expansion valves
66
The COP of the above system is given by:
67
Enthalpy at point 1 (inlet to compressor) is obtained by applying mass and
energy balance to the mixing of two refrigerant streams, i.e.,
68
Multi-evaporator system with single compressor and
multiple expansion valves
69
The COP of this system is given by:
70
Enthalpy at point 1 (inlet to compressor) is obtained by applying mass and
energy balance to the mixing of two refrigerant streams, i.e.,
h1
74
• mII is the mass flow rate of refrigerant through the high-stage
compressor
• mII 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:
energy balance:
75
3.Multi-evaporator system with individual compressors and multiple
expansion valves
• Figures below 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:
79
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 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.
80
Fig. A two-stage cascade refrigeration system
81
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.
ii. Migration of lubricating oil from one compressor to the other is prevented
Optimum cascade temperature:
where Te and Tc are the evaporator temperature of low temperature cascade and
condenser temperature of high temperature cascade, respectively.
82
Cascading
improves the
COP of a
refrigeration
system.
Some systems
use three or
four stages of
cascading.
83