ICAER-2015

Effect of inter-stage pressure on the performance of a two stage

refrigeration cycle using inter cooler
Nilesh Purohita1, Dileep Kumar Guptab, Mani Sankar Dasguptaa
a
Birla Institute of Technology and Science, Pilani, Pilani Campus, 333031
b
Department of Mechanical Engineeering, IITRAM, Gujarat (India)

Abstract

Effect of inter-stage pressure on the performance of a two stage refrigeration cycle using inter cooler is studied based on
thermodynamic modelling. Six common refrigerants are selected for the analyses. These are R134a, R22 and R143a as
synthetic refrigerants and propane, carbon dioxide and nitrous oxide as natural refrigerants. The designed input range is -50oC
to -30oC for evaporator temperature and 40oC to 60oC for heat rejection temperature. Three classical relations for estimating
inter-stage pressure in a two stage refrigeration system are selected and the performance is evaluated against optimized inter-
stage pressure corresponding to the best COP. Results show that for trans-critical cycles, the deviation of optimized inter-stage
pressure with the classical ones is considerable, while for sub-critical cycles, COP is very less sensitive to inter-stage pressure.
Further, comprehensive analysis of CO2 based trans-critical refrigeration system is presented for a wider range covering -50oC
to 10oC evaporation temperature and 35oC to 60oC gas cooler outlet temperature. A correlation for estimating optimum inter-
stage and gas cooler pressure for the same is also formulated. With gradual increase in focus towards adoption of natural
refrigerants like CO2, the effect of inter stage pressure is expected to be an important consideration in warmer climatic
condition.
Keywords: Two stage cycle; Inter-stage pressure ;Trans-critical; COP; Inter cooler.

1. Introduction

The performance of a single stage vapour compression cycle deteriorates at high heat rejection and low
evaporation temperatures. Classically this is overcome by employing multi staging. One of the options is to utilize
inter cooling using external fluid between the compression stages to reduce the specific volumes and the discharge
temperatures, which as a consequence reduces the work input to the compressor. Selection of the inter-stage
pressure is crucial for enhancing the performance of such systems. A few thumb rules exist for choosing
approximately the right inter-stage pressure for the subcritical systems [1]. However, such relations do not hold
good for trans-critical cycles [2]. Natural refrigerants like CO2 & N2O has low critical temperature (just above
30oC) and such cycles need to be run as trans-critical, in warm climatic conditions. Moreover, natural refrigerants
such as air, water, ammonia, carbon dioxide, nitrous oxide, isobutene, propane etc. are ecologically safer, have
zero ODP and low GWP and are, therefore, gaining importance [3, 4]. Both synthetic refrigerants (R134a, R22
and R143a) and natural refrigerants (propane, CO2 and N2O) are chosen for the analysis. Some salient properties
of selected refrigerant are listed in Table 1. Among the chosen natural refrigerants, CO2 is in focus for many
researchers. This may be attributed to the many favourable properties of CO2.

Table1. Properties of refrigerants

Refrigerant Type Critical Temperature (o C) Critical Pressure (MPa) ODP GWP
R134a Artificial 101.06 4.05 0 1300
R22 Artificial 96.14 4.99 0.005 1700
R143a Artificial 72.70 3.76 0 4300
Propane Natural 96.74 4.25 0 3
Carbon Dioxide Natural 31.1 7.37 0 1
Nitrous Oxide Natural 36.37 7.24 0 310

In this paper, the effect of inter-stage pressure on the performance of a two stage refrigeration cycle is
investigated for selected refrigerants which operates in sub and trans-critical cycle. The system performance is
evaluated over a range of condensing/gas cooler temperature (40 o C to 60 o C) and evaporator temperature (-50 o

* Corresponding author. Tel.: +91 9950980335.

E-mail address: purohitnilesh89@gmail.com
C to -30o C). Further, finding from our study that trans-critical cycle is more sensitive with respect to inter- stage
pressure and that CO2 as a refrigerant is gaining importance worldwide, the same is studied in more detail. Various
other operating parameters like inter-stage pressure, gas cooler pressure and compressor discharge temperature
for both stages are investigated thoroughly to see their effect on system COP. Finally, two correlations for
estimating optimum gas cooler and inter-stage pressure for the tested range of evaporators (-50oC to 10oC) and
gas cooler outlet temperatures (35oC to 60oC) are presented.

The classical relations from standard literature are invoked to obtain inter-stage pressures and
performance of the cycles are evaluated at these pressures. Further, the performance is compared with the
condition, when the system is operated at that value of inter-stage pressure (Po) which gives maximum COP. The
classical relations used in this study are as listed in equation 1 to 3, obtained from [6 & 7]:

P1=Pevap*Pg (1)
P2=Pevap*Pg*(Tg/Tevap) (2)
P3=Saturation pressure corresponding to temperature, Ts=Tevap*Tg (3)

2. Thermodynamic Modelling

The refrigeration cycle is modelled by employing energy balance across individual cycle components.
Representative P-h diagram for investigated cycles are given in Fig. 1. For both the subcritical and trans-critical
cycles, process 1-2 is first stage compression, process 2-3 is inter cooling at constant pressure, process 3-4 is
second stage compression, process 4-5 is heat rejection at constant pressure, process 5-6 is isenthalpic expansion
and process 1-6 is evaporation. The heat rejection in the subcritical cycles is done using condenser, whereas in
supercritical cycle a gas coolers replace the condensers. The compressor efficiency is assumed as 70% and the
intercooler effectiveness is taken as 80%. For subcritical cycles (R134a, R22, R143a and propane) the intercooler
exit temperature is taken as 5oC above the saturation temperature corresponding to the inter-stage pressure,
whereas in trans-critical cycles (CO2, N2O) inter cooling is done with ambient air at temperature (), which is
taken equal to the gas cooler exit temperature (assuming approach temperature as zero).

Fig. 1 P-h diagrams for two stage refrigeration cycle (a) subcritical cycle (b) supercritical cycle.

The mathematical equations involved in the simulation are:

1 =h2-h1, (Work done in LP Compressor) (4)

2 =h4-h3, (Work done in HP Compressor) (5)
1 = (h2i-h1)(h2-h1), (Efficiency of First Stage Compressor) (6)
2 = (h4i-h3)(h4-h3), (Efficiency of Second Stage Compressor) (7)
e= (T2-T3)(T2-To), (Effectiveness of Inter Cooler) (8)
RE=h1-h6 , (Refrigeration Effect) (9)
COP=RE/(1 +2 ) (10)

The simulation is done using MATLAB and the state point thermodynamic properties are taken
automatically by linking up with REFPROP version 9. Iterative method is employed to find optimum operating
conditions corresponding to the best COP. Published literature [2, 5, 6 & 8] shows that the choice of inter-stage
pressure affects the optimum conditions for refrigeration cycles. Hence, optimization of condensing pressure and
inter-stage pressure are done simultaneously. Further, the performance of the cycle is compared with that
determined from classical relations for calculation of inter-stage pressure.
3. Results and Discussions

The system is simulated for the defined parametric range. Choice of inter-stage pressure is made both by
using classical relations (equation 1-3) and by simultaneously optimizing it along with gas cooler pressure (for
trans-critical cycles P3 inter-stage from equation (3) is not valid to evaluate). The Fig. 2 shows the variation of
inter-stage pressure with condenser/gas cooler exit temperature for various evaporation temperatures. Fig. 3
shows the COP variation for the same conditions.

-50oC Po -40oC Po -30oC Po -50oC P1 -40oC P1 -30oC P1

-50oC P2 -40oC P2 -30oC P2 -50oC P3 -40oC P3 -30oC P3

800 1300
500
R134a 750 R22 1200 R143a
460 700
1100
420 650
1000
380
Pint (kPa)
Pint (kPa)

Pint (kPa)
600
340 900
550
300 800
500
260 450 700
220 400 600
180 350 500
140 300 400
40 45 50 55 60 40 45 50 55 60 40 45 50 55 60
Gas Cooler Outlet TemperatureoC Gas Cooler Outlet TemperatureoC Gas Cooler Outlet TemperatureoC
800 12000 12000
750 Propane 11000 Carbon Dioxide 11000
Nitrous Oxide
700 10000 10000
650 9000 9000
Pint (kPa)

Pint (kPa)

Pint (kPa)
600 8000 8000
550 7000 7000
500 6000 6000
450 5000 5000
400 4000 4000
350 3000 3000
300 2000 2000
40 45 50 55 60 40 45 50 55 60 40 45 50 55 60
o o
Gas Cooler Outlet Temperature C Gas Cooler Outlet Temperature C Gas Cooler Outlet TemperatureoC

Fig. 2 Variation of inter-stage pressure with condenser/gas cooler exit temperatures.

-50oC Po -40oC Po -30oC Po -50oC P1 -40oC P1 -30oC P1

-50oC P2 -40oC P2 -30oC P2 -50oC P3 -40oC P3 -30oC P3

1.9 1.9 1.9
1.7 1.7 R22 1.7 R143a
R134a
1.5 1.5 1.5
1.3 1.3 1.3
COP

COP

COP

1.1 1.1 1.1

0.9 0.9 0.9
0.7 0.7 0.7
0.5 0.5 0.5
0.3 0.3 0.3
40 45 50 55 60 40 45 50 55 60 40 45 50 55 60
o o
Gas Cooler Outlet Temperature C Gas Cooler Outlet Temperature C Gas Cooler Outlet TemperatureoC
1.9 1.9 1.9
1.7 Propane 1.7 Carbon Dioxide 1.7 Nitrous Oxide
1.5 1.5 1.5
1.3 1.3 1.3
COP

COP

COP

1.1 1.1 1.1

0.9 0.9 0.9
0.7 0.7 0.7
0.5 0.5 0.5
0.3 0.3 0.3
40 45 50 55 60 40 45 50 55 60 40 45 50 55 60
o o
Gas Cooler Outlet Temperature C Gas Cooler Outlet Temperature C Gas Cooler Outlet TemperatureoC
Fig. 3 Variation of COP with condenser/gas cooler exit temperatures.
The major findings from the Fig. 2 and Fig. 3 are:
Inter-stage pressure calculated using classical relations are significantly different from the optimum value for
both subcritical and trans-critical cycles for all evaporator temperatures. With increase in evaporator
temperature, the deviation of optimum inter-stage pressure from the classical relations decreases for both
subcritical and trans-critical cycle.
For subcritical cycles, the difference of COP computed from classical relations and optimization schemes is
negligible. The overlapping of COP for all tested values of inter-stage pressures is seen in Fig. 3. Hence,
classical relations are justified in subcritical conditions
For trans-critical cycles appreciable variation in COP with respect to different inter-stage pressure schemes
is observed as compared to sub-critical cycles. This implies that the classical relations for evaluating inter-
stage pressure are not satisfactory for trans-critical cycles.

Among the trans-critical cycles for refrigeration, CO2 cycles are being increasingly used. Owing to this,
we have chosen the same for our further analysis. From the point of view of material strength to withstand high
pressure, the compressor discharge temperature and pressure are another important parameter. Hence, effect of
working pressures on compressor discharge temperatures is also studied. The average ambient temperature
encountered in majority of cities in India is summarized in three distinct temperature zones identified as zone I
with design temperature of 29oC, zone II with design temperature of 40oC and zone III with design temperature
of 45oC [9]. We chose here zone II and zone III for analysis as required CO2 refrigeration system will be trans-
critical in nature. Fig. 4 demonstrates the effect of inter stage and gas cooler pressure on compressor discharge
temperature and system COP. Further, it compares the sensitivity of COP with respect to inter stage and gas cooler
pressure for trans-critical cycle. Evaporator temperature of -30oC and gas cooler outlet temperature of 40oC (zone
II) is considered for plotting Fig. 4.

Second Stage Compressor First Stage Compressor COP

165 0.8 165 0.8

Zone II Zone II

155 0.775 155 0.775

145 0.75 145 0.75

Compressor Discharge Temperature (K)

Compressor Discharge Temperature (K)

135 0.725 135 0.725

COP

COP
125 0.7 125 0.7

115 0.675 115 0.675

105 0.65 105 0.65

Evaporation Temperature= -30oC

Evaporation Temperature= -30oC
Optimum Gas Cooler Pressure= 17 MPa
95 0.625 Optimum Inter Stage Pressure= 9 MPa
95 0.625

85 0.6 85 0.6
6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11 12 13 14 15 16 17 18 19 20 21 22 23
Inter-stage Pressure (MPa) Gas Cooler Pressure (MPa)

Fig 4. Variation of Compressor Discharge Temperature and COP with respect to inter-stage and gas cooler pressures

Major findings from Fig. 4 are as follows:

For a fixed value of evaporation temperature, both the first and second stage compressor discharge
temperatures are found to be within limits for optimal set of working conditions.
Inter stage pressure closer to the optimal condition allows lower discharge temperatures for both the
compression stages and gives higher COP.
The COP of the cycle is less sensitive to inter stage pressure as compared to gas cooler pressure.
Further, investigation on sensitivity of system performance to the gas cooler pressure is required to formulate
some guidelines for cycle operation for the many practical considerations.

Fig. 5 shows the variation of COP with respect to gas cooler pressure for zone II and zone III plotted
corresponding to optimize inter stage pressure. We observe that the slope of the COP vs gas cooler pressure curve
is steeper at lower gas cooler pressure. From practical point of view a safe working zone can be marked out where
the pressure is not too high (practicability from material strength considerations) as well as the COP is almost
near its maxima. In general, for all investigated range of parameters, a pressure range of 10 to 12 MPa forms the
safe zone near to optimum working pressure range with optimized inter-stage pressure for better performance of
compressors.

-50oC -40oC -30oC -20oC -10oC 0oC 10oC

3 3

2.8 Zone II, 40oC 2.8 Zone III, 45oC

2.6 2.6

2.4 2.4

2.2 2.2

2 2

1.8 1.8
COP

COP
1.6 1.6

1.4 1.4

1.2 1.2

1 1

0.8 0.8

0.6 0.6

0.4 0.4
9 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
Gas Cooler Pressure (MPa) Gas Cooler Pressure (MPa)

Fig. 5 Variation of COP with respect gas cooler pressures for zone II and zone III

Fig. 6 shows the comparison of performance of two stage and single stage cycle for three evaporation
temperatures (-50, -20 & 10). For this set of figure, optimized inter stage pressure is taken for two stage cycle.
System COP, optimum gas cooler pressure and corresponding compressor discharge temperature are separately
plotted illustrating the pros and cons of multi staging. It is clear from the figure that COP is higher for two stage
cycle as compared to single stage for full range of investigation. However, single stage cycle offers lower optimal
discharge pressure. At the same time, two stage cycle is found to have lower compressor discharge temperature
which allows better compressor performance.

3.9
3.5
3.1 - 50 oC Two Stage

2.7 - 50 oC Single Stage

2.3 - 20 oC Two Stage

COP

1.9 - 20 oC Single Stage

1.5 10 oC Two Stage

1.1 10 oC Single Stage

0.7
0.3
35 40 45 50 55 60
Gas Cooler Outlet Temperature (oC)
Compressor Discharge Temperature (oC)

24 320
Optimum Gas Cooler Pressure (MPa)

22 290

20 260
230
18
200
16
170
14
140
12 110
10 80
8 50
35 40 45 50 55 60 35 40 45 50 55 60
Gas Cooler Outlet Temperature (oC) Gas Cooler Outlet Temperature (oC)

Fig. 6 Performance comparison of two stage and single stage cycle for CO2 based refrigeration system
 Two correlations for optimal values of inter-stage and gas cooler pressures for CO2 based two stage cycle
are formulated using Minitab. Equations 11 and 12 shows the correlation. Design of experiments is used to limit
the number of simulated experiments for this statistical analysis. Both these correlations are valid for the entire
range of investigation with R2 (correlation coefficient) value of 0.99.

Pint= 1752 + (25.6Tevap) + (141.7Tg) - (0.1389Tevap2 ) + (0.48Tg2 ) (11)

Pg= 4046 + (81.9Tevap) + (16.8Tg) + (0.347Tevap2 ) + (3.6Tg2 ) - (2.667TevapTg) (12)

4. Conclusions

The effect of inter-stage pressure on the performance of two stage cycle performance is studied. Various
schemes for selecting the inter-stage pressure are compared along with the optimization of the same for maximum
COP. Further, effect of inter stage pressure and compressor outlet pressure in trans-critical CO2 based cycle is
studied in detail. The following are major conclusion from the research:
For sub-critical cycles, the existing classical relations for estimating inter-stage pressure are satisfactory and
gives near optimum COP.
For trans-critical cycles the use of classical relations for estimating inter-stage pressure do not give optimum
COP. The inter-stage pressure needs to be simultaneously optimized with heat rejection (gas cooler) pressure.
Both inter-stage and gas cooler pressure in a trans-critical cycle affect system performance while gas cooler
pressure has a dominant effect.
Increase in COP is observed with increase in evaporator temperature. However, the rate of change of COP
with respect to gas cooler pressure is not uniform. It dominates between 10-12 MPa for zone II and zone III.
This working range is identified and prescribed as safe working conditions for near optimum operation with
practical considerations.
Comparison between CO2 based two stage inter cooler and single stage cycle shows that better performance
is obtained for the former cycle. While, optimal gas cooler pressure is higher for two stage cycle, the
compressor discharge temperature is lower offering better performance from practical point of view also.
Correlations have been formulated for estimating optimum inter-stage and gas cooler pressure for tested range
of parameters. COP of CO2 as refrigerant in trans-critical cycle is found to be between 0.4-3.7 for the
investigated cases.

5. Future Scope

In near future, use of natural refrigerants is expected to increase and COP of such system will be an issue
of concern particularly for warm weather condition operation. This study should be beneficial for design and
control of multistage compression system for trans-critical cycles. The future scope for research lies in
investigating the trans-critical cycle incorporating real time constraints like approach temperature, pressure drop
in heat exchangers, heat transfer in compression and expansion devices etc. Further, scope lies in investigating
other multi staging schemes like flash gas bypass, parallel compression etc. Integration of work recovery
expander, sub coolers and other possible devices at intermediate points in the cycle for COP improvement may
be another extension of this work.

6. Acknowledgement

Author will like to acknowledge partial financial support received from the host organization, BITS
Pilani, India & Government of India under research grant No: DST/TSG/NTS/2012/19-G.

Nomenclature

Evaporator pressure (kPa) Efficiency of compressor

Condenser/Gas cooler pressure (kPa) e Effectiveness of inter cooler
Evaporator temperature (oC) RE Refrigeration effect (KJ/Kg)
Condenser/Gas cooler outlet temperature (oC) COP Coefficient of performance
Intermediate temperature (oC) h Specific enthalpy (KJ/Kg)
Inter stage Pressure (kPa)
LP Low Pressure Subscripts
WD Work required by compressor (KJ/Kg) i isentropic
HP High Pressure
Ambient temperature (oC)
7. References

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