Performance analysis of 404a/508b

Cascade Refrigeration cycle for low

temperature
DEVANSHU PYASI 1*
Student, IV Semester M.E (Heat Power Engineering)

R.C. GUPTA2
Associate Professor

1*, 2 Mechanical Engineering Department, Jabalpur Engineering College Jabalpur. 482001 (India)
1* Corresponding author


Abstract:
This paper presents analytical results of analyzing blends of Hfc refrigerants such as 404a and 508b in Cascade
Refrigeration System. Refrigerant blend 508b is a low boiling refrigerant and advantageous in low stage of
cascade refrigeration system whereas 404a is used in high stage of cascade refrigeration system because of its
high boiling point which is suitable for high temperature circuit. The analysis includes three basic parameters
as :Evaporator temperature(Te),Condenser temperature (Tc), and temperature difference in cascade condenser
(Dt) .These parameters are varied one by one up to a limited range keeping other parameters constant and the
effect of these parameters on system COP , exergetic efficiency, mass flow ratio etc is analyzed. Analysis results
also give the optimum values of the evaporator, condenser and cascade condenser temperature.

Key words: Cascade refrigeration cycle, theoretical analysis, COP, Exergy, 404a, 508b etc.
Introduction
Cascade refrigeration system is a low temperature refrigeration system and is used for very low temperature
range about (-40C to -130C).At such low temperature simple Vapor Compression Refrigeration Cycle (VCRS)
is not efficient due to very high compression ratio that further leads to high discharge problem and low
volumetric efficiencies Whereas, cascade refrigeration is much efficient for such conditions. Cascade
refrigeration cycle is nothing but simply a combination of two VCRS cycles named as low and high temperature
circuit that are combined together by a cascade condenser. This cascade condenser unit act as evaporator for low
temperature circuit and condenser for high temperature circuit, the low temperature circuit uses low boiling
refrigerants such as R23, R744 etc and high temperature uses high boiling point refrigerants such as R717,
R290, R404A, R1270, R507A etc. Various refrigerants have been analyzed in cascade refrigeration system
among which few are CO
2
/Ammonia, Propane/CO
2
, 507A/R23, 404A/CO
2
etc. In the present study theoretical
analysis is done on cascade refrigeration system by using blends of Hfc refrigerants 404a/508b and analysis
results the effect of design and operating parameters on system performance.
Cascade Refrigeration (System Description):
The cascade refrigeration cycle is a combination of two vapor compression cycles which utilizes two different
refrigerants. The primary refrigerant flows from low temperature circuit evaporator to low stage compressor and
condensed in cascade condenser which also acts as evaporator for high temperature circuit. The heat rejected
from condenser of low temperature circuit is extracted by evaporator of high temperature circuit containing
secondary refrigerant then, this secondary refrigerant gets compressed in high stage compressor and finally
condensed to outer atmosphere. The desired refrigerating effect is occurred from evaporator of low temperature
Devanshu Pyasi et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6501
circuit. The temperature difference in cascade condenser is an important design parameter that decides the COP
of the entire refrigeration system.

7 6
Throttling valve W
Comp2
8 5
3 2
Throttling valve W
Comp1
4 1

Figure (1) shows systematic cascade refrigeration cycle with evaporator, condenser and cascade condenser.
Theoretical Analysis:
In present work a parametric study with fixed mass flow rate in low temperature circuit and varying different
parameters such as evaporator temperature, condenser temperature and temperature difference in cascade
condenser have conducted to determine effects of these parameters on system performance. The analysis is done
by making general assumptions so as to simplify the analytical procedure these are as follows:
a) Negligible change in kinetic and potential energy.
b) Isenthalpic expansion of refrigerant in expansion valve.
c) Negligible pressure and heat loss/gain in pipe or other components
d) Compressor process is irreversible and adiabatic.

(Fig:2) represents the (T-S) and (P-h) diagram showing decrease in compressor work and increase in refrigeration capacity for cascade
refrigeration system.
The range of parameters used for system analysis are the evaporating temperature (Te) varies from (-90C to -
70C), Condenser temperature (Tc) varied from (30C to 40C) cascade condenser temperature (T
CAC
) varies
from (-45C to -20C), temperature difference in cascade condenser (Dt) varies from (2C to 10C).Also the
parameters which are kept fixed by varying other parameters are T
E
=-85C, T
C
= 35C, DT=5C,mr
1
=0.2kg/min
.Based on the assumptions mentioned above the equations for mass and energy balance are described for
different components. Also each component is considered as a control volume. Therefore the following
sequence of equations was applied for the analysis of cascade refrigeration cycle:
CONDENSER (T
C
)
EVAPORATOR (T
E
)
T
CAE

CASCADE CONDENSR
Devanshu Pyasi et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6502

Mass balance

mr =
n
mr
out
(1)

Energy balance

Q W + mr
n
- mr
out
= 0 (2)


Heat transfer rate to the cycle in the evaporator:

Q
E
= m
r1
(h1

- h4

) (3)

Total Work input to both compressor:

W
comp1
+ W
comp2
= m
r1
( h
2
- h
1
) + m
r2
( h
6
- h
5
) (4)

Rate of heat transfer in cascade condenser:

Q
CAS
= m
r1
( h
2
- h
3
) = m
r2
( h
5
- h
8
) (5)

Heat rejected by condenser of high temperature circuit:

Q
COND =
m
r2
( h
6
h
7
) (6)

Mass flow ratio is given by equation:


mr2
mr1
=
h2-h3
hS-h8
(7)

Overall COP of the system:

COP =
QE
Wcom1+Wcom2
(8)

COP Of LTC and HTC:
(COP)
L
=
QE
Wccmp1
(9)

(COP)
H
=
Qccs
Wccmp2

(10)

Exergetic Efficiency of the whole system is given


II
=
COP
COPccrnct
(11)
Where, COP
Carnot

=

TE
TC-TE
(12)




Devanshu Pyasi et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6503
Flow Chart for Computational Analysis:

The analysis program is based on mathematical equations. Input parameter are taken Te= (-85C), Tc= (35C),
and DT= (5C) mr1= (0.2kg/min). At the initial stage enthalpies at each point are calculated which depend on
operating temperatures after that the entropies and specific heat are calculated. Using these enthalpies, specific
heat and entropies temperatures and enthalpies at point 2 and 6 are found out, at next step the various values
which are found are used for calculating m
r2
,Qe,Wc1,Wc2,Qcac,Qcond, m
r2
/m
r1
etc. Hence at last final
outcomes comes in form of COP
overall ,
COP
L ,
COP
H,
COP
Carnot
,
II
.




























Result and Discussion : To demonstrate the influence of operating parameters on system COP and Exergy
efficiency different range of variables as discussed above are varied and there effect are studied.

Fig.1 depicts, while varying the low circuit evaporator temperature (T
E
) and keeping other parameters constant
overall COP of the system increases from (0.88 to 1.19) as there is decrease in pressure ratio. Hence
refrigerating effect is increased with decrease in compressor work. Also Exergy efficiency increases with very
small amount from (0.602 to 0.626) with increase in evaporator temperature.

Fig.2 shows the overall COP and Exergy efficiency (N II) both decreases when high temperature circuit
condenser temperature (T
C
) is varied keeping other parameters constant. The COP deteriorates from (1.066 to
0.612) where as exegetic efficiency deteriorates from (0.652 to 0.439).If condenser temperature is varied
increasingly it increases work done on compressors and decreases system COP.

Input parameter
Te, Tc, Tcac, Tcae, m
r1
Calculate enthalpy of points
H
1
, H
3
,H
4
,H
5
,H
7
,H
8
Calculate entropy and sp. heat
S
1
, S
2
, Cp2, S
5
,S
6
,Cp
6

Calculate outlet temperature of
compressors and enthalpies
T
2
, T
6 ,
H
2
, H
6
Calculate
m
r2
,Qe,Wc1,Wc2,Qcac,Qcond,m
r2
/m
r1
Calculate
COP
overall ,
COP
L ,
COP
H,
COP
Carnot
,
II
Stop
Start
Devanshu Pyasi et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6504


Figure:1 Effect of low temperature evaporator(T
E
) COP Figure:2 effect of high stage condenser (Tc) on COP and on
and exergetic efficiency Exergy efficiency
Fig.3 displays the effect of low stage circuit condenser temperature (T
CAC
) on COP and Exergy efficiency. As
the condenser temperature is varied both COP and Exergy efficiency increases up to a certain temperature and
then stared decreasing. Therefore an optimal value of low stage condenser temperature for maximum COP and
Exergy efficiency exists. The maximum COP exists at -25 C and Exergy is at (-30 C).
Fig.4 demonstrates the effect of temperature difference (DT) of cascade condenser on system COP and
exergetic efficiency (N II). As the difference in cascade condenser increases the system cop reduces slightly
with also decrease in exergetic efficiency. Increase in temperature difference (DT) causes increase of
compressor work.



Figure 3 shows effect of varying temperature difference between Figure 4 shows effect of low temperature of cascade
condenser on COP and exergy cascade condenser on COP and Exergy and Exergy
.
Fig.5 depicts the effect of low stage condenser temperature (T
CAC
) on mass flow ratio (m
h
/m
l
). Low stage
condenser temperature is varied keeping other parameters as constant and result shows that mass flow ratio
diminishes from (1.846 to 1.343) as condenser temperature is varied.

0
0.2
0.4
0.6
0.8
1
1.2
1.4
-90 -85 -80 -75 -70
C
O
P
T E (C)
Tc=35c
DT=5c
Tcac=-39c
COP
II
0
0.2
0.4
0.6
0.8
1
1.2
30 35 40 45 50
C
O
P
T
c
(C)
T
E
=-85c
DT=5c
T
CAC
=-39c
COP
II
0
0.2
0.4
0.6
0.8
1
1.2
2 4 6 8 10
C
O
P
DT (c)
Te=-85c
TC=35c
Tcac=-39c
COP
II
0
0.2
0.4
0.6
0.8
1
1.2
-45 -40 -35 -30 -25 -20
C
O
P
Tcac c
Te=-85c
DT=5c
Tc=35c
COP
II
Devanshu Pyasi et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6505


Fig: 5 effect of low stage circuit condenser on mass flow ratio

Conclusion

This work analyzed the overall (COP), Exergy efficiency and mass flow ratio of 404a-508b cascade
refrigeration cycle. Refrigerant selection in cascade system is difficult task as it requires suitable refrigerant in
each circuit thus new combination of Hfc blends is analyzed. From above study following conclusions can be
made:

1) System overall performance (COP) and Exergetic efficiency gets increased by (0.88 to 1.19) and (0.60to
0.626) as the evaporator temperature is varied from (-90C to-70C) while other parameters are kept constant.

2) The system COP decreases by (1.06 to 0.61) and exergetic efficiency deteriorates by (0.65 to0.43) when
condenser temperature of high stage is varied from (30C to 50C) keeping other parameter constant.

3) Both COP and Exergy efficiency first increases up to certain temperature and then decreases when
temperature of lower stage condenser is varied. Thus an optimum values are determined.

4) System COP deteriorates by (0.95 to 0.84) and Exergy by (0.60 to 0.53) when temperature difference of
cascade condenser is varied from (2 to 10).

5) Mass flow ratio is decreased from (1.84 to1.34) when low stage condenser temperature is varied from (-45 to
-20) keeping various other parameter constant.

Nomenclature
COP Coefficient of Performance.
II Exergetic Efficiency.
T
CAC
Temperature of low stage Condenser (cascade condenser).
DT Temperature difference in Cascade Condenser.
M
r1
Mass flow rate in high temperature circuit.
M
r2
Mass flow rate in low temperature circuit.


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nd
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0.5
1
1.5
2
-45 -40 -35 -30 -25 -20
m
h
/
m
l
Tcac
T
E
=-85C
DT=5C
T
C
=35C
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ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6506
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Devanshu Pyasi et al. / International Journal of Engineering Science and Technology (IJEST)
ISSN : 0975-5462 Vol. 3 No. 8 August 2011 6507