CASCADE REFRIGERATION SYSTEM

The cascade refrigeration system is a freezing system that uses two kinds of
refrigerants having different boiling points, which run through their own independent
freezing cycle and are joined by a heat exchanger. The schematic view and the P-h
diagram of this system are shown above. This system is employed to obtain
temperatures of -40 to -80C or ultra-low temperatures lower than them. At such ultralow temperatures, a common single-refrigerant two-stage compression system limits the
low-temperature characteristics of the refrigerant to a considerably poor level, making
the system significantly inefficient. The efficiency is improved by combining two kinds of
refrigerants having different temperature characteristics.
This system has the following advantages compared to a two-stage
compression system:
1. Energy is saved because the system allows use of refrigerants that have suitable
temperature characteristics for each of the higher-temperature side and the lowertemperature side.
2. It allows stable ultra-low-temperature operation.
3. The running cost is inexpensive.
4. Repair is easy.
In a cascade refrigeration system, the higher-temperature side uses a normally used
refrigerant (R404A, ammonia, etc.), and the lower-temperature side uses R23, which is
an HFC refrigerant.
Among ammonia/CO2 systems, which are natural refrigerant systems, those that have
a compressor on the CO2 side as well fall into the category of the cascade refrigeration
system.

MULTI PRESSURE REFRIGERATION SYSTEM

A multi-pressure system is a refrigeration system that has two or more low-side

pressures. The low-side pressure is the pressure of the refrigerant between the
expansion valve and the intake of the compressor. A multi-pressure system is
distinguished from the single-pressure system which has but one low-side pressure.
Removal of Flash Gas
A savings in the power requirement of a refrigeration system results if the flash gas that
develops in the throttling process between the condenser and the evaporator is
removed and recompressed before complete expansion. The vapor is separated from
the liquid by an equipment called the Flash Tank. The separation occurs when the
upward speed of the vapor is low enough for the liquid particles to drop back into the
tank. Normally, a vapor speed of less than 1m/sec will provide adequate separation.
Inter-cooling
Inter-cooling between two stages of compression reduces the work of compression per
kg of vapor. Inter-cooling in a refrigeration system can be accomplished with a watercooled heat exchanger or by using refrigerant. The water-cooled intercooler may be
satisfactory for two-stage air compression, but for refrigerant compression the water is
not usually cold enough. The alternate method uses the liquid refrigerant from the
condenser to do the inter-cooling. Discharge gas from the low stage compressor
bubbles through the liquid in the intercooler. Refrigerant leaves the intercooler as
saturated vapor. Inter-cooling with liquid refrigerant will usually decrease the total power
requirement when ammonia is the refrigerant but not when R-12 or-22 is used.

STEAM JET REFRIGERATION SYSTEM

This system uses the principle of boiling the water below 1000 C. If the pressure
on the surface of the water is reduced below atmospheric pressure, water can be made
boil at low temperatures. Water boils at 60C, when the pressure on the surface is 5 cm
of Hg and at 100C, when the pressure is 6.5 cms of Hg. The very low pressure or high
vacuum on the surface of the water can be maintained by throttling the steam through
jets or nozzles. The general arrangement of the system is shown in the Fig.6.8.
Consider a flash chamber contains 100 kg of water. If suddenly 1 kg of water is
removed by boiling, as pressure is reduced due to throttling of steam through nozzles.
Approximately 2385 kJ of heat will be removed from the water, which is equivalent to
heat of evaporation of water. The fall in temperature of the remaining water will be,
Q m C dT = p
dT =

2385
=5.7
994.187

Evaporating one more kg of water reduces the remaining water temperature by

5.70C further. Thus by continuing this process, the remaining water can be made to
freeze. Water is the refrigerant used in the steam jet refrigeration system. As water
freezes at 00C, then either refrigeration has to be stopped or some device is required to
pump the ice.
Operation:
High pressure steam is supplied to the nozzle from the boiler and it is expanded.
Here, the water vapor originated from the flash chamber is entrained with the high
velocity steam jet and it is further compressed in the thermo compressor. The kinetic

energy of the mixture is converted into static pressure and mass is discharged to the
condenser. The condensate is usually returned to the boiler. Generally, 1% evaporation
of water in the flash chamber is sufficient to decrease the temperature of chilled water to
60C. The chilled water in the flash chamber is circulated by a pump to the point of
application. The warm water from the load is returned to the flash chamber. The water is
sprayed through the nozzles to provide maximum surface area for cooling. The water,
which is splashed in the chamber and any loss of cold water at the application, must be
replaced by makeup water added to the cold water circulating system.
Advantages:
a) It is flexible in operation; cooling capacity can be easily and quickly changed.
b) It has no moving parts as such it is vibration free.
c) It can be installed out of doors.
d) The weight of the system per ton of refrigerating capacity is less.
e) The system is very reliable and maintenance cost is less.
f) The system is particularly adapted to the processing of cold water used in
rubber mills,, distilleries, paper mills, food processing plants, etc.
g) This system is particularly used in air-conditioning installations, because of
the complete safety of water as refrigerant and ability to adjust quickly to load
variations and no hazard from the leakage of the refrigerant.
Disadvantages:
a) The use of direct evaporation to produce chilled water is usually limited as
tremendous volume of vapor is to be handled.
b) About twice as much heat must be removed in the condenser of steam jet per
ton of refrigeration compared with the vapor compression system.
c) The system is useful for comfort air-conditioning, but it is not practically
feasible for water temperature below 40.

ABSORPTION REFRIGERATION SYSTEM

The vapor absorption refrigeration system comprises of all the processes in the
vapor compression refrigeration system like compression, condensation, expansion and
evaporation. In the vapor absorption system the refrigerant used is ammonia, water or
lithium bromide. The refrigerant gets condensed in the condenser and it gets
evaporated in the evaporator. The refrigerant produces cooling effect in the evaporator
and releases the heat to the atmosphere via the condenser. The major difference
between the two systems is the method of the suction and compression of the
refrigerant in the refrigeration cycle. In the vapor compression system, the compressor
sucks the refrigerant from evaporator and compresses it to the high pressure. The
compressor also enables the flow of the refrigerant through the whole refrigeration
cycle. In the vapor absorption cycle, the process of suction and compression are carried
out by two different devices called as the absorber and the generator. Thus the absorber
and the generator replace the compressor in the vapor absorption cycle. The absorbent
enables the flow of the refrigerant from the absorber to the generator by absorbing it.
Another major difference between the vapor compression and vapor absorption
cycle is the method in which the energy input is given to the system. In the vapor
compression system the energy input is given in the form of the mechanical work from
the electric motor run by the electricity. In the vapor absorption system the energy input
is given in the form of the heat. This heat can be from the excess steam from the
process or the hot water. The heat can also be created by other sources like natural
gas, kerosene, heater etc. though these sources are used only in the small systems.
Simple Absorption System and How it Works:

1) Condenser: Just like in the traditional condenser of the vapor compression cycle, the
refrigerant enters the condenser at high pressure and temperature and gets condensed.
The condenser is of water cooled type.
2) Expansion valve or restriction: When the refrigerant passes through the expansion
valve, its pressure and temperature reduces suddenly. This refrigerant (ammonia in this
case) then enters the evaporator.
3) Evaporator: The refrigerant at very low pressure and temperature enters the
evaporator and produces the cooling effect. In the vapor compression cycle this
refrigerant is sucked by the compressor, but in the vapor absorption cycle, this
refrigerant flows to the absorber that acts as the suction part of the refrigeration cycle.
4) Absorber: The absorber is a sort of vessel consisting of water that acts as the
absorbent, and the previous absorbed refrigerant. Thus the absorber consists of the
weak solution of the refrigerant (ammonia in this case) and absorbent (water in this
case). When ammonia from the evaporator enters the absorber, it is absorbed by the
absorbent due to which the pressure inside the absorber reduces further leading to
more flow of the refrigerant from the evaporator to the absorber. At high temperature
water absorbs lesser ammonia, hence it is cooled by the external coolant to increase it
ammonia absorption capacity.
5) Pump: When the absorbent absorbs the refrigerant strong solution of refrigerantabsorbent (ammonia-water) is formed. This solution is pumped by the pump at high
pressure to the generator. Thus pump increases the pressure of the solution to about
10bar.

6) Generator: The refrigerant-ammonia solution in the generator is heated by the

external source of heat. This is can be steam, hot water or any other suitable source.
Due to heating the temperature of the solution increases. The refrigerant in the solution
gets vaporized and it leaves the solution at high pressure. The high pressure and the
high temperature refrigerant then enters the condenser, where it is cooled by the
coolant, and it then enters the expansion valve and then finally into the evaporator
where it produces the cooling effect. This refrigerant is then again absorbed by the weak
solution in the absorber.

When the vaporized refrigerant leaves the generator weak solution is left in it.
This solution enters the pressure reducing valve and then back to the absorber, where it

is ready to absorb fresh refrigerant. In this way, the refrigerant keeps on repeating the
cycle. The pressure of the refrigerant is increased in the generator, hence it is
considered to be equivalent to the compression part of the compressor.

CHILLED WATER REFRIGERATION SYSTEM

Fundamentally, the function of the chilled water system is to transport the cooling
fluid from the chillers, to the load terminals and back to the chillers to maintain space
comfort. Because a chilled water system uses water as its secondary refrigerant, a
chiller is used to remove heat from the water which is then circulated through other
components to absorb the heat from the space. Chilled water systems include both
supply and return piping in a closed circuit, which means they are sealed from the
atmosphere and do not need extensive chemical treatment to control contamination and
corrosion. The water is cooled by the chiller and supplied to cooling coils or heat
exchangers where it cools the air by absorbing energy. Once warmed, the water is
returned to the chiller to start the process all over again. As the water cools in the
chiller, absorbed energy is transferred through a refrigeration cycle to water circulating
in the condenser system and is subsequently transferred to the outside of the building.
A distinct advantage of using water is the fact that it is non-corrosive, has specific
heat value, it is non-toxic and inexpensive. This makes it an excellent choice when
compared to other secondary refrigerants such as sodium chloride brines, propylene
glycols, ethylene, methanol or glycerin. Another advantage to using a chilled water
system to provide climate control is that water cooled chillers typically last longer than
air cooled chillers. This is due to the fact that the air cooled chiller is installed outdoors,
whereas the water cooled chiller is installed indoors. Additionally, if it is well insulated,
theres no practical distance limitation to the length of a chilled water pipe. Water chiller

types include reciprocating, centrifugal and absorption chillers. Reciprocating water

chillers use piston-type, positive displacement compressors which are found in small
and medium capacity systems. Centrifugal chillers are the most commonly used in
commercial water chillers and are found in medium and large capacity systems. A
chilled water system that uses more than one type of fuel is referred to as a hybrid
system and absorption chillers are the preferred choice to run on fuels such as natural
gas, fuel oil or even waste heat in the form of steam or hot water.
UNIVERSITY OF BATANGAS
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT

REFRIGERATION SYSTEMS

SUBMITTED BY:
MAGDADARO, JENNYLYNN P.
1200549

SUBMITTED TO:
ENGR. CRISMON GUALBERTO
INSTRUCTOR

MARCH 2016