Republic of the Philippines

BATANGAS STATE UNIVERSITY

The National Engineering University
Alangilan Campus
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College of Engineering – Department of Mechanical Engineering

Technical Design Report

ME 417: Refrigeration Systems

SELECTION OF THE BEST COMBINATION OF REFRIGERANTS FOR A

THREE-STAGE CLOSE-TYPE CASCADE REFRIGERATION SYSTEM AND
DIRECT-CONTACT HEAT EXCHANGER TYPE CASCADE SYSTEM

Submitted to:
Engr. Francis Louie C. Como
Course Instructor

Submitted by:
Bajio, Jirah B.
Capuchino, Mary Lyka
Dimaano, Shiella Mae C.
Evangelista, Nathan S.
Mendoza, Paulo

ME-3201

March 2023
Abstract

Refrigeration is essential to human life and production; it is broadly utilized in day

to day routines, business, and modern creation. The removal of heat from a body and

subsequent cooling to a lower temperature than the actual constitutes refrigeration. The

primary concept that led to the development of the refrigeration method is food

preservation. Additionally, refrigeration aids in the destruction of food by inhibiting the

growth of microorganisms like yeast, mold, and bacteria. It is mostly used to store

foodstuffs for longer periods of time at low temperatures. There are some products that

can be stored for months or even years. When water freezes, it turns into ice, which is

essential to many processes. It is possible to preserve packed snow and ice for months.

M. Pan et al. (2020) states that two fundamental types of refrigeration technology

are the absorption refrigeration system (STARS) and the conventional single-stage

compression refrigeration system (STCRS). However, low evaporator temperatures

(between 40 and 50 C), a high compression ratio, or a significant temperature difference

in the heat exchanger are required for some applications, such as rapid freezing and the

storage of frozen food. The refrigerants' high output temperature and pressure will also

lower the volumetric efficiency and coefficient of performance (COP) of the STCRS.

Because it is effective at converting low-grade waste heat into high-grade cold energy,

STARS is frequently used in freezing applications. Nonetheless, both COP and the

economy of STARS will decline assuming the temperature differential between the

intensity source and the cool energy source rises. Since refrigeration systems can only

be used at low evaporation temperatures, CRS has been proposed as a means of

achieving lower refrigeration temperatures. Cryopreservation for instruments,

cryogenics like liquefied gas, and hypothermal medicine are just a few of the many

applications of CRS. It is also used extensively in supermarkets, air conditioning, and

small refrigeration equipment, as well as in food transportation and storage. Both a

reasonable evaporation pressure at a lower evaporation temperature and a moderate

condensation pressure at room temperature can be accommodated by the system.

According to the American Society of Mechanical Engineers (1998), the factors

that influence the development and selection of refrigerants vary and sometimes

conflict. In any case, a few choices are at present accessible that think about all parts of

the refrigeration framework. When choosing a refrigerant for a particular application,

design engineers must take performance, safety, reliability, environmental acceptability,

and straightforward economics into account. The unwavering quality of a refrigeration

framework depends generally on the substance security of the refrigerant and its

similarity with the different framework parts and the blower ointment. Engineering

Equation Solver (EES) will be used as a result. The commercial software package

Engineering Equation Solver (EES) is used to solve systems of simultaneous nonlinear

equations. It is a popular and useful program for mechanical engineers who work in the

fields of thermodynamics and heat transfer because it provides numerous specialized

functions and equations for solving these problems. EES stores thermodynamic

properties, making it unnecessary to manually solve iterative problems by calling

properties at the specified thermodynamic properties with code. With its built-in

functions, EES also performs iterative solving, eliminating the laborious and

time-consuming process of acquiring thermodynamic properties. This software will

assist in selecting the appropriate refrigerant

 Following a thorough analysis, it was determined that the most suitable

refrigerants for the 3-stage closed-type cascade refrigeration system are R718, R717,

and R32. Through experimentation with different combinations and sequences of these

refrigerants, it was discovered that the optimal arrangement for the system is to use

R718 in the high-temperature stage, R717 in the intermediate-temperature stage, and

R32 in the low-temperature stage.

Overall, it is essential to carefully consider several factors when designing and

optimizing a 3-stage closed-type cascade refrigeration system for low-temperature

applications, such as choosing the appropriate refrigerant and operating conditions. By

using R718, R717, and R32 in the recommended sequence, it is possible to achieve

efficient and cost-effective cooling for the system, which can benefit industries that

require low-temperature refrigeration, such as food processing, pharmaceuticals, and

petrochemicals.

Introduction

One of the limitations in a vapor compression refrigeration cycle in terms of the

temperature of the cold reservoir is that the temperature of refrigerant has to be less

than the temperature of the cold reservoir. A cascade refrigeration cycle uses two

separate refrigeration systems with two different working fluids optimized for different

temperature ranges.

This type of refrigeration system uses multiple radiation cycles that are

connected with one another through heat exchanger to improve the refrigeration effect.

It utilizes different types of refrigerant depending on the stage and it has different
freezing, and boiling points and critical pressure. The two stages in a cascade system

are the high temperature cycle and low temperature cycle. High temperature cycle has

a higher evaporator temperature and ammonia is the most commonly used refrigerant

for this type of cycle. Compared to the high temperature cycle, the low temperature

cycle has a lowest evaporator temperature. A cascade refrigeration system may be

used in temperature application in the range of (40°C to -80°C). This can reach

moderately low temperatures up to -127°C.

Cascade refrigeration systems may be used in systems up to many stages. This

3 stage cascade system is made up of three separate vapor compression systems that

operate in three different temperature ranges. These systems are most commonly used

for a low temperature application and composed of independent cycles but have a

common heat exchanger. In systems with the same refrigerant, the common cause of

the problem is the extreme values of pressure and specific volume in the stages of low

and high temperature. With the use of this system, problems coming from the high

pressure ratio in low temperature refrigeration systems can be resolved. Compared to

other refrigeration systems, cascade uses less energy per ton of refrigerant at full load.

This system has a higher coefficient of performance because of its lesser compression

work input and high amount of heat absorbed from the space. Overlapping of the cycles

is one of the advantages of this system, this is because the fluid use needs different

temperatures if any heat transfer occurs.

Low temperature refrigeration ranges temperature below -19°C and is used for

efficient medical freezers and chambers because of its sensitive temperature samples

and specimens. Medium temperature refrigeration ranges at -18°C to -4°C and is used
for walk-in cooler temperatures where perishable and frozen items are stored. While the

high temperature ranges above -5°C and is used for product storage above freezing.

This report aims to exhibit the possible combination of refrigerant and operating

conditions for a three stage closed type of cascade system. Moreover, the report

intends to design the engaging temperature difference between heat exchangers

interfaces. In the same condition, it will also present the result of running a direct

contact heat exchanger type cascade system with the use of R404A as the refrigerant.

Objectives

This technical paper aims to

● show the best possible combination of refrigerant and operating parameters for

a three-stage closed type cascade system that will perform under the provided

conditions;

● design the engaging temperature differential that exists between the interfaces of

heat exchangers;

● demonstrate the outcome of operating a cascade system of the direct contact

heat exchanger type while making use of R404A as the refrigerant.

Theory and Methodology

Cascade Refrigeration System

A cascade refrigeration system is a type of refrigeration system that utilizes two

or more refrigerants with different boiling points to achieve lower temperatures than

would be possible with a single-stage refrigeration system. Cascade refrigeration

systems are frequently utilized in industrial refrigeration applications requiring extremely

low temperatures, such as the manufacture of liquefied natural gas (LNG), air

separation units, and some scientific research applications.

The basic principle behind cascade refrigeration is that the refrigerant with a

lower boiling point is used in the lower temperature cycle, while the refrigerant with a

higher boiling point is used in the higher temperature cycle. The two refrigerants are

typically separated by a heat exchanger, which allows heat to be transferred from the

low-temperature cycle to the high-temperature cycle.

I. 3 Stage Closed Type Cascade Refrigeration System

A 3-stage closed cascade refrigeration system uses multiple refrigerants

to attain extremely low temperatures. It consists of three single stage

refrigeration cycles, with the higher-temperature cycle called the high-pressure

loop, using a refrigerant with a higher boiling point, with the intermediate

pressure loop, and the lower-temperature cycle, called the low-pressure loop,

using a refrigerant with a lower boiling point. The two cycles are connected

through a heat exchanger, which allows the heat to transfer from the high-stage

refrigerant to the low-stage refrigerant.

 Figure 1. Schematic Diagram of 3-stage Closed Type Cascade Refrigeration System

Figure 2. (a) T-s Diagram, (b) P-h Diagram of 3-stage Closed Type Cascade

Refrigeration System

The thermodynamic efficiency of a refrigeration system is primarily determined by

its operating temperatures and the kind of refrigerant chosen for a given application. In

this system as depicted by the schematic diagram, the refrigerant will be compressed

until it passes through the heat exchanger, which serves as the cycle's evaporator,

during the high-pressure loop cycle. With this, the heat exchanger will reduce the
refrigerant's temperature to an appropriate range for the condenser in the intermediate

pressure loop cycle. Similarly, the process will continue in the intermediate pressure

loop cycle, with the exception that both the condenser and the evaporator will be heat

exchangers. Further, for the low-pressure loop, the heat exchanger will function as a

condenser, further reducing the temperature of the refrigerant. Hence, in order to

accomplish the required overall temperature drop, the evaporation-condensation

temperatures of each cycle are continually decreased.

ENGINEERING EQUATION SOLVER (EES)

Engineering Equation Solver (EES) is a powerful tool in solving fluid mechanics,

thermodynamics and heat transfer problems and it works based on the number of

equations and unknown variables. This is a system of simultaneous equations for

instance, there are four variables then there is also a four equation needed. The EES

default for the ranges of variables to iterate is actually negative infinity to positive infinity

because this is a system of two linear equations. Compared to other existing numerical

equation solving programs, EES automatically identifies equations which need to be

solved. These features help the user to easily execute the process and guarantee that

the solver will operate at optimum efficiency. Furthermore, there are built in

mathematical and thermophysical properties included in this software that will be useful

for engineering calculations.

EES is also useful in solving design problems where the effect of one or more

parameters are being observed and determined. With the use of this solver, the user

can use a parametric table which is similar to a spreadsheet. The user will enter the

independent arable while the EEs will calculate the values of the dependent variable in
the table. With the use of this solver, users can effortlessly do design problems than to

solve manually. Additionally, this solver is used for many engineering applications

particularly the mechanical engineering courses and for the practicing engineer faced

with the need for solving practical problems.

EES is thereafter employed to test the combinations of refrigerants. Using the

parametric table function of the program, the assigned refrigerants for each system loop

can be modified. After carrying out each of the 360 possible combinations of

refrigerants, the software generates distinctive values for COP and compressor work.

R717 for the high-pressure loop, R744 for the medium-pressure loop, and R290 for the

low-pressure loop are the optimal combinations of refrigerants for the system

considering its refrigerant properties.

R717, also known as ammonia, is a common refrigerant that has been used in

industrial refrigeration systems for over a century. It is a colorless gas with a pungent

odor and is known for its excellent thermodynamic properties, which make it an effective

refrigerant. Ammonia is a common refrigerant that has been used in industrial

refrigeration systems for over a century. It is a colorless gas with a pungent odor and is

known for its excellent thermodynamic properties, which make it an effective refrigerant.

However, it is toxic and can be dangerous if not handled properly. It can also be

corrosive to some materials, which can lead to leaks in refrigeration systems.

Moreso, The refrigerant R290 also known as hydrocarbon or HC is natural,

non-toxic, and free of ozone-depleting qualities. Approved in 2011, HC is one of the

most environmentally friendly and cost-effective refrigerants on the market due to its low

GWP. R290 is also an excellent replacement for the hydrofluorocarbon (HFC)

refrigerants R134a (used in refrigerators) and R404a. (used in freezers). Additionally,

the use of this refrigerant might save energy expenses by up to 28%. In addition, its low

moisture content guarantees that it will not harm your refrigeration system or its

components.

Further, R744 signifies CO2 when it is used as a natural refrigerant in the

refrigeration and air conditioning industry. Compared to conventional and alternative

refrigerants, R744 CO2 has better thermodynamic features and considerable

advantages. It has no Ozone Depletion Potential (ODP=0) and a negligible Global

Warming Potential (GWP=1). CO2 is a viable alternative for industrial and commercial

refrigeration, but some safety precautions must be taken into account.

Results and Discussion

a) 3-Stage Close-Type Cascade Refrigeration System

There are several ways in designating the engaging temperatures to allow 5 deg

C difference in heat exchange interfaces. In this evaluation, the group developed a

step-by-step procedure to divide the temperature range into almost equal temperature

ranges while allowing 5 deg C difference between heat exchangers. The steps in

designating the engaging temperature are shown below.

 Figure 3. Schematic Diagram of 3-Stage Close-Type Cascade

Refrigeration System

The values acquired in this process are the assumed engaging temperatures for heat

exchange interfaces. These values are used to find the best possible combinations of

refrigerants for the given system. Upon designating the values for temperatures, the

group started encoding the necessary computations using Engineering Equation Solver

(EES). The first three refrigerants used are assumed in order to check if the coded

equations are valid.

 The refrigerants to be used are categorized based on their applicability. Upon

looking at the Refrigerant Selection Guide posted by Engr. Francis Louie C. Como in

Google Drive, the table of refrigerants based on their applications is shown below.

Low Temperature MediumTemperature High Temperature

R404A R22 R22

R32 R134a R134a

R125 R125 R32

R1270 R290 R407C

R290 R600a R410A

R717 R290 R125

R744 R717 R1234yf

R744 R1234ze

R290

R290

R717

R744

Table 1. Table of Refrigerants based on Application

 It was observed that there are few refrigerants that are colored red in the table.

These refrigerants are the exceptions due to their invalidity. These refrigerants are not

applicable for the assumed temperatures in the system due to their lack of saturation

pressure for the assumed temperature. Therefore, the group excluded these

refrigerants in finding the optimum combination of refrigerants for the system.

The applicable refrigerants are combined into three per group with the help of

Microsoft Excel. Different tables are made for each application of refrigerants. These

tables are merged using the Power Query Editor feature of the said software. After

merging the tables, it resulted in 360 possible combinations of refrigerants.

The combinations of refrigerants are then tested using EES. The designated

refrigerants for each loop of the system are altered using the parametric table feature of

the software. The data input was acquired from the data produced from Microsoft Excel.

The combination of three refrigerants is connected to the corresponding coefficient of

performance (COP) and the compressor work of the system. After running the 360

combinations of refrigerants, different values of COP and compressor work are

generated by the software. Upon manual inspection, the best combinations of

refrigerants for the system, taking into consideration the assumed heat exchange

temperatures, are R717 for the high-pressure loop, R744 for the medium-pressure loop,

and R290 for the low-pressure loop.

Presented below are the actual photos of the results obtained by using EES and

MS Excel. The best combination of refrigerants occurred during the 216th run of the

software. The combination resulted in a COP value of 492.9 % and a compressor work
of 107 kW. These are the maximum value of the COP and the minimum value of

compressor work among the 360 different combinations.

Figure 4-5. Refrigerant-Compressor Work - COP Table (Runs 1-60)

Figure 6-7. Refrigerant-Compressor Work - COP Table (Runs 61-120)
Figure 8-9. Refrigerant-Compressor Work - COP Table (Runs 121-210)
Figure 10-11. Refrigerant-Compressor Work - COP Table (Runs 211-300)
Figure 12-13. Refrigerant-Compressor Work - COP Table (Runs 301-360)
Figure14. Combination of Refrigerants (1st -200th Combinations)
Figure 15. Combination of Refrigerants (Continued, 201st - 360th Combinations)
 b) Direct-Type Cascade Refrigeration System

Upon running the system under a Direct-Contact heat exchanger type cascade

system, R404A has been subjected as the refrigerant. Freon™ 404A (R-404A) is a

blended hydrofluorocarbon (HFC) refrigerant composed of R-125, R-134a, and R-143a.

It was designed to replace R-502 and R-22 used in commercial refrigerator equipment

for low and medium temperature ranges. Its properties make it ideal for use in display

cases, refrigerated vehicles, ice makers, and other applications. (Freon, n.d.)

Figure 16. Results of Direct-Type Cascade Ref System with R404 Refrigerant using

EES Solver

At an evaporating temperature of -40 degree Celsius, the saturated pressure at

state point 11 was obtained through the R404A Refrigerant PT Chart by Johnson (2019)

by which it stated as 29.6 kPa. It was equal to the pressure at state point 10.

Meanwhile, the condensing pressure was calculated considering the given condensing
temperature of 65 degree Celsius. From the same PT table, the interpolated value of P2

was 3060 kPa. It was the same pressure value for P3.

In order to obtain the intermediate pressures in between the stages, the cube

root of the product of squared evaporating pressure and condensing pressure was

calculated as well as the cube root of the product of evaporating pressure and a

squared condensing pressure. The computed values were 652 kPa for P1, P4, P5 and

P8, and 138.9 kPa for P6, P7,P9 and P12. From here, the values of the enthalpies for

every state point were acquired.

For the first state point, the graph lies at the vapor saturation point in the curve

that indicates 100% quality which was one of the criterias considered along with the

previously derived intermediate pressure for attaining the enthalpy of 367.1 kJ/kg .

These same criteria were also utilized to attain the value of s1 of 1.606 kJ/kg-K. From

here, the refrigerant moves to a superheated region wherein ideally with isentropic

compression of entropy 1 and 2 of same values, the enthalpy finalized was 396.5 kJ/kg.

But since the isentropic efficiency was given, it was used to get the value of h2 in an

actual system. The next state point was lying within the saturation curve with 0 quality

and the enthalpy was computed through the intermediate pressure and quality. It was

then equated to the next enthalpy of 301.4 kJ/kg.

There was also 0 quality for the state point 5, and the obtained value of enthalpy

was just the same with h6, H7 has 100% quality while the refrigerant got forwarded to

the superheated region and the actual enthalpy was computed through the given

entropic efficiency. H9 considered the criteria of quality and intermediate pressure. It

was the same value with h10, while h11 was with 100% quality along with the
condensing pressure from the refrigerant table. More so, the actual and ideal enthalpy

under the state point 12 was obtained considering pressure, quality and entropy as well.
Figure 17-18. Parametric Table ( COP and Evaporating Pressure)

Figure 19-20 ; Parametric Table ( COP and Evaporating Pressure)

 The values were enlisted through establishing the parametric table for the system

by which the evaporating pressure and the coefficient of performance were tabulated. A

hundred run was designated along with the altered values of evaporating pressure of

100 until 1000 kPa. From this, it could be manifested from the shown result that it

started off with 97.11% of COP and it continued to rise up until the very last value tested

which indicates that expanding the range more would likely to welcome more changes.

With the used value in the system of 29.6 kPa as the evaporating pressure which could

be considered low. Higher COPs equate to higher efficiency, lower energy (power)

consumption and thus lower operating costs.

According to TheNews (2006), low evaporator pressure is caused by the

compressor being starved of refrigerant. The compressor is trying to draw refrigerant

into its cylinders, but there isn't enough refrigerant to satisfy it. The entire low side of the

system will experience low pressure. It is clear that lower evaporating/suction

pressure/temperature decreases RE per kg of refrigerant circulated in the system and

lower evaporating/suction pressure/temperature increases the work of compression per

kg of refrigerant circulated in the system. Thus, as lower evaporating/suction

pressure/temperature increases the heat to be removed at the condenser, lower

evaporating temperature/pressure reduces COP of the system which makes it not

desirable for the refrigeration system. It is recommended to operate a vapor

compression refrigeration system at the highest possible evaporating

pressure/temperature.
 Figure 21. XY Plot (COP and Evaporating Pressure)

The figure shows the relationship between the COP of the system and the

evaporating pressure wherein there is a direct proportional relationship among the

variables. The coefficient of performance (COP) of the system drops when the

evaporation temperature and pressure are lowered. It is possible to draw the conclusion

that a lower suction pressure or temperature is not something that the refrigeration

system would benefit from. It is strongly suggested that a vapor compression

refrigeration system be run at the greatest evaporation pressure and temperature that

are feasible.
 Figure 22-23. Minima and Maxima of Evaporating Pressure

Setting the bounds for pressure ranging from 10 to 3000 kPa, the minimum

pressure was obtained through the maxima-minima function of the EES wherein the

resulting best value showed was 21.27 kPa which would yield a COP of 59.27%.

Meanwhile, extending the range until 5000 kPa, the maximum evaporating attained was

3060 kPa. According to HVAC Systems (n.d.), at the low end, the pressure of 404A is

0.9 psig. At the high end, the pressure of 404A is 456.8 psig which if converted to metric

system yields 6.33 kPa and 3210.81 kPa.

 Figure 24. XY Plot (COP and Condensing Pressure)

In the meantime, a greater condensing pressure and temperature causes a

marginal increase in the amount of total heat that needs to be evacuated at the

condenser. The preceding study makes it abundantly evident that a rise in the

condensing temperature or pressure has a negative impact on the COP of the system.

This is because the refrigerating effect reduces while the work of compression

increases.

The temperature at which the condenser begins to reject heat can be brought

down to a lower level by reducing the operating pressure. A general increase in the
cycle's thermal efficiency is the end result of reducing the pressure in the condenser,

which had the opposite effect.

Thus, the coefficient of performance, which is a ratio of the rate of heat transfer

at the evaporator to the amount of power that is input into the compressor in the

refrigeration system, is essential. Either reducing the amount of work done by the

compressor or boosting the effect of the refrigeration system might lead to an increase

in the coefficient of performance.

Conclusion

One of the limitations placed on a vapor compression refrigeration cycle in terms

of the temperature of the cold reservoir is the requirement that the temperature of the

refrigerant be lower than the temperature of the cold reservoir. In a cascade

refrigeration cycle, two distinct refrigeration systems with two working fluids that are

optimized for various temperature ranges are utilized because the purpose of this paper

is to demonstrate various combinations of operating conditions and refrigerants that

might be utilized in a three-stage closed cascade system. Additionally, the paper aims to

produce an intriguing temperature difference at heat exchanger interfaces. Under the

same conditions, the results of running a cascade system with a direct contact heat

exchanger and R404A as the refrigerant will also be demonstrated.

R404A was used as the refrigerant when the system was operated using a

cascade system of the Direct-Contact heat exchanger type. Freon™ 404A (R-404A) is a

mixed hydrofluorocarbon (HFC) refrigerant made out of R-125, R-134a, and R-143a. It

was intended to supplant R-502 and R-22 utilized in business fridge gear for low and
medium temperature ranges. The parametric table's values indicate that as the system's

range expands, more values will change, and the COP continues to rise up until the

very last value tested. When the temperature and pressure at which evaporation occurs

are decreased, the system's coefficient of performance (COP) decreases. It is possible

to conclude that the refrigeration system would not benefit from a lower suction

pressure or temperature. A vapor compression refrigeration system should be operated

at the highest possible evaporation pressure and temperature.

The refrigerants that will be used are categorized according to how they can be

used. After looking over the Refrigerator Selection Guide that Engineer Como sent in

Google Drive. The group of refrigerants that were excluded are the exceptions due to

their invalidity. And also due to their lack of saturation pressure for the assumed

temperature, these refrigerants are inapplicable to the system's assumed temperatures.

As a result, these refrigerants were left out of the group's search for the system's best

mix. EES is used to test the refrigerant combinations. The parametric table feature of

the software allows for modifications to be made to the designated refrigerants for each

loop of the system. The data that was generated by Microsoft Excel served as the

source for the data that was input. The system's compressor work and the

corresponding coefficient of performance (COP) are linked to the combination of the

three refrigerants. The software generates various COP and compressor work values

after running the 360 refrigerant combinations. Upon reviewing the results, the best

blends of refrigerants for the framework, thinking about the expected intensity trade

temperatures, are R717 for the high-pressure circle, R744 for the medium-pressure

circle, and R290 for the low-pressure circle. During the software's 216th run, the best
refrigerant combination was found. The combination had a compressor work output of

107 kW and a coefficient of performance (COP) of 492.9 percent, the highest and

lowest values among the 360 possible combinations.

It is evident that a lower evaporating/suction pressure or temperature results in a

higher work of compression per kg of refrigerant circulated in the system and a lower

RE per kg of refrigerant circulated in the system. As a result, a system with a lower COP

is not good for the refrigeration system because a lower evaporating/suction

pressure/temperature increases the heat that must be removed at the condenser. A

vapor compression refrigeration system should be operated at the highest possible

evaporating pressure and temperature.

Recommendations

Cascade refrigeration systems are commonly used in industrial applications

where low temperatures need to be achieved. Listed below are some guidelines for

designing and operating a cascade refrigeration system:

1. Select the proper refrigerants: Cascade refrigeration systems employ multiple

refrigerants with varying boiling points. It is essential to select refrigerants that are

compatible with one another, have a low global warming potential (GWP), and are easily

accessible.

2. Optimize the heat exchangers : In a cascade refrigeration system, the heat

exchangers are crucial components. They transfer heat between the refrigerant circuits,

and their performance has a substantial effect on the total system efficiency. It is
essential to select heat exchangers with the proper design and materials, and to

maximize their operation by controlling the flow rates and temperatures with precision.
 References

(2012, October 18). Refrigeration & Air-Conditioning: Lesson 5. Effect of change

of operation conditions on the working of vapour compression refrigeration

plant. Retrieved March 26, 2023, from

[Link]

Fig. 3, Effect of evaporator temperature/pressure on COP at a constant... (n.d.).

ResearchGate. Retrieved March 26, 2023, from

[Link]

sure-on-COP-at-a-constant-area-ratio-generator_fig2_269977581

Freon™ 404A (R-404A) | HFC Refrigerant. (n.d.). Freon™ Refrigerants.

Retrieved March 26, 2023, from

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Home. (2019, April 11). YouTube. Retrieved March 26, 2023, from

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Johnson, A. (2019, March 20). R-404A Refrigerant PT Chart. Refrigerant HQ.

Retrieved March 26, 2023, from

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Open and Closed Type of Refrigeration System – Advantages and Application.

(n.d.). Mecholic. Retrieved March 26, 2023, from

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Yusoff, M. (n.d.). COP versus condenser pressure | Download Scientific Diagram.

ResearchGate. Retrieved March 26, 2023, from

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M. Pan et. al. (2020). A Review of the Cascade Refrigeration System. Retrieved from:

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600/Choosing-the-Right-RefrigerantGiven-Today-s?redirectedFrom=fulltext
 Appendix

a. Closed Type Cascade Refrigeration System

"----------------------------------------------------------------------------------------------"

f$ = 'R32'

g$ = 'R600a'

h$ = 'R717'

"High Pressure Loop"

T_1 = 33.4 [C]

T_cond = 65 [C]

eta_c = 0.74 []

"State Point 1"

h_1 = Enthalpy (f$, P=P_1, x=x_1)

s_1 = Entropy (f$, P=P_1, x=x_1)

P_1 = P_sat (f$, T=T_1)

x_1 = 1 []

"State Point 2 Ideal"

h_2s = Enthalpy (f$, P=P_2, s=s_2s)

s_2s = s_1
P_2 = P_sat (f$, T=T_cond)

"State Point 2 Actual"

eta_c = (h_2s - h_1)/(h_2 - h_1)

"State Point 3"

h_3 = Enthalpy (f$, P=P_3, x=x_3)

P_3 = P_2

x_3 = 0 []

"State Point 4"

h_4 = h_3

"----------------------------------------------------------------------------------------------"

"Medium Pressure Loop"

T_7 = 28.4 [C]

T_8 = -3.4 [C]

"State Point 5"

h_5 = Enthalpy (g$, P=P_5, x=x_5)

P_5 = P_8
x_5 = 0 []

"State Point 6"

h_6 = h_5

"State Point 7"

h_7 = Enthalpy (g$, P=P_7, x=x_7)

s_7 = Entropy (g$, P=P_7, x=x_7)

P_7 = P_sat (g$, T = T_7)

x_7 = 1 []

"State Point 8 Ideal"

h_8s = Enthalpy (g$, P=P_8, s=s_8s)

s_8s = s_7

P_8 = P_sat (g$, T=T_8)

"State Point 8 Actual"

eta_c = (h_8s - h_7)/(h_8 - h_7)

"----------------------------------------------------------------------------------------------"

"Low Pressure Loop"

T_evap = - 40 [C]

T_12 = - 8.4 [C]

"State Point 9"

h_9 = Enthalpy (h$, P=P_9, x=x_9)

P_9 = P_12

x_9 = 0 []

"State Point 10"

h_10 = h_9

"State Point 11"

h_11 = Enthalpy (h$, P=P_11, x=x_11)

s_11 = Entropy (h$, P=P_11, x=x_11)

P_11 = P_sat (h$, T=T_evap)

x_11 = 1 []

"State Point 12 Ideal"

h_12s = Enthalpy (h$, P=P_12, s=s_12s)

s_12s = s_11

P_12 = P_sat (h$, T=T_12)

"State Point 12 Actual"

eta_c = (h_12s - h_11)/(h_12 - h_11)

"----------------------------------------------------------------------------------------------"

RE = 150 [TOR]*(3.516 [kJ/s]/1 [TOR])

"Solving for Mass Flow Rates"

RE = m_dot_1*(h_11 - h_10)

Q_R1 = Q_A2

Q_R1 = m_dot_1*(h_12 - h_9)

Q_A2 = m_dot_2*(h_7 - h_6)

Q_R2 = Q_A3

Q_R2 = m_dot_2*(h_8 - h_5)

Q_A3 = m_dot_3*(h_1 - h_4)

"Solving for Work of Compressors"

W_C1 = m_dot_1*(h_12 - h_11)

W_C2 = m_dot_2*(h_8 - h_7)

W_C3 = m_dot_3*(h_2 - h_1)

W_T = W_C1 + W_C2 + W_C3

"Solving for COP"

COP = ((RE)/(W_T))*100[%]

"----------------------------------------------------------------------------------------------"
Result

Low Temperature Medium High Temperature

Temperature

R404A R22 R22

R32 R134a R134a

R125 R125 R32

R1270 R290 R407C

R290 R600a R410A

R717 R290 R125

R744 R717 R1234yf

R744 R1234ze

R290

R290

R717

R744

Refrigerant-Compressor Work - COP Table

Refrigerant-Compressor Work - COP Table (Runs 1-60)
Refrigerant-Compressor Work - COP Table (Runs 61-120)
Refrigerant-Compressor Work - COP Table (Runs 121-210)
Refrigerant-Compressor Work - COP Table (Runs 211-300)
Refrigerant-Compressor Work - COP Table (Runs 301-360)
Table. Combination of Refrigerants
Table. Combination of Refrigerants (Continued)
 b. Direct-Contact Cascade Refrigeration System

"PROBLEM 3"

"Direct Contact Heat Exchanger"

"Given"

f$='R404a'

T_evap=-40[C]

T_cond=65[C]

eta_c=0.74

"Psat values are from R-404A Refrigerant PT Chart by Johnson, 2019"

"State Point 1"

P_1=(P_2*P_2*P_11)^(1/3)

x_1=1

h_1=enthalpy(f$,P=P_1,x=x_1)

s_1=entropy(f$,P=P_1,x=x_1)

"State Point 2s-ideal"

P_2s=3060.335714[kPa]

s_2s=s_1

h_2s=enthalpy(f$,P=P_2s,s=s_2s)

"State Point 2-actual"

P_2=P_2s

eta_c=(h_2s-h_1)/(h_2-h_1)

"State Point 3"

P_3=P_2
x_3=0

h_3=enthalpy(f$,P=P_3,x=x_3)

"State Point 4"

P_4=P_1

h_3=h_4

"State Point 5"

P_5=P_1

x_5=0

h_5=enthalpy(f$,P=P_5,x=x_5)

"State Point 6"

P_6=P_9

h_5=h_6

"State Point 7"

P_7=P_9

x_7=1

h_7=enthalpy(f$,P=P_7,x=x_7)

s_7=entropy(f$,P=P_7,x=x_7)

"State Point 8s-ideal"

P_8s=P_1

s_8s=s_7

h_8s=enthalpy(f$,P=P_8s,s=s_8s)

"State Point 8-actual"

eta_c=(h_8s-h_7)/(h_8-h_7)
"State Point 9"

P_9=(P_11*P_11*P_2)^(1/3)

x_9=0

h_9=enthalpy(f$,P=P_9,x=x_9)

"State Point 10"

P_10=P_11

h_10=h_9

"State Point 11"

P_11=29.6[kPa]

x_11=1

h_11=enthalpy(f$,P=P_11,x=x_11)

s_11=entropy(f$,P=P_11,x=x_11)

"State Point 12s-ideal"

P_12s=P_9

s_12s=s_11

h_12s=enthalpy(f$,P=P_12s,s=s_12s)

"State Point 12-actual"

P_12=P_9

h_12=((h_12s-h_11)/eta_c)+h_11

"----------------------------------------------------------------------------------------------"

RE = 150*convert(ton,kW)
"Solving for Mass Flow Rates"

RE = m_dot_1*(h_11 - h_10)

Q_R1 = Q_A2

Q_R1 = m_dot_1*(h_12 - h_9)

Q_A2 = (m_dot_1+m_dot_2)*(h_7 - h_6)

Q_R2 = Q_A3

Q_R2 = (m_dot_1+m_dot_2)*(h_8 - h_5)

Q_A3 = (m_dot_1+m_dot_2+m_dot_3)*(h_1 - h_4)

"Solving for Work of Compressors"

W_C1 = m_dot_1*(h_12 - h_11)

W_C2 = (m_dot_1+m_dot_2)*(h_8 - h_7)

W_C3 = (m_dot_1+m_dot_2+m_dot_3)*(h_2 - h_1)

W_T = W_C1 + W_C2 + W_C3

"Solving for COP"

COP = ((RE)/(W_T))*100[%]

"----------------------------------------------------------------------------------------------"
Results:

Parametric Table (COP and Evaporating Pressure)

XY Plot ( COP and Evaporating Pressure)

Maxima and Minima of Evaporating Pressure

XY Plot ( COP and Condensing Pressure)