WESTERN INSTITUTE OF TECHNOLOGY
LA PAZ, ILOILO CITY
MECHANICAL ENGINEERING
Multi-Pressure Systems
A multi-pressure system in refrigeration refers to a system that operates at more than one
pressure level within the refrigeration cycle. This is done to improve efficiency, accommodate
different cooling loads, or handle various temperature requirements within the same system. A
multi-stage pressure system in refrigeration refers to a system where compression occurs in
multiple stages rather than a single stage. This approach improves efficiency, reduces compressor
work, and enhances system performance, especially in low-temperature applications. Multi-stage
systems are also used in applications requiring refrigeration at different temperatures.
Why Use Multi-Stage Compression?
1. Reduces Work per Stage: Instead of compressing gas in one go, the process is divided,
reducing the strain on compressors.
2. Improves Efficiency: Lower power consumption compared to single-stage compression.
3. Controls Discharge Temperature: Prevents excessive heating of refrigerant, which can
degrade lubricants and reduce efficiency.
4. Better Suction Pressure Control: Enables stable operation in systems requiring extremely
low temperatures.
Types of Multi-Stage Systems
1. Two-Stage Compression (Most Common)
o Common in industrial refrigeration (cold storage, ice plants).
o Uses an intercooler between stages to reduce temperature before entering the
second-stage compressor.
2. Three or More Stages
o Used for very low-temperature applications (e.g., liquefaction of gases, ultra-low
freezing).
o Incorporates multiple intercoolers and flash chambers for better efficiency.
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.
The Two Methods Employed During Multi Staging
Flash gas removal using flash tank
Flash gas does not contribute to the refrigeration effect as it is already in the form of
vapour, and it increases the pressure drop in the evaporator. A flash tank is a pressure vessel,
wherein the refrigerant liquid and vapour are separated at an intermediate pressure. The
refrigerant from condenser is first expanded to an intermediate pressure corresponding to the
pressure of flash tank, Pi using a low side float valve.
Intercooling in multi-stage compression
Intercooling using liquid refrigerant from condenser in the flash tank may or may not
reduce the power input to the system, as it depends upon the nature of the refrigerant. The heat
rejected by the refrigerant during intercooling generates additional vapour in the flash tank,
WESTERN INSTITUTE OF TECHNOLOGY
LA PAZ, ILOILO CITY
MECHANICAL ENGINEERING
which has to be compressed by the high stage compressor. Thus the mass flow rate of refrigerant
through the high stage compressor will be more than that of the low stage compressor.
Design Issues in multi-stage compression is the selection of suitable intermediate pressure for
two-stage air compressor with intercooling, the optimum intermediate pressure.
1. System With Flash Gas Removal
In compound compression the throttling expansion of liquid done in stages. The liquid form
the condenser 6 first expands into a flash chamber to 7 at the intermediate pressure Pi. Inside the
flash chamber the liquid & vapor refrigerants are separated by centrifugal action and only the
liquid refrigerant from the flash chamber at 8 enters the evaporator through another expansion
valve and expands at 9. Then instead of passing the refrigerant form the low-stage compressor
through the flash tank, vapor form the flash tank is mixed with the vapor coming from low-stage
compressor. As a result, the inlet condition to the high-stage compressor will be slightly
superheated. These systems is in used for Refrigerants R12 & R134a due to their low discharge
temperatures.
2. Flash Chamber as Liquid Sub Cooler
Another method of obtaining same result as that of gas removal is employ flash chamber as a
liquid a sub cooler which sub cools the liquid by the evaporation of the liquid refrigerant in the
flash chamber. As a result, a small amount of refrigerant vapor is generated in the flash tank, which
needs to be compressed in the high-stage compressor.
WESTERN INSTITUTE OF TECHNOLOGY
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MECHANICAL ENGINEERING
3. Flash Intercooling
Sometimes the flash tank is used for intercooling of the refrigerant vapor between the low
and high-stage compressors. It is not used for flash gas removal. The compressed vapors from the
lower stage are led and bubbled through the liquid in the flash chamber. The vapors are thus cooled
to the saturation temperature at the pressure of flash chamber and a apart of liquid evaporated
which goes to the higher stage along with the vapors from the lower stage. Flash inter cooling thus
enables the higher stage compression to takes place in steeper isentropic, nearer the saturation
vapor line.
4. Complete Multistage Compression System
A complete multi stage compression system is with flash gas removal using a flash tank,
and intercooling of refrigerant vapor by a water-cooled heat exchanger and flash tank. The
superheated vapor from the water-cooled heat exchanger bubbles through the refrigerant liquid in
the flash tank. It is assumed that in this process the superheated refrigerant vapor gets completely
de-superheated and emerges out as a saturated vapor at state.
WESTERN INSTITUTE OF TECHNOLOGY
LA PAZ, ILOILO CITY
MECHANICAL ENGINEERING
Multi Compressor Systems
1. Single Compressor- Individual Expansion Valve with a Pressure- Reducing Valve (PRV)
This system also uses individual expansion valves and a pressure regulating valve (PRV) for
reducing the pressure form the corresponding to the high temperature evaporator to the compressor
suction pressure. The PRV also maintains the required pressure in high temperature evaporator
(Evaporator-II). Compared to the earlier evaporator. However, this advantage is counterbalanced
by higher specific work input due to the operation of compressor in superheated region. However,
this system is still preferred to the earlier system due to proper operation of high temperature
evaporator.
2. Single Compressor Multiple Expansion Valves with PRV
The advantage of this system compared to the system compared to the system with individual
expansion valves is that the refrigeration effect of the low temperature evaporator increases as
saturated liquid enters the low stage expansion valve. Since the flash gas is removed at stage 4, the
low temperature operates more efficiently.
3. Multi- Evaporator System with Multi-Compression, Intercooling and Flash Gas removal
When one or more evaporators are in operating a very low temperatures and individual
compressors are installed then compound compression can be used for effective power saving with
multiple arrangement of expansion valves and flash inter cooling. The flash chamber is maintained
at the pressure of the high temperature evaporator.
WESTERN INSTITUTE OF TECHNOLOGY
LA PAZ, ILOILO CITY
MECHANICAL ENGINEERING
4. Multi- Evaporator System Individual Compressors and Multiple Expansion Valves
The total requirement can be reduced by the used of an individual compressor for each
evaporator and by multiple arrangement of expansion valve. This parallel operation of evaporators
is called sectionalizing. There may be separated condenser for each compressor or common for the
plant.
Cascade Systems
A cascade system uses one refrigerant to condense the other primary refrigerant that is
operating at the desired evaporator temperature. This approach is usually used for temperature
levels less than −80°F, when light hydrocarbon gases or other low boiling gases and vapors are
being cooled. To obtain the highest overall efficiency for the system, the refrigerants for the two
superimposed system are different.
A cascade system is a type of refrigeration system in which two systems are independent,
and where one of the systems – the lower temperature system – uses a heat exchanger as a
condenser, which is responsible for expelling the heat that accumulates in it. A more detailed
explanation of how these systems work and how refrigerants are used for ultra-low or low-
temperature applications is given below.