Chowdhury 2019

International Journal of Air-Conditioning and Refrigeration
Vol. 27, No. 2 (2019) 1930001 (9 pages)

© World Scienti¯c Publishing Company
DOI: 10.1142/S2010132519300015
by NATIONAL AUTONOMOUS UNIVERSITY OF MEXICO (UNAM) on 10/17/22. Re-use and distribution is strictly not permitted, except for Open Access articles.
A Review on Energy and Exergy Analysis of Two-Stage

Vapour Compression Refrigeration System
Shounak Chowdhury*, Ranendra Roy† and Bijan Kumar Mandal‡

Department of Mechanical Engineering
Indian Institute of Engineering Science and Technology
Shibpur, Howrah, West Bengal 711103, India
*shounak96.chowdhury@gmail.com
†
ranendraroy2009@gmail.com
Int. J. Air-Cond. Ref. 2019.27. Downloaded from www.worldscientific.com
‡
bkm375@yahoo.co.in
Received 16 November 2018

Accepted 28 April 2019
Published 17 June 2019
This paper presents a review on energy and exergy analysis of two-stage vapour compression
refrigeration (VCR) system. The use of alternative refrigerants instead of conventional refriger-
ants has also been addressed. The governing equations for the energetic and exergetic analysis of
two-stage VCR system have been identi¯ed and presented. Several experimental and numerical
investigations and their ¯ndings on the performance of the two-stage VCR system available in the
literature have been discussed in brief. Some of the results have also been reproduced as case
studies.
Keywords: Two-stage VCR system; refrigerants; °ash gas; COP; exergetic e±ciency.
Nomenclatures CFC : Chloro°uorocarbons

HCFC : Hydrochloro°uorocarbons
WHP : Work done on high pressure compressor
WLP : Work done on low pressure compressor
:
m HP : Mass °ow at high pressure compressor
:
mLP : Mass °ow at low pressure compressor Greek Symbols
ex : Exergetic e±ciency
: E±ciency
Ex : Exergy
: Reduced inter-stage saturation temperature
h : Enthalpy
s : Entropy
T : Temperature
VCR : Vapour compression refrigeration Subscripts
COP : Coe±cient of performance
ODP : Ozone depletion potential amb : Ambient
GWP : Global warming potential COND : Condenser
NBP : Normal boiling point EVA : Evaporator
TEWI : Total equivalent warming index HP : High Pressure
‡Corresponding author.
1930001-1
S. Chowdhury, R. Roy & B. K. Mandal
LP : Low pressure should be measured in the cycle because exergy losses

FT : Flash Tank are responsible for degradation of system perfor-
WI : Water Intercooler mance. Using exergy analysis, one can quantify the
EVHP : High pressure expansion valve
exergy losses in VCR systems. Exergy losses increase
EVLP : Low pressure expansion valve
with increase in temperature di®erence between the
Isen : Isentropic
mech : Mechanical system and the surrounding. In this paper, authors
elec : electrical have presented a brief review on the thermodynamic
i : Intermediate analysis of two-stage VCR system using some dif-
tot : Total
ferent refrigerants. An attempt has been made to
present methodically the ¯ndings of previous studies
available in the literature. Di®erent governing
1. Introduction equations to evaluate the performance parameters
Refrigeration is a science that deals with absorbing such as COP, exergetic e±ciency and exergy loss
heat at a temperature lower than that of the sur- have been presented in a systematic way. The issues
roundings by doing some external work in accor- of ozone depletion and global warming due to the use
dance with the Clausius statement of second law of of various refrigerants have also been reviewed.
thermodynamics as suggested by Badr et al.1 In the Thus, the authors feel that this paper will be very
past, refrigerants were selected based on their ther- much helpful to the people to start their research
modynamic properties only. But under the present work in this area of refrigeration for relatively high
scenario, ozone depletion potential (ODP) and temperature lift.
global warming potential (GWP) of refrigerants are
also considered. Focus on the research in refrigerants
has now shifted to ¯nd alternative refrigerants hav- 2. Two-Stage VCR System
ing low ODP and GWP values with comparable E®orts are continuously being made to increase the
thermodynamic performances. The most commonly COP of refrigeration systems used for various appli-
used method of refrigeration system is mechanical cations. As mentioned in Arora,3 multi-staging
vapour compression refrigeration (VCR) system. reduces the pressure ratio across each stage, which
Single-stage VCR systems are economical when the results in higher volumetric e±ciency and also
temperature di®erence between the evaporator and decreases the wear and tear of each stage compressor.
condenser is low. It has been observed that the A two-stage VCR system generally consists of
single-stage refrigeration cycle essentially has two low and high pressure compressors, condenser,
main disadvantages for operations having relatively evaporator, expansion valves, water intercooler
high temperature di®erence between the condenser and/or a °ash chamber. In practice, a combination
and the evaporator. These are: low volumetric e±- of water intercooler and °ash tank is used. The
ciency due to large pressure ratio, requiring large schematic diagram of a two-stage VCR system has
displacement volume per ton of refrigeration and low been shown in Fig. 1 and the corresponding p–h
coe±cient of performance, requiring more power per diagram has also been presented in Fig. 2.
ton of refrigeration. Due to the above-mentioned Flash tank helps to remove the °ash gas that
drawbacks, single stage systems are not recom- occurs during throttling process. The removal of
mended when the evaporator temperature becomes °ash vapour at intermediate pressure also leads to
very low and/or when the condenser temperature saving in work since if it is expanded to evaporator
becomes high. In such cases, either multi-stage sys- pressure then it has to be compressed through a high
tems or cascade refrigeration systems are used in pressure ratio without any signi¯cant contribution
practice. Chopra et al.2 pointed out that COP and to refrigerating e®ect.
exergetic e±ciency are the two main performance Incorporation of water intercooler decreases the
parameters of refrigeration systems. COP can be work input to the high pressure compressor. This
enhanced either by minimizing power consumption also reduces the compressor discharge temperature
or by increasing the refrigerating e®ect. However, which provides better lubrication and improves
COP provides no information regarding thermody- compressor life. However, intercooling using liquid
namic losses in the system components. In order refrigerant from condenser in the °ash tank may not
to improve the system performance, irreversibility reduce the power input to the system, as the heat
1930001-2
Energy and Exergy Analysis of a Two-Stage VCR System
Table 1. Properties of common refrigerants.
Substance R-Num BP( C) ODP GWP
Carbon dioxide R744 78.5 0 1

Ammonia R717 33.3 0 0
1,1,1,2-Tetra°uoro ethane R134a 26.3 0 1300

Isobutane R600a 11.6 0 20
Dichloro di-°uoro methane R12 29.8 0.84 10,600
Di°uoromonochloromethane R22 40.8 0.055 1700
important desirable properties of refrigerants are

listed following Emani et al.4 as:
. It should be chemically inert and stable.
. It should have low toxicity, zero °ammability, zero
ODP value and GWP value as low as possible.
. It should have low viscosity and high thermal
Fig. 1. Schematic diagram of a two-stage VCR system.

conductivity.
. It should have dielectric strength as high as
possible.
. It should have latent heat of vaporization, as high
as possible.
. It should have total equivalent warming index
value (TEWI) as low as possible.
. It should be easy to detect leaks if present.
Normal boiling point (NBP), ODP and GWP of
some commonly used conventional refrigerants have
been presented in Table 1.
3.1. Need for alternative refrigerants

The use of chloro°uorocarbons (CFCs) and hydro-
chloro°uorocarbons (HCFCs) were in vogue for a
Fig. 2. p–h plot of a two-stage VCR system.
long time due to their excellent thermodynamic
Table 2. Various alternate refrigerants used.

rejected by the refrigerant during intercooling gen-
erates additional vapour in the °ash tank, which has Alternate
to be compressed by the high pressure compressor.3 refrigerant For Purpose for replacement
Thus, the mass °ow rate of refrigerant through the
R1234yf HFC134a Zero ODP, Excellent life cycle
high stage compressor will be more than that of low climate performance
stage compressor. Henceforth, as a result of using R449A R22 Direct expansion, non-ODP, lower
both water-cooling and °ash-tank, the amount of GWP
refrigerant vapour handled by the high-stage com- R513A R134a Positive displacement and direct
pressor reduces leading to lower power consumption. expansion
DR55 R410A Easily convertible from R410A
designs, Low GWP
R401B R12 Low temperature retro¯ts
3. Selection of Refrigerants R407F R22 Air-conditioning and low
Selection of refrigerants has signi¯cant impact applications, Lower GWP
R422D R22 For direct expansion evaporators,
on safety, reliability, energy consumption, system
Non-ODP
performance and also on the environment. Some
1930001-3
properties. But they are being obsoleted eventually compared the two refrigerants R404A and R507A in
due to their high ODP and GWP values as sug- medium and low evaporating temperatures using a
gested by Emani et al.4 Some alternative refriger- facility which operated with two double-stage com-
ants have already been identi¯ed to replace pression cycles: the double-stage without interme-
commonly used old refrigerants as shown in Table 2. diate systems and the double-stage with a sub-cooler
It must be kept in mind that all alternative refrig- as an intermediate system. The comparison focused
erants should have comparable thermo-physical on energy parameters, covered an evaporating
properties and bare minimum environment impact temperature range from 36 C to 20 C for a
in terms of ODP and GWP. Table 2 shows the constant condensing temperature of 40 C. Aprea
replacements of the commonly used refrigerants. et al.11 performed an exergetic analysis based on
experimental data of a two-stage VCR system and
compared the performance of refrigerants R134a and
4. Performance of Two-Stage VCR
R744. They proposed to replace R134a refrigerant
System with R744 due to its large GWP value. The overall
Zubair et al.5 carried second-law-based thermody- exergetic performances of the classical vapour com-
namic analysis for two-stage mechanical-subcooling pression plant working with R134a were consistently
VCR cycles. He concluded that irreversible losses at better than that of R744. On analyzing the perfor-
high temperature di®erence can be minimized by mance of the individual components, it was observed
compressing the refrigerant in two stages. Chan- that there was decrease in the exergetic performance
drasekharan6 did exergy analysis of a two-stage of R744 mostly. Anjum et al.12 carried out thermo-
VCR system using R12 and R134a as refrigerants. dynamic analysis on two-stage refrigeration system
He found out that both COP as well as exergetic utilizing the waste heat of the intercooler for water
e±ciency increased with degree of sub-cooling for heating. Predicted results showed an increase in
both the refrigerants but with a steeper variation in COP by 4% to 5% within the investigated condenser
case of R134a than R12. temperature ranging from 40 C to 52 C. Bakeem
Oudha et al.7 calculated components exergetic et al.13 carried out energy, exergy and economic
losses of a VCR system operating at constant evap- analysis on a multistage VCR system using eight
orator temperature of 30 C and condenser tem- di®erent refrigerants. They optimized the system to
peratures of 30, 40, 50 and 60 C with two natural maximize COP of the multistage VCR system by
substitutes for refrigerant HCFC22, namely propane varying four optimization variables namely: sub-
(R290) and ammonia (R717) as working °uids. The cooling, desuperheating parameters, and evaporator
exergetic e±ciencies and losses were estimated as a and condenser temperatures of the system. Results
function of reduced inter-stage saturation tempera- showed that COP increased with increase in the sub-
ture to illustrate that the intermediate temperature/ cooling. They also found that the maximum COP of
pressure is responsible for exergy losses in every 6.17 was achieved with ammonia while minimum
component. They also discovered that the optimum COP of 4.95 was achieved with R407C. They per-
interstage pressure for a two-stage refrigeration formed optimization and ¯gured out R717 to be the
system is very close to the saturation pressure. best among the tested refrigerants, while R407C was
Cabello et al.8 found that speci¯c suction volume not recommended to use.
in°uenced variation in mass °ow rate and therefore
a®ected the cooling capacity and electrical power
consumption. Correa et al.9 carried out energy and 5. Mathematical Formulation
exergy analysis of a two-stage VCR system inte-
The researchers have used some mathematical
grated with an absorption system (NH3 þ H2 O).
model for the analysis of two-stage VCR system.
The cold water was supplied by ammonia-water
This involves some assumptions and the basic
absorption system integrated to the conventional
equations for the energetic and exergetic analysis.
compression system. The results showed that the
The assumptions are as follows:
COP of the integrated refrigeration system had been
reduced up to 19.73% and exergetic e±ciency and . Temperature and pressure losses are neglected.
referigerating capacity had been increased up to . All components are running under steady state
25.57% and 33.09%, respectively. Llopis et al.10 conditions.
1930001-4
. Energy and exergy losses due to kinetic and po- equation can be written:
tential energy are neglected. : : : :
m LP h3 þ m HP h7 ¼ m HP h4 þ m LP h8 : ð8Þ
. The enthalpy drop of the refrigerant when it °ows
from the water intercooler to the °ash tank is The COP of the system is thus de¯ned as
negligible. i.e., h3 h4 . :
mLP ðh1 h9 Þ
COP ¼ : ð9Þ
WHP þ WLP
5.1. Energy analysis of two-stage VCR
system
COP is one of the important performance para- 5.2. Exergy analysis of two-stage VCR
meters in a two-stage VCR system. To evaluate system
COP, one must perform energy analysis of the given The exergy at any point may be written following
system. Some basic governing equations needed for Cengel and Boles14 as:
the evaluation of COP have been presented as
:
Ex ¼ m ½ðh hamb Þ Tamb ðs samb Þ : ð10Þ
follows:
The expression for intermediate pressure, pi
provided by Baakeem et al.13 is given as Exergy losses in di®erent components of the two-
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi stage VCR system with °ash tank and water inter-
pi ¼ pEVA pCOND : ð1Þ cooler can be calculated using the mathematical
equations described by Roy and Mandal.15
The reduced inter-stage saturation temperature, Exergy loss in the high and low-pressure com-
is given as following the work of Oudha et al.7: pressors can be calculated as
Ti TEVA EDHP ¼ WHP þ Ex1 Ex2 ; ð11Þ
¼ : ð2Þ
TCOND TEVA
EDLP ¼ WLP þ Ex4 Ex5 : ð12Þ
The work done on the high-pressure compressor is
given by Exergy loss in the evaporator can be calculated as

:
m HP ðh5 h4 Þ T
WHP ¼ : ð3Þ EDEVA ¼ Ex9 Ex1 þ QEVA 1 amb :
mech elec isen TEVA
ð13Þ
The work done on the low-pressure compressor is
given by Exergy loss in the condenser is de¯ned by

:
m LP ðh2 h1 Þ
Tamb
EDCOND ¼ Ex5 Ex6 QCOND 1 :
WLP ¼ : ð4Þ TCOND
mech elec isen
ð14Þ
The total work done is equal to the sum of the
work done on the high-pressure and low-pressure Exergy loss in the high-pressure expansion valve
compressors and is expressed as can be expressed as
Wtot ¼ WHP þ WLP : ð5Þ EDEVHP ¼ Ex6 Ex7 : ð15Þ
The evaporator load is given by the equation as Exergy loss in the low-pressure expansion valve
can be expressed as
:
QEVA ¼ m LP ðh1 h9 Þ : ð6Þ
EDEVLP ¼ Ex8 Ex9 : ð16Þ
The condenser load can be expressed as
Exergy loss in the water intercooler is de¯ned by
:
QCOND ¼ m HP ðh5 h6 Þ : ð7Þ EDWI ¼ Ex2 Ex3 : ð17Þ
Energy balance equation across the °ash tank
: :
provides a relationship between m HP and m LP as
Exergy loss in the °ash tank is de¯ned by
done by Bakeem et al.13 Based on this the following EDFT ¼ Ex3 Ex4 þ Ex7 Ex8 : ð18Þ
1930001-5
So, the total exergy loss of system is evaluated

as sum of the exergy losses in every individual
component
EDtotal ¼ EDEVA þ EDCOND þ EDFT þ EDWI
þ EDLP þ EDHP þ EDEVHP þ EDEVLP :

ð19Þ
The exergetic e±ciency of the system is de¯ned as

QEVA 1 Tamb
TEVA
ex ¼ : ð20Þ
WHP þ WLP
6. Some Case Studies

6.1. E®ect of evaporator temp on COP
Fig. 4. E®ect of evaporator temperature on exergy loss.17

The e®ect of evaporator temperature on COP of
two-stage VCR system using various refrigerants
has been demonstrated in Fig. 3 following the work has been demonstrated in Fig. 4 following the work
of Chopra et al.2 and Khan et al.16 The ¯gure shows of Mishra.17 It shows that exergy destruction
that COP increases with the increase in evaporator increases with the increase in evaporator tempera-
temperature. This is due to the fact that pressure ture. This is so because with the increase in evapo-
ratio across each stage decreases with evaporator rator temperature, the ¯nite temperature di®erence
temperature and this results in increase in COP of between the evaporator and the refrigerated space
the system. Results also show that maximum COP decreases and this attributes to reduction of exergy
is obtained with the help of refrigerant 152a and losses in the evaporator. However, this reduction is
minimum with R404a. not much. The reduction in exergy losses with
evaporator temperature in other components such
6.2. E®ect of evaporator temperature as compressor and throttle valve are due to decrease
on exergy loss in pressure di®erence. Also, the exergy loss with
R134a is more than those with R12 and R22.
The e®ect of evaporator temperature on exergy loss
of two-stage VCR system using various refrigerants
6.3. E®ect of condenser temperature
on exergy loss
The e®ect of condenser temperature on exergy loss
for a two-stage VCR system using various refriger-
ants has been demonstrated in Fig. 5 based on the
results of Chandrasekharan6 and Chopra et al.2 It
can be observed from the ¯gure that with the in-
crease in condenser temperature, exergy destruction
or loss increases and the loss is more with R290
compared to R600a and 134a.
6.4. E®ect of evaporator temperature

on exergetic e±ciency
The e®ect of evaporator temperature on exergetic
e±ciency of two-stage VCR system using various
Fig. 3. E®ect of evaporator temperature on COP.2,16 refrigerants has been demonstrated in Fig. 6
1930001-6
for ¯xed evaporator and condenser temperature of

30 C and 40 C, respectively. They analyzed the
system by considering reduced inter-stage satura-
tion temperature, as variable parameter. They
found that the exergetic losses are maximum when
the reduced inter-stage saturation temperature is

equal to 0 or when it approaches to 1. In that case,
the system reduces to a single stage one. On the
other hand, exergetic losses are minimum when is
very close to 0.5. Keeping this in mind, distributions
of optimum exergy losses in di®erent components of
Fig. 5. E®ect of condenser temperature on exergy loss.2,6
(a) For refrigerant R717
Fig. 6. E®ect of evaporator temperature on exergetic

e±ciency.6,17
following the work of Chandrasekharan6 and

Mishra.17 The main reason behind this is that as
evaporator temperature increases, the compressor
work reduces which in turn reduces the exergy loss
occurring in the compressor.
6.5. Exergy losses in di®erent

components
The exergy losses in di®erent components of the two- (b) For refrigerant R290
stage VCR system using R717 and R290 as refrig- Fig. 7. Distribution of exergy losses in each component of the
erants are cited from the work of Ouadha et al.7 system at optimum condition for (a) R717 and (b) R290.
1930001-7
the system for ¼ 0:5 have been illustrated in References

Figs. 7(a) and 7(b) for refrigerants R717 and R290
1. O. Badr, P. W. O'Callaghan and S. D. Probert,
respectively in the form of pie chart. It can be noted Vapour compression refrigeration systems, Appl.
from the ¯gures that among all the components, the Energy 36 (1990) 303–331.
condenser is associated with maximum exergy de-
2. K. Chopra, V. Sahni and R. S. Mishra, Energy,

struction which is 25.49% of the total irreversibility exergy and sustainability analysis of two-stage va-
rate and the minimum exergy destruction is noted in pour compression refrigeration system, J. Therm.
the high pressure expansion valve which is just Eng. 1 (2015) 440–445.
5.76% of the total exergy destruction in the two- 3. R. C. Arora, Refrigeration and Air Conditioning
stage VCR plant operating with R717 as refrigerant. (PHI Learning Private Limited, 2015).
However, maximum exergy destruction occurs in 4. M. S. Emani, R. Ranendra and B. K. Mandal,
high-pressure compressor which is 21.07% of the Development of refrigerants: A brief review, Ind. J.
Sci. Res. 14 (2017) 175–181.
total destruction and minimum exergy destruction
5. S. M. Zubair, M. Yaqub and S. H. Khan, Second-
occurs in the °ash tank which is just 3.01% of the
law-based thermodynamic analysis of two-stage and
total exergy destruction of the system using R290 as mechanical-subcooling refrigeration cycles, Int. J.
refrigerant. The di®erences in exergy destructions at Refrig. 19 (1996) 506–516.
di®erent components of the two-stage VCR using 6. M. Chandrasekharan, Exergy analysis of vapour
the above mentioned two refrigerants may be at- compression refrigeration system using R12 and
tributed to their thermodynamic properties. R134a as refrigerants, Int. J. Students' Res. Technol.
Manage. 2 (2014) 134–139.
7. A. Ouadha, M. En-Nacer, L. Adjlout and O. Imine,
7. Conclusions Exergy analysis of a two-stage refrigeration cycle
using two natural substitutes of HCFC22, Int. J.
The following conclusions can be drawn from this
Energy 2 (2005) 14–30.
review work. The performance of a single stage VCR
8. R. Cabello, E. Torrella, R. Llopis and D. Sanchez,
system deteriorates when the temperature di®erence Comparative evaluation of the intermediate systems
between the condenser and evaporator becomes employed in two-stage refrigeration cycles driven by
large. This can be overcome by using a two-stage compound compressors, Energy 35 (2010) 1274–1280.
VCR system along with °ash gas removal at the 9. G. A. Corrêa, C. P. Hernandez, L. A. O. Rocha and
intermediate pressure. In a two-stage VCR system, J. A. Souza, Energy and exergy thermodynamic
the pressure ratio across each stage is reduced. This analysis of a two-stage compression refrigeration
reduces the compressor work and hence increases system integrated with an absorption system (NH3
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have already been phased out owing to their high 10. E. Torrella, R. Llopis and R. Cabello, Experimental
ODP and GWP values. Instead, some alternative evaluation of the inter-stage conditions of a two-stage
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refrigerants having zero ODP and negligible GWP
J. Refrig. 32 (2009) 307–315.
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11. C. Aprea, A. Greco and A. Maiorino, The substitution
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orator temperature due to decrease in exergy loss. experimental data, Int. J. Refrig. 36 (2013) 2148–2159.
Case studies also show that percentages of exergy 12. A. Anjum, M. Gupta, N. A. Ansari and R. S. Mishra,
destruction in di®erent components of two stage Thermodynamic analysis of a two-stage vapour
refrigeration system depend on the nature of compression refrigeration system utilizing the waste
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1930001-8
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International Journal of Air-Conditioning and Refrigeration

Vol. 27, No. 2 (2019) 1930001 (9 pages)

A Review on Energy and Exergy Analysis of Two-Stage

Shounak Chowdhury*, Ranendra Roy† and Bijan Kumar Mandal‡

Received 16 November 2018

Nomenclatures CFC : Chloro°uorocarbons

LP : Low pressure should be measured in the cycle because exergy losses

Table 1. Properties of common refrigerants.

Substance R-Num BP( C) ODP GWP

Carbon dioxide R744 78.5 0 1

1,1,1,2-Tetra°uoro ethane R134a 26.3 0 1300

important desirable properties of refrigerants are

Fig. 1. Schematic diagram of a two-stage VCR system.

3.1. Need for alternative refrigerants

Table 2. Various alternate refrigerants used.

Wtot ¼ WHP þ WLP : ð5Þ EDEVHP ¼ Ex6 Ex7 : ð15Þ

So, the total exergy loss of system is evaluated

þ EDLP þ EDHP þ EDEVHP þ EDEVLP :

6. Some Case Studies

Fig. 4. E®ect of evaporator temperature on exergy loss.17

6.4. E®ect of evaporator temperature

for ¯xed evaporator and condenser temperature of

the reduced inter-stage saturation temperature is

Fig. 5. E®ect of condenser temperature on exergy loss.2,6

(a) For refrigerant R717

Fig. 6. E®ect of evaporator temperature on exergetic

following the work of Chandrasekharan6 and

6.5. Exergy losses in di®erent

the system for ¼ 0:5 have been illustrated in References

2. K. Chopra, V. Sahni and R. S. Mishra, Energy,

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