Vapour Compression

Refrigeration Systems:

Performance Aspects

And
d Cycle
l Modifications
difi i

Mechanical Eng.U.O.K 1 13 ،7 ‫نيسان‬

1.Performance of SSS( VCRS)cycle:
The performance
Th f off a standard
d d VCRS cycle l can bbe obtained
b i db by
varying evaporator and condensing temperatures over the
required range.
range For a given condenser temperature as
evaporator temperature increases the specific refrigeration
g
effect increases marginally.y It can be seen that for a g
given
evaporator temperature, the refrigeration effect decreases as
condenser temperature increases. These trends can be
explained
l i d easily
il with
ith the
th hhelp
l off the
th PP-h
h di
diagram. It can also
l
be observed that the volumetric refrigeration effect increases
rapidly with evaporator temperature due to the increase in
specific refrigeration effect and decrease in specific volume of
refrigerant vapour at the inlet to the compressor. Volumetric
refrigeration effect increases marginally as condenser
temperature decreases.

Mechanical Eng.U.O.K 2 13 ،7 ‫نيسان‬

 Figure 1 shows that the specific work of compression
d
decreases rapidly
idl as the
th evaporator
t ttemperature t iincreases
and condenser temperature decreases. Once again these
effects can be explained using a T
T- s or P P- h diagram.
diagram For a
given condenser temperature, the volumetric work of
compression increases initially, reaches a peak, then starts
decreasing. This is due to the fact that as evaporator
temperature increases the specific work of compression
d
decreases and
d the
th specific
ifi volume
l att the
th iinlet
l t tto th
the
compressor also decreases. As a result, an optimum
evaporator temperature exists at which the volumetric work
of compression reaches a maximum. Physically, the
volumetric work of compression is analogous to mean
effective pressure of the compressor, as multiplying this with
the volumetric flow rate gives the power input to the
compressor.
Mechanical Eng.U.O.K 3 13 ،7 ‫نيسان‬
 Fig.1:‐Effect of evaporator and condenser temperatures 
on specific and volumetric work of compression of a 
p p
standard VCRS cycle

Mechanical Eng.U.O.K 4 13 ،7 ‫نيسان‬

For a given power input, a high volumetric work of
compression implies smaller volumetric flow rates
and hence a smaller compressor.
Fig. 2 shows the effect of evaporator and condenser
temperatures on COP of the SSS cycle. As expected,
for a given condenser temperature the COP increases
rapidly with evaporator temperature, particularly at
low condensing temperatures. For a given evaporator
temperature, the COP decreases as condenser
temperature increases. However, the effect of
condenser temperature becomes marginal at low
evaporator temperatures.

Mechanical Eng.U.O.K 5 13 ،7 ‫نيسان‬

 Fig.2:‐ Effect of evaporator and condenser temperatures 
on COP of a standard VCRS cycle.
f d d l

Mechanical Eng.U.O.K 6 13 ،7 ‫نيسان‬

The above results show that at very low evaporator
temperatures the COP becomes very low and also the
temperatures,
size of the compressor becomes large (due to small
volumetric refrigeration effect)
effect). It can also be shown
that the compressor discharge temperatures also
increase as the evaporator temperature decreases.
decreases
Hence, single stage vapour compression refrigeration
systems are not viable for very low evaporator
temperatures. One has to use multistage or cascade
systems for these applications.
applications These systems will be
discussed in the next lecture. One can also observe the
similarities in performance trends between SSS cycle
and Carnot cycle, which is to be expected as the VCRS
cycle is obtained by modifying the SSS cycle.
cycle
Mechanical Eng.U.O.K 7 13 ،7 ‫نيسان‬
2.Modifications to SSS cycle :
1.2- Sub-cooling
S b li andd superheating:
h i
In actual refrigeration cycles, the temperature of the heat sink
will be several degrees lower than the condensing temperature
to facilitate heat transfer. Hence it is possible to cool the
refrigerant
g liquid
q in the condenser to a few degrees
g lower than
the condensing temperature by adding extra area for heat
transfer. In such a case, the exit condition of the condenser
will
ill be
b iin the
h sub-cooled
b l d liquid
li id region.
i Hence
H this
hi process iis
known as sub-cooling. Similarly, the temperature of heat
source will be a few degrees higher than the evaporator
temperature, hence the vapour at the exit of the evaporator
can be superheated
p by
y a few
f degrees.
g

Mechanical Eng.U.O.K 8 13 ،7 ‫نيسان‬

If the superheating of refrigerant takes place due to
heat transfer with
ith the refrigerated space (lo
(low
temperature heat source) then it is called as useful
superheating as it increases the refrigeration effect.
effect
On the other hand, it is possible for the refrigerant
vapour to become superheated by exchanging heat
with the surroundings as it flows through the
connecting pipelines
pipelines. Such a superheating is called as
useless superheating as it does not increase
refrigeration effect
effect. Sub
Sub-cooling
cooling is beneficial as it
increases the refrigeration effect by reducing the
throttling loss at no additional specific work input.
input
Also sub-cooling ensures that only liquid enters into
the throttling device leading to its efficient operation.
operation
Mechanical Eng.U.O.K 9 13 ،7 ‫نيسان‬
Fig.3 shows the VCRS cycle without and with sub-cooling on
P-h
P h and TT-ss coordinates
coordinates. It can be seen from the T
T-ss diagram
that without sub-cooling the throttling loss is equal to the
hatched area b-4’-4-c, whereas with sub-cooling g the
throttling loss is given by the area a-4”-4’-b. Thus the
refrigeration effect increases by an amount equal to
(h4-hh4’) = (h3-hh3’).
) Another
A th practical ti l advantage
d t off
sub-cooling is that there is less vapour at the inlet to
the evaporator which leads to lower pressure drop in
the evaporator.

Mechanical Eng.U.O.K 10 13 ،7 ‫نيسان‬

Fig.3: Comparison between a VCRS cycle
without and with sub-cooling
sub cooling (a) on P-h
Ph
diagram (b) on T-s diagram

Mechanical Eng.U.O.K 11 13 ،7 ‫نيسان‬

Mechanical Eng.U.O.K 12 13 ،7 ‫نيسان‬
Useful superheating increases both the refrigeration effect as
well as the work of compression. Hence the COP (ratio of
refrigeration effect and work of compression) may or may not
i
increase with
ith superheat,
h t ddepending
di mainly
i l upon ththe nature
t off
the working fluid. Even though useful superheating may or
may not increase the COP of the system, a minimum amount of
superheat is desirable as it prevents the entry of liquid droplets
into the compressor.

Mechanical Eng.U.O.K 13 13 ،7 ‫نيسان‬

Fig.4 shows the VCRS cycle with superheating on P-h
and T-s coordinates. As shown in the figure, with
useful superheating, the refrigeration effect, specific
volume at the inlet to the compressor and work of
compression increase. Whether the volumetric
refrigeration effect (ratio of refrigeration effect by
specific volume at compressor inlet) and COP
increase or not depends upon the relative increase in
refrigeration effect and work of compression, which
in turn depends upon the nature of
the refrigerant used. The temperature of refrigerant
at the exit of the compressor increases with superheat
as the isentropes in the vapour region gradually
diverge.
Mechanical Eng.U.O.K 14 13 ،7 ‫نيسان‬
Fig.4: Effect of superheat on specific refrigeration
effect and work of compression (a) on P P-h
h diagram
(b) on T-s diagram

Mechanical Eng.U.O.K 15 13 ،7 ‫نيسان‬

Mechanical Eng.U.O.K 16 13 ،7 ‫نيسان‬
2.2. Use of liquid-suction heat exchanger:

Required degree of sub-cooling and superheating may not be

possible if one were to rely only on heat transfer between the
possible,
refrigerant and external heat source and sink. Also, if the
p
temperature of refrigerant
g at the exit of the evaporator
p is not
sufficiently superheated, then it may get superheated by
exchanging heat with the surroundings as it flows through the
connecting
ti pipelines
i li ( l
(useless superheating),
h ti ) which hi h iis
detrimental to system performance. One way of achieving the
required amount of subsub-cooling
cooling and superheating is by the use
of a liquid-suction heat exchanger (LSHX). A LSHX is a
counter-flow heat exchanger in which the warm refrigerant
liquid from the condenser exchanges heat with the cool
refrigerant vapour from the evaporator.

Mechanical Eng.U.O.K 17 13 ،7 ‫نيسان‬

Fig.5
Fig 5 shows
sho s the schematic
sche atic of a si
single
gle stage VCRS
with a liquid-suction heat exchanger.

Fig.6 shows the modified cycle on T-s and P-h

diagrams As shown in the T-s
diagrams. T s diagram
diagram, since the
temperature of the refrigerant liquid at the exit of
condenser is considerably higher than the
temperature of refrigerant vapour at the exit of the
evaporator it is possible to sub-cool
evaporator, sub cool the refrigerant
liquid and superheat the refrigerant vapour by
exchanging heat between them.
them

Mechanical Eng.U.O.K 18 13 ،7 ‫نيسان‬

Fig.5: A single stage VCRS system with
Li id
Liquid-to-Suction
S i Heat
H Exchanger
E h (LSHX)

Mechanical Eng.U.O.K 19 13 ،7 ‫نيسان‬

Fig.6:- Single stage VCRS cycle with LSHX (a) on T-
s diagram
diagram; (b) on PP-h
h diagram

Mechanical Eng.U.O.K 20 13 ،7 ‫نيسان‬

Mechanical Eng.U.O.K 21 13 ،7 ‫نيسان‬
If we assume that there is no heat exchange between
the ssurroundings
rro ndings and the LSHX and negligible kinetic
and potential energy changes across the LSHX, then,
the heat transferred between the refrigerant liquid
and vapour in the LSHX, QLSHX is given by:

Mechanical Eng.U.O.K 22 13 ،7 ‫نيسان‬

 if we take average values of specific heats for the
vapour and d liquid,
li id then
h we can write i the
h above
b
equation as;

since
si ce the specific
s ecific heat of liq
liquid
id (cpll) is la
larger
ge tha
than
that of vapour (cpv), i.e., cpl > cpv, we can write:

This means that,, the degree

g of sub-cooling
g ((T3-T4) will
always be less than the degree of superheating, (T1-T6).

Mechanical Eng.U.O.K 23 13 ،7 ‫نيسان‬

If we define the effectiveness of the LSHX, ε LSHX as
the
h ratio
i off actuall h
heat transfer
f rate iin the
h LSHX to
maximum possible heat transfer rate, then:

The maximum
a i possible
ossible heat transfer
t a sfe rate
ate is eq
equal
al to ,
because the vapour has a lower

thermal capacity, hence only it can attain the

maximum possible temperature difference,
difference which is
equal to

Mechanical Eng.U.O.K 24 13 ،7 ‫نيسان‬

If we have a perfect effectiveness LSHX with 100%
then from the above discussion it is

clear that the temperature of the refrigerant vapour

at the exit of LSHX will be equal to the condensing
temperature, Tc, i.e This gives rise to the
possibility of an interesting cycle called as Grindley
cycle, wherein the isentropic compression process
can be replaced by an isothermal compression
leading to improved COP.

Mechanical Eng.U.O.K 25 13 ،7 ‫نيسان‬

The Grindley cycle on T-s diagram is shown in Fig.7.
Though theoretically the Grindley cycle offers higher
COP, achieving isothermal compression with modern
high-speed
high speed reciprocating and centrifugal compressors
is difficult in practice. However, this may be possible
with screw compressor where the lubricating oil
provides large heat transfer rates.

Mechanical Eng.U.O.K 26 13 ،7 ‫نيسان‬

Fig.7:‐ Grindley cycle on T‐s coordinates (1‐2 is isothermal 
compression).
i )

Mechanical Eng.U.O.K 27 13 ،7 ‫نيسان‬

3. Effect of superheat on system COP.
A mentioned
As i d before,
b f when
h the
h refrigerant
f i i
is
superheated usefully (either in the LSHX or the
evaporator itself),
i lf) the
h refrigeration
f i i effect
ff i
increases.
However, at the same time the work of compression
also
l increases,
i primarily
i il due
d to increase
i i specific
in ifi
volume of the refrigerant due to superheat. As a
result,
l the h volumetric
l i refrigeration
f i i effect
ff and
d COP
may increase or decrease with superheating
d
depending
di on the
h relative
l i i
increase i refrigeration
in f i i
effect and specific volume.

Mechanical Eng.U.O.K 28 13 ،7 ‫نيسان‬

It is observed that for some refrigerants the COP is
ma im m when
maximum hen the inlet to the compressor is inside
the two-phase region and decreases as the suction
condition moves into the superheated region
region. For
other refrigerants the COP does not reach a
maximum and increases monotonically with
superheat. It was shown by Ewing and Gosney that a
maximum COP occurs inside the two-phase
two phase region if
the following criterion is satisfied:

Mechanical Eng.U.O.K 29 13 ،7 ‫نيسان‬

where COPsat is the COP of the system with saturated
suction
i condition,
di i T is
Te i the
h evaporator temperature
and T2sat is the compressor discharge temperature
when
h the h vapour at suctioni condition
di i iis saturatedd
(see Fig.8). For example, at an evaporator
temperature off –15oC (258( 8 K) andd a condenser
d
temperature of 30oC (303 K), the Table 1 shows that
f refrigerants
for f i such
h as RR11, R22,
R ammonia i the
h
maximum COP occurs inside the two-phase region
andd superheating
h i reducesd the
h COP and d also
l
volumetric refrigeration effect, whereas for
refrigerants
f i suchh as R
R12, carbon
b didioxide
id and dR
R502,
no maxima exists and the COP and volumetric
refrigeration
f i ti effect
ff t iincrease with
ith superheat.
h t
Mechanical Eng.U.O.K 30 13 ،7 ‫نيسان‬
Fig.8 :‐Ewing –Gosney criteria for optimum suction 
condition.
diti

Mechanical Eng.U.O.K 31 13 ،7 ‫نيسان‬

Table 1.:- Existence of max. COP, Te = 258 K, Tc
= 303 K

Mechanical Eng.U.O.K 32 13 ،7 ‫نيسان‬

It should be noted that the above discussion holds
under the assumption that the superheat is a useful
superheat. Even though superheat appears to be not
desirable for refrigerants such as ammonia, still a
minimum amount of superheat is provided even for
these refrigerants to prevent the entry of refrigerant
liquid into the compressor. Also it is observed
experimentally that some amount of superheat is
good for the volumetric efficiency of the compressor,
hence in practice almost all the systems operate with
some superheat.

Mechanical Eng.U.O.K 33 13 ،7 ‫نيسان‬

4 Actual VCRS systems:-
4. y
The cycles considered so far are internally reversible
and no changeg of refrigerant
g state takes p
place in the
connecting pipelines. However, in actual VCRS
several ir-reversibilities exist. These are due to:
1. Pressure drops in evaporator, condenser and LSHX
2. Pressure dropp across suction and discharge g valves
of the compressor
3. Heat transfer in compressor
3 p
4. Pressure drop and heat transfer in connecting pipe
lines

Mechanical Eng.U.O.K 34 13 ،7 ‫نيسان‬

Fig.9 shows the actual VCRS cycle on P-h and T-s diagrams
indicating various ir
ir-reversibilities
reversibilities. From performance point of
view, the pressure drop in the evaporator, in the suction line
and across the suction valve has a significant
g effect on system
y
performance. This is due to the reason that as suction side
pressure drop increases the specific volume at suction,
compression
i ratio
ti (h
(hence volumetric
l t i efficiency)
ffi i ) and
d di
discharge
h
temperature increase. All these effects lead to reduction in
system capacity
capacity, increase in power input and also affect the life
of the compressor due to higher discharge temperature. Hence
this pressure drop should be as small as possible for good
performance.

Mechanical Eng.U.O.K 35 13 ،7 ‫نيسان‬

Fig.9: Actual VCRS cycle on P-h and T-s
diagrams

Mechanical Eng.U.O.K 36 13 ،7 ‫نيسان‬

Mechanical Eng.U.O.K 37 13 ،7 ‫نيسان‬
Mechanical Eng.U.O.K 38 13 ،7 ‫نيسان‬
The pressure drop depends on the refrigerant
velocity,
l i llength h off refrigerant
f i tubing
bi and d llayout
(bends, joints etc.). Pressure drop can be reduced by
reducing
d i refrigerant
f i velocity
l i ((e.g. by
b iincreasing
i the h
inner diameter of the refrigerant tubes), however,
this
hi affects
ff the
h h heat transferf coefficient
ffi i iin
evaporator. More importantly a certain minimum
velocity
l i is i required
i d to carry the h llubricating
b i i oil il b
back
k
to the compressor for proper operation of the
compressor.

Mechanical Eng.U.O.K 39 13 ،7 ‫نيسان‬

Heat transfer in the suction line is detrimental as it
red ces the densit
reduces density of refrigerant vapour
apo r and increases
the discharge temperature of the compressor. Hence,
the suction lines are normally insulated to minimize
heat transfer.
In actual systems the compression process involves
frictional effects and heat transfer. As a result, it
cannot be reversible
reversible, adiabatic (even
(even-though
though it can be
isentropic). In many cases cooling of the compressor is
provided deliberately to maintain the maximum
compressor temperature within safe limits

Mechanical Eng.U.O.K 40 13 ،7 ‫نيسان‬

. This is particularly true in case of refrigerants such
as ammonia. Pressure drops across the valves of the
compressor increase the work of compression and
reduce the volumetric efficiency of the compressor.
Hence they should be as small as possible.
Compared to the vapour lines, the system is less
sensitive to pressure drop in the condenser and
liquid lines. However, this also should be kept as low
as possible. Heat transfer in the condenser
connecting pipes is not detrimental in case of
refrigeration systems. However, heat transfer in the
sub-cooled liquid lines may affect the performance.

Mechanical Eng.U.O.K 41 13 ،7 ‫نيسان‬

In addition to the above, actual systems are also
different from the theoretical cycles
c cles due
d e to the
presence of foreign matter such as lubricating oil,
water air,
water, air particulate matter inside the system
system. The
presence of lubricating oil cannot be avoided,
however the system design must ensure that the
however,
lubricating oil is carried over properly to the
compressor This depends on the miscibility of
compressor.
refrigerant-lubricating oil. Presence of other foreign
materials such as air (non-condensing
(non condensing gas),
gas) moisture
moisture,
particulate matter is detrimental to system
performance Hence systems are designed and
performance.
operated such that the concentration of these
materials is as low as possible.
possible
Mechanical Eng.U.O.K 42 13 ،7 ‫نيسان‬
The COP of actual refrigeration systems is sometimes
written
ritten in terms of the COP of Carnot refrigeration
system operating between the condensing and
evaporator temperatures (COPcarnot), ) cycle efficiency
(ηcyc), isentropic efficiency of the compressor (η) and
efficiency of the electric motor (η),
(η) as given by the
equation shown below:

An approximate expression for cycle efficiency (ηcyc)

in the evaporator temperature range of –50oC to
+40oC and condensing temperature range of +10oC to
+60oC for refrigerants such as ammonia, R 12 and R
22 is suggested by Linge in 1966.

Mechanical Eng.U.O.K 43 13 ،7 ‫نيسان‬

This expression for a refrigeration cycle operating without
(ΔTsub = 0) and with sub-cooling
sub cooling (ΔTsub = Tc-Tl,exit>
Tc Tl exit> 0 K)
are given in Eqns. (11.7) and (11.8), respectively:

In the above equations Tc and Te are condensing and

evaporator temperatures, respectively.

Mechanical Eng.U.O.K 44 13 ،7 ‫نيسان‬

The isentropic efficiency of the compressor (ηis)
depends on several factors such as the compression
ratio, design of the compressor, nature of the
working fluid etc. However, in practice its value
generally lies between 0.5 to 0.8. The motor
efficiency (ηmotor) depends on the size and motor
load. Generally the motor efficiency is maximum at
full load. At full load its value lies around 0.7 for
small motors and about 0.95 for large motors.

Mechanical Eng.U.O.K 45 13 ،7 ‫نيسان‬

 Complete
p vapour
p compression
p refrigeration
g
systems :-
In addition to the basic components,
p , an actual
vapour compression refrigeration consists of
several accessories for safe and satisfactoryy
functioning of the system. These include:
compressor
p controls and safetyy devices such as
overload protectors, high and low pressure cutouts,
oil separators
p etc.,, temperature
p and flow controls,,
filters, driers, valves, sight glass etc. Modern
refrigeration
g systems
y have automatic controls,,
which do not require continuous manual
p
supervision.
Mechanical Eng.U.O.K 46 13 ،7 ‫نيسان‬
Example :- In a R12 based refrigeration system, a
liq id to s ction heat eexchanger
liquid-to-suction changer (LSHX) with ith an
effectiveness of 0.65 is used. The evaporating and
condensing temperatures are 7.2 7 2oC and 54.4
54 4oC
respectively. Assuming the compression process to be
isentropic find:
isentropic,
a) Specific refrigeration effect
b) Volumetric refrigeration effect
c) Specific work of compression
d) COP of the system
e) Temperature of vapour at the exit of the compressor
Comment on the use of LSHX by comparing the performance of
the system with a SSS cycle operating between the same
evaporator and condensing temperatures.
Mechanical Eng.U.O.K 47 13 ،7 ‫نيسان‬