Liquid Suction Vapour Heat Exchanger

For the heat pump (HP) operation, heat rejected at the high temperature (Qhigh) is the objective, thus:


For a Carnot cycle (where AQ = TA s), the COP for the refrigeration application becomes (note than T is absolute temperature [K]):

high low and for heat pump application:

The COP in real refrigeration cycles is always less than for the ideal (Carnot) cycle and there is constant effort to achieve this ideal value.

Basic Refrigeration Methods Three basic methods of refrigeration (mentioned above) use similar processes for obtaining refrigeration effect: evaporation in the evaporator, condensation in the condenser where heat is rejected to the environment, and expansion in a flow restrictor. The main difference is in the way compression is being done (Fig. 11-71): using mechanical work (in compressor), thermal energy (for absorption and desorption), or pressure difference (in ejector).

: Vapor compression j 1. Compressor

; Ejector (steam jet)

j 1. Ejector fA'tisorption

; 1. Absorb vapor in ; liquid while ; removing heat j 2. Elevate pressure of ; liquid with pump ; 3. Release vapor by ■ applying heat

FIG. 11-71 Methods of transforming low-pressure vapor into high-pressure vapor in refrigeration systems (Stoecker, Refrigeration and Air Conditioning).

FIG. 11-71 Methods of transforming low-pressure vapor into high-pressure vapor in refrigeration systems (Stoecker, Refrigeration and Air Conditioning).

Ammonia Refrigeration System Diagram

In the next figure (Fig. 11-72) basic refrigeration systems are displayed more detailed. More elaborated approach is presented in the text.


Vapor-Compression Cycles The most widely used refrigeration principle is vapor compression. Isothermal processes are realized through isobaric evaporation and condensation in the tubes. Standard vapor compression refrigeration cycle (counterclockwise Rankine cycle) is marked in Fig. 11-72a) by 1, 2, 3, 4.

Work that could be obtained in turbine is small, and iturbine is substituted for an expansion valve. For the reasons of proper compressor function, wet compression is substituted for an compression of dry vapor.

Although the T-s diagram is very useful for thermodynamic analysis, the pressure enthalpy diagram is used much more in refrigeration practice due to the fact that both evaporation and condensation are isobaric processes so that heat exchanged is equal to enthalpy difference AQ = Ah. For the ideal, isentropic compression, the work could be also presented as enthalpy difference AW = A h. The vapor compression cycle (Rankine) is presented in Fig. 11-73 in p-h coordinates.

Figure 11-74 presents actual versus standard vapor-compression cycle. In reality, flow through the condenser and evaporator must be accompanied by pressure drop. There is always some subcooling in the condenser and superheating of the vapor entering the compressor-suction line, both due to continuing process in the heat exchangers and the influence of the environment. Subcooling and superheating are usually desirable to ensure only liquid enters the expansion device. Superheating is recommended as a precaution against droplets of liquid being carried over into the compressor.

There are many ways to increase cycle efficiency (COP). Some of them are better suited to one, but not for the other refrigerant. Sometimes, for the same refrigerant, the impact on COP could be different for various temperatures. One typical example is the use of a liquid-to-suction heat exchanger (Fig. 11-75).

The suction vapor coming from the evaporator could be used to

Cascade System And Diagram

FIG. 11-73 p-h diagram for vapor-compression cycle.

FIG. 11-73 p-h diagram for vapor-compression cycle.

Wet Compression Diagram

FIG. 11-74 Actual vapor-compression cycle compared with standard cycle.

FIG. 11-74 Actual vapor-compression cycle compared with standard cycle.

FIG. 11-75 Refrigeration system with a heat exchanger to subcool the liquid from the condenser.

subcool the liquid from the condenser. Graphic interpretation in T-s diagram for such a process is shown in Fig. 11-76. The result of the use of suction line heat exchanger is to increase the refrigeration effect AQ and to increase the work by AW The change in COP is then:

When dry, or superheated, vapor is used to subcool the liquid, the COP in R12 systems will increase, and decrease the COP in NH3 sys

FIG. 11-76 Refrigeration system with a heat exchanger to subcool the liquid from the condenser.

tems. For R22 systems it could have both effects, depending on the operating regime. Generally, this measure is advantageous (COP is improved) for fluids with high, specific heat of liquid (less-inclined saturated-liquid line on the p-h diagram), small heat of evaporation hfg, when vapor-specific heat is low (isobars in superheated regions are steep), and when the difference between evaporation and condensation temperature is high. Measures to increase COP should be studied for every refrigerant. Sometimes the purpose of the suction-line heat exchanger is not only to improve the COP, but to ensure that only the vapor reaches the compressor, particularly in the case of a malfunctioning expansion valve.

The system shown in Fig. 11-75 is direct expansion where dry or slightly superheated vapor leaves the evaporator. Such systems are predominantly used in small applications because of their simplicity and light weight. For the systems where efficiency is crucial (large industrial systems), recirculating systems (Fig. 11-77) are more appropriate.

Ammonia refrigeration plants are almost exclusively built as recirculating systems. The main advantage of recirculating versus direct expansion systems is better utilization of evaporator surface area. The diagram showing influence of quality on the local heat-transfer coefficients is shown in figure 11-90. It is clear that heat-transfer characteristics will be better if the outlet quality is lower than 1. Circulation could be achieved either by pumping (mechanical or gas) or using gravity (thermosyphon effect: density of pure liquid at the evaporator entrance is higher than density of the vapor-liquid mixture leaving the evaporator). The circulation ratio (ratio of actual mass flow rate to the evaporated mass flow rate) is higher than 1 and up to 5. Higher values are not recommended due to a small increase in heat-transfer rate for a significant increase in pumping costs.

Multistage Systems When the evaporation and condensing pressure (or temperature) difference is large, it is prudent to separate compression in two stages. The use of multistage systems opens up the opportunity to use flash-gas removal and intercooling as measures to improve performance of the system. One typical two-stage system with two evaporating temperatures and both flash-gas removal and intercooling is shown in figure 11-78. The purpose of the flash-tank intercooler is to: (1) separate vapor created in the expansion process, (2) cool superheated vapor from compressor discharge, and (3) to eventually separate existing droplets at the exit of the medium-temperature evaporator. The first measure will decrease the size of the low-stage compressor because it will not wastefully compress the portion of the flow which cannot perform the refrigeration and second will decrease the size of the high-stage compressor due to lowering the specific volume of the vapor from the low-stage compressor discharge, positively affecting operating temperatures of the high-stage compressor due to cooling effect.

If the refrigerating requirement at a low-evaporating temperature is Ql and at the medium level is Qm, then mass flow rates (m1 and mm respectively) needed are:

FIG. 11-77 Recirculation system.


FIG. 11-77 Recirculation system.

FIG. 11-78 Typical two-stage system with two evaporating temperatures, flash-gas removal, and intercooling.

The mass flow rate at the flash-tank inlet m, consists of three components (m, = mi + m„p + to^h):

m1 = liquid at pm feeding low temperature evaporator, msup = liquid at pm to evaporate in flash tank to cool superheated discharge, mflash = flashed refrigerant, used to cool remaining liquid. Vapor component is:

and liquid component is:

Liquid part of flow to cool superheated compressor discharge is determined by:

Since the quality xm is:

mass flow rate through condenser and high-stage compressor mh is finally:

The optimum intermediate pressure for the two-stage refrigeration cycles is determined as the geometric mean between evaporation pressure (pl) and condensing pressure (ph, Fig. 11-79):

based on equal pressure ratios for low- and high-stage compressors. Optimum interstage pressure is slightly higher than the geometric mean of the suction and the discharge pressures, but, due to very flat optimum of power versus interstage pressure relation geometric mean, it is widely accepted for determining the intermediate pressure. Required pressure of intermediate-level evaporator may dictate interstage pressure other than determined as optimal.

Two-stage systems should be seriously considered when the evaporating temperature is below -20°C. Such designs will save on power and reduce compressor discharge temperatures, but will increase initial cost.

Cascade System This is a reasonable choice in cases when the evaporating temperature is very low (below -60°C). When condensing pressures are to be in the rational limits, the same refrigerant has a high, specific volume at very low temperatures, requiring a large compressor. The evaporating pressure may be below atmospheric, which could cause moisture and air infiltration into the system if there is a leak. In other words, when the temperature difference between the medium that must be cooled and the environment is too high to be served with one refrigerant, it is wise to use different refrigerants in the high and low stages. Figure 11-80 shows a cascade system schematic diagram. There are basically two independent systems linked via a heat exchanger: the evaporator of the high-stage and the condenser of the low-stage system.

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  • Richard
    Why liquid to suction line heat exchangers are not used for r22?
    2 months ago
    How liquid suction heat exchanger improve the cop of vapour compression cycle?
    2 months ago
  • Vilho
    Why RE is constant in VCRS cycle when we use heat exachanger?
    1 month ago

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