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Performance Investigation of Cascade Refrigeration System Using CO 2 and


Mixtures

Article in International Journal of Air-Conditioning and Refrigeration · June 2015


DOI: 10.1142/S2010132515500224

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International Journal of Air-Conditioning and Refrigeration
Vol. 23, No. 3 (2015) 1550022 (9 pages)
© World Scienti¯c Publishing Company
DOI: 10.1142/S2010132515500224

Performance Investigation of Cascade Refrigeration


System Using CO2 and Mixtures

Nourheine Jemni, Mouna Elakhdar,


Ezzedine Nehdi and Lakdar Kairouani*
University of Tunis ElManar
Unite de Recherche Energetique & Environnement
Ecole Nationale d'Ingenieurs de Tunis
BP37 Le Belvedere 1002 Tunis Tunisia
*lakdar _kairouani@yahoo.fr
by Professor Lakdar Kairouani on 08/05/15. For personal use only.
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Received 13 March 2015


Accepted 19 June 2015
Published 23 July 2015

This paper presents reports on simulation and comparative analysis of single stage vapor com-
pression refrigeration system and cascade systems using carbon dioxide, hydrocarbons (HCs) and
CO2/HCs mixture. Thermodynamic parameters of °uids are given using the software REFPROP
9.0. To select the most suitable HCs, three criteria have been ¯xed: Tc , Tt and Tb . It is found
that the HCs chosen in low-stage are propane, propylene and ethane and those for the high-stage
are propane, propylene and isobutane. The fraction mixture in the two loops has been varied and
results are compared with single stage and cascade systems using CO2 and R22. The fraction
xCO2 is varied in the two loops. Results are compared for single and cascade systems using CO2
and R22. For the single stage system, we ¯nd for xCO2 ¼ 0.5, an improvement of COP of 14% for
CO2/propane mixture and 36% for the CO2/propylene mixture. It is found that for xCO2 ¼ 0.3,
cascade system using propane/CO2 and propylene/CO2 mixtures presents a COP lower
than that of cascade system using pure CO2. About of 70% of unfriendly °uids like CFCs and
HCFCs can be replaced with CO2, without a®ecting the performance of cascade refrigeration
systems.

Keywords: Cascade refrigeration system; CO2; COP; mixture; refrigerant.

Nomenclature Abbreviations
Q : Heat rate [kW] LS : Low stage
W : Work input [kW] HS : High stage
M : Mass low rate [kg/s] COP : Coe±cient of performance
T : Temperature [  C]
P : Pressure [MPa] Subscripts
h : Speci¯c enthalpy [kJ/kg] 1; 2; 3; . . . ; i : Cycle states
x : Mass fraction e : Evaporator

1550022-1
N. Jemni et al.

c : Condenser than that of system working with R12. Kuijpers


o,e : Out evaporator et al.6 analyze theoretically system with mixtures of
i,e : In evaporator R290/R600a (21/79%) and showed that this mix-
o,c : Out condenser
ture can be considered as a good substitute to R12.
comp : Compressor
LS : Low stage Hammad et al.7 studied experimentally four blends
HS : High stage of propane, butane and isobutene. They found that
i : Intermediate 50% propane, 38.3% butane and 11.7% isobutene
sys : System gave the best performance. Experimentations of
t : Triple Jung et al.8 showed that 60% mass fraction of pro-
b : Boiling
cr : Critical
pane in mixture of propane and isobutene gave
R : Relative higher COP than R12. Akash et al.9 analyzed re-
frigeration system with blends of propane 30%, n-
butane 55% and isobutene 15% as substitute to R12
and found a COP comparable to R12. Mani et al.10
1. Introduction studied experimentally vapor compression refriger-
Many researches were done to replace CFCs and ation system with R290/R600a (68/32). They found
HCFCs in one-stage and cascade refrigeration sys- a COP higher in the range 3.9–25.1% in the lower
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tems. Some researchers are interested in studying evaporating temperatures and 11.8–17.6% higher in
HFC mixtures as substitute. Hwang et al.1 investi- the higher evaporating temperature than R12. But
gated experimentally the relative performance po- they found that the new refrigerant consumed 6.8%
tential of HFCs (R404A and R410A) as compared to to 17.4% more energy than R12. Mohanraj et al.11
R290 for refrigeration systems representing direct investigated experimentally the hydrocarbon mix-
expansion commercial refrigeration systems with ture composed of 45.2% of R290 and 54.8% of
small charge. They found that R410A has less or R600a. They concluded that this mixture can be
equivalent environmental impact as compared to used as an alternative to phase out R134a in do-
R290 when safety, environmental impact, cost and mestic refrigerators because it improved the COP by
performance are considered. Wu et al.2 reports a up to 3.6% and 60 g of it consumes about 11.1%
ternary mixture R152a/R125/R32 with a mass ra- lesser energy compared to R134a.
tion of 48/18/34 as a potential alternative to R22 Other researchers studied pure carbon dioxide,
which was widely used in domestic air conditioner. nitrogen and blends of carbon dioxide with HFC
They found that both calculation and experimental and HC. Mortaza Yari12 presented a new two-stage
results showed that this new mixture could be con¯guration of ejector expansion transcritical re-
regarded as a most likely drop in substitute for R22 frigeration cycle. He found that, compared with
in many applications. Chen et al.3 presented a new conventional two-stages transcritical CO2 cycle, the
refrigeration cycle using binary nonazeotropic re- COP and second law e±ciency of the new two-stage
frigerant mixture R32/R134a. They obtained a cycle are about 12.5–21% higher than that of con-
conventional refrigeration cycle with a performance ventional two-stage cycle. Sarkar et al.13 analyzed
close to that obtained with R22 and that the max- transcritical N2O cycle and made energetic and
imal COP can be proved in a range of 8–9%. Gang exergetic comparison with CO2 cycle. They found
et al.4 built a two-stage cascade refrigeration testing that N2O cycle exhibits higher cooling COP, lower
apparatus using three R170 (ethane) mixtures as compressor pressure ratio and lower discharge
potential refrigerant substitutes for R508b. They pressure and temperature and higher second law
found that R170 þ R116 mixture showed the high- e±ciency higher, however, it is inferior in term of
est COP which is up to about 10% higher than that volumetric cooling capacity. Nicola et al.14 analyzed
of R508B. Other works were focusing in using nat- the performance of cascade refrigeration cycle op-
ural °uids such as water, ammonia, carbon dioxide erated with a blend of carbon dioxide and HFC
and hydrocarbons (HCs). Some studied the refrig- (R125, R41, R32, R23) as the low-stage and am-
erant propane/isobutane mixture as substitute to monia as the high-stage. They concluded that R744
R12. Richardson et al.5 investigated the perfor- blends can be considered as an attractive option for
mance of R290/R600a mixture in vapor compres- the low-stage in cascade system operating at 200 K.
sion refrigeration system. They found COP better Ni et al.15 proposed an environment friendly new

1550022-2
CO2 Refrigeration System

alternative refrigerant to R13 composed of R744/ and others pure °uids like ammonia, R134a,
R290 (71/29, mole fraction). Results showed that propylene.
R744/R290 blends can be considered as a good This work is interested in the use of carbon di-
substitute for R13 when the evaporator tempera- oxide. This °uid has some disadvantages such as
ture is higher than 201 K. Kim et al.16 developed a high pressure and high triple point which prevents it
fully instrumented air-conditioning system to eval- from working at lower temperature. To overcome
uate the transcritical cycle of CO2 and the sub- these disadvantages, we will mix carbon dioxide
critical cycle of CO2/propane mixture of 75/25 and with HCs. We will study cascade system and search
60/40 by the charged mass percentage. They found the suitable mixtures which allow the highest per-
that the CO2 refrigeration system could operate formance. These systems will be compared to those
without a signi¯cant impact on its COP over a working with R22.
relatively wider range near the optimum charge
level. Sarkar et al.17 proposed R744/R600 and
R744/R600a blends as working °uids in heat pumps 2. System Analysis
for medium and high temperature heating applica- 2.1. Systems description
tions. They found that R744/R600a-based heat
pumps exhibit the best performance for higher CO2 Refrigerator vapor compression is the most common
method for producing cold. It is based on the con-
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mass fraction compared to that for R744/R600.


Kim et al.18 presented the cooling performance of densation of a refrigerant after the compression and
several CO2/propane mixture measured in air con- the evaporation following an expansion.
ditioning system. They found that the COPs of We ¯nd single stage, Fig. 1, multistage and cas-
CO2/propane mixture of 85/15, 75/25 and 60/40 cade vapor-compression refrigeration system. The
are enhanced by 8%, 12.8% and 12.5%, respectively. last one is more e±cient when we need low cooling
Based on this work Min Cho et al.19 investigated temperature. It allows cooling temperature near
the evaporation heat transfer characteristics of 70  C.29
CO2/propane refrigerant mixtures. They found that As it is shown in Fig. 2, cascade system is com-
using 75/25 CO2/propane mixture for refrigeration posed of two separate loops, the high-stage and the
or air conditioning system, reduced operating low-stage. The two are connected by cascade con-
pressure is one of the great bene¯ts. Mohanraj denser which operates as evaporator in the high-
et al.20 reviewed the various experimental and the- stage and as condenser in the low-stage.
oretical studies carried out around the globe with The performance of cascade system is related to
environment friendly alternatives such as HCs, the intermediary temperature Ti (low-stage con-
hydro°uorocarbons and their mixtures. They densation temperature). When Ti increases, the
obtained that HC mixtures and R152a are good compression ratio increases, for the low-stage com-
alternative to R12 and R134a in domestic refriger- pressor and decreases for the other. Consequently
ation sector, R290, R1270, R290/R152a, R744 and COPLS decreases and COPHS increases which allows
HC/HFC mixtures are the best alternatives for R22 a simultaneous degradation and improvement of
in air conditioning and heat pump applications,
R123 is an attractive alternative to R11, R12 and
R22 in chiller applications and that R152a and HC
mixtures are the best refrigerant for automobile air
conditioner. Viewing all those work, we can see that
propane mixture, carbon dioxide and HCs have
attracted a considerable attention. But they present
some problems, which caused the limit of their
usage in the past, like °ammability, toxicity, safety
problem or low energy e±ciency. To overcome this
issue, Wang et al.21 proposed the use of the new
refrigerant in conjunction with a secondary loop
refrigeration system. Several researchers22–28 are Fig. 1. Schema of conventional one-stage subcritical carbon
interested in studying cascade systems using CO2 dioxide refrigeration cycle.

1550022-3
N. Jemni et al.

Condenser refrigeration cycle. One of the advantages of


zeotropic mixture is the possibility of reduction in
7 6 entropy generation by matching the temperature
Throttling valve glides of refrigerant and heat-transfer °uid in both
Compressor
condenser and evaporator. Consequently, irrevers-
Evapo-condenser ibility will be reduced and system performance will
8 5
be improved.

3 2
Compressor
Throttling valve 2.3. Energetic analysis
Evaporator
4 1 To simplify the thermodynamic study, some
assumptions are considered: the evaporation and the
condensation are isobaric (Ti;e < To;e ). The outlet
Fig. 2. Conventional two-stages refrigeration cycle.
states of condenser, evaporator, separator and cas-
cade condenser are saturated. The heat loss and the
COPSys . This signi¯es the existence of an optimum pressure drops in heat exchangers and in the con-
intermediary temperature.30 Hence, in this study, the necting pipes are negligible. The compression pro-
cycle will be studied in the optimum conditions (Ti ).
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cess is adiabatic with an isentropic e±ciency of 80%


for all cases.32 The expansion process is isenthalpic.
2.2. Characteristics of °uids used The cascade condenser's pinch temperature, T is
equal to 5  C. To;e ¼ 40  C and To;c ¼ 40  C. The
2.2.1. HCs system is subcritical.
HCs are organic compound containing only carbon Based on these assumptions, the compressors
atoms (C) and hydrogen (H). They are environment consumption powers, the rejected and the absorbed
friendly substitute, nontoxic and noncontributing to heat of each component are de¯ned by the following
the deterioration of the ozone layer, very e±cient expressions:
and can reduce energy consumption in refrigeration
and air conditioning systems, direct replacement for 2.3.1. Single stage system
CFC refrigerants, R12, R22-CFC and HFC 134a in The compressor consumption power, the condensing
their existing systems without change parts or oil, and the refrigerating heat are de¯ned by the fol-
cheaper and cheaper to use and Flammable. lowing expressions:

2.2.2. Carbon dioxide W_ comp ¼ mðh


_ 2  h1 Þ : ð1Þ
It is naturally present everywhere in our environment.
It was used from the late 1800s but with the advent of The refrigerating load is:
the Freon the use of CO2 was interrupted. It is: non- Q_ e ¼ mðh
_ 1  h4 Þ : ð2Þ
toxic, incombustible, complete compatible with nor-
mal lubricants and common machine construction The heat rejected is:
materials, easy available everywhere and Cheap. Q_ c ¼ mðh
_ 2  h3 Þ : ð3Þ
But it has:
The coe±cient of performance is:
. critical point temperature very low: 30.97  C
. critical point pressure very high: 73.77 bars. Q_ e ðh  h4 Þ
COP 1s ¼ ¼ 1 : ð4Þ
_
Wc ðh 2  h1 Þ
2.2.3. Mixtures of CO2 and HCs
The mixtures of carbon dioxide and HCs are good 2.3.2. Cascade system
refrigerants because mixing the two °uids over-
comes negative characteristics of each °uid: the high The compressors consumption powers are:
pressure of CO2 and the °ammability of HCs. These W_ compLS ¼ m_ LS ðh2  h1 Þ ; ð5Þ
mixtures are zeotropic: during change in phase's
state, there is a change in temperature at the W_ compHS ¼ m_ HS ðh6  h5 Þ : ð6Þ

1550022-4
CO2 Refrigeration System

The heat rejected is:

Q_ c ¼ m_ HS ðh6  h7 Þ : ð7Þ

The refrigerating load is:


Q_ e ¼ m_ LS ðh1  h4 Þ : ð8Þ
The energy balance at the cascade condenser is
written as:
m_ LS ðh2  h3 Þ ¼ m_ HS ðh5  h8 Þ : ð9Þ
In the low-stage the conservation of energy implies:
Fig. 3. The in°uence of xCO2 on the COP for two models.
m_ LS ðh2  h3 Þ ¼ W_ compLS þ Q_ e : ð10Þ
The coe±cients of performance of low-stage and
high-stage are given by those expressions:
Nicola et al. analyzed the performance of cascade
Q_ e ðh  h4 Þ refrigeration cycle operated with blends of CO2/
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COP LS ¼ ¼ 1 ; ð11Þ
W_ compLS ðh2  h1 Þ ethane in low-stage and ammonia in high-stage. By
m_ ðh  h8 Þ ðh5  h8 Þ comparing results, Fig. 3, we notice a substantial
COP HS ¼ HS 5 ¼ : ð12Þ agreement.
W_ compHS ðh6  h5 Þ
The global COP of the cascade system is:
3.2. Criteria of choice of HCs
Q_ e
COPsys ¼ : ð13Þ
W_ compLS þ W_ compHS Refrigerated system allows low temperature cool-
ing. This temperature is limited by the triple point
By combining (9)–(13), COPsys will be written as: which cannot fall below and by the boiling point of
COP LS COP HS the refrigerants that should be low enough in order
COP sys ¼ : ð14Þ to eliminate the possibility of air and moisture
COP HS þ COP LS þ 1
entering into the system (Tb < Ti;e < To;e ). The
Theoretical models are written by FORTRAN. critical temperature of the refrigerant should
The thermodynamic parameters of °uids are be very high, to work on subcritical conditions
given using the software REFPROP 9.0.31 (To;c < Tt ). So the choice of HC will be based on
these criteria.
Table 1 gives properties of CO2 and selected
3. Results and Discussion HCs.
When mixing the carbon dioxide and HCs all
3.1. Validation and simulation thermodynamic characteristics of the mixture de-
To validate our model, we compare our results with pend on the fraction of carbon dioxide. We will
the results obtained experimentally by Niu et al.15 therefore take the HCs having a boiling point in the
and theoretically by Nicola et al.33 pure state below Ts;e and those having Ts;c < Tc .
The model of Niu et al. is a vapor compression Table 2 gives the list of mixtures we can
cascade refrigeration system. It used R290 as high- use in low-stage and high-stage and the mole
stage's refrigerant and the mixture co2/propane fractions of carbon dioxide that respect the ¯xed
(71/29) as low-stage's refrigerant. Using the same assumptions.
parameters giving by Niu et al., our theoretical
model gives a COP ¼ 1:8 when we ¯x the isentropic
e±ciency of compressor to 0.8. We will thus have a 3.3. Single stage
deviation of 15% of the experimental value. This can Figure 4 shows the variation of the COP of vapor
be explained by the assumptions we have set for our compression single stage system as a function of
theoretical model. carbon dioxide mole fraction. COP is maximal when

1550022-5
N. Jemni et al.

Table 1. Tcr , Pcr , Tt and Tb of CO2 , R22 and HCs.

Fluids Tc (  C) Pc (bar) Tt (  C) Tb (  C)

CO2 30.97 73.77 56.55 78.4


R22 94.14 49.9 157.42 40.81
Propylene C3H6 91.06 45.55 185.2 47.62
Propane C3H8 96.74 42.51 187.62 42.11
Butane C4H10 151.98 37.96 138.26 0.49
Isobutane C4H10 134.66 36.29 159.42 11.74
Butene C4H8 146.14 40.05 185.35 6.31
Cis-butene C4H8 162.6 42.25 138.85 3.72
Ethane 32.17 48.72 182.78 88.58
Trans-butene C4H8 155.46 40.27 105.55 0.88
Isopentane C5H12 187.2 33.78 160.5 27.83 Fig. 5. Variation of Qe as function of xCO2 .
Pentane C5H12 196.55 33.7 129.68 36.06
Hexane C6H14 234.67 30.34 95.32 68.71
Figure 6 shows the variation of the relative per-
formance of the system using the mixtures CO2/
Table 2. List of °uids used in low-stage propane and CO2/propylene with the system using
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and high-stage. carbon dioxide. An improvement is noticed when


xCO2 decreases.
Fluids in LS xCO2 Fluids in HS xCO2
For xCO2 ¼ 0.5, the improvement reaches 14% in
Propane 0-1 Propane 0-0,7 the case of mixture CO2/propane and 35.9% for the
Propylene 0-1 Propylene 0-0,8 mixture CO2/propylene. Secondly for xCO2 ¼ 0.7,
Ethane 0-1 Isobutane 0-0,8 we note a degradation of 9% for the ¯rst mixture
and an improvement of 25% for the second.
Viewing these results it is observed that mixing
using both pure HCs. Once propylene is used, the propylene and propane with carbon dioxide increa-
COP is always greater than the COP of the system ses the COP of systems using pure CO2. But it
using pure carbon dioxide, but if propane is used, decreases the COP of systems using pure propylene
the COP decreased over the COP of CO2 when xCO2 and propane. For the fact that CO2 is the natural
reached 0.7. This result is explained in Fig. 5 in refrigerant with the lower environmental impact
which we notice that propylene mixture's Qe is and the lower °ammability, those blends with a
always greater than CO2 single stage one. higher concentration of CO2 are considered partic-
But the COP is lower than the COP of system using ularly interesting for the purpose of this research.
R22 independently of the mixture fraction (xCO2). To ameliorate these results we choose cascade
systems which could decrease compressor work.
These systems have also the advantage of using the
refrigerant that best suits the temperature range
encountered in each stage.

Fig. 4. Variation of the COP of vapor compression single stage Fig. 6. Variation of the relative performance as a function of
system versus xCO2. xCO2 .

1550022-6
CO2 Refrigeration System

Fig. 9. Variation of Qe and W as function of xCO2 in low-stage


Fig. 7. Variation of the COP of single and cascade system.
when using propane in high-stage.

3.4. Cascade system when xCO2 increases and the work increases to a
In cascade systems, we varied the °uids used in the maximum for xCO2 ¼ 0.5 and then decreases.
low-stage and the high pressure one. Figure 10 presents the variation of COP as a
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Figure 7 shows the variation of the COP of a function of xCO2 in high-stage when we use propane
single stage and cascade cycles using CO2, R22, in low-stage. We notice that when we increase xCO2
mixtures of propylene/CO2 and propane/CO2. An in the high pressure stage we ¯nd that the COP
enhancement in the performance appears when sin- decreases.
gle stage cycle replaces a cascade one if pure °uids This is due to the increase of pressure di®erence in
are used in the two loops. This improvement is less the compressor, when xCO2 increases, the mixture
than that of cascade cycle using R22. For fraction pressure tends to the CO2 critical pressure conse-
xCO2 ¼ 0.3, the cascade system using propane/CO2 quently the required work will be higher.
and propylene/CO2 mixtures presents a COP lower As it is shown in Fig. 6, we can see that when we
than that of cascade system using pure CO2. mix propylene/propane/isobutane with carbon di-
Figure 8 presents the variation of COP as a oxide we found that when xCO2 increases in the low-
function of xCO2 in low-stage for xCO2 ¼ 0 in high- stage there will be a remarkable improvement when
stage when mixture of CO2/propane is used in low- xCO2 ¼ 0:2, 0.8 and 0.9 but is still lower than the
stage. It seems that the COP decreases until it COP of system using CO2, propylene, propane and
reaches a minimum for xCO2 ¼ 0.5 then increases isobutane as pure °uids.
whatever the °uid used in mixture with carbon di- The highest COP is reached when pure HCs
oxide in high-stage. This evolution is explained in are used in the two loops, Figs. 7–9. COP ¼ 1:72
Fig. 9. We notice that the cooling capacity decreases is obtained for propane (low-stage)/isobutane
(high-stage) or propylene (low-stage)/isobutane

Fig. 8. Variation of COP as function of xCO2 in low-stage and Fig. 10. Variation of COP as function of xCO2 in high-stage
pure °uids in high-stage. and pure °uids in low-stage.

1550022-7
N. Jemni et al.

To enhance these results we can introduce ejectors


in the two-stages.

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