Multi-objective optimization and 4E (energy, exergy, economy, environmental impact) analysis of a triple cascade refrigeration system.

The post-pandemic energy crisis and ever-increasing environmental degradation necessitate researchers to scrutinize refrigeration systems, major contributors to these issues, for minimal environmental impact and maximum performance. Thus, this study aims to comprehensively examine a triple cascade refrigeration system (TCRS) equipped with hydrocarbon refrigerants (1-butene/Heptane/m-Xylene). This system is specifically designed for ultra-low temperature applications, including vaccine storage, quick-freezing, frozen food preservation, cryogenic processes, and gas liquefaction. The investigation integrates conventional thermodynamic analysis with economic and environmental impact assessments, and finally multi-objective optimization (MOO) to ascertain optimal operating conditions for the system. The effect of (1) evaporator temperature, T (2) condenser temperature, T (3) Lower Temperature Circuit (LTC) condenser temperature, T (4) Mid Temperature Circuit (MTC) condenser temperature, T and (5) Cascade Condenser temperature difference, on three objective functions (COP, exergy efficiency, and overall plant cost) have been investigated employing a parametric analysis. Subsequently, quadratic equations for these objective functions are generated using the Box-Behnken method, and MOO utilizing the Genetic algorithm has been performed to maximize COP and exergy efficiency while minimizing the overall cost rate. The decision-making techniques TOPSIS and LINMAP are used to retrieve a unique solution from the Pareto Front, and the system performance has been assessed at the optimal point. The optimization result demonstrates that for the 10-kW capacity TCRS, COP, exergy efficiency, and total plant cost are 0.71, 0.51, and 38262.05 $/year respectively, at optimum condition (T = -101.023 , T = 36.545 , T = - 69.047 and T = - 34.651 ). Exergy analysis identifies HTC compressor (19.3 %) and throttle valve (15.5 %) as key contributors to total exergy destruction, while economic analysis underscores capital and maintenance costs (72 %) as the primary contributors to the overall cost, with evaporator (43 %) and condenser (20 %) accounting for 63 % of this cost.