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Economizer Sizing Calculator

GPSA Ch. 14

Economizer Sizing Calculator
Sizes flash gas economizer vessels for refrigeration loops. An economizer flashes high-pressure liquid refrigerant at an intermediate pressure, routing the flash gas directly to the compressor interstage and subcooling the remaining liquid before the evaporator. Calculates flash fraction, power savings, COP improvement, and vessel dimensions for propane, ethane, propylene, or ammonia systems per GPSA Ch. 14.
GPSA Ch. 14
Calculation Mode:
Design: Size a new economizer vessel from refrigerant properties and chiller duty.

Refrigerant & Duty

MMBTU/hr
psig
psig
psig
°F

Vessel Design

min

Typical Economizer Operating Conditions

Parameter Range
Economizer PressureGeometric mean of Pcond & Pevap
Flash Fraction10–25 wt%
Power Savings5–15%
COP Improvement5–20%
Liquid Retention3–10 min

Engineering Basis

Flash Fraction:

x = (hin − hf,econ) / (hg,econ − hf,econ)

Where hin = enthalpy of subcooled liquid entering economizer, hf,econ = saturated liquid enthalpy at economizer pressure, hg,econ = saturated vapor enthalpy at economizer pressure.

COP Improvement:

COPecon = Qevap / (Wlow + Whigh)

The economizer reduces compressor work by routing flash gas to an intermediate compression stage, avoiding re-compression from the lowest suction pressure.

Vessel Sizing: The economizer vessel is sized as a flash drum to separate vapor from liquid at the intermediate pressure. Diameter is set by vapor disengagement velocity (Souders-Brown), and length by liquid retention time with the specified L/D ratio and design margin.

Design Guidelines

Optimal Pressure: The economizer pressure is typically set at the geometric mean of condenser and evaporator pressures: Pecon = √(Pcond × Pevap).
Flash Gas Routing: Flash vapor is routed to the compressor interstage or a separate sideload port, reducing the mass flow through the low-stage compression.
Subcooling Benefit: The remaining liquid leaving the economizer is subcooled relative to condenser conditions, increasing net refrigeration effect at the evaporator.