Optimizing cascade refrigeration systems with low GWP refrigerants for Low-Temperature Applications: A thermodynamic analysis

•Evaluated R744 in low temperature cycle and R717, R1234yf, R1234ze(E), R1336mzz(E), R1336mzz(Z) in high temperature cycle to boost system performance.•Focused on optimizing efficiency by determining optimal condensing temperature for maximal system performance.•The R744/R717 combination achieved a higher COP of 2.05 and lower compressor work across varying evaporator temperatures.•Exergy efficiency for R744/R717 increases from 26.47 % at −55 °C to 51.73 % at −20 °C.•Showed significant benefits of superheating and sub-cooling on system efficiency. This study offers a comprehensive thermodynamic analysis of a cascade refrigeration system conducted for low-temperature applications, focusing on the use of low-GWP and zero-ODP refrigerants to improve efficiency and sustainability. The target of this study is to explore the performance of the system using a combination of refrigerants: low-temperature cycle refrigerants such as R744, while high-temperature cycle refrigerants such as R717, R1234yf, R1234ze(E), R1336mzz(E), and R1336mzz(Z), respectively. The ECS model incorporating in REFPROP 10.0a tool was utilized to extract the data through coding for analysis. The assessment of this system involves the examination of various parameters such as its coefficient of performance, total compressor workload, total exergy, and exergy efficiency across various operational conditions. The results are compared with and without superheated and subcooled conditions to understand the impact of these parameters on the system performance. The system with R744 in the low-temperature cycle and R717, R1234yf, R1234ze(E), R1336mzz(E), and R1336mzz(Z) in the high-temperature cycle provides a higher COP and lower total compressor work compared to the conventional cascade refrigeration system. In optimal CRS, the R744-R717 pair attains the highest COP of 2.05 at the lowest possible compressor work from 9.53 to 4.87 kW than other refrigerants pair while evaporator temperature shifting from −55 °C to −20 °C. The exergy efficiency of R744/R717 is found at 26.47 % at an evaporator temperature of −55 °C, but it extends to a peak of 51.73 % at −20 °C. The study also shows that the superheating and sub-cooling of the refrigerants have a significant impact on the performance of the cascade refrigeration system. Superheating and sub-cooling at 10 °C, improves the COP of the system by reducing the compressor work and increasing the heat transfer efficiency. The research offers valuable insig