PROJECT GUIDE: Mr. RAM KUMAR Refrigeration system is the process of removing heat from an enclosed space or from a substance for the purpose of lowering the temperature.
They are basically of two types: VAPOR COMPRESSION REFRIGERATION SYSTEM(VCRS). VAPOR ABSORPTION REFRIGERATION SYSTEM(VARS). The VCRS system uses a circulating liquid refrigerant as the medium which absorbs and removes heat from the space to be cooled and subsequently rejects heat.
It consists of four components: A compressor A condenser A thermal expansion valve An evaporator A simple vapor compression refrigeration system removes the heat from a system through external energy input. Moreover heat energy from the system is directly dumped into the atmosphere as a waste. This heat energy which is rejected to the atmosphere can be utilized if we send the hot refrigerant after being compressed in the compressor to a cabin where heat can be exchanged with the cold object kept in that cabin. Heat energy released to atmosphere as a waste Thermodynamic processes in refrigeration systems release large amount of heat to the environment. Heat transfer between the system and the surroundings environment takes place at a finite temperature difference. Heat transfer is a major source of irreversibility for the cycle. Irreversibility causes the system performance to degrade. The first law is only concerned with the conservation of energy, and it gives no information on how, where, and how much the system performance is degraded. Exergy analysis is powerful tool in design, optimization and performance evaluation of energy systems.
contd. An important of Exergy analysis for the systems that consume work such as refrigeration, liquefaction of gasses and distillation of water is finding the minimum work required for a certain desired results. The Exergy of a system is the maximum useful work that can be extracted from that system until it reaches equilibrium with its environment. Exergy can be destroyed by irreversibility of a process. Since it is the ability of energy to do work which gives energy its value to society, we should strive to conserve available work (exergy), not energy.
contd. There have been several studies on the exergy analysis of refrigeration and heat pump systems: Gibbs introduced the term available energy for the useful part of the energy. Everybody possesses energy all the energy is not useful. The loss of work (Wloss) due to irreversibility of processes is equal to the product of the temperature of the environment, T, and the sum of the increases of entropy of all the bodies participating in the process.
Thus, W(loss)= TS Typically the heat of the refrigeration fluid, at the discharge from the compressor (commonly known as the hot gas line), is between 60 and 90C but can be as high as 110C. The hot gas discharge from the compressor, while passing through auxiliary condenser, gives us a part of heat content and gets de-superheated. The auxiliary condenser is called the de- superheater. About 20% of the heat rejection is due to de-superheating of the refrigerant prior to condensation and this heat has the potential to be recovered as high grade heat for other heating purposes.
I. To manufacture and fabricate refrigeration cum heating system II. To create extra new feature, by modifying the traditional method. III. Creative and innovative design including CAD model and analysis. IV. To design and fabricate the prototype of refrigeration system saving heat energy based on theories and practical application in Mechanical engineering method.
A process plant where demand for hot water is high, such as in steam boiler water pre- heating. Food processing plants where, for example, large amounts of hot water are needed for washing down. Buildings that need air conditioning and hot water, such as swimming pools and hospitals. Let T1 = Temperature of refrigerant before entering the compressor T2 = Temperature of refrigerant at exit of compressor T3 = Temperature of refrigerant after condenser T4 = Temperature of refrigerant after expansion valve P1 = Suction pressure P2 = Delivery pressure h1 = Enthalpy of refrigerant before entering the compressor h2 = Enthalpy of refrigerant at exit of compressor. h3 = Enthalpy of refrigerant after condenser h4 = Enthalpy of refrigerant after expansion valve.
Mass of refrigerant = 0.0036kg/sec Troom (Room temperature) = 20C
contd. h1 = 380kJ/kg h2 = 490kJ/kg h4 = 250kJ/kg
C.O.P = (h1-h4) / (h2-h1) = (380-250) / (490-380) = 1.18 Heat utilised = mref.Cp ref. (T2 Troom) = 0.0036*0.856 (40 20) = 20.1 kw Work input = Compression work = h2 h1 = 490 380 kJ/kg = 110 kJ/ kg Using the RAC chart of R-134a Refrigeration effect = h1 h4 = 380 250 (kJ/kg) = 130 kJ/ kg Capacity = (130/3.5) 0.00366 TR = 0.135 TR
Effect of Parameters on Refrigeration
Effect of sub-cooling
Effect of super heating
Effect of suction pressure
LIST OF PARTS OF PROJECT Compressor :A compressor is a mechanical device that increases the pressure of a gas by reducing its volume. We used a hermetic compressor for the set up because it is cheap and readily available and most feasible .
Hermetic compressor: A hermetic or sealed compressor is one in which both compressor and motor are confined in a single outer welded steel shell. The motor and compressor are directly coupled on the same shaft, with the motor inside the refrigeration circuit. Thus the need for a shaft seal with the consequent refrigerant leakage problem was eliminated. All the refrigerant pipeline connections to the outer steel shell are by welding or brazing. The electrical conductors to the motor are taken out of the steel shell by sealed terminals made of fused glass. A condenser is a device or unit used to condense a substance from its gaseous to its liquid state, typically by cooling it.
A coil type condenser was chosen for the project as it is cheap, easy to handle and it is readily available. It is largely used as a condenser in the refrigerator and capacity of cooling was appropriate for the project.
Capillary tube is one of the most commonly used throttling devices in the refrigeration and the air conditioning systems. The capillary tube is a copper tube of very small internal diameter. It is of very long length and it is coiled to several turns so that it would occupy less space. The internal diameter of the capillary tube used for the refrigeration and air conditioning Applications varies from 0.5 to 2.28 mm (0.020 to 0.09 inches). Capillary tube used as the throttling device in the domestic refrigerators, deep freezers, water coolers and air conditioners. CAD Model of Capillary Nozzle The tubing cutter is an essential plumbing tool if you are going to be doing any work with copper pipe. With copper pipe it is important to have smoothly cut and squarely cut ends and well fitted joints. Filter-driers are a key component in any refrigeration or air conditioning system. A filter-drier in a refrigeration or air conditioning system has two essential functions: one, to adsorb system contaminants, such as water, which can create acids, and two, to provide physical filtration. RELAY is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.
Compressor Hot Chamber Cold Chamber Capillary Tube Filter Condenser Step 1 Plywood was chosen as a base for support and assembly of all the components. Hand hacksaw was used for getting the desired dimension of the plywood needed Step 2- Drilling was done on the plywood with 10mm drill bit. Holes were drilled on the compressor, condenser and chambers Nut and bolt was used to tighten the components.
Step 3- Condenser is mounted on the plywood by drilling a hole on a mild steel plate and attaching it to the plywood by nut and bolt.
Step 4- Assembly of all the parts were done with connecting wires with the brazing process. Capillary tube was connected between condenser and cooling chamber. Set up was rechecked. Refrigerant was charged into the condenser.
The process goes on via following process:- 1.Refrigerant is charged to the compressor 2.Refrigerant is compressed in compressor increasing its temperature and pressure. 3.The heated refrigerant if passed through the hot chamber where heat is extracted. 4.The remaining heat is rejected to the atmosphere through condenser. 5.The cooled refrigerant is further cooled by decreasing its pressure by passing through capillary tube. 6.A copper strainer filter is attached in the line of the capillary tube after it comes out of the condenser to avoid any blockage of the refrigerant. 7.Now this cooled refrigerant passes through the cold chamber where it extracts the heat from the hot body kept inside it. 8. The refrigerant is again send to the compressor.
(I) Cutting Cutting process is used to make the base by cutting the plywood. Moreover the cutting of cast iron was also done to support the frame of the condenser. A hand hacksaw was used to cutting process. A hacksaw is a fine- tooth hand saw with a blade held under tension in a frame, used for cutting materials such as metal or plastics. Hand-held hacksaws consist of a metal arch with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other mechanism is used to put the thin blade under tension. The blade can be mounted with the teeth facing toward or away from the handle, resulting in cutting action on either the push or pull stroke. On the push stroke, the arch will flex slightly, decreasing the tension on the blade, often resulting in an increased tendency of the blade to buckle and crack. Cutting on the pull stroke increases the blade tension and will result in greater control of the cut and longer blade life.
(II) Drilling Drilling is used in this to drill number of holes in the components for the assembling of components with each other with the help of nuts and bolts. There are number of holes drilled of different sizes according to the feasibility of the project.
(III) Brazing Brazing is a metal-joining process whereby a filler metal is heated above melting point and distributed between two or more close-fitting parts by capillary action. The filler metal is brought slightly above its melting (liquidus) temperature while protected by a suitable atmosphere, usually a flux. It then flows over the base metal (known as wetting) and is then cooled to join the work pieces together. It is similar to soldering, except the temperatures used to melt the filler metal are higher for brazing. Components Quantity Cost(in Rs.) Compressor 1 2500 Condenser 1 300 Chambers 2 900 Filter 1 70 Capillary tube 2.44 meters 250 Connecting Wire N/A 200 Nut and Bolt 4 Taken from lab Plywood 1 100 Refrigerant N/A 120 Brazing N/A 450 Mild steel plate 2
Taken from lab COST REPORT Total cost- Rs. 4850(approx)
Various cycles in refrigeration Energy losses from the compressor Vapour compression refrigeration system Various fabrication processes (cutting, brazing, drilling etc.) Energy conservation Energy utilization There is always loss of energy in a mechanical process
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