SECOND LAW BASED OPTIMISATION OF REFRIGERATOR AND AIR CONDITIONER EVAPORATOR

SUPERVISOR:K. MANJUNATH Assistant Prof., Depar tment Of Mechanical Engineering, Delhi Technological Univer sity

TEAM MEMBERS:Aman Kumar(2K10/ME/019) Ankit Gupta(2K10/ME/027) Ankit Himmatramka(2K10/ME/028) Anurag(2K10/ME/033)

INTRODUCTION
REFRIGERATION The American Society of Refrigerating Engineers defines refrigeration as THE SCIENCE OF PROVIDING AND MAINTAINING TEMPERATURES BELOW THAT OF SURROUNDING TEMPERATURE.

PURPOSES OF REFRIGERATION: To reduce the temperature of substance. To transform a substance from one state to another. To maintain substance at desired state.

EVAPORATOR
The evaporator is one of the four basic and necessary hardware components of the refrigeration/AC system . It is basically a heat exchanger. In the evaporator, the refrigerant is evaporated by the heat transferred from the heat source . The heat source may be a gas or a liquid . Used in : Refrigerators, Air-Conditioners, Cold Storage, Industrial Waste Disposal etc.

HOW AN EVAPORATOR WORKS

T YPES OF EVAPORATOR
Domestic Refrigerator/Industrial Refrigerator Window AC/Split AC Natural and Forced Convection Type Refrigerant Flow Inside or Outside Tubes Flooded and Dry Type Shell-and-Tube Evaporator Shell-and-Coil Evaporator Double pipe type Evaporator Baudelot type Evaporator Direct expansion fin -and-tube Evaporator Plate Surface Evaporator

REFRIGERATION CYCLE

architerials.com

OBJECTIVE
OPTIMISATION OF EVAPORATOR ENTROPY GENERATION MINIMISATION(EGM) EXERGY ANALYSIS THERMAL DESIGN ANALYSIS TO ANALYZE PERFORMANCE FACTORS IDENTIFY & MINIMISE THE PROBLEMS ANALY TICAL CALCULATIONS SOFT WARE SIMULATION MATLAB GENETIC ALGORITHM

Topic

Literature Review

Future Scope

Problem Formulation-Entropy Generation Minimization

Analytical Calculations

Software Simulation-MATLAB

Thermal Design Analysis

Genetic Algorithm

LITERATURE REVIEW

Review of research papers and journals

ENTROPY GENERATION MINIMISATION(EGM)

ADRIAN BEJAN,1975 Book ENTROPY GENERATION MINIMIZATION(1995) Book - THE METHOD OF THERMODYNAMIC OPTIMIZATION OF FINITE-SIZE SYSTEM AND FINITE-TIME PROCESSES(1995) EGM combines the basic principles of Heat Transfer, Fluid Mechanics, Thermodynamics to modeling and optimization of real systems and processes that are governed by finite size and finite time constraints, and are limited by heat and mass transfer and fluid flow irreversibilities.

This work applies the second -law analysis of thermodynamics to quantify the exergy destruction of the components of screw liquid chiller, and to identify the potential for each component to contribute to improve the overall energy ef ficiency of the system .
A component associated with a higher propor tion of exergy destruction may more dramatically contribute to improve energy ef ficiency. Second-law analysis is demonstrated to be a feasible and ef fective means in improving the energy ef ficiency of a screw liquid chiller.
T Z O N G - S H IN G LEE ( 2 01 0 )

An extensive EGM -based optimization analysis of the peripheral finned -tube extended sur face geometr y has been conducted in this paper

There is an optimum NTU associated with a minimum entropy generation number for both types of heat transfer boundar y condition.
The heat exchanger ef fectiveness is not a suitable per formance parameter to evaluate the heat exchanger per formance because it increases monotonically with the NTU and does not take into account the fluid pumping power through the heat exchanger.

B RU N O F. P U S S OL I , JA D E R R . BARBOSA JR. ( 2 01 2 )

LAWS OF THERMODYNAMICS
First law of thermodynamics Based on energy conservation Energy can neither be produced nor destroyed, it can only change its form. Second law of thermodynamics Clausius statement of second law of thermodynamics: It is impossible to have a device that while operating in a cycle produces no ef fect other than transfer of heat from a body at low temperature to a body at higher temperature. Kelvin-Planck statement of second law of thermodynamics : It is impossible for a device operating in a cycle to produce net work while exchanging heat with bodies at single fixed temperature.

aos.wisc.edu

Fundamental data on two-phase flow boiling pressure drop are essential for the design and operation of heat exchangers.
The experimental pressure drop results of these study show that the pressure drop along the test section increases with mass flux and exit quality but decreases with system pressure. The pressure drop gradients in 2.01 mm tube are about 3 times higher than those in the 4.26 mm tube.
X. Huo, D. S h i f e r aw, T. G . K a r ay i a n ni s , Y. S . T i a n a n d D . B . R . Ke n n i n g (2008)

Analytical expressions for optimum flow rates in evaporator of refrigerating system

The expression derived can be used for, Design purposes Checking suitable flow velocities in existing plants. Incorporating in algorithms for optimal operation of systems with variable speed compressors.
E. Granr yd ( 2 01 0 )

Experimental investigation on 2 phase flow heat transfer of 5 refrigerants in horizontal small tubes of various inner diameter
The ef fects of mass flux, heat flux, saturation temperature and inner tube diameter on the heat transfer coef ficient are reported.
J o n g -Ta e k O h , A .S. Pamitran, K w a n g - Il C h o i , Pe g a H r n j a k ( 2 01 1 )

REFRIGERANT
Any substance capable of absorbing heat from another substance. Liquid/gas used in evaporator tubes. Source of cooling the gas (refrigerant) or air (air conditioning). High latent heat of vaporization. Ammonia, CO2, SO2, Ethane, Ethylene, Freon(fluorinated hydrocarbons) family like Freon -11 ,1 2,13,14,etc, Azetropes, Water Vapor, Air, NO2 etc. R600a (isobutane), R290 (propane), R134a, R22, R410A , and R32 etc.

An Optimized Design of Finned-Tube Evaporators Using the Learnable Evolution Model

We described an experimental system, ISHED1 , developed to assist a design engineer in optimizing finned -tube evaporator s. Specifically, given input parameter s and technical constraints, the system optimizes the refrigerant circuitr y in the evaporator. The novelty of this approach is in applying the recently developed learnable evolution model, which integrates knowledge-based evolutionar y computation with symbolic learning that guides the process of generating new designs. Generated designs are evaluated using the EVAP evaporator model, which simulates the designs.
Piotr A . D o m a n s ki , D av i d Ya s h a r, Ke n n et h A . Kaufman, Ryszard S. Michalski (2004)

A FUNCTIONAL ARCHITECHTURE OF ISHED1

Domanski, Yashar, Kaufman and Michalski (2004)

This paper presents a comparable evaluation of R600a (isobutane), R290 (propane), R134a, R22, R410A , and R32 in an optimized finned tube evaporator, and analyzes the impact of evaporator ef fects on the system coef ficient of per formance(COP).

They optimized evaporator circuitr y for each refrigerant using a non-Dar winian evolutionar y scheme, and per formed simulations of the optimized evaporators. better COP for low -pressure refrigerants (having a high critical temperature) ver sus high-pressure refrigerants (having a low critical temperature ).
The high-pressure refrigerants provided higher evaporator capacities than the low -pressure refrigerants.

Piotr A . D o m a n s ki , D av i d Ya s h a r, M i n s u ng K i m (2005)

Comparison of COP of various Refrigerants With R22

Domanski, Yashar and Kim (2005)

This paper presents an optimal design of a micro evaporator to maximize the heat transfer coef ficient for an active micro cooler They designed optimal parameters to maximize the heat transfer coef ficient. Selected parameter s are the number of gaps , the channel width, the lateral gap size. The optimal parameter set is determined as 3, 0.5 mm and 1 .25 mm respectively. The maximized heat transfer coef ficients are 0.465, 0.457 and 0.430 W/cm 2 K for the heater powers of 40, 60 and 80 W, respectively.

Ta i j o n g S u n g , Daesik Oh, Ta ew o n S e o and Jongwon Kim ( 2 0 07 )

This paper presents experimental per formance analysis of a window air conditioner(capacity, 1TR) with and without heat exchanger(IHE), along with per formance comparison of R22 and R407C in the same AC.

Use of IHC has increased coef ficient of per formance(COP) when running on R22(5.86%) and R407C(6.3%). When retrofitting R22 with R407C, COP is found to drop with(6.26%) and without(6.64%) IHE.

R V i j aya n a n d P S S S r i n i va s a n (2009)

This paper presents experimental results of the heat transfer per formance of New Tri -tube type evaporators The low temperature evaporator test facility was developed to closely simulate refrigerator-freezer conditions. The overall heat transfer coef ficient of tri tube type evaporator is increased about 1 20% comparing of finned tube type evaporator. The defrosting heater power of tri -tube type evaporator is decreased about 50% comparing of finned tube type evaporator.

Jang-Seok Lee, Ta e - H e e L e e , S e o n g - H un H a m , S e -Yo o n O h , K w a n - S hi k Cho ( 2 01 0 )

This paper describes a steady state model of a multiple ef fect evaporator system for simulation and control purposes . Steady state simulation is done successfully by using fsolve solver in MATLAB source code for three feeding sequences backward, mixed and splitting. The ef fect of variation of various input parameter s on steam economy is studied. They concluded that mixed feed is always optimal for entire range of each parameters.

D e e p a k Ku m ar, V i v e k Ku m a r, a n d V. P. S i n g h ( 2 01 0 )

FACTORS AFFECTING PERFORMANCE OF AN EVAPORATOR

Primary Factors :
Refrigerant used Air Flow Distribution Turbulence Area in contact with refrigerant Conduction Path Resistance and Piping Geometry Refrigerant Pressure Drop and Superheating Value

REFRIGERANT & AIR FLOW DISTRIBUTION

Refrigerant Used
It should be,

Air Flow Distribution

The air flow distribution should be uniform for maximum ef ficiency. Liu & Chen (201 2) found that for equal flow rates, ef ficiency of a multi-circuit evaporator decreased by 7.78% in case of non -uniform distribution of air flow as compared to uniform one. The decrease in per formance can be attributed to decreased heat transfer in case of non -uniform distribution of air flow.

Non-corrosive.
Safe (nontoxic, nonflammable, ecofriendly). Having favourable thermodynamic proper ties. Examples Ammonia, CFC, Freons, R22, R410A , R744 etc.

TURBULENCE & SURFACE AREA

Turbulence
Turbulence in evaporator should be minimised to prevent unwanted losses (in vibration etc.) and maintain system stability. To minimise turbulence, harsh angles or rough surfaces in coils should be avoided as they disrupt the normal flow pattern.

Area in contact with refrigerant

Area in contact with refrigerant vapour should be large. Large contact area allows more heat transfer per unit time for a given temperature dif ference between the evaporator coils and refrigerant.

PATH RESISTANCE & PRESSURE DROP

Conduction Path Resistance
Conduction path resistance should be low. Overall resistance of conduction path depends on thermal resistance of material used and the width & length of the conducting channel. So, they should be accordingly varied to get lowest resistance.

Pressure drop and Superheating value

In case of refrigerant pressure drop along coil length (Hermes, 2004), Without Superheating, flow is purely parallel. So, per formance of parallel flow evaporator is more than the counter flow arrangement. With Superheating, flow is par t counter, par t parallel. So, the per formances of above mentioned coil arrangements depend on predominant manner of flow.

PROBLEMS ENCOUNTERED
Major problems in the working of an evaporator :
Frost Formation
Fouling and unpleasant odour

Corrosion and leakage

Dirt accumulation

Foaming

The evaporator coils tend to be naturally cold, and generally hover right around the freezing point of water. If moisture stays on the fins too long, the water can freeze and begin to coat the blades. This is typically caused by blocked coils or failed expansion valves, and the frost layers can seriously inhibit the performance of the air conditioning system. (www.howstuffworks.com)

FROST FORMATION

 Fouling is the accumulation of unwanted material on solid surfaces to the detriment of function. The fouling material can consist of either living organisms or a non-living substance (inorganic or organic ). Foods, proteins and polysaccharides can create such deposits that reduce the efficiency of heat transfer.

Due to fouling there is a build-up of mold and bacteria on the evaporator fins which produce foul odour.
Air conditioning systems are flushed to remove these odours, and sometimes the fins are coated with a moldicide protectant. (Gerlach and Newell, 2001)

FOULING AND PECULIAR ODOUR

 Corrosion can occur when acidic solutions such as citrus juices are concentrated. The surface damage caused can shorten the long-life of evaporators.

CORROSION AND LEAKAGE

Brass tube with corrosion traces in it (wikipedia.org).

Excessive corrosion can lead to leakage of the refrigerant from the evaporator coil, thus hampering its operation and performance because of loss of heat circulation. (Shen, Su & Wang, 2000)

 In the normal process of operation, the evaporator coil and fins can become coated with normal dust, dirt and lint, which is often attracted by water. These layers of dirt are not as dangerous as frost, but they can still stop the evaporator from performing correctly and inhibit the ef ficiency of the entire system. Foaming can also create a problem since dealing with the excess foam can be costly in terms of time and ef ficiency. Antifoam agents are to be used, but only a few can be used when food is being processed. (Byuan and Lee, 2010) DIRT ACCUMULATION AND FOAMING

The following conclusions can be drawn from literature review :

The heat transfer between refrigerant and air/gas is two phase heat transfer. The pressure drop between refrigerant and air/gas is two phase pressure drop. Refrigerant undergoes phase change with dif ferent flow patterns. Performance parameters can be optimized using Entropy Generation Minimization (EGM) Technique. Common problems in evaporator operation have been identified and thus, ef forts to lessen them can be made. Exergy analysis can be further carried out to optimize the performance parameters. STILL THERE IS A SCOPE TO OPTIMIZE AN EVAPORATOR ON THE BASIS OF SECOND LAW OF THERMODYNAMICS

WORK DONE SO FAR

Problem Definition
TO OPTIMISE THE EVAPORATOR ON THE BASIS OF SECOND LAW OF THERMODYNAMICS AND ENTROPY GENERATION

Literature Review
TEXTBOOK, HANDBOOKS, RESEARCH PAPERS AND JOURNALS DIMENSIONS FUTURE SCOPE

FUTURE SCOPE
The first law analysis does not consider the irreversibilities occurring in the system which may lead to poorer thermal design of evaporators. By using second law analysis we will be able to analyse the irreversibilities taking place in the system easily. By the entropy generation analysis of thermal system, we will obtain the geometric and operating parameters which improve the performance of thermal systems and reduce operating cost. Exergy or entropy generation analysis provides easier way for optimizing the geometric and operating parameters.

CONCLUSION
In this project, initially we have worked to choose the area of field, topic of project work and method of analysis .

As a part of the initial step, we carried out literature survey and came to know some of scope for further work .
Based on the conclusions of literature survey, we have defined the problem and started working on it . In the future, work that we will be carrying out is problem formation and simulation . After doing parametric study of the system we will taking up the optimization procedure.

REFERENCES
Bejan, A . (1977) The concept of irreversibility in heat exchanger design: counter flow heat exchanger s for gas-to-gas applications, Journal Heat Transfer , Vol. 99, pp.374380. Bejan A . (1995) Entropy Generation Minimization , CRC Press, Boca Raton, NY. Bruno F. Pussoli, Jader R. Barbosa Jr (2012) Optimization of peripheral finned -tube evaporators using entropy generation minimization, International Journal of Heat and Mass Transfer 55 (2012) 78387846. CE Vincent and MK Heun (2006) Thermoeconomic Analysis & Design of Domestic Refrigeration Systems , Domestic Use of Energy Conference 2006. Deepak Kumar, Vivek Kumar, and V. P. Singh(2010) To Study the Parametric Ef fects on Optimality of Various Feeding Sequences of a Multief fect Evaporators in Paper Industr y using Mathematical Modeling and Simulation with MATLAB, International Journal of Chemical and Biological Engineering 3:3 2010.

 E. Granryd(2010) Analytical expressions for optimum flow rates in evaporators and condensers of heat pumping systems, international journal on refrigeration 33,2010. Jang-Se Jang-Seok Lee, Tae-Hee Lee, Seong-Hun Ham, Se-Yoon Oh, Kwan-Shik Cho(2000) A STUDY ON NEW TRI-TUBE TYPE EVAPORATORS IN DOMESTIC REFRIGERATOR/FREEZER, International Refrigeration and Air Conditioning Conference(2000). Jong-Taek Oh, A.S. Pamitran, Kwang-Il Choi, Pega Hrnjak (2011) Experimental investigation on two-phase flow boiling heat transfer of five refrigerants in horizontal small tubes of 0.5, 1.5 and 3.0 mm inner diameters, International Journal of Heat and Mass Transfer 54 (2011) 20802088. Piotr A. Domanski, David Yashar, Minsung Kim (2005), An Optimized Design of Finned-Tube Evaporators Using the Learnable Evolution Model, VOLUME 10, NUMBER 2 HVAC&R RESEARCH APRIL 2005. R Vijayan and P S S Srinivasan (2009) The influence of internal heat exchanger on performance of window AC retrofitted with R407C, 2009. S.C. Kaushik and K. Manjunath (2011) Second law analysis of condenser by using new heat transfer and pressure drop model based on flow regimes, Int. J. Exergy, Vol. 9, No. 3, 2011.

 Taijong Sung, Daesik Oh, Taewon Seo and Jongwon Kim (2007) Optimal design of a micro evaporator to maximize heat transfer coefficient, Asian Symposium for Precision Engineering and Nanotechnology 2007. X. Huo, D. Shiferaw, T.G. Karayiannis, Y.S. Tian and D.B.R Kennin (2008) BOILING TWO-PHASE PRESSURE DROP IN SMALL DIAMETER TUBES, Aspen Tech Inc., Berkshire, UK,2008. Douglas T. Reindl and Todd B. Jekel (2009) Frost on Air Cooling Evaporators, published in ASRAE Journal Xinzhou Song, Dong Huang, Xiaoyu Liu, Qun Chen (2012) Effect of non-uniform air velocity distribution on evaporator performance and its improvement on a residential air conditioner, published by Elsevier Ltd. B. Shen, Z. Shu and Y. Wang (2000) Research on characteristics of Double Evaporators in VRV Air Conditioner, International Refrigeration and Air Conditioning Conference. Christian J.L. Hermes, Marco E. Marques, Claudio Melo and Joaquim M. Goncalves (2004) Effect of coil Geometry on Frost-Free-Finned-Tube Evaporator Performance, International Refrigeration and Air Conditioning Conference.

Websites used google.com, wikipedia.org, howstuffworks.com, sciencedirect.com