Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Final Year Project Report Submitted towards the

Partial Fulfillment for the Requirements for the Award
of B. Sc. Degree in Mechanical Engineering

Submitted by
Engdawork Mulatu
&
Surafel Lulekal

Advisor
Ftwi Yohaness
(Lecturer, Mechanical Engineering, MU)

MECHANICAL ENGINEERING DEPARTMENT

FACULTY OF SCIENCE AND TECHNOLOGY
MEKELLE UNIVERSITY
Mekelle

Mechanical Engineering Dept. 1 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Ethiopia

2005-2006

Acknowledgement

First we thank God for everything. Then we would like to express our appreciation to our
adviser Mr.Ftwi Yohaness (Thermal engineer) for his patient and uninterrupted help in all
our works and also we are most grateful to Mr. Mesele Hayelom for his cooperation and
constructive ideas and suggestions about our project. Finally we wish to thank our family
for their encouragement, and support.

Mechanical Engineering Dept. 2 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Declaration by Candidate
We hereby state that the work which is being presented in this report entitled “Design of
Vapor – Absorption Refrigeration System Operated with Solar Energy”, for the
partial fulfillment of the requirements for the award of the B. Sc. Degree in Mechanical
Engineering, submitted to the Department of Mechanical Engineering, Science and
Technology Faculty, MU, is genuine record of our work carried out under the supervision
of Ato Ftwi Yohaness (Lecturer, Mechanical Engineering)

Engdawork Mulatu and Surafel Lulekal

Mechanical Engineering Dept. 3 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Certificate
This is to certify that the work which is being presented in this report entitled “Design of
Vapor – Absorption Refrigeration System Operated with Solar Energy”, is done by
graduating students Engdawork Mulatu and Surafel Lulekal towards the partial
fulfillment if the requirements for the award of the B. Sc. Degree in Mechanical
Engineering, submitted to the Department of Mechanical Engineering, Science and
Technology Faculty, MU under my supervision and guidance.
Up to my knowledge the matter embodied in this project report has not been submitted
for the award of any other degree.

Ftwi Yohaness
(Lecturer, Mechanical Engineering, MU)

Mechanical Engineering Dept. 4 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Abstract

This project was developed to determine a means of providing refrigeration to

communities lacking conventional energy source. The design of an absorption
refrigeration system having capacity of 5 tons and operating with solar energy was
carried out. The lowest temperature the evaporator reaches is -13 0c, the high and low
system pressure are 10 bar and 2 bar respectively. The refrigerant-absorbent mixture is
ammonia and water, where the refrigerant is ammonia.

Mechanical Engineering Dept. 5 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Table of content
PART- I------------------------------------------------------------------------------------------------1
General given data for Design of vapor-absorption Refrigeration system --------------1
CHAPTER ONE--------------------------------------------------------------------------------------
3
Introduction------------------------------------------------------------------------------------3
1.1 Refrigeration system -------------------------------------------------------------------3
1.2 Absorption refrigeration system------------------------------------------------------3
CHAPTER TWO-------------------------------------------------------------------------------------5
Thermodynamic analysis---------------------------------------------------------------------5
2.1 Introduction------------------------------------------------------------------------------5
2.2 Assumption------------------------------------------------------------------------------5
2.3 Energy and mass balance evaluation-------------------------------------------------5
2.3.1 At the condenser-----------------------------------------------------------------6
2.3.2 At the evaporator ---------------------------------------------------------------6
2.3.3 At the generator-----------------------------------------------------------------6

2.3.4 At the absorber-------------------------------------------------------------------7

2.3.5 At the refrigeration throttling valve-------------------------------------------7
2.3.6 At the absorbent throttling valve --------------- ------------------------------7
2.3.7 At the heat exchanger----------------------------------------------------------8
2.3.8 At the pump - -------------------------------------------------------------------8
2.4 Heat transfer duties of the components-------------------------------------------------8
2.4.1 The condense---------------------------------------------------------------------8
2.4.2 The evaporator-------------------------------------------------------------------9
2.4.3 The generator---------------------------------------------------------------------9
2.4.4 The pump------------------------------------------------------------------------10
2.4.5 At the heat exchanger ---------------------- -----------------------------------11
2.4.6 The absorber---------------------------------------------------------------------11
2.5 The coefficient of performance (COP) of the system---------- --------------------12
PART – II ------------------------------------------------------------------------------------------13
CHAPTER THREE- -------------------------------------------------------------------------------13
Design analysis of Tubular exchanger-------------------------------------------------------13
CHAPTER FOUR- ----------------------------------------------- ---------------------------------16
Design of condenser--------------------------------------------------------------------------16
4.1 Type of condenser-----------------------------------------------------------------------16
4.2 Given data and assumption-------------------------------------------------------------16
4.3 Tube material and dimension ---------------------------------------------------------16
4.4 Shell material and dimension ------------------- --------------------------------------17
4.5 Over all heat transfer coefficient (U o) --------------------------------- -------------17
4.5.1 Inside (tube side) heat transfer coefficient (hi) ----------------------------17
4.5.2 Out side (shell side) heat transfer coefficient ----------------- ------------19
4.6 The Log-mean temperature difference (LMTD) ------------------ -----------------20
4.7 The condenser capacity-----------------------------------------------------------------21
4.8 Design of condenser component------------ ------------------------------------------21
4.8.1 Shell thickness ------------------------------- ----------------------------------21

Mechanical Engineering Dept. 6 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

4.8.2 Tube sheet ------------------------------------------ ----------------------------22

4.8.3 Bolt design ----------------------------------------------------------------------22
4.8.4 Pressure drop calculation--------------------------------------------------------23
4.8.4.1 Tube inside pressure drop calculation ------------------------------23
4.8.4.2 Pressure drop in shell side -------------------------------------------24
4.8.5 Baffles------------------------------------------------- --------------------------25
4.8.6 Flange ------------------------------------------------ ---------------------------25
CHAPTER FIVE ----------------------------------------------- -----------------------------------26
Evaporator design - ------------------------------------------------------------ ---------------26
5.1 Evaporator type -------------------------------------------------------------------------26
5.2 Given data and assumption
------------------------------------------------------------26
5.3 Tube material and
dimension----------------------------------------------------------26
5.4 Shell material and
dimension----------------------------------------------------------27
5.5 Over all heat transfer coefficient (U
o)-----------------------------------------------27
5.5.1 Inside (tube side) heat transfer coefficient (hi) -----------------------------27
5.5.2 Out side (shell side) heat transfer coefficient-------------------------------27
5.5 The Log-mean temperature difference ------------------- ---------------------------28
5.6 The evaporator capacity is ------------------ ------------------------------------------29
5.7 Design of evaporator component - --- ------------------------------------------------29
5.8.1 Shell thickness --------------------------------- --------------------------------29
5.8.2 Tube sheet ------------------------------------------ ----------------------------29
5.8.3 Bolt design ----------------------------------------------------------------------29
5.8.4 Pressure drop calculation -----------------------------------------------------30
5.8.4.1 Tube inside pressure drop calculation----- --- ---------------------30
5.8.4.2 Pressure drop in shell side ------ ------- -----------------------------30
5.8.5 Baffles----------------------------------------------------------------------------30
5.8.6 Flange -------------------- -------------------------------------------------------30
CHAPTER SIX
-------------------------------------------------------------------------------------31
Design of absorber -- -------------------------------------------- ------------------------------31
6.1 Type of absorber
------------------------------------------------------------------------31
6.2 Given data and assumption
------------------------------------------------------------31
6.3 Tube material and dimension -------------
--------------------------------------------31
6.4 Shell material and dimension -
------------------------------------------------ -----32
6.5 Over all heat transfer coefficient (U o)
---------------------------------------------32

Mechanical Engineering Dept. 7 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

6.5.1 Inside (tube side) heat transfer

coefficient (hi)
----------------------------32
6.5.2 Out side (shell side) heat transfer
coefficient(ho) --------------------------33
6.6 Determining log mean temperature
--------------------------------------------------34
6.7 Obtaining correction factor
------------------------------------------------------------34
6.8 Capacity of the absorber is ------------------------------------------------------------35
6.9 Components of absorber design
------------------------------------------------------35
6.9.1 Shell thickness -------------------------
---------------------------------------35
6.9.2 Tube sheet ---------------------------------
-------------------------------------35
6.9.3 Bolt design
------------------------------------------------
----------------------35
6.9.4 Pressure drop calculation
------------------------------------------------
-----36
6.9.4.1 Tube inside pressure drop calculation ------------------------------36
6.9.4.2 Pressure drop in shell side ------------------------------------------36
6.9.5 Baffles------------------------------------------------------------------------
----36
6.9.6 Flange-
------------------------------------------------
--------------------------37
CHAPTER SEVEN ------------------------------------------------------------------------------38
Generator Design ----------------- -------------------------------------------------------------38
7.1 Type of generator
----------------------------------------------------------------------38
7.2 Given data and assumption
-----------------------------------------------------------38
7.3 Tube and shell material and dimension
----------------------------------------------38
7.4 Shell material and dimension
---------------------------------------------------------38
7.5 Heat input to generator
------------------------------------------------------- ---------39
7.6 Over all heat transfer coefficient (U o)
---------------------------------------------39
7.6.1 Inside (tube side) heat transfer
coefficient (hi)-----------------------------
39

Mechanical Engineering Dept. 8 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

7.6.2 Out side (shell side) heat transfer

coefficient (ho) ------------------------40
7.7 Determining true temperature
difference---------------------------------------------42
7.7.1 Calculating log mean temperature
difference -----------------------------43
7.7.2 Obtaining correction
factor-----------------------------------------
-----------43
7.8 Calculating capacity of generator
-----------------------------------------------------43
7.9 Components of generator design
-----------------------------------------------------44
7.9.1 Shell thickness
------------------------------------------------
-----------------44
7.9.2 Tube sheet
------------------------------------------------
----------------------44
7.9.3 Bolt design
------------------------------------------- --
-----------------------44
7.9.4 Pressure drop calculation
------------------------------------------------
----45
7.9.4.1 Tube inside
pressure drop
calculation
-----------------------
----45
7.9.4.2 Pressure drop in shell side -----------
-----------------------
-----45
7.9.5 Baffles ----------------------------------
----------------------- -------------45
7.9.6 Flange
------------------------------------------------
------------------------45
CHAPTER EIGHT --------------- -------------------------------------------- --------------------46
Design of Pre heater---------- ----------------------------------------------------------------46
8.1 Type of the pre heater --------------------------------------------
---------------------46
8.2 Given data and assumption
-----------------------------------------------------------46
8.3 Tube material and dimension
---------------------------------------------------------46

Mechanical Engineering Dept. 9 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

8.4 Shell material and dimension

-------------------------------------------------------- 47
8.5 Over all heat transfer coefficient (U o)
--------------------------- -------------------47
8.5.1 Inside ( tube side) heat
transfer coefficient (hi)
---------------------------47
8.5.2 Out side (shell side) heat transfer
coefficient-----------------------
-------48
8.6 Fouling factors [3]
----------------------------------------------------------------------4
9
8.7 The Log-mean temperature difference
----------------------------------------------49
8.8 The pre heater capacity
----------------------------------------------------------------49
8.9 Components of pre heater design
----------------------------------------------------49
8.9.1 Shell thickness --------------------------------------------------------------- 49
8.9.2 Tube sheet ---------------------------------------------------------------------49
8.9.3 Bolt design ----------------------------------------------------------------------50
8.9.4 Pressure drop calculation------------------------------------------------------50
8.9.4.1 Tube inside pressure drop calculation -----------------------------50
8.9.4.2 Pressure drop in shell side ----------------------- -------------------51
8.9.5 Baffles ------------------------------------------------------------------------51
8.9.6 Flange
------------------------------------
------------------------------------
-51
Conclusion ------------------------------------------------------------------------------------------52
Recommendation and Limitations----------------------------------------------------------------53
Bibliography --------------------------------------------------------------------------------------- 54
Appendix --------------------------------------------------------------------------------------------55

PART - I
Given Details
An ammonia vapor-absorption refrigeration cycle which has a capacity of 5 tons of
cooling operates under conditions indicated below

Mechanical Engineering Dept. 10 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Condenser 7
P=10 bar
Cooling water

8 hot water Generator

4
3
Pre-heater
EV1 5

9 EV2 2
6
Chilled water Evaporator
P=2.5 bar 10

Cooling water Absorber Pump

1
Conditions: Absorber

 Refrigeration capacity 5tons or 17.5kw

 Pressure of condenser and Generator (high pressure side) 10 bar
 Pressure of evaporator and absorber (low pressure side) 2.5 bar
 Temperature in the absorber 30oC
 Temperature in the Generator inlet 75oC
 Temperature in the Generator outlet:
o State point 4 (90oC)
o State point 7 (95oC)

Mechanical Engineering Dept. 11 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

Determinations:
 the pressure, temperature, specific enthalpy and mass flow rates (kg/hr) at each
point in the cycle
 the heat transfer duties of the various components:
o heat supplied in the generator,
o heat rejected in the absorber,
o heat rejected in the condenser and
o Heat transferred in the pre-heater.
 Thermal analysis and design of the various components of the vapor-absorption
Refrigeration system operating with solar energy. Analysis and design of:
o Generator
o Condenser
o The evaporator
o Absorber
o Pre-heater
 Thermal analysis and design of the thermal collector
Assumptions taken should be stated in detain in each of the calculations.

Mechanical Engineering Dept. 12 Engdawork M. and Surafel L.

Design of Vapor-absorption Refrigeration System Operating with Solar Energy

CHAPTER ONE
Introduction
Vapor absorption refrigerator is a means of providing refrigeration to communities
lacking conventional energy source, utilizing waste heat or heat from inexpensive source.

Most conventional refrigeration systems operate with electricity; however, there are
regions where it is difficult or not cost efficient to provide electric service. In addition,
the cost of generating electricity is high both economically and ecologically. Therefore, a
project was developed to determine a means of providing refrigeration to communities
lacking conventional energy sources. The design of an absorption refrigeration system
operating with solar energy was carried out.

1.1 Refrigeration system

Refrigeration is the achievement of temperatures below that of the local environment.
The main purpose of refrigeration is thermal conditioning (e.g. for food preservation or
air conditioning), and the basic apparatus is a refrigerator, a thermal machine producing
cold. Other names for special types of refrigerators are freezers, chillers, cryo-coolers, as
well as the informal word fridge

1.2 Absorption refrigeration system

Absorption refrigeration conceptually, an absorption-refrigeration machine corresponds
to a vapor-compression refrigerator in which the compressor is substituted by four
elements: a vapor absorber based on another liquid, a pump for the liquid solution, a
generator to release the vapor from solution, and a valve to recycle the absorbent liquid.
Its great advantage is that this cycle requires less work to operate (only that of the pump).

From fig.1.1 below we see that heat is transferred from the refrigerated space to an
evaporator, vaporizing the refrigerant (ammonia). The ammonia gas is absorbed into a
water-ammonia solution and heat is lost to water. The solution is pumped through a heat
exchanger to a generator. A heater boils off ammonia; the weakened ammonia-water
solution returns to the absorber. In the condenser, the ammonia gas loses heat to water
and returns to the evaporator as a liquid.

Mechanical Engineering Dept. 3 Engdawork M. and Surafel L.

 Fig.1.1 Vapor-absorption refrigeration
There are two working fluids in an absorption refrigerator, the refrigerant (as
for a vapor-compression refrigerator), and the carrier, that is the auxiliary
liquid that absorbs the refrigerant (in the absorber), is pumped up to high
pressure, and releases the refrigerant vapors at the generator. Ammonia has
been traditionally used as refrigerant in both types of refrigerators, down to
the -40 ºC range of commercial refrigeration. We use ammonia- water
solution for refrigerant media than Lithium bromide - water because of the
following reason that explained in table 1.1

Aqua-ammonia solution system LiBr-H2O system

Its generator requires a temperature of 95oc It generator require a temperature of 75oc to
to 120oc if water cooled 95oc.
Can operate below 0oc. Can not operate below 4oc.
Environmental friendly and low cost Absorbent charging or disposals are
refrigeration. expensive.
Use low pressure steam, hot water of Low pressure steam(single stage) and high
equivalent waste heat sources. pressure steam(two stage unit)
Table.1.1 Difference between LiBr-H2O and NH3-H
 CHAPTER TWO
Thermodynamic analysis
2.1 Introduction
The thermodynamic analysis of the vapor absorption refrigeration system is based on the
elementary properties of a binary homogeneous mixture, which is uniform in
composition.

The thermodynamics state of a binary mixture can be established by the pressure, the
temperature and the concentration of the mixture. The thermodynamics state of the binary
mixture are read enthalpy concentration diagram at the given temperature and pressure an
analysis is done based on energy and mass balance in the components. Finally the heat
transfer duties of the components and the coefficient of performance of the system are
determined.
2.2 Assumption
1. Steady state

2. No pressure change except through the flow restriction and the pump

3. State at point 1, 4 and 8 are saturated liquid

4. State at point 7 and 10 are saturated vapor

5. Flow restriction are adiabatic

6. Pump is isentropic

7. Since there is no rectifier, there would be appreciable amount of water in state 7.

2.3 Energy and mass balance evaluation

2.3.1 At the condenser

P = 10 bar

7
w in 8 w out

Fig.2.2 Schematic diagram of condenser

From total mass balance
 . . .

m7  m8  mref
2.1
And from energy balance
.

Qc  mref (h7  h8 )
2.2
2.3.2 At the evaporator
9
W in
P = 2.5 bar
10

W out
Fig.2.3 Schematic diagram of evaporator
From total mass balance
. . .

m9  m10  mref
2.3
From energy balance
.

Qe  mref (h10  h9 )
2.4
2.3.3 At the generator
7 3

hot w in P = 10 bar

4 hot w out
Fig.2.4 Schematic diagram of generator
From total mass balance
. . .

m3  m7  m4
2.5
From NH3 mass balance
. . .

m3 x3  m7 x  m4 x4
2.6
From Energy balance
. . .

Qg  m7 h7  m4 h4  m3 h3
2.7
From above equations, strong and weak solution mass flow rate can be calculated by
 . .

m4  x3  x7 x4  x3
2.8
.

m3  x4  x7 x4  x3 2.9
 2.3.4 At the absorber
6

P = 2.5 bar

10 1
W in W out
Fig.2.5 Schematic diagram of absorber
From Total mass balance
. . .

m10  m6  m1
2.10
From Energy balance
. . .

Qa  m10 h10  m6 h6  m1 h1
2.11

2.3.5 At the refrigeration throttling valve

8

9
Fig.2.6 Schematic diagram of expansion valve
From total mass balance
. . .

m8  m9  mref
2.12
From energy balance,
h8 = h9

2.3.6 At the absorbent throttling valve

5

Fig.2.7 Schematic diagram of expansion valve

From total mass balance
 . .

m5  m6
2.13
From Energy balance

h5  h6
2.14
 2.3.7 At the heat exchanger

4 3

5 2

Fig.2.8 Schematic diagram of pre heater

An energy balance on hot side of solution heat exchanger
. .

Qshx  h  m4 h4  m5 h5
2.15
and also on the cold side is
. .

Qshx  c  m3 h3  m2 h2
2.16

then, Qshx  h  Qshx  c

From total mass balance
. . . .

m4  m2  m3  m5
2.17
and from Energy balance
. .

h3  h2  m4 (h4  h5 ) m2
2.18
2.3.8 At the pump
Work done W on the pump is

W  h2  h1  m1 v1 ( p2  p1 )
2.19
At state (1), compressed liquid mixture will be rejected from the absorber.

Then, v1  (1  x1 ) vH 2O  0.85x1v NH 3
2.20
and the compressed liquid is approximated by the saturated liquid of the two
From energy balance
 .

Q p  m1 (h2  h1 )
2.21
2.4 Heat transfer duties of the components

2.4.1The condenser
Given
At the condenser,
 Pressure = 10bar = P7 = P8
 Temperature = 95oc = T7
From aqua-ammonia chart see Appendix A.2
 X7 = X (P7, T7) = X saturated vapor = 0.944
 h7 = h (P7, T7) = h saturated vapor = 1527.8kJ/Kg
and also we know that, X7 = X8 = X9 = X10
 h8 = h (P8, X8) = 87.5KJ/Kg
 T8 = T (P8, X8) = 26.67oc
Then from equ.2.2 the capacity of the condenser is calculated as,
.

Qc  m7 (h7  h8 )
Qc  0.0126(1527.887.5)
Qc 18.1kw
2.4.2 The evaporator
Given
At the evaporator,
 Pressure (P) = 2.5bar = P9 = P10
 Refrigeration capacity Q e = 17.5KW
From throttling effect,
h8 = h9 = 87.5KJ/Kg
From aqua-ammonia chart see Appendix A.2
h10 = h (P10, X10), but here X10 is at saturated vapor state
So, h10 = 1475kJ/Kg
 T9 = T (P10, X10) = -13oc = T10
From equ.2.4 Mass of refrigerator m ref can be calculated as
.

mref Qe h  h
10 9
.

mref  (17.5KW 1475kJ / kg 87.5kJ / kg )

.

mref  0.0126kg / s
2.4.3 The generator
Given
A t the generator,
 T7 = 95oc
 T4 = 90oc
 T3 = 75oc
We know that, P7 = P4 = P3 = 10bar
From aqua-ammonia chart see Appendix A.2
X4 = X (P4, T4) = X saturated liquid = 0.36
But we know that, X4 = X5 =X6
h4 = h (P4, T4) = h saturated liquid = 172.2kJ/kg
X3 = X (P3, T3) = X saturated liquid = 0.44
But we know that, X3 = X2 = X1
h3 = h (P3, T3) = 91kJ/kg
.
From equ.2.8 m4 is calculated as
.

m4  0.0794kg / s
and also from equ.2.9 m3 is calculated as
 . . .

m3  m4  m7
.

m3  (0.0794 0.0126)kg / s
.

m3  0.092kg / s
From equ.2.7 the capacity of the generator calculated as,

. . .

Q g  m7 h7  m4 h4  m3 h3
Q g  (0.01261527.8)  (0.0794172.2)  (0.092
Q g  24.551kw
2.4.4 The pump
From saturated water table [1]

vH 2 O (T 1 , P 1 ) 1.004 x10  3 m 3 / Kg
From saturated ammonia table [1]

v NH  3 m 3 / Kg
3 (T1 , P1 ) 1.68x10
From equ.2.20 saturated liquid V1 is calculated as

V1 [(1 0.44)(1.00410 3 )  (0.850.441.681

V1 1.190610 3 M 3 / kg
So from equ.2.19 work on the pump is calculated as,

W  (0.0921.190610 3 )(1000 250)

W  0.0274kJ / kg
and also h2 is calculated as

h2 W  h1
But, from aqua-ammonia chart see Appendix A.2
h1 = h (P1, T1) = h saturated liquid = -110kJ/kg

h2  0.0274  (110)
Therefore,
h2  109.97kJ / kg
2.4.5 At the heat exchanger
The value of h5 is obtained by combining equ.2.15 and 2.16
i.e.
. . .

m2 h2  m4 h4  m3 h3
h5  .

m5
(0.092)(109.97)  (0.0794172.2)  (0.092
h5 
0.0794
h5   60.35kJ / kg
But from equ.2.14, we know that h5 = h6
From equ.2.21 the capacity of the pump is calculated as,
.

Q p  m1 (h2  h1 )
Q p  0.092[(109.92)  (110)]
Q p  0.00736kw
2.4.6 The absorber
From equ.2.11, the capacity of the absorber is calculated as,
. . .

Qa  m10 h10  m6 h6  m1 h1
Qa  (0.01261475)  (0.0794)(60.35)  (0.0
Qa  23.91kw

Component Energy gain(KW) Energy losses (KW)

 Evaporator 17.5
Generator 24.551
Pump 0.00736
Absorber 23.91
Condenser 18.15
Total 42.06 42.06
Table.2.1 Energy balance of the system
2.5 The coefficient of performance (COP) of the system

Qe
COP 
(Q g W p )
17.5
COP 
24.551 0.00736
COP  71.26%
State Pressure Temperature Enthalpy Mass flow
concentration
point (bar) (o c) (kJ/kg) rate
1 2.5 30 0.44 -110 0.092
2 10 30 0.44 -109.97 0.092
3 10 75 0.44 91 0.092
4 10 90 0.36 172 0.0794
5 10 40 0.36 -60.35 0.0794
6 2.5 40 0.36 -60.35 0.0794
7 10 95 0.944 1527.8 0.0126
8 2.5 26.67 0.944 87.5 0.0126
9 10 -13 0.944 87.5 0.0126
10 2.5 -13 0.944 1475 0.0126
Table 2.2 Thermodynamics properties and flow rates of the system state point from
calculation
PART – II
CHAPTER THREE
Design analysis Theory of Tubular exchanger
In order to increase capacity or reduce the total length, more than one internal tube is
incorporated within the outer tube enclosure. The most common form for multi tubular
heat exchanger is the tube and shell exchanger. This is widely used for

 Liquid-liquid heat transfer

 Liquid-condensing vapor applications
 Liquid-evaporating vapor systems.

Tube Pattern: - Usually a triangular arrangement will decrease the overall size but it is
not as easy as to clean as the square pattern. The advantage of square pitch is accessible
for external cleaning and cause a lower pressure d

Coolant: - Gases are sometimes used as heat transfer fluids. Air is the most common heat
transfer fluid after water.

Compare with water

 Air is lighter

 Low density fluid with a low specific heat capacity and low thermal conductivity.

 It require higher amount of energy

 In terms of initial cost, the air-cooling option normally will often be highest

 Power consumption is normally higher on any of the systems that move air.

It is therefore much less effective than water in removing heat from a body and, per unit
of heat transferred, requires much more energy, in fan work, to move the air than the
equivalent pump work for water. For this reason we used water as coolant.

Tube – side and shell – side fluids:-The choice of which fluid to pass on the shell side
and which one pass in the tube side involves a number of factors and is generally a
compromise among conflicting requirements.
a) Pressure: - The wall thickness require (and hence the weight and cost of the material)
to contain a given pressure increase directly with the diameter. Therefore, high-
pressure fluids should be contained in the tubes.

b) Temperature: - High temperature reduces the permissibility stress level of material so

that a great wall thickness is required. So high temperature fluid should be in the
tube. Moreover, is the high temperature fluid in the shell, additional insulation may be
required to conserve energy or for safety?

c) Corrosiveness of fluids: - Corrosive fluids require the use of special (and therefore
expensive) alloys or other materials. If only one of the fluids is corrosive, passing it in
the tubes will avoid the need of an expensive alloys shell. Both tubes and shells of
corrosion resistant material will be required if the corrosive fluid is in the shell.

d) Clean lines of fluids: - For clear lines may require the use of special materials. It is
less costly to provide special tubes than to provide both special tubes and special
shell.
e) Hazard or expensive of fluids: - Leakage of fluid is less likely from tube side than
from shell side in most type of exchangers.

f) Pressure drop: - The pressure drop inside the tube can be moved accurately forecast
than in the shell. Where the fluid pressure drop is critical and must be accurately
predicted, fluid should pass through the tube.

g) Fluid viscosity: - Fluid of high viscosity may be laminar in the tube but turbulent in
the shell (depending on the clearance space between the tubes). If the flow is laminar
in both shall and tube, the viscous fluid should be in the tube, for which more reliable
heat transfer and flow-distribution prediction can be made.

h) Mass flow: - In general it is better to put the fluid having the lower mass flow on the
shell side. Turbulent flow is obtained at lowest Reynolds number on the shell side.

i) Cleaning: - The shell and the tube outer surface are more difficult to clean than the
tube internal surfaces. Therefore, the cleaner fluid passes through the shell

Baffle: -Various arrangement of baffles may used, four of which are segmental, strip,
disk and doughnut, and orifice. The segmental baffle is simply a disk with a segment
removed. It is characterized by the percent baffle cut, the ratio of the depth of cut to
baffle diameter is expressed as a percentage. Segmental baffle are arranged so that cut
edges of alternate baffles are at 1800 to each other. This causes the shell side fluid to
move perpendicularly back and forth in progressing along the shell. The flow over the
tubes is therefore partly cross flow and partly axial flow. Out of four baffles segmental
baffles are the most common types of baffle and we use it for our project. They are
associated with good heat transfer rate for the pressure drop and power consumed.

Every baffle supports the tubes, and their longitudinal spacing and the depth of baffle cut
can be varied from 45% to 75% of the inside diameter of the shell.

Baffle spacers or tie rods are used to hold the baffles squired.

Tube sheets: - It act as first as a diaphragm, separating the hot and the cold fluids in the
bonnet and shell of the exchanger.

They sustain the difference in pressure between the tube-side and the shell-side fluids.
The tube sheet is the primary support of the tubes in both the radial and longitudinal
directions. The material of the tube sheet between the tube holes, called the ligament,
provides the strength to maintain the integrity and stability of the tube sheet and the tube
bundle.

Fig.2.1 Tube sheet [15]

Heat exchanger tube: - Heat exchanger tubes are available in a variety of metal which
include steel, copper, brass, aluminum, bronze, stainless steels. They are obtained in a
number of different wall thickness defined by the Birmingham Wire Gage or gage of the
tube. See table. [3]

CHAPTER FOUR
 Design of condenser

4.1 Type of condenser

Shell and tube type
 Tube side -refrigerant
 Shell side – water

Fig 4.1 Schematic diagram of Fixed - tube - sheet condenser [Imported from AUTOCAD
drawing

4.2 Given data and assumption

Given
 refrigerant inlet temperature T7 = 950c
 refrigerant out let temperature T8 = 300c
Assumption
 cooling water inlet temperature Tin = 200c
 cooling water out let temperature Tout = 350c
 baffle spacing B = 80mm
 tube length L = 0.8m
4.3 Tube material and dimension
Tube material from standard table [10]
 normalized carbon and alloy steel of AISI number 1018
  tensile strength   424Mpa
 yield strength Sy = 324.1Mpa
 thermal conductivity of the tube material Kt = 47W/mK
Tube dimension from standard table [3]

- tube out side diameter ODt  25.4mm (1in)

- tube inside diameter IDt 17.88mm
- BWG (Birmingham Wire Gage or gage) = 9
- tube count Nt = 32
- tube pass Np = 1
- tube layout = square pitch
4.4 Shell material and dimension
Shell material [10]
- similar to tube material
Shell dimension from standard table [3]
- shell inside diameter Ds = 254mm (1in)
4.5 Over all heat transfer coefficient (U o)
The overall heat transfer coefficient is the reciprocal of overall resistance to heat transfer,
which is the sum of overall individual heat resistance.

1 1 ODt ODt ODt ODt 1

f
  0 ln ( )  f i ( )
Uo ho 2K s IDt IDt IDt h
i
4.1 [6]
Where, Uo - the overall heat transfer coefficient; W/m2K
h o - outside fluid film coefficient; W/m2K
h i - inside fluid film coefficient;W/m2K
f 0 – out side dirt coefficient (fouling factor); /m2k
f i – inside dirt coefficient (fouling factor); /m2K
K – thermal conductivity of tube wall material; W/m. K
d i – inside tube diameter; m
d o - out side tube diameter; m
4.5.1 Inside (tube side) heat transfer coefficient (hi)
The thermo physical properties of ammonia taken at film temperature
 T7 T8
Tf   95 26.67  60.835o c
2 2
Property of Cp Kf   h fg Pr
NH3 at (KJ/Kg .o c ) (W/m. K) (Kg/m3) (pa. s) (KJ/Kg0c)
T f =60.8350c
Value 5.244 0.39135 543.35 93.6  10- 1488.88 1.254
6

Table 4.1 properties of ammonia at film temperature = 60.8350c [1]


Where, Cp – specific heat Pr – prandtl number = Cp 
K
 - Viscosity V f - velocity

 - Density
Determining either the flow inside the tube is laminar or turbulent by calculating the
Reynolds number Re, if the value of Re less than 2300, then the flow inside the tube is
laminar other wise it is turbulent.

The Reynolds number Re inside the tube calculated as,

 f V f IDt
Re
f
4.2 [5]
.

mt
Vf 
 f At
4.3 [5]


At  IDt 2 N t
4
4.4 [5]
Combine equ.4.2, 4.3 and 4.4 result in,
 .

4 mt
Re 
 f N t IDt
.
4.5 [9] Where, mt  mass flow rate of
ammonia at the condenser (inside the tube)
Substituting the value, then Re = 299.56
Since the value of Re < 2300, then the flow is laminar. For laminar flow inside the tube
the inside heat transfer coefficient is obtained from,

K 3  2 g h fg
hi  0.725[ ]1 / 4
L(Ts Tw )
4.6 [13]
Substituting the value, then h i = 3124.94W/m2K
 4.5.2 Out side (shell side) heat transfer coefficient
The thermo physical properties of chilled water at the film temperature,

Ti To
Tf 
2
T f  20  35  27.50 c
2
Property of chilled water at the film temperature i.e. T =27.50c

 996kg / m 3
Cp  4.183kJ / kg
K f  611 .2510 3W / mk

 844.110  3 pa.s
Pr 5.776
Determining either the flow inside the shell is laminar or turbulent by calculating the
Reynolds number Re, if the value of Re less than 2300, then the flow inside the shell is
laminar other wise it is turbulent.

The Reynolds number Re inside the shell calculated as,

mw De
Re
As 
4.7 [13]
.
Where, mw  Mass flow rate of chilled water in the shell
De  Equivalent diameter of the shell
As  Area of the shell
 4 PT 2
De   OD
t
 ODt
4.8 [13]
Substituting the value, then De = 0.025

D s C  B
As 
PT
4.9 [13]

C  PT ODt
4.10[13]
Substituting the value, then C = 6.35  10-3m
And also A s = 4.06  10-3m2
Mass flow rate of chilled water in the condenser is calculated as.
.

Qc  m w  Cp  T
. Qc
mw 
Cp  T
.
18.144
mw   0.29kg / s
4.18312
Substituting the value in equ.4.7 then Re = 2126.53
Because, Reynolds number Re < 2300 shell side flow is laminar. So Nusselt number Nu
for laminar flow inside the shell is calculated as,

5/8 4/5
0.62 Re1/ 2 Pr1/ 3 [1 ( Re ) ]
Nu  0.3
0.4 2 / 3 1/ 4 28200
[1 ( ) ]
Pr
4.11 [7]
Substituting the value, then Nu = 57.34
Then the value of out side heat transfer coefficient (ho)

Nu  K
ho 
De
ho 1349.7W / m 2 k
Since we use water as a coolant for the condenser and the absorber fins are not required.
The values of fouling factors are read from table as [8]

 for tube side: - for refrigerant, fi = 0.0002

 for the shell side: - for city water, fo = 0.0003
then the over all heat transfer coefficient (U o) calculated by Substituting the value in
equ.4.1, then Uo = 540W/m2K
The total outside heat transfer area, A o is
 Ao    IDt  L N t
Ao 1.44m 2
4.12

4.6 The Log- mean temperature difference (LMTD)

The temperature difference between the fluid varies widely and continuously from one
end of the exchanger to the other. To overcome this difficulty, the concept of a mean
temperature difference is widely used. It is defined as
 Maximnu T  Minimum T
 
LMTD =  Maximum T 
Log  
 Minimum
 T 
4.13 [5]

T 7 = 950c

T 8 = 300c
0
T out = 35 c
T in = 200c

Fig. 4.2
From equ.4.13

T1  T2
Tm 
T1
ln ( )
T2
Where,
T1 T7 Tout  60 0 c
T2 T8 Tin 10 0 c

Substituting the value in equ.4.13, then  Tm = 27.90c

4.7 The condenser capacity is

The condenser capacity is evaluated as follow

Qc Uo ATm
Qc  21.7kw
The design capacity of the condenser is greater than the actual (18.144KW) by 16.39%,
which take in to account these factors, which are against its heat rejection capacity.

4.8 Design of condenser component

4.8.1 Shell thickness
The thickness of shell is given from pressure formula
 P d
t 4.14
2 t
[6]
Where, P – pressure of fluid = 10bar

 t  Permissible stress
d – Internal diameter of the shell = 254mm
If corrosion of pipe is taken in to account

Pd
t c
2 t
4.15 [6]
Where, C – is allowance for corrosion
C = 3mm for steel shell

Sy 321.1
t   108 Mpa
FS 3
So, t = 4.17mm, say 5mm
4.8.2 Tube sheet
The thickness (t1) of a plate with a diameter (d), supposed at the circumference and
subjected to a pressure (p) uniformly distributed over the area is given by

p
t1  K1d
t
4.16 [6]
Where, the coefficient K1 depends up on the material of the plate and the method of
holding the edges. We use mils steel for tube sheet, so K 1 for mild steel and fixed circular
plate is 0.35.
Then, t1 = 8.55mm, say 10mm
4.8.3 Bolt design
Bolts are designed against the maximum pressure

Pmax  P7 10bar 1Mpa

Total force exerted on the cover plates due to this pressure is

FT  P7  As
Where, A s – is shell inside area

 2
As  Ds
4
Then, Ft = 50670.75N
Assuming that number of bolt, nb = 6
Force on one bolt Fb1 is calculated as

Ft
Fb1  8445.12 N
nb
Material selected for bolt (Wrought stainless steel) [10]
 annealed type AISI martenstitic
 ultimate strength = 517.125Mpa
 yield strength = 275.8Mpa
Force on one bolt Fb1 also calculated as

Fb1  all  Ab
Sy 275.8
 all    91.93Mpa
FS 3
 2
Ab  db
4
Where, A b – area of bolt
Then, db = 10.82mm, so select a bolt with diameter M12

The spacing angle

 between successive bolts is
360 o
 60o
nb
4.8.4 Pressure drop calculation
The primary loss generally occurs in fluid flow through tubes, in cross flow over tube
bank or, as in shell – and – tube heat exchangers. Secondary loss occurs as a result of the
sudden contractions and expansions as fluid enters and leaves the inlet and outlet nozzles
or enters and leaves the tube bundles. The most important parameter affecting pressure
drop is the fluid velocity. The pressure drop increase as square of the velocity.
The pressure drop in the compensating side is difficult to predict as two phases are
present and the vapor mass velocity is changing throughout the condenser. A common
practice is to calculate the pressure drop using the methods for single-phase flow and
applies a factor to allow for the changes in vapor velocity, for total condensation Kern
suggest a factor of 50%.[5]

4.8.4.1 Tube inside pressure drop calculation

The pressure drop of the tube side is given by

 2
f  LG
i t
P
i  N
t 4.17
2 g    d
t
[13]
Where,
f = friction factor and = 64/Re (for laminar flow)
Np =Number of tube pass =1
L = length of tube pass = 0.8m
G t = Mass flow per m2 and is given by
.

mt
Gt 
 2 Nt , Where N t is number of tube = 32 4.18[13]
d 
4 t
N p
Substituting the value, then G t =4.93Kg/m2s
  Density of ammonia = 543.35Kg/m3
g = acceleration due to gravity = 9.81m/s2
d t = Inner diameter of tube =17.88  10-3m
Substituting the value in equ.4.17, then  Pi = 0.022N/m2
and applying kern’s factor
p i  1.5  0.022 = 0.033N/m2

4.8.4.2 Pressure drop in shell side

Pressure drop in shell side is given by

fG 2  D ( N  1)
s b
p s  4.19 [13]
2 g    D
e
Where,
f = friction factor and for shell side given by
0.227
f= , 300  Re  1000  10 3
R 0.193
e
Substituting values then f = 0.052
Ds  Shell inside diameter of shell side = 254mm
g = acceleration due to gravity = 9.81m/s2
 = density of water = 996kg/m3
 De = equivalent diameter of shell side = 25.13mm

N b  Number of baffles and is given by

L 0.8
N b  1  = 0.08 = 10
B
And mass flow per area
.

mw
G= . Then G = 71.43 Kg/m2s 4.20[13]
As
Then substituting values

N
p s  1.65
m2
4.8.5 Baffles
We take segmental baffles, they are drilled plate with height h which are generally 75%
of the inside diameter of the shell.
i.e. h = 75%  25.4 = 19.05mm
4.8.6 Flange
The use of flanged cover is attractive because it facilitates subsequent disassembly of the
exchanger shell for maintenance, repair and cleaning. Out side diameter of the flange is
given by
Do = Ds + 2t +6d1 4.21 [12]
Where, Ds = shell diameter = 254mm
t = thickness of the shell = 5mm
d1 = diameter of the bolt = M12
substituting values in equ.3.19
Do = 336mm
 CHAPTER FIVE
Evaporator design
5.1 Evaporator type
Shell and tube type
 Tube side – ammonia vapor
 Shell side – chilled water

Fig. 5.1 Schematic diagram of Fixed – tube – sheet evaporator [Imported from
AUTOCAD drawing]

5.2 Given data and assumption

Given
 pressure a the evaporator = 2.5bar
Assumption
 chilled water inlet temperature Ti = 200c
 chilled water out let temperature To = 80c
 tube length L = 0.95m
 baffle spacing B =200mm
5.3 Tube material and dimension
Tube material [10]
 Normalized carbon and alloy steel of AISI number 1018
 Tensile strength,  = 424Mpa
 Yield strength, Sy = 324.1Mpa
 thermal conductivity Kt = 47W/MK
Tube dimension from standard table [3]
 tube out side diameter OD t = 25.4mm, (1in)
 BWG = 16
  tube inside diameter ID t = 17.02mm, (0.67in)
 tube count N t = 32
 tube pass N p = 1
 tube lay out = square pitch

5.4 Shell material and dimension

Shell material [10]
 similar to tube material
Shell dimension from standard table [3]
 shell internal dimension Ds =254mm

5.5 Over all heat transfer coefficient (U o)

5.5.1 Inside (tube side) heat transfer coefficient (hi)
Property of ammonia at the film temperature

T f 
T9  T10

 
13 0 c   13 0 c
 13 0 c
2 2
f Cp f Kf  l  (pa. s) h fg Pr
(Kg/m3) (KJ/Kg .o c ) (W/m. K) (Kg/m ) 3 (KJ/Kg0c)
655.9 4.54 0.546 2.13 303.75  10-6 1306.355 1.69
Fig. 5.1 properties of ammonia at film temperature = -130c [1]
Determines the flow condition in the shell by calculating the Reynolds number
The mass flow rate of ammonia in the tube = 0.0126Kg/s = m t
So by the same procedure of equ.4.2
Re = 144.57
Since the value of Re < 2300, then the flow is laminar. For laminar flow inside the tube
the inside heat transfer coefficient is obtained similarly from equ.4.5, then
h i = 3321.3W/M2K

5.5.2 Out side (shell side) heat transfer coefficient

Property of water at the bulk temperature

T  T out 20  8
T f  in   14 0 c
2 2
 Cp f (KJ/Kg .o c ) K f (W/m. K)  (Kg/m3)  (pa. s) Pr
4.185 0.58 999.22 1.172  10 -6
8.356

Table 5.2 properties of water at film temperature = 140c [1]

Determining either the flow inside the shell is laminar or turbulent by calculating the
Reynolds number.
The Reynolds number Re inside the shell calculated similarly to equ.4.7, then
Re =734.83
Because, Reynolds number Re < 2300 shell side flow is laminar. So Nusselt number Nu
for laminar flow inside the shell is calculated similarly to equ.4.10, then
N u = 36.04
Then the value of out side heat transfer coefficient (ho)
Nu  K
h  , Substitute the value, then ho = 846.22W/m2K
o
De
Fouling factor [8]
 for tube side: - for refrigerant, fi = 0.0002
 for the shell side: - for city water, fo = 0.0003
Over all heat transfer coefficient (U o) calculated similarly equ.4.11, then

Uo  427.77W / m 2 k
The total outside heat transfer area, A o is calculated similarly to equ.4.14

Ao    IDt  L N t
Ao 1.62m 2
5.6 The Log-mean temperature difference

T in = 200c
T out = 80c

T 10 = -130c T 9 = -130c

Fig. 5.2
 The Log-mean temperature difference calculated similarly to equ.4.13, then

0
T1 Tin T10  33 c
T2 Tout T9  210 c
Tm  26.55 0 c
5.7 The evaporator capacity is

Qe Uo A Tm
Qe 18.44kw
The design capacity of the evaporator is greater than the actual (17.5KW) by 5.1%, which
take in to account these factors, which are against its heat rejection
4.8 Design of evaporator component
4.8.4 Shell thickness
The thickness of shell of evaporator is calculated similar to equ.4.15
Where, factor of safety is taken as = 3
Then t = 4.4mm, say 5mm

4.8.5 Tube sheet

The thickness (t1) of a plate of tube sheet of evaporator calculated similar to equ.4.16.
Then t1 = 4.28mm, say 5mm

4.8.6 Bolt design

Bolts are designed against the maximum pressure

Pmax  P7  2.5bar  0.25Mpa

Total force exerted on the cover plates due to this pressure is

FT  P9  As
Where, A s – is shell inside area

 2
As  Ds
4
F 

0.25    254  10 3  2

 12667.7 N
T 4
Assuming that number of bolt n b = 6
Force on one bolt Fb1 is calculated as

Ft 12667.7
Fb1    2111 .28 N
nb 6
Material selected for bolt from standard table [10] (Wrought stainless steel)
 annealed type AISI martenstitic
 Ultimate strength =517.125Mpa
 yield strength = 275.8Mpa
Force on one bolt Fb1 also calculated as

Fb1  all  Ab
Sy 275.8
 all    68.95Mpa
FS 4

Ab  db 2
4
Where, A b – area of bolt
Then, db = 6.24mm, so select a bolt with diameter M8

The spacing angle

 between successive bolts is
360 o
 60o
nb
4.8.7 Pressure drop calculation

4.8.7.1 Tube inside pressure drop calculation

The pressure drop of the tube side of evaporator is calculated similar to equ.4.17,
Then,  Pi = 5.76  10-3
and applying kern’s factor  Pi = 8.64  10-3Pa
4.8.1.2 Pressure drop in shell side
Pressure drop in the shell side of evaporator is calculated similar to equ.4.19
Then,  Ps = 1.95Pa
4.8.8 Baffles
We take segmental baffles, they are drilled plate with height h which are generally 75%
to 45%of the inside diameter of the shell. Let as assume the height h will be 75% of the
inside diameter of the shell.

i.e.
h  75% 25.4  19.05mm
4.8.9 Flange
With the same procedure as the condenser the out side diameter of the flange is 312 mm
 CHAPTER SIX
Design of absorber
6.1 Type of absorber

Shell and tube type

 Tube side -water
 Shell side – aqua-ammonia solution and vapor

Fig. 6.1 Schematic diagram of Fixed – tube – sheet absorber [Imported from AUTOCAD
drawing

6.2 Given data and assumption

 pressure at the absorber P  2.5bar

Assumption
 Inlet temperature of water Tin = 180c
 Out let temperature of water Tout = 270c

6.3 Tube material and dimension

Tube material [10]
 Normalized carbon and alloy steel of AISI number 1018

 Tensile strength,
  424Mpa
 Yield strength, Sy 324Mpa
Tube dimension from standard table [3]
 inside diameter of tube, IDt = 19.86mm
 out side diameter of tube , ODt = 25.4mm
 BWG  12
  number of tube , Nt = 58
 tube lay out = triangular pitch

6.4 Shell material and dimension

Shell material
 similar to tube material,
Shell material
 shell inside diameter, Ds = 336.55mm
 number of passes, Np = 4

6.5 Over all heat transfer coefficient (U o)

6.5.1 Inside (tube side) heat transfer coefficient (hi)
The thermo physical properties of water taken at film temperature because here water
passes inside the tube

T T
in out
T f  2
18  27
T f  2  22.5 0 c
w Cp w Kw  (pa. s) Pr w
3 o
(Kg/m ) (KJ/Kg . c ) (W/m. K)
997.6 4.183 0.603 946.3  10-6 6.56
Table 6.1 properties of water qt film temperature = 22.50c [1]
Calculating the Reynolds number in order to determines the condition of the flow inside
the tube.
The Reynolds number Re inside the tube calculated similar to equ.4.5
.
The mass flow rate of water inside the tube mw is calculated as
.

Qa  m w  Cp  T
. Qa
mw 
CpT
.
23.91
mw   0.635kg / s
4.1839
Substituting values in equ.4.5
Then, Re  2968.2
Because Reynolds number Re > 2300 then the shell side flow is turbulent. So Nusselt
number Nu for turbulent flow inside the tube is calculated as,

Nu  0.023 Re 0.8 Pr 0.33

6.1[8]
Substituting the value then in equ.6.1, then Nu =25.824
The value of in side heat transfer coefficient (hi)

Nu  K
w
i
h
ID
t
Substituting the value, then h i = 784W/m2k

6.5.2 Out side (shell side) heat transfer coefficient(ho)

The thermo physical properties of ammonia solution at the film temperature

T  T 6 30  40
T f  1   35 0 c
2 2
The property of ammonia solution is given by

 for property like  ,Cp,  , Pr the correlation is

Solution property = X NH 3 PNH 3  X H 2 O PH 2O 6.2 [13]

 for thermal conductivity of the solution the correlation is

K so ln  ( X NH3 K NH3 )  ( X H 2O K H 2O )  ( K  K NH )(1 X

H 2O 3
6.3[13]

Where, p - Properties

X - Concentration

K - Thermal conductivity

Properties of solution at film temperature

   832.04 Kg / M 3
Cp  4.466 KJ / KgK
K  0.512W / MK
Pr  3.426
  4.8  10 3 pa.s
Calculating Reynolds number Re similar to equ.4.7
Substituting values then Re = 806.3
Since the Reynolds number is less than 2300 so the flow inside the shell is laminar. For
laminar flow the Nusselt number Nu calculated similar to equ.4.11
Then, Nu = 25.8.
Out side heat transfer coefficient is

Nu  K
h 
o De
Where, for triangular tube pattern
 
 d 2 
 p o 
 2  0.86 P  8 
De  4    6.4 [3]
 0.5d o 
 
 
 
Substituting values inequ.6.4, De = 18.06mm
And also substituting values, h o =731.43Kg/Kg
Calculating over all heat transfer coefficient similarly to equ.4.1
Then, Uo = 267.52W/m2K

6.6 Determining log mean temperature

T 6 = 400c

T 1 = 300c
0
Tout = 27 c
T in = 180c

Fig. 6.2
Calculating the log mean temperature similarly to equ.4.14
T1  T6  Tout  130 c
Where,
T2  T1  Tin  12 0 c
Then, Tm  12.50

6.7 Obtaining correction factor, F

 Correction factors F is obtained from chart (appendix A.2) having P and R where
T6
Tout

Tin

T1
Fig.6.3 Schematic diagram of absorber

t t 27  18
P o i   0.4
40  18
T t
6 i

T  T o 40  30
R i   1.1
27  18
t o t i
Then, F = 0.92
And also then T  0.92  12.5  11 .52
Total area of flow is calculated similar to equ.3.12
Then, Ao = 7.87m2

6.8 Capacity of the absorber is

Q  Uo  Ao  T  L
Q  267.52  7.87  11 .5
Q  24.2 KW
The design capacity of the absorber is greater than the actual (23.91KW) by 1.2%, which
take in to account these factors, which are against its heat rejection capacity.

6.9Components of absorber design

6.9.1 Shell thickness
The thickness of the shell of absorber is calculated with similar procedure as equ.4.15
Then, t = 3.39mm, say 5mm

6.9.2 Tube sheet

The thickness (t1) of a plate of absorber is calculated similar to equ.4.16
Then, t1 = 5.665mm, say 6mm

6.9.3 Bolt design

Bolts are designed against the maximum pressure
 Pmax  P4  2.5bar  0.25Mpa
Total force exerted on the cover plates due to this pressure is

FT  P4  As
Where, A s – is shell inside area


As  Ds 2
4
Then, F = 7079.12N
Assuming that number of bolt, nb= 6
Force on one bolt Fb1 is calculated as

Ft
Fb1  1179 .85N
nb
Material selected for bolt from table [10] (Wrought stainless steel)
 annealed type AISI martenstitic
 ultimate strength = 517.125Mpa
 yield strength = 275.8Mpa
Force on one bolt Fb1 also calculated as

Fb1  all  Ab
Sy 275.8
 all   137.9Mpa
FS 2

Ab  db 2
4
A b – area of bolt
Then, d = 3.3mm a bolt with diameter M4

The spacing angle

 between successive bolts is
 o
360
  60 o
nb
6.9.4 Pressure drop calculation
6.9.4.1 Tube inside pressure drop calculation
The pressure drop of the tube side of absorber is calculated similar to equ.4.17
Then,  Pi = 9.7Pa
6.9.4.2 Pressure drop in shell side
Pressure drop in shell side of absorber is calculated with similar procedure as equ.4.19
Then  Ps = 0.95Pa
And applying kern’s factor  Ps = 1.423Pa
 6.9.5 Baffles
We take segmental baffles, they are drilled plate with height h which are generally 75%
to 45% of the inside diameter of the shell. Let us assume that the height will be 75% of
the inside diameter of the shell.

i.e.
h  75%336.55  252.4mm
6.9.6 Flange
With the same procedure as the condenser the out side diameter of the flange is =
370.5mm
 CHAPTER SEVEN
Generator Design
7.1 Type of generator
Shell and tube
Tube side – hot water
Shell side – aqua - ammonia solution and vapor

Fig. 7.1 Schematic diagram of fixed – tube – shell generator [Imported from
AUTOCAD drawing

7.2 Given data and assumption

Assume
 Heating water inlet temperature, Tin = 980c
 Heating water outlet temperature, Tout = 920c
 Tube length, L = 1.65m

7.3 Tube and shell material and dimension

Tube material [10]
 The same with that of condenser
Tube dimension from standard table [3]
 Outer diameter of the tube, Do = 25.4mm
 Inlet diameter of the tube, D i = 19.86mm
 Number of pass, 4 N p = 4
 Tube lay out = triangular arrangement

7.4 Shell material and dimension

Shell material
 The same with that of condenser
Shell dimension
  Inner diameter of the shell, Ds=336.55mm
 Number of pass, N p=1
 Number of tube =58

7.5 Heat input to generator

Heat input to generator is given by

Q
T  Q g  Q sep 7.1 [2]

Where, Q g = Heat from source

Q Sep = Heat of separation
Heat absorbed to separate NH3is given by Moltier equation
i.e., Q abs = 804(1- X w) – 930X w2 of ammonia absorbed 7.2 [2]
Where
X w  Concentration of aqua - ammonia solution.

X strong  X X X
weak 3 4
X  
w 2 2
0.44  0.36
w
X
2

w
X 0 .4
Substituting the value, then Q abs = 333.6KW
When multiplied by mass flow rate of ammonia vapor gives heat of separation.
.
Q sep  Q  (m NH ) 7.3[2]
abs 3
Substituting the value in equ.7.3, then Q Sep = 4.2KW
And from energy balance at generator, we know that Q g = 24.55KW
Substituting the value in equ.7.1, then QT= 28.55KW

7.6 Over all heat transfer coefficient (U o)

7.6.1 Inside (tube side) heat transfer coefficient (hi)
Properties are taken at film temperature

T T 98  92
in out
  2 
T 95 0 c
2

 Cp K  (pa. s) Pr
3
(Kg/m ) (KJ/Kg .o c ) (W/m. K)
961.9 4.21 0.6774 297.4  10-6 1.85
 Table 7.1 properties of water at film temperature = 950c [1]
Determining Reynolds’s number similar to equ.4.2
Where
.
m t  Is mass flow rate of heating water and determined from
.
Q  m  Cp  T
T t w
.
Substituting values, then m  1.13kg / s
t
Then, Re = 16799.65
Since 16799.65 > 2300 the flow inside the tube is turbulent then from Dittus and Boelter
equation for turbulent flow

Nu  0.023  Re 0.8  Pr 0.3 7.4[8]

Substituting the value in equ.7.4, then Nu = 36.372

Then the value of in side heat transfer coefficient (hi)
Nu  k
i
h
, then hi = 2264.57KJ/Kg
ID
t
7.6.2 Out side (shell side) heat transfer coefficient (ho)
Since the process in generator is nucleic boiling, then the forgoing dependence of q" on
Te characterize the first and most useful correlation for nucleate boiling, which was
developed by Rohsenow.
q
C  T 
l x A ]0.33
 C sf [  7.5 [5]
h fg  P 2
rl
 l  h fg g  (  l   v )
Where the subscripts l and v respectively, denote the saturated liquid and vapor state.
Where
C l = specific heat of saturated liquid

T x = temperature excess =T w – T sat

h f g = enthalpy of vaporization
p rl = pardenal number of saturated liquid

q
 q ''  heat flux per unit area,
A
 l = liquid viscosity
  v  density of saturated vapor,
 =surface tension of liquid-vapor interface
g = gravitational acceleration,
 l = density of saturated liquid,

C s f = constant determined from experimental data = 0.013(for water-steal) [9]

S = 1, for water [9]
Properties of solution are taken at film temperature
T3  T4 75  90
T    82.5 0 c
w 2 2
Properties H2O NH3 solution
 ( Kg / m 3 ) 970.2 500.1 782.16

4.195 5.852 4.86

0
Cp l ( Kj / Kg .c )

343.95  10-6 75.65  10-6 2.366  10-6

 l ( Kg / m.s)
K( w / m.c 0 ) 671.4  10-3 341.6  10-3 0.5
2.15 1.3 1.81
p rl
0.32 36 14.6
 v ( Kg / m 3 )
 ( MPa ) 6222  10-3 9.265  10-3 41.04  10-3
856 2301.85 1723.5
h fg ( KJ / Kg
Table 7.2 properties of aqua-ammonia solution at 82.50c [1]
Then substituting values in equation 6.5

1.56  10  3 T  2.42  10  4  q" 0.33

x
Then, T
x  0.155q" 0.33
7.6
 Fig. 7.7 Schematic diagram of heat exchanger tube in the heat exchanger
From convection inside the tube
T w – Ti =

q "

h l

7.7 [7]
From conduction at wall
 
r 
o
q ' '  ln 
 
 ri
Ti - T0= 7.8[8]

 
K
And from equ.6.6

T o T  0.155q" 0.33
 7.9

Summing together equ.7.7, 7.8 and 7.9 will result

 
 ro 
q "  ln  
 ri 
q"  
  
T
w
 T
  
K
h
i
0.155q "0.33
7.10
Then substituting values in equ.7.10 will give
12.8  4.42  10 4 q "  5.235  10 3 q " 
0.155q "0.33
Taking logarithm at both side and simplifying

q "  1743
 So from equ.7.6

x
T 1.82 0 c
Then from convection out side the tube
q "  h0
7.11[8]
Substituting values

h  958KJ / Kg 0 c
o
Over all heat transfer coefficient is obtained similarly from equ.7.12
Then Substituting values, Uo = 460W/m2K
7.7 Determining true temperature difference
True temperature difference for one shell pass and two or more tube pass is given by
t  Tm  F
Where,  Tm= log mean temperature difference
F = correction factor
7.7.1 Calculating log mean temperature difference

Ti n = 980c

T 4 = 900c T out = 920c

T 3 = 750c

Fig. 7.3
Calculating log mean temperature difference similar to equ.4.13

T  T  T  98  90  8
1 in 4
Where,
T T  T  92  75  17
2 out 3
Then,  Tm =11.940c
7.7.2 Obtaining correction factor, F
Correction factor is obtained from chart (appendix A.1) having P and R where
T3

Tout

Tin
T4
Fig.7.4 Schematic diagram of generator
 T T T T
P  out in  0.26 , and R

1 2  2. 5

T T T T
3 in out in
Then from fig. F= 0.77
Then, t  10.75 0 c
Calculating total heat transfer area similar to equ.4.12
Substituting values then, A = 5.8m2
7.8 Calculating capacity of generator
Designed capacity of generator is given by
Q  U o  A  t
Substituting the value, then Q  29.58KW
The design capacity of the generator is greater than the actual (28.55KW) by 3.48%,
which take in to account these factors, which are against its heat rejection capacity
 7.9 Components of generator design
7.9.1 Shell thickness
The thickness of the shell of generator is calculated similar to equ.4.15
Then, t = 4.558mm, say 5mm
7.9.2 Tube sheet
The thickness (t1) of a plate of generator tube sheet is calculated similar to equ.4.16
Then, t = 11.33mm say 12mm
7.9.3 Bolt design
Bolts are designed against the maximum pressure

Pmax  P4 10bar 1Mpa

Total force exerted on the cover plates due to this pressure is

FT  P4  As
Where, A s – is shell inside area

 2
As  Ds
4
Then, 1    (336.55) 2
F  88958.83N
4
Assuming that number of bolt nb = 12
Force on one bolt Fb1 is calculated as

Ft
Fb1   7413.24 N
nb
Material selected for bolt from standard table [10](Wrought stainless steel)
 annealed type AISI martenstitic
 ultimate strength = 517.125Mpa
 yield strength = 275.8Mpa
Force on one bolt Fb1 also calculated as
Fb1  all  Ab
Sy 275.8
 all    91.93Mpa
FS 3
 2
Ab  db
4
 A b – area of bolt
Then, d = 10.13mm so select a bolt with diameter M12

The spacing angle

 between successive bolts is
360 o
 30 o
nb
7.9.4 Pressure drop calculation
7.9.4.1 Tube inside pressure drop calculation
The pressure drop of the tube side of generator is calculated similar to equ.4.17
Then ,  Pi = 30Pa
7.9.4.2 Pressure drop in shell side
Pressure drop in shell side of generator is calculated as equ.3.19
Then, P s = 65.58  10-3Pa
Then applying kern’s factor P s = 98.82  10-3Pa
7.9.5 Baffles
We take segmental baffles, they are drilled plate with height h which are generally
75% to 45% of the inside diameter of the shell. Let assume the height will be 75% of
the inside diameter of the shell.
I.e. h = 75%  336.55= 254.4mm
7.9.6 Flange
With the same procedure as the condenser the out side diameter of the flange is
432.55mm
 CHAPTER EIGHT
Design of Pre heater

8.1 Type of the pre heater

Shell and tube type

 Tube side – strong solution of ammonia
 Shell side – weak solution of ammonia

Fig.8.1 schematic drawing of pre heater generator [Imported from AUTOCAD

drawing]

8.2 Given data and assumption

Assume
 Tube length L = 1m
 Baffle spacing B = 52mm

8.3 Tube material and dimension

Tube material [10]
 AISI number 1015 (Normalized)
 Tensile strength  = 424Mpa
 Yield strength Sy = 324 1mpa
 Thermal conductivity K t = 47W/mK
Tube dimension from standard table [3]
 inside diameter of the tube, ID t = 22.91mm
 Out side diameter of the tube , OD t = 25.4mm
  BWG = 16
 Tube arrangement – square
 Tube pitch, p = = 31.75mm
 Tube count N t = 48

8.4 Shell material and dimension

Shell material
 Similar material to the tube
Shell dimension from standard table [10]
 Internal diameter of the shell Ds = 304.8mm
 Number of pass N p = 1
8.5 Over all heat transfer coefficient (U o)
8.5.1 Inside ( tube side) heat transfer coefficient (hi)
Property of strong ammonia solution at the bulk temperature

T 3
T
T b 2
2
30  75
T 
b 2
The property of strong ammonia solution is given by

 for property like  ,Cp,  , Pr the correlation is

Solution property = X NH PNH  X H P
3 3 2O H 2O
8.1
 for thermal conductivity of the solution the correlation is

K so ln  ( X NH3 K NH3 )  ( X H 2O K H 2O )  ( K  K NH )(1 X

H 2O 3
8.2
Where, p - Properties
X - Concentration
k - Thermal conductivity
For strong solution of ammonia,

X NH 3  0.36, X H 2 O  0.64
Property
Cp   (N.S/M K (W/M
2
pr h fg (KJ/Kg
(KJ/Kg) (Kg/M3) ) k) )
5.102 558.53 101.7*10-6 0.4101 1.27 1037.06
NH 3
4.182 986.9 526.92*10-6 0.64621 3.41 2376.24
H 2O
solution 4.587 798.42 3.398*10-4 0.4684 2.47 1706.65
Table 8.1 Property of strong ammonia solution at the bulk temperature = 52.5oc [1]

Calculate the value of Reynolds number similar to equ.4.5

Then, Re = 313.48
This implies that the flow inside the tube is laminar. For laminar flow inside the tube the
inside heat transfer coefficient is calculated from equ.4.5
So, hi = 3071W/m2k
8.5.2 Out side (shell side) heat transfer coefficient
The property of weak solution of ammonia is at the bulk temperature

(T4 T5 )
T film 
2
90  40
Tf ilm   650 c
2
The property of strong ammonia solution is determined with similar procedure
as equ.8.1 and 8.2

Property
Cp   (N.S/M K (W/M
2
pr
3
(KJ/Kg) (Kg/M ) ) k)
5.324 535.85 90*10-6 0.3823 1.25
NH 3
4.184 980.5 433.4*10-6 0.6589 2.75
H 2O
solution 4.594 820.426 3.1*10-4 0.494 2.21
Table 8.2 Property of weak ammonia solution at the bulk temperature = 650c [1]
The Reynolds number Re inside the shell calculated similarly to equ.4.6
So, Re = 2019.94
Because, Reynolds number Re < 2300 shell side flow is laminar. So Nusselt number (N u)
for laminar flow inside the shell is calculated similar to equ.4.11
So, Nu = 39.3
 Then the value of out side heat transfer coefficient (ho)

Nu  K
ho 
De
ho  776.568W / m 2 k
8.6 Fouling factors [3]
 for tube side: - for refrigerant, f i = 0.0002
 for the shell side: - for city water, f o = 0.0003
Then the over all heat transfer coefficient (U o) calculated similar to equ.4.1

So,
Uo  454.89
The total outside heat transfer area A o is calculated similarly to equ.4.12
Then, A o = 3.45m2
8.7 The Log-mean temperature difference

T4 = 900c
T 3= 750c T 5 = 400c
T2= 300c

Fig. 8.2
The Log-mean temperature difference calculated similarly to equ.4.13

T1 T4 T3 150 c

Where,
T2 T5 T2 10 0 c
Then,  Tm = 12.330c
8.8 The pre heater capacity

Q pre Uo Ao  L Tm

Q pre 19.35kw
The design capacity of the pre heater is greater than the actual (18.99KW) by 1.86%,
which take in to account these factors, which are against its heat rejection capacity.
8.9 Components of pre heater design
8.9.1 Shell thickness
The thickness of the shell of pre heater is calculated similar to equ.4.15
Then, t = 4.41mm, say 5mm
 8.9.2 Tube sheet
The thickness (t1) of a plate of pre heater tube sheet is calculated similar to equ.4.16
Then, t = 10.26mm, say 12mm
 Bolt design
Bolts are designed against the maximum pressure

Pmax  P4 10bar 1Mpa

Total force exerted on the cover plates due to this pressure is

FT  P4  As
Where, A s – is shell inside area

 2
As  Ds
4
Then, 1    (394.08) 2
F  72621.56 N
4
Assuming that number of bolt, nb= 12
Force on one bolt Fb1 is calculated as

Ft
Fb1   6051.9 N
nb
Material selected for bolt from standard table (Wrought stainless steel)[10]
 annealed type AISI martenstitic
 ultimate strength = 517.125Mpa
 yield strength = 275.8Mpa
Force on one bolt Fb1 also calculated as

Fb1  all  Ab
Sy 275.8
 all   137.9Mpa
FS 2

Ab  db 2
4
A b – area of bolt
Then, d b = 13.25mm so select a bolt with diameter M14
The spacing angle
 between successive bolts is
360 o
 30 o
nb
8.9.3 Pressure drop calculation
8.9.3.1 Tube inside pressure drop calculation
The pressure drop of the tube side of pre heater is calculated similar to equ.4.19
Then, P = 12.29  10-3Pa
and applying kern’s factor P = 0.0184N/m2

7.9.4.2 Pressure drop in shell side

Pressure drop in shell side of pre heater is calculated similar to equ.4.19
Then, P s = 0.49Pa
Then applying kern’s factor P s = 0.735Pa
8.9.4 Baffles
We take segmental baffles, they are drilled plate with height h which are generally 75%
of the inside diameter of the shell.

i.e.
h  75%25.4  190.5mm
8.9.5 Flange
With the same procedure as the condenser the out side diameter of the flange is = 348mm
 Conclusion
The design of vapor absorption refrigeration using solar energy is feasible and it can be
an alternative to provide refrigeration to rural communities which do not have electric
service.

The size of main components of refrigerator: condenser, evaporator, absorber,

pre heater and generator depend on the capacity and are determine by iteration to have
better result.

Size of heat exchanger component depends on the operating pressure after being
calculated the size is standardize for ease of provision and manufacturing.

The ammonia absorption refrigeration plant offers a number of advantage at temperatures

below 00c and where waste heat or cheap steam is available, significant running costs
savings can be made.

With flexibility in operation, absence of compressor noise, very low maintenance and
high reliability, industrial ammonia absorption plants, should be considered as a viable
alternative to mechanical vapor compression plants
 Recommendation and Limitation

We assumed the temperature cooling water but better result could be achieved if the
correct temperature is determined by measuring from the working environment.

Although the initial cost of solar refrigerator is relatively highest, it should be mass
produced to significantly reduce the cost.

Many of its components could be improved and standardized in the future which will
lower the cost of solar refrigerator.

Even if this project the cover designs of vapor – absorption refrigeration system operating
with solar energy, we can’t cover the thermal analysis and design of thermal collector due
to shortage of time. We spent most of our time on searching of reference book for our
task but we couldn’t get enough reference book. So for the next the department should
prepare some basic reference if the department is interested to assign student in this area.
 Bibliography
1. ASHRAE Hand book CD, 1999
2. Ballaney. Thermal engineering. Khanna publisher, edition 24th.
3. Donald Q.Kern. Process Heat Transfer. McGraw – Hill Inc.
4. Frank Kreith and Mark S. Bohn. Principle of Heat Transfer. PWS
Publishing Company, 5th edition.
5. Frank P.Incropera and David P.Dewitt. Introduction to heat
Transfer. John wiley and sons.3rd edition.
6. G.R.Nagpal. Machine design. Khama publishers
7. J.B Jones and R.E Dugan. Engineering thermodynamics .A Simon
and Schuster Company.
8. J.P.Holman. Heat Transfer. United State of America. 8th edition.
9. Keith E.Herold, Keinhard, Radermacher and Sanfrord A.klein.
Absorption chillers and Heat Pumps. United state of America.
10. Kurt M.Marshek /Robert C.Juvinal. Fundamental of Machine
Component Design. United state of America, 3rd edition.
11. R.F.Boehm. Design Analysis of Thermal system. United state of
America
12. R.S.khurmi and J.K.Gupta. A text Book of machine design.India.
13. S.C.Arora and S.Domkundwar Anand V.Domkundwar. A course
In Heat and mass Transfer.Gagan kapur for Dhanpat Rai and Co.
(P).Ltd.Delhi-110006.
14. Yunus a. Cengal. Heat transfer A practical Approach. Tta
Mcgrawm – hill publishing Company limited, New Delhi 110008.

Appendix A
 Chart A .1 Correction factor plot for exchanger with one shell pass and
two, four, or any multiple of tube pass
Chart A.2 Aqua-ammonia chart