i

TITLE

CONSTRUCTION OF A PORTABLE REFRIGERATOR

A PROJECT
SUBMITTED TO THE DEPARTMENT OF MECHANICAL
ENGINEERING, SCHOOL OF ENGINEERING TECHNOLOGY
FEDERAL POLYTECHNIC OKO, ANAMBRA STATE.

BY

NWOHA SOLOMON U.

IN PARTIALFULFILMENT OF THE REQUIREMENT FOR THE

AWARD OF NATIONAL DIPLOMA (ND) IN MECHANICAL
ENGINEERING TECHNOLOGY

JUNE, 2015.
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ABSTRACT

This project write up focuses on the construction and analysis of a portable cooling
system with compressor capacity of 105W. The principles of improving the
operation of a cooling system, choice of materials, various methods used in the
construction and recommendation for advancement where duly treated. As the
cooling system composes of mechanical and electrical parts, a lot of efforts were
made to discuss the various stages and sequences of assembly. Stating a quite
number of safety rules which must be adhered strictly by anybody who may
embark on the project in future to achieve a satisfying result. With due
consideration that we are in the modern age of refrigeration due to the gradual
destruction of the ozone layer, refrigerant R134a (1,1,1,2-tetraflouroethane) was
used . The entire system was tested and the condenser and evaporator temperature
recorded 32oC and -4oC respectively. The results gotten from revealed that (i) the
rate at which water cools in the system reduces as water reaches its freezing point
(ii) the performance of the refrigerator is affected by the amount of load stored in
it. The C.O.P (coefficient of performance) of the system was calculated and found
to be high 6.33. Aprea et al (1996) reported that vapour compression refrigeration
systems are widely used for cold storage, domestic and super market refrigeration
because of its high coefficient of performance.
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TABLE OF CONTENTS

TITLE------------------------------------------------------------------------------------------------------------------------------ i
APPROVAL PAGE------------------------------------------------------------------------------------------------------------ ii
CERTIFICATION------------------------------------------------------------------------------------------------------------ iii
DEDICATION------------------------------------------------------------------------------------------------------------------ iv
ACKNOWLEDGEMENT--------------------------------------------------------------------------------------------------- v
ABSTRACT--------------------------------------------------------------------------------------------------------------------- vi
TABLE OF CONTENTS--------------------------------------------------------------------------------------------------- vii

CHAPTER ONE---------------------------------------------------------------------------------------------------------------- 1
1.0 INTRODUCTION---------------------------------------------------------------------------------------------------------- 1
1.1 IMPORTANCE OF PROJECT------------------------------------------------------------------------------------------ 2
1.2 NATURE OF THE STUDY---------------------------------------------------------------------------------------------- 4
1.3 OBJECTIVE OF THE PROJECT--------------------------------------------------------------------------------------- 5
1.4 SCOPE AND LIMITATION OF THE PROJECT------------------------------------------------------------------5

CHAPTER TWO--------------------------------------------------------------------------------------------------------------- 6
LITERATURE REVIEW---------------------------------------------------------------------------------------------------- 6
2.1 HISTORY OF REFRIGERATION------------------------------------------------------------------------------------- 6
2.2 THEORY OF REFRIGERATION CYCLE---------------------------------------------------------------------------8
2.2 VAPOR-COMPRESSION REFRIGERATION---------------------------------------------------------------------9
2.3 THE REVERSED CARNOT CYCLE--------------------------------------------------------------------------------13
2.4 CONDITION AT THE COMPRESSOR INLET------------------------------------------------------------------17
2.5 SUB-COOLING OF THE CONDENSED VAPOUR------------------------------------------------------------18

CHAPTER THREE---------------------------------------------------------------------------------------------------------- 19
3.0 PRINCIPLE OF OPERATION---------------------------------------------------------------------------------------- 19
3.1 DESCRIPTION OF CONPONENTS--------------------------------------------------------------------------------- 19
3.2 SELECTION OF MATERIALS--------------------------------------------------------------------------------------- 23
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3.3 CONSTRUCTION METHODS AND PROCEDURES----------------------------------------------------------25

3.4 BILL OF ENGINEERING MEASUREMENT AND EVALUATION (BEME)---------------------------27

CHAPTER FOUR------------------------------------------------------------------------------------------------------------ 28
DATA CALCULATION AND TESTING----------------------------------------------------------------------------28
4.0 TESTING------------------------------------------------------------------------------------------------------------------- 28
4.1 DATA COLLECTION--------------------------------------------------------------------------------------------------- 29
4.2 RESULT ANALYSIS---------------------------------------------------------------------------------------------------- 31
4.2 COEFFICIENT OF PERFORMANCE (C.O.P)--------------------------------------------------------------------32

CHAPTER FIVE------------------------------------------------------------------------------------------------------------- 36
SUMMARY, CONCLUSION AND RECOMMENDATION---------------------------------------------------36
5.1 SUMMARY---------------------------------------------------------------------------------------------------------------- 36
5.2 CONCLUSION------------------------------------------------------------------------------------------------------------ 37
5.3 RECOMMENDATION FOR USE.----------------------------------------------------------------------------------- 37

REFERENCES---------------------------------------------------------------------------------------------------------------- 39
 1

CHAPTER ONE

1.0 INTRODUCTION

A portable refrigerator is simply a refrigerator fitted with rollers at its ends

so that it can easily be moved to any direction with little application of force. Here,

the mechanical refrigeration has to do with the production of a machine that

controls a temperature lower than atmosphere temperature. This involves the

removal of heat from a low temperature level and rejecting it to a relatively higher

temperature level.

Naturally, heat flows from a body at a higher temperature to body at a lower

temperature. But in the reverse case, an external energy or work input is required.

The carrier substance used to transport heat is called a refrigerant. Therefore,

refrigerator is the reversed heat engine cycle

Refrigeration is accomplished by various methods, such as: the vapour

compression system, absorption system, and steam jet refrigeration cycle. In this

project only the vapour compression system of refrigeration shall be discussed as it

was the method adopted to accomplish the project.

Refrigeration contributes to the raising of standard of living of different

races. Although refrigeration is primarily an application of thermodynamics, but

 2

advances have made refrigeration in recent years to grow into so many phrase

where we need technicians, craft persons, engineers, scientists, and others from

phases of engineering to pool skills and knowledge in the design, manufacturer and

operation of the refrigeration system. A good knowledge of thermodynamics and

properties of refrigerants is required before the complete cycle analysis can be

made.

The application is limitless. The most common and readily recognized ones

are found in the preservation of food and chilling of our drinks and water

especially during the hot and dry season.

1.1 IMPORTANCE OF PROJECT

The importance attached to this project is to achieve a fast cooling system

with little or no adverse effects on the food tissues, the flavor, freshness and

natural nutrients of food materials. The construction intention is based on reduced

cost, longer life span, fast freezing techniques, compactness, and portability and so

on. We also employed the use of refrigerant that has no effect of man and his

environment. However, the refrigerant that was used in this project does not

enhance the ozone layer’s depletion.

 3

While taking the specification on the size, we also put into consideration the

items that are to be cooled or preserved. Also the cabinet dimensions and

compressor capacity also considered.

The essential design parameters of the portable refrigerator are as follows:

i. Compressor

ii. Capillary tube

iii. Condenser

iv. Evaporator
v. Thermostat
vi. Refrigerant
vii. Rubber seal
viii. Drier
ix. Relay and overload
x. Aluminum sheets
xi. Lagging materials
xii. Lubricating oil

xiii. Plywood

xiv. Vegetable basin

xv. Valve

xvi. Hinges

xvii. Rollers
 4

1.2 NATURE OF THE STUDY

The design for contemporary refrigerator is based on two basic laws of

physics: first, that heat flows from warmer material to cooler materials and never

the reverse; second, which decreasing the pressure of a gas also decreases its

temperature. In the refrigeration systems typically include a compressor, a

condenser, an expansion valve (capillary tube), and an evaporator. All components

interconnected to form a fluid circuit. Cooling is accomplished through

evaporation of a liquid refrigerant under reduced temperature and pressure.

The raw material in refrigerators today consists of several basic components:

the exterior cabinet and door, the inner cabinet or liner, the insulation inserted

between the two, the cooling system, the refrigerant, and the fixtures. The cabinet

and door are made of aluminum or steel sheet metal that is sometimes pre-painted.

The inner cabinet is made of sheet metal, like the outer cabinet, or of plastic, but in

this study, the researcher(s) used wood. The insulation that fills the gap between

the inner and outer cabinets consists of foam. The components of the cooling

system (compressor, condenser) are made of aluminum, copper, or an alloy.

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1.3 OBJECTIVE OF THE PROJECT

The main objectives of this project are to achieve the following purpose:

a. To construct a portable domestic cooling equipment that can be easily be

moved to any convenient position.

b. To construct a cooling system that is efficient with little or no complexity in

maintenance.

c. To construct a cooling system with low cost

d. To construct a cooling system with reduced weight and size.

1.4 SCOPE AND LIMITATION OF THE PROJECT

Portable mobile refrigerator as its name entails is for domestic application

and to some extent for commercial purpose due to its fast freezing nature and

mobility.

While the limitation of this mobile cooling system is basically on its

specification in terms of size, capacity and area of need in terms of power source.

Based on this specification, the equipment is not congruent for industrial use,

where large refrigeration unit are more ideal.

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CHAPTER TWO

LITERATURE REVIEW

2.1 HISTORY OF REFRIGERATION

In years back, refrigeration equipment has been mass produced and widely

used, it has achieved so much to have changed man over the years. People living in

very cold region where snow fall especially at winter always noticed that their food

or met are always frozen if kept outside and still fresh if allowed to melt. But

people living close to the equator with high temperature and humidity would have

their foodstuffs dry quickly and this made their food to decay more readily. The

use of ice as preservative was known and was in use for thousands of years ago. In

winter animals are cut and moved into the ice house which was built into the

ground to make use of the insulating properties of soil. Such structure was

described by a Chinese poet Shin Ching at 3000 years ago. Neuburger, Albert

(2003).

In the stone times, the Greeks and Romans harvested ice from the Alps for

use in “ice house” Anderson, Oscar Edward (1953). In middle East and India,

water were chilled by evaporating it through Provo clay pots, which were buried

overnight in favourable conditions, it could be made cooled enough to form ice.

For about, 1500 years after this little progress was made, until 1748 that the first
 7

move towards the use of modern systems was recorded. In that year, William

Cullen investigated the effects of evaporating ethyl either into a partial vacuum.

But it was difficult to arrange good vacuum in those days. In 1934 Jacob Perkins

built and patented the first working vapour compression refrigeration system in the

world; It was a close cycle refrigeration system. Burstall, Aubrey F. (1965)

recorded that His prototype worked although, it did not succeed commercially.

During the early 1800s, consumers preserved their food by storing food and ice

purchased form ice harvesters in iceboxes. In 1803, Thomas Moore patented a

metal lined butter storage tub which became a prototype for most iceboxes.

Freiberg and Susanne (2010).

Having made such development towards refrigeration cycles, the refrigerant

were the major setback of this development. The reason was that, the available

refrigerants were either poisonous or explosive or both. This gave those that

constructed baffle ships and pins movers a great problem, making the refrigeration

system unsafe for usage. However, a great break through was achieved when

Thomas Midgly and his associates in three days discovered dichloro-difloro

methane (CCl2F2) which was tested and confirmed to have a positive function of a

good refrigerant and it was nick named R12.

The boom of refrigeration was then restricted by the Second World War, but

by the end of the war, manufacturing facilities were made available and there was a
 8

boom in refrigeration and refrigerants with low ozone layer depletion potentials

were discovered notable are R134a, R744, R540 etc which had continued up till

the present day.

2.2 THEORY OF REFRIGERATION CYCLE

Commonly, refrigeration system works in a thermodynamic cycle which

obeys Second Law of Thermodynamic which consists of four thermodynamic

processes involving the working fluid, traversing four fluid states at low

temperature, flow and high temperature, Thigh [1] and Tlow [2] as shown below:

Figure 2.2: (a) Shows the process path on a pressure–enthalpy (P– h) diagram, and

(b) shows a schematic diagram of the process equipment.

The cycle of refrigeration start when the refrigerant enters the compressor at

low pressure superheated vapor and is compressed isentropically to the condenser

 9

pressure. The refrigerant enters the condenser as superheated vapor and leaves as

saturated liquid as a result of heat rejecting to the surroundings. The saturated

liquid refrigerant is throttled to the evaporator pressure by passing it through an

expansion valve or capillary tube. During this process, the temperature of the

refrigerant drops below the temperature of the refrigerant space. Then, the

refrigerant enters the evaporator as a low-quality saturated mixture, and it

completely evaporates by absorbing heat from the refrigerated space. The cycle is

complete as the refrigerant leaves the evaporator and re-enters the compressor.

Other refrigeration cycles include vapour absorption cycle that uses water-

ammonia as the working fluid and gas cycle that uses air as its working fluid.

2.2 VAPOR-COMPRESSION REFRIGERATION

According to Y.V.C. Rao (2003), Vapor-compression refrigeration, is the

process in which the refrigerant undergoes phase changes, is one of the many

refrigeration cycles and is the most widely used method for air-conditioning of

buildings and automobiles. It is also used in domestic and commercial

refrigerators, large-scale warehouses for chilled or frozen storage of foods and

meats, refrigerated trucks and railroad cars, and a host of other commercial and

industrial services.
 10

Oil refineries, petrochemical and chemical processing plants, and natural gas

processing plants are among the many types of industrial plants that often utilize

large vapor-compression refrigeration systems. Refrigeration may be defined as

lowering the temperature of an enclosed space by removing heat from that space

and transferring it elsewhere. A device that performs this function may also be

called an air conditioner, refrigerator, air source heat pump, geothermal heat pump

or chiller (heat pump).

The vapor-compression uses a circulating liquid refrigerant as the medium

which absorbs and removes heat from the space to be cooled and subsequently

rejects that heat elsewhere. Figure 2.2 depicts a typical, single-stage vapor-

compression system. All such systems have four components: a compressor, a

condenser, a thermal expansion valve (also called a throttle valve or metering

device), and an evaporator. Circulating refrigerant enters the compressor in the

thermodynamic state known as a saturated vapor and is compressed to a higher

pressure, resulting in a higher temperature as well. The hot, compressed vapor is

then in the thermodynamic state known as a superheated vapor and it is at a

temperature and pressure at which it can be condensed with either cooling water or

cooling air. That hot vapor is routed through a condenser where it is cooled and

condensed into a liquid by flowing through a coil or tubes with cool water or cool

air flowing across the coil or tubes. This is where the circulating refrigerant rejects
 11

heat from the system and the rejected heat is carried away by either the water or

the air (whichever may be the case).

The condensed liquid refrigerant, in the thermodynamic state known as a

saturated liquid, is next routed through an expansion valve where it undergoes an

abrupt reduction in pressure. That pressure reduction results in the adiabatic flash

evaporation of a part of the liquid refrigerant. The auto-refrigeration effect of the

adiabatic flash evaporation lowers the temperature of the liquid and vapor

refrigerant mixture to where it is colder than the temperature of the enclosed space

to be refrigerated. The cold mixture is then routed through the coil or tubes in the

evaporator. A fan circulates the warm air in the enclosed space across the coil or

tubes carrying the cold refrigerant liquid and vapor mixture. That warm air

evaporates the liquid part of the cold refrigerant mixture.

At the same time, the circulating air is cooled and thus lowers the

temperature of the enclosed space to the desired temperature. The evaporator is

where the circulating refrigerant absorbs and removes heat which is subsequently

rejected in the condenser and transferred elsewhere by the water or air used in the

condenser. To complete the refrigeration cycle, the refrigerant vapor from the

evaporator is again a saturated vapor and is routed back into the compressor.
 12

Refrigerants

According to R. K. Rajput in his book “Engineering Thermodynamics",

refrigerant is any substance that absorbs heat through expansion or vaporization

and loses it through condensation in a refrigeration system. Freon" is a trade name

for a family of haloalkane refrigerants manufactured by DuPont and other

companies. These refrigerants were commonly used due to their superior stability

and safety properties: they were not flammable at room temperature and

atmospheric pressure nor obviously toxic as were the fluids they replaced, such as

sulfur dioxide. Haloalkanes are also an order(s) of magnitude more expensive than

petroleum derived flammable alkanes of similar or better cooling performance.

Unfortunately, chlorine- and fluorine-bearing refrigerants reach the upper

atmosphere when they escape. In the stratosphere, CFCs break up due to UV

radiation, releasing their chlorine free radicals. These chlorine free radicals act as

catalysts in the breakdown of ozone through chain reactions. One CFC molecule

can cause thousands of ozone molecules to break down. This causes severe damage

to the ozone layer that shields the Earth's surface from the Sun's strong UV

radiation, and has been shown to lead to increased rates of skin cancer. The

chlorine will remain active as a catalyst until and unless it binds with another

particle, forming a stable molecule. CFC refrigerants in common but receding

usage include R-11 and R-12. Newer refrigerants with reduced ozone depletion
 13

effect such as HCFCs R-22, and HFCs R-134a used in most homes today, have

replaced most CFC use. HCFCs in turn are being phased out under the Montreal

Protocol and replaced by hydrofluorocarbons (HFCs), such as R-410A , which lack

chlorine . However, CFCs, HCFCs, and HFCs all have large global warming

potential. Newer refrigerants are currently the subject of research, such as

supercritical carbondioxide, known as R-744 (www.r744.com)

Aprea et al (1996) reported that vapour compression refrigeration systems

are widely used for cold storage, domestic and super market refrigeration.

Therefore, having compared the various refrigeration cycles, the Vapour

compression cycle is suitable for this project.

2.3 THE REVERSED CARNOT CYCLE

Before discussing the “Reversed Carnot Cycle”, let us take a look at the

Carnot cycle itself. The Carnot cycle is one in which heat is taken in at a constant

upper temperature (T1) and rejected at a constant lower temperature (T2). This

cycle was suggested by Sadi Carnot. It consists of two reversible isothermal

processes at T1 and T2 respectively, connected by two reversible adiabatic

(isentropic) processes. When the working fluid is a condensable vapour, the two

isothermal processes are easily obtained by heating and cooling at constant

 14

pressure while the fluid is a wet vapour. The temperature (T) entropy (S) diagram

below shows that.

T (K)

3 2
T1

T2 1
4

5 6 S(KJ/Kg)

Fig 2.3: T-S Diagram

There is no cycle that works completely as Carnot cycle describes it. This

therefore, made the production of refrigerator to work in a reversed sense. It is

observed that if the Carnot cycle is reversed it requires work input and heat is

transferred from a low temperature (T1) to a high temperature reservoir (T2). The

cycle is then said to operate as a refrigerator. The objective is to extract heat from
 15

the low temperature reservoir (evaporator) and reject it to a high temperature

reservoir (condenser).

This cycle is composed of four reversible processes as shown on the

pressure enthalpy diagram below

3 2
P1

P2 1
4

h
Fig 2

SCHEMATIC ILLUSTRATION OF AN IDEAL REVERSED CARNOT

CYCLE PROCESS

Process 1 – 2: isentropic compression work (Reversible)

Process 2 – 3: isothermal heat rejection (condenser)

 16

Process 3 – 4: isentropic expansion work

Process 4 – 1: isothermal heat addition (evaporation)

These processes are reversible

From the work done by the compressor W = h2 – h1

The net refrigerating effect or heat extracted = h1 – h4

Also h3 = h4 (Isentropic expansion)

The coefficient of performance (c.o.p) of a refrigerator is given by

heat extracted ∨refrigerating effect

¿
w orkdone by the compressor

h1−h4
¿
h2 −h1

Therefore, the coefficient of performance (C.O.P), of a refrigerator is

defined as a measure of the performance of a refrigeration system. It is the ratio of

heat absorbed by the refrigerant while passing through the evaporator to the work

input required to compress the refrigerant in the compressor.

Also from fig. 2.3,

Heat extracted by the refrigerant = Area 1456 = T2 × [14]

Work done per cycle = Area 4312 = T1 × [14]

 17

Area 1456 T 2 ×[14] T2

C.O.P = Area 4312 = (T −T ) = T
1 2 1−¿T ¿ 2

2.4 CONDITION AT THE COMPRESSOR INLET

Effect of suction pressure: the effect of decrease in the suction pressure is

shown in figure 2.0

T1 3 2

T2
4 1

Fig 3effect of decrease in suction pressure

h2−h 1
C.O.P of the cycle when suction pressure is decreased = h −h
3 2

( h2 −h1 )−(h2−h2)
c . o . p=
( h3−h 2) + ( h2−h2 ) +(h 3−h3 )

Where h1 =h1
 18

This shows that the refrigerating effect is decreased and work required is

increased. The net effect is to reduce the refrigerating capacity of the system and

subsequently, the coefficient of performance.

2.5 SUB-COOLING OF THE CONDENSED VAPOUR

Effect of sub-cooling of liquid refrigerant: fig 2.1 shows the effect of sub

cooling

P 3 3 2

4 4 1

Fig 4 Effect of sub cooling

h 1−h4 h1−h3
c . o . p= = (h4 = h3)
( h2−h1 ) ( h2−h1 )
 19

The effect of sub cooling is to increase the refrigerating effect. Thus the

cooling results in increase of C.O.P provided that no extra energy has to be spent to

obtain the extra cold coolant required.

CHAPTER THREE

3.0 PRINCIPLE OF OPERATION

Fig 2.3 gives a clue of the working principle of any refrigeration system

operating in vapour compression cycle. From the T-S diagram, the points 1, 2, 3

and 4 correspond to the different states of the refrigerant.

At point 1 the refrigerant which is at low temperature (T 2) enters the

compressors cylinder and is compressed adiabatically to 2 when its temperature

increases to the temperature T1. It is then condensed in the condenser (line 2-3)

where it gives up its latent heat to the condensing medium. It then undergoes

throttling expansion valve and its temperature again reduces to T 2, (3-4). This cycle

however continues provided there is no leakage.

3.1 DESCRIPTION OF CONPONENTS

There are several mechanical components required in a refrigerator system.

Basically, there are four major components of vapor-compression refrigeration

 20

system. These components are compressor, condenser, capillary tube and

evaporator.

Compressor

In a refrigeration cycle, the compressor has two main functions within the

refrigeration cycle. The function of the compressor is to pump the refrigerant vapor

from the evaporator so that the desired temperature and pressure of the system. The

second function is to increase the pressure of the refrigerant vapor through the

process of compression, and simultaneously increase the temperature of refrigerant

vapor. The pressure of the refrigerant vapor leaving the evaporator must be

elevated (or the vapor has to be compressed) to the level of the condensing

pressure, so that the refrigerant can be condensed into a liquid in the condenser and

fed to the evaporator for the continuous refrigeration.

The most common compressor used in domestic refrigeration is

reciprocating type. This type of compressor normally constructed with pistons,

cylinders, valves, connecting rods and crankshaft.

Condenser

The heat extracted from the substance to be cooled by the refrigerant in the

evaporator is rejected to the atmosphere through the condenser. There are several

types of condensers that commonly used in refrigeration system. They are air-
 21

cooled, watercooled, shell and tube, shell and coil, tube within a tube, and

evaporative condensers.

However, most of domestic refrigerators are used evaporative condenser.

The refrigerants forced through the condenser. In order to remove as much heat as

possible with the tubes arranged to provide maximize surface area. In the

condenser, the temperature of the superheated vapor has to be brought down to its

saturation temperature before condensed into a liquid. The first few tubes of the

condenser ‘desuperheat’ the vapor.

The pressure of the vapor, through superheated, remains the same, since the

compressor is in operation. Once the vapor has been cooled, and brought down to

the condensing temperature corresponding to the head pressure, the vapor begins to

condense. During this process, the pressure and condensing temperature remain

constant. In some watercooled condensers, provision is made for sub-cooling the

liquid from its saturation temperature by providing some water tubes at the bottom.

The liquid can be sub-cooled by the use of a liquid-suction heat exchanger also.

The use of heat exchanger, obviously, will increase the superheat of the suction

vapor. As too much superheating of the suction vapor will affect the compressor

capacity, a heat exchanger is only used where absolutely essential.

Expansion valve/Capillary Tube

 22

The capillary tube is the simplest type of refrigerant flow control device and

may be used in place of an expansion valve. The capillary tube is small-diameter

tubes through which the refrigerant flows into the evaporator. These devices,

which are widely used in small hermetic-type refrigeration system, reduce the

condensing pressure to the evaporating pressure in a copper tube of small internal

diameter, maintaining a constant evaporating pressure independently of the

refrigeration load range. These tubes are used to transmit pressure from the sensing

bulb of some temperature control device to the operating element. A capillary tube

may also be constructed as a part of heat exchanger, particularly in household

refrigerators.

Evaporator

Evaporator can be considered the point of heat capture in refrigeration

system and provides the cooling effect required for any particular application. In

evaporator operation, the metering device changes the entering liquid to a dense

fog of liquid droplets. During the same process, the high pressure liquid is lowered

to what is called the evaporator pressure, or suction pressure. This pressure relates

to the evaporator temperature. During evaporation, the refrigerant remains the

same temperature (its saturation temperature) throughout the coil until all droplets

of liquid are vaporized, or totally saturated.

 23

Meanwhile, the refrigerant nears the end of evaporator part is in fully

saturated vapor that can only absorb sensible heat; however it does not contribute

much to the overall refrigeration performance.

Electrical System in the Refrigerator

The power is supplied to the system, current flows from the plug to the

thermostat, from the thermostat to the overload, from the overload to the common

terminal of the compressor while the other terminal is connected to the relay of the

compressors.

3.2 SELECTION OF MATERIALS

The choice for material for this project is very important as it will go a long

way to determine the refrigerating effect, portability, durability, durability,

corrosion resistance, conductivity and lightness. The material we used for this

project work were of improved mechanical and physical properties, the strength of

each material was also examined. Some these materials are: compressor,

condenser, evaporator, expansion valve, relay and overload etc.

Below are the properties of some of these materials which make them

suitable for use.

Plywood: Wood is one of the raw materials readily available to man for

construction, furnishing and for domestic purposes due to its low cost, proximity
 24

and availability. Therefore due to its, function as a good insulator of heat and

electricity, reduced weight, durable and its flexibility, we used plywood for the

construction of the refrigerators cabinet.

Foam: this is a material used for the lagging of the refrigerator because of its

properties as a good insulator of heat and its cheap cost and availability, it was

used to prevent heat gain by conduction the walls of the.

Aluminum Sheet: This material was used because of its corrosion resistance, good

conductor of heat, availability, low cost and also for the purpose of water

infiltration and heat gain by radiation.

Refrigerant (R134a): Due the environmental dangers associated with refrigerant

dichloro-diflouro methane (CCl2F2) or R12 as regards to the depletion of the ozone

layer, its health risk and its toxicity, we used refrigerant R134a because of its low

freezing and boiling points, non-toxicity and corrosiveness, non-flammability and

non-explosiveness, high coefficient of performance and friendliness to the

atmosphere.

Copper: The condenser of this system is made of copper because of its properties

as a good conductor of heat and its corrosion resistance.

 25

Formica: this material was used to coat the exterior of the refrigerator cabinet

because of its shiny white surface to prevent heat gain by radiation, prevent

absorption of water by the cabinet and give the refrigerator a good finish.
 26

3.3 CONSTRUCTION METHODS AND PROCEDURES

STEP PROCEDURES TOOLS PRECAUTION
1 Get a well seasoned plywood of Engineering tape, Our eyes were
high quality of about 20mm correctly above
thickness mark to avoid error
due to parallax
2 We marked and cut out the Scriber, tape, We made sure that
required dimension pencil, saw and tri- the cutting was
square straight to avoid
wastage of
materials
3 We assembled the various parts Hammer, screw We made sure that
earlier cut using nails and driver, mallet we wore all the
screws protective wear
required for such
operation
4 We measured and cut the foam Tape, pencil, T- We made sure we
to the required dimension square and knife cut straight to
avoid wastage and
also we avoided
error due to
parallax while
measuring.
5 Fixing of the foam to the wood Brush, razor and We made sure we
abrasives wore glove to
avoid contact with
the body.
6 Fixing of the aluminum sheet Brush, scissors, We made sure that
screws and we wore gloves to
adhesive avoid contact with
our body.
7 We debugged sharp edges and Sand paper, hand We made sure that
filed of protruded nails file and hammer the protruded nails
was filed and
covered with
adhesives mixed
with saw dust
8 Connect the compressor, Plier, screws and We protected our
 27

condenser, evaporator and screw driver, eyes with goggle

expansion valve using gas coping saw, hand while welding and
welding machine drilling machine, we made sure that
flux gas welding the welded joints
machine were firmly
welded.
9 We fixed rollers at the base of Screws and screw We made sure that
the cabinet for mobility, hinges driver the rollers and
for the door and door handles hinges were firm
and well lubricated
10 We covered the cabinet with Knife, brush and We made sure it
Formica adhesive was held firmly.
 28

3.4 BILL OF ENGINEERING MEASUREMENT AND EVALUATION

(BEME)
S/ COMPONENTS QTY UNIT PRICE (N) AMOUNT (N)
N
1 Compressor 1 5000 5000
2 Condenser 1 1000 1000
3 Evaporator 1 2000 2000
4 Driers 2 100 200
5 Charging valve 1 200 200
6 Oil 1 can 300 300
7 Foam 1 sheet 1000 1000
8 Aluminum pawn 1 2000 2000
9 Plywood (one board) ¾ 5000 5000
10 Adhesive 1 can 500 500
11 Screws, bolts and rivets 200 200
12 Thermostat 1 800 800
13 Bulb and bulb sitting 1 400 400
14 Plug 1 100 100
15 Mains wire 1 200 200
16 Formica 1 roll 2000
17 Thermometer 1 500 500
18 Refrigerant R134a 600 600
19 Transportation 1000 1000
20 Labour 4000 5000
TOTAL = 28,000
 29

CHAPTER FOUR

DATA CALCULATION AND TESTING

4.0 TESTING
The need to test a project on completion cannot be overemphasized.

According to institute of electrical engineering (I.E.F) regulation, a completed

work must be inspected and tested. This rule does not only apply to electrical

engineers but to all other field of engineering.

The test was in completed in 5hours (11am-3pm). The first test was carried

out to determine the time taken for water to freeze. This test was performed at

intervals of 20mins, the initial temperature of the water is 30 oC. The graph of time

against temperature was plotted and analyzed. The second test was to determine

the cooling rate of the refrigerator as load is being added to it. Here, the

temperature reading of the system was taken as load is added at a interval of

30mins.
 30

4.1 DATA COLLECTION

Result of the first test carried out determines the time taken for water to

freeze.

Initial temperature of water = 30oC

Time interval = 20mins

Table 1
S/N Time (mins) Temperature (OC)
1 20 23
2 40 15
3 60 7
4 80 3
5 100 2
6 120 2

Result of the second test carried out determines the cooling rate of the

refrigerator as load is increased.

Initial temperature of water = 30oC

Time interval = 30mins

Table 2
S/N Time(mins) Load (Sachets of water) Temperature (OC)
1 30 4 25
2 60 6 15
3 90 8 10
4 120 12 7
5 150 16 5
6 180 20 5
 31

Graph showing the time taken for water to freeze at interval of 20mins
25

20 The
graph

15
temp. oC

10

0
0 20 40 60 80 100 120 140

showing the cooling temperature of the refrigerator as load is increased at

interval of 30mins
30

25

20
temp. oC

15

10

0
0 1 2 3 4 5 6 7 8
Load
 32

4.2 RESULT ANALYSIS

From the data collection of the first test, we observed that when the water

was placed in the refrigerator at an initial temperature of 30 oC, the rate at which the

water cools in the first 60mins is fast as shown in table 1 above, . It was observed

that as water reaches its freezing point, the temperature change reduces unlike the

initial state and it becomes hard for the water to reach its freezing point. There are

many factors that can reduce the freezing point of water e.g impurities in water.

Also from the data collected from the second test, we observed that as load

is added to the system, its cooling rate reduces and the time taken to cool or freezes

increases. We observed that small load (e.g four (4) sachets of water added) will

cool or freeze faster that (20) as shown by the graph reason is that they (Load)

struggles for space there by absorbing or sharing the same amount of cooling effect

as opposed to when the load is lesser.

Therefore, comparing the two test carried out on the system, we observe that

the more the load or commodity inside the refrigerator the longer the time taken for

the commodity to freeze. Conclusively, we deduced from the experiment that the

performance of a refrigerator is affected by the amount of load added.

 33

4.2 COEFFICIENT OF PERFORMANCE (C.O.P)

Coefficient of performance is simply the ratio of heat absorbed from the

refrigerator space to the heat rejected as a result of the compressors work input.

Since we have measured the condensers/ambient and evaporators temperatures of

this refrigerator to be respectively equal to 32oC and -4oC.

Here calculations were also made to determine the performance of this

refrigerator using R134a table as follows:

T (K)

3
32OC

-4OC
4 1

S(KJ/Kg)
Condenser temperature = 32 + 273 = 305k

Evaporator temperature = -4 + 273 = 267k

 34

From saturated refrigerant R134a Temperature table, we have

Temperature (oC) Entropy(KJ/Kg.K) Enthalpy (KJ/Kg)
Sf Sg hf hg
32 0.3490 0.9064 94.39 264.48
-4 0.1777 0.9213 44.75 244.90
Note: Sf = entropy at saturated liquid, Sg = entropy at saturated vapour and hf =
enthalpy at saturated liquid and hg = enthalpy at saturated vapour.

Calculation/Analysis

At state 1 at T = -4oC
S1 = Sg at -4oC = 0.9213 KJ/Kg.K

h1 = hg at -4oC = 244.90 KJ/Kg

At state 2 at T = 32oC

Isenthropically, S1 = S2 = 0.9213 KJ/Kg.K

Sf = 0.3490 KJ/Kg.K, Sg = 0.9064 KJ/Kg.K

Since Sf < S2 > Sg, h2 is superheated.

From refrigerant R134a superheated table we have

Entropy (S) Enthalpy (h)

0.9066 264.15
0.9213 h2
0.9374 273.66
By interpolating, we have
 35

0.9066−0.9213 264.15−h 2
=
0.9066−0.9374 264.15−273.66

−0.0147 264.15−h 2
=
−0.0308 −9.51

264.15−h 2
0.4772=
−9.51

−4.5389=264.15−h 2

h 2=264.15+ 4.5389

h 2=268.6889 KJ / Kg

At state 3 at T = 32oC

h3 = hf = 94.39KJ/Kg

At state 4 at T = -4oC
h3 = h4 (throttling process)
Calculating for the COP of the refrigerator, we have
heat extracted∨ref . effect
C . O . P=
workdone
h 1−h4
C . O . P=
h2−h1

244.90−94.39
C . O . P=
268.69−244.90
150.51
C . O . P=
23.79
C . O . P=6.33

 The coefficient of performance of the refrigerator is = 6.33

Calculating for the refrigerator Capacity, we have

Compressor power = 105W
 36

C.O.P = 6.33
Refrigerator capacity = compressor power × C.O.P
= 105 × 6.33 = 664.65W
Heat extracted per kg of refrigerant = h2 – h4
= 268.69 – 44.75 = 223.94KJ/Kg
 37

CHAPTER FIVE

SUMMARY, CONCLUSION AND RECOMMENDATION

5.1 SUMMARY
The project is centered on the construction of a portable refrigerator system.

Refrigeration is very helpful to man fright from birth and even at death. The

benefit of refrigeration starts from birth in the case of air-conditioned delivery

rooms and for few in the modern incubator and nursery for premature babies. Its

application is further appreciated throughout his life, and for some persons

refrigeration is applied at death in preservation of dead bodies before their proper

burial.

In summary, the importance of refrigeration can be classified into three

groups as follows:

 an aid to some other process (e.g to be used in AC/R lab and for further

experiment)

 a factor in comfort improvement and

 a means of preservation
 38

5.2 CONCLUSION

It is quite obvious that an attempt to go into the construction of this kind,

that will achieve its intended benefit efficiently and effectively is quite difficult

and tasking, especially to student who are financial incapable to go into full

procurement of materials for superb model of the design. Since it is not different

from most engineering projects which requires the application of the principles of

engineering design, which include recognition of need, definition of the problem,

synthesis, analysis and optimization evaluation and final presentation.

Finally, it can be conveniently concluded that the project is quire

challenging. However, it is undoubtedly interesting as well as inspirational as

sufficient information and basis have been made available for future and further

research relating to this project. We hope that the design will meet the day to day

need for refrigeration.

5.3 RECOMMENDATION FOR USE.

Below are some rules to be observed and cautions to be applied by the user

of this cooling system.

 39

1. Moisture must be prevented from entering the piping system either during

charging or during repair work.

2. Toxic items or corrosion chemical should not be placed in the system.

3. The condenser must be spaced from the walls to ensure air circulation.

4. Hot food must be allowed to cool at least at room temperature before being

cooled by the system.

5. The door of the cooling system must be kept closed when in operation to

avoid overloading of the compressor.

6. The frost (ice) should not be removed with sharp object

7. The system should not be positioned close to a heat source as it may affect

its operation.
 40

REFERENCES

American society for heating: Fundamental Handbook, Refrigeration and Air

Conditioning for Engineers (1977) Ashrae publishing U.S.A (p.272).

Anderson, Oscar Edward (1953). Refrigeration in America; a history of new

technology and its impact. (Princeton): Published for the University of
Cincinnati by Princeton University Press. Pp. 5-6

Aprea, C., Mastrullo, R. and Rossi, F.D., Behaviour and performances of R502
alternative working fluids in refrigerating plants. International Journal
of Refrigeration, Vol. 19(4), (1996), pp. 257-263

Burstall, Aubrey F. (1965). A history of Mechanical Engineering. The MIT Press.

D. P. Wilson and R. S. Basu (1988). “Thermodynamic Properties of a New

Stratospherically Safe Working Fluid - Refrigerant-134a,” ASHRAE
Trans. 94 pt. 2.

Freiberg and Susanne (2010). Fresh: A Perishable History (1st Havard University
Press Pbk. Ed.). Cambridge, Mass. Belknap. Pp. 20-23

Neuburger, Albert (2003). The Technical Arts and Science of the Ancients.
London: Kegan Paul. P.122

Offor, I. C. lecture notebook on refrigeration cycle. Departmental of Mechanical

engineering, federal polytechnic Oko, Anambra State.
R. K. Rajput: Engineering Thermodynamics. Fourth edition.

www.r744.com/everythingR744
 41

Y.V.C. Rao (2003). An Introduction to Thermodynamics (2nd ed.). University

Press.