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FABRICATION OF AN EVAPORATIVE CONDENSER

FOR ENHANCEMENT OF C.O.P OF AN AC UNIT


A major project report submitted to
Jawaharlal Nehru Technological University Hyderabad
In partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING

Submitted by
AJINKYA JOSHI : 16WJ1A0305
B. DHEERAJ KUMAR : 16WJ1A0320
C. INDRAKANTH REDDY: 16WJ1A0358
C. CHAITHANYA : 16WJ1A0327

Under the Guidance of


Mr. Yakkala M K Raghunadh

ASST PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING


GURU NANAK INSTITUTIONS TECHNICAL CAMPUS
(Affiliated to JNTU, Hyderabad, Approved by AICTE, New Delhi)
Ibrahimpatnam, Ranga Reddy District-501506
Telangana, India.
2019-2020
CERTIFICATE

This is to certify the Major-Project entitled "FABRICATION OF AN


EVAPORATIVE CONDENSOR FOR ENHANCEMENT OF C.O.P OF AN AC UNIT”
is being submitted by AJINKYA JOSHI (16WJIA0305), B.DHEERAJ KUMAR
(16WJ1A0320), C.INDRAKANTH REDDY (16WJIA0348) and C.CHIATHANYA
(16WJIA0350) in partial fulfillment for the award of the Degree of Bachelor of Technology
in Mechanical Engineering to the Jawaharlal Nehru Technological University
Hyderabad is a record of bonafide work carried out by them under my guidance and
supervision.

The results embodied in this Major-Project report have not been submitted to any other
University or Institute for the award of any Degree or Diploma.

Internal Guide

Mr. Yakkala M K Raghunadh

Asst Professor

External Examiner Head of the Department


(MECHANICAL ENGINEERING)
DECLARATION

We declare that this Major-Project report titled " FABRICATION OF AN EVAPORATIVE


CONDENSOR FOR ENHANCEMENT OF C.O.P OF AN AC UNIT” submitted in partial
fulfillment for the award of the Degree of Bachelor of Technology in Mechanical
Engineering to the Jawaharlal Nehru Technological University Hyderabad is a record of
original work carried out us under the guidance of Mr. Yakkala M K Raghunadh, Asst
Professor, Department of Mechanical Engineering and has not formed the basis for the
award of any other degree or diploma, in this or any other Institution or University. In keeping
with the ethical practice in reporting scientific information, due acknowledgements have been
made whenever the findings of others have been cited.

Mr. AJINKYA JOSHI Mr.B. DHEERAJ KUMAR

16WJ1A0305 17WJ5A0377

Mr. C. INDRAKANTH REDDY Mr. C. CHAITHANYA


16WJ1A0358 16WJ1A0327
ACKNOWLEDGEMENTS

We wish to express our sincere thanks to Dr.H.S.SAINI, Managing Director, Guru Nanak
Institutions and Dr.M.RAMALINGA REDDY, Director, Guru Nanak Institutions Technical
Campus, School of Engineering and Technology for providing us with all the necessary
facilities and their support.

We place on record, our sincere thanks to Dr.G.SANKARANARAYANAN, Professor and


Dean of Mechanical Engineering, for the continuous encouragement.

We place on record, our sincere thanks to Dr.A.RAJ KUMAR, Professor and Head of the
Department, Mechanical Engineering for his whole-hearted co-operation, providing excellent
lab facility, constant encouragement and unfailing inspiration.

We would like to say sincere thanks to Dr.S.NAGAKALYAN, Professor, Department of


Mechanical Engineering for Co-ordinating Projects.

We especially thank our internal guide Mr. YAKKALA M K RAGHUNADH, Asst


Professor, Department of Mechanical Engineering for the suggestions and constant guidance
in every stage of the project. We also like to thank all of our lecturers helping us in every
possible way.

On a more personal note we thank our BELOVED PARENTS and FRIENDS for their moral
support during the course of our project.

AJINKYA JOSHI : 16WJ1A0305


B.DHEERAJ KUMAR : 16WJ1A0320
C.INDRAKANTH REDDY : 16WJ1A0348
C.CHIATHANYA : 16WJ1A0350
ABSTRACT

Air Conditioning has great importance in many areas of human life. The main aim of
this project is to design of an evaporative condenser which is used to increase the heat transfer
rate and to increase the performance of Air Conditioning system. Evaporative cooling is an
energy efficient and environmentally friendly air conditioning technology. Direct evaporative
cooling systems technology which involves adiabatic humidification and cooling of air with
supplementary heat exchange facilities to the lower final air temperature and try to reduce the
relative humidity.

This concept is enhanced in all engineering fields due to its characteristics of


zero pollution, energy efficiency, simplicity and good indoor air quality. This cooling effect
has been used to the various scales use from small space cooling system to the large industrial
applications.

I
TABLE OF CONTENTS

DESCRIPTION PAGE NUMBERS


Abstract I
Table of contents II-III
List of figures IV-V
List of tables VI

1 INTRODUCTION 01-23

1.0 Heating Ventilation and Air Conditioning 01


1.1 Motivation 01
1.2 History of HVAC 02
1.3 Importance of HVAC 02
1.4 Classification of HVAC systems 03
1.4.1 All-air systems 03
1.4.2 Air-water systems 04
1.4.3 Water systems 04
1.4.4 Refrigerant-based systems (Unitary systems) 04

1.5 Basic components of an HVAC system 05


1.5.1 Outdoor Air Intake 06
1.5.2 Mixed-Air Plenum and Outdoor Air Controls 06
1.5.3 Air Filters 06
1.5.4 Heating and Cooling Coils 07
1.5.5 Humidification and Dehumidification Equipment 07
1.5.6 Supply Fans 07
1.5.7 Ducts 08
1.5.8 Terminal Devices 08
1.5.9 Return Air Systems 08
1.5.10 Exhausts or Exhaust Fans 09
1.5.11 Self-Contained Units 09

II
1.5.12 Controls 09
1.5.13 Boilers 10
1.5.14 Cooling Towers 10
1.5.15 Water Chillers 10
1.6 Working of Air conditioners 11
1.7 Types of Air Conditioning Systems 11
1.7.1 Window Air Conditioner 12
1.7.2 Split Air Conditioner 12
1.7.3 Packaged Air Conditioner 13
1.7.4 Central Air Conditioning System 13
1.7.5 Variable refrigerant flow 14
1.8 Main components in Air Conditioning System 15
1.8.1 Compressor 15
1.8.2 Condenser 16
1.8.3 Expansion Valve 16
1.8.4 Evaporator 17
1.8.5 Fans 17
1.9 Refrigerant 18
1.10 Types of Refrigerants 18
1.11 Various Lines and Curves in Psychometric Chart 19

2 LITERATURE REVIEW 20-22


3 METHODOLOGY 23-31
4 EXPERIMENTAL SETUP 32-35
5 CALCULATIONS 36-50
RESULT AND DISCUSSION 52-55
CONCLUSION 56
REFERENCES 57

III
LIST OF FIGURES

FIGURE TITLE PAGE NUMBER


Fig 1.1 Generic classifications of centralized AC system 3
Fig 1.2 Typical HVAC System Components 5
Fig 1.3 Window air conditioning system 12
Fig 1.4 Split Air Conditioning system 12
Fig 1.5 Packaged Air Conditioning System 13
Fig 1.6 Central air conditioning system 13
Fig 1.7 Variable refrigerant flow 14
Fig 1.8 Line diagram of Air Conditioning System 15
Fig 1.9 Compressor 15
Fig 1.10 Condenser 16
Fig 1.11 Expansion Valve 16
Fig 1.12 Evaporator 17
Fig 1.13 Fans 17
Fig 1.14 Working of chiller 19
Fig 1.15 Air Cooled Chiller 20
Fig 1.16 Water Cooled Chiller 21
Fig 1.17 Air Handling Unit 21
Fig 1.18 Psychometric Chart 22
Fig 3.1 Carnot refrigeration cycle 24
Fig 3.2 Temperature entropy diagram 25
Fig 3.3 Area on the temperature entropy diagram 26
Fig 3.4 Temperature requirements imposed on cycle 27
Fig 3.5 Standard vapour compression cycle 28
Fig 3.6 Pressure entropy diagram 29
Fig 3.7 Flow diagram 29
Fig 3.8 Actual vapour compression cycle 30

IV
Fig 4.1 Experimental setup at GNITC R&AC lab 32
Fig 4.2 Air cooled condenser for experiment 33
Fig 4.3 Hermetically sealed compressor 33
Fig 4.4 Capillary tube 34
Fig 4.5 Evaporator with sealed casing 34
Fig 4.6 Pressure gauges 35
Fig 4.7 Alcohol thermometer 35
Fig 4.8 Ammeter and voltmeter 35
Fig 5.1 COP vs flow rate of water 53
Fig 5.2 COP vs refrigeration effect 53
Fig 5.3 COP vs temperature drop after the condenser 54

V
LIST OF TABLES

TABLE NO. PAGE NO.


TABLE 1 51

TABLE 2 52

TABLE 3 52

VI
CHAPTER 1
INTRODUCTION

1.0 Heating Ventilation and Air Conditioning


Heating, Ventilation and Air-Conditioning (HVAC) systems control the indoor
environment throughout the year to ensure comfortable conditions in homes, offices, and
commercial facilities. Air conditioning is used in most commercial properties, ranging from small
shops and cafes to large office buildings and public spaces. To meet these diverse applications, air
conditioning systems have different heating and cooling capacities and come with various setups
and layouts.
Many of our homes, most offices and commercial facilities would not become fordable
without control of the indoor environment. The "luxury label" attached to air conditioning in
earlier decades has given way to appreciate it practicality in making our live healthier and more
productive. Along with rapid development in improving human comfort came the realization that
goods could be produced better, faster, and more economically in a properly controlled
environment.
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1.1 Motivation:
The awareness of the importance of living place and indoor air quality has increased for
both health and comfort. The growing requirements for closely controlled working environments
in laboratories, hospitals, and industrial facilities have rapidly increased overall energy
demands. Therefore the HVAC systems designers are challenged as never before to come up
with the most energy efficient systems. One way of addressing the challenge is by optimizing
conventional setups and introducing efficient innovative systems utilizing renewable energy
resources.

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1.2 History of HVAC (Heating, Ventilation and Air Conditioning):
In 1902, a 25-year-old Engineer from New York named Willis Carrier invented the first
modern air conditioning system. The mechanical unit, which sent air through water-cooled
coilswas not aimed at human comfort. However, it was designed to control humidity in the
printing plant where he worked.
The first modern electrical air conditioning unit was invented by Willis Carrier in 1902in
Buffalo, New York. After graduating from Cornell University, Carrier found a job at BuffaloForge
Company.
Heating, ventilation and air conditioning (HVAC) is the technology of vehicular and the
indoor environmental comfort. It’s goal is to provide thermal comfort and acceptable indoor air
quality. Air conditioners use chemicals that easily convert the gas to liquid and back again. This
chemical is used to transfer heat from the air inside of a home to the outside air. The machine has
three main parts they are compressor, condenser and an evaporator.
Heating, Ventilating and Air Conditioning(HVAC) equipment perform heating and/or
cooling for residential, commercial or industrial buildings, The HVAC system may also be
responsible for providing fresh outdoor air to dilute interior airborne contaminants such as
odors from occupants, volatile organic compounds(VOC's) emitted from interior furnishings,
chemicals used for cleaning etc,. A properly designed system will provide a comfortable
indoor environment year-round when properly maintained.

1.3 Importance of HVAC (Heating, Ventilation and Air Conditioning):


HVAC is an important part of residential structures such as family homes, apartments,
buildings, hotels and senior living facilities, medium to large industrial and office buildings
such as skyscrapers and hospitals, onboard vessels and in marine environments, where safe
and healthy building conditions are regulated with respect to temperature and humidity using
fresh air from outdoors.
Ventilating or ventilation(V in HVAC) is the process of exchanging or replacing air in
any space to provide high indoor air quality which involves temperature control, removal of
moisture, oxygen replenishment, odors, smoke, heat, dust, airborne bacteria, carbon dioxide
and other gases.

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1.4 Classification of HVAC systems:
Mostly, HVAC systems are categorized based on the fluid media used in the thermal
distribution system. Each type of the system has certain technical and economic benefit. Few
are better than others for specific applications. Four types of such HVAC systems are:
• All-air HVAC systems
• Air-water HVAC systems
• All water HVAC systems
• Refrigerant-based HVAC systems (Unitary systems)

Fig 1.1 Generic classifications of centralized air-conditioning systems

1.4.1 All-air systems:


An all-air system delivers both sensible and latent cooling, and possibly
humidification. The systems are often used in the buildings that require individual control of
multiple zones, for example, hotels, hospitals, schools, and office buildings. These systems
can be further classified as single/double duct systems and multi-zone systems with constant
or variable air volume. Single duct normally consumes less energy than dual duct system.
However, variable volume systems are more efficient than constant volume systems. The
major benefit of these systems are the greatest potential for use of outside air for free cooling.

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1.4.2 All-water systems:
In air-water systems both air and water are distributed to terminal units installed in the
zones to be conditioned throughout a building. The air and water are cooled or heated in
central HVAC system and from there are distributed to air-conditioned spaces. Air- water
systems are typically categorized in three types, such as induction system with two or four
pipe systems, fan-coil systems and radiant panels. In such systems it is possible to provide
simultaneous cooling and control on individual zone in an economic way through thermostats.
However, the overall operation and control are complicated due to handling both primary air
and secondary water. In general, such systems are limited to perimeter zones. Initial cost of
these systems could be high compared to all air systems.

1.4.3 Water systems:


In water systems, water is used in the thermal distribution system to heat and/or cool a
space. Direct heat transfer process occurs between water and the indoor air. These systems
can satisfy indoor cooling and heating loads except ventilation loads. The most common
terminal units that are being used with chilled-water systems include fan coils, chilled ceilings
and chilled floors. Such systems can also be used with systems using natural convection in
combination with cooling coils such as, silent cooling and chilled beams. In water systems,
the thermal distribution system required significantly less space compared to the all-air
systems. Individual room control and simultaneous cooling and heating are also possible.
However, these systems require higher maintenance compared to all-air systems.

1.4.4 Refrigerant-based systems (Unitary systems):


In such systems, cooling process takes place at a very short distance from the delivery
terminals. These systems are mostly window or wall mounted and factory assembled having
varying capacity and type. Examples of such systems are window, split and packaged air
conditioners. Advantages associated with such system are simple and inexpensive room
control and lower initial cost compared to central systems. But these systems are less flexible
in terms of air flow rate, condenser and evaporator sizes. Power consumption per kW could
be higher compared to central systems.

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1.5 Basic components of an HVAC system:
The basic components of an HVAC system that delivers conditioned air to maintain thermal
comfort and indoor air quality are:
• Outdoor air intake
• mixed-air plenum and outdoor air control
• Air filter
• Heating and cooling coils
• Humidification and de-humidification equipment
• Supply fan
• Ducts
• Terminal device
• Return air system
• Exhaust or relief fans and air outlet
• Self-contained heating or cooling units
• Control
• Boilers
• Cooling tower
• Water chillers

Fig 1.2 Typical HVAC System Components

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1.5.1 Outdoor Air Intake:
Building codes require the introduction of outdoor air for ventilation in most buildings.
Most non-residential air handlers are designed with an outdoor air intake on the return side of
the ductwork. Outdoor air introduced through the air handler can be filtered and conditioned
(heated or cooled) before distribution. Other designs may introduce outdoor air through air-
to-air heat exchangers and operable windows.
Indoor air quality problems can be produced when contaminants enter a building with
the outdoor air. Rooftop or wall-mounted air intakes are sometimes located adjacent to or
downwind of building exhaust outlets or other contaminant sources. Problems can also result
if debris (e.g., bird droppings) accumulates at the intake, obstructing airflow.

1.5.2 Mixed-Air Plenum and Outdoor Air Controls:


Outdoor air is mixed with return air (air that has already circulated through the HVAC
system) in the mixed-air plenum of an air handling unit. Indoor air quality problems frequently
result if the outdoor air damper is not operating properly (e.g., if the system is not designed
or adjusted to allow the introduction of sufficient outdoor air.
When dampers that regulate the flow of outdoor air are arranged to modulate, they are
usually designed to bring in a mini- mum amount of outdoor air (in the occupied mode) under
extreme outdoor temperature conditions and to open as outdoor temperatures approach the
desired indoor temperature. Systems that use outdoor air for cooling are called “air
economizer cooling” systems.

1.5.3 Air Filters:


Filters are primarily used to remove particles from the air. The type and design of filter
determine the efficiency at removing particles of a given size and the amount of energy needed
to pull or push air through the filter. Filters are rated by different standards and test methods
such as dust spot and arrestance which measure different aspects of performance.
Filters should be selected for their ability to protect both the HVAC system
components and general indoor air quality. In many buildings, the best choice is a medium
efficiency, pleated filter because these filters have a higher removal efficiency than low
efficiency filters, yet they will last without clogging for longer than high efficiency filters.

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1.5.4 Heating and Cooling Coils:
Heating and cooling coils are placed in the airstream to regulate the temperature of the
air delivered to the space. Malfunctions of the coil controls can result in thermal discomfort.
Condensation on under insulated pipes and leakage in piped systems will often create moist
conditions conducive to the growth of molds, fungus, and bacteria.
During the cooling mode (air conditioning), as water condenses from the air- stream
the cooling coil provides dehumidification. Dehumidification can only take place if the chilled
fluid is maintained at a cold enough temperature (generally below 45°F for water). Under
these conditions, molds and bacteria will proliferate unless the pan is cleaned.

1.5.5 Humidification and Dehumidification Equipment:


In some buildings (or zones within buildings), there are special needs that warrant the
strict control of humidity (e.g., operating rooms, computer rooms). This control is most often
accomplished by adding humidification or dehumidification equipment and controls. In office
facilities, it is generally preferable to keep relative humidity above 20% or 30% during the
heating season and below 60% during the cooling season.
Office buildings in cool climates that have high interior heat gains, thermally efficient
envelopes (e.g., insulation) and economizer cooling may require humidification to maintain
relative humidity within the comfort zone. When humidification is needed, it must be added
in a manner that prevents the growth of micro biological organisms within the ductwork.

1.5.6 Supply Fans:


After passing through the coil section where heat is either added or extracted, air moves
through the supply fan chamber and the distribution system. Air distribution systems
commonly use ducts that are constructed to be relatively airtight. Elements of the building
construction can also serve as part of the air distribution system (e.g., pressurized supply
plenums or return air plenums located in the cavity space above the ceiling tiles and below
the deck of the floor above).
Proper coordination of fan selection and duct layout during the building design and
construction phase and ongoing maintenance of mechanical components, filters and controls
are all necessary for effective air delivery.

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1.5.7 Ducts:
The same HVAC system that distributes conditioned air throughout a building air can
distribute dust and other pollutants, including biological contaminants. Dust accumulation or
dirt on any components of an air handling system its cooling coils, plenums, ducts, and
equipment housing may lead to contamination of the air supply.
The presence of dust in ductwork does not necessarily indicate a current micro
biological problem. A small amount of dust on duct surfaces is normal and to be expected.
Special attention should be given to trying to find out if ducts are contaminated only where
specific problems are present, such as water damage or biological growth observed in ducts.

1.5.8 Terminal Devices:


Thermal comfort and effective contaminant removal demand that air delivered into a
conditioned space be properly distributed within that space. Terminal devices are the supply
diffusers, return and exhaust grilles, and associated dampers and controls that are designed to
distribute air within a space and collect it from that space.
Occupants who are uncomfortable because of distribution deficiencies often try to
compensate by adjusting or blocking the flow of air from supply outlets. Adjusting system
flows without any knowledge of the proper design frequently disrupts the proper supply of air
to adjacent areas. Distribution problems can also be produced if the arrangement of movable
partitions, shelving, or other furnishings interferes with airflow.

1.5.9 Return Air Systems:


In many modern buildings the above ceiling space is utilized for the unducted passage
of return air. This type of system approach often reduces initial HVAC system costs, but it
requires the designer, maintenance personnel and contractors obey strict guidelines related to
life and safety codes (e.g., building codes) that must be followed for materials and devices
that are located in the plenum.
In addition, if a ceiling plenum is used for the collection of return air, openings into
the ceiling plenum created by the removal of ceiling tiles will disrupt airflow patterns. It is
particularly important to maintain the integrity of the ceiling and adjacent walls in areas that
are designed to be exhausted, such as closets, bathrooms and chemical storage areas.

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1.5.10 Exhausts or Exhaust Fans:
Most buildings are required by law (e.g., building or plumbing codes) to provide for
exhaust of areas where contaminant sources are strong, such as toilet facilities, janitorial
closets, cooking facilities and parking garages. Other areas where exhaust is frequently
recommended but may not be legally required include the reprographics areas, graphic arts
facilities, beauty saloons, smoking lounges, shops and any area where contaminants are
known to originate.
For successful confinement and exhaust of identifiable sources, the exhausted area
must be maintained at a lower overall pressure than surrounding areas. Any area that is
designed to be exhausted must also be isolated (disconnected) from the return air system so
that contaminants are not transported to another area of the building.

1.5.11 Self-Contained Units:


In some designs, small decentralized units are used to provide cooling or heating to
interior or perimeter zones. With the exception of induction units, units of this type seldom
supply outdoor air. They are typically considered a low priority maintenance item. If self
contained units are overlooked during maintenance, it is not unusual for them to become a
significant source of contaminants, especially for the occupants located nearby.

1.5.12 Controls:
HVAC systems can be controlled manually or automatically. Most systems are
controlled by some combination of manual and automatic controls. The control system can be
used to switch fans on and off, regulate the temperature of air within the conditioned space,
or modulate airflow and pressures by controlling fan speed and damper settings. Most large
buildings use automatic controls, and many have very complex and sophisticated systems.
Regular maintenance and calibration are required to keep controls in good operating order.
Local controls such as room thermostats must be properly located in order to maintain
thermal comfort. Problems can result from:
▪ Thermostats located outside of the occupied space (e.g., in return plenum).
▪ Poorly designed temperature control zones.

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1.5.13 Boilers:
Like any other part of the HVAC system, a boiler must be adequately maintained to
operate properly. However, it is particularly important that combustion equipment operate
properly to avoid hazardous conditions such as explosions or carbon monoxide leaks, as well
as to provide good energy efficiency. Codes in most parts of the country require boiler
operators to be properly trained and licensed.
Elements of boiler operation that are particularly important to indoor air quality and
thermal comfort include:
▪ Operation of the boiler and distribution loops at a high enough temperature to supply
adequate heat in cold weather.
▪ Design of the boiler combustion exhaust to prevent re-entrainment, (especially from
short boiler stacks, or into multi- story buildings that were added after the boiler plant
was installed).

1.5.14 Cooling Towers:


Maintenance of a cooling tower ensures proper operation and keeps the cooling tower
from becoming a niche for breeding pathogenic bacteria, such as Legionella organisms.
Cooling tower water quality must be properly monitored and chemical treatments used as
necessary to minimize conditions that could support the growth of significant amounts of
pathogens. Proper maintenance may also entail physical cleaning (by individuals using proper
protection) to prevent sediment accumulation and installing drift eliminators.

1.5.15 Water Chillers:


Water chillers are frequently found in large building air conditioning systems because
of the superior performance they offer. A water chiller must be maintained in proper working
condition to perform its function of removing the heat from the building. Chilled water supply
temperatures should operate in the range of 45°F or colder in order to provide proper moisture
removal during humid weather. Piping should be insulated to prevent condensation. Other than
thermal comfort, IAQ concerns associated with water chillers involve potential release of the
working fluids from the chiller system.

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1.6 Working of Air conditioners:
An air conditioner cools and dehumidifies the air, as it passes over a cold coil surface.
The indoor coil is an air-to-liquid heat exchanger with rows of tubes that supplies the liquid
through the coil. Finned surfaces connected to these tubes increase the over all surface area of
the cold surface thereby increasing the heat transfer characteristics between the air passing
over the coil and liquid passing through the coil. The type of liquid used will depends on the
system selected. Direct-expansion (DX) equipment uses refrigerant as the liquid medium.
Chilled-water (CW) can also be used as a liquid medium. When the required temperature of a
chilled water system is near the freezing point of water, freeze protection is added in the form
of glycols or salts.
Regardless of the liquid medium used, the liquid is delivered to the cooling coil at the
cold temperature. In case of direct expansion equipment, air passing over indoor cooling coils
heats the cold liquid refrigerant. Heating refrigerant causes boiling and transforms refrigerant
from a cold liquid to a warm gas. This warm gas (or vapour) is pumped from the cooling coil
to the compressor through a copper tube (suction line to the compressor) where the warm gas
is compressed. In some cases, accumulator is placed between the cooling coil and compressor
to capture unused liquid refrigerant and ensures that only vapour enters the compressor.
The compression process increases the pressure of refrigerant vapour and increase the
temperature of the vapour significantly. The compressor pumps the vapour through another
heat exchanger (outdoor condenser) where heat is rejected and the hot gas is condensed to a
warm high-pressure liquid. This warm high-pressure liquid is pumped through a smaller
copper tube (liquid line) to a filter (or filter/dryer) and then on to an expansion device.

1.7 Types of Air Conditioning Systems:


The Major types of Air conditioning systems are
• Window Air Conditioner
• Split Air Conditioner
• Packaged Air Conditioner
• Central Air Conditioning System
• VRV or VRF air Conditioning System

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1.7.1 Window Air Conditioner:
Window air conditioner is the most commonly used air conditioner for single rooms.
In this air conditioner all the components namely compressor, condenser, expansion valve,
evaporator and cooling coils are enclosed in a single box. This unit is fitted in a slot made in
the wall of the room or more commonly a window sill.

Fig 1.3 Window air conditioning system

1.7.2 Split Air Conditioner:


The split air conditioner comprises of two parts: The outdoor unit and The indoor unit.
The outdoor unit, fitted outside the room, houses components like the compressor, condenser
and expansion valve.The indoor unit comprises the evaporator or cooling coil and the cooling
cooling fan. For this unit you don't have to make any slot in the wall of the room. Further, at
present day split units have aesthetic appeal and do not take up as much space as a window
unit. A split air conditioner can be used to cool one or two rooms.

Fig 1.4 Split Air Conditioning system

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1.7.3 Packaged Air Conditioner:
An HVAC designer will suggest this type of air conditioner if you want to cool more
than two rooms or a larger space at your home or office. There are two possible arrangements
with the package unit. In the first one, all the components, namely the compressor, condenser
(which can be air cooled or water cooled), expansion valve and evaporator are housed in a
single box. The cooled air is thrown by the high capacity blower, and it flows through the
ducts laid through various rooms. In the second arrangement, the compressor and condenser
are housed in one casing.

Fig 1.5 Packaged Air Conditioning System

1.7.4 Central Air Conditioning System:


Central air conditioning is used for cooling big buildings, houses, offices, entire hotels,
gyms, movie theaters, factories etc. If the whole building is to be air conditioned, HVAC
engineers find that putting individual units in each of the rooms is very expensive making this
a better option. A central air conditioning system is comprised of a huge compressor that has
the capacity to produce hundreds of tons of air conditioning.

Fig 1.6 Central Air Conditioning system

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1.7.5 Variable refrigerant flow:

Variable refrigerant flow (VRF), also known as variable refrigerant volume (VRV), is
an HVAC technology invented by Daikin Industries, Ltd. in 1982. Like ductless minisplits,
VRF’s use refrigerant as the cooling and heating medium. This refrigerant is conditioned by a
single outdoor condensing unit, and is circulated within the building to multiple indoor units.

VRF’s come in two system formats, two pipe and three pipe systems. In a heat pump
two pipe system all of the zones must either be all in cooling or all in heating. Heat Recovery
(HR) systems have the ability to simultaneously heat certain zones while cooling others; this
is usually done through a three pipe design, with the exception of Mitsubishi and Carrier,
whose systems are able to do this with a two pipe system using a branch circuit (BC) controller
to the individual indoor evaporator zones. In this case the heat extracted from zones requiring
cooling is put to use in the zones requiring heating.

Fig 1.7 Variable refrigerant flow

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1.8 Main components in Air Conditioning System:
In order to operate the refrigeration cycle successfully each component must be present within the
refrigeration system. There are five major mechanical components of an Air Conditioning system,
they are:

• Compressor
• Condenser
• Expansion Valve
• Evaporator
• Fan

Fig 1.8 Line diagram of Air Conditioning System

1.8.1 Compressor:

The purpose of the compressor is to draw the low-temperature, low-pressure vapour


refrigerant from the evaporator through the suction line. Once drawn the vapour refrigerant the
vapour refrigerant is compressed. When vapour is compressed its temperature and pressure rises.
Therefore, the compressor transforms the vapour from a low-temperature, low pressure vapour to
a high-temperature. The vapour is then released from the compressor to the condenser.

Fig 1.9 Compressor

15
1.8.2 Condenser:

The purpose of the condenser is to extract heat from the refrigerant to the outside air. Fans
mounted above the condenser unit are used to draw air through the condenser coils. The high-
pressure and high temperature refrigerant will be cooled to low temperature without changing the
pressure and with Phase change. As heat has to flow from the condenser to all, the condensation
temperature must be higher than that of the air. The liquid refrigerant then passes from the
condenser in to the metering device.

Fig 1.10 Condenser

1.8.3 Expansion Valve:

Within the refrigeration system, the expansion valve is located at the end of the liquid line,
before the evaporator. The valve then reduces the pressure of the refrigerant as it passes through
the orifice. The high pressure liquid reaches the expansion valve to reduce the pressure. Due to
sudden expansion the temperature falls down to the low temperature. This low pressure, low
temperature liquid is then pumped in to the evaporator.

Fig 1.11 Expansion Valve

16
1.8.4 Evaporator:

The purpose of the evaporator is to remove unwanted heat from the space using the liquid
refrigerant. The liquid refrigerant contained within the evaporator boils at a low temperature. To
enable the transfer of heat, the temperature of the liquid refrigerant must be lower than the
temperature of the product being cooled. The liquid refrigerant is drawn from the evaporator by
the compressor suction line. When leaving the evaporator coil the liquid refrigerant is in vapor
state.

Fig 1.12 Evaporator

1.8.5 Fans:

Fans play a major role in the air conditioning unit. Here, the Fans generate ambient air in the air
conditioning system. The main purpose of the fans is to do two works that are to cool the evaporator
and to send the cool air inside the room and the other side the fan works to remove the heat from
the super heated vapour in the condenser.

Fig 1.13 Fans

17
1.9 Refrigerant:
A refrigerant is a substance or mixture, usually a fluid, used in a refrigeration cycle and
refrigeration cycle. Refrigeration is a process of moving heat from one location to other in
controlled conditions. The work of heat transport is traditionally driven by mechanical work,
but can also be driven by heat, magnetism, electricity, laser, or other means.
In most cycles it undergoes phase transitions from a liquid to a gas and back again.
Many working fluids have been used for such purposes. Fluorocarbons, especially chloro
fluoro carbons became commonplace in the 20th century, gerents used in various applications
are ammonia, sulfur dioxide, and non-halogenated but they are being phased out because of
their ozone depletion effects. Other common refry hydrocarbons such as propane.

1.10 Types of Refrigerants:


The most common and major types of refrigerants in use now a days are listed below. They
are:

• Halocarbons
• Isotropic refrigerants
• Zoetrope refrigerants
• Hydrocarbon refrigerants
• Inorganic refrigerants like carbon dioxide, ammonia, water and air.

Halocarbons are generally synthetically produced. Depending on whether they include


chemical elements hydrogen (H), carbon (C), chlorine (Cl) and fluorine (F) they are named
after as follows:

• CFCs (Chlorofluorocarbons): R11, R12, R113, R114, R115.


• HCFCs (Hydro chlorofluorocarbons): R22, R123.
• HFCs (Hydro fluorocarbons): R134a, R404a, R407C and R410a.

18
1.11 Various Lines and Curves in Psychometric Chart:
A psychometric chart is a graphical representation of the psychometric processes of air. All
the properties of the air indicated in the psychometric chart are calculated at standard
atmospheric pressure. For other pressures relevant corrections have to be applied. The
psychometric chart looks like a shoe. Psychometric processes include the physical and the
thermodynamic properties such as

• Dry Bulb (DB) Temperature Lines


• Wet Bulb (WB) Temperature Lines
• Dew Point (DP) Temperature Lines
• Relative humidity
• Specific humidity
• Humidity Ratio

Fig 1.14 Psychometric Chart

19
1.11.1 Dry Bulb (DB) Temperature Lines:
The dry bulb temperature scale is shown along the base of shoe shaped psychometric chart
forming the sole. The DB temperature increases from the left to the right. The vertical lines
shown in the chart are the constant DB temperature lines and all the points located along a
particular vertical line have same DB temperature.

1.11.2 Wet Bulb (WB) Temperature Lines:


The outermost curve along the left side indicates the Wet Bulb (WB) temperature scale. The
constant temperature lines are the diagonal lines extending from WB temperature curved scale
downwards towards the right hand side of the chart.

1.11.3 Dew Point (DP) Temperature Lines:


Since the dew point temperature of the air depends on the moisture content of the air, constant
moisture lines are also constant DP temperature lines. The scale of the DP and WB
temperature is the same. However, while the constant WB temperature lines are diagonal lines
extending downwards, the constant DP temperature lines are horizontal lines. Thus the
constant DP and WB temperature lines are different.

1.11.4 Relative humidity:


The ratio of the vapor pressure of moisture in the sample to the saturation pressure at the dry
bulb temperature of the sample.

1.11.5 Specific humidity:


It is the ratio of water vapour content of the mixture to the total air content on the mass basis.

1.11.6 Humidity Ratio:


These are the horizontal lines on the chart. Humidity ratio is usually expressed as mass of
moisture per mass of dry air (pounds or kilograms of moisture per pound or kilogram of dry
air, respectively). The range is from 0 for dry air up to 0.03 (blew/lamb) on the right hand ω-
axis, the ordinate or vertical axis of the chart.

20
CHAPTER 2
LITERATURE REVIEW

Many experiments have been carried out. AR and CR also take place in order to improve the COP of
AC system. Below there is brief literature survey is going to present related to EC condenser.
. [1] S.D.White et.al in this work aims to develop a system which requires less floor area, increase
the evaporation rate and to recover the fresh water from the water evaporated from the effluent. The
system works on the principle of simultaneous HAMT take place in air and soak liquor in the spray
tower leading to evaporation of water in soak liquor. Studies are carried out to utilize the heat rejected
from the condenser of the VCR system to increase the temperature of the soak liquor. The hot soak
liquor can be sprayed in the enclosed chamber to enhance the contact area between the soak liquor
and air. Thus, both the process will contribute for increase in the evaporation rate compared to the
conventional method. Moreover in present situation there is more scarcity for the availability of water.
It will be useful if we recover fresh water from the above evaporation process. Efforts are made to
recover the fresh water from the above evaporation process using the cooling load available in the
evaporator of the VCR system.
[2] Chan et.al aldescribed the EE of DEC of ACC is used to increase by using variable different
condition also with help of different position of fan condenser. In this fan is placed behind the ACC
in order to precooled the atmosphere air while entering into the c unit.
By using with the help of direct evaporative cooler, due to which compressor power dropped down
and there is decrease in the condensing temperature in most of favorable conditions, while there is
pressure drop across the cooler take place caused additional condenser fan power consumption. The
total saving of chiller power varies from 1.4% to 14.4%.
[3] Sethi et.al the evaporative cooling of greenhouses is based on the evaporation of the water in the
mass of warm incoming air enter, thus allowing a drop in temperature and rise in the humidity content
of the air. It can be achieved by directly spraying water inside the greenhouse and combining it with
natural ventilation or by forcing the incoming air to pass through dampened evaporative pads and
installing fans to ventilate the greenhouse artificially (pad-fan cooling systems.
[4] Wu et.al proposed a simplified cooling efficiency based on the energy balance analysis of air to
analyze the heat and mass transfer between air and water film in the direct evaporative cooler. The
analysis showed that the frontal air velocity and thickness of the pad module are two key factors
influencing the cooling efficiency of a direct evaporative cooler. 21
[5] Eghtedari H. et.al investigated about the uses of ECAC as compare to ACC to solve the
problem of maintaining higher COP in hot weather conditions. Finally he built an evaporative
cooler and joined it with same AC of SAC .So that they get higher COP of the system. While
performing the experiment they get higher COP increase and cooling rate high in ECAC as the
outside air temperature rise.
[6] Kachhwaha and Suhas et.al designed, fabricated, and predicted the performance of an
evaporative medium. The pad thickness and height were achieved for maximum cooling.
[7] Datekin et.al. Examine the overall effect of velocity of the air on it temp. and CE. Finally
result shown tells that velocity of air drop in temp. of air and CE. While it has no mathematical
formula generated. His results explain velocity of air changes from 0.5m/s to 1.5m/s while
performing the experiment.
[8] Franco et.al explain the different parameter which is a function of velocity of air by using
ECP in WT. He finds out that PD, the velocity of air, velocity of water and consumption of water
by CP. He finally concluded that SE varies from 64% to 70%
[9] Kulkarni and Rajput et.al Calculate COP theoretical of I/D two stage C system with CP
and AM in DS. They have ambient temperature 39.9oC dbt and 32.9 % of RH. finally they get
121.5% to 106.7% of S.E
[10] Yang et.al investigated about application of mist evaporative precooling to air cooled
chillers. The experimental results showed that the dry bulb temperature of entering condenser air
with water mist pre-cooling could drop up to by 9.40 oC from the required ambient air
temperature. The COP could be improved by up to 18.6%. This study showed that the water mist
system coupled to air-cooled chillers is an energy efficient and environment friendly technique.
[11] Adarsh Mohan Dixit et.al presents an experimental investigation of a high-efficiency air
conditioner that utilizes cellulose pad before the condenser. The heat and mass transfer
characteristics of the cellulose pads is first studied and the results are used for the design of the
air conditioner. A 1.5 ton air conditioner was constructed and tested in the current study. The
experimental results show that the coefficient of performance (COP) reaches 8.03 that are higher
than that of standard value (5.98) of those conventional residential split air conditioners.

22
CHAPTER 3
METHODOLOGY
The experimental setup consists of a single stage vapour compression system with the basic
components i.e. evaporator, compressor, expansion device and condenser. A frame is to be
manufactured and covered it with the help of CMP and is placed them before the ACC unit.

With help of small watt pump is used in order to provide water over the CP. It placed in bucket whose
one end placed at the top of CP. Flow of water will remain constant. When outside air passes from
the EMP and cooled down further it enter into the condenser unit. Ammeter and Voltmeter is used to
determine the EC and EV of input power respectively.
The bourdon pressure gauges are used to be measure the inlet and outlet pressure of compressor.
Temperatures of refrigerant and circulation air at different points are recorded with the help of
thermocouples. Insulation tapes are placed over the copper tubes to provide better contact and also
prevent any convection effect of ambient air on the temperature readings.

Fabrication

Experimental
process

Data Collection

Data
Interpretation

Result and 23
Discussion
3.1 Vapor compression cycle
The vapor-compression cycle is the most widely used refrigeration cycle in practice. In this
cycle a vapor is compressed, then condensed to a liquid, following which the pressure is
dropped so that fluid can evaporate at a low pressure.

3.2 Carnot refrigeration cycle

The Carnot cycle is one whose efficiency cannot be exceeded when operating between two
given temperatures. The Carnot cycle operating as a heat engine is familiar from the study of
thermodynamics. The Carnot refrigeration cycle performs the reverse effect of the heat engine,
because it transfers energy from a low level of temperature to a high level of temperature. The
refrigeration cycle requires the addition of external work for its operation. The diagram of the
equipment and temperature-entropy diagram of the refrigeration cycle are shown in Fig. 6. All
processes in the Carnot cycle are thermodynamics reversible. Processes 1-2 and 3-4 are
consequently isentropic.

Work

Turbine
(Expansion device)
Compressor

Fig. 3.1 Carnot refrigeration cycle

24
Temperature, K
Net work

- Entropy, kJ·kg-1·K-1
Fig 3.2 temperature-entropy diagram of the carnot refrigeration cycle

The withdrawal of heat from the low-temperature source in process 4-1 is the refrigeration step
and is the entire purpose of the cycle. All the other processes in the cycle function so that the
low-temperature energy can be discharged to some convenient high-temperature heat sink.

3.3 Coefficient of Performance (COP)

Before any evaluation of the performance of a refrigeration system can be made, an


effectiveness term must be defined. The index of performance is not called efficiency, however,
because that term is usually reserved for the ratio of output to input. The ratio of output to input
would be misleading applied to a refrigeration system because the output in process 2-3 is
usually wasted. The concept of the performance index of the refrigeration cycle is the same as
efficiency, however, in that it represents the ratio

Magnitude of demand
Magnitude of expenditure

The performance term in the refrigeration cycle is called the coefficient of performance,
defined as

useful refrigeration
net work

25
3.3.1 Condition for highest coefficient of performance₄
We can express the coefficient of performance of the Carnot cycle in terms of the temperatures
that exist in the cycle. Areas beneath reversible processes on the temperature-entropy diagram
therefore represent transfers of heat. Areas shown in Fig. 7 can represent the amount of useful
refrigeration and the net work. The useful refrigeration is the heat transferred in process 4-1,
or the area beneath line 4-1. The area under line 2-3 represents the heat reject from the cycle.
The difference between the heat rejected from the cycle and heat added to the cycle is the net
heat which for a cyclic process equals the net work. The area enclosed in rectangle 1-2-3-4
represents the net work. An expression for the coefficient of performance of the Carnot
refrigeration cycle is therefore:

T₁(S₁ − S₂) 𝑇₁
𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑝𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 = =
(T₂ − T₁)(S₁ − S₄) (𝑇₂ − 𝑇₁)

where s is entropy and T is temperature.

The coefficient of performance of the Carnot cycle is entirely a function of the temperature
limits and can vary from zero to infinity
Temperature, K

Net work

Refrigeration

Entropy, kJ·kg-1·K-1

Fig. 3.3 Area on the temperature-entropy diagram.

A low value of T2 will make the coefficient of performance high. A high value of T1 increases
the numerator and decreases the denominator, both of which increase the coefficient of
performance.

To summarize, for a high coefficient of performance (1) operate with T1 high and (2) operate

26
with T2 low. It means that the smaller temperature difference between condenser and
evaporator, the higher COP achieves.

Temperature limitation

Fig. 3.4 Temperature requirements imposed upon a refrigeration cycle

In Fig. 8, temperature T2 should be kept low, but it cannot be reduced below atmosphere
temperature, if the atmosphere air is used to cool it. On the other hand, temperature T1 should
be kept high, but it can be increased no higher than the target temperature of the room. Because
of that, it can concentrate on keeping the as small as possible.

In heat transfer, reduction of can be accomplished be increasing A or U in the equation:


q = UA∆t

where q = heat rate,


U = overall heat-transfer coefficient, W· m-2·K-1
A = heat-transfer area, m2
t= temperature change, K

In order to decrease to zero, either U or A would have to be infinite. Since infinite values of U
and A would require an infinite cost, the actual selection of equipment always stops short of
reducing to zero.

27
3.4 Standard vapour-compression cycle

The standard vapour-compression cycle is shown on the temperature- entropy diagram in Fig.
9. The processes constituting the standard vapour- compression cycle are:
1-2. Reversible and adiabatic compression from saturated vapor to the condenser pressure
2-3. Reversible rejection of heat at constant pressure, causing desuperheating and condensation
of the refrigerant
3-4. Irreversible expansion at constant enthalpy from saturated liquid to the evaporator pressure
4-1. Reversible addition of heat at constant pressure causing evaporation to saturated vapor
Temperature, K

Entropy, kJ·kg-1·K-1

Fig. 3.5 The standard vapor-compression cycle

3.4.1 Performance of the standard vapor-compression cycle

With the help of the pressure-enthalpy diagram, the significant quantities of the standard vapor-
compression cycle will be determined. These quantities are the work of compression, the heat-
rejection rate, the refrigerating effect, the coefficient of performance, the volume rate of flow
per kilowatt of refrigeration, and the power per kilowatt of refrigeration.

28
Fig. 3.6 Pressure-enthalpy diagram

3 2

Compressor

1
4

Fig 3.7 Flow diagram.

The work of compression in kilojoules per kilogram is the change in enthalpy in process 1-2
of Fig. 10 (a) or h1 – h2. This relation derives from the steady-flow energy equation:

h₁ + q = h₂ + w

where changes in kinetic and potential energy are negligible. Because in the adiabatic
compression the heat transfer q is zero, the work w equals h1 – h2. The difference in enthalpy
29
is a negative quantity, indicating that work is done on the system. Even though the compressor
may be of the reciprocating type, where flow is intermittent rather than steady, process 1- 2
still represents the action of the compressor. At a short distance in the pipe away from the
compressor, the flow has smoothed out and approaches steady flow.

The heat rejection in kilojoules per kilogram is the heat transferred from the refrigerant in
process 2-3, which is h3 – h2. This knowledge also comes from the steady-flow energy equation,
in which the kinetic energy, potential energy, and work terms drop out. The value of h3 – h2 is
negative, indicating that heat is transferred from the refrigerant. The value of the heat rejection
is used in sizing the condenser and calculating the required flow quantities of the condenser
cooling fluid.

The refrigerating effect in kilojoules per kilogram is the heat transferred in process 4-1, or h1
– h4. Knowledge of the magnitude of the term is necessary because performing this process is
the ultimate purpose of the entire system.

The coefficient of performance of the standard vapor-compression cycle is the refrigerating


effect divided by the work of compression:

ℎ₁−ℎ₄
Coefficient of performance = ℎ₂−ℎ₁

3.5 Actual vapor-compression cycle

The actual vapor-compression cycle suffers from inefficiencies compared with the standard
cycle. There are also other changes from the standard cycle, which may be intentional or
unavoidable. Some comparisons can be drawn be superimposing the actual cycle on the
pressure-enthalpy diagram of the standard cycle, as in Fig 1.6

The essential differences between the actual and standard cycle appear in the pressure drops in
condenser and evaporator, in the subcooling of the liquid leaving the condenser, and in the
superheating of the vapor leaving the evaporator. The standard cycle assumes no drop in
pressure in the condenser and evaporator. Because of friction, however, the pressure of the
refrigerant drops in the actual cycle. The result of these drops in pressure is that the
30
compression process between 1 and 2 requires more work than in the standard cycle.
Subcooling of the liquid in the condenser is a normal occurrence and serves the desirable
function of ensuring that 100 % liquid will enter the expansion device. Superheating of the
vapor usually occurs in the evaporator and is recommended as a precaution against droplets of
liquid being carried over into the compressor. The final difference in the actual cycle is that the
compression is no longer isentropic and there are inefficiencies due to friction and other losses.

Subcooling Pressure drop cycle


Pressure, kPa

2
3
cycle

Pressure drop

4
1
{

Superheating

Enthapy, kJ·kg-1

Fig. 3.8 Actual vapor-compression cycle

31
CHAPTER 4
EXPERIMENTAL SETUP
In the present work we have concentrated towards the improvement of the performance by adding
the evaporative condenser to the AC unit and also the COP varies with ambient temperature 31°C
to 33°C.

In the experiment setup (figure7.1) consist of single stage vapour compression system which
contains different components parts such as expansion device, compressor, evaporator and
evaporative cooled condenser. The compressors of volume are used to increase the pressure . and
temp. of (R22).Here the capillary tube is used, made up of a copper tube of very small diameter
0.36mm.Capillary tube used as expansion device. The evaporator is used to reduce the pressure,
dissipating heat and making liquid refrigerant to much cooler. Evaporator used in this experiment
setup is tube and fin type. whereas pumped water flow continuous vertically over the condenser
coils with the help pump of 35 watt. Flowing of water continuously circulate over the condenser
while performing the experiment.
Different measuring devices are used in this experiment setup such as Thermometer , which gives
the temperature at various points within the system. Pressure gauge is also used; Similarly ammeter
and voltmeter are used to measure the current and voltage to input to the system.

Fig 4.1 Experimental setup for Evaporative condenser

32
4.1 Major Component
The Air cooled condenser is cooled by the evaporative action of falling water which takes up the
latent heat of from the condensing coils .This cool water then passes through the condenser

Fig 4.2 Air cooled condenser for experiment

The compressor used in this experimental setup is hermetically sealed type of Kirloskar
KCJ515HAE. In this type, the shaft of the compressor is directly coupled to the motor which is
mounted on the same base and this complete system is enclosed in the housing as shown in Fig 7.3.
In the compressor, low press. and low temp. vapour from the Ev unit enters through the suction line
and the high pressure and high temperature vapour leaves from the discharge line. This type of
compressor gives minimum noise, since vibration in the system reduces due to mounting of the
compressor and motor on the same shaft.

Fig 4.3 Hermetically sealed compressor

33
When the refrigerant leaves the condenser and enters the capillary tube its pressure drops down
suddenly due to frictional resistance offered by the tube walls. The capillary tube which is used in
experimental setup is shown in Figure 7.4.

Fig 4.4 Capillary Tube

When the liquid refrigerant enters the evaporator, its pressure has been decreased due to which it
dissipating its heat related content and making it much cooler than the air flowing around across it.
Due to this it causes the refrigerant to absorb heat from the surrounding warm air and to reach its
low boiling point continuously. Now then the refrigerant vaporizes, and absorbing the maximum
amount of latent heat from surrounding air. This heat is then carried by the refrigerant from the
evaporator as a low-pressure gas through a hose to the inlet side of the compressor. The evaporator
removes heat from the region which is to be cooled.

Fig 4.5 Evaporator with sealed casing

34
Measuring Device
Four pressure gauges are used in this set up, one for the measurement of suction pressure before the
compressor and other for the measurement of discharge pressure after the compressor and the other
two for measuring the pressure after and before condensing and expanding repectively.

Fig 4.6 Pressure gauge

This is a device used to measure the temperature of the working fluid. The alcohol thermometers
are used, which directly gives the value of temperature at various points across each unit.

Fig 4.7 Digital thermometer

Voltmeter and ammeter are the devices used to measure the voltage and current of the input power
to the air conditioning system. Both voltage and ammeter are of dial gauge manual type.

Fig 4.9 Ammeter and voltmeter


35
CHAPTER 5
CALCULATIONS
Air conditioner performance without modification

Reading from the equipment before modification:

Absolute pressure after the evaporator, P₁ = 3.786 bar

Absolute pressure after the compressor,P₂ = 6.75 bar

Absolute pressure after the condenser, P₃ = 6.75 bar

Absolute pressure after the expansion valve,P₄ = 3.786 bar

Temperature after the evaporator, T₁ = -8℃

Temperature after the compressor, T₂ = 70℃

Temperature after the condender, T₃ = 31℃

Temperature after the expansion valve, T₄ = -10℃

Mass flow rate of refrigerator , ma = 0.425kg/sec

Flow rate of refrigerant, Vr = 0.005m3/sec

Wet bulb temperature of air before evaporator = 20.5℃

Dry bulb temperature of air before evaporator = -2℃

Wet bulb temperature of air after evaporator = 3℃

Time for 2rev of temperature of water , tcd = 35.5 sec

Time for 5rev of temperature of water , tc = 115 sec

Time to decrease 5℃ temp of water = 110 sec

Manometer difference, h = 0.0218m

36
Temperature difference of water = 5℃

Refrigeration effect = maCp∆

Ma = Va x ⍴a = 0.005 x 1000

= 2.5 kg

5
Refrigeration effect = 2.5 x 4.18 x 110

= 0.95 KJ/sec

𝑛 𝑥 3600
Work done in compressor (Wc) = 𝑁𝑥𝑡

5 𝑥 3600
= 1200 𝑥 115

= 0.42 KJ/kg

𝑛 𝑥 3600
Workdone in condenser (Wcd) = 𝑁𝑥𝑡

2 𝑥 3600
= 1200 𝑥 35

= 0.052 KJ/kg

Actual C.O.P

𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑒𝑐𝑡
C.O.Pact = 𝑛𝑒𝑡 𝑤𝑜𝑟𝑘 𝑑𝑜𝑛𝑒

0.95
= 042+ 0.052

C.O.Pact = 2.01

Theoretical C.O.P = h1 – hf3/ h2 – h1

From the P-H chart P1 =P4 = 3.786 bar

H1= 395 KJ/kg

At P2=P3 = 6.75 bar

37
Hf3 = 226 KJ/kg

H2 = 407 KJ/kg

395−226
Theoretical C.O.P = 404−395

= 14.083

Actual heat transfer to the atmosphere = Q = mCp∆t

Where m = mass flow rate of refrigerant in cycle = 0.425 kg/sec

Cp = specific heat of refrigerant R-22 at constant pressure

Cp = 1.084 kg/kg.K

∆t = temperature difference

Q = 0.425*1.084*(70-31)

= 0.425*1.084*39

Q = 17.967 KJ/kg

The actual heat transfer from the surface of the condenser is 17.967 KJ/kg

Tank capacity required for extract the complete amount heat from the condenser by water
spray through orifice.

Temperature of the surface of the condenser coil.

Q = UA∆t

Where U = overall heat transfer coefficient i.e. 393 KJ/kg.km2 for copper material

A = surface area of the condenser coil in mm2

∆t = temperature difference between refrigerant and coil surface

Surface area of the coil


38
As = P x length of tube x no.of tubes

Where P = perimeter of the tube = 2ℼr x l x n

= 2 x ℼ x 5 x 540 x 48

= 813888 mm2

= 0.813 m2

Therefore, Q = UA∆t

17.967 = 393 x 0.813 x (70-Ts)

17.967
(70-Ts) = 393 x 0.813

Ts = 70-0.0569

Ts = 69.9933

Ts ≈ 70 ℃

The surface temperature of the condenser coil is approximately 70 ℃

Required flow rate to extract the heat from the surface of the condenser to get more efficiency
with evaporative water = Q = mwCpw∆T

Where Q = heat transfer rate KJ/kg

mw = mass flow rate of water kg/sec

Cpw = specific heat of water i.e. 4.15 KJ/kg.K

17.967 = mw x 4.18 x (70-25)

17.967 17.967
mw = 4.18 x (70−25) = = 0.09548 KJ/sec
188.1

If the experiment is run for 1 hr then we need to supply the water for that particular time.

Therefore, supply of water for 1 hr = 0.095 x 60x60

39
= 343.728 kg/hr

In this project we are assuming a 20 litre water tank and recirculating the water continuously
after the use in order to minimize the wastage of water .

Water evaporation should happen at 70℃ instead of 100℃ for that pressure drop required to
be estimated as

Acc to the Charles law,

P∞T

P = T x constant

𝑃₂ 𝑇₂
= 𝑇₁
𝑃₁

Where ; P1 = atmospheric pressure

P2 = outlet pressure of the water from the copper tube

T1 = 100℃

T2 = 70 ℃

𝑃₂ 70
= 100
101.325

P2 = 0.7 x 101.35

P2 = 70.923 Kpa

Outlet pressure of water from the copper tubes through the orifice over the condenser surface

Required number of orifice to be obtained by

𝑇𝑆𝐴
Tsc = 2 x L x C x tan( )
2

Where ; Tsc = theoretical surface coverage in mm2

TSA = theoretical spray angle in degrees

40
L = length between orifice and surface of condenser

C = diameter of water sprayed on the surface of the condenser

Condenser parameters

Length of the condenser = 540 mm

Width of the condenser = 55mm

Height of the condenser = 410 mm

No.of fins per cm = n = 5

Surface area of the fins the over the condenser = thickness of fin x no.of fins over the length of
condenser

= 0.8 x 5

= 4 mm

Therefore , the surface area of the fins = 4mm x 70

= 1080 mm2

Therefore, As fin = 0.00108 m2

Specification of submergible pump

Discharge = Q = 1100L/H

= 1.1 m3/hr

Pump outlet pressure or pump discharge pressure, dp = P x 3600/Q

0.035 𝑥 3600
dp = 1.1

dp = 114.54 Kpa

For orifice diameter

According to the Bernoulli’s Theorem


41
𝑃₁ 𝑉₁2 𝑃₂ 𝑉₂2 𝑃₃ 𝑉₃2
+ + Z₁ = ⍴𝑔 + + Z₂ +⍴𝑔 + + Z3 (for three cross sections)
⍴𝑔 2𝑔 ⍴𝑔 2𝑔

Where, P1 = dp= discharge pressure of the pump in Kpa

⍴ = density in kg/m3

g = acceleration due to gravity in m/sec2

Z1,Z2 and Z3 = datum height in m

V1, V2 and V3 = section velocity m/sec

By cancelling the unwanted parameters, we get

P1 + 𝑉₁2 = P2 + 𝑉₂2

We know that Q = AV ( according to continuity equation )

𝑄
V1 = 𝐴₁


A1 = d12
4


=4 x (12)2

= 0.785 x 12x12

= 113.04 mm2

A1 = 0.00011304 m2

0.000305
Now V1 = = 2.702
0.00011304

V12 = 2.702 x 2.702 = 7.300804 m/sec

𝑞
Therefore V2 =𝐴₂


A2 = 4 x d22

= 0.785 x (8)2

42
A2 = 5.024 x 10-5 m2

3.818 𝑥 10⁻⁵
V2 = 5.024 𝑥 10⁻⁵ = 0.76055

V22 = 0.5784 m/sec

P 1 + V1 2 = P 2 + V2 2

114.54 + 7.3008 = P2 + 0.5784

P2 = 121.26 Kpa

Now for section 2 & 3, we have

P 2 + V2 2 = P 3 + V3 2

121.2620 + 0.5784 = 70.923 + V32

V32 = 50.9174

V3 = √50.9174 = 7.1356 m/sec

From the continuity equitation,

Q = VA

𝑄
A3 = 𝑉₃

ℼ3.818 𝑥 10⁻⁵
A3 = 7.1356

A3 = 5.3505 x 10-3 m2


Now A3 = 4 x d32

5.3503 𝑥 10⁻3
D3 2 = 0.7854

d32 = 6.815 x 10-3 m

d3 = √6.815 ∗ 10−3

43
d3 = 2.410 x 10-3 m

Hence, The diameter of the orifice = 2.410mm

So , the diameter of the orifice is taken as approximately 2 mm

d ≈ 2mm

Required no.of orifices to be obtained by

𝑇𝑆𝐴
Tsc = 2 x L x C x tan( )
2

60
Tsc = 2 x 4 x 6 x tan( 2 )

Tsc = 2 x 4 x 6 x 0.5773322

Tsc = 2.75194 x 10-5 m2

Number of orifice are required to spray the water on the total area of condenser is given by :

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑛𝑠 𝑜𝑣𝑒𝑟 𝑡ℎ𝑒 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 𝑐𝑜𝑖𝑙𝑠


𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝑐𝑜𝑣𝑒𝑟𝑎𝑔𝑒

0.001080
= 22.7519 𝑥 10⁻⁵

108
= 2.751

= 39.258

≈ 40

Therefore, the total number of orifice required to spray the water over the surface of
condenser to extract 17.976 KJ/kg of heat from the condenser coils are 40.

44
For more better increasing of COP of the refrigerating unit, we increase the flow
rate from the pump to the surface of the condenser by adjusting the 1/4th inch
ball valve. The mass output rate of the pump is 1100L/h means 18.33L/min
approximately 18L/min.

With the change of flow rate the outlet temperature of the condenser drops
down, while increasing the COP of the refrigerant unit.

Air conditioner readings with modification (1)

Reading from the equipment when the flow rate of water is 0.075 L/min

Absolute pressure after the evaporator, P₁ = 3.9 bar

Absolute pressure after the compressor, P₂ = 7.25 bar

Absolute pressure after the condenser, P₃ = 7.25 bar

Absolute pressure after the expansion valve, P₄ = 3.9 bar

Temperature after the evaporator, T₁ = -10℃

Temperature after the compressor, T₂ = 68℃

Temperature after the condenser, T₃ = 29℃

Temperature after the expansion valve, T₄ = -13℃

Mass flow rate of refrigerant, ma = 0.425kg/sec

Flow rate of refrigerant, Vr = 0.0065m3/sec

Wet bulb temperature of air before evaporator = 18℃

Dry bulb temperature of air before evaporator = -4℃

Wet bulb temperature of air after evaporator = 2℃

Time for 2rev of temperature of water, tcd = 50 sec

45
Time for 5rev of temperature of water , tc = 150 sec

Time to decrease 5℃ temperature of water = 118 sec

Temperature difference of water = 5℃

𝑛 𝑥 3600
Work done in compressor (Wc) = 𝑁𝑥𝑡

5 𝑥 3600
= 1200 𝑥 50

= 0.1KJ /kg

𝑛 𝑥 3600
Workdone in condenser (Wcd) = 𝑁𝑥𝑡

2 𝑥 3600
= 1200 𝑥 150

= 0.3 KJ/kg

Refrigeration effect = maCp∆t

Ma = Va x ⍴a = 0.0075 𝑥 1000

= 6.5 kg

6
Refrigeration effect = 6.5x4.18x118

= 1.35 KJ/sec

Actual C.O.P

𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑒𝑐𝑡
C.O.Pact =
𝑛𝑒𝑡 𝑤𝑜𝑟𝑘 𝑑𝑜𝑛𝑒

1.35
= 0.1+0.3

C.O.Pact = 3.375

Theoretical C.O.P = h1 – hf3/ h2 – h1

From the P-H chart P1 =P4 = 3.98 bar

46
H1= 420 KJ/kg

Hf3 = 205 KJ/kg

H2 = 435 KJ/kg

420 −205
Theoretical C.O.P = 435−420

= 14.864

Air conditioner readings with modification(2)

Reading from the equipment when the flow rate of water is 0.15L/min

Absolute pressure after the evaporator, P₁ = 3.015 bar

Absolute pressure after the compressor, P₂ = 7.5 bar

Absolute pressure after the condenser, P₃ = 7.5 bar

Absolute pressure after the expansion valve, P₄ = 3.015 bar

Temperature after the evaporator, T₁ = -10℃

Temperature after the compressor, T₂ = 70℃

Temperature after the condenser, T₃ = 27℃

Temperature after the expansion valve, T₄ = -12℃

Mass flow rate of refrigerant, ma = 0.425kg/sec

Flow rate of refrigerant, Vr = 0.0068m3/sec

Wet bulb temperature of air before evaporator = 16℃

Dry bulb temperature of air before evaporator = -3℃

Wet bulb temperature of air after evaporator = 4℃

Time for 2rev of temperature of water , tcd = 45 sec

47
Time for 5rev of temperature of water, tc = 159sec

Time to decrease 5℃ temperature of water = 129 sec

Temperature difference of water = 6℃

𝑛 𝑥 3600
Work done in compressor (Wc) = 𝑁𝑥𝑡

5 𝑥 3600
= 1200 𝑥 159

= 0.13 KJ/kg

𝑛 𝑥 3600
Workdone in condenser (Wcd) = 𝑁𝑥𝑡

2 𝑥 3600
= 1200 𝑥 45

= 0.09 KJ/kg

Refrigeration effect = maCp∆t

Ma = Va x ⍴a = 0.0078 𝑥 1000

= 6.5 kg

6
Refrigeration effect = 6.5x4.18x129

= 1.630 KJ/sec

Actual C.O.P

𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑒𝑐𝑡
C.O.Pact =
𝑛𝑒𝑡 𝑤𝑜𝑟𝑘 𝑑𝑜𝑛𝑒

1.63
= 0.13+0.09

C.O.Pact = 7.16

Theoretical C.O.P = h1 – hf3/ h2 – h1

From the P-H chart P1 =P4 = 3.98 bar

48
H1= 425KJ/kg

At P2=P3 = 15.26 bar

Hf3 = 201 KJ/kg

H2 = 438 KJ/kg

425−201
Theoretical C.O.P = = = 17.23
438−425

Air conditioner readings with modification(3)

Reading from the equipment when the flow rate of water is 0.225L/min

Absolute pressure after the evaporator, P₁ = 2.950 bar

Absolute pressure after the compressor, P₂ = 7.65 bar

Absolute pressure after the condenser, P₃ = 7.65 bar

Absolute pressure after the expansion valve, P₄ = 2.950 bar

Temperature after the evaporator, T₁ = -11℃

Temperature after the compressor, T₂ = 75℃

Temperature after the condenser, T₃ = 25℃

Temperature after the expansion valve, T₄ = -11℃

Mass flow rate of refrigerant , ma = 0.425kg/sec

Flow rate of refrigerant, Vr = 0.0065m3/sec

Wet bulb temperature of air before evaporator = 16℃

Dry bulb temperature of air before evaporator = -3℃

Wet bulb temperature of air after evaporator = 4℃

Time for 2rev of temperature of water, tcd = 48 sec

49
Time for 5rev of temperature of water, tc = 160sec

Time to decrease 5℃ temperature of water = 125sec

Temperature difference of water = 8℃

𝑛 𝑥 3600
Work done in compressor (Wc) = 𝑁𝑥𝑡

5 𝑥 3600
= 1200 𝑥 160

= 0.125 KJ/kg

𝑛 𝑥 3600
Workdone in condenser (Wcd) = 𝑁𝑥𝑦

2 𝑥 3600
= 1200 𝑥 48

= 0.093 KJ/kg

Refrigeration effect = maCp∆t

Ma = Va x ⍴a = 0.0079 𝑥 1000

= 7.9 kg

8
Refrigeration effect = 6.5x4.18x125

= 1.73 KJ/sec

Actual C.O.P

𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑒𝑐𝑡
C.O.Pact = 𝑛𝑒𝑡 𝑤𝑜𝑟𝑘 𝑑𝑜𝑛𝑒

1.73
= 0.125+0.109

C.O.Pact = 7.52

Theoretical C.O.P = h1 – hf3/ h2 – h1

From the P-H chart P1 =P4 = 2.95 bar


50
H1= 428KJ/kg

At P2=P3 = 7.65 bar

Hf3 = 200 KJ/kg

H2 = 439 KJ/kg

428−200
Theoretical C.O.P = = 20.72
439−428

Air conditioner readings with modification(4)

Reading from the equipment when the flow rate of water is 0.0.325L/min

Absolute pressure after the evaporator, P₁ = 2.950 bar

Absolute pressure after the compressor, P₂ = 7.65 bar

Absolute pressure after the condenser, P₃ = 7.65 bar

Absolute pressure after the expansion valve, P₄ = 2.950 bar

Temperature after the evaporator, T₁ = -10℃

Temperature after the compressor, T₂ = 78℃

Temperature after the condenser, T₃ = 22℃

Temperature after the expansion valve, T₄ = -13℃

Mass flow rate of refrigerant , ma = 0.425kg/sec

Flow rate of refrigerant, Vr = 0.0065m3/sec

Wet bulb temperature of air before evaporator = 14℃

Dry bulb temperature of air before evaporator = -4℃

Wet bulb temperature of air after evaporator = 4℃

Time for 2rev of temperature of water, tcd = 55 sec

51
Time for 5rev of temperature of water, tc = 170sec

Time to decrease 5℃ temperature of water = 130sec

Temperature difference of water = 9℃

𝑛 𝑥 3600
Work done in compressor (Wc) = 𝑁𝑥𝑡

5 𝑥 3600
= 1200 𝑥 170

= 0.08 KJ/kg

𝑛 𝑥 3600
Workdone in condenser (Wcd) = 𝑁 𝑥𝑡

2 𝑥 3600
= 1200 𝑥 160

= 0.10 KJ/kg

Refrigeration effect = maCp∆t

Ma = Va x ⍴a = 0.00 𝑥 1000

= 7.9 kg

8
Refrigeration effect = 6.5x4.18x125

= 1.88 KJ/sec

Actual C.O.P

𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑒𝑐𝑡
C.O.Pact =
𝑛𝑒𝑡 𝑤𝑜𝑟𝑘 𝑑𝑜𝑛𝑒

1.88
= 0.08+0.10

C.O.Pact = 10.44

Theoretical C.O.P = h1 – hf3/ h2 – h1

From the P-H chart P1 =P4 = 2.95 bar

52
H1= 428KJ/kg

At P2=P3 = 7.65 bar

Hf3 = 200 KJ/kg

H2 = 439 KJ/kg

430−202
Theoretical C.O.P = = 22.8
440−430

53
RESULTS AND DISCUSSION

The following tests were carried out in the laboratory of Gurunanak institute of technical campus,
Hyderabad,India during mid-daytime in the month of March (summer). The lab was sealed with plastic
curtains to prevent heat dissipation into the room from the surrounding. Other heat radiating machines
were also removed from the lab. The condenser ducts were also insulated with thermal insulation
lining. The following arrangements were done to achieve least amount of variation during the test.
The tests were conducted under two sections
• Without evaporative cooling.
• With evaporative cooling.
Readings were recorded at an interval of 5 minutes and the data was tabulated.

WITHOUT EVAPORATIVE COOLING

The window AC was run on conventional cycle (i.e. without evaporative cooling). Data recorded is
tabulated as under in Table -1.

S.NO Room Evaporator Compressor condenser Evaporator


outlet outlet outlet inlet
temperature
temperature temperature temperature temperature COP

(T1)℃ (T2)℃ (T3)℃ (T4)℃

1 28 -8 70 31 -10 2.54

Table.1

WITH EVAPORATIVE COOLING


After recording the observation without evaporative cooling of the air, the pump supplying water
to the pads was operated and temperature readings were recorded between time intervals of 5mins.
Following observations are recorded in the Table-2 given below.

54
Flow rate of Room Evaporator Compressor condenser Evaporator
outlet outlet outlet inlet
water in temperature
temperature temperature temperature temperature COP

(L/min) (T1)℃ (T2)℃ (T3)℃ (T4)℃

0.075 28 -10 68 29 -13 3.37

0.15 28 -10 70 27 -12 7.16

0.225 28 -11 75 25 -11 8.64

0.325 28 -10 78

Table.2

Modification Readings:

S.NO Temperature drop COP(act) COP(the) Refrigerating Total input


after condenser effect work

In ℃ N In KJ/sec

1 2℃ 3.375 14.33 1.53 0.4

2 2℃ 7.16 17.23 1.63 0.22

3 2℃ 8.64 20.7 1.89 0.21

Table. 3

55
Y-Values
10
9
8
7
COP (act)

6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25
`
flow rate of water in L/min

Fig.5.1 COP vs flow rate of water

Y-Values
10
9
8
7
6
COP (act)

5
4
3
2
1
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Refrigeration effect (N)

Fig.5.2 COP vs Refrigeration effect graph

56
Y-Values
10

6
COP (act)

0
0 1 2 3 4 5 6 7

Temperature drop after condenser in ℃

Fig.5.3 COP vs temperature drop after condenser graph

57
CONCLUSION

Using water for evaporation as a mean of decreasing air temperature is considerably the most
environmentally friendly and effective cooling system. We have to observe the condenser
discharge pressure we conclude that the compressor work would be reduced. Hence the COP will
be increases and decreased the power consumption. Saving the 20- 25% energy. In this way
adiabatic pre-air cooling system is beneficial for energy consumption.
Evaporative condenser results higher COP compare to conventional air-cooled and water-cooled
condenser. Also evaporative condenser is compact compare to conventional air-cooled and water
cooled condenser due to high overall heat transfer coefficient.
All these features make evaporative condensers a better option for condensation. They can be used
in industrial refrigeration, air-conditioning, cold storage and breweries.

58
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61

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