1 INTRODUCTION

1.1 Motivation

In any refrigeration system evaporator play key role in the whole cycle. The purpose of

evaporator is to extract heat from refrigerator cabin. At the inlet of evaporator, cold refrigerant in

liquid form enters. While passing through tubes it absorbs heat from surrounding and changes its

phase to vapor thus creating cooling effect. The design of the cooling fins in evaporator play key

role in cooling. The purpose of this project is to analyze different evaporator design with

different fins attached and by the means of numerical and analytical techniques, optimize it

further.

The opportunity to work on different evaporator systems presents a challenging task to the

authors and is a great test of their engineering knowledge and practical thinking. Due to the high

complexity of analysis involving phase change phenomenon, there is a lot of room for

improvement in each of its constituent sub-systems, with novel ideas being studied and

implemented on a continual basis.

The motivation to work on this project is derived from the aforementioned learning opportunity

it offers. Modifying the geometries of evaporators by attaching different shaped fins and

studying their impact on evaporator performance and then implementing the finalized deign in

practical applications is something that requires extensive research, design work, and

manufacturing.

In addition to this, the contribution of this project towards the environment and improved

commercial viability of finned evaporators is also a motivating factor for this group as its

implementation would lead to optimized heat exchanging applications.

1.2 Overview

This project deals with the comparative study of different evaporator models with fins attached

to study their behavior in refrigeration compartments. Four different configurations of fins are

selected constituting of staggered square fins, continuous rectangular fins, circular fins and spine

fins. The best optimized evaporator is selected based upon volume of fluid analysis numerically

and heat transfer related calculations analytically.

Firstly, for CAD modelling Creo parametric 6.0 was used. Then for VOF analysis CFD tool

ANSYS 2020 R1 was used. Refrigerant selected for VOF analysis was r600a based upon its low

global warming and ozone depletion potential. The material selected for tubes and fins was

aluminum. After performing CFD analysis, the numerical results were validated using analytical

calculations performed using designed testing setup which is further elaborated in upcoming

chapters.

1.3 Research Objectives

The core objective of this study is designing an energy sufficient evaporator model for high

energy rating applications. For this, a detailed concept about multi-phase flow was developed to

get an optimized design of a refrigerator evaporator system through comparison between various

models

For achieving higher efficiency, designing new fins or changing orientation of existing fins was

done. CFD analysis involving transient heat analysis, evaporation analysis and volume fraction

method were carried out over complex finned CAD geometries. Lastly, a test rig is used to

validate numerical and analytical results.

 2 LITERATURE REVIEW

2.1 Historical Background

Multi-phase fluid means that the fluid exist in both the phases that is liquid and gases with a

small region separating both the region from fluid is basically converting into the gaseous form.

Thus there are several forms of multiphase flow such as transient condition flows that converts

purely from the liquid phase to the vapor phase when any external heating source is applied. In

some cases of some separated flows and in the case of two-phase flow (dispersed) in which one

of the fluid is in the form of bubbles, droplets or particles.

There are so many applications historically that leads to such phenomena. Starting from the

power plant applications. In this area we the pressurized water was heated to convert it into

superheated form in order to run steam turbines to produce electricity. Similarly looking at the

another case of multiphase flow occurrence in the phenomena of the cavitation of pumps where

the pressure of the fluid reaches its saturation pressure and starts boiling and forms bubbles after

conversion into vapors. This bubbles and then explodes and damages the pump components

effectively. Moreover, considering our atmosphere it shows the simplest example of climate

effect of converting water vapors from soil land to the liquid rain above in clouds. Thus

multiphase phenomena exists from very little to large applications of interest and analysis related

to this is of interest for most of the researchers. (From 2nd lit rev)

2.2 Potential Refrigerants for Analysis

Mario and Strab conduct a research work on the performance of refrigerants in their conference

paper (1st lit rev) and looked for the potential material that can be used in household refrigerator

appliances. The working conditions was selected e.g. the compressing pressure and the
evaporating temperatures of each refrigerants and calculations was made to draw a graph of

cooling capacity and power requirement for a certain set of appliance. The main feature that were

also made part of this research work was to analyze the global warming potential of each

refrigerant with their ozone depletion potential and toxicity. Coming to the refrigerants selection

and their group types taken from the same conference paper and research work of *Herr.

Nowadays analysis usually carried out with a refrigerant that is under the range of less than 150

Global Warming Potential (GWP) and Ozone Depletion Potential (ODP) to be 0. Thus,

excluding refrigerants that lies beyond above this range. Some of the most suited refrigerants for

analysis are as follows:

Table 1: Selected Refrigerants for Analysis (*Herr)

Boiling
Name of the Molecular
GWP ODP Point at
Refrigerant Formula
1.013bar
R1234ze C3H2F4 7 0 -19˚C
R1234yF C3H2F4 4 0 -30˚C
R1270 C3H6 3 0 -48˚C
R717 NH3 0 0 -33˚C
R600 C4H10 3 0 -1˚C
R600a C4H10 3 0 -11.7˚C
R290 C3H8 3 0 -42˚C
*Herr, H. (2002). Tabellenbuch Wärme Kälte Klima. Europa Lehrmittel.

2.3 Selection of Refrigerant for Analysis

During the research study of Kalambe (2 nd lit rev) through CFD techniques the pressure drop and

pumping power requirements was observed through a use of two refrigerants. One was from the

range discussed in the research of conference paper (1 st literature review) i.e. R1234yf and other
one was common and typical used refrigerant, which is R134a. It was observed that the pressure

difference that was developed in case of R134a was reaching the value 12MPa and the R1234yf

was reaching 10MPa at the end of selected tube and at the same operating conditions this surely

increase the pumping power at the compressor and hence efficiency will be compromised.

Although they both gave the quality of liquid near to 1 formed in the condenser but at different

pressure. Thus current analysis of using R600a for ongoing study is in agreement of research

work of both the Kalambe and Mario and Strab.

2.4 Previous Work on Geometries and Fluid

Research work on evaporators is under consideration from the very beginning. Just like in study

of (3rd lit rev) with different configuration of fins of selected length evaporator tube was carried

out. The main purpose of this research work was to find the variation in heat flux, temperature,

pressure drop along with two tube materials such as aluminum alloys, copper. With certain

conditions of their own experimental setup they found that continuous fins with the zig-zag tube

configuration and using R22 produced better results with other selected parameters and values.

This work is in agreement of presented analysis of evaporator but one thing is different in present

case fluid or material is kept constant and only the effect of configuration is observed.

Similarly various fluid can be used for the multiphase modelling just like in the case of (4 th lit

rev) acetone is considered. Basically this research paper analyze both the condensation and

evaporation by varying the fluid velocity and temperature and observed the effects of the volume

fraction of liquid along the length and the heat transfer coefficient. The volume of fluid (VOF)

was used with multiphase flow mixture in ANSYS Fluent solver. Thus in case of evaporation

(which is of our concerned) the heat transfer coefficient was increased with increasing velocity
and temperature between the wall of tube and inlet. Whereas mass transfer rate was decrease

with increasing flow rate and decreasing wall temperature.

In this specific study of (Feng, H., Chen, L., Wu, Z., & Xie, Z. (2019). Constructed design of a

shell-and-tube heat exchanger for organic fluid evaporation process. International Journal of

Heat and Mass Transfer, 131, 750-756), the researcher carried out the study regarding

evaporation process of organic fluid in shell and tube heat exchangers. It is basically analysis of

different refrigerants in fixed heat transfer area and number of tubes configuration to find out

their complex functions. Seven fluids were discussed and their heat transfer rate, pumping power

and complex functions were calculated. The results generated indicated that R152a has smallest

value of complex function and R236fa has the biggest one. The objective of this study was to

improve the overall performance of the shell-and-tube heat exchanger can be further improved

by choosing appropriate working fluid, mass flow rate of the hot water and total tube number.

The study suggested that the complex function reduces a certain heat transfer rate but

significantly improves the fluid flow performance.

2.5 Importance of Fins

In the research work of (Cheng, H., Luo, T., Yu, J., Yang, X., Liu, Y., Gu, Z., & Jin, L. (2018).

Experimental study of a shell-and-tube phase change heat exchanger unit with/without circular

fins. Energy Procedia, 152, 990-996.), the experimental analysis of shell and tube heat exchanger

with and without circular fins was done. The major focus of this study was the injection flow rate

of heat transfer fluids on performance of the designed heat exchanger. Designs were

predetermined and the analysis on these designs with and without fins was carried out to get the

optimized configuration. Results showed that the application of fins had a great effect on

improving phase change heat transfer phenomenon and the full charging time was significantly
reduced. Similarly, it was observed that the injection flow rate of heat transfer fluids had little

effect over the performance of the heat exchanger.

 3 METHODOLOGY

Initial Research Simple Geomertry

on Evaporators CAD Design

Theoretical
Preliminary Fluid
Calculations of
Analysis
Basic Model

Research on Complex CAD

Complex Models with
Geometries Finns

VOF Analysis on
Comparison of
Finned
Different Models
Geometries

Fabrication of Setting up
Final Selected Experimental
Model Apparatus

Experimentation
& Results Review

Fig. 3-1: Methodology Adopted

3.1 Initial Research

It is a well-known study that the working of evaporator is to simply evaporate the fluid

(refrigerant) coming from expansion valve into the evaporator coils which is in contact with

outer environment/compartment. But this working is not as simple as it seems because changing

the only one thing, such as tube or refrigerant velocity may change the evaporating effect of fluid

and increases/reduces the heat transfer from outside environment to inside the tube. Thus even in

the simple working condition, for little optimization one or two parameters need to be changes

that changes the overall working of evaporator to some extent.

3.2 CAD Model for Preliminary Analysis

Step by step approach in any analysis is very important. Direct jump to the complex analysis or

collecting data on assumptions may yield wrong results at the end create problems in the

experimental setup.

Therefore it is very much important to take a start from basics. After that, clear understanding of

the concepts of evaporation and clear road map of analysis we will consider the complex portion.

Fig. 3-2: Basic CAD Model

3.3 Preliminary Analysis

The basic or simplest geometry that will be considered first for the analysis of evaporation that

falls under the consideration of preliminary analysis. It is necessary to figure it out whether the

project under consideration is viable or not. Or such conceptual analysis can be done on the

complex shapes or not. After that next step will be taken.

3.4 Theoretical Calculations

In preliminary analysis there are some data that need to be defined for the refrigerant that gives

some thermodynamic properties after running the calculations. Therefore by using these values

such as enthalpy etc. heat transfer rate was calculated theoretically of the evaporator and used

this concept to evaluate the same properties of the complex model.

3.5 Complex Model Research

After conducting successful analysis on the basic model, research work on evaporators with

different types of fins configuration continued. The main purpose of this research is to identify

the finned models that are in common used or in rarely used. Mostly evaporators are made with

the circular fins and rectangular continuous fins. Whereas, rectangular staggered fins are not

used commonly while spine finned tube is in research work and not in used in any application.

3.6 CAD Models of Finned Geometries

After identifying the fins style which are currently in use for analysis next step was to

development of geometries of new CAD models with four different type of fins configuration.

This four models will have a same tube length and area covered by their fins will be made same

approximately. And the analysis was carried out on each geometry.

3.6.1 Different Geometries CAD Models with Side View

Fig. 3-3: Rectangular Continuous Fins

Fig. 3-4: Circular Fins

 Fig. 3-5: Spine Fins

Fig. 3-6: Staggered Square Fins

3.7 VOF Analysis

VOF Analysis is basically the volume of fluid method or technique in which ANSYS Fluent is

used for the evaporation of selected fluid in each of the above selected geometries. By the term,

it is clear indicating that percentage volume of fluid is evaporating from the liquid surface and

this effect can also be seen in post processing of analysis.

3.8 Comparison of Models

The comparison was made on the basis of which design is effective in evaporating the fluid

readily. The more readily the fluid evaporates the more effective fins are working on the heat

transfer capabilities of evaporator. Thus final model with fastest conversion of liquid into vapors

selected with minimum losses in the evaporator tube.

3.9 Fabrication Phase

After analyzing the different model now is a phase of preparing the best one model for the

experimental setup. For fabrication phase first tubes and fins was needed, The pipe needs

bending and fins needs to be attached on pipe via flame welding with intense care else the fins

will be burned out.

3.10 Experimental Setup

The Experimental setup consists of flow rate sensors, DC pump, and variable controller for fluid

flow control, thermocouples, digital thermometer, and container for fluid and a board for fixing

these all the components along with the rubber pipes of different diameters. This setup is now

connected with fabricated inlet and outlet of evaporator.

3.11 Experimentation & Results Review

After successful connections and implementation of the components the setup is turned on to get

the readings of evaporator at inlet and outlet of model. Moreover, the working of all the sensors

and modules whether they are working perfectly fine or not was observed. After noting the

results calculations are performed and review was made to check any error.
 4 ANALYTICAL MODELING

4.1 Design Selection

4.2 Heat transfer Calculations from Experimental Setup

4.2.1 With AC on (Surrounding temperature 22 0C)

Tin = 16.59 0C

Tout = 18.28 0C

ΔT = 1.69 0C

The rate of heat transfer is to be calculated.

Q̇ = ṁwater Cp ΔT (1)

ṁ = ρAv (2)

In case of water, ρ = 998 kg/m3.

A = π r2 (3)

Here, r is inner radius of tubes with value of 0.0035 m. putting in equation (3) yields cross-

sectional area.

A = 0.000039 m2 (4)

Taking flow velocity of 2 m/s. Putting the values of involved parameters in equation (2) gives

mass flow rate of water at operating conditions.

ṁwater = 0.078 kg/s (5)

Cp is specific heat value at constant pressure. For water its value is 4184 J/kg-C. From equation

(1), the value of heat transfer rate can thus be calculated as.
 Q̇1 = 551.54 Watts

4.2.2 With AC off (Surrounding temperature 27 0C)

Tin = 17.5 0C

Tout = 20.08 0C

ΔT = 2.58 0C

Referring to equation (4) and equation (5), the values of flow cross-sectional area and mass flow

rate of water are 0.000039 m2 and 0.078 kg/s respectively. Cp value is also same as for previous

case which was 4184 J/kgºC. The rate of heat transfer will thus be.

Q̇2 = 841.99 Watts

4.2.3 In outside environment (Surrounding temperature 31 0C)

Tin = 17.75 0C

Tout = 21.64 0C

ΔT = 3.89 0C

The rate of heat transfer is given by.

Q̇3 = ṁwater Cp ΔT

Mass flow rate of water is 0.078 kg/s, Specific heat at constant pressure is 4184 J/kgºC.

Temperature difference is of 3.89 0C. Therefore, heat transfer rate in this case is.

Q̇3 = 1269.51 0C
4.3 Temperature Differences vs Heat Transfer

Temperature Difference vs Heat Transfer Rate

1400 1296.5
1200
Heat Transfer Rate (W)

1000 841.9
800
551
600

400

200
0
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Temperature Difference ΔT (ºC)

Fig. 4-1: Variation in Heat transfer with Increasing Temperature Difference

4.4 Surrounding Conditions vs Heat Transfer Rate

Surrounding Temperature vs Heat Transfer Rate

1400 1296.5

1200
Heat Transfer Rate (W)

1000
841.9
800
551
600

400

200

0
20 22 24 26 28 30 32
Surrounding Temperature Condition (ºC)

Fig. 4-2: Variation in Heat transfer with Increasing Surrounding Temperature

4.5 Heat Transfer Calculations from Simulations

For the cases of refrigerants, the total rate of heat transfer is sum of sensible and latent heat

transfer rate. The sensible heat transfer rate occurs as a result of stripping of cyclic thermal

boundary layer by the departing bubbles and latent heat transfer rate occur as a result of bubble

evaporation mechanism.

Q̇total = Q̇sensible + Q̇latent (6)

Q̇sensible = ṁref Cp ΔT (7)

Q̇latent = ṁref htotal (8)

Q̇total = ṁref (Cp ΔT + htotal) (9)

Now the mass flowrate of refrigerant can be calculated using equation (2).

ṁref = ρAv

The volumetric flow rate is taken same in both numerical and experimental estimations which is

0.000078 m3/s. The density of r600a at involved operating conditions is 591.5 kg/m3.

ṁref = 0.04614 kg/s

The value of temperature difference and total enthalpy is computed using ANSYS fluent. Their

values came out to be 15 0C and 1362.9 J/kg respectively in case of staggered square fins. The

value of specific heat at constant pressure in case of r600a at current operating conditions is

2019.67 J/kgºC. Therefore, from equation (9) the total rate of heat transfer comes out to be.

Q̇total = 1460.697 Watts.

4.6 Percentage Error

The estimation of percentage error is done by comparing the heat transfer rate calculated through

simulation and experimentation. The experimental value of Q̇ when evaporator was placed in

outside environment with surrounding temperature of 31 0C is compared with numerically

estimated Q̇.

Q̇ total −Q̇ 3
% Error = ( ) ×100
Q̇ total

% Error = 13.08

4.7 Method to Reduce Error

The error in the experimental setup was raised due to the environmental limitation and the fluid

properties. The refrigerant are highly volatile and evaporates readily in atmospheric conditions.

But on the other hand, water is liquid and it’s fully conversion to vapor requires surrounding

temperature to be 100ºC from which the water is extracting heat. Secondly, a complete

experimental setup of compressor, condenser, and expansion valve device along with the proper

refrigerant charge quantity is required to make a testing rig on which experiment can be

performed. Moreover for r600a which is a highly flammable gas, an environment should be free

of all sorts of danger and any leakage during charging or testing may cause the real danger. Thus

with proper fluid, safety and a secure contained environmental conditions testing the prototype

will surely decreases the percentage error.

 5 CFD ANALYSIS

5.1 Basic Introduction to Software

ANSYS FLUENT software is used to solve the complex fluid related problems numerically by

certain methods of discretization. The main aim of this software analysis is to look for the

changes in the fluid flow temperature, pressure, heat transfer, fluxes, velocity etc. with

time/without time variation at different points after dividing the geometry in small discretized

parts in mesh solver. The software basically prepares a specific mathematical model (controlled

by user) that represents the physical behavior of the flow according to the various applications.

The main advantage of this advanced tool is that engineers can predict or analyze the behavior of

so many complex systems by solving it through number of techniques with in the fluent solver.

This powerful tool is in used since 90s and till now find its applications for the analyzation of

complex geometries like the complex blade shapes of pumps, turbines or large shapes such as of

fighting jets etc.

5.2 Geometry Modification

First of all, the geometry needs to be inserted in the workbench and certain changes are required.

Since the geometry inserted does not have any sort of fluid inside it. It was simply a tube with

fins and having cavity. Thus with tools and concept commands a fluid domain is created inside

the cavity and then move forward to the mesh. All this work was done in ANSYS Design

Modeler.
 Fig. 5-3: Fluid Domain Isometric View

Fig. 5-4: Fluid Domain Side View

5.3 Meshing of Selected Model

The function of mesh solver is simple, just divide a whole domain into small pieces over which

governing equations of mass, energy and momentum conservation are solved. In most scenarios

the suitable approach is finite volume method as it is suitable on even grids elements that are

course. The elements can called as grid cells, control cells or simple cells. For the present four

different model, the mesh independence test was conducted on single model and then same

conditions/technique of mesh was applied on all other models as well.

 Fig. 5-5: Mesh Model of Circular Fins

5.4 Inflation Layer & Multizone Method

The motivation for applying the inflation layer arise from the fact that boundary layer region

near the inner fluid domain and pipe needs to capture in order to observe the no slip condition.

Whereas due to the complexity of outer tube surfaces and hence applying the same technique on

all other geometries, multizone method was selected where automatically mapped mesh was

generated easily in the region where it was possible and unmapped in few of the difficult region.

5.5 Grid Independence Test

Mesh independence test was necessary in order to save time in computation. In this test the

optimum number of elements was selected which was enough to get the correct output parameter

by avoiding time taking calculations. The pressure and max velocity at output was nearly

unchanged at different data point or at increasing number of nodes. But as far as enthalpy is

concerned it shows minimal change in its value 1362.9 J/Kg near 200000 number of elements.

Hence the simulations was run at this certain data point just for all other bodies as well.
 Fig. 5-6: Mesh Independence Study Graph

5.6 FLUENT Solver

In general specifications, the simple pressure based analysis is under consideration along with

the gravity effect on the fluid movement. The effect of gravity cannot be ignored since it is a

problem of phase change where density changes effectively and creating change in overall

extensive property of fluid and its effect on gravity.

5.6.1 Models

As discussed previously, the VOF model was used for current analysis. Although it is a type of

eulerian model but it is different from eulerian-eulerian model. In volume of fraction method,

each set of equation was solved on the surface interaction specifically on each element surface.

And the amount of liquid converts into vapors is described in fraction of 0-1 (from 0% to 100%).

The main difference between eulerian-eulerian model and eulerian-vof model is that in first case

the combination of equations were solved for a whole mixture whereas in later case two distinct

regions are considered by fluent where equations are solved at surfaces. Thus VOF approach

takes lesser computation time and is stable.

5.6.2 Phases

The term phase here indicates that how much phase change will take place under current

analysis. Since it is an evaporation case, it will be two eulerian phase. First one is liquid and

second one is vapor. But still an additional phase was defined after this considering pre-existing

of air which makes total number of eulerian phases two.

5.6.3 Phase Interaction

Phase interaction means the number of interaction surfaces during the whole process of analysis.

Considering the present case, the liquid refrigerant interacts with the air in the tube which is by

default material. Secondly the refrigerant vapors that is being converted will interact with the air

present in tube. And the mixture interface of liquid and vapor phase interaction will occur. Thus

in order to tell the fluent how this interaction works, it is necessary to define the surface tension

value at the saturation temperature. This value comes out to be 0.015N/m for all the interaction

of surfaces.

5.6.4 Material Introduction

After selecting the model there is definitely the requirement of introducing the material that must

be introduced in problem defining stages that is to be evaporated. Hence, in present case it is

r600a, therefore all its chemical properties of both liquid and vapor phase was defined prior to

calculations for the evaporation process.

 Fig. 5-7: Refrigerant Liquid & Vapor Phase Material Values (reference dalna hai yahan)

5.6.5 Boundary Conditions (reference dalna hai)

In any problem of fluid dynamics, the initial conditions are required from which the governing

equations are reduced to some extent and give the final output answers after calculations.

Similarly, this evaporations analysis also needs proper values that must lies within the suitable

range of flow movement. Hence from different literature these values are taken as:

I. Inlet Temperature = 258K

II. Surrounding Temperature = 281K

III. Inlet Velocity = 2m/s

IV. Volume Fraction of Liquid at Inlet = 1

V. Surface Tension = 0.015N/m

VI. No Slip Condition

VII. No Heat Generation

5.6.6 Time for Flow Analysis

The number of iterations depends upon the velocity at inlet defined and the time for it in certain

geometry. The main purpose of deciding the iteration it to provide the time for the flow to fully

circulate in geometry or selected region. It can be obtained by dividing the velocity over total

distance fluid needs to be cover. Since in selected design, the total length where fluid moves is

3.1m and velocity is 2m/s thus time comes out to be 1.55 seconds. Now if time step size after

hybrid initialization is take as 0.001/s then times steps must be 1555 seconds. Similarly for 0.01/s

the time steps will be 155.

 6 FABRICATION OF EVAPORATOR

6.1 Aluminum Tubes

Initially aluminum tube was purchased of gauge 20 and of length 12 feet. The gauge scale is

basically used to indicate the thickness of sheet metal. Similarly aluminum tubes and copper

tubes which are in common use of refrigeration applications have similar gauge numbers range.

And normally 20-22 gauge tubes are used for analysis purpose which is equivalent to 0.032-

0.025inches and 0.81-0.64mm.

6.1.1 Bending of Tubes

The shape of evaporator is serpentine with simple U-bends of radius 1 inch. Therefore we need a

bender tool for this purpose. By using the bender tool we will convert the straight tube into

serpentine shape tubes. Total seven bends will be created as in our CAD geometry. Each bend

was created after leaving the length of 12 inches on the tube which is 1 ft.

Fig. 6-8: Tubes after Bending

6.2 Aluminum Sheets

Similarly we arranged an aluminum sheet of desired length and width with the thickness of 24

gauge which is equivalent to 0.5mm or 0.02inches. The reason for buying sheet is to make out

square rectangular fins from it through laser cutting. Finns can be made of copper or any other

material that can be weld easily on the selected tube material. The selection of fins vary from

application to application.

6.2.1 Laser Cutting

In laser cutting the tool is basically a laser that vaporized the material to form a cut edge. These

machinery commonly used in industries for creating aesthetics designs or decorating pieces on

hard metal sheets. This process is very accurate and time saving. The final product don’t even

need any further finishing. Thus through laser cutting we cut about 210 pieces whereas our

requirement was of 192 square pieces of 1x1in2.

Fig. 6-9: Final Fins after Laser Cutting

6.3 Flame Welding with Aluminum Flux

Now the important task is to weld the fins on the tube. Too much heat simply burn the fins as the

fins thickness is much lower than the tube and tube can withstand the flame temperature. Mostly

neutral oxy acetylene flame is used for welding, brazing and soldering in such applications.

Since the melting point of aluminum is 660˚C the nozzle should be control in a way to not heat

the fins for longer time. By the time flux melts and drops on fins-tube gap it should be turned off.
 7 EXPERIMENTATION

7.1 Experimental Setup Components

The experimental setup consists of the simple components as already mentioned in previous

chapter. Now the details of each component will be presented in this chapter.

7.1.1 DC Pump

A 12V DC submersible pump was used to pump water from container with attached with

variable output controller to control the flow rate of water. This pump supports maximum head

of 5m and flow rate of 10lpm.

Fig. 7-10: Submersible Pump

7.1.2 Water Flow Rate Sensor

This flow rate sensor is basically equipped with the Hall Effect sensor and a water rotor. As the

fluid passes, the Hall Effect sensor gives output according to the corresponding pulse signal due

to the rotation of rotor. The maximum flow rate adjusted was around 4.68 liter/min.
 Fig. 7-11: Flow Rate Sensor

7.1.3 Arduino Nano

Arduino nano is used to display the flow rate value of by interpreting the flow rate sensor

signals. It is basically attached with the 9V DC battery that gets power and converts it into 5V to

run both the flow rate sensor and LCD display.

Fig. 7-12: Arduino Nano

7.1.4 16x2 LCD Display & 9V Battery

LCD display was simply integrated with Arduino nano to get the output of flow rate sensor while

the 9V DC battery is the power supply to this small unit.

 Fig. 7-13: 16x2 LCD

Fig. 7-14: DC Power Battery

7.1.5 Temperature Sensors

Digital Thermometer and K-type thermocouple with digital multimeter was used to get the

readings of temperature at various points of evaporator for calculation purpose.

Fig. 7-15: Digital Thermometer

 Fig. 7-16: K-Type Thermocouple

7.1.6 Digital Multimeter

This device is normally used to measure electrical parameters like voltages, current and

capacitance etc. with different units like of milli, centi, micro and nano. But it has another use of

measuring temperature because of having a slot for pins. The pins with same sign inserted in the

multimeter switch to simply get the readings of the medium in Celsius.

Fig. 7-17: UT55 Multimeter

7.1.7 Working of the Setup

After attaching the evaporator with all the components we will take readings at different

conditions. The flow will start flowing by pumping the water from container containing the ice

chilled water and enter the evaporator. After entering it, it goes through the whole tube bends and

starts exchanging heat with the environment and produces the cooling effect on the coil and its

near surrounding.

Fig. 7-18: Final Setup

At the outlet the flow rate sensor was attached to that displays the water flow rate. Now the

temperature was noted down at both the inlets and outlets through k-type thermometer and

digital thermometers and heat transfer was calculated.

 8 SOCIETAL IMPACT, ENVIRONMENT & SUSTAINABILITY

This study will lead to the production of a finned tube evaporator that is better in numerous

aspects as compared to its commercially available counterparts. The enhanced heat mechanical

efficiency brought by the SOHC valve train as compared to the prevalent OHV design will lead

to lesser mechanical losses, and thus a better fuel economy for users.

The replacement of refrigerant r600a with other commercially available options will serve as a

major game changer in the field of two-wheeler automobiles in Pakistan. The better fuel

economy will have a positive social impact in terms of reduced monetary pressure on users.

EFI also leads to a lower Carbon footprint as the combustion occurring inside the engine is more

complete and produces lesser harmful contents. This will lower the pollution produced by two-

wheelers in the country and contribute to reduce environmental degradation.

 9 CONCLUSION & FUTURE RECOMMENDATIONS

9.1 Conclusion

In volume fraction results the staggered square fins evaporator shows better results as refrigerant

evaporates readily in comparison to the other designs. This readily evaporating concept is

justified according to the present case as less charge quantity is used of refrigerant r600a as

compared to other refrigerants. At the end, the temperature achieve by fluid in staggered square

fins is maximum (273K) which means it will be in superheat form and best suitable for

compressor inlet. The term maximum fluid is used for this analysis because with proper setup the

amount of quantity evaporates will surely deviates from the ideal cases and at outlet of

evaporator may have some of the liquid phase portion.

The change in velocity around the bend which is basically the little increase shows that fully

developed flow is disturbed around bends and again reaching the fully developed region in the

next tube. Moreover the bends are the main reasons behind the minor losses in the flow that

effects the pumping power requirements. Thus the design have leverage of size compactness by

reducing the bends after testing it with proper refrigeration system.

An error of about 13.08% was observed between analytical and numerical results which shows

that only sensible heating is occurred in our experiment and fluid is in liquid phase. Thus no

latent heat was involved in the experiment which is due to vapor formation. For the water

reaching the vapor phase, the environment must be at higher than 100ºC which is not favorable.

Whereas from the experiment it is clear that a simple prototyping is enough to show the

qualitative working of design but not in agreement with the quantitative analysis or results.
9.2 Future Works

The future work for evaporators is basically the improvements in its components in order to

reach the A+++ standard. According to the research conducted in (e research) every 10 percent

change in each component of refrigeration system yields 2 percent change in the power rating of

the refrigerator applications. Thus it can be seen that for a friction of change so many design

changes needs to be done in evaporator, condenser, pumps or expansion devices. It is not

convenient to make changes in final optimized design, therefore an experimental setup is arrange

in the industries and after continuous testing with little variation in the components a new design

is launched in market.

It is better to perform the same analysis by varying the tube length or number of tubes after

selecting the final designs from the fins. Because this work is not limited to the fins

configuration but further changes can be made in final design to minimize the losses and

maximize the efficiency. The increasing or decreasing of tubes will help in the compactness of

the design. Similarly on final square staggered fins, different refrigerants should be used to check

which one is giving the best results and using the lowest volume of refrigerant after charging the

refrigerant in evaporator tubes.

Another important and interesting study can be conducted on this optimized design by installing

a thermostat along with humidity sensor measuring the ice deposition on the fins if placed in a

closed compartment and experimental setup was made to create vacuum in evaporator coils and

move the R600a with all other selected components like compressor, condenser and expansion

valve. The time will be noted that after how much time the ice accumulation starts on the tube

and hinders the effective heat transferring between the evaporator and the coil