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Design of a Compact Air-Cooled Refrigerant Condenser

Technical Report · October 2020

DOI: 10.13140/RG.2.2.13210.16327

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Nahian Masud Takreem Priom

Bangladesh University of Engineering and Technology Bangladesh University of Engineering and Technology
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 Bangladesh University of Engineering and Technology

Course Number: ME 310

Course Title: Thermo-fluid System Design

Group Number: 05

Project name:
Designing of a Compact Air-Cooled Refrigerant Condenser

SUBMITTED BY:
Student Name: Naimul Bashar
Student ID: 1610160
Department: Mechanical Engineering
Section: C

Group Members (ID):

• Naimul Bashar (1610160)
• Abdullah Al Hafiz Nirjhar (1610163)
• Nahian Masud (1610164)
• Takreem Priom (1610177)
Problem
Design of a Compact Air-Cooled Refrigerant Condenser

Specifications:

Cooling load (heat duty): Q = 125 kW

Refrigerant: R-134A condensing inside tubes at

Ts= 37°C (310 K)

Coolant: Air

Inlet temperature, Tc1 = 18°C

Outlet temperature, Tc2 = 26°C

Mean pressure P = 2 atm (0.2027 MPa)

Heat transfer matrix: to be selected

At least two different surfaces must be studied for thermal and hydraulic analysis and then compared;
the primary attention must be given to obtaining the smallest possible heat exchanger. A parametrical
study is expected to develop a suitable final design. The final report will include material selection,
economic analysis (both hand and software analyses), thermo-hydraulic calculations (both hand and
software), mechanical design, and technical drawings of the components and the assembly.
1.Introduction
In systems involving heat transfer, a condenser is a device or unit used to condense a gaseous substance
into a liquid state through cooling. In so doing, the latent heat is released by the substance and
transferred to the surrounding environment. Condensers are used for efficient heat rejection in many
industrial systems. Condensers can be made according to numerous designs, and come in many sizes
ranging from rather small (hand-held) to very large (industrial-scale units used in plant. The major types
of condensers used are (1) water-cooled, (2) air-cooled, and (3) evaporative. For a condenser that needs
to condense refrigerant with air, forced convection is used to transfer heat from the matrix. Usually, the
refrigerant is put into the tube. Inside the tube the hot fluid (Refrigerant) changes phase from vapor to
liquid state with the help of cold fluid (Air). Fin can be used on the tubes to increase heat transfer. A
compact air-cooled refrigerant condenser can be used for various industrial and other purpose. In this
report, detailed calculation and design of a compact Air-cooled Refrigerant condenser is shown.

2.Methodology
For the specified problem, the calculations were done for inline cross flow heat exchanger (HX). The HX
was of one tube pass. From given data, the properties of air and R-134a was calculated. Then two types
of pipe materials i.e., copper and wrought iron were chosen for experimental purpose. Pipes of various
diameters were checked for the eligibility of required specifications. Comparing them two pipes of best
dimension and material was chosen for design and rating calculation. Power requirement of motor and
compressor was calculated. Then, mechanical design and cost analysis was done for the condenser.
Finally, modeling was done with software to validate the calculated result. Also, a 3D design of the
condenser was also made with the help of 3D modeling software.

(a) (b)

Figure: 1(a) Schematic of Air-cooled condensers. 1(b) Bundle layouts inside the condenser
3. Calculation
3.1 Finding Properties
Properties of Air:
Given Data,
At 2 atm pressure and 22C temperature,
Density, = 2.39 kg/m3 Mean Pressure =2atm
Dynamic Viscosity,= 1.84*10-6 kg/m.s (26+18)
Mean Temperature= 2
Specific Heat at Constant Pressure, Cp =1010 J/kg.k
=22C
Heat Conductance, K =0.0259 W/m.k
Prandtl Number, Pr=0.715
Kinematic Viscosity, =7.69874*10-6 m2/s

Properties of Refrigerant R-134a:

At 37C And 938 KPa,
hfg=166130 J/kg
Density, = 2.39 kg/m3
Mass Flow Rate:
Air:
Q= ṁ Cp (Te−Ti)
ṁ= 15.47 kg/s
Refrigerant R-134a:
Q= ṁ hfg
ṁ R= 0.752 kg/s
3.2 Calculation for Pipes
Tube Material: Copper For standard size 3/8 inch:
Seamless copper tubing was considered Outer Diameter, OD= 0.5 inch
 =12.7mm
Cross-Sectional Area inside tube, AC = 4 (𝐼𝐷)^2
Inner diameter, ID=0.43 inch
=93.6904 mm2
=10.922mm
Inline Rows were considered,
Let,
Total number of pipes, N= NT*NL =105
Number of rows, NL =7
Mass flow rate of R-134a, ṁ R= VR *R *AC
Number of tubes/rows, NT =15
So, VR=1.6632 m/s
Length of pipes, L=3m
To match economic velocity, it was kept between 1.37-2.9 m/s
Total Surface Area of Tubes, AS=  * OD * N * L
=12.568 m2
Mass flow rate of air, ṁ air= *Va *NT *L*ST
Considering,
Velocity of air, Va=9.854 m/s
SL/D =1.15
Maximum Velocity for Inline Rows,
SL= 1.15*OD
ST
Vmax=Va ∗ ST−OD
=0.014605m
=75.7053 m/s Let,
𝑂𝐷∗𝑉𝑚𝑎𝑥
Maximum Reynold’s Number, Remax = ST=SL


=124885.02 =0.0146m
𝑃𝑟 For aligned configuration,
Nusselt Number, Num= C1*ReDm *Pr0.36[ Pr⁡(𝑤𝑎𝑡𝑒𝑟)]n
ST/SL=1 &
=345.74058
hm∗L
103< Remax<2*105,
Num = 𝐷 C1=0.27
hm=705.093 W/m2.K m=0.62
Maximum overall heat transfer coefficient,
U=hm= 705.093 W/m2.K
∆𝑇1−∆𝑇2
Log Mean Temperature Difference, LMTD= ∆𝑇1
𝑙𝑛
∆𝑇2

=14.64 C
Qmax= U*As*LMTD
=hm*As*LMTD
=129.734 KW >125 KW
So, achieved heat duty is greater than the required one.
Tube Material: Standard Wrought Steel
 For standard size 1/4 inch:
Cross-Sectional Area inside tube, AC = 4 (𝐼𝐷)^2
=0.00006647m2 Outer Diameter, OD=13.7 mm

Inline Rows were considered. Inner diameter, ID= 9.2 mm

Total number of tubes, N= NT*NL =112

Assuming,
Mass flow rate of air of Refrigerant, ṁ R= VR *R *AC
Number of rows, NL =8
Velocity of R-134a, VR=2.1976 m/s
Number of tubes/rows, NT =14
To match with economic velocity, it was kept between 1.37-2.9
m/s Length of pipes, L=3m
Surface Area, AS=  * OD * N * L Considering,
=14.4614 m2 SL/D =1.2
ṁ R= *Va *NT *L*ST SL= 1.2*OD
VR=9.3743 m/s =0.0164m
Maximum Velocity for Inline Rows, Let,

Vmax=VR * ST−OD
ST ST=SL
=0.0164m
=56.246 m/s
𝑂𝐷∗𝑉𝑚𝑎𝑥 For aligned configuration,
Maximum Reynold’s Number, Remax = ST/SL=1 &


=100090.64 103< Remax<2*105 ,

𝑃𝑟
Nusselt Number, Num= C1 ReDm Pr0.36[ Pr⁡(𝑤𝑎𝑡𝑒𝑟)]n C1=0.27
m=0.63
=338.19
hm∗L
Num = 𝐷

hm=639.35 W/m2.K
Maximum overall heat transfer coefficient,
U=hm= 639.35W/m2.K
∆𝑇1−∆𝑇2
Log Mean Temperature Difference, LMTD= ∆𝑇1
𝑙𝑛
∆𝑇2

=14.64 C
Q•max= U*As*LMTD
=hm*As*LMTD
=135.36KW >125KW
So, achieved heat duty is greater than the required one.
3.3 Choosing Pipe

Comparison:

Materials Total Surface Area Maximum Overall Heat Duty, Q

( m 2) Heat Transfer (KW)
Coefficient
(W/m2.K)
3
Copper 12.5679 705.093 129.734
8

1
Wrought Steel ⁡4 14.46 m2 639.35 135.36

From the comparison, it can be seen that copper provides higher overall heat transfer coefficient with
less amount of area. Both materials fulfill required heat duty.

As the design needs to be compact, Copper pipe was considered for the design of the condenser.
3.4 Power Requirements
Required power of Motor for air flow:
(Theoretical Calculation)
Pressure Drop, P= f (0.5 **V2max) NL (ST/D – 1)*(SL/D-1)= 0.0225
=56092.45 Pa And ReD=1.24885*105
ṁ From Chart, x=3
Motor Power =V• *P=P ∗ ⁡ 
For, ReD=1.24885*105 and SL/D =1.15
=486.69 HP
f/x =0.39
Considering 85% efficiency,
𝑀𝑜𝑡𝑜𝑟⁡𝑃𝑜𝑤𝑒𝑟
f=1.17
Required Power= 0.85

=572.58 HP
As a forced draft fan of 53.16KW was used, the
above calculation of motor was theoretical.

Power Required to pump R-134a:

𝐼𝐷∗𝑉 Roughness of Copper Pipe, €= 1.5*10-3mm
Reynold’s Number, ReD= 
Internal Diameter, ID= 10.922mm
=6548.60
€/ID= 1.37*10-4
From Moody diagram,
𝐿
Pressure Drop, P= f 𝐷(0.5 **V2max)
Friction Factor, f= 0.036
=628.605 Pa
ṁ
Compressor Power= ∗ P


=15KW
3.5 Mechanical Design
Tangential Stress, Here,
𝑟𝑖 2 ∗𝑃𝑖 𝑟𝑜 2 Inner Radius, ri=5.46mm
t|r=ri =𝑟𝑜2−𝑟𝑖 2 (1 + 𝑟𝑖 2 )
Outer Radius, r0=6.35mm
=6.266 MPa
Internal Pressure, Pi = 0.938 MPa
𝑟𝑖 2 ∗𝑃𝑖 𝑟𝑜 2
t|r=ro =𝑟𝑜2−𝑟𝑖 2 (1 + 𝑟𝑜2) External Pressure, P0=0 MPa
=5.328MPa
Radial Stress,
𝑟𝑖 2 ∗𝑃𝑖 𝑟𝑜 2
r|r=ri =𝑟𝑜2−𝑟𝑖 2 (1 − 𝑟𝑖 2 )

= −0.938MPa
𝑟𝑖 2 ∗𝑃𝑖 𝑟𝑜 2
r|r=ri =𝑟𝑜2−𝑟𝑖 2 (1 − 𝑟𝑜2)
As,
= 0 Pa
r|r=ri < r|r=ri < t|r=ri
Von-mises stress, ’=√(x 2 − x ∗ y + y 2 )
x=6.266 MPa
=6.78 MPa
y=−0.938 MPa
Yield Strength for Copper, Sy= 33.3 MPa
According to Distortion Energy (DE) theory,
𝑆𝑦
Design Safety Factor, nd= ’

=4.9

As it is a design problem, Distortion energy

theory was used which is conservative.

However, the safety factor is greater than 1, so

the design is reliable and safe.
3.6 Economic Analysis

Component Specifications Quantity Price (Dollar)

Pipe Outer diameter, Pipe Count = 105 0.786*105=82.53
OD=12.7 mm
Inner diameter,
ID=10.9 mm
Length = 3 m

Fan Power =140 kw Quantity = 2 60*2=120$

Hudson Company

Fin Aluminum high fin 80 fins per meter 50$

length
Motor Power = 1 kw 1 50$
Compressor For refrigerant= 0.02hp 1 50$

Extra cost 100$

Total Cost= 452.53$

The designed Compact air-cooled condenser has a component cost of approximately 460 US Dollars.
Which is a reasonable price. So, the condenser is cost effective.
4. Modeling
For the purpose of calculation and optimization the following softwires were used:

1. Microsoft Excel 2010

2. HTRI XChanger Suit 6.0
Calculation of various types of copper pipes

Calculation of various types of Wrought Steel pipes

The blue line indicates the acceptable pipes with lowest surface area that matches the required heat
duty.

Selection of Pipes:

The S3/8L Pipe with 105 tube counts was used for design problem and the pipe with 112 tube counts
was used for rating problem.
Calculation Result from HTRI for Rating Problem (Without Fin):
Calculation Result from HTRI for Design Problem (With Fin):
5. Schematic Diagram
The 3d designs are done in solidworks 2013.

2(a) 2(b)
Figure 2: (a) Front view of the condenser; (b) top view of the condenser

3(a) 3(b)
Figure 3: (a) 3D drawing of tube; (b) 3D drawing of flange
6.Result and Discussion
Area:
3
Standard Copper 8 was used for the design. The calculated area was 12.57 m2. Due to complexity, fin
area calculation was avoided during hand calculation.
For Modeling purpose High fin was used. The area from modeling was 27.99 m2 with fin. And without fin
the area was 24m2. It can be seen that the area is quite small. So, the design is compact.
Heat Parameters:
Overall heat transfer coefficient Heat duty
Required: 681.12 W/m2.K Required: 125 KW
Calculated: 705.096 W/m2.K Calculated: 129 KW
From Modeling: From Modeling,
Rating: Required: 394.89 W/m2.K Rating Problem: 125KW
Actual: 405 W/m2.K Design Problem: 126KW
Design: Required: 204.8 W/m2.K
Actual: 206 W/m2.K
In this design, fin was used in order to increase heat transfer. As surface area increased because of fin,
overall heat transfer coefficient dropped significantly.
Hydraulic Results:
Required fan power for air flow is 53.16KW and Compressor power is 15KW.
Overdesign:
There was 9.06% overdesign. The acceptable range for overdesign is 0% to 10%. Overdesign is done to
increase safety. Moreover, the fouling factor was not considered. As the machine will grow older, fouling
factor might occur decreasing overall heat transfer coefficient. So, for longevity of machine, 9%
overdesign can serve the purpose.
Costing and Safety:
From economic analysis the total manufacturing cost was calculated 460 Us dollars, which is cost
effective. Also, the material that were used has a safety factor of 4.9. So, the design is both safe and cost
effective.
Due to very short time limit some minor calculations were skipped.
7. Conclusion
The calculated value and the value obtained from modeling are almost same. So, it can be said that the
calculated value was correct. However, the condenser has a very low manufacturing cost and high
number of design safety factor. The overall heat transfer coefficient, pressure drop and air velocity in
the condenser are in permissible range. So, it is possible to design the condenser in real life with some
more effort and calculations.
 8. Acknowledgements
Dr. A.K.M Monjur Morshed
Professor, BUET, Dhaka Bangladesh.
Dr. Md. Ashiqur Rahman
Associate Professor, BUET, Dhaka Bangladesh.
Musanna Galib
Assistant Professor, BUET, Dhaka Bangladesh.
Saif Al-Afsan Shamim
Lecturer, BUET, Dhaka Bangladesh.

9. References
1. Sadik Kakac, Hongtan Liu, Anchasa Pramuanjaroenkij, Heat Exchangers, Selection Rating and Thermal Design 3rd
Edition.
2. Ramesh K. Shah and Dusan P. Sekulic, Fundamentals of Heat Exchangers Design.
3. Nnamdi Cyprian Nwasuka, Uchechukwu Nwaiwu, Nwadinobi Chibundo Princewill, Design and Performance
Evaluation of a Dual-Operation Condenser Using R-134A.
4. A Zukauskas, Heat Transfer in Turbulent Fluid Flows (Experimental and Applied Heat Transfer Equipment: A
Series of Guide Books),1st Edition
5. Ebrahim Hajidavalloo, H. Eghtedari, Performance improvement of air-cooled refrigeration system by using
evaporatively cooled air condenser.
6. Ali H. TarradAyad Khudhair Al-NadawiAyad Khudhair Al-Nadawi, A Rating Model for Air Cooled Condensers
Using Pure and Blend Refrigerants.
7. M. M. Awad, Hesham,M Mostafa, Gamal Ibrahim Sultan, A. M. K. El-ghonemy, Elbooz A, Performance
Enhancement of Air-cooled Condensers.
8. Yunus A. Cengel, Afshin J. Ghajar, Heat and Mass Transfer, Fundamentals and Applications, 5th Edition.

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