CHAPTER 1

INTRODUCTION
1.1Introduction
Due to the present worlds energy crisis and its related environmental issues as
well as increasing trend of fossil fuel prices, therefore, maximization utilization of
the energy use is vital matter. Regarding energy used in household, heating and
cooling is the largest energy use in the home, and water heating is the second
largest energy use in the home. Air conditioning units are designed to remove heat
from interior spaces and reject it to the ambient (outside) air. Waste heat rejected
from the air conditioning units, which is a large quantity, can be recovered and
applied for use in another system such as a water heating system .
From an energy conservation standpoint, it would be desirable to reclaim this
waste heat in a usable form. The best and most obvious form of heat recovery is for
heating water. Water heating system from waste heat recovery of an air
conditioning unit, which is one of the most cost effective energy conservation, has
the same concept as heat pump , which operates on vapor-compression cycle to
pump energy from surroundings into water. The heat pump water heater is a
promising technology in both residential and commercial applications due to its
improved energy efficiency and its improved air conditioning performance.
Typically commercialized window type air conditioning unit have rather big size.
Recently, portable air conditioning units, which have the smaller size, have been
designed for providing cooled air and for being movable to be used in the desired
area. Previous research studied the use of a combined water-cooled condenser and
a conventional split type air conditioning unit . In this research, the portable air
conditioning-heat pump unit using helical coil heat exchanger makes use of both
heating and cooling systems, to maximization utilization energy use by using the
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waste heat recovery of an air conditioning unit, for warming water. Considering the
helical heat exchangers, they are extensively applied in many applications such as
utilization of heat recovery systems, due to high heat transfer coefficient and
compact structure. Recently, there have been some scholars, who study in the use
of helical heat exchanger for recovering waste heat recovery of the domestic water
cooled air-conditioners. However, there are no reports of using the helical heat
exchanger with portable air conditioning unit, to improve the cooling performance
of a portable air-conditioning heat pump unit, and to enhance the heat recovery
performance of the heat recovery systems. Therefore, the objectives of this project
are to: i) design and development of a portable air conditioning:-heat pump unit
using helical coil heat exchanger, ii) improve the cooling performance of a portable
air-conditioning heat pump unit, iii) enhance the heat recovery performance of the
heat recovery system, and iv) improve the energy efficiency of the portable watercooled air conditioning unit.
The portable air conditioning-heat pump unit with helical heat exchanger was
fabricated and was then taken to test in laboratory. The tests are done at the water
flow rates ranging between 0.5 and 2.5 l/min. In the experiments with full load
condition, the cooling performance, the heat recovery, and the power consumption
for different water flow rates were measured and evaluated.
1.2Basic Vapour Compression Cycle
The Vapour Compression Refrigeration Cycle is a process that cools an enclosed
space to a temperature lower than the surroundings. To accomplish this, heat must
be removed from the enclosed space and dissipated into the surroundings.
However, heat tends to flow from an area of high temperature to that of a lower
temperature. How can we make the reverse happen? This is where the Vapour
Compression Refrigeration Cycle steps in. During the cycle, a substance called the
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refrigerant circulates continuously through four stages. The first stage is called
Evaporation and it is here that the refrigerant cools the enclosed space by
absorbing heat. Next during the Compression stage, the pressure of the refrigerant
is increased, which raises the temperature above that of the surroundings. As this
hot refrigerant moves through the next stage, Condensation, the natural direction of
heat flow allows the release of energy into the surrounding air. Finally, during the
Expansion phase, the refrigerant temperature is lowered by what is called the autorefrigeration effect. This cold refrigerant then begins the Evaporation stage again,
removing more heat from the enclosed space. Each of the four stages will now be
revisited in detail, explaining the physical changes that occur in the refrigerant and
the devices used to accomplish these changes. A visual representation of the cycle
is displayed below. With the explanation of each stage, a picture of the part
responsible is included to aid in identification.
A simple vapor compression refrigeration system represented as below:

Fig.1.1 basic vapour compression cycle

1.2.1 Evaporation
During this stage, the refrigerant travels through a device called an evaporator
that has a large surface area and typically consists of a coiled tube surrounded by
aluminium fins. The cold fluid is a mixture of liquid and vapour refrigerant as it
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begins this stage. While flowing through the evaporator, all the liquid evaporates
and absorbs heat from the enclosed space. The energy absorbed is used to change
the state of the refrigerant from liquid to vapour. This lowers the temperature of the
space, along with whatever food or beverages are stored in it. The refrigerant exits
this stage as a saturated vapour.

Fig. 1.2 evaporator

1.2.2Compression
The heat that was absorbed in the Evaporation stage must be released into the
surroundings, but this will not happen unless the temperature of the refrigerant is
higher than the outside air. This is the purpose of the Compression stage. A device,
predictably called a compressor, raises the pressure of the refrigerant vapour Due
to basic thermodynamic principles, this causes the temperature of the refrigerant to
rise, leaving the stage as a superheated vapour. Energy is needed to power the
compressor, which is why electricity is required to operate a refrigerator.

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Fig. 1.3 compression process

1.2.3 Condensation

Fig. 1.4 condensation equipment

Now that we have increased the temperature of the refrigerant above that of the
surroundings, we can dissipate the heat necessary to continue the process. This is
accomplished with a evince very similar to the evaporator. It also uses a coiled tube
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with aluminium fins, but may have different dimensions than the evaporator to
accommodate the different state of the refrigerant. As the hot vapour flows through
the condenser, the outside air removes energy and the refrigerant becomes a
saturated liquid. At this point the slightest drop in pressure will initiate
evaporation, which is the basis for the final stage of the process.

Fig. 1.5 condensers

1.2.4 Expansion

Fig. 1.6 capillary tubes

To begin a new cycle, all that must happen is a lowering of the refrigeration
temperature to below that of the enclosure. This is the key to the entire cycle,
because this was the problem that we started with. However, in this situation we
can utilise what is called the auto-refrigeration effect. When a saturated liquid
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experiences a sudden drop in pressure, a small amount of liquid is instantly

vaporised and the temperature of the mixture is drastically reduced. This cold
liquid-vapour mixture can now begin a new cycle. The pressure drop is
accomplished by the simplest, yet most important, part ofthe system a simple
flow restriction. This part is commonly called a throttle or expansion valve.
1. 3 representation of system on p-h & T-s chart:
1.3.1 p-h chart:

Fig. 1.7p-h chart

Below the critical point CP the saturated liquid line(SL)and saturated vapor
line (SV) enclose a two-phase (wet) region between them.
To the left of the saturated liquid line lie states which have lower
temperature than the saturation temperature at a given pressure. These are
states of subcooled liquid
To the right of the saturated vapor line lie states which have higher
temperature than the saturation temperature at a given pressure.

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 These are states of superheated vapor.

The area to the left of the liquid line is called the subcooled liquid region,
and the area to the right of the vapor line is called the superheated vapor
region.

Within the two-phase region the horizontal lines of constant pressure are
also lines of constant temperature

In the superheat region the lines of constant temperature leave the

saturation line as indicated.
As the pressure diminishes in the superheat region, the lines of constant
temperature tend to become lines of constant enthalpy, i.e. vertical on the
diagram, indicating that the vapor is beginning to behave like an ideal gas
with its enthalpy independent of pressure.
Lines of constant specific entropy and lines of constant specific volume
are shown in the superheat region.

1.3.2 T-s chart:

The thermodynamics of the vapor compression cycle can be analyzed on a
temperature versus entropy diagram as depicted in Figure 2. At point 1 in the
diagram, the circulating refrigerant enters the compressor as a saturated vapor.
From point 1 to point 2, the vapor is isentropically compressed (i.e., compressed at
constant entropy) and exits the compressor as a superheated vapor.
From point 2 to point 3, the superheated vapor travels through part of the
condenser which removes the superheat by cooling the vapor. Between point 3 and
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point 4, the vapor travels through the remainder of the condenser and is condensed
into a saturated liquid. The condensation process occurs at essentially constant
pressure.
Between points 4 and 5, the saturated liquid refrigerant passes through the
expansion valve and undergoes an abrupt decrease of pressure. That process results
in the adiabatic flash evaporation and auto-refrigeration of a portion of the liquid
(typically, less than half of the liquid flashes). The adiabatic flash evaporation
process is isenthalpic (i.e., occurs at constant enthalpy).
Between points 5 and 1, the cold and partially vaporized refrigerant travels through
the coil or tubes in the evaporator where it is totally vaporized by the warm air
(from the space being refrigerated) that a fan circulates across the coil or tubes in
the evaporator. The evaporator operates at essentially constant pressure. The
resulting saturated refrigerant vapor returns to the compressor inlet at point 1 to
complete the thermodynamic cycle.

Fig. 1.8 T-s chart

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1.4 Theoretical Vapour Compression Cycle with Dry Saturated Vapour after
Compression:
A vapour compression cycle with dry saturated vapour after compression is
shown on T-s diagrams in Figures 9 and 10 respectively. At point 1, let T1, p1
and s1 be the temperature, pressure and entropy of the vapour refrigerant
respectively. The four processes of the cycle are as follows :

Fig. 1.9 VCC on T-s chart

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 Compression Process
The vapour refrigerant at low pressure p1 and temperatureT1 is compressed
isentropically to dry saturated vapour as shown by the vertical line 1-2 on the T-s
diagram and by the curve 1-2 on p-h diagram. The pressure and temperature rise
from p1 to p2 and T1 to T2 respectively.
The work done during isentropic compression per kg of refrigerant is given by
w = h2 h1
where h1 = Enthalpy of vapour refrigerant at temperature T1, i.e. at suction of the
compressor, and
h2 = Enthalpy of the vapour refrigerant at temperature T2. i.e. at discharge of the
compressor.
Condensing Process :
The high pressure and temperature vapour refrigerant from the compressor is
passed through the condenser where it is completely condensed at constant
pressure p2 and temperature T2 as shown by the horizontal line 2-3 on T-s and p-h
diagrams. The vapour refrigerant is changed into liquid refrigerant. The refrigerant,
while passing through the condenser, gives its latent heat to the surrounding
condensing medium.
Expansion Process :
The liquid refrigerant at pressure p3 = p2 and temperature T3 = T2, is expanded by
throttling process through the expansion valve to a low pressure p4 = p1 and
Temperature T4 = T1 as shown by the curve 3-4 on T-s diagram and by the vertical
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line 3-4 on p-h diagram. Some of the liquid refrigerant evaporates as it passes
through the expansion valve, but the greater portion is vaporized in the evaporator.
We know that during the throttling process, no heat is absorbed or rejected by the
liquid refrigerant.

Evaporation Process
The liquid-vapour mixture of the refrigerant at pressure p4 = p1 and temperatureT4
= T1 is evaporated and changed into vapour refrigerant at constant pressure and
temperature, as shown by the horizontal line 4-1 on T-s and p-h diagrams. During
evaporation, the liquid-vapour refrigerant absorbs its latent heat of vaporization
from the medium (air, water or brine) which, is to be cooled, This heat which is
absorbed by the refrigerant is called refrigerating effect and it is briefly written as
RE. The process of vaporization continues up to point 1 which is the starting point
and thus the cycle is completed.
We know that the refrigerating effect or the heat absorbed or extracted by the
liquid-vapour refrigerant during evaporation per kg of refrigerant is given by
RE = h1 h4 = h1 hf3
where hf3 = Sensible heat at temperature T3, i.e. enthalpy of liquid refrigerant
leaving the condenser.
It may be noticed from the cycle that the liquid-vapour refrigerant has extracted
heat during evaporation and the work will be done by the compressor for isentropic
compression of the high pressure and temperature vapour refrigerant.

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Coefficient of performance, C.O.P. = (Refrigerating effect)/( Work done)

= (h1-h4)/(h2-h1)
= (h1-hf3)/(h2-h1)
1.5 Effect of various factors on system
1.5.1Effect of Suction Vapour Superheat
Superheating of the suction vapour is advisable in practice because it ensures
complete vaporization of the liquid in the evaporator before it enters the
compressor. Also, in most refrigeration and air-conditioning systems, the degree of
superheat serves as a means of actuating and modulating the capacity of the
expansion valve.

Fig. 1.10 Effect of suction vapour superheat

It can be seen from Figure, that the effect of superheating of the vapour from t1= t0
to t1 is as follows:
(a) Increase in specific volume of suction vapour from v1 to v1
(b) Increase in refrigerating effect from (h1 h4) to (h1 h4)
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(c) Increase in specific work from (h2 h1) to (h2 h1)

It is to be noted that (h2 h1) is greater than (h2 h1). This is because, although
the pressure ratio is the same for both lines, the initial temperature t1 is greater
than t1Increases with the initial temperature. That is why isentropic lines on the p-h
diagram become flatter in higher temperatures. An increase in specific volume
decreases the capacity. On the contrary, an increase in refrigerating effect will
increase the capacity effect of super- heating is to theoretically reduce the capacity.

1.5.2 Effect of Liquid Subcooling

It is possible to reduce the temperature of the liquid refrigerant to within a few
degrees of the temperature of the water entering the condenser. In some condenser
designs it is achieved by installing a sub-cooler between the condenser and the
expansion valve.
The effect of sub-cooling of the liquid from t3 = tkto t3 is shown in Figure. It will
be seen that sub-cooling reduces flashing of the liquid during expansion and
increases the refrigerating effect. Consequently, the piston displacement and
horsepower per ton are reduced for all refrigerants. The percent gain is less
pronounced in the case of ammonia because of its larger latent heat of vaporization
as compared to liquid specific heat.

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Fig. 1.11 Effect of liquid subcooling

Normally, cooling water first passes through the subcooler and then through the
condenser. Thus, the coolest water comes in contact with the liquid being
subcooled. But this results in a warmer water entering the condenser and hence a
higher condensing temperature and pressure. Thus, the advantage of subcooling is
offset by the increased work of compression.
This can be avoided by installing parallel cooling water inlets to the subcooler and
condenser. In that case, however, the degree of subcooling will be small and the
added cost of the subcooler and pump work may not be worthwhile. It may be
more desirable to use the cooling water effectively in the condenser itself to keep
the condensing temperature as near to the temperature of the cooling water inlet as
possible.
1.5.3 Effect of evaporating temperature
Figure shows the change in the basic cycle on the p-h diagram when the
evaporating temperature is increased, with a constant condensing
temperature. It is clear from the sketch that the refrigeration effect increases
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(4-1 instead of 4-1) and the heat of compression decreases (1 -2 instead of

1-2).

Fig.1.12 Effect of evaporating temperature

Following conclusions can be drawn from above Figure

Specific refrigerating effect q=h1-h3
At a given condensing temperature, the variation with evaporating
temperature depends on the variation of the specific enthalpy of saturated
vapor with temperature.
Increasing the evaporating temperature will correspondingly increase the
specific enthalpy of saturated vapor ( h1>h1).
The refrigeration effect increases.
1.5.5 Effect of condensing temperature
Figure shows the change in the basic cycle on the p-h diagram when the
condensing temperature is increased, with a constant evaporating temperature. It is
clear from the sketch that the refrigeration effect increases (4 -1 instead of 4-1), the
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specific work of isentropic compression decreases (1-2 instead of 1-2), and the
heat of rejection decreases (2-3 instead of 2-3).

Fig. 1.13 Effect of condensation temperature

Following conclusions can be drawn from figure

With decreasing condensing temperature h3 decreases, so that the specific
refrigerating effect increases with decreasing condensing temperature.
Specific refrigerating effect, q=h1-h3
The specific work of isentropic compression decreases with decreasing
condensing temperature
Specific work of isentropic compression, Win=h2-h1
Decreasing condensing temperature can markedly decreases the volume
work of isentropic compression and hence decrease the power required to
drive a given machine.
Volume work of isentropic compression, Wv=h2-h1/v1
With decreasing condensing temperature, (h1-h3) increases and (h2-h1)
decreases, so that the coefficient of performance increases.
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COP=h1-h3/h2-h1

1.6 Coefficient of performance of system

Considering a control volume enclosing the refrigerant side of the evaporator,

conservation of mass and energy applied to this control volume together give the
rate of heat transfer per unit mass of refrigerant flow in the evaporator as:

Qe
qe
h1 h4
musually adequate to assume that there is no
Next consider the compressor. It is
heat transfer to or from the compressor.
Conservation of mass and energy rate applied to a control volume enclosing the
compressor then give:
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wi

Wi
h2 h1
m

For a control volume enclosing the refrigerant side of the condenser, the rate of
heat transfer from the refrigerant per unit mass of refrigerant is:

h4 h3

qc

Qc
h2 h3
m

Finally, the refrigerant at state 3 enters the expansion valve and expands

to the evaporator pressure. This process is usually modeled as a throttling process

in which there is no heat transfer, i.e., for which

In the vapor-compression system, the net power input is equal to the compressor
power, the expansion valve involving no power input or output. Using the
quantities and expressions introduced above, the coefficient of performance, COP,
of the vapor- compression refrigeration system is given by:

COP

qe Qe / m h1 h4

wi Wi / m h2 h1

1.7 Comparison of Simple Vapor Compression Cycle with Carnot Cycle:

The Carnot cycle is the most efficient cycle possible for converting a given
amount of thermal energy into work or, conversely, for using a given amount
of work for refrigeration purposes. It is an idealized thermodynamic cycle
that describes a perfect heat engine.In the refrigeration system we need
cooling effect. So it has to operate in opposite nature to produce the cooling
effect. So we run the Carnot cycle reversely in the refrigeration system.
The coefficient of reverse refrigeration Carnot cycle is given by:
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T
e
Page
19
Tc Te

Fig. 1.14 comparison of VCC with carnot cycle

In vapor compression cycle, de-superheating between 2 and 2 is at constant

pressure rather than constant temperature. Therefore, more work has to be supplied
to the compressor. There is an equivalent amount of increase in the magnitude of
heat rejected.
In vapor compression cycle, no work is done by the system during the throttling
process. Hence, the network supplied to the cycle increases further by area 354as
compared to the reversed Carnot cycle. Because,
{(Area 1235) Area 354} = Area 1234
In vapor compression cycle, there is a loss of refrigeration effect equivalent to area
4466 due to increase in entropy during the irreversible throttling expansion.
The effect of all these deviations is to increase the compression work required or
to decrease the refrigeration effect and therefore the COP of the vapor compression
cycle will be less than that of reversed Carnot cycle.

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Chapter 2

CONCEPT
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2.1What is heat recovery system?

The heat absorbed in the evaporator Qo and the compressor work P in the form of
heat must be released again in the condenser. Instead of dissipating this heat
quantity Qc to the environment, appropriate measures can be implemented in order
to put this heat flow to meaning full use for heating purposes because of its
temperature level. Fig. 2-1 Refrigeration cycle on the h-log p diagram.

Fig. 2.1 h-log-P diagram

The condensers output Qc depends mainly on the refrigerant volume circulated

per unit of time and on the enthalpy difference h 3 h1at a given pressure pc. The
liquefaction of the hot refrigerant vapor takes place in several stages. In the initial
phase (I), heat is extracted from the hot compressed gas (e.g. 90 C) from the
compressor. The extracted heat amounts to 1020 % of the total condenser output.
Compared to the actual condensation temperature, this heat has a considerably
higher level (up to 60 C). It is particularly suitable for heat recovery if the
required heating media temperature is higher than the condenser temperature, and
the extracted heat alone can cover the heat demand. The actual condensation then
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occurs in a second phase (II). The temperature of the recoverable heat here
corresponds to the condensation temperature etc. The final phase (III) in the
condenser produces the subcooling of the now already condensed refrigerant. Due
to the low temperature and energy content, this zone is hardly relevant for heat
recovery. The condensation temperature and pressure vary with changing ambient
conditions, especially in the case of air-cooled condensers. Therefore, it is
recommendable to limit the condenser pressure to a minimum. It is also worth
checking whether it is worthwhile raising the condensation temperature during the
heating season.
2.2How much heat is available?
Before deciding whether heat recovery makes sense for your application, it is
useful to know just how much recoverable heat is available. At first glance, you
might be tempted to say that the heat available for recovery is the heat that is
removed from the room or space. This is only partially true since there is additional
heat available due to the compression of the refrigerant in the compressor.
Therefore, the total heat available is the heat removed from the space plus the heat
of compression. A simplified block diagram of an air conditioning system showing
the energy flows is presented below. Note that most of the electrical energy input to
the compressor shows up in the compressed refrigerant in the form of heat that
may be recovered. The actual amount of heat available varies as the load on the
system changes.

2.3Amount of heat recovered

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The amount of available heat that can be turned into useful heat in the form of hot
water is further limited. In a typical application the refrigerant line leaving the
compressor will be connected to a heat exchanger unit. A return line from the heat
exchanger will then be attached to the condensing unit. In this way, the hot
refrigerant gases will flow from the compressor, through the heat exchanger, and
then to the condenser. The heat exchanger has water circulating through it that is
heated by the hot refrigerant gases. When a cooling tower is used, the cooling
tower water instead of the refrigerant might circulate through the heat exchanger.
In both cases, heat is given up by the hotter fluid to the colder water circulating
through the heat exchanger.
2.4Benefits of Waste Heat Recovery
Benefits of waste heat recovery can be broadly classified in two categories:
Direct Benefits:
Recovery of waste heat has a direct effect on the efficiency of the process. This is
reflected by reduction in the utility consumption & costs, and process cost.
Indirect Benefits:
a) Reduction in pollution: A number of toxic combustible wastes such as
carbon monoxide gas, sour gas, carbon black off gases, oil sludge,
Acrylonitrile and other plastic chemicals etc, releasing to atmosphere
if/when burnt in the incinerators serves dual purpose i.e. recovers heat and
reduces the environmental pollution levels.
b) Reduction in equipment sizes: Waste heat recovery reduces the fuel
consumption, which leads to reduction in the flue gas produced. This results
in reduction in equipment sizes of all flue gas handling equipments such as
fans, stacks, ducts, burners, etc.

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c) Reduction in auxiliary energy consumption: Reduction in equipment sizes

gives additional benefits in the form of reduction in auxiliary energy
consumption like electricity for fans, pumps etc.
2.5Description of system:
In India, we are exposed to exorbitant slat of torrid summer and all of us are
longing of comforts so we would aggrandize Air conditioning system. The main
hitch of this system is that it dumped gob of heat to the surroundings. The drinking
water which we procured from water board is perpetually contaminated and we are
in need of expurgation of that water. So we are necessitated to heat the water to
certain temperature and concede it to cool for drinking. On confabulating these key
issues, an idea has come to light that we have delineated the system which deals
with the both issues and saves energy. The hot water system uses the unthriftiness
heat repudiated from Air conditioning system and heats the water which saves the
lot of LPG gas. The hot water is also supplied to the needy areas like hospitals,
commercial buildings, residential areas for washing vegetables, cooking etc. The
hot water system (Figure 1) consists of circulating chamber, insulating tank, pipe
lines for promulgating and for delivering of hot water. The heat required for this
process is carved out from the heat repudiated by the conventional Air conditioning
system.
We have taken the 1.5 TR Air conditioning units and the heat rejected from the
condenser unit. In normal AC system, there is an air cooled condenser and it have
to be put in place by water cooled condenser.
Circulating chamber is exerted for our required volume of hot water. It is
nothing but a tank with one inlet and one outlet for water flow. A head gradient is
needed for promulgating water from tank to the water cooled condenser and this
process continues until our desired temperature is reached. If thermostat operating
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valve is provided, hot water with our required temperature is achieved. We have to
erect an insulated tank for depository of the hot water and it has been used for
cooking, bathing etc.

Fig. 2.2 Schematic representation of working model

These components are put together to form a hot water system. By installing
this system, global warming is greatly reduced and the lavish amount of energy
gets saved and lavish amount of LPG gas is also rescued. This system meets the
demand of LPG gas also.

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Chapter 3

LITERATURE SURVEY
3.1 Introduction:
Industrial waste heat refers to energy that is generated in industrial processes
without being put to practical use. Sources of waste heat include hot combustion
gases discharged to the atmosphere, heated products exiting industrial processes,
and heat transfer from hot equipment surfaces. The exact quantity of industrial
waste heat is poorly quantified, but various studies have estimated that as much as
20 to 50% of industrial energy consumption is ultimately discharged as waste heat.
While some waste heat losses from industrial processes are inevitable, facilities
can reduce these losses by improving equipment efficiency or installing waste heat
recovery technologies. Waste heat recovery entails capturing and reusing the waste
heat in industrial processes for heating or for generating mechanical or electrical
work. Example uses for waste heat include generating electricity, preheating
combustion air, preheating furnace loads, absorption cooling, and space heating.
3.2 Heat Recovery Technologies
Heat recovery technologies frequently reduce the operating costs for facilities by
increasing their energy productivity. Many recovery technologies are already well
developed and technically proven; however, there are numerous applications where
heat is not recovered due to a combination of market and technical barriers. As
discussed below, various sources indicate that there may be significant
opportunities for improving industrial energy efficiency through waste heat
recovery. A comprehensive investigation of waste heat losses, recovery practices,
and barriers is required in order to better identify heat recovery opportunities and

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technology needs. Such an analysis can aid decision makers in identifying research
priorities for promoting industrial energy efficiency.
The objectives of this report were as follows:

provide an overview of conventional and developing heat recovery

technology

evaluate the quantity and quality (temperature) of key industrial waste heat

sources

describe current waste heat recovery practices in different applications

identify barriers to waste heat recovery

3.3 Waste Heat Recovery:

Waste heat losses arise both from equipment inefficiencies and from
thermodynamic limitations on equipment and processes. For example, consider
reverberatory furnaces frequently used in aluminum melting operations. Exhaust
gases immediately leaving the furnace can have temperatures as high as 2,2002,400F [1,2001,300C]. Consequently, these gases have highheat content,
carrying away as much as 60% of furnace energy inputs.
Efforts can be made to design more energy efficient reverberatory furnaces with
better heat transfer and lower exhaust temperatures; however, the laws of
thermodynamics place a lower limit on the temperature of exhaust gases. Since
heat exchange involves energy transfer from a high temperature source to a lower
temperature sink, the combustion gas temperature must always exceed the molten
aluminum temperature in order to facilitate aluminum melting. The gas
temperature in the furnace will never decrease below the temperature of the molten
aluminum, since this would violate the second law of thermodynamics. Therefore,
the minimum possible temperature of combustion gases immediately exiting an
aluminum reverberatory furnace corresponds to the aluminum pouring point

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temperature 1,2001,380F [650750C].In this scenario still 40% of heat is waste

heat again.
The paper A Critical Review on Air Conditioning for Energy Conservation and
Application by Dr.U.V.Kongrea,A.D.Rajeb ,A.L.Anantwarc ,A.B.Kaled also stated
that the technology of using a heat pump for a space conditioning and domestic
hot water heating in residences has been developed for half a century. The earlier
air to water heat pump and water heating heat pump gives only hot water and space
conditioning and suffered from drawbacks like high cost, unreliable operation and
inflexible application. But in this air conditioner cum water dispenser we get hot
and cold water with hot and cold air. Thus it becomes multifunctional easily. This
paper presented a review of a heat pump as well as a novel air-conditioning
product that can achieve the multi-functions with improved energy performance. It
obviously improving the efficiency of residential air conditioning units would
decrease utility bills and pollution produced by the power generation.
It is very much essential to put more efforts for improving the efficiency of thermal
systems because of increasing energy prices and increasing concern of global
warming. One of the methods of increasing efficiency is to recover and utilize
waste heat from thermal systems for various applications like water heating. Hot
water is required for various applications like bathing, processing, cooking, dish
washing, sterilization, and utensils cleaning in dairy.
In such applications, water is heated by electrical heating or burning the fossil
fuels which is costly and also increases global warming.
Use of waste heat recovery is an important technique of reducing total energy costs
in energy system design. Attachments need to be developed to recover waste heat
energy from air conditioning or refrigeration systems. If the heat recovery system
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is designed optimally and implemented in residential and small-scale commercial

systems, the cumulative benefits would be significant.
At many places, heating and cooling systems are simultaneously used. Air
conditioning and refrigeration systems are designed to remove the heat from
interior spaces and reject it to the ambient air. Heat rejection may occur directly to
the ambient, as in the case of most conventional air- cooled condenser, or to water,
circulating from a cooling tower. The circulating water eventually rejects the heat
to the ambient air, in the cooling tower. While this heat is of a "low grade variety,"
it still represents wasted energy. From an energy conservation standpoint, it would
be desirable to reclaim this heat in a usable form. The best and most obvious form
of heat recovery is for heating water. This waste energy can be recovered and
utilized for various applications, which not only saves the energy but also enhances
the performance of system. Heat recovery system will not change the basic
refrigeration cycle. It will simply change the type of combination of condensers
used to remove the heat from the refrigerant.
The energy performance of HVAC systems are usually evaluated based on the first
law of thermodynamics. However, compared to energy analysis, exergy analysis
shows better and accurate location of inefficiencies. Exergy analysis locates
inefficient areas having greater potential for improvement. Exergy analysis helps to
understand and quantify system irreversibilities, to measure to reduce these
irreversibilities to minimum level, and to optimize HVAC systems.
Use of waste heat recovery from thermal system is not a new technique altogether.
The focus is placed on a need to develop effective, less costly and maintenancefree auxiliary integrated with main system to achieve waste heat recovery. If this
idea is implemented at system design level, then there would be considerable
saving of energy. Following researchers contributed to the area of waste heat
recovery significantly.
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In refrigeration and air conditioning systems, heat removed from the controlled
space and heat added in the compressor during compression is rejected in the
condenser to the ambient. To recover this waste heat, an experimental setup is
developed by fitting heat recovery system to an existing refrigeration application.
Waste heat recovered will be used for water heating, which will be stored in an
insulated tank, and can be used for various applications.
Clark et al. carried out experimentation on 18 ft3domestic refrigerator. They used
water cooled condenser and regular air cooled condenser in parallel. Following are
the findings of this research:Rise in temperature of cooling water is 350C in 100 hours of continuing operation,
18% - 20% energy savings for hot water, and no deterioration of the refrigerant
performance.
Yilmaz carried out experimentation on air condition unit. He used concentric tube
type heat exchanger for heat recovery. He found that, when entering water
temperature is less than ambient air temperature, efficiency of air conditioning unit
is improved.
Stinson et al. conducted research in dairy refrigeration by recovering the heat from
condenser. They found out that by using the water cooled condenser COP of the
system is enhanced by 10% to 18%. They also found that increase in condenser
pressure reduces COP, and inclusion of heat recovery heat exchanger reduces head
loss.
Alex et al. prepared an analytical model of a residential desuperheater. They found
that the results of mathematical model and results of experimental setup vary
within 12%.
Rane et al. developed sensible heat recovery unit and carried out experiments.
Waste heat recovered is utilized for water heating. Their findings were:

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Chiller cooling capacity enhanced by 30% and COP by 20%, Fuel saving reported
81liters HSD/day, annual savings of Rs. 10 Lakh/year, Reduction in CO2
Emissions 450 ton in 4 years, and simple payback of 3 to 6 months.It is found from
the literature review that most of the research carried out is for recovery and
utilization of partial superheat from condenser, which is further used for various
applications. Studies aimed at recovery of total heat of condensation are not
reported in the available literature.
In this context, it is essential to carry out the research for recovery of superheat and
latent heat of condensation. In the proposed work, heat lost in condenser will be
recovered by using heat recovery unit, and the recovered heat will be utilized for
water heating. Effect of heat recovery on total system will be analyzed. For this
investigation, an experimental setup is developed. As per the energy balance
equation, total heat added in the system is equal to total heat rejected in the
condenser (waste energy).
In the experimental setup for removal of the waste heat, heat exchanger is used,
which is fitted between compressor and condenser in parallel. Valves are used to
bypass the heat recovery unit so that the system will work without the heat
recovery unit. Experiments are carried out with heat exchanger and bypassing the
heat exchanger. Mass flow rate of water circulation is changed and its effect on
system performance is studied. It is found out that by using desuperheater in the
cycle, discharge pressure is reduced and work required to drive the compressor is
reduced.
The paper on Development of Air Conditioning Condensing Heat Recovery and
Energy saving Device by Li Zhixiang, Xie Yi, Li Hengwu , Institute of Mechanical
and Electronic Engineering Wuhan China gave broad look on heat pump and
energy saving opportunities.

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This paper introduces a kind of simple structure, convenient installation and lower
cost energy-saving device, that can reclaim and utilize the household airconditioning condensing heat and is applicable to different kinds of condensation
system. When the temperature of the condensing agent rises to a certain extent that
needs to cost power to drop it, the device can utilize the heat energy to water
heating. In this way, it reduces the emission heat to the air and saves the electricity
consumption of water heater and air conditioning. This environment- friendly
device has already applied for the Chinese invention patent.
Nowadays household appliances plays an important role in the consumption. More
than 15% of the total power consumption is occupied by the household appliances,
and air conditioning alone accounts for 30% in all electrical appliances. In
addition, the emission heat is produced while the air-conditionings are working,
which not only leads to thermal pollution but also wastes lots of energy.
For the moment the designs of the air conditioners on the market dont get full use
of the heat, in the contrary, it consumes power to drive it. If this heat can be fully
used, we can not only reduce the environmental pollution, but also save energy.
Based on the above reasons, our aim is to get the air- conditioner and water heater
combined. Water heater is as the air-conditioning's second condensation device, it
collects the heat produced by air conditioning, and procreant hot water is used for
bathing and other daily needs. When the water gets to a certain temperature, the air
conditioning cooling device launches automatically. When we stop using the air
conditioning, water heater can also be used independently. In such way, it not only
reduces the heat that emits to the air, but also saves the electricity for the water
heater and air conditioning.

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3.3 Modified idea

As per different ideas working in this field, we come up with idea to replace whole
condenser with heat exchanger to recover sensible and latent heat from the
refrigerant .The design of heat exchanger was done according to various paper
presented in this area as well as design data book and with the help of reference
books.

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Chapter 4

PRINCIPLE
4.1Basic Refrigeration Principles
Refrigeration is the process of extracting heat from a space and rejecting that heat
typically to the surroundings. The devices that produce refrigeration are
refrigerators or air conditioning units and heat pumps. Both air conditioning units
and heat pumps are basically the same devices, but differ in their function. Air
conditioning unit is used to maintain the space at low temperatures by absorbing
heat, and extract that heat into a higher temperature environment.
On the other hand, the role of the heat pump is to maintain a heated space at higher
temperatures. Most air conditioning units consist of four major parts:
Compressor, condenser, expansion valve and evaporator.
These components form a complete refrigeration cycle. Each of them has an
important role within the cycle. The four major steps of the refrigeration cycle are
compression, condensation, expansion and evaporation.
4.2Coefficient of performance
The coefficient of performance (COP) is a measure of the efficiency of
refrigerators and heat pumps. The definition of the COP is the efficiency ratio of
the amount of heating or cooling provided by a heating or cooling unit to the
energy consumed by the system. The equation of calculating the coefficient is as
follows:
For a refrigerator or an air conditioning unit, as in (1)
COP refrigerator = QL /W net in..(1)

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For a heat pump, as in (2)

COP heat pump = Q H / W net in.(2)
Where Q L is the cooling effect or the desired output for the refrigerator, QH is the
heating effect or the desired output for the heat pump, and net in W , is the energy
that is needed to run the air conditioner or heat pump.

Fig. 4.1 working principle of a system

Since the less energy is needed to move heat than to create it, the effective waterheating efficiency of the unit system will be greater than 100%. The COP value
greater than 1.0 can be achieved especially when the unit is removing heat from an
object that is cooler than the ambient. Therefore warm water heating from waste
heat recovery of the unit by letting the water flows through the condenser. One of
the key factors that affect the COP value is the high temperature or pressure during
condensation. If the high temperature or pressure during condensation is lower, it
will lower the power used of the compressor and the energy will save more.

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4.3 working

Fig. 4.2 flow

In

process

the

process

stated

above

project

mainly

focuses on

utilizing the

waste heat

discharged at

the outlet.

The

heat

utilized

is

this

waste
by

transferring
the heat to the water and using it in many ways. In the first stage the calculated
quantity of water is filled in the tank via inlet and the volume of the water remains
fixed until it reaches the calculated temperature. The water from the tank is then
circulated in a circulating chamber. Condenser coil is placed in the circulating
chamber. Circulating water absorbs the heat rejected by the condenser and the heat
is added by constant volume process. The temperature of the circulating water
increases to the calculated temperature. When the desired temperature is reached in
the circulating water it is then drained into the separate insulated storage tank.
Suddenly fresh water will be filled into the tank as mentioned in the first stage and
this process continues as whenever the Air Conditioner operates. Thus this large
quantity of water is stored in the storage tank. Pipes can be connected from the
tank to the household appliances. Thus the vegetables and raw materials for
cooking can be washed cleanly in the hot water. This hot water is obtained by the
waste heat rejected by the condenser. Thus is more economic process of obtaining
the hot water. Water is the main course in each and every cooking. Hence utilizing
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hot water will save energy such as Liquefied Petroleum Gas, electrical energy in
case of using an induction stove. This system can also applied in the hospitals for
washing the patients clothes in hot water will save energy and also reduces the cost
of washing. Furthermore if need for the temperature of the water is high then one
should have a good refrigerant as a working substance otherwise the water to be
drained in the insulated tank should be raised to a temperature of a desired level.

Chapter 5

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METHODOLOGY
5.1

Designing of Heat Exchanger

5.1.1 Calculation of parameters

To design a heat exchanger it is required to know the amount of energy that heat
exchanger exhaust to the surrounding. Here this amount of heat is calculated step
by step.
We have the parameters of Videocon air-conditioning unit as follows:
Capacity: 1.5TR
Refrigerant used: R22
Compressor: 1940 W
From the above data, we can find the coefficient of performance of airconditioning unit,
COP = capacity/ compressor work
= 1.5*3567/194
= 2.75
Now, we measured condenser temperature and evaporator temperature using
thermometer. These are,
Condenser temperature: 55C
Evaporator temperature: 10C
Refrigeration cycle of R22 is as shown in figure.

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Figure 5.1 P-h diagram of R22

From refrigeration table of R22,

h1 = 408.67 kJ/kg
h3 = 268.5 kJ/kg
h = 268.5 kJ/kg
4
Now,
COP = (h1-h4)/ (h2-h1)
2.75 = (408.76-268.5)/ (h2-408.76)
Thus, we get h2 =459.67 kJ/kg
Now, we have,
m

= Q/q

Where, m = mass flow rate of refrigerant in kg/min

Q = refrigerant capacity in TR
q = refrigerant effect per unit mass in kJ/kg
Thus,
m

= Q/ (h1- h4)
= 1.5*211/ (408.76-268.5)

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= 2.25 kg/min
Therefore, mass flow rate of refrigerant = 0.037 kg/s
Now, heat energy exhausted by condenser per second is given by,

Q
= (h2-h3)* m

= (459.76-268.5)* 0.037
= 7.07 kW
Now, the amount of heat to be recovered by water is assumed to be 6.3 kW.
We have,

Q
= U*T*A

Where, U = overall heat transfer coefficient

T = Temperature difference which is assumed here as 25C
A = Area required to transfer the heat
Now, we have to found overall heat transfer coefficient first. It is given by the
formula as,

1
r0
r0
r0
r0
1
U = h 0 + Rf0+ k * ln ri + ri *Rfi+ ri * hi

r0= outer radius of copper tube = 6mm

ri = internal radius of copper tube = 5mm
k = conductivity of copper = 386 W/mk
Rf0 = outer surface fouling factor = 0.0000827
Rfi = inner surface fouling factor = 0.0001754
hi = heat transfer coefficient of R22= 2400 W/mk
h0 = heat transfer coefficient of water = 10000 W/mk
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Putting all the values in the formula we get overall heat transfer coefficient
U=1/10000 + 0.0000827 + 0.006/386*ln(0.006/0.005) +
0.00 6/0.005*0.0001754 +0.006/0.005 * 1/2400
= 1100 W/mk
Now,

Q
= U*T*A
6300 = 1100*25*A
Thus from above equation we get area A = 0.23 m
Now, it is necessary to find the required length of copper tube.
We assume the diameter of tube as 12mm as they are readily available in
the market.
= 0.23

DL

*0.012*L = 0.23

Thus we get length of copper tube as 6.07 m which can be approximated to 6 m.

5.1.2 Selection of heat exchanger
We have got the required dimensions of the copper tube, diameter and length,
which is able to transfer the calculated heat. Now it is to be decided what type of
heat exchanger is used. Selection of heat exchanger depends upon so many factors
such as pressure drop, the ease of manufacturing, heat transfer effectiveness, cost
etc. There are several types of heat exchangers such as plate heat exchanger, plate
and fin heat exchanger, spiral heat exchanger.
For this project we have selected helical coil heat exchanger because of
the following reasons and advantages. Helically coiled exchangers offer certain
advantages. Compact size provides a distinct benefit. Higher film coefficients, the
rate at which heat is transferred through a wall from one fluid to another, and more
effective use of available pressure drop result in efficient and less-expensive
designs. Helical geometry permits handling of high temperatures and extreme
temperature differentials without high induced stresses or costly expansion joints.
High-pressure capability and the ability to fully clean the service-fluid flow area
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add to the exchangers advantages. This concept is a good alternative for ordinary
shell-and-tube heat exchangers when it comes to fouling. This is mainly because
the curved form of the channels will create turbulence at any point in the flow,
even with low velocities. The same curved form causes high shear rates at the
walls. These two effects can prevent particles from clinging to the wall. The second
reason lies in the fact that the helical heat exchanger is just single-channeled. In
ordinary multiple-channel heat exchangers, when some foulant does manage to
stick to the wall of a channel, the flow is restricted in that channel and will divert
to less fouled channels. The velocity in the fouled channel will thereby be reduced,
causing even more foulant attachment to the walls. In helical heat exchangers, in
contrast, there is only one channel, so when some foulant does attach, the flow still
has to go through. The velocity will locally increase, as will the shear rate, thereby
removing the foulant again. Helical coil heat exchanger is easy to design and also
easy to manufacture. And can be manufactured from local technicians. Since not
much machinery used to manufacturing of this heat exchanger, cost of the
exchanger also become less.

5.1.3 Design of Helical Coil Heat Exchanger

We know the length and the diameter of copper tube. Depending on the
compactness, ease of manufacturing and spacing between tubes, diameter of coil is
assumed to be 150 mm. From this we find number of coils.
Coil perimeter, D = *150 = 471.23 mm
Number of turns required = length of the tube / coil perimeter
= 6000/471.23
= 12.73
So, the required number of turns of a coil is 13.
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Figure shows the schematic diagram of a helical coil heat exchanger. Heat
exchanger consists of three parts: shell, coil and inner cylinder. Inner cylinder is a
plastic pipe, of diameter 50mm, fitted to the shell at its center. Coil is fitted in the
annular portion of the shell and inner cylinder. Water flows inside the coil and the
annulus, with heat transfer taking place across the coil walls. Sufficient clearance
between the annulus walls and the coil, and between two consecutive turns of the
coil is necessary for better movement of water and heat transfer. The purpose of
inner cylinder and thus making an annulus is to assure uniform heating of water
and controlling the amount water that flows through it.
We have taken coil diameter as 150 mm. Inner cylinder is of 50 mm and fitted
at the center providing about 50 mm spacing between the walls of cylinder and coil
at both sides. Diameter of shell is taken as 250mm which provides same spacing
between walls of shell and coil as that of between walls of inner cylinder and coil
ie. 50mm. Shell is a cylinder made up of GI and closed at both the ends.

Figure 5.2 Schematic of heat exchanger

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Now, it is required to decide the height of the shell. Helical pitch, the distance
between two consecutive turns, is kept half of the spacing between walls of
cylinder and coil ie. 25mm. So, for 13 turns and having helical pitch as 25mm,
height of the coil can be obtained as follows:
12*25 = 300mm. by adding the tube radius at both the ends, height of the coil
becomes 300+5+5= 310mm. Clearance between top and bottom of the shell and
coil wall is kept as 10mm at the both ends. Thus we obtain height of the shell equal
to 330mm.

Figure 5.3 Helical Coil, cylinder tube and shell

In this project heat transfer is obtained through parellel flow. Part of copper coil is
brought outside the shell at the bottom and top and it is connected to the airconditioning unit through compressor and expansion valve, thus completing the
cycle of refrigerant flow. Refrigerant enters in the coil at the bottom and comes out
of the shell at upper side. Water inlet is provided at the bottopm side and water
outlet is provided at the upper side. It is simply because when water get heated, it
results in lowering the density of the water. Thus hot water remains above the cold

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water in the shell. So providing outlet at upper side makes it easy to get hot water
with high temperature.
5.1.4 Manufacturing process of the model
5.1.4.1

Manufacturing of Heat Exchanger

Heat exchanger basically consists of Copper coil and shell along with inlet and
outlet for the water flow.The manufacturing process of the heat exchanger is as
follows:
1. Firstly G. I. sheet is cut with cutter to the projection on the plane paper. This sheet
is rolled into the cylinder of required diameter i.e. 25cm.

Fig.5.4 cylindrical shell

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Fig. 5.5 helical coil

2. Rolled sheet is sealed with the help of soldering. This rolled sheet is fitted with
bottom surface and checked for leakage.
3. Then copper tube is turned into coil uniformly with the help of bending spring.
This coiled copper tube is then fitted in the cylinder.
4. After fixing tube in cylinder sealing at the boundaries, PVC pipe of calculated
diameter is put in middle of cylinder and then top surface is fitted and sealed.For
water inlet and outlet half inchnipple and socket arrangement is used.

Fig.5.6 Nipple

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5. After the manufacturing is complete whole assembly once again sealed with MSeal solution.

Figure 5.7 Arrangement of parts

Now installation on the window A/ C.

First of all conventional condenser is removed along with fan provided for the
forced convection. Then manufactured heat exchanger is fitted with compressor
outlet and capillary. In between one non Return valve is also mounted for the
charging and discharging of refrigerant R-22.Then using vacuum pump vacuum is
created inside the tube assembly and coils are charged with refrigerant R-22. The
whole assembly is tested for any leakage at the joints. After confirming that there is
no leakage the unit is run for first time.
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Fig. 5.8 Vaccum pump

Now arrangement is made for flow of water through the heat exchanger
One container with water source and water flow controlling valve. The required
flow is achieved with potential energy by keeping water source at certain minimum
required height and using flow control valve.
After checking for every parameter the A/C is run for certain period of time and
after getting required output of the model. Setup was tested for the different
operating conditions and readings were taken for calculation of different parameter.
5.1.5 Assmebly of air-conditiong unit with heat exchanger
In this design, Water supply is kept at sufficient height so that pressure of water in
the water suppling bucket can overcome the back pressure of the water in the heat
exchanger unit and shell can be filled completely with water. Water supplying
bucket is connected with the shell at its water inlet through pipe. An half inch
diameter nibble is used to connect the pipe to the bucket and the shell. To control
the water flow, tap is provided to the water source bucket in between the water
connection. Heat exchanger is mounted on the air-conditioning unit with the bucket
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to collect the hot water that comes through outlet, provided with an half inch
nibble, of heat exchanger. This arrangement is done for the experiment purpose.

Figure 5.9

overall assembly of heat recovery system

From commercial point of view, there must be continous water supply to the heat
exchanger unit and the arrangments such as pipe connections and storage are to be
provided necessarily to bring the hot water wherever it is required.
5.2 Testing & analysis
5.2.1 Experimental Analysis to calculate the saving of LPG gas
We have to appraise the amount of LPG gas needed for elevating the temperature
of water at 27 degree Celsius to attain 55 degree Celsius for 5 liters of water. A
vessel is taken with 5 liters of water at 27 degree Celsius and places it in a gas
stove. The temperature of water is periodically checked by using thermometer.
Then we have to calculate the time of 5 liters of water to attain 55 degree Celsius.
Mass flow rate of LPG gas is calculated and then appraise the amount of LPG gas

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needed to achieve our task. For a normal house, we have calculated the no of
cylinders saved per year.
A.

B.

Assumptions
Usage of water per person is 50kg/day
Loss of water in the pipeline is 5C
Minimum number of five cooking recipe is prepared per day
COP of Air Conditioner is taken as 2.5
Running hours of Air Conditioner is 8 hrs/day
Calculation for Air Conditioner
COP = QL/W
= QL/ (QH QL)
QH = QL * (1+ 1/COP)

Where,
QH = Quantity of heat rejected by Air Conditioner
QL = Total Capacity of Air Conditioner (Input Power)
For 1.5 ton AC,
Capacity of Air Conditioner = 5.25 kW
Average COP for 1 ton of AC = 2.5
QH = 5.25 * (1+1/2.5)
QH = 7.35 kW
For ideal case,
Waste heat rejected over a day = 7.35 * 8 * 3600
= 211680 kJ /day
For 7 persons in a house,
Quantity of water needed = 350 L/day
In summer season the temperature of water at inlet = 27C
Required temperature of water at insulated tank = 55C
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Quantity of heat required to raise the temperature

Q = m * Cp * dT
= 350 * 4.186 * 29
= 41022.8 kJ/day
Heat rejection rate = 7.35 kJ/s
Time for 350L water to reach 55C = 41022.8/7.35
T = 1.55 hrs
It was found that when cooking is done for 4 hour per day with 14.1 kg of LPG
gas, it will be depleted in 40 days.
Mass flow rate M = 2.4479 * 10-5 kg/s
Time to reach 55C for 5 L of water t1 = 13 min (780 sec)
Mass of gas consumed for t1 time = 19.09 g/ 5L of water boiling
For average of 5 cooking recipe is done per day then,
Mass of LPG gas saved = 95.45 g/day
For 40 days,
Amount of LPG gas saved = 3.818 kg
Number of days saved = 27 days/cycle
Number of LPG cylinders
It has saved per year = 4 per house
Cost Calculation for producing 350 litre of water at 27 to attain 55
Heat Required =41022.8 KJ/Day.
To achieve this amount of heat 11 KWh of Electricity is needed.
So Cost for one day is Rs.77
Amount of energy saved per year = mLPG*Cv* no of cylinders
= 14.1*10800/4.2*4
= 1457224.88 kJ
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5.2.2 Performance testing method

The test unit consists of a refrigerant loop, tap water supply system, and data
acquisition system. And the helical coil heat exchanger consists of a shell and
helically coiled unit. The test unit and the connections of the water sullied piping
system are designed such that parts can be changed or repaired easily. An
instrument for measuring and control of room temperature, refrigerant pressure and
airflow rate is installed at all important points in the circuit. The room temperature
is adjusted to the desired level and controlled by temperature controller. The flow
rates of the water are controlled by adjusting the valve and measured by the flow
meters.
Testing was conducted with various inlet water flow rates entering the test unit.
In the tests, the water flow rate was increased in small increments while the
refrigerant flow rate and inlet water temperatures were kept constant.

Fig. 5.10 layout of heat exchanger

5.2.2.1Procedure
1. Plug in the air conditioner.
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2. Fill the water storage tank up to the marked level and maintain that level
through continuous supply of water.
3. Open the tap of a storage tank so as to fill up heat exchanger chamber.
4. Run the air conditioner for about half an hour so that water starts heating.
5. Take out the water from heat exchanger chamber in to the measuring flask
for one minute to get the mass flow rate.
6. Measure the temperature at the refrigerant inlet, refrigerant outlet, water
inlet and outlet.
7. And repeat the procedure after 30 minutes interval.
8. Take 3-4 readings by variation of mass flow rate at outlet of storage tank.
5.2.3 Observation table
Flow rate of Inlet temp Outlet temp
water
of
water
of water
(lit/min)
(T1C)
(T1C)
0.630
29
54
1.5384
29
51
2.72
29
51
3.15
29
47

Inlet temp of Outlet temp

refrigerant of refrigerant
(T2C)
(T2C)
70
58
69
60
69
59
70
60

As design is of parallel flow heat exchanger hence LMTD

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LMTD

16
21
20
24.3

Fig. 5.11 parallel flow LMTD

Coefficient of performance of air conditioner with condenser in place:

COP = QL/ Wnet
=1.5 *3567/1940
=2.75
Coefficient of performance of heat pump& air conditioner:
COPheat pump = Q H / Wnet in
COP refrigerator = Q L/W net in
i. LMTD = (70-29)-(58-54)/ln(41/4)
= 16C
Q H = U*A* LMTD
=1.1*0.230*(16)
=4.048 KW
h2 = h2a+ cp(T2 T2a)
= 416.561 + 0.92(70-40)
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= 444.161 KJ/Kg
Wnet in = m refrigerator (h2 h1)
=0.037(444.161 408.835)
= 1.30 KW
COPheat pump = Q H / Wnet in
= 4.048/ 1.30
COPheat pump = 3.1
COP refrigerator = Q L/W net in
= (4.048-1.3)/1.3
COP refrigerator = 2.11
Amount of heat recovered = m* cp*dT
= 0.63*4.18*(54-29)/60
Amount of heat recovered = 1.09 KW
ii.

LMTD = (69-29)-(60-51)/ln(40/9)
= 21C
Q H =U *A* LMTD
= 1.1*0.230*21
= 5.313 KW
h2 = h2 + cp (T2 T2)
= 416.561 + 0.92(69-40)
= 443.241 KJ/Kg
Wnet in = m refrigerator(h2 h1)
= 0.037(443.241 408.835)
= 1.27 KW
COPheat pump= Q H / Wnet in
= 5.313/ 1.27

COPheat pump = 4.17

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COP refrigerator = Q L/W net in

= (5.313-1.27)/1.27
COP refrigerator = 3.1
Amount of heat recovered = m* cp*dT
= 1.5384*4.18*(51-29)/60
Amount of heat recovered =2.34 KW
iii.

LMTD = (69-29)-(59-51)/ln(41/8)
= 20C
Q H =U *A* LMTD
= 1.1*0.23*20
= 5.06 KW
h2 = h2 + cp (T2 T2)
= 416.561 + 0.92(69-40)
= 443.241 KJ/Kg
Wnet in = m refrigerator (h2 h1)
= 0.037(443.241 408.835)
= 1.27 KW
COPheat pump= Q H / Wnet in
= 5.06/ 1.27

COPheat pump = 3.98

COP refrigerator = Q L/W net in
= (5.06-1.27)/1.27
COP refrigerator

= 2.98

Amount of heat recovered = m* cp*dT

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= 2.72*4.18*(51-29)/60
Amount of heat recovered = 4.16 KW

iv.

LMTD = (70-29)-(60-47)/ln(41/13)
= 24.3C
Q H = U* A*LMTD
= 1.1*0.23*24.3
= 6.1479 KW
h2 = h2 + cp(T2 T2)
= 416.561 + 0.92(70-40)
= 444.161 KJ/Kg
Wnet in = m refrigerator(h2 h1)
= 0.037(444.161 408.835)
= 1.30 KW
COPheat pump= Q H / Wnet in
= 6.1479/ 1.3

COPheat pump = 4.72

COP refrigerator = Q L /W net in
= (6.1479-1.30)/1.30
COP refrigerator = 3.72
Amount of heat recovered = m* cp*dT
= 3.15*4.18*(47-29)/60
Amount of heat recovered = 3.95 KW
Chapter 6
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RESULT AND DESCUSSION

6.1 Result Table
Mass flow rate

Outlet temp of

COP of a heat

COP of a

heat recovered

of

water(C)

pump

refrigerator

0.630

54

3.1

2.11

1.09

1.5384

51

4.17

3.1

2.34

2.72

51

3.98

2.98

4.16

3.15

47

4.72

3.72

3.95

water(lit/min)

6.2 Graphical representation

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Chapter 7

CONCLUSIONS
7.1 Conclusions
1. This project investigated the benefits of applying a helical coil heat
exchanger for heat recovery of a portable air conditioning-heat pump unit.
2. The unit with heat recovery system was set up for study at various water
flow rates.
3. It was found that the heat recovery system could improve the coefficient of
performance for cooling of the unit by 28% at water flow rates 3.15/min
under full load conditions, and the level of improvement increased with the
tap water flow rate.
4. From the result table it is clear that with increases in mass flow rate of
water, temperature of water at outlet decreases
5. It has been perceived that by supplanting the normal Air Conditioner by this
system will vanguards to rescue 4 numbers of LPG gas cylinders per year
i.e. 1457224.88 kJ of energy is saved per year per house. This not only saves
the cost but also it bulwarks the environment by truncating the global
warming engendered because of LPG gas.
6. The results of this study clearly support widening the application of heat
recovery of a portable air conditioning unit by using a helical coil heat
exchanger to reduce energy use for air conditioning and water heating in the
general way.
7. If this system is established all over India, lavish amount of LPG gas gets
saved and global warming is controlled by certain extent and this could be a
surrogate to water heater and it is the scope for the future.

REFERENCES
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References
1. R. E. Jarnagin, Heat Recovery from Air Conditioning Units, FactSheet
EES-26, Florida Cooperative Extension Service, University ofFlorida.
2. R.Benstead, Industrial heat pumps, IEEE Power EngineeringJournal., vol.
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3. B.C. Langley, Heat Pump Technology, 3rd ed. New York: PrenticeHall,
2001.
4. Hepbasli, Y. Kalinci, A review of heat pump water heating systems,
Renewable and Sustainable Energy Reviews 13 (2009) 12111229.
5. N. Somsuk, T. Wessapan, and S. Teekasap, Conversion ofconventional
commercialized window type air conditioning unit intoa portable air
conditioning-heat pump unit, Sustainable EnergyTechnologies, 2008,
ICSET 2008, IEEE International Conference on,pp. 728-732, Singapore.
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energy storage with heat exchanger for solar trough powerplant, Energy
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7. Y. Xiaowen, and W.L. Lee, The use of helical heat exchanger forheat
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Management, Vol. 44, (2003)25092517.
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12.S.H. Noie-Baghban, G.R. Majideian, Waste heat recovery using heat pipe
heat Exchanger (HPHE)for surgery rooms in hospitals, Applied Thermal
Engineering, Vol. 20, (2000) 1271-1282.
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window Air Conditioning System by Liquid Cooling with helical inter
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American Society of Heating,Refrigerating, and Air-Conditioning Engineers,
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Recovery Domestic Water-Cooled Air-Conditioners,

Energy Conv.

Management, 50(2009), pp. 240246.

20.Y. A. Cengel and M. A. Boles, An Engineering ApproachThermodynamics,
6th Edition. New York:McGraw-Hill.
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22.Residential
consumption

of

electricity

in

(moef.nic.in/downloads/public.../Residentialpowerconsumption.pdf)

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India.

23.P.Sathiamurthi, PSS.Srinivasan Studies on waste heat recovery and

utilization. Globally competitiveeco-friendly technologies engineering
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Conditioning Analysis and Design, John Wiley & Sons,Inc., New York,
2005.

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