PROJECT REPORT ON

REFRIGERATION WITH HOT BOX

1
 OUR PROJECT

1. We are converting domestic refrigerator into twin

type Hot and Cooled Refrigerator.
2. Changing CFC system into HC system so that the
system becomes ecofriendly.

2
 ACKNOWLEDGEMENT

We would like to thank sincerly to our guide

whose able guidance gave us the direction of study and was eager
enough to quench or instable thirst of answering to the smallest
queries. We shall cherish his help and guidance for a long time to
come.

3
 PREFACE

In vapour compression cycle the condenser rejects heat to the

atmosphere. This heat is a waste heat we install a plate type heat
exchanger as used in the refrigerator evaporator in the discharge
line of the system and then insulate with glass wool. Now this
heat exchanger will act as an auxiliary condenser and the
refrigerator rejects its heat in the cabinet, which can be utilized
to keep the cooked food warm.

Our project also includes changing over the refrigerating

system from chlorofluorocarbon to hydrocarbon. As we know
R-12 is phased out in our country in this year so we switch over
our refrigerator to its substitute refrigerant that is HC blend (by
mass 50% Propane + 50% Isobutene) which posses an ozone
depletion potential (ODP) of value zero and negligible global
warming potential (GWP). Therefore, system becomes
completely eco friendly.

Also by providing an extra condenser with the main one will

leads to the sub cooling of the liquid refrigerant in the latter part
of the condenser resulting in a better-increased refrigerating
effect or increase a net COP...

4
It can be used in domestic applications to keep the cooked food
hot. It can also be used to make curd faster in the winter season
and so on.
.

5
 INTRODUCTION

In domestic refrigerator, the circulation of a refrigerant

achieves constant cooling in a closed system. The refrigerant is
compressed by means of compressor to a pressure at which
temperature obtained at the end of compression will be more than
atmosphere and will then be condensed. This condensed refrigerant
is then allowed to pass through a capillary so that the pressure and
temperature are lowered. Capillary device acts as a throttling
device. The pressure of the refrigerant when it leaves the capillary
maintained above atmosphere where as the temperature of
refrigerant will corresponds to the saturation temperature to be
maintained in the cabinet of the refrigerator, so that when this
vapour flows through the evaporator (placed in the cabinet of the
refrigerator), it will absorb heat. Due to heat absorption, refrigerant
evaporate and when it leaves the evaporator, it will be either dry or
saturated or super heated which compressor then sucks and the
cycle is repeated.

From the above discussion we have studied the working of

the domestic refrigerator. Now to switch over the normal domestic
refrigerator to a twin type hot and cool refrigerator, we have
proceeded as follows.

6
 Firstly, make a small box of sheet metal with a door in the
front and place that sheet metal box on the top of the refrigerator.
Now place a heat exchanger, which can be same as that of the
evaporator used in the domestic refrigerator, inside the sheet metal
box. Make sure the sheet metal box is such that there should be a
space of around 2” according to design between the heat exchanger
(auxiliary condenser) and sheet metal box for providing insulation.
Now insulate the auxiliary condenser with glass wool. Connect the
heat exchanger with normal refrigeration cycle after to the
compressor and before the existing the condenser. It should be in
series with the pre-existing condenser. Now that heat exchanger
will also act as a condenser, and heat rejected by high pressure,
high temperature refrigerant can be utilized as a useful heat.

7
 SPECIFICATION OF THE
REFRIGERATION SYSTEM

In this section, we dealt with the basic review of domestic

refrigerator cycle. The basic refrigeration cycle is as follows -

Compression system employs four elements in the

refrigeration cycle: compressor, condenser, expansion valve and
evaporator. In the evaporator, the refrigerant is vaporized and heat

8
is absorbed from the space being cooled and its contents. The
vapour is next drawn into a motor driven compressor and raised to
a high-pressure gas is than condensed to liquid in an air or water-
cooled condenser. From the condenser the liquid flows through an
expansion valve in which its pressure and temperature are reduced
to the conditions that are maintained in the evaporator.

9
 REFRIGERATION COMPONENTS

1. The Evaporator

2. The Compressor

3. The Condenser

4. The Expansion valve

5. The Receiver

6. The Filter drier

3.1 The Evaporator: The evaporator absorbs heat into the

system. When the refrigerant is boiled at a lower temperature than
that of the substance to be cooled, it absorbs heat from the
substance. The evaporator in a refrigerating system is responsible
for absorbing heat into system from whatever medium is to be
cooled. This heat absorbing process is accomplished by
maintaining the evaporator coil at a lower temperature than the
medium to be cooled. To summarize the three main function of the
evaporator are to:

10
 a) Absorb heat.
b) Allow the heat to boil off the liquid refrigerant to a vapour in
its tubing bundle.
c) Allow the heat to superheat the remaining refrained vapour in
it tumbling bundle.

3.2 The Compressor: The compressor is the heart of the

refrigeration system. It pumps heat through the system in the form
of heat. A compressor can be considered as vapour pump. It
reduces the pressure on the low-pressure side of the system, which
includes the evaporator and increases the pressure in the high-
pressure side of the system. The compressor actually increases the
pressure from suction pressure level to the discharge pressure
level. This creates refrigerant flow from low-pressure side to high-
pressure side. All compressors in refrigeration system perform this
function by compressing the vapour refrigerating.

3.3 The Condenser: The condenser rejects both sensible

(measurable) and latent (hidden) heat from the refrigeration
system. This heat can come from what the evaporator has absorbed
any heat of compression or mechanical friction generated in the
compression stroke, motor binding heat, and any heat absorbed by
super heating the suction line before entering the compressor. The

11
condenser receives hot gas after it leaves the compressor through
the short pipe (short pipe between the compressor and the
condenser called the hot gas line). The hot gas is forced into the
top of the condenser coil by the compressor, the gas is being
pushed along at high speed, and hot gas temperature is system and
application dependent. The condenser is a heat exchange device
similar to the evaporator; it rejects the heat from the system
absorbed by the evaporator. This heat is rejected from a hot super
heated vapour in the first passes of the condenser. The middle of
the condenser rejects vapour, which is in the process of the phase
changing to a saturated liquid. The last passes of the condenser
rejects heat from sub-cooled liquid. This further sub cooled the
liquid to below its condensing temperature.

In fact, the three function of a normal condenser is to de-

superheat, condense and to subcool the refrigerant. When the heat
was being absorbed in to the system, we pointed out that it is at the
point of change of state (liquid to vapour) of the refrigerant where
the greatest amount of heat is rejected.

The condenser is operated at a higher pressure and

temperature than the evaporator and is often located outside. The
same principle is applied to heat exchange in the condenser as in

12
the evaporator. The materials a condenser is made of the medium
used to transfer the heat make a difference in the efficiency of the
heat exchange.

3.4 The Expansion Devices: The expansion device, often

called the metering device, is the fourth component necessary for
the compression refrigeration cycle to function. The expansion
device is not as visible as the evaporator, the condenser, or the
compressor. Generally, the device is concealed inside the
evaporator cabinet and so obvious to the casual observer. It can
either be a valve or a fixed-bore device.

The expansion device is a division line between the high

side of the system and the low side of the system. The expansion
device is responsible for metering the correct amount of refrigerant
to the evaporator.

The evaporator performs best when it is as full of liquid

refrigerants as possible without leaving any in the suction line.
Any liquid refrigerant that enters the suction line may reach the
compressor because only a small amount of heat should be added
to the refrigerant in the suction line.

13
 The expansion devices are normally installed in the liquid
line between the evaporator and the condenser. The liquid line may
be warm to touch on a hot day and can be followed quite easily to
the expansion device where there is a pressure drop and an
accompanying temperature drop. For example, on a hot day the
liquid line entering the expansion device may be 110oF. If this is a
low temperature cooler using R-12, the low side pressure on the
evaporator side may be 3 psig at a temperature of –15oF. This is a
dramatic temperature drop and can be easily detected when found.
The device may be warm on one side and frosted on the other side.
Because some expansion devices are valves and some are fixed
bore devices, this change can occur in a very short space less than
an inch on a valve, or a more gradual change on some fixed bore
devices.

Expansion devices come in the following different types:

a) high side float
b) low side float
c) thermostatic expansion valve
d) automatic expansion valve
e) fixed bore such as the capillary tube.

14
 However, only three are currently being furnished with
refrigeration equipment. The high side float and the low side float
are not currently being used on typical refrigeration equipment and
should not be encountered in this field.

3.5 The Receiver: The condensed liquid refrigerant from the

condenser is stored in a vessel known as receiver from where it is
supplied to the evaporator through the expansion valve or the
refrigerant control valve.

3.6 The Filter Drier: Filter drier is used to remove the acid,
moisture and carbon sludge.

15
 BASIC VAPOUR COMPRESSION
DOMESTIC REFRIGERATION
SYSTEM

4.1.Working of refrigeration system

A refrigeration system does not cool products; they remove
product heat, causing temperatures to be lowered. All systems have
an area, which collects heat from inside an insulated cabinet,
dispersing it outside. This collection and disposal of heat continues
until the refrigerator cuts out, usually by thermostat when the
required product temperature has been achieved. Therefore a
refrigeration system is heat pump, collecting heat from one area
and disposing of it elsewhere with the consequence that the area
which heat is being removed from will be lowered in temperature.
Refrigeration system have three major components, each
connected in recycling circuit. The evaporator is the heat collector
located inside the cabinet. The condenser disperses the collected
heat elsewhere. The compressor pumps a refrigerants gas around
the circuit. (Other minor components also service these).

16
Refrigerant gas is the vehicle used to transport heat from the
evaporator to the condenser.

Refrigerant gas is pumped around the circuit above, (similar to

water circulating around a cars cooling system), performing

17
 different duties in each of the components. The compressor sucks
the heat laden gas vapour from the evaporator, pumping it at a high
pressure into the condenser. The condenser disposes heat from this
compressed hot gas, causing it to condense into high-pressure
liquid. This liquid returns to the evaporator via a restriction device
(set to cause the correct pressure build up). As this liquid is
released by the restriction into the low-pressure evaporator pipes, it
expands into a vapour, again absorbing heat. These activities are
simultaneous whenever the compressor is running.

WARM WARM
COPHP = QH
environmen house
t WNET IN

Qh Qh=desired output

Wnet,in=required
input
R HP
Wnet,in=required input
OPR = QL
WNET IN
QL =desired output QL
COLD
refrigerated COLD
space environmen
t

18
(A) Refrigerator (B) Heat pump

Fig: 4.2 Cooling Vs Heating

4.2.Domestic Refrigerators:

Most domestic refrigerators are of two types – either a

single door fresh food refrigerator or two- door refrigerator-freezer
combination, with the freezer compartment on the top portion of
the cabinet, or a vertically split cabinet (side by side), with the
freezer compartment on the left side of the cabinet. They are
completely self-contained units and are easy to install.

Most refrigerators use R-12 refrigerant, normally

maintaining temperatures of 0oF in the freezer compartment and
about 35oF to 45oF in the refrigerator compartment. The technician
must be able to perform various duties in the maintenance and
repair of domestic refrigerators, water coolers, and ice machines;
this section provides information to aid you in handling some of
the more common types of troubles. But let us remind you that the
information given here is intended as a general guide and should,
therefore, be used with the manufacture’s detailed instructions.

19
4.3.Vapour Compression Refrigeration Cycle

Introduction:

The challenge in refrigeration (and air conditioning, etc.) is

to remove heat from a low temperature source and dump it at a
higher temperature sink. Compression refrigeration cycles in
general take advantage of the idea that highly compressed fluids at
one temperature will tend to get colder when they are allowed to
expand. If the pressure change is high enough, then the compressed
gas will be hotter than our source of cooling (outside air, for
instance) and the expanded gas will be cooler than our desired cold
temperature. In this case, we can use it to cool at a low temperature
and reject the heat to a high temperature.

Vapour-compression refrigeration cycles specifically have

two additional advantages. First, they exploit the large thermal
energy required to change a liquid to a vapour so we can remove
lots of heat out of our air-conditioned space. Second, the

20
isothermal nature of the vaporizations allows extraction of heat
without raising the temperature of the working fluid to the
temperature of whatever is being cooled. This is a benefit because
the closer the working fluid temperature approaches that of the
surroundings, the lower the rate of heat transfers. The isothermal
process allows the fastest rate of heat transfer.

Some Other Parameter

An ideal refrigeration cycle looks much like a reversed

Carnot heat Engine or a reversed Rankine cycle heat engine. The
primary distinction being that refrigeration cycles lack a turbine,
using a throttle instead to expand the working fluid. (of course, a
turbine could be incorporated into a refrigeration cycle if one could
be designed to deal with liquids, but the useful work output is
usually too small to justify the cost of the device).

The cycle operates at two pressures, Phigh and Plow, and the
state points are determined by cooling requirements and the
properties working fluid. Most coolants are designed so that they
have relatively high pressures at typical application temperature to
avoid the need to maintain a significant vacuum in the refrigeration

21
 cycle. The T-S diagram for a vapour compression refrigeration
cycle is shown below.

1
2 cooler P high

T high
throttle compressor

T Plow
T low
3 heater 4

Fig: 4.4 Vapour compression refrigeration cycle

T-S diagram

22
 Cooling Requirements

For purpose of illustration, we will assume that a refrigeration

system used to cool air for an office environment. It must be able
to cool the air to 15.5oC (about 60oF) and reject heat to outside air
at 32oC (90oF).

The Working Fluid

We have working fluids available for use in refrigeration

cycles. Four of the most common working fluids are available in
cycle pad: R-12, R-134, ammonia. (Nitrogen is also available for
very low temperature refrigeration cycles). We will choose R-12
for this example.

Description of Cycle Stages

23
 We will examine each state point and component in the
refrigeration cycle where design assumptions must be made,
detailing each assumption. As we can see from the example design
constraints, very few members need be specified to describe a
vapour-compression refrigeration cycle. The rest of the
assumptions are determined by applying reasoning and background
knowledge about the cycle. The two principle numerical design
decisions are determining Phigh and Tlow at the cooler outlet and the
compressor inlet.

Cooler (Condenser) Inlet (S1)

Thi
s state does not involve any design decisions, but it may be
important to come back here after the cycle has been solved and
check that T2, which is the high temperature of the cycle, does not
violate any design or safety constraints. In addition, this is as good
a place as any to specify the working fluid.

Cooler (Condenser): Heat rejection (CLRI)

The cooler (also known as the condenser) rejects heat to

the surroundings. Initially, the compressed gas (at SI) enters the

24
condenser where it loses heat to the surroundings. During this
constant pressure process, the coolant goes from a gas to a
saturated liquid-vapour mix, and then continues condensing until it
is saturated liquid, but there is little gain in doing so because we
have already removed so much energy during the phase transition
from vapour to liquid.

Cooler (Condenser) Outlet (S2)

We cool the working fluid until it is a saturated liquid, for reasons

stated above. An important design question arises at this state: how
high should the high pressure of the cycle be?

We choose Phigh so that we can reject heat to the

environment. Phigh is the same as P2 and P2 determines the
temperature at state S2, T2 (T2 is just the saturation temperature at
Phigh). This temperature must at least be higher than that of the
cooling source otherwise no cooling can occur.

However, if T2 is too high (that is, higher than the critical

temperature Tc for the working fluid), then we will be beyond the
top of the saturation dome and we will loose the benefits of the

25
large energy the fluid can reject while it is being cooled.
Furthermore, it is often impractical and unsafe to have very high
pressure in our fluids in our system and the higher P2 we choose,
the higher T1 must be, leading to additional safety concerns. For
reference, Tc for our four working fluids is given below.

Critical Temperature of some refrigerants

Substance TC (OC)
R-12 (CCL2F2) 111.85
R-22 (CHCLF2) 96.15
R-134a (CF3CH2F) 101.05
Ammonia (NH3) 132.35
HC-blend 113.0
Table: 4.1
For example using R-12, we must be able to reject heat to air that
is 32oC. We can choose if T2 to be anywhere between that number
and the 96oC Tc. We will choose it to be 40oC for now.

Throttling (THR1)

The high pressure, saturated liquids are throttled down to a lower

pressure from state S2 to state S3. This process is irreversible and
there is some inefficiency in the cycle due to this process, which is

26
why we note an increase in entropy from state S2 to stateS3, even
there is no heat transfer in the throttling process. In theory, we can
use a turbine to lower the pressure of the working fluid and thereby
can extract any potential work from the high-pressure fluid (and
use it to offset the work needed to drive the compressor). This is
the model for the Carnot refrigeration cycle. In practice, turbines
cannot deal with the most liquid fluids at the cooler outlet and,
even if they could, the added efficiency of extracting this work
seldom justifies the cost of the turbine.

Heater (Evaporator): Heat Absorption (HTR1)

The working fluid absorbs heat from surroundings, which we

intend to cool. Since this process involves a change of phase from
liquid to vapour, this device is often called the evaporator. This is
where the useful “function” of the refrigeration cycle takes place,
because it is during this part of the cycle that we absorb heat from
the area we are trying to cool. For an efficient air conditioner, we
want this quantity to be large compared to the power needed to run
the cycle.

27
 The usual design assumption for an ideal heater in a
refrigeration cycle is that it is isobaric (no pressure loss is incurred
from forcing the coolant through the coils where heat transfer takes
place). Since the heating process typically takes place entirely with
in the saturation region, the isobaric assumption also ensures that
the process is isothermal.

Compressor Inlet (S4)

Typically, we want state S4 to be right at the saturated vapour side

of the saturation dome. This allows us to absorb as much energy
from the surroundings as possible before leaving the saturation
dome where the temperature of the working fluids starts to rise and
the (now non-isothermal) heat transfer becomes less efficient.

Of course, we would get the same isothermal behaviour if

we were to start the compression before the fluid was completely
saturated. Further, there would seem to be a benefit in that state
point S1 would be closer to the saturation dome on the Phigh isobar,
allowing the heat rejection to be closer to isothermal and,
therefore, more like the Carnot cycle.

28
 It turns out that, for increased efficiency, we can choose S4
such that S1 is on the saturation dome, instead of outside of it in
the superheat region. Following figure shows the T-S diagrams for
two refrigeration cycles, one where S4 is saturated vapour and the
other where S4 has been moved further into the saturation dome to
allow S1 to be a saturated vapour.

The advantages in the second case are that we have

reduced the compressor work. We have also reduced the heat
transfer somewhat; but the reduced compressor work has a greater
effect on the cycle’s coefficient of performance. Fig shows the
cycle’s COP Vs the Quality of S4. We note that the change in COP
is noticeable, but not terribly impressive.

Temperature (o C)
100

50 Compressor

-50

29
-100
-0.25 0.25 0.75 1.25
Entropy (kj/kg K)
Fig: 4.6 T-S diagram for different compressor conditions
Compressor (COMP1)

Ideal compressor is like ideal pumps like adiabatic and isentropic.

We also note that compressor is the only device in the system that
does work to the fluid. For an efficient air conditioner, we want
this quantity to be small.

4.4.Some Definitions:

1) Cooling Capacity: Maximum rate of heat removal from the

refrigerated space by refrigerator.
2) Heating Capacity: Maximum rate of heat addition to heated
space by heat pump.
3) 1 Ton of Refrigeration: Capacity of a refrigerator that can
freeze 1 ton of water in 24 hours (12000BTU/hr, 211Kj/min).

OR

30
1 tonne of refrigeration is defined as the refrigeration effect (RE)
produced by the melting of 1 tonne of ice from and at 0oC in 24
hours since the latent heat of fusion of ice is 336 Kj/Kg.

1 tonne of refrigeration =336 * 1000/24 = 14000 Kj/hr.

4) COP: It is defined as the ratio of heat absorbed by the

refrigerant by passing through the evaporator to the work
input required to compress the refrigerant in the compressor,
in short it is the ratio between heat extracted and work done.
COP = Net refrigerating Effect/ work expanded in by the machine
during the same time interval.

31
CHANGED VAPOUR COMPRESSION
DOMESTIC REFRIGERATION
SYSTEM
(Project Work)

In changed vapour compression system an auxiliary

condenser (hot cabinet) is used in the vapour compression cycle.
The auxiliary condenser is placed after the compressor outlet and
before the main condenser inlet. So due to this arrangement some
heat is rejected in auxiliary condenser and some heat is rejected in
the main condenser. Therefore, heat rejection by two condensers
results some sub-cooling of liquid refrigerant. Remaining cycle is
same as simple vapour compression cycle.

32
5.1.Working of changed system

A flow diagram of a changed vapour compression system

is shown in figure. The principle parts of the system are an
evaporator, whose function is to provide heat transfer surface
through which heat can pass from the refrigerated space or product
in to the vaporizing; a suction line, which conveys the low pressure
vapour from the evaporator to the suction inlet of the compressor;
a vapour compressor, whose function is to remove the vapour from
the evaporator and raise the temperature and pressure of the vapor
to a point such that the vapour can be condensed with normally
available condensing medium; a hot gas or discharge line which
delivers the high pressure, high temperature vapour from the
discharge or the compressor to the auxiliary condenser; an
auxiliary condenser whose purpose is to serve as a hot space by
utilizing the waste heat rejected in condenser; a main condenser,
whose purpose is to provide a heat transfer surface through which
heat passes from the hot refrigerant vapour to the condensing
media; a refrigerant flow control, whose function is to meter the
proper amount of refrigerant to the evaporator and to reduce the

33
 pressure of the liquid entering the evaporator so that the liquid will
vaporize in the evaporator at the desired low temperature.

HOT BOX

CONDENSER COMPRESSOR EVAPORATOR

(outside cabinet) (heat pump) (inside cabinet)

EXPANSION
Hdispersed FILTER DEVICE Hcollected
Fig 3.1 changed vapour compression cycle

T
sub cooling

∆TS 2
T cond 3
TH

T evap TL superheat

34
 4 ∆TS

S
Fig 5.2: T-S diagram of changed system
S. No. Parameter Size
1. Width 14.5”
2. Height 6.5”
3. Breadth 11.5”
4. Glass Wool Insulation 2”
5. Sheet Metal 22Gage

5.2.Practical Data’s
Hot Box Specification:

Table 5.1

Hot Cabinet Air Temperature:

S. No. Mode of Thermostat Air Temp. of Hot

Cabinet

35
1. Minimum 50oC
2. Normal 55oC
3. Maximum 60oC

Table 5.2

Evaluation of Temperature in Hot Box:

S . No. Substance Quantity Time T1oC T2oC

Duration
1. Water 200ml. 30 min. 25 45
2. Milk 200ml. 30 min. 12 44
3. Tea 200ml. 30 min. 60 56
4. Daal 200gm. 30 min. 55 52

Table 5.3

T1 – Temperature of substance before putting into hot case.

T2 – Temperature of substance after putting into hot case.

36
 5.3.Benefits of Changed System

1. An extra facility (hot cabinet) is obtained with small change

in price of the system.
2 Power consumption is same as in basic vapour compression
system (without hot cabinet).
3 Increment of room temperature is reduced.
4 Due to sub cooling C.O.P of system is increased.
5 Due to conversion of CFC to HC system becomes eco-
friendly

5.4.Applications of Hot Changed System

1. To keep the cooked food hot.

2. It can also be used to make curd faster in the winter season
and so on.
3. To keep the fast food in hot condition.

37
 CONVERSION OF CFC TO HC
SYSTEM

In changed system CFC (R-12) refrigerant is changed into HC

(blend of propane and isobutane) refrigerant due to some benefit.
So comparison of R-12 and HC mixture is given below.

6.1.Refrigerant R-12

Refrigerant R-12 probably has been the most widely used

of all the refrigerants. It is a safe refrigerant in that it is non-toxic,
non-inflammable, and non-explosive. Furthermore, it is a highly
stable compound that is difficult o break down even under extreme
operating conditions. However, if brought in contact with an open
flame or with an electrical heating element. R-12 will decompose
into highly toxic products.

Along with its safe properties the fact that R-12 condenses
at moderate pressure under normal atmospheric conditions and has

38
a boiling point of -21.6oF (-29.8oC) at atmospheric pressure makes
it a suitable refrigerant for use in high, medium and low
temperature application and with all three types of compressors.
When employed in conjunction with multistage centrifugal type
compressor, R-12 has been used to cool brine to temperature as
low as -80deg.C.

The fact that R-12 is oil miscible under all operating

condition not only simplifies the problem of oil return, but also
tends to increase the efficiency and the capacity of the system in
that the solvent action of the refrigerant maintain the evaporator
and the condenser tube relatively free of oils films, which
otherwise would tends to reduce the heat transfer capacity of these
two units.

Although the refrigerating effect per pound for R-12 is

relatively small compared with those of some of the other popular
refrigerants, this is not necessarily a serious disadvantage. Infact in
small systems, the greater weight of R-12 that must be circulated is
a decided advantage in that it permits closer control of the liquid.
In large systems, the disadvantage of the low latent heat value is
offset somewhat by a high vapour density so that the compressor
displacement required per Ton of refrigeration is not much greater

39
than that required for the other popular refrigerants. The power
required per ton of capacity also compares favorably with that
required for other commonly used refrigerants.

Some of the more common application for R-12 include

automotive air conditioning, home freezers and refrigerators, liquid
chillers, dehumidifiers, ice makers, water fountains and transport
refrigeration. Unfortunately, like R-11, R-12 has unusually high
ozone depletion potential and is being replaced by other
refrigerants. One frequent replacement refrigerant is R-134a and
HC.

6.2.Refrigerant R-134a

It is one of the leading candidates to replace R-12 in many of the

applications employing this refrigerant. It is an HFC and has a zero
ozone depletion potential and low green house effect. It is non-
inflammable and non-explosive and preliminary data indicate a
favorable toxicology as well as chemical stability within the

40
refrigerating system although it does have a relatively high affinity
for moisture.

The physical and thermodynamic properties of R-134a approach

those of R-12 closely enough to provide similar levels of
performance in system with evaporator temperature of -7 Deg. C
and above. For example, both the isentropic discharge temperature
and the horsepower required per ton of refrigeration nearly the
same for both refrigerants. Also with the saturation temperature of
-15.08 Deg. F at standard barometric pressure, evaporator
temperature of 0 Deg. F and below is practical without maintaining
a vacuum pressure on the low-pressure side of the system.

Also NBP of R-134a (-26.15) Deg. C is quite close to R-12’s NBP

(-29.8 Deg. C). Heat transfer coefficient is significantly higher for
R-134a than R-12. Depending on the temperature, the single-phase
increase varies from 27% to 37% for the liquid and 37% to 45%
for the vapor.

The two phase’s increases range from 28% to 34% in the

evaporator and from 35% to 41% in the condenser.

41
However there are still many unresolved issues related to its
compatibility. It should be noted that R-134a has relatively high
GWP. The use of oil in R-134a system requires a very stringent
quality control. It is not soluble in mineral oil.

The polyester based synthetic oil that is used with it should be

totally dry. This would be difficult considering the fact that
synthetic ester oils are 100 times more hygroscopic then mineral
oils.

Retrofitting an R-12 system with R-134a requires the following

changes:

 Compressor is changed in most of the cases.

 Capillary is changed.
 Filter drier is changed.
 Condenser size is increased.
 Flushing of mineral oil from the system is a difficult job and
takes time.

6.3.HC Refrigerant
These are designed to replace ozone depleting global-warming
refrigerant, HC Refrigerant Products are made of natural, organic

42
compounds – not a blend of pre-existing, chemically based
synthetic refrigerants, making them.

 Highly efficient
 Non-ozone depleting
 Non-corrosive
 Non-toxic
 Non-global warming
 Safe to use

In fact, HC Refrigerant Products can actually enhance the life and

performance of air-conditioning and refrigeration equipment.
Thanks to an anti-friction additive and their excellent thermal and
chemical stability, HC Refrigerant Products can help to improve
the performance and extend the service life of air conditioning and
refrigeration systems and components. This reduces energy
requirements and prevents system leakage. After more than 12
years of extensive testing, it’s clear that HC Refrigerant Products
provide more efficient performance than the man-made, synthetic
refrigerants they replace. HC Refrigerants Products are designed to
replace many environmentally harmful refrigerants currently in
use.

43
But because of their widely different N.B.P.s, neither R-290
(Propane) nor R-600a (Isobutane) can be used as drop-in
substitutes in place of R-12. However by mass a 50% R-290 +
50% R-600a mixture has exactly the same pressure as R-12. Its
volume refrigerating capacity is also the same. Hence, this mixture
is favored as a drop-in substitute.

In our system we are using HC blend (by mass a 50% R-290 +

50% R-600a mixture), which is a perfect refrigerant to replace R-
12 as it works as good as R-12 does. HC Refrigerants also
consume less power. These refrigerants do not react with materials
and works properly with mineral oils uses now days.

Properties of Propane/Isobutane blend (like care 30, ECFC-12,

Hichill-12, and EcoolPIB) are very much similar to R-12
refrigerant.

HC Refrigerants have low density so they are used 40% by mass of

R-12 in comparison to R-12; HC Refrigerants also absorb more
heat during evaporation.

Mass of HC blend = 0.4 * mass of R-12

Mass of HC blend = 0.45 * mass of R-134a

44
Suction pressure of HC is same as that of R-12 but discharge is
less by 1-2 bars.

Compressors, evaporator, condenser, refrigerant control devices

and pipe size selection using hydrocarbon tend to be virtually the
same design and same size as those used for conventional fluoro
carbon refrigerants that operate at similar pressure.

45
to knock while pumping down the low side, it should be stopped
for short time to allow the oil to settle down after which the
operation can be continue.

The refrigeration system should never be opened while

under vacuum, because air, dirt and moisture would quickly be
forced into the system by outside pressure. It is always advisable to
break the vacuum with refrigerant vapour.

8.4. Testing for Leakage:

After charging the system, it is necessary to test the entire

joint to make sure that they are leak proof. Test is necessary
because even a minute leak will cause a complete loss of the
refrigerant in a relatively short period.

There are two methods using for leakage testing in domestic

refrigerator.

1 Soap bubble test.

2 Halide torch test.

46
In soap bubble test the dry nitrogen gas or atm. Air are filled in the
piping and soap water are lapped on piping. At the place of leakage
the bubbles are formed.

In second method the intake tube of the halide (alcohol)

torch is brought near the leakage joint. Then the leakage gas will
enter into intake tube of the torch and gives a green hue, which is a
sure indication of refrigerant leak.

47
 SUMMARY

• Bacterial growth that causes food spoilage shows at low

temperature.

• Product temperatures above 45oF and below room

temperature are considered high temperature refrigeration.

• Product temperatures between 35oF and 45o F are considered

medium- temperature refrigeration.

• Product temperatures between 0oF to 10oF are considered

low-temperature refrigeration.

• Refrigeration is the process of removing heat from a place

where it is not wanted and transferring it to a place where it
makes little or no difference.

• One ton of refrigeration is the amount of heat necessary to

melt 1 ton of ice in 24 hr period or takes 288,000BTU in 1
min.

48
• The relationship of the vapour pressure and the boiling point
temperature is called the pressure/temperature relationship.

• A compressor can be considered a vapour pump. It lowers the

pressure in the evaporator to the desired temperature and
increase the pressure in the condenser to a level where the
vapour may be condensed to a liquid.
• The liquid refrigeration moves from the condenser to the
metering device where it again enters the evaporator.

• Refrigerants have a definite chemical makeup and are usually

designated with an “R” and a number for field identification.

• A refrigerant must be safe, must be detectable, must be

environment friendly, must have a low boiling point, and
must have good pumping characteristics.

• Refrigerant cylinders are colour coded to indicate the type of

refrigerant they contain.

• Refrigerants should be covered or stored while a refrigeration

system is being serviced, then recycled, if appropriate, or sent
to a manufacture to be reclaimed.

49
 PRECAUTIONS

1. Refrigerants should be stored in pressurized containers and

handled with care.

2. Do not apply pressure more then the prescribed value.

3. Goggles and gloves should be worm while transferring the

refrigerants from the container to the system and while doing
brazing.

4. Do not touch the compressor discharge line because you can

burn your finger.

5. All leakages must be properly checked.

6. Always work under an instructor or a supervisor.

50
 DRAWBACK

The major drawback of the system is that heating depends on

cooling. The temperature in the hot box depends on the cooling of
the refrigerator. More the value of cooling more the heat is
obtained in the hot box.

This hot box is very much successful where the cooling is

required for long period or where heavy cooling is required.

51
 CONCLUSION

In this project an extra facility is obtained in domestic refrigerator.

At large-scale production, very few amount of production cost is
increased (10% approx.) in comparison of extra facility. Due to
extra facility demand of the system will become double. This
system has cold as well as hot cabinet, so in both conditions (hot as
well as cold) this system can be used.

In this system the power consumption is same as in

domestic refrigerator (without hot cabinet). So extra facility of hot
cabinet is obtained without any power consumption, so operating
cost remains same as in domestic refrigerator. In this system heat
rejection in room is reduced so increment in room temperature
becomes less.

This system also involves conversion of CFC to HC. So

due to this system becomes eco-friendly. So it becomes more
suitable for the atmosphere because CGFC has the value of ODP

52
equal to one and high value of GWP but HC have the value of
ODP equal to zero and negligible value of GWP.

In this system some sub cooling of liquid refrigerant is also

existed. So when sub cooling is occurred the refrigerating effect is
increased and due to which COP of system is increased. In this
system practically small amount of compressor work is increased
due to increase in discharged line so due to which COP of the
system is decreased. So all of the above discussion results that in
future this system will become popular due to both facilities (hot
and cold cabinet) with very small amount of increase in
production cost of the system at large scale.

53
 FURTHER IMPROVEMENTS

Wide range of further improvements can be done on this project to

improve its working and efficiency. Some of the suggestions are as
follows:

Insulation of the hot box can be further improved.

Electronic temperature controller could be used to control

the temperature in the hot box.

The pipe carrying the gas from the compressor to the hot
box could be insulated and the rate of transfer of heat from
the outlet pipe could be increased that will lead to increase
in temperature in the heat box.

An additional fan can be used to cool the gas at the outlet.

54
 PROPERTIES OF CFC, HFC AND HC
REFRIGERANTS

Property, metric unit, CFC- HFC- R- HC

weight basis 12 134A 600A blend

Ozone Depleting Potential 1 0 0 0

(ODP)
Global Warming Potential 8500 1300 3 3
(GWP)
Boiling point at 1 atm.oC -29.8 -26.1 -11.8 -31.5
Specific heat of liquid at 0.99 1.45 2.49 2.54
30.oC, kj/kgK
Specific heat of vapour at 0.62 0.86 1.86 1.7
constant pressure at
o
30 C,Mj/kgK
Ratio of specific heat (Cp/Cv) 1.136 1.118 1.10 1.16
at 1 atm ,30oC
Density of liquid at 1292 1187 545 517
o 3
30 C,kg/m
Density of saturated vapour at 6.3 5.3 2.81 2.6
boiling point,kg/m3
Latent heat of vaporization at 165 217 362 405
boiling point, kj/kg
Thermal conductivity of liquid 0.07 0.08 0.098 0.1
at 20oC,W/moC
Thermal conductivity of 0.010 0.015 0.017 0.018
o o
vapour at30 C,1 atm, W/m C
Surface tension at 25oC,mn/m 8.5 8.4 9.55 8.6
Viscosity of liquid at 0.19 0.20 0.14 0.11
o
30 C,centipoise
Critical temperature, oC 112.04 101.06 135 113

55
Critical pressure (bar) 41.15 40.56 36.45 39.89
P P
2 1

V1 V5 V6

E V2 C
V O
A N
P D
O E
R COMPRESSOR N
A S
T O
O R
R
V3

V4
EV RECEIVER

Flexible
tube

Spring
balance

Refrigerant
cylinder

Fig: 8.1 Changing of refrigeration system

56
 TECHNICAL DATA

1. Compressor : 1/6HP,2850 RPM, Single phase,

1.1amp, 220 V, 50 hz.

2. Capillary : 0.82 mm(dia.)

3. Normal refrigerator charge : 60 gm

4. Refrigerant used : hydrocarbon mixture

5. Power consumption : 2 to 3 Kwh for 165 litre

6. Refrigerator capacity : 165 litre

7. Minimum evaporator temp : (-17± 2) 0C

8. Temperature in hill tray : 0 oC or below

9. Suction pressure : 4.5 psig

10. Discharged pressure : 180 psig

57
11. Insulation : glass wool

Temp. Density Thermal Thermal Specific Thermal Specific

diffusivity conductivity heat conductivity Heat

ToC Kg/m3 α x 103 K x 103 Cp K x 103 Cp kj/kgk

m2/hr. Kcal/m-hr.oC Kcal/kgoC W/mk

20 200 1.00 32 0.16 37.2 0.67

58
 INSTALLATION, CHARGING,
EVACUTION AND TESTING OF
DOMESTIC REFRIGERATOR

8.1. Installation

In installing the refrigeration system for commercial and

industrial purposes, the following few point must be noted.

The troubles in the refrigeration unit after installation come

under various heading such as no refrigeration, no continuous
running, a higher electric bill, poor refrigeration temp, frosted
suction line and so many.

The location of the condensing unit should be close to

various cabinets as possible in the multiple installation system. It is
always advisable to put it where it will be exposed to very low

59
temperatures. The location of considering unit is also governed by
the source of electric supply, water drainage.

Cooling coils should be carefully mounted and firmly

fastened. The cooling coils are usually fastened to the ceiling of the
cabinet. In few installations horizontal steel piping fastened to the
walls of the cabinet is used as supports for the coils.

The tubing of the installation in all cases should run

horizontally and vertically with neat bends as perfect radius as
possible. The tubing should not run near the sources of heat
because such sources of heat will cause poor refrigeration and low
efficiency of operation.

Tubing should not be placed in such a position, which will

come in the way of handling the articles. The compressor should
be placed in such a place that the noise of the compressor would
not disturb the occupants. It should as near to the suction line as
possible to avoid the superheat of the refrigerant along the tubing.

60
The position of the device should be as near to the cooling coils as
possible to avoid the cooling loss.

8.2. Charging

Charging a system refers to the adding of refrigerant to the

refrigeration system. The correct charge must be added for a
refrigeration system to operate as it was designed to and this is not
always easy to do. Each component in the system must have to be
added to the system in the vapour or liquid state by weighing,
measuring or using operating system charts.

Steps of charging refrigerant:

• Use dry nitrogen for pressure testing, test for leaks using
soap solution on each joint. The pressure of dry nitrogen
is between 150 to250pisg.

61
• Evacuate system using two stage vacuum pump to
vacuum of 500 to 1500 micron or lower of Hg (1000
micron = 1mm Hg)
• Always charge with correct amount of refrigeration by
weight.
(In our case weight of refrigerant = 60 gm.).

The systematic line diagram for charging in a domestic

refrigerator is shown in fig. It is necessary to remove the air
from the refrigeration unit before charging. First the valve
V2 is closed and pressure gauge P2 and vacuum V are fitted
as shown in fig. The valve V5 is also closed, valves V1 and
V3 are opened, the motor is started. Thus the air from the
condenser, receiver and evaporator is sucked through the
valve V1 and it is discharged into atmosphere through the
valve V6 after compressing into the compressor the vaccum
gauge V indicates sufficiently low vaccum when most of
the air is removed from the system. After removing the air,
the compressor stopped and the valves V1 and V6 are
closed and valve V5, V2and valve V7 of the refrigerant
cylinder are opened and then the compressor started.
Whenever the sufficient quantity of refrigerant is taken into

62
system, which will be noted on the spring balance as shown
in the figure, compressor is stopped. The valve V7 and V5
are closed and the valve V1 is opened. The refrigerant
cylinder is disconnected from the system. The pressure
gauge is used to note the pressure during charging the
system. The valve V1, V2, V5 and V6 are the integral parts
of the compressor.

8.3 SYSTEM EVACUATION:

Refrigeration systems are designed to operate with only

refrigerant and oil circulation inside them. When system are
assembled or serviced, air enters the system. Air contains
oxygen, nitrogen and water vapour, all for which are
detrimental to the system. Removing air and/or other non-
condensable gases from a system with a vaccum pump is
called degassing a system. Removing water vapour from a
system is known as dehydration. In the HVAC industry, the
process of removing both air and water vapour is referred to
as evacuation.

63
 Degassing + Dehydration = Evacuation

These gases cause two problems. The nitrogen is called

a non-condensable gas. It will not condense in the
condenser and move through like the liquid instead, it will
occupy condenser space that would normally be used for
condensing refrigerants. This will cause a rise in head
pressure, resulting in an increase in discharge temperature
and compression ratios, which cause unwanted
inefficiencies.

Air contains about 20% oxygen. Because

noncondensables in a system head pressures and discharge
temperatures to rise, this oxygen in the air will react with
refrigeration oil to form organic solids.

Purging:

Many times during the operation of the system, the air

leaks inside the system. It is necessary to remove the air
for maintaining the efficiency of the system. Owing to the

64
presence of air in the system, the high side pressure of the
condenser is increased. When this increase is 10% above
normal, it is necessary to remove the air from the system,
which is known as purging. During purging, the
compressor discharge valve V6 is intermittently opened
for few second at a time. Air and few grams of refrigerant
vapour escape under high-pressure side. A noticeable
pressure and temperature drop in the system occurs and
normal operating pressures are established. The refrigerant
is added from outside if excessive purging is occurred.

Pump Down of Refrigeration System:

If the refrigeration system is to be repaired or some

part of the system is not to be repared, then the refrigerants
must be pumped in to the receiver for the temporary
storage to do this, the liquid line shut off valve V4 and
compressor is started. The compressor pumps the entire
refrigerant into the receiver. The suction pressure reads
closed to zero the receiver inlet valve V2 is now closed
and the compressor stopped. The serviceman can open the
refrigerant system safely for repairs, as the refrigerant is

65
safely stored in the receiver. During the pumping down
process, the rapid decrease in the crankcase pressure
causes the refrigerant in the oil to vaporize. This causes
foaming, which will often result in the slugging of oil
through the valves of the compressor. This causes
knocking and if allowed to continue may damage the
compressor. If the compressor is heard to knock while
pumping the low side, it should be stopped for short time
to allow the oil to settle down after which the operation
can be continue.

The refrigeration system should never be opened while

under vacuum, because air, dirt and moisture would
quickly be forced into the system by outside pressure. It is
always advisable to break the vacuum with refrigerant
vapour.

8.4. Testing for Leakage:

After charging the system, it is necessary to test the

entire joint to make sure that they are leak proof. Test is

66
necessary because even a minute leak will cause a
complete loss of the refrigerant in a relatively short period.

There are two methods using for leakage testing in

domestic refrigerator.

2 Soap bubble test.

2 Halide torch test.

In soap bubble test the dry nitrogen gas or atm air is filled
in the piping and soap water is lapped on piping. At the
place of leakage the bubbles are formed.

In second method the intake tube of the halide (alcohol)

torch is brought near the leakage joint. Then the leakage
gas will enter into intake tube of the torch and gives a
green hue, which is a sure indication of refrigerant leak.

67
 BIBLIOGRAPHY

1.“Arora & Domkundwar” a text book of refrigeration and air

conditioning fourth edition year 2002.
2.“ Dossat R.J.” a textbook of refrigeration and air conditioning year
first reprint edition 2003.
3.“Khurmi & Gupta” a textbook of refrigeration and air conditioning
second edition year 2003.
4. Website: www.dupoint.com
5. Website: www.hcrefrigerant.com

68
69