Power Generation Using Waste Heat From Condenser of Vapour Compression Refrigeration System
Power Generation Using Waste Heat From Condenser of Vapour Compression Refrigeration System
Power Generation Using Waste Heat From Condenser of Vapour Compression Refrigeration System
https://doi.org/10.22214/ijraset.2020.31814
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
Volume 8 Issue X Oct 2020- Available at www.ijraset.com
Abstract: In this work, a detailed analytical study of the topic power generation using waste heat from condenser of vapour
compression refrigeration system were done. Here, a phase change material (PCM) cycle is incorporated along with basic
vapour compression refrigeration system. Enormous amount of waste heat energy is released from the conventional vapour
compression refrigeration system to the atmosphere through condenser. This project conduct the work on 200 TR Chiller of
R410A refrigerant. For 200 TR chiller, amount of 739.7 kW of heat energy is liberated to atmosphere with refrigerant mass flow
rate of 5.22 kg/s. Here the waste heat that liberated from the condenser of vapour compression refrigeration system is absorbed
by colourless phase change material (PCM), Trichlorouoromethane, also called freon-11, CFC-11, or R-11. It is non-flammable,
noncorrosive, non-explosive and sweetish odor liquid that boils at room temperature. Mass flow rate of R11 fluid used in this
project is 3.778 kg/s. First, liquid form of R11 PCM is converted into superheated gaseous form by absorbing the latent heat and
sensible heat from the condenser of vapour compression refrigeration system. This gaseous PCM passes through turbine, hence
turbine rotates and power is develops. The pressure of PCM reduces when it passes through turbine. The condition of PCM at
the exit of turbine is of dryness fraction of 0.85. This PCM is pass through the condenser and get cooled by liberating heat
energy to atmosphere. By liberating heat energy it become saturated liquid. Then PCM is pumped by external pump driven by
part of power from the turbine. Then this PCM is again go to heat absorbing medium to absorb waste heat from vapour
compression refrigeration system, hence cycle is completed. The ultimate goal of this project is analysis of the power develop by
the turbine through this. Here, shell and tube heat exchanger is used for both heat absorbing medium and heat releasing
medium for R11. For heat absorbing medium R410a is used as shell side fluid and R11 is used as tube side fluid. For heat
releasing medium, water or air is used as shell side fluid and R11 is used as tube side fluid. In this project, it is used a centrifugal
pump for pumping application.
Keywords: PCM, R410A, Trichlorofluoromethane, Heat exchanger, Turbine.
I. INTRODUCTION
There is an enormous amount of waste heat energy, that released from the condenser of vapor compression refrigeration system and
this waste heat energy is simply dumped into the environment even though it could still be reused for some useful and economic
purpose. Amount of waste heat energy liberated from condenser of vapor compression refrigeration system is 25% more than heat
energy absorbed by refrigerant on evaporator at which cooling creates. Similarly large quantity of heat energy is generated from
Boilers, Kilns, Ovens and Furnaces. If some of this waste heat could be recovered, a considerable amount of primary fuel could be
saved. Waste heat recovery and utilization is the process of capturing and reusing waste heat for useful purposes. Not all waste heat
is practically recoverable. However, much of the heat could be recovered and this waste heat energy can be utilized for power
generation and other useful purpose such as preheating of combustion air, pre-heating boiler feed water or process water, sanitary
hot water, preheating air for processes, space heating in winter, Reheat coils for humidity control, preheating water for washing
purposes. In this project, an attempt has been made to power generation by utilizing waste heat energy from condenser of
refrigerator. The main objective of this project is to generate power using waste heat recovery system of industrial chiller. Yinhai
Zhu and Peixue Jiang present a paper on hybrid vapor compression refrigeration system with an integrated ejector cooling cycle in
2012. Laia Miro et al., presented a paper on Thermal energy storage (TES) for industrial waste heat (IWH) recovery: A review in
2016. Alexandre Bertrand et al., presented a paper on In-building waste water heat recovery: An urban-scale method for the
characterization of water streams and the assessment of energy savings and costs in 2017. Waltteri Salmi et al., developed a concept
of energy source for an absorption refrigeration system using waste heat of ship in 2017. Haoxin Xu et al., conduct a study on
Application of material assessment methodology in latent heat thermal energy storage for waste heat recovery in 2017.
In this project, power is develop by Rankine cycle that is driven by waste heat energy from condenser. Waste heat that is absorbed
by R11 PCM and the Liquid R11 is converted into gaseous form. Then it passes through turbine. Then turbine rotates and power can
be derived.
The minimum dryness fraction at turbine outlet is 0.85 and this vapor/liquid mixture goes through condenser and release the heat
energy to form saturated liquid. From this it is pressurized by pump and returns the starting position and cycle continuous. In this
project, it is planned to study the case of chiller of 200 TR capacity.
V. SELECTION OF PCM
Fig. 4 List of PCMs, Currespounding Boiling point and Latent heat at atmospheric pressure
From this list, R11 (Trichloro Fluro methane) is selected for the following properties. It is the widely used refrigerant, because of its
high boiling point (compared to most refrigerants), it can be used in systems with a low operating pressure, making the mechanical
design of such systems less demanding than that of higher-pressure refrigerants R-12 or R-22. It is nonvolatile and not flammable
1) Tube Design (Standard sizes from Tables): R11 fluid, Carbon Steel, Tube outside diameter, (do) =19.05 mm, Tube length
(L)=4.877 m, Thickness= 0.889 mm(for Gauge 20), Tube Pitch=1.25 X do=23.81 mm
2) Shell Design (Standard sizes from Tables): R410A fluid, Carbon steel pipe, Nominal Shell diameter = 0.35 m, Thickness=
7.92mm for SCH 20 pipe, Shell side inside diameter, (Ds) =0.334 m, Tube to Baffle hole diametrical clearance, (dtb) =0.8 mm,
Shell to Baffle diametrical clearance, (dsb) =3.2 mm (for Ds=0.35 m diameter) Baffle spacing(Lbc) =[Minimum: 1/5 Ds or 51
mm ,Maximum: from Table ] = [0.0668 m, 1.524 m]=0.3 m, Baffle cut length(lc) =0.0835 m , Inlet Baffle spacing(Lbi )=0.32 m.
Outlet Baffle spacing(Lbo ) =0.32 m, Diameter of the outer tube limit(Dotl)=0.32 m, Width of bypass lane (ωp) =19 mm,
Longitudinal Tube pitch(Xl) =17 mm, Transverse tube Pitch(Xt) =35 mm, Number of tubes (Nt) =125
For window section(θb) =2 COS- (1-2 lc / Ds ) =2.094’=1200, Gross Window Area(Afrw ) =Ds2/4 (θb/2- (1-2 lc / Ds ) SIN(θb/2) = 0.0171
m2, Baffle cut angle(θctl) =2 COS- (Ds -2 lc / Dctl ) =1.965’ =112.60, Fraction Fw of total tubes in the window section(Fw) = θctl/(2Π)-
SIN(θctl)/(2Π) =0.1658, Number of tubes in window section(Ntw) =Fw x Nt = 21 nos, The net flow area in one window section(Aow)
= Afrw -Afrt = 0.0171-5.878 x 10-3 = 0.01122 m2, Hydraulic Diameter (Dhw) =4 Aow/( Π do Ntw + Π Ds (θb/2 Π )) =0.0283 m
For Cross Flow, Number of Effective tube rows in cross flow in each window(Nrcw) = 0.8/Xl (lc-1/2(Ds-Dctl) = 3, Number of tube
rows crossed during flow through one cross flow section between the baffle tips (Nrcc) =(Ds-2lc)/Xl=(0.334-2 x 0.0835)/(17 x 10-3)
=10, Cross flow area for the 45o tube layout bundle(Aocr )= Lbc [ Ds – Dotl +2 Dctl /Xt (Pt – do ) =0.02877 m2, Number of Baffles(Nb)
= (L – Lbi –L bo )/L bc +1 =(4.877-0.3-0.32)/0.3+1=15.12=15.
Tube to Baffle Leakage Area (Aotb ) = Π do dtb Nt /2 (1-Fw )=2.5 x 10-3 m2, Shell to Baffle Leakage Area (Aosb) =Π Ds dsb /2 (1-θb/2
Π)=1.11 x 10-3 m2
3) Shell side heat transfer Coefficient: Thermal Conductivity of tube wall = 53.6 W/mK, Tube side fluid = R11, Shell Side fluid
=R410 A, mt =3.778 kg/s, ms = 5.22 kg/s, Shell side mass velocity (Gs ) = ms /Aocr = 181.43 kg/m2 s, Shell side Reynolds
number (Res ) = Gs d0 / µs = 181.43 x 0.01905/(92 x 10-6 ) , Res =37567, Nus = 1.04 Res 0.4 Prs0.36 (Prs / Prw ) 0.25 , Prs = 1.05,
Here Prs =Prw, Nus = 71.58
Shell side fluid is condensing, So hid =0.943 ( k 3 ρ 2 g L/ (Ts - Tt) µs ) 0.25 = 159. 5W/m 2 K, Baffle Cut and spacing effect
correction factor(Jc)= 0.55+ 0.72 Fc = 0.55 + 0.72 x 0.6684 = 1.0312, where Fc = 1- 2Fw, rs = Aosb / (Aosb + Aotb ) =0.3074 , rlm =
(Aosb + Aotb ) / Aocr = 0.1254, Tube-to-baffle and baffle-to-shell leakage factor (Jl) = 0.44 (1- rs ) + (1-0.44 (1- rs ) ) e –(2.2 rlm) =
0.832, Unequal baffle spacing factor, Js, Li+ = Lbi/Lbc = Lo+= Lbo/Lbc =0.32/0.3 =1.0667, n=0.6 for turbulent flow, Js = (Nb - 1
+(Li+ ) 1-n +(Lo+ ) 1-n ) / (Nb - 1 +(Li+ ) +(Lo+ ) ), Js = 1.060, Adverse temperature gradient factor , Jr =1 for Re>100, Shell side
heat transfer coefficient hs = Jc Jl Js Jr hid = 1.0312 X 0.832 X 1.060 X 1 X 159.5 = 145.055 W/m 2 K
4) Tube side heat transfer Coefficient: Number of tube (Nt ) = 125, Tube-side flow area (Aot ) =Π/4 x di2 Nt = 0.0292 m2 , Ret = mt
x di /( Aot µt)) = 196891, Nu = 0.024 Re0.8 x Pr0.4 = 657 , Heat transfer coefficient = ht = Nu x K / di = 408 W/(m2 K)
B. Analysis of Turbine
ϒ =1.1391, R=8314/137.368=60.5 J/kg, T2=50O C =323 K, P2=2 bar =2 X 105 Pa , ρ2= 10.23 kg/m3, Take d2=0.18 m, m= ρ R T =
3.778 kg/s. 3.778 = 10.23 X 0.182 X C, C= 11.4 m/s. M2= C/a =11.4/ (1.1391 X 60.5 X 323 ).5 = 0.0764
Stagnation Temperature(To ) , Stagnation Pressure (Po), Corresponding density (ρo ), To / T = 1+ (ϒ -1)/2 M2 , Po / P = (1+ (ϒ -1)/2
M2 )ϒ/(ϒ-1)., ρo / ρ = (1+ (ϒ -1)/2 M2 )1/(ϒ-1), Substitute condition at inlet of Nozzle
To =323.13 K, Po=2.00704 bar, ρo = 10.4 kg/m3, for the condition at exit is sonic ,Substitute M=1
We get T2’=302.11 K, P2’ =1.153 bar, ρ2’=6.395 kg/m3
m= ρ2’ X A2’ X C2’ =3.778 kg, C2’= (1.1391 X 60.5 X 302.11).5 = 144. 3 m/s, Substituting we get, A2’= A*= 4.09 X 10-3 m2, d2’= 7.22
cm
Vr2 = 78.71 m/s , Vw2 = Vr2 cos(Φ)- u2= 8.273 m/s, We assume material of bucket as stainless steel of grade 409, Vr2 sin(Φ)= Vf2
=26.92 m/s, V2 = Velocity of Jet at Outlet = ((Vf2)2+ (Vw2)2)0.5 = 28.162 m/s, tan(β) = Vf2 / Vw2 = 26.92 / 8.273, β = 72.910
D. Design of Condenser
Term and pictorial representations are same as that in section design of Heat exchanger for exchanging heat from condenser to heat
absorbing chamber
Baffle cut length(lc) =0.0785 m, Lbi=0.3 m, Lbo=0.3 m, Dotl=0.3 m, ωp =17 mm, Xl=15 mm, Xt=27 mm, Number of tubes (Nt ) =160,
Gross Window Area( Afrw) =0.01514 m2, Baffle cut angle(θctl) =2 COS- (Ds -2 lc / Dctl ) =1.9547 =112.90, Number of tubes in window
section(Ntw) = Fw x Nt =0.1644 x 160 = 26.304 = 26 nos, Area occupied by tubes in window section (Afrt) = Π/4 do2 Fw x Nt =5.216 x
10-3 m2, The net flow area in one window section(Aow) = Afrw -Afrt = 0.00992 m2, Hydraulic Diameter ( Dhw ) =4 Aow/( Π do Ntw + Π
Ds (θb/2 Π )) =4 X 0.00992/( Π x 0.01589X26+ Π x 0.314 x 2/3 Π /(2 Π)) =0.0244 m, Number of Effective tube rows in cross flow
in each window (Nrcw) = 0.8/Xl (lc-1/2(Ds-Dctl) =3, Number of Baffles (Nb) = (L – Lbi –L bo )/L bc +1 =13. Bypass flow Area, Aobp =L
-3 2
bc (Ds-Dotl +0.5 Np ωp ) =5.625 x 10 m .
Fraction of cross flow area available for flow bypass (Fbp) = Aobp/Aocr =0.2305, Tube to Baffle Leakage Area (Aotb) = Π do dtb Nt /2
(1-Fw ) = 2.67 x 10-3 m2, Shell to Baffle Leakage Area (Aosb) =1.0523 x 10-3 m2
E. Design of Pump
Work done by the centrifugal pump on liquid
In case of centrifugal pump, work is done by impeller on liquid. Work done impeller = m (h1-h4), m = 3.778 kg/s, h1 = h4 + Cp (T1 -
T4), Work input to pump, Wp = m(h1 - h4) = m Cp (T1 - T4) = 8.207 kW
For best efficiency, the liquid enters the impeller radially at inlet, which means absolute velocity makes an angle of 900 with the
direction of motion of impeller at inlet, u1 = Tangential velocity of impeller at inlet = Π D1 N /60
u2 = Π D2 N / 60, V1 = Absolute velocity of liquid at inlet, Vr1 = Relative velocity of liquid at inlet, α = Angle made by absolute
velocity (V1) at inlet with direction of motion of vane, θ = Angle made by relative velocity (Vr1) at inlet with the direction of vane.
V2, Vr2, β, Φ are corresponding values at outlet.
As the liquid enters the impeller radially, means absolute velocity of water at inlet in the radial direction, α = 900, Vw1 = 0. Work
done by impeller on liquid per second per unit weight of liquid striking per second, Wp in m of liquid = -(Work done in case of
turbine) = Wp = 1/g (Vw2 u2 - Vw1 u1) , d1 = diameter of suction pipe = 7 cm =0.07 m, D2 = diameter of impeller at outlet = 0.8 m, D1
= diameter of impeller at inlet = 0.2 m, N = 1625.15 rpm , u2 = 68.27 m/s, Vw2 = 0.035 m/s, α= 900, θ = 2.240, β = 86.970, Diameter
of delivery pipe (d2 )= 6.9 cm
Specific speed of a centrifugal pump(Ns) = N(Q)0.5/(Hm)3/4, Q = A1 V1 = 2.57 x 10-3 m3 , Hm = 221.43 m of liquid, N = 1630 rpm,
Substitute these values in equation Ns = N(Q)0.5/(Hm)3/4. We get Ns = 1.44 rpm, Specific speed of pump = 1.44 rpm
REFERENCES
[1] Yinhai Zhu and Peixue Jiang. Hybrid vapor compression refrigeration system with an integrated ejector cooling cycle, International journal of refrigeration,
2012.
[2] Laia Miro, Jaume Gasia, and Luisa F Cabeza. Thermal energy storage (tes) forNindustrial waste heat (iwh) recovery: a review, Applied Energy, 2016.
[3] Kevin Merlin, Jerome Soto, Didier Delaunay, and Luc Traonvouez. Industrial waste heat recovery using an enhanced conductivity latent heat thermal energy
storage, Applied Energy, 2016.
[4] Alexandre Bertrand, Riad Aggoune, and Francois Marechal, In-building waste water heat recovery: An urban-scale method for the characterisation of water
streams and the assessment of energy savings and costs, 192, 2017.
[5] Waltteri Salmi, Juha Vanttola, Mia Elg, Maunu Kuosa, and Risto Lahdelma, Using waste heat of ship as energy source for an absorption refrigeration system,
Applied Thermal Engineering, 2017.
[6] Haoxin Xu, Alessandro Romagnoli, Jia Yin Sze, and Xavier Py, Application of material assessment methodology in latent heat thermal energy storage for
waste heat recovery, Applied Energy, 2017.