1.design & Analysis of AC System For Heavy Vehicles Using Exhaust Heat

Table of Contents
Abstract...........................................................................................................................................................1
1. Introduction ............................................................................................................................................2
1.1 PROJECT PREVIEW .................................................................................................................2
1.2 PROJECT INSPIRATION: ........................................................................................................7
1.3 Field Of Work:- ..........................................................................................................................12
2. Rational & Scope of the project ...........................................................................................................13
2.1 Intentions behind the study .......................................................................................................13
2.2 Scope of the Capstone project ...................................................................................................13
3. Objective & Hypothesis Of The Project ................................................................................................14
4. Complete Work Plan.............................................................................................................................16
4.1 Decision of the topic of Capstone Project.................................................................................16
4.2 Design of generator ....................................................................................................................20
4.2.1 Exhaust Pipe ...........................................................................................................................21
4.2.2 Cylindrical case to hold ammonium hydroxide...................................................................22
4.2.3 Aluminium fins .......................................................................................................................22
4.3 Retrieval of Material ..................................................................................................................26
4.4 Fabrication ..................................................................................................................................27
4.4.1 Sheet Metal Workshop ..........................................................................................................27
4.4.2 Machine Workshop ................................................................................................................27
4.4.3 Welding Shop .........................................................................................................................27
4.5 Analysis .......................................................................................................................................28
4.5.1 Water Heating Test ................................................................................................................28
4.5.2 Ammonium hydroxide heating test in chemistry lab ..........................................................28
4.5.3 Comparison of test results with actual conditions...............................................................28
5. Research & Experimental Work Done ..................................................................................................29
5.1 Test to check the quality of exhaust heat .................................................................................36
5.2 Test to check the heat required for ammonia vapors formation ...........................................39
5.3 Relate the data collected in both experiment ...........................................................................41
6. Expected Outcomes..............................................................................................................................43
7. Result & Discussion ..............................................................................................................................45
8. Conclusion ............................................................................................................................................47
References:....................................................................................................................................................48
Abstract
The topic of our study is “Design & Analysis of Air Conditioning
System for heavy vehicles using their exhaust heat”.
Air conditioning is a tedious job to do when it comes to heavy

vehicles like buses and trucks. The installation cost is not a problem but the
operating cost is not so economical which is why these AC systems are not
famous in heavy trucks.
The only way to improve the AC System of vehicle so that we could

enjoy conditioned air without compromising with the mileage is the replacement
of Compressor. And this is what our project is all about.
Swarnandhra Institute of Engineering & Technology Page | 1

1. Introduction
First of all in this topic we will discuss in detail that what our project
is all about. We will talk about the inspiration of the idea which led us to work on
this project and what improvements we decided to make in the available system.
1.1 PROJECT PREVIEW

The topic of our study is “Design & Analysis of Air Conditioning
System for heavy vehicles using their exhaust heat”.
Air conditioning is a tedious job to do when it comes to heavy

vehicles like buses and trucks. The installation cost is not a problem but the
operating cost is not so economical which is why these AC systems are not
famous in heavy trucks.
Where is the problem:-
The very first engine (A Stem Engine) was invented by James Watt.
It was a huge external combustion engine and its efficiency was not so
appreciable, only 35%.
After that tremendous improvements were done in this field of

engineering and at last we got these super compact latest internal combustion
engines running on vapours of Diesel and Gasoline efficiently, comparative to
the steam engine.
But the efficiency of modern engines is also somewhere in between

30% to 40 % only.

That means we utilize only 2/5 parts of the total fuel that we burn
and the rest of the energy is wasted.
Now talking about heavy trucks, the efficiency of these heavy duty
vehicles is way more less than the other vehicles we use. Reason behind this is
the way we use them. They are used for Transporting goods, Mining activities
and various other hard jobs.
And meanwhile a lot of waste heat is generated which does nothing

other than raising the body temperature of driver sitting inside the vehicle and is
also a cause of global warming.
Although the driver has not paid any extra money for air
conditioning but he deserve it.
At the same time we cannot compromise with the mileage of trucks

as it is already very less. So what can be the solution to this problem?
We need to take care of the standard conditions inside the truck cabin
for the easy survival of driver but we cannot compromise with the efficiency of
vehicle.
Why is mileage an issue for trucks?
A number of people don't realize that turning on the air conditioning

actually reduces the number of miles per gallon of your car. There is energy used
in removing the heat and moisture from the air in the car, and this consumes petrol
because of the extra engine load.
The AC systems that we are using nowadays in vehicles are

dependent on the energy produced by the engine of the vehicle and therefore it
reduces the efficiency of the engine.

We use them in cars because their mileage is enough to run one extra
machine (AC System).
But when it comes to the trucks, running an AC System will leave it

with only few kilometers of mileage as its efficiency is very less compared with
other small vehicles. So it is believed that air conditioning a truck is not worth it.
But there is something that can be changed about the AC Systems

which will make them common in heavy duty trucks too. This can be done by
utilizing the waste developed by the engine.
The only thing you get for free in a car is heat. The engine is always
producing heat whenever it's running, whatever you don't use to warm up the
cabin just goes outside through the radiator and exhaust manifold in the form of
hot flue gases.
Everything else uses up gasoline. All the energy in your car comes
from the engine, either directly in the form of mechanical energy, or indirectly in
the form of electricity (which is made from mechanical energy by the alternator).
The engine's job is simply to rotate a shaft. That shaft connects to

the transmission and then to the wheels, but it also connects to some belts that
turn your alternator, water pump, and air conditioner compressor, and maybe one
or two other things. The AC compressor is connected through a clutch, so when
it's not in use, it'll disengage from the engine and use very little power - but when
it's turned on, the engine has to work harder because it's turning more stuff.
When you turn on the radio or cigarette lighter, you're also using up
a little more gasoline.
Every extra electrical load makes the alternator a little harder to turn,
which means the engine has to work a little harder. However, the air conditioner
uses a lot more power than any other accessory. We can probably see a 2-5 miles
per gallon difference if we leave the AC on all the time.
How can we use the waste heat (hot gases coming out of exhaust manifold)
of engine for air conditioning?
Before we discuss on how to utilize waste heat to run AC System,

we should know about working of normal AC System being used in vehicles at
present.
Working of Conventional AC System:
Air conditioning like it says 'conditions' the air. It not only cools it down,
but also reduces the moisture content, or humidity. All air conditioners work the
same way whether they are installed in a building, or in a car. The fridge or freezer
is in a way an air conditioner as well. Now we will discuss the main components
of conventional AC Systems of mobile vehicle and their functions.
Air conditioning's main principles are Evaporation, Condensation,

Compression and Expansion. And we use different components to perform these
different processes.
Evaporator: The evaporator is another device that looks similar to a car
radiator. It has tubes and fins and is usually mounted inside the passenger
compartment. As the cold low-pressure refrigerant is passed into the evaporator,
it vaporizes and absorbs heat from the air in the passenger compartment. The
blower fan inside the passenger compartment pushes air over the outside of the
evaporator, so cold air is circulated inside the car. On the 'air-side' of the
evaporator, the moisture in the air is reduced, and the 'condensate' is collected and
drained away.
Compressor: The compressor is the work horse of the air conditioning

system, powered by a drive belt connected to the crankshaft of the engine. The
main function of the compressor is to increase the temperature and pressure of
the refrigerant vapours.
This is done so that hot vapours will lose large amount of heat in condenser
and we will get liquefied from of refrigerant ready to absorb heat in the next cycle.
When the air-conditioning system is turned on, the compressor pumps

refrigerant vapour under high pressure to the condenser.
Condenser: The condenser is a device used to change the high-pressure

refrigerant vapor to a liquid. It is mounted in front of the engine's radiator, and it
looks very similar to a radiator. The vapour is condensed to a liquid because of
the high pressure that is driving it in, and this generates a great deal of heat. The
heat is then in turn removed from the condenser by air flowing through the
condenser on the outside.
Receiver: The now liquid refrigerant moves to the receiver-dryer. This is

a small reservoir vessel for the liquid refrigerant, and removes any moisture that
may have leaked into the refrigerant. Moisture in the system causes havoc, with
ice crystals causing blockages and mechanical damage.
Expansion Valve: The pressurized refrigerant flows from the receiver-
drier to the expansion valve. The valve removes pressure from the liquid
refrigerant so that it can expand and become refrigerant vapour in the evaporator.
Refrigerant: The fluid that passes around the whole system is the
refrigerant. The refrigerant can evaporate at a low temperature, and then condense
again at a higher pressure. In the bad old days, R-12 was the refrigerant used in
almost all cars. It was widely available, however it was found to be a contributor
to the hole in the earth's ozone layer as it was a chlorofluorocarbon (CFC). These
refrigerants were discontinued, and all cars after 1996 use a non-CFC fluid called
R-134A which is kinder to the environment.
Which of these components consume the maximum energy from the

engine?
Yes, it is Compressor. So the only way to improve the AC System of

vehicle so that we could enjoy conditioned air without compromising with the
mileage is the replacement of Compressor. And this is what our project is all
about.
1.2 PROJECT INSPIRATION:

The main motto of our project in energy conservation. During winters we
have been using the heat of radiator and exhaust for heating the cabin of vehicles
which is one way of conserving energy as we are utilizing waste heat but during
summers we use the AC system to cool the cabin which puts extra load on engine
and as a result the total work produced by the engine divides up though we have
waste heat available at the exhaust.
First law of Thermodynamics:- It states that the heat cannot be changed

into work completely.

A part of it is wasted or drained into sink.
But since the invention of very first engine we have been trying to reduce
this waste heat and convert it into useful work and by doing this we have
developed some very efficient engines.
So we decided to do the same, obviously we cannot increase the efficiency

of the engine any more but we can use the waste heat so that we don’t have to
split the energy produced by the engine.
Therefore our project is based on using the exhaust heat for air conditioning
the cabin of the vehicle.
Source of Inspiration:-
In industries VAPOUR ABSOPRTION REFRIDGERATION SYSTEM

are being used for air conditioning purpose and its principle of working is
absolutely similar to what we are trying to do in our project. VARS uses the heat
to produce refrigeration effect in industries. The source of heat is either fuel
combustion or electrical heating. But sometimes it also uses the waste steam from
the power plants and uses it for heating purpose. And that’s where we got an idea
from to make a small change in the AC System so that its operating cost could be
reduced to minimum.
To understand this concept in a better way we should have a look over

VAPOUR ABSORPTION REFRIGERATION SYSTEM and its working.
VAPOUR ABSORPTION REFRIGERATION SYSTEM (VARS):-
A vapor absorption chiller machine (VAM) is a machine that produces

chilled water using a heat source rather than electrical input as in the more

familiar vapor compression cycle. It seems unreasonable that cooling can be
achieved with heat, but that is what occurs within an absorption chiller.
Both vapor compression and absorption refrigeration cycles accomplish

the removal of heat through the evaporation of a refrigerant at a low pressure and
the rejection of heat through the condensation of the refrigerant at a higher
pressure. The basic difference is that an electric chiller employs a mechanical
compressor to create the pressure differences necessary to circulate the refrigerant
whereas the absorption chillers use heat source and do not use a mechanical
compressor. The differences cause an absorption system to use little to no work
input, but energy must be supplied in the form of heat. This makes the system
very attractive when there is a cheap source of heat, such as solar heat or waste
heat from electricity or heat generation.
Absorption chillers have recently gained widespread acceptance due to

their capability of not only integrating with cogeneration systems but also because
they can operate with industrial waste heat streams.
What is Absorption?
Comparing the absorption refrigeration cycle with the more familiar vapor
compression refrigeration cycle is often an easy way to introduce it.
Vapor Compression Cycle

In the vapor-compression refrigeration cycle, refrigerant enters
the evaporator in the form of a cool, low-pressure mixture of liquid and
vapor (4). Heat is transferred from the relatively warm air or water to
the refrigerant, causing the liquid refrigerant to boil. The resulting
vapor (1) is then pumped from the evaporator by the compressor, which
increases the pressure and temperature of the refrigerant vapor.
The hot, high-pressure refrigerant vapor (2) leaving the
compressor enters the condenser where heat is transferred to ambient
air or water at a lower temperature. Inside the condenser, the refrigerant
vapor condenses into a liquid. This liquid refrigerant (3) then flows to
the expansion device, which creates a pressure drop that reduces the
pressure of the refrigerant to that of the evaporator. At this low
pressure, a small portion of the refrigerant boils (or flashes), cooling
the remaining liquid refrigerant to the desired evaporator temperature.
The cool mixture of liquid and vapor refrigerant (4) travels to the
evaporator to repeat the cycle.
Much like in the vapor compression cycle, refrigerant in the
absorption cycle flows through a condenser, expansion valve, and an
evaporator. However, the absorption cycle uses different refrigerants
and a different method of compression than the vapor compression
cycle.

Vapor Absorption Cycle
Absorption refrigeration systems replace the compressor with a generator

and an absorber. Refrigerant enters the evaporator in the form of a cool, low-
pressure mixture of liquid and vapor (4). Heat is transferred from the relatively
warm water to the refrigerant, causing the liquid refrigerant to boil. Using an
analogy of the vapor compression cycle, the absorber acts like the suction side of
the compressor—it draws in the refrigerant vapor (1) to mix with the absorbent.
The pump acts like the compression process itself— it pushes the mixture of
refrigerant and absorbent up to the high-pressure side of the system. The
generator acts like the discharge of the compressor—it delivers the refrigerant
vapor (2) to the rest of the system.
The refrigerant vapor (2) leaving the generator enters the condenser, where
heat is transferred to water at a lower temperature, causing the refrigerant vapor
to condense into a liquid. This liquid refrigerant (3) then flows to the expansion
device, which creates a pressure drop that reduces the pressure of the refrigerant
to that of the evaporator. The resulting mixture of liquid and vapor refrigerant (4)
travels to the evaporator to repeat the cycle.

1.3 Field Of Work:-
As discussed above, all the parts of the Vapour Compression

System and the VARS are same except the compression component,
therefore our field of work is design and analysis of the system that
will extract the heat from the flue gases flowing out of exhaust
manifold and use it for heating the aqueous solution of refrigerant to
produce ammonia vapour which can be used for air conditioning of
cabin of vehicle.
All other parts of the AC system are already available and the only
innovative aspect of this project is the design of heat exchanger cum
generator. Hence we declare it as our field of work in the Capstone
Project.

2. Rational & Scope of the project
2.1 Intentions behind the study
The main intention behind the project work is Conservation Of Energy.

By making this project we are trying to utilize the waste heat emitted by the
engine for the cooling purpose of the passenger compartment. This will help to
reduce the extra burden form the engine and we will get air conditioning in big
vehicles at minimum operating cost.
2.2 Scope of the Capstone project
It sounds strange that we are trying to produce cooling effect using heat of
engine; the same heat that puts the driver on sweating mode but if our project is
a Success, the whole scenario of air conditioning in big vehicle (Trucks, Buses)
may change.
Scope:-
It could be used in
The cooling system of transportation vehicle i.e. trucks, buses etc.
The air conditioning system of mining trucks, cranes and JCBs.
The air conditioning of steamrollers used for making roads.
And in all the vehicles where ample amount of waste heat is generated and Air
Conditioning is required.

3. Objective & Hypothesis Of The Project
The only objective of the project work is to alter the present AC System of
vehicle by removing its compressor which is the maximum power consuming
component in the system and replace it with the Heat Exchanger Cum Generator
which instead of putting extra load on engine will absorb the heat from waste flue
gases and produce ammonia vapours which will produce cooling effect in the
passenger’s compartment.
By doing this we will not use the useful energy of the engine but at the
same time can enjoy the cooling effect by just utilizing the waste heat.
BEFORE --This is being practiced.

AFTER— This is what we are trying to do.

4. Complete Work Plan
In this section we will discuss that how we planned the things and then
completed all the jobs step by step:-
4.1 Decision of the topic of Capstone Project
Our project work is to design and analyze a device that will extract
the heat (waste heat) from the exhaust gases of the vehicle and will use it to
produce vapours of ammonia by heating the Ammonium Hydroxide inside to
which will be used to produce cooling effect in the passenger cabin of vehicle.
Let us call it Generator as we do in the VARS.
There were certain reasons which lead us to do this project:-
1. First of all, this project is related with the conservation of energy and hence
is one of the best options to do a project on and secondly it’s a very unique
project in itself. And this project has various plus points such as.
2. It is always seen that whenever we switch on the AC of our vehicle then
the mileage of the vehicle decreases which leads to higher consumption of
fuel. It won’t be a problem anymore.
3. We were focused for not to use some external energy to run the A.C. We
don’t have to as we are using waste heat as a source of power.
4. Heavy vehicles produce large amount of heat so it is easier to run this
system on it.

5. Its applications are possible in transportation vehicles like trucks, buses
etc. so it can be a nice replacement for normal air conditioning system at
comparatively low cost than Vapour Compression System.
Our project is based on vapour absorption refrigeration system. And the

currently being used system is based on Vapour Compression System. SO let us
see the comparison of the vapor absorption cycle and vapor compression cycle.
1. The amount of power required: The compressor of the vapor
compression cycle requires large quantities of power for its operation and
it increases as the size of the refrigeration system increases. In case of the
vapor absorption refrigeration system, the pump requires very small
amount of power and it remains almost the same (or may increase slightly)
even for higher capacities of refrigeration.
2. Running cost: The vapor compression refrigeration system can run only
on electric power, and they require large amount of power. These days the
electric power has become very expensive, hence the running cost of the
vapor compression refrigeration system is very high. In case of the
absorption refrigeration system only small pump requires electric power
and it is quite low. In most of the process industries, where the absorption
refrigeration is used, there is some extra steam available from the boiler,
which can be used for running the system. Thus in absorption refrigeration
system no extra power in the pure electric form is required and the energy
that would have otherwise gone wasted is utilized in the plant. Thus the

running cost of the absorption refrigeration system is much lesser than the
vapor compression system.
3. Foundations required and noise: The compressor of the vapor
compression system is operated at very high speeds and it makes lots of
vibrations and noise. It also requires very strong foundation so that it can
remain intact under vibrations and high pressures of the refrigerant. These
are the main problems that occur mostly in heavy vehicles. In the
absorption refrigeration system there are no major moving parts hence they
don’t vibrate, don’t make noise and also don’t require heavy foundations
which makes it less bulkier. The absorption refrigeration systems operate
silently.
4. Maintenance: Compressor is the crucial part of the vapor compression
cycle, and it has number of moving parts. It is very important to do the
thorough lubrication of the compressor and also keep checking it regularly
for any defects. The compressor also requires changing of the piston, piston
rings, cylinder liner etc. from time-to-time. Thus the vapor compression
system requires lots of maintenance. Failure of compressor can be very
expensive at times as the suction and the discharge valve of the compressor
are very expensive. Even the motor of the compressor is very heavy and
expensive. The compressor also requires cooling, for which special pump
is required to pump the water from the cooling tower to the compressor.

Since there are number of moving parts of the compressor that move at
very fast speed some or the other failure occurs regularly. In the absorption
refrigeration system the only moving part is the small pump that fails
rarely. Thus the maintenance required by the vapor compression system is
much more than that required by the vapor absorption system.
5. Capacity control of the system: In the vapor compression cycle the
capacity control of the system is done from the compressor and in most of
the cases stepwise capacity control is obtained. In case of the absorption
refrigeration system it is possible to obtain step less capacity control and
zero capacity when there is no load on the system. Though these days
compressors with step less capacity control are available, but they will
consume lots of power even if there is zero load on the refrigeration system.
In absorption system, when there is zero load the power consumption is
almost zero.
6. Type of refrigerant used and its cost: In ammonia-water absorption
refrigeration system, ammonia is used as the refrigerant, which is easily
and cheaply available. In lithium bromide system, water is used as the
refrigerant, which is also available cheaply and easily. In case of the vapor
compression refrigeration system halocarbons are used as the refrigerants,
which are very expensive.

7. Leakage of the refrigerant: In the absorption refrigeration system there
are no (or very few) leakages of the refrigerant and the refrigerant itself is
very cheap. Thus there are almost zero refrigerant recharging costs. In case
of the vapor compression systems there are lots of leakages of the
refrigerant thus regular recharge of the refrigerant is required which is very
expensive.
8. Greenhouse effect: Most of the halocarbon refrigerants used in the
compression refrigeration system produces greenhouse effect. As per the
Montreal Protocol, their use has to stop completely by the year 2020. In
the absorption refrigeration system no refrigerant produces the greenhouse
effect, so their use won’t be stopped in future.
4.2 Design of generator
Generator

The Generator will be made using three main parts:
 Steel pipe to pass hot gases (RED PART)
 Steel cylinder for holding ammonium hydroxide solution (BROWN
PART)
 Aluminum Fins to increase the rate of heating (INSIDE THE
CYLINDER)
4.2.1 Exhaust Pipe
At first we decided to use the Aluminum as material for the exhaust pipe
as its heat conductivity is very high but it wasn’t available in the market.
Therefore we used steel pipe to make the exhaust pipe.
But in the final calculations we will also find the result by considering material
of exhaust pipe as aluminum.
The best material for the exhaust pipe could be Copper as its conductivity
is more that aluminum, but it react with ammonia to produce toxic gas so we
cannot use it. Aluminum:-If we use alumimium pipe for carrying gases we have
following advantages.
Heat conductivity:-Aluminum is an excellent heat and electricity conductor and

in relation to its weight is almost twice as good a conductor as copper. Its thermal
conductivity is 237 W·m−1·K−1.
Light weight:-Aluminum is a very light weight material therefore is proffered

for designing purpose.
Corrosion resistant:-Aluminum naturally generates a protective oxide coating

and is highly corrosion resistant. Different types of surface treatment such as
anodizing, painting or lacquering can further improve this property. It is

particularly useful for applications where protection and conservation are
required.
These were the three main properties that we needed the most in the
exhaust pipe. But since it wasn’t available in the market we had to manage using
steel pipe. Its heat conductivity is less than Aluminum’s but we well include the
properties of aluminum in the final calculation.
Dimensions:-Exhaust pipe
Length – 5 feet (150cm)
Outer Diameter- 2 inches (50mm)
Thickness- 3mm
4.2.2 Cylindrical case to hold ammonium hydroxide

The Cylindrical case will hold the solution of ammonium hydroxide which
will be heated using the heat of exhaust gases. Due to better malleable property
steel sheet is used to make a cylindrical case.
Dimensions: - Cylindrical case
Length- 1 feet (30cm)
Diameter- 6 inches (15.25cm)
Thickness of sheet- 3mm
4.2.3 Aluminium fins
6 Aluminum fins are inserted inside the exhaust pipe to increase the heat
conductivity into the ammonium hydroxide solution. The material of fins is
aluminum for the same reasons listed above.

Dimensions: - Fins
Thickness of aluminum sheet used- 3mm
Length-15mm
Width- 15mm

Working Fluid for the Absorption Refrigeration Systems: Performance of
absorption refrigeration systems is critically dependent on the chemical and
thermodynamic properties of the working fluid. A fundamental requirement of
absorbent/refrigerant combination is that, in liquid phase, they must have a
margin of miscibility within the operating temperature range of the cycle. The
mixture should also be chemically stable, non-toxic, and non-explosive. In
addition to these requirements, the following are desirable:
 The elevation of boiling point (the difference in boiling point between the
pure refrigerant and the mixture at the same pressure) should be as large as
possible.
 Refrigerant should have high heat of vaporization and high concentration
within the absorbent in order to maintain low circulation rate between the
generator and the absorber per unit of the cooling capacity.
 Transport properties that influence heat and mass transfer, e.g., viscosity,
thermal conductivity, and diffusion coefficient should be favorable.
 Both refrigerant and absorbent should be non-corrosive, environmental
friendly, and economical. There are some 40 refrigerant compounds and
200 absorbent compounds available. However, the most common working
fluids are water/ammonia and LiBr/water. Since the invention of
absorption refrigeration systems, water/ammonia has been widely used for
both cooling and heating purposes. The main properties are:

 Ammonia (refrigerant) and water (absorbent) are highly stable for a wide
range of operating temperature and pressure.
 Ammonia has a high latent heat of vaporization, which is necessary for
efficient performance of the system. Its latent heat of vaporization at -15℃
is 1315kJ/Kg. Thus, large refrigerating effects are possible with relatively
small size machinery.
 Its boiling point at atmospheric pressure is -33.3 ℃& freezing point is -77
℃The low boiling point makes it possible to have refrigeration at
temperatures considerably below 0 ℃ without using pressure below
atmospheric in the evaporator. It has highest refrigerating effect per Kg of
refrigerant.
 The leakage of this refrigerant may be quickly & easily detected by the use
of burning sulphurcandle which in the presence of ammonia will form
white fumes of ammonium sulphite.
 Ammonia is toxic in nature. This refrigerant attacks copper & bronze in
the presence of a little moisture but does not corrode iron and steel.
 It has high efficiency.
 It has low cost.
 Low weight of liquid circulated per ton of refrigeration since both ammonia
and water are volatile, the system require a rectifier to strip away water that
normally evaporates with ammonia.

4.3 Retrieval of Material
This section describes that from where we retrieved all the

components and material required making the model.
Steel Pipe: Diameter of steel pipe is most important factor that is to consider as
all the calculation is based. As it is directly connected to the exhaust it must fit to
the size of the exhaust diameter to avoid any leakage and to utilize all the heat
given out through the exhaust. This pipe is bought from Nagla hardware store,
Phagwara after a long search.
Aluminum Fins: Length, width and thickness is the consideration for maximum
heat transfer. We got the aluminum scrap from the workshop of Phagwara to
make the fins.
Cylindrical Case: Important factors that are taken into account is its volume
which include the length and diameter. Also the quality of sheet that is used
matters because during bending of sheet it must not fracture or crack during
hammering. Also it must be thick enough to avoid heat loss to the environment.
It is taken from Sheet metal shop in sitarganj.
Working Fluid: On the basis of concentration of ammonia in a solution test,

experiment and analysis is retrieved. With the help of mentor, HOS it is taken
from the Chemistry Lab of LPU and test are conducted at same lab (55-301) under
the supervision of Mr. Thakur.

4.4 Fabrication
4.4.1 Sheet Metal Workshop
Some of the following tools and machines are used for carrying out
operations in sheet metal shop:
Purpose Tools Machine
To make cylindrical Hammer, chisel, half Rolling machine

case round file,snip
For shearing sheet Cutter, Shearing cutter -
4.4.2 Machine Workshop
Purpose Machine
For Cutting rectangular slots in pipe for inserting Grinder

fins
4.4.3 Welding Shop
Purpose Type of welding
For Fixing Fin Gas welding
To fix case on a steel pipe Gas welding
For preventing leakage at certain Gas welding

area

Gas welding is mostly used because all other type of welding can melt the element
that has been used and we have selected the best materials for carrying out
specific job.
Gas Welding is done in Phagwara as other welding could not be used due to its
high welding temperature which can deteriorate the material. Tools and
Machines are used from LPU.
4.5 Analysis
For conducted two tests for the analysis of the Generator we designed.
4.5.1 Water Heating Test
In this test we will attach our generator with the exhaust manifold of
Bike’s engine and will heat the water inside cylindrical case.
This test is done to check the quality of heat coming out of flue gases and is the
most important test.
4.5.2 Ammonium hydroxide heating test in chemistry lab
This test will be conducted to check that how much heat and
temperature is required to produce the ammonia vapours. This test will be
conducted in the lab and by using this test we will check if the heat available in
test 1 is enough or not.
4.5.3 Comparison of test results with actual conditions
In this section we will try to correlate out test result with the actual
conditions and will reach the conclusion

5. Research & Experimental Work Done
Mathematical Formulation and study of model
While doing analysis we had to work on two different types of systems i.e.
OPEN & CLOSE SYSTEM. So we should know a little about these systems.
OPEN SYSTEM (Exhaust of the engine)
What is open system?

An open system is the system in which both mass and energy can interact
with surrounding via boundary
Important Assumption for open system

1. The mass flow through the system remains constants.
2. There is no change in chemical composition of fluid or there is no chemical
reaction.
3. The state of fluid at any point remains constant with time.
4. Fluid is uniform in composition.

5. The potential, kinetic, internal and flow energies are only considered in the
analysis. Other form of energy (electrical, chemical, magnetic etc) is not
considered.
Consider the Flow as Steady State flow so we can apply the Steady-flow Energy
Equation.
Steady State Energy Balance on an Open System
Putting the values for our system

Change in KE = 0
Change is PE = 0
Work done = 0
So above equation turn out to be
Q= H (in) - H (out)
Where,
Q = Heat loss by the fluid (Exhaust gas) by passing through the pipe, assuming
there is no heat interaction except the heat transfer b/w fluid and arrangement.
―Heat loss by the Fluid (Exhaust gas) is equal to the heat gained by the water‖.

This is cylindrical shape pipe which is made of Steel; let the inner radius of
cylinder is r1 outer radius is r2and the total length of the pipe is L.
Study of heat transfer
Heat Transfer by convection of exhaust gases, assume that temperature of

the exhaust gas is T3.
Q (Convection) = h*A*(T3- T1)
= 80*2*π*0.022*0.3*(100-25)
=248.8 Joule/sec
Heat conduction through a cylinder
Let assume that the inside and outside surface of the cylinder are
maintained at temperatures T1 and T2 respectively, and T1 is greater than T2.
Heat will be assumed to be flowing under steady state only in the radial direction,
and there is no heat conduction along the length or the periphery of the cylinder.
The rate of heat transfer through the thin cylinder of thickness dr is given by

Q = 2πkL( T1- T2)/ ln(r2/r1)
Assume that total heat of convection is transferred into the conductive heat.
Q (convection) = Q (conductive)
So,
Q (conductive) = 2πkL (T1- T2)/ ln (r2/r1)
By putting all values in the above equation we can find out the T2
Now,
Q = m*Cp*dT (Heat gain by water)
Q = 248.8 *300 = 74644 joule (because we are checking the temperature after 5
min of interval)
Q = 2.5*1000*4.18*(T-25)
So, from above equation
T = 32 degree Celsius.
So the temperature of water should be 32 degree Celsius theoretically.
This heat will raise the temperature of pipe and then subsequently heat will be
transferred to the water that is in contact with the outer surface of pipe.

Overall heat transfer (without Fins)
T (Exhaust
Gas)
Fluid
Steel Cylinder
Water
Calculation of Heat transfer with Fins
We have straight and pin fin of uniform cross section, fin is very thin and its
length l is long, it can be assumed that there is no radial temperature variation and
heat gets conducted axially along the length. The fin will take heat from exhaust
gas by convection and will give to the steel pipe and water through the
conduction. We will treat it as one dimensional heat conduction.

50mm
15mm
Fin with negligible thickness.

Calculation for adiabatic tip,
First assume some notation,
T = temperature at any point x within the fin.
T0 = temperature of source. (80 degree Celsius)
T∞ = temperature of fluid (in this case initial temperature of water or steel rod
is )(25degree Celsius)
m= (hp/kA) ^1/2. = 7.939(meter inverse)
ml = 7.939*.05 =0.396
M = (hpkA) ^1/2*Øo = 98.247
P = perimeter of the fin= 2(50+15) =130mm=0.13m
Ø = T - T∞
Øo = To - T∞ = 100 – 25 = 75 degree Celsius
Fin Heat transfer rate,
Q (fin) = M* tanh ml
= 37.07
Q (fin) = 37.07Joule/sec
This is the heat transfer rate of one fin, now calculating for 6 fins.
Q (6fin) = 6*37.07
= 222.43Joule/sec

Heat transfer with unfinned surface;
Q (unfinned surface) = h*A* Øo
= 80[π*0.0256*0.30) – (6*0.001*0.30)]*75
= 133.20 Joule/sec)
Total heat transfer from the cylindrical surface
Q (total) = 222.43 + 133.20= 355.6 Joule/sec
Without fins the heat transfer = 248.80 Joule/sec
Increase in Heat transfer due to Fins

= {355.6–248.8}/248.8
= 42.9%
Fin Effectiveness € = 355.6 / 248.8

= 1.429
The theoretical temperature rise of water due to the fins would be;
Q = 355.6*300= 106680 Joule
Heat gain by the water
Q = mCpdT
= 2.5*1000*4.18*(T-25)
So,
T= 35 degree Celsius.
So theoretically by using Generator with fins the Temperature of water
should be raised to 35 degree Celsius. (When tested on Bike).

Now we will check the increase of temperature practically by performing the
following experiments.
5.1 Test to check the quality of exhaust heat
To check the quality of exhaust heat we will use the equation and
relationship obtain by
SFEE for a heat exchanger device, and we will assume that the heat loss by the
exhaust gas equal to the heat gain by the water.
Assumption for the Quality check of exhaust gas:
1. There is no heat loss inside or outside the cylinder except the heat
interaction b/w exhaust gas and water.
2. We will assume the system is insulated so there is no loss from the
boundary.
3. There is only kinetic, potential and internal energy should be considered
no electrical and magnetic form of energy.
4. The atmospheric temperature and pressure is ideal.
5. The working condition is favorable for the maximum heat exchange.
6. The quantity (mass) of water for overall experiment is 2.5 l which is equal
to 2.5 kg and it don’t change with time.

Water Heating Test (Generator connected to exhaust manifold)
Mathematical representation
The heat loss by the exhaust gas = Heat gain by the water.
Q= H (in) – H (out) or Q = H (Final water) – H (initial water)
So,
Q= mc {T (final) – T (initial)}
Here,
m = mass of the liquid water
C = specific heat at constant pressure
To calculate the total heat gain by water we have to know the required
temperature by doing practical

Data collected by doing practical
Total heat gain by

water.
Initial Temperature Final Temperature Time
S.No. Q = m* C(p)* (T2
T1( in degree C) T2( In degree C) (Sec)
– T1)
(Joule)
1. 25 32 73255 300
2. 25 33 83720 298
3. 25 31 62790 301
By performing above experiment we have calculated the amount of heat

absorbed by the water in a particular time and at certain condition.
By taking average of all data,
Average Q (heat gain) = m* Cp* dT
Q = 73255 Joule
So we need are getting the 73255 joule amount of heat by performing the
above experiment. Now we will check this value and will compare it, to know are
we getting sufficient amount of heat to vaporize certain amount of ammonia.

5.2 Test to check the heat required for ammonia vapors
formation
We conducted a practical to know about the details of ammonia vapors

formation at chemistry lab (55 block – Room no. 301) in the supervision of Mr.
Thakur UID (17052).
The aim was to know the temperature and the time at which ammonia starts
to vaporize but as we know that ammonia doesn’t exist at room temperature, we
conducted the test with ammonium hydroxide because in Vapor absorption
system we are using the same.
Assumptions
1. The atmospheric temperature and pressure was ideal.
2. There was no other chemical reaction except the vaporization of ammonia.
3. The heating effect was constant.
4. Density of ammonia solution is 0.86g/ml and it is constant at 25 degree
Celsius.
5. Value of Cp for NH4oH is 4.4199 J/g*’C
Observation table of Experiment:
S.N. Quantity of NH4oH Temperature Time

( In ml) (IN degree C) (In sec)
1. 50 with 30 ml of water 40 190
We have used the different composition of NH4oH to avoid all errors.
Chemical used: NH4oH, Nessler reagent.
To insure the formation of the ammonia vapor we used the nessler reagent;
nessler reagent gives the yellow color if react with the ammonia vapor.
Calculation of Mass (at room temperature)
Mass of NH4OH = 0.2989 x mass of solution
But: mass of solution = density of solution x volume of solution
Mass of solution = 0.86 g/mL x 80 mL = 68.8 g
Mass of NH4OH = 0.2989 x 150.5 g = 20.56 g

Calculation table:
Total heat gain by

Initial Mass
Final NH4oH.
Temperature Time of
S.No Temperature Q = m* C(p)* (T2 –
T1( in degree (Sec) NH4oH
T2( In degree C) T1)
C) (gram)
(Joule)
1. 25 40 1363.09 190 20.56
2. 25 41 1817.09 230 25.70
3. 25 41 1998.80 239 28.27
Average Heat Gain by NH4oH to vaporize,
Q = (Q1+Q2+Q3)/3
Q = (1363.09+1817.09+1998.80)/3
Q = 1726.32 Joule
So we need 1726.32 Joule energy to vaporize the average 24.84 gram of

NH4oH and it will take average time of 219.66 sec.
5.3 Relate the data collected in both experiment
Density of ammonium hydroxide solution = .86g/ml
So in 2500 ml,
2150 gram of solution
―So we need 1726.32 Joule energy to vaporize the average 24.84 gram of
NH4OH and it will take average time of 219.66 sec‖.
We need 1726.32 joule energy = to vaporize the 24.84 gram

So for one gram we would need = 69.497 joule energy
So for 2150 gram we would need = 149419.807 joule of energy
But by the experiment of exhaust heat we are getting 73255 joule energy.

6. Expected Outcomes
The VARS is considered as the combination of Carnot engine & Carnot
refrigerator as shown in the figure below. And its max COP is given by the
expression:
While testing our device on bike’s Engine we got the following values of
temperatures:-
Tg= 32 degree Celsius= 32+273= 305 Kelvin
To= 24 degree Celsius= 24+273= 297 Kelvin
Te= 20 degree Celsius= 20+2713= 293 Kelvin

So the maximum COP in this case will be:-
293/ (297-293) * (305-297)/305
= 0.24
And when we will use this device in truck, the temperature of generator (Tg) will
increase and so will be the COP of the system.

7. Result & Discussion
We conducted two different tests:
1- Test to determine the temperature of formation of ammonia vapours from the
solution of ammonium hydroxide.
2- Test to check the quality of heat of the engine exhaust by heating water using
Generator.
In the ―test 1‖ we heated different quantities of ammonium hydroxide and found

that every time the formation of ammonia vapours started between 37-40 degree
Celsius.
After performing the calculations we found that the amount of heat required for
necessary temperature gain is as following:-
Result 1-
25grams of ammonium hydroxide absorbs 1726 joules of heat to start forming

vapours.
In ―test 2‖ we connected our Generator with the exhaust manifold of bike and
heated 2.5 liters of water. We found that the temperature of water increased by 6-
7 degree Celsius.
Result 2-
After performing all the calculations we determined that heat absorbed by the
water was
73255 joules in the interval of five minutes.

Therefore if the generator contained 2.5 liters or 2150 grams of ammonium
hydroxide then the heat required will be 149420 joules but the heat being
absorbed from the exhaust gases is 73255 joules as per the calculations. So by
performing experiment on bike’s engine we found that the amount of heat
extracted was 50% of the required heat.
But the actual application of this device is in trucks where the amount of heat
available at exhaust is way more than the bike’s engine. Therefore the results in
that case will be positive

8. Conclusion
After designing and analyzing the Generator we concluded that while

performing experiments on bike’s engine the amount of heat extracted was only
half of the required heat.
Heat required to be extracted: 149420 Joules

Heat actually extracted: 73255 Joules
Also the theoretical increase in temperature was 35 degree Celsius, whereas
actual increase in temperature of water inside generator was 32 degree Celsius.
This data is from the tests conducted using exhaust of bike’s engine but
this device is actually designed by keeping in mind the exhaust heat developed
by truck’s engine.
And the heat generated in truck’s engine is a lot more as compared to the bike’s
engine. Therefore the requirement of heat required for proper working of AC
System can be fulfilled easily.
Hence we can use this device for Air Conditioning of heavy vehicles.

References:
http://web.mit.edu/16.unified/www/FALL/thermodynamics/notes/node12
8.htm
http://autorepair.about.com/od/glossary/a/howitworks_ac.htm
http://www.airconcars.com/html/how_it_works.html
http://www.mhtl.uwaterloo.ca/courses_old/me353/calc/fin_calc.html
www.thermopedia.com/content/750/
PDF on Vapour Absorption Cooling systems by A.Bhatia
PDF on Design Analysis on 3TR Aqua Ammonia Vapour Absorption
Refrigeration System by ArunBangotra, AnshulMahajan.
Heat and Mass Transfer, Third Edition by PK Nag.
Basic Thermodynamics by PK Nag
Thermodynamics by R.K. Rajput
Refrigeration and Air Conditioning by C.P.Arora.
Refrigeration and Air conditioning by R.S.Khurmi.

1.design & Analysis of AC System For Heavy Vehicles Using Exhaust Heat

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Table of Contents

Air conditioning is a tedious job to do when it comes to heavy

The only way to improve the AC System of vehicle so that we could

Swarnandhra Institute of Engineering & Technology Page | 1

1.1 PROJECT PREVIEW

Air conditioning is a tedious job to do when it comes to heavy

Where is the problem:-

After that tremendous improvements were done in this field of

But the efficiency of modern engines is also somewhere in between

Swarnandhra Institute of Engineering & Technology Page | 2

And meanwhile a lot of waste heat is generated which does nothing

At the same time we cannot compromise with the mileage of trucks

Why is mileage an issue for trucks?

A number of people don't realize that turning on the air conditioning

The AC systems that we are using nowadays in vehicles are

Swarnandhra Institute of Engineering & Technology Page | 3

But when it comes to the trucks, running an AC System will leave it

But there is something that can be changed about the AC Systems

The engine's job is simply to rotate a shaft. That shaft connects to

Before we discuss on how to utilize waste heat to run AC System,

Working of Conventional AC System:

Air conditioning's main principles are Evaporation, Condensation,

Compressor: The compressor is the work horse of the air conditioning

When the air-conditioning system is turned on, the compressor pumps

Condenser: The condenser is a device used to change the high-pressure

Receiver: The now liquid refrigerant moves to the receiver-dryer. This is

Which of these components consume the maximum energy from the

Yes, it is Compressor. So the only way to improve the AC System of

1.2 PROJECT INSPIRATION:

First law of Thermodynamics:- It states that the heat cannot be changed

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So we decided to do the same, obviously we cannot increase the efficiency

In industries VAPOUR ABSOPRTION REFRIDGERATION SYSTEM

To understand this concept in a better way we should have a look over

VAPOUR ABSORPTION REFRIGERATION SYSTEM (VARS):-

A vapor absorption chiller machine (VAM) is a machine that produces

Swarnandhra Institute of Engineering & Technology Page | 8

Both vapor compression and absorption refrigeration cycles accomplish

Absorption chillers have recently gained widespread acceptance due to

Vapor Compression Cycle

Swarnandhra Institute of Engineering & Technology Page | 9

Swarnandhra Institute of Engineering & Technology Page | 10

Absorption refrigeration systems replace the compressor with a generator

Swarnandhra Institute of Engineering & Technology Page | 11

As discussed above, all the parts of the Vapour Compression

Swarnandhra Institute of Engineering & Technology Page | 12

The main intention behind the project work is Conservation Of Energy.

2.2 Scope of the Capstone project

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BEFORE --This is being practiced.

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Swarnandhra Institute of Engineering & Technology Page | 15

4.1 Decision of the topic of Capstone Project

There were certain reasons which lead us to do this project:-

2. It is always seen that whenever we switch on the AC of our vehicle then

the mileage of the vehicle decreases which leads to higher consumption of

fuel. It won’t be a problem anymore.

don’t have to as we are using waste heat as a source of power.

4. Heavy vehicles produce large amount of heat so it is easier to run this

Swarnandhra Institute of Engineering & Technology Page | 16

etc. so it can be a nice replacement for normal air conditioning system at

comparatively low cost than Vapour Compression System.

Our project is based on vapour absorption refrigeration system. And the