LPG Project Report

VISVESVARAYA TECHNOLOGICAL UNIVERSITY,
BELAGAVI
A PROJECT REPORT
ON
“LPG REFRIGERATION SYSTEM WITH ZERO

OPERATING COST”
(PROJECT SANCTIONED BY KSCST)
A Project report submitted in partial fulfillment of requirements for 8th semester B.E
course during the year 2017-2018
BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING

Submitted by:
VINAYAK UDCHAN (3GN13ME095)

ANAND (3GN14ME006)
BABURAYA (3GN14ME009)
SUBHASH (3GN14ME422)
Under the guidance of:
Dr. NAGRAJ R.G.
DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK DEV ENGINEERING COLLEGE
BIDAR-585403(KARNATAKA)
ABSTRACT
Supply of continuous electricity is still not available in several areas of the country and
the world. At such places, this work will be helpful for refrigeration of food, medicines, etc...
This paper investigates the result of an experimental study carried out to determine the
performance of domestic refrigerator when a liquefied petroleum gas (LPG) which is locally
available which comprises of 24.4% propane, 56.4% butane and 17.2% isobutene which is varied
from company to company is used as a Refrigerant. The LPG is cheaper and possesses an
environmental friendly nature with no Ozone Depletion Potential (ODP) and no Global Warming
Potential (GDP). It is used in world for cooking purposes. The refrigerator used in the present
study is designed to work on LPG. The performance parameters investigated is the refrigeration
effect in certain time. The refrigerator worked efficiently when LPG was used as a refrigerant
instead of R134a. Also from the experiment which done in atmospheric condition, we can predict
the optimum value of cooling effect with the suitable operating condition of regulating valve and
capillary tube of the system. The use of LPG for refrigeration purpose can be environment
friendly since it has no ozone depletion potential (ODP). Usually LPG is used as a fuel for
cooking food in houses, restaurants, hotels, etc.. and the combustion products of LPG are CO2
and H2O.
In this project we have designed and analyzed a refrigerator using LPG as refrigerant.
LPG is available in cylinders at high pressure. When this high pressure LPG is passed through
the capillary tube of small internal diameter, the pressure of LPG is dropped due to expansion
and phase change of LPG occurs in an isoenthalpic process. Due to phase change from liquid to
gas latent heat is gained by the liquid refrigerant and the temperature drops. In this way LPG can
produce refrigerating effect for a confined space.
From experimental investigations, we have found that the COP of a refrigerator which
uses LPG is higher than a domestic refrigerator.
i
TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.
ABSTRACT i
CONTENTS ii
LIST OF FIGURES v
LIST OF TABLES vi
CHAPTER 1: INTRODUCTION 01
CHAPTER 2: LITERATURE SURVEY 03
CHAPTER 3: DESIGN OF BASIC COMPONENT OF LPG

REFRIGERATION SYSTEM 05
3.1 Design of Capillary tube 05
3.2 Design of Evaporator 05
CHAPTER 4: TYPES OF REFRIGERATION SYSTEM 06
4.1 Natural Refrigeration 06
4.2 Art of Ice Making by Nocturnal cooling 07
4.3 Evaporative Cooling 07
4.4 Cooling by salt solution 08

ii
4.5 Artificial Refrigeration 08
4.6 Vapour Compression Refrigeration system 08
4.7 Domestic Refrigeration system 09
4.8 Air Conditioning System 10
4.9 Vapour absorption Refrigeration system 12
4.10 Gas Cycle Refrigeration system 14
4.11 Steam Jet Refrigeration system 15
CHAPTER 5: WORKING OF VCR SYSTEM 17
5.1 Comparison between Gas and Vapour Cycle 17
5.2 Mechanism of simple VCR system 17
5.3 Simple VCR cycle 19
5.4 Types of refrigerant used in VCR 21
5.5 Advantages & Disadvantages of VCR 23
5.6 Application of VCR 24
5.7 Fundamental of Refrigeration 25
5.8 Refrigerant 27
CHAPTER 6: LPG REFRIGERATION 30
6.1 Physical properties & characteristics of LPG 30
6.2 Hazards of LPG 32
6.3 Parts of LPG Refrigeration 33
iii
CHAPTER 7: CONSTRUCTION AND WORKIG OF LPG
REFRIGERATOR 39
7.1 Construction of LPG Refrigerator 39
7.2 Working of LPG Refrigerator 40
CHAPTER 8: ADVANTAGES, DISADVANTAGES &
APPLICATION 44
CHAPTER 9: CONCLUSION 46
REFERENCES 47
iv
LIST OF FIGURES
Figure No. Figure of Title Page No.
FIG 4.8 Basic VCR system 11
FIG 4.9 Components of Vapour Absorption Refrigeration system 13
FIG 4.10 Basic Open type Air cycle Refrigeration system 14
FIG 4.11 Steam Jet Refrigeration system 15
FIG 5.3.a T-S diagram for simple VCR system 19
FIG 5.3.b P-h diagram for simple VCR system 19
FIG 5.3.c VCR system 22
FIG 6.3.1 LPG cylinder 33
FIG 6.3.2 Capillary tube 34
FIG 6.3.3 Evaporator 35
FIG 6.3.4 Pressure gauge 36
FIG 6.3.5 High Pressure Pipe 37
FIG 6.3.6 High pressure Regulator 38
FIG 7.1 Construction of LPG Refrigerator 39
FIG 7.2.a Schematic diagram of simple VCR 41
v
FIG 7.2.b LPG Refrigeration & Heating system 43
LIST OF TABLES
PAGE NO.
TABLE 5.4.a Properties of Commonly used Refrigerant 19
TABLE 5.4.b Performance of Commonly used Refrigerant 19
vi
LPG REFRIGERATION SYSTEM WITH ZERO OPERATING COST
CHAPTER: 1
INTRODUCTION
Due to the huge demand of electricity over the world, we think of recovering the energy which is
already spent but not being utilized further, to overcome this crisis with less investment. The climatic
change and global warming demand accessible and affordable cooling systems in the form of
refrigerators and air conditioners. Annually Billions of dollars are spent in serving this purpose. Hence
forth, we suggest COST FREE Cooling Systems. Although government agencies are not able to
continuously supply a major portion of electricity in both the urban as well as in rural areas. Still the
people in these regions require refrigeration for a variety of socially relevant purposes such as cold
storage or storing medical supplies and domestic kitchens this project has the novelty of using LPG
instead of electricity for refrigeration. This solution is convenient for refrigeration in regions having
scares in electricity.
The term ‘refrigeration’ in a broad sense is used for the process of removing heat (i.e. Cooling) from a
substance. It also includes the process of reducing and maintaining the temperature of a body below
the general temperature of its surroundings. In other words, the refrigeration means a continued
extraction of heat from a body, whose temperature is already below the temperature of its
surroundings. For example, if some space (say in cold storage) is to be kept at -2 ᵒC, we must
continuously extract heat which flows into it due to leakage through the walls and also the heat, which
is brought into it with the articles stored after the temperature is one reduced to -2 ºC. Thus in a
refrigerator, heat is virtually being pumped from a lower temperature to a higher temperature. The
refrigeration system is known to the man, since the middle nineteenth century. The scientist, of the
time, developed a few stray machines to achieve some pleasure. But it paved the way by inviting the
attention of scientist for proper studied and research.
They were able to build a reasonably reliable machine by the end of nineteenth century for the
refrigeration jobs. But with the advent of efficient rotary compressors and gas turbines, the science of
refrigeration reached its present height. Hebrews, Greeks, and Romans places large amounts of snow
into storage pits dug into the ground and insulated with wood and straw. The ancient Egyptians filled
DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 1

earthen jars with boiled water and put them their roofs, thus exposing the jars to the night’s cool air. In
India, evaporating cooling was employed.
When a liquid vaporizes rapidly, it expands quickly. The rising modules of vapor abruptly increase their
kinetic energy and this increase is drawn from the intermediate surroundings of the vapor. These
surroundings are therefore cooled. The intermediate stage in the history of cooling foods was to add
chemicals like sodium nitrate or potassium nitrate to water causing the temperature to fall. Cooling wine
via above method was recorded in 1550.
According to the second law thermodynamics, this process can only be performed with the supply of
some external work. It is thus obvious, that supply of power (say electrical motor) is regularly required
to drive a refrigerator. The substance which work in a heat pump to extract heat from a cold body and to
deliver it to a hot body is called “refrigerant”.
When we think about refrigerator we only remember refrigeration in kitchen, but actually it is divided in
types in which each type having their own type of functioning. One which used I industrial purpose is
called industrial refrigerator, which is used as food processing, chemical processing, and cold storage.
Industrial refrigeration, which frequently uses ammonia refrigeration to maintain temperature, is
necessary for computer, foodstuffs, blood vaccines, and quite a few other goods that must maintain a
constant and steady temperature at all times.
It works on the principle that during the conversion of LPG into gaseous form, expansion of LPG
takes place. Due to this expansion there is a pressure drop and increase in volume of LPG that results in
the drop of temperature and a refrigerating effect is produced. This refrigerating effect can be used for
cooling purposes. So this work provides refrigeration for socially relevant needs as well as replaces
global warming creator refrigerants. While going through the literature review in LPG refrigeration
system, Conventional VCR (Vapour Compression Refrigeration System) uses LPG as refrigerant and
produced the refrigerating effect. But in our proposed very simple type of refrigeration system in which
the high pressure LPG is passing through a capillary tube and expands. After expansion the phase of
LPG is changed and converted from liquid to gas and then it passes through the evaporator where it
absorbs the heat and produces the refrigerating effect. After evaporator it passes through the gas burner
where it burns.

CHAPTER: 2
LITERATURE SURVEY
1 A.Baskaran & P.Koshy Mathews
A Performance Comparison of Vapour Compression Refrigeration System Using eco-friendly

refrigerant of low Global Warming Potential VCR system with the new R290/R600a refrigerant
mixture as a substitute refrigerant for CFC12 and HFC 134a. The refrigerant R290/R600a had a
refrigerating capacity 28.6% to 87.2% higher than that of R134a.
2 A.Baskaran & P.Koshy Mathews
A Performance Comparison of Vapour Compression Refrigeration System Using Eco Friendly

Refrigerants of Low Global Warming Potential. R600a performance have a slightly higher than
coefficient(COP) R134a for the condensation temperature of 50 C⁰ and evaporating temperatures
ranging between -30 C⁰ and10⁰C.Hence, The coefficient performance (COP) of this mixture was up to
5.7% higher.
3 M. Mohanraj et. al. , have studied experimentally the drop in substitute for R134a with the
environment friendly, energy efficient hydrocarbon (HC) mixture which consists of 45% HC290 and
55% R600a at various mass charges of 50g, 70g and 90g in domestic refrigerator. The experiments were
carried out in 165 liters domestic refrigerator using R134a with POE oil as lubricant. The discharge
temperatures of HC mixtures are found to be lower than R134a by 13.76%, 6.42% and 3.66% for 50g,
70g and 90g respectively. The power consumption of HC mixture at 50g and 70g are lower by 10.2%
and 5.1% respectively and 90g shows higher power consumption by 1.01%. The percentage reduction in
pull down time is 18.36%, 21.76% and 28.57% for 50, 70 and 90g mass charges respectively when
compared to R134a. The HC mixture because of its high energy efficiency will also reduce the indirect
global warming. In conclusion HC mixture of 70g is found to be an effective alternative to R134a in 165
liters domestic refrigerator.

4 B.O.Bolaji, have Experimental study of R152a/R32 to replace R134a in a domestic refrigerator and
find out that COP obtained by R152a is 4.7% higher than that of R134a. COP of R32 is 8.5% lower than
that of R134a and propane is an attractive and environmentally friendly alternative to CFCs used
currently used.
5 R.W.James & J.F.Missenden, have use of propane in domestic refrigerators and conclude that he
implications of using propane in domestic refrigerators are examined in relation consumption,
compressor costs, availability, to energy lubrication, environmental factors and safety propane is an
attractive and environmentally friendly alternative to CFCs used currently.
6 Bilal A. Akash et. al, has conducted performance tests on the performance of liquefied petroleum gas
(LPG) as a possible substitute for R12 in domestic refrigerators. The refrigerator which is initially
designed to work with R12 is used to conduct the experiment for LPG (30% propane, 55% n-butane and
15% isobutane). Various mass charges of 50, 80 and 100g of LPG were used during the
experimentation.LPG compares very well to R12. The COP was higher for all mass charges at
evaporator temperatures lower than −15˚C. Overall, it was found that at 80g charge, LPG had the best
results when used in this refrigerator. The condenser was kept at a constant temperature of 47˚C.
Cooling capacities were obtained and they were in the order of about three to fourfold higher for LPG
than those for R12
7 M. Fatouh et. al. investigated substitute for R134a in a single evaporator domestic refrigerator with a
total volume of 0.283 m3 with Liquefied petroleum gas (LPG) of 60% propane and 40% commercial
butane. The performance of the refrigerator, tests were conducted with different capillary lengths and
different charges of R134a and LPG. Experimental results of the refrigerator using LPG of 60g and
capillary tube length of 5 m were compared with those using R134a of 100g and capillary tube length of
4 m. Pull-down time, pressure ratio and power consumption of LPG refrigerator were lower than those
of R134a by about 7.6%, 5.5% and 4.3%, respectively. COP of LPG refrigerator was 7.6% higher than
that of R134a. Lower on-time ratio and energy consumption of LPG refrigerator was lower than 14.3%
and 10.8%, respectively, compared to R134a. In conclusion, the proposed LPG is drop in replacement
for R134a, to have the better performance, optimization of capillary length and refrigerant charge was
needed.

CHAPTER: 3
DESIGN OF BASIC COMPONENTS OF LPG REFRIGERATION

SYSTEM
Two main components (capillary tube and evaporator) have been designed in this system.
3.1 DESIGN OF CAPILLARY TUBE

The capillary tube is a fixed restriction-type device. It is a long and narrow tube connecting the
condenser directly to the evaporator. The pressure drop through the capillary tube is due to the
following two factors:
1. Friction, due to fluid viscosity, resulting in frictional pressure drop.
2. Acceleration, due to the flashing of the liquid refrigerant into vapour, resulting in momentum
pressure drop.
Design parameters for capillary tube are:
Cylinder size = 14 kg,
Dcylinder = 295 mm
dcapillary = 1.05mm
3.2 DESIGN OF EVAPORATOR

The evaporator is the component of a refrigeration system in which heat is removed from air, water or
any other body required to be cooled by the evaporating refrigerant. In experimental setup plate and
tube type evaporator has been used because it provides a gentle type of evaporation with low residence
time. It also preserves the food and other products from bacterial attack and requires low installation
cost.

CHAPTER: 4
TYPES OF REFRIGERATION SYSTEMS
REFRIGERATION:
Refrigeration may be defined as the process of achieving and maintaining a temperature below that of
the surroundings, the aim being to cool some product or space to the required temperature. One of the
most important applications of refrigeration has been the preservation of perishable food products by
storing them at low temperatures. Refrigeration systems are also used extensively for providing thermal
comfort to human beings by means of air conditioning. Air Conditioning refers to the treatment of air so
as to simultaneously control its temperature, moisture content, cleanliness, odor and circulation, as
required by occupants, a process, or products in the space. The subject of refrigeration and air
conditioning has evolved out of human need for food and comfort, and its history dates back to
centuries. The history of refrigeration is very interesting since every aspect of it, the availability of
refrigerants, the prime movers and the developments in compressors and the methods of refrigeration all
are a part of it.
4.1 Natural Refrigeration
In olden days refrigeration was achieved by natural means such as the use of ice or evaporative cooling.
In earlier times, ice was either:
1. Transported from colder regions,
2. Harvested in winter and stored in ice houses for summer use or,
3. Made during night by cooling of water by radiation to stratosphere.
In Europe, America and Iran a number of icehouses were built to store ice. Materials like sawdust or
wood shavings were used as insulating materials in these icehouses. Later on, cork was used as
insulating material. Literature reveals that ice has always been available to aristocracy who could afford

it. In India, the Mogul emperors were very fond of ice during the harsh summer in Delhi and Agra, and
it appears that the ice used to be made by nocturnal cooling.
In 1806, Frederic Tudor, (who was later called as the “ice king”) began the trade in ice by cutting it from
the Hudson River and ponds of Massachusetts and exporting it to various countries including India. In
India Tudor’s ice was cheaper than the locally manufactured ice by nocturnal cooling. The ice trade in
North America was a flourishing business. Ice was transported to southern states of America in train
compartments insulated by 0.3m of cork insulation. Trading in ice was also popular in several other
countries such as Great Britain, Russia, Canada, Norway and France. In these countries ice was either
transported from colder regions or was harvested in winter and stored in icehouses for use in summer.
The ice trade reached its peak in 1872 when America alone exported 225000 tones of ice to various
countries as far as China and Australia. However, with the advent of artificial refrigeration the ice trade
gradually declined.
4.2. Art of Ice making by Nocturnal Cooling:
The art of making ice by nocturnal cooling was perfected in India. In this method ice was made by
keeping a thin layer of water in a shallow earthen tray, and then exposing the tray to the night sky.
Compacted hay of about 0.3 m thickness was used as insulation. The water looses heat by radiation to
the stratosphere, which is at around -55°C and by early morning hours the water in the trays freezes to
ice. This method of ice production was very popular in India.
4.3. Evaporative Cooling:
As the name indicates, evaporative cooling is the process of reducing the temperature of a system by
evaporation of water. Human beings perspire and dissipate their metabolic heat by evaporative cooling
if the ambient temperature is more than skin temperature. Animals such as the hippopotamus and
buffalo coat themselves with mud for evaporative cooling. Evaporative cooling has been used in India
for centuries to obtain cold water in summer by storing the water in earthen pots. The water permeates
through the pores of earthen vessel to its outer surface where it evaporates to the surrounding,
absorbing its latent heat in part from the vessel, which cools the water. It is said that Patliputra
University situated on the bank of river Ganges used to induce the evaporative-cooled air from the
river. Suitably located chimneys in the rooms augmented the upward flow of warm air, which was
replaced by cool air. Evaporative cooling by placing wet straw mats on the windows is also very

common in India. The straw mat made from “khus” adds its inherent perfume also to the air. Now-a-
days desert coolers are being used in hot and dry areas to provide cooling in summer.
4.4. Cooling by Salt Solutions:
Certain substances such as common salt, when added to water dissolve in water and absorb its heat of
solution from water (endothermic process). This reduces the temperature of the solution (water + salt).
Sodium Chloride salt (NaCl) can yield temperatures up to -20°C and Calcium Chloride (CaCl 2) up to -
50°C in properly insulated containers. However, as it is this process has limited application, as the
dissolved salt has to be recovered from its solution by heating.
4.5. Artificial Refrigeration
Refrigeration as it is known these days is produced by artificial means. Though it is very difficult to
make a clear demarcation between natural and artificial refrigeration, it is generally agreed that the
history of artificial refrigeration began in the year 1755, when the Scottish professor William Cullen
made the first refrigerating machine, which could produce a small quantity of ice in the laboratory.
Based on the working principle, refrigeration systems can be classified as vapour compression systems,
vapour absorption systems, gas cycle systems etc.
4.6. Vapour Compression Refrigeration Systems:
The basis of modern refrigeration is the ability of liquids to absorb enormous quantities of heat as they
boil and evaporate. Professor William Cullen of the University of Edinburgh demonstrated this in 1755
by placing some water in thermal contact with ether under a receiver of a vacuum pump. The
evaporation rate of ether increased due to the vacuum pump and water could be frozen. This process
involves two thermodynamic concepts, the vapour pressure and the latent heat. A liquid is in thermal
equilibrium with its own vapor at a pressure called the saturation pressure, which depends on the
temperature alone. If the pressure is increased for example in a pressure cooker, the water boils at
higher temperature. The second concept is that the evaporation of liquid requires latent heat during
evaporation. If latent heat is extracted from the liquid, the liquid gets cooled. The temperature of ether
will remain constant as long as the vacuum pump maintains a pressure equal to saturation pressure at
the desired temperature. This requires the removal of all the vapors formed due to vaporization. If a
lower temperature is desired, then a lower saturation pressure will have to be maintained by the vacuum

pump. The component of the modern day refrigeration system where cooling is produced by this
method is called evaporator.
If this process of cooling is to be made continuous the vapors have to be recycled by condensation to
the liquid state. The condensation process requires heat rejection to the surroundings. It can be
condensed at atmospheric temperature by increasing its pressure. The process of condensation was
learned in the second half of eighteenth century. U.F. Clouet and G. Monge liquefied SO 2 in 1780 while
van Marum and Van Troostwijk liquefied NH3 in 1787. Hence, a compressor is required to maintain a
high pressure so that the evaporating vapours can condense at a temperature greater than that of the
surroundings.
4.7. Domestic refrigeration systems:
The domestic refrigerator using natural ice (domestic ice box) was invented in 1803 and was used for
almost 150 years without much alteration. The domestic ice box used to be made of wood with suitable
insulation. Ice used to be kept at the top of the box, and low temperatures are produced in the box due
to heat transfer from ice by natural convection. A drip pan is used to collect the water formed due to the
melting of ice. The box has to be replenished with fresh ice once all the ice melts. Though the concept
is quite simple, the domestic ice box suffered from several disadvantages. The user has to replenish the
ice assoon as it is consumed, and the lowest temperatures that could be produced inside the
compartment are limited. In addition, it appears that warm winters caused severe shortage of natural ice
in USA. Hence, efforts, starting from 1887 have been made to develop domestic refrigerators using
mechanical systems. The initial domestic mechanical refrigerators were costly, not completely
automatic and were not very reliable. However, the development of mechanical household refrigerators
on a large scale was made possible by the development of small compressors, automatic refrigerant
controls, better shaft seals, developments in electrical power systems and induction motors. General
Electric Company introduced the first domestic refrigerator in 1911, followed by Frigidaire in 1915.
Kelvinator launched the domestic mechanical refrigerator in 1918 in USA. In 1925, USA had about 25
million domestic refrigerators of which only 75000 were mechanical. However, the manufacture of
domestic refrigerators grew very rapidly, and by 1949 about 7 million domestic refrigerators were
produced annually. With the production volumes increasing the price fell sharply (the price was 600
dollars in 1920 and 155 dollars in 1940). The initial domestic refrigerators used mainly sulphur dioxide
as refrigerant. Some units used methyl chloride and methylene chloride. These refrigerants were

replaced by Freon-12 in 1930s. In the beginning these refrigerators were equipped with open type
compressors driven by belt drive. General Electric Company introduced the first refrigerator with a
hermetic compressor in 1926. Soon the open type compressors were completely replaced by the
hermetic compressors. First refrigerators used water-cooled condensers, which were soon replaced by
air cooled-condensers. Though the development of mechanical domestic refrigerators was very rapid in
USA, it was still rarely used in other countries. In 1930 only rich families used domestic refrigerators in
Europe. The domestic refrigerator based on absorption principle as proposed by Platen and Munters,
was first made by Electrolux Company in 1931 in Sweden. In Japan the first mechanical domestic
refrigerator was made in 1924. The first dual temperature (freezer-refrigerator) domestic refrigerator
was introduced in 1939. The use of mechanical domestic refrigerators grew rapidly all over the world
after the Second World War. Today, a domestic refrigerator has become an essential kitchen appliance
not only in highly developed countries but also in countries such as India. Except very few almost all
the present day domestic refrigerators are mechanical refrigerators that use a hermetic compressor and
an air cooled condenser. The modern refrigerators use either HFC-134a (hydro-fluoro-carbon) or iso-
butane as refrigerant.
4.8. Air conditioning systems:
Refrigeration systems are also used for providing cooling and dehumidification in summer for personal
comfort (air conditioning). The first air conditioning systems were used for industrial as well as
comfort air conditioning. Eastman Kodak installed the first air conditioning system in 1891 in
Rochester, New York for the storage of photographic films. An air conditioning system was installed in
a printing press in 1902 and in a telephone exchange in Hamburg in 1904. Many systems were installed
in tobacco and textile factories around 1900. The first domestic air conditioning system was installed in
a house in Frankfurt in 1894. A private library in St Louis, USA was air conditioned in 1895, and a
casino was air conditioned in Monte Carlo in 1901. Efforts have also been made to air condition
passenger rail coaches using ice. The widespread development of air conditioning is attributed to the
American scientist and industrialist Willis Carrier. Carrier studied the control of humidity in 1902 and
designed a central air conditioning plant using air washer in 1904. Due to the pioneering efforts of
Carrier and also due to simultaneous development of different components and controls, air
conditioning quickly became very popular, especially after 1923. At present comfort air conditioning is
widely used in residences, offices, commercial buildings, air ports, hospitals and in mobile applications

such as rail coaches, automobiles, aircrafts etc. Industrial air conditioning is largely responsible for the
growth of modern electronic, pharmaceutical, chemical industries etc. Most of the present day air
conditioning systems use either a vapour compression refrigeration system or a vapour absorption
refrigeration system. The capacities vary from few kilowatts to megawatts.
Figure 4.8 shows the basic components of a vapour compression refrigeration system. As shown in the
figure the basic system consists of an evaporator, compressor, condenser and an expansion valve. The
refrigeration effect is obtained in the cold region as heat is extracted by the vaporization of refrigerant
in the evaporator. The refrigerant vapour from the evaporator is compressed in the compressor to a high
pressure at which its saturation temperature is greater than the ambient or any other heat sink. Hence
when the high pressure, high temperature refrigerant flows through the condenser, condensation of the
vapour into liquid takes place by heat rejection to the heat sink. To complete the cycle, the high
pressure liquid is made to flow through an expansion valve. In the expansion valve the pressure and
temperature of the refrigerant decrease. This low pressure and low temperature refrigerant vapour
evaporates in the evaporator taking heat from the cold region. It should be observed that the system
operates on a closed cycle. The system requires input in the form of mechanical work. It extracts heat
from a cold space and rejects heat to a high temperature heat sink.
Fig.4.8 Schematic of a basic vapour compression refrigeration system
A refrigeration system can also be used as a heat pump, in which the useful output is the high
temperature heat rejected at the condenser. Alternatively, a refrigeration system can be used for

providing cooling in summer and heating in winter. Such systems have been built and are available
now.
4.9. Vapour Absorption Refrigeration Systems:
John Leslie in 1810 kept H2SO4 and water in two separate jars connected together. H2SO4 has very high
affinity for water. It absorbs water vapour and this becomes the principle of removing the evaporated
water vapour requiring no compressor or pump. H2SO4 is an absorbent in this system that has to be
recycled by heating to get rid of the absorbed water vapour, for continuous operation. Windhausen in
1878 used this principle for absorption refrigeration system, which worked on H 2SO4. Ferdinand Carre
invented aqua-ammonia absorption system in 1860.
Water is a strong absorbent of NH3. If NH3 is kept in a vessel that is exposed to another vessel
containing water, the strong absorption potential of water will cause evaporation of NH 3 requiring no
compressor to drive the vapours. A liquid pump is used to increase the pressure of strong solution. The
strong solution is then heated in a generator and passed through a rectification column to separate the
water from ammonia. The ammonia vapour is then condensed and recycled. The pump power is
negligible hence; the system runs virtually on low- grade energy used for heating the strong solution to
separate the water from ammonia. These systems were initially run on steam. Later on oil and natural
gas based systems were introduced.
Figure 4.9 shows the essential components of a vapour absorption refrigeration system. In 1922, Balzar
von Platen and Carl Munters, two students at Royal Institute of Technology, Stockholm invented a
three fluid system that did not require a pump. A heating based bubble pump was used for circulation
of strong and weak solutions and hydrogen was used as a non-condensable gas to reduce the partial
pressure of NH3 in the evaporator. Geppert in 1899 gave this original idea but he was not successful
since he was using air as non-condensable gas. The Platen-Munters refrigeration systems are still
widely used in certain niche applications such as hotel rooms etc.

Fig. 4.9 Essential components of a vapour absorption refrigeration system.
Another variation of vapour absorption system is the one based on Lithium Bromide water. This
system is used for chilled water air-conditioning system. This is a descendent of Windhausen’s
machine with LiBr replacing H2SO4. In this system LiBr is the absorbent and water is the refrigerant.
This system works at vacuum pressures. The condenser and the generator are housed in one cylindrical
vessel and the evaporator and the absorber are housed in second vessel. This also runs on low-grade
energy requiring a boiler or process steam.

4.10 Gas Cycle Refrigeration:
If air at high pressure expands and does work (say moves a piston or rotates a turbine), its temperature
will decrease. This fact is known to man as early as the 18 th century. Dalton and Gay Lusaac studied
this in 1807. Sadi Carnot mentioned this as a well-known phenomenon in 1824. However, Dr. John
Gorrie a physician in Florida developed one such machine in 1844 to produce ice for the relief of his
patients suffering from fever. This machine used compressed air at 2 atm. pressure and produced brine
at a temperature of –7oC, which was then used to produce ice. Alexander Carnegie Kirk in 1862 made
an air cycle cooling machine. This system used steam engine to run its compressor. Using a
compression ratio of 6 to 8, Kirk could produce temperatures as low as 40 oC. Paul Gifford in 1875
perfected the open type of machine. This machine was further improved by T B Lightfoot, A Haslam,
Henry Bell and James Coleman. This was the main method of marine refrigeration for quite some time.
Frank Allen in New York developed a closed cycle machine employing high pressures to reduce the
volume flow rates. This was named dense air machine. These days air cycle refrigeration is used only
in aircrafts whose turbo compressor can handle large volume flow rates. Figure 4.10 shows the
schematic of an open type air cycle refrigeration system. The basic system shown here consists of a
compressor, an expander and a heat exchanger. Air from the cold room is compressed in the
compressor. The hot and high pressure air rejects heat to the heat sink (cooling water) in the heat
exchanger. The warm but high pressure air expands in the expander. The cold air after expansion is sent
to the cold room for providing cooling. The work of expansion partly compensates the work of
compression; hence both the expander and the compressor are mounted on a common shaft.
Fig.4.10. Schematic of a basic open type air cycle refrigeration system

4.11 Steam Jet Refrigeration System:
If water is sprayed into a chamber where a low pressure is maintained, a part of the water will
evaporate. The enthalpy of evaporation will cool the remaining water to its saturation temperature at
the pressure in the chamber. Obviously lower temperature will require lower pressure. Water freezes at
0oC hence temperature lower than 4 oC cannot be obtained with water. In this system, high velocity
steam is used to entrain the evaporating water vapour. High-pressure motive steam passes through
either convergent or convergent-divergent nozzle where it acquires either sonic or supersonic velocity
and low pressure of the order of 0.009 kPa corresponding to an evaporator temperature of 4 oC. The
high momentum of motive steam entrains or carries along with it the water vapour evaporating from
the flash chamber. Because of its high velocity it moves the vapours against the pressure gradient up to
the condenser where the pressure is 5.6-7.4 kPa corresponding to condenser temperature of 35-45 oC.
The motive vapour and the evaporated vapour both are condensed and recycled. This system is known
as steam jet refrigeration system.
Figure 4.11 shows a schematic of the system. It can be seen that this system requires a good vacuum to
be maintained. Sometimes, booster ejector is used for this purpose. This system is driven by low- grade
energy that is process steam in chemical plants or a boiler.
Fig.4.11. Schematic of a steam jet refrigeration system
In 1838, the Frenchman Pelletan was granted a patent for the compression of steam by means of a jet of
motive steam. Around 1900, the Englishman Charles Parsons studied the possibility of reduction of

pressure by an entrainment effect from a steam jet. However, the credit for constructing the steam jet
refrigeration system goes to the French engineer, Maurice Leblanc who developed the system in 1907-
08. In this system, ejectors were used to produce a high velocity steam jet (≈ 1200 m/s). Based on
Leblanc’s design the first commercial system was made by Westinghouse in 1909 in Paris. Even
though the efficiency of the steam jet refrigeration system was low, it was still attractive as water is
harmless and the system can run using exhaust steam from a steam engine. From 1910 onwards, stem
jet refrigeration systems were used mainly in breweries, chemical factories, warships etc. In 1926, the
French engineer Follain improved the machine by introducing multiple stages of vaporization and
condensation of the suction steam. Between 1928-1930, there was much interest in this type of systems
in USA. In USA they were mainly used for air conditioning of factories, cinema theatres, ships and
even railway wagons. Several companies such as Westinghouse, Ingersoll Rand and Carrier started
commercial production of these systems from 1930. However, gradually these systems were replaced
by more efficient vapour absorption systems using LiBr-water. Still, some east European countries such
as Czechoslovakia and Russia manufactured these systems as late as 1960s. The ejector principle can
also be used to provide refrigeration using fluids other than water, i.e., refrigerants such as CFC-11,
CFC-21, CFC-22, CFC-113, CFC-114 etc. The credit for first developing these closed vapour jet
refrigeration systems goes to the Russian engineer, I.S. Badylkes around 1955. Using refrigerants other
than water, it is possible to achieve temperatures as low as –100 oC with a single stage of compression.
The advantages cited for this type of systems are simplicity and robustness, while difficult design and
economics are its chief disadvantages.

CHAPTER: 5
WORKING of VCR system:
A vapour compression refrigeration system is an improved type of air refrigeration system in which a
suitable working substance, termed as refrigerant is used. It condensed and evaporates at temperatures
and pressures close to the atmospheric conditions. The refrigerants usually used for this purpose are
ammonia, carbon dioxide and sulphur dioxide.
5.1 Comparison between gas cycles and vapor cycles
Thermodynamic cycles can be categorized into gas cycles and vapour cycles. In a typical gas cycle, the
working fluid (a gas) does not undergo phase change, consequently the operating cycle will be away
from the vapour dome. In gas cycles, heat rejection and refrigeration take place as the gas undergoes
sensible cooling and heating. In a vapour cycle the working fluid undergoes phase change and
refrigeration effect is due to the vaporization of refrigerant liquid. If the refrigerant is a pure substance
then its temperature remains constant during the phase change processes.. Hence, the required mass flow
rates for a given refrigeration capacity will be much smaller compared to a gas cycle. Vapour cycles can
be subdivided into vapour compression systems, vapour absorption systems, vapour jet systems etc.
Among these the vapour compression refrigeration systems are predominant.
5.2 Mechanism of simple vapour compression refrigeration system:
Compression refrigeration cycles take advantage of the fact that highly compressed fluids at a certain
temperature 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, fluid is used to cool a low
temperature environment and reject the heat to a high temperature environment.
Vapour compression refrigeration cycles have two advantages. First, a large amount of thermal energy is
required to change a liquid to a vapor, and therefore a lot of heat can be removed from the air-
conditioned space. Second, the isothermal nature of the vaporization allows extraction of heat without
raising the Simple Vapour Compression Refrigeration System temperature of the working fluid to the
temperature of whatever is being cooled. This means that the heat transfer rate remains high, because the

closer the working fluid temperature approaches that of the surroundings, the lower the rate of heat
transfer.
The refrigeration cycle is shown in Figure below and can be broken down into the following stages:
1 – 2 Low-pressure liquid refrigerant
In the evaporator absorbs heat from its surroundings, usually air, water or some other process liquid.
During this process it changes its state from a liquid to a gas, and at the evaporator exit is slightly
superheated.
2 – 3 The superheated vapour
Enters the compressor where its pressure is raised. The temperature will also increase, because a
proportion of the energy put into the compression process is transferred to the refrigerant.
3 – 4 The high pressure superheated gas
Passes from the compressor into the condenser. The initial part of the cooling process (3-3a) superheats
the gas before it is then turned back into liquid (3a-3b). The cooling for this process is usually achieved
by using air or water. A further reduction in temperature happens in the pipe work and liquid receiver
(3b - 4), so that the refrigerant liquid is sub-cooled as it enters the expansion device.
4 - 1 The high-pressure sub-cooled liquid
Passes through the expansion device, which both reduces its pressure and controls the flow into the
evaporator.

5.3 Simple Vapor Compression Refrigeration Cycle
It is shown on T-S below at point 1, let T1, P1, and s1 be the properties of vapour refrigerant . the four
processes of the cycle are as follows:
Fig. 5.3.a T-s diagram of simple vapor compression refrigeration cycle
Fig. 5.3.b P-h diagram for simple vapor compression refrigeration cycle

1. Compression process:
The vapour refrigerant at low pressure p1 and temperature T1 is compressed isentropically to dry
saturated vapour as shown by the vertical line 1-2 on T-s diagram and by the curve 1-2 on p-h diagram.
The pressure and temperature rises from 1 to 2.
The work done during isentropic compression is given by:
W=h2-h1……………………………………….1
2. Condensing process
The high pressure and temperature vapour refrigerant from the compressor is passed through the
condenser where it is completely condensed at constant pressure p2 and temperature T2. The vapour
refrigerant is changed into liquid refrigerant. The refrigerant while passing through the condenser, gives
its latent heat to the surrounding condensing medium.
3. Expansion process:
The liquid refrigerant at pressure p3=p2 expanded by throttling process through the expansion valve to a
low pressure p4=p1 and temperature T4=T1. Some of the liquid refrigerant evaporates as it passes
through expansion valve, but the greater portion is vaporized in the evaporator. During the throttling
process no heat is absorbed or rejected by the liquid refrigerant.
4. Vaporizing process:
The liquid vapour mixture of the refrigerant at pressure p4=p1 and temperature T4=T1 is evaporated and
changed into vapour refrigerant at constant pressure and temperature. During evaporation, the liquid
vapour refrigerant absorbs its latent heat of vaporization from medium (air, water or brine) which is to
be cooled. The heat absorbed or extracted by the liquid vapour refrigerant during evaporation is given
by: RE=h1-h4=h1-hf3……………………………….2
Where hf3 is sensible heat at T3 (enthalpy of liquid refrigerant leaving the condenser). The coefficient
of performance is ratio of refrigerating effect to the work done.
C.O.P = (h1-h4 ) / ( h1-hf3)
= (h1-hf3) / (h2-h1)
5.4 Types of refrigerant used in vapour compression systems
A variety of refrigerants are used in vapor compression systems. The required cooling temperature
largely determines the choice of fluid. Commonly used refrigerants are in the family of chlorinated
fluorocarbons (CFCs, also called Freons): R-11, R-12, R-21, R-22 and R-502. The properties of these
refrigerants are summarized in Table 1 and the performance of these refrigerants is given in Table 2
below.
Table 5.4.a. Properties of commonly used refrigerants
Table 5.4.b Performance of commonly used refrigerants

Fig 5.3.c VCR system

5.5 Advantages of VCR:
 Large amount of refrigeration at lower initial purchase and operating cost.
 Very efficient
 Very compact system for small to very large heat loads.
 Cycle can be reversed for heat pump operation.
Disadvantages of VCR:
 Parts can wear out.
 System causes noises.
 Potential refrigerant leaks.
 Operates in limited orientation.

5.6 Applications of VCR:
 Household refrigerator.
 Air conditioners.
 Water coolers.
 Ice and Ice cream makers.
 Deep freezers.
 Large industrial refrigeration.
 Air conditioning systems.

5.7 Fundamentals of Refrigeration
Refrigeration and Second Law of Thermodynamics:
Refrigeration is the removal of heat from a space at a temperature lower than the surrounding
temperature. Due to the natural frequency of heat to flow from higher to lower temperature, the rushes
to replace the heat removed. But a refrigerator rejects the heat that is entering into the system back to
the atmosphere. Hence input of work is essential, according to second law of thermodynamics systems
for pumping heat from lower to higher temperatures.
Second law of thermodynamics:
The second law of thermodynamics is a limit law. It gives the upper limit of efficiency of a system. The
second law also acknowledges that processes follow in a certain direction but not in the opposite
direction. It also defines the important property called entropy. It is common sense that heat will not
flow spontaneously from a body at lower temperature to a body at higher temperature. In order to
transfer heat from lower temperature to higher temperature continuously (that is, to maintain the low
temperature) a refrigeration system is needed which requires work input from external source. This is
one of the principles of second law of thermodynamics, which is known as Clausius statement of the
second law.
Clausius’ statement of second law: It is impossible to transfer heat in a cyclic process from low
temperature to high temperature without work from external source. It is also a fact that all the energy
supplied to a system as work can be dissipated as heat transfer. On the other hand, all the energy
supplied as heat transfer cannot be continuously converted into work giving a thermal efficiency of 100
percent. Only a part of heat transfer at high temperature in a cyclic process can be converted into work,
the remaining part has to be rejected to surroundings at lower temperature. If it were possible to obtain
work continuously by heat transfer with a single heat source, then automobile will run by deriving
energy from atmosphere at no cost. A hypothetical machine that can achieve it is called Perpetual
Motion Machine of second kind. This fact is embedded in Kelvin-Planck Statement of the Second law.
Kelvin-Planck statement of second law: It is impossible to construct a device (engine) operating in a

cycle that will produce no effect other than extraction of heat from a single reservoir and convert all of
it into work.

Mathematically, Kelvin-Planck statement can be written as: cycle ≤ 0W (for a single reservoir)
Reversible and Irreversible Processes:
Irreversible Processes: A process is reversible with respect to the system and surroundings if the
system and the surroundings can be restored to their respective initial states by reversing the direction
of the process, that is, by reversing the heat transfer and work transfer. The process is irreversible if it
cannot fulfill this criterion. If work is done in presence of friction, say by movement of piston in a
cylinder then a part of the work is dissipated as heat and it cannot be fully recovered if the direction of
process is reversed. Similarly, if heat is transferred through a temperature difference from higher
temperature to a lower temperature, its direction cannot be reversed since heat transfer from lower
temperature to higher temperature would require external work input. These are two examples of
irreversible processes.
Reversible process : It is a hypothetical process in which work is done in absence of friction and heat
transfer occurs isothermally. Irreversibility leads to loss in work output and loss in availability and
useful work.
Heat engines, Refrigerators, Heat pumps:
Heat engines : A heat engine may be defined as a device that operates in a thermodynamic cycle and
does a certain amount of net positive work through the transfer of heat from a high temperature body to
a low temperature body. A steam power plant is an example of a heat engine.
Refrigerators : A refrigerator may be defined as a device that operates in a thermodynamic cycle and
transfers a certain amount of heat from a body at a lower temperature to a body at a higher temperature
by consuming certain amount of external work. Domestic refrigerators and room air conditioners are
the examples. In a refrigerator, the required output is the heat extracted from the low temperature body.
Heat pumps : A heat pump is similar to a refrigerator, however, here the required output is the heat
rejected to the high temperature body.
Carnot’s theorems for heat engines:
Theorem 1: It is impossible to construct a heat engine that operates between two thermal reservoirs
and is more efficient than a reversible engine operating between the same two reservoirs.

Theorem 2: All reversible heat engines operating between the same two thermal reservoirs have the
same thermal efficiency. The two theorems can be proved by carrying out a thought experiment and
with the help of second law. Carnot’s theorems can also be formed for refrigerators in a manner similar
to heat engines. Carnot efficiency: The Carnot efficiencies are the efficiencies of completely reversible
cycles operating between two thermal reservoirs. According to Carnot’s theorems, for any given two
thermal reservoirs, the Carnot efficiency represents the maximum possible efficiency.
If we consider a combined system that includes the system and its surroundings, then the combined
system becomes an isolated system. Then one can write: Δ system + ΔSS surroundings = σisol > 0
since entropy is produced in all actual processes, only processes that can occur are those for which the
entropy of the isolated system increases. Energy of an isolated system is conserved whereas entropy of
an isolated system increases. This is called the principle of increase of entropy.
Units of Refrigeration:
A unit is used in the field of refrigeration is known as Ton of Refrigeration. A Ton of Refrigeration is
defined as the quantity of the heat required to be required to be removed from one ton of ice within 24
hours when the initial condition of water is 0 ᵒC, because same cooling effect will be given by melting
the same ice.
5.8 REFRIGERANTS:
The thermodynamic efficiency of refrigeration system mainly depends on its operating temperatures.
However, important practical issues such as system design, size, initial and operating costs, safety, and
serviceability etc.; depend very much on the type of the refrigerant selected for given application. Due to
several environmental issued such as ozone layer depletion and global warming and their relation to the
refrigerants used, the selection of suitable refrigerant has become one of the important issues in recent
times.
Replacement of an existing refrigerant by a completely new refrigerant, for whatever reason, is an

expensive proposition as it may call for several changes in the design and manufacturing of refrigeration
systems. Hence it is very important to understand the issues related to the selection and the use of
refrigerants. In principle, any fluid can be used as a refrigerant in vapor compression refrigeration
systems only.

Primary and Secondary Refrigerants:
Fluids suitable for refrigeration purpose can be classified into primary and secondary refrigerants.
Primary refrigerants are those fluids, which are used directly as working fluids, for example in vapor
compression and vapor compression refrigeration systems. When used in compression or absorption
systems, these fluids provide refrigeration by undergoing phase changing process in the evaporator. As
the name implies, secondary refrigerants are those fluids, which are used for transporting thermal energy
from one location to other. Secondary refrigerants are also known under the name brines or antifreezes.
Of course, if the operating temperatures are above 0ᵒC, then pure air blower can also be used as
secondary refrigerant, for example in large air conditioning systems. The secondary refrigerants do not
undergo phase change as they transport energy from one location to other.
An important property of secondary refrigerant is its freezing point. Generally, the freezing point of
brine will be lower than the freezing point of its constituents. The temperature at which the freezing
point of brine takes place depends on its concentration. The concentration at which a lowest
temperature can be reached without solidification is called as eutectic point. The commonly used
secondary refrigerants are the solution of air blower and ethylene glycol, propylene glycol or calcium
chloride. These solutions are known under the general name of brines. In vapor absorption system, a
refrigerant and absorbent combination is used as the working fluid.
Refrigerant Selection Criteria:
Selection of refrigeration for a particular application is based on the following requirements
 Thermodynamic and thermo physical properties

 Environmental and safety properties, and
 Economics
Thermodynamics and Thermo Physical Properties
The requirements are:

 Suction pressure: At a given evaporated temperature, the saturation pressure should be above
atmospheric for prevention of air or moisture ingress into the system and case of leak detection.
Higher suction pressure is better as it leads to smaller compressor and displacement.
 Discharge pressure: At a given condenser temperature, the discharge pressure should be as

small as possible to allow light weight construction of compressor, condenser etc.
 Pressure ratio: Should be as small as possible for the high volumetric efficiency as low power
consumption.
 Latent and heat of vaporization: Should be as large as large possible so that the required mass
flow rate per unit cooling capacity will be small.
Environmental and Safety Properties:
Next to the thermodynamic and thermos physical properties, the environmental and safety properties are
very important. In fact, at the present the environment friendliness of the refrigerant is a major factor in
deciding the usefulness of a particular refrigerant.

CHAPTER:6
LPG REFRIGERATION
In India, more than 80% of the domestic refrigerator utilizes HFC 134a as refrigerant, due to its
excellent thermodynamic and thermo physical properties. But HFC 134a has a high global warming
potential (GWP) of 1300. There is a need to evaluate various refrigerant options considering the
existing refrigerators in the field and for the future market. CFC’s are principally destroyed by
ultraviolent radiations in the stratosphere; the chlorine released in the high stratosphere catalyzes the
decomposition of ozone to oxygen; and ultraviolent radiations penetrate to lower altitudes. The ozone
impact of car air conditioners also cannot be ignored. Hydro fluorocarbons (HFC’s) can be thought of
as a replacement, but unfortunately the radiation properties of HFCs like R-134a make them powerful
global warming agents. HFC 134a and the HC blend have been reported to be substitutes for CFC 12,
but they have their own drawbacks in energy efficiency, flammability and service ability aspects of the
systems. HFC 134a is not miscible with mineral oil, and hence polyol ester oil is recommended, which
is highly hygroscopic in nature.
LIQUEFIED PETROLEUM GAS (LPG).
LPG is a mixture of commercial butane and commercial propane having both saturated
and unsaturated hydrocarbons. LPG marketed in India shall be governed by Indian
Standard Code IS-4576 (Refer Table 1.0) and the test methods by IS-1448.
6.1 PHYSICAL PROPERTIES AND CHARACTERISTICS OF LPG
DENSITY
LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times heavier than air. It is
readily liquefied under moderate pressures. The density of the liquid is approximately half that of water
and ranges from 0.525 to 0.580 @ 15 deg. C. Since LPG vapour is heavier than air, it would normally
settle down at ground level/ low lying places, and accumulate in depressions.

VAPOUR PRESSURE
The pressure inside a LPG storage vessel/ cylinder will be equal to the vapour pressure corresponding to
the temperature of LPG in the storage vessel. The vapour pressure is dependent on temperature as well
as on the ratio of mixture of hydrocarbons. At liquid full condition any further expansion of the liquid,
the cylinder pressure will rise by approx. 14 to 15 kg./sq.cm. for each degree centigrade. This clearly
explains the hazardous situation that could arise due to overfilling of cylinders. 1.2.3 FLAMMABILITY
LPG has an explosive range of 1.8% to 9.5% volume of gas in air. This is considerably narrower than
other common gaseous fuels. This gives an indication of hazard of LPG vapour accumulated in low
lying area in the eventuality of the leakage or spillage. The auto-ignition temperature of LPG is around
410-580 deg. C and hence it will not ignite on its own at normal temperature. Entrapped air in the
vapour is hazardous in an unpurged vessel/ cylinder during pumping/ filling-in operation. In view of this
it is not advisable to use air pressure to unload LPG cargoes or tankers.
COMBUSTION
The combustion reaction of LPG increases the volume of products in addition to the generation of heat.
LPG requires upto 50 times its own volume of air for complete combustion . Thus it is essential that
adequate ventilation is provided when LPG is burnt in enclosed spaces otherwise asphyxiation due to
depletion of oxygen apart from the formation of carbon-dioxide can occur.
ODOUR
LPG has only a very faint smell, and consequently, it is necessary to add some odourant, so that any
escaping gas can easily be detected. Ethyl Mercaptan is normally used as stenching agent for this
purpose. The amount to be added should be sufficient to allow detection in atmosphere 1/5 of lower
limit of flammability or odour level 2 as per IS : 4576.
COLOUR
LPG is colourless both in liquid and vapour phase. During leakage the vapourisation of liquid cools the
atmosphere and condenses the water vapour contained in them to form a whitish fog which may make it
possible to see an escape of LPG.

TOXICITY
LPG even though slightly toxic, is not poisonous in vapour phase, but can, however, suffocate when in
large concentrations due to the fact that it displaces oxygen. In view of this the vapour posses mild
anaesthetic properties.
6.2 Hazards of LPG
 LPG is approximately twice as heavy as air when in gas form and will tend to sink to the lowest
possible level and may accumulate in cellars, pits, drains etc.
 LPG in liquid form can cause severe cold burns to the skin owing to its rapid vapourisation.
 Vapourisation can cool equipment so that it may be cold enough to cause cold burns.
 LPG forms a flammable mixture with air in concentrations of between 2% and 10%.
 It can, therefore, be a fire and explosion hazard if stored or used incorrectly.
 Vapour/air mixtures arising from leakages may be ignited some distance from the point of escape
and the flame can travel back to the source of the leak.
 At very high concentrations when mixed with air, vapour is an anesthetic and subsequently an
asphyxiate by diluting the available oxygen.
 A vessel that has contained LPG is nominally empty but may still contain LPG vapour and be
potentially dangerous. Therefore treat all LPG vessels as if they were full.

6.3 PARTS OF LPG REFRIGERATOR:
6.3.1 LPG CYLINDER:
LPG is a mixture of butane and isobutene. It is generally stored at 12.7 bar for house hold purpose
cylinder. By using a suitable regulator LPG is sent into capillary tube. LPG is used as a fuel for
domestic, industrial, horticultural, agricultural, cooking, heating and drying processes. LPG can be used
as an automotive fuel or as a propellant for aerosol, in addition to other specialist applications LPG can
also be used to provide lighting through the use of pressure lanterns.
Fig 6.3.1: LPG gas cylinder

6.3.2 Capillary Tube:
The capillary tube is the commonly used throttling device in the domestic refrigeration. The capillary
tube is a copper tube of very small internal diameter. It is of very long length and it is coiled to several
turns so that it would occupy less space. The internal diameter of the capillary tube used for the
refrigeration applications varies from 0.5 to 2.28 mm (0.020 to 0.09 inch). The capillary tube is shown in
picture. The decrease in pressure of the refrigerant through the capillary depends on the diameter of
capillary and the length of capillary. Smaller is the diameter and more is the length of capillary more is
the drop in pressure of the refrigerant as it passes through the capillary tube.
Fig 6.3.2: Capillary tube

6.3.3 EVAPORATOR:
The evaporators are another important parts of the refrigeration systems. Through the evaporators the
cooling effect is produced in the refrigeration system. It is in the evaporators when the actual cooling
effect takes place in the refrigeration systems. For many people the evaporator is the main part of the
refrigeration system, consider other part as less useful. The evaporators are heat exchanger surface that
transfer the heat from the substance to be cooled to the refrigerant, thus removing the heat from the
substance.
Fig 6.3.3: Evaporator
The evaporators are used for wide variety of diverse application in refrigeration and hence the available
in wide variety of shape, sizes and designs. They are also classified in different manner depending on

the method of feeding the refrigerant, construction of the evaporator, direction of air circulation around
the evaporator, application and also the refrigerant control. In the domestic refrigerators the evaporators
are commonly known as freezers since the ice is made in these compartments. In the evaporators the
refrigerant enters at very low pressure and temperature after passing through the capillary tube. This
refrigerant absorbs the heat from the substance that is to be cooled so the refrigerant gets heated while
the substance gets cooled. Even after cooling the substance the temperature of the refrigerant leaving the
evaporator is less than the substance. In the large refrigeration plants the evaporator is used for chilling
water.
6.3.4 PRESSURE GUAGES:
Many techniques have been developed for the measurement of pressure and vacuums. Instruments used
to measure pressure are called pressure gauges or vacuum gauges.
Fig 6.3.4: Pressure gauge

6.3.5 High Pressure Pipes:
The range of high pressure pipes covers most application where there is a requirement to transfer gas at
high pressure. They consist of a steel pipe with steel ball fitted to both ends. Two swiveling connection
nipples press these balls against the seating of the connecting hole and thus sealing against gas leakage.
All pipes are pressure tested to 100 M Pa (14,500 psi) over recommended working pressure.
Fig 6.3.5: High pressure pipe

6.3.6 High Pressure Regulator:
This type of regulator is used to send high pressure gas from the cylinders. These are mainly used in
functions to Bhatti stoves.
Fig 6.3.6: High pressure regulators

CHAPTER: 7
7.1 Construction of LPG Refrigerator:
The LPG refrigerator is shown in the figure. We make the one box of the Thermo-coal sheet. The
thermo-coal sheet size is 15mm used for the LPG refrigerator. The size of the evaporator is
355*254*152 mm³. We kept the thermo-coal sheet because the cold air cannot transfer from inside to
outside of refrigerator. And the evaporator is wrapped totally with aluminum tape. The schematically
diagram of the LPG refrigeration system is shown in below diagram. The gas cylinder is connected to
high pressure regulator, which is connected to high pressure pipes. To the other end of the high pressure
pipes pressure guage is connected. To another end a copper tube is connected which is connected to the
capillary tube. The capillary tube is fitted with evaporator. The evaporator coil end is connected to the
stove by another high pressure pipe. One pressure guage is put between capillary tube and cylinder and
another is put at the end of the evaporator.
Fig 7.1 Construction of LPG Refrigerator

7.2 WORKING OF LPG REFRIGERATOR:
The basic idea behind LPG refrigerator is to use the LPG to absorb heat. The simple mechanism of the
LPG refrigeration working is shown in the figure below.
 LPG is stored in the LPG cylinder under high pressure. When the gas tank of regulators is
opened then high pressure LPG passes through the high pressure pipe. This LPG is going by high
pressure gas pipe to capillary tube.
 High pressure LPG is converted in low pressure at capillary tube with enthalpy remains constant.
 After capillary tube, low pressure LPG is passed through the evaporator. LPG is converted into
low pressure and temperature vapor from and passes the evaporator which absorbs heat from the
chamber. Thus the chamber becomes cool down. Thus we can achieve cooling effect in
refrigerator.
 After passing through the evaporator low pressure LPG is passed through the pipe to burner. And
we can use the low pressure of LPG in burning processes.
The LPG Refrigerator is work on the simple Vapour Compression Refrigeration system. The working of
VCR system is as follows:
Process 2-3: When the compressor is started, it draws the low pressure vapour from the evaporator at
state 2 and compresses it isentropically to sufficiently high pressure up to state 3. Since in compression
work is done on the vapour, its temp also increases and hence it is converted into low pressure
adiabatically i.e. enthalpy remains constant.
After capillary tube, this low pressure LPG is passed through evaporator. In the evaporator LPG is
converted into low pressure and temperature form which it absorbs the heat from the cooling chamber.
Thus the cooling chamber cools down.

Process 3-4: Hot vapour from compressor under pressure is discharged into the condenser where
condenser cooling medium usually water or surrounding air is absorb the heat from hot vapour. This
converts the hot vapour into liquid and the liquid is collected in liquid receiver at state 4.
Process 4-1: The liquid from the liquid receiver at high pressure is then piped to a refrigerant control
valve which regulates the flow of liquid into the evaporator. This control valve, while restricting the
flow, also reduces the pressure of the liquid with the result the liquid change into vapour of low dryness
fraction represented by state 1. During this process the temperature of the refrigerant reduces
corresponding to its pressure.
Process 1-2: Finally, the low pressure, low temperature refrigerant passes through the evaporator coil
where it absorb its latent heat from the cold chamber or from brine solution at constant pressure and
converts into vapour at state 2. It is again supplied to compressor. Thus, the cycle is completed.
Fig-7.2.a: Schematic diagram of simple VCRs

The idea behind working of LPG refrigeration is to absorb heat from surrounding by using the
evaporation of a LPG. The pressure of LPG which is stored in cylinder is at about 80 psi. We are
lowering this pressure of LPG up to pressure 15 psi by using capillary and so that cooling is done on
surrounding by absorbing heat isentropically.
Pressure of LPG in cylinder is high, when the regulator of gas tank is opened then high pressure LPG
passes through gas pipe. After that this high pressure LPG goes in the capillary tube from high pressure
pipe. In the capillary tube this high pressure LPG is converted into low pressure and hence low
temperature because of expansion of LPG gas in capillary tube.
Thus we can get refrigerating effect in refrigerator. After that the low pressure LPG from evaporator is
passed to the burner through high pressure pipe and we can use this low pressure LPG for burning for
further application. In this project we use recompressed LPG cylinder instead of compressor. In this way
we can achieve refrigerating effect from this system.
The actual setup and construction of LPG refrigeration system is shown in the following figure.

Fig 7.2.b: LPG refrigeration and heating system

CHAPTER: 8
ADVANTAGES, DISADVANTAGES AND APPLICATIONS
ADVANTAGES:
 Use of LPG as a refrigerant also improves the overall efficiency of by 10 to 20%.

 The ozone depletion potential (ODP) of LPG is 0 and Global warming potential (GWP) is 8
which is significantly negligible as compare to other refrigerant.
 A part from environment friendly, use of LPG also gives us lot of cost advantages.
 There is 60% reduction in weight of the system due to higher density of LPG.
 This fridge works when electricity is off.
 The parts are effectively silent in operation.
 Running cost is zero
 Eliminates the compressor and condenser.
DISADVANTAGES:
 Efficiency is poor.
 Leakage of LPG causes the blast.
 Repairing and servicing of the system is difficult.
 System is very bulky

APPLICATION:
 It can play an important role in restaurants where continuously cooling and heating is
required.
 It can be used in chemical industries for refrigeration purpose.
 It can be useful in remote parts where electricity is not available.
 It can be used in refineries where consumption of LPG is high.
 The system can universally be used in industrial central cooling and domestic refrigeration
and air conditioning as well.
 It can be used in automobiles running on LPG or other Gaseous fuels for air conditioning.
 It can be useful in remotes parts where Electricity is not available.
 Cooling and storage of essentials in remote areas and in emergency vehicles, such as storage
of essential bio-chemicals, injections, etc in an ambulance, is easily possible.
 It can be used for zero cost air-conditioning of spaces like airports, shopping malls, etc which
have their own gas turbine power-plants.

CHAPTER: 9
CONCLUSION
The aim of the LPG refrigerator was to use LPG as a refrigerant and utilizing the energy of the high
pressure in the cylinder for producing the refrigerating effect. We have the LPG at a pressure of 12.41
bar in Domestic 14.5 kg cylinder equipped with a high pressure regulator and this pressure has reduced
up to 1.41 bar with the help of capillary tube. But if we use a low pressure regulator as is the practice in
conventional domestic LPG gas stove, the pressure of LPG after the expansion device and before the
burner would be different. So we have calculated the refrigerating effect with the help of changes in
properties of LPG (pressure, temperature, and enthalpy) before and after the evaporator using high
pressure regulator and the amount of refrigerating effect is determined. With this energy input the COP
of the LPG refrigerator is 5.08 and it is greater than the domestic refrigerator. But in the future scope the
result may differ if energy input for 1Kg of LPG production, would be taken from the energy audit
report of any refinery.
This system is cheaper at initial as well as running cost. It does not require an external energy sources to
run the system and no moving part in the system. So maintenance cost is also very low. This system is
most suitable for hotel, industries, refinery, chemical industries where consumption of LPG is very high.
We conclude that:
 Propane is an attractive and environmentally friendly alternative to CFCs used currently.

 Mass flow rate increases with increase in capillary inner diameter rand coil diameter where as
mass flow rate decreases with increase in length. It was observed that the COP of system
increases with similar change in geometry of capillary tube.
 Cooling capacities were obtained order of about three- to four fold higher for LPG than those for
R- 12. capillary tube. COP of LPG refrigerator was higher than that of R134a by about7.6%.
LPG seems to be an appropriate long-term candidate toreplaceR134a in the existing refrigerator,
 High COP values were obtained No operation problems have been encountered compressor. The
use of LPG as a replacement refrigerant can contribute to the solution of (ODP) problem and
global warming potential.

REFERENCES
[1] Zainal Zakaria and Zulaikha Shahrun “ The possibility of using liquefied petroleum gas in domestic
refrigeration system” International Journal of Research and Reviews in Applied Science(IJRRAS),
December 2011, Volume9
[2] Vishwadipsingh J. Ghariya and Swastik R. Gajjar “International Journal for Scientific Research and
Development” ISSN (online): 2321-0613, March 2014, Vol.2
[3] Ibrahim Hussain Shah and Kundan Gupta “International Journal of Engineering Sciences and
Research Technology” ISSN: 2277-9655, July 2014, Vol. 3(206- 213).
[4] Khandare R. S. and Bhane A. B “International Journal of[4] Emerging Technology and Advanced
Engineering” ISSN: 2250-2459, March 2015, Volume 5.
[5] A Textbook of Refrigeration And Air Conditioning By R.S. Khurmi, S. Chand Publication.
[6] “PCRA energy audit report”, HPCL LPG bottling plant Asauda Bahadurgarh (Haryana) Dec. 2006.
[7] “Basic statics on Indian petroleum and natural gas” 2006-07.
[8] Shank K. Wang, “Handbook of air conditioning and refrigeration” page no. 11.14 chapter 11.
[9] S. J. Cleg, “Thermodynamic analysis of LPG as refrigerant for industrial refrigeration and
transportation”, Institute of Transport Studies, University of Leeds, Working paper of 471, 1996.
[10] Dr. Iqbal Husain, “Analysis of VCR and VAR systems using organic refrigerants”, CRC press,
Taylor and Francis Group, USA, 2012
[11] Text book of refrigeration and air conditioning by Arora and Domkundwar.
[12] Catalogue of Gas Authority of India on “Properties of combustible gases for industrial purpose

LPG Project Report

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VISVESVARAYA TECHNOLOGICAL UNIVERSITY,

“LPG REFRIGERATION SYSTEM WITH ZERO

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING

VINAYAK UDCHAN (3GN13ME095)

Under the guidance of:

Dr. NAGRAJ R.G.

DEPARTMENT OF MECHANICAL ENGINEERING

CHAPTER NO. TITLE PAGE NO.

CHAPTER 3: DESIGN OF BASIC COMPONENT OF LPG

3.1 Design of Capillary tube 05

3.2 Design of Evaporator 05

CHAPTER 4: TYPES OF REFRIGERATION SYSTEM 06

4.1 Natural Refrigeration 06

4.2 Art of Ice Making by Nocturnal cooling 07

4.3 Evaporative Cooling 07

4.4 Cooling by salt solution 08

Figure No. Figure of Title Page No.

FIG 4.8 Basic VCR system 11

FIG 4.9 Components of Vapour Absorption Refrigeration system 13

FIG 4.10 Basic Open type Air cycle Refrigeration system 14

FIG 4.11 Steam Jet Refrigeration system 15

FIG 5.3.a T-S diagram for simple VCR system 19

FIG 5.3.b P-h diagram for simple VCR system 19

FIG 5.3.c VCR system 22

FIG 6.3.1 LPG cylinder 33

FIG 6.3.2 Capillary tube 34

FIG 6.3.3 Evaporator 35

FIG 6.3.4 Pressure gauge 36

FIG 6.3.5 High Pressure Pipe 37

FIG 6.3.6 High pressure Regulator 38

FIG 7.1 Construction of LPG Refrigerator 39

FIG 7.2.a Schematic diagram of simple VCR 41

TABLE 5.4.a Properties of Commonly used Refrigerant 19

TABLE 5.4.b Performance of Commonly used Refrigerant 19

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 1

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 2

1 A.Baskaran & P.Koshy Mathews

A Performance Comparison of Vapour Compression Refrigeration System Using eco-friendly

2 A.Baskaran & P.Koshy Mathews

A Performance Comparison of Vapour Compression Refrigeration System Using Eco Friendly

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 3

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 4

DESIGN OF BASIC COMPONENTS OF LPG REFRIGERATION

3.1 DESIGN OF CAPILLARY TUBE

1. Friction, due to fluid viscosity, resulting in frictional pressure drop.

Design parameters for capillary tube are:

Cylinder size = 14 kg,

3.2 DESIGN OF EVAPORATOR

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 5

TYPES OF REFRIGERATION SYSTEMS

4.1 Natural Refrigeration

1. Transported from colder regions,

3. Made during night by cooling of water by radiation to stratosphere.

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 6

4.2. Art of Ice making by Nocturnal Cooling:

4.3. Evaporative Cooling:

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 7

4.4. Cooling by Salt Solutions:

4.5. Artificial Refrigeration

4.6. Vapour Compression Refrigeration Systems:

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 8

4.7. Domestic refrigeration systems:

DEPARTMENT OF MECHANICAL ENGINEERING, GNDEC, BIDAR Page 9