CDRB Report
CDRB Report
CDRB Report
AND CONDENSER
GROUPMEMBERS SUPERVISOR
Mr. Talha Usman Malik
Mr. Umair Aziz Dr.Tahir Abdul Hussain
Ratlamwala
Mr. Osama Ikhlaq Abbasi
Mr. Yousaf Akhlaq
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ABSTRACT
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Table of Contents
ABSTRACT...................................................................................................................................................... 2
INTRODUCTION .............................................................................................. Error! Bookmark not defined.
1.1 Background ......................................................................................................................................... 4
1.2 Problem statement .............................................................................. Error! Bookmark not defined.
1.3 Aim of the Project ............................................................................................................................... 6
1.4 Scope of the project ............................................................................................................................ 6
LITERATURE REVIEW ..................................................................................................................................... 7
2.2 Condenser ............................................................................................................................................. 11
2.3 Flash tank .......................................................................................................................................... 13
DESIGN CONSIDERATION ............................................................................................................................ 14
3.1 Condenser ......................................................................................................................................... 14
3.1.1 Classification of condenser ........................................................................................................ 15
TEST OF CONDENSER USING DIFFERENT MATERIALS ................................................................................. 18
Rating matrix ............................................................................................................................................... 20
3.1.3 Material Selection For Condenser............................................................................................. 21
Rating matrix ............................................................................................................................................... 22
3.2 Flash Tank............................................................................................. Error! Bookmark not defined.
3.2.1 Design consideration.................................................................................................................. 24
3.3 Valves ................................................................................................................................................ 25
3.3.1 Types of valves. .......................................................................................................................... 26
3.4 PUMPS............................................................................................................................................... 28
Risk assessment .......................................................................................................................................... 28
Gantt chart .................................................................................................................................................. 31
Biblography .................................................................................................... Error! Bookmark not defined.
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INTRODUCTION
1.1 Background
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Redesigning and fabrication of of parabolic trough collector, heat exchanger, flash tank
and condenser.
Using Nano fluid in pipes of parabolic trough collector instead of water to avoid
corrosion in pipes.
Use of Nano fluid instead of water because they have high rate of conductivity than
water.
Redesigning and fabrication of heat exchanger which can effectively exchange heat of
Nano fluid with water.
Redesign and fabrication of condenser and flash tank.
sun light are collected over parabolic trough collector in which there is Nano fluid
passing in tube which becomes hot, now this Nano fluid exchange heat with water in
heat exchanger thus water becomes hotter now this hot water taken
into the flash tank in which pressure is very low thus makes it steam, this steam is taken
into the condenser which is at same pressure.
Water is falling over the condenser which exchange heat of steam with water and
lowering the temperature of steam, as the temperature of steam becomes low it
converted into water which is pumped out at environmental condition into the container
now this water is fresh water which is stored in container.
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1.2 Problem statement
In spite of the fact that water covers about 71 percent of the Earth’s surface area,
however, it is a challenge to meet all humans, animals and plants demand to
freshwater. Freshwater is about 2.5% of total water quantity, most of it is as glaciers, ice
caps, and groundwater, only 0.008% represents the accessible surface freshwater.
Population growth and industrialization have worsened the problem of water shortage.
One-third of the world residents currently undergo severe water stress and the
percentage is expected to increase. Water scarcity occurs when water supply falls
below 1000 cubic meters per person per year. One of the most promising solution to
overcome the water shortcoming is desalination.
The main object of the project is to produce the fresh water by desalination system
from sun light. We are aiming to design and fabrication of flash tank and condenser for
desalination system. In flash tank hot water from the heat exchanger is converted into
steam by reducing its pressure which later taken into condenser to obtain fresh water.
Flash tank and condenser design and selection of pump and piping system,reviews
codes and standards.
Calculations and simulations
Project cost estimation
Fabrication of the project
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COMPLETE PROJECT
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SCOPE OF PROJECT
8
LITERATURE REVIEW
Renewable energy technologies show great promise for water desalination. These
energy technologies driven desalination systems fall into two categories.
The first includes distillation processes driven by heat produced directly by the
renewable energy system, while the second includes membrane and distillation
processes driven by electricity or mechanical energy produced.
With the world's fresh water demands increasing, much research has been directed at
addressing the challenges in using renewable energy to meet the power needs for
desalination plants.
The desalination plant is referred to as an indirect process if the heat comes from a
separate solar collector or solar ponds; whereas it is referred to as direct if all
components are integrated into the desalination plant. Particularly attractive is
desalination associated with concentrating solar power (CSP) plants.
CSP plants collect solar radiation and provide high-temperature heat for electricity
generation. Therefore, they can be associated with either membrane desalination units,
e.g. reverse osmosis (RO), or thermal desalination units.
CSP plants are often equipped with thermal storage systems to extend operation when
solar radiation is not available, and/or combined with conventional power plants for
hybrid operation.
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This paves the way to a number of design solutions which combine 3 electricity and
heat generation with water desalination via either thermal or membrane separation
processes.
CSP plants are also large enough to provide core energy for medium- to large-scale
seawater desalination. In desert regions (e.g. MENA) with high direct solar irradiance,
CSP is considered a promising multipurpose technology for electricity, heat and district
cooling production, and water desalination.
Solar desalination systems have low operation and maintenance costs but require large
installation areas and high initial investments. However, concentrating solar power
(CSP) offers a sustainable alternative to fossil fuels for large scale seawater
desalination.
CSP can help to solve the problem especially in Middle East and North Africa, but
market introduction must start immediately in order to achieve the necessary freshwater
production rates in time. Most of such technologies have already been demonstrated,
except for Solar/CSP-MED.
With the rapid decrease of renewable energy costs, technical advances and increasing
number of installations, renewable desalination is likely to reduce significantly its cost in
the near future and become an important source of water supply for regions affected by
water scarcity.
Attention has been directed towards improving the efficiencies of the solar energy
conversions, desalination technologies and their optimal coupling to make them
economically viable for small and medium scale applications.
Solar energy can be used directly as thermal or it can be converted to electrical energy
to drive reverse osmosis units.
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The thermal energy can be achieved in solar stills, collectors, or solar ponds. However,
electrical energy can be produced from solar energy directly by photo-voltaic (PV)
conversion or via a solar thermal power plant.
Interestingly, many areas such as the Middle East and North Africa were not always
arid. At the end of the Pleistocene, roughly 12,000 years ago, the melting of glacier ice
allowed many such areas have considerable fresh water.
These conditions persisted to a degree even up to the Classic period 2000 years ago,
and in those times for example certain areas that are now deserts in North Africa were a
significant source of grains for Rome.
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2.2 Condenser
Air Cooled condensers were first introduced in US power industry in early 1970’s, but
only during last 10-15 years number of installations greatly increased largely due to
growing attention being paid to environmental safety.
Also, growing demand for water for both domestic and industrial use has brought an
increased interest in use of Air Cooled condensers.
This is a review paper which studies the performance of Air-cooled condenser under
various operating conditions it is found that there is degradation in performance of air
cooled condenser under high ambient temperatures and windy conditions.
The heat rejection rate of ACC also depends on surface condition of fins and thus its
performance is reduced due to external fouling of finned tubes due to weather
conditions and by internal fouling from condensate (Ammonia corrosion). A Hybrid
(dry/wet) dephlegmator achieves major enhancement in performance when ambient
temperatures are high.
Also shading of condensers is done for air-conditioning units to mitigate the adverse
effect of high ambient temperatures due to solar radiation. Now a day’s wind walls are
used to reduce the effect of high wind velocity .second option is to increase the fan
speed Fin cleaning plays an important role in heat rejection. External cleaning improves
air side heat transfer coefficient.
In order to improve the performance of an ACC Flat tubes inclined at some angle to
horizontal can also be used in place of conventional circular horizontal tubes so that an
improvement in heat transfer rate occurs.
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2.3 Flash tank
Flash (or partial) evaporation is the partial vapor that occurs when a saturated liquid
stream undergoes a reduction in pressure by passing through a throttling valve or other
throttling device. This process is one of the simplest unit operations.
If the throttling valve or device is located at the entry into a pressure vessel so that the
flash evaporation occurs within the vessel, then the vessel is often referred to as a
Flash tank.
This type of flash evaporation is used in the desalination of brackish water or ocean
water by "Multi-Stage Flash Distillation."
The water is heated and then routed into a reduced-pressure flash evaporation "stage"
where some of the water flashes into steam.
This steam is subsequently condensed into salt-free water. The residual salty liquid
from that first stage is introduced into a second flash evaporation stage at a pressure
lower than the first stage pressure.
More water is flashed into steam which is also subsequently condensed into more salt-
free water.
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DESIGN CONSIDERATION
3.1 Condenser
Heat exchangers are used to transfer heat. Some process likes cooling, heating,
condensation, boiling or evaporation.
Different heat exchangers are named according to their application. For example, heat
exchanger used for boiling purposes are called boilers, similarly Heat exchangers being
used to condense are known as condensers
The condenser is a heat exchanger that usually rejects all the heat from the system.
The condenser accepts hot, high –pressure refrigerant usually a super-heated gas, from
the compressor.
The condenser is usually air cooled by natural or forced convection to increase the
cooling effect of the condenser.
Condenser: It is a closed vessel used to condense the steam. The low pressure steam
gives off its heat to the coolant (normally water) and gets converted into water during
the process of condensation.
There are following devices which are related with condenser.
Condensate Extraction Pump: It is a pump which is installed in between the condenser
and fresh water container. It transfers the condensate from the condenser to the fresh
water container.
Fresh water container:-It is a sump that lies after the condenser. It receives the
condensate water from the condenser by condensate pump.
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3.1.1 Classification of condenser
Air-cooled condensers utilize ambient air in order to cool and cycle refrigerant. These
can be readily seen oftentimes outdoors, as they are commonly used in residential and
rooftop cooling systems, and are housed in your standard exterior unit.
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The advantage of choosing an air-cooled system is that they:
Are typically lower in initial purchase cost.
Require less overall lifespan maintenance
Do not require a mechanical room. .
The system operates through a network of water coils used to transfer the heat from the
condenser coils. These systems typically work in-tandem with a cooling tower in order
to circulate out and exhaust heat.
Types of water cooled condenser.
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• Water-cooled systems are often chosen because:
They operate at better efficiencies.
Water is inexpensive
Extended lifespan
Can operate better at higher temperatures.
Liquid cooling offers higher thermal conductivity than air cooling
Water has unusually high specific heat capacity among commonly available liquids at
room temperature and atmospheric pressure allowing efficient heat transfer over
distance with low rates of mass transfer.
The evaporative condenser can be an efficient method of heat rejection. The heat is
rejected at a lower temperature than with simple air-cooling. However this advantage is
only realized above a certain size and loading conditions. This is shown that operating
costs can be higher than for air cooled, taking account of cost of water supply, disposal
and treatment.
The cooling effect of the evaporation of water is applied directly to the condenser
refrigerant pipes in the evaporative condenser
• Applications:
Evaporative condensers can be utilized inside or outside of a building and under run of
the mill conditions, work at a low gathering temperature.
Advantages:
These are used in large commercial air-conditioning units.
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TEST OF CONDENSER USING DIFFERENT MATERIALS
Steel 43 3037.9
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3.1.2 Selection of Condenser Type
1. Volume (a)
2. Efficiency (b)
3. Conductivity (c)
4. Cost (d)
Weighted table
1 for important
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Rating matrix
Type
1. Water Cooled(A)
2. Air Cooled(B)
WEIGHTEAGE A B A B
A 0.20 2 1 0.40 0.20
B 0.20 2 1 0.40 0.20
C 0.20 2 1 0.40 0.20
D 0.30 1 2 0.30 0.60
E 0.10 2 1 0.20 0.10
1.70 1.30
So on this basis we have selected water cooled condenser as it has a rating of 1.7.
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3.1.3 Material Selection For Condenser
3. Maintenance (c)
4. Cost (d)
5. Manufacturing (e)
Weighted table
(e) 0 0 0 0 _____ 0 0%
1 for important
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Rating matrix
Material
2. Aluminum (B)
3. Copper (C)
WEIGHTEAGE A B C A B C
A 0.30 2 3 3 0.60 0.90 0.90
B 0.10 2 3 2 0.20 0.30 0.20
C 0.40 3 1 2 1.20 0.40 0.80
D 0.20 3 2 1 0.60 0.40 0.20
E 0.00 2 3 2 0.00 0.00 0.00
2.6 2.00 2.1
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3.2 Flash Tank
Flash (or partial) evaporation is the partial vapor that occurs when a saturated liquid
stream undergoes a reduction in pressure by passing through a throttling valve or other
throttling device. This process is one of the simplest unit operations. If the throttling
valve or device is located at the entry into a pressure vessel so that the flash
evaporation occurs within the vessel, then the vessel is often referred to as a Flash
tank:-
This type of flash evaporation is used in the desalination of brackish water or ocean
water by "Multi-Stage Flash Distillation." The water is heated and then routed into a
reduced-pressure flash evaporation "stage" where some of the water flashes into
steam. This steam is subsequently condensed into salt-free water. The residual salty
liquid from that first stage is introduced into a second flash evaporation stage at a
pressure lower than the first stage pressure. More water is flashed into steam which is
also subsequently condensed into more salt-free water. This sequential use of multiple
flash evaporation stages is continued until the design objectives of the system are met.
A large part of the world's installed desalination capacity uses multi-stage flash
distillation. Typically such plants have 24 or more sequential stages of flash
evaporation.
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As it consist of multi stage due to its design objective but our project objective will be
achieved with in one flash tank as it converted water into steam which later takes into
condenser. So we are not using multistage rather we are using single stage flash tank.
•large liquid loads are involved, consequently hold-up will set the size
•Three phases are present
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3.3 Valves
Valves are mechanical devices that controls the flow and pressure within a system or
process. They are essential components of a piping system that conveys liquids, gases,
vapors, slurries etc.
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3.3.1 Types of valves.
Different types of valves are available: gate, globe, plug, ball, butterfly, check,
diaphragm, pinch, pressure relief, control valves etc. Each of these types has a number
of models, each with different features and functional capabilities. Some valves are self-
operated while others manually or with an actuator or pneumatic or hydraulic is
operated.
In piping following types of valves are used depending on the requirements. The cost of
Valve in the piping system is up to 20 to 30% of the overall piping cost. And the cost of
a given type and size of the valve can vary 100%. It means that if you choose ball valve
over butterfly valve for the same function. It can cost you more. So, the selection of
valves is essential to the economics, as well as operation, of the process plants.
• Check Valve
• Expansion Valve
.
The check valve prevents backflow in the piping system. The pressure of the fluid
passing through a pipeline opens the valve, while any reversal of flow will close the
valve.
Non return valves allow the fluid to flow only in one desired direction. Any flow in the
opposite direction is mechanically restricted from occurring. A non-return valve is fitted
to ensure that a medium flows through a pipe in the right direction, where pressure
conditions may otherwise cause reversed flow.
Non return valves are used to prevent back flow of fluid, which could damage
equipment or upset the process. Such valves are especially useful in protecting a pump
in liquid applications or a compressor in gas applications from back flow when the pump
or compressor is shut down. Non return valves are also used in process systems that
have varying pressures, which must be kept separate. All check valves are non return
valves.
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3.3.1.2 Expansion Valve
Expansion valves are essentially isenthalpic devices with no work interaction and
negligible heat interaction with the surroundings.
The expansion valve is a passive orifice through which the liquid refrigerant is forced by
the pressure difference between the condensing and the evaporating conditions. If a
system could always operate at fixed conditions, correctly charged, a simple restriction
would fulfil the requirement. In practice this is never the case and control is necessary.
Expansion devices in general use are the following:
1.Capillary tubes, for small hermetic systems. These are factory selected and cannot be
adjusted.
2.Solenoid valves with liquid level sensors or liquid level valves for flooded evaporators.
3.High-pressure float valves plus handset throttle valves for some flooded and low-
pressure receiver circuits.
4.Thermostatic expansion valves or electronic expansion valves for direct expansion
circuits.
Different types of valves serve these functions. These valves can be classified or
categorized based on :
• Function
• End connection
• How it operates
• Types of Actuator it used
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3.4 PUMPS
A hydrodynamic pump machine is a device for converting the energy held by
mechanical energy into fluid.
But it can be difficult to know exactly which pump you should choose. There are so
many designs and niches that identifying the pump which will meet these three needs
can be confusing. To simplify things when trying to select your pump, there are two
types of pump which work in very different ways and broadly encapsulate most pump
designs.
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Risk assessment
A systematic process of evaluating the potential risks that may be involved in a projected activity must
be analyzed and eliminated during design phase of the machine. This assessment is necessary to ensure
the 5S principle of safety for Atlas Honda ltd. Since company has strict policy against the happening and
root causes of any possible outcome that may result in staff or worker injury or may affect the
production line
• Risk Assessment
• Risk Management
• 2 = Medium
• 3 = High
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Risk rating = Likelihood x Impact
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Gantt chart
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32
SOR
1 Introduction
1.1 Preamble
1.2 Scope
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1.3.1 Books
1.3.2 Softwares
Solid works
EES
Ansys 13.0
1.4 Deliverables
1.5.5
Selection of suitable material
1.6 Design Considerations
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1.6.1 Cost consideration
1.6.3 Mobility
1.6.4 Sealing
Stress
1.6.5
pressure maintaince.
1.6.6
1.7 Hazards/Safety
1.8 Costs
Project Advisor's
Signature
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Bibliography
1.(25 years Experience with Seawater Cooled Heat Exchange Equipment in the Shell
Fleets, Shone, E. B. and G. C. Grim, 1986, UK, Institute of Marine Engineering, Science
and Technology, )
4. Khurmi R.S., and Gupta J.K., Refrigeration and Air Conditioning, S Chand,
2012.
5. Hundy G.F., Trott A.R., and Welch T.C., Refrigeration and Air Conditioning, 4th
Edition, Butterworth-Heinemann, 2008.
6. Admiraal D. M., and Bullard C. W., Heat Transfer in Refrigerator Conditioners
and Evaporators, University of Illinois, 1993.
7. Holman J.P., Heat Transfer, Mc Graw Hill, 2003.
8. Domkundwa and Arora, Refrigeration and Air Conditioning, Dhanpat Rai and
Sons, 1994.
9. Shan K. W., Handbook of Air Conditioning and Refrigeration, 2nd Edition, Mc
Graw Hill, 2003.
10. Smith, B.D., Design of Equilibrium Stage Processes, McGraw-Hill, 1963, pp. 105-6,
108-110.
11. McCabe, W.L., J.C. Smith, P. Harriott, Unit Operations of Chemical Engineering, 5th
Edition, McGraw-Hill, 1993. pp. 521- 525.
12. Treybal, R.E., Mass-Transfer Operations, 3rd Edition (Reissue), McGraw-Hill, 1987.
pp. 346, 348-349, 357-360, 363-365.
13. "Types of valve bodies and their specifications - Actuation Valves".
www.actuation.co.uk.
14. "European Commission Pressure Equipment Directive (PED)". Archived from the
original on 2010-08-15. Retrieved 2010-09-13.
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