Chapter - 1 & 2 Automobie Refrigeration and Air Conditioning
Chapter - 1 & 2 Automobie Refrigeration and Air Conditioning
Chapter - 1 & 2 Automobie Refrigeration and Air Conditioning
Air Conditioning
Chapter - 1
Department of Automobile
IOE, Thapathali Campus
and Mechanical Engineering
History of Air Conditioning
• Automobiles were not very comfortable for passengers in the early
years because the cabins were open.
• At first, vents were put in the floors of cars, bringing in more dirt and
dust than cool air
❖ As today’s vehicle drivers travel through different regions, they can enjoy
the same comfort levels as they do at home.
❖ For vehicles operating in the cold region, heating systems keep occupants
warm and comfortable and help keep the windshield clear of ice and snow.
❖ For those operating in the southern hot region, air conditioning greatly
improves the comfort level of the occupants.
❖ Human body heat and warm moist air from breathing constantly
radiate into the air in the cab.
1. Compressor 4. Evaporator
2. Condenser 5. Receiver-drier
3. Pressure regulating 6. Accumulator
devices:
❖ Orifice tube
❖ Thermostatic
expansion valve
Compressor
❖ The compressor can be referred to as the heart of the HVAC
system.
❖ Condensers must have air flow any time the system is in operation.
This is accomplished by the ram air effect or by the engine cooling
fan.
❖ The compressor pumps hot refrigerant gas into the top of the
condenser.
❖ A blower motor circulates air from the cabin through the evaporator
coil.
❖ As the warmer air travels through the cooler fins of the evaporator,
the moisture in the air condenses on their surface.
❖ The refrigerant temperature is lower than that of the air inside the
cab, and heat flows from a warm substance to a cooler one.
❖ The warm air from the cabin passes through the evaporator fins and
causes the liquid refrigerant in the evaporator to boil
❖ This heat is then carried off with the refrigerant to the outside of the
vehicle.
A refrigerant identifier is
used to test the type and
purity of refrigerant within
the system.
CAUTION
If the sample contains a flammable
hydrocarbon, it should not be serviced
unless extreme care is taken to prevent
serious personal injury.
Compressor Servicing Tools
❖Compressor servicing tools are used to
remove the compressor’s electromagnetic
clutch assembly and to remove and
replace the compressor’s rotary front drive
shaft seal.
❖These tools are usually quite compact so
that the technician can service the
compressor without having to remove it
from the vehicle.
Refrigeration can be classified into two types :
1.Natural method
2.Artificial or Mechanical Refrigeration
1.Natural method:
The natural method includes the utilization of
ice or snow obtained naturally in cold climate. Ice melts at zero degree
centigrade. So, when it is placed in a system or space warmer than that
temperature, heat is absorbed by the ice and the space is cooled.
1. Laboratories:
❖ This may involve precision measurement to performance testing
of equipment and processes at controlled temperature and
relative humidity. Laboratories carrying out research in
electronics and biotechnology ares require very clean
atmosphere. Many laboratories using high voltage
2. Printing
3. Manufacture of precision parts
❖ If the metal parts are maintained at uniform temperature during
manufacturing process, these will neither expand nor shrink,
maintain close tolerance
4. Textile Industry:
❖ The yarn in the textile industry is spun and it moves over spool at very
high speeds in modern machines. It is very sensitive to humidity the
generation of static electricity should be avoided. Its flexibility and
strength should not change. If it breaks during the process, the plant
will have to be stopped and yarn repaired before restarting the plant
5. Pharmaceutical Industries:
❖ In these industries to obtain sterile atmosphere, the airborne bacteria
and dust must be removed in the air-conditioning system by filters.
These industries require clean rooms. If capsules are made or used in
the plant, then air has to be dry otherwise the gelatin of capsules will
become sticky.
6. Farm Animals:
❖ The yield of Jersey cows decreases drastically during summer months.
Low temperature results in more efficient digestion of food and
increase in weight of cow and the milk yield. Animal barns have to be
ventilated in any case since their number density is usually very large.
In many countries evaporative cooling is used for creating comfort
conditions in animal houses.
6. Computer Rooms:
❖ The dust spoils the CD drives and printers etc.; hence the rooms
have to be kept clean also by using micro filters in the air-
conditioning system.
7. Power Plants:
❖ Most of the modern power plants are microprocessor controlled.
These days the control rooms are very compact, hence these
require air-conditioning for persons and the microprocessors.
8. Vehicular Air-conditioning:
❖ Bus, tram, truck, car, recreational vehicle, crane cabin, aircraft
and ships all require air-conditioning. In bus, tram, aircraft and
ship, the ccupancy density is very high and the metabolic heat
and water vapour generated by persons has to be rejected. The
cooling load in these is very high and rapidly changes that
provides a challenge for their design.
Comfort Air-Conditioning:
❖ Energy of food is converted into chemical energy for functioning
of brain, lungs, heart and other organs and this energy is
ultimately rejected to the surroundings. Also the internal organs
require a temperature close to 35oC for their efficient operation,
and regulatory mechanisms of human body maintain this
temperature by rejecting appropriate amount of heat. Human
beings do not feel comfortable if some extra effort is required by
the body to reject this energy. The air temperature, humidity and
velocity at which human body does not have to take any extra
action, is called comfort condition
Cryogenic car
Cryogenic Heat Engine
❖ It is a engine which uses very cold substances to produce useful
energy.
❖ There is always some heat input to the working fluid during the
expansion process.
Liquid Nitrogen(LN2)
❖ Liquid Nitrogen is the cheapest, widely produced and most
common cryogen.
❖ It is mass produced in air liquefaction plants
❖ The liquefaction process is very simple.
❖ Normal, atmospheric air is passed through dust precipitator and
pre-cooled.
❖ It is then compressed inside large turbo pumps to about 100
atmospheres(10.13 MPa).
❖ Once the air has been cooled to room temperature it is allowed
to expand rapidly through a nozzle into an insulated chamber.
❖ By running several cycles the temperature of the chamber becomes
low enough. The air entering it starts to liquefy.
❖ Liquid nitrogen is removed from the chamber by fractional distillation
and is stored inside well-insulated Dewar flasks .
Main Components of the Engine:
❖ A pressurized tank(24 gallon) to store liquid nitrogen.
❖ Pressurant bottles of N2 gas substitute for a pump. The gas
pushes the liquid nitrogen out of the Dewar that serves as a fuel
tank.
❖ A primary heat exchanger that heats (using atmospheric heat)
LN2 to form N2 gas, then heats gas under pressure to near
atmospheric temperature.
❖ An Expander to provide work to the drive shaft of the vehicle.
❖ An economizer or a secondary heat exchanger, which preheats
the liquid N2 coming out from the pressurized tank taking heat
from the exhaust.
Principle of Operation:
❖ LN2 at –320oF (-196oC) is pressurized and then vaporized in a
heat exchanger by ambient temperature of the surrounding air.
❖ This heat exchanger is like the radiator of a car but instead of
using air to cool water, it uses air to heat and boil liquid nitrogen.
❖ Liquid N2 passing through the primary heat exchanger quickly
reaches its boiling point.
❖ The N2 expands to a gas with a pressure of 150 KPa.
❖ The pressurized N2 gas drives the motor.
❖ The only exhaust is nitrogen, which is major constituent
of our atmosphere.
❖ Energy+N2(l)-->N2(g )Hence, there is no pollution
produced by running this car.
• Advantages over electric cars:
❖A liquid nitrogen car is much lighter and refilling its
tank takes only about 10-15 minutes.
❖The exhaust produced by the car is environmental
friendly.
❖A cryogenic car could have three times the range of
an electric car of the same weight and no battery
disposal concerns .
Drawbacks:
❖ The N2 passing through the tubes of the heat exchanger is so
cold that the moisture in the surrounding air would condense on
the outside of the tubes, obstructing the air flow.
❖ Should a nitrogen car be kept in a poorly ventilated space and, if
the Nitrogen leaks off, it could prove fatal.
❖ Turning N2 gas into a liquid requires a lot of energy. So while
cryogenic cars have zero emissions, they rely on energy
produced at emission generating power plants.
Efficiency:
❖ The LN2 car can travel 79 miles(127.58 km) on a full 24
gallon(90 liter) tank of liquid nitrogen going 20 MPH.
❖ Its maximum speed is over 35 MPH.
Chapter 2- Refrigerants
Introduction
❖ Refrigerant : is the primary working fluid used for
absorbing and transmitting heat in a refrigeration
system
❖ Refrigerants absorb heat at low temperature and
low pressure and release heat at a higher
temperature and pressure
❖ Most refrigerants undergo phase changes during
heat absorption (evaporation) and heat releasing
(condensation)
Introduction
❖ The thermodynamic efficiency of a refrigeration
system depends mainly on its operating
temperatures.
❖ However, important practical issues such as the
system design, size, initial and operating costs,
safety, reliability, and serviceability etc. depend
very much on the type of refrigerant selected for a
given application.
❖ Due to several environmental issues such as
ozone layer depletion, global warming and their
relation to the various refrigerants used, the
selection of suitable refrigerant has become one of
the most 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 use of refrigerants. In
principle, any fluid can be used as a refrigerant.
❖ Air used in an air cycle refrigeration system can also be
considered as a refrigerant.
❖ However, attention is mainly focused on those fluids that
can be used as refrigerants in vapor compression
refrigeration systems only.
Primary and Secondary
Refrigerants
❖ Fluids suitable for refrigeration purposes 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 absorption
refrigeration systems.
❖ When used in compression or absorption systems,
these fluids provide refrigeration by undergoing a
phase change process in the evaporator.
❖ As the name implies, secondary refrigerants are
those liquids, which are used for transporting
thermal energy from one location to other.
Secondary refrigerants are also known under the
name antifreezes.
❖ Of course, if the operating temperatures are above
0oC, then pure water can also be used as
secondary refrigerant, for example in large air
conditioning systems.
❖ Antifreezes or brines are used when refrigeration is
required at sub-zero temperatures.
❖ Unlike primary refrigerants, the secondary
refrigerants do not undergo phase change as they
transport energy from one location to other.
❖ Cooling Medium: is a working fluid cooled by the
refrigerant to transport the cooling effect between a
central plant and remote cooling units and terminals
❖ Chilled water, brine, and glycol are used as cooling
media in many refrigeration systems.
❖ The cooling medium is often called a secondary
refrigerant, because it reduces the extensive
circulation of the primary refrigerant
❖ An important property of a secondary refrigerant is its
freezing point. Generally, the freezing point of a brine will
be lower than the freezing point of its constituents.
❖ The temperature at which freezing of a 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
solutions of water and ethylene glycol, propylene glycol or
calcium chloride. These solutions are known under the
general name of brines.
Essential Properties of Refrigerants
❖ Chemical stability under conditions of use is the
most important characteristics
❖ Safety codes may require a nonflammable
refrigerant of low toxicity for most applications
❖ Cost, availability, efficiency, and compatibility with
compressor lubricants and materials with which the
equipment is constructed are other concerns
❖ Latent heat of vaporization is another important
property
Physical Properties
1. HaloCarbons
2. Azeotropic Refrigerants
3. Zeotropic Refrigerants
4. Inorganic Refrigerants
5. Hydrocarbon Refrigerants
Halocarbon Refrigerants
❖Examples :
❖CFC’s : R11, R12, R113, R114, R115
❖HCFC’s : R22, R123
❖HFC’s : R134a, R404a, R407C, R410a
Inorganic Refrigerants
❖Carbon Dioxide
❖Water
❖Ammonia
❖Air
❖Sulphur dioxide
Azeotropic Refrigerants
❖Normal reaction
❖ But CFC refrigerants leaked during the manufacturing and normal
operation or at the time of servicing or repair, mix with surrounding
air and rise to troposphere and then into stratosphere due to normal
wind or storm. The Ultraviolet rays act on CFC releasing Cl atom,
which retards the normal reaction:
Retarded reaction
Harmful consequences of ozone depletion
For Humans Increase in
❖ Skin cancer For marine life
❖ Snow blindness ❖Reduced
➢plankton
❖ Cataracts
➢juvenile fish
Less immunity to ➢larval crabs and
❖ Infectious diseases shrimps
❖ Malaria
❖ Herpes
For plants
❖ Smaller size
❖ Lower yield
❖ Increased toxicity
❖ Altered form•
Montreal protocol- Control Schedule
Global Warming Potential (GWP):
❖ Refrigerants should have as low a GWP value as possible to
minimize the problem of global warming. Refrigerants with zero
ODP but a high value of GWP (e.g. R134a) are likely to be
regulated in future.
Total Equivalent Warming Index (TEWI):
❖ The factor TEWI considers both direct (due to release into
atmosphere) and indirect (through energy consumption)
contributions of refrigerants to global warming. Naturally,
refrigerants with as a low a value of TEWI are preferable from
global warming point of view.
❖ TEWI factor for the chiller unit calculated over its lifetime of 25 years
:
❖ 128 800 + 342 930 + 32 663 850 = 33 135 580 kg CO2
❖ This implies that the chiller will contribute to the equivalent of
33 135 580 kg of CO2 over its useful life of 25 years.
❖ Direct emissions = 1.4 % of the indirect emissions
Improving TEWI of a System
❖Hydrocarbons
R152a
❖ ODP-0,GWP-140
❖ R152a is another attractive HFC with similar properties to R12.
❖ GWP is one order less than HFC134a but it is slightly flammable.
❖ Also it has lower energy consumption. Hence the Environmental
Protection Agency of Europe prefers HFC152a to HFC134a
Environmental Effect Of Some Refrigerants
HCFC
❖Transitional compounds with low ODP
❖Partially halogenated compounds of hydrocarbon
❖Remaining hydrogen atom allows Hydrolysis and can
be absorbed.
❖R22, R123
❖Production frozen at 1996 level
❖35% cut by 2005,65% by 2010
❖90% by 2015,100 % by 2030
❖10 year grace period for developing countries.
R22
❖ODP-0.05, GWP-1700
❖R22 has 40% more refrigerating capacity
❖Higher pressure and discharge temp and not suitable
for low temp application
❖Extensively used in commercial air conditioning and
frozen food storage and display cases
R123
❖ODP-0.02,GWP-90
❖As a replacement for R11 as similar thermodynamic
properties.
❖Very short atmospheric life but classified as
carcinogen
❖Retrofit alternative to R11
Carbon Dioxide as Refrigerant
❖ Non Flammable
❖ Non toxic
❖ Inexpensive and widely available
❖ Its high operating pressure provides potential for system
size and weight reducing potential.
Drawbacks:
❖Operating pressure (high side) : 80 bars
❖Low efficiency
Hydrocarbon
❖ Very promising non-halogenated organic compounds with no ODP and
very small GWP values
❖ Their efficiency is slightly better than other leading alternative
refrigerants
❖ They are fully compatible with lubricating oils conventionally used with
CFC12.
❖ Extraordinary reliability- The most convincing argument is the reliability
of the hydrocarbon system because of fewer compressor failures.
❖ But most of the hydrocarbons are highly flammable and require
additional safety precaution during its use as refrigerants.
❖ Virtually no refrigerant losses
❖ Hydrocarbons have been used since the beginning of the century and
now being considered as long term solutions to environmental
problems,
• Dominant in domestic market like household refrigerators and freezers
• Growing use in very small commercial systems like car air-conditioning
system
• Examples:
❖R170, Ethane, C2H6
❖R290 , Propane C3H3
❖R600, Butane, C4H10
❖R600a, Isobutane, C4H10
❖Blends of the above Gases
R290
❖ ODP-0,GWP-3
❖ Compatible with copper.Miscible with mineral oil
❖ Highest latent heat and largest vapour density
❖ A third of original charge only is required when replacing
halocarbons refrigerant in existing equipment
❖ Energy saving : up to 20% due to lower molecular mass and
vapour pressure
R 600a
❖ ODP-0,GWP-3
❖ Higher boiling point hence lower evaporator pressure
❖ Discharge temp is lowest
❖ Very good compatibility with mineral oil
Flammability
❖ALL refrigerants are flammable at some point
❖Lubricants, heated and under pressure have a
lower flash point to refrigerant
❖Source of ignition, Air, Fuel
❖Most HC’s are only flammable at between 2 and
10% when mixed with air
Flammability
❖ ODP = 0
❖ GWP = 0
❖ Excellent thermodynamic characteristics: small
molecular mass, large latent heat, large vapour density
and excellent heat transfer characteristics
❖ High critical temperature (132C) : highly efficient cycles
at high condensing temperatures
❖ Its smell causes leaks to be detected and fixed before
reaching dangerous concentration
❖ Relatively Low price
Some Drawbacks of Ammonia as Refrigerant
❖Toxic
❖Flammable ( 16 – 28% concentration )
❖Not compatible with copper
❖Temperature on discharge side of
compressor is higher compared to other
refrigerants
Properties of Ammonia
Concentration ( ppm ) Effect
5 Noticeable by smell
25 Irritation noticeable