International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

International Journal of Research and Innovation in

Thermal Engineering (IJRITE)
MODELING AND THERMAL ANALYSIS OF AIR-CONDITIONER EVAPORATOR

Potireddi Sriram1, S.Raja Sekhar2.

1 Research Scholar, Department of Mechanical Engineering, Godavari Institute of Engineering And Technology, Andhra Pradesh, India.
2 AssociateProfessor, Department of Mechanical Engineering, Godavari Institute of Engineering And Technology, Andhra Pradesh, India.

Abstract
Air conditioning evaporator works by absorb heat from the area (medium) that need to be cooled. It does that by maintaining the evaporator coil at low temperature and pressure than the surrounding air. Since, the AC evaporator coil
contains refrigerant that absorbs heat from the surrounding air, the refrigerant temperature must be lower than the air.
In our project we have modeling an air-cooled evaporator for a home 1.5ton air conditioner. Presently the material used
for coils is copper and the material used for fins is copper or aluminum. A 3D model of the evaporator is done in parametric software Pro/Engineer.
To validate the temperatures and other thermal quantities like flux and gradient, thermal analysis is done on the evaporator coil by applying properties copper and suitable material like aluminum. And also we are varying inside cooling
fluid Hydrocarbon (HC) and Hydro chloroflouro carbon (HCFC).The best material for the evaporator of our design can be
checked by comparing the results.
Thermal analysis is done in ANSYS.
*Corresponding Author:
Potireddi Sriram,
Research Scholar,Department of Mechanical Engineering, Godavari Institute of Engineering And Technology,
Andhra Pradesh, India.
Email: psriram365@gmail.com
Year of publication: 2016
Review Type: peer reviewed
Volume: III, Issue : I
Citation:Potireddi Sriram, Research Scholar "Modeling
And Thermal Analysis of Air-Conditioner Evaporator"
International Journal of Research and Innovation on
Science, Engineering and Technology (IJRISET) (2016)
92-97

In the refrigeration cycle, a heat pump transfers heat from

a lower-temperature heat source into a higher-temperature heat sink. Heat would naturally flow in the opposite
direction. This is the most common type of air conditioning. A refrigerator works in much the same way, as it
pumps the heat out of the interior and into the room in
which it stands as it pumps the heat out of the interior
and into the room in which it stands.
This cycle takes advantage of the way phase changes
work, where latent heat is released at a constant temperature during a liquid/gas phase change, and where
varying the pressure of a pure substance also varies its
condensation/boiling point.
Refrigeration cycle

INTRODUCTION TO AIR CONDITIONER

An air conditioner, often referred to as AC is a home appliance, system, or mechanism designed to dehumidify
and extract heat from an area. The cooling is done using
a simple refrigeration cycle. In construction, a complete
system of heating, ventilation and air conditioning is referred to as "HVAC". Its purpose, in a building or an automobile, is to provide comfort during either hot or cold
weather.
Air conditioning system basics and theories
A simple stylized diagram of the refrigeration cycle:
1) condensing coil,
2) expansion valve,
3) evaporator coil,
4) compressor.

INTRODUCTION TO EVAPORATOR
It is in the evaporators where the actual cooling effect
takes place in the refrigeration and the air conditioning
systems. For many people the evaporator is the main
part of the refrigeration system and they consider other
parts as less useful. The evaporators are heat exchanger
surfaces that transfer the heat from the substance to be
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

cooled to the refrigerant, thus removing the heat from the

substance. The evaporators are used for wide variety of
diverse applications in refrigeration and air conditioning
processes and hence they are available in wide variety
of shapes, 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 the freezers since the ice is made in
these compartments. In case of the window and split air
conditioners and other air conditioning systems where
the evaporator is directly used for cooling the room air, it
is called as the cooling coil. In case of large refrigeration
plants and central air conditioning plants the evaporator
is also known as the chiller since these systems are first
used to chill the water, which then produces the cooling
effect.
In the evaporator the refrigerant enters at very low pressure and temperature after passing through the expansion valve. 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 the than the substance. The refrigerant
leaves the evaporator in vapor state, mostly superheated
and is absorbed by the compressor.
COOLING LOAD CALICULATIONS
Floor Volume= length*Width*height
= 8*10*2.8=224m3
Door area =w*h
= 1.53*2.32 =3.55m2
Wall thickness =0.254m
No of systems =34
Window area =1.325*2.75=3.65m2
No of windows = 3
=3*3.65
= 10.95m 2
No of lights = 4
=4*40 = 160 watts
Florescent co-efficient = 1.25
Total lighting load = 160*1.25 = 200W
Solar heat gain factor (SHGF)
South wall = 140W/m2
North wall =120W/m2
West wall = 340W/m2
East wall = 60W/m2
Overall coefficient of heat transfer (U) W/m2K
UWALL = 1.56W/m2K
UROOF= 5.675W/m2K
UFLOOR = 159W/m2K
UDOOR =142W/m2K
UWINDOW =4.70W/m2K
Equivalent temperature difference (te)
te of north wall =90C
te of south wall =110C
te of west wall =110C
te of east wall =60C
te of roof =190C
te of floor =2.40C
No of persons =40
Sensible heat load per person =117W
Latent heat load per person =50W
Ventilation required per person =0.28m3/min
Outdoor Conditions:
Dry bulb temperature =380C RH =60%

W1=0.015kg/kg of dray air ratio

Indoor conditions:
Dry bulb temperature =270C RH=60%
W2 =0.011kg/kg of dry air ratio
Assumptions:
Using a factor of 1.25 for florescent light
Room latent heat load with 4% factor of safety
Estimation of sensible Heat gain
South wall area = 28*10 = 28m2
North wall area = 28*10 = 28m2
East and west wall area = 22.4m2
Equaling temp diff te0C
South wall Sensible heat gain = UAH

=1.56*28*110 = 480.4W
North wall Sensible heat gain = 1.56 *28*90 = 393012W
East wall Sensible heat gain =1.56*22.4*110 =384.384W
West wall F Sensible heat gain =1.56*22.4*60 =2090664W
Floor Area Sensible heat gain =159*80*2.40 = 30528W
Roof Area Sensible heat gain = 5.675*80*190 =8626W
Door Area Sensible heat gain = 142*3.55*90 =4536.9W
South wall = 3.65*4.70*2*110 =377.41W
North wall = 3.65*4.70*1*90 154.395W
Solar Heat Gain through South glass:
Area of windows* SHGE for south = 3.65*2*140=1022m2
Total Sensible heat gain per person* No of persons =
117*40 = 4680W
Q* Total No of persons per person* No of persons =50*40
=2000W
Amount of In filter air (vi) = length* Width*height*no of air
changes /60
= 224*1/60 = 30733m3/min
Sensible heat gain due to infiltration air =0.02044*V1*(tdb1
- tdb2)
= 0.02044*3.73*(38-27)
=0.83865kW
Tdb1 = outside temp
Tdb2 = inside temp
Latent heat gain due to infiltration Air =50*V1*(w1 w2)
= 50*3.73*(0.015-0.011)
= 0.746kW
Sensible heat gain for computer = wattage per system*no
of systems
= 450*36=16200W
Total room Sensible heat (RHS) = 1.0495 (heat gain form
walls + windows + solar heat gain through glass + heat
gain form persons + due to infiltration + due to ventilation
+due to lightening +due to computers)
= 1.045(556.115+1022+0.8386532+16200+200+63)
= 23754.892W
Total Room latent Heat (RHL) = 1.05*(from persons + unfiltered air +ventilation).
= 1.05(4680+3.733+10.95)
= 5070.2576W
Total heat=28825.15/3530
= 8.16tons
Hence we can take 9tons.
6x 1.5 ton Split ACs
INTRODUCTION TO CAD
Computer-aided design (CAD), also known as ComputerAided Design and Drafting (CADD), is the use of computer technology for the process of design and design93

International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

documentation. Computer Aided Drafting describes the

process of drafting with a computer. CADD software, or
environments, provides the user with input-tools for the
purpose of streamlining design processes; drafting, documentation, and manufacturing processes.
DATA POINTS

INTRODUCTION TO FEA
Finite Element Analysis (FEA) was first developed in 1943
by R. Courant, who utilized the Ritz method of numerical analysis and minimization of variation calculus to obtain approximate solutions to vibration systems. Shortly
thereafter, a paper published in 1956 by M. J. Turner,
R. W. Clough, H. C. Martin, and L. J. Top established a
broader definition of numerical analysis. The paper centered on the "stiffness and deflection of complex structures".
By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries. Since the rapid
decline in the cost of computers and the phenomenal increase in computing power, FEA has been developed to
an incredible precision. Present day supercomputers are
now able to produce accurate results for all kinds of parameters.

CURVES GENERATION

FEA consists of a computer model of a material or design that is stressed and analyzed for specific results. It
is used in new product design, and existing product refinement. A company is able to verify a proposed design
will be able to perform to the client's specifications prior
to manufacturing or construction. Modifying an existing
product or structure is utilized to qualify the product or
structure for a new service condition. In case of structural
failure, FEA may be used to help determine the design
modifications to meet the new condition.
THERMAL ANALYSIS OF EVAPORATOR USING COPPER FOR TUBE AND PLATE HYDROCARBON FLUID
Imported Model through IGES Format (Initial graphical
exchanging specification) it is used to convert 3d parts/
assemblys between graphical softwares

PIPES SECTON

PLATES FINAL MODEL

Tube Material - Copper

Element Type: solid 20 nodes 90
Material Properties: Thermal Conductivity 63W/mK
Specific Heat 14 J/kg K
Density - 0.00007500 kg/mm3
Plate Material - Copper
Element Type: solid 20 nodes 90
Material Properties: Thermal Conductivity 63W/mK
Specific Heat 14 J/kg K
Density - 0.00007500 kg/mm3

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

Meshed model- meshing is used to deconstruct complex

problem (model) into small problems (elements) to solve in
numerical method.

Above image is showing Thermal Gradient-rate of change of temperature per unit distance.

THERMAL ANALYSIS OF EVAPORATOR USING COPPER FOR TUBE AND AL 204 FOR PLATE HYDROCARBON FLUID

Above image is showing Temperature distribution on object

Above image is showing Temperature distribution on object.

Above image is showing Thermal Gradient-rate of change of temperature per unit distance.

THERMAL ANALYSIS OF EVAPORATOR USING COPPER FOR TUBE AND AL [AL99.0 (1100)] FOR PLATE
HYDROCARBON FLUID

Above image is showing Temperature distribution on object.

Above image is showing Thermal Gradient-rate of change of temperature per unit distance.

THERMAL ANALYSIS OF EVAPORATOR USING COPPER FOR TUBE AND PLATE HYDROCHLOROFLOUROCARBON FLUID

Above image is showing Temperature distribution on object.

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

RESULTS
Thermal analysis for fluid Hydrochlorofluorocarbon
Nodal Temperature (0C)

Thermal
Gradient (K/
mm)

Thermal Flux
(W/mm2)

Copper Tube
Copper Plate

16

0.658e-11

0.415e-11

Copper Tube
Al 99 Plate

16

0.186e-11

0.41e-11

Copper Tube
Al 204 Plate

16

8.93

1.34

Above image is showing Thermal Gradient-rate of change of temperature per unit distance.

THERMAL ANALYSIS OF EVAPORATOR USING COPPER FOR TUBE AND AL [AL99.0 (1100)] FOR PLATE
HYDROCHLOROFLOURO- CARBON FLUID

Thermal analysis for fluid Hydrocarbon

Nodal Temperature (0C)

Thermal
Gradient (K/
mm)

Thermal Flux
(W/mm2)

Copper Tube
Copper Plate

16

0.4e-11

0.252e-11

Copper Tube
Al 99 Plate

16

0.683e-11

0.15e-11

Copper Tube
Al 204 Plate

16

4.719

2.973

CONCLUSION
Above image is showing Thermal Gradient-rate of change of temperature per unit distance.

THERMAL ANALYSIS OF EVAPORATOR USING COPPER FOR TUBE AND AL 204 FOR PLATE HYDROCHLOROFLOUROCARBON FLUID

In our project modeling and analysis is done for air-cooled

evaporator for 1.5ton air conditioner.
3D Modeling is done using Pro/Engineer.
Performed Thermal analysis on the evaporator by taking
tube material as copper and varying the plate materials.
We also did analysis by varying refrigerant Hydrocarbon
and Hydro fluorocarbon.
In thermal analysis, we analyze the thermal properties
like nodal temperature, thermal gradient and thermal
flux.
By observing the results, for hydrocarbon or hydro fluorocarbon, by using plate material Al 204 has more thermal
conductivity.
So using Al 204 is advantageous.

Above image is showing Thermal Gradient-rate of change of temperature per unit distance.

When comparing Hydrocarbon and Hydro fluorocarbon,

using Hydro fluorocarbon is more advantageous since its
thermal conductivity is more.
FUTURE SCOPE
In further I would like to do experimental investigation on
the above conditions and CFD analysis to provide some
more accurate results and provisions.

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

REFERENCES

AUTHORS

1.HASHIM SAHAR MOHAISEN (2014) Modling and Thermal Analysis of Air Conditioner Evaporator, SEMAR
GROUPS TECHNICAL SOCIETY. Pages:4156-4160
2. Kiran.B.Parik(2013)ANALYSIS AND VALIDATION OF
FIN TUBE EVAPORATOR, International Journal of Application or Innovation in Engineering & Management
(IJAIEM), 430, 443
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Car Air Conditioning System Based On an Absorption Refrigeration Cycle Using Energy from Exhaust Gas of an
Internal Combustion Engine, Advanced Engineering and
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Potireddi Sriram,
Research Scholar,
Department of Mechanical Engineering,
Godavari Institute of Engineering And Technology,
Andhra Pradesh, India.

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S.Raja Sekhar,
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Godavari Institute of Engineering And Technology,
Andhra Pradesh, India.

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