AIR CONDITIONING USING EXHAUST GAS OF

AUTOMOBILES
 ABSTRACT
Our project deals with the fabrication of automobile exhaust air

conditioning system. It is well known that an IC engine has an efficiency of about

35-40%, which means that only one-third of the energy in the fuel is converted

into useful work and about 60-65% is wasted to environment. In which about 28-

30% is lost by cooling water and lubrication losses, around 30-32% is lost in the

form of exhaust gases and remaining by radiation, etc. In this air conditioning

System, a physicochemical process replaces the mechanical process of the Vapour

Compression System by using energy in the form of heat rather than mechanical

work. The heat required for running this type of air conditioning System can be

obtained from that which is wasted into the atmosphere from an IC engine.
 INTRODUCTION

Air conditioning is the process of removing heat from an enclosed or

controlled space or from a substance and moving it to a place where it is

unobjectionable. The primary purpose of air conditioning is lowering the

temperature of the enclosed space or substance and then maintaining that lower

temperature as compared to the surroundings. Cold is the absence of heat, hence

in order to decrease a temperature, one should "remove heat", rather than

"adding cold."

The basic objective of developing a vapour absorption refrigerant system for

cars is to cool the space inside the car by utilizing waste heat and exhaust gases

from engine. The air conditioning system of cars in today’s world uses “Vapour

Compression Refrigerant System” (VCRS) which absorbs and removes heat from

the interior of the car which is the space to be cooled and further rejects the heat

to be elsewhere. Now to increase an efficiency of car beyond a certain limit

vapour compression refrigerant system resists it as it cannot make use of the

exhaust gases from the engine. In vapour compression refrigerant system, the

system utilizes power from engine shaft as the input power to drive the

compressor of the refrigerant system. Hence the engine has to produce extra
work to run the compressor of the air conditioning system thus utilizing extra

amount of fuel. This loss of power of the vehicle for air conditioning can be

neglected by implementing this type of air conditioning system.

REFRIGERATION AND AIR CONDITIONING

In many ways air conditioning and refrigeration systems are very similar.

Both use specially designed chemicals, the physical effects of the compression and

expansion of gases, and the conversion of gas to liquid to reduce the temperature

of air. The varying uses of these systems, however, mean refrigeration and air

conditioning systems have a handful of key differences in the design and

operation.

Supply

A major difference between refrigeration and air conditioning is the point of

supply for the gases. Refrigeration systems have gas installed in a series of tubes.

In old refrigerators, this gas was chloro-flouro-carbon, or CFC, but this has harmful

effects on people, so refrigerators not contain HFC-134a. HFC-134a is the sole gas

used as a coolant in refrigeration systems. Air conditioning systems use built-in

chemicals, but also air from the room or rooms being heated. Gases built into air
conditioning units cool air that circulates through the unit; the unit then

redistributes the cooled air through the room.

Circulation

Air conditioners have circulation systems designed to project cool air away

from the units while refrigeration units have circulation systems designed to retain

coolant in a confined space. Refrigeration systems circulate cool liquids and gases

through a series of tubes and vents. Cool air from within a refrigerator is sucked

into a compressor that recycles the gas through the tubes. Air conditioners, while

also employing tubes in the coolant system, have fans for the dispersal of air.

Unlike refrigeration systems, which keep gases contained to a pre-determined

space, air conditioning systems disperse cool air throughout areas of unknown

volume.

Vaporization

Both air conditioning and refrigeration units depend on converting liquid to

gas in the cooling process, but the manner in which they achieve this is different

for each system.

AIR CONDITIONING

Air conditioning (often referred to as A/C or AC) is the process of altering

the properties of air (primarily temperature and humidity) to more comfortable

conditions, typically with the aim of distributing the conditioned air to an

occupied space such as a building or a vehicle to improve thermal comfort and

indoor air quality. In common use, an air conditioner is a device that lowers the air

temperature. The cooling is typically achieved through a refrigeration cycle, but

sometimes evaporation or free cooling is used. Air conditioning systems can also

be made based on desiccants.

In the most general sense, air conditioning can refer to any form of

technology that modifies the condition of air (heating, cooling,

(de-)humidification, cleaning, ventilation, or air movement). However, in

construction, such a complete system of heating, ventilation, and air conditioning

is referred to as heating, ventilation, and air conditioning (HVAC -as opposed

to AC).
 COMPONENTS AND DESCRIPTION

The major components used in this project are,

 Compressor,
 Condenser,
 Expansion valve,
 Evaporator,
 Fan or blower,
 IC engine.

COMPRESSOR

An air compressor is a device that converts power (using an electric motor,

diesel or gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,

compressed air). By one of several methods, an air compressor forces more and

more air into a storage tank, increasing the pressure. When tank pressure reaches

its upper limit the air compressor shuts off. The compressed air, then, is held in

the tank until called into use. The energy contained in the compressed air can be

used for a variety of applications, utilizing the kinetic energy of the air as it is

released and the tank depressurizes. When tank pressure reaches its lower limit,

the air compressor turns on again and re-pressurizes the tank.

There are numerous methods of air compression, divided into either positive-

displacement or negative-displacement types.

Positive displacement

Positive-displacement compressors work by forcing air into a chamber whose

volume is decreased to compress the air. Common types of positive displacement

compressors are:-

 Piston-type air compressors use this principle by pumping air into an air

chamber through the use of the constant motion of pistons. They use one-

way valves to guide air into a cylinder chamber, where the air is

compressed.

 Rotary screw compressors use positive-displacement compression by

matching two helical screws that, when turned, guide air into a chamber,

whose volume is decreased as the screws turn.

 Vane compressors use a slotted rotor with varied blade placement to guide

air into a chamber and compress the volume. A type of compressor that

delivers a fixed volume of air at high pressures.

Negative displacement

Negative-displacement air compressors include centrifugal compressors. In

this type, a rotating component imparts its kinetic energy to the air which is

eventually converted into pressure energy. These use centrifugal force generated

by a spinning impeller to accelerate and then decelerate captured air, which

pressurizes it.

Due to adiabatic heating, air compressors require some method of disposing of

waste heat. Generally this is some form of air- or water-cooling, although some

(particularly rotary type) compressors may be cooled by oil (that is then in turn

air- or water-cooled) and the atmospheric changes also considered during cooling

of compressors.

Most air compressors either are reciprocating piston type, rotary vane

or rotary screw. Centrifugal compressors are common in very large applications.

There are two main types of air compressor's pumps: oil-lubed and oil-less. The

oil-less system has more technical development, but is more expensive, louder

and lasts for less time than oil-lubed pumps. The oil-less system also delivers air of

better quality.
 The most common types of air compressors are: electric or gas/diesel

powered compressors. The power of a compressor is measured in HP

(Horsepower) and CFM (cubic feet of air per minute). The gallon size of the tank

tells you how much compressed air "in reserve" is available. Gas/diesel powered

compressors are widely used in remote areas with problematic access to

electricity. They are noisy and require ventilation for exhaust gases. Electric

powered compressors are widely used in production, workshops and garages with

permanent access to electricity. Common workshop/garage compressors are 110-

120 Volt or 230-240 Volt. Compressor tank shapes are: "pancake", "twin tank",

"horizontal", and "vertical". Depending on a size and purpose compressors can be

stationary or portable.

CONDENSER

In systems involving heat transfer, a condenser is a device or unit used to

condense a substance from its gaseous to its liquid state, by cooling it. In so doing,
the latent heat is given up by the substance, and will transfer to the condenser

coolant. Condensers are typically heat exchangers which have various designs and

come in many sizes ranging from rather small (hand-held) to very large industrial-

scale units used in plant processes.

For example, a refrigerator uses a condenser to get rid of heat extracted

from the interior of the unit to the outside air. Condensers are used in air

conditioning, industrial chemical processes such as distillation, steam power

plants and other heat-exchange systems. Use of cooling water or surrounding air

as the coolant is common in many condensers.

In the world of Heating, Ventilation, and Air Conditioning (HVAC),

condensers happen to be a topic of great importance. Instead of confusing

information, the goal is to provide some basic information on the different types

of condensers and their applications.

There are three other condensers used in HVAC systems

 Water-cooled
 Air-cooled
 Evaporative
Air cooled – If the condenser is located on the outside of the unit, the air cooled

condenser can provide the easiest arrangement. These types of condensers eject

heat to the outdoors and are simple to install.

Most common uses for this condenser are domestic refrigerators, upright

freezers and in residential packaged air conditioning units. A great feature of the

air cooled condenser is they are very easy to clean. Since dirt can cause serious

issues with the condensers performance, it is highly recommended that these be

kept clear of dirt.

Water cooled – Although a little more pricey to install, these condensers are the

more efficient type. Commonly used for swimming pools and condensers piped

for city water flow, these condensers require regular service and maintenance.

They also require a cooling tower to conserve water. To prevent corrosion

and the forming of algae, water cooled condensers require a constant supply of

makeup water along with water treatment.

Depending on the application you can choose from tube in tube, shell

and coil or shell and tube condensers. All are essentially made to produce the

same outcome, but each in a different way.

Evaporative – While these remain the least popular choice, evaporative

condensers can be used inside or outside of a building and under typical

conditions, operate at a low condensing temperature.

Typically these are used in large commercial air-conditioning units.

Although effective, they are not necessarily the most efficient.

EXPANSION VALVE

A thermal expansion valve is a component in refrigeration and air

conditioning a system that controls the amount of refrigerant flow into the

evaporator thereby controlling the superheating at the outlet of the evaporator.

Expansion valves are flow-restricting devices that cause a pressure drop of

the working fluid. The valve needle remains open during steady state operation.

The size of the opening or the position of the needle is related to the pressure and

temperature of the evaporator. There are three main parts of the expansion valve

that regulate the position of the needle. A sensor bulb, at the end of the

evaporator, monitors the temperature change of the evaporator. This change in

temperature creates a change in pressure on the diaphragm.

 For example, if the temperature in the evaporator increases, the pressure in

the diaphragm increases causing the needle to lower. Lowering the needle allows

more of the working fluid into the evaporator to absorb heat. The pressure at the

inlet of the evaporator affects the position of the needle and prevents the working

fluid from flowing back into the compressor. Since the pressure before the valve is

higher than the pressure after the valve, the working fluid naturally flows into the

evaporator. The pressure at the inlet of the evaporator acts on the diaphragm.

There is also a spring providing a constant pressure closing the valve needle. The

spring constantly restricts the amount of working fluid entering the evaporator.

The pressure spring can be adjusted to increase or decrease pressure based

on temperature needs. The pressure created by the spring acts on the opening of

the valve. When the pressure of the sensor bulb acting on the diaphragm is

greater than the combined pressure of the evaporator and spring, the valve opens

to increase the flow rate of the working fluid. An increase of flow rate lowers the

temperature of the evaporator and allows for more heat absorption.

There are two main types of thermal expansion valves: internally or

externally equalized. The difference between externally and internally equalized

valves is how the evaporator pressure affects the position of the needle. In
internally equalized valves, the evaporator pressure against the diaphragm is the

pressure at the inlet of the evaporator, whereas in externally equalized valves, the

evaporator pressure against the diaphragm is the pressure at the outlet of the

evaporator. Externally equalized thermostatic expansion valves compensate for

any pressure drop through the evaporator.

Internally equalized valves can be used on single circuit evaporator coils

having low pressure drop. Externally equalized valves must be used on multi-

circuited evaporators with refrigerant distributors. Externally equalized TXVs can

be used on all applications; however, an externally equalized cannot be replaced

with an internally equalized.

EVAPORATOR

An evaporator is a device used to turn the liquid form of a chemical into its

gaseous form. The liquid is evaporated, or vaporized, into a gas.

An evaporator is used in an air-conditioning system to allow a compressed

cooling chemical, such as R-22 (Freon) or R-410A, to evaporate from liquid to gas

while absorbing heat in the process. It can also be used to remove water or other
liquids from mixtures. The process of evaporation is widely used to concentrate

foods and chemicals as well as salvage solvents. In the concentration process, the

goal of evaporation is to vaporize most of the water from a solution which

contains the desired product. In the case of desalination of sea water or in Zero

Liquid Discharge plants, the reverse purpose applies; evaporation removes the

desirable drinking water from the undesired product, salt.

One of the most important applications of evaporation is in the food and

beverage industry. Foods or beverages that need to last for a considerable amount

of time or need to have certain consistency, like coffee, go through an evaporation

step during processing.

In the pharmaceutical industry, the evaporation process is used to eliminate

excess moisture, providing an easily handled product and improving product

stability. Preservation of long-term activity or stabilization of enzymes in

laboratories are greatly assisted by the evaporation process.

Another example of evaporation is in the recovery of sodium hydroxide

in kraft pulping. Cutting down waste-handling cost is another major reason for

large companies to use evaporation applications. Legally, all producers of waste

must dispose of waste using methods compatible with environmental guidelines;

these methods are costly. By removing moisture through vaporization, industry

can greatly reduce the amount of waste product that must be processed.

The solution containing the desired product is fed into the evaporator and

passes across a heat source. The applied heat converts the water in the solution

into vapor. The vapor is removed from the rest of the solution and is condensed

while the now-concentrated solution is either fed into a second evaporator or is

removed. The evaporator, as a machine, generally consists of four sections. The

heating section contains the heating medium, which can vary. Steam is fed into

this section. The most common medium consists of parallel tubes but others have

plates or coils typically made from copper or aluminium. The concentrating and

separating section removes the vapor being produced from the solution. The

condenser condenses the separated vapor, then the vacuum or pump provides

pressure to increase circulation.

Technical problems can arise during evaporation, especially when the

process is applied to the food industry. Some evaporators are sensitive to

differences in viscosity and consistency of the dilute solution. These evaporators

could work inefficiently because of a loss of circulation. The pump of an

evaporator may need to be changed if the evaporator needs to be used to

concentrate a highly viscous solution.

Fouling also occurs when hard deposits form on the surfaces of the heating

mediums in the evaporators. In foods, proteins and polysaccharides can create

such deposits that reduce the efficiency of heat transfer. Foaming can also create

a problem since dealing with the excess foam can be costly in time and efficiency.

Antifoam agents are to be used, but only a few can be used when food is being

processed.

Corrosion can also occur when acidic solutions such as citrus juices are

concentrated. The surface damage caused can shorten the long-life of

evaporators. Quality and flavor of food can also suffer during evaporation. Overall,

when choosing an evaporator, the qualities of the product solution need to be

taken into careful consideration.

FAN OR BLOWER

Blowers are machines whose primary function is to provide a large flow of

air or gas to various processes of many industries. This is achieved by rotating a

number of blades, connected to a hub and shaft, and driven by a motor

or turbine. The flow rates of these fans range from approximately 200 to

2,000,000 cubic feet (5.7 to 57000 cubic meters) per minute. A blower is another

name for a fan that operates where the resistance to the flow is primarily on the

downstream side of the fan.

Most blowers may be categorized into one of two general types: centrifugal

fans and axial fans.

Centrifugal

The centrifugal design uses the centrifugal force generated by a rotating

disk, with blades mounted at right angles to the disk, to impart movement to the

air or gas and increase its pressure. The assembly of the hub, disk and blades is

known as the fan wheel, and often includes other components with aerodynamic

or structural functions. The centrifugal fan wheel is typically contained within

scroll-shaped fan housing, resembling the shell of the nautilus sea creature with a

central hole. The air or gas inside the spinning fan is thrown off the outside of the

wheel, to an outlet at the housing's largest diameter. This simultaneously draws

more air or gas into the wheel through the central hole. Inlet and outlet ducting
are often attached to the fan's housing, to supply and/or exhaust the air or gas to

the industry's requirements.

There are many varieties of centrifugal fans, which may have fan wheels

that range from less than a foot (0.3 meters) to over 16 feet (5 m) in diameter.

Axial

The axial design uses axial forces to achieve the movement of the air or gas,

spinning a central hub with blades extending radially from its outer diameter. The

fluid is moved parallel to the fan wheel's shaft, or axis of rotation. The axial fan

wheel is often contained within a short section of cylindrical ductwork, to which

inlet and outlet ducting can be connected.

In general, axial fans are used where the principal requirement is for a large

volume of flow, and the centrifugal design where both flow and higher pressures

are required.

IC ENGINE

CONSTRUCTION

In this project we use SPARK IGNITION engine of the type two stroke single

cylinder of Cubic capacity 75 cc. Engine has a piston that moves up and down in cylinder.
A cylinder is a long round air pocket somewhat like a tin can with a bottom cut out.

Cylinder has a piston which is slightly smaller in size than the cylinder the piston is a

metal plug that slides up and down in the cylinder Bore diameter and stroke length of

the engine are 50mm and 49mm respectively.

WORKING

There are only two strokes involved namely the compression stroke and the

power stroke; they are usually called as upward stroke and downward stroke

respectively.

Upward Stroke

During this stroke, the piston moves from bottom dead center to top dead center,

compressing the charge-air petrol mixture in combustion chamber of the cylinder.

At the time the inlet port is uncovered and the exhaust, transfer ports are

covered. The compressed charge is ignited in the combustion chamber by a spark given

by spark plug.

Downward Stroke

The charge is ignited the hot gases compress the piston moves downwards,

during this stroke the inlet port is covered by the piston and the new charge is

compressed in the crankcase, further downward movement of the piston uncovers first
exhaust port and then transfer port and hence the exhaust starts through the exhaust

port. As soon as the transfer port open the charge through it is forced in to the cylinder,

the cycle is then repeated.

WORKING PRINCIPLE

The unit consists of four main parts - the boiler, condenser, evaporator and

the absorber. The unit can be run on waste exhaust gas heat. When the unit

operates on the exhaust gas, the heat is supplied by the exhaust gas which is fitted

underneath the central tube and when the unit operates on electricity the heat is

supplied by a heating element inserted in the pocket. The unit charge consists of a

quantity of ammonia, water and hydrogen at a sufficient pressure to condense

ammonia at the room temperature for which the unit is designed. When heat is

supplied to the boiler system, bubbles of ammonia gas are produced which rise

and carry with them quantities of weak ammonia solution through the siphon

pump.
 This weak solution passes into the tube, whilst the ammonia vapour passes

into the vapour pipe and on to the water separator. Here the water vapor is

condensed and runs back into the boiler system leaving the dry ammonia vapour

to pass to the condenser. Air circulating over the fins of the condenser removes

the heat from the ammonia vapour to cause it to condense into liquid ammonia

which flows into the evaporator. The evaporator is supplied with hydrogen. The

hydrogen passes across the surface of the ammonia and lowers the ammonia

vapour pressure sufficiently to allow the liquid ammonia to evaporate.

The mixture of the ammonia and the hydrogen vapour passes from the

evaporator to the absorber. Entering the upper portion of the absorber is a

continuous trickle of weak ammonia solution fed by gravity from the tube. This

weak solution, flowing down through the absorber comes into contact with the

mixed ammonia and hydrogen gases which readily absorbs the ammonia from the

mixture, leaving the hydrogen free to rise through the absorber coil and to return

to the evaporator.

The hydrogen thus circulates continuously between the absorber and the

evaporator. The strong ammonia solution produced in the absorber which flows

down to the absorber vessel and then to the boiler system, thus completing the

full cycle of operation. The liquid circulation of the unit is purely gravitational.
Heat is generated in the absorber by the process of absorption. This heat must be

dissipated into the surrounding air. Heat must also be dissipated from the

condenser in order to cool the ammonia vapour sufficiently for it to liquefy. Free

air circulation is therefore necessary over the absorber and the condenser. The

whole unit operates by the heat applied to the boiler system and it is of

paramount importance that this heat is kept within the necessary limits and is

properly applied.
2D DRAWING
ADVANTAGES

 The running cost of this system is less than air conditioning system.

 The coefficient of performance is quite high as the working cycle of this

system is near the Carnot cycle.

 Among the refrigerant circulated is less per ton of refrigeration than air

refrigeration system because the heat carried away by the refrigerant is

 the latent heat. As a result of this, the size of evaporator is smaller for

the same refrigerating effect.

 This system can be employed over a large range of temperatures. By

adjusting the expansion valve of the same unit, the required

temperature in the evaporator can be achieved.

DISADVANTAGES

 Prevention of leakage of refrigerant in this system is the major problem.

 First investment cost is high than the air conditioning system.

APPLICATIONS

The air conditioning effect from the waste heat from the cars has a wide

range of applications in the fields like,

 Commercial vehicles.

 All automobile industries.

 CONCLUSION

We are proud that we have completed the work with the limited time

successfully. The “AUTOMOBILE EXHAUST GAS AIR CONDITIONING SYSTEM” is

under process with the necessary satisfying conditions. We can able to

understand the difficulties in maintaining the tolerances and also the quality. We

have done to our ability and skill making maximum use of available facilities. In
conclusion remarks of our project work, let us add a few more lines about our

impression project work.

In this changing modern world, every day there is a new discovery in all the

fields of science and technology, benefiting the mankind. In this work, the design

of water cooler is slightly modified with an addition air cooler. If one utilizes

engine energy which goes as waste, even more useful things can be made.