Optimization Design And Fabrication Of VAR system Via Use Of Solar Energy

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Introduction

The subject matter related to “Optimization Design & Fabrication of VAR system via Use of Solar Energy” was carried out in detail for the academic purpose from the July 2105 to Nov, 2015 under the responsibility & inspection of Navdeep singh. Submitting the final report to the Department of K.C. College of Engineering & Information Technology, Nawanshahar, I completed the overall project successfully as a leader of the team.

Background

Nowadays, the use of the VAR system has been prevalent in the CO2 emission process as it delivers the requirement of high-grade energy driven from the compressor. The use of solar energy in the VAR system can increase COP value and reduce production cost.

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This project depended upon the design of the VAR system via the use of solar energy after which the prototype was constructed. For this, various parameters like no. of tubes, mass flow rate, the capacity of the absorber, and so on were determined in order to analyze the COP measurement.

In order to obtain the design of the VAR system, the project mainly applied solar energy, and it was focused to achieve the following specific objectives:

To attain improvement of COP index for VAR system.

To minimize the production cost for the suitability in combating energy consumption of the refrigeration function.

Working on this project, I conducted an investigation of various research articles on the same project. From the literature reviews, I specified the list of the materials required in the design of the VAR system. I further assigned the task division to members on the basis of their knowledge and skills. I further visited time to time to the department and supervisor to obtain the technical assistance required in the project.

The diagram indicating my role in this project is depicted below:

Figure: position representing chart

I executed the various roles that were assigned to me were:

I understood the operating principle of the VAR system.

I then assumed an appropriate consideration like temperature, ammonia concentration, and so on in each component of the VAR system.

I analyzed the COP index of the system.

I used the solar capacity to calculate the battery size and capacity of the battery required.

I assembled them together using CREO solid model of the system to create the prototype.

I tested the prototype of the system.

Before initiating the project, I carried out the literature review of the VAR system. I used various sources like internet, journals, textbooks, papers, research articles. I researched different projects related to this topic in order to gain some insight into the project. I understood the operating principle of the VAR system.

I then provided the specifications of required components like refrigeration, regeneration, solar panels & other components used in the VAR system. After components selection, I designed the layout of the solar based VAR system.

I then assumed an appropriate consideration like temperature, ammonia concentration, and so on in each component of the VAR system. Then, I calculated the mass flow rate. After that, I designed required no. of tubes and effective area for the design of each component. For which, I worked on the application of the heat exchange process of thermodynamics.

Finally, I analyzed the COP index of the system. I calculated the capacity of the power required to run the generator. Based on this capacity, I calculated the solar panel size and capacity required to supply these devices. I used the solar capacity to calculate the battery size and capacity of the battery required.

Then I acquired all the components required for the project based on the design and assembled them together using CREO solid model of the system to create the prototype. I carried out the costing and estimation of the different components used and the solar panel. Then I tested the prototype of the system.

Problem of low Coefficient of performance

After all the design of the different components were carried out, I calculated the coefficient of performance. The coefficient of performance of the system was very low. So I needed to increase the coefficient of performance. For that, I researched the topic COP and studied and read various books, papers and articles. After that, I found that the COP was highly dependent on the operating conditions like a temperature between the sink and system, absolute temperature and heat generator temperature. So after that, I increased the temperature of the generator, which was used to heat the ammonia liquid supplied by the pump. This increased the mass flow rate of the ammonia liquid of the system. As a result, the cooling effect of the liquid ammonia increased. Hence, the heat absorbed by the absorber was increased. As the COP of the system was directly proportional to the heat absorber resulting in an increase of the COP value. In this way, I increased the COP of the system.

Problem in the condenser and the expansion valve

After the design of the system was completed, I made the prototype of the system based on the design. Then I tested the system for its efficiency and performance. The results were not as I expected. In fact, it was far below than it normally should be. So after obtaining the results, I showed the results to the supervisor. After consulting about the result, we came to the conclusion that the results were not correct, and there were issues in the prototype or the design. So after that, I investigated the prototype and found that the expansion valve was not working properly, and the condenser was also not condensing as it was expected. So I examined these two devices and found that there was a leakage in the condenser due to which it was not able to condense the liquid properly. It affected the performance of the whole system in the expansion valve. I looked for the debris by disassembling the valve. I found the debris that was left in the valve from the installation. Due to this, the expansion valve was not working properly. So I replaced the expansion valve and checked beforehand for any debris and also replaced the condenser as it cannot be repaired. After replacing these devices, I tested the performance of the system once again and analyzed. This time it was showing great results.

Problem in the solar system

After the design of all the component of the system was completed. I carried out the design of the solar system required for operating the whole system. The solar power was mostly used for operating the generator for producing the heat required to heat the liquid. The capacity of the solar panel required was calculated based on the capacity of the generator. Then the capacity of the battery was also calculated based on the solar capacity. But during the testing phase of the system of the prototype, the generator was not operating on full capacity due to the low power source. The solar system was not providing the required capacity. So after analyzing the solar system, I found that the system was not able to generate the required capacity. This was due to the errors in the calculation of the capacity of the solar capacity and the battery size due to use of incorrect efficiency of the solar panel and battery and the inverters due to losses in these components. So I redesigned the solar system and considered all the losses in the process. After that, the new solar panel size was obtained, and a few more solar panel was added to the current solar system, and the battery size was also increased by adding the battery. After that, I tested the prototype of the system once again and observed the system. This time it was working properly.

Creative Work

For increasing the COP of the system, I increased the temperature of the generator by supplying more power to the generator which resulted in increasing the mass flow rate of the liquid used and increased the cooling capacity of the system. Then, I carried out the costing and estimation of the different components used and the solar panel, which provided the low cost of production.

I helped my team members in aspects of the project for providing the effective implementation of the project on time. I regularly talked with the supervisor in order to attain technical resolution when various problems had been encountered. I accumulated the various numerical data obtained from the design of each component and fed it to the members for COP determination. Furthermore, I managed to present the progress report at each meeting.

I followed ICS 71.100.45 standards for operation of the refrigeration system. I followed every rules & regulations set by the K.C. college of Engineering & Information Technology.

Summary

By starting the detail investigation of the various research articles, the components selection had been specified required for the design of the VAR system. Then, the appropriate determination of the design considerations of each component had been performed in order to obtain the high value of COP. After that, cost estimation was done to obtain the efficient & less costly VAR system via the use of solar panels.

It was really a great opportunity to learn more about the technical knowledge that had been studied from the academic curriculum. It provides a wide range of vision in the development of the CREO solid model of the various component of the designed VAR system. The continuous interaction with department & supervisor led to the improvement of my communication skills.

I contributed to the layout design of the solar based VAR system. I fully involved myself in thermodynamic analysis of components used in the system. I measured mass flow rate & heat exchange among them and finally determined the improved value of COP of the system. Eventually, the final report was submitted for approval to the College Department.

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