This document outlines the methodology, work plan, materials selection, and design of a solar powered air cooling system using fiber reinforced polymer (FRP) components. Key aspects include:
- Conducting literature reviews and material comparisons to select FRP over other materials like steel, wood, aluminum, and high density polyethylene for its corrosion resistance, strength, lighter weight, and lower lifetime costs.
- Designing the system with an axial fan, motor, water pump, storage tank, eliminator, cellulose pads, air filter, and 360W solar panels. Calculations are shown for humidity reduction, coefficient of performance, static pressure, cooling load, and duct sizing.
- 3D modeling and drafting plans
4. WORK PLAN
July- Aug Sept- Oct Nov- Dec Jan- Feb March- April May- June
Literature
Review
Literature
Survey
Experimental
Setup
Test and
Comparison
Working
Model
Completion
Conclusion of
Project
5. FRP vs STEEL:
PROPERTY FRP COMPONENTS STEEL
CORROSION RESISTANCE Resists a broad range of chemicals
and unaffected by water
Subject to oxidation and corrosion
which otherwise requires galvanization
for many complications – a expensive
and difficult process.
STRENGTH Gram for Gram stronger than Steel and
aluminium
Compressive strength – 206.5MPa
(LW)
Flexural Strength – 206.5MPa (LW)
Yield Strength – 248.22MPa
Compressive Strength – 172.4 MPa
Higher tensile strength and higher
tensile modulus
WEIGHT Weights 25% of steels and 70% of
aluminium
Due to high weight often requires lifting
apparatus where it would not be require
for FRP, lowering costs
ELECTRICAL CONDUCTIVITY Non conductive Requires grounding due to high
conductivity
6. THERMAL
CONDUCTIVITY
Good insulator with low thermal
conductivity
0.04W/mK
Low thermal coefficient of
expansion
12.6 – 14.4 m/m/C *10^-6
Thermal conductivity
50.2 W/mK
Low thermal coefficient of
expansion
13.5 – 14.4 m/m/C *10^-6 K
IMPACT RESISTANCE Will not permanently deform under
impact
Can permanently deform
COST Lower installation costs, less
maintenance, longer product life
cause lower lifespan cost
Lower initial material costs
MANUFACTURE AND
FABRICATION
Can be easily manufactured, easy
of complex shapes, can be
fabricated with simple carpenters
tools. No torches or torches
required
Often requires welding and cutting
tools, with heavy equipment
requiring special processes.
REFERENCE: https://protector.com.au/the-match-up-frp-fibre-reinforced-polymers-vs-steel/
7. FRP vs WOOD:
REFERENCE: https://www.lamilux.com/hub/standards-and-terms/material-comparison-between-
wood-and-glass-fibre-reinforced-plastic.html
8. FRP vs ALUMINIUM:
PROPERTY FRP COMPONENTS ALUMINIUM
CORROSION RESISTANCE Resists a broad range of chemicals
and unaffected by water
Can cause galvanic corrosion
STRENGTH Gram for Gram stronger than Steel and
aluminium
Compressive strength – 206.5MPa
(LW)
Flexural Strength – 206.5MPa (LW)
Yield Strength – 241.325MPa
Compressive Strength – 120 MPa
Higher tensile strength and higher
tensile modulus
WEIGHT Weights 25% of steels and 70% of
aluminium
33% of the weight of steel
ELECTRICAL CONDUCTIVITY Non conductive Requires grounding due to high
conductivity
9. REFERENCE: https://protector.com.au/the-match-up-frp-fibre-reinforced-polymers-vs-steel/
THERMAL
CONDUCTIVITY
Good insulator with low thermal
conductivity
0.04W/mK
Low thermal coefficient of
expansion
12.6 – 14.4 m/m/C *10^-6
Thermal conductivity
25 W/mK
Low thermal coefficient of
expansion
23.4 m/m/C *10^-6 K
IMPACT RESISTANCE Will not permanently deform under
impact
Can permanently deform
COST Lower installation costs, less
maintenance, longer product life
cause lower lifespan cost
Part Price comparable to FRP
MANUFACTURE AND
FABRICATION
Can be easily manufactured, easy
of complex shapes, can be
fabricated with simple carpenters
tools. No torches or torches
required
Good Machineability
10. FRP vs IRON:
PROPERTY FRP IRON
RESISTANCE Material has high Impact
Resistance, hence doesn’t Crack
on Impact
Thermal Conductivity: 0.04 W/mK
Material is Brittle, hence easily
Cracks on Impact
Thermal Conductivity: 73 W/mK
PAINTING Self- Pigmented. No Painting is
required
Painting required at Regular
Intervals
CORROSION RESISTANCE Is Corrosion Resistant Corrosion is deposited after a
certain period of time
ELECTRICAL CONDUCTIVITY Non conductive Requires grounding due to high
conductivity
PRODUCTION Production is easy and is low risk Production process is very
complex and is risky as very high
temperature heating is done
INSTALLATION TIME Installation time is less because of
the good finishing of the Product
Installation time is more due to
improper finishing and complex
processes
11. WEIGHT FRP’s are low weight materials
because of the glass wool and
resin used in it
Compressive Strength: 206.5
Iron is a heavy material as it is
obtained from the casting of Iron
Compressive Strength: 612 Mpa
MAINTENANCE Will not permanently deform
under impact and hence
maintenance is not required
certainly
Can permanently deform and
hence proper maintenance is
required after an interval of time
COST SAVINGS Lower installation costs, longer
product life cause lower lifespan
cost
Higher costs in installation and
lower lifespan thus high lifespan
cost as compared to FRP
DESIGN FLEXIBILITY Can be easily manufactured,
ease of producing complex
shapes, can be fabricated with
simple tools.
Can be manufactured only by
using different metallurgy
process i.e. casting, etc
REFERENCE: https://www.aldfrp.com/News/Comparison-of-FRP-Pipe-and-ductile-iron-pipe-187.html
12. FRP vs HDPE: (High Density Polyethylene)
THERMOPLASTIC
Comparison of FRP with HDPE
Property FRP HDPE
Pricing
Installation cost,
maintenance, and cost over
life of the system considered
less.
Lower initial Cost
Thermal expansion and
contraction
Lower thermal expansion,
with 1/10thof the expansion
and contraction of HDPE
Thermal Conductivity: 0.04
W/mK
Higher expansion per degree
than FRP
Thermal Conductivity: 2.8
W/mK
Operating and Design
temperatures
FRPs mechanical properties
do not degrade until roughly
83-104.5
HDPE tends to lose its
mechanical properties
drastically at 22 degrees.
Becomes not recommended
when the temperature
exceeds 80 degrees.
Strength
Ultimate Stress = 110MPa
Compressive Strength: 206.5
Ultimate Stress = 23MPa
Compressive Strength: 28
13. REFERENCE: https://protector.com.au/battle-of-the-plastics-frp-fibre-reinforced-polymers-vs-hdpe/
Pressure Design
Designs at minimum a 6:1 ratio
in pressure situations
Lower safety factor in designs
causing extreme occasions to
be big issue for HDPE
Fabrication and Installation
Can be manufactured more
simply and on site, whereas
HDPE requires fabrication in
manufacturing plants in
complex processes
Can be manufactured to
smaller diameters with HDE
being quicker to produce
Modulus of Elasticity
Hoop Modulus = 27.58GPa
Axial Modulus = 12.4GPa
HDPE Modulus = 0.69GPa
HDPE has higher in ground
deflection and pipe bending.
Requires piping supports ni
some installations
Weight Density = 2000 kg/m3 Density = 970 kg/m3
21. DESIGN DATA:
Fan:
Type: Tube Axial Flow Fan
Dia: 360mm dia,
RPM: 1200 RPM
Velocity: 900 FPM
Motor:
Power required: 0.5 HP
Power consumption: 0.37285 kW
Pump:
Power required: 0.04 HP
Power consumption: 0.03 kW
Tank:
Upto 180 litres storage capacity
Water Consumption: 2 litre per hour
Upto 9 days running capacity
Size: 900mm X 900mm X 200mm
Eliminator:
Type: ‘C’ Type
Material: PVC
Size: 100mm Width
Life: Minimum 9 yrs
Cellulose Pad:
Type: Honeycomb type
Material: Paper
Size: 450mm X 450mm X 200mm
Life: 4-5 yrs
Air Filter:
Type: Box type
Size: 450mm X 450mm X 50mm
Capacity: 10 micron
Solar Module:
Type: Polycrystalline
Size: 2000mm X 1000mm X 45mm
Capacity: 360 Watt
22. DESIGN CALCULATIONS:
RELATIVE HUMIDITY:
According to energy.gov, Air cooler can reduce 5 to 15°F i.e. from -15°C to -12°C
So assuming the reduced temperature to be -9°C,
SAY, SURROUNDING TEMPERATURE To (Outside Temperature) = 45° C
REDUCED TEMPERATURE Ti (Inside Temperature) = 36° C
RELATIVE HUMIDITY:
E/Es
Where E: Actual Vapour Density
Es: Saturated Vapour Density
Es = 6.11 * 10(7.5 * 318/(237.7+318))
Es = 262.2341
E = 6.11*10(7.5*309/(237.7+309))
E= 259.007
RH = E/Es * 100 = 259.007/262.2342 * 100
= 98.7 % inside our Cooling System
COEFFICIENT OF PERFORMANCE:
COP= POWER SUPPLIED TO FAN/ POWER DRAWN OUT OF HEAT PUMP
= 0.37285/0.099292331
= 3.755073491
23. DESIGN CALCULATIONS:
STATIC PRESSURE:
Static Pressure Loses (mm per water gauge): 3 mmwg Eliminator, 5 mmwg Cellulose
Pad, 1 mmwg extra loss for space, ducting, etc. Thus total Static Pressure Loses= 9
mmwg. Thus our Static Pressure Loss is 9 mmwg and we have selected 10 mmwg as
per standard as we will increase the Static Pressure than suction and air pressure
will also be increased
CELLULOSE PAD:
Approx 9 + 2° less as per standard
https://www.energy.gov/energysaver/evaporative-
coolers#:~:text=They%20can%20reduce%20the%20temperature,are%20now%20availa
ble%20as%20well.
ELIMINATOR: ‘C-100’ as it has minimum Size and minimum Static Pressure Loss
RELATIVE HUMIDITY INSIDE DEPARTMENT: 45 to 60 % will be there in the
Department as per standard
24. DESIGN CALCULATIONS:
COOLING LOAD CALCULATIONS:
Capacity: 1350 CFM
GRILL:
Quantity: 2
Size: 250 X 300, 300 X 100
Capacity: 650 CFM each
Velocity: 830 FPM
DUCT:
Length: upto 7 M for 1350 CFM
If we want to increase the length to pass the air in more area, CFM will reduce.
Velocity: 1800 FPM
Sq. metre: 6.37
Sq. feet: 68.54
25. SCENARIO:THERE IS A OFFICE IN WHICH 4 PERSON ARE WORKING ON 4 PERSONAL
COMPUTERS.
COOLING AREA: UPTO 270 Sq Ft.
PERSON: 4
MACHINES: 4
AIR CHANGES: 31 (AS PER STANDARD)
AIR CHANGES = CAPACITY OF UNIT/VOLUME OF ROOM
31 = 2292/VOLUME
where, 1350 CFM = 2292 CMH
VOLUME OF ROOM = 73.93 cubic mt. at HEIGHT = 3.05 M
SO, AREA OF ROOM = VOLUME/HEIGHT = 24,2413 Sq mt
SIZE OF THE ROOM = 4.92 X 4.92 X 3.05 (In M)
26. CAPACITY OF UNIT:1350 CFM
VELOCITY OF DUCT: 1800 FPM
DUCT:
Sq ft.= 1350/1800
= 0.75 sq ft.
Sq ft. to sq. mt.
0.75/10.76
0.0697 sq. mt.
