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15TH
ERU SYMPOSIUM, 2009: FACULTY OF ENGINEERING, UNIVERSITY OF MORATUWA
1
DEVELOPMENT OF LOW COST EVAPORATIVE COOLER UNIT TO SUIT
INDUSTRIAL ENVIRONMENT
Project Advisor: Prof. R.A. Attalage
G.P.T.K. Abeysekara, K.H.H.G. Ketanwila, K.A.P. Vithana
E-mail: thanujakasun@gmail.com,ketanwila@gmail.com,koswatta@gmail.com
Department of Mechanical Engineering, University of Moratuwa, Moratuwa, Sri Lanka
Abstract
The purpose of this paper is to demonstrate the adaptability of evaporative cooling technology to Sri Lankan
environment. Desiccant cooling technology is initiated to control the relative humidity level of the environment. A
generic model of the evaporative cooler is constructed using direct evaporative cooling method and solid desiccant
dehumidification method. The model was installed in the testing environment. The results show that the evaporative
cooler is provided the sufficient level of thermal comfort to the people changing relative humidity slightly.
1. Introduction
This paper based on the research and development project
conducted by the undergraduates as requirement of fulfilling
the degree to develop a cooler unit to suit industrial
environment. Evaporative cooling is ancient and common
technique within the middle-east countries. This paper
discusses the applicability of evaporative cooling technique
to the hot humid environment in Sri Lanka.
On behalf of the industrial engineering context, human
thermal comfort is key parameter of the efficiency and
ergonomic aspects of man power. To maintain the optimum
efficiency and industrial standards, maintaining a thermal
comfort is essential requirement.
Because of high relative humidity level in Sri Lanka,
direct evaporative cooling can’t be used to reach required
thermal comfort level. Solid dehumidification with heat
exchanger was added to the design to overcome the
problem. This paper analyses the results of the new method
and attempts to provide acceptable, cost-effective solution.
Dealing with small air capacities for evaporative cooling
was difficult than large air volume. So another goal of this
project is to check the adaptability to the industrial
environment. Almost all industries produce waste heat, this
project targets to utilize that heat as a source.
2. Methodology
Analysis for temperature and relative humidity readings of
Sri Lanka was done and project objective were clearly
identified. Existing evaporative cooling and desiccant
cooling technologies were studied. Optimum design
methodology was selected and cooler was fabricated to
install in controlled environment. After the test runs of the
machine, environmental data were collected and checked
for the adaptability of concept.
2.1 Construction
Design is constructed by two major parts. Primary air
preparation unit and evaporative chamber are those two key
elements of the design. Atmospheric air is taken as the
primary air. Dehumidification of primary air is done by
Silica gel in the desiccant wheel and water evaporation is
done by electronically controlled nozzles.
In the desiccant wheel construction, flat iron was used to
make the frame. No. 6 steel mesh is used to trap the Silica
Gel in the wheel. Nuts and bolts were used to fix the
desiccant particles to mesh. Wheel was rotated by a flat belt
in the outer perimeter so that it causes minimum disturbance
to the air flow. Special concern is taken to desiccant
packing system to reduce pressure drop as well as to archive
maximum efficiency of the wheel.
10mm Carbon steel mesh was used to fabricate the heat
exchanging body of heat recovery wheel with the guidance
of circular shaped flat iron frame supported by traverse iron
bars. By increasing the number of layers, the total heat
capacity of the wheel can be improved to meet the design
requirements.
Flow separation duct was constructed by 0.8mm a thick
plate which is developed from semi circular shape to cross
section with 2400
degree. 1200
duct resolute into a circular
duct and also 1800
side. This duct was made with high
precision to minimize flow mixing. For that plasma cutting
technique was used. Insulation is used to reduce conduction
heat exchange at the solid boundary.
Outer frame was constructed by L iron bars and using
6204 bearing and shaft, wheels and duct is fixed to frame.
Various reinforcements were used to get the stability of the
frame.
One motor is used drive both desiccant wheel and energy
recovery wheel. Two pulleys made out of wood are
emotionally involved to the motor using a long shaft and
this shaft is supported in several locations.
Main blower and secondary was attached to the main
frame using angle iron bars. It was constructed three ducts
also to perform following tasks.
 Supply air to the room
 Return air for the energy recovery wheel
 Air preheated to desiccant regeneration
Evaporation chamber consists of three nozzles with
different angles for testing purposes (one nozzle is enough
for the evaporation). Pump is used for pressurize the water
15TH
ERU SYMPOSIUM, 2008: FACULTY OF ENGINEERING, UNIVERSITY OF MORATUWA
2
supply to the room. Atomization pressure of the nozzle is
7bar.
Regeneration heat for silica is given by a Nichrome coil,
the coil is attached using ceramic insulations.
Insulation was placed where it is needed.
2.2 Process Diagram
Diagram for the complete process can be shown as below
figure. Atmospheric air is heated to provide hot air and cold
air is taken from the controlled environment.
2.3 Testing Methodology
Developed system was installed to controlled area and
testing run was carried out. By changing the evaporation
rate of the nozzles, changing the nozzle angels, changing the
temperature of the desiccant regeneration side, and on
different environmental conditions, tests were carried out
and results were recorded.
3. Results and Discussions
3.1 Results
Test conditioned are 7bar nozzle pressure and counter flow
nozzle angle.
Dry bulb
temperature
Relative
Humidity
Air velocity
Initial
reading
300
C 70% 1.3ms-1
After 15
minutes
28.60
C 79% 1.3ms-1
After 30
minutes
27.90
C 86% 1.3ms-1
Test conditioned are 7bar nozzle pressure and cross flow
nozzle angle.
Dry bulb
temperature
Relative
Humidity
Air velocity
Initial
reading
30.10
C 70% 1.3ms-1
After 15
minutes
28.30
C 83% 1.3ms-1
After 30
minutes
27.60
C 92% 1.3ms-1
Test conditioned are 5bar nozzle pressure and cross flow
nozzle angle.
Dry bulb
temperature
Relative
Humidity
Air velocity
Initial
reading
30.30
C 67% 1..3ms-1
After 15
minutes
28.20
C 85% 1.3ms-1
After 30
minutes
27.20
C 98% 1.3ms-1
Model test results show that the environmental condition
is reached to the margin of thermal comfort region after
installing evaporative cooler. With the advanced velocity of
the room gives additional comfort. This velocity mainly
suits industrial environment.
3.2 Discussion
Best suited conditioned are 7 bar and counter flow nozzle
angel.
After the testing period, it is apparent that the technology
is applicable to Sri Lankan environment. Most probably
suits industrial environment. Desiccant cooling technology
is the success factor of the design. By effectively controlling
the nozzles, the efficiency of the system will be improved.
Desiccant wheel has relatively high bypass factor than
commercially existing desiccant wheels. By using
physically bonded desiccant method would increase
efficiency of the wheel.
Coated aluminum mesh would be best suited for the
energy recovery wheel that will increase heat capacity and
also heat conduction rate.
Flow separation methods also can improve design
changes like overlap the ducts using a third duct to connect
other two.
Air volume of evaporation chamber is not enough in this
design, with a large evaporation chamber will be best suited
for the design.
Little amount of water vapor tends to come with the air
flow. Attaching baffle plates in the evaporation chamber
will reduce mist. With a proper air distribution duct system
will be an added advantage.
Main difficulty of this project is to manufacture desiccant
wheel. To hold the desiccant into a mesh and make it
turning is the most difficult part and most time consuming
part.
References
Watt, J. R. (1986). Evaporative Air Conditinoning
Handbook. London: Chapman & Hall.
Standard 55, BSR/ASHRAE. (2003, February). Thermal
Environmental Conditions for Human Occupancy. Atlanta.
ASHRAE. (2004). ASHRAE handbook of HVAC systems
and equipments. Atlanta.
Ryan, S. S. (2000, December). Desiccant Dehumidification
Wheel Test Guide. Cole Boulevard, Colorado, United
States.
Scheuchi, R. (2009, March 10). Hoval Rotary Heat
Exchanger for Heat Recovery in Ventilation Systems.
United States.

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International Journal of Computational Engineering Research(IJCER)
 

Extended_Abstract

  • 1. 15TH ERU SYMPOSIUM, 2009: FACULTY OF ENGINEERING, UNIVERSITY OF MORATUWA 1 DEVELOPMENT OF LOW COST EVAPORATIVE COOLER UNIT TO SUIT INDUSTRIAL ENVIRONMENT Project Advisor: Prof. R.A. Attalage G.P.T.K. Abeysekara, K.H.H.G. Ketanwila, K.A.P. Vithana E-mail: thanujakasun@gmail.com,ketanwila@gmail.com,koswatta@gmail.com Department of Mechanical Engineering, University of Moratuwa, Moratuwa, Sri Lanka Abstract The purpose of this paper is to demonstrate the adaptability of evaporative cooling technology to Sri Lankan environment. Desiccant cooling technology is initiated to control the relative humidity level of the environment. A generic model of the evaporative cooler is constructed using direct evaporative cooling method and solid desiccant dehumidification method. The model was installed in the testing environment. The results show that the evaporative cooler is provided the sufficient level of thermal comfort to the people changing relative humidity slightly. 1. Introduction This paper based on the research and development project conducted by the undergraduates as requirement of fulfilling the degree to develop a cooler unit to suit industrial environment. Evaporative cooling is ancient and common technique within the middle-east countries. This paper discusses the applicability of evaporative cooling technique to the hot humid environment in Sri Lanka. On behalf of the industrial engineering context, human thermal comfort is key parameter of the efficiency and ergonomic aspects of man power. To maintain the optimum efficiency and industrial standards, maintaining a thermal comfort is essential requirement. Because of high relative humidity level in Sri Lanka, direct evaporative cooling can’t be used to reach required thermal comfort level. Solid dehumidification with heat exchanger was added to the design to overcome the problem. This paper analyses the results of the new method and attempts to provide acceptable, cost-effective solution. Dealing with small air capacities for evaporative cooling was difficult than large air volume. So another goal of this project is to check the adaptability to the industrial environment. Almost all industries produce waste heat, this project targets to utilize that heat as a source. 2. Methodology Analysis for temperature and relative humidity readings of Sri Lanka was done and project objective were clearly identified. Existing evaporative cooling and desiccant cooling technologies were studied. Optimum design methodology was selected and cooler was fabricated to install in controlled environment. After the test runs of the machine, environmental data were collected and checked for the adaptability of concept. 2.1 Construction Design is constructed by two major parts. Primary air preparation unit and evaporative chamber are those two key elements of the design. Atmospheric air is taken as the primary air. Dehumidification of primary air is done by Silica gel in the desiccant wheel and water evaporation is done by electronically controlled nozzles. In the desiccant wheel construction, flat iron was used to make the frame. No. 6 steel mesh is used to trap the Silica Gel in the wheel. Nuts and bolts were used to fix the desiccant particles to mesh. Wheel was rotated by a flat belt in the outer perimeter so that it causes minimum disturbance to the air flow. Special concern is taken to desiccant packing system to reduce pressure drop as well as to archive maximum efficiency of the wheel. 10mm Carbon steel mesh was used to fabricate the heat exchanging body of heat recovery wheel with the guidance of circular shaped flat iron frame supported by traverse iron bars. By increasing the number of layers, the total heat capacity of the wheel can be improved to meet the design requirements. Flow separation duct was constructed by 0.8mm a thick plate which is developed from semi circular shape to cross section with 2400 degree. 1200 duct resolute into a circular duct and also 1800 side. This duct was made with high precision to minimize flow mixing. For that plasma cutting technique was used. Insulation is used to reduce conduction heat exchange at the solid boundary. Outer frame was constructed by L iron bars and using 6204 bearing and shaft, wheels and duct is fixed to frame. Various reinforcements were used to get the stability of the frame. One motor is used drive both desiccant wheel and energy recovery wheel. Two pulleys made out of wood are emotionally involved to the motor using a long shaft and this shaft is supported in several locations. Main blower and secondary was attached to the main frame using angle iron bars. It was constructed three ducts also to perform following tasks.  Supply air to the room  Return air for the energy recovery wheel  Air preheated to desiccant regeneration Evaporation chamber consists of three nozzles with different angles for testing purposes (one nozzle is enough for the evaporation). Pump is used for pressurize the water
  • 2. 15TH ERU SYMPOSIUM, 2008: FACULTY OF ENGINEERING, UNIVERSITY OF MORATUWA 2 supply to the room. Atomization pressure of the nozzle is 7bar. Regeneration heat for silica is given by a Nichrome coil, the coil is attached using ceramic insulations. Insulation was placed where it is needed. 2.2 Process Diagram Diagram for the complete process can be shown as below figure. Atmospheric air is heated to provide hot air and cold air is taken from the controlled environment. 2.3 Testing Methodology Developed system was installed to controlled area and testing run was carried out. By changing the evaporation rate of the nozzles, changing the nozzle angels, changing the temperature of the desiccant regeneration side, and on different environmental conditions, tests were carried out and results were recorded. 3. Results and Discussions 3.1 Results Test conditioned are 7bar nozzle pressure and counter flow nozzle angle. Dry bulb temperature Relative Humidity Air velocity Initial reading 300 C 70% 1.3ms-1 After 15 minutes 28.60 C 79% 1.3ms-1 After 30 minutes 27.90 C 86% 1.3ms-1 Test conditioned are 7bar nozzle pressure and cross flow nozzle angle. Dry bulb temperature Relative Humidity Air velocity Initial reading 30.10 C 70% 1.3ms-1 After 15 minutes 28.30 C 83% 1.3ms-1 After 30 minutes 27.60 C 92% 1.3ms-1 Test conditioned are 5bar nozzle pressure and cross flow nozzle angle. Dry bulb temperature Relative Humidity Air velocity Initial reading 30.30 C 67% 1..3ms-1 After 15 minutes 28.20 C 85% 1.3ms-1 After 30 minutes 27.20 C 98% 1.3ms-1 Model test results show that the environmental condition is reached to the margin of thermal comfort region after installing evaporative cooler. With the advanced velocity of the room gives additional comfort. This velocity mainly suits industrial environment. 3.2 Discussion Best suited conditioned are 7 bar and counter flow nozzle angel. After the testing period, it is apparent that the technology is applicable to Sri Lankan environment. Most probably suits industrial environment. Desiccant cooling technology is the success factor of the design. By effectively controlling the nozzles, the efficiency of the system will be improved. Desiccant wheel has relatively high bypass factor than commercially existing desiccant wheels. By using physically bonded desiccant method would increase efficiency of the wheel. Coated aluminum mesh would be best suited for the energy recovery wheel that will increase heat capacity and also heat conduction rate. Flow separation methods also can improve design changes like overlap the ducts using a third duct to connect other two. Air volume of evaporation chamber is not enough in this design, with a large evaporation chamber will be best suited for the design. Little amount of water vapor tends to come with the air flow. Attaching baffle plates in the evaporation chamber will reduce mist. With a proper air distribution duct system will be an added advantage. Main difficulty of this project is to manufacture desiccant wheel. To hold the desiccant into a mesh and make it turning is the most difficult part and most time consuming part. References Watt, J. R. (1986). Evaporative Air Conditinoning Handbook. London: Chapman & Hall. Standard 55, BSR/ASHRAE. (2003, February). Thermal Environmental Conditions for Human Occupancy. Atlanta. ASHRAE. (2004). ASHRAE handbook of HVAC systems and equipments. Atlanta. Ryan, S. S. (2000, December). Desiccant Dehumidification Wheel Test Guide. Cole Boulevard, Colorado, United States. Scheuchi, R. (2009, March 10). Hoval Rotary Heat Exchanger for Heat Recovery in Ventilation Systems. United States.