MAJORPROJECT

ON

SOLAR REFRIGERATOR

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CERTIFICATE

This is to certify that has successfully completed his term work in

SM-602 Project Work as per prescribed syllabus.

Submission date: -

H.O.D GUIDED BY:

Mechanical Engineering Dept.

PRINCIPAL

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Acknowledgement

We feel in great in presenting the report of our project “SOLAR REFRIGERETOR” which finds application in much modern equipment and system, this project is done in partial fulfillment of D.M.E. (Diploma in mechanical engineering) course at the

We wish to express our sincere gratitude and thanks to our guide professor. During our whole project work for his inspiration give to us and guidance showered open us. He was greatly helpful to us by solving all our queries and difficulties. We are also thankful to our head of the department of mechanical engineering

Last but not we are thankful to and all out lecturers who showered upon there help and guidance during the project work and also our friends who always ready to help.

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INDEXSR.NO. DESCRIPTION PAGE NO.

1 INTRODUCTION 1

2 PROJECT PLANING 14

3 MARKET SARVEY 17

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5 DETAILS 19

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8 COSTING 40

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CHAPTER:-1

INTRODUCTION

1.1. Importance of project1.2. Characteristics of Project1.3. Objectives of project

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1.1 Importance of project

The process of project work depends on intelligence, skills, creativity, and energy of group of student. Project work has been required studies of number of subject project work will provide an opportunity for coordination and integration of theory and practices a wide of cognitive skill and necessary in a technician.

The purpose of providing project work is to expose to problems and to introduce you to the procedures used to reach e efficient acceptable solution. By doing this you gain confidence in taking decision and taking problems project work will integrate and train the skill required by you in study.

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1.2 Characteristics of Project:

The following are the main characteristics of the project:

1. OBJECTIVE :A project has fixed set of objective have been achieved, the project cease to exit.

2. LIFE SPAN :A project cannot continue endlessly. It has to come to an end what represents the end would normally be spelt out in the set of objective.

3. SINGLE ENTITY :A project is one entity and is normally entrusted to one responsibility centre while the participants in the project are many.

4. TEAM WORK :A project call for a team work the team is constituted of members belonging to different disciplines and organization.

5. LIFE CYCLE :A project has life cycle, reflected by growth maturing and decay. It definitely has a learning component.

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6.UNIQUENEESS:No two projects are exactly similar, even if they are duplicated. The location, the infrastructure, the organics and the people make the project unique.

7.CHANGE :A project sees many changes may not have any major impact. The can be some changes which with change the entire character or course of the project.

8.SUCCESSIVE PRINCIPLE :What is going to happen during the life cycle of project is not fully known at any stage. The detail gets finalized successively with the passage of time.

9.MADE TO ORDER :A project is always made to the order of its customer. The customer states various requirements and puts constraints within which the project must be executed.

10.UNITY OF DIVERSITY :A project is a complex set of thousands of verities. The verities are in terms of technology, equipments and materials, machinery and people, work culture and ethics. But they remain inter related

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and unless this is so, it is not possible to complete the project successfully.

11.Risk AND UNCERTAINITY :Every project has risk and uncertainty associated with it. The degree of risk and uncertainty depends on how the project is passed through its various life cycle phases. An ill defined project has high degree of risk and uncertainty.

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1.3 Objectives of project:

The following are the main objective of project.

Project work enables a student to work as a group. This is a very mush important in engineering fields.

A student can developed his mind towards engineering field and they come to know various manufacturing techniques and processes.

A student can develop good knowledge about various machines and equipments used for manufacturing of various parts.

Each can develop his ability to plan a work and take appropriate decision.

It develops confidence and creativity of thinking. It helps to arrive at creative solution of problem. Student can understand his own strength and limitations and

try to improve it. Project is necessary to develop a leadership and work as a

member of team. Maintain level of problem while dealing with engineering

situation. Have a sense of purpose and pride of achievement for the

project. Reliably work independently.

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1.4 Aims of project work:

The course listed above can be achieved by designing suitable learning exercises in class room, laboratory, following aims could be achieved.

To develop planning and decision making skills. To provide student with an opportunity to develop and

demonstrative confident and ability to tackle problem and sprit of achievement.

To provide with experience and practices to teaching problems, that they are likely to meet in industry.

To integrate and reinforce skills required the students in separate subject.

To provide interdisciplinary studies of the subject. To develop higher level skills for solution of project. To given student an opportunity to learn to keep good

records and to presents an engineers and it can only achieved by practices.

To present an excision and demanding of the student. To develop ability to work in team positively. To make up student mind not work individually but also to

work in team. To get the knowledge of each student in various subjects

which have been studied before To treat the students to make work project and to decide

cost, time and its advantages themselves. The students can know work difficulties and right way of

mending those difficulties.

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To develop leadership in students with help of project work. To develop the estimation of mechanical instruments

prevailed in market. To develop unity in- group project.

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CHAPTER:-2

PROJECT PLANNING

2.1 Introduction

2.2 Steps of project planning

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PROJECT PLANNING

2.1 Introduction:

Planning of project is very important tasks and should be taken off with great care as the implementation of whole project largely depends on its planning saves the time, money, labor, which after all reduce cost of manufactures parts.

Project planning encourages an efficient output which completely meets the specification project selection along with material selection. In fact project planning is technique in which operation of all parts are analyzed and classified it includes.

Actual machining time. Manipulation time. Setting time, loading and unloading. Economy.

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2.2 Steps of Project Planning:

1. Selection of project2. Market survey3. Production capacity4. Investment decision5. Design and drawing6. Selection of material7. Selection machines, tools and equipments required.8. Resource labor, transportations, loss of manufacturing.9. Including material required process10. Inventory planning11. Process planning12. Preparation of F.P.C & O.P.C13. Coasting14. Testing of project15. Market response of project.

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CHAPTER:-3

MARKET SURVEY

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Market Survey

You need to check yourself a market prospect of the product selected by you before launch a venture. You should rely merely upon institution or here say to access the market prospect. A comprehension market study is must be specific advantage of such a study are.

It enables you to evaluate viability of an enterprise by arcing at a year estimate of seals.

It makes it possible for you to estimate scale and utilization of install capacity with reference propose enterprise.

You can judge weather proposed capacity is on higher and lower size.

It provident a preliminary input for the marketing strategy and process formulation or the enterprise (A market program is a set decision refried in a respect of various market related to issued it influents the market performance of an enterprise.)

Market survey is usually focused on gross market demands present and future. It typically highlights the gaps between expected market demand and supply in respect offer given product. Such a gap could be positive (demand exceed supply) and therefore favorable. The gap could be negative a favorable gap is does not guaranty market success for an enterprise a market success is and between of favorable demand supplies gap as well effective market program.

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CHAPTER:-5

DETAILS

1. components used in project:

A. solar penalB. standard refrigeratorC. heating coilD. solar collector

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Machinery Requirement

A.Machine:o Hacksaw machineo Drilling machineo Welding machine

B.Equipments:o Lathe machine tools & accessories.o Drilling toolso Cutting toolo Bench wiseo Centre punch

C.Measuring Instruments:o Vernier caliper

o Steel rule

o Measure tape

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SOLAR ENERGY

Solar power is the generation of electricity from sunlight. This can be direct as with photovoltaic’s (PV), or indirect as with concentrating solar power (CSP), where the sun's energy is focused to boil water which is then used to provide power.

Solar power has the potential to provide over 1,000 times total world energy consumption in 2008, though it provided only 0.02% of the total that year.

Solar power is a predictably intermittent energy source, meaning that whilst solar power is not available at all times, we can predict with a very good degree of accuracy when it will and will not be available.

Some technologies, such as solar thermal concentrators have an element of thermal storage, such as molten salts.

These store spare solar energy in the form of heat which is made available overnight or during periods that solar power is not available to produce electricity.

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REFRIGERATOR

A typical refrigerator with its door open

A refrigerator (often called a "fridge" for short) is a cooling appliance comprising a thermally insulated compartment and a heat pump—chemical or mechanical means—to transfer heat from it to the external environment, cooling the contents to a temperature below ambient.

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Cooling is a popular food storage technique in developed countries and works by decreasing the reproducton rate of bacteria. The device is thus used to reduce the rate of spoilage of foodstuffs.

A device described as a "refrigerator" maintains a temperature a few degrees above the freezing point of water; a similar device which maintains a temperature below the freezing point of water is called a "freezer."

The refrigerator is a relatively modern invention among kitchen appliances. It replaced the icebox, which had been a common household appliance for almost a century and a half prior. For this reason, a refrigerator is sometimes referred to as an "icebox".

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Solar powered refrigerator

Solar-powered refrigerators are most commonly used in the developing world to help mitigate poverty and climate change.

By harnessing solar energy, these refrigerators are able to keep perishable goods such as meat and dairy cool in hot climates, and are used to keep much needed vaccines at their appropriate temperature to avoid spoilage.

The portable devices can be constructed with simple components and are perfect for areas of the developing world where electricity is unreliable or non-existent.

Other solar-powered refrigerators were already being employed in areas of Africa which vary in size and technology, as well as their impacts on the environment.

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Environmental Impacts of Refrigerators

There is major environmental concern regarding conventional refrigeration technologies including contribution to ozone layer depletion and global warming.

Refrigerators which contain ozone depleting and global warming substances such as chlorofluorocarbons (CFC’s), in their insulation foam or their refrigerant cycle are the most harmful.

After CFC’s were banned in the 1980’s they were replaced with substances such as hydro chlorofluorocarbons (HCFCs), which are ozone depleting substances and hydro fluorocarbons (HFCs).

Both are environmentally destructive as potential global warming chemicals.

If a refrigerator is inefficient it will also contribute to global warming.

The use of solar energy to power refrigeration strives to minimize the negative impacts refrigerators have on the.

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History of Solar Refrigeration

"In developed countries, plug-in refrigerators with backup generators store vaccines safely, but in developing countries, where electricity supplies can be unreliable, alternative refrigeration technologies are required”.

Solar fridges were introduced in the developing world to cut down on the use of kerosene or gas-powered absorption refrigerated coolers which are the most common alternatives.

They are used for both vaccine storage and household applications in areas without reliable electrical supply because they have poor or no grid electricity at all.

They burn a liter of kerosene per day therefore requiring a constant supply of fuel which is costly and smelly, and are responsible for the production of large amounts of carbon dioxide.

They can also be difficult to adjust which can result in the freezing of medicine.

There are two main types of solar fridges that have been and are currently being used, one that uses a battery and more recently, one that does not.

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Battery Supplemented Solar Refrigerator

Traditionally solar-powered refrigerators and vaccine coolers use a combination of solar panels and lead batteries to store energy for cloudy days and at night in the absence of sunlight to keep their contents cool.

These fridges are expensive and require heavy lead-acid batteries which tend to deteriorate, especially in hot climates, or are misused for other purposes.

In addition, the batteries require maintenance, must be replaced approximately every three years, and must be disposed of as hazardous wastes possibly resulting in lead pollution.

These problems and the resulting higher costs have been an obstacle for the use of solar powered refrigerators in developing areas.

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Portable Solar Powered Fridge

A Portable solar powered fridge has been produced for use in the developing world. The basic design uses the principle of evaporation.

The fridge is solar powered, but does not require solar panels, and can be made from basic household material lowering the cost and making access to the developing world easier.

Without using any power the fridge can keep perishable at a temperature of 6 degrees Celsius for days.

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How it works

The refrigerator employs a combination of heat conduction and convection, requires no electricity and can be made for commonly available material such as cardboard, sand and recycled metal.

The device is composed of two cylinders. The inner metal cylinder is fitted inside the outer cylinder which can be made from what ever the person has access to including wood or plastic.

Space is left between the inner and outer chamber to be filled with organic material which can include sand, wool or soil that is then saturated with water.

As heat from the sun evaporates the water, the inner chamber cools reducing and maintaining the temperature at 43 °F (6 °C).

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The way a refrigerator keeps food cool is through the process of evaporation.

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Sun

Refrigerator

Solar PV Array

Battery Bank

DC Electrical Power

Sunlight

DC Compressor

Charge control

ler

When a liquid turns into a gas, it absorbs heat and makes the temperature lower.

In most electrically-powered refrigerators, this is achieved by the electric motor powering a compressor, which turns the refrigerant gas into a liquid.

When the pressure is removed, the refrigerant turns back into a gas and absorbs heat.

In a solar refrigerator, the refrigerant is replaced with ammonia or lithium bromide mixed with water.

The heat of the sun is used to increase the pressure of the gas, which turns into a liquid, just like in an electric refrigerator.

When the heat is removed, the liquid evaporates and lowers the temperature.

Scientists believe that solar refrigeration can be a great investment for the developing world.

It could allow small villages to store medication and food without electricity.

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Usage

The portable solar fridge is used in areas of Africa such as Zambia, Namibia, and South Africa in areas where electricity is often not readily accessible to help preserve perishable foods such as meat and dairy, however, is not yet being used for vaccines. It is easily transported and reduces negative environmental impacts but is limited by size and requires the availability of water.

Many of the vaccines used to control diseases require cold temperatures for preservation. Without a reliable power infrastructure, developing countries often lack the resources to keep these vaccines cool for an extended time period, hampering the ability to adequately protect citizens. It is estimated that 50 percent of vaccines in rural areas are wasted due to spoilage.

By NASA to provide power for satellites and spacecraft, photovoltaic’s is a viable source of energy used to light over 1 million rural homes around the world. Photovoltaic (PV) cells directly convert sunlight into electricity, without having to utilize limited fossil fuel resources. PV energy contributes to improved air quality and aids in the reduction of greenhouse gases that play a role in global warming. For example, when it displaces coal-fired generation, a common source of electricity among power plants, harmful sulfur dioxide and nitrous oxide emissions are eliminated.

Most homes running on PV energy, however, employ simplistic lighting systems that are incapable of providing refrigeration. This can be especially troublesome for areas in which no conventional power source exists, including remote automated weather stations, forest stations, and Third World villages.

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In the midst of developing battery-free, solar-powered refrigeration and air conditioning systems for habitats in space, David Bergeron, the team leader for NASA’s Advanced Refrigerator Technology Team at Johnson Space Center, acknowledged the need for a comparable solar refrigerator that could operate in conjunction with the simple lighting systems already in place on Earth. Bergeron, a 20-year veteran in the aerospace industry, founded the company Souls Refrigeration, Inc., in 1999 to take the patented advanced refrigeration technology he co developed with his teammate, Johnson engineer

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Drawback of solar refrigerator

Low COP: high thermal mass, poor thermal conductivity of the adsorbentSmaller Specific Cooling Power: larger cycle timeIntermitted Cycle: cooling effect occurs only during adsorption process

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Advantage of Solar Refrigerators

Energy saving using solar energy Environmental Friendly: based on natural

refrigerants: H2O, NH3, Methanol, CO2 Low maintenance cost Easy fabricate Designed to last a lifetime. Improved temperature regulation with Dual Refrigeration Coils, one in the freezer and a frost free coil in the refrigerator. Quiet, smooth running brushless DC Hermetic compressor. Fan cooled all copper condenser assembly for optimum efficiency,

especially in hot weather. Long life in marine environments. Low energy consumption using 4 inches of high efficiency

polyurethane foam insulation. Environmentally friendly non CFC materials (insulation and

refrigerant). The front door can accept various wood panels or steel finishes to

accent your interior design. Accepts up to 1/8 inch door panel. Reversible Doors. Rugged wire adjustable shelves.

The Challenges

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• Simplicity to offer reliability and price advantage

• Control of the transfer of “COLD” energy stored in the Thermal Energy Store to the vaccine compartment to ensure stable vaccine compartment temperatures in

different ambient settings.

NO batteries to reduce risks of premature failures and costs and insure long .

• Lab Development and Field trials on a battery-less PV refrigerator (Solar Chill) for vaccine storage complete

and units commercially produced for vaccine storage.Good scope to improve product’ and move

towards a next generation product.

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Building the solar collector

All fridges operate on the principal that a liquid boiling to a gas takes heat away from its surroundings.

It is also important to know that a liquid can be made to boil at a very low temperature by altering the pressure.

While water boils at 100°C at atmospheric pressure, it can be boiled at 0°C under a very high vacuum.

A refrigerator operates by allowing the refrigerant to boil at temperatures as low as the desired cold space temperature.

Eventually, the evaporated refrigerant must be condensed back to a liquid to repeat the cycle for continued cooling.

While a typical home refrigerator relies on an electric condenser to turn the gaseous refrigerant back to our liquid, our system uses chemical processes to drive the evaporation and condensation of the refrigerant.

While pure ethanol may be difficult to find in developing countries, liquor with high alcohol content can be used in its place. As our ethanol boils, it is absorbed by activated charcoal, a porous solid that is often used in fish tank and drinking water filters to remove impurities.

In our refrigerator, the activated carbon allows the system to maintain a constant pressure as the ethanol evaporates.

When the sun heats our solar collector and activated charcoal bed in the middle of the day, the heat causes the release of the adsorbed ethanol.

The raised pressure and condenser cooling allow the ethanol to return to a liquid state so it can be evaporated again to cool the refrigerator.

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CHAPTER:-8

COSTING

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COSTING

It is the determination of actual cost of an article after adding different expenses incurring in various department. It may also define as system which systematically records all the expenditure incurred in various departments to determine the cost of manufacture.

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AIM OF COSTING:

The important of costing are as follows…

1. To determine the cost of each article.2. To determine the cost of each article

Operation.3. To help in deciding sale price.4. To supply information for the detection of

Waste.5. It helps in reducing the total cost of manufacture.

PROCEDURE OF COSTING:

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Costing is the technique and process of ascertaining cost. It is the classifying, recording and appropriate allocation expenditure for determination of the cost of the production or service.

The main elements of cost of any product are as under,

1. Material cost. 2. Labour cost. 3. Expenses.

COST ESTIMATION

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An approximate costing of the project was done on the

basis of market survey. Costing of the product can be work

out based on some simple assumption used by the

industries:-

For the purpose of costing, some basic considerations are

given below:-

a. Direct expenses : 5% of the material cost

b. Factory overhead : 5% of the prime cost

c. Selling overhead : 10% of factory cost

d. Profit : 25% of production cost

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SELLING PRICE OF PROJECT IN MARKET

a. prime cost of products is:Material cost + Labour cost + Expenses

= + +

=

b. Factory overhead:5% of prime cost

=

c. Factory cost:Prime cost + Factory overhead

=

d. Selling overhead:20% of factory cost

=

e. Production cost:Factory cost + selling overhead

=

f. Profit:25% of the production cost

=

Therefore the selling price of the product is

Total cost + Profit = Rs.

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BILL OF MATERIALS

Sr.No. Name of Parts Mat. Qty. Mat.Cost Labor Cost

Total cost

1.

2.

3.

4.

5.

6. Total welding Cost

__ __ __ 400 400

7.

8.

9. Extra Material __ __ 324 __ 324

10. Transportation __ __ __ __ 200

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11. Other Charges __ __ __ __ 600

Total

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OUTLINE PROCESS CHART

It is often desired to obtain a birds eye view of a whole process of activities. It gives an overall view of the process or activity. It is a graphic representation of the sequence of all of the operation and inspection involved in a process or procedure.

The entry points of material are also indicated. It does not indicate where the work takes place or who performs it. Other activities like delays of materials are also indicated.

This chart is very useful for initial analysis and it proceeds starting point for critical e* animations. The OPC is shown in the figure…

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CONCLUSION

After completing the major project on “solar refrigeartor” we are much happy and would Like to thank our professor, guides and the lectures of the concerned department who have guided us.

While making this minor project we have been able to learn a lot and understand the various aspects of “Heat Exchanger” we can use our knowledge, which we get during our study.

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