CHAPTER 1

INTRODUCTION
1.1 GENERAL
Human always tries for better comfort at each level of his life. Considering air
conditioning, evaporative cooler is used in dry climates as well as in condition of higher
temperature. But such evaporative coolers are not suitable in humid environment and also their
performance is poor in the places where ventilation is not proper. Reason, behind this is nothing
but, uncontrollable humidity increment in the working environment (cabin) due to process of
evaporation. The important parameter in whole design is nothing but relative humidity which
should be maintained in specific range for getting better thermal comfort. The basic concept
required to understand evaporative cooling and performance of evaporative cooling.

1.2 IMPORTANCE OF AIRCOOLER

 Extreme conditions such as heat and humidity can impact on our overall physical
intellectual activity, making even the simplest of tasks an absolute chore. Having a proper
air conditioning system in place helps reduce heat and humidity, thus reducing the impact
on our ability to perform and complete work tasks.
 The lower temperatures that air conditioners create can help reduce dehydration as they
lessen the likelihood of excessive sweating.
 When the air conditioning system has been installed properly, it effectively helps renew
and improve air quality.

1.3 EVAPORATIVE COOLER

An evaporative cooler (also swamp cooler, swamp box, desert cooler and wet air cooler) is
a device that cools air through the evaporation of water. Evaporative cooling differs from
typical air conditioning systems, which use vapor-compression or absorption refrigeration cycles.
Evaporative cooling uses the fact that water will absorb a relatively large amount of heat in order
to evaporate (that is, it has a large enthalpy of vaporization). The temperature of dry air can be
dropped significantly through the phase transition of liquid water to water vapor (evaporation).
This can cool air using much less energy than refrigeration. In extremely dry climates, evaporative

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cooling of air has the added benefit of conditioning the air with more moisture for the comfort of
building occupants.

The cooling potential for evaporative cooling is dependent on the wet-bulb depression, the
difference between dry-bulb temperature and wet-bulb temperature. In dry climates, evaporative
cooling can reduce energy consumption and total equipment for conditioning as an alternative to
compressor-based cooling. In climates not considered arid, indirect evaporative cooling can still
take advantage of the evaporative cooling process without increasing humidity. Passive
evaporative cooling strategies can offer the same benefits of mechanical evaporative cooling
systems without the complexity of equipment and ductwork.

1.3.1 PHYSICAL PRINCIPLES

Evaporative coolers lower the temperature of air using the principle of evaporative cooling,
unlike typical air conditioning systems which use vapor-compression refrigeration or absorption
refrigerator. Evaporative cooling is the conversion of liquid water into vapor using the thermal
energy in the air, resulting in a lower air temperature. The energy needed to evaporate the water is
taken from the air in the form of sensible heat, which affects the temperature of the air, and
converted into latent heat, the energy present in the water vapor component of the air, whilst the
air remains at a constant enthalpy value. This conversion of sensible heat to latent heat is known
as a process because it occurs at a constant enthalpy value. Evaporative cooling therefore causes a
drop in the temperature of air proportional to the sensible heat drop and an increase in humidity
proportional to the latent heat gain. Evaporative cooling can be visualized using a psychometric
chart by finding the initial air condition and moving along a line of constant enthalpy toward a
state of higher humidity. The evaporation rate depends on the temperature and humidity of the air.

Vapor-compression refrigeration uses evaporative cooling, but the evaporated vapor is within a
sealed system, and is then compressed ready to evaporate again, using energy to do so. A simple
evaporative cooler's water is evaporated into the environment, and not recovered. In an interior
space cooling unit, the evaporated water is introduced into the space along with the now-cooled
air; in an evaporative tower the evaporated water is carried off in the airflow exhaust.

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1.4 EVAPORATION
It is the process of change of state of matter from its liquid form to gaseous form by
absorbing heat equal to the latent heat of vaporization. Process of evaporation takes place at the
surface of the liquid.

It absorbs the remarkable amount of heat from surrounding in the process. Evaporation is basic
principle behind conventional swamp coolers. Evaporation is the process which takes place
throughout the day.
1.4.1 DIRECT EVAPORATIVE COOLING (OPEN CIRCUIT)

Direct evaporative cooling (open circuit) is used to lower the temperature and increase the
humidity of air by using latent heat of evaporation, changing liquid water to water vapor. In this
process, the energy in the air does not change. Warm dry air is changed to cool moist air. The heat
of the outside air is used to evaporate water. The RH increases to 70 to 90% which reduces the
cooling effect of human perspiration. The moist air has to be continually released to outside or else
the air becomes saturated and evaporation stops.

A mechanical direct evaporative cooler unit uses a fan to draw air through a wetted
membrane, or pad, which provides a large surface area for the evaporation of water into the air.
Water is sprayed at the top of the pad so it can drip down into the membrane and continually keep
the membrane saturated. Any excess water that drips out from the bottom of the membrane is
collected in a pan and recirculated to the top. Single-stage direct evaporative coolers are typically
small in size as they only consist of the membrane, water pump, and centrifugal fan. The mineral
content of the municipal water supply will cause scaling on the membrane, which will lead to
clogging over the life of the membrane. Depending on this mineral content and the evaporation
rate, regular cleaning and maintenance is required to ensure optimal performance. Generally,
supply air from the single-stage evaporative cooler will need to be exhausted directly (one-through
flow) because the high humidity of the supply air. Few design solutions have been conceived to
utilize the energy in the air like directing the exhaust air through two sheets of double glazed
windows, thus reducing the solar energy absorbed through the glazing. Compared to energy
required to achieve the equivalent cooling load with a compressor, single stage evaporative coolers
consume less energy.

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Passive direct evaporative cooling can occur anywhere that the evaporative cooled water can cool
a space without the assist of a fan. This can be achieved through use of fountains or more
architectural designs such as the evaporative downdraft cooling tower, also called a “passive
cooling tower”. The passive cooling tower design allows outside air to flow in through the top of
a tower that is constructed within or next to the building. The outside air comes in contact with
water inside the tower either through a wetted membrane or a mister. As water evaporates in the
outside air, the air becomes cooler and less buoyant and creates a downward flow in the tower. At
the bottom of the tower, an outlet allows the cooler air into the interior. Similar to mechanical
evaporative coolers, towers can be an attractive low-energy solution for hot and dry climate as
they only require a water pump to raise water to the top of the tower. Energy savings from using a
passive direct evaporating cooling strategy depends on the climate and heat load. For arid climates
with a great wet-bulb depression, cooling towers can provide enough cooling during summer
design conditions to be net zero.

Fig 1.1 direct cooling system

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1.4.2 INDIRECT EVAPORATIVE COOLING (CLOSED CIRCUIT)

Indirect evaporative cooling (closed circuit) is a cooling process that uses direct
evaporative cooling in addition to some type of heat exchanger to transfer the cool energy to the
supply air. The cooled moist air from the direct evaporative cooling process never comes in direct
contact with the conditioned supply air. The moist air stream is released outside or used to cool
other external devices such as solar cells which are more efficient if kept cool. One indirect cooler
manufacturer uses the so-called Maisotsenko cycle which employs an iterative (multi-step) heat
exchanger that can reduce the temperature of product air to below the wet-bulb temperature, and
can a approach the dew point. While no moisture is added to the incoming air the relative humidity
(RH) does rise a little according to the Temperature-RH formula. Still, the relatively dry air
resulting from indirect evaporative cooling allows inhabitants' perspiration to evaporate more
easily, increasing the relative effectiveness of this technique. Indirect Cooling is an effective
strategy for hot-humid climates that cannot afford to increase the moisture content of the supply
air due to indoor air quality and human thermal comfort concerns. The following graphs describe
the process of direct and indirect evaporative cooling with the changes in temperature, moisture
content and relative humidity of the air.

Fig 1.2 indirect cooling system

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 Passive indirect evaporative cooling strategies are rare because this strategy involves an
architectural element to act as a heat exchanger. This element can be sprayed with water and cooled
through the evaporation of the water on this element. These strategies are rare due to the high use
of water, which also introduces the risk of water intrusion and compromising building structure.

1.4.3 COMBINED EVAPORATIVE COOLING

This type of evaporative coolers combine indirect with direct evaporative cooling. This is
accomplished by passing air inside a heat exchanger that is cooled by evaporation on the outside.
In the second stage, the pre-cooled air passes through a water-soaked pad and picks up humidity
as it cools. Because the air supply to the second stage evaporator is pre-cooled, less humidity is
added to the air, whose affinity for moisture is directly related to temperature. The two-stage
evaporative cooling provides air that is cooler than either a direct or indirect single-stage system
can provide individually. In many cases, these two-stage systems provide better comfort than a
compressor-based system, because they maintain a more favorable indoor humidity range.

Fig 1.3 combined cooling system

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1.5 DESIGN CONSIDERATIONS

1.5.1 WATER USE

In dry and semi-dry climates, the scarcity of water makes water consumption a concern in
cooling system design. Electricity generation usually requires a large amount of water, and
evaporative coolers use far less electricity, and thus comparable water overall, and cost less overall,
compared to chillers.

1.5.2 EVAPORATIVE PADS

Evaporative pad effectiveness depends highly on the capability of the evaporative pad or
media to provide the high wetted surface area and negligible air flow resistance. Evaporative pads
act as a medium for air cooler by means of evaporation of water into vapor.

Fig 1.4 [Courtesy this photograph taken from indiamart website to shows evaporative pad work flow]

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1.6 TYPES OF EVAPORATIVE PADS
1.6.1 CELLULOSE
In this cellulose 5090 type evaporative pad average distance between the two adjacent
layers are high as well as the angle between two chronological layer is high test pad modules are
fabricated from several wavy thin layers of corrugated papers bounded together.

Fig 1.5[Courtesy this photograph taken from https://www.123rf.com website to shows cellulose evaporative
pad]

1.6.2 COCUNUT COIR

Coconut coir is obtained from is basically a waste that is produced in a reasonable quantities in
some developing countries of the world. It is easily available in abundant quantity at very low cost.
It can be used for different purposes

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 Fig 1.6 [courtesy this photograph is taken from website https://www.123rf.com to show
coconut coir]

1.6.3 JUTE
Jute is a long soft shine vegetable fiber that can be spun into coarse, strong threads it is
produced from plants in the genus co chorus which was once classified with the family.

1.6.4 WOOD WOOL

Wood wool is a product made of wood slivers cut from logs. It is mainly used in packaging, for
cooling pads in home evaporative cooling systems known as swamp coolers, for erosion
control mats, and as a raw material for the production of other products such as bonded wood wool
boards. In the past it was used to fill stuffed toys. It is also sometimes used by taxidermists to
construct the armatures of taxidermy mount

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1.6.4.1 GRADES AND CLASSIFICATIONS OF WOOD WOOL BASED ON
THEIR SIZES

Table I. Strand size for type I class A and B excelsior

Grade Nomenclature Thickness of strand, Inch Width of strand, Inch

1 Superfine wood wool 0.006 0.020

2 Wood wool 0.012 0.020

3 Extra fine 0.015 0.031

4 Fine 0.018 0.031

5 Medium 0.021 0.041

6 Coarse or ribbon 0.015 0.167

1.6.4.2 PROPERTIES OF WOOD WOOL

Wood wool fibers can be compressed and when the pressure is removed they resume
their initial volume. This is a useful property for minimizing their volume when shipping. Due to
its high volume and large surface area, wood wool can be used for applications where water or
moisture retention is necessary. The width of wood wool fibers varies from 1.5 to 20 mm, while
their length is usually around 500 mm (depending on the production process).

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1.7 HUMAN COMFORT CONDITION
Every cooling system tries to fulfill the human comfort conditions. It is expected from an
efficient cooling system to satisfy thermal comfort within a smallest amount of input in the form
of money or energy.
Following are some important human comfort conditions:
• Oxygen supply
• Heat removal
• Moisture removal
• Air motion
• Purity of air
• Favorable temperature.

1.7.2 DIADVANTAGES OF EXISTING AIR COOLER

 Evaporative pad is costly.
 Existing design is complicated
 Power consumption is more
 Evaporation rate of existing design is very less.

1.8 EXISTING DESIGNS OF AIR COOLERS

1.8.1 360 DEGREE COOLERS (EXISTING PROJECTS)
1.8.1.1 360 DEGREE AIR COOLER AND HEATER
360 degree evaporative cooling is achieved by direct contact of water particles & a moving
air stream. When a hot and dry air is allowed to pass through a wet cooling pad, the temperature
of incoming air is reduced with an increase in specific humidity as some water from the pad is
evaporated taking the latent heat of vaporization from the incoming air.360 degree heater, is forced
convective heater that has an electric fan to speed up the air flow. In a convection heater, the

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heating element heats the air in contact with it by thermal conduction. Hot air is less dense than
cool air, so it rises due to buoyancy, allowing more cool air to flow in to take its place.

Fig 1.7[courtesy this image is taken from the journal paper Issue 8, Vol.3 (April- May 2018) ISSN 2249-
6149 title 360 degree air cooler cum heater]

FABRICATION OF THIS 360 DEGREE AIR COOLER

 This is the first step taken to manufacture a frame, water tank, and circular housing The
size of equipment is determined as per required size of the room to be cooled or heated
.cooling pad dimensions as per the design.
 The main components like pump, fan and heating coil are chosen based on design
calculations
 For cooling the water is used as refrigerant. Fan is used to drive the cool air to the
environment and drive less humid air to the heater.
 Distance between the fan and heating coil is less ids just avoid the expansion of air, as the
air moves from heater to the fan All the four side of the frame is encompassed from the
wood wool cooling pad inside, the pads are then sent with the water from the water tank
kept bottom the equipment and the water is pumped with the help of pump.

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1.8.2 Centripetal Air Flow Cooler
The centripetal air flow cooler maintains a better cooling effect and proper hygiene. The
better cooling effect is obtained by using the centripetal and axial flow fan. The important
components such as cylindrical cage, honey comb, and both the fans enable us to obtain higher
cooling effect. generally the normal air cooler provides a medium cooling effect by consuming
more power hence in order to minimize such problem in this system .the concept behind making
this cooler is to draw the air from the surrounding in the centripetal manner and then converting
the air in axial manner for better and effective cooling. The use of horizontal cylindrical cage
eliminates the pump and the honey comb eliminates the use of excelsior (wood wool). This enables
us to carry more water as compared to excelsior.

1.8.3 COMPACT EVAPORATIVE COOLER

The concept of evaporative cooling to provide comfort to human beings in a building is not
new and has been used in different parts of a world by using different ways and materials. Vapor
compression refrigeration system and Air-conditioning using gases like CFCs and HFCs reduces
the utility of evaporative cooling though they have capacity of ozone layer depletion. So many
manufacturers have come with different shaped evaporative coolers and different types of pad
materials. In this work new evaporative cooler is designed which is semi-circular in shape instead
of rectangular shape (normally used now a days) and the comparison between rectangular shaped
cooler and new designed semi-circular shaped cooler is made with Khus as a cooling pad material
in terms of temperature drop, humidity rise and cooling efficiency. By using Semi-circular shaped
utilization of water increases, more volume of air comes in contact due to stream line pattern,
require less cooling pad material and become compact, thus required less space for installation The
newly designed evaporative cooler is consists of two tanks which are perfectly insulated to reduce
heat transfer from water and is also incorporated with flow control valve to reduce water
consumption and effect of dust mites. The result obtained shows that temperature drop in semi-
circular shaped cooler is 5.80C as compared to 3.90C in rectangular shaped and also in rectangular
shaped cooler humidity rise is more as compared to semi-circular shaped. The cooling efficiency
is improved up to 20.43 % with new design. Also the cost of newly designed Semi-circular shaped
cooler is less than rectangular shaped cooler. As well as performance of different cooling pad

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materials like Celdek, Khus, Coconut coir and Bamboo fiber (new material) is analyzed in terms
of temperature drop, humidity rise and cooling efficiency by using normal water and chilled water
with newly designed semi-circular shape cooler. Also best cooling pad materials in terms of human
comfort and finally best cooling pad materials according to climate of Bhopal is analyzed in this
work. The result obtained shows that maximum temperature drop takes place for Celdek followed
by Khus, Coconut and least temperature drop is obtained for Bamboo fiber for both normal water
and chilled water .While minimum rise in humidity is obtained for Bamboo for both normal and
chilled water and maximum for Khus in normal water and Celdek in chilled water. But the
humidity rise is less for chilled water than normal water. With respect to human comfort Celdek
is a best materials followed by Coconut, Bamboo fiber and Khus.

1.8.3 MODIFIED AIR COOLER SYSTEM WITH STORAGE

This is a type of conventional air cooler which is used for providing room cooling as well
refrigeration systems. The system consists of a lower tank which is a mud pot whose outer
periphery is filled by sand slurry. The lower tank and the slurry are held by a larger mud pot, i.e.,
a pot-in-pot system. The lower tank is filled with water and it is connected to the upper tray through
a pump. The water in the upper tray is passed through a cooling pad which is used for absorbing
the water. A fan is fixed next to the cooling pad and is followed by a vent system. The tray also
has another port which is connected to the cold storage box. Hence providing the right temperature
for storage of perishable items.

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Fig 1.8 [courtesy this image is taken from journal modified air cooler and storage system e-ISSN: 2395 -0056 Volume:
03 Issue: 04 | Apr-2016 www.irjet.net p-ISSN: 2395-0072]

1.9 EXHAUST FAN

Exhaust ducts open windows must be used at all times to allow air to continually escape the air-
conditioned area. Otherwise, pressure develops and the fan or blower in the system is unable to
push much air through the media and into the air-conditioned area. The evaporative system cannot
function without exhausting the continuous supply of air from the air-conditioned area to the
outside. By optimizing the placement of the cooled-air inlet, along with the layout of the house
passages, related doors, and room windows, the system can be used most effectively to direct the
cooled air to the required areas. A well-designed layout can effectively scavenge and expel the hot
air from desired areas without the need for an above-ceiling ducted venting system. Continuous
airflow is essential, so the exhaust windows or vents must not restrict the volume and passage of
air being introduced by the evaporative cooling machine.

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