DESIGN AND FABRICATION OF ONBOARD FOOD

WARMER BY WASTE HEAT RECOVERY

A PROJECT REPORT

Submitted by

PANDIYARAJAN.S
SRIDHAR.R

SUGISH ANAND.S
VIPIN JOHNY

in partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

LOYOLA INSTITUTE OF TECHNOLOGY, CHENNAI

ANNA UNIVERSITY:: CHENNAI 600 025

APRIL 2012

1
 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF

ONBOARD FOOD WARMER BY WASTE HEAT RECOVERY” is the

bonafide work of “PANDIYARAJAN.S, SRIDHAR.R, SUGISH ANAND.S,

VIPIN JOHNY” who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr. NAVEEN CHANDRAN Dr. NAVEEN CHANDRAN

HEAD OF THE DEPARTMENT GUIDE

MECHANICAL DEPARTMENT MECHANICAL DEPARTMENT

LOYOLA INSTITUTE OF TECHNOLOGY LOYOLA INSTITUTE OF TECHNOLOGY

PALANCHUR PALANCHUR

CHENNAI – 602 103 CHENNAI – 602 103

2
 ACKNOWLEDGEMENT

No words can express our gratitude in full to the under mentioned for whom
this project would have remained a virtual scheme.
We have a great pleasure in putting on record our sincere and heartfelt
thanks to our beloved principal Dr. KARI THANGARATNAM for his
benevolent suggestions and encouragement that proved to be an incalculable help
in our endeavors’.
We wish to express our sincere thanks to our guide Dr. NAVEEN
CHANDRAN. M.E., Ph.D., Head of the Department, Department of Mechanical
Engineering for his whole hearted encouragement with valuable guidance and
facilities provided to us in completing this project.
It is pleasure to express our profound thanks to our supervisor
Mr. N. GODWIN RAJA EBENEZER. M.E., M.B.A., (PhD) Asst. Professor of
Mechanical Engineering, who motivated us to carry out this project for his timely
advice, constant monitoring and encouragement at various stages of work.
We express thanks to the members of project committee who encouraged us
with constructive criticism and valuable suggestion for the betterment of our
project work. We would also thank all teaching, non – teaching staff and friends of
our department for their unfailing support for our project work to this extent.

3
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT ii
LIST OF TABLES iii

LIST OF FIGURES iv
LIST OF SYMBOLS vi

1. INTRODUCTION 1
1.1 AIM 3

1.2 PROBLEM STATEMENT 4

1.3 DETAIL DISCUSSION 5

1.3.1 INTERNAL COMBUSTION ENGINE 5

1.3.2 COOLANT 8

1.3.3 THERMAL CONDUCTIVITY 10

1.3.3.1 MEASUREMENT OF THERMAL

CONDUCTIVITY 10

1.3.3.2 IMPORTANCE OF THERMAL CONDUCTIVITY 11

1.3.3.3 FACTORS AFFECTING THERMAL

4
 CONDUCTIVITY 12

1.3.4 TECHNICAL BACKGROUND 13

1.3.5 MATERIAL SELECTION 15

1.3.5.1 POISONING OF COPPER UTENSILS 15

1.3.5.2 STAINLESS STEEL 16

1.3.6 CONCEPT 21

1.3.7 PRINCIPLES OF HEAT TRANSFER 21

1.3.7.1 CONDUCTION 22

1.3.7.2 CONVECTION 23

1.3.8 WORKING 26

1.4 COMPONENT DESCRIPTION 27

2. LITERATURE REVIEW 32
2.1 FOOT WARMER FOR USE IN CAR 32

2.2 MOTOR VEHICLE HEAT STORAGE DEVICE WITH

COOLANT BYPASS 32

2.3 MOTOR VEHICLE FLUID HEATING DEVICE WITH

HEAT STORAGE 33

2.4 ENGINE WASTE HEAT RECOVERY SYSTEM 34

2.5 POWERING CAR WITH WASTE HEAT 34

3. PROJECT METHODOLOGY 35
4. FIRST PHASE OF FINISHED PRODUCT 43

5
 5. DESIGN AND IMPLEMENTATION 44
5.1 DESIGN PROCESS 44

5.2 SPECIFICATION OF COMPONENTS 46

5.3 PART DIAGRAM 48

5.4 FORMULAE USED 49

5.5 THEORITICAL CALCULATION 51

5.6 PRACTICAL APPROACH 54

5.7 GRAPHICAL ANALYSIS 55

5.8 COST ANALYSIS 56

5.9 HURDLES FACED 57

5.10 PROCESS CHART 58

5.11 ADVANTAGES 59

5.12 POSSIBLE AND RECOMMENDED APPLICATION 59

5.13 SUMMARY 60

6. CONCLUSION 61

7. FUTURE WORK 62

8. APPENDIX 63

9. BIBLIOGRAPHY 65

6
 ABSTRACT

This project is focused to use the heat rejected from the engine through
cooling system for a useful accessory during long distance travel of vehicle. In this
project, a system of water heater/food warmer has been designed and fabricated
using the principle of waste heat recovery. The heat energy required to heat food,
mostly water is extracted from the heat in the engine coolant which otherwise will
be rejected to the atmosphere by radiator.

Coolant from engine jacket is circulated in the radiator in automotive

engines. In this project, a branch line is added to coolant circuit. This branch line
bypasses some amount of coolant and feed to the heater chamber. Heater chamber
is a doubled walled container. Coolant is fed to the jacket of heater chamber.

The food material, liquid or solid, mostly water is kept in the chamber. Heat
is transferred from the coolant circulated in the jacket of heater chamber to the
food material.

Water was taken for testing food warmer and was found to effective. The
maximum heat transfer temperature from coolant was observed as 85oC. The inner
and outer wall temperature of heater chamber was found almost same for both
theoretical and practical cases.

7
 LIST OF TABLES

TABLE TITLE PAGE NO

3.1 CALCULATION OF EXPECTED 37

TIME

3.2 GANTT CHART 38

5.1 COST ESTIMATION 56

5.2 OVERVIEW OF PROJECT 60

8.1 COMPARISION OF HEATER 64

CHAMBER WITH CUP & STAND

8
 LIST OF FIGURES

FIGURE NAME PAGE NO

1.1 MODEL ASSUMPTION OF FOOD WARMER 2

1.2 COMMON RAIL DIRECT FUEL INJECTION 7

1.3 LIQUID COOLANT 9

1.4 COOLING SYSTEM LOOP 9

1.5 CONDUTION PROCESS 23

1.6 HEAT TRANSFER IN CONDUCTION 23

1.7 CONVECTION PROCESS 25

1.8 BLOCK DIAGRAM OF ENGINE HEAT 26

BYPASS

1.9 HEATER CHAMBER 27

1.10 HEAT JACKET HOSE 28

1.11 STEEL HOLDER PIPES 29

1.12 HEAT JACKET HOSE CLIPS 29

1.13 FLOW CONTROL VALVE 29

1.14 DIGITAL THERMOMETER 30

1.15 DIGITAL THERMOMETER 30

9
1.16 BEARING 31

1.17 BASE TRAY 37

4.1 FRONT DIAGRAM OF HEATER CHAMBER 43

4.2 SIDE VIEW OF HEATER CHAMBER 43

5.1 2D VIEW OF HEATER CHAMBER 48

5.2 2D VIEW OF STAND 48

5.3 TIME VS TEMPERATURE 55

10
 LIST OF SYMBOLS

SYMBOL ABBRIVATION PAGE NO

q CONDUCTIVE HEAT TRANSFER 23

A HEAT TRANSFER AREA 23

k THERMAL CONDUCTIVITY OF MATERIAL 23

dT TEMPERATURE DIFFERENCE ACROSS THE 23

MATERIAL

s MATERIAL THICKNESS 23

m2 SQUARE METER 23

W WATT 23

M METER 23

K KELVIN 23

o
C DEGREE CELSIUS 23

o
F DEGREE FARENHEIT 23

O OPTIMISTIC TIME ESTIMATE 36

P PESSIMESTIC TIME ESTIMATE 36

M NORMAL 36

TE EXPECTED TIME 37

11
Q loss HEAT LOST FROM HOT COOLANT 49

m MASS FLOW RATE 49

cp SPECIFIC HEAT 49

Tin INLET TEMPERATURE OF HOT COOLANT 49

Tout OUTLET TEMPERATURE OF HOT COOLANT 49

ρ DENSITY OF FLUID 49

A AREA OF BOILER 49

u VELOCITY OF COOLANT 49

J JOULE 49

Kg KILOGRAM 49

S SECOND 49

KJ KILOJOULE 50

D DIAMETER OF HEATER CHAMBER 50

H HEIGHT OF HEATER CHAMBER 50

Q gain HEAT GAINED BY HEATER CHAMBER 50

∆T TEMPERATURE DIFFERENCE 50

T∞ TEMPERATURE OF WATER BEING HEATED 50

IN THE CHAMBER

12
ReD REYNOLDS NUMBER 50

υ KINEMATIC VISCOSITY 50

NuD NUSSELT NUMBER 50

Pr PRANDLT NUMBER 50

hi CONVECTIVE HEAT TRANSFER 50

COEFFICIENT IN CHAMBER

k THERMAL CONDUCTIVITY 50

R THERMAL RESISTANCE 50

Ri THERMAL RESISTANCE IN CHAMBER 50

R wall THERMAL RESISTANCE IN WALL LAYER 50

∆Q OVERALL HEAT TRANSFER TO CHAMBER 50

13
 1. INTRODUCTION

One of the emerging fields found in widespread disciplines of mechanical

engineering is the field of advance study in automobile engineering. Particularly
the interest in heat recovery systems is growing rapidly as a substitute to extra
power usage from battery due to its ease of use, saving of power, cost
effectiveness, advanced concept etc... Further the application of heat from engine
has been in various theories such as foot warmer, heat storage devices etc.. Many
heat usage processes have been unused. So in this work, interest lies in the usage or
bypass of engine heat which is naturally available without any external source.

The main aim of this project is to use the engine heat in a new way of
approach and to develop it as a useful accessory in vehicles, especially in four
wheelers and heavy vehicles. In this project work, engine heat is bypassed into a
small Heater Chamber through a heat jacket hose and use this heat in an efficient
way to boil water, prepare milk etc...

The heat from engine is continuously passed to radiator for cooling purpose.
This is a cyclic process. More amount of heat from engine is wasted during the
operation of vehicle. This wasted heat is passed through heat jacket hose pipe and
connected to the heat exchanger inlet and piped back to engine through outlet. A
small passage is present between the outer and inner layer of the Heater Chamber
for flow of hot water. The inlet and outlet are welded to the outer layer of Heater
Chamber. Hot water along with coolant is passed through the inlet. Water to be
boiled or milk to be prepared is poured into the inner layer of Heater Chamber

14
from top section. Heat from hot coolant is transferred and exchanged to inner layer
of Heater Chamber. This heat is used for domestic heat processing applications.

A model assumption of our product is shown below:

Fig 1.1 Model Assumption of Food Warmer

15
1.1 AIM

The main aim of this project is to develop a new type of accessory in

automobile industry by waste heat recovery.

We have analyzed the various accessories that is used in cars and trucks such
as mobile charger, CD player, Air conditioner, Refrigerator etc.. The working
process of each accessory was deeply observed. Especially the thermal concept
involved in accessories like air conditioner and refrigerator was taken a note. This
project also comes under the thermal concept of utilization of the generated heat.

More amount of heat from engine is being dissipated in all forms during
vehicle operation. Our focus lies on this wasted engine heat. The utilization of heat
is the major work involved here. We have brought this concept into a working
model of real time use accessory in vehicles. A food warmer has been introduced
which is used as an accessory in this project. Food warmer can also be considered
as a heater chamber.

We concentrated upon the invention of food warmer and mainly to make the
accessory user friendly. The design of the food warmer has been accurately made
considering the user safety. It is designed so as to withstand maximum engine heat.
The food warmer that we had introduced has been constructed with utmost care
such that it can be altered for any type of vehicles.

We finally focused on the heater chamber, which is the proof of our concept
to make it 100% safe.

16
1.2 PROBLEM STATEMENT

Every project starts with a problem statement. The introduction of food

warmer in this project can overcome various customer needs. The first and
foremost problem identified is that heat from engine is wasted under operating
conditions of vehicle. Food warmer used in this project utilizes the engine waste
heat.

Many accessories for various needs have been developed, especially in four
wheelers. But no inventions on food accessories are developed up to date.

Customers who travel long distance journeys demand hot water. This may
be very useful during winter season. Warm water and milk would be useful to feed
baby infants during travel and also food can be kept warm at a steady temperature.

Thus the problem statement can be summarized as,

 Heat from engine is wasted under operating conditions of vehicle.

 No invention has been focused on food accessories up to date.
 Also, people demand hot water during long journeys especially during
winter seasons.
 Food should be kept warm for a long period.
 Baby infants need warm water.

17
1.3 DETAILED DISCUSSION

1.3.1 INTERNAL COMBUSTION ENGINE

The internal combustion engine is an engine in which the combustion of a

fuel (normally a fossil fuel) occurs with an oxidizer (usually air) in a combustion
chamber. In an internal combustion engine, the expansion of the high-temperature
and high -pressure gases produced by combustion apply direct force to some
component of the engine. This force is applied typically to pistons, turbine blades,
or a nozzle. This force moves the component over a distance, transforming
chemical energy into useful mechanical energy.

A large number of different designs for ICEs have been developed and built,
with a variety of different strengths and weaknesses. Powered by an energy-dense
fuel (which is very frequently gasoline, a liquid derived from fossil fuels). While
there have been and still are many stationary applications, the real strength of
internal combustion engines is in mobile applications and they dominate as a
power supply for cars, aircraft, and boats.

Internal combustion engines are most commonly used for mobile propulsion
in vehicles and portable machinery. In mobile equipment, internal combustion is
advantageous since it can provide high power-to-weight ratios together with
excellent fuel energy density. Generally using fossil fuel (mainly petroleum), these
engines have appeared in transport in almost all vehicles (automobiles, trucks,
motorcycles, boats, and in a wide variety of aircraft and locomotives).

18
 Internal combustion engines can be classified by their configuration.

Common layouts of engines are:

Reciprocating:

 Two-stroke engine
 Four-stroke engine
 Six-stroke engine
 Diesel engine
 Atkinson cycle
 Miller cycle

Rotary:

 Wankel engine

Continuous combustion:

 Gas turbine
 Jet engine (including turbojet, turbofan, ramjet, Rocket, etc.)

DIESEL ENGINE

The engine used in this project is ‘Diesel Engine’.

A diesel engine (also known as a compression-ignition engine) is an internal

combustion engine that uses the heat of compression to initiate ignition to burn
the fuel, which is injected into the combustion chamber. This is in contrast to
spark-ignition engines such as a petrol engine (gasoline engine) or gas engine
(using a gaseous fuel as opposed to gasoline), which uses a spark plug to ignite
an air-fuel mixture.
19
The diesel engine has the highest thermal efficiency of any regular internal or
external combustion engine due to its very high compression ratio. Low-speed
Diesel engines (as used in ships and other applications where overall engine
weight is relatively unimportant) the largest of which can have a thermal
efficiency that exceeds 50 percent.

COMMON RAIL DIRECT FUEL INJECTION

Common rail direct fuel injection is a modern variant of direct fuel injection
system for petrol and diesel engines.

On diesel engines, it features a high-pressure (over 1,000 bar/15,000 psi) fuel

rail feeding individual solenoid valves, as opposed to low-pressure fuel pump
feeding unit injectors. Third-generation common rail diesels now feature
piezoelectric injectors for increased precision, with fuel pressures up to
1,800 bar/26,000 psi.

Common rail engines require very short (< 10 second) or no heating-up time at
all, dependent on ambient temperature, and produce lower engine noise and
emissions than older systems.

Fig 1.2 Common Rail Direct Fuel Injection

20
1.3.2 COOLANT

A coolant is a fluid which flows through a device to prevent its overheating,

transferring the heat produced by the device to other devices that use or dissipate it.
An ideal coolant has high thermal capacity, low viscosity, is low-cost, non-toxic,
and chemically inert, neither causing nor promoting corrosion of the cooling
system. Some applications also require the coolant to be an electrical insulator.

While the term coolant is commonly used in automotive, residential and

commercial temperature-control applications, in industrial processing, heat transfer
fluid is one technical term more often used, in high temperature as well as low
temperature manufacturing applications.

The coolant can either keep its phase and stay liquid or gaseous, or can
undergo a phase change, with the latent heat adding to the cooling efficiency. The
latter, when used to achieve low temperatures, is more commonly known as
refrigerant.

Coolant is of solid, liquid and gaseous forms. Liquid coolant is used in this
project.

The most common liquid coolant is water. Its high heat capacity and low
cost makes it a suitable heat-transfer medium. It is usually used with additives, like
corrosion inhibitors and antifreeze. Antifreeze, a solution of a suitable organic
chemical (most often ethylene glycol, diethylene glycol, or propylene glycol) in
water, is used when the water-based coolant has to withstand temperatures below
0 °C, or when its boiling point has to be raised.

21
COOLANT HEAT TRANSFER

There are two types of coolants used to remove the heat from the engine
block and head: air, and water. With air as a coolant, the heat is removed through
the use of fins attached to the cylinder wall. With water as a coolant, the heat is
removed through the use of fluid filled internal cooling passages.

Fig 1.3 Liquid Coolant

Water systems can freeze unless additives are used. The water cooling
system is usually a single loop where a water pump sends coolant to the engine
block, and then to the head.

Fig 1.4 Cooling System Loop

22
 During engine warm up, a thermostatically controlled valve will recycle the
coolant flow through the engine block, bypassing the heat exchanger. As the
engine heats up, the valve will open up, and allow the coolant to flow to the
radiator.

1.3.3 THERMAL CONDUCTIVITY

In physics, thermal conductivity is the property of a material's ability

to conduct heat. It appears primarily in Fourier's Law for heat conduction.

Heat transfer across materials of high thermal conductivity occurs at a higher

rate than across materials of low thermal conductivity. Correspondingly materials
of high thermal conductivity are widely used in heat sink applications and
materials of low thermal conductivity are used as thermal insulation. Thermal
conductivity of materials is temperature dependent. The reciprocal of thermal
conductivity is thermal resistivity.

1.3.3.1 MEASUREMANT OF THERMAL CONDUCTIVITY

There are a number of ways to measure thermal conductivity. Each of these

is suitable for a limited range of materials, depending on the thermal properties and
the medium temperature. There is a distinction between steady-state and transient
techniques.

In general, steady-state techniques are useful when the temperature of the material
does not change with time. This makes the signal analysis straightforward (steady

23
state implies constant signals). The disadvantage is that a well-engineered
experimental setup is usually needed. The Divided Bar (various types) is the most
common device used for consolidated rock samples.

The transient techniques perform a measurement during the process of heating up.
Their advantage is quicker measurements. Transient methods are usually carried
out by needle probes. A method described by Angstrom involves rapidly cycling
the temperature from hot to cold and back and measuring the temperature change
as the heat propagates along a thin strip of material in a vacuum.

1.3.3.2 IMPORTANCE OF THERMAL CONDUCTIVITY

Thermal conductivity is important in material science, research, and

electronics, building insulation and related fields, especially where high operating
temperatures are achieved. However, materials used in such trades are rarely
subjected to chemical purity standards. Several materials are shown in the list of
thermal conductivities. These should be considered approximate due to the
uncertainties related to material definitions.

On the one hand solutions for computer cooling or turbine blades usually use high
thermal conductive materials such as silver, copper and aluminium, to cool down
specific components. On the other hand in construction or furnaces low thermal
conductive materials such as polystyrene and alumina are used to separate warm /
hot parts from cold ones.

24
1.3.3.3 FACTORS AFFECTING THERMAL CONDUCTIVITY

Temperature-

The effect of temperature on thermal conductivity is different for metals and

nonmetals. In metals conductivity is primarily due to free electrons.
Following Wiedemann–Franz law thermal conductivity of metals is approximately
proportional to the absolute temperature (in Kelvin) times electrical conductivity.
In pure metals the electrical resistivity often increases proportional to temperature
and thus thermal conductivity stays approximately constant. In alloys the change in
electrical conductivity is usually smaller and thus thermal conductivity increases
with temperature, often proportional to temperature.

On the other hand conductivity in nonmetals is mainly due to lattice vibrations

(phonons). Except for high quality crystals at low temperatures, the phonon mean
free path of phonons is not reduced significantly at higher temperatures. Thus the
thermal conductivity of nonmetals is approximately constant at not too low
temperatures. At low temperatures well below Debye-temperature thermal
conductivity decreases just like the heat capacity does.

Material phase-

When a material undergoes a phase change from solid to liquid or from liquid to
gas the thermal conductivity may change. An example of this would be the change
in thermal conductivity that occurs when ice (thermal conductivity of 2.18
W/(m·K) at 0 °C) melts into liquid water (thermal conductivity of 0.58 W/(m·K) at
0 °C).

25
Material structure-

Pure crystalline substances can exhibit different thermal conductivities along

different crystal axes, due to differences in phonon coupling along a given crystal
axis. Sapphire is a notable example of variable thermal conductivity based on
orientation and temperature, with 35 W/(m K) along the c-axis and 32 W/(m K)
along the a-axis.

1.3.4 TECHNICAL BACKGROUND

NEWTON’S LAW OF COOLING:

Newton's Law of Cooling states that the rate of change of the temperature of an
object is proportional to the difference between its own temperature and the
ambient temperature (i.e. the temperature of its surroundings).

Newton's Law makes a statement about an instantaneous rate of change of the

temperature. We will see that when we translate this verbal statement into a
differential equation, we arrive at a differential equation. The solution to this
equation will then be a function that tracks the complete record of the temperature
over time.

THERMAL CONDUCTIVITY:

Thermal Conductivity determines the quantity of heat which flows in unit time
through unit area of a layer of the substance of unit thickness with unit difference
of temperature between it's faces.

26
THERMAL DIFFUSIVITY:
Thermal Diffusivity measures the change of temperature which would be produced
in unit volume of the substance by quantity of heat which flows in unit time
through unit area of a layer of the substance of unit thickness with unit difference
of temperature between it's faces.

SPECIFIC HEAT:
Specific Heat is expressed as a quantity of heat necessary to rise the temperature of
unit mass of the substance by one unit.
THERMAL EXPANSION:
Thermal Expansion is the tendency of matter to change in volume in response to a
change in temperature.

THERMAL GRAVIMETRIC ANALYSIS:

Thermal Gravimetric Analysis is a type of testing performed on samples that
determines changes in weight in relation to change in temperature.

SIMULTANEOUS THERMAL ANALYSIS:

Simultaneous Thermal Analysis is the combination of a thermal gravimetric
analysis and specific heat measurements.

ENTHALPY:
Enthalpy is a measure of the total energy of a thermodynamic system. It includes
the internal energy, which is the energy required to create a system, and the
amount of energy required to make room for it by displacing its environment and
establishing its volume and pressure.

27
1.3.5 MATERIAL SELECTION

Safety is the first consideration for any material. Material selection must be
done carefully since boiling process is to be carried out in it. Various materials are
available for the manufacture of the accessory food warmer. Some of the available
materials are aluminium, copper, steel etc..

1.3.5.1 POISONING OF COPPER UTENSILS

Largely found in the brain and liver, copper is a naturally occurring

substance in our bodies. In fact, humans need trace amounts of copper to survive.
Some believe copper to be the best dishes for cooking, and lined as well as unlined
copper vessels serve many culinary purposes. These vessels however, do not fit
every culinary necessity because copper reacts with certain foods and this could
result in unpleasant health-related issues.

When acidic foods are cooked in unlined copper cookware or in lined

cookware where the lining has worn through, toxic amounts of copper can leech
into the foods being cooked. This effect is exacerbated if the copper has corroded,
creating reactive salts. Actual cooking may not be required for copper to leach into
acidic liquids if they are stored in copper for a long period.

LINED AND UNLINED COPPER:

Copper utensils are usually lined with another substance. There are a few
vessels such as those used specifically for caramelizing sugar or beating egg whites
that do not have a lining. Since copper is slightly acidic in nature, it does have a
tendency to react with certain foods if the vessel is not lined.

28
FOODS THAT REACT WITH COPPER:

Copper vessels should not be used for storing pickled foods or for pickling
foods. In addition, drinking water should not be stored in copper vessels. Also milk
and milk products like cream, butter, etc. should not be kept in copper vessels as it
could react with the metal and cause illness. The same goes for honey, citrus juice
and yogurt, as they have acidic properties that could react with the metal. Copper
utensils also should not be used to eat, drink and serve these foods. If a copper
utensil is left standing in dairy or acidic foods, the food should be discarded to
avoid health problems.

1.3.5.2 STAINLESS STEEL

In metallurgy, stainless steel, also known as inox steel or inox, is defined as

a steel alloy with a minimum of 10.5 or 11% chromium content by mass.

Stainless steel does not corrode, rust or stain with water as ordinary steel
does, but despite the name it is not fully stain-proof. It is also called corrosion-
resistant steel or CRES when the alloy type and grade are not detailed, particularly
in the aviation industry. There are different grades and surface finishes of stainless
steel to suit the environment the alloy must endure. Stainless steel is used where
both the properties of steel and resistance to corrosion are required.

TIG WELDING ON STAINLESS STEEL:

TIG welding can be performed with a large variety of metals. The two most
commonly TIG welded metals in the PRL are steel and aluminum. Steel is
relatively easy to TIG weld and it is possible to produce very tight, neat welds.
Aluminum takes a little more skill, and one should have at least a little bit of
experience in welding steel before making the transition to aluminum. However,

29
the basic technique is essentially the same and most people can make the jump to
aluminum fairly easily.

STAINLESS STEEL IN COOKAWARE:

Stainless steel’s resistance to corrosion and staining, low maintenance and

familiar luster make it an ideal material for many applications. There are over 150
grades of stainless steel, of which fifteen are most commonly used. The alloy is
milled into coils, sheets, plates, bars, wire, and tubing to be used in cookware,
cutlery, hardware, surgical instruments, major appliances, industrial equipment (for
example, in sugar refineries) and as an automotive and aerospace structural alloy
and construction material in large buildings. Storage tanks and tankers used to
transport orange juice and other food are often made of stainless steel, because of
its corrosion resistance and antibacterial properties. This also influences its use in
commercial kitchens and food processing plants, as it can be steam-cleaned and
sterilized and does not need paint or other surface finishes.

High oxidation-resistance in air at ambient temperature is normally achieved

with additions of a minimum of 13% (by weight) chromium, and up to 26% is used
for harsh environments. The chromium forms a passivation layer of chromium(III)
oxide (Cr2O3) when exposed to oxygen. The layer is too thin to be visible, and the
metal remains lustrous. The layer is impervious to water and air, protecting the
metal beneath. Also, this layer quickly reforms when the surface is scratched. This
phenomenon is called ‘Passivation’ and is seen in other metals, such as aluminium
and titanium.

30
RECYCLING AND REUSE:

Stainless steel is 100% recyclable. An average stainless steel object is

composed of about 60% recycled material of which approximately 40% originates
from end-of-life products and about 60% comes from manufacturing processes.[17]
According to the International Resource Panel's Metal Stocks in Society report, the
per capita stock of stainless steel in use in society is 80–180kg in more developed
countries and 15kg in less-developed countries.

There is a secondary market that recycles usable scrap for many stainless
steel markets. The product is mostly coil, sheet and blanks. This material is
purchased at a less-than-prime price and sold to commercial quality stampers and
sheet metal houses. The material may have scratches, pits and dents but is made to
the current specifications.

GRADES OF STAINLESS STEEL:

Various grades of stainless steel are available in market. They are in the
series of 100,200,300,400,500,600, Type 2205, Type 2304 etc.. Stainless steel of
grade 304 is used in the manufacture of food Warmer in this project.

Type 304 stainless steel is a T 300 Series Stainless Steel austenitic. It has a
minimum of 18% chromium and 8% nickel, combined with a maximum of 0.08%
carbon. It is defined as a Chromium-Nickel austenitic alloy.

Grade 304 is the standard "18/8" stainless that is most probably seen in pans
and cookery tools.

31
These are some of its characteristics:
- Forming and welding properties
- Corrosion/ oxidation resistance thanks to the chromium content
- Deep drawing quality
- Excellent toughness, even down to cryogenic temperatures which are defined as
very low temperatures
- Low temperature properties responding well to hardening by cold working
- Ease of cleaning, ease of fabrication, beauty of appearance

Grade 304L is the low carbon version of 304. It does not require post-weld
annealing and so is extensively used in heavy gauge components (over about
6mm).

Grade 304H with its higher carbon content finds application at elevated
temperatures.

APPLICATIONS:
It is used for a wide variety of home and commercial applications, this is
one of the most familiar and most frequently used alloys in the stainless steel
family. Typical applications include tanks and containers for a large variety of
liquids and solids.

32
  FOOD INDUSTRY-
It is used for manufacture of food processing equipment, particularly in beer
brewing, milk processing & wine making.
For example it is highly suitable and applied in dairy equipment such as
milking machines, containers, homogenizers, sterilizers, and storage and hauling
tanks, including piping, valves, milk trucks and railroad cars.

Very common in the brewing industry where it is used in pipelines, yeast

pans, fermentation vats, storage and railway cars, etc.
The citrus and fruit juice industry also uses Type 304 for all their handling,
crushing, preparation, storage and hauling equipment.

 DOMESTIC TOOLS INDUSTRY-

Because of its ability to withstand the corrosive action of various acids
found in fruits, meats, milk, and vegetables, Type 304 is used for sinks, tabletops,
coffee urns, stoves, refrigerators, milk and cream dispensers, and steam tables. It is
also used in numerous other utensils such as cooking appliances, pots, pans, and
flatware.

33
1.3.6 CONCEPT

Hot water along with engine coolant circulates continuously from engine to
radiator. Heat jacket hose is a separate pipeline connected from the engine. The
hose is connected back to the engine. Hot coolant passes through this heat jacket
hose when the flow control valve is turned on. This hot coolant enters the heater
chamber (food warmer) inlet and circulates through the two walls of the heater
chamber and exits from the outlet of the chamber. The exit line is piped back to the
engine.

The concept of our paper deals with the usage of hot coolant from the engine
for a domestic purpose such as heating food, water etc.. inside the vehicle.

As the hot coolant circulates around the two walls of the heater chamber, a
transfer of heat takes place from coolant to food warmer. The heat is transferred
from hot coolant to the inner wall of the heater chamber. The flow of hot coolant is
a continuous movement between the two walls of the Heater Chamber. Heat is
transferred from this continuous flowing liquid to the inner wall of the Heater
Chamber. Thus, a convective heat transfer takes place. This is generally referred to
as Convection.

1.3.7 PRINCIPLES OF HEAT TRANSFER

Two major principles are used in our project they are:

 Conduction

 Convection

34
1.3.7.1 CONDUCTION:

Conduction is the mechanism of heat transfer from a region of high

temp to a region of low temp within a medium or different medium in direct
physical contact.

In heat transfer, conduction (or heat conduction) is a mode of transfer

of energy within and between bodies of matter, due to a temperature gradient.
Conduction means collision and diffusive transfer of kinetic energy of particles of
ponder able matter (as distinct from photons). Conduction takes place in all forms
of ponder able matter, viz. solids, liquids, gases and plasmas. Heat spontaneously
tends to flow from a body at a higher temperature to a body at a lower temperature.
In the absence of external driving fluxes, temperature differences, over time,
approach thermal equilibrium.

Conduction will take place if there exist a temperature gradient in a solid (or
stationary fluid) medium.

In gases and liquids, conduction is due to the collisions and diffusion of the
molecules during their random motion.

Energy is transferred from more energetic to less energetic molecules when

neighboring molecules collide. Conductive heat flow occurs in direction of the
decreasing temperature since higher temperatures are associated with higher
molecular energy.

35
Fourier's Law express conductive heat transfer as

q = k A dT / s

where,

A = heat transfer area (m2)

k = thermal conductivity of the material (W/mK or W/m oC)

dT = temperature difference across the material (K or oC, oF)

s = material thickness (m)

Fig 1.5 Conduction Process Fig 1.6 Heat Transfer in Conduction

1.3.7.2 CONVECTION:

Convection is defined as the Process of heat transfer occurs between

solid surface and fluid medium when they are at different temperatures.

Convection is heat transfer by mass motion of a fluid such as air or water

when the heated fluid is caused to move away from the source of heat, carrying

36
energy with it. Convection above a hot surface occurs because hot air expands,
becomes less dense, and rises. Hot water is likewise less dense than cold water and
rises, causing convection currents which transport energy.

Convective heat transfer, often referred to simply as Convection, is the

transfer of heat from one place to another by the movement of fluids. Convection is
usually the dominant form of heat transfer in liquids and gases. It is often
mentioned as a distinct method of heat transfer. Convective heat transfer involves
the combined processes of conduction (heat diffusion) and heat transfer by bulk
fluid flow, a process technically called heat advection.

The term Convection can refer to transfer of heat with any fluid movement,
but advection is the more precise term for the transfer due only to bulk fluid flow.
The process of transfer of heat from a solid to a fluid, or the reverse, requires not
only transfer of heat by bulk motion of the fluid, but also diffusion/conduction of
heat through the still boundary layer next to the solid. Thus, this process with a
moving fluid requires both diffusion and advection of heat, a summed process that
is generally called convection.

Two types of convective heat transfer may be distinguished:

 Free or natural convection: When fluid motion is caused by buoyancy

forces that result from the density variations due to variations of
temperature in the fluid. In the absence of an external source, when the
fluid is in contact with a hot surface, its molecules separate and scatter,
causing the fluid to be less dense. As a consequence, the fluid is
displaced while the cooler fluid gets denser and the fluid sinks. Thus, the
hotter volume transfers heat towards the cooler volume of that fluid.

37
 Familiar examples are the upward flow of air due to a fire or hot object
and the circulation of water in a pot that is heated from below.
 Forced convection: When a fluid is forced to flow over the surface by an
external source such as fans, by stirring, and pumps, creating an
artificially induced convection current.

In short, the temperature of the solid due to an external field such as

fluid buoyancy can induce a fluid motion. This is known as "natural
convection" and it is a strong function of the temperature difference between
the solid and the fluid. Blowing air over the solid by using external devices
such as fans and pumps can also generate a fluid motion. This is known as
"forced convection".

Fluid mechanics plays a major role in determining convection heat

transfer. For each kind of convection heat transfer, the fluid flow can be
either laminar or turbulent. Laminar flow generally occurs in relatively low
velocities in a smooth laminar boundary layer over smooth small objects,
while turbulent flow forms when the boundary layer is shedding or breaking
due to higher velocities or rough geometries.

Fig 1.7 Convection Process

38
1.3.8 WORKING

When the vehicle is started, coolant gets circulated between the engine and
radiator. Coolant that is passed between the engine and the radiator gets heated
within few minutes. This heated coolant along with hot water passes to the radiator
and gets cooled down. Thus a nominal temperature is maintained inside the engine.

Heater is an accessory connected from engine. A parallel connection is taken

from the heat jacket hose. Hot water flows through this heat jacket hose when the
flow control valve is regulated. Heat from hot coolant is the source given to Heater
Chamber (accessory in vehicle) where heating takes place. A temperature of 75-
1200 C is obtained.

COLD WATER HOT WATER

RADIATOR ENGINE FOOD

WARMER

HOT WATER HOT WATER

Fig 1.8 Block Diagram of Engine Heat Bypass

39
1.4 COMPONENT DESCRIPTION

The components used in our project are listed below:

 HEATER CHAMBER (FOOD WARMER)

Heater chamber is the heart of our project. It is basically a type of heat

exchanger. It is a double walled container. This is used for heating process. A
heater chamber made of stainless steel and grade 304 is used. A gasket rubber
sheet is insulated around the chamber. A lid is kept at the top to close the Heater
Chamber.

The Heater Chamber is designed in such a way that there are two wall
layers.

 Inner wall layer

 Outer wall layer

There is a small gap between inner and outer walls. Hot coolant from engine
flows through this pathway. A nominal temperature is maintained between these
layers. The water to be heated is kept inside the inner wall of the heater chamber.

Fig 1.9 Heater Chamber

40
 HEAT JACKET HOSE:

A heat jacket hose is a hollow tube designed to carry fluids from one
location to another. They are also called as pipes or tubes. Hose used here is
a flexible material. It is usually made up of hardened rubber. The shape of
hose is cylindrical having a circular cross section. Hose design is based on a
combination of application of performance. GATES hose of common
standards is used in this project. One side of heat jacket hose is given as inlet
to the heater chamber from engine and another one as outlet from heater
chamber to the same engine.

Fig 1.10 Heat Jacket Hose

 STEEL HOLDER PIPES:

Holder pipes are usually made of iron or steel. They are also called as
connector pipes. Holder pipes are used to join heat jacket hose and heater
chamber or two heat jacket hoses. Two holder pipes are gas welded together
in order to increase the length of connector.

41
 Fig 1.11 Steel Holder Pipes

 HEAT JACKET HOSE CLIPS:

Heat jacket hose clips are simply known as hose clips. The function of
hose clip is used to hold heat jacket hose and steel holder pipes tightly.

Fig 1.12 Heat Jacket Hose Clips

 FLOW CONTROL VALVE:

Flow control valve is used to direct the flow of water to heater

chamber. It is used as regulator and fixed at the inlet heat jacket hose. It is made
up of iron.

Fig 1.13 Flow Control Valve

42
 DIGITAL THERMOMETER:

Digital thermometers are used to measure the temperature of the

boiling liquid. Two types of thermometers are –

 Thermocouple thermometer
 Thermopile thermometer

Thermocouple thermometers are widely used in digital thermometers. It is

water proof, accurate and user calibrated. It has a sensor fixed to one end of
the thermometer and a digital display at the other end. The temperature is
displayed in 2 – 5 seconds.

Fig 1.14 Fig 1.15

Digital Thermometer

 BEARING:

Two bearings of standards 629 2RH are used here. It is used for
smooth movement of Heater Chamber.

43
 Fig 1.16 Bearing

 TILTER:

Tilter is a device which is used to tilt the food warmer. It is fixed to

the flexible heat jacket hose. Liquids that are heated in the Heater Chamber
can be taken out by tilting the food warmer.

 BASE TRAY:

It is used to collect the spilled water or milk for disposal. It is kept at

the bottom of food warmer. The water spilled is passed to the base tray.

Fig 1.17 Base Tray

44
 2. LITERATURE REVIEW

2.1 PAPER BY:

Yutaka Ando

FILED ON:

Mar 31, 1987

TOPIC:

Foot Warmer for Use in Car

CONCEPT:

A device for warming passenger’s feet using waste engine heat

was introduced. It is proposed to be located at the base of car. It comprises
of a concave groove formed in a meandering form on one surface of a heat
insulating material. A heat radiating sheet is connected to the surface on
which the groove is formed. A tube is disposed in the groove for heat
transfer of water flowing to heat radiating sheet.

2.2 PAPER BY:

Robert M Uyeki

FILED ON:

Apr 18, 1985

TOPIC:

Motor Vehicle Heat Storage Device with Coolant Bypass

45
 CONCEPT:

It has heat storage devices which employ a rechargeable latent

heat storage device. This provides rapid warm up of engine of motor vehicle.
Heat storage battery is capable of storing and releasing substantial quantity
of heat energy upon demand. This gives an auxiliary source of heat to the
cabin interior.

2.3 PAPER BY:

Oskar Schatz

FILED ON:

Feb 18, 1992

TOPIC:

Motor Vehicle Fluid Heating Device with Heat Storage

CONCEPT:

A vehicle heating system supplied with coolant from the engine

and there is a bypass connecting two limbs of the heating circuit extending
downstream from the engine. A heating circuit with heating storage means is
arranged separated from the bypass in series with vehicle heating system.

46
2.4 PAPER BY:

Christopher Adam Bering

FILED ON:

Feb 21, 2008

TOPIC:

Engine Waste Heat Recovery System

CONCEPT:

It has heat generating components and engine cooling circuit.

Heat Collecting Circuit (HCC) operates on first working fluid. Power
Generating Circuit (PGC) operates on second working fluid. Heat is
transferred by heat transfer device from HCC to PGC. PGC has an exhaust
gas cooler for superheating second working fluid and a turbine is driven.
This turbine drives an electric generator.

2.5 PAPER BY:

Prachi Patel

FILED ON:

May25, 2011

TOPIC:

Powering Car with Waste Heat

47
 CONCEPT:

Thermoelectric semiconductors material is the device used. At

least two-thirds of the energy in gasoline used in cars and trucks is wasted as
heat. Thermo electrics, semiconductor materials that convert heat into
electricity, could capture this waste heat, reducing the fuel needs of the
vehicle and improving fuel economy by at least 5 percent.

3. PROJECT METHODOLOGY

Before starting the project work a rough Gantt chart is prepared. A Gantt
chart is a type of bar chart, developed by Henry Gantt that illustrates a project
schedule. A Gantt chart is a graphical representation of the duration of tasks
against the progression of time. A Gantt chart is a useful tool for planning and
scheduling projects. It is helpful when monitoring a project's progress.

Gantt charts illustrate the start and finish dates of the terminal elements
and summary elements of a project. Terminal elements and summary elements
comprise the work breakdown structure of the project. Some Gantt charts also
show the dependency relationships between activities.

Gantt charts can be used to show current schedule status using percent-
complete shadings and a vertical "Today" line. It lets us see immediately what
should have been achieved at any point in time. It also lets us see how remedial
action may bring the project back on course. Most Gantt charts include
"milestones" which are not part of a traditional Gantt chart.

48
 However, for representing deadlines and other significant events, it is
very useful to include this feature on a Gantt chart.

The Gantt chart prepared for our project is shown below:

A – Heat Conduction Metal

B – Movable Flask

C – Pipe connected to conducting material

D – Thermostat

E – Thermostat connected to radiator

F – Sensor

G – Sensor placed in the thermostat

TIME ESTIMATION:

 Optimistic time estimate – Opt (O)

 Pessimestic time estimate – Pess (P)

 Normal - (M)

49
FORMULA USED:

Expected Time, TE = (O + 4M +P)/6

ACTIVITY PREDECCESSOR TIME ESTIMATES EXPECTED

TIME
Opt Normal Pess

A - 10 12 16 12.3

B - 8 11 14 11.0

C A 6 7 9 7.2

D C,A 7 9 10 8.8

E D 14 16 19 16.2

F A 6 7 8 7.0

G D 10 13 15 12.8

Table 3.1 Calculation of Expected Time

50
TASK PREDEC DURATI AUG SEPT OCT NOV DEC JAN
NAME ESSORS ON 1-15 15-30 1-15 15-30 1-15 15-30 1-15 15-30 1-15 15-30 1-15 15-30

A - 12.3

B - 11.0

C C 7.2

D C, A 8.8

E D 16.2

F A 7.0

G D 12.8

Table 3.2 Gantt Chart

The car, Hyundai Terracan in which the experimental work is carried out is
brought to shed.

51
 All the steps involved in making the Food warmer (heat exchanger) are
described below:

 Purchasing of Heater Chamber.

 Welding steel pipes to heater chamber.

 Fabricating Chamber Stand.

 Preparation of Bearing.

 Fixing Lever.

 Manufacturing Base Tray.

 Assembly Process.

[1] PURCHASING OF HEATER CHAMBER:

A heater chamber of specification AISI 304 Stainless Steel is

purchased. Heater Chamber may also be considered as a food warmer.
Heater Chamber is designed in the form of a double walled container. A gap
of 2 mm is left in between the inner wall and outer wall of chamber.

Perfect finish of heater chamber is obtained. It is tested thoroughly for

leakages.

[2] WELDING STEEL PIPES TO HEATER CHAMBER:

Two cylindrical steel pipes of 20 mm length is welded to the outer

wall of heater chamber. TIG welding is done carefully to fix the steel pipes
to the heater chamber.

52
 TIG WELDING:

In the TIG (tungsten inert gas) welding process, an essentially non-

consumable tungsten electrode is used to provide an electric arc for welding.
A sheath of inert gas surrounds the electrode, the arc, and the area to be
welded. This gas shielding process prevents any oxidization of the weld and
allows for the production of neat, clean welds.

[3] FABRICATING CHAMBER STAND:

Simultaneously, six iron rods are taken and they are surfaced
thoroughly using sand project. These rods are welded to each other to make
it a stand. Arc welding is done on the iron rods.

`ARC WELDING:

Arc welding is a type of welding that uses a welding power supply to

create an electric arc between an electrode and the base material to melt the
metals at the welding point. They can use either direct (DC) or alternating
(AC) current, and consumable or non-consumable electrodes. The welding
region is usually protected by some type of shielding gas, vapor, and/or slag.

One of the most common types of arc welding is shielded metal arc
welding (SMAW), which is also known as manual metal arc welding
(MMAW) or stick welding. An electric current is used to strike an arc
between the base material and a consumable electrode rod or 'stick'. The
electrode rod is made of a material that is compatible with the base material
being welded and is covered with a flux that gives off vapors that serve as a
shielding gas and providing a layer of slag, both of which protect the weld
area from atmospheric contamination. The electrode core itself acts as filler

53
 material, making separate filler unnecessary. The process is very versatile,
requiring little operator training and inexpensive equipment. However, weld
times are rather slow, since the consumable electrodes must be frequently
replaced and because slag, the residue from the flux, must be chipped away
after welding. Furthermore, the process is generally limited to welding
ferrous materials, though specialty electrodes have made possible the
welding of cast iron, nickel, aluminium, copper and other metals. The
versatility of the method makes it popular in a number of applications
including repair work and construction.

[4] PREPARATION OF BEARING:

Two bearings are purchased. They are grinded accurately to the

required dimensions. It is fixed on either sides of heater chamber. These
bearings are arc welded to the outer wall of heater chamber. Bearings are
used for smooth tilting of heater chamber.

[5] FIXING LEVER:

A lever is fixed to the bearing to support the titling of heater chamber.

A user friendly handle is fixed to the lever for ease of tilt.

[6] MANUFACTURING BASE TRAY:

A base tray made of steel is kept over the stand. It is manufactured

using sheet metal. Sheet metal is formed to rectangular plate. It is then arc
welded on its four sides. Another sheet metal is formed to rectangular plate
(top base tray) to required dimensions as per base tray. Holes are drilled
evenly over this top base tray. This second plate is fixed inside the base tray.

54
[7] ASSEMBLY PROCESS:

Finally, heater chamber and stand are assembled. Base tray is kept
over the horizontal bottom stand. The whole section is placed near the
dashboard in the interior section of car.

Heater pipe connections are removed in the bonnet section of car.

Inlet and outlet connection of heater pipe is then made free.

Heat Jacket Hose is brought and it is connected to the removed inlet

and outlet of heater pipe. Steel holder pipes are used to join the hoses firmly.
Clips are used for tight fixing of joint.

Another end of heat jacket hose is extended to the interior section of

car. It is made connected to the inlet and outlet of steel holder pipes which is
welded to the heater chamber.

A digital thermocouple thermometer is purchased and it is fixed to the

inner section of heater chamber. The digital sensor display is kept out from
the heater chamber.

Finally, engine is started and coolant is bypassed to the heater

chamber. Several samples are tested using milk and water.

55
4. FIRST PHASE OF FINISHED PRODUCT

Fig 4.1 Front View of Heater Chamber

Fig 4.2 Side View of Heater Chamber

56
 5. DESIGN AND IMPLEMENTATION

5.1 DESIGN PROCESS

AIM: AIAI

To develop a new accessory in

vehicles by waste heat recovery.

BRAINSTROMING

(REFER APPENDIX)

UPGRADED

SELECTED IDEAS

(REFER APPENDIX)

2D DRAWING OF FINAL SELECTED IDEA

57
 SELECTED DESIGN

MATERIAL SELECTION

Stainless Steel of grade 304 is

selected

PROTOTYPE

58
 TESTING

The effectiveness of Food

Warmer is tested by taking
samples of water and milk.

COMMERCIALISATION

Food Warmer is finally

commercialized for future use.

5.2 SPECIFICATION OF COMPONENTS

HEATER CHAMBER

MATERIAL - AISI 304 SS

OUTER DIA - 130 mm

INNER DIA - 120 mm

THICKNESS - 2 mm

HEIGHT - 130 mm

59
HEAT HOSE JACKET

MATERIAL - RUBBER

DIAMETER - 20 mm

THICKNESS - 5 mm

STEEL HOLDER PIPE

OUTER DIA - STEEL

THICKNESS - 2 mm

STAND

MATERIAL - CAST IRON

LENGTH - 240 mm

WIDTH - 500 mm

HEIGHT - 220 mm

THICKNESS - 20 mm

60
5.3 PART DIAGRAM

DESIGN OF HEATER CHAMBER AND STAND

Fig 5.1 2D Diagram of Heater Chamber Fig 5.2 2D Diagram of Stand

All Dimensions are in mm

61
5.4 FORMULA USED:
Q loss = m cp (Tin – Tout)

m=ρxAxu

A=∏xDxH

Qgain = ∆T/R

∆T = Tin - T∞

ReD = (u x d)/υ

NuD = 0.023 x ReD4/5 x Pr0.4

hi = NuD x ( k/Di )

R = R i + R wall

∆Q = Q loss – Q gain

Where,

Q loss = Heat lost from hot coolant (J/kg)

m = mass flow rate (kg/s)

cp = Specific Heat (J/kg K)

Tin = Inlet temperature of hot coolant (oC)

Tout = Outlet temperature of hot coolant (oC)

ρ= Density of fluid (kg/m2)

A = Area of Heater Chamber (m2)

u = Velocity of coolant (m/s)

62
D = Diameter of heater chamber (m)

H = Height of heater chamber (m)

Q gain = Heat gained by heater chamber (J/kg)

∆T = Temperature difference (oC)

T∞ = Temperature of water being heated in the chamber (oC)

ReD = Reynolds Number

υ = Kinematic viscosity (m2/s)

NuD = Nusselt Number

Pr = Prandlt Number

hi = Convective heat transfer coefficient in chamber (W/m2K)

k = Thermal conductivity (W/mk)

R = Thermal Resistance (K/W)

R i = Thermal Resistance in chamber (K/W)

R wall = Thermal Resistance in wall layer (K/W)

∆Q = Overall heat transfer to chamber (KJ/kg)

63
5.5 THEORITICAL CALCULATION:
TO FIND HEAT LOSS AT COOLANT INLET AND OUTLET –

To calculate mass flow rate-

m=ρxAxu

From HMT Data book, Page no.22, for water at 90oC

ρ = 967.5 kg/m3

υ= 0.3285 x 10-6 m2/s

Pr = 1.98

c = 4205.5 J/kg K

k = 0.67455 W/m K

A=∏xDxH

=∏ x 0.124 x 0.13

=0.05061 m2

m = 967.5 x 0.05061 x 0.3285

m = 16.08722 kg/s

64
 To find heat loss-

Q loss = m cp (Tin – Tout)

= 16.08722 x 4205.5 (90 – 88)

Q loss = 135309.61 J/kg

TO FIND HEAT TRANSFER TO CHAMBER –

Q gain = ∆T/R

∆T = Tin - T∞

= 90 – 82

= 8o C

Re = (u x d)/υ

= (0.3 x 0.124)/(0.3285 x 10-6)

= 113242.009

Since Re ˃ 2300, the flow is turbulant

To calculate Nusselt’s Number-

NuD = 0.023 x ReD4/5 x Pr0.4

NuD = 0.023 x (113242.009)0.8 x (1.98)0.4

= 333.887

To find Thermal coefficient-

hi = NuD (k/Di)

hi = 333.887x (0.67455/0.124)

hi = 1816.32 W/m2K

65
 To find Thermal Resistance-

R = Ri + Rwall

= (1/hiA) + [ln(Do /Di)/2 ∏kL]

= [1/1816.32 x ∏ x 0.124 x 0.13] + [ln(0.124 /0.12)/2 x ∏ x 28x 0.002]

= 0.10411

Q gain = ∆T/R

= 8 / 0.10411

Q gain= 76.8387 J/kg

TO FIND OVERALL HEAT TRANSFER TO CHAMBER –

∆Q = Q loss – Q gain

= 76.838 – 134309.617

= -135232.778 J/kg

∆Q = -135.23 KJ/kg

Negative sign indicates that heat is transferred from the coolant.

RESULT:

 Mass flow rate, m = 16.08722 kg/s

 Heat loss from coolant, Q loss =135309.61 J/kg

 Heat transfer to chamber, Q gain = 76.8387 J/kg

 Overall heat transfer to chamber, ∆Q = -135.23 K J/kg

66
5.6 PRACTICAL APPROACH

The heat transfer temperature was practically taken using Digital

thermometer.

The inner and outer wall temperature of double wall container was found.

Inner wall temperature – 83oC

Outer wall temperature – 40oC

With water as coolant, the maximum temperature of coolant was obtained as

90oC.

Water for drinking purpose was heated in the food warmer. Water is warmed
at a sufficient temperature of 75oC in 17 minutes.

Milk sample was heated in the Heater Chamber at a sufficient temperature of

75oC in 20 minutes.

67
5.7 GRAPHICAL ANALYSIS

A graph was plotted by taking time in X axis and temperature in Y axis. A

gradual increase in temperature was observed as time delay increases. The graph
obtained is a straight linear line. A nominal temperature of 75oC was obtained in
17 minutes. The Time vs Temperature graph is shown below:

TIME vs TEMPERATURE
100

90

80

70
TEMPERATURE ( 0C )

60

50

40

30

20

10

0
4 6 8 10 12 14 16 18 20
TIME (minutes)

Fig 5.3 Time vs Temperature Graph

68
5.8 COST ANALYSIS

S.NO COMPONENT MATERIAL QUANTITY COST (Rs)

1 HEATER STAINLESS 1 500

CHAMBER STEEL

2 HEATER HOSE HARDENED 3m 1500

RUBBER

3 STEEL PIPE STEEL 1m 200

4 HOSE CLIPS BRASS 6 100

5 FLOW CONTROL IRON 1 1000

VALVE

6 DIGITAL 1 1250
THERMOMETER

7 JOURNAL STAINLESS 2 100

BEARING STEEL

8 BASE TRAY STAINLESS 1 500

STEEL

Table 5.1 Cost Estimation

TOTAL COST OF THE PRODUCT = Rs.5150/- (Approx)

69
5.9 HURDLES FACED

Any project cannot be completed successively without obstacles. We also

faced certain problems in order to complete our project in a successive manner.
Some of the hurdles faced are listed below:

 Accurate welding of steel holder pipes to outer wall of heater chamber was
difficult.

 Improper machining of bearing hole in stand.

 Fixing lever stand to rod with actual dimensions was not perfect.

 Heater Chamber was not tilted in a flexible manner.

 Proper placement of heater chamber in car.

70
5.10 PROCESS CHART

CAR IS BROUGHT REPAIRING AND WELDING OF

TO SHED INSPECTION IRON RODS FOR
STAND

CUTTING OF INSPECTION OF WELD

HEATER
CHAMBER IS HEATER PIPE IN
WELDED WITH CAR

INSPECTION OF HEATER
CHAMBER ASSEMBLING
HEATER
CHAMBER & IRON

STORAGE
OF HEATER FIXING ASSEMBLED
HEATER CHAMBER AND
CHAMBER
HEAT HOSE JACKET

INSULATION OF
HEATER
ASSEMBLY OF CHAMBER
HEATER
CHAMBER AND
INSPECTION OF INSULATED
HEATER CHAMBER PROCESS

INSPECTION OF
ASSEMBLED PRODUCT TRANSPORTATION
FIXING FLOW
CONTROL VALVE
INSPECTION

INSPECTION OF FINAL
71
PRODUCT
5.11 ADVANTAGES

Some of the main advantages of food warmer are listed below:

 This setup can be used as a useful accessory for long journey drive.

 Coolant temperature is reduced to a small extent before entering the radiator.

 External energy is not necessary.

 Useful for baby infants.

 Food can be kept warm in all conditions.

5.12 POSSIBLE AND RECOMMENDED APPLICATIONS

This setup is mainly used for food processing applications such as:

 Preparing milk from milk powder.

 Hot water.

 Preparing oats, noodles etc..

More applications can be arised in future…

72
5.13 SUMMARY

An overall view of the project is listed in the table:

MATERIAL USED HEATER CHAMBER (AISI 302 SS)

LOCATION NEAR DASHBOARD

DIMENSION 130 × 2 × 130 mm

HEATING PROCESS CONVECTION & CONDUCTION

COOLANT USED ETHYLENE GLYCOL + DISTILLED

WATER

HEATING SOURCE HOT COOLANT

TEST PERFORMED AS SHOWN IN PRACTICAL

APPROACH

NO. OF EXPERIMENTS 2

Table 5.2 Overview of Project

73
 6. CONCLUSION

Our project can be summarized as follows:

 Useful accessory in vehicles

 User friendly accessory

 Uses the heat present in the hot coolant for heating process

 No damage to engine

 No external power supply

The wasted heat from engine is converted into various useful forms. Many
inventions based on engine heat recovery and engine heat usage are still under
serious research in many automobile sectors. Our paper comes under the category
of one such research. A number of accessories are being invented every day. Thus
the Heater Chamber that we have experimented can become a useful accessory in
vehicles such as cars, buses, Lorries etc… This can create a new revolution in the
history of engine heat usage systems in the near future.

74
 7. FUTURE WORK

Every product needs advancement. Our project on Food Warmer is an

innovative idea of using waste heat recovery in vehicles. It can be considered as a
proof of the concept involved. Many researches and developments have to be done
for the manufacture of food warmer for real time use in vehicles. Some of them are
listed below:

 Temperature indicator can be added for visual display of heating process.

 Globe connection can be fixed to the steel holder pipes. This can make food
warmer portable.

 Our design is not fitting to the aesthetics of the vehicle. A well finished
product can be manufactured.

 The product should be placed firmly to a newly molded dash board.

75
 8. APPENDIX

BRAINSTROMING:

Various ideas were developed in order to design the food warmer, which is a
double walled container. Some of them are –

[1] Heater Chamber with a tap at its base can be fixed to a rigid stand.

[2] Heater Chamber can be fixed to a rotating lever.

[3] Heater Chamber can be fixed to a gear arrangement instead of lever.

[4] Heater Chamber with a tap and lever arrangement can be constructed.

[5] Heater Chamber with a damper at its base can be fixed to lever.

[6] A cup with a rubber pad at the bottom can be designed to place Heater
Chamber firmly inside the cup. Globe valve can be used in the steel holder
pipes.

[7] Heater Chamber can be fixed to a stand using bearing and lever
arrangement. A bottom tray can be kept over the base of stand.

SELECTED IDEAS:

Considering the safety, customer satisfaction, ease of use two ideas in

the design of food warmer were selected. The selected ideas are listed
below:

76
  A cup with a rubber pad at the bottom can be designed to place
Heater Chamber firmly inside the cup. Globe valve can be used in the
steel holder pipes.

 Heater Chamber can be fixed to a stand using bearing and lever

arrangement. A bottom tray can be kept over the base of stand.

COMPARISION OF TWO IDEAS:

S.No CUP WITH HEATER STAND WITH HEATER

CHAMBER CHAMBER

1. Many additional components such Only bearing and lever arrangement is

as cup, rubber pad, globe valves used.
etc.. are involved

2. Cost of setup is high. Cost of setup is low.

3. Time consumption for heating will Time consumption is less.

be more.

4. Fabrication of cup and heater Fabrication of bottom tray is simple.

chamber will be complicated.

Table 8.1 Comparison of Heater Chamber with Cup and Stand

77
 9. BIBLIOGRAPHY

1. The World Book of Encyclopedia (International-1995), pp 296-301

2. Yunus A. Cengel – “Heat and mass transfer”, Third Edison, Heat exchanger,
pp 77 – 83, 610 – 620

3. R.C Sachdeva – “Fundamentals of Engineering Heat and Mass Transfer”,

Shell and tube heat exchanger, pp 489 – 525

4. Dr.Kripal Singh – “Automobile Engineering”, vol 1, pp 531-537

5. C.J Leising – “Waste heat recovery in truck engines”, pp 1041-1049

6. US Patent Application Publication – No.5407130, 4653729, 7748226 B2

7. Wikipedia

8. www.ehow.com

9. www.engr.colodtate.edu

10.www.tprl.com

78
79