GROUP 5

0830-1130 T

ICE PLANT DESIGN FOR 900 TONS OF ICE PER DAY

Capacity of plant =900 Tons of ice (TOI) per day

Tons of Refrigeration Approximation:

From Kent’s Mechanical Engineer’s Handbook:

𝑇𝑂𝐼 900
TR≤0.61≤0.61≤1475.41 TOR

Size of can for 136 kg of ice:

From Kent’s Mechanical Engineer’s Handbook:

Size of can=11 x 22 x 44 in

Number of cans:

From Kent’s Mechanical Engineer’s Handbook:

𝑊𝐻 198000𝑙𝑏(24ℎ𝑟)
N=24𝐶= 300𝑙𝑏(24)
=6600 cans

Size of brine tank:

Vbrine=(60 ft3 per TR) x 1475.41 TR=88524.5 ft3

Vice=(10648 in3 per block) x 6600 cans=70276800in3=40669.44 ft3

Volume of brine tank=Vice+Vbrine=129194.04 ft3

Size of freezing tank:

800 cans for 1 brine tank

900 tons=8.25 brine tanks

L=2Cs+Nct+Ci(Nc-1)

Where:

Cs=wall clearance=13”(includes additional 18” for brine agitator space)

Nc=number of cans on a side=50

t=thickness of cake=11”

Ci=ice can spacing=3”

GROUP 5
0830-1130 T

L=2(13) + 50(11) + 3(50-1)

L=723 in

Width of tank:

W=2Cs+Ncw+Ci(Nc-1)

Cs=8”

w=22”

W=2(8)+16(22)+3(16-1)

W=413 in

Height of tank:

For 8.25 tanks:

VFT=8.25(L x W x H)

129194.04 ft3=8.25(723 x 413 x H)

H=90.62 in=91 in

Brine tank:

723 x 413 x 61 in
GROUP 5
0830-1130 T

PRODUCT TEMPERATURE FREEZING LATENT HEAT SPECIFIC HEAT SPECIFIC HEAT

RANGE, °F TEMPERATURE, OF FUSION, ABOVE BELOW
°F Btu lb-hr FREEZING FREEZING
(Btu/lb-hr-°F) (Btu/lb-hr-°F)
BEEF 30-32 27 98 0.75 0.40
HAMS AND 28-30 27 86.5 0.68 0.38
LOINS
LAMB 28-30 29 83.5 0.67 0.30
POULTRY 28-30 27 106 0.79 0.37
(FRESH)
MILK 40-45 32 124.25 0.9 0.47
EGGS 50-55 31 118.7 0.76 0.4
ICE CREAM -5-0 31.5 95.4 0.82 0.49
FISH 35-40 29 118.7 0.76 0.39
APPLES 30-40 28.4 120.4 0.86 0.45
BEER 50-60 28.4 129.4 1 0.48

Heat Load Calculations:

Raw meat is at 59°F and taken from the storage at 0°F (Frozen meat).

Q=m(CpAFΔt+LHF+CpBF)

Apple:

Q=4000(0.86(59-28)+120.4+0.45(28.4-0))=637984 Btu/hr

Milk:

Q=4000(0.9(59-32)+124.25+0.47(32-0))=654360 Btu/hr

Eggs:

Q=4000(0.76(59-31)+118.7+0.4(31-0))=609520 Btu/hr

Ice Cream:

Q=4000(0.82(59-31.5)+95.4+0.49(31.5-0))=533540 Btu/hr

Beer:

Q=4000(1(59-28.4)+129.4+0.48(28.4-0))=694528 Btu/hr

Fish:

Q=4000(0.76(59-29)+118.7+0.39(29-0))=611240 Btu/hr
GROUP 5
0830-1130 T

Beef:

Q=4000(0.75(59-27)+98+0.4(27-0))=531200 Btu/hr

Hams and Loins:

Q=4000(0.68(59-27)+86.5+0.38(27-0))=474080 Btu/hr

Lamb:

Q=4000(0.67(59-29)+83.5+0.3(29-0))=449200 Btu/hr

Poultry (fresh):

Q=4000(0.79(59-27)+106+0.37(27-0))=565080 Btu/hr

Product load:

Product=ΣProductQ=(637984+654360+609520+533540+694528+611240+531200+474080+
449200+565080)(Btu/hr)

=5760732 Btu/hr

Space required for refrigerated goods:

A =(beef, hams, lamb, poultry, fish): 28-30°F

=7500kg=16500 lb

B =(eggs, beer): 50-55°F

=3000kg=6600 lb

C =(apples, milk): 30-45°F

=3000kg=6600 lb

D =(ice cream): -5-0°F

1500kg=3300 lb

MT = 33000 lb
GROUP 5
0830-1130 T

Basis for 700lb beef:

Space occupied = 108 ft3

Floor height = 12 ft

Floor space = 9 ft2

Total space required=33000lbx(108ft3/700lb)=5091.43 ft3

Total floor space=33000lbx(9ft3/700lb)=424.29 ft2

Height=12 ft

*For easy handling of storing products height is halved and floor space is doubled.

Height=6 ft

Floor space=848.57 ft2≈850 ft2

A: 7500 kg = 16500lb x (108ft3/700lb)=2545.71 ft3 (Space req’d)

=16500 lb x (9 ft2/700lb)=212.14 ft2 (Floor space)

Height=12 ft

(A)Biggest floor space =212.14 ft2

(B) =84.85 ft2

(C) =84.85 ft2

(D) =42.4 ft2

Total=424.29 ft2

For 30% storage:

424.28
A= =1414.27 ft2
0.3

169.7
B&C= 0.3
=565.87 ft2 (2)

84.8
D= 0.3 =282.67 ft2

Total floor space=2828.68 ft2

GROUP 5
0830-1130 T

5% for shipping/receiving floors

=2970.114≈3000 ft2 (Total space req’d)

Dimension of cold storage:

Size= 60” x 50” x 12”

Wall Heat Gain Load

Cold storage is designed based from the hottest temperature of Manila/Luzon Philippines.

From ASHRAE: Month of May

Dry bulb temperature = 34.5 ⁰C or 94.1 ⁰F

Wet bulb temperature = 28.1 ⁰C or 82.58 ⁰F

Designed insulations:

From Kents’ Mechanical Engineers’ Handbook:

Thermal Capacitance, c
Thickness, Conductivity, k
Material BTU
(inches) BTU−in ( )
( 2 ) hr − ft 2 − F
hr−ft −F
Brick (common) 8 4.8 -
Corkboard 4 0.32 -
Side Walls Concrete
1.5 4.9 -
(cinder aggregate)
Gypsum plaster - - 4.4
Concrete
3 4.9 -
Flooring (cinder aggregate)
Corkboard 5 0.32 -
Concrete
4 4.9 -
Ceiling (cinder aggregate)
Corkboard 6 0.32 -
Still air Still air - - 1.65
Outside air Outside air - - 6.0

Qside walls = UAΔt

Asw = 2(L x H) + 2(W x H)

Asw = 2(60 x 12) + 2(50 x 12)

Asw = 2160 ft2

GROUP 5
0830-1130 T
1
U= 1 x1 x2 1 1
+ + + +
fo k1 k2 c fi

1
U=1 8 4 1 1
+ + + +
6 4.8 0.32 4.4 1.65

𝐁𝐓𝐔
U = 0.06463 𝐡𝐫−𝐟𝐭𝟐−𝐅

BTU
Qside walls = (0.06463 ) (2160 ft2) ( 94.1 – 0)⁰F
hr−ft2 −F

Qside walls = 13136.4353 BTU/hr

Qfloor = UAΔt

Afloor = L x W

Afloor = 50 x 60

Afloor = 3000 ft2

1
U= x1 x2 1
+ +
k1 k2 fi

1
U= 3 5 1
+ +
4.9 0.32 1.65

𝐁𝐓𝐔
U = 0.05937 𝐡𝐫−𝐟𝐭𝟐−𝐅

BTU
Qfloor = (0.05937 hr−ft2 −F) (3000 ft2) (94.1 – 0)⁰F

Qfloor = 16760.151 BTU/hr

Qceiling = UAΔt

Aceiling = Afloor = 3000 ft2

1
U= 1 x1 x2 1
+ + +
fo k1 k2 fi

1
U=1 6 4 1
+ + +
6 0.32 4.9 1.65

𝐁𝐓𝐔
U = 0.049166
𝐡𝐫−𝐟𝐭 𝟐 −𝐅
GROUP 5
0830-1130 T
BTU
Qceiling = (0.049166 hr−ft2 −F) (3000 ft2) (94.1 – 0)⁰F

Qceiling = 13879.5618 BTU/hr

Total Wall Gain Load

Qwall = Qside walls + Qfloor + Qceiling

Qwall = 13136.4353 + 16760.151 + 13879.5618

Qwall = 43776.1481 BTU/hr

Air Change Load

Computations for air properties outside the cold storage:

(Pt−Pvm)(DB−WB)
Pv = Pvm - 1546.622 − 1.44(WB)

(101.325−3.8046)(34.5−28.1)
Pv = 3.8046 -
1546.622 − 1.44(28.1)

Pv = 3.3902 kPa
0.622 Pv
wo = Pt−Pv

0.622 (3.3902)
wo = 101.325−3.3902

wo = 0.02153 kg/kg

ho = 1.0062t + whfg

ho = 1.0062 (34.5) + 0.02153(2564.4)

ho = 89.925 kJ/kg = 38.656 BTU/lb

GROUP 5
0830-1130 T

Computations for air properties inside the cold storage:

tdb = 0 ⁰F = - 17.778 ⁰C

RH = 80%

Pv
RH = Psat

Pv
0.80 = 0.12807 ; Psat @ -17.778 ⁰C = 0.12807 kPa

Pv = 0.10245 kPa

From RenewAire Energy Recovery Ventilators Psychrometric Chart for Low Temperatures:

hi = 0.7 BTU/lb

From Dossat’s Principles of Refrigeration, air change load may be computed using the formula:

Qv = W (ho - hi)

For W:

From Kent’s Mechanical Engineers’ Handbook, p. 11-48:

1
W = V( v )

V = volume of air per hour of ventilated air

V = volume of room x air change rate

For warehouses: ACR = 2 to 3 hr-1 (ASHRAE)

v = specific volume of air specified either outside space or as supplied space

0.287085(−17.778+273)
v= 101.325−0.10245

v = 0.7238 m3/kg = 11.58 ft3/lb

GROUP 5
0830-1130 T

Therefore:
1
W = 2(60 x 50 x 12) (11.58)

W = 6217.6166 lb/hr

Qv = 6217.6166 (38.656 – 0.7)

Qv = 235995.8549 BTU/hr

Heat Sources in Space

Heat from People/Workers

From Dossat’s Principle of Refrigeration, Table 10-14:

Qpeople = 0.378 kW/person x no. of workers

For 0 ⁰F or -17.778 ⁰C, use -15 ⁰C as reference:

Qpeople = 0.378 kW/person x 12 workers [assumed]

1 BTU 3600 s
Qpeople = 4.536 kW x x
1.055 kJ 1 hr

Qpeople = 15478.294 BTU/hr

Heat from Lightings

From Kent’s Mechanical Engineers’ Handbook

Qlights = 3.41 x total wattage of lights

Assume 80 fluorescent lamps with 15 W each:

Qlights = 3.41 x (80 x 15)

Qlights = 4092 BTU/hr

Heat from motors and equipment

From Kent’s Mechanical Engineers’ Handbook:

Qmo = 2950 BTU/hr per hp for 3-hp and above motors

Assume maximum of 10 hp motors inside the cold storage:

Qmo = 2950 BTU/hr x 10 hp

Qmo = 29500 BTU/hr

GROUP 5
0830-1130 T

Total Heat Load

Qtotal = Qproduct + Qwall + Qv + Qpeople + Qlights + Qmo

Qtotal = 6045798.149 BTU/hr

Tons of Refrigeration Required

From Kent’s Mechanical Engineers’ Handbook:

Heat Load 24 hr
Tons = 12000
x x hr

x = hours of operation

x = 16 for a system operating above 32 ⁰F

x = 20 for a system operating below 32 ⁰F

6045798.149 24 hr
Tons = 12000
x 20 hr

Tons = 604.5798 TR ≈ 605 TR

Refrigerating Unit
GROUP 5
0830-1130 T

Schematic Diagram of Refrigerating Unit

Condenser

40 ⁰C

Evaporator 2
130 TR
5 ⁰F

Evaporator 1
605 TR
-10 ⁰F A

As suggested by Kent’s Mechanical Engineers’ Handbook, for ice plants, evaporator temperature
is at 5 ⁰F.

As suggested by Macintire’s Handbook of Mechanical Refrigeration, there’s a 10 degree

difference between the temperatures of the coil and the room.

Condenser temperature is assumed based on the country’s air condition.

GROUP 5
0830-1130 T

For Ammonia as refrigerant:

Pressures:

Pressure at condenser = Psat @ 40 ⁰C

Pcon = 1557 kPa

Pressure at evaporator for ice plant = Psat @ -15 ⁰C

Pevap2 = 237.09 kPa

Pressure at evaporator for cold storage = Psat @ -23.33 ⁰C

Pevap2 = 164.283 kPa

Enthalpies:

h1 = hg @ -23.33 ⁰C

h1 = 1432.58 kJ/kg

h2 = h @ 237.09 kPa and s1 = s2

h2 = 1480 kJ/kg

h3 = hg @ -15 ⁰C

h3 = 1443.9 kJ/kg

h4 = h @ 1557 kPa and s3 = s4

h4 = 1742 kJ/kg

h5 = h6 = hf @ 40 ⁰C

h5 = h6 = 390.587 kJ/kg

h7 = h8 = hf @ -15 ⁰C

h7 = h8 = 131.2745 kJ/kg
GROUP 5
0830-1130 T

Mass Flow Rates

604.5798 𝑥 3.516
m1 = ℎ1−ℎ8

604.5798 𝑥 3.516
m1 =
1432.58−131.2745

m1 = m2 = m7 = m8 = 1.6347 kg/s

130 𝑥 3.516
m6 = ℎ3−ℎ6

130 𝑥 3.516
m6 =
1443.9−390.587

m6 = 0.4339 kg/s

Heat Balance about Intercooler

mh3

mh6 m2h2

m7h7

mh6 + m2h2 = mh3 + m7h7

m = 2.0932 kg/s

Mass flow rate through high-stage compressor

m3 = m + m 6

m3 = 2.5271 kg/s
GROUP 5
0830-1130 T

Compressor Power

For Low Stage Power

P = m1 (h2 – h1)

P = 1.6347(1480 – 1437.23)

P = 69.9161 kW

For High Stage Power

P = m3 (h4 – h3)

P = 2.5271(1742 – 1443.9)

P = 753.3285 kW

Refrigerant Piping

From Mark’s Standard Handbook, velocities for most refrigerants:

Liquid Lines: 3.3 to 22 m/s

Suction Lines: 38 to 250 m/s

Discharge Lines: 55 to 275 m/s

Suction Lines

 At point 1
V1 = m1v1
m1 = 1.6347 kg/s
v1 = vg @ -23.33 ⁰C
v1 = 0.7168 m3/kg
V1 = 1.6347(0.7168)
V1 = 1.1718 m3/s

For d = 3.5 in.:

V = Av
Π 1
1.1718 = 4 (3.5 x 39.37 )2 (v)

v = 188.6851 m/s [satisfied the range]

GROUP 5
0830-1130 T

 At point 3
V3 = m3v3
m3 = 2.5271 kg/s
v3 = vg @ -15 ⁰C
v3 = 0.508013 m3/kg
V3 = 2.5271(0.508013)
V3 = 1.2838 m3/s

For d = 3.5 in.:

V = Av
Π 1
1.2838 = 4 (3.5 x 39.37 )2 (v)

v = 206.7196 m/s [satisfied the range]

Discharge Lines

 At point 2
V2 = m2v2
m2 = 2.0932 kg/s
v2 = v @ 237.09 kPa and s1 = s2
v2 = 0.56 m3/kg
V2 = 2.0932(0.56)
V2 = 1.1722 m3/s

For d = 3 in:

V = Av
Π 1
1.1722 = 4 (3 x 39.37 )2 (v)

v = 256.9091 m/s [satisfied the range]

 At point 4
V4 = m4v4
m4 = 2.5271 kg/s
v4 = v @ 1557 kPa and s3 = s4
v4 = 0.13 m3/kg
V4 = 2.5271(0.13)
V4 = 0.3285 m3/s
GROUP 5
0830-1130 T

For d = 2 in:

V = Av
Π 1
0.3285 = (2 x )2 (v)
4 39.37

v = 162.0041 m/s [satisfied the range]

Liquid Lines

 At point 5
V5 = m5v5
m5 = 2.5271 kg/s
v5 = vf @ 40 ⁰C
v5 = 0.0017257 m3/kg
V5 = 2.5271(0.0017257)

V5 = 0.004361 m3/s

For d = 0.8 in:

V = Av
Π 1
0.004361 = 4 (0.8 x 39.37 )2 (v)

v = 13.4908 m/s [satisfied the range]

 At point 7
V7 = m7v7
m7 = 1.6347 kg/s
v7 = vf @ -15 ⁰C
v7 = 0.0015185 m3/kg
V7 = 1.6347(0.0015185)
V7 = 2.4823x10-3 m3/s

For d = 0.5 in:

V = Av
Π 1
2.4823x10-3 = (0.5 x )2 (v)
4 39.37

v = 19.5855 m/s [satisfied the range]

GROUP 5
0830-1130 T

Condenser

Based from Stoecker and Jones’ Refrigeration and Air Conditioning:

Designed Values for Condenser

Temperature at condenser = 40 ⁰C

Common temperature of water in and out the cooling tower:

Temperature entering the condenser = 85 ⁰F or 29.44 ⁰C

Temperature leaving the condenser = 95 ⁰F or 35 ⁰C

Nominal Size of Pipe = 1 ½ in. Schedule 40

Outside Diameter = 1.9 in or 0.04826 m

Inside Diameter = 1.61 in or 0.040894

Thickness = 0.145 in or 0.003683

Tubes per pass = 14

No. of Tubes = 112 tubes

No. of Passes = 112/14 = 8 passes

Rate of heat rejected at the condenser

Qr = m4 (h4 – h5)

Qr = 2.5271 (1742 – 390.587)

Qr = 3415.1558 kW
GROUP 5
0830-1130 T

Condensing Coefficient

𝑔𝜌2 ℎ𝑓𝑔 𝑘 3 1/4

hcond = 0.725 ( 𝜇𝛥𝑡𝑁𝐷
)

For Ammonia at 40 ⁰C
1
𝜌 = 1.7257 = 0.5795 kg/L = 579.5 kg/m3

hfg = 1490.42 – 390.587

hfg = 1099.83 kJ/kg

From Table 15.5, p. 300

𝜇 = 0.000122 Pa-s

k = 0.447 W/m-K

Average number of tubes in a vertical row, N

384
N= 48

N=8

(9.81)(579.5)2 (1099.83)(0.447)3 1/4

hcond = 0.725 ( 0.000122(5.56)(8)(0.04826)
)

hcond = 764.5443 W/m2-K

Resistance of Metal
𝑥𝐴
R = 𝑘𝐴 𝑜
𝑚

x = 0.003683

ksteel = 50 W/m-K

𝑥𝐴𝑜 (0.003683)(0.04826)
𝑘𝐴𝑚
= (50)(0.044577)

𝒙𝑨𝒐
𝒌𝑨𝒎
= 7.9746 x10-5 m2-K/W

Fouling Factor
𝟏
𝒉𝒇𝒇
= 0.000176 m2-K/W
GROUP 5
0830-1130 T

Water side coefficient

ℎ𝑤 𝐷 ρVD 0.8 𝑐𝑝 μ 0.4
𝑘
= 0.023( μ
) ( k)

Mass of flowing water

Qr
mw = CpΔt

3415.1558
mw =
4.187(35−29.444)

mw = 146.8065 kg/s

Volume flow rate

𝑚
V=
ρ

146.8065
V= 1000

V = 0.1468 m3/s

Water velocity
𝑉𝑜𝑙𝑢𝑚𝑒
v = (no.of tubes per pass)(Area)

0.1468
v= Π
14[ (0.040894)2 ]
4

v = 4.0494 m/s