Chapter 3

Methodology

3.1 Research Overview

The purpose of this study is to rehabilitate the Mini Ice Plant Test Rig for the students of

Mechanical Engineering in the university. This research project will help the students to observe

the fundamentals of ice plant operation and this will serve as a learning material and laboratory

material for the students enrolled in mechanical engineering laboratory subject.

This research project focuses on the rehabilitation of the existing brine tank on the

Mechanical Engineering Laboratory on the university. Because of the unavailability of the

device in the laboratory and the use of old test rig this research project will be focusing in

rehabilitation of the existing test rig, either or both to fabricate and sourcing of parts so as the test

rig will be effectively and efficiently operated by students conducting their laboratory

experiments.

3.2 Flow Process

Figure 3.2.1 Flow Process of the Methodology

3.3 Inspection

The researchers inspected the existing mini ice plant training module. The

following images show the current state of the training module. It is not properly

maintained or used for over a year and the leaked brine from the tank may also have been

the cause of corrosion. The base of the training module is partially rusted caused by the

exposure to the surrounding and also the leak from the tank.

Fig. 3.3.1 Actual Photo of Mini Ice Plant Test Rig

Some parts in the mini ice plant are need to be replaced due to their physical

attributes and malfunctioned.The evaporator coil is full of rust and is in a bad condition.

The compressor,stirrer motor, and ice cans is also in bad condition that need to be

rehabilitate for futurea and better use.

 Fig. 3.3.2 Shows the Rusted Compressor (left) and Stirrer motor (right)

Fig. 3.3.3 shows the rusted Ice cans

3.4 Components and parts of Mini Ice Plant Test Rig

In the study of an ice plant the components generally used are compressor, condenser,

receiver, drier, expansion valve, ice cans, cooling coil and brine tank.

3.4.1 Compressor

A refrigerating compressor, as the name indicates, is a machine used to compress

the vapour refrigerant from the evaporator and to raise its pressure so that the

corresponding saturation is higher than that of the cooling medium. It also continually

circulates the refrigerant through the refrigerating system. Since the compression of

refrigerant requires some work to be done on it, therefore a compressor must be driven by

some prime mover. In other words the purpose of the compressor in the vapour
compression cycle is to compress the low-pressure dry gas from the evaporator and raise

its pressure to that of the condenser.

Source: Jihan Retek industries inc.

Fig. 3.4.1 Compressor

3.4.2 Condenser

The condenser is an important device used in the high pressure side of a

refrigeration system. Its function is to remove heat of hot vapour refrigerant discharge

from the compressor. The heat from the hot vapour refrigerant in a condenser is removed

first by transferring it to the walls of the condensers tubes and then from the tubes to the

condensing or cooling medium.

Fig. 3.4.2 Condenser

3.4.3 Dryer

The function of filter dryer is to remove any physical material from compressor’s

wear and tear, and remove any moisture presence within an air conditioning system. The

Drier is made up of a metal outer container and inside there is a desiccant (moisture

removal material) and strainer. Refrigerant passes through the drier and give up any

moisture as well as any unwanted matter.

Source: india-manufacturer.com

Fig. 3.4.3 Filter Drier

3.4.4 Expansion Valve

The expansion device (also known as metric device or throttling device) is an

important device that divides the high pressure side and the low pressure side of a

refrigerating system. It is connected the receiver and the evaporator

Fig. 3.4.4 Expansion Valve

3.4.5 Cooling Coil

A device used to turn the liquid form of a chemical into its gaseous form. It

provides a heat transfer surface through which heat can pass from the refrigerated space

or product into evaporating refrigerant.

Source: coilcompany.com

Fig. 3.4.5 Cooling Coils

3.4.6 Brine Tank

Brine tank or ice tank contains the direct expansion coils, equally distributed

throughout the tank and these coils are submerged in brine. The brine in the tank acts as a

medium of contact only.

Source: cleanwaterstore.com

Fig. 3.4.6 Brine Tank

3.4.7 Suction Line Accumulator

A suction line accumulator prevents compressor damage from a sudden surge of

liquid refrigerant and oil that could enter the compressor from the suction line.

suction line accumulator is a temporary reservoir for this mixture, designed to meter both

liquid refrigerant and oil back to the compressor at an acceptable rate. This prevents

damage to the reed valves, pistons, rods, and crankshafts.

Source: Henrytech.com

Fig. 3.4.7 Suction Line Accumulator

3.4.8 Stirrer Motor

A magnetic stirrer or magnetic mixer is a laboratory device that employs a

rotating magnetic field to cause a stir bar (also called "flea") immersed in a liquid to spin

very quickly. The rotating field may be created either by a rotating magnet or a set of

stationary electromagnets, placed beneath the vessel with the liquid.

 Source: Alibaba.com

Fig. 3.4.8 Stirrer Motor

3.4.9 Temperature Indicator

A time temperature indicator (TTI) is a device or smart label that shows the accumulated

time-temperature history of a product. Time temperature indicators are commonly used on food,

pharmaceutical, and medical products to indicate exposure to excessive temperature (and time at

temperature).

Source: Alibaba.com

3.4.9 Temperature Indicator

 3.4.10 Ice Can

Use as a container to make a block of ice.

3.4.10 Ice Can

3.5 System Design

The proponents will evaluate the system design if it conforms to the best standard practice or

a system improvement on design shall be implemented.

Fig. 3.6 Schematic Diagram of the Mini Ice Plant Test Rig
 On the figure shown above, fig. 3.6, the brine solution is kept in constant motion by agitators

for increasing the heat transfer from the water in the can to the chilled brine. The agitators may

be either horizontal or vertical and are operated by means of electric motors .The brine

temperature is maintained by the refrigeration plant at -10º C to -11ºc. The high temperature,

high pressure ammonia vapours are condensed in a condenser which may be of shell and tube

type or evaporative type. The condensed liquid ammonia is collected in the receiver and then

expanded through the expansion valve. Due to the expansion, the pressure of the liquid ammonia

is considerably reduced it then passes through the evaporator coils surrounding a brine tank in

which brine solution is filled. The low pressure liquid ammonia absorbs heat from the brine the

brine solution, equivalent to its latent heat of vaporization, gets converted to vapour state and is

once again fed to compressor to complete the cycle. The depth of brine tank is such that the brine

level is around 25 mm higher than the water level in the cans. The Tank is insulated on all the

four sides and from the bottom. The insulated wooden lids are provided to cover the top in

segments, to facilitate the removal of ice cans. The ice cans are fabricated from galvanized steel

sheets and are given chromium treatment to prevent corrosion. In order to get transparent ice,

water in the can is agitated by the use of low pressure air through the tubes suspended from the

top. Due to agitation, the dissolved impurities such as salt, even colours get collected in the

unfrozen water core. It is desirable that it should be taken out and replaced with fresh water.

3.5.1 COP of an Ice plant model using refrigerant R134a

The coefficient of performance of refrigeration plant is given by the

ratio of heat absorbed, by the refrigerant when passing through the evaporator or

the system, to the working input to the compressor to compress the refrigeration.
 Figure 3.5 COP of R134a

3.6 Retrofitting Planning

Planning is focusing on rehabilitation and improvement of the Mini Ice Plant Test Rig. For

parts that need rehabilitation, the proponents would assess the materials required for better

performance of the existing test rig. For parts that require replacement, the proponents will

search for the best quality components.

The proponents are also planning to rehabilitate the whole frame of the test rig as due to its

rusty metals as well as its rollers that serve as the wheels of the test rig for easy transportation

when the students have to use it.

3.6.1. Time Frame

Since there’s an existing mini-ice plant, the restoration and the replacing
of several parts of the machine is our only focus. To reinforce the plans, setting
time frame is very important. The project is only good for one semester. The first
two weeks is for canvasing of the parts for the module. Another two weeks is
allotted for the fixing and repainting of the base. For the replacement of the brine
tank and evaporator coils, the estimated time is about two weeks. Two weeks for
the replacement of the parts and the addition of the recommended parts. The
remaining weeks is allotted for the testing and gathering of results. The
modification of the parts, if there’s something wrong in the data or the results
gathered.
 Number of Weeks from the Date of Start
ACTIVITIES
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1. CANVASSING
2. FIXING and
REPAINTING
3. ACQUISITION OF
EQUIPMENTS

4. FABRICATION

5. TESTING

6. GATHERING OF
RESULTS

7. PAPER WORKS

Figure 3.6: Gantt chart

The chart illustrates the start and finish dates of the terminal and summary elements of the Rehabilitation of existing
Mini Ice Plant Test Rig.
3.7 Canvassing

The researchers conducted a canvassing through online market to know the prices
and availability of the material based on the recommendation of the past researchers and
based on the inspection performed by the group. The table below shows the material with
their prices.

TABLE 3.1: Shows the summary of the materials used and prices

Materials Price/ Cost

*Brine Tank (Acrylic Glass) Php 6200.00

*Copper tube Php 1625.00

*High Side Meter Php 1250.00

*Low Side Meter Php 1250.00

*Pressure Switch Php 1950.00

*Ammeter Php 250.00

*Voltmeter Php 250.00

*Temperature Indicator Php 1250.00

*Solenoid Valve Php 2500.00

*Condensing Unit Php 16300.00

Refrigerant 134-A Php 2800.00

Spray Polyurethane Foam Php 1750.00

Other Expenses Php 8000.00

TOTAL Php. 48875.00

3.8 Rehabilitation