Transcript of A Proposed Design of Ice Plant

by: Jonnie Bayadas,Freddie Idul ,Roldan Villarma

A Proposed Design of Ice Plant
The plant can produce 30 tons of ice per day.

Capacity/day = tons of ice / mass of ice block

= 30000kg / 150kg/block
= 200 blocks/day

1. To determine the size of ice to be produced.

2. To be able to know the kind of refrigerant to be used.
3. To know the specifications of the important equipment to be used in the design.

Significance of the Study

Methodology
The design will use the international standard size of ice can, 11” (28cm) Long, 22” (56cm)
Wide, 48” (122cm) High.
The size of the ice block is approximately 330lbs (150kg).
ICE CUBE SPECIFICATION
BRINE TEMPERATURE
The brine temperature may be computed by using the equation
T=
Where:
T = brine temperature, °F
a = thickness of ice block, inches
n = no. of ice can / ton of ice / day
W = mass of ice block, (lbs); use 330lbs

For the value of n

n = no. of ice can / ton of ice produced
# of ice can = 200 say 400 to maximize and avoid shortage
n = 400 blocks /30 tons
n = 13 ice block / ton of ice
For the value of T
T = [ 32 – 582.3(11)² ]/(330)(13)
= 15.58 °F or -9.12 °C

FREEZING TEMPERATURE
From the book Refrigeration Engineering by Macintire and Hutchinson, p. 571 freezing time can
be evaluated using the equation and from the book
Refrigeration by Chris Langley constant varying varies from 5.5 to 7:

t=
t = Freezing temperature
C = Constant varying from 5.5 – 7
T = Brine temperature
X = Thickness of ice
t=
t = 39.65 hrs

COOLING LOAD CALCULATIONS:

Raw Water Temperature = 80.6°F (27°C)

Freezing Temperature = 32°F (0°C)
Brine Temperature = 15.58°F (-9.12°C)
Ice Temperature = 25.58°F (-3.5667 °C)

Q3 = raising the temperature of water from its freezing temperature to the brine temperature
= (mass) (specific heat of water) (temperature difference)
= (30,000 kg/day) (2.093 KJ/kg-°k) (0-9.12) (1/24) (1/3600)
= 6.628 KW

QT = (39.253 KW + 123.264 KW + 6.628 KW)

= 169.145 KW
For typical ice plant there is 15% allowance, therefore
Qt = Qt + Qt (.15)
= 169.145 + 169.145(.15)
= 194.52 KW

COOLING LOAD CALCULATIONS:

Raw Water Temperature = 80.6°F (27°C)

Freezing Temperature = 32°F (0°C)
Brine Temperature = 15.58°F (-9.12°C)
Ice Temperature = 25.58°F (-3.5667 °C)

Total heat load can be completed using

QT= Q1 + Q2 + Q3
Where:
Q1 = sensible heat required to lower temperature of water from its raw temperature to its
freezing temperature.
= (mass) (specific heat of water) (temperature difference)
= (30,000 kg/day) (4.187 KJ/kg-°k) (27-0) (1/24) (1/3600)
= 39.253 KW

Q2 = changing the latent heat of water at its freezing temperature from liquid to solid
= (mass) (latent heat of water)
(30,000 kg/day) (355 KJ/kg) (1/24)(1/3600)
= 123.264 KW
NUMBER OF TUBE REQUIRED:
Use a tube made of B.I. Pipe, 1”D. the area of one length of the B.I. Pipe 1”D is 6.89 ft2. In
determining the surface area of the condenser, using the equation from the book Principles of
Refrigeration by R. J. Dossat, 2nd Editon page 316,
Q=AxUxD
where:
Q = condenser capacity, Btu / hr; use 837,130.401 Btu/hr
A = surface area of the condenser, ft2
D = temperature difference between the condensing refrigerant and the condensing medium, °F;
use 10 °F
U = overall heat transfer coefficient in Btu/hr-ft2-°F
from the book Design Values of U for Metallic Surfaces of Refrigeration Engineering by
Macintire & Hutchinson, page 263,
the overall conductance factor for shell-and-tube condenser is 150 to 300 Btu/hr-ft2-°F. Use 200
Btu/hr-ft2-°F

A=Q/UxD
= 837,130.401 Btu/hr-ft2-°F/225(10°F)
= 372.057 ft2
A = 372.057 + 15% allowance
= 372.057 + 372.057(.15)
= 427.867 ft2
no. of tubes = A / surface area of the tube used
m = Qr/ (h1 – h3) = 245.277KW / 1443.9 kJ/kg – 390.587 kJ/kg
m = .233 kg/s

Volume flow rate, f

F = m/ρof ammonia = 681.92 kg/m3
f = (0.233kg/s) / (681.92 kg/m3)
f = 3.415x10-4 m3/s

Pipe Size
Q = AV
(use velocity of 2 m/s from INDUSTRIAL REFRIGERATION HANDBOOK, CHAPTER 9
PIPE SIZING, page 349.)
3.415x10-4 m3/s = [πD2 (2 m/s)]/ 4
D = 0.0147 m
= 0.557 in (use B.I pipe with nominal diameter of 1 in)
use 1.315in diameter from (http://gotocfr.com/tools/pipe-schedule.pdf)
= (1.315in) (1 ft/12 in) (20 ft)
= 6.89 ft2 per length of B.I. Pipe
= 427.867 ft2 / 6.89 ft2/ length
= 62.14 length of B.I. pipe
= 63 length of B.I. Pipe 1” D

ENTHALPIES
The enthalpies can be calculated by knowing this two
temperatures from the compressor model # VZ6AVT(HASEGAWA), the Evaporating
temperature (-15°C) and the Condensing temperature (40°C). The refrigerant is ammonia; we
can refer to the table A-3 page 420 RAC by Stoecker & Jones.

By interpolation:
h1 = 1443.9 kJ / kg
h3 = hf @ 40°C = 390.587 kJ / kg
S1 = S2 = Sg @ -15 °C = 5.827 kJ/kg K
h2 = h1 = 1,557 kpa = 1720 kJ/ kg
h4 = h3

CONDENSER
Qr = mr ( h2 – h3 )
where:
Qr = heat rejected
Qa = mr ( h1 – h2 )
mr = Qa / ( h1-h3 )

= 194.52 / (1443.9 – 390.587)

= .1845 kg/s
Qr = .1845 kg/s (1720 -390.587 )
= 245.277 KW
Mass of cooling water
Assuming:
Water outlet temperature = 30 - 32°C
Water inlet temperature = 26 - 28°C

mw = Qr / cp ( T )
= 245.277 / 4.187 kJ/kg – K) ( 31 – 27)
= 14.65 kg/s

FLOW RATE

f = Mw/Pw
= 14.65 kg/s / 1000 kg/m3
= .0146 m3/s

Based on the specification of the Model HVU-VZ6AMT(HASEGAWA) is appropriate in this

design with a capacity of 217 kW and operates at a maximum speed of 1075 RPM. Other data
from the manufacturer’s specification are listed below.
Capacity = 216.98 kW
No. of cylinder = 6
Cylinder: Bore mm) = 132
Stroke (mm) = 106
Speed = 1075 RPM
Piston Displacement = 561.38 m3/hr

Refrigerant Connection
Suction (mm) = 100
Discharge (mm) = 75
Standard Motor = 45 kW

COMPRESSOR
The compressor used in this design is a flanged motor compressor,
single stage and the refrigerant used is ammonia. The selection of the compressor is based on the
heat load.
Q = 194.52 kW

FOR TYPE OF BELT

Power transmitted = 60.35 hp (45 kW)
Speed of Motor = 1075 rpm
Design Power = power transmitted x normal torque
Normal torque = 1.2 from table 7.1 machine elements in
mechanical engineering by Robert L. Mott
Design Power = (60.35) (1.2)
= 72.42 hp

For sheave pulley

Most commercial available sheaves are cast iron,
which should be limited to 6500 ft/min Belt speed.

In this design use belt = 4000 ft/min

Vd = belt speed
Dd = Driver sheave
= 12 Vd/ n= 12(4000) / 3.1416(1075)
= 14.21

For length of V belt

From table 7-8 Machine Elements in Mechanical Design by
Robert L. Mott the center distance is ranging
D2 < C < 3 (D2 + D1)
D2 < C < 3 (21.1 + 13.9)
21.1 < C > 105
For the interest of conserving speed use C = 30
From the book Machine Elements in Mechanical Design by Robert L. Mott, equation 7-3
L = 2C + /2 (D2 + D1) + ( D2 – D1 )/ 4
= 2(30) + ( /2) (21.1 + 13.9) + (21.1 – 13.9/4(105))
= 136.04 inches

From table 7-2 Machine Elements in Mechanical Design by Robert L. Mott select standard belt =
140 inches

For actual center distance

The center distance assumed earlier is just for the purpose of solving L,
now that we have L, we can calculate the actual center distance by the equation 7-4 and 7-5 from
the book Machine Elements in Mechanical Design by Robert L. Mott

C=

B = 4L – 6.28 ( D2 + D1 )
= 4(136.04) – 6.28 (21.1 + 13.9)
= 324.36

Solving for C
C=
= 40.38

Number of Belts
Ө1 = 180°– 2 sin-1 [(D2 – D1) / 2C]
= 180°– 2 sin-1 [(21.1 – 10.8) / 40.38]
= 154°

Determine the correction factors from Figure 7-14 and Figure 7-15
Elements in Mechanical Design by Robert L. Mott
For Ө1 = 154°
CӨ = 0.93; For L = 140 in; CL = 1.0

Corrected Power = CӨ x L x CL
= (0.93) (27.69) (1.0)
= 25.75 hp
Number of Belts = 439.94 / 19.32
= 2.8 (use 3 belts)

LIQUID RECIEVER
The size of the liquid receiver is such that it
can store the total volume of the refrigerant when pumping down the system. From the
compressor capacity
Compressor Capacity = m (h2 – h3)
Compressor capacity = 194.52 kW
m = mass flow rate
m = 194.52 / (1720 – 390.5870)
m = .14632 kg/s
total required mass of ammonia refrigerant system is
= .14632 kg/s (15 min) (60sec/min)
= 131.688 kg
= 290.322 lb
V = m / ρ brine
ρ brine = 39.96 lbs/ ft3 from table RAC by Stoecker & Jones
V = 290.322 lb / 39.96 lbs/ft3

ACCUMULATOR
Normally accumulator is should be less than 30% to 40% of
the total evaporator capacity. (use 35% allowance).
D = .062 ft
R = .031 ft
V = Volume of evaporator coil
V = π (.031)2 (20) (203)
= 12.257 ft3 x (.35)
= 4.29 ft3

BRINE AGIGATOR
The brine agitator is installed in the end
portion of the brine tank because it is more convenient when removal is required for repair. The
brine agitator should have the capacity of 60 to 70 gallons/ton/min. (use 65gallons/ton/min).

P = ϒ Qb H
Qb = 65 gallons/ton/min (30 tons)
= 1950 gallons/min (1/60)
= 32.5 gal/s or .123 m3/s
P = (1.755)(9.81)(.123)(1)
= 2.117 kW or 2.84 hp

FREEZING TANK
Freezing tank or brine tank is provided with a race way,
which the evaporator coil is installed. In this design the coil race way has a width of 39.37
inches.

Base = base of ice x 20 blocks/row + 39.37 + .5 inch gap between blocks x 20 blocks
= 269.27 inches or 7 meters
Length = length of ice x 20 blocks + 1 inch gap x 20 gaps
= 470 inches or 12 meters

PUSH TROLLEY AND ELECTRIC HOIST

Ice blocks are too heavy for human labor to remove it from
brine tank so an electric hoist is needed.
Weight of ice block = 150 kg
Number of ice can per row = 20
Total weight per row = 150 (20)
= 3000 kg
Add 15% for the additional load
= 3000 kg x 1.15
= 3450 kg
Therefore,
Use a 3.5 ton hoist

COOLING TOWER
The selection of cooling tower is based on the computed quantity of the condensing medium,
which is water.

Quantity of condensing medium = flow rate of water in condenser

= .014 m3/ s
= 50.4 m3/ hr

From AOSUA table of specification model AB-60 is selected with the following specifications:

Nominal flow = 60 m3 / hr
Motor = 1.5kW (2hp)
Fan diameter = 990 mm
Water inlet diameter = 100 mm
Water outlet diameter = 100 mm
Net weight = 368 kg

Thank You!!