BOHOL ISLAND STATE UNIVERSITY

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sustainable development in Bohol and the country.
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technological fields; undertake research and development and extension services for the sustainable development of Bohol
and the country.

PME 424
ME Laboratory 3

Laboratory Report 4

DESIGN OF 3000KG ICE PLANT AND 5000KG OF CARROTS COLD

STORAGE

SUBMITTED BY:
MARC LYNDON BORDADOR
BSME4A

SUBMITTED TO:
ENGR. JUANITO ORIGINES JR.
INSTRUCTOR
 Introduction

Ice plants and cold storage facilities play a vital role in our food production and
preservation infrastructure. Ice production provides a readily available and affordable
cooling solution for various applications, from food transport and spoilage reduction to
medical uses. Cold storage warehouses create controlled temperature environments that
significantly extend the shelf life of perishable goods, minimizing waste and ensuring food
security. By establishing a reliable ice production and cold storage system, we can
improve food preservation capabilities, promote efficient distribution channels, and
ultimately contribute to a more sustainable and secure food supply chain.

This laboratory report explores the design and construction of a functional ice
production and cold storage system. The project investigates the key components
required for each system, including the ice plant's freezing tanks, brine solution, and
agitators for efficient heat transfer. It also delves into the design considerations for the
cold storage unit, focusing on maintaining optimal temperatures for product preservation.
Through this project, we aim to gain practical knowledge of the principles and processes
involved in creating and maintaining controlled temperature environments for ice
production and food storage.

Objectives:

This laboratory report aims to design and construct models of an ice plant and a
cold storage unit. The goal is to simulate the functionality of these systems while focusing
on the following aspects:

• Ice Plant:
o Design a model ice plant with a theoretical capacity of producing 3,000 kg
of ice per 24 hours.
o Investigate the key factors affecting ice production, such as brine solution
concentration and agitation.
o Analyze heat transfer principles within the model ice plant.
• Cold Storage:
o Design a model cold storage unit with a capacity of storing 5,000 kg of
carrots.
o Determine the product load, heat gain through walls, and the internal loads.
• Cooling Tower:
o Design a model cooling tower to effectively reject waste heat generated by
both the ice plant and the cold storage unit.
o Determine the temperature of the different points in the cooling tower.
 Methodology

This section details the construction process for the ice plant, cold storage and
cooling tower, followed by the methods used to evaluate their performance.

Ice Plant

The ice plant is designed with a theoretical capacity of producing 3,000 kilograms
of ice per 24 hours. To achieve this, the system will be configured to create individual ice
blocks. Each ice block will have a uniform weight of approximately 150 kilograms. The
process will begin with water at an initial temperature of 28 degrees Celsius entering the
freezing tank. The system will then efficiently remove heat from the water, causing it to
freeze and solidify. The final temperature of the produced ice will be approximately -8
degrees Celsius, ensuring it remains frozen for extended storage or use.

Table 2.1. Properties of Water to Ice

Properties
Mass Capacity of the Ice Plant 3, 000kg
Product Temperature 28°C
Freezing Point Temperature 0°C
Storage Temperature -8°C
𝑘𝐽
Specific Heat above Freezing 4.184
𝑘𝑔 − 𝐾
𝑘𝐽
Specific Heat below Freezing 334
𝑘𝑔 − 𝐾
𝑘𝐽
Latent Heat 2.093
𝑘𝑔

Brine Properties:

The concentration of the Sodium Chloride of the brine is 25%. From “The
Engineering Toolbox”, properties of the brine are then acquired by using its concentration.

Table 2.2. Properties of Brine

Properties Values

Freezing Point −23°C

kg
Density 1200
m3
 J
Specific Heat 3250
kg − K

Ice Block

For optimal space utilization and heat transfer efficiency, the ice plant model will
produce 3000 kg total of ice blocks in a rectangular shape. Each block will have a targeted
weight of approximately 150 kilograms. Rectangular ice blocks offer several advantages
over irregular shapes:

• Improved Stacking Efficiency: Rectangular blocks can be stacked neatly

and efficiently, minimizing wasted space within the freezing tank and cold
storage unit. This allows for maximizing the storage capacity for both ice
production and product preservation.
• Enhanced Heat Transfer: The flat surfaces of rectangular ice blocks
promote better contact with the cooling medium in the freezing tank. This
facilitates a more uniform and efficient heat transfer process, leading to
faster freezing times and potentially lower energy consumption.
• Simplified Handling and Transportation: Rectangular blocks are easier
to handle and transport due to their defined shape and stable base. This
reduces the risk of breakage or damage during handling, especially when
compared to irregularly shaped ice blocks.

Figure 2.1. Ice Can Figure 2.2. Ice can with Ice block
 Figure 2.3. Dimensions of the Ice Block

Freezing Tank

To ensure sufficient capacity for ice production, the dimensions of the freezing tank
will be determined by using the 'Kent's Mechanical Engineering Handbook' (pages 11-
50). This reference provides established guidelines for selecting appropriate tank sizes
based on desired ice production capacity. The chosen tank material will be a crucial factor
for optimal performance and durability. We will likely utilize a material with high thermal
conductivity, such as stainless steel, to facilitate efficient heat transfer from the water to
the cooling medium during the ice-making process. Additionally, the tank will be well-
insulated with polyurethane foam to minimize heat gain from the surrounding
environment. This will help maintain consistent low temperatures within the tank and
improve the overall efficiency of the ice plant model.

Figure 2.4. Dimensions of the Freezing Tank

Table 2.3. Materials and Insulation in the Freezing Tank

Thickness
Material K(W/m-K) H(W/m2-K)
(mm)
Still Air -- -- 9.37
Brine Solution -- -- 300
 Stainless Steel Side
7 16.3 --
316
Polyurethane 400 0.022 -- Side
Wood (Oak) 100 0.16 -- Top
Polyurethane 100 0.022 -- Top

Agitator

The ice plant model will utilize an agitator to continuously stir the brine solution.
This mixing offers several advantages:
• Uniform Temperature: Consistent circulation prevents stagnant zones, ensuring
all ice blocks experience the same cold brine for even freezing.
• Faster Freezing: The flow brings the brine into better contact with the water in
the molds, accelerating heat removal and shortening freezing times.
• Reduced Sedimentation: Agitation prevents salt from settling at the tank's
bottom, maintaining a uniform and effective brine mixture.
The agitator to be used is a Chemical Industry Agitators made by a company
named Mixtrap Solutions Private Limited with a capacity of 1000L-10000L.

Figure 2.5. Mixtrap Solutions Private Limited Agitator

Cold Storage

The primary function of this cold storage is to design the controlled environment
necessary for the long-term storage of carrots. With a targeted capacity of 5,000
kilograms, this model aims to effectively preserve the freshness and quality of this popular
root vegetable. The initial temperature of the incoming carrots will be approximately 35
degrees Celsius. The cold storage unit will be designed to efficiently lower the
temperature of the carrots to a target of 0 degrees Celsius, creating a controlled
environment that slows down their natural spoilage processes and extends their shelf life.
Carrots

Carrots are versatile root vegetables prized for their vibrant color, crisp texture,
and sweet flavor. As a staple ingredient in culinary dishes worldwide, carrots are valued
for their nutritional benefits and culinary versatility, making them a popular choice for
consumers and food manufacturers alike. However, to preserve their freshness, flavor,
and nutritional value, proper storage conditions are essential. Shown below are the
properties of carrots:

Table 2.4. Properties of Carrots

Properties
Mass Capacity of the Storage 5, 000kg
Mass of the Carrots per day 0.05787kg/s
Product Temperature 35°C
Freezing Point Temperature -1.2°C
Storage Temperature 0°C
𝑘𝐽
Specific Heat above Freezing 3.81
𝑘𝑔 − 𝐾
𝑘𝐽
Specific Heat below Freezing 1.84
𝑘𝑔 − 𝐾
𝑘𝐽
Latent Heat 293.1
𝑘𝑔

Cold Storage Design

To achieve the low and controlled temperature critical for preserving carrot
freshness, the walls will be equipped with a layered insulation system that combines the
benefits of two key materials. Polystyrene boards, known for their lightweight
construction, cost-effectiveness, and excellent thermal insulating properties, will form the
core layer. This layer significantly reduces heat transfer from the surrounding
environment. Encasing the polystyrene boards will be a layer of stainless steel 316. While
not a strong insulator itself, stainless steel provides crucial structural support and
durability to the overall insulation system. Additionally, it acts as a vapor barrier,
preventing moisture from entering and compromising the effectiveness of the polystyrene
layer.
 Figure 2.6. Dimension of the Cold Storage

Table 2.5. Materials and Insulation of the Cold Storage

Material Thickness (mm) K(W/m-K) H(W/m2-K)

Air -- -- 9.37
Air Inside -- -- 30

Stainless Steel 316 7 16.3 --

Polystyrene Board 200 0.034 --

Concrete 100 0.72 --

Internal Loads in the Cold Storage

While the primary focus of the cold storage unit's design is to minimize heat
transfer from the external environment, it's also important to consider internal heat
sources that can elevate the temperature within the unit.

Table 2.6. Internal Loads inside the Cold Storage

Equipment Number Watts(W) Efficiency

Incandescent
4 16 10%
Light
Evaporator Fan 2 200 80%

Vapor-Compression Cycle

Our ice plant model will utilize the established principles of the vapor compression
cycle to achieve efficient ice production. This closed-loop thermodynamic cycle serves as
the heart of many refrigeration systems, including ice plants. In essence, the vapor
compression cycle utilizes a working fluid to absorb heat from a low-temperature
environment and reject heat to a high-temperature environment.

The cycle typically involves four main stages:

• Evaporation: The working fluid, in a low-pressure, low-temperature state, absorbs

heat from the water in the ice molds. This heat absorption causes the working fluid
to evaporate and change from a liquid to a vapor state.
• Compression: The low-pressure vapor is then drawn into a compressor where its
pressure and temperature are significantly increased. This compression work
requires an energy input, typically provided by an electric motor.
• Condensation: The high-pressure, high-temperature vapor then flows through a
condenser. Here, the hot vapor releases its heat to the surrounding environment
through a heat exchanger. As it loses heat, the vapor condenses back into a liquid
state.
• Expansion: The high-pressure liquid then passes through an expansion valve
(also known as a throttle valve). This valve reduces the pressure of the liquid,
causing a drop in its temperature. This decrease in pressure and temperature
prepares the working fluid to return to the evaporator and repeat the cycle.

Figure 2.7. Vapor-Compression Cycle with Two Evaporators

Evaporator

The evaporator in a vapor compression cycle acts like a heat collector. It's a
component filled with a refrigerant at low pressure and temperature. Warm water or air
entering the evaporator transfers its heat to the refrigerant, causing it to evaporate and
turn into a gas. This process leaves the water or air significantly colder, preparing it for
freezing or cooling purposes. The evaporator used is from a company called Guangdong
Head-Power Air Conditioning Co., Ltd. Two different evaporators are used for the cold
storage and the ice plant. The cold storage used the ceiling type while the ice plant used
the standing type.

Figure 2.8. Standing Type Evaporator Figure 2.9. Ceiling Type Evaporator

Table 2.7. Data Sheet for Guangdong Head-Power Air Conditioning Evaporators
Compressor

A compressor in a vapor compression cycle is a mechanical device that

increases the pressure and temperature of the refrigerant vapor. It achieves this by
reducing the volume of the vapor, compressing it into a smaller space. This compressed
vapor then moves to the condenser where it releases heat and condenses into a liquid,
initiating the refrigeration cycle. The compressor used is from Elang Industrial Co., Ltd.
Direct Driven Screw Compressor model ERC-40SW.

Figure 2.10. Direct Driven Screw Compressor (ERC-30SA)

Table 2.8. Data Sheet for the Direct Driven Screw Compressor from Elang
Industrial Co.
Condenser

The condenser in a vapor compression cycle is a heat exchanger that removes

heat from the hot, high-pressure refrigerant vapor. It allows the refrigerant to release heat
to the surroundings, causing it to condense into a liquid state. This liquid refrigerant then
flows to the expansion valve or device to continue the refrigeration cycle. The condenser
used is from Bowa Solution Model B3-095-54D with a heating capacity of 90kW. The
condenser is water cooled and will be connected to the cooling tower to enhance the
performance of the condenser.

Figure 2.11. B3-095-54D Condenser

Table 2.9. Data Sheet from Bowa Solution for Condensers

Expansion Valve
 The expansion valve in a vapor compression cycle is a device that regulates the
flow of refrigerant from the high-pressure side to the low-pressure side of the system. It
causes a sudden drop in pressure, allowing the refrigerant to expand and cool rapidly.
This cooling effect prepares the refrigerant for absorbing heat in the evaporator,
completing the cycle. The expansion valve used is Danfoss R134 Thermal Expansive
Valve 068H8564 from VehicleAC Parts.

Figure 2.12. Danfoss R134 Thermal Expansive Valve 068H8564

Table 2.10. Technical Parameter for Danfoss R134 Thermal Expansive Valve
068H8564
 Cooling Tower

The laboratory report incorporates a cooling tower as an essential component for

managing waste heat. The ice plant and cold storage unit, despite their focus on
maintaining low temperatures, generate heat during operation. This heat byproduct,
primarily from the condenser in the vapor compression cycle, needs to be effectively
rejected to ensure optimal system performance. Without a cooling tower, this heat would
accumulate within the system, leading to inefficiencies. The cooling tower serves as a
crucial heat exchanger, utilizing water and air to dissipate the condenser heat and
maintain a cooler operating environment for both the ice plant and cold storage unit. This
ensures the continued effectiveness of these systems in ice production and carrot
preservation. The type of the cooling tower to be used is an Induced Counterflow Cooling
Tower.

Figure 2.13. Induced Counterflow Cooling Tower

Where,
T4 = Temperature of cooling water "cooled" leaving the cooling tower
T3 = Temperature of cooling water "hot" entering the cooling tower
Tdb = Dry bulb Temperature
Twb = Wet bulb Temperature
mmw = mass flowrate of make up water
ma = mass flowrate of air
mw = mass flowrate of cooling wate𝑟
 The cooling tower used is from HON MING model High Quality Round Cooling
Tower with a flowrate of 10m3/hr.

Figure 2.14. High Quality Round Cooling Tower

Table 2.11. Technical Parameters for the High Quality Round Cooling Tower

While designing the cooling tower, the following basis and assumptions are
followed:

1. Cooling tower’s cooling water range is 13.5°C.

𝑇𝑅 = 𝑇3 − 𝑇4 = 13.5°𝐶

2. Cooling tower efficiency is assumed to be 80%.

𝜂𝐶𝑇 = 0.80
 3. Make up water is maintained at 27°C.

𝑇5 = 27°𝐶

4. Due to imperfect conditions in the system the relative humidity is assumed to be

approximately 90%. The temperature of the air leaving the system and the entering
of the cooling water is assumed to have a temperature difference of 5°C.

𝛷 = 90%

𝑇3 − 𝑇2 = 5°𝐶

5. Atmospheric conditions in Bohol;

Table 2.12. Bohol Atmospheric Condition, Bohol Station, PAG-ASA 2020

Atmospheric Condition Temperature

Wet-Bulb Temperature 25.7°𝐶
Dry-Bulb Temperature 32.5°𝐶
 Results and Discussions

In the following section, the results and discussions are presented pertaining to the
performance and operational aspects of the ice plant, cold storage, vapor compression
cycle, and cooling tower.

Results for the Ice Plant

Table 3.1. Ice Plant Results

Summary of the Ice Plant

Product Load 16.246 𝑘𝑊
Heat Gain through Walls 0.93934 𝑘𝑊
Heat Gain from Equipment 14.400 𝑘𝑊
Total Load 𝟑𝟏. 𝟔 𝒌𝑾
Number of Ice Block 20 blocks
Ice Block Dimension (LxWxH) 0.5𝑚 × 0.5𝑚 × 0.656𝑚
Freezing Tank Volume 83.637 𝑚3
Freezing tank Dimension (LxWxH) 13.72 𝑚 × 7.62𝑚 × 0.8𝑚

The table indicates that the primary load on the Ice Plant stems from both the
product load and the heat generated by equipment. The product load, being the energy
required for water to transform into ice, represents the highest load. Following closely is
the heat generated by the equipment, particularly the agitator, which operates within the
brine and produces heat when it is working. Calculations are shown in Appendix A.

Results for the Cold Storage

Table 3.2. Cold Storage Results

Summary of the Cold Storage

Product Load 24.679𝑘𝑊
Heat Gain through Walls 1 .24965 𝑘𝑊
Heat Gain from Equipment 0.1376 𝑘𝑊
Total Load 𝟐𝟔. 𝟎𝟕𝒌𝑾
Cold Storage Dimension (LxWxH) 10𝑚 × 10𝑚 × 3𝑚
 The table shows that the highest load on the Cold Storage arises solely from the
product load. Although there is some heat gain through the walls, this is mitigated by the
insulation and the design of the cold storage facility, which effectively block off external
heat transfer. Consequently, the product load emerges as the primary factor influencing
the thermal dynamics within the storage environment. This underscores the importance
of efficient insulation and design considerations in maintaining optimal storage conditions.
Calculations are shown in Appendix B.

Results for the Vapor Compression

Table 3.3. Vapor Compression Results

Summary of the Vapor Compression

Evaporator 1 Temp −5°C
Evaporator 1 Work 26.07 𝑘𝑊
Evaporator 2 Temp −18°C
Evaporator 2 Work 31.6𝑘𝑊
Compressor Work 28.32𝑘𝑊
Heat Rejected 85.99𝑘𝑊
𝑘𝑔
Mass Flowrate of the Refrigerant 0.45320028998
𝑠
COP 2.036

The table above presents the outcomes derived from the vapor compression
analysis having two different evaporators. Evaporator 1 functions within the cold storage
environment, while evaporator 2 operates to extract heat from the ice plant. Utilizing the
refrigerant R134a, key parameters including the compressor's work, heat rejection, and
the mass flow rate of the refrigerant have been computed. These calculations shed light
on the energy dynamics involved in refrigeration processes, crucial for optimizing system
efficiency and performance. Calculations are shown in Appendix C.

Results for the Cooling Tower

Table 3.4. Cooling Tower Results

Summary of the Cooling Tower

𝑘𝑔
Mass Flowrate of the Cooling Water 1.522
𝑠
𝑘𝑔
Mass Flowrate of the Air 1.579
𝑠
 𝑘𝑔
Mass Flowrate of the Make-up Water 0.031
𝑠
Cooling Water Entering Temp 42.575°C
Cooling Water Leaving Temp 29.075°C
Cooling Water Range 13.5°C
Cooling Water Approach 3.375°C

The table above presents the results of the calculations for the cooling tower. The
cooling tower used is an Induced Counterflow Cooling Tower. Calculations are shown in
Appendix D.
 Appendix A

Ice Plant Calculations

Product Load:

Capacity of the Ice Plant: 3000kg of water in 24 hours

Initial Temperature of Water = 28°𝐶

Final Temperature of Ice = −8°𝐶

kJ
Cp of Water Above Freezing = 4.184
kg − K

kJ
Cp of Water Below Freezing = 2.093
kg − K

kJ
Specific Latent Heat of Water = 334
kg

𝑄1 = 𝑚𝐶𝑝 ∆𝑇

𝑘𝐽
𝑄1 = (3000𝑘𝑔) (4.184 ) (28°𝐶 − 0°𝐶)
𝑘𝑔 − 𝐾

𝑸𝟏 = 𝟑𝟓𝟏 𝟒𝟓𝟔 𝒌𝑱

𝑄2 = 𝑚𝐿𝐻

𝑘𝐽
𝑄2 = 3000𝑘𝑔 (334 )
𝑘𝑔

𝑸𝟐 = 𝟏 𝟎𝟎𝟐 𝟎𝟎𝟎𝒌𝑱

𝑄3 = 𝑚𝐶𝑝 ∆𝑇

𝑘𝐽
𝑄3 = (3000𝑘𝑔) (2.093 ) (0°𝐶 + 8°𝐶)
𝑘𝑔 − 𝐾

𝑸𝟑 = 𝟓𝟎 𝟐𝟑𝟐 𝒌𝑱

𝑄𝑃𝑟𝑜𝑑𝑢𝑐𝑡 = 𝑄1 + 𝑄2 + 𝑄3

𝑄𝑃𝑟𝑜𝑑𝑢𝑐𝑡 = 351 456 𝑘𝐽 + 1 002 000𝑘𝐽 + 50 232 𝑘𝐽

1 1ℎ𝑟
𝑄𝑃𝑟𝑜𝑑𝑢𝑐𝑡 = 1 403 688 𝑘𝐽 ( )( )
24ℎ𝑟𝑠 3600𝑠

𝑸𝑷𝒓𝒐𝒅𝒖𝒄𝒕 = 𝟏𝟔. 𝟐𝟒𝟔 𝒌𝑾

Design of the Ice Block:

Number of Ice Block:

Mass Per Ice Block = 150kg

3000𝑘𝑔
𝑁=
150𝑘𝑔

𝑁 = 20 𝐵𝑙𝑜𝑐𝑘𝑠

𝑘𝑔
𝜌𝑤𝑎𝑡𝑒𝑟 = 1000
𝑚3

𝑘𝑔
𝜌𝑖𝑐𝑒 = 917
𝑚3

150𝑘𝑔
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑖𝑐𝑒 𝑏𝑙𝑜𝑐𝑘 =
𝑘𝑔
917 3
𝑚

𝒗𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒊𝒄𝒆 𝒃𝒍𝒐𝒄𝒌 = 𝟎. 𝟏𝟔𝟒 𝒎𝟑

Figure A.1. Dimensions of the Ice Block

Design of the Freezing Tank:

From “Kent’s Mechanical Engineering Handbook p.11-50”, the size of the tank
can be obtained.

𝑊𝑖𝑑𝑡ℎ = 7.62𝑚

𝐿𝑒𝑛𝑔𝑡ℎ = 13.72𝑚

𝐻𝑒𝑖𝑔ℎ𝑡 = 0.8𝑚

Figure A.2. Dimensions of the Freezing Tank

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑇𝑎𝑛𝑘 = (0.8𝑚)(13.72𝑚)(7.62𝑚)

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒕𝒉𝒆 𝑻𝒂𝒏𝒌 = 𝟖𝟑. 𝟔𝟑𝟕𝒎𝟑

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝐵𝑟𝑖𝑛𝑒 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑇𝑎𝑛𝑘 − 𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐼𝑐𝑒 𝐵𝑙𝑜𝑐𝑘

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝐵𝑟𝑖𝑛𝑒 = 83.637𝑚3 − (20𝑏𝑙𝑜𝑐𝑘𝑠 × 0.164𝑚3 )

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒕𝒉𝒆 𝑩𝒓𝒊𝒏𝒆 = 𝟖𝟎. 𝟑𝟓𝟕𝒎𝟑

Number of Agitators:

The agitator to be used is a Chemical Industry Agitators made by a company

named Mixtrap Solutions Private Limited with a capacity of 1000L-10000L.
 1000𝐿
80.357𝑚3 ( )
𝑁𝑎𝑔𝑖𝑡𝑎𝑡𝑜𝑟 = 1𝑚3
10000𝐿

𝑵𝒂𝒈𝒊𝒕𝒂𝒕𝒐𝒓 = 𝟖. 𝟎𝟑𝟓𝟕 ≈ 𝟖 𝒂𝒈𝒊𝒕𝒂𝒕𝒐𝒓𝒔

Figure A.3. Layout of the Freezing Tank

Insulations and Material Specifications of the Freezing Tank:

Table A.1. Insulations and Material for the Freezing Tank

Thickness
Material K(W/m-K) H(W/m2-K)
(mm)
Still Air -- -- 9.37
Brine Solution -- -- 300
Stainless Steel Side
7 16.3 --
316
Polyurethane 400 0.022 -- Side
Wood (Oak) 100 0.16 -- Top
Polyurethane 100 0.022 -- Top

Toutside the freezing tank = 35°C

Tbrine = −13°C
 Figure A.4. Insulation Layout for the Walls of the Freezing Tank

Side Walls of the Freezing Tank:

𝑄 = 𝑈𝐴∆𝑇

𝐴𝑟𝑒𝑎𝑠𝑖𝑑𝑒 = (13.72𝑚)(0.8𝑚)(2) + (7.62𝑚)(0.8𝑚)(2)

𝐴𝑟𝑒𝑎𝑠𝑖𝑑𝑒 = 34.144𝑚2

1
𝑈𝑠𝑖𝑑𝑒 =
1 0.007𝑚 0.4𝑚 0.007𝑚 1
𝑊 + 𝑊 + 𝑊 + 𝑊 + 𝑊
9.37 2 16.3 𝑚 − 𝐾 0.022 𝑚 − 𝐾 16.3 𝑚 − 𝐾 300 2
𝑚 −𝐾 𝑚 −𝐾

𝑊
𝑈𝑠𝑖𝑑𝑒 = 0.05466646592
𝑚2 −𝐾

𝑊
𝑄𝑠𝑖𝑑𝑒 = (0.05466646592 2
) (34.144𝑚2 )(35°C + 13°C)
𝑚 −𝐾

𝑸𝒔𝒊𝒅𝒆 = 𝟖𝟗. 𝟓𝟗𝑾

Top of the Freezing Tank:

𝐴𝑟𝑒𝑎𝑡𝑜𝑝 = (13.72𝑚)(7.62𝑚)

𝐴𝑟𝑒𝑎𝑡𝑜𝑝 = 104.546𝑚2

1
𝑈𝑡𝑜𝑝 =
1 0.1𝑚 0.1𝑚 0.1𝑚 1
𝑊 + 𝑊 + 𝑊 + 𝑊 + 𝑊
9.37 2 0.16 𝑚 − 𝐾 0.022 𝑚 − 𝐾 0.16 𝑚 − 𝐾 300 2
𝑚 −𝐾 𝑚 −𝐾

𝑊
𝑈𝑡𝑜𝑝 = 0.16933334326
𝑚2 − 𝐾

𝑊
𝑄𝑡𝑜𝑝 = (0.16933334326 ) (104.546𝑚2 )(35°C + 13°C)
𝑚2 −𝐾

𝑸𝒕𝒐𝒑 = 𝟖𝟒𝟗. 𝟕𝟓𝑾

𝑄𝑊𝑎𝑙𝑙𝑠 = 849.75𝑊 + 89.59𝑊

𝑸𝑾𝒂𝒍𝒍𝒔 = 𝟗𝟑𝟗. 𝟑𝟒𝑾

Equipment Inside the Freezing Tank:

𝐴𝑔𝑖𝑡𝑎𝑡𝑜𝑟 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 98%

𝐴𝑔𝑖𝑡𝑎𝑡𝑜𝑟 𝑃𝑜𝑤𝑒𝑟 𝑅𝑎𝑡𝑖𝑛𝑔 = 90𝑘𝑊

𝑄𝑒𝑞𝑢𝑖𝑝 = (90 000𝑊)(1 − 0.98)(8)

𝑸𝒆𝒒𝒖𝒊𝒑 = 𝟏𝟒 𝟒𝟎𝟎 𝑾

Total Load Inside the Freezing Tank:

𝑄𝑇1 = 𝑄𝑒𝑞𝑢𝑖𝑝 + 𝑄𝑊𝑎𝑙𝑙𝑠 + 𝑄𝑃𝑟𝑜𝑑𝑢𝑐𝑡

𝑄𝑇1 = 14 400𝑊 + 939.34𝑊 + 16 246𝑊

𝑸𝑻𝟏 = 𝟑𝟏 𝟓𝟖𝟓. 𝟑𝟒𝑾 ≈ 𝟑𝟏. 𝟔𝒌𝑾

 Appendix B

Cold Storage Calculations

Cold Storage

Product: Carrots

Mass Capacity of the Storage = 5, 000kg

Mass of the Carrots per day = 0.05787kg/s

Design Data of Carrots:

Product Temperature = 35°C

Freezing Point Temperature = -1.2°C

Storage Temperature = 0°C

𝑘𝐽
𝐶𝑝𝑎 = 3.81
𝑘𝑔 − 𝐾

𝑘𝐽
𝐶𝑝𝑏 = 1.84
𝑘𝑔 − 𝐾

𝑘𝐽
ℎ𝑓𝑖 = 293.1
𝑘𝑔

𝑄𝑐𝑎𝑟𝑟𝑜𝑡 = [(𝑚)(𝐶𝑝𝑎 )(∆𝑇)] + [(𝑚)(ℎ𝑓𝑖 )]

𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
𝑄𝑐𝑎𝑟𝑟𝑜𝑡 = [(0.05787 ) (3.81 ) (35°C − 0°C)] + [(0.05787 ) (293.1 )]
𝑠 𝑘𝑔 − 𝐾 𝑠 𝑘𝑔

𝑸𝒄𝒂𝒓𝒓𝒐𝒕 = 𝟐𝟒. 𝟔𝟕𝟗𝒌𝑾

Cold Storage Design:

Figure B.1. Dimensions of the Cold Storage

Table B.1. Insulations and Material for the Cold Storage

Material Thickness (mm) K(W/m-K) H(W/m2-K)

Air -- -- 9.37
Air Inside -- -- 30

Stainless Steel 316 7 16.3 --

Polystyrene Board 200 0.034 --

Concrete 100 0.72 --

Toutside the cold storage = 35°C

Figure B.2. Insulation Layout for the Cold Storage

Walls and Roof of the Cold Storage

𝑄 = 𝑈𝐴∆𝑇

𝐴 = (3𝑚)(10𝑚)(4) + (10𝑚)(10𝑚)

𝐴 = 220 𝑚2

1
𝑈=
1 0.007𝑚 0.2𝑚 0.1𝑚 1
𝑊 + 𝑊 + 𝑊 + 𝑊 + 𝑊
9.37 2 16.3 𝑚 − 𝐾 0.034 𝑚 − 𝐾 0.72 𝑚 − 𝐾 30 2
𝑚 −𝐾 𝑚 −𝐾

𝑊
𝑈 = 0.16229191896
𝑚2−𝐾

𝑊
𝑄𝑤𝑎𝑙𝑙𝑠 = (0.16229191896 ) (220 𝑚2 )(35° − 0°C)
𝑚2 − 𝐾

𝑸𝒘𝒂𝒍𝒍𝒔 = 𝟏 𝟐𝟒𝟗. 𝟔𝟓𝑾

Internal Load:

Table B.2. Equipment inside the cold storage

Equipment Number Watts(W) Efficiency

Incandescent
4 16 10%
Light
Evaporator Fan 2 200 80%

𝑄𝑙𝑖𝑔ℎ𝑡 = (16𝑊)(1 − 0.1)(4)

𝑄𝑙𝑖𝑔ℎ𝑡 = 57.6𝑊

𝑄𝐹𝑎𝑛 = (200𝑊)(1 − 0.8)(2)

𝑄𝐹𝑎𝑛 = 80𝑊

𝑄𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐿𝑜𝑎𝑑 = 57.6𝑊 + 80𝑊

𝑸𝑰𝒏𝒕𝒆𝒓𝒏𝒂𝒍 𝑳𝒐𝒂𝒅 = 𝟏𝟑𝟕. 𝟔𝑾

Total Load of the Cold Storage

𝑄𝑇2 = 𝑄𝑐𝑎𝑟𝑟𝑜𝑡 + 𝑄𝑤𝑎𝑙𝑙𝑠 + 𝑄𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐿𝑜𝑎𝑑

𝑄𝑇2 = 24 679𝑊 + 1 249.65𝑊 + 137.6𝑊

𝑸𝑻𝟐 = 𝟐𝟔 𝟎𝟔𝟔. 𝟐𝟓𝑾 ≈ 𝟐𝟔. 𝟎𝟕𝒌𝑾

 Appendix C

Vapor Compression Calculations

Vapor-Compression Cycle (Two Evaporators):

Figure C.1. Schematic Diagram of Vapor Compression with 2 Evaporators

Using the thermodynamic property of R-134a from Chemours.

State 1

𝑘𝐽
ℎ1 = 391.45
𝑘𝑔

𝑘𝐽
𝑠1 = 1.75379275854
𝑘𝑔 − 𝐾

State 2

𝑘𝐽
ℎ2 = 435.94
𝑘𝑔

State 3

ℎ𝑓 @ 𝑇3 = 45°C

𝑃3 = 1161.01𝑘𝑝𝑎
 𝑘𝐽
ℎ3 = 264.2
𝑘𝑔

State 4

ℎ4 = ℎ3

𝑘𝐽
ℎ4 = 264.2
𝑘𝑔

State 5

ℎ𝑔 @ 𝑇5 = −5°C

𝑃5 = 243.39𝑘𝑝𝑎

𝑘𝐽
ℎ5 = 395.9
𝑘𝑔

State 6

ℎ6 = ℎ3

𝑘𝐽
ℎ6 = 264.2
𝑘𝑔

State 7

ℎ𝑔 @ 𝑇7 = −18°C

𝑃7 = 144.54 𝑘𝑝𝑎

𝑘𝐽
ℎ7 = 388
𝑘𝑔

Mass Flow Rate of Evaporator 1 (Cold Storage):

𝑄𝑇2 = 𝑚(ℎ5 − ℎ4 )

𝑄𝑇2
𝑚4 =
(ℎ5 − ℎ4 )

26.07𝑘𝑊
𝑚4 =
𝑘𝐽
(395.9 − 264.2)
𝑘𝑔

𝒌𝒈
𝒎𝟒 = 𝟎. 𝟏𝟗𝟕𝟗𝟒𝟗𝟖𝟖𝟔𝟏
𝒔

Mass Flow Rate of Evaporator 2 (Ice Plant):

𝑄𝑇1 = 𝑚(ℎ7 − ℎ6 )
 𝑄𝑇1
𝑚6 =
(ℎ7 − ℎ6 )

31.6𝑘𝑊
𝑚6 =
𝑘𝐽
(388 − 264.2)
𝑘𝑔

𝒌𝒈
𝒎𝟔 = 𝟎. 𝟐𝟓𝟓𝟐𝟓𝟎𝟒𝟎𝟑𝟖𝟖
𝒔

𝑚1 = 𝑚4 + 𝑚6

𝑘𝑔 𝑘𝑔
𝑚1 = 0.1979498861 + 0.25525040388
𝑠 𝑠

𝒌𝒈
𝒎𝟏 = 𝟎. 𝟒𝟓𝟑𝟐𝟎𝟎𝟐𝟖𝟗𝟗𝟖
𝒔

Energy balance for h1:

𝑚1 ℎ1 = 𝑚5 ℎ5 + 𝑚7 ℎ7

(𝑚5 ℎ5 + 𝑚7 ℎ7 )
ℎ1 =
𝑚1

𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
(0.1979498861 ) (395.9 ) + (0.25525040388 ) (388 )
𝑠 𝑘𝑔 𝑠 𝑘𝑔
ℎ1 =
𝑘𝑔
0.45320028998 𝑠

𝒌𝑱
𝒉𝟏 = 𝟑𝟗𝟏. 𝟒𝟓
𝒌𝒈

Work of the Compressor

𝑊𝑐 = 𝑚(ℎ2 − ℎ1 )

𝑘𝑔 𝑘𝐽 𝑘𝐽
𝑊𝑐 = (0.45320028998 ) (435.94 − 391.45 )
𝑠 𝑘𝑔 𝑘𝑔

𝑾𝒄 = 𝟐𝟖. 𝟑𝟐𝒌𝑾

Heat Rejected

𝑄𝑅 = 𝑚(ℎ2 − ℎ3 )

𝑘𝑔 𝑘𝐽 𝑘𝐽
𝑄𝑅 = (0.45320028998 ) (435.94 − 264.2 )
𝑠 𝑘𝑔 𝑘𝑔

𝑸𝑹 = 𝟖𝟓. 𝟗𝟗𝒌𝑾
Coefficient of Performance

𝑄𝑖𝑛
𝐶𝑂𝑃 =
𝑊𝑐

26.07𝑘𝑊 + 31.6𝑘𝑊
𝐶𝑂𝑃 =
28.32𝑘𝑊

𝑪𝑶𝑷 = 𝟐. 𝟎𝟑𝟔
 Appendix D

Cooling Tower Calculations

Cooling Tower Design

Figure D.1. Cooling Tower Diagram

𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑇𝑜𝑤𝑒𝑟 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 80%

𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 𝑅𝑎𝑛𝑔𝑒 = 13.5°C

Mass Flowrate of Cooling Water

𝑄𝑅 = 𝑚𝑤 𝐶𝑤 ∆𝑇

𝑄𝑅
𝑚𝑤 =
𝐶𝑤∆𝑇

85.99𝑘𝑊
𝑚𝑤 =
𝑘𝐽
4.186 (13.5°C)
𝑘𝑔 − °C

𝒌𝒈
𝒎𝒘 = 𝟏. 𝟓𝟐𝟐
𝒔

Volume Flowrate of Cooling Water

 𝑘𝑔 1 60𝑠 60𝑚𝑖𝑛
𝑣𝑤 = 1.522 ( )( × )
𝑠 𝑘𝑔 1𝑚𝑖𝑛 1ℎ𝑟
1000 3
𝑚

𝒎𝟑
𝒗𝒘 = 𝟓. 𝟒𝟕𝟗
𝒉𝒓

Cooling Tower Temperature

𝑇𝑅 𝑇𝑅
𝜂= =
𝑇𝑅 − 𝑇𝐴 𝑇3 − 𝑇𝑤𝑏1

𝑇𝑅
𝑇3 = + 𝑇𝑤𝑏1
𝜂

13.5°C
𝑇3 = + 25.7°C
0.8

𝑻𝟑 = 𝟒𝟐. 𝟓𝟕𝟓°𝐂

𝑇𝑅 = 𝑇3 − 𝑇4

𝑇4 = 42.575°C − 13.5°C

𝑻𝟒 = 𝟐𝟗. 𝟎𝟕𝟓°𝐂

Table D.1. State of each Point in the Cooling Tower

State Properties
𝑇𝑑𝑏1 = 32.5°C 𝜔1 = 0.0181
𝑇𝑤𝑏1 = 25.7°C 𝑘𝐽
ℎ1 = 78.97
1 𝑘𝑔
𝑚3
𝑣1 = 0.891
𝑘𝑔
Φ = 90% 𝜔2 = 0.038148
𝑇𝑑𝑏2 = 𝑇3 − 5°C 𝑘𝐽
ℎ2 = 135.791
2 𝑇𝑑𝑏2 = 37.575°C 𝑘𝑔
𝑚3
𝑣2 = 0.934
𝑘𝑔
𝑇3 = 42.575°C 𝑘𝐽
ℎ3 = 178.32
3 𝑘𝑔

𝑇4 = 29.075°C 𝑘𝐽
ℎ4 = 121.92
4 𝑘𝑔
 𝑇5 = 27°C 𝑘𝐽
ℎ5 = 113.25
𝑘𝑔
5 𝑚3
𝑣5 = 0.0010035
𝑘𝑔

Mass Flowrate of Air

𝑚𝑤 (ℎ3 − ℎ4 )
𝑚𝑎 =
(ℎ2 − ℎ1 ) − (𝑤2 − 𝑤1 )ℎ4

𝑘𝑔 𝑘𝐽 𝑘𝐽
1.522 𝑠 (178.32 − 121.92 )
𝑘𝑔 𝑘𝑔
𝑚𝑎 =
𝑘𝐽 𝑘𝐽 𝑘𝐽
(135.791 − 78.97 ) − (0.038148 − 0.0181)121.92
𝑘𝑔 𝑘𝑔 𝑘𝑔

𝒌𝒈
𝒎𝒂 = 𝟏. 𝟓𝟕𝟗
𝒔

Flow Rate of Make-up Water

𝑚5 = 𝑚𝑤 (𝑤2 − 𝑤1 )

𝑘𝑔
𝑚5 = 1.522 (0.038148 − 0.0181)
𝑠

𝒌𝒈
𝒎𝟓 = 𝟎. 𝟎𝟑𝟏
𝒔
 References

[1] Lucidos, M (2019). Ice Plant and Cold Storage Design(120 Tons of Ice)
https://www.scribd.com/document/401234789/Ice-Plant-and-Cold-
Storage-Design

[2] Sodium Chloride Water Solutions –

https://www.engineeringtoolbox.com/sodium-chloride-water-
d_1187.html

[3] Evaporative Water Cooled Package Unit –

https://headpower2.en.made-in-
china.com/product/wSYQidbyAUpR/China-35kw-Evaporative-
Water-Cooled-Packaged-Unit-Cabinet.html

[4] Elang Direct Driven Screw Compressor –

https://www.ielang.net/40hp-30kw-oil-free-screw-air-
compressor-15656809059493702.html

[5] B3-095-54D Condenser –

https://it.aliexpress.com/item/32699892797.html?src=google&af
f_fcid=348d7d2c8fcb4f12bbab6c8d28085d10-1714441728481-
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f&aff_trace_key=348d7d2c8fcb4f12bbab6c8d28085d10-
1714441728481-03969-
UneMJZVf&terminal_id=feaf534fa64b4072ad95e89c07d00469
&afSmartRedirect=y&gatewayAdapt=glo2ita

[6] Chemical Industry Agitators –

https://www.indiamart.com/proddetail/chemical-industry-
agitators-8770335330.html

[7] Danfoss R134 Thermal Expansive Valve 068H8564 –

http://www.vehicleacparts.com/bus-hvac-parts/expansion-
valve/denfoss/068h8564-bus-ac-thermal-expansion-valve.html

[8] Hon Ming High Quality Round Cooling Tower –

https://www.honminggroup.com/product/round-cooling-tower/