Mini Ice Plant Design

Capacity of plant = 0.056 Tons of Ice (TOI) per day

Tons of Refrigeration Approximation
From Kent’s Mechanical Engineers’ Handbook:
TOI
TR  0.61
0.056
TR  0.61

TR  0.0918

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

Table 1. Size of Standard Ice Cans & Freezing Time

Size of Can: 6 x 12 x 20 in
Thickness of Can Material: Gage 20 for both bottom & sides
Weight of Ice Block: 50 lbs.
Temperature of Brine: 15°F = -9.4°C
Time of freezing: 15 hrs.
𝑊𝐻
Number of Cans Required: 𝑁 = 24𝐶

Where: N = no. of cans

W = weight of ice, lbs.
H = freezing time, hr.
C = weight of one ice block, lbs.

2000𝑙𝑏
(0.056 𝑇𝑂𝐼)( 𝑇𝑂𝑁 )(15 ℎ𝑟𝑠)
𝑁=
24ℎ𝑟𝑠 (50 𝑙𝑏)
𝑁 = 1.4
𝑁 ≈ 2 𝑐𝑎𝑛𝑠

Volume of Freezing Tank: VFT = Vice + Vbrine

Where: VFT = volume of freezing tank
Vice = volume of ice
 Vice = L x W x H of ice can
Vice = 6 x 12 x 20 in/block x 2 block
1 𝑓𝑡
Vice = 2,880in x (12 𝑖𝑛)3

Vice = 0.83 ft 3
Vbrine = volume of brine
From Kent ′ s Mechanical Engineers ′ Handbook pp. 11-51
ft3
Vbrine = 60 TR x TR
ft3
Vbrine = 60 TR x 0.0918 TR

Vbrine = 5.508 ft 3

Volume of Freezing Tank: VFT = 0.83 ft 3 + 5.508 ft 3

VFT = 6.338 ft 3

Size of Freezing Tank

One freezing tank with two ice cans

Cs Ci

Cs

Length of Tank

Width of Tank

Ice Can Orientation

w = 12”

t = 6”
Length of Tank
L = 2Cs + Nc t + Ci (Nc -1)
Where: Cs = wall clearance = 4”
Nc = number of cans in the freezing tank = 2
t = thickness of can = 6”
Ci = ice can spacing = 0 (one line arrangement)

L = 2(4) + 2(6) + 0
L = 20 inches

Width of Tank
W = 2Cs + Nc w + Ci (Nc -1)
Where: Cs = wall clearance = 2”
Nc = number of cans in the freezing tank = 2
w = width of can = 12”
Ci = ice can spacing = 2”

W = 2(2) + 2(12) + 2(2-1)

W = 30 inches

Height of Tank
V
H = L xFTW
𝟏𝟐 𝐢𝐧 𝟑
6.338 ft3 ( )
𝟏𝐟𝐭
H= 20 in x 30 in

H = 18.25 inches
Dimension of Freezing Tank
20 x 30 x 18.25 inches = 0.508 x 0.762 x 0.46355 m
Plant Capacity (Tons of Refrigeration)
Qice = mCpw ∆Tw + mhice + mCpi ∆Ti
Where: Qice = heat rejected from ice (kW)
m = mass flow rate of water = mice
0.056 Tons 2000 lb 1 kg 1 Day 1 hr
mice = x x 2.205 lb x 24 hrs x 3600 𝑠
Day 1 Ton
kg
mice = 0.00058788947 s

Cpw = specific heat of water = 4.179 kJ/kg. K

∆Tw = temperature difference of water
(Raw water at 26°C)
hice = heat of fusion of ice 335 kJ/kg
Cpi = Specific heat of ice = 2.04 kJ/kg. K
∆Ti = temperature difference of ice

kg kg
Qice = 0.00058788947 (4.179 kJ/kg.K)(26°C -0°C) + 0.00058788947 (335 kJ/kg)
s s
kg
+ 0.00058788947 (2.04 kJ/kg.K)(0°C -(-9.4°C))
s
1 TR
Qice = 0.272kW x
3.51685 kW

𝐐𝐢𝐜𝐞 = 0.07734 TR
TOI
≥ TOR; 0.0918 ≥ 0.07734 (satisfied)
0.61

Heat Loss from Tank’s Material

Material Thickness Thermal U -Factor
(m) Conductivity (W/𝐦𝟐 𝐊)
(W/𝐦𝐊)
Extruded Polystyrene 0.0254 0.03 -
(Styrofoam)
Sheet Metal 0.002 14.3 -
Plywood 0.00635 - 18.170443
 Heat Gain
Q = UA∆T
Where: Q = heat gain (kW)
U = overall heat-transfer coefficient (W/m2 K)
A = surface area (m2 )
∆T = thermal difference

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

Aside = 2 (0.506m x 0.46355m) + 2(0.762m x 0.46355m)
Aside = 1.1755628 m2
1
Uside = 0.0254m 0.002m 0.005m
+ +
0.03W/mK 14.3W/mK 1W/mK

Uside = 1.173975508 W/m2 K

Qside = 1.173975508 W/m2 K(1.1755628 m2 )(30-(-9.4))
1 kW
Qside = 35.88213032 W x 1000 W
1 TR
Qside = 0.03588213032 kW x 3.51685 kW

𝐐𝐬𝐢𝐝𝐞 = 0.0102 TR

Abottom = L x W
Abottom = 0.508m x 0.762m
Abottom = 0.387096 m2
Ubottom = Uside = 1.173975508 W/m2 K
Qbottom = 0.387096 m2 (1.173975508 W/m2 K)( 26°C -0°C)
1 kW
Qbottom = 11.8154718 W x 1000 W
1 TR
Qbottom = 0.0118154718 kW x 3.51685 kW

𝐐𝐛𝐨𝐭𝐭𝐨𝐦 = 0.00336 TR

Total Cooling Load

𝐐𝐥𝐨𝐚𝐝 = 𝐐𝐢𝐜𝐞 + 𝐐𝐬𝐢𝐝𝐞 + 𝐐𝐛𝐨𝐭𝐭𝐨𝐦
𝐐𝐥𝐨𝐚𝐝 = 0.07734 TR +0.0102 TR + 0.00336 TR
𝐐𝐥𝐨𝐚𝐝 = 0.0909 TR
0.0909 TR  0.0918 (therefore, the design is OK)
Compressor (Hermetic type):
Power Rating = 120W
Refrigerant used = R-134a
Evaporator Design
State 1:
h1 = hg @ -10˚C = 392.28 kJ/kg
v1 = vg @ -10˚C = 0.09921 m3/kg
s1 = sg @ -10˚C = 1.7319 kJ/kg-K
State 2:
P2 = Psat @ 40˚C = 1017 kPa
s1 = s2 = 1.7319 kJ/kg-K
h2 = 426.0083317 kJ/kg
v2 = 0.0208435837 m3/kg
State 3:
h3 = h4 = hf @ 40˚C = 256.54 kJ/kg
1 𝑘𝑊
𝑊𝑐 120 𝑊𝑎𝑡𝑡𝑠 𝑥
ṁ=ℎ = kJ
1000 𝑊
kJ = 0.00355783977 kg/s
2 − ℎ1 426.0083317 −392.28
kg kg

Properties of R-134a @ -10˚C, 207.1 kPa (peace software)

ρ = density = 1327.340975 kg/m3
cp = specific heat = 1.3154645 kJ/kg – K
k = thermal conductivity = 98.10284x10-3 W/m-K
μ = dynamic viscosity = 278.1804x10-6 Pa.s
0.09921 𝑥 0.00355783977
(1327.340975)( 𝜋 2 )(10.92𝑥10−3 )
𝜌𝑉𝐷 (10.92𝑥10−3 )
Re = Reynold’s number = = 4
= 196374.5891
𝜇 278.1804x10−6

𝐶𝑝 𝜇 (1315.4645)(278.1804x10−6 )
Pr = Prandlt Number = = = 3.73
𝑘 98.10284x10−3

Nu = Nusselt Number = (0.023) (Re0.8)(Pr0.4) = (0.023)(196374.5890.8)(3.730.4)

= 668.1586441 W/m2-K
(𝑁𝑢)(𝑘) (668.1586441)(98.10284x10−3 )
ho = = = 6002.587963 W/m2-K
𝐷 10.92𝑥10−3

The conductivity of copper is 390 W/m-K

(0.0127−0.01092)
(𝑥)(𝐴𝑜 ) = 12.7
2
( 12.7+10.92 ) = 2.624x10-6 m2 – K/W
(𝑘)(𝐴𝑚 ) 390
2
2
hi = 150 W/m -K (for brine solution heat transfer coefficient)
 1 1 (𝑥)(𝐴𝑜 ) 𝐴𝑜
=ℎ + +ℎ
𝑈𝑜 𝑜 (𝑘)(𝐴𝑚 ) 𝑖 𝑥 𝐴𝑖
𝜋 2
1 1 −6
m2 − K (4 (0.0127) ) 1
= + 2.624x10 + 𝜋 ( ) = 2.4235𝑥10−3
𝑈𝑜 6002.587963 W/m2 − K W (4 (0.01092)2 ) 600

1 −1 𝑊
Uo = (𝑈 ) = 412.623868 𝑚2 −𝐾
𝑜

Back Pressure, psig @ 15˚F brine = 20 psig

Back pressure = 20 psig + 14.7 = 34.7 psia
Tsat @ 34.7 psia = 21.83˚F = -5.648˚C
(−6.67℃−(−5.648℃))−(−9.44−(−5.648))
LMTD = (−6.67℃−(−5.648℃))
= -2.11˚C
ln( )
(−9.44−(−5.648))

𝑄𝑒 (0.00355783977)(392.28− 256.54)(1000)
Ao = 𝑈 = = 0.5546990589 𝑚2
𝑜 𝐿𝑀𝑇𝐷 (412.623868)(2.11)
𝐴𝑜 0.5546990589
L= = 11 = 2.527790899 𝑚
𝑛𝜋𝐷 ( )(𝜋)(12.7𝑥10−3 )
2

Therefore, the length of the copper tube for the evaporator is 2.53m with OD = 12.70mm and
ID = 10.92mm (Table 7.1, Refrigeration and Air-Conditioning by Stoecker and Jones, p. 135)

Condenser Design
KJ
Condenser h fg  163.28
kg

kg
ρ= density = 1146.8462
m3

KJ
C p  SpecificHe at  1.467694
kg  K
W
k  ThermalConductivity  75.70666 x10 3
mK

µ = Dynamic Viscosity  162.768x10 -6 Pa  s

n = Number of Tubes per Pass = 11

Condensing Coefficient = hCond

 
1
 9.811146.84622 163,280 75.70666 x10 3  4
hCond  0.725 
 162.768 x10 6 5110.008 
W
hCond  1370.364929 2
m K
 
xAo  (0.00953  0.008) / 2  9.53 

  
kAm  390  8  9.53 
 2 
xAo
 2.13273948 x10 6
kAm

W
hi  150
m2k
1 1 xA A
  o  o
U o ho kAm hi Ai
U o  7.297326275 x10  4  2.301351929 x10 6  9.460510417 x10 3
U o  98.11092904

 
 
LMTD   40  26   40  31 
  40  26   
 ln   
  40  31  
LMTD  11.31649923

QCondenser  ṁ (h2  h3 )

kg KJ KJ
QCondenser  0.00355783977 (426.0083317 -256.54 )
s kg kg

QCondenser  0.6029411703 KW
 Qcondenser
Ao 
U o LMTD 
0.6029411703 KW(1000)
Ao 
(98.11092904)(11.31649923)
Ao  0.5430570463m 2

Ao
L
nD
0.5430570463m 2
L
(11)( )(0.00953m)
L  1.648959521m

Therefore, the length of the copper tube for the condenser is 1.65 m, with OD = 9.53 mm and ID = 8mm
(Table 7.1, Refrigeration and Air Conditioning by Stoecker & Jones, p 135)

Expansion Device Design

EXPANSION DEVICE (R-134a)

ID = 1.63 mm
40°C to -10°C
ṁ = 0.00355783977 kg/s

Conditions at entrance to capillary tube (sat. liquid at 40°C with x=0)

P1 = 1017 kPa v1 = vf = 0.000873 m3/kg
h1 = hf = 256.54 kJ/kg μ = 162.768x10-6 Pa•s

ṁ 0.00355783977 kg/s
= 𝜋 = 1704.987876 kg/s•m2
A (0.001632 )
4

ṁ𝑣
V1 = = (1704.987876 kg/s•m2)(0.000873 m3/kg) = 1.488454416 m/s
A

ρVD (1146.8462kg/m3 )(1.488454416 m/s)(0.00163m)

Re = μ
= 162.768x10−6 Pa•s
=17094.61389

0.33 0.33
f1 = R0.25 = 17094.613890.25
= 0.02886018535
e
Conditions at point 2 (T2 = -10°C)
P2 = 201.7 kPa hf2 = 186.72 kJ/kg hg2 = 392.28 kJ/kg
3 3
vf2 = 0.000755 m /kg vg2 = 0.09921 m /kg
μf = 298.9x10-6 Pa•s μg = 10.59x10-6 Pa•s

ṁ
a = (vg2 - vf2)2 ( A )2 (0.5) =(0.09921 m3/kg - 0.000755 m3/kg)2 (1704.987876 kg/s•m2)2 (0.5)

a = 14089.25883

ṁ
b = (1000)( hg2- hf2) + vf2 (vg2- vf2) ( A ) = (1000)( 392.28 - 186.72 ) + 0.000755 (0.09921 - 0.000755)

(1704.987876)
b = 205560.1267

ṁ (V1 )2
c = (1000)( hf2- hf1)+ ( )2((0.5)( vf2)2) -
A 2

= (1000)( 186.72 kJ/kg - 256.54 kJ/kg)+ (1704.987876 kg/s•m2)2((0.5)( 0.000755 m3/kg)2)

(1.488454416 m/s)2
- 2

c = -69820.29016

−𝑏 ± √(b)2 −4(a)(𝑐)
x=
2(a)

−205560.1267 ± √(205560.1267)2 −4(14089.25883)(−69820.29016)

= 2(14089.25883)

x= 0.08442613742

h2= (hf2) (1-x) + (hg2)( x)

= (186.72 kJ/kg) (1-0.08442613742) + (392.28 kJ/kg) (0.08442613742)
h2= 204.0746368 kJ/kg

v2 = (vf2) (1-x) + (vg2) (x)

= (0.000755 m3/kg) (1-0.08442613742) + (0.09921 m3/kg) (0.08442613742)
v2 =9.06717536 x10-3
μ2 = 278.1804x10-6

ṁ 𝑣2
V2 = A
= (1704.987876 kg/s•m2)( 9.06717536 x10-3m3/kg) = 15.45942406 m/s

ρVD (1327.340935kg/m3 )(15.45942406 m/s)(0.00163m)

Re = μ
= 278.1804x10−6Pa•s
=120236.6558
 0.33 0.33
f2 = = = 0.01772167296
R0.25
e 120236.65580.25

𝑓1 + 𝑓2 0.02886018535+0.01772167296
fm = 2
= 2
= 0.02329092915
m m
𝑉1 + 𝑉2 1.488454416 s + 15.45942406 𝑠
𝑈= = = 8.473939238 m/s
2 2

∆𝐿 𝑉1 2
𝐴(𝑃1 − 𝑃2 ) − 𝑓 (𝐴) = ṁ(𝑉2 − 𝑉1 )
𝐷 2𝑣1

∆𝐿1 (1.488454416)2
2.08672438 × 10−6 (1017 − 201.7) − (0.02886018534) (2.08672438 × 10−6 )
0.00163 2(0.000873)
= 0.00355783977(15.45942406 − 1.488454416)

∆𝐿1 = 1.023946332 𝑚

∆𝐿2 (15.45942406)2
2.08672438 × 10−6 (1017 − 201.7) − (0.01772167296) (2.08672438 × 10−6 )
0.00163 2(0.000755)
= 0.00355783977(15.45942406 − 1.488454416)

∆𝐿2 = 0.16 𝑚

∆𝐿𝑡 = ∆𝐿1 + ∆𝐿2 = 1.024 + 0.16 = 1.1839 𝑚

Therefore, the length of the expansion device is 1.1839m with an ID = 1.63mm.