TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

MANILA CAMPUS
DEPARTMENT OF MECHANICAL ENGINEERING

ICE PLANT AND COLD STORAGE DESIGN

(120 TONS OF ICE)

Submitted By:
Lucidos, Marjohn E.

Submitted To:
Engr. Jorge B. Yasay
FREEZING TANK
Design Conditions:
Production Rate = 120 TOI per Day
Ice Temperature = -7.5°C = 18.5°F
Brine Temperature = -9.44°C = 15°F
Raw Water Temperature = 26°C
Freezing Time = 48 Hrs.
Standard Ice Can Dimension = 11” X 22” X 44”
Weight of Ice per Can = 300 lbs.

Number of Ice Can Require:

Freezing Time
No. of Ice Can: N=Production Rate x
Wt . Of ICE BLOCK PER CAN

N=
(120TONS OF ICE) ( 2,000lb
TON )
( 48 hrs)

300 lb x 24 hrs
N = 1600 Cans
N (adjusted) = 1610 Cans

Volume of the Freezing Tank

Volume of Brine
TOI 120
TR= = =196.72 TOR
0.61 0.61

60 ft 3
 V BRINE =TOR [ ]
1 TOR

60 ft 3
V BRINE =196.72 TOR[ ]
1TOR

V BRINE =11803.2 ft 3

Volume of Ice Cans

h
 V IC= [B1 + B2 +4 M ] B1=11 x 22=242¿ 2
6
 B2=9 x 20=180 ¿2
B 1+ B2 242+180 2
M= = =211 ¿
2 2

44
V IC= [242+180+ 4 ( 211 ) ]
6

1 ft 3
V IC=9284 ¿ 3

123 ¿3( )
V IC=5.3727 ft 3 x 1610

V IC=8650.047 ft 3

Total Volume of Freezing Tank

V T =V IC + V BRINE

V T =8650.047 ft 3 + 11803.2 ft 3

V T =20453.247 ft 3

Dimensions of the Freezing Tank

46 x 35
1610 cans
From: L= 2C + (N-1) Ci + Nl + A
Where: C = Clearance between Walls
Ci = Clearance between Cans
N = No. of Cans
l = Length of the Side of the Can
A = Additional Space for Agitator
For L1:
L1= 2(10) + (35-1) (4) + (35) (22) +20
L1=946 in = 78.83 ft.
For L2:
 L2= 2(10) + (46-1) (4) + (46) (11)
L2=706 in = 58.83 ft.
For H:
VTOTAL= L1L2H

V TOTAL 20453.247 ft 3
H= =
L1 L2 78.83 ft . x 58.83 ft .
H=4.4103 ft ¿)
H=52.9236∈¿
Height of Freezing Tank > Height of Ice Can
52.9236∈¿ 44 ∈¿
DESIGN IS OKAY!

Insulations and Material Specifications to be used in the Freezing Tank

Thickness K H
Material
In Mm W/M-K W/M2-K
Steel Plate 0.25 6.35 14.3 -- Side
Cork Board 15 381 0.043  -- Side
Concrete 6 152.4 0.72  -- Side
Wood ; Oak 4 101.6 0.16  -- Top
Still Air -- -- --  9.37  
Brine Solution -- --  --  300  
Steel Plate 0.25 6.35 14.3 --  Bottom
Cork Board 5 127 0.043  -- Bottom
Concrete 5 127 0.72  -- Bottom

 Outside Dimension of the Freezing tank (insulations included)

Length
L = L1 +L (insulations)
L = 946 + 2(0.25 + 15 + 6); in
L = 988.5 in = 82.375 ft. = 25.1143 m

Width
W = L2 + L (insulations)
W = 706 + 2(0.25+15+6); in
W = 748.5 in. = 62.375 ft. = 19.0168 m

Height
 H = H1 + Top Cover + Insulation
H = 53 + 4 + 7 + 6
H = 70 in. = 5.8333 ft. = 1.7784 m

Plant Capacity (Kw or Tons of Refrigeration)

120 TONS 907.03 kg 1 DAY 1 hr
m H O =m ice= x x x
2
DAY 1 TON 24 hrs 3600 s
kg
m H O =¿1.2598
2
s

Q p=Q 1+Q 2 +Q 3

For Q1 = m H O Cp(t H O−t f )

2 2

kg kJ
Q1= (1.2598 )( 4.187 )(26-0)° C
s kg−° C
Q1=137.144 kW

For Q2 = ( mice ) ( hf ice

)
kJ
Q2= (1.2598 kg /s)(335 )
kg
Q 2=422.033 kW

For Q3 =( mH O )( C p ) ( t f −t ice )
2 ice

kg kJ
Q3= (1.2598 )(2.0935 )(0-(-7.5))° C
s kg−° C
Q 3=19.78 kW

For Qp= Q1 + Q2 + Q3
Q p=137.144 kW + 422.033 kW +19.78 kW
Q p=578.957 kW
1TOR
Q p=578.957 kW x
3.517 kW
Q p=164.617 TOR

TOI 120TOI
≥ TOR ; ≥ Qp
0.61 0.61
For Q1 = Q2 (Considering the width and height)
A ∆t
Q 1=
1 X 1 X2 X 3 1
+ + + +
ho k 1 k 2 k 3 h1

1.7784 (19.0168 ) (33+9.44)

Q 1=
1 6.35 x 10−3 381 x 10−3 152.4 x 10−3 1
+ + + +
9.37 14.3 0.043 0.72 300

Q1=156.31 W

Q1 = Q2 = 0.15631 KW

For Q3 = Q4 (Considering the length and height)

A∆t
Q 3=
1 X1 X2 X 3 1
+ + + +
ho k 1 k 2 k 3 h1

1.7784 ( 25.1143 )(33+9.44)

Q 3=
1 6.35 x 10−3 381 x 10−3 152.4 x 10−3 1
+ + + +
9.37 14.3 0.043 0.72 300
Q 3=206.42 W

Q3 = Q4 = 0.20642 KW

For Q5 (Considering the top cover portion)

A ∆t
Q 5=
1 X1 1
+ +
ho k 1 h1

19.0168 ( 25.1143 ) (33+ 9.44)

Q 5=
1 101.6 x 10−3 1
+ +
9.37 0.16 300
Q5=27204.73 W

Q5 = 27.20473 KW

Total Qloss= Qst(from tanks material)

 Qst= (0.15631 + 0.15631 + 0.20642 + 0.20642 + 27.20473)
Qst = 27.93019 KW

Brine Agitator Capacity and Power:

Production Rate = 120 TOI DAILY
Q p=164.617 Tons of Brine Agitator

65 gpm
Brine Agitator Capacity = ( 164.617TOR)
TOR
Brine Agitator Capacity = 10700.11 gpm
1 hp
Brine Agitator Power= ¿
TONS )
17.5
DAY
Brine Agitator Power=6.86 hp
 Use 7 Hp Motor for Each Brine Agitator.

Blower Power:
For Low Pressure Air Agitator, Approximately 0.5 cfm of Free Air is supplied at about 2 Psi per
300 lbs. per can.

0.5 cfm ( ft 3
V air = 1610 CANS =805
)
CAN min

3
lb ¿ 2 (805 ft )
Air Power=
( )2( ¿2
144 )
ft 2 min
= 7.03 hp
ft −lb
33,000
hp−min
Assuming Blower Efficiency = 80%
Blower Efficiency = Air Power / BPH
BPH = 7.03 hp. / .80
BPH = 8.79 hp
 Use 9 Hp Driving Motor for Blower of Freezing Tank.
STORAGE CAPACITY:
Product: Brine Meat
Mass Capacity of Storage = 180,000kg
Mass of Meat per Day = 2.08 Kg/S
From Design Data from Meat Storage
Product Temperature = 37.76° C
Freezing Point Temperature = -0.5° C
Recommended Temperature = -0.5° C
C p =¿ 3.14 kJ/kg-K
a

C p =¿ 1.67 kJ/kg-K
b

h f =¿ 228 kJ/kg
i

Q C =[ ( m ) ( C p ) ( ∆ t ) ] + [ ( m ) ( h f
a ice
) ] + [ ( m) ( C p ) ( ∆ t ) ]
b

Q C = [( 2.08 )( 3.14 )( 37.76+.5 ) ]+ [( 2.08 )( 228 ) ] + [ ( 2.08 ) ( 1.67 ) (−0.5+0.5 ) ]

Q C =¿ 724.124 kW
Storage Area :
L = 50 ft.
W = 50 ft.
H = 20 ft.

Thermal Conductivity of Materials Used in Cold Storage Walls

Thickness Thermal Conductivity Thermal Conductance
Materials
M (K) W/M.K (C) W/M2.K
Cork Board 0.0508 0.043 -
Air - - 9.37
Concrete Mortar
0.0508 0.72 -
Or Plaster
Sand Aggre.
- - 7.95
(100mm)
Steel Plate 6.35 X 10-3 14.3 -

Wall Area = L x H = 50 x 20 = 1000 ft2 = 92.96m 2

A∆t
QL =
wall
1 t1 t2 t3 1
+ + + +
Cair k 1 k 2 k 3 C1

92.96(32−(−0.5))
QL =
wall
1 0.0508 0.0508 6.35 x 10−3 1
+ + + +
9.37 0.043 .72 14.3 7.95
Q L =¿2034.609 W
wall

Q L =¿2.034609 kW
wall

Floor and Ceiling

Thickness Thermal Conductivity Thermal Conductance

Materials
M (K) W/M.K (C) W/M2.K
Expanded 0.0508 0.029 -
Polystyrene
Concrete Mortar Or 0.0508 0.72 -
Plaster
 Sand Aggre.(100mm) - - 7.95
Steel Plate 6.35 X 10-3 14.3 -

Floor Area = Ceiling Area = L x W = 50 x 50 = 2500 ft2 = 232.377m 2

232.377(32−(−0.5 ))
QL =
FandC
0.0508 0.0508 1 6.35 x 10−3
+ + +
0.029 .72 7.95 14.3
QL FandC
=¿3875.912 W

QL FandC
=¿3.875912 kW

Q L=Q L ( 4 ) +Q L (2)
wall fandC

Q L=2.034609 ( 4 ) +3.875912(2)

Q L=15.89026 kW

QT =Qc + QL =724.124+15.89026

Q T =740.01426 kW

Compressor:
Q P , Tons of Refrigeration = 578.957 KW
Q S , Tons of Refrigeration = 740.01426 KW
Refrigerant = Ammonia
Storage Evaporating Temperature = -6° C
Ice Evaporating Temperature = -10° C
Condenser Temperature = 43° C

From Table 1 Ammonia:

kJ
h1 =hg @−10 ° C=1450.22
kg
kJ
h3 =h g @−6 ° C=1455
kg
 kJ
h5 =h6=hf @ 43 ° C=405.416
kg
kJ
h7 =h8=hf @−6 ° C=172.371
kg
From Chart:
kJ
h2 =1460
kg
kJ
h 4=1691
kg

Total Work of Compressor

W CT =W C 1+W C 2

W C 1=m1 ( h2 +h1 )

Qp
m 1=
h1−h 8
578.957 kW
m 1=
kJ kJ
1450.22 −172.371
kg kg
kg
m 1=0.4531
s
kg kJ kJ
W C 1=0.4531
s (
1460 −1450.22
kg kg )
W C 1=¿ 4.4313 kW

W C 2=m 4 ( h4 −h3 )
m 4 =m 3+ m2
QS
m 3=
h3−h6
740.01426 kW
m 3=
kJ kJ
1455 −405.416
kg kg
kg
m 3=0.7051
s
m 2=?

Energy Balance
E¿ =EOUT
 m 2 h6 +m 1 h2 =m 1 h7 +m2 h3

m1( h7−h2)
m 2=
h6−h 3
kg kJ kJ
0.4531 (172.371 −1460 )
s kg kg
m 2=
kJ kJ
405.416 −1455
kg kg
kg
m 2=0.5559
s
kg kg
m 4 =0.7051 +0.5559
s s
kg
m 4 =1.261
s
kg kJ kJ
W C 2=1.261
s(1691 −1455
kg kg )
W C 2=297.596 kW

W CT =4.4313+297.596

W CT =302.0273 kW

302.0273(1 hp)
W CT = =404.86 hp
0.746 kW
404.86 hp
Actual Power For EachCompressor =
2
Motor Hp=202.43∨203 Hp

Condenser:
Condenser Temperature = 40° C
Entering Water Temperature = 28° C
Leaving Water Temperature = 33° C
 kg
m 4 =1.261
s

Heat Rejected By Condenser; Q R

Q R=m4 ( h4 −h5 )
kg kJ kJ
Q R=1.261 (1691 −405.416 )
s kg kg
Q R=1621.1214 kW

Mass Flow Rate of Cooling Water; M W

Q R=m w C p ∆ t
w

kJ
(
1621.1214 kW =m w 4.187
kg−° C )
( 33−28 ) ° C

kg
m w =77.44
s

Condenser Liquid Receiver:

Volume of Liquid Receiver; V LR
V LR=(TONS OF REF .)¿)

gal m3
V LR=(164.617 TOR)(0.50 )(0.003785 )
TON OF REF . gal

V LR=0.3115 m3

Diameter and Length of Liquid Receiver; D AND L

π L
V LR=( ) ( D )2 (L) ; ASSUME =3.5
4 D
π
0.3115 m3=( ) ( D )2 (3.5 D)
4
D= 0.4839 m AND L= 1.6937 m

Evaporator:
Ice Evaporator Temperature = -12° C
 Brine Temperature = -9.44°C

Required Surface Area of Evaporator; A Ie

Q P=U O A Ie (Lmtd)
QP
A Ie =
U O (Lmtd)
578.957 KW
A Ie =
Kw
.596 2 (−9.44+12)
M

A Ie =379.4548 M 2

HOISTING WINCH/OVERHEAD TRAVELLING CRANE:

5 Ice Cans / Lift
Weight of Ice + Can = 315 lbs
m
V F , Hoist Velocity = 0.15
S
Height of Lift = 2m
T, Time of Lift = 10 sec

From Design of Machine Elements by Faires

Design Factor, N=7 for Small Hoist
Min. Drum Diameter, DS =30 d R

Wire Ropes, Regular Lay 6x19 IPS

Weight of Rope, W R=1.6 D R

Length of Rope, LR =5 m

Total Load, W
W = 315(5) = 1575 Lbs
Ft
(
W R=1.6 D R2 ( LR ) =1.6 D R 2 ( 5 m ) 3.28
M )
= 26.24 D R2
 F=Ma
(W R + W )( A )
F T −W R −W =
G
M
(0.15 −0)
(V F −V O ) S
A= =
T 10 s
M Ft
A=0.015
S 2 (
3.28
M )
Ft
A=0.0492
S2
Ft =?
Ft
(26.24 D R2 +2,075 Lbs )( 0.0492 )
S2
F T −26.24 D R2−1575 Lbs=
Ft
32.174
S2

F T =26.28 D R2 +1577.41

Static Approach
A M (DW )( EW )
F B=
DS

Where:
Fb – Equivalent Bending Load

Am – Area of Metal = 0.4 D R2

Dw – Diameter Of Wire = 0.067 Dr

Ew – Modulus Of Elasticity = 3 x 107 Psi
Ds – Drum of Sheave Diameter = 30 Dr

( 0.4 D R 2)(0.067 D R )(3 x 107 )

F B=
30 D R

F B=26,800 D R2

F U −F B
N=
FT

Where:
 N = 7 (Design Factor)
Fu – Breaking Strength = 42 Dr2
Ft - Rope Tensile Force

lb
42 D r2 (2,000 )−26,800 Dr2
ton
7=
Ft

F t=8,171.43 D r 2

Rope Diameter, D R

26.28 D R 2+1577.41=8,171.43 D R2

8,145.15 DR 2=1577.41
1
D R=0.50∈¿ ∈.
2

Hoist Power
D S =30 D R =30 ( 0.5 )=15∈.

Π ( D S)( N S )
V=
12
Π (15)(N S)
( 0.15 ) (3.28)=
12(60)
N S =7.517 Rpm

DS
Hoist Power=2 π ( N S )( FT )( )
2

F T =8,171.43(0.5)2=2,042.86 Lbs

Hoist Power=2 π (7.517 Rpm)(2,042.86 Lbs) ¿ ¿

Hoist Power = 1.827 Hp
Therefore, Use 2hp Hoist Motor Power.
COOLING TOWER:
Temperature of Entering Water = 33° C
Temperature of Leaving Water = 28° C
Condition of Entering Air = 26° C, 65% Rh
Condition of Leaving Air = 32° C, 98% Rh
Temperature of Make-Up Water = 27° C
Barometric Pressure = 101.325 kpa

Amount Of Cooling Water , M W

M W =( M W )Condenser
Kg
M W =77.44
S
Air Properties: Using Psychometric Chart
@ 26° C, 65% Rh
Kj
H 3=61 ; Hr3=0.0136
Kg
@ 32° C, 98% Rh
Kj
H 4 =108 ; Hr 4 =0.0297
Kg

Mass of Air, M A
Heat Balance on the Cooling Water,
M 1=M 2=M W And M 3=M 4 =M A

( M ¿¿ W ) ( C P ) ( T 1−T 2 )+ ( M W )( C P ) ( T 5 ) =( M A ) ( H 4 −H 3 ) ¿
W 5 W
 [( M ¿¿ W ) ( C P ) ( T 1 −T 2 ) ]
M W =[ ( M A ) ( H 4 −H 3 ) ]−
W
¿
5
( C P ) (T 5)
W

MW =
[ ( M A ) ( 108−61 ) ]−[(77.44) ( 4.187 ) ( 33−28 ) ]
5
( 4.187 )( 27+ 273 )
M W =0.0374 m A −1.2907
5

Mass Balance by Water,

M W + M W + M A Hr3=M W + M A Hr 4
5 1 2

M W =M A ( Hr 4 −Hr3 ) =M A (0.0297−0.0136)
5

M W =0.0161 M A
5

Therefore;
0.0374 m A −1.2907=0.0161 M A

Kg
M A =60.5962 Of Water
S

Mass of Make-Up Water, M W

M W =0.0161( 60.5962)
5

Kg
M W =0.9756 Of Water
5
S

Volume Flow Rate of Air, V A

@26 ° C , 65 % Rh , P Sat =3.363 kpa

PV =Rh ( P Sat )=0.65 ( 3.363 kpa ) =2.186 kpa

Pv = mrt
Kg Kj
V A=
M A RA T A
=
60.5962
S (
0.287085
Kg−K )
( 26+273 ) K

PT −PV Kn
(101.325−2.186) 2
m

M3
V A =52.4666 Of Air
S
 28+33 Kg
T= =30.5 ° C ; D W =996.283 3
2 m
Kg
(77.44 )(1Gal )(60 s)
M S
VW= W =
DW Kg
( 996.283 3
)(0.003785 m 3)(1 min)
m
V W =1232.1625Gpm

1232.1625 Gpm M2
Cooling Tower Area= X
3
Gpm ( 3.28)2 Ft 2
Ft 2

Cooling Tower Area=38.1768 m2

Using Cooling Tower Length of 5m,

Area 38.1768 m 2
Width= = =7.6354 m
Length 5m

Number of Nozzles Required

Using 10 gpm Capacity per Nozzle
VW 1232.1625 Gpm
No .Of Nozzles= = =123.2163 Nozzles
Capacity 10
Nozzle
Say: 124 Nozzles
Nozzle Arrangement
No. of Rows = 4 Rows
No. of Nozzle/Row = 31 Nozzles/Row

FAN:
Wheel Diameter = 60 In. = 5ft.
Static Pressure = 15 In. WATER
Total Head
H T =H V
A A
 Ρ V2
HT = +
A
W 2g

m3
52.4666
Q S m
Velocity Of Air= = 2
=28.7475
A Π 2 m S
( ) ( 5 ft ) ( 2 2
)
4 3.28 Ft

m 2
( 28.7475
)
V2 S
= =41.3265 m of air
2g m
2(9.81 2 )
S
Ft M 1000 kg
(15∈. H 2 O)( )( )( 3 )
Ρ 12∈. 3.28 Ft M H 2 O
= =317.58 m
W Kg
1.2 3
M
H T =358.91 mof air
A

Fan Power
Kg N
H T (M A ) 358.91 M (60.5962 S )(9.81 Kg )
Fan Power= A
= =213.3536 Kw
FC W
1,000
Kw
1 Hp
Fan Power=213.3536 Kw X
0.746 kw
FAN POWER=285.9968 hp∨286 hp

DAY TANK:
Suction Pressure = 60kpa
Allowance for Fittings and Friction Loss = 5m

Elevation of Tank
Kn
)(1000 N )(1kg )
(60
M2
Elevation= +5 m
Kg
(1000 3 )(1 kn)(9.81 N)
M
 Elevation=11.12 M

Volume Of Day Tank ,V T

Vt=Make−Up Water+ Raw Water For Ice Production+Water Consumption Of Employees

For Ice Production:

TONS 2,000 Lb 1 kg m3 m3
V 1=120 X X X =108.8435
Day TON 2.205 Lb 1,000 kg Day

For Make-Up Water:

Kg m3 3,600 s 24 Hrs . m3
V 2=0.9756 X X X =84.2918
S 1,000 kg 1 hr 1 Day Day

For Employees Consumption and Other Uses:

m3
V 3=20
Day
V T =V 1 +V 2+ V 3

m3
V T =(108.8435+ 84.2918+ 20)
Day

m3
V T =213.1353
day

Dimensions of Tank
Use H = 8m
Π
V T= ( D )2 ( H )
4

m 3 Π ( )2 (
213.1353 = D 8 m)
Day 4
D = 5.8242 m

Thickness of Day Tank’s Cylinder, T

 P( D)
t=
2(S ¿¿ S ) ( E ) −P¿

Welding Efficiency, E=0.80

Kg 9.81 N Kn
P=D ( H )=1000 X 8 mx X =78.48 Kpa
M 3
Kg 1000 N

Su = For Mild Steel

Su=50,000 Psi ( 6.8948 mpa

1 Psi )
=344.74 Mpa

Fm = 0.92 ; Fs = 0.25
SS =SU (F M )(F S )

SS =344.74 ( 0.92 ) ( 0.25 )=79.29 Mpa

Kn 1000 mm
78.48 (5.8242 m)( )
M 2
1m
t=
Kn Kn
( )
2 79.29 X 103 2 ( 0.80 )−78.48 2
M M

t=¿3.6052 mm
USE, t = ½ In.

Refrigerant: Ammonia
43oC

-6oC

-10oC
STANDARD ICE CAN DIMENSION
11”x22”x44”
FREEZING TANKS

FLOOR PLAN
1. Cooling Tower 9. Main Office
2. Day Tank 10. Engineering Office
3. Condenser 11. Thaw Tank
4. Compressor 12. Dump and Refill
5. Liquid Receiver 13. Ice Storage
6. Freezing Tank 14. Control Board
7. Cold Storage 15. Loading Platform
8. Tool Room