A.

Freeze-drier (T-3)

1. Specification sheet

SPECIFICATION SHEET
IDENTIFICATION
Name of Equipment Freeze-drier
Equipment Code T-3
Number of Units 1
Function To turn Purified Collagen Hydrolysate
Crystals into Collagen Hydrolysate
Powder
Operation Batch
Method Bulk Method (feed is placed on shelf
trays)
Material Handled Water-Dialysed Collagen, Water
SHELF DESIGN
Shelf Temperature -20ºC to 70ºC
Total Shelf Area 144 m2
Number of Shelves 16
Shelf Size 1219mm x 1524mm
Shelf Depth 230 mm
Shelves Spacing 120 mm
Shelves Thickness 4.00 mm
Shelf Cooling Rate (-20ºC to +40ºC) <60 minutes
Material of Construction AISI Stainless Steel 316 L
COMPRESSOR: REFRIGERATION SYSTEM
Refrigerant R-507
Compressor Type Rotary
Compressor Power Requirement for 125 HP
Condenser Refrigeration
Compression Ratio 15:1
UNIT DIMENSIONS
Length 7150 mm
Width 2790 mm
Height 2470 mm

197
2. Diagram for freeze-drier

Figure 6.1 Sample freeze-drier design

198
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3. Summary of assumptions

1. The inlet and outlet temperature of water in tube side of heat

exchanger is 15ºC and 25ºC.

2. The tube of the heat exchanger used is ¾ inch schedule 40 carbon steel

pipe, square pitch for the condenser and ¾ inch schedule 40 stainless

steel pipe, square pitch for the evaporator.

3. The length of the tube in the heat exchanger is 2m long.

4. UNS G10200 Carbon Steel will be the material of construction to be

used for the (condenser) heat exchangers and AIS Stainless Steel 316L

for the (evaporator) heat exchangers..

5. Condenser configuration is external condenser

-Selecting a Freeze Dryer, Pharmtech.com Advancing Development

and Manufacturing

6. The initial pressure to be considered in the compressor computations is

the ambient pressure.

7. The total drying time (sublimation and desorption) is assumed 180

minutes because the process heats the frozen feed from -10⁰C to -

20⁰C. The time utilized by process condenser is also assumed 180

minutes.

8. The basis for shelf design is CUDRON: Freeze Dry

- Shelf size: 1219 mm x 1524 mm

- Shelf depth: 230 mm

- Shelves spacing: 120 mm

200
 - Shelves thickness: 4 mm

9. Freeze dryer have 2 columns inside and it is composed of 2 shelves per

column.

10. Adapted from GEA SmartLYOTM, the material of construction for

shelf is AISI Stainless Steel 316L.

11. The compressor efficiency is assumed 70%.

12. Refrigerant used for Refrigeration System is R-507.

13. The evaporator temperature is set 5ºC lower than the process

condenser temperature.

14. The refrigeration system’s condenser temperature is 10ºC higher than

the ambient temperature. The ambient temperature is assumed to be

27ºC.

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 4. Based from the “Development of the freeze drying process—

application to the collagen hydrolysate”, a drying rate equation is

given by:

dW −1 −0.85
= W dt
dt 77.5

Where,

dW kg H 2 O
=
dt kg collagen hydrolysate ∙ hr

W=
mass water kg
mass collagen h ydrolysate kg( )
t=time(hrs )

Time required for drying:

t 0.087
dW
∫ dt =− ∫ 77.5
W
−0.85
0 0.25

T=2.766 hours = 166 mins

Using Q=UA ∆T

202
Where Q= -79,258.40 kJ

J
U =3.7 2
m ∙ s∙K

∆ T =T ¿ −T out

∆ T =10−25

∆ T =−15 K

Q
AT =
U ∆T

−79,258.40 kJ 1000 J
x
60 s 1 kJ
166 mins x
1 min
AT =
J
3.7 2 x−15 K
m ∙s ∙K

AT =143.38 m2

From brochure Cuddon Freeze Dry FD 1500,

AT
A per shelf =
16
143.38
A per shelf =
16

2
A per shelf =8.96 m

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 E. Design computation

Based on Carlo Vecchio’s Freeze-drying Process Principle and Practice

Study, a freeze dryer equipment consists of: a chamber containing shelves through

which a heat transfer fluid can be circulated, a condenser for trapping water

vapor, and refrigeration system for cooling the condenser.

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 F. Refrigeration system

A B

Process Condenser Refrigeration System Initial Data

Q based on Chapter 5 201,280.42 kJ
Density of R507 at -40ºC kg
19.70 3
m C
Ratio of Specific Heats of R507 1.114
Process Condenser Temperature -35⁰C
D
Evaporator Temperature -30⁰C
Condenser Temperature 37⁰C

Based on ASHRAE Refrigeration Handbook 2010, the evaporator

temperature must be 5ºC lower than the process condenser temperature. Thus, the

condenser temperature should be 10 ⁰C higher than the ambient temperature. The

ambient temperature is assumed 27 ⁰C making 37 ⁰C as condenser temperature.

Thus, consider refrigerant used for Refrigeration System is R-507 as the

most recommended for the application of medium and low temperature

commercial and industrial refrigeration

Mass flow rate of refrigerant:

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 Q Freezing
mR −507 =
( H ¿ ¿ A−H D )¿

where:

mR −507 =Mass Flow Rate of Refrigerant

Q Freezing=Heat Transfer of FreezingH A =Enthalpy of Vapor State

H D=Enthalpy of Liquid State

State A: Saturated Vapor

T A=−30ᵒC

P A =0.21234 MPa

kJ
H A =34.1772
mol

kJ
S A =0.1692
mol−K

State B: Superheated Vapor

kJ
S A =SB =0.1692
mol K

PB =1.56 MPa

Temperature Pressure, MPa Enthalpy, kJ/mol Entropy, kK/mol K

300 1 37.686 0.16087
400 1 37.983 0.19047
300 5 23.498 0.11052
400 5 44.385 0.17014

By extrapolation:

At T =55.15℃ , P=1.56 MPa

206
 H = 35.86 kJ/mol

State C: Saturated Liquid

T C =37 ᵒC

kJ
H C =25.25
mol

State D: Mixture of Saturated Liquid and Vapor

kJ
H C =H D =25.25
mol

25.185−15.8185
x=
34.1772−15.8185

x=0.51

Mass flow rate of refrigerant:

Assume that the total drying time is 180 minutes

201,280.42 KJ
mR −507 =
kJ 1 kmol 1000 mol 60 sec
( 34.1772−25.185 ) x x x 180 mins x
mol 98.9 kg 1 kmol 1 min

kg
mR −507 =0.205
sec

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 G. For heating system, based on Carlo Vecchio’s Freeze-drying

Process Principle and Practice Study, heat is applied to the

shelves to provide energy required for sublimation of ice.

Based from the energy balance, Qsublimation =540,808.10 kJ

Theoretical power of compressor:

( )( )
k−1
k P2 k
W Theo =P1 Q 1 [ −1]
k −1 P1

where:

W Theo =Theoretical Compressor Power Requirement

Q1=Volumetric Flow Rate of Refrigerant

P1=Compressor Initial Pressure

P2=Compressor Final Pressure

k =Ratio of Specific Heats of Refrigerant

Volumetric flow rate of refrigerant:

kg 1lb
0.205
x 3
m sec 0.45359 kg ft
Q= = =8.87
ρ kg 1 lb 0.02831685m 3 sec
19.70 3 x x
m 0.45359 kg 1f t 3

Theoretical compression power:

( )( )
lb f144 i n
2
ft 1.114
3
226.3 psia
1.114−1
1 HP ∙ sec
W Theo =(2.2 2 x )(8.87 ) [ 1.114
−1]( )
in ft
2
sec 1.114−1 2.2 psia 550 ft ∙ lb f

W Theo =80.21 HP

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Actual compressor power requirement:

W Theo 80.21 HP
W Actual = =
n eff .70

P Actual =114.59 HP ≈ 85.45 kW

Horsepowera

1/20, 1/12, 1/8, 1/6, 1/4, 1/3, 1/2, 3/4, 1/2, 11-1/2, 2, 3, 5, 7-1/2, 10, 15, 20, 25,
30, 40, 50,60, 75, 100, 125, 150, 200, 250, 300, 350, 400, 450, 500, 600,
700, 800, 900, 1000, 1250, 1500, 1750, 2000, 2250, 2500, 3000, 3500,
4000, 4500, 5000and up to 30,000

Source: Chemical Process Engineering: Design and Economics by Silla

Since the computed actual power requirement is 114.59 HP, the

standard compressor size to be used is 150 HP based on the table

shown above.

Compression ratio requirement:

The initial pressure to be considered in this computation is the ambient

pressure.

Final Pressure: Using Thermodynamics Property Table,

T Final =55.15ᵒC

P Final=1.56 MPa

209
 R=P Final : PInitial =1560 KPa :101.325 KPa

R=15:1

Compressor type:

The different compressor types have attributes that make them more

suitable for different applications. The attributes like cooling capacity, efficiency,

reliability, etc. are key selection factors to consider. The Figure below shows the

capacity and application comparisons between different compressor types:

Source: Paul Lin & Victor Avelar’s The Different Types of Cooling

Compressors Study

210
Since the computed actual power requirement is 85.45 kW, the recommended

type of compressor will be used is Reciprocating compressor because it is suited

for refrigeration applications ranging in 70 to 1400 kW based on the figure

above.

For unit dimension of the freeze-drier,

(From Brochure CUDDON Freeze Dry FD 1500)

Length = 7150 mm

Width = 2790 mm

Height = 2470 mm

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