Daga, Kristan O’neal C.

ME 4121L
BSME IV 3174
Activity 1

Design of a Power plant with Cold Storage

I. What is an Ice Plant?

An ice plant is a complete installation for the production and storage of ice, including the
icemaker itself, which is the unit that converts water into ice together with the associated
refrigeration machinery, harvesting and storage equipment, and the building. Ice plants are
classified by the type of ice they produce and may be further subdivided into those that make dry
or wet ice.

II. Main Components of an Ice Plant

1. COMPRESSOR
 
The refrigerant compressor functions according to the counter flow principle with single-
stage compression; depending on the Plant's size, the compressors are arranged in reciprocating
or screw compressors. The compressor's drive is accomplished by pulleys or slip ring rotor
motors, depending again on the Plant's size and the local conditions. Monitoring and safety
equipment is arranged directly on the compressor.
 
2. REFRIGERANT FLOW CONTROL DEVICE
-For operation on Freon
It is used as a thermo-expansion or an electronic valve and electromagnetic valve, which
takes command from the electronic thermostat.
-For operation on R-717 (NH3)
It uses a flooded system with a liquid level regulator for safety and an electromechanical
float switch. Electro-valve takes command from the electronic thermostat and the
electromechanical float switch.
 
3. TUBE TYPE EVAPORATOR
 
Tube-type evaporators are used for NH3 or Freon refrigerants as they ensure favorable
overall heat transfer coefficients.
The evaporator comprises several evaporator elements. These elements are connected by
a header at the refrigerant inlet and outlet ends to form one or two evaporator groups. The
evaporator groups are attached to guarantee a uniform liquid refrigerant level in humid
situations. The evaporation temperature is approximately six °C less than the temperature of the
brine to be cooled.
 
4. LIQUID SEPARATOR (for NH3)
The liquid separator is mounted above the evaporator and designed as a vertical or
horizontal tank. It separates the liquid refrigerant particles possibly entrained from the
evaporator. The return of the separated liquid to the evaporator is guaranteed by a line sloping
downward. The injection of the refrigerant proceeding from the refrigerant flow control device is
accomplished via this downward line, too.
 
5. EVAPORATIVE CONDENSER
The heart of the compressor is the galvanized steel element -in which the refrigerant
liquid is circulated-cooled and from hot gas becomes humid. A re-circulating pump maintains a
closed cooling water circuit. In the evaporative condenser, the water is cooled due to the
evaporative cooling effect and reused for liquefying the refrigerant. This achieves lower
condensation pressure with the result of lower electric consumption.
 
6. AIR COOLED CONDENSER (ONLY FOR Freon)
It is used either to reduce water consumption to a small percentage or if there is
insufficient fresh water for the supply of a shell-and-tube condenser.
 
7. WHEELED FRAMES FOR ICE CANS & ICE CANS
The wheeled frame ice cans are metallic frames into which 10 to 22 ice cans can be fitted
each, depending on the size of the Plant. Each frame is equipped with casters on either side &
bocks are provided for the suspension from the crane beam. The ice cans are sheet metal tanks of
rectangular cross-section tapering downward. They are covered with an anti-corrosive coating.
 
8. BRINE TANK
The brine tank contains the brine. Furthermore, it accommodates:
- Tube-type evaporators
- Vertical agitators
- Frames with ice cans
- frame feed mechanics (On request)
 
For protection against refrigeration losses, the tank is provided with a wooden cover or
thermal panels. The walls and the bottom have to be covered by insulation.
 
9. AGITATOR
In the brine tank, there is mounted an agitator of corresponding capacity. It is used for
stirring the brine within the tank. Furthermore, the brine tank has related elements built in for the
agitators. The circulation of the brine by the agitator fosters the cold transfer from the evaporator
to the brine and ice cans.
 
10. ICE CAN DIP THE TANK
The thawing tank is a sheet metal tank. It is designed in such a way that it can
accommodate one ice can frame at a time. For reasons of water economy, stops are provided to
prevent the ice can communicate from submerging. To reduce the thawing time, the water in the
tank is constantly pumped through the heat exchanger by a re-circulating pump, which is heated
by the hot compressed gases. Besides, this tank is provided with a water inlet and outlet ports.
 
11. ICE CAN FILLER
This tank has filler pipes according to the number of ice cans in the ice can frame. When
turning the tank, this tank is filled with water, which flows into the empty ice cans via the filler
pipes. The tank is dimensioned to accommodate just the quantity of water necessary to load one
set of ice can frames. Depending on the building conditions, the ice can filler can be placed on a
bracket mounted to the ceiling or the crane track. Operation is affected manually.
12. ICE BLOCK DUMP TABLE
This is an inclined wooden plate with a flange at the bottom. The ice blocks sliding out of
the ice cans while tipping slip onto the dump table.
 
13. ICE CAN FRAME TIP
As mentioned earlier, the ice can dip tank is provided with the ice can frame tip. The tip
is used for supporting and tipping the ice can frames. When tilting the ice can frames, the ice
blocks thawed from the cans slide out. The handling is affected with the aid of the ice crane.
 
14. ICE CAN FRAME FEED MECHANISM (upon request)
Once started, the feed mechanism pushes the ice can frames forward. When withdrawing
the drive system, they are moved until another ice can prepare into the space. The ice can
formulate a feed mechanism driven by a geared motor and a reduction gearing through leverage.
 
15. ICE CAN FRAME A CRANE WITH A BEAM
A floor-controlled crane with two rope drums runs on rails mounted on a crane frame.
The two ropes are connected by a beam to which the ice can frames are hung. The crane is used
for handling the ice can frames. A control panel contains the corresponding push buttons for the
hoisting and crane traveling mechanisms.
 
16. GANGWAY
A gangway is provided near the liquid tank. It is possible to operate the crane from the
gangway, and the ice can frame the feed mechanism.
 
17. ELECTRIC SWITCH GEAR ASSEMBLY
The electric switch gear assembly contains the essential switch gears and monitoring
read-outs for the control and operation of the system.
 
18. COOLING BRINE
The cooling brine has to fulfill the following demands:
- No contamination by foreign matter (e.g., oil, etc.)
- Indifferent to metallic materials
- A lower cooling limit of at least 15°C below the average working temperature.
III. Ice Plant with Cold Storage Sample Layout
IV. Sample Computation
1 -Transmission loads
 Ambient air (where the warehouse is located) is 30°C with 50% relative humidity; indoor
air (desired air condition inside the warehouse) is one °C at 95% relative humidity.
 The walls, roof, and floors are insulated with 80 mm polyurethane with a U 0.28W /
m2.K value.
 We will use an XPS insulation plate since using floor panels in industrial warehouses will
not be suitable due to forklift passage. Thickness 80 mm U 0.42 W / m2.K
 The floor temperature is 10°C.
To calculate the transmission load, we will use a formula like this:
Q = L x A x (Outside Temperature – Inside Temperature) x 24 ÷ 1000
 Q = kWh / per day heat load
 U = U insulation value of sandwich panel (W / m2.K)
 A = Surface area of ceiling, wall, and floor (we will calculate this) (m2)
  Indoor Temperature = Air temperature inside the room (°C)
 Outside Temperature = Ambient outside temperature (°C)
 24 = Hours in a day
 1000 = Watt to kW conversion.
Calculating "A" is pretty easy:
1. Wall= 8m x 4m = 32 m2
2. Wall = 8m x 4m = 32 m2
3. Wall = 5m x 4m = 20m2
4. Wall = 5m x 4m = 20m2
Roof = 5m x 8m = 40m2
Floor = 5m x 8m = 40m2
It would be best to calculate the floor separately from the wall and ceiling because the
temperature difference is different under the bed, so the heat transfer will also be additional.
Walls and Ceiling
Q = U x A x (Outside temp – Indoor temp) x 24 ÷ 1000
Q = 0.28W / m2.K x 184 m2 x (30°C – 1°C) x 24 ÷ 1000
Q = 35.8 kWh / day
[184m2 = 32m2 + 32m2 + 20m2 + 20m2 + 40m2 + 40m2]
Floor
Q = U x A x (Outside temp – Indoor temp) x 24 ÷ 1000
Q = 0.42W / m2.K x 40m2 x (10°C – 1°C) x 24 ÷ 1000
Q = 3.62 kWh / day
Total daily conduction heat gain = 35.8 kWh/day + 3.62 kWh/day = 39.42 kWh/day
2- Products Load
In this step, we will calculate the cooling capacity due to the products placed in the warehouse.
For this example, we will store apples. If you carry out processes such as freezing and further
cooling in addition to cooling the products, you must also make separate heat gain calculations
for them. In this example, we only do cooling.
Every day, 6,000 kg of apples arrive at the warehouse at ten °C and a heat capacity of 0.87
kcal/kg.
We can use the following formula for this calculation:
Q = m x Cp x DT (Product inlet temperature – In-tank Temperature) / 860
 Q = kWh / day
 CP = Specific Heat Capacity of the Products (kJ/kg.°C)
 m = Mass of added products (kg)
 Product inlet temperature = Product inlet temperature (°C)
 The Temperature inside the cold room = Temperature inside the cold room (°C)
 860 = Kcal Kwh conversation rate
Calculation
Q = m x C x (Product inlet temperature – In-cold room temperature) / 860
Q = 6.000 kg x 0.87 kcal / kg°C x (10°C – 1°C) / 860
Q = 54.6 kWh / day
 
3-Calculating Cooling Load from Product respiration
The next step is to calculate the cooling load from the product respiration. In this example, let's
use the average respiratory heat of 1.9kJ/kg per day for storing the apple, but this rate varies with
time and Temperature. In our example design, we apply a single value only to simplify the
calculation, as this cooling load is not considered critical. In our sample design, 30,000 kg of
apples are stored in the warehouse. To calculate this, we will use the following formula:
Q = m x resp / 3600
 Q = kWh / day
 m = amount of product in the warehouse (kg)
 resp = resp = respiratory heat of the product (1.9kJ / kg)
 3600 = Converts kJ to kWh.
Q = m x resp / 3600
Q = 30.000kg x 1.9kJ/kg / 3600
Q = 15.9 kWh / day
That is when we calculate the cooling load from the new product entering the warehouse and the
cooling load due to the product's respiration, a total cooling load of 70.5 kWh/day.
4 -Internal Heat load – Calculation of Cooling Load from Humans
The amount of heat emitted by the working people in cold storage varies according to the
Temperature of the warehouse and volume.
If we consider that two people will work for 4 hours for the Apple store we have designed, the
formula will be as follows.
Q = Number of workers x time x heat / 1000
 Q = kWh / day
 Number of employees = Number of people working in the warehouse
 Time = Length of time spent in the warehouse per person (Hours)
 Heat = Heat losses per person per hour (Watts)
 1000 = Converts watts to kW only
Calculation:
Q = time x number of workers x heat power / 1000
Q = 4 hours x 2 person x 271 Watts / 1000
Q = 2.16 kWh/day
Internal heat load – Calculation of Cooling Load from Lighting
In the next step, we will calculate the heat produced by the lighting. The formula we will use for
this calculation is as follows;
Q = lamp x time x watts / 1000
 Q = kWh / day,
 Lamps = Number of lamps in the cold room
 Hour = daily usage hour of cold room lighting
 Watt = power rating of the lighting
 1000 = Watts to Kw
If there are three lamps at 120W each, running 4 hours a day, the calculation would be:
Q = lamp x time x watts / 1000
Q = 3 x 4 hours x 120W / 1000
Q = 1.44 kWh/day
Total internal load: We get a total of 3.6 kWh/day for the heat load from humans (2.16 kWh /
day) and the lighting heat load (1.44 kWh / day).
 
Equipment load – Calculation of Cooling Load from Fan Motors
Now, let's calculate the heat load from the fan motors of the evaporators.
Q = fans x time x watts / 1000
 Q = kWh/day
 Fans = Number of fans
 Time = Fan running time per day (hours)
 Watt = Fan motors nominal power (Watts)
 1000 = Watts to kW.
This cold room evaporator uses three fans of 300W each, and we assume they will run 16 hours a
day.
Calculation:
Q = fans x time x watts / 1000
Q = 3 x 16 hours x 300 W / 1000
Q = 14.4 kWh / day
 
Equipment load – Calculation of Cooling Load from Fan Motors Defrost
We will now calculate the heat load from defrosting the evaporator. To calculate this load, we
will use the following formula:
Q = Timex Power x defrost cycle x efficiency
 Q = kWh / day,
 Power = Heating element power (kW)
 Time = Defrost operation time (Hours)
 Defrost cycle = How many times per day the defrost cycle occurs
 Efficiency = what % of the heat will be transferred into the ambient
In this example, 1.5 kW resistances are used in our cold room. It works for 20 minutes thrice a
day, and 30% of all the energy it consumes is transferred to the cold room.
Q = 1.5kW x 0.4 hours x 3 x 0.3
Q = 0.54kWh/day
On the other hand, the total equipment cooling load is fan heat load (14.4 kWh/day) plus defrost
heat load (0.54 kWh/day), equal to 14.94 kWh/day.
Calculation of Cooling Load from Infiltration
At this stage, the heat load from air infiltration needs to be calculated. If we use the below
formula:
Q = volume x energy x change x (Outside Temperature – Inside Temperature) / 3600
 Q = kWh / d
 Change = Number of volume changes per day
 Volume = Cold storage volume
 Energy = energy per cubic meter in degrees Celsius
 Outdoor Temperature = Outdoor air temperature
 Internal Temperature = Cold room temperature
 3600= kJ to kWh.
Assuming that the door will create 5 volume air changes per day due to the product entering and
leaving the warehouse, the volume is calculated as 160m3, each cubic meter of new air is 2kJ
/°C, the outside air is 30°C, and the air inside the warehouse is 1°C.
Q = change x volume x energy x (Outside Temperature – Inside Temperature) / 3600
Q = 5 x 160m3 x 2kJ /°C x (30°C – 1°C) / 3600
Q = 12.88 kWh / day
Total cooling load
We will add all the calculated values to calculate the total cooling load.
Transmission load: 39.42 kWh / day
Product loading: 70.5 kWh / day
Internal bag: 3.6 kWh / day
Equipment load: 14.94 kWh / day
Infiltration load: 12.88 kWh / day
Total = 141.34 kWh / day

V. References

https://www.scribd.com/document/420313475/Ice-Plant-Cold-Storage
http://prdp.da.gov.ph/ice-plant-with-cold-storage-benefits-fisherfolks-in-bataan/
https://www.scribd.com/document/392263447/Ice-Plant-Computation
https://pdfcoffee.com/design-of-an-ice-plant-and-cold-storage-plant-pdf-free.html
https://www.studocu.com/ph/document/central-philippine-university/refrigeration-
systems/me3207-proposed-ice-plant-group-9-pdf/26036146