MINISTORY OF EDUCATION

West Yangon Technological University

Department of Mechanical Engineering

Analysis of Small Scale Ice plant

Second Seminar
Date:7.6.2020

Supervised by Presented by
Daw Khin Sandar Soe Naing Mg Thaung Shan Htet
(VI.Mech.92)
.

Outlines Of Presentation
 Principle of ice making
 The Ice Making Process
 Troubleshooting a Portable Ice Maker
 Consumer Icemakers
 Portable IceMakers
 Components Of Ice Plant
 Refrigeration Cycle
 Working Of An Ice Plant
 COP of an Ice plant model using refrigerant
R134a
 Future Plan
 Reference
Aim and Objective

AIM

 To analyze Small Scale Ice Plant

Objective

 To analyze of an ice plant model

 To study on COP of ice plant
 To analyze which cycle we should use to meets the
tons of ice that would like to produce.
 To analyze the types of ice plant.
Principle of ice making
• All refrigeration are made of four key components;
the evaporator, the condenser, the compressor and
the throttle valve.
• Ice machines all work the same way. The function of
compressor is to compress low-pressure refrigerant
vapor to high-pressure vapor, and deliver it to the
condenser. Here, the high-pressure vapor is
condensed into high-pressure liquid, and drained out
through the throttle valve to become low-pressure
liquid.

The Ice-Making Process

Making ice is something we’ve come to take
for granted in the last hundred years or so. Just fill a
tray with water, stick it in the freezer, wait 30 minutes
or so and, bam, ice! Whether you do it manually, or
rely on the convenience of an automatic ice maker in
your refrigerator, the process is pretty much the
same.Except when it’s not.
 .
(1) Water is added into the unit’s water reservoir, up to the fill
line. Because these units are meant to be portable, they’re
not connected to a water line and must be filled manually.
That means you just pour the water directly into it with a
faucet, bucket, jug, etc.

Fig.1
(2) The water is pumped via a hole in the bottom of the
reservoir through a water filter and up to an ice tray at the top
of the unit. Any overflow spills back into the reservoir.

Fig.2
 .

(3) When the refrigeration cycle begins, the 1/2-inch

prongs on the heat exchanger are lowered into the water of the
ice tray. 
These submerged spikes get cold very quickly, and
ice begins to form on them in a matter of minutes.

Fig.3
(5) The size of the ice cubes depends on how long the prongs
are left in the water. 
A longer cycle means thicker pieces of ice. Small ice
usually takes about 6 minutes, while large ice is about twice
that, though freezing times can be affected by the ambient
temperature and how long the unit has been running.

Fig.4
(5) When the ice has reached the proper size, the ice tray
.

empties any remaining water back into the water reservoir.

 At the same time, the heat exchanger reverses itself and
the spikes start to heat up – just enough so that the ice pieces
slide off the prongs and tumble into the ice bin that’s above
the water reservoir.

Fig.5

(6) A second sensor on storage basket monitors the amount

of stored ice, and shuts off the system if it gets too full.
.
Troubleshooting a Portable
Ice Maker

Fig.7

Consumer icemakers

Fig.8.Icemaker (for hotel customers)

Portable icemakers

Fig.9 Portable icemaker (for home use)

Built-in and freestanding
..

icemakers
Built-in icemakers are engineered to fit under a kitchen
or bar counter, but they can be used as freestanding units.
Some produce crescent-shaped ice like the ice from a
freezer icemaker; the ice is cloudy and opaque instead of clear,
because the water is frozen faster than in others which are clear
cube icemakers.

Industrial icemakers
Commercial ice makers improve the quality of ice by using
moving water.
The water is run down a high nickel content stainless steel
evaporator.
The surface must be below freezing. Salt water requires lower
temperatures to freeze and will last longer.

Flake ice machine

Flake ice is made of the mixture of brine and water (max
500 g [18 oz] salt per ton of water), in some cases can be directly
made from brine water.
Thickness between 1 and 15 mm (1⁄16 and 9⁄16 in), irregular shape
with diameters from 12 to 45 mm (1⁄2 to 1 3⁄4 in).
Applications
Sea water flake ice machine can make ice directly
from the sea water.
Flake ice can lower the temperature of cleaning
water and sea products, therefore it resists the growth of
bacteria and keeps the seafood fresh.

Cube icemaker
Cube ice machines are classified as small ice
machines, in contrast to tube ice machines, flake ice
machines, or other ice machines.
Common capacities range from 30 kg (66 lb) to
1,755 kg (3,869 lb). Since the emergence of cube ice
machines in the 1970s, they have evolved into a diverse
family of ice machines.
Tube ice generator

Fig.9.Tube ice
A tube ice generator is an ice generator in which the
water is frozen in tubes that are extended vertically within a
surrounding casing—the freezing chamber.
Tube ice can be used in cooling processes, such as
temperature controlling, fresh fish freezing, and beverage
bottle freezing. It can be consumed alone or with food or
beverages.
COMPONENTS OF AN ICE PLANT
.

In the study of an ice plant the components generally used

are viz. compressor, oil separator, condenser, receiver, drier,
expansion valve,evaporator, chilling Tank, refrigerant
accumulator andpressure gauge.

Refrigeration Cycle
A refrigeration system has four main components that
facilitate the transfer of heat via the coolant. These components
are:
• Compressor – compresses the coolant, turning it into a hot,
high pressure gas
• Condenser – a set of coiled pipes on (or near) the exterior of
the unit that dissipate heat as the coolant transforms into high
water pressure
• Expansion Water Valve – also known as an inlet valve –
releases the pressure on the coolant, turning it into vapor
again and lowering the temperature of the coolant
• Evaporator – another set of heat-exchanging pipes on the
interior of the unit that make the interior of the unit cold
Here is a diagram of how the system works in principle:

Fig.10
Compressor
There are four types of compressors which are in common use:
(a) Reciprocating compressor
(b) Rotary compressor
(c) Centrifugal compressor
(d) Screw compressor

HERMETICALLY SEALED, OPEN,

OR SEMI-HERMETIC COMPRESSOR
• In hermetic and most semi-hermetic compressors, the
compressor and motor driving the compressor are
integrated, and operate within the pressurized gas
envelope of the system.
• A semi-hermetic uses a large cast metal shell
with gasket covers that can be opened to replace
motor and pump components.

Fig.11 Small hermetically sealed compressor unit

Evaporator
.

An evaporator is that part of a mechanical refrigeration system in

which the liquid refrigerant is evaporated and the heat required for
evaporation is absorbed from the medium cooled may be gas such as air,
a liquid such as water or a solid such as packaged food.

Condenser
• There are three general types of refrigeration condensers air-
cooled, water-cooled, and a combination air and water-cooled
usually referred to as an evaporative condenser.
• Details of air-cooled condenser are described in the following
section.

Air cooled condenser

• An air cooled condenser is one in which the removal of heat
is done by air.
• It consists of steel or copper tubing through which the
refrigerant flows

Fig.12 p-h diagram for condenser Fig.13 air cooled condenser

Receivers
.

• A liquid receiver will be required if it is necessary totemporarily

store refrigerant charge within the system,or to accommodate the
excess refrigerant arising from changing operating conditions.
• A receiver requires a minimum operating chargewhich adds to
overall charge and cost, and also increases system complexity.
Hence receivers areavoided on many smaller systems.

Filter drier
• The function of filter dryer is to remove any physical material from
compressor’s wear and tear, and remove any moisture presence
within an air conditioning system.
• The Drier is made up of a metal outer container and inside there is a
desiccant (moisture removal material) and strainer.

Expansion Devices
• The expansion device (also known as metric device or throttling
device) is an important device that divides the high pressure side and
the low pressure side of are rfrigerating system.
• It is connected the receiver(containing liquid vapour at high
pressure) and the evaporator (containing liquid refrigerant at low
pressure).

Capillary Tube
• The capillary tube is used as an expansion device usedin small
capacity hermetic sealed refrigeration unitssuch as domestic
refrigeration, water cooler, room air conditioner and freezers.
• It is a cooper tube of small diameter and of varying length
depending upon the application.
Bare tube coil evaporator .

• The bare tube coil evaporators are also known asprime

surface evaporators.
• Because of its simple con-struction, the bare tube coil is easy
to clean and de-frost.

Chilling Tank
• The main components of chilling tank are viz.ice
tank,insulation of ice tank and ice block. Ice tanks aremade of
such material as wood, steel or concrete.
• Aswooden tanks do not last long enough and are liableto
leak, they should preferably be made of steel wellcoated with
waterproof paint.

Suction Accumulators
• Suction line accumulators are sometimes inserted
inhalocarbon circuits, to serve the purpose of separatingreturn
liquid and prevent it passing over to thecompressor.
• Since this liquid will be carrying oil, andthis oil must be
returned to the compressor, the outletpipe within the separator
dips to the bottom of thisvessel and has a small bleed hole, to
suck the oil out.
Oil Separators
.

• During the compression stroke of a reciprocating machine,

the gas becomes hotter and some of the oilon the cylinder
wall will pass out with the dischargegas.
• Some oil carry-over will occur with all lubricated
compressor types, and in small self-contained system sit
quickly finds its way back to the compressor.
• With larger more complex systems with remote evaporator
oil, it is desirable to fit an oil separator in the discharge line to
reduce carry-over to the system.

Working of an Ice Plant

• In ice plant the tanks are filled with chilled brine.
• The brine solution is kept in constant motion by agitators for
increasing the heat transfer from the water in the can to the
chilled brine. The agitators may be either horizontal or
vertical and are operated by means ofelectric motors .

Fig.14. Layout of Ice Plant

 .
Specification and Energy Equations
for Different Components
Compressor
The S.F.E.E equation
Q + m1 (h1 + (V1)2/2 + gz1) = W + m2 ( h2 + (V2)2/2 + gz2)
Applying steady flow energy equation in modified form
Q = 0 KE = 0 PE = 0
Wc = ( -ive ) work for compression
mh1 = -Wc + mh2 or Wc = m (h2- h1)
Adiabatic compression work = m(h2- h1) = mcp (T2 - T1)
Here T1,T2 are temperatures at inlet and outlet and m is mass
flow rate
Condenser
The S.F.E.E equation
Q + m1 (h1 + (V1)2/2 + gz1) = W + m2 ( h2 + (V2)2/2 + gz2)
Steady flow energy equation can be applied with thefollowing
assumptions:
• No work interaction, W = 0
• No change in kinetic energy, KE = 0
• No change in potential energy, PE = 0
Heat lost by steam = m (h2- h1), k
Expansion Device
.

During flow through these passages enthalpy remains constant,such that

h1 = h2
Joule-Thomson coefficient
µ = ( T/p)h = constt
And if µ = 0,
Temperature remains constant
µ>0,Temperature decrease.
µ<0, Temperature increase.

Evaporator coil
Heat transfer rate at evaporator or refrigeration capacity,
Qe is given by: Qe = mr (h1-h4)
Where,
mr is the mass flow rate in Kg/sec,
h1 and h2 are thespecific enthalpies (kJ/kg) at the exit and inlet to
theevaporator, respectively.
(h1-h4) is known as specificrefrigeration effect or simply refrigeration
effect, which isequal to the heat transferred at the evaporator
perkilogram of refrigerant.
Refrigerant
.

Refrigerant used in this prototype model is R-134aand it is also known

as Tetrafluoroethane (CF3CH2F)from the family of HFC refrigerant.
The properties ofrefrigerant R-134a are as under:
R134a is also known as Tetrafluoroethane(CF3CH2F) from the family
of HFC refrigerant.With the discovery of the damaging effect of
CFCsand HCFCs refrigerants to the ozone layer, theHFC family of
refrigerant has been widely usedas their replacement.

Brine solution used

In this prototype model the mixture of NaCl and wa-ter in the
proportion of 1:3 is used. The mixture ofCaCl2 and water can be used as
brine but it is notused because of its toxicity.
Table.1 Comparisons between Two Brines

Calcium Chloride Sodium Chloride

Used in other applications where Used for food processing

there would be no contact with
food stuff
Lower enthalpy (capacity) then Higher enthalpy(Capacity)
sodium
Lower obtainable eutectic point High eutectic point -6F
-67F
Corrosive Corrosive

Additives include toreduce Non toxic

formation of scaling and
corrosions
Toxic
COP of an Ice plant. model using
refrigerant R134a
The input and outlet temperature and pressure for the compressor of the
model is measured and the corresponding properties of R-143a are
depicted below in the Table 2 and Table 3.Based on the output results
the T-s and p-h diagrams of model are shown in figure 15 & 16.
T1= -5.2’C,
T2= 62.3’C,
P1= 0.124 MPa (18 psi),
P2 = 1.517 Mpa (220 psi),
T1 = T4 = -20.42’C,
T2 = T3 = 55.67’C
Table2: Properties of Saturated R-143a

Pressure SaturationTemperature,
OC
Enthaphy, KJ/kg
Vapour liquid
0.124 MPa (18 -20.42 385.82 173.21
psi)
1.517 MPa (220 55.67 425.85 280.80
psi)
Table 3: Properties of Superheated R-143a

Pressure, Mpa Saturation temperature ,0C Energy,kJ/Kg

Vapour
0.124 MPa (18 psi) -5.2 398.535
1.517 MPa (220 psi) 62.3 434.10
OBSERVATION & CALCULATION
.

The coefficient of performance of refrigeration plantis given by

the ratio of heat absorbed, by the refrigerant when passing through the
evaporator or the system, to the working input to the compressor to
compress the refrigeration.
During the run following data has been recorded:
Inlet temperature of compressor = -5.2’C
Outlet temperature of compressor = 62.3’C
Inlet pressure of compressor = 0.12 MPa
Outlet pressure of compressor = 1.5 MPa
Temperature of the evaporator = -20.42’C
Temperature of the condenser = 55’C
Coefficient of performance:

COP = Heat absorbed by the evaporator/Heat absorbed by the

compressor

= M*CpdT/dh
h1 = 395 kJ/kg
h2 = 435 kJ/kg
h3 = h4 = 280 kJ/kg

Cooling produced per hour:

COP = 3.2
Wactual = 435 – 395
= 40 kJ/kg
Net cooling produced = Wactual * COP
.

= 40 * 3.31
= 132.4 KJ/Kg
Net cooling produced per hour = M’ * Refrigerating Effect
= 1 * 132.4 KJ/min
= 132.4/210 = 0.56 TR
RESULT AND DISCUSSION
• In this prototype model the mixture of NaCl and water in the
proportion of 1:3 is used.
• On analysis of an Ice plant model we take some assumption
liketank is perfectly insulated and no heat loss from or to the
chilling tank.
• Wehave found Coefficient of Performance equals to 3.2and
Net cooling produced per hour to be 0.56 TR
Future Plan
• Require data collected from industry to calculate
design procedure for small scale ice plant.
• To introduce overall expression of thesis.
• To make component detail design and material
selection of ice plant.
Reference
 http://www.pdftop.com/ebook/ice+plant/
 mini-ice-plant-pre-feasibility-study
 Design Consideration For local Ice Plant Pdf.
 www.Wikipedia.org
 www.slideshare.net
 .

Thank You For Your Attention