SAINT LOUIS UNIVERSITY

SCHOOL OF ENGINEERING AND ARCHITECTURE

DEPARTMENT OF MECHANICAL AND MECHATRONICS ENGINEERING

DESIGN OF AN ICE PLANT AND COLD STORAGE

PLANT WITH A VENTILATION AND AIR
CONDITIONING SYSTEM

By:
CABASAAN, KIMBERLY KAYE L.
FAVOR, JOFFRION KIEL M.
GAJARDO, KHALE JOHN M.
JIMENEZ, JOHN EDGAR C.
MELENDEZ, DEXSON L.
MONIS, NICOLE ANNE A.
SALINAS, MILTON D.
BS ME IV

Submitted To:
ENGR. MAURICE LICDAN
Instructor

In Partial Fulfillment
Of the Requirements for the Course
ME 4121L: AIR CONDITIONING AND VENTILATION SYSTEMS LABORATORY
3681 5:30-8:30 PM T H204A

06 DECEMBER 2022

ME 4121 LABORATORY
 DESIGN OF AN ICE PLANT AND COLD STORAGE
PLANT WITH A VENTILATION AND AIR
CONDITIONING SYSTEM

I. Statement of the Problem

To design an ice plant and cold storage plant from a given load requirements including a
centralized air conditioning system

INTRODUCTION

Ice plant, Ice factory and cold storages alike plays a very significant role in the longevity
of crop products, dairies, and poultry. The production of blocks of ice starts with the
determination of volume of water and desired temperature for both the space and products, and
removal of heat energy enough to freeze the water. This is in the same manner how a
commercially available Refrigerator with freezer turn water into ice, through subjecting the
water into a colder environment until the system achieves thermal equilibrium.

Ice Plants are not limited to ice blocks they sustain the needs of different industries by
producing other types of cooling ice including dry ice and wet ice. Dry ice is the type of ice that
is more sensitive relative to the change in temperature of wet ice. Dry ice usually sublimates
evaporating without a trace of residue. Wet ice in the other hand is the most common type of ice.

Cold Storage as mentioned, helps to long maintained the quality and prolong the shelf life of
products that are out of seasoned. Cold storage at desired temperature helps slows the activity of
enzymes that may rot the products easily at atmospheric temperature.

II. Design Consideration

A. SPACE CONSIDERATION AND CALCULATIONS OF ICE PLANT BASED ON
THE FOLLOWING:

a. Tons of Capacity
 Ice plant production of 200 tons ice per 24 hours

b. No. of cans needed

 200 tons subdivided into 5 brine tanks
200 tons
¿
5brine tanks
¿ 40 tons per brine tank
WH
N=
24 C
H = Freezing Time
H=50 °
W = Weight of ice, pounds to be pulled everyday (24 hours)
2000 lb
W =200 tons×
1 ton
W =400,000 lb
N = Number of cans required
C = Weight of one block of ice, pounds
C=400 lb
2
7a
x=
32t
a=Thickness of block of ice
a=( 11× 22× 57 ) inches
t=Brinetemperature
t=50 ℉
WH
N=
24 C
400,000lb (50)
N=
24( 400 lb)
N=2083.3333cans ≅ 2085 cans
2085 cans
Corresponding cans per brine tank=
5 brine tanks
cans
Corresponding cans per brine tank=417
brine tank

c. Size of Brine Tank and Cold Storage

Dimensions of Brine Tank

cans
Corresponding cans per brine tank=417
brine tank
W =18 cans=23 ft ∧6∈¿
L=24 cans=53 ft ∧9∈¿

Dimension of the Cold Storage

d. Other spaces/equipment needed

 Brine solution, brine salt water, particularly a highly concentrated water

solution of common salt (sodium chloride). Natural brines occur
underground, in salt lakes, or as seawater and are commercially important
sources of common salt and other salts, such as chlorides and sulfates of
magnesium and potassium.
 Brine tank is the part of your water softener that holds the salt. Your water
level should always be slightly lower than your salt level in your water
softener brine tank. This is because the water needs to touch the salt so that it
can absorb it and create the correct concentration of brine.
 Condenser (or AC condenser) is the outdoor portion of an air conditioner or
heat pump that either releases or collects heat, depending on the time of the
year.
 Evaporator is one of the main parts of the cooling system. Evaporator
absorbs heat from the area that needs cooling. As the refrigerant in the
system occupies this area, it turns into a gas. The heat is transferred through
the surface of the refrigerant tubes in the system which causes the
temperature around the evaporator to drop.
 Compressor is a device used to compress air or other gases to pressures
higher than atmosphere pressure. It compresses the air taken from the
atmosphere and increases its pressure. Compressors are used in many
different industries such as the automotive, chemical and petrochemical,
textile, food, energy, healthcare and glass.
 Cooling coil is a device intended to allow the contents of the coil to cool as
they move through it. Cooling coils can be used in materials processing to
control the temperatures of various components, and they are also employed
in heating and cooling systems where space is at a premium and other
cooling arrangements are not feasible.
 Expansion valve are devices used to control the refrigerant flow in a
refrigeration system. They help to facilitate the change of higher pressure of
liquid refrigerant in the condensing unit to lower pressure gas refrigerant in
the evaporator. The term "low side" is used to indicate the part of the system
that operates under low pressure, in this case the evaporator. The "high side"
is used to indicate the part of the system that operates under high pressure, in
this case the condenser.
 Thermal insulators are materials resistant to the passage of energy. They
are employed in the construction of cold storage installations to create a
barrier that preets the transmission of energy and maintains the interior at a
suitable temperature.
B. COLD STORAGE BASED ON

a. Tons of product to be restored

VEGETABLE PRODUCTS WEIGHT, TONS
Broccoli 50
Cauliflower 100
Lettuce 50

b. Properties of product
PRODUCT FREEZING Cp (ABOVE Cp (BELOW
(200 tons) POINT (℉ ¿ FREEZING FREEZING
BTU /lb−℉ ) BTU /lb−℉ )
Broccoli 26 0.92 0.44
Cauliflower 26 0.93 0.44
Lettuce 25 0.96 0.45

Space Requirements
STORAGE WEIGHT PRODUCTS WIDTH LENGTH HEIGHT
NO. (TONS) (ft) (ft) (ft)
1 50 Broccoli 6.25 40 8
2 100 Cauliflower 6.25 40 8
3 50 Lettuce 6.25 40 8

c. Equipment Needed
 Forklift
 Crates
 Palettes
 Insulation
 Fan
 Vapor barrier
 Pipe covering

C. FINALIZED PLANT LAYOUT BASED ON

1. Position of Ice Plant, Cold Storage Rooms

2. Dimensions, Spaces, and other requirements such as office, receiving area, etc.

Single-acting, vertical ammonia compressors enjoy the primary preference in modern

plants because they do not require as much operating attention, particularly on lubrication
and shaft packing glands, as do horizontal types. They are less costly when under 75-ton
unit sizes; they occupy less floor area and require minimum foundations.

They possess no advantages over horizontal machines for pumping efficiency when both
types are fitted with adequate valve areas. Clearance and capacity control is essential for
economic performance. In Instead of this control, removing the suction from one cylinder
will affect a capacity control by that amount; mechanical balance is not affected, and rarely
electric balance in high-speed units.

Condensers finding the most significant usage in ice plants are shell-and-tube of both
vertical and horizontal multi-pass types. Next in order are tubular multi-shell, atmospheric
pipe, and double-pipe types. Shell-and-tube types are usually proportioned from 8 to 11 sq.
ft. of surface per ton refrigeration.

Evaporative condensers are slowly becoming more used, and they serve well when
properly proportioned to air volume and surface. With their use, means must be provided to
treat the water against scale formation and algae growth. They must be kept well-purged and
connected to ensure their bottling up when arranged in parallel operation. Inherent in them
is the tendency to bottle up liquid.

Several designs are now available that eliminate this difficulty of a high-temperature
differential between the condensed refrigerant and pan water. Condensing water supplies are
generally secured from spray cooling ponds, natural and fan draft towers, streams, and
shallow or deep wells. The use of wells is difficult to justify when the pumping power
requirements exceed 1/7 hp per ton of maximum daily ice production. At this point, the need
for spray ponds or towers is indicated.

Which spray ponds appear most economical to operate on a 5 F cooling range with a 6 F
approach to the prevailing summer wet bulb. With natural draft and fan towers, 7.5 to 10 F
cooling ranges, with a 3 to 4 F approach to the wet bulb, are the most practical. The use of
fan towers, preferably of the induced type, ensures tower performance, whether the filled or
spray type, during the worst summer conditions of high humidity and air stillness. Practice
indicates that a plant operates best with a single pump for summer duty.
 a. Provide space for travel of forklift and other equipment

III. COOLING LOAD CALCULATIONS

A. Ice plant and cold storage calculations:

a. Product load and heat load to be removed from the product at the cold storage and in
an ice production.
b. Other heat loads to be taken in considerations such as, but not limited to, infiltration,
conduction of heat from the equipment inside the room, etc.
B. Air conditioning load calculations: one story office

Q = UA (CHANGE IN TEMP.)
STORAGE 1: CAULIFLOWER
Maintaining temperature = 42.5 def F
Ceiling:
U = 0.0488 BTU/hr – deg F – sq. ft
A = 2536.8147 sq. ft
Above ceiling temperature = 75 deg F
Qceiling = (0.0488 BTU/hr – deg F – sq. ft) (2536.8147 sq. ft) (75-42.5 deg F) = 4023.3881
BTU/hr

Wall:
U = 0.0459 BTU/hr – deg F – sq. ft
Maintaining Temperature = 42.5 deg F
Outside Temperature = 69.8 deg F
Hallway Temperature = 50 deg F
Area of West = (9.2 ft) (86.0236 ft) = 791.4171 sq. ft
Area of East = [(9.2 ft) (86.0236 ft)] – 23.4724 sq. ft = 767.9447 sq. ft
Area of North and South = (9.2 ft) (31.0039 ft) = 285.2359 sq. ft
Qwest = (0.0459 BTU/hr – deg F – sq. ft) (791.4171 sq. ft) (69.8 -42.5 deg F) = 991.7010
BTU/hr
Qeast = (0.0459 BTU/hr – deg F – sq. ft) (767.9447 sq. ft) (50-42.5 deg F) = 264.3650 BTU/hr
Qnorth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (42.5-42.5 deg F) = 0 BTU/hr
Qsouth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (69.8-42.5 deg F) = 357.4205
BTU/hr

Door:
U = 0.0783 BTU/hr – deg F – sq. ft
Adoor = 23.4724 sq. ft
Qdoor = (0.0783 BTU/hr – deg F – sq. ft) (23.4724 sq. ft) (50-42.5 deg F) = 13.7842 BTU/hr

Qtramission = (4023.3881 + 991.7010 + 264.3650 + 357.4205 + 13.7842) BTU/hr = 5650.6588

BTU/hr
STORAGE 2: BROCOLLI
Maintaining temperature = 42.5 def F
Ceiling:
U = 0.0488 BTU/hr – deg F – sq. ft
A = 2536.8147 sq. ft
Above ceiling temperature = 75 deg F
Qceiling = (0.0488 BTU/hr – deg F – sq. ft) (2536.8147 sq. ft) (75-42.5 deg F) = 4023.3881
BTU/hr

Wall:
U = 0.0459 BTU/hr – deg F – sq. ft
Maintaining Temperature = 42.5 deg F
Outside Temperature = 69.8 deg F
Hallway Temperature = 50 deg F
Area of East = (9.2 ft) (86.0236 ft) = 791.4171 sq. ft
Area of West = [(9.2 ft) (86.0236 ft)] – 23.4724 sq. ft = 767.9447 sq. ft
Area of North and South = (9.2 ft) (31.0039 ft) = 285.2359 sq. ft
Qeast = (0.0459 BTU/hr – deg F – sq. ft) (791.4171 sq. ft) (69.8 -42.5 deg F) = 991.7010
BTU/hr
Qwest = (0.0459 BTU/hr – deg F – sq. ft) (767.9447 sq. ft) (50-42.5 deg F) = 264.3650 BTU/hr
Qnorth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (45-42.5 deg F) =32.7308 BTU/hr
Qsouth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (69.8-42.5 deg F) = 357.4205
BTU/hr

Door:
U = 0.0783 BTU/hr – deg F – sq. ft
Adoor = 23.4724 sq. ft
Qdoor = (0.0783 BTU/hr – deg F – sq. ft) (23.4724 sq. ft) (50-42.5 deg F) = 13.7842 BTU/hr

Qtramission = (4023.3881 + 264.3650 + 32.7308 +357.4205 + 13.7842) BTU/hr = 5683.3896

BTU/hr

STORAGE 3: CAULIFLOWER
Maintaining temperature = 42.5 def F
Ceiling:
U = 0.0488 BTU/hr – deg F – sq. ft
A = 2536.8147 sq. ft
Above ceiling temperature = 75 deg F
Qceiling = (0.0488 BTU/hr – deg F – sq. ft) (2536.8147 sq. ft) (75-42.5 deg F) = 4023.3881
BTU/hr

Wall:
U = 0.0459 BTU/hr – deg F – sq. ft
Maintaining Temperature = 42.5 deg F
Outside Temperature = 69.8 deg F
Hallway Temperature = 50 deg F
Area of West = (9.2 ft) (86.0236 ft) = 791.4171 sq. ft
Area of East = [(9.2 ft) (86.0236 ft)] – 23.4724 sq. ft = 767.9447 sq. ft
Area of North and South = (9.2 ft) (31.0039 ft) = 285.2359 sq. ft
Qwest = (0.0459 BTU/hr – deg F – sq. ft) (791.4171 sq. ft) (69.8 -42.5 deg F) = 991.7010
BTU/hr
Qeast = (0.0459 BTU/hr – deg F – sq. ft) (767.9447 sq. ft) (50-42.5 deg F) = 264.3650 BTU/hr
Qsouth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (42.5-42.5 deg F) = 0 BTU/hr
Qnorth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (32-42.5 deg F) = -137.4694
BTU/hr
Door:
U = 0.0783 BTU/hr – deg F – sq. ft
Adoor = 23.4724 sq. ft
Qdoor = (0.0783 BTU/hr – deg F – sq. ft) (23.4724 sq. ft) (50-42.5 deg F) = 13.7842 BTU/hr

Qtramission = (4023.3881 + 991.7010 + 264.3650 + (-137.4694) + 13.7842) BTU/hr =

5155.7689 BTU/hr

STORAGE 4: LETTUCE
Maintaining temperature = 45 def F
Ceiling:
U = 0.0488 BTU/hr – deg F – sq. ft
A = 2536.8147 sq. ft
Above ceiling temperature = 75 deg F
Qceiling = (0.0488 BTU/hr – deg F – sq. ft) (2536.8147 sq. ft) (75-45 deg F) = 3713.8967
BTU/hr

Wall:
U = 0.0459 BTU/hr – deg F – sq. ft
Maintaining Temperature = 45 deg F
Outside Temperature = 69.8 deg F
Hallway Temperature = 50 deg F
Area of East = (9.2 ft) (86.0236 ft) = 791.4171 sq. ft
Area of West = [(9.2 ft) (86.0236 ft)] – 23.4724 sq. ft = 767.9447 sq. ft
Area of North and South = (9.2 ft) (31.0039 ft) = 285.2359 sq. ft
Qeast = (0.0459 BTU/hr – deg F – sq. ft) (791.4171 sq. ft) (69.8 -45 deg F) = 900.8859 BTU/hr
Qwest = (0.0459 BTU/hr – deg F – sq. ft) (767.9447 sq. ft) (50-45 deg F) = 176.2433 BTU/hr
Qnorth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (32-45 deg F) = -170.2003 BTU/hr
Qsouth = (0.0459 BTU/hr – deg F – sq. ft) (285.2359 sq. ft) (42.5-45 deg F) = -32.7308 BTU/hr

Door:
U = 0.0783 BTU/hr – deg F – sq. ft
Adoor = 23.4724 sq. ft
Qdoor = (0.0783 BTU/hr – deg F – sq. ft) (23.4724 sq. ft) (50-45 deg F) = 9.1894 BTU/hr

Qtramission = (3713.8967 + 900.8859 + 176.2433 + (-170.2003) + (-32.7308) + 9.1894)

BTU/hr
= 4597.2842 BTU/hr

HEAT INFILTRATION
 -Conduction of heat from equipment inside the room.
 Cold storage (1 TOR)
 Storage room (4TOR)

Air condition load calculation

Qtotal = Qice + Qinfiltration (only cold storage)
Qtotal = For ice only

TOTAL HEAT LOAD

Qtotal = Qproduct + Qarea + Qmotorsequipment + Qpeople + Qlight

TOTAL REFRIGERATION LOAD = (HL/12000) + (24hr/50hr)

Qlight
BASIS KENTS (11-40)
Assumptions:
 3.41*WATTS
 60 Lamps with 15 watts

Qlight = 3.14 * NO. OF BULBS (WATTS)

Qlight = 3.14 * (60*15 WATTS) (assumed)
Qlight = 3069 BTU/HR

Qperson = (580 BTU/HR) * 8 WORKERS (assumed)

Qperson = 4640 BTU/HR

Qsidewalls = 2 (L*H) + 2(W*H)5

Qsidewalls = (2(54*61) +2(23.5) (61)(5))
Qsidewalls = 47275 ft^2

V = 1/(1/Fo) +(x1/k1) +(x2/k2) +(1/c)

V = 1 / (1/1.65) + (3/0.27) + (2/5) + (1/3.12)
V = 0.80401 BTU/HR-FT^2-F)
Qs = 0.80401 (47275) (60.9-15)
Qs = 174463.9389 BTU/HR

Qfloor = UA (CHANGE IN TEMP)

A = 2(54*61)
A = 6588 ft^2

U = k/x
U = 5/8
U = 0.6 BTU/ HR FT-F

Qfloor = (0.6) (6588) (60.9-15)

Qfloor = 181433.52 BTU/HR

Qcover = UA(CHANGE IN TEMP)

Acover=Afloor

V = 1 / (1/FO) + (X/K)
V = 1 / (1/1.65) + (0.75/1.15)
V = 0.7946 BTU/HR FT^2-F

Qcover = 0.7948(6588) (60.9-15)

Qcover = 240338.9362 BTU/HR

Qinsulation = Summation of Q
Qinsulation = 174463.9389 + 181433.52 + 240338.9362
Qinsulation = (596209.3951 BTU/HR) (TR/ (200 BTU/MIN)(60 MIN/HR))
Qinsulation = 49.6841 TR / 50 TR

PRODUCT LOAD IN COLD STORAGE

PRODUCT CP CP FREEZIN LATEN RAW MASS
ABOV BELO G POINT T HEAT MATERIAL, (LB)
E W TEMPERATUR
E
BROCOLLI 0.92 0.47 26 130 70 10000
0
CAULIFLOWE 0.93 0.47 26 132 65 20000
R 0
LETTUCE 0.93 0.48 25 136 65 10000
0

FORMULA TO BE USED:
Q = m (CPafp*CHANGE IN TEMP) + LH + (CPbfp*CHANGE IN TEMP)

BROCOLLI:
= 100000 (0.92 (70-26) + 130 + 0.47 (26-0) )
= 18270000 BTU/HR
CAULIFLOWER:
= 200000 ( 0.93 (65-26) + 132 + 0.47 (26-0) )
= 36098000 BTU/HR

LETTUCE:
= 100000 ( 0.93 (65-25) + 136 + 0.48 (25-0) )
= 18520000 BTU/HR

Qtotal = 72888000 BTU/HR

HEAT LOAD @ ICE PRODUCTION (WATER)

CP CP FREEZIN LATENT RAW MASS TIME CANS
ABOVE BELOW G POINT HEAT WATER
TEMP
1.0062 0.5031 32 144 77 DEG 400 50 HRS 2850
CELCIUS

FORMULA TO BE USED:
Q = m ( (CPafp*change in temp/t) + LH/t + (CPbfp*change in temp/t) ) * 24hrs/50hrs *2085
cans * 1TOR/12000 BTU/HR
Q = 400 ( (1.0062(77-32)/50) + 144/50 + (0.5031(32-15)/50)
Q = 1582.6536 BTU/HR-CAN * 2085 CANS * 24 HRS/50 HRS * 1 TOR/12000 BTU/HR
Q = 131.9933 TOR

Qtotal (COLD TORAGE)

Qspace = QT1 + QT2 + QT3 + QT4

Qspace = 5650.6588 + 5683.3896 + 5155.7689 + 4597.2842
Qspace = 21087.1015 BTU/HR

Qproduct = QBROCOLLI + QCAULIFLOWER + QLETTUCE

Qproduct = 18270000+36098000+18520000
Qproduct = 72888000 BTU/HR

Qpeople = 580 btu/hr * 8 workers

Qpeople = 4640 BTU/HR

Qlights = 3.41*(no.of bulbs)

Qlights = 3.41 * (60*15)
Qlights = 3069 BTU/HR

Qtotal = QSPACE + QPRODUCT + QPEOPLE + QLIGHTS

Qtotal = 72916796.1 BTU/HR

TOTAL REFRIGERATION LOAD = HL/1200 * 24HRS/50HRS

TOTAL REFRIGERATION LOAD = (72916796.1/12000) * (24/50)
TOTAL REFRIGERATION LOAD = 2916.6718 TOR

TOTAL COOLING LOAD = QICE + QSPACE (ICE PLANT)

TOTAL COOLING LOAD = 131.9933+50
TOTAL COOLING LOAD = 181.9933 TOR