HO CHI MINH CITY UNIVERSITY OF

TECHNOLOGY AND EDUCATION

FACULTY OF HIGH-QUALITY TRAINING

PROJECT OF FOOD PROCESSING AND MACHINERY

CALCULATE AND DESIGN THE FREEZE-DRYING

SYSTEM OF ROYAL JELLY PRODUCTS WITH THE
PRODUCTIVITY OF 1500 KG / BATCH

Student: Nguyễn Trần Hoàng Anh 19116012

Ngô Thị Phượng 19116054
Class: 19116CLA
Semester: 1 – School year: 2022-2023
Instructor: Assoc Prof. Dr. Nguyễn Tấn Dũng

HO CHI MINH CITY 2022

 MINISTRY OF EDUCATION AND TRAINING THE SOCIALIST REPUBLIC OF VIETNAM
Independence – Freedom– Happiness
Ho Chi Minh University of Technology and Education
Faculty for high-quality training
Food technology Program

ADVISOR’S EVALUATION SHEET

Student name: Nguyễn Trần Hoàng Anh Student ID: 19116012
Student name: Ngô Thị Phượng Student ID: 19116054
Major: Food Technology
Project title:
Calculate and design the freeze-drying system of royal jelly products with
the productivity of 1500 kg/batch
Advisor: Assoc Prof. Dr. Nguyễn Tấn Dũng
Evaluation:

1. Content of the project

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2. Strengths:
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4. Approval for oral defence? (Approved or denied)
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5. Overall evaluation (Excellent, Good, Fair, Poor)
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Mark ............................... In work:.......................................................................

Ho Chi Minh City, December…..2022

ADVISOR
(Sign with full name)
 TABLE OF CONTENTS

PREFACE .......................................................................................................................i
LIST OF FIGURES ...................................................................................................... ii
LIST OF TABLES .........................................................................................................v
DEFINITIONS AND SYMBOLS ...............................................................................vi
INTRODUCTION .........................................................................................................1
CHAPTER 1. OVERVIEW .......................................................................................... 4
1.1. Scientific basis of freeze-drying...........................................................................4
1.1.1. Definition ......................................................................................................4
1.1.2. The phase transition process of water ........................................................... 4
1.1.3. Relationship between pressure and temperature parameters in freeze-drying
.................................................................................................................................5
1.1.4. Stages of the freeze-drying process .............................................................. 6
1.2. Domestic studies on freeze-drying .......................................................................8
1.3. Overseas studies on freeze-drying .....................................................................11
1.3.1. Freezing – drying system of Germany........................................................ 11
1.3.2. Freezing- drying system of United States ...................................................12
1.3.3. Freezing- Drying system of Japan .............................................................. 13
1.4. Material ..............................................................................................................13
1.4.1. Overview of royal jelly ...............................................................................13
1.4.2 Chemical composition of royal jelly ............................................................ 14
1.4.3 Health benefits and nutritional value ........................................................... 16
1.4.4. Thermophysical of royal jelly composition influencing on freeze- drying
process...................................................................................................................17
1.5. Freeze-drying technology for royal jelly ........................................................... 18
1.5.1. Flowchart for the freeze-drying of royal jelly ............................................18
1.5.2. Technological factors influencing the process ...........................................19
1.6. Apparatus of freeze dryer ...................................................................................20
1.6.1. Structure of a freeze-drying chamber ......................................................... 21
1.6.2. Condenser-freezing device structure .......................................................... 22
1.6.3. Vacuum pump ............................................................................................. 24
1.6.4. Automated systems for measurement and control ......................................24
1.7. Principle diagram of freeze-drying system ............................................................ 24
1.7.3. Continuous Sublimation Drying System ....................................................29
CHAPTER 2. CALCULATING AND RESEARCH METHODS .......................... 32
2.1. Planning the construction site of the factory to install a system ........................ 32
2.1.2. Arrangement of equipment inside the workshop ........................................36
2.1.3. Design the overall ground ...........................................................................38
2.1. Calculating and research object .........................................................................43
2.2.1. Objects for freeze-drying system research..................................................43
2.2.2 Calculation for the cooling system .............................................................. 44
2.3. Freezing drying system research schematic...................................................45
2.4. Calculating and designing methods ...................................................................46
2.4.1 Calculating methods ....................................................................................46
2.4.2 Design method ............................................................................................. 52
CHAPTER 3. CALCULATING AND DESIGNING A SYSTEM ......................... 53
3.1. Initial parameters used for the calculation ......................................................... 53
3.2. Calculating the mass balance .............................................................................53
3.3. Calculating equipment in a system ....................................................................53
3.3.1. Calculating and designing a freezing system integrated into the sublimation
chamber of the freeze-drying system ....................................................................54
3.3.1.3. Calculate the refrigerant load for a refrigeration procedure to condense
and freeze moisture sublimating from dried product. ...........................................65
3.3.2. Calculating and selecting a compressor with the appropriate cooling
capacity .................................................................................................................69
3.3.3. Calculation and design of heat exchangers of the product refrigeration
system ...................................................................................................................73
3.4. Freeze drying system design calculation ........................................................... 88
3.4.1. Calculation of the energy balance ............................................................... 88
3.4.2. Calculation of ice condenser .......................................................................93
3.4.3. Calculation of the vacuum pump ................................................................ 96
3.4.4. Define defrost time ..................................................................................... 97
3.4.5. Durability test for the freeze drying equipment and ice condenser ............98
3.5. Designing the freeze-dryer ...............................................................................101
CHAPTER 4. BUILDING TECHNICAL DRAWINGS........................................105
4.1. Principle diagram drawing ...............................................................................105
4.2. Detailed drawings of the device .......................................................................106
4.3. System installation drawings............................................................................119
CHAPTER 5. ECONOMIC CALCULATION FOR DRYING SYSTEM ..........120
5.1. Determine the annual cost of the drying equipment system: ...........................120
 5.2. Energy cost .......................................................................................................120
5.3. Salary cost ........................................................................................................120
5.5. Estimated cost of material made of main equipment .......................................120
CONCLUSION ..........................................................................................................122
REFERENCES ..........................................................................................................123
APPENDIX.................................................................................................................127
PREFACE

First and foremost, we would like to express my deepest appreciation to Assoc

Prof. Dr. Nguyễn Tấn Dũng who enthusiastically guided and helped us throughout the
project implementation process. Moreover, words cannot express our gratitude to the
teachers we studied with and other the Department of Chemical and Food Technology
teachers at the Ho Chi Minh City University of Technical Education for their
commitment to teaching us basic knowledge, which establish the foundational elements
and conditions necessary for completing this project.
The project “Calculate and design the freeze drying system of royal jelly products
with the productivity of 1500 kg/batch” includes 7 main parts:
Introduction
Chapter 1. Overview
Chapter 2. Calculating and research methods
Chapter 3. Calculating and designing a system
Chapter 4: Building technical drawings
Chapter 5: Economic calculation of the freeze-drying system
Conclusion
Due to our lack of abilities and experience, mistakes are inevitable. Therefore, we
look forward to receiving valuable feedback and recommendations from you to correct
and improve not only this project but also other projects in the future.
Sincerely,
Nguyễn Trần Hoàng Anh and Ngô Thị Phượng

i
 LIST OF FIGURES
Figure 1.1. Diagram of phase status of water .................................................................4
Figure 1.2. Schematic state of water in the drying process ............................................5
Figure 1.3. Freeze-drying process (Baheti et al., 2010) .................................................6
Figure 1.4. Kinetics of the freeze-drying process........................................................... 7
Figure 1.5. Freeze dryer DS-1, DS-2 .............................................................................8
Figure 1.6. Freeze dryer DS-3 ......................................................................................8
Figure 1.7. Freeze dryer DS- 4 ....................................................................................... 9
Figure 1.8. Freeze dryer DS - 5 ......................................................................................9
Figure 1.9. Freeze dryer DS-6 ........................................................................................ 9
Figure 1.10. Freeze dryer DS-7 ......................................................................................9
Figure 1.11. Freeze dryer DS-8 ....................................................................................10
Figure 1.12. Freeze dryer DS-9 ...................................................................................10
Figure 1.13. Freeze dryer DS 11...................................................................................10
Figure 1.14. Freeze dryer DS-12 ..................................................................................10
Figure 1.15. Some freeze-dried products (Dzung, 2022b) ...........................................11
Figure 1.16. Epsilon 2-40D single chamber freezer dryer of Christ ............................ 12
Figure 1.17. Ultra 35 Super ES two–chamber freeze dryer of Virtis ........................... 12
Figure 1.18. FD-JP-01 freeze dryer ..............................................................................13
Figure 1.19. FD-JP-02 freeze dryer ..............................................................................13
Figure 1.20. Royal jelly is taken from the hive ............................................................ 14
Figure 1.21. Flow chart for the freeze-drying technology of royal jelly ...................... 18
Figure 1.22. Factors affecting the freezing process ...................................................... 20
Figure 1.23. Structure of the sublimation chamber of a separate freeze-drying system
.......................................................................................................................................21
Figure 1.24. Structure of sublimation chamber of a self-freeze drying system ...........22
Figure 1.25. Structure of condensation- Freezing equipment with snow curettage and
scraping device, beam tube form ...................................................................................22
Figure 1.26. Structure of condensation-freezing equipment with snow curettage and
scraping device ..............................................................................................................23
Figure 1.27.Busch R5 oil ring vacuum pump 0025-100F ............................................24
Figure 1.28. Image of a sublimation drying system with a separate freezing stage ....25
ii
Figure 1.29. Picture of a sublimation drying system with the freezing stage in the drying
chamber (DS-4 and DS-5) ............................................................................................. 26
Figure 1.30. Illustration of sublimation drying system with freezing stage right in the
drying chamber (DS-1 and DS-2)..................................................................................27
Figure 1.31. Illustration of sublimation drying system with freezing stage right in the
drying chamber (DS-3) ..................................................................................................28
Figure 1.32. Illustration of Sublimation drying system with freezing stage right in the
drying chamber (DS-7) ..................................................................................................29
Figure 1.33. Illustration of continuous freeze drying ...................................................30
Figure 2.1. Phu Hoi Industry part ................................................................................. 32
Figure 2.2. Phu Hoi Industry part was taken by satellite..............................................32
Figure 2.3. Location of some bee farms in Lam Dong (marked in red) ....................... 33
Figure 2.4. Map of Phu Hoi Industry part (IIP Vietnam, 2016) ...................................34
Figure 2.5. The right chain direction of production line ..............................................37
Figure 2.6. Main workshop's overall ground ................................................................ 39
Figure 2.7. Overall ground of factory ...........................................................................41
Figure 2.8. Calculation and research diagrams ............................................................ 45
Figure 3.1. Mollier diagram .......................................................................................... 59
Figure 3.2. Two spherical caps od the freeze-drying chamber.....................................61
Figure 3.3. Wall’s structure of freeze-drying chamber ................................................61
Figure 3.4. Two-stage refrigeration cycle compression, intermediate with spiral tube,
completely cooled, with two throttles ...........................................................................63
Figure 3.5. Thermodynamic graph of two levels of compression refrigeration cycle .65
Figure 3.6. The analysis of an ice transformation process on the water three phases
diagram .......................................................................................................................... 67
Figure 3.7. The temperature difference based on heat exchange area.......................... 74
Figure 3.8. The formation principle diagram of the ice condenser .............................. 93
Figure 4.1. Principle diagram of a freeze-drying system .......................................... 105
Figure 4.2. General drawings of components .............................................................106
Figure 4.3. Freeze-drying chamber.............................................................................107
Figure 4.4. Freeze-drying chamber body....................................................................108
Figure 4.5. Front freeze-drying chamber cap .............................................................109
iii
Figure 4.6. Back freeze-drying chamber cap ..............................................................110
Figure 4.7. Observation door ......................................................................................111
Figure 4.8. Heat transfer plate ....................................................................................112
Figure 4.9. Tray ..........................................................................................................113
Figure 4.10. Ice condenser equipment ........................................................................114
Figure 4.11. Vacuum pump ........................................................................................115
Figure 4.12. Receiver (Intermediate tank) ..................................................................116
Figure 4.13. Condenser ...............................................................................................117
Figure 4.14. Compressor ............................................................................................118
Figure 4.15. Freeze-drying system .............................................................................119

iv
 LIST OF TABLES
Table 1. 1. Table of the relationship between sublimation pressure (Pth) and sublimation
temperature (Tth) of ice ....................................................................................................5
Table 1.2. Chemical composition of raw royal jelly (Dzung, 2020) ............................ 14
Table 1.3. Composition of amino acids in royal jelly (calculated according to % of dry
matter protein in royal jelly ±0,5) (Dzung, 2020) ......................................................... 15
Table 1.4. Content of minerals in Royal Jelly (Dzung, 2020) ......................................16
Table 1.5. Content of vitamins in Royal Jelly (Dzung, 2020) ......................................16
Table 2.1. A summary of the sections inside the main workshop ................................ 40
Table 2.2. A summary of the sections of factory .......................................................... 42
Table 3.1. The state parameters of the refrigeration system cycle need to be designed
and built ......................................................................................................................... 64
Table 3.2. Summary of design data of freeze dryer system........................................101
Table 5.1. Other equipment cost estimation .............................................................. 121

v
 DEFINITIONS AND SYMBOLS
Symbols Definitions Units
ak Length of the tray m
bk Width of the tray m
C1 Specific heat of product before water freezes kJ/ (kg.K)
C3 Specific heat of ice in the material kJ/(kg.K)
cck Specific heat capacity of dry matter in royal jelly kJ/ (kg.K)
Ck Specific heat capacity of a glass tray kJ/(kg.K)
cn Specific heat of the water in royal jelly kJ/ (kg.K)
const Constant -
D, d Diameter m
d1 Specific humidity when φ1 =85% kJ/kg
d2 Specific humidity when the air humidity reaches kJ/kg
saturation state φ = 100%
F Surface area m2
G Productivity for freeze-drying system kg/batch
Gsp Maximum weight of royal jelly product in the freezing kg
chamber
Gkk Quantity of air in a freezing chamber or drying chamber kg
divided by the amount of dried air.

h1 Air enthalpy at the start of a freezing process kJ/kg

h2 Air's final enthalpy after a freezing process kJ/kg
hc Height of each globe cap m
hk Height of the tray m
Kv Coefficient of heat transfer through the wall of the freeze W/ (m2 .K)
–drying chamber
L Length m
m1 Mass flow rate of the refrigerant circulating through the Kg/s
evaporator (or through a high-pressure compressor)
m2 Mass flow rate of the refrigerant passing through the Kg/s
condenser (or through low-pressure compressor)
N2el Power supply of the motor kW
Ne2 Useful capacity of the compressor kW
Nms Priction power kW
NSK Number of glass trays in a freeze-drying chamber trays
Nttn Number of heat transfer plates in the freeze-drying plates
chamber

vi
Nu Nusselt number -
P Pressure mmHg
Pn Partial pressure of water vapor N/m2
PO Phe pressure triple point mmHg
Pth Sublimation pressure of ice mmHg
Q Amount of heat kJ
Q0mn Refrigeration capacity of the compressor kW
Q1 Amount of heat removed to reduce the product kJ
temperature from the initial temperature to the closing
temperature of the water in the product
Q2 Heat removed to freeze all water in the product kJ
Q3 Amount of heat removed to reduce the state temperature kJ
to the final temperature of the freezing process
Q4 Amount of heat removed to reduce the temperature of the kJ
non-freezing water in the product
Q5 The amount of heat removed to reduce the temperature of kJ
the dry matter component.

Qk Amount of heat taken from trays kJ

Qk Thermal load of the condensing device kW
Qkk Amount of heat taken to cool the air kJ
Qmt amount of heat that enters the freeze-drying chamber kW
from the outside
Qngtdb Amount of heat it needs to be removed to condense- kW
freezing moisture escapes during the freeze-drying process
Q1 ngtdb Amount heat should be removed to carry out the kW
condensation process-freezing moisture escape from
freeze-drying products
Q2 ngtdb Amount of heat required to condense - freeze moisture at kW
the vacuum drying stage
Qob Cooling capacity of the freezer kW
Qqn Quantity of heat entering the pipeline from outside, kW
which causes the steam to overheat and damage the
compressor
Qsp Amount of heat for the freezing process kJ
R Radius m
Rkk Air constant value of dried air J/ (kg.K )
o
T Temperature C
o
Te Freezing medium temperature C
vii
 o
TFopt Optimal freezing temperature of wet materials C
Tkk Absolute temperature of dried air K
o
Tproduct temp Temperature of product C
o
Tth Sublimation temperature of ice C
o
Ttk Crystallization temperature C
o
tf1 Average ambient temperature C
o
tf2 Cooling environment's temperature C
o
t1 Temperature of the air entering the freezer prior to the C
freezing process
o
t2 Temperature of at the end of the freezing process C
VNSK Volume of space that NSK occupies in the freeze-drying m3
chamber
Vk Volume of a tray m3
Vkk Absolute temperature of dried air m3
Vsock Volume of royal jelly in each tray m3
Vsp Maximum volume of royal jelly product in the freezing m3
chamber
Vt Volume of freeze-drying chamber m3
W0 , Wa Moisture of royal jelly material %
Wsp, We Moisture of product after the freeze-drying process %
Wth Amount of moisture released for hours kg/h
Wthm Amount of moisture released for each batch kg/batch
α Heat convection coefficient W/ (m2.K)
δ Thickness m
ΔP Difference in pressure mmHg
λ Thermal conductivity coefficient W/ (m.K)
ρ Density Kg/m3
τ1 Freezing time 1 batch hours (h)
τ2 Freeze-drying time 1 batch hours (h)
Τxb Defrost time hours (h)
ω Amount of water in frozen royal jelly -

viii
 INTRODUCTION
 Posing a problem
Technology advancement is greatly improving food yield production. As a result,
preservation technology has become more important than ever to help inhibit bacterial
growth and other types of spoilage to prolong the shelf-life of products. However, during
the preservation processes, there are some changes in physical and chemical properties
that lead to a reduction in the quality of the product. Therefore, one of the problems that
researchers might be interested in is "How to prolong the shelf life of products without
affecting their original quality?"
Many food preservation technologies are being researched and applied. The
common methods of food preservation that are widely used across the world include
drying, freezing, chilling, pasteurization, and chemical preservation (Amit et al., 2017).
Among them, freeze-drying is one of the most advanced drying technologies that help
remove water by sublimation and extends the shelf life of products while preserving
their original quality. (Ciurzynska & Lenart, 2011; Dzung, Tuan, et al., 2022).
Freeze drying consists of 3 main stages: Freezing the material – Sublimation
drying – Vacuum drying. These two final stages affect the quality of the product mostly
(Dzung et al., 2015). Hence, it is a highly complex process with the multi-stages leading
to the high cost of freeze-drying technology. However, the freeze-drying technique is
widely applied in not only pharmaceuticals and biological materials but also in
producing high-value food products because of the maximal retention of their quality
when compared to other drying techniques (Nowak & Jakubczyk, 2020; Prosapio &
Lopez-Quiroga, 2020).
Royal jelly (RJ), essential food for queen bee larvae and the queen herself, is one
of the most attractive functional foods derived from insects that were applied to the
freeze-drying technique. Royal jelly is well known as a health-promoting compound that
is rich in essential nutrients and has many biological effects such as cell proliferation,
disinfectant action, hypotensive, antitumor, antioxidant, antibacterial, anti-
inflammatory, and anti-hypertensive activities (Nowak & Jakubczyk, 2020; Ramadan &
Al-Ghamdi, 2012). Because of the high value of nutrients and bioactivities, more and
more royal jelly are harvested by beekeeping on an industrial scale. In Viet Nam, the
1
average yield of royal jelly is about 0.15 – 0.2 million liters/year (Dzung et al., 2015).
Therefore, applying the freeze-drying method to preserve royal jelly is necessary not
only to help prolong the shelf-life, and remain the nutrient value and bioactivity of the
product, but also can preserve the product at the temperature of 25oC and reduce the
energy cost consumption (Dzung et al., 2015).
As a result, it is essential to develop a freeze-drying capable of producing the
highest quality products with the highest productivity and the lowest energy
consumption. Thus, this project tends to calculate and design a royal jelly freeze-drying
system with a productivity of 1500 kg/batch.

 Content of project
The project “Calculate and design the freeze drying system of royal jelly products
with the productivity of 1500 kg / batch” includes 6 main parts:
Chapter 1. Overview
Chapter 2. Calculating and research methods
Chapter 3. Calculating and designing a system
Chapter 4: Building technical drawings
Chapter 5: Economic calculation
Conclusion

 Objective of the project

 To find out and research the basic scientific theory of the freeze frying technique
and its application in royal jelly products.
 Apply the optimum technology parameters in previous studies on the
technological process of freeze-dried royal jelly products for calculating and designing
freeze drying system with a capacity of 1500 kg/batch for the royal jelly of the best
quality with the lowest energy cost and satisfactory moisture.
 To analyze factors affecting the calculation and design of freeze drying on the
royal jelly product.

 Research area of the project

The freeze-drying system of royal jelly product in Viet Nam with the
productivity of 1500kg/batch.

 Scientific meaning
2
  Give a general overview of the royal jelly freeze-drying system and the freeze-
drying processes.
 Establish the scientific theoretical bases for calculating and designing the freeze-
drying system for royal jelly with a larger capacity, in particular, or other products in
general.

 Applied meaning
 Can be used as reference material to establish the freeze-drying system's
operating parameters for drying royal jelly products on an industrial scale.
 Gave technical parameters, technical drawings of systems, and the construction
site of the factory to install the realistic freeze-drying system of royal jelly with the
productivity of 1500 kg/ batch in a food factory.
 Apply to calculate and design a freeze-drying system for not only royal jelly but
also other materials with diverse required productivity.

3
CHAPTER 1
OVERVIEW
1.1. Scientific basis of freeze-drying
1.1.1. Definition
Freeze-drying is one type of drying process that dehydrate or remove the water
inside the material by sublimating water from solid (ice) to gas (Dzung, Chuyen, et al.,
2022), (Nowak & Jakubczyk, 2020). Freeze-drying is also known as “lyophilization”,
which is derived from the word “lyophile” – which means “likes the solvent”, showing
the dry product's ability for rehydration (Hua et al., 2010).
Low temperature and pressure are the conditions under which freeze-drying is
conducted. It must be under the Triple point (0.0098oC; 4.58mmHg or 6.0x10-3atm)
(Dzung, Chuyen, et al., 2022).

Figure 1. 1. Diagram of phase status of water

1.1.2. The phase transition process of water
In Figure 1.2, at point M, PM = const, if the temperature of water in point M
increase to point G, the state of the water change from liquid to gas (taken along the M-
G line). This phenomenon often happens when a material is dried by conventional heat.
In case of decreasing pressure of water at point M (PM < 760mmHg), water in the liquid
phase is converted to the gas phase (taken along the M-L line). This phenomenon often
occurs when the material is dried by a vacuum drying process. In contrast, when PM =
const, but the temperature reduces from M to N, the liquid phase of water is turned into
a solid phase (taken along the M-N line). This is often the phenomenon of the freezing
process. (Dzung, Chuyen, et al., 2022).

4
 At point N, water is a solid phase and the conditional temperature is constant (TN
= TR = TH = const). When pressure reduces to point R, water is in a solid phase with
PR<4.58mmHg. At this point, TR=TH. At point H, TH will have a corresponding
sublimation pressure value of PH and vice versa. Hence, if the ice is placed in a pressure
environment of point R with PH<PR< 4.58mmHg, the corresponding sublimation
temperature of ice is Tth = TF > TH. In the other words, at that time when ice is in the
condition of point R, it could not sublimate immediately until raising the temperature
TR=TH to TF (corresponding to PR = PF). It had to perform a heat transfer phase (RF
segment), and then the ice begins to sublimate.

Figure 1. 2. Schematic state of water in the drying process

1.1.3. Relationship between pressure and temperature parameters in freeze-drying
Temperature and pressure are two basic parameters that affect the process of
changing the phase of water. Below is a table showing the relationship between these
factors.

Table 1. 1. Table of the relationship between sublimation pressure (Pth) and sublimation
temperature (Tth) of ice
Tth, 0C 0.0098 -1.7 -5.1 -9.8 -17.5 -26.6 -29.3 -45.4 -57.6 -66.7
Pth, 4.58 4.00 3.00 2.00 1.00 0.40 0.10 0.05 0.01 0.001
mmHg
From Table 1.1, it is clear that a particular sublimation temperature corresponds
with a definite sublimation pressure value. Besides, the temperature and pressure must
be less than the triple point O (0.00980C; 4.58 mmHg) is the prerequisite for ice
sublimation (Peng, 1994).
5
 According to Dzung et al, the sublimation time of ice is decided based on the ice
sublimation temperature (Dzung, Chuyen, et al., 2022). Thus, it is essential to choose
sublimation drying pressure for having the most suitable sublimation temperature which
can shorten the sublimation time as much as possible. Because the cost of a product
mostly depends on the freeze-drying time (Nowak & Jakubczyk, 2020), decreasing the
sublimation time will maximize economic profit.

1.1.4. Stages of the freeze-drying process

Three main stages of the freeze-drying process include Freezing, Sublimation
drying (Primary drying), and Vacuum drying (Secondary drying), see Figure 1.3.

Figure 1. 3. Freeze-drying process (Baheti et al., 2010)

Note that Annealing is an optional step. This is typically used for materials with
precipitation tendencies. (Baheti et al., 2010; Dzung, Chuyen, et al., 2022).

Freezing stage
The process of freeze-drying begins with the freezing stage. Phase change and heat
transmission are both involved in the freezing stage. The freezing stage includes the
cooling, extreme cold, crystalline water inside the wet material stage (Dzung, Chuyen,
et al., 2022).
The optimal freezing temperature of wet materials (TFopt, o C) at which the water
inside the wet material crystallized 95 - 99 % or even 100% (𝜔 = 1) of the water inside
the moist substance crystallizes.
The freezing process is completed as rapidly as possible to avoid the creation of
huge ice crystals. The large ice crystals formation when sublimating cause the loss of
nutritional substances of the product. Besides, when 𝜔 < 1, it will increase the energy
consumption of freeze-drying, and prolong the time in the vacuum drying.

Sublimation drying – Primary drying

6
 The second step of freeze drying is sublimation drying, also known as primary
drying. During primary drying, water inside the food is transformed into vapor and
escapes from it. These vapors will be passed through an ice condenser by a vacuum
pump. A cold surface is provided for the water vapor to adhere to and solidify by this
condenser. The vacuum pump is also protected from water vapor by the condenser.
During freeze-drying, temperature and pressure change. At the end of freeze-
drying, the temperature of the product will increase to greater than the crystallization
temperature of the water inside the product (Tproduct temp > Tkt) (Figure 1.4).
Sublimation drying is a slow process that takes many hours to sublimate more than
90% to 95%, or even 100%, of the water present in the material. This process can be
given extra energy if wishing to speed it up. However, oversupplying can alter the
structure of the product after freeze-drying. Additionally, when the product's residual
water content is below 5%, the secondary drying procedure is not required, and the
drying process is completed.

Figure 1. 4. Kinetics of the freeze-drying process

(1)- Temperature of radiation plate; (4)- Temperature at the outlet of the sublimation chamber;
(2)-Temperature of the freeze-drying environment (5)- The residual water content of the product;
(3)-Temperature of the product; (6)- Pressure of sublimation chamber.

Low-temperature vacuum drying – Secondary drying

Throughout this process, energy is added, increasing heat and breaking the bonds
between the product and water molecules. Therefore, the product will lose its ionic-
bonding water molecules. Products have a porous structure with 1-5% residual moisture
after vacuum drying.
7
1.2. Domestic studies on freeze-drying
Nhu Khuyen and Minh Chien conducted a study that designed a freeze-drying
system STH-1 for drying Bat Bo bamboo. The initial result of drying on bamboo shows
its good quality of drying with a short drying time. However, the STH-1 consumes more
energy (50-60% higher) compared with different drying methods (Nhu Khuyen & Minh
Chien, 2005).
In 2006, Nhu Khuyen et al continued researching technology and equipment
systems for drying agricultural products and food by freeze-drying. The freeze-drying
process of shrimp, bamboo shoots, and herbs with a freeze-drying system of a capacity
of 20-50kg/batch was invested (Nhu Khuyen et al., 2006).
Truong Loi, Đuc Ba, et al conducted a study about “Research, design, and
manufacture freeze-drying equipment with the capacity of 50 kg/day”. The freeze-
drying with a capacity of 50 kg/batch has been successfully designed in Vietnam with
locally available materials and low cost. Gac, spirulina algae. , durian and mangosteen
are tested to dry by this freeze-drying (Truong Loi et al., 2017).
Since 1999, Dzung et al have successfully 12 versions of the freeze-drying system
from DS-1 to DS-12 with various outstanding features used at manufacturing enterprises
across Vietnam.
Below are some pictures of the freeze-drying system DS-XX (Dzung, 2022b):

Figure 1.5. Freeze dryer DS-1, DS-2 Figure 1.6. Freeze dryer DS-3

8
Figure 1.7. Freeze dryer DS- 4 Figure 1.8. Freeze dryer DS - 5

Figure 1. 9. Freeze dryer DS-6 Figure 1. 10. Freeze dryer DS-7

9
 Figure 1. 11. Freeze dryer DS-8 Figure 1. 12. Freeze dryer DS-9

Figure 1. 13. Freeze dryer DS 11 Figure 1. 14. Freeze dryer DS-12

The latest freeze-drying system designed by Dzung et al is DS-11 and DS-12. One
of the most important points is that the drying chamber is heated by short-wavelength

10
radiation, which helps to reduce the energy costs of the system. The system has a
productivity of about 10 kg/batch (12÷15) kg, automatic drying process, and production
cost is estimated to be 1/3 to 1/2 of imported units (Dzung, 2022a) (Dzung, Chuyen, et
al., 2022).
With versions of the freeze-drying system, many food products are produced
(Figure 1.15):

Figure 1.15. Some freeze-dried products (Dzung, 2022b)

1.3. Overseas studies on freeze-drying
In recent years, freezing drying technology has advanced significantly. Freezing-
drying systems are produced in several developed countries, including the US, Russia,
Japan, France, Germany, Italy, and Spain, and are utilized in a variety of industries,
including food technology, pharmaceutical technology, etc.

1.3.1. Freezing – drying system of Germany

One of the best drying systems is Christ's Epsilon 2-40D Single Chamber
Sublimation Dryer (Germany). (Figure 1.16)
Equipment parameters: (Dzung, 2020)
 Productivity of the equipment: evaporating 25 kg of water/24 hours
 Freezing ambient temperature (-50 ÷-45)°C
 The drying medium's pressure can reach 0.001 mmHg
 Controllable drying environment temperature (-50 ÷ 45)°C;
 Computer-controlled automatic system;
 The cost of this machine is 320,000 USD, equivalent to about 6.7 billion VND.
11
 Figure 1.16. Epsilon 2-40D single chamber freezer dryer of Christ
1.3.2. Freezing- drying system of United States
Two-chamber freeze dryer by Virtis, model Ultra 35 Super ES (Figure 1.17).
Machines from this generation have a lot of advanced features.
Equipment parameters:
 Productivity of the equipment: evaporating 25 kg of water/24 hours
 Freezing ambient temperature (-60 ÷-55)°C
 The drying medium's pressure can reach 0.002 mmHg
 Controllable drying environment temperature (-60 ÷ 45)°C;
 Computer-controlled automatic system;
 The cost of this machine is 280,000 USD, equivalent to about 5.1 billion VND.

Figure 1. 17. Ultra 35 Super ES two–chamber freeze dryer of Virtis

12
1.3.3. Freezing- Drying system of Japan
FD-JP sublimation dryer with many different types has many super features.

Figure 1. 18. FD-JP-01 freeze dryer

Figure 1.19. FD-JP-02 freeze dryer

1.4. Material
1.4.1. Overview of royal jelly
Royal jelly is referred to as "Gelee Royal" by Francois Hub (Dzung, 2014a). The
sole food available to the queen bee and bee larvae is royal jelly, which is made from
glands in the mouth of the worker bee. When baby bees eat pollen which is found by
worker bees over 20 days of age, these pollens will go by the blood pathway to the head
of the bees, mix with saliva and divide into two parts. The first part secretes milk that is
converted into food for the queen bee, and the second section stores the milk inside the
body. Royal jelly is ivory in color, sweet, and slightly sour. Vitamins, proteins, and
different amino acids abound in royal jelly, making it a nutrient-dense diet. Additionally,

13
it serves as the primary raw material for the manufacture of pelletized royal jelly
products.

Figure 1.20. Royal jelly is taken from the hive

1.4.2 Chemical composition of royal jelly
A complex bee product called royal jelly contains several different types of
components, including water, protein, carbohydrates, lipids, water-soluble vitamins,
minerals, and free amino acids.

Table 1.2. Chemical composition of raw royal jelly (Dzung, 2020)

Compounds Ratio Rate calculated according Dry matter
Symbol to fresh ingredients ratio of raw
materials
1 Water Xtp1 59,2 % -
2 Protein Xtp2 14,26% 34,95%
3 Glucid Xtp3 15,95% 39,09%
4 Lipid Xtp4 4,00% 9,80%
5 Mineral Xtp5 1,10% 2,70%
6 10-HAD - 3,1% 7,60%
7 Wax - 2,39% 5,86%
8 10-HAD and wax Xtp6 5,49% 13,46%
9 Vitamim B5 - 4,05 mg/100g 9,93 mg/100g
10 Free fatty acid - 558,95 mg/100g 1370 mg/100g
1.4.2.1. Water
With harvest sources coming from a variety of locations, the water content of
royal jelly is steady and makes up more than 60% of the total (Dzung, 2015).

14
1.4.2.2. Protein
Table 1. 3. Composition of amino acids in royal jelly (calculated according to % of
dry matter protein in royal jelly ±0,5) (Dzung, 2020)
No Amino % No Amino acid % No Amino acid %
acid
1 Alamine 1,2 11 Methinonine 3,7 21 Glutamine 6,3
2 Aspartic 2,8 12 Phenylalanine 0,5 22 Hydroxyproline 2,3
3 Arginine 3,3 13 Proline 0,97 23 Hydroxylysine 3,5
4 Cystein 2,9 14 Threonine 2,0 24 Phosphatserine 3,7
5 Cystin 4,1 15 Tyrosine 4,9 25 Amino butyric axit 2,6
6 Isoleucin 1,6 16 Tryptophan 3,4 26 Phosphatalamine 4,4
7 Glycine 3,0 17 Serine 2,9 27 Phosphatglycine 4,1
8 Histidine 1,6 18 Valine 1,6 28 Phosphatproline 5,6
9 Leucine 3,0 19 Aparagine 2,7 29 Phosphattyrosine 3,8
10 Lysine 2,9 20 Glutamic 8,3 30 Other components 6,33
Protein accounts for 27-41% which is one of the most important parts of dried
royal jelly. The amino acids present with the highest percentage content are Proline,
lysine, glutamic acid, p-alanine, phenylalanine, aspartate, and serin. (Dzung, 2014a)

1.4.2.3. Carbohydrates
In terms of fresh raw ingredients, royal jelly has (14–23%) % carbohydrates
(Dzung, 2014a). It mainly consists of the sugars fructose, glucose, and sucrose, which
together account for nearly 90% of all sugar. Additionally, there are a few other sugars
that have been identified in royal jelly, including maltose, trehalose, melibiose, ribose,
and erlose. These sugars are biologically active carbohydrates that help the body create
nitrogenous bases, RNA, DNA, and some enzyme structures.

1.4.2.4. Lipid
According to fresh royal jelly material, lipids make up 3-8% of the total weight
and are primarily made up of unsaturated fatty acids (80–90%). 10-HAD, a highly
beneficial substance found in lipids, has several health benefits, including antioxidant,
antimicrobial, skincare, and protection against cancer, diabetes, high blood pressure, and
stomach ulcers. That is why 10-hydroxy-2-decenoic acid (10-HAD) is the most
important ingredient of royal jelly (Antinelli, 2003), and also a specific active ingredient
to distinguish real from fake and evaluate the quality of royal jelly. In some developed

15
countries, it is required that royal jelly products have a minimum 10-HDA content of
1.4% for fresh royal jelly and 5% for freeze-dried royal jelly.

1.4.2.5 Minerals
Royal jelly contains 0.8 to 3% minerals. In decreasing order, these minerals are K,
Ca, Na, Mg, Zn, Fe, Cu, and Mn (Dzung, 2014a).

Table 1.4. Content of minerals in Royal Jelly (Dzung, 2020)

Mineral mg/100g
Potassium (K) 200-1000
Calcium (Ca) 25-85
Magnesium (Mg) 20-100
Zink (Zn) 0,7-8
Iron (Fe) 1-11
Copper (Cu) 0,33-1,6
1.4.2.6. Vitamin
There are many vitamins in royal jelly that are good for your health, and Vitamin
B5 is one of them. It has about 4.2–5.5 mg of Vitamin B5 per 100g of fresh material,
which can help prevent diseases like burning pains, skin deformities, growth retardation,
digestive disorders, vomiting, cramps, etc.

Table 1.5. Content of vitamin in Royal Jelly (Dzung, 2020)

Vitamin mg/100g Vitamin mg/100g
Vitamin A 1.1 - 1.12 Vitamin B5 3.82 - 4.28
Vitamin D 0.2 - 0.23 Vitamin B6 11.82 - 11.95
Vitamin E 5 – 0.51 Vitamin B9 0.4 - 0.43
Vitamin B1 2.06 – 2.08 Vitamin B12 0.15 – 0.17
Vitamin B2 2.77 – 2.82 Vitamin C 2.1 – 2.35
Vitamin B3 42.42 – 42.88 Cortisone and hydroxyl acid 0.24 – 0.26
1.4.3 Health benefits and nutritional value
It can be said that royal jelly is a rich source of nutrients, supporting comprehensive
health care (Antinelli, 2003). Royal jelly contains many nutritious ingredients such as
vitamins of group B, carbohydrates, proteins, fats, and other minerals. According to
scientific studies, royal jelly brings many benefits to the user's body such as:

16
  Reducing the risk of cardiovascular disease: Royal jelly has a positive
effect on blood cholesterol levels, helping to reduce the risk of cardiovascular
disease. According to the results of a study in a group of people with a history
of heart disease, when using royal jelly 2 grams per day, continuously for 2
months, their blood cholesterol levels were lowered by 11%.
 Reducing the aging process: Royal jelly is an extremely powerful source of
antioxidants, including phenolics, fatty acids, and a variety of amino acids.
These substances help slow down the aging process by eliminating free
radicals in the body, thereby helping to prolong the youth of women.
 Improves brain health: Royal jelly has the potential to help with
Alzheimer's treatment because it includes antioxidants that can defend the
fatty acids in brain tissue from attacks by free radicals.
 Helps fight cancer: It has been noticed that royal jelly may be used to stop
the spread of cancer. It has been discovered that cutting off the blood supply
to cancer cells, can limit their growth. Royal jelly's fatty components have
estrogenic effects.

1.4.4. Thermophysical of royal jelly composition influencing on freeze- drying

process
Royal jelly viscosity: The viscosity of royal jelly is an important thermophysical
parameter used to evaluate the quality of the milk solution, as the viscosity decreases,
the ability to bind dry matter components, especially proteins, with water decreases. The
reason is that royal jelly is degraded or denatured, making the bond between the dry
matter component and the water affected. Therefore, in the study on the moisture return
of royal jelly products after freezing -drying, it is necessary to determine the viscosity
of royal jelly.

When using freeze-drying technology to measure the reconstitution of protein in

royal jelly, people frequently make an indirect assessment by observing the decrease in
viscosity of the freeze-dried royal jelly after soaking in water that accurately represents
the moisture removed from royal jelly at 25°C, whether the viscosity remains the same
as the original freeze-dried royal jelly. It contains high-quality, non-denatured protein
with excellent reconstitution. Instead, the protein in it deteriorates as viscosity decreases.

17
As a result, the finished product is of poor quality and has a weak capacity for
reconstitution.

1.5. Freeze-drying technology for royal jelly

1.5.1. Flowchart for the freeze-drying of royal jelly

Figure 1. 21. Flow chart for the freeze-drying technology of royal jelly

Description of the freeze-drying technology of royal jelly

Raw royal jelly: Pick royal jelly harvested in Vietnam's Lam Dong. Royal jelly
must be obtained from a bee hive at a temperature of 37 to 38 °C in order to be fresh
100 percent of the time. The product is entirely organic and contains no chemical
additions. It has a light yellow color, a natural odor, and a sour flavor. It is a very thick
solution.
Preservation and pre-processing: Post-harvest royal jelly is placed in close-
mouthed brown glass jars, avoid direct sunlight, and refrigerated at a temperature (5-10
degree Celsius for 6 hours. After that, royal jelly is transported to the workshop or

18
laboratory for further production. Following that, the royal jelly is filtered to get rid of
the wings, bee carcasses, pollen, and insoluble wax (impurities).
Pouring into glass trays and waiting for freezing: After filtering, royal jelly has
a moisture level of W0 = 59.20% and is placed onto glass trays with a 12.93 mm layer
thickness. Once the lids have been sealed, they are left to freeze at a temperature of 25
°C.
Freezing stage: The moisture in royal jelly is totally crystallized during the
freezing process by utilizing the optimal mode: freezing medium temperature T∞ = Te =
- 40.46° C, freezing duration τ1 = 1.63 h, and appropriate frozen temperature TFopt = -
18.33 °C.
Freeze-drying stage: Open the lids once the freezing process is complete and then
perform the freeze-drying. The temperature required for freeze-drying is 20.58 °C. The
drying chamber's pressure will rapidly decrease once the vacuum pump is operating,
creating a condition where Pth=0.411 mm Hg. Due to the difference in temperatures
between the constant product and the drying medium, frozen material rapidly loses
moisture content and undergoes strong sublimation of water. An atmosphere with high
temperature and low pressure is used during the freeze-drying process. Royal jelly's
moisture sublimates at -18.33 oC, leaving Wsp = 4.19% of its original moisture after the
freeze-drying process has taken 18.283 hours.
Vacuum sealing: To prevent moisture absorption and microbiological
contamination, the freeze-dried royal jelly with a low moisture content of 4.19% is
placed in a brown glass jar and vacuum sealed.
Storage: After vacuum sealing, freeze-dried royal jelly is kept at room temperature
(25 °C) for 18 months as the environment's moisture varies (65-70%), ensuring that the
product's quality remains constant.

1.5.2. Technological factors influencing the process

The relationship between input influencing factors, such as material factors,
equipment factors, technological factors, dependent factors, and output factors, which
are objective functions, is depicted in figure 1.22 based on an objective analysis of
freeze-drying technology. These factors include energy cost, moisture content, and
product quality. The product sublimation drying process is directly impacted by the

19
sublimation drying environment pressure, drying time, equipment, and materials
(Heldman D. R, 1992).
According to Stawczyk and Pikal (Stawczyk J, 2004) (Pikal M.J, 2007), when the
temperature of the sublimation drying environment is high, above 33 0C, the kinetic
energy of dehumidification heat transfer increases, but at the same time causes the
temperature of the drying material to rise quickly, exceeding the crystallization
temperature (Tkt).) This causes the moisture to change to a liquid state and ends the
sublimation drying stage early, but the product moisture is not satisfactory.

Figure 1.22. Factors affecting the freezing process

1.6. Apparatus of freeze dryer
Typically, a sublimation drying system requires the following components of
major apparatus:
 Freeze-drying chamber: If a freeze-drying system is capable of self-freezing, a
freeze-drying chamber can also serve as a freezer for dried food.
 Condensation – freezing equipment
 Vacuum pump system
 Automatic control system
In addition to the above main equipment, the sublimation drying system must have
a cooling system for the condenser-freezing and a refrigeration system to freeze the dried
20
food (if the sublimation system is self-freezing for dried food). Depending on the
manufacturing design, sometimes these two systems are just one. Therefore, the
sublimation drying system is a very complex drying system and very difficult to design
and manufacture.

1.6.1. Structure of a freeze-drying chamber

Depending on the type of freeze-drying system, the sublimation chamber has
different structures. However, the sublimation chamber must meet the following
technical standards.

 Vacuuming requires that the sublimation chamber be totally sealed.

 The space where dried food is stored must have a high product density because
it is where evaporation occurs most frequently.
 Sublimation and heat drying in a vacuum has the maximum heat transmission
capacities.
 Utilize the most effective heat transfer technique to reduce the time needed for
sublimation and heat drying.

Figure 1. 23. Structure of sublimation chamber of a separate freeze-drying system

1-Freeze chamber lip, 2- connection to vacuum pump, 3-Parallel flat plate containing frozen food
for drying, 4-heating system, 5-vacuum relief valve

The freeze-drying chamber of a separate freeze-drying system (figure 1.23) is the

simplest sublimation chamber. In the sublimation chamber, there is only a heating
device system, a connection to the vacuum pump, and temperature sensors (Dzung,
2014a)
21
 Figure 1. 24. Structure of sublimation chamber of a self-freeze drying system
1- Vacuum relief valve, 2- connection to the vacuum pump, 3- refrigerant supply line after the
throttle is supplied to the indoor unit (evaporator), 4- refrigerant outlet is sucked in by the
refrigerant compressor, 5- the door of the sublimation chamber, 6- the route for the heating
carriers to enter and exit the sublimation drying chamber

The structure of this sublimation chamber (Figure 1.24) is very complicated.

Because the sublimation chamber is also the freezing chamber. Below the heating plates
placed parallel to each other in the drying space, heat exchange pipes of the indoor unit
(evaporator) of the product refrigeration system must be arranged for drying products,
and at the same time, it is necessary to arrange heating pipes for heating during the
drying process (Dzung, 2014b).
1.6.2. Condenser-freezing device structure
1.6.2.1.Condensation-freezing equipment without snow curettage and scraping device

Figure 1. 25. Structure of condensation- Freezing equipment with snow curettage and
scraping device, beam tube form
1-Connection to sublimation chamber, 2- connection to vacuum pump, 3- refrigerant from the throttle
valve to the indoor unit, 4- refrigerant out of the evaporator, 5- the shaft that attaches the snow
scraper and connects to the electric motor, 6- evaporator, 7- snow scraper, 8-ice scraper cover, 9-
water outlet, 10- space to store ice and snow after scraping, 11-drive dirty snow scraper unit.

22
 Figure 1.25 is the structure of the condenser-freezing tube in the form of a coil.
The device in this form has the same structure as the heat recovery device in a single-
stage compressed air system with a heat recovery device, it is difficult to machine and
has a pressure loss when the refrigerant is recirculated through the system. Lubricating
oil is difficult to completely pull to the compressor crankcase, but its heat exchange
capacity is relatively good. Currently, equipment in this form is only used for
refrigeration systems with small and medium drying capacities (Dzung, 2020)

1.6.2.2. Condensation-freezing equipment with snow curettage and scraping device.

Figure 1.26 is the structure of the condenser-freeze unit with the scraper. This type
of equipment in terms of heat transfer for icing has many advantages over condensers-
freezers without scrapers. Because the snow on the surface of the indoor unit will be
scraped - scraped down into the space (10) increasing heat transfer, but it has the
disadvantage that it takes more electrical energy to run the motor for the scraper.
Moreover, the process of processing this equipment is very complicated, the tightness
must be ensured, and the repair and maintenance process is very difficult (Dzung,
2014d).

1- the connection to the sublimation chamber, 2- the connection to the vacuum pump, 3- refrigerant
from the throttle valve to the indoor unit, 4- refrigerant out of the evaporator, 5- the shaft that attaches
the snow scraper and connects to the electric motor, 6-evaporator, 7- snow scraper, 8-ice scraper
cover, 9-water outlet, 10-space to store ice and snow after scraping, 11- drive shaft dirty for snow
scraper unit.
Figure 1.26. Structure of condensation-freezing equipment with snow curettage and
scraping device

23
1.6.3. Vacuum pump
Because the quantity of moisture evaporation depends mostly on the difference in
partial pressure of moisture and moisture on the surface of the dried food, the problem
of producing a vacuum during the sublimation drying process is crucial.
 The vacuum pressure of the drying medium must be less than the pressure triple
point (PO = 4.58 mmHg) means that the drying medium pressure is less than 4.58
mmHg
 Time of aspiration in the drying medium from atmospheric pressure to vacuum
pressure (0.001 ÷ 1.0) mmHg must be small enough.

Figure 1.27.Busch R5 oil ring vacuum pump 0025-100F

1.6.4. Automated systems for measurement and control
An automation system, often known as an automatic measurement and control
system, is a collection of automation. This group of control mechanisms, objects,
signals, and coordinated actions is used to carry out a specific technological process in
accordance with a pre-programmed logic scheme, suitable for the technological process
without any or all human involvement, and accomplish the desired result
simultaneously.

1.7. Principle diagram of the freeze-drying system

The freeze-drying system is classified into three types based on the structure of the
sublimation chamber:
Separate freeze-drying system: The product is frozen by an independent
refrigeration system, and after freezing, it is placed in the sublimation chamber to dry.
As a result, the refrigeration system in the sublimation drying system only serves one
purpose: to condense the moisture released from the product before the vacuum pump
takes the waste out.

24
 - Self-freezing refrigeration system: This system freezes the product directly in the
sublimation drying chamber. As a result, the refrigeration system in the sublimation
drying system performs two functions: the first is to freeze the product in stage 1; the
second is to condense the moisture released from the product before the vacuum pump
suckers it out in the second stage of sublimation drying and the third stage of low-
temperature vacuum drying.
- Continuous Sublimation Drying System: This system freezes the product
continuously product. As a result, the refrigeration system in the continuous sublimation
drying system only serves one purpose: to condense the moisture released from the
product before the vacuum pump sucks it out.

1.7.1. Separate freeze-drying system

Figure 1. 28 is a private freeze-drying system on an industrial scale. It uses a single-
stage compression refrigeration system that runs the condenser-freezer to freeze
moisture. The above refrigeration system uses ammonia (NH3) or freon 22 (R22)
refrigerant and can also use freon 502 (R502), and freon 400A (R400A) refrigerant.
Types of freon 22, and 502 are currently on the banned list because of their great
negative influence on the ozone layer, so they should be prohibited from use. This
refrigeration system can lower the temperature in the condenser – freezing down from
(-40 ÷ -25)C. However, in order to fully exploit the vacuum system, the moisture
condensing temperature in the condenser - freezing (snowing) is as deep as possible. If
the temperature in the condenser-freeze reaches (-80 ÷ -45)C, the vacuum pressure can
be lowered to near absolute vacuum and can reach 0.0001 mmHg (Dzung, Chuyen, et
al., 2022).

Figure 1.28. Image of a sublimation drying system with a separate freezing stage
25
 Separate freeze-drying system: Before sublimation drying products are frozen in
independent freezing equipment such as freezers, IQF freezers, or super-fast frozen by
liquefied nitrogen gas, CO2 dry ice, etc. After freezing, the product is transferred to the
sublimation chamber to perform the sublimation drying process. Currently, this system
is mainly manufactured on an industrial scale. This sublimation drying system can also
be used for vacuum drying and low-temperature vacuum drying. When drying food,
simply adjust the heating temperature at (21°C) up to a temperature between (45 ÷
65)°C, the drying environment pressure does not need to be below 4.58 mmHg and the
food does not need to be frozen, this is vacuum drying (Dzung, Chuyen, et al., 2022).

1.7.2. Self-freezing refrigeration system

Figure 1.29 is an industrial-scale self-freezing sublimation drying system. The
maximum product freezing environment temperature in the sublimation chamber is only
in the range of (-40 ÷-30) C, because this sublimation drying system uses a single-stage
compression refrigeration system. If the product needs to be frozen at a deeper freezing
temperature, below -45C, then a two- or three-stage refrigeration system, or a cascaded
refrigeration system, must be used to freeze the required product before freezing.
Freeze-drying, freezing time as fast as possible. The faster the freezing, the smaller the
ice crystals produced (can crystallize in place); so that less influence on product
structure, large ice surface area, better sublimation ability of ice crystals, shortening
drying time.

Figure 1.29. Picture of a sublimation drying system with the freezing stage in the
drying chamber (DS-4 and DS-5)

26
 The working principle is as follows: Initially, the food is put into the sublimation
chamber (3) for freezing, the vacuum pump (2) is not working, the refrigeration
compressor (1) is working, the SV2 solenoid valve and the throttle valve VTL2 works
to supply cold to the evaporator (12), solenoid valve SV1 and throttle valve VTL1 have
not worked because the condenser-freezer has not worked. When the sublimation
chamber reaches the temperature, the food is frozen to the required temperature, then
stop supplying cold to the sublimation chamber, SV2 solenoid valve and VTL2 throttle
closed, SV1 solenoid valve and throttle valve closed. VTL1 works (opens), the vacuum
pump works, heating resistor starts heating, maintaining the temperature of the drying
environment according to the technological requirements set forth (0 ÷ 45)C. The
drying process is carried out until the sublimation chamber temperature is equal to the
ambient temperature and the humidity is satisfactory, the drying process ends, and the
refrigeration compressor and the vacuum pump stop working.
The drying capacity of this system can only dry up to (1 ÷2) kg of products, for
each type of product when drying, there must be a separate process. If the process is
properly understood, the final product will have good quality (Dzung, Chuyen, et al.,
2022).

Figure 1.30. Illustration of sublimation drying system with freezing stage right in the
drying chamber (DS-1 and DS-2)
1-Compressor; 2-Vacuum pump; 3-Sublimation chamber; 4-Condensation system; 5-Condenser-
Freezer; 6-High pressure tank; 7-Oil separator; 8-Liquid separator; 9-Film filter; 10-Magnetic valve
SV1 – Throttling valve VTL1 ; 11-Magnetic valve SV2 – Throttling valve TL2 ; 12- Film-shaped
heater.

27
 The system is designed and manufactured as shown in Figure 1.30, using a single-
stage refrigeration system to freeze products before drying and to petrify moisture before
vacuum pumping. And to reach the temperature (-40 ÷-30)C, the refrigeration system
designs and manufactures a system that uses refrigerant R502 or R400A, because using
this refrigerant reduces the compression ratio somewhat when the system works working
in sub-zero temperatures. As for R22, when working at this temperature range, the vapor
pressure of the refrigerant in the evaporator is small, leading to a large compression
ratio, the compressor is very tired, and the compressor overheating occurs continuously
to damage the compressor. Moreover, refrigerants R502 and R400A have the ability to
dissolve with lubricating oil, this is one of the advantages over ammonia, it has the
ability to pull lubricating oil from equipment in the refrigeration system to the engine
crankcase. compression, but for ammonia at a deep negative temperature range of less
than -60C, it is very dilute, leading to a rapid decrease in the cooling capacity of the
refrigeration system.
Figure 1.31 is the DS-3 self-freezing sublimation drying system, this system uses
a two-stage compression refrigeration system to freeze the product before drying, the
freezing ambient temperature reaches (-50 ÷ -45)C, so the freezing in stage 1 happens
quickly. Besides, this two-stage compression refrigeration system is used to run the
dehumidifier, so the pressure of the drying medium drops very later, reaching 0.008
mmHg. In addition, the DS-3 machine has a measurement system and automatic control
of the drying process on a computer (Dzung, 2020).

Figure 1.31. Illustration of sublimation drying system with freezing stage right in the
drying chamber (DS-3)

28
 The DS-6 self-freezing sublimation drying system, is a heat pump type system,
using waste heat in the condenser for product freezing and condensing the moisture
vapor emitted from the product to provide heat for the process. The sublimation drying
process saves a lot of energy. This system uses a single-stage refrigeration system to
freeze products before drying, the temperature of the freezing environment as well as
the dehumidification environment can be lowered to (-40 ÷ -25)C, and the pressure of
the drying medium reaches 0.005mmHg. In addition, this system also has the function
of sterilizing the drying chamber before drying the product. In general, this is a rather
complicated system and the fabrication is difficult.

Figure 1.32. Illustration of Sublimation drying system with freezing stage right in the
drying chamber (DS-7)
Figure 1.32 is a self-freezing DS-7 sublimation drying system. This is a two-stage
compression refrigeration system with a fully cooled spiral tube intermediate for the
sublimation chamber to freeze the product before drying and running for the freezing
condenser. The freezing environment temperature as well as the humidity-condensing
environment temperature can reach (-50 ÷ -45)C. The vacuum system uses a two-stage
vacuum pump, and an oil ring and has lowered the vacuum pressure very deeply,
reaching 0.001 mmHg. This is a technically complete drying system, the technological
parameters are measured and automatically controlled by the computer (Dzung, 2020).

1.7.3. Continuous Sublimation Drying System

Figure 1.33 is an industrial-scale continuous sublimation drying system. Food to
be dried is made into small particles by mincing, grinding and granulating technology,
forming pellets, and then freezing separately before being dried thanks to the external

29
freezing system. After freezing, thanks to a conveyor or a screw to bring the food to be
dried to the input hopper, the drying process occurs continuously. A continuous
sublimation drying system is one of the drying systems.
The most complicated, because in addition to ensuring the vacuum tightness for
the drying flow, it also ensures the vacuum for the feeding stages, product unloading,
and conveyor control system..., so this system is enhanced manufacturing at very high
precision, requiring precise mechanical machining to meet the requirements.

Figure 1.33. Illustration of continuous freeze drying

The working principle of this system is the process of inputting and taking out
products continuously. When the compressor starts working, the refrigerant is led from
the high-pressure container (8) to the throttle valve (22) to reduce the pressure, reduce
the temperature, supply cold to the condenser - freeze to make the compressor cool. The
moisture evaporates from the product before the vacuum pump (10) sucks it out,
receives the heat of the refrigerant vapor, it boils and evaporates, then it is sucked in by
the compressor (9) and compressed onto the condenser (7), where the refrigerant solvent
gives off heat to the cooling medium, converting the phase from vapor to liquid, which
is then returned to the high-pressure reservoir (Dzung, 2020).
To sum up, royal jelly is a product with a high concentration of nutrients and
bioactivities. Using freeze-drying technology helps keep royal jelly fresh and helps
maintain the product's quality. The freeze-drying process includes freezing, sublimation
drying, and vacuum drying. The freeze-drying system is built based on the freeze-drying
process. It consists of the following system: the freeze drying chamber, condensation,
30
vacuum pump system, and automatic control system. In addition, the freeze-drying
system is classified into three types based on the structure of the sublimation chamber:
separate freeze-drying system, self-freezing refrigeration system, and continuous
sublimation drying system.

31
CHAPTER 2

CALCULATING AND RESEARCH METHODS

2.1. Planning the construction site of the factory to install a system

2.1.1.1. Choosing the location of the freeze-dried royal jelly factory

After researching and surveying, our group decided to set up the factory at Phu
Hoi Industrial Zone – placed at Phu Hoi Commune, Duc Trong District, Lam Dong
Province.

Figure 2. 1. Phu Hoi Industry part

Figure 2.2. Phu Hoi Industry part was taken by satellite

 For natural characteristics:

 Distance to the supplying location:

32
 Phu Hoi Industry part is located in Lam Dong province which is the main region
where the royal jelly is produced. There are several large beekeeping farms. According
to preliminary statistics (in 2017), there are nearly 1,000 households raising bees for
royal jelly in Lam Ha and Duc Trong districts (Hoang Hanh, 2017).

Figure 2.3. Location of some bee farms in Lam Dong (marked in red)
Besides, as can be seen in Figure 2.3, Phu Hoi Industry is located near various
beekeeping farms. Therefore, it can reduce the time and cost of transportation.
Moreover, it helps to reduce the spoilage and quality changes of royal jelly during
transportation before being processed.

 Soil and land characteristics:

Phu Hoi Industry is placed at Phu Hoi Commune, which is one of the communes
in Duc Trong. The area in there is mostly Basalt, with a small slope. It has hard soil with
1.5-2.5kg/cm2. The land here is assessed to have relatively good mechanization,
electrification, and irrigation capabilities (Lam Dong Provincial People’s Committee,

33
1985). Therefore, the land characteristic of the Phu Hoi Industry is suitable for building
factories.

 Major wind direction:

From figure 2.4, it shows that the major wind direction of Phu Hoi Industry part is
the East. Therefore, the main gate of the factory should face the East to catch the wind.

Figure 2.4. Map of Phu Hoi Industry part (IIP Vietnam, 2016)

 Meteorology and weather data

Duc Trong district is located in the tropical monsoon climate zone. The average
temperature in Duc Trong District is low, ranging from 19.2 to 22.3oC/month. The
average temperature of the year is around 21.1oC. The temperature fluctuation between
day and night is large. The air humidity there is low (Department of Culture and
Information Duc Trong district, 2017).

 Material supplying area

Lam Dong is one of the main regions that produce royal jelly products. Many
beekeeper families in Binh Thanh commune, Duc Trong district (Lam Dong) have
linked together into cooperative groups, producing royal jelly to provide a stable supply
for businesses (Hoang Hanh, 2017). From 2019 until now, 40 beekeeper families are
34
connecting to the main stable farming of 4,500 honey bee colonies, with a total output
of 40 tons of royal jelly/year (Vu Van, 2022). On the other hand, to take advantage of
the large area of forest and coffee fields, the biosafety honey beekeeping model has been
deployed and expanded in Lam Dong province. This model is suitable for small
household scales and large scales. It not only improves economic efficiency but also
helps to provide consumers with safe and non-antibiotic residues (Van Dac, 2020).

 Power, water supply, and water treatment (IIP Vietnam, 2016; Invest
Vietnam, 2017):
The power supply of the Phu Hoi Industry part is from Duc Trong 110 KV
substation. The industry part has 1 substation 110/220 KV and 3 substations 22/0.2 KV.
For the water supply, it has 2 sources: Da Nhim and the underground river.
Besides, it has advanced drainage and wastewater treatment systems. The
wastewater treatment facility has a capacity of 7.000m3/day. Water quality after
treatment reaches Level A (QCVN 40:2011/BTNMT).
 Transportation and integration with others (IIP Vietnam, 2016; Invest
Vietnam, 2017):
Phu Hoi Industry already has a road system. The main road is 32-47.5m wide with
4-6 lanes. The side road is 17-24m with 2 lanes.
From the Phu Hoi Industry, it has a road system go to National Highway 20, which
connects Lam Dong and Dong Nai provinces.
Distance from Phu Hoi Industry to Da Lat city is 30 km; Lien Khuong air-post is
6 km; Binh Thuan seaport is 130 km, and Ho Chi Minh City is 270 km. Thank these, it
is convenient to transport and connect with a large city, reducing the time and cost of
transportation.

 Human resources
In general, Lam Dong province, labor force aged 15 years and over of Lam Dong
province in the first quarter of 2022 is 786.9 thousand people. Thus, this is abundant
human resources for the factory. Besides, the Phu Hoi Industry part is near to Phu Hoi
residential area (about 1.5km), which can help to minimize the investment in the
construction of housing for the worker.

35
 In short, because of the stable material supply area with many other conveniences
of the Phu Hoi Industry part and the advantages in climate conditions, we choose the
Phu Hoi Industry part (in Lam Dong) where the freeze-dried royal jelly factory is placed.

2.1.2. Arrangement of equipment inside the workshop

The arrangement of equipment inside the workshop is important because it can
affect the work of the factory and the design of the overall ground in a later step.
This stage requires the arrangement to be suitable and reasonable for technological
requirements; Ensure convenience in traveling and manipulation (Chuyen, 2018):.
Designing steps (Chuyen, 2018):
Step 1. Establishment of the equipment list
Before the arrangement of equipment inside the main workshop, it is essential to
know what equipment is used, what are their dimension, etc. Therefore, all equipment
used must be listed.
Step 2. Determine travel routes and doorways based on estimated overall
ground design.
The main workshop and other structures are simply estimated based on the overall
ground design to plan the overall transport system and doorways.
Step 3. Arrangement of equipment inside the workshop
The way of arranging equipment inside the workshop will affect the dimensions
and type of the workshop.
Below are some principles of equipment arrangement (Chuyen, 2018):
Firstly, the equipment must be arranged in order and continually produced to
produce a continuous chain. The distance and time of transportation will be reduced.
Secondly, in some circumstances, it is feasible to stack one machine on top of
another to save space, reduce pumping, and guarantee good product quality.
Thirdly, there must be continual movement along the production line. Do not let
the line of process return to the previous position or carry out many processes in the
same region. The lines can be merged or separated depending on technological
requirements (Figure 2.5).
Fourthly, maximize utilizing the area of the workshop. Reduce the length of the
factory by reasonably placing the equipment on the ground, or simply increase the
height of the building where the equipment is high.
36
 Fifthly, should place large equipment in the center of the workshop. If it is placed
near windows, it will obstruct the room's natural lighting and airflow. Besides, placing
it near the door will block transportation.
Sixthly, comply with the conditions for working hygiene and safety:
 Two rows of machines must be separated by more than 1.8 meters. If there are
traveling vehicles, a distance of more than 3 meters is required. Space of 0.8 to 1
meter can be left in the appropriate places.
 The rails for the electric winch to move must be over 4 m high. The rails should
be fixed to walls, poles, or beams.
 Equipment installations surface with worker work must be 1.5 to 2 m wide.
Ladders over 0.7 m wide and a floor, which is 2 m high or higher from the ground,
are also required.
 Equipment placed deep into the ground such as containers must have tight lids or
have walls as high as 0.8 m above the floor.
Finally, ensure incident and fire safety:
 Extra doors must be installed in the lengthy workplace to allow for speedy escape
in the event of an emergency.
 Processing lines shouldn't be overly lengthy or blocked off from worker entry.
 Distances between machines that operate under pressure or vacuum must be
greater than 0.8 meters.
 The proper color must be used when painting the pipes. Heat transfer components
and steam pipes need to be insulated.
 Pressure gauges and safety valves should be installed on machinery that operates
under pressure and vacuum.

a) Normal production line b) For too lengthy a production line

c) If a production line uses several d) If the productivity of the factory later is

components for production small, some branches will need to be separated.

Figure 2.5. The right chain direction of the production line

37
2.1.3. Design the overall ground
 The overall ground design should adapt to some general requirements (Chuyen,
2018):
 Ensure the processing line from materials to products is as short as possible.
 Convenience in for the integration among the processing steps and
surrounding building.
 Making use of materials and removing waste products.
 Suitable internal and exterior transportation solutions.
 The placement of the structures and portions must be appropriate for the soil's
qualities.
 Ensure that the distances between the buildings adapt to the needs for
industrial hygiene, firefighting, ventilation, and lighting.
 Minimizing the construction area.
 Ensure the space for future industrial expansion.
 Besides some requirements, the overall ground of the factory is designed based
on 2 basic principles: Group design or Function design:
 Group design: The sections with similar processing characteristics and
construction requirements are in one large building.
 Function design: The workshops/groups are arranged based on their
functions.
In this case, we decide to design the overall ground of the factory based on
Function design because of their advantages. It is easier to arrange areas according to
technological requirements; can control, and operate the factory, organize traffic and
handle accidents, fires, and explosions more easily; have good natural ventilation and
lighting; satisfy industrial hygiene requirements. Nevertheless, it requires a large area
of the factory.
 To design the overall ground of the factory, follow the below steps (Chuyen,
2018):
Step 1. Calculating the supporting sections: Do this step after the arrangement
and calculation of the main workshop are completed.
Step 2. List all the construction sections for a summary.

38
 Step 3. Identify the total area required for the total ground of the factory.
Step 3. Drawing
Because of the limited scope of the project calculating and designing the freeze-
drying system for the royal jelly product with a productivity of 1500 kg/batch, the
arrangement of equipment inside the workshop and the overall ground of the factory are
just in theory based on principles for further research.
Below are just the predicted and estimated dimensions for the main workshop’s
overall ground:

Figure 2.6. Main workshop's overall ground

39
 Table 2.1. A summary of the sections inside the main workshop

Dimensions
No. Works/Buildings (length x width) Area (m2) Functions
(m)
Place produces dried royal
1 Processing area 45 x 45 2025 jelly product – where freeze-
drying system is installed
2 Packaging area 30 x 25 750 Packaging product
3 Material storage 45 x 20 900 Storage raw material
4 Product storage 30 x 25 750 Storage final product
Material receiving
5 15 x 10 150 Place receive raw material
area
Control electrical system of
6 Electrical room 5x5 25
main workshop.
Operation and maintenance
7 Technical room 5x5 25
of technical equipment
Control air circulation and
Air-conditioning
8 5x5 25 temperature inside main
room
workshop
Compressed air Control the compressor’s air
9 5x5 25
room quality
Director and vice-
director of Room of director and vice-
10 5x5 25
production director
department
Control for food safety and
11 QA-QC room 10 x 5 50
quality
Room for workers changing
12 Changing room 10 x 5 50
clothes
13 WC men 5x5 25 Personal sanitary
14 WC women 5x5 25 Personal sanitary
Space for
15 Remaining Remaining Transportation
transition
Total area of
main workshop 75 x 75 5625
(m2)

40
Below is the predicted and estimated dimensions for overall ground of factory:

Figure 2.7. Overall ground of factory

41
 Table 2. 2. A summary of the sections of factory

Dimensions
Area
No. Buildings (length x width) Functions
(m2)
(m)
For freeze-dried royal jelly
1 Main workshop 75 x 75 5625
production
For non-manufacture
2 Administrative building 25 x 10 250
activities
3 Product exhibition building 25 x 10 250 For exhibition products
For meals of workers and
4 Kitchen and canteen 25 x 10 250
staffs
5 WC (Men) 5x5 15 Personal sanitary
6 WC (Women) 5x5 15 Personal sanitary
Install and maintain
7 Mechanical workshop 15 x 10 150
equipment
Supplying water for
8 Water supplying 15 x 10 150
factory’s activities
Treat water and solid
9 Waste treatment 30 x 15 450
waste
Convert industrial zone
electricity into factory
10 Voltage converter 7 10 70 electricity. There is a
backup generator to
supply power to the plant.
Manage orders and
(5x5)x3 25 x 3 =
11 Security rooms (s) navigate traffic in the
rooms 75
factory.
12 Garage for trucks 60 x 30 1800 Parking space for trucks
Garage for motorbikes & Parking space for vehicles
13 72 x 10 720
cars staffs
Land for future upscaling
14 75.5 x 30 2265 Area for future expansion
production
Room for research and
Research and Develop -
15 10 x 10 100 developing products and
R&D -department
process activities
Roads, trees, and Remaini For aesthetic and
16 Remaining
landscape ng transportation purposes.

The total area of the

220 x 105 23100
factory (m2)

42
2.1. Calculating and research object
2.2.1. Objects for freeze-drying system research
 Cooling system
Firstly, create a cooling system calculation. Initial specifications required: The
freezing system required to prepare items for sublimation drying must be calculated,
designed, and built using these first fundamental parameters.
- Product freezing capacity and system productivity for freeze-drying are both G
kg/batch; alternatively, the capacity for dehumidification of the freeze-drying
system is Gn kg/batch.
- Selecting a system with an appropriate refrigerant;
- The cooling environment's temperature must be achieved at tf2 = (-45 ÷ -40) °𝐶;
- Identifying the type of compressor—a single-stage or two-stage compressor;
- The system is set up in a climate where the hottest days of the year have an
average ambient temperature of tf1 = (35 ÷ 45) °𝐶;
- Selecting a system that has a water-, air-, or water-air-cooled condenser;
- Identifying a system's primary thermodynamic cycle's purpose.

 Sublimation chamber
- Determine the amount of freezing water in the product;
- Determine the amount of heat required;
- Determine the heat transfer area;

 Condenser
The heat load of the refrigeration system that is operating for the condenser-
freezing is also produced by the heat discharged in the condenser. Therefore, we will
compute the technical specifications of the refrigeration system for the condenser-freeze
device while calculating the heat for the condenser-freezer.

 Vacuum system
Depending on the capacity of the sublimation chamber or the drying capacity, it is
possible to have a series or parallel vacuum pump diagram or just use a vacuum pump
to decide the specifications for the vacuum system.

43
2.2.2 Calculation for the cooling system
- Determine the specifications of the freezer chamber (also sublimation chamber)
- Calculating the heat load (kW) of the freezing process of a product prior to freeze
drying;
- Establishing a cooling system's thermodynamic cycle;
- Determine the cycle's precise cooling capacity, q0 (kJ/kg), as well as the volume
flow rate, Vtt (m3/s), and storage mass flow rate mtt (kg/s) of the refrigerant
moving through the refrigeration system;
- Determining the compressor's level coefficient (suction capacity) and selecting
an appropriate compressor;
- Figuring out the compressor 𝜆𝑚 level coefficient (suction capacity) and selecting
a suitable compressor;
- Calculate the compressor's adiabatic compression capacity Ns (kW), the friction
power Nms (kW), and the following capacity power on the motor Nel ( kW) should
all be determined;
- Determining the engine and calculating the compressor's Nc (kW) power;
- Determined heat exchanger parameters.

2.2.3 Calculation of heat for the sublimation chamber

Identifying the following quantities is crucial for determining the sublimation
chamber's parameters.
- Measuring how much-frozen water is there inside of materials. Typically, this
percentage needs to be 100% for the outside goods to evaporate during freeze-
drying and condense at the condenser;
- Calculate the water content of the frozen product to determine the amount of heat
needed for the freeze-drying process;
- Measurement of the drying process's heat transfer area.

2.2.4 Calculation for the ice condenser

There are a few quantities that need to be measured to calculate the technical
factors for the condenser.
- Calculating the heat output of the petrification device;
- Calculating the petrification apparatus's heat transmission area;

44
 - Calculating the sublimation chamber's thaw and oxygen removal times.

2.2.5 Calculation for the vacuum system

- Calculating the drying environment's vacuum pressure Pth (mmHg);
- Calculating the pump's vacuum-limited pressure Pgh (mmHg);
- Figuring out a vacuum pump's suction power;
- Lastly, determine the vacuum pump's electrical motor power.

2.3. Freezing drying system research schematic

Figure 2.8. Calculation and research diagrams

45
2.4. Calculating and designing methods
2.4.1 Calculating methods
 Calculating the freezing chamber:
The storage volume for products is calculated by:
𝐺𝑠𝑝
Vsp= (m3 )
𝜌

In which,
G sp – the maximum weight of royal jelly product in the freezing chamber, (kg);
V sp – the maximum volume of royal jelly product in the freezing chamber, (m3);
𝜌 = 1328.072kg/m3 – the average density of royal jelly product in the freezing
chamber
The volume of a tray:
Vk= ak.bk.hk, (m3)
In which,
ak (m) is the length of the tray; bk (m) is the width of the tray; hk (m) is height of
the tray;
The volume of royal jelly in each tray:
Vsock = ak. bk. 𝛿 (m3)
In which:
ak (m) is length of the tray; bk (m) is width of the tray; 𝛿 is average thickness of
royal jelly layer
The number of glass trays in a freeze-drying chamber:
𝑉 𝑠𝑝
NSK = (item)
𝑉𝑠𝑜𝑐𝑘

The volume of space that NSK occupies in the freeze-drying chamber:

VNSK = Vk. NSK (m3)
In which,
NSK is the number of glass trays in freeze-drying chamber;
Vk is the volume of each tray (m3)
Determine the specifications of the freezing chamber:
+The length of the cylinder of the freeze-drying chamber:
L= 2hc + L1, (m)
In which,

46
 hc= const (m) is height of two cylindrical drying chamber caps ( two globe caps);
L1 = const (m) is cylindrical body length.
+The number of heat transfer plates in the freeze-drying chamber:
𝑁𝑆𝐾
Nttn = (plate)
𝑛𝑡

In which,
NSK is the number of glass trays in freeze-drying chamber; nt (tray) = const is
number of trays in heat transfer plate.
+The distance between two heat transfer plates:
h = 𝛿1 + 𝛿2 (m)
𝛿2 (m) = hk +0.012
In which,
𝛿1 (𝑚) is the heat transfer plate thickness; hk (m) is height of the tray.
+Total height to arrange Nttm heat transfer plate:
𝛴 h = Nttn.h (m)
In which,
Nttn is the number of heat transfer plates; h (m) is distance between two heat
transfer plates; h (m) is distance between two heat transfer plates.
+The inner diameter of the freezer or freeze-drying chamber:
D1 = a√2, m
In which, a (m) = const is edge of heat transfer plate
+The outer diameter of the freezer:
D2 = D1 + 2.𝛿, m
In which,
D1 (m) is inside diameter of the freeze- drying chamber;
𝛿 (𝑚) = const is thickness of the freeze-drying chamber
The total surface area of the freezing heat transfer surface, as well as the freeze-
drying heat generation:
Fdl = 2.L.a.Nttn, m2
In which,

47
 L (m) is length of the cylinder of the freeze-drying chamber; a (m) = const is edge
of heat transfer panel; Nttm (plate) is number of heat transfer plates in the freeze-drying
chamber

 Calculating the cooling load of food freezing process before the

lyophilization process:
When calculating, constructing, and installing the refrigeration system for the
freezing chamber of products before freeze drying, it is important to make sure that the
system has the capacity to handle the heat Q (kW) that the products release during the
freezing process and exhaust to the outside.
𝑄𝑠𝑝 +𝑄𝑡𝑟 + 𝑄𝑘𝑘
Q=( + 𝑄𝑚𝑡 + 𝑄𝑞𝑛 ).𝛽, kW
𝜏

Where,
Qsp (kJ) – cooling cost for the freezing process;
Qk (kJ) – the amount of heat taken from trays;
Qkk (kJ) – the amount of heat taken to cool the air;
Qmt (kW) – the amount of heat that enters the freeze-drying chamber from the
outside.
Qqn (kW) – the quantity of heat entering the pipeline from outside, which causes
the steam to overheat and damage the compressor;
𝜏 (s) – time to freeze a batch of product;
𝛽 − 𝑎 safe load factor.
The cold cost of the product freezing process:
Qsp = Q1 + Q2 + Q3 + Q4 + Q5 , kJ
In which,
Q1 (kJ) is the amount of heat removed to reduce the product temperature from the
initial temperature to the closing temperature of the water in the product,
Q2 (kJ) is heat removed to freeze all water in the product,
Q3 (kJ) is the amount of heat removed to reduce the state temperature to the final
temperature of the freezing process
Q4 (kJ) the amount of heat removed to reduce the temperature of the non-freezing
water in the product;

48
 Q5 (kJ) is the amount of heat removed to reduce the temperature of the dry matter
component.
The heat removed from the air in the freeze-drying chamber to cool it:
The following formula is used to determine the amount of heat removed to cool
the air in a freeze-drying chamber (or a freezing chamber):
Qkk = Gkk. (h1 –h2), kJ
In which,
Gkk (kg): The quantity of air in a freezing chamber or drying chamber divided by
the amount of dried air.
h1 (kJ/kg): Air enthalpy at the start of a freezing process
h2 (kJ/kg): Air's final enthalpy after a freezing process
The amount of heat from environment enters the freezing or freeze-drying
chamber:
Qmt = Kv. Fv. 𝛥t, kW
With: Kv (W/(m2 . K)) is coefficient of heat transfer through the wall of the freeze-
drying chamber; Δt (°C) is the difference between the air temperature in the drying
chamber and the temperature of the air in the frozen lounge; Fv (m2) is area of the freezer
wall or freeze-drying chamber.
The coefficient of heat transfer through the wall of the freeze –drying chamber:
1
Kv = 1 𝛿1 𝛿 1 𝛿𝑝𝑜𝑙𝑦
W/ (m2 .K )
+ + 2 + +
𝛼1 𝜆𝑖𝑛𝑜𝑥 𝜆𝑖𝑛𝑜𝑥 𝛼2 𝜆𝑝𝑜𝑙𝑦

𝛿1 (m) = const is stainless steel layer thickness; 𝛿𝑝𝑜𝑙𝑦 (m) = const is polymethane
layer thickness; 𝛿2 (m) = const is outer layer thickness of stainless steel; 𝜆𝑖𝑛𝑜𝑥 = 64 W/
(m.K) is thermal conductivity of stainless steel; 𝜆𝑝𝑜𝑙𝑦 = 0,047 W/ (m.K) is thermal
conductivity of polymethane; 𝛼1 = 11,6 W/ (m2.K) is coefficient of exothermic air in the
environment outside the drying chamber; 𝛼2 = 8,2 W/ (m2. K) is coefficient of heat
emission of air in the environment outside the drying chamber.
The difference between the air temperature in the drying chamber and the
temperature of the air in the frozen lounge.
𝛥t = tkk – tf2, °C
With : tf2 (°C) is the air temperature in the drying chamber; tkk (°C) is temperature
of the air in the frozen lounge.
49
 The area of the freezer wall or freeze-drying chamber:
𝛼
Fv = 𝜋. D1. L + .4 R2c 𝜋, m2
360

With Rc =𝑅12 + hc2/2hc

The heat flow was removed from the tray.
Qk = Gk . Ck . ( t1tr – t2tr ), kJ
In which,
Ck (kJ/(kg.K )) = const is specific heat capacity of glass tray,
t2k (°C) is the temperature of the tray at the end of the freezing process,
t1k = 25 (°C) is the temperature of the tray when putting it into the freezer ( is equal
to the processing room temperature),
Gk (kg) = weight of each tray x Nsk is the total weight of the product trays.
Determine the specific cooling capacity q0 (kJ/ kg) of the cycle:
The specific cooling capacity
q0 = h1 – h7
with h1 = 386.55 kJ/kg ; h7 = 191.27 kJ/kg
Determine the Nms friction power (kW); useful capacity of the Ne2 (kW)
compressor; power supply of the motor N2el (kW):
Friction:
N2ms = Pms .V2tt , kW
Useful capacity:
N2e = Ni2 + N2ms, kW
With N2ms (KW) is friction:
Power supply of the motor:
N2el = N2e /( 𝜂𝑡𝑑 . 𝜂𝑒𝑙 ), kW
In which,
𝜂𝑡𝑑 =0.99 is transmission efficiency;
𝜂𝑒𝑙 = 0.98 is engine capacity;
N2el (k) is useful capacity
Determine the engine power for Ndc compressors (kW) and select motors:
The total power of the motor
Ndc = N1dc + N2dc , kW
With: N2dc = (1.1 ÷ 1.2 ). N2el
50
  Determine the calculation parameters of condensing equipment design:
The thermal load of the condensing device:
Qk = m2 .(h4 – h5 ) + ( N2i – N2s ), kW
In which,
m2 (kg/s) is the actual flow of circulating solvent through the condenser;
N2i (kW) is the indication power of the high-pressure compressor
N2s (kW) is the heat-compressing power of high pressure compressors
h4 = 446.23 (kJ/kg) is the enthalpy of the refrigerant state at the end of the
compression
h5 =249.99 (kJ/kg) The enthalpy of the refrigerant state at the end of condenser
before returning to the intermediate.
The average temperature of the air in the condensation device:
tkh =( tf1+ tf2) / 2 (°C)
The average temperature difference in condensation device versus air:
∆𝑡𝑚𝑎𝑥 − ∆𝑡𝑚𝑖𝑛
𝜃m = ∆𝑡 , (°C)
𝑙𝑛 𝑚𝑎𝑥
∆𝑡𝑚𝑖𝑛

The amount of air need to heat the condenser device:

𝑄𝑘
Gkh = , kg/s
𝐶𝑘ℎ .( 𝑡𝑓2 −𝑡𝑓1 )

Air volume flow cooling for condensation process:

𝐺𝑘ℎ
Vkh = , m3/h
𝜌𝑘ℎ

The Nusselt standard:

Nu = 0.021. Re0.8. Pr0.43 .𝜀 1
The wing area of 1m pipe:
𝜋 (𝐷 2 −𝑑𝑛𝑔2 𝜋 .𝐷.𝛿𝑑
Fc = + , m2/m
2.𝑆𝑐 𝑆𝑐

The interval area between the wings of 1m pipes:

𝜋 (𝐷 2 −𝑑2 𝑛𝑔 ) 𝜋.𝐷.𝛿𝑑
F0 = + , m2/m
2.𝑆𝑐 𝑆𝑐

The interval area between the wings of 1m pipes:

𝜋.𝑑𝑛𝑔 .( 𝑆𝑐 − 𝛿0 )
F0 = , m2/m
𝑆𝑐

The total wing area with wings and wings of 1m pipe:

F = Fc + F 0
51
 The surface area of 1 m pipe:
Ftr = 𝜋. dtr, m2/m
The outer surface area of 1m pipe:
Fng = 𝜋. dng, m2/m
The length of the convention:
𝐹0 𝐹𝑐 𝜋
lq =
𝐹
. 𝑑𝑛𝑔 +
𝐹
√ 4 (𝐷 2 − 𝑑 2 𝑛𝑔) , m

 Calculation of condensing- freezing equipment

Determine area of heat exchange surface of petrified equipment.

Determine defrosting time and air purging time in freeze- drying chamber

 Calculate the vacuum system

Determine vacuum pressure of drying environment Pth (mmHg).

Determine vacuum limit pressure that pump can produce Pgh (mmHg).
Determine electric motor power running for vacuum pump.

2.4.2 Design method

Designing piping and instrumentation diagram.
Designing part drawings, assembly drawings, and isometric drawings with solid
works software.

52
CHAPTER 3

CALCULATING AND DESIGNING A SYSTEM

3.1. Initial parameters used for the calculation
These are the initial main parameters required for the calculation, and design a
refrigeration system to freeze products before freeze-drying.
 The freeze-drying system capacity is 1500 kg/batch
 Initial moisture content of royal jelly (W1 %): 59.2 %
 A two-stage compression refrigeration system that uses R22 as the refrigerant
 Moisture content of royal jelly after drying (W2 %): 4.19%
 The crystallization temperature of water in royal jelly ( Tkt ° C ): -1.06 ° C
 Specific heat capacity of dry matter in royal jelly: 1681.577 (J/kg.K)

3.2. Calculating the mass balance

We have:
G1 = G 2 + W (3. 1)
G1.( 100 – W1 ) = G2. (100 – W2 ) (3. 2)
In which,
G1 (kg/batch) is raw material mass
G2 (kg/batch) is product mass after drying
W1 (%) is input moisture content of raw material
W2 (%) is final moisture content of product
W ( %) is moisture content released during freeze-drying
From equation 3.1 and 3.2
𝑊1 −𝑊2 𝑘𝑔 (59.20−4.19 )(%) 𝑘𝑔
W = G1. = 1500 ( ). (100−4.19 )(%)
= 861.24 ( )
100−𝑊2 𝑏𝑎𝑡𝑐ℎ 𝑏𝑎𝑡𝑐ℎ

𝑘𝑔 𝑘𝑔 𝑘𝑔
G2 = G1 –W = 1500 ( ) – 861.24 ( ) = 638.76 ( )
𝑏𝑎𝑡𝑐ℎ 𝑏𝑎𝑡𝑐ℎ 𝑏𝑎𝑡𝑐ℎ

𝑘𝑔
Hence, mass of royal jelly after drying is G2 = 638.76 ( )
𝑏𝑎𝑡𝑐ℎ

3.3. Calculating equipment in a system

In this section, it is divided into 3 main parts:

53
 - Calculating and designing a freezing system integrated into the sublimation
chamber of the freeze-drying system
- Calculating and selecting a compressor with the appropriate cooling capacity.
- Calculation and design of heat exchangers of the product refrigeration system.
The devices designed include a condenser, an evaporator, a receiver, a throttle valve,
and pipes.

3.3.1. Calculating and designing a freezing system integrated into the sublimation
chamber of the freeze-drying system
3.3.1.1. Calculating the freeze-drying chamber
The maximum volume of product contained in the freeze-drying chamber is
calculated by the following equation:
GSp 1500
Vsp = = = 1.27m3 (3. 3)
ρ 1183,22

Volume and size of the freeze-drying chamber:

The number of royal jelly trays for freezing and freeze-drying is determined as
follows:
+ Length of the tray: ak = 800mm = 0.8 m
+ Width of the tray: bk = 500mm = 0.5m
+ Height of the tray: hk = 28mm = 0.028 m
+ Thickness of the tray: 𝛿𝑘 = 3mm = 0.003 m
+ Thickness of royal jelly layer: 𝛿 = 12.93 mm = 0.01293m
Volume of each tray: Vk = ak. bk. hk = 0.8 × 0.5 × 0.028 = 0.0112 (m3)
The volume of royal jelly contained in each tray:
Vsock = ak. bk.𝛿 = 0.8 × 0.5 × 0.01293 = 0.005172 (m3)
The number of glass trays in a freeze-drying chamber is configured as follows:
VSP 1.27
Nsk = = = 246 trays (3. 4)
Vsock 0.005172

 VNsk = 246 × 0.0112 = 2.7552 (m3)

The freeze-drying chamber or freezer chamber has a cylindrical design with an
inner diameter of D1 (m), outer diameter is D2 (m), length is L (m).
Choosing the cylindrical body length: L1: 3.5 m
The two cylindrical drying chamber caps are two globe caps whose chosen height
is: hc = 0.2m
54
 The length of the cylinder of the freeze-drying chamber:
L = 2hc + L1 = 2 × 0.2 + 3.5 = 3.9 (m) (3. 5)
Each heat transfer plate contains nt = 16 glass trays, so each tray slips inside the
area of the heat transfer plate when:
Length: L1 = 3.5 > 4 × 0.8 = 3.2 (m) (3. 6)
Width (< Length ): a > 4 × 0.5 =2 (m) (3. 7)
The number of heat transfer plates in the freeze-drying chamber:
Nsk
Nttn = , plate (3. 8)
nt

In which,
Nsk (items) is number of glass trays in the freeze-drying dryer
nt (tray) = const is number of trays in heat transfer plate.
From equation 3.8, we have:
𝑁𝑠𝑘 246
Nttn = = = 16 plates
𝑛𝑡 16

The distance between two heat transfer plates:

h = δ1 + δ2 , m (3. 9)
δ 2 = hk + δ k (3. 10)
In which,
𝛿1 = 0.015 m is heat transfer plate thickness
ℎk (m) is height of the tray
𝛿𝑘 is thickness of the tray
From equation 3.9 and 3.10, we have:
𝛿2 = hk + 𝛿𝑘 = 0.028 + 0.003 = 0.031 (m)
h = 𝛿1 + 𝛿2 = 0.015 + 0.031 = 0.046 (m)
Total height to arrange 16 heat transfer plates:
∑ ℎ = Nttn .h = 16 × 0.046 = 0.736 (m)
The value of a must be selected so that both conditions are met
a ≥ ∑ ℎ =0.736 m , a > 2 m
So, choosing a=2.1 m is suitable (if choosing with a larger value, the price will go
up, if going with a smaller one, it won’t be able to fit 16 trays/ heating plate)
The inner diameter of the freeze-drying chamber:
D1 = a√2 = 2.1 × √2 = 2.97 (m)
55
 Choosing the thickness of the freeze-drying chamber to be 0.008 m, so the outer
diameter:
D2 = D1 + 2. 𝛿 = 2.97 + 2 × 0.008 = 2.99 (m)
The total surface area of the freezing heat transfer surface:
Fdl = 2.L.a. Nttn , m2 (3. 11)
In which,
L (m) is length of the cylinder of the freeze-drying chamber
a (m) = const is edge of heat transfer panel
Nttn ( plate) is number of heat transfer plates in the freeze-drying chamber.
From equation 3.11:
Fdl = 2.L.a. Nttn = 2 × 3.5 ×2.1 × 16 = 235.2 (m2)

3.3.1.2. Calculating the cool load for the freezing process of the product before
freeze-drying
The amount of heat to be loaded during freezing:
Qsp = Q1 + Q2 + Q3 + Q4 + Q5 , kJ (3. 12)
The initial temperature of royal jelly (usually at room temperature): t1= 25 °C
The initial temperature of royal jelly at the end of the freezing process to
completely crystallize The water: t2 = TFopt = - 18.33 °C
The crystallization temperature of water in royal jelly: tkt = -1.06 °C
+The amount of heat Q1 (amount of heat removed to reduce the product
temperature from the initial temperature to the closing temperature of the water in the
product):
Q1 = C1. G. (t1 –tkt ), kJ (3. 13)
In which,
C1 = cn.Wa + cck .(1-Wa) (kJ/(kg.K)) is specific heat of product before water freezes
cn = const (kJ/(kg.K)) is specific heat of water in royal jelly
cck = const = 1681.577 J/(kg.K) is specific heat capacity of dry matter in royal jelly
Wa = const is the average amount of water in the royal jelly
G = Gsp = 1500kg is mass of the product
From equation 3.13
1 t1
cn = ∫ (
t1 −tkt tkt
4167.2 − 9086.4 × 10-5 .T + 5473.1 × 10-6 .T2 ) dt (3. 14)

56
  cn = 4171,57 (J/ (kg.K)) = 4.172 (kJ/ (kg.K))
C1 = cn . Wa + cck . (1-Wa) = 4.172 × 59.20% + 1681.577 × 10-3 × (1 – 59.20%)
 C1= 3.16 ( kJ/ (kg.K) )
Q1 = C1. G. (t1 –tkt ) = 3.16 × 1500 × ( 25- (-1.06)) = 123524.4 kJ
+The amount of heat Q2 (heat removed to freeze all water in the product):
Q2 = L. G. Wa .ω, kJ (3. 15)
The average latent heat of fusion (L) in royal jelly is estimated:
1 𝑇𝑘𝑡
L = rnc = ∫ ( 333601.5 +1054. 10-3 . T – 21.10-6 .T2 ) dt
𝑇𝑘𝑡 −𝑇𝐹𝑜𝑝𝑡 𝑇𝐹𝑜𝑝𝑡

 L= 333602.76 J/kg = 333.602 kJ/kg

Q2 = L. G. Wa .𝜔 = 333.602 × 1500 × 59.20% × 1.0 = 296238.58 kJ
+The amount of heat Q3 (amount of heat removed to reduce the state temperature
to the final temperature of the freezing process):
Q3 = C3 .G . Wa . ω ( tkt –t2 ), kJ (3. 16)
In which,
C3 = const (kJ/kg.K)) is specific heat capacity of ice in royal jelly
G= Gsp =1500 kg is the weight of the product
Wa = const is the average amount of water in the royal jelly
𝜔 =1.0 is the amount of water in frozen royal jelly
tkt = const (°C) is average temperature of water in frozen royal jelly
t2 = const (°C) is average temperature of royal jelly at the end of the freezing
process.
Specific heat of ice in the material (C3):
1 𝑇𝑘𝑡
C3 = cnd =
𝑇𝑘𝑡 −𝑇𝐹𝑜𝑝𝑡
∫𝑇𝐹𝑜𝑝𝑡( 2062.3 + 6076.9 × 10-3 × T) dt = 2.102 kJ/(kg.K)

Q3 = C3 .G . Wa . 𝜔 ( tkt –t2 ) = 2.102 × 1500 × 59.20% × 1.0 × ( -1.06 - (-18.33))

 Q3 = 32235.77 kJ
+The amount of heat Q4 (amount of heat removed to reduce the temperature of
the non-freezing water in the product):
Q4 = C4 .G .Wa . ( 1- ω) . ( tkt –t2) , kJ (3. 17)
In which,
𝜔 = const =1 is the amount of water in frozen royal jelly
Other parameters are the same as described earlier.
57
 Thus Q4 = 0 kJ
+The amount of het Q5 (amount of heat removed to reduce the temperature of the
dry matter component):
Q5 = cck . G. (1-Wa) ( tkt –t2) (3. 18)
= 1681.577 × 10-3 × 1500 × (1-59.20%) × ( -1.06 – ( -18.33 )) = 17772.99 kJ
Thus, the cold cost of the product freezing process, from equation 3.12:
Qsp = Q1 + Q2 + Q3 + Q4 + Q5
= 123524.4 + 296238.576 + 32235.77 + 0 + 17772.99
= 469771.74 kJ
Calculating the amount of heat removed from the tray containing the product:
Number of trays containing 1500kg of product: Nsk = 246 trays
The mass of each tray is 0.4 kg
The total weight of the product trays: Gk = 0.4 × 246 = 98.4 kg
The temperature of the tray when putting it into the freezer is equal to the room
temperature tk1 =25 °𝐶
The temperature of the tray at the end of the freezing process is equal to the
temperature in the freezing chamber: tk2 = tf2 = -40.46 °𝐶
Specific heat capacity of glass tray: Ck = 0.48 kJ/(kg.K)
The heat flow removed from the tray:
Qk = Gk . Ck . ( tk1 – tk2 ), kJ (3. 19)
= 98.4 × 0.48 ( 25 – ( -40.46)) = 3091.81kJ
Thus, the cold cost of the product storage tray during freezing: Qk = 3091.81kJ
Calculating the amount of removed to cool the air in the drying chamber:
+The enthalpy of air in the freeze-drying chamber before freezing:
h1 = t1 + ( 2500.77 + 1.84 t1 ).d1, kJ/kg (3. 20)
In which,
t1 ( °𝐶 ) = 25 °𝐶 is temperature of the air entering the freezer prior to the freezing
process or air from the processing room with 𝜑1 =85% ( relative humidity )
d1 is specific humidity ( d1 = 0.017 (kg/kg) ( Looking up the state 25 °𝐶, 85% on
the h-d diagram of humid air (Appendix 2)).

58
 Figure 3.1. Mollier diagram

From equation 3.20: h1 = 25 + (2500.77 + 1.84 × 25) × 0.017 = 68.30 kJ/kg

The dry air mass:
( P− Pn )
Gkk = . Vkk , kg (3. 21)
Rkk .Tkk

In which,
P = 9.81 × 104 N/m2 is atmospheric pressure
8314
Rkk = = 287 J/ (kg.K ) is air constant value of dried air
29

Tkk = (25 + 273) K = 298 K is absolute temperature of dried air

Vkk (m3) is volume of dried air in a freeze- drying chamber
Pn (N/m2) is partial pressure of water vapor
Looking up the h- d diagram (Appendix 2) with t1 = 25 °𝐶, 𝜑1 =85%, we have:
Pn = 2.61 × 10 3 N/m2
+The volume of air in the chamber:
Vkk = 2/3 × Vt , m3 ( with Vt is volume in the freeze-drying chamber) (3. 22)

59
 +The volume of the freeze-drying chamber:
𝐡𝐜
Vt = 2. hc2 .π ( R1 - ) + π. R12. L1, m3 (3. 23)
𝟑

In which,
L1 ( m) is cylindrical body length
hc (m) is the height of each globe cap
R1 = D1/2 (m) is inner radius
From equation 3.23
Vt = 2 × ( 0.2) 2 × 3.14× ( 1.485 – 0.2/3 ) + 3.14× ( 1.485)2 × 3.5 = 24.59 (m3)
From equation 3.22: Vkk = 2/3 × 24.59 = 16.39 (m3)
From equation 3.21:
( 𝑃− 𝑃𝑛 ) ( 9.81 × 104 −2.61 ×103 )
Gkk = . Vkk = × 16.39 = 18.3 kg
𝑅𝑘𝑘 .𝑇𝑘𝑘 287 × 298

+The enthalpy of air –drying chamber at the end of a freezing process:

h2 = t2 + (2500.77 + 1.84. t2 ).d2 .kJ/kg (3. 24)
In which,
t2 = - 40.46 °𝐶 is the temperature at the end of the freezing process
d2 is specific humidity when the air humidity reaches saturation state 𝜑 = 100%
Looking up figure 3.1 (h-d diagram) to see the moisture content of the air in
saturation state corresponding to t2 = - 40.46 °𝐶
d2 max = 0,000123 kg / kg < d1 = 0.017 kg/kg
d2 = d2max = 0.000123 kg/kg
From equation 3.20
h2 = t2 + (2500.77 + 1.84. t2).d2
= - 40.46 + (2500.77 + 1.84 × ( -40.46)) × 0.000123
= -40.16 kJ/kg
+The refrigerant cost to cool the air in the freeze- drying chamber of the freezing
process:
Qkk = Gkk (h1 – h2)
= 18.3 × (68.30 – (-40.16)) = 1984.818 kJ
The amount of heat released by the environment entering the walls and chamber
of the dryer:

60
 Cylindrical freezer, with two spherical caps, is exposed to the air in the freezing
room, with a temperature of tkk = 25 °𝐶 and the temperature inside the drying chamber
during freezing must be maintained tf2 = - 40.46 °𝐶

Figure 3. 2. Two spherical caps od the freeze-drying chamber

Rc = (R12 + hc2) / 2hc = (1.4852 + 0.22) / (2 × 0.2) = 5.61 (m)

𝑅1 1.485
Sin 𝛼 = = = 0.26
𝑅𝑐 5.61

So 𝛼 = 15.07 °
+The area of the freeze-drying wall:
𝛼
Fv = 𝜋. D1. L1 + . 4Rc2 𝜋
360
15.07
= 3.14× 2.97 × 3.5 + × 4 × 5.612 × 3.14= 49.19 (m2)
360

+The difference between the air temperature in the drying chamber and the
temperature of the air in the frozen lounge:
∆t = tkk – tf2 = 25 – ( - 40.46 ) = 65.46 °𝐶
The freeze-drying chamber shell contains 3 layers: inside stainless-steel,
polyurethane and outside stainless-steel:

Figure 3.3. Wall’s structure of the freeze-drying chamber

+Therefore, the coefficient of heat transfer through the wall of the freeze-drying
chamber was calculated as:

61
 𝟏
Kv = 𝟏 𝛅 𝛅 𝟏 𝛅𝐩𝐨𝐥𝐲
W/ (m2 .K) (3. 25)
+ 𝟏 + 𝟐 + +
𝛂𝟏 𝛌𝐢𝐧𝐨𝐱 𝛌𝐢𝐧𝐨𝐱 𝛂𝟐 𝛌𝐩𝐨𝐥𝐲

In which,
Thickness of inside stainless-steel layer: 𝛿1 = 8mm = 0.008m
Thichness of polyurethane layer: 𝛿𝑝𝑜𝑙𝑦 = 100mm = 0.1 m
Thickness of outside stainless- steel layer: 𝛿2 = 1.5mm = 0.0015m
Thermal conductivity of stainless-steel: 𝜆𝑠𝑠 = 64 W/(m.K)
Thermal conductivity of polyurethane 𝜆𝑝𝑜𝑙𝑦 = 0.047 W/ (m.K)
Coefficient of exothermic air in the environment outside the freeze-drying
chamber: 𝛼1 =11.6 W/ (m2.K )
Coefficient of heat emission of air in the environment inside the freeze- drying
chamber : 𝛼2 = 8.2 W/ (m2.K)
Ks = 2.86 W/(m2/K) at ( 25°𝐶, 𝜑 = 85% )
From equation 3.25
1
Kv = 1 0.008 0.1 0.0015 1 = 0.43 W/( m2 . K)
+ + + +
11.6 64 0.047 64 8.2

+The amount of heat from the environment to enter the freeze-drying

chamber:
Qmt = Kv. Fv. Δt (3. 26)
= 0.43 × 49.19 × 65.46 = 1384.59 W = 1.38 kW
+The amount of heat penetrating from the environment through the pipe
causing it to overheat or the refrigerant draws into the compressor:

Cooling capacity of the freezer:

Qsp+ Qk +Qkk 469771.74+ 3091.81+ 1984.818
Qob = + Qmt = + 1.38 = 82.3 kW
τ 1.63 ×3600

Choosing refrigerant: The system uses R22 refrigerant.

Choosing the parameters of the working regime of the refrigeration system to be
designed using refrigerant.
Choosing the boiling temperature of refrigerant to evaporator (t0): it depends on
the freezing environment temperature.
t0 = tf2 – Δt0 = -40.46 – 9.54 = -50 °𝐶
Corresponding to t0 = -50 °𝐶, evaporation pressure is P0 = 0.6459 bar
62
 Choosing the condensing temperature of the medium in the condenser ( tk) : tk
depends on the cooling environment for the condenser. The cooling environment for the
equipment in this system is air.
tk = tf + Δt k (3. 27)
Choosing tf to be the hottest day in the summer. The average ambient temperature
in the harshest days in summer is 35 °𝐶. At that time, the condensation temperature of
tk refrigerant is chosen: tk = tf + Δ𝑡𝑘 = 35 + 5 = 40 °𝐶
Corresponding to tk = 40 °𝐶 , condensation pressure is Pk = 15.315 bar
Choosing the cooling cycle working for the refrigeration system.
Pk 15.315
β= = = 23.71 > 9 (3. 28)
P0 0.6459

Therefore, this must use two-stage refrigeration cycle, the average has a spiral
tube and fully intermediate cooling, there are two throttles in figure 3.4:

Figure 3. 4. Two-stage refrigeration cycle compression, intermediate with a spiral

tube, completely cooled, with two throttles
Depending on the temperature of the refrigerant, which is circulated into the
medium ttg, to completely cool the refrigerant from the low–end compressor, and at the
same time, to cool the refrigerant in the coil:
tql = ttg + ( 4 ÷ 6 ), °𝐶
Intermediate pressure:
Ptg = √ 𝑃𝑘 . 𝑃0 = √15.315 × 0.6459 = 3.145 bar

63
 Corresponding to intermediate pressure Ptg = 3.145 bar, ttg = -13 °𝐶
tql = ttg + ( 4 ÷ 6) = -13 + 5 = - 8 °𝐶
th = t0 + (5 ÷ 15) = -50 + 15 = -35 °𝐶
It is possible to select the working process status parameters of the refrigeration
system to be designed and installed as following:
Temperature Pressure
tk = 40 °𝐶 Pk =15.315 bar
t0 = -50 °𝐶 P0 = 0.6459 bar
ttg = -13 °𝐶 Ptg = 3.145 bar
tqn = -35 °𝐶
tql = t7 = -8 °𝐶
Note: Pk , Ptg , P0 respectively condensing pressure, intermediate pressure,
evaporation pressure; tk , ttg , t0 respectively the condensing temperature of the
refrigerant, the medium temperature of the refrigerant and the boiling temperature of the
refrigerant.

Table 3. 1. The state parameters of the refrigeration system cycle need to be designed
and built
Status h (kJ/kg) v (m3/kg) s ( kJ/ (kg.K)) P (bar) T ( °𝑪 )
1 383.56 0.2452 - 0.6459 -50
’ 392.48 0.3492 1.888 0.6459 -35
1
2 436.44 - 1.888 3.145 39.64
3 400.2 0.0725 1.772 3.145 -13
4 446.53 - 1.772 15.315 74
4’ 417.43 0.0154 - 15.315 40
5 249.99 - - 15.315 40
6 249.99 - - 3.145 -13
7 191.27 - - 15.315 -8
8 191.27 - - 0.6459 -50
Based on table 3.1, it is allowed to construct a graph of the freezing cycle of the
refrigeration system running for the freezer and petrification equipment as follow
(Figure 3.5):

64
 Figure 3. 5. Thermodynamic graph of two level of compression refrigeration cycle

Flow rate of each circulating substance through a primary compressor:

𝑄𝑜𝑏 82.3
m1, = = = 0.43 kg/s
( ℎ1 − ℎ8 ) ( 383,56−191.27 )

The quantity of heat that enters the pipe from environment superheats the
refrigerant vapor that is pulled to the compressor:
Qqn = m,1. (h,1 – h1), kW (3. 29)
In which,
m,1 (kg/s) is actual flow of refrigerant circulating through the compressor;
h,1 (kJ/kg) is enthalpy of refrigerant before leaving evaporator; h1 (kJ/kg) is enthalpy of
refrigerant before entering evaporator.
From equation 3.29
Qqn = m,1. (h,1 – h1) = 0.43 × (392.48 – 383.56) = 3.84 kW
The cooling capacity of the refrigeration system needs to be designed and
manufactured for freezing of the product freezing chamber:
𝑄𝑠𝑝 + 𝑄𝑘 + 𝑄𝑘𝑘
Q=( + Qmt + Qqn ). 𝛽
𝜏
469771.74+ 3091.81+ 198.818
=( + 1.28 + 3.84 ) × 1.15 = 99.06 kW
1.63 ×3600

The refrigeration capacity of the compressor:

Q0mn ≥ Q = 99.06 kW → Q0 minmn = 99.06 kW (3. 30)

3.3.1.3. Calculate the refrigerant load for a refrigeration procedure to condense

and freeze moisture sublimating from dried product.

Calculation of heat load raffinate in the condensing- freezing device, which serves
as the foundation for calculating the heat exchange surface, so that the moisture
65
produced during the freeze-drying process fully condenses. The air in the drying
chamber travels with the moisture to the petrification equipment and is pushed out by
the vacuum pump.

Calculating the amount of moisture released from the product:

The initial moisture of the royal jelly is Wa = 59.20%. When the final product
moisture level of the freeze-dried royal jelly is We = 4.19 % and the drying process is
only the freeze-drying phase (not include vacuum drying stage), with the productivity
of the drying system is G = 1500 kg of raw material, the moisture out Wthm (kg/ batch)
is determined as following:
Wa − We 59.20−4.19
Wthm = G. = 1500 × = 861.24 kg/batch (3. 31)
100− We 100−4.19

The amount of moisture that exits during the low temperature vacuum is Wckm =
0 (as the freeze-freeze drying process does not have this stage )
A batch drying time is 𝜏2 = 18.283 h
The amount of heat to condense –freeze completely
Wthm 861.24
Wth = = = 47.106 kg/h (3. 32)
τ2 18.283

Determination of the temperature of the freezing humidity:

Ambient temperature to condensation-freezing moisture is tng = - 40 °𝐶, so the
temperature of moisture freezing in icing chemistry equipment is
tb = tng + ∆tng = -40 + 2 = -38. °𝐶
Determination of the temperature of moisture after exiting the freeze-drying
chamber of ice condenser (or petrification equipment):
Because the moisture moving from the freeze-drying chamber to the ice condenser
is heated up at the exit of the freeze-drying chamber, the moisture's temperature will be
regarded to be the same as the temperature at the exit of the freeze-drying chamber:
th = tlr = ( 5 ÷ 15 ) °𝐶 = 10 °𝐶
Determination of temperature condensation-freezing of moisture:
Pressure in the medium of condensation- freezing with the freeze- drying chamber
pressure Pngtdb = Pbth = 0.411 mmHg, respectively will have the chemical temperature of
the moist Tht = -26.43 °𝐶 <TFopt = - 18.33 °𝐶 . However, in order to exploit the vacuum
system, the last temperature of the frozen moisture is – 38 °𝐶 < Tht = - 26.43 °𝐶 is
suitable.
66
 Figure 3. 6. The analysis of an ice transformation process on the water three-phase
diagram
Figure 3.6 displays that the moisture state from the freeze-drying chamber to the
ice condenser at point M has a temperature of th = 10 °C . The raw material is cooled
before freezing at point N, lowering the temperature from th = 10 °C to tht =-26.43 °C.
This operation takes place on MN road with Pbth = 0.411 mmHg = const and the heat to
be removed is Q11 ( kJ). Vapor turns to ice at point N. The process radiates to the energy
of Q12 (kJ). After converting into ice, the temperature of the ice reduced to point P with
tb = -38 °C , the process follows the NP line with Pbth =0.411mmHg = const. Because the
temperature of the ice is reduced after transformation, they do not have the conditions
to re-sublimate, causing the vacuum system to become unstable.
According to the above procedure of analysis, heat should be removed to carry out
the condensation process-freezing moisture escape from freeze drying products is
determined:
Q1 ngtdb = Q11 + Q12 + Q13, kW
With:
Q11 = Wth.Cpa.(th – tht), kW (3. 33)
Q12 = Wth.rth , kW (3. 34)
Q13 = Wth.Cnd.(Tht – tb), kW (3. 35)
Q1 ngtdb = Wth.(Cpa. (th – Tht) + rth + Cnd.(Tht –tb)) (3. 36)
1 t
Cpa = . ∫Th ( 1.833 + 0.0003111 × T )dT = 1.833 kj/ (kg.K) (3. 37)
th − Tht ht

67
 Cpa (kJ/(kg.K)) - specific heat of moisture, rth (kJ/kg) - latent heat of sublimation,
Cnd (kJ/(kg.K))- specific heat of ice after conducting the ice transformation in an ice
condenser.
Latent heat of sublimation of moisture at the ice transformation temperature:
T = Tht = a - 26.43 °𝐶
rth = 0.0024 × T2 + 3.0606 × T + 3284.074 (3. 38)
= 0.0024 × ( -26.43)2 + 3.0606 × (-26,43) + 3287.074 = 3207.86 kj/kg
𝟏 𝐓
Cnd = .∫𝐭 𝐡𝐭( 2062.3 + 6076.9×10-3 × T ) dt = 2104.13 J/ (kg.K) (3. 39)
𝐓𝐡𝐭 −𝐭 𝐛 𝐛

= 2.104 kj/ (kg.K)

 Q1 ngtdb = Wth.(Cpa. (th – Tht) + rth + Cnd.(Tht –tb ))
= 47.106 × ( 1.83 × (10 – ( -26.43) + 3207.86 + 2.104 × ( -26.43) – (-38) )
= 153420.3878 kJ/h = 42.62 kW
The amount of heat required to condense - freeze moisture at the vacuum drying
stage:
Q2 ngtdb = Wth.(Cpa.(th – Tht) + rth + Cnd .(Tht –tb)) (3. 40)
Q2 ngtdb = 0, due Wck = 0
The quantity of heat that enters the ice condenser from the surrounding
environment:
QMT ngtdb = KW.ng.FW.ng.(tf – twb)
1
KW.ng = δw δ 1 , W/ m2 . K (3. 41)
+ cn +
λw λcn α1

In which,
Thickness of equipment wall made of steel: 𝛿𝑤 = 0.005m
The equipment’s moisture- insulating wall thickness: 𝛿𝑐𝑛 = 0.08 m
Heat conductivity coefficient of steel: 𝜆𝑤 = 45.35 W/ (m.K)
Heat conductivity coefficient of polyurethane: 𝜆𝑐𝑛 = 0.047 W/(m.K)
Heat radiating coefficient of air and external wall of the device: 𝛼1 =11.6 (W/ (m2.K))
1 1
KW.ng = 𝛿𝑤 𝛿 1 = 0.005 0.08 1 = 0.56 ( W/m2.K)
+ 𝑐𝑛+ + +
45.35 0.047 11.6
𝜆𝑤 𝜆𝑐𝑛 𝛼1

The volume contains Wthm = 823.69 kg moisture/batch in the ice condenser:

𝑊𝑡ℎ𝑚
Va = , m3/ batch
𝜌𝑑

ρd = 917 × (1- 0.000155 × (-38)) = 922.4 kg/m3 (3. 42)

68
 𝑊𝑡ℎ𝑚 861.24
 Va = = = 0.93 m3/ batch
𝜌𝑑 922.4

Because the heat transfer tubes in the space of an ice condenser are handled in the
form of a beam tube, which is used to change the ice from moisture, it occupies a large
volume. As a result, the volume of an ice condenser may be computed as follows:
Vngtdb = (1.5 ÷ 2.5 ).Va = 2.16 × 0.93 = 2.01 m3
Choosing the diameter of ice condenser: Dtr = 800mm = 0.8 m
The outer line and length of ice condenser:
Dng = Dtr + 2. 𝛿𝑤 = 0.8 + 2 × 0.005 = 0.81m
4 .𝑉𝑛𝑔𝑡𝑑𝑏 4 ×2.01
L= 2 = =4m
𝜋 ×𝐷𝑡𝑟 3.14×0.82

Because the extra layer of external heat has a thickness of 0.08 m, the outer
diameter of the device is ice condenser:
Dngtdb = Dng + 2. 𝛿𝑐𝑛 = 0.81 + 2 × 0.08 = 0.97 m
The outside heat exchange area of the ice condenser:
2
𝐷𝑛𝑔𝑑𝑏 0.972
Fw.ng = 𝜋. Dngdb . L + 2 𝜋. = 3.14 × 0.97 × 4 + 2𝜋 × = 13.66 m2
4 4

Thus, it is possible to determine the heat loss from external environment into the
internal environment of the ice condenser:
QMT ngtdb = KW.ng.FW.ng .(tf – twb) = 0.56 × 13.66 × ( 35 - (-40.46 ))
= 577.24W = 0.577 kW
The amount of heat it needs to be removed to condense-freezing moisture
escapes during the freeze-drying process:
Qngtdb = k ×(Q1 ngtdb + Q2 ngtdb + QMT ngtdb ) = 2 × ( 42.62 + 0 + 0.577) = 86.39 kW
Showing that:
Qmn
0 min = Q = 99.06 kW > Qngtdb = 86.39 kW (3. 43)
In conclusion, the calculated refrigeration system designed to freeze the product
freezing chamber before freeze drying can completely be used to run for ice condenser.

3.3.2. Calculating and selecting a compressor with the appropriate cooling capacity
3.3.2.1. Calculation of low-pressure part
The actual refrigerant mass flow rate m1
Qmn
0
m1= , kg/s (3. 44)
h1 −h8

In which,
69
 m1 (kg/s) is actual mass flow rate via the first-stage compressor
𝑄0𝑚𝑛 (kW) is cooling capacity of compressor
h1 (kJ/kg) is enthalpy of refrigerant vapor from the evaporator.
h8 (kJ/kg) is enthalpy of refrigerant vapor exiting from the throttle valve in the
second time before entering the evaporator.
99.06
From equation 3.44, m1 = = 0.52 (kg/s)
383.56−191.27

The actual suction into the cylinder:

𝑉𝑡𝑡1 = m1× 𝑣𝑡′ = 0.52 × 0.3492 = 0.18 (m3/s)
Volume indicated coefficient and loss coefficient:
λ1 TA = λ1 i × λ1 w (3. 45)
1
1 P0 −∆P0 Ptg +∆Ptg n P0 −∆P0
Where: λ i = − C. [( ) − ] (3. 46)
P0 P0 P0

In which:
P0 = 0.6459 bar;
Ptg = 3.145 bar;
C = 0.05 (the useless spacious coefficient C=0.03÷0.05)
n=1.12 (multivariate exponential value of the compression)
∆P0 = ∆Ptg = 0.051 bar (the suction pressure loss and the intermediate pressure loss,
respectively)
1
1 0.6459−0.051 3.145+0.051 1.12 0.6459−0.051
 λ 𝑖 = − 0.05. [( ) − ] = 0.76
0.6459 0.6459 0.6459

1
𝑇0 −50 + 273.15
λ 𝑤′ = = = 0.86
𝑇𝑡𝑔 −13 + 273.15
1
 λ 𝑇𝐴 = λ1 𝑖 × λ1 𝑤 = = 0.76 × 0.86 = 0.65

Suction volume of a first-stage compressor in theory:

V1tt 0.18
Vlt1 = = = 0.28 (m3/s) (3. 47)
λ1 TA 0.65

The power of adiabatic compression:

Ns1 = m1.(h2-h1’) = 0.52×(436.44-392.48) = 22.86 (kW) (3. 48)
The indicated power:
N1s
Ni1 = , kW (3. 49)
η1i

70
Where: η1i = λ1 w′ + bt 0 = 0.86+0.0025×(-50) =0.735; b=0.0025 is coefficient of R22
refrigerant.
𝑁𝑠1 22.86
 𝑁𝑖1 = = = 31.1 (kW)
𝜂𝑖1 0.735

The friction power:

1
Nms = Pms . Vtt1 , kW (3. 50)
Pms = 0.4÷0.8 bar for compressors using R22 refrigerant, choosing Pms = 80.103 N/m2
1 80.103 .0.18
 𝑁𝑚𝑠 = = 14.4 (kW)
1000

The efficient power:

Ne1 = Nms
1
+ Ni1 = 14.4 + 31.1 = 45.5 (kW) (3. 51)
The first-stage compressor's power supply
1 N1e
Nel = , kW (3. 52)
ηtd ×ηel

𝜂𝑡𝑑 is transmission efficiency, choosing 𝜂𝑡𝑑 = 0.9; 𝜂𝑒𝑙 is engine efficiency,

choosing 𝜂𝑒𝑙 = 0.9
1 45.5
 𝑁𝑒𝑙 = = 56.17 (kW)
0.9×0.9

The power of the electric motor:

1 1
Ndc = (1.1 ÷ 1.2) × Nel = 1.2 × 56.17 = 67.404 (kW) (3.53)

3.3.2.2. Calculation of high-pressure part

Determined the flow of m2 refrigerant circulated through a high-pressure
compressor:
We have: the heat balance equation ΣQin = ΣQout
 m1 h2 + m1 h5 + (m2 – m1 )h6 = m2 h3 + m1 h7
m1 h2 – m1 h7 – m2 h6 + m1 h5 = m2 h3 – m2 h6
Because there is iso-enthalpy h5=h6:
 m1 (h2 –h7 ) = m2 (h3 - h6 )
ℎ2 −ℎ7 436.44−191.27
 m2 = 𝑚1 × = 0.52 × = 0.85 kg/s (3. 54)
ℎ3 −ℎ6 400.2−249.99

The actual suction into the cylinder:

𝑉𝑡𝑡2 = m1×v3 = 0.85 × 0.0725 = 0.06 (m3/s)
Volume indicated coefficient and loss coefficient:
λ2 𝐶𝐴 = λ2 𝑖 × λ2 𝑤 (3. 55)
71
 1
𝑃𝑡𝑔 −∆𝑃𝑡𝑔 𝑃𝑘 +∆𝑃𝑘 𝑛 𝑃𝑡𝑔 −∆𝑃𝑡𝑔
Where: λ2 𝑖 = − 𝐶. [( ) − ] (3. 56)
𝑃𝑡𝑔 𝑃𝑡𝑔 𝑃𝑡𝑔

In which,
Pk = 15.315 bar;
Ptg = 3.145 bar;
C = 0.05 (the useless spacious coefficient C=0.03÷0.05)
n=1.12 (multivariate exponential value of the compression)
∆Pk = ∆Ptg = 0.051 bar (the suction pressure loss and the intermediate pressure loss,
respectively)
1
2 3.145−0.051 15.315+0.051 1.12 3.145−0.051
 λ 𝑖 = − 0.05. [( ) − ] = 0.83
3.145 3.145 3.145

T0 −13+273.15
λ2 w′ = = = 0.83 (3. 57)
Ttg 40+273.15

 λ2 𝐶𝐴 = λ2 𝑖 × λ2 𝑤′ = 0.83 × 0.83 = 0.69

Suction volume of a second-stage compressor in
2
𝑉𝑡𝑡 0.06
𝑉𝑙𝑡2 = = = 0.087 (m3/s) (3. 58)
λ1 𝐶𝐴 0.69

The adiabatic compression power:

𝑁𝑠2 = m2.(h4-h3) = 0.85×(446.53-400.20)= 39.38 (kW)
The indicated power:
𝑁𝑠2
𝑁𝑖2 = , kW (3.59)
𝜂𝑖2

Where: 𝜂𝑖2 = λ2 𝑤′ + 𝑏𝑡𝑡𝑔 = 0.83 + 0.0025×(-13) = 0.80 ; b=0.0025 is coefficient

of R22 refrigerant.
𝑁𝑠2 39.38
 𝑁𝑖2 = = = 49.23 (kW)
𝜂𝑖2 0.80

The friction power:

2
𝑁𝑚𝑠 = 𝑃𝑚𝑠 . 𝑉𝑡𝑡2 , kW (3. 60)
Pms = 0.4÷0.8 bar for compressors using R22 refrigerant, choosing Pms = 40.103 N/m2
2 40.103 ×0.06
 𝑁𝑚𝑠 = = 2.4 (kW)
1000

The efficient power:

𝑁𝑒2 = 𝑁𝑚𝑠
2
+ 𝑁𝑖2 = 2.4 + 49.23 = 51.63 (kW) (3. 61)
Second-stage compressor power supply

72
 𝑁𝑒2
𝑁𝑒𝑙2 = , kW (3. 62)
𝜂𝑡𝑑 ×𝜂𝑒𝑙

𝜂𝑡𝑑 is transmission efficiency, choosing 𝜂𝑡𝑑 = 0.99; 𝜂𝑒𝑙 is engine efficiency,

choosing 𝜂𝑒𝑙 = 0.98
51.63
 𝑁𝑒𝑙2 = = 53.22(𝑘𝑊)
0.99×0.98

The electrical motor power:

2
𝑁𝑑𝑐 = (1.1 ÷ 1.2) × 𝑁𝑒2 = 1.1 × 53.22 = 58.54(𝑘𝑊) (3. 63)

3.3.2.3. The motor's overall power

1 2
𝑁𝑑𝑐 = 𝑁𝑑𝑐 + 𝑁𝑑𝑐 = 67.404 + 58.54 = 125.94 (kW)
As a result, we could select the engine power installed for the cooling system with
the appropriate cooling capacity as 𝑁𝑑𝑐 = 130 (𝑘𝑊).
Voltage: AC 3 phases/380 V; f = (50÷60) Hz

3.3.3. Calculation and design of heat exchangers of the product refrigeration

system
3.3.3.1. Condenser
The heat load:
Qk = m2.(h4 – h5) + (𝑁𝑖2 –𝑁𝑠2 ), kW (3. 64)
Where:
m2 = 0.85 kg/s – the actual mass flow rate of the refrigerant passing through the
condenser
𝑁𝑖2 = 49.23 kW – the indicated power of a high-pressure compressor;
𝑁𝑠2 = 39.38 kW – the adiabatic compression power of a high-pressure compressor.
h4 = 446.53 kJ/kg – enthalpy of the refrigerant state at the end of the compression
range of the high-level compressor and before entering the condenser.
h5 = 249.99 kJ/kg – enthalpy of the refrigerant state at the end of the condenser
before entering the intermediate tank.
 Qk = 0.85 × (446.43-249.53) + (49.23-39.38) = 177.22 (kW)
Calculating and designing for a condenser:
Some parameters of condenser, which fit for the load, need to be initially
recognized as follows:
+ The heat load: Qk = 177.22 kW

73
 + The enthalpy of the refrigerant in the condenser: ∆h = h4 – h5 = 196.54 kJ/k
+ The temperature of the air to be cooled at:
 The outlet: tf2 = 38oC
 The inlet: tf1 = tf2 - ∆𝑡 = 38 – (5÷10) = 32oC
+ The condensing temperature: tk = 40oC
+ The end-of range temperature of the high-pressure compressor:
t4 = 74 + (3  5) = 79oC
These parameters could be by looking up on the P-h diagram (Appendix 1) or
calculating by the equation of state. Note that: (35) represents the temperature rise at
the end of the compression range as a result of heat accumulation or because the
compression is not adiabatic in reality.
Point number (4):
P4 = Pk = 15.315 bar
s3 = s4 = 1.772 kJ/(kgK)
 Look up the overheating steam table R22 at 40oC (15.315 bar) with s2=1.772:
corresponding to s2, t2 can be found. In case there is no suitable value of s2, an
interpolation approach must be utilized to obtain the value of s2.

Figure 3.7. The temperature difference based on heat exchange area

The figure 3.7 is a graph of t-F displaying temperature changes in the heat
exchanger region of an air-cooled condensing device.
According to the original specifications, the heat transfer surface of the air-cooled
condenser is a staggered arrangement of bimetallic tubes. These tubes are made of two
materials: the inside is a basic steel tube, and the outer is a simple winged aluminum
tube. The following are some specifications:
+ Steel pipe's inner diameter: dtr = 21 mm = 0.021 m

74
 + Bottom diameter of the wing: dng = 28 mm = 0.028 m
+ Diameter’s wing: D = 49 mm = 0.049 m
+ The thickness of the top of the wing: 𝛿 d = 0,6mm = 0.0006 m
+ The wing's bottom thickness: 𝛿 o = 1.1mm = 0.0011 m
+ Pitch of wing: Sc = 3.5 mm = 0.0035 m
+ Pitch of stand tube: S1= 52 mm = 0.052 m
+ Pitch of vertical tube: S2= 45 mm = 0.045 m
+ Pitch of cross tube: S’2= 52 mm = 0.052 m
+ With tf1 = 32oC; t f2 = 38oC, the average temperature of the air in the condenser
is:
𝑡𝑓1 +𝑡𝑓2 38+32
𝑡𝑎𝑖𝑟 = = = 35 oC (3. 65)
2 2

+Physical parameters of air at 35 oC:

Cair = 1.005 kJ/(kgK); rair = 1.145 kg/m3;
λ air = 2.7210-2 W/(m2 .K); vair = 16.5310-6 m2 /s
+ The average temperature difference between the condenser and air is:
∆𝑡𝑚𝑎𝑥−∆𝑡𝑚𝑖𝑛 (79−32)−(40−38)
𝜃𝑚 = ∆𝑡 = (79−32) = 14.25 oC (3. 66)
ln 𝑚𝑎𝑥 ln
∆𝑡𝑚𝑖𝑛 (40−38)

+ The quantity of air needed to cool the condenser is calculated as:

𝑄𝑘 177.2×103
𝐺𝑎𝑖𝑟 = = = 29.39 (kg/s) (3. 67)
𝐶𝑎𝑖𝑟 .(𝑡𝑓1 −𝑡𝑓2 ) 1.005×103 ×(38−32)

+ The cooled-down air volume flow rate for condensation:

𝐺𝑎𝑖𝑟 29.39
𝑉𝑎𝑖𝑟 = = = 25.65 m3/s = 92412 m3/h (3. 68)
𝜌𝑎𝑖𝑟 1.145

+ Determine the heat transfer coefficient towards the air:

 Determine the Nusselt number: Nu= C.Cz.Cs.𝜑 −𝑚 .Ren (3. 69)
For staggered tube beams: C= 0.32 and m=0.5
Choosing the number of rows of the air movement by z=4, thus Cz=1
Cs is calculated as below:
0.1
𝑆1 −𝑑𝑛𝑔 0.052−0.028 0.1
𝐶𝑠 = ( ) =( ) =1 (3. 70)
𝑆′2 −𝑑𝑛𝑔 0.052−0.028

Reynolds standard:
Find 𝑙𝑞 :
The wing area per 1 m of tube:
75
 π(D2 −d2 ng ) πDδd
FC = + (3. 71)
2SC Sc

3.14(0.0492 −0.0282 ) 3.14×0.049×0.0006

= + = 0.752 m2/m
2×0.0035 0.0035

The area between the wings per 1 m of tube is:

πdng (SC −δ0) 3.14×0.028×(0.0035−0.0011)
Fo = = = 0.06 m2/m (3. 72)
SC 0.0035

 Per 1 m of tube, the total area of the winged and wingless portions is:
F = Fc+F0= 0.752+0.06=0.812 m2/m (3. 73)
The inner surface area of a 1 m pipe is as follows:
Ftr. pipe = πdtr = 3.140.021 = 0.066 m2 /m (3. 74)
The outer surface area of a 1 m pipe is as follows:
Fng. pipe = πdng= 3.140.028 = 0.088 m2/m (3. 75)
The converted length is:
𝐹0 𝐹𝑐 𝜋
𝑙𝑞 =
𝐹
. 𝑑𝑛𝑔 +
𝐹
√ 4 (𝐷 2 − 𝑑𝑛𝑔
2 ) (3. 76)

0.06 0.75 3.14

 𝑙𝑞 = × 0.028 + √ × (0.0492 − 0.0282 ) = 0.035 𝑚
0.81 0.81 4

Choose 𝜔air = 19.5 m/s is the velocity of air moving through the condenser. As
a result, the Reynolds number might be calculated as follows:
𝜔𝑘ℎ .𝑙𝑞 19.4×0.035
Re = = = 41743 (3. 77)
𝑣 16.35×10−6

The outer wing density is as follows:

𝐹 0.812
𝜑𝑛𝑔 = = = 9.23 (3. 78)
𝐹𝑛𝑔 0.088

The exponent n can be calculated as follows:

n=0.6×𝜑𝑛𝑔 0.07=0.6×9.230.07=0.7 (3. 79)
 Nu is: Nu=0.32×1×1×9.23-0.5×417430.7=180.7
 The coefficient of convective heat transfer towards air is:
𝑁𝑢×λ𝑎𝑖𝑟 180.7×2.72×10−2
𝛼𝑎𝑖𝑟 = = = 140.43 (W/(m2.K)) (3. 80)
𝑙𝑞 0.035

 The heat transfer coefficient towards the air and is converted according to
the external surface:
𝐹 𝐹
𝛼𝑎𝑖𝑟.𝑛𝑔 = 𝛼𝑛𝑔 ( 𝑐 × 𝐸 × 𝜓 + 0) , W/(m2.K) (3. 81)
𝐹 𝐹

Where:
76
  𝜓 is compensable factor = 0.85
 E is the wing efficiency calculated using the following formula:
𝑡ℎ (𝑚.ℎ ′ )
𝐸= (3. 82)
𝑚.ℎ′

With:
2×𝛼𝑎𝑖𝑟 2×140.43
𝑚= √ = √ = 40.3 (3. 83)
λ 𝑐 ×𝛿𝑐 203.5×0.00085

λ𝑐 (W/(m.K) is the aluminum wing's thermal conductivity

coefficient.
𝛿𝑐 = (𝛿𝑑 + 𝛿0 )/2 = (0.0006+0.0011)/2=0.00085 m
ℎ′ = ℎ × (1 + 0.35 × ln 𝜎) , m (3. 84)
h=0.5×(D-dng) = 0.5×(0.049-0.028) = 0.0105 m
𝐷 0.049
𝜎= = = 1.75
𝑑𝑛𝑔 0.028
 ℎ′ = 0.0105 × (1 + 0.35 × ln 1.75) = 0.0126 m
 𝑚. ℎ′ = 40.3 × 0.0126 = 0.51
𝑡ℎ (𝑚.ℎ ′ ) 𝑡ℎ(0.51)
 𝐸= = = 0.9215
𝑚.ℎ′ 0.51

Notice: chx = (ex+e-x)/2; shx = (ex-e-x)/2; thx=shx/chx; coth = chx/shx

0.752 0.06
 𝛼𝑎𝑖𝑟.𝑛𝑔 = 140.43 × ( × 0.9215 × 0.85 + ) = 112.24
0.812 0.812

(W/(m2.K))
 Heat flow density towards the air according to the inner surface of the
tube is determined by the following formula:
𝜃𝑚 −𝜃
𝑞𝑎𝑖𝑟.𝑡𝑟 = 1 𝐹𝑡𝑟 2×𝐹𝑡𝑟 𝛿 (3. 85)
× + ×∑ 𝑖
𝛼𝑎𝑖𝑟.𝑛𝑔 𝐹 𝐹𝑡𝑟 +𝐹𝑛𝑔 λ𝑖

𝛿𝑖 𝛿𝑡ℎ 𝛿𝑛ℎ 0.001 0.001

∑ = + = + = 0.27 × 10−4 m2K/W
λ𝑖 λ𝑡ℎ λ𝑛ℎ 45.3 203.5
𝜃𝑚 −𝜃
 𝑞𝑎𝑖𝑟.𝑡𝑟 = 1 𝐹𝑡𝑟 2×𝐹𝑡𝑟 𝛿
× + ×∑ 𝑖
𝛼𝑎𝑖𝑟.𝑛𝑔 𝐹 𝐹𝑡𝑟 +𝐹𝑛𝑔 λ𝑖

14.25−𝜃
= 1 0.066 2×0.066 =1661.29×(14.25- 𝜃) , W/m2
× + ×0.27×10−4
112.24 0.812 0.066+0.088

With 𝜃 (oC) = the temperature difference in the pipe wall

The physical parameters of liquid R22 at tk = 40oC is:
𝜌 = 1132 kg/m3

77
 λ = 0.0791 W/(m.K)
v=0.196×10-6 m2/s
 The heat transfer coefficient towards R22 is figured out by the following
formula:
4 ∆ℎ.𝜌.λ3 .𝑔 4 196.54×103 ×1132×0.07913 ×9.81
𝛼𝑎 = 0.72 × √ = 0.72 × √ (3. 86)
𝑣.𝑑𝑡𝑟 .𝜃 0.196×10−6 ×0.021×𝜃

𝛼𝑎 =2897.93𝜃 −0.25
 𝑞𝑎.𝑡𝑟 = 𝛼𝑎 × 𝜃 = 2897.93 × 𝜃 0.75 (W/m2) (3. 87)
Have:
𝑞𝑎𝑖𝑟.𝑡𝑟 = 1661.29 × (14.25 − 𝜃)
{ (3. 88)
𝑞𝑎.𝑡𝑟 = 2897.93 × 𝜃 0.75
 2897.93 × 𝜃 0.75 = 1661.29×(14.25- 𝜃)
 𝜃 = 6.86oC
 qtr =12283.75 W/m2
 The internal surface area of the condensate device
𝑄𝑘 117.22×103
Ftr= = = 14.43 m2 (3. 89)
𝑞𝑡𝑟 12283.75

 The total pipe length of the condensation device:

𝛽.𝐹𝑡𝑟 1.15×14.43
𝐿𝑝𝑖𝑝𝑒 = = = 251.66 m (3. 90)
𝜋.𝑑𝑡𝑟 3.14×0.021

With 𝛽 = 1.12÷1.15, is a safe thermal coefficient

Choosing the length of each pipe is l1 = 2.5 m
 The total number of tubes of condensation equipment:
𝐿 251.66
𝑛= = = 101 𝑡𝑢𝑏𝑒𝑠 (3. 91)
𝑙1 2.5

 The number of pipe layout on the main surface:

𝑛+2 101+2
𝑛𝑧 = = = 26 𝑡𝑢𝑏𝑒𝑠 (3. 92)
𝑧 4

Length of condensate device:

l=l1 + 2.lco = 2.5 +2×0.13 = 2.76 m
With lco=0.13 m is the length of the tubing and coupling of the pipes connected
together.
Recheck the air speed pass through condensation device:

78
 First, we need to determine for the air to pass through 1 m the length of the heat
exchanger tube:
(𝐷−𝑑𝑛𝑔 ).𝛿𝑐
𝑓𝑘ℎ = 𝑆1 − [𝑑𝑛𝑔 + ] (3. 93)
𝑆𝑐

(0.049−0.028)×0.00085
= 0.052 − [0.028 + ] = 0.0189 m2
0.0035

Total area for the air movement at the narrow cross section is:
𝐹𝑘ℎ = 𝑛𝑧 . 𝑙. 𝑓𝑘ℎ = 26×2.76×0.0189 = 1.36 m2 (3. 94)
The air velocity is:
𝑉𝑘ℎ 25.67
𝜔𝑘ℎ = = = 18.88 m/s (3. 95)
𝐹𝑘ℎ 1.36

Thus, the actual air velocity through the condenser calculated and designed above
is 18.88 m/s, this deviation is small as compared to the selected air velocity (19.5 m/s),
hence technical parameters which are selected and calculated to design a condenser are
completely qualified with reality. Therefore, a condenser can be easily manufactured.

3.3.3.2. The evaporator

Heat load of an evaporator
The heat load for an evaporator is defined as the amount of heat that needs to
release to the product freezing environment, also known as the compressor's cooling
capability.

Q0mn =Q= 99.06 kW (3. 96)

The design of the evaporation device should be calculated as follows:

+ Boling (evaporated) temperature of refrigerant: t0 = -50oC

+ Air temperature in freezing chamber always maintains: tbl=-40.46oC

+ Enthalpy of the refrigerant before entering the evaporator: h7=191.27 kJ/kg

+ Enthalpy of the refrigerant after exiting the evaporator: h1=383.56 kJ/kg

+Mass flow rate of the refrigerant circulating through the evaporator: m1= 0.51 kg/s

+ The evaporator has a direct contact refrigeration form, using R22 refrigerant.
Calculation and design of an evaporator:
The natural convective air in the freezing chamber: tkh1=-40.46oC

79
 The convective air at the evaporator: tkh2=-45oC
Because the heat transfer plate thickness is 𝛿1 = 0.015 m in the freezing chamber,
the diameter of a heat exchanger tube in the evaporator is selected as dtr=0.012m,
dng=0.014 m. This tube is made from copper;
The evaporator consists of Nttn=16 heat transfer plates installed in parallel in the
sublimation chamber to place products for freezing and drying.
The inner surface area of the heat exchange tubes in the evaporator, which the
refrigerant passes through:
+ Determining the heat-moisture ratio and temperature of the wall of the
evaporator, the moisture-separation coefficient:
 The heat-moisture ratio
 The air parameters of the refrigeration chamber at the state:

tkh1=-40.46oC, 𝜑1 = 90%

Look up in Humid air table:

=> d”1 = 0.12×10-3 kg/kg; h”1 = 0.293 kJ/kg; hk1 =-40.52 kJ/kg

 d1=𝜑1.d’’1=0.9×0.12×10-3=0.108×10-3 kg/kg
 h1= hk1 + 𝜑1.h’’1 = -40.52 +0,9×0.293 = -40.25 kJ/kg;
 The parameters of air passing through the evaporator’s surface at the state:
tkh2=-45oC, 𝜑1 = 95%

Look up the Humid air table:

=> d”2 = 0.065×10-3 kg/kg; h”2 = 0.375 kJ/kg; hk1 =-47,76 kJ/kg

 D2=𝜑2.d’’2=0.95×0.065×10-3=0.06175×10-3 kg/kg
 H2= hk2 + 𝜑2.h’’2 = -47.76 +0.95×0.375 = -47.4 kJ/kg;
Thus, the heat-moisture ratio:
ℎ1 − ℎ2 −40.25 + 47.4
𝜀= = −3
= 154.6 × 103
𝑑1 − 𝑑2 (0.018 − 0.06175) × 10
ℎ1 −ℎ𝑣
 𝜀= = 154.6 × 103 (3. 97)
𝑑1 −𝑑𝑣

 The moisture-separation coefficient: Searching on 𝜀 = f(tv) diagram in Humid air

table, the temperature at the evaporator’s surface: tv = -47.32oC.

80
 𝑑1 −𝑑2 (0.108−0.06175)×10−3
𝜉 = 1 + 2880 × = 1 + 2880 × = 1.0266 (3. 98)
𝑡1 −𝑡2 −40+45

+ The velocity of the refrigerant in heat exchange, circulation through evaporators:

4×𝑚1
𝜔= 2 ×𝑧×𝜌 , m/s (3. 99)
𝜋×𝑑𝑡𝑟

In which:
z=Nttn=16 (the number of pipe groups working in parallel)
𝜌 (kg/m3) is density of the refrigerant circulating through the evaporator
at t0 = -50oC. => Searching on the Humid air Table, 𝜌 = 𝜌′′ = 3.096 kg/m3
𝜆=0.116 W/(m.K)
v=0.275x10-6 m2/s
Pr=3.46
4×𝑚1 4×0.52
 𝜔= 2 ×𝑧×𝜌 = = 92.86 m/s
𝜋×𝑑𝑡𝑟 3.14×0.0122 ×16×3.096

 Cooling coefficient toward refrigerant:

Firstly, the Reynolds coefficient is calculated as follow:
𝜔.𝑑𝑡𝑟 92.86×0.012
𝑅𝑒 = = = 4052073 > 10000 (3. 100)
𝑣 0.275×10−6

 The refrigerant circulating through the pipes is in turbulent flow. Therefore, Nu is

calculated as:
Nu = 0.021Re0.8Pr0.43el=0.02140520730.83.460.431=6920.92 (3.101)
 Cooling coefficient toward refrigerant:
𝑁𝑢×𝜆 6920.92 ×0.016
𝛼𝑟 = = = 9227.89 (W/(m2.K) (3.102)
𝑑𝑡𝑟 0.012

 The converted heat flow towards the inside tube is:

𝜃 (−47.32)−(−50)
𝑞𝑎,𝑡𝑟 = 1 𝛿 = 1 = 2657.76 W/m2 (3.103)
+∑ 𝑖 +0.9×10−3
𝛼𝑟 𝜆𝑖 9227.89

 The area of heat exchange towards the refrigerant is:

𝑄0 99.06×103
𝐹𝑡𝑟 = = = 37.27 m2 (3. 104)
𝑞𝑎,𝑡𝑟 2657.76

 Total length of heat exchanger tubes is:

𝐹𝑡𝑟 37.27
𝐿= = = 989.12 m (3. 105)
𝜋×𝑑𝑡𝑟 3.14×0.012

 Length of total tubes in 1 heat plate is:

𝐿 989.12
𝐿𝑡 = = = 61.82 m (3. 106)
𝑁𝑡𝑡𝑛 16

81
  Total number of tube on each heat plate:
We have, each heat plate has the length of L1=3.5m and the width of a=2.1m. If
the heat exchanger tubes are arranged according to the width, the length of these tubes
will be chosen as lo = 2 m.
 The number of tubes on each heat plate is:
𝐿𝑡 61.82
𝑁𝑜 = = = 30.91~31 tubes (3. 107)
𝑙𝑜 2

Distance between tubes on each heat plate:

𝐿1 3.5
𝑎0 = = = 0.11 m (3. 108)
𝑁𝑜 31

Check the outer surface area of the heat plate, which transmits heat and makes
direct contact with products in the freezing chamber:

Inside the cooling chamber, the starting temperature is:

t air = 25oC; Tair = 273.15 + 25 =298.15 K
The heat exchange coefficient towards the air is calculated by:
0.25
𝜃
𝛼𝑘 = 𝐴1 × ( ) , W/(m2.K) (3. 109)
𝑑𝑛𝑔

At tkh= -42.5oC, we have: A1= 1.379; 𝜃 = tair-tv=25+47.32=72.32oC

0.25
72.32
 𝛼𝑘 = 1.379 × ( ) = 11.69 W/(m2.K)
0.014

The radiative heat transfer coefficient is:

𝑇 4 4
𝑇
( 𝑎𝑖𝑟 ) −( 𝑣 )
100 100
𝛼𝑏 = 𝐶𝑏 × 𝜓 × , W/(m2.K) (3. 110)
𝑇𝑎𝑖𝑟 −𝑇𝑣

For fronzen surfaces, choose: the radiative coefficient choosen Cb = 5.45; the
coefficient of illuminance ψ = 0.92:
25+273.15 4 −47.32+273,15 4
( ) −( )
100 100
 𝛼𝑏 = 5.45 × 0.92 × = 3.68 W/(m2.K)
25+47.32

The converted heat transfer coefficient:

1
𝛼𝑞 = 1 𝛿 , W/(m2.K) (3. 111)
+ 𝑡+𝑅𝑐
𝛼𝑘 .𝜉+𝛼𝑏 𝜆𝑡

Choose: 𝛿𝑡 = (5 ÷ 6) mm = 6 mm = 0.006 m; λt= 0.2 W/(mK); Rc = 0.059

1
 𝛼𝑞 = 1 0.006 = 6.55 W/(m2.K)
+ +0.059
11.69×1.026+3.68 0.2

The converted heat flows towards the air and is in contact with the products:

82
qng = 𝛼q (tair – tv) = 6.55×(25+47.32) = 473.7 W/m2 (3. 112)
The total heat-exchange outer surface area of an evaporator:
𝑄0 99.06×103
𝐹𝑛𝑔 = = = 209.12 m2 (3. 113)
𝑞𝑛𝑔 473.7

The heat exchange area is calculated in accordance with the capacity Q0mn = 99.06
kW is Fng= 209.12 m2 smaller than the designed area of the initial freezing chamber: Fdl
= 235.2 m2 . This difference is not great, the evaporator has a qualified heat exchange
design and is completely appropriate for the cooling capacity of the freezing chamber.

3.3.3.2. The receiver:

The amount of exchange heat in the receiver:
The operational characteristics of a receiver are chosen and computed in the same
way as in previous sections:
+ Temperature of liquid refrigerant in a receiver after it has been discharged from the
condenser and before it enters the spiral tube: tk= 40oC;
+ Temperature of liquid refrigerant in a receiver after exiting the spiral tube:tql = -8oC;
+ Temperature of the refrigerant outside the spiral tube within the receiver: ttg = -13oC;
+ Refrigerant evaporated temperature (boiling) in a receiver: t0 = - 50oC;
+ The enthalpy of the refrigerant before it enters the spiral tube: h5 = 249.99 kJ/kg;
+ The enthalpy of the refrigerant after exiting the spiral tube: h7 = 191.27 kJ/kg;
+ The refrigerant mass flow rate passing through the spiral tube: m1=0.51 kg/s
To accurately calculate the heat exchange area of the spiral tubes that cool the
refrigerant completely from the first-stage compression, supercooling the refrigerant
passing through the spiral tubes before throttling into the evaporator, the amount of
exchanged heat at the intermediate cooler must first be calculated. The heat emitted
during refrigerant supercooling in spiral tubes is computed using the following equation:
Qtg = m1 (h5 – h7)=0.52×(249.99-191.27)=30.53 kW (3.114)
Calculation and design of a receiver:
The average temperature of the liquid refrigerant before entering and after exiting
the spiral tube:
𝑡𝑘 +𝑡𝑞𝑙 40+(−8)
𝑡𝑎𝑣𝑒 = = = 16 oC (3.115)
2 2

With tave=16oC, we have physical parameters of R22 is:

𝜌 = 1227.4 kg/m3 ; 𝜆= 0.0762 W/(m.K); v = 0.197810-6m2 /s; Pr = 3.3254
83
 +The spiral tube formation could be chosen as follows:
 External diameter of the spiral tube: dng=0.021 m
 Internal diameter of the spiral tube: dtr=0.019 m
 This was made from copper creating two interlocking coils with the inner
diameters of the vessel:
D1=0.4 m; D2=0.5 m
+ R22 liquid velocity through the spiral tube:
𝑚1 0.52
w= 𝑑2
= 0.0192
= 0.75 m/s
𝜌×𝜋 𝑡𝑟×2 1227.4×3.14×
4
×2
4

𝑤.𝑑𝑡𝑟 0.75×0.019
+Reynolds number is: 𝑅𝑒 = = = 79626 (3.116)
𝑣 0.1978×10−6

 The refrigerant passing through the spiral tube is a turbulent-laminar transitional

flow because Re>10000.
+Nusselt equation is:
Nu= 0.021Re0.8Pr0.43𝜀 1 (3.117)
where 𝜀 1=1 because ratio: 1/dtr=1/0.019>50
 Nu= 0.021795260.83.32540.431=293.4
𝑁𝑢×𝜆 293.4×0.0762
𝛼𝑤′ = = = 1176.69 W/(m2.K) (3.118)
𝑑𝑡𝑟 0.019

+Bendable radius of the spiral tube beam in the receiver:

𝐷1 +𝐷2 0.4+0.5
𝑅= = = 0.225 m (3.119)
4 4

+Correction coefficient of the spiral tube:

𝑑𝑟 0.019
𝜀𝑥 = 1 + 1.8 × = 1 + 1.8 × = 1.152 (3.120)
𝑅 0.225

+Heat transfer coefficient towards liquid R22 after correction:

𝛼𝑤 = 𝛼𝑤′ 𝜀𝑥 =1176.691.152=1355.55 W/(m2.K) (3.121)
+Logarithmic mean temperature difference of a receiver is:
𝑡𝑘 −𝑡𝑞𝑙 40−(−8)
𝜃𝑚 = 𝑡𝑘 −𝑡𝑞𝑙 = 40−(−13) = 20.33 oC (3.122)
ln ln
𝑡𝑞𝑙 −𝑡𝑘 (−8−(−13))

+Heat flow density towards liquid R22 in the spiral tube:

𝜃𝑠 𝜃𝑚 −𝜃
𝑞𝑤,𝑡𝑟 = 1 𝛿 = 1 𝛿 (3. 123)
+∑ 𝑖 +∑ 𝑖
𝛼𝑤 𝜆𝑖 𝛼𝑤 𝜆𝑖

In which: 𝜃𝑠 = 𝑡̅ − 𝑡𝑤′ oC is the temperature difference between the heat transfer

surface of the spiral tube and the boiling point of R22 on the outside of the spiral tube.
84
 Therefore, 𝑡̅+ 𝜃= ts + 𝜃m+ tw – ts = 𝜃m+ tw 𝜃m-𝜃=𝑡̅ − 𝑡𝑤′ (3. 124)
𝛿
Choosing ∑ 𝑖 =0.83×10-3 W/(m2.K), the spiral tube is made from plain copper.
𝜆𝑖
20.33−𝜃
 𝑞𝑤,𝑡𝑟 = 1 = 650.32 × (20.33 − 𝜃) (3. 125)
+0.8×10−3
1355.55

+Heat flow density outside the spiral tube (boiling R22), converted according to
the inner side of the spiral tube, is calculated as:
𝐹𝑛𝑔 𝑅𝑧 0.8
𝑞𝑎,𝑡𝑟 = (𝐴 × 𝜃 × 𝜀𝑛 )4 × ×( ) W/m2 (3. 126)
𝐹𝑡𝑟 𝑅𝑧′

We have: tavg=16oC => A=2.3774; because of the number of rounds n<6

𝐹𝑛𝑔 𝑑𝑛𝑔 0.021
=> 𝜀𝑛 =1; =( )= ; Rz=4𝜇; R’z=1.
𝐹𝑡𝑟 𝑑𝑡𝑟 0.019
0.021
 𝑞𝑎,𝑡𝑟 = (2.3774 × 𝜃 × 1)4 × × 40.8 = 107.03𝜃 4
0.019

Solving: 𝑞𝑤,𝑡𝑟 = 650.320 × (20.33 − 𝜃)

𝑞𝑎,𝑡𝑟 = 107.03𝜃 4
 𝜃=3.19 oC => 𝑞𝑤,𝑡𝑟 = 11146.48 W/m2
+Heat trasfer area of the spiral tube:
𝑄𝑡𝑔 ×103 30.53×103
𝐹𝑡𝑟 = = = 2.74 m2 (3. 127)
𝑞𝑤,𝑡𝑟 11146.48

+Total length of the sprial tube:

𝐹𝑡𝑟 2.74
𝐿= = = 45.93 m (3. 128)
𝜋×𝑑𝑡𝑟 3.14×0.019

+The number of twists per spiral beam

𝐿 45.93
𝑛= = = 16.25~17 twists (3. 129)
𝜋×(𝐷1 +𝐷2 ) 3.14(0.4+0.5)

The height of spiral beams:

If the distance between two twists is ∆ = 35 mm:
 H= ndng + (n –1) ∆ = 17×21+(17-1)×35=917mm=0.917 m (3. 130)
The receiver could be fabricated in the following sizes based on the features listed
above:
Hbtg = 𝐻 + 𝛿 + 𝛿′= 0.917+0.2+0.075=1.19 m
Dbtg = 𝐷2 + 2𝛿1 = 0.5+ 2×0.03=0.56 m

3.3.3.3. The throttle valve:

Calculation of intermediate cooling throttle valve selection:

85
 𝑄𝑡𝑔
𝐹= m2 (3. 131)
3600×𝑞𝑡𝑔 ×𝜂×√∆𝑃×𝜌×𝑔

Where:
η = (0.5 ÷ 0.8): Compression coefficient of the flow through the throttle valve.
Choose: η = 0.8
ΔP is the difference in pressure before and after throttling:
ΔP = Pk – Ptg = 15.315 – 3.145 = 12.17 bar = 12.4 kg/cm2 = 12.4 x 104 kg/m2
𝑔 = 9.81 m/s2 is acceleration of the earth’s gravity.
ρ (kg/m3) is density of refrigerant before passing through the throttle valve.
At tk = 40o C => ρ” = 67.57kg/m3 ;
Qtg = 30.53 kW = 26251.08 kCal/h is the cold performance of an intermediate
cooling throttle valve.
qtg = h5 – h7 = 249.99 – 191.27 = 58 kJ/kg = 14.03 kCal/kg
F (m2 ) is cross-section of a throttle valve.
The first throttle cross-section in the receiver:
26251.08
 𝐹1 = = 7.166 × 10−4 (m2) = 71.66mm2
3600×14.03×0.8×√12.4×104 ×67.57×9.81

With the cross-section F1=71.66mm2 largest that the throttle valve can be opened,
it is possitble to choose Danfoss throttle for refrigeration systems with cold capacity
(45÷ 65) kW/ valve number 0/ maximum boiling temperature t0 = (-45 ÷ -50)oC.
Throttle valve calculation in the evaporator:
𝑄𝑜
𝐹= , m2 (3. 132)
3600×𝑞0 ×𝜂×√∆𝑃×𝜌×𝑔

Where:
η = (0.5 ÷ 0.8): Compression coefficient of the flow through the throttle valve.
Choose: η = 0.8
ΔP is the difference in pressure before and after throttling:
ΔP = Pk – P0 = 15.315 – 0.6459 = 14.7 bar = 14.8 kg/cm2 = 14.8 x 104 kg/m2
𝑔 = 9.81 m/s2 is acceleration of the earth’s gravity.
ρ (kg/m3) is density of refrigerant before passing through the throttle valve.
At tql = -8o C => ρ” = 17.38 kg/m3 ;
Qo = 99.06 kW = 85176.27 kCal/h is the cold performance of an intermediate
cooling throttle valve.
qo = h1 – h7 = 383.56 – 191.27 = 192.29 kJ/kg = 45.94 kCal/kg
86
 F (m2 ) is cross-section of a throttle valve.
The second throttle corss-section in the evaporator:
85176.27
𝐹2 = = 1.2817 × 10−4 m2 = 128.17 mm2
3600×45.94×0.8×√14.8×104 ×17.38×9.81

With the cross-section F2=128.17mm2 that the throttle valve can be opened, it is
possitble to choose Danfoss throttle for refrigeration systems with cold capacity
(100÷120) kW/ valve number 1/ maximum boiling temperature t0 = (-45 ÷ -50)oC.

3.3.3.4. Calculation of pipes

Calculation for low pressure:
+ Calculate the suction pipe:
𝑚1
𝐷𝑡𝑟.ℎ.1 = 2 × √ ,m (3. 133)
𝜋×𝜔1 ×𝜌

Where,
m1 = 0.53 kg/s: The refrigerant vapor flow rate through the low-end compressor.
𝜌 = 𝜌” = 3.096 kg/m3 is density of refrigerant vapor that circulates through the
evaporator, which is absorbed by the compressor.
Select refrigerant speed out of evaporator 𝜔1= 12 m/s Thus, the suction pipe
diameter of the primary compressor is determined:
0.52
𝐷𝑡𝑟.ℎ.1 = 2 × √ = 133.53 × 10−3 m=133.53 mm
3.14×12×3.069

 Choose 𝐷𝑡𝑟.ℎ.1 = 134 mm

+ Calculate the push pipe:
Choose the speed of solvent vapor out of primary compressor 𝜔2 = 15m/s
𝑚1 0.52
𝐷𝑡𝑟.ℎ.1 = 2 × √ =2×√ (3. 134)
𝜋×𝜔2 ×𝜌 3.14×15×3.069

= 119.43 × 10−3 m = 119.43 mm

Choose: 𝐷𝑡𝑟.ℎ.1 = 120 mm
Calculation for high pressure:
+ Calculate the suction pipe:
𝑚2
𝐷𝑡𝑟.ℎ.2 = 2 × √ ,m (3. 135
𝜋×𝜔11 ×𝜌

Where,
m2 = 0.83 kg/s: The refrigerant vapor flow rate through the high-end compressor.

87
 Choose the feed solvent speed into high-end compressor 𝜔11= 12 m/s
At the end point temperature of compression range of the first-stage compressor:
ttg = -13o C, Ptg = 3.145 bar => 𝜌 = 8,25 kg/m3 .
0.85
𝐷𝑡𝑟.ℎ.2 = 2 × √ = 104.58 × 10−3 m = 104.58 mm
3.14×12×8.25

 Choose: 𝐷𝑡𝑟.ℎ.2 =105 mm

+ Calculate the push pipe:
Choose the speed of solvent vaport out of primary compressor 𝜔12 = 15m/s

𝑚2 0.85
𝐷𝑡𝑟.ℎ.2 = 2 × √ =2×√ (3. 136)
𝜋×𝜔12 ×𝜌 3.14×15×8.25

= 93.54 × 10−3 m = 93.54 mm

Choose: 𝐷𝑡𝑟.ℎ.2 =94 mm

3.4. Freeze drying system design calculation

3.4.1. Calculation of the energy balance
The freeze-drying chamber is also the frozen product chamber which has been
calculated and designed before. However, in this case, we must calculate the heat
required for freeze drying in phase 2 and ensure that the heat exchange area of the heat
transfer plates is adequate. (If not, the problem will be reset to the freezer design stage.)
We can then calculate and choose the most appropriate heat supply choice for the freeze-
drying process.

3.4.1.1. Calculation of heat supplied to the freeze- drying chamber:

The heat required for the freeze-drying process includes the following basic
amounts of heat:
+ Freeze-drying heat Qth (kJ)
+ The amount of heat needed for dehumidification process remaining after freeze
drying, also known as heat evaporates moisture Qhh (kJ) during low temperature vacuum
drying
+ The amount of heat loss to the outside environment Qmt (kW)
+ The amount of heat resulting from the transport of drying materials Qvc(kW).
For the self-freeze-drying system Qvc = 0, the ambient temperature is always
greater than the temperature in the freeze-drying chamber, hence Qmt < 0. This is a
88
desirable quantity of heat, as it reduces the energy provided throughout the drying
process.
• Drying chamber capacity: G = 1500 kg/batch.
• Drying time 1 batch: 𝜏2 = 18.283 h.
• The raw material moisture of the royal jelly when freezing: Wa = 59.20%.
• In order to get the best quality of dried cordyceps, the drying process should be
carried out according to the technology set in the table. At that time, the final
product moisture of the freeze-dried royal jelly: We = 4.19%
• Average temperature of the product after freezing to allow the water in the product
to completely freeze Tth = TFopt = - 18.33°C. This is also the freeze-drying
temperature of royal jelly. Corresponding to this temperature the freeze-drying
pressure will be Pth = 0.901 mmHg.
• Freeze-drying pressure Pbth = 0.411 mmHg < Pth = 0.901 is perfectly suited,
corresponding to the temperature of snow (freezing) T h t = -26.43°C.
• The radiation plate temperature can be adjusted to the highest value: tdn = 40°C.
• The freeze-drying temperature can be adjusted to the highest value: tm t = 35°C.

• With the productivity of the drying system is G = 1500 kg/batch, the amount of
moisture that exits Wthm= 861.24 kg/batch.
𝑊𝑡ℎ𝑚 861.24
Wth = = = 47.106 kg/h (3. 137)
𝜏2 18.283

• Latent freeze-drying heat of frozen water in royal jelly at temperature:

T = Tth= - 18.33°C:
rth = 0.0024 × T2 + 3.0606 × T + 3287.74 (3. 138)

= 0.0024 × (-18.33)2 + 3.0606 × (-18.33) + 32887.704 = 3231.78 (kJ/ kg)

• The amount of heat required in the freeze-drying phase:

The heat needed for the entire freeze-drying process to sublimate all the water
crystallizes in royal jelly Wth = 47.106 kg/h:

Qth = Wth. rth = 47.106 × 3231.78 = 152236.23 kJ/h = 42.29 kW (3. 139)
• The amount of heat needed for the vacuum drying process:

Royal jelly freeze-drying process has only freeze-drying stage, not available

89
vacuum drying stage: Qhh = Wckm . rhh = 0 (3. 140)
• The heat from the outside environment penetrates reduced the amount of heat
supplied, which is a beneficial heat flow.
The freezer chamber is also the freeze-drying chamber in the self-freeze-drying
system. As a result, the surface area of the wall and the coefficient of heat transfer are
precisely the same as when calculating the heat loss through the wall of a freezer during
the freezing stage Fv = 49.19 m2 and Kv = 0.43 W/ (m2.K )
• The temperature differential between the inside and external environments:
∆𝑡 = tmt – tkk = 35 – 15 = 10 °C (3. 141)
• The quantity of heat from environment that enters the freezer or freeze-drying
chamber:
• Qmt = Kv. Fv. Δt = 0.43 × 49.19× 10 = 211.517 W = 0.21 kW (3. 142)
The energy balance equation in freeze-drying process:
Q = kth . (Qth + Qhh + Qvc – Qmt), kW (3. 143)
With: Q (kW) is the heat needed for drying process; kth= (1.5 - 2.5) is heat load
coefficient.
Q = kth . (Qth + Qhh + Qvc – Qmt) = 1.55×(42.29+0+0+0.21) = 65.224 kW
• The amount of heat needed separately for the freeze-drying chamber to separate 1
kg of moisture from the dried product:
𝑄 65.224
q= = = 1.38 kWh/kg moisture (3. 144)
𝑊𝑡ℎ 47.106

This is the basis for calculating the energy consumption norm in freeze-drying of
products, from which the cost and product cost are calculated.
• If additional energy is supplied to the vacuum pump, the pump, the fan of the
condenser, etc., the energy qr (kWh/kg moisture) needed to separate 1 kg of moisture
from the freeze-drying product: qr = ( 2 ÷ 3 )× q = ( 2 ÷ 3 )× 1.38 = ( 2.76 ÷ 4.14)
kWh/ kg moisture.

3.4.1.2. Calculation of re-examination of heat exchange area of heat exchange plate

in the freeze-drying chamber:
• The freeze-drying chamber in the self-freezing freeze-drying system is also the
product freezer chamber, according to the design calculations of the freezer
chamber, the total heat exchange area of Nttn = 16 heat exchange plates: Fdl = 235.2
90
 m2.
• The freeze-drying environment is considered to be almost absolute vacuum.
Therefore, heating during the freeze-drying process is mainly by radiation and
conduction, while convection is considered to be zero. Therefore, when calculating
the design so that the area of radiant heat and conduction during the freeze-drying
process and the heat supply must be sufficient, but it must satisfy:
Fbx < Fdl = 235.2 m2 (3. 145)
Allowing the errors (5-10) %.
The steps of conducting calculations, examining the area of heat exchange as
following:
• Radiation coefficient in the process of freeze-drying:
Freeze-drying process is carried out in a vacuum environment. Because there is
no physical environment, convection heat exchange decreases and heat exchange by
increased radiation. Experiments show that the heat exchanger is only (10-15) %
compared to the heat exchange by radiation. So:
𝛼 = 𝛼𝑑𝑙 . 𝛼𝑏𝑥 = 𝑘. 𝛼𝑏𝑥 , W/(m2.K) (3. 146)
• Choosing k = 1.2 is the adjustment coefficient because of a convection heat
exchanger.
• Choose the black level of the radiation plate 𝜀1 ≈ 0.95 and blackness of drying
material 𝜀2 ≈ 0.91
• The resulting radiation coefficient:
1 1
𝜀𝑞𝑑 = 1 1 = 1 1 = 0.868 (3. 147)
+ −1 + −1
𝜀1 𝜀2 0.95 0.91

• Heating area of radiation for drying cordyceps in freeze-drying chamber

𝑄
Fbx = , 𝑚2 (3. 148)
𝑘.𝛼𝑏𝑥.( 𝑇𝑚𝑡 − 𝑇𝑡ℎ )

Or :
𝑄
Fbx = 𝑇 𝑇 , 𝑚2 (3. 149)
𝑘.𝐶0 .𝜀𝑞𝑑 (( 𝑚𝑡 )4 − ( 𝑡ℎ )4 )
100 100

With: Co = 5.67 (W/(m2.K4) is the radiation constant of the absolute black body
𝑄 65.224×103
Fbx = 𝑇 𝑇 = 273.15+35 4 273.15−18.33 4
= 230.06 m2
𝑘.𝐶0 .𝜀𝑞𝑑 (( 𝑚𝑡 )4 − ( 𝑡ℎ )4 ) 1.2×5.67×0.868×{( ) −( ) }
100 100 100 100

It can be seen that, when conditions are satisfied, the heat exchanger area of the

91
freeze-drying chamber is completely consistent with the actual area when
manufacturing the freezing chamber of the product before freeze-drying.
Calculation for the flow of heating heat or the radiant thermal capacity
provided for the drying process
• The amount of heat that the thermal load or thermistor provides for the entire
freeze-drying process is Q =65.224 kW for drying 1500 kg of royal jelly with
moisture Wa = 59.20% to a satisfactory humidity We = 4.19%:

Q = Ctn . Gtn . ( tv – tr ) = P, kW (3. 150)

In with Cnt (kJ/(kg.K)), G> (kg/s) are specific heat capacity and heat load flow; P
(kW) is the capacity of the thermistor (if supplied by resistance); tv, tr (°C) is the in and out
temperature of the heat load.
• If heated by hot water, the required flow for the freeze-drying process:
The inlet temperature: tv= 50°C.
Output water temperature: tr= 42°C.
• The average specific heat of water from 42°C to 50°C:
1 𝑡𝑣
Cn = ∫ ( 4184.7
𝑇𝑣 − 𝑇𝑟 𝑡𝑟
+ 1.74 × 𝑇 ). 𝑑𝑇 = 4.195 kJ/( kg.K ) (3. 151)

• The flow of hot water supplied for heating:

𝑄 65.224
Gn = = = 1.94 kg/s (3. 152)
𝑐𝑛 .( 𝑡𝑣 − 𝑡𝑟 ) 4.195(50−42)

• Flow through each heat transfer plate:

𝐺𝑛 1.94
Gntn = = = 0.1213 kg/s (3. 153)
𝑁𝑡𝑡𝑛 16

• If provide heating by thermistor, the total heat resistance capacity arranged in 16

heat transfer plates: Q = 65.224 kW
• Each resistor level has power: 320 W = 0.32 kW.
• The number of resistors needed to place in the heat transfer plate:
𝑄 65.224
Ncdt = = = 204 (3. 154)
0.32 0.32

• The number of resistors arranged on each plate:

𝑁𝑐𝑑𝑡 204
Ncdtmt = = = 13 (3. 155)
𝑁𝑡𝑡𝑛 16

92
3.4.2. Calculation of ice condenser
3.4.2.1. Calculation the amount of heat generated in the ice condenser:
Qngtdb = 86.39 kW. This is the basis for calculating and designing condensing
equipment — freezing to completely snow the moisture content after freeze- drying
from the drying chamber to condensing — freezing equipment.

3.4.2.2. Calculation and design of ice condenser:

Calculation of refrigeration system running for petrification equipment
Due to the cooling capacity ( heat load) of the condensing – freezing equipment
Qngtdb = 86.39 kW ≤ 𝑄0𝑚𝑛
𝑚𝑖𝑛 = 99.06 kw, the cooling of the product freezing – chamber

before drying freeze- drying. On the other hand, freeze and drying stage are two stages
not working at the same time, they work in succession. In addition, to reduce the cost of
manufacturing freeze- drying systems, condensing – freezing equipment during freeze
drying and freezing chambers, the product can use the same refrigeration system as
calculated, design for the freezer chamber in previous part. Therefore, in this part, there
is no need to calculate and design refrigeration systems for condensing and freezing
equipment.
Calculation and design of ice condenser:

Figure 3. 8. The formation principle diagram of the ice condenser

Ice condenser has a cylindrical shape, the volume is Vngtdb (m 3); inner diameter is
Dtr (m); the outer diameter is D ng (m); length is L (m).

• Volume: Vngtdb = 2.01 m3

• Inner diameter: Dtr = 0.8 m.

• Outer diameter: Dng = 0.81 m

93
• Length: L = 4 m.

• Thickness of polyurethane insulation cover: 𝛿𝑐𝑛 = 0.08 m

• Outer diameter covered insulation: Dngdb = 0.97m

• Temperature of the moisture — air mixture: thv = th = 10°C.

• Moisture mixture temperature — air out: thr = tb + (5÷10) = — 38 + 8 = 30 OC.

• Boiling temperature of R22 go in heat exchange tube make of copper of ice
condenser: to = - 50°C.
• Ambient temperature in ice condenser always maintained: tbmt = - 40°C.
• Enthalpy of refrigerant before entering ice condenser: h7 = 191.27 kJ/kg.
• Enthalpy of the refrigerant out from ice condenser: h1 = 383.56 kJ/kg.
• Actual flow of refrigerant circulating through the compressor: m1 = 0.52 kg/s.

• Heat exchange tubes: dtr = 21m, = 0.021 m; dng = 28mm = 0.028 m.

• Ice condenser is designed as a horizontal smooth tube, consisting of three channels

(or three grooves), each channel divides z = 60 in and 60 out.

• At temp t0 = - 50 °C:
𝜌 = 𝜌,, = 3.096 kg/m3 𝜆 = 0.116 W/ ( m.K )
𝑣 = 0.275 × 10−6 m2/s Pr = 3.46
• The velocity of the liquid R22 in the coil:
𝑚1 0.52
w= 𝑑2
= 0.0212
= 8.09 m/s (3. 156)
𝜌.𝜋. 𝑡𝑟.𝑧 3.096 × 3.14×
4
×60
4

• The Reynolds standard:

𝑊.𝑑𝑡𝑟 8.09 ×0.021
Re = = = 617782 (3. 157)
𝑢 0.275×10−6

• Thus, the refrigerant that flows in the beam is excessive, because Re = 617782
> 10000 so the Nusselt standard equation:
Nu = 0.021 × Re0.8 × Pr0.43 × 𝜀1 (3.158)
= 0.021× (617782 )0.8 × (3.46)0.43 × 1 = 1537.06
𝜆 .𝑁𝑢 0.116×1537.06
𝛼𝑤 = = = 8490.43 W/ (m2.k) (3. 159)
𝑑𝑡𝑟 0.021

• Logarithm average temperature difference of the ice condenser:

94
 𝑡ℎ𝑣 −𝑡ℎ𝑟 10−( −30)
𝜃𝑚 = 𝑡 −𝑡 = 10−(−50) = 36.4 °C (3. 160)
𝑙𝑛 ℎ𝑣 0 𝑙𝑛
−30−(−50)
𝑡ℎ𝑟−𝑡0

• The density of heat flow toward R22 loosens in the pipe:

𝜃𝑠 𝑡𝑤 −𝑡𝑣 𝜃1 −𝜃
qw.tr = 1 𝛿 = 1 𝛿 = 1 𝛿 (3. 161)
+∑ 𝑖 +∑ 𝑖 +∑ 𝑖
𝛼𝑤 𝜆𝑖 𝛼𝑤 𝜆𝑖 𝛼𝑤 𝜆𝑖

With: 𝜃𝑠 = 𝑡𝑤 − 𝑡0 is the temperature difference between the average

temperature of the heat transfer surface temperature and the coolant boiling point. In
other words, the average temperature of the liquid R22 passes through the tube and
the surface exchange temperature of the tube.
 t0 = th - 𝜃𝑚
With: 𝜃 = 𝑡ℎ − 𝑡𝑤 is temperature difference between the average
temperature of the moisture — air mixture and the heat transfer surface of the coil;
th is average temperature of the moisture-air mixture in a petrified vessel.
𝜃 = t0 = th + tw + 𝜃m + th = 𝜃m – tw ↔ 𝜃m - 𝜃 = tw –t0
𝛿𝑖
Choosing ∑ = 0.8 × 10-2 is plain beam tubes made of copper.
𝜆𝑖

𝜃𝑠 36.4−𝜃
qw.tr = 1 𝛿 = 1 = 123.19 × ( 36.4 - 𝜃 ) (3. 162)
+∑ 𝑖 + 0.8 × 10−2
𝛼𝑤 𝜆𝑖 8490.43

• The heat flow density outside the tube of moisture-air mixture, converted
according to the surface of the tube:
𝐹𝑛𝑔 𝑅𝑧 0.8
qa.tr = (A.𝜃. 𝜀𝑛 )4 . .( ) , W/m2 (3. 163)
𝐹𝑡𝑟 𝑅𝑧,

With: to = — 50°C, at this temperature, the table will find a factor A = 0.799
because the number of tube beams n > 6 should 𝜀𝑛 = 1.1
𝐹𝑛𝑔 𝑑𝑛𝑔 0.028
= = = 1.33 (3. 164)
𝐹𝑡𝑟 𝑑𝑡𝑟 0.021

Choosing: Rz = 4 𝜇 ,𝑅𝑧, = 1 𝜇
𝐹𝑛𝑔 𝑅
qa.tr = (A.𝜃. 𝜀𝑛 )4 . . ( 𝑧, )0.8 = (0.799 × 1.1× 𝜃)4×1.33×40.8 = 2.41 × 𝜃 4 (W/m2 )
𝐹𝑡𝑟 𝑅𝑧

qw.tr = q a.tr ↔ 123.19 × (36.4 - 𝜃 ) = 2.41 × 𝜃 4 → 𝜃 = 6.26 0 C

Hence, qw.tr = 3712.95 W/m2
Heat transfer area of tube beam
𝑄𝑛𝑔𝑡𝑑𝑏 86.39×103
Ftr = = = 23.27 m2 (3. 165)
𝑞𝑤.𝑡𝑟 3712.95
95
 Total length of beam
𝐹𝑡𝑟 23.27
Lc = = = 352.90 m (3. 166)
𝜋𝑑𝑡𝑟 3.14 ×0.021

Number of tubes in the device:

The length of the freezing equipment is L = 4 m; The length of each tube is I0 = 2
m. Thus, the number of tubes:
𝐿𝑐 352.90
n= = = 177 tubes (3. 167)
𝐼0 2

Choose n = 180 tubes arranged on three channels: inlet channel: 60 tubes; outlet
channel: 60 tubes; middle channel: 60 tubes.

3.4.3. Calculation of the vacuum pump

3.4.3.1. Flow capacity of vacuum pump:
To calculate and choose the vacuum pump to suit the productivity of the freeze-
drying chamber and the volume of the freeze-drying chamber:
𝑉 𝐵−𝑃𝑔ℎ
Qb = 𝛽1 . 𝛽2 . ln( ) , m3/ h (3. 168)
𝜏𝑑 𝑃𝑡ℎ −𝑃𝑔ℎ

With: Nb (m3/h) is suction capacity of vacuum pump; V (m3) is volume of

freeze- drying chamber; 𝜏𝑑 (ℎ) is time to expel gas in the freeze-drying chamber.
In fact, the time to eliminate gas in the freeze drying chamber is (0.5 ÷5) minutes,
choose (0,5 ÷ 5) minutes, choosing 𝜏d= 4 minutes = 1/15 h; B = 760 mmHg is
atmospheric pressure; Pgh = 0.001 mmHg is pressure limits that vacuum pumps
can produce; Pth = 0.411 mmHg is working pressure of the freeze-drying chamber;
𝛽1 = (1.2 - 1.5): leakage coefficient of the freeze-drying chamber or characteristic
coefficient for the tightness of the freeze-drying chamber;𝛽2 = (1.12 - 1.15) is safety
factor of vacuum pump.
 The freeze-drying chamber volume:
2
𝜋.𝐷𝑡𝑟 4 𝛼
V= . L1 + 4 𝜋. 𝑅𝑐3 . (m3) (3. 169)
4 3 360

• Cylindrical body length: L1 = 3.5 m.

• The height of each cap: hc = 0.2 m
• Inner diameter: D1 = 2.R1 = 2.97 m.
• R C = 5.61 m; 𝛼 = 15.07°

96
 𝜋.𝐷12 4 𝛼
V= . L1 + 4 𝜋. 𝑅𝑐3 . (3. 170)
4 3 360
3.14×2.972 4 15.07
= × 3.5 + 4 × × 3.14 × 5.613 × = 148.01 m3
4 3 360
𝑉 𝐵−𝑃𝑔ℎ
Qb = 𝛽1 . 𝛽2 . ln( ) (3. 171)
𝜏𝑑 𝑃𝑡ℎ −𝑃𝑔ℎ

148.01 760−0.001
= 1.2 × 1.15 × × ln ( )= 23054.9 m3/h
1/15 0.411−0.001

3.4.3.2. Vacuum pump capacity:

∆𝑃𝑏 .𝑄𝑏 0.24 × 105 ×23054.9
Ndcbck = 𝛽. = 1.15 × = 202.11 kW (3. 172)
1000.𝜂𝐻. 𝜂𝑣. 𝜂𝑐𝑘 3600×1000 ×0.92×0.97 ×0.98

With:∆Pb = 0.24 × 10 5 N/m2 is the pressure created by the vacuum generated; 𝜂 H

= 0.92 is hydraulic performance; 𝜂 v= 0.97 is the volumetric efficiency; 𝜂 ck = 0.98 is
the mechanical performance of the vacuum machine; 𝛽 = 1.15 is the safety factor of a
vacuum machine.
Thus, based on calculations, choosing a vacuum pump suitable for drying system:
Capacity Ndcbck = 205 kW
Three- phase AC voltage/ 380 V

3.4.4. Define defrost time

The time to remove the ice from the condenser surface heat exchanger —
freezing in a batch:
𝑄𝑥𝑏
𝜏𝑥𝑏 = , s/ batch (3. 173)
𝐾.𝐹𝑛𝑔 .Δ𝑡𝑡𝑏

With: Qxb (kJ) is the amount of heat provided to melt the ice on the surface
of ice condenser; Fng is the heat exchanger area on the side of the condensing unit
• The amount of heat provided to melt the ice on the surface of the heat exchange
tubes of the ice condenser: Qxb = Wb.rnc, kj/ batch
With: Wb (kg/batch) is the amount of ice adhering to the surface of the heat
exchanger tube beam. The total amount of moisture extracted from the drying material
in a batch of 1500 kg of raw material of royal jelly is Wa = 59.20%; moisture product
satisfactory is We = 4.19% and Wthm = 861.24 kg/batch. Ideally, the quantity of the ice
condensing moisture reaches 100%, but the experiment reveals that this figure achieves
a maximum of 98% at a deep negative temperature, while the ice condensing moisture
falls into the bottom of the device body is 2%; rnc (kJ/kg) is latent molten heat of ice, at
temperature 0°C, Pkq= 1 at = 0.98 bar then rnc = 79.8 kCal/kg = 334.04 kJ/kg.
97
 Notice: When the ice condensing pressure equals the air pressure at the time of
defrosting, the drying process has been completed.
The amount of ice:
Wb = 0.98 ×Wthm = 0.98 × 861.24 = 844.02 kg/ batch
Qxb= Wb. Rnc = 844.02 × 334.04 = 281936.44 kJ/ batch
Ftr = 23.27 m2
𝑑𝑛𝑔 0.028
Fng = Ftr. = 23.27× = 31.03 m2
𝑑𝑡𝑟 0.021

In this drying system, the method is using defrosting method by hot gas, the
temperature of R22 is defrosting as the average tv = t2 = 78.5°C, the output temperature
of R22 is averaged tr =tk + (6 ÷10) = 38 + 7 = 45°C, defrosting temperature remains within
(0÷1). Choosing the defrosting temperature txb = 10C
𝑡𝑣 −𝑡𝑟 78.5−45
∆𝑡𝑡𝑏 = 𝑡 −𝑡 = 78.5−1 = 59.180 C (3. 174)
ln 𝑣 𝑥𝑏 ln
45−1
𝑡𝑟 − 𝑡𝑥𝑏

K (W/(m2.K)) is the converted heat transfer coefficient to the ice surface outside
the ice condenser, this coefficient can be computed directly or set to vary within a certain
range. (160 ÷ 240) W/(m2.K).
The defrost time:
𝑄𝑥𝑏 281936.44× 103
𝜏𝑥𝑏 = = (160÷240)×31.03×59.18×3600 = ( 0.18÷0.27) h = (11÷17) minutes
𝐾.𝐹𝑛𝑔 .Δ𝑡𝑡𝑏

3.4.5. Durability test for the freeze-drying equipment and ice condenser
3.4.5.1. Stability for the drying process:
Because during the working process of the freeze-drying system, the working
pressure of the freeze-drying chamber and the condensing equipment — varies from the
atmospheric pressure value. Pck = 0.001 mmHg ≈ 0 kg/cm2.
Pressure:
Ptt = Plv + 2.Pmt (3. 175)
With: Plv (kg/cm2) is the working pressure of the equipment; Pmt (kg/cm2) is the
pressure of the environment; Ptt = 0 + 3.1 = 3 kg/cm2 = 0.2943 N/mm2. When the freeze-
drying chamber and ice condenser work, the temperature in the drying chamber (or
freezer) and the ice condenser change from - 40°C (freezing temperature) arrives
20.59°C (temperature of the drying process).
• For safety we choose the calculated temperature: Ttt = 50°C.
98
 • Because the freeze-drying chamber and the ice-condenser equipment work at a
pressure smaller than the ambient pressure outside the drying chamber, that is, the drying
chamber is subject to external pressure, we will use the formula of durability for pressure
— resistant equipment. In addition to durability for the drying chamber.
• Materials for manufacturing stainless steel freeze-drying chambers SUS316.
Stress allowable standard of stainless steel SUS316 [𝜎]*= 123 N/mm2.
• Choosing correction factor: 𝜂 = 0.95.
• Allowable stress of the material: [ 𝜎] = 𝜂 [𝜎]* = 0.95 x 123 = 117.42 N/mm2.
• The thickness of the freeze-drying chamber body:
𝐷𝑡𝑟 .𝑃𝑡𝑡 2970 ×0.2943
𝑆1, = = = 3.92 mm (3. 176)
2.[ 𝜎].φ 2×117.42 ×0.95

With Dtr (mm) is the diameter of the drying chamber itself; Because the freeze-
drying chamber is cylindrical in shape with diameter: Dtr= 2.97 m = 2970 mm
• Actual thickness of freeze-drying chamber:
S1= 𝑆1, + C, mm (3. 177)
With C (mm) is the additional factor:
C= Ca +Cb + Cc + C0, mm (3. 178)
With: Ca (mm) is the additional coefficient due to chemical corrosion of
environment; Cb is the additional coefficient due to mechanical abrasion of the
environment; Cc (mm) is the additional coefficient due to deviations when
manufacturing or assembling; Co (mm) is the additional factor to circle.
• We recommend that the freeze-drying chamber be used for 10 years and that the
environment's chemical corrosion rate be 0.1 mm/ year:
Ca = 0.1 ×10 = 1m
• Vacuum pump suction rate has an impact on the environment's mechanical
corrosion:
Cb = 0.5
• With just slight variations, we assume the manufacturing and assembly is almost
accurate:
Cc= 0.5
• Looking up data, we can determine the thickness available in the market of 316
stainless steel.

99
 Choosing C0 = 0.2m
C= Ca +Cb + Cc + C0 = 1 + 0.5 + 0.5+ 0.2 = 2.2 (mm)
The thickness of the freeze-drying chamber;
S1= 𝑆1, + C = 3.92 + 2.2 = 6.12 (mm)
Choosing the actual thickness of the freeze- drying chamber, S1 = 8mm > 6.12 mm
The thickness of the ice condenser’s body:
𝐷𝑡𝑟 .𝑃𝑡𝑡 800×0.2943
𝑆2, = = = 1.06 (3. 179)
2.[ 𝜎].φ 2×117.42×0.95

With: Dtr (mm) is the diameter of ice condenser body; due to the condenser —
freezing device having a cylindrical shape with a diameter: Dtr= 0.8 m = 800 mm.
• Actual thickness of ice condenser: S2 = 𝑆2, +C, mm
With: C = 2.2 (mm) is the additional factor.
S2 = 𝑆2, +C = 1.06 + 2.2 = 3.26 (mm) (3. 180)
Choosing the actual thickness of the ice condenser:
S2 = 5mm > 3.26 mm

3.4.5.2. Check the thickness of freeze-drying chamber and ice condenser:

Check the drying chamber thickness
𝑆1 − 𝐶𝑎 8−1
= = 2.36 × 10-3 < 0.1 (accepted) (3. 181)
𝐷𝑡𝑟 2970

Permissible internal pressure for cylinder body:

2.[ 𝜎]𝜑 (𝑆1 −𝐶𝑎 ) 2×117.42×0.95×( 8−1)
[ P] = = (3.182)
𝐷𝑡𝑟 +(𝑆1 −𝐶𝑎 ) 2970+( 8−1)

= 0.52 N/mm2 > 0.2943 N/mm2

In conclusion, the thickness of the 8mm freeze drying chamber is safe during
working
Check condensation- freezing equipment thickness
Permissible internal pressure for cylinder body:
2.[ 𝜎]𝜑 (𝑆2 −𝐶𝑎 ) 2×117.42×0.95×( 5−1)
[ P] = = (3. 183)
𝐷𝑡𝑟 +(𝑆2 −𝐶𝑎 ) 800+( 5−1)

= 1.11 N/mm2 > 0.2943 N/mm2

In conclusion, the thickness of the ice condenser is 5mm is safe during working.

100
3.5. Designing the freeze-dryer
Summary of design data:
Table 3. 2. Summary of design data of freeze dryer system
Symbols Value Unit
FREEZE-DRYING CHAMBER
L1 The cylindrical body length 3.5 m
L The length of the cylinder of the freeze drying chamber 3.9 m
hc The height of each globe cap 0.2 m
Rc The radius of the spherical cap 5.61 m
D1 Inside diameter of the freeze- drying chamber 2.97 m
D2 Outer diameter of the freeze-drying chamber 2.99 m
𝜹𝟏 Thickness of outside stainless-steel layer 8 mm
𝜹𝒑𝒐𝒍𝒚 Thickness of polyurethane layer 100 mm
𝜹𝟐 Thickness of outside stainless- steel layer 1.5 mm
Vt Volume of freeze-drying chamber 24.59 m3
Fv The area of the freezer wall 49.19 m2
TRAYS
ak Length of the tray 0.8 m
bk Width of the tray 0.5 m
hk Height of the tray 0.028 m
𝜹𝒌 Thickness of the tray 0.003 m
Vk Volume of each tray 0.0112 m3
Nsk The number of glass trays in a freeze –drying chamber 246 Trays
nt Number of trays in each heat transfer plate 16 Trays
HEAT TRANSFER PLATES
The number of heat transfer plates in the freeze-drying
Nttn 16 Plates
chamber
h The distance between two heat transfer plates 0.046 m
𝜹𝟏 Heat transfer plate thickness 0.015 m
a Width of heat transfer plate 2.1 m
L1 Length of heat transfer plate 3.5 m
The number of resistors needed to place in the heat transfer
Ncdt 204 resistors
plate
Ncdtmt The number of resistors arranged on each plate 13 resistors
EVAPORATOR
Heat load for an evaporator: Q0mn = Q = 99.06 kW
dtr Inner diameter of the heat exchanger tube in the evaporator 0.012 m
dng Outer diameter of the heat exchanger tube in the evaporator 0.014 m
101
 z The number of pipe groups working in parallel (z= Nttn) 16 groups
lo Length of each tube 2 m
N0 The number of tubes on each heat plate 31 tubes
a0 Distance between tubes on each heat plate 0.11 m
Ftr The area of heat exchange towards the refrigerant 32.27 m2
ICE CONDENSER
Cooling capacity (heat load) of the ice condenser: Qngtdb = 86.39 kW
𝜹𝒘 Thickness of equipment wall made of steel 0.005 m
𝜹𝒄𝒏 The equipment’s moisture- insulating wall thickness 0.08 m
Dtr Inner diameter of ice condenser 0.8 m
Outer diameter of ice condenser (not include an insulated
Dng 0.81 m
layer)
Dngtdb Outer diameter of ice condenser (include insulated layer) 0.97 m
L Length of the ice condenser 4 m
Vngtdb Volume of the ice condenser 2.01 m3
Fw.ng The outside heat exchange area of the ice condenser 13.66 m2
Ftr Heat transfer area of tube beam 23.27 m2
I0 The length of each tube 2 m
Total number of tubes:
With three channels:
n +Inlet channel: 60 tubes; 180 tubes
+Outlet channel: 60 tubes;
+Middle channel: 60 tubes.
COMPRESSOR
Refrigeration capacity of the compressor Q0 minmn = 99.06 kW
Choose compressor with:
1
Power of the electric motor of the first-stage compressor Ndc = 67.404 (kW)
2
Power of the electric motor of the second-stage compressor: Ndc = 58.54(kW)
The motor’s overall power ( Ndc) : 130 kW
Voltage: AC 3 phases/380 V
Frequency (f): 50-60Hz
PIPES
Dtr.h.1 Suction pipe diameter of the low pressure - compressor 134 mm
Dtr.d.1 The push pipe diameter of low pressure - compressor 120 mm
Dtr.h.2 Suction pipe diameter of the high pressure - compressor 105 mm
Dtr.d.2 The push pipe diameter of high pressure - compressor 94 mm
CONDENSER
Heat load for condenser: Qk = 177.22 (kW)

102
 dtr Inner diameter of steel pipe 0.021 m
dng Diameter of the wing bottom 0.028 m
D Diameter’s wing 0.049 m
𝜹d The thickness of the top of the wing 0.0006 m
𝜹o The wing's bottom thickness 0.0011 m
Sc Pitch of wing 0.0035 m
S1 Pitch of stand tube 0.052 m
S2 Pitch of vertical tube 0.045 m
S’2 Pitch of cross tube 0.052 m
𝐅𝐂 The wing area per 1 m of tube 0.752 m2/m
F0 The area between the wings per 1 m of tube 0.06 m2/m
Ftr. pipe The inner surface area of 1 m pipe 0.066 m2/m
Fng. pipe The outer surface area of a 1 m pipe 0.088 m2/m
lq The converted length 0.035 m
h' The converted height of the wing 0.0126 m
𝜹th Thickness of the outside steel tube 0.001 m
Lpipe The total pipe length of the condensation device 251.66 m
l1 The length of each pipe 2.5 m
n The total number of tubes of condensation equipment 101 tubes
nz The number of pipe layout on the main surface 26 tubes
The length of the tubing and coupling of the pipes
lco 0.13 m
connected together
l Length of condensate device 2.76 m
Ftr The inner surface area of the condensate device 14.43 m2
Fkh Total area for the air movement at the narrow cross section 1.36 m2
Receiver (Intermediate tank)
Heat released during the supercooling of refrigerant in receiver: Qtg = 30.53 kW
dng Outer diameter of the spiral tube 0.021 m
dtr Inner diameter of the spiral tube 0.019 m
Inner diameters of the two interlocking coils with the inner
D1 0.4 m
diameters of the vessel
Outer diameters of the the two interlocking coils with the
D2 0.5 m
inner diameters of the vessel
R Bendable radius of the spiral tube beam in the receiver 0.025 m
L Total length of the spiral tube 45.93 m
n Number of twists per spiral beam 17 twists
∆ The distance between two twists 35 mm
H The height of spiral beams 0.917 m
Hbtg Height of receiver 1.19 m
103
 Dbtg Diameter of receiver 0.56 m
The throttle valve
For intermediate cooling throttle: choose Danfoss throttle
Cross-section area: F1=71.66 m2
Capacity: (45÷ 65) kW/ valve number 0/ maximum boiling temperature t0 = (-45÷-50)oC.
For throttle valve calculation in the evaporator: choose Danfoss throttle
Cross-section area: F2=128.17 m2
Capacity: (100÷120) kW/ valve number 1/ maximum boiling temperature t0 = (-45÷-50)oC.
Vacuum pump
Choose vacuum pupm with:
Capacity Ndcbck = 205 kW
Three- phase AC voltage/ 380 V

104
CHAPTER 4

BUILDING TECHNICAL DRAWINGS

4.1. Principle diagram drawing

Figure 4.1. Principle diagram of a freeze-drying system

1- Second-stage compressor; 2- Condenser; 3- High-pressure tank; 4- Throttle valve; 5- A first-
stage compressor; 6- Receiver (intermediate cooler); 7- Ice condenser (petrification equipment); 8-
Vacuum pump; 9- Sublimation chamber; 10- Heat plates (containing materials); 11-Condensing water
Figure 4.1 is a simple drawing of a freeze-drying system based on the principle
diagram of the freeze-drying system (DS-7), but without auxiliary devices such as
separating oil; filter; gas glass; solenoid valve; separating liquid; etc. The actual diagram
of the freeze-drying system might be more complicated.
On this schematic, the refrigerant from the high-pressure container (3) supercools
as it travels through the receiver's coils (or intermediate tank’s coils) (6) before leaving
the tank and splitting into two branches. There are 2 valves for directing the flow.
Remind that the ice condenser and the freezing chamber do not operate simultaneously.
When there is the freezing stage, a valve of a branch which connects with the ice
condenser (7) closes, preventing refrigerant is supplied. Meanwhile, a valve of the line
for the sublimation chamber (9) opens and delivers the refrigerant needed to freeze the
product in the freezing chamber. At the end of the freezing stage, the valve for this line
close, while the valve for the other line opens. The ice condenser (7) and vacuum pump
(8) work for the freeze-drying stage.

105
4.2. Detailed drawings of the device

Figure 4.2. General drawings of components

The drawings shown below include only the main equipment drawings. Please see
appendix 3 for additional details of eqipment.
106
Figure 4.3. Freeze-drying chamber

107
Figure 4.4. Freeze-drying chamber body

108
Figure 4.5. Front freeze-drying chamber cap

109
Figure 4.6. Back freeze-drying chamber cap

110
Figure 4.7. Observation door

111
Figure 4.8. Heat transfer plate

112
Figure 4.9. Tray

113
Figure 4.10. Ice condenser equipment

114
Figure 4.11. Vacuum pump

115
Figure 4.12. Receiver (Intermediate tank)

116
Figure 4.13. Condenser

117
Figure 4.14. Compressor

118
4.3. System installation drawings

Figure 4.15. Freeze-drying system

119
CHAPTER 5

ECONOMIC CALCULATION FOR DRYING SYSTEM

5.1. Determine cost of raw material required for each batch of freeze-drying
Cost of raw material: C1 = S1×G1(VND/batch) (5. 1)
Where:
S1: royal jelly prices in the market = 1.750.000 VND/kg
G1: input productivity 1500kg/batch
Cost = 1500 x 1.750.000 = 2.625.000.000 VND
5.2. Energy cost
The energy qr (kWh/kg moisture) needed to separate 1 kg of moisture from the
freeze-drying product: qr = ( 2.76 ÷ 4.14) kWh/ kg moisture.
The amount of moisture need to separate Wth= 47.106 kg/h
 Amount of electricity consumed in an hour:
E2 = Q = ( 2.76 ÷ 4.14) × 47.106 = 130.01 ÷ 195.02 kW
Electricity costs: C2 = E2×S2 (VND /h) (5. 2)
Where:
S2: the price of electricity (VND/h) = 2.629 VND/kWh
We have:
C2 = E2 × S2 = (130.01 ÷ 195.02 ) × 2.629 = 341.796 ÷ 512.708 VND/h
5.3. Salary cost
Number of operating personnel: 2
− Machine operator.
− Product quality inspection staff.
Salary costs: C3 = Ltb×M (VND/batch) (5. 3)
Where:
Ltb: average salary = 100.000 VND/batch
M: operating personnel = 2
We have:
C3 = Ltb × M = 100.000 × 2 = 200.000 VND/h
5.4. Estimated cost of material made of main equipment
Industrial SUS 316 stainless steel price S5 = 80.000 VND/kg
120
 Density of SUS 316 stainless steel: ρ𝑆𝑈𝑆 316 = 7980 kg/m3
Cost for material made of freeze-drying chamber:
Mass of SUS 316 stainless steel for freeze-drying chamber - 8mm layer
m4 =ρ316 stainless steel ×Vfreeze-drying wall
Where Vfreeze-drying wall = Fdrying chamber wall×δdrying chamber wall
= 49.19 x (8 x 10-3) = 0.39352 m3
 m4 = 7980 x 0.39352 = 3140.2896 kg
C4 = S4× m4 = 80.000 × 3140.2896 = 251.223.168 VND
Cost for material made of ice condenser:
Mass of SUS 316 stainless steel used for ice condenser - 5mm layer:
m5 = ρ316 𝑠𝑡𝑎𝑖𝑛𝑙𝑒𝑠𝑠 𝑠𝑡𝑒𝑒𝑙 × 𝑉𝑖𝑐𝑒 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 𝑤𝑎𝑙𝑙
Where Vice condenser wall = Fice condenser wall×δ ice condenser wall

= 13.66 x (5 x 10-3) = 0.0683 m3

 m5 = 7980 x 0.0683 = 545.034 kg

C5 = S5 × m5 = 80.000 × 545.034 = 43.602.720 VND

Cost for material made of trays:
A glass tray price:
S6 = 75.000 VND/ tray
Total 246 trays price:
C6= S6 × m6 = 75.000 × 246 = 18.450.000 VND
Expected production cost of the drying chamber (including costs of materials,
processing and other details): 2.000.000.000 VND
Table 5. 1. Other equipment cost estimation
No Name of equipment Cost (VND)
1 Evaporator 120.000.000
2 Condenser equipment 85.000.000
3 Compressor 365.000.000
4 Intermediator device 60.000.000
5 Throttle 17.000.000

121
CONCLUSION
Royal jelly is a unique natural product with a high commercial worth that is full of
health benefits. Therefore, applying the freeze-drying method to preserve royal jelly is
necessary not only to help prolong the shelf-life, and remain the nutrient value and
bioactivity of the product, but also can preserve the product at the temperature of 25oC
and reduce the energy cost consumption.
With royal jelly from the province of Lam Dong, a freeze-drying system was
constructed in detail to adapt the of capacity 1500kg/batch. For an input yield of 1500kg,
the royal jelly material, having 59.2 % for initial moisture content, is freeze-dried to get
4.19% moisture content after drying and reaches an output yield is about 638.76
kg/batch.
The freeze-drying system of royal jelly product goes through two main stages:
freezing (τ1 = 1.63 h), and freeze-drying (𝜏2 = 18.283 h). The vacuum drying stage
(Secondary drying) is not included because the moisture of the royal jelly product has
reached 4.19% (<5%) after freeze-drying,
Freeze-drying systems include a freeze-drying chamber, ice condenser, vacuum
pump, and other auxiliary equipment: receiver, heat exchanger systems, and pipes are
calculated and chosen to meet the requirement of the system. The calculation for the
durability test for the freeze-drying equipment and ice condenser also takes place with
the expectation the freeze-drying system can work well for 10 years. The economic
calculation, factory and factory construction plan, were also estimated.
These computations, nevertheless, were only calculated on paper using a variety
of sources. As a result, there can be mistakes and inconsistencies while building and
producing the actual system. It is necessary to install and operate the system to find out
errors, correct, and improve the system when applying the system in production practice.

122
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APPENDIX

APPENDIX 1: GRAPH P – H OF R22

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APPENDIX 2: MOLLIER DIAGRAM

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APPENDIX 3: ADDITIONAL DETAILS OF EQUIPMENT

Freeze-drying chamber base:

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Ice condenser base:

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Tube (Connect between ice condenser and freeze-drying chamber):

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Tank:

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Frame for freezing-system:

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