Republic of the Philippines

North Eastern Mindanao State University

Bislig Campus
Maharlika, Bislig City, Surigao del Sur

TECHNICAL REPORT: A DESIGN AND OPTIMIZATION FOR A 100-TON

PER DAY ICE BLOCK PRODUCTION PLANT

A TECHNICAL PAPER REPORT

Presented to:
ENGR. ALBERTO E. LASTIMADO, JR., MSENE

Mechanical Engineering Program

College of Engineering
North Eastern Mindanao State University
Bislig Campus

In Partial Fulfillment
of the Requirement for the Subject Course
MECHANICAL ENGINEERING LABORATORY 3
(ME 413L)

Presented by:
GUZON, JEFONE JADE G.

SEPTEMBER 24, 2024

CHAPTER 1
1.1 BACKGROUND OF THE STUDY

The plan of an ice plant fit for creating 100 tons of ice blocks each
day, with each block weighing 150 kg, includes a complex methodology
that consolidates designing standards, thermodynamics, and modern
plan. Ice plants assume a critical part in different enterprises, including
fishing, food protection, development, and occasion the executives, by
giving a dependable stockpile of ice. The developing interest for ice,
particularly in tropical and subtropical locales, requires the improvement
of effective ice plants with high creation limits.

Capacity and Production Rate - The plant's capacity to produce 140

tons of ice per day is central to the design process. With each ice block
weighing 150 kg, this translates to producing approximately 666 ice
blocks per day. The production process must be optimized to achieve
this output within a 24-hour operational cycle.

Ice Production Method - The most common methods for ice block
production include the brine freezing method and the direct
freezing method. In Brine Freezing Method, this method involves using
a brine solution (usually saltwater) to lower the freezing point of water.
The brine circulates around the ice-making apparatus, cooling the water
below its freezing point, which then freezes into ice. On the other hand,
direct freezing method in this method, water is directly frozen by placing
it in a freezing environment, such as a refrigeration unit. The
temperature of the water is lowered until it freezes solid without the use
of a brine solution.

This study expects to investigate various parts of ice plant estimations, given
with the principles. These estimations are fundamental to guarantee that the
ice plant works proficiently, dependably, and inside its planned limit. Via
cautiously thinking about the plan perspectives and playing out the vital
estimations.
1.2 STATEMENT OF THE PROBLEM

The primary problem in designing an ice plant is to produce 160 tons of ice
blocks per day, with each block weighing 150 kg. The design challenge
involves determining the appropriate refrigeration capacity, energy
requirements, and infrastructure needed to achieve this production rate
efficiently and cost-effectively.

1. What is the total cooling load required to produce 160 tons of ice per
day?
2. What refrigeration capacity (in tons of refrigeration) is needed to meet
the daily ice production target?
3. How much power is required for the refrigeration system to operate
efficiently?
4. What is the total amount of water required daily for this production?
5. What are the optimal operating conditions (e.g., temperature, freezing
time) to ensure the production process is both effective and energy-
efficient?

1.3 OBJECTIVE OF THE PROJECT

Achieve the Desired Production Capacity

Design an ice plant equipped for creating 100 tons of ice blocks each
day, with each block weighing 150 kg. In order to meet this daily production
goal without interruptions, check that the plant operates continuously and
effectively.

1.4 SIGNIFICANCE OF THE STUDY

This study's significance stems from its potential to improve ice

production's efficiency and sustainability, which are crucial for fishing, food
preservation, and healthcare. By planning an ice plant fit for creating 100 tons
of ice blocks each day, the review expects to help nearby organizations,
diminish functional expenses, and further develop sanitation by guaranteeing
a dependable stock of excellent ice. Additionally, putting an emphasis on
environmental sustainability and energy efficiency can help reduce the plant's
carbon footprint, encourage environmentally friendly industrial practices, and
lay the groundwork for future research into ice production and refrigeration
technologies.

1.5 DESIGN DESCRIPTION

The ice plant is designed to produce 160 tons of ice blocks per day, with
each block weighing 150 kg. This translates to producing approximately 1,036
ice blocks daily. The plant's design encompasses several key components,
including refrigeration systems, ice-making equipment, water treatment
facilities, and storage units.
 CHAPTER 2

2.1 ICE CUBE SPECIFICATION

The design will use the international standard size of ice can, 11” (28cm) Long,
22” (122cm) High. The size of the ice block is approximately 330lbs (150kg)

The plant can produce 160 tons of ice per day.

Capacity/day = tons of ice / mass of ice block

= 160,000 kg / 150 kg/block

= 1,067 blocks per day

2.2 BRINE TEMPERATURE

The brine temperature may be computed by using the equation

2
(32-582 a )
T=
Wn

Where:

T = brine temperature, °F

a = thickness of ice block, inches

n = no. of ice can / ton of ice/day
W = mass of ice block, (lbs.); use 330lbs

For the value of n

n = no. of ice can / ton of ice produced
# Of ice can = 1,300 to avoid shortage
n = 1,200 / 160 tons
n = 8 ice block / ton of ice
For the Value of T
T = [ 32 – 582.3 (11)2] / (330) (8)
= 25.2 °F or -3.8°C

2.3 FREEZING TEMPERATURE

From the book Refrigration Engineering by Macintire and Hutchinson, p. 571
freezing time can be evaluated using the equation and from the book
Refrigeration by Chris Langley constant varying varies from 5.5 to 7:

t=
t = Freezing temperature
C = Constant varying from
5.5 – 7 T = Brine
temperature

X = Thickness of
ice t =
t = 31.75 hrs.

2.4 WATER SOURCE FOR THE ICE PLANT

According to seatemperature.org, Surface Water (Lakes, and Rivers):

Assumption: Ice plants located near large bodies of water may draw from
these sources. Abundant supply, especially in areas with large water bodies.

Surface Water (Lakes and Rivers)

 Temperature Range: 0°C to 30°C (32°F to 86°F)

2.5 COOLING LOAD CALCULATIONS:

Raw Water Temperature (Lake) = 80.6°F(27°C)

Freezing Temperature = 32°F (0°C)
Brine Temperature = 25.2°F (-3.8 °C)
Ice Temperature = 25.58°F (-3.5667 °C)
Total heat load can be completed
using

QT= Q1 + Q2 + Q3

Where:

Q1 = sensible heat required to lower temperature of water from its raw

temperature to its freezing temperature.
*The value 4.187 kJ/kg is the specific heat capacity of water. It represents the
amount of heat energy required to raise the temperature of 1 kilogram of
water by 1 degree Celsius (or 1 Kelvin).

Q1= (mass) (specific heat of water) (temperature difference)

Q1= (160,000 kg/day) (4.187 KJ/kg-°k) (27-0) (1/24) (1/3600)
Q1= 209.35 KW

Q2 = changing the latent heat of water at its freezing temperature from liquid
to solid
Q2= (mass) (latent heat of water)
Q2= (160,000 kg/day) (355 KJ/kg) (1/24) (1/3600)
Q2= 657.41 KW

Q3 = raising the temperature of water from its freezing temperature to the

brine temperature
*The value 2.093 kJ/kg is the specific heat capacity of ice. It represents the
amount of heat energy required to raise the temperature of 1 kilogram of ice
by 1 degree Celsius (or 1 Kelvin).

Q3= (mass) (specific heat of water) (temperature difference)

Q3= (160,000 kg/day) (2.093 KJ/kg-°k) (0-3.8) (1/24) (1/3600)
Q3= 14.73 KW
QT = (209.35 KW + 657.41 KW + 14.73 KW) = 881.49 KW

For typical ice plant there is 15% allowance,

therefore
Qt = Qt + Qt (.15) = 881.49+ 881.49 (.15)
Qt= 1,013.71 KW

2.6 NUMBER OF TUBE REQUIRED:

Use a tube made of B.I. Pipe, 1” D. the area of one length of the B.I.
Pipe 1”D is 6.89 ft2. In determining the surface area of the condenser, using
the equation from the book Principles of Refrigeration by R. J. Dossat, 2nd
Editon page 316.

2.7 ENTHALPIES
The enthalpies can be calculated by knowing these two temperatures
from the compressor model SCV 250VSD/G (MYCOM), the Evaporating
temperature (-10°C) and the condensing temperature (35°C). The refrigerant
is ammonia; we can refer to the table A-3 page 420 RAC by Stoecker & Jones.
h1= 1450.22 kJ/kg

h3 = hf @ 35 °C = 366.072 kJ/kg

s1 = s2 = Sg @ -10°C = 5.7550 kJ/kg K

h2 = h1 = 1352.2 kpa

h4 = h 3
h2= 1769.8 kJ/kg – Interpolated (Superheated Ammonia)

Interpolation Process for h2:

Given:
s2 = 5.7550 kj/kg K
P = 1352.2 Kpa (Since pressure is high its in superheated ammonia tables)
(Borgnakke)

@1200 Kpa

5.7550-5.6632 x-1708.0
=
5.7860-5.6631 1757.5-1708.0

h @ 1200 Kpa = 1753. 1 kj/kg

@1400 Kpa

5.7550-5.7023 x-1752.8
=
5.8208-5.7023 1802.0-1752.8

h @ 1400 Kpa = 1775.1

Final interpolation for the pressure 1352.2 Kpa

1352.2-1200 h2 -1753.1
=
1400-1200 1775.1-1753.1

h2 = 1769.84 kJ/kg

CONDENSER
Qr = mr (h2 -h3)

where:

Qr = heat rejected
Qa = mr (h1 – h2)
mr = Qa / (h1-h3)
= 1,013.71 / (1450.22 kJ/kg - 366.072 kJ/kg)

= 0.9516 kg/s

Qr = 0.9516 kg/s

Qr = 0.9516 kg/s (1769.8 -366.072)

= 1335.79 KW

2.8 MASS OF COOLING WATER

Assuming:
Water outlet temperature = 30 - 32°C
Water inlet temperature = 26 - 27°C

mw = Qr / cp (T)
mw = 1335.79 / 4.187 kJ/kg – K) (31 – 27) °C
mw = 79.76 kg/s
2.9 FLOW RATE
f = Mw / P w
f = 79.76 kg/s / 1000 kg/m3
f = 0.07976 m3/s

The value 1000 kg typically represents the density of water at standard

conditions (4°C). This means that 1 cubic meter of water has a mass of 1000
kilograms.
Q=AxUxD
where:
Q = condenser capacity, Btu / hr; use 837,130.401 Btu/hr
* The 837,130.401 Btu/hr could be a refined value accounting for the real-
world operation of the condenser and specific conditions (such as ambient
temperature, condenser efficiency, etc.) required to produce the tons of ice
per day in 150 kg blocks.
A = surface area of the condenser, ft2
D = temperature difference between the condensing refrigerant and the
condensing medium, °F; use 10 °F
U = overall heat transfer coefficient in Btu/hr-ft2-°F from the book Design
Values of U for Metallic Surfaces of Refrigeration Engineering by Macintire &
Hutchinson, page 263, the overall conductance factor for shell-and-tube
condenser is 150 to 300 Btu/hr-ft2-°F. Use 250 Btu/hr-ft2-°F

A=Q/UxD
= 837,130.401 Btu/hr-ft2-°F/ 250 (10°F)
= 334.85 ft2

A = 334.85 + 15% allowance

A = 334.85 + 334.85 (.15)
A = 385.078 ft2

no. of tubes = A / surface area of the tube used

m = Qr / (h1 – h3)
m = 1335.79 KW / 1450.22 kJ/kg – 366.072 kJ/kg
m = 1.2321 kg/s
Volume flow rate, f
F = m/ρ of ammonia = 681.92 kg/m3

f = (1.2321 kg/s) / (681.92 kg/m3)

f = 1.8068 x 10-3 m3/s

2.10 PIPE SIZE

Pipe Flow Equation (Q = AV):

 Q is the volumetric flow rate in m³/s.

2
π D (2)
 A is the cross-sectional area of the pipe ( , where D is the diameter
4
of the pipe).
 V is the velocity of the fluid (given as 2 m/s from the Industrial
Refrigeration Handbook).


Given:

 Flow rate = 1.8068 x 10-3 m3/s

 Velocity V=2 m/s

2
π D (2)
D = 1.8068 x 10-3 =
4

D = 0.0339 m

If the calculated diameter is 0.0339 m (33.9 mm), we can convert this to

inches to compare it with standard pipe sizes:

¿
D = 0.0339 m ×39.97 ∈ 1 m =1.355∈¿ ¿

Using the CFR pipe tool, we look for the closest nominal pipe size. The
standard nominal pipe sizes are based on the inside diameter (ID), while the
outside diameter (OD) will vary with the pipe schedule (wall thickness).

For 1.256 inches, the closest nominal pipe size would likely be:
  1-inch nominal pipe, which has an actual outside diameter of 1.315
inches.

Thus, the nominal pipe size from the CFR tool would still be 1 inch, based
the calculated diameter.

Pipe Surface Area per Length

1.315 ×1 ft
Diameter = 1.315 =
12∈¿=0.1096 ¿

Circumference = π x 0.1096 = 0.3443

Multiply by the length of the pipe (assumed 20 ft here):

Surface Area per Length = 0.3443 x 20 = 6.89 ft2 per length of B.I Pipe
= 385.078 ft2 / 6.89 ft2 / length
= 55.89 length of B.I. pipe
= 56 length of B.I. Pipe 1” D

2.11 COMPRESSOR
The compressor used in this design is a Screw compressor, single stage,
open type and the refrigerant used is ammonia. The selection of the
compressor is based on the heat load. Qt= 1,013.71 KW

Based on the specifications of the model SCV-

SERIES 250VSD/G(MYCOM) is appropriate in this
design with a capacity of 1073.7 kW and
operates at a maximum speed of 2950 RPM.
Other data from the manufacturer’s catalogue
are listed below.

Capacity: 1073.7 kW
Theoretical Displacement: 1580
Gas Inlet Port: MYCOM 250A
Gas Outlet Port: MYCOM 150CD
Weight: 1180 Kg
Speed: 2950 RPM
2.12 FOR TYPE OF BELT

Power transmitted = 384.24HP (286.53kW)

Speed of Motor = 1075 rpm
Design Power = power transmitted x normal
torque

Normal torque = 1.2 from table 7.1 machine

elements in mechanical engineering by Robert
L. Mott

Design Power = (167.6) (1.5) = 251.4 HP

Time of Operation: 16 hours

Total Number of Blocks 666

Blocks per hour: = = 41 Blocks/Hour
16 16
Belt Chosen Suitability for the Desired Ice Plant Capacity:
Manufacturers Catalogue: FENNER CRE PLUS

Considering your plant produces 160 tons of ice per day, each block
weighing 150 kg, it needs a V-belt that can handle heavy loads and
continuous operation. Let's check the relevant parameters:

1. Power Transmission - The Fenner CRE PLUS is capable of transmitting

enough power that can handle heavy loads and will effeciently and effectively
operates motors.

2. Cold Resistance - Since the ice plant operates at low temperature, it must
have an equipment capable of operating under this condition in which the
Fenner CRE PLUS belt is capable of.

3. Durability - One factor of choosing equipment in a plant is its durability, all

equipment must be capable of working for a long period of time and will
suffice the needed operation the plant requires which suites this type of belt
because its durable.
FOR SHEAVE PULLEY
Since the ice capacity and operation is high load, we will choose a sheave
suited, which is reinforced aluminum sheave
According to apprep.com, belts-and-sheaves:

Reinforced Aluminum Sheaves:

 Typical Speed Range: Up to 9,842 to 16,404 ft/min (30 to 50 m/s)

In this design use belt = 10,000 ft/min

Vd = belt speed
Dd = Driver sheave
Dd = 12 x Vd / π x n
Dd = 12 (10,000) / π (2950)
Dd = 12.95

For length of V belt

From table 7-8 Machine Elements in Mechanical Design by Robert L. Mott the
center distance is ranging

D2 < CD < 3 (D2 + D1)

D2 < CD < 3 (15.9 + 10.2)
15.9 < C > 78.3
For the interest of conserving speed use C = 30
From the book Machine Elements in Mechanical Design by Robert L. Mott,
equation 7-3

( D2 - D1 )
L=2CD+1.57 ( D 2 + D1 ) +
4C

( 15.9- 10.2 )
L=2(30)+1.57 (15.9+10.2 ) +
4(30)
L = 101.02 in

From table 7-2 Machine Elements in Mechanical Design by Robert L. Mott

select standard belt = 100 inches
For actual center distance
The center distance assumed earlier is just for the purpose of solving L, now
that we have L, we can calculate the actual center distance by the equation 7-
4 and 7-5 from the book Machine Elements in Mechanical Design by Robert L.
Mott

B = 4L – 6.28 (D2 + D1)

B = 4(100) – 6.28 (15.9 + 10.2)
B = 236.09

CD =
B+ √ B -32 ( D - D
2
2 1 )2
16

CD =
236.09+ √ (236.09)2 -32 ( 15.9- 10.2 )2
16
CD = 29.37 in

Angle of wrap of the belt on the small sheave from equation 7-14 from the book Machine Elements
in Mechanical Design by Robert L. Mott

-1 D2 - D1
θ1 =180°-2 sin ( ¿
2 CD

-1 15.9- 10.2
θ1 =180°-2 sin ( ¿
2(29.37)
= 168◦

Determine the correction factors from Figure 7-14 and

Figure 7-15 Elements in Mechanical Design by Robert L.
Mott
For Ө1 = 168°
CӨ = 0.96;

For L = 140 in;

CL = 0.97
Corrected Power = CӨ x L x CL
= (0.96) (40) (0.97)
= 37.25 hp
Number of Belts = 301.73 / 37.25
= 8.1 (use 8 belts)

Ratio: to get the ratio we use the actual power from table 7-3 actual output
speed

= 1075 rpm / 744 rpm = 1.44

For actual rated power: to solve for corrected power we need to calculate
rated power

Refer to tables below

= 38 + 2.0 = 40 Hp
LIQUID RECIEVER
The size of the liquid receiver is such that it
can store the total volume of the refrigerant when pumping down the
system. From the compressor capacity

Compressor Capacity = m (h2 – h3)

Compressor capacity = 915.55 kW
h2 = 1769.8 kJ/kg
h3 = 366.072 kJ/kg
m = mass flow rate

m = 915.55 / (1769.8 – 366.072) kJ/kg

m = 0.6522 kg/s

total required mass of ammonia refrigerant system is

= 0.6522 kg/s (15 min) (60sec/min)
= 586.98 kg
= 1294.07 lb

V = m / ρ brine
ρ brine = 39.96 lbs/ ft3 from table RAC by Stoecker & Jones
V = 1294.07 lb / 39.96 lbs/ft3
= 32.38 ft3

ACCUMULATOR
Normally accumulator is should be less than 30% to 40% of the total
evaporator capacity. (Use 35% allowance).
For a large industrial ice plant producing around 140 tons/day of ice:

Heat Duty: Assume approximately 335 kJ/kg for the latent heat of
freezing water, with 140 tons (127,000 kg) of ice per day, which would
mean:

Q=127,000kg/day × 335kJ/kg ≈ 42,545,000kJ/day = 492kW

Using a typical heat transfer coefficient U=1000 W/m2⋅K and assuming a
temperature difference (ΔT) of around 10–15°C flowing inside tubes.
 Q 492,000 W 2
A= = =32.8 m
U × ∆T 1000 ×15

Coil Length Calculation - With a typical pipe outer diameter of 50 mm

(0.05 m), the surface area per meter is π×0.0334=0.105 m2. The total
length of the coil would then be:

2
32.8 m
L= 2
≈312 m
0.105 m /m
*In this case, the total coil length required could be approximately 300
meters, but this length can be divided into multiple coils or sections

Number of Sections
The length of tube depends on the size of area, compact or large area
For this design I will be using 8 meters long straight tubes
312 m
Number of Sections= =39 sections
8m

D = 5 in = 0.42 ft
R = 0.21 ft
V = Volume of
evaporator coil
R = Radius
L = Length of the
coil

V = πR2 x L
V = π (0.21)2 (8) (39)
= 43.23 ft3 x (.35)
= 15.13 ft3

BRINE AGITATOR
The brine agitator is installed in the end portion of the brine tank because
it is more convenient when removal is required for repair. The brine
agitator should have the capacity of 60 to 70 gallons/ton/min. (use
65gallons/ton/min).
*60-70 gallons/ton/min, this is the standard scaling factor used for
agitation in brine tanks for ice plants.

Qb = 70 (100 tons)
= 7000 gallons/min (1/60)
= 116.7 gal/s or 0.44 m3/s

P=γQHg

γ = 11.27 kN/m³ (brine density, NaCl solution)

A 15% NaCl brine solution has a freezing point of approximately -10°C

(14°F).

1,150 kg/m³ = 11.27 kN/m³

Q = 0.62 m3/s
H = 1 meter (head)
g = 9.81 m/s² (gravitational acceleration)

P = (11.27) (9.81) (.44) (1)

= 48.65 kW or 66.15 hp
FREEZING TANK
Freezing tank or brine tank is provided with a race way,
which the evaporator coil is installed. In this design the coil race way has
a width of 40 inches.

Base = base of ice x 40 blocks/row + 39.37 + .5-inch gap between blocks

x 40 blocks

= 11 in x 40 + 40 + 0.5 x 20

= 500 inches or 13 meters

Length = length of ice x 20 blocks + 1 inch gap x 20 gaps

= 22 in x 40 + 1 x 40

= 920 inches or 23 meters

PUSH TROLLEY AND ELECTRIC HOIST

Ice blocks are too heavy for human labor to remove it from brine tank so
an electric hoist is needed.
Weight of ice block = 150 kg
Number of ices can per row = 40
Total weight per row = 150 (40)
= 6000 kg
Add 15% for the additional load
= 6000 kg x 1.15
= 6900 kg
Therefore,
Use a 7.6-ton hoist
COOLING TOWER
The selection of cooling tower is based on the computed quantity of the
condensing medium, which is water.

Quantity of condensing medium = flow rate of water in condenser

= 0.071 m3/s
= 255.6 m3/hr

From CTS MODEL T-2400 table of specification:

Nominal flow = 1,190 GPM = 270.3 m3 / hr
Motor = 11 kW (15 hp)
Water inlet diameter = 204 mm
Water outlet diameter = 204 mm
Net weight = 6,883 kg
REFERENCES:
Refrigeration Engineering by Macintire and Hutchinson
Refrigeration by Chris Langley
Principles of Refrigeration by R.J. Dossat 2 nd Edition
Refrigeration and Air-Conditioning by W.F. Stoecker, J.W. Jones
Fundamental of Thermodynamics by Borgnakke C., Sonntag R.E
Industrial Refrigeration Handbook by W.F. Stoecker
Machine Elements in Mechanical Engineering by Robert L. Mott
https://gotocfr.com/CFR-Shell-and-Tube-Heat-Exchangers
https://www.mayekawa.com/mycom/screw_compressors
https://www.apprep.com/belts-and-sheaves-v.htm
https://www.coolingtowersystems.com/pages/tower-specifications?
srsltid=AfmBOooJhNm9hKDOPenJ2Pm5JcV4V0JM0NNVZBnX6WbtmWTdUA
edJKTa