Professional Documents
Culture Documents
INTRODUCTION
1. Meat and Poultry Storage
2. Fish Storage
3. Milk Products such as Ice Cream
4. Drinks or beverages
5. Ice Water or water stored in a piece of plastic which is
sold at sari-sari stores in the philippines
CLASSIFICATION
Block ice
Tapered rectangular metal cans filled with water are immersed in a tank
containing refrigerated sodium chloride brine. The dimensions of the
can and the temperature of the brine are usually selected to give a 24
hour production time, and batches of cans are emptied and refilled in
sequence during that period. Ice block weight can range from 12 to 150
kg depending on requirements; 150 kg is regarded as the largest size of
block one man can conveniently handle. A block ice plant requires
continuous attention and is labour intensive. The icemaker and the store
require a good deal of floor space and impose heavy loads on the
building structure. For these reasons block ice plants are going out of
use, and more modern automatic plants are replacing them.
TYPES OF ICEMAKER
Rapid block ice
It is possible to reduce the freezing time for blocks considerably, and thus
reduce the space required for the icemaker. This is done by reducing the
thickness of ice to be frozen; in one type of rapid icemaker this is achieved
by passing refrigerant through tubes around which the ice forms and fuses
into a block. The blocks can be released by defrosting and harvested
automatically, thus markedly reducing the labour requirement, but the
storage space required is slightly larger than for the same weight of
conventional block ice because the blocks have hollow centres after the
tubes are removed.
TYPES OF ICEMAKER
Flake ice
A sheet of ice 2-3 mm thick is formed by spraying
water on the surface of a refrigerated drum, and
scraping it off to form dry subcooled flakes, usually
100-1000 mm2 in area. In some models the drum
rotates against a stationary scraper on its outer
surface; in others the scraper rotates and removes ice
from the inner wall of a double walled stationary
drum. In some models the drum is horizontal, but
more usually it is mounted vertically. No water is
sprayed on that part of the drum immediately before
the scraper, so that the ice becomes dry and
subcooled prior to removal.
Refrigerant temperature, drum or scraper speed, and
degree of subcooling are all variable within designed
limits so that the capacity of the icemaker and the
thickness of the ice can be altered. Typical refrigerant
temperature in a flake ice machine is - 20 to - 25C,
lower than in most other types of icemaker, to give
rapid cooling and thus make the machine compact.
The low operating temperature requires more power,
but this is to some extent compensated for by the
absence of a need to defrost.
TYPES OF ICEMAKER
Tube ice
Water is frozen on the inner
surface of vertical refrigerated
tubes to form hollow cylinders
of ice about 50 mm in diameter
and with walls 10-12 mm thick.
The ice cylinders are released
by defrosting the tubes
automatically, and are chopped
into pieces about 50 mm long
by a rotating cutter as they slide
out. The cylindrical pieces can
be subcooled by storing them at
- 5C, but they may require
further crushing before being
suitable for some applications in
the fish industry.
TYPES OF ICEMAKER
Plate ice
Water is frozen on one face of a vertical refrigerated plate, and the sheet of ice is
released by running warm water on the other face of the plate. The size of ice
particle is variable, but the optimum thickness is 10-12 mm. The plates are usually
mounted in banks, often above the refrigeration machinery, to form a self contained
unit. Water for defrosting has to be heated if its temperature is below 23C. Like
most other icemakers the plate ice machine will operate unattended on an automatic
timing cycle.
Other icemakers
Machines are available that make ice by methods other than those described here,
but the size of unit is usually small, producing at the most only a few hundred
kilograms of ice a day; these are suitable for retail and catering services, but are
unlikely to be of interest to those providing icemaking services to the catching and
processing sectors of the fish industry.
TYPES OF ICEMAKER
Manufacturers usually quote a wide range of daily output for
specific icemaker units, because their capacity can be affected by
a number of factors, but this flexibility usually exists only at the
planning stage; once the icemaker has been matched to suitable
refrigeration machinery under given operating conditions, there is
little scope for changing the capacity of the installed unit.
Changes in demand are best catered for by reducing running time
or by installing multiple units and operating only as many as arc
needed.
Since the capacity of both the icemaker and the refrigeration
machinery is lower in warmer weather, the size of the plant
should be selected for warm weather operation, when demand for
ice is also likely to be greatest.
CAPACITIES OF ICEPLANTS
COMPONENTS AND
PROCESS
Compressor
A refrigerating compressor, as the name indicates, is a
machine used to compress the vapour refrigerant from the
evaporator and to raise its pressure so that the
corresponding saturation is higher than that of the cooling
medium. It also continually circulates the refrigerant
through the refrigerating system. Since the compression of
refrigerant requires some work to be done on it, therefore a
compressor must be driven by some prime mover.
block 190 50
rapid block 30 35
tube 33 66
flake 27 37
THE REFRIGERATION
SYSTEM
Storage of ice
Manufacture of ice can seldom be matched to meet immediate demand; therefore storage is necessary to cater for peak demand and to allow
the icemaker to be operated continuously. Storage also acts as a buffer against interruption of production due to breakdown or routine
maintenance.
The size of store required will depend on the pattern of operation, but it is never advisable to store less than 2 days' production, and in most
installations it is useful to be able to store 4-5 times the daily production.
Stowage rates vary with the kind of ice being made, and Table 3 gives the storage space required for the principal types.
The type of ice storage may range from a simple insulated bin to a large refrigerated silo or bin with automatic loading, unloading and weighing
of ice
flake 22-23
plate 17-18
tube 16-20
STORAGE OF ICE
Silo Storage
Silos are generally used only for freeflowing
subcooled ice, such as flake ice, and an
independent refrigeration system for the silo is
essential to keep the ice sub-cooled in storage.
It is usual to provide an air cooler to refrigerate
the jacket space between the inner lining of the
silo and the outer insulated structure; typically
the air cooler is located next to the icemaker on
top of the silo, and cold air either falls by gravity
into the jacket or is circulated by fan.
Ice is removed from the bottom of the silo,
gravity flow being assisted by an agitator, usually
a rotating chain; this means the oldest ice is
always used first. Ice adhering to the silo wall
needs to be freed periodically; otherwise this
wall of ice becomes permanent, and only the
central core of ice in the silo remains
freeflowing.
Silo storage is expensive for small amounts of
ice; units have been made to hold as little as 10
tonnes, but silos are best suited for storing 40-
100 t.
STORAGE OF ICE
Bin storage
Bins can be used to store any kind of fragmented ice, and may be of any size from a simple box
to hold 1/2 tonne to an installation holding 1000 t or more. Refrigeration of the bin is not always
essential but, whatever the size, adequate insulation is necessary to reduce meltage; 100-150
mm of cork, or an equivalent thickness in many other suitable insulating materials, should be
used.
A simple bin system is suitable for factories making ice for their own use. The icemaker can be
mounted above the bin, so that ice flows by gravity to a take off point at the bottom of the bin;
thus the oldest ice is used first. Where ice has to be distributed to customers, bins with a
capacity of up to 50 tonnes can be made with a sloping floor and so mounted that rapid
discharge direct to lorry or conveyor is possible. Some means of access to the bin is advisable in
order to be able to dislodge any compacted ice.
STORAGE OF ICE
Icemakers located directly above the store feed the ice by gravity.
Where an ice-maker produces wet ice, it is advisable to drain off excess
water before storing it; this is normally done on a conveyor between
icemaker and store. Large bins require some means of distributing ice
evenly throughout the storage space; silos and small bins do not require
such an arrangement.
Pneumatic systems have been used for moving ice, but the method is
unsuitable for ice that is to be stored again. The energy used in moving
the ice is dissipated as heat which can cause some meltage, and more
heat is transferred to the ice from the blown air, unless the air is
precooled. Ice can be weighed automatically on a conveyor belt to
within 2 per cent. Elsewhere ice is usually measured by volume, the
contents of a standard container having been weighed to determine the
density. Weight of crushed block ice supplied is checked by counting
the number of blocks delivered to the crusher.
PERFORMANCE TEST OF A
MINI ICE PLANT
Refrigeration is the process of removing heat from where it is not wanted.
Heat is removed from food to preserve its quantity and flavour. It is
removed from room air to establish human comfort. Therefore, as heat is
removed, a space or material becomes colder. The more heat is removed,
the colder it becomes.
The Ice Plant Test Rig designed by us works on simple vapour
compression refrigeration cycle and uses R134a or R 404 A as a refrigerant.
The system is designed such that students can observe and study ice
formation process without any confusion. It is also useful to understand
working of vapour compression system, due to its sophisticated yet simple
performance and controls. The first procedure of ice making is Pull down
test. This process would enable to lessen the time of actual ice formation.
The pull down test is done with the cooling of the secondary refrigerant in
the tank, brine, lowering its temperature to at least -4 to -5 degrees Celsius.
There are still different factors considered in the Pull down test and this
procedure has its independent cooling load calculation.
PROCEDURES
Mini Ice Plant and its accessories
- A working scale model for the study on analysis and fabrication of an Ice
Plant.
Beaker
- A simple container for stirring, mixing and heating liquids commonly used in
many laboratories. Beakers are generally cylindrical in shape, with a flat bottom. Most
also have a small spout (or "beak") to aid pouring as shown in the picture. Beakers are
available in a wide range of sizes, from one millilitre up to several litres.
Digital Thermometer
- is a device that measures temperature or temperature gradient using a variety
of different principles. A thermometer has two important elements: the temperature sensor
in which some physical change occurs with temperature, plus some means of converting
this physical change into a numerical value.
KW-Hour meter
- is the electric meter that measures the amount of electrical energy in kWh
that was consumed in the house. The kWh meter has a counter display that counts units of
kilowatt-hour (kWh). The energy consumption is calculated by calculating the difference
of the counter's reading in the specified period.
Low - side pressure gauge
- A gauge which measures the pressure in the cooling side of the ice plant.
High - side pressure gauge
- The gauge which measure the compressing side of the ice plant.
APPARATUS
Lap Suction Discharge Refrigerant Temperature (C)
Pressure (psi) pressure (psi) After compression After Condensation After Expansion After Evaporation
Time KWHR
(min)
0:00 20 140 73 43 11 16 6.8
0:00 30 160 76 41 11 26 6.8
15:00 40 168 80 41 11 26 6.8
17:00 45 173 82 43 13 18 6.8
20:00 45 173 83 42 12 17 6.9
22:00 45 173 85 42 13 15 6.9
24:00 45 173 85 42 12 13 6.9
25:00 45 173 85 42 12 12 6.9
27:00 45 173 84 41 12 11 6.9
29:00 45 173 84 41 11 10 6.9
30:00 43 160 84 41 11 9 6.9
31:00 48 160 84 41 11 8 6.9
32:00 48 160 84 42 11 5 6.9
33:00 48 160 84 41 10 4 6.9
34:00 43 160 84 41 10 4 7
35:00 40 160 84 41 10 3 7
38:00 39 160 81 41 8 4 7
40:00 39 155 81 40 7 3 7
43:00 36 152 79 40 7 3 7
47:00 32 150 78 39 5 -1 7.1
50:00 31 147 77 38 4 -2 7.1
53:00 30 140 76 38 3 -3 7.1
PRELIMINARY DATA
57:00 29 138 75 37 2 -4 7.1
Time Suction Pressure (Psi) Discharge Pressure (Psi)
0 20 140
0 30 160
15 40 168
17 45 173
20 45 173
22 45 173
24 45 173
25 45 173
27 45 173
29 45 173
30 43 160
31 48 160
32 48 160
33 48 160
34 43 160
35 40 160
38 39 160
40 39 155
43 36 152
47 32 150
50 31 147
53 30 140
57 29 138
180
160
140
120
60
40
20
0
0 0 15 17 20 22 24 25 27 29 30 31 32 33 34 35 38 40 43 47 50 53 57
This graph shows the relationship of the time to the suction pressure
and the discharge pressure. This shows that the times go further, the
suction pressure and the discharge pressure becomes lower.
After compression After Condensation
73 43
76 41
80 41
82 43
83 42
85 42
85 42
85 42
84 41
84 41
84 41
84 41
84 42
84 41
84 41
84 41
81 41
81 40
79 40
78 39
77 38
76 38
75 37
Temperature after compression Vs. Temperature after Condensation
44
43
42
41
40
39
38
37
36
35
34
73 76 80 82 83 85 85 85 84 84 84 84 84 84 84 84 81 81 79 78 77 76 75
11 16
11 26
11 26
13 18
12 17
13 15
12 13
12 12
12 11
11 10
11 9
11 8
11 5
10 4
10 4
10 3
8 4
7 3
7 3
5 -1
4 -2
3 -3
25
20
15
10
0
11 11 11 13 12 13 12 12 12 11 11 11 11 10 10 10 8 7 7 5 4 3 2
-5
-10
The graph shows the relationship of the temperature after expansion to the
temperature after evaporation. This shows that when the times go further the
temperature after compressor and after condenser decreases.
Brine is a solution of salt usually sodium chloride in water.
In different contexts, brine may refer to salt solutions
ranging from about 3.5%. A typical concentration of
seawater, or the lower end of solutions used
for brining foods up to about 26%. A
typical saturated solution is depending on temperature.
BRINE
POLYURETHANE FILM COEFFICIENT
Thickness (Side) 0.0986 m Inside air film 22.7 W/mK
Thickness (Bottom) 0.0508 m Outside air film 8.29 W/mK
Thermal Conductivity 8.29 W/mK Brine film 600 W/mk
BRINE
Length (cm) Width (cm) Depth(cm)
outside 55.3 42.6 36.2
inside 35.4 21.2 31.1
Level 24 cm
STAINLESS STEEL
GALVANIZED STEEL
Thickness 0.2 mm
Thickness 0.2 mm
Thermal 16 W/mK
Thermal 18 W/mK
Conductivity
Conductivity
MATERIAL PROPERTIES
Considering the steady-state cyclic operation of the system shown in
Figures 1 and 2, refrigerant vapour enters the compressor at state 4 and
saturated liquid exits the condenser at state 1.The refrigerant then flows
through the expansion valve to the evaporator. Referring to Figure 1,
using the first law of thermodynamics and the fact that change in
internal energy is zero for a cyclic process, we get
Qcond + Qloss, cond (Qevap + Qloss, evap) (W Qloss, W) = 0
(1)
where Qcond is the rate of heat rejection in condenser (kW), Qloss,
cond is the rate of heat leak from the hot refrigerant (kW), Qevap is the
rate of heat absorbed by the evaporator (kW), Qloss, evap is the rate of
heat leak from the ambient to the cold refrigerant (kW), W is the rate of
electrical power input to compressor (kW) and Qloss, W is the rate of
heat leak from the compressor shell to ambient (kW). Heat transfer to
and from the cycle occurs by convection to flowing fluid streams with
finite mass flow rates and specific heats. Therefore, the heat-transfer
rate to the cycle in the evaporator becomes
Qevap = (C) evap (Tin, evap Tevap) = mref (h2 - h3) (2)
THERMODYNAMIC ANALYSIS
where is the effectiveness of heat exchanger, C is capacitance
rate for the external fluids (kW/K), Tin, evap is the evaporator
coolant inlet temperature (K), Tevap is refrigerant temperature in
the evaporator (K), mref is the mass flow rate of refrigerant
(kg/s) and h is specific enthalpy of refrigerant at state point
(kJ/kg).Similarly, the heat-transfer rate between the refrigeration
cycle and the sink in the condenser is
Qcond = (C) cond (Tcond Tin, cond) = mref (h6 - h1)
(3)
where, Tcond is the refrigerant temperature in the condenser (K)
and Tin,cond is the condenser coolant inlet temperature (K).The
power required by the compressor, described in terms of an
isentropic efficiency, is given by
W = mref (h5 - h4) (4)
We assume that the heat leaking into the suction line is
Qloss, evap = mref (h4 - h3) (5)
THERMODYAMIC ANALYSIS
Similarly, the heat leakage from the discharge can be
expressed as
Q loss, cond + Q loss = mref (h6 - h5)
(6)
ThCOP=Qevap / W
(7)
Refrigeration efficiency = COP/ (COP) cannot
(8)
THERMODYANMIC ANALYSIS