SAINT LOUIS UNIVERSITY

SCHOOL OF ENGINEERING AND ARCHITECTURE

DEPARTMENT OF MECHANICAL ENGINEERING

ME 423B LABORATORY
DESIGN OF ICE PLANT AND COLD STORAGE PLANT WITH A VENTILATION AND
AIRCONDITIONING SYSTEMS

SUBMITTED TO: DATE DUE:

ENGR. CARULLA 28 MARCH 2019

SUBMITTED BY: DATE SUBMITTED:

ABADILLA, JUSTINE PHILIP C. 28 MARCH 2019
BALONG-ANGEY, REI ANGELO P.
DUMAYAS, RAYMOND JAYSON M.
IBAY, MARIO A.
BUCSIT, KRIZZA MHAY CARYL E.
CARTUJANO, SHERYL ANN D.
EMOCK, LYKA O.
MALABONG, GWYNZEL E.
 I. STATEMENT OF THE PROBLEM
To design an ice plant and cold storage plant from a given load requirements
including a centralized air conditioning system.

II. DESIGN CONSIDERATION

A. SPACE CONSIDERATIONS AND CALCULATIONS OF ICE PLANT

1. ICE PLANT PRODUCTION OF 120 TONS OF ICE PER 24 HOURS.

2. NUMBER OF CANS NEEDED

2000 lb
CAPACITY: 120 TONS ( ) = 240,000 LBS.
1TON
BLOCK OF ICE: 300 lbs.

WH
N=
24 C
2
(7 a )
x=
32−t
THICKNESS: 11 in.
(7(11)2)
x= =47.0556 ≈ 48 hrs .
32−14
lb
N=
(
( 120 TONS ) 2000
TONS ) =33.3333 ×48 hrs .=1600 ≈ 1610( adjusted)
24 ( 300 lb )

3. SIZE OF BRINE TANK AND COLD STORAGE

VOLUME OF FREEZING TANK

Volume of Brine:
TOI 120
TR= = =196.72TOR
0.61 0.61
60 ft 3 60 ft 3
VBRINE = TOR ( ) = 196.72 TOR ( ¿ = 11803.2 ft 3
1 TOR 1 TOR

Volume of Ice Cans:

 h
VIC = ( B1 + B2 + 4M )
6
B1 = 11 × 22 = 242 in2
B2 = 9 × 20 = 180 in2
B1 + B2 242+180 2
M= = =211 ¿
2 2

44 3 1 ft 3
VIC = ( 242 + 180 + 4(211) ) = 9284 in ( ¿ = 5.3727 ft 3 ×
6 123 ¿3
1610 cans
= 8650.047 ft 3

Total Volume of Freezing Tank:

VT = VIC + VBRINE
= 8650. 042 ft 3 + 11803.2 ft 3
= 20453.247 ft 3

* 2 BRINE TANKS NEEDED

Dimensions of a Freezing Tank:

N=
√ 1610
2
=28.3725 cans

35 cans × 23 cans

From: L = 2C + (N-1) Ci + NL + A
For L1:
L1= 2(10) + (23-1)(4) + (23)(22) + 20
= 634 in = 52.8333 ft.
L2= 2(10) + (35-1) (4) + (35)(11)
= 541 in = 45.0833 ft.
 For H:
VTOTAL= L1 L2H
V TOTAL 10226.6235
H= = =4.29347 ft .=51.5217∈¿
L1 L2 (52.8333 ft .)(45.0833 ft .)

51.5217 in ˃ 44 in
DIMENSIONS OF 1 BRINE TANK:
L = 52.8333 ft.
W = 45.0833 ft.
H = 4.2935 ft.

4. OTHER SPACES AND EQUIPMENT ROOMS NEEDED

a. EQUIPMENT:

Compressor
Single-acting, vertical ammonia compressors are the major preference in this ice
plant because they do not require as much operating attention, particularly on
lubrication and shaft packing glands, as do horizontal types.

Condenser
Shell-and-tube type of condenser with vertical multi-pass types are used in this
plant for greater efficiency which is usually proportioned upon the basis of from
8 to 10 sq. ft. of surface per ton of refrigeration.

Can Filler
Can filler used in this plant is elevated and lever operation with a pipe sprout
diameter of about 2 inches.

Can Lifts and Cranes

Crane lifts are designed overhead and a hand operated “crab” mounted on the
spiral diameter cable or chain drum.

Brine Agitators
Vertical agitators, directly connected in a single assembly of motor, frame and
propeller, are used in this plant because of their convenience for inspection and
maintenance as they can be readily lifted without any tank disturbances.
 Dip Tanks and Ice Dumps
Dip tank water used in this plant is preferably about 50 to 70oF to avoid ice
cracking and stressing due to fast melting. Ice dumps are made from slopped
galvanized-iron slide.

Air Agitators
Medium pressure air blowers of about 15 to 18 psi gage with air precooling that
will provide 0.2 ft3/min per can of air.

Scoring and Sizing Machines

Scoring machines marks the ice block with 1 to 1.5 in. of deep saw cuts. Sizing
machines are of electrical type and can be controlled to the size of ice.

b. SPACES/ROOMS:

Ice Storage Rooms

The size of ice storage room of this plant can accommodate a full day of
production. Ice stacking was also employed to save space or area.

Power Control Room

Control panels are placed in a room adjacent to brine tank room and ice
processing rooms to easily monitor the processes without using electrical
surveillances. Power systems are also of the same space as to control room for
frequent power monitoring.

Office
Office are designed to accommodate about 20 persons and have a size about
65ft. by 20ft.

Compressor and Condenser Spaces

Compressors are positioned in the same room as the brine tanks for monitoring
convenience while the condensers are placed outside to minimize equipment
loads and maximize its efficiency.

B. COLD STORAGE BASED ON:

1. TONS OF PRODUCTS TO BE STORED
The cold storage was designed with the following tons of products:
20 TONS OF FISH = 40,000 LBS.
 35 TONS OF ONION = 70,000 LBS.
35 TONS OF GINGER = 70,000 LBS.
25 TONS OF BROCCOLI = 50,000 LBS.
30 TONS OF CAULIFLOWER = 60,000 LBS.

2. PROPERTIES OF PRODUCTS AND CONTAINERS

a. PROPERTIES OF PRODUCTS:
SPECIFIC SPECIFIC
PRODUCT STORAGE RELATIVE APPX. HEAT ABOVE HEAT BELOW
TEMPERATURE HUMIDITY STORAGE FREEZING FREEZING
O
F % LIFE BTU BTU
LB−F LB−F
FISH 35 90-100 1 WEEK 0.82 0.41
BROCCOLI 41 95 2 WEEKS 0.93 0.43
CAULIFLOWER 32 95 2-4 WEEKS 0.93 0.47
ONION 32 65-70 4-8 WEEKS 0.9 0.43
GINGER 56 85-90 4 WEEKS 0.9 0.3

b. PROPERTIES OF CONTAINERS
PRODUCT TYPE OF PACKAGE DIMENSIONS OF DENSITY OF
PACKAGE PRODUCT
cm
FISH STYRO-BOX 60.96 × 30.48 × 53.25 543.0433 kg/m3
BROCCOLI WOODEN CRATE 35.56×29.21 × 21.336 777.72 kg/m3
CAULIFLOWER WOODEN CRATE 35.56 × 29.21 × 21.59 419.9235 kg/m3
ONION PLASTIC CRATE 39.37 × 38.1 × 29.21 619.5 kg/m3
GINGER WOODEN BOX 27.94 × 27.94 × 30.48 920 kg/m3

WEIGHT OF PRODUCT PER CONTAINER

a. FISH
Weight of fish per box
W = (DENSITY) (VOLUME)
= (543.0433 kg/m3) (0.6096 × 0.3048 × 0.5325) m3
= 53.7296 kg/box
b. BROCCOLI
Weight of broccoli per wooden crate
 W = (DENSITY) (VOLUME)
= (777.72 kg/m3) (0.3556×0.2921 × 0.21336) m3
= 17.2357 kg/crate
c. CAULIFLOWER
Weight of cauliflower per wooden crate
W = (DENSITY) (VOLUME)
= (419.9235 kg/m3) (0.3556×0.2921 × 0.2159) m3
= 9.4171 kg/crate
d. ONION
Weight of onion per plastic crate
W = (DENSITY) (VOLUME)
= (619.5 kg/m3) (0.3937×0.381 × 0.2921) m3
= 27.1433 kg/crate
e. GINGER
Weight of ginger per wooden box
W = (DENSITY) (VOLUME)
= (920 kg/m3) (0.2794×0.2794 × 0.3048) m3
= 21.8905 kg/crate

SIZE OF COLD STORAGE ROOMS PER PRODUCT

* Dimensions of pallet: 48 in × 48 in
FISH:
Weight of fish per pallet:
Arrangement: 2 × 4 × 2 (stack) box
* In 1 pallet, there are 16 boxes
W = WF × No. of boxes
= 53.7296 kg/box × 16 boxes
= 859.6743 kg/pallet
= 1891.2835 lbs./pallet
No. of pallet needed:
40,000lbs .
N= = 21.1497 pallets ≈ 22 pallets
1891.2835 lbs ./ pallet
No. of rows and columns:

N=
√ No . of pallet
2 √=
22
2
=3.3166

No. of rows = 3
 No. of columns = 4

Length = No. of columns × Length of pallet = 4 × 48 in =

Width = No. of rows × Width of pallet = 3 ×
Height = No. of stack × Box Height =2 × 0.5325 m =
ROOM DIMENSIONS ≈

BROCCOLI:
Weight of broccoli per pallet:
Arrangement: 3 × 4 × 2 (stack) crate
* In 1 pallet, there are 24 crate
W = WF × No. of crates
= 17.2357 kg/crate × 24 crate
= 413.6574 kg/pallet
= 910.0463 lbs./pallet
No. of pallet needed:
50,000lbs .
N= =54.9423 pallets ≈ 55 pallets
910.0463lbs ./ pallet
No. of rows and columns:

N=
√ No . of pallet
2 √
=
55
2
=5.2440

No. of rows = 5
No. of columns = 6

Length = No. of columns × Length of pallet = 5 × 48 in =

Width = No. of rows × Width of pallet = 6 × 48 in =
Height = No. of stack × Box Height =2 × 0.21336 m =
ROOM DIMENSIONS ≈
CAULIFLOWER:
Weight of cauliflower per pallet:
Arrangement: 3 × 4 × 4 (stack) box
* In 1 pallet, there are 48 crates
W = WF × No. of crates
= 9.4171 kg/crate × 16 crates
= 452.0197 kg/pallet
= 994.4433 lbs./pallet
No. of pallet needed:
60,000lbs .
N= = 60.3353 pallets ≈ 61 pallets
994.4433lbs ./ pallet
No. of rows and columns:

N=
√ No . of pallet
2 √
=
61
2
=5.5227

No. of rows = 4
No. of columns = 8

Length = No. of columns × Length of pallet = 8 × 48 in =

Width = No. of rows × Width of pallet = 4 × 48 in
Height = No. of stack × Box Height =4 × 0.2159 m =
ROOM DIMENSIONS ≈

ONIONS:
Weight of onions per pallet:
Arrangement: 3 × 3 × 3 (stack) box
* In 1 pallet, there are 27 plastic crates
W = WF × No. of crates
= 27.1433 kg/crate × 27 crates
= 732.8701 kg/pallet
 = 1612.3143 lbs./pallet
No. of pallet needed:
70,000 lbs .
N= = 43.4159 pallets ≈ 44 pallets
1612.3143 lbs ./ pallet
No. of rows and columns:

N=
√ No . of pallet
2 √=
44
2
=4.6904

No. of rows = 4
No. of columns = 6

Length = No. of columns × Length of pallet = 6 × 48 in =

Width = No. of rows × Width of pallet = 4 × 48 in =
Height = No. of stack × Box Height =3 × 0.2921 m =
ROOM DIMENSIONS ≈

GINGER:
Weight of ginger per pallet:
Arrangement: 4 × 4 × 2 (stack) box
* In 1 pallet, there are 32 boxes
W = WF × No. of boxes
= 21.8905 kg/box × 16 boxes
= 700.4959 kg/pallet
= 1541.0909 lbs./pallet
No. of pallet needed:
70,000 lbs .
N= = 45.4224 pallets ≈ 46 pallets
1541.0909 lbs ./ pallet
No. of rows and columns:

N=
√ No . of pallet
2 √=
46
2
=4.7950

No. of rows = 4
 No. of columns = 6

Length = No. of columns × Length of pallet = 6 × 48 in =

Width = No. of rows × Width of pallet = 4 × 48 in
Height = No. of stack × Box Height =2 × 0.3048 m =
ROOM DIMENSIONS ≈

DIMENSIONS AND PALLETING OF EACH PRODUCTS

Fish:
a. Dimensions (styro-box)

b. Palleting 2 × 4 × 2 (stack) box

Broccoli:
a. Dimensions (wooden crate)

b. Palleting 3 × 4 × 2 (stack) crate

CAULIFLOWER:
a. Dimensions (wooden crate)
 b. Palleting 3 × 4 × 4 (stack) crate

ONIONS:
a. Dimensions (plastic crates)

b. Palleting 3 × 3 × 3 (stack) box

GINGER:
a. Dimensions (wooden box)

b. Palleting 4 × 4 × 2 (stack) box

3. EQUIPMENT AND SPACES NEEDED

a. EQUIPMENT:
1. EVAPORATOR COILS
 Evaporator coils used in this plant are of overhead flooded
type ammonia coils for freezing temperature rooms.
SPECS: Aluminum tube 8.00 mm OD
Aluminum fins
Aluminum sheet
Serpentine pitch: 22mm
Width of finned pack: 140-555 mm
Height: 76.1 – 488.1 mm
Fins pitch: 5mm/multiple with a flexible fins
distribution
Depth: 50/60/75 mm or multiple
2. COOLING TOWERS
Cooling towers of induced fan type are used in with
pumping head not to exceed 50 ft.
SPECS: Nominal capacity TR:80
Height: 3000mm
Diameter: 2800mm
Fan diameter: 1500 mm
Motor: 3 HP
Operating weight: 1500 kg
Pump head: 3000 mm water
3. BRINE AGITATORS

vertical agitators, directly connected in a single assembly of

motor, frame and propeller, are used in this plant because of
their convenience for inspection and maintenance, as they can
be readily lifted without any tank disturbances.

4. AIR PURIFIER AND CONDITIONER

Air purifiers are carried out by activated coconut shell
carbon filters to clean and remove air odors. Conditioner
provides both humidifier and dehumidifier devices.
 SPECS: Removing PM 2.5, bacteria and gas pollutants
Rate of removing PM 2.5, formaldehyde, xylene,
total volatile organic compound
5. HOIST
Hoist is a device used for lifting or lowering a load by means of a
drum or lift-wheel around which rope or chain wraps. It may be
manually operated, electrically or pneumatically driven and may
use chain, fiber or wire rope as its lifting medium. The load is
attached to the hoist by means of a lifting hook.

6. CENTRIFUGAL WATER-OIL SEPARATOR

A centrifugal water-oil separator is a device designed to

separate oil and water by centrifugation. It generally contains a
cylindrical container that rotates inside a larger stationary
container. The denser liquid accumulates at the periphery of
rotating container, whereas the less dense liquid, accumulates at
the rotation axis.

7. DISTRIBUTION BOARD/PANEL BOARD

A distribution board is a component of an electrical supply

system which divides an electrical power feed into subsidiary
circuits, while providing a protective fuse or a circuit breaker for
each circuit, in a common enclosure.

8. CONDENSER

A condenser is a device or unit used to condense a substance

from its gaseous to its liquid state, typically by cooling it. In so
doing, the latent heat is given up by the substance, and will
transfer to the condenser coolant.

9. PUMP

A pump is a device that moves fluids by mechanical action.

Pumps can be classified into major groups according to the
method they use to move the fluid: direct lift, displacement and
gravity pumps.

SPECS: Power, HP 1.00-1.5

Amp 220V: 3.6 amps

RPM: 28

Qmax (1/min): 52
 Height max (m): 45

Pipe diameter (mm): 27

10. AMMONIA COMPRESSOR

An ammonia compressor creates refrigeration by removing heat

from objects or spaces. Compression systems refrigerate by
changing a refrigerant from a liquid state to gaseous state and
back to liquid. Ammonia is commonly used in cold-storage
plants, ice rinks and other commercial applications.

SPECS: Air quality standard: class 1

Inlet pressure: 2.01-2.5 MPa

Motor power: 4-4.5 KW

Outlet pressure: 1.6-4 MPa

b. SPACES

OFFICE

Main office is located near the receiving area and can occupy about 5 to 8 persons

RECEIVING AREA/LOBBY

Receiving area is the transaction area of the plant which is air conditioned for customers
and employers comfort.

MAINTENANCE AND EQUIPMENT ROOM

Main equipment’s are located in this room along with maintenance tools.

C. FINALIZED PLANT LAY-OUT BASED ON:

1. LOACATION OF ICED PLANT AND COLD STORAGE ROOMS.

2. DIMENSIONS AND OTHER SPACES SUCH AS OFFICE AND RECEIVING AREA.

*DIMENSIONS IN METERS
III. COOLING LOAD CALCULATIONS
A. ICE PLANT AND COLD STORAGE CALCULATIONS
a. ICE PLANT

1. Product Load

*Using a 60oF water:

QP = (m × c × (tw – 32)) + mL1

[
= 240,000 lb .× 1
BTU
lb F
×(60−32) F ] + (240,000 lb.) (144
BTU
lb
)
= 41,280,000 BTU/day

2. Other Heat Loads

T