Aircon-lab.docx

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 1TON BLOCK OF ICE: 300 lbs.

CAPACITY: 120 TONS (

) = 240,000 LBS.

N=

WH 24 C

2

x=

(7 a ) 32−t THICKNESS: 11 in. (7(11)2) x= =47.0556 ≈ 48 hrs . 32−14

(

( 120 TONS ) 2000 N=

24 ( 300 lb )

lb TONS

) =33.3333 ×48 hrs .=1600 ≈ 1610( adjusted)

3. SIZE OF BRINE TANK AND COLD STORAGE VOLUME OF FREEZING TANK Volume of Brine: TR=

TOI 120 = =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 6

VIC =

( B1 + B2 + 4M )

B1 = 11 × 22 = 242 in2 B2 = 9 × 20 = 180 in2 M=

44 6

VIC =

B1 + B2 2

=

242+180 2 =211 ¿ 2

1 ft 3 ¿ = 5.3727 ft 3 × ( 242 + 180 + 4(211) ) = 9284 in ( 123 ¿3 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 =28.3725 cans 2

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 H=

V TOTAL 10226.6235 = =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: PRODUCT

STORAGE TEMPERATURE O F

RELATIVE HUMIDITY %

APPX. STORAGE LIFE

FISH BROCCOLI CAULIFLOWER ONION GINGER

35 41 32 32 56

90-100 95 95 65-70 85-90

1 WEEK 2 WEEKS 2-4 WEEKS 4-8 WEEKS 4 WEEKS

SPECIFIC SPECIFIC HEAT ABOVE HEAT BELOW FREEZING FREEZING BTU BTU LB−F LB−F 0.82 0.93 0.93 0.9 0.9

0.41 0.43 0.47 0.43 0.3

b. PROPERTIES OF CONTAINERS PRODUCT

TYPE OF PACKAGE

FISH BROCCOLI CAULIFLOWER ONION GINGER

STYRO-BOX WOODEN CRATE WOODEN CRATE PLASTIC CRATE WOODEN BOX

DIMENSIONS OF PACKAGE cm 60.96 × 30.48 × 53.25 35.56×29.21 × 21.336 35.56 × 29.21 × 21.59 39.37 × 38.1 × 29.21 27.94 × 27.94 × 30.48

DENSITY OF PRODUCT 543.0433 kg/m3 777.72 kg/m3 419.9235 kg/m3 619.5 kg/m3 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: N=

40,000lbs . 1891.2835 lbs ./ pallet

= 21.1497 pallets ≈ 22 pallets

No. of rows and columns: N=

√

√

No . of pallet 22 = =3.3166 2 2

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: N=

50,000lbs . 910.0463lbs ./ pallet

=54.9423 pallets ≈ 55 pallets

No. of rows and columns: N=

√

√

No . of pallet 55 = =5.2440 2 2

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: N=

60,000lbs . 994.4433lbs ./ pallet

= 60.3353 pallets ≈ 61 pallets

No. of rows and columns: N=

√

√

No . of pallet 61 = =5.5227 2 2

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: N=

70,000 lbs . 1612.3143 lbs ./ pallet

= 43.4159 pallets ≈ 44 pallets

No. of rows and columns: N=

√

√

No . of pallet 44 = =4.6904 2 2

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: N=

70,000 lbs . 1541.0909 lbs ./ pallet

= 45.4224 pallets ≈ 46 pallets

No. of rows and columns: N=

√

√

No . of pallet 46 = =4.7950 2 2

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

[

2. Other Heat Loads T

]

+ (240,000 lb.) (144

BTU ) lb