Page | 1

REFRIGERATION SYSTEM

COLD STORAGE

MONDAY - FRIDAY

8:30 AM – 10:30 AM

ACDA,JOHN RONALD
BSME -IV

ENGR. RENATO ARRIOLA

PROFESSOR
.
Page | 2
Page | 3
COLD STORAGE DESIGN
Page | 4
For a 24-hour storage of frozen fish (tuna) products:

Latent Specific Specific

Optimu Heat Heat Heat
m Freezing of Above Below
Temperatur
Product Relative Temperatur Fusion Freezing Freezin
e Range, ⁰F
Humidit e, ⁰F , , g,
y BTU/lb (BTU/lb- (BTU/lb
-hr hr-F) -hr-F)

Fish 80 %
5-10 28 101 0.76 0.41
(frozen)

Heat Load Calculations

Fish is at 38 ⁰F and taken from the storage at 0 ⁰F (frozen fish).

FISH

For 1 box of tuna

m = 22.0462 lb or 10 kg

QB = m [ cpAFΔt + LHF + cpBF ]

QB = 22.0462 [ 0.76(10 – 28) + 101 + 0.41(28 – 0) ]

QB =2178. 16 BTU/hr

For 3000 box of tuna

10 kg (3000 pcs) = 30000 kg = 66138.679 lb

QB = m [ cpAFΔt + LHF + cpBF ]

QB = 66138.679 [ 0.76(10 – 28) + 101 + 0.41(28 – 0) ]

PRODUCT LOAD QB = 6534501.485 BTU/hr

Space Required for Refrigerated Goods

Page | 5

Space occupied = 120650.905 ft3

Floor height =19.685 ft

Floor space = 6129.07823 ft2

Using the same requirements for other tuna products:

Mass total = 3000 pcs x 22.04 lb

MT = 66138.6 lb

5 pallet = 2644.8 lb
𝟏𝟐𝟎𝟔𝟓𝟎.𝟗𝟎𝟓𝐟𝐭𝟑
Space required = 66138.6 lb x 2644.8 lb

= 3017121.123 ft3
𝟔𝟏𝟐𝟗.𝟎𝟕𝟖𝟐𝟑 ft2
Floor space = 66138.6 lb x 2644.8 lb

Floor space = 153270.05 ft2

Height of 5 pallet = 5.5m or 16.4042ft

Dimensions of Cold Storage

Size = 126.31 ft x 48.52 ft x 19.685 ft

L=38500 mm = 126.31 ft
Page | 6
W=14796.4mm = 48.52 ft

H= 19.685 ft or 6m
Page | 7
Wall Heat Gain Load

Cold storage is designed based from the hottest temperature of

Manila/Luzon Philippines Page | 8

From ASHRAE: Month of May

Dry bulb temperature = 34.5 ⁰C or 94.1 ⁰F

Wet bulb temperature = 28.1 ⁰C or 82.58 ⁰

Designed insulations:
Thermal Conductivity, Capacitance, c
Thickness, k
Material
BTU
(inches) BTU−in ( )
( ) hr − ft 2 − F
hr−ft2 −F

Brick (common) 8 4.8 -

Corkboard 4 0.32 -

Side Walls Concrete

1.5 4.9 -
(cinder aggregate)

Gypsum plaster - - 4.4

Concrete
3 4.9 -
Flooring (cinder aggregate)

Corkboard 5 0.32 -

Concrete
4 4.9 -
Ceiling (cinder aggregate)

Corkboard 6 0.32 -

Still air Still air - - 1.65

Outside air Outside air - - 6.0

 Page | 9

Qside walls = UAΔt

Asw = 2(L x H) + 2(W x H)

Asw = 2(126.3 x 19.685 ) + 2(48.52 x 19.685 )

Asw = 6882.66 ft2
1
U= 1 x1 x2 1 1
+ + + +
fo k1 k2 c fi

1
U=1 8 4 1 1
+ + + +
6 4.8 0.32 4.4 1.65

𝐁𝐓𝐔
U = 0.06593 𝐡𝐫−𝐟𝐭 𝟐 −𝐅

BTU
Qside walls = (0.06593 hr−ft2 −F) (6882.66 ft2 ) ( 94.1 – 0)⁰F

Qside walls = 42700.11 BTU/hr

Qfloor = UAΔt

Afloor = L x W
 Afloor = 126.31 x 48.52

Afloor = 6129.07823 ft2

Page | 10
1
U= x1 x2 1
+ +
k1 k2 fi

1
U= 3 5 1
+ +
4.9 0.32 1.65

𝐁𝐓𝐔
U = 0.05937 𝐡𝐫−𝐟𝐭 𝟐 −𝐅

BTU
Qfloor = (0.05937 hr−ft2 −F) (6129.07823 ft2) (94.1 – 0)⁰F

Qfloor = 34241.42 BTU/hr

Qceiling = UAΔt

Aceiling = Afloor = 6129.07823 ft2

1
U= 1 x1 x2 1
+ + +
fo k1 k2 fi

1
U=1 6 4 1
+ + +
6 0.32 4.9 1.65

𝐁𝐓𝐔
U = 0.049166 𝐡𝐫−𝐟𝐭 𝟐 −𝐅

BTU
Qceiling = (0.049166 hr−ft2 −F) (1500 ft2) (94.1 – 0)⁰F

Qceiling = 28356.30 BTU/hr

Total Wall Gain Load

Qwall = Qside walls + Qfloor + Qceiling

Qwall = 56221.878 + 34241.42+ 28356.30

Qwall = 118819.59 BTU/hr

Air Change Load

Page | 11

Computations for air properties outside the cold storage:

(Pt−Pvm)(DB−WB)
Pv = Pvm - 1546.622 − 1.44(WB)

(101.325−3.8046)(34.5−28.1)
Pv = 3.8046 - 1546.622 − 1.44(28.1)

Pv = 3.3902 kPa
0.622 Pv
wo = Pt−Pv

0.622 (3.3902)
wo = 101.325−3.3902

wo = 0.02153 kg/kg

ho = 1.0062t + whfg

ho = 1.0062 (34.5) + 0.02153(2564.4)

ho = 89.925 kJ/kg = 38.656 BTU/lb

Computations for air properties inside the cold storage:

tdb = 0 ⁰F = - 17.778 ⁰C
 RH = 80%
Pv
RH = Psat

Pv
0.80 = 0.12807 ; Psat @ -17.778 ⁰C = 0.12807 kPa Page | 12

Pv = 0.10245 kPa

Heat Sources in Space

Heat from People/Workers

Qpeople = 0.378 kW/person x no. of workers

For 0 ⁰F or -17.778 ⁰C, use -15 ⁰C as reference:

Qpeople = 0.378 kW/person x 10 workers [assumed]

1 BTU 3600 s
Qpeople = 3.78 kW x 1.055 kJ x 1 hr

Qpeople = 12898.5782 BTU/hr

Heat from Lightings

From Kent’s Mechanical Engineers’ Handbook

Qlights = 3.41 x total wattage of lights

Assume 40 fluorescent lamps with 15 W each:

Qlights = 3.41 x (40 x 15)

Qlights = 2046 BTU/hr

Heat from motors and equipment

Qmo = 2950 BTU/hr per hp for 3-hp and above motors

Assume maximum of 5 hp motors inside the cold storage:

 Qmo = 2950 BTU/hr x 5 hp

Qmo = 14750 BTU/hr

Total Heat Load

Page | 13
Qtotal = Qproduct + Qwall + Qv + Qpeople + Qlights + Qmo

Qtotal = 2019560 + 26996.68 + 117926.6 + 12898.5782 + 2046 + 14750

Qtotal = 2194177.858 BTU/hr

For miscellaneous loads, a safety factor of 10% of total heat load is

added based from Dossat’s Principles of Refrigeration.

Qtotal = 1.1 (2194177.858)

Qtotal = 2413595.644 BTU/hr

Tons of Refrigeration Required

From Kent’s Mechanical Engineers’ Handbook:

Heat Load 24 hr
Tons = x
12000 x hr

x = hours of operation

x = 16 for a system operating above 32 ⁰F

x = 20 for a system operating below 32 ⁰F

𝟐𝟒𝟏𝟑𝟓𝟗𝟓.𝟔𝟒𝟒 24 hr
Tons = x 20 hr
12000

Tons = 241.35 TR ≈ 245 TR

 EVAPORATOR

Page | 14

Details:
1. Place of Origin: Shandong, China (Mainland)
2. Brand Name: LYTTE or OEM Service-Air Cooler
3. Model Number: DL-Air Cooler(-5℃~5℃)
4. Type: Evaporator, Heat Exchange Air Cooler
5. Application: Refrigeration Parts
6. Certification: CE
7. Main Uasge: Cold Room
8. Application Cold Room Temperature: L: -5℃~5℃
9. Distance: 4.5mm

Specifications

Refrigeration Air Cooler

-Evaporative Air Cooler
-Air Cooler for Cold Room
-High Efficiency
-Advantage Refrigeration Part
Schematic Diagram of cold storage

Page | 15

For Ammonia as refrigerant:

Pressures:

Pressure at condenser = Psat @ 40 ⁰C

Pcon = 1557 kPa

Pressure at evaporator for ice plant = Psat @ -15 ⁰C

Pevap2 = 237.09 kPa

Pressure at evaporator for cold storage = Psat @ -35 ⁰C

Pevap2 = 164.283 kPa

Enthalpies:
 h1 = hg @ -23.33 ⁰C

h1 = 1432.58 kJ/kg

h2 = h @ 237.09 kPa and s1 = s2

Page | 16
h2 = 1480 kJ/kg

h3 = hg @ -15 ⁰C

h3 = 1443.9 kJ/kg

h4 = h @ 1557 kPa and s3 = s4

h4 = 1742 kJ/kg

h5 = h6 = hf @ 40 ⁰C

h5 = h6 = 390.587 kJ/kg

h7 = h8 = hf @ -15 ⁰C

h7 = h8 = 131.2745 kJ/kg

Mass Flow Rates

245 𝑥 3.516
m1 = ℎ1−ℎ8

245 𝑥 3.516
m1 = 1432.58−131.2745

m1 = m2 = m7 = m8 = 0.662 kg/s

130 𝑥 3.516
m6 = ℎ3−ℎ6

130 𝑥 3.516
m6 = 1443.9−390.587

m6 = 0.4339 kg/s
Heat Balance about Intercooler

mh3
Page | 17

mh6 m2h2

m7h7

mh6 + m2h2 = mh3 + m7h7

m(390.587) + 0.662(1480) = m(1443.9) + 0.622(131.2745)

m = 0.8477 kg/s

Mass flow rate through high-stage compressor

m3 = m + m6

m3 = 0.8477 + 0.4339

m3 = 1.2816 kg/s

Compressor Power

For Low Stage Power

P = m1 (h2 – h1)

P = 0.662(1480 – 1437.23)

P = 31.39 kW

For High Stage Power

 P = m3 (h4 – h3)

P = 1.2816(1742 – 1443.9)

P = 382 kW
Page | 18
*For high stage power, use 4 compressors with 96 kW power each.

Refrigerant Piping

Liquid Lines: 3.3 to 22 m/s

Suction Lines: 38 to 250 m/s

Discharge Lines: 55 to 275 m/s

Suction Lines

 At point 1
V1 = m1v1
m1 = 0.662 kg/s
v1 = vg @ -23.33 ⁰C
v1 = 0.7168 m3/kg
V1 = 0.662(0.7168)
V1 = 0.4745 m3/s

For d = 3 in.:

V = Av
Π 1
0.4745 = 4 (3 x 39.37 )2 (v)

v = 104 m/s [satisfied the range]

 At point 3
V3 = m3v3
m3 = 1.2816 kg/s
v3 = vg @ -15 ⁰C
v3 = 0.508013 m3/kg
V3 = 1.2816(0.508013)
V3 = 0.651 m3/s
 For d = 3 in.:

V = Av
Π 1 Page | 19
0.651 = 4 (3 x 39.37 )2 (v)

v = 142.75 m/s [satisfied the range]

Discharge Lines

 At point 2
V2 = m2v2
m2 = 0.662 kg/s
v2 = v @ 237.09 kPa and s1 = s2
v2 = 0.56 m3/kg
V2 = 0.662(0.56)
V2 = 0.3707 m3/s
For d = 2 ½ in:

V = Av
Π 1
0.3707 = 4 (2 ½ x 39.37 )2 (v)

v = 117 m/s [satisfied the range]

 At point 4
V4 = m4v4
m4 = 1.2816 kg/s
v4 = v @ 1557 kPa and s3 = s4
v4 = 0.13 m3/kg
V4 = 1.2816(0.13)
V4 = 0.165 m3/s

For d = 1 ½ in:

V = Av
Π 1
0.165 = 4 (1 ½ x 39.37 )2 (v)

v = 144.72 m/s [satisfied the range]

 Liquid Lines

 At point 5
V5 = m5v5
m5 = 1.2816 kg/s
Page | 20
v5 = vf @ 40 ⁰C
v5 = 0.0017257 m3/kg
V5 = 1.2816(0.0017257)
V5 = 0.002212 m3/s

For d = ½ in:

V = Av
Π 1
0.002212 = 4 (½ x 39.37 )2 (v)

v = 17.46 m/s [satisfied the range]

 At point 7
V7 = m7v7
m7 = 0.662 kg/s
v7 = vf @ -15 ⁰C
v7 = 0.0015185 m3/kg
V7 = 0.662(0.0015185)
V7 = 0.0009445 m3/s

For d = 3/8 in:

V = Av
Π 1
0.0009445 = 4 (3/8 x 39.37 )2 (v)

v = 13.26 m/s [satisfied the range]

Condenser

Based from Stoecker and Jones’ Refrigeration and Air Conditioning:

Designed Values for Condenser

 Temperature at condenser = 40 ⁰C

Common temperature of water in and out the cooling tower:

Temperature entering the condenser = 85 ⁰F or 29.44 ⁰C

Page | 21
Temperature leaving the condenser = 95 ⁰F or 35 ⁰C

Nominal Size of Pipe = 1 ½ in. Schedule 40

Outside Diameter = 1.9 in or 0.04826 m

Inside Diameter = 1.61 in or 0.040894

Thickness = 0.145 in or 0.003683

Tubes per pass = 14

No. of Tubes = 112 tubes

No. of Passes = 112/14 = 8 passes

Rate of heat rejected at the condenser

Qr = m4 (h4 – h5)

Qr = 1.2816 (1742 – 390.587)

Qr = 1731.97 kW

Condensing Coefficient

𝑔𝜌2 ℎ𝑓𝑔 𝑘 3 1/4

hcond = 0.725 ( )
𝜇𝛥𝑡𝑁𝐷

For Ammonia at 40 ⁰C
1
𝜌 = 1.7257 = 0.5795 kg/L = 579.5 kg/m3

hfg = 1490.42 – 390.587

hfg = 1099.83 kJ/kg

 From Table 15.5, p. 300

𝜇 = 0.000122 Pa-s

k = 0.447 W/m-K
Page | 22
Average number of tubes in a vertical row, N
384
N=
48

N=8

(9.81)(579.5)2 (1099.83)(0.447)3 1/4

hcond = 0.725 ( )
0.000122(5.56)(8)(0.04826)

hcond = 764.5443 W/m2-K

Resistance of Metal
𝑥𝐴
R = 𝑘𝐴 𝑜
𝑚

x = 0.003683

ksteel = 50 W/m-K

𝑥 𝐴𝑜 (0.00383)(0.04826)
=
𝑘𝐴𝑚 (50)(0.044577)

𝒙𝑨 𝒐
= 8.6335 x10-5 m2-K/W
𝒌𝑨𝒎

Fouling Factor
𝟏
= 0.000176 m2-K/W
𝒉𝒇𝒇

Water side coefficient

ℎ𝑤 𝐷 ρVD 0.8 𝑐𝑝 μ 0.4
= 0.023( ) (k)
𝑘 μ

Mass of flowing water

 Qr
mw = CpΔt

1731.97
mw = 4.187(35−29.444)

mw = 74.458 kg/s Page | 23

Volume flow rate

𝑚
V= ρ

74.458
V= 1000

V = 0.07446 m3/s

Water velocity
𝑉𝑜𝑙𝑢𝑚𝑒
v = (no.of tubes per pass)(Area)

0.07446
v= Π
96[ (0.040894)2 ]
4

v = 0.5905 m/s

To calculate the water-side heat transfer coefficient,

Use water properties at 32 ⁰C:

ρ = 995 kg/m3

cp = 4190 J/kg-K

μ = 0.000773 Pa-s

k = 0.617 W/m-K
0.023(0.617) (995)(0.5905)(0.040894) 0.8 (4190)(0.000773) 0.4
hw = [ ] [ ]
0.040894 0.000773 0.617

hw = 2644.97 W/m2-K
Overall Heat Transfer Coefficient

1 1 𝑥𝐴 𝐴 𝐴 Page | 24
= + 𝑜+ 𝑜 + 0
𝑈𝑜 ℎ𝑜 𝑘𝐴𝑚 ℎ𝑓𝑓 𝐴𝑖 ℎ𝑖 𝐴𝑖

1 1 (0.000176)(1.9) 1.9
= + (8.6335 x10-5) + + 2644.97(1.61)
𝑈𝑜 764.5443 1.61

Uo = 461.688 W/m2-K

Logarithmic Mean Temperature Difference

Δ𝑡𝑚𝑎𝑥 − Δ𝑡𝑚𝑖𝑛
LMTD = Δ𝑡
ln ( 𝑚𝑎𝑥 )
Δ𝑡𝑚𝑖𝑛

(40−29.44)−(40−35)
LMTD = 40−29.44
ln ( )
40−35

LMTD = 7.437 ⁰C

Heat Transfer Area

𝑄𝑟
Ao = 𝑈
𝑜 LMTD

1731.97 𝑥 1000
Ao = 461.688(7.437)

Ao = 504.421 m2

Length of Tube
 Ao = ΠDLN
504.421
L = Π(0.04826)(384)

L = 8.66 m Page | 25

Fans

Fan Capacity

Fan capacity ranges from 6 to 10 times the volume of the refrigerated

space per hour.

For 10 times the volume of cold storage:

Fan Capacity = 10 (30 x 50 x 12)

Fan Capacity = 180000 ft3/hr or 1.42 m3/s

Power Required

P = ƴQTDH

For a supply air temperature of -10 ⁰C:

Since at very low temperatures, the value of Pv is relatively small,

0.287085 (−10+273)
v= 101.325

v = 0.745 m3/kg

Then,
𝑔 9.81
ƴ= = 0.745
𝑣

ƴ = 13.165 N/m3

Q = Fan Capacity = 1.42 m3/s

 Assume a total head of 15 m.

TDH = 15 m

Page | 26
P = 13.165(1.42)(15)

P = 280.15 W

Assume 50% efficiency of fan.

Power = 560.3 W

Brine Pumps

Designed Temperature of Brine

Evaporator Temperature = 5 ⁰F

Temperature at tank entrance = 10 ⁰F

Temperature at tank exit = 15 ⁰F

Mass Flow of Brine

From Kent’s Mechanical Engineers’ Handbook, p.11-52

Mass Flow of Brine = 242.4 lb/min per ⁰F rise of brine temperature

mb = 242.4 (15 – 10)

mb = 1212 lb/min

Volume Flow of Brine

Volume Flow of Brine = 25.2 GPM per ⁰F rise of brine temperature

Vb = 25.2 (15 – 10)

Vb = 126 GPM
Brine Flow on Freezing Tank

Page | 27

Power Required For Six Pumps

P = ƴQTDH

Assume a total head of 10 m.

SGbrine = 1.16

Q = 126 GPM or 0.00795 m3/s

P = 1.16(9.81)(0.00795)(10)

P = 904.5 W

Assume 50% efficiency of pump.

Power = 1.809 kW