Mini Ice Plant

A
Technical Report
On
Mini ice plant

Submitted to partial fulfilment of the
Requirements for the award of the degree
Of
Bachelor of Technology
in
MECHANICAL ENGINEERING
Submitted by
Abhishek Yadav (1424040003)

Arvind Yadav (1424040017)
Ashish Kharwar (1424040018)
Piyush Tiwari (1424040056)
B.Tech-IVth Year
Under The guidance of

Mr. NEERAJ SARASWAT
Department of Mechanical Engineering
Sunder Deep College Of Engineering & Technology
[Type text] [Type text] [Type text]

ABSTRACT
Water when made into a solid mass by the application of cooling is known as
ice. ICE manufacture is used for producing refrigeration effect to freeze potable
water in standard cans placed in rectangular tank which is filled by brine. A
good definition of refrigeration is the removal of heat energy so that a space or
material is colder than its surroundings. An ice plant based on same principleas
a simple refrigeration system. An ice plant contains various parts such as
compressor, condenser, receiver, expansion valve, evaporator and
refrigerationaccumulator. A refrigeration is always been a great deal for human
being and play a vital role in preserving food , chemical, medicine, fisheries and
providing appropriate temperature in working Entity of any industry.
Refrigeration in the coming years becomes very essential deal for drastic
development of the industrial sector.

ACKNOWLEDGEMENT
I would like to thank to Asst. Professor Neeraj Saraswat in Mechanical
Engineering Department for his continuous support and precious guidance
throughout this study.
I sincerely thank the faculty members and Mr. B.P. Srivastava (H.O.D) and of
R.A.C. and H.M.T. LABS. For their helpful comments and on this Project .
Last but not least, my deepest thank goes to my family and friends for their
support and encouragement.

CERTIFICATE
This is certify that project progress report entitled “MINI ICE PLANT” which is submitted
by Abhishek Yadav, Arvind Yadav , Ashish Kharwar, and Piyush Tiwari in partial
fulfilment of the requirement for the award of degree B.Tech in department of Mechanical
Engineering at the Sunder Deep Engineering College Ghaziabad, is an authentic work carried
out by them under my supervision and guidance to the best of my knowledge, the matter
embodied in the thesis has been submitted to any other university/institute for the award of
the degree.
Mr. B.P.Srivastava
Head of Department
Mechanical Engineering Department
Sunder deep college of engineering & technology, Ghaziabad Sign...................
Mr. NEERAJ SARASWAT
Project Guide
Sunder deep college of engineering & technology, Ghaziabad Sign...................

TABLE OF CONTENTS
ABSTRACT.................................................................................................................ii
ACKNOWLEDGEMENT...........................................................................................iii
CERTIFICATRE......................................................................................................... iv
LIST OF TABLES........................................................................................................vi
LIST OF FIGURES.....................................................................................................vii
1. INTRODUCTION.....................................................................................7
2. FLOW IN COOLING TOWER...............................................................14
3. WORKING .........................................................................................
4. CALCULATION AND TABLE.............................................................

5. APPLICATION ..................................................................................
6. PARTS USED IN MANUFRACTURING ............................................
7. TOOLS USED.........................................................................................
8. REFERENCE ..............................................................

LIST OF FIGURES
Figure 1. PROCESS IN MINI ICE PLANT.............................................................
Figure 2. .......................................................................................
Figure 3. ....................................................................
Figure 4. ...................................................................
Figure 5. FLOW IN THE MINI ICE PLANT............................................................
Figure 6. SYSTEM
TABLES
TABLE 1.....................................................................................
TABLE 2.....................................................................................
TABLE 3.....................................................................................

Chapter 1
Introduction
Water when made into a solid mass by the application of cooling is known as
ice. It is one of the essential medium for short-term preservation of highly
perishable commodities such as marine foods, fresh meat and poultry products,
dairy products and fruit and vegetables. These goods can be stored for about 2
to 3 days with ice. This fact facilitate the transportation of these foods to the
consumer market. Ice is also used in the chemical, pharmaceutical, canning and
freezing industries. Besides, it is being used for children and serving synthetic
or fruit beverages, Jellies, etc. This Engineering Standard covers the
development and practical phase of refrigeration for those who are already
familiar with these fundamentals.
The development phase embrace a brief study of the processes essential to the
trouble-free operation of the refrigeration system, its load calculation, type,
safety and other characteristics including controls, cooling fluids such as water,
brine and refrigerants etc.The practical phase is the study of the refrigerating
priorities including compressor protection and compounding, compressor oil,
heat transfer and the function, and operating principles of an overall system..

PROCESS IN MINI ICE PLANT
STRUCTURE:Refrigerant, compressor, expansion valve (flow control device),

evaporator, condenser, pipes and tubes.
DEFINITIONS & TERMINOLOGY
1 ABSOLUTE ZERO
The zero point on the absolute temperature scale, 459.69 degrees below the zero
of the Fahrenheit scale, (termed Rankine) 273.16 degree below the zero on the
Centigrade scale (termed Kelvin).
2 REFRIGERANT
Refrigerants are heat carrying medium which during their cycle absorb heat at a
low temperature level, are compressed by a heat pump to a higher temperature
where they are able to discharge the absorbed heat together with that added
during the compression to the condenser, cooling water or circulating air.
3 CALIBRATIONS
Process of dividing and numbering the scale of an instrument; also of correcting
or determining the error of an existing scale, or of evaluating one quality in
terms of reading of another.
4 COEFFICIENT OF EXPANSION
The change in length per unit length or the change in volume per unit volume,
per degree change in temperature.
5 RATIO OF COMPRESSION
Ratio of absolute pressures after and before compression.
6 CRITICAL POINT
Of a substance, state point at which liquid and vapor have identical properties;
critical temperature, critical pressure and critical volume are the terms given to
the temperature or pressure and volume at the critical point. Above the critical
temperature or pressure there is no line of demarcation between liquid and
gaseous phases.
7 VAPOUR PRESSURE
The pressure exerted by the vapour released from any materials at given
temperature, when enclosed in a vapour-tight container.

8 UNITS
This Standard is based on International System of Units (SI).
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. In
other words the purpose of the compressor in the vapour compression cycle is
to compress the low-pressure dry gas from the evaporator and raise its pressure
to that of the condenser. compressors may be divided into two types, positive
displacement and dynamic. Positive displacement types compress discrete
volumes of low-pressure gas by physically reducing the volumes causing a
pressure increase, whereas dynamic types raise the velocity of the low-
pressure gas and subsequently reduce it in a way which causes a pressure
increase. Ammonia compressor is the heart of refrigeration plants like Ice
plants.
The hermitically sealed compressor is discussed in details ahead.
HERMETICALLY SEALED, OPEN, OR SEMI-HERMETIC

COMPRESSOR:
In hermetic and most semi-hermetic compressors, the compressor and motor
driving the compressor are integrated, and operate within the pressurized gas
envelope of the system. The motor is designed to operate and be cooled by the
gas or vapor being compressed. The difference between the hermetic and semi-
hermetic, is that the hermetic uses a one-piece welded steel casing that cannot
be opened for repair; if the hermetic fails it is simply replaced with an entire
new unit. A semi-hermetic uses a large cast metal shell with gasket covers that
can be opened to replace motor and pump components. The primary advantage
of a hermetic and semi-hermetic is that there is no route for the gas to leak out
of the system. Open compressors rely on either natural leather or synthetic
rubber seals to retain the internal pressure, and these
seals require a lubricant such as oil to retain their sealing properties. An open
pressurized system such as an automobile air conditioner can leak its operating
gases, if it is not operated frequently enough.

SMALL HERMETICALLY SEALED COMPRESSOR UNIT
CENTRIFUGAL COMPRESSOR
Centrifugal compressors use a rotating disk or impeller in a shaped housing to

force the gas to the rim of the impeller, increasing the velocity of the gas.
A diffuser (divergent duct) section converts the velocity energy to pressure
energy. They are primarily used for continuous, stationary service in
industries such as oil refineries, chemical and petrochemical plants and
natural gas processing plants. Their application can be from 100 horsepower
(75 kW) to thousands of horsepower. With multiple staging, they can achieve
high output pressures greater than 10,000 psi (69 MPa).
CENTRIFUGAL COMPRESSOR

CONDENSER
In systems involving heat transfer, a condenser is a device or unit used

to condense a substance from its gaseous to its liquid state, by cooling it. In so
doing, the latent heat is given up by the substance, and will transfer to the
condenser coolant. The condenser is an important device used in the high
pressure side of a refrigeration system. Its function is to remove heat of hot
vapour refrigerant discharge from the compressor. The condenser removes
heat given off during the liquefication of vaporized refrigerant. Heat is
given off as the temperature drops to condensation temperature. These are
air-cooled and water-cooled condensers, named for their condensing
medium. The more popular is the air-cooled condenser. The condensers consist
of tubes with external fins. The refrigerant is forced through the condenser. In
order to remove as much heat as possible, the tubes are arranged to maximize
surface area. Fans are often used to increase air flow by forcing air over the
surfaces, thus increasing the condenser capability to give off heat.
The selection of the condenser depends of the capacity of the refrigerating

system, the type of refrigerant used and the type of cooling medium
available. Generally the condensers used are water cooled condensers ( the
water cooled condensers are further divided into waste water and re-
circulated water system type) and evaporating condensers.
p-h DIAGRAM FOR CONDENSER

AIR COOLED CONDENSER:
An air cooled condenser is one in which the removal of heat is done by air. It
consists of steel or copper tubing through which the refrigerant flows. The size
of tube usually ranges from 6-mm to 18-mm outside diameter, depending upon
the size of condenser. Generally copper tubes are used because of its
excellent heat transfer ability. The condensers with steel tubes are used in
ammonia refrigerating systems. The tubes are usually provided with plate type
fins to increase the surface area for heat transfer. The fins are usually made from
aluminum because of its light weight. The fin spacing is quite wide to reduce
dust clogging. The condensers with single row of tubing provide the most
efficient heat transfer. This is because the air temperature rises at it passes
through each row of tubing. The temperature difference between the air and
the vapour refrigerant decrease in each row of tubing and therefore each row
becomes less effective. However, single row condensers require more space
then multi row condensers. The single row condensers are usually used in
small capacity refrigeration systems such as domestic refrigerators, freezers,
water coolers and room air conditioners. The air cooled condensers may
have two or more rows of tubing, but the condensers with up to six rows of
tubing are common. Some condensers have seven or eight rows. However, more
than eight rows of tubing are usually not efficient. This is because the air
temperature will be too close to the condenser temperature to absorb any more
heat after passing through eight row of tubing.
AIR COOLED CONDENSER

FORCED AIR
Many refrigerators have forced air condensers. Air is "forced" across the
condenser coils by a condenser fan to aid in removal of the heat being
pulled from the refrigerator. Forced air condensers are located under the
refrigerator with a fan sitting to the side pulling cool air in from the right front
of the refrigerator and exhausting the warm air out to the left front. This warm
air is also passed over the drip pan to aid in evaporating the water
accumulated from defrosting. As a general rule, automatic defrost models
will have a forced air condenser.
FORCED COOLED CONDENSOR
RECEIVERS
A liquid receiver will be required if it is necessary to temporarily store

refrigerant charge within the system, or to accommodate the excess
refrigerant arising from changing operating conditions. The total refrigerant
charge required in a circuit will vary with different operating loads and ambient,
and must be sufficient at all times so that only liquid enters the expansion valve.
A receiver requires a minimum operating charge which adds to overall charge
and cost, and also increases system complexity. Hence receivers are avoided on
many smaller systems.
FILTER DRIER
The function of filter dryer is to remove any physical material from

compressor’s wear and tear, and remove any moisture presence within air

conditioning system. The Drier is made up of a metal outer container and
inside there is a desiccant (moisture removal material) and strainer.
Refrigerant passes through the drier and give up any moisture as well as any
unwanted matter. The main job of the drier is to protect the metering device
from clogging either by Ice (moisture) or blockage by particles. It is not
uncommon for driers and filters to block due to their nature of picking up
unwanted agents - evidence of this can be seen by frost build up. Filtering
process is achieved by mechanical action of partitioning the flow. Particles will
be trapped, whilst the refrigerant flow will be maintained. These desiccants can
be of two types, viz. absorbent and adsorbent type.
FILTER DRIER
EXPANSION DEVICES
The expansion device (also known as metric device or throttling device) is an

important device that divides the high pressure side and the low pressure side
of a refrigerating system. It is connected the receiver (containing liquid vapour
at high pressure) and the evaporator (containing liquid refrigerant at low
pressure). The expansion device performs thefollowing functions like to reduce
the high pressure liquid refrigerant to low pressure liquid refrigerant before
being fed to the evaporator and to maintain the desire pressure difference
between the high and low pressure side of the system, so that the liquid
refrigerant vaporizes at the designed pressure in the evaporator. There are many
types of expansion devices used viz. capillary tubes, automatic or constant-
pressure expansion valve, low side float valve, high side float valve and
thermostatic expansion valve in an ice plant industry depending upon its
capacity.

CAPILLARY TUBE:
The capillary tub is used as an expansion device used in small capacity hermetic
sealed refrigeration units such as domestic refrigeration, water cooler, room air
conditioner and freezers. It is a cooper tube of small diameter and of varying
length depending upon the application. The inside diameter of the tube used in
refrigeration work is generally about 0.5 mm to 2.25 mm and the length varies
from 0.5 m to 5 m. It is installed in the liquid line between the condenser and
evaporator. A small filter drier is used on some system to provide additional
freeze-up application. In its operation, the liquid refrigerant from the condenser
enter the capillarity tube due to friction resistance offered by small diameter
tube, the pressure drops since the frictional resistance is directly proportional to
the length and inversely proportional to the diameter, therefore longer the
capillary tube and smaller its inside diameter, greater is the pressure drop
created in the refrigerant flow. In other words, greater pressure difference
between the condenser and the evaporators needed forgiven flow rate of
refrigerant.
The refrigerant system using capillary has the following advantages:
• The cost of the capillary is less than all other form of expansion
devices.
• In the compressor stops, the refrigerant continues to flow into the
evaporator and equalizes the pressure between the high side and
the low side of the system. This considerably decreases the starting load
on the compressor. Thus a low starting torque motor can be used to drive
compressor, which is a greater advantage.
• Since the refrigerant charge in a capillary tube system is critical, therefore
no receiver is necessary.
EVAPORATOR
The evaporator is an important device used in the low pressure side of the
refrigeration system. The liquid refrigerant from the expansion valve enters into
the evaporator where its boil and change into vapour.The function of the
evaporator is to absorb heat from the surrounding location or medium which is
to be cooled, by mean of a refrigerant. The temperature of the boiling
refrigerant in the evaporator must always be less than that of the surrounding
medium so that heat flows to the refrigerant. The evaporator becomes cold and
remains cold due to the following two reasons:
• The temperature of the evaporation coil is low due to the low temperature
of the refrigerant inside the coil.
• The low temperature of the refrigerant remains unchanged because any
heat it absorbs is converted to latent heat as boiling proceeds.

The liquid refrigerant at low pressure enters the evaporator at point 6, as shown
in figure, as the liquid refrigerant passes through the evaporator coil, it
continuously absorb heat through the coil walls, medium to be cooled. During
this, the refrigerant continues to boil and evaporate. Finally at point 1’, the
entire liquid refrigerant has evaporated and only vapours refrigerant remains
in the evaporator coil.
The liquid refrigerant’s ability to convert absorbed heat to latent heat is now
used up. Since the vapour refrigerant at point 1’ is still colder than the
medium being cooled, therefore the vapour refrigerant continues to absorb heat.
This heat absorption cause an increase in the sensible heat (or temperature) of
the vapour refrigerant. The vapour temperature continues to rise until the
vapour leaves the evaporator to the suction line at point 1. At this point the
temperature of the vapour is above the saturation temperature and the
vapour refrigerant is superheat. There are many types of evaporators used in
an ice plant industry depending upon their capacities.
p-h DIAGRAM OF SIMPLE REFRIGERATING SYSTEM

CHILLING TANK
The main components of chilling tank are viz.ice tank, insulation of ice tank and
ice block. Ice tanks are made of such material as wood, steel or concrete. As
wooden tanks do not last long enough and are liable to leak, they should
preferably be made of steel well coated with waterproof paint. Tanks made of
reinforced concrete are also recommended as superior to those of wood. The
ice tank contains the direct expansion coils, equally distributed throughout
the tank and these coils are submerged in brine. The tank is provided with a
suitable frame of hard wood for support the ice cans and a propeller or agitator
for keeping the brine in motion: the brine in the tank acts as a medium of
contact only, the ammonia evaporating in the ice coils extracts the heat from the
brine, which again absorbs the heat for the water in the cans. The tank itself
should not be much larger than is necessary to hold the cans, the coils, and the
agitator.
Insulation of the ice tank is accomplished by using twelve to eighteen
inches of good insulating material on each of the sides and not less than twelve
inches under the bottom. Commercial sizes of Ice cans vary with the weight of
ice cakes required.
CHILLING TANK

Chapter 2
FLOW IN MINI ICE PLANT
PRODUCTION PROCESS IN ICE MAKING
Raw water is pumped from local available water bodies such as pond /
stream through raw water pump to overhead tank . This raw water from
overhead tank is filled into the ice cans.The production area of the plant has an
Ice tank made of concrete. The ice tank contains the direct expansion coils,
equally distributed throughout the tank and these coils are submerged in brine
solution. The tank is provided with a suitable frame of hard wood for support
the ice cans and a propeller or agitator for keeping the brine in motion: the brine
in the tank acts as a medium of contact only, the ammonia evaporating in the ice
coils extracts the heat from the brine, which again absorbs the heat for the water
in the cans. The dimensions of the can and the temperature of the brine are
usually selected to give a freezing period of between 30-36 hours. Too rapid
freezing results in brittle ice. The Ice block weight is more than 100 kg,
depending on requirements. The thicker the block is the longer the freezing
time. The size of the tank required is related to the daily production capacity.
Water is chilled for 48 hours for complete ice block formation. The Sp. gravity
of brine is maintained at 1180 by adding salt of required quantity. Ice cans of
fully formed ice blocks are removed from the chilling tank. The cans are
emptied of the ice blocks and replaced into the chilling tank with water for the
next batch. The removed ice blocks are further cursed into smaller pieces by ice
crushers and loaded into plastic crates for transportation.
The ammonia or feron gas coming from the cooling coil at low temperature and
pressure is compressed into liquid and is passed through the cooling coil fixed
in the freezing tank. Due to the low boiling point of ammonia it changes its
shape from liquid to vapour and is condensed in side the condenser. The tank
contains brine of 30% salt, the cold brine is circulated by agitation to maintain
uniform temperature through out the tank. The brine temperature is
considerably reduced to as low as 15 F, this will take about 24 hours. After the
brine reaches the operating temperature the ice cans are filled with water and are
immersed inside the brine tank in such a way that the level of the brine should
be below the level of the top of the ice can. Due to the high freezing point of

water comparing to brine, the water in the can is solidified at 30 F to from ice.
To get clear solidised a small quantity of air is passed into the cans. It takes
about 18 hours to freeze a 250 kg. ice can
PROCESS FLOW
As shown in Figure for ice making by vapor compression cycle it includes the
following four main sections:
• Compressor unit.
• Condenser Unit.
• Expansion Unit.
• Evaporator Unit
The Process Flow diagram of Ice manufacturing industry is as follows:
PROCESS FLOW DIAGRAM ICE MAKING INDUSTRY

Brief description of the different process involved in the ice making industry is
discussed below:-
1. COMPRESSOR UNIT: This is composed of a motor and compressor set

where the electrical energy is converted to mechanical energy in the form of
compression stroke which results in increasing the temperature (greater than
150oC) and high pressure of the refrigerant (NH3)
2. CONDENSER UNIT: Here the high temperature refrigerant coming from

the condenser unit is allowed to cool down in a heat exchanger by the help of
cooling tower. The temperature drops down from 159oC to 40oC.
3.EXPANSION UNIT: Here the refrigerant is allowed to expand in the

expansion tank,which results in a sudden drop in temperature and pressure. The
temperature suddenly drops below (-10oC) which is then fed into the
evaporator.
4. EVAPORATOR TANK: It is a heat exchanger where the heat transfer

medium is brine solution, which is field in the tank. This solution is
continuously being agitated with an electrical agitator for proper mixing of the
temperature. The time cycle for ice formation is around 24 – 36 hours it
depends on the system performance of different pants.
The cans are manually or crane lifted and transports to a thawing tank at the end
of the freezing tank, where they are submerged in water to release the ice from
the moulds. In some cases, it is crushed for packing purposes.
FREEZING STORAGE SYSTEM
GENERAL : In order to keep freshness of products preventing shrinkage and

dryness for a long period, freezing process shall be used on all protein-rich and
agricultural products. (Reference is made to Attachment 5 for considering
periods of long term and short term storage requirements of products).
For type and application of freezers, designs are dictated by: - Wide range of
product to be frozen. - Wide range of capacities. - Differing performance
expectations/criteria.
Classification according to the nature of its system, the freezing method may be
classified into following categories.

a) By cooling system, which is further sub-divided into:
i) Air convection through: - Natural convection.
- Forced convection.
ii) Contact system through: - Horizontal type.
- Vertical type.
iii) Brine system through: - Immersion system.
- Spray system.
b) By handling system, which is further sub-divided into:
i) Batch system through: - Air blast freezing.
- Contact freezing.
- Brine immersion freezing.
ii) Continuous system or Individual Quick Freezing (IQF) through:
- Freezing tunnel system.
- Flow system.

Chapter 3
FABRICATION
The prototype model of an ice plant has been fabricated consist of compressor,
condenser, filter drier, capillary tube, evaporator, chilling tank, energy meter,
pressure gauge and digital temperature indicator whose detailed information are
given below for the thermal analysis of model.
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. In other words the purpose of
the compressor in the vapour compression cycle is to compress the low-pressure
dry gas from the evaporator and raise its pressure to that of the condenser.
Compressors may be divided into two types, positive displacement and
dynamic, as shown below. Positive displacement types compress discrete
volumes of low-pressure gas by physically reducing the volumes causing a
pressure increase, whereas dynamic types raise the velocity of the low-pressure
gas and subsequently reduce it in a way which causes a pressure increase.
DIFFERENT TYPE OF COMPRESSOR

1. POSITIVE DISPLACEMENT
1.1 RECIPROCATING COMPRESSORS
Reciprocating compressors use pistons driven by a crankshaft. They can be either

stationary or portable, can be single or multi-staged, and can be driven by electric
motors or internal combustion engines. Small reciprocating compressors from 5 to
30 horsepower (hp) are commonly seen in automotive applications and are typically
for intermittent duty. Larger reciprocating compressors well over 1,000 hp (750 kW)
are commonly found in large industrial and petroleum applications. Discharge
pressures can range from low pressure to very high pressure (>18000 psi or 180 MPa).
In certain applications, such as air compression, multi-stage double-acting
compressors are said to be the most efficient compressors available, and are typically
larger, and more costly than comparable rotary units. Another type of reciprocating
compressor is the swash plate compressor, which uses pistons moved by a swash plate
mounted on a shaft.Household, home workshop, and smaller job site compressors are
typically reciprocating compressors 1½ hp or less with an attached receiver tank.
RECIPROCATING COMPRESSOR
1.2 ROTARY SCREW COMPRESSORS

Rotary screw compressors use two meshed rotating positive-displacement helical
screws to force the gas into a smaller space. These are usually used for continuous
operation in commercial and industrial applications and may be either stationary or
portable. Their application can be from 3 horsepower (2.2 kW) to over 1,200
horsepower (890 kW) and from low pressure to moderately high pressure (>1,200 psi
or 8.3 MPa).
Rotary screw compressors are commercially produced in Oil Flooded, Water Flooded
and Dry type.

1.3 ROTARY VANE COMPRESSORS
Rotary vane compressors consist of a rotor with a number of blades inserted in
radial slots in the rotor. The rotor is mounted offset in a larger housing that is
either circular or a more complex shape. As the rotor turns, blades slide in and
out of the slots keeping contact with the outer wall of the housing. Thus, a series
of increasing and decreasing volumes is created by the rotating blades. Rotary
Vane compressors are, with piston compressors one of the oldest of compressor
technologies.
With suitable port connections, the devices may be either a compressor or a
vacuum pump. They can be either stationary or portable, can be single or multi-
staged, and can be driven by electric motors or internal combustion engines.
Dry vane machines are used at relatively low pressures (e.g., 2 bar or 200 kPa
or 29 psi) for bulk material movement while oil-injected machines have the
necessary volumetric efficiency to achieve pressures up to about 13 bar
(1,300 kPa; 190 psi) in a single stage. A rotary vane compressor is well suited
to electric motor drive and is significantly quieter in operation than the
equivalent piston compressor.
Rotary vane compressors can have mechanical efficiencies of about 90%.
2. DYNAMIC
2.1 AIR BUBBLE COMPRESSOR
Also known as a trompe. A mixture of air and water generated through
turbulence is allowed to fall into a subterranean chamber where the air
separates from the water. The weight of falling water compresses the air in the
top of the chamber. A submerged outlet from the chamber allows water to flow
to the surface at a lower height than the intake. An outlet in the roof of the
chamber supplies the compressed air to the surface.
AIR BUBBLE COMPRESSOR

2.2 CENTRIFUGAL COMPRESSOR
Centrifugal compressors use a rotating disk or impeller in a shaped housing to
force the gas to the rim of the impeller, increasing the velocity of the gas. A
diffuser (divergent duct) section converts the velocity energy to pressure
energy. They are primarily used for continuous, stationary service in industries
such as oil refineries, chemical and petrochemical plants and natural gas
processing plants.[1][14][15] Their application can be from 100 horsepower
(75 kW) to thousands of horsepower. With multiple staging, they can achieve
high output pressures greater than 10,000 psi (69 MPa).
Many large snowmaking operations (like ski resorts) use this type of
compressor. They are also used in internal combustion engines
as superchargers and turbochargers. Centrifugal compressors are used in
small gas turbine engines or as the final compression stage of medium-sized gas
turbines.
CENTRIFUGAL COMPRESSORS
2.3 HERMETICALLY SEALED, OPEN, OR SEMI-HERMETIC

A small hermetically sealed compressor in a common consumer refrigerator or
freezer typically has a rounded steel outer shell permanently welded shut, which
seals operating gases inside the system. There is no route for gases to leak, such
as around motor shaft seals. On this model, the plastic top section is part of an
auto-defrost system that uses motor heat to evaporate the water. Compressors
used in refrigeration systems are often described as being either hermetic, open,
or semi-hermetic, to describe how the compressor and motor drive are situated
in relation to the gas or vapour being compressed. The industry name for a
hermetic is hermetically sealed compressor, while a semi-hermetic is commonly
called a semi-hermetic compressor.

In hermetic and most semi-hermetic compressors, the compressor and motor
driving the compressor are integrated, and operate within the pressurized gas
envelope of the system. The motor is designed to operate in, and be cooled by,
the refrigerant gas being compressed.
The difference between the hermetic and semi-hermetic, is that the hermetic
uses a one-piece welded steel casing that cannot be opened for repair; if the
hermetic fails it is simply replaced with an entire new unit. A semi-hermetic
uses a large cast metal shell with gasketed covers that can be opened to replace
motor and pump components.
HERMETIC SEALED COMPRESSOR

The primary advantage of a hermetic and semi-hermetic is that there is no route
for the gas to leak out of the system. Open compressors rely on shaft seals to
retain the internal pressure, and these seals require a lubricant such as oil to
retain their sealing properties.
An open pressurized system such as an automobile air conditioner can be more
susceptible to leak its operating gases. Open systems rely on lubricant in the
system to splash on pump components and seals. If it is not operated frequently
enough, the lubricant on the seals slowly evaporates, and then the seals begin to
leak until the system is no longer functional and must be recharged. By
comparison, a hermetic system can sit unused for years, and can usually be
started up again at any time without requiring maintenance or experiencing any
loss of system pressure.
The disadvantage of hermetic compressors is that the motor drive cannot be
repaired or maintained, and the entire compressor must be replaced if a motor
fails. A further disadvantage is that burnt-out windings can contaminate whole
systems, thereby requiring the system to be entirely pumped down and the gas
replaced. Typically, hermetic compressors are used in low-cost factory-
assembled consumer goods where the cost of repair is high compared to the

value of the device, and it would be more economical to just purchase a new
device.
An advantage of open compressors is that they can be driven by non-electric
power sources, such as an internal combustion engine or turbine. However,
open compressors that drive refrigeration systems are generally not
totally maintenance-free throughout the life of the system, since some gas
leakage will occur over time.
EVAPORATER
Evaporator is an important component together with other major components in

a refrigeration system such as compressor, condenser and expansion device. The
reason for refrigeration is to remove heat from air, water or other substance. It is
here that the liquid refrigerant is expanded and evaporated. It acts as a heat
exchanger that transfers heat from the substance being cooled to a boiling
temperature. It is used in the low pressure side of the refrigeration system. The
liquid refrigerant from the expansion valve enters into the evaporator where its
boil and change into vapour. The function of the evaporator is to absorb heat
from the surrounding location or medium which is to be cooled, by mean of a
refrigerant. The temperature of the boiling refrigerant in the evaporator must
always be less than that of the surrounding medium so that heat flows to the
refrigerant.
EVAPORATER

CONDENSER
The condenser is an important device used in the high pressure side of a

refrigeration system. Its function is to remove heat of hot vapor refrigerant
discharge from the compressor. The hot vapour consists of the heat absorbed by
the evaporator and the heat of compression added by the mechanical energy of
compressor motor. The heat from the hot vapour refrigerant in a condenser is
removed first by transferring it to the walls of the condensers tubes and then
from the tubes to the condensing or cooling medium. The high temperature,
high pressure ammonia vapour is condensed in a condenser which may be of
shell and tube type or evaporative type. The selection of the condenser depends
of the capacity of the refrigerating system, the type of refrigerant used and the
type of cooling medium available. Generally the condensers used are water
cooled condensers (the water cooled condensers are further divided into waste
water and re-circulated water system type) and evaporating condensers.There
are two types of evap.:
1.FORCED CONVECTION TYPE: uses a fan or pump to force the liquid

being cooled over the evap. In forced circulation condenser liquid is circulated
through the tubes at high pressure by means of a pump. Hence boiling does not
takes places because boiling point is elevated. Forced circulation of the liquids
also creates some form of agitation. When the liquid leaves the tubes and enters
the vapor head, pressure falls suddenly. This lead to the flashing of super heated
liquor. Thus the evaporation is effected.
FORCED AIR CONDENSER
• ADVANTAGES
1. In forced circulation condenser there is a rapid liquid movement due to
high heat transfer coefficient.
2. Salting, scaling and fouling are not possible due to forced circulation.

3. This condenser is suitable for themolabile substances because of rapid
evaporation.
4. It is suitable for the viscous preparation because pumping mechanism

is used.
• DISADVANTAGES
1. In forced circulation condenser the hold up of liquids is high. The
equipments is expensive because the power is required for the circulating
the liquids.
2.NATURAL CONVECTION TYPE :has the liquid being cooled flows

naturally to the evap. due to the density differences of the chilled and warm
liquid. Natural Circulation evaporation is essentially based upon natural
convection currents manipulated through the system piping to create circulation.
Circulation through convection is achieved through bubble formation. Bubble
are of lower density and rise through the liquid to promote upward lift into the
evaporating vessel.
Physically Natural circulation condenser use a short tube bundle within the
batch pan or by having an external shell and tube heat exchanger outside of the
main vessel , External heating through heat exchangers is normally used as it
has the advantage that it is not dependent on the calandria size or shape.
NATURAL CONDENSER
• ADVANTAGE
1. Natural Circulation condenser is more economical than
Forced circulation and Falling Film Evaporator. As it consumes
very less energy than other type of Evaporators
2. Less Energy consumption is the biggest advantage of this
system.

• DISADVANTAGE
1. In this system the velocity of flowing fluid is less as
compares to others, so, the rate of heat transfer is less.
EXPANSION DEVICES
The expansion device (also known as metric device or throttling device) is an

important device that divides the high pressure side and the low pressure side of
a refrigerating system. It is connected the receiver (containing liquid vapour at
high pressure) and the evaporator (containing liquid refrigerant at low pressure).
The expansion device performs the following functions like to reduce the high
pressure liquid refrigerant to low pressure liquid refrigerant before being fed to
the evaporator and to maintain the desire pressure difference between the high
and low pressure side of the system, so that the liquid refrigerant vaporizes at
the designed pressure in the evaporator. There are many types of expansion
devices used viz. capillary tubes, automatic or constant-pressure expansion
valve, low side float valve, high side float valve and thermostatic expansion
valve in an ice plant industry depending upon its capacity. In this model the
capillary tube type expansion devise is used which is discussed in details ahead.
CAPILLARY TUBE
The capillary tube is used as an expansion device used in small capacity

hermetic sealed refrigeration units such as domestic refrigeration, water cooler,
room air conditioner and freezers. It is a cooper tube of small diameter and of
varying length depending upon the application. The inside diameter of the tube
used in refrigeration work is generally about 0.5 mm to 2.25 mm and the length
varies from 0.5 m to 5 m. It is installed in the liquid line between the condenser
and evaporator. A small filter drier is used on some system to provide additional
freeze-up application. In its operation, the liquid refrigerant from the condenser
enter the capillarity tube due to friction resistance offered by small diameter
tube, the pressure drops since the frictional resistance is directly proportional to
the length and inversely proportional to the diameter, therefore longer the
capillary tube and smaller its inside diameter, greater is the pressure drop
created in the refrigerant flow. In other words, greater pressure difference

between the condenser and the evaporators needed forgiven flow rate of
refrigerant.
The refrigerant system using capillary has the following advantages:
• The cost of the capillary is less than all other form of expansion devices.
• In the compressor stops, the refrigerant continues to flow into the
evaporator and equalizes the pressure between the high side and the low
side of the system. This considerably decreases the starting load on the
compressor. Thus a low starting torque motor can be used to drive
compressor, which is a greater advantage.
• Since the refrigerant charge in a capillary tube system is critical,
therefore no receiver is necessary.
CAPPILARY TUBE
REFRIGERANT
Refrigerant used in this prototype model is R-134a and it is also known as

Tetrafluoroethane (CF3CH2F) from the family of HFC refrigerant.
The properties of refrigerant R-134a are as under:
• R134a is also known as Tetrafluoroethane (CF3CH2F) from the family of
HFC refrigerant. With the discovery of the damaging effect of CFCs and
HCFCs refrigerants to the ozone layer, the HFC family of refrigerant has
been widely used as their replacement.

• It is now being used as a replacement for R-12 CFC refrigerant in the area
of centrifugal, rotary screw, scroll and reciprocating compressors. It is A
Study on analysis and fabrication of an Ice plant Model safe for normal
handling as it is non-toxic, non-flammable and non-corrosive.
• It exists in gas form when expose to the environment as the boiling
temperature is -14.9°F or - 26.1°C.
REFRIGERANT
BRINE SOLUTION
Brine solution used In this prototype model the mixture of NaCl and water in
the proportion of 1:3 is used. The mixture of CaCl2 and water can be used as
brine but it is not used because of its toxicity. The comparisons between these
two brines are established in table , below:

COMPARISONS BETWEEN TWO BRINES
(CALCIUM AND SODIUM CHLORIDES)

CHAPTER 4
MAKING OF ICE
ICE MAKING SYSTEM
Refrigeration system required to produce one ton of ice per day would require
6.3 kW of refrigerating capacity. This procedure requires water be cooled to the
freezing point overcoming various other losses. The ice generating units are
used for commercial applications, food trawlers, packing fresh protein products,
dairy products, concrete cooling and chemical processing applications.
1 BLOCK ICE SYSTEM
The principle equipment representing a typical conventional block ice plant

comprises of:
a) Single stage multi-cylinder reciprocating ammonia compressor with

electric motor, starter and oil separator.
b) Condenser either shell and tube or evaporative condenser based on

3800 kcal per one TR of compressor capacity.
c) Freezing tank in which an ammonia evaporating coil is immersed in a

brine solution comprising of brine agitator. The evaporating coil shall be
with accumulator and line valves.
d) Harvesting equipment including cans placed in wooden frame, can

grids etc.
e) Miscellaneous items such as water pumps, can filling tank, dip tank
(to thaw peripheral portion of ice in warm water) air blower with air
receiver and core sucker pump, overhead crane and insulation material
for the freezing tank.
A typical block ice plant producing 25 kg ice blocks shall preferably be

inclusive of ice storage chamber, ice stacker (stationary or movable type) and a
separate ice crusher unit of suitable capacity.

2 FRAGMENTARY ICE MAKING UNITS
These shall be packaged machine and is used according to application

requirements and can be of following types:
a) FLAKE ICE UNIT: These are of two types; drum rotating and scraper
turning type, where raw water is sprayed onto a freezing drum on which ice is
formed. The drum is either vertical or horizontal and may be either stationary or
fixed. The thickness of ice is in the range of 1 to 3 mm.
b) PLATE ICE UNIT: City water is sprayed on freezing plates and when
predetermined (adjusted) ice thickness of 6 to 20 mm is reached, ice is removed
by defrosting. Generally an ice crusher unit may be integrated and placed below
the plate.
c) TUBE ICE UNIT :City water is sprayed on the interior surfaces of number
of tubes which may be cooled by refrigerant gas where ice is formed on preset
thickness and falls down inside the tubes, the operation being controlled.
Generally ice in thicknesses of 8 to 15 mm may use an ice cutter unit.
Notes:
1) The ice producing method such as chipped ice, cube ice, ribbon or slab ice
are not covered in this Standard.
2) The ice storage rooms, to store ice in large volume, produced by above
machines shall be held at -10°C (14°F) temperature to prevent sticking of ice
into large pieces.
ISSUES
The following issues are identified while interacting with the Ice plants owners
and the other institutions during the technology Audit.
1. AVAILABILITY OF ELECTRICAL ENERGY:
All the Ice plants required electrical energy to operate the equipments installed
in their plants. These ice plants draw electrical energy from the power house by
registering their plants with contract maximum demand. There is shortage of
energy supply during the summer season from the power house. So far there
have not been any issues related to long term failure of power .

As the Ice plants are energy dependent, there is a vast opportunity for savings of
energy in every Ice Plant operation in various capacities in the cluster. The ice
plants are depending on the electricity. In the cluster energy conservation
awareness and conscious is required among the Ice plants Owners and operators
to conserve the energy. There is huge scope of Energy conservation in the Ice
plants by utilizing the energy efficient motors and pumps instead of normal
motors, pumps and re winded motors several times.
One more opportunity in the ice making plants is to install the flack ice /cube
ice plants where the crushed ice/ domestic requirements. The flack/cube ice
plant consumes less energy compare to the block ice plants.
2. TECHNOLOGICAL ISSUES
The other major issue in the Ice Plant is identification of the right technology
and equipments based on the requirements in the marketing the finished
products from the plant.
In the Ice Plants the ice production is mainly with the operation of compressor
and motors and pumps. The ice plant owners in the cluster not aware of energy
efficient equipments are neither available nor implemented to their plants.
However, the first change is still a challenge, upon success, later on duplication
and adaptation is extremely common in the cluster. The technologies need to be
demonstrated within the cluster to create awareness.
During visits and technology audit in the plant, many plant owners interested to
adopt the energy efficient technologies to their plants.
3. FINANCIAL ISSUES
The plant owners have good contacts with the local banks to avail a loans and
other services from the bank based on their transactions with the banks.
Among the SME’s (small and medium-sized enterprises) , the larger units, if
convinced, are capable of either financing themselves or get the finance from
their banks. The smaller units will require loan at comfortable rates and other
support to raise the loan. However, as most of them have been able to expand
their setup and grow, there is a readiness to spend for energy efficiency
technologies which have good payback periods. Energy Efficiency Financing
Schemes such as that of SIDBI’s, if focused on the cluster, will play a catalytic
role in implementation of identified energy conservation projects &

technologies. The cluster has significant potential of implementing the Energy
efficient equipments in the ice plants
4. MANPOWER RELATED ISSUES
The Ice plants, all the plants required limited skilled and unskilled manpower.
But the skilled man power required for training on operation and maintenance
of the equipments in the Ice plants. In Ice making cluster, availability of skilled
and trained manpower is one of the limitations. Number of Ice plants units has
grown fast as compared to the availability of skilled manpower. Few local
electrical persons are catering services of electrical equipments during the
failure in many ice plants. For major equipments like Refrigeration Compressor,
condensers in the plants etc. are maintenance and repair is take care by the
equipment suppliers themselves. The units have age-old inefficient practices
and well-experienced non qualified staff in these industries. Even if the
qualified staff joins for the sake of experience and jump to other industry after
getting sufficient experience this is because of low salaries.
Specialized and focused training of the local service providers on better

operation and maintenance of the equipments, importance of the energy and its
use and energy conservation measures will improve awareness among the unit
owners and workforce.
5. TECHNOLOGY AND SERVICE PROVIDER RELATED ISSUES
Many of the new technology providers have not shown keen interest for
implementation of their new innovative technologies due to higher price by the
SMEs (small and medium-sized enterprises) . Few of the service providers
have their activities to provide the service to the ice plants.
6.TEMPERATURE
Temperature increases can kill your ice machine's production This issue is faced
by those who allow their ice machine to operate in a commercial kitchen or any
other high temperature areas of your establishment. When forced to operate
under these conditions, your ice machine may struggle greatly. In fact, most ice
machines are rated by their performance in 90 degree heat, and some can lose
up to 30% of their ice production when making ice in elevated temperatures.
During my years of bartending, (although our ice machine made use of a remote
air cooled condenser) we would always notice a dip in ice production when it
became excessively hot (95+ degrees over a few days). When the air

temperature is too high, water temperatures often increase, and your ice
machine requires more time to bring the water to acceptable levels for ice
making. This can slow ice making or bring it to what seems like a standstill. For
this reason, it helps to purchase an ice machine that makes more ice than you
will require on a daily basis.
7. IMPROPER CLEARANCE
Almost every air cooled ice machine head and undercounter ice machine
requires six inches of clearance for optimum ice making. Manitowoc ice
machines advise more, with eight inches as the recommended value. If your ice
machine does not have the proper amount of room to operate, it will not be able
to take in air to keep the condenser cool. If the condenser is not cool, your ice
machine’s ice making power will suffer. Dust and dirt gathered on your
condenser coils can also affect ice machine performance, but we will address
this later at a greater length. You should always adhere to the minimum
clearance recommended by the ice machine manufacturer to get the most out of
your ice machine.
8. ICE / MINERALS ON EVAPORATOR PLATE
Sometimes, mineral deposits will affect the way ice is harvested after being
created on the evaporator plate. Ice may continue to grow and thicken as your
evaporator plate cannot warm efficiently enough to drop your ice into the bin.
Generally, lower quality water can leave behind mineral or scale deposits, and
those can build up on your evaporator plate. If these issues are left unattended,
your ice machine may continue to produce ice, but it will often be thin, watery,
and of low quality. In most cases, a thorough cleaning will solve these
problems. If you haven’t already, you should consider adding a water filter to
your ice machine, which will greatly reduce (if not completely eliminate) the
amount of sediment and minerals in the water used for ice making. Your
evaporator plate is one of the most important pieces of your ice machine, so it
should be cared for accordingly.
9.SCALE BUILDUP
As water travels from the clouds, through the soil, and eventually into your ice
machine, it may pick up small, microscopic minerals along the way. When this
water runs through your ice machine, these mineral deposits can be left along
way, and can build up over time. In doing so, your ice machine will create ice

less efficiently. Scale buildup is one of the most common causes of machine
malfunction. Everpure provides more information on scale buildup, and details
how to identify which minerals are most present in your water. Scale buildup
can be minimized and prevented with a proper water filter, and it can be
removed with any of the scale removal products found at Ice Machines Plus as
well.
10. DIRTY CONDENSER
Dust on Ice Machine Condenser The dust on this condenser is inhibiting airflow
to the ice machine. The condenser coils can be found behind the vents on the
sides or top of your ice machine (air cooled models). Through these vents,
warm air is filtered out and away from your ice machine to allow it to make ice
with greater ease and to keep the unit cool. These coils however, can collect
dust, dirt, and grease which can inhibit the transfer of heat away from the ice
machine. In the case of dust and dirt, you can easily wipe them away with a
moist towel with little effort. If it is grease buildup, a deeper clean may be
warranted, usually one that makes use of a cleaning solution or chemical if the
situation is exceptionally bad.
11.WATER ISSUES
Obviously, water is required to make ice. So, if your ice machine is not making
ice, you may need to check that your water supply is adequately connected and
providing water to your ice machine. If the water is warmer, it may take longer
for your ice machine to create ice. The optimal temperature for water used in
your ice machine is 50 degrees Fahrenheit.
TROUBLESHOOTING
Troubleshooting of an ice maker is very important if you have problems with it.
If you are having problems making ice with your ice maker then this is a very
serious issue which will need to correct. If you are suffering from problems with
your ice maker then there are a few simple things that you can do to diagnose
and correct the problem .
1.CHECKING THE LINES

The first thing that you should do is check the water supply lines to ensure that
they are not blocked. Sometimes ice can block the lines which may mean that
they need to be cleaned out. If the fill tube is frozen then this might need to be

defrosted so that you can use it again. If the tube is too badly damaged then it
might need to be replaced.
2.BROKEN LINES
If the lines break or become damaged then they can prevent water from getting
to the ice maker. In this case the lines will need to be replaced so that you can
restore the functioning of your ice maker.
3.NOT CONNECTED TO WATER

It's also worthwhile checking the connections between your freezer and the
water lines. If your freezer is not connected to the water lines, or if the tap is
turned off then this will cause the same problems. There will not be any water
available to make into ice. This is a very easy problem to correct and shouldn't
take long to identify. If you are not able to get any water from your freezer
either then this suggests it could be a problem with the water supply. You will
probably hear a buzzing noise when you're trying to make ice, this means that
the freezer is trying to pump water which isn't available.
4.VALVES
The valve which is connected to the tap could also be damaged or broken.
Check the valve opens and closes correctly and consider replacing it if it is
damaged.
5.TOO WARM
If the freezer is set to a too warm temperature then this will also create problems
with producing ice. You will also notice that this isn't keeping your food as long
as it should do. To correct this problem you will need to change the thermostat
on your freezer so that it is lower.
TROUBLESHOOTING AN ICE MAKER: ICE TASTES BAD

When troubleshooting ice makers there are a number of steps that you can take
to find the cause of the problem and put it right. One common problem is when
the ice doesn't taste right. If the ice tastes bad then there can be a number of
reasons for this.
When working out why the ice tastes bad there are several things that you will
need to consider. The problem could also be caused by one or more of the
factors which could make solving it slightly move complicated.

1.WASHING THE ICE BIN
The ice bin is the container which stores the ice, if this becomes dirty or moldy
it can make the ice taste nasty. Simply taking the ice bin out of the freezer and
then washing it will solve the problem. Read the instruction manual to find out
where the ice bin is located.Unscrew or unclip the ice bin and then wash it in
warm soapy water. Dry the ice bin and then reassemble it. Place it back into the
fridge and then find out whether it has resolved the problem.
2.FLUSHING THE SUPPLY LINE

The supply line carries water to the ice maker. Sometimes the water can become
stale which is why you might be able to cure the problem by flushing the water
pipe out with fresh clean water. Test the ice maker after flushing the supply line
to ensure that the water is now clean that the ice doesn't taste bad.
3.WATER INLET VALVE

If the water inlet valve is damaged then this could also be because of the water
inlet valve. If the water inlet valve is damaged or broken. This can leave the
water exposed to smells inside your fridge which can make the ice taste bad.The
water inlet valve will need replacing if it is damaged or broken. By replacing
this water inlet valve you will be able to correct the problem and enjoy better
tasting ice.
4.REPLACING THE WATER FILTER

There is a water filter inside of your fridges ice maker which is designed to
remove particles and bad smells from the water. The water filter needs to be
removed and replaced.The water filter should be replaced with the same type
and model suitable for your freezer. Use your freezers model to ensure that the
correct filter is fitted.
5.SUPPLY LINE FILTER

If your fridge doesn't already have a supply line filter then fitting one could
greatly help to reduce problems with the ice tasting bad. These can be fitted to
virtually any ice maker.

CHAPTER 5
CALCULATION
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.
EFFICIENCY CALCULATION
Mini ice plant Efficiency Calculation is described in this article COP of an Ice
plant model using refrigerant R134a The coefficient of performance of
refrigeration plant is given by the ratio of heat absorbed, by the refrigerant when
passing through the evaporator or the system, to the working input to the
compressor to compress the refrigeration. The input and outlet temperature and
pressure for the compressor of the model is measured and the corresponding
properties of R134a are depicted below in the Table 3 and Table 4.
PROPERTIES OF SATURATED R-134a

PROPERTIES OF SUPERHEATED R-134a
CALCULATION
Suction pressure = 5 psi
Discharge pressure=111 psi
1 psi = 0.06897 bar
111 psi = 0.06897*111 = 7.65bar
5 psi = 0.06897*5 = .34 bar
T1 ( discharge gas temp) = 390C
T2(condenser output) = 27.4OC
T3(expansion temp) = 25.5OC
T4(suction temp) = 27OC
T5(temp of brine) = -5OC
COP = Refrigeration effect/work done
= (h1-h4)/(h2-h1)
According to p-h diagram
h2 = 412KJ/KG
h1 = 368 KJ/KG
h3 = 237 KJ/KG
h4 = 237 KJ/KG

cop = (368-237)/(412-368)
=131/44
Cop=2.99
Actual cop = 0.5*thertical cop
= 0.5*2.99
=1.495
Refrigeration effect = (h1-h4)
=(580-450)
=120 KJ/KG
Cooling capacity = 1 kg of ice in 5 hrs
Insulation = thermacol
Number of ice canes= 1 to 4 (But we have taken 2 canes)
Tank → evaporator →l*b*h → 45*12.5*30
= 16.87 litre
Tank →50*30*17.5 = 20 litre
Size of ice cane = 8*10*25
=2 litre
Smaller ice cane = 6*8*18
=.8 litre
Brine solution = 33.75-2*6
=21.75litre*(1/20)
=1.75kg
Time required to obtain temp = 6 hrs
Total weight of ice cane = 2 kg

Initial temperature of water in ice cane = 28OC
Final temp=0oC
Final temp of brine = -2OC
Time required = 6hrs
Initial temp of brine setup = 15OC
CALCULATION-2
Suction pressure =4.4 psi

Discharge pressure=113 psi
1 psi = 0.06897 bar
113 psi = 0.06897*113 = 7.79 bar
4.4 psi = 0.06897*4.4= 0.341bar
T1 (discharge gas temp) = 37.30C
T2(condenser output) = 24.9OC
T3(expansion temp) = 23OC
T4(suction temp) = 27OC
T5(temp of brine) = -2OC
COP = Refrigeration effect/work done

= (h1-h4)/(h2-h1)
According to p-h diagram

h2 = 412 KJ/KG
h1 = 368 KJ/KG
h3 = 237 KJ/KG
h4 = 237 KJ/KG
COP = (372-243)/(423-372)
=129/51
COP=2.52
Actual cop = 0.5*theoretical cop
= 0.5*2.52
=1.264
Refrigeration effect = (h1-h4)

=(372-243)
=129 KJ/KG
RESULT:
COP THEORETICAL COP ACTUAL
1.READING 2.READING
2.99 1.495
2.52 1.264

CHAPTER 6
APPLICATION OF MINI ICE PLANT
Today, there are around 2 billion household refrigerators and over 40 million
square meters of cold-storage facilities operating worldwide. In the INDIA
alone, over 8 million refrigerators are sold each year. Beyond our homes,
restaurants and supermarkets, refrigeration has global applications with positive
impact upon the economy, technology, social dynamics, health, and the
environment.
Global Economic Applications
The refrigeration industry employs more than 2 million people worldwide,
especially in the service sectors. Refrigeration is necessary for the
implementation of many current or future energy sources (hydrogen liquefying
for alternative fuels in the automotive industry and thermonuclear
fusion production for the alternative energy industries).
• The petro-chemical and pharmaceutical industries also need refrigeration, as

it is used to control and moderate many types of reactions.
• Heat pumps, operating based on refrigeration processes, are frequently used
as an energy-efficient way of producing heat.
• The production and transport of cryogenic fuels (liquid hydrogen and
oxygen) as well as the long-term storage of these fluids is necessary for the
space industry.
• In the transportation industry, refrigeration is used in marine containers,
reefer ships, refrigerated rail cars, road transport, liquefied gas tankers etc.
Global Health Applications
In the food industry, refrigeration contributes to reducing post-harvest losses
while supplying safe, foods to consumers by enabling perishable foods to be
preserved at all stages from production to consumption by the end-user.
In the medical sector, refrigeration is used for vaccine, organs, stem cells’ and
others’ storage, while cryotechnology is used in surgery and other medical
research courses of action.
Global Environmental Applications
Refrigeration is used in biodiversity maintenance based on
the cryopreservation of genetic resources (cells, tissues, and organs of plants,
animals and micro-organisms);
Refrigeration enables the liquefaction of CO2 for underground storage, allowing
the potential separation of CO2 from fossil fuels in power stations via cryogenic
technology.

THE ENVIRONMENTAL DIMENSION OF REFRIGERATION
At an environmental level, the impact of refrigeration is due to: atmospheric

emissions of refrigerant gases used in refrigerating installations and the energy
consumption of these refrigerating installations which contribute to CO2
emissions – and consequently to global warming – thus reducing global energy
resources. The atmospheric emissions of refrigerant gases are based on the leaks
occurring in insufficiently leak-tight refrigerating installations or during
maintenance-related refrigerant-handling processes.
Depending on the refrigerants used, these installations and their subsequent

leaks can lead to: ozone depletion (chlorinated refrigerants like CFCs and
HCFCs) and/or global warming, by exerting an additional greenhouse effect
(fluorinated refrigerants: CFCs,HCFCs and HFCs). From a consumption point
of view, it is necessary to remember that households are responsible for about
26.2% of the global energy consumption. While the Montreal Protocol banned
the use of CFCs followed by HCFCs, the global efforts aimed at reducing the
environmental impact of refrigeration have taken three courses of action:
1. Reduction in direct emissions of fluorocarbons in the atmosphere based

on better containment of refrigerants.
2. Refrigerant charge reduction and development of alternative

refrigerants with negligible or no climate impact.
3. Reduction in energy consumption due to the increasing energy

efficiency of refrigerating plants.
ALTERNATIVE REFRIGERANTS
In their continuous research of methods to replace ozone-depleting refrigerants

and greenhouse refrigerants (CFCs, HCFCs and HFCs, respectively) the
scientific community together with the refrigerant industry came up with
alternative all-natural refrigerants which are eco-friendly. According to a report
issued by the UN Environment Programme, “the increase in HFC emissions is
projected to offset much of the climate benefit achieved by the earlier reduction
in the emissions of Ozone depleting substances’’ Among non-HFC refrigerants
found to successfully replace the traditional ones are ammonia, hydrocarbons
and carbon dioxide.

• AMMONIA
The history of refrigeration began with the use of ammonia. After more than
120 years, this substance is still the preeminent refrigerant used by
household, commercial and industrial refrigeration systems. The major
problem with ammonia is its toxicity at relatively low concentrations. On the
other hand, ammonia has zero impact on the ozone layer and very low global
warming effects. While deaths caused by ammonia exposure are extremely
rare, the scientific community has come up with safer and technologically
solid mechanisms of preventing ammonia leakage in modern refrigerating
equipment. This problem out of the way, ammonia is considered an eco-
friendly refrigerant with numerous applications.
• CARBON DIOXIDE (CO2)
Carbon dioxide has been used as a refrigerant for many years. Just like
ammonia, it has fallen in almost complete disuse due to its low critical point
and its high operating pressure. Carbon dioxide has zero impact on the ozone
layer, while its global warming effects are also negligible. Modern
technology is solving such issues and CO2 is widely used today as an
alternative to traditional refrigeration in several fields: industrial
refrigeration (CO2 is usually combined with ammonia, either in cascade
systems or as a volatile brine), the food industry (food and retail
refrigeration), heating (heat pumps) and the transportation industry (transport
refrigeration).
• HYDROCARBONS
Hydrocarbons are natural products with high thermodynamic properties, zero

ozone-layer impact and negligible global warming effects. One issue with
hydrocarbons is that they are highly flammable, restricting their use to
specific applications in the refrigeration industry.
In 2011, the EPA has approved three alternative refrigerants to replace hydro
fluorocarbons (HFCs) in commercial and household freezers via the Significant
New Alternatives Policy (SNAP) program. The three alternative refrigerants
legalized by the EPA were hydrocarbons propane, isobutane and a substance
called HCR188C a hydrocarbon blend (ethane, propane, isobutane and n-
butane). HCR188C is used today in commercial refrigeration applications
(supermarket refrigerators, stand-alone refrigerators and refrigerating display
cases), in refrigerated transportation, automotive air-conditioning systems and

retrofit safety valve (for automotive applications) and residential window air-
conditioners.
THE FUTURE OF REFRIGERATION
In October 2016, negotiators from 197 countries have reached an agreement to

reduce emissions of chemical refrigerants that contribute to global warming, re-
emphasizing the historical importance of the Montreal Protocol and aiming to
increase its impact upon the use greenhouse gases besides the efforts made to
reduce ozone depletion caused by the chlorofluorocarbons. The agreement,
closed at a United Nations meeting in Kigali, Rwanda set the terms for a rapid
phasedown of hydrofluorocarbons (HFCs) which would be stopped from
manufacturing altogether and have their uses reduced over time.
The UN agenda and the Rwanda deal aims to find a new generation of
refrigerants to be safe from both an ozone layer and greenhouse effect point of
view. The legally binding agreement could reduce projected emissions by as
much as 88% and lower global warming with almost 0.5 degrees Celsius (nearly
1 degree Fahrenheit) by 2100.

SAFETY PROVISIONS :
1.HANDLING REFRIGERANT CONTROL VALVES SAFELY
General For proper performance, refrigerant control valves used in large

commercial and industrial systems must be well designed and well built to
withstand the extreme conditions they are regularly subjected to.
Safety is always a primary concern for all personnel working on such valves be
qualified to work on refrigeration systems. The following safety procedures
shall be considered for both halocarbon system and those using ammonia
refrigerant.
a) Avoid altering or modifying any refrigerant valves or regulators

without checking such changes with the manufacturer. Threaded parts
should not be over torqued by using over-sized wrenches, wrench
extensions, or by hammering the wrench handle. It is important to follow
torque requirements for bolts, screws, and other threaded parts.
b) All spare parts for corrosion shall be checked before installation. Spare
part numbers should also be checked against current valve assembly
literature to make sure the parts are up to date.
c) Liquid shock can cause tremendous pressure increase in liquid lines

that end in solenoid valves or regulators with electric shutoffs, especially
in long runs of pipe sized 1½ inch and up.
d) Suction shock can occur when there is a sudden large-volume release

of defrost pressure into a low pressure suction line. This can cause even
large pipe lines to shake and bend. If such shocks repeatedly occur, they
can lead to failure at the piping system’s weakest point.
2 LIQUID EXPANSION PRECAUTIONS
2.1 In liquid lines or other lines that may contain substantial amounts of liquid
refrigerant, take care to avoid damage because of liquid expansion when a
section of line is isolated by positive shut off valves. This condition may occur
whenever the ambient temperature is higher than the liquid temperature. This
can happen in liquid lines, and other refrigerant or oil lines.
2.2 When low temperature lines are used, as in a liquid over-feed (recirculation)
system, and if these lines or control valves become exposed to warm ambient

conditions, extra care shall be provided because liquid expansion can occur very
rapidly.
2.3 Check valves should never be installed at the inlet of either a solenoid valve
or a regulator that has electric solenoid pilot shut-off features. Check valves
should also never be installed at the inlet of an outlet regulator in a system
where liquid may be trapped between the two valves. When needed, check
valve shall be installed on the outlet side of such valves.
2.4 Any hand valves in a system that could trap liquid when closed should be
marked with a warning against accidental closing.
2.5 Liquid refrigerant must be removed before closing hand valves on both
sides of a control valve or any other component. Liquid must also be removed
before closing a hand valve at the inlet of a solenoid valve or regulator with
positive electric shut-off, or some outlet pressure regulators, or at the outlet of a
check valve, unless these valves are manually open.
2.6 To protect personnel, product, and plant, all liquid from the section to be
isolated shall be removed before closing hand valves. Control valves shall
remain open when removing liquid. Manufacturer’s service and maintenance
instructions shall be checked before trying to dismantle a valve.
2.7 Relief devices or methods shall be used in all parts of a system where liquid
can become trapped and liquid expansion can occur. These valves shall be
installed in accordance to all applicable safety standards and codes, in
compliance to the manufacturer’s instructions and generally known safety
practices.
3 PRESSURE TESTING
3.1 Every segment of a refrigeration system, including control valves, should be

field pressure tested before being insulated or put into operation. Correct high
and low side pressures and proper refrigerant or gas for pressure testing shall be
used.
3.2 Use of halocarbons or CO2 to test an ammonia system or ammonia to test a

halocarbon system, or use of system’s compressor to build up test pressures
shall not be permitted.

CHAPTER 7
TOOLS USED
Mechanical Engineering Workshop is a place where students acquire

knowledge on the operation of various processes involved in manufacturing and
production. The Workshop Practice course makes students competent in
handling practical work in engineering environment. Mechanical Engineering
Workshop is also involved in different maintenance/repair works.
TOOLS BOX

MACHINE SHOP: Machine shop is a place in which metal parts are cut to the
required size and put together to form mechanical units or machines. The
machines so made are to be used directly or indirectly in the production of
necessities and luxuries of civilization. Machine shop is the base of all
mechanical production.
FITTING SHOP: Fitting shop is a place where fitting or assembling work is

carried out. Some repair / maintenance and Die punch work is also carried out
in Fitting shop.
SCREW DRIVER
A screwdriver is a tool, manual or powered, for turning (driving or

removing) screws. A typical simple screwdriver has a handle and a shaft, and a
tip that the user inserts into the screw head to turn it. The shaft is usually made
of tough steel to resist bending or twisting. The tip may be hardened to resist
wear, treated with a dark tip coating for improved visual contrast between tip
and screw—or ridged or treated for additional 'grip'. Handles are typically
wood, metal, or plastic[1] and usually hexagonal, square, or oval in cross-section
to improve grip and prevent the tool from rolling when set down. Some manual
screwdrivers have interchangeable tips that fit into a socket on the end of the
shaft and are held in mechanically or magnetically. These often have a hollow

handle that contains various types and sizes of tips, and a versible ratchet action
that allows multiple full turns without repositioning the tip or the user's hand.
A screwdriver is classified by its tip, which is shaped to fit the driving
surfaces—slots, grooves, recesses, etc.—on the corresponding screw head.
Proper use requires that the screwdriver's tip engage the head of a screw of the
same size and type designation as the screwdriver tip. Screwdriver tips are
available in a wide variety of types and sizes
HAMMER
Hammer Precautions: Using the wrong type of hammer for a given task will
damage the tools or create a hazard. Hardened hammers used on hardened
surfaces will shatter and send splinters in all directions.
HAMMER
USAGE: Ball Peen hammers are heavy and have a lot of mass; they are used to
move thick plate etc. They are never used on sheet metal; it would create more
damage to the surface.
SAFETY ITEMS, SAFETY GLASSES ,FACE SHIELD USAGE:
While in the lab area students and instructors should always wear protective
clothing and eye protection. Students will not be allowed to be in the lab
without safety glasses! Latex Gloves Leather Gloves Ear Plugs Usage: Because
of the wide variety of tools used in the labs, there will be high decibel levels at
times, it is advisable to protect your hearing by usin Screwdrivers Flat
Screwdrivers.

SAFETY PRECAUTIONS: Do not direct working forces toward your body
when using these tools, they can easily slip off the screw head and puncture
anything in its path. Usage: Flat head screwdrivers are used with flat head
screws only. Don't use screwdrivers as pry bars they will break. Philips
Screwdrivers Usage: Philips head screwdrivers are shaped like a" +" on the
head, and should only be used with corresponding size screws. g ear plugs
during those times.

CHAPTER 8
REFERENCE
• R. S. Khurmi
• Google
• R. K. Rajput
• B. L. Singhal
• Wikipedia
• www.indiastudychannel.com
• https://www.slideshare.net

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Mini ice plant

Requirements for the award of the degree

Abhishek Yadav (1424040003)

Under The guidance of

Sunder Deep College Of Engineering & Technology

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Mechanical Engineering Department

Sunder deep college of engineering & technology, Ghaziabad Sign...................

Mr. NEERAJ SARASWAT

Sunder deep college of engineering & technology, Ghaziabad Sign...................

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4. CALCULATION AND TABLE.............................................................

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STRUCTURE:Refrigerant, compressor, expansion valve (flow control device),

DEFINITIONS & TERMINOLOGY

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A refrigerating compressor, as the name indicates, is a machine used to

The hermitically sealed compressor is discussed in details ahead.

HERMETICALLY SEALED, OPEN, OR SEMI-HERMETIC

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Centrifugal compressors use a rotating disk or impeller in a shaped housing to

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In systems involving heat transfer, a condenser is a device or unit used

The selection of the condenser depends of the capacity of the refrigerating

p-h DIAGRAM FOR CONDENSER

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AIR COOLED CONDENSER

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FORCED COOLED CONDENSOR

A liquid receiver will be required if it is necessary to temporarily store

The function of filter dryer is to remove any physical material from

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The expansion device (also known as metric device or throttling device) is an

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p-h DIAGRAM OF SIMPLE REFRIGERATING SYSTEM

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FLOW IN MINI ICE PLANT

PRODUCTION PROCESS IN ICE MAKING

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The Process Flow diagram of Ice manufacturing industry is as follows:

PROCESS FLOW DIAGRAM ICE MAKING INDUSTRY

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1. COMPRESSOR UNIT: This is composed of a motor and compressor set

2. CONDENSER UNIT: Here the high temperature refrigerant coming from

3.EXPANSION UNIT: Here the refrigerant is allowed to expand in the

4. EVAPORATOR TANK: It is a heat exchanger where the heat transfer

FREEZING STORAGE SYSTEM

GENERAL : In order to keep freshness of products preventing shrinkage and

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i) Air convection through: - Natural convection.

ii) Contact system through: - Horizontal type.

iii) Brine system through: - Immersion system.