From the collagen drying rate equation

𝑑𝑊 1
=− 𝑊 −0.85 𝑑𝑡
𝑑𝑡 77.5

Where,
𝑑𝑊 𝑘𝑔𝐻2 𝑂
=
𝑑𝑡 𝑘𝑔 𝑐𝑜𝑙𝑙𝑎𝑔𝑒𝑛 ℎ𝑦𝑑𝑟𝑜𝑙𝑦𝑠𝑎𝑡𝑒 ∙ ℎ𝑟

𝑚𝑎𝑠𝑠 𝑤𝑎𝑡𝑒𝑟 𝑘𝑔
𝑊= ( )
𝑚𝑎𝑠𝑠 𝑐𝑜𝑙𝑙𝑎𝑔𝑒𝑛 ℎ𝑦𝑑𝑟𝑜𝑙𝑦𝑠𝑎𝑡𝑒 𝑘𝑔
𝑡 = 𝑡𝑖𝑚𝑒 (ℎ𝑟𝑠)

Time required for drying:

𝑡 0.087
𝑑𝑊
∫ 𝑑𝑡 = − ∫ 77.5
0 0.25 𝑊 −0.85

T=2.766 hours = 166 mins

Using Q = UA∆𝑇

Where Q= -79,258.40 kJ

𝐽
𝑈 = 3.7
𝑚2 ∙𝑠∙𝐾

∆𝑇 = 𝑇𝑠ℎ𝑒𝑙𝑓 − 𝑇𝑠𝑎𝑚𝑝𝑙𝑒

∆𝑇 = 10 − 25

∆𝑇 = −15𝐾

𝑄
𝐴𝑇 =
𝑈∆𝑇
−79,258.40 𝑘𝐽 1000 𝐽
60 𝑠 𝑥
166 𝑚𝑖𝑛𝑠 𝑥 1 𝑘𝐽
1 𝑚𝑖𝑛
𝐴𝑇 = 𝐽
3.7 𝑥 − 15𝐾
𝑚2 ∙𝑠∙𝐾

𝐴𝑇 = 143.38 𝑚2
From brochure ( ),

𝐴𝑇
𝐴𝑝𝑒𝑟 𝑠ℎ𝑒𝑙𝑓 =
4
143.38
𝐴𝑝𝑒𝑟 𝑠ℎ𝑒𝑙𝑓 =
4

𝐴𝑝𝑒𝑟 𝑠ℎ𝑒𝑙𝑓 = 35.85 𝑚2

1. Condenser design

As per Edward’s Freeze-Drying Application Manual, the purpose of the condenser is to attract
the vapors being sublimed off from the product. Because the condenser is maintained at a lower energy
level relative to the product ice, the vapors condense and turn back into solid form (ice) in the
condenser. The sublimated ice accumulates in the condenser and is manually removed at the end of the
freeze-drying cycle (defrosting).
Thus, the type of condenser to be used is Shell and Tube Condenser since it is the
recommended and widely used in commercial and industrial refrigeration plant. The condensing water
circulated through tubes and the refrigerant is contained in the shell. The end plates being baffled to act
as manifolds to guide the water low through the tubes.
Initial Data (Condenser)

Mass of H2O Sublimed and Desorbed based on Chapter 5,

296.99 𝑘𝑔
𝑚𝑠𝑢𝑏𝑙𝑖𝑚𝑒𝑑 𝑎𝑛𝑑 𝑑𝑒𝑠𝑜𝑟𝑏𝑒𝑑
𝐾𝐽
Latent Heat of Sublimation, 𝜆𝑆𝑢𝑏𝑙𝑖𝑚𝑎𝑡𝑖𝑜𝑛 2,838
𝑘𝑔
𝑊
Thermal Conductivity, U (from engineeringtoolbox.com) 2,000
𝑚2 ∙𝐾
Inlet Temperature, 𝑇1 55.15⁰C
Outlet Temperature,𝑇2 37.4⁰C

Condenser duty:
𝑄𝐺𝑎𝑖𝑛 = − 𝑄𝐿𝑜𝑠𝑡
𝑄𝑊𝑎𝑡𝑒𝑟 𝑆𝑢𝑏𝑙𝑖𝑚𝑒𝑑 = 𝑄𝐶
𝑄𝑊𝑎𝑡𝑒𝑟 𝑆𝑢𝑏𝑙𝑖𝑚𝑒𝑑 = 𝑚𝑠𝑢𝑏𝑙𝑖𝑚𝑒𝑑 𝑎𝑛𝑑 𝑑𝑒𝑠𝑜𝑟𝑏𝑒𝑑 (𝜆𝑆𝑢𝑏𝑙𝑖𝑚𝑎𝑡𝑖𝑜𝑛 )
𝐾𝐽
𝑄𝑊𝑎𝑡𝑒𝑟 𝑆𝑢𝑏𝑙𝑖𝑚𝑒𝑑 = 296.99 𝑘𝑔 𝑥 2838
𝑘𝑔
𝑄𝑊𝑎𝑡𝑒𝑟 𝑆𝑢𝑏𝑙𝑖𝑚𝑒𝑑 = 842,857.62 𝑘𝐽
 Therefore,
𝑸𝑪 = 𝟖𝟒𝟐, 𝟖𝟓𝟕. 𝟔𝟐 𝒌𝑱
Cooling water
t1= 15ᵒC

Superheated Liquid
Vapor T2 = 37.4ᵒC
T1 = 55.15ᵒC

Mass flow Warm water

rate of cooling water: t2= 25ᵒC
Assume that the total drying time is 180 minutes
1000 𝐽
𝑄𝐶 842,857.62 𝑘𝐽 𝑥 1 𝐾𝐽 𝑔 𝒌𝒈
𝒎𝑪𝒘 = = 𝐽 60 𝑠𝑒𝑐 = 1864.37 ≈ 𝟏. 𝟖𝟔
𝐶𝑝𝛥𝑇 4.186 (25 − 15)ᵒ𝐶𝑥 180 𝑚𝑖𝑛𝑠 𝑥 𝑠𝑒𝑐 𝒔𝒆𝒄
𝑔 ᵒ𝐶 1 𝑚𝑖𝑛

Temperature correction factor:

𝑅 = (𝑇1 − 𝑇2 )/( 𝑡1 − 𝑡2 ) = (55.15 − 37.4)ᵒ𝐶/(25 − 15)ᵒ𝐶 = 1.8
𝑆 = (𝑡2 − 𝑡1 )/( 𝑇1 − 𝑡1 ) = (25 − 15)ᵒ𝐶/(48 − 15)ᵒ𝐶 = 0.25
From Figure 12.19, Page 818 of Chemical Engineering Design by Gavin Towler:
𝐹𝑡 = 0.975
 Temperature
difference between
refrigerant and
water:

( 𝑇1 − 𝑡2 ) − ( 𝑇2 − 𝑡1 ) (55.15 − 25)ᵒ𝐶 − (37.4 − 15)ᵒ𝐶

𝛥𝑇𝑙𝑚 = = = 26.08ᵒ𝐶
ln( 𝑇1 − 𝑡2 )/( 𝑇2 − 𝑡1 ) ln( 55.15 − 25)ᵒ𝐶/(37.4 − 15)ᵒ𝐶

Total area, AT:

Assume that the total drying time is 180 minutes
1000 𝐽
𝑄 842,857.62 𝐾𝐽 𝑥
1 𝐾𝐽
𝐴𝑇 = = 𝑊 60 𝑠𝑒𝑐 = 1.53 𝑚2
𝑈𝐹𝑡 ∆𝑇𝐿𝑀 2000 𝑚2 ∙𝐾 𝑥 0.975 𝑥 26.08 𝐾 𝑥 180 min 𝑥 1 𝑚𝑖𝑛
Tube side:
Use ¾ inch schedule 40 steel pipe, 2m long, Square Pitch
Fluid Handled: Water
Mass Flow Rate = 1.86 kg/sec

Number of tubes, NT:

𝐴𝑇 𝐴𝑇 1.53 𝑚2
𝑁𝑇 = = = = 9.12 ≈ 10 𝑇𝑢𝑏𝑒𝑠
𝐴 𝑇𝑢𝑏𝑒 𝜋𝑑𝑜 𝐿 𝜋 𝑥 0.02667 𝑚 𝑥 2 𝑚
For two-tube passes, tubes per pass = 5 tubes

Square pitch tube arrangement:

𝑇𝑢𝑏𝑒 𝑃𝑖𝑡𝑐ℎ, 𝑃𝑇 = 1.25 𝐷𝑜
𝑇𝑢𝑏𝑒 𝑃𝑖𝑡𝑐ℎ, 𝑃𝑇 = 1.25 (26.67 𝑚𝑚)
𝑻𝒖𝒃𝒆 𝑷𝒊𝒕𝒄𝒉, 𝑷𝑻 = 𝟑𝟑. 𝟑𝟑𝟕𝟓 𝒎𝒎 ≈ 𝟑𝟑. 𝟑𝟒 𝒎𝒎
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 0.25 𝐷0
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 0.25 (26.67 𝑚𝑚)
𝑪𝒍𝒆𝒂𝒓𝒂𝒏𝒄𝒆 = 𝟔. 𝟔𝟔𝟕𝟓 𝒎𝒎 ≈ 𝟔. 𝟔𝟕 𝒎𝒎

Shell side:
Fluid Handled: R-507
Mass Flow Rate = 0.206 kg/sec
Bundle diameter, Db:
From Table 12.4, Page 809 of Chemical Engineering Design by Gavin Towler:

𝑘𝑙 = 0.156
𝑛𝑙 = 2.291
1 1
𝑁𝑇𝑢𝑏𝑒 𝑛𝑙 4 2.291
𝐷𝑏 = 𝑑𝑜 ( ) = 26.67 𝑚𝑚 ( ) = 109.9 𝑚𝑚
𝑘𝑙 0.156
𝑫𝒃 = 𝟏𝟎𝟗. 𝟗 𝒎𝒎

From Fig.12-10, p. 808 of Chemical Engineering Design by Gavin Towler

Since the minimum for Bundle Diameter is 0.2

m. Therefore, the Bundle Clearance used
is 10mm.

Shell diameter, DS:

 𝐷𝑠 = 109.9 𝑚𝑚 + 10 𝑚𝑚 = 119.90 𝑚𝑚
Since the shell inside diameter is less than 300 mm, therefore the available pipe should be used:

Shell
Diameter = 202.70
mm

Baffle diameter:

𝐵𝑎𝑓𝑓𝑙𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐷𝑆 − 1.60 𝑚𝑚

𝐵𝑎𝑓𝑓𝑙𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 119.9 𝑚𝑚 − 1.60 𝑚𝑚
𝑩𝒂𝒇𝒇𝒍𝒆 𝑫𝒊𝒂𝒎𝒆𝒕𝒆𝒓 = 𝟏𝟏𝟖. 𝟑𝟎 𝒎𝒎

Baffle spacing:
Baffle Spacing ranges from 0.2-1.0 of Shell diameter, optimum range: 0.2 – 0.3
𝐵𝑎𝑓𝑓𝑙𝑒 𝑆𝑝𝑎𝑐𝑖𝑛𝑔 = 0.25 (𝐷𝑆 )
𝐵𝑎𝑓𝑓𝑙𝑒 𝑆𝑝𝑎𝑐𝑖𝑛𝑔 = 0.25 (118.30 𝑚𝑚)
𝑩𝒂𝒇𝒇𝒍𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 = 𝟐𝟗. 𝟓𝟖 𝒎𝒎

Shell thickness:
𝑝𝐷
𝑡𝑆 = +𝐶
2𝑆𝑒
P = Pressure of R-507 at 55.15oC = 226.32 psi

Working stress, SW:

Source: Chemical Engineering Handbook, 8th Ed.
For UNS G10200 Carbon Steel
𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ, 𝑆𝑢𝑙𝑡 : 485 𝑀𝑃𝑎 ≈ 70,362.6958 𝑝𝑠𝑖

𝑆𝑊 = 𝑆𝑢𝑙𝑡 × 𝐹𝑆 × 𝐹𝑚 × 𝐹𝑎 × 𝐹𝑟
where:
Fs = 0.25; for temperatures up to 650oC
Fm=1.0; for grade A or high tensile strength carbon steels
Fa = 1.0; for non-radiograph vessels
Fr = 1.0; for plate thickness of the shell/head at any welded joints do not exceed 5/4 in.
𝑆𝑊 = 70,362.6958 𝑥 0.25 𝑥 1.0 𝑥 1.0 𝑥 1.0
𝑆𝑊 = 17,590.6740 𝑝𝑠𝑖

Shell thickness, ts:

𝑝𝐷
𝑡𝑆 = 2𝑆𝑒 + 𝐶
where:
C = 1/16 in
P = 253 psi; pressure of R-507 at 48oC
e = 0.80; for double welded V-butt
S = 17,590.6740 psi; working stress
 D = Ds = 202.70 mm ≈ 7.9779 in
(253 𝑝𝑠𝑖)(7.9779 𝑖𝑛) 1
𝑡𝑆 = +
2(17,590.6740 𝑝𝑠𝑖)(0.80) 16
𝑡𝑆 = 0.206𝑖𝑛 ≈ 0.0052 𝑚 ≈ 5.52 𝑚𝑚
𝒕𝑺 = 𝟓. 𝟓𝟎 𝒎𝒎 (insulation thickness must be expressed in a 0.5 mm interval)

Condenser configuration:
Installation of condenser falls into two categories: internal and external condenser. An internal
condenser is cheaper and provides unrestricted vapor flow. An external condenser is supplied with an
isolation valve to separate the product from the condenser, which protects the product from
reconstitution during power loss, and keeps the condensate out of the clean room environment. To
prevent the thermal denaturation and to protect the purity of the Collagen in the process, the chosen
configuration for the condenser is to be external.

2. Evaporator design

The Shell and Tube type of evaporators are widely used in the large refrigeration systems. The
evaporators in these systems are commonly known as the chillers. The chillers comprise of number of
the tubes that are inserted inside the shell.
Initial Data (Evaporator)
Q based on Chapter 5 201,280.42 𝑘𝐽
𝑊
Thermal Conductivity, U (from engineeringtoolbox.com) 2,000 2
𝑚 ∙𝐾
Inlet Temperature, 𝑇1 -40⁰C
Outlet Temperature,𝑇2 -30⁰C

Evaporator Diagram
Warm water
t1= 25ᵒC

Mixture of vapor Vapor

and liquid T2 = -30ᵒC
T1 = -40ᵒC
Cold water
t2= 15ᵒ
C

Temperature correction factor:

𝑅 = (𝑇1 − 𝑇2 )/( 𝑡1 − 𝑡2 ) = [−40 − (−30)]ᵒ𝐶/(15 − 25)ᵒ𝐶 = 1.0
 𝑆 = (𝑡2 − 𝑡1 )/( 𝑇1 − 𝑡1 ) = (15 − 25)ᵒ𝐶/(−40 − 25)ᵒ𝐶 = 0.1538

From Figure 12.19, Page 818 of Chemical Engineering Design by Gavin Towler:
𝐹𝑡 = 0.989

Temperature
difference between
refrigerant and
water:

( 𝑇1 − 𝑡2 ) − ( 𝑇2 − 𝑡1 ) (−40 − 25)ᵒ𝐶 − (−30 − 15)ᵒ𝐶

𝛥𝑇𝑙𝑚 = = = 54.39 𝐾
ln( 𝑇1 − 𝑡2 )/( 𝑇2 − 𝑡1 ) ln( − 40 − 25)ᵒ𝐶/(−30 − 15)ᵒ𝐶

Total area, AT:

Assume that the total drying time is 180 minutes
1000 𝐽
𝑄 201,280.42 𝑘𝐽 𝑥 1 𝐾𝐽
𝐴𝑇 = = 𝑊 60 𝑠𝑒𝑐 = 0.5732 𝑚2
𝑈𝐹𝑡 ∆𝑇𝐿𝑀 2000 𝑚2 ∙𝐾 𝑥 0.989 𝑥 7.38 𝐾 𝑥 180 min 𝑥 1 𝑚𝑖𝑛

Tube side:
Use ¾ inch schedule 40 steel pipe, 2m long, Square Pitch
Fluid Handled: Water
Mass Flow Rate = 1.86 kg/sec

Number of tubes, NT:

𝐴𝑇 𝐴𝑇 0.5732 𝑚2
𝑁𝑇 = = = = 3.42 ≈ 4 𝑇𝑢𝑏𝑒𝑠
𝐴 𝑇𝑢𝑏𝑒 𝜋𝑑𝑜 𝐿 𝜋 𝑥 0.02667 𝑚 𝑥 2 𝑚
For Two Tube Passes, Tube per Pass = 2 Tubes

Square-pitch tube arrangement:

𝑇𝑢𝑏𝑒 𝑃𝑖𝑡𝑐ℎ, 𝑃𝑇 = 1.25 𝐷𝑜
𝑇𝑢𝑏𝑒 𝑃𝑖𝑡𝑐ℎ, 𝑃𝑇 = 1.25 (26.67 𝑚𝑚)
 𝑻𝒖𝒃𝒆 𝑷𝒊𝒕𝒄𝒉, 𝑷𝑻 = 𝟑𝟑. 𝟑𝟑𝟕𝟓 𝒎𝒎 ≈ 𝟑𝟑. 𝟑𝟒 𝒎𝒎
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 0.25 𝐷0
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 0.25 (26.67 𝑚𝑚)
𝑪𝒍𝒆𝒂𝒓𝒂𝒏𝒄𝒆 = 𝟔. 𝟔𝟔𝟕𝟓 𝒎𝒎 ≈ 𝟔. 𝟔𝟕 𝒎𝒎

Shel side:
Fluid Handled: R-507
Mass Flow Rate = 0.205 kg/sec

Bundle Diameter, Db:

From Table 12.4, Page 809 of Chemical Engineering Design by Gavin Towler:

𝑘𝑙 = 0.156
𝑛𝑙 = 2.291
1 1
𝑁𝑇𝑢𝑏𝑒 𝑛𝑙 4 2.291
𝐷𝑏 = 𝑑𝑜 ( ) = 26.67 𝑚𝑚 ( ) = 109.9031 𝑚𝑚
𝑘𝑙 0.156
𝑫𝒃 = 𝟏𝟎𝟗. 𝟗𝟎𝟑𝟏 𝒎𝒎 ≈ 𝟏𝟎𝟗. 𝟗𝟎 𝒎𝒎
From Fig.12-10, p. 808 of Chemical Engineering Design by Gavin Towler

Since the minimum for Bundle

Diameter is 0.2 m. Therefore, the
Bundle Clearance used is
10mm.
Shell diameter, DS:

𝐷𝑠 = 109.9031 𝑚𝑚 + 10 𝑚𝑚 = 119.9031 𝑚𝑚
Since the shell inside diameter is less than 300 mm, therefore the available pipe should be used:

Shell

Diameter = 202.70 mm

Baffle diameter:
𝐵𝑎𝑓𝑓𝑙𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐷𝑆 − 1.60 𝑚𝑚
𝐵𝑎𝑓𝑓𝑙𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 119.9031 𝑚𝑚 − 1.60 𝑚𝑚
𝑩𝒂𝒇𝒇𝒍𝒆 𝑫𝒊𝒂𝒎𝒆𝒕𝒆𝒓 = 𝟏𝟏𝟖. 𝟑𝟎𝟑𝟏 𝒎𝒎 ≈ 𝟏𝟏𝟖. 𝟑𝟎 𝒎𝒎

Baffle spacing:
Baffle Spacing ranges from 0.2-1.0 of Shell diameter, optimum range: 0.2 – 0.3
𝐵𝑎𝑓𝑓𝑙𝑒 𝑆𝑝𝑎𝑐𝑖𝑛𝑔 = 0.25 (𝐷𝑆 )
𝐵𝑎𝑓𝑓𝑙𝑒 𝑆𝑝𝑎𝑐𝑖𝑛𝑔 = 0.25 (119.9031 𝑚𝑚)
𝑩𝒂𝒇𝒇𝒍𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 = 𝟐𝟗. 𝟗𝟕𝟓𝟖 𝒎𝒎 ≈ 𝟐𝟗. 𝟗𝟖 𝒎𝒎

Working stress, SW:

Source: Chemical Engineering Handbook, 8th Ed.
For AISI 316L Stainless steel
𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ, 𝑆𝑢𝑙𝑡 : 558 𝑀𝑃𝑎 ≈ 80,953.37 𝑝𝑠𝑖
 𝑆𝑊 = 𝑆𝑢𝑙𝑡 × 𝐹𝑆 × 𝐹𝑚 × 𝐹𝑎 × 𝐹𝑟
where:
Fs = 0.25; for temperatures up to 650oC
Fm=1.0; for grade A or high tensile strength stainless steel
Fa = 1.0; for non-radiograph vessels
Fr = 1.0; for plate thickness of the shell/head at any welded joints do not exceed 5/4 in.

𝑆𝑊 = 80,953.37 𝑥 0.25 𝑥 1.0 𝑥 1.0 𝑥 1.0

𝑆𝑊 = 20,238.34 𝑝𝑠𝑖

Shell thickness, ts:

𝑝𝐷
𝑡𝑆 = +𝐶
2𝑆𝑒
where:
C = 1/16 in
P = 0.4697 psi; pressure of Water at 25oC
e = 0.80; for double welded V-butt
S = 20,238.34 psi; working stress
D = Ds = 202.70 mm ≈ 7.9779 in

(0.4697 𝑝𝑠𝑖)(7.9779 𝑖𝑛) 1

𝑡𝑆 = +
2(20,238.34 𝑝𝑠𝑖)(0.80) 16
𝑡𝑆 = 0.0626𝑖𝑛 ≈ 0.00159 𝑚 ≈ 1.59 𝑚𝑚
𝒕𝑺 = 𝟐. 𝟎𝟎 𝒎𝒎 (insulation thickness must be expressed in a 0.5 mm interval)

3. Refrigeration system

A B

Process Condenser Refrigeration System Initial Data

Q based on Chapter 5 201,280.42 kJ
 Density of R507 at -40ºC 𝑘𝑔
19.70
𝑚3
Ratio of Specific Heats of R507 1.114
Process Condenser Temperature -35⁰C
Evaporator Temperature -30⁰C
Condenser Temperature 37⁰C

Based on ASHRAE Refrigeration Handbook 2010, the evaporator temperature must be 5ºC lower
than the process condenser temperature. Thus, the condenser temperature should be 10 ⁰C higher than
the ambient temperature. The ambient temperature is assumed 27 ⁰C making 37 ⁰C as condenser
temperature.
Thus, consider refrigerant used for Refrigeration System is R-507 as the most recommended for
the application of medium and low temperature commercial and industrial refrigeration

Mass flow rate of refrigerant:

𝑄𝐹𝑟𝑒𝑒𝑧𝑖𝑛𝑔
𝑚𝑅−507 =
(𝐻𝐴 − 𝐻𝐷 )

where:

𝑚𝑅−507 = 𝑀𝑎𝑠𝑠 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 𝑜𝑓 𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑛𝑡

𝑄𝐹𝑟𝑒𝑒𝑧𝑖𝑛𝑔 = 𝐻𝑒𝑎𝑡 𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑜𝑓 𝐹𝑟𝑒𝑒𝑧𝑖𝑛𝑔

𝐻𝐴 = 𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑉𝑎𝑝𝑜𝑟 𝑆𝑡𝑎𝑡𝑒

𝐻𝐷 = 𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝐿𝑖𝑞𝑢𝑖𝑑 𝑆𝑡𝑎𝑡𝑒

State A: Saturated Vapor

𝑇𝐴 = −30ᵒ𝐶
𝑃𝐴 = 0.21234 𝑀𝑃𝑎
𝑘𝐽
𝐻𝐴 = 34.1772
𝑚𝑜𝑙
𝑘𝐽
𝑆𝐴 = 0.1692
𝑚𝑜𝑙 − 𝐾

State B: Superheated Vapor

𝑘𝐽
𝑆𝐴 = 𝑆𝐵 = 0.1692
𝑚𝑜𝑙 𝐾
𝑃𝐵 = 1.56 𝑀𝑃𝑎
Temperature Pressure, MPa Enthalpy, kJ/mol Entropy, kK/mol K
300 1 37.686 0.16087
400 1 37.983 0.19047
300 5 23.498 0.11052
400 5 44.385 0.17014
 By extrapolation:
𝐴𝑡 𝑇 = 55.15℃, 𝑃 = 1.56𝑀𝑃𝑎
H = 35.86 kJ/mol

State C: Saturated Liquid

𝑇𝐶 = 37ᵒ𝐶
𝑘𝐽
𝐻𝐶 = 25.25
𝑚𝑜𝑙

State D: Mixture of Saturated Liquid and Vapor

𝑘𝐽
𝐻𝐶 = 𝐻𝐷 = 25.25
𝑚𝑜𝑙
25.185 − 15.8185
𝑥=
34.1772 − 15.8185
𝑥 = 0.51

Mass flow rate of refrigerant:

Assume that the total drying time is 180 minutes
201,280.42 𝐾𝐽
𝑚𝑅−507 = 𝑘𝐽 1 𝑘𝑚𝑜𝑙 1000𝑚𝑜𝑙 60 𝑠𝑒𝑐
(34.1772 − 25.185) 𝑥 𝑥 𝑥 180 𝑚𝑖𝑛𝑠 𝑥
𝑚𝑜𝑙 98.9 𝑘𝑔 1𝑘𝑚𝑜𝑙 1 𝑚𝑖𝑛
𝒌𝒈
𝒎𝑹−𝟓𝟎𝟕 = 𝟎. 𝟐𝟎𝟓
𝒔𝒆𝒄

Theoretical power:
𝑘−1
𝑘 𝑃2 𝑘
𝑊𝑇ℎ𝑒𝑜 = 𝑃1 𝑄1 ( ) [( ) − 1]
𝑘−1 𝑃1

where:

𝑊𝑇ℎ𝑒𝑜 = 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝑃𝑜𝑤𝑒𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡

𝑄1 = 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 𝑜𝑓 𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑛𝑡

𝑃1 = 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒

𝑃2 = 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝐹𝑖𝑛𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒

𝑘 = 𝑅𝑎𝑡𝑖𝑜 𝑜𝑓 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐻𝑒𝑎𝑡𝑠 𝑜𝑓 𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑛𝑡

Volumetric flow rate of refrigerant:

𝑘𝑔 1 𝑙𝑏
𝑚 0.205 𝑠𝑒𝑐 𝑥 0.45359 𝑘𝑔 𝑓𝑡 3
𝑄= = 3 = 8.87
𝜌 19.70 𝑘𝑔 𝑥 1 𝑙𝑏
𝑥
0.02831685 𝑚 𝑠𝑒𝑐
𝑚3 0.45359 𝑘𝑔 1 𝑓𝑡 3
Theoretical compression power:
1.114−1
𝑙𝑏𝑓 144 𝑖𝑛2 𝑓𝑡 3 1.114 226.3 𝑝𝑠𝑖𝑎 1.114
𝑊𝑇ℎ𝑒𝑜 = (2.2 2 𝑥 2
)(8.87 )( ) [( )
𝑖𝑛 𝑓𝑡 𝑠𝑒𝑐 1.114 − 1 2.2 𝑝𝑠𝑖𝑎

1 𝐻𝑃 ∙ 𝑠𝑒𝑐
− 1]( )
550 𝑓𝑡 ∙ 𝑙𝑏𝑓

𝑾𝑻𝒉𝒆𝒐 = 𝟖𝟎. 𝟐𝟏 𝑯𝑷

Actual compressor power requirement:

𝑊𝑇ℎ𝑒𝑜 80.21 𝐻𝑃
𝑊𝐴𝑐𝑡𝑢𝑎𝑙 = =
𝑛𝑒𝑓𝑓 . 70
𝑷𝑨𝒄𝒕𝒖𝒂𝒍 = 𝟏𝟏𝟒. 𝟓𝟗 𝑯𝑷 ≈ 𝟖𝟓. 𝟒𝟓 𝒌𝑾

Horsepowera

1/20, 1/12, 1/8, 1/6, 1/4, 1/3, 1/2, 3/4, 1/2, 11-1/2, 2, 3, 5, 7-1/2, 10, 15, 20, 25, 30, 40, 50,60, 75,
100, 125, 150, 200, 250, 300, 350, 400, 450, 500, 600,
700, 800, 900, 1000, 1250, 1500, 1750, 2000, 2250, 2500, 3000, 3500,
4000, 4500, 5000and up to 30,000

Source: Chemical Process Engineering: Design and Economics by Silla

Since the computed actual power requirement is 114.59 HP, the standard compressor size to
be used is 150 HP based on the table shown above.

Compression ratio requirement:

The initial pressure to be considered in this computation is the ambient pressure.

Final Pressure: Using Thermodynamics Property Table,

𝑇𝐹𝑖𝑛𝑎𝑙 = 55.15ᵒ𝐶
𝑃𝐹𝑖𝑛𝑎𝑙 = 1.56 𝑀𝑃𝑎
𝑅 = 𝑃𝐹𝑖𝑛𝑎𝑙 : 𝑃𝐼𝑛𝑖𝑡𝑖𝑎𝑙 = 1560𝐾𝑃𝑎 ∶ 101.325 𝐾𝑃𝑎
𝑹 = 𝟏𝟓: 𝟏

Compressor type:
The different compressor types have attributes that make them more suitable for different
applications. The attributes like cooling capacity, efficiency, reliability, etc. are key selection factors to
consider. The Figure below shows the capacity and application comparisons between different
compressor types:
 Source: Paul Lin & Victor Avelar’s The Different Types of Cooling Compressors Study
Since the computed actual power requirement is 85.45 kW, the recommended type of compressor will be
used is Reciprocating compressor because it is suited for refrigeration applications ranging in 70 to 1400
kW based on the figure above.

4. Shelf design

From Chapter 5 the capacity enter to the Freeze Dryer:

Mass Density Volume
Purified Collagen Solution (kg) (kg/m3) (m3)
Water-dialysed collagen 1187.97 1,110 1.07
Water 296.99 1,000 0.2699
Total 1616.34 1.34

Volumetric flow rate per batch:

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝑭𝒆𝒆𝒅 = 𝟏. 𝟑𝟒 𝒎𝟑