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CHAPTER I

INTRODUCTION

The Philippines, with an island-dwelling population of more than 93 million and more than

7,100 islands, is a major fishing nation and the world’s second largest archipelagic State. 

In 2012, the Philippines ranked among the major fish producing countries in the world with a

total production of 3.1 million tonnes of fish, crustaceans, mollusks and other aquatic animals.

Aquaculture contributed 790 900 tonnes, or 25.4 percent, to the total fish production. Much of its

production is consumed locally with per caput fish consumption amounting to 32.7 kg in 2011. In

addition, the Philippines is the world’s third largest producer of farmed seaweeds with a production

of 1.8 million tonnes in 2012.

The fisheries and aquaculture industry employed an estimated 1.5 million people in 2010

nationwide; with fisheries accounting for more than 1 million. The fishing industry contributes an

estimated 1.8 percent (valued at 196 billion pesos) to the country’s Gross Domestic Product (GDP) at

current prices, respectively in 2012. In 2013, exports of fish and fishery products were valued at

USD 1.2 billion. Tuna was the top export commodity, followed by shrimp and prawns. In the same

year, imports were worth USD 264 million. 

What does white fish mean?

White fish is not a type of fish — it generally means mildly flavored, quick-cooking fish that

usually isn't very expensive. Popular kinds of white fish are tilapia, cod, bass, grouper, haddock,

catfish, and snapper, and these are great for frying, searing, using in soups and chowders, and baking.
 Page |2

CHAPTER II

PROCESSING

Among the factors, which need to be considered during each step of the processing are:

Hygiene, Temperature control, Relative humidity of air and Handling. There are two primary tasks in

cooling; the fast reduction of the product temperature down to the desired low temperature, and

maintenance of the temperature over a longer period. The fast reduction of the temperature is

achieved by cooling equipment, in connection to some processing operation or storage and the

maintenance at a constant low temperature over a longer period during storage or transport.

2.1 PRODUCT PROCESSING

Filleting involves a number of operations: pretreatment, fish filleting, trimming of fillets,

packaging and storage. These processes generally take place within separate departments of the fish

processing plant. White fish species have a low oil content and, unlike their oily fish counterparts,

are generally gutted, cleaned and sometimes de-headed on board the fishing vessel. The fish are kept

on ice in boxes before being delivered to the fish processing plant. On arrival at the plant, fish may

be re-iced and place in chilled storage until required for further processing.

A. Receiving and Inspection

The raw materials will come from the docking area with an average temperature of 2°C. Fish

inspection is the use of all methods and procedures available in effectively measuring the adequacy

and value of quality control measures. The quantity and condition of the fish is determined. Only the

required species of fish that passed the standard will be processed.

 Page |3

Source: loe.org

Figure 2.A: Fish Inspection

B. Cold Storage (Raw Fish)

After the inspection process, fish is usually stored iced in tubs inside a chilled storage after it

has been landed. The holding time before processing can vary from a couple of hours up to days, and

since the cooling method on board differs between vessels, the temperature of the fresh fish can vary.

The temperature distribution inside a storage room is often inhomogeneous. To ensure that the tubs

experiencing the highest temperature load receive optimum handling, re‐icing must take place.

Source: Taxscan

Figure 2.B: Cold Storage

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C. Thawing

Defrosting of a product is called Thawing. During the freezing process ice is formed into the

fish, thawing involves transferring heat to the fish to melt the ice that formed into the product. The

temperature where the ice that was formed into the product converted back to water occurs

completely is 0°C. Thawing time is the required time to melt the ice in the frozen seafood. The

recommended maximum product temperature is 1°C and maximum water temperature is 21℃

±1.5℃.

Source: http://www.optimarstette.com

Figure 2.C: Fish Thawing

D. Grading

After Thawing the fish, it will be sorted according to their size and quality. This process

involves fish sorting by separating a mixed group of fish into different species, males and females,

immature and mature fish, diseased and clean, etc.

Source: https://marel.com

Figure 2.D: Fish Grader

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E. Removal of Slime

Slime constitutes 2-3% of body weight in some freshwater species. Slime should be removed

by thorough washing. Slime excretion stops before stiffening of the body after death.

Source: http://www.seafoodnews.com

Figure 2.E: Removing Slime

F. Beheading

The head of the fish is cut off as an inedible part and it constitutes 10-20% of the total weight

of the fish. Different cutting procedure can be used; round cut is a cut around the operculum. This

technique is 4-5% more efficient than straight cut commonly used in mechanized systems. The

contoured cut, which runs perpendicular to the fish’s backbone and then at an angle of 45o. This

particular beheading technique is used when filleting, mainly boneless and skinned is the final

product.
 Page |6

Source: http://4.bp.blogspot.com

Figure 2.F: Beheading of fish

G. Gutting

Gutting process is used to remove fish body parts like gonads and swim bladder that consist

about 10-15% of the total body weight. And it is also consists of cutting down the belly, and removal

of internal organs. Fish is cut longitudinally up to the anal opening, and special care is taken to avoid

cutting the gall bladder (FAO, 1984).

Source: VideoBlocks

Figure 2.G: Gutting process

H. Filleting

The removal of the bones which is 10-15% of the total fish biomass is done in Filleting. Fillets

are usually obtained by slicing the fish parallel to the spine, rather than perpendicular to the spine as

is the case with steaks (Amiza et al., 2011).

Source: https://thumbs.dreamstime.com
 Page |7

Figure 2.H: Filleting

I. Skinning

Fish fillets are skinned using automated machines in processing plants. It is comprising of a

swaying blade controlled with a little electric engine and a system of compression springs. One end

of the filet is set in an opening between the blade and pressure component and the tip grasped

manually in a wrench which allows the skin to be pulled off the meat from under the oscillating

knife.

Source: https://media.winnipegfreepress.com

Figure 2.I: Skinning automated machine

J. Packaging (Vacuum Packing)

Double chamber vacuum sealing machine is utilized to vacuum packed processed fish. It

eliminates with air from the package prior to sealing. The reason for vacuum sealing is to remove

oxygen from the container to expand time span of usability of fish product. Material utilized for

packaging is low density polyethylene.

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Source: www.europarl.europa.eu

Figure 2.J: Vacuum Packaging

K. Blast Freezing

Blast freezers for fishery products are generally small rooms in which chilly air is coursed by

at least one fans over an evaporator and around the product to be frozen, which is on racks or

shelves. The essential refrigeration impact is done by Ammonia flowing through a pipe coil

evaporator.

Source: http://www.eurofishmagazine.com

Figure 2.K: Air blast freezers

L. Glazing

Extreme drying prompts harm called "freezer burn". To avoid freezer burn the fish is glazed

before it is placed in frozen storage. The use of a layer of ice to the surface of a frozen product by

splashing is utilized to shield the product from the impacts of drying out and oxidation during cold

storage. The rate of oxidation diminishes in light of the fact that the ice layer bars air from the
 Page |9

surface, the ice layer sublimes instead of the fish beneath. Glaze rate ranges from 2% to 20 %.

Getting the nearest incentive to normal which is 10% will be showered on the fish filet.

Source: Alibaba

Figure 2.L: Glazing machine

M. Packaging

The finish products will now be packed in a plastic container. This will be ready for delivery or

cold storage.

Source: nutrology.blogspot.com

Figure 2.M: Box Packaging

N. Cold Storage (Processed Fish)

To prevent the products from spoilage that are waiting for delivery they are stacked inside the

cold storage. The temperature is -30°C of processed fish and the storage life at this temperature is up

to 8 months. The volume of fish fillet that can be stored in this cold storage is 25 tons which is

equivalent to 10 days production.

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Source: emountaintv.com

Figure 2.N: Finish product

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2.2. PROCESSING FLOW DIAGRAM

Flow chart displaying a typical fresh fish processing line. From the dock to cold storage to

beheading, grading, filleting, packaging and ready to deliver or cold storage.

Source: Ref. Design Fish Fillet (pdf)

Figure 2.2.A: Flow Diagram

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2.3. PLANT LAYOUT

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CHAPTER III

COLD STORAGE

In the industry of production of food there has many problems. One of the problems is

preservation of food. There have many foods that very short of shelf life after being harvested,

because they rot easily. To prevent the rotting of food they process it into the refrigerated or stored to

low temperature conditions after harvesting. To make the food product fresh for a long time.

3.1 Fish Storage

Temperature is a vital factor as to quality and time span of usability of fish. Low storage

temperature is an important factor to maintain the quality of fish as long as possible. Even slight

varieties from appropriate capacity temperature can result in shorter shelf life. It is important to keep

fish as close to 0°C as possible before consumption. Increase in every degree of temperature above

0°C leads to more rapid microbial growth resulting in shorter shelf life. For instance, the shelf life of

cod fillets at 0°C has been estimated 10-12 days, 5-6 days at 4-5°C and only 2-3 days at 10°C.

When fish is frozen, it should be done as quickly as possible and at a very low freezer

temperature (below -20°C). Freezing in a freezer compartment of a refrigerator is slow and can have

negative effects on the texture of fish. The longer fish is kept frozen, the more dry and tough it gets,

and off-odors and off-flavors tend to develop. Furthermore, the surface of the fish gets drier resulting

in white spots due to freeze damage.

Table 3.1: Fish Cold Storage

Design Room Temperature -30˚

Relative humidity 85-90%
Maximum Storage period 9 months
Source: www.fao.org
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The data in the Table 3.1 are the given that need to be included. After the process of fish

fillet, it is place in a crate. The crate that have filled with fish fillet is going to arrange in the pallet.

After being arranged it in the pallet it is going to put in racking system in the cold storage.

3.1.A. Crate

Boxes that stacking only should incorporate interlocking grips between boxes to prevent

sideways movement of boxes in the fish room at sea or during transportation on shore. Plastic and

aluminium boxes can be designed with this facility but not wooden boxes. The grips should allow

staggered patterns of stacking for better utilization of fish room space. Stack only boxes are

volumetrically more efficient than nesting boxes but require far greater storage volume when empty.

Figure 3.A: Crate Design

Table 3.2: Crate Specification

Dimensions L x W x H (mm) 600 x 400 x 125
Volume (liters) 22
Tara weight 1.3 kg
Capacity ice and fish  10 kg

in weight proportion 1:1

Total weight 11.3 kg

The Table 3.2 shown the dimension of crate, volume, weight of crate, capacity of fish that

can crate handle and the total amount of crate that filled of fish fillet. After the fillets were vacuum

packed, it will be loaded and arranged in the crate.

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3.1.B. Pallet

A pallet forms the base structure for a load in order that it may be handled by a fork lift or

pallet truck. A unit load may be built up of a number of smaller unit loads, for example, fish boxes,

on a pallet and transported and handled as a single load making the handling much simpler. They are

particularly useful with regular shaped loads such as fish boxes when they can be stacked one upon

another. If the loads are irregular, or if damage could occur due to crushing, post or box pallets can

be used to stack one upon another.

Figure 3.B: Pallet Design

Table 3.3: Pallet Specification

Dimension L x W x H (mm) 1500 x 1100 x 150

Weight 25 kg
Dynamic 1500 kg
Static 4000 kg

The weight of the pallet is 25 kg empty. Table 3.3 shows the specification of pallet used in

this design.

3.1.C. Stacking
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The stacking is combination of pallet and the crates that will used. The dimension of the pallet

is based on the pallet and the crates. There have also an air space between the crates and space before

the edge of the pallet.

Figure 3.C: Stacking System

Table 3.4 Stacking Specification

Number of crates per pallet 40 pcs

Height of the crates stacked 1250 mm
Total Stacking height 1400 mm
Weight of crate with product 11.3 kg
Weight of product per pallet 452 kg
Overall stacking weight 477 kg
Air space between the crates 100 mm

Table 3.4 shows the dimension and specification of stacking system. The table also shows the

air space between the crates, and weight of the stacking.

Calculation:

For Total Stacking Height:

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To compute the total stacking height, this is given as:

Total Stacking height=¿

Height of the crates stacked + Height of the pallet

Where, height of the crates stacked and the height of the pallet, are 1250 mm and 150 mm

respectively. The Total Stacking Height is equal to 1400 mm.

Total Stacking height=1250 mm+150 mm=1400 mm

For Weight of product per pallet:

To compute the weight of product per pallet, this is given as:

Weight of product per pallet =¿

Number of crates per pallet x Weight of crate with product

Where, number of crates per pallet and weight of crate with product are 40 pcs and 11.3 Kg

respectively. The Weight of product per pallet is equal to 452 Kg.

Weight of product per pallet =40 pcs x 11.3 Kg=452 Kg

For Overall Stacking Weight:

To compute the overall stacking weight, this is given as:

Overall Stacking Weight=¿

Weight of product per pallet + Weight of pallet

Where, weight of product per pallet and weight of pallet are 452 Kg and 25 Kg respectively.

The overall stacking weight is equal to 477 Kg.

Overall Stacking weight=452 Kg+25 Kg=477 Kg

3.1.D. Racking System

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The racks are designing to carry the load of the stacking. The load includes the weight of the

stacking and racks is inside the cold storage.

Figure 3.D.1 Racking System Figure 3.D.2 Front View of Racking System

Table 3.5 Racking Specification

Length 3300 mm
Width 1300 mm
Height 3050 mm
Height of the Stacking in the racking 1350 mm
Total Length Clearance 50 + 25 + 25 + 50 = 150 mm
Total Height Clearance 50 + 50 = 100 mm
Total width clearance 100 + 100 = 200 mm
Total Thickness for Length 50 + 50 + 50 = 150 mm
Total Thickness for Height 100 + 100 + 50 = 250 mm
Number of pallets per racking 4 pcs
Number of crates per racking 160 pcs
Weight of carried by one rack 1908 Kg
Table 3.5 shows the dimension and specification of the racking system. The number of crates

per racking is 160 pcs and total weight carried by one rack is 1908 kg.

Computation:

For Length:

To calculate the length of the racking system, this is given as:

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Length of the Racking=¿

(2 x Length of the pallet )+Total Thickness for Length +Total Length Clearance

Where, 2 times the length of the pallet, the total thickness of length and the total length of the

clearance are 1500 mm, 150 mm and 150 mm respectively.

Length of the racking = ( 2 x 1500 mm ) +150 mm+150 mm=3300 mm

For Width:

To calculate the width of the racking, this is given as:

Width of the racking= pallet width +( Total width clearance)

Where pallet width and the total width clearance are 1100 mm and 200 mm respectively. The

width of the racking is equal to 1300 mm.

Width of the racking=1100 mm+ 200 mm=1300 mm

For Height:

To calculate the height of the racking, this is given as:

Height of the racking=¿

(2 x Height of the Stacking∈the racking)+ Total Thickness for Height +Total Height clearance

Where, 2 times the height of the stacking in the racking, the total thickness for height and the

total height clearance are 1350 mm, 100 mm and 250 mm respectively. The Height of the Racking is

3050 mm.

Height of the racking=(2 x 1350 mm)+100 mm+ 250 mm=3050 mm

For Weight:

To calculate the weight of carried by one rack, this is given as:

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Weight of carried by one rack =¿

Weight of one stacking x Number of stacking per rack

Where, the weight of one stacking times the number of stacking per rack are 477 kg and 4 pcs

respectively. Weight of carried by one rack is equal to 1908 Kg.

Weight of carried by one rack =477 Kg x 4 pcs=1908 Kg

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3.1.E. Forklift

Forklift is a machine or vehicle the used to carry and lift the pallet that have a load of crate. It

is helping to easily carry and transfer the load in their destination.

Figure 3.E-1: Top view of Forklift

Figure 3.E-2: Side view of Forklift

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Table 3.6: Forklift Specification

Model RC5510/15
Load Capacity 1500 kg
Lift height 3910 mm
Turning Radius 1313 mm
Total height 2016 mm
Total width 1067 mm

The load capacity is 1500 kg and the turning radius is 1313 mm. Table 3.6 shows the

specification and dimension of the forklift used in this design.

3.1.F. Doors

Refrigerator door is the passage going to the cold storage. It is automatic to easily open and

close to reduce the air leak. The door dimensions are fit or wide to the dimensions of fork lift to can

passed easily. Door need a good insulator material and thermal resistance for a cold storage.

Source: www.metaflexdoors.com

Figure 3.F: Metaflex Orion Blast Freezer

Table 3.7 Door Specification

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Product Name Metaflex Orion Blast Freezer

Total Height 3000 mm
Total Width 3000 mm
Thickness 170 mm
Insulating Suitable for temperatures up to -40 °C
Thermal Transmittance 2.74 W/m2. K
Operation Automatic or manual
Description The Blast Freezer is a sliding door and cuts

through the air. Therefore, cold air

downdraught created when opening the door is

very low.

The door seals the doorway completely,

preventing unnecessary energy loss. The water

does not run from the room during cleaning.

The door’s thermal transmittance is 2.74 W/m2. K. It operates automatic or manual. Table

3.7 shows the specification and dimension of the door used in Cold Storage.
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3.1.G Light
Lightings gives bright and guide for the workers inside the cold storage room and the

production plan. Good light is good for the workers to see easily in the workplace. The specification

of light can affect the cooling load of a cold storage.

Source: www.hubbell.com

Figure 3.G: SNL

Table 3.8: Light Specification

Product name SNL

Lamp type LED
Input power 93 watts
Lumen output 8,861 lumens
Ambient temp. Range -30°C to 30°C
Lumens per watt 100 LPW

The lumen output is 8,861 lumens and the lumens per watt is about 100LPW. Table 3.8

shows the specification of the lights that is needed in the Cold Storage.

3.1.H Chill Storage

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The chill storage is placed near the Receiving and Inspection area. It has two doors, entrance

and exit. The clearance between the racking system is 1.5 meters for turning radius of the forklift. It

has 12 racking system.

Figure 3.H: Cold Storage

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Table 3.9 Chill Storage Specification

Length 19 m
Width 18 m
Height 4.5 m
Clearance in side left and right 1.5 m
Clearance in between the racking in length 1.5 m
Clearance in side top and bottom 1.7 m
Clearance in middle 1.8 m
Racking length 3.3 m
Racking width 1.3 m
Racking height 3.05 m
Allowable Height 1.45 m
Room Temperature -2 ˚C
Total number of crates 3,840
Total number of pallets 48
Total number of racking 24
Total number of Load 45,792 Kg

The total number of loads is 45,792 kg. This table shows the dimension of the Cold Storage

and the maximum number of equipment it can stack.

Computation:

For Length:

To calculate the length, this is given as:

Length =

(2 x clearance ∈side top∧bottom)+(6 x racking width)+(4 x Clearance ∈between theracking∈length)+ Cleara

Where, 2 times the clearance in side top and bottom, 6 times the racking width, 4 times the

clearance in between the racking in length and clearance in middle are 1.7 m, 1.3 m, 1.5 m and 1.8 m

respectively.

Length=( 2 x 1.7 m )+ ( 6 x 1.3 m )+ ( 4 x 1.5 m ) +1.8 m=19 m

For Width:
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To calculate the width, this is given as:

Width=¿ ¿+¿

( 4 x Racking Length)+Clearance ∈middle

Where, 2 times the clearance in side left and right, 4 times racking length and clearance in

middle are 1.5 m, 3.3 m and 1.8 m respectively.

Width=( 2 x 1.5 m ) + ( 4 x 3.3 m ) +1.8 m=18 m

For Height:

To calculate the height, this is given as:

Height =Racking height + Allowable Height

Where, racking height and allowable height are 3.05 m and 1.45 m respectively.

Height =3.05+1.45=4.5 m

For Total number of pallets:

To calculate the total number of pallets, this is given as:

Total number of pallets=Total number of racking x Number of pallets∈racking

Where, the total number of racking and number of pallets in racking are 24 and 4

respectively.

Total number of pallets=24 x 4=48 pallets

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For Total number of crates:

To calculate the total number of crates, this is given as:

Total number of crates=Total number of racking x Number of crates∈racking

Where, the total number of racking and number of crates in racking are 24 and 160

respectively.

Total number of crates=24 x 160=3,840 crates

For Total number of loads:

To calculate the total number of loads, this is given as:

Total number of Load=¿

Weight of carried by one rack x Number of racking∈cold Storage

Where, the weight of carried by one rack and number of racking in cold storage are 1908 Kg

and 24 respectively.

Total number of Load=1908 Kg x 24=45,792 Kg

3.1.I Cold Storage

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The design of Cold Storage has an area of 279 m 2. The clearances between the walls and

racking systems is 1.5 meters to give way for the forklift paths. It can fit 10 racking system and the

entrance and exit of the room is the same. It is located near the packing area in order to save time

carrying the products.

Figure 3.I: Cold Storage Design

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Table 3.10 Cold Storage Specification

Length 18 m
Width 15.5 m
Height 6m
Clearance in side 1.5 m
Clearance between the racking 1.5 m
Clearance in top and bottom 1.5 m
Clearance in middle 1.8 m
Racking length 3.3 m
Racking width 1.3 m
Racking height 3.05 m
Room Temperature -30 ˚C
Total number of crates 3200
Total number of pallets 40
Total number of racking 20
Total number of Load 38,160 Kg

The total number of loads is 38,160 kg. Table 3.10 shows the specification, dimension used

in this design.

Computation:

For Length:

To calculate the length, this is given as:

Length=(2 x Clearance ∈side)+(4 x Racking Length)+Clearance∈middle

Where, 2 times the clearance in side, 4 times the racking length and clearance in middle are

1.5m, 3.3m and 1.8m respectively.

Length=( 2 x 1.5 m )+ ( 4 x 3.3 m ) +1.8 m=18 m

For Width:

To calculate the width, this is given as:

Width=( 2 x Clearance∈ side ) + ( 4 x Clearance between theracking )+¿

(5 x racking width)+ Clearance∈middle

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Where, 2 times the clearance in side, 4 times the clearance between the racking, 5 times the

racking width and clearance in the middle are 1.5m, 1.5m, 1.3m and 1.8m respectively.

Width=( 2 x 1.5 m ) + ( 4 x 1.5 m ) + ( 5 x 1.3 m )+ 1.8 m=15.5 m

For Height:

To calculate the height, this is given as:

Height =Racking height + Allowable Height

Where, the racking height and allowable height are 3.05m and 1.45m respectively.

Height =3.05+1.45=4.5 m

For Total number of pallets:

To compute the total number of pallets, this is given as:

Total number of pallets=Total number of racking x Number of pallets∈racking

Where, the total number of racking and number of pallets in racking are 24 and 4

respectively.

Total number of pallets=20 x 4=40 pallets

For Total number of crates:

To compute the total number of crates, this is given as:

Total number of crates=Total number of racking x Number of crates∈racking

Where, the total number of racking and number of crates in racking are 24 and 160

respectively.

Total number of crates=20 x 160=3,200 crates

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For Total number of loads:

To compute the total number of loads, this is given as:

Total number of Load=¿

Weight of carried by one rack x Number of racking∈cold Storage

Where, the weight of carried by one rack and number of racking in cold storage are 1,908 Kg

and 24 respectively.

Total number of Load=1,908 Kg x 20=38,160 Kg

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3.1.J Blast Freezer

A blast freezer, or blast chiller as it is also known, is a cold storage unit that can freeze large

quantities of goods very quickly. These types of commercial freezers are essential for companies that

need to store and transport perishable goods before they make their way to their destination. They

work by pushing cold air around the specially designed unit at a high velocity, to reduce the

temperature of products as quickly as possible.

Source: https://www.crscoldstorage.co.uk

Figure 3.J: Wide Span Blast Freezer

Table 3.11 Blast Freezer Specification

Product Name Wide Span Blast Freezer
Design Blast Freezer Temperature -18˚C
Production Capacity 20 pallets
Freezing time 24-36 hours
Refrigerant used ammonia
Cooling capacity 16000-20000 Kg
Dimension 15.5m x 9m x 3m
Factor affect freezing time Product Size, Temperature, Thermal conductivity

and packing.
The cooling capacity is 16,000 kg up to 20,000 kg. Table 3.11 shows the specification, and

the dimension of the Blast Freezer design.

3.1.K Wall
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The walls are composed of 16mm gypsum plaster, 16mm gypsum board, 150mm concrete

hollow blocks, 114mm cellular polyurethane and 4mm rubber tile, with inside and outside air film.

The Figure 3.K shows the composition of walls.

Figure 3.K: Cold Storage and Chill Storage Wall Insulation

Table 3.12: Wall Specification

Insulation Thickness Thermal Conductivity Thermal Resistances

(m) (W/m-k) (m2k/W)

Concrete hollow blocks 0.15 0.517 0.29
Gypsum board 0.016 0.16 0.10
Gypsum plaster 0.016 2.424 0.066
Cellular Polyurethane 0.114 0.026 4.38
Rubber tile 0.004 0.13 0.03077
Air Inside Film - - 0.12
Air outside Film - - 0.029

The insulation material of the wall are concrete hollow blocks, gypsum board gypsum plaster,

cellular polyurethane, rubber tile and inside/outside air film. Table 3.12 shows the specification of

the wall used in the design.

3.1.L Ceiling
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The ceiling are composed of 100mm built-up roofing, 196mm cellular polyurethane and 4mm

rubber tile, with inside and outside air film. The Figure 3.L shows the composition of ceiling.

Figure 3.L: Ceiling Insulation

Table 3.13: Ceiling Specification

Insulation Thickness Thermal Conductivity Thermal Resistances

(m) (W/m-k) (m2k/W)

Built-up roofing .1 1.6667 0.06
Cellular Polyurethane .196 0.0447 4.38
Rubber tile .004 0.13 0.03077

The insulation material of the ceiling is built-up roofing, cellular polyurethane and rubber

tile. Table 3.13 shows the specification of the ceiling used in the design.

3.1.M Floor

The floor is composed 25.4mm asbestos cement, 152.4mm sand and gravel aggregate,

122.2mm sand and gravel and 100mm extruded polystyrene, with inside and outside air film. The

Figure 3.M shows the composition of floor.

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Figure 3.M: Floor Insulation

Table 3.14: Floor Specification

Insulation Thickness Thermal Conductivity Thermal Resistances

(m) (W/m-k) (m2k/W)

Asbestos cement .0254 0.147 0.173
Sand and Gravel Aggregate 0.1524 0.847 0.18
Extruded Polystyrene .1 0.044 2.27
Sand and Gravel 0.1222 1.993 0.0613

The insulation material of the flooring is asbestos cement, sand and gravel aggregate,

extruded polystyrene and sand and gravel. Table 3.14 shows the specification of the ceiling used in

the design.
 P a g e | 37

CHAPTER IV

COOLING LOAD CALCULATION

This chapter will focus on the design and dimensions of the cold storage for raw fish and

finished products. The design and arrangement for stacking the crates and pallets inside the cold

storage are also discussed in this chapter.

4.1 RAW COLD STORAGE

4.1.A. Transmission Load

Figure 4.1.A: Transmission Load

 P a g e | 38

Table 4.1: Transmission Load Specification for raw storage

TEMPERATURE CONDITIONS (oC)

Ambient Temperature of Warehouse 28 ˚C
Ground Temperature 21 ˚C
Outside temperature of Warehouse 35 ˚C
Chill Storage temperature -2˚C
Table 4.1 shows the temperature condition of the transmission load specification for raw

storage. The ambient and outside temperature of the warehouse are 28 ˚C and 35 ˚C respectively.

Computations:

To calculate the U-Value or Overall Thermal Coefficient use:

1
U=
R 1+ R 2+ R 3 … .+ Rn

Where:

U = overall heat transfer coefficient, W/m2K

R = resistance to heat flow

For U wall A

1 1
U A= = =0.1994
∑R 0.29+ 0.10+0.066+ 4.38+0.03077+ 0.12+ 0.029

For U wall B

1 1
U B= = =0.1994
∑R 0.29+0.10+0.066+ 4.38+0.03077+ 0.12+ 0.029
 P a g e | 39

For U wall C

1 1
UC= = =0.1994
∑R 0.29+0.10+ 0.066+4.38+ 0.03077+0.12+0.029

For U wall D

1 1
U D= = =0.1994
∑R 0.29+0.10+ 0.066+4.38+ 0.03077+0.12+0.029

For U ceiling

1 1
U ceiling = = =0.2165
∑R 0.06+4.38+ 0.03077+0.12+0.029

For U floor

1 1
U floor= = =0.3566
∑R 0.173+0.18+2.27+ 0.0613+ 0.12

For U Door A

U Door A =0. 274

For U Door B

U Door B=0.274

To calculate A-Value, the equations below will be applied:

For A wall A and C

A wall A and C = Width chill storage x Height chill storage

 P a g e | 40

A wall A ∧C =18 m x 4.5 m=81 m2

For A wall B and D

A wall B and D = Length chill storage x Height chill storage

A wall B∧D =19 m x 4.5 m=85.5 m2

For A ceiling

A ceiling= Length chill storage x Width chill storage

Aceiling =19 m x 18 m=342m2

For A floor

A floor= Length chill storage x width chill storage

Aceiling =19 m x 18 m=342m2

For A Door A and B

A Door A and B = Width Door x Height Door

A Door A∧B =3 m x 3 m=9 m2

To calculate the transmission load, the equation below will be applied:

Q = UA∆ T
 P a g e | 41

Where:

Q = heat load, Watts

U = U-value of insulation, W /m 2 ∙ K

A = surface area of walls roof and floor, m2

∆ T = change in temperature

First, calculate the change in temperature (∆ T ), the equations below will be applied:

For ∆ T wall A and B

∆ T wall A and B = T warehouse – T chill storage

∆ T wall A and B = 28˚C - (-2 ˚C) = 30 ˚C

For ∆ T wall C and D

∆ T wall C and D = T outside – T chill storage

∆ T wall C and D = 35˚C - (-2 ˚C) = 37 ˚C

For ∆ T ceiling

∆ T ceiling = T outside – T chill storage

∆ T ceiling = 35˚C - (-2 ˚C) = 37 ˚C

For ∆ T floor

∆ T floor = T ground – T chill storage

 P a g e | 42

∆ T floor = 21˚C - (-2 ˚C) = 23 ˚C

For ∆ T Door A and B

∆T Door A and B = T warehouse – T chill storage

∆T Door A and B = 28˚C - (-2 ˚C) = 30 ˚C

Then, calculate the heat load, the equation below will be applied:

Q=UA ∆T

For Q wall A

QWall A =UA ∆ T

QWall A =0.1994 x 81 m2 x 30 ˚ C=484.542 W

For Q wall B

Q Wall B=UA ∆T

QWall B=0.1994 x 85.5 m2 x 30˚ C=630.802 W

For Q wall C

QWallC =UA ∆ T

QWallC =0.1994 x 81m2 x 37 ˚ C=484.542W

For Q wall D
Q Wall D =UA ∆ T
 P a g e | 43

QWall D =0.1994 x 85.5 m2 x 37 ˚ C=630.802W

For Q ceiling

Qceiling =UA ∆ T

Qceiling =0.2165 x 342 m 2 x 37 ˚ C=2,739.591W

For Q floor

Qfloor =UA ∆ T

Qfloor =0.3566 x 342 m2 x 23 ˚ C=2,805.016W

For Q Door A

Q DoorA =UA ∆ T

Q Door A =0. 274 x 9 m2 x 30 ˚ C=73.98W

For Q Door B

Q Door B=UA ∆ T

Q Door B=0. 274 x 9 m2 x 30 ˚ C=73.98W

Finally, calculate the total transmission load, the equation below will be applied:

Q Total = Q wall A + Q wall B + Q wall C + Q wall D + Q ceiling + Q Floor + Q Door A+ Q Door B

 P a g e | 44

Q Total = 484.542 + 484.542 + 630.802 + 630.802 + 2,739.591 + 2,805.016 + 73.98 + 73.98

Q Total of Transmission Load = 7,923.255 W or 7.9 kW

4.1.B. Product Load

Figure 4.1.B: Cream dory fish

Table 4.2: Product Load Specification for raw storage

Specific heat above freezing (Cpa) kJ

3.77
kg·K
Latent heat of fusion (q2) kJ
268
kg
Specific heat below freezing (Cpb) kJ
2.15
kg·K
Mass per day 16000 kg
24 hrs
Initial temperature of fish 5 ˚C
Final temperature of fish -2 ˚C
Freezing point of fish -2.2 ˚C
Source: https://www.ukpandi.com and http://www.tgbgroup.co

Table 4.2 shows the product load specification for raw storage. The initial, final, and freezing

temperature of fish are 5 ˚C, -2 ˚C, and -2.2 ˚C respectively.

Computations:
To calculate the product load, the equation below will be applied:
Qa = mr (q1 + q2 + q3)

Where:
 P a g e | 45

Qa = ṁproduct ( q 1+q 2+q 3)

mr = mass of product in the storage, kg

q1 = CPa (Tinitial - Tfreezing)

q2 = LHf of the product

q3 = CPb (Tfreezing – Tfinal)

First, calculate q1, q2, and q3

For q1

q1 = Cpa (Tinitial – Tfreezing)

Where:

Cpa = Cp of product above freezing

KJ
q1 =3.77 ( 5−(−2.2 ) ) K
Kg−K

KJ
q1 =27.144
Kg

For q2

KJ
q2 =268
Kg

For q3

q3 = Cpb (Tfreezing – Tfinal)

Where:

Cpb = Cp of product below freezing

KJ
q3 =2.15 (−2.2−(−2) ) K
Kg−K
 P a g e | 46

KJ
q3 = −0.43
Kg

Finally, calculate the total product load

16000 kg 1 hr
Qa = x (27.144+268−0.43)
24 hr 3600 s

KJ
QT of Product load = 54.577 ∨kW
s

4.1.C. Material Load

 P a g e | 47

Figure 4.1.C.1: Pallet Figure 4.1.C.2: Crate

Table 4.3: Material Load Specification for raw storage

Mass of crate 1.3 Kg

Mass of pallet 25 Kg
Number of crates in chilled storage 3840
Number of pallets in chilled storage 48
T – time of production 24 hrs
Cpm – Cp of pallet and crates 2.3 KJ/ kg-K
Ta – Ambient temperature of warehouse 28 ˚C
Tc – Temperature of Chilled storage -2 ˚C
∆T= Ta – Tc 28 - (-2)

Table 4.3 shows the material load specification for raw storage. The number of crates and

pallets in the chilled storage are 3,840 and 48 respectively.

Computation:

To calculate the material load, the equation below will be applied:

mm
QT = x Cp m x ∆T
t

Where:
QT = material load
mm = mass
t = length of time
Cpm = Cp of pallets and crates
∆ T = change in temperature

Calculate the mm
mm = 1.3(3,840) + 24(48) = 6,192 kg
 P a g e | 48

Finally, calculate the QT of Material Load

6192 kg 1 day 1 hr KJ
QT = ( )( ) x 2.3 x ( 28−(−2 ) ) K
1 day 24 hrs 3600 s kg−k

QT of Material Load = 4,945W

 P a g e | 49

4.1.D: People Load

Figure 4.D: People in chilled storage

Table 4.4: People Load Specification for raw storage

NP - number of people 6 4
Types of work heavy Light
qs - Sensible heat gain per 580 250

BTU
person( )
hr
qL - Latent heat gain per 870 250

BTU
person ( ¿
hr
DF - Diversity factor 1 1
CLF - Cooling load factor 1 1

for given hour

t - Time of operation 8 hrs 8 hrs
Table 4.4 shows the people load specification for raw storage. The time operation and cooling

load factor for given hour are 8 hrs and 1 respectively.

Computation:
 P a g e | 50

To calculate the sensible heat, the equation below will be applied:

Qs = NP x DF x qs x CLF x t

Where:

Qs = sensible heat

NP = number of people

DF = diversity factor

qs = sensible heat per person

CLF = cooling load factor for given hour

t = time of operation

To compute for the heat equivalent per person/worker, the equation above will be used.

Substituting the value into the equation, computed sensible heat is 10,503 W.

BTU 1.055 KJ 1 hr BTU 1.055 KJ 1 hr

Qs = (6 x 1 x (580 x x ) x 1 x 8) +( 4 x 1 x( 250 x x )x 1 x 8)
hr 1 BTU 3600 s hr 1 BTU 3600 s

Qs = 10.503 kW ∨10,503W

To compute latent heat, the equation below will be applied:

QL = NP x DF x qL x t

Where:

QL = latent heat

NP = number of people

DF = diversity factor

qL = latent heat gain per person

 P a g e | 51

t = time of operation

To compute for the heat equivalent per person/worker, the equation above will be used.

Substituting the value into the equation, computed latent heat is 14,582 W.

BTU 1.055 KJ 1 hr BTU 1.055 KJ 1 hr

QL =(6 x 1 x (870 x x ) x 1 x 8) +( 4 x 1 x( 250 x x )x 1 x 8)
hr 1 BTU 3600 s hr 1 BTU 3600 s

QL =14.582 kW ∨14,582W

To calculate for the total people load, the equation below will be applied:

QT = Qs + QL

Where:

QT = total heat load

Qs = sensible heat

QL = latent heat

The Qs and QL are 10,503 W and 14,582 W respectively. Substituting the value into the

equation above, computed total heat of the people load is 25,058 W.

QT = 10,503 W +14,582W

QT of People Load =25,085 W

 P a g e | 52

4.1.E: Lighting Load

Figure 4.E: Light bulb

Table 4.5: Lighting Load for raw storage

LUX - Light level inside the cold storage 300 lumen/m2

φ r - Luminous flux 8,861 lumens/lamp

Length of ceiling 19 m
Width of ceiling 18 m
Capacity 98 W

Table 4.5 shows the lighting load for raw storage. The light level and luminous flux is 300

lumen/m2 and 8,861 lumens/lamp respectively.

Computations:

To calculate for the total flux, the equation below will be applied:

φ t= LUX x A Ceiling

Where:

φ t = total flux (lumen)

Lux = light level; lumen

A = area of the cold storage

 P a g e | 53

Before calculating the total flux, first calculate the area of the cold storage. The equation

below will be applied:

A ceiling = L x W

A ceiling = 19m x 18m

A ceiling = 342m2

The light level is 300 lumen/m2, and the area of the cold storage is 342m2.

lumen
φ t= 300 2
x 342 m 2
m

φ t= 102,600 lumens

To calculate the number of LED lights, the equation below will be applied:

φt
No. of Lights =
φr

Where:

φ t = total flux, lumen

φ r = rated lumen per lamp, lumen/lamp

The total flux, and rated lumen per lamp are 12,600 lumens and 8,861 lumens/lamp

respectively. Substituting the value into the equation, computed number of light is 12 lamps.

102,600lumens
No. of Lights = lumens
8,861
lamp
 P a g e | 54

No. of Lights = 11.58 lamps or 12 lamps

To calculate the lighting load per day, the equation below will be applied:

Q Lightings=No . of lights x Capacity

The number of lamps, and capacity are 12 lamps and 98 W respectively. Substituting the

value into the equation, computed total heat of lighting load is 1176 W.

Q Lightings=12 lamps x 98W

QT of Lightings Load =1176 W

4.1 F. Equipment load

Figure 4.F: Fork lift

Table 4.6: Fork lift for raw storage

Driving motor 8000 W

Lifting motor 1050 W
 P a g e | 55

T- time of operation 6 hrs/day

Table 4.6 shows the fork lift for raw storage. The time of operation is 6hrs/day.

Computations:

To calculate for the P, the equation below will be applied:

P = Dm + Lm

Where:

Dm = driving motor

Lm = lifting motor

The driving motor is 8,000 W, and the lifting motor is 1,050 W. Substituting the value into

the equation, computed P is 9050 W.

P = 8,000W + 1,050W

P = 9,050 W

Then calculate for total heat load, the equation below will be applied:

QT = P x T

Where:

QT = total heat load

P = power to lift

T = time of operation

The power to lift, and time of operation is 9,050 W and 6 hrs/day respectively. Substituting

the value into the equation, computed total heat of equipment load is 2,262.5 W.

6 hrs 1 day
QT = 9,050 W x x
1 day 24 hrs
 P a g e | 56

QT of Equipment Load = 2,262.5 W

4.1 G. Infiltration Load

Table 4.7: Infiltration Load Specification for raw storage

Volume of Chill storage 19 x 18 x 4.5 = 1539 m3

Temperature of Chill storage -2 ˚C
Ambient temperature of warehouse 28 ˚C
Table 4.7 shows the infiltration load specification for raw storage. The total heat infiltration

load is 461.7 W.

Computation:

To calculate the infiltration load, wherein 0.005 is an equation factor and the number of Air

Change per Hour is 2. The equation below will be applied:

QT of Infiltration Load = 0.005 x ACH x V x ∆T

2
ACH =
hr

Where:

0.005 is an equation factor

ACH = air change per hour

V = inside volume of the storage

∆T = change in temperature

Inside volume of the storage is 1,539m3 and the change in temperature is 30 °C. Substituting

the value into the equation, computed total heat of infiltration load is 461.7 W.

2
QT of Infiltration Load = 0.005 x x 1,539 m3 x(28−(−2 ) )˚ C
hr
 P a g e | 57

QT of Infiltration Load = 461.7 W

4.1 H. Total Cooling load (add 10% Factor of safety)

To calculate the heat of total cooling load, the equation below will be applied:

QTCL=Q Transmission +QT of Product +QT of material +QT of people+QT of lightnings +QT of equipment + QT of Infiltration

QTCL = 7,923.255 W + 54,577 W + 4,945 W + 25,085 W + 1,176 W + 2,262.5 W + 461.7W

Q TCL=96,430.455W

Calculate the heat of total cooling load with factor of safety, the equation below will be

applied:

QTCLwith factor of safety =QTCL +(10 % ¿ ¿ factor of safety x QTLC ) ¿

Q TCL with factor of safety =96,430.455 W +(10 %¿¿ factor of safety x 96,430.455 W )¿

QTCLwith factor of safety =106,073.5 W ∨106 kW

 P a g e | 58

4.2 FINISHED PRODUCT COLD STORAGE

4.2.A. Transmission Load

Figure 4.2.A: Cold Storage

Table 4.8 Transmission Load Specification for finished product

TEMPERATURE CONDITIONS (oC)

Ambient Temperature 28 ˚C
Ground Temperature 21 ˚C
Outside temperature 35 ˚C
Cold Storage temperature -30 ˚C

Table 4.8 shows the transmission load specification for finished product. The ambient and

outside temperature is 28 ˚C and 35 ˚C respectively.

 P a g e | 59

Computations:

To calculate the U-Value or Overall Thermal Coefficient use:

1
U=
R 1+ R 2+ R 3 … .+ Rn

Where:

U = overall heat transfer coefficient, W/m2K

R = resistance to heat flow

For U wall A

1 1
U A= = =0.1994
∑R 0.29+ 0.10+0.066+ 4.38+0.03077+ 0.12+ 0.029

For U wall B

1 1
U B= = =0.1994
∑R 0.29+0.10+0.066+ 4.38+0.03077+ 0.12+ 0.029

For U wall C

1 1
UC= = =0.1994
∑R 0.29+0.10+ 0.066+4.38+ 0.03077+0.12+0.029

For U wall D

1 1
U D= = =0.1994
∑R 0.29+0.10+ 0.066+4.38+ 0.03077+0.12+0.029

For U ceiling

1 1
U ceiling = = =0.2165
∑R 0.06+4.38+ 0.03077+0.12+0.029
 P a g e | 60

For U floor

1 1
U floor= = =0.3566
∑R 0.173+0.18+2.27+ 0.0613+ 0.12

For U Door A

U Door A =0. 274

To calculate A-Value(m 2) , the equations below will be applied:

For A wall A and C

A wall A and C = Width chill storage x Height chill storage

AWall A=19 m x 4.5m=85.5 m2

For A wall B and D

A wall B and D = Length chill storage x Height chill storage

AWall B =15.5 m x 4.5 m=69.75 m2

For A ceiling

A ceiling= Length chill storage x Width chill storage

Aceiling =19 m x 15.5 m=294.5 m2

For A floor
 P a g e | 61

A floor= Length chill storage x width chill storage

A floor=19 m x 15.5 m=294.5 m2

For A Door A

A Door A = Width Door x Height Door

A Door A=3 m x 3 m=9 m2

To calculate the transmission load, the equation below will be applied:

Q = UA∆ T

Where:

Q = heat load, Watts

U = U-value of insulation, W /m 2 ∙ K

A = surface area of walls roof and floor, m2

∆ T = change in temperature

First, calculate the change in temperature (∆ T ), the equations below will be applied:

For ∆ T wall A and D

∆ T wall A and D = T warehouse – T chill storage

∆ T wall A and D = 28˚C - (-30 ˚C) = 58 ˚C

For ∆ T wall B and C

∆ T wall D and C = T outside – T chill storage

 P a g e | 62

∆ T wall D and C = 35˚C - (-30 ˚C) = 65 ˚C

For ∆ T ceiling

∆ T ceiling = T outside – T chill storage

∆ T ceiling = 35˚C - (-30 ˚C) = 65 ˚C

For ∆ T floor

∆ T floor = T ground – T chill storage

∆ T floor = 21˚C - (-30 ˚C) = 51 ˚C

For ∆ T Door A

∆T Door A = T warehouse – T chill storage

∆T Door A = 28˚C - (-30 ˚C) = 58 ˚C

Then, calculate the heat load, the equation below will be applied:

Q=UA ∆T

For Q wall A

QWall A =UA ∆ T

QWall A =0.1994 x 85.5 m2 x 58 ˚ C=988.825 W

 P a g e | 63

For Q wall B

Q Wall B=UA ∆T

QWall B=0.1994 x 69.75 m2 x 65˚ C=904.030 W

For Q wall C

QWallC =UA ∆ T

QWallC =0.1994 x 85.5m2 x 65 ˚ C=1,108.166 W

For Q wall D
Q Wall D =UA ∆ T

QWall D =0.1994 x 69.75 m2 x 58˚ C=806.673 W

For Q ceiling

Qceiling =UA ∆ T

Qceiling =0.2165 x 294.5 m2 x 65˚ C=4,144.351 W

For Q floor

Qfloor =UA ∆ T

Qfloor =0.3566 x 294.5 m2 x 51˚ C=5,355.954 W

 P a g e | 64

For Q Door A

Q DoorA =UA ∆ T

Q Door A =. 274 x 9 m2 x 58 ˚ C=1,430.028 W

Finally, calculate the total transmission load, the equation below will be applied:

Q Total = Q wall A + Q wall B + Q wall C + Q wall D + Q ceiling + Q Floor + Q Door A+ Q Door B

Q Total = 988.825 + 904.030 + 1,108.166 + 806.673 + 4,114.351 + 5,355.954 + 1,430.028

Q Total of Transmission Load = 14,708.027 W or 14.7 kW

 P a g e | 65

4.2.B. Product Load for finish product

Figure 4.2.B: Cream dory fish fillet

Table 4.9: Product Load Specification for finished product

Specific heat above freezing (Cp1) 3.77 kJ/(kg·K)

Latent heat of fusion (Lf) 268 kJ/kg
Specific heat below freezing (Cp2) 2.15 kJ/(kg·K)
Mass per day 16000 kg/24 hrs.
Initial temperature of fish -16 ˚C
Final temperature of fish -30 ˚C
Freezing temperature of fish -2.2 ˚C
Source: https://www.ukpandi.com and http://www.tgbgroup.co

The table 4.9 shows the product load specification for finished product. The initial, final and

freezing temperature of fish is -16 ˚C, -30 ˚C, and -2.2 ˚C respectively.

Computations:
To calculate the product load, the equation below will be applied:
Qa = mr (q1 + q2 + q3)

Where:

Qa = ṁ product ( q 1+q 2+q 3)

mr = mass of product in the storage, kg

q1 = CPa (Tinitial - Tfreezing)

q2 = LHf of the product

 P a g e | 66

q3 = CPb (Tfreezing – Tfinal)

First, calculate the q1, q2, and q3

For q1

q1 = Cpa (Tinitial – Tfreezing)

Where:

Cpa = Cp of product above freezing

KJ
q1 =3.77 (−16−(−2.2 ) ) K
Kg−K

KJ
q1=−52.026
Kg

For q2

KJ
q2 =268
Kg

For q3

q3 = Cpb (Tfreezing – Tfinal)

Where:

Cpb = Cp of product below freezing

KJ
q3 =2.15 (−2.2−(−30) ) K
Kg−K

KJ
q3 = 59.71
Kg
 P a g e | 67

Finally, calculate the total product load

16000 kg 1 hr
Qa = x (−52.026+268+59.71)
24 hr 3600 s

kJ
QT of Product Load =51.064 ∨kW
s
 P a g e | 68

4.2.C. Material Load

Figure 4.2.C.1: Pallet Figure 4.2.C.2: Crate

Table 4.10: Material Load Specification for finished product

mass of crate 1.3 Kg

mass of pallet 25 Kg
Number of crates in cold storage 3,200
Number of pallets in cold storage 40
T – time of production 24 hrs
Cpm – Cp of pallet and crates 2.3 KJ/ kg-K
Ta – Ambient temperature of warehouse 28 ˚C
Tc – Temperature of Cold storage -30 ˚C
∆T= Ta – Tc 28-(-30)
Table 4.10 shows the material load specification for finished product. The ambient

temperature of warehouse and temperature of cold storage are 28 ˚C and -30 ˚C respectively.

Computation:

To calculate the material load, the equation below will be applied:

mm
QT = x Cp m x ∆T
t
 P a g e | 69

Where:
QT = material load
mm = mass
t = length of time
Cpm = Cp of pallet and crates
∆ T = change in temperature

Solve for mm
mm = 1.3(3200) + 24(40) = 5,160 kg

Finally, calculate the QT of Material Load

5160 kg 1 day 1 hr KJ
QT = ( )( ) x 2.3 x ( 28−(−30 ) ) K
1 day 24 hrs 3600 s kg−k

QT of Material Load = 7,966.94 W

 P a g e | 70

4.2.D. People Load

Figure 4.2.D: People in chilled storage

Table 4.11: People Load Specification for finished product

NP - number of people 5 3
Types of work heavy Light
qs - Sensible heat gain per 580 250

BTU
person( )
hr
qL - Latent heat gain per 870 250

BTU
person ( ¿
hr
DF - Diversity factor 1 1
CLF - Cooling load factor 1 1

for given hour

t - Time of operation 8 hrs 8 hrs

Computation:
 P a g e | 71

To calculate the sensible heat, the equation below will be applied:

Qs = NP x DF x qs x CLF x t

Where:

NP = number of people

DF = diversity factor

qs = sensible heat per person

CLF = cooling load factor for given hour

t = time of operation

Substituting the value into the equation above, computed heat is 8,557 W.

BTU 1.055 KJ 1hr BTU 1.055 KJ 1hr

Qs =(5 x 1 x (580 x x ) x 1 x 8) +(3 x 1 x (250 x x ) x 1 x 8)
hr 1 BTU 3600 s hr 1 BTU 3600 s

Qs =8.557 kW ∨8,557 W

To calculate latent heat, the equation below will be applied:

QL = NP x DF x qL x t

Where:

QL =

NP = number of people

DF = diversity factor

qL = latent heat gain per person

t = time of operation

Substituting the value into the equation above, computed heat is 11,597 W.
 P a g e | 72

BTU 1.055 KJ 1 hr BTU 1.055 KJ 1 hr

QL =(6 x 1 x (870 x x ) x 1 x 8) +( 4 x 1 x( 250 x x )x 1 x 8)
hr 1 BTU 3600 s hr 1 BTU 3600 s

QL =11.957 kW ∨11,597 W

To calculate for the total people load, the equation below will be applied:

QT = Qs + QL

Where:

QT = total heat load

Qs = sensible heat

QL = latent heat

The Qs and QL are 8,557 W and 11,597 W respectively. Substituting the value into the

equation above, computed heat is 20,514 W.

QT =8,557 W +11,597 W

QT of People Load =20,514 W

4.2.E. Lighting Load

 P a g e | 73

Figure 4.2.E: Light bulb

Table 4.12: Lighting Load Specification for finished product

LUX - Light level inside the cold storage 300 lumen/m2

φ r - Luminous flux 8,861 lumens/lamp

Length of ceiling 18 m
Width of ceiling 15.5 m
Capacity 98 W

Table 4.12 shows the lighting load specification for finished product. The light level inside

the cold storage and the luminous flux are 300 lumen/m2 and 8,861 lumens/lamp.

Computations:

To calculate for the total flux, the equation below will be applied:

φ t= LUX x A Ceiling

Where:

φ t = total flux (lumen)

Lux = light level; lumen

 P a g e | 74

A = area of the cold storage

Before calculating the total flux, first calculate the area of the cold storage. The equation

below will be applied:

A ceiling = L x W

A ceiling = 18 m x 15.5 m

A ceiling = 279 m2

The light level is 300 lumen/m2, and the area of the cold storage is 342m2.

lumen
φ t= 300 2
x 279 m2
m

φ t= 83,700 lumens

To calculate the number of LED lights, the equation below will be applied:

φt
No. of Lights =
φr

Where:

φ t = total flux, lumen

φ r = rated lumen per lamp, lumen/lamp

The total flux, and rated lumen per lamp are 12,600 lumens and 8,861 lumens/lamp

respectively.
 P a g e | 75

83700lumens
No. of Lights = lumens
8861
lamp

No. of Lights = 9.44 lamps or 10 lamps

To calculate the lighting load per day, the equation below will be applied:

Q Lightings=No . of lights x Capacity

The number of lamps, and capacity are 10 lamps and 98 W respectively.

Q Lightings=10 lamps x 98 W

QT of lightnings Load=980 W
 P a g e | 76

4.2.F. Equipment load

Figure 4.2.F: Fork lift

Table 4.13: Equipment Load Specification for finished product

Driving motor 8,000 W

Lifting motor 1,050 W
T- time of operation 6 hrs / day
Table 4.13 shows the equipment load specification for finished product. The driving and

lifting motor are 8,000 W and 1,050 W respectively.

Computations:

To calculate for the P, the equation below will be applied:

P = Dm + Lm

Where:
 P a g e | 77

Dm = driving motor

Lm = lifting motor

The driving motor is 8,000 W, and the lifting motor is 1,050 W.

P = 8,000W + 1,050W

P = 9,050 W

Then calculate the total heat load, the equation below will be applied:

QT = P x T

Where:

QT = total heat

P = power lifting

T = time of operation

The power lifting and time of operation is 9,050 W and 6 hrs/day respectively.

6 hrs 1 day
QT = 9,050 W x x
1 day 24 hrs

QT of Equipment Load = 2,262.5 W

4.2.G. Infiltration Load

 P a g e | 78

Table 4.14: Infiltration Load for finished product

Volume of Chill storage 18x15.5x4.5 = 1,255.5 m3

Temperature of Cold storage -30 ˚C
Ambient temperature of warehouse 28 ˚C
Table 4.14 shows the infiltration load for finished product. The volume of chill storage is

1,255.5 m3.

Computation:

To calculate the infiltration load, wherein 0.005 is an equation factor and the number of Air

Change per Hour is 2. The equation below will be applied:

QT of Infiltration Load = 0.005 x ACH x V x ∆T

2
ACH =
hr

Where:

0.005 is an equation factor

ACH = air change per hour

V = inside volume of the storage

∆T = change in temperature

Inside volume of the storage is 1,539m3 and the change in temperature is 58 °C.

2
QT of Infiltration Load = 0.005 x x 1,255.5 m3 x(28−(−30 )) ˚ C
hr

QT of Infiltration Load = 728.19 W

4.1 H. Total Cooling load (add 10% Factor of safety)

Computations:
 P a g e | 79

To calculate the heat of total cooling load, the equation below will be applied:

QTCL=Q Transmission +QT of Product +QT of material +QT of people+QT of lightnings +QT of equipment + QT of Infiltration

Q TCL=14,708.027 W + 51,064 W +7,966.94 W +20,514 W + 980 W +2,262.5 W +728.19 W

QTCL=98,223.657 W

Calculate the heat of total cooling load with factor of safety, the equation below will be

applied:

Q TCL with factor of safety =Q TCL +(10 % ¿ ¿ factor of safety x Q TLC ) ¿

QTCLwith factor of safety =98,223.657 W +(10 %¿ ¿ factor of safety x 98,223.657 W ) ¿

Q TCL with factor of safety =108,046.02 W ∨108 kW

 P a g e | 80

CHAPTER V
REFRIGERATION SYSTEM
This chapter shows the type of refrigeration system that will be used in the operation of the
chilled and cold storage design. The system that will be used for the design of chilled and cold
storage is Multi-evaporator system with multi-compression, intercooling and flash gas removal. The
chapter includes the type of refrigerant that will be used for the selected system. The refrigerant that
will be used is R-717 or also known as ammonia.

5.1 REFRIGERANT
A refrigerant is a substance or mixture, usually a fluid, used in a heat pump and
refrigeration cycle. In most cycles it undergoes  phase transitions from a liquid to a gas and back
again. Many working fluids  have been used for such purposes. Fluorocarbons,
especially chlorofluorocarbons, but they are being phased out because of their ozone
depletion effects. Other common refrigerants used in various applications are ammonia, sulfur
dioxide, and non-halogenated  hydrocarbons such as propane.

5.1.1 AMMONIA
Ammonia is a chemical consisting of one atom of nitrogen and three atoms of hydrogen. It is
designated in chemical notation as NH3. Ammonia is extremely soluble in water and is frequently used as a
water solution called aqua ammonia. Ammonia chemically combines with water to form ammonium
hydroxide. Household ammonia is a diluted water solution containing 5 to 10 percent ammonia. On the other
hand, anhydrous ammonia is essentially pure (over 99 percent) ammonia. "Anhydrous" is a Greek word
meaning "without water;" therefore, anhydrous ammonia in ammonia without water.

Operating Temperature of Ammonia

High Temperature of evaporator -8oC
Low Temperature of evaporator -36oC
Condensing Temperature ( oC) 40oC

5.1.1 A. The Good about Ammonia as a Refrigerant:

Ammonia offers three distinct advantages over other commonly used industrial refrigerants.
First, ammonia is naturally occurring and therefore environmentally compatible. Second, ammonia
has superior thermodynamic qualities, as a result ammonia refrigeration system use smaller pipe
sizes and require less heat transfer area and hence use less electricity – ammonia is approximately
15-20% more efficient than its HCFC counterparts. Third, ammonia’s recognizable strong pungent
odor is its greatest safety asset. Unlike most other industrial refrigerants that have no odor,
ammonia’s odor makes leaks more easily detectable. Besides the three distinct advantages above,
ammonia is also cheap and not as flammable as other chemicals that are used as refrigerants, such as
propane and butane.
5.1.1 B. The Bad about Ammonia as a Refrigerant:
 P a g e | 81

The major disadvantage of ammonia as a refrigerant is its toxicity. Due to ammonia’s

hygroscopic nature, it migrates to moist areas of the body, including the eyes, nose, throat and moist
skin and may cause severe burn injuries. Skin and respiratory-related diseases are aggravated by
exposure and even possible fatality at higher concentrations. Liquid ammonia will cause frostbite
since its temperature at atmospheric pressure is -28o F. The Occupational Safety and Health
Administration’s (OSHA) Permissible Exposure Level (PEL) is an 8-hour time weighted average of
50 parts per million (ppm). The National Institute of Occupational Safety and Health has established
Immediately Dangerous to Life Levels at 300 ppm for respirator selection. Concentrations of 5000
ppm can be lethal. The American Industrial Hygiene Association (AIHA) has developed Emergency
Response Planning Guidelines (ERPGs) for toxic substances to assist in planning for catastrophic
releases to the community. The ERGP-2 represents the concentration which individuals could be
exposed to for one hour without irreversible or serious health effects and was set at 200 ppm for
ammonia.
5.2 Multi-evaporator system with multi-compression, intercooling and flash gas removal
Figures 5.2.1and 5.2.2 show the schematic and P-h diagram of a multi evaporator system
which employs multiple compressors, a flash tank for flash gas removal and intercooling. This
system is good for low temperature lift applications with different refrigeration loads. As shown in
the system schematic, the pressure in the high temperature evaporator (Evaporator-II) is same as that
of flash tank. Superheated vapour from the low-stage compressor is cooled to the saturation
temperature in the flash tank. The low temperature evaporator operates efficiently as flash gas is
removed in the flash tank. In addition, the high-stage compressor (Compressor-II) operates
efficiently as the suction vapour is saturated. Even though the high stage compressor must handle
higher mass flow rate due to de-superheating of refrigerant in the flash tank, still the total power
input to the system can be reduced substantially, especially with refrigerants such as ammonia.\

5.2.1 Schematic Diagram of Multi-evaporator system with multi-compression,

intercooling and flash gas removal
The figure shown below is the schematic diagram of the Multi-evaporator system with multi-
compression, intercooling and flash gas removal refrigeration cycle that is used for the operation of
the Chill Storage and Cold Storage.
 P a g e | 82

Figure 5.2.1: Schematic Diagram of Multi-evaporator system with multi-compression, intercooling

and flash gas removal

5.2.2 P-h Diagram of Multi-evaporator system with multi-compression, intercooling and flash gas
removal
The diagram shown below shows the pressure-enthalpy diagram of the refrigeration system that is
used for the chilled and cold storage design, which is the Multi-evaporator system with multi-
compression, intercooling and flash gas removal.

5.2.2 P-h of Multi-evaporator system with multi-compression, intercooling and flash gas removal
5.2.3 ENTHALPIES AT EACH POINT

A.For enthalpy at point 1

h1 = hg at tevaporator = -8oC
kJ
h1 = 1452.64
kg
B. For enthalpy at point 2
B.1. First, get S2 = S1 = Sg at tevaporator = -8oC
kJ
S2 = 5.7269
kg−K
B.2. Where the pressure in P7 = P6 = P3 = P2

P7 = √ P 1 x P 4

P4 = at P sat at T4 or condenser
P4 = 1557 kPa
 P a g e | 83

P1 = at P sat at T1 or Evaporator I
P1 = 316.02 kPa
P7 = √ 316.02 x 1557
P7 =701.548 kPa
T sat of P7 =13.815 or 14 oC
B.3. Next, get Sf2 = Sf at t2 = 14oC
kJ
Sf2 = 1.23144
kg−K
B.4. Next, get Sg2 = Sg at t2 = 14oC
kJ
Sg2 = 5.4441
kg−K
B.5. Next, solve for the percent dryness using the formula below
S2=S f 2 + X ( S fg 2)

S2=S f 2 + X (S g 2−S f 2)
S 2−S f 2
X=
( S g 2−S f 2 )
5.7269−1.23144
X=
(5.4441−1.23144 )
X =¿1.07
B.6 Next, get hf2 = hf at t2 = 14oC
kJ
hf2 =265.334
kg
B.7 Next, get hg2 =hg at t2 = 14oC
kJ
hg2 = 1475.05
kg
B.8 Next, solve for h2 using the formula below
h2 =hf 2+ X (h fg2 )

h2 =hf 2+ X (h g 2−h f 2)
kJ kJ
h2 =265.334 + ( 1.07 ) ( 1475.05−265.334 )
kg kg
kJ
h2 =1556.259
kg
C. For enthalpy at point 3
h3 = hg at t2 = 14oC
 P a g e | 84

kJ
h3 =1475.05
kg
D. For enthalpy at point 4
D.1. First, get S3 = S4 = Sg at t3 = 14oC
kJ
S2 = 5.4441
kg−K
D.2. Next, get Sf4 = Sf at t4 = 40oC
kJ
Sf2 = 1.64377
kg−K
D.3. Next, get Sg4 = Sg at t4 = 40oC
kJ
Sg2 = 5.1558
kg−K
D.4. Next, solve for the percent dryness using the formula below
S4 =Sf 4 + X (S fg 4 )

S4 =Sf 4 + X ( S g 4 −S f 4 )
S 2−S f 2
X=
( S g 2−S f 2 )
5.4441−1.64377
X=
(5.4441−1.64377 )
X =¿1.08
D.5. Next, get hf4 = hf at t4 = 40oC
kJ
Hf4 =390.587
kg
D.6. Next, get hg4 =hg at t4 = 40oC
kJ
Hg4 = 1490.42
kg
D.7. Next, solve for h4 using the formula below
h 4 s=hf 2 + X (hfg 2)

h 4=h f 2 + X (hg 2−hf 2 )

kJ kJ
h 4=390.587 + ( 1.08 ) ( 1580.70−390.42 )
kg kg
kJ
h 4=1580.70
kg
E. For enthalpy at point 5
h5 = hf at t condenser = 40 oC
 P a g e | 85

kJ
h5 =390.587
kg
F. For enthalpy at point 6
h5 = h6
kJ
h6 =390.587
kg
G. For enthalpy at point 7
h7 = hf7 at t 7 = 14 oC
kJ
h7 =265.334
kg
H. For enthalpy at point 8
h8 = h7
kJ
h8 =265.334
kg
 P a g e | 86

5.2.4 Mass flow rate of the refrigerant

Using the calculated total heat load inside the chilled storage and cold storage, the mass flow rate of
the refrigerant can be calculated. By using energy balance in each evaporator, the mass flow rate of
the refrigerant can be calculated.

A.Ein = Eout
H8 + QI = H1
Q I =H 1−H 8

Q I =ṁ I h1−ṁ I h8

Q I =ṁI (h1−h8)
QI
ṁI =
h1−h8
kJ
106
s
ṁI =
kJ
( 1452.64−265.334 )
kg
Kg
ṁ I =0.08927
s
B.Ein = Eout
H6 + QII = H3
Q II =H 3−H 6

Q II =ṁ II h3−ṁ II h6

Q II =ṁII ( h3−h6 )
Q II
ṁ II =
h3 −h6
kJ
108
s
ṁII =
kJ
( 1475.05−390.587 )
kg
 P a g e | 87

Kg
ṁ II =0.09959
s
 P a g e | 88

5.2.5. Heat Rejected at the Condenser

Using the calculated mass II flow rate of the refrigerant, the heat rejected at the condenser can be
calculated. By using energy balance at the condenser.

Ein = Eout
H4 = Qr + H5
Qr=H 4 −H 5

Qr= ṁr II h4 −ṁr II h5

Qr= ṁr II (h 4−h 5)

kg kJ
(
Qr= 0.09959
s )
( 1580.70−390.587 )
kg
kJ
Q r =118.523 ∨kW
s
 P a g e | 89

5.2.6 Compressor Work

The Work of Compressor can be solving by Energy Balance in each Stage. Used designation mass
flow rate for their Stage.

Ein = Eout
H1 + WcI = H2
W cI =H 2−H 1

W cI =ṁ I h2−ṁ I h1

W cI =ṁI (h 2−h1 )

kg kJ
(
W cI = 0.08927
s )
( 1556.259−1452.64 )
kg
kJ
W cI =9.25 ∨kW
s
A.Ein = Eout
H3 + WcII = H4
W cII =H 4−H 3

W cII =ṁ II h 4−ṁ II h3

W cII =ṁII (h4 −h3 )

kg kJ
(
W cII = 0.09959
s )
( 1580.70−1475.05 )
kg
kJ
W cI =10.521 ∨kW
s
 P a g e | 90

5.2.7 Coefficient of Performance

Using the sum of total heat load at the chilled storage and cold storage, then sum of total
Work of compressor at the Low stage and High stage compressor, the coefficient of performance can
be calculated. By dividing the total heat load by the total work of the compressor.

Q I +Q II
COP=
W cI +W cII
106+108
COP=
9.25+ 10.521
COP=10.8239
 P a g e | 91

CHAPTER VI

EVAPORATOR SELECTION

6.1 Discussion about Evaporator

Evaporator is the name given to any heat exchanger where the refrigerant is evaporated at

low temperature and therefore at low pressure, but usually above atmospheric pressure to prevent gas

and/or water vapor leakages into the low-pressure circuit. The evaporator is the element of the

refrigerating circuit through which heat is absorbed from the environment that is being cooled. It can

absorb the heat necessary for refrigerant vaporization either from the air (direct expansion systems),

or from a liquid (usually water), or from a solution, which in the case of the fish industry is used as a

secondary refrigerant, being circulated through the air cooler inside the refrigerated room.

6.2 Evaporator Selection

Table 6.1: Evaporative Selection Temperature

Temperatures for Raw Fish, °C
Entering Temperature 2 °C
Cold Storage Temperature -2 °C
Refrigerant Temperature -8 °C
Temperatures for Finished Product, °C
Entering Temperature -16 °C
Cold Storage Temperature -30 °C
Refrigerant Temperature -36 °C

Table 6.1 shows the evaporative selection of the temperature. The refrigerant temperature for

raw and finish product is -8 oC and -36 oC respectively.

 P a g e | 92

6.3 Logarithmic Mean Temperature Difference

The log mean temperature difference (LMTD) is derived in all basic heat transfer texts. It

may be written for a parallel flow or counterflow arrangement. The LMTD has the form:

∆ T max −∆T min

∆ T LMTD =
∆ T max
ln
∆T min

Where ∆T1 and ∆T2 represent the temperature difference at each end of the heat exchanger,

whether parallel flow or counterflow. The LMTD expression assumes that Heat Exchangers 75 the

overall heat transfer coefficient is constant along the entire flow length of the heat exchanger. If it is

not, then an incremental analysis of the heat exchanger is required.

The fish is carrying temperature of 2 °C, the temperature in which the raw fish is received in

the plant, and will stored to a temperature of -2 °C. The refrigerant temperature will remain constant

and it is -8 °C.

Figure 6.1: Counter Flow Log Mean Temperature Difference for Raw Fish

To calculate the Logarithmic Mean Temperature Difference (LMTD) for raw material, the

equation below will be applied:

 P a g e | 93

∆ T max −∆T min

∆ T LMTD =
∆ T max
ln
∆T min

(2−(−8))−( (−2 )−(−8 ) )

∆ T LMTD =
2−(−8)
ln (
−2−(−8) )
∆ T LMTD =7.83° C

The fish entering the storage room at -16°C and will be stored at temperature of -30 °C. The

refrigerant temperature remain constant and it is -36 °C.

Figure 6.2: Counter Flow Log Mean Temperature Difference for Finish Product

To calculate the Logarithmic Mean Temperature Difference (LMTD) for finished product,

the equation below will be applied:

∆ T max −∆T min

∆ T LMTD =
∆ T max
ln
∆T min

(−16−(−36 ) )−(−30−(−36))
∆ T LMTD =
−16−(−36 )
ln (
−30−(−36) )
∆ T LMTD =11.63 ° C
P a g e | 94
 P a g e | 95

6.4 Evaporator Coil Capacity

To calculate the evaporator coil capacity, the equation below will be applied:

Q TCLwith factor of safety

Q coil =
LMTD

For raw material, QTCL with factor of safety is 106 kW and its LMTD 7.83 °C. To calculate for the

Qcoil1, substitute values from equation above

106 kW
Qcoil 1=
7.83° C

Btu

)( )
3,414
kW hr 1℃
(
Qcoil 1= 13.54
°C 1 kW
x
1.8 ℉

Btu
Q coil 1=25,680.87
hr ∙ ℉

For finished product, QTCL with factor of safety is 108 kW and its LMTD 11.63 °C. To calculate for

the Qcoil1, substitute values from equation above.

108 kW
Q coil 2=
11.63 ° C

Btu

)( )
3,414
kW hr 1℃
(
Qcoil 2= 9.29
°C 1 kW
x
1.8 ℉

Btu
Q coil 2=17,620.03
hr ∙ ℉
 P a g e | 96

6.5 Selected Evaporator

Figure 6.1: Selected Evaporator

Table 6.2: Selected Evaporator Specification

Capacity (kW) 67.6
Cooling Surface (m2) 330
Qty 4
ɸ (mm) 550
Fan

Air flow (m2/hr) 4 × 8720

Air pressure (pa) 90
Shot range (m) 15
Power (W) 4 × 600
Defrost Heater

Coil (kW/line) 1.1 x 16

Drip pan (kW) 1.1 x 2
Voltage (V) 380

Source: Alibaba.com

Table 6.2 shows the selected evaporator specification. Two evaporator will use in the storage.
 P a g e | 97

Chapter VII: Condenser

7.1 Discussion about condenser
The condenser is a heat exchanger where the refrigerant will pass through and change
its phase from gas to liquid and it will reject heat. The refrigerant enters the condenser in a
superheated state. It is first de-superheated and then condensed by rejecting heat to an external
medium. The heat of condensation will be released as the hot refrigerant fluid will enter the cold
tubes of the condenser. The refrigerant may leave the condenser as a saturated or a sub-cooled liquid,
depending upon the temperature of the external medium and design of the condenser. The amount of
the heat removed by the evaporator is directly proportional to the heat rejected by the condenser.
Eventually, in the last part of the condenser, all the refrigerant vapour condenses to liquid. Because
of the change of state, the velocity and volume of the refrigerant, as a gas, drops substantially as it
becomes a liquid. In general, most designs provide an adequate heat transfer surface area and
complementary pressure drop to cause the refrigerant to sub cool an average of 1 to 3 K before it
leaves the condenser coil.
In actual refrigeration systems with a finite pressure drop in the condenser or in a system
using a zeotropic refrigerant mixture, the temperature of the refrigerant changes during the
condensation process also. However, at present for simplicity, it is assumed that the refrigerant used
is a pure refrigerant (or an azeotropic mixture) and the condenser pressure remains constant during
the condensation process
Types of Condenser
There are different types of condenser, but the three mainly used are Air cooled condensers,
Water cooled condenser, and Evaporative condensers. In Air cooled condenser, it is commonly used
in small units like household refrigerators, deep freezers, water coolers, window air-conditional, split
type- air-conditioners, etc. It is used in plants where the cooling load is low and the total quantity of
the refrigerant in the refrigeration cycle is small. It is also called as Coil Condensers as they are
usually made of copper and aluminum coil. They occupy a larger amount of space than water cooled
condensers. There are two types of air cooled condenser: Natural convection and forced convection.
In natural convection, the air flows over it in natural way depending upon the temperature of the
condenser coil. In the forced air, there is a fan operating by a motor over condenser coil to help it
cool. Another type of Condenser is Water Cooled Condenser, it is commonly used for large
operating plants for refrigeration, such as big packaged air conditioner, central air-conditioning
plants, etc. It is used when the cooling loads are excessively high and the amount of refrigerant flows
through the condenser is large. There are three types of Water Cooled Condenser, double pipe type,
shell and coil type, and shell and tube type. In all these condensers the refrigerant flows through one
side of the piping while the water flows through the other piping, cooling the refrigerant and
condensing it. And the other type of Condenser is Evaporative Condenser. Usually used in Ice
plants, this is a combination of both water cooled and air cooled condensers. In these condensers, the
hot refrigerant will flow through the coils and water is sprayed over these coils at the same time the
fan draws air from the side of the condenser and discharge it from the top side of the condenser. The
spray water that meets the condenser coil gets evaporated in the air and it absorbs the heat from the
condenser, cools the refrigerant and condenses it.
 P a g e | 98

7.2 Evaporative Condenser Operation

The vapor to be condensed is circulated through a condensing coil, which is continually
wetted on the outside by a re-circulating water system. Air is pulled or pushed over the coil, causing
a small portion of the re-circulating water to evaporate. The evaporation removes heat from the vapor
in the coil, causing it to condense.
Evaporative condensers provide heat rejection for many types of systems, and the specific
application will largely determine which BAC Evaporative Condenser is best suited for a project.
The Available Product Configurations Table on the next page is intended as a general guide.
Evaporative condensers are used to provide lower condensing temperatures and compressor
kilowatts savings of up to 30 percent when compared with air-cooled systems

FIG. 7.2.a
 P a g e | 99

FIG 7.2.b

The figure shown above shows the different type of Evaporative Condenser that can be used in the
refrigeration system.
 P a g e | 100

7.3 Condenser Selection

The condenser is selected on the basis of total heat rejected at maximum load condition. This
occurs when the compressor works at full load and the condenser’s ambient temperature is at design
maximum. The condenser will function efficiently when the condensing surface is kept free from
non-condensables and liquid refrigerants. According to the computation of the Cold Storage design.

- Computation for Corrected Heat Rejection (Qr)

Based on the design of our refrigeration system. The calculated Heat Rejected is given at 5.2.5. The
Heat Rejected at the Condenser

Ein = Eout
H4 = Qr + H5
Qr=H 4 −H 5

Qr= ṁr II h4 −ṁr II h5

Qr= ṁr II (h 4−h 5)

kg kJ
(
Qr= 0.09959
s )
( 1580.70−390.587 )
kg
kJ
Q r =118.523 ∨kW
s
 P a g e | 101

7.4 Selected Condenser

The researchers chose an Ammonia type of Evaporative Condenser mainly because the
refrigerant to be used in our plant is R717 or Ammonia. We also chose this Condenser because it can
satisfy the Computed Heat Rejected which is 108 KW. The available range of the condenser is154 –
4300 KW.

Ammonia Evaporative Condenser with Centrifugal Fans (CC)

Ammonia Evaporative Condenser with Centrifugal Fans (CC)

http://ammonia21.com/products/view/ammonia_evap_condenser_cc
P a g e | 102
 P a g e | 103

Chapter VIII
COMPRESSOR SELECTION
8.1 Compressor discussion
The compressor does exactly as its name says: it compresses the refrigerant. The compressor
receives low pressure gas from the evaporator and converts it to high pressure gas. As mentioned
earlier, as the gas is compressed, the temperature rises.
8.2 Compressor selection
8.2.1 Computation for the actual power of the compressor
A. Ein = Eout
H1 + WcI = H2
W cI =H 2−H 1

W cI =ṁ I h2−ṁ I h1

W cI =ṁI (h 2−h1 )

kg kJ
(
W cI = 0.08927
s )
( 1556.259−1452.64 )
kg
kJ
W cI =9.25 ∨kW
s
B. Ein = Eout
H3 + WcII = H4
W cII =H 4−H 3

W cII =ṁ II h 4−ṁ II h3

W cII =ṁII (h4 −h3 )

kg kJ
(
W cII = 0.09959
s )
( 1580.70−1475.05 )
kg
kJ
W cI =10.521 ∨kW
s
Total Wc = WcI + WcII
Total Wc = 9.25 + 10.521 kW
Total Wc = 19.771 or 20 kW
 P a g e | 104

8.2.2 Computation for the actual volume flow rate

A. Volume flowrate at LPC
Vg1 at -8˚C

L 1 m3
Vg1 = 386.944 x
kg 1000 L

m3
Vg1 = 0.386944
kg
Mr1= 0.089277 kg/s
V1 = mr1 x Vg1

m3 kg
V1 = 0.0896944 x 0.386944
kg s

m3 3600 s m3
V1 = 0.03469 x = 124.873
s 1 hr hr

B. Volume flowrate at HPC

Vg3 = 14˚C

L 1 m3
Vg3 = 180.154 x
kg 1000 L

m3
Vg3 = 0.180154
kg

Mr2= 0.09959 kg/s

V3 = mr2 x Vg3

m3 kg
V3 = 0.09959 x 0.180154
kg s

m3 3600 s m3
V3 = 0.01794 x = 64.590
s 1 hr hr
8.2.3 computation for volumetric efficiency
V inlet
η v=
VD

VD = LAN
L=110mm
D=160mm
rev 1 min
N=1000 x
min 60 s
 P a g e | 105

N= 16.67rps
V1
A. Low Pressure Compressor η v =
VD
m3
0.03469
s
η v= x 100%
π
( 2
)
.110 m ( .160 m ) (16.67)
4

η v =¿94.09%
V3
B. High Pressure Compressor η v =
VD
m3
0.01794
s
η v= x 100%
π
.110 m
4(( 2
)
.160 m (16.67)
)

η v =¿48.66%

8.3 selected compressor
Source: https://2.imimg.com/data2/DS/DJ/MY-108012/kirloskar-heavvy-duty-refrigeration-
compressor-kc-series.pdf
Technical Data
Power of compressor
Cylinder Arrangement
Number of cylinders
Bore X Stroke mm
Permissible speed
Swept volume m3/hr at 1000 rpm
Weight of Compr (without flywheel)
User Application Sector
User Sub Sector
Industry Sector
Source: http://www.kirloskarkpcl.com/Pdf/products/ACR/Compressor-ref-systems/kc-kcx-
english.pdf
P a g e | 106
KC21
31.32 kW
1XW
3
160 X 110
Belt drive from 400 to 1000 rpm in steps of
50 rpm
265.4
535kg
Power, Oil and Gas, Construction,
Agriculture, Utilities, Refrigeration & Air-
conditioning, Industry, Chemical & process
Refrigeration, Low temp Application, Process
Cooling, Concrete Cooling, Food preservation
Fruits/vegetables preservation, Breweries,
Bottling, Dairy,Water chilling, Chemical
pharmaceutical, Cold storages, Ice plants
 P a g e | 107

CHAPTER IX

LIQUID RECEIVER

9.1 Liquid Receiver

A common accessory used on many refrigeration systems is the liquid receiver. It is basically

a storage vessel designed to hold excess refrigerant not in circulation. Refrigeration systems exposed

to varying heat loads, or systems utilizing a condenser flooding valve to maintain a minimum head

pressure during low ambient temperatures, will need a receiver to store excess refrigerant (Marchese,

2014).

Some of the refrigeration units have enough space within the condenser to accommodate the

entire refrigerant charge of the system. If the condenser does not have enough space, a receiver tank

should be provided. The amount of refrigerant required for proper operation of the system

determines whether a receiver is required. In practice, when proper unit operation requires

approximately 3.6 kg or more of refrigerant, the use of a receiver is essential (Langley, 1982).

9.2 Liquid Receiver Selection

To compute the volume, substituting to the equation.

L 1 m3 kg 3600 s
(
V = 1.7257 x
kg 1000 L )(
0.2053 x
s 1 hr )
m3
V =1.275
hr
 P a g e | 108

9.3 Selected Liquid Receiver

Source: http://www.iceage-hvac.com

Figure 9.1: Model FDC-333 Vertical Liquid Receiver

Table 9.1: Selected Liquid Receiver Specification

Connection (inch) 3/8 ODF

Volume (L) 3
Dimension (mm)
A 293
B 42
C 127
αº 20
Source: http://www.iceage-hvac.com

Table 9.1 shows the selected liquid receiver specification.

 P a g e | 109

Chapter X: Surge Tank

10.1 Discussion of Surge Tank

The surge tank is a storage device for water used to neutralize the pressure in hydropower
water conveyance system. Its purpose is to resists excess the pressure rose and the pressure dropped
conditions. The function of the Surge Tanks are as follows: (1) It should protect the conduit system
from high internal pressure. (2) It should help the hydraulic turbine regarding its regulation
characteristics. (3) It should store the water to raise the pressure in pressure drop conditions.
The surge tanks location is also important for better results. It must be placed near to the
power house to reduce the length of penstock. It must be located at which flat sloped conduit and
steep sloped penstock meets.
10.2 Surge tank selection

Source : http://www.genemco.com/catalog/surgedrum.html
 P a g e | 110

Chapter XI
COOLING TOWER SELECTION

11.1 Cooling Tower discussion

Warm water from industrial equipment, commercial ac system or any other heat source
enters the tower and spreads evenly at the top. As the water flows down the tower, the equipment
fills spreads it over a large area to increase the water-air contact, thus enhancing heat transfer via
evaporation.

A large volume of air is constantly moving along the fill courtesy of large fans in the tower.
As evaporation takes place, the water loses heat. It eventually enters the tower sump at the bottom.
The cool water then goes back to cool the initial heat source and the cycle repeats. For the sake of
system dilution, of portion of the system water goes to the drain through a bleed-off valve. The
makeup line feeds the cooling tower with fresh water for replenishment.

11.1 Computation for the actual volume flow rate of water.

Based in the condenser calculations the mass of water in chapter 7 used. The mass of water
divided by the density of water in 40˚C. Then the Volume flow rate of water can get that going in
cooling tower. That volume flow rate going in cooling tower the parameter used to select a cooling
tower that fit to the design chill and cold storage plant.
mw
Vw = ρw

mw = 2.35895 kg/s

Table 11.1 Standard density of water at 40 degree Celsius

Temp Density
Density Density Density
( °C) pure Specific Gravity Specific Gravity
pure water tap water pure water
water 4 °C reference 60 °F reference
(g/cm3) (g/cm3) lb/cu.ft
(kg/m3)
40 0.9922 992.2 0.99225 61.92 0.992 0.993
Source: https://hypertextbook.com/facts/2007/AllenMa.shtml
kg
2.35895
s
Vw = kg
992.2 3
m

m 3 3600 s
Vw =(2.37749 x 10−3 )x
s 1 hr

m3
Vw =8.559
hr
 P a g e | 111

11.2 selected Cooling Tower

FRP Cooling Tower

Source: http://www.paltechcoolingtower.com/cooling-towers.html

Type Induced Draft Type, Forced Draft Type,

Natural Draft Type
Temperature 34-60 Degree
Tower Design Cross Flow, Counter Flow, Closed Loop,
Open Loop
Flow Rate (L/min) 50-22500 per cell
Cooling Capacity (in tons) 3TR-1500TR per cell
Dimensions Height = 2800mm
Diameter = 2100mm
Fan Diameter 1250mm
Motor Hp 2Hp
Operating weight 700kg
Pump head mm H20 3000
Source: http://www.airtechcool.com/frp-cooling-tower.html and
http://www.paltechcoolingtower.com/cooling-towers.html