A

Project Report
on

DESIGN AND FABRICATION OF PEDAL POWERED

FLOUR MILL MACHINE
Submitted for partial fulfillment of the requirement for the degree
of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING

Submitted By

ASHWANI (1752540032)
GANESH PASWAN (1752540046)
PRADEEP KUMAR (1752540065)
ATUL KUMAR (1752540033)
DEEPAK BHARTI (1752540048)

Project Guide

Mr. ANKIT TRIPATHI (Assistant Professor)

DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW,

UTTAR PRADESH, INDIA

1
 JUNE, 2021

CERTIFICATE

It is certified that Ashwani, Ganesh Paswan, Pradeep Kumar, Atul Kumar,

Deepak Bharti has carried out the research work presented in the project
entitled “Design And Fabrication Of Pedal Powerd Flour Mil Machine” for
the award of Bachelor of Technology from Dr. A.P.J. Abdul Kalam Technical
University, Lucknow under my supervision. The project embodies the result of
original work and studies carried out by the student himself and the contents of
the project do not form the basis for the award of any other degree to the
candidate or anybody else.

Date:
Place:

Mr. Ankit Tripathi Mr. Sharique Hayat

(Assistant Professor) (Head of Department)

2
 ACKNOWLEDGMENT

I would like to place on record my deep sense of gratitude to Mr. Ankit

Tripathi, assistant professor Dept. of Mechanical Engineering, Buddha Institute
of Technology, Gorakhpur, Pradesh, for generous guidance, help and useful
suggestions.

I express my sincere gratitude to Prof. Ankit Tripathi, Dept. of Mechanical

Engineering, Buddha Institute of Technology, Gorakhpur, Uttar Pradesh, for his
stimulating guidance, continuous encouragement, and supervision throughout
the course of present work.

I am extremely thankful To Dr. R.A. Agrawal, Director, Buddha Institute of

Technology, Gorakhpur, Uttar Pradesh, for providing me infrastructural
facilities to work in, without which this work would not have been possible.

SIGNATURE:
NAME OF STUDENTS:

ASHWANI (1752540032)
GANESH PASWAN (1752540046)
PRADEEP KUMAR (1852540909)
ATUL KUMAR (1752540033)
DEEPAK BHARTI (1752540048)

3
 DECLARATION

We hereby declare that this thesis is our own work and effort.
throughout this documentation wherever contributions of others are
involved, every endeavour was made to acknowledge this clearly with
due reference to literature. this work is being submitted for meeting
the partial fulfilment for the degree of Bachelor of Technology in
Mechanical Engineering at Buddha Institute of Technology,
Gorakhpur for the academic session 2020-2021.

NAME OF STUDENTS: SIGNATURE:

ASHWANI (1752540032)
GANESH PASWAN (1752540046)
PRADEEP KUMAR (1752540058)
ATUL KUMAR (1752540033)
DEEPAK BHARTI (1752540048)

4
 ABSTRACT
Refrigeration can be defined as the process of achieving and maintaining the temperature

below that of the surroundings, the aim is to freeze water, cool some product, or space to the

required temperature. The basis of modern refrigeration is the ability of liquids to absorb

enormous quantities of heat as they boil and evaporate. One of the important applications of

refrigeration is in ice plant. Ice plant is used for producing refrigeration effect to freeze

potable water in standard cans placed in rectangular tank which is filled by brine. Our

project based on simple refrigeration system which uses the vapour compression cycle. The

vapour compression cycle comprises four process compression, condensing, and expansion and

evaporation process. Our ice plant model contains various parts such as- Compressor,

condenser, filter drier, Expansion valve, Evaporator coil, chilling tank and various measuring

equipments like digital temperature indicator, pressure gauges, energy meter etc. The

conventional ice plant has been studied and a prototype model of an ice plant has been

fabricated with above said accessories. The model is analyzed for its cooling capacity assumed

per unit mass flow rate of refrigerant. Its COP is also calculated. The model is compared for

its coefficient of performance (COP) and cooling capacity by using R-134 a refrigerant with a

theoretical COP and cooling capacity obtained using refrigerant R-22. The variations found in

COP and cooling capacity are 0.12 and 0.042 TR respectively for unit mass flow rate of the

refrigerant.

KEYWORDS- Fabrication, Refrigeration , Compression, Cycle, Evaporation, Coefficient of

performance.

5
 CONTENTS
CHAPTER I

HISTORICAL Page
1
....................................

I. Early developments ............................... 1

II. Origin of principles .................... ........ 1

MECHANICAL REFRIGERATING SYSTEMS ................... 3

III. Cold air system ................ 3

IV. Vacuum system ..................................

4

V. Absorption system ................. 5

VI. Compression system ............................. 5

(a) Principle ......................... 5

(b) Fundamental parts ........................ 6

(c) Sulphuric ether .................. ........ .6

(d) Carbonic acid ...................... 6

(e) Sulphurous acid ............. 7

(f) Ammonia ........... 7

(g) Wet and dry ....... .................,*.... 7

FREEZING SYSTEMS .........................................

9

VII. Plate system ................ 9

..
....................................

VIII. Can system 9

..........................

ICE STORAGE COOLING 10

IX. Direct expansion 11

X. Indirect expansion ................... 11

..............................................
DEFINITIONS 12

XI. Refrigeration .............................

12

6
 C H A P T E R I

HISTORICAL

I.- EARLY DEVELOPMENTS - There is evidence that attempts to produce refrigeration

mechanically were made as early as 1755 by experimenting with liquids under vacuum. However we

have no authentic information that anything of real importance was accomplished until the early part

of the 19th century. Several independant inventors built experimental machines about this time,

but the first to achieve success was Jacob Perkins, an Englishman, who in 1834 patented an

ether compression machine.

II.- ORIGIN OF PRINCIPLES - The two general types compression and absorption machines,

find their origin in the demonstrated possibility of liquifying so-called gases. In 1823 Faraday

announced to the world that he had succeeded in liquifying chlorine, carbon dioxide and ammonia as

well as several other gases of less importance to the refrigerating industry.

In 1824 a machine was patented by Vallance, who probably took his idea from the evaporating

system so long used in India. Under this patent, dry air was circulated over / shallow trays of water

from which evaporation took place and heat was abstracted.

7
The first ammonia absorption machine recognized as such was invented by Carre

about the year 1855. In the same year James Harrison, an

Australian, and Professor Twining, an American, are said to have

independantly perfected the Perkins ether machine. It should be a
matter of congratulation and pride to all Australians that the
first really practical compression machine was invented by Harrison
who thus paved the way for the frozen meat industry in Australasia.
Professor Twining had performed the then marvelous feat of
artificially freezing blocks of ice with fish inside.

In 1873 Professor Linde introduced the ammonia com

pression machine, which is now so well known. Three years later the
sulphur dioxide compression machine was introduced by Raoul Pictet

of Geneva. The seventies, more particularly in the United

States, were pregnant with patents and improvements in refrigerating

machinery.

A few men who distinguished themselves during this

period are: David Boyle, who perfected his designs during the

siege of Vicksburg; Charles Ball, who developed the absorption

machine to a considerable extent; Ferguson, who designed the

first machine for the Frick Compahy; and John De la Vergne who

introduced the oil-injection system whose name is now world-known .

8
 MECHANICAL REFRIGERATING SYSTEMS

The different methods of producing cold have passed through

various stages of development and have led to the construction

of various types of machines, of which the compression machine

has become the most prominent.

The following systems of mechanical refrigeration will be

briefly described:

Cold Air Absorption

Vacuum Compression

III.- Cold Air System - When air is compressed in a cylinder

by mechanical means, its temperature rises. The heat of compression

can be removed by injecting a spray of cold water into the

cylinder or by passing the compressed air through a heat
exchanger where the temperature of the air will be lowered
to nearly that of the cooling water.

When the air is now allowed to expand while doing work

in an air engine, the temperature will be reduced considerably

below the initial temperature, and the expanding air is capable of

absorbing the heat of the rooms to be cooled. Cold air machines

are used in many steamers, private yachts, etc.

comparing cold air machines, with compression

machines, it is evident that machines that do not liquify the

refrigerating medium cannot be as economical as those that do.

9
The compression and expansion cylinders of the cold air

machine have to be very large, which increases the friction

considerably. The efficiency is less than 33 per cent. The

reason for still using the cold air machine on board ship

is because of the harmless character of the refrigerating

medium.

IV.- VACUUM SYSTEM - The eva.poration of water at a low

temperature in order to produce refrigeration is brought about by

forming a vacuum by means of a vacuum pump. Vacuum is produced in

a closed vessel into which the water is injec ted. Part of the

water quickly evaporates, whereby the necesssary latent heat is

removed from the remaining water, which is cooled and finally

frozen. Theoretically about six parts of water can be frozen by

the evaporation of one part of the water in this manner.

order to avoid the excessive large pump, that would be

needed tfc maintain a vacuum with air and water alone Sulphuric

acid is used as an absorbent in present day vacuum machines.

The water vapors are quicfely absorbed by the acid 8L (which

has^great affinity for water) and removed by the air pump.

There are many reasons why the vapor machines are not

used now except in special cases. The ice frozen by this process

is not transparent, but is opaque and resembles chalk. The acid

has corrosive properties and attacks the metals. It is

10
necessary to distill the acid during its cycle of operation and

this process is an item' of considerable expense. The handling

of this liquid is also a considerable inconvenience because of

the precautions necessary.

V.- ABSORPTION SYSTEM - In the absorption machine liquid ammonia

under an average pressure of 150 lbs. per square inch gage is

admitted to the expansion coils which are under a pressure of

about 15 lbs. gage. Here it rapidly evaporates , thus producing a

refrigerating effect equal to its latent heat of vaporisation.

The expanded gas is subjected to a stream of cold water in the

absorber, where it is absorbed, forming aqua ammonia. This

liquid is pumped through a heat exchanger into the generator

where it is heated up by steam coils and the ammonia driven off

as gas. The hot gas being confined produces pressure. It passes

from the generator to the condenser, where it is reduced to a

liquid again under the influence of pressure and cold water.

The weak hot liquor leaves at the bottom of the generator and

gives up part of its heat into the exchanger to the incoming strong

liquor, before it is able to absorb anew the ammonia vapors in

the absorber. The economy of absorption machines has been greatly

increased since the manufacturers are able to produce an almost

perfect anhydrous gas from the generator and since it is

possible to use exhaust steam from the auxiliary machinery to

evaporate the ammonia in the geberator.

11
VI. - COMPRESSION SYSTEM -

(a) PRINCIPLE - Systems of refrigeration using the compression

types of machines base their operation on the utilization of the

latent heat of vaporization of substances having low boiling

points. Such substances as ammonia, sulphurous acid, ether, etc.

are used as media.

(b) FUNDAMENTAL PARTS - The fundamental parts of the

compression systems are:

(i).Compressor ~ which withdraws the gas from J?he

refrigerator coils and compresses it into the

condenser.

(ii).The Condenser - where the heat of compression

isbremoved by the cooling water and the gas becomes

liquiiied.

(iii).Refrigerator * where the liquid evaporates into a

gas taking the necessary heat of vaporization from

the surrounding substances, thus doing the work of

refrigeration.

(c).SULPHURIC ETHER - Compression machines using sulphuric ether as

the working medium were in favor in the early days of

refrigeration, but have been abandoned in recent practice owing

to the enormous size of compressors necessary. Large volumes are

12
required because of the low pressures used which correspond with

the low vapor tensions of the liquid and low heat of

vaporization. Sulphuric ether is also a very inflammable gas and

this made its use dangerous.

(d). CARBONIC ACID - Carbonic acid is used as the medium where but

small compressor space is available. It has a small latent heat

of vaporization, but its vapor tension is very high, thus

requiring high pressures. Carbonic acid is cheap and has no

deleterious effect upon metals, water, meat or other products

kept in storage. With it small compressors may be used. These

advantages are, however, offset by the in creased strength of

fittings ahd pipe necessary, the danger due to high pressures and

the greater liability of leakage.

(e). SULPHURIC ACID.- Sulphurous acid is used to some extent in

compressors. It has a low vapor tension thus large compressors

are necessary. The principal advantage of sulphu rous acid as a

medium is that in its liquid state it is an oily substance and

hence acts as a lubricant. This eliminates the necessity for oil

seperators or rectifiers. This acid is non-corrosive, but any

leakage may produce sulphuric acid which is detrimental to

metals.

13
(f).AMMONIA.- Ammonia is the medium most generally used with

compression systems. It has a high heat of vapori zation, thus

only small quantities of the fluid need be in use. Its vapor

tension is comparatively low and this admits of li-quifaction at

relatively low pressure and high temperature. . These pressures

do not require exceptionally large machines, nor do they

necessitate extra precaution as to strength of parts. Care should

be observed in making the system as leakproof as possible since

ammonia gas will spoil most products that are put in storage.

Water hasAgreat affinity for ammonia and much loss can be incurred

in this way due to leaks.

(g).WET AND DRY.- Compressors are operated with either wet or dry

compression. If superheating of the gas is prevented by carrying

liquid ammonia into the compressor to keep the vapor always in a

saturated condition, the operation is said to be by wet

compression.If the gas is dry or nearly so at the begining of

compression and becomes superheated during the compression stroke,

this operation is said to be by dry compression.

14
 Fig. Ammonia with dry compression

The sketch shows an ideal entropy temperature diagram for ammonia operated with dry

compression. Refrigeration is assumed to be taking place at 142 F , condensation at 682 F, and

final temperature of 1762 F after compression. Line "AH" represents the evaporation in the

refrigerator , point "H"

being complete vaporization or dry saturation, "HK" (dry) adiabatic compression during which

period superheating takes place, "KC" cooling of superheated gas at constant pressure to the

condenser temperature,"CD" condensation in the condenser, "DA" cooling of the condensed

liquid as it passes over into the refrigerator. If compression started at or to the left of "B" it

would be wet, while if it started from any point between "B" and "H" it would first be wet

till the line "CH" was cut by the adiabatic and then dry.

Theoretical investigations shows that the difference in the performance coefficients for the

two systems.,wet and sdry. is very small unless high degree A of superheat are obtained. In this

case the coefficient falls off. Under actual operating conditions experiments have been made by

Professor Schrbter which show that a slight degree of superheat is advantageous to

performance. This does not agree with the theory, but in practice true adiabatic compression

15
is not obtained and the indications are that the superheat helps the performance by decreasing

the heat exchange between the cylinders and gas.

FREEZING SYSTEMS

There are two methods of freezing ice in general use, the plate and the can systems, both of

which have their advantages.

VII. - PLATE SYSTEM - In the plate system, hollow through which cold brine or ammonia can be

made to circulate, are immersed vertically into tanks filled with water. The ice forms gradually on

both sides of the plates thus ridding itself of air or any other impurities on its surface. Owing to

this self purifying property it is not necessary to distill or boil water, which is otherwise pure,

for use in the plate system. The time required for freezing plates 10ft. x 14ft. x 12” to 14”

thick is from nine to fourteen days, and the original outlay of capital,is quite large. The

operation of the plate system is quite intricate, thus the cost of operation . is rather high,

also repairs amount to a considerable sum.

The advantages of this system are that pure ice and clear ice can be made without boiling the

water nor agitating it during freezing. /

VIII. - CAN SYSTEM - In the can system the water placed in cans made of galvanized iron of

convenient size and shape. Rows of the cans are placed in a tank filled with brine. The brine is

usually agitated by a pump or propeller and is kept cold by coils of expansion pipe which extend

the length of the tank between adjacent rows of cans. The usual time required for freezing ll"x

22" x 44" blocks is from 50 to 60 hours. In this system freezing takes place on all sides of the cans

16
at the same time thus driving the air and impurities toward the center of the block. For this

reason it is necessary to distill or boil the water before freezing. It is essential to keep air out of

the water as much as possible since its presence makes the core of the block cloudy. The

distilled water system must be made of galvanized metal throughout. It is customary to

condense the exhaust steam from the engine in the can system since distillation is necessary. It

is found that in the average plant of capacity less than from 60 to 75 tons of ice per 24 hours,

there is just about enough exhaust steam to supply the required amount of distilled water for

freezing.

ICE STORAGE COOLING

Ice storage rooms must be kept at a temperature several degrees below the freezing point
of ice, usually about 282 p.

This cooling is done by either the direct or the inderect expansion method.

IX. - DIRECT EXPANSION.- In the direct expansion the expansion pipes are placed directly in
the room to be cooled, the gas temperature being maintained at about 10- below that of the
room. Thus small pipes may be used and the system may be operated with a relatively high
back pressure. In cases where various rooms must be maintained at different temperatures,
the medium has a tendency to collect and clog up in the pipes in the room of the coldest
temperature.

X. - INDIRECT EXPANSION.- With indirect expansio is first cooled in a tank containing

expansion coils outside the room to be cooled. This cold brine is then circulated through the
pipes in the room. The brine must be at a temperature 102 below that of the room and
the expanding gas must be 102 colder than the brine which it cools. Thus it is seen that

17
for this systeni colder gas is necessary than in the direct expansion system and this requires a
lower back pressure on the compressor. Hence a larger compressor is also necessary. The brine
pipes are larger than the ammonia expansion pipes, thus making the indirect system more
expensive to install. The inderect has one great advantage over the direct system in that when a
shutdown is necessary the brine will remain cold for a considerable length of time after the
compressor stops; but the direct ex pansion of the medium will cease as soon as the high
pressure on the system falls off.

DEFINITIONS

XI. - REFRIGERATION - The process by means of while temperature of any body is reduced or

which keeps the same below the temppreture of the atmosphere is called refrigeration.

XII. - UNIT OF REFRIGERATION.- The unit used in r gerating practice is the "ton of refrigeration'.'

It is the heat required to be abstracted in freezing one ton (2000 lbs.) of pure solid ice from water

at 32° F. - It is also the heat absorbed by 2000 lbs. of pure solid ice at 32° F. in melting into

water at 32° F.

One pound of ice at 32° F. melting to water at 32° will take up 144 B. T. U. - this is the

latent heat of ice. One "ton of refrigeration" is therefore equal to 2000 x 144 = 288,000 B. T.

U.

XIII. - TIME BASIS - All refrigerating calculatio based on a 24 hour basis

18
XIV. - RATING OF REFRIGERATING MACHINES - Refrigeration machines are rated by the number

of tons of refrigeration" they are capable of extracting in 24 hours, with additional

information as to the temperature and pressure ranges used in operation.

XV. - ICE MAKING CAPACITY - The ice making capac a machine in tons of ice is assumed as

approximately one half its refrigerating capacity. In practice distilled water is supplied at about

90° F. and the ice is cooled to about 16° F.

is as follows: B. T. U.

To cool water from 90° to 32° “ 1x (90- 32)x2000 = 116,000

To freeze water at 32° to ice at. 32° I 144 x 2000 = 288,000

To cool ice from 32° to 16° = 0.5 x(32 -16)x2000 = 16,000

420,000

Adding 20$ for various losses ............... “84,000

Total ............... . = 504,000

One ton of refrigeration being equal to .. 288,000 B. T. U.

and one ton of icc making capacity being 504,000

The ratio ( Ton of refrigeration / Ice making capacity ) = 1 to 1.75 or approximately 1 to 2.

XVI. - REFRIGERATING EFFECT.- The refrigerating effect of 1 cu. ft. of gas is represented by the

ratio of the latent heat of 1 lb. of gas to the volume of 1 lb. of gas.

XVII. - NECESSARY CHARACTERISTICS OF A REFRIGERAT

MEDIUM.- For refrigerating purpose a medium must have the following characteristics;

19
A relatively low boiling point - upon which depends the degree of cold that can be produced. A

high latent heat of vaporization - upon which depends the total number of heat units that will be

abstracted by the eva poration of a given weight of the medium. A low specific heat - upon which

depends the amount of the refrigeration produced which can actually be utilized.

C H A P T E R II

THE PLANT

LOCATION:- As shown on the sketch, page 15, the site selected for the plant is on a hill

near a creek from which the water required is to be taken. It is necessary to dam the creek and

locate a pump house on the bank.

DESIGN:- The relative positions of the rooms are so designed as to admit of extension

without any considerable change. The rooms are arranged in such a manner that the course of the

product through the plant is direct and retraces itself in only a few unavoidable instances.

20
21
 CALCULATIONS FOR A PLANT PRODUCING 40 TONS OF ICE IN 24 HOURS.

Ice is to be made from the condensed exhaust ste?im. It is assumed

that the distilled condensate reaches the storage tank at a

temperature of 90° F. , that the water is frozen and the ice

formed is further reduced in temperature in the cans to 15°

F.

Specific heat of water ........... 1

" " " ice ........... 0.5

Latent " ” " ....... 144. B. T. U.

I. - REFRIGERATION REQUIRED FOR FREEZING:-

Heat abstracted from one ton of distilled w a t e r ___ 1 x(90 -

32)x 2000 = 116,000 B. T. U.

Latent heat abstracted ......... 144 x 2000 r 288,000 " ”

Heat abstracted to cool ice to 15° F ...........0.5 x(32 -

15)x 2000 = 17,000 " " "

22
Total heat abstracted per ton of ice ........ 421,000 "

" "

Heat abstracted for 40 tons of ice 40 x 421,000 - 16,840,000

(B.T.U.)

II. - HEAT LOSSES THROUGH BRINE TANK.-

The freezer tank will have the following approximate dimensions

62'-0M 28'-0” x 4'-0" deep. Insulation is to be 6" cork board

on bottom and on all sides and 2" wooden boards on top.

Assume temperature in tank room ........... 90° F.

"of ground below tank .. 50° F.

Assume temperature of brine ............... 15° F.

Heat transmission constants -

For 6" cork boards _i|6 = .043 B. T. U. / sq. ft. hour/

degree difference in temperature.

For 2" wood 2 —.42B.T.U./ sq. ft. / hour /

degree difference in

temperature.
Total surface on sides .. 4(62 x 2 + 2 8 x 2) z

23
 4(124 + 56) = ..... 720 sq. ft.

*» " " top or

bottom ... J........ .... 62 x 28 = .........

1736 " "

Heat losses:

Through sides ...720 x .043 x 24(90 - 15) = 55,700 B. T. U.

" bottom 1736 x .043 x 24(50 - 15) = 62,800 " " "

" top .. 1736 x .42 x 24(90 - 15) = 1,514,000 " " "

Total for 24 hours .........................

1,432,500 "" "

III.- LOSS DUE TO WARM CANS.- Size of ice cans used

11" x 22" x 44", capacity 300 lbs.

Number of cans used in 24 hours ... 40 g^ QQ° “ 267» say 270

Weight of one c a n ..... 70 lbs.

Temperature of warm cans ............ 90° F.

Final temperature of cans .......... . 15° F.

Specific heat of steel ............. 0.1165

Heat loss for 270 cans - 270 x(90 - 15)x 0.1165 x 70

r 165,000 B. T. U.

24
 18

IV. - HEAT LOSS THROUGH STORAGE ROOM.-

Assume outside temperature .......... 90° F.

temperature maintained inside 28° F.

size ... 50'-0" x 25'-0" x 10*-0” high.”13" brick

walls

ceiling 1" boards with 80° dead air space above. floor 6"

concrete.

Insulation 6" cork board all over.

Heat transmission in B. T. U. / sq. ft. / hour /

degree

difference in temperature - M - — 1-JL.ZL.kl— l fl , x2 U 1

t-^ = outside temperature,

tg - inside "

xx and x2 = thickness of material (inches)

U1 u2 = coefficient of heat transmissionwvx VofX material.

25
 lVA U w 4L JL C4. I*

For walls (90 - 28) 2.39

M = 2

6
T7&B+

ceilings t t floor t 2.14 .83

»t

Wall surface ... (2 x 50 + 2 x 25)x 10 I 1,500 sq. ft.

Ceiling or floor surface ..,..50 x 25 “ 1,250 " "

Loss through walls ... 2.39 x 24 x 1500 = 86,000 B. T. U.

” " ceiling 2.14 x 24 x 1250 “ 64,250 " " *

26
 f l o o r ........
Loss through 83 x 24 x 1250 Z 24,950 _B..T/CK
Total for 24 hours .............. .......... 175,200 " ' M

V.- TuTAL HEAT LOSSES-IN 24 HOURS:-

Distilled water and ice ................ 16,840,000 B. T. U.

Transmission through brine tank ....... 1,432,500 '* ”

Heating of cans used .... •...... . 165,000

Transmission from storage room ............ " " "

TOTAL ................... 16,612,700 " " "

This amount of heat must be taken up by the ammonia.

= 65 tons of refrigeration nearly, 288,000

add 5% for losses unaccounted for or 65 4 3.3 = 68.3

Ratio Tons of refrigeration _ 68.3 = 1 77

Tons of ice 40 *

VI.- AMMONIA CALCULATIONS:-

Assume the temperature of brine .............. 15° F.

Let ts s the temperature of

ammonia gas (10° lower than brine) ...... . 5° F.

Let tc = the temperature of condensed liquid

ammonia in reciever ............... ........... 95° F.

Let qc = heat of liquid corresponding to tg = 71.3 B. T. U.

” s zspecific heat of ammonia ........ = 1

27
 rs = latent heat of vaporization

corresponding to ts ..................... - 568.3 B. T. U.

Let qs aheat of liquid corresponding to ts = -28.4 " ” "

Let, Vo = specific volume of saturated

b = gas corresponding to ts ............ s *2 cu* Per3-*:

R = refrigerating effect of one pound of medium

R = (rs + q s) - q r (568.3 + 28.4) - 71.3 = 468.6

B.T.U.per It

Total amount of ammonia required =

Total amount of refrigeration
required. Refrigerating "effect per
lb. of medium

18>|iy QQ = 39,900 lbs. per 24 hours.

468.6 ’

27.6 minute.

■11^1 = .41 lbs. per minute per ton of refrigeration.

68.3

Total volume of saturated ammonia gas leving

28
evaporating coils ... = 27.6 x 8.2 = 227 cu. ft. per
minute.

As the displacement of compressor only is effected

by the one of gas entering the cylinder it is customary to assume
that the gas at the begining of compression is dry and saturated.
Also to assume a volumetric efficiency oi 72^ for double acting
and 82$ for single acting cylinders.

VII.- SIZE OF COMPRESSOR.-

Assuming 72$ volumetricefficiency for a double-single acting

compressor we have:-

Piston displacement required - ^yg - 315 cu. ft. per minute.

Try a standard size compressor 14" x 21" double acting

running at 85 R. P. M.

x 2 x 85 = 317 cu. ft.per minut

Piston displacement z 154..X—21
1728 r 1

29
317 x 1728 = 8010 cu. in. per ton of refrigeration per minute.

68.3
The 14” x 21” cylinder for the revolutions assumed is

sufficiently large. We will therefore use an ”Artie"

14" x 21" Horizontal double-single acting compressor directly

connected to a

16" x 36" Simple Corliss Engine.

VIII.- THEORETICAL HORSE POWER OF COMPRESSOR.

= pressure corresponding to temperature (95°F) of ammonia

receiver = 197.3 lbs. per sq. inch.

pressure corresponding to temperature 5° F of expanded

ammonia = 33.79 lbs. per sq. inch.

To = absolute temperature of ammonia entering compressor

= 460° - 5° = 465°, tg = 5°

30
T3 = absolute temperature at the end of compression

1.29-1
197.3\ 1*29

=465 " = 691 33.79,

t3 = 691 - 460 = 231° F.

tc z the temperature of the liquid leaving condenser corres

ponding to the pressure P2 or 197.3 lbs. absolute = 95° F.

^2 = saturation temperature at back pressure - 5° F .

31
 heat content at temperature tQ z 559.8 B. T. U.
H c

" " " « to s 539.9 " " "

H2

specific heat of superheated ammonia at constant pressure .65

I. H. P s 778 (H C + C„ ( t3 - tc ) - Ha)

33,000

778 (559.8 4 ,58 ( 231 - 95 ) - 539.9)

33,000

2.36 per lb.of ammonia circulated.

Total I. H. P. of compressor = 27.6 x 2.36 : 65.15

65.15
.954 I. H. P. per ton of refrigeration.

68.3

32
 IX.- SIZE OF COMPRESSOR ENGINE.-

I. H. P. of Engine Driving Compressor:

Assume mechanical efficiency of compressor = 90$

•* ” " ” engine s 90$

I. H. P. of the Engine .90 x.90 z— — §- = 88.5

Theoretical M. E. P. of the Engine

Assume number of expansions = 4

/
The corresponding ratio of mean to initial pressure = .5965

Assume steam pressure = 100 lbs. per sq. inch gage.

z 115 lbs. absolute.

33
Assume back pressure s 17 lbs. per sq. inch absolute.

Theoretical M. E. P. = 115 x .597 -17 =

51.6 lbs. per sq.

inch absolute.

Assume diagram factor = 0.80

Expected M. E. P. = 51.6 x .80 - 41.28

H P « pLAN ____

12 x 33,000

, _ 90 x 33,000 x 12
141 sq. inches .

R m 41.28 x 36 x 170

Diameter corresponding to 141 sq. inches - 13.5 inches.

A steam cylinder 16" x 36" is therefore sufficiently

large.

34
 X.- SIZE OF COOLING WATER PUMP.-

The cooling water is to be run through a double-pipe ammonia

condenser, then over the steam condenser and into the feed

water heater.

Assume cooling water required perton of ice = 5 gal. per minute.

Total cooling water required = 40 x 5 = 200 gal. per minute.

Total length of pipe required from the creek to the tank

500 ft.

Assuming 3" discharge pipe on pump-

Friction head per 100 ft. of 3" pipe discharging 200 gal. per

minute = 9.08 ft .

Friction head on pump * AOSLJ LiLOg = 45 ft.

Elevation head on pump:-

From top of foundations to water level in tank r 45 ft.

" water surface in creek to top of foundation s 40 "

35
 24

Total head on pump ......... 130 ft.

A Goulds-single stage, double suction centrifugal pump size "35"

- 12 B. H. P. will fulfill the requirements.

XI. - SIZE OP BRINE PUMP.- The ice storage room

i. be refrigerated by means of the brine circulating system. From

previous calculations (page 19) the refrigeration required for the
ice storage room - 175,200 B. T. U. per 24 hours = approximately one ton
of refrigeration.

In practice it is customary to allow 4 gal. of brine circulated per

minute per ton of refrigeration. A Goulds single acting triplex
(2” x 3") plunger pump, motor driven, is sufficient for this
purpose. Approximately 1 H. P. motor will be required.

XII. - STEAM CONSUMPTION:-

Of Main Engine:- Assume 30 lbs. dry steam per I. H. P. hour for main

engine. Assume radiation loss and auxiliary steam consump tion 10^.

Steam consumption for above : 90 x 30(1 +.10) 2970 lbs. Of Generator

Engine:-

36
Motor required for cooling water pump....... 12 H. P.
Equivalent motor H.P. for lighting purposes ..... 7 " "

Motor required for can hoist ...................... 5 " "

" " M brine agitator ................. 5 " "

” " " " circulating pump ....... .1 1 "

Total electrical horse power - 30

Assume efficiency of motors 85%

25

Assume efficiency of generator ............ .90$

” M U engine ........... . 90$

I. H. P. of the generator engine = — 17A
.90~~X T 85 S 43*6

Assume 42 lb. dry steam per I. H. P. hour for generator engine

Steam consumption s 42 x 43.6 - 1830 lbs. per hour.

Total dry steam consumption s 2970 + 1830 a 4800 lbs. per hour at

106 lbs. boiler pressure. Adding 10$ for losses and £or the

reboilerv

The total steam required a 4800(1 +.10) = 5280 lbs. per hour.

5280 x 24 - 69.5 tons of steam available for condensation.

2000 ~ •

37
This is sufficient to stipply the necessary distilled water to
produce 40 tons of ice.

XIII. * SIZE OF FEED PUMP.-

Water required = 5280 lbs. Per hour = 2------ s 10.6 gal. per minute.
(say * 60 x 8.311

38
A Dean Bros. 6"x4"xl0" simplex pump will fulfill the
requirements.

XIV. -SIZE OF BOILER.-

to = the temperature corresponding to boiler pressure or

121 lbs. absolute = 341.9° F.

t-^ = feed water temperature (assume) .......... 120° F.

1 s latent heat of steam at 121 lbs. absolute pressure 876.7

B. T. U.

z total heat at atmospheric pressure = 970 B. T. U.

Boiler horse power a

3'2 + (t2~ ti) x

Total steam consumption per hour
-
34.5 “
H1

—
876.7 +■ ( 541 «9 —120) ^ 5280 —
182
“ '
970 ~
34.5

For Horizontal Tubular Boilers assume 12 sq. ft. of heating

surface per B. H. P.

Heating surface required z 12 x 182 z 2190 sq. ft.

Assume 7 lbs. of water evaporated per lb .of coal.

39
 22.5 lbs. of coal burned per sq. ft. of grate area.

Coal Consumption = - 900 lbs. per hour.

Grate area required z 40 sq. ft.

22.5

Heating surface - 2190 - 54.8

Grate area 40

Coal consumption (from heating value of coal)

Assume efficiency of boiler and grate .......... 60$

” heating value of coil 11000 B. T. U. per lb. .

Coal consumption = 182 x 54.5 x 970 - 925 lbs. per

hour.

.60 x 11000

(This value checks with previous calculations.)

Boiler Specifications:- Horizontal tubular type.

200 H. P.

2190 sq. ft. heating surface.

40
 " " grate area.
/

XV.- CHIMNEY CALCULATIONS.-

Diameter in inches - 4.68 x (H.P.) v

27
~ 4.68 x 2002/5

r 39"

Draft losses:

Belov/ grates ........................

03 inches of water.

Through grates and fuel bed ......... 27 " 11 "

Between furnace and d a m p e r ............ 22 " ”

In damper box ...................... .08 "

Above damper (breeching) ............ .01 ” "

Total actual loss .... ... .61 "

Theoretical loss z 7/6 x .61 - .71 inches in water.

Height of chimney:

Dc z theoretical draft loss = .71

Ta - temperature of outside air r 60° ■

T z . " " gases z 500°

S z feet.

H height in

41
H z D.

0.96 _ _1_____

8
1460 +Ta" 460 4-Tg

.71
Z 109 ft. (say 100
ft.)
0.96
8

520 960

42
43
44
 REFERENCES

 Modern Refrigerating Machinery Lorenz,- Pope, Haven, Dean.

 Compend of Mechanical Refrigeration and Engineering

J.E. Siebel.

 The Mechanical Production of Cold J.A. Ewing.

 Refrigeration, ColdStorage, and Ice Making A.J. Tayler.

 Machinery for Refrigeration Norman Selle.

 Elementary Mechanical Refrigeration Fred E. Mathews.

45
 The Refrigerating Engineers Pocket Manual Oswald Gueth.

 SS Chauhan, R Kumar, SPS Rajput - Journal of the Brazilian Society of …, 2019 - Springer

 Power Plant Design Prof. 0.A. Leutwiler.

 Personal Notes of Prof. L.A. Harding.

 Jp Yadav,(2015). A Study on Anasysis and Fabrication of an Ice Plant Model. Journal Of

Samriddhi Journal of Physical Sciences Engineering and Technology , 2(1)

DOI:10.18090/samriddhi.v2i1.1599

 Soe Myat Thu, Thant Zin Win, Hti Lar Tun Kyi (2020). A Study on COP of Existing Ice Plant.

International Journal Of International journal of Science and Engineering.

doi: 10.7753/IJSEA0808,1021

 AK Dhamneya, SPS Rajput, A Singh - Case studies in thermal engineering, 2018 -

Elsevier

 P Pandey, AB Agrwal - International Journal of Advanced Technology & …, 2015 -

ijater.com

 H Tsukagoshi, T Suzuki, K Nishikawa, S Agarie… - PloS one, 2015 - journals.plos.org

 SG Sharma, A Petare, S Rawariya - researchgate.net, Rawlings (1985) studied the energy

management of ice-storage air conditioning system using ethylene glycol as working

fluid. David (1984) has applied system optimization in HVAC plant and state that

optimization provides comfort, efficiency.

 S Yosefzadeh, S Alizadeh… - JOURNAL OF …, 2019 - sustainagriculture.tabrizu.ac.ir

46