MASS AND ENERGY
BALANCE
OF ICE MANUFACTURING
PLANT
A mass balance, also called a material balance, is an application
of conservation of mass to the analysis of physical systems.
The law of conservation of mass leads to what is called a mass
or a material balance. Mass In = Mass Out + Mass Stored
Raw Materials = Products + Wastes + Stored Materials.
ΣmR = ΣmP + ΣmW + ΣmS (where Σ (sigma) denotes the sum
of all terms).
ΣmR = ΣmR1 + ΣmR2 + ΣmR3 = Total Raw Materials
ΣmP = Σmp1 + ΣmP2 + ΣmP3 = Total Products.
ΣmW= SmW1 + S mW2 + SmW3 = Total Waste Products ΣmS
= ΣmS1 + ΣmS2 + ΣmS3 = Total Stored Products.
Mass and Energy Balance ● Ice Manufacturing Plant
Problem 1:
An ice plant has a capacity load of 18 TR produce an amount of
ice at -9° C considering ah 10% heat losses for 24 hrs. If the
brine temperature is 10°F and raw water temperature is 27°C,
Calculate the number of cans can be made and the amount of
water needed for the process.
Given:
Qt = 18TR
Tice = -9°C
TWater = 27°C
TBrine = 10°F
n = 10%
Time = 24hrs
Mass and Energy Balance ● Ice Manufacturing Plant
Solution :
; { Cwater(Twater – TFreezing ) + L + CIce( TFreezing - Tice)
Therefore:
[ Cwater(Twater – TFreezing ) + L + CIce( TFreezing - Tice)] x
[ 4.187 kj/kg-°C(27°C – 0°C ) + 335 kj/kg-°C + 4.187 kj/kg-°C( 0°C – (-
9°C))] x
m = 0.1232 k/s x x
mice = 10644.48 kg/day
Mass and Energy Balance ● Ice Manufacturing Plant
Solution :
For the number of can of ice made per day:
; FT Note: use 11in x 22in x 44in (Standard)
Therefore:
N = 126.36
N = 126 Cans
Mass and Energy Balance ● Ice Manufacturing Plant
Solution :
For the Mass of water:
Pwater = 1000 kg/m3
Brine Chiller
Pice = 917 kg/m 3
Using Density:
mwater = 11607.94 kg/day
Mass and Energy Balance ● Ice Manufacturing Plant
Energy balances are used in the examination of the various stages
of a process, over the whole process and even extending over the
total production system from the raw material to the finished
product.
Energy In = Energy Out + Energy Stored
ΣER = ΣEP + ΣEW + ΣEL + ΣES
Where :
ΣER = ER1 + ER2 + ER3 + ……. = Total Energy Entering
ΣEp = EP1 + EP2 + EP3 + ……. = Total Energy Leaving with Products
ΣEW = EW1 + EW2 + EW3 + … = Total Energy Leaving with Waste
Materials
ΣEL = EL1 + EL2 + EL3 + ……. = Total Energy Lost to Surroundings
ΣES = ES1 + ES2 + ES3 + ……. = Total Energy Stored
Mass and Energy Balance ● Ice Manufacturing Plant
Problem 2:
It is desired to freeze 10,000 containers of water each weighing
0.75 kg from an initial room temperature of 18°C to a final
temperature of -18°C. The water-freezing operation is to be
carried out in an air-blast freezing tunnel. It is found that the fan
motors are rated at a total of 80 horsepower and measurements
suggest that they are operating at around 90% of their rating,
under which conditions their manufacturer's data claims a motor
efficiency of 86%. If 1 ton of refrigeration is 3.52 kW, estimate
the maximum refrigeration load imposed by this freezing
installation assuming
(a) that fans and motors are all within the freezing tunnel
insulation and
(b) The fans but not their motors are in the tunnel. The heat-loss
rate from the tunnel to the ambient air has been found to be
6.3 kW.
Mass and Energy Balance ● Ice Manufacturing Plant
Solution :
Given Extraction rate from freezing ice (maximum) = 104 kW
Fan rated horsepower = 80
Now 0.746 kW = 1 horsepower and the motor is operating at 90%
of rating,
And so (fan + motor) power = (80 x 0.9) x 0.746 = 53.7 kW
Mass and Energy Balance ● Ice Manufacturing Plant
Solution :
(a) With motors + fans in tunnel
Heat load from fans + motors = 53.7 kW
Heat load from ambient = 6.3 kW
Total heat load = (104 + 53.7 + 6.3) kW = 164 kW
164 kW ( 3.52 tons of ref. / 1kW) = 46 tons of refrigeration
Mass and Energy Balance ● Ice Manufacturing Plant
Solution :
(b) With motors outside, the motor inefficiency = (1- 0.86)
does not impose a load on the
Total heat load = (104 + [0.86 x 53.7] + 6.3)
= 156 kW
= 156 kW ( 3.52 tons of ref. / 1kW)
= 44.5 tons of refrigeration
Mass and Energy Balance ● Ice Manufacturing Plant
