Ice Plant

REFRIGERATION PLANT
INTRODUCTION
HISTORY OF
REFRIGERATION
1748 - William Coolen of Glasgow University produced refrigeration by cr
eating partial vacuum over ethyl ether. But, he could not implemen
t his experience in practice.
1834 - The first development took place when Perkins proposed a hand-o
perated compressor machine working on ether.
1856 - Linde developed a machine working on ammonia.
1920 - du Pont put in the market a family of new working substances, the
fluoro-chloro derivatives of methane, ethane, etc.popularly kno
wn as chloro fluorocarbons or CFCsunder the name of Freons.
INTRODUCTION
HISTORY OF
REFRIGERATION
1920 - Development was that of the ammonia-water vapour absorption ma
chine by Carre. These developments account for the major commerci
al and industrial applications in the field of refrigeration.
1834 - A phenomenon called Peltier effect was discovered in which is still no

t commercialized.
1877 - Advances in cryogenics, a field of very low temperature refrigeration,

were registered with the liquefaction of oxygen by Pictet .
1898 - Dewar made the famous Dewar flask to store liquids at cryogenic tem
peratures.
1908 - Liquefaction of other permanent gases including helium by Onnes wh

ich led to the discovery of the phenomenon of superconductivity.
INTRODUCTION
DEFINITION
Refrigeration may be defined as the process of achieving and

maintaining a temperature below that of the surroundings, the
aim being to freeze ice, 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.
REFRIGERATORS AND HEAT PUMPS
Heat flows in the direction of decreasing temperature, that is, from
high-temperature regions to low-temperature ones. This heat-transfer
process occurs in nature without requiring any devices.
The reverse process, however, cannot occur by itself. The transfer of hea
t from a low-temperature region to a high-temperature one requires
special devices called refrigerators.
Refrigerators are cyclic devices, and the working fluids used in the
refrigeration cycles are called refrigerants.
Heat flows in the direction of decreasing temperature, that is, from
high-temperature regions to low-temperature ones. This heat-transfer
process occurs in nature without requiring any devices.
The reverse process, however, cannot occur by itself. The transfer of hea
t from a low-temperature region to a high-temperature one requires
special devices called refrigerators.
Refrigerators are cyclic devices, and the working fluids used in the
refrigeration cycles are called refrigerants.
Another device that transfers heat from a low-temperature medium to

a high-temperature one is the heat pump. Refrigerators and heat
pumps are essentially the same devices; they differ in their objectives
only.
The objective of a refrigerator is to maintain the refrigerated space at a

low temperature by removing heat from it.
The objective of a heat pump, however, is to maintain a heated space

at a high temperature.
The performance of refrigerators and

heat pumps is expressed in terms of
the coefficient of performance (COP),
defined as:
COPHP = COPR + 1
The performance of refrigerators and

heat pumps is expressed in terms of
the coefficient of performance (COP),
defined as:
The cooling capacity of a refrigeration systemthat is, the rate

of heat removal from the refrigerated spaceis often expressed
in terms of tons of refrigeration.
It is equivalent to rate at which heat is removed from 1 ton of w

ater at 0 to freeze it into ice at 0 in one day.
THE REVERSED CARNOT CYCLE
All four processes that comprise the Carnot cycle can be reversed.
Reversing the cycle does also reverse the directions of any heat
and work interactions. The result is a cycle that operates in the
counterclockwise direction on a T-s diagram, which is called the
Reversed Carnot cycle. A refrigerator or heat pump that operates on the
reversed Carnot cycle is called a Carnot refrigerator or a Carnot heat
pump.
REFRIGERATION SYSTEMS
A refrigeration system is an assembly of four major components,
namely the Compressor, Condenser, Expansion Device and the
Evaporator, through which a very low boiling point substance
(refrigerant) flow in cycle, and absorbs heat from the immediate
surroundings, thereby producing the cooling effect (Refrigerating
effect).
TYPES OF REFRIGERATION SYSTEM
1. Vapor Compression Refrigeration System

2. Absorption Refrigeration System
3. Gas Refrigeration System
4. Cascade Refrigeration
5. Thermoelectric Refrigeration
VAPOR COMPRESSION CYCLE
The vapor-compression refrigeration cycle is the most widely used
cycle for refrigerators, air-conditioning systems, and heat pumps.
It consists of four processes:
1-2 Isentropic compression in a compressor

2-3 Constant-pressure heat rejection in a condenser
3-4 Throttling in an expansion device
4-1 Constant-pressure heat absorption in an evaporator
3
Condenser
High Pressure
4 Side
Expansion
Device Compressor
1 2 Low Pressure
Side
Evaporator
Low pressure liquid refrigerant

in evaporator absorbs heat and
changes to a gas 3
Condenser
High Pressure
4 Side
Expansion
Device Compressor
1 2 Low Pressure
Side
Evaporator
IDEAL VAPOR COMPRESSION CYCLE
The superheated vapour enters

the compressor where its
pressure is raised
3
Condenser
High Pressure
4 Side
Expansion
Device Compressor
1 2 Low Pressure
Side
Evaporator
The high pressure superheated
gas is cooled in several stages
in the condenser
3
Condenser
High Pressure
4 Side
Expansion
Device Compressor
1 2 Low Pressure
Side
Evaporator
Liquid passes through expansion device,
which reduces its pressure and controls
the flow into the evaporator
3
Condenser
High Pressure
4 Side
Expansion
Device Compressor
1 2 Low Pressure
Side
Evaporator
ACTUAL VAPOR COMPRESSION CYCLE
An actual vapor-compression refrigeration cycle differs from the ideal
one in several ways, owing mostly to the irreversibilities that occur in
various components. Two common sources of irreversibilities are fluid
friction (causes pressure drops) and heat transfer to or from the
surroundings.
REFRIGERANT SELECTION
When designing a refrigeration system, there are several refrigerants

from which to choose, such as chlorofluorocarbons (CFCs), ammonia,
Hydrocarbons (propane, ethane, ethylene, etc.), carbon dioxide, air
(in the air-conditioning of aircraft), and even water (in applications
above the freezing point). The right choice of refrigerant depends on
the situation at hand.
Two important parameters that need to be considered in the

selection of a refrigerant are the temperatures of the two media (the
refrigerated space and the environment) with which the refrigerant
exchanges heat. To have heat transfer at a reasonable rate, a
temperature difference of 5 to 10C should be maintained between
the refrigerant and the medium with which it is exchanging heat.
AMMONIA
Ammonia is predominantly used in food refrigeration facilities such as

the cooling of fresh fruits, vegetables, meat, and fish; refrigeration of
beverages and dairy products such as beer, wine, milk, and cheese;
freezing of ice cream and other foods; ice production; and
low-temperature refrigeration in the pharmaceutical and other process
industries.
The advantages of ammonia over other refrigerants are its low cost,
higher COPs (and thus lower energy cost), more favorable
thermodynamic and transport properties and thus higher heat
transfer coefficients (requires smaller and lower-cost heat exchangers),
greater detectability in the event of a leak, and no effect on the
ozone layer.
The major drawback of ammonia is its toxicity, which makes it

unsuitable for domestic use.
R-11
R-11 is used primarily in large-capacity water chillers serving air
conditioning systems in buildings.
R-12
R-12 is used in domestic refrigerators and freezers, as well as automotive air
conditioners.
R-22
R-22 is used in window air conditioners, heat pumps, air conditioners of
commercial buildings, and large industrial refrigeration systems, and offers
strong competition to ammonia.
R-502
R-502 (a blend of R-115 and R-22) is the dominant refrigerant used in
commercial refrigeration systems such as those in supermarkets because it
allows low temperatures at evaporators while operating at singlestage
compression.
R-134a - chlorine-free refrigerant

ICE PLANT
One of the important applications of refrigeration is in ice
making.
The term ice plant is used to mean a complete installation for

the production and storage of ice, including the icemaker itself,
the unit that converts water into ice, together with the associated
refrigeration machinery, harvesting and storage equipment, and
the building.
Ice plants are usually classified by the type of ice they produce;
hence there are block ice plants, flake ice plants, tube, slice or
plate ice plants and so on.
TYPES OF ICEMAKER
Block Icemaker
Tapered rectangular metal cans filled with water are immersed in

a tank containing refrigerated sodium chloride brine. The
dimensions of the can and the temperature of the brine are
usually selected to give a 24 hour production time, and batches
of cans are emptied and refilled in sequence during that period.
Ice block weight can range from 12 to 150 kg depending on
requirements; 150 kg is regarded as the largest size of block one
man can conveniently handle. A block ice plant requires
continuous attention and is labor intensive. The icemaker and the
store require a good deal of floor space and impose heavy loads
on the building structure. For these reasons block ice plants are g
oing out of use, and more modern automatic plants are replacing
them.
TYPES OF ICEMAKER
Block Icemaker
A regular schedule of pulling ice cans is maintained and

ice is transferred to a storage room that is apart from
the ice making plant. Ice plants are rated according to
capacity to produce ice in a 24 hour period. Brine tanks
located within the building are usually contained in pits
lined with concrete and cork or fiberglass insulation
TYPES OF ICEMAKER
Block Icemaker
TYPES OF ICEMAKER
Block Icemaker
TYPES OF ICEMAKER
Rapid Icemaker
It is possible to reduce the freezing time for blocks considerably,

and thus reduce the space required for the icemaker. This is done
by reducing the thickness of ice to be frozen; in one type of
rapid icemaker this is achieved by passing refrigerant through
tubes around which the ice forms and fuses into a block.
The blocks can be released by defrosting and harvested automati

cally, thus markedly reducing the labor requirement, but the
storage space required is slightly larger than for the same weight
of conventional block ice because the blocks have hollow centers
after the tubes are removed.
TYPES OF ICEMAKER
Flake Icemaker
A sheet of ice 2-3 mm thick is formed by spraying water on the

surface of a refrigerated drum, and scraping it off to form dry
subcooled flakes, usually 100-1000 mm2in area. No water is
sprayed on that part of the drum immediately before the scraper,
so that the ice becomes dry and subcooled prior to removal.
Refrigerant temperature, drum or scraper speed, and degree of

subcooling are all variable within designed limits so that the
capacity of the icemaker and the thickness of the ice can be
altered. Typical refrigerant temperature in a flake ice machine is -
20 to - 25C, lower than in most other types of icemaker, to give
rapid cooling and thus make the machine compact. The low
operating temperature requires more power, but this is to some
extent compensated for by the absence of a need to defrost.
TYPES OF ICEMAKER
Flake Icemaker
TYPES OF ICEMAKER
Flake Icemaker
TYPES OF ICEMAKER
Tube Icemaker
Water is frozen on the inner surface of vertical refrigerated tubes

to form hollow cylinders of ice about 50 mm in diameter and
with walls 10-12 mm thick. The ice cylinders are released by
defrosting the tubes automatically, and are chopped into pieces
about 50 mm long by a rotating cutter as they slide out. T
he cylindrical pieces can be subcooled by storing them at - 5C,
but they may require further crushing before being suitable for
some applications.
TYPES OF ICEMAKER
Tube Icemaker
TYPES OF ICEMAKER
Tube Icemaker
TYPES OF ICEMAKER
Plate Icemaker
Water is frozen on one face of a vertical refrigerated plate, and

the sheet of ice is released by running warm water on the other
face of the plate. The size of ice particle is variable, but the
optimum thickness is 10-12 mm. The plates are usually mounted i
n banks, often above the refrigeration machinery, to form a self c
ontained unit. Water for defrosting has to be heated if its
temperature is below 23C. Like most other icemakers the plate
ice machine will operate unattended on an automatic timing
cycle.
TYPES OF ICEMAKER
Plate Icemaker
TYPES OF ICEMAKER
Plate Icemaker
ICE PLANT CONSTRUCTION
ICE PLANT CONSTRUCTION
An Ice plant has two additional circuits that help to

create ice in huge quantity.
1. Refrigeration Circuit (Primary refrigerant)

2. Cooling Water Circuit (Cooling water)
3. Brine Circuit (Brine solution / Secondary Refrigerant)
Main Components of an Ice Plant
The main components generally used in an ice plant are:
Compressor
Condenser
Expansion Valve
Evaporator
Chilling Tank
EVAPORATOR
The evaporator is an important device used in the low pressure side of the
refrigeration system. The liquid refrigerant from the expansion valve enters into the
evaporator where its boil and change into vapour.
The function of the evaporator is to absorb heat from the surrounding location or
medium which is to be cooled, by means of a refrigerant. The temperature of the
boiling refrigerant in the evaporator must always be less than that of the surrounding
medium so that heat flows to the
refrigerant.
The evaporator becomes cold and remains cold due to the following two reasons:
The temperature of the evaporation coil is low due to the low temperature of the
refrigerant inside the coil.
The low temperature of the refrigerant remains unchanged because any heat it
absorbs is converted to latent heat as boiling proceeds.
TYPES OF EVAPORATORS
1. Bare-tube Coil Evaporator
The bare tube evaporators are made up of

copper tubing or steel pipes. The copper
tubing is used for small evaporators where
the refrigerant other than ammonia is used,
while the steel pipes are used with the large
evaporators where ammonia is used as the
refrigerant. The bare tube evaporator
comprises of several turns of the tubing,
though most commonly flat zigzag and oval
trombone are the most common shapes. The
bare tube evaporators are usually used for
liquid chilling.
2. Plate Evaporator
In the plate type of evaporators the coil usually

made up of copper or aluminum is embedded
in the plate so as so to form a flat looking
surface. Externally the plate type of evaporator
looks like a single plate, but inside it there are
several turns of the metal tubing through which
the refrigerant flows. The advantage of the
plate type of evaporators is that they are more
rigid as the external plate provides lots of
safety. The external plate also helps increasing
the heat transfer from the metal tubing to the
substance to be chilled. Further, the plate type
of evaporators are easy to clean and can be
manufactured cheaply.
3. Finned Evaporator
The finned evaporators are the bare tube type
of evaporators covered with the fins. When the
fluid (air or water) to be chilled flows over the
bare tube evaporator lots of cooling effect from
the refrigerant goes wasted since there is less
surface for the transfer of heat from the fluid to
the refrigerant. The fluid tends to move
between the open spaces of the tubing and
does not come in contact with the surface of
the coil, thus the bare tube evaporators are less
effective. The fins on the external surface of the
bare tube evaporators increases the contact
surface of the of the metallic tubing with the
fluid and increase the heat transfer rate, thus
the finned evaporators are more effective than
the bare tube evaporators.
4. Shell and Tube Evaporator
The shell and tube types of evaporators are used in the large refrigeration and
central air conditioning systems. The evaporators in these systems are
commonly known as the chillers. The chillers comprise of large number of the
tubes that are inserted inside the drum or the shell. Depending on the direction
of the flow of the refrigerant in the shell and tube type of chillers, they are
classified into two types: dry expansion type and flooded type of chillers.
In dry expansion chillers the refrigerant flows along the tube side and the fluid
to be chilled flows along the shell side. The flow of the refrigerant to these
chillers is controlled by the expansion valve. In case of the flooded type of
evaporators the refrigerant flows along the shell side and fluid to be chilled
flows along the tube. In these chillers the level of the refrigerant is kept
constant by the float valve that acts as the expansion valve also.
4. Shell and Tube Evaporator
COMPRESSOR
A refrigerating compressor, as the name indicates,
is a machine used to compress the vapour
refrigerant from the evaporator and to raise its
pressure so that the corresponding saturation is
higher than that of the cooling medium. It also
continually circulates the refrigerant through the
refrigerating system. Since the compression of
refrigerant requires some work to be done on it,
therefore a compressor must be driven by some
prime mover. In other words the purpose of the
compressor in the vapour compression cycle is to
compress the low-pressure dry gas from the
evaporator and raise its pressure to that of the
condenser. Compressors may be divided into two
types, positive displacement and dynamic.
Two Types of Compressors:
Positive displacement types compress

discrete volumes of low-pressure gas by
physically reducing the volumes causing
a pressure increase.
Dynamic types raise the velocity of the

low-pressure gas and subsequently
reduce it in a way which causes a
pressure increase.
Three Commonly Used Types of Compressors:
Reciprocating - uses piston to compress the Centrifugal - usually used in

refrigerant driven by a crankshaft in a straight line large capacity refrigerating
back and forth motion. Vapor from the suction system. In this compressor,
line is moved through the intake valve as the the vapor is moved in a
piston move downward. As the piston moves circular motion known as
upward, it compresses the vapor refrigerant centrifugal force. An impeller
which is then pushed through the exhaust valve which is a disk with radial
into the condenser. blades spins rapidly inside
this housing causing the gas
to gain velocity.
Rotary - A positive displacement machine in
which compression of the fluid is effected directly
by a rotor and without the usual piston,
connecting rod, and crank mechanism of the
reciprocating compressor.
Types of Compressors based on enclosure:
Hermetically Sealed
Semi-Hermetic
Open
The difference between the hermetic and semi-hermetic, is that the

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

drive cannot be repaired or maintained, and the entire
compressor must be removed if a motor fails. A further
disadvantage is that burnt out windings can contaminate whole
systems requiring the system to be entirely pumped down and
the gas replaced. Typically hermetic compressors are used in low-
cost factory-assembled consumer goods where the cost of repair
is high compared to the value of the device, and it would be
more economical to just purchase a new device. An advantage of
open compressors is that they can be driven by non-electric
power sources, such as an internal combustion engine or turbine.
Hermetic
Open Type
Semi-Hermetic
CONDENSER
The condenser is an important device used
in the high pressure side of a refrigeration
system. Its function is to remove heat of hot
vapor refrigerant discharge from the
compressor. The hot vapour consists of the
heat absorbed by the evaporator and the
heat of compression added by the
mechanical energy of compressor motor.
The heat from the hot vapour refrigerant in
a condenser is removed first by transferring
it to the walls of the condensers tubes and
then from the tubes to the condensing or
cooling medium. The selection of the
condenser depends of the capacity of the
refrigerating system, the type of refrigerant
used and the type of cooling medium
available.
Types of Condenser:
Water-cooled
Air-cooled
Evaporative
.Water-Cooled Condenser
It is a heat exchanger that removes heat from refrigerant vapor and transfers it to the running
water. Having the refrigerant vapor condensed on the outside of a tube does this. In doing so, the
vapor condenses and gives up heat to the water running inside the tube.
Air-Cooled Condenser
An air cooled condenser is one in which the removal of heat is done by
air. It consists of steel or copper tubing through which the refrigerant flows.
The size of tube usually ranges from 6-mm to 18-mm outside diameter,
depending upon the size of condenser. Generally copper tubes are used
because of its excellent heat transfer ability. The condensers with steel tubes
are used in ammonia refrigerating systems. The tubes are usually provided
with plate type fins to increase the surface area for heat transfer. The fins are
usually made from aluminum because of its light weight. The fin spacing is
quite wide to reduce dust clogging. The condensers with single row of tubing
provide the most efficient heat transfer. This is because the air temperature
rises at it passes through each row of tubing. The temperature difference
between the air and the vapour refrigerant decrease in each row of tubing
and therefore each row becomes less effective. However, single row
condensers require more space then multi row condensers.
The single row condensers are usually used in small capacity refrigeration
systems such as domestic refrigerators, freezers, water coolers and room air
conditioners. The air cooled condensers may have two or more rows of tubing, but
the condensers with up to six rows of tubing are common. Some condensers have
seven or eight rows. However, more than eight rows of tubing are usually not
efficient. This is because the air temperature will be too close to the condenser
temperature to absorb any more heat after passing through eight row of tubing.
EXPANSION DEVICES
The expansion device (also known as metric device or throttling
device) is an important device that divides the high pressure side
and the low pressure side of a refrigerating system. It is connected
the receiver (containing liquid vapour at high pressure) and the
evaporator (containing liquid refrigerant at low pressure). The
expansion device performs the following functions like to reduce the
high pressure liquid refrigerant to low pressure liquid refrigerant
before being fed to the evaporator and to maintain the desire
pressure difference between the high and low pressure side of the
system, so that the liquid refrigerant vaporizes at the designed
pressure in the evaporator.
There are many types of expansion devices used like capillary

tubes, automatic or constant-pressure expansion valve, low
side float valve, high side float valve and thermostatic
expansion valve in an ice plant industry depending upon its
capacity. In an ice plant the capillary tube type expansion
devise is generally used which is discussed in details ahead.
CAPILLARY TUBE
The capillary tube is used as an expansion device used in small capacity
hermetic sealed refrigeration units such as domestic refrigeration, water
cooler, room air conditioner and freezers. It is a cooper tube of small
diameter and of varying length depending upon the application. The inside
diameter of the tube used in refrigeration work is generally about 0.5 mm
to 2.25 mm and the length varies from 0.5 m to 5 m. It is installed in the
liquid line between the condenser and evaporator. A small filter drier is
used on some system to provide additional freeze-up application. In its
operation, the liquid refrigerant from the condenser enter the capillarity
tube due to friction resistance offered by small diameter tube, the pressure
drops since the frictional resistance is directly proportional to the length
and inversely proportional to the diameter, therefore longer the capillary
tube and smaller its inside diameter, greater is the pressure drop created in
the refrigerant flow. In other words, greater pressure difference between
the condenser and the evaporators needed forgiven flow rate of refrigerant.
CAPILLARY TUBE
CHILLING TANK (BRINE TANK)
The main components of chilling tank are : ice tank, insulation of ice tank and ice
block. Ice tanks are made of material such as wood, steel or concrete. As wooden
tanks do not last long enough and are liable to leak, chilling tanks are usually made
of steel or reinforced concrete.
The tank contains the direct expansion coils, equally distributed throughout the tank
and these coils are submerged in brine. The tank is provided with a suitable frame to
the ice cans and a propeller or agitator for keeping the brine in motion: the brine in
the tank acts as a medium of contact only, the refrigerant evaporating in the ice coils
extracts the heat from the brine, which again absorbs the heat for the water in the
cans.
The tank itself should not be much larger than is necessary to hold the cans, the
coils, and the agitator. Commercial sizes of Ice cans vary with the weight of ice cakes
required. The cans are made to contain about 5% more than their rated capacity to
compensate for thawing.
CHILLING TANK
Ice Plant Auxiliaries
Some of the ice plant auxiliaries are:
Receiver
Filter Drier
Suction Accumulator
Oil Separators
RECEIVER
A liquid receiver will be required if it is
necessary to temporarily store refrigerant
charge within the system, or to
accommodate the excess refrigerant
arising from changing operating
conditions. The total refrigerant charge
required in a circuit will vary with different
operating loads and ambient, and must be
sufficient at all times so that only liquid
enters the expansion valve. A receiver
requires a minimum operating charge
which adds to overall charge and cost, and
also increases system complexity. Hence
receivers are avoided on many smaller
systems.
FILTER DRYER
The function of filter dryer is to remove
any physical material from compressors
wear and tear, and remove any moisture
presence within an air conditioning
system. The Drier is made up of a metal
outer container and inside there is a
desiccant (moisture removal material) and
strainer. Refrigerant passes through the
drier and give up any moisture as well as
any unwanted matter. The main job of the
drier is to protect the metering device
from clogging either by Ice (moisture) or
blockage by particles.
It is not uncommon for driers and filters

to block due to their nature of picking
up unwanted agents - evidence of this
can be seen by frost build up. Filtering
process is achieved by mechanical
action of partitioning the flow. Particles
will be trapped, whilst the refrigerant
flow will be maintained. These
desiccants can be of two types, viz.
absorbent and adsorbent type. In this
model adsorbent type filter drier is
used which is defined ahead.
SUCTION ACCUMULATOR
Suction line accumulators are
sometimes inserted in halocarbon
circuits, to serve the purpose of
separating return liquid and prevent it
passing over to the compressor. Since
this liquid will be carrying oil, and this oil
must be returned to the compressor, the
outlet pipe within the separator dips to
the bottom of this vessel and has a small
bleed hole, to suck the oil out.
OIL SEPARATOR
During the compression stroke of a
reciprocating machine, the gas becomes
hotter and some of the oil on the cylinder
wall will pass out with the discharge gas.
Some oil carry-over will occur with all
lubricated compressor types, and in small
self-contained systems it quickly finds its
way back to the compressor. Start up after
a long idle period can result in a large
amount of oil carryover for a short period
due to foaming. With larger more complex
systems with remote evaporator oil, it is
desirable to fit an oil separator in the
discharge line to reduce carry-over to the
system.
AGITATOR
The propeller of the agitator is located in
the brine tank and the agitator motor
extends above the brine tank. Usually the
agitator is located at the opposite corner
of the brine tank from the accumulator.
The function of the agitator is to circulate
brine through the brine tank and raceway
The agitator consists of a propeller guide
vanes a vertically mounted motor and a
housing. The agitator motor drives the
propeller which circulates brine by
drawing it from around the evaporator
and discharging it by the ice cans. The
agitator must be operated whenever the
plant is in operation .
ICE CANS
Ice cans are made of galvanized steel and
are tapered from the bottom to facilitate
ice removal. Ice cans usually contain from
50 to 300 pound ice blocks. Often two or
even four ice cans are fastened together
so that two or four ice cans may be
removed from the brine tank in one
operation
ICE PLANT WATER FILTERS

Clear palatable ice is not produced in an ice plant without
proper treatment of the raw water to be frozen. A water filter is
installed for this purpose. To assist in filter operation water is
treated with alum to coagulate suspended foreign substances in
water. The water filter contains quartz sand or gravel through
which water is passed for removal of suspended matter.
Periodically material accumulated by the filter is flushed from
the bed by reversing water flow. Accumulated material is then
disposed to a sewer. This operation is called back washing .
CAN FILLERS
Can fillers are used to facilitate filling of ice cans with water. Small plants
use a portable can filler that is connected to the water supply by a hose.
The can filler is inserted in an ice can and water flows into the can. A float
valve which is part of the can filler stops flow of water into the ice can
when water reaches the proper level. Large ice plants use wall mounted
can fillers. These can fillers are located over a can dump and are used to fill
ice cans just after ice has been removed from the cans. A wall mounted can
filler consists of one or more tanks depending on the number of ice cans in
a group a float valve to regulate the amount of water in the tanks and an
operating lever which controls flow of water from the can filler into the ice
cans. The lever also acts to shut off the float valve so that the can filler will
not begin to fill until the lever is released. Can fillers in large ice plants are
automatic
CAN DUMPS
Can dumps are used to facilitate removal of ice from ice cans Ice cans are
placed in the can dump while it is in a vertical position. The can dump is
then pushed to a horizontal position and ice slides out of the cans and
down an ice chute to the storage room. The can dump is so balanced that
when ice blocks slide out of the can it returns to a vertical position. In
some plants, ice is dipped in a dip tank to loosen it in ice cans. In some
installations, a method for loosening ice in ice cans is incorporated directly
in the can dump. When the can dump is pushed to a horizontal position, a
spray of water is directed on the ice cans until ice loosens in the cans and
slides down the ice chute. Water supply stops when the can dump returns
to a vertical position
DIP TANK
A dip tank is used to loosen ice in the ice cans when this function is not
accomplished by a can dump. The dip tank contains warm water which
melts the ice sufficiently to loosen it in the cans. A dip tank water heater
keeps the temperature of the water in the dip tank within a range where it
will loosen ice in the ice cans effectively. This heater which is of the shell
and tube type is installed in the discharge line between compressor and
condenser. A dip tank water heater serves to heat water in the dip tank,
cool discharge gas before it enters the condenser and separate oil out of
ammonia gas.
ICE CHUTE
The ice chute which is located between the ice plant and storage room
consists of a reinforced wall frame with a counterweighted swinging door
and an inclined ramp. The chute acts as guide to receive ice dumped from
ice cans and facilitates movement of ice into the storage room. The
swinging door is usually lined with a canvas seal to prevent transfer of heat
from ice plant to storage room.
HOISTS
Hoists are used to raise ice cans from the brine tank and to convey filled
cans to the can dump. In small ice plants truck hoists are generally used. A
truck hoist has wheels and a manual hoisting mechanism. In most large ice
plants electric cross mounted joists are used Intermediate size plants may
use manually operated cross mounted lifting hoists.
AIR AGITATION SYSTEM

Water produces a better grade of ice when it is kept in constant motion
while being frozen. Lack of an air agitation system will cause opaque ice to
be produced. To produce clear ice, air is bubbled through water at 1 to 3
pounds pressure from centrifugal or rotary blowers. Air pressure is
controlled by means of blast gates or relief valves and air is distributed by a
piping system installed directly under ice can covers. From distributing
mains or laterals, air is fed to each ice can through a flexible connection
and a small diameter tube that extends almost to the bottom of the ice
can. This tube has small holes drilled at intervals throughout its length
through which air passes beneath the water surface. Tubes may be
removed from ice just before it is completely frozen or may be loosened
from ice with a thawing needle.
COOLING TOWER
Cooling towers are used to cool water from water cooled condensers and
water cooled compressors of ice plants. Cooling towers are incorporated in
ice plants so that water can be recirculated rather than disposed of. Natural
draft cooling towers are usually mounted on the roof of the ice plant where
they can make use of prevailing winds. Water is circulated through natural
draft cooling towers at a rate of approximately 5 gallons per minute per ton
of refrigeration required. Mechanical draft towers are usually installed
outdoors but may be installed indoors if a duct system is provided. Water is
circulated through mechanical draft cooling towers at a rate of
approximately 3 gallons per minute per ton of refrigeration required.
BRINE
A brine is any liquid cooled by the refrigerant and used for the transmission of
heat without a change in its state, having no flash point above 65 as
determined by the ASTM.
Water solutions of calcium chloride and sodium chloride are the most common
refrigeration brines.
BRINE
Being inexpensive, most common

refrigerant brines are based on
calcium chloride, sodium chloride
and glycols. Brine is used because
the addition of salt to water lowers
the freezing temperature of the
solution and the heat transport
efficiency can be greatly enhanced
for the comparatively low cost of
the material. The lowest freezing
point obtainable for NaCl brine is
21.1 C (6.0 F) at 23.3wt% NaCl.
This is called the eutectic point.
BRINE
BRINE
BRINE
BRINE
Brines of low density freeze around evaporator coils and may damage or reduce
efficiency of the evaporator. Specific gravity calcium chloride brines should not
be less than 1.20 and not more than 1.24 at 60 F. Calcium chloride brines with
specific gravities between these two limits have freezing points varying from 7.0
F to 21.5 F. The exact specific gravity of brine that should be maintained is
dependent on temperature of the refrigerant in evaporator coils. This
temperature is the saturation temperature of the refrigerant at suction pressure
for which the system was designed to operate. Freezing temperature of the
brine must be several degrees below temperature of the refrigerant in
evaporator coils. Brine temperature must be read daily as a precautionary
measure so that freezing of brine at the evaporator coils can be detected .
ICE PLANT OPERATION
ICE PLANT OPERATION
ICE PLANT INSPECTION AND MAINTENANCE
1.) TESTING FOR AMMONIA LEAKS
Ammonia has a disagreeable and pungent odor. A small leak is readily noticed. To
locate an ammonia leak the following procedures are recommended:
a) Use of reagents. Detector reagents such as sulfur taper sensitive paper caustic
soda and Nessler's solution are satisfactory to detect ammonia leaks. The
suitability of various reagents to test for ammonia leaks depends on conditions
under which the leak may occur.
b) Use of soap suds. To prepare soap suds for testing use a soap and water solution
of about the consistency of liquid hand soap which will lather freely or work up a
lather on a brush by rubbing the wetted brush on a cake of soap. A few drops of
glycerine added to the solution will cause lather to remain wet longer. When
applying soap suds paint soap lather completely around a joint and examine the
joint thoroughly for bubbles. When the joint is located so that a part of it is not
visible use a pocket mirror. It will sometimes take a full minute or more for
bubbles to appear at a small leak. Questionable spots should be covered with
lather and reexamined
2.) SERVICING AMMONIA LEAKS
For objectionable leakage at crankshaft stuffing boxes of enclosed compressors,

tighten gland bolt nuts gradually and equally to keep gland pressure equal on all
sides.
For leakage at valve bonnet stuffing boxes, pull up turn clockwise the stuffing box
gland gradually.
For leakage at cylinder head or flange gaskets, tighten flange bolts gradually and
equally all way around.
For bad leaks that have filled the space with ammonia fumes, first put a gas mask on
then try to get ventilation with fans to blow the fumes to open air. Location of the
leak will generally be indicated by a hissing sound from escaping
If liquid ammonia has escaped and is on the floor, play a stream of water on it to
absorb the escaping ammonia. Close the valve before and after the section where
the leak has occurred. Apply a torch for cutting welding or for making other repairs
only after the affected section has been thoroughly pumped out.
3.) PUMPING OUT COMPONENTS
Sizable components must be pumped out before they are removed from the system
to prevent loss of ammonia or contamination of the area.
a) Evaporator. During normal plant operation, the compressor is trying to pump
out the evaporator. However, liquid refrigerant is constantly being supplied to the
evaporator to replace the gas that is being exhausted from it. To pump out the
evaporator, close the valve that admits liquid refrigerant to the evaporator and
run the compressor as in normal operation until a vacuum of at least 26 inches is
obtained.
b) Condenser. To pump out the condenser, close the valves that allow liquid
refrigerant to pass from the condenser to the evaporator and allow the
evaporator to pump out slightly then stop the compressor. Drain water from the
condenser tubes. Close the discharge and suction shutoff valves at the
compressor and open the discharge and suction bypass valves. This allows the
compressor to reverse its action and create a suction in the line to the
condenser. Start the compressor and pump a 15 inch vacuum in the condenser.
Stop the compressor when the compressor comes to rest close the discharge
and suction bypass valves.
4.) NORMAL OPERATION
Observe all components of the ice plant for normal operation Investigate unusual
noises vibrations and odors during operation
5.) EQUIPMENT GUARDS

Check protective screens and fan belt guards for damage and security.
6.) FAN ASSEMBLIES

Check fan bearings of the cooling tower fan. Replace bearings if found defective.
Observe operation of the fan and check for bent blades and excess vibration. Wipe
dirt from shaft bearings and pulley.
7.) FAN DRIVES

Fan drives Check the fan drive for pulley alinement belt tension and condition of
belt. Replace frayed or worn belt. Wipe dirt and oil or grease from pulley sheaves
and belts.
8.) FAN MOTORS
Check motor bearings for rough running tendencies. Replace defective bearings.
Lubricate only when required. Observe the motor when starting for proper speed
pickup. Wipe dirt from the motor housing.
9.) EVAPORATOR COILS

Check the outside of evaporator coils for ice formation. Presence of ice around the
coils indicates that the brine solution is not at the required specific gravity. Test the
brine solution with a hydrometer. Check the coils for excessive corrosion. Check the
evaporator supports baffles and spacer bars for dirt and rust. Paint when necessary.
10.) EXPANSION VALVE

Check operation of the hand expansion valve in the ammonia float regulator bypass.
Be sure that this valve is used only when the ammonia float regulator does not
operate properly. When in use see that the hand expansion valve is properly
adjusted to permit correct flow of liquid ammonia to the suction trap.
11.) COMPRESSORS
Check the compressor and shaft seals for signs of gasket or seal failures. Replace any
defective shaft seal or gasket. Check oil level and observe condition of the oil.
Replace contaminated oil with ammonia compressor oil only. Fill the crank case to
proper level when necessary.
Proper operation of the compressor can best be judged by listening to the sound of
the compressor while it is operating. Leaky rings and leaky valves in the compressor
cause noticeably and abnormally high discharge temperatures. For example assume
that condenser pressure is 185 psi as indicated on the discharge pressure gage. At
this pressure temperature of saturated ammonia is 96F which also is indicated on
the discharge pressure gage.
12.) REFRIGERANT PIPING ASCCESORIES
Check to see if the float valve of the oil separator is draining the oil separator
properly. If not adjust the float or repair the valve as required. Replace defective
parts. Remove clean and replace filter elements located in recesses of the
compressor housing. Replace the screen if found defective.
Clean or replace the filter element of the ammonia strainer located between the
condenser and float regulator. Check the efficiency of compressor suction and
discharge valves by recording the maximum vacuum obtainable. Check the operation
and setting of the high pressure relief valve located on the condenser and the low
pressure relief valve located above the accumulator. Replace defective cartridges.
13.) WATER SUPPLY AND DRAINAGE SYSTEMS
Check water supply and drain systems of cooling tower water pump, condenser,
compressor, can filler, can dump, and brine tank for leaks tightness of fittings and
proper operation of water gate valves. Tighten fittings repair defective valves and
replace defective segments of piping.
14.) WATER-COOLED CONDENSER
a) Performance Test
An overall check for condenser performance may be used to indicate condition of
the condensing. To obtain an overall check for condenser performance proceed as
follows. Make preliminary preparations to the system. Read the condensing
temperature that corresponds with pressure in the condenser. Read the
temperature of the water leaving the condenser. Then subtract the temperature of
the water leaving the condenser from the condensing temperature obtained above.
Temperature of the water leaving the condenser will be several degrees below the
condensing temperature of pure ammonia This temperature difference is affected by
the amount of condensing surface per ton of refrigeration by the condition of the
condensing surface and by the presence of noncon densable gases Therefore
condenser performance should be checked when load conditions are known and
when the condenser is known to be clean and free of non condensable gases and
results used as a measure of good performance.
14.) WATER-COOLED CONDENSER
a) Cleaning Condenser Tubes

To clean condenser tubes, drain the condenser and then remove water connections
and pass heads. When pass heads are removed be not to damage the rubber
between the condenser and heads If the gaskets become detached from the heads
use household cement to hold them in while assembling the pass heads the
condenser. To prevent the gaskets from adhering to the shell and being damaged
when heads are removed again, coat condenser side of the gasket with mixture of oil
and graphite thoroughly clean condenser tubes tube cleaner consisting of a brush
attached to the end of a rod should be used. When tubes are dirty, it may be
necessary to run stiff wire brush through them and then finish up with tube cleaner.
By connecting a water hose to pipe to which the tube cleaner fastened and by
drilling a small holes in the pipe at the cleaner end water can be to the tubes during
the process cleaning. Water prevents the cleaner from becoming clogged also
insures cleaner tubes.
15.) COOLING TOWER
Clean the water distribution basin on top of the cooling tower. Make sure
that the holes in the splash box are not clogged. Check water distribution
over the wooden fill pieces. Check piping and fittings for water leaks. Check
float valve operation to see that it opens when water level in the float basin
falls below a predetermined level and closes when water level reaches a
predetermined level. If the float valve does not open and close properly
adjust the valve. If adjustment cannot be made, replace with a new float
valve. See that overflow pipes in the steel distribution basin and in the float
box are in good condition Replace defective wooden fill pieces. Do not nail.
Check for presence of algae formations.
16.) CAN FILLER
Check operation of the can filler float valve. Clean the float valve when it
becomes clogged. Replace any punctured float ball. Adjust the float valve by
trial and error so that the can filler fills ice cans to a level approximately 3
inches from the top. If the float valve cannot be adjusted or is defective,
replace the valve .
17.) AGITATOR
Check the agitator for noisy operation or vibration. Lubricate motor and shaft
bearings as required. Replace defective bearings. Check the agitator coupling for
proper alignment. If deposits of calcium chloride appear on any parts, soak the parts
in a cleaning solvent such as alcohol until the deposit dissolves. Any deposits left on
the impeller will greatly impair its efficiency. Before the agitator is installed in the
brine tank, check clearance between the agitator impeller and lower shaft bearing To
do this bolt the motor to its base butt motor and agitator shafts together and tighten
setscrews in the coupling. Then place a pry bar under the shaft coupling and force
the motor rotor to its highest position. The top bearing grease cup must be filled
with grease and given a turn every day .
18.) ICE CANS
Check ice cans for corrosion. Clean as required. Check ice can covers for
loose fits and warped boards. Repair or replace as required.

Ice Plant

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REFRIGERATION PLANT

1856 - Linde developed a machine working on ammonia.

1834 - A phenomenon called Peltier effect was discovered in which is still no

1877 - Advances in cryogenics, a field of very low temperature refrigeration,

1908 - Liquefaction of other permanent gases including helium by Onnes wh

Refrigeration may be defined as the process of achieving and

The basis of modern refrigeration is the ability of liquids to

Another device that transfers heat from a low-temperature medium to

The objective of a refrigerator is to maintain the refrigerated space at a

The objective of a heat pump, however, is to maintain a heated space

The performance of refrigerators and

The performance of refrigerators and

The cooling capacity of a refrigeration systemthat is, the rate

It is equivalent to rate at which heat is removed from 1 ton of w

TYPES OF REFRIGERATION SYSTEM

1. Vapor Compression Refrigeration System

1-2 Isentropic compression in a compressor

Low pressure liquid refrigerant

The superheated vapour enters

When designing a refrigeration system, there are several refrigerants

Two important parameters that need to be considered in the

Ammonia is predominantly used in food refrigeration facilities such as

The major drawback of ammonia is its toxicity, which makes it

R-134a - chlorine-free refrigerant

The term ice plant is used to mean a complete installation for

Tapered rectangular metal cans filled with water are immersed in

A regular schedule of pulling ice cans is maintained and

It is possible to reduce the freezing time for blocks considerably,

The blocks can be released by defrosting and harvested automati

A sheet of ice 2-3 mm thick is formed by spraying water on the

Refrigerant temperature, drum or scraper speed, and degree of

Water is frozen on the inner surface of vertical refrigerated tubes

Water is frozen on one face of a vertical refrigerated plate, and

An Ice plant has two additional circuits that help to

1. Refrigeration Circuit (Primary refrigerant)

The main components generally used in an ice plant are:

1. Bare-tube Coil Evaporator

The bare tube evaporators are made up of

In the plate type of evaporators the coil usually

Two Types of Compressors:

Positive displacement types compress

Dynamic types raise the velocity of the

Three Commonly Used Types of Compressors:

Reciprocating - uses piston to compress the Centrifugal - usually used in

The difference between the hermetic and semi-hermetic, is that the

The disadvantage of hermetic compressors is that the motor

There are many types of expansion devices used like capillary

Some of the ice plant auxiliaries are:

It is not uncommon for driers and filters

ICE PLANT WATER FILTERS

AIR AGITATION SYSTEM

Being inexpensive, most common

For objectionable leakage at crankshaft stuffing boxes of enclosed compressors,

5.) EQUIPMENT GUARDS

6.) FAN ASSEMBLIES

7.) FAN DRIVES

9.) EVAPORATOR COILS

10.) EXPANSION VALVE

a) Cleaning Condenser Tubes

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