Design Brewery Cooling System

RIZAL TECHNOLOGICAL UNIVERSITYCollege of Engineering and Industrial Technology

Boni Avenue, Mandaluyong City

A Proposed Design Brewery Cooling System

In

Refrigeration Engineering and Design

In Partial Fulfillment of the Requirements for the

Degree in Bachelor of Science in Mechanical Engineering

Submitted by:

Atega, Windell C.

Bene, Alvin E.

Prado, Rodel N.

Urbano, Dan CarloCEIT-09-801E

Submitted to:

Engr. Arleigh Rafael Lozano

(S.Y. 2009-2010)



INTRODUCTION

The introduction of mechanical refrigeration technology a century earlier has created a huge

impact in the proper application of a controlled atmospheric storage. This innovation is widely used in

many industries nowadays due to its potential and affectivity.

In line with the conditions that must be meet in order to have a good storage room, the design of

storage and fermentation in brewing process involves several factors. It must be convenient for handling

and management of the stored products. The structural design must be right for the products. In general,

any type of building can be a good storage if it is structurally adequate, well insulated and meets the

functional needs. Environmental control, including a good insulation system, is the key.

In relation to this rapid growth of refrigeration and cold storage technology, we the Mechanical

Engineering student of Rizal Technologiocal University – Mandaluyong campus, in supervision of

Engineer Arleigh Rafael Lozano, created our own design of cold storage system for up to 500,000kg of

brewery product (beer). This design is essential for food industry, food processing, and food marketing

applications.



CONTENT OUTLINE

1. Background of the Project

1.1. Socio – economic Impact1.2. Environmental Impact

2. Related Literature Review

2.1. Definition of Terms and Processes

3. Survey and Infrastructure

3.1. Location Map3.2. Vicinity Map3.3. Floor Plan3.4. Electrical and Mechanical Plan

4. Brewery Refrigeration and Load Calculation

4.1. Product Load4.2. Heat Transmission through Walls, Floor and Ceiling 4.3. Heats Transfer through Air change4.4. Human or Personnel4.5. Lights4.6. Defrosting4.7. Machine

5. Specification of Selected Units and Equipment

6. Bill of Materials

7. Recommendation

8. Appendix



BACKGROUND OF THE PROJECT

Proper storing and fermenting in brewing process such as beer is our aim of this project. In

refrigeration, constant cooling is achieved by the circulation of refrigerant in cooling system, in which it

evaporates to a gas and then condense back again into a liquid in continues cycle. If it is no leakage

occurs, the refrigerant last indefinitely through out the entire life of the system. All that is required to

maintain cooling is a constant of energy, or power, and a method of dissipating waste heat.

Brewing beer is a process which requires a great deal of energy, wherein both electrical energy

and thermal energy are required. Taken overall the energy costs represent a considerable share of the

total production costs of beer. As a trend it must be assumed that the share of the energy costs will

increase further due to the shortage of fossil fuels and the higher energy prices associated with it.

Brewing, in the modern acceptation of the term, a series of operations the object of which is to

prepare an alcoholic beverage of a certain kind—to wit, beer—mainly from cereals (chiefly malted barley),

hops and water. Although the art of preparing beer (q.v.) or ale is a very ancient one, there is very little

information in the literature of the subject as to the apparatus and methods employed in early times. It

seems fairly certain, however, that up to the 18th century these were of the most primitive kind. With

regard to materials, we know that prior to the general introduction of the hop (see Ale) as a preservative

and astringent, a number of other bitter and aromatic plants had been employed with this end in view.

Thus J.L. Baker (The Brewing Industry) points out that the Cimbri used the Tamarix germanica, the

Scandinavians the fruit of the sweet gale (Myrica gale), the Cauchi the fruit and the twigs of the chaste

tree (Vitex agrius castus), and the Icelanders the yarrow (Achillea millefolium).

The safe storage period depends upon the product and the storage temperature and

operational techniques vary greatly. The purposed was restarted as to provide a fermentation room of

high quality product to be stored to a long time, especially beer for human consumption. In our point of

view, economic provides a mean of selecting project. It plays a vital role in the lives of the individual who

will believe in capability of serving as well as in the country’s economic growth. Undoubtedly, this project

can harm the environment if precautions are not undertaken, endangering not only the nature but also

people’s welfare.



SOCIO-ECONOMIC IMPACT

It is important that we understand the nature of our choices, because individual decisions directly

affect the economy. Why, for example, do we choose private cars, instead of public buses, or more

armaments instead of more swimming pools? Why, indeed, don’t we choose both, in sufficient quantities

to satisfy all desires?

One basic constraint in our production and consumption choices is scarcity of resources. In order

to produce anything, we need resources, or factors of production. Factors of production are the inputs-

land, labor, and capital (building and machineries) and the economic stability of the area.

Unfortunately, the quantity of available resources is limited. We cannot produce anything we want

in the quantities we desire. Resources are scarce, relative to our desires. This fact forces us to make

difficult choices. However promising the prospects for growth may be, we still have to be contend with our

current production constraints.

Our menu of choices was based upon the illustration by the prevailing production possibilities

curve in Taguig. The ambient temperature of the location is around 25 to 35 depending on the season. It

could be accessible to travel in service roads and highways due to wide construction ways around the

said location.

The actual choices individual consumers and firms make are expressed for the most part in

market purchases and sales. Therefore we decided to put up our brewery plant near the market area,

malls, supermarket, and especially residential area where in we have observed the greater potential of

production of growth. Thus, the essential feature of the market location is the numerous supplies and

demands of beer, since beer is the common beverage in Filipino delicacies. Mostly, all residence of

Taguig belongs to what we can say is Class B. Class B refers to those people living in a very normal

condition of lifestyle. Although, there is a reflection of the mass people, but they are not totally dependent

to the government.



From this perspective, our good services is a very efficient method of communication to our

customers, although we do have not yet direct confrontation to the wholesalers and retailers, and this may

serves us an invisible hand towards customer satisfaction.

After analyzing on our market mechanism, we are still looking forward to some potential problems

we may encounter. The first of these problems concerns equity. One of the price systems pressure

allegiances to certain standards of fairness. In particular, reliance on prices for our services a mechanism

for distributing goods and resources implies that we believe such a distribution is “fair” for example goods

and services distributed through the market mechanism go disproportionately to those with the greatest

ability to pay. We should also take note the 12% expanded value added tax implementation. Another

problem is the competition, furthermore we cannot avoid, because we all know that Filipino is much likely

known for being an imitator. Another problem is the competition, furthermore we cannot avoid, because

we all know that Filipino is much likely known for being an imitator. It is obviously that our service

efficiency will convey the competition among the competitors. Another problem that strikes at the very

heart of our business venture is the pricing increase with our different building facilities, construction

materials and machineries. The land cost also gives pressured on us, because the terms and conditions

specified and dealt were in the state of being city.

Despite of all these market imperfections, we must definitely take the risk as being good

entrepreneurs. But, we thought this storage has strong potential and great money back guarantee due to

numerous demands and good locations we choose. Our customers can only declare our success, so let

see what may happen next.

The ambient temperature of the location is around 25 to 35 depending on the season. It could be

accessible to travel in service roads and highways due to wide construction ways around the said

location.



ENVIRONMENTAL IMPACT

In refrigeration process, the major compounds used in the cooling and insulating system is called

refrigerant. It absorbs heat while undergoing a phase change in the evaporator and then is compressed to

a higher pressure and higher temperature, allowing transferring energy in the condenser directly or

indirectly to the atmosphere.

It has been found, however, that CFS’s are posing major hear to the global environment trough

higher role in the destruction of ozone layer. Reduction of ozone levels in the atmosphere can lead to

reduce screening of ultraviolet rays from the sun. This is turn to increase the risk in skin cancer, and

perhaps lead to other damaging effects on the living materials. Several of the most popular refrigerants

not only contain chlorine but as good refrigerant, are also stable. This stability released refrigerants being

able to persist until they reach the upper atmosphere where sunlight promotes reaction to the ozone. Less

stable materials containing chlorine are not as likely reach the high altitudes and to cause damage to the

ozone layer, concern about the greenhouse effect or the global warming, the depletion of the ozone layer

at high altitudes and the government regulations that have and the full attention of industry. A major level

of interest and activity is in the development and use of refrigerant with low ozone depletion potential and

low greenhouse warming potential. A search has therefore begun for replacements, and to phase out

these products.

Safety of people, environment and living organism is our concern so we assure that this project

“Cold Storage” will not harm the said concern. Some refrigerant are dangerous to our environment that

causes global warming. Because we want our project to be environment friendly, we choose to use

Ammonia as the refrigerant. Ammonia is not a contributor to ozone depletion, greenhouse effect or global

warming. Thus, it is an “environmentally friendly” refrigerant. Ammonia has no cumulative effects on the

environment and a very limited (a few days) atmospheric lifetime. Because of the short lifetime of

ammonia in the atmosphere, it is considered to be “biodegradable.” It is even used to reduce harmful

stack gas emissions by injection into boiler and gas turbine exhaust streams. Proper waste disposal is



also our concern to ensure not only the health of the consumers but also the people living near the

project.

Advantage: The City Planning and Engineering office has labeled the site as industrial zone;

therefore it is ideal for the site construction. Its proximity to places of delivery e.g. market and malls is a

good choice. The site is 60 minutes away from the slaughter house in Laguna which could be our source

of supply. The site bounded by access roads on all its side could facilities and prevent traffic. Land area is

elevated therefore minimal flooding is an advantage. It is near sewer system for easy disposal of

wastewater. And has a solid local garbage collector.

Disadvantage: The only disadvantage that we’ve unlock in this design of our cold storage are

limited. Primarily, the cost of per square unit of land area in Taguig is high since the city is considered

prime site for industry. The second, being located at places near to market and malls, market

competitions is evident. And lastly refrigerant when not handled properly is harmful both to humans and

the environment.

GEOPHYSICAL AND BIOLOGICAL ENVIRONMENT

Location



Taguig is situated at the northwestern shore of Laguna de Bay at the upper mouth of the

legendary Pasig River, also known as the Napindan Channel. Taguig joins Laguna Lake at a shoreline

stretching 7.5 kilometers from Napindan to Bagumbayan in the south.

It is bounded to the north by the towns of Pateros and the City of Pasig; to the east by the towns

of Taytay and Laguna Lake; to the south by Laguna Lake and the City of Muntinlupa; and in the west by

cities of Parañaque, Makati and Pasay all of Metro Manila. Except for the hilly portion on the western and

southern ends, Taguig is a vast plain once devoted to agriculture.

Taguig enjoys the nation's tropical months of rain and even longer months of sun. It has two

major rivers that feed from the Laguna Lake - the Taguig River and the Napindan Channel. Taguig River

runs through barangays Wawa, Sta. Ana, Bambang, Tuktukan and enters the town of Pateros through

Ususan. Napindan Channel is part of the Pasig River. Five other rivers flow across Taguig - The

Bagumbayan River, Mauling/Tabacuhan Creek, Hagunoy Creek, Tipas/Labasan River and the Sta. Ana

River.

As of the year 2003 Census, Taguig is home to 532,641 people with mixed cultural backgrounds.

Its population density of approximately 8,000-person/sq. km. in 1999 is believed to grow by 4.45%

annually, mostly by the tremendous in-migration. The native Taguigeños is now a minority with only 30%

of the population and the new settlers comprise the majority at 70% of the population.

As highly urbanized city, Taguig is home to Fort Bonifacio Global City and five (5) thriving

industrial centers - (1) the Mañalac Estate in Bagumbayan; 2) the Food Terminal, Inc., the nation's food

center, is situated in Western Bicutan. It boasts of over 300 medium scale companies with businesses

covering food manufacturing, electronics, garments and service industries; (3) the Veteran's Center and

the (4) RSBS in Western Bicutan are also home to industrial companies. (5) The Napindan-Elizalde

Industrial compound produces steel.

TOPOGRAPHY



The topography of the land is about 65% level, the rest rolling or hilly. Being an inland in town, it

is accessible by land transportation from the other towns of Metropolitan Manila and through water

transport routes from towns bordering the Laguna Lake. It is fifteen (15) kilometers east of the City of

Manila.

CLIMATE AND WEATHER

The climate is characterized by two types of season:

1. Dry season from November to April

2. Wet season from May to October

Rainfall is less evenly distributed. Maximum rainfall is 2,000 milimeters with a peak of 400 mm. In August

and a low of 4mm. in march. Highest temperature usually occurs during the month of January.

Predominant wind direction is southwesterly from October to April, northeasterly from June to September

and predominantly northerly during the month of May. The average relative humidity is 81%.

DEMOGRAPHICS

Land Area: 4,538.2 hectares

Population: 620,000 (approx.)

Annual growth rate: 4.45% (mostly by in-migration)

No. of Barangays: 18

Class: 1st Class, Urban

Region: National Capital Region

COMPONENTS



Evaporator. An evaporator changes liquid into gaseous state. For instance, water is heated and

changed into steam. Therefore, it is the opposite of a condenser.

Operation: The solution containing the desired product is fed into the evaporator and passes

a heat source. The applied heat converts the water in the solution into vapor. The vapor is removed from

the rest of the solution and is condensed while now the concentrated solution is either fed into a second

evaporator or is removed. The evaporator as a machine generally consists of four sections. The heating

section contains the heating medium, which can vary. Steam is fed into this section. The most common

medium consists of parallel tubes but others have plates or coils. The concentrating and separating

section remove the vapor being produced in the solution. The condenser condenses the separated vapor,

then the vacuum or pump provides pressure to increase circulation.

Types of Evaporators

Natural/Forced circulation evaporator – these kinds of evaporators are based on the natural

circulation of the product caused by the density differences that arise from heating. In an evaporator

tubing, after the water begins to boil, bubbles will rise and cause circulation, facilitating the separation of

the liquid and the vapor at the top of the heating tubes. The amount of evaporation that takes place

depends on the temperature difference between the steam and the solution.

Falling film evaporators – this kind of evaporator is generally made of long tubes (4-8 meters in

length) which are surrounded by steam jackets. The uniform distribution of the solution is important when

using this type of evaporator. The solution enters and gains velocity as it flows downward. This gain in

velocity is attributed to the vapor being evolved against the heating medium, which flows downward as

well.

Condenser. Condensers are heat exchangers which convert steam from its gaseous to its liquid state,

also known as phase transition. In so doing, the latent heat of steam is given out inside the condenser.



Types of Condensers

Water-cooled condenser - Water-cooled condensers are of the multi-pass shell and tube type,

with circulating water flowing through the tubes. The refrigerant vapor is admitted to the shell and

condensed on the outer surfaces of the tubes.

Air-cooled condensers – The construction of air-cooled condensers makes use of several

layers of small tubing formed into flat cells. The external surface of this tubing is provided with fins to ease

the transfer of heat from the condensing refrigerant inside the tubes to the air circulated through the

condenser core around the external surface of the tubes (fig. 6-20). Condensation takes place as the

refrigerant flows through the tubing, and the liquid refrigerant is discharged from the lower ends of the

tubing coils to a liquid receiver on the condensing unit assembly.



Compressor. A compressor is a mechanical device that increases the pressure of a gas by reducing its

volume. Compression of a gas naturally increases its temperature. Compressors are similar to pumps:

both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are

compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible, so

the main action of a pump is to transport liquids.

Types of compressors

Centrifugal compressors – use a vane rotating disk or impeller in a shaped housing to force the

gas to the rim of the impeller, increasing the velocity of the gas.

Diagonal or mixed flow compressors – are similar to centrifugal compressors, but have a radial

and axial velocity component at the exit from the rotor.



Reciprocating compressors – use pistons driven by a crankshaft. They can be either stationary

or portable, can be single or multi-staged, and can be driven by electric motors or internal combustion

engines.

Fan Coil Units. A Fan Coil Unit (with supplementary air) is a “below-window unit which moves the room

air as it provides either heating or cooling. Centrally conditioned, tempered fresh air is brought to the

space in a constant-volume stream; the fan moves both fresh and room air across a coil that either heats

or cools the air, as required.” In addition, Fan Coil Units have a flexible installation, and may be located in

arrangements other than below-window, as required.

Circulating Pump. A pump is a device used to move liquids or slurries. A pump moves liquids from

lower pressure to higher pressure, and overcomes this difference in pressure by adding energy to the

system (such as water system).

Expansion Valve. An expansion valve is precision device used to meter the flow of liquid refrigerant

entering the evaporator at a rate that matches the amount of refrigerant being boiled off in the evaporator,

This is it’s main purpose but like all the other metering devices it also provides a pressure drop in the

system, separating the high pressure side of the system from the low pressure side. Thus allowing low

pressure refrigerant to absorb heat onto it’s self.

Operation: The operation of the refrigeration system of our design follows the simple vapor

compression cycle: at first the refrigerant will enter the compressor as a vapor; the vapor is compressed

at constant entropy and exits the compressor superheated. The vapor travels through the condenser

which first cools and removes the superheat and then condenses the vapor into a liquid by removing

additional heat at constant pressure and temperature.

The liquid refrigerant goes through the expansion valve where its pressure abruptly decreases,

causing flash-evaporation and auto-refrigeration of, typically, less than half of the liquid. That results in a



mixture of liquid and vapor at a lower temperature and pressure. The cold liquid-vapor mixture then

travels through the evaporator coil or tubes and is completely vaporized by cooling the warm water that is

from the fan coil units being returned by the water pump.

The chilled water serves as the secondary refrigerant. It is needed to cool the fan coil units which

are located inside the storage room to absorb the heat. The resulting refrigerant vapor returns to the

compressor.



TERMINOLOGIES

Ale - A beer brewed from a top-fermenting yeast with a relatively short, warm fermentation.

Alpha Acid Units (AAU) - A homebrewing measurement of hops that quantifies the amount of alpha

acids (bittering agents) going into the beer before fermentation. Equal to the weight of hops in ounces

multiplied by the percent of Alpha Acids.

Atmospheric pressure – The pressure exerted on all the things on the Earth’s.

Attenuation - The degree of conversion of sugar to alcohol and CO2.

Barometric pressure – Same as atmospheric pressure. The absolute pressure on a barometer in inches

of mercury.

Beer - Any beverage made by fermenting malted barley and seasoning with hops.

BTU (British Thermal Unit) – The amount of heat required to raise the temperature required of 1 pound

of water 1ºF. A quantity of heat.

Centigrade (°C) – The scale temperature measurement commonly used world wide.

Cold – Having less heat energy than the object against which it is compared. A relative term for

temperature.

Cold Break - Proteins that coagulate and fall out of solution when the wort is rapidly cooled after the boil.

Condensation – The process by which a gas is change into liquid at constant temperature by heat

removal.

Condenser – A heat exchange coil within a mechanical refrigeration system used to reject heat from the

system. The coil where condensation takes place.



Conditioning - An aspect of secondary fermentation in which the yeast refine the flavors of the beer.

Conditioning continues in the bottle.

Conduction – A means of heat transfer whereby heat is moved from molecule to molecule of a

substance by a chain collision of those molecules.

Conductor – A material which facilitate heat transfer by conduction.

Convection – Heat transfer within a fluid by the movement of heated molecules from one place to

another.

Cooling load – Heat which flows into a space from outdoors or indoors.

Density – The mass of a substance per unit volume, measured in pounds per cubic foot for gases.

Design cooling load – The rate at which heat flows into a space on a design day. The design day

usually presents the space with 95% or more of its highest possible load.

Enthalpy – Total heat content expressed in Btu per pound of the substance (Btu/lb).

Evacuation – The process of moving air, moisture, and other gases from the inside of refrigeration

system.

Fahrenheit – The scale of temperature measurement most commonly used in the United States.

Fermentation - The conversion of wort to beer, defined here as three parts, Lagtime, Primary, and

Secondary.

Fluid – Any substance in its liquid or gas state.

Gravity - Like density, gravity describes the concentration of malt sugar in the wort. The specific gravity of

water is 1.000 at 59F. Typical beer worts range from 1.035 - 1.055 before fermentation, OG (Original

Gravity). The finished beer gravity (FG) will range from 1.005 - 1.015, depending on the OG and type of

yeast.



Heat transfer – The movement of heat from one place to one another, between two substances, or within

the substances.

Heating capacity – The rate of heat at which a device can add heat to a substance, expressed in Btu/h.

Hops - Hop vines are grown in cool climates and brewers make use of the cone-like flowers to add

bitterness and balance the sweetness of the malt sugar. The dried cones are available in pellets, plugs, or

whole.

Hot Break - Proteins that coagulate and fall out of solution during the wort boil.

Insulator – A material which inhibits heat transfer conduction.

International Bittering Units (IBU) - A more precise method of measuring hop bitterness. An IBU is a

measure of the amount of alpha acid in the beer after fermentation. Various equations have been devised

to estimate the IBU’s in a beer based on the AAU’s and factors for percent utilization, wort volume and

wort gravity.

Iodophor - An iodine-based sanitizing solution which does not require rinsing.

Krausen (kroy-zen) - Used to refer to the foamy head that builds on top of the beer during primary

fermentation. Also an advanced method of priming.

Lager - A beer brewed from a bottom-fermenting yeast and given a long cool fermentation.

Lagtime - The period of time from pitching the yeast until primary fermentation is evident. The lagtime

should preferably be less than 12 hours.

Latent heat – The energy of molecular separation and arrangement. It cannot be measured with a

thermometer. Associate with change of state of a substance.

Latent heat of fusion – The heat required to change 1 pound of a substance from a solid to a liquid at its

melting temperature.

Latent heat of vaporization – The heat required to change 1 pound of a substance from a saturated

liquid into a saturated vapor.

Low temperature refrigeration – The application of mechanical refrigeration for maintaining very low

temperatures.



Pitching - Term for adding the yeast to the fermenter.

Pressure – Force per unit area.

Primary fermentation - The high activity phase marked by the evolution of carbon dioxide and krausen.

Most of the attenuation occurs during this phase.

Priming - The method of adding a small amount of fermentable sugar prior to bottling to give the beer

carbonation.

Process air conditioning – Conditioning air so that a product can be beneficially manufactured,

maintained or controlled.

Racking - The careful siphoning of the beer away from the trub.

Rate – How fast something proceeds. Occurrences per unit time.

Refrigerant – A fluid that picks up heat by evaporating at a low temperature and pressure. It gives up

heat by condensing at a higher temperature and pressure.

Saturated liquid – A liquid that contains all the heat it can hold without changing into a vapor.

Saturated temperature –The boiling point of a refrigerant. It is dependent upon pressure.

Saturated vapor – A vapor that contains all the heat it can hold without becoming superheated.

Secondary Fermentation - A period of conditioning and settling of the yeast after primary fermentation

and before bottling.

Sensible cooling capacity – The rate at which refrigeration system can remove sensible heat.

Sensible heat – The energy of molecular motion. Measured with temperature.

Specific heat – The amount of heat required to raise 1 pound of a substance 1ºF.

Subcooled liquid – A liquid at temperature below the saturation temperature of a substance.



Total cooling load – The rate at which total heat enters a space.

Trub (trub or troob) - The sediment at the bottom of the fermenter consisting of hops, hot and cold break

material, and dormant (sometimes dead) yeast.

Wort (wart or wert) - The malt-sugar solution that is boiled with hops prior to fermentation.

Wort cooling - After the whirlpool, the wort must be brought down to fermentation temperatures (20-

26°Celsius) heat exchanger. A plate heat exchanger has many ridged plates, which form two separate

paths. The wort is pumped into the heat exchanger, and goes through every other gap between the

plates. The cooling medium, usually water, goes through the other gaps. The ridges in the plates ensure

turbulent flow. A good heat exchanger can drop 95 °C wort to 20 °C while warming the cooling medium

from about 10 °C to 80 °C. The last few plates often use a cooling medium which can be cooled to below

the freezing point, which allows a finer control over the wort-out temperature, and also enables cooling to

around 10 °C. After cooling, oxygen is often dissolved into the wort to revitalize the yeast and aid its

reproduction before yeast is added. In modern breweries this is achieved through a plate.

Zymurgy - The science of Brewing and Fermentation.

BREWERY LOAD CALCULATION

A. For the fermentation tank in a brewery factory, the cooling load is to be calculated.

Data:1. Insulating Material : Styrofoam

thickness = 30mmdensity, ρI = 40kg/m3 for Coefficient of Heat Transfer, k = 0.14W/m2K (from table, by interpolation:) = ; k = 0.71 W/m2K

2. Fermenting vessel structure (see sketch)3. Weekly incoming volume of beer = 9m3 per vessel at 30°C4. Design beer fermentation (temperature that beer will ferment at), tR = 15°C5. Ambient room air temperature, ta = 27°C

http://en.wikipedia.org/wiki/Freezing_point

http://en.wikipedia.org/wiki/Heat_exchanger



6. Refrigerant used = R717 (Ammonia)A. All lacking values are to be determined.B. Appropriate type of evaporator and air-cooled type condensing unit including compressor are to be

determined and recommended.C. Sketch the location of all the refrigeration components with piping diagram.

Fermentation Tank Dimensions

Survey of Brewing Vessels:

10 45BBL (fermenting) 450BBL

10 45BBL (Conditioning) 450BBL

_____________ __________________

20vessels 900BBL

= 45 (average BBL)

Computations:

1.) Calculation of total mass capacity of the Fermentation tank considering space for inspection,

partitions and palette; m:

m = AT x hS x mBeer x η

m = (24.98m2 x 3.5m x 1050kg/m3 x 0.50)



m = 46,291.09kg

where: m = total mass capacity of room

AT = inside lateral area of tank = π Dm h = (π)()(3m) = 25.19m2

hS = Staple Height, 3.5m

mBeer = amount per unit volume = 1.05g/cm3 ~ 1050kg/m3

η = 0.50 (for short storage)

2.) Heat of Transmission from the outside tank area, QD:

QD = (π Dm h) (k) (ΔT);

ΔT = (tR + 273) – (ta + 273), Kelvin; for Styrofoam, k = 0.71W/m2K

QD = π(2.673m)(3m) (0.71W/m2K) [(25°C + 273K) – (15°C + 273)]

QD = 178.87W

3.) Heat Load from fermenting, QB:

QB =

QB =

QB = 35,808.16W

where: m = mass of capacity of the Fermentation tank

(From M.E. Tables and Charts by Del Rosario)

CB = specific heat of product before heating = 4.18kJ/kg-K

CA = specific heat of product after heating = (not indicated ~ 0)

q = latent heat of freezing of product = (not indicated ~ 0)

ΔTB = (30°C) – (-2.25°C) = 32.25°C ~ 32.25K

ΔTA = (15°C) – (-2.25°C) = 17.25°C ~ 17.25K

4.) Preliminary evaporator’ s Heat Load, QO:

QO =

QO =

QO = 17,993.51W ~ 18kW ~ 5.12 T.O.R. say, QO = 18.10kW

where:

ΣQ’s = (178.87W) + (35,808.16W) = 35,987.03W

5.) Heat Load from evaporating fan and defrosting, add 20% to QO:

QO = (17,993.51W)(1.20)



QO = 21,592.21W ~ 6.14T.O.R.

B. For Conditioning room in a brewery factory the cooling load is to be calculated.

STORAGE/CONDITIONING ROOM (Walk-in Cooler Type)

The following data were known:1. Insulating Material = Styrofoam

Thickness, t - 140mm; density, ρI - 40kg/m3; Coefficient of Heat Transfer, k - 0.14W/m2K

2. Floor Plan (see sketch)3. Daily incoming volume of wort = 9.5m3 per vessel x 10 vessels = 95m3 at 20°C4. Fermentation Room Temperature, tR = 5°C at 70% relative humidity5. Ambient Air Temperature, ta = 32°C at 55% relative humidity6. Operating time of chilling system = 16hrs per day7. Defrosting time = 8hrs per day8. Lightning = 12 lamps, 40 watts, 14hrs per day “ON”9. Inspection in the Fermentation Room = 2persons, 4hrs per day10. Refrigerant used = R717 (Ammonia)

A. All lacking values are to be determined.B. Appropriate type of evaporator and air-cooled type condensing unit including compressor are to be determined

and recommended.C. Sketch the location of all the refrigeration components with piping diagram.



Computations:

1.) Calculation of total mass capacity of the Fermentation Room considering space for

inspection, partitions and palette; m:

m = AF x HS x mBeer x η = (226.114m3 x 4.5m x 1050kg/m3 x 0.60)

m = 641,032.056kg

where: m = total mass capacity of room

AF = inside floor area of room = L x W = 19.56m x 11.56m = 226.114m3

HS = Staple Height, 4.5m (assume)

mWort = amount per unit volume = 1.05g/cm3 ~ 1050kg/m3

η = 0.60 (for long storage)

2.) Heat of infiltration/ Transmission from the outside wall, Qn:

Qn = A x k x ΔT;

ΔT = (tR + 273) – (ta + 273), Kelvin;

for Styrofoam, k = 0.14W/m2K (from table for heat transfer coefficient for selected insulating material)

Wall 1: Q1 = (12m x 6m)(0.14W/m2K)(300K – 278K) = 221.76W

Wall 2: Q2 = (20m x 6m)(0.14W/m2K)(307K – 278K) = 487.2W

Wall 3: Q3 = (12m x 6m)(0.14W/m2K)(307K – 278K) = 292.32W

Wall 4: Q4 = Q2 = 487.2W

Ceiling: Q5 = (20m x 12m)(0.14W/m2K)(200K – 278K) = 739.2W

Flooring: Q6 = (20m x 12m)(0.14W/m2K)(298K – 278K) = 672W

3.) Heat Load through air change, Qair:

Qair = = = 2461.12W

where:

VR = inside room volume = L x W x H = 19.56m x 11.56m x 5.56m = 1257.192m3

i = number of Air change (from table, by interpolation):

i = = = 2.17 per day

Δh = enthalpy difference per unit volume = - = 77.94kJ/m3

From ASHRAE Psychrometric Chart (from Mech’l Eng’g Tables and Charts):



@ tR = 5°C, 70% relative humidity (based on Low Temperature) : =

@ ta = 34°C, 60% relative humidity (based on Normal Temperature) : =

4.) Heat Load from Wort, Qwort:

Qwort =

Qwort =

Qwort = 121,215.65W

where: m = incoming mass of beer delivered per week

= 9m3 x 1050kg/m3 = 103,320kg

(From M.E. Tables and Charts by Del Rosario)

CB = specific heat of product before heating = 4.18kJ/kg-K

CA = specific heat of product after heating = (not indicated ~ 0)

q = latent heat of freezing of product = (not indicated ~ 0)

ΔTB = (25°C) – (-2.25°C) = 27.25°C ~ 27.25K

ΔTA = (5°C) – (-2.25°C) = 7.25°C ~ 7.25K

5.) Heat Load from Person, QP:

QP = = = 94W

where:

p = number of person = 2

q = heat from a person @ tR = 2°C; (by interpolation): =

q = 282W/person

τ = hours of inspection per day = 4hr/day

6.) Heat Load from Lights, QL:

QL = = = 364W

where:

P = wattage per lamp = 40W

f = factor of lamp with ballast = 1.25 or 1.3

n = number of lamp = 12 lamps



τ = hours of operation = 14hr/day

7.) Preliminary evaporator’ s Heat Load, QO:

QO = =

QO = 36,907.82W say, QO = 37,000W

QO = 43.34 Tons of Refrigeration;

where: QT = ΣQ’s = 24,605.22W

8.) Heat Load from evaporating fan and defrosting, add 20% to QO:

QO = (36,907.82W)(1.20) = 44,289.40W

QO = 44.49kW = 52.01 Tons of Refrigeration

9.) Preliminary evaporator’ s Fan, QF:

QF = = = 1360W

where:

P = wattage of fans = 340W

n = number of fans = 4

t1 = operating hours of fans = 16hr/day

t2 = operating hours of compressors = 16hr/day

SPECIFICATION OF SELECTED UNITS

EVAPORATORSelect 5 units of evaporator to be used in Fermentation tanks:

TO = 10°C ; Relative Humidity = 50%QO = 6 - 8 TOR

SPECIFICATION2003 Frick/York Refrigeration 3-Fan EvaporatorBrand Frick/YorkModel DC25-384



Refrigerant R-717(ammonia)

Normal Capacity 8 tons with a 10ºF TD, liquid recirculation and a wet coil.

Overall dimensions9 ft. L x 7 ft. 1 in. W x 2 ft. 8 in. H.

(ACN150)(BI).

Design pressure 230 psigAir flow 12,897 cfm

Coil volume 3.85 cu. Ft.Inlet (1) 2in. dia. Port

Outlet (1) 1in. dia. port. (2) 1-1/2 in. drain.Approximate weight 2,787 lbs.Number of coil rows 8Nominal fin spacing 5 fins/in.

For the conditioning area (walk-in cooler type), select 4 units of evaporator that is to be installed:

TO = 5°C ; Relative Humidity = 70%QO = 13 TOR

SPECIFICATION(2) Krack 4-Fan Ammonia Evaporator.

Brand KrackModel SHG-6850-RBA


Normal Capacity 82,300 Btuh with a 10°F TD or 6.86 tons.

Overall dimensions 10 ft. L x 3 ft. 1 in. W x 3 ft. 2 in. H. (BL)(BI).

Design pressure 320 psigInlet (1) 2in. dia. Port

Outlet (1) 1in. dia. port. (2) 1-1/2 in. drain.Fin material of construction galvanized steel

Fins per inch:

5. (2) Baldor industrial motor, 1/3hp, 1140 rpm, 208-230/460 V, 1.7-

1.6/0.5 amps, 60 Hz, 3 phase. (2) Franklin electric motor, 1/3 hp, 1140 rpm, 208-230/460 V, 2.24-1.96/1.0

amps, 60 Hz, 3 phase.

COMPRESSOR



Select same type of compressor units; 5 units to be used for 10 Fermentation tanks, and for the conditioning area (walk-in cooler type), select 1 unit of compressor that is to be installed:

TO = 10°C ; Relative Humidity = 50% QO = 30 – 90kW

SPECIFICATIONRWBII ROTARY SCREW COMPRESSOR UNIT

Brand Frick/YorkModel 60

Refrigerant R-717(ammonia)Nominal horsepower 40Overall dimensions 3 ft. L x 2 ft. W x 2 ft. H.

Design pressure 230 psigSuction temperature rating -10°F to 50°F.

Displacement @ 1750rpm 99 cfmInlet (1) 2in. dia. Port

Outlet (1) 1in. dia. port. (2) 1-1/2 in. drain.

Power supply 208-230/460/400 V, 690/345, LRA, 50/60 Hz, 3 phase.

Approximate weight 3000 lbs.

CONDENSERSelect 5 units of condenser to be used for the 5 units of compressor:

TC = 40°C ; TA = 34°C ; Relative Humidity = 60% QC = 6 - 8 TOR

SPECIFICATIONEvapco Evaporative Condenser

Brand EvapcoModel LSC-35


Normal Capacity

35 tons using R-22 at 40°F suction, 105°F condensing and 78° wet bulb. Rated at 25 tons using R-717 at 20°F suction, 96.3°F condensing and 78°F wet bulb. (2) Centrifugal Fans with (1) Marathon Electric Motor, 2 hp, 1740 rpm, 208-230/460 V, 6.2/3.1 amps, 60 Hz, 3 phase.

Overall dimensions



6 ft. 6 in. L x 4 ft. 11 in. W x 7 ft. 6 in. H. (ACN96-81)

S/N 813498

Belt numberB-90. (1)

Inlet (1) 2 in. dia. water infeed port, (1) 2 in. dia. refrigerant infeed port

Outlet 1) 2 in. dia. Refrigerant discharge port, (1) 2-1/2 in. dia. Drain port.

Manway diameter 1 ft. 8 in. dia.

For the conditioning area (walk-in cooler type), select 1 unit of condenser that is to be installed:

TA = 34°C ; Relative Humidity = 60% QC = 13 TOR

SPECIFICATIONHelpman HTC-N series

Brand HelpmanModel HTC-N 091/100

Refrigerant R-717(ammonia), all H(C)FC

Normal Capacity 20 up to 930 kW, 15 K TD, ambient temperatures up to 25°C.

Overall dimensions(A)9350 (B)8690 (C1)3340 (C2)1810 (D)5x1750

Coil

Coil manufactured from stainless steel tubes ø 13 mm and corrugated Alu-fins, tube pitch 50x50mm triangle. Available with 1 or 2 separated coils.

Casing

Casing and framework of corrosion resistant pregalvanised sheet steel (ssendzimir), epoxy coated light grey RAL 7035 on both sides. Mounting feet epoxy coated dark grey RAL 7016. All models are provided with easily removable header panels.

Fan motors 1 to 12 Fans available in a range of different executions, diameters 762, 900 or 1000 mm. Enclosed design spray-tight fan motors, protection class IP-555 (0076 range) or IP-554. All fan motors of HTC-N ranges 090, 091 and 100 are equipped with a thermal safety device in the windings, connected to separate terminals in



the box. Motors are wired to one or more common terminal boxes. All fans have corrosion resistant fan blades and fan guards.

Design pressure 33 bar

BILL OF MATERIALSReliance Commercial Inc. (Davila St. cor. Pasong Tamo Extension Tejeros, Makati City)

QUANTITY/UNIT DESCRIPTION AMOUNT

1 unit Acetylene tank 5,000.002 pcs. Adjustable wrench 1,000.001 unit Air compressor 17,000.003 pcs. Ball hammer 850.001 unit Bench vise 1,900.00



1 set Combination wench 1200.001 set Cutting torch and hose 5,000.002 unit Clamp hoist (electric) 7,800.002 pcs. Crocodile jack 2,000.002 pcs Chain block 2,100.001 set Drill press 5,500.001 unit Electric grinder 5,100.001 unit Electric hand drill 5,000.005 pcs Fire extinguisher 13,000.001 set Flaring tools 1,500.00

15 meters Fire hose 3,200.001 unit Generator set 150,000.001 set Grease gun 600.001 unit High pressure washer 10,000.001 unit Multi-tester (electrical) 3,000.001 unit Oxygen tank 3,500.003 pcs Pipe wrench 2,000.001 unit Pipe treading 25,000.002 unit Pliers 600.002 unit Pullers 1,200.001 set Screw drivers 1,200.003 pcs Vise grip 1,000.002 pcs. Evaporator 70,000.001 pc Semi-Hermetic compressor 80,000.001 pc. Condenser

(ALV-VL056/2L)180,000.00

Total 605250.00Php

9 unit Evaporator 1,350,000.006 unit Condenser 1,400,000.006 unit Reciprocating Compressor 593,950.00

Lot/ Land Price 4,500,000.00Building Price 5,000,000.00

Total 12,843,950.00Php

RECOMMENDATION

Brewery Refrigeration System

Beer making is becoming an increasingly popular past-time all around the world. Making beer

does not need to be a terribly complex process, and has the potential of bringing many rewarding hours of

fun. One of the parts of the process that can be frustrating in making beer, however, is keeping the beer

stored at the right temperature both during fermentation and bottling. The unique and convenient Coolbot



is able to make this process simple and easy, converting any well-insulated room into a walk-in cooler

room. This is ideal for beer makers.

If beer is not cooled properly, and maintained at the proper temperatures, it runs the risk of

infection which means that it all needs to be thrown out and the beer maker must start again.

Most domestic beers ought to be stored at a temperature of 38°F (bottled), but it depends what

kind of beer you are making. In the fermenting process, Ales need to be cooled at 60-70°F and Lagers at

45-55°F. This is because the fermentation process is different for each type (Lagers being 'bottom

fermenting' and Ales being 'top fermenting.') Traditionally, Lagers were kept in deep rock cellars or caves

to maintain their cool temperature and to allow the bottom-fermenting process to occur. With modern

technology and walk-in cooler rooms, Lagers can be fermented even at the home at the correct

temperatures, ensuring that even in the hottest climates a good lager is not impossible to make.

If ales are lagers are not cooled properly, not only do they run the risk of infection, but also they

lose their unique flavor and aroma. Ale can become unpleasant and acetic, lager can taste too 'fruity' or

have no taste at all. A refrigerator is not ideal, since vibrations can occur, and the keg needs to be

allowed to ferment. A walk-in cooler is ideal since the fermenting beer needs to be away from sunlight.

Once fermented, beer also needs to be bottled and kept cool as well, which a walk-in cooler room can

help produce.

Every beer type has its own cooling profile. We can optimally influence the temperature and thus

convection in the tank through targeted design and control of the cooling zones. Not only the individual

cooling zones but also the required refrigerant temperature are controlled depending on the beer type. To

avoid the formation of ice, the temperature of the inner tank wall is taken into account during refrigeration

of the tank content dependent on the beer type. Therefore a separate recipe for each beer type is created

in the process control. Temperature stratification is reliably prevented by individual cooling of the tank

zones. The entire tank content is fermented uniformly and reaches the required storage temperature

faster. It is possible to operate every fermenting tank variably within a system.



In addition to personal hygiene, and cleaning and disinfecting programs in slaughterhouses,

chilling facilities and cutting rooms, particular care should be taken when cutting and deboning and

packaging, keeping contamination of the brewery products to a minimum. Carcasses should preferably be

cut while hanging or on regularly cleaned surfaces, with tools frequently sterilized during operation and

the beer stored in clean containers. The packaging material should be of good quality and clean.

It is recommended that carcasses be thawed at 4° to 6°C, in a hanging position and without any

covering (plastic or jute is removed), inside a cold chamber with a reasonably low level of air circulation -

about 0.2 m/s. Relative humidity must be kept low at the beginning (70 percent) to avoid frost forming on

the product, with an increase at the end of the thawing period up to 90–95 percent. In these conditions

thawing of beef carcasses lasts about four to five days and of smaller carcasses one to three days. It

must take place in installations specifically designed for this purpose.



Date post:	21-Nov-2014
Category:	Documents
Upload:	albin-benny
View:	110 times
Download:	1 times

Design Brewery Cooling System

Documents