JSPM’s

Rajarshi Shahu College of Engineering

Tathawade, Pune-411033
Department of Mechanical engineering
Approved by AICTE (An Autonomous Institute Affiliated to Savitribai
Phule Pune University)
(NBA & NAAC Accredited)

“ ICE CONVEYING SYSTEM”

Project by:
   1. Suyog Repale-   BE C 05   
2. Nikhil Jagdale- BE C 03
  3. Ritesh Sabale-   BE C 11 
  4. Sahil Yeole-        BE C 08

Guided By, Prof. K.K.Pawar

INTRODUCTION:

 The function of an ice plant or ice factory is to make or produce ice in large quantities
and in larger sizes. 
 The ice making process is quite similar to the one we observe in a domestic
refrigerator. The only difference lies in the ice making stage.
 In the freezer compartment, the tray with water comes in contact with very low-
temperature environment and becomes ice.
  But in an ice plant, which is a huge commercial factory, separate ice making or ice
freezing circuits are used. 
 The cold fluid is produced in one circuit and it is transferred to the water cans by
another circuit.
 Ammonia: It is the primary refrigerant which takes heat from brine. This ammonia changes
phase while moving in the circuit
 Brine: It is the secondary refrigerant which keeps the heat capacity of water and produces
ice. (ICE Heat capacity) 
LITERATURE SURVEY:

 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. One of the most important applications of refrigeration is in
ice plant. 
 Ice plant is used for producing refrigeration effect to freeze water in ICE maker. Our project is
based on simple refrigeration system which uses the vapour compression refrigeration cycle.
  The VCR cycle comprises four processes viz. compression, condensation,  expansion and
evaporation. Our ice plant model contains various parts such as- Compressor, condenser, filter
drier, Expansion valve, Evaporator coil, Ice Maker, Water cooling tower and various
measuring devices like digital temperature indicator, pressure gauges, energy meter etc. 
 The conventional ice plant has been studied and an improvement for ice conveying system 
has been proposed.
 The model is analysed for its cooling capacity assumed per unit mass flow rate of refrigerant.
Its COP is also calculated. The model is compared for its coefficient of performance (COP)
and cooling capacity by using Ammonia. The variations found in COP and cooling capacity
are 0.12 and 0.42 TR respectively for unit mass flow rate of the refrigerant.
OBJECTIVE AND PROBLEM STATEMENT:

 To design an Ice Conveying System for Ice Plant by utilising Screw

conveyers, Blowers, Racking System and Air Condenser.
 To replace conventional system of manually filling Ice Flakes in
drums and their transportation via forklifts.
 Distribute Ice as per Requirement.
 Increasing Ice Availability time.
 Reducing Manpower by utilizing Automated System.
 Reducing overall time by automizing the ice delivery system. 
ICE MAKING PLANTS:

 M 90
 P 90
 KTI P90
 40 TPD
 NEW ICE PLANT 80 TPD
 KTI DCS 80 TPD
 20 TPD & 30 TPD
 QA PLANT 15 TPD
METHODOLOGY:
Expansion Valve

Cooling Tower
To Plant

Ice
condenser maker

Ammonia Receiver

Discharge
Oil Valve
separator Ice
Silo

Compressor Air
Blower

ICE
PLANT 6
ICE CONVEYING SYSTEM:
Ice Maker

Silos

Screw Conveyer

Flaked ice
Blower

Pipeline
0.5 kg/cm2
ICE 90 TPD
OPERATING PARAMETERS:

 Suction pressure of compressor=      0 – 1 kg/cm^2

 Discharge pressure of compressor=  12 -16 kg/cm^2

 Water temp. at inlet of condenser=    around 30°c

 Water temp. at outlet of condenser=  around 33°c

 Ammonia temperature after expansion valve= -30°c

 ICE PLANT OVERALL LAYOUT:

Ice maker

silo

To factory

blower
pipeline
Discharge screw
EQUIPMENTS OF ICE PLANT:

OIL 10
ICE MAKER
SEPERATOR
EQUIPMENTS OF ICE PLANT:

ICE MAKER 11
EQUIPMENTS OF ICE PLANT:

Motors for screw

operation
Ice delivered here from silo

12
Clumped ice is separated and Blower pipeline end
delivered to blower pipeline DISCHARGE
SCREW
EQUIPMENTS OF ICE PLANT:

 In shell and tube type

condenser cooling water
flow through the tubes
and refrigerant flow over
the tubes. 
 Efficient in heat transfer.

13
CONDENSER
EQUIPMENTS OF ICE PLANT:

 A cooling tower is a heat

rejection device which
rejects waste heat to the
atmosphere through the
cooling of a water stream to a
lower temperature. Cooling
towers may either use the
evaporation of water to
remove process heat and cool
the working fluid.
INDUCED DRAUGHT
COOLING TOWER 14
PROPOSED OUTCOMES AND CONCLUSION:

 Proposed Outcomes:
 Replace Manual labour and Operations by Automated Ice
Conveying System for higher working efficiency and safety.
 Decreased time for delivery of ice.

 Conclusion:
 Achieved increased 20% operating efficiency by utilizing a
mechanical delivery screw, blower and ice pipeline.
 50ton ice – 3 manpower – cost of forklift replaced by Ice
Conveying System (One Time investment and operation cost.)
Graphs of Comparison:-
Time – Pre vs Post- Implementations

Time Distribution Pre ( min. )

17%
Ice Drum Filling
33% Loading of Ice Drums on
Forklift
Actual Transportation of Ice
from Source to Destination via
Forklift
Unloading of Ice Drums at
Destination
33%

17%

Total Time Utilized Per Ton= 30 min

 Time Distribution Post ( min. )

13%

33% Discharge Screw Declumping

Ice Transportation through Ice
Pipes
Ice Discharge directly to
Destination

53%

Total Time Utilized Per Ton= 15 min

 Time Utilization ( Pre vs Post Implementation)

Pre Post

40

35 35

30

20

15 15

10

Day 1 Day 2 Day 3 Average

In First graph above we can observe time distribution before implementation of our project which
can be clearly observed that the total task of transporting Ice from Ice plant i.e. Source, to the
destination i.e Chemical Plant takes 30 minutes on average to transport 1 TON of Ice
Whereas after implementation of our Project the distribution of time is shown above which can be
clearly comprehended that there is a significant reduction of time, more than 50%.
Now the time required to transport 1 TON of Ice has been optimized to 15 minutes, wherein the
actual delivery time for 1 Ton ice is 8 minutes only. Making our system highly scalable to
transport bulk amount of Ice as per requirement.
 Operational Cost Pre Implementation (Rs.)
2%

12%

Forklift Fuel cost for 1 Ton Ice

Delivery per Km
10%
Manpower Cost per ton
Maintenance of Equipments per
day
Pine Wooden Pallet and Drums
per day

76%
 Manpower Count Pre vs Post Implementation
4.5

3.5

3
Manpower Count Pre vs Post
2.5 Implementation
2

1.5

0.5

0
Pre Post

Pre Implementation of our project required 4

men for 1 ton of ice delivery
Post Implementation of our project reduced it
to 2 men for same amount of ice delivery.
THANK YOU!