CALCULATE AND DESIGN THE

FREEZE-DRYING SYSTEM OF ROYAL

JELLY PRODUCTS WITH THE
PRODUCTIVITY OF 1500 KG / BATCH

Instructor: Assoc Prof. Dr. Nguyễn Tấn Dũng

Student:   Nguyễn Trần Hoàng Anh    19116012

                   Ngô Thị Phượng                19116054

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 TABLE OF CONTENTS

01 INTRODUCTION

02 METHODS

03 RESULTS OF CALCULATION AND DESIGN

04 CONCLUSIONS

05 REFERENCES

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 01
INTRODUCTION

3
MATERIALS

● Royal jelly is the sole food of

the queen bee and its larvae
which is produced from the
oral ganglia of worker bees.

● Royal jelly is rich in nutrients

that are beneficial to your
health.

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Currently, Lam Dong province and Southeast regions, people
raise bees on an industrial scale the yield of royal jelly is
relatively high
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 FREEZE-DRYING
Freeze-drying is one type of drying process that dehydrate or remove
the water inside the material by sublimating water from solid (ice) to gas

Figure 1 : Phase diagram of water 6

● There are three main stages in the freeze-drying process

● Final products after freeze drying have very good quality

as the same initial material

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 02
METHODS

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 ❖ Methods for a self-freeze drying
system:

● Calculating and designing a freeze-drying

system integrated into the drying chamber

● Calculating and designing the freeze-

drying system

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Flow chart for the freeze drying technology of royal jelly
 Initial parameters:
● The freeze-drying system capacity is 1500 kg/batch

● W1: 59.2 %

● W2: 4.19%

● Tkt: -1.06 C

● A two-stage compression refrigeration system that uses

R22 as the refrigerant
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 03

RESULTS OF CALCULATION
AND DESIGN
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 RESULTS

3.1. MASS BALANCE

G1 = G 2 + W (1)

G1.( 100 – W1 ) = G2. (100 – W2 )

In which, (2)
G1 (kg/batch) - raw material mass

G2 (kg/batch) - product mass after drying

W1 (%) - input moisture content of raw material

W2 (%) - final moisture content of product 12

3.1. MASS BALANCE
From eq (1), (2):

=> Mass of royal jelly after drying: G2 = 638.76 kg/batch

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 RESULTS
3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING PROCESS
OF ROYAL JELLY
Freeze stage:

Where β- safe load factor

𝜏 is time of freezing (𝜏1 = 1.63 h)

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 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:
❏ Qsp (kJ) - heat loaded during the freezing process

Qsp = Q1 + Q2 + Q3 + Q4 + Q5 , kJ
Q1= 123524.4 kJ

Q2= 296238.58 kJ Qsp = 469771.74 kJ

Q3= 32235.77 kJ

Q4= 0 kj
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3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:

❏ Qk (kJ) - heat removed from the tray

Qk = Gk . Ck . ( tk1 – tk2 ), kJ
Gk - total weight of the trays
Nsk = 246 trays, assume mass of each tray is 0.4 kg

=> Gk = 246 x 0.4 = 98.4 kg

Ck = 0.48 kJ/(kg.K) - Specific heat capacity of glass tray
tk1 =25 °C, tk2 = tf2 = -40.46 °C
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3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:

❏ Qkk (kJ) - heat taken out to cool the air in the freeze drying chamber

Qkk = Gkk (h1 – h2)

Gkk - mass of dried air

= 18.3 kg

h1 - enthalpy of air in the freeze-drying chamber before freezing

h1 = t1 + ( 2500.77 + 1.84 t1 ).d1, kJ/kg

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 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:

h1 - enthalpy of air in the freeze-drying chamber before freezing

h1 = t1 + ( 2500.77 + 1.84 t1 ).d1, kJ/kg

Have: t1 = 25 °C - temperature of the air entering chamber before freezing

d1 = 0.017 (kg/kg) - specific humidity of air with t1 = 25 °C and φ1 =85%

Look up h-d diagram of humid air for finding d

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 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:

h2 - enthalpy of air –drying chamber at the end of a freezing process

h2 = t2 + ( 2500.77 + 1.84 t2 ).d2, kJ/kg

Have: t2 = - 40.46 °C - temperature of the air at the end of the freezing process

d2 = 0.000123 (kg/kg) - specific humidity of air with t1= - 40.46 °C and φ2 =100%

h2 = - 40.16 kJ/kg

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3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:
❏ Qkk (kJ) = Gkk (h1 – h2) = 1984.818 kJ

❏ Qmt (kW) - heat from the ambient environment entering walls

and doors of the freeze drying chamber

Qmt = Kv. F2 v. Δt
Kv = 0.43 W/ (m .K ) - heat transfer coefficient of freeze-drying chamber
Fv = 49.19 m2 - surface area of wall’s freeze-drying chamber
∆t = tkk – tf2 = 25 – (-40.46) = 65.46 °C
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Q = 1.38 kW
 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:
❏ Qqn (kJ) - amount of superheated heat

Qqn = m,1. (h,1 – h1)

m,1 = 0.43 kg/s - actual flow of refrigerant circulating through the compressor

h,1 = 392.48 kJ/kg - enthalpy of refrigerant before leaving evaporator

h1 = 383.56 kJ/kg - enthalpy of refrigerant before entering evaporator

Qqn = 3.84 kW
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3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze stage:

Q = 99.06 kW

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3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze-drying stage:

Where kth = (1.5 ÷ 2.5) - safe load factor

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 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze-drying stage:

❏ Qth (kW) - Freeze-drying heat

Qth = Wth. rth

Latent heat of sublimation of frozen water in royal jelly at - 18.33°C

rth = 0.0024 × T2 + 3.0606 × T + 3287.74 => rth = 3231.78 (kJ/ kg)

Qth = Wth. rth = 152236.23 kJ/h = 42.29 kW

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 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze-drying stage:

❏ Qhh (kW)-heat evaporates moisture during low temperature vacuum drying

Qhh = 0 because no vacuum drying stage

❏ Qvc = 0 (kW) - heat resulting from the transport of drying materials

1 26
3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze-drying stage:

Qmt (kW) - heat loss to the outside environment

Kv = 0.43 W/ (m2.K ) - heat transfer coefficient of freeze-drying chamber

Fv = 49.19 m2 - surface area of wall’s freeze-drying chamber

∆t = tmt – tkk = 35 – 15 = 10 °C

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 3.2. ENERGY REQUIRED FOR THE WHOLE FREEZE-DRYING
PROCESS OF ROYAL JELLY
Freeze-drying stage:

Amount of heat needed to separate 1 kg moisture from the dried product:

If additional energy is supplied to: vacuum pump, fan of the condenser, …

qr = ( 2 ÷ 3 )× q = ( 2 ÷ 3 )× 1.38 = ( 2.76 ÷ 4.14) kWh/ kg moisture 28
 RESULTS
3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Freeze-drying chamber
Symbols Value Unit
FREEZE-DRYING CHAMBER
L1 The cylindrical body length 3.5 m
The length of the cylinder of the freeze drying
L 3.9 m
chamber
hc The height of each globe cap 0.2 m
Rc The radius of the spherical cap 5.61 m
D1 Inside diameter of the freeze- drying chamber 2.97 m
D2 Outer diameter of the freeze-drying chamber 2.99 m
Thickness of outside stainless-steel layer 8 mm
Thickness of polyurethane layer 100 mm
Thickness of outside stainless- steel layer 1.5 mm
Vt Volume of freeze-drying chamber 24.59 m3
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F The area of the freezer wall 2
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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Heat transfer plate
Symbols Value Unit
HEAT TRANSFER PLATES
The number of heat transfer plates in the freeze-
Nttn 16 Plates
drying chamber
h The distance between two heat transfer plates 0.046 m
Heat transfer plate thickness 0.015 m
a Width of heat transfer plate 2.1 m
L1 Length of heat transfer plate 3.5 m
If heated by hot water
Gn Flow of hot water supplied for heating 1.94 kg/s
If provide heating by thermistor
The number of resistors needed to place in the
Ncdt 204 resistors
heat transfer plate
Ncdtmt The number of resistors arranged on each plate 13 resistors
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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Tray
Symbols Value Unit
TRAYS
ak Length of the tray 0.8 m
bk Width of the tray 0.5 m
hk Height of the tray 0.028 m
Thickness of the tray 0.003 m
Vk Volume of each tray 0.0112 m3
The number of glass trays in a freeze
Nsk 246 Trays
–drying chamber
Number of trays in each heat transfer
nt 16 Trays
plate

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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Ice condenser
Symbols Value Unit
ICE CONDENSER Heat load for
Thickness of equipment wall made of 0.00 condenser:
m Qngtdb = 86.39 kW
steel 5
The equipment’s moisture- insulating
0.08 m
wall thickness
Dtr Inner diameter of ice condenser 0.8 m
Outer diameter of ice condenser (not
Dng 0.81 m
include an insulated layer)
Outer diameter of ice condenser
Dngtdb 0.97 m
(include insulated layer)
L Length of the ice condenser 4 m
Vngtdb Volume of the ice condenser 2.01 m3
The outside heat exchange area of the 13.6
Fw.ng m2
ice condenser 6
Heat transfer area of tube beam 23.2 35
F 2
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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Vacuum pump

Choose vacuum pump with:

Capacity Ndcbck = 205 kW
Three-phase AC voltage/ 380 V

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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Receiver
Symbols Value Unit
Heat released
Receiver
during the
dng Outer diameter of the spiral tube 0.021 m
supercooling of
dtr Inner diameter of the spiral tube 0.019 m
refrigerant in
Inner diameters of the two interlocking coils
D1 0.4 m receiver:
with the inner diameters of the vessel
Qtg = 30.53 kW
Outer diameters of the the two interlocking
D2 0.5 m
coils with the inner diameters of the vessel
Bendable radius of the spiral tube beam in
R 0.025 m
the receiver
L Total length of the spiral tube 45.93 m
Number of twists per spiral beam twist
n 17
s
The distance between two twists 35 mm
H The height of spiral beams 0.917 m
Hbtg Height of receiver 1.19 m 39
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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION

✔ Condenser

Heat load for condenser:

Qk = 177.22 (kW)
CONDENSER

Inner diameter of steel

dtr 0.021 m
pipe
The total pipe length of the
Lpipe 251.66 m
condensation device
l1 The length of each pipe 2.5 m
Length of condensate
l 2.76 m
device

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 3.3. FREEZE DRYING SYSTEM DESIGN CALCULATION
✔ Compressor

- Power of the electric motor of the first-stage

compressor: 67.404 (kW)
- Power of the electric motor of the second-stage
compressor: 58.54 (kW)

- The motor’s overall power ( Ndc) : 130 kW

- Voltage: AC 3 phases/380 V
- Frequency (f): 50-60Hz
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 Figure: Principle diagram of a freeze-drying system
1- Second-stage compressor; 2- Condenser; 3- High-pressure tank; 4- Throttle valve; 5- A first-
stage compressor; 6- Receiver (intermediate cooler); 7- Ice condenser (petrification equipment);
8- Vacuum pump; 9- Sublimation chamber; 10- Heat plates (containing materials); 11-
Condensing water 45
 04

CONCLUSION

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CONCLUSIONS
Freeze-drying system was designed to
adapt: productivity 1500 kg/batch
Input yield: 1500 kg/ batch (59.2% moisture)

Output yield: 638.76 kg/batch (4.19% moisture)

Process goes through 2 main stage

Freezing: 𝜏1 = 1.63 h

Freeze-drying: 𝜏2 = 18.283 h

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 Freeze-drying systems include various equipment

Freezing-drying chamber
Cooling system and others
Vacuum pump
Ice condenser

Limitations: only build on theory

Recommendations:install and operate actual system
to find out problems correct, improve 48
 5. REFERENCES
Dzung, N. T., Chuyen, H. V., Linh, V. T. K. L., Nhiem, L. T., Hoan, P. T., Linh, D. T. K., Duy, N. Q. D., Duyen, N. D. M. D., &
Tung, P. T. (2022). Freeze drying. HCMC-VNU Publishing house.

Dzung N.T, (2014a). Optimization the freeze drying process of Royal jelly to determine the optimal technological mode,
Jokull Journal (Iceland), Vol 64, No 4, Section 1, Apr 2014, pp 312-327. 82.

Dzung, Tuan, C. T., & Linh, D. T. K. (2022). Study on Designing and Manufacturing the Freeze Drying System with the
Process of Freezing Moist Materials inside the Freeze Drying Chamber to Preserve Valuable Products. Journal of Technical
Education Science, 70B, 1–14. https://doi.org/10.54644/jte.70B.2022.1136
Heldman D. R, D. B. (1992.). Handbook of Food Engineering, 4th ed. Marcel Dekker New York – Basel – Hong Kong.

Nowak, D., & Jakubczyk, E. (2020). The Freeze-Drying of Foods—The Characteristic of the Process Course and the Effect of
Its Parameters on the Physical Properties of Food Materials. Foods, 9(10), 1488. https://doi.org/10.3390/foods9101488

Chuyen, H. V. (2018). Cơ sở thiết kế nhà máy hoá chất & thực phẩm.
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