Design Brewery Cooling System

RIZAL TECHNOLOGICAL UNIVERSITY
College 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 Carlo
CEIT-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 Impact

1.2. Environmental Impact
2. Related Literature Review

2.1. Definition of Terms and Processes
3. Survey and Infrastructure

3.1. Location Map
3.2. Vicinity Map
3.3. Floor Plan
3.4. Electrical and Mechanical Plan
4. Brewery Refrigeration and Load Calculation

4.1. Product Load
4.2. Heat Transmission through Walls, Floor and Ceiling
4.3. Heats Transfer through Air change
4.4. Human or Personnel
4.5. Lights
4.6. Defrosting
4.7. 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 = 30mm
density, 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°C
4. Design beer fermentation (temperature that beer will ferment at), tR = 15°C
5. Ambient room air temperature, ta = 27°C
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°C
4. Fermentation Room Temperature, tR = 5°C at 70% relative humidity

5. Ambient Air Temperature, ta = 32°C at 55% relative humidity
6. Operating time of chilling system = 16hrs per day
7. Defrosting time = 8hrs per day
8. Lightning = 12 lamps, 40 watts, 14hrs per day “ON”
9. Inspection in the Fermentation Room = 2persons, 4hrs per day
10. 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

EVAPORATOR
Select 5 units of evaporator to be used in Fermentation tanks:
TO = 10°C ; Relative Humidity = 50%
QO = 6 - 8 TOR
SPECIFICATION
2003 Frick/York Refrigeration 3-Fan Evaporator
Brand Frick/York
Model DC25-384
Refrigerant R-717(ammonia)
8 tons with a 10ºF TD, liquid
Normal Capacity
recirculation and a wet coil.
9 ft. L x 7 ft. 1 in. W x 2 ft. 8 in. H.
Overall dimensions (ACN150)(BI).
Design pressure 230 psig

Air 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 8
Nominal fin spacing 5 fins/in.
For the conditioning area (walk-in cooler type), select 4 units of evaporator that is to be installed:
QO = 13 TOR
SPECIFICATION
(2) Krack 4-Fan Ammonia Evaporator.
Brand Krack
Model SHG-6850-RBA
82,300 Btuh with a 10°F TD or 6.86
Normal Capacity
tons.
10 ft. L x 3 ft. 1 in. W x 3 ft. 2 in. H.
Overall dimensions
(BL)(BI).
Fin material of construction galvanized steel
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)
Fins per inch:
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:
QO = 30 – 90kW
SPECIFICATION
RWBII ROTARY SCREW COMPRESSOR UNIT
Brand Frick/York
Model 60
Nominal horsepower 40
Overall dimensions 3 ft. L x 2 ft. W x 2 ft. H.
Suction temperature rating -10°F to 50°F.
Displacement @ 1750rpm 99 cfm
208-230/460/400 V, 690/345, LRA, 50/60
Power supply
Hz, 3 phase.
Approximate weight 3000 lbs.
CONDENSER
Select 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
SPECIFICATION
Evapco Evaporative Condenser
Brand Evapco
Model LSC-35
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
Normal Capacity 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
B-90. (1)
Belt number
(1) 2 in. dia. water infeed port, (1) 2 in. dia.
Inlet
refrigerant infeed port
1) 2 in. dia. Refrigerant discharge port, (1) 2-
Outlet
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
SPECIFICATION
Helpman HTC-N series
Brand Helpman
Model HTC-N 091/100
Refrigerant R-717(ammonia), all H(C)FC
20 up to 930 kW, 15 K TD, ambient
Normal Capacity
temperatures up to 25°C.
Overall dimensions
(A)9350 (B)8690 (C1)3340 (C2)1810 (D)5x1750
Coil manufactured from stainless steel tubes ø
13 mm and corrugated Alu-fins, tube pitch
Coil
50x50mm triangle. Available with 1 or 2
separated coils.
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
Casing 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 MATERIALS
Reliance Commercial Inc. (Davila St. cor. Pasong Tamo Extension Tejeros, Makati City)
QUANTITY/UNIT DESCRIPTION AMOUNT

1 unit Acetylene tank 5,000.00
2 pcs. Adjustable wrench 1,000.00
1 unit Air compressor 17,000.00
3 pcs. Ball hammer 850.00
1 unit Bench vise 1,900.00
1 set Combination wench 1200.00
1 set Cutting torch and hose 5,000.00
2 unit Clamp hoist (electric) 7,800.00
2 pcs. Crocodile jack 2,000.00
2 pcs Chain block 2,100.00
1 set Drill press 5,500.00

1 unit Electric grinder 5,100.00
1 unit Electric hand drill 5,000.00
5 pcs Fire extinguisher 13,000.00
1 set Flaring tools 1,500.00
15 meters Fire hose 3,200.00
1 unit Generator set 150,000.00
1 set Grease gun 600.00
1 unit High pressure washer 10,000.00
1 unit Multi-tester (electrical) 3,000.00
1 unit Oxygen tank 3,500.00
3 pcs Pipe wrench 2,000.00
1 unit Pipe treading 25,000.00
2 unit Pliers 600.00
2 unit Pullers 1,200.00
1 set Screw drivers 1,200.00
3 pcs Vise grip 1,000.00
2 pcs. Evaporator 70,000.00
1 pc Semi-Hermetic compressor 80,000.00
1 pc. Condenser 180,000.00
(ALV-VL056/2L)
Total 605250.00Php
9 unit Evaporator 1,350,000.00

6 unit Condenser 1,400,000.00
6 unit Reciprocating Compressor 593,950.00
Lot/ Land Price 4,500,000.00
Building 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.


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Design Brewery Cooling System

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RIZAL TECHNOLOGICAL UNIVERSITY

College of Engineering and Industrial Technology

A Proposed Design Brewery Cooling System

Refrigeration Engineering and Design

In Partial Fulfillment of the Requirements for the

Degree in Bachelor of Science in Mechanical Engineering

industries nowadays due to its potential and affectivity.

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

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

1. Background of the Project

1.1. Socio – economic Impact

2. Related Literature Review

3. Survey and Infrastructure

4. Brewery Refrigeration and Load Calculation

5. Specification of Selected Units and Equipment

BACKGROUND OF THE PROJECT

satisfy all desires?

serves us an invisible hand towards customer satisfaction.

what may happen next.

has a solid local garbage collector.

GEOPHYSICAL AND BIOLOGICAL ENVIRONMENT

kilometers from Napindan to Bagumbayan in the south.

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

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

Land Area: 4,538.2 hectares

Population: 620,000 (approx.)

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

Class: 1st Class, Urban

Region: National Capital Region

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

vacuum or pump provides pressure to increase circulation.

temperature difference between the steam and the solution.

the outer surfaces of the tubes.

receiver on the condensing unit assembly.

of a pump is to transport liquids.

and axial velocity component at the exit from the rotor.

other than below-window, as required.

system (such as water system).

pressure refrigerant to absorb heat onto it’s self.

constant pressure and temperature.

fan coil units being returned by the water pump.

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

Conductor – A material which facilitate heat transfer by conduction.

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

Pitching - Term for adding the yeast to the fermenter.

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

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

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

BREWERY LOAD CALCULATION

Fermentation Tank Dimensions

Survey of Brewing Vessels:

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

3.) Heat Load from fermenting, QB:

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

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

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:

4. Fermentation Room Temperature, tR = 5°C at 70% relative humidity

A. All lacking values are to be determined.

where: m = total mass capacity of room