Chapter 10

COOLING LOADCALCULATIONS
10-1. The Cooling Load

The cooling load on refrigerating equipment seldom results from any one
single source of heat. Rather, it is the summation of the heat which usually
evolves from several different sources. Some of the more common sources
of heat that supply the load on refrigerating equipment are:

1.

Heat that leaks into the refrigerated space from the outside by
conduction through the insulated walls.

2.

Heat that enters the space by direct radiation through glass, or

other transparent materials.

3.

Heat that is brought into the space by warm outside air entering the
space through open doors or through cracks around windows and
doors.

4.

Heat given off by a warm product as its temperature is lowered to

the desired level.

5.

Heat given off by people occupying the refrigerated space.

6.

Heat given off by any heat-producing equipment^ located inside

the space, such as electric motors, lights, electronic equipment, steam
tables, coffee urns, and hair driers.

It will be shown later that all of these sources of heat are not present in
every application and that the Importance of any one heat source with
relation to the total cooling load will vary considerably with each
application.
10-2. Equipment Running
Time Because of the necessity for defrosting the evaporator at frequent
intervals, it is not practical to design the refrigerating system in such a way
that the equipment must operate continuously in order to handle the load.
In most cases, the air passing over the cooling coil is chilled to a
temperature below its dew point and moisture is condensed out of the air
onto the surface of the cooling coif. When the temperature of the coil
surface is above the freezing temperature of water, the moisture
condensed out of the air drains off the coil into the condensate pan and
leaves the space through the condensate drain. However, when the
temperature of the cooling coil is below the freezing temperature of water,
the moisture condensed out of the air freezes into ice and adheres to the
surface of the coil, thereby causing "frost" to accumulate on the coil
surface. Since frost accumulation on the coil surface tends to insulate the
coil and reduce the coil's capacity, the frost must be melted off periodically
by raising the surface temperature of the Coil above the freezing point of
water and maintaining it at this level until the frost has melted off the coil
and left the space through the condensate drain.
No matter how the defrosting is accomplished, the defrosting requires a
certain amount of time, during which the refrigerating effect must be
stopped in the coil being defrosted.*

One method of defrosting the coil is to stop the compressor and allow the evaporator
to warm up the space temperature and remain at this temperature for a sufficient

length of time to allow the frost accumulation to melt off the coil. This method of
defrosting is called ''off-cycle defrosting. Since the heat required to melt the frost in
off-cycle defrosting must come from the air in the refrigerated space, defrosting occurs
rather slowly and a considerable length of time is required to complete the process.
Experience has shown that when off-cycle defrosting is used, the maximum allowable
running time for the equipment is 16 h out of each 24 h period, the other 8h being
allowed for the defrosting. This means, of course, that, the refrigerating equipment
must have sufficient capacity to accomplish equivalent of 24 h of cooling in 16 h of
actual running time. Hence, when off-cycle defrosting is used, the equipment running
time used in Equation 10-1 is approximately 16 h.
When the refrigerated space is to be maintained at a temperature below 1.5C, offcycle defrosting is not practical. The variation in space temperature which would be
required in order to allow the cooling coil to attain a temperature sufficiently high to
melt off the
* an exception to this is where a continuous brine tray is employed to keep the coil
free of frost, in which case the equipment can be selected for continuous operation.
frost during every off cycle would be detrimental to the stored product. Therefore,
where the space temperature is maintained below 1.5C, some type of supplementary
heat defrosting is ordinarily used. In such cases the surface of the coil is heated
artificially either with electric heating elements, with water, or with hot gas from the
discharge of the compressor (see Chapter 20).
Defrosting by any of these means is accomplished much more quickly than when offcycle defrosting is used. Hence, the shut-down time required is less for supplementary
heat defrosting and the maximum allowable running time for the equipment can be
greater than for the aforementioned off- cycle defrosting. For systems using supplementary heat defrosting maximum allowable running time is usually from 18 to 20 h
out of each 24-h period, depending upon how often defrosting is necessary for the

application in question. It is of interest to note that since the temperature of the cooling
coil in comfort air conditioning applications is normally around 4.5C, no frost
accumulates on the coil surface and, therefore, no down time is required for
defrosting. For this reason, air conditioning systems ate usually designed for continuous run and cooling loads for air conditioning applications are determined directly
in kilowatts. This holds true also for other applications where there is no frost accumulation on the cooling surface. In cases where it is inconvenient to calculate the
refrigeration load on a 24-h basis, the load may be determined directly in kilowatts
provided that the result is multiplied by an appropriate factor which makes an
allowance for the desired equipment operating time. Where the desired equipment
operating time is 16 h out of each 24, the refrigeration load in kilowatts should be
multiplied by (24/16) 1.5, which in effect increases the required equipment capacity of
50% so that the equipment selected will have the capacity to handle the 24-h cooling
load in the required 16 h of operating time. Similar multipliers can be determined for
other desired operating times.

24h (qt)
RT

(10- 1)

Where: Q required equipment capacity in kilowatts

RT running times in hours (h)
qt total cooling in kilowatts (the sum of the heat loads)
10-3. Cooling Load Calculations
To simplify cooling load calculations, the total cooling load is divided into a number of
individual loads according to the sources of heat supplying the load. The summation of
these individual loads is the total cooling l load on the equipment.

In commercial refrigeration, the total cooling load is divided into four separate loads
viz: (1) the wall gain load, (2) the air change I load, (3) the product load, and (4) the
miscellaneous or supplementary load.

10-4. The Wall Gain Load

The wall gain load, sometimes called the wall leakage load, is a measure of the heat
flow rate by conduction through the walls of the refrigerated space from the outside to
the inside. Since there is no perfect insulation I there is always a certain amount of
heat passing from the outside to the inside whenever the inside temperature is below
that of the outside. The wall gain load is common to all refrigeration applications and is
ordinarily a considerable part of the total cooling load. Some exceptions to this are
liquid chilling applications, where the outside area of the chiller is small and the walls
of the chiller are insulated. In such cases, the leakage of heat through the walls of the
chiller is so small in relation to the total cooling load that is effect is negligible and it is
usually neglected.
On the other hand, commercial storage coolers and residential air conditioning
applications are both examples of application wherein the wall gain load often
accounts for the greater portion of the total load.
10-5. The Air Change Load
When the door of a refrigerated space is opened, warm outside air enters the space to
replace the more dense cold air which is lost from the refrigerated space through the
open door. The heat which must be removed from this warm outside air to reduce its
temperature and moisture content to the space design conditions becomes a part of
the total cooling load on the equipment. This part of the total load is called the air
change load.

The relationship of the air change load to the total cooling load varies with the applica tion. Whereas in some applications the air change load is not a factor at all, in others it
represents a considerable portion of the total load. For example, with liquid chillers,
there are no doors or other openings through which air can pass and therefore the air
change load is nonexistent. On the other hand, the reverse is true for air conditioning
applications, where, in addition to the air changes brought about by door openings,
there is also considerable leakage of air into the conditioned space through cracks
around windows and doors and in other parts of the structure Too, in many air
conditioning applications outside air is purposely introduced into the conditioned
space to meet ventilating requirements. When large numbers of people are in the
conditioned space, the quantity of fresh air which must be brought in from the outside
is quite large and the cooling load resulting from cooling and dehumidifying this air to
the space design conditions is often a large part of the total cooling load in such
applications.
In air conditioning applications, the air change load is called either the ventilating load
or the infiltration load. The term ventilating load is used when the air changes in the
conditioned space are the result of deliberate introduction of outside air into the space
for ventilating purposes. The term infiltration load is used when the air changes are
the result of the natural infiltration of air into the space through cracks around doors
and other openings. Every air conditioning application will involve either an infiltration
load or a ventilating load, but seldom both in the same application.
Since the doors on commercial refrigerators are equipped with, well-fitted gaskets, the
cracks around, the doors are tightly sealed and there should be little, if any, leakage of
air around the doors of a commercial fixture in good condition. Hence, in commercial
refrigeration, the air changes are usually limited to those which are brought about
by .actual opening and closing of the door of doors.
The importance of minimizing or eliminating the leakage of air from the outside to the'
inside of coolers and freezers through the cracks around doors and through other
openings cannot be overemphasized. Although such air leakage may or may not have
an appreciable effect on the refrigeration load, the water vapor that condenses from

the warm air in the affected crack spaces and that frequently freezes into ice in these
openings can be Very troublesome and should be prevented.
In addition to well-aligned and well-aligned doors and, gaskets and the careful sealing
of other wall openings to reduce air leakage, good design practice prescribes the use
of a heater wire around the perimeter of the door to prevent condensation on these
surfaces by maintaining their temperature above the DP temperature of the entering
warm air. In addition the installation of a small heated air vents to equalize the
pressure between the inside and outside of the cooler or freezer is also important.
Without such controlled venting, negative pressures can develop inside the cooler or
freezer as a result of the air pressure drop that occurs in accordance with Charles
Law when the temperature of the warm air, which enters the space as the doors are
opened and closed, is subsequently reduced to the space design temperature.
Naturally, any air pressure differential between the inside and outside of the fixture
greatly increases the tendency for air leakage around the door seals and through
other wall openings, such as those through which refrigerant and water piping, drain
lines, and electrical conduits pass to the outside.
10-6. The Product Load
The product load is made up of the heat that

must be removed from the

refrigerated product in order to reduce the temperature of the product to

the desired level. The term "product" as used here is taken to mean any
material whose temperature is reduced by the refrigerating equipment arid
includes not only perishable commodities, such as foodstuff, but also such
.items as welding electrodes masses of concrete, plastic, rubber, and
liquids of all kinds. In some instances, the product is frozen; in which case
the latent heat removed is also a part of the product load.

The importance of the product load in relation to the total cooling load, like
all others, varies with the application. Although it is nonexistent in some
applications, in others it represents practically the entire cooling load.

Where the refrigerated cooler is designed for product storage, the product
is usually chilled to the storage temperature before being placed in the
cooler and no product load need be considered since the product is already
at the storage temperature.* However, in any instance where the product
enters a storage cooler at a temperature above the storage temperature,
the quantity of heat which must be removed from the product in order to
reduce its temperature to the storage temperature must be considered as a
part of the total load on the cooling equipment.

* In the design of short-term storage coolers, general practice is to allow for

5C of product cooling.

In some few instances, the product enters IV the storage fixture at a

temperature below the normal storage temperature for the product. A case
in point is ice cream, which is frequently chilled to a temperature of -18C
or -23C during the hardening process, but is usually stored at about -12C,
which is the ideal dipping temperature. When such a product enters
storage at a temperature below the space temperature, it will absorb heat
from the storage space as it warms up to the storage temperature and
thereby produce a certain amount of refrigerating effect of its own. In other
words, it provides what might be termed a negative product load which
could theoretically be subtracted from the total cooling load. This is never
done, however, since the refrigerating effect produced is small and is not
continuous in nature.

The cooling load on the refrigerating equipment resulting from product

cooling may be .either intermittent or continuous, depending on the
application. The product load is a part of the total cooling load only while

the temperature of the product is being reduced to the storage

temperature, or while freezing is taking place. Once the product is cooled to
the storage temperature, it is no longer a source of heat and the product
load ceases to be a part of the load on the equipment. An exception to this
is in the storage of fruit and vegetables which give off respiration heat for
the entire time they are in storage at temperatures above the freezing
temperature, even though there is no further decrease in their temperature
(see Section 10-18).

There are, of course, a number of refrigeration applications where product

cooling is more or less continuous in which case the prophet load is a
continuous load on the equipment. This is true, for instance, in chilling
coolers where the primary functions is to chill the warm product to the
desired storage temperature.* When the product has been cooled to the
storage temperature, it is usually moved out of the chilling room into a
storage room and the chilling room is then reloaded with warm product. In
such cases the product load is continuous and is usually a large part of the
total load on the equipment.

Liquid chilling is another application wherein the product provides a

continuous load on the refrigerating equipment. The flow of the liquid being
chilled through the chiller is continuous with warm liquid entering the chiller
and cold liquid leaving. In this instance, the product load is practically the
only load on the equipment since there is no air change load and the wall
gain .load is negligible, as is the miscellaneous load. In air conditioning
applications there is no product load as such, although there is sometimes
a "pull-down load" which tends to disappear as steady-state design
conditions are attained.

10-7. The Miscellaneous Load

The miscellaneous load, sometimes referred to as the supplementary load,

takes into account all miscellaneous sources of heat. Chief among these are
people working in or otherwise occupying the refrigerated space, along with
lights or other electrical equipment operating inside the space.

In most commercial refrigeration applications the miscellaneous load is

relatively small, usually consisting only of the heat given off by lights and
fan motors used inside the space.

In air conditioning applications, there is no miscellaneous load as such. This

is not to say that human occupancy and equipment

*In some instances, the product is not completely chilled to the final
storage temperature in the chilling cooler, and some additional chilling is
accomplished in the holding storage cooler.

are not a part of the cooling load in air conditioning applications. On the
contrary, people and equipment are often such large factors in the air
conditioning load that they are considered as separate loads and are
calculated as such. For example, in those air conditioning applications
where large numbers of people occupy the conditioned space, such as
churches, theaters, restaurants, etc., the cooling load resulting from human
occupancy is frequently the largest single factor in the total load. Also,
many air conditioning systems are installed for the sole purpose of cooling
electrical, electronic, and other types of heat-producing equipment. In such
cases, the equipment usually supplies the greater, portion of the cooling
load.

10-8. Factors Determining the Wall Gain Load

The quantity of heat transmitted through the walls of a refrigerated space

per unit of time is the function of three factors whose relationship is
expressed in the following equation:

Q = (A) (U) (TD)

(10-2)

Where:
Q = the rate of heat transferred in watts (W)
A = the outside surface area of the wall (square metres)
U = the overall -coefficient of heat transmission in watts per
square metre per kelvin.

TD = the temperature differential across the wall in kelvins (K)

The coefficient of transmission or U" factor is a measure of the rate at

which heat will pass through a 1 m2 area Of wall surface from the air on one
side to the air on the other side for each 1 K of temperature difference
across the wall. The value of the U factor depends on the thickness of the
wall and on the materials used in the wall construction. Since it is desirable
to prevent as much heat as possible from entering the space and becoming
a load on the cooling equipment, the materials used in the construction of
cold storage walls should be good thermal insulators so that the value of U
is kept as low as is practical.

According to Equation 10-2, once the U factor is established for a wall, the
rate on heat flow through the wall varies directly with the surface area of
the wall and with the temperature differential across the wall. Since the
value of U is given in watts per square metre per kelvin, the heat flow rate
through any given wall can be determined by multiplying the U factor by
the wall area in square metres and by the temperature difference across
the wall in kelvin or degrees Celsius, that is, by application of Equation 102.

Example 10-1 Determine the heat flow rates in watts through a wall 3 m by
6 m, if the (M factor for the wall is.0.37 W/m 2 K and the| temperature on
one side of the wall is 4cr while the temperature on the other side is!
35C.

Solution:

Total wall area:

= (3 m)(6 m)
= 18 m2

Temperature differential across wall, K=35C-4C

= 31 K
Applying Equation 10-2,
the heat gain through the wall = (18 m 2)(0.37 )W/m2 K(31 K)
= 206 W or 0.206 kW
10-9. Determination of the U Factor

Should it be necessary, the U factor for any type of wall construction can be
readily

calculated

provided

that

either

the

conductivity

or

the

conductance of each of the materials used in the wall construction is

known. The conductivity or conductance of most of the materials used in
wall construction can be found in tables. Also, this information is usually

available from the manufacturer or producer of the material. Table 10-1 lists
the thermal conductivity or the conductance of some materials frequently
used in the construction of cold storage walls. The thermal conductivity or k
factor of a material is the rate in watts at which heat "passes through a 1
m2 cross section of the material 1m thick for each kelvin of .temperature
difference across the material and is given in watts per metre per kelvin.

Whereas the thermal conductivity or K factor is available only for

homogeneous materials and the Value given is always for aim thickness of
the material, the thermal conductance or. C factor is available for both
homogeneous and nonhomogeneous materials and the value given in watts
per square metre per kelvin is for the specified thickness of the material.

For any homogeneous material, the thermal conductance, can be

determined for any given thickness of the material by dividing the k factor
by the thickness in metres. Hence, for a homogeneous material,

K
X

(10-3)

where x = the thickness of material in metres.

Example 10-2 Determine the thermal conductance for a 125 mm thickness

of polyu- rethane.

Solution: From Table 10-1, k factor of

polyurethane = 0.025 W/m K

Applying Equation 10-3,

w
mk
0.125m

0.025

c= 0.2

Since the rate of heat transmission through nonhomogeneous materials,

such as the concrete building block in Fig. 10-1, will vary the several parts
of the material, the C factor for nonhomogeneous materials must be
determined by experiment. The resistance that a wall or a material.

Air spaces

Fig. 10-1 Concrete aggregate building block

offers to the flow of heat is inversely proportional to the ability of the wall or
material to I transmit heat. Hence, the overall thermal resistance of a wall can
be expressed as the reciprocal of the overall coefficient of transmission,
whereas the thermal resistance of an individual material can be expressed as
the reciprocal of its conductivity or conductance that is

overall thermal, resistance R

=
Thermal resistance of an individual material
= or

or

The terms 1/k and 1/C express the resistance to heat flow through a
single material from surface to surface only and do not take into
account the thermal resistance of the thin film of air which adheres
to all exposed surfaces. In determining the overall thermal
resistance to the flow of heat through a wall I from the air on one
side to the air on the other | side, the resistance of the air on both
sides of the wall should be considered. Air film coefficients or
surface conductance for average wind velocities are given in Table
10-1.

When a wall is constructed of several layers of different materials

the total thermal resistance of the wall is the sum of the resistances
of the individual materials in the wall construction, including the air
films, that is

Therefore:

(10-4)

Where = convection coefficient (surface conductance) of inside wall, floor, or

ceiling
= convection coefficient (surface conductance) of outside wall, floor, or roof
Note When nonhomogeneous materials are used, 1/C is substituted for x/k.
Example 10-3 Assuming a wind velocity of 3.35 m/s, calculate the value of 1/
for a wall constructed of 200 mm sand aggregate building blocks, insulated
with 75 mm of polyurethane, and finished on the inside with 13 mm of cement
plaster.
Solution:
From Table 10-1, 200 mm sand aggregate block Polyurethane Cement plaster
Inside convection coefficient
Outside convection coefficient
G =5.11

=9.37

k =0.025=22.70
k =0.72
Applying Equation 10-4, the over-all thermal resistance,

1
1
0.075 0.013
1

22.70 5.11 0.025 0.72 9.37

=0.044 + 0.196 + 3.0 + 0.018 + 0.107

= 0.37
Therefore, U = 1/3.37
=0.297 W/m2 K
For the most part is the insulating material used in the wall construction that
determines the value of U for cold storage walls. The surface conductance
and the conductance of the other materials in the wall have very little effect on
the value of U because the thermal resistance of the insulating material is so
large with relation to that of the air films and other materials. Therefore, for

small coolers, it is sufficiently accurate to use the conductance of the

insulating material alone as the wall U factor.
As a matter of convenience, overall coefficients of transmission or U factors
have been determined for various types of wall construction and these Values
are available in tabular form. Table 10-2 lists U factors for typical cold storage
walls, roofs, ceilings, and floors. The values listed in the table vary with the
type and thickness of the wall insulation.
Example 10-4. From Table 10-2, determine the U factor for a wall constructed
of 150 mm clay tile with 150 mm of corkboard insulation.
Solution. In Table 10-1, the k factor of cork- board is listed as 0.043 W/m K. In
Table 10-2, locate the insulation thickness (150 mm) in the column at the left
side of the table. Move across the table under the column headed 0.045 mm
and read the wall U factor as 0.267 W/m2 K.

A realization of the full insulating values listed for the walls and materials
described in the tables is dependent on proper installation and good
workmanship. For example, many insulating materials are permeable to water
vapor, and unless an adequate and unbroken vapor barrier is installed on the
warm side of the insulating material, the higher vapor pressure on the warm
side of the insulation will cause water vapor to migrate through the insulation
toward the lower vapor pressure on the colder side. At some point in the travel
of the vapor through the insulation, the temperature of the vapor will fall below
the saturation temperature corresponding to its pressure, thereby causing the
vapor to condense into water in the insulation, with the result that the
insulation eventually becomes waterlogged. Moreover, in those cases where
the temperature in the insulation is below the freezing temperature of the
water, the condense vapor

Fig. 10-2 Temperature gradiant through a typical cold storage (see

Example 10-4)
will subsequently freeze into ice. In either case, since both water and ice are
good conductors, the insulating value of the insulating material will be
completely destroyed.
The temperature gradient through a typical cold storage wall is illustrated in
Fig. 10-2. Notice that the temperature drop (difference) across the individual
wall components is proportional to the thermal resistance offered by that
component and that the overall temperature drop (differential) across the wall
is the summation of the individual temperature drops across the several wall
components
10-10. Temperature Differential across Cold Storage Walls
The design temperature differential across cold storage walls is usually taken
as the difference between the inside and outside design temperatures.
The inside design temperature is that which is to be maintained inside the
refrigerated space and usually depends upon the type of product to be stored
and the length of time the product is to be kept in the space.

The recommended storage temperatures for various products are given in

Tables 10-8 through 10-11.
The outside design temperature depends on the location of the cooler. For
cold storage walls located inside a building, the outside design temperature
for the cooler wall is taken as the inside temperature of the building. When
cold storage walls are exposed to the outdoors, the outdoor design
temperature for the region (Tables 10-3A and 10-3B) is used as the outside
design temperature.
10-11. Temperature Differential across Ceilings and Floors
When a cooler is located inside a building and there is adequate clearance
between the top of the cooler and the ceiling of the building to allow free
circulation of air over the top of the cooler, the ceiling of the cooler is treat ed
the same, as an inside wall. Likewise, when the top of the cooler is exposed
to the outdoors, the ceiling is treated as an outdoor wall. The same holds true
for floors except when the cooler floor is laid directly on a slab on the ground.
As a general rule, the ground temperature under a slab varies only slightly
the year round and is always considerably less than the outdoor design dry
bulb temperature for the region in summer. Ground temperatures used in
determining the temperature differential across the floor of cold storage
rooms are given in Table 10-4 and are based on the regional outdoor design
dry bulb temperature for winter.

Where the floor of a freezer is laid directly on a slab on the ground, some
provision should be made to prevent the migration and eventual freezing of
ground water under the freezer floor, since the expansive forces created by
such freezing will eventually cause ground heaving and severe damage to
the freezer structure. Preventive measures usual include some means of

monitoring the ground temperature under the freezer, along with some means
of supplying heat to the surface when ground temperatures under the freezer
approach the freezing point. Warm air ducts, electric heating cables, and pipe
coils for the circulation of brine or antifreeze solutions have all been
employed to supply the heat necessary to maintain the ground, temperature
above the freezing point.
10-12. Effect of Solar Radiation
Whenever the walls of a refrigerator are so situated that they receive an
excessive amount of heat by radiation, either from the sun or from some other
hot body, the outside surface temperature of the wall will usually be
considerably above the temperature of the ambient air. A familiar example of
this phenomenon is the excessive surface temperature of an automobile
parked in the sun. The temperature of the metal-surface is much higher than
that of the surrounding air. The amount by which the surface temperature
exceeds the surrounding air temperature depends upon the amount of radiant
energy striking the surface and upon the reflectivity of the surface. Recall
(Section 2-18) that radiant energy waves are either reflected by or absorbed
by any opaque material that they strike. Light-colored, smooth surfaces will
tend to reflect more and absorb less radiant energy than dark, rough-textured
surface. Hence, the surface temperature of smooth, light-colored walls will be
somewhat lower than that of dark, rough-textured waifs under the same
conditions of solar radiation. Since any increase in the outside surface
temperature will increase the temperature, differential across the wall, the
temperature differential across sunlit walls must be corrected to compensate
for the sun effect. Correction factors for sunlit walls are given Table 10-5.
These values are added to the normal temperature differential. For walls facing at angles to the directions listed in Table 10-5, average values can be
used.

TABLE 10-5 Allowance for Solar Radiation (Degrees Celsius to be added to

the normal temperature difference for heat leakage calculations to
compensate for sun effectnot to be used for air-conditioning design.
10-13. Calculating the Wall Gain Load
In determining the wall gain load, the heat gain through all the walls,
including the floor and ceiling, should be taken into account, when the several
walls or parts of walls are of different construction and have different U
factors, the heat leakage through the different parts is computed separately.
Walls having identical U factors may be considered together, provided that the
temperature differential across the walls is the same. Too, where the
difference in the value of U is slight and/or the wait area involved is small, the
difference in U factor can be ignored and the wails or parts of walls can be
grouped together for computation.
Example 10-5
A walk-in cooler 5 m x 7 m x 3 m high is located in the southeast corner of a
store building in an area where the outdoor design DB temperatures in
summer and winter are 35C and -6C, respectively (Fig. 10-3).

The south and east walls of the cooler are adjacent to and a part of the south
and east walls of the store building. The store has a 4 m ceiling so that there

is a 1, m clearance between the top of the cooler and .the ceiling of the store.
The store is air conditioned and the temperature inside the store is maintained
at approximately 26C. The inside design temperature for the cooler is 2C.
The north and west (inside) walls, floor and ceiling are insulated with 75 mm
of closed-cell (smooth surface) polystyrene, and the south and east walls are
insulated with 100 mm of closed-cell polystyrene. Determine the wall, gain
load in kilowatts.
Solution
From Table 10-1, the k factor for smooth surface polystyrene is 0.029 W/m K.
From Table 10-2, the U factor for the north and west walls, floor and ceiling
(75 mm insulation thickness) is 0.346 W/m 2 K, and the U factor for the south
and east walls (100 mm Insulation thickness) is 0.267 W/m 2 K. From Table
10-4, the design ground temperature, based on a winter, outdoor design DB
of. -6C is 25C. From Table 10-5, the allowance for solar radiation on the
south and east walls (to be added to the indoor-outdoor temperature
difference) are 2C and 3C, respectively. Applying Equation 10-2,
North and west walls, and ceiling
= (71 m2) (0.346 W/m2 K)(26C - 2C) = 589.6 W
South wall = 15 m2) (0.267 W/m2 K)(37C - 2C) = 140.2 W
East wall = (21 m2) (0.267 W/m2.K)(38C~2"C) = 201.9 W
Floor = (35 m2) (0.267 W/m2 K)(25C - 2C) = 215.0 W
Total wall gain load = 1147 W or 1.147 kW

10-14. Calculating the Air Change Load

The space heat gain resulting from air Ranges in the refrigerated space is
difficult to determine with any real accuracy except in pose few cases where
a known quantity of air introduced into the space for ventilating purposes.
When the mass flow rate of the outside air entering the space is known, the
space heat gain resulting from air changes can be determined by applying
the following equation:
Q = m(h0 - ht)

(10-5)

where: Q=air change load (kilowatts)

m=mass of air entering space(kilograms per second)
ho=enthalpy of outside air (Kj per kg)
hi= enthalpy of inside air (KJ per kg)

However, since air quantities are usually given in units of volume rather than
in units of mass, to facilitate calculations, the heat gain per liter of outside air
entering the space is listed in Tables 10-6A and 10-6B for various inside and
outside air conditions. To determine the air change load in kilowatts, multiply
the air infiltration rate in litres per second by the appropriate enthalpy change
factor from Table 10-6A or 10-6B.

Example 10-6: The rate of air infiltration into I a refrigerated space is 8 Us. If
the inside of the cooler is maintained at 2C and the out- ; side dry bulb
temperature and humidity are 30C and 50%, respectively, determine the ; air
change load in kilowatts.

Solution:

By interpolation in Table 10-6A, the enthalpy change factor is 0.0598

kJ/L.

Air change load

= (8 L/s) (0.0598 kJ/L)

=0.478 kw

Except in those few cases where air is purposely introduced into the
refrigerated space for ventilation, the air changes occurring in the space are
brought about solely by infiltration through door openings. The quantity of
outside air entering a space through door openings in a 24-h period depends
upon the size, and location of the door or doors, and upon the frequency and
duration of the door openings. Since the combined effect of all these factors
varies with the individual installation and is difficult to predict with accuracy, it
is general practice to estimate the air change quantity on the basis of
experience with similar applications. Experience has shown that, as a general
rule, the frequency and duration of door openings and, hence, the change
quantity, depend on the inside volume of the cooler and the type of usage.
Table 10-7 lists the approximate infiltration rate for various cooler sizes. The
values given for average usage (see table foot- The ASRE Data Book defines
average and heavy usage as follows:

Average usage includes installations not subject, to extreme temperatures

and where the quantity of food handled in the refrigerator is not abnormal.
Refrigerators in delicatessens and clubs may generally be classified under
this type of usage. Heavy usage includes installations such as those in busy
markets, restaurant and hotel kitchens where the room temperatures are likely
to be high, where rush periods place heavy loads on the refrigerator, and
where large quantities of warm foods are often placed in it.

Employing factors from Tables 10-6 and 7, the space heat gain
resulting from air infiltration can be determined by the following
equation:

Air Change Load

= (infiltration rate L/s) (enthalpy change kJ/L)

(10-6)

Example 10-7 A storage cooler has outside dimensions of 4mx5mx3m high.

The outside temperature is 25C and the RH is 50%. The inside of the cooler
is maintained at 2C and usage is average. The walls of the cooler are
approximately 150 mm thick. Calculate the air change load in kilowatts.
Solution:
Since the walls of the cooler are 150 mm thick the inside dimensions of the
cooler are 0.3 m less than the outside dimensions, so that the inside volume
is (3.7 m x 4.7 m x 2.7 m) 47 m 3. From Table 10-7 by interpolation, the
infiltration rate for an inside volume of 47 m 3 is 7.3 L/s. By interpolation in
Table 10-6A the air change factor is found to be 0.0451 kJ/L.
Equation 10-6.
Air change load
= (7.3 L/s) (0.0451 kJ/L) 0.329 kW

Applying

10-15. calculating the Product Load

When a product enters a storage space at a temperature above the

temperature of the space, the product will give off heat to the space
until it cools to the space temperature. When the temperature of the
storage space is maintained above the freezing temperature of the
product, the amount of heat given off by the product in cooling to
the space temperature depends upon the temperature of the space
and upon the mass, specific heat, and entering temperature of the
product. In such cases, the space heat gain from the product is
computed by the following equation:

Q = (m) (G) (AT)

(10-7)

Where: Q = the quantity of heat in kilo joules per kilogram

m = mass of the product (kilo grams)
c = the specific heat above freezing, kilojoules per kilogram per
kelvin.
A T = the change in the product temperature (K)

Example 10-8 Thirty-five hundred kilograms of fresh beef enter a chilling

cooler at 39C and are chilled to 7C each day. Compute the product load in
kilojoules.
Solution:

From Table 10-8, the specific heat of beef above freezing is 3.14 kJ/kg Applying Equation 10-7,
Q = (3500)(3.14)(39C - 7C) = 351,680 kJ
Notice that no time element is inherent in Equation 10-7 and that the result
obtained is merely the quantity of heat the product will give off in cooling to
the space temperature. In Example 10-8 the product-is to be cooled over a
24-h period. However, in many instances the desired cooling time may be
less than 24 h. Since time is always a consideration in determining the
cooling rate, in all cases the product load or product cooling rate is
determined by following equation:

(m)(c)(T )
(desired cooling time in seconds)

Example 10-9 Determine the product load in kilowatts assuming that the
beef described in Example 10-8 is chilled in 20 h.
Solution:
Applying Equation 10-8, product load
(3500 kg)(3.14 kJ/kg K)(39C - 7C)
20(3600 s)
= 4.88 kW

10.16. Chilling Rate Factor

During the early part of the chilling period, the product load on the equipment
is considerably greater than the average hourly product load as calculated in

the previous examples. Because of the high temperature difference which

exists between the product and space air at the start of the chilling period, the
chilling rate is higher and the Product load tends to concentrate in the early
part of the chilling period (Section 9-23).
Therefore, where the equipment selection is based on the assumption that the
product load is evenly distributed over the entire chilling period, the equipment
selected will usually have insufficient capacity to carry the load during the initial
stages of chilling when the product load is at a peak. Consequently, a
significant rise in the space temperature can be expected during the early part
of the chilling period.

When such a rise is undesirable, a chilling rate factor is sometimes introduced

into the chilling load, calculation to compensate for the uneven distribution, of
the chilling load. The effect of the chilling rate factor is to increase the product
calculation by an amount sufficient to make the average hourly cooling rate
approximately equal to the hourly load at the peak condition.
This results in the selection of larger equipment, having sufficient capacity to
carry the load during the initial stages of chilling.

Chilling rate factors for various products are listed in tables 10-8 through 1011. The factors given in the tables are based on actual tests and on
calculations and will vary with the ratio of the loading time to total chilling time.
As an example, test results show that in typical beef and hog chilling
operations the chilling rate is 50% greater during the first half of the chilling
period than the average chilling rate for the entire period. The calculation
without the chilling rate factor will, of course, show the average chilling rate for
the entire period. To obtain this rate during the initial chilling period, it must be
multiplied by 1.5. For convenience, the chilling rate factors are given in the
tables in reciprocal form and are used in the denominator of the equation.
Thus the chilling rate factor for beef as shown in the table is 0.67 (1/1.5),

Where a chilling rate factor is used, Equation 10-8 is written

(m)(c)(T )
(desired cooling time in seconds)

(10-9)

(chilling rate factor)

Example 10-10 Recalculate the product load described in Example 10-9

employing the appropriate chilling rate factor.
Solution: From Table 10-8, the chilling rate factor for beef chilling is 0.67.
Applying Equation 10-9, product load
= (3500 kg)(3.14 kj/frg K)(39C - 7C)
20(3600 s)(0.67)
= 7.3 kW
Chilling rate factors are usually applied to chilling rooms only and are not
normally used in calculation of the product load for storage rooms. Since the
product load for storage rooms usually represents only a small percentage of
the total load, the uneven distribution of the product load over the cooling
period will not ordinarily cause overloading of the equipment and/or
unacceptable fluctuations in the space temperature and therefore no
allowance need to be made for this condition.
10-17. Product Freezing and Storage
When a product is to be frozen, and stored at. some temperature below, its
freezing temperature, the heat involved is calculated, in three parts:

1. The quantity of heat given off by the product in cooling from the
entering temperature to its freezing temperature.
2. The quantity of heat given off by the product in solidifying or freezing.
3. The quantity' of heat given off by the product in cooling from its
freezing temperature to the final storage temperature.
The method of determining the quantity of resulting from temperature
reduction (1 and 3) has already been established. The quantity of heat
resulting from freezing (part2) is calculated from the following equation:
Q = (m)(hlf)

(10-10)

where :
m = the mass of the product in kilograms
hjf = the product latent heat in kJ/kg

The summation of the three parts is divided by the desired processing time in
seconds to determine the equivalent product load in kilowatts.
Example 10-11: Three hundred kilograms of poultry enter a chiller at 5C and
are frozen and chilled to a final temperature of -15C for storage in 12 h.
compute the product load in kilowatts.
Solution:
From Table 10-8,
Specific heat above freezing
= 3.18 kJ/kg K
Specific heat below freezing
= 1.55 kJ/kg K Latent heat
= 246 kJ/kg

Freezing temperature = -3C

To cool poultry from entering temperature to freezing temperature,

applying
Equation 10-7
= (300 kg)(3.18 kJ/kg K)[5C-(-30C)]
=7630 kJ
To freeze, applying Equation 10-10
= (300 kg)(246 kJ/kg)
= 73,800 kJ
To cool from freezing temperature to final storage temperature,
applying
Equation 10-7
= (300 kg)(1.55 kJ/kg K)[(-3C) - (-15C)
= 5580 kJ
Total heat given up by product (summation of 1, 2, and 3)
= 87,010 kJ
Equivalent product load
=87010Q kJ
12(3600 s)
= 2.01 kW

10-18. Respiration Heat

Fruits and vegetables are still alive after harvesting and continue to
undergo changes while in storage. The more important of these
changes are produced by respiration, a process during which
oxygen from the air combines with the carbohydrates in the plant
tissue and results in the release of carbon dioxide and heat. The
heat released is called respiration heat and must be considered as a
part of the product load where considerable quantities of fruit
and/or vegetables are held in storage at temperatures above the
freezing temperature. The amount of heat evolving from the
respiration process depends upon the type and temperature of the
product. Respiration heat for various fruits and vegetables is listed
in Table 10-12.

Since respiration rate is given in watts per kilogram, the product

load accruing from respiration heat is found by the following
equation.

Q (watts) = Mass of product (kg) x respiration rate (W/kg)

(10-11)

10-19. Containers and Packing Materials

When a product is chilled in containers, such as milk in bottles or
cartons, eggs in crates, and fruit and vegetables in baskets and
lugs, the heat given off by the containers and packing materials in
cooling from the entering temperature to the space temperature

must be considered as a part of the product load (see Example 1015).

10-20. Calculating the Miscellaneous Load
The miscellaneous load consists primarily of the heat given off by
lights and electric motors operating in the space and by people
working in the space. The space heat gain from lights in watts is
computed by multiplying the wattage of the lights by the number of
hours per day the lights are in use divided by 24 hours.
Q( watts )

wattsxhours
24hours

The space heat gain from motors and from people working in the space is
listed in TABLES 10-13 and 10-14, respectively. The following calculations
are made to determine the heat gain from motors and occupancy:
Q (kW) = Motor output kW x factor (Table hours in use 10-13)
x hours in use / 24hours

eq. (10-13)

Q (kW) = No. of people x heat equivalent (kW) (Table 10-14) eq.

(10-14)

The heat gain from other miscellaneous heat sources, such as forklift trucks and other handling or processing equipment, should also
be taken into account in determining the total rate of heat gains for
the refrigerated space.
10-21. Use of Safety Factor
The total cooling load is the summation of the heat gain as
calculated in the foregoing section. It is common practice to add 5%

to 10% to use as value as a safety factor. The percentage used

depends upon the reliability of the information used in calculating
the cooling load. As general rule 10% is used.
After the safety factor has been added, the cooling load is multiplied
by 24 hours and divided by the desired operating time in hours for
the equipment to determine the average load (see Section 10-2).
The average cooling load is used as a basis for equipment selection.

10-22. Short Method Load Calculations

Whenever possible the cooling load should be determined by using

the procedures set forth in the preceding sections of this chapter.
However, when coolers are used for general-purpose storage, the
product load is frequently unknown and/or varies somewhat from
day to day so that it is not possible to compute the product load
with any real accuracy. In such cases, a short method of load
calculation can be employed which involves the use of load factors
which have been determined by experience. When the short
method of calculation is employed, the entire cooling load is
divided into two parts: (1) the wall gain load and (2) the usage or
service load.
The wall gain load is calculated as outlined in Section 10-13. the
usage load is computed by the following equation:

Usage load (W) = interior volume (m3) x usage factor x TD

(10-15)

Notice that the usage factors listed in Table 10-15 vary with the
interior volume of the cooler and are given in watts per cubic metre

per kelvin. Too, an allowance is made for normal and heavy usage.
Normal and heavy usage have already been defined in Section 1014. No safety factor is used when the cooling load is calculated by
the short method. The calculated cooling load is multiplied by 24
hours and divided by the desired equipment operating time in
hours to find the average kilowatt load used to select the
equipment (see Example 10-1-3). Since the values listed in Table
10-15 are average values based on experience, some judgment
should be exercised in their use.

Example 10-12 A storage cooler 6 m x 4 m x 3.4 m high is insulated

with 100 mm of glass fiberboard. Overall wall thickness is
approximately 200 mm. The outside temperature is 30C and usage
is average. Twelve, hundred and fifty kilograms of wet mixed
vegetables are cooled 25C to the storage temperature of 5C each
day. Compute the cooling load kilowatts based on a 16-h/day
operating time for the equipment.
Solution:
The outside surface area of the cooler is 116 m 2 and the inside
volume is (5.8 m x 3.6 x 3 m) 60.5 m3. From Table 10-1, the k factor
of glass fiberboard is 0.036 W/m K. From Table 10-2, for 100 mm
insulation thickness and a k factor of 0.035 W/m K, the wall U factor
is 0.31 W/m2 K. By interpolation in Table 10-7, the infiltration rate
for an interior volume of 60.5 m3 is 8.13 L/s. Assuming an inlet air
RH of 50%, the air change factor from Table 10-6A is 0.0536 kj/L.

From Table 10-9, the specific heat of wet mixed vegetables-Is 3.77
kj/kg K. From Table 10-12, an average respiration heat for
vegetables is 0.097 W/kg

Applying Equation 10-2,

Wall gain Ioad

= (116 m2)(0.31 W/m2 K)(30O C - 5OC)
= 899 W or 0.899 kW

Applying Equation 10-6,

Air change load

= (8.13 L/s)(0,0536 KJ/L)
=0.43 kW Applying Equation 10-8,

Product cooling load

(1250 kg)(3.77 kj/kg K)(5 K)

24 (3600 s).

=0.273 kW
Applying Equation 10-11,
Respiration load
= (1250 kg)(0.097 W/kg)
= 121.25 W or 0.121 kW

Summation of heat loads = 1.729 kW

Safety factor (10%) = 0.173 kW
Total cooling load = 1.902 kW
Required equipment capacity (kW)
= (1.902 kW)(24 h)
16h
=2.85 kW

Example 10-13 Recalculate the refrigeration load for the cooler described in
Example 10-12 using the short-form calculation.
Solution:
From Example 10-12, the wall gain load is 0.B99 kW and the interior volume
is 60.5m3. By interpolation in Table 10-15, the usage factor for an interior
volume of 60.5 m2 is 0.642 W/m3 K

Applying Equation 10-15,

Usage load
= (60.5 m3)(0.642 W/m3 K) (30C - 5C)
= 971 W or 0.971 kW
Summation heat loads = 1.87 kW
Equipment load (kW) =
(1.87kW)(24h)
(16 h)
= 2.81 kW

Example 10-14: A holding cooler 6m x 10 m x 4 m high is to be used for the

short- term storage of fresh beef. Thirty four hundred kilograms of beef enter
the cooler at 7C and are cooled to the storage temperature of 2C each day.
All the walls are partitions adjacent to unconditioned spaces (30C and 50%
RH) except the east wall (6 m x 4 m), which is adjacent to a chilling room
maintained at the same inside design temperature. Wall-construction is 100
mm cinder block insulated with 100 mm corkboard equivalent. The floor,
located over an unconditioned space, is a 125 mm concrete slab insulated
with 100 mm corkboard equivalent and finished with 75 mm of concrete. The
ceiling, situated under an unconditioned space, is a 100 mm concrete slab
with wood sleepers and insulated, with the equivalent of 100 mm of
corkboard. Two people work in the space during the loading periods (4 h),
usage is average, the lighting load is 500 W and the lights are in use 4 h/day.
Determine the required equipment capacity in kW based on a 20 h operating
time.

Solution:
All of the walls including floor and ceiling are insulated with 100 mm of
insulation having a k factor of approximately 0.043 W/m K (Table 10-1). From
Table 10-2, the wall U factor, based on 100 mm insulation thickness and k
factor of 0.045, is 0.383 W/m2 K. The outside surface area of the cooler,
excluding the east wall, which is adjacent to a chilling room maintained at the
same temperature as the storage cooler, is 224 m 2. The inside volume is (5.6
m x 9.6 m x 3.5 m)

188

ft.' From Table 10-7, the air infiltration rate is 13.56 L/s

based on an inside volume of 190 m 3. By interpolation in Table 10-6A, the air

change factor is 0.0598 kJ/L From Table 10-14, the heat gain per person is
261 W. From Table 10-8, the specific heat of fresh beef is 3.14 kJ/kg K.

Applying Equation 10-2,

Wall, gain load m
=(224 m2)(0.383 W/m2 K)(30C - 2C)
= 2402 W or 2.402 kW
Applying Equation 10-6,
Air change load
= (13.56 L/s)(0.0598 kJ/L)
=0.810 kW
Applying Equation 10-8,
Product load
=(3400kg)(3.14kJ/kgK)(7C-2C)
24(3600 s)
= 0.618 kW

Miscellaneous load:
Light = (500 W)(4 h)
(24 h)
= 83 W or 0.083 kW
People = (2)(261 W)(4 h)
(24 h)
= 87 W or 0.087 kW
Summation of heat loads = 4.0 kW
Safety factor (10%) = 0.4 kW
Total cooling load = 4.4 kW

Required equipment capacity (kW)

=(4.4 kW)(24 h)
(20 h)
= 5.28 kW
Example 10-15 Three thousand lug boxes 1L of apples are stored at .2C in a
storage p cooler 16 m x 12 m x 3.4 m high. The apples enter the cooler at a
temperature of 30C and at the rate of 200 lugs per day each, day for the 15day harvesting period. The walls including floor and ceiling are constructed of
25 mm boards on both sides of 50 mm x- t00 mm studs and are insulated with
100mm of mineral wool. All of the walls are shaded and the ambient
temperature is 30C. The average weight of apples per lug box is 27 kg. The
lug boxes have an average weight of 2 kg and a specific heat value of 2.5
kJ/kg- k.
The lighting load is 500 W for 3 h per day. Two people and one battery
operated lift truck (4.17 kW) are in the space 3 h per day. Determine the
average load in kilowatts on the equipment based on a 16 h per day
equipment operating time.

Solution:
The load calculation is made for the maximum load, which occurs on the
fifteenth day. The outside surface area is 574 m 2 and the inside volume is
(15.7 m x 11.7 m x 3.1 m) 570 m3. The insulation k factor (Table 10-1) is 0.039
W/m K and is increased to 0.045 W/m K to compensate for the wood studs.
From Table 10-2, the wall U factor, based on 100 mm insulation thickness and
a k factor of 0.045 W/m K, is 0.383 W/m 2 K. From Table 10-7, the air change
rate, assuming heavy usage is 34.41 Us. From Table 1.0-6A, the enthalpy
change factor (assuming 50% RH) is 0,0598 kJ/L. From Table 10-10 the

specific heat of apples is 3.72 kJ/kg K and the chilling rate factor is 0.67. From
Table 10-12, the respiration heat of apples at 2C is 0.015 W/kg! From Table
10-14, the heat gain per person is 261 W. Applying Equation 10-2,
Wall gain load
= (574 m2)(0.045 W/m2 K)(30C - 29C)
= 723 W or 0.723 kW
Applying Equation 10-6,
Air change load
=(34.41 Us)(0.0598 kJ/L)
= 2.058 kW
Applying Equation 10-9,
Product cooling Apples
=(2D0 x 27kg)(3.72kJ/kgK).(30C- 2C)
0.67
= 839,499 kJ

Boxes
(200 x 2 kg)(2.5 kJ/kg K)(30C - 2C)
0.67
= 41,791 kJ.
Total product load
= 839,499 kJ + 41,791 kJ
24(3600 s)
= 10.2 kw
Applying Equation 10-11,

Respiration load
= (3000 x 27 kg) (0.015 W/kg)
= 1215 W or 1.215 kW
Miscellaneous load:
Lights = (500WH3h)/24 h
= 62.5 W or 0.063 kW
People = (2)(261 W)(3 h)/24h
= 65.25 W or 0.065 kW
Lift truck = (4.17kw)(3h)
24h
= 0.521kw

Summation of heat gains = 14.845 kW Safety factor (10%) = 1.485

kW Total cooling load = 16.33 kW
Required equipment capacity
=(16.33 kW)(24h)
16h
=24.5Kw

Regarding Example 10-15, if larger fluctuations in the storage

temperature are acceptable, the chilling rate factor can be
neglected, in which case the product cooling L load will be reduced
by 33% and the required equipment capacity by 22.7%, from 24.5
kW to 18.94 kW. As another alternative, if the chilling rate factor is
used, the respiration load could be neglected in that all of the
products load, except the respiration load, will disappear on the
sixteenth day.

Example 10-16: Ten thousand kilograms i of dressed poultry are blast-frozen

on hand v trucks each day (24 h) in a freezing tunnel 4 m x 3 m x 3.5 m high

(see Fig. 10-4). The poultry is precooled to 7C before entering the freezer
where it is frozen and its temperature lowered to -20C for storage. The lighting load is 200 watts and the lights are on h per day. The hand trucks carrying
the poultry total 700 kg per day and have | specific heat of 0.47 kJ/kg K. The
north and east partitions adjacent to the equipment room and vestibule are
constructed of 150 mm clay tile insulated with 150mm polyurethane. The
south and west partitions adjacent to storage cooler are 100 mm clay tile with
50 mm polyurethane insulation. The roof is a 150 mm concrete slab insulated
with 150 mm polyurethane and covered with tar, felt, and gravel. The floor is a
150 mm concrete slab insulated with 150 mm polyurethane and finished with
100 mm of concrete. The floor is over a ventilated crawl space. Roof is
exposed to the sun. The equipment room is well ventilated so that the
temperature inside is approximately the outdoor design temperature for the
region (33C). The inside design temperature for both the storage room and
the freezer is -20C. The vestibule temperature and relative humidity are 10C
and 70%, respectively. Determine the average hourly refrigeration load based
on 20 h per day operating time for the equipment.

Solution:
The combined outside surface area of the floor and north and east partitions
is 36.5 m2. The area of the roof is 12 m 2. The interior volume is 25 m3. From
Table 10-1, the k factor for polyurethane insulation is 0.025 W/m K. From
Table 10-2, the wall U factor is 0.153 W/m2 K. The roof sun factor is 11C
(Table 10-5). From Table 10-7, the air change rate, based on 25 m 3 interior
volume and vestibule entrance, is (4.2 x 0.5). 2.1 Us. The enthalpy change
factor (Table 10-6B), based on an entering air temperature of 10C and 70%
RH, is 0.0456 kJ/L. From Table 10-8, the specific heats of poultry above and

below freezing are 3.18 kJ/kg K and 1.55 kJ/kg K, respectively, the latent heat
is 246 kJ/kg and the freezing temperature is -2.75C. Applying Equation 1.0-2,

Transmission gain Walls and floor

= (36.5 m2)(0.153 W/m2 K)
[33C - (-20C)]
= 296 W or 0.296 kW
Roof
= (12 m2)(0.153 W/m2 K) [33 + 11C-(- 20C)]
=117.5 W or 0.118 kW
Applying Equation 10-6,
Air Change load
= (2.1 Lys) (0.0456 kJ/L)
= 0.096 kw
Applying Equation 10-7,
Product cooling load
= (10,000 kg) (3.18 kJ/kg K)[7C - (-3C)] - 318,000 kJ
= (10,000 kg) (1.55 kJ/kg K)
[(-3C) - (-20)]
= 263,500 kJ
Trucks
=(700 kg)(0.47kJ/kgK)[7-(--20C)]
=8883 KW
Applying Equation 10-10,
Freezing load
= (10,000kg)(246 kJ/kg)
=2,460,000 kJ
Total

= 3,050,383 kJ

product load

24(3600 s)

=35.3kW
Miscellaneous load
Lights =

(200W)(16
h)
24h

= 133.3 W or 0.133 kW Summation of heat loads = 35.43 kW Safety factor

(10%)
= 3.54 kW
Total heat gain
= 38.97 kW
Required equipment capacity
= (38.97 kW)(24 h) (20 h)
= 46.76 kW

Example 10-17 Twenty three hundred litres of partially frozen ice cream at
-4C are entering a hardening room 3 m x 5 m x 3 m high each day.
Hardening is completed and the temperature of the ice cream is lowered to
-28C in 10 h. The walls, including floor

and ceiling, are insulated with 150

mm of polyurethane and the overall thickness-of the walls is 250 mm. The
ambient temperature is 32C and the RH is 50%. Assume the average density
of ice cream is 0.6 kg/L, the average specific heat below freezing is 2.1 kJ/kg
K,

and the average latent heat per kg is 233 kJ. Determine the average

hourly load based on 18 h operation.

Solution:
The outside surface area is 78 m 2 and the interior volume is (2:5 m
x 4.5 m x 2.5 m) 28 m3. The insulation k factor is 0.025 W/m K (Table
10-1). The wall U factor (Table 10-2), based on 150 mm insulation
thickness and k factor of 0.025 W/m k, is 0.153 W/m 2 K. By
interpolation in Table 10-7, the air change rate Ms 4.44 L/s. By
interpolation in Table 10-6B, the enthalpy change factor is 0.1104
KJ/L).

Applying Equation 10-2,

Wall gain load = (78 m2)(0.153 W/m2 K)
[32 - (-28)]
= 716 W or 0.716 kW
Applying Equation 10-6,
Air change load = (4.44 L/s)(0.1104 kJ/L)
= 0.490 kW

Applying Equation 10-7,

Product cooling
= (2300 L x 0.6 kg/L)(2.1 kJ/kg K)
[(-4) - (-28C)]
= 69,550 kJ
Applying Equation 10-10
Product Freezing
= (2300 L x 0.6 kg/L)(233 kJ/kg)
= 321,540 kJ

Total product Load

391,090 kJ
24 3600 s

= 4.53 kW
Summation of heat

= 5.74 kW

Safety factor (10%)

= 0.57 kW

Total heat gain

= 6.32 kW

Required equipment capacity

(6.32kW)(24
h)
= 8.43 kW
(18h)

Example 10-18 A cooler 4m x 3m x 3m high equipped with 6 x 0.7

m x 1 m triple-glass doors is used for general purpose storage in a
grocery store. The cooler is maintained at 2C and the service load
is heavy. The walls are insulated with the equivalent of 100 mm of
corkboard and the ambient temperature is 25C. Determine the
cooling load in kW based on a 16 h operating time.

Solution :
The glass area is 4.2 m2 (6 x 0.7 x 1) and the net wall area is 61.8 m 2 (664.2). The inside volume is approximately 40.4 m 3. From Table 10-2, the wall U
factor, based on 100 mm insulation thickness and a k factor of 0.045 W/m K,
is 0.383 W/m2 K. From Table 10-1, the conductance factor for triple-pane
glass is 1.65 W/m2 K. Assuming heavy usage, from Table 10-15, the usage
factor is approximately 1.18 W/m3 K.
Applying Equation 10-2,
Wall gain load
= (61.8 m2)(0.383 W/m2 K)(25C-2C)
= 544 W of 0.544 kW
Glass
= (4.2 m2)(1.65 W/m2 K)(25C - 2C)
= 159 W or 0.159 W
Applying Equation 10-15,
Usage load
= (40.4 m3)(1.18 W/m3 K(25C -2 C)
=1096 W or 1.096 kW
Total heat load = 1.799 kW

( 1.799kW)(24

(16 h)

h)

2.7kW

Problems
10-1 Determine the value of C for a 125 mm thickness of an
insulating material having a k value of 0.043 W/m K.
10-2 Assuming a wind velocity of 12 km/h, compute the value of U
for a wall constructed of-200 mm hollow clay tile insulated with
150 mm of polyurethane foam and finished on the inside with
13 mm of cement plaster.
10-3 A cooler wall 3 m by 8 m is insulated with the equivalent of 75
mm of expanded smooth cell polystyrene. Compute the heat
gain through the wall in kilowatts if the inside temperature is
2C and the outside temperature is 25C.
10-4 A reach-in cooler is equipped with eight triple-pane glass
doors, each measuring 0.8 m by 0.6 m. Compute the
conduction heat gain-through the doors in watts if the
temperature difference between the inside and out- side is 22
K.
10-5 The north wall of a cold storage warehouse is 4 m by 18 m
and is constructed of 200 mm hollow clay tile insulated with
150 mm of corkboard. The outdoor design temperature is 35C
and the inside design temperature is -25C. Determine the
rate of heat gain through the wall in kW.
10-6 A cold storage warehouse, located where the outdoor design
temperature is 32C, has a 10 m by 16 m flat roof constructed
of 100 mm of concrete covered with tar and gravel and
insulated with the equivalent of 100 mm of corkboard. If the
roof is unshaded and the inside of the warehouse is
maintained at 2C, compute the rate of heat gain through the
roof in kilowatts.

10-7 The floor of the cold storage room described in Problem 10-6
consists of a 50 mm concrete slab insulated with the
equivalent of 75 mm of cork- board and finished with 50 mm of
concrete. If the outdoor design temperature in winter is 0C,
determine the rate of heat gain through the floor in kilowatts.
10-8 A frozen storage room has an interior volume of 75 m 3 and is
maintained at a temperature of -25G. The usage is light, and
the outside design conditions (anteroom) are 10C and 70%
RH. Compute the air infiltration load in kilowatts.
10-9 Twenty five hundred kilograms of fresh lean beef enter a
chilling cooler at 38C and are chilled to 3C in 24 h Compute
the chilling load in kilowatts.
10-10 Eighteen hundred kilograms of green beans packed in baskets
(15 kg per basket) enter a chilling cooler at a temperature of
27C and are chilled to a temperature of 1C in 20 h. The
empty baskets have a mass of 1.4 kg and a specific heat of
2.5 kJ/kg K. Compute the product load in y kilowatts.
10-11 Three hundred kilograms of pre-pared, packaged beef enter a
freezer at a temperature of 2C. The beef is to be frozen and
its temperature reduced to -18C in 5 h. Compute the product
load.
10-12 Fifty-five hundred crates of apples are in storage at 3C. An
additional 500 crates enter the storage cooler at a temperature
of 29C and are chilled to the storage temperature in 24 h. The
average mass of apples per crate is 27 kg. The Crate has a
mass of 4.5 kg and a specific heat of 2.5 kJ/kg K. Determine
the product load in kilowatts.
10-13 A walk in cooler 3 m by 5 m by 3m High equipped with twelve
0.6 m by 0.6 m triple-glass doors is used for general purpose
storage in a drive-in market (heavy usage). The walls are
insulated with 50 mm of expanded cut cell polystyrene, and

the cooler is to be maintained at 2C. Compute the cooling

load in kilowatts based on a 16-h operating time if the ambient
temperature is 25C.