MINISTRY OF EDUCATION AND TRAININGHO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MAJOR: THERMAL ENGINEERING TECHNOLOGY INSTRUCTOR: DANG THANH TRUNG HUYNH HOANG
OVERVIEW
Topic Overview
Refrigeration has been utilized for centuries, with archaeological findings revealing that ancient civilizations stored food and provisions in caves featuring underground low-temperature water around 500 years ago.
Modern refrigeration technology began with Professor Black's discovery of latent heat of vaporization and fusion between 1761 and 1764 Prior to this, people understood that cooling could be achieved through the evaporation of liquids at low pressure.
Modern refrigeration technology has advanced significantly, now rivaling other engineering fields in sophistication The refrigerant temperature range has broadened considerably, approaching vacuum temperatures For heat pump applications, the condenser temperature can reach up to 100 degrees Celsius, facilitating functions such as heating, hot water preparation, and drying.
In recent years, Vietnam has emerged as a rapidly growing economy, leading to a significant increase in demand for the refrigeration industry This growth has resulted in millions of USD in foreign currency income from refrigeration equipment annually However, the country still faces limitations in its refrigeration sector, as it has yet to master advanced technologies and primarily produces small ammonia air refrigerants.
The topic “Calculating, checking, and developing the refrigerant system of
Heineken factory using the Autocad Plant 3D software” may still have many shortcomings We look forward to receiving the comments of advisors and friends
Significance of the Topic
As the economy of our country continues to grow, there is an increasing demand for housing, entertainment, and shopping, leading to the emergence of modern facilities The alcohol industry plays a crucial role in socio-economic development, creating thousands of jobs and contributing significantly to the state budget, with beverage manufacturers contributing between 50,000 to 60,000 billion Vietnamese dong annually and employing around 80,000 workers This growth in the alcoholic beverage sector also fosters the development of related ecosystems in agriculture, logistics, mechanics, biochemistry, packaging, and services.
European countries boast a rich heritage of beer production, with Belgium, Germany, Austria, Ireland, and the United Kingdom being particularly notable for their brewing traditions Additionally, countries like France, the Nordic nations, Poland, the Czech Republic, and Spain contribute to this diverse landscape, each offering unique beers that reflect their distinct histories, specialized production techniques, and a variety of styles.
The beer production industry has evolved into a vast global market, featuring numerous multinational corporations alongside thousands of small-scale producers, ranging from local breweries to regional operations Innovations in refrigeration, marketing, and trade have created an international marketplace, offering consumers an extensive array of choices from various local, regional, national, and international breweries.
Refrigeration systems play a crucial role in modern breweries, enabling them to refine their products using optimal production technology As such, these systems are indispensable for achieving high-quality brewing results.
An effective refrigeration system should fulfill both technical specifications and economic efficiency Accurate capacity calculation is crucial for meeting technical requirements, while selecting equipment based on economic factors and ensuring energy savings are vital for cost-effectiveness.
21 operation, are also crucial These requirements have determined the decision to implement the project: " Calculating, checking, and developing the refrigerant system of
Heineken factory using the Autocad Plant 3D software."
During the project implementation, the team will gain practical knowledge and insights into water and sanitation standards, as well as international regulations This expertise will be valuable in their future career opportunities.
Project Introduction
The brewery in District 12 - Ho Chi Minh City - began construction in 1991 and currently covers an area of 12.7 hectares, prominently located on Le Van Khuong Street, spacious, elegant, and modern
Address: 170 Le Van Khuong, Thoi An Ward, District 12, Ho Chi Minh City
HEINEKEN Vietnam produces and distributes renowned brands including Heineken®, Tiger, Larue, BIVINA, Bia Viet, Strongbow, and Edelweiss, with HEINEKEN Hoc Mon focusing on Tiger and Heineken beer After nearly thirty years of development, this brewery is recognized as one of the most advanced and sustainable in Asia Located in Ho Chi Minh City, it has received numerous awards that attest to the high quality of Heineken and Tiger beer, showcasing the commitment to producing world-class beer products.
With modern infrastructure and equipment meeting the highest standards of safety, quality, and hygiene, the new facility is dedicated to meeting the increasing demands of users in Vietnam
HEINEKEN Vietnam generates 152,000 jobs across its value chain, representing approximately 0.7% of the national GDP As a leading taxpayer, the company has consistently contributed significantly to the state budget over the years By blending international expertise with deep understanding of the Vietnamese market, HEINEKEN Vietnam showcases its commitment to innovation and economic growth.
22 bring Vietnamese consumers a diverse portfolio of products, including those created by Vietnamese beer experts, specifically for Vietnamese people” Heineken Brewery District 12”
The Heineken Brewery - District 12, Ho Chi Minh City is built on a plot of land with a total area of 14,000 m2 divided into 40 different areas
The facility encompasses two parking lots, a memorial and coaching house, and two silo areas designated for barley storage Additionally, it features an office area, a brewing house, and ten fermentation tank areas There are also four storage areas for empty bottles, alongside an energy supply area for production and a water supply processing area.
The facility features a dedicated oil storage tank area, a backup power generator zone, and five beer bottling lines Additionally, it includes a CO2 recovery system, a CTNH storage area, and a waste disposal section Employees can enjoy amenities such as a cafeteria and a playground, while the site also accommodates a wastewater treatment area, a forklift parking zone, and a finished goods warehouse.
In this project, the team will conduct calculations and verifications for the refrigeration control system, starting with the experimental determination of the plant's heat load using the Carrier method They will assess the cooling capacity of the main equipment based on the "Total plant cooling" diagram and evaluate the selected equipment cluster Additionally, the team will calculate and verify supporting equipment, such as water pipes Each test will be accompanied by detailed comments and insights derived from the calculation results.
Initial figures
The brewery refrigeration system is a vital component in the industrial refrigeration sector, essential for various stages of beer production Key processes that require effective cooling include the rapid cooling of wort post-boiling, fermentation beer storage, yeast preservation, finished beer storage, and CO2 condensation.
Based on outdoor temperature [1], we have the outdoor temperature of Ho Chi Minh City
According to T1 and 𝜑1 , we calculate dew point temperature and wet bulb temperature:
1 - Summer air state t1 - Air temperature (Dry bulb temperature)
CALCULATIONS HEAT LOSS AND REFRIGERANT PROCESS
Beer Production Technology Process
Beer is produced according to the classical fermentation process over a period of
With a main fermentation period of 5 - 7 days [3]
Secondary fermentation period of 14 - 23 days [3]
The manufacturing process at the Heineken Vietnam Brewery is described through the following stages:
The production process involves key materials such as malt and rice, along with various additives These ingredients are stored in silos before being moved to the material processing system, where they are ground into smaller pieces This grinding process enhances the transformation of materials and optimizes wort extraction for brewing.
In the brewing process, malt and rice flour are combined with water, allowing enzymes to convert starch into sugar at a specific temperature This crucial transformation significantly impacts the type and quality of the beer produced To optimize enzyme activity, acid and calcium are added to adjust the pH The primary goal is to dissolve sugars, minerals, and essential proteins.
Temperature and time during the saccharification process:
Start from 48°C - 62°C, held for 10 - 20 minutes
Gradually increase the temperature to 66°C over 5 - 15 minutes
Maintain this temperature for about 10 - 30 minutes
Gradually increase the temperature to 76°C - 78°C over 10 - 15 minutes
Check the amount of residual flour in the saccharification process If there is still residue, continue to maintain this temperature; otherwise, the saccharification process is terminated
Once the saccharification process concludes, the mixture is transferred to a filter tank where the liquid is separated from the bran, fiber, and germ of the rice Following the initial filtration, hot water is introduced to extract any residual sugars clinging to the bran.
Sugar water is boiled for about 70 minutes, during which hops are added to enhance the beer's flavor Additionally, acid and calcium are introduced to adjust the pH levels.
During boiling, many reactions directly related to the quality occur Here are some important reactions:
Dissolution and transformation of hop constituents
Interaction between proteins and polyphenols
Evaporation of odoriferous compounds that negatively affect beer quality Separation of hop residues and insoluble components:
During boiling, proteins react with polyphenols to form insoluble compounds Before fermentation, these residues are removed
Beer yeast thrives at low temperatures, as high temperatures can quickly kill it To prevent contamination by other microorganisms, it is essential to rapidly cool the wort to around 10°C after boiling.
Fermentation mainly occurs in the primary fermentation tank for about 5 - 7 days at a temperature of 9 - 10°C Fermentation is divided into two stages: primary and secondary
During the primary fermentation stage, sugars are transformed into alcohol, carbon dioxide, and aromatic compounds, accompanied by the release of heat This process primarily produces cloudy beer, which is known for its distinctive aroma and flavor.
During fermentation, yeast multiplies significantly, tripling in number before settling at the bottom of the fermentation tank The sediment is then separated for reuse or for industrial waste treatment The young beer, produced at the end of primary fermentation, is stored in low-pressure tanks (approximately 0.5 - 0.7 bar) for 14 to 23 days This period also marks the onset of secondary fermentation, a slow process characterized by minimal sugar conversion, yeast sedimentation, and CO2 saturation, all while maintaining a reduced storage temperature of 0°C.
The final processing step to produce finished beer involves filtration, carbonation, and packaging into cans, bottles, and kegs.
Calculating the beer production process and selecting equipment
2.2.1 Calculate the main ingredients for 1000 liters of beer
2.2.1.1 Calculating the amount of soluble material from malt and rice [2]
Loss due to the lautering process is 3% So, the beer before lautering is
Loss during the CO2 loading process is 0.5% The beer volume before CO2 loading is
1030 × 1.005 = 1035 (liters) Loss during the filtration process is 1% The beer volume before filtration is
Loss during the primary and secondary fermentation process is 2.5% The liquid volume before fermentation is:
Loss during the chilling and sedimentation process is 1.5% The liquid volume before chilling and sedimentation is:
When chilling from 100°C down to the fermentation temperature, the volume coefficient is considered The volume of the wort after boiling at 100°C is
The wort has a density of about 1.043 kg/liter
1131 × 1.043 = 1180 kg The total amount of dissolved dry matter in the liquid is:
During the boiling process with hops, some precipitated materials dissolve while additional soluble compounds from the hops are introduced Consequently, to produce 1000 liters of beer at 110 Bx, a total of 129.8 kg of soluble material is required.
Selecting 70% of soluble material from malt and 30% from rice:
So, the amount of soluble material from malt would be:
129.8 × 0.7 = 90.9 kg The amount of soluble material from rice:
2.2.1.2 The amount of malt needed for 1000 liters of beer [2]
Loss during the milling process: 0.5%
Therefore, the total amount of malt required is:
2.2.1.3The amount of rice needed for 1000 liters of beer [2]
Loss during the milling process: 0.5%
Therefore, the amount of rice required is:
2.2.2 Amount of hops needed for 1000 liters of beer [2]
Using 0.1 grams of flower hops and 1 gram of hop cones per liter of beer
So, the amount of hops needed for 1000 liters of beer is:
2.2.3 Calculation of water consumption for 1000 liters of beer [2]
During brewing, the water ratio on the raw material is 5/l
Therefore, the amount of water consumed during brewing is:
Malt with 8% moisture content, so the amount of water present in malt is:
145 × 0.08 = 11.64 liters Rice with 13% moisture content, so the amount of water present in rice is:
55.5 × 0.13 = 7.22 liters During the sparging process, the loss of water due to evaporation is 5%
Therefore, the remaining water content in the wort after sparging is:
(1005 + 11.64 + 7.22) × 0.95 = 972.66 (liters) The volume of wort to be fermented is: 1180 kg
The amount of dry matter in the wort before fermentation:
During boiling, the loss of water is 10% Therefore, the amount of water in the wort during boiling is:
So, the amount of water used for rinsing is:
The total amount of water consumed for the brewing, saccharification, and rinsing process is:
2.2.4 Calculation of yeast amount needed for 1000 liters of beer [2]
The yeast strain used here is Saccharomyces carlbergenis, which can use both seed yeast and regenerated yeast
If using seed yeast, the proportion of seed yeast added to the tank is 10% of the volume
So, the amount of seed yeast solution needed for 1000 liters of beer is:
If using regenerated yeast, the proportion of regenerated yeast added to the tank is 1% of the volume
So, the amount of regenerated yeast solution needed for 1000 liters of beer is:
In practice, for every 1000 liters of fermented wort, 20 liters of yeast milk with a moisture content of 85% is recovered So the amount of yeast milk recovered is:
1000= 21.43 (liters) Out of 21.43 liters of yeast milk, only about 50% is used for the next batch
2.2.5 Calculation of the amount of Carbonic (CO2) needed for beer before bottling
During fermentation, Maltose undergoes the following transformation [2]
From one molecule of C12H22O11, 4 molecules of CO2 are produced Therefore, 342g of
4 × 44 = 476 g The dry mass in 1071.6 liters of wort (with a density of 1.043 kg) is:
100= 122.94 kg During fermentation, the dry matter content of the wort decreases from 110 Bx to 3.50
So, the dry matter participating in the alcohol formation process is:
We consider this dry matter as an approximation of Maltose Therefore, the amount of CO2 produced during fermentation is:
The amount of CO2 dissolved in beer is 2.5g/l , so the amount of CO2 dissolved in 1045.5 liters of beer is:
1045.5 × 2.5 = 2613.7g = 2.6137 kg Therefore, the amount of CO2 released during fermentation is:
About 60% of the released CO2 is recovered, and the rest escapes So, the amount of recovered CO2 is:
To achieve the desired carbonation in beer, it is essential to account for the CO2 loss during fermentation and filtration Initially, the dissolved CO2 content is 2.5 g/l, but after filtration, it reduces to 2 g/l The finished beer should have a CO2 concentration of 3.5 g/l, factoring in a 20% saturation loss and a loss coefficient of 1.2 Therefore, the total required amount of CO2 for proper carbonation is calculated based on these parameters.
Therefore, the amount of CO2 needed to be injected is
Calculating the beer production process and selecting equipment [2]
Beer consumption varies seasonally, with statistical data indicating that to achieve an annual production volume of 680 million liters, consumption levels fluctuate throughout the year During rainy months, production is about 70% of the average capacity, while in the remaining months, it must exceed the average capacity by reaching 110%.
To produce 680 million liters of beer per year, a brewery can be designed with one brewing systems
So the following design calculations need to be considered:
- Reduction factor of wort volume from 100°C to 20°C is 0.96
- Maximum number of batches brewed per day: 30 batches
- One day per week is reserved for cleaning, during which 5 batches are brewed
- The highest average batch per day is:
- Capacity for one batch is:
Therefore, the capacity chosen for the brewing system is 745 hectoliters of hot wort per batch
The amount of raw materials per batch:
- Flower Hops 0.1 × 744.736 = 74.47 (kg per batch)
- Hops Cone 1 × 744.736 = 744.736 (kg per batch)
Determining the refrigeration load for the brewery plant
Beer Production Technology at the Brewery
Primary and secondary fermentation for 11 days
Rapid chilling using cold water technology at 20°C
The refrigeration system efficiently cools glycol to -50°C, which is then circulated to fermentation tanks and heat exchange equipment, ultimately producing chilled water at 20°C essential for beer production.
The brewing kettle has a capacity of 70 m 3 of hot wort per batch
The refrigeration capacity is calculated as follows:
Q1: Heat loss due to thermal transfer from the environment through the insulation into the fermentation tanks, finished product tanks, chilled water tanks, glycol cooling tanks, and along the pipelines
Q2: Heat generated by product waste during the fermentation process, cooling of beer after filtration and CO2 saturation, and cooling for product preservation
Q3: Heat generated during the operation of the fermentation room, cooling of beer after filtration and CO2 saturation, and cooling for product preservation
Q4: Heat from ventilation through the air-conditioned rooms
Q5: Heat content of the raw product, essentially Q2
2.4.1 The heat loss due to thermal transfer 𝐐 𝟏
The heat transfer losses due to heat transfer include:
- Heat transfer losses in fermentation tanks
- Heat transfer losses in finished tanks
- Heat transfer losses in 3°C chilled water tanks
- Heat transfer losses in glycol storage tanks
- Heat transfer losses in cooling rooms, filtration rooms, etc., if refrigerated
Device Inside refrigeration Temperature Insulation
Fermentation tanks, yeast seed tank
Glycol moves rapidly through the cooling jacket
Finished tanks Glycol moves rapidly through the cooling jacket
1°C water tank Cold water stands still inside
Glycol tank Glycol has slight movement
Evaporation tank Liquid NH3 is evaporating
STT Material layer name Thickness
1 Outer layer of stainless steel
2.4.2 The heat loss in yeast fermentation tanks
The process of heat transfer from outside air into the fermentation tank has the following characteristics:
The internal surface of the tank features three distinct layers: refrigerant in glycol, beer liquid, and cold air This complexity makes it challenging to ascertain the internal heat dissipation coefficient However, since the primary exposure is to glycol, which is where the majority of damage occurs, calculations should focus solely on the contact with glycol for accuracy.
The object features a cylindrical body, a conical base, and an elliptical nail shape, making it challenging to identify the top and bottom using standard formulas To simplify the analysis, we can temporarily model the entire structure as a cylinder with an equivalent height H, while it is internally exposed to glycol.
Therefore, heat loss in the fermentation tank
Insulation layer thickness Polyurethane δ = 150 mm
Main fermentation at a temperature of 16°C for 7 days
Secondary fermentation at a temperature of 4°C for 4 days
Glycol temperature into the cooling jacket -8°C
Glycol temperature out of the cooling jacket 1°C Average cooling jacket temperature
Determine the insulation wall area
F 1 = π × D × H Elliptical area (approximately equal to cylinder area)
The insulation wall areas are summary in the table
(m 2 ) Small Fermentation Tank 4.7 8.75 2.53 0.4 129 6 19 154 Horizontal Fermentation Tank 4.6 7.65 1.2 0.36 111 5 9 124 Medium Fermentation Tank 6.0 8.95 2.58 0.42 169 8 24 201 Large Fermentation Tank 6.4 19 5.48 0.9 382 18 55 455
Determine the heat transfer coefficient
Due to the large diameter of the fermentation tank, we consider the outer shell as a straight wall
1 #.3 W/m 2 K Heat transfer coefficient on the outside of air
= 0.15 m Thickness of the insulation layer
= 0.047 W/m.K Thermal conductivity coefficient of the insulation layer
The stainless steel cladding layers have a very large thickness and very high thermal conductivity coefficient , thus they can be neglected
2 The section with the cold beer dispenser has a large power, so can be approximated as 1/2 0
The thermal conductivity coefficient of the insulation layer is 0.047 W/m.K
The heat loss during the secondary fermentation period is 4°C with an outdoor air temperature of 37.3 °C
Q11: Heat loss through the jacket
Q12: Heat loss through the remaining insulation
The equation Q 12 = k × (F t − F t ′ ) × ∆t 1 represents the heat loss in fermentation tanks A summary of the heat loss for each fermentation tank type is provided in the table below Additionally, it is noted that there is an extra cold loss of 10% attributed to the lack of insulation on the tank lid during operation.
(kcal/h) Small Fermentation tanks 270 154 280 1096 383 1480 1627 Horizontal Fermentation tanks 232 124 236 901 327 1228 1351 Medium Fermentation tanks 353 201 365 1441 494 1935 2129 Large Fermentation tanks 800 455 828 3727 742 4469 4916
Total Heat loss in Fermentation tanks
Cold loss during the main fermentation period
Heat loss during the main fermentation period is 16°C with an outdoor air temperature of 42°C
Q 21 : Heat loss through the jacket
We have Q 21 = Q 11 (This part does not change because it is assumed that the temperature of glycol in and out is the same as during the secondary fermentation process.)
Q 22 : Heat loss through the remaining insulation
Heat loss through the remaining insulation is
The additional cold loss due to operation, accounting for 10% cause by the tank lid not being insulated
TABLE2 6COLDLOSSDURINGTHEMAINFERMENTATION PERIOD Type of fermentation tanks Q21
Total cold loss in the main fermentation period
2.4.3 Heat flow loss in the finished tank
Heat loss in finished tanks is calculated in a manner similar to that of fermentation tanks, focusing on the tank's body while adjusting for the height of the H2 to account for the bottom and elliptical lid Both fermentation and finished tanks experience heat loss through the insulation layer, which transfers heat into the glycol.
The finished tank has the following specifications
Height of the cylindrical part H = 8.75 m
Height of the elliptical cone h2 = 0.43 m
Height of the conical bottom h1 = 2,45 m
Cold loss in the finished tank
F 2 = π × D × h 2 = π × 4.7 × 0.43 = 6.35 (m 2 ) Area of the conical bottom [2]
F t = F 1 + F 2 + F 3 = 258.4 + 6.35 + 20.88 = 285.63 (m 2 ) The length of the cooling jacket is 4 m
The area of the cooling jacket is
Cold loss in the finished tank
Q31 Heat loss through the jacket
Q32 Heat loss through the remaining insulation we have
= 1280.45 ( kcal h ) Heat transfer through the remaining part of the tank:
Cold loss when considering an additional 10% due to operation because the tank lid is not insulated
The number of small fermentation tanks is 20 tanks
The number of horizontal fermentation tanks is 15 tanks
The number of medium fermentation tanks is 24 tanks
The number of large fermentation tanks is 50 tanks
The number of finished tanks is 16 tanks
So, the total heat loss from the tanks is
2.4.4 Cold loss in the 3 0 C water tanks (Q I4 ) [2]
The 3 o C water tanks has these dimension
= 254.79 (m 2 ) Total heat loss from the 3 o C cold water tank
2.4.5 Heat loss through the glycol tank wall [2]
The glycol tank consists of 2 concentric cylinders, each with a volume of 33.6 m3 One tank supplies while the other returns
- Height of the cylindrical part H = 9 m
Area of the cylindrical part
2× 2.18 × 1.5 = 5.13 (m 2 ) Total area of both tanks:
1 = 23.3 W/m 2 K Heat transfer coefficient on the outside of air
= 0.15 m Thickness of the insulation layer
= 0.047 W/m.K Thermal conductivity coefficient of the insulation layer
The stainless steel cladding layers have a very large thickness and very high thermal conductivity coefficient , thus they can be neglected
2 The section with the cold beer dispenser has a large power, so can be approximated as 1/2 0
The thermal conductivity coefficient of the insulation layer is 0.047 W/m.K k = 1 1
2.4.6 Cold Loss through the Plate Heat Exchanger (PHE) [2]
- Height of the cylindrical part H = 2 m
Area of the Plate Heat Exchanger
F = D 2 × H + 2 × D 2 = 1.5 2 × 2 + 2 × 1.5 2 = 9 m 2 Plate Heat Exchanger heat insulation
1 = 23.3 W/m 2 K Heat transfer coefficient on the outside of air
= 0.15 m Thickness of the insulation layer
= 0.047 W/m.K Thermal conductivity coefficient of the insulation layer
The stainless steel cladding layers have a very large thickness and very high thermal conductivity coefficient , thus they can be neglected
2 The section with the cold beer dispenser has a large power, so can be approximated as 1/2 0
The thermal conductivity coefficient of the insulation layer is 0.047 W/m.K k = 1 1
2.4.7 Cold Loss in the Filtration Room [2]
The filtration room has these dimensions, with a preservation temperature of 20 o C The calculated heat area is
- Plaster layer with a thickness of 0.02 m
- Brick wall layer with a thickness of 0.2 m
- Moisture-proof mortar layer with a thickness of 0.006 m
- Insulation layer with a thickness of 0.1 m we have k = = 1 1
1 #.3 W/m 2 K The coefficient of external thermal dissipation
2 = 0.2 m ; 2 = 0.81 W/m.K : One layer of brick wall
3 = 0.06 m ;3 = 0.23 W/m.K : One layer of moisture-proof bitumen
= 0.8 W/m 2 K The coefficient of internal thermal dissipation in the refrigeration chamber
Heat loss through the walls:
2.4.8 Heat Loss from the Fermentation Room [2]
The fermentation room has dimensions L = 8 m, W = 6 m, and H = 4 m, and assuming a room temperature of 2 o C with similar insulation as the filtration room, we can calculate the heat loss similar to the filtration room:
Q = k F t = 0.379 × 208 × (37.7 – 2) = 2814.3 W = 2418 (kcal/h) Heat dissipated by worker
2 × 350 = 700 W = 602.9 (kcal/h ) Heat dissipated by the engine approximately 3617.2 kcal/h
4 × 80 = 320 W = 275.6 (kcal/h ) Total heat loss in the wort boiling room
Calculating heat quantity Q II
2.5.1 Cooling load required for rapid cooling
After the slurry process, the sugar solution reaches approximately 80°C and must be rapidly cooled to a fermentation temperature of 6 to 8°C within 30 to 45 minutes Slow cooling can lead to the growth of harmful microorganisms that negatively impact beer quality To achieve this rapid cooling, specialized equipment is employed, and the cooling process is conducted in two stages.
Use 3°C water to lower the sugar solution temperature from 80°C to about 20°C
Use glycol (or salt water) with a low temperature of about -4°C to lower the sugar solution temperature from 20°C to 8°C
The amount of heat needed to quickly cool 100,000 liters syrup in 40 minutes
Gn.Cpn tn = Gd.Cpd td [2]
So, the amount of water needed for cooling [2]
So, the amount of glycol needed for cooling [2]
3.56 × (1 − −4) = 96928.78 (kcal/h) The amount of heat required to produce chilled water for cooling beer [2]
The amount of heat required to produce Glycol for cooling beer [2]
Q gl = Ggl × Cgl × (t2 – t1) = 96928.78 × 3.56 × (1 − − 4) = 1725332.3 (kcal/h) Total heat required to cooling beer
2.5.2 Cooling load required to produce chilled water
The technology requires chilled water at 3°C with a water production rate of 25024 kg/h
2.5.3 Heat is generated during fermentation
The heat generated during the fermentation process is approximately 6300 kJ per
1000 liters over the entire fermentation process Each day, 30 batches are brewed, with each batch being 74.5 m 3
So, the total volume of beer brewed in one day is :
74.5 × 30 = 2235 m 3 The heat energy generated during fermentation is:
Dividing this heat energy evenly over 24 hours in a day, we get the heat flow rate during fermentation:
2.5.4 Heat load Quantity in Cooling Processes of Technological TemperatureReductions
The calculation of heat quantity during the cooling processes in beer production is crucial, encompassing the main fermentation, secondary fermentation, and the final cooling of beer from 16°C to 0°C.
24×3600 m3 /s (a rate of 132 cubic meters per day)
Cp = 3.875 kJ/kg.K Specific heat capacity of beer t = 16 - 0 = 16 K (Temperature difference from 16°C to 0°C)
2.5.5 Heat Loss Due to the Wort Boiling Process
The heat energy required to cool 74.5 m 3 of beer from 45°C to 0°C over 8 hours:
During the fermentation process, thanks to hydrolysis processes, a lot of CO2 gas is produced in the fermentation tanks
CO2 gas plays a crucial role in beer production, particularly during the filling and fermentation stages It is essential to recover and store the CO2 released from fermentation tanks to maintain efficiency in the brewing process To effectively preserve CO2, it must be stored in liquid form, which requires a condensation pressure of nearly 100 atm at normal temperatures (saturated temperature of 40.73°C) Consequently, to reduce the storage pressure to below 20 kg/cm², the temperature must be significantly lowered to between -30 and -35°C.
The heat flux due to CO2 condensation is determined by the formula :
C p,CO 2 - The specific heat capacity of CO2 gas is approximately 0.846 J/gãK t 1 - CO2 inlet temperature ( o C) t CO 2 - CO2 condension temperature ( o C) r - The latent heat of condensation of CO2 is approximately 572 kJ/kg
Q II = Q II1 + Q II2 + Q II3 + Q II4 + Q II5 + Q II6
2.5.7 Heat flow due to operation
Q III1 : Heat flow due to pump
Q III2 : Heat flow due to filtration room
Q III3 : Heat flow due caused by enamel rinsing
Heat flow due to pump
= 118787.62 (kcal h ) Heat flow due to filtration room
Q III2 = 6541.9 kcal/h Heat flow caused by enamel rinsing
Q III3 = 7864.5 kcal/h Heat flow due to operation
= 133194.02 (kcal/h ) Total cooling capacity of the factory
To ensure the safe operation of the plant, 25% spare capacity is required
Cooling load as per factory design consultation Calculated cooling load
NH3 ABB-Stal S83 Compressor 2600 kW
The total calculated heat loss differs by 1.85% from the factory design consultation, as the factory runs a backup system to ensure system safety
NH3 York-SAB 233S Compressor 1300 kW
NH3 Grasso TB-2B Compressor 3000 kW
Calculation of single-stage refrigeration cycle
Low-pressure vapor is drawn into the compressor suction from the respective evaporator coils From here, the compressor compresses the low-pressure vapor into
56 superheated vapor, which is then sent to the oil separator attached to the compressor At the same time, non-condensable gases are vented into a water tank
Superheated vapor is compressed to five condensers cooled by a combination of air and water The refrigerant, after condensation, passes through the liquid receiver to the high-pressure receiver
100% of the high-pressure liquid from the high-pressure receiver is divided into three directions:
The initial pathway is cooled to -9°C as it enters the surge drum for the evaporation process, where it exchanges heat with brine via a plate heat exchanger (PHE) Following evaporation, the refrigerant vapor is then directed back to the compressor suction.
The second path involves cooling to -2°C in the low-pressure receiver, where liquid refrigerant is pumped to cooling coils in traditional storage rooms that require a preservation temperature of 5°C for effective heat exchange and evaporation Once the refrigerant evaporates, it returns to the low-pressure receiver to separate the liquid from the vapor, with the vapor being drawn back to the compressor suction to restart the cycle.
High-pressure liquid from the liquid trap is routed to the oil cooler attached to the compressor, where it separates oil from the refrigerant The oil then returns to the oil reservoir, while the refrigerant moves back to the liquid receiver Any residual liquid settles at the bottom of the receiver, maintaining its function, while the refrigerant vapor advances to the condenser for the condensation process.
2.6.1.2 For the oil in the system
Each oil collection tank will extract vapor from the discharge and suction sides of the compressor to create suction pressure
High side oil collection tank 1200L: Collects oil from 6 oil separators of the compressors, high-pressure receiver, liquid overflow tank, and plate heat exchanger (PHE)
Low side oil collection tank 1000L: Collects oil from the low-pressure receiver at - 47°C and 2 corresponding liquid pumps
Low side oil collection tank 1200L: Collects oil from 2 receivers and the remaining
2.6.1.3 For the non-condensable gas
Each device, including the oil separator, high-pressure receiver, low-pressure receiver, oil collection tank, liquid overflow tank, condenser, and plate heat exchanger (PHE), is connected by pipes that direct non-condensable gases to the discharge water tank.
The water in the non-condensable gas discharge tank is also pumped into the condenser to facilitate heat exchange, thereby improving the efficiency of the refrigerant condensation process
2.6.1.4 Concept of Economizer in screw compressor
An Economizer is a system or an individual unit (equipment) that does something that reduces energy consumption and increases the cooling coefficient, thereby improving the cooling performance of the system
The economizer in a boiler operates differently compared to those in refrigeration systems, where it is paired with a screw compressor This compatibility arises from the unique design of screw compressors, which enable side load connections in the compressor housing By integrating the economizer directly into the axial screw compressor system, the compressor's capacity can be slightly enhanced, leading to improved overall system efficiency.
Currently, there are many compressor manufacturers that produce screw compressors equipped with economizers such as Refcomp, MyCom, Bitzer and York
In refrigeration systems, two prevalent types of economizers are the Flash Tank Economizer (FTE) and the Liquid Subcooling Economizer (LSE) While they vary in design and operational methods, both economizers are essential for enhancing system efficiency and reducing energy consumption.
The Liquid Subcooled Economizer (LSE) is installed directly after the condenser in a refrigeration system, similar to the FTE The refrigerant enters the LSE through two pathways: one flows into a coiled tube at the bottom of the tank, while the other passes through a throttling valve as a vapor-liquid mixture The liquid refrigerant at the tank's bottom absorbs heat from the liquid in the coiled tube, vaporizing and mixing with the vapor in the upper tank before returning to the compressor's suction inlet for the next compression cycle.
59 process The liquid portion in the coiled tube, after being subcooled, passes through the second throttling valve into the evaporator
The LSE economizer features refrigerant entering the evaporator that is significantly subcooled compared to the FTE economizer This leads to the vapor returning from the economizer tank to the compressor being at intermediate pressure and temperature due to insufficient cooling Consequently, this design reduces the compressor workload for screw compressors when compared to systems that do not utilize economizers.
The P-H diagram of the cycle featuring the LSE economizer illustrates enhanced system efficiency, attributed to the overcooling of the liquid within the economizer tank.
2.6.2 Cycle Check Calculation and Compressor Selection for the System Using Refrigerant at -9°C
Refrigerant capacity Qo = 7511434.963 kcal/h = 8735.8 kW
Referencing the thermodynamic properties table of saturated NH3, we have pk 513 bar, p0=3.0339 bar,
Referencing the thermodynamic properties table of saturated NH3, we have [1] p1’ = 3.0339 bar v1’ = 0.40173 m 3 /kg h1’ = 1750.3 kJ/kG
The suction vapor temperature, which refers to the temperature of the refrigerant before it enters the compressor, must always exceed the refrigerant's boiling temperature This is crucial to prevent the compressor from drawing in any liquid, ensuring optimal performance and efficiency.
For ammonia refrigerant, ∆t h = 5 ÷ 15K, we choose ∆t h = 5 o C
Referencing the thermodynamic properties table of superheated NH3 vapor, we have [1] t1= th = t0 + ∆t h = −9 + 5 = − 4 o C p1 = p1’= 3.0339 bar v1 = 0.3344 m3/kg h1 = 1561.4 kJ/kG s1 = 5.808 kJ/kG 0 C
To prevent overheating and extend the lifespan of compressors, manufacturers typically set a maximum allowable discharge temperature of 90°C This limit is crucial for maintaining the integrity of the oil structure, which can break down at high temperatures Additionally, the dry saturated vapor from the economizer tank helps cool the compressor's suction head, resulting in a reduced discharge temperature of 80°C.
Referencing the thermodynamic properties table of superheated NH3 vapor, we derive [1] t2 = 80 o C p2 = 13.513 bar v2 = 0.095566 m 3 /kg s2 = 5.1974 kJ/kg o C
Referencing the thermodynamic properties table of saturated NH3, we derive [1] t3’ = tk = 35 o C p3’ = pk = 13.513 bar v3’ = 0.001703 m3/kg s3’ = 1.5584 kJ/kG.oC h3’ = 663.6 kJ/kG
Referencing the thermodynamic properties table of saturated NH3, we derive [1] p3 = p3’ = 13.503 t3 = tk – 5 o C = 35 – 5 = 30 o C v3 = 0.00168 m 3 /kg s3 = 1.4816 kJ/kg o C h3 = 639.9 kJ/kg
Referencing the lgp-h diagram for NH3 refrigerant, we derive [1] p4 = p0 = 3.0339 bar t4 = t0 = - 9 o C h3 = h4 = 639.9 kJ/kg s4 = 0.8467 kJ/kg o C v4 = 0.00153 m 3 /kg
Referencing the lgp-h diagram for NH3 refrigerant, we derive [1] p 5 = p k p 0 = 13.503
3.0339= 4.4507 bar t5 = 0.91 o C h5 = 504.216 kJ/kg s5 = 1.0153 kJ/kg o C v5 = 0.0015692
Point 2’ m = m 1 + m 2 7.86 = 0.122 + m 1 => m 1 = 7.738 kg/s m : refrigerant flow rate through all compressors m = Q 0 h 1′ − h 4 = 8735.8
1750.3 − 639.9= 7.86 kg/s m2 : cooling medium mixing flow rate for Economizer m1 : throttling medium flow rate for the evaporator
Node equation at the mixing point m 2 × (h 3 − h 3 ′ ) = m 1 × (h 2 ′ − h 5 ) 0.122 × (663.6 − 639.9 ) = 7.738 × (h 2 ′ − 504.216) h2’ = 504.589 kJ/kg
Referencing the lgp-h diagram for NH3 refrigerant, we derive [1] t2’ = 1 o C p2’ = 4.4643 bar v2’ = 0.001569 (m 3 /kg)
Point t ( o C) p (bar) h (kJ/kg) v (m 3 /kg) s (kJ/kg o C)
The actual suction volume of all compressor
V tt = (m + m 2 ) × v 1 = (7.86 + 0.112) × 0.3344 = 2.66m 3 s = 9597 m 3 /h According to the technical drawing of the Heineken brewery and based on the "SCV series Screw Compressor" catalogue from MYCOM, we have the following selection list of compressors (V*)
For safety requirements, there are three standby compressors model : 250VSD/G in operation in case of failure of the other compressors [6]
The compression ratio of the compressor
We have, the compression ratio П = p k p 0 = 13.513
With П = 3.4 refer to the graph of the Compression Ratio of the screw compressor depending on the compression ratio λ = 0,88
The theoretical suction volume of the total compressors [1]
The coefficient of performance (COP) of the system [1] ε =Q o
Where p ms : Specific frictional pressure For NH3 straight flow compressors p ms = 0.049 ÷ 0.069 (MPa) Choose p ms = 0.069
N ms = 2.66 × 0.069 × 10 6 = 183540 (N ×m s) = 183.54(kW) Effective compression power :
Where η tđ : Transmission efficiency : η tđ ≈ 0.95
66 η el : Motor efficiency : η el = 0.8 ÷ 0.95 (Choose η el = 0.95)
To ensure safety for the refrigeration system, the installed motor power must be greater than the calculated electrical power by a factor ranging from 1.1 to 2.1 We choose 1.1
So, we choose eight motor with an installed power of
2.6.3 Calculate and choose the condenser
There are various types of condensers, including shell-tube, element, telescopic, panel, water-cooled, air-cooled, and evaporative condensers Each type offers unique advantages, allowing for tailored selection based on specific factory needs However, when prioritizing efficiency and cost-effectiveness, evaporative condensers emerge as the optimal choice for industrial applications.
When using an evaporator condenser, we save water and reduce electricity consumption.We have the condenser heat discharge from the cycle as Qk0 = 8814.204 kW
Based on the 'VXC - R717 Evaporative Condenser' catalog from Baltimore Aircoil Company and the technical drawings of the Heineken brewery, we have selected the following list of condensers [7]
The refrigerant vapor condenses in the vapor manifold at the top of the heat exchange tubes and then flows into the high-pressure reservoir beneath To maintain optimal cooling, a spray system with evenly distributed nozzles is employed just above the heat exchange tubes.
The water is heated through heat exchange with the refrigerant and is then cooled by upward-moving forced air, ensuring a consistent water temperature This heat load from the refrigerant is completely managed by the air, which is circulated by fans positioned either above (suction fans) or below (blow fans) the system.
Make-up water is automatically supplied through a float valve, ensuring efficient operation When using blow fans positioned below, there is no risk of water exposure, which protects the fans and extends their lifespan Conversely, suction fans placed above may draw in water, potentially shortening their operational life Despite this drawback, the compact design and ease of manufacturing make the overhead fan configuration a popular choice Additionally, the heat exchange process leads to substantial water evaporation, which is subsequently removed by the airflow.
Selecting a compressor using BITZER software
2.7.1 The calculation using Bitze software
Step 1: Launch the BITZER SOFTWARE
Step 2: In the software interface, select " Screw Compressors Open Drive"
Step 3: Enter the corresponding parameters into the software
Step 4: Press "Calculate." and wait the results
Step 5: Based on the calculation results, select the model OSNA95103-K with the following specifications
With the manual calculation results, we observe a deviation of 19.5% compared to the software calculation and a deviation of 20.3% compared to the drawing
CALCULATION AND VERIFICATION OF AUXILIARY EQUIPMENT
Ammonia Liquid Receiver
The high-pressure receiver, positioned below the condenser, serves to store condensed liquid while optimizing the heat exchange surface of the condenser This setup guarantees a steady supply of liquid to the expansion valve, enhancing system efficiency.
The superheated vapor from the compressor is cooled in the condenser, where it transitions into a high-pressure liquid To maintain pressure balance, the high-pressure receiver should be positioned below the condenser and connected via a pipeline, utilizing the principle of communicating vessels for automatic refrigerant flow It's crucial that the liquid refrigerant is drawn from the bottom of the high-pressure receiver to ensure it is fully liquid; if the supply line is taken from the top, it must extend close to the bottom of the receiver.
According to safety regulations, a high-pressure tank must have a capacity that is 30% of the entire evaporative system, which includes all coils and air chillers, for the refrigerant supply system, and 60% of the rig volume for the liquid supply refrigeration system This refrigeration system utilizes a bottom-up liquid supply method, allowing for an increased tank volume The capacity of the high-pressure reservoir is determined using a specific formula.
VBCCA : Ammonia Liquid Receiver volumne (m 3 )
Surge Drum
Contains low temperature refrigerant to pump stable fluid supply to the refrigeration system
Loosely separate the gas flow to the compressor In refrigeration systems, fluid supply pumps are used
Excess liquid accumulation behind the evaporator can lead to flooding if a liquid separator is employed To prevent this issue, the liquid is directed back to the low-pressure container, allowing the liquid to settle at the bottom while the vapor rises and is drawn into the compressor.
In this system, a vertical low-pressure tank is used and a magnetic liquid supply pump system is used bottom up
The volume of the low-pressure tank is calculated according to the expression [(8.15),TL1, Page.307]
Vdq : Fan Volume (m 3 ) k1, k2, k3, k4, k5, k6, k7 are the factors
Factor Liquid supply system from bottom to top k1 Static filling 0.7 k2 Fan filling 0.7 k3
Liquid overflow from the fan 0.3 k4
Capacity of risers and pipelines 1.2 k5
The liquid fill-up in the working tank ensures the pump operates (the tank is vertical.)
Allowable liquid level in the vertical tank 1.45 k7 Safety Factor 1.2
According to factor k1 in the table (k1 = k2) and
Plate Heat Exchanger (PHE)
The Plate Heat Exchanger is an essential component in refrigeration systems, designed to enhance energy efficiency by reducing overall energy consumption This device significantly improves the cooling coefficient (COP), thereby optimizing the cooling performance of the system.
Plate Heat Exchangers are commonly utilized in refrigeration systems that incorporate screw compressors, primarily due to the unique capability of these compressors to accommodate external loads directly on their housing This design allows for the seamless integration of Plate Heat Exchangers with screw compressors, significantly enhancing the overall performance of the refrigeration system.
The device features rectangular panels crafted from ultra-thin stainless steel, each equipped with four corner holes Additionally, the surface of these panels is designed with a network of grooves, enhancing turbulence and maximizing the heat transfer area.
Two fluid streams, one hot (alcohol at 20 degrees Celsius) and the other cold (glycol at -8 degrees Celsius), flow alternately between grooved plates designed to enhance turbulent flow This design optimizes the heat exchange capacity between the two fluids, ensuring efficient thermal transfer.
Plate heat exchangers (PHE) offer superior heat exchange performance due to their large surface area, enhancing the heat transfer between fluids Compared to traditional tube-tube heat exchangers with equivalent capacity, PHEs are more efficient Additionally, the design of PHEs simplifies cleaning, maintenance, and overall care, making them a practical choice for various applications.
Q0 - Required cooling capacity of the evaporator, W
Based on Table 7.1 [TL2, p.287], we have the heat transfer coefficient of the plate heat exchanger with glycol as the working fluid
∆t max , ∆t min : The maximum and minimum temperature differences at the inlet and outlet of the heat exchanger
The plant's technical drawings indicate the presence of four plate heat exchangers (PHEs) designed for heat exchange between ammonia (NH3) and water, each with a capacity of 1400 kW Additionally, there is one PHE dedicated to heat exchange between glycol and alcohol, boasting a capacity of 2000 kW The total area calculated for these systems is 2500 × 15.6, resulting in 224 m².
Alcohol water Plate Heat Exchangers: F = 64m 2
Oil Separator
The oil separator plays a crucial role in separating oil from compressed vapor, ensuring that oil does not enter the condenser Instead, it effectively redirects the oil back to the compressor or to the oil recovery tank, maintaining system efficiency and performance.
Separation occurs in a bowl mounted on a vertical spindle, driven by a vertically positioned electric motor through a flat belt Two motor options are available: a standard motor for variable frequency drive and a control-torque motor All metallic components in contact with the process liquid are constructed from high-grade stainless steel Technicians can easily and quickly access the 18 tungsten carbide nozzles, designed for abrasive solids, through a hatch in the frame hood, eliminating the need to dismantle the frame for replacement.
99 device is equipped with flanges The bowl casing has connections for flushing above and below the bowl
The feed, comprising both liquid and solids, is introduced into a rotating centrifuge bowl through a stationary inlet pipe, where it is accelerated by a distributor before entering the disc stack Within the disc stack, separation occurs, with the lighter phase moving towards the center of the bowl and being pumped out under pressure by a built-in paring disc Meanwhile, the yeast is collected at the bowl's periphery and continuously discharged through nozzles, with filler pieces preventing solid build-up The discharged flow is collected in a cover surrounding the bowl and directed into a pump, allowing part of the effluent to be recirculated back to the nozzles via a pipe and a separate recirculation chamber.
Throttle valve
The elongated cylindrical valve plate 3 features grooves that allow for precise and easy adjustment of the fluid orifice cross section as the valve shaft moves it up and down Connected to valve shaft 8, the valve plate solely moves vertically without rotation during the shaft's rotation This vertical movement is facilitated by a threaded joint between the valve shaft and valve body 5, which has a finer thread than that of a standard stop valve, enabling more accurate control of the throttle mode and up-and-down range.
In automatic refrigeration equipment, people use automatic expansion valves In air conditioners that use hermetic compressors, capillary tubes are often used instead of throttle valves
Gate Valve
The STC valve is essential for regulating the flow of mediums within industrial refrigeration systems, effectively opening and closing as needed Its design caters specifically to the demands of equipment repair and maintenance in these applications, ensuring optimal performance and reliability.
Symbols in the Drawing b) Classification
Gate valves come in various types, each distinguished by size or function, including suction gate valves, discharge stop valves, tank-mounted valves, angle valves, and valves installed on compressors.
According to material: cold-resistant alloy steel, currently Danfoss valves are mainly used
There are two types of valves installed on straight pipelines: handwheel valves designed for large refrigeration systems that are frequently operated, and cap-type valves intended for systems that are used less often.
Installed on pipelines with 90-degree elbows Angle shut-off valves also come in two types: valves with a handwheel and valves without a handwheel
FIGURE3.7ANGLESHUT-OFFVALVES WITHOUTHANDWHEEL(A)AND
7 Gasket ring c) Principle of Operation
The shut-off valve features a valve seat with a gasket and sealing ring to prevent leaks in the pipeline Positioned between the valve seats is the valve plug, linked to the stem and handwheel Turning the handwheel clockwise opens the valve plug to facilitate fluid flow, while turning it counterclockwise closes the valve plug, stopping fluid passage.
The SVA is a shut-off valve designed to control fluid flow within a system, facilitating maintenance and repairs Its structure and operation are akin to the STC valve, and it comes in two primary types: standard neck valves and long neck valves.
FIGURE3.9 SVASHUT-OFFVALVE:STRAIGHTAND90° ANGLETYPES
Advantages of SVA Shut-off Valve over STC Shut-off Valve:
- The valve protective cap is designed to ensure tightness and withstand high vibrations in the system, especially in push pipelines
- Easy repair in case of damage as the valve can replace the flange face without the need for welding or cutting
- The valve function can be changed by replacing the flange face with another face that serves a different function such as pressure regulating valve, check valve, filter, etc b) Construction
FIGURE3.10THECONSTRUCTIONOFTHE SVA-SSS15-40GLOBE
The NRV piston-type check valve is specifically engineered for use in commercial refrigeration and residential or industrial air conditioning systems, effectively regulating the one-way flow of refrigerant and preventing backflow This versatile valve can be installed in straight pipelines or at 90° angles, ensuring optimal performance in various configurations.
107 a) Construction of NRV Check Valve:
When fluid flows into the valve inlet, it exerts a force on the piston, which overcomes the spring force, allowing fluid to pass through the valve In the absence of fluid flow, the piston closes as the force on the spring diminishes The Teflon disc aids in the smooth return of the piston to its original position, preventing any impact.
Safety valves are widely used in industrial systems, often installed for hot water pipes, solutions, corrosive fluids, acids, bazo, alkalis, salts,
Normal safety valves come with a double stop valve This double valve is there to ensure that there is always one valve in the open state
Symbols in the Drawing a) Operating Principle
The gas viewing glass, installed on the safety pipe, allows for the observation of NH3 gas discharge from the safety valve during operation, and is filled with oil to ensure visibility.
Ensure the use of undamaged safety valves to maintain the integrity of the entire production system This practice not only enhances operational efficiency but also mitigates risks to both the system and its operators, promoting a safer working environment.
DEVELOPING THE REFRIGERANT SYSTEM OF THE HEINEKEN
Introducing AutoCAD Plant 3D
AutoCAD Plant 3D, part of the Autodesk AutoCAD suite, is an essential tool for designing and editing 3D and P&ID models in plant design This software streamlines the engineering drawing and 3D modeling processes, enabling users to generate isometric drawings for ducts and create efficient perspective views.
Using industry-standard icon libraries helps design faster and more accurately
Automatically check for errors by scanning P&IDs to ensure data consistency
Rapid 3D modeling with parametric equipment models and structural steel libraries
Users can collaborate on plant design models through a common cloud-based data environment, ensuring compliance with security requirements and effective project management
AutoCAD Plant 3D provides complete documentation, from video tutorials to troubleshooting resources, making it easy for beginners to access and use the software
AutoCAD Plant 3D, developed by Autodesk, is a robust design software tailored for the mechanical processing and manufacturing sectors It enables users to craft intricate 3D models for process plants, encompassing everything from P&ID (Pipe and Control Diagram) to comprehensive layout designs This software seamlessly integrates with other Autodesk products, enhancing project management and facilitating data collaboration in cloud environments.
Design P&IDs quickly and accurately with an industry-standard symbol library
Create 3D models easily with parametric duct and equipment modeling tools
Supports automatic production of isometric and orthographic drawings from 3D models
AutoCAD Plant 3D also includes data validation and testing tools to ensure accuracy and compliance with industry standards
Benefits of AutoCAD Plant 3D
AutoCAD Plant 3D provides essential advantages for designers and engineers in the plant design sector, enhancing work efficiency and leading to substantial time and cost savings throughout the project's lifecycle, from design through construction and maintenance.
Increase productivity up to 74% compared to the basic version of AutoCAD, thanks to automating and optimizing the P&ID and 3D design process
Enables efficient engineering data management, from P&ID creation and editing to mechanical design information management
Automate the creation of isometric and orthographic drawings from 3D models, helping to reduce errors and ensure data consistency
In addition, AutoCAD Plant 3D also supports secure collaboration in a common cloud- based data environment, helping project teams work together effectively, even when working remotely.
Outstanding features of AutoCAD Plant 3D
AutoCAD Plant 3D, a specialized tool in the Autodesk AutoCAD suite, offers many powerful features for industrial plant design, from P&ID creation and editing to 3D modeling and technical drawing creation
Advanced P&ID design: Provides an industry-standard symbol library for faster and more accurate design
3D Modeling: Create 3D plant models quickly with parametric equipment modeling tools and structural steel libraries
Automating the production of isometric and orthographic drawings: From 3D models, detailed technical drawings can be automatically created, minimizing errors and construction time
Other features include customizing duct specifications to project requirements, supporting automatic report generation, and working with other software such as Revit and Navisworks for model evaluation and clash detection
F IGURE 1GLYCOL PUMP OF COOLING SYSTEM
Basic instructions for use
To effectively use AutoCAD Plant 3D, it is essential for users to familiarize themselves with its fundamental tools and features This article outlines key steps and instructions to enhance your understanding and proficiency in utilizing AutoCAD Plant 3D.
Startup and Installation: Open the software and set up initial parameters, including selecting and downloading content packages that suit your project requirements
Create new P&ID: Use available symbol libraries and tools to design Piping and Instrumentation Diagram (P&ID)
3D Modeling: Convert from P&ID diagrams to 3D models, using tools to add equipment, ducts, and support structures
View and Edit Models: Inspect your 3D model, using viewing tools to detect and fix visual conflicts
Export Drawings and Reports: Create technical drawings and reports from 3D models, including isometric and orthographic drawings
Additionally, you can access video tutorials and online training resources to learn more about using AutoCAD Plant 3D's advanced features.
Industry applications and specific examples
AutoCAD Plant 3D is a popular software for designing processing and manufacturing plants across various industries, including oil and gas, chemicals, and energy It offers specialized tools that enhance the design process and ensure precision in technical drawings.
Oil and Gas Industry: Used to design refineries, including modeling equipment such as tanks and pipeline systems
Water treatment: Design of water and wastewater treatment plants, application in modeling pipe systems and support structures
Chemical Industry: Used to develop chemical manufacturing plants, from P&ID diagrams to comprehensive 3D modeling
As a specific example, AutoCAD Plant 3D was used to design a battery factory in
Canada, where the software supported complex equipment modeling and factory layout optimization.
Project implementation (Refrigeration system of Heineken Vietnam 12 Dirict brewery)
Bill of quantity for Heineken brewery
Refrigeration system of Heineken HVBHM brewery
No Description Specification Unit Qty' Manufacturer
10 Tank and heat exchange system board
5 Angle valve DN80 pcs 1 Kieselmann,
6 Angle valve DN65 pcs 7 Kieselmann,
7 Angle valve DN40 pcs 22 Kieselmann,
11 Hand valve DN50 pcs 11 Kieselmann,
12 Hand valve DN32 pcs 46 Kieselmann,
13 Hand valve DN25 pcs 82 Kieselmann,
24 Relief valve DN25 pcs 9 Kieselmann,
37 Ball valve DN250 pcs 4 Kieselmann,
38 Ball valve DN200 pcs 1 Kieselmann,
39 Ball valve DN150 pcs 8 Kieselmann,
40 Ball valve DN100 pcs 8 Kieselmann,
Tee, reducing elbow, Bolt, Hanger rod, washer, nut, Expansion Bolt, Angle steel, flange, Welding rod…
CONCLUSIONS AND RECOMMENDATIONS
Conclusions
After conducting thorough calculations, verification, and research on the cold storage system at Heineken Vietnam Brewery in District 12, it has been found that the theoretical calculations closely match the technical parameters depicted in the drawings While the calculated data aligns well with the system overall, some discrepancies exist in specific equipment, attributed to variations in coefficient selection and efficiencies in the formulas, which may differ from the designer's original choices or reflect the practical experiences of the engineering team.
Utilizing software for equipment selection calculations significantly enhances accuracy and efficiency For instance, when selecting a compressor, manual calculations reveal a discrepancy of 13-28%, whereas software reduces this deviation to 16-21%, highlighting its essential role in achieving near-optimal precision Similarly, in the case of the manual expansion valve REG by DANFOSS, manual calculations yield numerous options with a valve opening deviation of 5-32%, complicating the selection process In contrast, software selection achieves a much lower deviation, with accuracy rates around 80-90%, effectively minimizing errors and facilitating the choice of the right equipment.
Volume calculations for tanks often show discrepancies of approximately 9-76%, particularly in low-pressure tanks, due to variations in evaporator coefficients that are not precisely known in practice Relying on standard book coefficients results in approximate values, contributing to significant calculation errors Similarly, pump deviations range from 10-40% because of the complexities in determining pipe lengths and the reliance on estimated cold storage layouts, which leads to substantial discrepancies with the original drawings Additionally, errors in calculating refrigeration cycles within the actual system can further compound these inaccuracies.
Inaccuracies in determining node values in the cycle can lead to a deviation of approximately 7% in heat rejection from the condenser compared to the design specifications; however, this deviation is considered negligible To ensure optimal system performance, it is common practice to select equipment that is slightly larger than the calculated capacity.
From the above data, we can see the importance of theoretical calculations and the use of supporting software, making it easier to approach large systems in practice
Recommendations
Further optimize the system by selecting the most suitable equipment, adding backup devices, and additional compressors or evaporators in case of emergencies
Ensure uniformity in equipment selection, especially for identical designs such as tanks from the same manufacturer, to synchronize operations and prevent operational disruptions
Avoid using tanks with capacities equal to or smaller than calculated, opting instead for larger capacities to accommodate losses and operational needs
Utilize supportive software tools during design and calculation processes for enhanced ease and efficiency
[1] Nguyễn Đức Lợi (2002), Hướng dẫn thiết kế hệ thống lạnh, Nhà xuất bản khoa học và kỹ thuật, Hà Nội
[2] Đinh Văn Thuận & Võ Chí Chính, Hệ thống máy và thiết bị lạnh, Nhà xuất bản khoa học và kỹ thuật, Hà Nội
[3] PGS TS Nguyễn Đức Lợi ,Hướng dẫn thiết kế hệ thống lạnh ,Nhà xuất bản khoa học và kỹ thuật
[4] Hoàng Đình Tín (2013), Cơ sở Truyền nhiệt và Thiết kế thiết bị trao đổi nhiệt, Nhà xuất bản Đại học Quốc Gia TPHCM
[5] PGS TS Bùi Hải – PGS TS Trần Thế Sơn,Bài tập truyền nhiệt và kỹ thuật lạnh cơ sở, Nhà xuất bản khoa học và kỹ thuật
[6] Catalouge MYCOM, Compound 2-stage Screw Compressor 2016**C Instruction Manual
[7] Catalouge Baltimore Aircoil Company , VXC Stainless Steel Evaporative Condenser/ Stainless Steel Fluid Cooler
FACULTY OF INTERNATIONAL EDUCATION SOCIALIST OF REPUBLIC OF VIETNAM
Ho Chi Minh City, July 10 2024
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