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| Factory Information |
CPF Korat Project is an integrated poultry
processing plant complex, integrating slaughter plant and further
processing plant in one single building. This project is huge
so that special design concepts were created in order to get
the sustainable and energy saving operation. |
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| Regarding to the refrigeration of this project,
they had been divided into the building as follows : |
1) Domestic processing plant
2) Primary (slaughter) and further processing complex
3) Refrigeration machine room |
Due to it is a very large complex consisting
of 46 screw compressors, 18,000 horse power and having all kind
of facility such as offices, retail, food services, laboratories,
guest / patient rooms, laundry and etc. |
We focused only on the major facility (primary
and further processing complex) and on the low temperature air
conditioning processing room and spiral freezer that have the
most significant innovation, energy and saving cost area. |
| Outdoor Design Condition |
Apart from the outdoor design condition from
ASHRAE fundamental Handbook of the plant's location at Korat
/ Nakhon Ratchasima, Thailand, we based our design on the Tender
of Requirement (TOR) of the end user specify outdoor dry-bulb
37Deg.C 60% RH and the evaporative condenser had specified to
base on 28.3 Deg.C WB |
| Project Description |
1. Type of building or process: Refrigeration
system and low temperature air conditioning for poultry slaughter
and further processing plant. |
2. Size gross floor area of building : In the
building area of 50,000 m2. |
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3. Function of major areas (such as offices,
retail, food services, laboratories, guest/patient rooms, laundry,
operating rooms, ware house/storage, computer rooms, parking,
manufacturing, process, etc., or industrial process description): |
| The refrigeration facility
consists of the following important capacity; |
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• 46 sets of Ammonia Screw
Compressors with total power are 18,000 hp, |
• 21 sets of Evaporative Condensers with
200 kilometers of Evaporative Condensers stainless steel. |
• 2 Lines of Air Chilling Tunnel with
total chilling capacity of 21,000 bird/hr, |
• 6 sets of IQF Spiral Freezers with
total freezing capacity is 12 ton/hr, |
• 6 rooms of Air Blast Freezer with total
freezing capacity were 15 Mton/hr, |
• 6,000 m2 Processing Area controlled
room temperature at +8 °C, |
• 49,000 m3 Cold Storage at -20 °C, |
• 50 Mton of Ammonia charge into the
system, |
• 360,000 birds/day Slaughter Capacity. |
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4. Project study period: |
• Design January – April
2004 |
• Installation April – October 2005 |
• Start-up November 2005 – February 2006. |
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| System Design Goal |
1. The refrigeration
system should be safe for workers and improve the quality
of life. |
2. The refrigeration system
should be less environmental impact and sustainable design. |
3. The refrigeration system
should be save the investment cost. |
4. The refrigeration system
should have a stable and minimum of down time operation. |
5. The refrigeration system
should be the energy efficient system. |
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| Design Consideration |
To design the
refrigeration system for this plant, some areas were emphasized
and concerned to meet the purpose of the project. |
1.
Suction pressure drop : |
Distance
between Spiral Freezer and machine room is very far away,
approximately 230 meter (755 feet) long. How to reduce
pressure loss in the wet return line of the recirculation
system? How to reduce the risk of liquid hammer within
the two phase flow wet return line and vapor propel of
hot gas defrost line? |
2.
Corrosion from ambient air : |
 |
Boiler
room and refrigeration machine room cannot separate
far enough, so the exhaust gas from boiler will
contaminate air intake of evaporative condenser,
then cooling water in the evaporative condenser
become acid and high corrosion will occur. |
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3.
Special production demand : |
Continuous
Freezing for 6 days x 24 hours is demanded from the customer. |
4.
Climate and raw water supply |
The
location of this plant has hot and humid climate. High
CaCO3 content in raw water supply and the limitation of
water supply cause the soft water supply quality is hardly
to control. This will cause difficulty in reject heat
through condenser which will impact on the stability of
screw compressor oil temperature |
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