Design of a Low-Cost Seawater Flake Ice Maker for Small Fishing Vessels

Abstract

This paper presents the design and engineering validation of a compact, low-cost vertical seawater flake-ice maker intended for small fishing vessels operating in hot climates. The system employs a stationary double-walled stainless-steel drum (of the dimensions of 150 mm inner diameter, and 400 mm active freezing length) with an internal rotating scraper and a vapor-compression cycle using ana Refrigerant type of (R404A). Thermodynamic analysis based on the selected cycle (of evaporation −25 °C, condensing 40–45 °C with 5 K subcooling and 10 K superheat) , yields a refrigeration effect of 108.14 kJ/kg, specific compressor work of 56.43 kJ/kg, and a COP of 1.73. Heat-transfer sizing of the scraped-surface evaporator confirms that the fabricated surface area (is 0.188 m²) that exceeds the minimum required area by a factor of approximately 2.5, providing robustness against fouling, scraper inefficiency, and elevated ambient temperatures. Mechanical design of the scraper drive (, vector-control VFD with worm gearbox) , ensures stable operation at 4.5–14 rpm and maintains a high torque safety margin (≈approximately equal to 5.4) under conservative ice shear assumptions. Prototype operation targets 5–6 kg/h of dry, sub-cooled flake ice at approximately −7 °C, with a practical pull-down period of 10–12 minutes before the first kilogram is harvested. The presented methodology and validated component sizing provide a journal-ready reference design for affordable onboard ice production. The proposed compact, low-cost vertical seawater flake-ice maker directly supports several United Nations Sustainable Development Goals (SDGs) such as SDG 2 of Zero Hunger, SDG 8 of Decent Work and Economic Growth, SDG 9 of Industry, Innovation, and Infrastructure, SDG 12 of Responsible Consumption and Production and SDG 13 of Climate action. Also, aligns strongly with the strategic pillars of Egypt Vision 2030, particularly in the pillars of Economic Development, Energy, Knowledge, Innovation, and Scientific Research and Environmental Sustainability.