patna dairy project

PROJECT ON SEMESTER TRAINING( FOUR WEEKS )

Submitted By The Students Of Polytechnic

In

Mechanical Engineering

MECHANICAL ENGINEERING DEPARTMENT

N.S.I.T, BIHTA(PATNA)

SUBMITTED BY:-NIKHIL KUMAR

ROLL - 51872514004

ACKNOWLEDGEMENTI would like to express my deepest sense of gratitude

and reverence to my major guide and chairman of myadvisory committee M.M.Singh Netaji subhas Institude ofTechnology, Amhara,Bihta,Patna,Bihar for his ableguidance,critically going throught the manuscript andrendering me all the possible help during the entireMechanical engineer studies.

I am thankful to my minor advisor Sujeetkumar , Netaji subhas Institude of Technology forproviding all the needed instruction and guidance aboutmy research work and thesis writing work and othermember of my advisory committee Sushilkumar.NetajiSubhas Institude of Technology andZeeshan sir of my institude for their worthysuggestion,even willing help and unbiased attitudethroughout the course of this investigation.

I also gratefully acknowledge the valuablehelf, constant attentionand useful suggestion renderedby Mr. Ravi Bhushan , Mr. Rajendra Prasad singh and allthe staff members of NSIT engineer university for theirvaluable guidance and co-operation throughout thecourse of my studies.

My vocabulary fails to get word to expressmy respect and sense of gratitude to my beloved familymember;my mother,my father,my brothers,constantencouragement inspiration, prayer,moral,support andguidance.Lastly,I would like to express my enormousindebtedness and deep sense of gratitude to the Godproviding me spiritual exuberance and infinitum.

(Nikhil kumar)

INTRODUCTION

SYUDY OF PLANT

BOILER SECTION

REFRIGERATION SECTION

START UP PROCEDURE

COMMON OPERATIONAL PROBLEM AND TROUBLE SHOOTING

REUSE,REUTILIZATION & MINIMIZATION OF THE WASTE WATER

STUDY OF EXISTING EFFLUENT TREATMENT PLANT AT P.D.P PATNA

CONTENT

India with a population of more than 100 crores ispotentially one of the largest Consumer market in theworld. With urbanization and development ofeconomy, tastes and interests of the people changesaccording to the advance Nation. Marketing is aboutwinning this new environment. It is aboutUnderstanding what consumer’s wants a supplying it’smore efficiently and more conveniently. The consumermarket may be identified as the market for productand Service that are purchased by individuals ashousehold for their personal consumptions. Milk istypical consumer products purchased by Individuals formany purposes primarily making tea and sweets. Themarket of milk is also facing a competition and manycompanies are floating in the market with theirproducts with different brand names. In such a factorswhich influence the people choice for milk are tasteand quality. So, marketing is both philosophy andtechnology. It is Technology because it suggests waysand means for effective production and Distribution ofgoods and services in the market to give maximumsatisfaction to the consumer the marketing manager isresponsible for both Determining and suitability of

INTRODUCTION

goods and services in the market to give maximumsatisfaction to the consumer. The marketing manageris responsible for both Determiningand suitability ofgoods and services presented by the company to themarket and also determining about potential marketand make better relation with retailer.

PATNA DAIRY PROJECT, SUDHA PLANTPHULWARI SHARIF, PATNA

TECHNICAL INPUTS

at the door-step has been providing the inputsrequired for milk production enhancementviz.Artificial The union (VPDUSS), in addition toproviding a ready and state market for therurallyproduced milk Insemination (AI) with Frozen Semen,

Veterinary First Aid (VFA),

Vaccination,

Supply of Balanced Cattle Feed,

Supply of Folder Seeds,

Treatment of paddy straw/wheat bhusa with Urea,

Supply of Urea Molasses Block (UMB) etc. on

No profit no loss basis

.The response from the milk producers for all these hasbeen exceedinglyencouraging and the Union is in theprocess of extending these facilities to more andmoreDairy Cooperative Societies and farmers.

FEEDER BALANCING DAIRY(FBD):

The Feeder Balancing Dairy(FBD)

with a capacity to handle

1.5 lakhs liter perday (LLPD),

has facilities for manufacture of

Milk powder, Butter, Ghee, Ice CreamPeda, Panner,Plain/Misti Dahi, Lassi Mattha etc.

STUDY OF PLANT

1. Raw Milk Receiving Dock

2. Process Section

3. Different section

(dahi,butter,ghee,utility,icecream,peda,packing)

4. Effluent Treatment plant (ETP)

5. Quality Control Section

PROCESS SECTION

The Raw milk is being processed with the help ofclarification and homogenization system . In thissection , actually two plants are being operatedcontinuosly.

The continuous process is followed by HTST (HIGHTEMP. SHORT TIME) system for pasteurisation.

In each section important parts are sa mentionedbelow-

A) Balance TankB) ClarifierC) PasteurizerD) Hot water tankE) Homogenizer

Effluent Treatment Plant:

The dairy waste effluent from all above section comesto this plant.

Huge quantity of milky water mainly from receivingdock, process and packing section is drained out dailyand flows to ETP. The dairy

Waste water is being added by butter, ghee and Ice-cream section.

Huge quantity of water is coming from process andengineering section.

The ETP is situated at one corner in north east of thedairy campus.

This comprises the airetion type treatment process.The carrying capacity of ETP is 50,000 litres/day.

POWER SECTION

Milk from shallow tank is concentrated in triple effectevaporaters,

This way condensed milk is formed. Now thiscondensed milk is seat to dryer , finally milk powdercollected in bag after being converted into powder into spray dryers.

QUALITY CONTROL SECTION

The quality of received raw milk, process milk andhomogenized pasteurized milk is being checked byvigoriously as per requirement.

BOILER SECTION

The boiler used in industry is of fire tube boiler.

The fluid is used in this boiler is C.N.G gas & coal.

The vapour formed by this boiler is being used bydifferent section

to gain heat from it such as ghee, dahi, peda, makingpowder & most importantly in pasteurisation of milk.

There are 3 horizontal type fire tube boiler are used inthis industry.

Capacity is approx 500kg/hr evaporation forproducing 1500 litres/day milk.

The different sections are joined by through pipe lineto the steam generators.

Fire tube boiler

The source of heat for a boiler is combustion of any ofseveral fuels, such as wood, coal, oil, or natural gas.Electric steam boilers use resistance- or immersion-type heating elements. Nuclear fission is also used as aheat source for generating steam, either directly (BWR)or, in most cases, in specialized heat exchangers called"steam generators" (PWR). Heat recovery steamgenerators (HRSGs) use the heat rejected from otherprocesses such as gas turbines.

In fire tube boiler, hot gases pass through the tubesand boiler feed water in the shell side is converted intosteam. Fire tube boilers are generally used forrelatively small steam capacities and low to mediumsteam pressures. As a guideline, fire tube boilers arecompetitive for steam rates up to 12,000 kg/hour andpressures up to 18 kg/cm2. Fire tube boilers areavailable for operation with oil, gas or solid fuels. Foreconomic reasons, most fire tube boilers are nowadaysof “packaged” construction (i.e. manufacturers shoperected) for all fuels.

REFRIGERATION SYSTEM

In the whole process different components areused they are inlisted below:-

Kirlosker reciprocating compressor Discgarge line Oil separator Condenser Receiver Supply line Expansion valve Evaporating or cooling oil Suction line Ice bank tank

AIR AND SURFACE CONDITIONING PROCESSIN PLANT

DIAGRAM

The fuel used in compressor is FREZOL 68 OIL.

The compressor compresses d gas and passes throughoil seperator through which oil seperates fromcondensed gas

Now it passes through condensor and get condensedthe receiver collect all the condensed gas and send itto supply line. There is a expansion valve in pipe lineto control the supply of condensed gas. Now there is acooling coil or evaporator. Through suction line itagain comes back to

Compressor.

Uses of cooling gas

PASTURISATION

IN ICE CREAM SECTION

DAHI SECTION

FOR AIR CONDITIONING IN OFFICERSROOMS

IN COLD STORAGE

START UP PROCEDURE

Clean all the units of constructiondebis,gunny bags,wooden pieces,metal etc.

Clear all interconnecting piping ofobstructions.

Tighten all bolted joints on pipeline especiallysuction and discharge end of pumps.

Check lubrication and free movement ofagitator aerator and pump shafts by hand.

Take no load trial of equipment. Start filling the plant units starting from

screen chamber with raw water. Check free flow water of each unit and all the

structures of water tightness. Start taking effluent into the ETP. Gradually start fat removal,chemical

treatment.

COMMON OPERATION AND TROUBLESHOOTING

Sudden variation in quality nor quantityof the effluent.

Incorrect procedure followed due to lackof sufficient operating skill.

Carelessness during power or equipment. Sludge bulking in clariflocculator Sludge bulking in secondary clarifier. Power failure in the ETP. Obnoxious odours from ETP. Odour associated with sludge bulking in

secondary clarifier.

REUSE, REUTILISATION & MINIMIZATION OFTHE WASTE WATER

In aggreculture and land scape irrigation Ground water recharge with treated waste

water Cooling system water reuse

Now, waste water generating in sudha industry isquite large and thus it should minimized by this-

Source reduction Recycling