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SUMMER TRAINING REPORT

VERKA MILK PLANT, MOHALI

SUBMITTED BY:-

SHINEY Roll No. 100801057

Chemical Engineering (B.E)

Declaration

I hereby declare that the project work is an authentic record of my own work carried out at verka milk plant mohali as requirement of six weeks training for the award of the degree of B.E(Chemical Engineering).TU under the guidance of Mr. Bikramjit during the training from 1st june to 15th july 2010.

Name : SHINEY

Roll Number: 100801057

Date:

Certified that the above statement made by the students is correct to the best of my knowledge and belief.

Signature of co-ordinator

ACKNOWLADGEMENTI am very thankful to THAPAR UNIVERSITY to provide me with the wonderful opportunity to increase my technical skills with the six weeks industrial training. This report is in relation to the process descriptions, details, findings and problems of VERKA milk plant mohali. The training and report has enabled me to understand the practical aspects of the theoretical knowledge imparted in the classroom programs at the institute. The report contains a detailed description of the industrial experience I have gained during the six weeks of training and some of the major problems which are being faced by the industry.

CONTENTS

1)INTRODUCTION

2)ENGINEERING SECTION

a) Refrigerationi) Principleii) Working

b)BOILERi) Functional Requirementsii) Technical Specificationsiii) Firing Systemiv) Water Supplyv) Air Compression Unit

c) PASTEURIZATIONi) Introductionii) Componentsiii) Process Handling Equipment

d) EFFLUENT TREATMENT PLANT (ETP)

INTRODUCTION

DAIRY DEVELOPMENT IN PUNJAB:

Punjab is a state of agriculture out of area of 1.9 million hectare is well cultivated land. Punjab is one of the most naturally irrigated states in India with 5 rivers flowing across it. Nearly 80% of its population lives in villages and they earn their livelihood from agriculture. But along with agriculture milk animals are an integral part of life in Punjab. Mixed farming is generally practiced in Punjab. Scientific and organized production of milk earns a good source of income to farmers. The procurement of milk by milkfed is based on Amul pattern. Milkfed was 1st started in 1983 and that cooperative movement in Punjab has a breakthrough.

Now milk procurement is increased due to its more favourable conditions provided to the farmers say free veterinary services, artificial insemination, technical advice, distribution of cattle feed on no profit no loss basis. So villagers are more interested in milk production enhancement. Now a day’s dairy farming is on its way which means cattle’s are specially grown cattle feed. Punjab has an edge over milk production and per capita availability of milk in Punjab is increasing day by day and presently its 867gm per man.

COMPANY PROFILEMILK PLANT MOHALI:

Period to rolling up of Mohali, the Chandigarh city demand for milk was met by the Chandigarh plant. But later on due to increased demand of milk of milk, Chandigarh plant was not able to meet it due to its less capacity and other problems. So in September 1980, the milk plant was set up at Mohali. Initially the plant was run by Punjab dairy development cooperation and undertaking of Punjab govt. the procurement of milk, then was carried out through private owned concern called agencies. The PODC was headed over to Milkfed in april 1983. Since then Ropar district milk producers union, milk plant Mohali had never looked back to achievement gained by it.

The Ropar district milk producer union, milk plant Mohali has a marked distinction in that it has earned its ISO 9002 certification way back in 1994 and also HACCP as per 15000 in 1998. Initially the main purpose of plant was to meet the cities demand of milk, but along with it started making paneer, cheese, curd, lassi where as Chandigarh plant shifted to product manufacturing plant with UHT plant located there. The installed capacity of Mohali plant was 1 lakh litres per day, it has an initial investment of rupees 2 crores and located in SAS nagar Mohali over 50 acres of land. Milk plant is working in ‘Anand’ pattern. The achievement of milk union Ropar are not only more then other milk unions of Punjab but the whole of northern India.

GEOGRAPHICAL LOCATIONSMilk plant Mohali is located in Ropar district of Punjab by the side of important national highway no. 21 joining Chandigarh, Ropar and Amritsar via jalandhar G.T road. The plant is an SAS nagar, industrial area, from that national highway subline is going just in front of plant to Chandigarh city. Chandigarh city is about 8 kms from the plant and the plant is nearest to MILKFED head office in sector 34 A.

Milk plant sorrunding is an industrial trade centre. The plant is situated next to Raja Ram Corn products and on the opposite side of ‘PUNWIRE’. There is a canal in north west side of the plant in west side a village Balon is located.

The dairy plant is distantly located from the city line, overcome several environmental problems which are very essential for a food industry. There is a great advantage that the plant is directly connected to national highway which facilitates easy transportation and allied activities. The chilling centers for milk plant is located at:

Morinda Jhinjhir N.P.Bedi

ENGINEERING SECTION

As time passes, automation goes on expanding its hand in industry. This is not necessary for faster growth of industry. Automation is nothing but replacement of man power with machines. This good side of automation leads to better economy. By reducing the cost of production .Few years earlier, milk plant Mohali had many sophisticated machineries fields. But due to absence of skilled labor all are now just garbage.

Engineering section at Mohali milk plant four subsections and these are:

1. Refrigeration section

2. Boiler section

3. Workshop section

4. Effluent treatment plant (ETP)

REFRIGERATION SECTION

Refrigeration, which is the extraction of heat from a body at temperature lower than that of surrounding, is one of the most important processes in diary industry. Milk and milk products are perishable commodity and microbial lead spoils them at room temperature. Hence low temperature storage is necessary for them and this is carried out by refrigeration. In milk plant, mohali cooling system comprises of two systems.

1. Direct cooling system used in:

(a). milk cold store

(b). ghee cold store

(c). processed cheese cold store

(d). cheese ripping store

(e). dahi and paneer cold store

2. Ice bank cooling system for supply chilled water to:

(a). chiller

(b). milk pasteurizer

(c). multipurpose vat

(d). butter churn

Refrigeration cycle may be::

1. Vapour–compression type

2. Vapour-absorption type

The one which is employed at Mohali plant is vapour-compression type and is most important one. At milk plant(Mohali) the cooling system for supplying chilled water to various section is done by the ice bank unit and cold stores are fully flooded system or direct expansion systems.

PRINCIPLE OF VAPOUR COMPRESSION SYSTEM:

The four essential parts of this system are:

1.Evaporator

2.Compressor

3.Condensor

4.Exapansion valve

During a Vapour Compression system process 1-2 is evaporation of liquid ammonia(refrigirant) into low pressure vapour. The low pressure vapour is compressed by a compressor which is high quality pump into high pressure high temp vapours. Though temperature should not rise much. Again high pressure vapour are converted into high pressure liquid by condensers. Process 2-3 is compression and process 3-4 is called condensing. Now process 4-1 is throttling

process by expansion valve. It controls the flow of refrigerants side(high pressure) to the evaporator coils at low pressure.

From the discharge side of compressor to the suction or inflow side of expansion valve is high pressure side and from outlet of expansion valve to compressor suction is called low pressure side. In this way cycle goes on and refrigeration effect is produced by evaporating coils. These coils can be used in cold store or in ice bank system to chill water.

WORKING ASPECT OF REFRIGERATION PLANT

To start the compressor 416 volts 3 phase supply is required. The three compressors in summer season and two compressors is working for 16 hours in water. Compressor is provided with water jacketed system for cooling the compressor water coming from

condenser water pumped from compressor jacket and through outlet is going to back to spray ponds.

Lubrication is done by oil trade name servofriz-68.

Through discharge line oil and refrigerant gas is coming in oil separator which is located after compressor and before condenser to separate the oil from refrigerant (ammonia gas).

1. to remove super heat

2. to remove latent heat

3. to remove subcooled liquid

Receiver is located after condenser and before evaporator. Condensed high pressure liquid stored in it. Receiver is provided with main outlet valve from it goes to corresponding section for cooling.

There is fully flood type evaporator in this plant .in flooded system liquid to through float control valve. When liquid level increase the valve closed and vice versa. In chilled water tank , chilling coil is distributed through accumulators and 3 agitator’s fans are provided to circulate incoming water of every corner tank for proper cooling by removing layer from evaporative coil.

In every cold store blower is connected after evaporative coil forced the cool air inside room.

Condenser coil is cleaned through proper brushing potassium permagenate(KmNO4).

Used in spray ponds which preserve the water from organisms,insects etc. it is also serve as condenser cleaner. Sometime bleaching powder is used for same purpose.

When suction pressure become low refrigerating effect decreases and vice-versa , suction pressure depends upon how much cooling effect is required in plant. Suction pressure become high when there is two much load on evaporator. Increase in discharge pressure is necessary to increase condensing temp. if there is not proper condensation in condenser heat pressure increase also suction pressure increase.

LEAK DETECTION

Any leakage of refrigerant is primarily detected by its odour. For detection of place of leakage of sulphur dust is burnt on cloth which give white condensed smoke with ammonia. Sometime sulphur candles are used to detect the place of leakage.

CHARGING OF AMMONIA

Charging of ammonia is done by seeing the liquid level in receiver. Charging line is after main valve(outlet) in which BH-3 cylinder is connected. During running condition main valve is stopped so liquid goes in evaporative coil for vapourization as result vacuum is created in suction line. Then gas cylinder valve is open. Due to vacuum ammonia gas is sucked in plant and again come back in receiver through inlet.

INSULATION OF COLD STORES AND PIPES

Pipe is insulated with thermocol. Pipe is first covered with thermocol then by using wire net. After connection a heavy thick cloth is covered and finally it is painted by painting oil. Aluminium foil paper is pasted in wall first and then thermocol is used in wall. After that it is plastered by cement by using wire net.

  Section:REFRIGERATION      

1 Ammonia Receiver One 3500 ltr 50,000

2 Oil Seperator Four 300 ltr  

3 Oil Seperator One 100 ltr  

4 Accumulator Two    

5Ammonia Compressor 9×9 motor with starter Two

70 Tonn,120 Hp  

6Ammonia Compressor 7×5 motor with starter One

30 Tonn,75 Hp 2,50,000

7 Cold Store Blower with motorEleve

n    

8 Chilled Water Pump Three7.5Hp/60klph  

9 Chilled Water Tank Agitator Three12.5

HP(each)  

10 Chilled Water Tank Agitator Three12.5

HP(each)  

11 Booster One 10 hp  

12 Condensor Pump Five 7.5 hp(each)  

13Vilter Compressor with motor & stator Two

70 Tonn,456 XL  

14 Condensor coil set Two17 COIL,20

COIL           

BOILER SECTIONSteam is the most important and popular source of heat for general use in diary plant because of its economy. Flexibility, and other properties which adapt it for conveying large quantities of heat from a heat source to the product which is to be processed. Steam is defined as water in a vapour or gaseous state, usually at temperature of 180 F or above. It is informed by boiling water, through the process of vaporization.

The steam boiler is a pressure vessel designed to generate steam .it consists essentially of a clos Fed chamber having space for water and space above that for steam. A diary boiler is a compact and small sized boiler. Boilers may be fire-tube or water-tube boiler depending upon whether fire or flue gases passes through tube or water respectively. Again they can be horizontal or vertical , single tube or multiple tube, external or internal fired etc.

The boiler installed at Mohali plant is firetube ,horizontal, 3pass,externally fixed boiler . water is contained in the shell and flue gases passes thrice through the tubes that is why it is 3 pass boiler. Steam collected in the shell is ready for use in diary plant .water level is mainted in the boiler for safe working.

  Section:BOILER      

1 Water Softening Plant One 2.5lakh litre  

2 Water Softening Plant One Not in use  

3 Water Pump Motor Two 10,00 litre  

4 Boiler One 2 TON/hour  

5 Boiler One 3 ton/hour  

6 Furnace Oil Tank with pump & motor Two32000 litre

each  

7 Feed Water Tank Two 5000 Litre  

8 Day Oil Tank One 2000 Litre  

9 Plastic Tank Two 500 Litre  

10 Water Storage Tank Two    

11 LPG storage bank One             

SPECIFICATION OF OIL FIRED BOILER FUNCTIONAL REQUIREMENTS

GENERAL DESCRIPTION:

The fully automatic furnance oil fired package IBR boiler would be required to generate dry saturated steam for use in a variety of diary processes . the demand for steam would vary considerably depending upon scheduling of various processes.

CAPACITY:

A continuous evaporation rate of upto 3000 kg/hr. From and at 100 deg C. Operating pressure :10.54 kg/cm^2 guage.

DESIGN REQUIREMENTS

CONFORMITY WITH REGULATION :

All materials of construction, standards of fabrication, quality control, test procedures, components and operating safe guards must comply with the latest indian boiler regulations and other statutory requirements.

The electrical components and installation must comply with the indian electicity regulations.

The boiler should got approved by the suppliers from the statutory authorities and any modifications, changes if suggested by the authorities shall be carried out by the supplier.

Evidence of conformity and test test certificate will be required.

BOILER:

A horizontal multi-pass/3 pass ,wetback,or semi-wetback shell boiler is preferred although alternatives would also be considerd.

The gross thermal efficiency should exceed 85% under normal working conditions with the discharge of flue gases at a safe working temperture.

BOILER FITTINGS

All fittings should be provided to facilitate safe,efficient and convenient operationin accordance with latest IBR and including:

2 saftey valves having a total discharge rate exceeding the maximum steaming capacity.

An access manway and sufficient number or hand role doors into the shell.

One main steam stop valve plus one auxiliary stop valve with counter flanges.

One blow down valve with the counter flanges. One auxiliary steam connection and stop valve with counter

flanges . Flame obeservation port . One pressure guage with siphon tube and cock . 2 water level sight glasses with saftey shields and isolating

cocks. All water control and alarm transmitters with isolating valves

and drain points. Arrangements with cock for fixed a test pressure guage. Burner control transmitters. Vent with cock for the removal of air .

Access ladder and top walkway complete with hand rails . A rigid base frame on which the whole assembly is mounted. Suitable insulation to ensure a safe working temperature on

the outer casing. Galvanized M.S or alluminium sheets should be firmly secured

overall thermal insulation.Any components not listed in this specification but required for statutoryRequlations shall have to be supplied by the supplier without any additional cost.

BURNER:

The burner complete with a forced draft fan must be suitable for fully automatic ignition and stepless modulation with a minimum turn down capability of 4:1. Efficient combustion must be maintained through its full operating range when burning furnance oil. The burner oil auxiliaries should include 2 nos.pumps (one duty and one stand by) duplex filter with changeover valves ,thermostatically controlled electric ans steam pre- heaters,instruments insolating valve, pressure relief valves and interconnecting pipework.the oil piping from oil service tank to burner and return piping also be supplied and installed by the supplier.

FEED WATER PUMPS:

Two electronically driven feed water pumps(one duty and one stand by) to match with the boiler operation should each be fitted with a suction strainer suction isolating valves ,non return valves, feed check valves and pressure guages. pipe work from feed water service

tank to feed water pumps shall be supplied and installed by the supplier.SERVICE TANK OF FURNANCE OIL:

The service tank will be fabricated from 5mm thick MS sheet complete with air vent ,electric heat tracing system for the existing service tank as well as connecting pipe line and header ,man hole, headerdrain cock, dip stick etc . The capacity of tank should designed for 24 hrs consumption or not less than 2000 L. The tank will be duly insulated with glass wool insulation duly fitted with chicken wire mesh and 20 SWG aluminium sheet . the pre heating system should be capable to heat the heavy grade furnance oil upto 60deg C.

CONTROL AND ALARMS:

The control and alarms for fully and semi-automatic operation should include:

Burner ignition and modulation to maintain a steady steam pressure.

Correct fuel inlet conditions for firing

Proof of ignition and flame failure lockout and alarm.

Water level controls to ensure that the correct levels maintained in the boiler.

Audible high and low water level alarms.

Extra low water alarm and lockout.

ELECTRIC CONTROL PANEL:

All automatic controls, motors starters, fuses and isolators should be mounted in a dust proof control panel with the selectors, indicators and manual controls on the outside.

All electrical and control devices should be pre wired to this panel which terminates with one main incoming isolator.

FINISH:

All exposed ferrous components must be properly finished. The minimum requirement is to coating of a heat resistant paint applied to a prepared and prime surface.

Electrical supply – 400/440 volts – phase -50Hz AC supply.

The boiler should be approved from the appropriate authorities of the state of its origin .also if the concerned authorities of the state where it is installed suggest any improvement/ modification ,the same should be carried out by the suppliers without any charges. All statutory clearances from chief inspectors of boilers , pollution control board will be arranged by the bidder.

All steam and condensate pipe lines should be M.S. ‘O’ class I.B.R. approved . All fitting valves , pressure reducing stations have also to be I.B.R approved . Unit price may be quoted from 1’’ to 4’’ size.

Technical details of the boiler should be furnished in the enclosed Performa.

The I.B.R approval documentation pertaining to boiler , Accessories , mountings etc.

Operation and maintenance of the boiler will be provided in duplicate.

We have existing MS boiler chimney (common for two boilers) with height of 28 mtrs. At our milk plant mohali and same is to be connected with proposed new 3 ton boiler. The bidders are requested to check the feasibility of the same and quote accordingly for required ducting for inter connection.

TECHNICAL SPECIFICATION

BOILER NO.1 BOILER NO. 2

1. Boiler capacity 2 Ton/hour 3 Ton/hour

2. Make western works Thermax

3. Year of manufacture 1972 2009

4. Fire tube type tube type

5. Identification no. CH-16 PI-4492

6. Fuel furnance oil LPG

7. Max. Pressure 150 psi 150 psi

8. Boiler rating 728 sq ft. 64 sq mtr.

OPERATIONAL CONDITIONS:

a) Initial fuel temp. 35 deg C

b) Furnance oil pre heating temp. 85 deg C

c) Furnance oil pressure at burner 35 deg psi

d) Steam pressure 70-100 psi

e) Fuel gas temp. In chimney 200-220 deg C

FIRING SYSTEM:

Fuel used in the boiler here is furnace which is coming to the furnace oil jacket from oil tank of cap:33680lts

During winter season it is necessary to warm the fuel oil i.e furnace oil. Before the fuel is fed to the boiler it is preheated so that it can easily or readily be combustible. Furnace oil is pumped to the furnace and the excess oil return back to the reservoir. The furnace oil is usually preheated to a temp of 90-95deg C,and the ignited in the furnace chamber.

A powerful air blower is attached to the furnace which forces air to mix with fuel and pass the flame through the bigger tube. The hot gases i.e flue gases when shows a blackish smoke it is indication of very low combustion i.e excess fuel supply and low air supply when it because whitish it indicates low fuel supply, a balance should be maintained. An induction fan is provided in the lower part which allows flue gases to finally draft out and also cools down them. Thus air induced draft is produced by it, which is necessary for fresh air and fuel supply and to maintain temp of the furnace. Flue gases after passing 3 consecutive passes comes out via a chimney and so on the process of firing goes on.

WATER SUPPLY TO THE BOILER:

The water supplied to the boiler is of good quality i.e it should be soft water free from salts which may cause scaling problem. Water supply in the boiler is governed by a feed check valve which allows water to go inside when level goes down and doesn’t allow steam to come out. A centrifugal pump is used to fed fresh soft water in the boiler from tank at pressure.

WATER SOFTENING PLANT:

Hardness of water is attributed to insoluble salts of calcium and magnesium especially sulphates etc. In order to run the boiler efficiently water supplied should be free from hardness i.e it should be soft water. For this water softening plant is installed. The water softening tank consists of sodium zeolite bed which removes soluble calcium and magnesium salts from water and give soft water. The soft water is stored in underground tank and then they are pumped to storage tank where they are stored under pressure and then fed to boiler. Principle chemical reaction occurring in softening tank are:

CaSO4 + Na2(Ze) Na2SO4 + CaZe

MgSO4 + Na2(Ze) Na2SO4 + MgZe

(Salts) (Zeolite)

CHARGING:

The is the operation of activating the zeolite so that it can be reused. For this NaCl solution is circulated in the water softening tank and thus it is charged.

CaZe + 2NaCl CaCl2 + Na2(Ze)

MgZe + 2NaCl MgCl2 + Na2(Ze)

WATER SUPPLY SYSTEM:

Dairy industry without fresh water , one cannot imagine. No dairy can have its operation being performed without water . Cleaning and maintainance hygiene is the most important aspect of successfull dairy plant. Milk plant ,Mohali has also its own water supply system. Two tubewells are located ,one inside the campus and one outside the campus. Water bored out from underground is hard water with haziness 250 ppm. To 300 ppm which is reduced to 10 ppm by water softening plant. Tubewell outside the dairy plant is turbine system. In this filter is provided at bottom and impellor pulls the water up. Impellor is operated by a 20 hp,kirloskr electric motor which pump the water to overhead tank of capacity 45 gallon. The tubewell in dairy compound is submerged or sumercible pump of 5 hp is located. Another pump of capacity 7.5 hp pumps the water to overhead pump.

After treatmemt soft water si going to sump tank(underground tank). From there soft water is pumped by 7 hp beacon level pump to hyoro flow tank. These are horizontal tank provided with water level indicator. Water is maintained at 20 to 25 psi due to pressure water is circulated through the plant.

AIR COMPRESSION UNIT

Air compression unit is needed for proper working of pouch filling section and ghee filling section. All the pneumatic control values are also operation on this. Thats why compressed air unit is installed with five kirloskr air compressor located for pouch filling section and one for ghee filling section.

PASTEURIZATION

Pasteurization refers to the process of heating each and every particle of milk to atleast 630C for 30 minutes or 72 0C for 15 seconds in approved and properly oriented equipment and immediately cooling it to 50C or below.

Pasteurizer is cleaned sanitized before use. Chilled raw milk from storage tank flows to balance tank of pasteurizer due to gravity. From here it is pumped to regeneration section 1. In regeneration section 1, incoming raw milk exchanges heat with outgoing hot pasteurized milk and its temperature raises to 38-450C. This is known as preheating. Then goes to filter for filteration. There are 2 filters attached to regeneration section 1 for continuing pasteurization process even if one filter is cut off for cleaning purpose. After filteration it goes to clarifier for removal of suspended foreign particles by centrifugal sedimentation. Then milk goes to regeneration section 2 where it exchanges heat with hot pasteurized out going milk and its temperature raises to 600C. if the milk has high fat percentage then after clarification it is passed through cream separator. Cream is chilled by plate chiller and stored in multipurpose vat and if we don’t want to extract cream from milk or fat percentage is low, then milk goes to Heating Section where its

temperature raises to 75-800C by exchanging heat with hot water in alternate plates. Milk then goes to holding section at 75-800C where it is held at this temperature for 15-16 seconds. Then it goes to regeneration section 2 and exchanges heat with incoming chilled raw milk. In this heat exchange process its temperature falls considerably. The it goes to chilling section where it is chilled to4-50C by incomingchilled water at 1-20C. Flow Diversion Valve(FDV) is attached to the outlet of heating section. Its function is to check that pasteurization temperature is attained or not. If the temperature is below pasteurization it diverts the milk coming out from outlet vlave of heating section to balance tank of pasteurizer for re-processing.

Mohali Milk Plant processes following types of milk:

TYPE FAT% (min) SNF%(min)

a) Verka Premium Milk 6.5 9b) Verka Pasteurized Standard Milk 4.5 8.5c) Verka Pasteurized Milk 1.5 9d) Verka Pasteurized Skimmed Milk 0.5 8.7

Components of Pasteurizer:

FILTERS:

The filter removes suspended foreign particles by straining. The pasteurizer has two filter so that the operation is not interrupted when it becomes necessary to change the filter cloth or pad of the desired pore size which can retain the smallest particles for washing. The frequency of washing the cloth changes depending upon the amount of foreign matter present in the received milk.

HOMOGENISER:

In this plant the homogenizer is not used for market milk as it is sent for sale immediately after packaging. Here it is used it the mizing of cream or oil in skim milk is required. It is also used for adding vitamin A concentrate in milk cans at 600C which is homogenized at a pressure.

PLATE HEAT EXCHANGER:

A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluids spread out over the plates. This facilitates the transfer of heat, and greatly increases the speed of the temperature change. A plate heat exchanger consists of a series of thin, corrugated plates. These plates are gasketed, welded or brazed together depending on the application of the heat exchanger. The plates are compressed

together in a rigid frame to form an arrangement of parallel flow channels with alternating hot and cold fluids.

STORAGE AND PACKAGING OF MILK:

There are ten storage tanks. Four tanks are used for storing chilled raw milk received from societies and chilling centers and the rest are used to store pasteurized milk. Multipurpose tanks have a facility to circulate chilled water. These are used to store cream, cheese whey and extra milk when head load is more. Standardized and pasteurized milk is filled in sachets which are formed from a sealed film over a shoulder and tube scalar.

Process handling equipment

Functional Description

PLATES

The plate pack consists of contoured heat exchange plates with gaskets. The number and arrangement of plates as well as their shape and size are dictated by the demanded thermodynamic performance.

GASKETS

Gaskets are either fixed with adhesive in to the gasket grooves or pressed into the gasket grooves 9 (“loc-in”) without adhesive, according to requirements.

Thee gasket groove has been pressed on to the perimeter of the plate to fix specially produced gaskets. Gaskets are designed to seal the plate channels from each other and to prevent external product leakage. The gaskets are made of high quality food grade material depending upon the temperature and pressure conditions.

FRAME

The frame consists of:

1. Fixed plate2. Pressure plate 3. Intermediate plates4. Carrying beam5. Guiding bar6. Support beam7. Tightening studs

EFFLUENT TREATMENT PLANT

Usually known as Water Treatment Plant, its purpose is to treat the effluents from the industry to dispose water.

Effluents means industrial liquid waste that cannot be discharged directly as it contains many harmful chemicals, oils, grease. The whole effluent treatment is done in different steps:-

Firstly, the raw effluents which comes directly from different sections of plant are passed through OIL AND GREASE TRAPS to remove the filtrating oil and scum.

Secondly, after being separated from oil, grease and scum, this water is then collected in the COLLECTION SUMP. With the help motor, water is then pumped to the GOIT REMOVAL TANK. In this stage the small stones, grits or lime pieces are separated for effluent water.

This water is then carried/pumped to Aeration tank 1 where the bacteria/ microbes present in water are used for water cleaning process with the help of the Oxidation reaction. The aeration tanks are provided with oxygen providers as mainly aeration tank is aerobic.

Suspended growth Bio-reactor is based on sludge process. The oxygen providers are also called as Surface Aerator as its main function is to impart oxygen to the bio-mass and to keep the contents of bio-reactor under complete mixing. This process is carried out for 4-6 hours. After this the effluent is sent to Secondary Clarifier 1 where the sludge is separated from the effluent water.

After passing from Clarifier 1 water is again sent to Aeration tank 2 where the same process occurs as above and then to Clarifier 2.

After being totally separated from sludge the water finally goes to the polishing tank and separated sludge is sent to Sludge beds. Mainly sludge drying beds are provided for the de-watering and drying of sludge so that it can be further disposed off as land fill.

Water in the polishing tank is then finally disposed off using V-notch as it also marks the flow rate of treated water.

Urea and DAV is used (2:1) in the water tank to maintain level of MLSS. MLSS is Mixed liquor Suspended Solid Concentration.

  Section:Effluent Treatment Plant      

1 Submercible Pump/Tubewell One 52 hp 10,00,000

2 Submercible Pump/Tubewell One 30HP  

3 Submercible Pump Two 15HP  

4 Clarifucator System One    

5 USAB Motor/Pump Two 12.5 hp  

6 Compressor (Air Blower) Two 25 Hp  

7 Compressor (Air Blower) One 10 Hp  

8 Diffuser System Two -  

9

Primary/Secondary Clarifier with

Agitator system Two

Ratio-

25:1,2 Hp  

10 Recirculation Pump Three 5 Hp  

11 Surface Aerator With Motor 2 sets 20KW 1,50,000

12 UASB STYSTEM + Gas collector One   5,00,000

PARAMETERS OF RAW EFFLUENT

1. pH 6-102. Oil and grease 100 mg/l3. Color dirty white/muddy4. Dissolved solid 3000 mg/l5. BOD 1000mg/l6. Suspended solid 600 mg/l

PARAMETERS OF TREATED EFFLUENT

1. pH 5.5- 8.52. Oil and grease 10 mg/l3. Color clear/ greenish4. Dissolved solid 2100 mg/l5. BOD 100-150 mg/l6. Suspended solid 30 mg/l

BOD – Biochemical Oxygen Demand

*Sampling point for treated water is V-notch.

REFERENCES:

Chemical Process and Design Handbook- James G. Speight

Perry’s Chemical Engineers’ Handbook, 7th edition-Late Robert H. Perry, Don W. Green and James O. Maloney

www.thermaxindia.com ( PRODUCERS OF SHELLMAX BOILERS)

www.Google.com

www.wikipedia.com