Summer Training Report at IFB Agro Industries

A REPORT ON
SUMMER
TRAINING AT
IFB AGRO
INDUSTRIES
Ltd.
NOORPUR
SUBMITTED BY
ABHISHEK MONDAL
&
RANDHIR KUMAR

CONTENTS
1. Introduction
2. Acknowledgement
3. Overview of this plant
4. Safety
5. Production
i) Unloading and storage
ii) Milling
iii)Liquefaction
iv)Fermentation
v) Distillation
6. Centrifugation & Decantation
7. Dried Distillery Grain Solid
8. ETP and Organic Manure
9. Boiler, Turbine and water treatment plant
10. Noorpur Gasses Plant Ltd.(CO2 Plant)
11. Q.C. Department
12. Mechanical Maintenance
13. Electrical Maintenance & Instrumentation
14. Conclusion
Introduction
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IFB is an ISO 14001 certified company with four wings spread all over
India- IFB Agro, IFB Marine, IFB Automotive, and IFB Appliances.
After visiting our sight in the past few days at IFB Agro Noorpur
Distillery, we get know that this unit was established at 1985 with
very small scale production of country sprit, after crossing various
milestones, IFB Agro has become the only distillery at the West
Bengal. From its quarry of gems one is ISO 9001 certificates its
premises highly safe & secure.
We, RANDHIR KUMAR and ABHISHEK MONDAL, students of The
Department of Food Technology, TECHNO INDIA SALTLAKE are
thankful to the IFB Agro. authority to allow us do our summer
training with them at their Noorpur distillery.
Acknowledgement
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We would like to take this opportunity with great pleasure, to
acknowledge and extend our heartfelt gratitude to-
Mr. Alok Kumar Dey, Administrator, IFB Agro Pvt. Ltd., for his
encouragement and vital support.
Mr. Santanu Ghosh, Deputy General Manager, IFB Agro Pvt. Ltd., for
his understanding and assistance.
And Mr. Dilip Kumar Dey, Mr. Snehasis Bera, Mr. S. Mallick,
Mr. T. K. Aich, Mr. N. Roy, Mr. M. Roy, Mr. N. C. Pal, Mr. Santanu
Sarkar, Mr. Krishna Mohan, Mr. K. Goswami, Mr. J. Roy Chowdhury,
Mr. T. Maity, Mr. Shankar Paul, Mr. Prasun Samanta, Mr. A. Mondal,
Mr. S. Mukherjee, Mr. S. B. Bhattacharyya, Mr. S. Bandopdhyay, Mr.
S. Khan, Mr. Ranbir Mukherjee, Mr. Kaushik Goswami for their
constant support and guidance and therby playing a vital role in
successfully completing the project report and the training program.
We also like to thank all the staffs and officials of IFB Agro. for their
help.
We would also like to thank Mr. Soumitra Banerjee, HOD, Food
Technology, Techno India, Salt Lake and all other respected faculty of
our department, who have been constantly encouraging throughout
our course.
Overview of This Plant
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IFB Agro Industries Limited is a reputed Public Limited Company. The
company has various consumers oriented products both for
domestic & export markets. The corporate office is situated at EM
Bypass, Kolkata, West Bengal. The company is listed in BSE & NSE.
This plant in 1985 started its journey under supervision of excise
department, with the production of rectified spirit. After crossing lots
of milestones it became only one Distillery Company in West Bengal.
The main production started from molasses, but now days to
compete with its uprising price, broken rice grains are used to
produce ethanol. As it is a fermentation industry, Carbon di-oxide is a
major bi-product, and also a greenhouse gas so it is processed at
“Noorpur Gas Pvt. Ltd.” to liquefied Co2. All the wastage water are
treated as ETP & Produces Methane gas, which is used as fuel at
boiler to produce steam, which can be used both at the process line
& at turbine to produce electricity, which is consumed within the
industry. Being ISO 14001 certified, it strictly follows the
environment safety rules with time to time checking of the
environmental parameters.
The plant is undergoing an extension work in its premises upon
whose running the production capacity would highly increase.
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Special thanks to
Mr. Dilip Kumar Dey
&
Mr. Snehasis Bera
SAFETY
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• What is safety?
Safety is the freedom from unacceptable risk or harm.
• What is Hazard?
Hazard is a potential cause for harm in terms of injury, health
damage to the property and environment or combination of all
Chemical reaction:
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A chain reaction can occurs when the three element of fire are
present in the proper condition and proportion. Fire occurs when
this rapid oxidation or burning takes place.
Take any one of these factors away and the fire cannot occur or
will be extinguished if it is already burning.
Classes of fire:
• Class A: Extinguish ordinary combustibles by cooling the material
below its ignition temperature and soaking the fibers to prevent re-
ignition.
Use pressurized water from or multipurpose (ABC-rated) dry
chemical extinguishers. Do not use carbon di-oxide or ordinary (BC-
rated) dry chemical extinguishers on class A.
•Class B: Extinguish flammable liquids, greases or gases by removing
the oxygen, preventing the vapors from reaching the chemical chain
reaction.
From Carbon dioxide, ordinary (BC-rated) dry chemical,
multipurpose dry chemical, & halon extinguishers may be used to
fight class B fires.
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•Class C: Extinguish energized electrical equipment by using an
extinguishing agent that is not capable of conducting electrical
currents.
Carbon dioxide, ordinary (BC-rated) dry chemical,
multipurpose dry chemical & halon* fire extinguishers may be used
to fight class C fires. Do not use water extinguisher on energized
electrical equipment.
*Even through halon is widely used, EPA legislation is phasing is out of use in favor of agents less harmful to
the environment.
Safety rules followed in this industry:
As this industry is an ISO 14001 certified, various safety rules are
strictly followed here. This safety rules makes this premises safe &
secure.
The color codes followed here to indicate various risk zones are:
Material classification Color of field Color of letters for
legends
HAZARDOUS MATERIALS
Flammable, Explosive,
Chemically active, Toxic,
Extreme pressure or
extreme temperature
YELLOW BLACK
LOW HAZARD MATERIALS
Liquid or liquid admixture
Gas or Gaseous admixture
GREEN
BLUE
BLACK
WHITE
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Fire quenching materials
Water, foam, CO2
RED WHITE
•The plant has some zone division to indicate various places.
Some instruction strictly followed:
• Use of P.P.E:P.P.E or personal protective equipment (such as
helmet, shoes, goggles, mask, ear protector and apron) must be used
at appropriate area.
•Smoking: Smoking is strictly prohibited within this industry, as
highly inflammable substance ethanol is produced & stored here
especially at the bio-gas plant where marsh gas (Methane) is
generated.
•Fire protection: As this industry has high risk of fire, every office
room, laboratory contains fire ball which is capable of fire
distinguishing, every employee is trained how to protect from fire,
fire alarm bell is attached on the wall of every high risk zone. Water
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Zone division Indication
Zone-0 Where an explosive atm. is always present for
long period. Ex. Diesel storage, Bio-gas storage
area
Zone-1 Where an explosive atm. Likely to Occur in
normal operation. Ex. Distillation plant, Dryer-
evaporation Unit, Spirit storage area.
Zone-2 Where an explosive atmosphere is not likely to
occur in normal operation & if it does it will exist
for only a short time. Ex. Rice husk storage area.

monitor is affixed on some point of the plant where from fire can be
distinguished.
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Special thanks to
Mr. S. Mallick,
Mr. T. K. Aich,
MR. N. Roy
&
Mr. M. Roy.
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Unloading and Storage
Primarily, the process of production starts with the receiving of the
broken rice grains. The rice grains arrive to the plant in truck loaded
with sacks of broken rice grains. They are primarily, checked for-
•Moisture content
•Ash
•Husk %
•Starch
•Dust
After going through and passing the quality check, they are moved to
the weigh bridge for taking their weight and allotment of batch
number.
They are then moved to the unloading point. During the process of
unloading, they are passed through a primary sieve as to remove,
large unwanted particles and strings that may come.
After this, they are then moved to storage silo by belt conveyors and
bucket conveyor system.
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Milling
The main motive of the milling section is to clean the rice grains
coming from the silos from various foreign impurities (jute rope,
pebble etc.) and also to reduce the size of the grain into smaller
particles (not grinding) so that the liquefaction and fermentation
process can become easier.
Particle size is reduced to some optimum size (5μm), so that the
enzyme (α-amylase) can work on it, as surface area gets increased.
The grains are not grinded to granular size because it can choke the
pipe lines internally. The grains come from the silos through
conveyor belt or chains and goes to the pre-classifier where it is
separated from foreign materials present. Then the grain is
transferred to the milling machine where the size reduction is done
by hammer milling process.
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Liquefaction
This process is the consecutive process done just after the milling of
the grains. Hot water is mixed with the milled grain and then cooked
through various processes. The flour coming from the milling section
is mixed with hot water and kept to the slurry tank. This tank is filled
up to 60% of its volume. Then the slurry goes to initial liquefaction
tank where the first enzyme (α-amylase) is introduced. The initial
liquefaction tank is filled up to 78%of its volume and the
temperature is maintained at about 60-65°C.This enzyme works on
the slurry grain: I) Reduces its viscosity and ii) Breaks the 1-4 linkage
in starch molecules and convert it to dextrin. This dextrin further
converts to glucose by the second enzyme (Amylo-glucosidase) in the
grain fermenter as yeast cannot convert starch to alcohol but it can
convert glucose to ethanol which is the desired product of the plant.
From the initial liquefaction tank, the slurry goes to the jet cooker
through control valves. Some portion of the slurry is recycled to the
initial liquefaction tank. The jet cooker temperature is maintained at
88-90°c so that the enzyme does not get destroyed. From the jet
cooker, it goes to the retention coil where it stays for about 12
minutes at about 90°c. Then it goes to the flash tank from where it
goes to the final liquefaction tank when the temperature is fixed at
90°c. This tank is also filled up to 78% of its volume. Here more
enzymes (about 70% of total enzyme used) are introduced in case
there is any destruction of enzymes in the heating process, though
30% of the enzyme is used in the initial liquefaction tank. The slurry,
before going to the fermenter is cooled by plate type heat exchanger
and the temperature is brought down to 36-38°c. It is done because
the yeast cannot work on the slurry at a high temperature of 90°c.
Some part of the slurry is recycled to the final liquefaction tank and
the rest is sent to the fermenter. The slurry should get proper
retention time so that all the 1-4 linkages can be broken down by the
enzyme. So the slurry is passed through a jet cooker where the
required temperature is attained and then through a retention coil
where the 1-4 linkages is broken down properly and completely.
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The whole liquefaction process is described by a flow diagram shown
below: -
OVERALL FLOW DIAGRAM OF THE
LIQUEFACTION PROCESS
Pre-mashing (flour + hot water)
↓
Slurry tank (mixing of flour and hot water)
(60-65 ̊C)
↓
Enzyme 1 → Initial liquefaction tank (80- 90 ̊C) ← Steam
↓
Jet Cooker ← high pressure steam
(75Kg/cm2
, 80-90 ̊ C)
↓
Retention Coil (12 minutes, 90 ̊C)
↓
Flash Tank
↓
Enzyme 1→Final liquefaction tank
(80- 90 ̊C)
↓
Plate heat exchanger ← Cold water
(Outlet temperature 36-38 ̊C)
↓
Fermentation Section
COMMENTS: Ammonium hydroxide solution was added to the slurry
during the process to maintain the pH of the slurry at 5.7 and also
acted as a nutrient for the yeast later.
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Grain Fermentation
After being treated at liquefaction section, cereal slurry comes to the
fermentation section, where the dextrin monomer is converted to
glucose molecules and then it is fermented to produce ethanol.
Fermenter section contains primarily of two sections, namely the
pre-fermenter and the main fermenters.
Pre Fermenter
In the pre-fermenter section, the ‘culture’ (genetically modified yeast
Saccharomyces Cerevisiae) is allowed to grow on the culture media,
so that their desire count can be obtained. Also this is done to note
the stage of growth and the health of the yeast culture. In the pre-
fermenter, the slurry is also treated with Amylo-glucosidase enzyme
to let the dextrin convert to glucose upon which the yeast cells can
easily act on. Additionally in the pre-fermenter tank, urea, SMBS,
Zinc sulphate, Velly gur, DAP is added according to their
requirement. Urea is added as a nutrient for the yeast, water is
added to maintain the viscosity. The cell count in the slurry is
repeatedly checked every hour. It is kept for near about 24 hours for
the preparation of the culture. Now this prepared culture with the
desired cell count is then transferred to the main fermenter as per
requirement. The specific Gravity is maintained at 1.040
Main Fermenter
In the main fermenter, yeast containing media from the pre-
fermenter is transferred to the slurry in the main fermenter vessel,
which has been obtained from the liquefaction section. Here the
second enzyme, along with some other additional compounds like
urea, anti-foam, SMBS, Zinc sulphate are added according to
requirement of the batch. Here the Urea is used as a nutrient for the
yeast cells, primary source of essential nitrogen. Antifoam is used to
stop excess foaming during the conversion from sugar to ethanol and
other products. SMBS is used so as to stop unwanted microbial
growth in the slurry during or post fermentation. The process needs
almost 35-36 hours. The process time is found out from the specific
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gravity measurement. The process is stopped when the specific
gravity reaches 1.000 and is begun at around 1.070.
After the process has been completed, the fermented mash in the
tank is transferred to the beer well, which acts as a hold for the
mash. The mash is then passed to the distillery section for further
processing from here.
Here is a short flow diagram for the fermentation section.
COMMENTS: The temperature of fermenters were maintained at 38 ̊
C by the use of PHE and the thus obtained discharge water was
reused in the process during liquefaction, thus saved energy which
would be otherwise used in the heating process. Also the fermenters
are cleaned properly after each batch by following a standard
protocol so as to prevent contamination of the mash. The CO2 that is
generated in the process is passed through a water scrubber so as to
collect the alcohol vapors and then is sent to the CO2 for processing.
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DISTILLERY SECTION
After the mash reaches the beer well, the mash is directly pumped to
the distillery section for final recovery of ethanol. A flow diagram is
given below for better understanding of the sections.
• There are basically seven columns for the recovery of ethanol
from the mash namely analyzer, aldehyde, pre-rectifier, purifier,
rectifier and simmering sections.
• The mash is taken into the analyzer column where the volatile
gases are separated from the mash. This column contains a
number of sieve plates. The mash is let in from the top of this
section and as it passes through the degasifying section, the
residual gasses are recovered. Simultaneously, the process is
refluxed for a number of times maintaining a ratio of 4:1 until
most of the alcohol has been extracted. The spent wash is then
sent to the centrifugation and decantation section. The column is
maintained in vacuum condition with bottom pressure of 0.57
Kg/cm2
, temp 85 ̊ C and top pressure of 0.42 Kg/cm2
, temp. 70 ̊ C
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Now from the analyzer column, two sections are removed. One is
sent to the pre-rectifier which basically comprises mainly of the
alcohols, esters and other fusel oils. The other part is sent to the
aldehyde column.
• Next we come to the aldehyde column. In this section, the
aldehydes are removed. This column is run with total reflux
initially and a technical cut is drawn at a measured rate. This
column uses a bubble cap tray for better removal and more
retention time of the gases at each tray. This column is also
maintained at high vacuum with bottom pressure of 0.42 Kg/cm2
,
temp 60 ̊ C and top pressure of 0.30 Kg/cm2
, temp. 53 ̊ C
• The other part from the analyzer column comes directly to the pre
rectifier column. This column is also a high vacuum column with
bottom pressure of 0.42 Kg/cm2
, temp 80 ̊ C and top pressure of
0.25 Kg/cm2
, temp. 49 ̊ C. Fusel oil draw is taken from the section
maintaining temperature at 56-69 ̊ C. This contains both the high
fusel oil and the low fusel oils. This cut is then passed through
decanters to remove the oils and also entrap the alcohol escaping,
which would otherwise escape with the oils and is resent back to
the column.
The fusel oil thus obtained is sent to a feed tank for storage and
further rectification. The main technical cut from this section is called
rectified spirit and is 96% concentration. But this contains other
impurities, so is sent to the next column called the Purifier column.
• Now the 96% rectified spirit contains esters and other fusel oils
which could not be removed. It is then passed on to the purifier
column. Here a lot of water is added and heated under vacuum to
maintain a top temp. of 66 ̊C, pressure of 0.30 Kg/cm2
and a
bottom temp. of 68 ̊C, pressure of 0.45 Kg/cm2
. In this process,
the esters are removed from the section having temperature of
around 67.5 ̊C and are collected in the Feed tank. This section also
has bubble cap trays.
• After passing through the purifier column, the 13% concentrated
alcohol solution is then passed to the rectification column. This
column is basically a high pressure column and maintains a top
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pressure of about 2.2 Kg/cm2
, temp. 96.5 ̊C and bottom pressure
of about 2.43 kg/cm2
, temp. 126 ̊C. This column is also called the
exhaust column as it is again concentrated to 96% and also a few
fusel oils are also removed which would not be possible at low
temperatures.
• Now the fusel oil draw is collected in the feed tank and from there
is sent to the ISP (Impure spirit purification) column. Here the
bottom temp. is 107 ̊C, pressure 1.22 kg/cm2
and the top temp is
78 ̊C, pressure 1.033 kg/cm2
. The technical cut is taken from the
section having temp. 79 ̊C. Other draws are taken from temp.
higher than this and is mainly taken as rectified spirit. The
technical cut should be checked at regular intervals for % alcohol
and purity.
• Finally the 96% alcohol from the rectification column is sent to the
simmering column. Primarily here the alcohol is freed from any
methanol that may be present at ppm levels. This column is thus
made of copper sieve plates, which acts as a catalyst in the
conversion of methanol to ethanol. The product obtained is thus
the final Extra Neutral Alcohol with a concentration of about 96%.
This product is finally collected from the bottom of the simmering
section and is sent to storage tanks. The draw is taken at about 84
̊C temp. and at atmospheric pressure. The charge in this column is
kept very less at about 5% maximum for proper product quality.
With this, we come to the end of the distillation section and the
product drawn is taken to storage tanks, while the slurry from the
analyzer column is sent to the centrifugation and decantation section
for further processing. Also the fusel oil and the ester contained
impure spirit is stored and sold out to other industries.
COMMENTS: In the distillery section, the vapors from the rectifier
column are used up to heat up the mash in the analyzer column; the
vapors from the simmering column are reused to heat the liquid in
the purifier column. Thus, these are good ways of cutting the energy
requirements of the plan and effectively using the energy.
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CENTRIFUGATION & DECANTATION
The process effluents that have a major amount of solid suspended
particles are sent from the analyzer column to the centrifugation and
decantation section. In this section, the solid suspended particles are
separated from the liquid portion. This is done by the use of a
horizontal industrial centrifuge. An industrial centrifuge is shown
below:
In this type of centrifuge, the feed is fed at one end and the solids
due to the centrifugal action are pushed under pressure to the end
with a narrow diameter due to a screw form inside this machine. The
liquid escapes from the broader end freely. The screw inside is
rotated by a single motor with counter rotating lever which allows
the casing of the screw to rotate in the opposite direction. Thus, the
solids are pushed more effectively and the entire liquid portion is
removed from the left over mash. The solid part mostly comprises of
uncooked rice which if properly processed can be used as cattle feed.
So from the decanter section the rice cake is sent to the DDGS i.e.
Distillery Dried Grain Solids. The liquid part is also re used to save
water from wastage and disposal problems.
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Special thanks to
Mr. K. Goswami
&
Mr. J. Roy Chowdhury
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DISTILLERY DRIED GRAIN SOLIDS
The rice cake obtained from the centrifugation and decantation
section is rich in nutrients which are good for use as cattle feed. But
directly after the centrifugation process, the water content in the
rice cake was found to be very high. The life period of the cake was
found to be about 24-48 hours after which it would start to rot. So
this DDGS plant was set up. The main objective of this plant was to
extend the life period of this rice cake so that it can be stored for
some weeks or more.
This DDGS plant basically consists of two parts
1. The evaporation section and
2. The dryer section.
EVAPORATION SECTION
Firstly the liquids that are let off from the various sections specially
that obtained from the decanter, is taken into the dryer section
which is called thick slop. This section basically comprises of five
calendrias and the feed is let in from the third one. Steam is fed from
the first calendria and vacuum is created in the last one. So the
steam flows from the first to the last thus doing the evaporation and
concentration of the liquid to its desired syrup form. The fluid is
taken in from the third calendria. This is of falling film type
evaporation technique. Thus in this way the liquid is passed on to the
next calendria. This also has the same technique and is under
vacuum but no heat is supplied. In the same way it passes on to the
next calendria slowly losing its moisture. In this section a part of the
liquid is discharged having very low total solids content. This liquid
called thin slop is sent to the ETA plant for processing. On reaching
the 5th
calendria, it is sent to the first calendria where heat in the
form of steam is applied. By this time, the liquid starts attaining its
desired TS% and thus has to be pumped by force from the bottom.
So this column and the next and final column has forced circulation.
After passing through all these five sections, the liquid takes a syrupy
form with total solid about 35%.
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A flow diagram of the evaporator section has been shown in the
figure below:
DRYER SECTION
After passing through the evaporator section, the syrup is sent to the
dryer section for further processing. In this section the syrup is added
to the rice cake obtained from the decanter section in such a ratio
that the total solid content of the mixture is 5%. Before mixing the
syrup with the rice cake it is called DDG i.e. Distillery Dried Grain on
drying. The drying is done by fluidized bed drying where the fluidized
bed is produced by air both hot and then dry. Here air is drawn from
the atmosphere in two different sections. In the first section, the air
is first passed through hot air for heat exchange by means of coils.
Then this air is further passed through two coils having steam to gain
more heat. After this the air is let into the dryer. On the other hand
the other part of the air is taken and is passed through coil
containing chilled water. So the moisture is condensed and is let out
as water. Then this dry air is passed through coils containing hot
water so that some temperature is gained by the air. After this, it is
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introduced into the dryer. The feed is given from the top portion and
along the process it loses its moisture and thus the total solids
percent raises to about 35%. This can be stored for weeks as the
moisture content is low and is like fine powder. There may be
particles escaping with the air that is sent out from the dryer, so four
cyclone separators are installed so as to settle all the particles and
resent it to the storage facility. The capacity of the drier is about 5
tons per hour. The fine powder is then sent to storage tank and from
there it is even sent for bagging or is loaded to trucks for direct
selling.
A short flow diagram is shown below of the drying section below:
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EFFLUENT TREATMENT PLANT
All the effluents from the whole plants cannot be directly let into the
environment. Also this plant is a zero waste discharge plant. In this
plant most of the bi-products are made use of in a very unique way.
So the treatment with the effluents is also different. In the first case
there is very less effluents. So whatever effluents that comes in the
form of liquid or solid comes to the effluent treatment plant for final
treatment as they have high BOD and COD values. The thin slop
which comes from the evaporator section is taken into the clarifier
tank and then from there it comes to the collection tank where it
gets collected. From this collection tank, the waste water is then sent
to the digester along with some ash which comes from the ESP from
the boiler section. Now in the digester, the methane gas which is
emitted is again used as fuel for the boiler and also now being used
in the staff canteen due to its high purity.
A brief flow diagram is shown below of the ETP section below for
better understanding:
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ORGANIC MANURE
This is another section present under IFB Noorpur plant which deals
with the waste products of the effluent treatment plant. This
basically is a combination of different types of animal excreta like
cow dung, poultry litter, etc. They are bought, dried and then they
are mixed with the left over ash from the factory’s boiler. These are
especially good for the soil. Organic manure is produced and packed
directly from this section of the plant and is marketed under the
brand TATA named as “Nabjiban”. Now a days use of this type of
organic manure has increased drastically as this many beneficial
qualities such as it increases the buffering capacity of the soil,
nutrient availability increases for the plant and also makes the soil
porous for aeration. So, plants also grow well with the use of this
kind of organic manures. In this kind of organic manure, 25% water is
present, phosphorus as P2O5 0.5%, potassium as K2O 0.5% which act
as nutrient for the growth of the plants. There is a restriction to
heavy metals which hinder plant growth so they are maintained at
very low levels such as As <5 ppm, Cd <0.15 ppm, Hg <0.15 ppm, Ni
<50 ppm, Cr <50 ppm, Cu <30 ppm, Zn <1000ppm. Quality checking is
done periodically to maintain the levels under permissible limits.
A short flow diagram is given below for better understanding of the
system:
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Special thanks to
Mr. T. Maity,
Mr. Sankar Paul
&
Mr. Prasun Samanta
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BOILER
In this plant there are three boiler of different capacity, these are
12T, 15T, 20T, among these boilers, two are tube type and one is fire
tube.
The general principle of boiler is as follows:
1. Bio-gas (as fuel), rice husk (as media), D.M. water (as heating
substance) comes through pipe-lines to boiler section.
2. As D.M. water may contain dissolved oxygen, which has
corrosive effect on boiler is de-aeration in de-aerator tank,
and passed to boiler.
3. After producing steam the flue gas (contains ash particles) is
passed to dust collector (which is termed as cyclone
separator) and again passed to venture wet scrubber to
maximize the separation process and the separated particles
are collected in bag separator and cleaned flue gas is passed
to stack.
4. Generated steam (super-heated or saturated) is by passed to
the place of requirement.
5. And the ash generated from the boiler is scrubbed out and
used as land filler. Working principle of the three boiler is
more-or-less same, except the steam generation procedure
& the steam usage procedure
Use of 12T boiler:
This medium pressure maintained boiler is a fire tube type
boiler, where fire is passed through number of tubes surrounded by
a tank of water the fire is charged through a fire box, containing
diesel, channelized through some tube thus surrounded water get
heated, steam is produced and supplied to the processing plant.
Use of 15T & 20T boiler:
These two boilers are also a medium pressure maintained boiler.
these boiler are water tube type boiler, where water get heated
using the heat generated from the surrounded fire, as this type of
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steam contains higher temperature, is used on the turbine to
produce electricity, which is consumed within this plant. After
discussing on the working principle of this section plant, it can be
said that this plant is saving energy & also reduces the costing which
brings profit to this industry.
The turbines connected to the steam from the boiler is of 2
megawatt capacity and under full functionality, the turbine can
generate 2.5 megawatts of electricity which is more than enough for
the functioning of the plant. The power consumption of the plant is 2
megawatts only so the boilers are run at low load and the steam is
reused in various section of the plant to reduce energy consumption
by the plant and thus save energy, save earth.
ELECTRO STATIC PRECIPITATOR:
At IFB Agro. the air discharged from the boiler previously contained
ash particles and other small particles that did not precipitate in the
cyclone separator, so they have recently installed this high capacity
ESP which stops any unwanted particles to be vented out with the
air. At regular intervals, hammering is done so as to collect and settle
the ash to the bottom and is thereby carried away to be stored into
tanks for use in the making of organic manure.
Comments: Environmental factors like air has been taken special
care of and required equipment have been installed to control
pollution of the environment. Also the water used for the boiler is
reused and the water intake from water sources has been
minimized.
31 | P a g e

Water Treatment Plant
Any distilleries cannot be run without a water treatment plant, as the
water should be used here should be as much chemically pure as
commercially feasible, since traces of impurities react with other
constituents of the drink. Water treatment plant has its necessity in
this regard, i.e. to soften the hardness of water as well as chemically
& biologically pure.
The treated water is being used as molasses & grain distillation,
boiler, fermenter. The vessels used here are
1. Raw water storage tank
2. Header
3. Pumps
4. Soft water storage tank
5. R.O water storage tank
6. Degasifying tank
7. De-alkalize
8. IRF
9. MGF
1. Raw water storage tank:
This is the first storage tank, where impure water drawn from
underground water storage by means of deep tube well. From this
storage point water is send to a header where 5 different pumps are
set to distribute water to different location as per requirement.
2. Pumps:
 Soft water feed pump
 Old R.O. feed pump
 D.A. feed pump
 New R.O. feed pump
3. Soft water storage tank:
32 | P a g e

The water shared in the tank is get pumped from 1& 2 no. pump.
Water from no. 1 pump firstly gets treated at M.G.F. (Multi-grand
filter, removes iron present in water). Water from no.2 pump gets
treated at “mixed bed” tower where both MGF & IRF is set. Both the
treated water is stored in this soft water tank. From this tank there
are two distributing lines, one is for molasses distillation and another
one is for grain distillation.
4. Reverse osmosis filtration:
This is a very important filtration system, used to filter the treated
water. The principle of osmosis passes of solvent molecules from a
solution of lower solute concentration through a semi permeable
membrane, R.O. system or reverse osmosis system relies in the
reverse of this principle, i.e. passes of solvent molecule from a
solution of higher solute concentration through a semi permeable
membrane.
Water pumped from no. 3 pumps firstly filtered at IRF, before
entering at MGF its gets mixed with NaOCl (to kill the bacteria
remain in water) after filter at MGF it mixed with sodium meta-
bisulphate (to neutralize CI), HCL(to avoid membrane chocking), anti-
scaling agent (to avoid scaling). After chemically treatment water is
passed from two cartridge filter, which are connected a t series, and
treated containing permeable filter, where highly pressured water
leave the solute portion (impurities) & transmitted to the outlet and
passed from next treatment. In the following step dissolved CO2 is
removed, by means of blowing air at the falling water, and then it is
stored in the storage tank and again processed to demineralized and
stored in tank.
Water pumped from no. 5 is treated in same way filtered in a
reverse osmosis system and stored in the same tank. The old set up
has two separate filters installed in a pot but at the new setup
around 30 cartridges are installed in one stainless steel container.
5. De-alkalizing tank:
From the no.4 pump, water comes to the DE-alkalized tank: De-
alkalized water is passed to 12T boiler.
33 | P a g e

Special thanks to
Mr. S.
Bandopadhyay
&
Mr. S. Khan
34 | P a g e

Noorpur Gasses Private Limited
This is a unit in the main plant premises as a supporting plant or
re-processing plant of emitted CO2 from the fermenters of the main
processing plant, to produce liquefied CO2, which is a useful material
for the carbonated beverage producing industries.
The principle of this plant is to produce liquid CO2. In the
fermentation process CO2 is produced which is received & clarified
from the impurities present in it, compressed, dried and chilled so
that its natural temperature reduce to around -78°C, which becomes
solidified under normal atmospheric pressure. The floe diagram of
this plant is given below:
35 | P a g e

Foam trap:
It is the first point where the CO2 from the processing plant gets
processed. The foam produced during fermentation is separated
from CO2.
Booster blower:
It is nothing but a pump which supplies pressure to the CO2 so that
it can be transfer from one vessel to another. In this plant there are
two booster blowers, among them one is kept stand by.
Water scrubber:
Here the water soluble impurities present in the CO2 gas is removed.
PPM scrubber:
Though it looks like a single column it is divided internally by a
perforated plate. The upper portion is a water scrubber & the
bottom portion is a PPM or potassium permanganate scrubber,
where all the aldehyde is separated.
Double acting double stage gas compressor:
This is a compressor used to compress the CO2 gas, so that the
required amount of refrigerant gets compressed. During
compression the temperature increase highly to reduce the
temperature, there is a water flow. This increased temperature also
helps to reduce the moisture percentage, within the next stage.
Activated Carbon Filter:
This is vessel full of activated charcoal with the CO2 gas is flew & due
to its adsorption capability activated charcoal arrests all the
impurities, foul smelling organic compounds. This activated charcoal
gets deactivated after 8 hours and then it is activated using steam
flow on it.
Pre-cooler:
Here the CO2 is cooled at around 10-15°C. As up to activated carbon
filter tank, CO2 remains hot & to chilling the gas, the energy cost will
higher, that is for CO2 is being pre-cooled, so that the temperature
gradient does not become too much sloppy.
Moisture separator:
Here from the CO2 gas present moisture is removed partially.
Dehydration unit:
36 | P a g e

Most of the moisture present in the CO2 is removed in this heat
treating unit. After this point CO2 get released from most of the
moisture & changing its state from gaseous liquid.
Chilling unit:
Here the purified CO2 is chilled by means of ammonia.
Mini stripper:
Here the SO2 (if any present) is stripped of from CO2. If there is any
amount of NH3 is present, collected in reboiler tank and transferred
again to chilling unit.
NOX tower:
Here all the oxide of nitrogen is absorbed and the chemically &
biologically pure “food grade ” CO2 is stored in the three CO2 tanks.
COMMENTS: The quality parameters of this section has been taken
special care of and so various awards from recognized food
companies have been awarded for the quality of the finished
products.
37 | P a g e

Special thanks to
Mr. N. C. Pal.
38 | P a g e

QUALITY CONTROL
Quality control is a huge aspect of any company and plays a very
important role in the industry. Right from the unloading area to the
final finished product, it has to look deeply. So coming from the
beginning, we first come to the assessment of the raw material at
the point of arrival.
MILLING SECTION
Here the raw broken rice is initially checked for a few factors like
Serial no. Factor Acceptable limit
1. Moisture content 13.5%
2. Ash 2.15%
3. Husk and dust 2%
4. Paddy 3%
5. Starch 69%
Moisture content is calculated from IR moisture meter which gives
the moisture reading after a certain period of moisture removal by
means of infrared radiations.
Ash content is found out by means of ashing a measured amount of
sample.
Similarly, husk and paddy percent is found out by taking a measured
amount of sample and blowing off the husk and dust. After blowing
off the dust and husk, the weight is taken again.
STARCH ESTIMATION
Starch is found out by taking a weighed sample and grinding it in a
mixer grinder, then the starch is converted to sugar by the use of
enzymes and then sugar is estimated. This is done to test the milling
efficiency and also to check
PROCEDURE: We take 3 gm. of sample flour and add a small amount
of distill water then heat it. We then add two drops of 1st
enzyme
alpha amylase and then boil for 1 hour. After this we add cool the
mixture to room temperature. Then we add 4 drops of 2nd
enzyme
amyloglucosidase. The mixture is then constantly maintained at a
39 | P a g e

temperature of 60° C for another two hours. The volume of the
mixture is then made up to 250 ml. Now from the stock solution, we
take 25 ml and volume make up to 100 ml. The solution is filtered
and pH is neutralized by NaOH solution. After this it is titrated
against 5ml Fehling’s A +5 ml Fehling’s B solutions. The burette
reading is noted.
CALCULATIONS:
TIS% (Total Inverted Sugar %)
TIS% = ( =70%
Here, 0.2 gm. standard glucose in 100 ml solution is titrated against 5
ml Fehling’s A and 5 ml Fehling’s B solution. The burette reading on
standardization was found out to be 25.8 ml.
Dilution Factor = (3/250)*(25/100) =0.003
As 3 gm. Sample flour was taken and volume was made up to
250 ml and from there 25 ml was taken and volume made up to 100
ml.
Burette reading on titration with sample was found to be
22.1
(C6H10O5)n→C6H12O6
Thus, (162)n→180
So, conversion factor = 180/162 =1.11
1.11 is the conversion factor for starch to sugar
Thus the total starch content was found to be 70% i.e. 70 gm. sugar
was obtained from 100 gm. of flour.
MILLING EFFICIENCY
Milling efficiency is checked by checking the particle size of the
milled flour. This is also checked because if the particle size would be
large, the activity of the enzymes would be highly hindered due to
less surface area. If they get lesser surface area for acting, then the
conversion of the flour or rather starch to sugar would be less.
Ultimately the yeast will get less sugar to act upon, leading to
reduction in the production of alcohol. Thus particle size checking is
done in this section as a check for quality.
40 | P a g e

This is done by taking a measured amount of the milled flour and is
passed through sieves of pore size of 5 micron. Thus if more than 90
% of the milled flour passes through the sieves then it accepted
otherwise it is resent for milling.
FERMENTER SECTION
Now, coming to the quality control parameters in fermenter unit, we
have the microbial count, specific gravity test and various other tests
for the fermented mash and also we have a lab parallel to detect the
various parameters of the process.
1. MICROBIAL COUNT:
This is done by the means of a haemocytometer. In this the mash is
taken from the pre fermenter at intervals and a small portion is
taken into this slide. It is then placed under the microscope and cell
count is taken. With the help of this device, the growth phase of the
cells can also be understood and depending on that the decision
regarding the transfer of the pre fermenter mash to the main
fermenter is taken.
There are 25 small squares in the H shaped portion of the
haemocytometer and each of this has 16 even smaller squares within
them. The cell count is taken as an average of the number of cells in
the 16 boxes.
RESULTS:
Thus the cell count obtained for our sample was found to be 10 in
each of the 25 boxes. So the cell per ml is 10*25*106
i.e. 2.5*108
which is quite good. Acceptable range is 1.25 to 1.85*108
.
A brief diagram of this haemocytometer is shown below:
41 | P a g e

Next, we come to the process of fermentation. Here, the duration of
fermentation is decided based on the specific gravity of the
fermented mash which is checked at frequent intervals.
2.SPECIFIC GRAVITY:
PROCEDURE: sample mash is taken from the fermenter. Then it is
half diluted, after that it is taken in the measuring cylinder up to the
brim. Then the specific gravity meter is inserted in the sample and
the reading is noted along with the temperature of the fermented
mash.
Process time calculation:
The process time is calculated on the basis of the specific gravity of
the sample as has been stated earlier.
Initial specific gravity of the mash = 1.070
Final specific gravity of the mash (desired) =1.000
Per hour fall in specific gravity (estimated) =0.002
Thus, time required by one batch to
Complete fermentation process =0.070/0.002
=35 hours approx.
42 | P a g e

DISTILLERY SECTION
In the distillery section many tests are performed so as to ensure
quality of the final Extra Neutral Alcohol. The tests include alcohol
percentage, Potassium Permanganate test, test for esters, test for
fusel oils, test for methanol and test for volatile acidity. Each of these
tests is discussed below:
1) ALCOHOL PERCENTAGE:
PROCEDURE: we take test spirit in a measuring cylinder of 100 ml
and fill to the brim. Then we put a standard alcohol meter with
calibrations from 90-100. We swirl the alcohol meter in it so as to
make the liquid of homogeneous. Then we note the reading along
with the temperature. After this we calculate the % of alcohol from
alcohol table.
RESULTS:
In our test sample, we got indication of 98.7 at a temperature of 33°
C.
Thus, from alcohol table we get alcohol % as 96.1%.
2) POTASSIUM PERMANGANATE TIME TEST:
PROCEDURE: We take 50 ml of sample alcohol in a nesla tube. Then
we maintain temperature at 15° C and add 2.5 ml of 0.0316% KMnO4
and constantly monitor the temperature. Also simultaneously note
the time for the color to change to salomon red color. If there is high
amount of impurities then color change occurs very rapidly.
RESULTS:
In our case the PP time for ENA was found to be 40 minutes and for
rectified spirit it was found to be 28 minutes which maintain the
quality norms of the plant. Minimum PP time for quality acceptance
is 27 minutes.
3) TEST FOR VOLATILE ACIDITY:
PROCEDURE: We take 50 ml of sample in 250 ml round bottom flask
and titrate against standard NaOH solution.
RESULTS: Test was not performed only method discussed.
4) Test for fusel oils:
43 | P a g e

PROCEDURE: We take a clean stoppered flask and rinse it twice with
the sample to be tested. Now we take 10 ml of the test sample in the
flask and add 1 ml of 1% salicylic aldehyde and keep it in ice bath for
sufficient cooling. Add 20 m concentrated sulfuric acid, mix well and
put the lid immediately. Allow it to stand at room temperature for
over 12 hours.
For a quick routine analysis the color changes may be noted after a
shorter interval of about 30 minutes at 15 to 20° C.
RESULTS: Test not performed due to long test duration.
5) TEST FOR METHANOL:
PROCEDURE: Take 1 ml alcohol in a test tube and dilute with 4 ml of
distilled water. Shake well. Then we put the test tube on an ice cold
water bath and add with it 2.0 ml of potassium permanganate
solution in phosphoric acid. Then we keep the test tube in water
bath for 30 minutes. We then add few crystals of sodium bisulphate
and shake till disappearance of color of the test solution. Add 1 ml of
5% till the disappearance of color of the test solution. After this add
1 ml of concentrated sulphuric acid and heat the test tube on a water
bath at 60-70° C for 10 minutes. The development of a violet to red
color indicates the presence of methanol
RESULTS: Normal and does not show any development of color.
6) TEST FOR ESTER:
PROCEDURE: We take 50 ml of test sample in 250 ml round bottom
flask and neutralized it as like as the acidity determination
procedure. We cool and back titrate the excess alkali with standard
sulphuric acid. Simultaneously run a blank taking 50 ml of distilled
water in place of the sample in the same way. The difference in
titration value in millimeters of standard acid solution gives the
equivalent.
CALCULATIONS:
Ester expressed as ethyl acetate,
grams per 100ml of absolute
alcohol = (v*100*0.0088*2)/v1
where v is difference in ml of standard sulphuric acid used for blank
and sample.
44 | P a g e

V1 is the alcohol, percent by volume.
Note: 1 ml of standard sodium hydroxide solution is equivalent to
0.0088 of ethyl acetate.
RESULT: Test was not performed.
LAB PARALLEL
Sample flour’s lab parallel was performed for the clarification of
concept. The procedures, results and conclusion are as follows:
Amount of flour taken = 150 gm.
1st
enzyme used for the purpose as 0.65 Kg/ton flour
2nd
enzyme used for the purpose as 0.75 kg/ton of flour
Estimation for 1st
enzyme:
1000 Kg flour requires 0.65 Kg of enzyme
So, 150 gm. requires (0.65*150)/ (1000) gm. of enzyme
=0.0975 gm. of enzyme.
Estimation for 2nd
enzyme:
1000 Kg flour requires 0.75 Kg of enzyme
So, 150 gm. of enzyme requires (0.75*150)/ (1000) gm. of enzyme
=0.1125 gm. of enzyme.
PROCEDURE: The 150 gm. sample flour was taken in a pre-cleaned
beaker. In this the measured amount of sample of 1st
enzyme was
taken and then boiled for 1 hour. After this the mixture was taken
and kept for some time to cool to room temperature. Then the 2nd
enzyme was added and the temperature was constantly maintained
at 60° C for 1 hour. Then this mash was kept to cool to room
temperature. After this a measured amount of yeast about 2.5 gm.
was added to the solution. The mash was then cotton plugged and
kept for 2 days for the yeast cells to ferment the sugars into alcohol.
After 2 days, 250 ml of the mash was then transferred to a round
bottomed flask. A small distillation setup up was made with a
condenser and another flask. The liquid was boiled and the vapors
were collected for further analysis.
45 | P a g e

RESULTS AND CALCULATIONS:
After distillation, alcohol estimation was done and it showed an
indication of 11.7 at 25° C. Thus from alcohol table alcohol % was
found out to be 10.7.
Total volume of the fermented mash was found to be 620 ml.
TOTAL SUGAR TEST:
PROCEDURE: 25 ml of the mash was taken in 100ml flask and then
heated in water bath for 1 hour after adding the calculated amount
of the 1st
enzyme.
After heating for 1 hour, the mash was cooled to room temperature
and then the 2nd
enzyme was added. It was then maintained at a
temperature of 60° C for another 1 hour. Finally after that the mash
was cooled to room temperature and then sugar estimation was
done by neutralizing first and then titrating against 5 ml Fehling’s A
and 5 ml Fehling’s B.
RESULTS:
Burette Reading = 29.00 ml.
Total Sugar = (0.002*25.8*100%)/ (Dilution Factor*Burette
Reading)
=0.717%
Dilution Factor =25/100
=0.25
RESIDUAL SUGAR TEST:
PROCEDURE: 100 ml of mash was filtered and taken in a beaker and
to it 2 drops of phenopthlein was added to check the pH of the
liquid. If not neutral pH adjusted by adding NaOH solution and the
liquid was then taken in a burette and titrated against 5 ml Fehling’s
A and 5 ml Fehling’s B. The burette reading was noted.
RESULTS:
Burette Reading = 29.6 ml.
Residual Sugar = (0.002*25.8*100%)/ (Burette Reading)
= 0.17432%
Thus, sugar from residual starch = (0.7117-0.17432)
0.53742%
46 | P a g e

So, Residual Starch = 0.53742/conversion factor of starch to
sugar)
= 0.53742/1.111
= 0.48373%
FERMENTATION EFFICIENCY:
FE% = Alcohol%*Total Volume*100%)/
(0.644*1.111*70.05*150)
= 88.18%
Where,
Alcohol% = 10.7%, Total Volume = 620 ml
C6H2O6→C2H5OH
180 → 92
1→ 0.511
Specific gravity of alcohol = 0.795
So, 1 mole of sugar = 0.511 /0.795alcohol
=0.644 alcohol.
IN DETAILS
THEORETICAL ALCOHOL
100 gm. flour gives 70 gm. starch
So, 150 gm. flour gives (70*150)/100 gm.
= 105 gm. starch.
Again, 105 gm. starch gives 105*1.111 gm. sugar
= 116.821 gm. sugar
Then, 150 gm. flour gives 116.821 gm. sugar
Now, we know theoretically that,
1 ton flour gives 644 liter alcohol
So, 1 gm. flour gives 644*103
ml alcohol
So, 116.821 gm. sugar gives (644*103
*116.821)/103
= 75.23 ml of alcohol
PRACTICAL ALCOHOL = (10.7*620)/100
=66.34 ml alcohol
Thus, Efficiency of the process = (Practical alcohol/
Theoretical alcohol)*100
= (66.34/75.23)*100
=88.18%
47 | P a g e

QUALITY ANALYSIS OF CO2
As CO2 products is a major products at the IFB Noorpur Plant and has
trusted customer like Coca-Cola. The main parameters of quality
checking in the CO2 plant are the purity, the moisture and the
percentage of impurities checking is prime task of the quality
analysis. A few of the methods of quality checking are listed below:
 Purity of CO2 :
Purity of CO2 is checked by an apparatus called Zahm & Nagel. This is
an L-shaped apparatus in which both the gases during the time of
receiving as well as during filling into tanks is checked one at a time.
Basically what is done is that the gas is pushed through one end and
then enclosed. Then a solution of NaOH is let into the apparatus.
After this, the level is checked to determine the purity. Only gases
with 99.89 % purity are accepted or else are vented off.
 Online moisture analyzer:
This apparatus monitor the percentage of moisture content of the
gas continuously and based on this a report is generated within the
system. Only gases with moisture content less than 20% is accepted
for both industrial and food grades.
 Gas chromatography:
This instrument is basically of two types:
a) One uses Flame for detection of impurity level called FID
(flame ionizing detector)
b) One which gives Photographic images for various impurities
called PID (photo ionizing detector)
These two chromatography instruments are operated manually and
thus have to be checked periodically for variations in impurities
percentage.
 Total quality analyzer:
This is an online instrument which continuously monitors the sulphur
content and the total hydrocarbon continuously. On the basis of the
readings it generates a report and thus the quality of the product is
monitored.
48 | P a g e

Special thanks to
Mr. A. Mondal,
Mr. S. Mukherjee
&
Mr. S. B.
Bhattacharyya
49 | P a g e

MECHANICAL MAINTENANCE
A pump is a device used to move fluids, such as liquids or slurry. A
pump displaces a volume by physical or mechanical action.
A positive displacement pump causes a fluid to move by trapping a
fixed amount of it then forcing (displacing) that trapped volume into
the discharge pipe. A positive displacement pump can be further
classified according to the mechanism used to move the fluid:
• ROTARY-TYPE, for example, the external gear, screw, shuttle block,
helical twisted roots (e.g. the wendelkoiben pump) or vacuum
pumps.
• RECIPROCATING-TYPE, for example piston or diaphragm pump
Positive Displacement Pumps has an expanding cavity on the suction
side and a decreasing cavity on the discharge side. Liquid flows into
the pumps as the cavity on the suction side expands and the liquid
flows out of the discharge as the cavity collapses. The volume is
constant given each cycle of operation.
CENTRIFUGAL PUMP:
A centrifugal pump is a roto dynamic pump that uses a rotating
impeller to increase the pressure and flow rate of a fluid. Centrifugal
pump are the most common type of pump used to move liquids
through a piping system. The fluid enters the pump impeller along or
near to the rotating axis and is accelerated by the impeller, flowing
radially outward or axially into a diffuser or volute chamber, from
where it exist into the downstream piping system. Centrifugal pumps
are typically used for large discharge through smaller heads.
Cooling Tower
50 | P a g e

Cooling tower are large diameter columns with special types of
packing designed to give good gas-liquid contact with low pressure
drop. When warm liquid is brought into contact with unsaturated
gas, part of the liquid evaporates and the liquid temperature drops.
With respect to drawing air through the tower, there are two types
of cooling towers:
• Natural draft, which utilizes buoyancy via a tall chimney. Warm
most air naturally rises due to the density differential to the dry
cooler outside air. Warm moist air is less dense than drier air at the
same pressure. This moist air buoyancy produces current of air
through the tower.
• Mechanical draft, which uses power driven fan motors to force or
draw air through the tower.
1. Induced draft: A mechanical draft tower with a fan at the
discharge which pulls air through tower. The fan induces hot moist
air out the discharge. This produces low entering and high exiting air
velocities, reducing the possibility of recirculation in which
discharged air flows back into the air intake. This fan/fin
arrangement is also known as draw-through.
2. Forced draft: A mechanical draft tower with a blower type fan at
the intake. The fan forces air into the tower, creating high entering
and low exiting air velocities. The low exiting velocity is much more
susceptible to recirculation. With the fan on the air intake, the fan is
more susceptible to complications due to freezing conditions.
Another disadvantage is that a forced draft design typically requires
more motor horsepower than an equivalent induced draft design.
The forced draft benefit is its ability to work with high static
pressure.
51 | P a g e

Heat Exchanger
Heat exchangers are devices built for efficient heat transfer from one
fluid to another and are widely used in engineering processes. Some
examples are intercoolers, preheaters, boilers and condensers in
power plants. By applying the first law of thermodynamics to a heat
exchanger working at steady-state condition, we obtain:
mi (hi1-hi2) = 0
where,
mi = mass flow of the i-th fluid
del hi = change of specific enthalpy of the i-th fluid
There are several types of heat exchanger:
• Recuperative type, in which fluids exchange heat on either side of a
dividing wall
• Regenerative type, in which hot and cold fluids occupy the same
space containing a matrix of material that works alternatively as a
sink or source for heat flow
• Evaporative type, such as cooling tower in which a liquid is cooled
evaporative in the same space as coolant.
The heat exchanger may be classified according to the flow pattern
as:
• Parallel-flow heat exchanger
• Counter-flow heat exchanger
• Cross-flow heat exchanger
52 | P a g e

ELECTRICAL & INSTRUMENTATION
Firstly, the electricity is supplied from FIGC (Falta industrial growth
center) in the form of overhead high tension cables (HT) to the plant.
It comes at 11kv when received at the plant. The plant has HT
isolator and then connected to HT fuse and jumper. Now from there
it comes to OCB (oil circuit breaker) which is metered online by
WBSEDCL. Now it comes to another circuit breaker which is VCB
(vacuum circuit breaker). These are according to safety guidelines of
WBSEDCL. The pant additionally has a VCB for its own safety. From
here it is charged to the transfer which step-downs it to 430 volts
and 2500 amp. After this it send by PCC to various sections of the
plant.it also has various SFU (single fuse unit) for different sections to
control and stand by any power failure in any sections.
In order to prevent pant shutdown due to power failure, two standby
diesel generator of high capacity have been placed in the plant.
53 | P a g e

Control Valves:
Control valves are valves used to control conditions such
as flow, pressure, temperature, and liquid level by fully or partially
opening or closing in response to signals received from controllers that
compare a "set point" to a "process variable" whose value is provided
by sensors that monitor changes in such conditions. Control Valve is
also termed as the Final Control Element.
A control valve consists of three main parts in which each part exist in
several types and designs:
• Valve's actuator
• Valve's positioner
• Valve's body
THERMOCOUPLE:
A thermocouple is a junction between two different metals that
produce a voltage related to a temperature difference.
Thermocouples are a widely used type of temperature sensor for
measurement and control and can also be used to convert heat into
electric power. They are inexpensive and interchangeable, are
supplied fitted with standard connectors, and can measure a wide
range of temperatures. The main limitation is accuracy: system
errors of less than one degree Celsius (C) can be achieved.
Any junction of dissimilar metals will produce an electric potential
related to temperature. Thermocouples for practical measurement
of temperature are junctions of specific alloys which have a
predictable and repeatable relationship between temperature and
voltage. Different alloys are used for different temperature ranges.
Properties such as resistance to corrosion may also be important
when choosing a type of thermocouple. Where the measurement
point is far from the measuring instrument, the intermediate
connection can be made by extension wires which are less costly
than the materials used to make the sensor. Thermocouples are
usually standardized against a reference temperature at the
instrument terminals. Electronic instruments can also compensate
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for the varying characteristics of the thermocouple, and so improve
the precision and accuracy of measurements.
Thermocouples are widely used in science and industry: applications
include temperature measurement for kilns, diesel engines, and
other industrial processes
PRINCIPLE OF OPERATION:
When any conductor is subjected to a thermal gradient, it will
generate a voltage. This is now known as the thermoelectric effect or
seebeck effect. Any attempt to measure this voltage necessarily
involves connecting another conductor to the “hot” end. This
additional conductor will then also experience the temperature
gradient, and develop a voltage of its own which will oppose the
original. Fortunately, the magnitude of the effect depends on the
metal in use. Using a dissimilar metal to complete the circuit creates
the circuit in which the two legs generate different voltages, leaving
a small difference in voltage available for measurement. That
difference increases with temperature, and is between 1 and 70
microvolts per degree Celsius (μV/°C) for standard metal
combinations
MAGNETIC FLOW METER:
Magnetic flow meter, is an electromagnetic flow meter or more
commonly known as mag meter. A magnetic field is applied to the
metering tube, which results in a potential difference proportional to
the flow velocity perpendicular to the flux lines. The physical
principle at work is electromagnetic induction. The magnetic flow
meter requires a conducting fluid, for example, water that contains
ions, and an electrical insulating pipe surface, for example, rubber-
lined steel tube.
Usually electrochemical and other effects at the electrodes make the
potential difference drift up and down; making it hard to determine
the fluid flow induced potential difference. To mitigate this, the
magnetic field is constantly reversed, cancelling out the static
potential difference.
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CONCLUSION
This article is not about any technical discussions, neither it is any
acknowledgement, both are already done. This is to share our
experience and give our feedback after these 15 very informative
days.
This was our first industrial exposure, and in true sense it added a
practical dimension to our theoretical knowledge. We may have
studied distillation column, their principle in books, but watching a
real column with different type of trays is fantastic. Interaction with
personal working here on field did boost our practical knowledge. It
was pleasure on our part to use the quality control lab facilities,
hearing experiences from skilled individuals who have huge industrial
experiences and it was really nice to practically witness the
functioning of different systems which till now we had only known
theoretically. These would create a long lasting memory for us and
would also be of great help for us in our near future.
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Summer Training Report at IFB Agro Industries

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