Summer Training presentation on Gujarat Ambuja Exports ltd.

Submitted to

Department of mech. Engineering

Alwar institute of engineering and technology, Alwar

Acknowledgement

First of all , I would like to thank Gujarat Ambuja expo. Ltd. , Mr. k. k. Rai , HR officer (who organized my training schedule ) & DGM’S and AGM’S of various department who provided important information about their respective shops.

I also thanks the workers , who were always read to clarify our doubt .

I wish to express my deep gratitude to all the concerned person with whose cooperation and coordination I have successfully completed the training in the organization

About GAEL

Established in 1983

GAEL is principally involved in agro-processing & trading and has focused on exports , competing in the global market.

GAEL start with just a textile processing unit in 1983 , the year 1993-1994 was crucial period for the company , with major project being taken up like the most modern cotton yarn spinning project and maize-based starch project( Uttaranchal division),Soya processing unit .

GAEL is focus on international trade has setup a wholly-owned subsidiary at Singapore and has recently promoted a vanaspati and oil refinery project in Srilanka.

In its19th year of operation , GAEL is poised to scale newer heights and is fully geared to achieve the magical Rs.1800 corers operational turn over.

Department

Starch production plant

Chiller

Cooling tower

ETP

Gas engine

Steam generation (boiler)

Starch production plant

Receiving :-

The corn is transported to the unit in trucks in gunny bags and offloaded in receiving area or in silos. The receiving area should be designed in such a manner that there is enough space for smooth movement of expected number of vehicles. The grain is fed to the belt conveyor which takes the maize grains to cleaning section.

Cleaning:-

The grain contain various impurities like cobs, stones, metal parts, dust, other foreign matter etc. These unwanted materials are removed in cleaning section. The grain is passed over perforated metals sheets, air blowers, electromagnets to remove the impurities.

Steeping vat

Vat tank receive feed from cleaning section with hot water at 52 0C.

70 hrs. time required for fermentation process.

Steeping mixture containing sulfur dioxide (SO2) @ 0.2 per cent concentration in hot water.

The steeping conditions the grain for later steps by softening of the maize kernels and loosen the bonds between germ, fiber and starch.

Grinding machine

The grinding process is completed in 2 stages.

The grinders are made of stainless steel

In first stage, the steeped maize grains are ground coarsely to loosen the husk and germ. adjustable RPM with BFD.

The second stage grinding, known as fine grinding, help in detaching the germ from the grain.

Germ separation Due to grinding process germ separate from maize.

Germ cyclone are used to separate the germ from the gulten and starch.

The pasty mix obtained after fine grinding is pumped to water filled settling troughs, known as germ separators or germ cyclone.

The light density over flow germ is skimmed off.

Then it is forwarded to germ press.

Finally it goes to germ dryer.

Fiber Washing Section The slurry of husk, starch and gluten is ground for better recovery of

slurry.

The fiber washing is a 6 stage process which is carried out by DSM box.

The husk is separated from the soluble starch and gluten slurry by a counter current flow system.

The husk is sent to either drying section or used as animal feed in wet form. The husk is mainly carbohydrate which also contains 8 per cent protein.

And the under flow is contain starch And gluten.

Thickener

The slurry of starch and protein is passed through a centrifugal concentrator to get the concentrated slurry. This machine is also called as milk stream thickener.

Primary starch thickener:-

The thickened slurry is passed through a high speed centrifuge to separate the heavier starch from the lighter protein (Gluten).

Motor used in PST is 200 HP and rpm is 1485

Rpm of disc is 3337 .

No. of blade on disc 104.no. of nozzle are used

20-20(top and bottom)

Hydro clone system The starch slurry received from the primary separation is passed

through a multi stage hydro clone system.

This is used to separate the starch , gluten from slurry.

A nozzle system is used no. of nozzle provide in a disc called battery.

Slurry forced through it then over flow is gluten and starch found in under flow.

Centrifugal pump are used

No. of battery used=12

No. of pump are used=11

From one end feed is provide then in just apposite direction water also feed by centrifugal pump

Gluten thickener

The protein slurry is passed through a centrifuge to get concentrated slurry of gluten.

The gluten contains 65 per cent protein and is a good source of protein for the animals.

Motor=300 HP and rpm=1490

No. of nozzle used =30-30 (top & bottom)

Rpm of disc = 2700(BFD)

Drying Process & Dryer Drying process done by dryer.

Two types of dryer mainly used=

1.spin flash dryer(commonly use)

2.spray dryer

The concentrated starch slurry is then dried by hot air application (175 0C) to 11-12 per cent moisture content level.

The main product of slurry, is starch and four major coproducts for the feed industry namely the steep water, fiber, germ and gluten.

Component=

Induce draf fan

Force draf fan

Heater(by steam)

Rotary valve

Cyclone

Dryer Blower

Cello

In let temp.=120-130

Out let temp.=75-65

I D fan motor=75HP

F D fan motor=50HP

After the drying process powder is forwarded to FMG

Dextrose monohydrate, anhydrate and liquid glucose The starch is raw material for various ancillary industries like dextrose

monohydrate , dextrose anhydrate.

An another product also produce called liquid glucose

DMH:-

Cooling tank(for cooling purpose by cooling tower water)

Crystallizer(for crystal formation)

Centrifuge( separate product from the water )

Spin flash dryer

Packing section

DAH:-

Carbon treatment

Filter press

Ion exchange

Filter press

Crystallizer

Centrifuge

Spin flash dryer

LIQUID GLUCOSE:-

1.Jet cooker

2.dextiniser

3. Process tank

4.Filter press

5. Ion exchange

6.EVAPORATOR=a. Falling film b. Rising film

Boiler Steam boiler or simple boiler is a basically a closed vessel in which water is

heated until the water is converted into steam at required pressure .

TYPE:-

1.fire tube boiler 2. water tube boiler

MOUNTING:-

1.NRV

2.gauge glass

3.main stop valve

4.flow down

5.drum:- a .Steam drum b. Mud drum

6.main hole

7.safety valve

Boiler ACCESERISE:-

1. I D fan SPECIFICATION:-

2 . F D fan 1. Capacity=30TPH

3. P A fan 2 .Boiler type =water tube type

4. Economizer 3. Pressure=17kg/cm₂

5. Air pre heater

6. Scrubber

7. Cyclone

8. Chimney

Chiller Chiller is used to remove heat from a liquid via a vapor –compression and

evaporation cycle.

MOUNTING:-

1.Ammonia gas type compressor

2.Oil separator

3.Condenser

4.Receiver

5.Expansion valve

6.Chiller

7.Suction valve

8.Dischage valve

RECOPROCATING COMPRESSOR:-

A. GAS COMPRESSOR:-a gas compressor is a mechanical device that increase the pressure and temperature of a gas by reducing its volume .

CHILLER FLOW CHART

Chiller:-

CHILLER

RECIEVER

CONDENSOR

C

EXPANSION VALEVE

Gas compressor specification Name=KC-3 Ammonia compressor

1.Piston no.=3 6.Bore=160mm

2.Suction pr.=2kg 7.Stroke =110mm

3.Discharge pr.=16kg 8.max. pr.=21kg/cm₂

4.Condenser temp.=40⁰c 9.Motor power=75HP

5.Chilled water temp.=10⁰c 10.max. rpm=1000

HEAT TRANSFER PROCESS:-

A .condenser=convection

B. Chiller=convection

FLOW TYPE:-

counter flow(in condenser and chiller)

REFRIGRANT AGENT SPECIFICATION:-

Refrigerant agent= ammonia gas

Freezing point=-77.7 ⁰c Boiling point=-33.34 ⁰c

Cooling tower Evaporative heat rejection devices called cooling tower .

PRINCIPLE:-

The basic principle of cooling tower is that water evaporates by coming in contact with cross air flow (which is being pumped out by a fan).This evaporating water also absorbs the latent heat from the water surrounding it .Due to this process water is cooled.

TYPES OF COOLING TOWER:-

1.Natural draft cooling tower

2.Mechanical draft cooling tower

COOLING TOWER COMPONENT:-

Splash bar

Nozzle

Centrifugal pump

Fan with motor

FLOW TYPE:-

Cross flow

Cooling tower and specification Type:- mechanical draft cooling tower

Capacity=300CMH

Temperature difference=6-8 ⁰c

Inlet temp.=40⁰c

Outlet temp.=34⁰c

Evaporator An evaporator is a device used to turn the liquid form of a chemical into gas form

.The liquid is evaporate , or vaporized into gas.

TYPES:-

1.Falling film evaporator

2.Rising film evaporator

1.Falling film evaporator-

a. Single effect evaporator

b. Triple effect evaporator

A. SINGLE EFFECT EAVOPRATOR- B. SPECIFICATION:-

1.Chamber 1.capacity=12 ton

2.steam jacket 2.steam pr.=1.2-2kg/cm₂

3.Pre heater 3.batch wise production

4.Vaccum pump 4.final DS=85%

5.Steam coil

6.Steam supply

Evaporator TRIPPLE EFFECT:-

It have three evaporator stage or effect .

Energy consume by it very less compare to single effect.

COMPONENT:-

3 Calandriya

3 pre heater

3 vapor separator

1 condenser

no. of tubes =360

SPECIFICATION:-

Flow rate- TEMPRATURE:-

inlet=10m₃/hr 1 Calandriya =90-95⁰c

outlet=3.5m₃/hr 2 calandriya=70-75⁰c

Feed DS=36.3.8% 3 calandriya=50-55 ⁰c

outlet DS=70 %

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THANK YOU