Presentation

on
Learning Exposure

Oct – Dec 2019

Name of Trainee(s) : Devilal Prajapat (30022619)

Abhishek Pratap Singh(30022613)
Vikram Singh Kitawat (30022618)
Location Name: AWL Bundi
Major Area’s Covered During Training Period

Safety
Commercial
Crushing (oil mill & Chillex)
Soya prep
SEP
Refinery, Acid oil, lecithin
ETP
Quality Assurance
Packaging & warehouses
Utilities(RO, Boiler)
E&I
Maintenance
SAFETY
• Fire-hydrant system
 Safety policies:
Line pressure: 7 kg/cm²
EHS, safety disciplinary, minimum PPE, policy
Jockey pump: 6 kg/cm²
Plant safety rules
Main pump: 5.5 kg/cm²
HRW Standards AND COMPLIANCE
• Fire extinguisher (A,B,C,BC, ABC)
 PERMITS TO WORK SYSTEM
• Enablon (Incident reporting portal)
Height work, Hot work, Confined space Energy
isolation(LOTO) • 5W1H system
• Risk management: • 3 Assembly point
Job safety and environment analysis • Multi purpose gas detector:
Step1. Identify hazards LEL, H2S,CO, O2
Step2. Assess risks
Step3. Control risks
Step4. Review control measure
 Hierarchy of control:
Elimination Most effective
Substitution
Engineering control
Administration
PPE Less effective
 Risk reduction(ALARP)
 Emergency management system (EMS)
COMMERCIAL

 Inward and outward operations of process.

 Production planning and control:
Stock, Inhouse availability, Bargain pending, Shortage and excess.
(Planning, Routing, Dispatching)
 Logistics:
o Warehouse, Transportation, Dispatch
o Daily stock reporting
o Bidding process for vehicle placement
o Rate negotiation
o FOR and Ex-factory delivery (in terms of freight)
o Vehicle planning according to sale order
o Rack loading
o Dispatch process
 Inventory management
Scrap handling
ABC analysis.
 OIL MILL
 Capacity: 400 TPD
Mustard seed unloading
 36 expellers: Gurutech:
Seed cleaner P Roy:
 Feed seed in kolhu: 22-25kg for 45
Silo 2500 MT*2 min
Day bean 400MT*2  RPM
 Water addition: 5-6%
Flaker*2
 Motor: p HP

Storage*3
 Quality parameter:
seed: Oil:
Kolhu 594
O/C: 40% FFA: 0.5%
FM: ≤ % Colour:
1st press Oil tank 1st +2nd press
M/C: % M&V: 0.27-0.33%
Allyl: 0.23-0.27%
2nd press Filter 3rd press
press
MOC:
O/C:9.5-10%, M/C:%,
3rd press
Storage FFA-%, Thickness:8mm
Dry cooler
tank Milling defect: 1.3%
SEP
 CHILLEX
 Capacity:100 TPD

Day Bean  17 chillex m/c:

9 m/c- ”, 8m/c-
 Chamber size: 11” & 12”
Water Humidifier Tank
agitation  Worm : no.
 Motor: KW
1st press
Decanter  Water addition: % (°C)
 Jacket water: °C
2nd Press
Filter  Humidifier: compartment 6
Press
RPM
3rd Press
 Parameter:
Micro Oil : FFA:
4th Press filter
Colour: l
M&V:
5th Press
Final Allyl: %
storage
6th press Sediment: NIL
Myrocinase
Singrin Allyl iso-thiocynate
To SEP 5-6% H2O
30-35 °C
 Material balance:  Costing:
oil content:%, FM: %
moisture: % Parameter Chillex Oil mill
Total seed: 1 MT Power Consp. kwh kwh
(FM: kg, m/c: kg, o/c: kg) Unit rs 8.95 8.95
Dry seed: kg Total 927.01rs/mt 692.6rs/mt
1. KGMO/expellers oil: kg Steam Consp. - mt/mt
moisture in oil: kg Unit rs - 1535 rs/mt
net KGMO oil: kg Total - 107.4rs/mt
recovery: % loss: % Soft Consp. kl/mt kl/mt
water
2. MOC production: kg (%) Unit rs 31.13 rs/kl 31.13 rs/kl
moisture: kg Total rs/mt rs/mt
oil in cake: ) Operating 244.73rs/mt 391 rs/mt
expenses
FM in cake:kg
Total VC1 1174rs/mt 1194rs/mt
Dry cake: kg
Total VC2 349.54rs/mt 178.6 rs/mt
3. Total oil recovered: kg
Fixed cost 12.26 rs/mt 12.26rs/mt
over all yield: %
Total cost/MT
SOYA PREP
Seed unloading Cyclone

Seed pre-cleaning Hull screener(4.5 & A Aspirator

(10mm & 1.5mm) 1.5 mm) s
pi
ra Flaker*7
Silos 10000MT*3
Hull grinder (44 to 1300*600mm
hammer) r
Day bean 1000 MT
Expander (11-14%)
90-95ºC
Seed cleaner*2
Beg filter
(9mm&1.5mm)
Dryer cooler(8-
Aspirator (8mbar ) Hull silo 140 MT*2 9.5%)

Destoner*3
To SEP 45ºC
B
e Grader(8mm & 6mm)
g
fi
l Aspirator hull Cooker (60-70ºC)
t Cracker*2 (2mm gap)
separator RT-20-25 min
e
r
124 bag
e

Dust
MUSTARD SEP

Extractor DT Dry cooler Final DOC

Fine separator
Dust Safety
Intermediate miscella catcher boiler
tank (55-60ºC)

Heat exchanger Final oil tank(55ºC)

Economiser

Econflasher 250mmhg

1st heater 80ºC Condenser 1

1st Flasher 320 mmhg

Hexane
To
Condenser 2 water
2nd heater 95ºC extractor
separator

2nd Flasher 400mmhg

Condenser 3
3rd heater 105ºC

Stripper 530mmhg
Recuperation unit
VD 700mmhg,108ºC
SEP PARAMETERS
 Costing:
 Material balance:
Cake: Parameter SEP MUSTARD
O/C: 9.83%, M/C: 9.34%, FM: 1.18% Power Consp. 19.51kwh
DOC: ROC: 1.2%, M/C: 10.39%, S/S:0.37%, FM: Unit rs 8.95
0.92%
Total 174.53rs/mt
Total cake: 1 MT Steam Consp. 0.25 mt/mt
Moisture: 93.4kg, oil: 98.3kg, FM: 11.8kg Unit rs 1598 rs/mt
Dry cake: 796.5kg Total 398.42 rs/mt
Net DOC processed: 911.2kg (91.12%) Soft Consp. 0.26kl/mt
Moisture:94.67kg oil: 12kg, FM: 9.2 kg, cooling
Unit rs 48.68 rs/kl
water
S/S: 3.7 kg Total 12.69 rs/mt
Dry DOC: 791.63kg Chemical Consp. 4.1 lt/mt
Gross oil production: 87.2kg Unit rs 52.93 rs/lt
MIV: 1.64 kg Total 216.78 rs/mt
Net oil production: 85.6kg Operating exp. 182.83 rs/mt

Oil recovery: 8.56% Total VC1 985.26 rs/mt

Total recovery: 99.6% Total VC2 138.79 rs/mt

Fixed cost 12.26 rs/mt
Total cost/MT 1136.30 rs
LECITHIN
• Water degumming: • Drying process:

Solvent soya oil Soya Gums

(6.85 TPH)
Reactor 1&2( 2.5 MT)
Shell & tube 70-80ºC RT-5-6hr
(60-65 °C)
Water First stage heater Evaporator 1(700-
(90-
95ºC)&
(90-110 ºC) 710 mmHg)
90 LPH Static mixer
Evaporator 2 (700- Second stage heater
Hydration tank 710 mmHg) (90-110 ºC)
RT:25-30 min

Roto-screw pump Micro filter 50,25 micron

Magnetic strainer Cooler (55-60 ºC)

Centrifugal Separator Lecithin Storage Tank,3*50 MT

Magnetic strainer
Wet Gums Degummed oil
Micro filter 25 micron
To drying To storage
process Barrel filling (200 kg and 1 MT)
LECITHIN PARAMETER

Parameter Degummed oil Solvent

oil
FFA 0. 4- 0.9 0.7
MV 0.5 0.3
Sediments 0.1 % 0.05
Parameter Lecithin Gums
P-content 140-170 PPM 850-1000
M/C 0.5 % max 30-35%

AIS 62-65% 63-65%

HIS 0.3% max - • Total consumption:

Power cost: (106kwh) 862rs/MT

PV 0.24 - Steam cost: (1.027MT) 1668 rs/MT
COLOUR 11+ - Soft cooling water:(2.7KL) 113rs/MT
Total cost: 2500-2600 rs/MT
VISCOSITY 6000-15000 cp -
 REFINERY
DSBO Tank T=35 -
45ºC Knife Slurry
Soap off
mixture mixer
Plant DSBO tank

Separator
PHE (60-65ºC)
2
H
3
P Knife mixture VD(660-670mmhg) Candle filter 5
O micron
4
Retention tank30-35mi NOT
BOT(100-110ºC)
PHE (50-55 ºC) PHE(95-100ºC)
C
a Candle filter
Bleachin
u
Knife mixture g earth Slurry mixer
s
ti
Dearator
c
Caustic RT() Bleacher (105-
115ºC), 600-
Deo section
Shell&tube80-85ºC 700mmhg

Separator 1(BP: 1.8 PLF*3(15 leaf)

kg/cm²)

PHE (90-95ºC)
 From dearator  Capacity: 200 TPD (Soya)
105ºC
100 TPD (Mustard)
To VHE  Oil processed in 200 TPD
PHE 224ºC
Solvent soya oil & degummed soya oil
VHF
 Parameters:
Steam(260 252ºC
-270ºC) at
48- Deo stripper Para. Crude Neutr Bleach Refine
60kg/cm² oil al ed d oil
Deo tray
248ºC
Oil Oil
FFA 0 0 0
4 Stage
Fatty scrubber
vacuum s/s
51ºC Colour -
Cooling PHE

48ºC
P-
content
To fatty storage

Soap - -
ppm
Refinery calculation

 Losses in Soya Refining:  Material balance:

 CDSBO FFA=0.873%, Neutral oil FFA=0.129%, FFA=%, MIV=%
Bleached oil FFA=0.162%,Refined oil FFA=0. P-content=
042% , MIV=0.1%, Soap stock FFA=50%, DFA
FFA=59.45% , P-content=0.538% Yield: Net oil produced=%
 Neutralization loss =100/FFA(Crude oil FFA Oil loss=%
-Neutral oil FFA)+(Gums) Total by product recovery=%
=100/50(0.873-0.129)+(0.538) Acid oil=%
=2.0269% Sludge=%
 Bleaching loss FAD=%
 = % of (B.E.+ soap off + filter aid) used*oil c Unaccounted loss=%
ontent in B.E.+ 0.1
 Consumption:
= (1+0.05)*0.2+0.1=0.31%
Steam:kg/MT
 Deodorization loss
Power: kwh/MT
=100/FFA(Bleached oil FFA-Ref oil FFA)+E Soft cooling water: KL/MT
ntrapment loss
Bleaching earth: kg/MT
=100/59.45(0.162-0.042)+0.05 =0.251%
H3PO4: kg/MT
 Total loss =%
Citric acid: kg/MT
Caustic lye: kg/MT
Soap off: kg/MT
ACID OIL PLANT

 Parameter:
Soap stock from
refinery Parameter Soya Mustard

TFM 42.6% 21.3%

FFA 50.2% 46.5%

Reactor
H2SO4 2*8MT Steam Acid oil recovery 35.6% 23.6%
2*10MT

 Costing and consumption:

Oil Sludge Acid
trap tank oil Para. Soya Mustard

Steam 0.44*1598=7 0.43*1598=69

• Process time:6-7 hr 03rs/mt 0.9rs/mt
• Temperature: 80-85ºC Power 4.9*8.95= 4.7*8.95=
• Steam temp: 150-180ºC at 3kg/cm² 43.9rs/mt 42.6rs/mt
• Batch: 6 MT(Mustard)
Chemical 0.21*6838=1 0.24*6838=
7-8 MT(Soya)
495 rs/mt 1651 rs/mt
• Reaction:
2RCOONa+H2SO4 2RCOOH+Na2SO4 other 2312 rs 92.5 rs
Total 4554 rs/mt 2477 rs/mt
cost/MT
 ETP
 Capacity: 300 KLPD

Influent water  Daily waste treated: 40-50 KL

from process  Total cost / MT: 700 RS/MT
 Quality Parameter:
Oil trap
Para. In Aeration Out
Equalisation tank tank
TS 10872- 2382-12454 1041-
Lime,
42959 9091
poly, Dosing tank
alum TDS 10081- 2222-12254 939-8959
Filter 41133
Primary settling tank press
Cl 460-518 - 150-175

Aeration tank*6 O/G 795-1036 - 10-16

Secondary settling tank COD 8939- 196-291

Sludge circ 11676
MLSS 23700-
&MLVSS 38160&
Sand filter 14450-19470

Carbon filter PH - - 8-8.2

Final storage tank

QUALITY ASSURANCE

SEED OIL DOC LECITHIN PACKAGING WATER COAL

Oil color, FFA, Moisture, Acid Dimension, pH, GCV,

content, Allyl, oil- Value, Thickness, TDS, TSS, Moisture,
Moisture Break-test content, Color, Drop Test, TH, Ash
Foreign Moisture, PV, protein, HIS, Overflow Phosphate, content
material SV, fibre, Moisture, Capacity, sulfite, Unburned
Odour IV, sand- AIS, Closure turbidity, carbon.
Small, RI@400C, silica. Viscosity Leakage chloride,
Damage, BTT, TBHQ, Flame test. Test, Conductivi
green shelf life, Weight, ty
(soya) vitamins, P- Stack Load, COD,
seed content Product MLSS,
Fungus GC test, etc. Resistance, MLVSS
Visual
Inspection,
Fitment
Accessories
GSM etc.
PACKAGING & WAREHOUSE

 Capacity: Packaging: 300 TPD (Mustard) & 200 TPD (SOYA)

Warehouse: 800 T (Mustard) & 550 T (SOYA)
Dispatch : 450 TPD
 Filling section:
VARIANTS PRODUCT CAPACITY

TIN 15 ltr/kg 12000 tin/12hr

15 5 jar/min (2 nozzle)
SOYABEAN JAR
(ADPRO) 5 8 jar/min (5 nozzle)
2 12 jar/min (5 nozzle)
POUCH 2* Setpack= 36ppm
1* Samarpan= 36ppm

200ml 3265 BPH

PET

MUSTARD 1 ltr 4800 BPH

POUCH 3* Samarpan= 120
1* Setpack= 18
JAR/BURNI 2 & 5 lt. =6 burni/min
=10/14 jar/min
TIN PLANT
Tin sheet  Capacity-12000 Tin/12 hr
Slitting cutter  Dimensions:
Body-0.27*885*650mm
Body part Top and bottom part Bottom-0.28*1020*764mm
Bottom press Manual and auto
 Yield- 1 ton= 981.25 kg(1105
folding tins)+18.75 kg (scrap)
Solution m/c  JSW tinplate and TATA steel.
Side Seamer
 Leakage test-0.8 TO 1.5Kg/c
oven 110 °C Stretch Forming m2
 Cost per tin= 70 RS
Flanging m/c
Gala press and
flanging
Seamer for top and
Spot welding for bottom sealing
chapadi &
handle on top Leakage test &
part dryer

Capping & storage

 JAR MOULDING
 Capacity: 2/5 Ltr- 6000 jar/day
Batch mixing
15 Ltr - 1500 jar/day
Hopper  Total 4 Jag Mohan m/c
 Batch: 64%HDPE+ 2% master batch+34 regrind
Extruder (screw rotation)  HPL haldia and GAIL
 MFI: 0.4 gm/10 min and 0.35 gm/10 min
Accumulator
 Temperature: 175-190ºC
Blowing : 6-7 kg/cm²
Regrind

Parison formation 
 Total heating 8 zone
Mould blowing  Parameters:

Cooling Jar Cap+Jar Pinch Thickness Cost

off
Finishing 2 ltr 6+110 gm 1 mm 14 rs
5 ltr 6+210 gm 90 gm 1 mm 22 rs
Weight check & cap fitting
15 ltr 18+(535- 272 gm 1 mm 54 rs
Final storage 540) gm
PET Blowing Process

Preform hopper  Capacity: 200 ml(3300 BPH)

500 ml,1ltr(5200 BPH)
Distributed on roller conveyer  M/C type: SR1/2 NOVA & SR2/4 N series
 Cycle time: 2.2 sec (200ml)

Heating unit
3 sec (1 ltr)
 IR lamp: 1500 watt
Clamping and stretching  Heating Temp: 90-110ºC
 Parameters:
Pre blow(6-8 kg/cm²) and final
blow (35-40 kg/cm²)
Type Weight Cost
(RS/Nos.)
Cooling (8-10ºC at 4 kg/cm²)
and ejection 200 ml 11 g 1.39
500 ml 14.5,16.5 g 1.70, 1.99
Oil filling and capping
1 ltr. 19.5, 24 g 2.36, 2.81
Final labelling and storage
WATER TREATMENT PLANT
 Chemical:
Raw water storage HCL, PC191T, PC-98, N- 8130,NaCl
 Total water cost:
Sand filter and softener
Typ RO Soft Soft Soft cooling
Row water storage for RO e water cooling water
water solvent
DMF refinery
Cost 78RS 31 RS 47 RS 47 RS
MCF*4 (0.5 micron)  Quality parameter:

HPM 38.5 m³/hr. Parameter Raw Soft RO Feed

water water water water
ROmembrane3:1(0.0001) PH 7-8 7-8 6-7 8-8.5
TH 500-600 20-25 0-5 Nil
Permeate 75% Reject 25%
TDS 1000 1000 20-25 25-30
COND 1700- 1600- 30-40 40-45
RO storage
1800 1700
tank

Degasser

Softener DM tank
 BOILERS
Specification:
Capacity: Thermax: 22TPH and CVL: 8TP Boilers Capacit Heating W.P.
y S. area (kg/cm2)
H
Thermax TPH
Steam to coal ratio: 6.25
CVL H
Material of construction: High carbon al
loy steel. Thermosy
phon
Size of bed material: 2-4 mm. Thermosy lakh
Size of feed coal: up to 6 mm. phon (oil) kcal
Parameter Coal Ash
Coal Yard Capacity: 1500 MT for 22 TP specifications specification
H and 300 MT for 8 TPH. GCV kcal/kg Kcal/kg

Imported coal is used.

Ash content %
Bed capacity for 22 TPH : A- 12 ton & B
Moisture % %
-10 ton content
FD Fan: 450 MMWC and PA Fan: 800 M Unburn %
MWC 22 TPH 8 TPH
Air nozzles
Condensate recovery: 21-23%
Coal nozzles
Blow down losses: 1.2% B.D. at TDS of 3
000 Bed coils

Thermic fluid : Therminol-66 Efficiency

 22 TPH Cost:

Cost Consump Rs./Unit Total (Rs.)

RO storage tank
tion/MT

Deaerator(105°C) Power 14.72 8.95 131.71

Water 0.77 100.76 77.9

F
Boiler Drum
u Charcoal 0.000346 23500 8.14
Coal r F
n Boiler Tubes l
a u Coal 0.16 7137.29 1141.96
c e
e Steam drum Bed 0.000085 5199.95 0.44
material

PA APH FD Nalco 0.00831 352.34 2.93

2556
Bag filter(88 Cyclone
bags (48/4”)) separator Nalco 0.006 154.06 0.93
22341
ID Fan
Nalco 0.0223 123.27 2.75
2548
Chimney(120-130°C)
Other cost 169.62

Total steam cost 1536.38

E&I AND MAINTENANCE
E&I: Maintenance:
Total sanctioned load: 5000 KVA Preventive, corrective, emergency, CBM, others.

High tension line:33KV Lathe, Drill, Shaper, Surface grinder, bench grinder.

low tension line: 433 V Tools: Pliers, screwdriver, wrench, spanner, hamme
rs, files, hacksaw, allen key, vernier callipers, etc.
Transformer: (3000, 2*2500, 1600)KVA
Lubricants, oils are used for hydraulics, pumps ,ge
Make: ABB, CG power ar box, etc.
DG: 2*500KVA(auto), 3*380KVA (manual) Arc and TIG welding are incorporated.
Made by: Sudhir( Gen:Kirloskar, Stamford PM module is followed for the maintenance.
engine: Cummins) Mechanical:
PCC & MCC panel Chiller: Prasad GWK=8(TR= 9.7,7,28.5,25.7)
VCB(4), ACB, CT, PT cooling refrigerant= R22
Solar plant: 540KW Daiken= 9.7 TR
Total panel: 1680 panel (1 panel=320 w) Compressors:
72 cell=1 panel Kaiser, Ingersoll Rand(294 CFM),
Instrument: PT,TT, Actuator, control valve AF compressor(132 CFM)
vaccum transmitter LT, etc.
PLC, SCADA (Siemens, GE)
TEST: ELCB, IR, megger, earth resistance
Suggestions & Action taken

 In the mustard pouch packaging line the weight rejecter m/c design can be modified b
ecause of it the carton gets damaged.
 In the 1lt pet bottle line at the case sealing section the time delay providing between t
wo carton can be increased due to which the carton can’t get damaged.
 In the boiler section the ash which is collected at the bottom of APH, Cyclone and Beg
filter can be collected by pneumatic system by which it can be collected at the ash silo
for easy handling of ash.
 In various plant units the stair toe guard is missing in almost every staircase which is ha
zardous in terms of safety and can cause tripping to the person. And hence they shall
be installed at all the required stairs.
 Food safety needs to be improved in oil mill oil runway (nali) should be properly cover
ed. Pots being used to pour water into kolhu shouldn't be made of plastic.
 Underground oil storage tanks shall have a secondary closing beneath the primary do
or and it should be of wire mesh with a small opening provided for dipping. It will ensu
re that not any larger foreign material gets into the oil tank during the opening of prim
ary doors.
 Some instrument like pressure and temperature gouges not working in mustard SEP T
hey should be replaced so that process become more accurate.
 In the oil mill the plastic jar should be avoided for putting water in kohlu, Instead of thi
s SS material bucket should be used.
Facilitating factors
Support from plant team.
Daily meetings.
Various training sessions happening in the plant.

Hindrances (if any)

Canteen food quality can be improved.
Some learning hindrances during plant exploration.