A Project report

On Acalmar Oils & Fats Limited Plant Layout

B.Tech in MECHANICAL ENGINEERING Under the guidance of Prof.A.Swarna Kumari Department of Mechanical Engineering University College of Engineering Jawaharlal Nehru Technological University Kakinada 533 003

ACKNOWLEDGEMENT

We are grateful to the Human Resource Manager,Acalmar,Mr.Suraj Varma,for granting us the permission to do the mini-project work in the esteemed organization.we express our profound gratitude to the technicians for their valuable guidance and providing valuable information about the plant. With profound sense of reverence and gratitude ,we express our sincere thanks to our reverted project guide Smt.a.Swarna kumara, Associate Professor& Head of the Department ,Mechanical Engineering Dept.University college of Engineering,Kakinada for her expert guidance throughout the project work.

ABSTRACT The demand for branded edible oil in the country is growing at a galloping pace. To address this potential ,Acalmar has set up a vegetable oil processing complex at Kakinada ,a port city in the state of Andhra Pradesh. The plant is equipped with many facilities of international standards for vegetable oil processing such as hydrogenation, fractionation, Interesterification , shortening & packaging . Aadhaar & Alpha are two leading Edible oils &Fats brands manufactured by Acalmar Oils& Fats Lt. Aadhaar is currently available in two variants : Sunflower oil & Palm oil. Alpha is the brand of Vanaspati and Palmolein. Acalmar equipped with worlds finest oil technology.It uses many components such as Boilers,Filters,Compressors etc in its plant. Our report furnishes information on different mechanical components used in the plant.

Acalmar Oils & Fats Limited, is a joint venture between the Singapore based Acalpo Pvt Ltd and Wilmar International Limited, Singapore. Wilmar is one of the world largest groups of companies dealing in Palm Oil products. Acalmar has its head office at Hyderabad, Andhra Pradesh, India and has a team of professionals bringing varied experience and expertise. In the year 2002, Acalmar has set up a vegetable oil processing complex at Kakinada, a port city in the state of Andhra Pradesh. This vegetable oil processing complex has three refineries with combined capacity of 900 MTs per day, supplied by Desmet Ballestra, Belgium who is the leaders in the world for edible oil processing technology. In addition to the refineries, this vegetable oil processing complex has the state of art facilities, such as fractionation, interesterification, hydrogenation, shortening & packaging to meet the demands of various categories of customers. Acalmar is process driven with excellent R & D facilities and has an obsession for perfection. High quality control, hygiene & safety standards and strong ethics are the hallmarks of the organization.

CONTENTS:

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Introduction Refining Process Mechanical Components a. Boilers b. Valves c. Pumps

Heat Exchangers a. Purpose and Classification of Heat Exchangers b. Drafting system

Conclusion

INTRODUCTION

The fundamental task of a Plant is to convert crude oil to palm oil through a series of refinements, untouched by the human hand. Palm oil is obtained from the flesh ("mesocarp") of the oil palm fruit. Like olive oil, palm oil is a fruit oil.The primary stages of production are refining, fractionation, hydrogenation, interesterification, shortening, & packing. Palm oil is semi-solid at room temperature (20C). The liquid portion could be physically separated from the solid portion of palm oil by fractionation. After fractionation the liquid portion is called "palm olein", which is commonly bottled and sold as cooking oils. The solid fat portion is called "palm stearin" and it is commonly used to formulate trans-free fats such as margarine, shortening and vegetable ghee. Sometimes the palm olein is further fractionated to a more liquid fraction called "super palm olein". This oil fraction could withstand colder temperature than palm olein before they cloud or solidify. In this process steam is obtained using boilers, and other mechanical components play their respective role.

Physical Refinery Process Description: The raw material which is used by physical plant is crude palm oil (CPO) from the CPO storage tank. CPO is feed at the flow rate about 35-60 tons/hour. The initial temperature of CPO is at 40 60C. The feed is pumped through the heat recovery system, that is plate heat exchanger to increase the temperature around 60 90C. After that, there is about 20% of the CPO feed to into the slurry and mix with the bleaching earth (6 12kg/ton CPO) to form slurry (CPO + Bleaching earth). The agitator inside the slurry tank will mixed the CPO and bleaching earth completely. Then, the slurry will go into the bleacher. At the same time, another 80% of the CPO is pumped through another plate heat exchanger (PHE) and steam heater to increase the CPO temperature to 90 130C (it is a desired temperature for the reaction between CPO and phosphoric acid). Then, the CPO feed is pumped to static mixers and the phosphoric acid is dosed at 0.35 0.45 kg/ton. Inside there, the intensive mixing is carried out with the crude oil for precipitation up the gums. The precipitation of gums will ease the later filtration process, avoid the scale formation in deodorizer and heating surface. The degumming CPO then will go into bleacher. In the bleacher, there are 20% slurry and 80% degummed CPO will mix together and the bleaching process occur. The practice of bleaching involves the addition of bleaching earth to remove any undesirable impurities (all pigments, trace metals, oxidation products) from CPO and this improves the initial taste, final flavor and oxidative stability of product. It also helps to overcome problems in subsequent processing by adsorption of soap traces, pro-oxidant metal ions, decomposes peroxides, colour reduction, and adsorbs other minor impurities. The temperature inside the bleacher must be around 100C 130C to get the optimum bleaching process for 30 minutes of bleaching period. The low pressure steam is purged into bleacher to agitate the concentrated slurry for a better bleaching condition. The slurry containing the oil and bleaching earth is then passed through the Niagara filter to give a clean, free from bleaching earth particles oil. The temperature must be maintain at around 80 120C for good filtration process. In the Niagara filter, the slurry passes through the filter leaves and the bleaching earth is trapped on the filter leaves. Actually, the bleaching earth must be clear from Niagara filter after45minutes in operation to get a good filtration. Bleached palm oil (BPO) from Niagara filter is then pumped into buffer tank as a temporary storage before further processing. Usually, a second check filter, trap filter is used in series with the Niagara filter to double ensure that no bleaching earth slips occur. The presence of bleaching earth fouls deodorizer, reduces the oxidative stability of the product oil and acts as a catalyst for dimerizaition and

polymerization activities. So, the blue test is carried out for each batch of filtration to ensure the perfect filtration process. This test indicates whether any leaking is occurring in Niagara filter or trap filter. Hence, any corrective actions can be taken intermediately. The BPO comes out from the filter and passes through another series of heat recovery system, Schmidt plate heat exchanger and spiral (thermal oil: 250 305C) heat exchanger to heat up the BPO from 80 120C until 210 250C. The hot BPO from spiral heat exchanger then proceeds to the next stage where the free fatty acid content and the color are further reduced and more important, it is deodorized to produce a product which is stable and bland in flavor. In the pre-stripping and deodorizing column, deacidification and deodorization process happen concurently. Deodorization is a high temperature, high vacuum and steam distillation process. A deodorizer operates in the following manner: (1) dearates the oil, (2) heat up the oil, (3) steam strips the oil and (4)cools the oil before it leaves the system. All materials if contact are stainless steel. In the column, the oil is generally heated to approximately 240 280C under vacuum. A vacuum of less than 10 torr is usually maintained by the use of ejectors and boosters. Heat bleaching of the oil occurs at this temperature through the thermal destruction of the carotenoid pigments. The use of direct steam ensures readily removal of residue free fatty acids, aldehydes and ketones which are responsible for unacceptable odor and flavors. The lower molecular weight of vaporized fatty acids rises up the column and pulls out by the vacuum system. The fatty acid vapor leaving the deodorizer are condensed and collected in the fatty acid condenser as fatty acid. The fatty acids then is cooled in the fatty acid cooler and discharged to the fatty acid storage tank with temperature around 60 80C as palm fatty acid distillate (PFAD), a byproduct from refinery process. The bottom product of the pre-stripper and deodorizer is Refined, Bleached, Deodorized Palm Oil (RBDPO). The hot RBDPO (250 280C) is pumped through Schmidt PHE to transfer its heat to incoming BPO with lower temperature. Then, it passes through another trap filters to have the final oil polishing (120 140C) to prevent the earth traces from reaching the product tank. After that, the RBDPO will pass through the RBDPO cooler and plate heat exchanger to transfer the heat to the CPO feed. The RBDPO then is pumped to the storage with temperature 50 80C. Palm Fatty Acid Distillation Plant: The separation of liquid mixture into their several components is one of the major process of the chemical industries, and distillation is the most widely used method of achieving this end: it is the key operation of the oil refinery. Though out the chemical industry the demand for pure

products, coupled with a relentless pursuit of greater efficiency, has necessitated continued research into techniques of distillation. The distillation column is used in this purpose. The distillation column which have to be designed with a larger range in capacity than any other types of chemical engineering equipment, with single columns from 0.3 to 10m in diameter and from 3m to upwards of 75m in height. The purpose of designing is to achieve the desired product quality at minimum cost, but also to provide constant purity of product even though there may be some variation in feed composition. The vertical cylindrical column provides in a compact form, with the minimum of ground utilization, a large number of separate stages of vaporization and condensation. In practice, distillation may be carried out by either of two principal methods. The first method is based on the production of a vapor by boiling the liquid mixture to be separated and condensing the vapors without allowing any liquid to return to the still. There is then no reflux. The second method is based on the return of part of condensate to the still under such condition that this returning liquid is brought into intimate contact with the vapor on their way to the condenser. Either of these methods may be conducted as a continuous process or as a batch process. Mechanical Components: In an oil refinery the use of mechanical components like boilers , pumps, condensers etc is of utmost importance .Various Mechanical components used are 1.Boilers : For the production of steam to heat the crude oil to separate Free Fatty acids 2.Condensers: To cool the oil to a temperature at which it remains stable. 3.Pumps: Pumps are used to pump high pressurized oil for cooling. Generally Vertical Multistage centrifugal pumps are used owing to their high performance and maximized delivery pressure. 4.Valves : These are helpful in maintaining the adequate supply of crude oil. 5.Drafting Systems: Used to force the exhaust gases.

Boilers: A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications. The pressure vessel in a boiler is usually made of steel (or alloy steel), or historically of wrought iron. Stainless steel is virtually prohibited (by the ASME Boiler Code) for use in wetted parts of

modern boilers, but is used often in superheater sections that will not be exposed to liquid boiler water There are two types of boilers used in the plant : 1) Combipac Boiler 2) FBC Boiler

Combipac Boiler :
Model : CPFD 60/10.54 & 17.54 kg/cm^2

Combipac is an ideal alternative to expensive oil fired boilers.It enables large savings on fuel bills through the use of low cost agro waste, and other solid fuels,that are abundantly and easily available in India.

Salient Features: y y y y y Hybrid design of smoke and water tube. External furnace and four-side membrane panel,with cycloidal air injection. Capacity -2 to 10TPH. Fuel Indian and Imported coal,Lignite,Bagasse,Groundnut shell,Paddy Husk,wood,saw dust etc Fuel firing Manual\Automatic.

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Standard design pressure 10.54 and 17.54 kg\cm . Air pre heater an Integral part of boiler. A unique 4 side water wall provides advantages like Reduced refractory,Higher heat transfer area in radiation zone,lower flue gas entry temperature to shell

Types of Furnaces:

Boiler mountings Boilers are equipped with two categories of components: boiler mountings and boiler accessories. Boiler mountings are the machine components that are mounted over the body of the boiler itself for the safety of the boiler and for complete control of the process of steam generation. Various boiler mountings are as under: 1)Pressure gauge. 2)Fusible plug. 3)Steam stop valve 4)Feed check valve 5)Blow off cock 6)Man and mud holes.

1.Pressure gauge: Function:To record the steam pressure at which the steam is generated in the boiler. 2.Fusible plug: Function: To extinguish fire in the event of water level in the boiler shell falling below a certain specified limit. 3.Steam stop valve A valve is a device that regulates the flow of a fluid (gases, fluidized solids, slurries, or liquids) by opening, closing, or partially obstructing various passageways Function: to shut off or regulate the flow of steam from the boiler to the steam pipe or steam from the steam pipe to the engine. When the hand wheel is turned, the spindle which is screwed through the nut is raised or lowered depending upon the sense of rotation of wheel. The passage for flow of steam is set on opening of the valve. 4.Feed check valve: i) To allow the feed water to pass into the boiler. ii) To prevent the back flow of water from the boiler in the event of the failure of the feed pump. 5.Blow off cock. Function: To drain out the water from the boiler for internal cleaning, inspection or other purposes. 6.Man and mud holes: To allow men to enter inside the boiler for inspection and repair.

Boiler accessories
Boiler accessories are those components which are installed either inside or outside the boiler to increase the efficiency of the plant and to help in the proper workingoftheplant. Various boiler accessories are: 1)Air Preheater 2)Economizer 3)Superheater 1.Air preheater: Waste heat recovery device in which the air to on its way to the furnace is heated utilizing the heat of exhaust gases 2.Economiser: Function: To recover some of the heat being carried over by exhaust gases (This heat is used to raise the temperature of feed water supplied to the boiler. 3. Superheater : To superheat the steam generated by boiler Super heaters are heat exchangers in which heat is transferred to the saturated steam to increase its temperature.

Valves
A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, but are. In an open valve, fluid flows in a direction from higher pressure to lower pressure. Valves are used in a variety of contexts, including industrial, military, commercial, residential, and transport. The industries in which the majority of valves are used are oil and gas, power generation, mining, water reticulation, sewerage and chemical manufacturing

Types: 1) Gate Valve:

A gate valve is a linear motion valve used to start or stop fluid flow; however, it does not regulate or throttle flow. The name gate is derived from the appearance of the disk in the flow stream. The disk of a gate valve is completely removed from the flow stream when the valve is fully open. This characteristic offers virtually no resistance to flow when the valve is open. Hence, there is little pressure drop across an open gate valve. When the valve is fully closed, a disk-to-seal ring contact surface exists for 360, and good sealing is provided. With the proper mating of a disk to the seal ring, very little or no leakage occurs across the disk when the gate valve is closed.

GATE VALVE

Non return valve:

Check valves, or non-return valves, are installed in pipeline systems to allow flow in one direction only. They are operated entirely by reaction to the line fluid and therefore do not require any external actuation. In this text, the expected, or desired direction of flow is termed 'forward flow', flow in the opposite direction is 'reverse flow'.

There are a number of reasons for using check valves, which include:
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Protection of any item of equipment that can be affected by reverse flow, such as flowmeters, strainers and control valves. To check the pressure surges associated with hydraulic forces, for example, waterhammer. These hydraulic forces can cause a wave of pressure to run up and down pipework until the energy is dissipated. Prevention of flooding. Prevention of reverse flow on system shutdown. Prevention of flow under gravity. Relief of vacuum conditions.

Pumps:
A pump is a device used to move fluids, such as liquids, gases or slurries.A pump displaces a volume by physical or mechanical action. Pumps fall into three major groups: direct lift, displacement, and gravity pumps. Their names describe the method for moving a fluid.

Three-Spindle screw pumps are used for transport of viscous fluids with lubricating properties. They are suited for a variety of applications such as fuel-injection, oil burners, boosting, hydraulics, fuel, lubrication, circulating, and feed and so on. Advantages: y y y The pumped fluid is moves axially without turbulence which eliminates foaming that would otherwise occur in viscous fluids. They are also able to pump fluids of higher viscosity without losing flow rate. Changes in the pressure difference have little impact on PD pumps compared to centrifugal pumps

Centrifugal pumps:

Many hydraulic systems employ centrifugal pumps to move fluid through a piping system. These pumps all rely on centrifugal force as the fundamental principle by which they operate. Centrifugal force affects an object or material moving in a circular pattern by causing it to pull away from the central axis or center point of the path along which it travels. This force can be used to regulate the pressure and motion within a pumping unit, and when applied in combination with a number of other centrifugal pumping principles, forms an integral part of hydraulic mechanisms. Generally, a centrifugal pump is based around a casing filled with fluid, usually water. A special unit within the casing exerts fast rotary motion that causes the water to spin, generating centrifugal force that channels it through a discharge outlet. Discharged water creates a vacuum for atmospheric pressure to force more water out of the casing. It is a continuous process,

dependant mostly on continued rotary motion and a constant supply of water. Most centrifugal pumps rely on rotating impellers or vanes to provide rotary motion, though the design and implementation of these systems can vary according to capacity and project requirements.