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INDUSTRIAL TRAINING REPORT
PERERA P.O.
EN11ME2049
DEPARTMENT OF MECHATRONICS ENGINEERING
FACULTY OF ENGINEERING
SOUTH ASIAN INSTITUTE OF TECHNOLOGY AND MEDICINE
SRI LANKA
INDUSTRIAL TRAINIG REPORT
TRAINEE
NAME : PERERA P.O.
STUDENT ID : EN11ME2049
TRAINING ORGANIZATION
NAME : SUNTEL PVT (LTD)
BRANCH/DFEPARTMENT : NETWORK MAINTENNANCE AND PLANING
SUPERVISING OFFICER :
PERIOD OF TRAINING : FROM 01.01.2012 TO XX.XX.2012
TRAINING DURATION : 12 WEEKS
FIELD OF TRAINING : ELECTRONIC ENGINEERING
The Ceylon Brewery Limited
Is there a LION in YOU…..?
ACKNOWLEDGEMENTS
Since it was my first hand industrial and professional experience as a trainee engineer, it has been a great privileged for
me to be a part of the Lions brewery for the last 12 weeks. And the knowledge that I gained at the Lions brewery is
immense.
The most importantly I should note here that the friendly environment made me very ease to adjust to the first
industrial exposure. Otherwise it would have been a dilemma for me to get entangled with such very well experienced
and knowledgeable echelons in the industry. But I was lucky enough to learn more than I ever expected before the
starting of the endeavor.
And, specially, I would like to forward my heartiest acknowledgement to the entire Lions Brewery family. Specifically
Chief executive officer Mr. Shah, Chief Engineer Mr. Hiran, Channel Development manager Mr. Chaminda, HR Executive
Ms. Anusha who arranged me a such a valuable training program.
In other hand the Assistant Chief Engineer Mr. Chandana, Electrical Engineer Mr. Widhura, Instrumentation Executive
Mr. Senadheera and the entire factory echelons for teaching me each and every process and instruments of the factory,
precisely. And it is very important to mention here, even they were busy with their jobs, always they had spare time for
the trainees to answer at all our questions.
And it is not fair to forget the other trainees, who were trained at the Lions Brewery, who shared their valuable
knowledge with me.
Thank you very much…!!!
ABSTRACT
It was a great experience to gain my first industrial experience in Lions Brewery PLC, Sri Lanka, from 21 st May 2012 to 29th June 2012, as it is the main beer company in the Sri Lanka. And its beer factory is a very well equipped one with the latest technologies in the world. And it was a fresh experience to expose to those new technologies.
As I was a part of the factory for the last six weeks, the things I learnt are incalculable. Simply it was a rare opportunity for a budding engineer. The entire training programmed was a practical exposure to the industry, and the practical engineering applications I learnt were immense. There for I decided to segregate the all this documents into one report.
Here I started with a small description about the company. And then the time line of the internship is included briefly.
Mainly, in this internship report almost all the devices, instruments used in the factory is described and explained briefly. Furthermore, I have included some more information, which is related to the topics I discussed here (From Internet). In addition, all the processes applied in the factory are precisely explained with all the details. And at necessary positions figures, diagrams and pictures are included to make the explanation more precise.
During our training period we used dairy then I included day to day activities in that dairy. Therefore our chief engineer Mr. Hiran gave us to complete the assignment. That CAPEX assignment we were completed during our trading period and I attached it in this report.
Finally my opinions related to the factory are included, in order to bring some more profits to the company as well as for the good sake of the company. And I would be really grateful if you could consider them.
Thank You Very Much,
Perera G P O
Trainee Industrial Engineer,
South Asian Institute of Technology and Medicine (SAITM), Sri Lank
CONTENTS
Page
1. Introduction...........................................................................................................................1
CHAPTER 1
INTRODUCTION
Lions Brewery PLC in Sri Lanka
Is there a LION in YOU…..?
The Ceylon Brewery was the initial brewery in Sri Lanka. It was established in 1881 by Sri Samuel Backer as a
cottage industry, catering for the British colonial tea estates in the hill country retreat of NuwaraEliya. It was the
ideal location for a brewery because of its cool climate and natural spring water. Ceylon Brewery acquired as a
limited liability company in 1911.
In 1993, the Ceylon Brewery became a subsidiary of Carson Cumberbatch & Co Ltd, a diversified group of Sri
Lankan businesses. Primarily the Ceylon Brewery started as a family company and then it became the leader
and creator of the national beer industry.
Today, the Lion Brewery Ceylon Limited is located just outside the capital Colombo. It is equipped with state-
of-the-art manufacturing facilities that enable it to fulfill the increasing demand and export beer to new and
current export markets, such as England, Japan and Australia. And now in their factory latest technologies have
been installed to bring the customers best and real beer. It is the only beer factory in Sri Lanka to achieve this
much of high production per day. And their production capacity is 20,000 bottles per hour. Lion Brewery is the
market leader with a share of 86%. All five brands in its portfolio as follows;
Lion Lager
Carlsberg, for this a capital is payed for the trade name and the all raw materials are taken under the
supervision of the Carlsberg mother company and then the production is taken place in Lions brewery
factory.
Carlsberg Special Brew
Lion Stout
Strong Beer
Corona, this brand is directly imported and distribute in Sri Lanka.
They increase their manufacturing capacity day by day with high quality products. In present they produce
20,000 beer bottles per hour and they are planning to expand that manufacturing speediness up to 60,000
bottles per hour in a near future, and will lead them to be a large scale beer producer and it will be the Asia’s
largest beer factory.
Very friendly and helpful working environment of the factory usually helps to achieve their aims and targets
successfully. As well as friendly working environment directly link with the high profit margin of the company
also. That helps to increase employee loyalty and moral.
Ceylon Brewery is not only engaging to profit earning activities; they normally engage the CSR projects as
well. They normally allocate small percentage of their annual profit to provide books for rural areas helpless
students. Not only that after the tsunami disaster they stopped manufacturing beer and they started
manufacturing water bottles for victims.
CHAPTER 2
Brewing process
When the malt is brought, it is stored, conditioned and Milled at the Malt tower. The milled wet Malt is mixed with the milled dry rice and stored in the Mash Tun. And the mash is sent to the Brew house, at where Brewing takes place. Then the brew is separated, while Mash is sent off. The brew is sent to the fermentation process after purging the sterile air and Yeast. Then Brew is kept for fermentation at the Fermentation Valve tanks (FVT) for 14 days. When fermentation is completed, Carbon Dioxide is taken off as a byproduct, and then it is filtered through filters, Centrifuge and Horizontal filters. And then the carbon dioxide is purged by the Dearation plant (Diessel Plant). Now the Beer is made. Then it is sent to The Brite Beer Tanks (BBT). From there, it is sent for the Bottling.
CHAPTER 3
Malt TowerThis is the first process at the Brewery, and at this process Malt and rice are stored and milled for the brewing process. For this process different types of conveyers are used to convey the malt and rice. Main functions of this process are
Storing Malt Separate the dust and iron from the malt. Conveying to the mills. Milling in the mills. Forward the Mash to the Brew house.
When the malt is brought first, it is stored. Then it is lifted to the Malt storage silos by a Bucket elevator. Then the dust is removed at the top and then to convey the dust removed malt to different silos another type of conveyer is used. And it is called Chain conveyer. Then the malt is stored in the silos.
After that, Magnetic separator is used to separate the iron from the malt. When the iron is separated malt is forwarded to remove the stones to the Destone. Now the malt is almost prepared for the milling.
Now it is sent to the Malt Conditioner and then to the Mill, Wet Mill.
Then the milling process takes place and the product, Mash is sent to the Mash Tun.
CHAPTER 4
Main Devices used in the Malt Tower
1. ConveyersI. Bucket Elevators.
II. Chain Conveyer.III. Screw Conveyers
2. Screen filters (Classifiers)3. Magnetic separator.4. Mills.5. Dust remover
I. Conveyers
In this process basically three types of mechanical conveyers are used.
I. Bucket ElevatorII. Chain Conveyer.
III. Screw Conveyer.
Bucket Elevators
The Bucket elevator is used to lift up materials to a higher level from the ground or any below point. It is a basically mechanical device, where buckets are fixed on a chain and the chain in moving. Therefore automatically the buckets are moving upwards, so the materials.
Different types of buckets are used for the different types of practices. As an example for malt or rice small buckets are used but in cement factories a bigger and hardened buckets are used to lift the raw materials. It is applied in any industry where the materials are to be lifted to a higher level from the neutral.
Chain Conveyers.
It is also a motor driven mechanical device which is basically used to convey the materials horizontally from a place to another. It consists of arms as it is shown in the diagrams which are used to push the materials forward while the arm connected chain is rotating. As a result of the chain movement the arms are moved, so the materials are pushed.
Screw Conveyers.
It is one of the most used conveyer type in the industries. It can be applied not only vertical and horizontal directions, also in an inclined direction. Here the screw is fixed to a motor and when the motor is driven automatically screw starts rotating around its own shaft. Therefore according t the design of the screw the materials are pushed and conveyed forward.
2 Screen Filter
It is a mechanical strainer. And it is used to separate the different sizes of materials Malt, rice, flour, sugar etc. And also it is used to clean the impurities mixed in the raw materials.
It contains one or more screens (according to the necessity) and those are being vibrated continuously. And due to the movement of the screens small size materials are filtered down and fall through the holes in the screens and the bigger materials are left on the top of the screen. So the differentiated materials are collected from different ends.
3 Magnetic Separators
Magnetic separator is used to separate the iron particles from any non-metallic materials. Basically this is used in the food industries such as malt, rice, sugar etc.
Here basically a magnet is used to attract the iron particles from the materials.
4 Mills
Mill is presently, electrically driven machine to break or make small sizes of materials. And it is vastly used in food industries. It has been used in different purposes as well. Such as,
I. Increase the surface area of a solid
Example: - Wire manufacturing industry.
II. Manufacture the smaller sizes of grains.
Example: - Rice industry, Metal chip industry.
III. Pulping materials
Example:-. Paper manufacturing industry.
In industries, basically there are different types Mills are used.
I. Rod/Roller Mill.
Roller mills accomplish size reduction through a combination of forces and design features. If the rolls rotate at the same speed, compression is the primary force used. If the rolls rotate at different speeds, shearing and compression are the primary forces used. If the rolls are grooved, a tearing or grinding component is introduced. There is little noise or dust pollution associated with properly designed and maintained roller mills. Their slower operating speeds do not generate heat, and there is very little moisture loss. Particles produced tend to be uniform in size; that is, very little fine material is generated. The shape of the particles tends to be irregular, more cubic or rectangular than spherical. The irregular shape of the particles means they do not pack as well. For similar-sized particles, bulk density of material ground on a roller mill will be about 5 to 15 percent less than material ground by a hammer mill.
Advantages: - energy efficient- uniform particle-size distribution- little noise and dust generation
Disadvantages: - little or no effect on fiber- particles tend to be irregular in shape and dimension- may have high initial cost (depends on system design)- when required, maintenance can be expensive
General DesignThere are many manufacturers of roller mills, but they all share the following design features shown adjacent picture: - a delivery device to supply a constant and uniform amount of the material to be ground - a pair of rolls mounted horizontally in a rigid frame - one roll is fixed in position and the other can be moved closer to or further from the fixed roll - the rolls counter rotate either at the same speed or one may rotate faster; roll surface may be smooth or have various grooves or corrugations - bar; pairs of rolls may be placed on top of one another in a frame.
To ensure optimum operation, material must be introduced between the rolls in a uniform and constant manner. The simplest feeder is a bin hopper with an agitator located inside it and a manually set discharge gate. This type of feeder is best suited for coarse processing. For grinding operations, a roll feeder is suggested. In this type of feeder, the roll is located below the bin hopper and has a manually set or automatic adjustable discharge gate. If the gate is adjusted automatically, it will be slaved to the amperage load of the main motor of the roller mill.
The rolls that make up a pair will be 9 to 12 inches (23 to 30.5 cm) in diameter, and their ratio of length to diameter can be as great as 4:1. It is very important to maintain the alignment between the roll pairs. Sizing of the material is dependent upon the gap between the rolls along their length. If this gap is not uniform, mill performance will suffer, leading to increased maintenance costs, reduced throughput, and overall increased operation costs. The gap may be adjusted manually or automatically through the use of pneumatic or hydraulic cylinders operated through a computer or programmable controller.
Each pair of rolls is counter rotating. For improved size reduction one of the rolls rotates faster. This results in a differential in speed between the roll pair. Typical differentials range from 1.2:1 to 2.0:1 (fast to slow). Typical roll speeds would be 1,300 feet per minute (~ 395 m/min) for a 9-inch (~23 cm) roll to 3,140 feet per minute (~957 m/min) for a 12-inch (~30.5 cm) roll. Usually a single motor is used to power a two high roll pair, with either belt or chain reduction supplying the differential. In a three high roll pair, the bottom pair will have a separate drive motor. In addition, the roll faces can be grooved to further take advantage of the speed differential and improve size reduction.
By placing (stacking) pairs of rolls on top of one another, two or three high, it is possible to reduce particle sizes down to 500 microns, duplicating the size-reducing capability of a hammermill for grain. For coarse reduction of grain, a roller mill may have a significant advantage (perhaps as high as 85 percent) over a hammermill in terms of throughput/kwh of energy. For cereal grains processed to typical sizes (600 to 900 microns) for the feed industry, the advantage is about 30 to 50 percent. This translates into reduced operating expense.
II. Buhler Hammer Mill
In the feed processing process there may be a number of ingredients that require some form of processing. These feed ingredients include coarse cereal grains, which requires particle size reduction which will improve the performance of the ingredient and increase the nutritive value. There are a many ways to achieve this particle size reduction, here we are looking at using hammer-mills, for information on roller mills, see the related links at the bottom of this page.
Both hammering and rolling can achieve the desired result of achieving adequately ground ingredients, but other factors also need to be looked at before choosing the suitable method to grind. Excessive size reduction can lead to wasted electrical energy, unnecessary wear on mechanical equipment and possible digestive problems in livestock and poultry. For more in depth information regarding what actually occurs to the ingredients during size reduction please refer to this link: particle size reduction.
Advantages:- they are able to produce a wide range of particle sizes- work with any friable material and fibre- ease of use- lower initial investment when compared with a roller mill
- minimal maintenance needed - particles produced using a hammer mill will generally be spherical, with a surface that appears polished.
Disadvantages: - less energy efficient when compared to a roller mill- may generate heat (source of energy loss)- produce greater particle size variability (less uniform)- hammer mills are noisy and can generate dust pollution
5 Dust remover
Dust collector is a device which is used to enhance the quality of the released air from an industry. And this system basically has few steps.
I. Blower.II. Dust filler.
III. Filter cleaning systemIV. Dust removal process.
CHAPTER 5
Dust removal system
In this factory normally use three dust removal systems.
I. Cyclonic separatorII. Bag filter
III. Buhler filter system
Cyclonic separator
Purpose of Equipment: To remove particulates of air
Principle and Working:
A high speed rotating (air) flow is established within a cylindrical or conical container called a cyclone. Air
flows in a spiral pattern, beginning at the top (wide end) of the cyclone and ending at the bottom (narrow)
end before exiting the cyclone in a straight stream through the center of the cyclone and out the top.
Larger (denser) particles in the rotating stream have too much inertia to follow the tight curve of the
stream and strike the outside wall, falling then to the bottom of the cyclone where they can be
removed. In a conical system, as the rotating flow moves towards the narrow end of the cyclone the
rotational radius of the stream is reduced, separating smaller and smaller particles.
Features Required:
High efficiency over a broad flow range
Flow-optimized design
Low pressure drop resulting in energy savings
High safety during operation under pressure
Long-term corrosion protection
Bag filter
Bag filters consist of numerous bags, each one arranged on cages all arranged in a bag house. Each bag receives equal quantities of air. The direction of the particle loaded air is from outside in through the filter material (typically polyester) to the inner part of the bag, from where the cleaned air enters the exhaust fan via the clean air plenum to the stack.
The collected powder on the outside of each bag is shaken off by blowing compressed air through a specially designed nozzle into the center of each bag. The collected powder is discharged at the conical bottom of the bag house. It may be sold directly as a secondary product, mixed back to feed material or the main powder fraction.
Low cost bag filters are typically designed with radial air inlet into the bag house resulting in severe wear on the bags.
Buhler filter system
Effective dust control is indispensable for many machines and installations. The low-pressure filter MVRT and the high-pressure filter MVRU are dependable aspiration filters used for the efficient filtration of dust-laden air, e.g. in grain storage elevators (silos), scales, conveying systems, airlocks and manual intake hoppers. Each filter is available in a mild steel or stainless steel version and can be employed in the food processing and feed production industries as well as in many other industrial fields. Both decentralized aspiration of individual machines and centralized aspiration of entire plant sections are possible. The filters conform to all current regulations regarding environmental protection and can be installed indoors or outdoors.
The low-pressure filter MVRT is used for aspiration systems with a working pressure of +/- 0.2 bar and a purge air (bag clean off) pressure of 0.5 bar. Depending on machine dimensions, the SIDE Removal and TOP Removal versions allow the unit to filter air volumes ranging from 18 to 624 m3/min optimally.
The high-pressure filter MVRU can be used for aspiration systems with a working pressure of +/- 0.5 bar up to a maximum of 0.7 bar (purge air pressure 4 – 6 bar). The SIDE Removal version of the machine purifies pneumatic conveying air volumes of 2 to 700 m3/min easily.
CHAPTER 6
BREW HOUSE 1
Wet Mill Dry Mill
Malt Rice
Mash Tank Cereal Tank
Lauter Tank Mash Husk Tank Screw Conveyer Pneumatic Conveyer
Wort
Sugar Tank
Wort Kettle
Hop Hop Tank-1 + Hop Tank-2
Whirlpool
Trub Tank Air Compressor
Sterile Air
PHE (Cooling) Fermentation
1. Cereal Tank
It is the tank where Milled wet malt and milled ice is mixed together.
2. Mash Tank Here the mixed malt and rice, which is known as mash, is heated and stored in the process.
3. Lauter Tank The heated Mash is bought to the lauter tank to make sugar out of the mash. Here some extra chemicals are added. Then the mash is kept in solitude condition to settle the mash at the bottom, meanwhile the wort is remained on the toip of the mash layer. And then The settles mash layer starts working as a filtering layer and the wort is filtered through the mash layer and collected from the collectors placed in the bottom of the Lauter tun. And it is sent to the Wort kettle. After this process mash is taken off and takes in to a tank by the gravitational force.
Here a special technique is used to convey the mash out from the tank. At first the mash is pushed forward by a screw conveyer. And it comes to a poit like a chamber, where a small flap is there to open the path for the mash.It can be open by a valve(pneumatic automated valve).and this chamber is connected to a pneumatic air line as well.when an amount of mash is pushed forward by the screw conveyer,flap is closed and the amount of mash is stored in the chamber and the same time air stream is sent through the pneumatic line and the mash is sent of to the mash silos. And this process continuously takes place. And this technique is known as “Pneumatic Conveyer”.
Air (Pneumatic Line)
Mash
Mash
Screw Conveyer Flap gate
4. Wort KettleThe wort filtered from the Lauter tun is bought to the Wot kettle. Basically it acts as a kettle, where the
wort is heated upto 100◦C. since the amount of sugar is not sufficient an extra sugar is mixed at this tank,
simillaly ‘ hop’ is added to the kettle in oder to gain the taste and the colour of the beer.Then the boiled wot is sent to the whirl pool for the filtering process.
Sugar Tank- It is the tank where additional sugar is stored and in this pocess Screw conveyer is used to lift the sugar fom the earth level to the tank,and at there sugar is mixed with water and send to the Wort kettle.
5. Whirlpool This is the point where finally mash is separated from the wort. Here centrifugal foce is used to separate the wort fom the mash. But in the whirlpool a motor is not used to build up the rotational movement to build the centrifugal foce in the Wort. To rotate the shaft the wort from the wot kettle is sent ina direction perpendicular to the radial of the tank.therefo a rotational movement takes place and wort starts rotating.then after some time it is kept to settle the mash in the bottom of the tank. And then wort is taken from the top of the tank gently not to stir the settle mash once again with the wort. And then fom the bottom. Then the filtered and collected wort is sent to the “Plate heat Exchanger (PHE)” via Trub tank to cool the heated wort 14oC.
6. Aeration The compressed and sterilized air is purged before sending to the fermentation process.
CHAPTER 6
BREW HOUSE 2
Brew house 2 also implemented the same procedure as the brew house 1.but instead of a Leuter Tun they have used a mash filter.
Brew house Summary
CHAPTER 6
Heat Exchangers
Heat exchanger is a device which is built to exchange the heat in an efficient way between any two mediums. This is widely used in almost all the industries. And the two mediums are separated by a solid wall. And basically there are two type of flow methods in heat exchangers, Parallel flow and counter flow.
Counter flow(A) and Paralle flow(B) temperature variation in heat exchanging
There are different types of heat exchangers.
I. Shell And Tube Heat Exchanger
Here a shell and tube carry the two mediums. And it is vastly used in industries since it can bear a high pressure level. Whiled engine this type of heat exchanger it is necessary to take care of few major facts. Such as tube thickness, tube length, tube diameter etc.
II. Plate Heat Exchanger
It is used to heat o cool any two liquids. In this PHE number of plates are fixed together and alternativey through one by one two liquids are flowing.therefor heat from the high temperature liquid is transferred to the other. Since the high possibility of mixing liquid mostly the In food industries harmless(non-poisoness) cooling or heating liquids are selected.
III. Direct Contact Heat Exchanger
Here the heat exchange takes place with the absence of a separation wall. the two mediums come into direct contact.
Gas – liquid Immiscible liquid – liquid Solid-liquid or solid – gas
But in most industries the Gas-Liquid type is preferred.
IV. Phase Change Heat Exchanger
Here phase change is used to cool or heat the medium. When it is required to cool the medium the medium is condensed and gets heated. And similarly the medium is evaporated while getting cooled.
In some industries this is also used as a re-boiler, where condensate air is re evaporated.
Main facts to be considered before selecting Heat Exchanger.
1. Thermal power.2. Temperature range.3. Pressure limits.4. Clean ability, maintenance and repairs.5. Space available.6. Ability to ease in future expansion.
CHAPTER 7
Fermentation Process Wort
Yeast Yeast Tank
FVT Co2 Plant
Brew
Yeast Waste yeast Tank
Centrifuge
Horizontal Filter Drain
Buffer Tank
CO2 Deaeration Plant (Diessel Plant)
PHE(Cooling)
BBT
When the sterilized air is purged to the wort it is then sent to the fermentation process. At there the Yeast is pitched from yeast tanks. And then the mixture is sent to the Fermentation Valve Tanks (FVT), at where the mixture is kept for
fourteen days for fermentation, but since high demand, some simulators are used to accelerate the fermentation process.
As a result of the fermentation process Carbon dioxide is released. And it is collected and purified in the Carbon dioxide plant (this is discussed later on).
After taking the CO2, the yeast has to be separated from the beer. There for filtering system is used.
Beer Filtering
It takes place under two major devices.
1. Centrifuge.2. Horizontal filter.
Centrifuge
It is used to separate the beer from yeast. And the principle used is Centrifugal force. So this is called as Centrifuge.
It basically contains Motor, Bowl and set of cones.Here from motor the shaft is driven at a speed of 7000-7500 rpm. As a result of this high speed rotation of the cones, Cones get separated from each other and make a space between every two adjacent cones. When the cones are rotating, centrifugak force is created and the heavy yeast is pushed towards the wall of the Bowl and it comes out of the holes in the Bowl and is collected to the yeast tank, mwanwhile the beer is taken from the bottom and send back to the Treated Beer tanks (TBT).
Horizontal Filter
It is the device which does the final filtering of the beer before preparing for bottling. Its technique is sending the beer through different layers and filtered the beer.
Beer Filtering powder
Filtering Powder tank
Motor
+
Here the filtering powder is pumped and placed on each 56 large plates and 4 small plates. And the powder acts as sand in the sand filter. When the beer is sent from the top of the filter it flow over one by one of each plate, Strainers. at the same time the shaft is driven by a motor with a help of belt. At the end of this process yeast and used powder is collected and drained meanwhile the beer is taken off to a buffer tank.
After completion of filtering, carbon dioxide is purged from the Deaeration plant and send to the Brute Beer Tanks (BBT) via a Plae Heat exchanger to cool the beer. From there the beer is sent to the bottling plant for the bottling.
Beer Bottling
In the bottling plant at used beer bottles are brought and cleaned with use of NaOH then it is screened, and then it is filled with the beer under the standardized temperature. Then the bottles are pasteurized. Then it is sent to the labeling and then the bottles are packaged and sent to the distribution.
Yeast metabolism in fermentation
Flow chart in fermentation process.
CHAPTER 7
Boiler Process
Plant
Condensed Hot Water
Steam
Treated Water Tank Raw Water Treatment Header
Chimney
Boiler
Air
Water Remover
Oil
Preheater Oil Tank
This is one of the main devices equipped in the factory premises. The produced steam is utilized in the entire process for different purposes. Mainly it use for heating. And for cleaning process as well.
Boiler
Here “Horizontal, oil fired, fire tube, Automatic control package type boiler” is used. Its capacity is 10 tons/hr, max. Pressure is 10 bars.
In this steam generating process, first a few steps has to be accomplished. When the ignition takes place the flue is released through the three paths, and as this is a fire tube boiler, the water outside gets heated.
1. Oil Pre heater
It is the device which is used to heat the oil which directly comes from the tank to the boiler ignition point. At there the oil is heated up to 67 Celsius, which is the minimum temperature level maintained at that point. And then it is sent to the ignition point, where the heated oil is mixed with the air.
2. Raw Water Treatment
Raw Water
Resin
Treated water Salt
It is a container which is filled with the Resins, where all the (+) ions in the raw water is trapped and cleaned the water. And also it works as a filter.
And salt is used to clean the (+) ions trapped in the filter. Because its (-) ions combined with the (+) ions and taken drained off.
3. Treated Water Tank Hot Condensed Water
Treated Cold water
104 C tempered water Boiler
The hot condensed water is mixed with the Treated Cold Raw Water to increase the temperature of the treated cold water. And it is done as it is shown in the figure. And this increases the efficiency of the Boiler.
4. Header
Steam
Hot Condensed Water
It is the device used to separate the particles and the condensed water in the steam, after this the steam is directly sent to the plant. And the condensed water is filtered and taken to the Treated water tank.
5. Oil Combustion
Here at first the ignition starts with the LP gas, it mixes with the air and ignited.
Then the oil comes into the play, the heated oil is injected by a rotating jet, at same time air is injected by another rotating jet, which is rotating in the opposite direction of the oil jet.As a result of the impact of the oil and air oil is atomized.There for it is ignited very fast. And this process continuous at the ignition point.
And the built flame igoes through the chamber, at high flame situation it covers ¾ of the length of the boiler, otherwise 1/3 of the boiler length.
6. Water Removing Process
At the bottom of the boiler, there is a drainer, at where the quality of the water is always checked. If the TDs level increases the 3500, the boiler is automatically switched off and drained.
CHAPTER 7
Compressed Air Plant
Air
Compressor
Tank
Dryer
Filters (4)
Plant
The air compressing plant is one of the main plants inside the factory premises, because it provides the compressed sterile air to the entire factory process. Such as,
1. To purge the sterile air to Wort from the Brew house.2. For the Pneumatic valves.3. For the Pneumatic conveyers. Etc
Here there are a few steps to accomplish the process.
1. Compressor
Here a Screw compressor is used to compress the air (which is taken from the atmosphere), at the same time it gets heated as well. Then this compressed air is taken into a tank.
2. Dryer
Then the compressed air is taken to a dryer where it is cooled by R22 refrigerant and also it is dried.
3. Filter
Then the dried and cooled air is sent through a filter (Bag type filter) to sterile the air. At this point air is sterilized and it can be used in the plants. Then it is directly used in the plant.
CHAPTER 7
Refrigeration System
Since the contrast between the temperature levels of the processing, high temperature and bottling, very low temperature, the refrigeration system is very much essential in the Brewery industry. Therefore it is required to have a very well equipped refrigeration system. Above all as this is a food product the mediums used for the refrigeration should be armless, non-poisons. But as a industry it is necessary to establish a refrigeration system which contains high efficiency at the optimum cost.
Considering all this facts at Lions brewery, refrigeration is performed under very much particular way. Basic cooling mediums used are
1. Ammonia
2. Glycol3. Cold water
Since ammonia is a poison medium it cannot be directly used to cool the brew or the beer. Therefore at first place ammonia is used to cool the glycol then glycol is used to cool whatever it is necessary. At the same time water is cooled by using glycol and it is also used as a cooling medium, as example hot wort from the whirlpool is cooled down with cold water. After cooling the other respective medium Ammonia, Glycol and water is recycled and used again for the refrigeration process. Ammonia is taken back to ammonia plant and cool it again, glycol is taken to the “Hot Well” and cool it with the help of ammonia and heated water (at the refrigeration process) s taken back to the Boiler. Therefore refrigeration system is very efficient in the Lions Brewery.
Why to Use Glycol as cooling medium of the Beer?
1. It contains less pressure than the liquid beer at the atmospheric temperature, therefore in case of leakage due to the pressure difference, glycol will not move to the Beer tanks, but beer will be moved to the glycol tank. Therefore Beer tanks will be always free of any other impurities.
2. It is very less poisons medium. It is not harmful to human.
Refrigeration plant SCADA
CHAPTER 6
Ammonia Plant
Liquid Separator (2)
Compressor (4)
Condenser (4)
Expansion Valve Glycol Tanks
Hot Well Cold Well
Evaporator (PHE)
Liquid Separator The used hot ammonia is brought here and stored. There are two tanks. one is for the storing used ammonia and second one is to separate the cooled liquid ammonia and gaseous ammonia.
Compressor The heated ammonia is first brought to the Compressor, and then it is compressed and heated with the help of Screw type compressor. And at there, oil is mixed with the ammonia and the mixed oil is filtered at the oil filter which is set up adjacent to the compressor before the ammonia is discharged to the condenser. the filtered oil is then cooled with the glycol in a Shell type heat exchanger.
Condenser
Screw Compressor Oil Filter
Condenser The heated and compressed ammonia is brought to the condenser in order to cool it. The cooling process is taken place with the cooled water and the water is cooled with the air.
Expansion Valve
Then the compressed cooled air is expanded at the expansion valve, SO the pressure reduces and volume increases. Expansion valve is used to control the expansion of the ammonia.
Evaporator Then the ammonia is ready for the refrigeration process. So the ammonia is sent to the evaporator. Here the plate heat exchanger is used as an evaporator. The other medium is Glycol. Then the heated ammonia is sent back to the liquid separator tanks.
Glycol Cooling System
The cooled ammonia absorbs the heat in used Glycol come from the Glycol hot well at the PHE and cool the Glycol.
Compressors
Basicaly there are three types of compressors.and it is classified according to their performances.1. Reciprocating Compressors2. Rotary Screw compressors3. Rotary Centrifugal compressors
Reciprocating Compressors
This is the most basic type of the compressors.
Here, as it is shown in the diagram two valves are place on the bottom of the cylinder, and their action is opposite to each other, when one is opening other gets closed, vice versa. At first the piston pulls down, then one valve gets open and then medium flows into the cylinder. And when the piston pushes upward the first gate is closed and the next is open and the compressed air is taken out.
Rotary Screw Compressors
It is one of the main compressors used in industries for gas compression. Here two meshing male and female screws compress the medium.
Since high effectiveness and less vibrations it vastly used in industries.
Basically it is classified to two types.
1. Oil Free 2. Oil flood
Oil Free Screw Compressor
In this type the gas is completely compressed due to the meshing action of the two screws. There for its compression efficiency is less than the oil flood type compressors. But this is used when the compressed gas has to be highly purified.
Oil flood Screw Compressor
In this type an amount of liquid is added in between the screws. And it creates a seal for the gas and screws. There for its compressing efficiency is high. But as the oil gets mixed with the gas the mixture must be filtered before sending out the system. For that an oil filter is installed at the end of the system. This type is used in most of the industries.
Rotary Centrifugal Compressors
In this type compressors, at first speed of the flow and energy is increased and then it is forwarded to a diffuser, where it velocity decreases, so the pressure increases.
Main parts of a simple Centrifugal Compressor
1. Inlet2. Impeller3. Diffuser
Inlet is a simple straight pipe which helps in flowing the medium to the impeller with a high speed. Then the impeller sucks the medium and increases the speed of the flow. Then the high speed medium is forwarded to a diffuser where the speed is decreases and according to Bernoulli’s theorem Pressure increases. Now the air is compressed.
This is widely applied in Jet engines. And some of the impellars are designed to speed up the flow of the medium up to almost speed of the light.
Expansion valves
There are basically two types.
1. Thermal Expansion Valve2. Electrical Expansion valve
Thermal expansion Valve
Thermal Expansion Valves (TXVs) are precision devices designed to regulate the rate of refrigerant liquid flow into the evaporator in the exact proportion to the rate of evaporation of the refrigerant liquid in the evaporator.
Electronic Expansion Valve
Electronic expansion valves provide system performance over a wide range of system operating capacity under tighter operating conditions. It allows for reduction of system costs and energy saving and it can be used for high pressure applications
CHAPTER 6
Water Treatment
Well
Chlorine+ Sodium Sulphate
Aeration
Particle Settling Tanks
Plant
Carbon Filter Iron Filter Sand Filter
The water treatment plant is the heart of the Brewery process. Because as we know more than 90 % of water in contained in the beer. There for to produce a hygienic beer, it is very much essential to treat the water very well. This Water treatment process consists of a few steps.
1. Well
Well is placed near the river, to make ease the gaining of water. And the water is taken from the bottom of the earth by pumping.
Then from the well, water is taken in to a buffer tank, at where Chlorene and Sodium sulphate are added.
When chlorine is added
Cl2 + H2O -> HOCl + H+ + Cl-
Depending on the pH value, underchloric acid partly expires to hypochlorite ions: Cl2 + 2H2O -> HOCl + H3O + Cl-
HOCl + H2O -> H3O+ + OCl-
This falls apart to chlorine and oxygen atoms: OCl- -> Cl- + O
This ion has the ability to penetrate through the cell of the micro bacteria and kill it. There for Cl2 is used to disinfect the water from bacteria.
2. Aeration
Where the water is reacts with the air and air is mixed at this point. At here the dissolved ions are removed and also manganese is removed.
Water
Tank
3. Particle Settling Tanks
Here a number of tanks are there. And aerated water is sent one by one as it is shown in the figure above. There for at each tank particles are settled and the rest water is pumped to the next. So the finally a water with very less particles can be obtained.
4. Sand Filter
Then water is sent through a sand filter, where all the particles are stucked in the sand and only the water is sent to the next level.
5. Iron filter
Here the iron dissolved in the water is removed.
Here filter oxidizes the dissolved iron in the water and creates the rust particles and it is filtered. There for iron particles are filtered. Various types of iron filter media are available including Birm, Greensand etc. Then the tank should be back washed to remove the collected articles.
6. Carbon Filter
Activated carbon is used to filter the water, where it acts as a germ killer. After this the water is fully treated and ready to use.
CHAPTER 6
Carbon Dioxide Plant
CO2 generation in brewery
o Fermentation of sucrose produces ethanol and CO2 as per the following reaction.
o Every 100 Kg of sucrose fermented would produce 48.4 Kg ethanol, 46.6 Kg CO2 & 5 Kg of other compounds.
o Carbon Dioxide is recovered and purified by two CO2 recovery plants namely, Seeger Hypro
o Capacities of two plants Seeger - 200 Kg/hr flow rate
20000m3 Storage tank
Hypro - 300 Kg/hr flow rate
20000m3 Storage tank
FVT
95% purity
Form Separator Beer Form
Washer Impurity Particles
Compressor
Dryer & Purifier
Cooler
99.99% purity
Liquid Co2 Tank
Carbon dioxide which is released at the fermentation process is taken and purified at the carbon dioxide plant. When the carbon dioxide comes from the fermentation tanks it is not purified, it is purified about 95%. But to use in the beer process it should be contained 99.99% of purity. So this requirement is fulfilled at the Carbon dioxide plant. This process contains a few steps as it is depicted in the flow chart.
1. Form Separator
When the CO2 (95 % purity) is brought to the plant first it comes across the “Form separator”, where the yeast form is separated from the carbon dioxide.
2. Washer
Then the carbon dioxide is washed with cooled water at this point, at there all the impure particles are washed away.
3. Compressor
Then the washed CO2 is compressed and heated at the Reciprocating compressor and turned the entire CO2 gas into a liquid.
4. Dryer and Purifier
Then this compressed CO2 liquid is sent through a dryer and a purifier. Where Silica gel chamber is used to dry the liquid and Activated carbon is to purify the CO2 liquid, meanwhile a heater coil is used to dry the liquid more.
Silica gel is used, because it contains high surface area (800m sqr/gram) and it is non-toxic, non-flammable etc.
Activated carbon is used. Because it also contains 300 m sqr/gram surface area and also it is less costly, non-toxic and can be regenerated.
5. Cooler
Then the purified and dried CO2 is sent through a cooler where R22 is used as refrigerant. Here Shell –Tube type heat exchanger is used.Now the CO2 is very well purified, 99.99%.
CO2 (Gas) R22
CO2 (Liquid) Tank
6. Liquid CO2 Tank
When the refrigerant absorbs the heat from the CO2 gas, it is transverse into liquid format. Then it flows down and collected at the Liquid tank at the bottom of the cooler. From here the CO2 liquid ( 99.99 % purified) can be used for the further processes.
CO2 is used in brewery
Filtering
• Pressure and push the unfilted buffer tank
• Pressure and Mix the Kieselguhr recovery tank
• Empty and push back filter buffer tank
• Carbonator mixing
BBT
• Pressure and empty B.B.T tanks
• Pressure and push keg line
• Pressure and Push Bottling and canning line
Bottling plant
• Pressure bottling filler ball
• Push bottling beer line
Centrifuge
• Pressure PVP tank mixing line
Canning
• Pressure Canning ball
• For bubble breaker
FV tanks
• Pressure and empty the FV tank line
Keg plant
• Pressure filling head
• Pressure filling tank
CHAPTER 6
Waste Water Treatment Plant
All waste water from process and factory is purified up to the given European environmental standards before sent to river
Anaerobic and Aerobic methods are used It is the 3rd highest energy consumer in the plant There is a ongoing research to use the byproduct methane for electricity generation Capacity 52 m3/h
Influent Water from Plant
Sand Trap
HCl
Equalization Basin
Anaerobic Tank Aerobic Tank
(Sludge Deposits)
Effluent Sump Final Clarifier
Treated Water to the River
NaOHInfluent Sump
As a pioneer industry in the country it is necessary to maintain well functioning Waste Water Treatment Plant (WWT).Even it is an illegal if an industry doesn’t function any WWT plant. Basic function of this process is to clean the waste water from its impurities and maintain the Ph level before releasing to the river. But it can be further developed to reuse the waste water.
Basically there are three types of WWTs.
1. Chemical Treatment2. Mechanical treatment3. Aerobic/Anaerobic treatment
Here in the Lions brewery, Aerobic/Anaerobic treatment is functioned. And this process contains a few steps.
A few Basic Tests
Chemical Oxygen Demand (COD)
This is used to measure the organic compounds in the waste water. Its result can be taken within 2 hours. There for this test takes place every day. Unit comes mg/l, which expresses the consumed mass of the oxygen in the water.
Biological Oxygen Demand (BOD)
It is the dissolved oxygen needed by the aerobic bacteria to consume the organic oraginsms. It takes around five days to give the result. There for this is done to have an idea about the performance of the plant.
Total Solid
It is divided into two
1. Total Suspended Solid (TSS)
It is the total solid particles, which are not dissolved in the water. As these particles are large, it is very difficult to digest to bacteria. There for this amount should be as minimum as possible.
2. Total Dissolved Solid (TSS)
It is the dissolved solid in the water. These are easily digested by bacteria, there for it is not as effective as TSS.
Aerobic/Anaerobic Waste Water Treatment
Sand Trap
The waste water from the entire factory, at first, come across the sand trap, where sand is filtered from a strainer. Then its large non-dissolved particles, such as broken bottle parts, nuts etc, are trapped by a steel grill. Then it is guided to the Influent Sump/Equalization Basin.
Equalization Basin
This contains 15,000 meter cube of capacity (this may vary from factory to factory).
Malt husk
Air Injector
Here when the tank is filled with the waste water, air is injected to keep the waste water stiring all the time. And this will guide to increase the aeration in the tank, therefor Aerobic bacteria comes into action while Anaerobic bacteria becomes weak. Since only anaerobic bacteria releases the stink,and as it is controlled the stink comes out from the tank is very less. There for smell release to the environment is very less.
And from the top of the tank husk collector is placed, where the non-filtered husk is removed.
For the further treatments it is required to have a Ph range between 6 - 8.5, because in case of high or less Ph ranges treating bacteria can’t survive. There for, if the Influent water is acidic “NaOH” is added similarly if it is basic “HCl” is added and maintain the Ph value in between the 6-8.5.
Why the large tank is used for influent tank?
1. In a case of high acidic or basic waste water come from the factory, it must be neutralized before send under the treatments. There for if the volume of the waste water in the influent tank is high and it is almost neutral, when
this two get mixed the mixture will be, obviously, neutral. There for maintaining a large volume in the Influent tank is important.
2. In case of repair in the treatment plant, the waste water of the factory must be stored somewhere. For that influent tank can be used. There for in emergency it is required to have a large tank.
Anaerobic tank
Bio Gas (CH4, H2S, Co2)
Anaerobic Bacteria
Pre Treated Water
The pre treated waste wate is sent to the tank with number of inlets to increase the area, there for impact of between bacteria and waste water get increased, as a result of this the efficiency of the tank gets increased.
When the bacteria digestd the impurities the TSS and COD levels get decreased. And the bacteria released the CH4, H2S, etc, bio gases. And it is one of the major by products of the WWT plant.
And at the out let COD, Ph levels are checked, if it is not upto the optimum level the treated water is sent back to the tank b y using a bypass. Then it is again treated and then checked the all the tests and sent back to the Aerobic Plant.
Here Carbohydrate, sugar particles are removed.
Aerobic Tank
Here aerobic bacteria perform to clean the water. They don’t release any kind of gas but they release sludge in their process. At this tank this sludge has to be removed. This entire water and sludge is taken to the Final Clarifier and removed the sludge from the water. Then the water is ready to use.
And the removed sludge is taken into a sludge tank. And it is high grade fertilizer. It is also another byproduct of this process.
Here all the carbonic impurities are removed from the water.
Final Tests
Now the all the tests, COD, BOD, TSS, Ph, Temperature, are checked. If they are under the optimum level water is ready to release to the river.
Optimum levels
COD :- 0 – 250 mg/l BOD :- 0 – 30 mg/l TSS :- 0 – 50 mg/l Ph :- 6 – 6.5 Temp. :- 0 – 40 C
Important Notes
1. Rain water should never be mixed with waste water, because in one hand it reduces the space for the waste water and in other, it is useless to expend money to treat waste water.
2. All the Ph, Level, Flow sensors must be checked regularly to prevent failures.3. In each steps all the test must be done and should compare with the immediate previous process test results, if
any error is there then there is a problem in the process between the two processes.4. If the Ph levels get higher or lower, it is monitored for 30 mints and if it remains same, automatically plant is
shut down, in order to save the bacteria.
Byproducts
1. Bio gas2. Sludge (Composts)3. Treated water.
CHAPTER 6
Process of Pump House
CHAPTER 6
Pumps Types
In Industries basically a number of pumps are used for different purposes. In industries water, oil, seeds, sludge, flours etc. has to be pumped up. There for different pumps must be used to different types of mediums.
1. Peristaltic Pump
Here a flexible medium carrying pipe is fixed around the pump. And at the centre of the pump a shoe is set, which is driven by a motor and due to the motion of the shoe the medium in the pipe is pushed forward and it results in pumping the medium.
It is widely used in food industry, because it has no contamination risk as the medium is in contact only with the pipe. And it can pump the slurry type mediums as well. And its process resists the back flow.
Its main advantage is, high risk of tearing the pipe. The flow is pulsed at a low rpm. There for it is not suitable when the flow is to be frequent and smooth.
2. Centrifugal Pump
Here due to the rotary motion of the impeller, an extra energy is added to the medium. And it accelerates the speed of the medium and it is result in pumping the fluid forward. And when it is discharged from the impeller it is sent through a diffuser where speed is increased further more.
Open Type Impeller
Open type contains an impeller which has open vanes, which can be used for any kind of medium.
Closed type impeller
This type has closed vanes, which can be used only for liquid mediums as the medium can get trappen in the vanes.
3. Multistage Centrifugal Pump
A centrifugal pump containing two or more impellers is called a multistage centrifugal pump. The impellers may be mounted on the same shaft or on different shafts.
If we need higher pressure at the outlet we can connect impellers in series.
If we need a higher flow output we can connect impellers in parallel.
CHAPTER 6
Basic Instruments Used In the Factory
During the process of brewing, to accomplish the best standard of the product it is necessary to maintain the entire process under the optimum conditions. Therefore it is necessary to observe the each and every simple activity in the entire process. In order to gain the above mentioned standardized product, different types of instruments are installed in the process. And these instruments help us to measure whether the process at the particular point, takes place is under the optimum condition or not. If not the actions can be taken then and there to maintain the quality of the product, which is the main fact of a production, maintaining the quality of the product.
Since these instruments continuously underperform, it is required to maintain them properly. Therefore calibration of the each instrument must be taken place at the optimum intervals, more precisely before any failure takes place. And this calibration is performed with special instruments.
To achieve the above mentioned fact, in Ceylon Brewery we use the instruments which are stated below.
1. Pressure Transmitter2. Pressure Gauge3. Temperature Transmitter4. Digital Thermometer5. Flow Meter6. Conductivity Meter7. Weighing Scale8. Ph meter9. Oxygen meter10. Temperature Gauge11. Variable Speed/frequency device(VSD/VFD)
In addition, but not used in the factory premises. Vibration Sensors Air flow meters
Pressure Transmitters.
The deflection of the diaphragm is used to measure the pressure of the liquid.
When the sealed diaphragm is deflected, the connected liquid filled pipe is pressurized and it causes to deflect the ceramic diaphragm, and it is connected with an electrode it detects the amount of deflection and sends the signal to the
transmitter, at there, signal is conditioned and displayed in the display. The range of pressure depends upon the thickness of the diaphragm.
This can be applied to measure the pressure in liquid flowing pipe, liquid filled tank etc.
Level measuring Device
Basically there are three type of devices used in the factory premises.
1. Vibrating Fork type
This device is not used to display the exact level, but to detect the point of the level. It is placed in the bottom, medium and the top of the tank to detect the level of the tank.
Max
Medium
Low
It contains two vibrating Stainless Steel forks, which are vibrating at their resonant. When it is disturbed by the medium which is being filled to the tank, the signal is created and from there the level is detected.
2. Hermetically sealed hanging type
This device has the capability to measure the exact amount available in the tank. And this should be placed in the bottom of the tank by a rope from the top
It contains a pressure sensor, and it detects the pressure at the bottom of the tank. And the signal is sent to the transmitter, at where according to the density of the tank the height is calculated and displayed.
H =P/ῤ g
3. Ultra sonic Level measurement
This is also used to measure the exact level of any kind of medium, which is filled in a tank.
Here transducer is installed in the sensor, which emits the ultra sonic waves and it reflects from the surface of the medium. The time taken to receive the reflected wave is proportional to the empty level. There for according to the time, taken by the wave the transmitter measures the level of the tank.
Since this performs with the ultrasonic waves, can be applied in any kind of medium to measure the level.
Flow Measuring Device
This is one of the most important devices used in most of the industries. Because it +-measure the amount of flow through a pipe.
Its basic principal used is a voltage induced in a conductor that is moved through a magnetic field.
A magnetic field is induced across the flow of medium. And when the medium flows across this magnetic field, a voltage is automatically induced. And this voltage is proportional to the flow of the medium. And this is detected by an electrode and sent it to a transistor where the signal is conditioned and displayed according to the given cross sectional area.
Oxygen Measuring Device
In this Oxygen measuring device, luminescence sensor and a temperature sensor is installed.
The oxygen sensor optically measures the liquid’s O2 content based on the luminescence measurement principle, where an oxygen- sensitive layer is exposed to blue light. As a result, molecules in the oxygen-sensitive layer are exited.
In the absence of the oxygen, the molecules light up red. In the presence of oxygen, oxygen molecules collide with the molecules in the layer. The molecules that collide with oxygen no longer light up. Through this process, a link is created between the oxygen concentration and both the light intensity and the speed at which the light intensity is reduced. The light intensity reduces when the oxygen concentration is higher, whilst the light intensity reduces at a faster speed. The oxygen content is calculated using the time difference between the exposure to the blue light and the molecules lighting up and the product temperature.
Ph sensorIt is the device used to measure the Ph level of a liquid. In this the chemical sensing action is played by Glass tube electrode.
Main Parts of a Glass tube Electrode
1. A sensing part of electrode, a bulb made from a specific glass2. Internal electrode, 3. Internal solution, usually a pH=7 solution .4. Agcl5. reference electrode, 6. reference internal solution, usually 0.1 mol/L KCl7. Junction with studied solution, 8. Body of electrode, made from non-conductive glass or plastics.
In this sensor the basic principle used is, comparison of the reference liquid (ph 7) with the solution in the outside. And this difference measures the Ph value of the solution.
Temperature Measurement
Basically there are number of different types of measuring devices to mewasure the temperature.
1. Thermocouple
It contains two different types of conductors, and due to the temperature different between this two conductors, automatically a voltage is induced. And there is a cold junction, which is considered as the reference. In basic configuration one conductor is kept inside an ice water, but presently, cold junction is made within the device.
2. Resistance Thermometer
Here resistance of a material is used to measure the temperature.
Here, the Resistance Thermometer Detector (RTD) elements resistant for the different temperatures are already taken. And accordingly when the temperature is changed the resistance changed, there for the temperature can be measured.
Basically it contains three types
1. Thin Film Type
This is formed by depositing a very thin layer of resistive material, normal platinum, on a ceramic.
2. Wire wounded type
Here the sensing wire is wrapped around an insulating mandrel
3. Coiled type
This design has a wire coil which can expand freely over temperature, held in place by some mechanical support which lets the coil keep its shape.
CHAPTER 6
Power System
As it is shown the figures, the 33kV power is directly taken from the Ceylon Electricity Board (CEB). And then it is sent to a Step down transformer, at where the voltage is stepped down to the 400V.And this power is directly given to Main Panel Board.
In a case of Voltage failure, may be Load shedding as well as the Voltage is decreased a generator (1000kV) is kept stand by.
And it is coupled serially with the CEB power.
There are two types of generator connection systems
1. Open Type (which is used in the factory)2. Closed type
In the close type when CEB current is reestablishing after a power failure, the generators are switched off and then CEB power coupled with the system.
In case of a power failure, the panel board detects and sends the signal to the generator, and then it is switched on and starts producing power. At the same time, the bus coupler switches on and three generators starts working together. When any generator synchronized with the required power, next two will follow the above. All three starts generators are performing together.
Generator operation in a power failure
CEB Supply Generator
Re-Transferring of CEB supply
And when the CEB power comes again, micro processor in the panel board monitors the power flow of the CEB for four minutes. To make sure that the flow of the power is steady.
If the power flow is steady at first this CEB power is synchronized with the generator power, this is known as open system and for this first permission must be taken from the CEB as in case of phase difference a large scale accident can be taken place. At this time all three generators and CEB power work together.
And then the generators start ramping out gradually. This is done by a flywheel in the generator. And it will work till it gets cooled down. Then it is switched off.
Abbreviations in the circuit diagram.
Bus bar
Factory without power
Tr- Transformer
G- Generator
P- Switches (P4,8 are bus couplers)
LV room- Low Voltage room
At the low voltage room, the power is distributed according to the requirement of the each device (Power distribution is shown in the second diagram). And this three power supplies are coupled with bus couplers, which is basically used to couple the power of one with another in case of failure in one power supply.
And here a capacitor bank is installed to maintain the power consumption, which is used to optimize the reactive current in the main (apparent) current line ( apparent current=active current+ reactive current)
When the UPS system is established it will connect to a few major devices in the factory premises
Tariff
CHAPTER 6
Project Information
Capacity Expansion Projects
Brew house Expansion Project
Process Improvement Projects
Installation of UPS System Power factor improvement Energy Management System Inline alcholizer Office Upgrade Energy Saving Projects Dust Extraction System
CHAPTER 6
Cleaning Process
The cleaning process of any food industry is very important.It guides to the hygienic factor of the factory. There for cleaning process must be performed very well and carefully.
In the Lions Brewery, CIP process takes place after every process. At that time, entire pipe lines, tanks, valves etc are cleaned.
Basically it is done with four processes.
1. Hot water is sentAfter each process first hot water (120 C) is flown through pipes. Then the washed water is drained.
2. NaOH is sent
Then NaOH is flown thorugh pipes. And here it is sent under different concentration for different type of processes. As an example to clean sugar tank, it is required to send high concentrated hot NaOH, due to its sticky quality.
High concentrated, Low concentrated, hot and cold NaoH are the type of NaOH used in the cleaning process.
And it is kept in the pipes and tanks for 20 minutes, then it reacts with the materials and clean them.
3. HNO3 is sent
Then HNO3 is flown. Which is used to neutralize the NaOH, as well as to remove the basic materials trapped in the lines. It is also used in different concentration for different processes like NaOH.
4. Oxanium is sent
Finally Oxoinum is sent to clean the entire unit, which is a harmless chemical. From that all the contaminated materials are sterilized and removed.
Now the line is ready to use again
Important
The cleaning process must be taken place as soon as the process is over, to arrest the bacteria grown in the lines due to materials trapped.
Cleaning process must be done by a professionally trained personal as it is worked with acids and basics.
CHAPTER 6
My Opinions
As I was a part of the Industry, I learnt a number of new things. And as a budding engineer I would like to note some my opinions which may helpful for the company in the future.
Utilization of Byproducts.
In waste water treatment plant, there are main three by products,
1. Bio gas
The bio gas release from the anaerobic treatment can be utilized in the boiler ignition unit, where LP gas is used. And also it can be further utilized in the quality control unit, Laboratory for the firing processes.
And this will save a large amount of expense to the company, and it will helpful in enlarging the profits.
2. Sludge
The sludge removed from the Aerobic tank is high concentrated compost. Presently it is dried and thrown away. But if it is mixed with the normal soil with the optimum measurements, it will be a very well fertilizer, which can be utilized in the newly started project “RANSAHAL”, paddy fields. Or else it can be sold to any agricultural company or a farm. And it will guide to attain some amount from something thrown daily off.
3. Treated water
This is one of the main wastes of the company. Here for the waste water treatment a considerable amount is spent but it is then thrown to river. And it is a complete useless.
But if further treating devices are added to the process, we can obtain very well cleaned water. Even it can be used as drinking water. There for according to my vision I would like to mention install a further treatment plant and recycle the waste water and use in the process. And the primary installation cost will save large amount in the future.
New Establishments
1. Usage of Solar Power
Since the factory is placed in an area where intense solar power received, the solar power can be used in some of the basic devices, such as Street Lamps, Lighting system etc. which will cost an initial cost, but will save a considerable amount later on.
Tools and Equipments must be arranged well.
It is very important to arrange and place the tools and equipments precisely, not to make any delay in an emergency. Because as an example in case of leakage of a tank, it is required to repair it as soon as possible, otherwise it will cost a lot to company. There for at such situation, the entire required tools must be able to pick with in no time. There for it is very important to arrange the factory properly.
And the entire corridors, lobbies must space full in case of emergency, there should not be any disturbance on the way. The path should be clear.
Safety System must be highly upgraded
As this is a highly recognized factory, in all over the world, it is required to maintain high safety system in the premises. Because, it is one of the main standard measuring fact. And also safety of the echelons is the prior responsibility of the administration.
CHAPTER 6
CHAPTER 6
