A REPORT ON SUMMER TRAINING AT IFB AGRO INDUSTRIES Ltd.NOORPUR

SUBMITTED BY

ABHISHEK MONDAL

&

RANDHIR KUMAR

CONTENTS1. Introduction

2. Acknowledgement

3. Overview of this plant

4. Safety

5. Productioni) Unloading and storageii) Millingiii) Liquefactioniv) Fermentationv) Distillation

6. Centrifugation & Decantation

7. Dried Distillery Grain Solid

8. ETP and Organic Manure

9. Boiler, Turbine and water treatment plant

10. Noorpur Gasses Plant Ltd.(CO2 Plant)

11. Q.C. Department

12. Mechanical Maintenance

13. Electrical Maintenance & Instrumentation

14. Conclusion

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IntroductionIFB is an ISO 14001 certified company with four wings spread all over India- IFB Agro, IFB Marine, IFB Automotive, and IFB Appliances.

After visiting our sight in the past few days at IFB Agro Noorpur Distillery, we get know that this unit was established at 1985 with very small scale production of country sprit, after crossing various milestones, IFB Agro has become the only distillery at the West Bengal. From its quarry of gems one is ISO 9001 certificates its premises highly safe & secure.

We, RANDHIR KUMAR and ABHISHEK MONDAL, students of The Department of Food Technology, TECHNO INDIA SALTLAKE are thankful to the IFB Agro. authority to allow us do our summer training with them at their Noorpur distillery.

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AcknowledgementWe would like to take this opportunity with great pleasure, to acknowledge and extend our heartfelt gratitude to-

Mr. Alok Kumar Dey, Administrator, IFB Agro Pvt. Ltd., for his encouragement and vital support.

Mr. Santanu Ghosh, Deputy General Manager, IFB Agro Pvt. Ltd., for his understanding and assistance.

And Mr. Dilip Kumar Dey, Mr. Snehasis Bera, Mr. S. Mallick,

Mr. T. K. Aich, Mr. N. Roy, Mr. M. Roy, Mr. N. C. Pal, Mr. Santanu Sarkar, Mr. Krishna Mohan, Mr. K. Goswami, Mr. J. Roy Chowdhury, Mr. T. Maity, Mr. Shankar Paul, Mr. Prasun Samanta, Mr. A. Mondal, Mr. S. Mukherjee, Mr. S. B. Bhattacharyya, Mr. S. Bandopdhyay, Mr. S. Khan, Mr. Ranbir Mukherjee, Mr. Kaushik Goswami for their constant support and guidance and therby playing a vital role in successfully completing the project report and the training program.

We also like to thank all the staffs and officials of IFB Agro. for their help.

We would also like to thank Mr. Soumitra Banerjee, HOD, Food Technology, Techno India, Salt Lake and all other respected faculty of our department, who have been constantly encouraging throughout our course.

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Overview of This PlantIFB Agro Industries Limited is a reputed Public Limited Company. The company has various consumers oriented products both for domestic & export markets. The corporate office is situated at EM Bypass, Kolkata, West Bengal. The company is listed in BSE & NSE.

This plant in 1985 started its journey under supervision of excise department, with the production of rectified spirit. After crossing lots of milestones it became only one Distillery Company in West Bengal. The main production started from molasses, but now days to compete with its uprising price, broken rice grains are used to produce ethanol. As it is a fermentation industry, Carbon di-oxide is a major bi-product, and also a greenhouse gas so it is processed at “Noorpur Gas Pvt. Ltd.” to liquefied Co2. All the wastage water are treated as ETP & Produces Methane gas, which is used as fuel at boiler to produce steam, which can be used both at the process line & at turbine to produce electricity, which is consumed within the industry. Being ISO 14001 certified, it strictly follows the environment safety rules with time to time checking of the environmental parameters.

The plant is undergoing an extension work in its premises upon whose running the production capacity would highly increase.

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Special thanks to

Mr. Dilip Kumar Dey

&

Mr. Snehasis Bera

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SAFETY

• What is safety?

Safety is the freedom from unacceptable risk or harm.

• What is Hazard? Hazard is a potential cause for harm in terms of injury, health damage to the property and environment or combination of all

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Chemical reaction:

A chain reaction can occurs when the three element of fire are present in the proper condition and proportion. Fire occurs when this rapid oxidation or burning takes place.

Take any one of these factors away and the fire cannot occur or will be extinguished if it is already burning.

Classes of fire:• Class A: Extinguish ordinary combustibles by cooling the material below its ignition temperature and soaking the fibers to prevent re-ignition.

Use pressurized water from or multipurpose (ABC-rated) dry chemical extinguishers. Do not use carbon di-oxide or ordinary (BC-rated) dry chemical extinguishers on class A.

•Class B: Extinguish flammable liquids, greases or gases by removing the oxygen, preventing the vapors from reaching the chemical chain reaction.

From Carbon dioxide, ordinary (BC-rated) dry chemical, multipurpose dry chemical, & halon extinguishers may be used to fight class B fires.

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•Class C: Extinguish energized electrical equipment by using an extinguishing agent that is not capable of conducting electrical currents.

Carbon dioxide, ordinary (BC-rated) dry chemical, multipurpose dry chemical & halon* fire extinguishers may be used to fight class C fires. Do not use water extinguisher on energized electrical equipment.

*Even through halon is widely used, EPA legislation is phasing is out of use in favor of agents less harmful to the environment.

Safety rules followed in this industry:As this industry is an ISO 14001 certified, various safety rules are strictly followed here. This safety rules makes this premises safe & secure.

The color codes followed here to indicate various risk zones are:

Material classification Color of field Color of letters for legends

HAZARDOUS MATERIALS

Flammable, Explosive,

Chemically active, Toxic,

Extreme pressure or

extreme temperature

YELLOW BLACK

LOW HAZARD MATERIALS

Liquid or liquid admixture

Gas or Gaseous admixture

GREEN

BLUEBLACK

WHITE

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Fire quenching materials

Water, foam, CO2 RED WHITE

•The plant has some zone division to indicate various places.Zone division Indication

Zone-0 Where an explosive atm. is always present for long period. Ex. Diesel storage, Bio-gas storage area

Zone-1 Where an explosive atm. Likely to Occur in normal operation. Ex. Distillation plant, Dryer-evaporation Unit, Spirit storage area.

Zone-2 Where an explosive atmosphere is not likely to occur in normal operation & if it does it will exist for only a short time. Ex. Rice husk storage area.

Some instruction strictly followed:• Use of P.P.E:P.P.E or personal protective equipment (such as helmet, shoes, goggles, mask, ear protector and apron) must be used at appropriate area.

•Smoking: Smoking is strictly prohibited within this industry, as highly inflammable substance ethanol is produced & stored here especially at the bio-gas plant where marsh gas (Methane) is generated.

•Fire protection: As this industry has high risk of fire, every office room, laboratory contains fire ball which is capable of fire distinguishing, every employee is trained how to protect from fire, fire alarm bell is attached on the wall of every high risk zone. Water

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monitor is affixed on some point of the plant where from fire can be distinguished.

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Special thanks to

Mr. S. Mallick,

Mr. T. K. Aich,

MR. N. Roy

&

Mr. M. Roy.

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Unloading and StoragePrimarily, the process of production starts with the receiving of the broken rice grains. The rice grains arrive to the plant in truck loaded with sacks of broken rice grains. They are primarily, checked for-

•Moisture content•Ash•Husk %•Starch•DustAfter going through and passing the quality check, they are moved to the weigh bridge for taking their weight and allotment of batch number.They are then moved to the unloading point. During the process of unloading, they are passed through a primary sieve as to remove, large unwanted particles and strings that may come.After this, they are then moved to storage silo by belt conveyors and bucket conveyor system.

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MillingThe main motive of the milling section is to clean the rice grains coming from the silos from various foreign impurities (jute rope, pebble etc.) and also to reduce the size of the grain into smaller particles (not grinding) so that the liquefaction and fermentation process can become easier.Particle size is reduced to some optimum size (5μm), so that the enzyme (α-amylase) can work on it, as surface area gets increased. The grains are not grinded to granular size because it can choke the pipe lines internally. The grains come from the silos through conveyor belt or chains and goes to the pre-classifier where it is separated from foreign materials present. Then the grain is transferred to the milling machine where the size reduction is done by hammer milling process.

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LiquefactionThis process is the consecutive process done just after the milling of the grains. Hot water is mixed with the milled grain and then cooked through various processes. The flour coming from the milling section is mixed with hot water and kept to the slurry tank. This tank is filled up to 60% of its volume. Then the slurry goes to initial liquefaction tank where the first enzyme (α-amylase) is introduced. The initial liquefaction tank is filled up to 78%of its volume and the temperature is maintained at about 60-65°C.This enzyme works on the slurry grain: I) Reduces its viscosity and ii) Breaks the 1-4 linkage in starch molecules and convert it to dextrin. This dextrin further converts to glucose by the second enzyme (Amylo-glucosidase) in the grain fermenter as yeast cannot convert starch to alcohol but it can convert glucose to ethanol which is the desired product of the plant. From the initial liquefaction tank, the slurry goes to the jet cooker through control valves. Some portion of the slurry is recycled to the initial liquefaction tank. The jet cooker temperature is maintained at 88-90°c so that the enzyme does not get destroyed. From the jet cooker, it goes to the retention coil where it stays for about 12 minutes at about 90°c. Then it goes to the flash tank from where it goes to the final liquefaction tank when the temperature is fixed at 90°c. This tank is also filled up to 78% of its volume. Here more enzymes (about 70% of total enzyme used) are introduced in case there is any destruction of enzymes in the heating process, though 30% of the enzyme is used in the initial liquefaction tank. The slurry, before going to the fermenter is cooled by plate type heat exchanger and the temperature is brought down to 36-38°c. It is done because the yeast cannot work on the slurry at a high temperature of 90°c. Some part of the slurry is recycled to the final liquefaction tank and the rest is sent to the fermenter. The slurry should get proper retention time so that all the 1-4 linkages can be broken down by the enzyme. So the slurry is passed through a jet cooker where the required temperature is attained and then through a retention coil where the 1-4 linkages is broken down properly and completely.

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The whole liquefaction process is described by a flow diagram shown below: -

OVERALL FLOW DIAGRAM OF THE LIQUEFACTION PROCESS

Pre-mashing (flour + hot water)↓

Slurry tank (mixing of flour and hot water)(60-65 ̊C)

↓Enzyme 1 → Initial liquefaction tank (80- 90 C̊ ) ← Steam

↓Jet Cooker ← high pressure steam

(75Kg/cm2, 80-90 C) ̊↓

Retention Coil (12 minutes, 90 C)̊↓

Flash Tank↓

Enzyme 1→Final liquefaction tank(80- 90 C)̊

↓Plate heat exchanger ← Cold water

(Outlet temperature 36-38 C)̊↓

Fermentation SectionCOMMENTS: Ammonium hydroxide solution was added to the slurry during the process to maintain the pH of the slurry at 5.7 and also acted as a nutrient for the yeast later.

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Grain FermentationAfter being treated at liquefaction section, cereal slurry comes to the fermentation section, where the dextrin monomer is converted to glucose molecules and then it is fermented to produce ethanol.Fermenter section contains primarily of two sections, namely the pre-fermenter and the main fermenters.

Pre FermenterIn the pre-fermenter section, the ‘culture’ (genetically modified yeast Saccharomyces Cerevisiae) is allowed to grow on the culture media, so that their desire count can be obtained. Also this is done to note the stage of growth and the health of the yeast culture. In the pre-fermenter, the slurry is also treated with Amylo-glucosidase enzyme to let the dextrin convert to glucose upon which the yeast cells can easily act on. Additionally in the pre-fermenter tank, urea, SMBS, Zinc sulphate, Velly gur, DAP is added according to their requirement. Urea is added as a nutrient for the yeast, water is added to maintain the viscosity. The cell count in the slurry is repeatedly checked every hour. It is kept for near about 24 hours for the preparation of the culture. Now this prepared culture with the desired cell count is then transferred to the main fermenter as per requirement. The specific Gravity is maintained at 1.040

Main FermenterIn the main fermenter, yeast containing media from the pre-fermenter is transferred to the slurry in the main fermenter vessel, which has been obtained from the liquefaction section. Here the second enzyme, along with some other additional compounds like urea, anti-foam, SMBS, Zinc sulphate are added according to requirement of the batch. Here the Urea is used as a nutrient for the yeast cells, primary source of essential nitrogen. Antifoam is used to stop excess foaming during the conversion from sugar to ethanol and other products. SMBS is used so as to stop unwanted microbial growth in the slurry during or post fermentation. The process needs almost 35-36 hours. The process time is found out from the specific

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gravity measurement. The process is stopped when the specific gravity reaches 1.000 and is begun at around 1.070.After the process has been completed, the fermented mash in the tank is transferred to the beer well, which acts as a hold for the mash. The mash is then passed to the distillery section for further processing from here.Here is a short flow diagram for the fermentation section.

COMMENTS: The temperature of fermenters were maintained at 38 ̊ C by the use of PHE and the thus obtained discharge water was reused in the process during liquefaction, thus saved energy which would be otherwise used in the heating process. Also the fermenters are cleaned properly after each batch by following a standard protocol so as to prevent contamination of the mash. The CO2 that is generated in the process is passed through a water scrubber so as to collect the alcohol vapors and then is sent to the CO2 for processing.

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DISTILLERY SECTIONAfter the mash reaches the beer well, the mash is directly pumped to the distillery section for final recovery of ethanol. A flow diagram is given below for better understanding of the sections.

There are basically seven columns for the recovery of ethanol from the mash namely analyzer, aldehyde, pre-rectifier, purifier, rectifier and simmering sections.

The mash is taken into the analyzer column where the volatile gases are separated from the mash. This column contains a number of sieve plates. The mash is let in from the top of this section and as it passes through the degasifying section, the residual gasses are recovered. Simultaneously, the process is refluxed for a number of times maintaining a ratio of 4:1 until most of the alcohol has been extracted. The spent wash is then sent to the centrifugation and decantation section. The column is maintained in vacuum condition with bottom pressure of 0.57 Kg/cm2, temp 85 C ̊ and top pressure of 0.42 Kg/cm2, temp. 70 C ̊

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Now from the analyzer column, two sections are removed. One is sent to the pre-rectifier which basically comprises mainly of the alcohols, esters and other fusel oils. The other part is sent to the aldehyde column. Next we come to the aldehyde column. In this section, the

aldehydes are removed. This column is run with total reflux initially and a technical cut is drawn at a measured rate. This column uses a bubble cap tray for better removal and more retention time of the gases at each tray. This column is also maintained at high vacuum with bottom pressure of 0.42 Kg/cm2, temp 60 C ̊ and top pressure of 0.30 Kg/cm2, temp. 53 C ̊

The other part from the analyzer column comes directly to the pre rectifier column. This column is also a high vacuum column with bottom pressure of 0.42 Kg/cm2, temp 80 C ̊ and top pressure of 0.25 Kg/cm2, temp. 49 C ̊ . Fusel oil draw is taken from the section maintaining temperature at 56-69 C. This contains both the high ̊fusel oil and the low fusel oils. This cut is then passed through decanters to remove the oils and also entrap the alcohol escaping, which would otherwise escape with the oils and is resent back to the column.

The fusel oil thus obtained is sent to a feed tank for storage and further rectification. The main technical cut from this section is called rectified spirit and is 96% concentration. But this contains other impurities, so is sent to the next column called the Purifier column. Now the 96% rectified spirit contains esters and other fusel oils

which could not be removed. It is then passed on to the purifier column. Here a lot of water is added and heated under vacuum to maintain a top temp. of 66 C, pressure of 0.30 ̊ Kg/cm2 and a bottom temp. of 68 C, pressure of 0.45 ̊ Kg/cm2. In this process, the esters are removed from the section having temperature of around 67.5 C and are collected in the Feed tank. This section ̊also has bubble cap trays.

After passing through the purifier column, the 13% concentrated alcohol solution is then passed to the rectification column. This column is basically a high pressure column and maintains a top

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pressure of about 2.2 Kg/cm2, temp. 96.5 C and bottom pressure ̊of about 2.43 kg/cm2, temp. 126 C. This column is also called the ̊exhaust column as it is again concentrated to 96% and also a few fusel oils are also removed which would not be possible at low temperatures.

Now the fusel oil draw is collected in the feed tank and from there is sent to the ISP (Impure spirit purification) column. Here the bottom temp. is 107 C, pressure 1.22 kg/cm ̊ 2 and the top temp is 78 C, pressure 1.033 kg/cm ̊ 2. The technical cut is taken from the section having temp. 79 C. Other draws are taken from temp. ̊higher than this and is mainly taken as rectified spirit. The technical cut should be checked at regular intervals for % alcohol and purity.

Finally the 96% alcohol from the rectification column is sent to the simmering column. Primarily here the alcohol is freed from any methanol that may be present at ppm levels. This column is thus made of copper sieve plates, which acts as a catalyst in the conversion of methanol to ethanol. The product obtained is thus the final Extra Neutral Alcohol with a concentration of about 96%. This product is finally collected from the bottom of the simmering section and is sent to storage tanks. The draw is taken at about 84 C temp. and at atmospheric pressure. The charge in this column is ̊kept very less at about 5% maximum for proper product quality.

With this, we come to the end of the distillation section and the product drawn is taken to storage tanks, while the slurry from the analyzer column is sent to the centrifugation and decantation section for further processing. Also the fusel oil and the ester contained impure spirit is stored and sold out to other industries.COMMENTS: In the distillery section, the vapors from the rectifier column are used up to heat up the mash in the analyzer column; the vapors from the simmering column are reused to heat the liquid in the purifier column. Thus, these are good ways of cutting the energy requirements of the plan and effectively using the energy.

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CENTRIFUGATION & DECANTATIONThe process effluents that have a major amount of solid suspended particles are sent from the analyzer column to the centrifugation and decantation section. In this section, the solid suspended particles are separated from the liquid portion. This is done by the use of a horizontal industrial centrifuge. An industrial centrifuge is shown below:

In this type of centrifuge, the feed is fed at one end and the solids due to the centrifugal action are pushed under pressure to the end with a narrow diameter due to a screw form inside this machine. The liquid escapes from the broader end freely. The screw inside is rotated by a single motor with counter rotating lever which allows the casing of the screw to rotate in the opposite direction. Thus, the solids are pushed more effectively and the entire liquid portion is removed from the left over mash. The solid part mostly comprises of uncooked rice which if properly processed can be used as cattle feed. So from the decanter section the rice cake is sent to the DDGS i.e. Distillery Dried Grain Solids. The liquid part is also re used to save water from wastage and disposal problems.

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Special thanks toMr. K. Goswami

&Mr. J. Roy Chowdhury

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DISTILLERY DRIED GRAIN SOLIDSThe rice cake obtained from the centrifugation and decantation section is rich in nutrients which are good for use as cattle feed. But directly after the centrifugation process, the water content in the rice cake was found to be very high. The life period of the cake was found to be about 24-48 hours after which it would start to rot. So this DDGS plant was set up. The main objective of this plant was to extend the life period of this rice cake so that it can be stored for some weeks or more.This DDGS plant basically consists of two parts

1. The evaporation section and2. The dryer section.

EVAPORATION SECTIONFirstly the liquids that are let off from the various sections specially that obtained from the decanter, is taken into the dryer section which is called thick slop. This section basically comprises of five calendrias and the feed is let in from the third one. Steam is fed from the first calendria and vacuum is created in the last one. So the steam flows from the first to the last thus doing the evaporation and concentration of the liquid to its desired syrup form. The fluid is taken in from the third calendria. This is of falling film type evaporation technique. Thus in this way the liquid is passed on to the next calendria. This also has the same technique and is under vacuum but no heat is supplied. In the same way it passes on to the next calendria slowly losing its moisture. In this section a part of the liquid is discharged having very low total solids content. This liquid called thin slop is sent to the ETA plant for processing. On reaching the 5th calendria, it is sent to the first calendria where heat in the form of steam is applied. By this time, the liquid starts attaining its desired TS% and thus has to be pumped by force from the bottom. So this column and the next and final column has forced circulation. After passing through all these five sections, the liquid takes a syrupy form with total solid about 35%.

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A flow diagram of the evaporator section has been shown in the figure below:

DRYER SECTIONAfter passing through the evaporator section, the syrup is sent to the dryer section for further processing. In this section the syrup is added to the rice cake obtained from the decanter section in such a ratio that the total solid content of the mixture is 5%. Before mixing the syrup with the rice cake it is called DDG i.e. Distillery Dried Grain on drying. The drying is done by fluidized bed drying where the fluidized bed is produced by air both hot and then dry. Here air is drawn from the atmosphere in two different sections. In the first section, the air is first passed through hot air for heat exchange by means of coils. Then this air is further passed through two coils having steam to gain more heat. After this the air is let into the dryer. On the other hand the other part of the air is taken and is passed through coil containing chilled water. So the moisture is condensed and is let out as water. Then this dry air is passed through coils containing hot water so that some temperature is gained by the air. After this, it is

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introduced into the dryer. The feed is given from the top portion and along the process it loses its moisture and thus the total solids percent raises to about 35%. This can be stored for weeks as the moisture content is low and is like fine powder. There may be particles escaping with the air that is sent out from the dryer, so four cyclone separators are installed so as to settle all the particles and resent it to the storage facility. The capacity of the drier is about 5 tons per hour. The fine powder is then sent to storage tank and from there it is even sent for bagging or is loaded to trucks for direct selling.A short flow diagram is shown below of the drying section below:

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EFFLUENT TREATMENT PLANTAll the effluents from the whole plants cannot be directly let into the environment. Also this plant is a zero waste discharge plant. In this plant most of the bi-products are made use of in a very unique way. So the treatment with the effluents is also different. In the first case there is very less effluents. So whatever effluents that comes in the form of liquid or solid comes to the effluent treatment plant for final treatment as they have high BOD and COD values. The thin slop which comes from the evaporator section is taken into the clarifier tank and then from there it comes to the collection tank where it gets collected. From this collection tank, the waste water is then sent to the digester along with some ash which comes from the ESP from the boiler section. Now in the digester, the methane gas which is emitted is again used as fuel for the boiler and also now being used in the staff canteen due to its high purity.A brief flow diagram is shown below of the ETP section below for better understanding:

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ORGANIC MANUREThis is another section present under IFB Noorpur plant which deals with the waste products of the effluent treatment plant. This basically is a combination of different types of animal excreta like cow dung, poultry litter, etc. They are bought, dried and then they are mixed with the left over ash from the factory’s boiler. These are especially good for the soil. Organic manure is produced and packed directly from this section of the plant and is marketed under the brand TATA named as “Nabjiban”. Now a days use of this type of organic manure has increased drastically as this many beneficial qualities such as it increases the buffering capacity of the soil, nutrient availability increases for the plant and also makes the soil porous for aeration. So, plants also grow well with the use of this kind of organic manures. In this kind of organic manure, 25% water is present, phosphorus as P2O5 0.5%, potassium as K2O 0.5% which act as nutrient for the growth of the plants. There is a restriction to heavy metals which hinder plant growth so they are maintained at very low levels such as As <5 ppm, Cd <0.15 ppm, Hg <0.15 ppm, Ni <50 ppm, Cr <50 ppm, Cu <30 ppm, Zn <1000ppm. Quality checking is done periodically to maintain the levels under permissible limits.A short flow diagram is given below for better understanding of the system:

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Special thanks toMr. T. Maity,

Mr. Sankar Paul&

Mr. Prasun Samanta

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BOILERIn this plant there are three boiler of different capacity, these are 12T, 15T, 20T, among these boilers, two are tube type and one is fire tube.

The general principle of boiler is as follows:1. Bio-gas (as fuel), rice husk (as media), D.M. water (as heating

substance) comes through pipe-lines to boiler section.2. As D.M. water may contain dissolved oxygen, which has

corrosive effect on boiler is de-aeration in de-aerator tank, and passed to boiler.

3. After producing steam the flue gas (contains ash particles) is passed to dust collector (which is termed as cyclone separator) and again passed to venture wet scrubber to maximize the separation process and the separated particles are collected in bag separator and cleaned flue gas is passed to stack.

4. Generated steam (super-heated or saturated) is by passed to the place of requirement.

5. And the ash generated from the boiler is scrubbed out and used as land filler. Working principle of the three boiler is more-or-less same, except the steam generation procedure & the steam usage procedure

Use of 12T boiler: This medium pressure maintained boiler is a fire tube type boiler, where fire is passed through number of tubes surrounded by a tank of water the fire is charged through a fire box, containing diesel, channelized through some tube thus surrounded water get heated, steam is produced and supplied to the processing plant.

Use of 15T & 20T boiler: These two boilers are also a medium pressure maintained boiler. these boiler are water tube type boiler, where water get heated using the heat generated from the surrounded fire, as this type of

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steam contains higher temperature, is used on the turbine to produce electricity, which is consumed within this plant. After discussing on the working principle of this section plant, it can be said that this plant is saving energy & also reduces the costing which brings profit to this industry.The turbines connected to the steam from the boiler is of 2 megawatt capacity and under full functionality, the turbine can generate 2.5 megawatts of electricity which is more than enough for the functioning of the plant. The power consumption of the plant is 2 megawatts only so the boilers are run at low load and the steam is reused in various section of the plant to reduce energy consumption by the plant and thus save energy, save earth.

ELECTRO STATIC PRECIPITATOR:At IFB Agro. the air discharged from the boiler previously contained ash particles and other small particles that did not precipitate in the cyclone separator, so they have recently installed this high capacity ESP which stops any unwanted particles to be vented out with the air. At regular intervals, hammering is done so as to collect and settle the ash to the bottom and is thereby carried away to be stored into tanks for use in the making of organic manure.

Comments: Environmental factors like air has been taken special care of and required equipment have been installed to control pollution of the environment. Also the water used for the boiler is reused and the water intake from water sources has been minimized.

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Water Treatment PlantAny distilleries cannot be run without a water treatment plant, as the water should be used here should be as much chemically pure as commercially feasible, since traces of impurities react with other constituents of the drink. Water treatment plant has its necessity in this regard, i.e. to soften the hardness of water as well as chemically & biologically pure.The treated water is being used as molasses & grain distillation, boiler, fermenter. The vessels used here are

1. Raw water storage tank2. Header3. Pumps4. Soft water storage tank5. R.O water storage tank6. Degasifying tank7. De-alkalize8. IRF9. MGF

1. Raw water storage tank: This is the first storage tank, where impure water drawn from underground water storage by means of deep tube well. From this storage point water is send to a header where 5 different pumps are set to distribute water to different location as per requirement.

2. Pumps: Soft water feed pump Old R.O. feed pump D.A. feed pump New R.O. feed pump

3. Soft water storage tank:

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The water shared in the tank is get pumped from 1& 2 no. pump. Water from no. 1 pump firstly gets treated at M.G.F. (Multi-grand filter, removes iron present in water). Water from no.2 pump gets treated at “mixed bed” tower where both MGF & IRF is set. Both the treated water is stored in this soft water tank. From this tank there are two distributing lines, one is for molasses distillation and another one is for grain distillation.

4. Reverse osmosis filtration: This is a very important filtration system, used to filter the treated water. The principle of osmosis passes of solvent molecules from a solution of lower solute concentration through a semi permeable membrane, R.O. system or reverse osmosis system relies in the reverse of this principle, i.e. passes of solvent molecule from a solution of higher solute concentration through a semi permeable membrane.Water pumped from no. 3 pumps firstly filtered at IRF, before entering at MGF its gets mixed with NaOCl (to kill the bacteria remain in water) after filter at MGF it mixed with sodium meta-bisulphate (to neutralize CI), HCL(to avoid membrane chocking), anti-scaling agent (to avoid scaling). After chemically treatment water is passed from two cartridge filter, which are connected a t series, and treated containing permeable filter, where highly pressured water leave the solute portion (impurities) & transmitted to the outlet and passed from next treatment. In the following step dissolved CO2 is removed, by means of blowing air at the falling water, and then it is stored in the storage tank and again processed to demineralized and stored in tank. Water pumped from no. 5 is treated in same way filtered in a reverse osmosis system and stored in the same tank. The old set up has two separate filters installed in a pot but at the new setup around 30 cartridges are installed in one stainless steel container.

5. De-alkalizing tank: From the no.4 pump, water comes to the DE-alkalized tank: De-alkalized water is passed to 12T boiler.

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Special thanks toMr. S.

Bandopadhyay&

Mr. S. Khan

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

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

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

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Special thanks toMr. N. C. Pal.

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QUALITY CONTROLQuality control is a huge aspect of any company and plays a very important role in the industry. Right from the unloading area to the final finished product, it has to look deeply. So coming from the beginning, we first come to the assessment of the raw material at the point of arrival.

MILLING SECTIONHere the raw broken rice is initially checked for a few factors like

Serial no. Factor Acceptable limit1. Moisture content 13.5%2. Ash 2.15%3. Husk and dust 2%4. Paddy 3%5. Starch 69%

Moisture content is calculated from IR moisture meter which gives the moisture reading after a certain period of moisture removal by means of infrared radiations.Ash content is found out by means of ashing a measured amount of sample.Similarly, husk and paddy percent is found out by taking a measured amount of sample and blowing off the husk and dust. After blowing off the dust and husk, the weight is taken again.

STARCH ESTIMATIONStarch is found out by taking a weighed sample and grinding it in a mixer grinder, then the starch is converted to sugar by the use of enzymes and then sugar is estimated. This is done to test the milling efficiency and also to check PROCEDURE: We take 3 gm. of sample flour and add a small amount of distill water then heat it. We then add two drops of 1st enzyme alpha amylase and then boil for 1 hour. After this we add cool the mixture to room temperature. Then we add 4 drops of 2nd enzyme amyloglucosidase. The mixture is then constantly maintained at a temperature of 60° C for another two hours. The volume of the

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mixture is then made up to 250 ml. Now from the stock solution, we take 25 ml and volume make up to 100 ml. The solution is filtered and pH is neutralized by NaOH solution. After this it is titrated against 5ml Fehling’s A +5 ml Fehling’s B solutions. The burette reading is noted.CALCULATIONS:TIS% (Total Inverted Sugar %) TIS% = ( =70%Here, 0.2 gm. standard glucose in 100 ml solution is titrated against 5 ml Fehling’s A and 5 ml Fehling’s B solution. The burette reading on standardization was found out to be 25.8 ml.

Dilution Factor = (3/250)*(25/100) =0.003As 3 gm. Sample flour was taken and volume was made up to

250 ml and from there 25 ml was taken and volume made up to 100 ml.

Burette reading on titration with sample was found to be 22.1

(C6H10O5)n→C6H12O6

Thus, (162)n→180So, conversion factor = 180/162 =1.11

1.11 is the conversion factor for starch to sugarThus the total starch content was found to be 70% i.e. 70 gm. sugar was obtained from 100 gm. of flour.

MILLING EFFICIENCYMilling efficiency is checked by checking the particle size of the milled flour. This is also checked because if the particle size would be large, the activity of the enzymes would be highly hindered due to less surface area. If they get lesser surface area for acting, then the conversion of the flour or rather starch to sugar would be less. Ultimately the yeast will get less sugar to act upon, leading to reduction in the production of alcohol. Thus particle size checking is done in this section as a check for quality.This is done by taking a measured amount of the milled flour and is passed through sieves of pore size of 5 micron. Thus if more than 90

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% of the milled flour passes through the sieves then it accepted otherwise it is resent for milling.

FERMENTER SECTIONNow, coming to the quality control parameters in fermenter unit, we have the microbial count, specific gravity test and various other tests for the fermented mash and also we have a lab parallel to detect the various parameters of the process.

1. MICROBIAL COUNT: This is done by the means of a haemocytometer. In this the mash is taken from the pre fermenter at intervals and a small portion is taken into this slide. It is then placed under the microscope and cell count is taken. With the help of this device, the growth phase of the cells can also be understood and depending on that the decision regarding the transfer of the pre fermenter mash to the main fermenter is taken.There are 25 small squares in the H shaped portion of the haemocytometer and each of this has 16 even smaller squares within them. The cell count is taken as an average of the number of cells in the 16 boxes.RESULTS:Thus the cell count obtained for our sample was found to be 10 in each of the 25 boxes. So the cell per ml is 10*25*106 i.e. 2.5*108 which is quite good. Acceptable range is 1.25 to 1.85*108.A brief diagram of this haemocytometer is shown below:

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

=35 hours approx.

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DISTILLERY SECTIONIn the distillery section many tests are performed so as to ensure quality of the final Extra Neutral Alcohol. The tests include alcohol percentage, Potassium Permanganate test, test for esters, test for fusel oils, test for methanol and test for volatile acidity. Each of these tests is discussed below:1) ALCOHOL PERCENTAGE: PROCEDURE: we take test spirit in a measuring cylinder of 100 ml and fill to the brim. Then we put a standard alcohol meter with calibrations from 90-100. We swirl the alcohol meter in it so as to make the liquid of homogeneous. Then we note the reading along with the temperature. After this we calculate the % of alcohol from alcohol table.RESULTS:In our test sample, we got indication of 98.7 at a temperature of 33° C.Thus, from alcohol table we get alcohol % as 96.1%.

2) POTASSIUM PERMANGANATE TIME TEST:PROCEDURE: We take 50 ml of sample alcohol in a nesla tube. Then we maintain temperature at 15° C and add 2.5 ml of 0.0316% KMnO4 and constantly monitor the temperature. Also simultaneously note the time for the color to change to salomon red color. If there is high amount of impurities then color change occurs very rapidly.RESULTS:In our case the PP time for ENA was found to be 40 minutes and for rectified spirit it was found to be 28 minutes which maintain the quality norms of the plant. Minimum PP time for quality acceptance is 27 minutes.3) TEST FOR VOLATILE ACIDITY:PROCEDURE: We take 50 ml of sample in 250 ml round bottom flask and titrate against standard NaOH solution.RESULTS: Test was not performed only method discussed.4) Test for fusel oils:

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

where v is difference in ml of standard sulphuric acid used for blank and sample.

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V1 is the alcohol, percent by volume.Note: 1 ml of standard sodium hydroxide solution is equivalent to 0.0088 of ethyl acetate.RESULT: Test was not performed.

LAB PARALLELSample flour’s lab parallel was performed for the clarification of concept. The procedures, results and conclusion are as follows:Amount of flour taken = 150 gm.1st enzyme used for the purpose as 0.65 Kg/ton flour2nd enzyme used for the purpose as 0.75 kg/ton of flourEstimation for 1 st enzyme: 1000 Kg flour requires 0.65 Kg of enzymeSo, 150 gm. requires (0.65*150)/ (1000) gm. of enzyme

=0.0975 gm. of enzyme.Estimation for 2 nd enzyme: 1000 Kg flour requires 0.75 Kg of enzymeSo, 150 gm. of enzyme requires (0.75*150)/ (1000) gm. of enzyme

=0.1125 gm. of enzyme.PROCEDURE: The 150 gm. sample flour was taken in a pre-cleaned beaker. In this the measured amount of sample of 1st enzyme was taken and then boiled for 1 hour. After this the mixture was taken and kept for some time to cool to room temperature. Then the 2nd enzyme was added and the temperature was constantly maintained at 60° C for 1 hour. Then this mash was kept to cool to room temperature. After this a measured amount of yeast about 2.5 gm. was added to the solution. The mash was then cotton plugged and kept for 2 days for the yeast cells to ferment the sugars into alcohol.After 2 days, 250 ml of the mash was then transferred to a round bottomed flask. A small distillation setup up was made with a condenser and another flask. The liquid was boiled and the vapors were collected for further analysis.

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RESULTS AND CALCULATIONS:After distillation, alcohol estimation was done and it showed an indication of 11.7 at 25° C. Thus from alcohol table alcohol % was found out to be 10.7.Total volume of the fermented mash was found to be 620 ml.TOTAL SUGAR TEST:PROCEDURE: 25 ml of the mash was taken in 100ml flask and then heated in water bath for 1 hour after adding the calculated amount of the 1st enzyme.After heating for 1 hour, the mash was cooled to room temperature and then the 2nd enzyme was added. It was then maintained at a temperature of 60° C for another 1 hour. Finally after that the mash was cooled to room temperature and then sugar estimation was done by neutralizing first and then titrating against 5 ml Fehling’s A and 5 ml Fehling’s B.RESULTS:Burette Reading = 29.00 ml.Total Sugar = (0.002*25.8*100%)/ (Dilution Factor*Burette

Reading)=0.717%

Dilution Factor =25/100=0.25

RESIDUAL SUGAR TEST:PROCEDURE: 100 ml of mash was filtered and taken in a beaker and to it 2 drops of phenopthlein was added to check the pH of the liquid. If not neutral pH adjusted by adding NaOH solution and the liquid was then taken in a burette and titrated against 5 ml Fehling’s A and 5 ml Fehling’s B. The burette reading was noted.RESULTS:Burette Reading = 29.6 ml.Residual Sugar = (0.002*25.8*100%)/ (Burette Reading)

= 0.17432%Thus, sugar from residual starch = (0.7117-0.17432)

0.53742%

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So, Residual Starch = 0.53742/conversion factor of starch to sugar)= 0.53742/1.111= 0.48373%

FERMENTATION EFFICIENCY:FE% = Alcohol%*Total Volume*100%)/

(0.644*1.111*70.05*150)= 88.18%

Where,Alcohol% = 10.7%, Total Volume = 620 ml

C6H2O6→C2H5OH180 → 921→ 0.511

Specific gravity of alcohol = 0.795So, 1 mole of sugar = 0.511 /0.795alcohol

=0.644 alcohol.IN DETAILS

THEORETICAL ALCOHOL100 gm. flour gives 70 gm. starchSo, 150 gm. flour gives (70*150)/100 gm.

= 105 gm. starch.Again, 105 gm. starch gives 105*1.111 gm. sugar

= 116.821 gm. sugarThen, 150 gm. flour gives 116.821 gm. sugarNow, we know theoretically that,1 ton flour gives 644 liter alcohol So, 1 gm. flour gives 644*103 ml alcoholSo, 116.821 gm. sugar gives (644*103*116.821)/103

= 75.23 ml of alcoholPRACTICAL ALCOHOL = (10.7*620)/100

=66.34 ml alcoholThus, Efficiency of the process = (Practical alcohol/

Theoretical alcohol)*100= (66.34/75.23)*100=88.18%

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QUALITY ANALYSIS OF CO2As CO2 products is a major products at the IFB Noorpur Plant and has trusted customer like Coca-Cola. The main parameters of quality checking in the CO2 plant are the purity, the moisture and the percentage of impurities checking is prime task of the quality analysis. A few of the methods of quality checking are listed below:

Purity of CO 2 : Purity of CO2 is checked by an apparatus called Zahm & Nagel. This is an L-shaped apparatus in which both the gases during the time of receiving as well as during filling into tanks is checked one at a time. Basically what is done is that the gas is pushed through one end and then enclosed. Then a solution of NaOH is let into the apparatus. After this, the level is checked to determine the purity. Only gases with 99.89 % purity are accepted or else are vented off.

Online moisture analyzer: This apparatus monitor the percentage of moisture content of the gas continuously and based on this a report is generated within the system. Only gases with moisture content less than 20% is accepted for both industrial and food grades.

Gas chromatography: This instrument is basically of two types:

a) One uses Flame for detection of impurity level called FID (flame ionizing detector)

b) One which gives Photographic images for various impurities called PID (photo ionizing detector)

These two chromatography instruments are operated manually and thus have to be checked periodically for variations in impurities percentage.

Total quality analyzer: This is an online instrument which continuously monitors the sulphur content and the total hydrocarbon continuously. On the basis of the readings it generates a report and thus the quality of the product is monitored.

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Special thanks to

Mr. A. Mondal,

Mr. S. Mukherjee

&

Mr. S. B. Bhattacharyya

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MECHANICAL MAINTENANCEA pump is a device used to move fluids, such as liquids or slurry. A pump displaces a volume by physical or mechanical action.

A positive displacement pump causes a fluid to move by trapping a fixed amount of it then forcing (displacing) that trapped volume into the discharge pipe. A positive displacement pump can be further classified according to the mechanism used to move the fluid:

• ROTARY-TYPE, for example, the external gear, screw, shuttle block, helical twisted roots (e.g. the wendelkoiben pump) or vacuum pumps.

• RECIPROCATING-TYPE, for example piston or diaphragm pump

Positive Displacement Pumps has an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant given each cycle of operation.

CENTRIFUGAL PUMP:

A centrifugal pump is a roto dynamic pump that uses a rotating impeller to increase the pressure and flow rate of a fluid. Centrifugal pump are the most common type of pump used to move liquids through a piping system. The fluid enters the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward or axially into a diffuser or volute chamber, from where it exist into the downstream piping system. Centrifugal pumps are typically used for large discharge through smaller heads.

Cooling Tower

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Cooling tower are large diameter columns with special types of packing designed to give good gas-liquid contact with low pressure drop. When warm liquid is brought into contact with unsaturated gas, part of the liquid evaporates and the liquid temperature drops.

With respect to drawing air through the tower, there are two types of cooling towers:

• Natural draft, which utilizes buoyancy via a tall chimney. Warm most air naturally rises due to the density differential to the dry cooler outside air. Warm moist air is less dense than drier air at the same pressure. This moist air buoyancy produces current of air through the tower.

• Mechanical draft, which uses power driven fan motors to force or draw air through the tower.

1. Induced draft: A mechanical draft tower with a fan at the discharge which pulls air through tower. The fan induces hot moist air out the discharge. This produces low entering and high exiting air velocities, reducing the possibility of recirculation in which discharged air flows back into the air intake. This fan/fin arrangement is also known as draw-through.

2. Forced draft: A mechanical draft tower with a blower type fan at the intake. The fan forces air into the tower, creating high entering and low exiting air velocities. The low exiting velocity is much more susceptible to recirculation. With the fan on the air intake, the fan is more susceptible to complications due to freezing conditions. Another disadvantage is that a forced draft design typically requires more motor horsepower than an equivalent induced draft design. The forced draft benefit is its ability to work with high static pressure.

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Heat Exchanger

Heat exchangers are devices built for efficient heat transfer from one fluid to another and are widely used in engineering processes. Some examples are intercoolers, preheaters, boilers and condensers in power plants. By applying the first law of thermodynamics to a heat exchanger working at steady-state condition, we obtain:

mi (hi1-hi2) = 0where,mi = mass flow of the i-th fluiddel hi = change of specific enthalpy of the i-th fluidThere are several types of heat exchanger:

• Recuperative type, in which fluids exchange heat on either side of a dividing wall• Regenerative type, in which hot and cold fluids occupy the same space containing a matrix of material that works alternatively as a sink or source for heat flow• Evaporative type, such as cooling tower in which a liquid is cooled evaporative in the same space as coolant.

The heat exchanger may be classified according to the flow pattern as:

• Parallel-flow heat exchanger• Counter-flow heat exchanger• Cross-flow heat exchanger

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

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Control Valves:

Control valves are valves used to control conditions such as flow, pressure, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "set point" to a "process variable" whose value is provided by sensors that monitor changes in such conditions. Control Valve is also termed as the Final Control Element.

A control valve consists of three main parts in which each part exist in several types and designs:

Valve's actuator Valve's positioner

Valve's body

THERMOCOUPLE:A thermocouple is a junction between two different metals that produce a voltage related to a temperature difference. Thermocouples are a widely used type of temperature sensor for measurement and control and can also be used to convert heat into electric power. They are inexpensive and interchangeable, are supplied fitted with standard connectors, and can measure a wide range of temperatures. The main limitation is accuracy: system errors of less than one degree Celsius (C) can be achieved.Any junction of dissimilar metals will produce an electric potential related to temperature. Thermocouples for practical measurement of temperature are junctions of specific alloys which have a predictable and repeatable relationship between temperature and voltage. Different alloys are used for different temperature ranges. Properties such as resistance to corrosion may also be important when choosing a type of thermocouple. Where the measurement point is far from the measuring instrument, the intermediate connection can be made by extension wires which are less costly than the materials used to make the sensor. Thermocouples are usually standardized against a reference temperature at the instrument terminals. Electronic instruments can also compensate

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for the varying characteristics of the thermocouple, and so improve the precision and accuracy of measurements.Thermocouples are widely used in science and industry: applications include temperature measurement for kilns, diesel engines, and other industrial processesPRINCIPLE OF OPERATION: When any conductor is subjected to a thermal gradient, it will generate a voltage. This is now known as the thermoelectric effect or seebeck effect. Any attempt to measure this voltage necessarily involves connecting another conductor to the “hot” end. This additional conductor will then also experience the temperature gradient, and develop a voltage of its own which will oppose the original. Fortunately, the magnitude of the effect depends on the metal in use. Using a dissimilar metal to complete the circuit creates the circuit in which the two legs generate different voltages, leaving a small difference in voltage available for measurement. That difference increases with temperature, and is between 1 and 70 microvolts per degree Celsius (μV/°C) for standard metal combinations

MAGNETIC FLOW METER: Magnetic flow meter, is an electromagnetic flow meter or more commonly known as mag meter. A magnetic field is applied to the metering tube, which results in a potential difference proportional to the flow velocity perpendicular to the flux lines. The physical principle at work is electromagnetic induction. The magnetic flow meter requires a conducting fluid, for example, water that contains ions, and an electrical insulating pipe surface, for example, rubber-lined steel tube.Usually electrochemical and other effects at the electrodes make the potential difference drift up and down; making it hard to determine the fluid flow induced potential difference. To mitigate this, the magnetic field is constantly reversed, cancelling out the static potential difference.

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CONCLUSIONThis article is not about any technical discussions, neither it is any acknowledgement, both are already done. This is to share our experience and give our feedback after these 15 very informative days.

This was our first industrial exposure, and in true sense it added a practical dimension to our theoretical knowledge. We may have studied distillation column, their principle in books, but watching a real column with different type of trays is fantastic. Interaction with personal working here on field did boost our practical knowledge. It was pleasure on our part to use the quality control lab facilities, hearing experiences from skilled individuals who have huge industrial experiences and it was really nice to practically witness the functioning of different systems which till now we had only known theoretically. These would create a long lasting memory for us and would also be of great help for us in our near future.

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