TWO EFFECT FALLING FILM MILK EVAPORATING PLANT

TWO EFFECT FALLING FILM MILK EVAPORATING PLANT

A. Technical Specification & Operating Parameters

           

Product	Skim milk
Feed Rate	2600 Kg/hr
Feed Temp	5 to10°C
Initial Solid	8 %
Final Solid	45%
Concentrate rate	450 Kg/hr
Water Evaporations	2150 kg/h
Holding Time	10-15 secs
Concentrate Temp	48°C
Steam consumption for TVR	475Kg/hr @ 8 bar
Steam consumption for high heater	125Kg/hr @ 3 bar
Installed Load	Kw
Average Power load	Kw
Cooling water Temp.	32°C   /40°C
Cooling Water	30 m3/hr
Compressed Air	Air at 8 Bar (Nominal)

                                     

B. Electrical Load Data Sheet

Pumps	Power load (Kw)
Feed Pump	2.2 Kw
Cal 01	1.1 Kw x 2
Cal 02	1.1 Kw x 1
Cal03	1.1 kw x2
Vacuum Pump	5.6 Kw
Condensate pump	1.1 Kw
Cooling water pump	3.7 Kw x2
Total	22 Kw

C. Scope of Supply

S. No.	Equipments	Quantity
1	Feed Balance Tank Capacity: 300 Ltrs. MOC: SS 304 It will be fabricated from stainless steel   conforming to AISI 304 quality.  It will be supported on 3 No. S. S. legs & adjustable ball feet.  It will further comprise of inlets for concentrated product, concentrated product of the sampling line and one number outlet connection for product complete with union.	01 No.
2	Inline Filter Cap: Matching with feed rate MOC: SS 304. This filters the foreign material.	01 No.
3	Feed pump Cap: Mentioned in Electrical load data sheet	01 No.
4	Preheater TYPE: Coil type  M.O.C: SS 304 The preheaters will utilize the vapors from the Evaporating plant and will be suitable for heating the milk from 6º C to 65ºC.	02 Nos.
5	High-heater TYPE: shell & tube l type  M.O.C: SS 304 The high heaters  will be suitable for heating the milk from 65º C to 85ºC.	02 Nos.
6	Holding tube assembly  To hold milk on pasteurizing temp for 3 min	01 No.
7
8	Calandria MOC: SS 304 All the Calandria will be fabricated from stainless steel confirming to 304 quality.  Around the evaporator tubes S. S. shell will be provided with necessary connections for steam vapors, condensate outlet, Air vent thermometer pockets etc.      Calendria will be supported on the ground floor.  It will be Al cladded.	03 Nos.
9	Vapor Separator M.O.C: SS 304 Each calandria will be connected to the vapor separator.  It will be fitted with sight and light glass assembly, vacuum gauge, thermometer pockets with thermometer, manhole, and cleaning nozzles. will be polished from inside to 150 grits & from outside to dairy finish.	03 Nos.
10	Intermediate Product & Concentrate Transfer Pumps To transfer product from one pass to next within the same Calendria or from one effect to next.	One lot
11	Condenser M.O.C: SS 304  Shell & tube type, To condense the vapor released from the vapor separators	01 No.
12	Vacuum pump	01 No.
13	Condensate Pump	01 No.
14	SS Pipes, Valves & Fittings	01 lot
15	Water balance Tank MOC: SS 304 Cap; 100 lit	01 No.
16	Steam Pipes ‘C’ Class M.S. From Header to TVR ASSEMBLY only	01 lot
17.	TVR MOC: SS 304	01 No.
18.	Instrumentation The control panel shall comprise of the following: a. Main incoming SFU’s step down transformers.      Starters for all pumps & Vacuum pumps. b. All panel mounted instruments. c. Fault annunciators, which shall be of Audio/Visual type.     Test- accept- reset type push buttons shall be provided.      d. A mimic diagram depicting the flow in the system. e. Auto TVR Control system shall be provided f. Auto high heater steam control	01 lot
19.	MCC Panel: Low tension switch board in totally weather and vermin proof sheet steel construction (Powder coated), floor mounting and compartmental design, with bus bars suitable for 3 phase, 415 volts, 50 cycles, 4 wire AC supply. Starter and relays will be of ABB/Siemens/L&T make. Incoming: 1No. Incoming feeder with ammeter of suitable rating with nenecessary current transformer and selector switch. 2  No. voltmeter with necessary selector switch 3 No. Indicating lamps. Outgoing: Switch gear for various motors included in our scope in the plant. Auxiliary contacts for alarm annunciators One 10 amp. Toggle switch and 10 amp. HRC fuse arrangement for 230 volts AC supply for instrument panels.	01 lot

THREE STAGE SPRAY DRYER

A. Performance parameters for Dryer

Particulars	Skim milk powder
Feed Rate	465 Kg/hr
Temperature of Feed before Preheater	48 Deg C
Temperature of Feed after Preheater	75 Deg C
Feed solids	45%
Total Water Evaporation	248 kg/hr
Powder Production	217  Kg/hr
Powder Moisture	3.5%
Inlet Air Temp.	185 Deg C
Total Steam for dryer	750 Kg/hr @ 14Bar
Total steam for dehumidifier	100 Kg/hr
Chilled Water (2—8) 0C	10  m3/hr
Total Power Installed  (with high pressure atomizer)	60  Kw/hr
Total power consumed	50 Kw/hr

NOTE:

1.              Temperatures are indicative.

2.              Consumption Figures and performance are valid with a tolerance of + 10 %.

3.              The energy consumption figures are average for the production period.

B. Electrical Load Data sheet

Feed Pump		2.0 HP
Atomizer/High pressure pump		25.0 HP
Supply Fan		20.0 Hp
Exhaust Fan		25.0 Hp
Rotary Valve/ Blow Through Valve		1 Hp X 3
Sifter		2.0 Hp
TOTAL		77 hp

 

C. Scope of Supply

S. No.	Equipments	Quantity
1.	Concentrate Balance tank MOC: SS 304 Capacity –  300 Lit. The balance tank is vertical, UN-insulated, with conical bottom and flat top. The tank is supported by legs with SS ball feet for vertical adjustment in level up to 50 mm. The tank is complete with following accessories: 1 No. No foam inlet at top surface. 1 No. outlet SMS connection at tank bottom. 1 Set of semicircular removable top covers. All inside welds to be ground smooth and internal surfaces to be ground to sanitary finish.	01 No.
2.	Duplex filter MOC: SS 304 For filtering the product with valves & fittings.	01 No.
3.	Water balance tank Cap: 100 liters MOC: SS 304 A water funnel is provided in feed line for feeding water to the plant during starting / stopping operations.	01 No.
4.	Feed pumping system      It will comprise of the following
4.1	Feed Pump MOC: SS 304	01 No.
4.2	Feed pre-heater system MOC: SS 304 For preheating the feed product up to 75 Deg. C. temperature. The preheating system comprises of: -Shell & Tube pre-heater -Steam valves, pipes & fittings	01 No.
4.3	Feed pipes and fittings MOC: SS 304 To interconnect concentrate storage tanks, water tank and feed pump with the Pressure atomizer and return line from atomizer for in place of cleaning of the feed line.  The fittings will be of SMS.	01 No.
6.1	High pressure feed pump   Suitable high pressure feed pump with product contact parts SS304 easy for cleaning.  The pump shall be complete with necessary motor.  The feed rate to the atomizer is varied by regulating the Pressure adjusting Valve mounted on High Pr. Pump.
6.2	Nozzle Atomizer   One set of nozzle atomizer complete with high-pressure rubber pipe of food grade quality.  Swirl chamber, orifice plate and the other components of nozzle assembly shall be supplied.  The atomizer shall be complete with high-pressure tubes, accessories and a set of nozzles all assembled in an atomizer head i.e. fitted in the space provided at the centre of the drying chamber.	01 No.
7.	Atomizer stand For support of the atomizer during cleaning and maintenance, A washing trough in SS with a drain is mounted on the support for easy cleaning and maintenance of the atomizer	01 No.
8.	Drying chamber system
8.1	Air distributor Placed in the center of the chamber ceiling.  The Special designed construction gives a uniform distribution of the air in the chamber and secures a well-defined air velocity profile around the atomizer at a moderate pressure loss.  The air enters the chamber via a Vertical inlet duct .Air flow direction is maintained vertically down co-current to feed by means of special Wire Mesh. The air distributor hot air contact parts are made of stainless steel.	01 No.
8.2	Drying Chamber Made of SS 304 with welded joints, outside bracing made of structural MS. The cylindrical chamber has conical bottom & a flat reinforced ceiling upon which the air distributor is placed. The part of the chamber ceiling, which is in contact with the hot air, is cooled on order to prevent possible overheating of powder particles. The chamber consists of: -Reinforced chamber ceiling duly insulated & covered with top plate of the skid proof type of mild steel painted with an anti-corrosion paint including kick plate. -Cylindrical part with horizontal stiffeners of mild steel welded  to the outside of   the cylinder -Conical bottom with vertical and horizontal stiffeners of mild  steel welded to the cone. -Light source for inside illumination. -Access door in the cylindrical part. The prefabricated chamber ceiling and bottom cone in  sections will be supplied.  Fabrication of chamber shell and assembly will be done at site.  The chamber shall be insulated & cladded with Aluminum sheets.	01 No.
8.3	Air outlet duct MOC: SS 304 Designed to convey the drying air and the powder to the cyclone where the separation of the powder will take place.	01 No.
9.	Cyclone separator Designed for highly efficient separation of the powder from the drying air.  The separation of the powder from the air occurs during a spiral movement inside the cyclone and the powder leaves the cyclone at the bottom. The cyclone consists of: -Tangential inlet -Cone -Center tube -Cyclone top with detachable cover for easy inspection and cleaning The cyclone is made of Stainless Steel AISI 304.	01 Nos.
10.	Blow through Valve For continuous discharge of powder from cyclone separator.  The valve is of sanitary design. The rotary valve comprises of: -       -SS Housing -       -SS 304 rotor -       -Solid stainless shaft TEFC drive motor with gearbox.	01 Nos.
11.	Fines Recycle System For transporting the fine fraction of the powder to the wet atomization zone in the drying chamber by pneumatic transport system. The system consists of:
11.1	Fines distributor Installed in the air distributor of the drying chamber, is made of AISI 304.  The distributor introduces the fines around the atomizer assembly.  Air-cooling of fines tubes prevents overheating of the powder when passing through the hot air zone. -fines injection tubes -cooling jacket for the tubes cooling air supply (part of neck cooling system	01 No.
11.2	High pressure blower For supplying high-pressure air for transporting the fines to fines distributor or External fluid bed. -TEFC motor	01 No.
11.3	Fines Return Pipe Includes a set of pipes to introduce the fines being blown from the blow through rotary valves provided at the bottom of the cyclone separators, to the following points.  It consists of three number deviator Joint to divert the fines to -To the wet zone in the nozzle spray area in the chamber -To the first drying section of the external fluid bed dryer -To cooler section of the external fluid bed dryer section	01 No.
11.4	Air ducts MOC: SS 304 From cyclone to exhaust fan. Necessary transition pieces, flanges and gaskets, etc. are included.	01 No.
12.1	Exhaust Fan For the exhaust air. The fan will be of the centrifugal type. It shall consists of -housing with inspection opening and drain -Statically & dynamically balanced robust impeller of self cleaning type. -Shaft with heavy duty ball/roller bearings, grease lubricated. -TEFC Motor -V-Belt drive with safety guard. -Base frame etc.	01 No.
12.2	Exhaust Chimney In MS Construction. The duct will lead the spent air from exhaust fan to atmosphere. Necessary transition pieces, gaskets, flanges and air hood are included. The chimney shall terminate at 1 M above building.	01 No.
13.	Integrated Fluidized bed dryer
13.1	Integrated Bed Fluidizing Chamber It shall be made of SS 304 & it shall consist of single compartments for drying . It shall have specially designed perforated sheet so as to direct the hot air with powder flow. Also it will have Inspection doors                                          :           02 Nos,          Hot Air inlet                                                    :           01 Nos.	01 No.
13.4	Air heating system For indirect heating of the dehumidified supply air.  The air heater is designed with special attention to high thermal efficiency and a low pressure drop.	01 No.
13.5	Hot air duct For conveying the air from the air heater to air distributor.  The duct will be complete with transition pieces, flanges, packing, hardware and insulation supports. The duct will be made in stainless steel  AISI 304 .	01 No.
14.	External fluid bed dryer MOC: SS 304 Of vibrating type for continuous drying & cooling of the powder. The fluidized powder passes through the fluid bed in crosscurrent flow with cooling air and is discharged by overflow at the outlet weir.  The cooling air and drying air enter through the bottom of the perforated plate. The perforated plate with directional holes has been specially designed for easy emptying of fluid bed by opening of the outlet weir.  The upper part of the fluid bed has been specially designed with larger cross sectional area, which effects stabilization of the fluidization process and separation of fines from outlet air. The fluid bed consists of: -Air distribution bottom part with cleaning doors -Drain funnels -Inlet air duct connections -Perforated plate welded to a supporting frame -Inclined powder inlet with a perforated plate at the bottom -Upper part housing with cleaning and inspection openings -Air outlet -Powder outlet -Flexible connections for inlet and outlets -Light source for internal illumination -Vibro motors -base frame with spiral springs The fluid bed is in sanitary design.	01 No.
15.	Hot air system for spray drying chamber
15.1	Air intake filter For the pre and fine filtration of drying air, comprising Stainless steel housing and filter mats. Filter mats are made of special fiber and washable.	01 No.
15.2	Delivery fan Of the centrifugal type with fan and motor assembled on a common base frame and consisting of: -housing with inspection opening and drain -Impeller, statically and dynamically balanced -Shaft with heavy duty ball/roller bearings, grease lubricated -Totally enclosed, fan cooled motor -V-belt drive with safety guard -Base frame with vibration dampers -Flexible connections for air inlet and outlet The fan, including housing, impeller and base frame are made of painted carbon steel with an anticorrosion paint.  The air quantity can be adjusted by means of a damper situated at the inlet of the fan.	01 No.
15.3	Air duct Including necessary transition pieces, flanges and gaskets connecting the delivery fan and the air heater.  The duct is made of galvanized steel.	01 No.
15.4	Air heating system For indirect heating of the supply air.  The air heater is designed with special attention to high thermal efficiency and a low pressure drop The air heater consists of: -Steam heating coil made of SS, Al fins -SS housing -Necessary connections complete with flanges	01 No.
15.5	Hot air duct For conveying the air from the air heater to air distributor.  The duct will be complete with transition pieces, flanges, packing, hardware and insulation supports.  The duct will be made in stainless steel AISI 304.  The steam air heater shall be installed at atomizer level and the length of the duct has accordingly been estimated & included. Insulation and cladding will be done at site.	01 No.
16.	Hot air supply system for external fluid bed
16.3	Air duct Including necessary transition pieces, bends, flanges and gaskets connecting the delivery fan and the dehumidifier battery.  The duct is made of SS.	01 No.
16.4	Air Heater For indirect Heating of the supply air. The Air Heater is designed with special attention to high efficiency and a low-pressure drop. The Heater consists of: -Steam heating coil made of SS tube with Al fins -SS housing with drip collection & drain -Necessary connections complete with flanges.	01 set.
17.	Cool air supply system for external fluid bed
17.3	Air duct Including necessary transition pieces bends flanges and gaskets connecting the delivery fan and the dehumidifier battery.  The duct is made of SS.	01 set.
17.4	Dehumidifier battery For indirect chilling of the supply air, The dehumidifier is designed with special attention to high cooling efficiency and a low-pressure drop. The dehumidifier consists of: -Cooling coil made of SS tube with Aluminum fins -SS housing with drip collection & drain -Necessary connections complete with flanges.	01 set
17.5	Air Heater For indirect Heating of the dehumified air from 11 deg C to 28 Deg C. The Air Heater is designed with special attention to high efficiency and a low-pressure drop. The Heater consists of: -Steam heating coil made of MS tube with MS Galvanized fins -GI housing with drip collection & drain -Necessary connections complete with flanges.	01 set
18.	Instrumentation & control system Instrument panel in S. S. & front plate of acryl in which a flow sheet will be screen printed.  The instrument panel is pre-wired to terminal connections and complete with following: 3 Nos Temp. Indicators, Range 0 to 200 Deg. C for the following concentrate preheating temperature drying air inlet temperature outlet air temperature. 3 Nos Temp. Indicators, Range 0 to 100 Deg. C for hot air and cold air for FBD, Integrated bed 1 No Ammeter, for exhaust fan. 1 No Lockable key for control supply 1 Set Push buttons ON/OFF for motors with indication lamps 1 Set 24V, DC, 2A power supply for lighting 1 No. Auto temperature control for Hot air supply to main chamber 1 No. auto temperature control for FBD heater. 1 No. auto temperature control for Integrated bed .	01 set.
19.	MCC Panel Low tension switch board in totally weather and vermin proof sheet steel construction (Powder coated), floor mounting and compartmental design, with bus bars suitable for 3 phase, 415 volts, 50 cycles, 4 wire AC supply. Starter and relays will be of ABB/Siemens/L&T make. Incoming: 1 No. Incoming feeder with ammeter of suitable rating with necessary current transformer and selector switch. 1  No. voltmeter with necessary selector switch 3  No. Indicating lamps. Outgoing: Switch gear for various motors included in our scope in the plant. Auxiliary contacts for alarm annunciators One 10 amp. Toggle switch and 10 amp. HRC fuse arrangement for 230 volts AC supply for instrument panels.	01 set