1.1 Company Profile

A Study on Boiler and Feed Water Treatment Units at KOMUL 2018-19
CHAPTER 1
INTRODUCTION
KMF was found in 1974 as Karnataka Dairy Development Corporation (KDDC) to

implement a diary development project run by the World Bank. In 1984 the organization
was renamed as KMF, KMF has Milk Unions throughout the Karnataka State with
procure milk from primary Diary Co-operative Societies (DCS) and distribute milk to
consumers in various urban and rural markets in Karnataka State. Karnataka Co-operative
Milk Producer’s Federation Limited (KMF) is Apex Body for the diary co-operative
movement in Karnataka. It is the second India largest diary co-operative amongst the
diary the diary co-operatives in the country. In South India it stands first in terms of
procurement as well as sales. One of the cure functions of the Federation is marketing of
Milk and Milk products. The Brand “Nandini” is the household name Pure and Fresh
milk and milk products. KMF has 14 milk Unions covering all the districts of the states
which procure milk from Primary Diary Co-operative Societies (DCS) and distribute milk
to the consumers in various Towns/Cities/Rural markets in Karnataka.
Milk may be defined as whole, fresh, clear lacteal sureties by the complete milking of
one or more healthy milk giving animals. It is nature’s perfect food. Milk is the only food,
which is designed by the nature solely as food. It serves as the foundation as adequate
diet. It supplies bodybuilding protein, bone forming minerals and health giving vitamins
furnishes energy giving lactose and milk fat. It is delicious and appetizing food as well as
being healthful. The constituents of milk are water, butterfat, lactose and mineral water.
The major constituents are phospholipids, sterols, vitamins, enzymes, pigments etc. The
true constraints are milk fat, fat casein and lactose.
1.1 Company Profile
Karnataka Milk federation which is popular as KMF, evolved itself as a premier and
most profitable diary farmer’s organization in the state of Karnataka.
Karnataka Co-operative Milk producer’s Federation Limited (KMF) is the apex Body
for the diary co-operatives movement in Karnataka. It is the second largest diary co-
operatives in the country. One of the core functions of the Federation is marketing of
DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 1

Milk and Milk products. The Brand “Nandini” is the household name for Pure and Fresh
milk and milk products.
KMF has 14 Milk Unions covering all the districts of the state which procure milk
from Primary Diary Co-operative Societies (DCS) and distribute milk to the consumers in
various Towns/Cities/Rural markets in Karnataka.
The Kolar-Chikkaballapura Co-operative Milk Producers Societies Union Ltd was

registered on 23.03.1987, the KOMUL diary is shown in figure 1.1. The jurisdiction
extended to the entire kola-chikkaballapura District and Eleven Taluks of kolar-
chikkaballapura District. The Union undertook the work of organization of Milk Co-
operatives in ‘BAMUL pattern’ with the main objective of socio-economic reformation of
the farmers in the rural areas through Dairying a main subsidiary occupation. Later the
Union was bifurcated into kolar-chikkaballapura District Co-operative Milk Producers
Societies Union from 23.03.1987.
Figure:1.1: Komal diary

Kolar diary was established during 1994 with a processing capacity of 1 LLPD of milk.
The processing capacity of the diary was increased to 2.5 lakh liters during 2005 under
Perspective plan phase 1 and again to handle 4.0 lakh liters per day in the year 2011.
Their continuously increasing milk in 2019 as 10.54 lakh per day

KMF handed over chilling centers at Kolar, sadali, Chintamani, Gowribidnur to Kolar
Milk Union Ltd.
1.2 Objectives of the Union
 To improve Dairy farming activities in rural area by establishing Milk producers co-
operative societies (MPCS) under co-operative principles.
 To provide assured and remunerative market round the year for the Milk produced by
the producer members.
 To provide package of technical inputs to its Milk producers for the enhancement of
milk production. This includes facilities such as emergency visit service, Infertility
camps, First Aid services, Artificial insemination, and Mass Vaccination programme
against diseases.
 Supply of balanced cattle feed at subsidised rate, Fodder development programmes,
beside extension programmes.
 To provide necessary training for producers, members and staff of the Dairy co-
operative Society.
 To facilitate rural development by providing self-employment opportunities for
unemployed youths at village level. In other words to prevent migration of
unemployed youths from rural area there are by providing an opportunity for steady
income.
 To eliminate middleman by organizing MPCS which is owned and managed by
producers themselves.
 To provide quality milk and milk products to urban consumers rates consented by
GOK fromtime to time.
 To uplift the Socio economic status of the rural people.
1.3 Mission Statement:

Kolar - Chikkaballapura Milk Union to continuously procure quality milk by providing
remunerative price & technical input services to Producers and to supply quality Milk &
Milk Products to the consumers. It also strives to achieve top position in the dairy
industry by improving the financial position of the union.
1.4 Values
 Honesty
 Discipline

 Quality
 Hard Work
 Mutual Trust & Belief
 Transparency
 Co-Operation & Team Work
1.5 Milk Procurement
The present average Milk procurement during the month of June – 18 is 10.23 lakh kgs
per day from 1843 DCS comprises of 2.86 lakh members. The milk daily procurement of
diary as shown in table 1.1. The Union had registered a growth to the tune of 7% for the
last 5 years.
Table 1.1 Milk procurement Details

Sl.
No Particulars
1 Area of operation Kolar-chikkabalpura
2 No. of Taluks covered 11
3 No. of revenue villages 2919
4 No. of functional DCS 1843
5 No. of Milk procurement routes 127
6 No. of chilling centers 3
7 No. of village covered 2809
8 Milk distribution routes 113
9 No. of retailers 687
1.6 KOLAR-CHIKKABALLAPURA MILK UNION MILESTONES
 27.03.1987 Bifurcation of the district from an operational area of Bangalore Milk

Union Ltd.,(BAMUL) to form a separate milk union with 422 functional DCS and
Rs 8.56 Lakhs Share Capital.

 1987 Establishment of first Women Dairy Co-operative Society in the Union.
 1989 Inauguration of Sadali chilling center.
 1990 Initiation of milk marketing at Inter-dairy rate.
 1991 Inauguration of Gowribidnur chilling center.
 1991 KMF handed over chilling centers at Kolar, Sadali, Chintamani and
Gowribidnur to Kolar Milk Union Ltd.,
 1994 Inauguration of full-fledged dairy at Kolar with a processing capacity of 1.0
lakh Liter per day.
 1994 Union started liquid milk marketing under the brand name of Nandini in
Polythene Packets.
 1995 Inauguration of Administrative Building in the Dairy campus.
 1998 Inauguration of Cheese Plant.
 1999 For the first time in Karnataka State Union started marketing Nandini UHT
milk in the name of “Good life”,“Slim” and “Smart”.
 1999 Expansion of processing capacity of Chintamani chilling center.
 2000 Outside the state, entry into the Chennai for Milk marketing.
 2001 Kolar Dairy certified for ISO-9002 Quality Management System.
 2001 Installation of AMC Units at DCS level.
 2001 Union started marketing Masti Dahi.
 2001 Expansion of UHT Unit in KOMUL.
 2002 Started implementation of TIFAC Project.
 2007 UHT Processing Capacity was increased from existing 0.4 LLPD to 1.5 LLPD.
 2008 Union started to export Goodlife milk with a shelf life of 1year to Singapore.
 2008 Union started to supply Goodlife milk to Indian army.
 2008 Our Union was renamed to “KOLAR CHIKKABALLAPURA
COOPERATIVE MILK PRODUCERS SOCIETIES UNION LTD”.
 2009 Introduced Goodlife milk 200ml Fino packets to market.
 2009 Launched New 1000ml Brik UHT variant Milk called “Sampoorna” with Fat
4.5% & SNF 8.5% to market.
 2010 Enhanced UHT plant for 2.5 lakhs ltrs per day packing capacity.
 2010 Constriction of Mega Dairy has been Started near Nandi Cross Chikkabalapur.
 2011 Expansion of Processing Capacity from 2.5LLPD to 4.5 LLPD.
 2014 State Govt has Transferred 10Acre of Land to KOMUL near Srinivasapur.
 2015 RO Plant & Multiplayer Boiler Inaugurated.
 2017 Expansion of Cheese plant from 2MT to 5MT.
 2017 Union Started Mysore Pak Production.
 2017 New Transformer Capacity of 1600 KVA have been Started.
 2017 Foundation Stone for "Automated Corrugated box manufacturing unit" has
been laid.
 2018 March Mega Dairy Inaugurated at Chikkaballapur
1.7 Achievements
 Second in Procurement among KMF unions.
 1994-95 Union was the first to introduce the “Operation Theileriasis” vaccination
program in India.
 1999 Installation of AMC Units at DCS level and For the first-time in the history of
Karnataka, inauguration of BMC centers in the jurisdiction of KOMUL
 2001 Inauguration of Animal Disease Diagnostic Laboratory at Chintamani chilling
center campus.
 2002-03 Inauguration of Community Machine Milking Parlors (centers) first of its
kind in India.
 2003-04 started “Clean Milk Program” for the first time in Karnataka.
 2003-04 started mass vaccination programs for Foot and Mouth Disease in
coordination with Animal Husbandry Department, Govt of Karnataka.
 2006 Producer welfare trust was started.
 05/03/2016 Highest UHT Milk Sales is 4.88 LLPD.
 23/06/2017 Highest Milk Procured is 10.9 LKPD.
 25/07/2018 Highest Liquid Milk Sales is 3.25 LLPD.
 2017 Union received "QUALITY MARK" certification from NDDB.
1.8 Awards
 2003 Union bagged National Productivity Council Award – 2nd Place.
 2004 Union bagged National Productivity Council Award – 2nd Place.
 2006 Union bagged Best Co-operative Union Award in the state.
 2008 Union received Energy Conservation Award both from Central and State
Governments in Dec.
 2009 Union got 1st Place in National Energy Award and 2nd place in State
Energy Conservation Award.

1.9 Milk price

The cost per kg of Milk is caluculated based on fat and SNF quality of milk basic price
is caluclated for 3.5% Fat and 8.5%SNF. At present Milk is purchased from DCS at price
23.00 and DCS pays Rs 22.00 to prducers. In 2017 -18 the Union has paid 916.17 crores
to milk prodcers. In june 2018 Union paid Rs 87.05 crores.
Figure 1.2 Plant layout

CHAPTER 2
STUDY ON BIOLER
2.1 Introduction
A steam generator or a boiler is defined as a closed vessel in which water is converted

into steam by burning of fuel in presence of air at desired temperature, pressure and at
desired mass flow rate.
Principle: In case of boiler, any type of fuel burn in presence of air and form flue gases
which are at very high temperature (hot fluid). The feed water at atmospheric pressure
and temperature enters the system from other side (cold fluid). Because of exchange of
heat between hot and cold fluid, the cold fluid (water) temperature raises and it form
steam. The flue gases (hot fluid) temperature decreases and at lower temperature hot fluid
is thrown into the atmosphere via stack/chimney.
2.2 Classification of boilers
The different ways the boilers are as follows
1) According to location of boiler shell axis
 Horizontal.
 Vertical.
 Inclined boilers.
When the axis of the boiler shell is horizontal the boiler is called horizontal boiler. If
the axis is vertical the boiler is called vertical boiler and if the axis of the boiler is inclined
it is known as inclined boiler.
Examples: Horizontal boiler are Lancashire boiler, Locomotive boiler, Babcock and
Wilcox boiler etc. Vertical boiler are Cochran boiler, Vertical boiler etc.
2) According to the flow medium inside the tubes
 Fire tube boliers.

 Water tube boilers.
The boiler in which hot flue gases are inside the tubes and water is surrounding the
tubes is called fire tube boiler. When water is inside the tubes and the hot gases are
outside, the boiler is called water tube boiler.
Examples : Fire tube boilers are Lancashire, Locomotive, Cochran and Cornish boiler.
Water tube boilers are Simple vertical boiler, Babcock and Wilcox boiler.
3) According to the draft used
 Natural draft.
 Artificial draft.
Boilers need supply of air for combustion of fuel. If the circulation of air provided with
the help of a chimney, the boiler is known as natural draft boiler. When either a forced
draft fan an induced draft fan or both are used to provide the flow of air the boiler is
called artificial draft boiler.
Example: Natural draft boiler are Simple vertical boiler, Lancashire boiler. Artificial
boiler: Babcock and Wilcox boiler, Locomotive boiler.
4) According to furnace position
 Internally fired.
 Externally fired boilers.
When the furnace of the boiler is inside its drum or shell, the boiler is called internally
fired boiler. If the furnace is outside the drum the boiler is called externally fire boiler.
Examples: Internally fired boilers are Simple vertical boiler, Lancashire boiler,
Cochran boiler. Externally fired boilers are Babcock and Wilcox boiler.
5) According to number of tubes
 Single-tube.
 Multi-tube boiler.

A boiler having only one fire tube or water tube is called a Single-tube boiler. The
boiler having two or more fire or water tubes is called Multi-tube boiler.
Examples: Single tube boiler are Cornish boiler, vertical boiler. Multi-tube boiler are
Lancashire boiler, Locomotive boiler, Babcock and Wilcox boiler
2.3 Study on Boiler Units in KOMAL
2.4 Boiler 1: Lancashire boiler make Thermax
In Komal diary manufactures as using fire tube boiler. Horizontal drum axis, natural
circulation, artificial draft, two-tubular, medium pressure, stationary, fire tube boiler with
furnace located internally. And there are three pass fire tube boilers shown in figure2.1 of
4 tons capacity called Lancashire boiler. A fire-tube boiler is type of boiler in which hot
gases from a fire pass through one or (many) more tubes running through a sealed
container of water. The heat of the gases is transferred through the walls of the tubes by
thermal conduction, heating the water and ultimately creating steam. This boiler fuel
using as wood. The fire tube boiler efficiency as calculated in annexure 1
Figure2.1: Lancashire boiler.

2.4.1 Boiler specfications
Table 2.1: Boiler details
Boiler name Lancashire boiler(Thermax)
Operating pressure 10.34kg/cm2/180o C
Fuel used Furnace oil
Evaporation 4000kg/hr
Steam temperature 170o C

2.5 Operating Principle
Figure.2.2: Working Circuit of Thermax Boiler
 The fuel fired packaged boilers are specially designed for manual operation by
fireman. The furnace is fitted with specially designed heat resistant fire bars. Solid fuels
are fed manually on the bars. Primary air flows into the furnace through the openings in
the fire bars. The fire bars are so designed that they are kept cool by the cooling action of
the primary air, secondary air flows into the furnace through the openings provided in
front end of the furnace. The air imparts a circular motion to the flame and the
combustion gasses.
 An induced draught fan maintains a negative pressure in the furnace. The unique
proportionating of the two streams of primary air and secondary air prevent the ash
fusion and clinker formation. This also ensures complete combustion of the fuel. Semi/
wet- back chamber located in the rear of the furnace effectively absorbs the flames
entering it, which ensures complete mixing of the gases prior to entering the second pass.
Access door is provided on the rear wall of the chamber to facilitate quick removal of fly
ash, thus avoiding chocking in the tubes. The front smoke box also ensures complete
turn around and mixing of the gases prior to entering the third and final pass of the tubes.
As all the useful heat is absorbed the thermal efficiency increases. The GCV of the fuel
used is 3000-3500 kcals/kg. This boiler produces 3 tonnes of steam. In fig.3.2 The
Working circuit of Thermax boiler is shown in figure 2.2.

2.6 Boiler Parts

2.6.1. Water Float indicator
In case of the automatic boiler water level is controlled through the a dual control
which is a magnetically operated water level of the vertical type in a float chamber for
external mountings on the steam boiler. One switch of the dial control operates the
electric feed water pumps on/off. The figure.3.3 Shows the water float setting. The second
switch cuts or locks out the ID and FD fan in case of low level alarm. In the event of low
level, the same goes to be manually started.
Figure.2.3: Water Float Indicator
2.6.2. Thermostats
In the automatic boiler, the thermostat is located at the top of the boiler pressure
switch. The switch cuts off the ID and FD fan when the boiler pressure or temperature
rises above pre – determined limit. This switch automatically switches on when the
pressure or temperature falls by a pre-set amount.
2.6.3. Control Panel
In case of an automatic boiler, a control panel is directly pre wired which includes
the automatic controls for the feed water controller, switch gear with applicable fuses,
switches and indicating lamps.

2.6.4. Blow Down Valve

The boiler blow down is water intentionally wasted from a boiler to avoid
concentration of impurities during continuous evaporation of steam. The blow down vavle
shown in figure.3.4 The water is blown out of the boiler with some force by steam
pressure within the boiler. In case automatic switch is not operational, this is done
manually.
Figure.2.4: Blow Down Vavle.

2.6.5 Handholes and Manholes
Handholes and Manholes provide maintenance personnel access into a boiler to inspect
and clean it internally as needed. These Handholes and Manholes will be covered in depth
when boiler maintenance is discussed later in this chapter.
2.6.6 Fusible plug
Its function is to extinguish fire in the furnace of a boiler when the water level in the
boiler fails ro an unsafe extent thereby preventing the explosion which may takes place
furnace plate.
2.6.7 Feed check valve
Feed check valve between the feed pump and the stop valve in the feed water pipe.
Prevent backflow from the boiler through the feedwater line into the
condensate/feedwater tank during the off cycle of the pump.
2.6.8 Feed stop valve
In the feedwater line as close to the boiler as possible between the boiler and feed
check valve. Permit or prevent the flow of water to the boiler.
2.6.9 Water level Indicator
In function is to indicate level of water, it’s upper and open in steam space and lower
and opens to water space.
2.6.10 Pressure Gauge

It is for indicating the pressure of the steam in a boiler.
2.6.11 Steam Stop Valve
It stops or allows the flow of steam from the boiler to the steam pipe.
2.6.12 Blow Off Cock
It is for removal of sediment periodically collected at the bottom of the boiler.
2.7 Boiler Fuel

Nilgeri wood plenty available in the forests. This wood consists gross calorific valve is
3200kcal/kg. the cost of wood per kg is 3.57 Rs.
Figure2.5 : Nilgeri Wood
Some of the advantages are:-
 Economical and cheaper than other solid fuels.
 Pollution free and non-hazardous.
 Low ash content about 2% to 10% no fly ash when burning
 Easy transportation and feeding.
 Combustion is more uniform.

2.8 Boiler Accessories
2.8.1 Economizer
Economizer some of the heat recovered and sent back to the boilers in the feed water if
an economizer is placed between the boiler and chimney. The waste fire gases flow
outside the economizer tubes and heat is transferred to the fuel water which flows upward
inside the tubes. The external surfaces of the tubes are kept free from soft by scrapers
which travels slowly and continuously up and down the tubes.
2.8.2 Ash Control Equipment
Mechanical multi-cyclone dust collector and multi air bag filter is provided to reduce
particulate emission from the flue gases before exhausting through chimney at 30 meter
height. Particulate emission after dust collection system will be less than 150ppm due to
highly efficient tangential entry multi-cyclone provided in dust collector. Air bag
filtration system provided with rayton bags further reduces the suspended particulate
matter at outlet to less than 150(milligram per nano meter cube). Further high pressure air
supplied from inside of bag filter removes ash and is collected at the bottom with the help
of motorized rotary lock valve. Figure.2.6 shows the (ash control unit) means removing
the solid particals from flue gass coming from boiler befor enter in to chimny.
Figure.2.6: Ash Control Equipment

2.8.3 Steam Generation System
Energy pack boilers are designed with 3-pass horizontal smoke tube having inbuilt
furnace. Water level controller provided to ensure minimum water level inside the boiler
and auto operation of feed water pump as per the steam generation. Furnace is designed to
absorb maximum radiant heat generated from the combustion of briquette. After
absorption of heat, the flue gases pass through the horizontal smoke tube releasing heat by
convection. Inbuilt moisture separator provided to separate moisture content from steam
to ensure 97% to 98% dry steam at the outlet.
2.8.4 Heat Recovery System
Flue gas generated from the firing of briquette is free from sulphur content and hence
flue gas temperature can be reduced to optimum level without having any corrosion
problem at outlet of chimney.
Figure.2.7: Heat Recovery System

Accordingly energy pack steam generation system is designed with water preheater
and air preheater. Part of the flue gases passes through water preheater to preheat the
water by circulating pump in the water service tank. Water preheater will preheat the feed
water by 30-40 (deg. Centigrade). Remaining flue gas is passed through air preheater to
preheat the combustion air fed by forced draught fan and tube type heat exchangers.

Combustion air will be preheated by 40-50(deg. Centigrade). The heat recovery system is
designed to reduce the temperature of flue gases up to 120 deg. Centigrade. The figure.3.7
shows that Heat recovery system.
2.8.5 Feed pump
Installed between the condensate/makeup/feedwater tank and the boiler shell or steam
drum. Supplies water to boiler as required. According to actual evaporated water quantity
the same amount needs to be feed in to the boiler generally water level in the drum is used
for this case of once through type boiler it has to be connected with power level control.
2.8.6 Feedwater pipe
This line extends from the discharge side of the feedwater pump to the boiler shell or
drum. Provide feedwater to the boiler when required.
2.8.7 Ash Removal System
Ash drop is provided in each furnace to collect ash on rear side of furnace manually by
sliding ash door with the handle. Ash can be collected in trolley kept below the ash drop
and conveyed for disposal. Both the smoke boxes are provided with hand hole with cover
at bottom side to remove the ash collected in front and rear smoke box. Economiser and
air pre heater are also provided with hand hole with cover at bottom side to remove the
ash collected.
2.8.8 Chimney
After the heat recovery system, the flue gases are directed towards the chimney
situated outside the boiler house. The height and design of the chimney complies with
existing smoke pollution act laws prevalent at the site. Steel chimney is constructed with
adequate thickness to compensate for metal corrosion factors and weather conditions.
Insulation is done with glass wool inside and aluminium sheets outside.
 Stack cross sectional diameter 0.533
 Stack diameter 0.824m
 Temperature of flue gases 1120C
 Ambient temperature 320C
 Velocity of flue gas 9.62m/s

Figure 2.8 Chimney
2.9 Testing of Gauge Glass
 When the boiler is in operation, the steam cocks A, D and water cocks B, E are
open and drain cock C is shut.
 First shut both steam and water cocks A, D, B and E. Open drain cock C to prove
that all the gauge cocks are in order. Then, with the drain cock C still open, cocks
B and E should be opened. If water blows out freely from cock C, cocks B and E
are clear.
 Shut off cocks B and E and open cocks A and D with the drain cock C still open.
If steam blows out freely from cock C, cocks A and D are clear.
 To cross test, close cocks D and B, leaving E, A and C open. If water blows out
from cock C, then E, A and the water-column are in order.
 Close cocks E and A leaving D, B and C open. If steam blows out from cock C,
then D, B and the water-column are in order.

Figure 2.9 Testing of Gauge Glass
The figure.2.9 shows that control of water by operating vavles for required process.
2.10. Steam Pressure Testing of Safety Valve
 The safe operation of steam boiler depends on the correct functioning of the safety
valve. The safety valve should be lifted daily with the easing gear to prevent sticking
of valve seat and it should be pressure tested weekly as follows:
 Shut off main steam stop valve.
 Adjust steam pressure switch to a setting slightly higher than maximum permissible
working pressure.
 With boiler on maximum firing rate, observe the pressure gauge. When steam
pressure reaches m.p.w.p., safety valve will automatically open to release steam
pressure. That means safety valve is set correctly and working. Maximum
permissible working pressure can be obtained from the Certificate of Fitness.

 If the safety valve does not open when the steam pressure reaches the m.p.w.p., boiler
should be stopped immediately, and the easing gear operated to release steam and
lower the boiler pressure. Call the Appointed Examiner for examination immediately.
Figure.2.10: Steam Pressure Testing of Safety Valve
2.11 Flashing up Procedure
 Check maximum permissible working pressure on pressure gauge fitted.
 Check and close drain valves.
 Open water and steam cocks of water gauge glass and shut its drain cock.
 Clean and examine filter in feed water system.

 Open feed water tank outlet valve, and ensure water level in tank is at least half the
gauge glass.
 Shut main steam stop valve and open air vent.
 Switch on power supply. Feed water pump will automatically supply water to boiler
till approximately half gauge glass.
 Fuel, if briquette is supplied through the grate, if heavy diesel, it will circulate
through fuel oil heater till the desired operating temperature reached.
 The blower motor will start and purge furnace for at least 1-2 minutes to clear any
combustible gas accumulated in the furnace and avoid a blow back.

 The burner will be ignited according to an automatic sequence, initially at low fire
rate.
 When steam comes out from air vent, shut off air vent and switch to high fire rate.
Steam pressure will gradually increase to normal working pressure.
 Check gauge glass, safety valve, and all automatic safety devices to ensure they are
functioning normally.
 Open steam valve very slowly to permit warming through and draining of the cold
steam pipes to avoid damage due to water hammer.

2.12 BOILER 2: Cornish Boiler make AERW

In this boiler single tube and internally firing and firing and flue gases flowing 3 pass
and horizontal tube, medium pressure, artificial draft called Cornish boiler . Water
surrounds the tubes through which hot combustion gases pass before venting to
atmospheric through gas uptakes. Water converted into high pressure steam by transfer of
heat from very high temperature combustion gases on water. Boilers are of fully
automatic design as shown in figure 2.11. and this boiler efficiency calculation shown in
annexure 2.
Figure 2.11: Cornish Boiler AERW

2.12.1 Specifications
Table 2.2 Boiler details
Boiler name Cornish boiler AERW
Operating pressure 10.34 kg/cm2/180oC
Steam temperature 170oC

2.13 BOILER 3: Cornish Boiler make Forbes Marshall

In this boiler single tube and horizontal firing and flue gases flowing 3pass and air
flow into the boiler using ID fan and air and fuel mix together firing medium pressure,
artificial draft called Cornish boiler. Water surrounds the tubes through which hot
combustion gases pass before venting to atmosphere through gas uptakes. Water
converted into high pressure steam by transfer of heat from very high temperature
combustion gases on water. Boilers are fully automatic design as shown in figure 2.12.
And this boiler efficiency calculations shown in annexure 3
Figure 2.12: Cornish Boiler make Forbes Marshall

Table 2.3 Boiler Details
Boiler name Cornish boiler (Forbes Marshall)
Steam temperature 177.69oC

2.14 BOILER 4: Cornish Boiler make Forbes Marshall

In this single tube horizontal and internal firing firing and flue gases flowing 3 pass
and medium pressure, artificial draft called Cornish boiler. Water surrounds the tubes
through which hot combustion gases pass before venting to atmosphere through gas
uptakes. Water converted into high pressure steam by transfer of heat from very high
temperature combustion gases on water. And this boiler efficiency calculation shown in
annexure 4. Boilers are fully automatic design as shown in figure 2.13
Figure 2.13: Cornish Boiler Forbes Marshall

Table 2.4: Boiler Details
Boiler name Cornish boiler (Forbes Marshall)

2.15 BOILER 5: Cornish Boiler make Shellmax

In this boiler single tube and horizontal firing and flue gases flowing 3pass and air
flow into the boiler using ID fan and air and fuel mix together firing medium pressure,
artificial draft called Cornish boiler. Water surrounds the tubes through which hot
combustion gases pass before venting to atmosphere through gas uptakes. Water
converted into high pressure steam by transfer of heat from very high temperature
combustion gases on water. Boilers are fully automatic design as shown in figure 2.14.
And this boiler efficiency calculations shown in annexure 5. Essential mounting include
safety valve, steam pressure switch, pressure gauge, gauge glass, valve fittings, low-water
level cut off and alarm devices etc.
Figure 2.14 Cornish Boiler Shellmax

Table 2.5: Boiler Details
Boiler name Cornish boiler (Shellmax)

2.16 Furnace oil
Moisture test:1000 ml round bottom flask 100 ml furnace oil 80 ml xylene + 20 ml

Toluene 6-7 glass bites( to prevent bumping).Then it will be heated up in heating
mention the vapours will be calling using condenser 1% is allowable.
Definition: a dark viscous residential obtained by blending mainly heavier component

from crude distillation Unit Short Residue and clarified oil from fluidized catalytic
cracker unit.
Nomenclature: Bunker fuel furnace oil fuel oil are other names for the same product
through fuel oil is a General term applied to any oil used for generation of power or heat
C Anil can included distillates and blends of digital ads and Residue such as light diesel
oil.
Specification: furnace oil in the current marketing range meets Bureau of Indian
Standards specifications IS 1593 1982 Perfume oils grade mv2 shown in table 2.6 and
Cost Analysis of wood and furnace oil shown in table 2.7.
Table 2.6 Specification of Furnace oil

SLNo. PARAMETER SPECIFICATION TYPICAL QUALITY
1 Density at 15oC kg/m3 0.9600 0.9600
2 Flash Point (PMC), deg. C 66min 78min
3 Viscosity, kg/ms. 50oC 165max 160max
4 Calorific Value, gross Cal/kg 10200 10200
5 Water Content %vol 1 max <0.5
6 Ash % wt 0.1 max 0,04
7 Sulphur, Total % wt 2.8Max 2.70
8 Pour point OC 27max 3
9 Cost Liter 48Rs
Viscosity: viscosity is the most important characteristic in the furnace oil specification it
influences the degree of preheat required for handling storage under satisfactory
atomization if the oil is to viscous it may become difficult to pump burner may be hard to
light under operation maybe erratic poor atomization may result in the carbon deposits on
the burner tips or on the walls the upper viscosity limit for furnace oil is such that it can
be handled without heating in the storage tank is expecting under severe cold conditions .
Preheating is necessary for proper atomization.
Flash point: as per the controller of explosives classification for nature in falls in the
class ‘C’ category with minimum Flashpoint standard of 66 degree Celsius scenes
Penskey martens closed cup method is used it is Apparent that a small quantity of low
boiling point hydrocarbons is sufficient to lower the Flashpoint drastically.
Pour point: It is very rough indication of the lowest temperature at which furnace iron is
readily pump able in the specification the power point of furnace oil is not stipulated
details shown in table 2.6 however for furnace iron manufactured indigenously and for
imported parcels the PowerPoint is such that current supplies normally can be handled
without heating the fuel oil handling installation.
2.17 Cost Analysis
Table 2.7 Cost analysis for wood and furnace oil
SL Type of Quantity Quantity Quantity Fuel Cost of Total Total

No. fuel of Steam of Fuel of Fuel Cost per Kg cost of Cost of
Generated Used Used in Rs of Steam Steam
per Hour For 16 Per Steam Per For 16
in kg Hour in Hour in in Rs. hour in Hour in
kg/hr kg/hr Rs Rs
1 Wood 3500 13000 812.5 3.57 .82875 2900.65 46410
2 Furnace 4750 5846.15 365.38 45.02 2.463 16449 163184
Oil

CHAPTER 3
WATER TREATMENT SECTION
3.1 Boiler Feed Water Treatment
Water consists of organic matter in solution or suspension, dissolved gases which

are main causes of corrosion problems and other difficulties. The treatment and
conditioning of boiler feed water must satisfy three main objectives:  Continuous heat
exchange
 Corrosion protection.
 Production of high quality steam.
 Continuous heat exchange.
External treatment: The reduction or removal of impurities from water outside the
boiler. In general, external treatment is used when the amount of one or more of the feed
water impurities is too high to be tolerated by the boiler system in question. There are
many types of external treatment (softening, evaporation, deaeration, membrane
contractors etc.) which can be used to tailor make feed-water for a particular system.
Internal treatment: The conditioning of impurities within the boiler system. The
reactions occur either in the feed lines or in the boiler proper. Internal treatment may be
used alone or in conjunction with external treatment. Its purpose is to properly react with
feed water hardness, condition sludge, scavenge oxygen and prevent boiler water foaming
Feed water treatment is carried out for the following reasons
To prevention of hard scale formation on the heating surfaces
To prevent heat loss due to scaling decreasing efficiency
To elimination of corrosion

To prevention of silica deposition
3.2 Water Softener
Mineral-rich water, or "hard water," is one of the leading causes for poor boiler
performance. Hard water clogs the tubes and water side of your boiler system, leaving
calcium scale deposits that can degrade over 30% boiler efficiency loss.
Water softening systems eliminate hard water and scale build up by introducing
soluble sodium compounds (rock salt, solar salt, and evaporated salt) to the water system.
These sodium compounds replace calcium and magnesium compounds, effectively
reducing lime hardness build up and increasing the life of boiler or heat exchanger. Water
softener systems provide increased flow rates, additional capacity and continuous,
uninterrupted softened water.
Inside the water softener is a synthetic mineral which is petroleum by product
called resin.as water flows over the resin, it attracts hardness minerals into it.in exchange
resin beads give off sodium which is absorbed into water. The resin bead exchanges only
a specific amount of sodium. This is called softening capacity. Once the softening process
is done salt water under goes regeneration process. Regeneration is simple consisting of
drawing of salt water from a salt tank, introducing the salt to the exhausted mineral,
rinsing the retained hardness down the drain and rinsing the excess sodium down the
drain. Once this is completed softening process is started again.
3.3 Reverse Osmosis Process
Reverse osmosis (RO) is a water purification technology that uses a semipermeable

membrane to remove ions, molecules, and larger particles from drinking water. In reverse
osmosis, an applied pressure is used to overcome osmotic pressure, a colligative property,
that is driven by chemical potential differences of the solvent Reverse osmosis can
remove many types of dissolved and suspended species from water, including bacteria,
and is used in both industrial processes and the production of potable water. The result is
that the solute is retained on the pressurized side of the membrane and the pure solvent is
allowed to pass to the other side. To be "selective", this membrane should not allow large
molecules or ions through the pores (holes), but should allow smaller components of the
solution (such as solvent molecules) to pass freely.
The water is first passed through a filter containing a layer of sand, gravel which
separates the solid impurities in water. Then the water is sent to the filter cartridge. The
chemical maxtreat 9430 is added to the feed water that controls hardness, silica, mineral
oil and oxides. After adding chemical to the water, RO system uses permeable membrane,
spirally wound membrane housed inside round pressure vessel. Water pressure is applied
at the membrane inlet to remove dissolved solids from the water the water is passed
through the membrane until required hardness of water is obtained. The figure.4.1 shows
that how the water is purification by using reverse osmosis process. The overall capacity
of RO system is 8000 litres purified water obtained is around 5000 litres and 3000 litres
of water containing salts, organic solvents is obtained which is then removed.
Figure 3.1 Reverse Osmosis Unit
Figure 3.2 RO Plant Flow Diagram
Several designs are available for making RO membrane and elements. These
membrane devices are available in plate and frame, tubular and hollow fiber membrane
module configuration.The lewabrane RO membrane elements from LANXESS are
manufactured as “spiral wound RO membrane elements.”

The most common element device for RO membrane application is assembled
according to spiral-wound configuration. The format provides the highest degree of
packing density. The spiral- wound module uses flat sheets wound around a center pipe.
Figure.3.3: Element of RO membrane
The membrane are glued along three sides to form membrane leaves attached to a
permeate channel (center pipe) placed along the unsealed edge of the membrane leaf. The
internal side of the leaf contains a permeate spacer designed to support the membrane
sheet without collapsing under pressure.
This permeate spacer is porous and conducts permeate to the center pipe. A feed
channel spacer (a net –like sheet) is placed between the leaves to define the feed channel
height (typically round 1 mm) and provide mass transfer benefits. The membrane leaves
are wound around the center pipe and given an outer casing as shown in Figure 3.3
3.4 DM Plant
Demineralization is the process of removing mineral salts from water by using the
ion exchange process. Demineralization the by ion –exchange process Ion exchange is the
reversible interchange of ions between a solid (ion exchange material) and a liquid in
which there is no permanent change in the structure of the solid . ion exchange is used in
water treatment and also provides a method of separation for many processes involving
other liquids. As shown in figure 3.4.Chemicals using HCL and caustic soda. It has
special utility in chemical synthesis, medical research, food processing mining,

agriculture, and a variety of other areas. The utility of ion exchange rests with the ability
to use and reuse the ion exchange material. Flow diagram as shown in figure 3.5.
Demineralized water also known as Deionized water.Deionization is a physical
process which uses specially-manufactured ion exchange resins which provides ion
exchange site for the replacement of the mineral salts in water with water forming H+ and
OH- ions. Because the majority of water impurities are dissolved salts , deionization
produces a high purity water that is generally similar to distilled water, and this process
is quick and without scale buildup.
Figure 3.4: DM plant

The following ions are widely found in raw waters Cations anions Calcium Chloride
Magnesium Bicarbonate Potassium Nitrate Sodium Carbonate ion Exchange resins.
 Cation exchange resins will release hydrogen ions (H+) or other positively charged
ions in exchange for impurity cations present in water.
 Anion exchange resins will release hydroxyl(OH)ions or other negatively chargedions

or exchange for impurity anions percent in water.
The application of ion -exchange technology can be used in water treatment and
purification. There are three ways in which ion-exchange technology can be used in water
treatment and purification. Water of this quality can be produced by deionization. The
two most common types of deionization are.

1)two bed deionization.
2)mixed bed deionization
The two bed ionizer consist 0f two vessels-one containing a cation-exchange resin in
the hydrogen (H+)FORM AND OTHER CONTAINING an anion resin in the hydroxyl
(OH-)form . water flows through the cation column, whereupon all the cations are
exchanged for hydrogen ions .to keep the water electrically balanced, her using this type
of cation, two hydrogen ions are exchanged. Her using this type of DM PLANT REFER
FIGURE3.4. The same principle applies when considering anion-exchange. The
decationised water then flows through the anion column.
Figure 3.5: DM Plant Flow Diagram
This time all the negatively charged ions are exchanged for hydroxide ions which then
combine with the hydrogen ions which then combine with the hydrogen ions to form
water (H2O).
In mixed bed deionizers the cation-exchange and anion exchange resins are
intimately mixed and contained in a single pressure vessel. the throgh mixture of cation
exchangers and anion exchangers in a single column make a mixed bed deionizer equilent
to a lengthyseries of two bed plants.
3.4.1 Activated carbon filter: Acts on the principle of adsorption which is a surface
active phenomenon . It removes organic molecules to control color and odor.it removes
free residual chlorine present in filter water (0.5ppm) the activated carbon filter contains
gravels, fine sand and carbon.as shown in figure 3.4
3.4.2 Degasifier: In water demineralization, a degasifier, or degasser, of often used to

remove dissolved carbon dioxide cation exchange. The most common degassers are of the
so-called forced draft or atmospheric type. As shown in figure 3.5
Limitations
 Like other ion exchange systems, demineralizers require filter water in order to
function efficiently.
 Resin foulants and degarding agents, such as iron and chlorine, should be avoided
or remove.
 Anion resins are very susceptible to fouling and attack from the organic materials
present in may surface water supplies .some form of silica, known as colloidal, or
non-reactive.
3.4.5 Advantages
 Improved aesthetics and rugged design.
 User friendly, low maintainence and easy to install.
 Simpler distribution and collection systems.
 Pre dispatch assembly check.
 Less power consumption.
 Durable
 Economical
 High shelf life

CONCLUSION
This industrial training helps to understand the actual working practice and process
flow in diary industry and to gain practical experience and understanding of theoretical
principles learnt as an undergraduate at the university on steam generator, refrigeration
system and waste water treatment and bio gas plant in the company. The diary offers best
quality milk which is pure and fresh. The company should lay emphasize on
modernization and product diversification by which the company can meet the fast
growing requirement of market.
Performance of the boiler, like efficiency and evaporation ratio reduces with time,
due to poor combustion, heat transfer fouling and poor operation, deterioration of fuel
quality and water quality also leads to poor performance of boiler. The purpose of the
performance test is to determine actual performance and efficiency of the boiler and
compare it with design valves or norms. For tracking day-to-day and season-to-season
variations in boiler efficiency and energy efficiency improvements.
I would like thank the management of KOMuL for giving me this opportunity which
helped me to improve my technical knowledge and skill. I would also like to thank all
staff and guide members of KOMUL who have helped me in completing the internship
successfully.

REFERENCES
1. Nandini product plant details from www.kmfnandini,coop

2.www.indiadiary.com
3.Komul diary functional activities and milk procurement details from www.komul.com
4.Steam Boiler Operation by Bureau of energy efficiency.
5.Water purification process of RO and DM plant details from earthwaterpurifier.com

Annexure 1
Boiler 1: Lancashire boiler make by Thermax
Calculations
Heat output data
Quantity of steam generated: 3500 kg/hour
Steam pressure/ temperature: 7.35 bar/166.935°C
Enthalpy of steam(dry and saturated) : 2765.58kj/kg
Feed water temperature: 45 degree Celsius
Enthalpy of water: 188.4 kilo joule per kg
Heat input data

Quantity food consumed for 16:00 hours: 13000 kg
Quantity of food consumed: 812.5 kg per hour
GCV of coal gross calorific value: 13388.8 kilo joule per kg
Boiler Efficiency (ɳ)= ms*(h1-h2)

mf*GCV
Where
ms= quantity of steam generated per hour ( kg/hr )
mf = quantity of fuel used per hour ( kg/hr )
GCV = gross calorific value of the fuel (KJ/kg)
h1 = enthalpy of steam (KJ/kg)
h2 = enthalpy of feed water
Boiler Efficiency (ɳ)= 3500*(2765.58-188.4)*3600*100

3600*812.5*13388.8
ɳ=82.91%
Evaporation ratio = 3500 kg of steam / 812.5 kg of wood
Evaporation ratio = 4.3
Note: 1 KJ/kg = 0.238846 kcal/ kg

1 kcal/kg = 4.1868 KJ/ kg

Annexure 2
Boiler 2: Cornish boiler make AERW
Calculations
Heat output data
Quantity of steam generated: 1600kg/hour
Steam pressure/ temperature: 6.55 bar/161.229°C
Enthalpy of steam (dry and saturated) : 2759.435kJ/kg
Heat input data

Quantity food consumed for 16:00 hours: 2135 liters
Quantity of food consumed: 133.3 LPH
GCV of coal gross calorific value: 42676.8 kJ/kg

mf*GCV
Where

3600*133.3*42676.8
ɳ=72.31%
Evaporation ratio = 1600 kg of steam / 133.3 kg of wood furnace oil


Annexure 3
Boiler 3: Cornish boiler make Forbes Marshall
Calculations
Heat output data
Steam pressure/ temperature: 9.31bar/176.8122°C
Enthalpy of steam (dry and saturated): 2773.026kJ/kg
Heat input data

Quantity of food consumed: 150LPH

mf*GCV
Where

3600*150*42676.8
ɳ=72.67%
Evaporation ratio = 1800 kg of steam / 150 kg of furnace oil


Annexure 4
Boiler 4: Cornish boiler make Forbes Marshall
Calculations
Heat output data
Heat input data

Quantity of food consumed: 215LPH

mf*GCV
Where

3600*215*42676.8
ɳ=78.88%
Evaporation ratio = 2800 kg of steam / 215 kg of furnace oil


Annexure 5
Boiler 5: Cornish boiler make Shellmax
Calculations
Heat output data
Heat input data

Quantity of food consumed: 365.3LPH

mf*GCV
Where

3600*365.3*42676.8
ɳ=78.74%
Evaporation ratio = 4750 kg of steam / 365.3 kg of furnace oil


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A Study on Boiler and Feed Water Treatment Units at KOMUL 2018-19

KMF was found in 1974 as Karnataka Dairy Development Corporation (KDDC) to

1.1 Company Profile

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 1

The Kolar-Chikkaballapura Co-operative Milk Producers Societies Union Ltd was

Figure:1.1: Komal diary

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 2

1.3 Mission Statement:

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 3

1.5 Milk Procurement

Table 1.1 Milk procurement Details

1.6 KOLAR-CHIKKABALLAPURA MILK UNION MILESTONES

 27.03.1987 Bifurcation of the district from an operational area of Bangalore Milk

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 4

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 6

1.9 Milk price

Figure 1.2 Plant layout

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 7

A steam generator or a boiler is defined as a closed vessel in which water is converted

2.2 Classification of boilers

The different ways the boilers are as follows

1) According to location of boiler shell axis

2) According to the flow medium inside the tubes

 Fire tube boliers.

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 8

3) According to the draft used

4) According to furnace position

5) According to number of tubes

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 9

2.3 Study on Boiler Units in KOMAL

2.4 Boiler 1: Lancashire boiler make Thermax

Figure2.1: Lancashire boiler.

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 10

2.5 Operating Principle

Figure.2.2: Working Circuit of Thermax Boiler

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 11

2.6 Boiler Parts

Figure.2.3: Water Float Indicator

2.6.3. Control Panel

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 12

2.6.4. Blow Down Valve

Figure.2.4: Blow Down Vavle.

2.6.10 Pressure Gauge

2.7 Boiler Fuel

Figure2.5 : Nilgeri Wood

Some of the advantages are:-

 Economical and cheaper than other solid fuels.

 Pollution free and non-hazardous.

 Low ash content about 2% to 10% no fly ash when burning

 Easy transportation and feeding.

 Combustion is more uniform.

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 14

2.8 Boiler Accessories

2.8.2 Ash Control Equipment

Figure.2.6: Ash Control Equipment

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 15

Figure.2.7: Heat Recovery System

DEPARTMENT OF MECHANICAL ENGINEERING,CBIT KOLAR Page 16