A REPORT ON VISIT TO
1.NANDAN DAIRY, MALEGAON(BK)
2.THE MALEGAON CO-OPERATIVE SUGAR
FACTORY, MALEGAON (BK)
(On 22nd September 2014)
DEPARTMENT OF MECHANICAL ENGINEERING,
VPCOE, BARAMATI
2014-15
As per instructions and permission granted from the Principal of VPCOE
Baramati, Department of Mechanical Engineering had organized one day visit at
“Nandan Dairy” and “The Malegaon Co-Operative Sugar Factory” at Malegaon
(Bk), Tal. Baramati. The purpose of visit was to see actual industrial boiler and
use of boiler for different processes. Around 73 students of SE mechanical along
with four staff members visited “Nandan Dairy” and “The Malegaon Co-Operative
Sugar Factory” at Malegaon (Bk), Tal. Baramati on 22nd September 2014.
"BARAMATI TALUKA SAHAKARI DOODH UTPADAK SANGH MARYADIT,
BARAMATI” is well-known for its popular brand. ‘NANDAN’ is a cooperative dairy project
established on 1st December 1977 and since then it has achieved many landmarks in milk
procurement, extension, animal health and milk processing, product making and marketing.
At present “NANDAN” has modern 1.5 lac liters/day capacity dairy plant with modern
packing unit at Malegaon (Bk), Tal. Baramati. Students started from the college for visit on 22nd
September 2014, at 9 am and reached “Nandan Dairy” plant at 9:30 am. Teachers divided these
students into four batches for the visit. At 10:00 am students entered the boiler room. The total
area of the dairy is 35 acres. The dairy produces 43000 packets of milk daily.
The instructor gave us the detailed information about each and every aspect of the boiler,
boiler mounting, accessories and detailed processes on milk from collection to packing. Two
types of boilers were used there: one is the wood fired fire tube boiler and another one is oil fired
fire tube boiler. The Oil Fire boiler is manufactured in 1985 and wood fired boiler is
manufactured in 2009.
Specification of Oil Fired Fire Tube Boiler
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Boiler Manufacturer :
Boiler No.
:
Boiler Type
:
Boiler fuel
:
Boiler installed
:
Working Pressure
:
Two oil tanks:
Working Time for boiler:
Efficiency
:
Revotherm
MR 11368
Fire tube boiler
Oil (1000 lit. /day)
1985
10.55 kg/cm2
capacity of each is 1000 liters
14-15 hours per day
70-80%
Photo: Oil Fired Fire Tube Boiler Used in Nandan Dairy Plant.
Specification of Wood Fired Fire Tube Boiler
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Boiler Manufacturer :
Boiler No.
:
Boiler Type
:
Boiler capacity
:
Boiler fuel
:
Boiler installed
:
Working Pressure
:
Two safety valves
Steam temperature :
Boiler runs for 14-15 hours per day
Wood Used
:
Boiler Efficiency
:
Forbe’s Marshall Boiler
MR 14820
Fire tube boiler
1.5 ton
Wood(2 ton/day)
2009
10.55 kg/cm2
184°C
Babhul, neem, 2 tons per day.
70-80%
Photo: Wood Fired Fire Tube Boiler Used in Nandan Dairy Plant.
Boiler uses water which is softened by using softener, which reduces its PPM from 90 to
10 PPM. Both boilers are used to generate steam of temperature 450 K, maximum Pressure 10
kg/cm2 which is directly used for various processes like Pasteurization and cleaning of cans. The
requirement of steam as a working substance is either for power generation or for process and
space heating in industrial application. Steam generator or boiler as per Indian boiler act 1923 is
a closed pressure used generation of steam under pressure. A boiler is usually made of steel in
which the chemical energy of fuel is converting by combustion into heat and this heat energy of
product of combustion is transferred to water to produce steam.
In case if steam is used for power generation, it is generated at high pressure and in large
quantity due to high efficiency requirement. The design of such boiler is quite intricate and it
depends upon the type of fuel use and its capacity. All students understood the details about
operation and the use of boiler and boiler mountings like water level indicator, feed check valve,
safety valve, pressure gauge, Blow off Cock etc. Students also saw accessories and use of the
steam for different purposes. Students also understood the role of different workers and
management in the plant.
Pressure gauge
A pressure gauge is used to measure the pressure of the steam inside the boiler. It consists
of an elastic metallic type of elliptical cross-section and is bent in the form of circular arc. One
end of the tube is fixed and connected to the steam space of the boiler and other end is connected
to a sector wheel through a link. The sector remains in mesh with a pinion fixed on a spindle. A
pointer is attached to the spindle to read the pressure on a dial gauge. When high pressure steam
enters the elliptical tube, the tube section tries to become circular which causes the other end of
the tube to move outward. The movement of the closed end of the tube is transmitted and
magnified by link and sector. The magnitude of the movement is indicated by the pointer on the
dial.
Water level indicator
It is an important fitting which indicates water level inside the boiler to the observer.
Usually two water level indicators are fitted in front of the boiler. The water indicator shows the
level or water in the boiler drum and warns the operator if by any chance the water level goes
below a safe level, so that corrective action may be taken in time to avoid any accident. A water
level indicator is used in low pressure boiler. It consists of three cocks and a glass tube. The
steam cock-1 keeps the glass tube in connection with the steam space and cock-2 puts the glass
tube in connection with the water space in the boiler. The drain cock-3 is used to drain out the
water from the glass tube at intervals to ascertain that the steam and water cocks are clear in
operation.
The glass tube is generally protected with a shield. For the observation of the water level
in the boiler, the steam and water cocks are opened and drain cock is closed. In this case, the
handles are placed in vertical positions as shown in photo. The steam enters from the upper end
of the glass tube and water enters from the lower end of the tube. So the water level inside the
boiler will be same as seen in the glass. The rectangular passage at the ends of the glass tube
contains two balls. In case the glass tube is broken, the balls are carried along its passage to the
ends of glass tube and steam out of the boiler is prevented.
Feed check valve
The function of the feed check valve is to allow the supply of water to the boiler at high
pressure continuously and to prevent the back flow of water from the boiler when the pump
pressure is less than boiler pressure or when pump fails. A commonly used feed check valve is fit
to the shell slightly below the normal water level of the boiler. The lift of the non-return valve is
regulated by the end position of the spindle which is attached to the hand wheel. The spindle can
be moved upward or downward with the help of hand wheel as the upper portion of the spindle is
screwed to a nut.
In normal working conditions, the non-return valve is lifted due to the pressure of water
from the pump and water is fed to boiler. But when the pump pressure falls below boiler pressure
or if the pump stops, non-return valve is closed automatically due to pressure of the water from
the boiler and prevents the escape of water from the boiler.
Photo : Milk Collection Unit Used In “Nandan Dairy”
Photo: Chimney of boiler
Photo : Pressure gauge
Photo: Packing Unit used in Dairy
Blow-off cock
The blow off cock is used for dual functions:
1. To remove water from the boiler for cleaning, repairs or inspection.
2. To discharge mud and sediments carried with feed water and accumulated at the bottom of the
boiler.
After visiting the boiler section students observed milk processes there. Inspector of milk
process plant gave detailed information about different types of milk processes carried in Nandan
Dairy.
Pasteurization
Raw milk has a lot of bacteria, which spoils milk. Some bacteria are harmful to human
beings. Pasteurization kills the pathogens and some of the spoilage organisms. Ultra high
temperature is designed to kill essentially all of the bacteria from milk. In the process of
pasteurization; milk is initially boiled and then hold at above 70 0C and then it is made cold.
After Pasteurization processes milk is transferred to storage tank which is also kept at low
temperature and then milk is packed on packing machine. Different volumes of packet like half
litre, one litre, five litre etc are packed on automated machine. Collected packets are transferred
to market. Nandan Dairy is also famous in the production of different types of milk products
with brand “Nandan”.
Photo: Pasteurization Unit used in Dairy
Photo : Product of Dairy
VISIT TO “MALEGAON CO-OPERATIVE SUGAR FACTORY”
Malegaon Co-Operative Sugar Factory, Malegaon well-known for its Sugar
Production and Power Generation is a cooperative sugar factory established in
1955 and since then it has achieved many landmarks in Sugar production and
power generation. At present “Malegaon Co-Operative Sugar Factory” has sugar
crushing capacity of 4000 MT/Day capacity sugar plant with power generation unit
at Malegaon (BK), Tal. Baramati.
After visiting Nandan Dairy plant, students visited “Malegaon Co-Operative
Sugar Factory”, which is 3 km away from Nandan Dairy plant. Students reached
sugar factory at 2 pm, after taking lunch at Malegaon (Bk). Teachers divided these
students into three batches for the visit. At 2:30 pm students entered the sugar
factory. The instructor in the factory gave us the detailed information about each
and every aspect of the boiler. There were two boilers which uses bagasse as a fuel.
Raw Material Used
Technically, sugarcane is a highly efficient converter of solar energy and in
fact, has the highest energy to volume ratio among all energy crops. Bagasse is
generated after crushing of sugarcane is used as main fuel in all the three boilers.
The average number of days for which the power plant operates with bagasse as
fuel ranges from 160-180 days. During off season boilers in factory uses saved
bagasse as fuel.
For additional requirement, they purchase bagasse from other sugar mills.
Malegaon SSK puts into operation only 1/3rd of the installed capacity during offseason. Therefore, they have commissioned two different capacity turbogenerators. SSSKL is more progressive in outlook for operating the power plant
even in off season by saving more bagasse. Effective load management is the key
for ensuring viability of renewable energy based power projects.
Load Management
Power and steam generated by different boilers is used for:
1. Sugar mill
2. Power requirement of distillery
3. Cogeneration unit for its internal consumption
4. Surplus power is exported to grid.
A comparison of power distribution planned in the two cogeneration units is
presented in tables in next sessions.
Technology Used
The efficient operation of a cogeneration system intrinsically depends upon
the chosen technology. This has a direct impact on loss in power generation.
Cogeneration based on Rankine cycle is not new to the sugar industry, however
cogeneration based on high pressure boilers and recirculation of condensed water
are definitely new. In cogeneration the excess power can be sold to the MSEB
through grid or to a third party for a price.
The cogeneration project with modernization and energy saving are expected
to make optimum use of available bagasse generated during the seasonal operation.
1. Bagasse required during season and off-season
Sugar Cane
Crushed
Bagasse
Production
Available
bagasse after
deducting
losses
Bagasse used
for boiler
Bagasse saved
for
off-season
(MT)
200 TPH
60TPH
58TPH
49TPH
31680
Bagasse
required in
off season (MT)
29868
(For 6.76 MW)
2. Power distribution (21MW)
Cogen. internal
consumption
(MW)
0.3+0.8
Power to
sugar plant
(MW)
5.14
Power to
distillery
(MW)
13.05
Power
exported
(MW)
0.9
3. Boiler and turbine generator capacities
Boilers
80 TPH+ 40 TPH
Turbine and Generator
14 MW (backpressure) +
7 MW(double extraction condensing)
Photo: Turbine and Generator unit
Photo: Control panel monitor
Photo: Chimney Used in Sugar Factory
Students’ Feedback
Students of SE-Mechanical Engineering are extremely thankful to the Principal of
VPCOE, Baramati, Dr. S. B. Deosarkar, Head of Mechanical Engineering Department Prof. P.
V. Gogte, and staff coordinators of the visit for arranging such a visit. We hope that this visit will
help us in our future practical life and bring a positive change in our thinking and practical
behavior regarding engineering education. Educational visit to Nandan Dairy and Malegaon
Sugar Factory was very informative. The guidance of the staff and industrial members was very
useful for all the students during the entire visit. We request our college to organize such type of
visits in future also to enhance and explore students’ technical skills.
List of Student for visit
Sr. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Name of Student
ADHAV ANJALI BALBHIM
BANKAR RUSHIKESH SHIVAJI
BANKAR SUMIT SATISH
BHOR SHUBHAM DATTATRAYA
BHOSALE ABHISHEK JANARDAN
BONGALE NIKHIL NETAJI
CHAUDHARI MRUDULA DEEPAK
CHITNIS ONKAR SHASHIDHAR
DHAMANKAR RHUTUJA RAJKUMAR
DHANAPUNE AJINKYA KAILAS
DHAWAN ASMITA DNYANESHWAR
DHOTRE VIJAY SANJAY
DUDHANE MAYUR DATTATRYA
GAIKWAD MAHESH BALASAHEB
GARUDKAR SHRUTI VITTHAL
GHULE PRASAD WALMIK
GUDE SHUBHAM RAVIKANT
HARADE KIRAN DATTATRAYA
HATWALANE OMKAR AVINASH
HOLKAR RAHUL ANANDKUMAR
INGALE GAURAV KISHOR
JADHAV ANIKET TANAJI
JADHAV MAYUR RAJENDRA
JADHAV RUTUJA JAGANNATH
JOSHI ABHISHEK AVINASH
JOSHI ANIKET ANIL
KADAM SAYALI SUNIL
KADAM VISHWANATH TUKARAM
KAMBALE SHRIDHAR DHULAPPA
KHOBRAGADE SHUBHAM ABHINANDAN
KOKARE AKSHAY AVINASH
KOKATE RAHUL RAJENDRA
KOTHULE DHANANJAY VISHNU
KUCHEKAR MOHIT MURLIDHAR
LOMATE ADITYA CHINTAMANI
MAGAR PRAVIN RAJENDRA
Sr.
No.
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
Name of Student
MALBHAGE RAVI RAMLING
MANAS MILIND KULKARNI
MANDGE SANDIP DHANAJI
MANDHARE SOHAM SUNIL
MANE NILESH CHANDRAKANT
MULANI AJIM SIKANDAR
MUNJAWADE VIJAY SUKHADEV
NAGANE VISHALSADASHIV
NANAWARE SUMIT PRAKASH
NASHIKKAR AISHVARYA ANANT
NAVALE DHIRAJ SHASHIKANT
NERKAR BHUNESH BAPURAO
PARDESHI AKSHAY SANJAY
PARTHE TUKARAM DNYANOBA
PATIL MAKARAND DIGAMBAR
PATIL SUSHRUT SUNITKUMAR
PHULPAGAR KIRAN RAMESH
PRATEEK SHINDE BHAKTI
RASAL DIGVIJAY DILIP
RODGE MANGESH NAGNATH
SABLE SHWETA SANTOSH
SALUNKE AKSHAYKUMAR
SAWANT VINAYAK GOPAL
SHAH PRATHAMESH PRADEEP
SHINDE DATTA DHONDIRAM
SHINDE VIKEEN VILAS
SHITOLE VISHWAJEET
KAILASRAO
SONWANE ALISHA APPASAHEB
SOUVIK CHANDA DEVI
TAKSALE AJINKYA RAJENDRA
TAWARE PRIYANKA RAVINDRA
THORAT RUPALI ASHOK
THORAT SIDDHANT ASHOK
TIKE AMIT TANAJI
UNAWANE AKSHAY RAMESH
VITEKAR MUKUL MUKUNDRAO
VITTHAL CHAVAN ARUNA
List of Staff Members who coordinated the visit:
1. Prof. K. M. Jadhav, Assistant Professor in Mechanical Engineering Dept.
2. Prof. H. P. Borate, Assistant Professor in Mechanical Engineering Dept.
3. Mr. S. B. Markad, Lab. Technician in Mechanical Engineering Dept