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Ammonia charge reduction and revamping of refrigeration system installed for dairy in India.

Number: pap. n. 21

Author(s) : GULANIKAR A. D.

Summary

In this paper we have elaborated about revamping of the old refrigeration system for one of the largest milk processing unit in India. After 15 years the plant came under city limit. Government restriction was, the ammonia charge to be reduced from 20,000 kg to 5000kg, otherwise relocates the plant outside city limit. Prohibitive outskirts land cost and constrains of supply chain and logistics, it was not economically viable to relocate to the outskirts. It was a challenging task to reduce ammonia charge despite of 100% increase in peak production from 600,000 to 1,200,000 lit/day. The other problem faced was maintenance of required milk temperature and no flexibility of operation in case of equipment breakdown resulting in to production loss. The approach/ methodology selected was, formulation of revised basis of design, replace high ammonia charge equipments such as Ice Silo, study how we can decentralize the plant but achieve flexibility of operation. It was decided to execute the revamping project in phases. Considering main objective of ammonia charge reduction, we selected indirect cooling in place of direct cooling by ammonia. In first phase we installed 2 x 880 kW brine chilling packages out of required 7 packages , each having 350 kg of ammonia charge. Heat recovery system generating 65°C hot water using condenser discharge gas was installed. All work was meticulously planned to avoid production loss. Key achievements were, substantial reduction in ammonia charge, thereby avoiding relocation of the plant to the outskirts. Considerable energy saving as compared to the earlier refrigeration plant achieved. Total 47 MT of Furness Oil (FO) saving/year achieved from heat recovery amounting to US $ 38,154. In addition flexibility of operation was increase avoiding down time of production.

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Pages: 8 p.

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Details

  • Original title: Ammonia charge reduction and revamping of refrigeration system installed for dairy in India.
  • Record ID : 30014622
  • Languages: English
  • Source: 6th Conference on Ammonia and CO2 Refrigeration Technology. Proceedings: Ohrid, North Macedonia, April 16-18, 2015.
  • Publication date: 2015/04/16

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