Water treatment process

INTRODCTION
The water treatment process is performed in two ways where one is performed by direct insertion of chemicals (calcium chloride, aluminum sulfate, lime, chlorine) in to the coagulation tank and they reacted each other. The Treated water by this process is used for a major component for sugar dissolving and syrup blending section. And the other one is water softening process is using ion exchange resins with salt (NaCl) this water is used in bottle washer make-up used for rinsing purpose and water used in boilers and heat exchange equipment.

PRINCIPLES &OPERATION OF WATER TREATMENT

In the water treatment chemical and physical process takes places which include coagulation, clarification, sand filtration, carbonation purification and UV.

Coagulation
Coagulation is the process by which this done, and consists of making this particle heavier, So that they can quickly settle out. Additives used as a coagulant are calcium chloride, Aluminum sulfate, lime, chlorine. These chemicals are dosed to the reaction tank through a thin hose from their storage tank.

CALCIUM CHLORIDE
Addition of calcium chloride which forms calcium carbonate from the sodium bicarbonate as the calcium bicarbonate is formed. It reacts with the lime to reduce the water alkalinity. Sodium alkalinity is present when the total alkalinity (m reading) is greater than the hardness (h reading) of the water.

Reaction
Na+HCO3 + Na+HCO3 (Na. Bicarbonate soluble) + Ca OH CaCl2
Ca HCO3

HCO3
+ 2Nacl
(Nacl Soluble)

OH (Insoluble)

ALUMINIUM SULPHATE

The most widely used coagulant for water treatment is aluminum sulfate (Alum). At high alkaline (PH) prevalent in the water these salt produce insoluble aluminum hydroxide Al2 (SO4)3 +6H2O----- 2Al (OH) 3 +3H2SO4 3H2SO4+3Ca (HCO3)2------3CaSO4 +6H2CO3 6H2 CO3 ---------------- 6CO2 +6H2O

AL2 (SO4)3 + 3Ca (HCO3)2 ----- 2AL (OH) 3 + 3Ca SO4 + 6 CO2

LIME
Lime is an alkaline material it reacts with the dissolving water alkalinity (Ca and Mg bicarbonate) to form CaCO3. Ca OH + Ca HCO3 ----------- 2 Ca CO3 + 2H2O OH Ca HCO3

OH

HCO3
(Soluble)

Ca ----- CaCO3 +2H2O

Lime

(Insoluble)

CHLORINE
Performs a number of tasks -Destroy bacteria -Oxidize metallic hydroxide. -Destroy odors, such as hydrogen sulfide. -Destroy of tastes derived from organic or certain in organic materials. Sand filtration The function of sand filtration is to remove any trace of flock or suspended materials carried over in the treated water from the reaction tank .To perform the function properly depends up on the flow rate of water. Flow rate of water should not exceed 2gallones per minute per square foot of sand surface. Activated carbon

Adsorption is a surface phenomenon where dissolved substances in water are attracted to and adhere to the surface of the adsorbent. it is the most commonly used adsorbent in granular form. Adsorption on activated carbon is probably the most economical and technical attractive method available for removing soluble organic such as phenol, chlorinated hydrocarbons, surfactants, odor and color producing substances from water. POLISHER Suspended particles are removed from the water by passing the water through a polishing medium containing cotton art ridges which are polisher the polishing media. It is be stain less steal. Ultra violet light Used to remove scaling or other build up transmittances which are left over from other method should be completely maintained. Then the treated water goes to DEARATION TANK. In the dearation tank removing of air from water takes place using vacuum pump in order to achieve maximum filling speed and less foaming at the filler. Then finally it goes to the heat exchanger to cool from 25oc to 4oc in order to minimize foaming and it mixes with syrup and carbon dioxide in the mixing tank.

Process flow chart of water treatment

Raw Water Intake Storage and micro control Coagulation Sand filtration Inter mediate tank Carbon purification Polishing UV-disinfection Dearation Sugar dissolving tank 800c Heat exchange Mixing unit (syrup) water and Co2 Water testing chemicals receiving inspection Starting and handling Buffer starting Weighting Dissolving Dosing

BACK WASHING It is a very important function of the sand filter and carbon purifier. Back washing consists of reversing the water flow rate through the unit by a combination of water flow and pressure, the sand or carbon beds are raised, the granules become suspended in the water and vigorously agitated. The agitation causes the sand grain to rub and grind against each other. This removes the adhered, filtered out flock particles which are washed out of the unit by back washing water and cleans the surface of the sand grains. Proper back washing requires a water flow rate 5 to 6 times the forward flow rate to 10 to 12 gallons per minute per square foot of flitter or purifier bed area.

Principles and operation of water softener

The most common treatment needed for heat exchanger and rinsing water to eliminate scale forming tendencies. This is especially important for the water used in bottle washer, case washer make-up used for rinsing purpose and the water used in boiler. In Zeolite softener there are different sizes of sands used for ion exchange resins with salt (NaCl) for regeneration. Ca R=ion exchange resin R + (Nacl) = Na2R + Cacl2 Mg salt to drain. Mgcl2 Ca Ca HCO3 + Na2R R +NaHCo3 Mg Mg Ca So4/Cl +Na2R Mg Mg Mg Water usually requires softening when the hardness (Ca&Mg) is over 85ppm. Boiler manufacturer recommends softening when the hardness is more than 50ppm zeolite softener will reduce water hardness by ion exchange to keep the hardness at a level between 15 and 30ppm.This prevent corrosion due to the fact water hardness. Ca R +Na2So4 + Ca R +salt

Chemicals used for laboratory water test

Phenolphthalein(p-solution) Mixed indicator (m-solution) Sodium thiosulphate (t-solution) Calcium Hardness indicator Buffer solution

Titranets
0.02N H2SO4 N/44 0.01M EDTA

Equipment used in the laboratory for water testing.

1. Measuring cylinder 2. beaker 3. analytical balance Laboratory test of water

1. total hardness
take 100ml water sample add 12-15 drop of 10%NH3 buffer add 3 drop of hardness indicator Color change from color less to pink Then titrate using 0.01M EDTA Color from pink to blue

2. Alkalinity
Take water sample 100ML Add 3 drop T- solution Add 3 drop m-solution 1. Color change from colorless to light green Then titrate using 0.02N H2 S04 Color change from light green to pink. Then measure the volume of 0.02N H2SO4

3. Carbon dioxide Take 100ml water sample

Add 3 drop of p-solution

 Then titrate using N/44 until the first pink color change Measure the volume of N/44 3. Calcium hardness
Take water sample 100ml Add 3 drop of (T-solution) Add 0.5g of Ca hardness Then titrate using 0.01EDTA COLOR change from pink to purple

Pepsi cola water standard

Appearance-------------------clear Taste --------------------------none Odor ---------------------------none Turbidity ----------------------1.0ppm maximum Total hardness ---------------500ppm max Sulphate ---------------------250ppm max Chloride ----------------------250ppm as so4 max Total alkalinity --------------50ppm as CaCO3 max Organic matter --------------none Manganese -------------------none Florien ------------------------1.0ppm Chlorine ----------------------none Nitrate ------------------------25ppm as NO3 DAILY CHECK LIST Measure the chemicals properly and dissolve in their tank. Check all tanks are clean Check all pumps and agitators functioning properly. Check all the water line and valves are function properly. Checks the chemical spraying pumps especially LIME pump it closed by lime granules. Check the amount of chlorine ortolidine solution and chlorine detector equipment which is founded between 68ppm.

 Check the alkalinity rang between 2 & 8 Check water hardness by taking water sample with in 4 hrs If the hardness of water is greater than 20ppm then change the other softener which generated by NaCl.

The cooling system

Introduction
The refrigeration or the cooling system of the plant consists of components where the action takes place, such as, evaporators, compressor, condenser, expansion value, oil separator, heat exchanger, glycol water and ammonia. The cooling media are ammonia and glycol water the refrigeration system which circulated in the closed vapor compression cycle. The first cooling media is ammonia and the second cooling media is glycol water.

Principles and operation of refrigeration system

In the first cooling system we use ammonia instead of using glycol water because is more toxic and has bad smell so, to cool the treated water and syrup by using glycol water and to cool glycol water by using ammonia. First the ammonia goes out from evaporated to compressor to gate or in order to increase its temperature and pressure and using discharging pipe it transferred to oil separator tank to separate ammonia gas and a compressor lubricant oil, after separation ammonia gas goes to a condenser which contains a ventilator which is responsible for cooling water in the condenser. The ammonia will be cool down inside the condenser by showering the cooling water over the ammonia pipe. The ammonia loss its temperature and changes its state from gas to liquid but still the pressure is high until it inserts to expansion value in order to decrease. Its pressure and it also regulate the refrigerant flow rate required in the evaporator.

In the evaporator there is plate type heat exchanger then the glycol water inters to the evaporator at 80c and it reaches to 10c and returned back to glycol water tank and finely it goes to shell and tube heat exchanger to cool water and syrup which come to contact at 25 0c after heat exchange takes place the glycol water returned back to its storage tank and the cooled water and syrup are goes to mixing tank.

The daily check list of the cooling system

-Clean all the important parts of the plant. -Check the temperature at the suction discharge connection of the compressors and the coolant. -Check all electric devices - check the viscosity of lubricant oil.