Milk Chilling Proposal

RE-CYCLING ADOPTING MEMBRANCE TECHNOLOGY
FLOW CHART OF RE-USE SYSTEM
(290.0 KLD @ 14.5 KLH)
OUTLET FROM MGF SYSTEM
DOUBLE STAGE MICRON FILTER
MEMBRANE TECHNOLOGY
(REVERSE OSMOSIS)
RECOVERY REJECT
70% 30%
(i.e 203 KL) (i.e 87 KL)
COLLECTION TANK
MULTI GRADE FILTER
1
2ND STAGE R.O. SYSTEMS
RECOVERY REJECT
60% 40%
(i.e 52.2 KL) (i.e 34.8 KL)
(TDS < 50 mg/l)
COLLECTION TANK
MULTI GRADE FILTER
3rd STAGE R.O. SYSTEMS
RECOVERY REJECT
50% 50%
(i.e 17.4 KL) (i.e 17.4 KL)
(TDS < 50 mg/l)
COLLECTION TANK
MULTI GRADE FILTER
2
4th STAGE R.O. SYSTEMS
RECOVERY REJECT
50% 50%
(i.e 8.7 KL) (i.e 8.7 KL)
(TDS < 50 mg/l)
TO MEE (Triple Stage)

0.435 KLH
Condensate Concentrate
7.83 KL 0.87 KL
To SEP-200 sq.m
3
INPUT QUALITY OF R.O. SYSTEM
The most important factor for the life of membrane is its input water quality conditions.
The effluent has pre-treated to the level before feeding in to the Reverse Osmosis system.
Sl.No. Description R.O. feed water quality
01) pH 6.0 - 6.5
02) Total Dissolved Solids < 6000 mg/l (Max.)
03) Total Suspended Solids < 5 mg/l
04) Bio-chemical Oxygen < 5 mg/l

Demand
05) Chemical Oxygen < 50 mg/l

Demand
06) Turbidity < 1 NTU
07) Total Hardness < 150 mg/l
08) Alkalinity < 100 mg/l
09) Iron < 0.01 mg/l
10) Silica < 25 mg/l
11) Oil and Grease absent
4
FINE FILTRATION
A micron cartridge filter of 5 micron is incorporated prior to RO Plant for removal of fine
particulate matter, which will otherwise clog the RO membranes.
REVERSE OSMOSIS
Reverse Osmosis process is a membrane process in which a synthetic semi-permeable
membrane is used to separate water from dissolved impurities. When a semi-permeable
membrane separates a dilute and concentrates solution of salts, due to osmosis, the water
from the dilute solution side passes through the membrane to the concentrated side till
osmotic equilibrium is attained. Now, if the pressure is applied and increased gradually on
the concentrated side, the flow of water continues to reduce till the applied pressure
reverses the direction of flow of water and water from the concentrated side enters the
dilute side. This process is called the Reverse Osmosis.
It is very essential to ensure that the water fed to reverse osmosis membranes is free
from particulate matter to prevent membrane fouling. Also, the water should be free from
organic matter, heavy metals and oxidizing agents like free chlorine.
 All limiting conditions must be observed during the plant’s operation for satisfactory
performance throughout the membrane/ plant life.
 The treated effluent parameters are dependent on the inlet conditions. The fluctuations
from the design conditions will affect the quality of the treated effluent.
5
TURBIDITY
Turbidity of feed water to RO shall be less than 1 NTU. Experience has shown that
prolonged operation on feed water turbidities greater than 1 NTU generally results in
prohibitively frequent cleaning requirements. We Strongly recommends that the
performance of the pre-treatment equipment be monitored once a shift and corrective
action is taken.
SILT DENSITY INDEX
The SDI of feed water to RO shall be kept below 4. The SDI is a measure of colloidal
particles in the feed water and hence SDI value of 4 indicates that the feed water has very
low content of colloidal particles. This ensures minimal colloidal fouling of RO membranes.
This test shall be carried out once in a week and its value recorded.
BACTERIAL CONTAMINATION
The feed water to RO shall be free from bacterial contamination. The check for bacterial
content (CFU per ml) shall be carried out once a day and action initiated to minimize
membrane fouling.
ORGANIC CONTAMINATION
To minimize organic fouling of membranes, it is necessary to monitor this parameter once a
day and cleaning of membranes as per recommended procedure should be followed. The
frequency of cleaning will have to be determined by RO plant operating conditions.
6
OIL & GREASE
The Oil & Grease should be NIL and removed completely in the pre-treatment. The
presence of it in the feed water to RO, severely affects the membrane performance. The
presence of Oil and Grease physically fouls the membrane and make it ineffective, which is
then very difficult to remove even by cleaning.
TEMPERATURE
The operating temperature of feed water shall not be exceed 45 deg. Celsius. We
understand that the RO system will be treated only pre-treated surface water at ambient
temperature and hence we do not anticipate any problem on this account.
FREE RESIDUAL CHLORINE (FRC)
FRC at inlet to RO shall be monitored at least once a shift and recorded, as presence of FRC
is detrimental to the performance of membrane.
pH RANGE
The allowable operating pH range is 4 to 11 during normal operation of RO Plant. The pH of
feed water shall be monitored once in a shift in a lab.
7
On achieving the limiting conditions of RO, it is further dosed with chemicals such as
SMBS and Antiscalant dosing.
SMBS DOSING / ORP METER with DUMP VALVE
The filtered water is dosed with SMBS for de-chlorination of any residual chlorine present.
ORP meter is provided after SMBS dosing to measure the free residual chlorine present, if
any.
ANTISCALANT DOSING
The water is dosed with antiscalant to avoid calcium and magnesium scaling on the
membranes.
8
SPECIFICATION OF REVERSE OSMOSIS SYSTEM -1 (14.5 KLH)
01) MICRON FILTER
MoC : PP
MoC of catridge : PP spiral wounded
Filtration : 5micron & 1 micron
Size of catridge : 30” long
Qty. : 2 Nos.
02) ANTISCALANT DOSING PUMP
Type : Electronic metering pump

Capacity : 0-6 litres per hour
Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK
Cap of tank : 50 litres

MoC of tank : PVC/HDPE
Qty. : 1 No.
03 SMBS DOSING PUMP

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
9
04) HIGH PRESSURE PUMP
Type : Vertical Multistage pump

Capacity : 15.0 cu.m/hr
Head : 200 m
MoC of pump : SS 316
Make : Groundfos
Power : 10.0 HP
Qty. : 1 No.
05) R.O. MEMBRANE
MoC : Thin film composite

Spirally wound and
Polyamide in multi-arrays
Make : Hydranautics
Working Pressure : 250-300 PSI
Recovery : 70%
Average Salt : 99.5%
Rejection
No. of membrane : 15 Nos.
06) PRESSURE VESSEL
Size : Dia 8” – 5 elements

Pressure : 300-400 PSI
MoC : FRP
Qty. : 3 Nos.
Make : Standard.
08) CHEMICAL CLEANING SYSTEM
PUMP
Type : Monoblock (Centrifugal)

Capacity : 2 cu.m/hr
Head : 30m
MoC : SS-316
Power : 1.0 HP
TANK
Capacity : 500 litres

MoC : HDPE
Make : SINTEX/equivalent
10
09. INSTRUMENTATION
S. NO. DESCRIPTION QUANTITY TYPE
1. Pressure Gauge 1 Lots Bourdon gauge
2. Flow Indicator 2 Nos. Rotometer
3. Conductivity Indicator 1 No. Online
4. pH indicator 1 No. Online
5. Pressure Switches 2 Nos. Online
7. MS SKID FOR R.O. SYSTEM
8. INTER CONNECTING PIPING
9. ELECTRONIC CONTROL PANEL WITH WIRING (INTERNAL)
11
SPECIFICATION OF REVERSE OSMOSIS SYSTEM –STAGE-2 (4.35 KLH)
01) MICRON FILTER
MoC : PP
Filtration : 5 & 1 micron
Qty. : 2 Nos.

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
03 SMBS DOSING PUMP

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
12
04) HIGH PRESSURE PUMP
Type : Vertical Multistage pump

Head : 200 m
Make : Groundfos
Power : 7.5 HP
Qty. : 1 No.
05) R.O. MEMBRANE

Spirally wound and
Make : Hydranautics
Recovery : 60%
Average Salt : 99.5%
Rejection
06) PRESSURE VESSEL

Size : Dia 8” – 1 elements
MoC : FRP
Qty. : 1 No.
Make : Standard.
09. INSTRUMENTATION
S. NO. DESCRIPTION QUANTITY TYPE
1. Pressure Gauge 1 Lots Bourdon gauge
2. Flow Indicator 2 Nos. Rotometer
3. Conductivity Indicator 1 No. Online
4. pH indicator 1 No. Online
5. Pressure Switches 2 Nos. Online
10. MS SKID FOR R.O. SYSTEM
11. INTER CONNECTING PIPING
12. ELECTRONIC CONTROL PANEL WITH WIRING (INTERNAL)
13
PROPOSED SPECIFICATION OF 3rd STAGE – (1.74 KLH)
REVERSE OSMOSIS SYSTEM
01) MICRON FILTER
MoC : PP
Qty. : 2 Nos.

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
03) SMPS DOSING PUMP

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
14
04) R.O. FEED PUMP
Type : PISTON
Head : 200m
Pressure : 40-50 Kg./sq.cm
Make : HIRONISHA
Power : 5.0 HP
Qty. : 1 No.
05) R.O. MEMBRANE

Spirally wound and
Make : HYDRANAUTICS.
Type : LFC-4040
Feed Flow : 1.8 cu.m/hr
Recovery : 50%
Recovery Ratio : 5:1
06) PRESSURE VESSEL
Size : Dia 4”-3 element

MoC : FRP
Qty. : 1 No.
Make : Suitable for the above pressure.
15
PROPOSED SPECIFICATION OF 4th STAGE – (0.87 KLH)
01) MICRON FILTER
MoC : PP
Qty. : 2 Nos.

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
03) SMPS DOSING PUMP

Head : 30m
Make : Standard
MoC of pump : PP
Qty. 1 No
DOSING TANK

Qty. : 1 No.
16
04) R.O. FEED PUMP
Type : PISTON
Head : 200m
Pressure : 40-50 Kg./sq.cm
Make : HIRONISHA
Power : 3.0 HP
Qty. : 1 No.
05) R.O. MEMBRANE

Spirally wound and
Make : HYDRANAUTICS.
Type : LFC-4040
Feed Flow : 0.9 cu.m/hr
Recovery : 50%
Recovery Ratio : 5:1
06) PRESSURE VESSEL
Size : Dia 4”-4 element

MoC : FRP
Qty. : 1 No.
Make : Suitable for the above pressure.
17
EXPECTED PRODUCT WATER QUALITY FROM
Sl.no Parameter Value
1. pH 6.0 - 6.5
2. Total Suspended Solids NIL
3. Total Dissolved Solids Re-usable grade water

for processing(< 50 mg/l)
4. Chemical Oxygen Demand NIL
5. Bio-Chemical Oxygen Demand NIL
6. SDI NIL
TOTAL PRODUCT WATER
a) From 1st Stage R.O. : 203.0 KL

b) From 2nd Stage R.O. : 052.2 KL
c) From 3rd Stage RO system : 017.4 KL
d) From 4th Stage RO system : 008.7 KL
----------
TOTAL VOLUME : 281.3 KL
FINAL REJECT FROM THE R,O SYSTEM IS 8.7 KLD with TDS Level of 35,000-
40,000
18
REJECT MANAGEMENT SYSTEM
EVAPORATION SYSTEM
TOTAL REJECT FROM R.O. : 8.7 KLD @ 0.435 KLH
EXPECTED TDS LEVEL IN REJECT : 30,000 – 40,000 mg/l
Designed Evaporator capacity : 10.0 KLD
EVAPORATION FEED COLLECTION TANK

P
LIVE STEAM PRE-HEATER
TRIPLE STAGE MULTIPLE EFFECT EVAPORATOR

st
(1 & 2nd Stage falling film 3rd Effect – Forced circulation)
Concentrate to Solar CONDENSER
Re-use
19
SOLAR EVAPORATION PAN
Final reject from evaporator : 0.87 KLD
Efficiency of the Evaporator : 90%
Temperature of the Rejects : 50-55 C
The total area required for disposal of the final concentrate from the evaporator is 176.0
sq.m. The unit propose to provide 200 sq.m of solar evaporation pan.
**************************
The final product water will be used for Boiler purpose, Vessel washing,
Domestic, Floor washing, Silo washing, tank washing etc.,
20
DESIGN CALCULATION OF REVERSE OSMOSIS SYSTEM
FOR 300 KLD (Max.)
A)1ST STAGE REVERSE OSMOSIS SYSTEM
Flow : 300 cu.m/day

Operating Hours : 20 Hours
15.0 cu.m/hr
Designed Recovery : 70%
Salt Rejection : 99.5%
Design Pressure : 225 lb/Sq.cm(15.95 at atmospheric
pressure)
Design Temperature: Ambient (32 C)
Total TDS level : < 7000 mg/l
Q = Q/R
Q = Flow
R - Recovery
= 300/0.7
= 428.57 cu.m/day
Brain to be disposed of is 428.57 – 300.0 = 128.57 cu.m/day

Normal range of flux between 0.414 - 1.02 cu.m/sq.m/day
Assuming Flux of 0.420 cu.m/sq.m/day
Membrane area required (A) : Flow/Flux
: 300/0.420
: 714.285 sq.m
Normal Packing Density of membrane between 160 to 1640
sq.m/cu.m
Assuming packing density : 300 sq.m/cu.m
V : 714.285/300
= 2.3 cu.m
Assuming 0.1256 cu.m of volume per module
No. of Modules = V / module per volume
= 2.3/0.15
= 15.2 modules
Say = 15 Nos. of 8” module
We have provided 8” 40” long elements of 5 Nos.
which is adequate.
No. of pressure vessel = 15/5
- 3 Nos.
Total No. of Pressure Vessel provided 3 Nos.
Total No. of membrane required will be 15 Nos.
21
15 Nos. of 8”40” element for 300 KLD shall be adequate as per
our design calculation.
B) SECOND STAGE REVERSE OSMOSIS SYSTEM
Reject from 1st Stage R.O. : 90.0 cu.m/day

Flow Per hour : 4.5 cu.m/hr
Design Pressure : 50 Kg/Sq.cm
Design Temperature : Ambient (32 C)
Flux : 0.45 cu.m/sq.m/day
: 90.0/0.45
: 200.0 sq.m
sq.m/cu.m

V : 200/300
= 0.6 cu.m
= 0.6/0.1256
= 4.8 modules
Say = 5 No. of 8” module.
We have proposed to provide 5 Nos. of 8” membrane which is a

dequate to handle 90.0 KLD as per the design.
No. of pressure vessel (1 Nos.) = 5 in 1 elements
We have provided 5 elements of 8”40” long brakaish membrane.
22
C) 3rd STAGE REVERSE OSMOSIS SYSTEM
Reject from 2nd Stage R.O. : 36.0 cu.m/day

: 36.0/0.4
: 72 sq.m

sq.m/cu.m

V : 72/300
= 0.24 cu.m

= 0.24/0.2
= 1.6 modules
= 2.0 module
No. of pressure vessel = 1 in 2 elements
We have provided 2 elements of 8”40” long sea water membrane in 1

pressure vessel which is adequate as per our design calculation.
23
C) 4th STAGE REVERSE OSMOSIS SYSTEM
Reject from 2nd Stage R.O. : 18.0 cu.m/day

: 18/0.4
: 45 sq.m

sq.m/cu.m

V : 72/350
= 0.128 cu.m

= 0.128/0.12
= 1.06 modules
= 1.0 module
No. of pressure vessel = 1 in 4 elements
We have provided 4 elements of 4”40” long sea water membrane in 1

pressure vessel which is adequate as per our design calculation.
24
SPECIFICATIONS FOR TRIPLE EFFECT EVAPORATOR
FEED RATE - 450 Liters/Hr (Reject of RO)
TYPE OF EVAPORATOR : Triple stage Multiple evaporator

(1ST & 2nd falling film, 3rd Forced circulation)
CAPACITY
1. Evaporator Feed Rate : 450 liiters/hr @ 65,000 ppm TDS.
2. Evaporation rate : 90%
3. Concentrate outlet : 45 lph @ 28% Concentration
4. Condensate outlet : 405 lph @ 150ppm
FEED PROPERTIES
1. Feed Concentration : 50-65,000ppm solution of Sodium Salts

2. Solvent : Water
3. Solution Appearance : Clear Solution with totally dissolved solids
4. Total Hardness : Less than 800ppm
5. Silica : Less than 30ppm
STEAM REQUIRMENTS
1. Operating Pressure : 6 kg/cm2(g)

2. Quantity : 200 (+/- 5%) Kg/Hr.
MATERIAL OF CONSTRUCTION
1. Heat Exchanger Tubes : Stainless Steel AISI 316L.
2. Condensate/vapor Line : Stainless Steel AISI 304
25
Regarding multiple effect evaporator, the efficiency of the MEE is based on the
No of effects only. As per the board norms more than 3 effects the efficiency
will be 90%. Since we have provided 3 effects, please consider the reject flow
based on the 90% efficiency to meet out the SEP area and salt recovery system.
The final concentrate from MEE will be 0.9 KL (as per design) and required
solar evaporation area will be 198.0 sq.m. we are propose to provide Elevated
SEP (200 sq.m) is adequate to handle the final concentrate from MEE.
Hence adequate.
****************************
26

Milk Chilling Proposal

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RE-CYCLING ADOPTING MEMBRANCE TECHNOLOGY

FLOW CHART OF RE-USE SYSTEM

(290.0 KLD @ 14.5 KLH)

OUTLET FROM MGF SYSTEM

DOUBLE STAGE MICRON FILTER

MULTI GRADE FILTER

MULTI GRADE FILTER

3rd STAGE R.O. SYSTEMS

MULTI GRADE FILTER

TO MEE (Triple Stage)

Sl.No. Description R.O. feed water quality

01) pH 6.0 - 6.5

02) Total Dissolved Solids < 6000 mg/l (Max.)

03) Total Suspended Solids < 5 mg/l

04) Bio-chemical Oxygen < 5 mg/l

05) Chemical Oxygen < 50 mg/l

06) Turbidity < 1 NTU

07) Total Hardness < 150 mg/l

08) Alkalinity < 100 mg/l

09) Iron < 0.01 mg/l

10) Silica < 25 mg/l

11) Oil and Grease absent

particulate matter, which will otherwise clog the RO membranes.

Reverse Osmosis process is a membrane process in which a synthetic semi-permeable

membrane is used to separate water from dissolved impurities. When a semi-permeable

dilute side. This process is called the Reverse Osmosis.

performance throughout the membrane/ plant life.

prohibitively frequent cleaning requirements. We Strongly recommends that the

performance of the pre-treatment equipment be monitored once a shift and corrective

SILT DENSITY INDEX

To minimize organic fouling of membranes, it is necessary to monitor this parameter once a

frequency of cleaning will have to be determined by RO plant operating conditions.

then very difficult to remove even by cleaning.

temperature and hence we do not anticipate any problem on this account.

FREE RESIDUAL CHLORINE (FRC)

is detrimental to the performance of membrane.

The allowable operating pH range is 4 to 11 during normal operation of RO Plant. The pH of

feed water shall be monitored once in a shift in a lab.

SMBS DOSING / ORP METER with DUMP VALVE

01) MICRON FILTER

02) ANTISCALANT DOSING PUMP

Type : Electronic metering pump

Cap of tank : 50 litres

03 SMBS DOSING PUMP

Type : Electronic metering pump

Cap of tank : 50 litres

Type : Vertical Multistage pump

05) R.O. MEMBRANE

MoC : Thin film composite

06) PRESSURE VESSEL

Size : Dia 8” – 5 elements

08) CHEMICAL CLEANING SYSTEM

Type : Monoblock (Centrifugal)

Capacity : 500 litres

S. NO. DESCRIPTION QUANTITY TYPE

1. Pressure Gauge 1 Lots Bourdon gauge

2. Flow Indicator 2 Nos. Rotometer

3. Conductivity Indicator 1 No. Online

4. pH indicator 1 No. Online

5. Pressure Switches 2 Nos. Online

7. MS SKID FOR R.O. SYSTEM

8. INTER CONNECTING PIPING