Orientation Report

Sameed Rasheed Khan

Assistant Manager- Engineering
4th- July- 2022

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 ACKNOWLEDGEMENT

All praise for the Almighty Allah, the Lord of all skies, who bestowed upon me with the
ability and fortitude to complete my induction report successfully.

Extremely grateful to:

• Farhan Mehmood Malik (Works Manager)

• Fawad Quraishi (Operation Manage)
• M. Nabeel (E&I Engineer)
• Fahad Ejaz (Deputy Manager)

I take this opportunity to record my gratitude to the Heads of different departments who made
it possible for me to understand and to acquire the in-depth knowledge about their respective
departments and their activities.

Last but not the least, my induction program would not have been a success without the
constant support, help and appreciation of my fellow colleagues of Engineering department.

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Table of Contents

Acknowledgement 2
DALDA THROUGH THE AGES 4
VISION 5
GOALS & OBJECTIVES 5
PRODUCTS 5
MARGARINE 6-11
REFINERY 12-22
PORT QASIM SEED EXTRACTION PLANT 23-24
PACKING AND FILLING DEPARTMENT 25-26
REFRIGERATION SYSTEM 27
COOLING TOWERS IN DFL 28
DALDA SKU'S 29
BOILER HOUSE 30-32
RO PLANT 33
ETP 34

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 DALDA THROUGH THE AGES

Dalda’s story starts in initial 1930’s when Hindustan Vanaspati Manufacturing Co (today’s
Hindustan Lever Limited) wanted to start manufacturing Vanaspati locally. Formerly
hydrogenated vegetable oil was trade in in India by a Dutch company, Dada& Co. Dada & Co,
insisted that their name should be reflected in the branded product, therefore in an offer to
inaugurate their proprietorship of the brand Hindustan Lever presented the letter ‘L’ for Lever
into the name, giving intensification to the name DALDA.

Dalda Banaspati with its promise of superior quality & taste has won the hearts millions of
consumers making it not only a household tag in the sub-continent by synonymous with the
genre vanaspati. Dalda, in its mission to encounter the fluctuating needs of its consumers move
in the oils division through the initiation of Dalda Cooking oil. In 1999 Unilever assimilated
International Technology to cultivate Dalda Banaspati to Dalda VTF, making it the only
Virtually Trans-fat Free Bansapati in Pakistan. In July 2004 Unilever Pakistan sold its "Dalda"
brand to Westbury Group in partnership with Unilever Employee Welfare Group, who formed
a separate company under Dalda Foods (Private) Ltd.

It is the homage for the company that it is obtained all certification like ISO certification, SHE
certification (Safety Health Environment) and the most important that Dalda follows all rules
and regulation according to SHE rules.

There are three brands of DFL i.e. DBP (Dalda Banaspati), DCO (Dalda Cooking Oil), PCO
(Planta Cooking Oil), DCCO (Dalda Canola Cooking Oil), DOO (Dalda Olive Oil) Manpasand,
Tullo brands but there are 67 SKU’s (Sales Keeping Unit) for consumer, they can use any SKU
by own wish.

It is very honor for the Dalda Company that it is the only organization in Pakistan which is
introduce to Dalda Olive Oil. This brand is easily available into the market.

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VISION
Vision of Dalda Foods Ltd. Is “Five by Five (5x5)” that after every five years, we have to
increase ourselves by five times of the previous position in all the aspects.

GOALS AND OBJECTIVES

The goals and objectives of Dalda Foods Ltd. are:

• Commitment to quality
• To understand customers need
• Strive to be ahead in edible oil sector
• Offer healthy products
• Continuous research and continuous innovation
• Capture market share
• To have the strongest distribution network across Pakistan

PRODUCTS
• Dalda Cooking Oil
• Dalda Corn Oil
• Dalda Banaspati
• Dalda Olive Oil
• Manpasand Cooking Oil
• Manpansad Banaspati
• Sunflower Oil
• Canola Oil
• Planta Oil
• Tullo Cooking Oil
• Tullo Banaspati
• Kalongi Oil
• Knockout
• Bash
• Dalda Cupshup
• Creamo
• Puff
• Bisco

Upfield Products
• Blueband Tablets
• Blueband Tubs

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Margarine
The margarine is manufactured in Dalda Foods and owned by Upfield. The margarine section
is divided into three sub-divisions.

1. Process Area
2. Packing Area
3. Storage Area

1. Manufacturing Products
BBM margarine is manufactured in different tablet and in different sizes. They are classified
as follow

a) Tablets
a) BBM 50 Gm
b) BBM 100 Gm
c) BBM 200 Gm

b) Tubs
d) BBM 25 Gm
e) BBM 250 Gm
f) BBM 500 Gm

c) Professional Marketing Group

g) Puff
h) Creamo
i) Bisco

2. Process Area

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a) Process flow diagram for the BBM Normal.

b) Process flow diagram for the BBM Tubs.

c) Process flow diagram for the PMG (Puff/ Bisco).

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3. Manufacturing Procedure
Oil from refinery reached to Margarine (Process Area) to Tank A & B (for BBM Normal)
Tank C (for Bisco/Puff) and Tank D (for BBM Tubs).

In aqueous phase Skimmed milk is produced by adding refined salt (NaCl), Potassium
Sorbate and Citric Acid) then its Ph and salt percentage is checked (Ph should be 4.4-4.8 and
salt should be 3.3-3.5%). The Aqueous phase milk is then sent for pasteurization as to kill
microbacteria formation). The milk kept circulating in the HX circuit till its temperature
reaches to 85C). The pasteurized milk then sent to the milk holding tank where its
temperature further dropped to 4C as tank is provided with glycol water dressing for cooling
purpose.

The pasteurized milk and oil is mixed in the common header by means of dosing pump, then
from header another dosing pump operating around bar (25 bar) makes the mixture to flow
from DFL Wotator/ PMG Spass/ Unitator. The emulsion (feed) then formed is sent to the
packing zone for filling.

4. Packing Zone

a) Tablet Packing Process

The feed that was prepared in process area is filled in the dies. Pneumatic actuator operating
at 0.5-1 bars direct the fed to the packets (dies). The packets then wrapped and an arm push
the tablets from the rotating disc to the belt conveyor. The arm motion is governed by cam
action. The tablets formed is sent to exit of conveyor where packers put the tablet in outers.

b) Tub Packing Process

The feed that was prepared in process area is filled in the tub. This process is known as
forming. Then it is heated and aluminum lid is applied over the mouth of tub as to seal the
tub. Pneumatic actuator operating at 0.5-1 bars direct the fed to the tubs. The tubs formed is
conveyed to the packers by belt conveyor where packers put the tubs in outers.

c) Puff Packing Process

The feed that was prepared in process area is reaches the puff towing machine where the feed
is cut at a defined length and is wrapped in a foil. One pouch is termed as a block of 2kg in
weight.

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 d) Bisco Packing Process
Fat from the feed pipe is poured in to the box being placed on weighing machine as soon as
its weight reaches to 16kg solenoid valve get a feedback and give command to turn off the
flow line of feed.

e) Reworks Tanks
The feed that fed into cavity is set to operate at 0.5-1 bar excessive feed is sent back to the
rework tank. The pipelines that carry extra feed to the rework tank are provided with jacket
water dressing as the feed won’t get stuck in the line. Rework tank is also dressed with jacket
water line and all feed gets melted into the tank and a dosing pump pumped the melted feed
back into the VFD Wotator/Unitator dosing pump suction line.

5. Storage Area
The temperature of cold storage area is maintained at 6-10 C. The manufactured products are
placed on pallet and fork lifter put the pallet in storage room, from there it is dispatched.

6. Machine Production Capacity

Line Description Capacity Machine

mTon Speed(tab/min)
Benhil 2 BBM 50 gm 4.5 90
Benhil 4 BBM 50 gm 3.6 60
Benhil 1 BBM 50 gm 4.5 80
BBM 100 gm 9.6 80
BBM 200 gm 15 80
Benhil 3 BBM 250 gm 10 30
BBM 500 gm 10 10-12
Pak Form BBM 25 gm 3.5 12
Puff Towing B Unit Puff 18 -

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7. Packing and Palletization:

Palletization Product Unit Outer per Layer Per

in Outer Layer Pallet

PMG 8 kg 1 22 4
PMG 16 kg 1 10 4
BBM 50 gm 120 17 5
BBM 100 gm 80 16 5
BBM 200 gm 40 22 4
BBM 250 gm 32 10 4
BBM 500 gm 16 10 5
BBM 25 gm 256 14 3

8. Equipment Specification

Equipment Operating Temperature Capacity

°C mton

Oil Tank 55-60 11

Aqueous Phase Tank 78-80 5

Pasteurizer 85 -

Ammonia 2 -

Glycol 6 -

Jacket Water Tank 90.7 -

Rework Tank 65 1

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9. Cooling System in Margarine

Equipment Cooling Units Qty

VFD Wotator Ammonia Compressor 1

PMG Spass Ammonia Compressor 1

Unitator Ammonia Compressor 2

Packing area Ammonia Compressor 1

Pasteurizer Glycol Water 1

Milk Holding tank Glycol Water 1

Storage Area Freon Compressor 3

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Refinery
1. Raw Material Stock
The raw oil material is imported whereas the raw material required for packaging is locally
manufactured. The raw material is properly defined by an SOP to ensure procurement of right
quality material that conforms to specified purchase requirement at competitive price and
timely delivery for uninterrupted production. The raw material reaches to the Dalda Extraction
Plant at Port Qasim where the soya beans, cotton seeds, canola, and palm olean are extracted
and the crude oil is delivered to the Dalda Refinery at Karachi.

2. Refinery Capacities
➢ New Refinary (SCD) Semi Continuous Deodorizer
Capacity: 300 mton

Production: Batch Wise

➢ DCD (Desmet Continuous Deodorizer)

Production: Continuous

Capacity: 300 mton

➢ Tundra
Production: Continuous

Capacity: 600 mton

Total Production Capacity: 1200 mton

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 3. Refinery Process
Physical Process:
1. Degumming
2. Bleaching
3. Deodorization

Chemical Process
1. Neutralization

Processing of Cooking Oil

1. Degumming
2. Neutralization
3. Bleaching
4. Blending of oil as per product formulation
5. Deodorization
6. Blending of Vitamins & Aroma

Processing of Banaspati
1. Degumming
2. Neutralization
3. Bleaching
4. Hydrogenation
5. Interestification
6. Blending of oil as per product formulation
7. Deodorization
8. Blending of Vitamins & Aroma

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Degumming
This process is used to remove the water-hydratable phosphatides from the crude oil to
prevent the oil from rancid and to increase the shelf life of the oil. Here the oil is given the
acidic treatment with phosphoric acid. The gyms are precipitated and separated out which is
removed from the oil through water washing and settling and draining process.

Neutralization
The main purpose of the neutralization process is to remove the free fatty acid present in the
crude oil to reduce the acidity of the oil to bring it back to acceptable level. In this process
liquid caustic soda is added to react with FFA. As a result of reaction soap is formed which is
removed by oil by water washing and settling and draining process.

Bleaching Process
The neutralized oil is treated with bleaching earth for removal of coloring pigments to reduce
the colure of oil. It is a physical process in with coloring pigment is physically adsorbed on
the surface of bleaching earth particle. Bleaching earth and coloring pigment are removed
through filtration by very thin filter. The clear oil pass through the filter and stored in the
storage tank.

Blending of Oil
The degummed, neutralized and bleached oils are blended as per blend formulation of the
product.

Deodorization Process
This process leads to removal of odor. Every vegetable oil has its own distinct natural odor, it
therefore necessary to remove this odor. The process is carried out at high temperature by
injecting steam and maintaining high vacuum at which all odoriferous matter is distilled off
and drawn out of oil making oil odorless.

This oil is odorless and free from harmful substances that would make oil rancid during its
shelf life.

Blending of Aroma and Vitamins

Aroma and vitamins are added to the oil after it is deodorized. Vitamin AD3 is added to all
products. Aroma is added to DFL standard for each product.

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Hydrogenation Process
Hydrogenation is essential for banaspati production. Hydrogenation makes the oil/fat more solid by
increasing its melting point. This process is convert unsaturated compound to saturated compounds by
adding of hydrogen atoms in the reaction vessel that contain the oil.

Following changes occur as a result of hydrogenation of oil

• Reduce IV (iodine value) which reduce the unsaturation of oil

• Increase the melting point
• Change solid fat index and solid content index.
• Improve stability of oil
• Improve taste of oil

Interesterification Process
The process is carried out in the banaspati production to make the product virtually trans free
fat. During hydrogenation trans free acid is developed. This is a harmful fatty acid for
coronary diseases, it increases LDL and reduce HDL.

Interesterification is a fat modification process in which melting and crystallization properties

of fats are changed by randomizing the distribution of Fatty acid to produce virtually trans-fat
free Banaspati.

In interesterification process hydrogenated oil is blended with non-hydrogenated oil in a

vessel. The mixture is heated and dried under vacuum.

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 4. Neutralization/Bleaching Plant
There are 6 vessels where the neutralization and bleaching process is carried out i.e. NB1 to
NB6 where only NB1 and NB4 are used for hard oil processing otherwise all are used for soft
oil. It is a batch-wise process where each batch produced has an amount of around 30 tons. The
process involves the following steps:

For Soft Oil:

• 30 ton batch is charged to the weighing scale from where it is fed to the required NB
vessel through pump
• The oil is then heated to a set point of 92°C within vessel. There are coils inside the
vessel in which sparking steam is present which heats up the oil. There is also an
agitator present inside the vessel which is used for vigorous shaking of the oil so that
uniform heating can be achieved.
• When the temperature reaches to 60°C, phosphoric acid is dosed into the vessel which
converts the unhydratable phosphatide groups into the hydratable phosphatide that can
be easily washed away with water. This process is called Degumming. As a result of
this process, the oil becomes thin and light.
• When degumming is done, 5% warm (around 95-98°C) water wash is given to the oil
and a settling time of 30 minutes is provided so that the oil, water and the hydratable
phosphatide can form separate layers due to the density difference. After this the water
alongwith the phosphatide group is drained out of the NB vessel.
• After degumming, the caustic soda solution of 0.8N is dosed into the vessel to reduce
the free fatty acid (FFA) content of the oil. The caustic solution is added as per the
amount of original content of FFA in oil. The caustic neutralizes the oil by reacting
with the FFA present in it and produces salt in the form of soap and water.
• After neutralization reaction, a 10% warm water wash is given to the oil which carry
away the soap with it from the oil and drains out.
• The neutralized oil is now dried under vacuum to remove the moisture content. The
vacuum is created using an LRP (Liquid Ring Pump). In this step, the temperature of
the oil reduces to 80°C because the molecules of vapour present at the surface of the oil
are saturated vapours so when vacuum is provided the saturated vapour gets heated and
attains their vapourization temperature at much lower temperature and thus they start
to convert into dry vapour carrying away the heat energy with them in the form of latent
heat that’s why the temperature of the oil gets reduced
• After removing the moisture, a sample is taken in which the FFA content of oil and
Soap content is checked. The standard to be followed is such that FFA should be less
than 0.1%, and soap content should be less than 500 ppm.
• Now to change the undesirable dark color of the oil, we do bleaching. For this process,
the oil is heated to 110°C under vacuum at 730 mm of Hg and activated bleaching earth
is added to the oil. The color is observed between the spectrum of red and yellow.
Bleaching earth absorbs the colored pigments from the oil and makes the oil color more
desirable.

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 • Now all the pre-NB processes are completed, and the oil is now filtered through the
AMA filter (whose leaf’s have meshes of 80 microns/sq-in) and the GAF filter. This
filtration is done to remove the activated earth from the oil. After this, the oil is stored
in storage tanks.

For Hard Oil:

(This process is carried out after neutralization and before drying)

• If hard oil processing is carried out, then one additional process is required that is
Interesterification. In this process, Sodium methylate catalyst Is dozed into the oil
around 20 kg per batch under high vacuum. The agitator of the vessel is set to the
maximum and temperature is maintained to 110°C. As a result of this, the catalyst
reduces the slip melting point of the oil by converting all the trans-bond into the cis
bond. The range of the slip melting point is between 33-45°C depending upon the
recipe.
• Vacuum is then removed, and the oil is allowed to cool down using cold water in
between 90-92°C.
• 10% warm water wash is given to the oil to remove the catalyst from the oil.

5. Semi-Continuous Deodorizer (SCD) Plant

Deodorization is a steam-distillation process to remove free fatty acids and volatile
components present in crude edible oil at this stage of processing. These unwanted
substances negatively affect the odors, flavor, color, and stability of the final product. To
strip these substances from the oil, steam is passed through the oil at very low pressure,
relatively high temperature and high vacuum condition.

SCD is batch-wise and it has 5 columns where oil is charged batch-wise from the top and
allowed to stay in those trays for some time and then pass onto the other succeeding tray.
Each column is maintained at high vacuum pressure of 5 milli-bar. This vacuum is created
using the venturi-vacuum generation system. The daily production of SCD is 300 tons.

The step-by-step processes involved in SCD are as follows:

• The oil is charged into the weighing scale using pumps from where a 7.5-ton batch of
oil is sent to the degasser for preheating. The degasser contains coils in it in which hot
steam is coming from the main boiler. When the oil meets these coils, the temperature
of the oil reaches to 120°C.
• The preheated oil is then dosed from top into the SCD column in the 1st stage where the
temperature of the oil is further increased to 160°C. This rise in temperature is due to
the closed coil known as thermo-syphon connecting 1st stage to the 4th stage. This coil
contains water in the 4th stage. When the hot oil comes down to the 4th stage, it will
vaporize the water in the coil. These vapors are hot as they carry heat in the form of

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 latent energy. These hot vapors travel to the 1st stage where they exchange heat with the
oil coming from the degasser while itself condensing back to the water state and move
to the 4th stage in a cycle. This is how oil is heated in the 1st stage to 160°C.
• From 1st stage, the oil is transferred to the 2nd stage where the oil is further heated to
240°C using the GEKA boiler. The retention time in this stage is 1400 minutes. The
GEKA boiler is maintained at a pressure of 50 bar. After the retention time is completed,
the valves are opened, and the oil is transmitted to the next stage.
• In the 3rd stage, there are no coils in the vessel so there won’t be any change in the
temperature (i.e., 240°C). Instead, in this stage, there is sparging steam which is used
for the vigorous shaking of the oil so that the volatile fatty acids get separated out from
the oil and sucked by the high vacuum of the column. These volatile compounds are
then sent to the scrubber tank where it is used as a by-product to produce soap. The
retention time of oil in this stage is 1800 minutes.
• Now, the oil is sent to the 4th stage where the sealed thermo-syphon pipe is connected
as discussed earlier. In this stage, the thermo-syphon contains water which takes the heat
from the oil and cools it down to 180°C.
• In the 5th stage, the oil coming from 4th stage is further cooled. This cooling is done by
the heat exchange with the cold water coming from the cooling tower and the
temperature further reduces to 110°C. Citric acid of 0.01% concentration is added to
increase the shelf life of the oil. After all these 5 stages, the oil is sent to the buffer tank
where some tests are being conducted from the sample of it. If the oil is not of standards,
then from the buffer tank, it is again passed through all stages of SCD and if the oil is of
standards then from buffer, it is stored in the storage tank.

6. Tundra
The most advanced technology used for refining is Tundra and it works in a continuous
process or cycle. Its daily production is 600 tons, also with greater amount of production,
the other advantage is that it has its own neutralization bleaching and deodorization section
so in short in this machine, raw oil is inserted, and it converts it into the finished product
as the output. The steps involved are as follows:

• The raw crude oil is dosed from the storage tanks to the tank T1101. From this tank,
the oil is strained passing through 2 strainers to remove any solid particle from the
oil. Then it is pumped to the heat exchanger 1121A where it exchanges heat with
the hot oil coming from the drier 1106. Then this hot oil is again sent to an
exchanger 1121B where it is further heated through the hot steam.
• Now, the heated oil (between 80-90°C) is passed through a mixer pump 1104AC
(mixer shear pump) where it is mixed with phosphoric acid. Phosphoric acid is
supplied in the line before the mixer pump in the amount of 0.07% of the oil from
phosphoric tank via valve P1104AC. The pump then mixes and transfers the
mixture to the acid reactor 1104AC that has an agitator in it for further mixing.
• After degumming, the oil is sent to another mixer shear pump 1104NA and in the
similar pattern now caustic solution is supplied to the line before the pump from the

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 caustic tank via valve P1104NA. The caustic solution is added according to the FFA
content present in the oil (usually 14%). The pump then mixes and transfers the
mixture to the caustic reactor 1104NA that has an agitator in it for further mixing.
• After neutralization, the oil is sent to Centrifuge 1118NA where soap is removed
and collected in the soap collector 1182S. Water is then added to this oil and it is
sent to another centrifuge 1118W where water is separated out along with the
remaining soap content. Now the remaining soap content is collected in the fat
collector 1132.
• From centrifuge 1118W, the oil is sent to the drier where the moisture is removed
from it by creating vacuum of 67 milli=bar pressure. Some temperature is dropped
here due to the removal of moisture and some heat is exchanged with the fresh oil
coming from T1101. So, this cooled oil can be charged into PST tanks for storage
or it can be sent for further processing as well.
• If the oil is sent for further processing, then it enters the bleaching section at around
62 °C, from where it passes through exchangers T521A (oil to oil heat transfer) and
T521B (steam to oil heat transfer) where it gains heat. It is then sent for bleaching.
• For bleaching, the oil is dosed into the bleacher vessel 622. This vessel is connected
to a hopper 609A from top through which bleaching earth is added into the vessel.
The bleaching earth is added under the presence of vacuum of 62milli-bar pressure
while the oil is at about 110°C.
• After completing the retention time here, the oil is pumped through 2 pumps i.e.,
622(1) and 622(2). These pumps sent the oil to the 2 AMA filter i.e. 616(A1) and
616(A2). The mesh size of each AMA filter is 80 microns per sq. inch. AMA filters
filtered out the bleaching earth from the oil and the filtered oil is sent to the buffer
tank 682B.
• From the buffer tank, the oil is further passed through GAF filters i.e. 616(B1) and
616(B2) which has much smaller and fine meshes about less than 10 microns per
sq. inch. This is done to completely filter the oil.
• Now the oil is sent to the 802 degasser where it is preheated to about 100°C. From
degasser, the oil is sent to the 5th stage of deodorization column QE882. The column
has 6 stages, but we connect the degasser through several tubing to the 5 th stage
where it exchanges heat with the hot processed oil coming from the 1st stage of the
column. From stage 5, after gaining heat, it is moved to the top stage of the column
where it is further heated by main GEKA boiler working at 50 bar pressure.
• The oil temperature reaches to 240°C in the 1st stage. As the oil needs to be
deodorized, it means that the column is under a vacuum pressure, here 2milli-bar.
The retention time in each stage is 1800 minutes. The oil comes down from the top
in each stage. Each stage has a tray with tapered cross-section. When the tray gets
overflow, the oil comes down to the next tray by sticking to the outer surface of the
previous tray. There is no prominent change in temperature in the first 4 stages
whereas parging steam is used to shake the oil vigorously as a result of which the
non-volatile fatty acids get separated out from the oil and collected through the
vacuum and sent to the scrubber. From scrubber, the fatty acid is sent to the fatty
acid catcher tank 823LT.

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 • The deodorization is completed till the 4th stage. In the 5th stage, oil is cooled to
about 150°C by giving its heat to the newly feed oil after that in the 6th stage, the
oil is further cooled by the cold water coming from cooling tower and thus as a
result, the oil temperature comes down from 240°C to 110°C. 0.01% Citric acid
(25% concentration) is also dosed to the oil in the last stage to increase the shelf life
of the oil.
The oil that is at 110°C can’t be stored in the storage tank but it is still considered as hot for
the storage purpose, so we extract more heat by passing through HX 821S (oil to water heat
exchanges) further it is passed through HX T521A and T881B and finally at 50°C, passing
through GAF filter, it is stored in the storage tanks.

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 7. Gas Cracking Plant
The process of breaking down the larger, heavier, and more complex hydrocarbon molecules
into simpler and lighter molecules at higher temperatures is known as cracking. The plant
involves different chemical processes which are as follows:

1. Desulphurization: It refers to the removal of Sulphur content from the gas. In natural
gas, there are H2S and CO2 content which can be removed by this chemical process. It
is also done to protect the Nickel catalyst used in the hydrogenation plant.
2. Steam Reforming: Steam reforming or the steam methane reforming (SMR) is the
chemical process used to produce carbon monoxide and carbon dioxide.
3. High Temperature Shift Convertor: At the outlet of steam reformers, partial
oxidation reactors or coke oven gas units the syngas contains H2, CO, CO2, CH4 and
water in chemical equilibrium at high temperatures in the range of 700 to 1400 °C
depending on the process pressure and the mixture of feed stock and process steam or
water.
By means of the CO shift conversion an important portion of the CO content in the
cracked gas is used for additional hydrogen generation, which is following the chemical
reaction.
CO + H2O => H2 + CO2
This process is exothermic and is limited by the chemical equilibrium.

The steps involved in the GCP are as follows:

• Natural gas at 0.5bar pressure and temperature about 30-35°C is sent to a multistage
compressor (2-stage compressor) where the natural gas is compressed and its
pressure rises to 16 bar and due to compression, temperature reaches to about 90°C.
• This high pressurized gas is then sent to feed pre-heater E5 where it is heated to
about 420 °C.
• Now, as we know that the Sulphur is a poisonous and hazardous gas and it can also
make the other substance poisonous that’s why it is removed in the desulphurizer.
In the desulphurizer, we have a bed of cobalt and molybdenum catalyst along with
the zinc oxide which is used to remove Sulphur. It is an endothermic process so the
temperature will be reduced after this step.
• Then, this desulphurized gas is sent to the feed super-heater E4 where steam is
added to it and its temperature rises to 480°C.
• This mixture is sent to reformer where reforming reaction happens at around 724
°C.
• This hot mixture is then passed through a process gas boiler E6 where the water
absorbs some of this mixture’s heat and allowing the mixture to cool, as a result of
which the mixture’s temperature reduces to 340°C.

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 • After passing through E6, the gas is passed through the high temperature shift
converter where the carbon monoxide present in the gas changes its shift to the
carbon dioxide at around 450°C.
• After the removal of CO, the gas is passed through the feed water heater where it
exchanges heat with water and cools down to 200°C
• Its temperature is further reduced by sending this mixture to process condenser E7,
temperature here falls to 90 °C. It is then sent to condenser separator.
• From the condenser separator, the mixture is sent to pressure swing absorber where
zeolite adsorbs the hydrogen, which is sent to hydrogen storage tanks. The rest of
the mixture of gases are passed to the reformer, where it serves as fuel to the burner.

Water Circulation in the GCP:

• From demins tank, the demineralized water is first sent to a deaerator where oxygen
is removed from the water.
• Then this water is sent to the steam drum where it is collected at the bottom.
• Now, this steam drum is connected to a process gas boiler E6 where this water
converts into steam by gaining heat from the processed hot gas.
• Then the steam is passed through the E3A and E3B heat exchangers, where it is
further heated.
• This steam is then sent back to steam drum, from where it is supplied to the feed
super heater, for the reforming reaction.

8. Hardening
In DFL there are two HV (HV 1 & 2). Initially suction is created in the vessel by LRP. Oil
starts entering into the vessel. Oil is heated by circulating steam in the coil. The temperature
of oil is maintained at 160°C. Catalyst are added via oil tank when its passing through the
press filter. At press filter new catalyst is added (some proportion). The circulating catalyst is
a mixture of old and new catalyst. This lead to the saturation of oil where its melting point
increases. To remove the further traces of catalyst oil is also passed through Gap filter. The
saturated oil is sent to HT Tank 1 2 3 6 and CT tank 1 2 3.

9. Winterization
Winterization is only done for soft oil (corn oil/sunflower) as to remove wax from its oil. The
oil that needs to be winterized is stored in Crystallize tank 1,2,3. Glycol water is circulating
in the crystallizer tank that decrease the temperature of oil to 10C. The oil kept on circulating
from Gap filter till its reaches to diminish yellow. After the desired color is obtained, the
cooled winterized oil is sent to WD tank.

22
Port Qasim Seed Extraction Plant
Lab Testing
1. Meal Testing
In meal there should be max 1.5% of oil present in it. Two parameters of meal are
tested.

a) Crude Protein Quantity (CP)

b) Crude Protein Solubility (KOH Solubility)

2. Crude Oil Testing

a) Moisture: It should be below 0.5%
b) Impurity (Solid matter): It should be below 0.5%
c) Free Fatty Acid (FFA): It should be below 1%

3. Utilities
The Port Qasim Plant utilities comprises of following machines

a) Compressors
b) Boilers
c) Engines
d) Generator
e) EPT Plant

Boiler Type Coal Fired Boiler

Capacity 10 T/hr
Max.
Pressure 1.25 Mpa
Temperature 194 °C

23
 Engines Model KVA Load
1.02
CATERPILLAR 3512c 1275 MW
1.02
Cummins KT 50 325 MW
0.26
Cummins - 325 MW

4. Process of Oil Extraction

Seeds from the dumping pit is carried to the Silos via bucket elevators. There are three
Silos each having a capacity of 3300 mTons. From silos is reached the pre-press plant.
Bucket elevator carries seed from silos to the hopper. The seed is cleaned by seed
cleaner. Then it entered in to the flake where seeds are broken. In order to crack the
seeds, it is desired to raised its temperature. Elevated temperature is achieved by
boiler steam. The crushed seeds are then fed into the press where oil is extracted from
the seeds. Oil and cake got separated, the cake is send to the expellers. Further oil is
separated from the cake. Oil is sent to the storage tank. All these methods of
extracting oil are physical method.

The remaining cake is fed into the extractor where its is showered by hexane. Its
capacity is 18 mton. This leads to a chemical reaction that extract oil from the cake
(remaining 12% oil is separated from the cake). The mixture is sent to the distillation
chamber where it is passed through series of heat exchangers. The hexane got separate
out from oil under high temperature. The hexane then again enters to the extractor and
the loop begin over and over again.

The oil is sent to the storage tank.

The meal formed is sent to the desolventizer toaster where remaining traces of hexane
is removed and cake is transformed to powder form (powder meal). The meal
produced is then exported for animal feeds.

24
FILLING AND PACKAGING
DEPARTMENT

1. Tin Filling:
There are 2 machines for the filling of tin i.e. Comeco 1 and Comeco 2. Comeco 1 is used to
fill 5 kg tin at a rate of 48 tins/min whereas Comeco 2 is used for 2.5 kg tin at a rate of 60
tins/min. The step by step procedure of filling is stated as follows:

• Empty tins on a slanted conveyor belt are on their way for filling. In their path, there is
a blower present which is used to remove dust particles inside the tin.
• After that, there is a coder that generates a code on the tin.
• Then, 4 tins can be filled at a time by this machine and strainer is placed for filtration.
• Now, the tins are needed to be sealed. For this purpose, a seaming assembly seals the
tins by lids being dozed by the hopper.
• For inspection, the 4 consecutive tins are inspected. Their weight, their sealing and the
print quality.
• Then a machine called Euro pack wraps the tins. After wrapping, the tins are passed
through the heat sealer. Euro pack system is controlled by the PLC.

2. Pouch Filling:
The pouches are filled by a machine called Pre-Pack. There are 29 pre-pack machines in total
which have the filling rate of 27 pouches per minute. The step-by-step procedure for filling of
pouches are as follows:

• From the vessel, the oil passes through the GAF filters and come down to the header at
the filling department.
• From where, the oil that needs to be filled flows through the pump to the pouch filler
machine which has a capacity of 3 tons each.
• Pouch fillers have nozzle extended through a pipe for flow of oil.
• The packaging reel has markings which are sensed and indicated sealing positions,
water cooling is attached to ensure temperature does not exceed and damage the
packaging
• Oil is filled in these pouches followed by upper horizontal seal and then these pouches
are manually packed in boxes such that 5 pouches per box.

3. Bottle Filling:
Filling plant of bottles consists of conveyors, laser sensors, break tanks and fillers. Manual
filling stations are used after coding is performed. Caps are placed manual and tightened by a
machine while induction seal process seals the cap internally, some bottles are tilted to check
leak, neck seal is placed, and a heat sealer completes the job. Coding is done on an outer

25
manually. The filing speed is 4 tons/nozzle shift for bottle filling while for bulk filling is
7ton/nozzle shift. The step-by-step procedure is given below:

• The sensor senses the presence of the bottle.

• 3 functions are triggered by another sensor. A) Actuates the solenoid valve which
prevents the oil in the cylinder to go towards the vessel. B) It removes the spillage tray.
C) Pushes the piston forward to start the filling process of the bottle.
The position of another sensor is adjusted such that it breaks the filling speed at a certain
instant to prevent the over-filling of the bottle

Machines Capacity Capacity

5lit 2.5lit
COMACO
48ton/min 60ton/min
Euro Pack Shrink plastic packing
Pre-Pack Pouch 27poch/min

Bottle Filling Actuator Weighing

(Local Manufacturer) System System
20 Ton/shift 20 Ton/shift

4. RGII
There are two parties working SPI and ZCI for making the cans (5/2.5lit)

5. Wilco mat Machine

This machine checks weather the can is damaged from flange side or not, is there any pinhole
or not. The machine has turn table and is operated pneumatically. Difference of pressure is
maintained and in case of any leakage the Delta P falls beyond the permissible limit.

26
 Refrigeration System

Refrigeration System Compressor & Type Quantity Condenser Application Refrigeration

purpose Tons
Ammonia Refrigeration Carrier- Reciprocating 1 Water cooled type Cooling Room # 9 60 TR
System type

Freon Gas Refrigeration Carrier- Reciprocating 8 Water cooled type Cooling Room 1-8 40 TR
System type

Ammonia Chiller Carrier- Reciprocating 2 Water cooled type Winterize 60+60 TR

(Glycol Water end type Crystallization
product) Tank

Carrier- Reciprocating
Ammonia Refrigeration type 2
System Water cooled type Unitator 60+60 TR
Carrier- Reciprocating
Ammonia Refrigeration type
System 1 Water cooled type Spass 40 TR

Carrier- Reciprocating
Ammonia Refrigeration type
System 1 Water cooled type DFL Wotator 40 TR
Freon Chiller (Glycol Carrier- Reciprocating 2 Water cooled type Pasteurizer 40+40 TR
Water end product) type

Carrier- Reciprocating
type
Freon Condensing Unit 1 Air cooled type Packing Area 20 TR
Carrier- Reciprocating
Freon Gas Refrigeration type
System 1 Water cooled type Packing Area 40 TR
Carrier- Reciprocating 1
Freon Gas Refrigeration type Margarine Cold
System Water cooled type Storage area 20 TR
Carrier- Reciprocating 2
Freon Gas Refrigeration type Margarine Cold
System Water cooled type Storage area 30 TR

27
Cooling Towers in DFL

Cooling Towers Application Area

Cooling Towers # 1 SCD
Dirty cooling tower
Cooling Towers # 2 DCD & Denim
Dirty cooling tower

Cooling Towers # 3 Tundra

Clean cooling tower

Cooling Towers # 4 SCD & DCD

(Jallal CT) Clean cooling tower

Cooling Towers # 5 Tundra

(in front of ETP) Dirty cooling tower

Cooling Towers # 6 Margarine Storage Area/Spass

(Ghanna CT)

Cooling Towers # 7 Margarine

(near building block) Cooling Room # 9
Winterize Chiller

Cooling Towers # 8 For GCP

(old refinery-bottle type)

Cooling Tower # 9 For Blending Vessel

(near building block)

Cooling Tower # 10 For Winterize Plant

(At the roof top of winterize plant)

Cooling Towers # 11 For Cooling Room 1-8

(near Masjid- Bottle type)

Cooling Towers # 12
(near Masjid-Rectangular Type)

28
 Dalda SKUS

SKUS

DBP 2.5kg Tin 5kg Tin 1 kg pouch

DCO 2.5 lit Tin 5 lIt Tin 3 lit bottle 4.5 lit 5 lit Can 10 lit Can 1 lit
bottle Pouch
MPB 2.25 kg 4.5 kg Tin 0.9 kg pouch 1kg pouch
Tin
PCO 5 lit 3 lit Bottle 4.5 lit Bottle
MCO 4.5 lit tin 0.9 Lit 0.9 Lit Pouch
Pouch (1X16)
(1X5)
CCO 3 lit Bottle 10 lit Can 16 lit Can 1 lit Pouch
Corn 5 lit Tin 3 lit Bottle 4.5 lit Bottle
Oil
SFO 3 lit Bottle 4.5 lit 10 lit Can
Bottle
TBP 2.5 kg Tin 5 kg Tin 16 kg Tin 5 kg 10 kg 16 kg 1 kg 1 kg 1 kg
Bucket Bucket Bucket pouch pouch pouch
(1X5) (1X10) (1X16)
TCO 5 lit Tin 16 Lit Tin 1 lit pouch 1 lit pouch 500 ml
(1X5) (1X16) pouch
(1X10)

BISCO 16 kg
PUFF 16 kg 16 kg 16 kg
(winter) (summer) (spring)
Fry'All 16 lit
Tins

29
BOILER HOUSE
There are three boilers in Dalda Foods, Karachi Factory. First boiler is of Cocohon, having a
capacity of 13 Tons. Boiler # 2 is of Ruby having a capacity of 16-ton steam per hour and
boiler # 3 is of Boasch having capacity of 20 ton/hr.

Existing Boiler Capacity

Boiler water level 40-50%
Boiler # 2

Steam Pressure Max 14.2 bar

HFO temperature 2.5-4bar
Diesel Pressure -
Stack Temperature Max 260 C
NG Pressure 4.5-8.5psi
Boiler water level 40-50%
Boiler # 3

Steam Pressure Max 14.2 bar

HFO temperature 2.5-4bar
Diesel Pressure
Stack Temperature Max 260 C
NG Pressure 4.5-8.5psi

Plant Steam Requirement

Steam Flow T/H in Boiler # 1 7

Steam Flow T/H in Boiler # 2 8

Steam flow T/H 6" line 4

Steam flow T/H 8" line 6

Feed Water Tank Level 60-90%

Dearator water level 50%

Dearator water temperature 90-100 C

Day tank HFO temperature 75-80 C

30
 Plant Steam Requirement
Steam Flow T/H in Boiler # 1 7
Steam Flow T/H in Boiler # 2 8
Steam flow T/H 6" line 4
Steam flow T/H 8" line 6
Feed Water Tank Level 60-90%
Deaerator water level 50%
Deaerator water temperature 90-100 C
Day tank HFO temperature 75-80 C

New Boiler

Min 300mbar Min 4.35 psi

NG Pressure for boiler operation Max 500mbar Max 7.2 psi
HFO suction pump 5 bars
HFO Ring man pump 30-35 bar
Day tank pump capacity 8 ton
Day tank pump capacity (old) 3 ton
Feed Tanks (deaerator) 10 ton

Q= 39.1m3/h
H= 5m
Booster Pump Imp Dia=5.24in

Q= 22.6m3/h
Feed water pumps H= 247/275m
HFO Sulphur content 3.18%

ECO 5 135C
Flue gas temp 125C
Water temperature before ECO 6 103 C
As to avoid acid rain

31
Raw water TDS
540-800
Raw water hardness

RO Water_1 TDS
130 ppm
RO Water_2 TDS
150 ppm
Boiler TDS
>=3400

1200+1200lit Zeolite
Softner_1 Capacity resin (Cationic
Treatment)
700+700lit Zeolite resin
Softner_2 Capacity (Cationic Treatment)
3 regeneration/day on
raw water
1 regeneration on RO
Regeneration (Brine) water

32
RO PLANT

Margarine RO Plant
Company Aqua Dem

2
Carta rage filter (5 micron each)
Membrane 4
Backwash 20min/shift
Rejected Water 9 Gpm
Produced Water 5 Gpm

TDS of produced water 15-25 ppm

Big RO Plant
Company Water Remedy Pvt. Ltd

2
Carta rage filter (5 & 1 micron)

Membrane 8

Backwash 20min/shift

Rejected Water 26 m3/hr

Produced Water 19 m3/hr

TDS of produced water 55-65 ppm

Total Capacity 23 m3/hr

33
Effluent Treatment Plant (ETP)

The major aim of wastewater treatment is to remove as much of the suspended solids as
possible before the remaining water, called effluent, is discharged back to the environment. As
solid material decays, it uses up oxygen, which is needed by the plants and animals living in
the water.

"Primary treatment" removes about 60 percent of suspended solids from wastewater. This
treatment also involves aerating (stirring up) the wastewater, to put oxygen back in. Secondary
treatment removes more than 90 percent of suspended solids.

There are 4 different steps involved in ETP are:

1) Preliminary Fat traps/ Physical

2) Primary Physical/Chemical (Filtration and neutralization)

3) Secondary Use of micro-organisms

4) Tertiary Sampling Analysis

The effluent treatment is a must for every industry as ordered by the Government of Pakistan.

Currently the treated water is not suitable for drinking, but it is suitable for watering plants etc.

ETP SPECS
Incoming water TDS 800-10000 ppm

Outgoing water TDS 2000-2200 ppm

TSS 200-5000

PH 8-Jul

Chemical Oxygen Demand 75-146

Biological Oxygen Demand 20-30

34