INTERNSHIP REPORT

Submitted by: Muhammad Yasir Ghuman

University: University of Engineering and Technology Lahore,
(KSK Campus)

DATE OF SUBMISSION: 08-09-2019

Sadiq Oil Extraction (Pvt). Ltd. Sahiwal
Sadiq Oil Extraction (Pvt). Ltd. Multan Road, Chak 138/9 AL, District Sahiwal, Punjab
INTERNSHIP REPORT

Preface
This report based upon the arrangement and data that I have learned from my
internship at Sadiq Oil Extraction (Pvt). Ltd. It consolidates all the data that has
been passed to me at this industry either by theoretical or practical strategies. The
plan to form this report is to share a meaningful material and thoughts regarding
the field of Oil Extraction and Ghee production.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 1

INTERNSHIP REPORT

Acknowledgement
The internship opportunity I had with Sadiq Oil Extraction Ltd. was a great
chance for learning and professional development. Therefore, I consider myself
as a very lucky individual as I was provided with an opportunity to be a part of it.
I am also grateful for having a chance to meet so many wonderful people and
professionals who led me though this internship period.
I would like to thank all the staff, engineers and management members of SB Oil
mills for making this internship happen. I am thankful to all engineers and staff
members who took out time for internees from their busy schedule and gave us
knowledge about the Plant and Mechanical maintenance.

Thank You!
Muhammad Yasir Ghuman
Internee Session 2019
University of Engineering and Technology Lahore, KSK Campus.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 2

INTERNSHIP REPORT

Table of Contents

Preface…………………………………………………………………………………………………………………………………………1
Acknowledgment………………………………………………………………………………………………………………………...2
Introduction to Company……………………………………………………………………………………………………………..4
Products……………………………………………………………………………………………………………………………….5
Main Suppliers……………………………………………………………………………………………………………………..5
Company Strategy………………………………………………………………………………………………………………..6
Sadiq Oil Extraction……………………………………………………………………………………………………………………...7
Suppliers………………………………………………………………………………………………………………………………7
Solvent Extraction………………………………………………………………………………………………………………………..9
Mechanical Unit…………………………………………………………………………………………………………………..9
Seed House…………………………………………………………………………………………………………….10
De-Hulling Section………………………………………………………………………………………………….11
Preparation Section………………………………………………………………………………………………..12
Oil Press Section……………………………………………………………………………………………………..13
Chemical Unit……………………………………………………………………………………………………………………..15
Extraction……………………………………………………………………………………………………………….15
Hexane Recovery…………………………………………………………………………………………………...16
Oil Recovery Section………………………………………………………………………………………………17
Stripping Section…………………………………………………………………………………………………….18
Crude Oil Refining Unit………………………………………………………………………………………………………………..19
Chemical Refining Unit……………………………………………………………………………………………………….20
Crude Oil Storage……………………………………………………………………………………………………21
Mixing…………………………………………………………………………………………………………………….21
Hydration……………………………………………………………………………………………………………….21
Separation………………………………………………………………………………………………………….....21
Neutralization…………………………………………………………………………………………………………21
Drying…………………………………………………………………………………………………………………….22
Safety Precautions………………………………………………………………………………………………………………23
Physical Refining Unit…………………………………………………………………………………………………………24
Heating…………………………………………………………………………………………………………………..25
De-dusting………………………………………………………………………………………………………………25
Hydration……………………………………………………………………………………………………………….25

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 3

INTERNSHIP REPORT

Bleaching…………………………………………………………………………………………………………..25
Filtration……………………………………………………………………………………………………………25
De-aeration……………………………………………………………………………………………………….25
De-odorization………………………………………………………………………………………………….26
Cooling……………………………………………………………………………………………………………..26
Laboratorial Tests………………………………………………………………………………………………………...27
Ghee Mill……………………………………………………………………………………………………………………………….29
Utilities…………………………………………………………………………………………………………………………………..32
Electricity………………………………………………………………………………………………………………………..34
Steam………………………………………………………………………………………………………………………………34
Water………………………………………………………………………………………………………………………………34
Conclusion……………………………………………………………………………………………………………….……………… 35
Suggestion………………………………………………………………………………………………………………………………..35
Feedback…………………………………………………………………………………………………………………………..……..35

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 4

INTERNSHIP REPORT

Introduction to Company

SB Feeds (Pvt). Ltd

Sadiq Feeds is an integral part of Sadiq Group, One of the pioneer and leading group of
companies in Pakistan with its Premier leadership in production of Chicks, Fresh Table Eggs,
Fresh Chicken Meat, Organic Fertilizers, Edible Oil, Poultry & Cattle Feeds and Livestock
Pharmaceuticals.

Sadiq Feeds (Pvt).Ltd. produces different types of poultry & cattle feeds for birds and livestock
of different types and age groups. The feed mills are equipped with highly sophisticated and
modern technology pallet lines of Buhler-Switzerland. The feed formulation is totally
computer-controlled using advanced feed management software programmed by highly skilled
nutritionists and supported by state of the art laboratories and R&D centers.

Sadiq Feeds (Pvt). Ltd was introduced on July 07, 2005 through change in name of Prime Feeds
(Pvt).Ltd. That was acquired by Sadiq Brothers Poultry in 1996. The Capital strength of
company is well known. Its already turnover is over Rs. 12.000 billion. The work force of the
company exceeds 800 personnel.

Sadiq Feeds (Pvt). Ltd. has two production units producing Poultry Feed & Cattle Feed. One
is situated at GT Road, near Mandra and Second poultry feed mill is situated at Lahore-Multan
Road. Sahiwal. Mandra Feed Mill has a production capacity of 70 M Ton per hour and Sahiwal
Feed Mill is currently producing poultry feed with one Plant of 70 M Ton per hour. Extension
is in process of construction/installation that makes the Mill capacity to 110 M Ton per hour in
near future. These feed mills are equipped with modern hi-tech pellet lines of Buhler-
Switzerland.

Sahiwal Feed Mill produces different types of poultry feed for birds of different age groups.
Feed formulation is computer-controlled using Brill feed management software (used by most
major companies), but it is programmed by a nutritionist.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 5

INTERNSHIP REPORT

This state-of-the-art pellet line is completely automatic and is computer controlled. The pellet
mill has two conditioners to ensure a longer residence time of the mash in the conditioners,
enabling complete destruction of pathogens present in the feed. Feed ingredients to various Lab
tests.

To ensure highest quality feed the company has established R&D facilities and employed
specialist staff headed by experienced and competent managers who hold Doctorate degree in
nutrition. The quality of feed that produced by these mill rank among the bests. The Company
has its Feed Sales offices in all the big cities of Pakistan and network of agents in all towns of
the country.

The head office of the Company is located in Rawalpindi, quite close to Islamabad the capital
of Pakistan.

Products:
▪ Complete range/grade of mesh and pellet feed for poultry
▪ Over 40 different formulations/mix are available according to the type of bird and its
age
▪ Medicated feed is also available on request
▪ Cattle feed (SB wanda) experiments have shown 15% milk production increase when
given SB wanda as compared to normal silage
▪ SB Gold Cooking Oil
▪ SB Banaspati Ghee

Main Suppliers:
Some of the major suppliers are:
▪ Major imports (Almost 20% of total purchases) form India, china, USA, Europe,
Malaysia etc
▪ Glutton from M/s Fauji Corn Comlex, Rafhan Maize Products
▪ Molasses from M/s Al-Mustaqeem Traders, M Sultan, Samundri
▪ Meal from Sadiq Oil Extraction Unit, Sahiwal Multan Road
▪ Grains from Punjab & NWFP several parties
▪ Premix material form Mehta Brothers, B.A Traders, Lahore

Key Success Factors:

1. The key success factors are purchase of ingredients at low prices and maintaining stock.
Because some seasonal growing crops, are available at low rates during season for
which we have sufficient storage capacity. Sadiq feeds had up to 250000 M tons grain
storage facility (silos) and more than 60000 sq.ft meal storage covered area.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 6

INTERNSHIP REPORT

2. Feed formulation is main factor, because it is a chemistry by which we can produce

feed at low cost with full nutrition required for each category of feed:
1) Use of modern equipment to enhance the quality of products.
2) Induction of most talented and experienced staff an edge on competitors.

Company Strategy:
The Company strategy is to fully utilize its production capacity so to minimize its
production cost and thus earn highest growth in the stock holder’s wealth.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 7

INTERNSHIP REPORT

Sadiq Oil Extraction (Pvt). Ltd, Sahiwal

Sadiq Oil Extraction is a private Company which uses modern and highly effective technology
for the Extraction of vegetable oil and converting it into the Cooking Oil and Banaspati Ghee.
In the district of Sahiwal, this Company holds a completely automated plant with the highly
skilled and experienced operators, engineers and workers which are the key factors of a good
and progressed Institute.
The Company performs several processes regarding the extraction of oil from different
vegetable seeds.

Vegetable Seed Suppliers:

The company Imports the vegetable seed from different countries like:
 China
 India
 USA
 Brazil
 Argentine

The main Extracts involve:

▪ Soya bean
▪ Canola
▪ Rape seed oil
▪ Sunflower
▪ Cotton
▪ Palm
▪ Olive
Many process contribute to the extraction and refining of oil. The major units are:
1) Solvent Extraction Unit
2) Crude Oil Refining Unit
3) Ghee Mill

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 8

INTERNSHIP REPORT

These processes contribute to the extraction and refining of the crude oil extracted from the oil
seeds. The company has a high capacity of Oil Extraction and refining to about 250 Tons.
The following sequence will give us a better understanding of how these process work to aid
the company for good quality oil production and economics.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 9

INTERNSHIP REPORT

1) Solvent Extraction Unit

This unit involves the extraction of oil form the vegetable seed which goes further for refining
purposes. The overall extraction plant capacity is 600 Tons/day. There are two main extraction
process in this unit which contribute in the extraction:
 Mechanical Method
 Chemical Method
These process contribute to the most important part of the whole plant. Mostly soya-bean oil
is extracted, but sometimes Canola oil is also extracted.

Mechanical Oil Extraction

Fig. 1. Mechanical Extraction Unit

The major units involved in the extraction of oil by mechanical method are:
1. Seed House
2. De-Hulling Section
3. Preparation Section
4. Oil Press

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 10

INTERNSHIP REPORT

Seed House
Seed house is the primary section of the solvent extraction unit which involves storage and
cleaning of seed. Parts of seed house are:
1. Silos
2. Seed storage Godown
3. Drum Cleaner
4. Magnet Rotary
5. Vibro
6. Storage Bins

1- Silos
Silos are the long elevated storage vessels
(shown in fig.1.1) approximately 85 feet high where
the imported seed is kept for the storage purpose from
where the seed is taken to the seed storage godown
for easy availability of seed according to the required
demand. The silos has a storage capacity of 5000
Tons each.
Fig. 1.1: Silos

2- Seed Storage Godown

It is a vast, properly ventilated storage house
(shown in fig.1.2) which has a storage capacity of up-
to 7500-8500 Tons. The house is properly ventilated
to avoid moisture, high temperature conditions and
humidity which makes the seed black making it
unsuitable for the oil extraction purpose. The
purpose of this unit is the easy availability of the
seed.
Fig. 1.2: Seed Godown

3- Drum Cleaner
From the seeds storage godown, the seed is
brought to the drum cleaner by means of a chain
conveyer (Model -400). Drum cleaner is the
mechanical equipment used for the cleaning of dust,
straws and other solid impurities from the seed. The
equipment has different sized mesh (soya bean mesh
= 5mm) which separate the seed from the solid
impurities. Dust is removed by high pressure blower
which removes the dust. Fig. 1.3: Drum Cleaner

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 11

INTERNSHIP REPORT

4- Magnet Rotary
Clean seed form the drum cleaner is taken to
the magnet rotary by means of a bucket elevator for
the removal of magnetic impurities like Iron
particles which separates the impurities from the
seed and forwards it for the further processing.

Fig. 1.4: Magnet Rotary

5- Vibro
Seed from the Magnet Rotary is brought to the vibro (shown in fig. 1.7) which
separates the broken seed from the good seed which is to be further processed.

6- Storage Bins
The clean seed from before is brought to the
clean storage bins No. 1,2,3 which has a storage
capacity of 25 Tons each (25×3= 75 Tons). The
purpose of these bins is the storage of clean seed
and for the swift availability of seed to the
crusher/cracker.

Fig. 1.5: Storage Bins

De-Hulling Section

1. Cracker/ Crusher
2. Vibro
3. Aspirator
4. Meat Storage Bins

1- Cracker / Crusher
Clean seed from Bin (1,2,3) moves to the
Cracker/ Crusher (Roller Crusher by means of
spiral conveyor and bucket elevator) having four
rollers(having 14 inch diameter) Which have
grooves (Groove depth = 4-5 mm) on their
surface. The purpose of the grooves is to only
crack the surface of the seed to separate the hull. Fig. 1.6: Cracker
The distance between the rollers can be adjusted by means of a hydraulics. The 1st two
rollers cracks the seed into two and the seed hull gets separated from the seed surface.
Then the 2nd two rollers breaks the seed into 4 pieces, which is also called as Meat.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 12

INTERNSHIP REPORT

2- Vibro
A mechanical vibrator which has meshed
surfaced meant to separate the hull and very
broken seed from the meat and move it to the
aspirator. The seed is brought to the vibro by
means of bucket elevator and then to screw
conveyor from the cracker.

Fig. 1.7: Vibro

3- Aspirator
A mechanical device which separates the
meat and hull on basis of their relative densities
with the help of high pressure air draft. Here the
hull separates form the meat and is sucked by the
highly pressure draft created by a blower at the
exhaust end which takes the hull to hull crusher
and further for packaging.

Fig. 1.8: Aspirator

4- Meat storage Bins
Clean and broken seed (meat) from the aspirator moves to the Meat storage bins
No. 4,5,6 (by means of spiral conveyor) which are shown in fig.1.5. They have the
storage capacity of 25 Tons each (25×3= 75 Tons)

Preparation Section

Preparation section is the preparing and cooking of Meat to make the seed cells loose its oil
pores and then for the extraction of oil by means of shear force. The main equipments involved
are:
1. Flaker
2. Cookers

1- Flaker
Meat from the meat storage bins is
brought to a seed leveling hoppers to maintain the
constant and equal flow of meat into the flaker.
The flaker is a Roller Crusher type machine
having a smooth and plane roller surface which
has a capacity of 200-250 Tons.
Roller Diameter = 3.5 ft
Rotation = rollers rotate at the opposite direction
No. of rollers = 2 Figure 1.9: Flaker
Drive pulley = diameter = 12 inch
Driven pulley = diameter = 40 inch
The purpose of the flaker is to shape the meat/ seed into flakes for better cooking.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 13

INTERNSHIP REPORT

2- Cooker
The flake shaped meat is brought to the cooker
for cooking. Cooker is a long elevated tank having 7
decks, which uses thermal heat to toast and cook the
seed properly to make the seed structure loose its oil
pores. The temperature is adjustable according to the
moisture level present in the seed/ meat. Usual
temperature range is 95-105 oC.
Steam is brought to the cooker from the seed house.
No. of decks = 7 Fig. 1.10: Cooker
th
Length of 7 deck = 27 inch
Length of 1-6 deck each = 25 inch
Diameter of cooker = 10.5 ft
Retention time = 50 minutes
Meat from the flaker moves to the top of the cooker and moves from the 7th deck to 1st
one respectively. An agitator is installed which mix up meat to maintain uniform
temperature distribution.

Oil Press Section

The oil press section is the area where the oil extraction begins by Mechanical method (shear
force). It involves different units:

1. Oil Press
2. Settler Tank
3. Crude Oil Storage
4. Oil Filter
5. Cake Cooler

1- Oil Press
Cooked meat from the cooker goes to feeder to
maintain feed of 4kg at a time. The meat goes to the
Oil Press which presses the meat into its moving shaft
with a very high pressure. It has 9 chamber having
strips installed for the separation of oil form the meat
and oil. The standard parameters are:
Size of strips = 1 ft
Strip space = 0.5- 2.5 mm
No. of strips in 1 chamber = 48 ×2 Fig. 1.11: Oil Press
Capacity = 200 tons /day
Soya bean seed imported from USA usually contains 20% oil of its weight, of which
4-5% is extracted in the oil press.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 14

INTERNSHIP REPORT

2- Settler Tank
Oil from the oil press goes to an underground vessel which is called as settler
tank where any kind impurities like the meat particles are precipitated out and the oil is
then moved to the crude oil storage tank

3- Crude Oil Storage

Crude oil from the settler tank goes to the storage tank which has storage
capacity of 25 tons where it has a temperature about 40-50 oC.

4- Oil Filter
Oil from storage tank is brought to a
vessel having capacity of 18-20 tons/hr, installed
with filters having leaf like structure also known
as Pressure leaf filters. Oil enters in the vessel
and passes through the filters with high pressure
where all the dust particles or other impurities are
removed and the clean oil is moved to clean oil
storage tank which has the capacity of 75 tons.
Fig. 1.12: Oil Filter
5- Cake Cooler
When the oil separates from the meat in
the oil press, the remaining content becomes like
a cake due to high compression, which usually
has a temperature about 90-95oC due to the
thermal heat addition in the cooker and
mechanical heat addition in the press.
This cake is processed further in the Chemical
Extractor.
Fig. 1.13: Meal Cooler

Why the cake is to be cooled?

During the processing in the Chemical Extractor, Hexane (a petroleum fraction,
Corrosive, Boiling point = 65 oC) is sprayed which is highly volatile.
If the cake enters at this much high temperature, it may vaporize the incoming hexane
in the extractor and creates an azeotrope with water which causes poor extraction and
in some cases ignition of hexane. So the cake is to be cooled before entering the
extractor.
For this the cake moves on a belt conveyor inside a closed compartment, where
the air draft is generated is generated by means of blower at the exhaust end. The
residual heat is sucked by draft with which some cake particles may be sucked out
which are settled in a cyclone settler between the blower and cooler and the hot air is
exhaust out. By which the temperature of cake is brought down to 45-55 oC, which is
then transported to the Chemical Extraction Unit.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 15

INTERNSHIP REPORT

Chemical Oil Extraction

Fig. 2: Chemical Extraction Unit

Chemical Extraction is the method of extracting the oil from the cake which comes from the
Mechanical Extraction Unit by means of using Hexane. Hexane is a Petrochemical extract
which holds a major contribution to the Gasoline and Naphtha. It is highly volatile
Hydrocarbon having chemical formula C6H14.
It is separated from the crude oil in Petrochemical Industries by means of Fractional
Distillation.
Precautions related to Hexane:
 Due to low boiling point about 65oC, hexane is a highly flammable and corrosive
compound which is to be treated very carefully
 It should be treated with cake in the extractor under vacuum to avoid any fire
 If left unchecked and unrecovered from the meal after extraction, it may cause
poisonous effects in the feed production
 Cake should be introduced at a temperature lower than the hexane boiling temperature
to avoid azeotrope formation in the extractor

Major sections involved in the Chemical Extraction are:

1. Extractor
2. Hexane Recovery Section
3. Oil Recovery Section

1- Extractor
The cake from the mechanical extraction unit is brought to the extractor where
it is sprayed by the hexane. The extractor has 7 sprays at top side and 7 hoppers at the
bottom line of extractor. The extractor has length of about 60 ft. The fresh hexane is
entered from the 1st spray and the cake moves on the meshed belt. The hexane entered
from the spray passes through the cake and pores of the belt and moves down to the
hopper 1 where it becomes a mixture of hexane + oil from where it is sprayed again
into the 2nd spray which again flows to the 2nd hopper.
This cycle continuous to the last 7th hopper where the mixture has maximum oil
concentration. The retention time in the extractor is 1hr 20 mins. In the extraction unit
the separation is done by means of relative difference of density. The whole extractor
works under the vacuum to avoid any fire hazards and hexane loss.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 16

INTERNSHIP REPORT

The speed of extractor is variable according to end result. If the end result
sample has less concentration of oil then the extractor rotation is reduced and vice versa.
The non-oiled cake/ Meal is collected in the hopper at the final end of the extractor is
transported to hexane recovery section
The oil + Hexane moves to the Miscella Tank where it is collected and the concentration
of miscella is kept about Hexane = 75% and Oil = 25%. About 15-16% of oil is
extracted from the cake but still there is small fraction which goes un-extracted in the
meal.

2- Hexane Recovery Section

Hexane during the extraction process is mixed with oil and the residual non-
oiled cake/ Meal which is to be recovered otherwise this causes the poisonous effects.
For that purpose, there are several recovery process which are used.

1) Hexane Recovery from Oil using Economizer and Heaters

2) Hexane Recovery from Meal using DTDC (De-solventizer, Toaster, Dryer and
Cooler)
3) Separator Tank
4) Condensation and cooling
5) Stripping Section

1) Hexane Recovery From Oil:

When the Miscella leaves the extractor, it is brought to the Miscella tank from
where it is pumped to the Economizer.
(Economizer: Economizer is a type of heat exchanger in which there is no utility is
applied. The exhaust streams (having heat contents) from any process which are usually
to be wasted are used for heating of incoming feed streams)

The Miscella is heated in the economizer

by the incoming hot vapors of hexane form
DTDC which are condensed and goes to the
bottom of economizer, where the hexane in
MIscella is vaporized and sucked to the
condenser for condensation by naturally
developed draft.
Fig. 2.1: Economizer and heater
The remaining mixture is pumped again to a heater in which steam tubes are
installed for heating purpose. There the residual hexane is removed through
vaporization due to high temperature (about 80o C) which is again brought to the
condenser through a suction line. The hexane free oil is collected in the final oil column.

2) Hexane Recovery from DTDC:

DTDC is the equipment where the meal from the extractor us brought for hexane
recovery. Meal has 25-35% hexane contents which are to be recovered for the further
processing of meal. This a long elevated vessel where a high temperature steam is
provided for the heating purpose for the removal of volatile components form the meal.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 17

INTERNSHIP REPORT

It has 7 compartments/ ducts in which

heat exchange occurs. Following are some
details about the DTDC:

Fig. 2.2: DTDC

No. Of Ducts Temperature Purpose

1 75-80 o C Heating up
2 90-96 o C Heating / Indirect jacket
steam.
3 100 o C Heating
4 100 o C To flow steam through
meal pores to evaporate
residual hexane.
5 103-105 o C Remaining hexane
evaporation.
6 108-110 o C With the help of hot air,
residual moisture and
steam traces removal.
7 45-50 o C Meal cooling for
storage purpose.

The hexane recovery is targeted up-to 96-97% where some of hexane is lost during the
process. The hot vapors of hexane are moved to the economizer (usually at 110 o C).
The cool and cleaned meal is transported to the packaging house for further use.
3) Separator:
Separator or also named as hexane settler tank, is a closed vessel in which the
recovered hexane from the economizer and heater is brought after condensation. There
are some traces of water in the recovered hexane with some other impurities. Water
being denser than hexane is settled down and the hexane floats. So the water is removed
at the bottom by a dump line and the final hexane is provided to the extractor again.

4) Condensation and Cooling:

A type of heat exchanger used to draw heat from the vaporized/hot streams and
cool them down (shown in Fig. 2.3). In the extraction, Shell & Tube type heat exchanger
is used for the condensation of hexane. The water flows in the tubes while the hexane
vapors are in the shell side. The cold water for condensation is provided through the
Cooling Towers. The cooling tower installed in this unit is Induced Draft Cooling
Tower.

(Induced Draft: The type of cooling tower in which the fan is installed at the top of the
tower which causes a suction/ Induction pressure to remove the heat from water (shown
in Fig.2,4). Water flow from the top and the fan causes the suction of air from the

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 18

INTERNSHIP REPORT

bottom. Water flows through the packings installed in the cooling to increase the
retention time also known as liquid hold-up of water for more cooling.)

If the atmospheric temperature high and the water temperature cannot be

achieved for condensation, there is also a Water Chiller (which usually cools the water
to about 12-15 o C) installed between condenser and cooling tower. It cools down the
water to even lower temperature.

Fig. 2.3: Condenser Fig.2.4: Induced Draft Cooling Tower

5) Stripping Section:
The purpose of stripping section is to eliminate the dissolved gases from the oil
to make it impurity free.
(Stripper: A stripper is an equipment which separates the dissolved gases from the
liquid. Absorption is done at low temperature and high pressure so the stripper performs
the reverse process by providing the low pressure and high temperature so the dissolved
gases gets separated.)

Some gases like CO and N2 gets dissolved during the processing at low temperature so
the stripper separates the dissolved gases by reverse phenomena at high temperature
and low pressure, which are collected to a separate vessel.

After all the processing, the final product from the extraction unit which crude oil is
collected and transported to the Refining Unit for refining and cleaning it form the impurities
which are in separable in the extraction unit. The color of crude oil is brown black which is not
useable for cooking purpose so the cleaning and refining is important.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 19

INTERNSHIP REPORT

2) Crude Oil Refining Unit

Fig.3: Refining Unit

Refining is the process of removing un-wanted components in an oil fraction to make
useable and cooking purpose. Certain reactions and heat treatments are involved during this
process. These treatments are essential to remove the impurities from the oil to make cooking
oil and suitable for ghee production. So there are certain parameters which are to be taken care
of for further processing:
 Red of Oil
 Free Fatty Acid (FFA)
 Moisture
 Blue od Oil
 Yellow of Oil
 Bleachability
(Bleachability: Bleachability is the property of oil to how much extent the oil is
soft to bleach. The term generally refers to the de-colorization and de-
odourization etc.)

Depending on these parameters, the quality of oil is considered. Red, yellow and blue of oil are
the color pigments naturally existing in the vegetable oil. These pigments create an appearance
which always effects the customers. Following are the naturally existing parameters and market
demands:

Components Natural Quantity Market Requirement

Red of Oil 6-7 0.8-0.9
FFA (Free Fatty Acid) 1-1.5% Less than 0.20
Moisture 0.40% Less than 0.15
Blue 60-70 Nill
Yellow 5-6 1.5-1.8
Bleachability 60-65 55-60
POV 15-20 meq/kg Less than 5meq/kg

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 20

 INTERNSHIP REPORT

These parameters are to be taken care of because they cause the poor quality oil which is
unsuitable for the market demand. Moisture causes the dullness in oil and FFA is unhealthy
which are removed by means of chemical and physical treatments. The chemical treatment
gives the gateway to the removal of the fats which may cause choking and accumulation on
direct heat contact. Depending upon the utilities applied this process is economical and there
are less chances of the machinery choking and fouling.

The main refining section involves two major units:

1. Chemical Refining Unit
2. Physical Refining Unit
The processed oil from these two units is considered good for cooking and for the Ghee
production.

1. Chemical Refining Unit

Chemical refining is the process of elimination of undesired fraction and impurities from
the oil with the help of a chemical reactions. Here the undesired impurities like FFA, gums,
phosphatides etc. are removed with the help of an acid base reaction and saponification
reactions which separate out these impurities in the form of raw soap and salts etc.
The main components involved in the chemical unit are:

i. Crude oil storage

ii. Mixing (Knife Mixers shown in Fig.3.1)
iii. Hydration
iv. Separation (Disk Separators shown in Fig 3.2)
v. Neutralization
vi. Vacuum drying (Vacuum Dryer shown in Fig.3.3)
vii. Phosphoric Acid
viii. Caustic Soda

After the chemical processing, there are many useful fractions which are collected along
with refining of oil. The main by-product of this unit soap which is in raw form and can be
purified for the domestic and regular uses. Saponification reaction usually are endothermic
reaction which are to be dealt with absolute heat treatments. Any increase in temperature can
cause the re-dissolution of fats rather than the precipitation in the form of soaps.

Following process flow diagram will elaborate the general processing of chemical refining
section:

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 21

 INTERNSHIP REPORT

i. Crude Oil storage

Oil from the extraction plant is brought to the crude oil storage tank from where
it is pumped to the plate heat exchanger/Economizer (Oi-to-oil) where it is heated to
about 104-113 o F (40-45 o C) and then moves to the second heat exchanger (steam-to-
oil) where it is heated up to 140-149 o F (60-65 o C) which is then pumped to the Mixer
1.
ii. Acidification of Oil
Heated oil form the heat exchanger is pumped to the Mixer 1 (Fig: 3.1) where
the phosphoric acid is added (0.5-1 kg/Ton) from a separate vessel and mixed by means
of an agitator. Here the temperature remains about 131-140 o F (55-60 o C) and the FFA
starts to react with the phosphoric Acid (H3PO4). The reaction causes the formation of
Lecithin formation (a food product) which is separated by means of Separator 1(Disk
Separator) and the remaining Oil+ Phosphoric acid mixture goes to the hydration retort

iii. Hydration of Oil (Endothermic)

Mixture from the mixer 1 is collected in the hydration retort where the de-
ionization of phosphoric acid begins and the fats begin to react with the phosphoric
ions. Also known as hydration of oil.

iv. Caustic Soda Addition

The mixture from the hydration retort goes to the mixer 2 where the Caustic
Soda (NaOH, 8 kg/Ton) is added from a separate vessel and mixed properly with an
agitator. The saponification reaction starts here. The purpose is the removal of all
dissolved fats in the form of precipitates.

v. Neutralization of Oil (Endothermic)

Reaction mixture from Mixer 2 is pumped to the neutralization tank for
neutralization of the unreacted phosphoric acid and soap formation by means of reacting
with caustic soda. The mixture is then moved to a plate heat exchanger where it is heated
to about 158-167 o F (70-75 o C).

vi. Separation of soaps

The heated mixture form the plate heat exchanger moves to the Separator 2
(Disk separator) which contains the conical disks to about 110 in number usually set on
a vertical shaft over and over. The shaft rotates with the help of a motor which rotates
the disks and the mixture is shaken up hardly which separates out the soap and gums
from the oil and oil is pushed through the largely perforated disks and to Mixer 3 by
pipelines.

vii. Washing of Oil

The soap free oil from the separator 2 is pumped to the mixer 3 for the addition
of hot water having about 194-203 o F (90-95 o C) and temperature of oil gets about 194
o
F(90 o C). The purpose of the addition of hot water is that the soap contents and other
fats are precipitated out due to the heat contact. This mixture moves to the separator 3.

viii. Separation of Water

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 22

INTERNSHIP REPORT

The purpose of this separator is to washout all the soap remains and fats from
the oil along with the hot water. The oil gets separated and the soap and fats are moved
to a separate vessel. The clean oil moves to the heat exchanger for heating purpose
which heats the oil to 212-230 o F (100-110 o C).

ix. Vacuum Drying

The heated stream from the heat exchanger moves to a vertical vessel having
vacuum developed inside by means of a vacuum pump. As the oil enters the vacuum
dryer, due to the boiling point of water being as 100 o C, the traces of water left in the
oil begins to vaporize which are sucked by means of a suction line. The water free oil
moves to the oil header (shown in Fig:3.4) which indicates the purity level of oil from
the chemical refining section. If the oil is not of the required standard, it moves back to
the crude oil storage tank through a bypass line for re-processing. The final product
form this unit is considered semi-refine. This heated oil goes to the economizer
mentioned earlier (oi-to-oil) for heat exchange and cooling purpose.

x. Oil Recovery
The washing water from the separator 3 may contain enough concentration of
oil mixed in which is to be recovered. For this purpose the used water goes to the
washing tank where this water is allowed to settle for a time. Oil being lower dense
floats on the surface which is recovered to a recovery tank and the water is drained from
the bottom.

Fig.3.1: Knife Mixer Fig.3.2: Disk Separator

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 23

INTERNSHIP REPORT

Fig. 3.3: Vacuum Dryer Fig.3.4: Semi-refine Header

The Semi-Refine oil is the final product of the chemical section which is of light
brownish color having certain colored and fatty impurities which are non-suitable for using
purpose. This semi-refine is to be refined again to a maximum content to use it for cooking
purpose. There are still some impurities e.g: chloroform, phosphates and FFA etc. which cause
a burning smell and a corrosive effect to the Thyroid when used for cooking. If the FFA is not
removed properly, it produces HDL (High Density Lipoids) which include lecithin, wax etc.
which then solidify at room temperature and cause poor quality oil. Furthermore, these HDL
causes an enough increase in cholesterol level in human body which is the cause of
Ethrosacrosis (Heart attack) a chronic disease. For the removal of all these undesired impurities
the oil is further moved to the physical refining unit.
Utilities:
 Steam = 1.5-2 T/hr
 Water = 10-12%/Ton
 Electricity = 15 units/Ton

Safety Precautions Related to Chemical Unit:

 Caustic soda stored in the storage tank is of 50% concentration which is then diluted to
18-20%. But this much concentration can cause the corrosive effects on the skin and
any physical contact. So be careful while handling with NaOH.
 Phosphoric Acid is a pure acid which cause the oxidation at the direct contact with the
air and may cause fumes which when inhaled cause breathing problems and choking
etc.
 Hot water which is used at 110 o C is to be handled with very care to avoid and nay
burning effects.
 Avoid any physical contact to the machines because all the process are operated at the
endothermic conditions (heat is applied) so the burning chances are present if there is
any damage in the insulation.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 24

 INTERNSHIP REPORT

2. Physical Refining Unit

Physical Refining is the process of removal of impurities from the oil by means of physical
treatment like temperature, Aeration, De-colorization and filtration. The process is same as the
refining in the petrochemicals but a slightly easier and simpler. The semi-refine oil from the
chemical unit is brought to the storage tanks for further processing in physical unit.
Chloroform, ethers, esters, phosphatides, FFA and other dissolved impurities which are not
removed by the chemical process are removed by the physical process. Depending upon their
boiling point they begin to separate in the physical treatment.
Following are the key process description involved:

i. Heating of semi-refine
ii. Removal of dust particles
iii. Hydration of Oil
iv. Bleaching
v. Filtration
vi. De-aeration
vii. De-odorization
viii. Cooling

Utilities Involved:
 Steam from the boiler house
 Water from cooling tower
 Electricity

Boiler House:
The furnace is installed for the heating of water to generate steam for the plant. The fuel
burned in the furnace is coal which is imported from the India and Afghanistan. Pakistan has
the very high reserves of coal but this coal is high in moisture, volatile matter and free ashes
which gives off low heat energy and very high environmental pollution.
The boiler is Fire Tube Boiler (See Process Heat Transfer by D.Q Kern chapter #15).
Considered as the efficient one for the steam generation the continuous process. The standard
capacity of this boiler is 20 ton/hr.

. The following process flow diagram will give the better understanding of physical refining:

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 25

INTERNSHIP REPORT

i. Heating of Semi-refine
The semi-refined oil from the chemical section is stored in a tank which has a steam
coil installed at the bottom to continuously heat it up to 60-70 o C for the lowering the
utilities applied during the process.

ii. Removal of Dust Particles

The heated oil is passed through a strainer to remove dust particles mixed up during the
transport. These particles are to be removed to avoid the choking and scaling in the heat
exchanger. The phenomena used is the gravity separation by shear force. The oil is
heated to 110o C by means of an economizer (oil-to-oil) where the hot oil from the de-
odorizing column accommodates its heat.

iii. Hydration of Oil

Hydration is the process of generation of hydrated compound (water) ions in the
solution. Most often this process is done in the presence of an acid which temporarily
goes to an ionized state giving off hydrogen and hydroxal ions. Water is generated from
the fatty acid present in the oil.
The same process happens in the physical refining systems where the phosphoric acid
is added to precipitate out the dissolved FFA in the cloudy appearance. The oil and
phosphoric acid are mixed in a mixing pump form where they are settled and allowed
to stay in the Retention Tank for reaction to be completed. The fats and water a settled
down which can be separated by dump valve and the level of the retention tank is set
up to 70% above that the overflow is started towards the bleaching section.

iv. Bleaching of Oil

The hydrated water is brought to the bleaching section (shown in Fig.3.5) for the
removal of colors. The key catalyst used in this process is Bleaching Earth (H2Al2
(So3)4.nH2O). Bleaching earth is an active white powder (also known as Bentonite acid-
leached) which readily absorbs the color pigments present in the semi-refine oil.

v. Filtration
Filtration is the process of removal of any larger impurities form the oil and for the
separation of the bleaching earth after the color absorption after the bleaching section.
The filters used for this purpose are leaf filters installed in a vertical tank having a the
dump valve (Butterfly valve) for the removal of settled and separated B.E from the oil
and the clean oil moves to the Buffer tank form where it is again filtered to remove
cloudy appeared fats in the Polishing bag filters and Cartridge filters (shown in Fig.3.6).
The spent earth goes to the spent earth room for to be disposed.

vi. De-Aeration
The clean oil form the bleaching section is to be de-aerated to remove any kind of air
traces which can be harmful for oil because they create the POV (per-oxide value) of
oil. The de-aerating section involves the removal of smell creating substances from the
oil by heating it at a temperature of 90-95 o C. the heated oil is to be de-odorized in the
De-odorizing column.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 26

 INTERNSHIP REPORT

vii. De-odorization
The de-odorization is the process of removal of smell creating components like fats,
phosphatides etc. which should be removed to avoid harmful impacts on oil. The length
of the de-odorizing column is 90 feet having 6 separate ducts. The oil is pre-heated to
the 110 o C (230 o F) and is entered from the top of the column in the first duct. Where
the oil is heated again to 250o C (482 o F) by means of HP (high pressure) boiler. The
oil moves to the 2nd duct where the fats are collected by the creation of suction through
the steam (Negative Pressure) when is expanded. The cold fats are sprayed from the top
to cool down the vapor fats and they are separated in the separate vessel with the help
of draft created by the steam. Here the temperature drops by 2o C. The fresh steam flow
form the bottom with high pressure which is utilized to separate out the dissolved fats
which are still in the oil by the opposite side contact. The oil moves to the 3 rd one and
temperature drops by some degrees in every duct. The oil at 240o C (464o F) enters the
5th duct where the economizer (shown in Fig.3,7) is installed where the hot oil preheats
the incoming oil. The temperature of oil drops to 140o C (284o F) in the 6th duct where
it is brought to the oil-to-oil heat exchanger (Economizer) discussed earlier.

viii. Cooling
The de-heated oil from the economizer is to be cooled further for storage purpose. This
oil passes through a cooler (plate type) where the cold water is flowing from the cooling
tower which cools the oil to 40-45o C. The cooled oil is stored in the storage tank.

All this processing gives the refined, de-odorized and final cooking oil which is then packed
and sold in the market for the buyers. Following are the pictures related to some equipment’s:

Fig.3.5: Bleacher Fig.3.6: Economizer Fig.3.7: Filters

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 27

 INTERNSHIP REPORT

To check the parameters of oil if they are of required market demand, several tests are
performed in the Laboratory. These tests include:

 FFA Test
 Color Test
 Soap Test
 POV Test

All these tests have a detailed knowledge related to their chemistry and skill level. The general
overview of these tests is:

The Chemicals Involved in tests

FFA Test Color Test Soap Test POV Test

Ethanol = 25ml Tintometer Pure Acetone = 25ml Sat. solution of Potassium

NaOH = 0.1 Normality Bromophenol Blue = 5 idodie = 0.5ml
Oil sample = 5 g drops Oil = less than 5g
Phenolphthalein = 2-3 HCl = 0.01N Starch = Indicator
drops Oil = 20g POV solution (Acetic Acid+
Chloroform) = 3:2=
End Point: More the FFA End Point: Golden 30ml/sample
the darker the solution Yellow layer Sodium Thiosulphate = 0.01 N

End Point: Disappearance of

dark color slowly.

FFA:
FFA (Free Fatty Acids are the organic compounds lipids which are harmful for human
body. They can react and form coagulates wherever they are settled giving birth to the high
cholesterol level in human body. They are to be removed to avoid harmful effects. They are
usually determined by the concentration of Oleic Acid.

POV:
POV (Per oxide value) is the term of rancidity in the oils. They can be of three forms
Hydrative, Oxidative (by oxygen) and enzymatic. Due to this the oil quality gets deteriorated
and unsuitable for market requirement. For this reason it needs be removed or prevented for
long term storage. Citric acid forms an inert layer which is non-reactive to oxidation. For this
purpose, citric acid is added in the refined oil form the physical section to prevent it and
preserve it for long time. Moreover, all the water activity is removed because of approximately
zero moisture.

Water Activity:
Water activity is term in the presence of water in an oil causes the growth of biological
organisms like algae and fungi etc. These micro-organisms cause the damage to the oil making
it uneatable and unhealthy for body. For this purpose the moisture content is removed.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 28

INTERNSHIP REPORT

3) SB Gold Ghee Mill

Fig.4: Ghee Mill

Cooking Oil from the refining section is either packed, dispatched to market or it is
converted into ghee. On another side, ghee mill also has its own refining unit for other oil
fraction which include Palm oil and Rape seed which follows the same process as the physical
refining unit. The semi-refined oil is imported and refined to the stage of cooking oil.
As we are discussing the overall oil refining and ghee manufacturing so we will take a look at
the process involved in the manufacturing of Banaspati ghee.
There only a few key process involved during the ghee formation. Depending upon quality
maintenance and market demand, ghee is to be refined through following process:

 Pre-Neutralization of Oil
 Pre-Bleaching
 Filtration
 Hydrogenation
 Post-Neutralization
 Post-Bleaching
 De-Odorization
 Cooling
 Addition of Vitamin A&D
 Packing
 Storing and Dispatch

Process Description
 Pre-Neutralization
Neutralization is the process of removal of all basic and acidic components form the
oil. These acidic compounds can either be the FFA or other contamination compounds.
For this purpose the oil is pre-neutralized. Caustic Soda (NaOH) and Sodium Chloride
(NaCl) is added in the pre-neutralization tank in the presence of heat. The optimum
temperature range is 40-50o C. The retention time is about 1-1.5 hrs. The fats are reacted
to form soap which precipitate out due to lower density and separated out in a separate
vessel. The neutralized oil goes for the further processing.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 29

INTERNSHIP REPORT

 Pre-Bleaching
The pre-neutralized oil is then brought to the bleaching chamber to remove any
unwanted color pigments by means of Fuller earth/Bleaching earth. Bleaching earth
absorbs the unwanted color pigments when introduced and agitated in the oil at 120 o
C. The vacuum is about 15-20mmHg. The oil is allowed in the bleaching tank for 1-
1.5hrs.

 Filtration
The bleached oil is then passed through the press filter which separates the B.E from
the oil and clean oil is then allowed to enter the hydrogenation section. The pore size
of the filter is 5 micron.

 Hydrogenation
Hydrogenation is the process of addition of hydrogen to the unsaturated compounds to
make them saturated. Oils are the saturated compounds which have double bonding
inside them. The hydrogen is introduced in gaseous form from the Electrolytic Process
(Use of electricity with an anode and cathode to form the H+ and OH- ions from the
water due to ionization process). The temperature range 150-190 o C. Reaction time is
about 5-7hrs. Active Nickel is used as a catalyst for this process. The unsaturated bonds
of oil are saturated by the addition of hydrogen which converts the oil into ghee
(containing solid like grains). The reaction equation for hydrogenation is:

Oil + H2(gas) → Ghee (solid)

While hydrogenation, the melting temperature of ghee is kept in mind. If the
hydrogenation is greater, the greater will be the grain density and the melting point
increases. So the melting temperature is to be kept at 37 o C or below.

 Post-Neutralization
In post-neutralization, neutralization reaction is performed to remove the unwanted
compounds if some left during ghee processing. The process involves the addition of
NaOH and the temperature range is 90-95 o C. The retention time is 1-2 hrs.

 Post-Bleaching
For the further removal of the colored impurities the bleaching is performed for the
ghee. The fuller earth is added at the temperature of 120 o C and pressure of 15-
20mmHg. The retention time is about 1-2hrs. The colored impurities are absorbed in
the leaching earth. After the bleaching the melted ghee is passed through the press filter
which separates out the earth and the ghee is passed. The used earth is then sent to the
spent earth room where it is disposed.

 De-odorization
The ghee is meant to be fat free which cause the increased cholesterol level.
Furthermore the free fats are harmful for the storage purpose. So the ghee is then de-
odorized in the de-odorizer. Where the ghee flows from the top and the steam is flowing
from the bottom. The free fatty acids are vaporized when the temperature goes to 180-
200 o C at 30mmHg. These vaporized fats are separated by means of a steam ejector
which creates a suction due to the creation of vacuum by sudden expansion of steam.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 30

INTERNSHIP REPORT

The fats are collected in a separated vessel. The retention time for ghee in de-odorizing
column is 4-6hrs. After the ghee leaves the de-odorizing column, the ghee is stored in
a separate vessel where the citric acid is added to preserve it and increase its shelf life.

 Cooling
The ghee leaving the de-odorizing column has a high temperature which is unsuitable
for storage purpose, so it needs to be cooled. Therefore a shell and tube exchanger is
installed where ghee flows through the shell and water flows in the tubes. The ghee is
cooled down to 40-45 o C from where it goes for again filtration to remove any solid
impurities.

 Vitamin Addition
Ghee needs nutritional additions which are good for body. So they are pre-mixed in the
ghee before selling in the market. Vitamin A&D are added to a specific content for
healthy ghee production. To maintain the ghee quality and health requirement, Food
technologist always take care of the processing throughout.

 Packing
The processed ghee is then packed into the required size packings which the buyers and
customers demand. The packing unit is installed in the ghee mill which performs a clean
and good packing procedure.

 Storing and Dispatch

After packing the ghee is stored in the cold storage room where Ammonia gas (NH3) is
used as a coolant. The temperature in cold storage is about 1 o C. The purpose of this
cooling is the formation of solid grains in the ghee which determine the ghee quality.
After the cold storage section the ghee is dispatched to market for customers on the
required demand Process flow diagram will elaborate the processing.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 31

INTERNSHIP REPORT

Utilities involved in the Process

The plant owns heavy duty machine which consume enough electricity and other requirements.
For this purpose, company owns some utility facilities. The utilities include:
 Electricity
 Steam
 Cold water

 Electricity
The plant has a variety of equipment which operate on only electricity needing a high
quantity of electricity. The average consumption of electricity per ton of oil
manufacturing is 0.63 kW. The overall production per day gives 766kW /250tons of
oil. The source of this electricity is WAPDA where the company has no personal
electricity generation unit yet. For emergency conditions, the electricity auto-generators
of 1 MW are at standby in case of load shedding keeping in view the current electricity
crisis of Pakistan. The company has plans to generate their own electricity in future.

 Steam Requirement
Steam is the basic utility used in the process for heating purpose. The whole plant
requires approximately 55 tons/hr steam. For this purpose boilers are used to generate
steam of required demand.

 Boiler House
A boiler is a thermal equipment which
converts water into steam by means of heat.
There are certain parts which a boiler is
consisting of:

Fig.4.1: Boiler House

o Furnace
Furnace is a mechanical and thermal device which utilizes the fuels, burn them
and use their thermal energy for heating purpose. The design of furnace is another
complex chemistry which needs skill and
knowledge both. (See chapter #19, Process Heat
Transfer by D.Q Kern). The fuel used is coal which
is a good source of thermal energy. The crushed and
fine coal is conveyed to the moving belt inside the
furnace where the hot air is entered from the bottom
to start ignition. The air is heated in the pre-heating
section and heating section to attain about 110 o C
temperature for burning purpose.
The water from the boiler flows in the tubes installed on the walls and roof of
the furnace where the water is converted into steam and the minimum temperature
maintained in the furnace is 300-1000 o C to maintain the steam pressure.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 32

INTERNSHIP REPORT

o Boiler Feed Tank

Boiler feed tank is vessel installed on the top of the furnace where the water
flowing water in the furnace tube is coming from. The furnace the water into steam and
the water in the vessel is heated up and converted into steam from where it is transported
by its own natural pressure to the required place.

o RO System
RO (Reverse Osmosis) system is installed to clean the water pumped form the
ground by means of turbine. This water has a TDS (Total dissolved solids) level upto
450 which causes the clogging and scaling in the boiler feed tank decreasing its
efficiency. For this purpose it needs to be cleaned. A sand filter is installed which
removes any biological impurities like algae etc. A micro filter which separates out the
dust particles which has the size up to 5 micron.
An RO membrane comes after which separates out the minerals dissolved which
cannot be separated out by micro filters. This pore size of the membrane is up to 1
micron. The boiler feed water contains the TDS level up to 5.
\
o Air Intake Section
For the air intake, an induced draft fan is installed which sucks the air form the
atmosphere and provides it for heating. An Economizer is installed in between which
act as air-preheater. It contains the hot exhaust gases which are sucked out by means of
ID fan. These gases have approximately temperature up to 200o C. this heat is utilized
for the air preheating. This preheated air then passes through a heater which heats it up
to the desired temperature to bring the ignition in the furnace. The exhaust gases contain
several impurities due to coal burning like ash, oxides of Sulphur and unburned carbon
which are to be removed because they are harmful for the environment.

o Exhaust gas cleaning

To clean the exhaust gases, the air passes through a
cyclone settler which settles down the ash particles
present and let the rest of the gases pass. To remove the
most fine dust particle and oxides etc. there is a wet
scrubber installed which dissolve these harmful gases
in the showering water from the top of the scrubber.
The clean air passes to the open atmosphere through
chimney and the water is then dumped to the dumping
area.

Fig.4.2: Wet Scrubber

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 33

INTERNSHIP REPORT

 Cold Water
For the availability of cold water for cooling and condensation purpose the
cooling towers are installed.

The cooling tower is used for the availability of cold water to use in the cooling
section. Induced draft cooling towers (See page #
16) are installed because they give better results
with less humidification in the tower. The
standard capacity of these cooling towers is
30,000 lit/day.
Moreover, where there is an intense cooling
requirement in the hot days of summer the
temperature for cooling is not achieved by cooling
towers only. For this purpose the chillers are also
installed to achieve the required temperature. Fig.4.3: Cooling Tower

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 34

INTERNSHIP REPORT

Conclusion
The FOUR weeks internship at plant operations unit Sadiq Oil Extraction (Pvt). Ltd. developed an
understanding of oil Extraction, Refining and Ghee production. The limitation of knowledge and
experience was not only to process flow, but it was opened for operating logics, process control,
economics, production, problem handling and safety. Literature review from area general course, study
of PFD manuals and SOP of different plant areas and equipment, discussions with engineers and
technical staff and visit to plant site added a sound and potion knowledge.

Suggestion
I would like to suggest that this internship program be upgraded to an internship leading to job program
as to raise the incentive for those who are blessed with opportunity.

Feedback
The internship program here in Sadiq Oil Extraction is tremendous; it enabled us to apply our theoretical
knowledge into practicality in the care of experienced engineers. Sitting with shift engineers gave us
the idea of how an engineer deals with daily problems and shift work. The overall experience was
remarkable with much to learn. If given the opportunity I would like to be a part of Sadiq Oil Extraction
(Pvt). Ltd.

SADIQ OIL EXTRACTION (Pvt). Ltd. SAHIWAL 35