Food plant engineering systems

Theunis Christoffel Robberts, Theunis C. Robberts1566769698, 9781566769693

Pumps. Boilers. Power transmission. Water treatment. Waste disposal. Efficient lighting. Maintain them, and you’ll experience optimal performance. Ignore them, and the system will collapse. While many texts adequately describe the processing lines used in food manufacturing, none address the importance of the ancillary equipment that allows the plant to operate. Food Plant Engineering Systems fills this gap by focusing on these crucial but frequently forgotten parts of the system.With clear, easy-to-understand language, this book details the bits and pieces that keep systems running and explains how they fit within the bigger picture:·Properties of fluids·Pumps and piping·Electrical systems including motors, starters, electrical heating and lights·Steam generation and heating systems·Cooling and refrigeration systems·Water and waste and material handling systems·Food plant design, including site, foundations, floors, walls roofs, drains, and insulation·Safety and EPA regulations Getting all the units to work together as a well-orchestrated system is what manufacturing design and management are all about. This book provides the first truly comprehensive look at food plant operation. Food Plant Engineering Systems ensures that all elements of the system are properly balanced to efficiently accomplish the job.

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Table of contents :
Food Plant Engineering Systems
……Page 1
Dedication……Page 3
Preface……Page 4
The Author……Page 7
Contents……Page 8
Contents
……Page 0
1.2 HISTORY……Page 17
1.3.1 BASE UNITS……Page 18
1.3.1.1 Definitions……Page 19
1.3.1.2 Supplementary Units……Page 20
1.3.2.1 Definitions……Page 21
1.4 DIMENSIONAL ANALYSIS……Page 22
1.5 UNITS FOR MECHANICAL SYSTEMS……Page 24
1.6 CONVERSIONS AND DIMENSIONAL ANALYSIS……Page 27
1.7 PROBLEMS……Page 28
2.2.1.1 Mass Balances……Page 29
2.3 PROBLEMS……Page 41
3.2.1 PRESSURE……Page 42
3.2.3 SPECIFIC MASS (W)……Page 43
3.2.7 VISCOSITY……Page 44
3.2.8 TEMPERATURE EFFECTS ON FLUID FLOW……Page 46
3.2.9.2 Pseudoplastics……Page 47
3.3 SURFACE TENSION AND CAPILLARY ACTION……Page 48
3.3.2 ATMOSPHERIC PRESSURE……Page 49
3.4.1 PRESSURE INTENSITY……Page 50
3.5.1 INTRODUCTION……Page 52
3.5.2 CONSERVATION OF MASS……Page 53
3.6.1 TURBULENT AND LAMINAR FLOW……Page 54
3.6.1.1 Reynolds Number……Page 55
3.6.3 STEADY AND UNSTEADY FLOW……Page 57
3.7.2 PRESSURE HEAD……Page 58
3.7.4 ENERGY CHANGES AND FLOW……Page 59
3.7.5.1 Frictional Losses in Straight Pipes……Page 61
3.7.6 MECHANICAL ENERGY REQUIREMENT……Page 63
3.8 PROBLEMS……Page 65
4.2 GENERAL PRINCIPLES……Page 66
4.3 PUMP EFFICIENCY……Page 67
4.4 CENTRIFUGAL PUMPS……Page 68
4.4.1 OPERATION……Page 69
4.5 SUCTION SYSTEMS AND SUMP DESIGN……Page 71
4.6 POSITIVE DISPLACEMENT PUMPS……Page 74
4.6.1.1.1 External Gear Pumps……Page 76
4.6.1.1.2 Internal Gear Pumps……Page 77
4.6.1.1.4 Peristaltic Pump……Page 78
4.6.1.1.5 Progressive Cavity Pump……Page 80
4.7.1 PIPING MATERIALS……Page 81
4.7.3 WELDING OF SANITARY PIPE……Page 82
4.8 PIPELINE CONSTRUCTION……Page 85
4.9 PROBLEMS……Page 86
5.3 CHARACTERISTICS OF A SYSTEM……Page 87
5.3.1 ENERGY OF A SYSTEM……Page 88
5.4 GASES AND VAPORS……Page 89
5.4.1 IDEAL GAS EQUATION……Page 90
5.4.2 PRESSURE EXPRESSIONS……Page 91
5.4.2.1 The Perfect Gas Law……Page 92
5.4.3 MIXTURES OF GASES……Page 94
5.5 PROBLEMS……Page 97
6.2 ELECTRICITY GENERATION……Page 99
6.3 DEFINITIONS……Page 100
6.4 ENERGY CONVERSION……Page 101
6.5.1.2 Single-Phase Split-Phase Motor……Page 102
6.5.2 THREE-PHASE SQUIRREL-CAGE INDUCTION MOTORS……Page 103
6.6 MOTOR MANAGEMENT……Page 104
6.7.1 FLAT BELTS……Page 105
6.7.2 V-BELTS……Page 106
6.7.4 CALCULATION OF SHAFT RPM……Page 107
6.8 CONTROL EQUIPMENT FOR ELECTRICAL APPARATUS……Page 108
6.9 ILLUMINATION OF THE PROCESSING FACILITY……Page 109
6.9.2 TYPES OF LAMPS……Page 110
7.2 CONDUCTIVE HEAT TRANSFER……Page 112
7.2.1 RESISTANCE TO HEAT FLOW……Page 114
7.2.2.1 Steady-State Conduction through a Composite Cylinder……Page 116
7.3 CONVECTIVE HEAT TRANSFER……Page 118
7.3.1 HEAT TRANSFER BY CONDUCTION AND CONVECTION……Page 119
7.4.1 STEFAN’S LAW……Page 121
7.5.2 SPECIFIC HEAT CAPACITY……Page 123
7.6 HEAT PRESSURE DIAGRAM FOR WATER……Page 124
7.6.1.2 Saturated Vapor……Page 126
7.6.1.4 Superheated Steam……Page 127
7.7 STEAM TABLES……Page 128
7.8.2 CULINARY STEAM……Page 129
7.9.1 ENERGY CALCULATIONS FOR WATER HEATING……Page 130
7.10.1 EXPANSION OF PIPES……Page 132
7.11 PROBLEMS……Page 133
8.3 FIRE-TUBE BOILERS……Page 135
8.4 WATER-TUBE BOILERS……Page 136
8.5 BOILER EFFICIENCY……Page 137
8.5.1.2 Thermal Efficiency……Page 138
8.5.2 BOILER
BLOWDOWN……Page 139
8.6 BOILER SELECTION CRITERIA……Page 140
8.6.3 SYSTEM
LOAD……Page 141
8.6.3.4 Load Variations……Page 142
8.6.4 NUMBER OF BOILERS……Page 143
8.6.6.1 Fuel Oil……Page 144
8.6.6.2 Gaseous Fuels……Page 145
8.6.6.3.1 Combustion of Solid Fuels……Page 146
8.6.6.4.3 Carbon Monoxide……Page 147
8.7.2 STEAM PRESSURE REGULATING VALVE……Page 148
8.7.4 WATER COLUMNS……Page 149
8.7.7 FUSIBLE PLUG……Page 150
8.8 STEAM PURITY……Page 152
9.1 OVERVIEW……Page 153
9.2 NATURAL REFRIGERATION……Page 154
9.4 MECHANICAL REFRIGERATION……Page 155
9.4.2.1 Removal of Oil……Page 157
9.4.3 EXPANSION VALVE……Page 158
9.4.4 BACK-PRESSURE REGULATOR……Page 159
9.4.7 AUTOMATIC CONTROL……Page 160
9.4.8 REFRIGERANTS……Page 161
9.4.8.2.1 R-134a……Page 162
9.5 THERMODYNAMICS OF VAPOR COMPRESSION……Page 165
9.5.1 COEFFICIENT OF PERFORMANCE……Page 167
9.6.1 CONGEALING TANK SYSTEM……Page 170
9.6.2 BRINE SYSTEM……Page 171
9.7 MANAGEMENT……Page 174
9.8.1 INSULATION……Page 175
9.8.2 PREFABRICATED POLYURETHANE PANELS FOR COLD
ROOM CONSTRUCTION……Page 176
9.8.4 MANAGEMENT OF COLD ROOMS……Page 177
9.8.4.1 Defrosting……Page 178
10.3 POTABLE WATER……Page 179
10.3.1.1 Health Concerns……Page 180
10.3.1.1.2 Microbiological Concerns……Page 181
10.3.1.2 Aesthetic Concerns……Page 182
10.4.1 HARDNESS……Page 183
10.4.6 GASES……Page 184
10.5.1 TREATMENT TO REMOVE TURBIDITY……Page 185
10.5.2.1 Cold Lime Method……Page 186
10.5.2.2.1 Base Exchange……Page 187
10.5.3 WATER DEMINERALIZING……Page 188
10.5.5 CARE
OF FILTERS AND ION EXCHANGERS……Page 189
10.6 TREATMENT OF BOILER FEEDWATER……Page 190
10.7 WASTEWATER TREATMENT……Page 191
10.7.1 WATER CONSERVATION……Page 192
10.8.1 AERATED LAGOON……Page 193
10.9 WASTE DISPOSAL……Page 194
10.9.2 SOLID WASTES……Page 195
10.9.3.1 Controlled Incineration……Page 196
10.9.4.1 Landfill Methods……Page 197
10.9.4.2 Public Health and Environment……Page 198
11.1 IMPORTANCE OF MATERIALS HANDLING……Page 199
11.2 INCREASING MATERIALS HANDLING EFFICIENCY……Page 200
11.2.2 KINDS OF SYSTEMS……Page 201
11.2.3 ANALYSIS OF A MATERIALS HANDLING SYSTEM……Page 202
11.3.1.1 Chutes……Page 204
11.3.1.2 Roller Conveyors……Page 206
11.3.1.4 Slat Conveyors……Page 207
11.3.2 TRUCKS……Page 208
11.3.4 BULK HANDLING……Page 209
11.4.1 SPACE ARRANGEMENTS……Page 210
11.5.1 MAINTENANCE……Page 211
12.2.2 SANITATION CODES……Page 213
12.3 EXPANSION……Page 214
12.4 PLANT LOCATION……Page 215
12.5 PLANNING THE BUILDING ON THE SITE……Page 217
12.6 THE STRUCTURE……Page 218
12.6.2 SUPPORTING STRUCTURE……Page 219
12.6.3 WALLS……Page 220
12.6.4.2.2 Metal Plate Floor……Page 221
12.6.4.2.4 Tile or Paver Floors……Page 222
12.6.5 WINDOWS……Page 223
12.6.8 ELECTRICAL……Page 224
12.7 FACILITIES LAYOUT……Page 225
12.8 SUMMARY……Page 226
13.2 CAUSES OF ACCIDENTS……Page 227
13.3.2 HANDLING MATERIALS……Page 229
13.4.2 OPERATING INSTRUCTIONS……Page 230
13.5 GENERAL PLANT SAFETY……Page 232
13.6 FIRE PROTECTION……Page 233
13.6.1 FIRE FIGHTING……Page 236
13.7 NOISE CONTROL……Page 237
13.8 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION……Page 240
References……Page 242
CONVERSION TABLES……Page 243
TEMPERATURE CONVERSION……Page 249
A2.3.1 THE DIAGONAL RULE……Page 250
A2.3.2 DO ON BOTH SIDES RULE……Page 251
A2.3.3 ADDING FRACTIONS……Page 252
A2.4 EXPONENTS……Page 253
A2.5.2 SOLUTION USING THE FORMULA……Page 256
A2.6 SIMULTANEOUS EQUATIONS……Page 257
A2.7.1 RULE 1……Page 259
A2.7.3 RULE 3……Page 260
A2.8 APPLICATIONS OF DIFFERENTIATION……Page 262
Appendix 3 Steam Tables……Page 264