Final Internship Report and Project Paper: Declaration

FINAL INTERNSHIP REPORT AND PROJECT PAPER
Declaration
We are 4th year chemical engineering students. And our hosting company is Rorank business
S.C alcoholic liquor factory. We have approved our practical skills, theoretical knowledge,
interpersonal communication skills, and work ethics. We assure that the report contains actual
events and facts that was observed and performed during our internship practice program. An
internship program is the program that experiences gained was approved by the monitor from the
university and supervisor from the hosting company.
We certify that our work is original and complied according to the internship report writing
guidance given by industry linkage office.
Name of students: Atefrachew Seyfu

Signature: ---------------------------------------------------------------------------------------
Brihanu Cheru
Signature: ---------------------------------------------------------------------------------------
Yeshi Tadesse
Signature: ---------------------------------------------------------------------------------------
Asinake Helawi
Signature: ---------------------------------------------------------------------------------------
Ayelech Aragaw
Signature: ---------------------------------------------------------------------------------------
Approval of supervisor:
Signature: ---------------------------------------------------------------------------------------
Approval of mentor: Ins. Brihan
Signature: ---------------------------------------------------------------------------------------
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Acknowledgement
First of all we would like to express our profound gratitude and sincere appreciation to our
advisor Ins. Birihan Getachew for her encouragement, unending support and valuable advice
before and throughout the internship period.
Our thanks extended to all workers of Rorank business S.C alcoholic liquor factory, especially
for Mr. Niguse and the company manager Mr.Nway who accept our internship application. Also
for shift engineer Demis and Haile Gebire for their help by motivating us to do our project
successfully and giving us the chance to see and practice in every section of the company that we
want.
Finally, we would like to thank all the staffs and friends of the department of chemical
engineering at Debire Brihan University for their support and corporation.
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Table of content
Declaration ....................................................................................................................................... i
Acknowledgement .......................................................................................................................... ii
Table of content ............................................................................................................................. iii
List of tables ................................................................................................................................... ix
List of figures .................................................................................................................................. x
Abbreviations ................................................................................................................................. xi
Abstract ......................................................................................................................................... xii
CHAPTER ONE ............................................................................................................................. 1
1INTRODUCTION ........................................................................................................................ 1
1.1 Historical Back Ground ........................................................................................................ 2
1.2 Vision and mission of the factory ......................................................................................... 4
1.3 Products of the company....................................................................................................... 4
1.5 Job organization and structure of the company .................................................................. 6
1.6 Scope and Purpose of the Factory......................................................................................... 9
1.7 Objective ............................................................................................................................. 10
1.7.1 General objective ......................................................................................................... 10
1.7.2 Specific objective ......................................................................................................... 10
CHAPTER TWO .......................................................................................................................... 11
2 LITRETUR EREVIEW ............................................................................................................. 11
2.1 Definitions........................................................................................................................... 11
2.2 World Alcohol Production and Ethiopia‟s Case ................................................................. 11
2.3 Ethanol Production Technologies ....................................................................................... 12
2.4 Alcohol Production from Molasses .................................................................................... 12
CHAPTER THREE ...................................................................................................................... 13
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3 GENERAL PROCESS OVERVIEW OF THE FACTORY ...................................................... 13
3.1 Raw materials...................................................................................................................... 13
3.2 Major unit operation involved in this factory ..................................................................... 14
CHAPTRE FOUR ......................................................................................................................... 17
4 FERMENTATION HOUSE ...................................................................................................... 17
4.1 Introduction ......................................................................................................................... 17
4.2 Raw material for fermentation ............................................................................................ 17
4.2.1 Molasses....................................................................................................................... 17
4.2.1.1 Molasses Storage ................................................................................................................ 18
4.2.2 Nutrients ....................................................................................................................... 18
4.2.2.1 DAP (Di ammonium phosphate) and Urea ......................................................................... 19
4.2.3 Yeast ............................................................................................................................ 19
4.2.4 Sulphuric acid .............................................................................................................. 20
4.2.5 Water ............................................................................................................................ 20
4.3 Fermentation process (Methods)......................................................................................... 21
4.4 Major process step in fermentation ..................................................................................... 21
4.4.1 Raw material preparation ............................................................................................. 21
4.4.1.1 Molasses treatment ............................................................................................................ 21
4.4.2 Yeast propagation (inoculum preparation) .................................................................. 22
4.4.3 Final fermentation ........................................................................................................ 23
4.4.3.1 Stages of fermentation ....................................................................................................... 24
4.4.3.2 Abnormal fermentation ...................................................................................................... 24
4.4.3.3 Foaming............................................................................................................................... 25
4.5 Fermentation process description ....................................................................................... 26
4.6 Factor affecting fermentation process ................................................................................. 27
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4.6.1 Temperature ................................................................................................................. 27
4.6.2 Amount of sugar .......................................................................................................... 28
4.6.3 PH ................................................................................................................................ 28
4.6.4 Duration of fermentation.............................................................................................. 28
4.7 Calculations on fermentation .............................................................................................. 28
4.7.1. Material balance on fermentation house ..................................................................... 28
4.7.2 Process Efficiencies and Yields ................................................................................... 33
4.8 Equipment used .............................................................................................................. 36
CHAPTER FIVE .......................................................................................................................... 37
5 DISTILLERY HOUSE .............................................................................................................. 37
5.1 Introduction ......................................................................................................................... 37
5.2. Types of equipment............................................................................................................ 38
5.3. Process description............................................................................................................. 41
5.3.1. Frist stage process ....................................................................................................... 42
5.3.1.1 Decantation......................................................................................................................... 42
5.3.1.2. Degasifying column ............................................................................................................ 42
5.3.1.3 Analyzing column ................................................................................................................ 43
5.3.1.4 Aldehyde column ................................................................................................................ 45
5.3.2. Second stage process................................................................................................... 45
5.3.2.1 Extractive distillation (ED) column ...................................................................................... 45
5.3.2.2. Stripping section (stainless steel column).......................................................................... 46
5.3.2.3. Rectification section (copper column) ............................................................................... 47
5.3.2.4 Methanol column................................................................................................................ 48
5.4. Distillation column control ................................................................................................ 49
5.5 Process flow diagram .......................................................................................................... 49
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5.6 Calculations......................................................................................................................... 52
5.6.1. Material balance .......................................................................................................... 52
5.6.1.1. Material balance on the first stage .................................................................................... 53
5.6.1.2 Material balance on the second stage ................................................................................ 57
5.6.2 Energy balance ............................................................................................................. 63
CHAPTER SIX ............................................................................................................................. 71
6 LIQUIOR PREPARATION AND BOTTLING HOUSE.......................................................... 71
6.1 Liquor formulation and preparation (blending) .................................................................. 71
6.2 Bottle washing and packing ................................................................................................ 73
6.3 Calculation on liquor formulation ....................................................................................... 73
CHAPTER SEVEN ...................................................................................................................... 75
7 EVAPORATOR AND DRYING HOUSE ................................................................................ 75
7.1 Evaporator section .............................................................................................................. 75
7.1.1 Types of evaporates used ............................................................................................. 76
7.1.3 Process description....................................................................................................... 77
CHAPTER EIGHT ....................................................................................................................... 79
8 WASTE WATER TREATMENT PLANT ............................................................................... 79
8.1 Introduction ......................................................................................................................... 79
8.2 process description .............................................................................................................. 80
CHAPTER NINE .......................................................................................................................... 84
9 UTILITY .................................................................................................................................... 84
9.1 Boiler................................................................................................................................... 84
9.2 Cooling tower...................................................................................................................... 85
9.3 Zeolite water softener ......................................................................................................... 87
CHAPTER TEN............................................................................................................................ 89
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10 BENEFITS OF INTERNSHIP ................................................................................................ 89
10.1 Improving practical skills ................................................................................................. 89
10.2 Upgrading theoretical knowledge ................................................................................... 89
10.3 Inter personal communication skill ................................................................................... 89
10.4 Improving leadership skills ............................................................................................... 90
10.5 Work Ethics Related Issues .............................................................................................. 90
10.6 Improving team playing skill ............................................................................................ 91
10.7 entrepreneurship skill ........................................................................................................ 92
CHAPTRE ELEVEN .................................................................................................................... 93
11 CONCLUSION AND RECOMMENDATION ....................................................................... 93
11.1 Conclusion ........................................................................................................................ 93
11.2 Recommendation .............................................................................................................. 94
11.3 Potential for further research and assistance ..................................................................... 94
CHAPTER TEWELVE ................................................................................................................ 95
12 PROJECT TITLE: SUBSTITIUTION OF CHEMICAL FLOCULANT BY NATURAL

FLOCULANT (CACTUS MUCILAGE) IN WASTE WATER TREATMENT ......................... 95
Abstract ..................................................................................................................................... 95
12.1 Introduction ....................................................................................................................... 95
12.2 Statement of the problem .................................................................................................. 97
12.3 Objectives ......................................................................................................................... 97
12.3.1 General objective ....................................................................................................... 97
12.3.2 Specific objectives ..................................................................................................... 97
12.4 Literature review ............................................................................................................... 97
12.5 Material and Methods ....................................................................................................... 99
12.5.1 Chemicals used .......................................................................................................... 99
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12.5.2 Equipment and accessories used ............................................................................. 99
12.6 Methods............................................................................................................................. 99
12.6.1 Mucilage extraction ................................................................................................... 99
12.6.2 Analysis of PH and coagulant dosage ...................................................................... 100
12.6.3 Measuring the parameter.......................................................................................... 100
12.6 Results and discussions ................................................................................................... 100
12.6.1 The effect of cactus mucilage and aluminum sulphate on waste water treatment ... 102
12.6.2 The effect of cactus mucilage and (Al2 (SO4)3 dosage.......................................... 102
12.7 Conclusion ...................................................................................................................... 103
12.8 Recommendation ............................................................................................................ 103
Bibliography ............................................................................................................................... 104
Appendices .................................................................................................................................. 105
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List of tables
Table 3-0-1 Raw materials and their corresponding purposes...................................................... 14
Table 4-0-1 composition of molasses ........................................................................................... 18
Table 4-0-2 expected fermentation yield ...................................................................................... 35
Table 5-0-1 operating temperature and pressure of each columns ............................................... 48
Table 6-0-1 different type of liquor with their different amount of ingredient ............................ 74
Table 12-0-1 the result of physicochemical analysis by using cactus mucilage ......................... 100
Table 12-0-2 the result of physicochemical analysis by using Aluminum sulphate................... 101
Table 12-0-3 the result of comparison of cactus mucilage with aluminum sulphate on
physicochemical analysis for waste water treatment. ................................................................. 101
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List of figures
figure 1-1 job structure of the company.......................................................................................... 7
Figure 3.1 the generalized flow diagram of Rorank SC alcoholic liquor factory ......................... 16
Figure 4.1 dilution tank ................................................................................................................. 22
Figure 4.1 the generalized flow diagram for fermentation ........................................................... 26
Figure 5.1 decantation tank ........................................................................................................... 42
Figure 7.1Process flow chart for spent wash evaporation ............................................................ 77
Figure 8.1 flow diagram of waste water treatment plant at Rorank SC Company. ...................... 83
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Abbreviations
BOD : Biochemical Oxygen Demand
COD : Chemical Oxygen Demand
CEO : Chief executive officer
DAP : Di-ammonium phosphate
COO : Chief operating officers

o
Br : Degree Brix
TSS : Total Suspend Solids
RALF: Rorank alcoholic liquor factory
SC : Share Company
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Abstract
Rorank Alcohol and Liquor Factory (RALF) is a share company of Ethiopian and foreign share-
holders. The factory was established in 2013 G.C in Chacha town and uses molasses as raw
material for the production of potable and technical alcohols. It consists of a distillery and filling
plants. Its installed daily production capacity is 18,000 liters of potable alcohol and about 5000
liters of various liquors. The current production capacity was found to be on average 14,000
liters of 96.3 % alcohol grade potable (fine) and 250 liters of 95 % alcohol grade technical
alcohols per day when the factory was running normally.
Water balance, material balance and energy balance were drawn for the fermentation and
distillation section. In fermentation material balance were employed so as to determine the
amount of molasses and water necessary to prepare one batch and then to determine the
fermentation efficiency. In distillation unit material balance and energy balance were used to
determine the amount of alcohol produced within their alcohol grade in each column and the
amount of steam energy required respectively. The molasses, water and energy consumption
were found. The average BOD, COD and TDS in the wastewater were 20,866, 53,514 and 19000
mg/l respectively. The total alcohol loss from the fermentation, decantation and distillation
process units was significant. The stillage from analyzer column is found a severe source of
water pollution.
The fermentation efficiency, alcohol recovery at distillation unit and overall alcohol conversion
efficiency were found to be low compared to values of similar technologies in India, South
Africa and Brazil.
The steam generation and distribution systems and the boiler combustion efficiency were found
extremely low resulting from excess air supply. Similarly, other sources of heat loss were
identified and carefully examined.
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RORANK BUSINESS S.C ALCOHOLIC LIQUOR FACTORY Page 1

CHAPTER ONE
1INTRODUCTION
Alcohol any of a class of organic compounds characterized by one or more hydroxyl (-OH)
groups attached to a carbon atom of an alkyl group (hydrocarbon chain). Alcohols may be
considered as organic derivatives of water in which one of the hydrogen atoms has been replaced
by an alkyl group.
Alcohols are among the most common organic compounds. They are used as structures and in
making perfumes, are valuable intermediates in the synthesis of other compounds, and are
among the most abundantly produced organic chemicals in industry. Perhaps the two best known
alcohols are ethanol and methanol or (methyl alcohol). Ethanol is used in toiletries,
pharmaceuticals, and fuels, and it is used to serialize hospital instruments, it is, moreover, the
alcohol in alcoholic beverages. The anesthetic ether is also made from ethanol. Methanol is used
as solvent, as a raw material for the manufacture of formaldehyde and special fuels, in antifreeze,
and for cleaning metals.
Alcohols may be classified as primary, secondary, or tertiary, according to which carbon of the
alkyl group is bounded to the hydroxyl group. Most alcohols are colorless liquids or solids at
room temperature. Alcohols of low molecular weight are highly soluble in water, and their
boiling points, vapor, and pressure densities, and viscosities increase.
Ethyl alcohol, also called ethanol, grain alcohol, a member of class of organic compounds that
are given the general name alcohols. Its molecular formula is C2H5OH. Ethyl is an important
industrial chemical. It is used as a solvent, in the synthesis of other organic chemicals, and as an
additive to automotive gasoline. Ethyl alcohol is produced by fermentation of the sugars using
yeast. The sugars are derived mainly from molasses. After the fermentation process, the ethanol
is purified by a multiple distillation and rectification process commonly referred to as alcohol or
spirits ethanol is also called ethyl alcohol and potable alcohol. It is the principal type of alcohol
found in alcoholic beverage.
Ethanol is a clear liquid alcohol group compound which is made by the fermentation of different
biological materials of grain cereals such as sorghum, wheat, maize barely etc. This alcohol is

known to have many uses, but one in particular becoming more popular, serving as energy
source when it is mixed with fuel oil and secondly its wide consumption as beverage. The
production process of alcohol involves the fermentation process of simple carbohydrates in to an
alcohol solution and purification of this alcohol from the solution through distillation mechanism
using boiling point difference of component parts of mixture solution. The single sugar used in
this process is currently collected by harvesting and conversion of agricultural products such as
sugar cane, corn, wheat and sorghum. The production and utilization of ethanol alcohol is nearby
human activity starting from ancient lives so that writing and talking about ethanol alcohol
history and back ground is related to human being and life generation and civilization. Its
production process goes through three major stages each of which involves various ingredients,
techniques and time lines.
The first stage is dilution of the concentrated ethanol with soft water and other diluting agent
additives such as colorings, flavorings and syrup sugar. The main raw material which is a
product of sugar is cane molasses in most ethanol factory by the action of yeast. It is a viscous
dark and sugar reach which can be fermented to ethanol alcohol easily. Cane molasses is a
byproduct of manufacturing of sugar refining of sucrose from sugar cane. This molasses have 80
degree brix sugar content.
The second stage is known as preparation of fermented mash or wine through dilution of the raw
material and fermentation reaction (mainly when molasses serves as raw material). The third
stage is distillation which is the process of separation of the two most competing components of
the solution using boiling point difference in the presence of steam energy which generates from
the boiler. The last stage is bottling which is a process of preparing or blended drinkable alcohol
or liquor.
1.1 Historical Back Ground

Ethanol is a clear, colorless chemical compound made from the sugars found in crops such as
corn, sugar beets and sugar cane. Hence bio ethanol technology and fermentation have been used
for very long time in human history even if it is not known when and who as well as where the
technology has been started exactly and specifically. But until recent years ethanol was produced
for beverage application in home level even until now. As time arrives its application has been

started to turn back to serve as energy source for vehicles. The first prototype of a car was
produced or manufactured and tested with ethanol in 1986G.C in United States of America. In
Brazil bio- ethanol from sugarcane molasses has been utilized for automotive fuel since 1920 s.
In the 1850s nearly 90 million gallons of ethanol were produced every year in the US. At that
time it was used as a fuel for lamps. It could also be consumed as an alcoholic beverage. In 1862
the Union Congress put a $2 per gallon excise tax on alcoholic beverages to help finance the
Civil War. The tax made ethanol too expensive to use for lighting, so people started using
kerosene and methanol instead.
In 1896, Henry Ford built his first automobile, the quadricycle, to run on pure ethanol. In 1906,
the liquor tax was repealed, and Ford declared ethanol the fuel of the future. Ford designed his
model T to run on a mixture of gasoline and ethanol.
During World War I, ethanol use increased rapidly, not only as a fuel but in the manufacture of
war materials also. The year 1919 brought Prohibition and a denaturing process was developed
which made ethanol poisonous and undrinkable. In the 1920s ethanol was replaced as a booster
to gasoline by other products.
Prohibition ended in 1933, and ethanol production rose to 600 million gallons a year to meet the
needs of World War II. After the war, production once again declined because there were no
more government contracts. Farmers began exporting grain formerly used to make ethanol to
help feed countries whose agriculture had been destroyed by the war. Large supplies of cheap
foreign oil made gasoline less expensive than ethanol.
In 2012 there were 211 refineries in the United States that produced 13.8 billion gallons of
ethanol. Unlike gasoline, ethanol is biodegradable. It quickly breaks down into harmless
substances if spilled. When small amounts of ethanol are added to gasoline, usually less than 10
percent, there are many advantages. Ethanol reduces the emissions of carbon monoxide and other
toxic pollution. It keeps engines running smoothly without the need for lead or other chemical
additives. Because ethanol is made from crops that absorb carbon dioxide and give off oxygen, it
helps reduce the total volume of greenhouse gas emissions. There are several ways to make
ethanol from crops. One process uses yeast to ferment the sugars crop molasses.

Currently, most ethanol produced in the Ethiopia is made from molasses because molasses is
plentiful and cheap. Since ethanol is created by fermenting sugar, sugar crops are the easiest
ingredients to convert into ethanol. In 1979 the Ethiopian sugar corporation initiated the program
of alcohol production from molasses. The promoters were the ministry of industry and united
nation industrial development organization. Almost all ethanol plants designed in Ethiopia
independently are fuel grade except those installed in sugar factories simultaneously. National
and Balezaf ethanol production plants in Addis Ababa are among such types of plants. Roark
S.C alcohol factory production plant is also recently designed small size industry erected in
Chacha of Amhara region of Ethiopia. Chacha lies between 110Km from A.A and 20KM from
Debre Birhan town. Chacha is known with cold and windy climatic condition almost throughout
the year.
The factory was established on February 2013 for the production of Alcohol. During this year for
the production different alcohols the factory use main raw material is<< technical alcohol>>
which is originated from<< Methara >>. After one year ago; that is on January 2014, the factory
change its raw material from technical alcohol into molasses because the latter is cheaper than
the former one and it can be easily gets from sugar factory.
1.2 Vision and mission of the factory

Rorank S.C alcohol and liquor factory attempts to produces and distribute alcohol and various
liquor products based on customer demand.
 The vision of the factory is to improve the quality of its products,

expand its market share and maintain its leadership in the liquor
industry of the country as well as to make at most effort to enter
foreign markets.
 The mission of the factory is to produce internationally recognized
quality liquor products to the taste of the customer.
1.3 Products of the company

The main products or service of RALF are; pure alcohol, denature alcohol, and liquors
1.3.1 Pure alcohol

Which is the first product in the distillation process has an alcohol content of 96.3%. It is used
for many purposes. Among which some of them are:-
• Production of different liquors
• Preparation of medicine
• Laboratory work
• Perfumes and cosmetic production
• Production of chemical and plastic products
1.3.2 Denature alcohol

This is also one of the products in the distillation process with an alcoholic content of 95%. This
product is used for many purposes. To mention few of them are: -
• Clinical purpose
• Beauty salons and barberries
• Cleaning electrical equipment
• Cooking purpose
• Band saws in ripping logs in to boards and cutting very thick wood.
1.3.3 Liquors
Liquors are drinkable alcohol, which prepared in bottling house by mixing soft water, flavor,
coloring, sweetener or syrup and pure alcohol.
In Rorank S.C there are different liquor products are produced. These are given below
1. Gin 6. Double ouzo
2. Vodka 7. Fernet
3. Super mint 8. Apprative
4. Ouzo 9. Cognac
5. Pine apple 10. Lemon
1.4 Main customers or end users of its products or services

 Pure ethanol export to Kenya

 Domestic consumption in Ethiopia

 Hospitals and clinics
 Different factories as solvent
1.5 Job organization and structure of the company

Every area of work has its own structural organization of professionals and labor works
according to their level and work experience to perform the work responsibly and effectively.
The number of people increases when we go from to bottom of the skeleton of the structure. So
as to perform its tasks super eagle alcoholic beverage plant has the following structure of
workers (1).

Board of director
Chief executive officer
Operational manager
Plant Human and Finance Supply chain Sales
Manager Resource management manager market

managemet
Casher Key
Human resource
accou
assistant
ntant
Production
department Accounta Sales
nt super
visor
Administrat
ion Electrician
Store clerk Sales
department
driver
Maintenance
Technic
ian and
. finance Welder
figure 1-1 job structure of the company
Chief Executive
Officer Chief operating officers are responsible for the management of a wide variety of
departments in a manufacturing business. The COO must be knowledgeable in the
manufacturing operations and the needs and capabilities of each department. In some
manufacturing organizations, chief operating officers are responsible for overseeing human
resources, sales and other administrative departments in the company.

Chief operating officers must prepare reports for the CEO on the day-to-day activities in each
department. The reports should evaluate the performance of each department in a company,
including whether they met production goals and budgets. The COO and CEO work together to
develop strategies for each department's success. Chief operating officers allocate the resources
department manager need, such as funds, labor and equipment, to ensure they meet their goals.
COOs conduct regular meetings with department managers to remain up to date on the status of
each area of the company. They might also develop and implement department budgets.
General Manager
General Managers usually have more responsibility than plant managers, with the biggest
differences being the teams they manage and profit-and-loss responsibility. A general manager
usually has a greater scope of management and responsibility than a plant manager. While a sole
responsibility for running the day-to-day operations of a manufacturing site, a general manager
handles this role along with other tasks, most notably, the profit and loss responsibility for his
business segment. A general manager has production supervisors reporting to him that spend
time on the plant floor to keep the operations running smoothly. While a general manager makes
important operations decisions, he often manages other aspects of the business, including sales,
finances or supply chain.
Plant manager
Plant managers are the people who watch over and organize the daily operations of
manufacturing plants and similar places. Plant managers oversee employees, production and
efficiency, to make sure the plant is running smoothly, quickly, efficiently and safely.
Plant managers might oversee an entire location, or just a section of the operation. Plant
managers maintain optimum operation by assigning workers, creating and keeping work and
production schedules, hiring and training new employees, collecting and looking through data to
find places of waste or places of improvement, keep an eye on worker safety and plant safety,
monitor the production equipment to make sure that it stays in good working order, and repair or
replace the equipment when needed. Plant managers are the last line of defense for quality
control when the item manufactured leaves the plant. They communicate with other departments
or parts of the plant to make sure everything runs smoothly.

A plant manager typically is responsible for the operations of a manufacturing plant. Although
the sales dollars for his plant may be a metric for success, he often does not have direct control
over customer orders and sales. Rather, he is more focused on operating the plant efficiently and
ensuring that orders are made and shipped on time.
Operational manager
Leads day to day management of facility operations and maintenance, specifically activities
associated with quality, production, costs, capital expenditures, assets, and human capital
development to ensure productions goals are met in a safe and environmentally efficient manner
Operational manager Lead change and execute strategic priorities to meet business objectives.
Develop direct reports through career development, coaching and performance management to
maximize effectiveness of resources Collaborate with key business stakeholders to identify
opportunities that will optimize and improve facility performance engage leadership to achieve
production/quality results that align with business plans and standards.
1.6 Scope and Purpose of the Factory

The factory have been placed around 10,000m2 near north of chacha river in wider area such that
800m away in west of the town. This wider factory compound have to hold many man powers
through each plant units, like Boiler, distillery, fermentation, bottling including cleaners,
gardeners, security keepers, erector and top management sector workers as we have seen later in
the above.
The main purpose of the factory is:
 To improve the quality of the product for the satisfaction of its customer.
 To produces enough job opportunity for the society.
 To be more profitable.
 To grow the country's economy.

1.7 Objective
1.7.1 General objective
The general objective of this report paper is to evaluate the knowledge that we have obtained
through the industrial internship and to documentaries descriptions about Rorank S.C alcohol
factory.
1.7.2 Specific objective

The specific objectives of the paper include the following points.
 To know the energy requirement of each unit operations that needs

energy in the plant such as distillery through energy balance.
 To have practical material balance in real ethanol plants.
 To know the process description of ethanol plant hold in super eagle
alcoholic and liquor production plant.
 To know the phenomenon held in each unit operations and to know the
functions of all equipment.
 To have practical exercise on the energy balance of each unit operation
of ethanol plant.
 To identify the main energy consuming unit operations of the plant.

CHAPTER TWO
2 LITRETUR EREVIEW
2.1 Definitions
Alcohol - In industrial nomenclature alcohol means ethyl alcohol (C2H5OH), this is also known
as “ethanol”, “grain alcohol”. It has a specific density 0.7937 and a boiling point 78.32oC at 1
atmospheric pressure (2). Ethyl alcohol is a versatile product which can be used for various
purposes, mainly as solvent, beverages, and raw material for making hundreds of chemicals,
such as aldehydes, ethyl acetate, acetic acid, glycols, ethyl chloride, and many other organic
compounds.
2.2 World Alcohol Production and Ethiopia’s Case

Ethyl alcohol has been used by man since the dawn of history (2). Ethanol must have been
originally produced by the spontaneous fermentation of sugars, but as time went modern man
learned to control this fermentation to produce alcoholic beverages. With the advancement of
synthetic organic chemistry in the second half of the 19th century, alcohol became indispensable
as a fuel, as solvent, as an antiseptics and as an intermediate for the production of a number of
organic compounds.
The trend towards cleaner, reformulated gasoline has been largely responsible for the growing
ethanol industry in the world. World demand for ethanol has increased substantially in recent
years for use in ethanol/gasoline blends. The world annual ethanol production in 2000 was about
17.6 billion liters, but this figure has grown to 40.8 billion liters by 2006. The production of
alcohol (ethanol) in Ethiopia in factories traces back to the beginning of the 20th century, even
though the number of firms involved in this sub-sector is still very limited. Today, there are only
few distilleries, namely „Fincha‟, „Mechanisa‟, „Akaki‟, Rorank SC, „Sebeta‟ and „Balezaf‟.
Finicha which is under Fincha Sugar Factory produces 8 million liters of technical alcohol per
annum for domestic and export market; the other four are autonomous plants producing both
potable and technical alcohols with annual total production of about 2.8 million liters.
All sugar factories in the country are under preparation to include distillery plants and produce
mainly fuel alcohol. When these distilleries start producing, it is expected that by the year 2009

annual total alcohol production will be over 95 million liters and this figure will grow to 128
million liters by the year 2012.
2.3 Ethanol Production Technologies

The nature of the feedstock puts certain constraints on the technology required for the
manufacture of ethanol. For example, molasses or sugar solutions can be fermented directly by
yeast, using traditional and well-established technology. However, cellulose feedstock such as
wood or bagasse must be hydrolyzed into component molecules and sugars before fermentation
by one or more specifically selected microorganisms.
Ethanol alcohol production technology can generally be divided into two main categories:
Technologies that convert starch or sugar-based feedstock into ethanol; and technologies that
convert cellulose feedstock into ethanol. The majority of ethanol produced today falls into the
first category, and utilizes corn, potatoes and other grains as feedstock to produce ethanol using
either a dry or wet process or sugar-based feedstock such as sugar juice or molasses. Since at
present, all Ethiopian distilleries uses only cane molasses, this study paper did not considered
technologies using other feedstock.
2.4 Alcohol Production from Molasses

The molasses can be either blackstrap or invert molasses. Blackstrap molasses is a by-product
from sugar centrifuge whereas invert or high-test molasses is produced by heating sugarcane
juice at acid reaction, neutralizing it, and evaporating it (2). Blackstrap and invert molasses
contain about 50% and 95% of fermentable sugar respectively (3). However, exact composition
of molasses is difficult to predict. It is influenced by soil and climatic conditions, variety and
maturity of cane and the processing conditions in the factory (3).

CHAPTER THREE
3 GENERAL PROCESS OVERVIEW OF THE FACTORY

3.1 Raw materials
Ethanol either for the purpose of fuel or consumption as drinkable beverage uses sequential steps
to change the raw sugar or starch in the raw material in to ethanol alcohol even though the
conversion is held during fermentation. These raw materials which serve as the source of these
starches or sugars which can be decomposed to ethanol alcohol directly include molasses which
can be either cane molasses or beet molasses as sources of sugars as one group. In the other
group starch containing raw materials are known and these groups are mainly cereals such as
wheat, barley, sorghum, maize etc.
In most countries where sugar factories are erected, molasses is the main profitable raw material
due to its high sugar content which can be decomposed to ethanol and carbon dioxide with the
action of yeasts. Ethanol plants can be erected simultaneously to these sugar factories or
independently. In Rorank S.C alcoholic factory molasses is the raw material for the source of this
convertible sugar from which it is received from Wonji Showa sugar factory. The other main raw
material which involves from the beginning to the final process of beverage ethanol plant is
water for which at the initial stage its application is for the sake of molasses dilution. Molasses
from the source is dense black raw material such that its solid content is about 75-80 brix (the
solid content of the solution by volume) with a specific gravity of 1.45-1.6. This solidus raw
material is impossible for fermentation process if dilution is not performed with water. This is
because that it will not be suitable for yeast movement during propagation as well in
fermentation. Therefore water is essential at this stage. The amount of water needed depends on
the initial brix of the molasses, if the brix is less the water required will be small unless high.
The lightest and more diluted molasses supplied from sugar factory is at the state of high
component of convertible sugar which also requires a small amount of water for dilution. This
phenomenon is called low brix preparation or dilution process. Therefore these characteristics of
molasses enable to be effective cost wise even if it may be more difficult for transportation
process. The raw materials applied in ethanol plant are urea, DAP, and yeast, sulphuric acid,

essences (flavors), colorings, citric acid, white crystallized sugar. The purpose of these raw
materials can be summarized in the following table.
Table 3-0-1 Raw materials and their corresponding purposes.
Raw materials Purpose

Molasses As main food source for the yeast.
DAP & Urea As phosphors and nitrogen source for the yeast
Citric acid As bleaching agent during syrup preparation

from crystalized sugar using steam.
Crystalized sugar For syrup preparation so as to maintain the test

of beverage by increasing sweetness and
decreasing burning test.
Sulfuric acid For treating the molasses by maintain PH low.
Yeast Mysterious ingredient used to convert

molasses(sugar) in to alcohol
Flavor & coloring To give specific taste and specific color

respectively.
3.2 Major unit operation involved in this factory

The major unit operations involved in this factory to produce bottled alcoholic liquor and to treat
the by-product are; fermentation, distillation, blending, evaporation, and drying. Also there are
many utilities to produce distilled alcohol and alcoholic beverages. This utilities are; boiler
cooling tower, water softening, and compressors. In fermentation a diluted molasses is converted
in to fermented tela by the action of yeast with in a maximum of three day. And the fermented
tela goes to decantation tank to remove the sludge it. The pure tela introduced in to distillery
house to separate ethanol from the mixture and from this unit pure alcohol with high alcohol
grade (96.3%) is cultivated. Simultaneously spent wash is removed as a by- product. In this
house there is seven distillation columns arranged in serious so as to produce the desired alcohol.

These are; degasifying column, analyzing column, aldehyde column, extractive distillation
column (ED), stainless steel column, copper column, and methanol column. By products from
distillation columns which are degassing head, aldehyde head, ED head, fusel oil, light oil,
copper main and vent heads, and methanol head are goes to their storage tank.
The pure alcohol transported to bottling or liquor production house so as to produce different
kind of alcoholic beverages. They contain different alcoholic concentration, different type of
flavor or essence, different type of coloring, and different amount of syrup.
Spent wash coming out from the bottom of analyzer column goes to evaporation house to
evaporate the water and make it concentrated syrup. And after its much amount of water is
removed it goes to drying section for further removal of moistures and produces a solid spent
wash which have a high nutritional value for animals. But during our internship period the drier
was not in operation and there was no production of this solid spent. The vaporized water goes to
condenser to cool.
The condensed water then transferred in to waste water treatment plant for treatment purpose
since it contains high BOD, COD and acidic chemicals. This treatment employed by using both
anaerobic and aerobic digestion process.

Molasses Water
Water Dilution house High brix Dilution tank
High brix Low brix

Air DAP Urea H2SO4
Fermentation Inoculum preparation
(Yeast propagator)
Fermented tela co2
Decantation
Sludge
Pure tela
Spent wash Raw conde
Distillation Evaporation
sed water
Ethanol high brix spent
Ethanol storage Drying

Marketing
Flavor Color
Blending Waste
water
treatment
Alcoholic beverage
Figure 3.1 the generalized flow diagram of Rorank SC alcoholic liquor factory plant

CHAPTRE FOUR
4 FERMENTATION HOUSE
4.1 Introduction
Fermentation is a metabolic reaction in which chemical changes are brought by an enzyme
secreted by micro-organism. For molasses fermentation, Yeast is used as micro-organism.
Molasses free from suspended particles is transferred to molasses to receiving tank & is weighed.
Weighed molasses is distributed to fermenter. Special Yeast is developed in laboratory during
plant startup. After laboratory Yeast propagation is carried at plant up to desire cell mass. This
cell mass is transferred to Fermenter. Molasses, Process water and Nutrients are added to
fermenter. This fermentation process is exothermic process, optimum temperature required for
Yeast activity is maintained by forced circulation through fermenter wash cooler. The
implementation of cooling of fermentation system was an assignment for Rorank SC operation
and maintenance team since it installed simply without functioning.
4.2 Raw material for fermentation
 Molasses
 Nutrients
 Yeast
 Sulphuric Acid
 water
4.2.1 Molasses
In the extraction of sucrose from juice of sugar cane, crystallization inhibitors are collected in the
industrial syrup or mother liquors. This mother liquor is called molasses. These black strip
molasses is a residue remaining after sucrose has been crystallized from cane juice. Molasses is
a heavy viscose material which contains sucrose, fructose & glucose at a total concentration of
50 to 60% of which about 70% sucrose and 30% is invert. The color, taste and composition of
molasses vary with the stage of extraction. The impurities imparted to the molasses are from ash
content and coloring matter. The colors of final molasses is usually a dark brown or reddish
brown, partially due to caramelization of the sugar content and also due to chemical or thermal

degradation of some of the non-sugar constituents. The molasses has different composition as
shown in table below.
Table 4-0-1 composition of molasses
Components Amounts (in percentage)

Sucrose 30-35
Reducing sugar 10-15
Ash 10-12
Water 12-20
Total sugar % dry solids 55-60
4.2.1.1 Molasses Storage

There should be proper molasses storage facility so that the quality does not deteriorate during
storage. It has been observed that the quality of molasses get deteriorated in open tanks
particularly in rain season which causes bacterial contamination and ultimately may result in
poor fermentation efficiency. If also molasses is stored for a longer time there is a growth of
microorganism, as a result there is a degradation of molasses sugar in to any other compounds
which changes the composition of molasses. This will affect the fermentation efficiency and in
the production of ethanol which in turn causes separation problem.
4.2.2 Nutrients
In addition to sugar the fermentation mash must also be provided with additional nutrients for
cell growth and maintenance. Glucose medium supplemented with Ammonium chloride,
Magnesium Sulphate and yeast extract supports rapid cell growth and ethanol productions. The
yeast extract provides all necessary growth factors such as amino acid, purines, vitamins as well
as minerals. Phosphorus, Potassium Magnesium and Calcium are incorporated in to cell mass
and are also Co- factors (activators) of several enzymes. Ammonium ion provides nitrogen for
protein nucleic acid synthesis. Vitamins such as biotin & pantothanate are stimulatory to growth,
while thiamine may also increase ethanol tolerance.
Nitrogen (N) is essential to yeast metabolism. If the medium to be fermented lacks this element,
the yeasts are unable to synthesize proteins, nucleic acids, enzymes and certain vitamins. It is

important to remember that the alcohol yield from sugar conversion reaches a peak when the
nitrogen in the medium is at certain concentration but drops rapidly if this level is exceeded. The
presence of high level of amino acids in the medium to be fermented also causes problem. In the
absence of sufficient ammonical nitrogen yeasts assimilate certain amino acids and convert them
to higher alcohols that have adverse effect on the quality of the final product and the
fermentation yield.
4.2.2.1 DAP (Di ammonium phosphate) and Urea

DAP ((NH4)2PO4) and Urea (CO (NH2)2) used as phosphorus and nitrogen source for yeast as
a food during propagation and fermentation
Nitrogen (N) is essential to yeast metabolism. If the medium to be fermented lacks this element,
the yeasts are unable to synthesize proteins, nucleic acids, enzymes and certain vitamins. It is
important to remember that the alcohol yield from sugar conversion reaches a peak when the
nitrogen in the medium is at certain concentration but drops rapidly if this level is exceeded. The
presence of high level of amino acids in the medium to be fermented also causes problem. In the
absence of sufficient ammoniac nitrogen yeasts assimilate certain amino acids and convert them
to higher alcohols that have adverse effect on the quality of the final product and the
fermentation yield
4.2.3 Yeast
Yeasts are eukaryotic microorganisms classified in the kingdom Fungi. These unicellular
organisms reproduce asexually by budding. Yeast species grow aerobically. Unlike bacteria,
there are no known yeast species that grow only anaerobically. Yeasts grow best in neutral or
slightly acidic PH environment. Most yeast cells die above 500 C. There is little activity in the
range of 00 C to 100 C. The cells can survive freezing under certain conditions with viability
decreasing over time. The most common mode of vegetative growth in yeast is asexual
reproduction or fission. Yeast of species Schizo Saccharomyces pombe reproduce by binary
fission instead of budding.
The fermenting yeast is still the best ethanol producer among all ethanol producing
organisms, and is a very important factor in fermentation. The common strains of yeast used in
the distilleries are as follows:

i. Saccharomyces Cerevisiae
ii. Saccharomyces Ellipsoides
iii. Saccharomyces Carisbergensis
iv. Saccharomyces Fragilis
v. Schizosaccharomyces Pombe
vi. Saccharomyces Ovaru
These different strains of yeasts are large in size and robust as compared to bacteria, which is
also responsible for fermentation of molasses. For the fermentation of substrates like molasses,
the common type of yeast i.e. Saccharomyces Cerevisiae is very effective and it was used at
Rorank SC The multiplication of this type of yeast is by budding, which means that one yeast
cell grows larger and larger in the substrate of sugar and at a particular stage, mother yeast cell
buds out of the mother cell and this process of multiplication is repeated, where by a large
number of cells are produced. It is therefore, important to know the conditions in which this type
of multiplication is very fast and then create such condition in the fermentation tanks, so as to
develop the required number of yeast cells for achieving fast fermentation.
4.2.4 Sulphuric acid

PH in fermentation process should be maintained 4.5 to 5 for getting optimum yeast activity and
reducing contamination growth. Any bacteria/microbes get killed at lower PH. Hence it is
advisable to reduce to PH of media in pre-fermenter to 4.2 to 4.5 before transferring to
fermenter. At Rorank SC the same procedure was practiced and during fermentation process, PH
of the media was checked every two hours and maintained in between 4.5 to 5 by addition of
sulphuric acid if required.
4.2.5 Water
In fermentation process water plays high role to dilute high molasses brix (78-85%) to the
needed low brix. Water is also used as a general cleaning. The nature of water to be used for
producing alcohol is very important. Its composition is very much dependent on the condition of
soil. The dissolved matters influence the production of alcohol thus the following points must be
attentively controlled hardness of water, iron content of water, manganese content of water, odor
and taste of water.

4.3 Fermentation process (Methods)

There are two types of fermentation processes:-
1. Batch fermentation process and
2. Continues fermentation process.
In the batch fermentation process specific volume of mash is fermented at one time. The process
continues until maximum yields are obtained. Fermentation is then stopped, the products
recovered, the equipment cleaned and sterilized, and another batch started.
In continuous fermentation process, additional mash is added continuously or more commonly,

at short time intervals to the fermenters. And there is recycling of yeast
At Rorank SC Alcoholic liquor factory Batch fermentation process is in on operation by erecting

five tanks which sizes 232,000 litters.
4.4 Major process step in fermentation

The major process steps in alcohol production by fermentation are:-
 Raw material (molasses) preparation
 Yeast propagation( inoculums preparation)
 Final fermentation
4.4.1 Raw material preparation

4.4.1.1 Molasses treatment
Molasses can be treated by diluting and heating. Dilution is simply the addition of water to
adjust the amount of sugar in the mash or (ultimately) the amount of alcohol in the beer. It
is necessary because the yeast, used later in the fermentation process can be killed by too great a
concentration of alcohol. The objective of dilution is to end up with a beer as close to (but,
not more than) 10% alcohol when fermentation is complete. The optimum dilution, then, is a
compromise between the highest alcohol concentration and the point where the particular yeast
strain being used is killed.at Rorank SC alcoholic liquor factory there are two types of Dilution
made. High brix dilution and low brix dilution. The former is for pre-fermentation and the latter
is for batch feeding.

Dilution and heating can be performed simultaneously. Since molasses form a viscous fluid,
containing approximately 78 to 83% dissolved solids (sugar or non-sugar), it is necessary to
reduce the molasses viscosity by heating. Heating will increase the reaction between Sulphuric
acid and calcium and or/ magnesium salts. It is also necessary for sterilization of the molasses
and hence prevents microbial contamination. But there is no molasses treatment by heating in
this alcoholic liquor factory.
Figure 4.1 dilution tank
4.4.2 Yeast propagation (inoculum preparation)

When left to stand, sugar products, either at natural concentrations (fruit juices) or diluted
normally starts to ferment by the action of yeasts. The microorganisms which may already be
present in the product, originates from the atmosphere or adheres to the container. The type and
yield of fermentation depends amongst other things, on the naturally occurring genus and species
responsible. However in order to ensure regular and healthy fermentation and a high yield, a
suitable quantity of active yeast with a high alcoholic potential must be intentionally added to the
liquid to be fermented. This quantity of yeast is known as the inoculums or "Leaven".
Before adding the inoculums, it is essential to check that the medium to be fermented
provides suitable conditions for the yeasts:-
 Appropriate sugar concentration

 Adequate supply of nutrients

 PH of 4.5 to 5.0
 Temperature not exceeding 300 C
The inoculums should consist of a rich and active suspension of the most efficient type of yeasts
for the required purpose.
The inoculum to be used should have to be:
i. Abundant
ii. Active
I. The inoculum should be abundant

Although a single yeast cell is able to produce millions of cells in a very short period of time, it
is essential to use abundant inoculums to ensure that the medium is quickly dominated by yeast.
This prevents competition from bacteria, which generally reproduces much faster than yeasts.
Ideally the inoculums added should be of sufficient quantity so as to provide the medium with
the sufficient number of yeasts. This would result in a state of saturation with dual advantages:-
 Minimal risk of bacterial contamination
 Minimal sugar dissipation forming new yeast cell protoplasm.
II. The inoculum must be active

Not only do the inoculums have to be abundant, it must be active as well. There can be no doubt
that the preparation of the inoculums is vital to the success of alcoholic fermentation technology,
affecting both the quantity and quality of the final product. Before using yeasts for the
preparation of inoculums, the selection of appropriate yeast is essential for effective fermentation
process.
4.4.3 Final fermentation

Although fermentation is only one step in the production process, it is the key step.
Fermentation is a biochemical process in which enzymes produced by microorganisms
transform an organic substance in to ethanol. The substance used in ethanol fermentation is a six
carbon sugar.

4.4.3.1 Stages of fermentation

After yeast has been introduced in the mash, fermentation precedes in a number of
characteristics stages which manifest themselves in changes of the physical appearance of the
fermenting mash. The mash, liberation of carbon dioxide and heat is generated. Finally at the end
of fermentation the yeast settles down leaving more or less clarified fermented mash.
In the first stage of fermentation, some hours after pitching (addition of yeast) the time limit
depending on the amount and vigor of the yeast inoculum and the temperature. The dirt cover
appears on the surface of the mash surrounded by a ring of white foam on the periphery which
gradually spreads over the whole surface. This indicates the beginning of the fermentation and
the carbon dioxide liberated in the process holds the yeast in suspension.
The foam increases and becomes compact more resembling a cauliflower hence called
cauliflower stage. It is supported by the rising carbon dioxide set free in the fermentation. The
gravity falls rapidly with simultaneous quick rate of rise in temperature.
The third stage is marked by greatest activity showing the maximum multiplication of yeast,
decrease the gravity and rise in the temperature in which the foam reaches its maximum height.
This is followed by reduced activity of the yeast due to the exhaustion of the main part of the
sugar. The decreased liberation of carbon dioxide gas is not sufficient to support the high foam
which begins to collapse. The yeast agglomerates in lumps and sinks. Only a thin cover of fine
foam remains on the surface. The fermentation is now almost completed and marks the fifth
stage of fermentation.
4.4.3.2 Abnormal fermentation

Sometimes large quantities of yeast accumulate in lumps at certain places, which
subsequently disintegrate causing increased local activity and the liberated carbon dioxide
bubbles so rapidly as to give the mash the appearance of the boiling. This is called “Boiling
Fermentation” and can be cured by vigorous rousing. Sometimes i so happens that fermentation
comes to a standstill before the mash has completely fermented. This phenomenon is
known as resting fermentation and may due to the weekend condition or limited fermenting

power of the yeast or sudden drop in the temperature of the mash. The former can be remedied
by adding fresh yeast and later by restoration of proper temperature.
4.4.3.3 Foaming
Excessive foaming is an undesirable feature which may be caused by number of factors, in
particular the characters of the mash itself. Rapidly fermenting yeast, low acidity, high
fermentation temperature and bacterial contamination are additional contributory causes.
Foaming is rarely due to one single cause. Selection of different strain of yeast, or addition of
yeast containing a large proportion of old cells, and lowering of the initial PH of the mash help in
reducing foam. High foam can be made to subside by the addition of fats, lard or oils.

Water
Molasses Dilution (preparation
storage of low brix)
Water Air DAP Urea H2SO4
Dilution (preparation of Yeast propagation
high brix) (inoculum preparation)
Fermentation
Tela to decanter co2

Figure 4.1 the generalized flow diagram for fermentation
4.5 Fermentation process description
From storage molasses is transferred to holding tankers and water is added to prepare diluted
molasses. The diluted molasses with low brix (15o brix) is transferred to yeast propagation tank
and filled 70% of it. Then nutrients urea and DAP added as per recommended dose which is 8 kg
each for 45,000 litters tank and sulphuric acid to maintain PH 4.5 to 5. Filtered air will be
admitted by sparging for agitation and as oxygen supplement for cell growth. Now a suitable
quantity (8kg) of active yeast with a high alcoholic potential will be added to the liquid to be
inoculated. This quantity of yeast is known as the inoculums. Brix, temperature and PH are
Checked and noted with in 2 hour time interval.
When brix of the yeast propagation vessel falls to half of initial set up brix (which is
around 8obrix) and cell concentration and activity were reached to desired value, then this
vessel is ready to transfer to the fermenter.
Initially fermenter tanks are cleaned with water. All pipelines are cleaned. When fermenter is
cleaned, the dilute molasses with high brix feed of desired brix to fermenter particularly 25o-28o
brix is started. 20% level of dilute molasses in fermenter was filled. The Yeast culture

(propagated yeast) from propagation tank was transfer to the fermenters. After transferring the
Yeast culture (propagated yeast) after waiting for 30 minute to 1.0 hr. feeding dilute molasses of
desired brix was started to the fermenter and when level of fermenter is 80% the dilute molasses
feed to the fermenter was stopped. The volume of fermentation tank is 232,000 litters.
After that the following activity was done. Foaming maintained by spraying antifoam. No excess
amount of antifoam should add to fermenter as excess antifoam will form a covering layer
around the yeast cell and restrict the yeast activity. Fall of brix, PH, temperature and alcohol
percentage was record every two hours in lab analysis log book. Record was checked by shift
chemist to take the corrective action.
Maintain the pH of fermenter up to 4.5 to 5. Low PH will indicate the formation of by- product.
To increase the PH, dilute ammonia can be used. High PH will indicate the decrease in yeast
activity. By adding dilute H2SO4, PH can be maintained. Retention time of fermenter depends
upon the quality of molasses, yeast activity and maintain the parameters. Once the fall of brix
remain constant for 4.0 hrs. It assumed that fermentation is completed.
This fermented wash (tela) will be transferred to decanters so as avoid the sludge transfer to the
distillation column. After transfer of fermented wash to decanters was completed, cleaning of the
fermenter as said above was done to keep ready for next batch fermentation.
4.6 Factor affecting fermentation process

Factors that affect fermentation process are:-
 Temperature
 Amount of sugar (brix of the medium)
 PH
 Duration of fermentation
4.6.1 Temperature
As the fermentation progresses, the temperature of the wash tend to rise because the reactions
taking place are exothermic. Cooling units are required to prevent the temperature from
exceeding 30 – 32oC. Anomalies in the temperature curve imply the presence of fermentation
irregularities. Hence, a very slow rise in temperature points to the deficiencies in the

inoculums (insufficient inoculums, infection, lack of adaptation to the medium on the part of the
yeast), while too rapid a rise indicates that the wash is excessively rich in sugar or that the initial
temperature of the wash was too high.
4.6.2 Amount of sugar

A small amount of sugar spends up the fermentation process but the alcohol content decrease.
Large amount of sugar will slows down the fermentation process but the alcohol content inside
the fermented wine increase.
4.6.3 PH
The PH decreases during fermentation (once it has reached the true level of acidity),
particularly during the supplementary fermentation phase. Fermentation is taken to be normal if
the PH drop does not exceed 20% of the initial PH.
4.6.4 Duration of fermentation

The fermenting period is dictated by several factors: the nature of the beer, the fermentation
process, the fermenting energy of the inoculums, the volume of the inoculums, etc. Excessive
prolongation of the fermenting period indicates an excessive sugar level, inadequate or
insufficient inoculums, bacterial infection or that the temperature in the fermenting room is too
low. On the other hand, a very short fermenting cycle may indicate a paralysis of yeast activity,
resulting from contamination, a mash that is very low in sugar or other nutrients, Or excessive
temperature.
4.7 Calculations on fermentation
4.7.1. Material balance on fermentation house

A) For preparation of low brix from 80o brix to 150 brix
In the laboratory test to dilute 1.2 Litter of raw molasses to reduce 150 brix from 800 brix we use
8.9L of water. So by using the above laboratorial scale we can determine the overall water and
molasses content in the dilution tank for low brix.
1.2L of raw molasses + 8.9 L of water = 10.1 L of dilute molasses. Therefore in 10.1L
diluted molasses with low brix contain 1.2 L raw molasses and the rest 8.9L is water.
For yeast propagation tank we use 36,000 L of dilute molasses solution with 15o brix

Thus using the above relation

1.2 L of raw molasses = 10.1 of dilute molasses
RM = 36,000L of dilute molasses
RM = (1.2 L * 36000L)/ 10.1L

RM= 4320L of raw molasses are used for low brix preparation which is used for yeast
propagation tank.
Litter of water = litter of dilute molasses (solution) - litter of raw molasses
Litter of water = 36000L – 4320 L =31680L
Litter of water = 31680 L of water. So to dilute 4320 L of raw molasses we use 31680 L of water
Low
W=31680 L brix DM =?
dilution
RM = 4320 L tank
Now we have to convert the above volume values into its appropriate mass
 Change the volume of molasses into mass basis using the relation below
Mm=Vm * ρm
Where Mm = Mass of molasses
Vm = volume of water=31680L
ρm= density of Molasses = 1450kg/m3=1.45kg/L
Mm =4320 L* 1.45kg/L
Mm = 6264kg of molasses
 Change the volume of water into mass basis

Mw = Vw * ρw where Mw = mass of water
Vw= Volume of water = 31680L
ρw=density of water = 1000kg/m3 = 1kg/L
Mw = 31680L * 1kg/L
Mw = 31680kg of water
Now mass balance on dilution tank

Low
Mw=31680 Kg brix
Dm=?
dilution
tank
Mm=6264 Kg
Assuming steady state

Input = Output
Mw + Mm = Dm
Dm = 31680 + 6264
Dm = 37944 Kg of dilute molasses for large yeast propagation
B) For preparation of high brix from 80o brix to 25o brix
In the laboratory test to dilute 1.2 Litter of raw molasses to reduce the concentration of sugar
from 80-250brix we use 3.8L of water. We can determine the overall molasses and water content
in the high brix dilution.
1.2L of raw molasses + 3.8 L of water = 5L of dilute molasses

For fermentation we use 190,000L of high brix dilute molasses
1.2 L of raw molasses = 5L of dilute molasses

Rm ? = 190,000L of dilute molasses
Rm = 45,600L of raw molasses are used for low brix preparation which is used for yeast
propagation tank.
Litter of water = Litter of molasses - Litter of raw molasses

Litter of water = 190,000L - 45600L
Litter of water = 144,400L of water
So to dilute 45,600L of raw molasses we use 144,400L of water.
W=144,400 L High
brix Dm =?
dilution
Rm = 45600 L tank

Now we have to convert the above volume values into its appropriate mass
 Change the volume of molasses into mass basis using the relation below
Mm=Vm * ρm
Where Mm = Mass of molasses
Vm = volume of water=144,400L
ρm= density of Molasses =1450kg/m3=1.45kg/L
Mm =45600L* 1.45kg/L
Mm = 66120kg of molasses
 Change the volume of water into mass basis

Mw = Vw * ρw where Mw = mass of water
Vw= Volume of water = 144,400L
ρw=density of water = 1000kg/m3 = 1kg/L
Mw = 144.400L * 1kg/L
Mw = 144,400kg of water
Now mass balance on dilution tank

High
Mw = 144,400 Kg
brix
Dilution Dm=?
Tank
Mm = 66,120 Kg

Input = Output
Mw + Mm = Dm
Dm = 144,400 + 66,120
Dm = 210,520 Kg of dilute molasses for fermentation
C) For large yeast propagation tank
The prepared low brix molasses in dilution tank with 37944kg are added in the large
propagation tank and 8kg of raw yeast, 8kg of DAP ,8kg of urea, and 2L H2SO4 are added in the
propagation tank to propagate the yeast.

Yeast (Y) =8Kg H2SO4 = 2L
Urea (U) =8K
Dm (low brix) = 37,944Kg Propagation propagated yeast (Py)=?

tank
DAP=8Kg
 Change the volume of H2SO4 into mass

mH2SO4 = VH2SO4 * ρH2SO4
Where VH2SO4 = Volume of sulfuric acid = 2 L
mH2SO4 = Mass of sulfuric acid
ρH2SO4 = Density of sulfuric acid = 1.84kg/L
mH2SO4 = 2L * 1.84kg/L
mH2SO4 = 3.68kg of sulfuric acid used in the smaller the low brix dilution
Assume steady state
Input = Output
DM + DAP + U + Y+ mH2SO4= PY
PY = {37,944 + 8+ 8 +8+3.68} kg
PY = 37,971.68 kg of propagated yeast medium are produced
D) For Fermentation tank
37,971.68kg of propagated yeast and 210,520kg of high brix dilute molasses are added in the
fermentation tank for the preparation of wine (fermented mash)
Dm (high brix) =210,120Kg
Fermentati Mft (mass of fermented tela) = ?

on tank
Py = 37,971.68 Kg
h = 0.25m
The total height of the fermentation tank is 9 meter

To calculate the volumes of accumulation first determine the radius of cylinder the total volume
of fermentation tank (Vft) is 230,000L (230m3) thus using the formula below we calculate its
radius
Volume = π*r2h
Vfk = 230m3=3.14*r2 *9
r2 = 8.14m
r=2.85m
Then we have to calculate the accumulation of fermentation tank Va =π*r2h

Va= 3.14*(2.85m) 2*0.25m=6.37616m3=6376.16L
Where Va is the fermented tela accumulated in tank.
The density of accumulated fermented tela is 0 .979kg/L, so the mass of accumulation (Ma) is
given by
Ma = Va * ρ a
Ma = 6376.16L * 0.979kg/L
Ma = 6,242.6kg of accumulation
Assume: There is no generation, the fermentation tank is cylindrical, disappearance and
Consumption of mass, but there is accumulation of mass.
Mass in = Mass out + Accumulation
Mass out = Mass in - Accumulation (A)
Mft = (DM + PY) - MA
Mft = (210,520Kg + 37,971.68) kg – 6,242.6kg
Mft = 242,249.08kg of fermented tela (wine) are produced and transported in to decanter.
The amount of raw material used for yeast propagation and fermentation is summarized in the
table below.
Reactor Volume(L) Input
Molasses(Kg) DAP Urea Yeast H2SO4 Water Air
(Kg) (Kg) (Kg) (L) (L) (m3/h)
yeast 45,000 6264 8 8 8 2 31,680
propagator
Fermenter 230,000 66,120 - - - - 144,400
Table 4.2 the generalized amount of raw material used for fermentation in Rorank SC
4.7.2 Process Efficiencies and Yields

There are a number of ways to determine operational efficiency and yield in a distillery.
According to the South Africa Sugar Manufacturers Association, the four commonly used
measures of yield are fermentation yield, fermentation efficiency, alcohol recovery and overall
conversion efficiency

Fermentation yield
Fermentation yield is measured in liters of absolute alcohol in the fermented mash or beer per ton
of sugars in molasses, and is calculated by the formula below
Yf
Where: Yf= fermentation yield,

Vb = volume of beer [liter]
Ab = alcohol content of beer (v/v)
M = mass of molasses [in tonne] and
Sm = fermentable sugars content of molasses (m/m)
Once we have mass of fermented beer or tela which is 242,249.08kg we can calculate volume of
beer using the formula below
ρb = Mb/Vb so Vb= Mb/ρb where Mb = mass of fermented beer, ρb = density of beer. And
density of beer (ρb) is given by;
1/ ρb = (Xw/ρw) + (Xa/ρa) where Xw is fraction of water in beer, Xa is fraction of alcohol in
beer, ρw is density of water (ρw=1kg/L), ρa is density of ethanol (ρa = 0.789). Since the alcohol
concentration of the beer is 8%. Therefore Xw = 0.92 and Xa = 0.08
1/ ρb = (0.92/1) + (0.08/0.789)
ρb = 0.979kg/L now we can calculate volume of beer
Vb = Mb/ρb = 242,249.08kg/0.979kg/L
Vb = 247,445.4L.
Mass of molasses is the sum of molasses used for yeast propagation and for fermentation
M = 6264kg +66,120kg
M= 72,384kg = 72.384tonne.
Fermentable sugar content of molasses is 50% and alcohol content of the beer is 8%. So now we
can calculate fermentation yield by using equation 1 since all the information are available.
Yf = 247,445.4L*0.08/72.384tonne*0.5
Yf = 547L/tonne. It means that 547 litter of beer or tela is produced from one tonne of molasses.
Fermentation efficiency

Fermentation efficiency is an expression of how much alcohol was actually produced in beer
relative to the amount that could be theoretically produced, and is given by
*100
The factor 0.794 corresponds to the specific gravity of absolute alcohol and the factor 0.5111 is
best explained as follows: according to Gay-Lussac equation, if one kilogram of sugar was
completely fermented (using theoretical 100% efficient yeast); 511.1 grams of alcohol and 1000
- 511.1 = 488.9 grams of carbon dioxide would result (Prescott et al, 1949; Paturau, 1969).or
from the reaction below the amount of theoretically produced alcohol is determined.
C₆H1₂O₆ + Yeast 2C₂H₅OH + 2CO2

Theoretical productivity = molecular mass of product/molecular mass of substrate
Yp/s = Mw of two mole of ethanol/Mw of glucose
Yp/s = 2*46/180 = 0.5111 from this we conclude that from 1000gram substrate it is possible to
produce 511.1gram alcohol and 488.9 gram carbon di-oxide. Thus fermentation efficiency will
be
Ef = * 100
Ef = 84.99%.
However, Pasteur (1857) demonstrated through a series of experiments that the optimum yield to
be expected would be as follows, expressed as a percentage of sugar fermented Table 4.2
Expected fermentation yield, Pasture (1850s)
Table 4-0-2 expected fermentation yield
Substance % by weight
Ethyl alcohol 48.4
Carbon dioxide 46.6
Glycerol 3.3
Succinic acid 0.6
Cellulose, etc. 1.2

The above value of 48.4% ethyl alcohol obtained by Pasteur represents about 94.85% of the
theoretical 51.11% of Gay-Lunacy. Therefore, the actual fermentation efficiency is greater than
the fermentation efficiency based on theoretical alcohol yield and can be calculated from the
formula below;
Ef = *100
Ef = *100
Ef = 89.7%
4.8 Equipment used

Pumps: - Gear pump- used to pump the highly viscous molasses from storage in to a shell and
tube heat exchanger.
- Centrifugal pump: - used to pump propagated wine and high brix in to holding tanks
and then to fermentation tanks.
 Mixer (Agitator): - used to mix molasses and dilution water as they flow in together.
 Propagation tank (propagator):- it is a tank where the propagation takes place. Has a
volume of 43,000 liters.
 High brix tanks: - used to contain high brix molasses.
 Fermentation tank: - are tanks where the high and low brix molasses are brought together
to start the fermentation. There are five fermentation tanks.
 Air Blower: - used to blow air into the bottom of propagation tank and holding tanks.
 Saccharometer: - used to measure the sugar content of the solution.
 Ebullio meter: - used to measure the alcohol content of fermented wine.
 PH meter used to measure acidity of the medium
 Valves: - to control the flow and pressure during transportation

CHAPTER FIVE
5 DISTILLERY HOUSE
5.1 Introduction
Distillation is the most important technical process for the separation of liquid or gaseous
mixture in to different component. And its principle depends on thermodynamic property of the
mixture. The aim of distillation process is the separation of component from its mixture and this
process to happen there must be boiling point (volatility) difference between the components of
the mixture, if no they will form azetrope.
Distillation is used for the separation or purification of mixtures of alcohol and water by using
the different evaporation rates, or boiling points, of the water and the alcohol. As alcohol
evaporates at a lower temperature, it vaporizes first and, therefore, its separation will start before
the water evaporates.
Distillation does not produce alcohol; it is merely a separating or refining process. Alcohol is
created through fermentation. Therefore, prior to distillation there must have a base product
which already contains alcohol at this firm base product is fermented wash. The distillation of an
alcoholic base product produces spirit.
The fermented mash (tela) may contain a number of other components such as essential oils,
esters, carbon dioxide and other alcohols such as methyl, propyl, butyl and amyl. All of these
components are undesirable or undrinkable and must be substantially removed from the mixture.
This process involves dividing tela into a number of parts depending on when that part is
produced during the distillation process. These parts may be separated during the initial
distillation process or during a re-distillation of alcohols by diluting with pure water (spirits from
the first distillation run). Rorank SC has special distillation columns like degasifying, analyzer,
aldehyde, extractive distillation, stainless steel, copper and methanol column to undergo
distillation and re-distillation process in order to remove such impurities and to have very pure
potable alcohol. The first components that are produced during distillation are known as heads.
Heads are the highly volatile components with a lower boiling point than ethanol. The heads
vaporize first and therefore condense first. Heads consist mainly of low molecular weight

material or highly volatile compounds. Heads may contain a number of poisonous components,
including high levels of methanol, which can be hazardous to health. Usually, the heads are not
desired in the finished product and are run to a different receiver from the rest of the alcohol.
Once all the heads have been removed the pure alcohol transferred in to pure alcohol storage
tank.
5.2. Types of equipment

In distillery house there are different types of equipment‟s these are:-
I. Distillation tower
There is no distillation process without distillation tower. Distillation tower has two parts
 The upper part or rectifying section

 Lower par or stripping section
Basically distillation columns divided in to two these are:
1 tray type column

Tray column utilize a pressure and temperature differential to separate the product. For most tray
columns, the weir holds liquid level of each tray liquids enters from the down comer of the tray
above. The vapor must overcome this liquid head to move up the column. On the tray the vapor
and liquid are contacted become bubble or froth where the mass transfer takes place and then
above the tray they are separated where froth flows over the out let weir and vapor with the light
volatile compound is disengaged.
Tray column performs well in high liquid and vapor holding. Tray have higher pressure drop
than packed, and it also have high resistance to corrosion. There are three major types of tray
column.
a) Bubble cup tray

A bubble cap tray is perforated flat which has a riser (chimney) for each hole cover with a cap
mounted. Usually equipped with slots to allow the passage of vapor then the vapor will contact
with liquid forming bubble on the next tray. It is able to operate at low vapor and liquid rates.
Bubble cap tray has high pressure drop and it costs is maximum for new installation. Bubble

trays are capable of dealing with very low liquid rates and are therefore useful for operation at
low reflux ratios.
b) Sieve deck tray

Sieve deck tray is perforated plate with holes punched into the plate usually has hole 3/16 in to 1
in diameter. Vapor comes out from the holes to give a multi orifice effect. The vapor velocity
keeps the liquid from flowing down through the holes (weeping). The number and hole size are
based on vapor flow up he tower. The liquid flow is transported down the tower by down-
comers, a dam and overflow device on the side on the plate. Sieve deck tray has a minimum
capacity approximately 70%. And they are cheap and simple.
c) Valve tray
Valve tray is using valve which is rise as vapor rate increases and then reduces as vapor rate
fails, this stop the liquid from weeping. Valve can be round or rectangular, with minimum
capacity approximately 60%.
2 Packed columns
The other type of column is packed type of distillation column. Packed column utilizes packing
to contact between the phases (liquid-vapor) on the surface. Packed column performs well at low
pressure; low liquid and low vapor loading that make packed column have the most efficient in
these terms. At high flow parameters the capacity and efficiency can significantly reduce, also in
heavy fouling application and corrosive condition. Packed column has less pressure drop than
tray column and it reduces foaming since it generates thin film instead of fine droplets for mass
and heat transfer. Packed column is divided by random, structured and grid packed columns
which is generate a mass transfer area by providing a large surface area over (50%) which the
liquid can transfer heat and mass to the vapor.
a) Random packed column

Random packing is packing of specific geometrical shapes which are dumped into the tower and
oriented themselves randomly. Random packing has more risk than structured packing and less
ability to handle mal-distributed water.
b) Structured packed column

Structured packed column is crimped layer or corrugated sheets which is stacked in the column.
Each layer is oriented at 70o to 90o the layer below. Structured packed offers 30% capacities
higher than random packed for equal efficiency up to 50% higher at the same capacity.
c) Grid packed column

Grid packed column is symmetrically arranged packing use an open-lattice structure. These
devices are composed of panel that promotes mass transfer and enhance entrainment removal.
They have high open area, resulting in high capacity, low pressure drop, and high tolerance to
fouling.
N.B. there is only one tray column analyzing column) and the rest are packed column.
II. Heat exchanger, Condenser, and Re-boiler

 The purpose of heat exchanger is to cool down the hot liquid
 The purpose of condenser to cool down the vapor. And we can recycle back some of the
vapor to the column. In this plant the type of condenser is shell and tube.
 Re-boiler is used as heat exchanger and the difference from other heat exchanger we create
steam from the cold feed, in our case 8% ED product and the steam will condense goes back
to steam plant.
III. Steam trap

It used to trap steam from 8% hot alcohol liquid that comes from the re-boiler.
IV. Tank
There are basically two type of tank these are decantation tank and storage tank Decantation tank
used to store fermented tela until the sludge separate from its wine. And it used to store
fermented tela. Storage tank used to store liquid like; katikala (raw alcohol), pure alcohol
denature alcohol and so on.
V. Valves
Valves are used to control flow rate of tela, raw alcohol, steam, cooling water and etc. in this
plant basically there are four types valve, and these are:

Gate valve: the gate valve is a general service valve used primarily for on-off, non-throttling
service. The valve is closed by a flat face, vertical disc, or gate that slides down through the
valve to block the flow. Gate valves working by inserting a dam (“gate”) in to the path of the
flow to restrict it, in a manner similar to the action of a sliding door. Gate valves are more often
used for on/off control than throttling.
Butterfly valve: is a valve which can be used for isolating or regulating flow. The closing
mechanism takes the form of the disk.
Check valve: check valves are two port valves, meaning they have two opening in the body, one
for fluid to enter, and the other for fluid to leave. Check valve allows the fluids to pass in one
direction only. Although they are available in a wide range of sizes and costs, check valves
generally are very small, simple, or inexpensive. Check valves works automatically and most are
not controlled by a person or any external control; accordingly, most do not have any valve
handle or stem. The important concept in check valve is the cracking pressure which is the
minimum upstream at which the valve will operate.
VI Sensors
The function of sensor is to detect the change in the required parameter. The parameter which is
controlled by this device in distillation house is temperature.
VII Flow meter and pressure gauge

Flow meter is used to read flow rate of liquids (i.e. tela, katikala, water to ED and pure alcohol)
and pressure gauge used to read the steam pressure also used to measure the pressure of fluids.
VII Alcoholmeter
Alcoholmeter is used to measure the grade quality of alcohol or concentration in the mixture.
5.3. Process description

In Rorank SC alcoholic liquor factory the production of pure alcohol starts at decantation tank.
And for clarity it is better to separate the process in to two, these are:
 First stage, in which katikala produced from fermented tela. In this stage there
are three columns, these are; degasifying column, analyzing column and
aldehyde column.
 Second stage, in this stage the process is the production of pure alcohol from
katikala, in this stage process pass through four column and these are;
extractive distillation column, stainless steel column, copper column and
methanol column.
5.3.1. Frist stage process

5.3.1.1 Decantation
The first stage process starts at decantation tank. In the decantation tank the fermented tela that
comes from fermentation house store in it. As we said in the equipment description part of this
report, the purpose of decanter tank not only storage of tela but also used as a separation of wine
from its sludge. The separation process takes place due to gravitational force. And in actual case
the time required for the separation is about 24 hour.
Figure 5.1 decantation tank

After decantation process takes place, the separated tela will heated around 70-80oc by passing
through copper main condenser shell side to condense the vapor coming from the copper
columns, which is in tube side. And if the tela attain the temperature in between 70-80oc it
introduced in to degasifying column, unless it is heated by spent wash that comes from analyzing
column then return back and enters in to degasifying one. And the type of heat exchanger is
plate.
5.3.1.2. Degasifying column

Degasification is the removal of dissolved gases from liquids. The heated tela from the heat
exchanger transported through flow meter to degasifying column, the degasing capacity is about

15,000 lit per hour, but the factory don‟t work always with this flow rate i.e. the working flow
rate of degasifying column depend on different factor like weather and steam generation
capacity, tela concentration in decanter tank and the market demand.
Degasifying column used to remove chemical which has smell and chemicals which can‟t
condense easily like carbon dioxide (co2). Degasifying column operated by feed temperature i.e.
there is no heat (steam) addition. Alcohol feed concentration is around 8-12% and the rest is
more water and the mixture boiling point is near to water boiling point temperature. So at this
feed temperature, unwanted chemicals will escape through degasing vent line.
The degasing vapor products will pass through heat exchanger to cool down and the condensed
chemicals store in degasing head storage and the un-condensed vapor will released as a degasing
vent. The degasified tela leaves from the bottom of this column send to analyzer column by
making a loop. In this factory degasing head flow rate around 5 liters per hour and degasing vent
temperature is 20-26oc.
N.B. since there is no flow meter and concentration sensor around degasing vent line, so we
don‟t know its flow rate or concentration.
5.3.1.3 Analyzing column

It consists of a series of metal plates with hole punched in them and baffles to control the liquid
levels on the plates. The analyzer column operated under a temperature of 88-900c and pressure
of 180-300 mbar.
It is a tray type distillation column which contain sieve tray with two down comers in one side.
Since there might be a scale formation in this column tray type is preferable rather than packed
type. In the fermentation process there is a formation of caso4 from the addition of sulphuric acid
in the molasses which contain calcium ion. This calcium sulphate forms a scale when heat is
supplied in the analyzer column.
The degasified tela introduced from side of this column falls through the down comers by gravity
from one tray to another. Heat in the form of steam supplied to the base of the column and rises
via the openings on each tray. As the steam passes through the feed on the tray, it transfers heat

to the feed. Because of the heat input from the steam the liquid on the tray boils generating vapor
which is richer in the more volatile component.
The continuous contacting between steam and liquid occurs on each tray brings about the
separation between alcoholic component with low boiling point and the spent wash(nonalcoholic
component)with higher boiling point. Some amount of alcohol together with steam might leave
with spent wash.
In order to trap these steam the spent wash water is send to 6 meter underground with larger tube
and hits the ground this made the steam to be released and send to the lower side of the analyzing
column through the pipe. Steam free spent wash water returned with a narrower tube with
increased pressure to preheat the fermented wine. The increased pressure reduces the fouling
formation in the plate heat exchanger. The vapor leaves through the top of analyzing Column
with improved alcoholic grade is sent to aldehyde for further purification.
If there is an alcohol in the spent wash this might be caused by sufficient steam is not supplied or
excessive fermented wash is supplied to the column.
Pressure might increase at the base of the column due to:-

 Excessive steam due to sudden increase in the boiler steam
pressure
 Failure of pressure reducing valve
 Scale build up on the trays
The other problem shown in this column is flooding. Which occurs as the vapor flow is higher
compared to liquid flow so liquid is unable to comes down through down comers and also by
simultaneous increase of bottom pressure and the decrease of top pressure due to abnormal liquid
buildup of scale on tray and the feed rate is more than vapor flow rate.
Analyzer column is designed to handle a dirty liquid liable to foam and is fitted with man doors
for cleaning purposes.

5.3.1.4 Aldehyde column

Aldehyde column is the last tower in the first stage process, and in this process our desire is to
produce raw alcohol (katikala). It is a packed type column operates under a temperature of 74-
760c and a pressure of 100mbar. It is used to separate highly volatile low boiling point
components.
The vapor which leaves the analyzer column enters in to lower side of the aldehyde column. The
more volatile component rises into the overhead two consecutive heat exchangers.
The vapors which do not condense in the first pass to the next heat exchanger. The non-
condensing gas leaves off as a T5 vent from the last heat exchanger. The condensing vapor in the
two heat exchangers Aldehyde heads 1, amounting to about 100L/h, is drawn off from the two
heat exchanger reflux loop and refluxed back to the column. The raw alcohol portion of the feed
tends to go down the column.
The product coming from this column is called raw alcohols (katikala) with alcohol grade 35-
50%v/v. It passes through plate type heat exchanger to be cooled and stored in the shift tanker.
5.3.2. Second stage process

In this stage the raw alcohol (katikala) produced in the first stage purified more to produce
alcohol with > 96.3% alcohol grade.
5.3.2.1 Extractive distillation (ED) column

Extractive distillation is a distillation in the presence of a miscible high boiling point relatively
non-volatile component, the solvent that forms no azoetrope with the other components in the
mixture. It used for mixtures having a low value of relative volatility, nearing unity. It uses a
separation solvent, which is generally non-volatile, has a high boiling point and is miscible with
the mixture, but doesn‟t form an azeotropic mixture.
The solvent interact differently with the components of the mixture there by causing their
relative volatilities to change. Extractive distillation column is a packed type column operated at
a temperature of 132-137oc and a pressure of 2.8-3 bars. The raw alcohol which stored in a shift
tanker pumped and preheated by heat exchanger passes through the flow meter and fed into ED
column. Hot water comes from stainless steel rectification column which used as a solvent
passes through heat exchanger. It enters into the column at some height above the raw alcohol
for showering purpose. Steam comes from the re-boiler introduced into the lower side of the
column. It used to separate a high boiling component from the non-volatile. The component with
the greatest volatility separates out as the top and enters into the condenser. The vapor with a
temperature of 132-1370c condenses by the water from the stainless steel column (T=70oc), then
the water recycled back to the stainless steel column as re-boiler.
Head3 is collected 100L/h from the condenser then pass through heat exchanger and stored in the
tanker. The rest refluxed back to the top side of the column near the hot water. The bottom
product consists of a mixture of the solvent and the other component that is 6-8%v/v diluted
alcohol, which can again be separated easily because the solvent doesn‟t form an azeotrope with
it. The diluted alcohol enters into the re-boiler and passes through the steam trap. The steam trap
holds the steam and allows the condensate to be discharged then pass through the Heat
exchanger. Both the raw alcohol from the shift tanker and the hot water from the stainless steel
column preheated by the 6-8%v/v diluted alcohol in the heat exchanger. The diluted alcohol
enters into stainless steel rectification column.
5.3.2.2. Stripping section (stainless steel column)

The stripping section and the rectifying section can be built as a single vertical column. However
in order to make the total height shorter the two section built side by side interconnected with
tubing to return the output of the stripping unit to the rectifying section and vice versa. But it
requires a pump to lift liquid from the bottom of the second column to the top of the first. It is a
packed type distillation column with operating temperature of 75-82oc and pressure of 250-450
mbar. The main objective of this column is to remove much of the water contained in the feed
and it also separate light and fusel oil from the alcohol mixture. The diluted alcohol feed below
light and fusel oil extraction point and steam entering at the base. The steam separates the more
volatile alcohol from the water. The more volatile component rises up to the column and the
alcohol free water (lease water) withdraws at the bottom. The lease water is send to 6 meter
underground same as analyzer column in order to trap some amount of vapor containing with
trace amount of alcohol. And it passes through the heat exchanger to preheat the boiler feed.

The light oil (ethyl acetate) and fusel oil (amyl alcohol) extracted at the top sides of the column
and collected each 40L/h with alcohol grade 70%v/v. The main product stream of this column is
the top vapor product and it is feed line for the next column i.e. copper column.
5.3.2.3. Rectification section (copper column)

As the vapor moves out of the stripper, the rectifying section increases the alcohol concentration
by allowing the vapor flow to move up the column against some of the final liquid product flow
(reflux) moving down. This column operates under a temperature of 72-74oc and a pressure of
250-450mbar.It used to upgrade the concentration of more volatile component and it also used to
separate methanol from the mixture.
In this column the latent heat available increases the alcohol concentration as the vapor rise.
Vapor leaving from the top of the column feed in to the main condenser to condense and the rest
which couldn‟t condense in the main condenser passes through vent condenser for further
condensation to prevent vapor loss.
The incoming water from the cooling tower used as a cooling fluid in the condenser. Then vapor
which couldn‟t condense in the two condensers released to atmosphere as vent. Then 40l\hr. of
heads 2 main and 40l\hr. heads 2 vents is collected from the reflux loop and collected in a
denature tank after passing through heat exchanger, while large fraction refluxed(re-circulated)
into the top of the column to control the final concentration of the product output. This reflux
flow is required to produce a down ward flowing liquid stream in the section of the column.
Without the reflux stream, there can be liquid in the rectifying section of the column, which
means no separation would occur in the rectifying section. The condensate with low grade of
alcohol pumped from the lower side of this column to the upper side of stripping column by feint
pump to strengthen its alcoholic content. The product coming from this column transported in to
methanol column.
The upper part of the column is made up of copper. Copper is preferable because it improve the
quality and taste of the alcohol by reacting with sulphate ion and form copper sulphate.

5.3.2.4 Methanol column

It is a packed type column operate under a temperature of 68-70oc and pressure of 300-400mbar.
And it is used to separate methanol from the product since it is hazardous to health during
drinking. Methanol causes eye defect unless it is separated and removed from the produced
alcohol. Unlike the other columns the heat (steam) don‟t supplied directly but it gains indirectly
by using shell and tube heat exchanger. The alcohol coming from copper column enters in tube
side and steam in shell side then the heated alcohol enters in to methanol column.
The more volatile component (methanol) rise in to the overhead two consecutive heat
exchangers. The vapors which do not condense in the first heat exchanger pass to the next one.
The non-condensing gas leaves off as a methanol vent from the last heat exchanger. The
condensing vapor in the two heat exchangers methanol head, amounting about 100 liters per
hour, is drawn off from the two heat exchanger reflux loop and refluxed back to the column.
The product coming from this column which is pure alcohol having 96.8%v\v alcohol grade
collected at the lower side of the column and stored in pure alcohol storage tank. The following
table shows operating temperature and pressure range
Table 5-0-1 operating temperature and pressure of each columns
Column type Operating temperature (oc) Operating pressure

Degasing By feed temperature (70-80) -
Analyzer 88-90 0.18-0.3
Aldehyde 74-76 -
Extractive distillation 132-137 2.8-3
Stainless steel 75-82 0.25-0.45
Copper 72-74 -
Methanol 68-70 0.2-0.4
Roranc SC alcohol and liquor do not only produce pure alcohol but also denature alcohol.
Denature alcohol production start at extractive distillation tower and end in methanol column.

The feed material for this process are aldehyde heads product i.e. head one, ED condenser head
i.e. heads three, light oil, and fusel oil. The copper‟s condensers heads product i.e. main head and
vent head store as denature alcohol in denature storage tank.
5.4. Distillation column control

A continuous distillation unit separates a feed material containing several volatile components
into a distillate product and bottom product. Certain limits are usually set on concentration of key
materials in the distillates and in the bottoms and the equipment usually must handle a set
amount of feed per unit time. These specifications set the values of the following variables in the
distillation operation.
 The feed rate
 The distillate composition
 The bottom composition
 The rate of distillate product
 The rate of bottom product
There are two crucial variables which the operator can control to obtain the desired operating
Condition. These are:-
 The reflux ratio
 Amount of heat input to the column.
The Other factors affecting the overall operation of the unit are:-
 Temperature of the feed
 The temperature of the reflux returned to the column and
 The location of the feed plate.
5.5 Process flow diagram


Where;
Equipment
 DG.C…………………………………………..Degasifying column
 AN.C…………………………………………..Analyzer column
 AL.C……………………………………… …..Aldehyde column
 DC.T……………………………………………Decantation tank
 K.T……………………………………………...Katikala tank
 ED.C……………………………………………Extractive distillation column
 SS.C……………………………………………Stainless steel column
 CU.C…………………………………………...Copper column
 R………………………………………………..Reboiler
 M.C…………………………………………….Main condenser
 V.C……………………………………………..Vent condenser
 C1………………………………………………ED column condenser
Lines
 T……………………………………………....tela line
 S……………………………………………...steam line
 K……………………………………………...katikala line
 H1…………………………………………….head one line
 Ad.vent………………………………………Aldehyde vent line
 Deg.H………………………………………..degasifying head line
 Deg.vent……………………………………..degasifying vent line
 PD……………………………………………from degasifying to analyzer
 PA……………………………………………from analyzer to aldehyde
 S.S……………………………………………stainless steel line
 L.W…………………………………………..lease water line
 P……………………………………………..pure alcohol line
 H.M………………………………………….heads main line
 H.V………………………………………….heads vent line
 H3……………………………………………head three (ED condenser head)
 L.O…………………………………………..Light oil
 F.O………………………………………….Fusel oil
 S.pr…………………………………………stainless column product
 ED.pr……………………………………….ED column product line
 W…………………………………………….Water to ED column line

5.6 Calculations
5.6.1. Material balance
For simplicity we divide distillation column in to two stages
 Stage one: from decantation till katikala production
 Stage two: the production of pure alcohol from katikala
N.B. the basic assumption in our calculation is ignoring all vent flow rate.
Known data
Flow type Flow rate (litter Alcohol conc. in
per hour) it(% )
Tela(Ftela) 15,000 8
Degasing head (Fdeg.head) 5 65
Katikala from aldehyde(FK1) - 55
Head one (H1) 100 95
Spent wash(Fspent wash) - 0
Lease water(Flease water) - 0
Hot water to ED(FW) - 0
Katikala to ED(FK2) 2000 55
ED bottoms product(FEd) - 8
Head three(FH3) 100 70
Light oil(FLO) 50 70
Fusel oil(FFO) 50 70
Copper Heads main(FHM) 50 95
Copper Heads vent(FHV) 50 95
Methanol head(FMH) 50 97
Alcohol from copper column(FPC) - -
Pure alcohol from methanol - 96.3
column (Fp)

5.6.1.1. Material balance on the first stage

 Material balance on all columns.
Deg.vent Ad.vent
Fdeg.head FH1
DG.C AN.C AL.C

Ftela FPD FPA FK1
Fsteam Fspent
For overall material balance

Input =out
Ftela + Fsteam = FK1 + FH1 + Fdeg.head +Fdeg.vent + FAd.vent + Fspent wash………………………….1
Component balance for ethanol
Xtela Ftela = XK1FK1 + XH1FH1 + Xdeg.headFdeg.head + Xdeg.ventFdeg.vent + XAd.ventFAD.vent + Xspet washFspent
wash………………………………………………………………………………………………2
By assuming, there is no ethanol concentration in the spent wash and if we ignore all vent flow
rate, the above two equation will reduce to the following two equation.
Ftela + Fsteam = FK1 + FH1 + Fdeg.head + Fspent wash………………………………………………….3
And, component balances for ethanol. Since there is no ethanol on steam and spent wash the
equations become;
XtelaFtela = XK1FK1 + XH1FH1 + Xdeg.headFdeg.head………………………………………………….4
Thus using equation 4 we can calculate flow rate of katikala from aldehyde column to katikala
tank.
0.08*15,000 = 0.55*FK1 + 0.95*100 +0.65*5
FK1 = 2003.2 liters/hr.
N.B It is necessary to convert all volumetric flow rate in to mass flow rate basis by using the
formula below. Since energy balance can be done using mass flow rate.

Density =mass flow rate/ volumetric flow rate

Mass flow rate of mixture =density of density of mixture*volumetric flow rate of mixture
1/ρk1 = Xw/ρw +Xa/ρa where ρk1 =density of katikala
Xw= fraction of water

Xk1=fraction of alcohol
ρw =density of water
ρa =density of alcohol
1/ ρk1=0.45/1+0.55/0.789
ρk1= 0.87 Kg/L
Thus MK1= ρk1*FK1
MK1= 0.87*2003.2
MK1=1742.78 Kg/hr.
 Material balance on each column of the first stage

I on degasing column Fdeg.vent
DG.C Fdeg.head =5 L/hr.

Ftela =15,000 L/hr.
FP.D
Once we have flow rate of feed tela and degasing head flow rate we can find their mass flow rate
and analyzer feed mass flow rate or degasing output mass flow rate (MP.D).
 Change the volumetric flow rate into mass flow rate
Mass flow rate of fermented tela
Mtela=Ftela*ρtela
ρtela (density of fermented tela) is given by
1/ρtela= Xw/ρw +Xa/ρa
=0.92/1kg/L +0.08/0.789kg/L
ρtela=0.979kg/L
Mtela=15,000L/h*0.979Kg
Mtela=14,685Kg/h

Mass flow rate of degasifying head (Mdeg.head)
Mdeg.head = ρdeg.head*Fdeg.head
Density of degasifying head (ρdeg.head) is given by
1/ρdeg.head = Xw/ρw +Xa/ρa
Degasifying head contains 65% of alcohol and 35% of water. Thus Xw=0.35 and Xa=0.65
1/ρdeg.head =0.35/1Kg/L +0.65/0.789Kg/L
ρdeg.head=0.85Kg/L
Mdeg.head=5L/h*0.84Kg/L
Mdeg.head =4.25Kg/h
Where; Mdeg.head is the mass flow rate of degasifying head.
ρdeg.head is density of degasifying head.

ρw is density of water.
ρa is density of alcohol
Therefore the material balance in a degasifying column is calculated as shown below

Mdeg.vent
DG.C
Mtela=14,685kg/hr. Mdeg.head=4.25kg/hr.
Degasifying output mass flow rate (MPD) =?
Assuming steady state overall mass balance

Mass in = mass out
Mtela =Mdeg.head +Mdeg.vent + MPD by ignoring Mdeg.vent
MPD =14,685kg/hr. - 4.25kg/hr.
MPD = 14,680.75kg/hr. this much amount of degasified tela feed to analyzer column.
Component balance to calculate concentration of degasified tela
Xtela*Mtela = Xdeg.head*Mdeg.head +MPD*XPD
XPD = (Xtela*Mtela –Xdeg.head*Mdeg.head)/MPD

XPD = (0.08*14,685 – 0.65*4.25)/14,680.75

XPD = 0.0798 ≈ 0.08
II on analyzer column and aldehyde column
The degasified tela which leave from the degasifying column and entered into the analyzer
column in a mass flow rate of 14,680.75Kg/hr. consequently the vapor which leaves from the
analyzer entered into Aldehyde column. The aldehyde head leaves with the flow rate of 50 L/h
and also spent wash (vinasses) are removed as by product as shown below.
FH1 = 100L/h
MPD=14,680.75kg/hr. AN.C AD.C MH1=?
Mspent wash =? MK1 =1742.78kg/hr.

Change the volumetric flow rate of aldehyde head into mass flow rate. So as to do this first find
the density of aldehyde head (ρH1)
1/ρH1 = Xa/ρa *Xw/ρw
Aldehyde contain alcohol 95% alcohol and 5% .Thus Xw =0.05 and Xa =0.95
1/ρH1 = 0.95/0.789 (kg/L) + 0.05/1(kg/L)
ρH1 = 0.80kg/L
Density of aldehyde alcohol and volume flow rate of aldehyde is 100L/h
ṀH1 = FH1 *ρH1
ṀH1 = 100L/h * 0.80kg/L
ṀH1 =80Kg/h
Over all mass balance by assuming steady state and ignoring aldehyde vent mass flow rate.
Mass in =Mass out
MPD =Mspent wash + MK1 + MH1
Mspent wash = 14,680.75kg/hr – 1742.78kg/hr – 80kg/hr.
Mspent wash = 12,857.97kg/hr.

Since we have determined spent wash mass flow rate (Mspent.wash) and feed mass flow rate of
analyzing column (MPD) we can evaluate analyzing head product mass flow rate (MPA) by
employing material balance on analyzer column only.
Mass in = mass out
MPD = 14,680.75kg/hr AN.C MPA =?
Mspent wash = 12,857.97kg/hr

Thus MPD = MPA + Mspent wash
MPA = 14,680.75kg/hr – 12,857.97kg/hr
MPA = 1822.78kg/hr.
Component balance to calculate concentration of analyzer top product
XPDMPD = XPAMPA + Xspent.washMspent wash assume there is no alcohol spent wash
(Xspentwash=0) and
XPA = XPDMPD/ MPA
XPA = 0.0798*14,680.75/1822.78
XPA = 0.64
5.6.1.2 Material balance on the second stage

 Material balance on the total process
ED head (FH3) FLO FFO FHM FHV FMH
Hot water (Fw)

Katikala (FK2) ED.C SS.C CU.C MT.C
Lease water (FLW) pure alcohol (FP)

So the material balance will be as follow;

FK2 + FW = FLW+ FP+FHM+FHV+FLO+FFO+FH3+ FMH +Fcopper vent + Fmetanol vent

If we ignore copper and methanol vent the above equation become
FK2 + FW = FLW+FP+FHM+FHV+FLO+FFO+FH3+FMH assume no ethanol on lease water
XK2FK2 =XPFP+XHMFHM+XHVFHV+XLOFLO+XFOFFO+XH3FH3+XMHFMH
Thus using the above equation we can determine pure alcohol flow rate then convert in to its
appropriate mass flow rate
0.55*2000 = 0.963*FP +0.95*50+0.95*50+0.7*100+0.7*50+0.7*50+0.97*50
FP=816.5L/hr.
Mass flow rate of pure alcohol (MP) can be calculated as follows
MP = ρp*FP
But density of pure alcohol is
1/ρP = Xw/ρw + Xa/ρa
Pure alcohol contains 96.3% of alcohol and 3.6% of water. Thus Xw=0.0360 and Xa=0.963
= (0.036/1) + (0.963/0.789)
ρP = 0.796kg/L therefore mass flow rate of pure alcohol becomes
MP = 0.796kg/L*816.5L/hr.
MP = 650kg/hr. This much amount of alcohol is cultivated from the last (methanol) column
 Material balance on each column
I Material balance on ED
Katikala alcohol entered into the extraction distillation column in a volumetric flow rate of
2000L/h within unknown flow rate of water to produce dilute alcohol and 100L/h of head 3.
Hot water (Fw) ED head (FH3) = 100L/hr.

ED.C
Katikala (Fk2) = 2000L/hr.
ED bottom product (FED) =?

Once we have flow rate of feed katikala, and ED head flow rate we can find their mass flow rate
and ED bottom product mass flow rate or diluted alcohol mass flow rate (MED).


Mass flow rate of katikala feed in to ED column
MK2 = FK2 + ρK2
But ρK2 (density of katikala) is given by;
1/ρK2 = (Xw/ρw) + (Xa/ρa) since it is calculated before ρk2 = 0.87kg/l. Thus
MK2 = 2000L/hr * 0.87kg/l
MK2 = 1740kg/hr.
Mass flow rate of ED head (MH3)
MH3 =ρ H3FH3
Density of ED head (ρH3) is calculated as
1/ρH3 = Xw/ρw + Xa/ρa
ED head contains 70% of alcohol and 30% of water. Thus Xw=0.30 and Xa=0.70
= 0.30/1 – 0.7/0.789
ρH3 = 0.84kg/l
MH3 = 0.84kg/l* 100L/hr.
MH3 = 84kg/hr.
Once we determined the mass flow rate now we can employ mass balance
Mw=? MH3 = 84 kg/hr.

ED.C
MK2 =1740kg/hr.
MED =?
Assume steady state operation
Overall material balance
Min = M out
MK2+Mw = MED+MH3
MED=MK2+Mw - MH3
MED=1740kg/h +Mw -84kg/h …………………………………………………………. (1)

XEDMED =XK2MK2 + XwMw – XH3MH3 since there is no ethanol in hot water XwMw = 0
0.08*MED =0.55*1740kg/hr – 0.7*84kg/hr……………………………………………… (2)
MED =11,227.5kg/hr
Now by using equation 1 we can determine mass flow rate of water
Mw = MED – 1740kg/hr+84kg/hr
Mw=11,227.5kg/hr -1740kg/hr +84kg/hr
Mw =9,571.5kg/hr this much amount of hot water is needed to extract ethanol from the
mixture and produce diluted alcohol with concentration of 8%.
II material balance on methanol column
Since number of unknown is less than number of equation in this column. First by calculating the
unknown we can proceed to the other column.
Material balance on this column
Product line from copper FMH=50L/hr

MT.C
MPC =?
MP =650kg/hr
 Change the volumetric flow rate of methanol head (FMH)into mass flow rate(MMH)
MMH = ρMH*MMH
But density of methanol head (ρMH) can be evaluated as
1/ ρMH = (Xw/ ρw) +Xa/ ρa
Methanol head contains 97% of alcohol and 3% of water. Thus Xw=0.030 and Xa=0.97
= 0.03/1 + 0.97/0.789
ρMH = 0.793kg/l
MMH = 0.793kg/L* 50L/hr.
MMH = 39.65kg/hr.
By assuming steady state operation do mass balance
Mass in = mass out
MPC = MMH + MP
MPC =39.65kg/hr + 650kg/hr.
MPC =689.65kg/hr
XPC*MPC = XMH*MMH+ XPMP
XPC*689.65 = 0.97*39.65kg/hr + 0.963*650kg/hr.
XPC =0.963 hence the concentration of alcohol coming out from copper column is about
96.3%.
III material balance copper column
Once we determined the copper product mass flow rate we can determine the feed (stainless steel
product) mass flow rate. Before going to mass balance first convert the flow rate of copper main
and vent head in to its corresponding mass flow rate.
Volumetric flow rate of copper main head (FHM) is 50L/h and its mass flow rate (MHM)
calculated as
MHM = ρHM*FHM
But density of copper main head (ρMH) can be evaluated as
1/ ρMH = (Xw/ ρw) +Xa/ ρa

Copper main head contains 95% of alcohol and 5% of water. Thus Xw=0.05 and Xa=0.95
= 0.05/1 + 0.95/0.789
ρMH = 0.797kg/L
MMH = 0.797kg/L* 50L/hr.
MMH = 39.85kg/hr.
Since the concentration and flow rate of copper main and vent heads are the same
MMV=MMH= 39.85kg/hr.
MHV=39.85kg/hr MHM =39.85kg/hr
Product from SS.C (MSpr) = ? CU.C
MPC = 689.65k/hr.


Mass in = mass out
MSpr= MHM+MHV+MPC
= 39.85 + 39.85 + 689.65
MSpr = 769.35kg/hr.
Component balances for ethanol to determine the composition of alcohol coming out
from the of stainless steel column.
XSprMSpr = XHMMHM +XHVMHV +XPCMPC
XSpr = (0.95*39.85 +0.95*39.85 +0.963*689.65)/769.35
XSpr = 0.96
V material balance on stainless steel column
 Here first the volumetric flow rate of light oil and fusel oil converted in to mass flow rate.
Mass flow rate of fusel oil
MFO= ρFO*FFO
But density of copper main head (ρ FO) can be evaluated as
1/ ρFO = (Xw/ ρw) +Xa/ ρa
Fusel oil contains 70% of alcohol and 30% of water. Thus Xw=0.3 and Xa=0.7
= 0.3/1 + 0.7/0.789
ρFO = 0.84kg/L
MFO = 0.84kg/L* 50L/hr.
MFO = 42kg/hr.
Since the concentration and flow rate of fusel oil and light oil are the same
MFO=MLO= 42kg/hr.
MFO=42kg/hr. MLO =42kg/hr.
MED =11,227.5kg/hr. SS.C MSpr=769. 35kg/hr.
Mw = 9,571.5kg/hr
MLW=?

Assuming steady state operation

Mass in= mass out
MED = Mw + MFO +MLO + MLW+ MSpr
MLW = MED – MFO – MLO - MSpr
= 11,227.5 –9,571.5 - 42 – 42 – 769.35
MLW = 802.65kg/hr.
5.6.2 Energy balance

The general energy balance can be performed by assuming no energy accumulation.
Ein = Eout
The basic energy source is steam and the total steam inlet to the distillation plant is around 4.5
bar. And by assuming energy loss through the vent line insignificant the energy balance can be
calculated by:
Esteam + Etela = EP +EK + EH1 + EH3 + EHM +EHV + EMH + Edeg.head + EFO + ELO + Elease water +
Espentwash assume energy of all heads.
And energy is the product of mass flow rate and enthalpy or it is the product of mass flow rate,
specific heat capacity and temperature. Like;
E=M*H =M*CP*T; where, M is mass flow rate, H is enthalpy CP is specific heat
capacity and T is temperature.
And we know their mass flow rate from the above material balance calculation part except total
steam flow rate. And we can read their enthalpy and specific heat capacity from reference book
based on temperature the steam enthalpy can be found based on its pressure.
Mixture specific heat capacity can be calculated by using;
CPmix = ∑ i is stands for each component and n is total number of component in the
mixture.
Energy balance on the columns that has steam inlet
I Energy balance on analyzer column
QPA
QF AN.C
QST QSW

Where
QF=the rate of heat energy of the degasified tela feed

QST=the rate of heat energy supplied to the column in the form of steam.
QPA= the rate of both sensible and latent heat of vaporized alcohol.
QSW= the rate of heat energy of spent wash (vinasses)
Assumption
Heat loss in the column is negligible.
The energy for each tray is the same.
There is no chemical reaction inside the column.
The operation is operated at steady state.
The fermented mash is a mixture of water and alcohol.
The exist spent wash is as a waste water
Given information
The initial temperature of the feed (fermented tela) is 250c
The mass flow rate of the feed from degassing column (ṁF) is 14,680.75kg/h
The mass flow rate of the vaporized alcohol (ṁPA) is 1822.78kg/h
The mass flow rate of vinasses or spent wash (ṁSW) is 12,857.97kg/h
The maximum temperature of the analyzer is 900c
 Energy on the feed (sensible heat) since temperature of the feed is below the vaporization
temperature we only consider sensible heat of the feed (QF= QSF)
QF = ṁFC pF ∆T
Where
CpF = specific heat capacity of feed which is given by:
CpF=XA CpA +X w Cpw
Where XA = Mole fraction of alcohol in analyzer feed = 0.08
XW= Mole fraction of water in analyzer feed = 0.92
CpA= Specific heat capacity of alcohol = 2.46 KJ/kg k
Cpw = Specific heat capacity of water = 4.2 KJ/kg k
CpF=XA CpA +XW CpW
CpF = 0.08* 2.46KJ/kg k + 0.92 * 4.2KJ/kg k

CpF =4.06KJ/kg k
Then for QF = ṁF CpF ∆T
QF = 14,680.75kg/hr * 4.06KJ/kg k *(76-25) k
QF = 3,039,796.1 KJ/h
The temperature of the feed after pre heating is 760c
 Energy on the vaporized alcohol (64% alcohol) here we consider both sensible heat and
latent heat.
QPA = Sensible heat + Latent heat
For sensible heat
QS = ṁPA*Cp PA * ∆T
But Cp PA =XACpA +XwCpw
Where XA is fraction of alcohol in vaporized alcohol= 0.64
Xw is fraction of water in vaporized alcohol= 0.36
Cp PA = XACpA +XwCpw
Cp PA = 0.64 *2.46KJ/kg k + 0.36* 4.2KJ/kg k
Cp PA = 3.0864KJ/kg k
QS PA = ṁPA*Cp PA * ∆T where QS PA is sensible heat of vaporized alcohol
QS PA = 1,822.78kg/hr. * 3.0864KJ/kg k (90-25)
QS PA= 365,678.8KJ/hr.
For latent heat of vaporized alcohol (QLPA)
QLPA = ṁPA * hPA
Where hPA= latent heat of vaporization of vaporized alcohol is given by:
hPA =XAhA +Xwhw
hPA =838.3KJ/kg
hw = 2257 KJ/kg
hPA = XAhA +Xwhw
hPA = 0.64 *838.3KJ/kg + 0.33*2257KJ/kg
hPA=1349.032KJ/kg
Since QL PA =ṁPA*hPA
QL PA= 1,822.78kg/hr * 1349.032KJ/kg

QL PA = 2,458,988.55KJ/hr.
Therefore
QPA=Sensible heat + Latent heat =QS PA +QL PA
QPA = 365,678.8KJ/hr+2,458,988.55KJ/hr.
QPA =2,824,667.4KJ/hr.
 Energy in the spent wash
Assume, the vinasses (spent wash) attains at a temperature of 1000c. Since at this temperature
water is not vaporized so we consider sensible heat only.(QSW =QSS)
The specific heat capacity of vinasses is equal to the specific heat of water = 4.2KJ/kg k
The initial temperature of vinasses is 840c.
QsW = ṁSW * CpSW *∆T
QSW = 12,857.97kg/h* 4.2KJ/kg k* (100-25)k
QSW = 4,050,260.55KJ/h
Therefore the total energy balance in the analyzer column is given by:
Ein =Eout
QF +QST = QPA +QSW
QST = QPA +QSW - QF
QST = 2,824,667.4KJ/h + 4.050,260.55KJ/h -3,039,796.1KJ/h
QST =3,835,131.5KJ/hr. of steam energy is needed for the analyzer column.
II Energy balance on extractive distillation (ED) column
Condenser
QHW
H3
ED.C
QK
QED
QST
Assumption
The entering katikala energy is negligible (QK=0)

The condenser is total condenser

The temperature of hot water before entering into the ED column 780c
The energy of the by product that is head three is negligible.
Where
QHW = the rate of heat energy of hot water
QST =the rate of heat energy supplied to the ED column in the form of steam
QED =the rate of both latent heat + sensible heat of energy of Dilute vaporized alcohol or ED
bottom product
 Energy of hot water is equal to sensible heat only considered since the temperature of hot
water is below the vaporization temprature (QHW= QSHW)
QHW = ṁHW*CpW*∆T
QHW = 9,571kg/h*4.2KJ/kg* (78-25)K.
QHW = 2,130,504.6KJ/h of hot water
 Energy on the Dilute vaporized alcohol. It contain (8%) alcohol and 92% water from this
fraction of water and alcohol is determined (Xw=0.92 & XA=0.08)
QED =Latent heat of ED bottom + sensible heat of ED bottom (QLED + QSED)
For sensible heat of ED bottom (QSED)
QSED = ṁED*C pED*∆T
The specific heat capacity of diluted alcohol or ED bottom is calculated as follows
CpED =XwCpw +XACpA
CpED= 0.92*4.2+0.08*2.46
CPED = 4.06KJ/Kg k
Qs =11,227.5kg/hr.*4.06KJ/kg k*(78-25)k
Qs = 2,415,933.45KJ/hr.
For latent heat of ED bottom
QLED = ṁED (XA h A + XW h W)
QLED= 11,227.5kg/hr.{0.08*838.3+0.92*2257}KJ/kg
QLED = 24,066,191.2KJ/hr.
QED =QLED+QSED
QED = (2,415,933.45 + 24,066,191.2) KJ/h
QED = 26,482,124.65KJ/h.

Then the energy balance in the extractive column is

QHW+QST = QED
QST= QED- Q HW
QST = (26,482,124.65- 2,130,504.6) KJ/h
QST = 24,351,620KJ/h of steam energy are needed for the ED column
III Energy balance on stainless steel (stripping) column

QSpr
QF
SS.C
QHW
QST QLW
Assumption
The feed energy which enter in to stainless steel is negligible (QF=0)
Heat loss is negligible
Where
QSpr is the rate of heat energy of vaporized alcohol or product line of stainless steel column.
QHW is the rate of heat energy in hot water which is entered into ED column.
QST is the rate of heat energy supplied to the column in the form of steam.
QLW is the rate heat energy in the less water.
ṀSpr = mass flow rate of vaporized alcohol
Known data from material balance;
ṀSpr =769.35kg/h of vaporized alcohol that goes to copper column.
Alcohol concentration is 96% thus Xw=0.04 & XA=0.096
 Energy on the vaporized alcohol
QSpr=Latent heat + Sensible heat
Sensible heat of stainless steel product line or vaporized alcohol (QsSpr)
QsSpr=ṁSpr CpSpr∆T
=ṁ (XACpA+ XwCpw) ∆T

=769.35kg/hr. ((0.96*2.46+0.04*4.2) kJ/kg k (80-75)) k

QsSpr=9,730.73kJ/h
Latent heat of stain less steel product line or vaporized alcohol (QLSpr)
QLSpr=ṁSpr hSpr
Where
hSpr =latent heat of vaporization of vaporized alcohol.
QLSpr =ṁSpr (XAh A + Xwhw)
QLSpr = 769.35kg/h (0.96*838.3+0.04*2257)kJ/kg
QLSpr =688,605.2kJ/h
The rate of heat energy of stainless steel product line calculated as below
QSpr = QsSpr+QLSpr
QSpr =9,730.73kJ/h+688,605.2kJ/h
QSpr =698,335.94kJ/h
 Energy in the lease water (sensible heat energy)
QLW = ṁLW CpLW∆T
QLW =802.65 kg/h*4.2kJ/kg k*5k
QLW = 16,855.65kJ/h
 The energy of hot water is calculated in ED column
QHW = 2,130,504.6KJ/hr.
So the total energy balance in the stain less steel column is
QST =QSpr + QLW + QHW
QST =698,335.94kJ/h+16,855.65kJ/hr.+ 2,130,504.6KJ/h
QST =2,845,696.2kJ/h of steam energy is needed for stainless steel column.
IV Energy balance on methanol column

QMH Condenser
QST
Methanol head
HX MT.C
Cooling water
QF
Condenser
QP cooled alcohol

HX=heat exchanger hot water to cooler

Assumptions
The entering feed energy is negligible (QF=0)
The condenser is total condenser
The energy of the by product that is methanol head is negligible (QMH=0).
Heat loss on heat exchanger is negligible
Where
QF = the rate of heat energy of the feed which is from copper column
QST =the rate of heat energy supplied to the methanol column in the form of steam
QP =the rate of heat energy of pure alcohol
QMH = the rate of energy of methanol head.
Known information from material balance
Ṁp = 650kg/h of vaporized alcohol that goes to copper column.
Alcohol concentration is 96.3% thus Xw=0.037 & XA=0.0963
Energy on pure alcohol is equal to sensible heat energy only since the temperature is below
vaporization point.
Sensible heat of pure alcohol (QP)
QP=ṁPCpP∆T
= ṁ(XACpA+ XwCpw) ∆T
=650kg/hr. ((0.963*2.46+0.037*4.2) kJ/kg k (72-68)) k
QP=6,390.7kJ/h, and from the energy balance QP = QST
QST = 6,390.7KJ/hr. steam energy is needed for methanol column.
Cooling water flow rate can be calculated by using conservation of energy, Qh = Qc
Qh = ṁcCpcP∆Tc, 6,390.7kJ/h = ṁc*4.2kJ/kg k*(80-15)K
ṁc =23.5kg/hr. amount of cooling water required to cool the alcohol.
Therefore now we can calculate the total amount of steam energy required for distillery house
Qtotal = steam for analyzer + steam for ED + steam for stainless steel+ steam for methanol
Qtotal = 3,835,131kJ/h + 24,351,620kJ/h +2,845,696.2kJ/h + 6,390.7kJ/h
Qtotal = 31,038,837.9kJ/hr. This much amount of steam energy is required for distillery house.

CHAPTER SIX
6 LIQUIOR PREPARATION AND BOTTLING HOUSE

This section of the factory consists of the bottle washing, liquor formulation and filling units.
6.1 Liquor formulation and preparation (blending)

Liquor are alcoholic beverages that can be prepared by the dilution of pure alcohol (96.3%
alcohol by volume) by adding some flavoring agents (essences),sweeteners (syrup) ,and mixing
with the aid of treated water. The major process takes place in this section is preparation of
ingredients, mixing, filtration, and storing in storage tank.
i. Preparation of ingredients
The main ingredients for preparations of liquor are:
 Ethanol (96.3% alcohol by volume)
 Soft water
 Essence
 Syrup
 Colorings
Ethanol
Ethanol is the main ingredient for the preparation of alcoholic beverage. And it is produced in
this factory by using fermentation and distillation process. In fermentation the raw material
molasses is converted in to ethanol by the action of yeast. Since the produced alcohol from
fermentation contain much amount of water and other toxic chemicals it entered in to distillation
so as to separate the ethanol from that toxic chemicals and water. Finally 96.3% ethanol
concentration is cultivated after the last distillation column. This alcohol is used for liquor
preparation by diluting with soft water to reduce its concentration then blended with specific type
of flavor and coloring to produce specific kind of alcoholic beverage.
Soft water
To dilute the alcohol soft water is needed. Water softening takes place by using ion exchanging
equipment.

Essence
It is extract components directly from aromatic vegetables, fruits, spices, herbs, and etc. by
means of distillation and maceration process. There are different types of essences for different
types of liquors. An important point in producing liquor is the choice of flavoring materials this
is the distinguishing point of any alcoholic beverage. Flavoring should be power full and plain, it
must express the character of the beverage clearly.
Syrup
Syrup is prepared from sugar and water for imparting taste to the liquors. And to prepare it firstly
200L of water is added into the sugar melting tank and then 250 kg of sugar is added. Then after
the sugar is added steam is applied at a temperature of 80oc to melt the sugar crystal. Finally
Citric acid is added as bleaching agent.
Colorings
There are several types of colorings. Some of them are brown cornmeal, yellow lemon, green &
so on. The quality of these colorings should be checked before use. They should free of
calcium& iron salts.
Colorings should dissolve in high grade sprits. If wrong choice of coloring is done, this will be
cause turbidity in sprits. Colorings are sensitive to frost & its solubility will decrease at lower
temperature. The finished colored sprits should not be stored under frosty condition.
ii. Mixing
First preparation tanks, pumps, hose, filter and preparation house are cleaned. Then pure alcohol
is transferred to preparation tank in needed volume and soft water is added then mixed by stirrer
for 45min. Now the prepared essence is selected for specific type of liquor and added to the
beverage and homogenized for 45min. after 45min add soft water which 10% of the preparation
pure alcohol and wait for 30min to homogenize. By the recipe add the measured syrup and
homogenize for 30min. then add soft water when the alcohol grade come good condition and
homogenize.
iii. Filtration

The suspended solid material in prepared liquors is removed by using press filter. And then goes
to holding tank for temporary storage till it is filled in bottles.
6.2 Bottle washing and packing

After the blended liquor is stored in the storage tank different machines are used for packing the
prepared (blended) liquors. These are; washer, filler, caper, levelers, and conveyor.
1. Washer: is a machine which used to wash the bottle by using steam. Caustic soda and
water. Bottle washer machine operational cleaning steps are; drain the residues of
returnable bottles, pre-soaking bottles, caustic bath dipping bottle, caustic spray of bottle,
intermediate spray, warm water spray, and finally fresh water spray.
2. Filler: is used to fill the prepared liquor into the washed up bottle.
3. Caper: Is a type of that can be used to cap (cover) the filled bottle.
4. Conveyor: is a machine which is used to transport bottles in the factory, like bottled
liquor and washed up bottles.
6.3 Calculation on liquor formulation

In Rorank SC alcoholic liquor factory there are different types of liquor or alcoholic beverage
some of these are; Gin, ouzo, superment, lemmon, cognac, vodka, pineapple, double ouzo, and
fernet. The difference between this liquor is by their alcoholic content, amount of syrup added,
type of flavor used, and color.
For one batch 2800L liquor is prepared and the initial concentration of ethanol used to prepare
this liquor is 96.3% also the concentration of the liquor to be prepared is known. Thus from this
information we can know how much amount of pure ethanol is used to prepare one batch for
specific type of alcoholic liquor using dilution formula.
C1V1 = C2V2
Where C1 is initial concentration of pure alcohol which is 96.3%v/v
C2 is concentration of liquor to be prepared
V2 is volume of liquor to be prepared
V1 is volume of pure alcohol needed

Now using this relation we can evaluate the volume of pure alcohol needed to prepare each type
of liquors (V1).
V1 =
Using the above formula the volume of pure alcohol needed for each type of liquior is
summarized in the table below.
Table 6-0-1 different type of liquor with their different amount of ingredient
Type of Concen Volume Concentr Volume Volume Volume Volume Volum
liquor tration of liquor ation of of pure of of flavor of e of
of the to be
pure alcohol syrup in L coloring soft
liquor prepared
(C2in (V2 in alcohol needed in L in L water
v/v) L) (C1in v/v) (V1 in L) in L
Gin 0.41 2800 0.963 1192 27.47 2.1 - 1578.4

Ouzo 0.41 2800 0.963 1192 33.94 1.45 - 1572.6
Superm 0.25 2800 0.963 727 278.25 0.265 10.6 1783.9
ent
Lemmo 0.30 2800 0.963 872 220 5.74 0.73 1098.4
n
Cognac 0.37 2800 0.963 1076 4.42 0.32 0.143 1719
Vodka 0.43 2800 0.963 1250 - - - 1550
Pineapp 0.30 2800 0.963 872 9.7 0.486 - 197.8
le
Double 0.43 2800 0.963 1076 27.16 0.3388 - 1103.5
ouzo

CHAPTER SEVEN
7 EVAPORATOR AND DRYING HOUSE

This factory has spent wash or vinasses treatment plant based on evaporation and drying
technology with a treatment capacity of 10m3/hr. And consist of an evaporation section and
spray drying section. But during our internship time the drying section was not working it is
simply installed only.
7.1 Evaporator section

Evaporation is the removal of solvent as vapor from a solution, slurry or suspension of solid in a
liquid. The aim is to concentrate a non-volatile solute, such as organic compounds, inorganic
salts, acids or bases from a solvent. The most common solvent in most of the evaporation system
is water.
Evaporation differs from the other mass transfer operations such as distillation and drying. In
distillation, the components of a solution are separated depending upon their distribution
between vapor and liquid phases based on the difference of relative volatility of the substances.
Removal of moisture from a substance in presence of a hot gas stream to carry away the moisture
leaving a solid residue as the product is generally called drying. Evaporation is normally stopped
before the solute starts to precipitate in the operation of an evaporator.
The effluent from distillery plant (spent wash) is often processed with evaporator to recover the
water and produce concentrated syrup, which can be added to the spent grain prior to drying.in
this case the solids have value as animal feed.
Evaporators are classified by the number of effects. In case of a single-effect evaporator, the
vapor from the boiling liquor is condensed and the concentrated product is withdrawn from the
bottom of the evaporator. Although the operation is simple, the device does not use steam
efficiently. Typically 1.1 to 1.3 kg of steam is required to evaporate 1 kg of water. The steam
consumption per unit mass of water evaporated can be increased by putting more than one
evaporator in series such that the vapor from one evaporator is used in the second evaporator for
heating. The vapor from the second evaporator is condensed and the arrangement is called

double-effect evaporators. The heat from the vapor generated in the first evaporator is used in
the second evaporator. Evaporation of water is nearly doubled in double effect evaporation
system compared to single effect per unit mass of steam used. Additional effects can be added in
series in the same way to get a triple-effect evaporator, quadruple-effect evaporator and so on.
There are several configurations based on feeding arrangement.
Multiple effect evaporators (quadruple effect) are used for concentrating spent wash in Rorank
alcoholic liquor factory. Normally falling film tubular calendars are employed for the pre
evaporator with forced circulation tubular evaporator as the finisher.
7.1.1 Types of evaporates used

In this plant two types of evaporators are used for the purpose of concentrating distillery spent
wash (vinasses). These are falling film evaporator (pre evaporator), and forced circulation
evaporator (finisher).
a) Falling film evaporator
In a falling film evaporator, the liquid (spent wash) is fed at the top of the tubes in a vertical tube
bundle. The liquid is allowed to flow down through the inner wall of the tubes as a film. As the
spent wash travels down the tubes the solvent (water) vaporizes and the concentration gradually
increases. Vapor and liquid are usually separated at the bottom of the tubes and the thick liquor is
taken out. Evaporator liquid is re-circulated through the tubes by a pump below the vapor-liquid
separator. The distribution of liquid in the inner wall of the tubes greatly affects the performance
of this type of evaporator. The falling film evaporator is largely used for concentration spent
wash and heat sensitive materials because of the low holdup time. The device is suitable for scale
forming solutions as boiling occur on the surface of the film.
b) Forced circulation evaporator
Forced circulation evaporators are usually more costly than falling film evaporators. However
the falling film evaporators are not suitable under some situations such as: - highly viscous
solutions due to low heat transfer coefficient - solution containing suspended particles - for heat
sensitive materials. All these problems may be overcome when the liquid is circulated at high
velocity through the heat exchanger tubes to enhance the heat transfer rate and inhibit particle
deposition. Any evaporator that uses pump to ensure higher circulation velocity is called a forced
circulation evaporator. The main components of a forced circulation evaporator are a tubular

shell and tube heat exchanger (either horizontal or vertical), a flash chamber (separator) mounted
above the heat exchanger and a circulating pump. The solution is heated in the heat exchanger
without boiling and the superheated solution flashes off (partially evaporated) at a lower pressure
are reduced in the flash chamber. The pump pumps feed and liquor from the flash chamber and
forces it through the heat exchanger tubes back to the flash chamber.
7.1.3 Process description

Spent wash from analyzer Spent wash
storage tank
8-100 brix
First effect
Steam
15-20obrix
Second effect
15-25obrix
Vapor
Third effect
Con
25-30obrix dens
Vapor er
Steam Fourth effect
Raw condensed water
High brix (40-60obrix)

Spent to drying
Figure 7.1Process flow chart for spent wash evaporation
The solution containing the undesired product (spent wash) from the analyzer bottom column is
collected in the storage tank of spent. These spent wash having 8-10o brix enters in to feed tank

for temporary storing, and is fed into the first effect evaporator and steam is applied to evaporate
water and concentrate the spent. This effect maintained at the highest temperature (85-100℃) by
using steam that is generated in boiler house. The vapors and the concentrated product from this
effect enter in to the second effect which is maintained a temperature of in between 80-85oc. The
vapor comes from the first effect is then further concentrate the spent in the second effect by
vaporizing high volatile components. Similar to first effect the vapor and concentrated product
coming out from the second effect faded in to third effect for further removal of solvent. The
vapor leaves from the top of this effect goes to condenser and the bottom concentrated spent
introduced in to fourth effect. The third effect evaporator temperature is in between 70-80oc.
fourth effect which is the last effect and its type is forced circulation evaporator. In this effect the
concentrated spent coming from third effect is more concentrated by applying steam directly like
first effect. The temperature of this effect is in between 60-70oc.The vapor comes out from this
effect enters in to condenser to cool down. The concentrated spent goes to drier to produce solid
spent which has high nutritional value for animals and or can be used as fertilizer. But during our
internship time the drier was not in operation due to this reason the high brix spent discharged to
the surrounding.
Since the temperature is decreased from the first effect up to the last one the evaporators are
under vacuum. The effect of vacuum on evaporation is good in case of stem saving because;
when the pressure on liquids varies the boiling point temperature of the liquids also varies. i.e.
pressure increases-boiling point also increases, therefore when a liquid is heated under vacuum
the boiling point of liquid decreased which also reduce the amount of heat energy needed to boil
the liquid.

CHAPTER EIGHT
8 WASTE WATER TREATMENT PLANT

8.1 Introduction
Wastewater treatment refers to processes that treat or remove pollutants and contaminants, such
as soluble organic matter, suspended solids, pathogenic organisms, and chemical contaminants,
from wastewater prior to its reuse or discharge from the facility. These pollutants and
contaminants are removed from wastewater using physical and chemical processes (such as
sedimentation and chlorine disinfection) and biological processes. Biological wastewater
treatment processes can produce CO2 and anthropogenic CH4 and N2O emissions.
Analysis of physicochemical characteristics of distillery waste has been carried out, molasses is
the most common raw material used in distilleries for ethanol production. After alcohol
distillation, huge volume of darkish colored spent wash remains in the stills (to extract 1 litter
alcohol above 12 litter waste). And since this spent contain high amount of polluting substance it
introduced in to evaporator and then drying unit so as to reduce that toxic chemicals by
producing solid biomass, which has high nutritional value for animal. But still the water comes
out from the evaporator condensers has high BOD, COD, TSS, and acidity thus the raw
condensed water transferred in to waste water treatment plant for further treatment.
The waste water treatment plant found in Rorank SC factory is diagrammed in figure 8.1. It is
designed to remove BOD, COD, acidity, color, odor, turbidity, and other contaminants. The
major waste water processing steps are;
 Raw water storage

 Equalization
 Anaerobic digestion
 Degasifying of chemicals
 Aerobic digestion -1
 Settling tube -1
 Aerobic digestion -2
 Settling tube -2

 Chlorination
 Multimedia filter
 Activated carbon filter
8.2 process description

Raw water storage
In this tank the waste water from the evaporator and bottle washer is introduced and acidic or
basic chemicals are added so as to maintain the PH neutral in between 7-8. For example if the
PH is below seven limes (Ca(OH2)) is added until it become in the range of needed PH value and
if the PH is above eight sulfuric acid is added. The neutralized water is now ready for anaerobic
digestion hence it transferred in to anaerobic digestion tank by passing through flow equalization
tank.
Equalization tank
Wastewater does not flow into wastewater treatment plant at a constant rate for various reasons.
Such constant variations in the amount and strength of wastewater to be treated make it difficult
to operate the treatment processes efficiently.
Also, many treatment units must be designed for the maximum flow conditions encountered, it
actually results in their being oversized for average conditions. Thus, the purpose of flow
equalization is to dampen these variations so that the wastewater can be treated at a nearly
constant flow rate.
In addition, flow equalization can also be used to overcome the operational problems caused by
flow rate variations, to improve the performance of the downstream processes, and to reduce the
size and cost of downstream treatment facilities.
Anaerobic digestion
Anaerobic digestion process is continuously undergoing modifications with improvement and
development of new and complex technologies which are rapidly emerging. The anaerobic
digestion process is temperature influenced and dependent. Some of the anaerobic bacteria have
optimal degrading rate at mesophlic temperature of 32-35°C range, while other digesting bacteria
have maximal potentials at thermophilic temperature range of 50-55°C range. But in Rorank

there is no temperature adjustment simply the neutralized waste is introduced to this tank and
animal dung is added for bacteria inoculation and finally the anaerobically digested water which
contain CH4, CO2, and other gases faded to degasifying section.
Degassing section
In this section the gases produced during anaerobic digestion are removed to the atmosphere by
stabilizing the flow in laminar zone.
Aerobic tank -1
After the degasified water charged in to this tank the chemicals that are not digested by anaerobic
bacteria will degraded with the aid of aerobic bacteria. These aerobic bacteria require free
dissolved oxygen, carbon, nitrogen, and phosphorus for their growth. Dissolved oxygen is
supplied by compressing the atmospheric air using compressor. And the bacteria obtain the other
nutrients from DAP, urea, and sugar. Then the aerobically decomposed water transferred to
settling tank one to settle out the bacteria used.
Settling tube-1
Water from aerobic tank -1 usually has significant turbidity caused by turbulence during
aeration. These particles carried an electromagnetic charge that keeps them in continual motion
and prevents them from colliding and sticking together. Chemicals like alum (aluminum
sulphate) are added to the water both to neutralize the particle electrically and to aid in making
them “sticky” so that they can coalesce and form large particle called flocs. This process is called
coagulation or flocculation.
When the flocs have been formed they must be separated from the water. This is invariably done
in gravity settling tank that allow the heavier than water particle to settle to the bottom. The
sludge from the bottom of settling tank -1 contain bacteria thus some of its amount recycled back
to the aerobic tank -1 and the other goes to sand filter. And the water from the top transferred in
to aerobic tank -2 for further digestion of chemicals by aerobic bacteria.
Aerobic tank-2
Similar to that of aerobic tank it uses aerobic bacteria for further decomposition of chemicals.
The required dissolved oxygen is fed using compressor and nutrients like nitrogen, phosphor and

others from DAP, urea, and sugar. The bacteria cell is recycled from the bottom of settling tank-
2.
Settling tube -2
Similar to that of settling tank one aluminum sulphate is added to stick the suspended particles
together and form flocs to facilitate the separation by gravity settling. Since large flocs have
higher density it will settle easily. And the sludge contains bacteria cell thus the needed amount
of bacterial concentration recycled to aerobic tank two. The aerobically digested water now
transferred to intermediate tank for further chemical treatment.
Intermediate tank (disinfection)

After biological treatment the finished water is often disinfected with chlorine. Disinfection kills
the remaining microorganisms in the water. Some of which may be pathogenic. Chlorine from
bottle of drums fed in correct proportion to the water to obtain a desired level of chlorine in the
treated water. When chlorine comes in contact with organic matter, including microorganism, it
oxidize this material and in turn itself reduced. The chemically treated water now goes to
multimedia filter.
Multimedia filter
In this filter media the treated water introduced so as to remove any suspended solid in water.
Activated carbon filter

This filter media is filled with activated carbon. And the treated water from multimedia filter
introduced at the top and when it passes through this filter media the odor will adsorbed to the
pours of activated carbon.

Li Gases Nutrients Poly
Animal Nutrient
me H2SO4 to like CH4, like DAP, Poly
dung (Al2SO4)
adjust PH CO2, urea, sugar (AlSO4)
Raw
Raw Equal Anaer Degass Aerobi Aerobi Settlin
water Settling
water izatio obic ing c tank- c tank- g tank
tank-1
storage n tank tank section 1 2 2
Cells recycle
Cells recycle
Cells recycle
RORANK BUSINESS S.C ALCOHOLIC LIQUOR FACTORY

Sand filter
Chlorine
Treated water Activated Multimed Intermedi

Disposal to the surrounding storage tank carbon filter ia filter ate tank
Figure 8.1 flow diagram of waste water treatment plant at

Rorank SC Company.
Page 83
CHAPTER NINE
9 UTILITY
9.1 Boiler
Boiler is a closed vessel in which water is heated to generate steam. The boiler found in Rorank
SC factory is used to supply a steam to distillation columns like; analyzer column, ED column,
stainless steel column, and, methanol column, moreover to evaporators, drier, and for bottle
washer. There are three types of boiler available in the company which uses different type of
energy source. These are; wood, electricity, and fuel boilers.
Fuel boiler
Fuel fired boilers use controlled combustion of the fuel to heat water. The key boiler
components involved in this process are the burner, combustion chamber, heat exchanger, and
controls.
The burner mixes the fuel and oxygen together and, with the assistance of an ignition device,
provides a platform for combustion. This combustion takes place in the combustion chamber,
and the heat that it generates is transferred to the water through the heat exchanger. Controls
regulate the ignition, burner firing rate, fuel supply, air supply, exhaust draft, water temperature,
steam pressure, and boiler pressure.
Hot water produced by a boiler is pumped through pipes and delivered to equipment throughout
the building, which can include hot water coils in air handling units, service hot water heating
equipment, and terminal units. Steam boilers produce steam that flows through pipes from areas
of high pressure to areas of low pressure, unaided by an external energy source such as a pump.
Steam utilized for heating can be directly utilized by steam using equipment or can provide heat
through a heat exchanger that supplies hot water to the equipment.
Wood boiler
Wood boiler systems use technology that converts woody biomass fuels to thermal energy
through the processes of:
•combustion – burning fuels in the presence of oxygen,

• Pyrolysis – rapid thermal degradation in absence of oxygen, or

• Gasification – converting biomass fuels into combustible syngas.
At Rorank SC factory the wood boiler converts dried wood in to thermal energy with the aid of
oxygen. This thermal energy is then used for space and domestic hot water heating so as to
produce steam. Forced draft fan (FD) is used to suck the oxygen needed for combustion of wood
and induced draft fan (ID) is used to suck the ash produced in the furnace during burring of
wood. Then the ash goes to cyclone after it preheats the oxygen sucked by FD fan to separate the
solid ash from the smoke. Finally the smoke realized out from the boiler house through chimney
to the environment.
9.2 Cooling tower

A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though
the cooling of a water stream to a lower temperature. The type of heat rejection in a cooling
tower is termed "evaporative" in that it allows a small portion of the water being cooled to
evaporate into a moving air stream to provide significant cooling to the rest of that water stream.
The heat from the water stream transferred to the air stream raises the air's temperature and its
relative humidity to 100%, and this air is discharged to the atmosphere.
At Rorank SC There are two direct mechanical-draft cooling towers rely on power-driven fans to
draw or force the air through the tower. These cooling towers have an enclosed structure with
internal means to distribute the warm water fed to it over a labyrinth-like packing or "fill." The
fill provides a vastly expanded air-water interface for heating of the air and evaporation to take
place. The water is cooled as it descends through the fill by gravity while in direct contact with
air that passes over it. The cooled water is then collected in a cold water basin below the fill from
which it is pumped back through the process to absorb more heat. The heated and moisture laden
air leaving the fill is discharged to the atmosphere at a point remote enough from the air inlets to
prevent its being drawn back into the cooling tower.
Since cooled water is returned from the cooling tower to be reused, some water must be added
to replace, or make-up, the portion of the flow that evaporates. Because evaporation consists of
pure water, the concentration of dissolved minerals and other solids in circulating water will tend
to increase unless some means of dissolved-solids control, such as blow-down, is provided.

Some water is also lost by droplets being carried out with the exhaust air (drift), The make-up
amount must equal the total of the evaporation, blow-down, drift, and other water losses such as
wind blowout and leakage, to maintain a steady water level.
Make up Water
Makeup requirements for a cooling tower consist of the summation of evaporation loss, drift
loss, and blow down.
Therefore,
Wm = We + Wd + Wb
Where,
Wm = makeup water,
Wd = drift loss, and
Wb = blow down [consistent units, m3/ (h*gal*min)].
Evaporation loss can be estimated by the following equation:
We = 0.00085 Wc (T1 - T2)
Where,
Wc = circulating-water flow, gal/min at tower inlet
T1 - T2 = inlet-water temperature minus outlet-water temperature, °F Drift is entrained water in
the tower discharge vapors. Drift loss is a function of the drift- eliminator design, which typically
varies between 0.1 and 0.2 percent of the water supplied to the tower. New developments in
eliminator design make it possible to reduce drift loss well below 0.1 percent.
Blow down discards a portion of the concentrated circulating water due to the evaporation
process in order to lower the system solids concentration. The amount of blow down can be
calculated according to the number of cycles of concentration required to limit scale
formation.
Cycles of concentration are the ratio of dissolved solids in the recirculating water to dissolved
solids in the makeup water. Since chlorides remain soluble on concentration, cycles of
concentration are best expressed as the ratio of the chloride content of the circulating and
makeup waters. Thus, the blow down quantities required are determined from
Cycles of concentration = (We + Wb)/Wb
Or Wb = We / (cycles - 1)

Cycles of concentration involved with cooling-tower operation normally range from three to five
cycles. Below three cycles of concentration, excessive blow down quantities are required and the
addition of acid to limit scale formation should be considered.
9.3 Zeolite water softener

Rorank SC alcohol factory sets up high standards and as the distillery needs different types of
water for different purposes. It has set up a water treatment plant in the same premises. Tap
water or source of water cannot provide water as required for different units. Some of the
requirements of different units are as follows:-
 For boiler since it requires water without having hardness to avoid scaling
problems.
 For alcoholic beverage preparation since it requires de-mineralized water.
The main goal of a water filter is to provide clean, contaminant-free water for drinking and other
purposes whereas water softener is to remove hardening minerals like calcium and magnesium
from the water.
As the water required for different purposes is different water treatment plant produces water of
different qualities and supply it to different units. Water treatment plant requires to remove or
adjust hardness, free mineral acid, pH, Cl2, SO4, alkalinity etc. to required values. Water
treatment plant uses ion exchange mechanism. Ion exchange mechanism: Ion exchange
operations are essentially chemical reactions between an electrolyte in solution and an insoluble
electrolyte with which the solution is contacted. The mechanisms of these reactions and the
techniques used to bring them about resemble those of adsorption so closely that for most
engineering purposes ion exchange can simply be considered as a special case of adsorption
application.
Principle of ion exchange: the ion exchange solids first used were porous, natural or synthetic
minerals containing silica, the zeolites, such as the mineral Na2O, Al2O3, 4SiO2, 2H2O, for
example. Positively charged ions (cations) of a solution which are capable of diffusing through
the pores will exchange with the Na+ ions of such a mineral, which is therefore called a calcium
exchangers. For example,
Ca2+ + Na2R=========► CaR + Na+

Where “R” represent the residual material of a zeolite. In this manner “hard” water containing
Ca2+ can be softened by contact with zeolites, the less objectionable Na+ replacing the Ca2+ in
solution and the latter becoming immobilized in the solid. The reaction is reversible, and after
saturation with Ca2+ the zeolites can be regenerated by contact with a solution of salt,
CaR + 2NaCl ============► Na2R + CaCl2

CHAPTER TEN
10 BENEFITS OF INTERNSHIP
10.1 Improving practical skills
In our internship period we improved our practical skills by relating with our theoretical back
ground. And we have gained an experience that helps us to change our theoretical knowledge in
to real or practical one. Internship is an opportunity to become professionals and also it has the
exposure to understand the east technology. The knowledge we have in the class room is depend
on theoretical process description but in the internship time we develop it to practical knowledge.
Internship skill would have acquired practical experience to complement the theoretical content
of our studies in the University.
10.2 Upgrading theoretical knowledge

A theoretical (conceptual) is an abstract concept that defines a term in academic discipline.
Theoretical knowledge is knowledge of why something is true. This internship was use full for
us in case of upgrading our theoretical knowledge. This could be performed by operating and
watching all sections in the factory like; fermentation, distillation, bottling, evaporation, drying,
boiler and waste water treatment in serious manner.
During the time we were in each unit operation we asked a number of questions which is not
clear for us and we take a manuals and related documents from the operators and shift engineers.
This positive habit helps us to develop our theoretical knowledge.
Generally our internship correctly gives us a direction to convert or apply our theoretical
knowledge we have gained in the previous class rooms into tangible form of payment able
practical knowledge.
10.3 Inter personal communication skill

This is the common and one of the most important skills that we have gained during our
internship period. This skill helps a person to interact with others in much better and pleasant
manner. It is an art to present ones views, thoughts and ideas before its listeners. Our internship
period helped us to develop our interpersonal communication skills by creating smooth relations
with all workers. Generally our interaction and dealings with the customers helped us; to broaden

ourselves social network, to build up self-confidence, to exchange new ideas and knowledge,
improves our speaking listening skills, and etc.
10.4 Improving leadership skills

Our internship, we think, partly voids the bad image we had for the leaders. We were brought in
a society who thinks the leadership as stand for power and dominance over the other. Leadership
to us, as applied to someone to whom other people are entrusted, is an art of inspiring others to
give of their best, and courage to use this art. This is what leadership is meant to us; it demands
that the leader should not use it as a position, not from above of the workers; that in setting a
good example, he doesn‟t steal the initiative of the others; that he takes his full share but not
more than his share of the job in hand. Acquire the appropriate technical competence and
experience, gives direction, share danger/hardship on equal footing, sets an example etc. As a
good leader, we have learned a lesson to have these characters. In addition we learned and
convicted to have the following attributes to be successful leaders:
 General intelligence, to make sense of the complexity and difficulty of the task
 Personality: leaders should be energetic and committed, maintain contact with
their people, and understand their strengths and weaknesses
 The ability to inspire, although this quality may be rarer than some of the others
and is perhaps the most difficult to develop.
 Listening, sharing and delegating skills (and not interfering unnecessarily),
because in groups of more than around five people it becomes impossible to know
all the necessary detail Self-knowledge, understanding one‟s own strengths and
weaknesses, which in turn will enable them to turn to other in their group to
compensate for their own biases or deficiencies.
10.5 Work Ethics Related Issues

Developing keen organizational skills in the workplace eliminates unnecessary ineffectiveness
and enables individuals to efficiently perform essential job tasks. Establishing organizational
skills help individuals perform their work according to their job duties and responsibilities.
Therefore, maintaining organization in the workplace not only helps individuals work efficiently,
but also helps to promote the overall objectives of an individual‟s job or profession. Maintaining

organization enables individuals to be productive while performing their job duties. On the other
hand, it is important for companies to establish organizational objectives in the workplace to help
achieve the company‟s overall mission. Time management is one of the most important skills to
maintain organization in the workplace. Managing one‟s time simply involves designating
enough time in work day to complete report and setting up practical and useful work schedules.
Some individuals plan their work schedules daily, while others may establish monthly or weekly
schedules. Another essential organizational skill includes having a clean and orderly work space.
Thus employer expects employees to develop certain desirable traits that will help them to
perform their jobs well so that the company can succeed. Some of these traits include the
following:
 Loyalty
 Honesty
 Trustworthiness
 Dependability
 Reliability
 Initiative
 Self-discipline
 Self-responsibility
With respect to work ethics related issues we have seen how a worker struggles for fulfilling the
irresponsibility at work place, respecting their working time respecting the order of the company
manager, etc.
10.6 Improving team playing skill

Team work involves working confidently within a group, contributing your own ideas
effectively, taking a share of the responsibility, being assertive rather than passive or aggressive,
accepting and learning from constructive criticism and giving positive, constructive feedback to
others.
All employers are keen to recruit graduates who are able to cooperate, solving problems and
work in teams. As less hierarchical organizations have emerged with project teams, self-managed
work teams and management teams, so the requirements to 'Get on well with people', and to

'Work with and through others' become increasingly important. And this internship helps us to
know the advantage of team work and to create great team work with people working in the
company.
10.7 entrepreneurship skill

During internship we have met with some entrepreneurs on way of our work and our part time
activity; and we gained greater insight into business and entrepreneurship. The basic
entrepreneurship skills that these peoples have and we noted are: business planning, risk
assessment, team building. After of completion of our study we may get employed in company.
However, we will not confine source of financial income to the company pay only. For these
days, we have vision to own a firm, business, or venture, and responsibly develop it in parallel
with my employers work. It is our opinion that managing one‟s own business offers far greater
security than being an employee elsewhere. We feel entrepreneurship enables us to acquire
wealth quickly and cushion us against financial insecurity. Additionally, an entrepreneur‟s future
is not at peril owing to the faulty decisions of a finicky employer. A wide range of skills are seen
as entrepreneurial and Useful to entrepreneurs, these include both personal traits and
Management skills.
Internship is an important tool for gaining experience and learning about one‟s preferences and
interests. Perhaps most importantly, the experience obtained has a great importance upon our life
to choose and plane each of our future activity. Being an intern student built an individual‟s
knowledgeable in;
 Selection of the effective way of doing work

 Increasing efficiency work
 Easiest methods for producing a product
 Creative mined in solving the problem of company
 Risk taking ability for doing work
 Extend different projects upon existing problem concerning certain company, etc.

CHAPTRE ELEVEN
11 CONCLUSION AND RECOMMENDATION

11.1 Conclusion
The raw materials used in ethanol plant to produce both ethanol and alcoholic beverages are
molasses, urea, DAP, yeast, sulphuric acid, essences (flavors), colorings, citric acid, white
crystallized sugar ,and water
The major unit operations involved in this factory to produce bottled alcoholic liquor and to treat
the by-product are; fermentation, distillation, blending, evaporation, and drying. Also there are
many utilities to produce distilled alcohol and alcoholic beverages. This utilities are; boiler
cooling tower, water softening, and compressors.
The fermentation is only one step in the production process, it is the key step.
Fermentation is a biochemical process in which enzymes produced by microorganisms that
is yeast transforms an organic substance in to ethanol. The substance used in ethanol
fermentation is a six carbon sugar. The amount of molasses used for one batch is determined by
using laboratory test then using material balance the amount of produced fermented beer is
determined. From the mass of beer produced fermentation yield and fermentation efficiency
evaluated.
Distillation process of Rorank alcohol and liquor factory has multi stage distillation columns this
is important for getting pure alcohol. The product of this plant are two types that are pure
(ethanol) 96.5% alcohol and denature alcohol 95% alcohol is directly distributed to the
local market where as pure alcohol is used to produce different liquors with different alcohol
composition. The byproduct spent wash goes to evaporator and then drier to produce stable solid
spent.
The pure alcohol transported to bottling or liquor production house so as to produce different
kind of alcoholic beverages. They contain different alcoholic concentration, different type of
flavor or essence, different type of coloring, and different amount of syrup. Finally the product
produces in this company is distributed to the market for their customer.

The boiler found in Rorank SC factory is used to supply a steam to distillation columns like;
analyzer column, ED column, stainless steel column, and, methanol column, moreover to
evaporators, drier, and for bottle washer.
11.2 Recommendation
Although Rorank SC alcoholic liquor factory has been producing very pure distilled beverage
products by fermenting molasses with a fermentation by applying current fermentation method,
we would recommend the following considerations that a firm need to consider in order to
improve distillery performance i.e. fermentation efficiency, distillation efficiency, productivity
and quality of alcohol.
 Appropriate control of temperature
 Adequate supply of nutrients to batch fermenters as well as pre-fermenters
 Appropriate control of infections
 Appropriate control of sugar concentration
In Rorank SC there is no effective by product utilization and we would recommend that the
company to convert the byproducts in to valuable price. For example by installing;
 Carbon dioxide recovery from fermentation process that can be sold for soft drink
producing factory.
 Another decantation tank to recover ethanol found in the sludge by giving extra time
for settling.
 Anaerobic digester to recover biogas that can be used for boiler
11.3 Potential for further research and assistance

- In this report, it is found that the efficiency of the distillery at the fermentation unit is
low and the factory applies relatively old technology compared to distillers using the
same raw material (molasses). More investigation for improvement of fermentation
efficiency is recommended.
- This report also illustrates that distilleries produce large amount of organic load that
can have a potential for biogas generation and fertilizer. However, the potential must
be supported with further research so that constituents are exactly identified and
appropriate technologies are selected.
CHAPTER TEWELVE
12 PROJECT TITLE: SUBSTITIUTION OF CHEMICAL FLOCULANT BY

NATURAL FLOCULANT (CACTUS MUCILAGE) IN WASTE WATER
TREATMENT
Abstract
RALF uses chemical flocculants aluminum sulfate in waste water treatment. In treatment process
flocculation play an important role for the removals of pollutant or impurities. But our project
focused on natural flocculants. Materials from biological (bean, moringa, and maize) have been
investigated for their potential use for waste water treatment. Interestingly, cactus an abundant
plant, offers various options for the treatment of waste water. The present RALF waste water
treatment uses aluminum sulfate (Al2 (SO4)3 for flocculation purpose. This chemical can be
involved as flocculants and after use it remains in treated water may induced healthy problems
(related with Alzheimer‟s disease). To solve thus problems it is possible to substitute such
chemical flocculent by natural flocculent cactus. This bio material can be involved as flocculent
and eco-friendly with environment. The results obtained in the depollution of waste waters using
various cactus preparations showed very high and promising removal efficiency. Generally,
cactus reduced significantly many waste water parameters (turbidity, conductivity, etc.).
Comparison against the commonly used synthetic flocculants aluminum sulfate demonstrated the
high efficiency of the cactus to eliminate the contaminant or impurities. The cactus mucilage
which consists of complex carbohydrates has a unique surface activity characteristic that make it
an ideal candidate for enhancing dispersion properties, creating emulsification and for reducing
the surface tensions of high polarity liquids. These results indicated that the nopal cactus
mucilage has the potential to the basis for new “Green” technology, which is environmental
friendly and cost effective.
12.1 Introduction
Different methods are used to treat waste water from various origins. Each method is selected
depending on the characteristics of the waste water and the treatment objectives. Depending on
its origin waste water contain complex mixture of organic and in organic pollutants. Discharged
in the environment without treatment, waste water leads to the breakdown of the ecosystem and

creating potential health risks. A complete sequence of waste water treatment may consist of the
combinations of a number of physical, chemical, and biological processes. In spite of their
availability to remove various pollutants from waste water, these methods represent some
disadvantages. For example, although the advantages offered by the coagulation-flocculation
process (lower sensitivity to toxic loadings and to higher amounts of organics, the easy
operation, the energy saving, etc.); the used chemical aluminum sulfate remain in treated water
and may induce health problems. In addition chemical for waste water treatment may react
together and generated new product with unknown health effects.
Generally depending on the used processes and the waste water subjects to treatment, the
technology costly economically in feasible and also not eco-friendly, due to negative impact of
its secondary effluent into the environment. Various natural material of biological origin has
been investigated for their potential use for waste water treatment. Interestingly, cactus is an
abundant natural product, cost effective, safe for human health and biodegradable.
Application of cactus species for waste water treatment is rather recent compared to other natural
coagulant such as nirmali, moringa, maize, etc. the most commonly studied cactus genus for
waste water treatment is opuntia which is colloquially known as “Nopal” in Mexico or prickly
pear in “North America”. This cactus type has long been associated with it is medicinal
properties and dietary food sources.
The coagulation capability of opuntia is most likely attributed to the presence of mucilage which
is a viscous and complex carbohydrate stored in inner parts and outer pad has that has a great
water retention capacity. The cactus mucilage, which consists of complex carbohydrates and
sugars, has unique surface activity characteristics that make it an ideal candidate for enhancing
dispersion properties, creating emulsifications and for reducing the surface tensions of high
polarity liquids. These results indicated that the nopal cactus mucilage has the potential to the
basis for new “Green” technology, which is environmental benign and cost-effective. The cactus
mucilage is a thick substance comprised of proteins, monosaccharaides and polysaccharides,
grows abundantly and is inexpensive and edible.

12.2 Statement of the problem

RALF waste water treatment process uses synthetic chemical flocculants which is Aluminum
sulfate (Al2 (SO4)3) for flocculation purpose. But this chemicals are costly, no degradable, cause
of health problems such as Alzheimer‟s disease and other neurological problems, not
environmental benign and less efficient for turbidity removal.
In order to reduce this problem we have intended to substitute this synthetic chemical flocculants
by natural flocculants from cactus mucilage which is cost effective, easily available,
environmental benign and has high efficiency for turbidity removal in the flocculation process.
12.3 Objectives
12.3.1 General objective
The General Objective of this project is to substitute the synthetic chemical flocculants by
natural flocculants from cactus mucilage for waste water treatment.
12.3.2 Specific objectives

 To extract the natural flocculants from cactus mucilage
 To determine the optimum dosage and pH of natural and synthetic
coagulants for treating waste water.
 To examine the total dissolved solid, conductivity and PH of
treated waste water.
 To compare the effect of natural flocculants on the reduction of
turbidity with aluminum sulfate.
12.4 Literature review

According to Zhang et al. (2006), cetaceous have received great attention in recent years due to
their chemical and structural composition, nutritional components and medical applications, such
as protein, amylose, malic acid, resins, vitamins and cellulose (4).
Saenz, Sepulveda and Matsuhiro (2004) attributed the clotting ability of Opuntia the presence of
mucilage, a complex with viscous large water retention capacity, made of carbohydrate
molecules such as arabinose, galactose, lrhamnose, xylose and galacturonic acid, and stored in
internal and external parts of the cactus. Cactáceas having cladodes (modified stems that can

make the gas exchange with the environment, since the leaves are adapted for minimal loss of
water in photosynthesis) containing mucilage (5).
According to Miller et al. (2008), the ability Opuntiaspp coagulation occurs through the
mechanism of forming chemical bridges, through hydrogen bonds or dipole interactions. The
flakes formed in the study are long and thin, mucilage derived from the common species of
cactus, aloe versa and okra. The authors attribute the polygalacturonic acid, component present
in mucilage, as responsible for the formation of chemical bridges in flocculation (6).
Diaz et al. (1999) used the cactus latifaria as the primary coagulant for the removal of turbidity
from synthetic water, obtaining good results. In this study, the authors made a comparison of the
use of moringa, prosopisjuliflora and aluminum sulfate polymer with cactus, getting in the latter
case the best results (7).
A study by Zhang et al. (2006), using polymer extracted from cactus opuntia as the primary
coagulant, concluded that this presents great turbidity removal efficiency, which can be
compared to the action of moringa as a coagulant. Compared to metallic aluminum sulfate
coagulant, the authors obtained better results than removal of turbidity and total organic carbon
in the polymer cactus, for the same dosage of the coagulant metal. With the results, the authors
attribute the cactus as a substitute for aluminum sulfate in water treatment process, and indicate
cactáceos as potential application in large scale, even though its development is limited to
laboratory scale (4).
Lenz, Zara and Thomazini (2011) studied the efficiency in terms of removing turbidity of raw
water from the river, the extract obtained Mandacaru cactus (Cereus jamacaru), as an aid to
coagulation and flocculation aluminum sulfate. The polymer added to the process mixture
rapidly, after the metal coagulant, allowed the removal of turbidity higher than that obtained by
the aluminum sulfate without the use of the extract.
The use of cactus extract Mandacaru possible the formation of flakes of larger size than that
shown by aluminum sulfate, increasing the settling velocity of the aggregate material. Thus, it is
expected to reduce the time of flocculation and decantation, making the process faster and

greater production of treated water. The use of the extract also caused no significant variation in
pH and alkalinity of the clarified water (8)
The authors emphasize that the extract Mandacaru is viable as an aid in the treatment of water.
Developed from a natural source of cheap and abundant in the country, this product can generate
socio-economic impacts, such as generating income for small farmers and alternative planting in
the Brazilian semiarid region. Cactusopuntia contained 2.3% nitrogen, 29.4%carbon and 1.7%
hydrogen.
12.5 Material and Methods

12.5.1 Chemicals used
 Cactus mucilage
 Aluminum sulfate
 Waste water
 Treated water
12.5.2 Equipment and accessories used

 Knife
 Mass balance
 Beaker
 PH meter
 Pipette
 Conductivity meter
 Vibrator (mixer)
 Dish
12.6 Methods
12.6.1 Mucilage extraction
Fresh Cactus pad was collected from cactus plant which is easily available in some parts of
amhara region. Then; the cactus pad thrones were removed. The cactus pad was washed and the
outer part of the cactus pad was removed which is unnecessary for our work. The pad was heated
which causes high potential for mucilage secretion and allowing it to flow easily. The pad cut

into small pieces with the help of knife. Finally, the piece part of the pad was pressed on the dish
by hands and the mucilage was separated from the dish into plastic bottle.
12.6.2 Analysis of PH and coagulant dosage

Mixing process: Six (6) beakers contain 500ml of waste water was prepared and the dosage of
aluminum sulfate and mucilage was measured. The cactus mucilage was added into the three
beakers contains 500ml of waste water at the dosage of 1.6,3.1 and 5.4g/l. Aluminum sulfate was
added into the remaining three beakers contains 500ml of waste water at the same dosage of
cactus mucilage. Then, each beaker was placed on the vibrator which is used as a mixer. It was
mixed for 20 minutes at the same speed and it was settled for 35 minutes.
12.6.3 Measuring the parameter

Conductivity and TDS measuring: These parameters were measured directly by insert the
conductivity meter into the waste water sample and treated water.
PH measuring: The pH value was measured by directly insert the PH meter into the waste water
sample and treated water.
12.6 Results and discussions

The results that we have gotten from the experiment are listed below in the table.
Table 12-0-1the result of physicochemical analysis by using cactus mucilage
Dosage Before treatment After treatment

(g)
No PH Conductivity TDS(mg/L) PH Conductivity TDS(mg/L)
(µsm/cm) (µsm/cm)
1 1.6 7.75 375 179 6.79 205 185
2 3.1 7.75 375 179 6.65 147 208
3 5.4 7.75 375 179 6.56 155 215
4 1.6 8.75 375 179 6.97 179 199
5 3.1 8.75 375 179 6.85 125 195
6 5.4 8.75 375 179 6.70 175 189
7 1.6 9.75 375 179 7.60 186 221

8 3.1 9.75 375 179 7.34 138 229

9 5.4 9.75 375 179 7.25 182 225
Table 12-0-2 the result of physicochemical analysis by using Aluminum sulphate
Before treatment After treatment

No Dosage PH Conductivity Turbidity PH Conductivity Turbidity
(g) (µsm/cm) (mg/L) (µsm/cm) (mg/L)
1 1.6 7.75 375 179 6.80 243 201
2 3.1 7.75 375 179 6.75 215 213
3 5.4 7.75 357 179 6.69 228 220
4 1.6 8.75 375 179 7.95 234 205
5 3.1 8.75 375 179 6.95 137 203
6 5.4 8.75 375 179 6.88 182 202
7 1.6 9.75 375 179 7.67 195 227
8 3.1 9.75 375 179 7.54 187 232
9 5.4 9.75 375 179 7.38 190 241
Using the above tables the comparison between can be tabulated using one table
Table 12-0-3 the result of comparison of cactus mucilage with aluminum sulphate on
physicochemical analysis for waste water treatment.
Dosag Treated with cactus mucilage Treated with Aluminum sulphate

e (g)
No PH Turbidity( Conductivity PH Turbidity Conductivity

mg/L) (mg/l) (µs/cm)
(µs/cm)
1 1.6 6.7 2.61 205 6.80 2.85 243
2 3.1 6.65 2.68 147 6.75 2.93 215

3 5.4 6.56 2.71 155 6.69 3.04 228
4 1.6 6.97 2.75 179 7.05 3.12 234
5 3.1 6.85 2.15 125 6.95 2.45 137
6 5.4 6.7 2.35 175 6.83 2.57 182
7 1.6 7.6 2.65 186 7.67 2.79 195
8 3.1 7.34 2.3 138 7.54 2.67 189
9 5.4 7.25 2.25 182 7.38 2.60 190
In order to optimize the flocculation process, the effect of PH and the flocculent dosage was
examined. By taking the best value of the parameter, we can identify the optimum value.
12.6.1 The effect of cactus mucilage and aluminum sulphate on waste water
treatment
The effect of pH was adjusted in the range of 7.75 to 9.75.but from the above table we have seen
that the best value was at PH value of 8.75. As the results are presented in the above table the
percentage removal of metal ions, and suspended solid depends greatly on PH.
When we see the removal of metal ion and other flocculating substance or suspended solids from
the waste water using cactus mucilage is much better than that of aluminum sulphate. Because as
we see in the table above at a PH of 8.75 and dosage of 1.6 the conductivity and turbidity of
waste water after treatment by using cactus mucilage is 179 µs/cm and 2.75NTU, whereas the
conductivity of waste water after treatment by using aluminum sulphate is 234 µs/cm and
3.12NTU. This indicates that in both case cactus mucilage has good performance so as to remove
both conductive and turbid materials from the waste water.
12.6.2 The effect of cactus mucilage and (Al2 (SO4)3 dosage

We have done the experiment to determine the optimum dosage and test at the pH value of
8.75.The cactus mucilage Al2(SO4)3 dosage were varied in the range from 1 .6,3.1and 5.4 gram
and constant the other factors in order to know the relationship between the percentage removals
of metal ions and suspended solid with flocculent dosage. The result in the above table shows the

percentage removal of this suspended solid and metal ion increased with increase the dosages up
to the optimum dosage of 3.1g per 500ml of sample water after which its gradual decrease was
observed. The increase in dosage resulted in increase in negatively charged sites available for
metal ion aggregation. However, after the optimum dosage, further increase in dosage caused the
aggregated particles to respreads and would also disturb particle settling presented that the
flocculent forms an envelope on the suspended particles and causes them to remain in
suspension; thus, removal efficiency decreases with increasing dosage beyond the optimum.
12.7 Conclusion
We have conclude that from the project the efficiency of cactus mucilage is higher than that of
aluminum sulfate for removal of metal ions and turbidity reduction and the percentage removal
of metal ion is increased with the increasing of pH and flocculent dosage up to the optimum
value was obtained. But we have seen that the TDS was increased with increasing dosage.
12.8 Recommendation
When we employ our project it was necessary to dry the cactus using drying equipment before
we extract, so as to reduce the moisture found in cactus and extract the flocculants from it. But
due to the unavailability of drier we didn‟t used. We recommend that for the future the lab to
fulfill this device.

Bibliography
1. Document of the factory.
2. Paturau, J.M. By-product of the sugar industry. New York : Elsevier publishing company,
1969.
3. Houghton-Alico, Doann. Alcohol fuels:policies,production, and potential. s.l. : West view,
1982.
4. al., Zhang et. Coagulation and Flocculation Process Fundamentals . s.l. : MRWA: Minnesota
Rural Water Association, 2006.
5. Saenz, Sepulvede and Matsuhiro. Coagulation Flocculation dnd Clarification.In: Fact sheet
on Environmental Sanitation . 2004.
6. al., Miller et. Optimization of Coagulation-Flocculation Process with Aluminum Sulphate
Based on Surface Methodlogy. 2008.
7. al., Diaz et. Coagulation,Flocculation and Clarification of Drinking Water. s.l. : HACH
company, 1999.
8. Lenz, Zara Thomazini. Reuse of Drinking Water Treatment Plants Slugdes in Agriculture.
2011.
9. al, zhang et. coagulation and floculation process fundamentals. MRWA : Minnesota Rural
Water Association, 2006.

Appendices
Beer: fermented mash. In some literature it is also called wine.
Degree Brix: Unit of solid content in molasses Feint alcohols: mixtures of low volatile alcohols
which are difficult to separate.
Fusel oil: higher alcohols (90-150oC) formed decomposition by yeast of amino acids and
collected in the rectification column.
Inoculum or leaven: the amount of yeast that is added to the mash to be fermented.
Mash: a fresh and diluted molasses ready either for fermentation or as medium for yeast
propagation. It is also known as must.
Stillage: the wastewater discharged off from the mash column. It is also known by the names
slop,vinnase or dunder.

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FINAL INTERNSHIP REPORT AND PROJECT PAPER

Name of students: Atefrachew Seyfu

RORANK BUSINESS S.C ALCOHOLIC LIQUOR FACTORY Page i

RORANK BUSINESS S.C ALCOHOLIC LIQUOR FACTORY Page ii

Table of content ............................................................................................................................. iii

List of tables ................................................................................................................................... ix

List of figures .................................................................................................................................. x

Abstract ......................................................................................................................................... xii

CHAPTER ONE ............................................................................................................................. 1

1.1 Historical Back Ground ........................................................................................................ 2

1.2 Vision and mission of the factory ......................................................................................... 4

1.3 Products of the company....................................................................................................... 4

1.5 Job organization and structure of the company .................................................................. 6

1.6 Scope and Purpose of the Factory......................................................................................... 9

1.7 Objective ............................................................................................................................. 10

1.7.1 General objective ......................................................................................................... 10

1.7.2 Specific objective ......................................................................................................... 10

CHAPTER TWO .......................................................................................................................... 11

2 LITRETUR EREVIEW ............................................................................................................. 11

2.2 World Alcohol Production and Ethiopia‟s Case ................................................................. 11

2.3 Ethanol Production Technologies ....................................................................................... 12

2.4 Alcohol Production from Molasses .................................................................................... 12

CHAPTER THREE ...................................................................................................................... 13

RORANK BUSINESS S.C ALCOHOLIC LIQUOR FACTORY Page iii

3 GENERAL PROCESS OVERVIEW OF THE FACTORY ...................................................... 13

3.1 Raw materials...................................................................................................................... 13

3.2 Major unit operation involved in this factory ..................................................................... 14

CHAPTRE FOUR ......................................................................................................................... 17

4 FERMENTATION HOUSE ...................................................................................................... 17

4.1 Introduction ......................................................................................................................... 17

4.2 Raw material for fermentation ............................................................................................ 17

4.2.1.1 Molasses Storage ................................................................................................................ 18

4.2.2 Nutrients ....................................................................................................................... 18

4.2.2.1 DAP (Di ammonium phosphate) and Urea ......................................................................... 19

4.2.3 Yeast ............................................................................................................................ 19

4.2.4 Sulphuric acid .............................................................................................................. 20

4.2.5 Water ............................................................................................................................ 20

4.3 Fermentation process (Methods)......................................................................................... 21

4.4 Major process step in fermentation ..................................................................................... 21

4.4.1 Raw material preparation ............................................................................................. 21

4.4.1.1 Molasses treatment ............................................................................................................ 21

4.4.2 Yeast propagation (inoculum preparation) .................................................................. 22

4.4.3 Final fermentation ........................................................................................................ 23

4.4.3.1 Stages of fermentation ....................................................................................................... 24

4.4.3.2 Abnormal fermentation ...................................................................................................... 24

4.5 Fermentation process description ....................................................................................... 26

4.6 Factor affecting fermentation process ................................................................................. 27

RORANK BUSINESS S.C ALCOHOLIC LIQUOR FACTORY Page iv

4.6.1 Temperature ................................................................................................................. 27

4.6.2 Amount of sugar .......................................................................................................... 28

4.6.4 Duration of fermentation.............................................................................................. 28

4.7 Calculations on fermentation .............................................................................................. 28

4.7.1. Material balance on fermentation house ..................................................................... 28

4.7.2 Process Efficiencies and Yields ................................................................................... 33

4.8 Equipment used .............................................................................................................. 36

CHAPTER FIVE .......................................................................................................................... 37

5 DISTILLERY HOUSE .............................................................................................................. 37

5.1 Introduction ......................................................................................................................... 37

5.2. Types of equipment............................................................................................................ 38