Final Report

ADDIS ABABA UNIVERSITY
ADDIS ABABA INSTITUTE OF TECHNOLOGY
SCHOOL OF CHEMICAL AND BIO ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
INTERNSHIP FINAL REPORT
HOST COMPANY:ARJO DIDESSA SUGAR FACTORY
Prepared by :Tesfaye Bulti
ID No_:UGR/4207/12
ACEDAMIC ADVISOR:
COMPANY ADVISOR:
PREIOD OF INTERN:
[Type the document subtitle]

Final Internship Report
Contents
1.3. The Vision, Mission and Value of Arjo Didessa Sugar Factory......................................
1.3.1. Vision....................................................................................................................
1.3.2. Mission..................................................................................................................
1.3.3. Values and Principles............................................................................................
1.4. General Objectives...................................................................................................
1.4.1. Factory Objectives....................................................................................................
1.4.2 Specific Objectives.................................................................................................
1.7. The main customer and end users of the company.....................................................
2.1Methedologies Used..................................................................................................
2.1.1. Teaching learning process with company advisor at factory................................
2.1.2. Observation..........................................................................................................
2.1.3. Questionnaires......................................................................................................
The reaction takes place as follows during the plant growth..........................................
3.2.4. Bagasse Elevator...................................................................................................
3.2.5. BOILER HOUSE......................................................................................................
3.2.5.1. Boiler Fans.............................................................................................................
3.2.5.2. Super heater..........................................................................................................
3.2.5.3. Air Pre-heater........................................................................................................
3.2.5.5. Boiler Water treatment plant............................................................................
3.2.5.5.1. Physical treatment plant.....................................................................................
It’s a mechanism that treating or softening the water that comes from lake or river.
First water is treated physically by storing the fresh water comes from river and the
mud and an undissolved material is settled down...............................................................
Then this water is pumped through overhead tanker to water softening plant. In this
plant there is a tank called multi grade filter and the tank is full of sand. When this
water is passed through the suspended material in the tank the mud is further trapped
in and the filtered water is going to chemical treatment for further treatment.....................
3.2.5.5.3. Why we need Water Treatment…?.....................................................................
Deaerator............................................................................................................................
3.2.5.5.5. BOILER COMPONENTS....................................................................................
3.2.8.10. Packaging.........................................................................................................
4. OVERALL BENEFITS GAINED FROM THE INTERNSHIP..........................................................
4.9. The measures I take in order to overcome these challenges.......................................
5. CONCLUSION
Department AND RECOMMENDATION..................................................................
of Chemical Engineering Page
AAiT
Department of Chemical Engineering Page

Acknowledgments
First and foremost I would like to acknowledge my God that helped me in
everything .In addition would like to thank my supervisor Dr.Abiy Tirfe
at AAiT, who gave me the chance to do my internship at Arjo Didessa
sugar factory .Moreover ,my heartfelt gratitude goes to my mother , my
dear two brothers and my dear sister.
Last but not least, I owe whole hearted gratitude to the whole Arjo
Didessa sugar factory workers specially my advisors and machine
operators, who told me everything.

Declaration
The undersigned declaration declares that I have been at Arjo Didessa
Sugar factory from March 1, 2023 to June 30, 2023 for my internship
from Addis Ababa University in Chemical Engineering. It is approved
that this paper is my own work during my internship time is approved by
company advisor, University advisor and myself as below by writing our
name with our sign.
Name and signature of the evaluator advisor and department
Name of Advisor Signature Date
___________________ ______________ ______________
Name of Department Head Signature Date
___________________ ______________ ______________
Prepared By: Signature Date
Tesfaye Bulti______________ ___June 30,2023__________

Abstract
An internship means knowledge skill developing practically whatever we
learn theoretically. During this practically program we have develop
professional and practical skills by working in different section of the
industry. This report generally shows that the internship have been
worked for four months in Arjo Didessa sugar factory.
In all sugar factories the main objective is to produce maximum amount

of sucrose from cane. In Arjo Didessa Sugar Factory sugar cane is used as
a raw material to produce a commercial sugar. In the process many unit
operations exits such as Conveyors (transportation), Size reduction(sets
of knives),mill(extraction),Boilers(steam generation), Door
clarifier(separation of clear juice from mud), Pre heaters(heating of
juice), Evaporators(for syrup formation), Vacuum pans(grain
formation),Crystallizers(crystal develop), Centrifugal(separation of sugar
and molasses), Dryer(removal of sugar moisture), Cooler, Packing and
storage.
Those all machineries in Arjo Didessa Sugar Factory obtained operating

energy from steam produced by boilers and ELPA (by electric power).As
well there are a lot of loss problems due to its old process technology and
improper supervision in that factory. These losses are through: - bagasse,
inversion and filter cake.
Key words:-Bagasse, Syrup, Sugar cane

1. INTRODUCTION
Sugar is a very important flavored ingredient used in much food, drink

and pharmaceutical purpose world wide .It is extracted from sugar cane
and sugar beet from which it can be obtained in economical way. Among
the sugar factories producing sugar in Ethiopia Arjo Didessa sugar
factory is one that produces refined sugar from raw sugar in integrated
way from sugar cane.
The factory have 80,000 tone crushing capacity per day which is
established by an individual owner.
1.1. Company overview
Arjo Didessa Sugar Factory is 395km to the west far from Addis Ababa.
For this factory the main issue is the production of sugar. Area covered
by this factory for production of cane is 50,000hectar. But for now the
area on which the cane is produced is 40,000hectar and the rest one is
assigned for future plan. The main purpose of this factory is to produce
the sugar continuously with a good quality and sell the sugar in
international market. It also opened the chance of work for non-employer.

Figure 1.1 Arjo Didessa Sugar Factory gate
1.2. Back Ground of the Company
Arjo Didessa sugar Factory is established an individual person named

Hajji Margie paradise in 2001 E.C and this person’s citizenship is
Pakistan. His purpose is to increase the economic development by
producing sugar, using the modern technology. In 2003 it started
producing some sugar, but fully not succeeded his work and then sell his
factory to the Arjo Didessa sugar factory was first established by
individual person Ethiopian Democratic Government in 2005 E.C. Arjo
Didessa sugar factory is located in the western part of the country,
Oromia National Regional state, bordered in East Wollega, Buno Beddele
zones and Jimma zones within Didessa valley. It’s located at 395kms
distance from Addis Ababa through Nekemte towns. At North western of
Jimma 160km distance route. It is one of the sugar factories and sugar
development projects that are given due attention by our developmental
government. The total concession area of the factory is about 50
thousand hectares and 49 kebeles of east Wollega, Buno Beddele and
Jimma zones are included within its command area. Arjo Didessa within
an average altitude of 1350 meters above sea level, as nearly hot climate
the average annual rainfall is 1400 milliliters. The rain extends from May
to October. The bulk of the soil within the command area of the factory
is black cotton and there is also reddish brown in small quantity.

Generally, the climate and the soil around the command area of the
factory are suitable for sugar cane production. The command area of Arjo
Didessa sugar factory encompasses 15 kebeles of 4 Woredas from east
Wollega zone, 31 kebeles of 5 woredas from Buno Beddele zone and 5
kebeles of 1 Woreda from Jimma zone. The command area of the factory
is to be used for sugar cane plantation, irrigation, infra-structure and other
purposes. Arjo Didessa sugar factory, previously called Al-Habash (by
Pakistan) sugar mills and established by Pakistan investor in 2009, was
transferred to FDRE Sugar Corporation and commenced operation as of
August, 2012. The erection of the factory was completed by 90 percent
when the factory was transferred to our government. Members of the
management have been assigned and the needed man power has gradually
been fulfilled starting from the year 2013 during the current budget year
the remaining 10 percent of the erection of the factory was completed and
the factory commenced production of refined sugar as of April, 2015.The
produced sugar is refined and meets export standard so that our country
will earn foreign currency by exporting it for world market. The factory
has the crushing capacity of 8000 tone cane per day (TCD).
The factory can have the crushing capacity of 12000 TCD by further
improving its design capacity in the future. About 117,481 quintals of
refined sugar was produced during the current budget year. In
collaboration with worked and zonal administrative bodies, a number of
discussions were held with farmers found in immediate premises of the
factory with the aim to enable them beneficiary of the development in
connection with sugar projects. The source of the water for irrigation is
Didessa River and river side dam construction is under way by Oromia
water works enterprise. Currently, about 2729 hectares is planted and
covered by sugar cane plantation. In addition, sugar to the factory can
have the capacity to produce products like ethanol by using sugar by
products. After satisfying its self electrical power for national grid. The
factory has also the opportunity to carry out animal fattening by using
byproducts. Currently the factory has carried out multi furious activities
and creates job opportunity for 1000 permanent and 1750 contract and
seasonal workers. It has played its share in efforts exerted to eradicate
poverty by making the community beneficially of all available
opportunities. A part from these about 200 people drown from the local
community being organize under 20 micro and small-scale enterprises
and provide different services to users. They are striving to bring change

to their life. Some important factors that make Arjo Didessa sugar factory
different from other sugar factories;
The factories found by the side of the asphalted Nekemte-Beddele route.
It’s the only factory that produced refined sugar in Ethiopia.
Cane handling and cane preparation units operates hydraulically and this
makes cane preparation operation very easy.
It’s the only factory that own wood chipper. Two wood chippers that are
found in the factory easily prepare woods that are needed as a fuel for
boilers.

Figure 2.Picture of Arjo Didessa Sugar Factory during operation
1.3. The Vision, Mission and Value of Arjo Didessa Sugar Factory
Arjo Didessa Sugar factory has its own vision, mission and value as listed
below: -
1.3.1. Vision
To create sugar industries competitive enough at international level based

on a sustainable growth pattern.
1.3.2. Mission
Arjo Didessa as an agro industry striving to increase stake holders’

satisfaction through core business activity including.
 Expanding and optimizing sugar cane plantation of own and out

growers’ cane to meet own requirement and creating income for
the out growers, sufficient employment opportunities in plantation.
 Producing and marketing sugar and downstream products.
1.3.3. Values and Principles
 Team work brings individual and organizational growth

 Sustainable change and competitiveness
 We encourage creativity and best performance
 We never stop learning
 Productivity is our typical feature

1.4. General Objectives
1.4.1. Factory Objectives
The main objective of this factory is production of the sugar above the
planned by using the modern technology to decrease the accident in the
factory, especially in electrical system because of that if the fault is
appeared in electric system, some machine and the life of employers may
be affected. So, to decrease this problem we must use the safety rule and
modern technology.
1.4.2 Specific Objectives
 To plan and grow sugar cane

 To carry on specific industrial and agricultural research
 To study plan and implement varies sugar development programs
 Produce white sugar (refining sugar)
 Create direct job opportunities for more than 1000 citizens.
1.5. Significance of factory.
The factory is still very necessary for our country to produce clarified
sugar. This means if we look another sugar factory in Ethiopia, have no
refinement room, Because of this after production send to another place
to refine. But Arjo Didessa sugar factory have its own refinement room to
clarify.
1.6. Main product or service of the Arjo Didessa sugar factory.
The main product of Arjo Didessa sugar factory is sugar. It produces

clarified sugar in Ethiopia.
Bagasse is the byproduct because it has refinement room which is not

found in other sugar factory by-product used as fuel in boiler to produce
electricity.
By-products during production process:

Bagasse: accounting for 30-33% of the weight of sugarcane, is used as

fuel in boilers to produce electricity. Produced electricity will be used for
sugarcane crushing mills and for sale.
Molasses: accounting for 5% by weight, is used in food processing and

production of ethyl alcohol; and is used as input materials for producing
alcohol or ethanol.
Microbiological: accounting for 3% -5% by weight, is used as fertilizer

in the cultivation process.
1.7. The main customer and end users of the company
The main customers and end users of ADSF are;
Soft drink Company.
Medicinal factories.
Our community.
Some are exported.

1.8. Organizational Structure of Arjo Didessa sugar factory
Figure 1 Overall organization structure of Arjo Didessa Sugar Factory.

2. MATERIALS AND METHODOLOGIES

2.1Methedologies Used
During the internship at the company the following methodologies were

used to collect data, change what is obtained theoretically into real word
practice.
2.1.1. Teaching learning process with company advisor at factory
This methodology was used during the intern when the company advisors
told us every process and procedures of sugar production. This method of
acquiring knowledge is preferred to know the production process
theoretically before the real world is seen.
At the every process from the start to the end is learned theoretically first.
2.1.2. Observation
This methodology of getting knowledge is preferred after the theoretical

knowledge is acquired. This methodology is used during the intern when
the company advisors and process operators showed us every process and
procedures practically after telling us theoretically. This methodology is
most suited to the internship objective.
Through observation every process skills in that factory is learned easily

and quickly.
2.1.3. Questionnaires
While doing the internship many questions are asked and answered
between company advisors and internship doers. This methodology is
used to obtain specific information on a certain topic by asking question.
During the intern I asked many process operators and my advisors.
2.1.4. Laboratory experiment
In sugar factory laboratory experiment is important to be used; in order

avoid wastage of juice during the heating process, for testing final
product quality to meet the market demand.
Laboratory experiments done during the internship:
Before using the water that is released from all evaporators that water is
being tested for whether or not it contains sugar. The test is being done by
adding chemicals like alphanatol and sulfuric acid to water released from
evaporator. If the color is changed to blue the solution contains sugar and
some adjustment should be taken.

The final sugar is tasted in the lab before packing for its purity and pol.
2.2. Materials
2.2.1. Sugarcane
With its high fiber and carbohydrate content constitutes an important

renewable Source of energy. Sugarcane is planted in soil and the plant
growth in the course of its life cycle, during which it converts water and
CO2 from atmosphere into carbohydrates in the presence of sunshine, a
phenomenon termed as photosynthesis.
The reaction takes place as follows during the plant growth.

6CO2 + 6H2O + Light energy → C6H12O6 (sugar) + 6O2
The principal components of the cane stalks to be processed for

commercial sugar production are:-
 Water ------------------------------70-75%
 Sucrose ----------------------------10-17%
 Reduced sugars ------------------ 0.4-2%
 Organic non-sugar-------------- 0.5-1%
 Mineral matters -------------------0.5-1%
 Fiber-------------------------------10-16%
Besides these the composition of juice extracted from cane is marked by

varying amounts of mineral salts and organic compounds. The
composition of sugarcane is conditioned by the variety of cane, soils and
agricultural factors in addition to the climate during the different phases
of growth of the plant.
Sugars in general are known as carbohydrates being formed of carbon,

hydrogen and oxygen. Simple sugars like glucose, fructose etc. are
monosaccharide’s which cannot be further decomposed into simple
carbohydrates by either acids or enzymes
The sugar industry processes sugar cane and sugar beet to manufacture
edible sugar. More than 60% of the world’s sugar production is from
sugar cane and the rest is from sugar beet, but in our country sugarcane is
the only raw material used for sugar production, due to our country’s
tropical climate. In addition white sugar is produced from sugar cane.
Figure 1 the sugar cane
2.2.2. Sugar beet

Sugar beet is the other raw material used for sugar production worldwide.
The sugar beet is a root crop that flourishes in temperate climates where
the growing season is about five months long. Farms can be found in
California, Colorado, Idaho, Michigan, Minnesota, Montana, Nebraska,
North Dakota, Oregon, Washington, and Wyoming.
Beets are planted in late March/early April and harvested in late

September and October. When fully grown, a sugar beet is about a foot
long, weighs two-to-five pounds, and is about 18% sucrose. They are
processed at 20 factories that are located near the fields, because beets are
a perishable vegetable.
Factories generally operate around the clock, seven days a week, from
October through April. Beet sugar represents about 54% of domestically-
produced sugar. There is no difference between beet and cane sugar.
Some beet sugar brands you might recognize are: Crystal Sugar, Western
Sugar, Pioneer Sugar, White Satin, and Speckles’ Sugar.

Figure 1 Picture of sugar beet
3. METHODS AND PROCESS OF SUGAR PRODUCTION

3.1 Methods of sugar production
A different sugar factory produces sugar differently by using different

methods of production. Some factories produce raw sugar only while
others produce refined sugar from raw sugar.
In general there are two methods of sugar production by using the sugar
cane as raw material. These methods are:
1. Raw sugar production method and

2. Refined sugar production method
Raw Sugar: The product of cane sugar factories which is an intermediate

crystalline product resulting from the evaporation of water from sugar
cane stalk juice.
Refined Sugar – High purity white sugar manufactured from remelted

raw sugar.
Arjo Didessa sugar factory is one of the sugar factories in Ethiopia that
produces both refined and raw sugar in integrated manner as follows:
3.2 Sugar production process

3.2.1. Cane Preparation unit operation

Cane preparation is the process of reducing and cleaning cane to make

ready for juice extraction or the process of the cane fed to mill and into
small pieces suitable for the subsequent juice extraction.
In sugar production the process from burning to milling is known as cane

preparation process, since it makes ready the cane for juice extraction.
The main purpose of cane preparation includes:
 To cut the cane into small pieces for feeding the mill.
 To produce material that has right characteristics for juice
extraction.
 To get clean material for obtaining clean juice.
That process includes the following activities.
3.2.1.1. Cane Burning
First and foremost the matured cane that is ready for harvesting is burned
by fire to remove leaves and a layer of wax for a short period of time after
which only the stalk remains.
Purpose of burning of cane:-
 To remove impurities

 To reduce transportation cost
 To reduce the man power needed
 To reduce loading
 To reduce sugar losses
3.2.1.2. Harvesting
At Arjo Didessa sugar factory harvesting is done by man power. During

harvesting the stalk is cut slightly above the ground which remains the
root intact, that allow the cane to be harvested many times without
planting.
3.2.1.3. Transportation and balancing the cane

The harvested sugar cane is transported to the factory and balanced by a

machine called weight bridge before the cane is unloaded to be stored at
the cane yard for a temporary period of time. Sugar cane is balanced for
the following reasons:
To compare the amount of sugar that can be obtained from a certain

amount of sugar cane with the world standard per ton of cane.
 To estimate amount of chemicals that needs to be added to the

sugar during production process.
 To accurately know the different cane varieties and calculate the
yield of cane.
 To determine input and output capacity. To estimate the cost which
is paid for the farmer whose the cane is belongs.
 To know the chemical control and determination of factory
performance
3.2.1.4. Storage at Cane Yard
Storing the balanced cane at the cane yard is not always advisable but, it
is stored during:
1) The production process is interrupted due to a certain problem in the

factory.
2) When the amount of cane harvested is not enough to start crushing.
To avoid evaporation of water from the cane and inversion of sucrose the
cane must reach the production process at most within 24 hrs.
3.2.1.5. Cane Unloading
Is a process of dumping cane from cart, lorry and trailer by a material

called fixed type crane which have high lifting capacity known as hello
crane.

Figure 3.1 hello crane
Hello crane fed the cane to feeding table having crane is leveled by the
leveler. Hello crane is used to feed sugar cane into cane table that in
return inter the cane to the machine called Main cane
Carrier( MCC).Without size reduction transported to main cane carrier.
Cane Leveler is a set of knives which can even out the layer of the cane in
order reduce overloading before reaching the first cuter.
Then the cane is transported to the first cutter.
3.2.1.6 Crushing and shredding
Hello cane is used to feed sugar cane into cane table that in return inter
the cane to the machine called Main cane Carrier( MCC).
MCC is a machine that transfer the cane to the machine called Auxiliary
cane carrier (ACC).
3.2.1.6.1. The first cutter

Before the cane started to be reduced in size by the first cutter leveler is
used to level the cane to make suitable condition for the first cutter.
ACC feeds the cane to the first Cutters that cut the cane into pieces that
make it suitable for shredding the cane. Arjo Didessa sugar factory have
two cutters both of them are operated by the turbines that convert
mechanical energy to electrical energy which is operated by steam
generated byre boiler. The first cutter cuts the cane into pieces .
3.2.1.6.2. The second cutter
The cane from the first cutter enters the second cutter where it cut into
smaller pieces after which it enters the shredder.
Both cutters have knives that cut the cane into pieces, in which the first
cutter have 60 knives and rotates at 600 rpm and the second cutter have
80 knives.
3.2.1.6.3 The Shredder
In the shredder the cane cut into finest pieces that, expose the inner part
without juice extraction which have 172 hammer on it that allow the cane
to be reduced into pieces.
Figure 3.2 shredder

3.2.1.7. Magnetic separation
Magnetic separator is used to trap and collect magnetic substance

specially broken knives, iron and the broken machine parts etc, In order
to save our rollers.
There is a magnetic separation between milling and shredding that help to

avoid the entrance of metals into the mills.
3.2.2. Milling (Juice Extraction)

The finest pieces of cane enter the mill where juice is separated from the
bagasse. Milling is the process of extracting juice from prepared cane or
the process where bagasse is removed. Arjo Didessa sugar factory have
five (5) mills one after another.
The shredded pieces of sugarcane travel on a conveyor belt through a

series of heavy duty rollers consisting of two rolled crushers .At every
mill juice is extracted and the one that is not extracted in first mill is
extracted in the second mill, that not extracted in the second mill will be
extracted in the third mill and son.
During juice extraction
The cane is made to pass through a succession of rollers that comprises

the milling tandem, and its juice is squeezed out as it goes through. To
help to extract the maximum juice, use of imbibitions water is made. The
extracted juice is sent to process and the fibrous material left after
milling, known as final bagasse, is sent to the boilers to be used as fuel
for the generation of steam.
3.2.2.1. Methods of Separation of Juice from Bagasse
The sugar content of cane is dissolved in juice contained in millions of

plant cells. There are two different systems of extracting the sugar
containing juice from the cane. Such methods of extraction are: -
3.2.2.1. Applying pressure

By means of pressure in a number of mills provided with three rollers

through which the cane is forced.
3.2.2.2. Using diffusion
By means of diffusion, extracting juice by applying heat, immersion in

water drum and squeezing of the bagasse. In this room there is about 80%
of the juice are extracted by adding imbibitions water and lime. The lime
used for settling material by increasing density difference.
Mill is a combination of three rollers
Top roller: - is driven from prime mover through a redaction gearing. it is

controlled by hydraulic drum may rise or float with the variation in the
feed cane. It is flexible roller.
Delivery and feed roller: - are moved by the fraction of top roller .they
are rigidly fixed on their position.
The main objective of mill tandems;-
 To extract a maximum amount of juice from the prepared cane.

 To produce a bagasse with minimum amount of pol content.
First mill: - 65%of juice is extracted from the prepared cane in the first
mill. The juice extracted is called primary juice. To extract this juice the
prepared cane is delivered to top roller with the aid of under feeder when
top roller rotates it produce frictional force. With both feed roller where
the first extraction takes place and frictional force.
B. Trash plate: - The plate is which act as a bridge between the feed and
delivery roller. It maintains a part of compaction achieved at the feed roll
while turning the bagasse in to the nip between the top and discharge roll.
Also it conducts the bagasse from feed roller to the real mill opening have
the teeth cut in the side of feed roller.
C. Roller scraper: - it is fitted on the top and delivery rollers. Their purpose
is to scratch of the bagasse caught.

D. Second mill-fourth mill:-the left 35% of juice is extracted by these mills.

This juice is called secondary juice.
3.2.2.3. Imbibitions technique
It is not possible to remove all juice from the bagasse by pressure. In

order to obtain a satisfactory extraction of sugar, it is necessary to dilute
the juice remaining in the bagasse by adding water. Therefore;
imbibitions is the process in which the water is put on the bagasse to mix
with and dilute the juice present in the bagasse. The water so used is
termed as inhibitions water. The motor used in those milling 850 kW for
each of them and the rpm 1200 for each. The juice obtained from the mill
is known as mixed juice.
Finally mixed juice is separated from bagasse at fifth mill that is used in
the boiler for steam generation and the mixed juice enters the first heater.
3.2.3. Mixed juice tank
It is a tank which stores extracted juice for further processing in process

house.
3.2.4. Bagasse Elevator
Bagasse elevator is a type of inclined carrier which transports the bagasse

from last mill outlet to all boilers’ inlet as well as towards the additional
bagasse storage point.
Block Flow Diagram [Feed Section + Milling House]

Diagram 1.Block Flow Diagram [Feed Section + Milling House]
3.2.5. BOILER HOUSE
A steam generator or a boiler is defined as a closed vessel in which water

is converted into steam by burning of fuel in presence of air at desired
temperature, pressure and at desired mass flow rate.
Boiler is extremely dangerous equipment which should have to be treated

with ultimate care.
Figure 3 boiler
Function of a boiler:

 Used in steam turbines to develop electrical energy

 Used to run steam engine.
 In the textile industries, sugar mills or in chemical industries as a
co generation plant
 Heating the buildings in cold weather
 Producing hot water for hot water supply Producing hot water for
hot water supply
 The battery of boilers and its connections form one of the most
important parts of any factory, and are of peculiar interest in a
sugar industry, in view of the evaporation produced by the steam
here generated, in addition to that required to supply motive power
for the engines.
A water tube boiler is a type of boiler in which water circulates in tubes

heated externally by the fire. Fuel is burned inside the furnace, creating
hot gases which heats water in the steam-generating tubes.
The boilers we use in sugar factories are almost water tube boiler type
and entirely of the multi tubular class.
The water tube boilers have the advantage of being built in large units, of
being adapted for high pressure, and of being capable of raising steam
quickly.
In water tube Boiler a number of water tubes are arranged in and around
the furnace. This type generally gives high steam production rates, but
less storage capacity. Water tube boilers are also capable of high
efficiencies and can generate saturated or superheated steam.
In Arjo Didessa Sugar Mill (Factory) two water tube boilers are installed
to generate steam from water at the same conditions.
A steam super heater is integrated with boiler and in this saturated steam
is converted to superheated steam by exchanging heat with flue gases.
An air Pre-heater is also integrated with boiler. Flue gases enter the air
per-heater at 250°C and leave at 180°C. 2 tons of steam is produced per
ton of bagasse combusted.

Steam from all two boilers combine in the steam header at 350°C
temperature and 24 kg f/cm2 (bar) pressure, and then this steam is
transferred to milling house, feed section, and power house to run
turbines.
When steam reaches the milling house and power house its temperature
becomes 325 ~ 330°C due to heat losses to environment. While the
pressure of the steam reduces to 22 kg f/cm2 due to pressure drops in
pipes and valves. After steam turbines its temperature becomes near
about 180°C and then it goes to steam superheated, where its temperature
is reduced to 125°C which is the requirement of process house.
3.2.5.1. Boiler Fans:

ID Fan (Induced Draught Fan)
: Induced draught fan draw gases out of the boiler. The gas has already
passed through the air heaters and precipitators before it has reached
these fans.
FD Fan (Forced Draught Fan):
It takes air from atmosphere and passes it through the air per-heater tubes,
which is then blown into the furnace from its base through dumping gate.
This warm air helps in combustion and spreading bagasse. Each unit has
forced draught fan. The fan draws warm air from the top of the boiler
house through large air heaters becoming the primary and secondary air
used for the boiler combustion process. The air heater warms the
incoming air by transferring heat energy from the outgoing flue gases.
SD Fan (Secondary Fan):
Secondary Fan is also admitted turbulently to complete the combustion.

This fan supplies air to the furnace from the bottom surface to ensure
complete combustion. This fan is only used when Bagasse is used as fuel
otherwise it is kept off.
3.2.5.2. Super heater:

A super heater is a device in a boiler that heats the steam generated by the
boiler again, increasing its thermal energy and decreasing the likelihood
that it will condense inside the header.
Super heaters increase the efficiency of the boiler, and were widely
adopted. Steam which has been superheated is logically known as
superheated steam.
3.2.5.3. Air Pre-heater:

This air Pre-heater is used to heat the air inducted to the boiler by the hot
flue gases. Thus, raising the temperature of inlet air up to 110 C.
3.2.5.4. Economizer:
It is a device which heats the feed water on its way to boiler by deriving
heat from the flue gas. This results in raising boiler efficiency, saving in
fuel and reduced stresses in the boiler due to higher temperature of feed
water. An economizer consists of a large number of closely spaced
parallel steel tubes connected by headers of drums. The feed water flows
through these tubes and the flue gases flow outside. A part of the heat of
flue gases is transferred to feed water, raising the temperature of the later.
3.2.5.5. Boiler Water treatment plant
Boiler requires clean and soft water for longer life and better efficiency.
However, the source of boiler feed water is generally a river or lake
which may contain suspended and dissolved impurities, dissolved gases
etc. Therefore, it is very important that water is first purified and softened
by chemical treatment and then delivered to the boiler. There are two
plants for treatment of water that is fed to the boiler.
Physical treatment plant
Chemical (Demineralization) plant

3.2.5.5.1. Physical treatment plant
It’s a mechanism that treating or softening the water that comes from lake
or river. First water is treated physically by storing the fresh water comes
from river and the mud and an undissolved material is settled down.
Then this water is pumped through overhead tanker to water

softening plant. In this plant there is a tank called multi grade filter and
the tank is full of sand. When this water is passed through the suspended
material in the tank the mud is further trapped in and the filtered water is
going to chemical treatment for further treatment.
3.2.5.5.2. Chemical (Demineralization plant):
We use NaCl (table salt) in chemical treatment to remove Ma, Ca, K and
sulfates from water.
A Demineralization Plant consists of two pressure vessels containing cat

ion and anion resins.
3.2.5.5.3. Why we need Water Treatment…?
Impure water may cause many problems in the boiler so it must be

poured some way to avoid problems in the boiler. The most common
problems caused by the impure water are as followed:
Scaling: Total hardness in the water if not properly removed will cause in
scale formation. A layer of scale on the metal surface of the boiler will
acts as an insulator and reduces the rate of heat transfer from hot zone to
water.
Scaling results in more fuel will be used to maintain boiler output at

acceptable level. Since heat transfer is retarded the metal become hotter
to a point where it deforms and even rapture with disastrous results.
Corrosion: The most common source of corrosion in boiler systems is

dissolved gas: oxygen, carbon dioxide and ammonia. Of these, oxygen
is the most aggressive.

The importance of eliminating oxygen as a source of pitting and iron

deposition cannot be over-emphasized. Even small concentrations of this
gas can cause serious corrosion problems.
Sludge formation: The impurities which are floating on the surface in

the form of light fluffy mass are called sludge's.
These are insoluble impurities that float at the surface of water at high
temperature. Treatment is as follows:
The impurities of Na, Ca, Mg, react with ant scaling agent and form their
sulphates and phosphates which are easily removed. However due to
sludge formation the rate of water evaporation is decreased. The sludge
formation starts at 40oc and maximum sludge is produced at 80oc, at this
temperature it is automatically drained off.
Deaerator:
Purposes of deaeration are:
 To remove oxygen, carbon dioxide and other non-condensable

Gases from feed water.
To heat the incoming makeup water and return condensate to an optimum

temperature for:
 Minimizing solubility of the undesirable gases

 Providing the highest temperature water for injection to the boiler
3.2.5.5.4. Cooling Tower

In order to improve the efficiency of the plant, the steam exhausted from
the turbine is condensed by means of a condenser. Water is drawn from a
natural source of supply such as a river, canal or lake and is circulated
through the condenser. The circulating water takes up the heat of the
exhausted steam and it becomes hot. This hot water coming out from the
condenser is discharged at a suitable location down the river. Hot water
from the condenser is passed on to the cooling towers where it is cooled.
The cold water from the cooling tower is reused in the condenser and
transported through the injection pipe.

The flow of water from lake to boiler is described as blow

Didessa river Main Pond Overhead Tank Softening plant
Reservoir tank Deaerator Water feed pump Boiler. Condenser
Figure 2 the flow of water from lake to boiler
3.2.5.5.5. BOILER COMPONENTS

1. Combustion Chamber (Burner)
It’s a place where combustion takes place and used to gain a heat that
used in turns evaporate the steam from water. Without combustion
chamber we can’t get a desired stream.
There are three types of combustion. Those are incomplete, perfect and
complete combustion. To get a complete combustion the stoichiometry of
air, heat and fire must be equal.
3. Furnace material:
Is cast iron. Furnace inside layer is made of refractory bricks, grate and
middle is of insulating bricks and outer is of cast iron. Furnace tube
material is Mild Steel (M.S.). Tubes are of M.S. No. A192/A520 ASME
(American Standard for Mechanical Engineers).
Bagasse is used as a fuel for boiler furnaces. Bagasse having 52%

moisture is burned. Bagasse is the final solid product of mill section.
Bagasse from the last mill is sent to the boilers by bagasse elevator.
Air is supplied to furnace by Forced Draft Fan, Secondary Fan, and

Induced Draft Fan. The furnace is operated under negative draft. To
produce negative draft Speed Ratio of (F.D. Fan) : (I.D. Fan) is kept to
1:1.2 ~ 1.5. Inside the burner there are certain ways or holes used to
intake different ingredients such as air, furnace oil (sprayer.) and bagasse.
There a lot of tubes (bank tubes) mounted on the wall of burner which
transports hotted water hot in burner. There are four types of headers
available in this section. Those are Front header, two Side header and
Back header.
Front header is the most vulnerable section if the water is low in the
boiler b/c it gains a water from upper drum only.
The rest two headers’ gains water from mud drum.
3. Mud drum
It used to feed water for lower and back header.
It’s a place where a mud in water is removed.
It has a drainage tube to discharge unwanted water.
4. Feed Water Pump
It’s a type of pump which is used to pump water from reservoir tank to
boiler. It has four stages because if it’s single stage it can’t pump that
much pressurized water (r. 24 bars). So, to pump this water we have to
use a four-stage feed pump.
In this plant there is a turbine that operated (run) by steam and its used
only during the emergency time if the water is stopped to transported to
boiler during operation time. Water is the life of boiler. If the boiler can’t
get water, it will cause great damage on the plat. E.g., the tube may be
burst.
The speed of this turbine is controlled by the machine called governor.

There are two types of governors those are hydraulic and piston.
Now we are using hydraulic type of governor.
Furnace Oil

It used to initiate and ignite the combustion and stored in reservoir tank.
It pumps by gear pump.
There is a dust filter in this plant to trap the dust from oil.
The viscosity of oil is decreased by heat ex changer and its convenient to

transport this oil by gear pump to combustion chamber.
There is a coil in tubes and heat ex changer and which is used to lowering
the viscosity of oil.
Bagasse: Bagasse is the fibrous residue of sugar cane remaining after the
extraction of juice. It is well suited for use as a fuel, having adequate
calorific value, is low in ash and virtually free of environmental
contaminants such as sulfur. The energy content per one-ton bagasse
(50% moisture content) is 2.85 GJ. Bagasse is burnt in suitable boilers to
produce steam which in turn is transformed via prime movers, for
example turbines, to mechanical or electrical energy.
3.2.6. CLARIFICTION AND EVAPORATION PLANT
3.2.6.1 Juice Clarification
Clarification is a process of removing maximum possible impurities from

the extracted juice as easy as possible in the process. The mixed juice
from the extraction plant reaches the clarification station as a complex
mixture of the integral components of cane plant. The main purposes of
clarification are:
 To separate soluble and insoluble matter than can precipitate.

 To reduce color and turbidity of the juice.
 To produce clear juice of correct PH.
 To kill or inactivate micro organism in the juice by heat treatment.
 Effective clarification is important for:
 Raising sucrose recovery by reducing the loss through the final
molasses.

 Minimize the fouling effect of heat exchanger by reducing the

hardness of clarified juice.
 Increase the quality of final sugar produced.
 Maintains the Operation constancy in the boiling house.
3.2.6.1.1. Juice heating

Is the process heating mixed juice or liquid in the shell and tube heat ex-
changer? Juice heating takes place in four sequential steps.
1. Vapor line heating

2. Primary juice heating
3. Secondary juice heating
4. Clarified or third juice heating
3.2.6.1.1.1. Vapor Line Juice Heaters

After juice accumulator tank, juice comes to the tubes of vapor line juice
heater and where it is heated to some extent of temperature. Vapor line
juice heater is the shell and tube heat exchanger in which heating media is
vapors which are generated by multiple effect evaporators.
Vapor flows in shell side. There are two vapor line juice heaters are
installed in the industry. Only one of them is operated in season.
There are three heaters in this factory and all are differ in each other
with their working temperature
3.2.6.1.1.2. Primary Heaters
After passing through the vapor line juice heater, the juice goes to the
primary heaters.
Primary heaters are actually shell and tube heat ex changers. Vapors from
the multiple effect evaporators are the heating media used in the shell
side. Juice from vapor line juice heater is fed to the tube side of the
primary heaters. There are five primary heaters are installed in the
industry. Only three heaters operate during production.

In the first heater the juice is heated to a temperature of 70 to 75°C .The

temperature is controlled by varying the steam given to the heater. After
the juice passed through the first heater it flows to be mixed.
3.2.6.1.1.3. Defecation tank
Lime (CaO) has remained the universal basic defecant from the
beginning. The treatment of juice with lime is called defecation.
Defecation is carried out in order to raise the PH value of the juice. It is

necessary to
Raise the PH value because at low PH and high temperature juice

decomposes which causes
Sucrose losses and it is not feasible for industry. Inversion losses can also
take place.
In the industry there are two tanks.
There are three chemicals which are used in Arjo Didessa sugar factory
for purification of juice in general. This are:
Lime (CaO); the treatment with lime is called ―defecation.
Sulphurous acid; from SO2; treatment with SO2 is called ―Sulphitation.
Phosphorous acid; from P2O5; treatment with P2O5 is called

―phosphatation.
Advantage of lime on juice clarification
Eliminate (neutralize) the organic acid (oxalic acid and tartaric acid).
(i.e.3ca (OH) 2+p2O5 ca3 (p2O5)2+3H2O)

Easily separating of juice from mud.
Advantage of Sulphitation on clarification
Neutralize excess quantity of lime added
(i.e.Ca (OH) 2 + H2SO3 CaSO3 + H2O)
Fast crystallization of sucrose
For whitening of sugar
The mud settles more rapidly (hence improved capacity of clarifier s).
3.2.6.1.1.4. Retention Tank
After defecation juice enters into retention tank where two other streams
also enter. One of them comes from entertainment separator (liquid) and
the other one is scum from talo clarifier.
3.2.6.1.1.5. Secondary Heaters
Before defecation process the juice goes to the secondary heaters.
Secondary heaters are shell and tube heat ex changers. Juice from
retention tanks is fed to the tube side of the secondary heaters. Vapors
from the multiple effect evaporators are the heating media used in the
shell side
After the two components i.e. the juice and milk of lime are mixed in a
required proportion turns back to secondary heater .In this heater The
mixed components are heated together at a temperature of 100 to
105°C.Heating at this temperature is required to eliminate unwanted gas that may
disturb the process to atmosphere through the flash tank and the juice will flow to the
door clarifier. The temperature is controlled by giving proper amount of steam. There
are two secondary heaters are installed in the industry.
3.2.6.1.1.6. Flash tank
After the secondary heating the juice goes to the flash tank. The main
purpose of flash tank is removing the reactor vapor from the hot juice and
also for the removal of non non-condensable gas. Removal of gasses prior
to clarification or sedimentation is necessary otherwise mud rising

phenomenon will take place in the clarification vessel, which causes
clarification deficiency in the clarification operation.
3.2.6.1.1.7. Third Juice heater (clarified)

In this heater the juice is heated at the temperature of 110 to
115°C .Heating at this temperature is required facilitate evaporation in the
next process. The temperature in this process is also controlled in the
similar manner as that of the two previous heaters because remained that
there the pressure and the flow rate also has to be controlled.
3.2.6.1.1.8 Juice Clarification from mud

The separation of precipitate formed by liming of juice is done on the
tank designed for that purpose called Clarifier. The precipitate or mud
settles at the bottom of clarifier and clear juice or clarified juice is
extracted at the top. Arjo Didessa sugar factory used SRI clarifier.
Cane juice clarifier aims at:
 Elimination of suspended impurities and colloids.

 Removal of maximum amount of non sugar components in
solution.
 To obtain clarified juice
3.2.6.1.1.9. SRI (Short Return Interval)

Precipitate or sediment has settled it’s a tank where clear juice is
separated from the mud juice. The mud is settled down due to density
difference and the clear juice is gone through the prepared channel.
In this tank there is a device called agitator used to mix the juice and
there is a scrapper used to clean and guides the clean juices. The clear
juice goes to the clear juice tank
In this unit process a chemical called Flocculent (poly

electrolyte) is added to the limed juice to coagulate the impurities and
increase their density as they settle down to the bottom. In SRI clear juice
and muddy juice are separated by Decantation process. Clear juice was
sent to evaporation plant while muddy juice was sent to OC filter.
Decantation process is Separation of juice from muddy juice. Decantation

is a process for the separation of mixtures of immiscible liquids or of a
liquid and a solid mixture such as a suspension. [1] The layer closer to the
top of the container—the less dense of the two liquids, or the liquid from
which the precipitate out—is poured off .
Lime (CaO); the treatment with lime is called ―defecation‖.
Sulphurous acid; from SO2; treatment with SO2 is called

―Sulphitation‖.
Phosphorous acid; from P2O5; treatment with P2O5 is called

―phosphatation‖
Advantage of lime on juice clarification
Eliminate (neutralize) the organic acid (oxalic acid and tartaric acid).
(i.e.3ca (OH) 2+p2O5 ca3 (p2O5)2+3H2O)
Easily separating of juice from mud.
Advantage Neutralize excess quantity of lime added
(i.e.Ca (OH) 2 + H2SO3 CaSO3 + H2O)
Fast crystallization of sucrose
For whitening of sugar
The mud settles more rapidly (hence improved capacity of clarifiers).
They are less viscous and boil faster (better crystallization in cons
Mud from the clarifier goes into the Mud Mixer. The main purpose of
mud mixer is to

Form the thick (viscous) mud, by adding the milk of lime,

polyelectrolyte, and bagacillo into it.
Addition of bagacillo to the mud, is necessary, otherwise vacuum filter

will not furnish a satisfactory filtration.
Roll of Phosphate
The phosphate content of the juice is the most important factor in

efficient clarification. In sugar Cane the phosphates are found as
inorganic as well as organic forms. It is obvious that only the Free
phosphate ions (inorganic form) take part in juice clarification.
Therefore, the juice with adequate quantity of inorganic phosphate is

most desirable. During Cane growing, if fertilizers are not properly
applied, there may be more organic phosphate in the Juice than inorganic
phosphate. Then the juice may not respond well to clarification.
It is demonstrated that the inorganic phosphate level in raw juice is less

than 300ppm, the juice can’t be properly clarified and addition of
phosphate is required.
The advantages of phosphate adding are:-
Greater colloid elimination
Fewer lime salts in clarified juice
More rapid settling
Faster mud filtration
The disadvantages of phosphate addition
The precipitate tri-calcium phosphate is difficult to filter
Increased mud volume
Higher lime consumption and extraction.

3.2.6.1.1.10. OC-Filter
It is a type of filter used to separate the solid and liquid in the sugar
factory, which has many thin pipes inside its body in which the pipe juice
passes to the tube and the filter works under vacuum pressure. The main
purpose of OC filter is:
 To separate solid impurity from muddy juice.

 To recover the sucrose in the juice as much as possible.
OC filter has three zones:
Low vacuum zone (20 to25 mm Hg)
High vacuum zone (40 to 45 mm Hg)
Zero vacuum zones
3.2.6.1.1.11. Bagacilo
Bagacilo is generally separated at its separation point to the cyclone by an

air stream. Bagacilo is a fine particle of bagasse which is used in the
filtering aid to increase the porosity of the mud in the filtration process
and mix with mud by the mixer in mud conditioner tank.
3.2.6.2. Evaporators
Evaporator is equipment that is used to concentrate the solution by
evaporating the Solvent (water). Evaporation generally refers to the
removal of water by vaporization of solution; in this case clear juice
comes from clarification plant. Clear juice consists of:
 Water (85%) from imbibitions, naturally available.

 Solids (15%) sugar and non sugar materials.
After the juice is heated it is pumped to the evaporators.
There are two types of evaporators are used in the industry. Those are:
1- Falling Film Evaporator (FFE)
2- Multiple Effect Evaporators (MEE)

For our case we I’ll deal (discuss) with the second one.
1. Multiple Effect Evaporators
It is also a type of shell and tube heat exchange. This type of evaporator
is used in that factory. In this evaporator vapors or steam which is used
for first effect as a heating media will condense and the vapors produced
by evaporation of solution will be used in next effect as heating media,
while the same solution is evaporated in multiple effects. This Process
repeats in the remaining effects. Such type of ten effects is installed in the
industry while five of them work for the produced capacity.
Juice enters from the bottom of calandria and after heat exchange it
comes back from central well. Water present in the juice is evaporated
and collected from the top and is further utilized as heating media to the
next evaporator. Concentrated juice is collected from the bottom and it is
sent to the next body.
The main purposes of evaporators are:
 To evaporate water to concentrate the sucrose as the water

evaporates from the juice the viscosity of the juice increases.
 To remove by far the greatest weight of material, water from
clarified juice without affecting crystallization process.
 It is used to concentrate the juice from about 19 brix to 60 to 65
brix.
3.2.6.2. Evaporators arrangement in Arjo Didessa sugar

Factory
An arrangement of four effects in series is known as Quadruple effect
evaporator. These arrangements of evaporator are:
Vapor cell (pre-evaporator): heated by exhaust steam to generate vapor at

110 °c. It receives clear juice of brix about 15 °brix
First effect: heated by exhaust steam and receives juice from vapor cell.
Second effect: generates vapor at 98 °C.Is heated by vapor of first effect.
Third effect: heated by vapor from the second effect.

Fourth effect: Is the last effect which delivers syrup at a brix of 60 °. It

works at a temperature of 60 °C.
Evaporator Diameter Length in(m) Number of Heating

type in(mm) Tubes surface area
in(m2)
Vapor cell 38.5 3 9645 3500
First effect 38.5 2.5 8267 2500
Second Effect 38.5 2.5 6613 2000
Third effect 38.5 2.5 4960 1500
Fourth effect 38.5 2.5 3637 1100
Table 3.1 comparisons of individual evaporators.
Juice discharges as concentrated juice termed as syrup is collected from

last body (evaporator).
3 .2.7. RAW SUGAR PLANT

Raw Sugar: The product of cane sugar factories which is an intermediate crystalline
product resulting from the evaporation of water from sugar cane stalk juice .
The main objective of raw sugar plant is to get:
1. Concentrated A sugar.
2. Purified sugar.
3.2.7.1. Pans
Pan is an apparatus in which syrup or molasses are boiled so as to obtain
sugar crystal of the desired size.

Syrup is concentrated clear juice from evaporator. In raw sugar plant first
we get solid sugar which called Asugar.After evaporation syrup is stored
in syrup storage tank from which it is provided for syrup storage tank.
There are two types of pans. Those are:
Batch Pans
It is a pan in which grain or seed is prepared by addition of syrup and

slurry (alcohol and sugar) by heating it under Vacuum. By increasing
temperature vacuum decreases, while by decreasing temperature Vacuum
increases. The prepared seed is used in continuous pan for preparation of
massecuite. The syrup is sent to A-Batch Pan A1-Molasses and B-Sugar
is added into it which improves the rate of nucleation. In the pan the
mixture is boiled through vapors under Vacuum. In the similar way A-
Heavy after dilution is sent to the B-Batch pan where it is mixed with c-
seed and the mixture is heated with vapors under vacuum. B-Heavy after
dilution is sent to the C-Batch pan where it is mixed with c-light and the
mixture is heated with vapors under vacuum. Vapors from 2nd effect are
used for heating purposes.
Continuous Pans
It’s a pan in where the prepared grain is used to prepare massecuite,

which is transported to centrifugal machine.
Continuous pans are used in which further syrup vaporization is achieved

by heating with vapors under vacuum.
Syrups after batch pans are sent to their corresponding continuous pans
for further vaporization.
Pan boiling
Syrup obtained from evaporation at a brix of 60 is boiled in the pan to

add concentration. A fine part named seed(slurry) sugar added to syrup to
form massecuite, which is a mixture of sugar crystal and molasses is not
advisable to be heated at a temperature greater than 20 °C. The main
purpose of pan is to produce satisfactory sugar crystals from the syrup
and molasses. The concentration of the feed in the pan is usually 60° to
65° brix.

Raw supply tanks are storage tanks for syrup, molasses and wash liquor
from which feeding to the pan is done. Their position is higher or at equal
position with the pan.
The pan boiling operation can be divided into four stages. These are:
Concentrating, seeding, crystal growing and tightening or brixing.
3.2.7.2. Crystallization
Sugar manufacturing involves crystallization of sucrose from
concentrated sucrose solution.
Crystallization is the process whereby sugar is recovered by boiling in the

vacuum pans by cooling and crystallization. The main raw material from
which crystalline sugar is obtained is syrup of 65° brix, purity 83% to
85% and PH of 5 to 5.5.Crystallization not only removes dissolved
sucrose from solution and recovers it as a solid sucrose crystals, it is also
a very powerful purification process. In the pan more water is boiled off
until conditions are right for sugar crystals to grow. In the Arjo Didessa
Sugar Factory usually some amount of sugar dust is thrown into to
initiate crystal formation. Once crystals have grown mixture of crystal
and mother liquor is formed.
There are two main types of crystallizers:
1- Horizontal crystallizer
2- Vertical crystallizer
1. Horizontal Crystallizer
The crystallizer, horizontal in shape with open top side is called

horizontal crystallizer.
The crystallization process consists of two major events, nucleation and

crystal growth.
Nucleation is the step where the solute molecules dispersed in the solvent
start to gather into clusters that become stable under the current operating
conditions.

The crystal growth is the subsequent growth of the nuclei that succeed in
achieving the critical cluster size. Nucleation and growth continue to
occur simultaneously while the super saturation exists. Super saturation is
the driving force of the crystallization hence the rate of nucleation and
growth is driven by the existing super saturation in the solution.
2. Vertical Crystallizers
Vertical crystallize is used in cane sugar industry for efficient sugar

crystallization from low-purity crystal suspensions. In this factory the
vertical Crystallizers is out function.
3.2.7.3. Pug Mills

After Crystallizers their respective massecuite are sent to the respective
pug mills.
The main purpose of pug mill is to prevent the massecuite from

solidifying by the mixing process, through rotating shaft on which the
rods are fixed.
3.2.7.4. Centrifugal machine
It is a machine in which separation of sugar crystal from molasses in

massecuite is carried out. Batch and continuous centrifugal machines are
the two centrifugal machine used in Arjo Didessa Sugar Factory. In this
factory the process is done with continuous centrifugal machine which
rotates with speed of 1500rpm.The massecuite from pug mill is pumped
to centrifugal machine baskets, which is driven by motor. When it starts
to rotate the mother liquor flows through the screen of basket to outside
and sent to its tank while sugar crystal left in the basket enters to remelter
tank passing through screw conveyor.
3.2.8. Talo Clarification Unit Operation and Refinery

plant
At this stage there are around four unit operations such as Talo
clarification, Batch centrifugal machine, sugar drier grading and Bagging.

3.2.8.1. Remelter
After A-centrifuge, A-sugar is sent to the remelter and wasted sugar is
also added in the remelter. This remelter melts both sugars and makes a
homogeneous mixture. This mixture is sent to the buffer tank.
3.2.8.2. Talo clarification

A sugar which we get from continuous centrifugal is remelted and
pumped to Talo for purifying, coloring and for neutralization. The main
purpose of talo clarification is to remove maximum possible impurities
from raw sugar. In Talo clarification four chemicals are added. Those are:
Flocculent (Talo float)
Lime saccharine
Talo flock
Phosphoric acid.
In this process the principal mechanism is flocculation. Phosphation

relies on the formation of a flock formed by the addition of lime and
phosphoric acid which with the addition of flocculent, captured fine
colloidal matter is separated by floatation with dissolved air.
3.2.8.3. Buffer Tank

The main purpose of the buffer tank is to give the residence time to make
the mixture homogeneous. The entering temperature to the buffer tank is
70°C.
3.2.8.4. Baby Heater

After buffer tank the mixture goes to the baby heater. The main purpose
of the heater is to heat up the mixture. The entering temperature of the
mixture is 68°C and the outer temperature is approximately 80 to 85°C.
3.2.8.5. CENTRIFUGAL MACHINE

It’s a rotating machine used forseparation of sugar crystal from mother
liquor (crystal from molasses). They separate the phases by filtration
using centrifugation process. The walls of the centrifuge basket are

porous, and the liquid filters through the deposited cake of solids and is
removed. After pug mill massecuites are sent to centrifugal machines for
separation of crystals from mother liquor.
There are two types of centrifugal machine used in ADSF. Those are;
Batch Centrifugal
Continuous Centrifugal
1. Batch centrifugal machine
Batch Centrifuges are filtration machines used to separate sugar mesquite

into its constituent crystals and mother liquor under the action of
centrifugal force. The product is processed in a cylindrical perforated
basket fitted with filtering screens which is hung on the bottom end of a
long spindle
2. Continuous centrifugal machine
As this name implies this type of centrifugal machines are used to cure
continuously low grade massecuite of high viscosity at constant speed of
1500 – 2000 rpm. The centrifugal is fed continuously by the massecuite
and the cured sugar is discharged continuously at high speed.
3.2.8.6. Sugar Grader

Sugar grader is used to separate the different sizes sugar crystals for
market and industrial operation demands. 3.2.8.7. Dryer
Drier is used to dry the final product sugar crystals with the help of
steam.
3.2.8.8. Hopper
Hopper is used to supply the final sugar to packaging section.
3.2.8.9. Bucket Elevator

It’s a type of conveyor which is used to transport the produced sugar from
hopper to sugar bin.
3.2.8.10. Packaging
After hopper sugar is packed into 50 kg bags. Manual packaging is used

and it is closed by sewing machine.
3.2.8.11. Store
It’s a place where the final product (Refine or White sugar) is stored and
transported by belt conveyor.
4. OVERALL BENEFITS GAINED FROM THE

INTERNSHIP
4.1 Benefit I gained in terms of improving my Practical skill:
As we know most students have no practical skill because they mostly
engage to theoretical learning and teaching process with regard to the
curriculum. But throughout our internship program I gain a lot of
practical skills which helps us to be friendly with the industrial
environment and to improve our knowledge about applied engineering.
Generally, in this internship I get the following practical skills.
How sugar is produced and I get a practical knowledge on a mechanical

device used in this factory to produce this sugar.
How power is generated by steam boiler using a bagasse the byproduct of

cane.
Differentiate types of conveyors (belt, chain, bucket, screw, oscillating)

and hoisting materials such as cranes and lifting cars that used in the
factories.
I deeply now how different types of pumps works according to their

nature of function.
Different types mechanical components such as; Couple, Bearing, Shafts,

Gears, Pumps, Gearbox, Turbines, measuring equipment, bolt and nuts
and other fastening material.
I had gain practical knowledge of different types of welding such as Arc

welding and oxyacetylene welding
Different types of material handling equipment and different types of

rope chains.
4.2 Benefit I gained in terms of improving my Theoretical

knowledge
There is a slight difference between what we have learned in class and the
practical work around industries. However, having a deep knowledge
about the practical work makes us more intensive for the theoretical
knowledge. Moreover, we are upgraded what we have been learned in the
class.
4.3 Benefit I gained in terms of improving my Interpersonal

communication skill
Now days, having healthy inter personal relationship with coworkers
makes your entire intern ship program much interesting and root full.
Although having such communication with workers makes the
knowledge transfer much easier. Because it is vital to ask what you do not
know and helps you to persuade others to show their undisputed effort.
As you know, different persons have their own personality and behavior.
Having that in mind, tolerate their behavior makes it easy to cooperate
with them at work place. Further, having a bad communication around
working place expose you to depression and loss of interest at work.
Generally, I have developed communication skills through:
Adaptation of those different workers
Most of the workers have practical knowledge rather than the theoretical
one that makes a barrier between us. But through time we can solve our
problem by sharing ideas.
Through working my project, i were having a deep connection with the

company`s advisor, our mentors and coworkers.
4.4 Benefit I gained in terms of improving my Team playing skills
Team playing skills are one of the basic requirements for the proper
working of a good company, regardless of its size and its service. A
company with properly functioning dedicated working team will always
have a graph going up wards with different workers, working as different
team. However, they work to contribute same goal for the progress of the
company.
For the proper functioning of a team, each member must be aware of its
mission, vision, behavior, working style, and goal. They must personally
and organizationally dedicate to the team. Team members must believe in
one another and must be ready to work hand to hand in both adverse and
favorable situations.
General skills such as; good communication, concentration, fast decision

making, self-confidence and a wellbeing feeling are important for all
team members to engage profitable work. For instance, during our project
work we notice that team playing skill is very crucial. Because in our
company any work or problems are accomplished with the co-operation
of each other. This situation helps us to develop a team playing skill,
since i were one of the members of the company.

4.5 Benefit I gained in terms of improving my Leader ship

skills
A leader is a person who has strong principles, courage and dedications to
a clear vision. Developing a power full vision, building strong team and
bringing out the best in those you lead are key facts to experience success
as a leader. People follow the leader because he is representative of their
believes. This person has to focuses on common benefits and goals.
Leader ship is critical management and skill is being the ability to motive
a group of people towards a common goal. As a manager he must master
to be successful and shows his management skills to build a way towards
success.
The leader should have to control his fear and forward his knowledge or
an idea about what he going to do with a confidence. A leader must have
a communication skill that helps him to persuade his followers.
In three-month, duration of the internship, I learn some skills and

techniques of leader ship. Among these; how to decide around a
management carrier and intended to do large projects, how to lead,
motive, inspire and encourage workers, develop work ethics and values;
like accountability, which is answerable to the decision and acts we took
and transparency, which is our openness of activities that we done to the
customers and works of the company.
4.6 Benefit I gained in terms of improving my Work ethics

skills
If a person shows his accountability, punctuality, transparency and
reliability to his work we can say that the individual has work ethics skill.
Some of the methods to develop strong work ethics are: -
Arrive to work on time
Eliminate or reduce absence
Respect yourself and others, without regarding their religion, race,

language and customs.

Put a positive spin on negative comments, cause a positive attitude is

crucial to have a strong work ethics and bring a fresh perspective to
problems at work.
Be confident and self- motivated in your ability to handle job

responsibility
Honor your commitment, being independent and creates confidence in

your working capacity. Seek to serve the interests of the company’s goal,
objectives and missions. Do your part to create a productive work
environment.
The quality and quantity of work is a direct reflection of personal

characters and integrity.
Respect what others contribute to the work environment. Concentrate on

your job and commitment to proactive attitude.
Work ethical employees are a key to productive. All of the employees

have to be disciplined and ethical in their working environment.
4.7 .Benefit I gained in terms of improving my

Entrepreneurship skills
It is defined by their habit of innovation and redefines markets. It can be
realized that when someone engages or creates profitable job, which
is/are significant for the society. From entrepreneur principle i notice the
following points
If you have enough money, even if you have neither talent nor profession,
you can make a business by employee those educated or talented persons.
To do so, you have to analyze the most needed demand in the
community.
If you are not educated/have no profession and money, you may have
talent. Therefore, you can start a business regard to your talent.
If you have not money and talent, but you are an educated/you have
profession, you can also make a business specially this is related to us.

As we know, our country is one of the developing countries in our entire

planet earth. Therefore, we have a chance to create a lot of things by
using our resources. For instance, after finishing our internship project
successfully i understand that i can also make another problem solving
and profitable mechanisms for different organizations.
The leader should have to control his fear and forward his knowledge or
an idea about what he going to do with a confidence. A leader must have
a communication skill that helps him to persuade his followers.
In three-month, duration of the internship, I learn some skills and

techniques of leader ship. Among these; how to decide around a
management carrier and intended to do large projects, how to lead,
motive, inspire and encourage workers, develop work ethics and values;
like accountability, which is answerable to the decision and acts we took
and transparency, which is our openness of activities that we done to the
customers and works of the company.
4.8. Challenge I faced while performing my work

During the training in the company, I faced many challenges that
influence my work. This includes:
Peace and security around the factory is difficult or unavailability of

peace condition.
Since the factory was so old and don’t have well equipped air
conditioning system it was so hot and difficult to work.
It was difficult to get engineers while they were on work as they show us
what we didn’t know before.
Sound of some machine can be disturbing.
Lack of safety facilities.
Transportation problem since it locates far away from where I live.
4.9. The measures I take in order to overcome these challenges
For the lack of safety material, I use my material and taking high care
while working hazardous area of the factory
No more measure has taken for unavailability of peace condition, without

taking care.
Wakeup early to get in work place on time.
Asking some experienced technicians, the details of certain machineries

and processes to visualize mechanisms behind machineries.

5. CONCLUSION AND RECOMMENDATION
5.1 Conclusion
The aims of the study were to reduce the moisture content of sugarcane
bagasse in order to improve boiler efficiency; increase electrical energy
power production of the factory; to reduce bagasse loses; to make
comfortable work place for man power; Increase steam production
capacity; and increase boiler life time. To do that Bagasse Dryer were
designed to dry bagasse and the results obtained show clearly that these
aims were achieved. The moisture content reduced from 52% to 42%.
5.2 Recommendation
There are many problems in the factory which affects the industry
directly or indirectly not to fulfill its vision and mission by using its full
capacity. So the factory shall try to implement the following solutions;
 In Arjo Didessa sugar factory there is no continuous supply of cane

to factory these may be transport problem or agriculture sector
problem this problem must be solved for continuous production of
the plant.
 The bagasse handling system of the factory is not safe or it is not
protected from rain. So I recommended that the factory have to
build bagasse storage house.
 Eliminating unnecessary wastage of bagasse by recycling and
reducing its amount that is drying it well using bagasse dryer.

 The company has to provide basic necessities with good

standard.Example, clean water and economically quality foods
have to be provided for workers.
 They transport lime from store to lime mixer by using of man
power. so I recommended the factory should develop conveyor to
transport the lime.
REFERANCE
1. Hand Book of Cane Sugar Technology R.B.L MATHUR – 1978.

2. Training Manual of Robert Antoine Sugar Industry Training Center
1998
3. Process and Apparatus of Chemical Technology A.N. Planoviski –
1968.
4. Principles of Sugar Technology Pieter Honig Vol. 1, 2, 3 – 1963.
5. Hand Book of Cane Sugar Engineering e-hugot 3rd Edition 1986.
6. Standard Fabrication Practices for Cane Sugar Mille e-delden –
1981.
7. Cane Sugar Hand Book Spencer and Meaden – 9th Edition.
8. Cane Sugar Hand Book – 12th Edition James C.P. Chen Chung Chi
Chou - 1993.
9. South African Sugar Manufacturing Training Manual – 1999.
10.Basic Process and Apparatus of Chemical Technology A.G.
Kasatkin – 1971.
11.Sugar Technology A.R. Sapronov – 1983.
APPENDIX


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ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL AND BIO ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP FINAL REPORT

HOST COMPANY:ARJO DIDESSA SUGAR FACTORY

Prepared by :Tesfaye Bulti

[Type the document subtitle]

Department of Chemical Engineering Page

Department of Chemical Engineering Page

Name and signature of the evaluator advisor and department

Name of Advisor Signature Date

___________________ ______________ ______________

Name of Department Head Signature Date

___________________ ______________ ______________

Prepared By: Signature Date

Tesfaye Bulti______________ ___June 30,2023__________

Department of Chemical Engineering Page

In all sugar factories the main objective is to produce maximum amount

Those all machineries in Arjo Didessa Sugar Factory obtained operating

Key words:-Bagasse, Syrup, Sugar cane

Department of Chemical Engineering Page

Sugar is a very important flavored ingredient used in much food, drink

1.1. Company overview

Department of Chemical Engineering Page

Figure 1.1 Arjo Didessa Sugar Factory gate

1.2. Back Ground of the Company

Arjo Didessa sugar Factory is established an individual person named

is black cotton and there is also reddish brown in small quantity.

Department of Chemical Engineering Page

The factories found by the side of the asphalted Nekemte-Beddele route.

It’s the only factory that produced refined sugar in Ethiopia.

Department of Chemical Engineering Page

Figure 2.Picture of Arjo Didessa Sugar Factory during operation

To create sugar industries competitive enough at international level based

Arjo Didessa as an agro industry striving to increase stake holders’

 Expanding and optimizing sugar cane plantation of own and out

1.3.3. Values and Principles

 Team work brings individual and organizational growth

Department of Chemical Engineering Page

1.4. General Objectives

1.4.1. Factory Objectives

1.4.2 Specific Objectives

 To plan and grow sugar cane

1.5. Significance of factory.

1.6. Main product or service of the Arjo Didessa sugar factory.

The main product of Arjo Didessa sugar factory is sugar. It produces

Bagasse is the byproduct because it has refinement room which is not

By-products during production process:

Department of Chemical Engineering Page

Bagasse: accounting for 30-33% of the weight of sugarcane, is used as

Molasses: accounting for 5% by weight, is used in food processing and

Microbiological: accounting for 3% -5% by weight, is used as fertilizer

1.7. The main customer and end users of the company

The main customers and end users of ADSF are;

Soft drink Company.

Some are exported.

Department of Chemical Engineering Page

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Tesfaye Bulti____________ _June 30,2023__________