Addis Ababa Science and Technology University: College of Biological and Chemical Engineering

ADDIS ABABA SCIENCE AND TECHNOLOGY
UNIVERSITY
NATIONAL ALCOHOL & LIQUOR FACTORY

ብሔራዊ አ ልኮልና አ ረ ቄ ፋብሪካ
COLLEGE OF BIOLOGICAL AND CHEMICAL ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
INTERNSHIP REPORT ON NATIONAL ALCOHOL AND LIQUOR FACTORY
Prepared by Ermiyas Geremew
Submitted to
1. Mr. Tedros Eyasu

2. Mr. Ermiyas Abebe
3. Mr. Astrat
Submission date
Friday, 26 January 2018
Addis Ababa Science and Technology university 2010 E.C
DECLARATION
It is well known that Addis Ababa Science and Technology University want to establish
sustainable network with private and public sectors to create better linkage between the
Industries and the school. With this regard, I, the 4th year student from chemical engineering
department have been assigned to NALF Industry from early 11/ oct /2017 to jan/31/2018 in
order to gain practical skill in chemical engineering profession. Due to this, I student Ermiyas
Geremew from chemical engineering department of the school of technology worked in NALF
for the given four successive months successfully. Thus, I want to certify that I have completed
the internship program successfully.
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ACKNOWLEDGMENTS
I acknowledge with gratitude the contributions of colleagues and students who have helped me
since I began work on this internship report. My thanks go to our advisors Mr. Ermiyas Abebe,
Mr. Tedros Eyasu, Mr. Asrat, and all colleagues in parameter controlling room in NALF, who
read my reports and offered many helpful suggestions for its improvement; our ﬁrst department
head, Mr. Beruk Alemu, who gave me invaluable encouragement when I brashly (and some
might say, foolishly) launched into the report. I am sorry I never managed to get to detail energy
balances with the distillation and fermentation sections. I also thank the many current NALF
internship students and my listed advisors, who took the trouble to point out errors in the text,
who I know did it out of a sense of professional responsibility.
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EXECUTIVE SUMMARY
The purpose of this report to put in writing the work experience that I had performed and the
learning attained from performing specific task while working in professional environment. In
the first part of my report, I briefly described the background of my internship hosting company,
including its history and objectives of the company, its main products and services, the overall
organizational branches. In the second part of my report I include process description in
molasses treatment, fermentation, propagation, distillery, and liquor section. Finally I summarize
utilities and give recommendations and conclusions for my company
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Table Contents page no.

CHAPTER ONE
1. BACKGROUD ……………………………………………………………. 1
1.1. Historical Background …………………………………………………. 1
1.2. Factory Branch ………………………………………………………… 2
1.3. Vision and mission of the factory ………………………………………. 2
1.4. Main products ……………………………………………………………..3
1.5. Customers of the product …………………………………………………5
CHAPTER TWO
2. INTRODUCTION ………………………………………………………….. 6
2.1.Pre-Treatment……………………………………………………………… 7
2.1.1. Factors affecting the molasses treatment process ……………………………. 8
2.1.2. The advantages of treating molasses ………………………………………….... 8
2.2. Fermentation Process …………………………………………….. 9

2.2.1. Chemical Reactions During Fermentation…………………………………… 10
2.2.2. Factors affecting fermentation of molasses ………………………………… 11
2.3. Distillation ……………………………………………………………….. 13
2.3.1. Types of distillation column ………………………………………………… 16
2.3.2. Factors Affecting the Distillation Process …………………………………… 17
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CHAPTER THREE
3. PROCESS DISCRIPTION ………………………………………………… 19

3.1. The molasses treatment ………………………………………………. 19
3.1.1. Material and energy balance calculations ……………………………………….22
3.1.1.1. Material balance calculation …………………………………………….22
3.1.1.2. Energy balance calculations …………………………………………… .25
3.1.2. Discussion ……………………………………………………………………… 28
3.2. Fermentation …………………………………………………………. 29
3.2.1. Material balance calculations ………………………………………………….. 33
3.2.2. Discussion ……………………………………………………………………….35
3.3. Distillation …………………………………………………………….. 36
3.3.1. Material balance calculations ……………………………………………………44
3.3.2. Discussion …………………………………………………………………… 50
CHAPTER FOUR
4. MAJOR UTILITIES ………………………………………………………52

4.1. Boiler …………………………………………………………………....52.
4.2. Water softener …………………………………………………………...53
4.3. Cooling tower ………………………………………………………….. 54
4.4. Compressor ………………………………………………………………54
4.5. Generator ………………………………………………………………...54
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CHAPTER FIVE
5. LIQUOR PREPARATION………………………………………………..55
CHAPTER SIX
6. BENEFITS OF INTERNSHIP………………………………………………59
6.1. Introduction……………………………………………………………….59
6.2. Interpersonal communication skills……………………………………….59
6.3. Team playing skill…………………………………………………………60
6.4. Leadershipskills………………………………………………………… 60
6.5. Work ethics related issues……………………………………………… 61
6.6. Entrepreneurship skills…………………………………………………….61
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List of figures and tables page no.
Figure1.1 Organizational structure ……………………………………………………..5

Figure 2.3.1 Vapor formation with temperature………………………………………..…14
Figure 2.3.2 Ideal distillation system. ……………………………………………………15
Figure 3.1.1 Process Flow Diagram of Molasses Treatment……………………………...21
Figure 3.2.1 Process flow diagram of yeast propagation………………………………….31
Figure 3.2.2 Process flow diagram of fermentation…………………………………...….32
Figure 3.3.1 Process flow diagram of Mash / Degassing / Concentration Column………38

Figure 3.3.2 Process flow diagram of Hydro-selection Column………………………….39
Figure 3.3.3 Process flow diagram of Rectification Column……………………………..40
Figure 3.3.4 Process flow diagram of Demethylizer Column…………………………….41
Figure 3.3.5 Process flow diagram of Fusel oil Column………………………………….43
Figure 4.2.1 working principle of softeners ………………………………………............55
Figure 4.4.1 Cooling Water System .…………………………………………………..…..56
Figure 5.1: Flow chart for liquor production…………………………………………….57
Table 1.1: Types of liquor products………………………………………………………4

Table 3.3.1: Top and bottom products of each column…………………………………….44
Table 4.2.1: hardness stages in mg/liters……………………………………………………..54
Table 5.1: Material that are used in bottling……………………………………………...59
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CHAPTER ONE
1. BACKGROUND
Alcohol is organic compound having a hydroxyl (-OH) group bound to a carbon atom. Ethanol is
the alcohol found in alcoholic drinks. Some other alcohols include ethanol, methanol, propanol, and
butanol. Alcohols are also used to make dyes and perfumes and solvents in lacquers and varnishes.
The two most known alcohols are ethanol and methanol. Ethanol (ethyl alcohol) is color less,
volatile alcohol (C₂H₅OH), produced by the catalytic hydration of ethylene. Ethanol is also known
as grain alcohol, its uses include alcoholic beverages, cleaning solutions, antifreeze, rocket fuels,
cosmetics and pharmaceuticals. Its boiling point is 78.5ºc. Methanol (methyl alcohol) is colorless,
poisonous chemical. Mainly used as a solvent, petrol additive, and in rocket fuel and petrol. It has
melting point of 93.9˚c and boiling point of 64.9◦c.
1.1. Historical Background

National Alcohol & liquor factory (NALF) produced pure alcohol and varieties of liquor. It
Distribute its products to the customers. The factory is established in 1928 E.C by private company
and transferred to the government institute in 1969 E.C. The mekanisa site factory is the biggest
pure alcohol producer of NALF at this moment. It’s time-honored since 1949 E.C under Awash
Wine Factory. But the factory was not on the process for the long period of time since 1971 E.C.
through the decision of Ethiopian government Beverage corporation it was separated from Awash
Wine factory to join National Alcohol and Liquor factory have got a big investment to produce pure
Alcohol.
National alcohol & Liquor Factory (NALF) is a pioneer sole government owned state enterprise in
manufacturing & selling liquors and alcohol products in our country. The factory consists of four
branch factories which was once established and owned by individuals in different period. Three of
them are in Addis Ababa and the other is in Sebeta town which is located 25 K.M. from Addis.
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1.2. Factory branch

 Michew(mexico) Branch Factory
 Mekanisa Branch Factory
 Sebeta Branch Factory
 Akaki Branch Factory
Sebeta branch; this branch is established in 1898E.C to produce pure alcohol from cereal crops
used by wood boiler technology until the factory began uses modern technology and extracts
alcohol from molasses.Now a days this factory is produce only denature alcohol and liquors from
pure alcohol which produced in Mekanissa branch.
Mekanissa branch; this branch is the biggest pure alcohol producer of NALF at this time. it’s
time honored since1949 E.C under awash wine factory. Since 1971 E.C through the decision of
Ethiopia government Beverage corporation it was separated from awash wine factory to join NALF
on 1974E.C the factory have got a big investment to produce pure alcohol from molasses. This pure
alcohol is feed to other branches to produce liquors.
Mexico branch; established in 1930E.C located in Mexico square behind Addis Ababa industrial
Technology college the former “Tegebared’’ .Now it is used only for marketing purpose.
Additionally the head office is also located at this branch.
Akaki branch; this branch also established in 1930 E.C but now this branch it is not in
production. But it is used to store spoiled equipment.
In 1976 G.C. the Ethiopian Government nationalized and owned the factories under National
Alcohol & Liquor Factory. Since then, the factory attempts to produce and distribute Alcohol and
various Liquor products based on customer demand.
1.3. Vision and mission of the factory

Vision
To be the best pure alcohol and liquor products producer and distributer in the local market and
become competent in the export market.

Mission
To fully satisfy our customer’s needs and expectation by producing high quality alcohol and liquor
products consistently using modern technology, modern management system and employing
experienced and qualified professionals and also satisfy other stakeholders by creating value as well
as enhancing the well-being of the society and protecting the environment to contribute our share
for the growth of our country.
1.4. Main products

The factory produce alcohol by two main process those are alcohol production from molasses and
alcohol production from technical alcohol which come from sugar factories.
Product and service of NALF
1. Pure alcohol
2. Denature alcohol (by product)
3. Liquors
1. Pure alcohol: is the first product in the distillation process has an alcohol content of
96.2%. It is used for production of different liquors, laboratory work, perfumes and cosmetic
production, preparation of medicine, production of chemical and plastic products.
2. Denature alcohol: is also one of the products in the distillation process with an
alcoholic content of 92%. This product is used for clinical purpose, cooking purpose,
cleaning electrical equipment, beauty salons and barberries
3. Liquor: Different types of liquor are produced those are listed under the table

Table 1.1: Types of liquor products
No. Type of liquor Alcohol in (%v/v)
1 Baro’s dry gin 41
2 Ouzo 41
3 Double ouzo 43
4 Fernit 37
5 Bitter 25
6 Aperative 32
7 Cognac 37
8 Brandy 41
9 Coffee 30
10 Lemon 30
11 Pineapple 30
12 Orange 30
13 Pernod 45
14 Super mint 24

1.5. Customers of the product
There are so many customers for the liquors and alcohol which is produced in NALF like hotels for
drinks and for hospital for medical treatment. Before the product is produced those customers of the
product communicate with the NALF and the factory produces according to their need. The second
product of the company is Denature alcohol it is used for clinical purpose, cleaning electrical
equipment.
ORGANIZATIONAL STRUCRE OF NALF
General manger of
NALF
Branch manager of Branch manager of Branch manager of
Mexico mekanisa sebeta
Logistic department Human resource and

Production department
development
administration department
Process purchasing
control
finance
Quality Inventory
control
Human
Store resource and
Production and
administration
maintenance
Figure1.1 organizational structure

CHAPTER TWO
2. INTRODUCTION
The main source used in the factory to produce pure Alcohol is molasses which is by-product of
sugar factories. The sugar content in the molasses is changed in to alcohol by the process of
fermentation with yeasts. Even though the use of fermentation process for alcohol production was
started in early period of human beings, it is revised in modern way in 19th century with the
discovery of Lewis Pasteur. He discovered that as sugar has an alcoholic content and can be
changed in to pure alcohol and other by-product compounds with the help of yeasts. In our country
Ethiopia pure alcohol can be produced in traditional as well as in factory level. During fermentation,
different compounds will be produced. From these the main is pure alcohol which is the target of the
factory. In addition to this aldehydes, acid and fusel oil which are unnecessary compounds. The
amounts as well as the grade (purity level) of the alcohol produced depend on the efficiency of the
fermentation process taking place. So following the correct scientific method from the raw material
till the well fermented wine transferred to alcohol distillery.
Production of ethyl alcohol from cereals and molasses for drinking and power alcohol comprises
different unit processes and operations such as Fermentation, Distillation, Water treatment,
ingredient preparation and Effluent handling process. In order to obtain good quality and maximum
conversion of fermentable sugar in to ethanol it is necessary to focus on fermentation process
(DR.Nalini B.2009)
Alcohols are among the most common organic compounds. They are used as sweeteners 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. Ethanol is the largest volume fermentatively produced organic solvent of
immense utility as chemical feedstock. Ethanol is used in toiletries, pharmaceuticals, fuels and
moreover used in alcoholic beverages. And methanol is as a solvent and raw material for the
manufacture of formaldehyde and special resins, in special fuels, in antifreeze, and for cleaning
metals.

In the alcoholic beverages ethanol is the main desired material using molasses as a raw material.
Molasses will pass through certain processes to form ethanol, such as molasses treatment, anaerobic
fermentation, and distillation.
Main Raw materials
The basic raw material NALF is using the produce alcohol are the following.
I. Molasses: - Molasses is known to be the byproduct of sugar industries. Therefore, it is expected

to contain several components like sucrose, glucose, fructose, minerals (mainly lime), and other
components including non-reducing sugars. The solid content which is contained in molasses is
called Brix. The raw molasses used here is in the range of 78-82 Brix having 45-50% sugar
content (sucrose).
II. Water: - Since molasses treatment process includes diluting it,water is necessary raw material
here. Two types of water are used for this section. These are process water and white stillage
water.
 Process water is a normal and chemically untreated water.
 White stillage water is the hot water that comes from distillery.
III. Steam: - For the purpose of adjusting the desired temperature in some tanks, steam is generated
in boiler house.
2.1. Pre-Treatment
In this section, the main raw material, molasses should be pretreated so that it is expected that it is
easy to be fermented with little loss. Therefore, it will be diluted and broken-down in to simple
sugar and passed to fermentation process. The process in this section is installed to operate 24 hours
per day in continuous system. Buffer is necessary after each section to cover normal fluctuations. It
also takes the energy consumption, the water recovery system, and utility consumption in
accordance to minimize the CO2 foot print as much as possible.
When molasses is the raw material for fermentation, pre-treatment improves the overall process
efficiency and also the quality of product ethanol.

2.1.1. Factors affecting the molasses treatment process

I. Temperature – Temperature adjustment is critical for the molasses treatment since sterilization
is the one and maybe the main task occupied here. This can be done by controlling steam inlets
to the tanks. 80°C is the optimum temperature to pre-treat the raw molasses. If the given
temperature lowers the micro-organisms in the molasses will not be denatured, and they
influence o propagation and fermentation. And if the temperature is adjusted over the optimum,
the water in the raw molasses will evaporate, and highly efficient cooler would be expected to
cool the pre-treated molasses to store, which is not economical.
II. Content of raw molasses–for the safety of all tanks the content of raw molasses should be
considered seriously. For example, if raw molasses contains lot of ash treating capacity lowers,
and tendency to form scale on the inner walls of the tanks.
2.1.2. The advantages of treating molasses

 Faster fermentation
 Higher ethanol yield during fermentation
 Improved heat transfer in cooling fermenters
 Reduced scaling problems in distillation
 Reduced BOD of distillers effluent
 To reduce level of impurities
 To reduce scale formation
 Lower steam consumption
2.2. Fermentation Process
Fermentation is the term used by microbiologists to describe any process for the production of a
product by means of the mass culture of a microorganism. The usual product of fermentation is
known to be ethyl alcohol or ethanol. Actually, ethyl alcohol can be produced synthetically by
indirect or direct hydration of ethylene, fermentation of sacchariferous (sugar containing) or

amylaceous (starch containing) raw materials, by hydrolysis and fermentation. Here we are dealing
with alcoholic fermentation by the means of mass culture of selected yeast cells. In NALF and most
of the alcoholic beverages in Ethiopia, alcohol (ethyl alcohol) is produced by fermenting molasses-
the by-product of sugar companies with the help of yeast cells, usually saccromyces cerevisae
culturing them in a suitable media. The media is the feed solution for the yeasts. It must contain the
essential nutrients needed for the microbe (yeasts) to grow. Some factors must be considered when
choosing media for yeast cell culture, like ensuring
 Quality consistence and availability

 Ensure there are no problems with Media Preparation or other aspects of production process
Ex. Cane molasses, beet molasses, cereal grains are proved to be the best media for better
growth of yeast cells.
The alcoholic fermentation is commonly obtained by means of two main process steps, namely the
"aerobic stage" and the "anaerobic stage". The aerobic one deals with the growth of yeast cell. This
inoculum preparation stage needs a big focus since it is considered as the backbone of the whole
fermentation.
It can be seen from the above data that fermentation process is the primary source of ethyl alcohol in
the above regions. Ethanol production from cane or beet molasses has been done for longer time by
using fermentation processes as a drinking liquor and bio fuel. For longer time fermentation is done
by using batch process in the world till 1985. But currently utilization of continuous bio reactor has
been started to produce alcoholic distilled liquors and power alcohols and brought an enormous
benefits to this sector with regard to reduction in man power requirements.
Production of ethyl alcohol from cereals and molasses for drinking and power alcohol comprises
different unit processes and operations such as Fermentation, Distillation, Water treatment,
ingredient preparation and Effluent handling process. In order to obtain good quality and maximum
conversion of fermentable sugar in to ethanol it is necessary to focus on fermentation process
(DR.Nalini B.2009)
Fermentation is a bio-chemical process in which six carbon sugars such as fructose, glucose, etc are
converted to ethyl alcohol and carbon dioxide which is catalyzed by enzymes generated from yeast.
Any polymeric hexose sugar present in any materials in the first instance must be converted to
hexose sugar units and then fermented in to ethyl alcohol. Conversion of polyhexose to hexose is
called hydrolysis and it is carried out either enzymatic ally or by chemical means in batch and
continuous fermenters. But here in NALF all the fermenters are operating according to the fed-
batch pattern.
In the fed-batch process, substrate is added in increments as the fermentation progresses. In the fed-
batch method the critical elements of the nutrient solution are added in small concentrations at the
beginning of the fermentation and these substances continue to be added in small doses during the
production phase.
2.2.1. Chemical Reactions During Fermentation

There are different chemical reactions occurred during fermentation processes such as the
production of alcohol from glucose by the action of Zymes-enzyme, inversion of sucrose to glucose
is done by invertase and different other types of biochemical reactions will occur to form Acetic
acid, lactic acid, diacetyl, acetone, Iso propyl alcohol, n- propyl alcohol, n-butyl alcohol, etc. The
biochemical reaction rather than formation of ethanol which occurs during fermentation of molasses
are not important as it resulted in reduction of fermentation efficiency. The overall process of
fermentation is to convert glucose sugar (C6H12O6) to alcohol (CH3CH2OH) and carbon dioxide gas
(CO2). The reactions within the yeast cell which make this happen are very complex but the overall
process is as follows:
C6H12O6 ====> 2(CH3CH2OH) + 2(CO2) + Energy (which is stored in ATP)
Sugar ====> Alcohol + Carbon dioxide gas + Energy
(Glucose) (Ethyl alcohol)
From the above it seems nice and simple chemistry one mole of glucose is converted into two moles
of ethanol and two moles of carbon dioxide but in reality it is far from this clear. There are many by

products. In addition to CO2 and alcohol, the sugar is incorporated into other by products such as
yeast biomass, acids (pyruvic, acetaldehyde, ketoglutaric, lactic), and glycerol.
The sugars used can be a range of fermentable sugars. These sugars are converted by enzymes to
glucose which is then converted to alcohol and CO2. Some sugars are not able to be fermented and
will remain in the levels.
The success of a fermentation process is highly dependent on environmental factors. The fermenter
needs to be able to control such factors as temperature, pH, and dissolved oxygen levels. Both
aerobic and anaerobic processes are used to complete the whole fermentation. The aerobic one is
essential for the yeast growth during the propagation before the main fermentation is started. Then
the anaerobic process follows in which the desired product- the ethanol is produced.
2.2.2. Factors affecting fermentation of molasses

In the anaerobic pathway every mole of glucose is converted into 2mole of ethanol, 2mole of carbon
dioxide, and 2mole of ATP along with 56kcals of heat. The ATP produced is used in biosynthesis or
maintenance. In this pathway every gram of glucose converted will yield 0.511gram of ethanol. On
the other hand, under aerated metabolism, sugar is converted completely to CO 2, water, cell mass
and by-products with no ethanol formed. The formation of these products is affected by certain
factors.
I. Effect of sugar concentration
Hexoses sugars such as glucose are the primary reactants in the yeast metabolism. Under
fermentative conditions, the rate of ethanol production is related to the available sugar concentration
by a Monod equation,
V 2.1

Where, V is the specific ethanol productivity (g of ethanol/g of cell/h)
Cs is the sugar substrate concentration (g/l)
Ks is the saturation constant having a very low value typically 0.2 – 0.4 g/l. At
very low sugar concentration(less than 0.3%), the yeast is starved and the productivity decreases.
Sugar concentration up to 15%, the rate of ethanol production per cell is essentially at its maximum,
beyond this concentration, catabolite inhibition of enzyme in the fermentative pathway takes place
and the conversion rate is slowed. At concentration above 0.3 to3% the production of oxidative
enzyme is inhibited, thus forcing fermentative metabolism. This catabolite suppression is a desirable
characteristic in industrial strain.
II. Effect of pH
The pH is the measure of acidity or alkalinity of aqueous solution expressed on scale of 1 – 14.
Neutral is pH 7, pH 1 -7 is acid, and pH 7-14 is alkaline. The pH is most conveniently measured
with test papers that change colour according to the pH of the solution being tested. Control of pH
during the mashing and fermentation process is important for two reasons; the growth of harmful
bacteria is retarded by acid solutions, and yeast will grow only in an (slightly) acid solution.
Generally Distiller’s yeast shows a broad pH optimum from 4 to 5. The development of bacteria is
severely repressed at pH value under 5. The acid most commonly used is sulfuric acid, although any
mineral acid is perfectly suitable. Further, yeast can tolerate as low pH as 2 without permanent
damage.
III. Effect of Temperature
As heat energy is liberated during fermentation of sugar by yeasts there is always an increase in
temperature and cooling of fermenters is required, and, therefore, it is desirable to use temperature
tolerant strains. Most strains have a temperature growth optimum of 30 – 35ºC. However, the
optimum fermentation temperature at a low alcohol concentration is often slightly higher (38ºC), but
alcohol tolerance is improved at reduced temperature. S. Cerevisiae strains usually have 32ºC as
optimum temperature for ethanol production. Exposure to higher temperature results in excessive
enzyme degradation and loss of yeast viability. Yeast can be stored inactive at low temperatures
(above 0ºC) and are readily revived.

IV. Effect of Oxygen
It has been found that trace amount of oxygen may greatly stimulate yeast fermentation, which is
used as building block for synthesis of poly-unsaturated fats and lipids required in mitochondria and
plasma membrane . High sugar concentration is adequate to repress aerobic sugar consumption in
yeasts which show the Crabtree effect. For other yeasts or at low sugar concentration, the oxygen
supply should be limited. Trace amounts (0.7 mm Hg oxygen tension) of oxygen are adequate and
do not promote aerobic metabolism. Conversion of sucrose to glucose is taking place outside cell
wall, whereas conversion of glucose to ethanol takes place inside cell wall in the mitochondria. If
there is no sufficient air the yeasts will be weak.
2.3. Distillation
Distillation is a commonly used method for purifying liquids and separating mixtures of liquids into
their individual components. Familiar examples include the distillation of crude fermentation broths
into alcoholic spirits such as gin and vodka, and the fractionation of crude oil into useful products
such as gasoline and heating oil. In the organic lab, distillation is used for purifying solvents and
liquid reaction products. To understand distillation, first consider what happens upon heating a
liquid. At any temperature, some molecules of a liquid possess enough kinetic energy to escape into
the vapor phase (evaporation) and some of the molecules in the vapor phase return to the liquid
(condensation). Equilibrium is set up, with molecules going back and forth between liquid and
vapor. At higher temperatures, more molecules possess enough kinetic energy to escape, which
results in a greater number of molecules being present in the vapor phase. If the liquid is placed into
a closed container with a pressure gauge attached, one can obtain a quantitative measure of the
degree of vaporization. This pressure is defined as the vapor pressure of the compound, and can be
measured at different temperatures.

Figure 2.3.1 vapor formation with temperature
Certain fundamental principles are common to all distilling systems. Modern distillation systems
are multi-stage, continuous, countercurrent, vapor-liquid contacting systems that operate with in the
physical laws that state that different materials boil at different temperatures. Represented in Figure
2 is a typical distillation tower that could be employed to separate an ideal mixture. Such a system
would contain the following elements:
a) a feed composed of the two components to be separated,

b) a source of energy to drive the process (in most cases, this energy source is steam, either
directly entering the base of the tower or transferring its energy to the tower contents
through an indirect heat exchanger called are boiler),
c) an overhead, purified product consisting primarily of the feed component with the lower boiling
point,
d) a bottoms product containing the component of the feed possessing the higher boiling point,
e) an overhead heat exchanger (condenser), normally water-cooled, to condense the vapor
resulting from the boiling created by the energy input. The overhead vapor, after
condensation, is split into two streams. One stream is the overhead product; the other is the
reflux which is returned to the top of the tower to supply the liquid down flow required in
the upper portion of the tower.

The portion of the tower above the feed entry point is defined as the rectifying section of the tower.
The part of the tower below the feed entry point is referred to as the stripping section of the tower.
The system shown in Figure 2 is typical for the separation of a two component feed consisting of
ideal, or nearly ideal, components into a relatively pure, overhead product containing the lower
boiling component and a bottoms product containing primarily the higher boiling component of the
original feed. If energy was cheap and the ethanol-water system was ideal, then this rather simple
distillation system would suffice for the separation of the mash feed into a relatively pure ethanol
overhead product and a bottoms product of stillage, cleanly stripped of its ethanol content.
Unfortunately, the ethanol-water mixture is not an ideal system.
Figure 2.3.2 ideal distillation system
2..2. Types of distillation column

There are two commonly known types of distillation columns; namely tray and packed columns.
Therefore, distillation can be carried out in a tray or a packed column. The major considerations
involved in the choice of the column type are operating pressure and design reliability.
Tray Columns
A tray is chemical equipment used to carry out unit operations where it is necessary to transfer mass
between a liquid phase and a gas phase. In other words, it is a particular gas-liquid contactor. The
peculiarity of this gas-liquid contactor is that the gas comes in contact with liquid through different
stages; each stage is delimited by two plates (except the stage at the top of the column and the stage
at the bottom of the column).Tray columns are suitable for both continuous and batch operations.
Packed Columns
Packed columns are used for distillation, gas absorption and liquid-liquid extraction. The gas-liquid
contact in a packed column is continuous, not stage-wise, as in a plate column. The liquid flows
down in the column over a packing surface and the vapor (or the gas) moves counter-currently, up
the column. The performance of a packed column is very dependent on the maintenance of good
liquid and gas distribution through the packed bed, and this is an important consideration in packed
column design.
In NALF there are five distillation columns to perform the tasks of extracting extra neutral
alcohol (ethanol) from fermented mash. All the distillation columns are of tray types namely
Mash, degassing, and concentration column, hydro-selection column, rectification column,
methyl alcohol column, and fusel oil column which are used for extraction of alcohol.
2..3. Factors Affecting the Distillation Process

 Feed Conditions
The state of the feed mixture and feed composition affects the operating lines and hence the number
of stages required for separation. It also affects the location of feed tray. During operation, if the
deviations from design specifications are excessive, then the column may no longer be able handle
the separation task. To overcome the problems associated with the feed, some column are designed
to have multiple feed points when the feed is expected to containing varying amounts of
components.
 Column Diameter
Most of the above factors that affect column operation is due to vapor flow conditions, either
excessive or too low. Vapor flow velocity is dependent on column diameter. Weeping determines
the minimum vapor flow required while flooding determines the maximum vapor flow allowed,
hence column capacity. Thus, if the column diameter is not sized properly, the column will not
perform well. Not only will operational problems occur, the desired separation duties may not be
achieved.
 State of Trays and Packings
The actual number of trays required for a particular separation duty is determined by the efficiency
of the plate, and the packings if packings are used. Thus, any factors that cause a decrease in tray
efficiency will also change the performance of the column. Tray efficiencies are affected by fouling,
wear and tear and corrosion and the rates at which these occur depends on the properties of the
liquids being processed. Thus appropriate materials should be specified for tray construction.
 Feed Tray Position
As the feed stage is moved lower down the column, the top composition becomes less rich in the
more volatile component while the bottoms contains more of the more volatile component.
However, the changes in top composition is not as marked as the bottoms composition. It should not
be used to generalize to other distillation systems, as the effects are not straightforward.
 Weather Conditions
Most distillation columns are open to the atmosphere. Although many of the columns are insulated,
changing weather conditions can still affect column operation. Thus the reboiler must be
appropriately sized to ensure that enough vapour can be generated during cold and windy spells and
that it can be turned down sufficiently during hot seasons. The same applies to condensers.

These are some of the more important factors that can cause poor distillation column performance.
Other factors include changing operating conditions and throughputs, brought about by changes in
upstream conditions and changes in the demand for the products. All these factors, including the
associated control system, should be considered at the design stages because once a column is built
and installed, nothing much can be done to rectify the situation without incurring significant costs.

CHAPTER THREE
3. PROCESS DISCRIPTION
In the previous chapter we have discussed the theories of alcohol (ethanol) production process due
fermentation then distillation process. And in this chapter we will discuss the process description of
each unit operations in NALF.
3.1. The molasses treatment
Molasses is a byproduct of Sugar Company and it should be treated to avoid some unwanted
products like carbon dioxide, calcium hydroxide created in the process of bleaching, and other
components. In this section, molasses will be diluted and broken-down in to simple sugar and then
passed to fermentation process. Optimized fermentation conditions are expected to achieve the
maximum ethanol yield from sugar molasses. The process in this section is installed to operate 24
hours per day in continuous system. Buffer is necessary after each section to cover normal
fluctuations. It also takes the energy consumption, the water recovery system, and utility
consumption in accordance to minimize the CO2 foot print as much as possible. When molasses is
the raw material for fermentation, pre-treatment improves the overall process efficiency and also the
quality of product ethanol.
Raw molasses which is averagely at 80 Brix from bulk storage is transported to the first tank, the
dilution tank in the molasses treatment section using a gear pump.Mass flow meter permits the flow
control adjusting the speed controller of the pump.In the dilution tank the raw molasses is diluted
down to 45-50 Brix by adding first white stillage waterfrom distillery which helps for pH reduction
and then fresh water. Steam is directly injected to the tank for the purpose of sterilization. The
temperature of the dilution tank is maintained at 80˚C by the steam control valve. After the mixture
is homogenized well with the blade type mixer in it, it is fed to the first static decanter from the
overflow nozzle of the dilution tank. There was also a sulfuric acid inlet to this tank which is
connected to a pH sensor installed outside the tank to correct the pH of the mixture, however it is
failed to operate now.

First sedimentation will be realized in the first static decanter with the help of extraction type mixer
in it. At the bottom of this decanter a certain amount of sediment is stored for some time until it is
expected to have neglected amount of sugar content in it, and then drained out. Again here, the plant
was designed to recycle the sediment to the recovery or steam tank, which is currently seen as a
failed process too.
The recovery or steam tank has feed of 40% process water and the rest of 60% white stillage water
from distillery. The temperature of this tank is maintained at 80˚C by the steam control valve.
The overflow of the steam tank goes to the second static decanter, which is currently used as just a
pathway of the hot water from the steam tank to the dilution tank. But it was designed to extract the
sugar remaining in the sediment of first static decanter which is recycled to recovery or steam tank.
Again the overflow water of the second static decanter is fed to the dilution tank to dilute the raw
molasses.
The air scrubber over all tanks suck CO2, steam, and other gasses from each 5 tanks

white
raw molasses stillage
H2SO4 coustic soda
solution
3
dilution 7 8
1 4
water
steam
cw
cw
cw 5
24 dilution water
cw
6 to fermentation
key symbols
1. dilution tank
..........plate heat exchanger
2. first static decanter
3. steam/recovery tank .........centrifugal pump
4. second static decanter
5. buffer/storage tank
6. static mixer
7. CIP tank 1
8. CIP tank 2
Fig 3.1.1 Process Flow Diagram of Molasses Treatment

3.1.1. Material and energy balance calculations

3.1.1.1. Material balance calculation
The objective of material balance is by using known values finding unknown values that flow
through the process. the objective of this material balance is calculating the volumetric flow rate of
the diluted molasses from static mixer to fermentation and propagation tanks.
Block diagram of the molasses treatment section
Bulk Dilution First Static Cooling

Storage Tank Decanter
of
Molasses
Water
Steam Steam Discharge
Second Static Buffer Tank

Decanter Recovery
Tank
Dilution Water
White stillage and process water Static Mixer
To Fermentation

Given
 First dilution water ʋw= 3024L/hr. (60% white stillage & 40% process water)
 Dilution water on static mixer ʋ1 = 3360lit/hr.
 Molasses feed to dilution tankṁm= 3040kg/hr.
 Density of diluted molassesρm=1103kg/m3=1.103kg/lit
 Density of water ρw=1000kg/m3=1kg/lit
Assumption
 Amount of steam is negligible because it has no significant effect on 3040kg/hr. input.

 Steady state operation.ʋw= 3024 lit/hr. water
 The discharge from first static decanter is negligible,
since it is performed once when the process stops.
Recovery Tank
Material balance on the Recovery Tank.X1 = ?
The outlet flow rate from the overflow nozzle of recovery tank
is unknown. Let’s calculate thisin terms of mass flow rate;
Accumulation = input – output ……… steady state
0 = input – output
Output = input
……… the recovery tank has an output of the input itself, because there is no other
input or output. In mass flow rate it becomes;

Material balance on the Second Static Decanter. X2=?
We are going to calculate the outlet from the overflow nozzle of
Second Static Decanter
Accumulation = input – output ……… steady state Second Static

Decanter
0 = input – output = 3024
output = input
X2 = ………similarly the Second Static Decanter has an output of the input itself. This
means the second static decanter is just a pathway for the hot water from the recycle tank.
Material balance on the Dilution Tank
The unknown here is also the outlet solution flow rate to the first static decanter. We will use the
same equation to calculate.
Output = input ṁm=3040 ṁs =?

Dilution Tank
ṁs= + ṁm
ṁs = 3024 + 3040
= 3024
Material balance calculation for the next three units (first static decanter, cooling and buffer tank) is
not necessary because the mass flow rate of the outlet solution of dilution tank itself goes until it
reaches buffer tank.so lets proceed to the static mixer.

Material balance on the Static or Online Mixer ʋ1 = 3360lit/hr.

water
Now let’s calculate at what flow rate the treated and ṁs = 6064 kg/hr.
Static Mixer
diluted molasses goes to fermentation. ʋf =?
Output = input
but
Therefore, theoretically it is expected that, 8857.73 liter of treated molasses is leaving the treatment
section per hour currently.
3.1.1.2. Energy balance calculations
The energy balance calculation is necessary to know what amount of energy is used or lost to
perform the given action.
Given
 Specific heat capacity of steam at 125˚C (Cps) =4.2533
 Specific heat capacity of water at 80˚C (Cpw) = 4.1969
 Cp of molasses =3.2
 Steam T0 = 1250C
Assumptions
 Atmospheric is constant at T0 = 25 0C
 Steady state operation
 Temperature in= temperature out (insulated tanks)

Energy Balance for the Recovery Tank
mw=3024kg/hr, Q1 steam Q2
Input = output
Q3=Q1+Q2 …………………………. Eq. 1 Recovery Tank
T0 = 800C
Q1=mwCpw∆Tʋw=3024kg/hr, Q3
Q3=mwCpw∆T
Substituting to the Eq 1
Q3=Q1+Q2
Q2 = 0 = 3024 , Q5
Energy Balance for the Second static decanter
Input= output Second Static

Decanter
Q3=Q4 = 3024 ,
Therefore,

Energy Balance on Dilution Tank
Q4+Q6=Q5ṁm =3040 ,Q4ṁs = ,Q5 Dilution

Tank
Q6= Q4=
Therefore, = 3024 , Q6
Q5=
Energy Balance on First Static Decanter
output =input First Static

Decanter
Q7=Q5= ṁs = ,Q5 ṁs = ,Q7
Energy Balance on cooling
Assumption
 There is energy lose. Therefore, energy lose = output-input Cooling
loss of enegy =Qout @ T= 80˚C-Qin@ T=30˚Cṁs = ,Q7
= mCp∆Tout - mCp∆Tinṁs = ,Q8
=( )
= 1273009.456 kJ/hr.

3.1.2. Discussion
As it is described above raw molasses is being treated with only temperature. Of course this
sterilizes the mixture, but sulphuric acid was used to facilitate the precipitation of lime in the
molasses in the first static decanter. This process fails because of the failure of storage tanks and
pump which transfers it to the dilution tank by the sulphuric acid. Since sulphuric acid is a strong
acid the container should be chosen carefully. In NALF the acid containers are made of plastic and
they could not resist it. The nozzle pump also is continuously failed because of their weak acid
resistance.
To choose sulphuric acid storage first there are some things we need to consider:
 Container should be kept in cool, dry and well-ventilated area

 Container should be tightly sealed to prevent exposure to foreign materials and
temperature change
 Due to the weight of sulphuric acid it will push the limits of mechanical integrity of any
plastic or polyethylene tank
As a solution the most recommended materials to store sulphuric acid (>70%) are carbon steel. This
material is relatively inexpensive and offers good corrosion resistance. For small tanks which is less
than 4500 gallons with sulphuric acid concentration below 95%, high density cross-linked
polyethylene (HDXPE) may be suitable.
The most recommended pumps types are centrifugal seal less magnetic drive chemical pump made
from polypropylene or kynar plastic, encapsulated impeller, Viton O-ring, and either a carbon or
mica Teflon Bushing. These materials could have better acid and corrosion resistance, and are able
to transport it.
This sulphuric acid storage tank and pump problem surely decreases the efficiency of the treatment
plant because it breaks the recycle line of the precipitate which is expected to have some amount of
fermentable sugar in it to the recovery tank. The reason is, sulphuric acid decreases the density of
the sediment reacting with Ca(OH)2 (the bleaching agent in sugar factories) and then turning it to
salt solution which is comfortable for the pumps to recycle it.

For dilution, two types of water are used; process water and white stillage. Among the use of white
stillage; steam consumption, process water saving and pH adjustment are the commons.
In the theoretical material balance calculation the flow rate of diluted molasses from static mixer is
8857.73 lit/hr., but the actual flow rate of diluted molasses is averagely 9200 lit/hr. this difference
occurred because of the failure occurred on the recycling process. This is also integrated with the
problem described above, the sulphuric acid addition in dilution tank. In addition, the pH, and brix
sensors play significant role in fluctuating the outlet value since they transmit information to the
automatic valves to let the right amount of the dilution water to the static mixer each time.
3.2. Fermentation
The processing cycle in alcoholic fermentation are;
I. Raw material (substrate) preparation

II. Yeast propagation( inoculums preparation)
III. Mash feeding
IV. Conversion Termination and Emptying
V. Cleaning
I. Raw material (substrate) preparation
As we have discussed in chapter 1 the basic raw material, molasses must be treated with acid and
high temperature. And the raw molasses is diluted till it is good for fermentation and yeast
propagation purpose.
II. Yeast propagation( inoculums preparation)
As we have mentioned before, the yeast propagation part takes place aerobically. This section
consists of two reactors yeast, propagation tank A and B which operate one after the other.. The
scheduling for the yeast production foresees successive cycles of re-propagation and only a part of
propagated yeast is sent to anaerobic fermentation and 10% of it is sent into a footing drum as
footing for the re-propagation in next cycle. Anyway this operation is repeated a maximum of 3
times to reduce the risk of infection. The air necessary for the yeast growth is injected, through the

Air Compressors and before being fed to the propagation tanks is filtered and cooled in a double
pipe heat exchanger with cold water inlet. The propagation tanks are provided with a jacket for
cooling water circulation, because the reaction is exothermic, therefore mash temperature is
controlled. Propagators are provided with lines nutrients (necessary for yeast growth). Nutrients
solution is prepared within the Nutrients Preparation Drum, diluting of solid salts with process
water, by means of the mixer in it. Nutrients Pump that is installed under the drum sends the nutrient
solution to the yeast propagators. The Antifoam Drum was designed to prepare antifoam and then to
transport it to each fermenters, and the pumps pressurize a line where the antifoam is immediately
made available according the opening of manual valves installed on each fermenter. But currently
this antifoam drum is not working due to the small line radius, and pump effectiveness. Thus, now
antifoam is added manually when foam is formed. The propagation process takes place for 18 hrs.
Note: - 2% of maximum alcohol formation is tolerable during the propagation process.

Water
from
dilution CIP
water
molasses
from
treatment
CW
CW CW
1 1 7
CW CW Air
CW
6
propagated yeast to
drainage fermentation
2 3 4 5
1. Propagation tank
2. Anti foam container ..........gate valve
3. Sulphuric acid tank
4. Nutrition tank
..........ball valve
5. Yeast footing tank
6. Air compressor .........centrifugal pump
7. Double pipe heat exchanger
Fig 3.2.1 Process flow diagram of yeast propagation
III. Mash feeding
The mash from static mixer is fed continuously to the main fermenters. The mash to the main
fermenters is fed, at constant flow rate (8130 L/hr.) until the tank is filled 20%. Ten the propagated
yeast follows, which accounts 10% of the fermenters. Operating in such way the yeast is not overfed
with sugars, thus minimizing the substrate inhibition mechanisms and obtaining at each time the
maximum practical figure for the reaction rate. The reaction heat is maintained by cooling jackets.
A temperature control is foreseen to maintain predetermined operating temperature during the
reaction. Side entering mixers for each fermenters is installed to allow homogenization of the

fermenting mash, and improve the removal of the CO2 produced, thus resulting in optimum reaction
development. After the fermentation has finished its scheduled time (48hr.), it is sent to a buffer
tank where there is no reaction take place. Here also there is a manual antifoam addition when foam
is formed. From the fermented mash 8-12% of alcohol is produced. The CO2 produced is sent to a
scrubber where the ethanol is recovered by absorption with water in a washing column. In order to
not to cause overpressure inside the fermenters the fan is provided, feeding the CO2 to the scrubber.
The scrubbed CO2 is released to the atmosphere. The weak alcoholic solution recovered fed to the
fermented mash tank (buffer tank) is sent to the distillation unit for more extraction.
Water from CIP
propagated yeast
treated molasses
1A 1B 1C
water
1D 1E 3
1F
fermented
mash to
distillery
legend symbols
1. A-F. fermentation tank ....................centrifugal pump
2. buffer tank
3. antifoam tank ....................gate valve
....................electrical ball valve
..................drainage during cleaning
Fig 3.2.2 Process flow diagram of fermentation

IV. Conversion termination and emptying
The conversion termination is accomplished for each fermentation stage, both in the aerobic section
and anaerobic. When the fermenter has been fed to its full operating capacity, the feed is switched to
the next fermenter and the solution is leaved to complete the conversion, thus consuming all the
sugars present in the substrate. After that time, the fermenter is emptied and cleaned, to be ready for
the next cycle the fermenter have been designed for a total operating cycle of 48 hours. The mash is
discharged from fermenters by means transfer impeller pumps and is fed into the Fermented mash
tank (buffer tank). Also this tank is provided with side-entering mixer to allow homogenized
solution feeding to the distillation unit. The same pump type transfer the mash from the buffer tank
to the mash column of the distillation unit.
V. Cleaning
After the emptying, the fermenter is cleaned by appropriate internal spraying devices that are
connected to the Cleaning In Place (C.I.P.) system; the same system provides for cleaning the
mother yeast propagation vessels at the end of the relevant cycles. The CIP process takes place in
three steps. First the tank is rinsed with water in high pressure through the spray ball on the CIP line
in the tank in order to recover the fermented mash on the inner walls of fermenters. Then it is
washed with a hot 5% caustic soda (NaOH) solution in the same manner for three minutes. The tank
is ecpected to be clean from fermented mash now. Finally rinsing again with water follows which is
used to clean the washing solution from the walls of the fermenters. Therefore it is ready for the
next fermentation. The CIP system and the whole operating cycle are automatically controlled.
3.2.1. Material balance calculations

From the data we have we can calculate that, how much ethanol is formed from the feed molasses
due fermentation. Our process is fed batch, which means there is no input and output during the
process.
Given
 V Diluted molasses fed = 81.3 m3

 Brix of diluted molasses fed to fermentation = 26 Brix

 Molar mass of C6H12O6 = 180kg/kmol
 Molar mass of CH3CH2OH = 46 kg/kmol
 Molar mass of CO2 = 44kg/kmol
Reaction: - →
Molar mass: - 180kg/kmol 92kg/kmol 88kg/kmol
Assumptions
 All the sugar feed is consumed/no sugar loss

 Productions of other alcohols other than ethanol are neglected since they have small amounts
compared to ethanol.
Therefore, for fermentation the material balance equation is simplified to;
Accumulation = generation
Accumulation = ethanol produced + CO2 produced + stillage = 81.3 m3
,where stillage = water + unfermented materials after fermentation.
The amount of fermented sugar (C6H12O6) in 26 Brix molasses is expected to be about 17%.
Therefore,

Material balance on ethanol
Then the volume of ethanol produced can be calculated using the given molar masses since a given
mass and molar mass are directly proportional to each other.
180 kg/kmol of C6H12O6 92 kg/kmol of CH3CH2OH
. 15.244 kg of C6H12O6 mEt =?
i.e. 9.92 m3 of ethanol is produced from the fermentation of 13.82m3 glucose.
3.2.2. Discussion
Comparing these results to the actual values seen on the controlling computer and laboratory
reports, there is a bit difference seen between. From the theoretical calculation we can understand
that 7.064 m3 of alcohol is produced from 13.82m3 of glucose which is 17% of the 26 brix molasses
feed. This means that, 12.2 % of alcohol is produced where it is designed to produce in the range of
8-12%. Therefore the theoretical alcohol production is seen to be in the higher extreme of the
desired production. But the actual value indicates that averagely 10% alcohol is being produced
currently, however here is some fluctuations on the grade levels of alcohol each fermentation. The
difference between the actual value and the theoretical value is appeared because of some factors
before and during the fermentation. Some of them could be the neglected amount of other alcohols /
products, the effect of air compressor installation, and the effect of molasses treatment.
The air compressor is needed to supply enough oxygen to the yeast propagation tanks so as it helps
for sake of healthiness of the yeasts. In NALF the compressor is installed inside the fermentation
house where there is a possibility for many gasses like carbon dioxide from the fermenters, steam

from treatment including atmospheric gasses to exist. Since it is placed on the ground, there is also a
probability for dusts to enter the compressor. This can reduce the ability of filtering the entering
gasses and dusts over a period of times. Such gasses other than oxygen are not useful for the yeast
growth. As a solution for this problem, rearranging the location of the compressor could solve the
question of the demand of oxygen for the yeasts. This means placing the compressor outside the
fermentation house where it could get fresh air.
On the other hand the neglected amounts of the other alcohols produced during fermentation also
affected the material balance calculation. Taking only ethanol and carbon dioxide as the products of
the process increases the theoretical amount of carbon dioxide more. The actual value tells as there
is only 5.69 m3 of CO2 is produced when the alcohol grade level is 10% (8.13 m3). This situation
indicates that the more alcohol is produced the less carbon dioxide released.
3.3. Distillation
For the neutral spirit production the distillation system consists of 5 columns plant operating
continuously capable of giving high performances and high quality., byproducts are expected to be
lower than 6 % and steam consumption will not exceed 350 kg of steam for 100 liter of total
alcohol produced (reference condition: latent heat = 520 kcal/kg). The plant uses fermented sugar
cane molasses having alcohol strength in the range 8-10 % v/v.
In the distillation system, the following are main columns:- Mash / Degassing / Concentration
Column
 Rectification Column
 Hydroselection Column
 Fusel Oil Column
 Demethylizer Column
 Heads (washing) Column
In order to optimize the steam consumptions, a double effects configuration have been proposed: the
rectifier overhead vapour is reboiling the mash-degassing-concentration, and the overhead vapour
from hydroselection column is reboiling the demethylizing column. Thus steam from boiler house
provides heating directly to hydroselection column and rectification column, to heads column, and
partially to the fusel oil column. The heating of fusel oil column is integrated with flashing white
stillage from rectifying column.To achieve this thermal integration between the columns occurs that
the rectification column is working under pressure, the fusel oil, heads columns are operating at
atmospheric conditions, while the mash-degassing-concentration and demethylizing are operating
under vacuum.
Mash / Degassing / Concentration Column
This column operates below the normal atmospheric pressure due to the vacuum pumps sucking gas
from the degassing column. Fermented mash is pumped to the degassing column, where the
elimination of carbon and sulphur dioxide is achieved by means of heating under vacuum
conditions. In this column the selection of copper as tray construction material has been made in
order to facilitate the removal of the volatile sulphur compounds which have a negative effect on
distillate quality: these compounds undergo a chemical reaction in presence of copper which acts as
a catalyst, renders them insoluble and removes them from the product vapour thereby improving
distillate quality. Alcohol contained in the mash is then stripped in the mash column. The mash
reboiler heat the mash to 80°C by the overhead of rectification column (impure alcohol to be
refluxed) and collected as vapour in the concentration section, which operate with a minimum reflux
to ensure a cleaning of vapour and minimize any eventual entrainment. Overhead vapour is fed to
the hydroselection column. The dark stillage, with residual alcohol content lower than 100 ppm, is
discharged as waste from the mash column bottom. After condensation, recovered alcohol, with an
alcoholic strength variable from 40 to 50°G.L (alcohol grade) is still rich of impurities and is refined
in the hydroselection column.

from fusel oil Vent

top
mash
reflux to DA
CW
storage
1 CW
2
CW CW
CW CW
fermented
mash
bad alcohol
from
rectification 3
top
to fusel
4 oil
column
reflux for
rectification to hydro-selection column
column
key
1. mash/ degasssing /concentration column ..............centrifugal pump

2. washing column
............vacuum pump
3. reflux drum
4. first alcohol storage ..............sight glass
CW = cold water
DA = denatured alcohol ..............plate heat exchanger
.........shell and tube heat exchanger
......gate valve
.......pneumatic valve
Figure 3.3.1 Mash / Degassing / Concentration Column flow diagram

Hydro-selection Column
Within this column an extractive distillation takes place and the congeners (group of impurities) are
removed within the overhead stream. The extractive distillation is obtained by diluting the alcohol
stream with softened water and part of the spent lees(white stillage) coming from rectification
column bottom product. The alcohol is recovered, at a dilution of about 10%vol, from the bottom of
and is then sent to the rectifying column. The hydroselection column is heated by direct steam
injection.
dilution water reflux
CW
1
CW alcohol to
demethylizer
2 3 alcohol from
DA
demethylizer
alcohol to rectifying
steam column
key
1. hydro-selection column ............centrifugal pump
2. first alcohol storage
3. condensed congeners storage
.............plate heat exchanger
Figure 3.3.2 Hydro-selection Column flow diagram

Rectification Column
In the rectifying column the ethanol is concentrated up to 96.2 °G.L., and sent to the final
demethylization stage. The rectifying overhead is condensed within the mash column reboiler,
which is a vertically installed shell and tube heat exchanger. The reboiler heat indirectly the mash
column using the rectifying overhead. The flash drum is a small container between fusel oil column
and demethylization column. It is used to reduce the white stillage dose to the mash reboiler. A
guard condenser (-is plate type heat exchanger) achieves the condensation of any excess vapour and
provide pressure regulation for rectification column. All condensates are then collected in the reflux
drum and recycled to the rectifier as reflux and a part is sent to technical alcohol storage.
The spent lees from the bottom of rectifying column, is flashed in the flash drum, which is also used
for heat recovery in Fusel oil column. The spent lees from the bottom of flash drum is partially
recycled, after cooling, for dilution in the fusel oil decanter and washing column while the
remainder is then goes to the CIP.
reflux
to mash reboiler
To
demethylizer 1
column HT to DA
HHT
storage
LT
2 3
to DA to fusel oil
storage column
white stillage
alcoholfreom hydro-
selection column
key
1. Rectification column ..............centrifugal pump

2. Flash Drum
3. First alcohol storage ........plate heat exchanger
Figure 3.3.3 Rectification Column flow diagram

Demethylizer Column
The alcohol extracted from the rectifier is fed to the demethylization column where practically any
trace of methanol is removed. Ethanol stream rich stream is withdrawn from the top of the column,
and sent to the technical alcohol storage after final cooling. Purified alcohol is removed from the
bottom and also sent to the storage after final cooling. The demethylizing column is indirectly
heated by a reboiler beside the column at bottom. The main route of the alcohol product is then
ended.
CW
extracted alcohol
from rectification CW
reflux
CW
CW
1
CW CW
to technical/DA
congene storage
rs from
2
HS
Reflux to
hydro-
selection
column
key
1. Demethylizer column .............centrifugal pump
2. condensed congeners storage .............plate heat exchanger
3. Extra Neutral Alcohol storage
..........shell and tube heat exchanger
............sight glasss
Figure 3.3.4 Demethylizer Column flow diagram

Fusel Oil Column

The processing of the congeners is carried out in the fusel oil concentration column. The feed to this
column, coming from hydroselection top, contains both fusel oils (containing some alcohols) and
heads congeners, which undergoes one more stage of concentration. The fusel oils are extracted as a
side stream which is fed to the fusel oil decanter. The white stillage water is sent at the bottom of
the decanter to push the oil up and sent to the storage through the cup in it. The heavy layer (the
water), which remains at the bottom due to their density difference, still contains small amount of
ethanol that it gains through absorption principle from the fusel oil, and is recycled back to the
column.
The overhead vapour of the this column, after condensation is partially refluxed while the remaining
is fed to technical alcohol storage; to this storage top products of degassing column, rectifying
column, high and high high tails of rectifying column and fusel oil column are also sent. A side
stream near to the top of fusel oil column is recycled to hydroselection.
In order to reduce the emission to the atmosphere as well as the alcohol losses, the vents from
vacuum pumps are washed in a vent scrubber (washing column) which is a thin and short column
compared to the others. This column also operates using the principle of absorption. Washing liquid
is white stillage that comes from oils column bottom, after cooling. This water absorbs the alcohol
from the scrubbed gas when it showers the gas, and alcohol is recovered in oils column.

CW
CW
white stillage Reflux

from diluted alcohol to CW
rectification C. rectification column
CW
diluted alcohol 1
from HS to DA
storage
steam
2 CW
CW
to hydro-selection white
for dilution
stillage to
white stillage to CIP
treatment
legend symbol
1. Fusel oil column ...........centrifugal pump
2. Flash drum
...........plate heat exchanger
...........sight glass
...........pneumatic control valve

...........gate valve
...........shell and tube heat exchanger
Figure 3.3.4 Fusel oil Column flow diagram

The following table shows that top and bottom products of each columns with their corresponding
temperature and pressure.
Table3.3.1: top and bottom products of each column
Top products Bottom products
Column Fluid T (° P Fluid T (°C) P (bar)

(bar)
C)
Mash / Degassing / Alcohol 50% v/v 67 0.34 Spent wash 81 0.48

Concentration Column 1.0 (dark stillage)
Rectification Column Alcohol 96.2% 98 2.1 Spent lees 127 2.5

v/v (white stillage)
Hydroselection Column Bad alcohol 95 1.0 Alcohol 10% 101 1.3

50% v/v v/v
Fusel Oil Column Alcohol 95% v/v 78 1.0 Spent lees 105 1.2
(white stillage)
Demethylizer Column Alcohol 90% v/v 66 0.6 Pure alcohol 76 0.9

96.2 % v/v
3.3.1. Material balance
As it is discussed in chapter 2, the alcohol grade level from fermented mash fluctuates in the range
of 8-12. So it is needed to take the average alcohol grade of some consecutive days to calculate the
theoretical alcohol extraction efficiency and the final alcohol grade, then to compare with the actual
one. For this calculation the average of results of 10 days are taken, and found to be 9.5 °GL to
produce 19200 total alcohol with a feed rate of 8420 L/hr.

Note: each inlets and outlets flow rates used below in the material balance are taken from the
software in control room.
Material balance on Mash / Degassing / Concentration Column

F = feed (fermented mash)
D = distillate (pure alcohol + denatured alcohol(DA))
Conc, R = reflux
F R D W = waste (dark stillage)
Degassing
Mash
Given
F = 8420
D = 1535 +6 = 1541
Assumption
 The process is steady state,

 There is no loss of alcohol,
 There is no leakage.
Input = Output
F=D+W W=F–D
W =8420 1541 = 6879
Therefore, 6879 of dark stillage is drained through the process.

Material balance on hydro-selection column

Given
Dilution water = SW + WS
dilution water = 786 + 527
Hydro-
alcohol from conc. R D = 1313
selection
column
F column alcohol from conc. = 1535
recycle from fusel recycle from fusel oil = 98
oil column F = (1313 + 1535 + 98) = 7690
steam W D = congeners(to fusel oil + to DA)
= 109 +3 = 112
Assumption W = diluted (10%) alcohol
 The amount of steam is neglected,

 The process is at steady state,
Input = Output
F=D+W W=F–D
W = 7690 112 7578
Therefore 7578 of alcohol is sent to rectification column for more extraction.

Material balance on rectification column

Given
F = diluted alcohol from hydro-selection
R D = 7578
Rectificati-
on column
F D = pure alcohol + diluted alcohol
= 874 + 14 = 888
steam HHT+HT+ LT HHT+HT+ LT = 107 + 8 + 8 = 123
Assumption

Input = Output
F = D + W + (HHT+HT+ LT) W = F – D – (HHT+HT+ LT)
W = 7578 – 888 – 123
W = 6567
This indicates, 6567 of white stillage water leaves the column which is used to recover heat in the
fusel oil and remaining to CIP through the flash drum.

Material balance on Demethylizer column

D = Extracted methanol
R= Reflux
Demethyl
F -izer R D F= Feed from rectification column
column
W=extra neutral alcohol (pure ethanol)
Given
W F= 874
D= 14
Assumptions
Input = Output
F=D+W
W=F–D
W = 874 14 = 860 …….Extra neutral alcohol to storage

Material balance on Fusel Oil column
bad alcohol from HS= 109 Demethyl R D = Recycle to HS = 98

-izer
bad alcohol from Rectif.=102 column
Weak alcohol from washing C.= 525 Denatured alcohol(HT & HHT) = 16
W = white stillage
Assumptions
Input = Output
F=D+W
W = D + W + Recycle to HS
W = 736 – 16 – 98 = 622 ………..white stillage to CIP

3.3.2. Discussion
The construction material of the degassing column and its four trays, and the Demethylizer Column
is copper, where the other columns and trays are made of stainless steel. The reason why degassing
and Demethylizer Columns are copper is to produce liquor with better odor and taste. Let's see the
difference between using copper and stainless steel.
Stainless Steel
The problem with stainless is that it is a poor conductor of heat. This is not a problem with direct
heat applied to a boiler, but presents problems in any column where you are looking for naturally
generated reflux as the steam vapors rise through the column. Stainless steel also contributes
nothing to the breakdown of esters and sulphuric compounds which is necessary to produce high
quality spirits. There are several manufacturers who build all stainless small scale distillers. They
typically concentrate their efforts on forced reflux designs that produce high proof tasteless alcohol.
This is the only way they can avoid most of the foul tastes resulting from the absence of any
chemical catalysis occurring in the process.
Copper
Copper is the traditional material used in commercial distillation column construction and for good
reason:
 Copper catalyzes the breakdown of esters and sulphuric compounds in the steam vapors.
These volatile compounds are produced during the fermentation process and are highly
undesirable in the distilled spirit.
 Copper avoids the production of ethyl carbamide which is a toxic substance formed from
cyanides. Again these are nasty chemicals you don’t want in beverage spirits.
 Copper improves the quality of the final product when the mash is not biologically perfect.
 Copper improves the aroma of the final product.
 Copper is a great conductor of heat. This allows for good natural reflux production in a
column as well as very efficient condensers.

The problem with copper is that it must be used in greater thickness to be strong enough, which
drives costs beyond the budgets of most distilleries. This is why the demethylyzing column and the
four trays of degassing column are made of copper.
It is obvious that the thickness of the copper decreases over a period of time which needs
replacement with another one. What if the alloy of the two material is used? Some researches
indicates that, combined use of the two materials results the best combination of functionality,
durability and cost. Copper is a recommended material according to its catalyzing capacity,
improving taste of final product,... And stainless pots are durable, easy to clean and economical.
This design may use to maximize the contact with the steam vapors to achieve the full chemical
reaction that copper offers. (Moonshine Still Pro .el.)
On the material balance, 6879 of dark stillage is drained from the bottom of mash column, this
means that, about 18.3% of the feed is vaporized by the mash reboiler, where the rest 81.7% is
removed as waste expecting no alcohol in it. Recalling the feed was 9.5% alcohol, the distillate
contains 52% alcohol.
From the hydro-selection column 7578 of alcohol is sent to rectification column for more
extraction, but when it is compare to the actual value, 8500 there is a difference of 922 . This is
because of the neglected amount of steam in it.

CHAPTER FOUR
4. MAJOR UTILITIES
4.1. Boiler
A boiler is a steam generator that is used to create steam by applying heat energy to water.or Boiler
is a device used to boil a liquid(water) under certain temperature at specified pressure to create
steam(dry steam) for different purpose of the factory .there are two boilers in national alcohol and
liquor factory at mekanisa branch but only one of them is currently operational the other does not
operate for the mean while .the steam produced from the boiler is sufficient for the current proper
operation of the company . A boiler or steam generator is used wherever a source of steam is
required. Boiler incorporates a firebox or furnace in order to burn the fuel and generate heat. The
generated heat is transferred to water to make steam, the process is known as boiling. This produces
saturated steam at a rate which can vary according to the pressure above the boiling water. The
higher the furnace temperature, the faster the steam production. The saturated steam thus produced
can then either be used immediately to produce power or else may be further superheated to a higher
temperature to produce dry steam ; this notably reduces suspended water content making a given
volume of steam produce more work and creates a greater temperature gradient, which helps reduce
the potential to form condensation.
Use of steam
Steam is used for many purpose in the industry such as
 used for washing of bottle

 for melting of sugar
 for distillery purpose(main use for alcohol industry)
Energy use of boiler
Many different boilers uses different type of energy source some of them are

 Fuel oil
 system Gas
 stem Coal
 automatic combustion systems etc.
Failure of boiler
Boiler may have some problem or failure which are
 The over pressurization of the boiler

 insufficient water in the boiler causing overheating and vessel failure
 pressure vessel failure of the boiler due to inadequate construction or maintenance
4.2. Water softener
Hard water is very common in many areas of Alberta. Hard water causes scale to form in pipes,
plumbing fixtures and kitchen appliances. Soap reacts with hard water to form a curd, and hard
water can also cause skin flaking and irritation. More soap or detergent is needed when washing or
laundering with hard water.

Hardness is primarily caused by the dissolved chemical compounds of calcium and magnesium. The
amount of hardness is expressed in milligrams per litre (mg/L) or grain per gallon (gpg) as calcium
carbonate.
Table 4.2.1 hardness stages in mg/liters
Type of water Amount of hardness (mg/liter)
Soft 0 - 50
Moderately soft 50 - 100
Moderately hard 100 - 200
Hard 200 - 400
Very hard 400 - 600
Extremely hard over 600
Feed water for boilers needs to be as pure as possible with a minimum of suspended solids and
dissolved impurities which cause corrosion, foaming and scaling on the boiler.Water hardness is
measured in grains per gallon (GPG) or milligrams per liter (mg/l, equivalent to parts per million, or
ppm). Water up to 1 GPG (or 17.1 mg/l) is considered soft, and water from 60 to 120 GPG is
considered moderately hard. A water softener's effectiveness depends on how hard the incoming
water is. Water over 100 GPG may not be completely softened. In many cases it simply means that
the water contains minerals found in the earth, like calcium and magnesium are because they affect
the water's ability to function in the boiler. These minerals make the water hard. These minerals
generate a scale buildup that reduces the efficiency and life of the heater
The working mechanism of water softener

Water softeners operate on the principle of ion exchange. A synthetic resin (zeolite) bed is charged
with sodium ions by regeneration with salt (sodium chloride). Hard water, containing calcium and
magnesium ions, flows through the resin.
Ion exchange occurs when the calcium and magnesium ions attach themselves to the resin,
displacing the sodium ions. The resultant water is softened, being free from calcium and
magnesium, but the sodium content is increased. Usually, the sodium increase will be approximately
50 mg/L sodium per 100 mg/L of hardness.
The heart of a water softener is a mineral tank. It's filled with small polystyrene beads, also known
as resin or zeolite, clay, brine solution, sand stone and others in layers. The beads carry a negative
charge, the hard water pass through the beds from bottom to top. Calcium and magnesium in water
both carry positive charges. This means that these minerals will cling or stick to the beads as the
hard water passes through the mineral tank so that mineral free water (soft water) leaves the softener
in the top pipe and store in a larger tank. i.e. substitution reaction takes place.
Figure 4.2.1 working principle of softeners

To clean the water softener when a very strong brine solution is flushed through a tank that has
beads already saturated with calcium and magnesium, the sheer volume of the sodium ions is
enough to drive the calcium and magnesium ions off the beads and go down the drain. Water
softeners have a separate brine tank that uses common salt to create this brine solution.
4.4. Cooling tower
The primary task of a cooling tower is to reject heat into the atmosphere. They represent a relatively
inexpensive and dependable means of removing low-grade heat from cooling water. The make-up
water source is used to replenish water lost to evaporation. Hot water from heat exchangers is sent
to the cooling tower. The water exits the cooling tower and is sent back to the exchangers or to other
units for further cooling.
Here in NALF the cooling tower cools the water that comes from different sections (molasses
treatment, heat exchangers, fermentation, propagation and distillery). In the cooling tower the hot
water and air from the atmosphere enters to the tower then when the motor at the top of the tower
rotate it reject the heat from hot water with the air to the outside environment, so that the water will
cool down to 24°C and return to where it comes from.
Distillery, heat HOT WATER Cooling tower

exchangers,…
AIR AIR
COLD
Make-up
Water Source
Figure 4.4.1 Cooling Water System

4.5. Compressor
Compressor is a device that used to filter and pressurize air. This filter air used to open/close
pneumatic/ball valve, shrink machine, filling machine, etc.
4.6. Generator
Generator is a device that converts mechanical energy to electrical energy for use in an a external
circuit to overcome power problems acting as a alternative.
CHAPTER FIVE
5. LIQUOR PREPARATION
Pure alcohol Sugar Essence Soft water

Liquor preparation
(mixing) tank
Bottle washer
Filler and capping
Empty bottle
Labeling
Transportation
Figure 5.1: Flow chart for liquor production
Difference between Alcohol and Liquor
Alcohol is a term used for any beverage that contains ethanol alcohol or drinking alcohol. Beer,
wine and liquor are all example of alcohol.
Liquor is a distilled alcoholic beverage i.e. stronger than alcohol example brandy, whiskey, vodka
etc. and only includes edible beverages.
Raw materials:-materials that are used in alcoholic liquor production of national alcohol and liquor
factory are listed below.
 Pure alcohol
 Soft water

 Sugar and
 Essences
Major unit operations in processing the liquor
 Alcohol storage tank

 Water treatment
 Mixing (blending tank)
 Syrup preparation tank
 Filtration
 Bottle washer
 Filler and capping machine
 Labeling
Alcohol storage tank: - pure alcohol 96.2% from distillation is stored.
Water treatment: - water should be treated to soft water for better processing. It is treated by the
ion exchange method and used for preparation of liquors.
Syrup preparation tank: - syrup is prepared diluting sugar with water for imparting taste to the
liquors.
Mixing (blending tank): - in this unit all raw materials are mixed and liquor is prepared. In this
section the preparation tanks first are washed and cleaned to store the pure alcohol. Soft water is
added, then mixed well for 45min, to prepare the selected liquor taste adding the essence which
measured by the operators. Then it is homogenized. Finally the syrup is added according to the
recipe, then checking to the alcohol grade, soft water is added until the alcohol grade comes to good
condition.
Filtration:-After the liquor is produced in the preparation tank, it is filtered and goes to a tank for
temporary storage till it is filled in bottles.
Bottle washer: - returnable bottles(from customers) could have some dirt and is labeled which
should be cleaned before refilling. These bottles are fed to the washing machine where the inside
and outside of the bottles are washed and cleaned by using 55-70˚C hot diluted caustic soda solution

After washing the clean bottles are transported by conveyer belt to the manual (visual) inspection
point and then to filling and capping machine. The capacity machine is 8000 bottles per day. The
bottle do not only clean the visible dirt from the inside and outside of the bottle but also to ensure
that the bottles are sterilized.
Filler and capping machine: - here, prepared liquor is filled in washed bottle. The filled bottles are
inspected manually for any foreign matter before it is labeled. Its capacity is maximum of 7000
bottles per hour and 32 filling stations with 8 capping heads.
Labeling: - the filled bottles are conveyed to the labeler. Labels are used to make the customers
aware of the product.
Table 5.1 material that are used in bottling
Material Function
Sugar and raw water For preparing syrup
Flavor To tell the types of liquor
Citric acid To avoid coagulation of syrup
Steam For heating of water for softens
Caustic soda Revolves had dirt from bottles
Filler machine Files bottles with liquor
Heat exchange Transfer heat energy from hot liquid to cold

liquid
Bottle washer To wash water
Filter press Used to separate impurities from syrup
Mixing tank For mixing raw materials

Electricity Operates any electrical materials
Packaging section
After the liquor is produced in different taste, alcohol content and flavor, filled and labeled then it is
sent to the next room to be packed. The products are packed in the packaging section in differently
constructed bottles, either in size or in the material type. Most of the materials used for packaging
purpose are glasses and plastic bottles. the plastic bottles are designed with capacities of 100ml and
250ml, while the glass bottles are designed with the capacities of 750ml, 890ml and 1000ml.
CHAPTER SIX
6. BENEFITS OF INTERNSHIP
6.1. Introduction
Internship is very important as it helps us to know the application of what we learned theoretically.
It helps us improve interpersonal communication skills, upgrades theoretical knowledge, and creates
awareness about work ethics related issues, improves team playing skills and the like. Gives us
opportunities to test and refine our skills. It helps us gain industry knowledge we wouldn’t get
anywhere else.
Familiarize our self for working environment and have better performance for technician’s skill.

 Have better interpersonal communication skills with workers.

 Able to under about work ethics relate issues
 Able to have team playing skill
 To know leadership skills with in working environment.
 Helps to improve our confidence.
6.2. Interpersonal communication skills

The purpose of communication is to get our message across to others leaving no doubt and clearly.
Inability to communicate will toughen or make it nearly impossible to compete effectively in the
workplace and stands in the way of career progression. During the internship we have got the
following experiences with respect to interpersonal communication;
 Steps for communicating with workers situated at its level
 How to communicate with people operating on machines
 How to communicate with people working in various sections.
 Improved communication skills with workers working in the company.
6.3. Team playing skill

Teams need strong team players to perform well. Teams need people who speak up and express
their thoughts and ideas clearly, directly, honestly, and with respect for others and for the work of
the team.
That’s what it means to communicate in a constructive manner. Such a team member does not shy
away from asking a point but makes it in the best way possible in a positive, confident, and
respectful manner.
An effective team can help an organization achieve incredible results.strategic failure.
Nowadays it is almost impossible to avoid being a member of team. A team that is not working can
cause an interruption to the flow of the working progress, failed delivery and Therefore, it is
important for our personal and career development to know our team working strengths and
weaknesses. This implies that team work skill is the backbone of team playing skill.

6.4. Leadership skills

Leadership is a process of motivating individuals and coordinating resources in pursuit of goals
shared by members of a working group. It is the art of inspiring others to give of their best and
courage to use this art. We were brought in a society who thinks leadership stands for power and
dominance over the other. Leadership to us 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 the leader operate from inside from his group, not from above it; 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.
He allows workers to grow professionally and also helps them to grow as people. We have to have
these characters. In addition we learned and convicted to have the following attributes to be
successful leaders: During the internship with respect to leadership skills we have learned and
convicted to have following attributes to be successful leader;
 General intelligence, to make sense of the complexity and difficulty of the task
 Guiding workers through any challenge that may arise at work
 The ability to make tough decisions
 Listening, sharing and delegating skills (and not interfering unnecessarily)
 Taking responsibility for everyone’s performance including their own.
6.5. Work ethics related issues

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. It enables individuals to
be productive while performing their job duties. Establishing organizational skills help individuals
perform their work according to their job duties and responsibilities. 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. 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:
 Reliability
 Honesty
 Trustworthiness
 Cooperation with colleagues
 Neatness
 Initiative
 Self-discipline
 Self-responsibility
With respect to work ethics related issues we have seen how workers struggle for fulfilling their
responsibility at work place, respecting their working time respecting the order of the company
manager, etc.
6.6. Entrepreneurship skills

During internship we met with some entrepreneurs on way of outwork and helped us gain 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. For these days, we have vision to own a firm, business, or
venture, and responsibly develop it in parallel with our 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 face our
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 skills. Being sn intern built an individual’s
knowledge in:
 Selection of the effective way of doing work
 Easiest methods of producing a product
 Creative mind in solving a problem
 Risk taking ability for doing work


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ADDIS ABABA SCIENCE AND TECHNOLOGY

NATIONAL ALCOHOL & LIQUOR FACTORY

COLLEGE OF BIOLOGICAL AND CHEMICAL ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP REPORT ON NATIONAL ALCOHOL AND LIQUOR FACTORY

Prepared by Ermiyas Geremew

1. Mr. Tedros Eyasu

NATIONAL ALCOHOL AND LIQUOR FACTORY Page ii

NATIONAL ALCOHOL AND LIQUOR FACTORY Page iii

NATIONAL ALCOHOL AND LIQUOR FACTORY Page iv

Table Contents page no.

2.2. Fermentation Process …………………………………………….. 9

NATIONAL ALCOHOL AND LIQUOR FACTORY Page v

3. PROCESS DISCRIPTION ………………………………………………… 19

4. MAJOR UTILITIES ………………………………………………………52

NATIONAL ALCOHOL AND LIQUOR FACTORY Page vi

NATIONAL ALCOHOL AND LIQUOR FACTORY Page vii

List of figures and tables page no.

Figure1.1 Organizational structure ……………………………………………………..5

Figure 3.3.1 Process flow diagram of Mash / Degassing / Concentration Column………38

Table 1.1: Types of liquor products………………………………………………………4

NATIONAL ALCOHOL AND LIQUOR FACTORY Page viii

NATIONAL ALCOHOL AND LIQUOR FACTORY Page ix

1.1. Historical Background

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 1

1.2. Factory branch

1.3. Vision and mission of the factory

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 2

1.4. Main products

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 3

Table 1.1: Types of liquor products

No. Type of liquor Alcohol in (%v/v)

1 Baro’s dry gin 41

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 4

1.5. Customers of the product

ORGANIZATIONAL STRUCRE OF NALF

Branch manager of Branch manager of Branch manager of

Mexico mekanisa sebeta

Logistic department Human resource and

Figure1.1 organizational structure

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 5

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 6

Main Raw materials

I. Molasses: - Molasses is known to be the byproduct of sugar industries. Therefore, it is expected

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 7

2.1.1. Factors affecting the molasses treatment process

2.1.2. The advantages of treating molasses

2.2. Fermentation Process

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 8

 Quality consistence and availability

2.2.1. Chemical Reactions During Fermentation

C6H12O6 ====> 2(CH3CH2OH) + 2(CO2) + Energy (which is stored in ATP)

Sugar ====> Alcohol + Carbon dioxide gas + Energy

(Glucose) (Ethyl alcohol)

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 10

2.2.2. Factors affecting fermentation of molasses

I. Effect of sugar concentration

NATIONAL ALCOHOL AND LIQUOR FACTORY Page 11