Desta Alcohol

Bahir Dar Institute of Technology 2017
Declaration
We declare that this project is based on our original work. We write this paper by the knowledge
gets from the company during our internship months in DALF. We gather the information about
the process and machineries from the chemists and operators who work in the company. We
expect that other may get some information about DALF and how it works different liquor.
School advisor; signature
Mr. Addis lemessa ……………………………………………….
Company advisor;
Mr. Kiros………..………………………………………………….
Name of student
Mahlet Reda………….………………………………………………
Abadi Brhanu………………………………………………………..
Ashenafi H/Michael………………………………………………..
Tieumay Tesfay…………………………………………………..
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Acknowledgement
Above all we thank the almighty GOD for helping us to perform all the activities well, then we
would like to thank all of the employees of DALF for their help and technical assists. We would
also like to thank our teachers specially our mentor Mr. Addis in his professional supports and
communications. We also would like to hire higher gratitude for the school of chemical and Food
engineering (Bahir Dar University). We would also like to praise our company’s supervisors Mr.
Kiros for his initiation, best advices and for his kindness help which make us stronger in
observation and investigating solutions for problems. We would like to give the best gratitude for
our families for their financial and ideal support to this report.
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Executive Summery
This project concerns on the four month internship program on Desta Alcohol and Liquor factory
plc. We have been working four months and in this time we have got practical skill more and we
knew the aim of the internship.
This project has nine parts including the history of Desta alcohol and liquor factory in the
introduction part, the overall internship experience, the process technology of the factory, case
study project (the heat recovery on the mash column), the mass and energy balance of some unit
operations, the equipment design specifically heat exchanger design including thermal design
and mechanical design, the economic analysis, the overall benefits from the internship and
finally the conclusion and recommendation to the hosting company.
This internship project focuses deeply on the recovery of heat from the mash column in the
process of the production of ethanol alcohol at Desta alcohol and liquor factory. Depending on
the amount of time, energy and money put into this process plant, the company has lots of raw
spent wash that leaves from the mash column. This raw spent wash has high temperature and this
high temperature is recovered to save the economy of the plant that we spent to energy and to
make the environment save.
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List of Tables
Table 1: Liquors Production

Table 2: Composition of Molasses
Table 3: The parameters that indicates the completion of yeast propagation
Table 4: Parameters that indicates the completion of final fermentation
Table 5: Physical properties of ethanol
Table 6: Chemical combustion of ethanol
Table 7: Tables of the ingredients added in liquor preparation
Table 8: Data analysis for the sludge
Table 9: Equipment costs
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List of figures
Figure 1: Denature Alcohol

Figure 2: Types of Alcoholic Beverages (Liquor)
Figure 3: Block Diagram of Overall Organizational Structure
Figure 4: Process flow chart for pure alcohol production
Figure 5: Process flow chart for liquor production
Figure 6: Mother Tank
Figure 7: Fermenter tanks/reactors
Figure 8: Process flow chart for fermentation
Figure 9: Decanter tanks
Figure 10:The flow diagram of distillation column
Figure 11:Mash , Dilution and Rectification columns
Figure 12: Liquor section
Figure 13: The block flow diagram of waste water treatment
Figure 14:Cooling tower
Figure 15:Process flow chart of water treatment
Symbols and abbreviations
1. DALF = Desta Alcohol and Liquor Factory.
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2. OH = hydroxyl
3. C2H5OH = Ethanol
4. DAP = Diammonium Phosphate
5. P = phosphorus
6. C6H12O6 = glucose
7. H2SO4 = Sulfuric acid
8. H2S = Hydrogen sulfide
9. CO2= Carbon dioxide
10. NH3= Ammonia
11. Na2O = Sodium Oxide
12. Al2O3 = Aluminum Oxide
13. H2O = Water
Table of Contents
Declaration ....................................................................................................................................... i
Acknowledgement .......................................................................................................................... ii
Executive Summery ....................................................................................................................... iii
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List of Tables ................................................................................................................................. iv

List of figures .................................................................................................................................. v
Symbols and abbreviations ............................................................................................................. v
Chapter One .................................................................................................................................... 1
1. Introduction ............................................................................................................................. 1
1.1 Ethyl alcohol (Ethanol) .................................................................................................... 1
1.2 Background ...................................................................................................................... 2
1.3 Growth of the company .................................................................................................... 3
1.4 Objectives of Desta Alcohol and liquor factory ............................................................... 4
1.5 Vision and mission of the factory .................................................................................... 5
1.6 End products and service of the company........................................................................ 5
1.7 The main customers or end users: .................................................................................... 8
1.8 Over all organizational structure and work flow ............................................................ 10
Chapter Two.................................................................................................................................. 11
2. Alcohol production ................................................................................................................ 11
2.1 Raw material used for the production of alcohol ........................................................... 14
Chapter Three................................................................................................................................ 16
3. Sections (units) in the production of alcohol ......................................................................... 16
3.1 Fermentation processes .................................................................................................. 16
3.2 Distillation Process: - .......................................................................................................... 24
Chapter Four ................................................................................................................................. 49
4. Overall benefits I have got from the internship ..................................................................... 49
4.1 Conclusions and recommendations for the company ..................................................... 50
4.1.1 Conclusions:............................................................................................................ 50
4.1.2 Recommendation .................................................................................................... 50
Chapter Five .................................................................................................................................. 51
5. Project title: - Recovery of Heat on Mash Column in Case of Desta Alcohol and Liquors
Factory .......................................................................................................................................... 51
5.1 Problems of Statement: .................................................................................................. 52
5.2 Objective ........................................................................................................................ 52
5.2.1 General Objective ................................................................................................... 52
5.2.2 Specific objective .................................................................................................... 52
Chapter Six.................................................................................................................................... 53
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6. Literature review.................................................................................................................... 53
6.1 Methodology .................................................................................................................. 55
6.2 Equipment that used for heat recovery............................Error! Bookmark not defined.
Chapter Seven ................................................................................Error! Bookmark not defined.
7. Equipment Design ................................................................................................................. 58
7.1 Thermal design of heat exchanger: - .................................................................................. 58
7.2 Conclusion and recommendation ................................................................................... 65
7.2.1 Conclusion .............................................................................................................. 65
7.2.2 Recommendations ................................................................................................... 65
References ..................................................................................................................................... 66
Appendixes ................................................................................................................................... 67
Figure 1: Denature Alcohol .................................................................................................................................................. 6

Pure alcohol production ..................................................................................................................................................... 12
Figure 4: process flow chart for alcohol production ............................................................................................... 12
Figure 5: Process flow chart for liquor production ............................................................................................... 13
Figure 6: Mother Tank ......................................................................................................................................................... 20
Figure 7: Fermenter tanks/reactors .............................................................................................................................. 21
Figure 8: Process flow chart for fermentation ....................................................................................................... 23
Figure 9: Decanter tanks .................................................................................................................................................... 24
Figure 13: The block flow diagram of waste water treatment ........................................................................... 44
Figure 14: cooling tower..................................................................................................................................................... 46
Figure 15: processes flow chart of water treatment............................................................................................... 49
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Chapter One
1. Introduction
Alcohol, any of a class of organic compounds characterized by one or more hydroxyl (‐OH)
Groups attached to a carbon atom of an alkyl group (hydrocarbon chain). Alcohols may be
considered as organic derivatives of water (H₂O) in which one of the hydrogen atoms has been
replaced by an alkyl group. Typically represented by R in organic structures. 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 or (methyl alcohol). Ethanol is used in toiletries, pharmaceuticals, and
fuels, and it is used to serialize hospital instruments, it is, moreover, the alcohol in alcoholic
beverages.
Alcohols may be classified as primary, secondary, or tertiary, according to which carbon of the
Alkyl group is bonded to the hydroxyl group. Most alcohols are colorless liquids or solids at
room temperature.
1.1Ethyl alcohol (Ethanol)
Ethyl alcohol, also called ethanol member of class of organic compounds that are given the
general name alcohols. Its molecular formula is C₂H₅OH. Ethyl is an important industrial
chemical. It is Used as a solvent, in the synthesis of other organic chemicals, and as an additive
to automotive Gasoline (forming a mixture known as a gasohol). Ethyl alcohol is also the
intoxicating ingredient of many alcoholic beverages such as beer, wine, and distilled spirits.
There are two main processes for the manufacture of ethyl alcohol the fermentation of
Carbohydrates (the method used for alcoholic beverages) and the hydration of ethylene.
Fermentation involves the transformation of carbohydrates to ethyl alcohol by growing yeast
Cells. The chief raw materials fermented for the production of industrial alcohol are sugar crops
Such as beets, sugarcane and grains crops such as corn (maize). Hydration of ethylene is
achieved by passing a mixture of ethylene and a large excess of steam at high temperature and
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Pressure over an acidic catalyst. Ethyl alcohol produced either by fermentation or by synthesis is
obtained as a dilute aqueous solution and must be concentrated by fractional distillation. Direct
distillation can yield at best the constant-boiling-point mixture containing 95.6 percent by weight
of ethyl alcohol. Dehydration of the constant-boiling-point mixture yields anhydrous, or
absolute, alcohol. Ethyl alcohol intended for industrial use is usually denatured (rendered unfit to
drink), typically with Methanol, benzene, or kerosene. Pure ethyl alcohol is a colorless,
flammable liquid (boiling point 78.5⁰c) Ethyl alcohol is toxic, affecting the central nervous
system.
Moderate amounts relax the muscles and produce an apparent simulating affect by depressing the
inhibitory activities of the brain, but larger amounts impair coordination and judgment, finally
producing coma and death. It is an addictive drug for some persons, leading to the disease
(Alcoholism). Ethyl alcohol is produced by fermentation of the sugars using yeast. The sugars
are derived mainly from molasses. After the fermentation process, the ethanol is purified by a
multiple distillation and rectification process. Commonly referred to simply as alcohol or spirits
ethanol or is also called ethyl alcohol and potable alcohol. It is the principal type of alcohol
found in alcoholic beverage.
1.2 Background
Desta alcohol and liquor factory plc is one of the three big alcohol as well as alcoholic liquor
production companies in the country. It is established in 2001G.C as private owned company in
Mekelle city industrial zone to produce potable alcohol, denature alcohol and various types of
alcoholic liquors. At present, Desta alcohol is located at the periphery quiha town to the north,
about 13 km east of Mekelle city. The factory has an installed capacity of producing 6000 liters
of potable alcohol and filling 24000 bottles of 9 varieties of alcoholic liquors per a day. Now, the
distillery plant produces on average 5000 litters and 325 liters of pure alcohol and denatures
alcohol a day respectively. Since 2013G.C, desta alcohol installed a new method of waste water
treatment plant that the distillery waste water (raw spent wash) changed in to bio-gas, condensate
water and dry powder through anaerobic digester and multiple effect evaporators. The company
has 177 permanent workers and operators.

In Desta alcohol and liquor factory there are five main sections. These are molasses preparation,
fermentation, distillation, boiler and bottling section and waste water treatment. The mother
fermentation is called the pre-fermentation to the use of yeast multiplication under aerobic
condition. In mother tank fermentation low brix molasses is used. The next fermentation is the
production of bio ethanol under anaerobic condition. The high brix molasses is supplied for the
five concrete tankers under batch operation system. The distillation plant of desta and liquor
factory consists of three type of distillation column (mash column, dilution column and
rectification column.) in function with continuous stage distillation. Mash column works at
vacuum pressure to break the azoetropic.
DALF has been working day and night to satisfy all the demands of its customers and put in
effect quality management systems. This quality manual is prepared based on it. This quality
manual looks at ethanol and the different liquors produced by DALF, their specification and
technicians of analysis, sampling procedure. Currently the Quiha branch works for 24 hours
three shifts in eight hours.
1.3 Growth of the company
The growth of the company has four steps. These steps are discussed in detail as follows:-
STEP 1: Blending of sprit (December 2000 July up to 2002 G.C):- The main raw material of
ethanol alcohol was purchased from national alcohol and liquor factory. At this stage simple
mixing of the inputs without distillation and water softening plant. The supplier of the ethanol
alcohol has been also the producer distributor of sprit products. The human and non-human
resource of the factory at that time was shown as follows:-
 Initial investment- 2,014,000 birr

 Number of employee- 29
 Annual sale volume- 1,808,000 birr
STEP 2: Purchasing semi processed alcohol (July 2002-january 2005 G.C):- At this stage,
distillation of technical alcohol has been established, but the owners could not be satisfied by

doing that as it was not cost effective that would result in profit lowering. As the result, they
decide to expand the plant so as to reduce the production cost and increase sales volume.
The human and non-human resource of the factory at that time was shown as follows:-
 Investment 7,721,000 birr
 Number of employee-68
 Annual sale volume-12,577,000 birr
 Owner equity5,072,000 birr
 Type of product-10 sprit product
Step 3: Fermentation from cane molasses (January 2005 – till now):-In this stage automation of
certain lines have been established such as filling capping, big capacity boiler.
 The human and non- human resource of the factory at that time was shown as follows:-
 Investment-23 million
 Number of employee-141
 Sale volume-23.56million
 Owner equity-12.19million
 Type of product-10 sprit product and 2 line product
Step 4: Owning waste water treatment plant:-This is used to treat or change the water coming out
from the distiller plant into business. But, till recent time it is not applicable. Hence, they decided
to place the plant in Quiha rather than Mekelle due to the environmental analysis and having
insufficient area in Mekelle.
1.4Growth of the company of Desta Alcohol and liquor factory
 To produce standardized quality beverage products at different levels for local and
export market that quench the thirst of its customers in the community.
 Create different outlets (wholesalers, retailers) and there by distribute its products to
local as well as export market so as to enhance the development of commerce. As it is a
business entity, generate a higher return on investment to the owners of the project.

 To determine the vertical and horizontal relationship among the different work units.
 To produce Alcohol of high quality with optimum cost, time and fitness.
 To achieve the required quantity of alcohol from a given raw material.
1.5Vision and mission of the factory
Vision
 To improve the quality of its products

 To expand its market share
 To maintain its leadership I the liquor industry of the country
 To make at most effort to enter foreign markets as widely
Mission
 The company strives to produce high quality liquor and pure Alcohol.
 Maximizing the benefits of customers need attempt to must be strong competitor and
profitable.
 Enable to contribute for the national economic development.
 To produce internationally recognized quality liquor products to the taste of costume.
1.6 End products and service of the company
DALF mainly produces alcoholic beverages, pure ethanol and denature alcohols. Desta produces
11 types of consumption alcohol and liquors and two types of Industrial Alcohols. The types of
products produced by DALF Company are classified as: Consumer product and industrial
product.
Industrial products: - Are refers to the byproduct of ethanol production which is applicable for
different purpose in pharmaceutical and soap industry, e.g methanol alcohol.
Consumer products: - Are refers to the main product of the company which is applicable for
drinking consumption and different industrial purpose.

A. Denatured alcohol (methanol)
 This alcohol is also known as fire alcohol. These products contain poisonous substances
that humans should not swallow is regarded as a by-product of DALF. This is also one of
the products in the distillation process with in alcohol content of 95%.
This alcohol is separated from the ethanol alcohol at the rectification column. These
products use different colorants from the other products in order to identify the costumer
from the other alcoholic beverages (It has pink color). These are used to reduce infection
when there is some damage is found on external part of our body.
Figure 1: Denature Alcohol

A. The denatures alcohol is used in the following places:-
 In hospital and pharmacy.
 In barberry house and beauty salons.
 In house for food preparation to burn the materials.
 In animal treatment for disease, and for washing electronic material.
B. Potable alcohol (ethanol)
Ethanol (C2H5OH) or ethyl alcohol generally refers to purified ethanol, containing no more than
one percent water. It is not possible to obtain absolute alcohol by simple fractional distillation,
because a mixture containing around 96.4% alcohol and 3.6% water becomes a constant boiling
mixture (an isotropic mixture). In one common industrial method to obtain absolute alcohol, a

small quantity of benzene is added to rectified spirit and the mixture is then distilled. Ethyl
alcohol is obtained in the third fraction that distills over (351.3 K). Because a small amount of
the benzene used remains in the solution, ethyl alcohol produced by this method is not suitable
for consumption as benzene is Carcinogenic.
There is also an absolute (ethyl) alcohol production process by desiccation using glycerol.
Alcohol produced by this method is known as spectroscopic alcohol so called because the
absence of benzene makes it suitable as a solvent in spectroscopy.
C. Alcoholic beverages (Liquors or sprites):
These alcoholic beverages are making from ethanol alcohol by adding different ingredients.
These are the main products of the company. There are 11 kinds of alcoholic beverage produced
in the company which are differing based on their alcohol content and their flavor. From the ten
kinds of the product the most which the costumer and consumer needed are the only three
products. These are Gin, Zebib and Ouzo products. These have around 41% of alcohol by
volume.
Figure 2: Types of Alcoholic Beverages (Liquor)

Table 1: Liquors Production
Liquors Alcohol Ethanol Sugar Essence(ml)

content (%) content(l) content(ml)
Ouzo 41 0.426 8 0.9
Gin 41 0.426 8 1.2
Cognac 37 0.382 8 0.85
Aperitive 32 0.332 68 6.33
Pinapeal 32 0.332 68 0.91
Lemon 32 0.332 68 0.91
Brandy 41 0.426 8 1.2
Fernit 37 0.384 8 4.9
Super mint 25 0.26 145.6 2.6
Zebib liquor 41 0.426 8 1.2
Vodka 42 0.421 10
By product of alcohol
 Carbon-dioxide:-Large quantities are evolved during the fermentation process. This is
used in the solid form as ice.
 Fusiel oil:-is a liquid with nauseating odor. It is used in confectionery and fruit
essences.
 Acetaldehyde:-Obtained during the alcohol distillation.
 Spent wash:-The residual liquor from which ethyl alcohol has been removed by
distillation. It contains nitrogenous matter which can be used as manure and fodder.
1.7The main customers or end users:
The main products of DALF are not exported in to foreign country; it’s distributed in the whole
country. DALF have no main customer of the pure alcohol rather the company uses the pure
alcohol to produce liquors.
This is due to the fact that the Company is using small boiler; which is used to produce steam.
All operational system of the company are manually and the capacity of the distillation section is
small.

o Main Customers of Fire Alcohol (Denature alcohol);

 Barberry
 Hospital
 Pharmacy
 In house for food preparation
Main Customers of Pure Alcohol (Ethanol);

 Adigrat medicinal factory
 Mekelle university
Main Customer of alcoholic Beverages;
 Mekelle town
 Shire town
 Alamata town
 Axum town
 Amhara region
Those customers are directly contacts with the factory marketing managers. The end user of
Desta alcohol and liquor factory is the whole people of Tigray, some people of Amhara and
some people of Addis Ababa.
Current markets:-
Markets are mainly institutional, industrial and individuals of Ethiopia. Major sales are in
the Tigray Region.
Competitors:
There are two other competitors in the Organized Market namely National Alcohol and Balezaf.
There are also many unorganized and clandestine competitors in the markets and in traditional
brewing. All of them pose a threat to the company.

Company strengths:
 Access to natural resources.

 Access to Sugarcane molasses from the nearby farms in Mekelle.
Technical expertise: - The Technical team of the company is well qualified and many of
them have been trained abroad.
Managerial expertise:- The management team has wide experience in the industry and is
well known in the institutional customer base. The Alcohol Capacity utilization is
60%.Sometimes the capacity utilization decreases this is due to waste water treatment problems
and reduced demand due to increase in price and taxes and customers going to unorganized
clandestine brewers “products
1.8Over all organizational structure and work flow
Overall organization: Desta Alcohol & liquor factory plc is organized at different level to
perform its goal. Each level has backward & forward integrating with close vertical & horizontal
communicating to accomplish its planned activities accordingly.

Chapter Two
2. Alcohol production
In DALF Alcohol is produced from fermentation of molasses. The main & principal way of
producing ethyl alcohol is the production of alcohol by fermentation. The production of pure
alcohol from the raw materials that contains sugar content by using yeast is done through the
process of biochemical reactions. Biochemical Reactions can be done in the following process.
Sugar + Water using alcohol + heat + carbon dioxide
Yeast
The main overall process flow chart for the production of alcohol (pure and denature) and liquor
at Desta alcohol and liquor factory (DALF) is described in figure 1 & 2

Molasses from storage
15° brix molasses
3kg yeast Mother tank for 12 hours

Dap
H2SO4 propagated yeast
Sludge Fermenter tank for 3 days 25° brix molasses
CO2 2kg Dap
Mixed
Wash
Decanter (settling) tank for 1 day Sludge
Pure wash Stillage
Water Distillation unit Fusel oil as by product
Steam Denatured alcohol
Pure alcohol condensed water
Pure alcohol production
Figure 4: process flow chart for alcohol production

Pure alcohol
Hot water
Caustic soda Washing machine Liquor preparation
Dirty bottle Sugar
Dryer Mixer Essence
Treated water
Coloring if it is needed
Filler Filtration unit
Copping machine
A% alcohol of liquor (B)
Labeling
Packaging
Marketing
Figure 5: Process flow chart for liquor production

2.1Raw material used for the production of alcohol
A. Cane molasses: it consist of fermentable portion of sugars, assumed to contain 50% sugar
with specific gravity of 1.4 and mixture of sucrose, glucose, fructose and other CHO. Molasses is
obtained from sugar factories such as Metehara and Wenji sugar factory.
Table 2: Composition of Molasses
Component 30-35
Sucrose 10-15
Reducing sugar 10-12
Ash 12-20
Water 12-20
Total sugar % of dry solids 55-60
B. Sulphuric acid(H2SO4): it help to optimize the media or to lower the PH range because
acidic media with pH of 4.0-4.5 is optimum condition for yeast, and used as antifoam by mixing
with edible oil and used the growth and activities of other microorganism such as bacteria, not to
compute yeasts by these microorganism.
C. Dry instant yeast (saccharomyces cervices): is microorganism which is widely

found in fruits, grape and other sugar foods. The important nutrients required for the growth and
proper functioning yeasts are CHO, nitrogenous compounds, vitamins, salts and other growth
promoters.
D. Di ammonia phosphate (DAP): used as sources of nutrient for the growth of yeast. Its
amount is in the order of 1 kg per 500liters of molasses solution. If the amount of DAP is less,
the yeast may not activated well and if the amount of DAP is exceeded from the average
consumption, other cells will attack the yeast and also results in sugar wastage and sugar
spoilage.
E. Purified air: it is used to supply the yeast with necessary oxygen for cells growth. The
amount of air feed to the mother tank shall be proportional to the amount yeast feed into it. If the
amount of air feed is more than enough, new cells will start emerge and results in alcohol

wastage. If the amount of air is small relative to the yeasts, the yeast propagation will weakened
and infected by other bacteria.
F. Water: used for cleaning of overall processing units and play a great role for dilution
purpose (molasses, pure alcohol and liquor preparation). It boils and widely used for steam
production.
G. Essence: an extracted compound directly from aromatic vegetable, fruits, spices, herbs
etc…by means of destination and maceration processes. They primarily used as flavoring agents
which are ready to use mixtures of juices, fruits and brandies etc
H. Sugar: will be added and mixing during the liquor preparation in the syrup form to facilitate
the Agitation process.
I. Anti-foam: used for preventing the overflowing of the fermenting solution
J. Steam: plays a great role for creating the boiling difference while the distillation process
taken place.
Chemical Reagent
1. Lime: Is added to neutralize the wastage of overall process alcohol fermentation,

because it is an acidic media.
2. Sodium hydroxide (optional): Is rarely used to optimum the fermentation medias,
if the PH of this media is too low.
3. Caustic soda: It is necessary as washing detergent for the dirty bottles in the washing
machine.
4. Methane: Is used as fire heat sources for the boiler to produce steam by burning the
fernus.

Chapter Three
3. Sections (units) in the production of alcohol
The productions of alcohol in desta alcohol and liquor factory (DALF) have four units (sections)
these are:
 Fermentation processes
 Distillation columns
 Liquor preparation(blending)
 Waste treatment
3.1Fermentation processes
Processes description
The object of this unit is the conversion of sugar content in mash to obtain ethanol.
Process theory
The breakdown of carbohydrates to ethanol, carbon di-oxide and water using microorganisms is
called fermentation process. On the other hand fermentation is a process in which a chemical
change brought in organic substance through the action of microorganism. These
microorganisms are yeast, moods, bacteria and etc.. They cannot synthesize their own food and
they depend on organic matter.
The following bio chemical reaction represents sugar fermentation:-
C12H22O11+ H2 inverts (enzyme) from yeast C6H12O6 +C6H12O6
Hydrolysis rxn glucose fructose
C6H1206 enzymes (enzyme) from yeast 2C2H5OH + 2CO2

Decomposition rxn ethanol
There are two popular microorganisms that can produce high concentration of alcohol. Those
are :-
 Zymomonas mobiles and

 Saccharomyces cervisae
Type of fermentation processes
To obtain alcohol from sugar compound with the aid of yeast one can follow the batch or
continuous processes.
Batch system
This process is traditional and is done by propagating the yeast separately before the main
fermentation and then taking the required quantity to the fermentation tanks. This yeast are
mostly propagated in the mother tank and discharged as a residue after the final fermentation.
Desta is also applying such system. Since batch system is taken place by inculcating new yeast, it
consumes large amount of molasses even through improving handling of the molasses may
compensate this and as compared to the continuous processes it has some advantages over the
continuous processes.
 It is simple to run the whole process

 It is easily viable to contamination
Continuous process
Refer propagating and recycling the yeast through the help of cream so that wastage of yeasts
will be minimized and this in turn plays significant roles in exploiting the sugar amount from the
molasses. In this case the alcohol produced if fully extracted from the given molasses so that
there will not be wastage of sugar as in the case of batch processing. Hence the yeasts will have

good correspondence (high) with the general condition of the process. Despite its advantage is
easily affected by contamination as the yeasts are used repeatedly by recycling.
Phases of yeasts in the fermentation process
There are three phases of yeasts in the fermentation process.
Aerobic Phase
This phase takes place in the mother tank and the yeast start to multiply or propagate in number.
Here the purpose of compressing oxygen is to duplicate the yeasts.
Anaerobic Phase
This phase of reaction takes place in the main fermentation tank. Having the yeasts enough food
for survival and this helps to facilitate the chemical reaction, which may result latter to end its
reaction. This shows the sugar content is decreasing and changing to alcohol and carbon dioxide.
End Fermentation
The yeast cells start to die due to lack of sugar as the sugar is converted in to alcohol and CO2 at
the same time the fermentation reaction ends. During the overall process, a great care should be
taken to control the temperature and should undertake the reaction in its optimum way. The
optimum temperature for the yeast activity is 28-30oc. The rate of fermentation decreases
considerable below this so that the minimum temperature may be taken as 28oc on the other
hand ,the maximum temperature can reach 33oc.If the temperature reaches 35oc, it leads to
boiling fermentation, which is uncontrollable and large foams will excessively be formed and
results in wastage of mash. But if it is above 36oc the volatility of the yeast begins to fall off and
the activity of other undesirable bacteria reaches maximum which, this turn leads to other side
reaction. Therefore, the optimum temperature T for yeast is 27.5<T<30.5 oc.
The process of preparation fermentation depending is upon:
 Alcohol content of the mash.

 The amount of carbon dioxide created during the reaction.

 The degree of temperature in the chemical reaction.
 The general condition of yeast in the fermentation.
Plant description
Based on these criterions, fermentations follow three steps.
 Pre fermentation
 Main fermentation
 Final fermentation
1. Pre-fermentation
Pre fermentation process takes place in mother tank which is used to grow/propagation the
microorganism in an aerobic condition. This microorganism is growing in side of the mother
tank with different nutrients. This tank is cylindrical, conical section at bottom which has a
volume of 4,000 litters. The advantage of this tank is to grow the microorganisms in an aerobic
condition. Molasses for pre-fermentation is mixed with water in a static mixer to form 15o brix.
Molasses, process water and nutrients are added to the yeast for activation and growth of yeast
cell mass. Filtered air is sparged and provision is made for the addition of acid to maintain pH
and anti-foam agent to reduce foaming. In this stage, a small amount of carbon dioxide is
observed as yeasts are propagated themselves &the syrup may not have foam. Longer
propagation of sugar is used for the yeast propagation rather than converting in to alcohol. Due
to this reason the amount of alcohol (3-4%by volume) to little as compared to the other stages.
The procedures in the pre-fermentation process are:-
 The mother tank was cleaned and sterilized.

 The molasses is diluted to 15° brix.
 DAP, H2SO4 and purified air is added.
 Inoculate the dry instant yeast (from local market)

 Keep all condition optimum for the yeast, then after 12 hour the yeast reached at its
maximum point of propagation
It can be cheeked by the following measurements weather the yeast is completely grown.
Table 3: The parameters that indicates the completion of yeast propagation


 Alcohol content 3-4%
 Degree bricks 3.2°
 Yeast percentage 2-4% by volume
 Density of the solution 1012.2
 kg/m3


PH value Minimum 4
Figure 6: Mother Tank


2. Main Fermentation
In Desta alcohol & liquor factory there are 5 tankers/fermenters/reactors with 40,000 litres each
and fermentation tank is cylindrical, conic bottom provided with side entry agitator to have
uniform distribution. Yeast from the pre-fermentors is transferred to fermentor which is then fed
with mash at 25o brix. In this fermentation the yeasts are redeye propagated and growth. The

amount of carbon dioxide will start to increase the chemical reaction & formation of foam will
be facilitated under this stage the temperature must be controlled not to exceed more than 33°c as
there is high rate of chemical reaction & foam formation. In such cases, the cooling system will
be activated. It is also maximum point of alcohol content (7-9%) is observed.
The procedures of the main fermentation tank:-
 Clean and sterilize the main fermentation tank

 Prepare molasses at 250bricks the add to the some level
 Transfer all the media in the mother tank(propagated yeast)
 then inter the prepared molasses at 250bricks to tank till get the volume
 keep and adjust all the condition comfortable and wait for 72 hours
 send the mash to the decanter tank to remove the sludge 
Figure 7: Fermenter tanks/reactors
3. Final Fermentation
The process of fermentation becomes to realize lends & except a tiny movement on side of
fermentation tanks. The life span of this stage is shorter & if prolonged the yeasts can be infected
easily by bacteria, the sugar is finished, no oxygen because an aerobically, and the yeast is
started to die. During fermentation, sugars are broken down into alcohol and carbon dioxide.
Significant heat is released during the fermentation process. The temperature is kept constant at
28-32°C by forced recirculation flow of mash through mash coolers for Fermenter using
fermented recirculation cum transfer pumps. Hence, if the bricks measurements are constant for
three hours, the mash must be transformed in to decantation tank.
 The fermentation process is completed when the following values are achieved.
Table 4: Parameters that indicates the completion of final fermentation
Sugar concentration 0.2-0.5%

Alcohol content 8% by volume
Dry substance 3-4% by volume
Density of solution 1028.93 kg/m3
Degree bricks 15°

PH value Minimum 5
The operation of fermentation starts with the simple exothermic reaction of fermentable sugars
and water to produce alcohol and CO2 with the help of catalyst known as saccharomyces
cervices, which is a type of yeast required in this specific industrial process.
Alcoholic fermentation:-are used to produce high alcohol content of beverages called sprits. Its
chemical reaction is represented as follows:-
C6H12O6 (glucose) yeast 2C2H5OH (Ethyl alcohol) +CO2 + Energy (2ATP)
Industrial alcoholic fermentation:-Industrial alcohol is used in beverages and food complex

industries.

Anti- H2SO4 DAP Starter

foam
Mother tank
A
A B C D E
Fermenter tanks
Decanter
Distillery
Tank
Figure 8: Process flow chart for fermentation
Decantation tank
The main objective of decantation tank at the Desta alcohol and liquor factory is as temporary
storage of the product that rises from the fermentation which is mash before it enters to the
distillation column. There are two decantation tanks with volume of 70,000 litters each and they
are cylindrical, conical bottom.

Figure 9: Decanter tanks
3.2 Distillation Process: -
Process description
Is employed in order to separate the ethanol from these by products by making use of the
different boiling point characteristics of compounds obtained during fermentation. Ethanol can
be purified by distillation to a concentration just below its azeotropic point, i.e. 96%, which will
be called “hydrated ethanol.

Figure 10: The flow diagram of distillation column
The distillation process in Desta alcohol and liquors factory has three columns to undertake
effective and efficient separation system.
 Mash column
 Purifying column/dilution column and
 Rectification column

Figure
Figure 11: Mash, Dilution and Rectification columns
Plant description
Mash column:-
This column operates in a vacuum pressure in order to reduce the boiling point of water which is
help full in controlling the precipitation of CaSO4 as temperature goes beyond the relative
vacuum pressure or above 800c.This process is done with the help of condensers and pumps. In
this column, the completely fermented mash of 7-9% alcohol by volume is preheated & fed to
the distillation column. Alcohol concentration on this column is about 50%.
Mash column is used to remove most of the unpleasant odor & CO2 gas dissolved in the mash
there is head product that is removed from this column & inter to the byproduct denature alcohol
line.
The procedures in mash column:-

 The pure mash that came from decantation tank is preheated about 30-500c in the top
then inter to mash column
 Steam at 1800c is injected to the column due to boiling point difference are separation
started
 Then condenser is condense the vapor to liquid, in this reflux is add for to separately
efficiently or increase the concentration
 Remove the waste at the bottom about 84.337% from the total feed at 800c (it remove in
this are most of unpleasant odor and carbon dioxide gas dissolved in the mash.
 The rest goes to the dilution column at temperature 45°c.
Material and Energy Balance
 Material Balance
VT=?
XAT=0.5, XIT=0.5
V=2,000 L/h MMash

Column
XAF=0.08, XIF=0.92 VDS=0.00926L/h
VS=?
XAB=0.002, XIB=0.998
To determine the volumetric flow rate of the bottom product/sludge and the top product/alcohol:-
In put = Accumulated sludge on the sieve + Out put
1. Over all material balance; V=VT+VDS+VS
=>VT=V-VDS-VS………..…….……………………………………………….…………. (1)
2. Alcohol balance; V (XAF) =VT (XAT) + VS (XAB)……………………………….… (2)
Where; V = volumetric flow rate of mash,

VT = volumetric flow rate of alcohol,

VDS = volumetric flow rate of sludge that stay on the sieve, and
VS = volumetric flow rate of sludge respectively.
XAF, XAT and XAB are mass fraction of alcohol in the feed, in the top product and in the
bottom product respectively.
XIF, XIT and XIB are mass fraction of sludge in the feed, in the top product and in the bottom
product respectively.
Now substituting equation (1) in to equation (2);
V˟XAF=XAT (V-VDS-VS) + VS˟XAB =>2000(0.08) =0.5(2000-0.00926-VS) +0.002VS
160=999.9954-0.5VS +0.002 VS => 999.9954-160 = (0.5-0.002) VS
 839.9954= 0.498 VS
VS= 1686.74L/h
Now from equation (1), VT=V-VDS-VS=2000L/h-0.00926L/h-1686.74L/h
=>VT= 323.25L/h
This means 323.25 liters of alcohol having 50% concentration enters from the mash column to
the dilution column within one hour after condensed from the condenser.
 Energy Balance
Mash
V = 2,000 L/h Column
T1 = 52°C T2 = 80°C
Q=MCpΔT; where, M= mass flow rate of mash
Cp= specific heat of the mash

ΔT= T2-T1, T1= 52°C, T2= 80°C
But the mass flow rate of the mash should be calculated as follows.
M=ρ˟ V, where: - M=Mass flow rate of the mash,
ρ=Density of the mash and
V = volumetric flow rate of the
 M=1028.93Kg/m3˟ 2m3/h = 2057.86Kg/h
Again Cp of the mash should be calculated;
Cp = XAlcohol*CpAlcohol + XH2O*CpH2O + Xsludge*Cpsludge
= 0.08(2.44KJ/Kg.K) + 0.6(4.182KJ/Kg.K) + 0.32(3.671KJ/Kg.K)
= (0.1952+2.5092+1.175)KJ/Kg.K


 Items M(kg/h) ρ(Kg/m3) Cp(KJ/Kg.K) Δ T(K) Q= MCpΔT,
 KJ/h
 Mash 2057.86 1028.93 3.879 28 ?

Then Q=MCpΔT= (2057.86Kg/h)(3.879 KJ/kg.K)(28K)= 223508.29KJ/h
This means to rise the temperature of the mash from 52°C to 80°C 223,508.29KJ energy is
supplied with in one hour for alcohol separation process with in the mash column.



B. Purifying/dilution column:-

The condensate of the mash column is pumped to this column. The alcohol entering to this
column is diluted to about 15% to enhance the separation process of the mixtures. The working
temperature of this column is at about 70-90oc. This column works under atmospheric pressure.
The procedures in the dilution column:-
 The alcohol sprite in the form of vapor is entering to pre-distillation column at 450c at
top.
 Water is also entered to the column for dilution purpose (to facilitate the separation
process). 700 liters of hot water is entered to the dilution column from the rectification
column within one hour.
 Steam is injected at the bottom to the column at 128.80c it help to separate product due
to boiling difference
 Then condenser is condense the vapor to liquid, in this reflux is add for to separately
 The concentration alcohol is decrease to the 15wt%
 The dilute alcohol are gone to the rectification column at 700c
Material balance
VT=323.25L/h
Dilution
column
XEF=0.5, X IF=0.5
VDA=?
VH2O = 700L/h
Input = out put
VT+VH2O = VDA, where; VT=Volumetric flow rate of alcohol
VH2 = Volumetric flow rate of water
VDA=Volumetric flow rate of dilute alcohol 


=>323.25L/h+700L/h=VDA


=>VDA= 1023.25L/h

This means 1023.25 Liters of diluted alcohol enters from the dilution column to the rectification
column within one hour for further separation process.
Energy balance


 
VT=323.25L/h Dilution
 column

T1 = 45°C T2 = 70°C



Q=MCpΔT ; where; M= mass flow rate of the alcohol that enters to the dilution column.
Cp= specific heat of the alcohol and
ΔT= T2-T1, T1= 45°C, T2= 70°C
But the mass flow rate of the raw material should be calculated as follows.
Items M(Kg/h) ρ(Kg/m3) Cp(KJ/Kg.K) ΔT(K) Q=MCpΔT, M=ρ˟VT,

KJ/h where;
Alcohol 280.096 866.5 ? 25 ? ρ=Density of
the alcohol =
967.74Kg/m3an
d

VT=volumetric flow rate of the alcohol

M=967.74Kg/m3˟ 0.32325m3/h =312.82Kg/h
Again the Cp of the dilution alcohol should be calculated as follows.
VAlcohol = 323.25l/h, VH2O = 700l/h,
Then, VTotal = VAlcohol + VH2O = 323.25l/h + 700l/h =1023.25l/h
The mass fraction is then can be calculated as

XAlcohol =VAlcohol =323.25 = 0.316
VTotal 1023.25
XH2O = 1- XAlcohol = 1-0.316 = 0.684

Cp = CpH2O(XH2O) + CpAlcohol(XAlcohol) = 4.182KJ/Kg.K(0.684) + 2.44KJ/Kg.k(0.316)
= (2.860+0.771)KJ/Kg.K = 3.631KJ/Kg.K
Then, Q=MCpΔT= (280.096Kg/h)(3.631KJ/Kg.K)(25K)= 25425.7144KJ/h
C. Rectification column: -
The bottom products from the purifying column are pumped as liquid feed to the rectifying
column. A cool zone is provided in this column, which prevents the fusel oil vapor from reaching
the top of the column. The working temperature in this column is at 100-108oc in the bottom and
when it increases level thee temperature is decrease. . The alcohol entered to the rectification is
contains water, in most ethanol and in small part amount methanol. The alcohol solution entered
to this column will be processed in to three products.
Rectified alcohol having a concentration about 96.4% by volume is taken off as liquid from a
place near the top of this column & sent pure alcohol cooler through pump then to pure alcohol
storage. The overhead vapor it is condensed & partially returned to the column as reflex while
the rest is removed and sent to storage as denatured alcohol as head products.
Impurities from the side of the rectification column are fed to fusiel oil separator. The fusiel oils
are tail side products and feed to a settler as high tails.
Finally the heads, tails, and high tails will be recovered as impurities and sent to denature alcohol
line, while the high tails go to fusel oil separator for separation.
The overall procedures in the rectification column (Purifying):-
 The dilute alcohol at concentration of 15wt% is interred to rectification column

 And steam is also added at the bottom to this column at 1800c to separated the product by
boiling point difference

 Then condenser is condense the vapor to liquid, in this reflux is add for to separately
 The waste are recover at the bottom (water) and the fusel oil at half of the column is
removed at temperature 1080c.
 Pure alcohol and denature alcohol are found at the top column 78.10c then cool the vapor
by condenser
VD= 16 L/h
Material balance
VDA=1023.25L/h VE=150L/h
XEF=0.15, X IF=0.85 Rectification

column
VF= 24L/h
Vw=?
Input = out put
VDA= VD+VE + VF+VW, where; VDA=Volumetric flow rate of dilute alcohol
VD=Volumetric flow rate of denature alcohol
VE = Volumetric flow rate of ethanol alcohol
VW = Volumetric flow rate of water
VF =Volumetric flow rate of fusiel oil
=>1023.25L/h=16L/h +150 L/h+24L/h +VW

=> 1023.25L/h=190L/h+ VW=>VW=1023.25L/h-190L/h
=>VW = 833.25L/h
This means 833.25 Liters of hot waterleaves from the rectification column within one hour and
this is used as a raw material for Dilution column to dilute the alcohol to make easy for
separation process.
N.B. All the output hot water from the rectification column (i.e. 833.25 liters) is not used by
dilution column. Only 700 liters flows to the dilution column to dilute the alcohol within one
hour. That means 133.25 liters of hot water is released with the sludge as a waste.
Energy balance
VDA=1023.25L/h Rectificatio
n column T2 = 108°C
T1 = 70°C
Q=MCpΔT; where; M= mass flow rate of the dilute alcohol entering to the rectification column.
Cp = specific heat of the dilute alcohol
ΔT= T2-T1, T1= 70°C, T2= 108°C
But the mass flow rate of the dilute alcohol can be calculated as follows.
M=ρ˟ VDA, where; ρ=Density of the dilute alcohol = 967.74Kg/m3and
VDA=1023.25L/h, volumetric flow rate of the dilute alcohol


M=967.74Kg/m3˟ 1.02325m3/h = 990.24Kg/h
Then Q=MCpΔT= (990.24Kg/h )( 3.631KJ/Kg.K)(38K)= 136631.335KJ/h
This means 136631.335KJ energy is needed by the rectification column to rise the temperature
from 70°C to 108°C to separate pure alcohol, denature alcohol, fusiel oil, aldehyde and water.
3.1.8Liquor preparation (blending):-
Liquor are alcoholic beverages that can be prepared by the dilution of pure alcohol (96.4%
alcohol by volume) by adding some flavoring agents (essences),sweeteners (sugar) ,and mixing
with the aid of treated water. This can be obtained in different ways such as: The beverages
where the alcohol concentration is obtained only by Saccharification process (the direct break
down of starch in to glucose by using invert's enzymes) and fermentation processes. During
Saccharification, the starch is crushed and milled, and then the starch is saccharified with natural
or artificial enzymes, the glucose fermented to obtain Ethyl alcohol. Then finally flavoring
agents & sweetener are mixed with their percentage composition & proportion.
 An artificial enzyme, then the glucose is fermented to obtained ethyl alcohol .then
finally flavoring agent and sweeteners are mixed with their percentage composition
and proportion.
 The beverage where the alcoholic concentration is obtained by adding or mixing the
pure alcohol with sweeteners and flavoring agents, or by distillation of fermented raw
materials
The main raw materials for preparations of liquor are:
 Ethanol Alcohol
 Water
 Essence
 Sugar (local sucrose)
 Colorings

Ethanol Alcohol
Use best ethanol alcohol for obtaining first class products. To have quality sprits extra fine fil
tered alcohol could be used. For gin bitter &high grade brandies absolutely neutral refined
alcohol is important .sprit should not be used at all if it has a penetrating after taste of Aldehyde
& any other taste originating from barrels. In some cases secondary qualities may be can be
improved by special techniques &made suitable .If the shorter coming in the taste and smell do
not penetrate too much ,such alcohol quality could be used to prepare economically priced
brandies and bitters of lower consumers quality. In this situation however, an extra flavor or
essence must be used in addition to what is stated in the cross ponding receive so as to quickly
test the quality of the sprit.
Properties of ethanol
Physical Properties:
Table 5: Physical properties of ethanol
Molecular formula C2H6O

Molar mass 46.07gm/mole
Appearance Colorless liquid
Density 0.789g/cm3
Melting point -114-C,159-K , -173-F
Boiling point 78-C ,351-K, 172-F
Vapor pressure 5.95 kpa(@ 20-C)
Acidity(pka) 15.9
Basicity(pka) -1.9
Viscosity 0.0012 pa(@ 20oC)

Chemical Properties
Alcohols are reactive compounds. They are attacked by polar or ionic reagents. This is because:
a) The C–O and O–H bonds of alcohols are polar since oxygen is highly electronegative.
b) The oxygen atom of alcohols is an electron – rich center because it has two unshared pairs of
electrons.
. 1) Reaction with Sodium or Potassium:
2CH3CH2O – Na+ + H 2CH3CH2OH + 2Na
Ethanol Sodium Sod. Ethoxide
2) Reaction with Phosphorus Halides:
C2H5OH + PCI5 C2H5CI + POCI3 + HCI
Ethyl Chloride
3C2H5OH + PBr3 3C2H5Br + H3PO3
Ethyl Bromide Phosphorus Acid
3) Reaction with Thionyl Chloride:
C2H5OH + SOCI2 C2H5CI + SO2 + HCI
No Catalyst
4) Reaction with Hydrogen Halides:
C2H5OH + HBr C2H5Br + H2O
ZnCl2C2H5OH + HCI C2H5CI + H2O

5) Reaction with Nitric Acid:
C2H5OH + HO – NO2 CH3CH2 – O – NO2 + H2
Ethyl Hydrogen Sulphate
Table 6: Chemical combustion of ethanol
Parameters Composition (%)

Fermentable sugar 51.43
Total sugar 53.92
Total dry material 80.50

Ash 6.64
Nitrogen mater 4.16
Gum-Wax 2.85
Water
The nature of water to be used for the production sprite is very important. Its composition is very
much dependent on the condition of soil whether it is taken from springs or well water for the
production. It has trickled through soil and mineral has become saturated with the inorganic
impurities. These dissolved maters influence the producer of sprits and unforeseen troubles could
result. The following points must be attentively controlled
 Hardness of water
 Iron content of water
 Magnesium & Calcium salts of water
 Odor& test of water
Essence
An important point in producing sprit is the choice of flavoring materials this is the
distinguishing point of any sprit. Flavoring should be power full and plain, it must express the
character of the sprit clearly.

It is extracted component directly from aromatic vegetable, fruits, spices, herbs…. Etc by a
means of distillation and maceration processes.
There are different types of essence for different type of liquors. Example as gin essence is used
for preparation of dry gin liquor; anitole essence is used for ouzo liquor.
The primarily used as flavoring agent which are ready-to-use mixtures of fruits, juices,
brandies………etc. Sugar (local sucrose):
 It should be first class refined product

 This will be added and mixed during the liquor preparation in the syrup form in order
to facilitate the agitation process.
 It is used as a sweetener for the liquor
Colorings:
There are several types of colorings. Some of them are brown cornmeal, yellow lemon, green &
so on. The quality of these colorings should be checked before use. They should free of
calcium& iron salts.
Colorings should dissolve in high grade sprits. If wrong choice of coloring is done, this will be
cause turbidity in sprits. Colorings are sensitive to frost & its solubility will decrease at lower
temperature. The finished colored sprits should not be stored under frosty condition. Input
consumption to prepare one liter of sprit given ethanol alcohol of 96.5% by volume.
Table 7: Tables of the ingredients added in liquor preparation
S/n Product type Inputs

Ethanol sugar Essence treated water coloring
alcohol (liter) (gm) (milliliter) (milliliter) (gm)

Ouzo/zebib
1 (41%) 0.426 8 0.9 574
2 Gin (41%) 0.426 8 1.2 574
3 Cognac (37%) 0.382 8 0.85 616 300
4 Appretive (32%) 0.332 68 6.33 668 600
5 Annanas (32%) 0.332 68 0.91 668 600
6 Lemon (32%) 0.332 68 0.91 668 600
7 Fernit (37%) 0.384 9.9 616 400
8 Superment (25%) 0.26 145.6 2.6 740 0.14
N.B: Appretive essence is a mixture of 0.53 ml of gin essence, 0.116 ml of cognac essence,
0.1149 ml of brandy essence, 5.5 ml of bitter essence, and 0.04 ml of Fernit essence.
Mixing Process
As ethanol is extracted fully enough from molasses with an alcohol content of above 96.4%, it is
transferred to this section where, the ethanol alcohol only is mixed with an amount of 2365 liter
for 20 minutes without any addition of substances to remove unpleasant odor. After this, around
1200 litre of water is added and mixed for 20 minutes for the purpose of reduction of alcohol
content to a desired level. Finally, the essence or flavoring substances are added as sweetening
agent depending on the type of sprits which produce the company. Sugar also added in the form
of syrup with its amounts of 44-45 kg and diluted with hot water to soluble easily unless, it is
precipitated. The company produces different type of sprit products with their specific essence
but, it is well known by manufacturing of ouzo/Zebib liquor. The name of essence added is
anathole. Liquor are alcoholic beverages that can be prepared by the dilution of pure alcohol
96% alcohol by volume and by adding some flavoring agents (essences),sweeteners (sugar) ,and
mixing with the aid of treated water. This can be obtained in different ways such as:
The beverages where the alcohol concentration is obtained only by Saccharification process (the
direct break down of starch in to glucose by using invertase enzymes ) and fermentation
processes. During Saccharification, the starch is crushed and milled ,then the starch is

saccharified with natural or era. Hence, if the bricks measurements are constant for three hours,
the mash must be transformed in to decantation tank.
An artificial enzyme, then the glucose is fermented to obtained ethyl alcohol .then finally
flavoring agent and sweeteners are mixed with their percentage composition and proportion.
Example of liquor is gin, brandy, ouzo, lemon, aperitif, orange, and zebib etc. depending on the
essence that w use as a flavor.
Filtration of liquors The preparation liquor must appear perfectly clear without any impurities or
suspensions. Filtration is a process that accomplishes this. It is the passage of a cloudy liquid
through a porous body, which retains the matter in suspension. It is highly important stage in the
manufacturing of liquors because it is responsible system for the final appearance of the drink
A filter press does filtration where the filtering material remains stationary between metal or
plastic plates so that the entire filtering process is uniform pressure is used so that filtering time
is cut down.
Washing Machine
Machine function is to wash the bottle that came from the consumer (returnable bottle). The
washing capacity is 3500 bottles per hour. The temperature of hot water machine at 75oc after
that inters the bottle. Checking the impurities of the bottle everything is done by inspection
method. Caustic soda is use for washing the bottle.
Filler Machine
These machines are 16 filler machine and 3 crap canners that packages the bottle in correct
mannered. There are vacuum pressure former this is used for control during filling the bottle or
control the gap between the liquor and the canner. After the liquor is capping, it is labeled
manually and stored at cool temperature.
Pure Alcohol
Sugar

Flavor
Color
Filter Storage
press Ageing
tank
Water Mixer tank
Labeling Capping Filler

machine machine
Bottled liquor demanding markets bottles (recycled from markets)
Figure 12: liquor section
Waste water treatment principle
Sludge discharged directly from distillation column to the primary clarifier and then to the
pumped to buffer tank. When it comes it is acidic and neutralized by a weak base. After then it
becomes neutral before entering to the bioreactor. After neutralization the sludge is pumped to
the bioreactor. The dug is added in the bioreactor to develop microorganisms, and then they
consumed the nutrients present in the sludge .In bio reactor the microorganism produce different
type of gas like methane, H2S, CO2 and NH3. After 24 days the sludge in the bioreactor is
replaced by another new sludge. Thus, gases and reacted water it over flow to upward when new
sludge entered at bottom. The bio reactor it has empty space to hold gases according to weight,
lighter gas found at upper surface (i.e. gases lighter than methane). The lighter gases go with in
pipe connected to bio reactor to burn because they have bad smell and to prevent environment
pollution. The methane gas goes to the gas holder, after that goes to the boiler plant. The boiler
plant works by methane gas as electric power to produce steam. When new sludge discharged

from distillation column coming again to the buffer tank and bio reactor, so the reacted sludge
(water) entered before the new sludge goes to the degasify to remove thus gas coming with
water. Half of the degasify was empty space that why may some gas coming with water (sludge)
to remove to the atmosphere, thus gases lighter than water, but heavier than methane. From
degasifying the sludge sent to the laminar. The discharged water entered from bottom to upper
space of the laminar. At this time there is plate put in the horizontal place. Thus plate collect very
small particles present with water. The collected particles go back to the bioreactor it used as
food for microorganism. Some water (sludge) sent back to the buffer tank to optimize the PH of
incoming sludge from the distillation column, because it is acidic. Higher amount of water send
to the temporary container. From the container it sends into multiple evaporators to evaporate
water and condensed. At this time some particles found they are not remaining at the laminar
(with the plate). After water evaporated we obtained semi solid particles (about 60% semi
solid).and this goes to the spray dryer to avoid a water present in the particles. Finally we obtain
powder compost (i.e. fertilizer) and also used as colures .water condensed from the evaporator
used for cleaning and irrigation. So this company obtains three advantages. These are:-
 Methane gas as source of energy

 Produces compost product
 Water used again for different purpose

Weak base Dugs
Gas
Sludge
Buffer
Bioreactor Degasify
tank
Semisoli particles
Biogas Laminar
Boiler plant Methane Gasholder Sludge (reacted H2O)
Temporary
Evaporator Container
Product Spray dryer
(compost)
Figure 13: The block flow diagram of waste water treatment
Boiler plant: is a closed vessel in which water or other fluid is heated. The heated or
vaporized fluid exits the boiler for use in various processes or heating applications, including,
boiler based power generation. There are two types of boiler available in the company. These are
differing based on their capacity which they produce the amount of steam and are working
interchangeably; the main utilities of the companies used for the proper functioning of boiler
are:-
 furnace oil,
 butane gas,
 compressed air and
 Soft water

Furnace oil
 It is the source of heat energy.

 It should be preheated and reach at the burner within a temperature range of 90-
110oc.
 This temperature range is varies depending on the viscosity of fuel oil.
 It is estimated that 0.35 liter of furnace is consumed to produce one liter of
ethanol alcohol.
Butane gas:-
 It is used to start burning or flame formation during ignition.

 It has lower flash point than furnace oil.
Combustion air (O2):-
 Used for combustion of fuel energy so as to generate heat energy.

Compressed air:-
 Used to adjust the particle size of furnace to make easiest for burning.
 If excess air is supplied, the particle size will be very small and exposed to:
 Inconvenient burning
 Inadequate heat energy generation.
 If less air is supplied, the particle size will be very large.
 Therefore, the furnace will collect on the burner nozzle
.
Treated water:-
 It is treated or softened by ion exchange or reverses osmosis method to reduce the scale
forming ion.
 Used for saving of fuel energy the boiler is used to supply a steam to all distillation
columns, buffer tank and evaporator. The smallest capacity of the boiler doesn‟t operate
with presence of butane gas and it will be supplied a steam to both pre-distillation and
rectification column and only mash column. The water consumption of the boiler is 1000-

12,000kg/hr for the smallest largest boiler respectively. There are many types of boiler
used in different industry but, the type of boiler which is found in DALF Company is fire
tube boiler. It is used to supply small steam capacities and easily available in the market.
It works in which the hot gasses of combustion are passes through the boiler tubes and
water surrounds these tubes to absorb heat.
Cooling tower: Are heat removal device used to transfer process waste heat to the
atmosphere. It may either use the evaporation of water to remove process heat and cool the
working fluid to near the wet bulb air temperature or in the case of closed circuit dry cooling
tower rely solely on air to cool the working fluid to near the dry-bulb air temperature common
applications include cooling the circulating water used in oil refineries, chemical plant, power
station and building cooling. The cooling tower is works as warm water from the heat source is
pumped to the water distribution system at the top of the tower. The water is distributed over the
wet deck fill by means of nozzles. Simultaneously, air is drawn through air inlet louvers and
through the wet deck surface causing a small portion of the water to evaporate. The evaporative
process removes heat from water. The warm moist air is drawn out of the top of the tower. The
resulting cold water is then recirculating back through the heat source in a continuous cycle.
Fan
Hot water
Cooling tower
Cold water
Figure 14: cooling tower
Energy balance
VT= 323.25L/h
T2 = 45°C
Condenser

Q=MCpΔT ; where M = mass flow rate of alcohol
Cp= specific heat of alcohol
ΔT= T2-T1, T1= 80°C, T2= 45°C
But the mass flow rate of the alcohol should be calculated as follows.
M=ρ˟ VT, where M=Mass flow rate of the alcohol,
ρ=Density of the alcohol and
VT=volumetric flow rate of the alcohol
 M=913.84Kg/m3 ˟ 0.32325m3/h = 295.4Kg/h
The specific heat of impure alcohol that enters to the condenser from the mash column is
calculated by:
Cp = CpH2O*XH2O +CPAlcohol*XAlcohol = 4.182KJ/Kg.K(0.5)+2.44KJ/Kg.K(0.5)
 Cp = (2.091+1.22)KJ/Kg.K = 3.311KJ/Kg.K
Then, Q=MCpΔT= (295.4Kg/h)(3.311KJ/kG.K)(-35K)= -34232.429KJ/h
This means 34,232.429KJ energy is removed to condense the alcohol from 80°C to 45°C within
one hour before entering to the dilution column.
Water treatment plant: Desta alcohol sets up high standards and as the distillery needs
different types of water for different purposes. It has set up a „water treatment plant‟ in the same
premises. Tap water or source of water cannot provide water as required for different units.
Some of the requirements of different units are as follows:-

 Boiler requires water without having hardness to avoid scaling problems.

 Foreign and country liquor requires de-mineralized water.
 The main goal of a water filter is to provide clean, contaminant-free water for
drinking and other purposes whereas water softener is to remove hardening minerals
like calcium and magnesium from the water.
 As the water required for different purposes is different water treatment plant
produces water of different qualities and supply it to different units. Water treatment
plant requires to remove or adjust hardness, free mineral acid, pH, Cl2, SO4,
alkalinity etc. to required values. Water treatment plant uses ion exchange
mechanism.
Ion exchange mechanism: Ion exchange operations are essentially chemical reactions
between an electrolyte in solution and an insoluble electrolyte with which the solution is
contacted. The mechanisms of these reactions and the techniques used to bring them about
resemble those of adsorption so closely that for most engineering purposes ion exchange can
simply be considered as a special case of adsorption application. Principle of ion exchange: the
ion exchange solids first used were porous, natural or synthetic minerals containing silica, the
zeolites, such as the mineral Na2O, Al2O3, 4SiO2, 2H2O, for example. Positively charged ions
(cations) of a solution which are capable of diffusing through the pores will exchange with the
Na+ ions of such a mineral, which is therefore called a calcium exchangers. For example, Ca2+
+ Na2R=========► CaR + Na+
Where “R” represents the residual material of a zeolites. In this manner “hard” water containing
Ca2+ can be softened by contact with zeolites, the less objectionable Na+ replacing the Ca2+ in
solution and the latter becoming immobilized in the solid. The reaction is reversible, and after
saturation with Ca2+ the zeolites can be regenerated by contact with a solution of salt,
CaR + 2 NaCl ============► Na2R + CaCl2
Later certain carbonaceous cation exchangers were manufactured by treating substances such as
coal with reagents such as fuming sulphuric acid, and the like. The resulting exchangers can be
regenerated to hydrogen from, HR, by treatment with acid rather than salt. Thus hard water

containing Ca(HCO3)2 would contain H2CO3 after removal of the Ca2+ by exchange, and since
the carbonic acid is readily removed by degasification procedures, the total solids, content of the
water can be reduced in this manner. This method is limited to water softening only.
Deep ground water
Pumping and containment
Pre chlorination Minimize the growth of fouling organisms
Sand filtration Large suspended particles
Carbon filtration Contaminants & impurities
Bag filtration Dirt & dust
MembraneMMfiltration All particles larger than 0.2µm

Membrane filtration
Zeolite Ionembrane
exchange
filtration Ca2+ & M a2+
embrane filtration
Figure 15: processes flow chart of water treatment
Chapter Four
4. Overall benefits I have got from the internship
 I improved and upgrade my theoretical knowledge that I know before for the last
four years
 Improved my practical skills including other fields job
 Developed team working skill with students that are from other university
 I improved leadership skill
 I got and understand what work ethics means

 I am really satisfied and enjoyed about the alcohol production science and how
the engineering skills interpreted with the benefits of economics.
 Developed the entrepreneurship skill
4.1Conclusions and recommendations for the company

4.1.1 Conclusions:
In general we observe all the company work and know how liquor produced. Also it helps us to
know about the work ethics and to be punctual. To increase the yield of production of the
company, they should minimize the cost and optimize the raw material and product. Most of the
time there is a problem with a mash column and with the boiler so as this materials are the basic
production facilities they should take serious measures.
4.1.2 Recommendation
 To clean the storage of molasses within six month.

 Using re boiler for better energy consumption.
 In the waste treatment it will be advantageous to use medium pores to increase its
capacity.

Chapter One
1 Project title: - Recovery of Heat on Mash Column in Case of Desta

Alcohol and Liquors Factory
1.1 Short summary: Distillation process is the back bone of every beverage industry;
similarly DALF uses this process to separate Alcohol from other impurities. The plant produces
huge amount of liquid impurities which is called raw spent wash. To separate the alcohol from
other liquid impurities (raw spent wash) from 180-190°c steam is supplied from the boiler, using
furnace oil as a main source to rise the temperature in the mash column to 80°c.The bottom
product of mash column i.e the sludge/raw spent wash that is heated to this temperature is
directly released to the primary clarifier in the waste water treatment plant department with a
temperature of about 70°c. Therefore in this project we attempt to use this heat as a pre-heater
using heat exchanger to heat the mash before entering to the mash column for cost minimization
and to reduce separation time by recovering and reusing the released heat from a mash column.
1.2 INTRODUCTION
1.2.1 Background
A waste heat recovery unit is an energy recovery heat exchanger that recovers heat from hot
streams with a potential high energy content. Waste heat found in the exhaust fluid of a various
process or even from exhaust stream can be used to preheat the incoming fluid. This is one of the
basic methods for recovery of waste heat. Recovering industrial waste heat can be achieved via
numerous methods. The heat can either be “reused” within the same process or transferred to
another process.
1.2.2 Heat recovery method
Pump: It is a machine that is used to force the raw spent wash/sludge coming from the mash
column to the heat exchanger.

Pipe- Is a tube through which fluids flows with in it.
Heat exchanger:- is a device that allows heat from a fluid (a liquid or a gas) to pass to a
second fluid (another liquid or gas) without the two fluids having to mix together or come into
direct contact or simply heat exchanger is a device designed to efficiently transfer or "exchange"
heat from one matter to another. Heat exchangers may be classified according to transfer process,
construction, flow arrangement, surface compactness, number of fluids and heat transfer
mechanisms.
1.2.3 Problems of Statement:
Desta alcohol and liquors factory spends on average 2.6 million birr annually on importing
furnace oil from Djibouti for energy consumption. That is why we are focusing on cost and time
minimization for our mini project. This project proposal has targeted to apply heat recovery
system and keep the benefits from it in terms of cost and time.
1.2.4 Objective
1.2.5 General Objective:
 Recovering heat released from mash column in the distillation process of alcohol
separation.
1.2.6 Specific objective
 To minimize energy cost of the company

 To reduce separation time
 To provide high quality beverage products
Properties of the sludge
 It has a dark brown color

 It has a specific heat capacity of 3.678KJ/Kg .K
 It has a density of 1041.28Kg/m3
 Its PH value is about 4.053

 Its overall heat transfer coefficient is 150W/m2.K [11]
Chapter Two
2 Literature review
Captured and reused waste heat is an emission free substitute for costly purchased fuels or
electricity. Numerous technologies are available for transferring waste heat to a productive
end-use. Nonetheless, anywhere from 5-13 quadrillion Btu/yr of waste heat energy remains
unrecovered as a consequence of industrial manufacturing.
Three essential components are required for waste heat recovery; 1) accessible sources of
waste heat, 2) a recovery technology, and 3) a use for the recovery energy. This study
specifically examines large energy-consuming processes (totaling 8,400 trillion btu/yr, or
Tbtu/year) and identifies unrecovered waste heat losses in exhaust gases totaling-1500
TBtu/year. The results from this investigation serve as a basis for understanding the state of
waste heat recovery and providing recommendations for to advance waste heat recovery
technologies. Technology needs are identified in two broad areas: 1) extending the range of
existing technologies to enhance their economic feasibility and recovery efficiency, and 2)
exploring new methods for waste heat recovery, special for un conventional waste heat
source.
Factor Affecting Waste Heat Recovery Feasibility: Evaluating the feasibility of waste
heat recovery requires characterizing the waste heat source and the stream to which the heat will
be transferred. Important waste stream parameters that must be determined include:
 Heat quantity with in the raw spent wash,

 Composition of the raw spent wash,
 Minimum allowed temperature to preheat the mash
 operating schedules, availability, and other logistics, and
 Possible materials/design limitations. For example, corrosion of heat transfer media
is of considerable.

 The following parameters should be analyzed for the proper design of heat exchanger
in the plant. These are:-
 TSS,
 TDS, and
 COD
Total suspended solids (TSS)

Is the dry-weight of particles trapped by a filter. It is a water quality parameter used for example
to assess the quality of wastewater after treatment in a wastewater treatment plant. TSS was
previously called non-filterable residue ( NFR ), but was changed to TSS because of ambiguity
in other scientific disciplines.
Total dissolved solids (TDS)
Is a measure of the combined content of all inorganic and organic substances contained in a
liquid in molecular, ionized or micro- granular ( colloidal sol ) suspended form. The principal
application of TDS is in the study of water quality for streams, rivers and lakes , although TDS is
not generally considered a primary pollutant (e.g. it is not deemed to be associated with health
effects) it is used as an indication of aesthetic characteristics of drinking water and as an
aggregate indicator of the presence of a broad array of chemical contaminants. The most
common chemical constituents are calcium , phosphates , nitrates , sodium , potassium and
chloride , which are found in nutrient runoff, general storm water runoff and runoff from snowy
climates where road de-icing salts are applied.
Chemical oxygen demand (COD)
The standard method for indirect measurement of the amount of pollution (that can’t be oxidized
biologically) in a sample of water.
The chemical oxygen demand test procedure is based on the chemical decomposition of organic and
inorganic contaminants, dissolved or suspended in water. The result of a chemical oxygen demand
test indicates the amount of water-dissolved oxygen (expressed as parts per million or milligrams per

liter of water) consumed by the contaminants, during two hours of decomposition from a solution of
boiling potassium dichromate. The higher the chemical oxygen demand, the higher the amount of
pollution in the test sample.
For the contaminants that can be oxidized biologically, the biological oxygen demand (BOD) method
is used.
Chemical oxygen demand (COD) does not differentiate between biologically available and inert
organic matter, and it is a measure of the total quantity of oxygen required to oxidize all organic
material into carbon dioxide and water. COD values are always greater than BOD values, but COD
measurements can be made in a few hours while BOD measurements take five day.
CHAPTER THREE
3.1 MATERIAL AND METHODS
3.1.1 MATERIAL AND EQUIPMENT
Operating data
Number Material and equipment Function

1 Test tube To hold sludge sample
2 Centrifugation To rotate the sample
3 PH meter To measure the PH
4 Watch To know retention time
5 Thermo meter To measure temperature
Data analysis: The property of the sludge is analyzed in laboratory by using different
laboratory materials to determine the PH, total suspended solid (TSS), total dissolved solid
(TDS) and chemical oxygen demand COD) of the sludge as follows.

Parameter data analyzed

To 39.7 42.5 45.3 46.0 47.7 49.3 53.8
TSS(ppm) 6900 4500 4200 4800 4000 3900 6700
TDS(ppm) 103000 103400 108800 10800 103100 119600 97,00
COD(ppm) 78,000 92,000 92,000 78,000 82,000 92,000 78,000
PH 3.702 3.998 4.080 3.965 4.100 4.125 4.055
3.1.2 METHODOLOGY
From the mash column the raw spent wash/sludge is first led to the pump. In this stage the raw
spent wash/sludge is pumped to the heat exchanger. At the same time the mash from the decanter
is pumped to the heat exchanger.
Heat exchangers are basically two chambers separated by a wall, with each chamber containing
one type of fluid substance. Here heat passes from hot fluid (raw spent wash/sludge) to the cold
fluid (mash), which warms the cold fluid and cools the hot fluid. The circulating fluid then
transfers its heat to the mash through the separating wall, warming the mash and taking heat
from the raw spent wash/sludge. Here the mash and the sludge flow in opposite direction/counter
flow. The mash flows with the initial temperature of 34°c and the sludge flows with initial
temperature of 70°c and the sludge loss the heat to the mash and the mash becomes hot before
entered to the Mash column. The sludge is then released after heating the mash.
3.1.3 EQUIPMENTS THAT USED FOUR HEAT RECOVERY
A. Pump: -It is a machine that is used to force the raw spent wash/sludge coming from the
mash column to the heat exchanger. The construction of material for the pump is stainless steel
and has a discharge diameter of 2inch. Centrifugal pump is used for this case.
B. Pipe- Is a tube through which fluids flows with in it. The selected material for the pipe is
stainless steel and its outer diameter is 2 inch and thickness of 0.07874inch.

C. Heat exchanger:- is a device that allows heat from a fluid (a liquid or a gas) to pass to a
second fluid (another liquid or gas) without the two fluids having to mix together or come into
direct contact or simply heat exchanger is a device designed to efficiently transfer or "exchange"
heat from one matter to another. Heat exchangers may be classified according to transfer process,
construction, flow arrangement, surface compactness, number of fluids and heat transfer
mechanisms. The thermal and mechanical design of the heat exchanger is discussed on chapter
six.
NB. The desired pump and pipe are available in the plant and no need of design.
Process description from the mash column the raw spent wash/sludge is first led to the pump. In
this stage the raw spent wash/sludge is pumped to the heat exchanger. At the same time the mash
from the decanter is pumped to the heat exchanger. Heat exchangers are basically two chambers
separated by a wall, with each chamber containing one type of fluid substance. Here heat passes
from hot fluid (raw spent wash/sludge) to the cold fluid (mash), which warms the cold fluid and
cools the hot fluid. The circulating fluid then transfers its heat to the mash through the separating
wall, warming the mash and taking heat from the raw spent wash/sludge. Here the mash and the
sludge flow in opposite direction/counter flow. The mash flows with the initial temperature of
34°c and the sludge flows with initial temperature of 70°c and the sludge loss the heat to the
mash and the mash becomes hot before entered to the Mash column. The sludge is then released
after heating the mash.

3.1.4 Equipment Design
A. Thermal design of heat exchanger: -
For the thermal design of the heat exchanger the following condition should be in mind.
 The flow rates of both hot and cold streams,

 Their terminal temperatures and
 Fluid properties are the primary inputs of thermal design of heat exchangers.
Known data: -
 Hot fluid inlet temperature (T1) = 70°c

 Hot fluid outlet temperature (T2) = 55°c
 Cold fluid inlet temperature (t1) = 34°c
 Cold fluid outlet temperature (t2) = 52°c
 Working pressure = 130 mbarr = 0.013 N/mm
 Design pressure = 14,300N/m2 = 0.0143N/mm2, which is more than the working
pressure by 10%.
 The design stress(f) = 3.786N/mm2
 Shell diameter (Ds) = 680mm
 Mass flow rate of cold fluid (Mm) = 2057.86Kg/h and
 Mass flow rate of hot fluid (Ms) =1756.34Kg/h, both flow rates are calculated
values. (Subscripts ``m``for mash and ``s``for sludge)
Calculation of heat transfer area and tube numbers
Let as we have1 shell pass and 4 tube pass shell and tube exchanger with following dimensions
and considerations.

 Fixed tube plate

 Outer diameter of tube = 22mm = 0.022m
 Tube length (Lt) =2m
 Tube ID (di) = 20mm = 0.02m
 Fluid arrangement: Mash is placed in tube side.
 Square pitch arrangement.
The log mean temperature correction factor (FT) for 1-4 shell and tube exchanger:
R = (T1-T2) ÷ (t2-t1) = (70-55) ÷ (52-34)
=> R= 15/18= 0.8333
S = (t2-t1) ÷ (T1-t1) = (52-34) ÷ (70-34)
=> S=18 /36= 0.5
Ft= √R2 +1 ln (1-S/1-RS) , substituting all known values,
(R-1) ln 2-S(R+1-√R2 +1)
2-S(R+1+√R2 +1)
Ft= √0.83332+1 ln (1-0.5/1-0.8333 (0.5))
(0.8333-1) ln 2-0.5(0.8333+1-√0.83332+1
2-0.5(0.8333+1+√0.83332+1
=>Ft= 1.302ln (0.857) = 0.866
-0.1667ln (4)

LMTD= [(T1-T2)-(t2-t1)]
ln [(T1-T2)/(t2-t1)]
= [(70-55)-(52-34)] = -3
Ln[(70-55)/(52-34)] ln[0.8333]
=>LMTD=16.45°K
Determining the heat transfer area (A):
The value of overall heat transfer coefficient (U) of 150w/m2.k is taken from internet to initiate
the design calculation for the mash and sludge heat exchanger.
A= Q = Mm CP T
U.LMTD.Ft U.LMTD.Ft
= (2057.86kg/h)(3.879kj/kg.k)(52-34)k)) = 143683.901kj/h =39912.195w
150w/m2.k (16.45k) (0.866) 2136.855w/m2 2136.85w/m2
 A= 18.678m2 = 201.05ft2
Calculating no.of tubes (nt):
nt= A = 18.678m2
𝜋. 𝐷𝑜. 𝐿𝑡 𝜋(0.022𝑚) ∗ 2𝑚
=> nt = 135.2

But the number of tubes cannot be fraction and hence number of tubes (nt) = 136 tubes.
Mechanical design of heat exchanger: - The structural rigidity and satisfactory service
of heat exchangers depends on the appropriate mechanical design.Mechanical design is
generally performed according to the design standards and codes.
The major mechanical design components of shell and tube heat exchangers are:
 Shell thickness
 Shell cover thickness
 Channel cover thickness and
 Tube sheet thickness
Shell thickness
ts = PDs + C, But the joint efficiency (j) = 1, Double welded [ 3 ] and
Corrosion allowance (c) = 3mm [3]
fj-0.6p
(0.0143N/mm2)(680mm) 9.724N/mm
ts= + 3mm= + 3mm=2.57mm+3mm
2 2 2
3.786N/mm -0.6 (0.0143N/mm ) 3.77742N/mm
 ts = 5.57mm
Shell cover thickness- Let the shell cover be a Tori spherical head for our design.
Here we are considering Shell diameter and head, Ds = 680mm is equal to Crown radius.
i.e. Ri = Ds = 680mm.
According to ASE design codes and standards Knuckle radius (ri) = 6% of Ri = 0.06(680) mm
 ri = 40.8mm
Inside depth of the head can be calculated as:

hi = Ri-[(Ri-Ds/2)×(Ri+Ds/2)+2ri]1/2
hi = 680mm-[(680-680/2)(680+680/2) +2×40.8mm]1/2 = 680mm-(340×1020+ 81.6)1/2
= 680mm-(346,800 + 81.6)1/2 = 680mm-588.967mm
=> hi = 91.033mm
Effective exchanger length (Leff):

Leff = Lt + 2×hi= 2m + 2×0.0.091033 m = 2m + 0.182066m= 2.182066m
Thickness of head, th = PRiW +3mm

2fj-0.2p
But w= 1
4 3+-√Ri/ri =1/4 3+√680mm/40.8mm =0.25( 3+4.0825) => w = 1.770625
Then, th= (0.0143N/mm2) (680mm)(1.770625) 17.21756N/mm

+ 3mm= +3mm
2(3.786N/mm2) (1)-0.2(0.0143N/mm2) 7.56914N/mm2
=> th = 2.275mm+3mm= 5.275mm
Channels cover thickness:

For our design the Channel cover material is selected as carbon steel:
tcc =Dc * √CI.P/f +C, where, CI = 0.3 when bolted with narrow faced or ring type gasket.
10 Dc = Cover diameter usually equal to the outer diameter
i.e. Dc =Din+2t=680mm+2(2.57mm) => Dc =685.14mm
*√ 0.3(0.0143N/mm
Substituting all known values, tcc=685.14mm 2) + 3mm
10
= (68.514mm) (0.0173) +3mm = 1.2mm+3mm
=>tcc = 4.2mm
Tube sheet thickness:

tts=F.Gp √P/kf + C,F=1 for fixed tube sheet; K =0.5 (square pitch); Gp = Ds = 680mm
3
Substituting all known values,tts=1(680mm) √ 0.0143N/mm2 +3mm

2
3 0.5(3.786N/mm

tts=680mm 0.0869 + 3mm => tts =19.7mm+3mm = 22.7mm

3
ECONOMIC ANALYSIS
Equipment cost
No Type of Equipment Material of construction Cost(Birr)
1 Heat Exchanger Carbon steel 243,090.00
Table 9: Equipment costs
Saving Potential
During heat recovery, the energy saving potential is mainly depends on:-

The amount of raw spent wash produced in the mash column. 

The price rate of furnace. 

The separation efficiency of the mash column. 

The type of heat exchanger and 

The flow arrangement of the fluids in the heat exchanger. 
Amount of heat recovered = 96,897.278KJ/h
But we know that the price rate of furnace =1.85*10-3 Birr/KJ
Money from heat recovery = (Amount of heat recovered) (price rate of furnace)
= (96,897.278KJ/h) (1.85*10-3 Birr/KJ) = 179.26 Birr/h = 4302.24Birr/day
Based on this within one month we can have 129,067.2 Birr. Therefore, the money that we invest
for heat exchanger is recovered with in about 1 month and 27 days.

Energy Balance
VS= 1686.74L/h

Heat
T1= 70°C Exchanger T2= 55°C
T2= 55°C
Q= MCp∆T;Q = where; Heat lost by raw spent wash/sludge
M= mass flow rate of the sludge that leave from the bottom of the mash column
Cp= specific heat of the sludge
∆T= T2-T1, T1= 70°C, T2= 55°C
But the mass flow rate of the mash should be calculated as follows.
M=ρV , where M=Mass flow rate of the sludge,
˟S
ρDensity of the sludge = 1041.28Kg/m3and
=
VS=volumetric flow rate of the sludge

M=1041.28Kg/m3×1.68674m3/h = 1756.34Kg/h
Again the specific heat of the sludge is calculated as;
Cp = XAlcohol*Cp Alcohol + Xsludge*Cpsludge
=0.002(2.44KJ/Kg.K) + 0.998(3.671KJ/Kg.K) = (0.00488+3.6636)KJ/Kg.K

Cp = 3.678KJ/Kg.K
Then; Q=MCp∆T=1,756.34Kg/h)(3.678KJ/kg.K)(-15K)= -96897.278KJ/h
The negative sign indicates the sludge loss the energy to heat the mash. This amount of heat i.e.
96,897.278KJ is recovered from the sludge that is now designed to heat the mash before inter in
to the mash column within one hour. Environment and affects the workers and the people who leaves
around there.

CHAPTER FOUR
4.1 Conclusion and recommendation
4.1.1 Conclusion
In DALF raw spent wash/sludge is one of the most by product of the distillation process in the
mash column. Here the raw spent wash/sludge that leaves from the mash column has a
temperature of 70°c.
This project proposal has targeted to apply heat recovery system and keep the benefits from it in
terms of cost, separation time, efficiency, quality and quantity. On this project 96,897.278KJ
energy is recovered from the raw spent wash or sludge realizing from the mash column within
one hour. By recovering this energy 4302.24 Birr per a day can be collected. Annually about
1.57 million Birr can be collected from the recovery of heat.
4.1.2 Recommendations
We would like to recommend the following recommendation so as to be profitable for the plant

As we describe it earlier the raw spent wash with a temperature of 70°c that is
released from the mash column should be recovered to minimalize the energy cost
of the company. 

It is better to use stainless steel for the heat exchanger to resist the corrosion of
tubes and shell of the heat exchanger. 

The physico-chemical properties of the raw spent wash and the mash should be
analyzed for the proper design of heat exchanger. 

References
 the company supervisors, operators, employees;

 Google files;
 Chemical engineering apparatus design exercise book.

 Coulson & Richardson's Chemical Engineering.
 Perry´s chemical engineers` hand book.
 Siegel, Robert (2007-02-15). "Ethanol, Once By passed, Now Surging Ahead". NPR.
 Technical manual of Desta alcohol & liquor factory of Ethiopian standard.
 The Engineering ToolBox website.
 Donald Q. Kern, Process heat transfer.

Appendixes
Anti-foam:- A chemical that prevents a substance to form a large collection of bubbles or

is a chemical that prevent over flowing of warts.
Beverage:- A liquid to consume, usually excluding water; a drink.
Column:- A solid upright structure designed usually to support a large structure above it.
Degree Bricks:- The measure of the concentration of molasses for alcohol production.
Demerit:- A quality of being inadequate; a fault; a disadvantage.
Mash:- A mass of mixed ingredients reduced to a soft pulpy state by beating or pressure.
Merit:- Something deserving good recognition.
Process technology:- The process flow of the plant for producing the desired product.
Recovery:- The act or process of regaining or repossession of something thing lost.
Sludge:- A generic term for solids separated from suspension in a liquid.
Vigorous:- Physically strong and active

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Bahir Dar Institute of Technology 2017

School advisor; signature

Mr. Addis lemessa ……………………………………………….

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Table 1: Liquors Production

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Figure 1: Denature Alcohol

Symbols and abbreviations

1. DALF = Desta Alcohol and Liquor Factory.

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List of Tables ................................................................................................................................. iv

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Figure 1: Denature Alcohol .................................................................................................................................................. 6

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1.1Ethyl alcohol (Ethanol)

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1.3 Growth of the company

 Initial investment- 2,014,000 birr

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1.4Growth of the company of Desta Alcohol and liquor factory

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1.5Vision and mission of the factory

 To improve the quality of its products

1.6 End products and service of the company

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A. Denatured alcohol (methanol)

Figure 1: Denature Alcohol

B. Potable alcohol (ethanol)

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C. Alcoholic beverages (Liquors or sprites):

Figure 2: Types of Alcoholic Beverages (Liquor)

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Table 1: Liquors Production

Liquors Alcohol Ethanol Sugar Essence(ml)

1.7The main customers or end users:

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o Main Customers of Fire Alcohol (Denature alcohol);

Main Customers of Pure Alcohol (Ethanol);

Main Customer of alcoholic Beverages;

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 Access to natural resources.

1.8Over all organizational structure and work flow

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Sugar + Water using alcohol + heat + carbon dioxide

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Molasses from storage

15° brix molasses

3kg yeast Mother tank for 12 hours

H2SO4 propagated yeast

Sludge Fermenter tank for 3 days 25° brix molasses

CO2 2kg Dap

Decanter (settling) tank for 1 day Sludge

Pure wash Stillage

Water Distillation unit Fusel oil as by product