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JIMMA, ETHIOPIA
Final internship report (RORANK BUSINESS SHARE COMPANY)
Declaration
We hereby humbly declare that the presented report of internship titled “final internship report on
Rorank business share company and project paper” is uniquely prepared by us after the completion of
three months’ work experience at Rorank business S.C.
We also confirm that, the internship report is only prepared for fulfillment of internship time. It might not
be used with the interest of opposite party of cooperation. To the best of knowledge we didn’t breach any
copyright act intentionally. We would be happy to provide you with any clarification regarding the report.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
ACKNOWLEDGEMENT
First of all, we would like to thank the almighty GOD for giving everything that is important for us
to complete our internship program efficiently. Next we are thankful to our family for giving strength
with in financial and moral support. We would also like to thank Jimma University, Jimma Institute
of Technology for creating the internship program opportunity and our advisor Ms.Ebise G. for
helping and advising us during the internship program. We would also like to thank Rorank business
Share Company for giving chance to get in to the company & its workers and chemists who are very
willing to show us around and give their material and ideal support without hesitation. The people
we would like to thank the most from the company are Mr.Amare.A, Mr. Dereje.D, Mr.
Hailegebriel.G(Shift engineers). They were the most helpful.
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ABSTRACT
Rorank Alcohol and Liquor Factory (RALF) is a share company of foreign share- holders. The
factory was established in 2013 G.C in Amhara region, north shoa zone in debre birhan and uses
molasses as raw material for the production of potable and technical alcohols. It consists of a
distillery and filling plants. Its installed daily production capacity is 18,000 liters of potable alcohol
and about 5000 liters of various liquors. The current production capacity was found to be on
average 250 liters of 95 % alcohol grade technical alcohols per day when the factory was running
normally.
In fermentation material balance were employed so as to determine the amount of molasses and
water necessary to prepare one batch and then to determine the fermentation efficiency. In
distillation unit material balance were used to determine the amount of alcohol produced within
their alcohol grade in each column. The molasses, water and energy consumption were found. The
total alcohol loss from the fermentation, decantation and distillation process units was significant.
The stillage from analyzer column is found a severe source of water pollution.
The project was done on production of alcohol from fruit waste (Banana, orange mango). We
choose this title because of the alcohol production in RORANK BUSINESS SHARE COMPANY
is based on the raw material (molasses) that have been received from sugar factories’ there is no
sugar factories around the area and also the company spends a lot of money to receive and, to
transport molasses Even after receiving the raw material the molasses have a bad smell in the
environment and also the spent wash after fermentation couldn’t be disposed because of its color
and it also affects aquatic animals so as we observed the main challenge and problem of the
company is raw material.
So, the main aim of this project production and characterization of ethanol from fruit waste.
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Contents
ACKNOWLEDGEMENT .................................................................................................................................................. ii
ABSTRACT .................................................................................................................................................................... iii
LIST OF TABLES ............................................................................................................................................................ vi
LIST OF FIGURES .......................................................................................................................................................... vi
ABBREVIATIONS.......................................................................................................................................................... vii
CHAPTER ONE ............................................................................................................................................................... 1
1. INTRODUCTION ........................................................................................................................................................ 1
1.1 Historical Background ......................................................................................................................................... 1
1.2 Vision and mission of the factory...................................................................................................................... 2
1.3 Products of the company ................................................................................................................................... 2
1.4 Main customers or end users of its products or services ............................................................................. 3
1.5 Job organization and structure of the company................................................................................................. 3
1.6 Scope and Purpose of the Factory ...................................................................................................................... 6
CHAPTER TWO .............................................................................................................................................................. 7
2. GENERAL PROCESS OVERVIEW OF THE FACTORY .................................................................................................... 7
2.1 How we get into the company ........................................................................................................................... 7
2.2 Fermentation technology ................................................................................................................................... 8
2.3 Fermentation process (Methods) ..................................................................................................................... 11
2.4 Major process step in fermentation ................................................................................................................. 12
2.5 Stages of fermentation ..................................................................................................................................... 14
2.6 Fermentation process description ................................................................................................................... 15
2.7 Factor affecting fermentation process ............................................................................................................. 16
2.8 Equipment used................................................................................................................................................ 24
2.9 Distillery House ................................................................................................................................................. 25
2.10 Types of equipment ........................................................................................................................................ 26
2.11 Process description......................................................................................................................................... 28
2.12 Distillation column control ............................................................................................................................. 61
2.13 Liquor Preparation and Bottling House .......................................................................................................... 62
2.14 Evaporator and Drying House ........................................................................................................................ 67
2.15 Waste Water Treatment Plant and Water Treatment Plant .......................................................................... 71
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2.16 Water Treatment ............................................................................................................................................ 74
2.17 Challenges....................................................................................................................................................... 78
CHAPTER 3 .................................................................................................................................................................. 79
3. BENEFITS OF INTERNSHIP ....................................................................................................................................... 79
3.1 Benefits ............................................................................................................................................................. 79
CHAPTER 4 .................................................................................................................................................................. 82
4. PROJECT ON PRODUCTION OF ALCOHOL FROM FRUIT AND VEGETABLE WASTE ................................................. 82
4.1 Introduction ...................................................................................................................................................... 82
4.2 Statement of Problem ...................................................................................................................................... 82
4.3 Objectives of The Project.................................................................................................................................. 83
4.4 Scope ................................................................................................................................................................ 83
4.5 Methodology .................................................................................................................................................... 84
4.6 Experimental Procedure ................................................................................................................................... 85
4.7. Characterization of product ............................................................................................................................ 90
4.8 Material Balance ............................................................................................................................................... 91
4.9. Effect of Parameters On Ethanol Production .................................................................................................. 98
4.10 Conclusions and Recommendation .............................................................................................................. 100
REFERENCE ............................................................................................................................................................... 102
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LIST OF TABLES
Table 1 Dver all flow of distillation ............................................................................................................ 31
Table 2 Distillation columns operating temperature and pressure .............................................................. 61
Table 3 Ethanol yield and concentration ..................................................................................................... 97
Table 4 Optimum condition for different parameter on optimum yield of ethanol from experiment ......... 99
LIST OF FIGURES
Figure 1:Structure of the company ................................................................................................................ 4
Figure 2: Molasses ......................................................................................................................................... 8
Figure 3: Content of molasses ....................................................................................................................... 9
Figure 4: Decantation tank .......................................................................................................................... 29
Figure 6 flow sheet of distillation process ................................................................................................... 60
Figure 5: Bottle washer................................................................................................................................ 65
Figure 6: Bottling house .............................................................................................................................. 67
Figure 7: Waste Water treatment plant at Rorank S.C company................................................................. 74
Figure 8: Cooling tower ............................................................................................................................... 77
Figure 9: Fruit wastes .................................................................................................................................. 86
Figure 10: Autoclave ................................................................................................................................... 86
Figure 11: Media prepared .......................................................................................................................... 88
Figure 12: Simple distillation ...................................................................................................................... 89
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ABBREVIATIONS
BC Business Company
BOD Biochemical Oxygen Demand
CEO Chief executive officer
COD Chemical Oxygen Demand
COO Chief operating officers
DAP Di-ammonium phosphate
ED Extracted distilled
FD Fan distributor
ID Intermediate distribute
IST Intermediate settling thanks
o
Bx Degree Brix
PH power of hydrogen
RALF Rorank alcoholic liquor factory
RO Reverse osmosis
TSS Total Suspend Solids
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CHAPTER ONE
1. INTRODUCTION
1.1 Historical Background
Ethanol is a clear liquid alcohol group compound with a chemical formula CH3-CH2-OH and which is made by the
fermentation of different biological materials. It is a clear, colorless chemical compound made from the sugars
found in crops such as corn, sugar beets and sugarcane
Rorank liquors factory was located at Amhara regional state 113 km away from Addis Ababa city in the
northern Shewa Debre Birhan. The factory was established in 2013 G.C to fulfill domestic requirements
of alcohol and liquors.
This company start to produce alcoholic liquor in 2014G.C and starts with initial cost of 25 million Birr
and .Now day this company reached in cost of 358 million Birr. Rorank Alcohol and Liquor factory have
got a big investment to produce pure Alcohol.
The company also established newly modified plant in 2016G.C and normally start to work in 2016G.CThis
newly Rorank business share company liquor factory comprises six interconnected plants, Fermentation,
Distillery, evaporate, boiler, dryer and bottling plants. But the dryer and evaporator plants are not properly
in working duo to the lack of steam. The distillery plants, produces two types of products potable alcohol
and industrial (technical) alcohol. Pure (potable) alcohol is the primary raw material production of liquors
for local consumption whereas industrial (technical) alcohol was sold as denatured alcohol. .The raw
material used at this factory was molasses which is obtained from state owned sugar factory. Factories but
starting from last year the raw material has been changed to TA (technical alcohol) originated from
methera
Rorank liquor Factory (RALF) is a pioneer sole government owned state enterprise in manufacturing &
selling liquors and alcohol products in our country. Now a day the Company has 175 permanent, 40
temporary & 40 contract employees. This popular factory had been consistently mining a wealth of
experience in industrial production and marketing of pure alcohol, denatures alcohol a variety of liquors.
And thus, Company is currently working with the capacity (50,000) litters/day, of potable alcohol 96.3.0%
v/v.
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1.3.3 Liquors
Liquors are drinkable alcohol, which prepared in bottling house by mixing soft water, flavor, coloring,
sweetener or syrup and pure alcohol. In Rorank S.C there are different liquor products are produced. These
are given below
GIN
SUPERMINT
OUZO
DOUBLE OUZO
FERNET
VODKA
LEMON
WHITE APPRATIVE
COGNAC
RED APPRATIVE
PINE APPLE
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Chief Executive
Officer Chief operating officers are responsible for the management of a wide variety of departments in
a manufacturing business. The COO must be knowledgeable in the manufacturing operations and the
needs and capabilities of each department. In some manufacturing organizations, chief operating officers
are responsible for overseeing human resources, sales and other administrative departments in the
company. Chief operating officers must prepare reports for the CEO on the day-to-day activities in each
department. The reports should evaluate the performance of each department in a company, including
whether they met production goals and budgets. The COO and CEO work together to develop strategies
for each department's success. Chief operating officers allocate the resources department manager need,
such as funds, labor and equipment, to ensure they meet their goals. COOs conduct regular meetings
with department managers to remain up to date on the status of each area of the company. They might
also develop and implement department budgets.
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General Manager
General Managers usually have more responsibility than plant managers, with the biggest differences
being the teams they manage and profit-and-loss responsibility. A general manager usually has a greater
scope of management and responsibility than a plant manager. While a sole responsibility for running
the day-to-day operations of a manufacturing site, a general manager handles this role along with other
tasks, most notably, the profit and loss responsibility for his business segment. A general manager has
production supervisors reporting to him that spend time on the plant floor to keep the operations running
smoothly. While a general manager makes important operations decisions, he often manages other
aspects of the business, including sales, finances or supply chain.
Plant manager
Plant managers are the people who watch over and organize the daily operations of manufacturing plants
and similar places. Plant managers oversee employees, production and efficiency, to make sure the plant
is running smoothly, quickly, efficiently and safely.
Plant managers might oversee an entire location, or just a section of the operation. Plant managers
maintain optimum operation by assigning workers, creating and keeping work and production schedules,
hiring and training new employees, collecting and looking through data to find places of waste or places
of improvement, keep an eye on worker safety and plant safety, monitor the production equipment to
make sure that it stays in good working order, and repair or replace the equipment when needed. Plant
managers are the last line of defense for quality control when the item manufactured leaves the plant.
They communicate with other departments or parts of the plant to make sure everything runs smoothly.
A plant manager typically is responsible for the operations of a manufacturing plant. Although the sales
dollars for his plant may be a metric for success, he often does not have direct control over customer
orders and sales. Rather, he is more focused on operating the plant efficiently and ensuring that orders
are made and shipped on time.
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Operational manager
Leads day to day management of facility operations and maintenance, specifically activities associated
with quality, production, costs, capital expenditures, assets, and human capital development to ensure
productions goals are met in a safe and environmentally efficient manner Operational manager Lead
change and execute strategic priorities to meet business objectives. Develop direct reports through career
development, coaching and performance management to maximize effectiveness of resources
Collaborate with key business stakeholders to identify opportunities that will optimize and improve
facility performance engage leadership to achieve production/quality results that align with business
plans and standards.
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CHAPTER TWO
2. GENERAL PROCESS OVERVIEW OF THE FACTORY
In most countries where sugar factories are erected, molasses is the main profitable raw material due to its
high sugar content which can be decomposed to ethanol and carbon dioxide with the action of yeasts.
Ethanol plants can be erected simultaneously to these sugar factories or independently. In Rorank B.C
alcoholic factory molasses is the raw material for the source of this convertible sugar from which it is
received from Wonji Showa sugar factory. The other main raw material which involves from the beginning
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to the final process of beverage ethanol plant is water for which at the initial stage its application is for the
sake of molasses dilution. Molasses from the source is dense black raw material such that its solid content
is about 75-80 brix (the solid content of the solution by volume) with a specific gravity of 1.45-1.6. This
solidus raw material is impossible for fermentation process if dilution is not performed with water. This is
because that it will not be suitable for yeast movement during propagation as well in fermentation.
Therefore, water is essential at this stage. The amount of water needed depends on the initial brix of the
molasses, if the brix is less the water required will be small unless high.
The lightest and more diluted molasses supplied from sugar factory is at the state of high component of
convertible sugar which also requires a small amount of water for dilution. This phenomenon is called low
brix preparation or dilution process. Therefore, these characteristics of molasses enable to be effective cost
wise even if it may be more difficult for transportation process. The raw materials applied in ethanol plant
are urea, DAP, and yeast, sulphuric acid, essences (flavors), colorings, citric acid, white crystallized sugar.
The purpose of these raw materials can be summarized in the following graphic design.
Figure 2: Molasses
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Molasses is the dark, sweet, syrupy byproduct made during the extraction of sugars from sugarcane and
sugar beets. During the sugar-making process, juice extracted from sugarcane or sugar beets is boiled down
until the sugars crystallize and precipitate out. The syrup left over after crystallization is referred to as
molasses. Typically, sugar cane juice undergoes three cycles of boiling and crystallization to extract as
much sugar as possible. With each successive cycle, the leftover molasses contains less sugar.
content of molasess
sucrose 30-35
water 12-20
reducing sugar 10-15
ash 10-12
Molasses is a heavy viscose material which contains sucrose, fructose & glucose at a total concentration of
50 to 60% of which about 70% sucrose and 30% is invert. The color, taste and composition of molasses
vary with the stage of extraction. The impurities imparted to the molasses are from ash content and coloring
matter. The colors of final molasses is usually a dark brown or reddish brown, partially due to
caramelization of the sugar content and also due to chemical or thermal degradation of some of the non-
sugar constituents.
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2.2.2 Yeast
A microscopic single-celled fungus capable of converting sugar into alcohol and carbon dioxide. There are
two forms of active yeast the
The powdered yeast is about three time’s active than the moist one. When the temperature in the
fermentation tank has reached 25 to 30-degree Celsius se adjust the thermostat or light dimmer control to
hold it in this range.
Saccharomyces cerevisiae
Saccharomyces cerevisiae, also known as brewers or baker's yeast, has been a key ingredient in baking,
winemaking, and brewing for millennia. It derives its name from the Latinized Greek meaning “sugar
fungus” because it converts sugars and starches into alcohol and carbon dioxide during the fermentation
process.
Saccharomyces cerevisiae is a species of yeast. It has been instrumental to winemaking, baking, and
brewing since ancient times. It is the microorganism behind the most common type of fermentation. S.
cerevisiae cells are round to ovoid, 5–10 μm in diameter. It is reproduced by a division process known as
budding. The process in which it produces ethanol is one way this yeast converts glucose into energy.
There are two ways Saccharomyces cerevisiae breaks down glucose.
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✓ To restrict the production of bacteria & the movement of unwanted yeast & ready it for
fermentation.
✓ To make the good & comfortable yeast PH & quality
✓ To reduced unnecessary yeast that share the fermentation yeast used to ferment ale.
✓ Creates good environment for yeast & give good quality for alcohol
2.2.6 Water
In fermentation process water plays high role to dilute high molasses brix (78-85%) to the needed low brix.
Water is also used as a general cleaning. The nature of water to be used for producing alcohol is very
important. Its composition is very much dependent on the condition of soil. The dissolved matters influence
the production of alcohol thus the following points must be attentively controlled hardness of water, iron
content of water, manganese content of water, odor and taste of water.
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The inoculums should consist of a rich and active suspension of the most efficient type of yeasts for
the required purpose.
The inoculums to be used should have to be:
Abundant
Active
The inoculums should be abundant
Although a single yeast cell is able to produce millions of cells in a very short period of time, it is
essential to use abundant inoculums to ensure that the medium is quickly dominated by yeast. This
prevents competition from bacteria, which generally reproduces much faster than yeasts. Ideally the
inoculums added should be of sufficient quantity so as to provide the medium with the sufficient
number of yeasts.
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In the first stage of fermentation, some hours after pitching (addition of yeast) the time limit depending
on the amount and vigor of the yeast inoculums and the temperature. The dirt cover appears on the
surface of the mash surrounded by a ring of white foam on the periphery which gradually spreads over
the whole surface. This indicates the beginning of the fermentation and the carbon dioxide liberated in
the process holds the yeast in suspension.
The foam increases and becomes compact more resembling a cauliflower hence called cauliflower
stage. It is supported by the rising carbon dioxide set free in the fermentation. The gravity falls rapidly
with simultaneous quick rate of rise in temperature.
The third stage is marked by greatest activity showing the maximum multiplication of yeast, decrease
the gravity and rise in the temperature in which the foam reaches its maximum height.
This is followed by reduced activity of the yeast due to the exhaustion of the main part of the sugar.
The decreased liberation of carbon dioxide gas is not sufficient to support the high foam which begins
to collapse. The yeast agglomerates in lumps and sinks. Only a thin cover of fine foam remains on the
surface. The fermentation is now almost completed and marks the fifth stage of fermentation.
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completely fermented. This phenomenon is known as resting fermentation and may due to the weekend
condition or limited fermenting power of the yeast or sudden drop in the temperature of the mash. The
former can be remedied by adding fresh yeast and later by restoration of proper temperature.
2.5.2 Foaming
Excessive foaming is an undesirable feature which may be caused by number of factors, in particular
the characters of the mash itself. Rapidly fermenting yeast, low acidity, high fermentation temperature
and bacterial contamination are additional contributory causes. Foaming is rarely due to one single
cause. Selection of different strain of yeast, or addition of yeast containing a large proportion of old
cells, and lowering of the initial PH of the mash help in reducing foam. High foam can be made to
subside by the addition of fats, lard or oils.
When brix of the yeast propagation vessel falls to half of initial setup brix (which is around 8obrix) and
cell concentration and activity were reached to desired value, then this vessel is ready to transfer to the
fermenter.
Initially fermenter tanks are cleaned with water. All pipelines are cleaned. When fermenter is cleaned,
the dilute molasses with high brix feed of desired brix to fermenter particularly 25o-28o brix is started.
20%level of dilute molasses in fermenter was filled. The Yeast culture (propagated yeast) from
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propagation tank was transfer to the fermenters. After transferring the Yeast culture (propagated yeast)
after waiting for 30 minutes to 1.0 hr. feeding dilute molasses of desired brix was started to the
fermenter and when level of fermenter is 80% the dilute molasses feed to the fermenter was stopped.
The volume of fermentation tank is 232,000 litters.
After that the following activity was done. Foaming maintained by spraying antifoam. No excess
amount of antifoam should add to fermenter as excess antifoam will form a covering layer around the
yeast cell and restrict the yeast activity. Fall of brix, PH, temperature and alcohol percentage was record
every two hours in lab analysis log book. Record was checked by shift chemist to take the corrective
action.
Maintain the pH of fermenter up to 4.5 to 5. Low PH will indicate the formation of by- product. To
increase the PH, dilute ammonia can be used. High PH will indicate the decrease in yeast activity. By
adding dilute H2SO4, PH can be maintained. Retention time of fermenter depends upon the quality of
molasses, yeast activity and maintain the parameters. Once the fall of brix remain constant for 4.0 hrs.
It assumed that fermentation is completed.
This fermented wash (tela) will be transferred to decanters so as avoid the sludge transfer to the
distillation column. After transfer of fermented wash to decanters was completed, cleaning of the
fermenter as said above was done to keep ready for next batch fermentation.
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2.7.1 Temperature
As the fermentation progresses, the temperature of the wash tends to rise because the reactions taking
place are exothermic. Cooling units are required to prevent the temperature from exceeding 30-32 0C.
Anomalies in the temperature curve imply the presence of fermentation irregularities. Hence, a very
slow rise in temperature points to the deficiencies in the Inoculums (insufficient inoculums, infection,
lack of adaptation to the medium on the part of the yeast), while too rapid a rise indicates that the wash
is excessively rich in sugar or that the initial temperature of the wash was too high
Using in the laboratory test to dilute 0.135 Litter of raw molasses to reduce 140BX from 760BX we use
0.865L of water. So, by using the above laboratorial scale we can determine the overall water and
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molasses content in the dilution tank for low brix. 0.135L of raw molasses + 0.865L of water = 1 L of
dilute molasses. For law brix we use 40,000 L of dilute molasses solution in large yeast propagation
tank
𝑋 = (0.135𝐿 ∗ 40000𝐿)/ 1
𝑋
= 5,400 𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑎𝑟𝑒 𝑢𝑠𝑒𝑑 𝑓𝑜𝑟 𝑙𝑜𝑤 𝑏𝑟𝑖𝑥 𝑝𝑟𝑒𝑝𝑎𝑟𝑎𝑡𝑖𝑜𝑛 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑢𝑠𝑒𝑑 𝑖𝑛 𝑙𝑎𝑟𝑔𝑒 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑖𝑜𝑛 𝑡𝑎𝑛𝑘.
𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
= 34600 𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟. 𝑆𝑜, 𝑡𝑜 𝑑𝑖𝑙𝑢𝑡𝑒 5400𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑤𝑒 𝑢𝑠𝑒 34600 𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
𝑤𝑎𝑡𝑒𝑟 = 34600𝐿
Low brix
Raw molasses=5400L dilutio n ta nk 𝐷𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 =?
Now we have to convert the above volume values into its appropriate mass
𝑀𝑤 = 𝑉𝑊 ∗ 𝜌
1000kg/m3 = 1kg/L
𝑀𝑤 = 34600𝐿 ∗ 1𝑘𝑔/𝐿
Mw = 34600kg of water
𝑀 𝑖𝑛 = 𝑀𝑜𝑢𝑡
𝑀 𝑤 + 𝑀𝑚 = 𝐷𝑀
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Final internship report (RORANK BUSINESS SHARE COMPANY)
42430kg of low brix dilute molasses are added in the propagation tank and 8kg of raw yeast, 8kg of
DAP ,and 8kg of urea are added in the propagation tank to propagate the yeast
Total diluted molasses which is add into the propagation tank
(Mt) is 42430Kg
Yeast(y)=8kg
Assumption:
There is no accumulation, generation, disappearance of mass and consumption of mass no addition
of H2SO4,
𝑀𝑖𝑛 = 𝑀 𝑜𝑢𝑡
𝑀𝑡 + 𝐷𝐴𝑃 + 𝑈 = 𝑃𝑌
𝑃𝑌 = {42430 + 8 + 8 + 8} 𝑘𝑔
Using in the laboratory test to dilute 1.2 Litter of raw molasses high brix the concentration of sugar
from 25-280brix we use 3.8L of water. We can determine the overall molasses and water content in the
high brix dilution.
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𝑀𝑚 = 𝑉𝑀 ∗ 𝜌𝑀
Mm = VM* ρ M Mm =
45,600𝐿 ∗ 1.45𝑘𝑔/𝐿
𝑀𝑚 = 66,120𝑘𝑔 𝑜𝑓 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠.
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𝑀𝑤 = 𝑉𝑊 ∗ 𝜌𝑊
𝑀𝑤 = 𝑉𝑊 ∗ 𝜌𝑊
𝑀𝑤 = 144,400𝐿 ∗ 1𝑘𝑔/𝐿
Mw = 144,400kg of water
𝑊 + 𝑀 = 𝐷𝑀
144,400𝑘𝑔 + 66,120𝑘𝑔 = 𝐷𝑀
𝐷𝑀 =
42,454kg of propagated yeast and 210,520kg of high brix dilute molasses are added in the fermentation
tank for the preparation of wine (fermented mash)
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Accumulation
To calculate the volume of accumulation first determine the radius of cylinder the total volume of
fermentation tank (Vft) is 230,000L (230M3)
𝑉𝑓𝑘 = 𝜋𝑟2𝐿
230𝑚3
= 9 ∗ 3.14 ∗ 𝑟2 𝑟2
= 8.13𝑚2 𝑟 = 2.85𝑚
𝑉𝐴 = 𝜋 ∗ 𝑟2ℎ
The density of accumulated fermented wine is 0 .979kg/L, so the mass of accumulation is given by
𝑀𝐴 = 𝑉𝐴 ∗ 𝜌 𝐴
𝑀𝐴 = 6376.16𝐿 ∗ 0.979𝑘𝑔/𝐿
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Final internship report (RORANK BUSINESS SHARE COMPANY)
𝑀𝐴 = 6,242.6𝑘𝑔 𝑜𝑓 𝑎𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛
𝐹𝑀 = (𝐷𝑀 + 𝑃𝑌) − 𝑀𝐴
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Distillation is used for the separation or purification of mixtures of alcohol and water by using the
different evaporation rates, or boiling points, of the water and the alcohol. As alcohol evaporates at a
lower temperature, it vaporizes first and, therefore, its separation will start before the water evaporates.
The fermented mash (tela) may contain a number of other components such as essential oils, esters,
carbon dioxide and other alcohols such as methyl, propyl, butyl and amyl. All of these components are
undesirable or undrinkable and must be substantially removed from the mixture. This process involves
dividing tela into a number of parts depending on when that part is produced during the distillation
process. These parts may be separated during the initial distillation process or during a re-distillation
of alcohols by diluting with pure water (spirits from the first distillation run). Rorank BC has special
distillation columns like degasifying, analyzer, aldehyde, extractive distillation, stainless steel, copper
and methanol column to undergo distillation and re-distillation process in order to remove such
impurities and to have very pure potable alcohol. The first components that are produced during
distillation are known as heads. Heads are the highly volatile components with a lower boiling point
than ethanol. The heads vaporize first and therefore condense first. Heads consist mainly of low
molecular weight material or highly volatile compounds. Heads may contain a number of poisonous
components, including high levels of methanol, which can be hazardous to health. Usually, the heads
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Final internship report (RORANK BUSINESS SHARE COMPANY)
are not desired in the finished product and are run to a different receiver from the rest of the alcohol.
Once all the heads have been removed the pure alcohol transferred in to pure alcohol storage tank.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
4. Tank
There are basically two types of tank these are decantation tank and storage tank Decantation tank used
to store fermented tela until the sludge separate from its wine. And it used to store fermented tela.
Storage tank used to store liquid like; katikala (raw alcohol), pure alcohol denature alcohol and so on.
5. Valves
Valves are used to control flow rate of tela, raw alcohol, steam, cooling water and etc. in this plant
basically there are four types valve, and these are:
a) Gate valve: the gate valve is a general service valve used primarily for on-off, non-throttling
service. The valve is closed by a flat face, vertical disc, or gate that slides down through the
valve to block the flow. Gate valves working by inserting a dam (“gate”) in to the path of the
flow to restrict it, in a manner similar to the action of a sliding door. Gate valves are more often
used for on/off control than throttling.
b) Butterfly valve: is a valve which can be used for isolating or regulating flow. The closing
mechanism takes the form of the disk.
c) Check valve: check valves are two port valves, meaning they have two opening in the body,
one for fluid to enter, and the other for fluid to leave. Check valve allows the fluids to pass in
one direction only. Although they are available in a wide range of sizes and costs, check valves
generally are very small, simple, or in expensive. Check valves works automatically and most
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Final internship report (RORANK BUSINESS SHARE COMPANY)
are not controlled by a person or any external control; accordingly, most do not have any valve
handle or stem. The important concept in check valve is the cracking pressure which is the
minimum upstream at which the valve will operate.
6. Sensors
The function of sensor is to detect the change in the required parameter. The parameter which is
controlled by this device in distillation house is temperature.
8. Alcohol meter
Alcohol meter is used to measure the grade quality of alcohol or concentration in the mixture.
First stage, in which katikala produced from fermented tela. In this stage there are three
columns, these are; degasifying column, analyzing column and aldehyde column.
Second stage, in this stage the process is the production of pure alcohol from katikala, in this
stage process pass through four column and these are; extractive distillation column, stainless
steel column, copper column and methanol column.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
After decantation process takes place, the separated tela will heated around 70-80oc by passing through
copper main condenser shell side to condense the vapor coming from the copper columns, which is in
tube side. And if the tela attain the temperature in between 70-80oC it introduced into degasifying
column, unless it is heated by spent wash that comes from analyzing column then return back and enters
in to degasifying one. And the type of heat exchanger is plate.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
B. Degasifying column
Degasification is the removal of dissolved gases from liquids. The heated tela from the heat exchanger
transported through flow meter to degasifying column, the degassing capacity is about
15,000 lit per hour, but the factory don’t work always with this flow rate i.e. the working flow rate of
degasifying column depend on different factor like weather and steam generation capacity, tela
concentration in decanter tank and the market demand.
Degasifying column used to remove chemical which has smell and chemicals which can’t condense
easily like carbon dioxide (co2). Degasifying column operated by feed temperature i.e. there is no heat
(steam) addition. Alcohol feed concentration is around 8-12% and the rest is more water and the
mixture boiling point is near to water boiling point temperature. So at this feed temperature, unwanted
chemicals will escape through degassing vent line.
The degassing vapor products will pass through heat exchanger to cool down and the condensed
chemicals store in degassing head storage and the un-condensed vapor will released as a degassing
vent. The degasified tela leaves from the bottom of this column send to analyzer column by making a
loop. In this factory degassing head flow rate around 5 liters per hour and degassing vent temperature
is 20-260C.
N.B. since there is no flow meter and concentration sensor around degassing vent line, so we don’t
know its flow rate or concentration.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
The fermented mash or wine of 242,266.77kg is inter into the degasifying column in a volume flow
rate of 12000L/h and 50L/h of degasifying vent are collected, and the mass of fermented mash are
244,972kg
Degasifying head=50L/h
Degasifying column
Change the volumetric flow rate into mass flow rate Mass of fermented mash
𝐹𝑚 = 𝑉𝑚 ∗ 𝐷𝑚
𝐹𝐷 = 0.979𝑘𝑔/𝐿
𝐹𝑚 = 12000𝐿/ℎ ∗ 0.979𝐾𝑔/𝐿
Fm=11748Kg/hr.
𝑀 𝑑 = 𝐷𝑑 ∗ 𝑉𝑑
= 0.84𝐾𝑔/𝐿
𝑀𝑑 = 50𝐿/ℎ ∗ 0.84𝐾𝑔/𝐿
𝑀𝑑 = 42𝐾𝑔/ℎ
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Final internship report (RORANK BUSINESS SHARE COMPANY)
ρw is density of water
ρa is density of alcohol
The degasifying head contains 70% of alcohol and 30% of water. the material balance in a degasifying
column is calculated as shown below
𝐹𝑚 = 𝑀𝑑 + 𝐴𝑡
C. Analyzing column
It consists of a series of metal plates with hole punched in them and baffles to control the liquid levels
on the plates. The analyzer column operated under a temperature of 88-9000C and pressure of 180-300
mbar.
It is a tray type distillation column which contain sieve tray with two down comers in one side. Since
there might be a scale formation in this column tray type is preferable rather than packed type. In the
fermentation process there is a formation of cas Of from the addition of sulphuric acid in the molasses
which contain calcium ion. This calcium sulphate forms a scale when heat is supplied in the analyzer
column.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
The degasified tela introduced from side of this column falls through the down comers by gravity from
one tray to another. Heat in the form of steam supplied to the base of the column and rises via the
openings on each tray. As the steam passes through the feed on the tray, it transfers heat
to the feed. Because of the heat input from the steam the liquid on the tray boils generating vapor which
is richer in the more volatile component.
The continuous contacting between steam and liquid occurs on each tray brings about the separation
between alcoholic component with low boiling point and the spent wash(nonalcoholic component)with
higher boiling point. Some amount of alcohol together with steam might leave with spent wash.
In order to trap these steam the spent wash water is send to 6 meter underground with larger tube and
hits the ground this made the steam to be released and send to the lower side of the analyzing column
through the pipe. Steam free spent wash water returned with a narrower tube with increased pressure
to preheat the fermented wine. The increased pressure reduces the fouling formation in the plate heat
exchanger. The vapor leaves through the top of analyzing Column with improved alcoholic grade is sent
to aldehyde for further purification. If there is an alcohol in the spent wash this might be caused by sufficient
steam is not supplied or excessive fermented wash is supplied to the column.
The other problem shown in this column is flooding. Which occurs as the vapor flow is higher
compared to liquid flow so liquid is unable to comes down through down comers and also by
simultaneousincreaseofbottompressureandthedecreaseoftoppressureduetoabnormalliquid buildup of
scale on tray and the feed rate is more than vapor flow rate.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Analyzer column is designed to handle a dirty liquid liable to foam and is fitted with man doors for
cleaning purposes.
D. Aldehyde column
Aldehyde column is the last tower in the first stage process, and in this process our desire is to produce
raw alcohol (katikala). It is a packed type column operates under a temperature of 74- 760c and a
pressure of 100mbar. It is used to separate highly volatile low boiling point components.
The vapor which leaves the analyzer column enters in to lower side of the aldehyde column. The more
volatile component rises into the overhead two consecutive heat exchangers.
The vapors which do not condense in the first pass to the next heat exchanger. The non- condensing
gas leaves off as aT5vent from the last heat exchanger. The condensing vaporing the two heat
exchangers Aldehyde heads 1, amounting to about 100L/h, is drawn off from the two heat exchanger
reflux loop and refluxed back to the column. The raw alcohol portion of the feed tends to go down the
column.
The product coming from this column is called raw alcohols (katikala) with alcohol grade 35- 50%v/v.
It passes through plate type heat exchanger to be cooled and stored in the shift tanker.
Mass Balance for the Analyzer and aldehyde column.
The fermented mash or wine which leave from the degasifying column and entered into the analyzer
column in a mass flow rate of 14,680.8Kg/hr. consequently the vapor which leaves from the analyzer
entered into Aldehyde column. The aldehyde head leaves with the flow rate of 50 L/hr. and also
vinasses are removed as by product as shown below.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Aldehyde aldehyde
head=50L/hr
Alcohol(Xm)=0.08 Katikala=2000L/h
vinasses(Fv)
alcohol(Xk)=0.58
Change the volumetric flow rate of aldehyde head into mass flow rate.
Because in the aldehyde alcohol 95% alcohol and 5% of water that means it is a solution of alcohol and
water.
and volume flow rate of aldehyde head is 50L/h ṁAA = VAA *ρ A.A ṁAA = 50 L/hr. * 0.797kg/L ṁAA
Fm= MAA+Fk+Fv
Component balance:
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Fk = 1,346.24Kg/h
11748Kg/h=39.85Kg/h+1,346.24Kg/h +Fv
Fv =10361.9Kg/h
To determine the mass flow rate of vaporized alcohol we can do material balance on analyzer column.
Fermented mash=11706kg/h
analyzer
alcohol(Xm)=0.08 column VA=?
vinasse(Fv)
Fv=10,116.8kg/hr
Therefore, the mass balance in the analyzer is Assume, in the analyzer there is no accumulation,
generation and disappearance of mass.
M Fm= + M VA +MF V
MVA = M Fm-MFv
MVA = 1386.1kg/h
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Final internship report (RORANK BUSINESS SHARE COMPANY)
QSF Qu
column
QST QSV
Where
QSF=the rate of sensible heat of the feed
QST=the rate of heat energy supplied to the
QSV= the rate of sensible heat of heat of vaporized alcohol
QVA= the rate of both sensible and latent heat of vaporized alcohol
Assumption
Heat loss in the column is negligible.
The energy for each tray is the same.
There is no chemical reaction inside the column.
The operation is operated at steady state.
The fermented mash is a mixture of water and alcohol.
Given information
CpF =4.06KJ/kg k
QF = 3,039,806.45KJ/h
QF=ṁ F CpF ∆T
Where
CpF =4.06KJ/kg k
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Final internship report (RORANK BUSINESS SHARE COMPANY)
CpF =4.06KJ/kg k
QS = ṁ VA*C PVA * ∆T
XW= 0.45
C PVA = XACpA+XwCpw
QS = ṁ VA*C PVA * ∆T
QL = ṁ VA * h VA
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Final internship report (RORANK BUSINESS SHARE COMPANY)
The solvent interacts differently with the components of the mixture there by causing the irrelative
volatilities to change. Extractive distillation column is a packed type column operated at a temperature
of 132-137oc and a pressure of 2.8-3 bars. The raw alcohol which stored in a shift tanker pumped and
preheated by heat exchanger passes through the flow meter and fed into ED column. Hot water comes
from stain less steel rectification column which use data solvent passes through heat exchanger. It
enters into the column at some height above the raw alcohol for showering purpose. Steam comes from
the re-boiler introduced into the lower side of the column. It used to separate a high boiling component
from the non-volatile. The component with the greatest volatility separates out as the top and enters
into the condenser. The vapor with a temperature of 132-1370c condenses by the water from the
stainless-steel column (T=70oc), then the water recycled back to the stainless-steel column as re-boiler.
Head 3 is collected 100L/h from the condenser then passes through heat exchanger and stored in the
tanker. The rest refluxed back to the top side of the column near the hot water. The bottom product
consists of a mixture of the solvent and the other component that is 6-8%v/v diluted alcohol, which can
again be separated easily because the solvent doesn’t form an azeotrope with it. The diluted alcohol
enters into the re-boiler and passes through the steam trap. The steam trap holds the steam and allows
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Final internship report (RORANK BUSINESS SHARE COMPANY)
the condensate to be discharged then pass through the Heat exchanger. Both the raw alcohol from the
shift tanker and the hot water from the stainless-steel column preheated by the 6-8%v/v diluted alcohol
in the heat exchanger. The diluted alcohol enters into stainless steel rectification column.
Katikala alcohol entered into the extraction distillation column in a volumetric flow rate of 2000L/h
with in 4000L/h of water to produce dilute alcohol and 100L/h of head 3.
Water(W)4000L/hr Head3=100L/hr
Katikala alcohol(KA)
ED column
Vka=2000L/hr dilute alcohol=?
The change above volume flow rate into mass flow rate to calculate the mass balance katikala alcohol
flow rate is
ṁ𝐾𝐴 = 𝑉𝐾𝐴 ∗ 𝜌 𝐾𝐴
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Final internship report (RORANK BUSINESS SHARE COMPANY)
𝑋𝐴/ 𝜌 A
ṁ𝐻 = 𝑉𝐻 ∗ 𝜌 𝐻 ṁ𝐻
= 100𝐿/ℎ
∗ 0.8423𝑘𝑔/𝐿
𝑆𝑜, 𝐻 = 84.23𝑘𝑔/ℎ
Katicala alcohol
ED column
Vka=1698kg/hr Dilute alcohol=?
Assume there is no generation, disappearance and accumulations of mass in the extraction distillation.
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Final internship report (RORANK BUSINESS SHARE COMPANY)
= ṁ𝐾𝐴 + ṁ 𝑊 − ṁ 𝐻 ṁ𝐷𝐴
= 1698𝑘𝑔/ℎ + 4000𝑘𝑔/ℎ
− 84.23𝑘𝑔/ℎ ṁ𝐷𝐴
= 5613.77 𝑘𝑔/ℎ
Assumption
The temperature of hot water before entering into the ED column 780c
Where:
QS = The rate of heat energy supplied to the ED column in the form of steam
QD =the rate of both latent heat + sensible heat of energy of Dilute vaporized alcohol
𝑄𝑊 = ṁ 𝑊 ∗ 𝐶𝑃𝑊 ∗ ∆𝑇
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Energy on the Dilute vaporized alcohol (8%) alcohol content and 92% water
QS = ṁ DA*CPDA*∆T
𝐶𝑃𝐷𝐴 = 4.06𝐾𝐽/𝐾𝑔 𝑘
𝑄𝑠 = 2,407,395.2𝐾𝐽/ℎ𝑟
𝑄𝐿 = ṁ 𝐷𝐴 (𝑋𝐴 ℎ 𝐴 + 𝑋𝑊 ℎ 𝑊)
𝑄𝐿 = 23, 981,136.9𝐾𝐽/ℎ𝑟
𝑄𝐷𝑎 = 𝑄𝐿 + 𝑄𝑠
𝑄 ℎ 𝑊 + 𝑄𝑆 = 𝑄𝐷𝐴
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Final internship report (RORANK BUSINESS SHARE COMPANY)
𝑄𝑆 = 𝑄𝐷𝐴 − 𝑄 ℎ 𝑊
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Fusel oil(Fo)=70L/hr.
Lightoil(LO)=70L/hr.
Copper main&vent=70L/hr.
Lease water(Lw)
Before calculating the mass balance, we should to be change every volume flow rate to mass flow
rate.
V' = 70𝐿/
𝜌 ∗ 𝑣′
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Final internship report (RORANK BUSINESS SHARE COMPANY)
density of water.
ρW=1000kg/m3 XW = 30%
= 0.3 XA = 70% = 0.7
ρA=789kg/m3
So 1/𝜌 𝐿𝑂 = 0.7/0.789𝑘𝑔/𝐿 ∗
58.961𝑘𝑔/ℎ𝑟
ṁ𝐹𝑂 = 𝑉′𝐹𝑂 ∗ 𝜌 𝐹𝑂
Where: ṁFO= mass flow rate of fusel oil V'FO =
volume flow rate of fusel oil
ρFO =density of fusel oil
VFO = 70L/h
But density of fusel oil can be calculated as
1/ 𝜌 𝐹𝑂 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/ 𝜌 𝑊
Where XA= 0.7 XW = 0.3 ρW
=1000kg/m3 = 1kg/L
𝑉′𝐹𝑂 ∗ 𝜌 𝐹𝑂
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Final internship report (RORANK BUSINESS SHARE COMPANY)
Mfo=58.961kg/hr
MLO=58.961kg/hr Mc(m&c)=39.85kg/hr
DA=5613.77kg/hr
Copper
Mw=4000kg/hr SS column column Mpa=512.85kg/hr
Lease water(W)
Assumption
There is no accumulation generation and generation consumption of mass
The operation is steady state
Over all mass balance
𝐷𝐴 = 𝐿𝑜 + 𝐹 𝑜 + 𝑊 + 𝐻𝑊
Where DA = Dilute alcohol
LO = light oil
W = water
FO = Fusel oil
𝐷𝐴 = 𝐿𝑜 + 𝐹 𝑜 + 𝑊 + 𝐻𝑊
5613.77 = 58.961 + 58.961 + 4000 + 𝑊
W=1495.848kg/h of hot water are removed from the stain less steel column
Lease water =1495.85kg/h
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Final internship report (RORANK BUSINESS SHARE COMPANY)
QVA
QF
SS.colum
n
QLw
steam( Qs)
𝑄𝑆 = ṁ 𝑉𝐴 𝐶𝑝𝑉𝐴∆𝑇
= ṁ (𝑋𝐴𝐶𝑃𝐴 + 𝑋𝑊𝐶𝑃𝑊) ∆𝑇
596.5𝑘𝐺 ((0.8 ∗ 2.46 + 0.2 ∗ 4.2) 𝑘𝐽\𝑘 (80 − 75)) 𝑘
𝑄𝑠 = 8374.312𝑘𝐽
𝐿𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 (𝑄𝐿)
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Final internship report (RORANK BUSINESS SHARE COMPANY)
𝑄𝐿 = ṁ 𝑉𝐴 (𝑋𝐴 ℎ 𝐴 + 𝑋𝑊 ℎ)
𝑄𝐿 = 596.5𝑘𝑔/ℎ (0.8 ∗ 838.3 + 0.2 ∗ 2257)𝑘𝐽/𝑘𝑔
𝑄𝐿 = 668031.9𝑘𝐽/ℎ
QVA = QS+QL
𝑄𝑉𝐴 = 8374.314𝑘𝐽/ℎ + 668031.9𝑘𝐽/ℎ
𝑄𝑉𝐴 = 676406.21𝑘𝐽/ℎ
Energy in the lease water (sensible heat energy)
𝑄𝐿𝑊 = ṁ 𝐶𝑝∆𝑇
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Final internship report (RORANK BUSINESS SHARE COMPANY)
450mbar.Itused to upgrade the concentration of more volatile component and it also used to separate
methanol from the mixture.
In this column the latent heat available increases the alcohol concentration as the vapor rise. Vapor
leaving from the top of the column feed in to the main condenser to condense and the rest which
couldn’t condense in the main condenser passes through vent condenser for further condensation to
prevent vapor loss.
The incoming water from the cooling tower used as a cooling fluid in the condenser. Then vapor which
couldn’t condense in the two condensers released to atmosphere as vent. Then 40l\hr. of heads 2 main
and 40l\hr. heads 2 vents is collected from the reflux loop and collected in a denature tank after passing
through heat exchanger, while large fraction refluxed(re-circulated) into the top of the column to
control the final concentration of the product output. This reflux flow is required to produce a down
ward flowing liquid stream in the section of the column. Without the reflux stream, there can be liquid
in the rectifying section of the column, which means no separation would occur in the rectifying
section. The condensate with low grade of alcohol pumped from the lower side of this column to the
upper side of stripping column by feint pump to strengthen its alcoholic content. The product coming
from this column transported in to methanol column.
The upper part of the column is made up of copper. Copper is preferable because it improve the quality
and taste of the alcohol by reacting with sulphate ion and form copper sulphate.
V'CV = volume flow rate of copper vent ρCV = density of copper vent
Where: - ṁCV = mass flow rate of copper vent vent can be calculated
1/ 𝜌 𝐶𝑉 = 𝑋𝐴 / 𝜌 𝐴 + 𝑋𝑊 / 𝜌 𝑊
Where XA = 0.95
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Final internship report (RORANK BUSINESS SHARE COMPANY)
XW = 0.05
ṁ𝐶𝑉 = 𝑉′𝐶𝑉 ∗ 𝜌 𝐶𝑉 ṁ𝐶𝑉 = 50𝐿/ℎ ∗ 0.797 𝑘𝑔/𝐿 ṁ𝐶𝑉 = 39.85 𝑘𝑔/ℎ 𝜌𝑃𝐴
= 0.795𝐾𝑔/𝐿
𝑉𝐶𝑚 = 50𝐿/ℎ 𝜌𝐶𝑚 = 𝜌𝐶𝑉 = 0.797𝑘𝑔/𝐿 𝑇ℎ𝑒𝑛 ṁ𝑐𝑚 = 50𝐿/ℎ ∗ 0.797𝑘𝑔/𝐿 ṁ𝑐𝑚
= 39.85𝑘𝑔/𝐿
0.795𝐾𝑔/𝐿
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Final internship report (RORANK BUSINESS SHARE COMPANY)
𝑉𝐴 = 𝐶𝑉 + 𝐶𝑀 + 𝑃𝑎, 𝑉𝐴 = (39.85
D. Methanol column
It is a packed type column operate under a temperature of 68-70oc and pressure of 300-400mbar. And
it is used to separate methanol from the product since it is hazardous to health during drinking.
Methanol causes eye defect unless it is separated and removed from the produced alcohol. Unlike the
other columns the heat (steam) don’t supplied directly but it gains indirectly by using shell and tube
heat exchanger. The alcohol coming from copper column enters in tube side and steam in shell side
then the heated alcohol enters in to methanol column.
The more volatile component (methanol) rise in to the overhead two consecutive heat exchangers. The
vapors which do not condense in the first heat exchanger pass to the next one. The non-condensing gas
leaves off as a methanol vent from the last heat exchanger. The condensing vapor in the two heat
exchangers methanol head, amounting about 100 liters per hour, is drawn off from the two-heat
exchanger reflux loop and refluxed back to the column.
The product coming from this column which is pure alcohol having 96.8%v\v alcohol grade collected
at the lower side of the column and stored in pure alcohol storage tank. The following table shows
operating temperature and pressure range
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Final internship report (RORANK BUSINESS SHARE COMPANY)
When the pure ethanol has some amount of methanol then to separate methanol from ethanol the
products are entered into methanol column. In this column the input flow rate is not known
Pa=? PA=816.5L/hr.
methanol head(MH)=50L/hr.
methanol head
VMH = 60L/hr
1/ 𝜌 𝑀𝐻 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/ 𝜌 𝑊
XW = 0.037
1/ 𝜌 𝑀𝐻 = 0.963/0.789 + 0.037/1
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Final internship report (RORANK BUSINESS SHARE COMPANY)
1 𝐿
𝜌 𝑀𝐻 = 0.795 𝜌𝑊
ℎ
0.789𝑘𝑔
= ṁ𝑀𝐻
𝐿
= 𝑉 ′ 𝑀𝐻 𝜌 𝑀𝐻 ṁ𝑀𝐻
60𝐿 𝑘𝑔
= ∗ 0.795
ℎ 𝐿
ṁ𝑀𝐻 = 47.7𝑘𝑔/ℎ𝑟
Where
1/ 𝜌 𝑀𝐻 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/ 𝜌 𝑊
XW = 0.037
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Assumption
Where
The concentration of alcohol which leaves from the methanol column is 96.5% The energy of feed is
negligible
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Where
QhPA is the rate of both sensible and latent heat energy of vaporized alcohol which is exited from
methanol column.
QS Is the rate of heat energy supplied to the column in the form of steam.
𝑄𝑠 = 2788𝑘𝐽
𝑄𝐿 = ṁ 𝑉𝐴 ℎ 𝑉𝐴
𝑄𝐿 = ṁ 𝑉𝐴 (𝑋𝐴 ℎ 𝐴 + 𝑋𝑊 𝐻𝑊)
𝑄𝐿 = 669240.758𝑘𝐽/ℎ
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𝑄ℎ𝑃𝐴 = 𝑄𝑆 + 𝑄𝐿
𝑄ℎ𝑃𝐴 = 672028.821𝑘𝐽/ℎ
𝑄𝑠 = 𝑄 ℎ 𝑃𝐴 = 𝑄 𝐶𝑃𝐴 = 672028.82𝑘𝐽/ℎ
𝑄ℎ = ṁ 𝐶𝑝∆𝑇 ṁ = 𝑄
ℎ𝑃𝐴/𝐶𝑝∆𝑇
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Aldehyde 7o-72 -
Copper 72-74 -
Rorank S.C alcohol and liquor do not only produce pure alcohol but also denature alcohol. Denature
alcohol production start at extractive distillation in to methanol column
The feed material for this process are aldehyde heads product i.e. head one, ED condenser head
i.e. heads three, light oil, and fuel oil. The copper “condensers heads product i.e. main head and vent
head store as denature alcohol in denature storage tank.
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Bottling is the final unit operation for most alcoholic beverages like beer wine, whisky and so on which
produced bottled drinks. In rorank the bottles used are glass. The bottling section mainly contains
blending and packaging room. In blending room, the ethanol, syrup, raw water color and flavor are
mixed in the mixing thank to produce desired liquor while in packaging room washing, felling,
labelling is done.
Equipment used in packaging room are washer, sighter, packer, filler and conveyer.
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Alcohol holding tank: this tank holds alcohol that are transported from distillery section with
concentration of 96.1-96.8 percent. There are two alcohol holding tanks with capacity of holding 10000
and 11000 litter.
Syrup holding tank: this type of tank holds dissolved sugar in water that is heated at 65 degrees
Celsius and mixed in syrup mixing tank.
Mixing tank: as a name indicates in this tank all the raw materials are mixed. Distilled alcohol, flavor,
Row water, color and syrup are well mixed in this section.
Syrup mixing tank: In this type of tank sugar and water are mixed at the
Liquor holding tank: this type of tank holds liquor that comes from mixing tank and are filtered in
filter sheet.
In bottling we use 4 types of conveyors. These are roller, chain, belt and air conveyor.
First the distilled alcohol from distillery with alcohol concentration 96.3-96.5 is transported to alcohol
holding tank. Then a sufficient amount of alcohol can be transferred from holding tank to mixing tank
for blending purpose. This alcohol will be mixed in the mixing tank with syrup, water, color, and
flavors.
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Syrup Preparation
Syrup is a thick viscous liquid consisting primarily of a solution of sugar and water containing a large
amount of dissolved sugar. Syrup is prepared by mixing the sugar and water in the syrup mixing tank
by applying steam temperature at 650C.
The main components in this factory for process are sugar and RO (reverse osmosis) water. Before
proceeding, make sure that the syrup preparation tank has properly cleaned. It has to be cleaned by soft
water. Then the syrup preparation tank has filled with RO water. The reason that we use RO water is
to avoid side reactions. Then steam inters from the top to boil the water. Then the sugar is transfer from
the sugar tank to the syrup preparation tank using a pump. After waiting a few minutes until the sugar
is dissolved add some amount citric acid in order to prevent bacteria formation, other contaminants and
uses as preservation.
Finally, the prepared syrup passes in to a PHE to get cooled and filter press for clarity. Then the syrup
passes in to syrup holding tank.
Blending process
Raw materials that used in blending process are pure alcohol, color, raw water, syrup sugar and flavor.
Equipment used in blending room are holding Tanks, Filter paper and filter, pipe, mixing, filter bag
valve, pump
Blending process is a process in which two or more materials have mixed properly to produce liquor.
It is the main process in bottling room, which takes place in mixing tank. The mixing tank has a mixer
inside it. After the mixing tank has cleaned, about 96.1% alcohol of ethanol is poured to tank. Then
add some amount of RO water, flavor, and color.
At the end add the prepared syrup and wait until it’s well mixed. The prepared liquor will be filtered
and stored in liquor holding tank. There are 11 liquor holding tanks.
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Filter press
In this factory, filter press uses for filtering the prepared syrup and liquor by using the filter sheets. The
filter sheet retains the contaminants. Filtration takes place due to pressure drop when there is pressure
difference between the inlet and outlet of the liquor.
In addition to filter press, there is a filter that used to filter intermediate, warm, and cold water in the
washer. Filter bag is used to filter the recycled caustic solution in the washer bottling and packaging.
WASHER
Bottles are collected and transported by chain conveyor. By using out packer the bottles are pickup
and sent to washing machine the same time the crates go to the crate’s washer. In the bottle washer, the
bottles have washed through a different step.
First, fill the washer with a solution that contains 2% caustic soda (NaOH) and all intermediate(31c)
warm(55c) and cold(23c)-water tank inside the washer, then turn on the washer’s motor. Fresh water
comes from the water treatment. The warm solution that contains the 2% caustic soda washes the bottle
at a temperature of 76.5c, at
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this step labels be removed, the caustic solution can be recycled and used for about 1 month but
concentration of the caustic soda should not be less than 1% if it is below 1% add some amount of
NaOH until it is approximated 2% by using titration. Finally, the bottles have dried by using blower
and goes to filling section. In washer there are 214 carriers. Each carrier has the capacity to hold bottles.
Sighter
There are two sighter in bottling section. those are empty bottle and full bottle sighter .The use of the
sighter is to identify if there is breakage or uncleaned bottle.
Filler
Filler is to fill a space or add weight or size. It is a process of filling a desired product in to the empty
bottle. This process is done by level sensing. The filling operation is processed by sucking the vacuum
air inside the bottle, then when the vacuum air becomes equal to the atmospheric air the filling process
stop.
Labeling
Label is a sign giving information about something to which it is intended to be attached. Glue is a
higher viscous liquid which used to stick a label on the bottle. Date coder: it is a machine that stamps
the manufacture date and time. After this process the in packer used to put the bottle in the crate. By
the help of convey the crate transported to the store room.
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The effluent from distillery plant (spent wash) is often processed with evaporator to recover the water
and produce concentrated syrup, which can be added to the spent grain prior to drying.in this case the
solids have value as animal feed.
Evaporators are classified by the number of effects. In case of a single-effect evaporator, the vapor
from the boiling liquor is condensed and the concentrated product is withdrawn from the bottom of the
evaporator. Although the operation is simple, the device does not use steam efficiently. Typically, 1.1
to 1.3 kg of steam is required to evaporate 1 kg of water. The steam consumption per unit mass of water
evaporated can be increased by putting more than one evaporator in series such that the vapor from one
evaporator is used in the second evaporator for heating. The vapor from the second evaporator is
condensed and the arrangement is called Double-effect evaporators. The heat from the vapor generated
in the first evaporator is used in the second evaporator. Evaporation of water is nearly doubled in double
effect evaporation system compared to single effect per unit mass of steam used. Additional effects can
be added in series in the same way to get a triple-effect evaporator, quadruple-effect evaporator and so
on. There are several configurations based on feeding arrangement.
Multiple effect evaporators (quadruple effect) are used for concentrating spent wash in Rorank
alcoholic liquor factory. Normally falling film tubular calendars are employed for the pre-evaporator
with forced circulation tubular evaporator as the finisher.
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Vapor and liquid are usually separated at the bottom of the tubes and the thick liquor is taken out.
Evaporator liquid is re-circulated through the tubes by a pump below the vapor-liquid separator. The
distribution of liquid in the inner wall of the tubes greatly affects the performance of this type of
evaporator. The falling film evaporator is largely used for concentration spent wash and heat sensitive
materials because of the low hold up time. The device is suitable for scale forming solutions as boiling
occur on the surface of the film.
Shell and tube heat exchanger (either horizontal or vertical), a flash chamber(separator)mounted above
the heat exchanger and a circulating pump. The solution is heated in the heat exchanger without boiling
and the super-heated solution flashes off (partially evaporated) at a lower pressure are reduced in the
flash chamber. The pump pumps feed and liquor from the flash chamber and forces it through the heat
exchanger tubes back to the flash chamber.
2.14.3 Dryer
Drying of the more viscous feed or spent (40-60 ºbrix) which were not evaporating section. It operates
by supplying of steam in the waste drying and change to powder waste. The machines that operate in
this section are dryer champers, FD fan, atomizer and ID and blower. The dry chamber is boiled before
the spent is sprayed by atomizer machine.
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FD fan is sac the air from environment and boil the dry chamber by supplying of steam. Then the spent
which were sprayed in the dry champers changed to powder. The fine powder is separated by the ID
blower and remove these by cyclone separation. The liquid spent which are not removed in the form
of powder is removed by saver tank diluting with water and in the form of gases to the environment.
The effluent from distillery plant (spent wash) is often processed with evaporator to recover the water
and produce concentrated syrup, which can be added to the spent grain prior to drying.
In the factory spray dryer is used before at this moment it is not work due to loss of energy.
Spray drying is a method of producing a dry powder from a liquid or slurry by rapidly drying with a
hot gas. This is the preferred method of drying of many thermally sensitive materials such as foods and
pharmaceuticals. Air is the heated drying medium; however, if the liquid is a flammable solvent such
as ethanol or the product is oxygen sensitive then nitrogen is used. All spray dryers use some type of
atomizer or spray nozzle to disperse the liquid or slurry into a controlled drop size spray. Atomizer
wheels are known to provide broader particle size distribution. A spray dryer takes a liquid stream and
separates the solute or suspension as a solid and the solvent into a vapor. The solid is usually collected
in a drum or cyclone. The liquid input stream is sprayed through a nozzle into a hot vapor stream and
vaporized. Solids form as moisture quickly leaves the droplets. A nozzle is usually used to make the
droplets as small as possible, maximizing heat transfer and the rate of water vaporization.
Spray dryers can dry a product very quickly compared to other methods of drying. They also turn a
solution, or slurry into a dried powder in a single step, which can be advantageous as it simplifies the
process and improves profit margins. The fine powders generated by the first stage drying can be
recycled in continuous flow either at the top of the chamber (around the sprayed liquid) or at the bottom,
inside the integrated fluidized bed. The drying of the powder can be finalized on an external vibrating
fluidized bed.
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Analysis of physicochemical characteristics of distillery waste has been carried out, molasses is the
most common raw material used in distilleries for ethanol production. After alcohol distillation, huge
volume of darkish colored spent wash remains in the stills (to extract 1 litter alcohol above 12 litter
waste). And since this spent contain high amount of polluting substance it introduced in to evaporator
and then drying unit so as to reduce that toxic chemical by producing solid biomass, which has high
nutritional value for animal. But still the water comes out from the evaporator condensers has high
BOD, COD, TSS, and acidity thus the raw condensed water transferred in to waste water treatment
plant for further treatment.
The waste water treatment plant found in Rorank SC factory is diagrammed in figure 8.1. It is designed
to remove BOD, COD, acidity, color, odor, turbidity, and other contaminants.
2.15.2 Process description
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I. Equalization tank
Wastewater does not flow into wastewater treatment plant at a constant rate for various reasons. Such
constant variations in the amount and strength of wastewater to be treated make it difficult to operate
the treatment processes efficiently.
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V. Settling tube-1
Water from aerobic tank -1 usually has significant turbidity caused by turbulence during aeration.
These particles carried an electromagnetic charge that keeps them in continual motion and prevents
them from colliding and sticking together. Chemicals like alum (aluminum sulphate) are added to the
water both to neutralize the particle electrically and to aid in making them “sticky “so that they can
coalesce and form large particle called flocs. This process is called coagulation or flocculation.
VI. Aerobictank-2
Similar to that of aerobic tank it uses aerobic bacteria for further decomposition of chemicals. There
queried dissolve deoxygenize fed using compressor and nutrients like nitrogen, phosphor and
others from DAP, urea, and sugar. The bacteria cell is recycled from the bottom of settling tank- 2.
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Type of hardness
1. Temporary hardness:
•Temporary Hardness is due to the presence of Ca2+, Mg2+in the form of the bicarbonate ion HCO3-
being present in the water.
•This type of hardness can be treated by addition of lime (calcium hydroxide) through the softening
process of lime softening or by boiling the water to expel the CO2, as indicated by the following
equation:
•Ca2++ 2HCO3-→CaCO3+ H2O + CO2
•Mg2++ 2HCO3-→MgCO3+ H2O + CO2
•Bicarbonate hardness is classified as temporary hardness
2. Permanent Hardness
•Permanent hardness is due to the presence of the ions Ca2+, Mg+2 in the form of Cl-and SO4. This
type of hardness cannot be eliminated by boiling.
•The water with this type of hardness is said to be permanently hard
•As it can’t be treated easily, so it’s treated by chemical treatment such as: ion exchange resin.
Problems of hard water
Originally, water hardness was defined as the measure of the capacity of the water to precipitate.
It forms scales in the boiler that may cause:
1. Decreasing in heat exchange and boiler efficiency.
3. Explosion.
Zeolite is micro-porous mineral which is used as catalyst in many industrial purposes such as water
purification and air purification .it is hydrated alumina silicates.
Sodium zeolite (NaZ) is softening an ion exchange-based process designed to remove hardness
(calcium and magnesium) from raw water. NaZ softening will remove other soluble cation species such
as iron and copper and will act as a filter for small suspended solids.
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The soft water and hard water can be determined or tested by EBTA solution (solution of Erio chrome
black T powder with ammonium solution and ammonium chloride) and diluted with ethanol alcohol.
When tested both water type with this solution the hard water seems like slightly red color and soft
water is slightly blue color.
2.16.2 Utilities
Boiler
Treated Water
Distillery cooling tower
Boiler
Boiler is one of utilities of this factory that used to generate steam by using heat energy. A boiler is a
closed vessel in which fluid (generally water) is heated. The fluid does not necessarily boil. The
heated or vaporized fluid exits the boiler for use in various processes or heating applications
including water heating, central heating, boiler-based power generation, cooking, and sanitation.
Boiler use different energy source to produce steam like wood, coal, fuel and electric current.
Boiler type
A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or more tubes
running through a sealed container of water. The heat of the gases is transferred through the walls of
the tubes by thermal conduction, heating the water and ultimately creating steam.
Water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire.
Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In
smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely
on the water-filled tubes that make up the walls of the furnace to generate steam
Treated water
It is a part of utility, which reduces the concentration of calcium and magnesium ions that are
contained in hard water. The water to be treated is comes from underground. We call water is hard
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when it contains large amount calcium and magnesium dissolved in it. Water softening mainly relies
on the removal of Ca²+ and Mg²+ ions from a solution of these ions that is binding them to molecule
that removes their ability to form a scale or interface with detergent. Sequestration entails the
addition of chemical compound called sequestration agents. Since Ca²+ and Mg²+ ion exists as non-
volatile salts they can removed by distilling the water, but distillation is expensive in most cause.
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2.17 Challenges
There are different challenges during the internship. Such as:
• Lack of safety wears like safety shoe, glove
• Lack of internet access
We cannot see internal part of the machines. Because all machines are under works. They will
disassemble when the failure occurs on them.
2.17.1Measurnment taken to overcome those challenges
To be fully profitable from this internship we have to take some measurements instead of leave those
challenges.
• To get attention from the technicians we discuss with them and we tell them what we want from
them.
• To increase their awareness about the internship we talk with the workers about this program
to aware them. Even though they have no motivation to give a defined task instead of keeping
them. We try to take some tasks by ourselves. We read different references, we learned earlier,
and we understand the working principles of each machine parts.
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CHAPTER 3
3. BENEFITS OF INTERNSHIP
3.1 Benefits
This internship program helped me to get the following knowledge’s.
o Practical skill
o Up grading theoretical knowledge
o Improving inter personal communication skill
o Improving team playing skills
o Improving leadership skills
o Improving work ethics
o Entrepreneurship skills
3.1.1 Practical skill
Within an internship period different activity are taking place in the company and I practice those
activities and act to improve their problems through finding solutions.
1) I developed the habit of being safe at work.
2) Act on solving problems and work flow practically
3) Practice how drawing in takes place and draw –in on different unit operations by hand.
4) Practice how to measure quality of the products.
5) Principles of quality control and the major parameters to taste finished.
3.1.2 Upgrading theoretical knowledge
This internship program provided us with the opportunity to expand our intellectual knowledge and
practical skills. As we know coming before in the previous theoretical awareness or familiarity and
actual place could be distinguishable, so the objective reality and theoretical knowledge may be slightly
different. The above theoretical learning is upgrading during my internship program by seeing and
doing some work. So the internship program is essential for us to upgrade theoretical knowledge’s.
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CHAPTER 4
4. PROJECT ON PRODUCTION OF ALCOHOL FROM FRUIT AND
VEGETABLE WASTE
4.1 Introduction
Ethanol (also called ethyl alcohol, grain alcohol, drinking alcohol, or simply alcohol) is an organic chemical
compound. It is a simple alcohol with the chemical formula C2H6O. Its formula can be also written as
CH3−CH2−OH or C2H5OH (an ethyl group linked to a hydroxyl group), and is often abbreviated as EtOH.
Ethanol is a volatile, flammable, colorless liquid with a characteristic wine-like odor and pungent taste. It
is a psychoactive drug, recreational drug, and the active ingredient in alcoholic drinks. (Ishola, M. M.,
Brandberg, T., & Taherzadeh, M. J. (2015)).
The production of ethanol from lignocelluloses biomass has received considerable attention because of the
potential of producing large quantities of ethanol. Hemicellulose and cellulosic components of
lignocelluloses biomass are hydrolyzed to their component sugars for subsequent conversion to ethanol by
a fermentative process. Hemicellulose and cellulose are usually hydrolyzed with a chemical process (acid)
or biological (enzyme) attack. (Lujan-rhenals, D. E. (2013)).
Acid hydrolysis is an important chemical modification that can significantly change the structural and
functional properties of starch without disrupting its granular morphology. A deep understanding of the
effect of acid hydrolysis on starch structure and functionality is of great importance for starch scientific
research and its industrial applications. During acid hydrolysis, amorphous regions are hydrolyzed
preferentially, which enhances the crystallinity and double helical content of acid hydrolyzed starch.(Lujan-
rhenals,D.E.(2013)).
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because of brown color, which is found affecting aquatic animals by making them unable
to get the sun light. this leads to disturbance of the living organisms.
On the other hand, fruit and vegetable wastes contribute directly to greenhouse gas emission through the
generation of methane and emission of nitrous oxide. This is the main cause of climate change by trapping
heat, which in turn affects various lives through drought and food supply disruption.
4.4 Scope
This project work involves the collection of waste fruit peel from hotels Industries and residence’s. Then
after an analysis made to determine physical and chemical properties of waste fruit peel for the production
of bioethanol as fuel and hydrolysis with diluted sulfuric acid and adjust the PH. by using sodium
hydroxide. Then prepare fermentation media and fermentation process were carried out. Finally, the
fermented product was distilled, and characteristics of produced product are analyzed.
Generally, the aim of this project was to investigate the possibility of using and transforming fruit peel waste to
something valuable, namely ethanol using the fungus Saccharomyces cerevisiae as ethanol producing organism.
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4.5 Methodology
4.5.1 Materials Used for the Experiments
Equipment’s
• Plastic bags: - to collect and transport samples to the laboratory.
• Knife: - for cutting the fruit wastes in to pieces.
• Digital and non-digital driers or ovens: - to dry the sample.
• Crushers: - to crush the dried sample.
• Sieves: - to sieve the crushed sample to the particle size of 2mm.
• Balances: - to weigh samples and yeast.
• Digital pH meter: - to measure the pH of the hydrolyzes before fermentation.
• Thermostats: - to control temperature of the sample under experiment (fermentation and distillation)
isothermally at the set point.
• Vessels: - to hold samples and additives for hydrolysis, fermentation and distillation
• Pycnometer: - for density measurement
Chemicals
• 98% Sulfuric Acid (H2SO4):- used as a pretreatment and hydrolysis fruit peel.
• Sodium Hydroxide (NaOH):- used to adjust the pH of soluble cellulose and hemicelluloses before
fermentation.
• Yeast extracts (Agar):- used as media preparation.
• Urea: - used as media preparation.
• Dextrose sugar: - used as media preparation.
• Mg SO4.7 H2O:- used as media preparation.
• Yeast (Saccharomyces cerevisiae)
4.5.2 Method
Collection of raw material from source, washing, drying, milling by mortar and pestle machine and sieving
it in order to obtain fine powder for further process. This unit operation prevents the degradation or loss of
carbohydrate and byproduct inhibitory to subsequent hydrolyses and fermentation.
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4.6.3 PH Adjustment
First, we Mix pretreated and hydrolyzed solution, filtered, shaken substrate primarily checked for pH using
a digital pH meter. Then the pH adjusted to 5.0-5.5. Mix samples (pretreated and hydrolyzed) were acid
hydrolyzed, so it needs highly basic solution to bring the pH in the range of 5.0-5.5 and hydroxide solution
was added drop wise to the other flask with constant stirring until the pH reaches to a range of 5.0-5.5. If
suppose the pH goes beyond 5.0-5.5, concentrated sulfuric or hydrochloric acid was added drop wise to
maintain the pH in the range.
4.6.4 Sterilization
The reactor and all the equipment’s that were used for fermentation purposes were sterilized (autoclaved).
The sterilization was carried out at a temperature of 121oC for 15 up to 25 minutes for different samples.
4.6.5 Filtration
A process of extracting ethanol is done in order to know the amount of substrate the enzymes had acted
upon. After monitoring the pH and concentration for a period of 48hrs, the biomass was separated from the
crude bioethanol using a coarse filter paper inserted in the separating funnel into a receiver flask or conical
flask. At this point, the biomass is then put in an oven at a temperature of 105 C for 2hours.
4.6.6 Fermentation
Media Preparation
For preparing 100 ml media, add
• Sugar (Dextrose) = 10 gm
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To the above 100 ml media, 0.5 gm of yeast, Saccharomyces cerevisiae (instant premium) was added in a
250 ml conical flask. Then conical flask was properly covered with aluminum foil. Finally, the conical flask
then placed in incubator for 24 hours, a temperature of 300C
4.6.7 Distillation
Distillation was the last step in the production of ethanol from fruit peel experiments. This method is used
to separate two liquids based on the difference of their boiling points.so distillation is used to separate water
and ethanol based on their boiling point. In this experiment simple distillation set up was used at a
temperature of 78 ºC for 30 minutes for each run. The ethanol concentrations of the samples were collected
on the other end of distillation column to collect the distillate at 78.40C (standard temperature for ethanol
production). Although the boiling point of bio ethanol 78.4℃, and water 100℃, we can’t get pure bio
ethanol by distillation. In order to use bio ethanol as fuel it should be free from water, so dehydration is
required to get pure ethanol.
Sample A
First, we prepare 100 gram of sample weight mixing with 1000 ml of distilled water then hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1320 c. the hydrolysis at pH adjustment of 5.5
and for fermentation 6.5. lastly Prepare 100ml fermentation media contain 5-gram baking powder then the
separated liquid was fermented for 7 days at room temperature.
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Sample B
First, we Prepare 100 gram of sample weight mixing with 1000 ml of distilled water and hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1320 c. hydrolysis at pH adjustment of 5.5
and for fermentation 6.5. finally Prepare 100ml fermentation media contain 7- gram baking powder Then
the separated liquid was fermented for 7 days at room temperature.
Sample C
First, we Prepare 100 gram of sample weight mixing with 1000 ml of distilled water. Hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1210 hydrolysis at pH adjustment of 5.5 and
for fermentation 6.5 and Prepare 100ml fermentation media contain 5.0- gram baking powder. Then the
separated liquid was fermented for 12 days at room temperature.
Sample D
First, we Prepare 100 gram of sample weight mixing with 1000 ml of distilled water then hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1210 c. after hydrolysis at pH adjustment of
5.2 and for fermentation 6.2 and Prepare 100ml fermentation media contain 5-gram baking powder then
the separated liquid was fermented for 7 days at room temperature.
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4.7.5 Solubility
It is fully miscible in water.
4.7.6 Viscosity
It is more viscose than water. And it viscosity is 1.1cp at 25oC.
annual
𝐼𝑡 𝑖𝑠 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑤ℎ𝑖𝑐ℎ 𝑓𝑜𝑙𝑙𝑜𝑤𝑖𝑛𝑔 𝑡ℎ𝑒 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑐𝑜𝑙𝑢𝑚𝑛 𝑎𝑛𝑑 𝑏𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 95% 𝑡𝑜
99%.
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𝑋𝐸 = 95% 𝑋𝑊 = 5%
𝑋𝑤𝑏 = 100%
𝑋𝑤=water percentage
𝑀 𝑤𝑎𝑡𝑒𝑟 = 100.042𝑡𝑜𝑛/𝑦𝑒𝑎𝑟
𝑋𝑤 =Fraction of water
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𝐹 𝑋𝑓 = 𝑊 𝑋𝑒 + 𝐷𝑋ℎ𝑒
𝐹 =𝑊+𝐷
𝑊 = 𝐹 − 𝐷 = 24553.2359𝑡𝑜𝑛/𝑦𝑒𝑟 − 2476.042𝑡𝑜𝑛/𝑦𝑟
𝑤 = 22077.2359𝑡𝑜𝑛/𝑦𝑟
C6H12O6 2C2H5OH+2CO2
180gm/mol 92gm/mol+80gm/mol
(1 + 3%)/2 = 2%
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𝑀𝑔𝑓 + 𝑀𝑚 = 𝑀𝑓 + 𝑀 𝐶𝑂2
𝑀ℎ 0.1 = 𝑀𝑠 0.8
From liquid
𝑀𝑠 = 3490.1428𝑡𝑜𝑛/𝑦𝑟
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𝑀ℎ = 27921.14 𝑡𝑜𝑛/𝑦𝑟
𝑀𝑠𝑎 = 681.57𝑘𝑔/ℎ𝑟
hydrolysis
𝑇1=250c 𝑇𝑓=280c
𝑀ℎ=4700.5kg/hr
𝑀𝑝𝑡𝑚 = 4018.95𝑘𝑔/ℎ𝑟
C6H10O5+H2O C6H12O6
1mol of cellulose 1 mol of glucose for 100% conversion but not complete conversion and assume
that 95% of cellulose convert to glucose.
𝑀𝑝𝑡𝑚 + 𝑀𝑠𝑎 = 𝑀ℎ
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𝑀𝑑𝑝 + 10 𝑀 𝑑𝑝 = 𝑀𝑝𝑡𝑚
𝑀𝑓𝑝𝑋𝑠 = 𝑀𝑑𝑝𝑋𝑑
𝑀𝑓𝑝 = 𝑀𝑤 + 𝑀𝑑𝑝
𝑡𝑜𝑛
𝑀𝑤 = 𝑀𝑓𝑝 – 𝑀𝑑𝑝 = 10851.17 − 2170.234 = 8680.936 𝑦𝑒𝑎𝑟
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Results
Determination of yield
𝑚𝑎𝑠𝑠𝑜𝑓𝑑𝑟𝑖𝑒𝑑𝑝𝑒𝑒𝑙𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐴
43.92 ∗ 100%
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑦𝑖𝑒𝑙𝑑 (%) =
100
= 43.9%
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐵
48.576 ∗ 100%
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑦𝑖𝑒𝑙𝑑 (%) =
100
= 48.6%
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐶
44.75 ∗ 100%
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑦𝑖𝑒𝑙𝑑 (%) =
100
= 44.7%
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𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐷
39.27 ∗ 100%
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑦𝑖𝑒𝑙𝑑 (%) =
100
=39.3%
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Table 4. Optimum condition for different parameter on optimum yield of ethanol from
experiment
No sample Compare by Concentration Volume Optimum
sample
1 A with D Hydrolysis temperature 73 and 72.4 48 and 42 A
2 A with B Yeast amount 73 and 75.2 48 and 55.2 B
3 B with C Fermentation time 75.2 and 73.5 55.2 and 50 B
4 C with D pH factor 73.5 and 72.4 50 and 42 C
DISSCUSION
In this project ethanol was produced and characterized from wastes generated from fruit peel (mango,
orange & banana). Starch hydrolysis with dilute acid was carried out. The effect of temperature, time, Ph,
acid concentration & yeast amount from fruit peels were investigated
The project uses raw material from the agricultural waste. Which also provides environmental protection
The by-product is also biodegradable and we can use it for the production of fertilizer. A mixture of waste
fruit peel (mango, orange and banana) found as a promising carbon source for ethanol production and also
relatively inexpensive and high yield compared with other feedstock or sources.
When we compare produced ethanol from standard literatures such as color, boiling point, melting point,
solubility and others it is slightly accomplish almost all requirements.
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The main objective of the company is to compute and win by supplying the end products. In the company
there are different departments which are various functions in the production of liquors.
Our project is on alcohol production in RORANK BUSINESS SHARE COMPANY is based on the raw
material (MOLASSES) that have been received from sugar factory’s. But as we all know in and around
Debre Birhan there is no sugar producing industry, because of its weather condition and raw material
source. So, as we observed the main challenge and problem of the company is RAW MATERIAL. The
company spent a lot of money to receive the molasses, to transport to the company including other labor
costs. Even after receiving the raw material the molasses has a bad smell in the environment and also the
spent wash after fermentation couldn’t be disposed because of brown color, which is found affecting aquatic
animals by making them unable to get the sun light. this leads to disturbance of the living organisms.
On the other hand, fruit and vegetable wastes contribute directly to greenhouse gas emission through the
generation of methane and emission of nitrous oxide. This is the main cause of climate change by trapping
heat, which in turn affects various lives through drought and food supply disruption.
The challenges that are facing in the internship are obstacles that Blocks smoothly running working
conditions. The internship has benefits to improve an awareness of theoretical.
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4.10.2 Recommendations
• In washing room the bottle lifting system is manual system, it will decreases the bottle washing
machine speed, we recommended that the company better to be replace the lifting system with
automatic lifting machine.
• The problem we saw in this factory is that there are no machine modules which make difficult to
know the operation system of the machine, but we recommended that it is better to put each machine
module in each department, that makes easy to operate the machine, especially for new employees
as well as internship students.
• The faculty should give necessary course which are related with laboratory works.
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REFERENCE
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1982.
2. Http://Www.Google.Com/Books.Engineeringcourses 09/10/2015
3. Ishola, M. M., Brandberg, T., & Taherzadeh, M. J. (2015). Simultaneous glucose and
xylose utilization for improved ethanol production from lignocellulosic biomass through
SSFF with encapsulated yeast. Biomass and Bioenergy, 77, 192–199.
https://doi.org/10.1016/j.biombioe.2015.03.021
4. Karimi, K., Emtiazi, G., & Taherzadeh, M. J. (2006). Production of ethanol and mycelial
biomass from rice straw hemicellulose hydrolyzate by Mucor indicus. Process
Biochemistry, 41(3), 653–658. https://doi.org/10.1016/j.procbio.2005.08.014
5. Lenz, ZaraThomazini.Reuse of Drinking Water Treatment Plants Slugdesin
Agriculture.2011.
6. Lujan-rhenals, D. E. (2013). Production of bioethanol by fermentation of sugars released
by dilute-acid and enzymatic hydrolysis of soybean meal.
7. Millati, R., Niklasson, C., & Taherzadeh, M. J. (2002). Effect of pH, time and temperature
of over liming on detoxification of dilute-acid hydrolyses for fermentation by
Saccharomyces cerevisiae. Process Biochemistry, 38(4), 515–522.
https://doi.org/10.1016/S0032-9592 (02)00176-0
8. Paturau, J.M.By-product of the sugar industry. New York: Elsevier publishing company,
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9. Saenz, Sepulvede and Matsuhiro. Coagulation Flocculation and Clarification. In: Fact
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