Escolar Documentos
Profissional Documentos
Cultura Documentos
1. BERHE TADEL..0254/06
2. MELES HAGOS...1071/06
3. MHRET G/MESKEL/06
4. NETSANET ABRHA./06
DECLARATION
Our names are HAYLAY GEBREMEDHIN, NEBIAT GEBREMEDHIN, FSHA GEBREHAWERIA and
HADUSH TESFALEM. We are fourth year chemical engineering students, we have undertaken our
internship experience in WALIA ALCOHOLE AND LIQOUR company, from a period of February
15/2009 to June 20/2009 E.C. under the guidance of INSTRACTOR AYALEW (Academic advisor) and
Mr. HAFTOM (company supervisor).
We certify that our work is original and compiled according to the internship report writing guideline
given by the Institute-Industry Linkage office of the Institute.
As the students academic advisor, we certify that the internship report written by the student is their
original work and compiled according to the guideline provided by the institutes UIL office as far as our
knowledge is concerned.
INTR.AYALEW
.
Abbreviations and Acronyms
List of Figures and Tables
EXCUTIVE SUMMERY
Walia alcohol and liquors factors is one of the liquor factory in Ethiopia, in the region of tigray and use
katikala (technical alcohol) as a raw material. Our internship at Walia alcohol and liquor factory
Company was deals with the production and treatment of the alcohol and liquor. We gathered practical
experiences about injection machine, and blowing machine in the production section of the company. We
gathered practical experiences about injection machine equipment like boilers, condenser, feed
water tank, gas treatment and other equipment. We also got practical experiences about three in one
machine which involving Bottle Rinsing, Filling, Capping. During this internship, we got the
opportunity to work as a member of a team, which was involved in production section, combined
cycle production area, treatment area, operation section, instrumentation and control section. After
completion of a complex procedure, the alcohol and liquor is filled to the bottle.
CHAPTER ONE
1. GENERAL HISTORY OF THE COMPANY
1.1. Introduction
Walia alcohol and liquor factory is found in Tigray region at Adigrat Town far apart from mekelle town
by 125 km that covers 2000 care meter. It prsoduces different alcohol contents of liquors, and it is the
only main factory produce alcohol and derivatives of alcohol products in Tigray region. The raw material
to this plant is called katikala (un purified ethanol) which is purchased from fincha and wenji sugar
factory, come to this by transportations of the Walia alcohol and liquor factory. At this time the plant
produce 167 bottles per hour.
Water softening plant. The supplier of the ethanol alcohol has been also the producer
distributor of sprit products.
The human and nonhuman resource of the factory in 1995-1997 was shown as follows-
Initial investment-10,000,000birr
Number of employee-20
Annual sale volume-5,000,000 birr
Purchasing semi processed alcohol ( 1998 -2000 G.C):-At this stage, distillation of
technical alcohol has been established, but the owners could not be satisfied by doing that
as it was not cost effective that would result in profit lowering. As the result Of that, they
decide to expand the plant so as to reduce the production cost and increase sales volume.
Hence increase the return
Investment 27,000,000 birr
Number of employee53
Annual sale volume-25,029,766.30 birr
The term alcohol is being recognized at middle century and derived from Arabic word al-kuhul. Its
meaning is taken from the element antimony extract. The name alcohol is given to a class of
compounds derived from alkanes by substituting hydrogen atom by hydroxyl group. The general name
of alcohol is CnH2n+1OH
As described above, the sprit production is found in Adigrat eastern zone around` chianadug
preparatory school(Agazi school) Kebele 01 .The distiller was found in eastern part of Adigrat
which is 1 km apart from the center city of Adigrat (local name piasa). The selection criteria for
Nearness to market
Availability of infrastructure
Situation of atmosphere
Nearness
1.3. Vision, mission and objective of the company
1.3.1. Vision of the company
The company aspires to be the best alcohol and Liquor products producer and distributer in
To fully satisfy our customer needs and expectations by producing high quality alcohol and liquor
products consistently using modern technology, applying modern management system and employing
experienced and qualified professionals also satisfy other stack holder by creating values as well as
enhancing the wellbeing of the society and protecting The environment to contribute it shares for the
growth of the country.
To identify specifically the detail of cause for the prevalence of poor performance in the
company with regards to production, purchasing, marketing, human resource
development & quality related activities
To design & implement a comprehensive solution strategy to enhance the performance of
the company towards attainment of most criteria international standards/parameters
To manufacture finished quality Beverages from un purified ethanol (katikala)
To produce purified alcohol and liquor production that promotes trade and investment.
More specifically the objectives of the Chamber are:
To support business by supplying information and services,
To provide technical assistance, training and research to upgrade the quality of economic
activity,
To promote a more flexible and hospitable economic environment with additional focus
on small and medium businesses,
To encourage and promote business ventures that contribute to a large employment base
1.4. Raw material and inputs to the company
The main raw material and inputs of the company is technical alcohol or katikala (its local name) and soft
water are the main components of the raw materials .but we have another raw material such as flavor,
sugar and color.
1.4.2. Water:-
The nature of water to be used for the production sprite is very important. Its composition is very much
dependent on the condition of soil whether it is taken from springs or well water for the production. It has
trickled through soil and mineral has become saturated with the inorganic impurities. These dissolved
maters influence the producer of sprits and unforeseen troubles could result. The following points must be
attentively controlled
Hardness of water
Iron content of water
Magnesium & Calcium salts of water
Oder& test of water
It is used for the cleaning of overall processing units.
It play a great for the dilution purpose( during distillation with alcohol sprit, during
liquor preparation)
Primarily used to sterilize the mother tank, main settling tank, mixer, and distillation unit.
It play a great rule for creating the boiling point difference while the distillation
process is taken place to separate the impurities
It is also for alcohol wa-shing column in distillation in order to remove the impurities and
odours of the ethanol.
1.4.4. Essence
An important point in producing sprit is the choice of flavoring material as this is the distinguishing point
of any sprit. Flavoring should be power full and plain, it must express the character of the sprit clearly.
It is extracted component directly from aromatic vegetable, fruits, spices, herbs. Etc by
means of distillation and maceration process.
There are different types of essence for different type of liquors. Example as gin essence
is used for preparation of dry gin liquor; anitole essence is used for ouzo liquor.
The company use flavor for:
gin -3500ml
Areki (liquor)-2000ml
Super mint -6.844 liter
1.4.5. Sugar
1.4.6. Color
There are several types of colorings. Some of them are brown cornmeal, yellow lemon, green & so on.
The quality of these colorings should be checked before use. They should free of calcium& iron salts.
Colorings should dissolve in high grade sprits. If wrong choice of coloring is done, this will be cause
turbidity in sprits Colorings are sensitive to frost & its solubility will decrease at lower temperature. The
finished colored sprits should not be stored under frosty condition. Input consumption to prepare one
liter of sprit given ethanol alcohol of 96% by volume.
The company use For 1125 liter tank of (ouzo, dry gin and zebib )and for 600 liter tank for super mint
listed in the table below.
The types of products produced by WALF Company are classified as consumer and
industrial product. Industrial products are refers to the by-product of un purified ethanol
Production which are applicable for different purpose in pharmaceutical and soap industry. E. G
methanol alcohol. Consumer products are refers to the main product of the company which is
This alcohol is also known as fire alcohol. These products contain poisonous substances that
humans should not swallow is regarded as a by-product of WALF. This alcohol is separated from
the ethanol alcohol at the rectification column. The denature alcohol is used in the following places
Ethyl Alcohol is a clear, colour less, and flammable oxygenated hydrocarbon. The type consumed as
alcoholic beverages (brandy, rum, whisky, etc., and called just 'alcohol') is produced by the natural
process of fermenting grapes, malt, sugar cane juice, etc. Even ethanol that can be consumed is still
considered toxic to the human body. When a person drinks alcohol, it is absorbed into the blood stream. It
is taken to the brain, and produces an effect. The body immediately tries to eliminate this foreign
substance, and in doing so, the liver produces acetaldehyde. As the process of producing ethanol
alcohol is complex and timely, so is the bodys process for eliminating it. There is a limit as to how much
alcohol the body can dispose of within an hour. The more a persons drinking exceeds this limit, the more
others may be able to notice the effects that ethanol alcohol can produce. The ethanol produced in
Walia Alcohol and Liquor Factory is about 97% of purity and the remaining 3% is water. This is
found at the end of distillation unit (rectification column). The first phase about alcohol and liquor is as
follow: The use of ethanol is used
For drinking
For pharmaceutical ingredients
For laboratory service
For other factory serve as raw material.
As source of fuel
The ethanol will convert to the following liquors
1. Dry gin
2. Ouzo Liquor
3. Zebib Liquor
4. Super mint
Figure 1 dray gin and superment
Figure 2 zebib and ouzo liquor
These alcoholic beverages are making from ethanol alcohol by adding different ingredients. These are the
main products of the company. There are 5 kinds of alcoholic beverages produced in the company which
are differing based on their alcohol content and four kinds of the product the most which the costumer and
consumer needed are the only three products. These are Gin, Zebib and ouzo products. These have
around 41% of alcohol by volume. The products which are produced in the company are given in table
form below.
1.5.4. Alcoholic Beverages Verses Health
When alcohols are consumed in excess they can result health problem rather than giving
Liver attack
Stomach attack
Addicted with alcohol
Diabetes
Barberry
Hospital ,and
Pharmacy.
The main customer of the alcoholic beverages produced in WALF is local markets like general
distributers and shops. And it covers around all Tigray market, Gambella and Amhara region
Boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the
boiler for use in various processes or heating applications, including, boiler based power generation.
There are two types of boiler available in the company. These are differing based on their capacity which
they produce the amount of steam and are working interchangeably. The largest capacity of the boiler is
available for operation with fuel oil, butane gas, combustion air and compressed air and it is used to
supply a steam to all distillation column. The smallest capacity of the boiler doesnt operate with presence
of butane gas and it will be supplied a steam to both pre-distillation and rectification column and only
mash column. The water consumption of the boiler is 1000-12,000kg/hr for the smallest largest boiler
respectively. There are many types of boiler used in different industry but, the type of boiler which
is found in wALF Company is fire tube boiler. It is used to supply midium steam capacities and easily
available in the market. It works in which the hot gasses of combustion are passes through the boiler tubes
and water surrounds these tubes to absorb heat.
The main utilities of the companies used for the proper functioning of boiler are:-
Compressed air
Butane gas
Treated water
Fuel oil
Compostion air(o2)
i. Fuel oil
An air compressor is a device that converts power (using an electric motor, dieseor gasoline
engine, etc.) in to potential energy storage in pressurized air (compressed air). By one of several methods,
an air compressor forces more and more air in to a storage tank, increasing the pressure when tank
pressure reaches its upper limit the air compressor shut off, the compressed air then is held in the tank
until called in to use. The energy contained in the compressed air can be used for variety of applications,
utilizing the kinetic energy of the air as it is released and tank depressurizes. When tank pressure reaches
its lower limit the air compressor turns on and re pressurizes the tank. Up on being compressed, the
temperature and pressure of the vapor are increased.
It is used to adjust the particle size of furnace to make easiest for burning.
If excess air is supplied, the particle size will be very small and exposed to:
Inconvenient burning
Inadequate heat energy generation.
If less air is supplied, the particle size will be very large.
Therefore, the fuel will collect on the burner nozzle.
v. Treated water:-
It is treated or softened by ion exchange or reverses osmosis method to reduce the scale
forming ion.
Used for saving of fuel energy
The main function of cooling tower is cooling the hot soft water that is retained from the Distillation
column. Cooling tower is heat removal device used to transfer process waste Heat to the atmosphere. It
may either use the evaporation of water to remove process heat and cool the working fluid to near the wet
bulb air temperature or in the case of closed circuit dry cooling tower rely solely on air to cool the
working fluid to near the dry-bulb air temperature common applications include cooling the circulating
water used in oil refineries, chemical plant, power station and building cooling. The cooling tower is
works as warm water from the heat source is pumped to the water distribution system at the top of the
tower .the water is distributed over the wet deck fill by means of nozzles .simultaneously, air is drawn
through air inlet louvers and through the wet deck surface causing a small portion of the water to
evaporated. The evaporative process removes heat from water. The warm moist air is drawn out of the top
of the tower .the resulting cold water is the recercuilated back through the heat source in a continuous
cycle.
Distillation is water purification process that uses a heat source to vaporize water and separate it from
contaminants and other undesirable elements. It is used to heat raw or untreated water until the water
reaches its boiling point and begins to vaporize. The heat is then kept at a constant temperature to
maintain water vaporization while prohibiting other undesirable elements from vaporizing. It is a physical
method of separating mixtures depending upon the difference in the boiling point of the component
substances. The main function of distillation is to heat a mixture at a specific temperature, collect the hot
vapour and condense to separate the component substance. In simpler terms, a highly volatile compound
is separated from a less-volatile or non-volatile compound by using distillation. Alcohol distillation
is a complex phenomenon and need a great care to obtain high quality beverages.
NB:-dilution of concentrated alcohol with water will facilitate the separation of ability of the impurities
from ethanol.
1. The wart is obtained from the decantation tanker is preheated and evaporation taken based
The vapour is cooled with the help of condensers by using cold water from cooling tower and then
changed in to liquid state to be separated in to reflux, head and tail and pure alcohol. The distillation
equipment is designed to distil 2000 litter/day of pure alcohol at over 96% alcohol by volume( v/v).to
produce pure alcohol we First distil a katicala at about 35%alcohol by volume. This alcohol is then
mixed with water in an alcohol washing column, so that most of the impurities go up the column whilst
the water and alcohol go down. Alcohol at sum 10%by volume (v/v) is finally concentrated to over 96%
in the hot water column and the pure alcohol column. Pure alcohol is within drawn at about 100liter /hour
at 96.5 to 97% v/v.
There are several methods of distillation depending on the procedure and the instrument
setup. Each distillation type is used for purification of compounds having different properties.
The following are the most common type of distillation column which the factory has been used.
This appears to be an upside down column in that the alcohol comes out of the base not the
top. The impurities rise to the top part of the column. An earlier version, patented in1902 by
Emilee guillaume, had purified alcohol leaving the base at 18 to 25% v/v. john chambers in his
patent of 1949 specifies that the purified alcohol should leave the base at 6%v/v. actual operation
if too much dilution water is added then the steam must be increased for the hot water column and pure
alcohol column. Alcohol washing column is consists of the following terms.
The function of this item is to condense substantially all of the vapors leaving the alcohol
washing column and to act as a re boiler providing most of the heat required by the hot water
This permits a vapor heads stream to be removed from the top of alcohol washing column.
It consists of two columns. These are striping column and rectification column. Striping
column is found below the feed section which contains un purified alcohol. But rectification
column is found on the top of the column or upper part of the feed that contains pure alcohol.
This column comprises two sections: a stainlees steal hot water recovery section and a copper pure
alcohol section. The purpose of the lower 18 plates in the stainless steel section is to strip alcohol from
the water to provide clean hot delusion water for the alcohol washing column. In the copper section the
alcohol concentration progressively increases as the vapors rise. Vapours are totally condensed in
the main condenser and cool condenser and are returned to the top. the heavy bad alcohols (fuel oils)
accumulate in the stain less steel section above tray 18 and may be removed by withdrawing small
amounts, about 2 to 5 L/h of the mixture from one tray. The light bad alcohol or the esters principally
alcohol containing ethyl acetate, we concentrate above tray 22 in the upper stainless steel section
above the fuel oil. They are removed by withdrawing about 2 to 5 L/h from one tray.
Pure alcohol main condenser:- The function of this item is to condense substantially all of the vapours
leaving the pure alcohol column.
Pure alcohol cool condenser:- This may be regarded as a guard to reduce vapour losses to a minimum.
Pure alcohol cooler:- This cools the distilled pure alcohol below 40 deg C.
1.7.4. PUMP
A pump is a device that moves fluids (liquids or gases), or something slurries, by mechanical action.
Pumps operate by some mechanism (typically reciprocating or rotary), and consume energy to
perform mechanical work by moving the fluid. Pumps operate via many energy sources, including
manual operation, electricity, engines, or wind power, come in many sizes, from microscopic for use in
medical applications to large industrial pumps.
When the distillery stops operating, the liquid in the copper section will drain to
the base where it will cool on standing. On restarting, care must be exercised
to avoid throwing too much of this liquid in to the stainless steel section
Fig.6. Pump
There are different types of machines in the production areas. From these:
1. Filtration of Liquors
The preparation liquor must appear perfectly clear without any impurities or suspensions. Filtration is a
process that accomplishes this. It is the passage of a cloudy liquid through a porous body, which retains
the matter in suspension. It is highly important stage in the manufacturing of liquors because it is
responsible system for the final appearance of the drink. A filter press does filtration where the filtering
material remains stationary between metal or plastic plates so that the entire filtering process is uniform
pressure is used so that filtering time is cut down. This machine function is to wash the bottle that
came from the consumer (returnable bottle).the capacity is 4008bottle per hour. The temperature of hot
water machine at 75oc after that inters the bottle. Checking the impurities of the bottle everything is
done by inspection method
2. Washing Machine
3. Filler Machine
These machines are 10 filler machine and 3 crap canners that packages the bottle in correct mannered.
There are vacuum pressure former this is used for control during filling the bottle or control the gap
between the liquor and the canner. After the liquor is capping, it is labeled manually and stored at
cool temperature
Packaging is the technology of enclosing or protecting products for distribution, storage, sale, and use.
Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be
described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end
use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully
integrated into government, business, and institutional, industrial, and personal use. It is Preparation of
product or commodity for proper storage and/or transportation. It may entail blocking, bracing,
cushioning, marking, sealing, strapping, weatherproofing, wrapping. The machine in WALF packs 167
bottles per hour
Water treatment is refers to any modifications made to raw water or water from the original source, like
rivers, lakes, streams, etc. Water treatment is serving as both water softeners and water filters and has
very different purpose. The main goal of a water filter is to provide clean, contaminant-free water for
drinking and other purposes where as water softener is to remove hardening minerals like calcium and
magnesium from the water. Water softener does not remove dangerous chemicals or bacteria. Water is
termed as hard if it contains large amounts of dissolved calcium and magnesium. Hard water causes
two major problems. It can initiate scaling on the inner surface of pipes, water heaters, and/or tea kettles.
When scaling occurs, the calcium and magnesium separate from the water and form a hard, thin
layer on the inside of such appliances, causing the appliances to block and reducing their ability to
conduct heat. Hard water causes soap scale to build up on dishes and tile. Hard water also reduces the
soaps ability to foam.In order to remove calcium and magnesium from water, water softeners chemically
replace the calcium and magnesium ions with sodium ions. Because sodium does not separate and scale
on pipes or react badly with soap, both problems of hard water are solved. From a health
perspective, calcium and magnesium are better and healthier for our body systems than sodium. Water
filters will generally solve the same problems as water softeners, without adding sodium to the water. The
water treatment plant of the WALF Company works by dissolving salts in some amount of hard water.
When the hard water feeds to the clarifier cylinder or water treatment tanker the water would be
circulated through a jacket of a tube which is found inside the cylinder. Besides, to that the dissolved salt
solution of hard water which contains sodium ion would also be added. In the jacket portion of the tube
there is a chemical which is called zeolite. Zeolite are chemicals which have a negative charge and used
to attracts the positive charge of hard water such as Ca2+ and Mg2 + Where as the negative charges of
carbonate forms are remains there and sodium ion is substituted instead of Ca and Mg ions. Then, the free
mineral of water will start to pass through inner side of the tube to the storage tanker. There, some amount
of steam would be given to pre-heat the water before sent to boiler. Then, it feeds to boiler machineto heat
the water till it changes in vapour form or steam. The purpose of this is to heat or boil the wine mash that
comes from decantation process to separate the desired product by their vitality.
I. The resin tanker:-contains the zeolite resin and same times a sand layer to support the
resin bed.
II. The salt tanker :-contain the salt and saturated brine solution used in regeneration.
III. The filter head:-contain a timer that automatically operates the control valve that initiates the
five cycles of the water softener. This clock control the time of day that regeneration occurs, and the
number of day between regeneration.
The function of zeolite is by making soft water to supply for boiler to produce steam.
The objective of this equipment is to change the hard water to soft water by using ion
exchange:-Initially softening tank has zeoliite. This zeolites ion attach to zolaite and the sodium ions
bond to water molecules and the water becoming to softening. The softening tanks regenerate by
salt solution. The salt solutions have sodium chloride. Then this solution enter in to the system the
magnesium and calcium ions bond to chloride ions and out the system by salt form but sodium attach to
zeolites and regenerate the system.
When we say challenges it may be very difficult or it may be easy to facing. As we think facing of any
challenges during work progress might be one of part of the objective of the internship, so while
we performing our task there were some challenges that invite me to challenging them, such as ; in
WALF there are an engineers but they have no full knowledge about the company because they are new
comers. The Chemists and the operators are doing any work through experience. So they did not have
full knowledge about the machines unit operations.
And also there is no enough accesses such internet service, good manuals &there were the problem of
cafe and restaurant. In the company we get a lot of challenges that is almost everything is done by
challenges starting our university assigned to the company, that is in the first few days there is a problem
of service that cannot be given with in short period of time. Generally the main challenges that w efacing
in the company are:
As stated above in the first few days the company cannot be given service, due to this reason we suffered
much problem in terms of cost for taxi until the company allowed service. Some of the persons that work
in the service especially assistance of the driver have not be politeness when we enter.
The factory is organized at different levels of perform it goal. Each level has back ward
and forward integration with close vertical and horizontal communications to accomplish
its planned activities accordingly .the company has four departments and their
accountability is to general manager from four departments production .department are
four unit operations (sections).thus Are fermentation, distillation, liquor preparation
(blending), waste treatment. The detail organizational structure of walia alcohol and
liquor factory private limited company They create and administer the advertising of a
product usually from conception to completion.
In other words, they develops the advertising campaign and works with the
public relations department to place their jobs in various trade magazines
and newspapers so that the peoples and other companies will know what they have.
They also develop campaigns to promote the product to distributors
and customers. Thus, the product becomes more attractive to purchase,
either by customers directly or by distributors who will sell the product for
consumer.
They concerned with knowing and understanding the requirements of customers,
so that Production can provide the market led products that are required.
This also requires an excellent communication system to be in place.
For businesses to be competitive, production and marketing department need to
work in an integrated way.
Hiring (including recruiting candidates, the interview process, negotiations, and signing
contracts)
Employee benefits
Training and continued professional development
Annual appraisals (in many companies)
Promotions and raises
Warnings and layoffs
The finance department of a business takes responsibility for organizing the financial and
accounting affairs including the preparation and presentation of appropriate accounts, and the provision
of financial information for managers. The main areas covered by the financial department include:
Keeping records of the purchases and sales made by a business as well as capital spending.
Records of purchases and sales are totalled up to create a Profit and Loss account.
It will be responsible for calculating the wages and salaries of employees and organizing
the collection of income tax and national insurance for the Inland Revenue.
It will also be responsible for the technical details of how a business raises supervise
the payment of dividends to shareholders.
2.1.3. Quality control department
As ethanol alcohol is fully extracted from cane molasses through a process of fermentation and
distillation, it is checked its quality parameters whether it is acceptable or not for human
consumption as follows.
Alcohol content
Aldehyde test
Permanganate time test
Acidity
Furfural test
Fusel test
Specific gravity
2.2. Process flow diagram and description of the company
2.2.1. Organizational structure of WALF
In any part of chemical industry, the raw materials enter as a feed and after the chemicalor physical
reaction is completed it gives products. Therefore, it must know the amounttheentering and leaving of the
process. Then the amount of the process in any factory will be known by material balance and energy
balance. Material balance is apply based on the law of conservation of mass which states that any matter
can be neither created nordestroyed, but can be converted from one form to another form. The material
balance equation will be:
Where,
If the balance quantity is total mass; generation = 0 and consumption =0, expect in
nuclear reactions.
But all the material balance in the factory is without chemical reaction
MH2o=3500kg/hr MSteam=3430kg/hr
According to the first law of thermodynamics, energy can neither be created nor destroyed but can be
change from one to another form , form the first law of their mod iambics for an open system at steady
state has this form.
Energy balance on the boiler
Than according to the first law of thermodynamic listed about generation and consumption
becomes zero. So the equation becomes accumulation = in put-out put. Accumulation also
becomes zero due to steady state rule. Therefore the above equation is reduced to
input =output.
H+ KE+ PE =Q-WS
Q=H
=3.14*2*0.6*1.5=6.6 cm3
Min=3500 MOUT=3430
Tin=25 TOUT=200c
Then from the above simplified equation
Q= H where h=enthalpy
Q=H = 3500 (295023454)
Q=H = 42322 but 1kj = 1000j, 1hr = 3600sec
Then Q= H = 42322 * Q=H= 18.4 kw, so there is some losses
3600
It is obvious that most alcohol and liquor factory institutions are more profitable, because alcohols and
liquors are the needs of many persons. Walia alcohol and liquor factory is also satisfactory, because of the
following reasons;
Pollution aspect: - WALF has solid and liquid wastes which can pose potential damage to the
environment. Addition of extra material or increase in the concentration to actual concentration creates
the pollution which is direct contact with environment. In WALF the solid wastes can be removing
[removed] using land filling &incineration methods, means that incineration, burning solid waste
or heat treatment for the solid waste simply burring &sanitary land filling (open dumping )throw out
the wastage to the green area especially for water soluble and hazardous solid wastes. Aside far from a
ground water sources should be selected..
Generally, WALF which can cause pollution to the environment directly or indirectly due to the lake
of chemical engineer which is highly related to the controlling of waste water treatment control
unit operation, or environmental engineer which can control at any wastes (solid, liquid , or gases )
also causes environmental protection Finally WALF which contain many chemicals to convert the raw
material to the finished (final) product the waste removed also direct contact with environment cause the
pollution ( solid ,liquid , etc )
CHAPTER THREE
We gained some good experience during the four month internship period. Some of the experiences
includes As the purpose and aim of this industrial internship for the student has a big value in terms of
different field of practical application and others what he is going to get when he/she is graduated after
some year staying in campus then this industrial internship makes the next life of the student to be easy.
Therefore, there some benefits that a student can get from an industrial internship.But in our stay, the
overall benefits we got from the internship program include:
Since we was participating in the section that work all its tasks practically called utility, this helps us to
improve our practical skill that we was learnt theoretically in different subjects of courses we took by
participating ourself in person. By participating in some departments of the company especially in
production and maintenance departments we have improved our practical skill and we have we learnt
about working process of the departments.
Here in Adigrat University we have learnt more and knew theoretically knowledge almost in all courses
and in right water bottled company we have proved our theoretical knowledge that we was learnt before
because the practical application are the result of theory of different observations of nature. Then we was
free to gain any knowledge and we knew new theoretical knowledge more and proved our previous
theoretical know how. For example expressing and telling the working process, injection machine,
ozone producer machine etc...
We have learnt how to visualize our theoretical knowledge, how to relate it with the practical work of the
company, and we have observed that which course in what process of the department should exercise and
advantages of the courses in solving the problems of the company.
To improve our interpersonal communication this industrial internship helps us starting from the early
day that we went to WALF to apply our paper there till the time we finished the internship. As we know
to have such place the behaviour of good interpersonal communication has great value because one
person may judge you from your speaking whether you are talented or not so, the four months we
pasting Walf were good enough for improving our interpersonal communication skill with different
workers of the company because nothing is to be hide there.
As we all know, let alone in one company even in social life team work is required to facilitate
the task in short period of time. So, teaming is a valuable working behaviour in solving problems, giving
and sharing ideas for common good of company production working in team plays a great role then we
have learnt team work makes the work light or ease. As one hand cant clap alone working alone even for
small task in big company like Right is difficult and so every activity that are done in right is worked by
groups this team work helps to the workers and for me to increase interpersonal communication with
workers and help to know what social life is. We have learnt how to improve tolerance and team work
with different workers of the company even they have different habit and skill.
3.5. In terms of improving leadership skill
To be a leader, anyone should participate in every task of the related jobs and there must be team in the
work place of different section or department and the group leader is well trained in the job by education
or practical knowledge. So being a leader is taking the risk of the job that is done by the group members
of the department. Then the place or position of being a leader has a great responsibility in the work so
being leader is being responsible to each work. we have improved how can we feels a strong leadership
and how can we fulfill our leadership skill honesty in every activities of the company without any
discrimination of work.
As we all know work ethics is the most needed criteria in every work place that everybody should have in
all his/her job activities that he/she gave to the society by respecting the rules and obligations like:-
Punctuality , Responsibility , Transparency etc. And other criteria of industriousness have high
value in developing one country so these criteria we have learnt in right highly in order to be respected
and the company and even the countrys wellbeing. And anybody cant be full in his job if he/she doesnt
full fill the work ethics even he/she is silent.
The word entrepreneurship is define as a process of creating new things with value by devoting
the necessary time and effort, assuming the accompanying financial, physic, and social risk, and receiving
the resulting rewards of monetary and personal satisfaction and independence. So by understanding the
definition and clarification with what we have done in Right any work we do for better off on company or
work place has a great value so this internship plays a role in changing my mind that we are learning has
value.
CHAPTER FOUR
PROJECT TITLE:
Today, water resources have been the most exploited of the natural systems, most of our water
bodies are seriously polluted due to rapid population growth, industrial proliferation,
urbanizations, increasing living standards and wide spheres of human activities. Many rivers of
the world receive heavy flux due to industrial effluents. The wastewater consisting of substances
varying from simple nutrients to highly toxic hazardous chemicals, which when used for
irrigation caused both beneficial and damaging effects to various crops including vegetables
(Madhavi, A, & Rao, A. P.,2003). Many industries are playing the crucial role in water pollution
such as textile industries, dairy industries and distillery etc. Distilleries are the major agro-based
industries, which utilize molasses as raw material for the production of rectified spirit. In
addition to rectified spirit, distilleries also produce ethanol, which can be mixed with diesel and
used as bio fuel and helps in reducing import of crude oil thereby saving foreign exchange.Ethyl
alcohol can be produced synthetically by indirect or direct hydration of ethylene fermentation
ofsacchariferous (sugar containing) or amylaceous (starch containing) raw materials, by
hydrolysis and fermentation of cellulose from sulphite liquors of paper factories. The proportion
of ethyl alcohol production in U.S.A., Western Europe, Japan and Brazil are
given below.
Fermentation process --------------- 94.6%
Synthetic process -------------------- 5.0%
Sulphite liquors ----------------------- 0.4%
Total --------------------------------- 100%
It can be seen from the above data that fermentation process is the primary source of ethyl
alcohol in the above regions.
Ethanol production from cane or beet molasses has been done for longer time by using
fermentation processes as a drinking liquor and bio fuel. For longer time fermentation is done
by using batch process in the world till 1985. But currently utilization of continuous bio reactor
has been started to produce alcoholic distilled liquors and power alcohols and brought an
enormous benefits to this sector with regard to reduction in man power requirements as well as
in eliminating batch to batch variation.
Production of ethyl alcohol as a beverage or drinking liquors in Ethiopia was started in the
house hold level and practiced for long time in the high land parts of the country. This liquor is
manufactured on fermenting maize, barley and other cereals. In industrial scale production of
fermented liquors in Ethiopia had been started at small scale level in different industries like
available in the country. Besides, two of the existing sugar factories Metahara and Finchaa were
equipped with ethanol plant to utilize their by product molasses to value adding product such
as impure sprit, rectified sprit and power alcohol. The country has huge potential with respect
to production of alcohol for beverage as well as bio fuel and Ethiopian sugar corporation has
planned all sugar factory projects to have ethanol plant.
Recent advancement in fermentation technology creates good opportunity in the development
of continuous types of Bio- fermenter.
The main goal of Ethanol plant is to have an efficient and profitable as well as Environmental
friendly operation with the required Rectified, technical as well as Power alcohol quality and
maximum recovery. One of the biggest problems in Ethanol plant is the disposal of acidic and
concentrated effluent generated from distillation section. Damping this effluent directly to river
stream will harm aquatic animals. In other hand treating the effluent will incur additional non
value adding cost to the product.
4.2. Objectives
4.2.1. General Objectives
The main objective of this project is to study the effect of reusing distillery effluent to
fermentation process in order to maximize alcohol production and reduce effluent generation.
4.2.2. Specific Objectives
to Conduct compositional analysis of input materials.
Study the effect of varying different nutrients and concentration of fermentable sugar
on the overall performance of fermentation process.
Study the effect of using spent lees, spent wash and process condensate water
obtained from vinase multiple effect falling film evaporators in order to reduce
effluent.
Study the effect of yeast cream separator machine on bulk fermentation process.
Carrying out the impact of re-circulating effluent on the food safety and quality of
rectified sprit as drinking liquor.
To carry out material and energy balance for fermentation process and suggest
suitable vinasse, spent lees and process condensate cooler and piping system for
recycling.
In the anaerobic pathway every mole of glucose is converted into 2mole of ethanol, 2mole of
carbon dioxide, and 2mole of ATP along with 56kcals of heat. The ATP produced is used in
biosynthesis or maintenance. In this pathway every gram of glucose converted will yield
0.511gram of ethanol. However, in practice since both biomass and some secondary products
are produced by the yeasts, the yield is reduced to 95% of the theoretical yield. In certain cases,
the yield is further reduced to typically to only 90% of the theoretical yield when complex
substrates are used. On the other hand, under aerated metabolism, sugar is converted
completely to CO2, water, cell mass and by-products with no ethanol formed and is typical
bakers yeast fermentation as it yields more ATP, (38moles) and more biomass(0.52g/g of
sugar). ATP is a nucleoside triphosphate used in cells as co-enzymes which is capable of
transporting chemical energy within the cell for metabolism.
Effect of sugar concentration
Hexoses sugars such as glucose are the primary reactants in the yeast metabolism. Under
fermentative conditions, the rate of ethanol production is related to the available sugar
concentration by a Monad type equation.
V = Vmax Cs 2.1
(Ks + Cs)
Where, V is the specific ethanol productivity (g of ethanol/g of cell/h)
Cs is the sugar substrate concentration (g/l) and
Ks is the saturation constant having a very low value typically 0.2 0.4 g/l (Maiorella,
1985). At very low sugar concentration(less than 0.3%), the yeast is starved and the
productivity decreases. Sugar concentration up to 15%, the rate of ethanol production per cell
is essentially at its maximum, beyond this concentration, catabolite inhibition of enzyme in the
fermentative pathway takes place and the conversion rate is slowed. At concentration above 0.3
to3% the production of oxidative enzyme is inhibited, thus forcing fermentative metabolism.
This catabolite suppression is a desirable characteristic in industrial strain.
Effect of pH
The pH is the measure of acidity or alkalinity of aqueous solution expressed on scale of 1 14.
Neutral is pH 7, pH 1-7 is acid, and pH 7-14 is alkaline. The pH is most conveniently measured
with test papers that change color according to the pH of the solution being tested.
Control of pH during the mashing and fermentation process is important for two reasons; the
growth of harmful bacteria is retarded by acid solutions, and yeast will grow only in an
(slightly) acid solution.
Generally Distillers yeast shows a broad pH optimum from 4 to 5. The development of
bacteria is severely repressed at pH value under 5. The acid most commonly used is sulfuric
acid, although any mineral acid is perfectly suitable. Further, yeast can tolerate as low pH as 2
without permanent damage.
Effect of Temperature
As heat energy is liberated during fermentation of sugar by yeasts there is always an increase
in temperature and cooling of fermenters is required, and, therefore, it is desirable to use
temperature tolerant strains. Most strains have a temperature growth optimum of 30 35C.
However, the optimum fermentation temperature at a low alcohol concentration is often
slightly higher (38C), but alcohol tolerance is improved at reduced temperature. S. Cerevisiae
strains having 37C as optimum temperature for ethanol production have been selected.
Exposure to higher temperature results in excessive enzyme degradation and loss of yeast
viability. Yeast can be stored inactive at low temperatures (above 0C) and are readily revived.
Effect of Oxygen
It has been found that trace amount of oxygen may greatly stimulate yeast fermentation, which
is used as building block for synthesis of poly-unsaturated fats and lipids required in
mitochondria and plasma membrane . High sugar concentration is adequate to repress aerobic
sugar consumption in yeasts which show the Crabtree effect. For other yeasts or at low sugar
concentration, the oxygen supply should be limited. Trace amounts (0.7 mm Hg oxygen
tension) of oxygen are adequate and do not promote aerobic metabolism.
Conversion of sucrose to glucose is taking place outside cell wall, where as conversion of
glucose to ethanol takes place inside cell wall in the mitochondria. If there is no sufficient air
the yeasts will be weak.
Effect of Ethanol and Secondary Component Inhibition
Ethanol tolerance is a desirable trait in industrial yeast strains. Ethanol concentration above 2
%( w/v) show toxic effect and cell growth is halted (stopped) completely at about 11% (w/v).
However, slow fermenting sake yeast (Saccharomyces sake) can tolerate ethanol concentration
up to 16 %( w/v) at low temperatures as it contains lipoproteins. Ethanol inhibition is directly
related to the inhibition and denaturation of important glycolytic enzymes as well as to
modification of the cell membrane. S. Cerevisiae that can tolerate high ethanol (12%v/v) at
400C is being isolated by chemo stat selection.
The by-products of fermentation such as acetate and lactate may inhibit yeast growth and
ethanol production at high concentration. Some non metabolized feed components may
become concentrated when back-setting is used and may inhibit the yeast growth.
Blackstrap molasses may contain high concentration of calcium salts which are inhibiter to
yeast growth. Sterilization of sugar at high temperature in presence of salts (phosphates) and
proteins can produce yeast toxins. High salt concentration may encourage glycerol formation.
Yeasts may tolerate 16 to 20% non fermentable dissolved solids in industrial fermentation.
fig4.1 Total material balance of walya factory distillery plant
s
4.8. Conclusion and Recommendation
4.8.1. Conclusion
This study clearly indicates that there can be significant technical potential for maximum
economic use of effluent recirculation to fermenters with the view of implementing cleaner
industrial production system. The experiment was designed in series of steps aiming on
reducing effluent production in increasing alcohol productivity through optimizing nutrient
application to fermenters and increasing cell mass on efficiently using yeast recycling
machines followed by returning optimum amount of effluent to fermenters. Beside to this the
quality of input materials such as process water and molasses were also checked and found in
optimum ranges. But the calcium oxide content of molasses is found beyond the required
22,171 ppm which is above 16,500 ppm. This can cause incrustation on evaporator and
distillation column which resulted in high effluent generation. In addition to this accumulation
of sludge inside fermenters can occur as the calcium gets precipitated by the action of acid
added to maintain the pH of fermenters around 4.5 and this can reduce the effective volume of
the fermenters which has the consequence of reducing alcohol% fermented wash and
increasing effluent generation.
Response surface method was used to analyze the data generated from nutrient optimization
and effluent recirculation system. The experiments were conducted in the current operating
condition of MSF fermentation (15bx) of molasses and future optimum molasses feed rate.
The optimum nutrient dose for the current operating condition of fermentation was 62.51 and
14.51mg/lt Urea and DAP respectively. It was found in the experiment that the optimum macro
nutrient required slightly varies according to fermentable sugar concentration of fermented
wash. The study shows nutrient requirements of fermentation process increases for DAP with
the increase in concentration of fermentable sugar but remains the same for Urea. At 15 bx
fermented wash concentration the optimum amount of Urea and DAP application was 62.51
and 14.51 mg/l where as at 25bx fermented wash sugar concentration 62.51 and 31.26 mg/l
Urea and DAP quantity are required. Experiment were conducted on the existing fermentable
sugar concentration of fermented wash(15 brix) and at different sugar concentration (15, 20
and 25 brix) to get optimum recirculation of effluent and sugar concentration which resulted in
higher alcohol production with low effluent generation. The optimum effluent rate for the
existing sugar concentration were Spent wash 1%, Spent lees 92% and process condensate
99%. As a result the response variable became yeast cell mass count 2.15488 E+008,
Alcohol% fermented wash 6.57 and residual sugar content of 0.274. The optimum effluent
recirculation to fermenter at different sugar concentration became sugar concentration of 25%,
spent wash 50%, spent lees 68.5% and process condensate 85.83%. Yeast cell mass count
2.40674E+008, Alcohol% fermented wash 7.43, residual sugar content of 0.417 were obtained
as response variables. After obtaining the optimum effluent recirculation rate to fermenter
comparative test has been conducted by preparing fermented wash on using optimum effluent
recirculation and by using only process water and fermenting them for 40 hours, distilling the
fermented wash by using lab scale distillation mantle to produce rectified sprit alcohol. Then
analysis of the sprit collected were done for total solid , furfural, fusel oil, aldehyde, ester and
other attributes which is related from food safety point of view and all the results were found in
the required ranges for both samples.
Material and Energy balance was conducted based on optimized effluent recirculation rate and
suitable types of cooler, pumps and piping were suggested in order to implement the findings
of the research. Besides, cost benefit analysis was done for effluent recirculation system and
all financial indicators have shown the viability of the project.
4.8.2.Recommendation
According to the experimental results and observations of Walya Alcohol Factory distillery
plant the following recommendations to be implemented to reduce effluent discharge from the
plant to environment and increase productivity:
To utilize strictly the research results of this thesis.
In order to reduce effluent generation per liter of alcohol from the plant the factory has to
focus on increasing alcohol % of fermented wash on increasing retention time .which will avoid
accumulation of sludge inside fermenters which has a possibility of reducing
reaction volume and retention time of fermented wash.
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