ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING
COMPANY NAME: WALIA ALCOHOL AND LIQUOR FACTORY

ADVISERS NAME: INSTRUCTOR TSIGE

PREPARED BY:-
NAME ID NO

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

Name of the Academic advisor Signature Date

Mr. HAFTOM Signature Date

Name of the company Supervisor

HAYLAY GEBREMEDHIN Signature Date

NEBIAT GEBREMEDHIN Signature Date

FSHA GEBREHAWERIA Signature Date

HADUSH TESFALEM Signature Date

Internship students
 ACKNOELEDGMENT
First and for most, we would like to thank our Lord for giving us a blessed time to do this. Next it is our
great pleasure to thank those individuals who helped us in preparing this project work. we would like to
express our heart full thanks to our adviser instructor TSIGE For open handily and kindly guided,
assisted, supported and also encouraged us to make this project successful and also his brotherly
approach we would also like to express our deepest appreciation and heartfelt gratitude to the staff of
Walia alcohol and liquor factory Company especially for Mr. Haltom for his guidance and great help
during the internship period. Finally, we would like to express our deepest special and long lasting thanks
to our friends, our dorm mates, our beloved family and everyone who helped us for everything that they
have done for us and sacrificed a lot for our project from starting up to completion.

.
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.

1.2. Background of the company

Walia alcohol and liquor factory has been established in 1987 E.C with the name of Adigrat alcohol and
liquor factory by two motivated husband and wife of ato Futsum hadush and miss Asgelet Gaym sharing
of 51% and 49% of capital respectively at a surface area of 2000m2.Its building construction has been
finished from 1990_1996 period of time. The amount of money used for buying of machines was 10
million birr without the construction. In 1997 the company has started its job effectively with 20 numbers
of workers. From 1997to 1999 the main material that the company used was technical alcohol which is a
byproduct of sugar plant that comes from wenji and fincha sugar factory, but later it was changed to
Katikala because of bad odor to the surrounding of the society. In terms of transportation, Walia alcohol
and liquor factory has 7 service cars , one used for transportation of workers and the other 6 are used for
the transport of the products. Walia alcohol and liquor factory produces alcohols and liquors mainly
Ouzo, zebib, Gin, Super mint.

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

1.2.1.Background of Alcohol and Sprit Production

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

1.2.2. Location of the Plant

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

plant location will be based on;

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

the local market and become competent in the global market.

1.3.2. Mission of the company

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.

1.3.3. Objective of the company

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.

1.4.1. Katikala (Un purified ethanol)

It consists of the fermentable portion of sugars.

It is mixture of sucrose, glucose, fructose, and other carbohydrate.
It is assumed to contain 95% unpurified ethanol with specific gravity of 1.4.
The main raw materials used to produce ethyl alcohol are Katikala and water.
It used to control the growth of and activity of other microorganisms such as bacteria,
no to compute the yeast by this microorganism.

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)

It boils and widely used for steam production

It is used for washing purpose in production area.
1.4.3. Steam:-

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

It should be first class refined product

This will be added and mixed during the liquor preparation in the syrup form in order to
Facilitate the agitation process.
It is used as a sweetener for the liquor
The company use sugar for:
Areki 50kg
Gin-28kg and Super mint -469.96kg

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 color only for:

Super mint -1.095liter

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.

Table 1 necessary information of the liquor

NO TYPES OF FLAVOUR COLOUR SUGER ALCOHOL

LIQUOR CONTENT CONTENT CONTENT CONTENT

1 OUZO 2000 ML NO 50 KG 41%

2 SUPERMINT 6.844 L 1.095 L 469.96 KG 25%

3 DRY GIN 3500 ML NO 28 KG 41%

4 ZEBIB 2000 L NO 50 KG 41%

1.5. Main products of the company

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

applicable for food consumption and different industrial purpose.

The main product of the company is the followings;

Denature alcohol(methanol)
Potable alcohol(ethanol)
Alcoholic beverages (Liquors or sprites) OR Areki (local name).

1.5.1. Denature Alcohol (Methanol)

This alcohol is also known as fire alcohol. These products contain poisonous substances that

humans should not swallow is regarded as a by-product of WALF. This alcohol is separated from

the ethanol alcohol at the rectification column. The denature alcohol is used in the following places

In Hospital and pharmacy

In Barbary house
In house for food preparation to burn the materials
In animal treatment for disease
For washing electronic materials

1.5.2. Ethanol (C2H5OH) Potable Alcohol

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

Fig.3 Zebib liquor fig.4 Ouzo liquor

1.5.3 Alcoholic Beverages (Sprites)

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

Moderate alcohol consumption has the following importance on our body.

Reduce the chance of attacking by heart disease

Reduce the chance of attacking by diabetics
Reduce the LDL cholesterol level which is harmful to our health
Increase the HDL cholesterol level which is important to our health
Increase short term memory
It gives high energy to our body since it is high caloric value.
Facilitates digestion system of our body.

When alcohols are consumed in excess they can result health problem rather than giving

importance to our body. These includes

Liver attack
Stomach attack
Addicted with alcohol
Diabetes

1.6. Main customers of the company

1.6.1. Main Customers of Fire Alcohol (Methanol);

Barberry
Hospital ,and
Pharmacy.

1.6.2. Main Customers of Pure Alcohol (Ethanol);

Adigrat medicinal factory

1.6.3 Main Customer of Alcoholic Beverages

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

1.7 Technology and machinery of the company

1.7.1. Boiler Plant

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

It is the source of heat energy.

It should be preheated and reach at the burner within a temperature range of 90-110oc.
This temperature range is varies depending on the viscosity of fuel oil.
It is estimated that 0.35 litter of fuel is consumed to produce one liter of ethanol
alcohol.

ii. Butane gas

It is used to start burning or flame formation during ignition.

It has lower flash point than fuel oil.

iii. Combustion air (o2)

Used for combustion of fuel energy so as to generate heat energy.

iv. Compressed air:-

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

Figure 3 boiler plant

Fig.5. Boiler plant

1.7.2. Cooling tower

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.

1.7.3. Distillation Process:

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.

The following conditions must be fulfilled:-

NB:-dilution of concentrated alcohol with water will facilitate the separation of ability of the impurities
from ethanol.

The distillation process is obtained or performed as the following steps:-

 evaporation of the mixture:-

1. The wart is obtained from the decantation tanker is preheated and evaporation taken based

boiling point difference of the component.

condensation of the produced alcohol:-

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.

Types of Distillation Column

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.

1. Alcohol washing column

2. Hot water column

3. Pure alcohol column (copper column)

1. Alcohol washing column

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

of alcohol washing column in modern distilleries is usually between 8 to 10%v/v, depending up

on impurities present. We propose to operate with a base alcohol concentration of 10%v/v.

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.

alcohol washing column main condenser

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

and pure alcohol columns.

Alcohol washing column bad alcohol condenser

This permits a vapor heads stream to be removed from the top of alcohol washing column.

2. Hot water 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.

3. Pure alcohol column

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 column consists the following terms.

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.

Three pumps are used during distillation.

Katikala pump; this pumps katikala in to the alcohol washing column.

Hot water pump; this pumps hot water from the base of the hot water recovery section in
to the washing column.
Copper column pump ; the weak impure alcohol in the base of the copper
column is pumped to the stainless steel hot water column .

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

and possibly producing a vacuum.

Fig.6. Pump

1.7.5. Production machines

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

. Caustic soda is use for washing the bottle.

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

Fig.7. Filler machine

 4. Labeling machine

It is a machine applicable to write electronic or graphic communication on the package or on

separate and its labels 167 bottles per hour.

Fig1.3 Labeling machine

5. Packing machine

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

Fig.8. Packing machine

1.7.6. Water Treatment Plant

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.

The fully automatic water softeners consists of the following

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.

Process description of Water Softening

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.

1.8. Main challenges that faced us during internship time

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.

1.9. The measures you have taken to solve the challenges

As much as possible I have taken the following measurements

We am to going the factory by taxi.

At different time by asking some person that work in the site we understand the walia
alcohol and liquor factory process.
 CHAPTER TWO
over all company structure
2.1. Management structure of the company

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.

2.1.1. Human Resource Department

Its main function is to provide services regarding jobs in various government

 and nongovernment department and to Full fill aspiration of young generation
regarding employment.
It works with people from other departments, is responsible for the people in the

organization. This often includes:

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

2.1.2. Finance Analysis Department

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

Chemical and Physical Analysis of Ethanol Alcohol

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

Fig.9. Organizational structure of WALF

2.2.2. Process flow of the company

Fig.10. Block diagram of WALF
2.3. Material and energy balance on selected equipments

2.3.1. Material balance

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:

INPUT + GENERATION OUT PUT CONSUMPTION = ACCOMULATION

Where,

Input = enters through the system boundaries.

Generation = produced wit in the system.

Output = leaves through the system boundaries.

Consumption = consumed with in system.

Accumulation = build up within the system.

The following rule is used to simplify the material balance equation:

If the balance quantity is total mass; generation = 0 and consumption =0, expect in

nuclear reactions.

If the balanced substance is nonreactive species; generation = 0 and consumption =0.

For steady state process accumulation will zero.

Therefore, the material balance equation will be;

 INPUT = OUTPUT

The material balance has used for:

To calculate the unknown quantity.

To know the performance of factory.
Helps to minimize utility production coast.

Material balance is classified in to two types those are:

1.Material balance with chemical reaction.

2Material balance without chemical reaction.

But all the material balance in the factory is without chemical reaction

Material balance on the boiler

MH2o=3500kg/hr MSteam=3430kg/hr

Material balance, input=out put

3500kg/hr=3430kg/hr+ X, then X=70Kg/hr lost

2.3.2. Energy balance

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

Accumulation= input -output + generation - consumption

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

Where Q=Heat H=Change in enthalpy

PE=0(there is no change in length) WS=0(no moving part)

KE=0(there is no movement velocity) so, the equation will be reduced

Q=H

lmportant information gained from the company of WALF steam boiler

Temperature of cold water before pre-heated = 25c

Temperature of out let steam = 200c
Temperature of out let chimney to west gas for = 225c
Working pressure = 8 bar
Mass flow rate steam = 3430kg/hr
safety pressure = 11.74 bar
Specific heat water capacity = water = 4.2kj/kg
Enthalpy of feed water = 80 kcal/kg

Time =four hour

Density of water =1000kg/m3

Density=m/v so, m=density*volumetric flow rate

 R=d/2

Volume of the water tgank= r2h

=3.14*2*0.6*1.5=6.6 cm3

But volumetric flow =v/t

Then the tanker takes five hour for filling.

Volumetric flow =3.3m3/4hr

Volumetric flow=3.3cm3/hr Density of water= mass flow rate of water/volumetric flow

Mass flow rate = density * volumetric flow

=1000kg /m3 *3.3/hr =3500kg/hr

Then energy balance on the boiler

Min=3500 MOUT=3430

Tin=25 TOUT=200c
Then from the above simplified equation

Q= H where h=enthalpy

H = mh mhfg m=mass flow rate

hfg = enthalpy at saturated water

1 atm l bar then 8 bar = 0.8 M pas

Then enthalpy at 8 bar =2950 kj/kg= 665 kcal/kg

And also at temprature of 60c saturated water enthalpy will be

hfg =2345.4 kj/kg =80kcal/kg

Then Q=H = mh mhfg = m ( h hfg)

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

2.4. Over all plant efficiency analysis

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;

The workers of the company are too clovers.

It dominates and owns too much consumers.
 The water the company used for any application is their own from ground water not from
the towns supply.

2.5. Environmental impact analysis

Disposal of liquid from machines to the circumstance without any treatment

of water.
Disposal of heavy and light bad alcohols to the circumstance.
Emission of carbon dioxide to the surrounding from boiler and washer machine.
Disposal of solid waste materials like broken bottles.

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

THE OVERALL BENEFIT OF INTERNSHIP PROGRAM

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:

1. Helps us improve our practical skills.

2. Helps us upgrade our theoretical knowledge.

3. Helps us improve our interpersonal communicational skills.

4. Helps us develop team-playing skills.

5. Helps us develop costume of leadership skills.

6. Helps us understand work ethics related issues.

7. Helps us develop entrepreneurship skills.

3.1. In terms of improving practical skill

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.

3.2. In terms of upgrading theoretical knowledge

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.

3.3. In terms of improving interpersonal communication skills

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.

3.4. In terms of improving team playing skills

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.

3.6. In terms of understanding about work ethics

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.

3.7. In terms of entrepreneurship skills

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:

OPTIMIZATION OF ETHANOL FROM MOLASSES

FERMENTATION TO REDUCE EFFLUENT

4.1 Introduction and Background

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.

4.3. Significance of the Study

In these days the competitiveness of industries mainly depends on their own performance of
utilizing all available resources and minimizing waste. In addition, due to government policies
concern for environment create high pressure on organization. As a result, in order to assure
their sustainability, organizations start to focus on the reduction of effluent streams as well as
improve their productivity (product output per input).
The main aim of this thesis is to provide vital information to the power alcohol and liquor
producing factories with the view of preventing environmental pollution, maximizing
profitability and reducing cost of production through utilizing the available resource
efficiently. Moreover, this thesis work is expected to provide vital information for liquor
factories, sugar and other food industries which mainly faces high effluent problem. In
addition, it can also serve as a reference in the area of distillery technology.
4.4. Literature Review
Production of ethyl alcohol from cereals and molasses for drinking and power alcohol
comprises different unit processes and operations such as Fermentation, Distillation, Water
treatment, ingredient preparation and Effluent handling process. In order to obtain good quality
and maximum conversion of fermentable sugar in to ethanol it is necessary to focus on
fermentation process (DR.Nalini B.2009).
Fermentation Process
Fermentation is a bio-chemical process in which six carbon sugars such as fructose, glucose,
levulose etc are converted to ethyl alcohol and carbon dioxide which is catalyzed by enzymes
generated from yeast. Any polymeric hexose sugar present in any materials in the first instance
must be converted to hexose sugar units and then fermented in to ethyl alcohol. Conversion of
polyhexose to hexose is called hydrolysis and it is carried out either enzymatic ally or by
chemical means in batch and continuous fermentors. The major processing steps in alcoholic
fermentation are:
Raw material (substrate) preparation
Yeast propagation( inoculums preparation)
Final fermentation
Raw Material Preparation/Molasses treatment
Objective of molasses treatment (preparation):-
To reduce level of impurities
To obtain better performance & yield
To reduce scale formation
Lower steam consumption
Any sugar containing substances can be used as a raw material for alcohol production. The
raw material preparation process differs from substance to substance. Here we will consider the
raw material (molasses) which is used for ethanol production in distillery plants integrated to
sugar factories. The molasses supplied to the distillery must be prepared for alcoholic
fermentation. Raw material preparation includes dilution molasses to adjust the concentration
of the molasses media suitable for yeast, heating the media to increase the reaction of acid with
calcium in side molasses to avoid scale formation within distillation unit and decantation to
remove out precipitate (Ethiopian sugar corporation Training Manual.
Yeast Culturing and Recycling System
Yeasts are eukaryotic micro-organisms classified in the kingdom Fungi, with about 1,500
species currently described. These unicellular organisms reproduce asexually by budding.
Yeast species grow aerobically. Unlike bacteria, there are no known yeast species that grow
only an aerobically. Yeasts grow best in neutral or slightly acidic pH environment. Most yeast
cells die above 50C. There is little activity in the range of 0C to 10C. The cells can survive
freezing under certain conditions with viability decreasing over time. The most common mode
of vegetative growth in yeast is asexual reproduction or fission.
Propagation of yeast are done in two main steps such as first in the lab scale followed by
culturing in the bulk fermentation step on using culture vessels to increase the number of yeasts
suitable for bulk fermentation. In the lab about 10 liter molasses solution 14.0 brix in water and
maintain its pH 4.0-4.2 by sulfuric acid /H3PO4 with following supplements- 10 gram urea,
DAP 5 gram, 1.5 gram magnesium sulfate, 5.1 gram zinc sulphate, 30 gram yeast extract.
About 20 ml of this media is taken and poured to test tube which contains slanted yeast and
after propagation for 10 hours the media will be transferred to 250 ml flask having 125 ml
prepared media. Here after retention time of 10 hours it is transferred to 1 liter flask which
contains 800 ml media and finally after retention time of 10 hours the yeast mass is transferred
to bigger stainless vessel having 15 liter gross volume and 8 liter media here after passing for
10 hours, the propagated media will be transferred to fermentation station for further
propagation.
Yeast Recycling
In order to get maximum amount of alcohol from the same quantity of molasses matured yeast
will be re circulated. This process will be done by using either Separating the yeast after the
fermentation is completed in a fermentation tank by using a high speed centrifugal machine
and recycling the yeast so separated or separating the yeast from the fermented wash by
sedimentation of the yeast by adopting suitable technology
Final Fermentation Process
Fermentation is a process by which a chemical changes are brought about in an organic
substrate through the action of biochemical catalysts, called enzymes, elaborated by specific
types of living microorganisms. It is a metabolic process characterized by: incomplete
oxidation, and the transformation of large amounts of substances by comparatively small
amounts of organisms (paturau, 1989). There are different types of fermentations among which
the batch and continuous fermentation processes are the most common.
Batch Fermentation
Fermentation of molasses can be carried out in batch as well as in continuous bio reactors. In
batch fermenter, molasses having brix of 90 and 50% fermentable sugar is diluted with water
to give a solution of about 25 bx and 15 % fermentable sugars. This solution is called Wort.
The wort is pumped in to fermentation tanks, which are made of mild steel. Yeast which is
usually a strain of saccharomyces cervisiae is added to the wort contained in the fermentation
tanks. In some distilleries the yeast is developed every day from a test tube slant to about
20,000 liters in four stages of propagation by aerobic fermentation. The wort used for the
development of yeast is sterilized with steam heating, so that the yeast is not contaminated with
any kind of microorganisms which may lead to the production of undesirable products, other
than alcohol during fermentation. As the fermentation starts and the yeast multiply, a part of
the fermentable sugars content in the wort is consumed by the yeast for its own survival and
multiplication. Then anaerobic fermentation takes place, when the enzyme invertase contained
in the yeast converts the disaccharides like sugar in the molasses in to mono saccharides like
glucose and fructose. Subsequently the Enzyme Zymase contained in the yeast converts the
monosaccharides in to ethyl alcohol and carbon dioxide. When CO2 tries to escape from the
fermented wort it forms bubble and foam and needs addition of anti foaming agents like turkey
red oil. Since yeast needs nutrients for their survival, nutrients like ammonium sulphate, urea,
Phosphatic salts, etc are added to the wort in small quantities. In some distilleries in order to
arrest the growth of undesirable micro organisms, antibiotics like Benzyl Pencillin is added to
the wort in small doses. To maintain fermentation pH in the range of 4.3-5 sulfuric acid has
been usually added to the wort.(AgrawlPk etal,1998)
Anaerobic fermentation of feed stock in the distillery is an exothermic process. Therefore, the
temperature of wort in the fermentation tank goes up. The ideal temperature during
fermentation is between 30 to 33C, and beyond 37C, the yeast becomes in active and the
yield of alcohol will be reduced. Therefore, cooling of the fermented wort has been done by
spraying water on the surface of the fermenter to keep temperature of the fermenter in the
range of 30-33C. After the fermentation is completed in about 36 to 48 hours, which is
indicated by chemical analysis, the fermented wort is now known as wash containing about 6
to 8% alcohol in the wash. The activity of yeast will slow down as the alcohol % of wash goes
up. The fermentation efficiency, which is the ratio of actual production of ethyl alcohol in the
wash to the theoretical yield of alcohol calculated on the basis of the total fermentable sugar is
usually 80-85% in the batch process. The efficiency is relatively low as most of the batch
fermenters are open to atmospheres and liable for attack by micro organisms as well as for the
escape of alcohol with CO2 as the fermentation was carried out briskly. In some distilleries
CO2 the fermentation tanks are covered with mild steel hoods to collect and scrub it with
water and use this water for diluting the molasses and there by recovering the alcohol escaping
with the CO2 ( Bansal R.,SinghR,2003).
Control of microbial contamination as well as ethanol quality per batch are considered as a
merit for batch fermentation where as requirements of high capital investment for large scale
production, decrease in volumetric efficiency of fermentors and possible variation in
fermented wash quality from batch to batch on the other hand are taken as a demerit.
Continuous Fermenter
In continuous fermentation process, additional mash is added continuously or more commonly,
at short intervals to the fermenters. Continuous fermentations are simply a number of separate
fermentation tanks in series. The mash should enter at the bottom of the first fermenter, exit the
top, enter the bottom of the second fermenter, and so on. Total fermentation time is determined
by dividing the total capacity of the fermenter by the flow rate. There are different types of
continuous fermenters designs like Biostil, Hiferm, Encillium, Hoechst-UHDE, STRACOSA
Membrane all are working under continuous operation and with greater fermentation
efficiency it is greater than 90%. However, fermented wash brix was varied for different
fermenter design and consequently the alcohol % fermented wash is to the higher sides.
Continuous fermentation has also advantage and disadvantages.
Chemical Reaction During Fermentation
There are different chemical reactions occurred during fermentation processes such as the
production of alcohol from glucose by the action of Zymes-enzyme, inversion of sucrose to
glucose is done by invertase and different other types of biochemical reactions will occur to
form Acetic acid, lactic acid, diacetyl, acetone, Iso propyl alcohol, n- propyl alcohol, n-butyl
alcohol, etc. The biochemical reaction rather than formation of ethanol which occurs during
fermentation of molasses are not important as it resulted in reduction of fermentation.
C6H12O6 yeast 2C2H5OH + CO2 + heat
Glucose zymase Ethanol carbon dioxide
100 kg 51.1kg 48.9 kg 17935 KJ

C12H22O11 + H2O Yeast C6H12O6 + C6H12O6

Sucrose Invertase Glucose Fructose

fig4.1 Total material balance of walya factory distillery plant

4.5Methodology

4.6.Material and Energy Balance

Material and energy balance was done for effluent recirculation system in order to suggest
proper equipment size, such as pumps, cooler, piping and cooling water required in order to
use vinasse, spent lees and process condensate. The balance was done twice based on the
current operating brix of fermenters (15Bx) and the near future operating brix after installing
molasses clarification plant( as per this research 25Bx).
4.6.1. Material and Energy Balance for 15Bx Fermenter Brix
The distillery plant of Walya Alcohol Factory will generates about 568 tons of Spent
wash from Primary Column, 87 tons Spent lees from Rectifier Column and 238 tons of process
condensate from Spent wash Evaporators respectively per day. Out of this, 1% of spent wash
about 5.85 tons/day, 92% of Spent lees about 80 tons/day and 99% process condensate about236
tons/day will be expected to recirculate according to optimization of Effluent recirculation.
4.6.2. Energy Balance
Energy balance was done on Buffer tank and on re circulated effluent cooler to determine final
temperature of the re circulated effluent before cooler and after cooler. Besides, physical
characteristics of the effluent were determined.
Energy Balance on Buffer Tank :
Spent Wash(5.85 t/d, brix=13.6 %, temp= 85 C)
Spent residue(80.4 t/d, 120C) Re circulated
Process Cond(236 t/d, 55C ) Effluent (322.25t/d)
Energy in put to Buffer Tank with Effluent Stream = Energy out with Re circulated Stream
Buffer Tanks
Energy in : Mass of SW* Cp1*T1 + Mass of SL*Cp2*T2 + Mass of Pc* Cp3* T3
Energy in = 5.85 * Cp1*85C + 80.4t/d* Cp2 * T2 + 236 * Cp3* 55C
Where Cp1 is the Specific heat capacity of vinasse and it is found more accurately by using the
correlation derived by Gucker and Ayres(E.Hugot cane Sugar Hand Book 3rd edition page449).
Cp1 = [1- (0.6- 0.0018*T + 0.0008(100-P)*(B/100)]*4.182 KJ/kg/C
T = temperature of spent wash in C = 85C
B = brix of spent wash in % = 13.6%
P = Purity of Spent wash which is zero for this case.
Cp1 = 0.928*4.182= 3.88KJ/kg C
Cp2 andCp3 are the specific heat of Spent lees and Process condensate; and estimated by the
following equations (Perry Chemical Engineers hand Book page 2-174, Table 2-196).
Cp = C1 + C2* T2 +C3*(T2 )2 + C4*(T2)3 + C5*(T2)4
Where the value of C1 is 15359, C2 = -116.12, C3 = 0.4514, C4 = -0.00078422 and 5.206 E-
007 forC5. Taking the temperature of spent lees to be 120C (393K) and 55C (328K)for
process condensate. The value of Cp2 and Cp3 became 4253.24 J/kg.K and 4181.7 J/kg.K.
Substituting the above values in energy equation yields
Energy input = 97,188,568KJ
Energy out : Mass of Re circulated Stream* Cp4 * T4
Energy out = 322.25 t/d* Cp4 * T4
Where: Cp4 = [1- [0.6- 0.0018*T + 0.0008(100-P)]*(B/100)]*4.182 KJ/kg/C
= 4.176 kj/kg/C
Equating the equation of Energy in put = Energy out put
The final temperature of effluent in buffer tank became 72.4 C
Energy Balance on Cooler
Thermal energy entered to the cooler = Thermal energy leaving the cooler
Thermal Energy input = Energy with Effluent in + Energy in with cooling water
Thermal Energy output = Energy with cooled effluent+ Energy with warm water
Thermal Energy in = Mass of effluent* Cp4 * T4 + mass of cooling water* Cp*T cooling water
in
Thermal Energy out= Mass of effluent* Cp4 * T5 + mass of cooling water* Cp *T cooling water
out
Where T4= 72.4 C and T5 is the desired temperature of fermenter which is 34C. Cooling
water inlet and outlet temperatures will be maintained at 5 and 33C respectively.
Equating the energy balance equations and on rearranging
Mass of effluent*(72.4-34)*4.176 = Mass of cooling water* 4.182* (33-28)
322.25*(72.4-34)*4.176 = Mass of cooling water* 4.182*(33-28)
Mass of cooling water required = 441 tons/day.

4.7. Environmental Impact analysis

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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