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 MEKELLE UNIVERSITY

EIT-M

DEPARTMENT OF CHEMICAL ENGINEERING

PROJECT TITE EVALUETION OF BOILER EFFICENCY

HOSTING COMPANY - DESTA ALCOHOL AND LIQOURS FACTORY

GROUP MEMBERS

NAME ID. No
1 MASHO TEKLU 1748/05
2 MEHARI HAGOS 1180/05
3 NIGISTI ABADI 1754/05

OCTOBER; 2009 E.C

MEKELLE; ETHIOPI

ADIVISED BY G/AMLAK W/AREGAY

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 ACKNOWLEDGMENT

we would like to thank God for his merciful and endless guidance through our life
and for giving us a supportive and loving family and friends that are always there
through all our success and failure, supporting, cherishing and lifting us morally and
financially.

Next to God we would like to express our deepest gratitude to our advisor, Instructer
G/amlak W/aregay; we are grateful for his sincere commitment in offering invaluable
support, advice and motivation during the preparation of this project. Special thanks
go to the faculty members of the department of chemical engineering, for always
being available for consultation. We would also like to convey thanks to the
administrative and program staff for their patience in dealing with our seemingly
endless educational and research policy inquiries.

It is difficult to acknowledge every individual who contributed valuable efforts when

we were in internship program, but it is worth mentioning some of them. We would
like to humbly acknowledge our company supervisor Mr.GEBREMESKEL, giving us
the chance to practice in every section of the company.

Finally, we wish to express our love and gratitude to our beloved family and friends
for their moral and financial support in the successful completion of this dissertation.

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 ABSTRACT

The main objective of qualified internship program is useful to relate what we

have learned theoretically with how it is done at the factory. This project deals about
four month qualified internship practice program on DALF P.L.C. At QUIHA
considering all the PRODUCTION process. It has seven parts, in the first part of our
project; we briefly described the back ground of our internship hosting company.
Including the history and objective of the company, its main products and services, the
overall organization and work flow, the second party of our project briefly described
we explain the overall experience of the factory; we started by describe in which
section of the company we have been working in and the work piece and the activity
occurring in the factory. The third party of our project described about evaluation of
the efficiency for Furness oil fired boiler. The Fourth part of our project describes
about material and energy balance of the plant. The Fivth parts of our project
describes about mechanical and thermal design of boiler. The six parts of our project
briefly explains the about the overall benefits we gained from our internship in terms
of improving our practical and theoretical skills, interpersonal communication skills,
team playing skills, leadership skills, upgrading our theoretical knowledge and work
ethics. Finally covered our conclusions and recommendations for my company.

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Contents
ACKNOWLEDGMENT ................................................................................................................... i
ABSTRACT ................................................................................................................................... ii
LIST OF TABLES & FIGURES ......................................................................................................... v
LIST ABBREVIATION ................................................................................................................... vi
CHAPTER ONE ............................................................................................................................. 1
1.1 INTRODUCTION ................................................................................................................ 1
1.2. BACK GROUND................................................................................................................. 2
1.3. OBJECTIVES OF DESTA ALCOHOL FACTORY ..................................................................... 2
1.4. MISSION & VISION OF THE CAMPANY ............................................................................. 3
1.4.1. MISSION OF THE CAMPANY...................................................................................... 3
1.4.2. VISION OF THE COMPANY ........................................................................................ 3
1.5. LOCATION OF THE PLANT ................................................................................................ 3
1.6. RAW MATERIALS FOR PRODUCTION OF ALCOHOL ......................................................... 3
1.8. MAIN CUSTOMER OR END USERS ............................................................................................ 8
CHAPTER-TWO.......................................................................................................................... 10
OVERALL INTERNSHIP EXPERIENCE .......................................................................................... 10
2.1. THE SECTIONS OF THE COMPANY WHERE WE HAVE BEEN WORKING ......................... 10
2.2. THE WORK FLOW OF THE SECTIONS ............................................................................. 10
2.2.1. THE FERMENTATION PROCESS ............................................................................... 10
2.3. IN GENERAL WE EXECUTE THE FOLLOWING ................................................................. 13
2.4. THE PROCEDURES AND METHODS ................................................................................ 13
2.5. CHALLENGES WE HAVE FACED AT THE DALF................................................................. 14
CHAPTER THREE........................................................................................................................ 15
EVALUETION OF THE EFFICIENCY FOR FURNESS OIL FIRED BOILER ......................................... 15
3.1. INTRODUCION ............................................................................................................... 15
3.2. PROBLEM STATEMENT .................................................................................................. 16
3.3. LITERATURE REVIEW .................................................................................................. 17
3.4. METHODOLOGY ............................................................................................................. 19
CHAPTER FOUR ......................................................................................................................... 25
MATERIAL AND ENERGY BALANCE OF THE PLANT ................................................................... 25
CHAPTER FIVE ........................................................................................................................... 32
MECHANICAL AND THERMAL DESIGN OF BOILER .................................................................... 32
PART1: THERMAL DESIGN OF BOILER................................................................................... 32

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 PART2: MECHANICAL DESIGN OF BOILER ............................................................................ 37
CHAPTER SIX ............................................................................................................................. 40
OVER ALL BENEFIT FROM THE INTERNSHIP ............................................................................. 40
6.1. IN TERMS OF UP IMPROVING THEORETICAL KNOWLEDGE........................................... 40
6.2. IN TERMS OF IMPROVING OUR PRACTICAL SKILLS........................................................ 40
6.3. IN TERMS OF IMPROVING OUR TEAM PLAYING SKILLS ................................................. 40
6.4. IN TERMS OF IMPROVING OUR LEADERSHIP SKILLS ..................................................... 41
6.5. WHAT GAINED IN TERMS OF OUR ENTREPRENEURSHIP SKILLS.................................... 42
6.6. INDUSTRIAL PROBLEM SOLVING SKILL .......................................................................... 42
6.7. WORK ETHICS RELATED ISSUES ..................................................................................... 43
CHAPTER SEVEN........................................................................................................................ 44
CONCLUSION AND RECOMMENDATION .................................................................................. 44
CONCLUSION ........................................................................................................................ 44
RECOMMENDATIONS ........................................................................................................... 45
REFERENCE ............................................................................................................................... 46
APPENDIX-1: THEORETICAL AIR REQUIREMENT....................................................................... 47
APPENDIX-2 .............................................................................................................................. 49

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 LIST OF TABLES & FIGURES
Tables

Table-1 Molasses ............................................................................................................ 4

Table-2boiler efficiency ............................................................................................... 19
Table- 3 result boiler efficiency.................................................................................... 24
Table-4 thermo physical properties of fluids ................................................................ 33

FIGURES

Figure-1alcohols ............................................................................................................. 7
Figure-2 Denature Alcohol ............................................................................................. 8
Figure-3 over all organization and work flow ................................................................ 9

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LIST ABBREVIATION

 GCV = gross caloric value

 q= quantity of fuel
 Q= quantity of steam
 M =mass
 V =volume
 D =density
 ts= shell thickness
 th= head cover thickness
 tc=channel cover thickness
 tts= tube sheet thickness
 tn =nozzle thickness
 A=area
 Cp=specific heat capacity
 TC =caloric temperature of hot gas
 Tc=caloric temperature of cold gas
 NCV=net caloric value
 EA=excess air supplied
 DAP= di ammonium phosphate
 hf=enthalpy of feed water
 hg=enthalpy of saturated steam

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 CHAPTER ONE

1.1 INTRODUCTION

The ethanol production is among the oldest technology and is produced commercially
by fermentation of cereal grains, molasses or other materials with high starch and/or
sugar contents. The fermentation process involves conversion of sugars to alcohol and
carbon dioxide by the yeast Saccharomycescerevisiae. Ethanol is produced through
the fermentation of agricultural by-products such as sugarcane, wheat, sugar beet and
cassava, among others.
Molasses is commonly used as a feedstock for bioethanol production. Molasses, the
non crystallizable residue remaining after sucrose purification, has some advantages: it
is a relatively inexpensive raw material, readily available, it does not require starch
hydrolysis and already used for ethanol production The molasses obtained after sugar
beet processing contains about 60% sucrose and 40% other components. The non-
sucrose substances include inorganic salts, refines, ketoses, organic acids and nitrogen
containing compounds.
Ethanol known as ethyl alcohol or grain alcohol is a flammable, colorless, mildly toxic
chemical compound with a distinctive perfume like odor.Ethanol (CH3C2OH), the active
ingredient in alcoholic beverages, is almost always produced by fermentation- the
metabolism of carbohydrates by certain species of yeasts in the absence of oxygen.
The process of culturing yeast under alcohol-producing conditions is referred to as
brewing.

Depending on the type of beverage the concentration of these liquors can range
between 3% & 30% by volume. The main ingredient, ethanol, can be obtained from a
variety of agricultural products such as grain molasses, fruits grapes etc. As our
country is rich enough in molasses which can be found easily & relatively with
cheaper price alcohol is extracted from molasses. Desta alcohol & liquor factory
produces ethyl alcohol with 97% volume by volume for preparation of different
liquors or sales purpose.

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1.2. BACK GROUND

While no one knows when beverage alcohol was first used, it was presumably the
result of a fortuitous accident that occurred at least tens of thousands of years ago.
However, the discovery of late Stone Age beer jugs has established the fact that
intentionally fermented beverages existed at least as early as the Neolithic period
(10,000 B.C). Desta alcohol and liquor factory was established by two brothers Mr.
Tsegabu Belay and Gebre Belay. The Belay family established Desta Alcohol in
2000G.C as a separate entity in Mekelle Industrial Area to produce alcohol and liquors
for consumption and industrial purposes. Desta produces 8 types of consumption
alcohol and liquors and two types of Industrial Alcohols. DALF has been working day
and night to satisfy all the demands its customers. Desta alcohol & liquors factory plc.
has been established in the year 2000G.C with the name of “desta zebib liquor
factory” by two motivated brothers holding 50%_50% share focusing in producing &
distribution of alcohol sprit product.

1.3. OBJECTIVES OF DESTA ALCOHOL FACTORY

 To produce standardized quality beverage products at different levels for local

and export market that quench the thirst of its customers in the community.
Based on continual assessment of the demand, expand the provision of alcohol
and liquor products.
 Create different outlets (wholesalers, retailers) and there by distribute its
products to local as well as export market so as to enhance the development of
commerce. As it is a business entity, generate a higher return on investment to
the owners of the project.
 To determine the vertical and horizontal relationship among the different work
units.
 To produce Alcohol of high quality with optimum cost, time and fitness.
 To achieve the required quantity of alcohol from a given raw material.

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1.4. MISSION & VISION OF THE CAMPANY

1.4.1. MISSION OF THE CAMPANY

 To be the best and most successful industry in the beverage industry.
 Provide high quality beverage products.

1.4.2. VISION OF THE COMPANY

 To ensure that desta alcohol and liquor factory plc. is the customer‟s first
choice through the delivery of sustainable quality productions in the beverage
industry.

1.5. LOCATION OF THE PLANT

 As described above, the sprit production is found in Mekelle industrial zone in

semen woreda at quiha.The distiller and fermentation process are found in
northern part of quiha which is 12 kilometers apart from Mekelle.
 The selection criteria for plant location will be based on the following:-
a. Nearness to market
b. Availability of infrastructure
c. Situation of atmosphere
d. Nearness to raw material

1.6. RAW MATERIALS FOR PRODUCTION OF ALCOHOL

 Molasses
 Yeast
 Water
 Diammonium phosphate (DAP)
 Sulfuric Acid
 Purified air
 Steam
 Anti foam
 Essence
 Sugar (local sucrose)

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A. Molasses

Pure alcohol is produced from the main raw materials that we call molasses in our country.
Molasses is produced from sugar factories as a byproduct it is more (suitable & comfortable )
then for handling amount of production as compared to other raw materials used to produce
alcohol. Molasses is a brown black color, having a concentration of 80% brix and pumped to the
fermentation room diluted by water to 15% brix and 25%brix and 1.4-1.5 true density. It is a
very highly viscous liquid. Molasses is a Latin language which means “Honey”. Molasses is
obtained from sugar factories such as Mathura and Wangi sugar factory. It is unloaded and stored
in a concrete tanker with two compartment of dimensions (width of 8.83m, length 22.35m and
height 4m each) and costs 70 birr/Tone. It is transported to the Alcohol factories by a trucks
owned by the factory itself.

Table-1 Molasses

Component 30-35

sucrose 10-15

Reducing sugar 10-12

Ash 12-20

Water 12-20

Total sugar % dry solids 55-60

B. WATER
The water which used in distillation or to make pure alcohol is soft water. Soft water is water
which has relatively low concentration of calcium carbonate and other ions. In all fermentation
process water plays high role to dilute high molasses brix (78-85%) to low brix molasses (10-16)
Water is also used as a general cleaning.

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C. Di Ammonium phosphate (DAP)
Di ammonium phosphate (DAP) is the world‟s most widely used phosphorus (p) fertilizer. It is
made from two common constituents in the fertilizer industry and it is because of its relatively
high nutrient content and its excellent physical properties. It is used as nitrogen source of the
yeast. Its amount is in order of 1kg per 500liter of molasses of solution. It‟s obtained from local
market and costs about 14.36 birr/kilo
D. Sulfuric Acid (H₂SO₄)
Sulfuric acid is used in this factory or industry during propagating of yeast that means Sulfuric
acid mainly used by killing different kind of bacteria that growing inside the tanker. The
concentrated H₂SO₄ of 96% concentrated is added at the unit of low brix mash preparation. This
is in order to:-
 Restrict the production of bacteria & the movement of unwanted yeast &
ready it for fermentation.
 Optimize the media or to lower the ph range because acidic media with ph of
4.0 to 4.5 is optimum condition for yeast.
 Reduced unnecessary yeast that share the fermentation yeast used to ferment
ale.
 Creates good environment for yeast & give good quality alcoholic ale
E. Yeast
Yeasts are eukaryotic microorganisms classified in the kingdom Fungi, with 1,500 species (1%
of all fungal species). Yeasts are unicellular, although some species with yeast forms may
become multi cellular Yeast size can vary greatly depending on the species, typically measuring
3-4 μm in diameter, although some yeast size can reach over 40μm.
In fermentation process, the yeast species Saccharomycescerevisiae converts carbohydrates to
carbon dioxide and alcohols. It is one of the most important fungi in the history of the world.
This yeast is responsible for the production of ethanol in alcoholic drinks. This specific type of
yeast is selected because:-
 They grow vigorously
 They have high tolerance for alcohol
 They have a high capacity for producing a large yield of
alcohol.

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The process in which it produces ethanol is one way this yeast converts glucose into energy.
There are two ways Saccharomycescerevisiae breaks down glucose. One way is through aerobic
respiration. This process requires the presence of oxygen. When oxygen is not present the yeast
will then go through anaerobic fermentation. The net result of this is two ATP, and it also
produces two by products; carbon dioxide and ethanol. So if this yeast is allowed to grow in a
container lacking oxygen it will produce ethanol (alcohol).
Yeast is facultative anaerobes, and can grow with or without oxygen. In the presence of oxygen
converts sugars to CO₂ energy and biomass. In anaerobic conditions, as in alcoholic
fermentation, yeast do not grow efficiently, and sugars are converted to intermediate by products
such as ethanol, glycerol and CO₂. Saccharomycescerevisiae is obtained from local market and
costs about 200 birr/ kilo.
1.7. THE MAIN PRODUCT AND SERVICE

The main products of Desta alcohol and liquor factory is two in general, ethanol and liquor as
well as denature alcohol as well as from the effluent treatment plant is methane gas and powder
urea.
The first phase about alcohol and liquor is as follow
The use of ethanol is
 For drinking
 For pharmaceutical ingredients
 For laboratory service
 For other factory serve as raw material.
 As source of fuel

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The physical parts of liquors are as follow

Figure-1alcohols
The use of these liquor are for different drinking purpose in every hotel, in almost in every house
of the region, especially those are used in the new year, in holiday, in wedding, etc.
Denatured alcohol (methanol); this alcohol is also known as fire alcohol. These products
contain poisonous substances that humans should not swallow is regarded as a byproduct of
DALF. This is also one of the products in the distillation process with in alcohol content of 95%.

This alcohol is separated from the ethanol alcohol at the rectification column. These products
use different colorants from the other products in order to identify the customer from the other
alcoholic beverages (It has pink color). These are used to reduce infection when there is some
damage is found on external part of our body. In other case they are used for medicinal purpose,

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 clinical purpose, beauty salons barberries, cleaning electrical equipment, and for cooking
purpose.

 The denature alcohol is used in the following places

 In Hospital and pharmacy
 In Barberry house and beauty salons
 In house for food preparation to burn the materials
 In animal treatment for disease
 For washing electronic material

1.8. MAIN CUSTOMER OR END USERS

The main products of DALF are not exported in to foreign country; it‟s distributed in the whole
country. DALF have no main customer of the pure alcohol
rather the company uses the pure alcohol to produce
liquors. The reasons are the followings; The Company
uses small boiler; which is used to produce steam, All
operational system of the company are manually and the
capacity of the distillation section is small.
The main customers of the factory are found in

 Mekelle town Shire town Figure-2 Denature Alcohol

 Alma-Ata town Axum town
 Adigrat town
1.9. OVER ALL ORGANIZATION AND WORK FLOW

The company (Desta alcohol & liquor factory plc.) is oriented at different level to perform its
goal. Each level has back ward & forward integrating with close vertical & horizontal
communicating to accomplish its planned activities accordingly. The company has four
departments and their accountability is to general Manager. From these four departments,
production department are four unit operations (sections).Those are fermentation, distillation,
liquor preparation (blending) &waste water treatment. The detail organizational structure of
Desta alcohol &liquors factory private limited company is as follow.

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 OVER ALL ORGANAZATION STRUCTURE

Share holder

Audit committee

GENERAL MANAGER

Legal service Executive secretary

Finance & Quality

Marketing &sales
Production administration control
department
&maintenance department department
Type equation here.

n
Producti Maintena Supplies &general
on Marketing Sales&
nce Finance services sections
division promotio product
division
n division division division

Maintenance
repair
section Sales&
Liquor
produc customer General
Marketing Supplies
tion service account
research section
Elect Mech section
section section
rical anica
unit l unit
Finished
Promotion product Costs General
section service &budget service section
Alcohol
production section
`Figure-3 over all organization and work flow

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 CHAPTER-TWO
OVERALL INTERNSHIP EXPERIENCE
2.1. THE SECTIONS OF THE COMPANY WHERE WE HAVE BEEN WORKING

we have grasped experiences in Desta alcohol and liquor factory in the sections of fermentation
process, distillation process, liquor production process and waste water treatment plant. During
our internship practices we have inset know how on the production of alcohol and liquor look
like in practical over view, and how the is working practically for treatment of the ethanol
alcohol wastage. However, the fermentation process, the distillation process, the waste treatment
plant section are where we particularly work at.

2.2. THE WORK FLOW OF THE SECTIONS

2.2.1. THE FERMENTATION PROCESS;

The fermentation process follows three steps based on the alcohol content of the mash, the
amount of carbon dioxide created during the reaction, the degree of temperature in the chemical
reaction and the general conditions of yeast in the fermentation process.

1. Pre-fermentation process;

In this stage, a small amount of carbon dioxide is observed as yeast are propagated and the syrup
may not have foam. Large amount of sugar is used for the yeast propagation rather than
converting into alcohol due to this reason the amount of alcohol 3-4% by volume which is less
compared to other stages. The time needed to undertake fermentation depends upon the amount
of yeast transformed from the mother tank thus if large amount is used the time will be shorter.
The time taken to end the propagation stage of yeast in the mother tank is about 12 hrs. and it can
be checked using the following measurements weather the yeast is completely grown. In this
stage sugar concentration is 1.5-2%, alcohol content 2-4% by volume, degree of brix 3.2 and PH
value 4.

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 2. Main fermentation process;

The amount of carbon dioxide released will start to increase the chemical reaction and formation
of foam will be facilitated under this stage and the temperature must be controlled not to exceed
more than 32c it can cause high rate of chemical reaction and formation of foam. Maximum
amount of alcohol content (7-9%) is observed.

3. Final fermentation process;

In this stage the process of fermentation becomes to end and if the bricks measurement are
constant for three hrs. The mash must be transformed into decantation tank. In this stage the
sugar concentration is 0.2-0.5%, alcohol content 7.9% by volume, degree of brix 6.96, and PH
value is the distillation process;

In Desta alcohol and liquors factory has three columns to undertake effective and efficient
separation s/m. An average plant daily output capacity is 5000-6000 liters of ethanol alcohol.

I. Mash column (degasifying & exhausting column)

II. Purifying column
III. Rectification column
I. Mash column;
This column operates in a vacuum pressure in order to reduce the boiling point of water which is
help full in controlling the precipitation of CASO4 as temperature goes beyond the relative
vacuum pressure or above 800c.This process is done with the help of condensers and pumps. In
this column, the completely fermented mash of 7-9 % alcohol by volume is preheated in E-510
& fed to the distillation column.

The mash column is composed of C-510 bottom analyzing column and C-520 top degasifying
column. Degasifying column is used to remove most of the unpleasant odor& CO2 gas
Dissolved in the mash. The vapor leaving the top of this column is usually removed as by
product alcohol of low strength and unpleasant odor through F-521.The liquid flowing through
this degasifying column reaches the bottom analyzing column(C-510) which is condensed in
water cooled condensers and contains about 30%-50% alcohol. To obtain good percentage yield,
the mash coming from fermentation must have at least 7.5-8% alcohol and to save energy, the
vapor leaving the top of degasifying column is used to pre heat the incoming mash.

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II. Purifying column;

The condensate of the mash column is pumped to this column (C-530). The alcohol entering to
this column is diluted to about 15% through the F-540 to enhance the separation of the mixtures.
This column operates under atmospheric pressure and the undesirable lighter alcohols are
recovered as head products through E-530. Some part of product is returned as a reflux to C-530
with FI-530 and the remained will goes to E-531 to condensation and produced as denatured
alcohol with FI-531, while purified alcohol of low strength is recovered as a bottom product of
this column through the lower segment together with the discharge to the C-540. The alcohol
content of the liquid leaving this column is estimated to be about 33%.

III.Rectification column;

The bottom products from the purifying column are pumped as liquid feed to the rectifying
column. A cool zone is provided in this column, which prevents the fusel oil vapor from reaching
the top of the column. The alcohol solution entered to this column will be processed in to three
products.

 Rectified alcohol having a concentration about 96% by volume is taken off as liquid from
a place near the top of this column & sent pure alcohol cooler through FI-546 and then to
pure alcohol storage.
 The overhead vapor it is condensed & partially returned to the column as reflex while the
rest is removed and sent to storage as technical alcohol F-541 as head products.
 Impurities from the side of the rectification column are fed to fusel oil separator. The
fusel oils are tail side products and feed to a settler through FI-543 as high tails. Finally,
the heads, tails, and high tails will be recovered as impurities and sent to denature alcohol
line, while the high tails go to fusel oil separator for separation.

In general, there are two types of impurities. These are light (head) products and heavy (tail)
products.

a.Light products-; having lower boiling point than ethanol alcohol and obtained from the top of
the columns.

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  Aldehydes expressed in acetic aldehyde with boiling point of pure substance around 35
0C
 Easter expressed in methyl and ethyl with boiling point from 56-760C
 Methyl alcohol with boiling point 77 0C
b.Heavy alcohols–with higher boiling point than ethanol alcohol.
 High alcohols-their chemical structure is more complex than ethanol, expressed in
aisobuthylic alcohol and separated with boiling point from 81-110C
 Fusel oil- is expressed in iso-metric alcohol with boiling point around 1300C.
Acetic acid- it can be obtained from fermentation or from ethanol oxidation and separated
with boiling point of 1180C.

2.3. IN GENERAL WE EXECUTE THE FOLLOWING;

In the fermentation section all activity is done manually such as mixing of molasses with water
to get the desired bricks , adding yeast, sulphuric acid and DAP thus we have been executing the
task mentioned above. And we were in charge of checking the temperature of the fermenter
tankers and mother tank to keep the temperature on the range of 27-40 and 27-33 consecutively.
The temperature can be controlled through the aid of thermometer installed in the mother and
fermentation tanks, we have been reading the temperature at a time interval.

If the temperature in the fermentation tank is fluctuating then one of the following problem are
encountered lass/excess sugar amount, less yeast, low/high temperature, low/high PH value.

2.4. THE PROCEDURES AND METHODS

I.Procedure in the mother tank

 Prepare a 15 brix molasses
 Add 5 kg of DAP, 2 litters of sulphuric acid,. of purified air, 3 kg of yeast
 Keep all conditions optimum for the yeast such as temperature, the temperature
should be at the range of 27-32c. if its below 27c the yeast will not activate as a
result ethanol yield is poor and if its above 32c the yeast begins to fall off and the

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 activity of other undesirable microorganisms arise and this will lead to other side
reactions. After 12 hrs. the yeast reach its maximum point of propagation.
II. In the main fermentation
 Transfer all the media (propagated yeast) to the mother tank.
 Keep all condition at the required level. If the temperature in the fermentation tank is
fluctuating then one of the following problem are encountered lass/excess sugar amount,
less yeast, low/high temperature, low/high PH value.
 After 72 hrs. Send the fermented mash to decantation tank in order to settle and remove
the sludge.
 Send the fermented mash to the distillation unit.
III. Procedure in distillation

The feed is introduced at one point along the column shell; the column is derived into upper
section, which is called rectifying section and the lower section called exhaustion section.

Begin by slowly heating up of the two columns by opening corresponding steam line valves.
When C-530 starts to work, the reflux FI-530 running and the bottom level of it reaches 50%
from sight glass, start feeding C-540 column by opening discharge valve and start feeding by
switching on P-530 pump with FI-500.open inlet and outlet valve of FI-530 depuration reflux
flow meter to permit circulation when over heads begin condensation in E-530 and E-531
condensers When the bottom level of C-540 reaches 50%, extraction of white stillage can be
started. The bottom temperature (TI-540) is more than 100c, open fully to send white stillage
discharge. Start dilution in C-530 by switching on P-540. Open corresponding valves, pump and
adjust the flow FI-542. Start low tails extraction from C-540, opening one of the different
extraction lines of FI-543 flow meter. Start high tails extraction from C-540 opening. Open inlet
and outlet valves of cooling water.
2.5. CHALLENGES WE HAVE FACED AT THE DALF.
 The workers of the factory didn‟t explain the production process in detail.
 Lack of technology in that factory means the process is not computer aided.
 Limitation of reference as well as guidelines about the production.
 There was no body specifically suggested advisor so they could not advise us properly.
The measure to overcome the challenge

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  We were gathering different information‟s from office manager and internet.
 We asked any Personnel (workers) to give me any information related to their job.

CHAPTER THREE
EVALUETION OF THE EFFICIENCY FOR FURNESS OIL FIRED BOILER
3.1. INTRODUCION

Boilers
Are closed steel vessels for heating and vaporizing water (or other fluid) into steam, often
driving turbines or generators, or heating buildings. Most boilers are welded alloy-steel
structures (but not stainless steels), per many industry codes

Liquid fuels like furnace oil are predominantly used in industrial application. This is due to
the high content of GCV and fair cost. So in this project the efficiency of boiler that use
liquid fuel that is Furness oil is analyzed in simple manner by calculating the following
parameters.

 Loss of heat due to dry flue gas

 Loss of heat due to moisture in fuel and combustion air

 Loss of heat due to combustion of hydrogen

 Loss of heat due to radiation

 Loss of heat due to un burnt

Finally the values of the above parameters are subtracted from 100% and compare the value
with standard efficiency.

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\

3.2. PROBLEM STATEMENT

Desta alcohol and liquor factory has a fire tube boiler type of boiler that uses oil and natural
gas as a source of fuel to produce steam for the distillation process. As a result we want to
evaluate the efficiency of the boiler when it uses Furnace oil for the steam production.

General objective

 To determine the boiler efficiency that uses fuel oil.

Specific objective

 To determine heat loss due to flue gas.

 To determine heat loss due to evaporation of water of moisture.
 To determine heat loss due to moisture percentage in air.
 To determine heat loss due to unburned in fly ash.

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3.3. LITERATURE REVIEW
The various types of fuels like liquid, solid and gaseous fuels are available for firing in boilers,
furnaces and other combustion equipment‟s. The selection of right type of fuel depends on
various factors such as availability, storage, handling, pollution and landed cost of fuel.

The knowledge of the fuel properties helps in selecting the right fuel for the right purpose and
efficient use of the fuel. The following characteristics, determined by laboratory tests, are
generally used for assessing the nature and quality of fuels.

Properties of Liquid Fuels

Liquid fuels like furnace oil are predominantly used in industrial application. The various
properties of liquid fuels are given below.

Density

This is defined as the ratio of the mass of the fuel to the volume of the fuel at a reference
temperature of 15°C. Density is measured by an instrument called hydrometer. The knowledge
of density is useful for quantity calculations and assessing ignition quality. The unit of density is
3
kg/m .

Specific gravity

This is defined as the ratio of the weight of a given volume of oil to the weight of the same
volume of water at a given temperature. The density of fuel, relative to water, is called specific
gravity. The specific gravity of water is defined as 1. Since specific gravity is a ratio, it has no
units. The measurement of specific gravity is generally made by a hydrometer.

VISCOSITY

The viscosity of a fluid is a measure of its internal resistance to flow. Viscosity depends on
temperature and decreases as the temperature increases. Any numerical value for viscosity has no

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meaning unless the temperature is also specified. Viscosity is measured in Stokes / Centistokes.
Sometimes viscosity is also quoted in Engler, Saybolt or Redwood. Each type of oil has its own
temperature - viscosity relationship. The measurement of viscosity is made with an instrument
called Viscometer.

Viscosity is the most important characteristic in the storage and use of fuel oil. It influences the
degree of pre-heat required for handling, storage and satisfactory atomization. If the oil is too
viscous, it may become difficult to pump, hard to light the burner, and tough to operate. Poor
atomization may result in the formation of carbon deposits on the burner tips or on the walls.
Therefore pre-heating is necessary for proper atomization.

Specific Heat

o
Specific heat is the amount of kcals needed to raise the temperature of 1 kg of oil by 1 C. The
o
unit of specific heat is kcal/kg C. It varies from 0.22 to 0.28 depending on the oil specific
gravity. The specific heat determines how much steam or electrical energy it takes to heat oil to a
desired temperature. Light oils have a low specific heat, whereas heavier oils have a higher
specific heat.

Calorific Value

The calorific value is the measurement of heat or energy produced, and is measured either as
gross calorific value or net calorific value. The difference being the latent heat of condensation
of the water vapor produced during the combustion process. Gross calorific value (GCV)
assumes all vapor produced during the combustion process is fully condensed. Net calorific
value (NCV) assumes the water leaves with the combustion products without fully being
condensed. Fuels should be compared based on the net calorific value.

Sulphur

The amount of sulphur in the fuel oil depends mainly on the source of the crude oil and to a
lesser extent on the refining process. The normal sulfur content for the residual fuel oil (furnace
oil) is in the order of 2-4 %. The main disadvantage of sulphur is the risk of corrosion by

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 sulphuric acid formed during and after combustion, and condensing in cool parts of the
chimney or stack, air pre heater and economizer.

3.4. METHODOLOGY

 direct and Indirect or heat loss method

Table-2boiler efficiency

I.DIRECT METHOD

This is also known as „input-output method‟ due to the fact that it needs only the useful output
(steam) and the heat input (i.e. fuel) for evaluating the efficiency.
This efficiency can be evaluated using the formula

Equation-1 boiler efficiency

Parameters to be monitored for the calculation of boiler efficiency by direct method are:

 Quantity of steam generated per hour (Q) in kg/hr.

 Quantity of fuel used per hour (q) in kg/hr.

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  The working pressure (in kg/cm2) and superheat temperature (oC), if
any

 The temperature of feed water (oC)

 Type of fuel and gross calorific value of the fuel (GCV) in kcal/kg of
fuel

• Where,

 hg – Enthalpy of saturated steam in kcal/kg of steam

 hf - Enthalpy of feed water in kcal/kg of water

• Advantages of direct method:

 Plant people can evaluate quickly the efficiency of boilers

 Requires few parameters for computation

 Needs few instruments for monitoring

• Disadvantages of direct method:

 Does not give clues to the operator as to why efficiency of system is lower

 Does not calculate various losses accountable for various efficiency levels

II.INDIRECT METHOD
It is also called as heat loss method.
The efficiency can be arrived at, by subtracting the heat loss fractions from 100.
The principle losses that occur in a boiler are:
 Loss of heat due to dry flue gas

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  Loss of heat due to moisture in fuel and combustion air
 Loss of heat due to combustion of hydrogen
 Loss of heat due to radiation
 Loss of heat due to unbur
• The data required for calculation of boiler efficiency using indirect method are:

 Ultimate analysis of fuel (H2, O2, S, C, moisture content, ash content)

 Percentage of Oxygen or CO2 in the flue gas

 Flue gas temperature in 0C (Tf)

 Ambient temperature in 0C (Ta) & humidity of air in kg/kg of dry air.

 GCV of fuel in kcal/kg

 Percentage combustible in ash (in case of solid fuels)

 GCV of ash in kcal/kg (in case of solid fuels)

Theoretical air required = [(11.6*C)+{34.8*(H2-O2/8)}+4.35*S]/100

Kg/kg of fuel. [from fuel analysis]
=[(11.6 x 84) + [{34.8 x (12 – 1.5/8)} + (4.35 x 1.5)] / 100
=12.67892 kg/kg of oil

b) Excess Air supplied = (O2)%/(21-O2%)*100

(EA) [from flue gas analysis]

=7.4/(21-7.4)*100
=53.4 %

c) Actual mass of = {1 + EA/100} x theoretical air supplied/ kg of fuel (AAS) air

={1 + 54.4/100} x 12.67892

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 =21.49 kg / kg of fuel

Mass of dry flue gas = Mass of (CO + SO + N + O ) in flue gas + N in air we are supplying.
2 2 2 2 2

Mass of dry flue gas =

. . . . .

=21.3345kg / kg of oil

% Heat loss in dry flue gas =

= . .

L =7.8546%
1

Heat loss due to evaporation of = p T Ta

o ue
water due to H in fuel (%)
2

= .

L =7.0789%
2

% Heat loss due to moisture in fuel =

. .
= .

L = 0.033567%
3

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Heat loss due to moisture in =
air
.
= . .

L = 0.38456 %
4

Radiation and convection loss (L )

5
4 4 1.25
=0.548 x [ (T / 55.55) – (T / 55.55) ] + 1.957 x (T – T ) x sq.rt of [(196.85 V +
s a s a m

68.9) / 68.9]

4 4 1.25
=0.548 x [ (353 / 55.55) – (303 / 55.55) ] + 1.957 x (353 – 303) x sq.rt of [(196.85 x
3.8 + 68.9) / 68.9]
2
=1303 W/m
=1303 x 0.86
2
=1120.58 kCal / m
Total radiation and convection loss per hour
2
= 1122 .58 x 90 m
=100851.2 kCal
% Radiation and convection loss
=

.
.

L = 0.3782 %
6

Normally it is assumed as 0.5 to 1 % for simplicity

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Boiler efficiency by indirect method =100 – (L + L + L + L + L )
1 2 3 4 6

=100-(7.86 + 7.08 + 0.033 + 0.38 + 0.38)

=100 – 15.73
=83.9827 %

Table- 3 result boiler efficiency

Heat Input = 10000 100

Losses in boiler :
1. Dry flue gas, L = 786 7.86
1

2. Loss due to = 708 7.08

hydrogen in fuel, L
2

3. Loss due to Moisture = 3.3 0.033

in fuel, L
3

4. Loss due to Moisture = 38 0.38

in air, L
4

5. Partial combustion of = 0 0
C to CO, L
5

6. Surface heat losses, = 38 0.38

L
6

Boiler Efficiency = 100 – (L + L + L + L + L ) = 84.27 %

1 2 3 4 6

This implies the use of liquid fuels as source of boiler is necessary. The reason is that the
efficiency of an efficient boiler that uses Furness oil is measure from 80 up to 85 %.

Generally from this number we can say Desta alcohol and liquor factory is in an efficient
way. So, since heavy fuel oil is very viscous, and this property varies sharply with
temperature. The meter, which is usually installed on the combustion appliance, should be

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regarded as a rough indicator only and, for test purposes, a meter calibrated for the particular
oil is to be used and over a realistic range of temperature should be installed. Even better is
the use of an accurately calibrated day tank.

CHAPTER FOUR
MATERIAL AND ENERGY BALANCE OF THE PLANT
Basis: one operation day/24hr Production: 230 lit/hr of ethanol (97%).

To calculate the mass of ethanol we use the formula, Mass = Density*Volume

= ƍ*v

Whereƍ of ethanol, ƍ = 6.61 . and 230 = 60 .

M = 6.61 .*60 . = 396.6 . M = mass

= 396.6 .* . which is the output of the distillation column D.

.

Material balance for distillation

It is the equipment used for the purification of ethanol from water-ethanol mixture. the mixture
from fermentation enter in to the distillation with the mixture of 10% ethanol and the rest water,
then with two series distillation column the purification of ethanol come to 97%.

F D

Feed Distillation Xe =
97

Xe = 10 Xw =3

Xw = 90 W Xe = 0

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Xw = 100

Mass balance based on ethanol,

F*Xfe = W*Xwe +D*Xde but, W*Xe = 0

F= . . .

F=W+D

W = 1744 – 179.89 = 1563.11 .

Material Balance for Fermentation

Mass media

Molasses dilluted
Fermentation
Mass mesh

M Co2

To calculate the unknown masses can be calculated based on the reaction

C6H12O6 2C2H5OH + 2CO2

180 92 88

Assume 100 conversion.

Then 180 = 92

X = 178.89

X = 352.95 kg/hr. glucose in the molasses.

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To calculate the mass of carbon dioxide

180 = 352.95

88 = Y

Y = 173.06. Of carbon dioxide.

Then the mass of media is to be assumed 10 % of the diluted molasses.

So, the total material balance on the fermentation is as follow

Mmolassesdillutted + Mmedia =Mmesh + MCO2

Mmolassesdillutted + 0.1Mmolasses = 1564.11 + 172.06

Mmolassesdillutted = 1577.33 kg/hr

Mmedia = 0.1*1579.33 157.8 kg/hr.

Energy Balance

Energy balance on the Fermenter

Mass media = 156.83

Molise diluted = 156.33

Fermentation
Mmesh = 1744

M CO2 = 172

The fermentation reaction is exothermic reaction and the average temperature is 30 0c

Then we have the following data CPmixture at 30 0c = 4.152

CPCO2at 30 0c = 0.846

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And assuming the referencetemperature at 0 0c.

Qmix = QCO2 + Qf + Q

Q =Qmix – QCO2 – Q f

Q =Mmix*CPmix*T – Mco2*CPCO2*T – Mf*CPf*T

Then cpf is calculated as follow

Cpf = CPmix*Xmix + CPCO2*XCO2

Xco2 = 172/(157.83+1578.33) = 0.099

Xmix = 1 – 0.099 = 0.9

So, CPf = 4.142*0.9+0.846*0.099 = 3.791kj/kg k.

So, Q = 1736*4.142(30-0) – 172*0.846*(30-0) – 1744*3.81(30-0)

1201087.9kj.

Energy balance on Distillation column

On Rectification column

Input output

D = 179.89

FTemerature = 35 0c Xe=97

Xe=10Xw=3

Xw=90

F = 1744 B=1564.2

Xe=0

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Xw=100

Then as we have done above we need to do material balance based on ethanoto calculate the heat
on the distillate

Based on overallbalanceon ethanol

F*Xfe = D*Xde

1744*0.1 = D*0.97

D == 179.79.

Total mass balance

F =W+D

W = F–D

W = 1744 – 179.79

= 1564.2kg/hr.

So the energy balance becomesimpler now

Starting with heat capacity on the top and assuming basis T =250c and 1 hr.

CP of Distillate = Xe*CPe +Xw*CPw

CP of ethanol = 2.72.and CPw = 4.18

Then CP distillate = 0.95*2.72 + 0.05*4.18

= 2.793kj/kgk.

Balance around the condenser

Assume Reflux ratio = 2.5

Then R = L/D

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L = R*D = 2.5*179.79

= 449.475

But V = L+D

V = 449.475 +179.79

= 629.26

From vapor equilibrium data the boiling point of ethanol (97%) = 78.2 0c.

At steady state

Input = output

HF =Hd + Hl + Qc

Qc =Hf – Hd – Hl

Assume complete condensation Hd = 0.

Then Enthalpy of vapor = Latent heat + sensible heat

Qc = Hv= Mv*ƛv + Mv*CP*T

Where ƛv of ethanol = 789

= 629.26*789 + 629.26*2.72*(78.2-25)

= 576,532.9

At the last QB is calculated by balance over the complete system

Impute = Output

QB + HF = Qc + HD + HW

QB = Qc + HD - HF

HF = MF*CP*T

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 = 1744*4.18*(35-25)

= 82,204

HF =MW*CP*T

= 1564.11*4.18*(100-25)

= 490,348.485

So QB = QC + HD + HW -HF

= 586,533+0+490,343 485 -72,202

= 1,01324.679

Where QB = reboiler heat impute

Qc= condensation cooling

QB is supplied by condensing steam.

Latent heat of steam at 274 KN/m3, ƛv = 2174 kj/kg

Steam required Ms QB/ƛv = 1,004,678/2174 = 464.134

Qc is removed by cooling water with the rise of 30 0c.

Qc = MW*CP*T

Mw = QC/CP*T = 529,964/(4.19*30) = 42265.9kg/hr

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 CHAPTER FIVE
MECHANICAL AND THERMAL DESIGN OF BOILER

PART1: THERMAL DESIGN OF BOILER

Boiler is one of the components of steam power plant that is used to produce steam .

The parameters we take to design this boiler are

Mass flow rate of water to be heated =1200 ⁄hr

Temperature of water inlet to boiler =30

Temperature of the hot gas (hot air) entered to the boiler =400

The hot gas is cooled to 300

The inlet water is heated to 330

Specific gravities of both water and hot gas at 86 are 1 and 0.97 respectively.

We assumed a fouling factor of 0.0003 and 0.0001 should be provided for the cold and hot streams
respectively

Allowable pressure drop on each stream =10psi and a number of 10 –ft hair pins of 2- by 1 ⁄ inch Ips
are available.

From energy conservation principle: the energy lost from the hot gas is equal to the energy
gained by the water.

Energy lost from hot gas = Energy gained by water

( ̇ Cp) hot gas =( ̇ cp) water.

cp ( T1 –T2) = ̇ cp (t2 –t1)

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The overall energy balance of the heat exchanger is

Q= ̇ cp (T1-T2) = ̇ cp( t2-t1) = UAFLMTD Where, F=LMTD correction factor

LMTD =logarithmic mean temperature difference

T1= initial temperature of the hot gas

T2= out let temperature of the hot gas

t2 = out let temperature of water

t1= initial temperature of water

cp= specific heat capacity

–
LMTD= for parallel flow arrangement

= =286

Determination of the caloric temperature and finding the thermo-physical properties. We can take
the caloric temperature (Tc&tc) as average temperature of the hot and cold fluids respectively.

TC = , TC= caloric temperature of hot gas

Tc= = = 356 , tc = caloric temperature of water

Thermo-physical properties of the fluids evaluated at the caloric temperature are given in the table
below.
Table-4 thermo physical properties of fluids

Water Hot gas (air)

0.21 0.029
K 0.41 0.001
Cp 1.3 0.4
SG 1 0.97
0.1 0.58

And we have other parameters such as

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ID=1.4 inch; tube inner diameter
D1=1.82 inch; shell inner diameter
D2=2.134 inch; outside diameter of the shell
Now, by having the above parameters we can calculate the mass flow rate of hot gas.
̇ cp(T1-T2) hot gas= ̇ cp(t2-t1) water= ̇
̇ .
̇ hot gas= = =116900 ⁄
.

Area of the tube side and shell side can be calculated as shown below;
Since our boiler type is a fire tube boiler the hot gas is placed in side the tube and water is placed in the
shell of the boiler.

Area of tube side: At Area of shell side:As

At= , ID=1.4 inch As= ( )

.
= = 1 foot=12 inch = ( . . )

= 0.011007 =0.006906

Determination of overall heat transfer coefficients:

Clean over all heat transfer coefficients(UC)

UC = or = Ri + Ro where, Ri and Ro are the fouling factors

.
UC = = 68.8.32 ⁄
.

Design overall heat transfer coefficient (UD)

= + ( Ri + RO)

= + 0.0001 + 0.0003
. ⁄

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UD = 66.9 ⁄

Estimation of area(A)
Q = UDALMTD then A =

From energy balance equation Q = Qh =Qc where, h=hot fluid and c= cold fluid
Q = 842400 ⁄

⁄
A=
⁄

.
Estimation of Reynolds number (Re):

Ret = 180538 calculated above Res = where, De = D2 D1

=2.134-1.82
.
= =0.314/12
.

= 8755 =0.0259
Estimation of ∆p due to friction

∆ = ∆ =
. .
f = 0.0035 + .
for Re f = 0.0035 + .

. .
= 0.0035 + .
= 0.0035 + .

= 0.004914 = 0.008933

∆ = ∆ =
. . . .
= ∆
. . . . . .

= 1.4ft = 4.923ft
∆ ∆p due to exit and entrance losses (∆Fl )

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 . . ⁄
= ME = KE + PE = 0

= 0.589psi = m + mgh = 0

h= , n = number of hairpins

h = ∆Fl
v=

⁄
v=
. ⁄

= 0.755 ⁄

.
∆Fl = = 0.044ft
.

∆p =

. .
=( ) 61.95 ⁄

= 2.256psi
Therefore, our design is acceptable. Since the pressure drop is less than the allowable pressure i.e
2.256psi

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PART2: MECHANICAL DESIGN OF BOILER

Given data
Design stress =100 ⁄ ⁄ (average)

Design pressure = 10psi = 44.484 ⁄

Outer diameter of the shell =3.2inch

Inner diameter of the shell = 2.9inch
Inner diameter of the tube = 1.5inch
Outer diameter of the tube = 1.84inch
Corrosion allowance = 3mm
Construction material = carbon steel (cs)
Joint efficiency (j) = 0.9
1. Shell thickness calculation(ts)
ts = + c;
.

. ⁄ .
= +c
⁄ . . . ⁄

= 0.002523in + c
= 0.055946mm + 3mm
= 3.0565646mm
2. Channel cover thickness calculation (tcc)

√
tcc = + c ci =0.3 for ring type ofgasket

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where, Dc is diameter of the cover usually the same as the outside diameter of the shell = 3.2in

. √ . .
tcc = + 3mm

= 0.000018999mm + 3mm
= 3.000018999mm

3. Head cover thickness (th)

th = where, w = 0.25(3+ √ ⁄
.

Ri =crown radius
ri =knuckle radius

But = 0.059 Ri = 2.9inch

ri = 2.9inch . = 0.1694inch

w = 0.25(3+ √ ⁄ = 0.25(+√ . ⁄ . = 1.7788

. . .
th = + 3mm
. .

=3.0017788mm

1. Tube sheet thickness(tts)

.
tts = √ +c where, k = 1 for triangular pitch

p = pt + ps = 2.66645 psi

d = 1.25inch

F = 1 for fixed tube

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 GP =1.52 inch,tube sheet diameter

K =0.9
.
tts = 0.33 . √ + 3mm
.

tts = 3.0136789 mm

2. Nozzle thickness(tn)

tn = where, Dn = 2inch for inside shell diameter less than 12inch

.
= +3mm
. .

= 3.000778904mm

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 CHAPTER SIX
OVER ALL BENEFIT FROM THE INTERNSHIP

6.1. IN TERMS OF UP IMPROVING THEORETICAL KNOWLEDGE

In this internship program help us to relate academic knowledge with practical one. Almost all
the course we took was focused on theoretical part but after the internship program; we came up
with realizing that what we have been learning is not 100% applicable in practical.

 we get and understand the organizational structure of the company

 we learn the function of each of the divisions/departments
 we understand what is production, marketing, finance, purchasing, maintenance
and utility
 we focus on the science behind the production alcohol and liquor preparation
 we theoretically focus on the company`s top customers & where is their location
which also is a key beginning in developing entrepreneurship skills.

6.2. IN TERMS OF IMPROVING OUR PRACTICAL SKILLS

We gain practical experience to applying our engineering judgments and working successfully
with others. Also develop creativity and innovative approach to solving problems.

 The different stages, steps and process in industry.

 The use of new kind of techniques and the way they were applied to different
factories.
 The different type of chemical process that are used in chemical engineering.
 Different types of problems that can occur during chemical processing and
possible ways to address these problems.
 The important of safety and health in the industry.

6.3. IN TERMS OF IMPROVING OUR TEAM PLAYING SKILLS

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Teamwork involves working confidently within a group, contributing your own ideas effectively,
taking a share of the responsibility, being assertive rather than passive or aggressive, accepting
and learning from constructive criticism and giving positive, constructive feedback to others.

All employers are keen to recruit graduates who are able to cooperate, solving problems and
work in teams. As less hierarchical organizations have emerged with project teams, self-managed
work teams and management teams, so the requirements to 'Get on well with people', and to
'Work with and through others' become increasingly important. And this internship helps to
attain and understand great team work with people working there and the students who are in
intern as us.

6.4. IN TERMS OF IMPROVING OUR LEADERSHIP SKILLS

Our internship, we think, partly voids the bad image we had for the leaders. We were brought in
a society who thinks the leadership as stand for power and dominance over the other. Leadership
to us, as applied to someone to whom other people are entrusted, is an art of inspiring others to
give of their best and courage to use this art. This is what leadership is meant to us; it demands
the leader operate from inside from his group, not from above it; that in setting a good example,
he doesn‟t steal the initiative of the others; that he takes his full share but not more than his share
of the job in hand .Acquire the appropriate technical competence and experience, gives direction,
share danger/hardship on equal footing, sets an example etc. ... As a good leader, we have
conviction that we have to have these characters. In addition we learned and convicted to have
the following attributes to be successful leaders: Leadership is an art of inspiring others to give
of their best and courage to use this art. During the internship with respect to leadership skills we
have learned and convicted to have following attributes to be successful leader;
 General intelligence, to make sense of the complexity and difficulty of the task
 Personality: leaders should be energetic and committed, maintain contact with their
people, and understand their strengths and weaknesses
 The ability to inspire, although this quality may be rarer than some of the others and is
perhaps the most difficult to develop
 Listening, sharing and delegating skills (and not interfering unnecessarily), because in

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groups of more than around five people it becomes impossible to know all the necessary detail
Self-knowledge, understanding one‟s own strengths and weaknesses, which in turn will enable
them to turn to other in their group to compensate for their own biases or deficiencies.

6.5. WHAT GAINED IN TERMS OF OUR ENTREPRENEURSHIP SKILLS

During internship we have met with some entrepreneurs on way of our work and our part time
activity; and we gained greater insight into business and entrepreneurship. The basic
entrepreneurship skills these peoples have and we noted are: business planning, risk assessment,
team building. After of completion of our study we may get employed in company. However, we
will not confine source of financial income to the company pay only. For these days, we have
vision to own a firm, business, or venture, and responsibly develop it in parallel with our
employers work. It is our opinion that managing one‟s own business offers far greater security
than being an employee elsewhere. We feel entrepreneurship enables us to acquire wealth
quickly and cushion us against financial insecurity. Additionally, an entrepreneur‟s future is not
at peril owing to the faulty decisions of a finicky employer. A wide range of skills are seen as
entrepreneurial and useful to entrepreneurs, these include both personal traits and Management
skills.
Communication skills and the ability to sell ideas and persuade others
The ability to work both as part of a team and independently
Able to plan, coordinate and organize effectively
Financial literacy
Able to research effectively, for example available markets, suppliers, customers and
Other more specific or business related skills, will be of use to entrepreneurs, these may
include: being able to draw up a business plan for a new venture being able to market and
Sell a new product or idea financial skills, such as book-keeping and calculating tax
Awareness of intellectual property and possible patent law.

6.6. INDUSTRIAL PROBLEM SOLVING SKILL

The real problem may not surface until facts have been gathered and analyzed. Therefore, we
start with what we assume to be the problem that can later be confirmed or corrected. We

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gathered some data from staff members and by observing our self. We have been generating
some ideas that can possibly be solutions until several have been discussed. So generally the
internship program helped us to experience and improves such problem solving skills.

Work ethics is being personally accountable and responsible for work that someone does.

6.7. WORK ETHICS RELATED ISSUES

Developing keen organizational skills in the workplace eliminates unnecessary ineffectiveness

and enables individuals to efficiently perform essential job tasks. Establishing organizational
skills help individuals perform their work according to their job duties and responsibilities.
Therefore, maintaining organization in the workplace not only helps individuals work efficiently,
but also helps to promote the overall objectives of an individual‟s job or profession. Maintaining
organization enables individuals to be productive while performing their job duties. On the other
hand, it is important for companies to establish organizational objectives in the workplace to help
achieve the company‟s overall mission. Time management is one of the most important skills to
maintain organization in the workplace. Managing one‟s time simply involves designating
enough time in work day to complete report and setting up practical and useful work schedules.
Some individuals plan their work schedules daily, while others may establish monthly or weekly
schedules. Another essential organizational skill includes having a clean and orderly work space.

Thus employer expects employees to develop certain desirable traits that will help them to
perform their jobs well so that the company can succeed. Some of these traits include the
following:
 Loyalty
 Honesty
 Trustworthiness
 Dependability
 Reliability
 Initiative
 Self-discipline
 Self-responsibility

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With respect to work ethics related issues we have seen how a worker struggles for fulfilling
their responsibility at work place, respecting their working time respecting the order of the
company manager, etc.

CHAPTER SEVEN
CONCLUSION AND RECOMMENDATION
CONCLUSION

Desta alcohol and liquid factory uses various types of fuels like liquid, solid and gaseous fuels
are available for firing in boiler furnaces and other combustion equipment‟s. So we can
determine the efficiency of boiler by direct and indirect method. But when we determine by
indirect method we can get more efficiency of the boiler.

B/c It gives clues to the operator as why efficiency of the system is lower & It gives information
to calculate the various losses accountable for various efficiency levels

This implies the use of liquid fuels as source of boiler is necessary. The reason is that the
efficiency of an efficient boiler that uses Furness oil is measure from 80 up to 85 %.

Generally from this number we can say Desta alcohol and liquor factory is in an efficient
way. So, since heavy fuel oil is very viscous, and this property varies sharply with
temperature. The meter, which is usually installed on the combustion appliance, should be
regarded as a rough indicator only and, for test purposes, a meter calibrated for the particular
oil is to be used and over a realistic range of temperature should be installed. Even better is
the use of an accurately calibrated day tank.

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RECOMMENDATIONS

 Desta alcohol and liquor factory should use Furness oil for the boilers to produce
steam even for the future but according to the fluctuation of cost of the Furness oil.
 The feasibility study should examine all implications of long-term fuel availability
and company growth plans. All financial and engineering factors should be
considered. Since boiler plants traditionally have a useful life of well over 25 years,
replacement must be carefully studied.
 Ensure that steam pressure is no higher than need be for the job.
 Have the plant checked to ensure that severe load fluctuations are not caused by
incorrect operation of auxiliaries in the boiler house, for example, ON/OFF feed
control, defective modulating feed systems or incorrect header design.
 Every rise of 6ºC in boiler feed water temperature through waste heat recovery would
offer about 1% fuel savings.
 Good control of combustion is important as it helps to achieve efficient combustion
conditions by excess air control and reduction of CO in flue gases.
 Complete combustion with minimum excess air should be always our goal since heat
losses due to high excess air in flue gases are unaffordable and unacceptable from the
point of view of efficiency.
 The flue gas temperature must be a proven value for the efficiency calculation to be
reflective of their fuel usage of the boiler.
 Pre-heating is necessary for proper atomization.

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REFERENCE
 Technical Papers, Boiler Congress - 2000 Seminar, 11 & 12 January 2000
 TERI, GTZ and EMC .Steam Generation, Distribution and Utilisation
 Thermax Babcock & Wilcox Limited. CFBC Boilers. 2001.
 www.tbwindia.com/boiler/cfbc_system.asp
 Combustion Engineering and Fuel Technology, Oxford & IBH Publishing
Company - A.K.Shaha
 www.pcra.org
 Efficient Boiler Operations Sourcebook, Fourth Edition, F. William Payne and
Richard E. Thompson, 1996.
 Energy audit Reports of National Productivity Council
 Energy Hand book, Second edition, Von Nostrand Reinhold Company -
Robert L.Loftness
 Industrial boilers, Longman Scientific Technical 1999 www.boiler.com
 www.eng-tips.com
 www.worldenergy.org
 Enhanced ethanol production from brewer's spent grain by a
fusariumoxysporumconsolidatedsystem.biotechnol biofuels. 2009; 2:
4./published online 2009 february 10
 Kassim, e.a.; el-shahed, a.s. enzymatic and chemical hydrolysis of certain
cellulosic materials. agr. Wastes
 Taherzadeh, m. j. (1999).ethanol from lignocellulose: physiological effects of
inhibitorstechnology, göteborg, swedenchemical reaction engineering,
chalmers university ofand fermentation strategies
 Celeste L. Todaro and Henry C. Vogel, Second edition 1997. Fermentation
and Biochemical Engineering Handbook. Noyes. (New Jersey) USA.

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APPENDIX-1: THEORETICAL AIR REQUIREMENT

• Actual mass of air supplied/ kg of fuel (AAS) = {1 + EA/100} x theoretical air

• m = mass of dry flue gas in kg/kg of fuel

• Cp = Specific heat of flue gas (0.23 kcal/kg 0C)

Percentage heat loss due to evaporation of water formed due to H2 in fuel

Percentage heat loss due to evaporation of moisture present in fuel

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 • In a relatively small boiler, with a capacity of 10 MW, the radiation and unaccounted
losses could amount to between 1% and 2% of the gross calorific value of the fuelwhile
in a 500 MW boiler, values between 0.2% to 1%are typical.

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 APPENDIX-2

The following are the data collected for a boiler using furnace oil as the fuel. Find out the boiler
efficiency by indirect method.
Ultimate analysis (%)
Carbon = 84
Hydrogen = 12
Nitrogen = 0.5
Oxygen = 1.5
Sulphur = 1.5
Moisture = 0.5
GCV of fuel = 10000 kCal/kg
Fuel firing rate = 2648.125 kg/hr
Surface = 80 oC
Temperature of
boiler
Surface area of = 90 m2
boiler
Humidity = 0.025 kg/kg of
dry air
Wind speed = 3.8 m/s

Flue gas analysis (%)

Flue gas = 190oC
temperature
Ambient = 30o C
temperature
Co2% in flue = 10.8
gas by
volume
O2% in flue = 7.4
gas by
volume

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