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ADIGRAT UNIVERSITY

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

ADVISER’S 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 student’s 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 institute’s UIL office as far as our knowledge is concerned. INTR.AYALEW Name of the Academic advisor Mr. HAFTOM

Signature

Date

Signature

Date

Name of the company Supervisor HAYLAY GEBREMEDHIN NEBIAT GEBREMEDHIN

Signature Signature

Date 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.

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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

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%

CONTENT

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.

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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 body’s process for eliminating it. There is a limit as to how much alcohol the body can dispose of within an hour. The more a person’s 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 doesn’t operate with presence of butane gas and it will be supplied a steam to both pre-distillation and rectification column and only mash column. The water consumption of the boiler is 1000-12,000kg/hr for the smallest largest boiler respectively. There are many types of boiler used in different industry but, the type of boiler which is found in 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.

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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 separate and its labels 167 bottles per hour.

Fig1.3

Labeling machine

on

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 soap’s 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 engineer’s 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 job’s 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 equipment’s 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 = 25°c  Temperature of out let steam = 200°c  Temperature of out let chimney to west gas for = 225°c  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= πr2h =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 Tin=25°𝑐

MOUT=3430 TOUT=200°c

Then from the above simplified equation Q= ∆H

where h=enthalpy ∆H

= εmh – εmhfg

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 60°c saturated water enthalpy will be hfg =2345.4 kj/kg =80kcal/kg Then Q=∆H = ∑ mh − ∑ mhfg = m ∑( h − hfg) 𝑘𝑔

Q=∆H = 3500 ℎ𝑟(2950−23454) Q=∆H = 42322

𝐾𝑗 ℎ𝑟

Then Q= ∆H

but 1kj = 1000j,

1hr = 3600sec

= 42322

𝐾𝑗 ℎ𝑟

ℎ𝑟 3600𝑠𝑒𝑐

*

Q=∆H= 18.4 kw, so there is some losses

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 can’t 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 country’s wellbeing. And anybody can’t be full in his job if he/she doesn’t 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 50ºC. There is little activity in the range of 0ºC to 10ºC. 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 monosaccharide’s 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 33ºC, and beyond 37ºC, 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 30-33ºC. 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 Glucose

yeast

2C2H5OH + CO2 + heat

zymase

Ethanol carbon dioxide

100 kg C12H22O11

Sucrose

51.1kg + H2O

Yeast Invertase

48.9 kg

17935 KJ

C6H12O6 + C6H12O6 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 (15˚Bx) and the near future operating brix after installing molasses clarification plant( as per this research 25˚Bx). 4.6.1. Material and Energy Balance for 15˚Bx 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, 120˚C) Re circulated Process Cond(236 t/d, 55˚C ) 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*85˚C + 80.4t/d* Cp2 * T2 + 236 * Cp3* 55˚C 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 = 85˚C 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 E007 forC5. Taking the temperature of spent lees to be 120˚C (393˚K) and 55˚C (328˚K)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/ºC = 4.176 kj/kg/ºC 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 34˚C. Cooling water inlet and outlet temperatures will be maintained at 5˚ and 33˚C 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 baker’s 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 Distiller’s 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 – 35ºC. However, the optimum fermentation temperature at a low alcohol concentration is often slightly higher (38ºC), but alcohol tolerance is improved at reduced temperature. S. Cerevisiae strains having 37ºC 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 0ºC) 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 (15˚bx) 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 15ᵒ bx fermented wash concentration the optimum amount of Urea and DAP application was 62.51 and 14.51 mg/l where as at 25ᵒbx 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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