Ebisa Lamesa Diriba

Finchaa Sugar Factory (FSF) JUNE, 2020G.
WACHEMO UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF CHEMICAL ENGINEERING
TITLE: - INTERNSHIP REPORT
COMPANY NAME: FINCHAA SUGAR FACTORY
ADVISER NAME: - INSTRUCTOR ZELALEM GETAHUN
DURATION OF INTERNSHIP: - FROM MARCH TO JUNE
PREPARED BY:- ID No
LAMESA AMBISA…………………………..055/08
DIRIBA TASISA……………………………....081/08
EBISA ABDISA…………………….………….229/08
Submission date 7/10/2019

Wachemo University Chemical Engineering Department ii
Finchaa Sugar Factory (FSF) JUNE, 2020G.c
Declaration
Our name is Lamesa ambisa,Diriba tasisa,Ebisa Abdisa .We are fourth year chemical
Engineering student, have under take our internship experience in Finchaa Sugar
factory from a period of March 02/2019 to June 30/2019. Under the guidance of
Mr.Zelalem Getahun (academic advisor) and Engineer Mengistu (company advisor).
We certify that our work is original and compiled according to the internship report
writing guideline given by the University - Industry linkage office of the University.
Signature Date
Academic advisor
Mr.-Zelalem Getahun ____________
____________
Name of students
Lamesa Ambisa ____________ _____________
Diriba Tasisa ____________ _____________
Ebisa Abdisa _____________ _____________
Wachemo University Chemical Engineering Department iii

Acknowledgments
Next to God We would like to express our heartfelt gratitude to our academic Advisor
Mr.Zelalem Getahun for his great help in the case of moral support, data collect for
the project and correct the error that we have done and lead to perfection, our great
thanks also for Engineer Kalbessa Dabalo for his unreserved help in the case of
showing willingness to accept this project and support that everything we need for the
project including materials and economy. In addition to these we need to thanks to
our company Advisors Mengistu, and Bekele Fufa for their great help to grasp Good
knowledge during our internship period, lastly but not the list we would like to
express our heartfelt gratitude to Chemical Engineering Department Head and all
Chemical Engineering Le
Executive summary
Today, Finchaa Sugar factory grown to be the first oldest sugar factory in Ethiopia
.This factory uses Sugar canes as a raw material for the production of white granular
sugar using different section of the plants like:- milling, clarification, evaporation and
pan housing plant and other related equipment’s like, heat exchanger, cooling tower,
rotary filter, fans, pumps and other unit operation in different sections.
The finchaa sugar factory consists four inter connected plant’s;-milling, evaporation,
clarification, pan house and Boiler (power generation plant) .Each section in the
company has its own purpose; some of them are;-A milling plant which is used to
separate the mixed juice from the bagasse, Clarification which is used to the removing
of impurities, non Sugar and coloring matters from the mixed juice, Evaporation
which is used to the removing of water by vaporization from the solution of non-
volatile substances. And the other thing is the production of Ethanol from by product
from that of molasses. the others are water treatment which is used to prepare hard
water to soft water by removing hard ions and minerals and also there is utility house
which generation steam.
Wachemo University Chemical Engineering Department iv

Table of Contents
Declaration.................................................................................................................................ii
Acknowledgments......................................................................................................................iii
Executive summary....................................................................................................................iv
List of table...............................................................................................................................vii
List of Figure............................................................................................................................viii
CHAPTER ONE..............................................................................................................................1
Back ground of the company........................................................................................................1
1.1. Brief history..................................................................................................................1
1.1.1 Vision..........................................................................................................................1
1.1.2 Mission........................................................................................................................1
1.1.3 Value...........................................................................................................................1
1.1.4Objectives....................................................................................................................2
1.2. Main Production of the company.................................................................................2
1.3. Main Customers of Company.......................................................................................2
1.3 FSF Overall Organization and Work Flow Chart.........................................................2
1.3.1 Man power..................................................................................................................2
1.3.2 General Manager........................................................................................................3
1.3.3. Purchasing and supplies, finance and administration related task...........................3
1.3.4. Maintenance related tasks.........................................................................................3
1.3.5 Administration............................................................................................................3
1.3.6 Finance........................................................................................................................3
1.3.7 Quality control............................................................................................................3
Wachemo University Chemical Engineering Department v

1.3.8 Store............................................................................................................................4
1.3.9 Marketing...................................................................................................................4
CHAPETER TWO...........................................................................................................................5
2. How we get in to the company.................................................................................................5
2.1 Sugar cane production......................................................................................................5
2.2 Cane sugar processing at Finchaa Sugar Factory.............................................................5
2.3 Cane Preparation..............................................................................................................6
2.1.1. Object of Cane Preparation..........................................................................................6
2.1.2. Cane preparation Equipment’s.....................................................................................6
2.2 Milling plant.......................................................................................................................9
2.3 Clarification plant.............................................................................................................10
2.4 Heaters............................................................................................................................11
2.5 The Rotary Vacuum Filter..............................................................................................15
2.6 Evaporation plant............................................................................................................16
2.6 Pan House Plant...............................................................................................................23
2.7. Crystallization of massecuite..........................................................................................25
2.8. Centrifugal separation plant..........................................................................................26
2.8.1. Batch centrifuge...........................................................................................................26
2.8.2. Continuous Centrifuge................................................................................................27
2.9. Sugar Conveyers............................................................................................................27
2.9.1. Sugar Drying.................................................................................................................27
2.9.2. Sieve Grading...............................................................................................................29
2.10 General flow diagram....................................................................................................29
2.11. Ethanol production in fichaa sugar factory..................................................................29
2.11.1. Fermentation process.................................................................................................31
2.11.2. Continuous Fermentation..........................................................................................31
CHAPTER THREE.........................................................................................................................34
3. The overall benefits...............................................................................................................34
3.1 Improving practical skills..................................................................................................34
3.2 Knowledge gained from internship.................................................................................34
3.3 Communication skills........................................................................................................34
3.5 Leadership skills...............................................................................................................35
Wachemo University Chemical Engineering Department vi

3.6 Work ethics......................................................................................................................35

3.7 Entrepreneur ship skill......................................................................................................35
CHAPTER FOUR..........................................................................................................................36
4. Conclusion and recommendation.........................................................................................36
Conclusion.............................................................................................................................36
Recommendation..................................................................................................................38
References.............................................................................................................................39
Abbreviation.........................................................................................................................40
List of table
Table 1…………………………………………………………………………………….21
Table 2……………………………………………………………….………………...….30
Table 3…………………………………………………………………………………..…31
Table 4 ………………………………………………………………………………… ....31
Table5……………………………………………………………………………………...32
List of Figure
Figure 1: Company
Structure ..............................................................................................4
Figure 2: Cane un loader..................................................................................................... 6
Wachemo University Chemical Engineering Department vii

Figure3: Auxiliary cane

carrier............................................................................................7
Figure4: shredder…………………………………………………………………….
…......8
Figure 5: milling ……………………………………………………………………………………..
FEgure 6:…………………………………………………………………………………….
Figure7: …………………………………….………………………………………..
….16
Figure8:Body ………………………………………………………………………..…....17
Figure9:Over all flow
diagrams...................................................................................................24
Wachemo University Chemical Engineering Department viii

Finchaa Sugar Factory (FSF) JUNE,
2020G.c
CHAPTER ONE
Back ground of the company
1.1. Brief history
Finchaa sugar Factory is located in Horro Guduru Wollega administrative zone
of Oromia regional state, Abay Comman Woreda. factories general boundaries
of 9° 30' to 10° N and 37° 15' to 37° 30' E. It is about 335 kilometer from Addis
Ababa.FSF is situated at a wet kola agro-climatic zone receiving an average of
1300mm rain per annual. The altitude ranges between 1400m downstream and
1650m upstream. The mean maximum and minimum temperatures are 31 and
15 respectively. The Finchaa sugar factory has a crushing capacity of 12500 tons
of cane per day (TCD) and produce 2.6 million quintals of sugar and about
20,000,000 liters of ethanol annually. FSF has paid a capital of birr 567, 000,000
with the following major objectives:-  To plant and grow sugarcane and other
plants that can produce sugar.
 To produce commercial plantation white sugar and other products including

molasses, Ethanol and etc. from its byproducts.
 Performing other job that would help it to realize its main objectives.
The total cost of FSF is 1.8 billion birr which is financed by government equity capital,
soft loan and grants obtained from various governments, international institution,
local banks and the Ethiopian government. The major sources of finances are African
development fund. However, the Swedish, Australian and Spanish government has
also played a significant role in financing this huge project or factory
1.1.1 Vision
 To be the leading company in sugar industry and make more customers.
1.1.2 Mission
Finchaa as an agro industry striving to increase stakeholders’ satisfaction
through core business activity including Expanding and optimizing sugar cane
plantation of own and out growth cane to meet own requirement and creating
income for the out growers, sufficient employment opportunities in plantation.
1.1.3 Value
Team work bring individual and organization growth
Wachemo University Chemical Engineering Department 1

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1.1.4Objectives
 Continually increase the production of sugar so as to attain a production
capacity of 2,700,000 quintals by the year 2019/2020.
 Increasing land productivity of existing cane area to 18,000 quintal/hectare

by the year 2020/21.
 Continually decrease production cost.
1.2. Main Production of the company

 To produce the commercial sugars 600ton per day
 To produce the molasses
 To produce 34Mw electrical power.
 8000,000 Liter Ethanol from it’s by product molasses per annual
1.3. Main Customers of Company

Main customer of commercial sugars
 Moha soft drink factory

 Coca cola soft drink factory
 Café, restaurants and hotels
 Rural and urban people of Ethiopia.
Main customer of final molasses

 Balezaf alcohol and liquor factory
 Rural and urban people of Ethiopia
1.3 FSF Overall Organization and Work Flow Chart
1.3.1 Man power

The company is organized with a combined workforce of more than 45000
employees. The company is coordinate by sugar co-operation. The manager is
Electrical engineer by profession.
The company has chemical engineers, mechanical engineers, electrical engineers,
chemists, finance manager, accountants, and marketing personnel, electrical
technologist, senior mechanics, welder, and the number of workers running the
factory.

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1.3.2 General Manager

Overall management related tasks
 Formulate and ensures the implementation of quality policy.

 Provides necessary resources to maintain and improve the system.
 Appropriate internal communication process.
1.3.3. Purchasing and supplies, finance and administration related task

 Over major supplier selection and purchasing.
 Control Monitor and review supplier performance.
 Ensures customers are credit worthy.
 Process and production planning.
 Control and monitor process.
 Preservation and packing of finished goods.
 Technical evaluation of raw materials for production line before purchasing.
 Preparation of product specification.
1.3.4. Maintenance related tasks

 Maintenance of production equipment’s and machineries.
 Control over engineering activities.
 Maintain and ensure calibration of inspection, measuring and testing
equipment’s.
1.3.5 Administration
Define qualification of personal and ensures recruitment of suitable qualified staff at
the time required.

General administration.

Provide induction training to new recruits
1.3.6 Finance
 Ensures customers are credit worthy.
 Ensures all sales are invoiced properly.
1.3.7 Quality control

 Incoming inspection.
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 In process inspection.
 Final inspection of final product.
1.3.8 Store
 Ensure final product, raw material, spare part and auxiliary materials are
stored.
 Safety and securely under appropriate condition until required.
1.3.9 Marketing
 Study current and future market and propose appropriate actions.
 Maximizes sales through use of various marketing structure.
 Measures customers.
 Satisfaction regularly and take prompt action
Workflow sheet of FSF organization
General Manager
Agriculture Factory Human resource Finance Linguistic
Seed production Technician Heath centers Budget Material

planning
Irrigation Production Human resource
Purchaser
Maintenance Electric Power
Resource
Cane cutter Ethanol group management

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Figure 1: Workflow sheet of FSF organization (Sources from finchaa sugar

factory)
CHAPETER TWO
2. How we get in to the company
When we move from our main campus Wachemo University to the company, the
company was do his daily activity. But our expectation and the reality there were
not balancing each other. Specially, in sector of general administration there
were some problems like, facility management, supervising system and other
technical problems.
2.1 Sugar cane production

Agricultural operations comprises various activities that directly or indirectly
contribute to sugarcane production like land preparation, sugar cane cultivation
and harvesting which are essential to the sustainable supply of sugar cane at
required quality and quantity. The total cane plantation, area an average of 70%
is harvested annually.
2.2 Cane sugar processing at Finchaa Sugar Factory

The existing sugar factory comprises two types of extraction of cane juice. Cane
milling and cane diffusion. The cane milling is the process by which pressure is
applied to the prepared cane to extract as much juice as possible from it. The
cane is made to pass through a succession of rollers that comprise the milling
tandem, and its juice is squeezed out as it goes through. In order to extract the
maximum juice, use of imbibitions water is made. The extracted juice is sent to
process and the fibrous material left after milling, known as final bagasse, is sent
to the boilers to be used as fuel for the generation of steam. The classic
combination of three rollers arranged in triangular form is the standard milling
unit used in the cane milling process. The cane diffusion principle consists of two
physical processes which occur simultaneously. That is, leaching of juice from the
broken cells of the sugar cane and diffusion of sugar by osmosis across the wall of
the cane cells. Cane diffusers of every conceivable shape and type have been
patented such as U-shaped diffusers and vertical annular diffusers are still in
operation. However, the Finchaa sugar factory has the widely adopted horizontal
bed diffusers.

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These diffusers are long conveyors on which prepared cane is moved in mat, 1 to
2 meters thick, at a speed of 0.5 to 1.0 m/min while being subjected to
countercurrent washing by a series of sprays of juice of decreasing concentration
and a final washing by water. along the diffuser is by a series of centrifugal
pumps. The juice drawn off from the diffuser is called draft juice which is the
same as mixed juice and sent to the process.
2.3 Cane Preparation

The cane is prepared by the help of sets of cane knives to open the juice cells in
the cane for extraction of juice. The prepared cane is passed through three/four
mills with water imbibitions at the last mills. The juice is collected from all the
mills. It is then filtered through screen to remove the fiber particles in it before
sending for processing. The mills and the cane preparation units are driven by
electric motors/steam turbine.
2.1.1. Object of Cane Preparation

1. To increase capacity by increase of bulk density of the feed.
2. To assist extraction at the mills by breaking down the structure of the cane
3. To render the juice more readily available by breaking and opening cane cells.
2.1.2. Cane preparation Equipment’s

Cane weighing
For the first time cane was weighed in order to know the tone of cane crushed per
day (TCD).then it passed to cane un loader.
Cane un loader
Cane un loader is used to unload the cane from trolleys trucks in to the cane carrier
and is responsible for cane feeding required to meet the crushing capacity of the mill.

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Figure 2: Cane un loader
Auxiliary cane carrier

Cane is unloaded in auxiliary carrier by trucks and in main carrier by means of
Feeder table, cane unloaders and Bullock carts.The speed control of main carrier
and auxiliary carrier control is by eddy current control followed by ACFC (Auto
Cane Feed
Controller).

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Figure 3: Auxiliary cane carrier

Cane Kicker
The cane kicker is installed on the carrier to prevent excessive Cane being fed to
cane leveler which causes jamming of the leveler set. It consists of a Steel shaft
directly coupled to a motor with arms or knives mounted on it, running normally
at 50-100rpm.in reverse direction to the flow of cane on the cane carrier.
Main cane carrier

Main cane carrier is wider than the width of mills, this facilitate better preparation
and less power consumption in preparatory devices. Inclination of main carrier
depends upon the preparatory drives installed.
Cane chopper
Chopper is a mechanical device to cut the cane in pieces. The cut cane is also
leveled in a manner that there are no peaks & valleys throughout the width of
cane carrier. The cane choppers are provided with cane cutting knives (hard
faced) which are mounted on the hub and the shaft (Forged Steel)

The chopper generally has less no. of knives and more cane bed clearances. Cane
chopper is installed at inclined portion of main cane carrier with a suitable device
for adjusting the clearance in between the knife tips and slats from 1000mm to
1100mm. Cane Leveler
The construction of cane leveler is almost similar to Cane chopper. In some cases
no. of cane knives are more in cane leveler as compared to chopper. This is
because of cane preparation to be maintained which is required at the input of
fibrazor. Cane leveler is installed at inclined portion of main cane carrier with a
suitable device for adjusting the clearance in between the knife tips and slats from
300mm to 350mm.
Sheredder
Figure 4 A typical whole-stick cane preparation stations with gravity-fed shredder.
Sources from google.com//http:shereder.com
Equalizer
It used to label the fiberized cane, in order to avoid the accumulation of fiber in one
side.
Magnetic iron separator

With the advent of mechanical harvesting and field mechanization, loose iron and
steel Pieces from machine parts find their way to sugar factory with sugar cane,
when it became imperative to remove them before milling operation to prevent
damage to machinery. Power consumption of a set of cane knives depends on the
following factors:
 Tons of Cane Crushed/Hour  Fiber % Cane.
 Clearance of the Set of Knives  The Pitch of the
9
 Speed of Rotation Knives

 The Radius of the Cutting Circle  Quality of the
Knives
 Cane Varieties
Wachemo University Chemical Engineering Department

Extent of Cane Preparation Preparation Index (PI)
The state of disintegration of the cane is expressed by the preparation Index (PI).
(PI) is the percentage of pol in the open calls. PI is obtained from laboratory
determination of pol by extraction in cold water, relative to complete
disintegration of the cane in the cold.
2.2 Milling plant

Milling is the process by which pressure is applied to the prepared cane to extra
juice as much as Possible from it. The cane is made to pass through a succession
of rollers that comprises the milling tandem, and its juice is squeezed out as it
goes through. To help to extract the maximum juice, use of imbibitions water is
made. The extracted juice is sent to process and the fibrous material left after
milling, known as final bagasse, is sent to the boilers to be used as fuel for the
generation of steam.
Methods of Extraction are

 By means of pressure :-In a number of mills provided with three rollers
through which the cane is forced.
 By means of diffusion,:- extracting juice by applying heat and immersion in
water and squeezing of the bagasse. The oldest system of juice separation is by
means of mills
Main Equipment’s of Milling

1. Drives/prime movers (motors 7. Scrapper.
or turbines). 8. Hydraulic
accumulator.
2. Gearing train.
9. Trash beam.
3. Combination of rollers.
10. Hydraulic assembly.
4. Inter rake carriers (Cane blanket conveyors).
11. Bearing GM/white
5. Donnelly chute.
metal.
12. Pressure chute.

13. Mess.chart
6. Trash plate.
Imbibitions
Water is known as imbibitions water. It is first applied on the bagasse in the inter
carrier before the last mill of a tandem. The diluted juice obtained from the last mill is
pumped back and applied on the bagasse in the carrier of the mill preceding it.
Types of Imbibitions:-
1. Simple Imbibitions – Where water only is applied to the various mills,
simple imbibitions is not practical in modern installations.
2. Double Imbibitions – Where water is applied to the bagasse from the next
to last two mills and combined thin juice from the last two mills is returned
to the earlier mills in the train. Now this system is obsolete.
3. Compound Imbibitions – Applicable to trains of four or more mills, where
water is applied to bagasse going to last mill. The last mill juice is returned
to bagasse going to the next to last mill..
Flow diagram of milling plants
Sugar Cane Feeder Auxiliary Main cane

Cane Weigh
Rotary screen
Mill 1 mill 2 mill 3 mill 4 mill 5
Fig 5: Flow sheet of milling
(Sources from the company data)
2.3 Clarification plant

Juice coming from mills is opaque and contains sucrose, reducing sugars, organic and
inorganic matter in solution. It contains also insoluble matter in suspension (fine
bagasse, soil…). The pH of juice extracted from fresh cane is about 5.5 and can be as
low as 4.0 if the cane is deteriorated or has reached the mill several days after harvest.
2.3.1 The objectives of clarification are:

a) To separate soluble and insoluble matter that can precipitate.
b) To reduce color and turbidity of the juice
c) To produce clear juice of correct pH (7.0)
d) To kill or inactivate microorganisms in the juice by heat treatment.
Juice weighing
The mixed juice weighing is the starting point for control of the whole factory.
Accurate weighing, sampling and analysis of juice for pol, brix, sucrose is essential for
determination of extraction, boiling house recovery and boiling house efficiency.
The purposes of mixed juice weighing carried out in sugar industries
 To determine the weight of bagasse  To determine

the boiling house supplied to boiler plant. recovery.
 To determine the milling plant extraction.
Methods of Juice Weighting Servo – Balance
This scale was designed and manufactured in Holland; it outclassed and eventually
replaced the Maxwell-Boulogne due to its greater accuracy and modern concept. Its
design is based on a beam scale using the servo principle to move the poise along the
beam to balance the load, through a complicated system of levers. The weighting
mechanism automatically registers and totals the difference in weight at each
weighting.
Therefore the net weight of juice are obtained and totaled. Oil under pressure is
admitted by means of small valve to larger pistons, which develop enough force for
opening and closing juice valves on the inlet to and discharge from the weigh hopper,
as well as acting on the totalize mechanism.
2.4 Heaters
Two main types of heaters are in used in FSF:-
1. The Shell and The Tube Type: (S & T), which is common in all sugar mills. The
can be divided into:
 Horizontal Heaters
 Vertical Heaters
2. The Plate Heat Exchanger: (P.H.E), which have in some installations replaced
the Shell and the Tube Type, (S & T), heaters.
They are of two types:
 The Plate and Gasket P.H.E
 The All-Welded (No Gasket) P.H.E, a newcomer to the Sugar
Industry.
The main objective of heating
1. Measured mixed juice is heated to a temperature of 75 °C and directed to liming

and sulphuring.
 For protein coagulation.
 To destroys micro-organisms and enzymes preventing loss of sucrose by
microbiological activity.
 To accelerate the reaction rate between the juice acids and the lime this
will be subsequently added.
2. The sulphited mixed juice is heated to about 5 °C above boiling point.
 Therefore the pressure in the juice will be above atmospheric pressure
and it is left to flash out its air bubbles that would retard settling of
impurities in the clarifier.
3. The clear juice from the clarifier is heated to 110 - 115 °C before it flows to
evaporators such heating of the clear juice would bring the immediate starting
of boiling in the 1st vessel as the result evaporation capacity is raised. This
heating operation is carried out in heat exchangers known as juice heaters
Steps in Juice Clarification
 Coagulation of proteins in the juice by heat.
 Neutralization of juice by calcium oxide.
 Precipitation of certain soluble impurities.
 Separation of the precipitate by decantation and filtration to obtain a clear
juice.
In juice clarification milk of lime is prepared at concentration of 6-10 brix.It is

recommended to use condensate from juice heaters and evaporators.
CaO + H 2O Ca (OH) 2

SO2 gas generation
The Sulphur has to be melted first. The melt Sulphur is sent to the furnace. In the
furnace Sulphur is burned by oxygen by pump in air compressor pump
S + O2 SO2
First sulphitation (simultaneous sulphitation)
The heated mixed juice is limited at the top compartment and the PH became 8.4-8.86
and neutralized with SO2 gas.
Purpose of first sulphitation
 Neutralization of the mixed juice.
 Facilitate clarification.
 Better elimination of phosphate and waxes .
 Juice clarification: the purpose of clarification is to remove maximum possible
impurities from the juice as early as possible in the process.
The importance of effective juice clarification:-
 Sucrose recovery is raised as the loss through final molasses is reduced.

 Fouling effect of heat exchangers is minimized.
Methods of Juice Clarification

Sulfitation Process in FSF
In the sulfitation system clarification is done by heat lime and sulphur dioxide gas.
The mixed juice is heated to 75 °C, more lime slurry is added to the raw juice and the
excess of lime is neutralized by SO 2 gas. The process is called after the name of the
acid used for neutralization of excess lime "sulphitation". The treated juice is heated
to 98 °C and separation of flocculated non-sugars takes place in a continuous settler.
Addition of Reagents
The liming and sulphuring process advanced in favor of simultaneous liming and
sulphuring at 75 °C. The sulphitation system is practices in Finchaa-Sugar Factories.
a) Shock Liming Modification

The mixed juice heated to 75 oC is first prelimed to pH 7.2 - 7.5. After a very short
period of time, the same juice is subjected to 2 nd liming (shock liming) where its pH is
raised to 9.2 - 9.5 and gassed with SO2 simultaneously in a suitably designed sulphiator

tank. After gas treatment the pH is regulated to 7.2 - 7.5 again heated to 100 – 102 OC
in secondary juice heaters and directed to settlers through the flash tank and splitter
Dorr Clarifier and Juice Setting

It is a large vessel which consists of four supper imposed compartments with feed
chamber at the top and each forming a complete clarifier independent of the other.
It is provided with a central hollow shaft, rotating very slowly and movers the
scrapers at approximately 12 revolutions per hour which slowly brush the bottom of
the compartments, i.e. tray. Each compartment of the door clarifier is provided with
baffle plates (deflectors) to ensure good distribution of the treated juice with
minimum turbulence and it is provided also with mud boot to collect the settled mud.
Each compartment contains a circumferential internal pipe with seven openings
though which the juice withdrawal is carried out. In Addition, each compartment is
provided with clear juice pipe, muddy juice pipe; four test cock (sampling pipes) and
dearating tube. With the exception, the fourth compartment is provided with the three
fast juice liquidating pipes additionally.
The Flocculants
The flocculent is a polymer of high molecular weight, which is added to lime juice
before entry into the clarifier to enhance the production of large flocs in the mud.
Mud with large flocks will settle more rapidly.
The efficiency of a flocculants depends on its molecular weight and the degree of
hydrolysis. Molecular weight can vary between 18 and 24 million and degree of
hydrolysis between 30 and 40 %. The dosage of flocculants in limed juice depends on
cane quality and climatic conditions. In practice, if a dosage of more than 4ppm on
cane is required, another flocculants with a different degree of hydrolysis should be
used.
Preparation of Flocculent Solution

Flocculants are costly and their efficiency will depend on the care with which they are
utilized. The following precautions must be taken:
 Flocculants must be stored in well-closed packing to avoid formation of lumps.

 The addition of flocculants to water when preparing a solution must be done at
a slow and uniform rate to avoid formation of lumps.

 Water used for preparation of solution should be of good quality and at a

temperature of less than 50 0C. It is advisable to use cooled condensate.
 The agitators for the mixing should run at low speed.
 The concentration of the stock solution should not exceed 0.2 %.
 Let the prepared stock solution lie idle for 2 hours to allow the polymer to
develop properly before dropping it into another tank from which dosing will
be done.
 The flocculants tanks as well as piping should be of fiberglass or stainless steel
or epoxy painted. Never allow flocculants solution to be in contact with rust.

JUNE, 2020G.c
Finchaa Sugar Factory (FSF)
2.5 The Rotary Vacuum Filter

The filter is made up of a hollow drum rotating about a horizontal axis. The filtering
surface is made up of 48 independent screening sections arranged around the
circumference, occupying 150 each. These sections are arranged symmetrically on
both sides of the vertical center of the horizontal drum, thus having two groups of 24
filtering sections extending from the middle of the drum to each end. Each filtering
section is serviced by a manifold along its length, which is individually connected to a
distribution head at both ends of the drum. Each filtering section is covered by a
stainless steel screen provided with some 97 perforations/Cm2 (625/sq in), each
perforation being 0.5 mm in diameter. The open are per screen is about 24 %.
Figure 6: The Rotary Vacuum Filter (sources from the company data)
(a) A rotating part to which the 24 juice manifolds are connected.
(b) Wear plates to allow for wear from the rotation of parts.
(c) A fixed part provided with vacuum/juice ports connected to:
 A “low ‘’ vacuum of between 12 - 25 Cm mercury.

 A “high” vacuum of between 43 - 50 Cm mercury.
17

Flow Diagram of Juice Clarification and Filtration.
Figure 7: Flow Diagram of Juice Clarification and Filtration.
2.6 Evaporation plant

The evaporation process is the process of raising the concentration of juice with
evaporation of water. There are two effect evaporators in Finchaa sugar factory.
 The first phase is done multiple-effect evaporators.
 The second phase is performed in a single-effect vacuum pan.
The evaporator is not complete without the following accessories.
 Clear Juice Feed Pump  Incondensable Gas
 Syrup Extraction Pump Extraction
 Condensate Extraction Pump (air Pump)

Pump
 Barometric Condenser  Water Circulation Pump
for

JUNE, 2020G.c
Condenser  Level Control (For Efficient
 Cooling Pond/Tower Performance)
Finchaa Sugar Factory (FSF)
Body Parts of Evaporators
Figure 8: Body Parts of Evaporators (source from the company)
In the evaporator, juice is concentrated to syrup of Brix between 65 and 70, the upper
limit of evaporator being determined by the fact that sucrose will start to crystallize at
between 78 and 80 Brix. There are two types of evaporators in multiple-effect:-
Semi-kestner
Consists of long tube vertical raising film:
 Heating surface of the first semi3000m2 was as the second is 3500m kestner.
 Juice should be filled one-third of the calandria tubes.
The advantage of semi-kestner

The Advantages of a Kestner are:
 It gives a short juice retention time, which prevents color formation and 
Reduces inversion at high temperature.
 It provides a high concentration of heating surface due to the tubes.
19
 It does not require a heavy steel structure for support and is  Erected on a
thick concrete foundation at ground level.

The Disadvantages are:
 It used to require an external separator to separate juice from vapour.
Nowadays, this can be avoided.
 It must be preceded by a juice heater to supply it with juice at a temperature
that will ensure flashing the tube-plate.
 Depending on its construction, it may require chemical cleaning. Robert type
evaporator
 heating surface area of each Robert is 1000m 2
 It consists of short calanderia tubes, vapor space top and bottom
Factors Covering Evaporation Operation

The evaporator bodies being interconnected are interdependent. It is the quantity of
steam supplied to the first body that drives the whole apparatus and governs its
performance. The evaporator is also subjected to the influence of various operating
conditions was given by the following parameters.
Juice Temperature
To have the best performance, it is desirable to have the juice temperature at the
evaporator inlet at least 3 – 5 0C above boiling point. A juice heater on the evaporator
feed in necessary, although Roberts’ type bodies may do without it.
Juice Level and Juice Level Control System

In the case of rising film evaporators (Roberts and Kestners), there is optimal level for
their operation. For Roberts, it is between 30 – 40 % and for Kestners 20 – 25 % of the
tube lengths. This is to provide the “film effect” which favors heat transfer. A level
control or indication systems helps a lot. It is also recommended to have a control on
the juice flow to achieve stable conditions. In case of juice shortage, it I essential to
compensate with hot condensates to avoid drying up of the evaporator Conditions of
Steam to the Set

JUNE, 2020G.c
Steam from the turbo-alternator and other steam turbines will be superheated and has
a poor heat transfer coefficient. Consequently, steam has to be de-superheated before
entering the 1st effect. A de-superheated is installed in the exhaust main to reduce the
degree of superheat by spraying hot water in a very fine mist inside the main.
21
If the level of juice in the calandria tubes is too low, the boiling juice cannot reach the
top of the tubes and as a result there will not be circulation of juice in the calandria.
On the other hand, if the juice level is too high, the tubes will be fully submerged, i.e.
increasing the hydrostatic level of the juice in the calandria will result in the boiling
point elevation of the juice and thus prevents evaporation. Moreover, too low or too
high juice level causes entrainment.
Therefore, the optimum juice level that must be maintained in the evaporator vessels is
between 30 – 40 % of the height of calandria tubes.
All evaporators are provided with automatic level control, which consists of:
 The controller
 The level transmitter (Sensor)
 The pneumatically actuated valve
 We may need a “let down” station using high pressure steam to stabilize the exhaust
steam pressure. To optimize the thermal balance of the factory, it is better to get that
steam from the first stages of a condensing turbo alternator.
Temperature and Pressure Distribution

The performance of the evaporator is governed by the “Capacity Equation”.
Q = c. A .T
Where/ Q = Amount of Evaporation
c = Coefficient of
Evaporation A = Heating
Surface Area
T = Temperature Difference
Consider that the 1st effect is fed with saturated exhaust steam at 121 0C, and 205 KPa,
and that the condenser is at 54 0C and 15 Kpa. The overall temperature difference
across the evaporator (T 0C) is then:

T 0C = 121 0C – 54 0C = 67 0C
This overall temperature difference will be reduced by the total amount of the boiling
point elevation in the set so that we effectively have T = (67 – Sum of B.P.E).
That “T” will be distributed in the various effects according to their evaporation
rate.
Boiling Point Elevation (B.P.E)

As a sugar solution becomes more concentrated, its boiling point increases relative to
water at the corresponding pressure. This increase is known as the Boiling Point
Elevation or B.R.E. and is directly proportional to the Brix or solids content of the
solution. Extra amounts of heat will be needed to raise the boiling temperatures of the
liquor at various concentrations in an evaporator, the B.P.E. being small in the first
effect and increasing to a maximum in the last.
B.P.E is given by:
B.P.E  ((2100.4  BrixBrix))
Temperature Distribution
The available net temperature difference will distribute itself across the different
effects in relation to the amount of evaporation in each one. The T between the last
effects is greater than the T in the 1st effects, due o the increasing viscosity as
concentration of the liquor increases: this will reduce the heat transmission across the
heating surface. The vapor bleeding duties in a evaporator results in unequal heating
surfaces in effects.
Pressure and corresponding vapor temperatures will be higher in the 1 st and 2nd effects
as vapor bled from them will be used for juice heating and pan boiling. The amount of
vapor bled is sometimes important and may require larger heating surface in these
effects.

Influence of Retention Time

The vapor temperature in a 1st effect ranges normally from 108 0C to 112 0C, if final
juice heating is done on first vapor. Second vapor temperatures would be from 104 0C
to 105 0C in cane diffusion factories.
Juice retention ties at these temperatures could be too high with consequent destruction of
reducing sugars and inversion of sucrose, especially at low juice pHs In order to reduce these
influence, it is essential to keep the products of Temperature  pH  Time as small as
possible. In respect of time, the use of Kestner or eventually falling film for 1 st and 2nd vessels
will provide much shorter residence times than with Roberts’s vessels. As regards the pH of
juice entering the evaporator, a value of 7.2 to 7.3 is satisfactory
Second sulphitation (syrup sulphitation)

The purpose of syrup sulphitation:-
 Bleach of the sugar.

 To decrease the viscosity of syrup.
 For fast boiling of massecuite.
 Fast crystallization of sucrose
The Calandria Tubes

The calandria tubes of each of the five evaporators are identified with the following
specifications.
Table 1 calanderia tubes

Tube Outer Tube Length Total Heating
Diameter (mm) (mm) Surface (m2)
Evaporator
Vapor Cell 38 2.13 1400
1st –Effect 38 2.13 1400
2nd –Effect 38 2.13 1100
3rd – Effect 38 2.13 850
4th – Effect 38 2.13 850

Source (from the company)

The Vapor Body
The vapor space/body represents the greater part of the volume taken up by the vessel to
diminish the risk of entrainment of droplets of juice projected by evaporation. “High vapor
space is the best entrainment separator.” Height of the vapor space is 1.5 - 2.5times the
height of the calenderia tubes.
Exhaust Steam (Vapors) Admission Connection Pipe

Exhaust steam (vapors) admission pipes are provided for each of the evaporators for
evaporation purpose. Moreover, 2nd -, 3rd _ and 4th – effect evaporators are provided
with exhaust steam supply lines in addition to the vapors admission lines for the
purpose of caustic soda (NaOH) solution boiling.
For the vapor cell and 1st – effect evaporators, the same exhaust steam connection pipes
used for juice evaporation are also utilized for caustic soda solution boiling.
Sugar Losses
Two main sources of sugar losses are:
 Inversion Losses
 Entrainment Losses
a) Inversion Losses
For inversion losses, little can be done apart from keeping watch on the pH of the juice
and the temperature reached.
It is the transformation of sucrose (non- reducing sugar) into reducing sugars, glucose
and fructose. These inverted sugars are “lost” in the final molasses, as they never
crystallize under any circumstances in the vacuum pans and crystallizers. Inversion is
mainly e. As temperature increases, the rate of inversion increases and vice versa. It is
pronounced at temperatures above 100 0C. The lower the pH (or the higher the
acidity) of juice, the higher the rate of inversion is and vice versa. At pH lower than
6.5, inversion becomes more and more significant.
b) Entrainment Losses
Entrainment losses are monitored by frequently analyzing the condensates from each effect.
High sucrose content of condensate indicates inefficient save-alls or else a too high
evaporation rate.

Mechanical Cleaning
Mechanical cleaning of tubes is done by means of brushers or tool heads equipped
with cutters that are rotated (1500 or 3000 rpm) by means of a flexible drive coupled
to an electric motor placed outside the evaporator.
Safety regulations recommended the use of low voltage (24 V) motor.The evaporator is
filled with water up to the upper tubular plate and the rotating tool is inserted in each
tube, one after the other. A stop on the flexible cable helps to make sure that the tube
has been brushed .
2.6 Pan House Plant

Depending on the purity of syrup generally in Finchaa sugar factory there are nine
vacuum pans. Four batch vacuum pans are for masscuite and the other are for low
grade massecuite and one continuous vacuum pan for B1 masscult. The calandria
tube is bigger in pan than in evaporator and Length of the calandria tube smaller in
pan than in evaporator for better circulation of the mass in the pan especially.
The basic material used in the pan boiling is syrup of 60 to 65 degree brix and purity
82 up to 85. The pH is 5 to 5.4. The brix % of sugar is assumed as 100 degree. As a
result the concentration of syrup to masscult is from 62 to 100 degree in brix.
2.6.1. Purpose of pan house

 Producing white sugar with minimum losses of sugar to final molasses.
 For separation of sucrose by evaporating water content.
 Forming and growing sugar crystals.
 To concentrate the syrup brix from 62.5 to 99 degree brix .
Process of Pan Boiling

Preparing footing is development of grain or seed to sufficient size for further massecuite
boiling.
 Transferring or cutting footing in to vacuum crystallizer.
 Boiling masscults on the footing.
 Grain development or seed development. General sequence of operations
 vapor or steam inlet to calandria is closed
 condenser water flow stopped by closing water valve
 Pan wash out steam or vapor valve is open
 discharge valve is opened
 After discharge of strike the bottom valve is closed and the pan washing valve is close
then it start it work.
Boiling of Syrup
During sugar boiling, sucrose from syrup is obtained in the form of crystals whereas,
non sugars remain in the mother liquor. The mixture thus obtained is known as
massecuite. Diameter of tubes is bigger in pans than evaporators.
Massecuites boiling is a delicate task and great skill is required for good quality
production of uniform grain sugar. In the process of crystallization, the solution has to
be boiled at lowest possible temperature (under vacuum) in order to:-
 Avoid sucrose destruction by heat

 Formation of color to be minimized.
 To use low pressure steam. improves the heat transfer by maintaining sufficient
temperature difference between the steam/vapor and boiling liquid, there
maintaining a good evaporation rate.
2.6.2. System of boiling

The scheme of Boiling can be divided in to two main categories in white sugar manufacturing
three or four masscuite system.
‘’A’’ massecuite being purged for white sugar production. In Finchaa sugar
factory there are three boiling system resulting ‘’A’’ massecuite,‘’B ‘’massecuite
and ‘’C’’ massecuite.
‘’A” massecuite
There are four vacuum pan used to produce A-massecuite operated under
resulting ‘’A’’ massecuite vacuum. This pan commonly have 2 steam inlet which
came from second effect evaporator for boiling, exhaust steam (body steam) for
pan heating and for cleaning, vacuum breaker, feed and pneumatic discharge
valve, body water for washing pan, chest water for checking the calandria tube,
cut over line, condenser injection, proof stick and mirror to check thickness and
size of the massecuite inside the pan.
The gage for reading pressure, temperature and brix, also have discharge, slurry
entrance and cut over line washer steam on the back of pan body. False Grain

False grain is innumerable tiny new crystals which are visible. They can occur at all stages of
the boiling process and caused in areas of too high a degree of super saturation e.g. top layer of
massecuite in poor circulation pans. They may results from a high rate of evaporation. When
still in the pan, be dissolved by raising the temperature of the massacutie by lowering the
vacuum, or by washing the strike with water.
Factors for maintaining good standard of white sugar 
Seed must be white and contains uniform size
grain.
 Syrup must be bleached properly.
 A- Molasses should be Light colored and of high purity.
2.7. Crystallization of massecuite

Crystallization process not only removes dissolved sucrose from solution and recovers it
as solid sucrose crystals, but it is also a very powerful purification process.
A massecuite
It can be defined as concentrated sugar liquor in which crystallization has taken
place. It is, therefore, a mixture of crystals and mother liquor. A massecuite,
depending on its final concentration and purity, is a highly viscous material.
:
Figure 9: Process of Crystallization in Vacuum Pan
A massecuite will have certain crystal content, which is the percentage of crystals in it.
Crystal content depends on the purity and final Brix of the massecuite.If we consider
syrup of 85 purity, giving crystals of 100 purity and final molasses of 35 purity, the
crystal content of a hypothetical massecuite will have to be

100  (85  35)  76.9 %

( 100  35)
This, unfortunately, is physically impossible, as the massecuite would be a solid mass

with no spacing or voids between crystals. Therefore, it is not possible to exhaust the
syrup of sugar in one boiling.
Some amount of crystal is formed in vacuum pan after seed (either magma or sillier)
is added to the pan. The massecuite boiled in pans and contain some amount of crystal
are discharged into open mild steel vessels which are fitted with stirrer Known as
Crystallize.
The location of the crystallizer should be below the pans and the massecuite from the
pan flows by gravity into crystallizer. The crystallization process of A,B and C-
massecuite is not the same.
B-massecuite
Is crystallized first by air cooling crystallizer and sent to a vertical mono
crystallizer .at mono crystallizer takes place by means of crystallization by water
during this operation hot and cold water are feed in to the crystallizer the
temperature of the massecuite inside the crystallizer must be at optimum. The
optimum temperature is 45 degree cent grade. C-massecuite
Is first crystallized by air cooling system and then after sent to twin vertical
crystallizer. At this crystallization takes place by water (hot water and cold water
process). If the temperature of massecuite inside the twin crystallizer is above the
optimum cooled water is added and if bellow hot water is added.
The main purpose of twin crystallizer is to increase the retention time of massecuite
inside the crystallizer because C-massecuite is less purity and brix. Rate of
Crystallization
The rate of crystallization depends on:
 The Viscosity
 The Temperature
 The Supersaturation
 The Purity of The Mother Liquor

2.8. Centrifugal separation plant

2.8.1. Batch centrifuge
In Finchaa sugar factory there are 6 batches centrifugal for separating high
grade massecuite .In a batch centrifugal machine the basket is a cylindrical
drum with perforation Supported on a heavy vertical shaft with drive
arrangement at the top. Batch centrifugal machine essentially consists of
revolving basket with drive arrangement, Monitor casing
2.8.2. Continuous Centrifuge

The principal disadvantages of batch machines for centrifugal separation are:-
 Low efficiency in the use of energy because of acceleration and braking in
separation.
 Complex nature of motor which has to have different speeds for different
phases.
 Loss of time in charging and discharging.
 Continuous centrifugal are applicable in low grad massecuit separation or
applicable at B1, B2, and C-mother liquor separation. Factors affecting
centrifugal performance  Uniformity of grain size and  Viscosity of
mother liquor.
2.9. Sugar Conveyers

White sugar discharged from centrifugal is conveyed on grass hopper to sugar
elevator chute. The grass hopper conveyer is a wide shallow trough usually of G.I.
sheet which vibrates by an eccentric drive.
2.9.1. Sugar Drying

After white sugar separated from molasses the next step is drying that is removal of
moisture content. Drying is done by first absorbing atmospheric air by FD fan and in
the other side steam is supplied immediately the steam heats the air then the air will
heat the sugar and becomes dry solid followed by cooling Sugar. In order for sugar to
be properly handled and successfully stored, it has to be dried to a safe moisture level.
Raw sugar, depending in its polarization, is surrounded by a film of molasses, which

contains non-sugars and reducing sugars .if the sugar is not dried sufficiently, growth
of microorganisms could develop, which would causes deterioration and loss in
storage. The level of drying is determined by the required polarization to satisfy its
market values, both international and local.
Permissible Moisture Content
This is determined by the ratio of non-Pol to the moisture in the film of molasses
around the crystals. Micro-organisms cannot develop in solutions of high
concentration so that if the moisture is driven off to a controlled level, no
deterioration will take place. Two formulations have been developed to control the
moisture content of sugars.
The Safety Factor (S.F)
( % H 2O)
The Safety Factor ( S.F ) 
(100  Pol % )
A Value of 0.25 or Less is Re quired
The Dilution Indicator

The Dilution Indicator (D.I )  %
H2O)

 %
H2
(100  Pol %
O
AValue of 0.33 or Less is Considered Satisfactory.
If Pol % = 98.50
and Moisture % = 0.35

0.35) )
DilutionIndicator(D.I ) 

(100 
(100  98.50 0.35
 30.44
 SafetyZone
DilutionIndicator(D.I )  33.3
 DoubtfulZone
DilutionIndicator(D.I ) 33.3  50  Zoneof
Deterioration
DilutionIndicator(D.I )  50
Raw sugar of 98.50 Pol is generally dried to between 0.2 – 0.5 % moisture, and very
high Pol sugar of 99.30 Pol to less than 0.18 %. Refined sugar is dried to between 0.02
– 0.03 % moisture. A sugar dryer provides heated air in counter flow to a sugar
stream to drive the moisture out of the sugar to the desired level. A dryer consists of a
drying section followed by a cooling section.
2.9.2. Sieve Grading

The grading of sugar involving separation of different size grains is performed in the
sugar house. The elevator delivers the sugar from hopper to the top of grader through
a bucket elevator. A rotating distributor spreads the incoming sugar over the entire
width of the top coarse screen.
The function of the grader is to classify sugar into different size grains and to separate small
lumps as well as dust from the sugar to be marketed.
The grader is a vibrating mechanism with screens. The oversize grains flowing over
screens are collected at the chute.
2.10 General flow diagram

Figure 10: General Flow Diagram (Source from the company module)
2.11. Ethanol production in fichaa sugar factory

In fincha sugar factory there is production of ethanol from the byproduct of sugar that is
obtained from C- molasses. By using this molasses they produce bio ethanol alcohol.
Raw Material
Total sugar is the most quality criterion in the sale of molasses since it is the factor that
determines its value in the most common uses of molasses.
The first step is to know how much molasses will be supplied to the distillery plant. The next
step is to calculate the amount of fermentable sugars (FS) in the molasses. The fermentable
sugars in molasses are sucrose, glucose and fructose.
Table 2: Important parameters of molasses for Ethanol production
Parameters Standard value
Total sugar as invert, % 50-52

RDS, % 85
Gravity Purity,% 37.0

Fructose, % 7.0-8.0
Glucose% 5.0-6.0
% Fermentable Sugar % brix in molasses 45-50
Ash content, % < 10
Sources (finchaa sugar factory ethanol production quality centers)
Molasses treatment
Molasses has to be treated before feeding to pre-fermenters and/or fermenters.. Thus, one of
the usual important specifications for molasses as an alcohol feedstock is that it should not
contain more than 10 % ash which can lead to serious scaling problems.
Table 3: Standard parameters of molasses treatment for batch fermentation
Parameters Standard values
Ratio of condensate to molasses 0.67 - 0.7
Working temp of pre-diluter - heaters, oC 60 – 65
pH of molasses in the pre-diluter – heaters 4.7- 4.9
H2SO4 kg/ton of mol at 85 oBx 2.6 - 3.0
Exhaust steam 120 -130 oC (1.1-1.5 kg/cm2)
Temp at the diluted mol heater, oC 95 – 100

2.11.1. Fermentation process
2.11.2. Continuous Fermentation
The decanted molasses has to be diluted further in such a way that it could not cause
any osmotic stress to the yeasts. In the pre fermentation and fermentation section, the
following operational phases needs.
 yeast propagation
 wash preparation for yeast propagation and fermentation
 fermentation control
 yeast recovery
Before starting any fermentation operation, cleaning of all the culture vessels,
continuous mixed bioreactors or fermenters, holding tanks, plate heat exchangers,
pipes are extremely important.If wash and fermentation residues are allowed to

accumulate, bacterial contamination will be out of control and will greatly reduce
alcohol yield and even leads to rejection or replacement of the wash in a new batch.
Table 3: Standard Parameters for Continuous Bio fermentation process
Initial volume of fermentable wash in the bio- 40 % of the fermented

reactor before putting culture
Bx of mash feed for yeast culture 18
Temperature of fermented wash to be maintained in 30 - 32

bioreactors, oC
Yeast to be added 6 - 8 g/L of wash
Bx of mash to bio-reactor 18 – 20
Nutrients for yeast culture 2 g/L Urea and 1 g/L DAP
Nutrients for bio-reactor 0.1 kg Urea / m3 of mash

0.1 kg DAP/ m3 of mash
Antifoam 0.575 kg/ton of molasses
To start yeast multiplication process, the molasses has to be diluted to about 18 oBx or
s.g of 1.07 and for that of continuous fermentation, fermentable wash of 18 o - 20o brix
is used.The most preferred nitrogen source is urea. Another common nitrogen source
in industrial fermentation is liquid ammonia but is not encouraged to be used since it
will raise the pH which subsequently favors bacterial contamination.
Distillation columns A-columns

Separation operation achieve their objective by the creation of two or more coexisting
zones which differ in temperature, pressure, composition, and/or phase state.
Distillation utilizes vapor and liquid phases at the same temperature and pressure for
the coexisting zones.
Table 4: Standard parameters for Multi pressure distillation process.
Alcohol content of fermented wash in % 8- 9
Temp. of the preheated fermented wash in °C 85 – 90
Wash level to be maintained in primary column 60

reboiler,
%
Operating Conditions of A-Column
 Top vacuum  0.37 - 0.45 bar(a)

 Top temperature  Bottom  68 - 72 oC
vacuum  0.55 - 0.65 bar (a)
 Bottom temperature  72 - 75 oC
Operating Conditions of B-Column
 Top vacuum  0.55 - 0.65 bar(a)

 Top temperature  Bottom  72 - 74 oC
vacuum  0.4 - 0.55 bar (a)
 Bottom temperature  80 - 84 oC
Hydrous alcohol, oGL ≥ 96 oGL
Grade of Power alcohol, oGL ≥ 99.9 oGL
Stillage alcohol content, % < 0.03 %
Liquid runs down the column, cascading from tray to tray, while vapor flows up the column,
contacting liquid at each tray.
Liquid reaching the bottom of the column is partially vaporized in a heated re boiler/or
direct injected steam to provide boil-up which is sent back up the column.
The remainder of the bottom liquid is withdrawn as bottoms, or bottom product. Vapor
reaching the top of the column is cooled and condensed to liquid in the overhead condenser.
Part of this liquid is returned to the column as reflux to provide liquid overflow. The
remainder of the overhead stream is withdrawn as distillate, or overhead product.
The alcohol (the lower-boiling component) tends to concentrate in the vapor phase,
while the water (the higher-boiling component) tends toward the liquid phase. The
result is a vapor phase that becomes richer in ethanol as it passes up the column and a
liquid phase that becomes richer in water as it cascades downward. The feed is
introduced at a point along the column shell at which the column is divided into an
upper section, which is often called the rectifying section, and a lower section, which is

often referred to as the stripping section. The performance of the distillation process is
measured by the distillation efficiency.
B-columns
The spent wash is colored and highly acidic with a very offensive odor, which poses
serious environmental problems. To overcome the ill effects of spent wash and reduce
the cost of the effluent treatment, manufacturing bio-compost using the press mud
and spent wash has helped industry to achieve zero pollution status.
CHAPTER THREE
3. The overall benefits
The aim of inter ship practice is to improve the understanding of technology
students in practical and general professional ethics for the development of our
country in science and technology.During practicing this program we have got
some skills from the community and the work which is exciting in the company
because of practicing on are the following.
3.1 Improving practical skills

We were grasping different practical skills in our internship months. The
performance of workers of the factory was shown practically by different sections
and workers of the factory at the spots of the machines by demonstration method
in addition they share their merit and demerit experiences, exchanging ideas and
standardized production systems.  To improve production qualities  How to
check the pH variation.
 How to reduce total suspended solids
 How to control the color of the product sugar
 The purpose Sulphitation and liming
 The maximization of sugar production and reduction of final molasses purity etc.
3.2 Knowledge gained from internship

In Finchaa sugar factory there are so many people work together; due to this we
ask questions in order to get information. In this factory we made a group to solve
some problems, such as; practical in laboratory for this reason we improve our

knowledge and understanding skills. As we know coming before in the previous

theoretical awareness or familiarity and actual place could be distinguishable, so
the objective reality and theoretical knowledge may be slightly different.
3.3 Communication skills

We have seen the transparent communication between group members with their
product consumers and suppliers. Communication skill is very important for us to
get full information about our needs. We use communication in the factory to
develop our; Knowledge, Listening, Thinking and so on.
3.4 Team Playing

Team playing skill is law full. Team playing skills are very important for their good well-
being. General skill such as; Good communication, Good concentration, Fast decision
making, Self-confidence are required for each team. In general, this internship program has
given towards a common purpose a lot in making student work different kinds of plan in
group. This helps to share different kinds of knowledge from different perspectives.
3.5 Leadership skills

We have to develop a deep understanding of what is valuable to us. It is also
essential for us to understand ethics. In daily activities he always control and
manage all of the workers. Such as: processer, Mechanics, Electricians,
Laboratorial, Power house controller and water treatment examiner.
In our internship activity we have gate leader ship skill.
Such as:  How communicate with worker on
working is  Employ professional worker.
 Give know how for worker about the production quality with related profit.
 How control the level of quality of raw materials.
 How give service for person.
3.6 Work ethics

Developing a strong work ethics, Respect what others contribute to the work
environment, Got to extra time whenever necessary to ensure that your verbal and
written interaction switch others are productive. Work ethics includes;
 Punctual(on time)  Accountable and responsible.
 Respecting other worker.
 Keep the property of the company etc.

3.7 Entrepreneur ship skill

The state of being an entrepreneurship can be realized when one engages in
profitable risks and creates something of value. It is defined by their habit of
innovating and redefines market trends and limits.
CHAPTER FOUR
4. Conclusion and recommendation
Conclusion
We conclude that every chemical Engineering students working in such like
factories can get good knowledge and tangible information that they learned
theoretically in the class and can do practically in the factory. This internship
program played a great role to break the convection thought that the student
and other skilled labors. We developed our skills during this practice and
confidence to deal with problem arises in the factory, community and other
technological world. The internship program essential for any chemical engineer
in order to develop: Practical skill, communication skill, team playing skill and
Work ethics.
The present process aims at covering theoretical and practical aspects of each
and every operation involved in the present process of white sugar manufacture
from sugar cane and deals with recent techniques established in various cane
sugar producing countries of the world. The cane is passed through preparatory
devices like knives, for fine cutting before being subjected to crushing in a
milling tandem comprising 4 to 6 four roller mills. Fine preparation, with its
impact on final extraction, is receiving special attention and shredders and
particularly the fibroses are gaining popularity. The mills are of modern design,
being equipped with turbine drive, special feeding devices, efficient compound
imbibitions system etc.
The clear juice with about 85% water is concentrated in a multiple effect
evaporator under vacuum to yield syrup with about 35% water content. The
syrup is again treated with sulphur dioxide before being sent to the pan station
for crystallization of sugar.

The main function of the evaporator station is to concentrate clear juice

containing around 85% water, and transform it into syrup containing 35% water
with minimum expenditure of steam without bringing about any change in the
composition of dissolved constituents, which would affect adversely the
recoverable sugar at the crystallization stage. At the time of commencement of
this operation the condenser water is started and vacuum developed in the last
body connected to a condenser.
Evaporation or heating in any process operation like juice heating, pan boiling
or juice concentration depends on the rate at which the heat is transferred from
the hot condensing steam or vapor to the cooler liquid through the tube walls.
The process of pan boiling for plantation white sugar manufacture differs
considerably from that followed in raw sugar plants and also sugar refineries, in
as much as the objectives in this case are to produce white crystalline sugar from
syrups of purities varying from 77 to 86 and at the same time to ensure
minimum loss of sugar in final molasses.
However to bring down the final molasses purity, the final massecuite purity has
to be as low as practicable, which many times calls for practicing four stage
boiling in place of the conventional three massecuite system These masscults are
designated by letters as A, B, C depending on first, second or third stage of
boiling respectively.
The 'Molasses' is the mother liquor separated from sugar crystals during
centrifuging of massecuite. When the molasses is separated with minimum
washing in centrifuges or without any application of water it is comparatively of
high brix and low purity and is denoted as heavy molasses like A Heavy from A
massecuite B heavy from B massecuite. Separation of heavy molasses is followed
by liberal wash or resorting to second time curing in centrifugal. The liquor thus
obtained is of higher purity than the heavy molasses and is named as light
molasses and from A massecuite A light is obtained after A heavy is separated
and similarly for 'B' and 'C'.
In a batch centrifugal machine the basket is a cylindrical drum with perforations,

supported on a heavy vertical shaft with drive arrangement at the top. The
perforated basket is lined with wire gauze and a perforated brass liner for
allowing the separated molasses to flow out, while retaining the sugar crystals.

Generally, as chemical engineers we identify the problem in order to maximize the

efficiency of the factory and we design the lime stone transporter by belt conveyor.


Recommendation
We would like to recommend the following points for FSF and company
supervisor: The dropping of sugarcane from bullock carts during transportation
should be analyzed, since it decreases the productivity of the company. It could
be solved by changing the container of bullock carts.
In SO2 generation there is great problem that affect the sulphitation process and
the color of the final sugar product. This is happened due to the formation of SO 2
gas vapor in melting of Sulphur and burned with oxygen. This creates scale and
blockage of the pipes. It can be solved by the adjustment of temperature and
pressure and also the application of pure oxygen and proper cooling of the
gas.The formation of scale on heaters and evaporators which affect the heating
surface and juice transferring tubes and the heat requirement. To avoid this, the
applicant should perform proper clarification, liming, sulphitation and flocculent
addition and vent of incondensable gases.
The loss of sucrose through filter cake, crystallizers due to the absence of level
sensors and final molasses as the result shows above the purity standards. It is not
easy to recover all loss of the factory in a short period of time. But we can reduce
it step by step. Thus in order to bring this loss recovery visible, the process and
technical departments has to do their jobs together without pointing their hands
at each other.
The company supervisor should take action to clean up (good sanitation) all
injection areas including the milling plant, to decrease amount of inversions and
creation of bacteria.

References
1. Different data books from the factory.
2. Sugar Technology A.R Sapronov – 1983
3. Hand Book of Cane Sugar technology R.B.L MATHUR – 1978
4. Cane Sugar Hand book Spencer and Meaden – 9th Edition.
5. Principles of Sugar Technology Pieter Honig Vol. 1,2,3 – 1963
6. Cane Sugar Hand Book – 12th Edition James C.P. Chen ChungeChichon – 1993.
Abbreviation
B=bagasse
B’ = bagasse % cane
C=cane crushed
E=evaporated sucrose amount
FSF=Finchaa sugar factory
F=filter cake
ICUMSA=international commission for uniform methods of sugar analysis
I=intake sucrose amount
M=final molasses
Pty=purity

Qt=quintals
Q=total heat flux
Rpm=revolution per minute
S=syrup amount
TCD=ton of cane crushed per day
U= overall heat transfer coefficient
∆T= temperature drop of condensing steam to boiling juice

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Finchaa Sugar Factory (FSF) JUNE, 2020G.

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

TITLE: - INTERNSHIP REPORT

COMPANY NAME: FINCHAA SUGAR FACTORY

ADVISER NAME: - INSTRUCTOR ZELALEM GETAHUN

DURATION OF INTERNSHIP: - FROM MARCH TO JUNE

Submission date 7/10/2019

Wachemo University Chemical Engineering Department iii

Wachemo University Chemical Engineering Department iv

Wachemo University Chemical Engineering Department v

Wachemo University Chemical Engineering Department vi

3.6 Work ethics......................................................................................................................35

Wachemo University Chemical Engineering Department vii

Figure3: Auxiliary cane

Wachemo University Chemical Engineering Department viii

 To produce commercial plantation white sugar and other products including

Wachemo University Chemical Engineering Department 1

 Increasing land productivity of existing cane area to 18,000 quintal/hectare

 Continually decrease production cost.

1.2. Main Production of the company

 To produce the molasses

 To produce 34Mw electrical power.

 8000,000 Liter Ethanol from it’s by product molasses per annual

1.3. Main Customers of Company

 Moha soft drink factory

Main customer of final molasses

1.3 FSF Overall Organization and Work Flow Chart

1.3.1 Man power

Wachemo University Chemical Engineering Department 2

1.3.2 General Manager

 Formulate and ensures the implementation of quality policy.

1.3.3. Purchasing and supplies, finance and administration related task

1.3.4. Maintenance related tasks

1.3.7 Quality control

Workflow sheet of FSF organization

Agriculture Factory Human resource Finance Linguistic

Seed production Technician Heath centers Budget Material

Wachemo University Chemical Engineering Department 4

Figure 1: Workflow sheet of FSF organization (Sources from finchaa sugar

2.1 Sugar cane production

2.2 Cane sugar processing at Finchaa Sugar Factory

Wachemo University Chemical Engineering Department 5

2.3 Cane Preparation

2.1.1. Object of Cane Preparation

2.1.2. Cane preparation Equipment’s

Wachemo University Chemical Engineering Department 6

Figure 2: Cane un loader

Auxiliary cane carrier

Wachemo University Chemical Engineering Department 7

Figure 3: Auxiliary cane carrier

Main cane carrier

Wachemo University Chemical Engineering Department 8

Figure 4 A typical whole-stick cane preparation stations with gravity-fed shredder.

Sources from google.com//http:shereder.com

Magnetic iron separator

 Speed of Rotation Knives

Wachemo University Chemical Engineering Department

2.2 Milling plant

Methods of Extraction are

Main Equipment’s of Milling

Wachemo University Chemical Engineering Department 10

Flow diagram of milling plants