UGANDA PETROLEUM INSTITUTE KIGUMBA

P.O BOX 50, KIGUMBA

DEPARTMENT OF DOWNSTREAM PETROLEUM OPERATIONS

MUHONGE BARNABUS

19/UPIK/DDPO/020G

YEAR TWO

INDUSTRIAL TRAINING REPORT CONDUCTED FROM 10TH JANUARY, 2022 – 17TH

FEBRUARY,2022 AT BWENDERO DAIRY FARM COMPANY LIMITED.

ACADEMIC SUPERVISOR: MR. ILUKOL DAVID

FIELD SUPERVISOR: MR ORONE JOSEPH

APPROVAL

i
DECLARATION

I MUHONGE BARNABUS hereby declare that this industrial training report has best done to the best of my
knowledge and effort and it has never been presented elsewhere for any professional award in any
institutional of higher learning

ii
APPROVAL

This industrial training report has been done and submitted by MUHONGE BARNABUS under the guidance
and supervision of Company and Institute supervisors.

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ACKNOWLEDGMENT

I extend my heartfelt gratitude to the management of Bwendero Dairy farm for granting me an opportunity to
train at their company. I thank the Human Resource manager and the entire staff for granting me an
opportunity to train with their companies.

I also thank my field supervisor for his tireless efforts put in to help me learn beyond my expectations.

To my Institute supervisor Mr. Illukol David, thank you so much for the efforts put in place to see that we
complete our course successfully.

I also take this opportunity to thank all the workers and my fellow trainees for the support they showed me
through out the training.

Finally, my parents and my guardian for the support they have given me during my training period.

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EXECUTIVE SUMMARY

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CHAPTER ONE

1. INTRODUCTION
1.1 OVERVIEW OF INDUSTRIAL TRAINING
This report entails a short description of my training carried out at Bwendero dairy farm as a requirement for
the award of a Diploma in Downstream Petroleum Operations. Industrial Training is a field -based practical
training that exposes trainees to the various skills required in the labour market. It is a Prerequisite for the
award of Diploma in Downstream Petroleum Operations at Uganda Petroleum Institute Kigumba

1.2 OBJECTIVES OF INDUSTRIAL TRAINING

To produce graduates who have the necessary practical skills to meet the demands of the labor market.

To get an opportunity of transferring theories taught in lecture rooms into practical.

To enable learners, get ethics necessary for engineering profession.

To give students ample time for hands on study.

1.3 BWENDERO DAIRY FARM

1.3.1 HISTORICAL BACKGROUND

The business started as a dairy factory by late ceaser Magara. In 2007, the industry started distilling alcohol
by the river. This developed into a crude factory in 2009.

In 2009, it was registered as a formal company in 2010 as Bwendero Dairy Farm with the directors John
Magara, Kato Magara and Flora Magara.

In 2011, modern distillation columns were built. In 2014, the company secured a loan from Orient Bank to
build a plant to produce high quality ENA.

After the ENA plant was operational in 2016, there was a challenge of getting molasses locally. This
prompted the company to get molasses from as far as Tanzania and Burundi in very small quantities.

As a stock gap Measure, the company had to resort to maize and cassava to produce the alcohol in order to
service the loans. Bwendero makes portable spirit, carbon dioxide and biogas.

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As a long-term investment, BDF applied for and got a license from the Ministry of Trade and industry to
start growing sugar cane and make sugar for a sustainable supply of feed stock for the spirit plant. Therefore,
BDF got another loan from Orient Bank and imported machinery for the sugar plant which was also for co-
generation to run the spirit plant

The initial plan of the plant was to crush sugar cane and produce syrup for the spirit plans. From the obtained
loan, BDF ordered for machinery and started growing sugar cane.

Owing to flooding of spirit products on market in the country, BDF was forced to acquire machinery for the
crystallization of sugar.

BDF now approached Uganda Development Bank because of its lenient terms. UDB agreed to absorb the
orient bank loan and added more money to BDF for agricultural development on longer terms. A total of
11.4billion was acquired as Term loan and working capital.

BDF was able to complete the erection of the syrup plant and in May 2019 was able to start milling cane,
producing syrup and sending it to the spirit plant. Meanwhile the company was able to complete the erection
of the sugar plant and on 23rd April, 2020 was able to make crystal sugar, drying and packaging it in
Bwendero sugar bags.

Much as the company has the capacity to crush 500 tons of sugarcane per day, its milling 215tonnes. The
syrup sugar plant, power generation plant and crystallization plant are valued at about 4.8 million dollars.

At the moment, BDF has developed and owns over 1600 hectares of sugar cane which is still 60% of our
requirement.

1.3.2 LOCATION
Bwendero Dairy Farm is located in Dwooli, Kitoba subcounty in Hoima district. e. The company is about
10km away from Hoima town and is along Hoima-Butiaba Road about 200m off Dwoli trading Centre.

1.3.3 BWENDERO DAIRY FARM VISION

To be the best company in the greater lakes region in networking, environment, quality of production and
profitability of spirit.

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1.3.4 BWENDERO DAIRY FARM MISSION
To grow from strength to strength to create employment opportunities and to continuously, financially
empower local communities in our environment, pass engineering skills to the youths through job training
and eradicate poverty in communities.

1.3.5 BWENDERO DAIRY FARM ORGANISATION STRUCTURE

1.3.6 HEALTH AND SAFETY POLICY

1.3.7 TASKS CARRIED OUT BY BWENDERO DAIRY FARM

Bwendro dairy farm deals in the manufacture of sugar. The raw materials mainly sugar cane is grown by
factory and some of it is got from outgrowers.

The factory also deals in alcohol production which uses molasses from the sugar plant. Starch is also used in
addition to molasses. Normally the fermentation process produces carbondioxide, so the factory has got a
carbondioxide plant where carbondioxide is treated to meet consumer requirements.

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2. ACTIVITIES I CARRID OUT WHILE AT BWENDERO DAIRY FARM
The activities I carried out while at Bwendero dairy farm as shown below. Mainly these activities describe
the process of sugar manufacture and then the utilization of molasses from the sugar factory to make alcohol.

2.1 Cane weighment:

This is the first step in sugar manufacturing process. This is carried out at the weigh bridge. With the help of
one of the weigh bridge attendants, I was able to learn how to use the weigh bridge. The following were
determined;

Gross weight: This is the total weight of the truck loaded with sugar cane.

Tare weight: This is the weight after the truck has been offloaded.

Net weight: This is the difference between tare weight and the gross weight which is expressed as;

Net weight ¿ gross weight−tare weight

From the net weight, the payable weight is calculated from the formular shown below;

Payable weight¿ net weight−trash where trash is 5% of the net weight.

2.2 Primary preparation

2.3 Cane milling.

There are four sets of mills which are used to extract juice from the shredded sugar cane. Each mill has three
rollers that is the feed roller, top roller and the discharge roller. The top roller drives the rest.

Mill 1 extracts juice from the threaded juice and then discharges off the remaining to mill 2 via a conveyor
known as the intercarrier which extracts more juice. Hot water is added at mill 3 to the fiber being discharged
at 800c to avoid contamination of fuel in the boiler with much vapour. Finally mill 4 has bargass going to the
boiler to act as fuel.

2.4 Juice treatment

2.4.1 Phosphorylation:
This is the first step in juice treatment and involves and addition of phosphoric acid to increase phosphate
ions in the juice. The normal phosphate ion in the juice which is 250ppm is boasted to 500ppm.

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2.4.2 Lime addition:
A milk of lime was prepared by dissolving 4 bags of calcium hydroxide in water for over 30 minutes. Lime
helps in the clarification process in order to raise the PH of the juice and removal of impurities and non-
sucrose components to form floc.

CaO(s) + H2O Ca(OH)2 (aq).

Lime combines with phosphates in the mixed juice in the reaction tank to form calcium phosphate precipitate
; it also combines with acids and other impurities in the juice to form mud that easily settles out in the
clarifier.

2.4.3 Juice heating

This is done to raise juice temperature to meet clarification. Before the reaction tank, the juice is heated to a
temperature of 700c-750c in the primary heater and it is sent to defaecated tank one. Juice from defaecated
tank one is then heated to about 850c in the intermediate heater and then goes defaecated tank two from
where it is heated to about 105oc in the secondary heater.

2.4.4 Flashing
This is the removal of non-condensable gases from the juice which is done by swirling the juice in the flash
tank. The juice then enters the clarifier.

2.4.5 Clarification
This takes place in a short retention time clarifier that is to say SRTC where impurities sediment out and
clear juice is obtained. Sedimentation is achieved by addition of a flocculant that enables clamping of fine
solid materials. In the clarifier, clear juice settles on top while mud settles on the bottom where it is
constantly drained. The clarifier uses density difference.

2.4.6 Mud filtration

Muddy juice from the clarifier is then collected in the mud tank where it combines with bargacillo from mill
four for better filtration. The mixture is then pumped into a rotary vacuum filter fitted with an external filter
and suction tubes. Juice from the filtration process is recycled back to the mixed juice tank.

2.5 EVAPORATION
The clear juice from heater 3 is then concentrated by boiling to form in order to form syrup of 60-65%
concentration.

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At Bwendero sugarfctory, multiple effect evaporators are used that is DE and TE where the vapor produced
in one vessel was used to boil to boil the syrup in the next vessel and some vapor was carried to the pans.
DE1 is used to boil DE2 whose vapor is sent to heater one and some to pans.

For TE1, exhaust steam is used directly and vapor produced boils TE2 whose vapor boils TE3 and is then
condensed and sent to a hot water pond.

2.5.1 Requirements for evaporation

 Condensates should be effectively drained out so as to clear the heating space and mobilize the vapors
 Catchall drainage should Steam pressure in the calandria mostly for DE1 should be high to increase
evaporator capacity.
 Evaporator vacuum has to be kept as high as possible.
 Optimum juice level has to be maintained to prevent carryover at higher juice levels and entrainment
at lower juice levels due to increased juice velocity.
 Calandria tubes must not be loose or broken to prevent juice losses in condensates.
 Incondensable gases should be effectively extracted from the calandria since these gases affect heat
transfer.be effective so as to trap all the juice escaping with the vapor.

2.6 Crystallization (pan boiling)

This produces crystals ready for curing.

2.6.1 Components of a pan

 Multiple jet condenser that enables vacuum creation in the pan
 Main feeding valve that contains material feed lines that is to say syrup, magma, molasses, melt and
water depending on the pan being boiled
 Cut over valve for transfer of materials from one pan to another or from pan to vacuum crystallizer.
 Steam valve for supply of steam into the pan
 Ammonia vent that constantly removes incondensable gases from the calandria.
 Body and catch-all: upper part of the pan where vapor collects and entrainment is trapped
 Calandria portion which is the heating surface made up of tubes for maximum heat transfer.
 Discharge valve where massecuite passes while dropping the pan into receivers.

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  Vacuum crystallizes: these temporarily store massecuites that is footed in the process of pan cutting
to increase the crystal size of the half that remains in the pan.
 Open air-cooled crystallizers: receive massecuites from the dropped pans and cools the massecuites.

2.6.2 Pan boiling criteria

The vacuum is raised. This is done by first raising the temperature in the pan so as to produce vapor to be
used in the condenser. The body washing valve is then closed and material fed into pans in the following
order:

For pan A, syrup is fed. Concentrated magma is added from the cut over line; false grain washed using hot
water and then boiling and dropping of the pan

For pan B, A molasses are fed and concentrated, slurry added and false grains washed off with hot water. It is
then boiled with A molasses and then dropped.

For C, A molasses are concentrated due to lower purity of B-molasses, slurry added and false grains are
washed off with hot water. Boiling is done with B molasses up to fifth glass and then pan is dropped.

2.7 Curing of sugar

This involves use of centrifugals that uses centrifugal force, steam and hot water to separate molasses from
sugar crystals. This is after the massecuites from pans passes through receivers, to the purge Mills then to the
centrifugals.

2.7.1 Batch centrifugals

This cures A massecuite to produce sugar and A molasses. A sugar is obtained and is conveyed to the bucket
elevators, to drying. A molasses contained sucrose and were sent to storage tank for B boiling.

2.7.2 Continuous centrifugal

These centrifugals cure B and C massecuites to produce B molasses with B seed and C molasses with C seed.
B seed is s then mixed with little water to form B magma that is sent to magma tank for A pan footing. C
seed is sent to a re-melt tank, it is mixed with water and steam treated to melt all the crystals and then stored
in melt storage tank to be used for A boiling. C molasses are the final molasses and are taken to the distillery.
B molasses are stored and they are used as main feed for pan C boiling.

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2.8 Drying and packaging
2.8.1 Drying
A sugar is taken to a conveyor belt by a hopper with magnetic separators to remove any magnetic particles
from the sugar. The sugar is then conveyed to a bucket elevator that is then poured into a fluidized bed drier.

Drying is done by heating atmospheric air in a heater and blowing it into the hot air chamber of the dryer.
The air passes around the sugar crystals either co- currently or counter-currently in the dryer as it removes
moisture from the liquor covering the crystals. The sugar is then cooled, usually within the dryer where
ambient air is blown into the cooler section of the dryer.

Other sets of magnets are also installed to remove any magnetic materials before packaging.

2.8.2 Packaging
Commercial sugar from drying is then sent to the sugar bin for primary storage.10, 25 and 50kg of sugar are
automatically weighed and fed into the packaging materials where they are sent to the storage house, ready
for dispatch.

2.9 Laboratory analysis

This is done in order to monitor the quality of raw materials and products being produced. Some of the
analysis is done on a weekly basis while others are done per hour. The table below shows some of the
analysis carried out At

BSF

Table 2.1 showing parameters that are analysed in the sugar laboratory.

SAMPLE PARAMETER INTERVAL

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 FEJ Brix, pol,pty, PH Hourly
LEJ Brix, pol, PH Hourly
BAGASSE Pol and moisture 4 hours.
MOLASSES Brix, pol and pty Every strike.
FILTER CAKE Pol and moisture 4 hours
RAW SYRUP Brix, pol, pty and PH 2 hours

2.10 DM plant
This is used for water treatment. The DM plant is used for removal of hardness from the water that is used in
the factory to prevent damage to process equipment.

Raw water is passed through a pressured sand filter tank with fine sand, coarse sand and pebble layers to
remove insoluble substances. The water is pumped through an SAC tank which contains cationic resins that
removes cations from the water. These resins are regenerated by Hydrochloric acid. The water is then
pumped through an SBA that has anionic resins for removal of anions. These resins were regenerated by
sodium hydroxide which also rectified the pH of the water.

2.11 Steam production and power generation(cogeneration)

The boiler is a unit where water is converted into super-heated steam at a high pressure that is able to run the
turbines which in turn run the generator that produces electric power. The boiler is also the source of steam
for the process unit and chemical operations. The BDF boiler is a bidrum and it is a water tube boiler. The
boiler uses bargass as the fuel.

2.11.1 Steam generation

Feed water is pumped to the deaerator tank which basically acts as an air scavenging tank. The water flows to
the high pressure heaters which heats up the water to about 1500C before it is fed into the economizer.

In the economizer, flue gas from the furnace passes through the coils and heats up the steam water to about
2500C before it is forced to the steam drum.

The steam drum acts as a reservoir of steam. It is connected to the primary super heater pipes in the furnace.
Impurities from the steam drum sink to the mud drum, which is located at a lower level. The mud drum is a
collection center for mud and other solids from the steam drum. These solids are removed from the mud
drum through the intermediate blow-down. The steam drum has the continuous blow down connection for
discharging some impurities in the steam before it flows to the mud drum by gravity.

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It is from the steam drum that the steam is forced to the super heaters at the top of the furnace. Flue gas from
the furnace to do their work. Steam leaves the steam drum at about 270oC as wet steam to the primary super
heaters which heat up the wet steam and it leaves at a temperature of 445-450oC to the secondary super
heaters. In the secondary super heaters, the steam is heated up to a temperature of 510-520oC. At this
temperature, the dry superheated steam is super saturated and is used to run the turbines which in turn run the
generators to produce electric power.

2.11.2 Power generation

The live steam from the boilers is used to drive the turbine blades which in turn drives the generator with the
aid of a shaft connected to a generator. The turbine turns mechanical energy of the live steam into electrical
energy by running the generators. The rotary action of the shaft in the generator induces electric current in
the generator hence power generation. The steam that has passed the turbines gains less pressure and is sent
to the process house as exhaust steam for boiling purposes.

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3. FERMENTATION
This is a metabolic process that converts sugars such as glucose, fructose and sucrose into cellular energy,
producing ethanol and carbon dioxide.

3.1 Chemicals used in fermentation

The table below shows the chemicals used in fermentation and their uses

Table 3.2 shows chemicals used in fermentation

Chemical Uses
Zinc sulphate Provides zinc required in small quantities for yeast
cell growth.
Magnesium sulphate Provides magnesium which plays a role of
preventing of cell death when ethanol builds within
the cell.
Urea This is a source of assimilable nitrogen. Nitrogen is
used for for formation of essential amino acids
necessary for normal growth
Sulphuric acid This is used to correct PH yeast growth. It also kills
bacteria present in the molasses that would compete
with yeast and produce non alcoholic by products.

3.2 Yeast for preparation

The propagation of yeast started from the laboratory then culture vessels and finally prefermenters.

3.2.1 Procedure for preparation of cultured yeast

Clear molasses were tapped off the sludge and then diluted by adding water Upto a brix of 10-11, 2.5g of
magnesium sulphate, 2.5g of zinc sulphate and 4g of urea were added. The mixture was then transferred into
portions like 100ml,500ml and 400ml. The mixture was then sterilised using an autoclave about 1200c. The
autoclave was then switched off and the safety valve was opened to allow steam to exit. The sterilised media
was then allowed to allow and then transferred to a safety cabinet were innoculation takes innoculation was
then done. Innoculation is the transfer of yeast from a smaller to larger media to allow growth and increase in
number.

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3.2.2 Culture vessels
These are vessels that are used in the production and increase in the yeast biomass The required nutrients
were prepared according to the yeast biomass in each vessel.

For culture vessel one, 15 kgs of molasses was diluted with water and it's specific gravity was adjusted to
1.040-1.045 and the brix adjusted to 10-12.

250ml of sulphuric 250ml of sulphuric acid, 500ml of phosphoric acid , 3kgs of urea, 100g of magnesium
sulphate and 300g of zinc sulphate were added. The contents were pasteurised by feeding in steam to a
temperature of Upto 950c followed by cooling. For culture vessels 2 and 3, the same procedures above were
followed however with increasing amounts of mollases and nutrients.

In culture vessel 2

200ml of phosphoric acid, 500ml of sulphuric acid and 300g of magnesium sulphate, 300g of zinc sulphate
and 2kgs of urea were added. 0.07g of mollases were also added and the contents of cv1 were transferred into
cv2. 20ml of antiform were also added.

In culture vessel 3

2l of phosphoric acid, 500ml sulphuric acid, 1kg of magnesium sulphate, 1kg of zinc sulphate and 5kgs of
urea were added and 30ml of antiform.

3.2.3 Pre-fermenters.
This is where the yeast population reaches a maximum and sugars are converted rapidly. Alcohol flavours
and aromas are also formed.

17.5kg of phosphoric acid, 10kg of sulphuric acid, 800g of magnesium sulphate, 300g of zinc sulphate 5kg of
urea and antifoam were added.3-4 tonnes of mollases were also added and the it was left to react for 6 hours.
The prefermenter one was cut to a half and the other half was transferred to prefermenter two. Two tonnes of
mollases were added and then left for 6 hours.

3.2.4 Procedure for setting the main fermenter

The fermenter was cleaned with water, steamed at a temperature about 95oc. Water and molasses were added
but not upto the top of the fermenter,14kg of urea, 20 litres of of sulfuric acid and antifoam were added.

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The fermenter was put under recycle so as to obtaining perfect mixing such that parameters as temperature
and PH would become uniform throughout the fermenter. This agitation also brought uniform distribution of
yeast cells and nutrients.

The process of fermentation was left to take place for about 38 hours while monitoring parameters like PH,
temperature, brix. The alcohol content was determined by simple distillation in the laboratory. After 38
hours, the fermented wash was transferred to the beer well.

3.3 Quality control

To ensure quality of the alcohol produced, the following analysis is carried out on the raw materials as well
as the alcohol produced as well as monitoring the fermenters.

 Molasses were analyzed for the volume V, sg, SG as well as the brix.
 Fermenters were analyzed for temperature, PH and brix. Any fermenter before being transferred to
the beer well was analyzed for the alcohol content and residue sugars.
 Alcohol is analyzed for its strength in terms of alcohol percentage
3.3.1 Determination of parameters of fermenters
Fermenters were monitored for PH, temperature and brix at an interval of two hours.

PH was got using a PH meter and the temperature is got from the temperature monitor.

The brix is obtained using a hydrometer.

3.3.2 Analyses of molasses

Molasses were analyzed as shown below

100g of molasses was weighed and then dissolved in 100ml of water and Volume, V was determined. The sg
hydrometer was then used to determine sg. The solution was further diluted in 800ml of water and mixed
thoroughly well and a brix hydrometer was then used to determine the brix of molasses. The SG can be
calculated using the formula;

Equation 3.1 shows a formula for calculating SG of molasses

( V × sg )−100
SG=
V −100

3.3.3 Determination of alcohol content in the fermented wash

200ml of fermented wash was mixed with 200ml of water and then distilled to obtain 200ml of the distillate.
The distillate was transferred into a cylinder and its temperature was obtained and then converted to 0F. The

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sikes hydrometer was then used to determine the sikes reading which enabled me to get the under proof
percent corresponding to the temperature The alcohol content was then obtained.

3.4 Distillation
This is separation of more volatile components from less volatile components based on boiling point
difference. It is based on the fact that the vapor of a boiling mixture will be richer in the components that
have lower boiling points. Therefore, when this vapor is cooled and condensed, the condensate will contain
more volatile components. At the same time, the original mixture will contain more volatile components. At
Bwendero Dairy farm, rectified spirit.

The distillation plant at Bwendero dairy farm, the distillation plant consists of three columns each with
analyser and rectifier column.

In the analyzer column, initial boiling of the beer takes place and 45% concentration of alcohol was obtained,
here the beer enters from the top and steam enters from the bottom. 45% concentrated alcohol then enters the
rectifier column for further boiling to obtain alcohol of about 96%.

Heatex Main Vent

Beerw Beerhe Analyz Rectifi
change conden conden
elll ater er er
r ser ser Figure 3.1
showing
process of
distillation

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Beer flowed by gravity from the beer well to the beer heater where initial heating took place to reduce on the
amount of steam required and then flows to the heat exchanger before it entered the analyzer column where
boiling took place to obtain 45% alcohol. 45% alcohol proceeded to the rectifier coloumn where more
boiling took place and 96% alcohol was obtained. In the vent condenser, technical alcohol was tapped off.

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4. KNOWLEDGE AND SKILLS OBTAINED, CHALLENGES FACED AND
HOW THEY SOLVED
4.1 INTRODUCTION
This chapter includes skills and knowledge obtained, challenges faced and how they were solved.

4.2 Knowledge and skills acquired

The skills I acquired include the following;

 Interpersonal skills.
 Operation of laboratory equipment skills such as polarimeter, hydrometer, refractometer, PH meter,
autoclave.
 Report writing skills.
 Good communication skills.
 Sampling skills.
 Mill operation skill
 Skills in analyzing raw materials and final products such as brix of molasses, alcohol content.
 Monitoring of fermentation process.
 Use of sikes table to get alcohol content.
 Operation of the weigh bridge and feeder table.
 Mud filter operation.
 Control of the distillation process using a computer program.
 Team work skills.

4.3 Challenges faced and how they were solved

 Lack of theoretical back ground of some of the operations carried out by factory such as fermentation.
However, I got some notes from the supervisor and I was able to get some knowledge.
 Language barrier.
 Some of equipment was not calibrated which would affect the results.

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  I further faced challenges in getting a placement for industrial training and fortunately, I was accepted
by the Human resource manager of BDF.
 The institute delayed to send us internship facilitation money but I was able to use my personal funds.

5. Conclusion and recommendation

5.1 Conclusion
I was able to obtain hands on skills and knowledge for example distillation which will prepare me as a
downstream petroleum operations technician for the oil and gas industry. The training further improved my
communication and interpersonal skills. I therefore do not regret of time I have spent at Bwendero dairy
farm.

5.2 Recommendation.
I recommend the following to be done for betterment of industrial training in the future.

 The institute should consider extending the training period to at least two months so that students can
achieve much.
 The industrial training facilitation fee should be given to students a week before to avoid
inconveniences.

The following should be done by Bwendero dairy farm in order to improve its output

 Close supervision and monitoring to reduce on the stoppages.

 The company should prioritize safety and welfare of the workers.
 Regular calibration of laboratory equipment.

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6. References

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7. Appendicies

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