Balezaf Alcohol

BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF CHEMICAL & FOOD ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
FINAL INTERNSHIP REPORT AND PROJECT
HOSTING COMPANY- BALEZAF ALCOHOL AND LIQUOR
FACTORY(BALF) P.L.C
INTERNSHIP REPORT AND PROJECT BY

NAME ID
WASIHUN ALEMNEW……………….0702433
DURATION OF INTERNSHIP ( FEB. 7—JUNE 11)
ADVISOR MR. SOLOMON .H
SUBMISSION DATE 22 /10/2010 E.C

Internship Report on BALF p.l.c 2010 EC
Declaration
I have been at Balezaf alcohol and liquor factory for the last 4 months to gain an internship
experience. I have done a project during the internship program and is included as part of this
report. I was fully engaged to write this report and also to perform my project. Under the
guidance of Academic adviser ―Mr.Solomon‖ and Company Supervisors ―Mr. Habtamu and Mr.
Tedla ‖ who supported me during the internship period from February, 2010 up to June
2010E.C.
During this internship period, I have gained many interesting and useful knowledge including
chemical applications, processes and control techniques used in the factory.
I want everyone to know that this report is uniquely prepared by my own effort and no one else
is neither involved in its preparation nor it is copied.
Name of Academic Adviser Signature Date

Mr. Solomon.H .………………. ....………..
Name of Company Supervisors Signature Date
Mr. Habtamu ………………. ………………
Mr.Tedla ………………… ………………
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page I

Acknowledgment
Before all, I would like to thank the almighty God for helping me to finish the internship period
as well as the project. And also, I would like to thank Bahir Dar Institute of Technology & my
faculty for providing internships experience at Balezaf alcohol and liquor factory for the last four
months. In particular, I would like to express my respect and gratefulness to my academic
adviser Mr. Solomon for his supervision, special guidance, cooperation & encouragement
throughout this work. And I would like to thank Mr. Habtamu and mr.Tedla , supervisors of the
company & also would like to thank ms. Alemtsehay and ms. Mekides the secretaries of the
company I would like to thank m.r Melkamu the chemist of the company. And I would like to
express my respect to each section operators and all compound societies for supporting by
different idea and materials.
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page II

Executive Summery
This document basically consists of two parts; the company‘s internship report and Project work.
The internship report contains the background, all over organization, final products of the
company, main costumers, objectives and management structure and contains the flow diagram,
conclusion, recommendation and raw materials used for each sections of the company and
challenges that I have faced during the internship period. And I tried to do material balance and
efficiency of selected unit operations of the company. The project was on the reduction of
TDS,TSS and COD by using an activated carbon produced from waste paper from the washer
machine in bottling section. And this project contains introduction, adsorbent development,
methodology, result and discussion and finally conclusion and recommendation of the project
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page III

Tables of Contents
Declaration ..................................................................................................................................................... I
Acknowledgment ......................................................................................................................................... II
Executive Summery .................................................................................................................................... III
List of figure ............................................................................................................................................. VII
List of Tables ........................................................................................................................................... VIII
List of Acronyms ........................................................................................................................................ IX
CHAPTER ONE ........................................................................................................................................... 1
1.1 Introduction ....................................................................................................................................... 1
1.2 Historical background of the company ............................................................................................... 2
1.3 Objective ................................................................................................................................................. 3
1.4 Mission of the company: ..................................................................................................................... 3
1.5 Vision : ................................................................................................................................................ 3
1.6 Values of the company: ...................................................................................................................... 4
1.7 Main product of the company ............................................................................................................. 4
1.8 Main customers and end users of the company: ................................................................................. 5
1.9 Over all organization and work flow the company ............................................................................. 5
1.10 Tasks of the division ........................................................................................................................ 8
CHAPTER TWO ........................................................................................................................................ 11
OVERALL PROCESS DESCRIPTION ..................................................................................................... 11
2.1 Raw Materials for the production of alcohols ................................................................................... 11
2.2 Units or sections in the production of alcohol .................................................................................. 12
2.2.1 Raw water treatment section ...................................................................................................... 12
2.2.2 Raw material for raw water treatment ........................................................................................ 14
2.2. 3 Equipment used in raw water treatment section ....................................................................... 15
2.2.4 Process description of raw water treatment section ................................................................... 16
2.2.5 Unit operation in water treatment section .................................................................................. 17
2.3 Boiler section .................................................................................................................................... 21
2.3.1 Introduction to boiler ................................................................................................................. 21
2.3.2 Raw materials used in boiler section.......................................................................................... 22
2.3.3 Equipment used in boiler section ............................................................................................... 23
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page IV
2.3.4 Process description of boiler section .......................................................................................... 24

2.3.6 Boiler Efficiency Calculation..................................................................................................... 25
2.4 Fermentation section ......................................................................................................................... 28
2.4.1 Introduction to fermentation ...................................................................................................... 28
2.4.2 Raw materials used in fermentation section............................................................................... 28
2.4.3 Equipment used fermentation section ........................................................................................ 29
2.4.4 Process description of fermentation section ............................................................................... 30
2.4.5 Flow chart of fermentation section ............................................................................................ 31
2.5 Distillery section ............................................................................................................................... 31
2.5.1 Introduction to distillery............................................................................................................. 31
2.5.2 Raw material used in distillery section ...................................................................................... 32
2.5.4 Process description of distillery section ..................................................................................... 33
2.5.5 Flow chart of distillery section................................................................................................... 37
2.5.6 Material balance for selected distillery column ......................................................................... 38
2.6 Bottling section ................................................................................................................................. 44
2.6.1 Introduction to bottling .............................................................................................................. 44
2.6.2 Raw material used in bottling section ....................................................................................... 45
2.6.3 Equipment used in bottling section ............................................................................................ 45
2.6.4 Process description of bottling section....................................................................................... 46
2.6.5 Flow chart of bottling................................................................................................................. 50
CHAPTER THREE .................................................................................................................................... 51
3.1 Overall benefits of the internship ...................................................................................................... 51
3.1.2 Improving Interpersonal Communication Skill ......................................................................... 51
3.1.3 Improving team playing skill ..................................................................................................... 52
3.1.4 Improving leadership skill ......................................................................................................... 52
3.1.5 Work ethics ................................................................................................................................ 53
3.1.6 Entrepreneurship skills ............................................................................................................... 53
CHAPTER FOUR....................................................................................................................................... 54
Over all Conclusion and Recommendations ............................................................................................... 54
4.1 Conclusion on each section ............................................................................................................... 54
4.2 Recommendation on each section ..................................................................................................... 56
CHAPTER FIVE PROJECT................................................................................................................... 59
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page V

Title ............................................................................................................................................................. 59
Reduction of COD, TDS, TSS, pH of the waste mixture by using an activated carbon produced from
waste paper that discharge from bottling section. ....................................................................................... 59
Abstract ................................................................................................................................................... 59
5.1 Introduction ....................................................................................................................................... 59
5.2 Problem of statement ........................................................................................................................ 60
5.3 0bjective ............................................................................................................................................ 61
5.3.1 General objective: ...................................................................................................................... 61
5.3.2 Specific objective ....................................................................................................................... 61
5.4 Literature review ............................................................................................................................... 62
5.5 material and method ......................................................................................................................... 63
5.5.1 Material used:............................................................................................................................. 63
5.5.2 Chemical used: ........................................................................................................................... 64
5.6 Method .............................................................................................................................................. 64
5.6.1 Adsorbent development and methodology................................................................................. 64
5.6.2 Reductions of COD,TDS,TSS and pH by using activated carbon as an adsorbent ........................... 64
5.7Characteristics of the waste mixture sample ...................................................................................... 67
5.8 Result and discussion ........................................................................................................................ 68
5.8.1 Result ......................................................................................................................................... 68
5.8.2 Discussion .................................................................................................................................. 70
5.9 Conclusions and Recommendation ................................................................................................... 71
5.9.1 Conclusion ................................................................................................................................. 71
5.9.2 Recommendation: ...................................................................................................................... 71
Reference .................................................................................................................................................... 73
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page VI

List of figure
Figure 1.1 organizational structure of the company ...................................................................... 7

Figure 2.1 water treatment section……………………………………………………………….13
Figure 2.2 BALF filter bag ........................................................................................................... 17
Figure 2.3softeners (ion exchange machine) ................................................................................ 18
Figure 2.4 brine tank .................................................................................................................... 19
Figure 2.5 RO machine ................................................................................................................. 20
Figure 2.6 flow diagram of water treatment section ..................................................................... 20
Figure 2.7 boiler section ............................................................................................................... 21
Figure 2.8 flow diagram of boiler section ..................................................................................... 25
Figure 2.9 flow diagram of fermentation ...................................................................................... 31
Figure 2.10 distillery section........................................................................................................ 32
Figure 2.11 decanters ................................................................................................................... 34
Figure 2.12 flow diagram of distillery .......................................................................................... 37
Figure 2.13 blending and bottling section................................................................................... 45
Figure 2.14 flow diagram of bottling section................................................................................ 50
Figure 5.1oven drying of the sample ............................................................................................ 66
Figure 5.2sun drying of waste paper ............................................................................................. 66
Figure 5.3 measuring mass of activated carbon………………………………………………….66
Figure 5.4 mixtures of activated carbon and waste sample .......................................................... 67
Figure 5.5 Effects of different amount of adsorbent on COD,YDS and TSS .............................. 68
Figure 5.6 Effects of different amount of adsorbent on pH…………………………………..…69
Figure 5.7 Effects of time on COD,TSS and TDS ....................................................................... 70

Figure 5.8 effects of time on pH…………………………………………………………………70
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page VII

List of Tables
Table 1.1 main product of the company…………………………………………4
Table 5.1 characterization of waste mixture in BALF ………………………….67
Table 5.2 result on different amount of activated carbon dosage………………..68
Table 5.3 result of contacting time on the waste water…………………………..69
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page VIII

List of Acronyms
AC…………………………………………………………….…Activated carbon
BALF……………………………………………………………Balezaf alcohol and liquor factory
BOD ……………………………………………………………. Biological oxygen demand
COD …………………………………………………………….chemical oxygen demand
ED………………………………………………………………….Extractive distillery
FT…………………………………………………………………Fermenter tank
gm………………………………………………………………..gram
HFO ……………………………………………………………….Heavy fuel oil
PHE………………………………………………………………plate heat exchanger
RC…………………………………………………………………Rectification column
RO…………………………………………………………………Reverse osmosis
TDS………………………………………………………………total dissolved solid
TSS………………………………………………………………total suspended solid
UV………………………………………………………………Ultraviolet
Local language international language
Heads 1 …………………………………………………………..Acetaldehyde
Heads 3…………………………………………………………… Isopropanol
Fusil oil……………………………………………………………..amyl alcohol
Light oil ……………………………………………………………ethyl acetate
Heads 2 main………………………………………………………methanol (condensed)
Heads 2 vent …………………………………………………….…methanol (uncondensed)
Pure alcohol…………………………………………………………ethanol
Copper column……………………………………………………..rectifying section rectification column
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page IX

CHAPTER ONE
1.1 Introduction
Alcohol are organic compounds characterized by one or more hydroxyl (‐OH)
Groups attached to a carbon atom of an alkyl group (hydrocarbon chain).
some facts about alcohol:
 It's a colorless liquid.

 It's sometimes used as a fuel.
 It's sometimes used as an industrial solvent.
 It's sometimes used as a disinfectant.
 It can be poisonous.
 It catches on fire easily.
 Many people drink it.
Some types of alcohol aren't used for drinking and are very poisonous if ingested. An example is
isopropyl alcohol, or rubbing alcohol, that's used as a medical disinfectant. I'd also suggest you
avoid drinking any types of alcohol used as industrial solvents or fuel. The kind of alcohol
people drink is called ethyl alcohol or ethanol. Many popular beverages contain ethanol. Two
categories of alcoholic beverages based on how they are made are fermented beverages and
distilled beverages. There are also hybrid alcoholic beverages. No matter how an alcoholic
beverage is produced, the ethanol in each kind of drink is the same drug. However, different
types of beverages have different concentrations of ethanol. It's important to know how much a
beverage contains before you drink it, so that you know the dosage of the ethanol that you're
ingesting. Fermented Beverages fermented beverages are produced through the process of
fermentation. Fermentation in the case of alcoholic beverages refers to a metabolic process by
which yeast converts sugar to ethanol. Yeast is a type of fungus used in the fermentation of
alcohol. In order for fermentation to take place, you begin with some type of carbohydrate that is
needed to feed the yeast. The type of carbohydrate used determines what the final product will
BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page 1

be. Let's look at some examples. Beer is produced by fermenting grain. Wine or hard cider is
produced by fermenting fruit. Mead is produced by fermenting honey. There is a limit to the
alcoholic content of fermented beverages because yeast cannot survive in alcohol. Once the
concentration of ethanol produced by the fermentation process reaches about 15%, the yeast will
die and fermentation process will end. Distilled is then usually aged for a period of time before
drinking. This adds to the flavor of the beverage. A typical concentration of ethanol in a distilled
alcoholic beverage is around 40%, but this can vary greatly. Let's look at some examples of
distilled beverages. Brandy is made by distilling wine. Whiskey is made by distilling a specific
type of beer. Rum is made by distilling the molasses left In order to produce beverages above the
concentration of ethanol achieved through fermentation, a distillation process is used. Distillation
of alcoholic beverages is the process by which water is removed from a mixture of ethanol and
water. During distillation, the difference in the boiling points of water and alcohol is used to
separate the two liquids from each other. Ethanol has a lower boiling point, so when heated, it
will evaporate more easily. The evaporated steam is then cooled back into a liquid with a higher
over when sugar is extracted from sugarcane. Vodka is made by distilling fermented potato juice
or grains like wheat or rye. Tequila is made by distilling fermented agave, a plant similar to
asparagus.
1.2 Historical background of the company
Established in 1948 as a liquor factory, Balezafe alcohol and liquor factory (BALF) has grown
radically to be the biggest portable alcohol and liquor factory in Ethiopia.it is engaged in
production of portable alcohol and different type of liquor for local consumption so far and has
finalized its preparation to go to global export market this year. Pure (portable) alcohol is the
primary row material for the production liquors. The factory produces its pure alcohol in its own
factory using molasses as a raw material. The molasses is obtained from the state owned sugar
factories. The factory will have a key role in the country‘s economy by transforming the row
material, molasses to a higher value product extra natural alcohol. This is used for producing
different variety of liquors in the same factory and also used as ingredients for manufacturing of
cosmetics, pharmaceuticals and other relevant produces. The factory has also been producing
portable alcohol using molasses as its row material. However over the course of the last few

years, potable alcohol production has expanded at an incredible pace throughout the country. The
company focuses on finding alternative feedstock other than molasses to produce extra neutral
alcohol. The company has already finalized preparation start construction to produce extra
neutral alcohol from corn. The development of distillery in Ethiopia dates back to 1942
established by national alcohol and liquor a state owned factory. Balezaf alcohol and liquor
factory is equipped with all the modern state or art technology where the present design of
distillation column is reached. BALF has purification column sometimes called extractive
distillation column, that alcohol comes out of the base not from the top part the column that
behaves like the fuel oil column. An earlier version now called a hydro selection column,
patented (1902) by Emile Guillermo had purified alcohol leaving the base at 18-20%.ioin
chambers in his extractive distillation patented (1948) specifies that the operation of extraction
column at 6%v/. Actual operation of extraction column in modern distilleries is usually between
8-10% depending up on impurities present.
1.3 Objective : the main objectives of the company is producing, selling and distributing the
pure alcohol, denatured alcohol and different types of liquors
1.4 Mission of the company:

The company is:-
• Committed to serve the need of customers, employees, manager and share holders
• Works to create and sustain a combination of individual excellence (manifested in purposeful,

visionary, and exemplary leadership of their management) shared company values (expressed as
the creative harmonious, and motivated team sprite of their employees) that will ensure the
vitality, strength and propagation of the business
• Upholding the maximum that all things are changed and they are changing with them since
change is universal phenomenon that positively affects their customers, employees, managers
and shareholders, so as to always prepare and cater for change.
1.5 Vision :
 To improve the quality of its products

 To expand its market share
 To maintain its leadership I the liquor industry of the country
 To make at most effort to enter foreign markets as widely
1.6 Values of the company:

Teamwork:
 developing and utilizing a strong spirit among employees
 Accountability is clear and personal.
 work and win in terms across the business.
1.7 Main product of the company

The existing bottling plant has a capacity to produce 6000 bottles per hour it produces 14
different types‟ liquors those are listed below. including denatured alcohol.
Table 1.1 main product of the company
No Types of liquors Concentration, %

v/v
1 Double ouzo 42
2 Ouzo 41
3 Dry Gin 41
4 Mini Gin 41
5 Zebib 41
6 Pernoud 41
7 Cognac 37
8 Fernit 37
9 Aperitif 32
10 Lemon liquor 30
11 Pineapple liquor 30
12 Superment 25

13 Mini vodka 43
14 Denature 96.8
1.8 Main customers and end users of the company:
Main customers of pure alcohol

 Silva liquor factory
 Bereket liquor factory
 Asnake liquor factory
 Senay liquor factor
Main customers of liquors
 Bars, restaurants and hotels
 Rural peoples and community of Ethiopia
Main customers of denatured alcohol

 Beauty salon
 Hospital
 Pharmacy
1.9 Over all organization and work flow the company
The company is organized with a combined workforce of more than 250 employees. The owner
who is an industrial engineer by profession is the managing director, and his deputy who is a co-
owner is a graduate of business management. Of the total man power, the company has four
chemical engineers, one mechanical engineer, seven chemists, finance manager, accountants,
marketing personnel, electrical engineer, senior mechanic, welders, electricians and a number of
workers running the factory. In addition to its highly skilled and experienced man power, the
factory is well equipped with the latest technology equipment machineries and other facilities
that are necessary to successfully expand and maintain the factory by the in house work force.

General
manager
Production and marketing Finance department HR

technique
personnel
Sales supervisor secretary
Quality Shift engineer
control head
Sales Men Environmental Secretary/
General Service
expert receptionist
chemists
security Compound cleaner

Bottling
supervisor Senior mechanics&
senior electrician
Blending supervisors
chemists
operators
Boiler operators Water treatment operators
Distillation
Fermentation operators
operators
Figure 1.1 organizational structure of the company

1.10 Tasks of the division

General Manager:
 Overall management related tasks
 appropriate internal communication process
 ensure if customer interest are handled appropriately
 Purchasing and supplies, finance and administration related task
 control over major supplier selection and purchasing
 process and production planning
 control and monitor process
 technical evaluation of raw materials for production line before purchasing
Production and technique :

 Maintenance of production equipment‘s and machineries
 Control over engineering activities
 Maintain and ensure calibration of inspection, measuring, and testing equipment‘s.

 Manage and control over all utilities supporting the product realization process
Administration
 General administration
 Provide induction training to new recruits.
Finance:
 Ensures customers are credit worthy

 Ensures all sales are invoiced properly
 Ensures all transactions are accurately recorded in the accounting records
 Ensures all purchase are properly authorized, paid and accounted.
 Ensures audit and other statutory and regulatory compliance issues are handled correctly,
efficiently and promptly
 Conduct timely financial analysis leading to informed and analyzed decisions

Quality control:
 In process inspection of production.
 Final inspection of final products.
 Make sure non-conforming products handling process is functioning well.
 Make goods inward inspection before receiving.
 Ensure final product, raw material, spare parts and auxiliary materials are stored.
 Safely and securely under appropriate condition until required
Stores:
 Make sure non-conforming products handling process is functioning well.
 Make goods inward inspection before receiving.
 Ensure final product, raw material, spare parts and auxiliary materials are stored.
 Safely and securely under appropriate condition until required.
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.
Human Resource
 promotions, annual leaves control discipline of community in the company
 Design and develop human and marketing policies and procedure to ensure performance
standards, consistency and transparency in the course of human resource management.

 Carry out proper manpower planning to ensure supply of man power in terms of quality and
quantity.
 Carry out recruitment and selection of employers based on the man power plan.
 Carry out induction and orientation program for newly recruited staff.
 Design and Developing trained and developed policies and procedure.

CHAPTER TWO
OVERALL PROCESS DESCRIPTION
2.1 Raw Materials for the production of alcohols
 Molasses
Sugar industries produce molasses from sugar cane processing. Molasses have 50- 55 %
concentration of sugar in the form of sucrose with chemical formula C12H22O11.This source of
compound is used for preparing ethyl alcohol. During the sugar making process, juice extracted
from sugar cane or sugar beet is boiled down until the sugars crystallized and precipitate out. The
syrup left over after crystallization is referred to as molasses. Typically sugar cane juice under
goes three cycles of boiling and crystallization to extract as much sugar as possible. With each
successive cycle the left over molasses contains less sugar.
 Sulphuric acid(H2SO4): it help to optimize the media or to lower the PH range because
acidic media with pH of 4.0-4.5 is optimum condition for yeast, and used as antifoam by
mixing with edible oil and used the growth and activities of other microorganism such as
bacteria, not to compute yeasts by these microorganism.
 Di ammonia phosphate (DAP): used as sources of nutrient for the growth of yeast. Its
amount is in the order of 1 kg per 500liters of molasses solution. If the amount of DAP is
less, the yeast may not activated well and if the amount of DAP is exceeded from the average
consumption, other cells will attack the yeast and also results in sugar wastage and sugar
spoilage.
 Water: used for cleaning of overall processing units and play a great role for dilution
purpose (molasses, pure alcohol and liquor preparation). It boils and widely used for steam
production. Used for dilution purpose of molasses for specific brix. . The raw molasses
degree brix is around 78 – 80 so by addition of water reduce the brix of molasses for specific
purpose to produce high brix (24-28) and low brix (14.5-15).

 Anti-foam: used for preventing the overflowing of the fermenting solution

 Purified air: it is used to supply the yeast with necessary oxygen for cells growth. The
amount of air feed to the mother tank shall be proportional to the amount yeast feed into it.
If the amount of air feed is more than enough, new cells will start emerge and results in
alcohol wastage. If the amount of air is small relative to the yeasts, the yeast propagation
will weakened and infected by other bacteria.
 Sugar: will be added and mixing during the liquor preparation in the syrup form to
facilitate the Agitation process.
 Steam: plays a great role for creating the boiling difference while the distillation process
taken place
2.2 Units or sections in the production of alcohol
Balezaf alcohol and liquor factory have five sections or units for the production of alcohol
those are :
 Raw water treatment section
 Boiler section
 Fermentation section
 Distillery section
 Bottling section
2.2.1 Raw water treatment section

Introduction
Water treatment is collectively the industrial scale process that makes water more acceptable for
end-use which may be drinking, industrial or medicine. Water treatment removes existing
contaminant or so reduces their concentration that the water becomes fit for its desired end use
which may be safely returning used water to the environment. Water treatment may be either
drinking or industrial water treatment. This water treatment process involves different unit
operations such as filtration, softening and reverses osmosis.
Treatment for industrial uses of water production involves the removal of contaminants from raw
water to produce water that is pure enough for industrial purpose. Substances that are removed
during the process of industrial water treatment include suspended solids, bacteria, algae, viruses,
fungi, and minerals such as iron and manganese. Industrial water treatment mainly involves the
removal of cations and anions which makes water hard, to produce soft water .It is used to
optimize most water based industrial process such as heating ,cooling ,processing and cleaning
so that the operating costs and risks are reduced. The hardness of water is the presence of
dissolved ions mainly of calcium and magnesium ions which are acquired through contact with
rocks and sediments within the environment. There are two types of hardness. These are
permanent hardness and temporary hardness .Temporary hardness refers to hardness whose
effect can be removed by boiling the water in an open container. Permanent hardness refers to
hardness of water that contains other ions such as chlorides or sulfates which cannot be removed
by boiling .The only practical treatment is to remove these ions by water softening, which is a
process of converting hard water into soft water by removing different ions using ion exchange
methods.
Figure 2 .1 water treatment section

The basic reason or purpose for treatment of industrial water

 To reduce content of undesirable chemicals such as calcium and magnesium
 To reduce reproduction of biological organisms like bacteria and algae
 To reduce the PH by reducing the alkaline or basic property
 To prevent scale formation on the process equipment
2.2.2 Raw material for raw water treatment
 Hard water or ground water
 Brine solution
 Anti scalant
 Color indicator
Hard water: Hard water is water that has high minerals content. Hard water is formed when
water percolates through deposits of lime stone and chalk which are largely made up of calcium
and magnesium carbonates.
Brine solution: is a solution of salt (sodium chloride) in water. It is used in regeneration process
the sodium ions will replace the magnesium and calcium ions and used clean the resin bead
during regeneration cycle, allowing the system to containable removes of hardness from feed
water or hard water.
Anti scalant: it is used to avoid mineral scaling and for membranes cleanings.
Color indicator: used to indicates water is hard, soft or permeate to add in the water

2.2. 3 Equipment used in raw water treatment section

Valves: Valves are an equipment that control, adjust or manipulating the flow of water to and
from a process. There are different types of valves used in water treatment process such as get
valve, ball valve, check valve, and butterfly valve.
Types of valve used in the company
 Get valve: is the valve that regulates the flow rate in its adjustable manner. It manipulates
either increasing or decreasing the flow rate of water. But it adjusts manually.
 Check valve: is a valve that adjusts to the pump in order to protecting the turning effect of
water these causes due to different problems like electrical system and other process
problems. check valves are two port valves, meaning they have two openings in the body,
one for fluid to enter, and the other for fluid to leave. Check valves allows the fluid to pass
in one direction only. Check valves work automatically and most are not controlled by a
person or any external control.
 Ball valve: Ball valve is a valve that used for on/off control without pressure drop, and
ideal for quick shut off.
Pump: A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action. Basically pumps are works or operate by the action of typical rotary and
reciprocating mechanism, and consume energy to perform mechanical work by moving the fluid.
Tubes (pipe)
Tube is a device that transfers fluids (liquids and gases) in the form raw materials and wastes.
Basically water treatment processes uses two types of tubes. These are PVC and stillness steel
joined to each processed equipment. Some tubes are sensitive to temperature but others are
insensitive.
Tanks: Tanks are equipment that made from a heavy metal used for holdup or store water.

Brine solution tank: It is the tank that made from plastics and highly resists corrosion effect.
This tank stores sodium chloride solution for the purpose of washing resin. Around 3500kg of
salt is used per a week to soften the raw water.
UV light (disinfectant): It is equipment it helps to destroy biological microorganisms that

delivers to the bottling, cooling tower, heat exchanger, and boiler.
ROM (reverse osmosis machine): is a membrane technical filtration method that remove many
types of large molecule and ion from solution by applying pressure to the solution when it is one
sides of a selective membrane.
Water softener or ion exchanger: The methods of softening noncarbonated hardness include
the additions of sodium carbonate and lime and filtration through natural or artificial zeolites
which absorb the hardness producing metallic ions and release sodium ions to the water. It is a
chemical process that takes place in softener tank using ion exchange mechanism.
Filter bag: is advice used to remove suspended solid and particulate matter from water
2.2.4 Process description of raw water treatment section

Hard water pumped from the ground and stored in hard water tank then by pumped and goes to
filter. The filter is used to separate unwanted material like soil ,sand, animal hair and other. After
that water goes to water softening tank the mainly purpose of this equipment is the hard water
change to soft water by ion exchanging initially softening tank has zeolite. This zeolite ion attach
to the zeolites and sodium ions bond to water molecules and the water becoming to softening .
the softening tank regenerate by salt solution .the salt solution have sodium chloride. Then this
solution enters in to the system the magnesium and calcium ions bond to chloride. Then this
solution enter in to the system the magnesium and calcium ions bond to chloride ions and out the
system by salt form but sodium attaché to zeolites and regenerate the system, the soft water
stored in soft water tank after that soft water treated by UV this treatment is used to kill
microorganism and reduced the conductivity. After UV treatment water goes to for needed
purpose like boiler, distillery, cooling tower and bottling. But for liquor preparation water most

free from any ions and a mineral so that the water most is pass in revers osmosis after that RO
water transfer RO tank and goes to liquor preparation section.
2.2.5 Unit operation in water treatment section
Filtration: is the process of separating suspended and very small colloidal particle from raw
water. In this process only the suspended particle is removed. It operates with maximum gauge
pressure of 5-6 bars at its suction and discharge end. When the maximum suction pressure
reach‘s 6 bar its discharge pressure is 5.6-5.8 bar and the pressure difference reach 0.4-0.2 bar.
This pressure difference helps to know the efficiency of filter guard. That is as the pressure
difference decreases the efficiency of filter guard increases because increase in pressure drop can
cause low efficiency.
Figure 2.2 BALF filter bag
Softening: Water softening is another unit operation next to filtration that used to remove
calcium and magnesium ions from hard water. It is a chemical process that takes place in
softener tank using ion exchange mechanism. In this ion exchange process hardness ions trade
place with sodium ions that are loosely bounded to a zeolite. Zeolite are micro pores aluminum
silicate minerals commonly used as commercial adsorbents and catalysts they have a porous
structure that can accommodate a wide variety of cations ,such as Ca2+,Mg2+,Na+ ,K+ and
others. The zeolite used to remove the cations in the hard water has a formal tank packed by a
negatively charged zeolite attached to a positive sodium ion. The calcium and magnesium ions
displace the sodium ions while the hard water passes though the softener and the sodium ions are
released into water. This is because sodium is more reactive than calcium and magnesium. As
the zeolite becomes converted into their calcium and magnesium forms the softer or ion
exchange machine gradually loss their effectives of softening. Then it needs another process
known as regeneration.
Figure 2.3 softeners (ion exchange machine)
Regeneration: Is the process that refresh or washing the softener by brine (sodium chloride)
solution to increase the resin capacity. During refreshing time the softener can sack the brine
solution (NaCl) for 2 hour and 20 minutes and sodium ion is replace in place of magnesium and
calcium ion to reduce hardness of water and removed as waste with high flow rate. The waste
that removed has high salt content in the form of magnesium chloride and calcium chloride salt
and the amount of sodium ion accumulates in the softener.

Figure 2.4 brine tank
Reverse osmosis (RO) process:

In addition to the softening and filtration unit operations another unit operation is required to
remove the sodium, carbonate and sulfate ions released in to water during softening process. This
unit operation is called reverse osmosis .Reverse osmosis is the flow of molecules and ions
through a semi permeable membrane, which allows a selected molecule or ion to pass through
and retain the other. In our case the aim of reverse osmosis is to demineralized the soft water. i.e
to remove Na+,CO32-and SO42-to produce reverse osmosis water. This water can stored in RO
water tank and distributed in to bottling for preparation of syrup and dilution of ethanol to
produce the final product.

Figure 2.5 RO machine
2.2.6 Flow chart of raw water treatment section
Figure 2.6 flow diagram of water treatment section

2.3 Boiler section
2.3.1 Introduction to boiler

A boiler is a closed vessel intended to heat water and produce hot water or steam through the
combustion of a fuel or through the action of electrodes or electric resistance elements. Boiler is
a process unit or equipment that generate steam from pre heated water by combustion of any of
several fuel such as wood, coal oil or natural gas. Burner is the heart of the boiler that converts
water to steam This burner is heated up by supplying fuel in to it The burner can be heated by
using different fuels like natural gas, coal or wood pellets. After the burner is heated using the
required fuel then the gases or the fire from the burner is directly released to the boiler The water
can be boiled in the boiler depending on the two mostly used types of boilers, which are fire tube
and water tube boiler.
Water tube boiler: - is the type of boiler in which the water is and heated through the tube side
and fuel gases surrounds them in the shell side.
Fire tube boiler: - is the type of boiler in which the fire is in the tub side and the water is
surround through the shell side and heated to produce steam. It operates at a pressure of 8-10.4
bars and produces 2800-10000 kg/hr of steam depending on the size of boiler. BALF uses these
types of boiler.
Figure 2.7 boiler section

2.3.2 Raw materials used in boiler section

 Treated Water
 Heavy fuel oil
 Air or oxygen
Treated water:-
It is treated or softened by ion exchange or reverses osmosis method to reduce the scale forming
ion.
Heavy fuel oil
Heavy fuel oil is the residue of crude oil distillation that flow waste oil from other industries is
added. This HFO is heated before entering to the boiler with steam, electrical heater. Since HFO
contains solid and semisolid particles (minerals, metallic particles and chemical wastes) it uses
filters to remove those solid particles because solid particles and other metallic minerals can
cause a problem inside the boiler and tubes which reduces production of steam and decrease the
efficiency of equipment such as pump , nozzle, servo meter etc
generally heavy fuel oil :
 It is the source of heat energy.

 It should be preheated and reach at the burner within a temperature range of 90-110oc.
 This temperature range is varies depending on the viscosity of fuel oil.
Air or oxygen
The main purpose of using air is to provide oxygen for combustion. Excess air is needed to burn
completely the fuel. When the amount of excess air is below its stoichiometric value some fuel
that is not burned completely is accumulates in the boiler and causes or creates unburned
minerals, ash and environmental problem. These unburned components of heavy fuel oil are
mostly organic compounds that have high energy content
2.3.3 Equipment used in boiler section

Pumps : A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action. Basically pumps are works or operate by the action of typical rotary and
reciprocating mechanism, and consume energy to perform mechanical work by moving the fluid.
Fuel Heater ; heavy fuel oil require fuel heaters to reduce the fuel viscosity, so the fuel can be
atomized by the burner system for complete combustion.
Flow Control Valve:- it consist of gate value, boll valve, butter fly valve and diaphragm valve
used to semi open and semi closed flow operation.
Air Fan: used to supply air from the environment and inject the air into the boiler to accelerate
the formation spark inside the chamber and the tube.
Water Level Sensor: is used to indicate the amount of water present inside the boiler
Brunner: is a special device contain, photo cell, electrode and pressure reducer used to inject
furnace oil and form spark by crating friction between two oppositely charged electrodes.
Chamber is a place in which furnace oil and air are contact each other and form spark.
Water Pump: is high pressurized pump used to transfer fluid (water) from law pressure head to
high pressure head.
Blow down:-Is water intentionally wasted from a boiler to avoid concentration of impurities
during continuing evaporation of steam. The water is blow out of the boiler with some force by
steam pressure within the boiler.
Safety Valve used to remove steam when excess amount of steam is generated inside the boiler.
Heavy Oil storage tank: used to store heavy fuel oil
Soft Water pre heater: used to pre heat soft water with an intermediate temperature of 80 -
85
Electrical Heater: -used to increase the temperature of furnace oil and decrease its viscosity by
using electrical energy.
Pressure and Temperature Sensor: is a device used to sense the pressure and temperature
create inside the boiler during the process respectively.
Servo meter: - used to regulate the pressure in and out let of heavy oil from the burner
Filter: - used to removes solid particles and other metals from the heavy oil.
Steam trap: used to prevent flow of steam by passing liquid.

Steam regulator valve: - is a valve that regulates the flow of steam to the header.
2.3.4 Process description of boiler section

Soft water from treatment plant is pumped to the pre heater tank and heated with a temperature
of 80 -87 and pumped to the boiler. The water feed to the boiler is controlled with level
measurement of sight glass. The level of water in the boiler increase the production of steam is
decrease because more water is evaporated with dry steam and it causes shortage of steam on
distillation and bottling because it condense in the header. This soft water is heated in the shell
side of the boiler and the vapor water is removed to the environment by using safety valves.
Heavy fuel oil, which extracts from crude oil. It transported by track and stored in heavy oil
storage tank. Heavy oil is delivered from storage tank by gravitational effect and fed into pre
heater to decrease it viscosity. In this heater heavy oil is heated by counter current flow of steam
up to a temperature of 65 . In order to remove solid particles and other semi solid impurities
such as minerals, metals and other chemicals from liquid heavy oil it passes through a filter bag
and pumped to pre heater decanter to reach its temperature from 65 to 90 . After the oil temp
is riches to 90 it passes through the filter bag to remove unwanted impurities. Then the heavy
oil is pumped to the pre heater to increase its temperature and passes through the electrical heater
to reach its temperature120 and above for further reduction of its viscosity. The oil leaves from
electrical heater is directly pass through burner at high pressure and fed to chamber side of the
boiler with the help of excess air. Hot and less viscous heavy oil is fed to the chamber at high
pressure and form spark when it combines with heat and excess air. This heat is produced by the
friction force of two opposite charged electrodes connected with electrical heater. The fire is
passing through the chamber side and turn back through the top side tubes and removes through
the bottom side tubes. The steam generated around 6000 kg/h for electrical boiler and 2800
kg/hr for mechanical boiler is goes through insulated tubes and fed to the steam header for the
purpose of bottling, and distillery. At the same time flue gas containing Co2, Co, So2 and NOx
are removed to the environment through chimney with a temperature of 200 -250 in the
electrical boiler and temperature of 100 -180 in the mechanical boiler.

2.3.5 Flow diagram of boiler section
Figure 2.8 flow diagram of boiler section
2.3.6 Boiler Efficiency Calculation

The overall boiler efficiency depends on many more parameters apart from combustion and
thermal efficiencies. These other parameters include ON-OFF losses, radiation losses,
convection losses, blow down losses etc. In actual practice, two methods are commonly used to
find out boiler efficiency, namely direct method and indirect method of efficiency calculation.
Direct Method
This method calculates boiler efficiency by using the basic efficiency formula-

η=(Energy output)/(Energy input) X 100
In order to calculate boiler efficiency by this method, we divide the total energy output of a
boiler by total energy input given to the boiler, multiplied by hundred.
Calculation of Efficiency by direct method
E= [Q (H-h)/q*GCV]*100
Where,
Q= Quantity of steam generated (kg/hr)
H= Enthalpy of steam (Kcal/kg)
h= Enthalpy of water (kcal/kg)
GCV= Gross calorific value of the fuel.
Parameters to be monitored for the calculation of boiler efficiency by direct method are :
Quantity of steam generated per hour (Q) in kg/hr.
Quantity of fuel used per hour (q) in kg/hr.
The working pressure (in kg/cm (g)) and superheat temperature ( C), if any
The temperature of feed water ( C)
Type of fuel and gross calorific value of the fuel (GCV) in kcal/kg of fuel
Enthalpy of saturated steam (H) in kcal/kg of steam
Enthalpy of feed water (h) in kcal/kg of water.
Boiler Efficiency by Direct Method ,This is also known as ‗input-output method’ due to the
fact that it needs only the useful output (steam) and the heat input (i.e. fuel) for evaluating the
efficiency.
E= [Q (H-h)/q*GCV]*100
Let h1- height of empty space in the tank before starting to pump the fuel=0.76 m
h2 - height of additional empty space in the tank after starting to pump=0.8 m
H- total height of the tank =3.1 m
D- diameter of the tank =3.01 m
Take the difference i.e h2-h1=0.04 m
In order to get the volume ,let me calculate the area
A= 3.14 D2/4 =3.14×(3.01 m)2/4 =7.11 m2
Total volume(Vt) =At × H =7.11 m2× 3.1m =22.04 m3
3.1 m =22.04 m3
0.04 m=? v
v =0.284 m3.
q =mass flow rate =density of fuel× volumetric flow rate
=900 kg/m3 ×0.284 m3/hr
=255.9 kg/hr.
Now it is possible to compute boiler efficiency
E= [Q (H-h)/q*GCV]*100
=[6000 kg/hr(2562 kJ/kg-1378 kJ/kg)/ 255.9 m3/hr ×43.6MJ/kg]×100
0.636×100 =63.6 %.
Therefore boiler efficiency (electrical one) using direct method becomes 63.6 %.

2.4 Fermentation section
2.4.1 Introduction to fermentation

Fermentation is the process in which yeast breaks down sugar in to alcohol and carbon dioxide.
On the other hand fermentation is a process in which a chemical change brought in organic
substance through the action of microorganism. These microorganisms are yeast, moods, bacteria
and etc.. The alcoholic fermentation that takes place inside the fermenters is expressed in the
following reaction:
C6H12O6→2CH3CH2OH + 2 CO2 + energy
SUGAR→ALCOHOL + CARBON DIOXIDE +ENERGY
2.4.2 Raw materials used in fermentation section

 Molasses
Sugar industries produce molasses from sugar cane processing. Molasses have 50- 55 %
concentration of sugar in the form of sucrose with chemical formula C12H22O11.This source of
compound is used for preparing ethyl alcohol.
 Sulphuric acid(H2SO4): it help to optimize the media or to lower the PH range because
acidic media with pH of 4.0-4.5 is optimum condition for yeast.
 Di ammonia phosphate (DAP): used as sources of nutrient for the growth of yeast. Its
amount is in the order of 1 kg per 500liters of molasses solution. If the amount of DAP is
less, the yeast may not activated well and if the amount of DAP is exceeded from the average
consumption, other cells will attack the yeast and also results in sugar wastage and sugar
spoilage.
 Water: used for cleaning of overall processing units and play a great role for dilution
purpose (molasses, pure alcohol and liquor preparation). It boils and widely used for steam
production. used for dilution purpose of molasses for specific brix. The raw molasses degree

brix is around 78 – 80 so by addition of water reduce the brix of molasses for specific
purpose to produce high brix (24-28) and low brix (14.5-15).
 Anti-foam: used for preventing the overflowing of the fermenting solution

2.4.3 Equipment used fermentation section
 Preheater: just to decrease the viscosity of the molasses.
 Valves: butterfly, gate and ball valves used for controlling the flow rate of molasses, water
and steam inlet.
 Pipes: different pipes that used for transport the inlet material and the out let product of
process from and to holding tank such as galvanized steel pipe for hard water, packed or
insulated pipe for steam..
 Sterilizer: it just like shell and tube heat exchanger that sterilize the low brix molasses to
ready the molasses for yeast growth by kill the pathogens mainly bacteria
 Propagation tank: it is a 10,000L open tank that growth of yeast taken place.
 Fermenter tanks: - are tanks where the high and propagate low brix molasses are brought
together to start the fermentation process. There are four 80,000lit, three 45,000lit and two
35,000lit fermentation tanks in BALF.
 Molasses storage tanks: it holds high brix and low brix molasses.
 Brix meter: it measures the brix of molasses.
 Decantation tanks: store the fermented wine for settling of its slurry and to remove.
 Mixer: - used to mix (dilute) molasses with water as they flow in together.
 Air Blower: used to blow air into the bottom of propagation tank and sterilizer.
 Ebulliometer: - used to measure the alcohol content of fermented wine.

 Pump : gear pump- used to pump the highly viscous molasses from storage in to a shell and
tube heat exchanger.
2.4.4 Process description of fermentation section

The raw molasses collected from wonji and metehara sugar factories and analyzed for its
necessary elements or nutrients before its use to fermentation. Then the molasses passed in the
preheater for reducing the viscosity of the molasses at 40 after that dilute the molasses with
soft water for perform low brix (14.5-15 brix) and high brix molasses (24-28). The low brix
molasses is goes to 2500L sterilizer tank to ready for propagation of yeast. Add 1kg urea,
1kgDAP as a nutrient and concentrated sulfuric acid (H2SO4) to adjust pH of molasses to 4-4.5
(unsuitable for bacteria that means it kills bacteria). After sterilizer the molasses is inserted into
propagation tank and add 8kg yeast for10, 000 L sterilizes molasses. In addition the propagator is
continuously supplied with air blown from a blower, so that the yeasts increase in number and
yield higher product. Propagation process takes about 18 hours for developing new yeasts. And
also need to check the brix within 3 hours‘ time interval and it will be pumped to opened
fermentation tanks when its brix drops to 8. First small amount of the high brix pumped to the
fermenters as nutrients for initial feed of propagated yeast and the propagated yeast is transferred
to the fermentation tanks. Then again the high brix molasses is filled in the fermenter tanks.
As the fermentation process is carried on, while carbon dioxide tries to escape from the
fermenter it creates bubbles and foam. Sometimes the foam comes to the brim of the
fermentation tanks and as such, in order to break the foam, anti-foaming agent is sprayed on the
surface of the foam and the foam starts to settle down. Fermentation takes place in temperature
range between 30 -33 .After fermentation is completed in about 36 hours, the fermented wine
is expected to contain 6-8% v/v alcohol; which is detected by laboratory analysis, by taking
samples from the fermentation tanks and testing it by using an instrument known as
Ebulliometer. Finally, the fermented wine will be pumped to the decanter where unnecessary
particles are separated from the wine and it will be ready to pass to the distillery for produced
raw alcohol

2.4.5 Flow chart of fermentation section
H2SO4 and fertilizer

Higher brix molasses tank
Yeast storage tank
Molasses heater
air
storage Yeast propagation tank
Fermentation tank
sludge
fan decanter
water
Figure 2.9 flow diagram of fermentation
2.5 Distillery section
2.5.1 Introduction to distillery

Distillation is the most common method of separating chemical substances based on differences
in their volatilities. It is normally used to separate Liquid Mixtures into more vapor or liquid
products with different compositions. The Separation obtained is due to the boiling point
differences volatility. It is typically performed in vertical cylindrical columns known as

―distillation towers‖ or ―distillation columns‖ and is operated at continuous steady state The
alcohol in mash produced in fermentation section is mainly ethanol, but other minor components
such as methyl alcohol, Esters, Acids, Aldehydes, can be contained in the mash. In this case,
main aim of the distillation columns is to separate the ethanol from the other products.
Figure 2.10 distillery section
2.5.2 Raw material used in distillery section
 Fermented wine: 6- 8% v/v alcohol grade wine comes from fermentation section. Or
technical alcohol uses as a raw material.
 Soft water: purified water that freely from ca and mg ions.
 Steam: it facilitate the separation process in distillery
2.5.3 Equipment used in distillery section
 Pressure and temperature gauges: to control the pressure and temperature parameter of
the column.
 Tanks: to store raw alcohol, pure alcohol and denature alcohol.
 Valves: It‘s a device that regulates directs or controls the flow of Fluid and steam. There is
butterfly, ball, gate and check valves exist in this section.

 Pumps: to transfer the raw and product from one operation to others.
 Alcohol meter: is used to measure the grade of the alcohol.
 Header: - used to store steam that come from boiler and can distribute the stem to the
columns.
 Flow meter: it is the quantification of bulk fluid movement flow can be measured in
variety of ways.
 Plate heat exchanger (PHE): to cooled the product and by products with in water.
 Shell and tube heat exchanger (STHE): to exchange heats between raw alcohol and soft
water.
 Condenser: is a device or unit used to condense a substance from its gaseous to its liquid
state, typically by cooling it.
 Decanter: Decanters are used to separate liquids where there is a sufficient difference in
density between the liquids for the droplets to settle readily.
2.5.4 Process description of distillery section

In Balezaf Alcohol and liquor factory the multi column distillation column consists of
Degasifying column, Analyzer column, Aldehyde column, Extractive distillation column,
stainless stripping section column and copper rectification column. The distillation section strips
off the ethanol from 6-8% fermented wine and increases the concentration of ethanol up to
96.8%.
Decanter
Decantation is a process for the separation of mixtures, by removing a layer of liquid, generally
one from which a precipitate has settled. Decanters are used to separate liquids where there is a
sufficient difference in density between the liquids for the droplets to settle readily. The
fermented wine from the fermentation entered into decantation tank where the precipitate settled.
Then it is pumped and passes through by flow meter and heat exchanger then feed into
degasifying column at a temperature of 70 -80 .

Figure 2.11 decanters
Degasifying column
Degasification is the removal of dissolved gases from liquids. The wine from the decanter enters
tangentially into this column at a temperature of 70 -80 The vapor leaves at the top of the
column and passes through plate heat exchanger. The condensing gas passes through a loop form
and leaves as degasing heads1(acetaldehyde) collected as 5L/h while the non-condensing gas
leaves as degasing vent. The degasified wine leaves from the bottom of this column send to
analyzer column.
Analyzer column
The analyzer column operated under a temperature of 88 -90 and pressure of 180-300 mbar.
It is a tray type distillation column which contain sieve tray with two down comers in one side.
Since there might be a scale formation in this column tray type is preferable rather than packed
type. The degasified wine introduced from side of this column falls through the down comers by
gravity from one tray to another. Heat in the form of steam supplied to the base of the column
and rises via the openings on each tray. As the steam passes through the feed on the tray, it
transfers heat to the feed. Because of the heat input from the steam the liquid on the tray boils
generating vapor which is richer in the more volatile component. The continuous contacting
between steam and liquid occurs on each tray brings about the separation between alcoholic
component with low boiling point and the nonalcoholic component with higher boiling point. In
order to trap these steam the spent wash water is send to 6 meter underground with larger tube
and hits the ground this made the steam to be released and send to the lower side of the analyzing

column through the pipe. Steam free spent wash water returned with a narrower tube with
increased pressure to preheat the fermented wine. The vapor leaves through the top of analyzing
Column with improved alcoholic grade is sent to aldehyde for further purification.
Aldehyde column
It is a packed type column operates under a temperature of 74 -76 and a pressure of 100mbar.
It is used to separate highly volatile low boiling point components. The vapor which leaves the
analyzer column enters in to lower side of the aldehyde column. The more volatile component
rises into the overhead two consecutive heat exchangers. The vapors which do not condense in
the first pass to the next heat exchanger. The non-condensing gas leaves off as a vent from the
last heat exchanger. The condensing vapor in the two heat exchangers Aldehyde heads 1,
amounting to about 100L/h, is drawn off from the two heat exchanger reflux loop and refluxed
back to the column. The raw alcohol portion of the feed tends to go down the column. The
product coming from this column is called raw alcohols with alcohol grade 45-60%v/v. It passes
through plate type heat exchanger to be cooled and stored in the shift tanker.
Extractive distillation column(ED)

Extractive distillation column is a try type column operated at a temperature of 132 -137 and
a pressure of 2.8-3 bars. The raw alcohol which stored in a shift tanker pumped and preheated by
heat exchanger passes through the flow meter and fed into ED column. Hot water comes from
stainless steel rectification column which used as a solvent passes through heat exchanger. It
enters into the column at some height above the raw alcohol for showering purpose. Steam
comes from the re boiler introduced into the lower side of the column. It used to separate a high
boiling component from the non-volatile. The component with the greatest volatility separates
out as the top and enters into the condenser. The vapor with a temperature of 132 -
137 condenses by the water from the stainless steel column (T=70 ), then the water recycled
back to the stainless steel column as reboiler. Head3 (acetalaldehyde) is collected 100L/h from
the condenser then pass through heat exchanger and stored in the tanker. The rest refluxed back
to the top side of the column near the hot water. The bottom product consists of a mixture of the
solvent and the other component that is 6-8%v/v diluted alcohol, which can again be separated

easily. The diluted alcohol enters into the re boiler and passes through the steam trap. The steam
trap holds the steam and allows the condensate to be discharged then pass through the Heat
exchanger. Both the raw alcohol from the shift tanker and the hot water from the stainless steel
column preheated by the 6-8%v/v diluted alcohol in the heat exchanger. The diluted alcohol
enters into stainless steel rectification column.
Stripping section (stainless steel column)

It is a packed type distillation column with operating temperature of 75 -82 and pressure of
250-450 mbar. The main objective of this column is to remove much of the water contained in
the feed and it also separate light and fusel oil from the alcohol mixture. The diluted alcohol feed
below light and fusel oil extraction point and steam entering at the base. The steam separates the
more volatile alcohol from the water. The more volatile component rises up to the column and
the alcohol free water (lease water) withdraws at the bottom. The lease water is send to 6 meter
underground same as analyzer column in order to trap some amount of vapor containing with
trace amount of alcohol. And it passes through the heat exchanger to preheat the boiler feed.
The light oil (ethyl acetate) and fusel oil (amyl alcohol) extracted at the top sides of the column
and collected each 40L/h with alcohol grade 70%v/v.
Rectification section (copper column)

As the vapor moves out of the stripper, the rectifying section increases the alcohol concentration
by allowing the vapor flow to move up the column against some of the final liquid product flow
(reflux) moving down. This column operates under a temperature of 72 -74 and a pressure of
250-450mbar.It used to upgrade the concentration of more volatile component and it also used to
separate methanol from the mixture. Vapor leaving from the top of the column feed in to the
main condenser to condense and the rest which couldn‘t condense in the main condenser passes
through vent condenser for further condensation to prevent vapor loss. The incoming water from
the cooling tower used as a cooling fluid in the condenser. Then vapor which couldn‘t condense
in the two condensers released to atmosphere as vent. Then 40l\hr. of heads 2 main and 40l\hr.
heads 2 vents is collected from the reflux loop and collected in a denature tank after passing
through heat exchanger, The product coming from this column which is pure alcohol having

96.8%v\v alcohol grade collected at the upper side of the column and stored in pure alcohol
storage tank. The upper part of the column is made up of copper.
2.5.5 Flow chart of distillery section
Figure 2.12 flow diagram of distillery

2.5.6 Material balance for selected distillery column
To determine the volumetric flow rate of the bottom product of degasifying column
DH1=5L/hr
Xdh=0.70
Degasifying
column
VD=2000l/hr
Xd =0.15
Vg
Xvg=0.2
where
VD=volumetric flow rate of alcohol from decanter
xd=mass fraction of alcohol in the
vg =volumetric flow rate of degasifying column

DH1=degasifying acetaldehyde(degasifying head 1)
xdh =mass fraction of degasifying head 1
Vg=out put volumetric flow rat of degasifying column
Xvg =mass fraction of degasifying out put
Over all material balance
Input +generation- out put-consumption =accumulation
Input= out put
VD=HD1+Vg
Vg= VD-HD
Alcohol balance
VD(xd)=DH1(xdh)+vg(xvg)
VD(xd)=DH1(xdh)+vg(xvg)
Vg=(VD(xd)-DH1(xvg))/xvg
Vg=2000(0.15)-5(0.70)/0.2
Vg=1482.5L/hr
This 1482.5L/hr of alcohol having 20%v/v concentration exits from degasifying column and
enters into analyzing column

To determine the volumetric flow rate of the bottom product of aldehyde column
HA1=100L/hr
XHA1=0.75
Aldehyde
VLi=950L/hr
column
Xvli=0.34
VLo=?
XALo=0.45
Where
VLi=volumetric flow rate of alcohol enter into aldehyde column
xvli mass fraction of input alcohol to aldehyde column
HA1=volumetric flow rate of aldehyde head one
XHA1 =mass fraction of aldehyde head one
VLo=volumetric flow rate of alcohol that exit from
aldehyde columon
xALo =mass fraction of output alcohol from

Input= out put
VLi=HAL+VALo
Alcohol balance
VLi(xALi)=HAL(xHAl)+VLo(XALi)
VLo=(VLi(XAL)-HA1(XHA1))/XALo
VLo=9950(0.34)-100(0.75) )/0.45
VLo=551 L/hr
This 551L/hr of alcohol having 45%v/v concentration aldehyde column

Exits from aldehyde column and stored in raw alcohol tank
To determine the volumetric flow rate of the bottom product of stainless steel column
Vfo=40L/hr Vlo=40L/hr
Xfo=0.75 Stainless Xlo=0.75
column
VSi=2000L/hr
Xsi=0.48 VSo=?
XSVo=0.68
where :

VSi= volumetric flow rate of alcohol that enters into stainless steel
Vfo=volumetric flow rate fusil oil
Vlo=volumetric flow rate of light oil
VSo= volumetric flo rate of alcohol exits from Stainless steel column
XSi=mass fraction of input alcohol
xfo=mass fraction fusil oil
xlo=mass fraction of light oil
Xsvo =mass fraction of exit alcohol from Stainless steel column
Input= out put
VSi=Vfo+Vlo+Vso
Alcoholic balance
Vsi(xsi)=vfo(xfo)+vlo(xlo)+VSo(xsv )
2000L/hr(0.48)=40L/hr(0.75)+40L/hr(0.75)+Vso(0.68)
960L/hr=30L/hr+ 30L/hr+vso(0.68)
VSo=((960-60))/0.68
VSo=1323.5L/h
This 1323.5L/hr alcohol having 68%v/v concentration of alcohol exits from stainless steel
column and this amount of alcohol enters into copper column(rectification column )

To determine the volumetric flow rate of exit alcohol from rectification column or to determine
the volumetric flow rate of pure alcohol from the copper column
Hm=40L/hr Hv=40L/hr
Xhm=0.95 Xhv=0.95
Rectification
column
VRi=1323.5 L/hr
Xri=0.68
VRo=?
Xvro=0.968
where :
VRo= volumetric flow rate of pure alcohol
VRi=volumetric flow rate of alcohol enters in to rectification column
Xvro=mass fraction of pure alcohol
Hm =volumetric flow rate of head2 mean
Hv= volumetric flow rate of head 2 vent

Xvri=mass fraction of input alcohol to rectification column
xhm= mass fraction of head2 mean
Xhv=mass fraction of head2 vent
Overall material balance
VRi=Hm+Hv+VRo
Alcoholic balance
VRi(Xri)=Hm(xhm)+Hv(xhv)+VRo(xvro)
1323.5(0.68)=40(0.95)+40(0.95)+VRo(0.968)
899.98=38+38+VRo(0.968)
VRo=(899.98-76)/0.968
VRo= 851.2 L/hr
This 851.2L/hr alcohol having 96.8 %v/v concentration exits from copper column or the
company produce 851.2 L/hr of pure alcohol
2.6 Bottling section
2.6.1 Introduction to bottling

Bottling is the final unit operation for most alcoholic beverages like beer, wine, whisky and so on
which produce bottled drinks. The bottles may be glass or plastic but in BALF, glass bottles are
used. In this factory, the bottling section mainly contains blending and washing room. In
blending room the ethanol, syrup, RO water, color and flavor are mixed in a mixing tank to
produce desired liquor, while in washing room bottles are cleaned by using caustic soda solution
and then the cleaned bottles are filled with the prepared liquor.

Figure 2.13 blending and bottling section
2.6.2 Raw material used in bottling section

 Sugar syrup: Syrup is a thick viscous liquid consisting primarily of a solution of sugar in
water, containing a large amount of dissolved sugar. Which uses as sweetener for the
liquor..
 Citric acid: used as a bleaching agent in a syrup preparation to kill bacteria. Or to
increase the life time
 Flavor: it is apperceived in a liquor for different test in mouth.
 Ro water: it used as a solvent in blending of liquor.
 Soft water: for washing of the holding tan, mixing tank , bottle and crates
 Caustic soda: used for washing agent of bottle washer.
 Steam: used for the preparation of syrup and in washing machine for washing bottles
2.6.3 Equipment used in bottling section

 Filter press: In this factory, filter press uses for filtering the prepared syrup and liquor by using the
filter sheets. The filter sheet retains the contaminants. When there is a pressure difference between the
entrance and exit, the filter sheet should be replaced or cleaned. In addition to filter press, there is a
filtro that used to filter intermediate, warm, and cold water in the washer.
 Pumps :are device for moving or compressing a liquid or gas.
 Pipe : There are different types of pipes in bottling room. These are plastic, stainless steel, and PVC
pipes. The advantages of these pipes are-
 Filter bag: is used to filter the recycled caustic solution in the washer.
 Filler: machine which fill the liquor with in bottle.

 Inspection glass: to control contaminated, broken glass.
 Labeling machine: machine to label the company identity for customer safety.
 Conveyer: easily transportation in operation. BALF uses chain conveyer for transporting
bottle and crate , belt and manual conveyer for transporting crate
 Blowers and compressors: A blower is used to produce negative pressures for industrial
vacuum systems. Blower uses for drying the bottles in the washer on the other hand
compressor uses for operating the automatic valve during the entrance of steam in to the
washer .
 Valve: used to regulate the flow of fluid.
 Heat exchanger (HE) The transfer of heat to and from process fluid is an essential part of
most chemical process. The most commonly used type of heat-transfer equipment is shell
and tube heat-exchanger. In this factory especially in bottling room there are two types of
HE. These are shell and tube HE which used for heating the caustic solution in washer and
plat type HE which used for cooling the syrup.
 Holding tank: hold the syrup and the prepared liquor.

 Brix meter: measure the brix of syrup.
 Alcolhometeric: measure the alcohol grade.
 Mixing tank with stirrer: which used to blending of liquor with well stirrer to minimize
mixing time and to well mix for required alcohol grade.
 Level sensor: to control the level in mixing and holding tank.
 Washer machine: bottle washer and create washer to reuse the bottle and crates again.
2.6.4 Process description of bottling section
Cleaning process:
In BALF cleaning process takes place using soft water, in order to prevent the formation of scale,
supplied from the water treatment room, In bottling section there are so many equipment‘s like

mixing tank, syrup preparation tank, holding tanks, filter press, washer and so on. All this
equipment are cleaned by using cold water except the mixing tanks. Mixing tanks are cleaned by
using both cold and warm water twice. The first step is cleaning the tank using warm water and
then by coldwater. The reason behind this cleaning process using cold water {2 times} and hot
water {2 times} is to avoid contamination, and the effect of one liquor on the others. I.e. balezaf
alcohol and liquors factory produces 14 different kinds of products and each alcohol types have
different color, odor and flavor. Therefore, washing the tanks properly is an important task in this
factory.
Syrup preparation:
The main components in this factory for process are sugar and RO {reverse osmosis) water. Before
proceeding, make sure that the syrup preparation tank has properly cleaned. It has cleaned by soft water.
Then the syrup preparation tank has filled with RO water. The reason that we use RO water is to avoid
side reactions. Then steam inters from the top to boil the water. Then the sugar is transfer from the sugar
tank to the syrup preparation tank using a pump. After waiting a few minutes until the sugar is dissolved
add some amount citric acid in order to prevent bacteria formation, other contaminants and uses as
preservation and bleaching agent. Finally the prepared syrup passes in to a PHE to get cooled and filter
press for clarity. Then the syrup passes in to syrup holding tank (ouzo and dry gin) but for the other
liquors the syrup directly added to the mixing tank. The reason of storing the syrup in the syrup holding
tank is ouzo and gin doesn‘t need all of the syrup produced rather needs small amount. A physical
reaction that takes place in the syrup preparation tank is:
C6H12O6 (solid) + water steam C6H12O6 (aq)
Blending process:
Blending process is a process in which two or more materials have mixed properly to produce
liquor. It is the main process in bottling room, which takes place in mixing tank. The mixing tank
has a mixer inside it. After the mixing tank has cleaned and about 96.8% alcohol of ethanol,
some amount of water, flavor, and color are added. At the end add the prepared syrup and wait
until it‘s well mixed. The prepared liquor will be filtered and stored in liquor holding tank.

Washer:
Washer in bottling room has used to clean the bottles and crates. The crate which contain the
bottles comes from store and separated by the out picker machine after the separation the bottles
goes to the bottle washer as the same time the crates goes to the crate washer. In the bottle
washer, the bottles have washed through a different step. First, fill the washer with a solution that
contains 2% caustic soda (NaOH) and all intermediate, warm and cold water tank inside the
washer, then turn on the washer‘s motor. Bottle washer needs intermediate (37 ), warm (31 ),
cold (28 ) , and fresh water(23 ). Fresh water comes directly from the water treatment room.
After filling, steam has released in order to heat the caustic solution and then warm, intermediate
and cold water heated by body contact with caustic solutions part which is heated by using shell
and tube type heat exchanger (STHE). The bottles that comes from the out picker machine enters
to carriers in the washer with the help of fingers to push it. Then the warm solution that contains
the 2% caustic soda washes the bottle at a temperature of 76.50 . At this step labels has
removed. The caustic solution can be recycled and used for about 1 month but the concentration.
Of the caustic soda should not be less than 2%. If it is below 2%, add some amount of NaOH
until it is approximately 2% by using titration methods. During cleaning process, the NaOH
solution has transported and stored in the NaOH solution tank. After cleaning, the solution has
filtered and recycled back to the washer. Finally the bottles have dried by using blower and goes to
filling section.
EBI (Empty Bottle Inspection)

inspects bottles with defects before filling such as:
 Bottles with cracks
 Bottles with adhesive residues or contaminations
 Bottles with foreign bodies

Filling process:
Bottle is filled when the liquid is transferred from the tank to the filler machine . during the filling
process first the air is removed by using vent tube and then the fill the alcohol into the bottle

Crowning: From the cork containing container the cork conveyed to the crowner machine and
then immediately after filling the bottles are crowned using cork
FBI (Full Bottle Inspection)

Due to the fast process of filling machine, there may be some problems. This machine therefore
separate or removes the defected bottles from the group. These include under fill, uncapped and
broken bottles.
Labeling
The full bottles are send to the labeler through the chain conveyor. This machine stamps the company‘s
label on the neck and body of the bottle using glue as a sticking material. It can label 5,000 bottles/hr.

2.6.5 Flow chart of bottling
H2o
Bottle +crate
crate
Out Crate washer

picker
bottele
compressor
inpic Product/storage
crate
H2O ker
Bottle +liquor
air
Bottle washer
Inlet stem
water dating labeling
Outlet stem
Inspection cop
1
filler Inspection 2
ping
water
flavourRO water
color
Final alcohol syrup
alcohol
RO water tank Soft
Liquor Liquor
liquior
water
holding holding
holding
tank tank
tank
Mixing tank
V-7
Soft water
stem syrup
Ro water Alcohol from distilation

Citric acid
Syrup holding Alcohol holding

tank tank
Syrup preparation tank
Plate HE Filter press
syrup water
Figure 2.14 flow diagram of bottling section

CHAPTER THREE
3.1 Overall benefits of the internship

Internship program is a very important program in helping students to introduce their self with
the real world. From the four month internship period I have developed the team cooperation
with the coworkers and learned the work ethics and I have understood the organizational
structures in the factory. During my internship time in the company, I have spent most of my
time with company mentor, operators, chemists, and quality assurance department workers by
observing practical skills, working procedures, proper use of materials and identifying the right
material for the right purpose. Generally in overall section of the company such as fermentation,
distillery, water treatment boiler and bottling plant helps to know the operating and working
principles of equipment‘s and machineries, the overall process description, process flow sheet,
evaluating the material and efficiency on selected materials.
3.1.1 Improving practical skills
Internship is the encourage able program and needs for all students in their practical knowledge
on the overall process description, the operating and working principles of equipment‘s and
machineries the laboratory analysis by observing or asking the operators ,supervisors and shift
engineers. Finally internship also enhances the students to solve specific general problems facing
in the industries. The major skill I gained from this internship is the practical skill. I got this
while working in different sections of the factory, Fermentation, Distillery, Water treatment,
Boiler and Bottling. So it was a great chance for me to see different equipment‘s physically and
understand their working principle.
3.1.2 Improving Interpersonal Communication Skill

Working anywhere without communication is difficult. There has to be interpersonal
communication. In this factory, there are different sections and in each section, there are
different kinds of workers with their own special behavior. To relate with the workers, one has to
be taught and better to do what he/she can. And also I have to treat every person equally and

kindly. The following are some of values i have gained from the internship in terms of
interpersonal communication skills.
 Diversity
 Helping others
 Listening carefully
 Respect each other
 Responsibility
 Tolerance
 Team work
3.1.3 Improving team playing skill

Chemical engineering is a team work. Because it needs the participation parties mainly chemical
engineers, chemists, electricians, mechanical engineers, different operators, Owner and daily
laborers. So all team members should share common goal and work in harmony to get the
desired goal of the company
As a team member I learned
 To listen and respond to others in an objective and productive way
 To take different role in the group
 Respecting the difference between group members.
3.1.4 Improving leadership skill

From the internship period I should observed how to lead (manage) or the organized factory
workers the compound. The company worker could be lead by their leader orders like separating
them in their professional job. Leaders are assigned depending on their personal skill ability and
their profession.. The leaders should organized the factory's material how and when used, where
their proper site is and how to control them from damage by inspiring the factory's worker.
Generally, leader ship is the main promoter of the factory by organized the compounds system
for each necessary condition

3.1.5 Work ethics

Work ethics is the belief of the work that has a moral benefit and on inherent ability to strengthen
characters. This work ethics is a vital use full system of both the workers and the leaders.
The following are some of the values I have gained from the internship in terms of the improving
work ethics.
 Responsibility
 Self confidence
 Hard working
 Morality
 Professionalism
 Punctuality
3.1.6 Entrepreneurship skills

It is the development of a business from the ground up to coming with an ideal and turning it into
a profitable business. It is a journey of opportunity exploration and risk management and risk
management to create value for profit or social goods.
In our intern ship stability in the factory we have to get some (little) knowledge based on how
develop our entrepreneur ship. Through it our entrepreneur ship skill in the factory is how to
develop (expand) the factory capacity from low level size to higher level of the company's new
profitable system.

CHAPTER FOUR
Over all Conclusion and Recommendations
4.1 Conclusion on each section
Raw water treatment section :

Generally water treatment is one unit for preparation of raw materials, water, for other sections
such as distillery ,boiler, cooling tower and bottling. In water treatment hard water is treated into
soft water and reverse osmosis water. The ROW is used in the preparation of syrup and dilution
of ethanol to prevent side reaction which caused by water contains ions in it.Where as the soft
water is used rather than hard water to minimize scale formation in different unit operation .
Boiler section:
A boiler is a closed vessel in which water or other fluid is heated and the heated or vaporized
fluids exit the boiler for various purposes such as for heating, cooling, distillation, sanitation and
others. Boilers can be classified in different ways depending on different criteria. In our case
depending on construction method boilers are classified as water tube and fire tube. All boilers in
this factory are fire tube and are three different types. These are loos international boiler,
Babcock wanson and ygnis boiler. The first one is operated automatically, where as the latter two
are operated manually.
Fermentation section:
Generally the fermentation process is the process that converts sugar in to alcohol in the presence
of yeast which contains two enzymes: invertase and zymase. Invertase converts sucrose into
glucose. Zymase converts glucose into ethanol and carbon dioxide.

Molasses is first diluted with water to adjust the sugar content to about 15%in the batch
fermentation process. Though normally running water from its source is supposed to be clean,
sometimes it may be polluted. Fermentation, being biological process, brought about by living
organism like yeast.
The process of fermentation is anaerobic where as that of yeast propagation is aerobic. To
produce sufficient quantity of yeast it needs: to maintain the temperature at around 32oc, acidify
the mixture, and add fertilize, and maintain aerobic process.
Distillery section
The major operation in the distillery is to separate ethanol from the fermented wine by using
steam as a heat energy. The fermented wine which is coming from the decanter passes through
the different columns which are degasifying column, analyzer column, aldehyde column,
extractive distillation column, stainless striping section column and copper rectification section
column. Through these process alcohols like isopropanol, light oil, fusel oil is separated out. The
product coming from the last column which is copper column has alcohol content of 96.8%v/v
pure alcohol and denatures alcohol as a byproduct.
Bottling section:
Generally bottling is the final stage in this factory and it has sub unit operations. These are
blending (mixing), syrup preparation, washing and packing. In bottling room, the alcohol from
the distillery room, RO water from the water treatment section and syrup from the syrup
preparation tank have added to the mixing tank with color and flavor. After that, the liquor that is
prepared in the mixing tank is transfer to the liquor-holding tank. The liquor has transported to
the filler and the bottles that come from the washer has filled with liquors and inspected before
and after filling. Then capping, labeling and dating takes place. Finally using the in packer
machines the bottled liquor puts in to the crate and then stored in the finished storage room.

4.2 Recommendation on each section
Raw water treatment section :
 During regeneration process calcium and magnesium chlorides are removed as a waste.
These salts are dangerous for cattle and the environment. So it needs a waste treatment to
use these salts as a useful product and to clean the environment.
 During reverse osmosis process more amount of water remove as a waste, this water is
not contaminate so use for cleaning the compound and other purpose to save water
because to use electric city during to pump water from underground.
Boiler section:
 In the boiler section there is no economizer, but economizer is energy consumption, or to

perform another useful function such as preheating a fluid .The term economizer is used
for other purpose as well. Boiler and other power plant lose much amount of heat or use
high amount of energy to produce small amount steam but if use economizer improve
boiler efficiency by extracting heat from the discharged flue gas and transferring it to
feed water so, the company must be consider this problem and solving simply.
 Another problem of boiler section is on mechanical boiler is some leakage, which still it
loss high amount heat by the temperature pressure control stage and at the back of those
boiler body . due to this problem the company forced to extravagancy and loss high
amount of energy so, the company should be find the solution for problem by spearing or
changing the old material and by using additional insulator it jacketing those boiler.
Fermentation section :
 The fermentation tank is not made from the stainless still, all tanks are galvanized due to
this case every time rest is happened by reacting with fermented wine and forming
another by product, this by product reduced the amount of ethyl alcohol

and decreased the quality of pure ethanol also diminished
 In the fermentation section some fermenter tanks are not closed, due to that cause during
the fermentation time high amount of ethyl alcohol are evaporating in the form of vent
from each fermenter tank. And also high amount of dust are entering from the
environment to each open fermentation tank, in the cause of those problem, reduce
reduces the quality of alcohol and alcohol grade
 Since fermentation chamber has no a temperature control system it needs a stainless

steel material with heating coils and jacketed provisions to maintain the require
temperature for the process.
 The open air system in fermentation release carbon dioxide to the atmosphere which
affects the environment. So use the released CO2 in soft drink, fire extinguisher and
fertilizer production processes rather than open air system.
Distillery section
 The temperature of vent is between 20-40 but sometimes greater than 40 due to this
some amount of alcohol will release as a vent so the company should be change the
temperature sensor as well as the operators should be operate properly
Bottling section
 The most significant problem in this company is in the bottling section, that means
every day large amount of paper uses for labeling purpose ,and also the washer machine
washed 40000 bottles per day, that means it discharged this amount of paper per day as a
waste form . but this waste paper is possible to change reuse purpose to produce poly
wood and free carbon charcoal and produce activated carbon
 Steam leakage
In bottling section steam need to melt the sugar, during this process steams are leak at
the bottom part of syrup preparation tank.

 Flow measuring devices:
In order to know equipment efficiency and other process property calculation must be
done but due to the lack of such device we do not performs calculation part.
 Detection method
Instead of using only sight glasses, it is preferable to use more advanced technologies.

CHAPTER FIVE PROJECT
Title
Reduction of COD, TDS, TSS, pH of the waste mixture by using an activated

carbon produced from waste paper that discharge from bottling section.
Abstract
One of the most important environmental problems faced by the world is management of wastes.
Industrial process create a variety of waste water pollutants vary significantly from industry to
industry. Pollution prevention focuses on preventing the generation of wastes, while waste
minimization refers to reducing the volume or toxicity of hazardous wastes by water recycling
and re use The aim of this project was to investigate the reduction of chemical oxygen demand
(COD),total dissolved solid (TDS) , total suspended solid (TSS), PH from the effluent of
Balezaf alcohol and liquor factory using activated carbon produced from waste paper. By using
this adsorbent to reduced the COD from 8100mg/l to 7365mg/l, TDS from 9800mg/l to 9320
mg/l,TSS from 370mg/l to 240 mg/l.
5.1 Introduction
Ethanol manufacture from molasses generate large volume of high strength waste water that is a
serious environmental concern. The effluent is characterized by extremely high chemical oxygen
demand (COD) and biological oxygen demand (BOD) apart from low PH, bad odor The
development of industries, on the one side, will produce valuable materials for the people
welfare and, on the other hand, industries also will generate wastes. Among wastes which are
generated from industrial activities, there is poisonous and dangerous material waste (hazardous
waste). The disposal of untreated wastes from Balezaf alcohol and liquor alcohol factory is the
major environmental problem A major source of waste water in the factory was water used

mainly for cooling purpose in evaporators, heat exchangers, to decreases the degree of brix in
treatment section, to minimalize the alcohol percent in hydro selection and in the leaker section,
in washing of bottle and washing of equipment‘s accounted for the organic matter present in the
wastes. Factory effluent contains mainly organic waste, small amount of salt.
Activated carbon has been used in various industries for many years. Recently, it has become an
essential material that can be used to reduce air pollution, water cloudiness, and bad odor, and
for environmental protection and high quality water purification. Activated carbon is widely used
in industrial production processes and various systems that form an integral part of our daily life,
and demand for it has been increasing. Traditionally, activated carbon has been manufactured
mainly from coal, wood, or coconut shell. Recently, many studies have been carried out
regarding the preparation of activated carbon by using various waste organic materials such as
organic waste sludge, used ion exchange resin, bean-curd refuse, bagasse, waste paper or waste
wood material as the raw material. Activated carbons are high-grade carbonaceous products,
having a porous structure and a large internal surface area. Such properties enable then to adsorb
a wide variety of substances, i.e. they are able to capture molecules of gases and liquids in their
internal surfaces. Therefore, they are used in industry in several applications including those for
purification, chemical recovery and environmental remediation. Activated carbon has a porous
structure that provides excellent adsorption properties. Activated carbons represent a family of
carbonaceous substances manufactured by processes which specifically develop adsorptive
properties of carbon. They normally have high surface areas and high adsorption capacities.
They are often the material of choice for many environmental applications, as waste-water
treatment processes, and are gaining increasing popularity for adsorbing volatile organic
compounds, from gases and liquid phases.
5.2 Problem of statement

In any alcohol industry water have a major roll on all over the process. Balezaf alcohol and
liquor factory (BALF) uses water for different purpose including steam production, heating and
cooling, dilution of molasses and dilution of ethanol , washing of bottle, cleaning the equipment
and syrup preparation. After finishing its work water leaves from the factory as a waste with a
composition of different residues. All waste gather together they form a dark black color and

create bad odour and causes environmental pollution. Decaying organic solids, oil and grease are
present in the waste water this cases the clothing of soil pores. The waste water contains
considerable amounts of suspended solids which deposited in drains, it causes blockage. The
waste water discharging from the factory degrades surface water body, fertility of soil, pollute
the ground water. In aquatic region wastewater can block out sunlight from rivers and streams,
thus reducing oxygenation of the water by photosynthesis and hence, become detrimental to
aquatic life. The waste of balezaf alcohol and liquor factory (BALF) released in to the
environment without any treatment due to this irrigation based farmers affected by the effluent
and yield and soil health were reduced. Due to highest amount of wastage the company uses
technical alcohol as a raw material for its product instead of molasses because molasses has high
amount of spent wash than technical alcohol. To solve this problem I am going to reduce the
waste from balezaf alcohol and liquor factory by using activated carbon as an adsorbent prepared
from waste paper from washing machine in bottling section .
5.3 0bjective
5.3.1 General objective:

The primary objective of this study is to reduce the COD ,TDS, TSS, PH and of waste water that
remove from balezaf alcohol and liquor factory
5.3.2 Specific objective
 To characterize the properties of the effluent waste water from the factory
 To analyze and determine the effects of adsorbent on waste water treatment by using
Different amount of adsorbent
 To analyze and know the effect of settling time on the adsorption rate

5.4 Literature review

Effluent draining from the distillery industries during the production of ethanol is considered as
a major source of the environmental pollution. Distillery spent wash is considered as one of the
big issues of pollution. This is because this effluent has extremely high values of chemical
oxygen demand (COD), biological oxygen demand (BOD), inorganic solids, and low pH (Shin et
al., 1992) and (Saha et al., 2005). Basically, distillery spent wash industries are the agro-based
industries and their waste effluent having high organic and inorganic compounds which are high
strength based and difficult to disposed
(Rajor, A. Kalia, et al) reported that a typical cane molasses based distillery generates 15 liters of spent
wash per liter of ethanol produced. and (Chuhan, ) and (Haroon et al) are reported that dark brown spent
wash is being over loaded with high organic nitrogen – nutrients, high organic and inorganic salts as a
result having high electrical conductivity (EC) causes depletion of oxygen and produces bad smell.
Ansari, 2012), stated that. generally distillery spent wash is made to flow into water courses and other
water bodies either after the incomplete treatment or without treatment, while some of the industries
release their effluents on open land. Sometimes effluents are used for irrigation purpose which poses a
serious threat to the soil and water environment.
Manoj. P. Wagh proposed that activated carbon is a well known adsorbent due to its extended
surface area, microporous structures, high adsorption capacity and a high degree of surface
reactivity. Adsorption techniques are considered to be most effective and proven technology
having potential application in both water and waste water treatment. Activated carbon is a
widely used adsorbent for the removal of organic pollutants from wastewater, but the relatively
high cost restricts its usage.
The levels of waste water treatment

Preliminary Treatment: –includes simple processes that deal with debris and solid material. the
purpose of preliminary treatment is to remove those easily separable components. This is usually
performed by screening (usually by bar screens) and grit removal. Their removal is important in
order to increase the effectiveness of the later treatment processes and prevent damages to the
pipes, pumps and fittings. Primary Treatment is mainly the removal of solids by settlement.
Simple settlement of the solid material in sewage can reduce the polluting load by significant

amounts. It can reduce BOD by Up to 40%. Some examples of primary t treatment is septic
tanks, septic tanks with up flow filters
Secondary Treatment: In secondary treatment the organic material that remains in the
wastewater is reduced biologically. Secondary treatment actually involves harnessing and
accelerating the natural process of waste disposal whereby bacteria convert organic matter to
Stable forms. Both aerobic and anaerobic processes are employed in secondary treatment. Some
Examples of secondary treatment are UASB, reed bed systems, trickling filters and stabilization
Ponds.
Tertiary treatment: –is the polishing process whereby treated effluent is further purified to
acceptable levels for discharge. It is usually for the removal of specific pollutants e.g. nitrogen or
Phosphorus or specific industrial pollutants. Tertiary treatment processes are generally
specialized Processes. Some examples of tertiary treatment are bank‘s clarifiers, grass plots, etc.
The majority of secondary treatment processes are biological in their nature:-i.e. they use the
natural activity of the bacteria to break down polluting material. Biological treatment processes
can themselves be divided into two general subdivisions aerobic and anaerobic processes.
Advanced treatment applicable only to industrial wastes to remove Specific contaminants
5.5 material and method
5.5.1 Material used:

 Oven
 Sieve
 Filter paper
 Plastic beaker
 Electronic balance
 Stop watch
 PH meter
 Funnel
 Waste paper activated carbon

5.5.2 Chemical used:

 Hydrogen per oxide
 Deionized water(RO water)
5.6 Method
5.6.1 Adsorbent development and methodology

The waste paper was collected from the washer in the bottling section. It was taken to the
laboratory and sun dried for two days. Parts of waste paper was soaked in hydrogen per oxide
(30% by concentration) at 70 for 24 hr to remove the organic matter for surface modification.
Then it was repeatedly washed with deionized water (RO) water for the adjustment of pH. This
modified waste paper was place into an oven at 80 until it was dried completely and it was
again soaked with hydrogen per oxide for 24 hr for another surface modification and washed
with deionized water. Heated the sample by increasing the temperature at a rate of 100 and the
temperature kept at 500 for 24 hr and the sample was cooled down rapidly. And it was
grounded and was sieved in 250μm size sieves.
5.6.2 Reductions of COD,TDS,TSS and pH by using activated carbon as an

adsorbent
To know the effect of amount of adsorbent dosage taking the discharged waste water from the
treatment section, distillery section and from washing of bottle at the point where all of the
effluent mixed with each other. Measure five 200 ml of waste water sample from the mixed
effluent by volumetric flask and Sample of activated carbon are taken and then Weigh and
measure 5gm, 10gm, 15gm, 20 gm and 25 gm of activated carbon sample since most literature
uses from 100ml to 500ml waste mixture samples and uses from 3gm to 30 gm of adsorbent
sample and uses the time of 1hr to 5 hr to know check the adsorption efficiency of activated
carbon reaches 60% to 92%. after that transfer the weigh amount of activated carbon to the five
200 ml of volumetric flask Waiting for 5 hours until the sample becomes completely wet . Filter
each the mixture of activated carbon and waste water by filter paper and take the first 200ml of
the mixture then measure each of the mixtures of TDS, COD and pH. But to measure the TSS of
the sample, first measure the total solid(TS) of the sample. In order to measure the TS firs take
100ml of mixture sample and filter it by using filter paper and measure the mass of evaporator
dish then put the filter sample on the evaporator dish and then dry it by 80 oven for 1hr and
then measure the dried sample and the evaporator dish together.
TS=(m1-m2)*1000
v
TSS=TS-TDS
Where
TS= total solid
m1 =mass of the evaporator dish(gm)
m2= mass of sample + mass of evaporator dish(gm)
TDS= total dissolved solid
V= volume of the sample(ml)
To analyzing the effect of contacting time Measure five 200ml of waste water sample from the
mixed effluent by volumetric flask and a sample of activated carbon are taken then Weigh and
measure 10gm of activated carbon sample after this transfer the weigh amount of activated
carbon to the five 200ml of volumetric flask. Wait the waste water and the activated carbon
sample for 1hr, 2hr, 3hr, 4hr and 5hr until them becoming completely settled. Start to filter each
mixtures with filter paper then take a first 200ml of the mixture and then measure each of the
mixtures of TDS, TSS, COD, and PH.

Figure 5.1 sun drying of waste paper

Figure 5.2 oven drying of the sample
Figure 5.3 measuring mass of activated

carbon

Figure 5.4 mixtures of activated carbon and waste sample
Characteristics of the waste mixture sample

Table 5.1 characterization of waste mixture in BALF
Parameter Value
PH 8.33
TSS (mg/l) 370
TDS (mg/l) 9800
COD(mg/l) 8100
Temperature 30

5.8 Result and discussion
5.8.1 Result
Effects of the amount of activated carbon dose at 5hr and 30

Table 5.2 result on different amount of activated carbon dosage
Amount of
AC Parameters
PH TSS(mg/l) TDS(mg/l) COD(mg/l)
5gm 8.21 352 9720 7920
10gm 8.19 330 9660 7800
15gm 8.17 302 9580 7620
20gm 8.16 280 9465 7561
25gm 8.15 240 9320 7365
Graphical Representation of analytical data

12000
10000
8000
TSS
6000
TDS
COD
4000
2000
0
5 10 15 20 25
Figure 5.5 Effects of different amount of adsorbent on COD,TDS and TSS

pH
8.22
8.21
8.2
8.19
8.18
8.17
pH
8.16
8.15
8.14
8.13
8.12
5gm 10gm 15gm 20gm 25gm
Figure 5.6 Effects of different amount of adsorbent on pH

Analyzing the effect of contacting time at 10 gm of adsorbent load
Table 5.3 result of contacting time on waste water
Time (hr)
Parameters
pH TSS(mg/l) TDS(mg/l) COD(mg/l)
1 8.28 360 9748 7932
2 8.25 351 9726 7911
3 8.24 346 9692 7863
4 8.18 333 9663 7817
5 8.16 321 9613 7762

12000
10000
8000
TSS
6000
TDS
COD
4000
2000
0
1 2 3 4 5
Figure 5.7 Effects of time on COD,TSS and TDS
Ph
8.3
8.25
8.2
Ph
8.15
8.1
1 2 3 4 5
Figure 5.8 effects of time on pH
5.8.2 Discussion
The result obtained showed that activated carbon was the most efficient in reducing COD,TDS
and TSS of the waste sample.

The result also shows that after treated the waste mixture with activated carbon the value of
COD, TDS and TSS are reduced. The concentration of TDS, COD and TSS decrease
significantly in the treated effluent as compared to the untreated mixture. The reduction of COD
was from 8100mg/l (waste mixture )to 7365mg/l(treated mixture),the reduction of TSS was from
370mg/l(waste mixture) to 240mg/l(treated mixture),the reduction TDS was from
9800mg/l(waste mixture )to 9320mg/l(treated mixture). And when the amount of activated
carbon increases the extent at which waste removed from the water is improved. This indicates
that the greater amount of activated carbon would affect the treatment process. At the same time
the amount of TSS,TDS and COD decreases and PH slightly decrease And The result obtained
showed that the settling time had greater impacts on the removal of COD,TDS,TSS, pH . The
result shows that when the settling time passes the result of TSS, TDS and COD of the waste
effluent decrease .this means that when the settling time increases the reduction of COD,TDS
and TSS also increase
5.9 Conclusions and Recommendation
5.9.1 Conclusion
In this paper attempt have been made for studying the removal of pH, TDS, TSS and COD from
BALF effluent by using activated carbon as adsorbent. From the experimental finding it has been
observed that activated carbon can be used as an effective adsorbent for the reduction of TDS,
TSS and COD from industrial effluent. And the adsorption can be influenced by adsorbent mass and
contact time. The amount of activated carbon and the settling time increases the reduction of TDS, COD
and TSS also increases.
5.9.2 Recommendation:
It is better to Use other adsorption agent like Amino-functionalized Nano porous silica SBA-3
instead of activated carbon. Because of high adsorption capacity. And before treating the waste
water by the adsorbent the company builds the primary and secondary waste Water Treatment
Plant, which is beneficiary in both economic and environmental aspects. Instead of hydrogen per
oxide it is better to use other chemicals like MgSO4 in order to increase the surface modification. And
in the company there is no commercial activated carbon in order to compare the adsorbent capacity of
activated carbon produced from waste paper with that of commercial one. Due to the shortage of time I

didn‘t check the effect of time on each adsorbent load and also I didn‘t check the effect of amount of
activated carbon dosage on different time. and due to the shortage of mixer I didn‘t check the agitation
effects on the adsorbent

Reference
1. Chowdhary P, Raj A, Bharagava RN (2018) Environmental pollution and health hazards
from distillery wastewater and treatment approaches to combat the environmental.
Chemosphere 194: 229-2
2. APHA 1989. Standard Methods for the Examination of Water and Wastewater. American
Public Health Association, 17thedn.
3. the company supervisors, operators, employees, company manual and Google files
4. APHA-AWWA-WPCF (1998). Standard methods for the examination of water and
wastewater.
5. Nandy, T., S, S., and Kaul, S. (2002). ―Wastewater management in cane molasses
distillery involving bioresource recovery.
6. Mattson J. S. and Mark H. B., activated carbon, New York: Dekker, (1971).
7. Smisek M. and Cerney S., Active carbon: manufacture, properties and applications,
Elsevier:
8. Khalili N. R., Campbell M., Sandi G. and Gola J., Production of micro and mesoporous
9. activated carbon from paper mill sludge.
10. Marsh, H. and Menendez, R. In Introduction to Carbon Science
11. Kenneth, C. L., Nasrin, R. K., Marta, C., Giselle, S. and Thiyagarajan, Microstructural
analysis of activated carbons prepared from waste paper sludge
12. Mall ID, Mishra N, Mishra IM (1994). Removal of organic matters from
sugar mill effluent using bagasse fly ash activated carbon.
13 the company boiler, water treatment and distillery manual

Balezaf Alcohol

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Balezaf Alcohol

Uploaded by

Copyright:

Available Formats

BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

INTERNSHIP REPORT AND PROJECT BY

DURATION OF INTERNSHIP ( FEB. 7—JUNE 11)

ADVISOR MR. SOLOMON .H

SUBMISSION DATE 22 /10/2010 E.C

Name of Academic Adviser Signature Date

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page I

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page II

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page III

2.3.4 Process description of boiler section .......................................................................................... 24

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page V

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page VI

Figure 1.1 organizational structure of the company ...................................................................... 7

Figure 5.7 Effects of time on COD,TSS and TDS ....................................................................... 70

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page VII

Table 1.1 main product of the company…………………………………………4

Table 5.1 characterization of waste mixture in BALF ………………………….67

Table 5.2 result on different amount of activated carbon dosage………………..68

Table 5.3 result of contacting time on the waste water…………………………..69

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page VIII

BOD ……………………………………………………………. Biological oxygen demand

COD …………………………………………………………….chemical oxygen demand

HFO ……………………………………………………………….Heavy fuel oil

PHE………………………………………………………………plate heat exchanger

TDS………………………………………………………………total dissolved solid

TSS………………………………………………………………total suspended solid

Local language international language

Heads 3…………………………………………………………… Isopropanol

Fusil oil……………………………………………………………..amyl alcohol

Light oil ……………………………………………………………ethyl acetate

Heads 2 main………………………………………………………methanol (condensed)

Heads 2 vent …………………………………………………….…methanol (uncondensed)

Copper column……………………………………………………..rectifying section rectification column

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page IX

some facts about alcohol:

 It's a colorless liquid.

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page 1

1.2 Historical background of the company

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page 2

1.4 Mission of the company:

• Works to create and sustain a combination of individual excellence (manifested in purposeful,

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page 3

 To expand its market share

 To maintain its leadership I the liquor industry of the country

 To make at most effort to enter foreign markets as widely

1.6 Values of the company:

1.7 Main product of the company

Table 1.1 main product of the company

No Types of liquors Concentration, %

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page 4

1.8 Main customers and end users of the company:

Main customers of pure alcohol

 Bereket liquor factory

 Asnake liquor factory

 Senay liquor factor

Main customers of liquors

 Bars, restaurants and hotels

 Rural peoples and community of Ethiopia

Main customers of denatured alcohol

1.9 Over all organization and work flow the company

BAHIRDAR INSTITUTE OF TECHNOLOGY(BIT) Page 6

Production and marketing Finance department HR

security Compound cleaner