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JIMMA UNIVERSITY
JIMMA INSTITUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL ENGINEERING
Host campany:RORANK BUSINESS SHARE COMPANY
Final internship report and project paper
MIHERET GIRMA ID- RU3255/11

TIZETATEREFE ID-RU4310/11
11/1/2022
JIMMA, ETHIOPIA
Final internship report (RORANK BUSINESS SHARE COMPANY)
Declaration
We hereby humbly declare that the presented report of internship titled “final internship report on
Rorank business share company and project paper” is uniquely prepared by us after the completion of
three months’ work experience at Rorank business S.C.
We also confirm that, the internship report is only prepared for fulfillment of internship time. It might not
be used with the interest of opposite party of cooperation. To the best of knowledge we didn’t breach any
copyright act intentionally. We would be happy to provide you with any clarification regarding the report.
Miheret Girma ID RU3255/11
Tizeta Terefe ID RU4310/11
Adviser name Signature Date

Mr.Amare.A /company advisor ________________ __________________
Mr. Dereje.D /company advisor ________________ __________________
Mr. Hailegebriel.G /company advisor ________________ __________________

Ms.Ebise. G/university advisor ________________ __________________
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ACKNOWLEDGEMENT
First of all, we would like to thank the almighty GOD for giving everything that is important for us
to complete our internship program efficiently. Next we are thankful to our family for giving strength
with in financial and moral support. We would also like to thank Jimma University, Jimma Institute
of Technology for creating the internship program opportunity and our advisor Ms.Ebise G. for
helping and advising us during the internship program. We would also like to thank Rorank business
Share Company for giving chance to get in to the company & its workers and chemists who are very
willing to show us around and give their material and ideal support without hesitation. The people
we would like to thank the most from the company are Mr.Amare.A, Mr. Dereje.D, Mr.
Hailegebriel.G(Shift engineers). They were the most helpful.
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ABSTRACT
Rorank Alcohol and Liquor Factory (RALF) is a share company of foreign share- holders. The
factory was established in 2013 G.C in Amhara region, north shoa zone in debre birhan and uses
molasses as raw material for the production of potable and technical alcohols. It consists of a
distillery and filling plants. Its installed daily production capacity is 18,000 liters of potable alcohol
and about 5000 liters of various liquors. The current production capacity was found to be on
average 250 liters of 95 % alcohol grade technical alcohols per day when the factory was running
normally.
In fermentation material balance were employed so as to determine the amount of molasses and
water necessary to prepare one batch and then to determine the fermentation efficiency. In
distillation unit material balance were used to determine the amount of alcohol produced within
their alcohol grade in each column. The molasses, water and energy consumption were found. The
total alcohol loss from the fermentation, decantation and distillation process units was significant.
The stillage from analyzer column is found a severe source of water pollution.
The project was done on production of alcohol from fruit waste (Banana, orange mango). We
choose this title because of the alcohol production in RORANK BUSINESS SHARE COMPANY
is based on the raw material (molasses) that have been received from sugar factories’ there is no
sugar factories around the area and also the company spends a lot of money to receive and, to
transport molasses Even after receiving the raw material the molasses have a bad smell in the
environment and also the spent wash after fermentation couldn’t be disposed because of its color
and it also affects aquatic animals so as we observed the main challenge and problem of the
company is raw material.
So, the main aim of this project production and characterization of ethanol from fruit waste.
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Contents
ACKNOWLEDGEMENT .................................................................................................................................................. ii
ABSTRACT .................................................................................................................................................................... iii
LIST OF TABLES ............................................................................................................................................................ vi
LIST OF FIGURES .......................................................................................................................................................... vi
ABBREVIATIONS.......................................................................................................................................................... vii
CHAPTER ONE ............................................................................................................................................................... 1
1. INTRODUCTION ........................................................................................................................................................ 1
1.1 Historical Background ......................................................................................................................................... 1
1.2 Vision and mission of the factory...................................................................................................................... 2
1.3 Products of the company ................................................................................................................................... 2
1.4 Main customers or end users of its products or services ............................................................................. 3
1.5 Job organization and structure of the company................................................................................................. 3
1.6 Scope and Purpose of the Factory ...................................................................................................................... 6
CHAPTER TWO .............................................................................................................................................................. 7
2. GENERAL PROCESS OVERVIEW OF THE FACTORY .................................................................................................... 7
2.1 How we get into the company ........................................................................................................................... 7
2.2 Fermentation technology ................................................................................................................................... 8
2.3 Fermentation process (Methods) ..................................................................................................................... 11
2.4 Major process step in fermentation ................................................................................................................. 12
2.5 Stages of fermentation ..................................................................................................................................... 14
2.6 Fermentation process description ................................................................................................................... 15
2.7 Factor affecting fermentation process ............................................................................................................. 16
2.8 Equipment used................................................................................................................................................ 24
2.9 Distillery House ................................................................................................................................................. 25
2.10 Types of equipment ........................................................................................................................................ 26
2.11 Process description......................................................................................................................................... 28
2.12 Distillation column control ............................................................................................................................. 61
2.13 Liquor Preparation and Bottling House .......................................................................................................... 62
2.14 Evaporator and Drying House ........................................................................................................................ 67
2.15 Waste Water Treatment Plant and Water Treatment Plant .......................................................................... 71
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2.16 Water Treatment ............................................................................................................................................ 74
2.17 Challenges....................................................................................................................................................... 78
CHAPTER 3 .................................................................................................................................................................. 79
3. BENEFITS OF INTERNSHIP ....................................................................................................................................... 79
3.1 Benefits ............................................................................................................................................................. 79
CHAPTER 4 .................................................................................................................................................................. 82
4. PROJECT ON PRODUCTION OF ALCOHOL FROM FRUIT AND VEGETABLE WASTE ................................................. 82
4.1 Introduction ...................................................................................................................................................... 82
4.2 Statement of Problem ...................................................................................................................................... 82
4.3 Objectives of The Project.................................................................................................................................. 83
4.4 Scope ................................................................................................................................................................ 83
4.5 Methodology .................................................................................................................................................... 84
4.6 Experimental Procedure ................................................................................................................................... 85
4.7. Characterization of product ............................................................................................................................ 90
4.8 Material Balance ............................................................................................................................................... 91
4.9. Effect of Parameters On Ethanol Production .................................................................................................. 98
4.10 Conclusions and Recommendation .............................................................................................................. 100
REFERENCE ............................................................................................................................................................... 102
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LIST OF TABLES
Table 1 Dver all flow of distillation ............................................................................................................ 31
Table 2 Distillation columns operating temperature and pressure .............................................................. 61
Table 3 Ethanol yield and concentration ..................................................................................................... 97
Table 4 Optimum condition for different parameter on optimum yield of ethanol from experiment ......... 99
LIST OF FIGURES
Figure 1:Structure of the company ................................................................................................................ 4
Figure 2: Molasses ......................................................................................................................................... 8
Figure 3: Content of molasses ....................................................................................................................... 9
Figure 4: Decantation tank .......................................................................................................................... 29
Figure 6 flow sheet of distillation process ................................................................................................... 60
Figure 5: Bottle washer................................................................................................................................ 65
Figure 6: Bottling house .............................................................................................................................. 67
Figure 7: Waste Water treatment plant at Rorank S.C company................................................................. 74
Figure 8: Cooling tower ............................................................................................................................... 77
Figure 9: Fruit wastes .................................................................................................................................. 86
Figure 10: Autoclave ................................................................................................................................... 86
Figure 11: Media prepared .......................................................................................................................... 88
Figure 12: Simple distillation ...................................................................................................................... 89
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ABBREVIATIONS
BC Business Company
BOD Biochemical Oxygen Demand
CEO Chief executive officer
COD Chemical Oxygen Demand
COO Chief operating officers
DAP Di-ammonium phosphate
ED Extracted distilled
FD Fan distributor
ID Intermediate distribute
IST Intermediate settling thanks
o
Bx Degree Brix
PH power of hydrogen
RALF Rorank alcoholic liquor factory
RO Reverse osmosis
TSS Total Suspend Solids
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CHAPTER ONE
1. INTRODUCTION
1.1 Historical Background
Ethanol is a clear liquid alcohol group compound with a chemical formula CH3-CH2-OH and which is made by the
fermentation of different biological materials. It is a clear, colorless chemical compound made from the sugars
found in crops such as corn, sugar beets and sugarcane
Rorank liquors factory was located at Amhara regional state 113 km away from Addis Ababa city in the
northern Shewa Debre Birhan. The factory was established in 2013 G.C to fulfill domestic requirements
of alcohol and liquors.
This company start to produce alcoholic liquor in 2014G.C and starts with initial cost of 25 million Birr
and .Now day this company reached in cost of 358 million Birr. Rorank Alcohol and Liquor factory have
got a big investment to produce pure Alcohol.
The company also established newly modified plant in 2016G.C and normally start to work in 2016G.CThis
newly Rorank business share company liquor factory comprises six interconnected plants, Fermentation,
Distillery, evaporate, boiler, dryer and bottling plants. But the dryer and evaporator plants are not properly
in working duo to the lack of steam. The distillery plants, produces two types of products potable alcohol
and industrial (technical) alcohol. Pure (potable) alcohol is the primary raw material production of liquors
for local consumption whereas industrial (technical) alcohol was sold as denatured alcohol. .The raw
material used at this factory was molasses which is obtained from state owned sugar factory. Factories but
starting from last year the raw material has been changed to TA (technical alcohol) originated from
methera
Rorank liquor Factory (RALF) is a pioneer sole government owned state enterprise in manufacturing &
selling liquors and alcohol products in our country. Now a day the Company has 175 permanent, 40
temporary & 40 contract employees. This popular factory had been consistently mining a wealth of
experience in industrial production and marketing of pure alcohol, denatures alcohol a variety of liquors.
And thus, Company is currently working with the capacity (50,000) litters/day, of potable alcohol 96.3.0%
v/v.
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1.2 Vision and mission of the factory

Rorank B.C alcohol and liquor factory attempts to produces and distribute alcohol and various liquor
products based on customer demand.
• The vision of the factory is to improve the quality of its products, expand its market share and
maintain its leadership in the liquor industry of the country as well as to make at most effort to
enter foreign markets.
• The mission of the factory is to produce internationally recognized quality liquor products to the
taste of the customer.
1.3 Products of the company

The main products or service of RALF are; pure alcohol, denature alcohol, and liquors
1.3.1 Pure alcohol
Which is the first product in the distillation process has an alcohol content of 96.3%. It is used for many
purposes. Among which some of them are: -
• Production of different liquors
• Preparation of medicine
• Laboratory work
• Perfumes and cosmetic production
• Production of chemical and plastic products
1.3.2 Denature alcohol
This is also one of the products in the distillation process with an alcoholic content of 95%. This product is
used for many purposes. To mention few of them are: -
• Clinical purpose
• Beauty salons and barberries
• Cleaning electrical equipment
• Cooking purpose
• Band saws in ripping logs into boards and cutting very thick wood.
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1.3.3 Liquors
Liquors are drinkable alcohol, which prepared in bottling house by mixing soft water, flavor, coloring,
sweetener or syrup and pure alcohol. In Rorank S.C there are different liquor products are produced. These
are given below
GIN
SUPERMINT
OUZO
DOUBLE OUZO
FERNET
VODKA
LEMON
WHITE APPRATIVE
COGNAC
RED APPRATIVE
PINE APPLE
1.4 Main customers or end users of its products or services

• Domestic consumption in Ethiopia
• Hospitals and clinics
• Different factories as solvent
1.5 Job organization and structure of the company

Every area of work has its own structural organization of professionals and labor works according to
their level and work experience to perform the work responsibly and effectively. The number of people
increases when we go from to bottom of the skeleton of the structure. So as to perform its tasks super
eagle alcoholic beverage plant has the following structure of workers (1).
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Figure 1:Structure of the company
Chief Executive
Officer Chief operating officers are responsible for the management of a wide variety of departments in
a manufacturing business. The COO must be knowledgeable in the manufacturing operations and the
needs and capabilities of each department. In some manufacturing organizations, chief operating officers
are responsible for overseeing human resources, sales and other administrative departments in the
company. Chief operating officers must prepare reports for the CEO on the day-to-day activities in each
department. The reports should evaluate the performance of each department in a company, including
whether they met production goals and budgets. The COO and CEO work together to develop strategies
for each department's success. Chief operating officers allocate the resources department manager need,
such as funds, labor and equipment, to ensure they meet their goals. COOs conduct regular meetings
with department managers to remain up to date on the status of each area of the company. They might
also develop and implement department budgets.
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General Manager
General Managers usually have more responsibility than plant managers, with the biggest differences
being the teams they manage and profit-and-loss responsibility. A general manager usually has a greater
scope of management and responsibility than a plant manager. While a sole responsibility for running
the day-to-day operations of a manufacturing site, a general manager handles this role along with other
tasks, most notably, the profit and loss responsibility for his business segment. A general manager has
production supervisors reporting to him that spend time on the plant floor to keep the operations running
smoothly. While a general manager makes important operations decisions, he often manages other
aspects of the business, including sales, finances or supply chain.
Plant manager
Plant managers are the people who watch over and organize the daily operations of manufacturing plants
and similar places. Plant managers oversee employees, production and efficiency, to make sure the plant
is running smoothly, quickly, efficiently and safely.
Plant managers might oversee an entire location, or just a section of the operation. Plant managers
maintain optimum operation by assigning workers, creating and keeping work and production schedules,
hiring and training new employees, collecting and looking through data to find places of waste or places
of improvement, keep an eye on worker safety and plant safety, monitor the production equipment to
make sure that it stays in good working order, and repair or replace the equipment when needed. Plant
managers are the last line of defense for quality control when the item manufactured leaves the plant.
They communicate with other departments or parts of the plant to make sure everything runs smoothly.
A plant manager typically is responsible for the operations of a manufacturing plant. Although the sales
dollars for his plant may be a metric for success, he often does not have direct control over customer
orders and sales. Rather, he is more focused on operating the plant efficiently and ensuring that orders
are made and shipped on time.
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Operational manager
Leads day to day management of facility operations and maintenance, specifically activities associated
with quality, production, costs, capital expenditures, assets, and human capital development to ensure
productions goals are met in a safe and environmentally efficient manner Operational manager Lead
change and execute strategic priorities to meet business objectives. Develop direct reports through career
development, coaching and performance management to maximize effectiveness of resources
Collaborate with key business stakeholders to identify opportunities that will optimize and improve
facility performance engage leadership to achieve production/quality results that align with business
plans and standards.
1.6 Scope and Purpose of the Factory

The factory has been placed around 10,000m2 near north of chacha river in wider area such that 800m
away in west of the town. This wider factory compound have to hold many man powers through each
plant units, like Boiler, distillery, fermentation, bottling including cleaners, gardeners, security keepers,
erector and top management sector workers as we have seen later in the above.
The main purpose of the factory is:
• To improve the quality of the product for the satisfaction of its customer.
• To produces enough job opportunity for the society.
• To be more profitable.
• To grow the country's economy.
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CHAPTER TWO
2. GENERAL PROCESS OVERVIEW OF THE FACTORY
2.1 How we get into the company

Jimma University, Jimma Institute of Technology has an internship program for students who are qualified
to the requirements asked by the institution. First we received a letter from university industry linkage
(UIL) to request different companies to get their willingness to do our internship program. RALF is one of
the company we reported the letter. They accept and encourage our group to involve in all tasks to make
the internship program more practical and theoretical. Then we meet shift engineers, to visit all-round the
company. After rounding understood the working place the company, they promised our group to help in
every aspect during our entire duration in the company.
2.1.1. Work Pieces that we have been executing during the internship period
Some work tasks that we have been executing during the internship period were:
• Observing the works that have done in the company
• Seeing how unit operation are work
• Know what raw material use for production of Alcohol.

2.1.2 Raw materials
Ethanol either for the purpose of fuel or consumption as drinkable beverage uses sequential steps to change
the raw sugar or starch in the raw material in to ethanol alcohol even though the conversion is held during
fermentation. These raw materials which serve as the source of these starches or sugars which can be
decomposed to ethanol alcohol directly include molasses which can be either cane molasses or beet
molasses as sources of sugars as one group. In the other group starch containing raw materials are known
and these groups are mainly cereals such as wheat, barley, sorghum, maize etc.
In most countries where sugar factories are erected, molasses is the main profitable raw material due to its
high sugar content which can be decomposed to ethanol and carbon dioxide with the action of yeasts.
Ethanol plants can be erected simultaneously to these sugar factories or independently. In Rorank B.C
alcoholic factory molasses is the raw material for the source of this convertible sugar from which it is
received from Wonji Showa sugar factory. The other main raw material which involves from the beginning
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to the final process of beverage ethanol plant is water for which at the initial stage its application is for the
sake of molasses dilution. Molasses from the source is dense black raw material such that its solid content
is about 75-80 brix (the solid content of the solution by volume) with a specific gravity of 1.45-1.6. This
solidus raw material is impossible for fermentation process if dilution is not performed with water. This is
because that it will not be suitable for yeast movement during propagation as well in fermentation.
Therefore, water is essential at this stage. The amount of water needed depends on the initial brix of the
molasses, if the brix is less the water required will be small unless high.
The lightest and more diluted molasses supplied from sugar factory is at the state of high component of
convertible sugar which also requires a small amount of water for dilution. This phenomenon is called low
brix preparation or dilution process. Therefore, these characteristics of molasses enable to be effective cost
wise even if it may be more difficult for transportation process. The raw materials applied in ethanol plant
are urea, DAP, and yeast, sulphuric acid, essences (flavors), colorings, citric acid, white crystallized sugar.
The purpose of these raw materials can be summarized in the following graphic design.
2.2 Fermentation technology

Raw materials of fermentation are
2.2.1 Molasses
Figure 2: Molasses
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Molasses is the dark, sweet, syrupy byproduct made during the extraction of sugars from sugarcane and
sugar beets. During the sugar-making process, juice extracted from sugarcane or sugar beets is boiled down
until the sugars crystallize and precipitate out. The syrup left over after crystallization is referred to as
molasses. Typically, sugar cane juice undergoes three cycles of boiling and crystallization to extract as
much sugar as possible. With each successive cycle, the leftover molasses contains less sugar.
content of molasess
sucrose 30-35
water 12-20
reducing sugar 10-15
ash 10-12
Figure 3: Content of molasses
Molasses is a heavy viscose material which contains sucrose, fructose & glucose at a total concentration of
50 to 60% of which about 70% sucrose and 30% is invert. The color, taste and composition of molasses
vary with the stage of extraction. The impurities imparted to the molasses are from ash content and coloring
matter. The colors of final molasses is usually a dark brown or reddish brown, partially due to
caramelization of the sugar content and also due to chemical or thermal degradation of some of the non-
sugar constituents.
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2.2.2 Yeast
A microscopic single-celled fungus capable of converting sugar into alcohol and carbon dioxide. There are
two forms of active yeast the
✓ instant, dry, powdered type and the active,

✓ Moist variety which comes in blocks.
The powdered yeast is about three time’s active than the moist one. When the temperature in the
fermentation tank has reached 25 to 30-degree Celsius se adjust the thermostat or light dimmer control to
hold it in this range.
Saccharomyces cerevisiae
Saccharomyces cerevisiae, also known as brewers or baker's yeast, has been a key ingredient in baking,
winemaking, and brewing for millennia. It derives its name from the Latinized Greek meaning “sugar
fungus” because it converts sugars and starches into alcohol and carbon dioxide during the fermentation
process.
Saccharomyces cerevisiae is a species of yeast. It has been instrumental to winemaking, baking, and
brewing since ancient times. It is the microorganism behind the most common type of fermentation. S.
cerevisiae cells are round to ovoid, 5–10 μm in diameter. It is reproduced by a division process known as
budding. The process in which it produces ethanol is one way this yeast converts glucose into energy.
There are two ways Saccharomyces cerevisiae breaks down glucose.
 Aerobic respiration: requires the presence of oxygen.

 Anaerobic fermentation: when oxygen is not present the yeast. The net result of this is two ATP,
and it also produces two by products; carbon dioxide and ethanol.
2.2.3 Urea (CO (NH2)2)

Urea is an organic compound with chemical formula CO (NH2)2. This amide has two –NH2 groups joined
by a carbonyl (C=O) functional group. Urea serves an important role in the metabolism of nitrogen-
containing compounds by animals and is the main nitrogen-containing substance in the urine of mammals.
Urea is widely used in fertilizers as a source of nitrogen and is an important raw material for the chemical
industry
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2.2.4 DAP ((NH4)2PO4)

Used as phosphorus and nitrogen source for yeast as a food during propagation and fermentation.
2.2.5 Sulfuric acid

Sulfuric acid also known as vitriol with molecular formula H2SO4. The concentrated H2SO4 of 96%
concentrated is added at the unit of low brix mash preparation. These is because of
✓ To restrict the production of bacteria & the movement of unwanted yeast & ready it for
fermentation.
✓ To make the good & comfortable yeast PH & quality
✓ To reduced unnecessary yeast that share the fermentation yeast used to ferment ale.
✓ Creates good environment for yeast & give good quality for alcohol
2.2.6 Water
In fermentation process water plays high role to dilute high molasses brix (78-85%) to the needed low brix.
Water is also used as a general cleaning. The nature of water to be used for producing alcohol is very
important. Its composition is very much dependent on the condition of soil. The dissolved matters influence
the production of alcohol thus the following points must be attentively controlled hardness of water, iron
content of water, manganese content of water, odor and taste of water.
2.3 Fermentation process (Methods)

There are two types of fermentation processes: -
1. Batch fermentation process and
2. Continues fermentation process.
In the batch fermentation process specific volume of mash is fermented at one time. The process continues
until maximum yields are obtained. Fermentation is then stopped, the products recovered, the equipment
cleaned and sterilized, and another batch started.
In continuous fermentation process, additional mash is added continuously or more commonly, at short
time intervals to the fomenters. And there is recycling of yeast
At Rorank SC Alcoholic liquor factory Batch fermentation process is in on operation by erecting five tanks
which sizes 232,000 litters.
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2.4 Major process step in fermentation

The major process steps in alcohol production by fermentation are: -
 Raw material l(molasses)preparation
 Yeast propagation (inoculums preparation)
 Final fermentation
❖ Raw material preparation
Molasses treatment
Molasses can be treated by diluting and heating. Dilution is simply the addition of water to adjust the
amount of sugar in the mash or (ultimately) the amount of alcohol in the beer. It is necessary because
the yeast, used later in the fermentation process can be killed by too great a concentration of alcohol.
The objective of dilution is to end up with a beer as close to (but, not more than) 10%alcoholwhen
fermentation is complete. The optimum dilution, then, is a compromise between the highest alcohol
concentration and the point where the particular yeast strain being used is killed. at Rorank SC alcoholic
liquor factory there are two types of Dilution
❖ Yeast propagation (inoculums preparation)
When left to stand, sugar products, either at natural concentrations (fruit juices) or diluted normally
starts to ferment by the action of yeasts. The microorganisms which may already be present in the
product, originates from the atmosphere or adheres to the container. The type and yield of fermentation
depends among to their things, on the naturally occurring genus and species responsible. However, in
order to ensure regular and healthy fermentation and a high yield, a suitable quantity of active yeast
with a high alcoholic potential must be intentionally added to the liquid to be fermented. This quantity
of yeast is known as the inoculums or "Leaven”. Before adding the inoculums, it is essential to check
that the medium to be fermented provides suitable conditions for the yeasts: -
• Appropriate sugar concentration

• Adequate supply of nutrients
• PH of 4.5to5.0
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• Temperature not exceeding 300C
The inoculums should consist of a rich and active suspension of the most efficient type of yeasts for
the required purpose.
The inoculums to be used should have to be:
 Abundant
 Active
 The inoculums should be abundant
Although a single yeast cell is able to produce millions of cells in a very short period of time, it is
essential to use abundant inoculums to ensure that the medium is quickly dominated by yeast. This
prevents competition from bacteria, which generally reproduces much faster than yeasts. Ideally the
inoculums added should be of sufficient quantity so as to provide the medium with the sufficient
number of yeasts.
This would result in a state of saturation with dual advantages: -

 Minimal risk of bacterial contamination
 Minimal sugar dissipation forming new yeast cell protoplasm.
❖ The inoculums must be active
Not only do the inoculums have to be abundant, it must be active as well. There can be no doubt that
the preparation of the inoculums is vital to the success of alcoholic fermentation technology, affecting
both the quantity and quality of the final product. Before using yeasts for the preparation of inoculums,
the selection of appropriate yeast is essential for effective fermentation process.
❖ Final fermentation
Although fermentation is only one step in the production process, it is the key step. Fermentation is a
biochemical process in which enzymes produced by microorganisms transform an organic substance
into ethanol. The substance used in ethanol fermentation is a six-carbon sugar.
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2.5 Stages of fermentation

After yeast has been introduced in the mash, fermentation precedes in a number of characteristics stages
which manifest themselves in changes of the physical appearance of the fermenting mash. The mash,
liberation of carbon dioxide and heat is generated. Finally, at the end of fermentation the yeast settles
down leaving more or less clarified fermented mash.
In the first stage of fermentation, some hours after pitching (addition of yeast) the time limit depending
on the amount and vigor of the yeast inoculums and the temperature. The dirt cover appears on the
surface of the mash surrounded by a ring of white foam on the periphery which gradually spreads over
the whole surface. This indicates the beginning of the fermentation and the carbon dioxide liberated in
the process holds the yeast in suspension.
The foam increases and becomes compact more resembling a cauliflower hence called cauliflower
stage. It is supported by the rising carbon dioxide set free in the fermentation. The gravity falls rapidly
with simultaneous quick rate of rise in temperature.
The third stage is marked by greatest activity showing the maximum multiplication of yeast, decrease
the gravity and rise in the temperature in which the foam reaches its maximum height.
This is followed by reduced activity of the yeast due to the exhaustion of the main part of the sugar.
The decreased liberation of carbon dioxide gas is not sufficient to support the high foam which begins
to collapse. The yeast agglomerates in lumps and sinks. Only a thin cover of fine foam remains on the
surface. The fermentation is now almost completed and marks the fifth stage of fermentation.
2.5.1 Abnormal fermentation

Sometimes large quantities of yeast accumulate in lumps at certain places, which subsequently
disintegrate causing increased local activity and the liberated carbon dioxide bubbles so rapidly as to
give the mash the appearance of the boiling. This is called “Boiling Fermentation” and can be cured by
vigorous rousing. Sometime so happens that fermentation comes to a standstill before the mash has
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completely fermented. This phenomenon is known as resting fermentation and may due to the weekend
condition or limited fermenting power of the yeast or sudden drop in the temperature of the mash. The
former can be remedied by adding fresh yeast and later by restoration of proper temperature.
2.5.2 Foaming
Excessive foaming is an undesirable feature which may be caused by number of factors, in particular
the characters of the mash itself. Rapidly fermenting yeast, low acidity, high fermentation temperature
and bacterial contamination are additional contributory causes. Foaming is rarely due to one single
cause. Selection of different strain of yeast, or addition of yeast containing a large proportion of old
cells, and lowering of the initial PH of the mash help in reducing foam. High foam can be made to
subside by the addition of fats, lard or oils.
2.6 Fermentation process description

From storage molasses is transferred to holding tankers and water is added to prepare diluted molasses.
The diluted molasses with low brix (15o brix) is transferred to yeast propagation tank and filled 70%of
it. Then nutrients urea and DAP added as per recommended dose which is 8kg each for 45,000 litters
tank and sulphuric acid to maintain PH 4.5 to 5. Filtered air will be admitted by sparging for agitation
and as oxygen supplement for cell growth. Now a suitable quantity (8kg) of active yeast with a high
alcoholic potential will be added to the liquid to be inoculated. This quantity of yeast is known as the
inoculums. Brix, temperature and PH are Checked and noted with in 2-hour time interval.
When brix of the yeast propagation vessel falls to half of initial setup brix (which is around 8obrix) and
cell concentration and activity were reached to desired value, then this vessel is ready to transfer to the
fermenter.
Initially fermenter tanks are cleaned with water. All pipelines are cleaned. When fermenter is cleaned,
the dilute molasses with high brix feed of desired brix to fermenter particularly 25o-28o brix is started.
20%level of dilute molasses in fermenter was filled. The Yeast culture (propagated yeast) from
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propagation tank was transfer to the fermenters. After transferring the Yeast culture (propagated yeast)
after waiting for 30 minutes to 1.0 hr. feeding dilute molasses of desired brix was started to the
fermenter and when level of fermenter is 80% the dilute molasses feed to the fermenter was stopped.
The volume of fermentation tank is 232,000 litters.
After that the following activity was done. Foaming maintained by spraying antifoam. No excess
amount of antifoam should add to fermenter as excess antifoam will form a covering layer around the
yeast cell and restrict the yeast activity. Fall of brix, PH, temperature and alcohol percentage was record
every two hours in lab analysis log book. Record was checked by shift chemist to take the corrective
action.
Maintain the pH of fermenter up to 4.5 to 5. Low PH will indicate the formation of byproduct. To
increase the PH, dilute ammonia can be used. High PH will indicate the decrease in yeast activity. By
adding dilute H2SO4, PH can be maintained. Retention time of fermenter depends upon the quality of
molasses, yeast activity and maintain the parameters. Once the fall of brix remain constant for 4.0 hrs.
It assumed that fermentation is completed.
This fermented wash (tela) will be transferred to decanters so as avoid the sludge transfer to the
distillation column. After transfer of fermented wash to decanters was completed, cleaning of the
fermenter as said above was done to keep ready for next batch fermentation.
2.7 Factor affecting fermentation process

Factors that affect fermentation process are: -
❖ Temperature
❖ Amount of sugar (brix of the medium)
❖ PH
❖ Duration of fermentation
16
2.7.1 Temperature
As the fermentation progresses, the temperature of the wash tends to rise because the reactions taking
place are exothermic. Cooling units are required to prevent the temperature from exceeding 30-32 0C.
Anomalies in the temperature curve imply the presence of fermentation irregularities. Hence, a very
slow rise in temperature points to the deficiencies in the Inoculums (insufficient inoculums, infection,
lack of adaptation to the medium on the part of the yeast), while too rapid a rise indicates that the wash
is excessively rich in sugar or that the initial temperature of the wash was too high
2.7.2 Amount of sugar

A small amount of sugar spends up the fermentation process but the alcohol content decrease. Large
amount of sugar will slow down the fermentation process but the alcohol content inside the fermented
wine increase.
2.7.3 PH
The PH decreases during fermentation (once it has reached the true level of acidity), particularly during
the supplementary fermentation phase. Fermentation is taken to be normal if the PH drop does not
exceed 20% of the initial PH.
2.7.4 Duration of fermentation
The fermenting period is dictated by several factors: the nature of the beer, the fermentation process,
the fermenting energy of the inoculums, the volume of the inoculums, etc. Excessive prolongation of
the fermenting period indicates an excessive sugar level, inadequate or insufficient inoculums, bacterial
infection or that the temperature in the fermenting room is too low. On the other hand, a very short
fermenting cycle may indicate a paralysis of yeast activity, resulting from contamination, a mash that
is very low in sugar or other nutrients, Or excessive temperature.
Material balance on fermentation
A). mass balance in the dilution tank for low brix (140BX)
Using in the laboratory test to dilute 0.135 Litter of raw molasses to reduce 140BX from 760BX we use
0.865L of water. So, by using the above laboratorial scale we can determine the overall water and
17
molasses content in the dilution tank for low brix. 0.135L of raw molasses + 0.865L of water = 1 L of
dilute molasses. For law brix we use 40,000 L of dilute molasses solution in large yeast propagation
tank
0.135𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 = 1 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
𝑋 = 40,000𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
𝑋 = (0.135𝐿 ∗ 40000𝐿)/ 1
𝑋
= 5,400 𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑎𝑟𝑒 𝑢𝑠𝑒𝑑 𝑓𝑜𝑟 𝑙𝑜𝑤 𝑏𝑟𝑖𝑥 𝑝𝑟𝑒𝑝𝑎𝑟𝑎𝑡𝑖𝑜𝑛 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑢𝑠𝑒𝑑 𝑖𝑛 𝑙𝑎𝑟𝑔𝑒 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑖𝑜𝑛 𝑡𝑎𝑛𝑘.
𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 𝑙𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 (𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛) − 𝑙𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 40000𝐿 – 5400𝐿 = 34,600𝐿
𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
= 34600 𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟. 𝑆𝑜, 𝑡𝑜 𝑑𝑖𝑙𝑢𝑡𝑒 5400𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑤𝑒 𝑢𝑠𝑒 34600 𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
𝑤𝑎𝑡𝑒𝑟 = 34600𝐿
Low brix
Raw molasses=5400L dilutio n ta nk 𝐷𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 =?
Now we have to convert the above volume values into its appropriate mass
Change the volume of molasses into mass
𝑀 𝑚 = 𝑉𝑚 ∗ 𝜌𝑚 Where : Mm = Mass of molasses
Vm = volume of molasse =5400 ρm
density of Molasses = 1450kg/m3 = 1.45kg/L

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𝑀𝑚 = 5400𝐿 ∗ 1.45𝑘𝑔/ 𝐿 𝑀𝑚 = 7830𝑘𝑔 𝑜𝑓 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
Change the volume of water into mass
𝑀𝑤 = 𝑉𝑊 ∗ 𝜌
Where: Mw = mass of water VW= Volume of
water = 34600L ρW =density of water =
1000kg/m3 = 1kg/L
𝑀𝑤 = 34600𝐿 ∗ 1𝑘𝑔/𝐿
Mw = 34600kg of water
dilution molasses, Dm=?

low brix dilution
molasses=7830 kg
Assume: There is no accumulation of mass
There is no generation and consumption of mass
The operation is steady state
Therefore, the mass balance will be
𝑀 𝑖𝑛 = 𝑀𝑜𝑢𝑡
𝑀 𝑤 + 𝑀𝑚 = 𝐷𝑀
(34600 + 7830) 𝑘𝑔 = 42430𝐾𝑔
𝐷𝑀 = 42430𝑘𝑔 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
19
B) Mass balance for propagation tank
42430kg of low brix dilute molasses are added in the propagation tank and 8kg of raw yeast, 8kg of
DAP ,and 8kg of urea are added in the propagation tank to propagate the yeast
Total diluted molasses which is add into the propagation tank
(Mt) is 42430Kg
Where Md =diluted molasses
Urea(U)=8kg Yeast propagation

tank
DAP=8kg Yeast (Py ) =?
Yeast(y)=8kg
Assumption:
There is no accumulation, generation, disappearance of mass and consumption of mass no addition
of H2SO4,
𝑀𝑖𝑛 = 𝑀 𝑜𝑢𝑡
𝑀𝑡 + 𝐷𝐴𝑃 + 𝑈 = 𝑃𝑌
𝑃𝑌 = {42430 + 8 + 8 + 8} 𝑘𝑔
𝑃𝑌 = 42454𝑘𝑔 𝑜𝑓 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑒𝑑 𝑦𝑒𝑎𝑠𝑡 𝑎𝑟𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑖𝑛 𝑙𝑎𝑟𝑔𝑒 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑖𝑜𝑛 𝑡𝑎𝑛𝑘.
C) Mass Balance for High Brix Dilution
Using in the laboratory test to dilute 1.2 Litter of raw molasses high brix the concentration of sugar
from 25-280brix we use 3.8L of water. We can determine the overall molasses and water content in the
high brix dilution.
1.2𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 + 3.8 𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 5𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
20
For fermentation we use 190,000L of high brix dilute molasses
1.2 𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 = 5𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
𝑋 = 190,000𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
𝑋 = 45,600𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑎𝑟𝑒 𝑛𝑒𝑒𝑑𝑒𝑑 𝑓𝑜𝑟 ℎ𝑖𝑔ℎ 𝑏𝑟𝑖𝑥
𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 − 𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠
𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 190,000𝐿 − 45600𝐿
𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 144,400𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
𝑆𝑜, 𝑡𝑜 𝑑𝑖𝑙𝑢𝑡𝑒 45,600𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑤𝑒 𝑢𝑠𝑒 144,400𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
W=144,400L of water molasses dilution Dm=?
M=45600L of molasses High brix dilution
𝐶ℎ𝑎𝑛𝑔𝑒 𝑡ℎ𝑒 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 𝑖𝑛𝑡𝑜 𝑚𝑎𝑠𝑠
𝑀𝑚 = 𝑉𝑀 ∗ 𝜌𝑀
Where Mm = Mass of molasses
VM = Volume of molasses = 45,600L
ρM=Density of molasses = 1.45kg/L
Mm = VM* ρ M Mm =
45,600𝐿 ∗ 1.45𝑘𝑔/𝐿
𝑀𝑚 = 66,120𝑘𝑔 𝑜𝑓 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠.
21
Change the volume of water into mass
𝑀𝑤 = 𝑉𝑊 ∗ 𝜌𝑊
Where Mw = mass of water VW =
Volume of water = 144,400L
ρW= Density of water = 1kg/L
𝑀𝑤 = 𝑉𝑊 ∗ 𝜌𝑊
𝑀𝑤 = 144,400𝐿 ∗ 1𝑘𝑔/𝐿
Mw = 144,400kg of water
Assume there is no accumulation, disappearance generation and consumption of mass
Therefore, 𝑚𝑎𝑠𝑠 𝑖𝑛 = 𝑚𝑎𝑠𝑠 𝑜𝑢𝑡
𝑊 + 𝑀 = 𝐷𝑀
144,400𝑘𝑔 + 66,120𝑘𝑔 = 𝐷𝑀
𝐷𝑀 =
210,520𝐾𝑔 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 (ℎ𝑖𝑔ℎ 𝑏𝑟𝑖𝑥)
𝑫)Mass Balance for Fermentation.
42,454kg of propagated yeast and 210,520kg of high brix dilute molasses are added in the fermentation
tank for the preparation of wine (fermented mash)
High brix dilute molasses
22
𝐷𝑚 = 210,520𝑘𝑔 L=9 m eter

Fermentation
𝑃𝑦 = 42,454𝑘𝑔
tank
Accumulation
The total height of the fermentation tank is 9 meters
To calculate the volume of accumulation first determine the radius of cylinder the total volume of
fermentation tank (Vft) is 230,000L (230M3)
𝑉𝑓𝑘 = 𝜋𝑟2𝐿
230𝑚3
= 9 ∗ 3.14 ∗ 𝑟2 𝑟2
= 8.13𝑚2 𝑟 = 2.85𝑚
Then we have to calculate the accumulation of fermentation tank
𝑉𝐴 = 𝜋 ∗ 𝑟2ℎ
𝑉𝐴 = 3.14 ∗ (2.85𝑚) 2 ∗ 0.25𝑚 = 6.37616𝑚3 =
6376.16𝐿 𝑊ℎ𝑒𝑟𝑒 𝑉𝐴 𝑖𝑠 𝑡ℎ𝑒 𝑣𝑜𝑙𝑢𝑚𝑒 ℎ=
0.25 𝑚 𝑓𝑒𝑟𝑚𝑒𝑛𝑡𝑒𝑑 𝑤𝑖ne which is accumulated in tank.
The density of accumulated fermented wine is 0 .979kg/L, so the mass of accumulation is given by
𝑀𝐴 = 𝑉𝐴 ∗ 𝜌 𝐴
𝑀𝐴 = 6376.16𝐿 ∗ 0.979𝑘𝑔/𝐿
23
𝑀𝐴 = 6,242.6𝑘𝑔 𝑜𝑓 𝑎𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛
Assume: There is no generation, the fermentation tank is cylindrical, disappearance and
Consumption of mass, but there is accumulation of mass.
𝑀𝑎𝑠𝑠 𝑖𝑛 = 𝑀𝑎𝑠𝑠 𝑜𝑢𝑡 + 𝐴𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛
𝑀𝑎𝑠𝑠 𝑜𝑢𝑡 = 𝑀𝑎𝑠𝑠 𝑖𝑛 − 𝐴𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛 (𝐴)
𝐹𝑀 = (𝐷𝑀 + 𝑃𝑌) − 𝑀𝐴
𝐹𝑀 = (210,520𝐾𝑔 + 42454) 𝑘𝑔 – 6,202𝑘𝑔
𝐹𝑀 = 246,772𝑘𝑔 𝑜𝑓 𝑓𝑒𝑟𝑚𝑒𝑛𝑡𝑒𝑑 𝑚𝑎𝑠ℎ (𝑤𝑖𝑛𝑒) 𝑎𝑟𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑
2.8 Equipment used

❖ Pumps: - Gear pump- used to pump the highly viscous molasses from storage in to a shell and
tube heat exchanger.
❖ Centrifugal pump: - used to pump propagated wine and high brix in to holding tanks and then
to fermentation tanks.
❖ Mixer (Agitator): -used to mix molasses and dilution water as they flow in together.
❖ Propagation tank (propagator): -it is a tank where the propagation takes place. Has a volume
of 43,000 liters?
❖ High brix tanks: -used to contain high brix molasses.
❖ Fermentation tank: - are tanks where the high and low brix molasses are brought together to
start the fermentation. There are five fermentation tanks.
❖ Air Blower: -used to blow air in to the bottom of propagation tank and holding tanks.
❖ Saccharo meter: -used to measure the sugar content of the solution.
❖ Ebullio meter: -used to measure the alcohol content of fermented wine.
❖ PH meter: used to measure acidity of the medium
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❖ Valves: -to control the flow and pressure during transportation

2.9 Distillery House
2.9.1 Introduction
Distillation is the most important technical process for the separation of liquid or gaseous mixture in
to different component. And its principle depends on thermodynamic property of the mixture. The aim
of distillation process is the separation of component from its mixture and this process to happen there
must be boiling point (volatility) difference between the components of the mixture, if no they will
form azoetrope.
Distillation is used for the separation or purification of mixtures of alcohol and water by using the
different evaporation rates, or boiling points, of the water and the alcohol. As alcohol evaporates at a
lower temperature, it vaporizes first and, therefore, its separation will start before the water evaporates.
The fermented mash (tela) may contain a number of other components such as essential oils, esters,
carbon dioxide and other alcohols such as methyl, propyl, butyl and amyl. All of these components are
undesirable or undrinkable and must be substantially removed from the mixture. This process involves
dividing tela into a number of parts depending on when that part is produced during the distillation
process. These parts may be separated during the initial distillation process or during a re-distillation
of alcohols by diluting with pure water (spirits from the first distillation run). Rorank BC has special
distillation columns like degasifying, analyzer, aldehyde, extractive distillation, stainless steel, copper
and methanol column to undergo distillation and re-distillation process in order to remove such
impurities and to have very pure potable alcohol. The first components that are produced during
distillation are known as heads. Heads are the highly volatile components with a lower boiling point
than ethanol. The heads vaporize first and therefore condense first. Heads consist mainly of low
molecular weight material or highly volatile compounds. Heads may contain a number of poisonous
components, including high levels of methanol, which can be hazardous to health. Usually, the heads
25
are not desired in the finished product and are run to a different receiver from the rest of the alcohol.
Once all the heads have been removed the pure alcohol transferred in to pure alcohol storage tank.
2.10 Types of equipment

In distillery house there are different types of equipment’s these are: -
1. Distillation tower
There is no distillation process without distillation tower. Distillation tower has two parts
✓ The upper part or rectifying section
✓ Lower par or stripping section Basically distillation columns divided in to two these are:
I. Tray type column

Tray column utilize a pressure and temperature differential to separate the product. For most tray
columns, the weir holds liquid level of each tray liquids enters from the down comer of the tray above.
The vapor must overcome this liquid head to move up the column.Tray column performs well in high
liquid and vapor holding. Trays have higher pressure drop than packed, and it also have high resistance
to corrosion.
II. Packed columns

The other type of column is packed type of distillation column. Packed column utilizes packing to
contact between the phases (liquid-vapor) on the surface. Packed column performs well at low pressure;
low liquid and low vapor loading that make packed column have the most efficient in these terms. At
high flow parameters the capacity and efficiency can significantly reduce, also in heavy fouling
application and corrosive condition. Packed column has less pressure drop than tray column and it
reduces foaming since it generates thin film instead of fine droplets for mass and heat transfer.
N.B. there is only one tray column analyzing column and the rest are packed column.
2. Heat exchanger, Condenser, and Re-boiler
26
 The purpose of heat exchanger is to cool down the hot liquid

 The purpose of condenser to cool down the vapor. And we can recycle back some of the vapor
to the column. In this plant the type of condenser is shell and tube.
 Re-boiler is used as heat exchanger and the difference from other heat exchanger we create
steam from the cold feed, in our case 8% ED product and the steam will condense goes back to
steam plant.
3. Steam trap
It used to trap steam from 8% hot alcohol liquid that comes from the re-boiler.
4. Tank
There are basically two types of tank these are decantation tank and storage tank Decantation tank used
to store fermented tela until the sludge separate from its wine. And it used to store fermented tela.
Storage tank used to store liquid like; katikala (raw alcohol), pure alcohol denature alcohol and so on.
5. Valves
Valves are used to control flow rate of tela, raw alcohol, steam, cooling water and etc. in this plant
basically there are four types valve, and these are:
a) Gate valve: the gate valve is a general service valve used primarily for on-off, non-throttling
service. The valve is closed by a flat face, vertical disc, or gate that slides down through the
valve to block the flow. Gate valves working by inserting a dam (“gate”) in to the path of the
flow to restrict it, in a manner similar to the action of a sliding door. Gate valves are more often
used for on/off control than throttling.
b) Butterfly valve: is a valve which can be used for isolating or regulating flow. The closing
mechanism takes the form of the disk.
c) Check valve: check valves are two port valves, meaning they have two opening in the body,
one for fluid to enter, and the other for fluid to leave. Check valve allows the fluids to pass in
one direction only. Although they are available in a wide range of sizes and costs, check valves
generally are very small, simple, or in expensive. Check valves works automatically and most
27
are not controlled by a person or any external control; accordingly, most do not have any valve
handle or stem. The important concept in check valve is the cracking pressure which is the
minimum upstream at which the valve will operate.
6. Sensors
The function of sensor is to detect the change in the required parameter. The parameter which is
controlled by this device in distillation house is temperature.
7. Flow meter and pressure gauge

Flow meter is used to read flow rate of liquids (i.e. tela, katikala, water to ED and pure alcohol) and
pressure gauge used to read the steam pressure also used to measure the pressure of fluids.
8. Alcohol meter
Alcohol meter is used to measure the grade quality of alcohol or concentration in the mixture.
2.11 Process description

In Rorank SC alcoholic liquor factory the production of pure alcohol starts at decantation tank. And
for clarity it is better to separate the process in to two, these are:
 First stage, in which katikala produced from fermented tela. In this stage there are three
columns, these are; degasifying column, analyzing column and aldehyde column.
 Second stage, in this stage the process is the production of pure alcohol from katikala, in this
stage process pass through four column and these are; extractive distillation column, stainless
steel column, copper column and methanol column.
28
2.11.1. First stage process

A. Decantation
The first stage process starts at decantation tank. In the decantation tank the fermented tela that comes
from fermentation house store in it. As we said in the equipment description part of this report, the
purpose of decanter tank not only storage of tela but also used as a separation of wine from its sludge.
The separation process takes place due to gravitational force. And in actual case the time required for
the separation is about 24 hour.
Figure 4: Decantation tank
After decantation process takes place, the separated tela will heated around 70-80oc by passing through
copper main condenser shell side to condense the vapor coming from the copper columns, which is in
tube side. And if the tela attain the temperature in between 70-80oC it introduced into degasifying
column, unless it is heated by spent wash that comes from analyzing column then return back and enters
in to degasifying one. And the type of heat exchanger is plate.
29
B. Degasifying column
Degasification is the removal of dissolved gases from liquids. The heated tela from the heat exchanger
transported through flow meter to degasifying column, the degassing capacity is about
15,000 lit per hour, but the factory don’t work always with this flow rate i.e. the working flow rate of
degasifying column depend on different factor like weather and steam generation capacity, tela
concentration in decanter tank and the market demand.
Degasifying column used to remove chemical which has smell and chemicals which can’t condense
easily like carbon dioxide (co2). Degasifying column operated by feed temperature i.e. there is no heat
(steam) addition. Alcohol feed concentration is around 8-12% and the rest is more water and the
mixture boiling point is near to water boiling point temperature. So at this feed temperature, unwanted
chemicals will escape through degassing vent line.
The degassing vapor products will pass through heat exchanger to cool down and the condensed
chemicals store in degassing head storage and the un-condensed vapor will released as a degassing
vent. The degasified tela leaves from the bottom of this column send to analyzer column by making a
loop. In this factory degassing head flow rate around 5 liters per hour and degassing vent temperature
is 20-260C.
N.B. since there is no flow meter and concentration sensor around degassing vent line, so we don’t
know its flow rate or concentration.
30
Mass Balance for degasifying column
Table 2.1.over all flow of distillation

Product, by product, column Flow rate m3/h, L/h Grade(alcohol content)V/V
Wine 8-16m3/h 6-12

Katikala 2 40-67
Hot water 4 0
Lease water -- 0
Pure alcohol 8-10 96.5
Degasifying head 50L/h 60
Aldehyde head 50 95
Extractive distillation head 100 70
Light oil 70 70
Fusel oil 70 70
Copper m&v 50 95
Methanol head 60 95
Spent - 0
Ed bottom product - 8-9
important information used in calculation
Flow rate of wine =12000L/h
Flow rate of katikala=2000 L/h
Flow rate of ED diluted alcohol =3600L/h
Flow rate of ED dilute vaporized alcohol=11187.82kg/hr
Flow rate of pure alcohol=816.5L/h
Flow rate of hot water =9571.5L/h
31
The fermented mash or wine of 242,266.77kg is inter into the degasifying column in a volume flow
rate of 12000L/h and 50L/h of degasifying vent are collected, and the mass of fermented mash are
244,972kg
Degasifying head=50L/h
Degasifying column
12000 L/hr. To analayzer
Change the volumetric flow rate into mass flow rate Mass of fermented mash
𝐹𝑚 = 𝑉𝑚 ∗ 𝐷𝑚
𝐷𝑚 (𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑒𝑟𝑚𝑒𝑛𝑡𝑒𝑑 𝑤𝑖𝑛𝑒) 𝑖𝑠 𝑔𝑖𝑣𝑒𝑛 𝑏𝑦
1/𝐷𝑚 = 𝑋𝑤/𝐷𝑤 + 𝑋𝑎/𝐷𝑎 = 0.92/1𝑘𝑔/𝐿 + 0.08/0.789𝑘𝑔/𝐿 =
𝐹𝐷 = 0.979𝑘𝑔/𝐿
𝐹𝑚 = 12000𝐿/ℎ ∗ 0.979𝐾𝑔/𝐿
Fm=11748Kg/hr.
Mass flow rate of degasifying head
𝑀 𝑑 = 𝐷𝑑 ∗ 𝑉𝑑
1/𝜌𝑑 = 𝑋𝑤/𝜌𝑤 + 𝑋𝑎/𝜌𝑎
1/𝜌𝑑 = 0.30/1𝐾𝑔/𝐿 + 0.70/0.789𝐾𝑔/𝐿 𝜌𝑑
= 0.84𝐾𝑔/𝐿
𝑀𝑑 = 50𝐿/ℎ ∗ 0.84𝐾𝑔/𝐿
𝑀𝑑 = 42𝐾𝑔/ℎ
32
Where Md is the mass flow rate of degasifying head.
ρd is density of degasifying head.
ρw is density of water
ρa is density of alcohol
The degasifying head contains 70% of alcohol and 30% of water. the material balance in a degasifying
column is calculated as shown below
Fermented mash=11,748kg/hr. degasifying degasifying head=42 kg/hr.

column To analyzed (At)=?
𝑀𝑎𝑠𝑠 𝑖𝑛𝑝𝑢𝑡 = 𝑚𝑎𝑠𝑠 𝑜𝑢𝑡 𝑝𝑢𝑡
𝐹𝑚 = 𝑀𝑑 + 𝐴𝑡
𝐴𝑡 = (11748 − 42) 𝐾𝑔/ℎ = 11706𝑘𝑔/ℎ
C. Analyzing column
It consists of a series of metal plates with hole punched in them and baffles to control the liquid levels
on the plates. The analyzer column operated under a temperature of 88-9000C 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. In the
fermentation process there is a formation of cas Of from the addition of sulphuric acid in the molasses
which contain calcium ion. This calcium sulphate forms a scale when heat is supplied in the analyzer
column.
33
The degasified tela 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 spent wash(nonalcoholic component)with
higher boiling point. Some amount of alcohol together with steam might leave with spent wash.
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 increased pressure reduces the fouling formation in the plate heat
exchanger. The vapor leaves through the top of analyzing Column with improved alcoholic grade is sent
to aldehyde for further purification. If there is an alcohol in the spent wash this might be caused by sufficient
steam is not supplied or excessive fermented wash is supplied to the column.
Pressure might increase at the base of the column due to: -
❖ Excessive steam due to sudden increase in the boiler steam pressure

❖ Failure of pressure reducing valve
❖ Scale build up on the trays
The other problem shown in this column is flooding. Which occurs as the vapor flow is higher
compared to liquid flow so liquid is unable to comes down through down comers and also by
simultaneousincreaseofbottompressureandthedecreaseoftoppressureduetoabnormalliquid buildup of
scale on tray and the feed rate is more than vapor flow rate.
34
Analyzer column is designed to handle a dirty liquid liable to foam and is fitted with man doors for
cleaning purposes.
D. Aldehyde column
Aldehyde column is the last tower in the first stage process, and in this process our desire is to produce
raw alcohol (katikala). It is a packed type column operates under a temperature of 74- 760c 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 aT5vent from the last heat exchanger. The condensing vaporing 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 (katikala) with alcohol grade 35- 50%v/v.
It passes through plate type heat exchanger to be cooled and stored in the shift tanker.
Mass Balance for the Analyzer and aldehyde column.
The fermented mash or wine which leave from the degasifying column and entered into the analyzer
column in a mass flow rate of 14,680.8Kg/hr. consequently the vapor which leaves from the analyzer
entered into Aldehyde column. The aldehyde head leaves with the flow rate of 50 L/hr. and also
vinasses are removed as by product as shown below.
35
Aldehyde aldehyde
head=50L/hr
Fermented mass =11,706kg /hr. analyzer column Alcohol(XAA)=0.95column
Alcohol(Xm)=0.08 Katikala=2000L/h
vinasses(Fv)
alcohol(Xk)=0.58
Change the volumetric flow rate of aldehyde head into mass flow rate.
1/ ρAA= XA/ ρ A +XH2O/ρH2O
Because in the aldehyde alcohol 95% alcohol and 5% of water that means it is a solution of alcohol and
water.
1/ ρ A.A=0.95/0.789 (kg/L) + 0.05/1(kg/L)ρAA = 0.797kg/l = 797kg/m3 = density of aldehyde alcohol
and volume flow rate of aldehyde head is 50L/h ṁAA = VAA *ρ A.A ṁAA = 50 L/hr. * 0.797kg/L ṁAA
=39.85 Kg/hr. Over all mass balance
Mass in =Mass out
Fm= MAA+Fk+Fv
11748Kg/h=39.85KG/h +Fv +Fk…………………… (1)
Component balance:
Xm*Fm =Xv*Fv +Xk*Fk +XAA*FAA
Assuming there is no alcohol concentration in vinasses i.e. (Xv=0)
36
Then 0.08*11748Kg/h =0 +0.67*Fk + 0.95*39.85Kg/h
Fk = 1,346.24Kg/h
Then substitute Fk in equation one
11748Kg/h=39.85Kg/h+1,346.24Kg/h +Fv
Fv =10361.9Kg/h
To determine the mass flow rate of vaporized alcohol we can do material balance on analyzer column.
Fermented mash=11706kg/h
analyzer
alcohol(Xm)=0.08 column VA=?
vinasse(Fv)
Fv=10,116.8kg/hr
Therefore, the mass balance in the analyzer is Assume, in the analyzer there is no accumulation,
generation and disappearance of mass.
M Fm= + M VA +MF V
MVA = M Fm-MFv
MVA = 11748 kg/h– 10361.9 kg/h
MVA = 1386.1kg/h
37
Energy balances for analyzer column
QSF Qu
column
QST QSV
Where
QSF=the rate of sensible heat of the feed
QST=the rate of heat energy supplied to the
QSV= the rate of sensible heat of heat of vaporized alcohol
QVA= the rate of both sensible and latent heat of vaporized alcohol
Assumption
Heat loss in the column is negligible.
The energy for each tray is the same.
There is no chemical reaction inside the column.
The operation is operated at steady state.
The fermented mash is a mixture of water and alcohol.
The exist vinasses is as a waste water.
Given information
The initial temperature of the feed (fermented mash) is 250c
The mass flow rate of the feed is14680.8 kg/h

Where XA = Mole fraction of alcohol =
0.08
XW= Mole fraction of water = 0.92
CPA= Specific heat capacity of alcohol =

2.46 KJ/kg k
CPW = Specific heat capacity of water =

4.2 KJ/kg k
38
CpF=XA CpA +XW CpW
CpF = 0.08* 2.46KJ/kg k + 0.92 * 4.2KJ/kg k
CpF =4.06KJ/kg k
The for QF = ṁFCp ∆T
QF = 14680.8kg/hr. * 4.06KJ/kg k *(76-25) k
QF = 3,039,806.45KJ/h
The mass flow rate of the vaporized alcohol is 1719.1kg/h
The mass flow rate of vinasses is 12961.7kg/h
The maximum temperature of the analyzer is 90c
Energy on the feed (sensible heat)
QF=ṁ F CpF ∆T
Where
CpF= specific heat capacity of feed which is given by:
CpF=XA CpA +X w Cpw
CpF=XA CpA +XW CpW
CpF = 0.08* 2.46KJ/kg k + 0.92 * 4.2KJ/kg k
CpF =4.06KJ/kg k
CpF=XA CpA +XW CpW
39
CpF = 0.08* 2.46KJ/kg k + 0.92 * 4.2KJ/kg k
CpF =4.06KJ/kg k
For sensible heat
QS = ṁ VA*C PVA * ∆T
But C PVA =XACpA+XwCpw Where XA = 0.55
XW= 0.45
C PVA = XACpA+XwCpw
C PVA = 0.55 *2.46KJ/kg k + 0.45*

4.2KJ/kg k
QS = ṁ VA*C PVA * ∆T
QS = 1,719.1 kg/hr. * 3.243KJ/kg k (90-25)
For latent heat (QL)
QL = ṁ VA * h VA
40
2.11.2. Second stage process

In this stage the raw alcohol (katikala) produced in the first stage purified more to produce alcohol with
> 96.3% alcohol grade.
A. Extractive distillation (ED)column

Extractive distillation is a distillation in the presence of a miscible high boiling point relatively non-
volatile component, the solvent that forms no azoetrope with the other components in the mixture. It
used for mixtures having a low value of relative volatility, nearing unity. It uses a separation solvent,
which is generally non-volatile, has a high boiling point and is miscible with the mixture, but doesn’t
form an azeotropic mixture.
The solvent interacts differently with the components of the mixture there by causing the irrelative
volatilities to change. Extractive distillation column is a packed type column operated at a temperature
of 132-137oc 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 stain less steel rectification column which use data 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 132-1370c condenses by the water from the
stainless-steel column (T=70oc), then the water recycled back to the stainless-steel column as re-boiler.
Head 3 is collected 100L/h from the condenser then passes 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 because the solvent doesn’t form an azeotrope with it. The diluted alcohol
enters into the re-boiler and passes through the steam trap. The steam trap holds the steam and allows
41
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.
Mass balances for extractive distillation
Katikala alcohol entered into the extraction distillation column in a volumetric flow rate of 2000L/h
with in 4000L/h of water to produce dilute alcohol and 100L/h of head 3.
Water(W)4000L/hr Head3=100L/hr
Katikala alcohol(KA)
ED column
Vka=2000L/hr dilute alcohol=?
The change above volume flow rate into mass flow rate to calculate the mass balance katikala alcohol
flow rate is
ṁ𝐾𝐴 = 𝑉𝐾𝐴 ∗ 𝜌 𝐾𝐴
Where VKA = Volume flow rate of katikala alcohol = 2000L/hr
ρKA=density of katikala alcohol = 0.849kg/L ṁKA=
2000𝐿/ℎ ∗ 0.849𝑘𝑔/𝐿 ṁ𝐾𝐴 = 1698𝑘𝑔/ℎ
𝑊𝑎𝑡𝑒𝑟 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑖𝑠 ṁ𝑤 = 𝑉𝑤 ∗
𝜌 𝑤 𝑆𝑜 𝜌𝑤 = 1 𝑘𝑔/𝐿 𝑎𝑛𝑑 𝑉 𝑤 = 4000𝑙/ℎ ṁ𝑤 =
42
4000𝐿/ℎ ∗ 1𝑘𝑔/𝐿 ṁw=4000kg/ hr. mass flow rate of
Head3 is ṁ𝐻 = 𝑉𝐻 ∗ 𝜌 𝐻 𝐵𝑢𝑡 1/ 𝜌 𝐻 = 𝑋𝑊/ 𝜌 𝑊 +
𝑋𝐴/ 𝜌 A
Because head 3 has 70% alcohol and 30% water solutions
Where XW = mole fraction of water = 0.3
XA Mole fraction of alcohol = 0.7
M = Mass flow rate of head 3 1/ ρ H =
0.3/1(𝑘𝑔/𝐿) + 0.7/0.789 (𝑘𝑔/𝐿) 𝜌𝐻 =
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 ℎ𝑒𝑎𝑑 3 = 0.8423𝑘𝑔/
𝐿 𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 ℎ𝑒𝑎𝑑 3 𝑖𝑠
ṁ𝐻 = 𝑉𝐻 ∗ 𝜌 𝐻 ṁ𝐻
= 100𝐿/ℎ
∗ 0.8423𝑘𝑔/𝐿
𝑆𝑜, 𝐻 = 84.23𝑘𝑔/ℎ
The mass balance for the extractive distillation will be
water(ṁ)= 4000kg/hr H3=84.23kg/hr.
Katicala alcohol
ED column
Vka=1698kg/hr Dilute alcohol=?
Assume there is no generation, disappearance and accumulations of mass in the extraction distillation.
43
So, 𝑀𝑖𝑛 = 𝑀 𝑜𝑢𝑡
ṁ𝐾𝐴 + ṁ 𝑊 = ṁ𝐷𝐴 + ṁ 𝐻 ṁ𝐷𝐴
= ṁ𝐾𝐴 + ṁ 𝑊 − ṁ 𝐻 ṁ𝐷𝐴
= 1698𝑘𝑔/ℎ + 4000𝑘𝑔/ℎ
− 84.23𝑘𝑔/ℎ ṁ𝐷𝐴
= 5613.77 𝑘𝑔/ℎ
Energy Balance on the Extractive Distillation
Assumption
The entering katikala energy is negligible (QK=0)
The condenser is total condenser
The temperature of hot water before entering into the ED column 780c
Where:
Qhw = the rate of sensible heat of water
QS = The rate of heat energy supplied to the ED column in the form of steam
QD =the rate of both latent heat + sensible heat of energy of Dilute vaporized alcohol
Energy on the hot water
𝑄𝑊 = ṁ 𝑊 ∗ 𝐶𝑃𝑊 ∗ ∆𝑇
𝑄𝑊 = 9571.5𝑘𝑔/ℎ ∗ 4.2𝐾𝐽/𝑘𝑔 ∗ (78 − 25)𝐾
𝑄𝑊 = 21,306,15𝐾𝐽/ℎ 𝑜𝑓 ℎ𝑜𝑡 𝑤𝑎𝑡𝑒𝑟
44
Energy on the Dilute vaporized alcohol (8%) alcohol content and 92% water
𝑄𝐷𝐴 = 𝐿𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 + 𝑠𝑒𝑛𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡
For sensible heat
QS = ṁ DA*CPDA*∆T
The specific heat capacity of diluted alcohol is calculated as follows
𝐶𝑝𝐷𝐴 = 𝑋𝑤𝐶𝑝𝑤 + 𝑋𝐴𝐶𝑝𝐴
The diluted alcohol contains 8% of alcohol.
𝐶𝑝𝐷𝐴 = 0.92 ∗ 4.2 + 0.08 ∗ 2.46
𝐶𝑃𝐷𝐴 = 4.06𝐾𝐽/𝐾𝑔 𝑘
𝑄𝑠 = 11187.82 ∗ 4.06 ∗ (78 − 25)
𝑄𝑠 = 2,407,395.2𝐾𝐽/ℎ𝑟
𝑄𝐿 = ṁ 𝐷𝐴 (𝑋𝐴 ℎ 𝐴 + 𝑋𝑊 ℎ 𝑊)
𝑄𝐿 = 11187.82𝑘𝑔/ℎ𝑟{0.08 ∗ 838.3 + 0.92 ∗ 2257}𝐾𝐽/𝑘𝑔
𝑄𝐿 = 23, 981,136.9𝐾𝐽/ℎ𝑟
𝑄𝐷𝑎 = 𝑄𝐿 + 𝑄𝑠
𝑄𝐷𝑎 = (23,981,136.9 + 2,407,395.2) 𝐾𝐽/h
𝑄𝐷𝑎 = 26,388,532.65𝐾𝐽 = 26.4𝐺𝐽/ℎ𝑟.
Then the energy balance in the extractive column is
𝑄 ℎ 𝑊 + 𝑄𝑆 = 𝑄𝐷𝐴
45
𝑄𝑆 = 𝑄𝐷𝐴 − 𝑄 ℎ 𝑊
𝑄𝑆 = (26,388,532.65 − 2130615) 𝐾𝐽/ℎ
𝑄𝑆 = 24257917.5𝐾𝐽/ℎ = 24.3𝑔𝑖𝑔𝑎𝐽/ℎ 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑒𝑟𝑔𝑦 𝑎𝑟𝑒 𝑛𝑒𝑒𝑑𝑒𝑑 𝑓𝑜𝑟 𝑡ℎ𝑒 𝐸𝐷 𝑐𝑜𝑙𝑢𝑚𝑛
B. Stripping section(stainless steel column)

The stripping section and the rectifying section can be built as single vertical column. However in order
to make the total height shorter the two section built side by side interconnected with tubing to return
the output of the stripping unit to the rectifying section and vice versa. But it requires a pump to lift
liquid from the bottom of the second column to the top of the first. It is a packed type distillation column
with operating temperature of 75-82oc 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 fuel oil from
the alcohol mixture. The diluted alcohol feed below light and fuel 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 fuel oil (amyl alcohol) extracted at the top sides of the column and
collected each 40L/h with alcohol grade 70%v/v. The main product stream of this column is the top
vapor product and it is feed line for the next column i.e. copper column.
46
Mass balance for the stain less steel column
Fusel oil(Fo)=70L/hr.
Lightoil(LO)=70L/hr.
Copper main&vent=70L/hr.
Copper column Pure alcohol(

SS column
PA)=600L/h
Vaporized alcohol (VA)=?
Lease water(Lw)
Before calculating the mass balance, we should to be change every volume flow rate to mass flow
rate.
For light oil
V' = 70𝐿/
ℎ 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 ṁ =
𝜌 ∗ 𝑣′
But density of light oil is calculated as
1/𝜌 𝐿𝑂 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/
𝜌 𝑊 𝑊ℎ𝑒𝑟𝑒: 𝑋𝐴 = mole fraction of alcohol
ρA=density of alcohol XW= mole fraction of water

ρLO=density of light oil ρW=
47
density of water.
ρW=1000kg/m3 XW = 30%
= 0.3 XA = 70% = 0.7
ρA=789kg/m3
So 1/𝜌 𝐿𝑂 = 0.7/0.789𝑘𝑔/𝐿 ∗
0.3/1𝑘𝑔/𝐿 𝜌𝐿𝑂 = 0.8423𝑘𝑔/
𝐿 𝑇ℎ𝑒𝑛 ṁ 𝐿𝑂 = 𝑉′𝐿𝑂 ∗ 𝜌 𝐿𝑂 ṁ𝐿𝑂 =
70𝐿/ℎ ∗ 0.8423𝑘𝑔/𝐿 ṁ𝐿𝑂 =
58.961𝑘𝑔/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑓𝑜𝑟 𝑓𝑢𝑠𝑒𝑙 𝑜𝑖𝑙
ṁ𝐹𝑂 = 𝑉′𝐹𝑂 ∗ 𝜌 𝐹𝑂
Where: ṁFO= mass flow rate of fusel oil V'FO =
volume flow rate of fusel oil
ρFO =density of fusel oil
VFO = 70L/h
But density of fusel oil can be calculated as
1/ 𝜌 𝐹𝑂 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/ 𝜌 𝑊
Where XA= 0.7 XW = 0.3 ρW
=1000kg/m3 = 1kg/L
ρA=789kg/m3 = 0.789kg/L ṁ𝐹𝑂 =
𝑉′𝐹𝑂 ∗ 𝜌 𝐹𝑂
ṁ𝐹𝑂 = 70𝐿/ℎ ∗ 0.8423𝑘𝑔/𝐿

ṁFO=58.961kg/h
48
Mfo=58.961kg/hr
MLO=58.961kg/hr Mc(m&c)=39.85kg/hr
DA=5613.77kg/hr
Copper
Mw=4000kg/hr SS column column Mpa=512.85kg/hr
Lease water(W)
Assumption
There is no accumulation generation and generation consumption of mass
The operation is steady state
Over all mass balance
𝐷𝐴 = 𝐿𝑜 + 𝐹 𝑜 + 𝑊 + 𝐻𝑊
Where DA = Dilute alcohol
LO = light oil
W = water
FO = Fusel oil
𝐷𝐴 = 𝐿𝑜 + 𝐹 𝑜 + 𝑊 + 𝐻𝑊
5613.77 = 58.961 + 58.961 + 4000 + 𝑊
W=1495.848kg/h of hot water are removed from the stain less steel column
Lease water =1495.85kg/h
49
Energy Balance in the Stain less Steel Column
QVA
QF
SS.colum
n
QLw
steam( Qs)
The feed energy which enters in to the SS column is negligible.

SS the grade of alcohol which leaves from the SS column is 80%.
QF Heat loss is negligible Where:
QVA is the rate of both sensible and latent heat energy of vaporized alcohol.
QHL is the rate of sensible heat energy in hot water which is entered into ED column.
QS Is the rate of heat energy supplied to the column in the form of steam.
Q LW is the rate of sensible heat energy in the less water.
ṁVA = mass flow rate of vaporized alcohol

VA =596.5kg/h of vaporized alcohol are entering in to the copper column.
Energy on the vaporized alcohol
QVA=Latent heat + Sensible heat
Sensible heat(QS)
𝑄𝑆 = ṁ 𝑉𝐴 𝐶𝑝𝑉𝐴∆𝑇
= ṁ (𝑋𝐴𝐶𝑃𝐴 + 𝑋𝑊𝐶𝑃𝑊) ∆𝑇
596.5𝑘𝐺 ((0.8 ∗ 2.46 + 0.2 ∗ 4.2) 𝑘𝐽\𝑘 (80 − 75)) 𝑘
𝑄𝑠 = 8374.312𝑘𝐽
𝐿𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 (𝑄𝐿)
50
QL=ṁ VA h VA Where hVA=latent heat of vaporization

of vaporized alcohol.
𝑄𝐿 = ṁ 𝑉𝐴 (𝑋𝐴 ℎ 𝐴 + 𝑋𝑊 ℎ)
𝑄𝐿 = 596.5𝑘𝑔/ℎ (0.8 ∗ 838.3 + 0.2 ∗ 2257)𝑘𝐽/𝑘𝑔
𝑄𝐿 = 668031.9𝑘𝐽/ℎ
QVA = QS+QL
𝑄𝑉𝐴 = 8374.314𝑘𝐽/ℎ + 668031.9𝑘𝐽/ℎ
𝑄𝑉𝐴 = 676406.21𝑘𝐽/ℎ
Energy in the lease water (sensible heat energy)
𝑄𝐿𝑊 = ṁ 𝐶𝑝∆𝑇
𝑄𝐿𝑊 = 802,65𝑘𝑔/ℎ ∗ 4.2𝑘𝐽/𝑘𝑔 𝑘 ∗ 5𝑘

𝑄𝐿𝑊 = 16855.65𝑘𝐽/ℎ
The energy of hot water is calculated in ED column
QHW =2130615KJ/hr
So, the total energy balance in the stain less steel column is:
𝑄 = 𝑄𝑉𝐴 + 𝑄𝐿𝑊 + 𝑄𝐻𝑊
𝑄𝑆 = 676406.21𝑘𝐽/ℎ + 16855.65𝑘𝐽/ℎ𝑟
+ 2130615𝐾𝐽/ℎ 𝑄𝑆
= 2,823,876.86𝑘𝐽
/ℎ 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 𝑒𝑛𝑒𝑟𝑔𝑦 𝑖𝑠 𝑛𝑒𝑒𝑑𝑒𝑑.
C. 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 72-74oc and a pressure of 250-
51
450mbar.Itused to upgrade the concentration of more volatile component and it also used to separate
methanol from the mixture.
In this column the latent heat available increases the alcohol concentration as the vapor rise. 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, while large fraction refluxed(re-circulated) into the top of the column to
control the final concentration of the product output. This reflux flow is required to produce a down
ward flowing liquid stream in the section of the column. Without the reflux stream, there can be liquid
in the rectifying section of the column, which means no separation would occur in the rectifying
section. The condensate with low grade of alcohol pumped from the lower side of this column to the
upper side of stripping column by feint pump to strengthen its alcoholic content. The product coming
from this column transported in to methanol column.
The upper part of the column is made up of copper. Copper is preferable because it improve the quality
and taste of the alcohol by reacting with sulphate ion and form copper sulphate.
V'CV = volume flow rate of copper vent ρCV = density of copper vent
Density of copper ṁCV=𝑉′𝐶𝑉 ∗ 𝜌𝐶𝑉 𝑉′𝐶𝑉 = 50𝐿/ℎ
Where: - ṁCV = mass flow rate of copper vent vent can be calculated
1/ 𝜌 𝐶𝑉 = 𝑋𝐴 / 𝜌 𝐴 + 𝑋𝑊 / 𝜌 𝑊
Where XA = 0.95
52
XW = 0.05
1/ 𝜌𝐶𝑉 = 0.95/ 0.789 𝑘𝑔/𝐿 + 0.05 / 1𝑘𝑔/𝐿 𝜌𝐶𝑉 = 0.797𝑘𝑔/𝐿
ṁ𝐶𝑉 = 𝑉′𝐶𝑉 ∗ 𝜌 𝐶𝑉 ṁ𝐶𝑉 = 50𝐿/ℎ ∗ 0.797 𝑘𝑔/𝐿 ṁ𝐶𝑉 = 39.85 𝑘𝑔/ℎ 𝜌𝑃𝐴
= 𝑋𝐴/ 𝜌𝑃𝐴 + 𝑋𝑤/ 𝜌𝑤 𝜌𝑃𝑎 = 0.963/0.789 + 0.037/1 𝜌𝑃𝑎
= 0.795𝐾𝑔/𝐿
Hence the mass flow rate of alcohol is
ṁ𝑃𝑎 = 𝑉𝑃𝑎 ∗ 𝜌𝑃𝑎 ṁ𝑃𝑎 = 650𝐿/ℎ ∗ 0.795𝐾𝑔/𝐿 ṁ𝑃𝑎 = 516.75𝐾𝑔/ℎ
Where:-V'PA = volume flow rate of alcohol

= 650L/h
Mass flow rate for copper main
ṁ𝐶𝑚 = 𝑉′𝐶𝑚 ∗ 𝜌𝐶𝑚
𝑉𝐶𝑚 = 50𝐿/ℎ 𝜌𝐶𝑚 = 𝜌𝐶𝑉 = 0.797𝑘𝑔/𝐿 𝑇ℎ𝑒𝑛 ṁ𝑐𝑚 = 50𝐿/ℎ ∗ 0.797𝑘𝑔/𝐿 ṁ𝑐𝑚
= 39.85𝑘𝑔/𝐿
Mass flow rate for alcohol contains 96.5% of alcohol
ρPa=density mixed of alcohol = 0.789kg/L ṁ VA= CV+CM+Pa, 𝑉𝐴 = (39.85

PA
+516.75) 𝐾𝑔/ℎ =596.45 Kg/h
Component mass balance for copper column
Where VA =Vaporized alcohol
ρPA = 𝑋𝐴/ 𝜌𝑃𝐴 + 𝑋𝑤/ 𝜌𝑤 𝜌𝑃𝑎 = 0.963/0.789 + 0.037/1 𝜌𝑃𝑎 =
0.795𝐾𝑔/𝐿
53
Hence the mass flow rate of alcohol is
ṁ𝑃𝑎 = 𝑉𝑃𝑎 ∗ 𝜌𝑃𝑎 ṁ𝑃𝑎 = 650𝐿/ℎ ∗ 0.795𝐾𝑔/𝐿 ṁ𝑃𝑎 = 516.75𝐾𝑔/ℎ
Where:-V'PA = volume flow rate of alcohol

= 650L/h
ρPa=density mixed of alcohol = 0.789kg/L ṁ PA
Component mass balance for copper column
𝑉𝐴 = 𝐶𝑉 + 𝐶𝑀 + 𝑃𝑎, 𝑉𝐴 = (39.85
+516.75) 𝐾𝑔/ℎ = 596.45 𝐾𝑔/ℎ
D. Methanol column
It is a packed type column operate under a temperature of 68-70oc and pressure of 300-400mbar. And
it is used to separate methanol from the product since it is hazardous to health during drinking.
Methanol causes eye defect unless it is separated and removed from the produced alcohol. Unlike the
other columns the heat (steam) don’t supplied directly but it gains indirectly by using shell and tube
heat exchanger. The alcohol coming from copper column enters in tube side and steam in shell side
then the heated alcohol enters in to methanol column.
The more volatile component (methanol) rise in to the overhead two consecutive heat exchangers. The
vapors which do not condense in the first heat exchanger pass to the next one. The non-condensing gas
leaves off as a methanol vent from the last heat exchanger. The condensing vapor in the two heat
exchangers methanol head, amounting about 100 liters per hour, is drawn off from the two-heat
exchanger reflux loop and refluxed back to the column.
The product coming from this column which is pure alcohol having 96.8%v\v alcohol grade collected
at the lower side of the column and stored in pure alcohol storage tank. The following table shows
operating temperature and pressure range
54
When the pure ethanol has some amount of methanol then to separate methanol from ethanol the
products are entered into methanol column. In this column the input flow rate is not known
Pa=? PA=816.5L/hr.
methanol head(MH)=50L/hr.
Mass flow rate methanol headṁMH = V'MH * ρ MH
Where: - ṁMH = mass flow rate of methanol head V'MH =
volume flow rate of methanol head ρM= density of
methanol head
VMH = 60L/hr
But density of methanol head can be calculated as
1/ 𝜌 𝑀𝐻 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/ 𝜌 𝑊
Where XA= 0.963
XW = 0.037
1/ 𝜌 𝑀𝐻 = 0.963/0.789 + 0.037/1
55
1 𝐿
𝜌 𝑀𝐻 = 0.795 𝜌𝑊
ℎ
1000𝑘𝑔 1𝑘𝑔 789𝑘𝑔

= = 𝜌𝐴 =
𝑚3 𝐿 𝑚3
0.789𝑘𝑔
= ṁ𝑀𝐻
𝐿
= 𝑉 ′ 𝑀𝐻 𝜌 𝑀𝐻 ṁ𝑀𝐻
60𝐿 𝑘𝑔
= ∗ 0.795
ℎ 𝐿
ṁ𝑀𝐻 = 47.7𝑘𝑔/ℎ𝑟
Hence the overall material balance is
ṁ𝑃𝑎 = ṁ 𝑃𝐴 + ṁ 𝑀𝐻 ṁ𝑃𝑎 = 649.56 + 47.7𝐾𝑔/ℎ𝑟 ṁ𝑃𝐴 = 697.26𝐾𝑔/ℎ
Where
Pa = ethyl alcohol with less amount methanol
PA =pure ethyl alcohol free from methanol
1/ 𝜌 𝑀𝐻 = 𝑋𝐴/ 𝜌 𝐴 + 𝑋𝑊/ 𝜌 𝑊
Where XA= 0.963
XW = 0.037
56
1/ ρ MH =0.963/0.789 + 0.037/1 1/ 𝜌 𝑀𝐻 = 0.795 𝐿/ℎ ρW = 1000kg/m3 =
1kg/L ρA= 789kg/m3 = 0.789kg/L ṁMH = 𝑉′𝑀𝐻 𝜌 𝑀𝐻 ṁ𝑀𝐻 = 60𝐿/ℎ ∗
0.795 𝑘𝑔/𝐿 ṁ𝑀𝐻 = 47.7𝑘𝑔/ℎ𝑟
Assumption
There is no gain and loss of energy
The condenser is total condenser
Where
Pa = ethyl alcohol with less amount methanol
PA =pure ethyl alcohol free from methanol
Hence the overall material balance is
ṁ𝑃𝑎 = ṁ 𝑃𝐴 + ṁ 𝑀𝐻 ṁ𝑃𝑎 = 649.56 + 47.7𝐾𝑔/ℎ𝑟 ṁ𝑃𝐴 = 697.26𝐾𝑔/ℎ
Energy Balance for methanol Column
The energy of the cooling water and feed is negligible
The energy of other by products that is methanol head is negligible
The concentration of alcohol which leaves from the methanol column is 96.5% The energy of feed is
negligible
feed QVA Hot pure alcohol(QhPA)

methanol Condenser
QS hot water column
57
Where
QhPA is the rate of both sensible and latent heat energy of vaporized alcohol which is exited from
methanol column.
QS Is the rate of heat energy supplied to the column in the form of steam.
Q CPA is the rate of sensible heat energy of cold pure alcohol.
ṁVA = mass flow rate of pure vaporized alcohol ṁhPA=477Kg/h of vaporized
alcohol are exited in to the methanol column.
Energy on the vaporized alcohol
QhPA=Latent heat + Sensible heat
Sensible heat (QS)
𝑄𝑆 = ṁ 𝑉𝐴 𝐶𝑝𝑉𝐴∆𝑇 = ṁ (𝑋𝐴𝐶𝑃𝐴 + 𝑋𝑊𝐶𝑃𝑊)∆𝑇
496.45𝑘𝑔/ℎ((0.8 ∗ 2.46 + 0.2 ∗ 4.2) 𝑘𝐽\𝑘 (77 − 75)) 𝑘
𝑄𝑠 = 2788𝑘𝐽
Latent heat (QL)
𝑄𝐿 = ṁ 𝑉𝐴 ℎ 𝑉𝐴
Where h VA=latent heat of vaporization of vaporized alcohol.
𝑄𝐿 = ṁ 𝑉𝐴 (𝑋𝐴 ℎ 𝐴 + 𝑋𝑊 𝐻𝑊)
𝑄𝐿 = 596.45𝑘𝑔/ℎ (0.8 ∗ 838.3 + 0.2 ∗ 2257)𝑘𝐽/𝑘𝑔
𝑄𝐿 = 669240.758𝑘𝐽/ℎ
58
𝑄ℎ𝑃𝐴 = 𝑄𝑆 + 𝑄𝐿
𝑄ℎ𝑃𝐴 = 2788𝑘𝐽/ℎ + 669240.758𝑘𝐽/ℎ
𝑄ℎ𝑃𝐴 = 672028.821𝑘𝐽/ℎ
𝑇ℎ𝑒𝑟𝑒 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑒𝑛𝑒𝑟𝑔𝑦 𝑏𝑎𝑙𝑎𝑛𝑐𝑒 𝑏𝑒𝑐𝑜𝑚𝑒𝑠:
𝑄𝑠 = 𝑄 ℎ 𝑃𝐴 = 𝑄 𝐶𝑃𝐴 = 672028.82𝑘𝐽/ℎ
The initial temperature of cooling water is 15c
The final temperature of hot water is 80C
Then calculate the mass flow rate of cooling water is
𝑄ℎ = ṁ 𝐶𝑝∆𝑇 ṁ = 𝑄
ℎ𝑃𝐴/𝐶𝑝∆𝑇
ṁ = 672028.82/ (0.979 ∗ (80 − 15))

ṁ = 10560.67𝑘𝑔/ℎ
59
Figure 5 flow sheet of distillation process
60
Table 2.2.Distillation columns operating temperature and pressure

Column type Operating temperature (oc) Operating pressure
Degassing By feed temperature (70-80) -
Analyzer 88-90 0.18-0.3
Aldehyde 7o-72 -
Extractive distillation 95-99 2.8-3
Stainless steel 75-79 0.25-0.45
Copper 72-74 -
Methanol 70-75 0.2-0.4
Rorank S.C alcohol and liquor do not only produce pure alcohol but also denature alcohol. Denature
alcohol production start at extractive distillation in to methanol column
The feed material for this process are aldehyde heads product i.e. head one, ED condenser head
i.e. heads three, light oil, and fuel oil. The copper “condensers heads product i.e. main head and vent
head store as denature alcohol in denature storage tank.
2.12 Distillation column control

A continuous distillation unit separates a feed material containing several volatile components into a
distillate product and bottom product. Certain limits are usually set on concentration of key materials
in the distillates and in the bottoms and the equipment usually must handle a steam out of feed per unit
time. These specifications set the values of the following variables in the distillation operation.
 The feed rates
61
 The distillate composition

 The bottom composition
 The rate of distillate product
 The rate of bottom product
There are two crucial variables which the operator can control to obtain the desired operating
Condition. These are: -
 The reflux ratio
 Amount of heat input to the column.
The Other factors affecting the overall operation of the unit are: -
 Temperature of the feed
 The temperature of the reflux returned to the column and
 The location of the feed plate.
2.13 Liquor Preparation and Bottling House

This section of the factory consists of the bottle washing, liquor formulation and filling units.
Liquor are alcoholic beverages that can be prepared by the dilution of pure alcohol (96.3% alcohol by
volume) by adding some flavoring agents (essences), sweeteners (syrup), and mixing with the aid of
treated water. The major process takes place in this section is preparation of ingredients, mixing,
filtration, and storing in storage tank.
Bottling is the final unit operation for most alcoholic beverages like beer wine, whisky and so on which
produced bottled drinks. In rorank the bottles used are glass. The bottling section mainly contains
blending and packaging room. In blending room, the ethanol, syrup, raw water color and flavor are
mixed in the mixing thank to produce desired liquor while in packaging room washing, felling,
labelling is done.
Equipment used in packaging room are washer, sighter, packer, filler and conveyer.
62
Alcohol holding tank: this tank holds alcohol that are transported from distillery section with
concentration of 96.1-96.8 percent. There are two alcohol holding tanks with capacity of holding 10000
and 11000 litter.
Syrup holding tank: this type of tank holds dissolved sugar in water that is heated at 65 degrees
Celsius and mixed in syrup mixing tank.
Mixing tank: as a name indicates in this tank all the raw materials are mixed. Distilled alcohol, flavor,
Row water, color and syrup are well mixed in this section.
Syrup mixing tank: In this type of tank sugar and water are mixed at the
Liquor holding tank: this type of tank holds liquor that comes from mixing tank and are filtered in
filter sheet.
Filter: which is used to separate the liquor from particles
Conveyor: (conveying) is a term used for the transport of bulk solids.
In bottling we use 4 types of conveyors. These are roller, chain, belt and air conveyor.
2.13.1 Process description

The first process action is takes place in blending room. Blending is the process of mixing two or more
components together.
First the distilled alcohol from distillery with alcohol concentration 96.3-96.5 is transported to alcohol
holding tank. Then a sufficient amount of alcohol can be transferred from holding tank to mixing tank
for blending purpose. This alcohol will be mixed in the mixing tank with syrup, water, color, and
flavors.
63
Syrup Preparation
Syrup is a thick viscous liquid consisting primarily of a solution of sugar and water containing a large
amount of dissolved sugar. Syrup is prepared by mixing the sugar and water in the syrup mixing tank
by applying steam temperature at 650C.
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 to be 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.
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.
Blending process
Raw materials that used in blending process are pure alcohol, color, raw water, syrup sugar and flavor.
Equipment used in blending room are holding Tanks, Filter paper and filter, pipe, mixing, filter bag
valve, pump
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, about 96.1% alcohol of ethanol is poured to tank. Then
add some amount of RO water, flavor, and color.
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. There are 11 liquor holding tanks.
64
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. Filtration takes place due to pressure drop when there is pressure
difference between the inlet and outlet of the liquor.
In addition to filter press, there is a filter that used to filter intermediate, warm, and cold water in the
washer. Filter bag is used to filter the recycled caustic solution in the washer bottling and packaging.
WASHER
Figure 6: Bottle washer
Bottles are collected and transported by chain conveyor. By using out packer the bottles are pickup
and sent to washing machine the same time the crates go to the crate’s 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(31c)
warm(55c) and cold(23c)-water tank inside the washer, then turn on the washer’s motor. Fresh water
comes from the water treatment. The warm solution that contains the 2% caustic soda washes the bottle
at a temperature of 76.5c, at
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this step labels be removed, the caustic solution can be recycled and used for about 1 month but
concentration of the caustic soda should not be less than 1% if it is below 1% add some amount of
NaOH until it is approximated 2% by using titration. Finally, the bottles have dried by using blower
and goes to filling section. In washer there are 214 carriers. Each carrier has the capacity to hold bottles.
Sighter
There are two sighter in bottling section. those are empty bottle and full bottle sighter .The use of the
sighter is to identify if there is breakage or uncleaned bottle.
Filler
Filler is to fill a space or add weight or size. It is a process of filling a desired product in to the empty
bottle. This process is done by level sensing. The filling operation is processed by sucking the vacuum
air inside the bottle, then when the vacuum air becomes equal to the atmospheric air the filling process
stop.
Labeling
Label is a sign giving information about something to which it is intended to be attached. Glue is a
higher viscous liquid which used to stick a label on the bottle. Date coder: it is a machine that stamps
the manufacture date and time. After this process the in packer used to put the bottle in the crate. By
the help of convey the crate transported to the store room.
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Figure 7: Bottling house
2.14 Evaporator and Drying House

This factory has spent wash or vinasses treatment plant based on evaporation and drying technology
with a treatment capacity of 10m3/hr. And consist of an evaporation section and spray drying section.
But during our internship time the drying section was not working
2.14.1 Evaporator section
Evaporation is the removal of solvent as vapor from a solution, slurry or suspension of solid in a liquid.
The aim is to concentrate a non-volatile solute, such as organic compounds, inorganic salts, acids or
bases from solvent. The most common solvent in most of the evaporation system is water.
Evaporation differs from the other mass transfer operations such as distillation and drying. In
distillation, the components of a solution are separated depending upon their distribution between vapor
and liquid phases based on the difference of relative volatility of the substances. Removal of moisture
from a substance in presence of a hot gas tream to carry a way the moisture leaving a solid residue as
the product is generally called drying. Evaporation is normally stopped before the solute starts to
precipitate in the operation of an evaporator.
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The effluent from distillery plant (spent wash) is often processed with evaporator to recover the water
and produce concentrated syrup, which can be added to the spent grain prior to drying.in this case the
solids have value as animal feed.
Evaporators are classified by the number of effects. In case of a single-effect evaporator, the vapor
from the boiling liquor is condensed and the concentrated product is withdrawn from the bottom of the
evaporator. Although the operation is simple, the device does not use steam efficiently. Typically, 1.1
to 1.3 kg of steam is required to evaporate 1 kg of water. The steam consumption per unit mass of water
evaporated can be increased by putting more than one evaporator in series such that the vapor from one
evaporator is used in the second evaporator for heating. The vapor from the second evaporator is
condensed and the arrangement is called Double-effect evaporators. The heat from the vapor generated
in the first evaporator is used in the second evaporator. Evaporation of water is nearly doubled in double
effect evaporation system compared to single effect per unit mass of steam used. Additional effects can
be added in series in the same way to get a triple-effect evaporator, quadruple-effect evaporator and so
on. There are several configurations based on feeding arrangement.
Multiple effect evaporators (quadruple effect) are used for concentrating spent wash in Rorank
alcoholic liquor factory. Normally falling film tubular calendars are employed for the pre-evaporator
with forced circulation tubular evaporator as the finisher.
2.14.2 Types of evaporators used

In this plant two types of evaporators are used for the purpose of concentrating distillery spent wash
(vinasses). These are falling film evaporator (pre-evaporator), and forced circulation evaporator
(finisher).
a) Falling film evaporator
In a falling film evaporator, the liquid (spent wash) is fed at the top of the tubes in a vertical tube
bundle. The liquid is allowed to flow down through the inner wall of the tubes as a film. As the spent
wash travels down the tubes the solvent (water) vaporizes and the concentration gradually increases.
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Vapor and liquid are usually separated at the bottom of the tubes and the thick liquor is taken out.
Evaporator liquid is re-circulated through the tubes by a pump below the vapor-liquid separator. The
distribution of liquid in the inner wall of the tubes greatly affects the performance of this type of
evaporator. The falling film evaporator is largely used for concentration spent wash and heat sensitive
materials because of the low hold up time. The device is suitable for scale forming solutions as boiling
occur on the surface of the film.
b) Forced circulation evaporator

Forced circulation evaporators are usually more costly than falling film evaporators. However, the
falling film evaporators are not suitable under some situations such as: - highly viscous solutions due
to low heat transfer coefficient - solution containing suspended particles - for heat sensitive materials.
All these problems may be overcome when the liquid is circulated at high velocity through the heat
exchanger tubes to enhance the heat transfer rate and inhibit particle deposition. Any evaporator that
uses pump to ensure high circulation velocity is called a forced circulation evaporator. The main
components of a forced circulation evaporator are a tubular.
Shell and tube heat exchanger (either horizontal or vertical), a flash chamber(separator)mounted above
the heat exchanger and a circulating pump. The solution is heated in the heat exchanger without boiling
and the super-heated solution flashes off (partially evaporated) at a lower pressure are reduced in the
flash chamber. The pump pumps feed and liquor from the flash chamber and forces it through the heat
exchanger tubes back to the flash chamber.
2.14.3 Dryer
Drying of the more viscous feed or spent (40-60 ºbrix) which were not evaporating section. It operates
by supplying of steam in the waste drying and change to powder waste. The machines that operate in
this section are dryer champers, FD fan, atomizer and ID and blower. The dry chamber is boiled before
the spent is sprayed by atomizer machine.
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FD fan is sac the air from environment and boil the dry chamber by supplying of steam. Then the spent
which were sprayed in the dry champers changed to powder. The fine powder is separated by the ID
blower and remove these by cyclone separation. The liquid spent which are not removed in the form
of powder is removed by saver tank diluting with water and in the form of gases to the environment.
The effluent from distillery plant (spent wash) is often processed with evaporator to recover the water
and produce concentrated syrup, which can be added to the spent grain prior to drying.
In this case the solids have value as animal feed.
In the factory spray dryer is used before at this moment it is not work due to loss of energy.
Spray drying is a method of producing a dry powder from a liquid or slurry by rapidly drying with a
hot gas. This is the preferred method of drying of many thermally sensitive materials such as foods and
pharmaceuticals. Air is the heated drying medium; however, if the liquid is a flammable solvent such
as ethanol or the product is oxygen sensitive then nitrogen is used. All spray dryers use some type of
atomizer or spray nozzle to disperse the liquid or slurry into a controlled drop size spray. Atomizer
wheels are known to provide broader particle size distribution. A spray dryer takes a liquid stream and
separates the solute or suspension as a solid and the solvent into a vapor. The solid is usually collected
in a drum or cyclone. The liquid input stream is sprayed through a nozzle into a hot vapor stream and
vaporized. Solids form as moisture quickly leaves the droplets. A nozzle is usually used to make the
droplets as small as possible, maximizing heat transfer and the rate of water vaporization.
Spray dryers can dry a product very quickly compared to other methods of drying. They also turn a
solution, or slurry into a dried powder in a single step, which can be advantageous as it simplifies the
process and improves profit margins. The fine powders generated by the first stage drying can be
recycled in continuous flow either at the top of the chamber (around the sprayed liquid) or at the bottom,
inside the integrated fluidized bed. The drying of the powder can be finalized on an external vibrating
fluidized bed.
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2.15 Waste Water Treatment Plant and Water Treatment Plant

2.15.1 Introduction
Wastewater treatment refers to processes that treat or remove pollutants and contaminants, such as
soluble organic matter, suspended solids, pathogenic organisms, and chemical contaminants, from
wastewater prior to its reuse. These pollutants and contaminants are removed from wastewater using
physical and chemical processes (such as sedimentation and chlorine disinfection) and biological
processes. Biological wastewater treatment processes can produce CO2 and anthropogenic CH4 and
N2O emissions.
Analysis of physicochemical characteristics of distillery waste has been carried out, molasses is the
most common raw material used in distilleries for ethanol production. After alcohol distillation, huge
volume of darkish colored spent wash remains in the stills (to extract 1 litter alcohol above 12 litter
waste). And since this spent contain high amount of polluting substance it introduced in to evaporator
and then drying unit so as to reduce that toxic chemical by producing solid biomass, which has high
nutritional value for animal. But still the water comes out from the evaporator condensers has high
BOD, COD, TSS, and acidity thus the raw condensed water transferred in to waste water treatment
plant for further treatment.
The waste water treatment plant found in Rorank SC factory is diagrammed in figure 8.1. It is designed
to remove BOD, COD, acidity, color, odor, turbidity, and other contaminants.
2.15.2 Process description
Raw water storage

In this tank the waste water from the evaporator and bottle washer is introduced and acidic or basic
chemicals are added so as to maintain the PH neutral in between 7-8. For example, if the PH is below
seven limes (Ca (OH2)) is added until it be come in the range of needed PH value and if the PH is above
eight sulfuric acid is added. The neutralized water is now ready for anaerobic digestion hence it
transferred in to anaerobic digestion tank by passing through flow equalization tank.
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I. Equalization tank
Wastewater does not flow into wastewater treatment plant at a constant rate for various reasons. Such
constant variations in the amount and strength of wastewater to be treated make it difficult to operate
the treatment processes efficiently.
II. Anaerobic digestion

Anaerobic digestion process is continuously undergoing modifications with improvement and
development of new and complex technologies which are rapidly emerging. The anaerobic digestion
process is temperature influenced and dependent. Some of the anaerobic bacteria have optimal
degrading rate automorphic temperature of 32-35°C range, while other digesting bacteria have maximal
potential sat thermophilic temperature range of 50-55°C range. Butin Rorank there is no temperature
adjustment simply the neutralized waste is introduced to this tank and animal dung is added for bacteria
inoculation and finally the anaerobically digested water which contain CH4, CO2, and other gases faded
to degasifying section.
III. Degassing section

In this section the gases produced during anaerobic digestion are removed to the atmosphere by
stabilizing the flow in laminar zone.
IV. Aerobic tank-1

After the degasified water charged into this tank the chemicals that are not digested by anaerobic
bacteria will degraded with the aid of aerobic bacteria. These aerobic bacteria require free dissolved
oxygen, carbon, nitrogen, and phosphorus for their growth. Dissolved oxygen is supplied by
compressing the atmospheric air using compressor. And the bacteria obtain the other nutrients from
DAP, urea, and sugar. Then the aerobically decomposed water transferred to settling tank one to settle
out the bacteria used.
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V. Settling tube-1
Water from aerobic tank -1 usually has significant turbidity caused by turbulence during aeration.
These particles carried an electromagnetic charge that keeps them in continual motion and prevents
them from colliding and sticking together. Chemicals like alum (aluminum sulphate) are added to the
water both to neutralize the particle electrically and to aid in making them “sticky “so that they can
coalesce and form large particle called flocs. This process is called coagulation or flocculation.
VI. Aerobictank-2
Similar to that of aerobic tank it uses aerobic bacteria for further decomposition of chemicals. There
queried dissolve deoxygenize fed using compressor and nutrients like nitrogen, phosphor and
others from DAP, urea, and sugar. The bacteria cell is recycled from the bottom of settling tank- 2.
VII. Settling tube-2

Similar to that of settling tank one aluminum sulphate is added to stick the suspended particles together
and form flocs to facilitate the separation by gravity settling. Since large flocs have higher density it
will settle easily. And the sludge contains bacteria cell thus the needed amount of bacterial
concentration recycled to aerobic tank two. The aerobically digested water now transferred to
intermediate tank for further chemical treatment.
VIII. Intermediate tank (disinfection)

After biological treatment the finished water is often disinfected with chlorine. Disinfection kills the
remaining microorganisms in the water. Some of which may be pathogenic. Chlorine from bottle of
drums fed in correct proportion to the water to obtain a desired level of chlorine in the treated water.
When chlorine comes in contact with organic matter, including microorganism, it oxidizes this material
and in turn itself reduced. The chemically treated water now goes to multimedia filter.
IX. Multimedia filter

In this filter media the treated water introduced so as to remove any suspended solid in water.
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X. Activated carbon filter

This filter media is filled with activated carbon. And the treated water from multimedia filter introduced
at the top and when it passes through this filter media the odor will adsorbed to the pours of activated
carbon.
Figure 8: Waste Water treatment plant at Rorank S.C company
2.16 Water Treatment

Water treatment refers the processes that treat or removal of ions, pollutant and contaminants. There
are many types of water treatment such as ground water treatment, waste water treatment, surface water
treatment and so on.
2.16.1 Ground water treatment
Ground water treatment is a part of treatment, which reduces the concentration of calcium and
magnesium ions that are presented in hard water. The water to be treated is comes from underground.
We call water is hard when it contains large amount calcium and magnesium ions.
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Type of hardness
1. Temporary hardness:
•Temporary Hardness is due to the presence of Ca2+, Mg2+in the form of the bicarbonate ion HCO3-
being present in the water.
•This type of hardness can be treated by addition of lime (calcium hydroxide) through the softening
process of lime softening or by boiling the water to expel the CO2, as indicated by the following
equation:
•Ca2++ 2HCO3-→CaCO3+ H2O + CO2
•Mg2++ 2HCO3-→MgCO3+ H2O + CO2
•Bicarbonate hardness is classified as temporary hardness
2. Permanent Hardness
•Permanent hardness is due to the presence of the ions Ca2+, Mg+2 in the form of Cl-and SO4. This
type of hardness cannot be eliminated by boiling.
•The water with this type of hardness is said to be permanently hard
•As it can’t be treated easily, so it’s treated by chemical treatment such as: ion exchange resin.
Problems of hard water
Originally, water hardness was defined as the measure of the capacity of the water to precipitate.
It forms scales in the boiler that may cause:
1. Decreasing in heat exchange and boiler efficiency.
2. Corrosion takes place.
3. Explosion.
Zeolite is micro-porous mineral which is used as catalyst in many industrial purposes such as water
purification and air purification .it is hydrated alumina silicates.
Sodium zeolite (NaZ) is softening an ion exchange-based process designed to remove hardness
(calcium and magnesium) from raw water. NaZ softening will remove other soluble cation species such
as iron and copper and will act as a filter for small suspended solids.
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The soft water and hard water can be determined or tested by EBTA solution (solution of Erio chrome
black T powder with ammonium solution and ammonium chloride) and diluted with ethanol alcohol.
When tested both water type with this solution the hard water seems like slightly red color and soft
water is slightly blue color.
2.16.2 Utilities
Boiler
Treated Water
Distillery cooling tower
Boiler
Boiler is one of utilities of this factory that used to generate steam by using heat energy. A boiler is a
closed vessel in which fluid (generally water) is heated. The fluid does not necessarily boil. The
heated or vaporized fluid exits the boiler for use in various processes or heating applications
including water heating, central heating, boiler-based power generation, cooking, and sanitation.
Boiler use different energy source to produce steam like wood, coal, fuel and electric current.
Boiler type
A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or more tubes
running through a sealed container of water. The heat of the gases is transferred through the walls of
the tubes by thermal conduction, heating the water and ultimately creating steam.
Water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire.
Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In
smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely
on the water-filled tubes that make up the walls of the furnace to generate steam
Treated water
It is a part of utility, which reduces the concentration of calcium and magnesium ions that are
contained in hard water. The water to be treated is comes from underground. We call water is hard
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when it contains large amount calcium and magnesium dissolved in it. Water softening mainly relies
on the removal of Ca²+ and Mg²+ ions from a solution of these ions that is binding them to molecule
that removes their ability to form a scale or interface with detergent. Sequestration entails the
addition of chemical compound called sequestration agents. Since Ca²+ and Mg²+ ion exists as non-
volatile salts they can removed by distilling the water, but distillation is expensive in most cause.
Distillery cooling tower
Figure 9: Cooling tower

Cooling tower is a special type of heat exchanger that allows water and air come in contact with each
other to lower the temperature of the hot water. During the cooling tower working process, small
volumes of water evaporate, lowering the temperature of the water that is being circulated throughout
the cooling tower.
A cooling tower is a heat rejection device which extracts waste heat to the atmosphere through the
cooling of a water stream to a lower temperature. Cooling towers may either use the evaporation of
water to remove process heat and cool the working fluid to near the wet bulb air temperature. The
water is used to condense the alcohol in the condenser at distillation process and in the fermentation.
The purpose of cooling tower is to cool down the water that gets heated up by industrial equipment
and process. Water comes in the cooling tower hot (from industrial process) and goes out of the
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cooling tower cold (back into industrial process).
2.17 Challenges
There are different challenges during the internship. Such as:
• Lack of safety wears like safety shoe, glove
• Lack of internet access
We cannot see internal part of the machines. Because all machines are under works. They will
disassemble when the failure occurs on them.
2.17.1Measurnment taken to overcome those challenges
To be fully profitable from this internship we have to take some measurements instead of leave those
challenges.
• To get attention from the technicians we discuss with them and we tell them what we want from
them.
• To increase their awareness about the internship we talk with the workers about this program
to aware them. Even though they have no motivation to give a defined task instead of keeping
them. We try to take some tasks by ourselves. We read different references, we learned earlier,
and we understand the working principles of each machine parts.
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CHAPTER 3
3. BENEFITS OF INTERNSHIP
3.1 Benefits
This internship program helped me to get the following knowledge’s.
o Practical skill
o Up grading theoretical knowledge
o Improving inter personal communication skill
o Improving team playing skills
o Improving leadership skills
o Improving work ethics
o Entrepreneurship skills
3.1.1 Practical skill
Within an internship period different activity are taking place in the company and I practice those
activities and act to improve their problems through finding solutions.
1) I developed the habit of being safe at work.
2) Act on solving problems and work flow practically
3) Practice how drawing in takes place and draw –in on different unit operations by hand.
4) Practice how to measure quality of the products.
5) Principles of quality control and the major parameters to taste finished.
3.1.2 Upgrading theoretical knowledge
This internship program provided us with the opportunity to expand our intellectual knowledge and
practical skills. As we know coming before in the previous theoretical awareness or familiarity and
actual place could be distinguishable, so the objective reality and theoretical knowledge may be slightly
different. The above theoretical learning is upgrading during my internship program by seeing and
doing some work. So the internship program is essential for us to upgrade theoretical knowledge’s.
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3.1.3 Improving interpersonal communication skill

Developing Interpersonal skills are very important. IN RORANK BUSINESS S.C there are many
workers and they have different behaviors. Therefore, we can develop interpersonal skills and smooth
relationship with the workers.
3.1.4 Improving team playing skills
Team playing is a basic requirement for getting solution for a specific problem and to share experience.
During internship we have developed a team playing skills with operator mostly laboratory chemists
and technical to get experience, to grasp knowledge.
I improved my team playing by;
• Avoiding weight of work from one person
• Increasing production of the company using a small number of employers
• Simplifying the works and speed up production process
• Decreasing idle time of production
• Work in order to fulfill the customers need within a specified time
• Helping workers when they become tired
3.1.5 Improving leadership skills
A leadership skill is a critical management skill, which is the ability to motivate a group of people
towards a common goal. Always trying to share your opinions with workers frankly is the Key way to
achieve the goal and it makes your company profitable.
From all these I learnt
• leading the work
• solving the problems faced
• Handling the employees
3.1.6 Improving work ethics
We have been guided and obeyed by the rule and regulation of RORANK BUSINESS S.C. Some of
the work ethics includes;
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• Honesty, integrity and morality.

• Adaptability and flexibility.
• Dedication and work ethic.
• Dependability, reliability and responsibility.
• Loyalty.
• Positive attitude and motivation.
• Professionalism.
• Self- confidence and self-motivation.
• Ability to work with little or no supervision.
• Willingness to learn.
• Empathy for other people.
3.1.7 Entrepreneurship skills
Emphasizing the growth of entrepreneurship would not only lead to a new robust industry of its own
but also is a base for improving the social and economic capability of the country. We have a wide
range of entrepreneur skills including personal traits and management skills. In this internship program
we learned small business startup skills where we should be empowered with knowledge and skills to
become effective entrepreneur. The state of being an entrepreneurship can be realized when one
engages in profitable risks and creates something of value. It is defined by their habit of innovating and
redefines market trends and limits. Generally, entrepreneurs who are able to create worthwhile good
and services give a greater impact to society; have faithful and often tested with good results. Generally,
entrepreneurship can be realized when we engage in profitable system and create something value from
theoretical to practical learning. This means a person who is able to develop a new business area and
affect the global economic condition.
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CHAPTER 4
4. PROJECT ON PRODUCTION OF ALCOHOL FROM FRUIT AND
VEGETABLE WASTE
4.1 Introduction
Ethanol (also called ethyl alcohol, grain alcohol, drinking alcohol, or simply alcohol) is an organic chemical
compound. It is a simple alcohol with the chemical formula C2H6O. Its formula can be also written as
CH3−CH2−OH or C2H5OH (an ethyl group linked to a hydroxyl group), and is often abbreviated as EtOH.
Ethanol is a volatile, flammable, colorless liquid with a characteristic wine-like odor and pungent taste. It
is a psychoactive drug, recreational drug, and the active ingredient in alcoholic drinks. (Ishola, M. M.,
Brandberg, T., & Taherzadeh, M. J. (2015)).
The production of ethanol from lignocelluloses biomass has received considerable attention because of the
potential of producing large quantities of ethanol. Hemicellulose and cellulosic components of
lignocelluloses biomass are hydrolyzed to their component sugars for subsequent conversion to ethanol by
a fermentative process. Hemicellulose and cellulose are usually hydrolyzed with a chemical process (acid)
or biological (enzyme) attack. (Lujan-rhenals, D. E. (2013)).
Acid hydrolysis is an important chemical modification that can significantly change the structural and
functional properties of starch without disrupting its granular morphology. A deep understanding of the
effect of acid hydrolysis on starch structure and functionality is of great importance for starch scientific
research and its industrial applications. During acid hydrolysis, amorphous regions are hydrolyzed
preferentially, which enhances the crystallinity and double helical content of acid hydrolyzed starch.(Lujan-
rhenals,D.E.(2013)).
4.2 Statement of Problem

The alcohol production in RORANK BUSINESS SHARE COMPANY is based on the raw material (MOLASSES)
that have been received from sugar factory’s. But as we all know in and around debrebirhan there is no sugar
producing industry, because of its weather condition and raw material source. So, as we observed the main
challenge and problem of the company is raw material. The company spent a lot of money to receive the
molasses, to transport to the company including other labor costs. Even after receiving the raw material the
molasses has a bad smell in the environment and also the spent wash after fermentation couldn’t be disposed
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because of brown color, which is found affecting aquatic animals by making them unable
to get the sun light. this leads to disturbance of the living organisms.
On the other hand, fruit and vegetable wastes contribute directly to greenhouse gas emission through the
generation of methane and emission of nitrous oxide. This is the main cause of climate change by trapping
heat, which in turn affects various lives through drought and food supply disruption.
4.3 Objectives of The Project

4.3.1 General Objectives:
The general objectives of the project producing alcohol from fruit waste (banana, orange, and mango
peel).
4.3.2 Specific Objectives

1. Production of ethanol from fruit/vegetable waste
2. Characterization of produced ethanol
3. Determination of mass balance
4.4 Scope
This project work involves the collection of waste fruit peel from hotels Industries and residence’s. Then
after an analysis made to determine physical and chemical properties of waste fruit peel for the production
of bioethanol as fuel and hydrolysis with diluted sulfuric acid and adjust the PH. by using sodium
hydroxide. Then prepare fermentation media and fermentation process were carried out. Finally, the
fermented product was distilled, and characteristics of produced product are analyzed.
Generally, the aim of this project was to investigate the possibility of using and transforming fruit peel waste to
something valuable, namely ethanol using the fungus Saccharomyces cerevisiae as ethanol producing organism.
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4.5 Methodology
4.5.1 Materials Used for the Experiments
Equipment’s
• Plastic bags: - to collect and transport samples to the laboratory.
• Knife: - for cutting the fruit wastes in to pieces.
• Digital and non-digital driers or ovens: - to dry the sample.
• Crushers: - to crush the dried sample.
• Sieves: - to sieve the crushed sample to the particle size of 2mm.
• Balances: - to weigh samples and yeast.
• Digital pH meter: - to measure the pH of the hydrolyzes before fermentation.
• Thermostats: - to control temperature of the sample under experiment (fermentation and distillation)
isothermally at the set point.
• Vessels: - to hold samples and additives for hydrolysis, fermentation and distillation
• Pycnometer: - for density measurement
Chemicals
• 98% Sulfuric Acid (H2SO4):- used as a pretreatment and hydrolysis fruit peel.
• Sodium Hydroxide (NaOH):- used to adjust the pH of soluble cellulose and hemicelluloses before
fermentation.
• Yeast extracts (Agar):- used as media preparation.
• Urea: - used as media preparation.
• Dextrose sugar: - used as media preparation.
• Mg SO4.7 H2O:- used as media preparation.
• Yeast (Saccharomyces cerevisiae)
4.5.2 Method
Collection of raw material from source, washing, drying, milling by mortar and pestle machine and sieving
it in order to obtain fine powder for further process. This unit operation prevents the degradation or loss of
carbohydrate and byproduct inhibitory to subsequent hydrolyses and fermentation.
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4.5.2.1 Process Flow Diagram
Figure 8 flow diagram
4.6 Experimental Procedure

4.6.1 Sample Preparation
The sample that was acquired had to be prepared and conditioned for pretreatment, hydrolyze, fermentation
and distillation. Sample preparation process include: manual size reduction (Knife cutting), drying, grinding
and sieving after the samples were collected. Waste peel of orange, mango and banana, each 3kg was used
for the sample preparation. They were cut by knife into pieces of about 3-5 cm length for drying and
grinding. Sample drying was carried out in sun light to obtain easily crushable material. After drying, each
of the samples was milled separately. The maximum particle sizes of the ground mixed sample were 2 mm.
The sample of larger particle size than 2 mm was ground over and over again until all particle size became
2 mm. The sample was kept at low temperature until the next stage of experiment. Grinding of fruit peel
into powder form increases the surface area of the sample which enhances the contact between
hemicellulose and cellulose with dilute acid to reduce cellulose crystallinity.
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Figure 10: Fruit wastes
Pre -Treatment of Fruit Peel Powder

The purpose of the pretreatment was to remove lignin, reduce cellulose crystallinity and increase the
porosity of the materials. Pretreatment must meet the following requirements: improve the formation of
sugar, avoid the degradation or loss of carbohydrate, avoid the formation of by product inhibitors and must
be cost effective.
First, we Add 100 g of grinded fruit peel in to 2000 ml conical flasks and add 1000ml of distilled water the
cellulose molecules which are composed of long chains are broken down to simple sugar, before it is
fermented for alcohol production. Autoclave at a temperature of (100-132) o C for 15 minutes after
finishing the given pretreatment time and temperature the sample in autoclave and allowed to cool and
separate soluble from the non-soluble portion. The non-soluble portion is hydrolyzed in the next steps and
put the soluble solution in another 2000ml conical flask.
Figure 11: Autoclave
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4.6.2 Acid Hydrolysis

Add 1 liter of 1% (v/v) diluted sulfuric acid to the non-soluble component from pretreatment steps in the
order of experimental design for all experiment and soak for 24hr.The fruit peels will then hydrolyze in the
reactor between (100 and132oC) for 15 min.After hydrolysis, neutralize with 10 M NaOH until the pH
became around 7.Separate the solid particles from the liquid in the hydrolyze by centrifugation (to remove
the non-fermentable lignin portion).After separate the solid part, wash the solid part with distilled water
two times. The washing was performed in order to extract all soluble sugars from the solid fruit peel
material. To obtain the original sugar concentration in the hydrolyzes, the liquid parts were boiled until the
liquid weight become 1.0 kg. Then solid and liquid parts placed in the freezer until used. Then mix the
soluble component with the previously filter solution from the pretreatment step for the next procedure.
4.6.3 PH Adjustment
First, we Mix pretreated and hydrolyzed solution, filtered, shaken substrate primarily checked for pH using
a digital pH meter. Then the pH adjusted to 5.0-5.5. Mix samples (pretreated and hydrolyzed) were acid
hydrolyzed, so it needs highly basic solution to bring the pH in the range of 5.0-5.5 and hydroxide solution
was added drop wise to the other flask with constant stirring until the pH reaches to a range of 5.0-5.5. If
suppose the pH goes beyond 5.0-5.5, concentrated sulfuric or hydrochloric acid was added drop wise to
maintain the pH in the range.
4.6.4 Sterilization
The reactor and all the equipment’s that were used for fermentation purposes were sterilized (autoclaved).
The sterilization was carried out at a temperature of 121oC for 15 up to 25 minutes for different samples.
4.6.5 Filtration
A process of extracting ethanol is done in order to know the amount of substrate the enzymes had acted
upon. After monitoring the pH and concentration for a period of 48hrs, the biomass was separated from the
crude bioethanol using a coarse filter paper inserted in the separating funnel into a receiver flask or conical
flask. At this point, the biomass is then put in an oven at a temperature of 105 C for 2hours.
4.6.6 Fermentation
Media Preparation
For preparing 100 ml media, add
• Sugar (Dextrose) = 10 gm
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• Yeast extract = 0.5 gm

• Urea = 1.0gm
• Make up water = 100 ml
• Mg SO4.7 H2O = 1.0g
Procedures in Media Preparation
To the above 100 ml media, 0.5 gm of yeast, Saccharomyces cerevisiae (instant premium) was added in a
250 ml conical flask. Then conical flask was properly covered with aluminum foil. Finally, the conical flask
then placed in incubator for 24 hours, a temperature of 300C
Figure 12: Media prepared
The Procedure for Fermentation

The sample was conditioned to temperature of 30oC before fermentation step was started and the adapted
media with the proportion of 1:10 to the soluble sample mix then placed in the incubator at a temperature
of 30oC, for one 1 day finally the sample was mixed with the prepared media and it is putted into plastic
bottle under anaerobic condition, at room temperature, where it will remain inside the bottle during this
stage.
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4.6.7 Distillation
Distillation was the last step in the production of ethanol from fruit peel experiments. This method is used
to separate two liquids based on the difference of their boiling points.so distillation is used to separate water
and ethanol based on their boiling point. In this experiment simple distillation set up was used at a
temperature of 78 ºC for 30 minutes for each run. The ethanol concentrations of the samples were collected
on the other end of distillation column to collect the distillate at 78.40C (standard temperature for ethanol
production). Although the boiling point of bio ethanol 78.4℃, and water 100℃, we can’t get pure bio
ethanol by distillation. In order to use bio ethanol as fuel it should be free from water, so dehydration is
required to get pure ethanol.
Experimental Procedure at Different Parameter
Figure 13: Simple distillation
Sample A
First, we prepare 100 gram of sample weight mixing with 1000 ml of distilled water then hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1320 c. the hydrolysis at pH adjustment of 5.5
and for fermentation 6.5. lastly Prepare 100ml fermentation media contain 5-gram baking powder then the
separated liquid was fermented for 7 days at room temperature.
89
Sample B
First, we Prepare 100 gram of sample weight mixing with 1000 ml of distilled water and hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1320 c. hydrolysis at pH adjustment of 5.5
and for fermentation 6.5. finally Prepare 100ml fermentation media contain 7- gram baking powder Then
the separated liquid was fermented for 7 days at room temperature.
Sample C
First, we Prepare 100 gram of sample weight mixing with 1000 ml of distilled water. Hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1210 hydrolysis at pH adjustment of 5.5 and
for fermentation 6.5 and Prepare 100ml fermentation media contain 5.0- gram baking powder. Then the
separated liquid was fermented for 12 days at room temperature.
Sample D
First, we Prepare 100 gram of sample weight mixing with 1000 ml of distilled water then hydrolysis by 1%
(v/v) of diluted sulfuric acid and hydrolysis temperature was 1210 c. after hydrolysis at pH adjustment of
5.2 and for fermentation 6.2 and Prepare 100ml fermentation media contain 5-gram baking powder then
the separated liquid was fermented for 7 days at room temperature.
4.7. Characterization of product

4.7.1. Density measurement
The density of each run experiment was obtained by using pycnometer equipment.
Density measurement is calculated by using pycnometer.
• Density reading for sample A = 0.715 gm/ml
• Density reading for sample B = 0.788 gm/ml
• Density reading for sample C = 0.795 gm/m
• Density reading for sample D = 0.735 gm/ml
4.7.2. Color
The color of ethanol which produced from fruit peel powder is colorless. Therefore, the one thing belongs
to ethanol characterization is satisfied.
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4.7.3 Boiling point

An instrument used to measure boiling point is Thermometer. And the boiling point of ethanol is 78.40c .
4.7.4 Melting point
Method used to measure melting point is capillary method. This method involves placing the sample in a
capillary tube and running an experiment that will heat the sample until it reaches melting point. And the
melting point of the sample is -114.5oC.
4.7.5 Solubility
It is fully miscible in water.
4.7.6 Viscosity
It is more viscose than water. And it viscosity is 1.1cp at 25oC.
4.8 Material Balance

In all the mass balance calculations, no mass accumulation in the design process is assumed. Since the mass
balance involved reaction, it is calculated by using the mole flow of each compound when reaction is
involved in the process. Each reaction depends on the conversion of reaction since all the reactions are
assumed in equilibrium and the number of moles consumed in the reaction
∑(𝐹𝑖)𝑖𝑛𝑝𝑢𝑡 + ∑(𝐹𝑖)𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 = ∑(𝐹𝑖)𝑜𝑢𝑡𝑝𝑢𝑡 + ∑(𝐹𝑖)𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑
4.8.1. Material Balance on Dehydration

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑦𝑖𝑒𝑙𝑑 = 3 ∗ 106𝑙𝑖𝑡/𝑦𝑒𝑎𝑟
annual
𝑊𝑖𝑡ℎ 𝑝𝑙𝑎𝑛𝑡 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑑𝑎𝑦 = 330/𝑦𝑒𝑎𝑟
𝐴𝑛ℎ𝑦𝑑𝑟𝑜𝑢𝑠 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 (𝑙𝑖𝑡/ℎ𝑟. ) = 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝑙𝑖𝑡/𝑦𝑟)/330 𝑑𝑎𝑦/𝑦𝑟 × 18ℎ𝑟/𝑑𝑎𝑦 = 505.05𝑙𝑖𝑡/ℎ𝑟
𝑀 = 505.05𝑙𝑖𝑡/ℎ𝑟.× 792𝑘𝑔/𝑚^3 × 1𝑚^3/1000𝑙𝑖𝑡 = 400𝑘𝑔/ℎ𝑟 × 18ℎ𝑟/1𝑑𝑎𝑦 × 330𝑑𝑎𝑦/1𝑦𝑒𝑎𝑟

= 2376 𝑡𝑜𝑛/𝑦𝑒𝑎𝑟
𝐼𝑡 𝑖𝑠 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑤ℎ𝑖𝑐ℎ 𝑓𝑜𝑙𝑙𝑜𝑤𝑖𝑛𝑔 𝑡ℎ𝑒 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑐𝑜𝑙𝑢𝑚𝑛 𝑎𝑛𝑑 𝑏𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 95% 𝑡𝑜
99%.
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Hydrous ethanol Dehyderation 𝑋𝑒 𝑎𝑛ℎ𝑦𝑑𝑟𝑜𝑢𝑠 = 99%
𝑋𝐸 = 95% 𝑋𝑊 = 5%
𝑋𝑤𝑏 = 100%
Where 𝑋𝐸=ethanol percentage
𝑋𝑤=water percentage
𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑏𝑎𝑙𝑎𝑛𝑐𝑒 𝑜𝑛 𝑑𝑒ℎ𝑦𝑑𝑟𝑎𝑡𝑖𝑜𝑛
0.95 × ℎ𝑦𝑑𝑟𝑜𝑢𝑠 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 (𝑡𝑜𝑛/𝑦𝑟) = 99% × 2376 𝑡𝑜𝑛/𝑦𝑟/0.95
𝐻𝑦𝑑𝑟𝑜𝑢𝑠 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 0.99 × 2376𝑡𝑜𝑛/𝑦𝑟 = 2476.042𝑡𝑜𝑛/𝑦𝑟
The overall material balance on dehydration
𝑀 ℎ𝑦𝑑𝑟𝑜𝑢𝑠 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 𝑀 𝑤𝑎𝑡𝑒𝑟 𝑙𝑒𝑎𝑣𝑒 + 𝑀 𝑎𝑛ℎ𝑦𝑑𝑟𝑜𝑢𝑠 𝑒𝑡ℎ𝑎𝑛𝑜𝑙
2476.042𝑡𝑜𝑛/𝑦𝑒𝑎𝑟 = 𝑀 𝑤𝑎𝑡𝑒𝑟 + 2376𝑡𝑜𝑛/𝑦𝑒𝑎𝑟
𝑀 𝑤𝑎𝑡𝑒𝑟 = 100.042𝑡𝑜𝑛/𝑦𝑒𝑎𝑟
4.8.2. Material Balance on Distillation

It is the equipment used for the purification of ethanol from water-ethanol mixture. The mixture from
fermentation enter in to the distillation with the mixture of 9.58% ethanol and the rest water, then with two
series distillation column the purification of ethanol come to 95%
Where 𝑋𝑑𝑒=fraction of diluted hydrous ethanol
𝑋𝑤 =Fraction of water
𝑋ℎ𝑒 =Fraction of hydrous ethanol
From ethanol component balance
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𝐹 𝑋𝑓 = 𝑊 𝑋𝑒 + 𝐷𝑋ℎ𝑒
𝐹 = 2476𝑡𝑜𝑛/𝑦𝑟 0.95/0.0958 = 24553.2359𝑡𝑜𝑛/𝑦𝑟
From distillation general material balance
𝐹 =𝑊+𝐷
𝑊 = 𝐹 − 𝐷 = 24553.2359𝑡𝑜𝑛/𝑦𝑒𝑟 − 2476.042𝑡𝑜𝑛/𝑦𝑟
𝑤 = 22077.2359𝑡𝑜𝑛/𝑦𝑟
4.8.3. Material Balance on Fermenter

Total material balance in fermenter
Where, 𝑀𝑐𝑓=mass of centrifuge or filter mash

𝑀𝑚=media mass
𝑀𝑓 =mass of fermenter mash
𝑀𝐶𝑂2 = mass of carbon dioxide
From the reaction of fermentation
C6H12O6 2C2H5OH+2CO2
180gm/mol 92gm/mol+80gm/mol
of CO2 But (1-3%) of glucose is not changed to ethanol from literature.
(1 + 3%)/2 = 2%
Therefore 98% efficiency
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑔𝑙𝑢𝑐𝑜𝑠𝑒 𝑓𝑒𝑒𝑑/𝑀 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

= 𝑚𝑎𝑠𝑠 𝑜𝑓 ℎ𝑦𝑑𝑟𝑎𝑡𝑒𝑑 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 /𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙
𝑀 𝑔𝑙𝑢𝑐𝑜𝑠𝑒/180 = 2476.042 𝑡𝑜𝑛/𝑦𝑟
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑔𝑙𝑢𝑐𝑜𝑠𝑒 𝑓𝑒𝑒𝑑 = 4844.43 𝑡𝑜𝑛/𝑦𝑟 98% = 4747.5 𝑡𝑜𝑛/𝑦𝑒𝑟
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𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑟𝑏𝑜𝑛 𝑑𝑖𝑜𝑥𝑖𝑑𝑒 = 𝑀𝑔𝑓 /180 = 𝑀𝑐𝑜2/88
𝑀𝐶𝑂2 = 2321.02 𝑡𝑜𝑛 /𝑦𝑟
𝐻𝑒𝑛𝑐𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑒𝑑𝑖𝑎 𝑖𝑠 10% 𝑜𝑓 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑓𝑖𝑙𝑡𝑒𝑟 𝑚𝑎𝑠ℎ
𝑀𝑔𝑓 + 𝑀𝑚 = 𝑀𝑓 + 𝑀 𝐶𝑂2
1.1𝑀𝑐𝑓 = 𝑀𝑓 + 𝑀𝐶𝑂2 = 24553.35 + 2321.02/1.1 = 24431.245
𝑀𝑚 = 0.1 𝑀𝑐𝑓 = 2443.1245 𝑡𝑜𝑛/𝑦𝑟
4.8.4 Material Balance on Centrifuge

Centrifuge is used for separated insoluble solid from liquid mixture content of centrifuge solid is 20%.
Where, 𝑀ℎ=mass flow rate of acid treated
𝑀𝑠 = mass flow rate of bottom centrifuge solid
𝑀𝑐𝑓 = mass flow rate of centrifuge fluid
From the solid component balance
𝑀ℎ𝑋𝑠𝑖𝑛 = 𝑀𝑠. 𝑋𝑠𝑜𝑢𝑡
𝑀ℎ 0.1 = 𝑀𝑠 0.8
From liquid
𝑀ℎ𝑋𝑙𝑖𝑛 = 𝑀𝑠𝑋𝐿𝑜𝑢𝑡 + 𝑀𝑐𝑓𝑋𝑙𝑜𝑢𝑡
𝑀ℎ 0.9 = 𝑀𝑠 0.2 + 24431 0.1
𝐹𝑟𝑜𝑚 𝑡ℎ𝑒 𝑎𝑏𝑜𝑣𝑒 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛
(𝑀𝑠 0.8/0.1) 0.9 = 𝑀𝑠 0.2 + 24431 𝑡𝑜𝑛 /𝑦𝑒𝑟
7.2 𝑀𝑠 − 0.2 𝑀𝑠 = 24431𝑡𝑜𝑛/𝑦𝑒𝑟
𝑀𝑠 = 3490.1428𝑡𝑜𝑛/𝑦𝑟
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𝑀ℎ = 𝑀𝑠 0.8/0.1 = 3490.1428 𝑡𝑜𝑛/𝑦𝑟 0.8/0.1
𝑀ℎ = 27921.14 𝑡𝑜𝑛/𝑦𝑟
𝑀𝑠𝑎 = 681.57𝑘𝑔/ℎ𝑟
hydrolysis
𝑇1=250c 𝑇𝑓=280c
𝑀ℎ=4700.5kg/hr
𝑀𝑝𝑡𝑚 = 4018.95𝑘𝑔/ℎ𝑟
Where 𝑀𝑝𝑡𝑚=mass flow rate of pretreated mixture
𝑀𝑠𝑎=mass of diluted sulfuric acid
From the reaction
C6H10O5+H2O C6H12O6
1mol of cellulose 1 mol of glucose for 100% conversion but not complete conversion and assume
that 95% of cellulose convert to glucose.
𝑀𝑝𝑡𝑚/162 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑔𝑙𝑢𝑐𝑜𝑠𝑒/180 = 27921.14 0.95/180
𝑀𝑝𝑡𝑚 = 23872.5747 𝑡𝑜𝑛/ 𝑦𝑒𝑎𝑟
𝐴𝑝𝑝𝑙𝑦𝑖𝑛𝑔 𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑏𝑎𝑙𝑎𝑛𝑐𝑒
𝑀𝑝𝑡𝑚 + 𝑀𝑠𝑎 = 𝑀ℎ
𝑀𝑠𝑎 = 27921.14 − 23872.5747 = 4048.56 𝑡𝑜𝑛/𝑦𝑒𝑎𝑟
From the component of mass of sulfuric acid
0.01 4048.56 𝑡𝑜𝑛/ 𝑦𝑟 = 404856 𝑡𝑜𝑛/𝑦𝑟 of sulfuric acid 0.02
95
4.8.5 Material Balance on Mixing

It is the equipment used to make homogenous suspension of distilled water and dry fruit peel powder.
Where 𝑀𝑑𝑝 = mass flow rate of dry fruit powder
𝑀𝑑𝑤 = mass flow rate of distilled water
𝑀𝑑𝑝 + 10 𝑀 𝑑𝑝 = 𝑀𝑝𝑡𝑚
𝑀𝑑𝑝 = 23872.5747 / 11 = 2170.2340 𝑡𝑜𝑛 / 𝑦𝑟
𝑀𝑑𝑤 = 21702.34 𝑡𝑜𝑛 / 𝑦𝑟
4.8.6. Material Balance on Dryer

It is used to dry the wet fruit peel to make agreeable for easily crushing.
Where 𝑀𝑓𝑝 = mass flow rate of wet fruit peel
𝑀𝑑𝑝 = mass flow rate of dry fruit peel
𝑋𝑑 = fraction of dry powder
𝑋𝑤 = fraction of wet fruit peel
𝑋𝑠= fraction of solid in wet fruit peel
Component mass balance for wet fruit peel
𝑀𝑓𝑝𝑋𝑠 = 𝑀𝑑𝑝𝑋𝑑
0.2 𝑀𝑓𝑝 = 2170.234 100%
𝑀𝑓𝑝 = 2170.234 100% / 0.2 = 10851.17 𝑡𝑜𝑛/ 𝑦𝑟
From over all material balance
𝑀𝑓𝑝 = 𝑀𝑤 + 𝑀𝑑𝑝
𝑡𝑜𝑛
𝑀𝑤 = 𝑀𝑓𝑝 – 𝑀𝑑𝑝 = 10851.17 − 2170.234 = 8680.936 𝑦𝑒𝑎𝑟
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Results
Determination of yield
4.8.7. Ethanol concentration and yield

Table 3. Ethanol yield and concentration
Run No . Sample volume(ml) Concentration(mol/l)
1 A 48 73
2 B 55.2 75.2
3 C 50 73.5
4 D 42 72.4
Ethanol yield (%) = 𝑚𝑎𝑠𝑠𝑜𝑓𝑒𝑡ℎ𝑎𝑛𝑜𝑙𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 ∗ 𝟏𝟎𝟎%
𝑚𝑎𝑠𝑠𝑜𝑓𝑑𝑟𝑖𝑒𝑑𝑝𝑒𝑒𝑙𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐴
43.92 ∗ 100%
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑦𝑖𝑒𝑙𝑑 (%) =
100
= 43.9%
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐵
48.576 ∗ 100%
100
= 48.6%
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐶
44.75 ∗ 100%
100
= 44.7%
97
𝐹𝑜𝑟 𝑠𝑎𝑚𝑝𝑙𝑒 𝐷
39.27 ∗ 100%
100
=39.3%
4.9. Effect of Parameters On Ethanol Production

4.9.1. Effect of yeast amount (A and B)
Yeast is used to facilitate fermentation process. We used equal amount of yeast in all our samples, but for
one of our sample (sample B) we have added additional amount of yeast (baking powder) to check if this
action of ours can facilitate the fermentation process and give us maximum yield of ethanol. And as we
have seen the numbers, it gave us positive feedback by increasing the yield of ethanol for the sample B.
4.9.2. Effect of hydrolysis temperature at fixed time (A and D)

At fixed hydrolysis time at low level of temperature we observed that from sample D the amount of ethanol
was small. This might be due to the reason that the starch was not converted to glucose at low hydrolysis
temperature, therefore the concentration of ethanol is low when we were compared with sample A.
4.9.3. Effect of fermentation time (B and C)

At a fixed temperature, fermentation time have an effect on the production of bio ethanol. Fermenting the
sample for longer days or below the optimum days needed for fermentation has its own effect. That is may
be due to death of yeast for the lack of nutrient, which the effect is seen in sample C. Therefore, fermentation
in the optimum time as in sample B gives the maximum yield.
4.9.4. Effect of PH (B and D)

In many literature the optimum value of pH is 5 -5.6 for hydrolysis process and 6.2-6.8 for fermentation
process to get the maximum ethanol yield. Therefore, we tried to compare experiment B with that of
experiment D by adjusting the varies of pH as (5.5 and 6.5) for sample B and (5.2 and 6.1) for sample D
with the same all parameter in hydrolysis and fermentation respectively. So, we observed that sample B
was more concentrated and yield greater than sample D.
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Table 4. Optimum condition for different parameter on optimum yield of ethanol from
experiment
No sample Compare by Concentration Volume Optimum
sample
1 A with D Hydrolysis temperature 73 and 72.4 48 and 42 A
2 A with B Yeast amount 73 and 75.2 48 and 55.2 B
3 B with C Fermentation time 75.2 and 73.5 55.2 and 50 B
4 C with D pH factor 73.5 and 72.4 50 and 42 C
DISSCUSION
In this project ethanol was produced and characterized from wastes generated from fruit peel (mango,
orange & banana). Starch hydrolysis with dilute acid was carried out. The effect of temperature, time, Ph,
acid concentration & yeast amount from fruit peels were investigated
The project uses raw material from the agricultural waste. Which also provides environmental protection
The by-product is also biodegradable and we can use it for the production of fertilizer. A mixture of waste
fruit peel (mango, orange and banana) found as a promising carbon source for ethanol production and also
relatively inexpensive and high yield compared with other feedstock or sources.
When we compare produced ethanol from standard literatures such as color, boiling point, melting point,
solubility and others it is slightly accomplish almost all requirements.
99
4.10 Conclusions and Recommendation

4.10.1 Conclusion
During this internship program in RALF we saw some have seen different practical works. The company
produced different liquors and distributes to different direction of the country. By integrating different
departments and skill up person. The company has different work divisions to facilitate the production and
easy to control.
The main objective of the company is to compute and win by supplying the end products. In the company
there are different departments which are various functions in the production of liquors.
Our project is on alcohol production in RORANK BUSINESS SHARE COMPANY is based on the raw
material (MOLASSES) that have been received from sugar factory’s. But as we all know in and around
Debre Birhan there is no sugar producing industry, because of its weather condition and raw material
source. So, as we observed the main challenge and problem of the company is RAW MATERIAL. The
company spent a lot of money to receive the molasses, to transport to the company including other labor
costs. Even after receiving the raw material the molasses has a bad smell in the environment and also the
spent wash after fermentation couldn’t be disposed because of brown color, which is found affecting aquatic
animals by making them unable to get the sun light. this leads to disturbance of the living organisms.
On the other hand, fruit and vegetable wastes contribute directly to greenhouse gas emission through the
generation of methane and emission of nitrous oxide. This is the main cause of climate change by trapping
heat, which in turn affects various lives through drought and food supply disruption.
The challenges that are facing in the internship are obstacles that Blocks smoothly running working
conditions. The internship has benefits to improve an awareness of theoretical.
100
4.10.2 Recommendations
• In washing room the bottle lifting system is manual system, it will decreases the bottle washing
machine speed, we recommended that the company better to be replace the lifting system with
automatic lifting machine.
• The problem we saw in this factory is that there are no machine modules which make difficult to
know the operation system of the machine, but we recommended that it is better to put each machine
module in each department, that makes easy to operate the machine, especially for new employees
as well as internship students.
• The faculty should give necessary course which are related with laboratory works.
101
REFERENCE
1. Houghton-Alico, Dolan.Alcoholfuels: policies, production, and potentials’. Westview,
1982.
2. Http://Www.Google.Com/Books.Engineeringcourses 09/10/2015
3. Ishola, M. M., Brandberg, T., & Taherzadeh, M. J. (2015). Simultaneous glucose and
xylose utilization for improved ethanol production from lignocellulosic biomass through
SSFF with encapsulated yeast. Biomass and Bioenergy, 77, 192–199.
https://doi.org/10.1016/j.biombioe.2015.03.021
4. Karimi, K., Emtiazi, G., & Taherzadeh, M. J. (2006). Production of ethanol and mycelial
biomass from rice straw hemicellulose hydrolyzate by Mucor indicus. Process
Biochemistry, 41(3), 653–658. https://doi.org/10.1016/j.procbio.2005.08.014
5. Lenz, ZaraThomazini.Reuse of Drinking Water Treatment Plants Slugdesin
Agriculture.2011.
6. Lujan-rhenals, D. E. (2013). Production of bioethanol by fermentation of sugars released
by dilute-acid and enzymatic hydrolysis of soybean meal.
7. Millati, R., Niklasson, C., & Taherzadeh, M. J. (2002). Effect of pH, time and temperature
of over liming on detoxification of dilute-acid hydrolyses for fermentation by
Saccharomyces cerevisiae. Process Biochemistry, 38(4), 515–522.
https://doi.org/10.1016/S0032-9592 (02)00176-0
8. Paturau, J.M.By-product of the sugar industry. New York: Elsevier publishing company,
1969.
9. Saenz, Sepulvede and Matsuhiro. Coagulation Flocculation and Clarification. In: Fact
sheet on Environmental Sanitation. 2004.
102

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JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

Final internship report and project paper

MIHERET GIRMA ID- RU3255/11

Miheret Girma ID RU3255/11

Tizeta Terefe ID RU4310/11

Adviser name Signature Date

Mr. Dereje.D /company advisor ________________ __________________

Mr. Hailegebriel.G /company advisor ________________ __________________

1.2 Vision and mission of the factory

1.3 Products of the company

1.4 Main customers or end users of its products or services

• Hospitals and clinics

• Different factories as solvent

1.5 Job organization and structure of the company

Figure 1:Structure of the company

1.6 Scope and Purpose of the Factory

2.1 How we get into the company

• Seeing how unit operation are work

• Know what raw material use for production of Alcohol.

2.2 Fermentation technology

Figure 3: Content of molasses

✓ instant, dry, powdered type and the active,

 Aerobic respiration: requires the presence of oxygen.

2.2.3 Urea (CO (NH2)2)

2.2.4 DAP ((NH4)2PO4)

2.2.5 Sulfuric acid

2.3 Fermentation process (Methods)

2.4 Major process step in fermentation

• Appropriate sugar concentration

• Temperature not exceeding 300C

This would result in a state of saturation with dual advantages: -

2.5 Stages of fermentation

2.5.1 Abnormal fermentation

2.6 Fermentation process description

2.7 Factor affecting fermentation process

2.7.2 Amount of sugar

0.135𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 = 1 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

𝑋 = 40,000𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

𝐿𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 𝑙𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 (𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛) − 𝑙𝑖𝑡𝑡𝑒𝑟 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

Change the volume of molasses into mass

𝑀 𝑚 = 𝑉𝑚 ∗ 𝜌𝑚 Where : Mm = Mass of molasses

Vm = volume of molasse =5400 ρm

density of Molasses = 1450kg/m3 = 1.45kg/L

𝑀𝑚 = 5400𝐿 ∗ 1.45𝑘𝑔/ 𝐿 𝑀𝑚 = 7830𝑘𝑔 𝑜𝑓 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

Change the volume of water into mass

Where: Mw = mass of water VW= Volume of

water = 34600L ρW =density of water =

dilution molasses, Dm=?

Assume: There is no accumulation of mass

There is no generation and consumption of mass

The operation is steady state

Therefore, the mass balance will be

(34600 + 7830) 𝑘𝑔 = 42430𝐾𝑔

𝐷𝑀 = 42430𝑘𝑔 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

B) Mass balance for propagation tank

Where Md =diluted molasses

Urea(U)=8kg Yeast propagation

𝑃𝑌 = 42454𝑘𝑔 𝑜𝑓 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑒𝑑 𝑦𝑒𝑎𝑠𝑡 𝑎𝑟𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑖𝑛 𝑙𝑎𝑟𝑔𝑒 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑖𝑜𝑛 𝑡𝑎𝑛𝑘.

C) Mass Balance for High Brix Dilution

1.2𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 + 3.8 𝐿 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 5𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

For fermentation we use 190,000L of high brix dilute molasses

1.2 𝐿 𝑜𝑓 𝑟𝑎𝑤 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠 = 5𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

𝑋 = 190,000𝐿 𝑜𝑓 𝑑𝑖𝑙𝑢𝑡𝑒 𝑚𝑜𝑙𝑎𝑠𝑠𝑒𝑠

Mr. Dereje.D /company advisor __

Mr. Hailegebriel.G /company advisor __