CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND INFORMATION

In the earlier stage of Science and Technology education in Nigeria, students

were graduating from their respective institution without any technical

knowledge or work experience. It was in this view that students undergoing

Science and Technology courses where mandated for students in different

institution in the view of widening their horizons so as to enable them have

technical knowledge or working experience before graduation.

The student industrial work experience scheme (SIWES) is the acceptable skill

training program, which forms part of the approved minimum academic

standard in the various degree programs for all the Nigerian universities. It is

an effort to bridge the gap between theory and practice of engineering and

technology, sciences, agriculture, medical, management and other professional

educational programs in Nigerian tertiary institutions. It is aimed at exposal to

machines and equipments, professional work areas and workers in industries

and other organizations. The minimum duration of the program is directed by

the industrial training fund (I.T.F) and the National universities commission

(N.U.C). The scheme is a tripartite program involving the students, universities

and industries (employers of labour). It is founded by the federal government

of Nigerian and jointly coordinated by I.T.F and N.U.C.

1
1.2 BRIEF HISTORY OF THE SIWES UNIT

The Industrial Training Fund (ITF) established Student Industrial Work

Experience Scheme (SIWES) in 1973 to solve the problems of lack of adequate

practical skills preparatory for employment in the industries by Nigeria

graduates of tertiary institutions. The scheme was designed to expose students

to industry based skills necessary for smooth transition from the classroom to

the world of work and enable them develop occupational competencies so that

they can readily contribute the quota to national economic and technological

development after graduation. It offers students of tertiary institutions the

opportunity of being exposed familiarized and exposed to the needed

experience in real time job demands.

1.3 OBJECTIVES OF SIWES

Specifically the objectives of the student’s industrial work experience scheme

are to:

i. Provide an avenue for students in Nigerian universities to acquire

industrial skills and experience in their course of study.

ii. Prepare students for the work situation they are likely to meet after

graduation.

iii. Expose students to work methods and techniques in handling

equipments and machinery that may not be available in their

universities.

2
iv. Make the transition from the university to the labour world easier and

thus enhance students’ contacts for later job placement.

v. Provide students with an opportunity to apply their theoretical

knowledge in real work situation, thereby bridging the gap between

universities and actual practices.

vi. Enlist and strengthen employers’ involvement in the entire

educational processes of preparing university graduates for

employments in the industries.

3
 CHAPTER TWO

2.1 BRIEF HISTORY OF DANGOTE SUGAR REFINERY

The Dangote Sugar Refinery is a subsidiary of Dangote Group located in Lagos

State, at Nigeria’s largest port, The Apapa Wharf. The company commenced

business in March 2000 and the sugar refining plant was commissioned in

2001, with an initial capacity of 600,000MT p.a. The company imports raw

sugar from Brazil and refine it into white granulated sugar which is divided

into two types; FORTIFIED and NON –FORTIFIED sugar.

The fortified white sugar contains Retinol (vitamin A) while the non-fortified

white sugars are for industrial use and it is not fortified with retinol. Dangote

Sugar Refinery PLC is in the business of refining white sugar using new

technology of ION EXCHANGE RESIN (I.E.R).

The Dangote Sugar Refinery has excellent facilities designed and installed by

TATE and Lyle for production of refined sugar. TATE and TYLE is the

largest sugar refinery in Europe and its refining technology is regarded as one

of the best in the world.

The company’s operation comprises two key business areas; refining of raw

sugar imported from Brazil and marketing and distribution for direct

consumption and industrial needs. In compliance with the National Agency For

Food Drug Administration And Control (NAFDAC) policy, which makes the

fortification of staple foods mandatory in Nigeria, Dangote Sugar Refinery

PLC produces and packages fortified refined white sugar in 1kg, 500grams,

4
250grams and 50kg bags for direct consumption under the brand name

‘DANGOTE SUGAR’ as well as the unfortified white sugar for industrial use

and sells its product across Nigeria. Interestingly, ‘D.S.R’ is one of the very

few sugar refined in the world that produces RETINOL fortified white sugar at

its Apapa factory under strict NAFDAC policy.

2.2 OBJECTIVE OF DANGOTE SUGAR REFINERY

 Touch the lives of people by providing their basic needs.

 To become a global, integrated, low cost sugar producer focused on

maximizing long term shareholder returns while establishing a leading

presence in domestic and regional African market.

5
2.3 ORGANOGRAM OF DANGOTE SUGAR REFINERY

6
2.4 INDUCTION ON SAFETY WHICH IS VERY NECESSARY IN

THE REFINERY

Safety is an act of being safe in the line of duty. It ensures that all staffs must

observe and adhere to all protocols, precautions and procedures in order to

avoid accidents and injuries. Safety entails in using what is known as P.P.E

that is ‘personal protective equipments’ which includes:

 Wearing of Hand-gloves to avoid chemicals eating up the fingers etc,

then eye goggles to avoid spillage of chemical or light rays.

 Safety boots to avoid metals or nails perforating through your soft shoes.

 Nose mask to avoid inhaling the chemicals.

 Helmet to prevent any metal drop or accidental hit on the head.

 Laboratory coat to prevent spillage of chemicals on the body.

 Hair net to avoid contamination of the sugar.

The basic precaution is the use of our hand sanitizers to get rid of germs and to

prevent the dangerous disease called EBOLA. There is always a penalty for

staffs that are reported for lack of P.P.E. and if an accident is reported also, the

first question is if the P.P.E is on or not on use.

7
PICTORIAL VIEW OF DANGOTE RAW SUGAR

8
 CHAPTER THREE

PROCESS DEPARTMENT

STAGES IN THE REFINERY

 PRE- MELTING STAGE

 MELTING STAGE

 CLARIFICATION STAGE

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 DECOLORIZATION STAGE

 EVAPORATION STAGE

 CRYSTALLIZATION STAGE

 CENTRIFUGATION STAGE

 DRYING STAGE

 BLENDING/ROTEX STAGE

 FORTIFICATION STAGE

 BAGGING STAGE

PRE-MELTING STAGE

This stage is the first unit in Dangote Sugar Refinery and is also known as the

VERY HIGH POLARITY [V.H.P] STAGE. The pay loaders conveys the

raw sugar into the oban pan which have a hole underneath that allows sugar to

drop on the belt drag out conveyor, then it drags the sugar down to the elevator

and inside the drag out there is a magnet which magnets any metal found in the

raw sugar before it goes to the elevator. The elevator, which have a bucket

inside now transfers the raw sugar to the silo [V.H.P sugar hoppers], then the

screw drag out conveyor drags the sugar to the pre melting tank which have a

sever that sieves all the unwanted particles from the raw sugar. Inside the

boiling tank there is a rod stirrer that spins around to dissolve the sugar once it

gets to the tank to avoid clots/lumps of sugar. The water used in boiling the

10
sugar is called sweet water after boiling the slurry pump will open and transfers

the liquor to the next stage. Expected Brix here is 66-67.

MELTING STAGE

This stage detects and corrects the carryovers done in the first stage. If the brix

is too high or too low this stage will report to the first stage and they will make

amendment. They use steam to control the brix, the higher the steam the lower

the brix and vice versa. There is Lin catchers here that further detects the

carryover dirt from the first stage and then trap them. At this stage it is

assumed that the sugar has been completely dissolved before it goes to the next

stage.

N.B: At every stage there is an expected range of brix. Expected brix here is

62-64.

TALOCLARIFICATION STAGE

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This is where the Dangote Sugar Refining unit place more emphasis in

removing the impurities present in the melted liquor, this stage is an essential

part of the raw sugar processing. Taloclarification is the removal of color and

turbidity from melted liquor through the process of flocculation, floatation and

separation techniques. The main objective here is removal of 90percent of

turbidity and 40percent of color then the main parameters we check here is the

brix, temperature, and the pH. When we have a low brix it creates high

turbidity of the liquor and when it’s too low it creates filtration problem. The

expected brix in taloclarification is 62-63.Also when we obtain a high

temperature it tends to increase the expected color of the liquor while low

temperature will result to incomplete reaction of the liquor. Expected

temperature here is 80-84. PH of the liquor is very important here, when the pH

is low the sugar will be very wet and will not dry well because it is acidic, and

also it will cause inversion of sugar that is the splitting of sucrose to glucose

and fructose. It will be inform of dust and the expected grain size will be lost.

But when the pH is high it causes high color formation. Expected pH here is

6.9-7.2.

NOTE; When we discover a high pH and high temperature in the liquor

solution we recycle it back to the melting stage for curing.

4 chemicals are added here in talo-clarification namely;

12
 Phosphoric acid which is colorless and odorless. It serves as a neutralizing

agent.

 Hydrated lime; it helps in the decolorization of the liquor.

 Talofloc; this is the main decolorizing agent that further breaks down the

particles into smaller particles and they come together with the aid of stirrer

in the reaction tank.

 Taloflote[flocculants]; this makes the aggregated particles in the liquor

solution to float on the liquor thus enable proper separation of the scum

from the clarified liquor .flocculants are advantageously use in the sugar

clarification cause it helps to float the scum present in the liquor solution.

SCUM

This is a layer of dirt formed on the surface of a liquid, or the firmly layer of an

impure matter that rises to the surface of the liquor solution.

HEAT EXCHANGER: This is a device in taloclarification process that

increases the temperature of the liquor solution to the expected temperature

[80-84] so that a complete reaction can take place as the liquor gets to the

reaction tank. Shell and tubes heat exchanger is used such that the liquor will

run through the heated tubes and the steam flows through the shell so that heat

can be exchanged between the two fluids. In Dangote Sugar Refinery we have

about 144 tubes in one heat exchanger.

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DECOLORIZATION STAGE

This stage makes use of ion exchange resin and resin is the chemical that

mainly extracts all the colorants from the liquor solution. By definition; ion

exchange resin or ion exchange polymer is an insoluble matrix normally in

form of small [0.5-1mm diameter] beads, usually white or yellow in color. The

beads are typically porous, providing a high surface area. The trapping of ions

occurs with concomitant releasing of other ions thus the process is called ion

exchange. Resins are widely used in different separation, purification and

decontamination processes.

We have two types of resin commonly use in ion exchange process. Namely;

the cation resin and anion resin.

Cat ion resin are those resins that attract the positively charge ions in a

solution. Anion resins are those resins that attract the negatively charged ions

in a solution, and that is the one we make use of in Dangote Sugar Refinery

because the liquor is cationic in nature. The resin inside the batteries is what

carries out the decolorization process because it attracts all the cationic ions

and colorants to itself and an improved state of liquor will be obtained. In this

stage we are focusing on bringing down the turbidity of the liquor sample by

30-40 with the help of our pressure filters. One pressure filter pan in Dangote

Sugar Refinery contains about 36filter beds and the membrane is about

46micron meter in space that can hardly allow any form of impurity to

penetrate. Normally once the pressure filters absorb much impurity it will

14
automatically stop functioning until the beds are changed. The liquor gotten

from the pressure filters are named polished filter liquor because it is now free

from any form of impurity and thus ready for crystallization.

EVAPORATION STAGE

Evaporator is a device in Dangote Sugar Refinery that is used to brix up the

liquor solution by eliminating excess water from the liquor solution thereby

providing a fine liquor very thick example pap. The expected brix in this stage

is about 70-80.from this stage we get our massecuite which is the mixture of

syrup and the sucrose then it goes to the next stage which is crystallization

stage

CRYSTALLIZATION STAGE

Crystallization is done under vacuums in Dangote Sugar Refinery to avoid

color formation, to reduce the rate of steam consumption, to avoid excess loss

of sucrose, to lower the evaporative equipment and to reduce the operative

temperature. Slurry is added in this stage for crystal formation and the slurry

timing determine a good grain size of the sugar. One vacuum pan contains

about 600-750bags of sugar per yield batch. In this stage liquor boils at about

1; 30minutes per strike before it goes on to the next stage called centrifugal

stage

15
PREPARATION OF SLURY

Take 1.620kg of sieved sugar [600micron or 0.6mm] with 3.6 liters of

Isopropyl alcohol. Put into the slurry machine and switch the machine on for

24hours then slurry is formed.

CENTRIFUGAL STAGE

This is the stage were separation of sugar crystals from the mother syrup takes

place using a batch centrifuge. Batch centrifuges consist of a metal

basket1220mm in diameter, the holes of which are smaller moving towards the

centre. A thin perforated copper plate called a mesh or cloth with 0.5mm

diameter holes is placed on the side. The basket is mounted on a vertical shaft

through a bearing which connects to an overhead drive motor. There will be

between 20-26batches or cycles per hour, each cycle starts by charging the

basket with massecuite as it rotates at 250rpm. An evenly distributed full

charge of massecuite would be 203mm thick and weigh 1250kgs. The basket

accelerates to 1500rpm for a present period then decelerates to 50rpm at which

speed the spun sugar is removed by a ploughing mechanism. The unit is then

ready for the next cycle. During the cycle, a wash is applied to centrifugal

machine to remove residual syrup adhering to the crystals. From the centrifuge

the sugar is then conveyed to the next stage which the sugar dries

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DRYER

Sugar leaves the centrifuges containing between ½ and 1 1/2 moisture. The

majority of water is driven off in the driers. There are three driers in Dangote

Sugar Refinery each capable of drying 30 tones of sugar per hour. The driers

are horizontal cylindrical vessels approximately 2.7m in diameter by 12m long

[9 feet in diameter by 40 feet long]. The driers are of co-current design, that is

the air and the sugar both travels through the driers in the same direction. Both

hot air and cold air are applied to the drier for drying and subsequent cooling of

the product. The hot air enters the drier through a vent inside the vessel and

passes through a bed of sugar. The air then travels down the air space inside the

drier. As the drier drum is rotating at 10rpm, sugar is carried up to a height and

then falls to the bottom forming a curtain down the length of the drier. The hot

air passes through the curtain of sugar. Typical hot air temperatures are 50 to

60’c. Air at ambient temperature is applied to the drier to cool the sugar.

BLENDING STAGE

This is a unit in Dangote Sugar Refinery were the grain sizes of the sugar sent

from driers are determined before going to the fortification section. They make

use of a Rotex machine which have a screen mesh opening of 0.067mm.it

sieves the sugar and send the lumps to be recycled.

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FORTIFICATION STAGE

Fortified sugar is made by adding the vitamin A premix to the sugar either in

the centrifuge at the end of centrifugation, over the belt conveyor that leads the

sugar to the drying turbines or after drying when the sugar is moving down to

the packing chutes. A reliable mechanism is used to ensure that homogeneity

of the vitamin A content in sugar is maintained. Premix contains sugar, retinyl

palmitate, vegetable oil, and an antidioxidant. The premix is a free flowing

product that is light yellow in color, slightly oily to touch, and smells like

retinol. Premix that is stored for more than 2months or that is badly prepared or

inadequately stored can develop an unpleasant rancid smell indicating that the

oil has been oxidized. The premix is prepared inside the v-shaped blender and

the range at which we add it is 1kg of vitamin into 1000kg of sugar. The

cremix (coconut oil) we use in dangote sugar refinery is imported from

Malaysia.

BAGGING SECTION

The sugar leaves the driers and is conveyed to silo, which is capable of storing

a maximum of 80 tones of sugar each. From the silo the sugar passes over

magnets to further check if there is trace of any metal object, then is sieved

again to remove coarse lumps of sugar, and finally bagged in 50kilo bags. Then

the belt conveyor carries it down to where the trucks are packed.

18
THE TYPES OF SUGAR WE GET IN THE REFINERY.

HIGH GRADE SUGARS

- R1 == This is the very first sugar and is very white.

- R2 == This is the second run off sugar and is not as white as R1

- R3 == This is called run off 3 sugar not as white as R2 but closer

- R4 == This is run off 4 sugar more or less like a brown sugar

LOW GRADE SUGAR

A- SUGAR= This is gotten from the R4 sugar and is brownish in color just like

the raw sugar.

NOTE: From A Sugar we get our molasses which some industries order to

make their chocolate, malt, biscuit and other foods.

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 CHAPTER FOUR

QUALITY ASSURANCE DEPARTMENT

ANALYSIS CARRIED OUT IN THE LABORATORY

 pH determination; collect your samples and cool to room

temperature then using your glass beaker take some samples out and

immerse the probe of the electrode inside the sample and take the

reading on the display of the meter.

 Calibration of pH meter; this is a process whereby the pH meters

are standardized or made ready for efficient measurement via buffer

solutions. (i.e. 7,4,10 etc) to forestall deviations and/or correct errors.

Types of buffer for calibration of the pH:

1). Buffer 4 solution: This is used to calibrate the pH meter based on the

acidity level or range.

20
2). Buffer 7 solution: This is used to calibrate the pH meter based on the

neutral range.

3). Buffer 10 solution: This is used to calibrate the pH meter based on the

alkalinity range.

Pictorial View Of the p.H meter.

21
DETERMINATION OF COLOR AND TURBIDITY IN SUGAR

SAMPLES

EQUIPMENTS USED: spectrophotometer

- spectrophotometer cells

- brixometer

- vacuum filtration apparatus, capable of supporting 0.45um filter pads

- vacuum filtration flasks 250ml or 500ml capacity

- vacuum pump

- filter pads 0.45um

- beakers

- shakers/stirrers

- analytical balance

- distilled water

PROCEDURE:

 Weigh 50g of sugar sample into your conical flask, dilute with 50g

of distilled water making it 100g.

 Using your orbital shaker, dissolve properly until no trace of sugar

grains

Check the brix on the brixometer machine.

22
  Using the vacuum pump filter the sample through a membrane

filter of pore size/diameter 50mm respectively into a clean dry

conical flask

 Using the talameter machine, determine absorbance of filtered

solution with 10cell lens

 Take your readings and calculate the results.

 Formula: IU= A/BC, where A is the absorbance

B is the cell length

C is the brix factor

IU is ICUMSA, unit for measuring colour

ICUMSA stands for international commission for uniform method of sugar

analysis.

 Determine absorbance of unfiltered solution and calculate the

turbidity using

AU= (Aunf --Afil) *f/b where Aunf is unfiltered absorbance

Afil is filtered absorbance

f is the brix factor from turbidity table

b is the cell length and AU is absorbance

unit, unit for measuring turbidity.

DETERMINATION OF VITAMIN PRESENT IN THE SUGAR.

SAMPLE; BAGGING LINES.

23
Equipments; Orbital Shaker, Weighing balance, Text tubes, Text tube rack,

Glass beaker, Distilled water and Spatula.

Procedure:

 Using ratio 1:1, weigh your sample and dissolve with distilled water

 Place on the orbital shaker and switch it on to further dissolve the

solution evenly

 Using your text tube rack, pour small quantity of the dissolved

sample

 Add 5ml of chromogenic reagent and take your reading immediately

you see color change. If no color change it means vitamin is absent.

24
 Orbital Shaker

ANALYSIS ON A- SUGAR SAMPLE

EQUIPMENT: metal beaker, hot plate stirrer, brixometer, distilled water,

weighing balance and spatula.

Procedure:

 Place your metal beaker on the weighing balance and tare

25
  Measure 30g of sample and dilute with 70g of distilled water

 Put magnetic stirrer into the sample and place on the hot plate stirrer

and dissolve

 Check your brix using the brixometer machine

 Filter straight using the vacuum pump

 Check the absorbance using the talameter machine with 1cm cell lens

 Take your readings and calculate your result.

 Formula; filtered absorbance/cell length/brix factor

ANALYSIS ON MOLASSES ALSO KNOWN AS RECOVERY

The molasses include; A molasses, B molasses, C molasses and final molasses.

Procedure; using your metal beaker weigh ratio 1:1 of sample and distilled

water

- add your magnetic stirrer and place on the hot plate then dissolve

- allow to cool to room temperature and check your brix

- using your 50mil flask place on the weighing balance and tare then

measure out 13gram of diluted sample

- add octapol to it and fill the flask up to the mark with distilled water

- filter straight using the acetate filter paper then take the filtrate

- using the saccharimeter machine place the sample and check the polarity

- Then calculate your readings using the formula: 4 multiply by the

polarity/2 multiply by brix factor then multiply by 100/1.

26
 Vacuum Pump

ANALYSIS ON SCUM

- Using your 50ml flask place on the weighing balance and tare

- Measure 26g of sample add octapol and dilute with distilled water up to

the mark

- Filter using the acetate filter paper and collect the filtrate

- Using the saccharimeter machine place the sample on it and take your

readings

- From the polarity we determine if the impurity is high or not.

27
DETERMINATION OF THE SUGAR SIZES (MA/CV)

- Arrange preweighed sieves of varying apertures sizes, 850u, 600u, 500u,

425u, 300u, 212u and base pan in descending order recording the

weights.

- Weigh in 100g of the refined sugar sample into the first sieve and cover

- place on the mechanical shaker, shake for 15minutes

- Reweigh and record the final weight and take the readings

- With the result the sugar analyst will determine if the grain sizes are

okay or if is too dusty.

SPECIAL LABOURATORY ANALYSIS ON LOW POUR FUEL OIL

(LPFO)

A). FLASH POINT

This is the temperature at which the vapor of the fuel wills a flame. This

analysis is carried out to check the burning ability of automated gas oil

(A.G.O) and the burning ability is the temperature explosion of the product.

PROCEDURE:

-Fill the sample chamber to the mark with the sample

- Ignite the gas source

28
- Switch on the tester

- Insert the thermometer

- Stir the sample with the stirrer checking the temperature at intervals

- Note and record the exact temperature at which the vapor of the sample

flashes

- Then you switch off the tester.

REDUCING SUGAR ANALYSIS (INVERT SUGAR)

Inverted or invert sugar syrup is a mixture of glucose and fructose, it is

obtained by splitting sucrose into two components. Compared with its

precursor, sucrose, inverted sugar is sweeter and its product tends to retain

moisture and is less prone to crystallization. Sucrose is a disaccharide which

means that it is a molecule derived from two simple sugars (monosaccharide).

In the case of sucrose, these monosaccharide building blocks are fructose and

glucose. The splitting of sucrose is a hydrolysis reaction and hydrolysis is a

chemical reaction in which a molecule breaks down by the addition of water.

The essence of carrying out this analysis is to stop inversion of sugar from

taking place in the sugar refinery because once inversion of sugar takes place

we term to have a very low yield of the sugar. Things that could stop inversion

29
of sugar from taking place may include regulation of the temperature to the

expected range and pH.

PREPARATION OF SOME REAGENTS USED:

A). EDTA solution: prepare a solution containing 0.930g per liter of the

disoldium salt of ethylenediaminetetra-acetic acid (EDTA) as required and

discard after use. Alternatively dilute 50ml of o.o1mol\L EDTA solution to

200ml as required.

B).MUREXIDE INDICATOR: Prepare by grinding with pestle mortal 0.5g of

the murexide which is in powder form and store in a dessicator over silica gel

because humid conditions tend to cause caking. A solution of an indicator is

not stable.

PROCEDURE:

- Weigh accurately 5g of sugar into a text tube

- Dissolve in 5ml of distilled water by shaking without warming

- Add exactly 2ml of alkaline copper solution

- Thoroughly mix the tube and immerse in a boiling water bath for

5minutes

- Cool immediately in a cold bath

- Transfer the tube contents and washings to a white conical flask

30
 - Add approximately 0.1g of the indicator by means of a small spatula or

flattened glass rod

- Titrate the solution with the EDTA solution while stirring with a glass

rod

NOTE: EDTA should be added from the burette to the conical flask

continuously through the titration procedure and maintain the stirring of the

solution at all times. As the end point is approached the rate of addition of

EDTA can be slowed to 2-3drops per second but should never be stopped, until

the end point is reached. The reason for this is that the color formed can

disappear due to oxidation, meaning that if the titration is stopped an incorrect

estimation of the end point may be made, after restarting the titration. The

colour change during the titration is gradual, the solution starts from green, will

turn to grey and finally purple. These changes are gradual, but the end point

can be considered to be reached when the first full purple colour (i.e. ., when

the body of he whole solution is purple) has been reached.

On stopping the titration, there should be no concern if the colour starts

disappearing. This is due to oxidation and no more EDTA should be added,

every sample should be analyzed in duplicate to ensure accurate estimation of

reducing sugars. The reducing sugar content is obtained from the table.

MOISTURE ANALYZER

31
This is one important aspect in final stage of granulated white sugar before the

bagging stage in order to avoid caking of sugar because we cannot bag a wet

sugar. The normal sugar

Moisture value should not exceed 0.04.

OPERATING INSTRUCTIONS:

- Switch on the moisture analyzer

- Open the sample chamber and place an unused sample pan on the

support

- When “g” appears, press enter key to tare the sample pan.

- Weigh approximately 10g of your sample

- Close the sample chamber

- When “g” appear again, press the enter key to start the analysis

- The machine will make a sound and indicate end then you take your

readings.

LIQUOR ANALYSIS

1). BRIX

- Pace the liquor in the sample compartment of the meter

- Take direct reading from the brixometer as displayed on the screen

2). pH

- Cool the liquor in a cold water bath

- Insert the pH probe into the liquor sample

32
 - Take the reading displayed on the screen when the meter beeps

3). COLOR/TURBIDITY

- Take the original brix of the liquor

- Weigh 30g of melt and 50g for other liquors

- Add distilled water to make to a weight equivalent to the original brix

and mix well with your spatula

- Filter the sample solution under vacuum through a membrane filter of

pore size 0.45um/50mm respectively into a clean dry conical flask

- Turn on the talameter, set the wavelength at 420nm and zero with

distilled water using your cell lens

- Determine absorbance of filtered and unfiltered solution

- Take your readings and calculate its colour and turbidity.

MICROBIOLOGY DEPARTMENT

This is another department in Quality Assurance that sees to the progress of

dangote sugar refinery.

Equipments used in carrying out analysis in microbiology

laboratory:

 Autoclave: This is a machine used to sterilize our prepared agar under

heat and pressure at a temperature of 121%C.

 Incubator: This is a machine where we incubate or culture our plates.

33
 Laminar flow cabinet: This is a hood where we carry out analysis

because is said to be free from microorganisms.

 Lumitester: This is a machine used to carry out swab test.

 Ultra violet light: This helps in sterilizing the environment before an

analysis is carried out.

 Air conditioner: This machine prevents the growth of microorganisms

because some microbes grow at a higher temperature so with the help of

air conditioner we regulate their temperature.

 Colony counter: This is a machine used in counting our incubated

plates.

 Refrigerator: This is a place where we store our Petri dishes, Agar,

Sterilized swab sticks, Spatula etc.

 Microscope: This machine is used to view organisms that can not be

seen with naked eyes.

 Magnetic stirrer/hotplate: This is a machine used to dissolve a

substance.

 Analytical weigh balance and Top weigh balance: This is machine

used to take measurement of samples.

 Thermometer: This is an instrument used to measure the temperature of

products.

 Hot air oven: An instrument used in drying our equipments examples;

conical flask, spatula, glass Petri dishes, sampling bottles, pipettes, etc.

34
 Analysis carried out in microbiology laboratory:

 Raw sugar analysis

 Refined sugar analysis

 In process liquors

 Water analysis

 Sanitation

 Environmental hygiene monitoring (swab test)

 Miscellaneous.

Determination of temperature of all the equipments used in the

microbiology labouratory. All the equipment has a standard temperature for

example:

 Incubator 25*C

 Big incubator 35*C

 Refrigerator 4*C

 Thermometer 100*C

 Air conditioner 18*C

 Hot air oven 50*C

NOTE: This analysis is done every Monday before carrying out

analysis of that week.

Procedure:

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  Using ethanol and cotton wool clean your thermometer very well

to sterilize it.

 Insert or place the thermometer on the equipment

 Allow to stand for 5minutes

 Take your readings in that equipment before bringing it out so

that the temperature in the environment will not affect your

readings.

 Using your Hot plate machine, boil water until bubbles appear

 Insert the thermometer in the hot water, once the red mark reach

100* then is ready

 Allow to cool and store in the refrigerator.

Water Analysis

SAMPLES: Boreholes

 Aqua - plant A, B, C

 Treated water tank

 Refinery taps

 Canteen/kitchen taps

Control: negative and atmospheric

Frequency: Weekly

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SAMPLING:

Samplings are carried out using sterilized 25ml capacity universal sampling

bottle with caps. Clean disposable hand gloves and nose masks should be worn

during sampling. Samples are collected aseptically from representative points

within the refinery.

METHOD:

 Clean and disinfect the working area with ethanol before commencing

the analysis.

 Prepare and sterilize your agar medium in the Autoclave at 121^C for

15minutes

 Aseptically expose two poured plates of plate count agar (PCA) and

potato dextrose agar (PDA) on work surface area to serve as atmospheric

control.

 Pipette 1ml of water sample into sterile marked plates with dates for

PCA and MCA

 Cool sterilized agar (medium) to about (45-47)*C in a water bath, then

pour about 20ml each of molten prepared agar of PCA and MCA into

marked plates.

 Tilt/mix plate by rotating gently to avoid spilling of content, pour about

20ml of same molten prepared agars of PCA and MCA into another

sterile labeled plates without water samples. These represent the

37
 negative control and if any growth is found in this control, it invalidates

the result of the analysis done.

 Allow plate to solidify then invert and incubate plate. PCA plate and

MCA plate are incubated at 30*C for 48hrs.

 Count colonies and record.

NOTE; Results are reported in colony forming unit (CFU) per ml.

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 CHAPTER FIVE

WATER TREATMENT DEPARTMENT

Water treatment is, collectively, the industrial scale processes that make water

more acceptable for end-use, which may be drinking, industry, or medicine.

In Dangote sugar refinery, we have 3 divisions of Aqua plants in water

treatment department and each comprises of 3 different sections.

 The reaction tank chamber

 The sedimentation chamber

 The filtration chamber.

REACTION TANK CHAMBER:

Here the chemical added is known as the caustic soda (NaOH). The essence of

adding this chemical is to boost the pH of the water from 6.5 to 7.0 normally

the source of the water we used in the Dangote sugar refinery is from boreholes

and there are about 7 boreholes in the refinery and the pH of the different

boreholes are very acidic and thus not good for human consumption and

industrial use. We therefore add this chemical to increase it to be neutral.

Another chemical that is being added in this stage is known as sodium

Aluminates (Alum). This serves as a catalyst and catalyst are chemical reaction

that changes the state of a substance. So the sodium Aluminate’s removes the

charges of the microorganisms found in water thereby rendering them

immobile and thus coagulate together to form clogs, and this will then make

39
their density to be very heavy than water and they will sediment at the bottom

of the chamber. Coagulation removes dirt and other particles suspended in

water. Alum and other chemicals are added to water to form tiny sticky

particles called “floc” which attracts the dirt particles. The combined dirt and

the alum {floc} become heavy enough to sink to the bottom during

sedimentation.

SEDIMENTATION CHAMBER:

As the water and the floc particles progress through the treatment process, they

move into the sedimentation basins where the water moves slowly and the

heavy particles (floc) settle to the bottom and the clear water moves to

filtration.

In this chamber, chlorine is added to the tank to further perform the

following functions:

 Render the microorganisms present in water inactive but doesn’t kill

them.

 It helps to clarify the water and thus making it colourless.

FILTRATION CHAMBER

The water flows through a filter designed to remove particles in the water,

some made of layers of sand, gravel, and charcoal that help remove even

smaller particles. Filtration collects the suspended impurities in water and

40
enhances the effectiveness of disinfection. The filters are routinely cleaned by

backwashing.

Sand, stones, and gravels of various sizes are used to make beddings

example:

 0.5-0.8mm

 1-2mm

 2-6mm

 6-14mm

 14-20mm

They are arranged in layers to aid proper filtration of water as it flows from the

sedimentation chamber. Only filtrate is allowed to pass through the filtration

chamber and then enters into the sand filters with the aid of filter pumps with

pipes.

DISINFECTION

Water is disinfected before it enters the distribution system to ensure that any

disease causing bacteria, viruses, and parasites are destroyed. Chlorine is used

because it is a very effective disinfectant, and residual concentrations can be

maintained to guard against possible biological contamination in the water

distribution system.

41
STORAGE: Water is placed in a closed tank or reservoir in order for

disinfection to take place. The water then flows through pipes to all round the

refinery where it is needed.

42
 CHAPTER SIX

CONCLUSION

My Industrial training in Dangote Sugar Refinery at Apapa whorf in Lagos

State was indeed a remarkable one. I was able to put into practice all I was

taught in school and also learnt more. I was able to acquire all the necessary

skills and by God’s grace today am proud to say that I can cope in any industry

I find myself after graduation because Dangote Sugar Refinery Industry is one

of the best Industries in the whole world wide. Thanks to Student Industry

Work Experience Scheme (SIWES) for organizing the program and Federal

University of Technology Owerri (FUTO) for granting me the opportunity to

participate in the program.

Finally, the aim of the training was achieved as necessary training has been

acquired.

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RECOMMENDATION

Organizations should try as much as possible to encourage students participate

in this training exercise by making Job placement easy after graduation.

Research has shown that industrial training is important for student to acquire

practical experience of the theoretical skills.

In every organizations student should be appreciated and supervisors should be

pleased to correct them. However, student should take this program very

serious because the merits are more than the demerits.

Organizations should Endeavour to pay students well during this training and

make provision of staff bus for the students who comes from a far distance.

44
GLOSSARY OF SOME TERMS USED IN SUGAR REFINING

 BRIX : Percentage by weight of sugar present in a solution

 CAKE: The solid waste material from a filter press or pressure filter

 COLOUR: Complex molecules of impurity

 CRYSTALLISATION: Production of sugar crystals from a solution

 EVAPORATION : Increase in the concentration of a sugar solution by

removing water through boiling.

 FILTRATION: Removal of suspended solids from a liquid.

 FINE LIQUOR: Liquor after the final purification.

 LIQUOR: Solution of sugar before crystallization.

 MASSECUITE: Mixture of crystals and its mother syrup boiled in a

vacuum pan, often shortened as *masse*.

 MOLASSES: Sugar from the last boiling in the recovery process.

 pH: Measurement of how acidic or alkaline a solution is. A neutral

solution is 7 pH.

 RAW SUGAR: The product of a raw sugar factory. A raw sugar has

between 96 and 95% sucrose. The rest is impurity.

 RESIN: This is a man-made compound used to remove colour and

impurities from liquor.

 SYRUP: Sugar solution that contain high amount of impurities.

 VACUUM PAN: Vessel for crystallization of sugar.

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 APPENDICES

School supervisor and industrial based supervisor

46