Addis Ababa Institute of Technology

School of Chemical and Bio- Engineering

Balezaf Alcohol and Liquor factory Final report

Performed by:

Name: ID Number
Mamaru Habtamu…………………………………...ATR/3033/09

Yakoral Adugnaw………………………………..……ATR/0034/09

Gima Mengistu……………………………..………..ATR/5369/09

Duration of internship: Oc,01 2019 to Jan, 30, 2020

Submitted to: Mr. Elias.T

Submission date: Jan, 17, 2020

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Contents
Acknowledgment.........................................................................................................................................v

Executive summary......................................................................................................................................v

History of balezaf alcohol and liquors factory.............................................................................................vi

The management structure of balezaf factory...........................................................................................vii

Chapter one.................................................................................................................................................1

Fermentation...............................................................................................................................................1

1.1 Introduction.......................................................................................................................................1
1.1.1 Raw material for fermentation process......................................................................................2

1.1.2 Material and equipment used...................................................................................................2

1.1.3 Flow diagram of fermentation....................................................................................................3

1.1.4 Process description.....................................................................................................................3

1.1.5 Material balance.........................................................................................................................4

1.1.6 Conclusion................................................................................................................................12

1.1.7 Recommendation.....................................................................................................................12

Chapter two...............................................................................................................................................13

Distillation.................................................................................................................................................13

2.1 Introduction.....................................................................................................................................13
2.1.1 Batch or differential distillation................................................................................................14

2.1.2 Continuous distillation columns................................................................................................14

2.1.3 Process Descriptions of distilation............................................................................................15

2.1.4 General process description....................................................................................................20

2.1.5 Process Flow Diagrams of Distillation......................................................................................21

2.1.6 Material and Equipment’s Used...............................................................................................22

2.1.7 Material balances.....................................................................................................................23

2.1.8 Conclusion................................................................................................................................27

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 2.1.9 Recommendation.....................................................................................................................27

Chapter three............................................................................................................................................29

Water treatment.......................................................................................................................................29

3.1Introduction......................................................................................................................................29
3.1.1 Water hardness........................................................................................................................30

3.1.2 Temporary hardness.................................................................................................................31

3.1.3 Permanent hardness.................................................................................................................31

3.1.4 Filtration...................................................................................................................................31

3.1.5 The Ion Exchange (softening) Process.......................................................................................32

3.1.6 Re-generation Process.............................................................................................................32

3.1.7 Dis-infection.............................................................................................................................33

3.1.8 . Reverse osmosis......................................................................................................................33

3.1.9 working principle of Reverse Osmosis.....................................................................................33

3.2 Cooling tower..................................................................................................................................34

3.2.1 Types of cooling tower.............................................................................................................34

3.2.2 The equipment and materials used..........................................................................................35

3.2.3 Process description.................................................................................................................35

3.2.4 The flow diagram for the water treatment...............................................................................37

3.2.5 conclusion.................................................................................................................................37

3.2.6 Recommendation.....................................................................................................................37

Chapter four..............................................................................................................................................38

Boiler.........................................................................................................................................................38

4.1 Introduction.....................................................................................................................................38
4.1.1 Types of Boiler..........................................................................................................................41

4.1.2 De-aerator................................................................................................................................41

4.1.3 Economizer...............................................................................................................................42

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 4.1.4 Working principle of Boilers:.....................................................................................................42

4.1.5 Boiler efficiency........................................................................................................................43

4.1.6 The materials and equipment used are;...................................................................................43

4.1.7 The flow diagram for boiler......................................................................................................44

4.1.8 Process description...................................................................................................................45

4.1.9 Conclusion...............................................................................................................................46

4.2 Recommendation............................................................................................................................46
Chapter five...............................................................................................................................................48

Bottling......................................................................................................................................................48

5.1 Introduction.....................................................................................................................................48
5.1.1 Syrup Preparation....................................................................................................................48

5.1.2 Blending of Liquors..................................................................................................................48

5.1.3 Process block Diagram for Blending and syrup preparation....................................................49

5.1.4 Equipment and material used..................................................................................................50

5.1.5 Washer.....................................................................................................................................50

5.1.6 The Bottling section.................................................................................................................50

5.1.7 Bottling Process Description....................................................................................................51

5.1.8 Process Flow Diagram of Bottling............................................................................................52

5.1.9 Conclusion and Recommendation............................................................................................52

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List of figures

Fig i The management structure of balezaf factory ……………………………………………………………………….v

Fig 1.1 Flow diagram of fermentation……………………………………………………………………………………………….3

Fig 2.1 Overall block diagram for distillery……………………………………………………………………………………..15

Fig 2.2 Process Flow Diagrams of Distillation………………………………………………………………………………….22

Fig 3.1 The flow diagram for the water treatment…………..……………………………………..……………………..37

Fig 4.1 The flow diagram for boiler………………………………………………………………..……..……………………….44

Fig 5.1 Process block Diagram for Blending and syrup preparation………………..……………………………….50

Fig 5.2 Process Flow Diagram of Bottling…………………………………………………………………………………………52

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 Acknowledgment

First we would like to thank our GOD to complete our internship in a good manner. Also we
would like to thank the school of chemical and bio-engineering department and our advisor
Mr.Elias who gives his un-limited advice to perform our internship in a good way. He advised
us, in what way can we get the practical knowledge from the balezaf factory. And also we would
like to give respect for all workers of the balezaf factory who treated us their brother and their
sister. we have learnt a lot of things from the workers like their politeness, co working habit in a
good way, how to respect others when they are coming to this factory for the first time, and also
their ways of giving their knowledge for the intern students. We would like to thank Mr. Aklilu
who devotes his time to work with us when we perform our project and also we would like to
thank Mr.Chalachew who initiate and gives different materials to perform our project.

vi
 Executive summary
The balezaf alcohol and liquor factory produces different types of alcohol after it is processed in
the following processes. On the first case the molasses is coming from its storage and mixed with
water forms a fermented wine which is a form of ethanol. This process requires yeast, DAP,
urea, sulphuric acid. Then after this process, it is transferred to the decanter and further processed

is called distillation process. It is a process of separating more light components from the given
mixture. Since this factory contains multicolumn distillation process, which can produces more
concentrated alcoholic liquors. This concentrated product is transferred to the final bottling
process and at this process, the concentrated alcohol is diluted to reduce its concentration depend
on the required alcohol content and finally becomes packed.

Also this factory contains another three plants which are ground water treatment, fire type boiler
and waste treatment (evaporator). When we see the ground water treatment, its aim is to remove
the hardness of water and also to make the water is dematerialized. To perform this process it
follows certain steps starting from the ground storage to the final softening and reverse osmosis
process. The boiler is the processes for producing of steam from the furnace oil and the soft
water. After the certain pre conditions, the hot soft water having an average feed temperature of
70oc-80oc and the hot furnace oil having the temperature of 120oc is interacted with each other
using the principle of conduction to change the soft water into the required steam. And this steam
which is produced from the boiler can runs the overall function of the plant.

The final part of this factory contains the colored water treatment plant which is called falling
film evaporating process. This evaporator is comprised of five effects. Through each effect the
amount total suspended solid composition is increased. This means that the amount of total
suspended solid at the feed is on the range of 5%-9% and the final composition is on the range of
35%-40% but it is more labor manual intensive.

The detail explanation for the working principle of the factory is given below for each chapter.

vii
 History of balezaf alcohol and liquors factory

Established in 1948 as a liquor factory, balezaf alcohol and liquor factory has grown radically to
be the biggest potable alcohol and liquor factory in Ethiopia. It is engaged in the production of
potable alcohol and different types of liquors for local consumption so far and has finalized its
preparation to go to global export market. Pure (potable) alcohol is the primary raw material for
the production of liquors. The factory produces its pure alcohol and in its own factory using
molasses as a raw material. The molasses is obtained from the state owned sugar factories. The
factory will have a key role in the country’s economy by transforming the raw material,
molasses, to higher value product extra neutral alcohol, which is used for producing different
variety of liquors in the same factory and also used as ingredients for manufacturing of
cosmetics, pharmaceuticals, and other relevant products. The factory has also been producing
potable alcohol using molasses as its raw material however, over the course of the last few years,
potable alcohol production has expanded at an incredible pace throughout the country. The
company focuses on finding alternative feedstock other than molasses to produce extra neutral
alcohol. The company has already finalized preparations to produce commercial crops(such as
maize and tubers ,cassava, potatoes and sweet potatoes) in order to produce extra neutral alcohol.
BALF have purification column which is used to purify the intended product potable alcohol that
can meet international specification for extra neutral alcohol.

Location: The factory is located in Alemgena Wereda, Oromia regional states, 25Km from the
capital, Addis Ababa.

Manpower: The Company is organized with a combined workforce of more than 250
employees. The owner, who is an industrial engineer by profession, is the managing director, and
his deputy who is a co-owner, is a graduate of business management. Of the total man power the
company has four chemical engineers, one mechanical engineer, four chemists, finance manager,
accountants, marketing personnel, electrical technologist, highly experienced mechanics,
welders, electricians and a number of semi-skilled workers running the factory. At this time there
are more than five hundred workers running in the factory.

viii
 The management structure of balezaf factory

Fig i The management structure of balezaf factory

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 Chapter one

Fermentation

1.1 Introduction

Fermentation is a chemical process by which molecules such as glucose are broken down an
aerobically to produce alcohol. Fermentation processes starts with suitable microorganisms and
specified conditions, such as careful adjustment of nutrient concentration, temperature

and others. The products are of many types: alcohol, glycerol and carbon dioxide from yeast
fermentation of various sugars. Those specified conditions highly affect the rate of fermentation.
For molasses fermentation we use yeast as a catalyst rather than bacteria. When we use bacteria
mostly the main product is lactic acid.

Within the molasses there is 75-80% sucrose, there for this sucrose should be converted in to
simple sugar (glucose).

The chemical reaction is written as:

C12H22O11 +H2O →2 C6H12O6

C6H12O6 + yeast → 2C2H5OH + 2CO2+ Energy

The output energy is due to exothermic nature of the reaction.

As we have seen from the reaction one mole of sucrose produce two moles of glucose, and one
moles of glucose produce two moles of ethanol, therefore one moles of sucrose produce four
moles of glucose.

The carbon dioxide gas is escape from the fermenter and leave to the environment since there is
no mechanism to collect carbon dioxide.

1
The rate of fermentation depends on:

1. Temperature.
2. Type and Number of yeast
3. Quality of molasses :which is the measure of sugar content

1.1.1 Raw material for fermentation process

Molasses: is the byproduct of sugar production and source of sucrose.it is the mother liquor left
after the crystallization of sugar cane juice. It is a dark colored viscous liquid, which contains
about 35-40% wt% sucrose is 20-wt% invert sugar such as glucose and fructose and 28-35wt%
of non-sugar solids. Blackstrap (syrup) is collected as a bi-product of cane sugar manufacture.

Yeast: converts to ethanol by consuming glucose.

Water: which save the yeast from shrinking due to osmosis (transfer of water from yeast towards
molasses due to water concentration difference between yeast and molasses) and it can be easily
pumped by reducing the viscosity of the molasses.

During fermentation there is a formation of foam and bubble by carbon dioxide escaping the
process. This foam is not desired as it can cause defects on surface coating. It prevents the
efficient filling of the tank. For batch fermentation is anti-foam is added and after emptying, the
tank is cleaned & prepared for a new batch. Considering is availability edible oil is used as an
anti-foaming agent.

1.1.2 Material and equipment used

To get the final fermented wine from the fermentation there are different material and
equipment’s that we use:

1. Fermentation tank
2. Propagator
2
3. High brix tank
4. Low brix tank
5. Pipe, pump, valve and mixer.
6. Air blower
7. Heat exchanger

1.1.3 Flow diagram of fermentation

Fig 1.1 Flow diagram of fermentation

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 1.1.4 Process description
As we have seen from the flow diagram the molasses is pumped from the molasses house and pass
through the heat exchanger in order to make the flow easy by decreasing the viscosity. then , less
viscous molasses is pumped to pass through a mixer where it mixes with ground water which
is supplied at the same time. Along the same pipe line we prepare two types of brix; high brix and
low brix. But, we can control easily by increasing and decreasing the opening of the valves. After
preparing the high brix and the low brix we pumped to the high brix tank and the low brix tank
respectively. Since the two types of brix are pumped on the same pipe line it should be controlled by
valve. If we prepare high brix only the high brix tank valve is open the other valve is closed the same
is true for low brix. Based on our proportion the high brix (around 25%-28% brix) is store in the
high brix tank and the low brix (around 10%-15%) is store low brix tank. The brix is measured by
saccharometer. The two high brix tanks simply store and feed the nine fermentation tank. The low
brix tank is to propagate the yeast and distribute to each fermentation tank. To propagate the yeast
fertilizer, sulfuric acid, air, starter yeast, low brix molasses is added to the propagator. Sulfuric acid is
used to maintain the PH of the solution around 4 -5, because it favors yeast to produce catalytic
enzymes and to grow fastly, and to create un-favorable condition to bacterial growth. Also the
purpose of fertilizer is as a source of nitrogen and phosphorous which are the nutritional contain of
the yeast. When the level of brix is decrease from 15% to 8% it is mature for the fermentation and at
this level of brix there is maximum number of yeast is produced. To lower the brix level to 8% takes
around 18 hours. But, it may slightly vary based on different external factor. Once the yeast is ready
it pumps to the fermentation tank. Then; the high brix is feed to the fermentation tank. After around
36 hours the fermentation process end up and the reaction almost completed. During the fermentation
process heat is liberated to the environment due to the exothermic nature of the reaction. Also carbon
dioxide is removed from the fermentation tank to the environment. But, the main useful expected
product is ethanol. After the reaction is completed it pumps to the decantation.

1.1.5 Material balance.

To know the amount of molasses and water in each fermentation tank, first we try to prepare simple
laboratory experiment and then scale up by the volume of the fermentation tank.

The volume of the fermentation tank is as follow:

1. Volume of Fermentation tank 1,2,3

4
 Circumference (C)=10m ; C=2πr ; h=5m
10m=2πr, r=1.592m
V=; v=3.14*1.592^2*5
=39.79m^3
=39,790L
2. Volume of fermentation tank 4,5
C=2πr, c=10.66m, r=1.697m, h=5m
V= π*r^2*h , v=3.14*1.697^2*5
=45.213m^3
=45,213L
3. Volume of fermentation tank 6
C=2πr, c=20.23m r=3.22m, h=2.95m
V= π*r^2*h , v=3.14*3.22^2*2.95
=96,042.5L
4. Volume of fermentation tank 7,8,9
C=2πr, C=15m, r=2.388, h=4.5m
V= π*r^2*h , v=3.14*2.388^2*4.5m
=80,576.9L

There for scale up our laboratory experiments per this much volume of the
fermentation tank.
Data: density of the molasses =1.45g/cm^3
Mass of molasses=0.1095kg.
For high brix
From this calculate the volume of molasses.
Mass =density *volume
v=m/ , v=109.5g/1.45g/cm^3, v=75.51cm^3 , v=0.07551L
Total volume of mixture=0.324L
Volume of water =0.324L-0.07551L
=0.24849L
Then calculate the volume composition of the mixture;

5
 Water =0.24849/0.324*100%
=76.69%
Molasses =0.07551/0.324*100%
=23.31%
For low brix

Here the volume of molasses is constant

V mo=0.07551L, total volume of mixture=0.601L.

Volume of water=0.601L-0.07551L

=0.52549L

Then calculate volume composition of the mixture.

Water= 0.52549/0.601*100%

= 87.435%

Molasses = 0.07551/0.601*100%

=12.565%

Then it is possible to know the amount of the molasses and water in each fermentation tank.

Since different fermentation tank have different volume and get different amount of high brix
and low brix so, it is necessary to calculate the amount in each fermentation tank.

1. For Fermentation tank 1,2,3

v=39,790L; from this much volume 5000L is low brix the rest 34,790L is high brix.

From volume composition of low brix calculate the volume of molasses and water.
Volume of water=5000*0.87435
=4,371.75L
Volume of molasses =5000-4371.75=628.25L.
Convert the volume of molasses in to mass

6
 Mass of molasses = *v, m=1.45g/cm^3*628250cm^3.
m=910.96kg
The remaining 34,790L is high brix
From the composition of the high brix the amount is calculated as follow.
Volume of water=34,790*0.7669
=26,680.45L
Volume of molasses=34,790*0.2331
=8109.549L
Mass of molasses = *v, m=1.45g/cm^3*8109549cm^3
m=11,758.846kg.
In general the amount of the water and molasses in this fermentation tank only is:
Mass of molasses = 910.96kg +11,758.846kg
=12,669.8kg
Volume of molasses=8,737.799L
Volume of water= 31,052.2L.
Since the three fermentation tank (1, 2, 3) have the same volume, calculate the total
amount molasses and water.
Mass of molasses =3*12,669.8kg, m=38,009.4kg
Volume of water=3*(4371.75L+26,680.45L), v=93,156.6L
Volume of molasses=3*8737.799L, v=26,213.397L
2. For fermentation 4,5
The volume of fermentation 4 and 5 is 45,213L, from this 5000L is low brix and the
rest 40,213L is high brix.
For low brix

Volume of molasses=0.12565*5000L

=628.25L
Mass of molasses= *v, m= 1.45g/cm^3 *628250*cm^3
m=910.962kg
Volume of water=5000L-628.25L
V=4,371.75L

7
 For high brix

Volume of water=0.7669*40,213
=30,839.35L
Volume of molasses=9373.65L
Mass 0f molasses= *v , m=1.45g/cm^3*9373650cm^3
=13,591.7925kg
Then calculate the total amount of molasses and water.
Total mass of molasses in one fermentation tank=
910.962kg +13,591.7925kg =14,502.7545kg, since this is for one fermentation tank it
should be multiplied by 2.
Total molasses in the two fermentation tank=2*14,502.7545kg
=29,005.509kg
Total water consumption in one fermentation tank=30,839.35L + 4,371.75L,
V=35,211.1L

Total volume of water in two fermentation tank =2*35,211.1L,

V total=70,422.2L

3. For fermentation tank 6

The volume of fermentation 6 is 96,042.5L, from this 10,000Lis low brix and the
remaining 86,042.5L is high brix.
For low brix
Volume of molasses = 0.12565*10000L
=1256.5L
Volume of water= 10000L-1256.5L
=8743.5L
Mass of molasses= *v, m=1.45g/cm^3*1256500cm^3
=1821.925kg
For high brix
Volume of molasses =0.2331*86,042.5L, v=20,056.5L
Mass of molasses =  *v, m=1.45g/cm^3*20056500cm^3

8
 =29,081.925kg
Volume of water =86,042.5L-20,056.5L, V=65,986L
Total amount of molasses and water
Total volume of water=8743.5L + 65,986L
=74,729.5L
Mass of molasses =1821.925kg +29,081.925kg
=30,903.85kg
4. For fermentation tank 7,8,9
The volume is 80,576.9L; from this 10,000L are low brix and the remaining
70,576.9L.

For low brix

Volume of molasses=0.12565*10,000L
=1256.5L
Volume of water =10000L-1256.5L, V=8743.5L
Mass of molasses= *v, m=1.45g/cm^3*1256500cm^3
=1821.925kg
For high brix
Volume of molasses=0.2331*70,576.9L, V=16,451.47L
Volume of water=70,576.9L-16,451.47L, V=54,125.43L
Mass of molasses= *v, m=1.45g/cm^3*16451470cm^3
=23,854.6315kg
Total molasses =1821.925kg +23,854.6315kg
=25,676.5565kg
But, here there are three identical fermentation tanks. There for we should calculate
the total molasses in the three fermentation tank.
Total molasses in three fermentation tank=3*25,676.5565kg
=77,029.6695kg
Total water consumption in three fermentation tank=3*(8743.5+54,125.43)
=188,606.79L

9
 Finally calculate the total consumption of molasses and water in one batch
fermentation with in nine fermentation tank.
Total molasses= 38,009.4kg + 29,005.509kg + 30,903.85kg + 77,029.6695kg
=174,948.4285kg

Total water consumption=93,156.6L + 70,422.2L + 74,729.5L + 188,606.79L

=426,915.09L

Therefore how much alcohol is produced from 174,948.4285kg of molasses. First we should
know how much molasses is consumed for 1 liter of ethanol production.

Molecular weight of ethanol=46g/mol

Density of ethanol=0.8g/cm^3

Molecular weight of sucrose =342g/mol

Density of molasses=1.45g/cm^3

Density=mass/volume, m= *v, m=0.8g/cm^3*1000cm^3

=800g, this is the equivalent amount of one liter of ethanol.

C12H22O11 +H2O →2 C6H12O6

C6H12O6 + yeast → 2C2H5OH + 2CO2+ Energy

C12H22O11 + H2O → 4C2H5OH + 4CO2, this implies that one mole of sucrose produce
four mole of ethanol. From the total brix around 46% is sucrose. From 80% brix in the molasses
46% is sucrose. The ratio is 1:4.

Mole (n) =mass (m)/molecular mass(M) , n=m/M, n=800g/46g/mol

=17.39mol, the equivalent form of one liter

1mole of sucrose=4mole of ethanol

? Mole of sucrose=17.39mole of ethanol

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Mole of sucrose=(17.39mole of ethanol*1mole of sucrose)/4mole of ethnol

=4.3475mole of sucrose

There for the amount of sucrose in mass is:

m=n*M , m=4.3475mol*342g/mol

m=1486.845g

Since the amount of sucrose is 46% of the brix, which is 80% of the molasses.

Mass of molasses=1486.845g/0.46*0.8

=4040.34g

This is the amount of molasses consumption to get 1 liter of ethanol. From this it should be
easily calculated the production of ethanol in one batch of fermentation from the nine
fermentation tank. As I try to calculate the amount of molasses consumption in one batch is
174,948.4285kg so the amount of ethanol is calculated as:

1li. Of ethanol=4.04034kg

? li. Of ethanol=174,948.4285kg

Amount of ethanol = (1 li. Of ethanol *174,948.4285kg)/4.04034kg

= 43,300.42237L

C12H22O11 + H2O → 4C2H5OH + 4CO2

As we have seen from this chemical reaction carbon dioxide produce: the amount of carbon
dioxide produced from 174,948.4285kg of molasses is:

Amount of sucrose=174,948.4285*0.46*0.8

=64,381.02169kg

n=m/M , n=64,381.02169kg/342g/mol

11
 =188,248.6mol

From the reaction 1 mol of sucrose produce 4 mol of carbon dioxide.

1 mol of sucrose = 4 mol of carbon dioxide

188,248.6mol = ? mol of carbon dioxide

Mol of carbon dioxide= (4 mol of carbon dioxide*188,248.6mo of sucrose)/1 mol of sucrose

=752,994.4mol

Convert this in to mass

n=m/M , m=M*n , m=44 g/mol*752,994.4mol

=33,131.7536kg

The density of carbon dioxide in liquid state is 771g/L.

Volume =mass/volume , V=33,131.7536kg/771g/L

V=42,972.443L

Per batch of fermentation this much of carbon dioxide is produced.

1.1.6 Conclusion
Generally the fermentation process is the process of producing ethanol from the fermentable
sugar. For this beverage factory, the molasses after it is diluted is taken to the low and high brix
tanker. And the low brix molasses is used for the yeast propagation process and then the high
brix molasses and propagated yeast is fed to the different size fermenters. Based on the types of
molasses used and the environmental condition, the fermentation process may takes long or short
fermentation time and also the percentage of alcohol vary. Which means as the amount of
sucrose found in the molasses is lower, the environment have either hot or cold condition the rate
of fermentation becomes decreased and the alcoholic percentage is low. Since the yeast cannot
withstand high alcoholic concentration as the concentration of alcohol increase, the yeast become
die and removed as sludge. Then, the fermented wine is sent to the decanter.

12
 1.1.7 Recommendation
We would like to recommend on some points:

1. Temperature regulator on the fermentation tank. The fermenter work with the
environment temperature, since the yeast cannot get their optimum temperature, it cannot
ferment effectively. Therefore using cooling/heating system on the fermentation tank is
the better solution to regulate the operating temperature.
2. Carbon dioxide collection. As we try to calculate high amount of carbon dioxide is
release to the environment. Since per batch of fermentation it is possible to collect
42,972.443L.
3. Sensor. On the fermentation process there is no application of sensor. So , it is better to
use sensor on propagator , fermentation tank , and high brix tank
4. Pretreatment of molasses is required in order to facilitate the propagation of yeast, rate of
fermentation and to reduce the formation of scale on evaporator and plate of distillation
column.

13
 Chapter two

Distillation

2.1 Introduction

Distillation is the separation mechanism of two or more mixtures that exist in the same phases
based on difference boiling pointes by creating another phase that means the component which
has lower boiling points vaporize first and goes to the upper column and the other one which has
high boiling point goes to the lower part of the column. The vapor pressure creates by supplying
heat as separating agent. It is the most energy intensive plant especially when the relative
volatility of the components as it approaches to unity. It takes 50%of the total energy used in the
plant.

Relative volatility is a measure of the differences in volatility between two components,

and hence their boiling points. It indicates how easy or difficult a particular separation
will be occurred.
There are many types of distillation columns each of which is designed to perform
specific types of separations. One way of classifying distillation column type is to look at
how they are operated.

Based on operation, they are of two types: batch or differential and continuous columns.

 Batch distillation

 Continuous distillation

2.1.1 Batch or differential distillation

In batch operation, the feed is introduced batch-wise to the column. That is, the column is
charged with a 'batch' and then the distillation process is carried out. When the desired
task is achieved, a next batch of feed is introduced.

14
 2.1.2 Continuous distillation columns
In contrast, continuous columns process a continuous feed stream. No interruptions occur unless there
is a problem with the column or surrounding process units. They are capable of handling high
throughputs.

Continuous column is the more common of the two types. Types of Continuous Columns
Continuous columns can be further classified according to the nature of the feed that they
are processing:

 Binary distillation column: feed contains only two components

 Multi-component distillation column: feed contains more than two

components the number of product streams they have
 Multi-product distillation column: column has more than two product streams
where the extra feed exits when it is used to help with the separation,
 Extractive distillation: where the extra feed appears in the bottom product
stream

 Azeotropic distillation: where the extra feed appears at the top product stream
the type of column internals.
 Tray distillation column: where trays of various designs are used to hold up
the liquid to provide better contact between vapor and liquid, hence better
separation
 Packed distillation column: where instead of trays, 'packings' are used to
enhance contact between vapors and liquid.

15
 2.1.3 Process Descriptions of distillation
In Balezaf, alcohol and liquor factory the distillation process description is as follows:

Fig 2.1 Overall block diagram for distillery

2.1.3.1 Decanter
Decantation is a process for the separation of mixtures, by removing a layer of liquid,
generally one from which a precipitate has settled. Decanters are used to separate liquids
where there is a sufficient difference in density between the liquids for the droplets to
settle readily du to force of gravity. The fermented wine from the fermentation entered
into decantation tank where the precipitate settled after 24 hours. Then it is pumped and
passes through by flow meter and heat exchanger then it exchange heat from spent
washes that comes from analyzer after that it feed into degasifying column at a
temperature of 650c -800c.

2.1.3.2 Degasifying Column

Degasification is the removal of dissolved gases from liquids. The wine from the
decanter enters tangentially into this column at a temperature of 650c800c. Due to helical
motion caused by tangential injection of the feed, create sufficient time for the vapor and
the liquid phase to separate. The vapor leaves at the top of the column and passes
through plate heat exchanger. The condensing gas passes through a loop form and leaves
as degassing heads1(acetaldehyde) collected as 5L/h while the non-condensing gas
leaves as degassing vent.

16
The degasifying vent and heads 1 are carbon dioxide and some other dissolved gases.
From the fermentation process, yeast uses sugar to produce alcohol and carbon dioxide.
Carbon dioxide is an undesired by product. The degasified wine leaves from the bottom
of this column send to analyzer column.

2.1.3.3 Analyzer 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 880c-
900c 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 scale fermentation in this column tray type is preferable
rather than packed type. In the fermentation process there is a formation of solid salts
from the addition of Sulphuric acid in the molasses that contain calcium ion. This
calcium sulphate forms a scale when heat is supplied in the analyzer column.

The degasified wine introduced from side of this column falls through the down comers
by gravity from one tray to another. Heat in the form of steam supplied to the base of the
column and rises via the openings on each tray. As the steam passes through the feed on
the tray, it transfers heat to the feed. Because of the heat, input from the steam the liquid
on the tray boils generating vapor that 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 was sent to aldehyde for further
purification.

17
If there is an alcohol in the spent wash this might be caused by, sufficient steam is not
supplied or excessive fermented wine 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 simultaneous increase of bottom pressure and the decrease of top pressure
due to abnormal liquid buildup of scale on tray and the feed rate is more than vapor flow
rate.

2.1.3.4 Aldehyde Column

It is a packed type column operates under a temperature of 740c-760c and a pressure of
100mbar. It is used to separate highly volatile low boiling point components.

The vapor that 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 that do not condense in the first pass to the next heat exchanger.
The non-condensing gas leaves off as a T5 vent from the last heat exchanger. The
condensing vapor in the two heat exchangers Aldehyde heads 1, amounting to about
100L/h, is drawn off from the two heat exchanger reflux loop and refluxed back to the
column. The raw alcohol portion of the feed tends to go down the column.

The product coming from this column is called raw alcohols (katikala) with alcohol
grade 4555%v/v. It passes through plate type heat exchanger to be cooled and stored in
the shift tanker.

18
 2.1.3.5 Extractive distillation column
Extractive distillation is a distillation in the presence of a miscible high boiling point
relatively non-volatile component, the solvent that forms no azeotrope 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 does not form an azeotrope mixture.

The solvent interact differently with the components of the mixture there by causing their
relative volatilities to change. Extractive distillation column is a packed type column
operated at a temperature of 1300c-1370c and a pressure of 2.8-3 bars. The raw alcohol
that 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 striping section column that
used as a solvent pass 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 1300c-1370c condenses by the water from the stripping
section column (T=700c), then the water recycled back to the striping section column as
re-boiler. Head3 (acetal aldehyde) is collected 100L/h from the condenser then pass
through heat exchanger and stored in the tanker. The rest refluxed back to the top side of
the column near the hot water. The bottom product consists of a mixture of the solvent
and the other component that is 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 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
stripping section column preheated by the 6-8%v/v diluted alcohol in the heat exchanger.
The diluted alcohol enters into stainless steel rectification column.

19
 2.1.3.6 Stripping process
The stripping section and the rectifying section can be built as a 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. However, 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 750c820c and

pressure of 250450 mbar. The main objective of this column is to remove much of the
water contained in the feed and it separate light and fuel oil from the alcohol mixture.
Steam inters at the bottom and also the feed dilutes raw alcohol (8%v/v) inter at middle
in addition to that hot water comes from the condenser (it used as re-boiler for stripping
section) inter at the bottom parallel with steam.

Lease water comes out below steam feed and also hot water comes out at the bottom and
some goes to re-boiler and some goes to condenser. After that steam used as energy
source and the one that have small boiling point have goes to rectification column in the
form of vapor.

2.1.3.7 Rectification process

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 720c-740c and a pressure of 250-450mbar.It used to upgrade the
concentration of more volatile component and it also used to separate methanol from the
mixture. 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 could not 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 30L/hr of heads 2 main and 40L/hr heads 2 vents is collected from the reflux

20
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, which is pure alcohol, having 96.8%v/v alcohol
grade collected at the upper side of the column and stored in pure alcohol storage tank.
The upper part of the column is made up of copper. Copper is preferable because it
improve the quality and taste of the alcohol by reacting with sulphate ion and form
copper sulphate.

2.1.4 General process description

Fermented wine store for 24 hours at the decanter in order to remove sludge then it
transfer to the first heat exchanger. In this heat exchanger, the spent wash comes from
analyzer increase temperature of fermented wine after that it moves to degasifying
column in this column CO2 and other light component is removed at the top and cooled
by coolant water in heat exchanger. Fermented wine out at the bottom and inter to
analyzer at the top of the plate steam inter at the bottom 2m above the ground and spent
wash out at bottom 1m above the ground. At the top alcohol and water mixture move to
aldehyde column in this column aldehyde group removed in the form of head one (H1) at
the top of the column after it pass the two-heat exchanger. Raw alcohol is out the bottom
of the column and store.

After that, raw alcohol is pumped to shell and tube heat exchanger in this dilute alcohol
comes from extractive distillery and inter to re-boiler. In the re-boiler steam heated dilute
alcohol and then this dilute alcohol heat both leas water and raw alcohol. Raw alcohol
feed below hot water feed in extractive distillery because alcohol is light. At the bottom
dilute alcohol (8vpercentagev) out and at the top out is inter to condenser. In this hot

21
water comes from striping section Condense top of extractive distillery and un-condense
is out in the form of head three (H3) other is reflux to extractive column (ED).

Dilute alcohol feed to striping section, steam at the bottom with hot water comes from
ED condenser, and then leas water out at the bottom and alcohol out at the top and light
oil and fusil oil out. Alcohol inter to rectification section in this column most of the time
methanol and ethanol separate. Ethanol is separate at the top by five-extraction line and
methanol is out and inters to mean and vent condenser and some reflux and other
removed as denature alcohol.

2.1.5 Process Flow Diagrams of Distillation

Fig 2.2 Process Flow Diagrams of Distillation

2.1.6 Material and Equipment’s

Valves: It is a device that regulates directs or controls the flow of Fluid like gases,
liquids, fluidized solids.

Steam trap: A steam trap is an automatic valve that allows condensate, air and other non-
condensable gases to be discharged from the steam system while holding or trapping the steam in

22
the system. For any steam, system to operate properly a method must be used to remove the
condensate, air and other non-condensable gases such as carbon dioxide from the steam.

Pump; It used to deliver fluids from one location to another through conduit. The
selection is made on the flow rate and head required together with other process
consideration such as corrosion or the pressure of solids in the fluids.
Heat exchanger: It is a device, which used for the transfer (exchange) of heat. They are used in
cooling and heating application.

Re-boiler: is used with distillation columns to vaporize a fraction of the bottom product.

Condenser: is a device or unit used to condense a substance from its gaseous to its
liquid state.

Pressure gage: Is used for measuring the pressure of a gas or liquid. Flow meter: - it is
the quantification of bulk fluid movement flow can be measured in variety of ways.

Temperature sensor: Is used to indicate the temperature of the column. Header: - is receives
steam from the source and gives equivalent distribution for recommended section.

2.1.7 Material balances

The general equation for any process system can be written as:

Material out=Material in+ Generation-Consumption- Accumulation

For steady process, there is no generation, consumption that means the equation becomes

Material out=Material in

Now let us calculate in each column of the aldehyde

23
Given=11,000L/H, H1D=5L/H

Head1 (H1d)

tella (T1)
Fermented DDegasifying column

wine (F )

From the data F=11,000l/h and H1d=5l/h F=T1+H1d

T1=F-H1d=11,000l/h-5l/h=10,995l/h

Head1a

Aldehyde column
Analyzer column
T1

Steam Spent wash Katikala

24
Solution

Input=out put T1=spent

wash+head1a+katicala
Spent wash (sw) =?
But head1a=100l/h and katikala=2000l/h

Then 10,995l/h=spent wash+100l/h+2000l/h

From this spent wash=10,995l/h-(100+2000) l/h

Spent wash=8895l/h

Head3
Hot water Diluted katikala
Extractive distillation column

Katikala

Solution s team

To calculated the amount of diluted katikala total mass balance hot water(hw)
+katikala(k)=head3+diluted katikala(Dk) let us take the component balance of the alcohol
Rk*xk=Dk*xd+H3*x3 from this
Dk=(Rk*xk-H3x3)xd but from the grade reader xk=0.475 ,x3=0.8 and xd=0.125 now

Dk=((2000l/h*0.475)-(100l/h*0.8))/0.125,Dk=6960 or by using total balance

HW+Rk=H3+Dk from this HW=Dk+H3-Rk

HW=6960+100-2000

25
Hot water used in this column is ~5000l/h

Now to calculate the amount of leather water take the over balance of the alcohol component

Dk=diluted alcohol

Lo=light oil

Fo=fuse oil

LW=Leath water

M=mean=Vent=pure alcohol

From the data taken in the grade reader

Xkd=0.125, xlo=0.675, xfo=0.68, xm=xv=0.966 xp=o.97, xLw=0

M=30l/h,V=40l/h,p=800l/h,Fo=Lo=40l/h

26
General flow rate

Dk=Lo+Fo+M+V+Lw+P

Component balance

DK*Xd=LW*Xlw+Fo*Xfo+Lo*Xlo+M*Xm+V*Xv+P*Xp

P= ( DK*Xd-(LW*Xlw+FO*Xfo+Lo*Xlo+M*Xm+V*Xv))/XP

P=((6960*0.125)-(0*LW+40*0.68+40*0.675+30*0.966+40*0.966))/0.97

P=770L/h

Then the recycled lease water

LW=DK-(LO+FO+M+V+P)

=6960-(40+40+30+40+770)

=6040L/H

2.1.8 Conclusion
The major operation in the distillery is to separate ethanol from the fermented wine by
using steam as a heat energy. The fermented wine, which is coming from the decanter,
passes through the different columns which are degasifying column, analyzer column,
aldehyde column, extractive distillation column, stainless striping section column and
copper rectification section column. Through these process alcohols like isopropanol,
light oil, fuel oil is separated out. The product coming from the last column, which is
copper column, has alcohol content of 96.6%v/v pure alcohol and denatures alcohol as a
byproduct.

27
 2.1.9 Recommendation

In this distillation column, there is so many un-functional tube.so it is wastage of money.

The other one is if you replace the rectification totally by copper is important to get more
purified Ethanol. The temperature sensor before the fermented wine enters to degasifying
section is unfunctional.so it is difficult to know the temperature before it entered. There is
no any sensor to detect the concentration and type of component in any vent. So may be the
alcohol is going out.

A loss of heat along the column causes increased condensation and reduced evaporation.
The distillation column should be well insulated to prevent loss of heat and to protect
against burns

28
 Chapter three

Water treatment

3.1Introduction
Water treatment is the process that improves the quality of water to make it more acceptable for
a specific use. This use may be for drinking, industrial water supply, irrigation, river flow
maintenance, water recreation or many other uses, including being safely returned to the
environment. Water treatment removes contaminants and undesirable components, or reduces
their concentration so that the water becomes fit for its desired use. This treatment is crucial to
human health and allows humans to benefit from both drinking and irrigation use. The processes
involved in removing the contaminants include physical processes such as settling and filtration,
chemical processes coagulation. Measures taken to ensure water quality not only relate to the
treatment of the water, but to its conveyance and distribution after treatment. It is therefore
common practice to keep residual disinfectants in the treated water to kill bacteriological
contamination during distribution.

As I have seen in the water treatment plant, it is also used to optimize most water-based
industrial processes, such as heating, cooling, processing, and cleaning, so that operating costs
and risks are reduced. Poor water treatment lets water interact with the surfaces of pipes and
vessels which contain it. Steam boilers can scale up or corrode, and these deposits will mean
more fuel is needed to heat the same amount of water. Cooling towers can also scale up and
corrode, but left untreated, the warm, dirty water they can contain will encourage bacteria to
grow.

Industrial water treatment needs to manage the following main problems, such as: scaling,
corrosion, microbiological activity.

Scaling occurs when the chemistry and temperature conditions are such that the dissolved
mineral salts in the water are caused to precipitate and form solid deposits. These can be mobile,
like a fine silt, or can build up in layers on the metal surfaces of the systems. Scale is a problem
because it insulates and heat exchange becomes less efficient as the scale thickens, which wastes

29
energy. Scale also narrows pipe widths and therefore increases the energy used in pumping the
water through the pipes.

Corrosion occurs when the parent metal oxidizes (as iron rusts, for example) and gradually the
integrity of the plant equipment is compromised. The corrosion products can cause similar
problems to scale, but corrosion can also lead to leaks, which in a pressurized system can lead to
catastrophic failures. Without effective water treatment, a cooling water system can suffer from
corrosion and fouling and may become a breeding ground for harmful bacteria. This reduces
efficiency, shortens plant life and makes operations unreliable and unsafe. Since the production
of alcohol requires the soften water; it is necessary to study about the hard water as follows.

3.1.1 Water hardness

Water hardness is determined by the concentration of multivalent cations in the water.
Multivalent cations are positively charged metal complexes with a charge greater than 1+.
Usually, the cations have the charge of 2+. Common cations found in hard water include Ca2+
and Mg2+. These ions enter a water supply by leaching from minerals within an aquifer.
Common calcium containing minerals are calcite and gypsum. A common magnesium mineral is
dolomite (which also contains calcium). Rainwater and distilled water are soft, because they
contain few ions.The following equilibrium reaction describes the dissolving and formation of
calcium carbonate and calcium bicarbonate:

CaCO3 (s) + CO2 (aq) + H2O (l) ⇌ Ca2+ (aq) + 2 HCO−3 (aq)

The reaction can go in either direction. Rain containing dissolved carbon dioxide can react with
calcium carbonate and carry calcium ions away with it. The calcium carbonate may be re-
deposited as calcite as the carbon dioxide is lost to atmosphere.

The are two main types of the hard water. These are:

30
 3.1.2 Temporary hardness
Temporary hardness is a type of water hardness caused by the presence of dissolved bicarbonate
minerals (calcium bicarbonate and magnesium bicarbonate). When dissolved, these type of
minerals yield calcium and magnesium cations (Ca2+, Mg2+) and carbonate and bicarbonate
anions (CO2−3 and HCO−3). The presence of the metal cations makes the water hard. However,
unlike the permanent hardness caused by sulfate and chloride compounds, this temporary
hardness can be reduced either by boiling the water, or by the addition of lime (calcium
hydroxide) through the process of lime softening. Boiling promotes the formation of carbonate
from the bicarbonate and precipitates calcium carbonate out of solution, leaving water that is
softer upon cooling.

3.1.3 Permanent hardness

Permanent hardness (mineral content) are generally difficult to remove by boiling. If this occurs,
it is usually caused by the presence of calcium sulfate/calcium chloride and or magnesium
sulfate/magnesium chloride in the water, which do not precipitate out as the temperature
increases. Ions causing permanent hardness of water can be removed using a water softener, or
ion exchange column.

In order to change the hard water to the soften water we can apply the following main processes.
This includes;

3.1.4 Filtration
Filtration plays an important role in the natural treatment of groundwater as it percolates through
the soil. It is also a major part of most water treatment. Groundwater that has been softened, or
treated through iron and manganese oxidation, requires filtration to remove floc created by
coagulation or oxidation processes. Since surface water is subject to runoff and does not undergo
natural filtration, it must be filtered to remove particles and impurities. Filtration can be
compared to a sieve that traps suspended material between the grains of filter media. However,
since most suspended particles can easily pass through the spaces between grains of the filter
media, straining is the least important process in filtration. Filtration primarily depends on a
combination of complex physical and chemical mechanisms, the most important being

31
adsorption. Adsorption is the process of particles sticking onto the surface of the individual filter
grains or onto the previously deposited materials.

3.1.5 The softening Process

Calcium (Ca2+) and magnesium (Mg2+) ions that cause water hardness can be removed fairly
easily by using an ion exchange procedure. Standard water softeners are cation exchange
devices. Cations refer to positively charged ions dissolved in the water. Cation exchange
involves the replacement of the hardness ions with a non-hardness ion. Water softeners usually
use sodium (Na+) as the exchange ion. Sodium ions are supplied from dissolved sodium chloride
salt, also called brine. In the ion exchange process, sodium ions are used to coat an exchange
medium in the softener. The exchange medium can be natural “zeolites” or synthetic resin beads
that resemble wet sand. As hard water passes through a softener, the calcium and magnesium
trade places with sodium ions. Sodium ions are held loosely and are replaced easily by calcium
and magnesium ions. During this process, free sodium ions are released into the water and make
it soft.

Generally the ion exchange machine involves the following main reactions:

Softening:

AlSiO8Na2+CaCO3 AlSiO8Ca+Na2CO3

AlSiO8Na2+MgCO3 AlSiO8Mg+NaCO3

AlSiO8Na2+MgSO4 AlSiO8Mg+NaSO4

3.1.6 Re-generation Process

After softening a large quantity of hard water, the exchange medium becomes coated with
calcium and magnesium ions. When this occurs, the exchange medium must be recharged or
regenerated to recharge the softener with sodium ions, a softener is back flushed with a salt brine
solution. During a back flush, the brine solution replaces the calcium and magnesium ions on the
exchange medium with sodium ions from the salt solution.

32
Regeneration:

AlSIO8Ca+2NaCl AlSiO8Na2+CaCl2

AlSiO8Mg+2NaCl AlSiO8Na2+MgCl2

3.1.7 Dis-infection
If biological contamination is a concern, the water may then be disinfected to remove any
pathogens. Disinfection may be accomplished through the application of chemical disinfectants
(e.g. chlorine), physical disinfectants (e.g. UV or heat), as well as some forms of membrane
filtration. Certain contaminants in water can reduce the transmission of UV light through the
water, which reduces the UV dose that reaches the bacteria. These UV absorbing contaminants
include turbidity, iron, and humic and fulvic acid, common to surface water supplies. Suspended
particles are a problem because microorganisms buried within particles are shielded from the UV
light and pass through the unit unaffected. UV disinfection is most effective for treating high-
clarity purified reverse osmosis or distilled water.

3.1.8. Reverse osmosis

Reverse Osmosis is a technology that is used to remove a large majority of contaminants from
water by pushing the water under pressure through a semi permeable membrane. A reverse
osmosis membrane is a semi permeable membrane that allows the passage of water molecules
but not the majority of dissolved salts, organics, and bacteria. However, the need to push the
water through the reverse osmosis membrane by applying pressure that is greater than the
naturally occurring osmotic pressure in order to desalinate (de-mineralize or de-ionize) water in
the process, allowing pure water through while holding back a majority of contaminants. A
simple example is a screen door. It allows air molecules to pass through but not pests or anything
larger than the holes in the screen door. Reverse Osmosis is also the process of Osmosis in
reverse process, Whereas Osmosis occurs naturally without energy required, to reverse the
process of osmosis it need to apply energy to the more saline solution.

3.1.9 working principle of Reverse Osmosis

Reverse osmosis works by using a high pressure pump to increase the pressure on the salt side of
the RO and force the water across the semi permeable RO membrane, leaving almost all of

33
dissolved salts behind in the reject stream. The amount of pressure required depends on the salt
concentration of the feed water. The more concentrated the feed water, the more pressure is
required to overcome the osmotic pressure. In very simple terms, feed water is pumped into a
Reverse Osmosis system and the product becomes two types of water coming out of the RO
system: these are: good water and bad water. The good water that comes out of an RO system
has the majority of contaminants removed and is called permeate. Permeate is the water that was
pushed through the RO membrane and contains very little contaminants. The other water is
called bad water which is the water that contains all of the contaminants that were unable to pass
through the RO membrane and is known as the concentrate, reject, or brine. All three terms
(concentrate, reject, and brine) are used interchangeably. As the feed water enters the RO
membrane under pressure (enough pressure to overcome osmotic pressure) the water molecules
pass through the semi-permeable membrane and the salts and other contaminants are not allowed
to pass and are discharged through the concentrate stream, which goes to drain or can be fed
back into the feed water supply in some circumstances to be recycled through the RO system to
save water.

3.2 Cooling tower

Cooling Tower is a device for reducing the temperature of the hot water by bringing it into
contact with an airstream. During this cooling process there is some amount of water is
evaporated and this water is replaced by other water which is coming from the soft water tanker
called make up water. The hot water to be cooled is coming from the distillation process and
after it is cooled, it becomes reused again for the condensation and heat exchanging processes.

3.2.1 Types of cooling tower

Mainly there are two types of cooling tower based on the way is works.

These are:

A. Natural cooling tower

As the name indicates it works without the applying of the external force like fan. Since it works
naturally it is cheaper than mechanical cooling but it is less efficient.

34
B. mechanical cooling tower

Mechanical draft towers have large fans to force or draw air through circulated water. The water
falls downwards over fill surfaces, which help increase the contact time between the water and
the air - this helps maximize heat transfer between the two. Cooling rates of mechanical draft
towers depend upon various parameters such as fan diameter and speed of operation.

3.2.2 The equipment and materials used

The equipment’s used in the water treatment plant are given below.

 Pump used for forcing of water to be flow

 Valves used for controlling flow rate, as on/off system
 Tankers for storage of hard, soft and permeate water.
 Filtration guard
 Filter bag
 Sensor for level, temperature measurement
 Voltmeter for power used measurement
 Pipes for the flowing of water
 Ground water is fresh water (from rain or melting ice and snow) that soaks into the soil
and is stored in the tiny spaces (pores) between rocks and particles of soil. Groundwater
can also come to the surface as a spring or be pumped from a well. Both of these are
common ways we get groundwater to drink and for industrial uses.
 Brine solution for regeneration process
 UV light as disinfectant.

3.2.3 Process description

The ground water is pumped and taken to the hard water tanker. Using the centrifugal pump the
hard water is transfer to the first treatment process called filtration which is the physical process.
At this process the suspended solid is separated and the hard water with some amount of
suspended particle and other components like the carbonate, bicarbonate, and sulphates of
magnesium and calcium salt passes through the filter bag and entered to the second process
which is softening (ion exchanging). The equipment used for this process is softener which

35
contains the complex compound of aluminum silicate combined with an active element sodium
which is called zeolite and its working principle is as the hard water enters to the softener, the
magnesium and calcium ion is replaced by sodium ion and this sodium ion is reacted with the
salt coming with magnesium and calcium such as carbonate, sulphate at the entered water. The
magnesium and calcium ion is reacted with the zeolite. As the time is increased its efficiency
becomes decreased and its can be regenerated by using the brine solution. To know whether its
efficiency is decreased or not, we use an indicator solution. As we drop this indicator solution on
the sample and if the color is changed into blue, it indicates the water is soft and if it is red color,
it indicates hard water. Therefore regeneration of the zeolite is required in order to re increased
the efficiency of the softener. During the regeneration time, brine solution is used to replace
magnesium and calcium ion for about 2:15 hour, finally the performance of the softener is
recovered. The calcium and magnesium ions becomes reacted with chlorine and remove a as a
waste with some amount of water. In a continuous process the hard water is changed into soft
water, it is transfer to the soft water tanker. Then after this process, the microorganisms like
bacteria, fungus and other organisms are treated with UV light system, and distributed into
different direction for different purpose like for boiler, bottling, gin production, cooling tower
and some amount of soft water is taken for further treatment process which is called reverse
osmosis of soft water. The equipment used for this process is semi permeable membrane. Which
is used pass only the pure neutralized water and it blocks the flow of salts and other suspended
particles, bacteria, fungus. The name the water output to the RO system is permeate and salt and
other component is discharged to the environment as a waste. This process is used for
demineralization of the soft water. This demineralized water is used for the liquor preparation
process as a dilution for concentrated ethanol into different products.

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 3.2.4 The flow diagram for the water treatment

Fig 3.1 the flow diagram for the water treatment

3.2.5 Conclusion
Generally proper ground water treatment is necessary to produce the more qualified alcoholic
product. Since untreated water having ionized salt causes for occurrence of reaction and gives
other undesired products. And also good ground water treatment increases the working time of
the machines designed for the liquor production like boiler, pipes. This is due to the formation of
scaling and corrosion. These soft water is distribute to the distillery, cooling tower , boiler and
the RO water is to bottling to prevent from side reaction. When the softeners become saturated it
should be regenerate by using brine.

3.2.6 Recommendation

From the water treatment plant we have seen the following limitations to be reviewed as an idea:

 During the regeneration of the softener, there is the discharge of mineralized water
containing calcium and magnesium salts to the environment. Even if it has little impact

37
 on the environment, why not use this mineralized water for other purpose. Since this
water contains high amount of calcium and magnesium salts, we can use it for other
purposes therefore discharging into the environment is not advisable.

 For the UV light, the voltmeter reads zero volts which indicate it does not work properly
therefore why not review it?

 The concentrated water leaves from the RO machine is directly discharge to the
environment. But, it is better to recycle to the soft water tanker. This water is already
treated and its hardness is removed, so we can use it for boiler and cooling tower.

If we use it for this purpose properly:

We reduce and save the hard water consumption for the overall process.

We can reduce the amount of brine solution used for regeneration of the softener.

Also we can save the amount of power used for disinfection process and the overall
process.

 During the regeneration process there is a limitation. Since the process of checking the
softness of water is performed manually in a certain period of time and during this time
there may be an error occurring which gives insufficient softened water so, in order to
minimize this error, it is better to use the automatic way of checking water hardness.

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 Chapter four

Boiler

4.1 Introduction
Boiler is a closed pressure vessel in to which water can be fed and by applying heat
continuously, evaporated in to steam. The function of the boiler is to generate steam at the
desired conditions efficiently and with low operating costs. Low pressure steam is used in
process an application whereas high pressure superheated steam is used for generating power via
steam turbines. Boilers consist of a number of tubes for maximum heat transfer. These tubes runs
between steam distribution drum at the top of the boiler and water collecting drums at the bottom
of the boiler. Steam flows from the steam drum to the super heater before entering the steam
distribution system. Boiler, also called Steam Generator, apparatus designed to convert a liquid
to vapor. In a conventional steam power plant, a boiler consists of a furnace in which fuel is
burned, surfaces to transmit heat from the combustion products to the water, and a space where
steam can form and collect. A conventional boiler has a furnace that burns a fossil fuel.

The three feed systems for one boiler:

1. Feed water system

2. Steam system

3. Fuel system

The feed water system: provides water to the boiler and regulates it automatically to meet the
steam demand. The water supplied to boiler that is converted to steam is called feed water. The
sources of feed water are:

Some key components of the feed water system include:

 Boiler Feed water Heaters – Feed water heaters make boilers more efficient by preheating the
feed water so that the boiler doesn’t have to work as hard to get the temperature of the feed
water high enough to convert into steam. The heat for the feed water heater is usually recovered
and rerouted from the boiler itself.

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 De-aerators: it helps treat the feed water before it enters the boiler by removing excess oxygen
from it. This is done by passing a stream of steam through the feed water, which thereby strips it
of oxygen because oxygen is less and less soluble at higher temperature levels.
 Feed Pump – The feed pump is the pump which pumps the feed water into the boiler.
 Economizer – As their name implies, economizers help make the boiler more economical to run.
They accomplish this by extracting heat from the exhaust of the boiler and re-routing it to the
feed water. Not all boilers have economizers.
Condensate or condensed steam returned from the processes

Makeup water which is the raw water which must come from outside the boiler room and plant
processes.

The steam system: collects and controls the steam produced in the boiler. Steam is directed
through a piping system to the point of use. Throughout the system, steam pressure is regulated
using valves and checked with steam pressure gauges.

Some components of the steam system.

 Steam Drum – The steam drum is the upper drum of a water-tube boiler where the steam
separates from the liquid water. The lower drum is referred to as the mud drum and it contains
the liquid water.
 Boiler Tubes – The boiler tubes are the tubes through which the steam passes as it makes its way
through the boiler. High strength carbon steel is often used in the fabrication of boiler tubes to
make it more durable and to resist problems associated with corrosion or mineral deposits.
 Super heater – The super heater is used to remove excess moisture content from the steam by
raising it above its saturation point. This is particularly important if the steam is being used for
power generation because water droplets in the steam could damage the turbines. Because of the
high temperature demands placed on super heaters, higher alloy steel is typically used in their
construction.
 Condenser – The condenser condenses the steam back into water so that it can be reused in the
feed water system. This improves the overall efficiency of the boiler.
 Condensate Pump – The condensate pump pumps the condensate back to the storage tank.

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 The fuel system: includes all equipment used to provide fuel to generate the necessary heat. The
equipment’s required in the fuel system depend on the type of fuel used in the system.

The fuel and combustion system is the system that ignites the fuel source which in turn
releases the heat needed to convert the liquid water into steam.

Some components of fuel system.

 Burner – The burner introduces the fuel and the air needed for combustion into the furnace at the
desired concentration. Maintaining the right balance of each is important because too much or
too little fuel or air can reduce the efficiency of the boiler and create extra waste.
 Furnace – The furnace is the enclosed space where the combustion actually takes place.
 Firebox – In a water-tube boiler the firebox is what houses the combusted heat. It is surrounded
by water and heats the water by radiant energy.
 Stack – The boiler’s stack acts as a type of chimney through which the combustion gases exit the
boiler as exhaust.
 Bag house and Bags – The bag house acts as a filtration system for the boiler’s exhaust. The
dirty gases enter the bag house and are filtered by fabric or felt bags which capture solids such
as ash and soot. This allows clean air to exhaust the entire system.

4.1.1 Types of Boiler

Mainly there are two types of boiler according to the flow of water and gases. These are:

A. Water tube: It 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.
B. Fire-tube boiler: It is a type of boiler in which hot gases pass from a fire through one or
(many) 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.

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 4.1.2 De-aerator

It is a device that removes oxygen and other dissolved gases from liquids. De-aerators are
commonly used to remove dissolved gases in feed water for steam-generating boilers. Dissolved
oxygen in feed water will cause serious corrosion damage in a boiler by attaching to the walls of
metal piping and other equipment and forming oxides like rust. Dissolved carbon dioxide
combines with water to form carbonic acid that may cause further corrosion. The de-aerators in
the steam generating systems of most thermal power plants use low pressure steam obtained
from an extraction point in their steam turbine system. However, the steam generators in many
large industrial facilities such as petroleum refineries may use whatever low-pressure steam is
available.

De-aerators are also used to remove dissolved gases from products such as food, personal care
products, cosmetic products, chemicals, and pharmaceuticals to increase the dosing accuracy in
the filling process, to increase product shelf stability, to prevent oxidative effects (e.g. dis
coloration, changes of smell or taste, rancidity), to alter pH, and to reduce packaging volume.

4.1.3 Economizer
It is basically tubular heat transfer surfaces used to preheat boiler feed water before it enters
the steam drum. By recovering the energy from the flue gas before it is exhausted to the
atmosphere this performs a key function in providing high overall boiler thermal efficiency.
Flue gases from boilers are typically in the range of 230-345°C depending upon boiler pressure.
Stack Economizers recover some of this heat for pre-heating water. The water is most often used
as boiler make-up water or some other need that coincides with boiler operation. Stack
Economizers should be considered as an efficiency measure when large amounts of make-up
water are used, i.e. when there is no / low condensate return or there is a simultaneous need for
large quantities of hot water for some process requirement.
How does it work is: Boiler stack economizers are simply heat exchangers with hot flue gas on
shell side and water on tube side with extended heating surface like Fins or Gills. Economizers
must be sized for the volume of flue gas, its temperature, the maximum pressure drop allowed
through the stack, what kind of fuel is used in the boiler, and how much energy needs to be
recovered.

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 4.1.4 Working principle of Boilers:
Both gas and oil fired boilers use controlled combustion of the fuel to heat water. The key boiler
components involved in this process are the burner, combustion chamber, heat exchanger, and
controls. The burner mixes the fuel and oxygen together and, with the assistance of an ignition
device, provides a platform for combustion. This combustion takes place in the combustion
chamber, and the heat that it generates is transferred to the water through the heat exchanger.
Controls regulate the ignition, burner firing rate, fuel supply, air supply, exhaust draft, water
temperature, steam pressure and boiler pressure.

4.1.5 Boiler efficiency

The percentage of the heat energy contained in the fuel that is captured by the working fluid (e.g.
water) in the boiler is defined as the combustion efficiency of the boiler. Combustion efficiencies
of 80% or higher are usually possible for hot water boilers and low pressure steam boilers for
commercial buildings. Efficiency is used as a measure of economic performance of any piece of
equipment. There are several terms used to define efficiency when used in the context of a boiler.
These include simply efficiency, combustion efficiency, thermal efficiency, boiler efficiency,
and fuel-to-steam efficiency. Following are their definitions. Complete combustion results when
a hydrocarbon fuel such as natural gas or oil burns and produces only carbon dioxide, water and
heat. If there is insufficient oxygen and/or poor mixing of fuel and oxygen, then incomplete
combustion will occur resulting in other products of combustion including carbon monoxide and
unburned fuel. When incomplete combustion occurs, the chemical energy of the fuel is not
completely released as heat and the combustion efficiency is reduced. This is also a safety
concern as unburned fuel could ignite in the stack and cause an explosion. Boilers must be tuned
to achieve complete combustion. One strategy to ensure complete combustion is to provide some
amount of excess air. However, a small amount of excess air will improve combustion
efficiency, but a large amount will reduce efficiency which is depends on the amount of fuel.

43
 4.1.6 The materials and equipment used are;

Furnace oil tanker for storing of the furnace oil soft water
Electrical and steam heater servomotor
Different type of valves solenoid valves
Deaerator filters
Steam and condensate water pumps
Electrodes fun

4.1.7 The flow diagram for boiler

Fig 4.1 The flow diagram for boiler

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 4.1.8 Process description

A. for the fire tube boiler

As it is stated above on the introduction part boiler is an enclosed machine which used to form
steam from the makeup water and the condensed steam coming from the water treatment plant
and the re boiler of the distillation process respectively. This process contains two main feed
streams which are the furnace oil feed and water feed streams.

Furnace oil feed pre-conditions: in order to feed the furnace oil, the oil must be pre heated since
direct feeding of the oil may causes for the pump energy consumption why because the unheated
oil has more viscose properties and it is difficult to pump this furnace oil using minimum power.
So the process is given as: first the furnace oil is entering to the heat primary exchanger which is
called primary heating of furnace oil. The primary heat exchanger heat the furnace oils up to the
temperature of 40oc. the primary heater contains both the mechanical and electrical heaters. The
mechanical heater uses the steam whereas the electrical heater uses electricity. If the heating
system is running for the first time it uses electrical heater and after the steam is generated the
steam is used as the primary hearer. Then after the furnace oil is leaving from the primary heater,
the heated furnace oil becomes filter and the filtered oil is pumped to the secondary heating
device which is secondary heat exchanger. The secondary heater is used to heat the furnace oil
up to the temperature of 80oc. Then using the gravitational effect this more heated furnace oil is
distributed to other two shell and tube heat exchanger before it is entered to the two boilers. Also
this heat exchanger contains both steam and electrical means of heating process. As the process
is started the electrical heater is used unless both of the two heaters are used during the working
time of the boiler. These heaters are used to heat the furnace having 80oc temperature up to the
120oc and finally this furnace oil is entered to the boiler, at the feed position. There is the
solenoid valve used to check the temperature of the oil whether it is reached to 120 oc. if does not
reach, it becomes recycled to the heater to heat it up to 120oc. since the two electrodes having
maximum voltage creates a fire when this oil is fed to the boiler and after the fire forms, there is
the supply of air using fan in order to facilitate the combustion time based on the amount of
furnace oil feed. This air is regulated by using the servomotor valves.

45
 B. The preparation of water for the boiler:

There are two water sources for the production of steam. These water as stated above of the
introduction parts which are makeup water which called permeate water coming from the water
treatment plant and the second one is the condensate water coming from the re boiler of the
distillation process after heat up the approximately 8%v/v alcohol content. The treated water is
taken into the plate type heat exchanger and it is heated using the hot lease water leaving from
the stripping section column of distillation process. Then this hot water is mixed with the
condensate steam stored at its storage tank. Also the steam is added at the water and condensate
steams to increase its temperature for increasing of steam production then this water is entered to
the de-aerator to remove the dissolved oxygen and other carbon dioxide to reduce its impact on
the performance of the boiler. Since this dissolved oxygen can cause for the creation of
corrosion, then the de-aerated water is pumped to the shell side boiler and contact with the fire
which creates steam depends on the pressure of steam. As the applied steam pressure becomes
maximum, the feed water becomes block to enter the boiler and as the pressure of the steam
becomes decreased the water can again feed to the boiler and the process is continued in such
some batch and some continuous process. And the steam formed is stored in the steam holder
and distributed into different part of the plant like to bottling, distillation process, and evaporator.

4.1.9 Conclusion

Generally boiler is the process of producing steam using soft water, condensate water coming
from the re-boiler at distillation process, and the fire creating from the combustion of furnace oil.
The quantity and quality of producing steam is depends on the quality of furnace oil to be
combusted and the temperature at which the water is fed. That means as the feed water
temperature is maximum; it can only consume minimum amount combusted oil (fire) to form
steam.

46
 4.2 Recommendation

When we have working my internship on the boiler, we have the following limitation and we
would like to recommend on it.

 The first thing that we have seen is the emission of flue gases into the atmosphere. Since
these flue gases contain multiple gas components which has direct negative impact on the
atmosphere, therefore it must be either be treated or minimize its emission from the
source by improving the working performance of the boiler.
 Also the feed water to the boiler is heated by using the steam and the hot lease water
leaving from the stripping section, but we would like to recommend that, use of
economizer as one unit operation for heating of the feed water is important for both
minimizing of consumption of steam and reducing of the impact of flue gases on the
atmosphere. Since the flue gases leaving from the boiler have maximum temperature, so
in place of discharging of it, is important for heating of feed water.
 The amount of feeds and outputs for the boiler is not known unless I have read it from its
manual literature. So the amount of its feed and the output must be known to know its
performance unless it may fail to risk one day. Since it is not known whether it works
properly in a good condition or not.

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 Chapter five

Bottling

5.1 Introduction
Blending is a process of preparing the final bottled liquor. In Balezaf alcohol, different varieties
of liquors like; ouzo, dry gin, lemon liquor, pineapple liquor, aperitif, cognac, super mint, zebib
are produced. The liquor is prepared in a batch stirrer tank mixer by adding the ingredients of the
liquor. The liquor ingredient consists mainly, pure potable alcohol or ethanol (96.5-97% v/v),
permeate water, sugar, flavors and color of the liquor. And also needs another utilities steam (for
melting sugar inside the syrup preparation tanker), soft water (for cooling syrup and clean the
equipment) electric supply to run pumps, valves and other machines and others. To overcome
and satisfy the blending process there are a lot of individual operation before, after, on the
process. The preparations of raw material needs its own process and preparation of utility also
have own process. So the blending section is a very inter connected department throughout the
industry.
5.1.1 Syrup Preparation
Syrup is prepared from the sugar; permeate water, steam, and citric acid which are prepared in
conical concentric steel ness steel tanker. The concentric shapes are used to heat the sugar
without contact of steam directly. So the steam entered to melt the sugar in concentric hole of the
tanker from up and the condensed steam is removed from the bottom. The steam and the sugar is
contacted on the back to back sides of their opposite surface by conduction heat transfer. The
procedures for syrup preparation are; RO water depending on the type of liquor to be produced
different amount of litter is entered to the syrup preparation tank. Then the raw sugar conveyed
by screw conveyor from sugar holding hoper is entering to the tanker depending up on the
different liquor produced. After adding of sugar, the added solution is starrier until the sugar is
solutes and the steam is supplied until the sugar is melted. Then pumping the syrup to plate heat
exchanger to decrease the temperatures of the syrup before it enters to the mixer.
5.1.2 Blending of Liquors
Blending is a process of creating product by mixing different types mixture. In Balezaf Alcohols
Industry, blending is taken placed in staleness stirrer tank mixer, having an inclined stirrer that

48
has two Three-bladed propellers. The procedure for blending is first alcohol depends up on the
liquor produced is added to the mixer by pumping by digital counter valve. These concentrated
raw alcohol is around 97% is diluted by permeate water depends up on the type of liquor
prepared. Also flavor is added depends on the type of liquor prepared. After flavor is added the
mixer is turned on and agitated throughout the mixer. Then color is also added to make our
liquor have its own color. The color type used and amount of color used are also the big secret of
a factory. Final the permeate water is added until it reached to the required concentrated type of
liquors. Then the liquor produced is filtered by filter press by filter sheet depend up on the liquor
prepared, each liquor contain their own holding tanker. And finally it is transported to the
bottling section.

5.1.3 Process block Diagram for Blending and syrup preparation

Sugar citric acid Permeate water

Permeate
Syrup Water
Steam
preparation

Liquor Liquor
Preparation Preparation
Syrup
(Mixing Tank (Mixing Tank
holding tank
Filters 1) 2)
(Filtered
syrup

Pure Holding
Alcohol Holding
Tank
Holding Tank
Tank

Sludge to bottling section

Fig 5.1 Process block Diagram for Blending and syrup preparation

49
 5.1.4 Equipment and material used

 Permeate water and citric acid

 Sugar and steam
 Filter guard
 Sheet filter and bag house filter
 Chain and roll conveyer
 Crate and bottles
 Different storage tank
 Mixers
 Pump and glue
 Pipes having different diameter
 Leveler and counter of number of bottles
 Caustic soda and heat exchanger
 Different types of flavors e.t.c

5.1.5 Washer
Washing process is one of the main processes of bottling plant. Because, since it is using
recycled crate and bottles. The bottle washer washes in five stages by caustic, intermediate
water, warm water, cold water and fresh water washing stages. The bottles are entered through in
feeder contains of 11 bottle carrier and rejected from out feeder after washed by those stages.
And the crate is washed only by hot water in a crate washing machine.

5.1.6 The Bottling section

The bottling section is one of the sections that are interconnected with blending section. The
liquor produced in blending section filled, sealed and packed in this section. In Balezaf Alcohol
Industry the existing bottling plant has the capacity to produce 6000 bottles per hour and
produces more than 12 kinds of liquors with different alcoholic content, color and flavor.

50
 No Types of liquor Concentration, % v/v
1 Double ouzo 42
2 Ouzo 41
3 Dry Gin 41
4 Brandy 41
5 Zebib 41
6 Pernoud 41
7 Cognac 37
8 Fernit 37
9 Apretif 32
10 Lemon liquor 30
11 Pineapple liquor 30
12 Superment 25

Table 1 types of alcohol

5.1.7 Bottling Process Description

First bottles which are stored in the storage place are conveyed by chain conveyer and roll
conveyers and then the out packer which has the capacity to pick 15 bottles at once takes of the
bottles and the empty bottles move to the bottle washer machine, while the crate goes to the crate
washer machine. Before it starts to wash the bottles, the washer has to attain a temperature of 60-
660c and it has a capacity of holding 2000 bottles and it takes 20 minutes to wash 2000 bottles. In
the washer, the bottles are treated at different stages, with caustic soda having a concentration of
0.5-2.5%, intermediate water (400c), warm water and finally fresh water (all being soft). The
labels on the bottles are also removed in the washer. Then after, the cleaned bottles will be
conveyed to the filler machine. On their way, they pass through a magnifying glass, where the
sighter picks those bottles, which are not cleaned well. Liquor from liquor holding tank is
transferred into the filter guard where it is treated physically and then goes to the filler machine
which has a capacity of filling 6000 bottles per hour. Then, it passes to the cap-sealing machine,
which seals 3 bottles in one revolution. After it is sealed, it passes through a magnifying glass,

51
which is used to identify under filled and over filled bottles. Next, the filled bottles pass to the
labeling machine and date of production and time is printed on the neck of the bottles. Passing
through the digital filled bottle counter, it goes to the in packer where it meets with the crate
coming from crate washer and then, it is conveyed to the finished goods store.
5.1.8 Process Flow Diagram of Bottling

Fig 5.2 Process Flow Diagram of Bottling

5.1.9 Conclusion and Recommendation

Generally the bottling process is the final process for the overall ethanol production. For the
bottling room, it covers the topics starting from the process of preparing of syrups and making of
appropriate type of ethanol like super mite, vodka, lemon, dry gin, ouzo e.t.c to the final bottled
ethanol storing space. Based on the amount of the sugar, we use the different amount of steam
and water for preparing of syrups and also the types of color and flavor can determines the types
of alcohol we can produce. This means for making of different types of alcohol, we use different
types of flavors and colors. Then after making of the mixture of desired alcohol content, it
becomes stored to the storage tanker and transfer to the final bottling section after the bottle and
the crate is washed. Finally it is transferred to the storage place after passing the labeling, coding,
and packing process.

As the recommendation we have seen the following limitation to be reviewed:

52
 The amount of syrup is manually added to the mixture preparation, this makes an error of
determining the accurate amount syrup to be added for the required formation of
mixtures. So we would like to say, it is advisable to use pipe to determine the exact flow
rate and its amount to be added for the given process.
 We have seen that some storage tanks found in the bottling room is used for more than
one types of alcohol at different time which may causes for the reduction or increasing of
the alcohol content for we want to produce, since the tank which is washed by water may
not be clean well. Therefore to reduce its effect we would like to advise to use addition
chemicals to clean the tanks before storing another alcohol after using the first alcohol.
 Also the bottle after moved out from the washer contains its labeling which indicates the
washer is less efficient which may be caused by the lowering of operating temperature
and the amount of caustic soda we used. So we would like advise that increasing of the
steam supply which increases the operating temperature and either adding the caustic
soda or reviewing of the effect of caustic soda on the washing process.

Work experience we have gained

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The balezaf alcohol and liquor factory contains basic components of equipment’s like heat
exchanger, re-boiler, condenser, distillery column, which are necessary to be designed by one
chemical engineer student. When we have learnt the theory on the class, we didn’t visualize the
real working principle of the materials and equipment’s that we have seen the course still now.
But after we start working our internship, we have got the practical knowledge to know how the
real working principle of the equipment’s are in this factory and also the way of designing the
equipment’s listed above and criteria’s to be consider during designing processes. Also from this
factory, not only we have got the academic knowledge but also we have learnt the habit of co
working is the basic things to perform works without any load on the other workers. Also we
have got the ways how to give respect for others when we live and work together. Also we have
learnt the working ethics and how to manage our works in a proper time. Even if the factory
main product (final liquor product) feed component is secret to know how to start our
entrepreneur based on the company feed, we have got the knowledge of way of designing the
equipment’s.

Reference

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Wikipedia

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