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A REPORT ON

“INDUSTRIAL IN PLANT – TRAINING ”

Completed At

SHREE DATTA SHETKARI SAHAKARI SAKHAR KARKHANA LTD.SHIROL

POST: DATTANAGAR 416120, TALUKA – SHIROL, DIST-KOLHAPUR.

Submitted by

MR. KUNDAN SATYAWAN PATOLE

(B.E. CHEMICAL)

TRAINING DURATION
18 MAY 2015 TO 08th JUNE 2015
st

Department Of Chemical Engineering

Academic Year 2015-2016

PADMABHOOSHAN VASANTRAODADA PATIL

INSTITUTE OF TECHNOLOGY (PVPIT)
BUDHGOAN, DIST. SANGLI,
MAHARASHTRA, (INDIA)
PIN. 416 304
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PADMABHOOSHAN VASANTRAODADA PATIL

INSTITUTE OF TECHNOLOGY, BUDHGAON, SANGLI.

CERTIFICATE

This is to certify that,

Mr. KUNDAN SATYAWAN PATOLE

Of B.E. Chemical Engineering has satisfactory completed the training

report on

“ DATTA SUGAR FACTORY, SHIROL”

This is in partial fulfillment of the requirement for award of Bachelor’s

Degree in Chemical Engineering by Shivaji University, Kolhapur.

Guide H.O.D.

Prof. Mr. U. S. PATIL Prof. Mr. U. S. PATIL

Principal

Prof. Dr. S. V. JOSHI

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PREFACE

Technology has been advancing at an incredible pace and so there has been
as enormous demand of skilled professionals but without practical knowlege an
engineer can never be complete.

Industrial training helps to relate theoretical knowledge with practical. The

principal objective of the vocational training is to get the details of the operations
which are carried out in the industries and equipments used in the chemical
process industries.

This report consists of various unit operations and unit processes with
detailed diagrams of equipments & flow sheets of ammonia preparation and that
of urea preparation.
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CONTENT
Title Page No.

1. INTRODUCTION 06
2. DISTILLARY 08
3. PRODUCT ETHANOL 09
 A VIEW ON ETHANOL
 PURIFICATION TECHNIQUES USED
 ANALYSIS TECHNIQUE USED

4. FERMENTATION PROCESS 13

 FERMENTATION TANKS

5. WHAT IS MOLASSES 17

6. SUGARCANE MOLASSES 19

 MOLASSES STORAGE
 TANK SPECIFICATION

7.YEAST USED 24

8.. PRESSURE VACCUM DISTILLATION 25

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INTRODUCTION

A pioneering effort of starting an Agro-Industrial project in the Co-

Operative field for achieving social up liftment through rural development was
made for the first time in Ahmednagar District in the year 1950 by Pravara
Sahakari Sakhar Karkhana Ltd., under the guidance of distinguished co-operative
leaders like Sarvashri Dr. Dhananjayrao Gadgil, Shri Vaikunthbhai Mehta and Shri
Vitthalrao Vikhe-Patil and it proved to be very successful venture mainly on
account of efforts of the rural co-operative leaders.

This has ushered in an era of Sugar Co-Operative in Maharashtra which has

resulted in transforming Rural Economy in the vicinity of Sugar Factories by
ensuring stability and better return to the cultivate
Shirol Taluka of Kolhapur District is gifted by the presence of natural irrigation
potential on account of five rivers viz: KRISHNA, PANCHGANGA, WARANA,
DOODHGANGA and VEDGANGA and very fertile land of alluvial type soil. The
agriculturists in this area were very eager to have a Sugar Factory so as to ensure
all-round development and economic prosperity to the higher to poor and
marginal farmers.

A preliminary meeting was, therefore, held at KURUNDWAD in Shirol

Taluka on 31st December 1960 for organizing a Sugar Factory. After collecting
requisite amount of share capital, an application for Industrial Licence was
forwarded to the Government of India. During initial phase Late Shri. Dattajirao
Baburao Kadam, Late Shri. Dinkarrao BhausahebYadav, Late Shri. Vishwasrao
Santajirao Ghorpade – Dattawadkar and Dr. Appasaheb alias S. R. Patil put their
joint efforts to get the License from Government of India.

These main promoters put very hard efforts to establish the Sugar Factory
in adverse condition. The persistent efforts put forth by the Promoters of the
proposed Shree Datta Shetkari Sahakari Sakhar Karkhana Ltd., Shirol, ultimately
proved to be successful and the Government of India issued a Letter of Intent in
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the month of May, 1969, in accordance with its enlightened Agro-Industrial

Policy.

Shree Datta Shetkari Sahakari Sakhar Karkhana Ltd., Shirol, was registered
as a Co-Operative Society under the Maharashtra Co- Operative Societies Act,
1960 on 9th June 1969 vide Registration No. KPR/PRG/(A)-1. An Industrial Licence
for establishing a Sugar Factory on Co-Operative basis with initial crushing
capacity of 1250 M. Tonnes per day was issued.
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DISTILLARY

The capacity of distillery was 30,000 LPD an additional plant of 30,000 LPD
capacity based on continuous fermentation and Multi pressure Vacuum
Distillation Technology has been installed and commissioned from 27th Feb.2002.

M/s Praj Industries Ltd., Pune, has supplied the plant and machinery for
additional capacity of 30,000 LPD. An Ethanol plant of 30,000 LPD capacity based
on Molecular Sieve Technology has been installed and successfully commissioned
on 25th May 2002 the plant and machinery of Ethanol Plant has been supplied by
M/s. Praj Industries, Pune.

The capacity of distillery was 30,000 LPD an additional plant of 30,000 LPD
capacity based on continuous fermentation and Multi pressure Vacuum
Distillation Technology has been installed and commissioned from 27th Feb.2002.
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PRODUCT-ETHANOL

Ethanol is the only clean-burning liquid fuel available to replace oil used in
our cars and light trucks. In 2012, we produced 13.3 billion gallons of ethanol,
another annual production record. This production accounts for 10 percent of the
nation's gasoline supply. In doing so, we eliminated the need for more than 465
million barrels of imported oil. Ethanol is domestic, supplying over 383,000 jobs in
2012 from agriculture to manufacturing to the service sector. It is also made from
renewable resources.

A) VIEW ON ETHANOL

The growth of ethanol production and the use in the U.S. directly translates
to reductions in the amount of oil the nation needs to import. The U.S. has been
the lowest-cost producer of ethanol in 2010, 2011, and much of 2012. America’s
ethanol industry not only leads the world in the production and use of ethanol, it
is also one of the largest exporters of fuel ethanol in the world.

Ethanol exports in 2012 dipped from 2011’s record levels, but went down
as the second-highest in history. American producers sent 739 million gallons of
denatured and undenatured ethanol to 70 countries, with more than three-
quarters shipping to just three regions: Canada, the EU, and Brazil. The remaining
exports headed to countries such as Mexico, United Arab Emirates, Peru, and
Oman.

In addition to ethanol, the U.S. also exported an estimated 7.7 million

metric tons of distillers grains to top destinations for this nutrient-rich feed
included Mexico, Canada, and many Asian nations like China and Vietnam.

Technologies are rapidly becoming available that allow ethanol to replace

even larger volumes of oil in domestic gasoline. Ethanol blends such as E20, E30,
and E50 (mid-level blends or MLEBs) are gaining popularity as consumers seek
affordable alternatives to imported oil.
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B) Environmental Impacts

The use of an increasing amount of ethanol in American gasoline supplies is

making the air we all breathe much cleaner. There is no fuel available at scale
today that can match ethanol's ability to improve overall environmental quality
compared to gasoline. From its biodegradable nature to reductions in greenhouse
gas emissions to tailpipe pollution, ethanol provides a tool to address
environmental concerns without requiring an entirely new way for goods and
people to get from one place to another. Naturally, ethanol also requires far less
fossil fuel inputs than gasoline refining.

An interesting shift in ethanol trade is also occurring. Deemed “The Ethanol

Shuffle,” carbon footprint calculations in both the federal Renewable Fuel
Standard and the California Low Carbon Fuel Standard (LCFS) encourage the
import of Brazilian ethanol even as the Brazilian industry falls short in meeting its
own domestic demand.

As a result, America has been importing ethanol from Brazil while

simultaneously exporting ethanol to Brazil to backfill its market. All the while, a
doubling of carbon emissions from transporting these ethanol shipments will
occur, partly undermining the carbon reduction goals of both policies.

C) Ethanol's Future

The future of American ethanol is diverse. Corn will continue to be the basis
upon which the industry grows. Ethanol use helps provide American consumers
with a real energy choice.

Existing ethanol production in the U.S. has been and will continue to be the
foundation of America’s transition away from a fossil fuel economy. Many existing
ethanol bio refineries are exploring technology upgrades that will allow for the
production of ethanol from a broader range of feed stocks. These so-called bolt-
on technologies will allow ethanol producers to increase ethanol production by
converting both grain starch and cellulosic material into fuel at the same facility.
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Ethanol, also commonly referred to as ethyl alcohol, pure alcohol, grain

alcohol, and drinking alcohol, is most known as the alcohol present in alcoholic
beverages. Ethanol, which can also be abbreviated as EtOH, is a colorless liquid
with a slight odor, and it is soluble in water. It is flammable and volatile, so it
evaporates easily when left in an open container.

Ethanol's chemical formula is C2H6O. This chemical formula can also be

written as CH3CH2OH or C2H5OH. It is made of nine atoms that include two carbon
(C) atoms, six hydrogen (H) atoms, and one oxygen (O) atom.

Its chemical structure is illustrated in the following picture. Here, there is a methyl
group (which is the CH3-), a methylene group (which is the –CH2-), and a hydroxyl
group (which is the -OH) in the chemical structure.
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PURIFICATION TECHNIQUES USED

Ethanol purification is critical for any kind of purpose. In the industry,

purification is done by mainly distillation. Although distillation is a strong
separation technique, it has several disadvantages, mainly its separation capacity
of volatile compounds and cost. Not many studies have done on the area of
ethanol purification techniques which could take a place of distillation. However,
it is expected that purification techniques for water and wastewater, such as
ozonation, adsorption, and gas stripping, are applicable to ethanol.

ANALYSIS TECHNIQUES USED

Ethanol analysis techniques have been developed to improve the value of

ethanol. Gas chromatography (GC) and High performance liquid chromatography
(HPLC) are common techniques to identify and quantify components of ethanol.
Infrared spectroscopy (IR) is used alcoholic beverages. With a rapid increase in
ethanol production, more extensive researches on ethanol have done recently. In
this paper, the current ethanol production, purification, and analysis techniques
are reviewed. The comprehensive knowledge of the current ethanol study will
encourage further
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FERMENTATION PROCESS

Fermentation is the process in which a substance breaks down into a

simpler substance. Microorganisms like yeast and bacteria usually play a role in
the fermentation process, creating beer, wine, bread, kimchi, yogurt and other
foods.

Fermentation comes from the Latin word fermentare, meaning “to leaven.”
To make bread rise, you use a leavening agent to “wake up” dry yeast by mixing it
with water. The yeast then starts “eating” the sugar in the dough and off-gassing
alcohol: that’s fermentation. Grape juice becomes wine as the fermentation
process is complete.

“a process in which an agent causes an organic substance to break down

into simpler substances; especially, the anaerobic breakdown of sugar into
alcohol”

Alcoholic fermentation, also referred to as ethanol fermentation, is a

biological process in which molecules such as glucose, fructose, and sucrose are
converted into cellular energy and there by produce ethanol and carbon dioxide
as metabolic waste products. Because yeasts perform this conversion in the
absence of oxygen, alcoholic fermentation is considered an anaerobic process.

Alcoholic fermentation occurs in the production of alcoholic beverages and

ethanol fuel, and in the rising of bread dough.
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In ethanol fermentation, one glucose molecule breaks down into two

pyruvates :

(1). The energy from this exothermic reaction is used to bind inorganic
phosphates to ADP and convert NAD+ to NADH. The two pyruvates are then
broken down into two acetaldehydes and give off two CO2 as a waste product

(2). The two acetaldehydes are then converted to two ethanol by using the
H- ions from NADH; converting NADH back into NAD+

(3) Sugar industries produce molasses from the sugar cane processing.
Molasses have 50 -55% concentration of sugar in the form of sucrose, with
chemical formula C12H22O11. This source of compound is used for preparing ethyl
alcohol. Ethanol in the form of absolute and rectified spirit can be made from
molasses. Basis raw materials for an industry to produce 1 ton of ethyl alcohol
requires, molasses up to 5.6 tons, sulfuric acid 27 kg and ammonium sulphate 2.5
kg.
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FERMENTATION TANKS

Large volume storage tanks of molasses provide continuous supply of

molasses and store the fresh molasses from sugar processing section during the
fermentation process. The molasses from the tanks are diluted with water to
obtain the sugar concentration around 10-15%. The acidic nature of molasses
supports the growth of yeast during breaks up of sucrose, for that purpose acids
are added to maintain the pH between 4 and 5. Continuous diluter equipment
takes up this task. A yeast culture tank, which is provided with nutrition supply of
ammonium and magnesium phosphate or sulphate, is used as nutrient to the
yeast. The acidic condition favours the yeast to produce catalytic enzymes,
invertase and zymase.

Diluted and treated molasses and the yeast from storage are fed to the
fermentation chamber. Modern fermentation tanks are made with stainless steel
material provided with heating coils or jacket provision. The temperature 20-30 oC
is maintained in the tanks by the heating and cooling system. The process of
fermentation takes place around 30-70 hours based on the temperature and
sugar concentration to yeast count. Final temperature 35 oC is attained at the end
of the process. During the fermentation process, microorganism yeast produces
carbon dioxide as by-product.

After the process cycle, the product liquid mixture is fed to beer still to
perform distillation. Solid and slurry mass is separated leaving the solution of
alcohol and water. The concentration of alcohol in the liquid mixture would
around 8-10%. A series of beer still work out to produce different quality of beer
products. The slurry form of material obtained from bottom of beer still is called
as slops. It is used for cattle feed and fertilizer after some waste treatment
operations.

However, the aldehydes are not allowed in consumable beer so aldehydes

present in the solution are removed by aldehyde column. The streams coming out
at different section of the column are aldehydes from top, fusel oil and ethanol
mixture from middle and bottom stream with water. The middle stream is fed to
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rectification column to produce a product called rectified spirit having 95%

ethanol. Rectified spirit further made to absolute alcohol by anhydrous still using
benzene as third component. Absolute alcohol with 100% ethanol concentration
is a standard product used as intermediate for producing other chemical products
and blending agent in power fuels.

The end use of the ethanol would be largely in solvent, acetaldehyde,

acetic acid, polyethylene and synthetic rubber production
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WHA IS
MOLASSES
On industrial scale, ethanol can be prepared by the
fermentation of molasses. Molasses is the mother liquor left after the
crystallization of sugarcane juice. It is a dark coloured viscous liquid.
Molasses contains about 60% fermentable sugar.
METHOD OF PREPARATION

Following steps are involved in the preparation of ethyl alcohol :

DILUTION OF MOLASSES

Molasses is first diluted with water in 1:5 (molasses : water) ratio

by volume.

ADDITION OF AMMONIUM SULPHATE

If nitrogen content of molasses is small, it is now fortified with

ammonium sulphate to provide adequate supply of nitrogen to yeast.

ADDITION OF SULPHURIC ACID

Fortified solution of molasses is then acidifies with small quantity of

sulphuric acid. Addition of acid favours the growth of yeast but
unfavours the growth of useless bacteria.
FERMENTATION
The resulting solution is received in a large tank and yeast is added
to it at 30O C and kept for 2 to 3 days. During this period, enzymes
sucrase and zymase which are present in yeast, convert sugar into
ethyz alcohol.
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C12H22O11 + H2O C6H12O6 + C6H12O6

C6H12O6 C2H5OH + 2CO2

FRACTIONAL DISTILLATION
Alcohol obtained by the fermentation is called WASH, which is
about 15% to 18% pure. By using fractional distillation technique, it is
converted into 92% pure alcohol which is known as rectified spirit or
commercial alcohol.
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SUGAR CANE MOLASSES

Premium Blend sugar cane Molasses is a natural and nutritious sweetener

extracted from sugar cane during the production of refined sugar. With a distinct
and rich flavor, molasses can serve as a cost-effective substitute for highly-refined
sugar and other nonnutritive syrups. Over a long history, molasses has been used
as a health supplement for its natural combination of sweetness, vitamins, and
antioxidant properties.

Molasses has a light sweet delicate cane flavor of the best quality refined
molasses with a typical sugar profile of 68-75%

Traditional Blend sugar cane molasses has a robust, dark flavor with a
typical sugar profile of 54-68%

Molasses for Brown Sugar is a unique blend of selected sugar cane

molasses which when mixed with granulated sugar will produce a finished brown
sugar having the full flavor and color profile of commercially produced brown
sugar.

Dry Molasses is a free flowing molasses made from all natural pure sugar
cane molasses ideal for flavor and color enhancement. It’s perfect in dry
applications where product constraints prevent use of liquid molasses

MOLASSES STORAGE

The two main tasks required to make molasses from sugar cane are to
separate out the sugar cane juice from the pulp, and then to extract the sugar
(mostly sucrose) from the juice. What's called molasses is the syrup that remains
after the sugar has been extracted from the juice.
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These tanks are usually designed to a design code such as:

 API 650
 BS 2654
 IS 803

TANK SPECIFICATION

A tank consists of four major components :

1. Foundation
2. Base plate
3. Shell
4. Roof

FOUNDATION

The foundation can be simply a raised platform of compacted earth topped

with asphalt, or it may be concrete raft supported either on the underlying soil or
on piles, and finally it may be a reinforced concrete ring beam, the inside of the
ring beam filled with compacted earth that may be stabilised with cement and
topped with a 3cm to 5cm layer of asphalt.

The base plate is usually of 6mm plates and the plates may be joined by lap
joints or butt joints (with backing strip). The base plate may also have annular or
sketch plates

Shell

The shell is made of a number of rectangular plates that may be rolled to

the correct curvature and then welding using butt joints. The butt joints V-groove
or square groove welded, depending on plate thickness and welding process.
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Roof

On most sugar mill tanks a self supporting membrane roof is adequate,

however on larger tanks the roof may be supported on girders and maybe even
columns. The roof angle is normally 15°

Appurtenances

The following appurtenances are required for each tank

 An overflow
 A roof vent
 A manhole in the shell for maintenance access
 A manhole in the roof for maintenance access
 Stairs or ladder for access to the tank roof
 A drain

Materials of Construction

The tanks are usually of mild steel although stainless steel and 3CR12 are also
used sometimes.
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Diagram describing the process of ethanol production from molasses

fermentation. Molasses from the storage tank is sent to continous diluter and fed
to fermentation tanks. In the flow diagram the yeast preparation and storage is
shown on top of fermentation tank. Carbon dioxide from the fermentation tank is
scrubbed using water. The right section of the process diagram show the
distillation section that separates aldehydes, fusel oil and water. 100 % to 95%
pure ethanol is produced.

C12H22O11 + H2O → 2C6H12O6 ,with enzyme invertase.

C6H12O6 → 2C2H5OH + 2CO2 -31.2 KCal ,with enzyme zymase.

Side reaction:
2C6H12O6 + H2O → ROH +RCHO (high molecular weight alcohols C2H5OH)
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YEAST USED

Yeasts can be used in many industrial processes, such as the production of

alcoholic beverages, biomass (baker’s, food, and fodder yeasts), and various
metabolic products. Among these categories, fuel ethanol production from
sugarcane molasses by thermo tolerant strains (from terrestrial environments)
has been studied extensively, because they are capable of growth and
fermentation during the summer months in non tropical countries as well as
under tropical climates.
However, there had been no reports about the ethanol producing ability of
yeasts from aquatic environment with high temperatures. We found various
thermo tolerant, fermentative yeasts together with yeast-like un pigmented algae
from a hot spring environment and the ethanol-producing abilities of these
eukaryotes have been reported already. Nevertheless, we have not investigated
the potentials of these yeasts for ethanol production from substrates other than
glucose (i.e.; sugarcane molasses, sweet sorghum, and maize starch).In the
present report, the seven yeast strains from hot spring drain0_ were evaluated
for their ethanol-producing ability from sugarcane molasses at elevated
temperatures.
We also tested the ability of these yeasts to reduce total organic carbon
(TOC) in molasses during fermentation, because increase of TOC, resulting from
death of yeast culture, may cause environmental deterioration after the
fermentation broth has been disposed. In taxonomic study of the yeast strains
described above, morphological and physiological characteristics of the strain
named RND 2, +,, +2, A,, and D.
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PRESSURE VACCUM DISTILLATION

Vacuum distillation system consists of three to four distillation columns namely –

 Analyzer column – Operated under vacuum.
 Pre rectifier column – Operated under Vacuum
 Rectifier cum Exhaust Column – Operated under pressure

Fusel oil concentration column may be added to improve quality of alcohol

further.
Fermented wash is preheated in fermented wash pre-heater and fed at the
top of the Analyzer column, Analyzer column is fitted with thermosyphon
reboiler. Top vapors of analyzer column are sent to pre-rectifier column. Rest of
the fermented wash flows down and is taken as spent wash from analyzer column
bottom. Pre-rectifier bottom liquid is preheated with spent-lees and fed to
rectifier cum exhaust column. Low boiling impurities are concentrated in the pre-
rectifier column. A top draw is taken out as impure alcohol from the pre-rectifier
column. The bottom of pre-rectifier column is sent to rectifier feed tank. Rectifier
exhaust is operated under pressure and heats analyzer column through reboiler.
Alcohol is enriched towards the top and is drawn out as Rectified spirit (RS).
Fusel oil build-up is avoided in the Rectifier column by withdrawing outside
streams of fuel oil. These are sent to fuel oil concentration column from where
the fuel oil is sent to decanter for further separation. The fuel oil wash water is
recycled back to the column. A top draw is taken out as impure alcohol from the
top of fuel oil column & pre-rectifier column.