University of San Carlos

Cebu City, Philippines

ON-THE-JOB TRAINING REPORT

A terminal report submitted to the

Department of Chemical Engineering

In partial fulfillment of the requirements

for the course ChE 431
by

YNNO C. IGUT
June 6, 2015

I.

Basic OJT Information

Host Company

: San Carlos Bioenergy Inc.

San Carlos Ecozone,
Brgy. Punao and Palampas
San Carlos City, Negros Occidental

Official Contact Person : Elvira Despi-Catalan

OJT Coordinator
(034) 312 5539
OJT Period

: April 27, 2015 May 22, 2015

Total OJT Hours

: 245

Area of Assignment

: -Mill and Boiling House Department

-Distillery Department
-Quality Control and Assurance Department
-Environmental Management Department

Direct Supervisor

: Efren A. Gromea Jr.

Mill and Boiling House Department
egromea@scbiph.com
(034) 213 1195
(+63) 923 265 7761

Bienvenido Tanaman
1

Distillery Department
btanaman@scbiph.com
(+63) 917 543 8101

Jocelyn S. Sorrilla
Quality Control and Assurance Department
jsorrilla@scbiph.com
(+63) 917 300 5842
Jaymar J. Relota
Environmental Management Department
jrelota@scbiph.com
(+63) 922 454 1464

II.

Host Company Profile

San Carlos Bioenergy Incorporated (SCBI), located in San Carlos City Negros
Occidental, is the first integrated Bioethanol plant in the Philippines and in
Southeast Asia. The company is still young with the actual first operation in
January 2009. SCBI is a PEZA registered company incorporated in May 2005 to
construct, own and operate an integrated fuel bioethanol distillery and power cogeneration facility, thus marking both Philippine and Southeast Asian history as
the First Fuel Bioethanol and Co-generation Facility.
The company produces bioethanol, an additive to vehicle fuel. Their aim is
to produce 125, 000 L of bioethanol (99.8%) per day. The Petron Company is the
main buyer of the bioethanol produced in SCBI. The company has a ten (10) year
2

sales agreement with Petron Corporation, the country's leading oil company and
gasoline retailer, for the supply of bioethanol. In addition to that, the company
also produces semi refined liquid sugar which is sold to sugar centrals in Negros
Occidental. The company also produces power (electricity), and contributes to the
Negros Occidental power grid using the bagasse of the sugarcane extracted from
the milling department. On a daily basis, SCBI processes a maximum of 1,500
tons of sugarcane to produce 125,000 liters of Bioethanol and generate a rated
capacity of around 7.4MW where at least 2.4 MWh is to be supplied to the power
grid. The production of both alternative and renewable energy is governed by
separate contracts, apart from those executed with other government agencies
under the Executive Branch.
SCBI uses sugarcane as their raw material during the first few years of
operation. Negros Occidental, being the sugarcane capital of the Philippines, is
strategically the best location to put up this plant. Situated at the San Carlos AgroIndustrial Economic Zone on the Eastern coast of Negros Occidental, SCBI takes
advantage of both favorable weather patterns and the best quality and yield in
sugarcane to supply the country's fuel and energy demands, in compliance with
the mandates of the Biofuels Act of 2006, otherwise known as RA 9367 and the
Renewable Energy Act (REA) of 2008, otherwise known as RA 9513. The
company has a fifteen (15) year agreement with three (3) local plantations for the
supply of the bulk of its sugarcane requirements and works with smaller
sugarcane planters and cooperatives for the balance of its feedstock requirements.
There came a time when the price of sugarcane rose up to the point where the
same amount of sugarcane can be bought for the same amount of bioethanol. The
company called this event as the perfect storm. The effects of this event is drastic
to the point where the company is almost at ground zero.
The company decided to modify the production of the company by using
another type of raw material which is molasses. Molasses is a viscous liquid
containing fermentable sugars which is the by-product of refined sugar
production. The company succeeded to restore profits and the Milling Department
which produces cane syrup intended mainly for fermentation is also gaining
3

money by selling semi refined liquid sugar to sugar centrals around Negros
Occidental.
Majority of the shares of the company is owned by the Roxas Holdings
Incorporated. The new management just took over last May 2015.

III.

On the Job Training Program

Mill and Boiling House Department

Cane and Syrup Processing Familiarization

o Cane Preparation
The supervisor explained the process as well as the different
equipment used in cane preparation namely the belt conveyor
(Figures 3 and 4), primary mill and the leveler.
o Cane Juice Extraction
The supervisor explained the process as well as the different
equipment used for juice extraction. The focus of the discussion
was mainly on efficient sugar extraction. The process was a
combination of size reduction and solid-liquid extraction using
fork crushers (Figure 5) and water as extraction solvent.
o Juice Clarification
The juice clarification process is located in the boiling house. The
process as well as the different equipment used in this process was
explained by the supervisor. The different equipment in the juice
clarification process are the liming tank, bed clarifier and the
rotary drum filter (Figure 9).
o Cane/Juice Evaporation
This process involves the use of the multiple effect evaporator with
5 effects (Figures 7 and 8). The process and the design of the
equipment was explained by the supervisor. I also did Brix
Analysis of the output syrup in the 5th effect (last effect) using the
Brix spindle.
The processes in the Mill and Boiling House department is automated and
is monitored in the control room (Figure 10). There is no hands on monitoring on
4

the different parameters of the process for all of which are carefully monitored in
the control room.
The supervisor also showed us the material balance for the multiple effect
evaporator (Figure 11).
Distillery Department

Fermentation Section Process Flow Familiarization

o Equipment, machineries & instrumentation
The process as well as the different equipment in the fermentation
section was discussed by the supervisor. The different equipment
involved in the fermentation section are the culture vessels (Figure
12), pre-fermenters (Figure 13), fermenters (Figure 14), yeast
separators and the buffer tank. All of the working parameters
(temperature, pH, etc.) are monitored in the control room since the
process is also automated. The supervisor allowed me to have
hands on experience in the monitoring of parameters.
o Yeast propagation, cell count, etc.
Every morning (8:00 A.M.), we are tasked to get samples from the
two fermenters. The samples are then analyzed under the
microscope to check yeast activities and also for contaminants
inside the fermenter. The cell count of which is done by the QC/A

department and our task is to go there and get the results.

Every 9 A.M., we are tasked to get the culture broth (inoculum)
prepared by the microbiologist in the QC/A department. The
contents of which is then poured in the culture vessel 1. The
nutrient source for the yeast is also manually prepared using urea,

biocide and magnesium sulfate.

During a specific time, we are tasked to prepare the culture vessels.
The preparation involves sterilization of the tanks using steam
which can be monitored in the control room. It also involves the
preparation of the culture broth, molasses solution with sugar

content of ~12 brix. The Brix of the molasses solution was

measured using digital refractometer.
o Materials involved in the fermentation process, its uses
The different materials involved in the fermentation process was
explained by the supervisor. The supervisor discussed to us the
yeast used for fermentation, Saccharomyces pombe, and its
advantages and disadvantages over Saccharomyces cerevisiae. The
nature and the source of molasses, the nutrient source and the
defoamer (Turkey red oil) was also shown and its uses were

discussed.
A manual for the fermentation section was also handed so as to
study the different materials involved in the fermentation process
and its corresponding uses.

o Stoichiometry and Material Balance

The supervisor handed as a manual so as to study the material and
energy balance along the fermentation section.
o Process Control and Monitoring, Troubleshooting
The process is monitored in the control room using 4 computers.
The control room displays the working parameters of each
equipment and displays any change in the trend of the conditions.
The pumps also can be automatically controlled (on or off) in the
control room. The supervisor allowed us to manage the control
room but we are up to monitoring the operating conditions only
(checking for deviations in temperature, pH, pressure, etc.) because
the pumping system is a critical part of the process.

Distillation and Dehydration Section

o Process Flow Familiarization (Equipment, machineries & instrumentation)
The distillation process and the different equipment used was
explained by supervisor. The process from the buffer tank of the
fermentation section to the distillation columns (primary column,
dealdehyde column, rectification column, recovery column. Figure
6

15) until the molecular sieve was discussed by the supervisor. A

process flow diagram was also printed to have a full grasp of the

process.
The whole process was also toured together with the supervisor.
Other equipment present such as the plate heat exchangers (Figure
16) and the cooling towers (Figure 17) were also toured and the
uses of such were explained.

o Material and Energy Balance

A manual was handed by the supervisor for us to study the mass
and energy balances across the distillation process.
o Process Control, Monitoring and Troubleshooting
The working conditions of the process were monitored in the
control room (Figure 18). The supervisor also let us manage the
monitoring of the parameters.

Quality Control and Assurance Department

Weighing House
o A weighing bridge (Figure 21) is used to measure the weight of the
sugarcanes being delivered to SCBI. The weighing bridge is also used to
measure the incoming molasses and other materials (bagasse, salt, coconut
shells, etc.). We are tasked to weigh these materials and also placing the
results in the computer system.

Cane Acceptance and Analysis

o The cane acceptance part involves the use of the machine called corer
(Figure 22) in which it is used to obtain sugarcane samples from the
delivery trucks.
o The cane analysis part involves the analysis of the absolute juice, the juice
extracted from pressing the sugarcane samples using hydraulic press. The
analysis uses an apparatus called Saccharomat, a digital polarimeter to

measure the apparent purity and brix of the sample. Moisture content is

also analyzed in this part.

Mill and Boiling House Section
o The Mill and Boiling house lab involves the analysis of the sugar solution
samples from the Mill and Boiling house department. The analysis
includes measurement of the sugar concentration (Brix), the apparent

purity, pH and turbidity.

Boiler Section
o The boiler section involves the analysis of the boiler house wastewater and
also the water used to generate steam. The analysis involves the
measurement of the silica content of the water and the chemical oxygen

demand (COD).
Incoming Process Materials Section
o The IPM section involves the analysis of the molasses (sugar content, pH,
etc). Analysis of the sugar content was mainly done by Total Sugar as
Inverts analysis. The unfermentable sugar concentration was also analyzed
using the Unfermentable Reducing Sugar (UFRS) analysis procedure.
o It also involves the analysis of the moisture content of the wood fuels

being bought.
Fermentation and Distillation Section
o This section involves the analysis of the alcohol content, density and
moisture content of the samples from the different sections of the
distillation column. This also involves the total cell count of the
microorganism present in the fermenters.
o Analyzed in this section is also the amount of residual sugar (unfermented
sugars) in the fermenters in a specific time of the day.

Quality Assurance
o The QA lab involves the analysis of the denatured alcohol (pH, alcohol
content, acidity etc.)

Environmental Management Department

Anaerobic Digestion/Biogas Plant

o Process Familiarization
8

The process of anaerobic digestion was explained by the

supervisor and operators. The supervisor toured us to anaerobic
digestion plant and explained to us the different equipment used
such as AD tank (Figure 24), the lamella clarifier (Figure 25), the
degasser and the biogas storage tanks. The input and output
materials and how they were disposed were also discussed. The
Biogas plant flow was also explained by the supervisor and
operators.

o Anaerobic Digestion Control and Monitoring

The pH of the incoming spent wash to the AD tank, the solution

inside the AD tank and the overflow were analyzed every hour.
This part of the training also involves the analysis of the Chemical
Oxygen Demand (COD) of the incoming spent wash and also the
exit wash from the AD tank and the Total Volatile Fatty Acids (T-

VFA) content and alkalinity of the wash inside the AD tank.

o Environmental Management Practices
The manager explained to us the wastewater treatment flow
diagram. We also toured the compost area (Figure 31) where the
materials for composting are the mud press from the boiling house,

ash and distillery spent wash.

We also toured the offsite lagoons used for the untreated spent
wash and the lagoon for the wastewater from the boiler house
(Figure 32).

IV.

Narrative of Learning Acquired Through the OJT Experience

Mill and Boiler House Department
First, I was exposed in the milling department where I spent 8 hours. The
milling department involves several processes. First is the crusher part where the
sugarcanes are reduced in size by the action of cutters. The crushed sugarcanes
are then passed to a leveler which uniformly feeds the crushed sugarcanes to the
extractor. The extractors are termed as fork crushers (Figure 5). These fork
9

crushers first extract juice from the sugarcane without any additives. The
extracted juice from this part is called the absolute juice and is stored in the juice
tank. The bagasse (leftover fibers of sugarcanes) from the first extraction are
passed to the next set of fork crushers (second stage) in which they are mixed
with water so as to dissolve the remaining sugars. The principle of solid liquid
extraction can be applied in this part. The bagasse after the second stage is passed
again to another set of fork crushers (third stage) where pure water is further
added to increase the concentration gradient and extract more sugar from the
bagasse. Finally it is passed on to the fourth stage (Figure 6) where the exiting
bagasse is now fed to the boiler house so that it can be used as fuel for power
generation. It is really evident in the plant, that they make the most out of their
raw material.
The Milling department also includes the boiling house. The boiling house
also involves several processes. First, the extracted juice from the different stages
of extraction are placed in a heater for clarification purposes. Then the heated
juice is passed on to the liming tank where Calcium Oxide (CaO) is added also for
clarification purposes and so as to regulate the pH of the solution. The optimum
pH should be around 6.8-7.2. Then the solution is further heated to 100 oC and is
placed on an isothermal clarifier tank. At 100oC, the juice from the solution is
separated from the heavy solid particles also termed as mud. The juice from the
clarifier is termed as clear juice with sugar concentration of approximately 15
brix. Brix is a measure of the sugar content of the solution. The clarified juice is
now passed to the multiple effect evaporators with 5 effects (Figure 7). On the
other hand, the settled mud is passed through a rotary drum filter (Figure 9) in
which the filtrate is also fed to the evaporators. Using the concepts learned from
the academe, the filtrate has the same concentration as the clarified juice for they
are in equilibrium. This part of the process caught my interest for we have studied
theories and design parameters for rotary drum filters in ChE 425, Introduction to
Particle Technology and design for multiple effect evaporators in ChE 424, Heat
and Mass Transfer Processes. The type of evaporators used is a vertical tube
evaporator. It was not hard understanding the flow of process at this part because
10

of the fact that this was discussed in my ChE 424 class. The aim of the evaporator
is to reach a syrup concentration of 65 brix by removing water from the clarified
juice. A brix spindle is used at the 5th effect to measure the brix of the overflow.
We also got the chance to look at the theoretical material and energy
balances prepared by the Design Engineer himself (Figure 11). The concept of
conservation is truly the governing principle for such design. It was not a simple
in and out process but there are many recycle streams placed to conserve energy. I
tried also to connect the diagram in the actual setting but it was definitely hard
especially because the piping systems are too hard to follow.

Distillery Department
The next department that I have been into is the distillery department
where I spent 77 hours. At first, I was introduced to the supervisor and the
operators of the section. The distillery department involves the fermentation and
the distillation section where each section is manned by a single operator and
guided by the supervisor. I was very excited since we have been designing
theoretical fermenters in ChE423, Engineering of Homogenous Chemical
Reactions and in ChE426, Introduction to Biotechnology. Also we have been
introduced to the basics of design for continuous distillation columns in ChE421N
Separation Processes.
The fermentation process involves the use of three culture vessels (CVs)
namely the CV-1, CV-2 and CV-3 (Figure 12). The higher the number the bigger
is the size of the culture vessel. The purpose of these vessels is for growth and
multiplication of the yeast used for fermentation, the Saccharomyces pombe. The
culture started from a 6 L Florence Flask in which the yeast activity is analyzed
through the microscope. It is then transferred to CV-1 containing diluted molasses
(~12-16 brix) with a retention time of approximately 10-12 hrs. CV-1 is also
fortified with nutrients for the yeast to thrive namely the Biocide, Urea (Nitrogen
source) and MgSO4 (Magnesium source). I have tried pouring the culture in CV-1
11

and preparing the nutrient mix. After the retention time, it is expected that the
yeasts consumed the nutrients inside, have grown and multiplied so that they
should now be transferred to CV-2 for further multiplication and growth and then
to the CV-3. Each of the vessels before the growth and multiplication period must
be sterilized using steam. I have tried operating the sterilization part of the CV-3
and CV-2 and monitoring these operation through the computers in the control
room. It is actually good that each vessels are now automated for any changes in
the operating conditions (e.g. temperature, mixture level, etc.) can be closely
analyzed. The operators are very critical in the working conditions of the process.
Any deviations from the normal working conditions are immediately attended to.
After the sterilization, the culture media is prepared by filling the tank with
diluted molasses (~12-16 brix). Concentrated molasses is fed to the tanks (~85
brix) which is simultaneously added with water to obtain the desired
concentration. I have also tried preparing the molasses solution in the culture
vessels and sadly, the process is trial and error. Water is fed with the molasses and
then measuring its brix in a specified volume. We have suggested to make mass
balance around the culture vessels so as to know the theoretical amount of water
and molasses needed and they said that they will take it into consideration.
The yeasts from the CV-3 are then transferred to two pre-fermenters (PFs)
working in parallel. Then after the specified retention time, the contents from PF1
and PF2 (Figure 14) are transferred to the Fermenter 1. There are actually two
fermenters coined as F1 and F2 (Figure 15) both having a capacity of 1,250 m 3
(1,250,000 L). The method of introducing the solution in F2 is by cascading
motion, meaning the solution in F1 will enter a pipe connecting F1 and F2 once
the contents in F1 reaches a certain level. A syrup tank was constructed initially
for storage of syrup but since the raw material for fermentation is now molasses,
the syrup tank is converted into another fermenter namely F3. The solution from
F1 and F2 will also cascade to F3. All fermenters have a retention time of
approximately 36-48 hours. The solution from these fermenters is then transferred
to the buffer tank and is passed to the yeast separators and then to the storage tank
for distillation.
12

The distillation process for me is one the processes that I look forward to
seeing in the actual scale. The distillation process in SCBI is continuous.
Honestly, I expected that the stripping and rectification part is connected in a
single column yet in SCBI, it is separated. In the academe also we are used to
designing distillation columns with 20 stages at maximum yet the number of
stages in the stripping section alone is 72. The distillation process also kept true in
its schematic diagram in the sense the condensers are located at the top and the
reboilers at the bottom except for the reflux tank which is located at the bottom. It
was interesting exploring the distillation columns and tracing the entry and exit of
materials involved in the process. The actual setting is really harder but the
principles governing the process is still the Vapor-Liquid equilibria of ethanol and
water mixture. This was also emphasized in the explanation of our supervisor. The
distillation section has 4 columns in order namely the primary column,
dealdehyde column, the rectification column and the recovery column (Figure
14). One smart thing in the distillation section for me is that the process ends in a
molecular sieve which uses ceramic zeolites with pores small enough to trap
water moisture and recover ~99.8% of absolute ethanol. I have also seen the
material and energy balances around the column and what amazed me is the
actual conservation of energy specifically the heat energy. For example, the heat
from the vapor output of another column is used to heat the incoming solution in
the reboiler. This in return condenses the vapor product. The true sense of
conservation and economics is observed in the distillery.

Quality Control and Assurance Department

I spent 56 hours in the Quality Control department. The quality control
department is divided into 7 parts namely the weighing house, the cane
acceptance and analysis section, the mill and boiling house section, the boiler
section, incoming process materials section and the fermentation and distillation
section. I have been in all 7 sections and have worked for 8 hours each section.
13

Doing the work of an analyst is definitely not like my analytical chemistry

laboratory. The pace is very fast and every movement must be precise especially
because we are dealing with explicit amounts and there is no second trial. Every
hour we get new samples to analyze. Some of the samples like the molasses takes
an hour to analyze and during that hour there are samples coming in. What I have
learned from the QC department is the art of multitasking. For example, I am
doing an analysis on the alcohol content of the sample. The titration is automated
and will take several minutes that is why the total cell count (TCC) in the
fermenters can be done while waiting for the results. This skill I know will help
me in the future to do my tasks well.
It was truly a very knowledgeable experience especially because the
analysts explained to me the theory behind the analysis and taught me proper
laboratory techniques like the proper handling of pipets and proper titration etc.
The analysts also taught me to use advanced chemistry apparatus like the
Saccharomat, a digital polarimeter used for measuring the apparent purity of the
syrup sample and the spectrophotometer which is used for measuring turbidity
and silica content (ppm). I also had the chance to work with several heavy
machineries like the corer machine which is used to get sugarcane samples, the
hydraulic press which is used to extract absolute juice from the sugarcane samples
and the weighing bridge which is used to weigh the contents of the sugarcane
trucks.
One of the most nerve-wrecking part in my experience in the QC
department is the part where I get to do advanced analysis without any
demonstration and just reading theories behind the analysis and the actual
experimental procedure. Personally I would say that it all boils down to trust. I
believe that I have been diligent enough to not miss out on the important points in
the analysis that I have performed to the point where they gave me tasks in which
they think I can do without their supervision. I managed to do Total Sugar as
Inverts (TSI) analysis without any experience in titrating a sample while keeping
it in contact with a heating surface.
14

The experience was also amazing because the manager treated us like
regular analysts. She reprimands us whenever we missed out on important points
during the analysis which in a way is very helpful so that we will never make the
same mistakes again. Not all analysts in the QC/QA department are Chemistry
majors but they are very critical on their analysis.

Environmental Management Department

I spent 91 hours in the Environmental Management Department (EMD).
As they say, the most critical and important part of every plant is not the
production but the waste disposal. Having molasses as their raw material, the
plant is producing thrice the amount of waste because the plant was originally
designed for syrup. The plant is equipped with an Anaerobic Digester System
(Figure 24) which can accommodate only 200,000 L/day of spent wash (waste
from the distillery section) but during the usage of molasses, the waste rose up to
500,000 L/day. Because of this, the EMD accommodated 40 hectares of land so
that they can store the untreated spent wash and do natural decomposition of
organic matter. The problem now is the foul smell it brings which at abnormal
weather conditions covers the whole city. The main lesson I obtained from the
EMD is trying to balance waste production with the desired product production. It
is not always good hearing that the production has increased for it could also
mean that the waste production also has increased. Furthermore, I know this
learning will help me soon in my future endeavors as a Chemical Engineer
especially if Im in charge in the design part.
The EMD supervisors and operators toured us to the Anaerobic Digester
and we even climbed the tank to see the different safety devices installed at the
top. There are pressure breakers and vacuum breakers present at the top. All these
safety devices are used to monitor the biogas production. The AD tank is used to
convert the organic matters present in the spent wash to methane biogas which is
also further utilized as additional source of fuel in the boiler house.

15

The Manager discussed to us the design for the Anaerobic Digester tank
(Figure 25). The design as I quote from him is the first and last because it is not
the usual AD design. Instead of a single room tank, the inside is divided into five
compartments. The AD however does not function the way it should have as it
was originally designed. Some modifications were done so that the AD can
function like an Upflow Anaerobic Digester Tank (UASB). This goes to show that
equipment designs can change from time to time depending on the significance
and efficiency of operation.
During a specific time, we get samples from the AD tank to analyze its
volatile fatty acids (VFA) content, chemical oxygen demand (COD) and
alkalinity. These factors are important for the flow rate of waste into the AD is not
constant and will depend on these factors. For example, if the VFA content is
high, the flowrate should be decreased for the acidogens will produce more acids
that the methanogens cannot accommodate. This can also lead to a decrease in pH
which the methanogens are sensitive to.
I have also learned in EMD the importance of teamwork in accomplishing
tasks. The manager itself is very hands on in the actual operation.

V.

Recommendations
SCBI includes a boiler house which generates power from the dried bagasse in
the mill. Sadly, we havent got the chance to explore this part of the plant. I would
strongly recommend that the boiler house can also be toured by ChE students for
energy generation is also a field in which Chemical Engineers can be an expert of.
Also, I would like to recommend handing out OJT manuals where the different
processes and equipment of the plant are there for reference.
SCBIs OJT program is really good. The fact that I was exposed in almost all
of the processes in the industry further strengthened my knowledge in Chemical
Engineering. I strongly recommend this company to the future practicums.
16

Lastly, I believe that my training from the University of San Carlos has been
an enormous help in understanding the different processes in SCBI. The things
going on in the different equipment and analysis are not that hard to understand
because of the theories learned in the academe.

VI.

Annexes

Figure 1. Safety shoes, hard hat and official practicum I.D.

issued by the San Carlos Bioenergy Inc.

Mill and Boiling House Department

17

Figure 2. Service Bus of SCBI.

Figure 4. Belt conveyor in the Mill

Department (Closer look)

Figure 3. Belt conveyor of the Mill and Boiling House

Department

Figure 5. Fork crushers for juice extraction

Figure 6. Bagasse in the final stage of

extraction. These are then delivered to the
boiler house as fuel.

18

Figure
Figure
9. Rotary
7. Multiple
Drumeffect
Filter evaporators (5 effects)

Figure
Figure10.
8. Evaporator
Mill and Boiling
window.
house control room

19

Figure 11. Theoretical Mass Balance along the multiple effect evaporators.

Distillery Department
Fermentation Section

1
2

Figure 12. Culture vessels 1, 2 and

3.

20

Figure 13. Pre-fermenters 1 and 2.

Figure 12. Plate heat exchangers for cooling of the

solutions in the distillation section.

Figure 14. Fermenters 1 and 2.

Distillation Section

21

Figure 15. Continuous distillation columns.

Figure 16. Plate Heat Exchangers

22

Figure 18. Distillery section control room.

Figure 17. Cooling towers for the Fermentation

section (Top) and for the Distillation section
(BOTTOM)

Figure 20. Pumps and other accessories.

QC/QA Department
Figure 19. Bioethanol storage tanks.

23

Figure 21. Weighing house and the

weigh bridge.

Figure 22. Corer machine used in the

Cane Acceptance part.

24

Figure 23. Quality control and analysis laboratory equipments and

reagents.

Environmental Management Department

Figure 24. SCBI's Anaerobic Digester Tank

Figure 25. Lamella Clarifier.

25

Figure 26. Sand Filters. These are used to clarify the

wastewater from the boiler house.

Figure 27. Cartridge filters. Clarifies further

the treated wastewater from the sand filters.

Figure 28. Biogas storage tank. The Biogas

produced in the A.D. is stored here and is further
transferred to the boiler house as additional fuel.

26

Figure 29. SCBI's Reverse Osmosis (RO). Used to clarify

spent wash from the distillery but the operation was
stopped since the maintenance cost is very expensive.

Figure 30. Ultrafiltration unit. The final

stage after the reverse osmosis system.
The treated water that comes out form this
equipment is comparable to that of
softened water.

Figure 31. Compost area of the Environmental Management

Department.

27
Figure 32. Storage lagoons for the clarified wastewater from the
boiler house. Organic matters left in the wastewater undergo
natural decomposition. Once treated, it is recycled back to the
cooling towers.