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The main products of this industry are Alcohol with different percentages
(95%-100%) exported all over the world.
Aside from the Alcohol it also contain different type of plant to make the main
product maximum and efficient like it contain CO2 Plant which consumes the
byproduct of Fermentation process (Carbon Dioxide)
It contains ETP which treats the spent wash and gets Bio gas which is used to burn
Boilers which power industry up and nothing is useless in this industry it also
contain RO plant which provides fine purified water.
All these process will be discussed in detail. Starting from the first
Fermentation Process
Fermentation Process
Introduction:
The main process of Unicol Limited is Fermentation and
Distillation so it is considered as very important.
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, yogurt
and other foods. Fermentation comes from the Latin word
fermentare, meaning “to leave.”
Instruments
Before heading towards the process it is important to
discuss the instruments used in the process
PUMPS
A pump is used to move liquids from one place
to another
Centrifugal Pumps: it is the type of pump that
uses an impeller to move fluids. Centrifugal pumps are
used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid
flow.
PD Pump
A Positive Displacement Pump has an expanding cavity on the
suction side and a decreasing cavity on the discharge side. Liquid flows
into the pumps as the cavity on the suction side expands and the
liquid flows out of the discharge as the cavity collapses. The
volume is a constant given each cycle of operation.
Gear Pump
A gear pump uses the meshing
of gears to pump fluid by displacement.
They are one of the most common types
of pumps for hydraulic fluid power
applications. Gear pumps are also
widely used in chemical installations
to pump high viscosity fluids.
Rotation Pumps
It is the type of Positive
displacement pumps and used to
circulate fluids in order to
decrease it viscosity
Valves
Used to regulate and control the flow
of fluids
Ball Valve
Ball valve is a quarter turn operated valve. The closure member is a spherical plug with a through
hole.
Gate Valve
Gate valve is a sliding type of valve. In gate valves, the closing member is a metal gate
Butterfly Valve
Butterfly valves are most simple yet versatile valves. They are quarter turn operated valves which
are commonly used in multiple industries for varied applications
Globe Valve
In globe valves, the flow of the fluid through valve follows an S-path. Due to this, the flow direction changes
twice which results in higher pressure drops.
Safety Valves
a valve that opens automatically to relieve excessive pressure
Heat Exchangers
A heat exchanger is a device used to transfer heat between a solid object and a fluid, or
between two or more fluids. The fluids may be separated by a solid wall to prevent mixing
or they may be in direct contact.
Shell and tube heat exchangers consist of series of tubes. One set of these tubes contains the
fluid that must be either heated or cooled. The second fluid runs over the tubes that are
being heated or cooled so that it can either provide the heat or absorb the heat required. A
set of tubes is called the tube bundle and can be made up of several types of tubes: plain,
longitudinally finned, etc
Flow Indicators
Flow Indicator Controller
Mixers
Process
The process of Fermentation starts from the pits
Step1: Molasses to the Plant
The Raw Material (Molasses) is transported to the
Unicol by different industries and stored in Pits and
Storage tanks (Unicol has 10 storage tanks of
15,000metric tons capacity)
Distillation Process
Once after the formation of alcohol the process of distillation takes place
Distillation is the process of separating the component or
substances from a liquid mixture by
selective evaporation and condensation. Distillation may result in
essentially complete separation (nearly pure components), or it may
be a partial separation that increases the concentration of selected
components of the mixture.
The same process carried out in this industry the alcohol is purified
and concentrated in Distillation columns
The Liquid first travels to the heat exchanger (Shell and Tube) and
attains the temperature and then the liquid is transported to the
column where evaporation takes place and consecutively liquid
passes through different columns resulting in purification and
increase in the concentration of alcohol.
Unicol produces three type of Alcohol percentage A grade
(99.9% Pure Alcohol) B grade (95% and 96.5%).
CO2 Plant
The CO2 is byproduct of fermentation process and releasing it
is harmful for humans and other living things.
In Unicol CO2 is Liquefied and then transported to the
beverage industries.
The Process of purification and liquefaction of Carbon
Dioxide is as follows
Step1: Scrubbers
When raw Carbon Dioxide is transported to the Plant .It first
goes to the Scrubber where, it is washed with the Water, Ethyl
alcohol is removed from it (As Ethyl alcohol is soluble in the
water)
After two columns of KMnO4 another Scrubber is installed
which further removes impurities.
Step2:KMnO4 Columns