Beruflich Dokumente
Kultur Dokumente
A REPORT ON
Completed At
Submitted by
(B.E. CHEMICAL)
TRAINING DURATION
18 MAY 2015 TO 08th JUNE 2015
st
CERTIFICATE
Guide H.O.D.
Principal
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.
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.
5
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
INTRODUCTION
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
7
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.
8
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.
9
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.
B) Environmental Impacts
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.
11
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.
12
FERMENTATION PROCESS
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.
(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.
15
FERMENTATION TANKS
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.
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
DILUTION OF MOLASSES
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.
19
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%
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.
20
API 650
BS 2654
IS 803
TANK SPECIFICATION
1. Foundation
2. Base plate
3. Shell
4. Roof
FOUNDATION
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
Roof
Appurtenances
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.
22
23
Side reaction:
2C6H12O6 + H2O → ROH +RCHO (high molecular weight alcohols C2H5OH)
24
YEAST USED