Description
Managing waste and process study
MANAGING WASTE AND UNDERSTANDING THE PROCESS OF ETHANOL MAKING IN INDIA GLYCOL LTD.
Summer Internship Project Report Submitted towards Partial fulfillment of Post Graduate Diploma in Management (Approved by AICTE, Govt. of India) Academic Session 2011-2013
Under the Guidance of: Industry Guide Mr. Praveen Srivastava SR. Manager (Production) Mr. Anoop kumar Srivastava DY. Manager (Production and Microbiology) INDIA GLYCOL LTD. Faculty Guide Dr. Shailendra Dube Professor Operations management IMS, Ghaziabad Submitted By: Shivam Dubey Roll No: BM-011203
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PREFACE
The project entitled as “MANAGING WASTE AND UNDERSTANDING THE PROCESS OF ETHANOL MAKING IN INDIA GLYCOL LTD.” is basically a study about the production process of ethanol making ,fermentation and waste management in INDIA GLYCOL LTD. Gorakhpur U.P. The major aspects of the process are been covered and a study on the loopholes in the process is done to detect the process and provide the alternative route for the use of waste , in continuation to that the solution to those problems are also been provided. The major problem faced during the on goings of the project is related to data unavailability and the technical unawareness about the machines employed in the production process apart from these drawbacks there was a constraint of lack of support from the employees and the workers who were consulted for the technical specifications. In a manufacturing company, production process is very important as it affects the efficiency through which the company can manufacture with minimum defects and wastes. Thus it is necessary to understand each parts and steps in the process of a manufacturing machine for an employee, so that he can handle the machine properly and bring about possible innovative changes which can bring down the cost. Understanding about the production process helps to cut down cost to provide the customer product at minimum price. It is necessary for maintaining the quality of the products. A good process maintains the standard necessary to be in competition. Thus it is the most important part to be understood in a company.
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ACKNOWLEDGEMENTS
I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to Mr. Praveen Srivastava and Mr. Anoop Srivastava for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards my parents & member of INDIA GLYCOL LTD. for their kind co-operation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to Mr.Sanjeev khanna (Head HRD) and to industry persons for giving me such a motivation ,attention and time for the full fill ment of my project. My thanks and appreciations also go to my colleague in developing the project and people who have willingly helped me out with their abilities.
Shivam Dubey IMS Ghaziabad
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TABLE OF CONTENTS
Chapter 1 Chapter 2
Executive summary Alcohol industries in INDIA Introduction about company
Page 1 Page 2 Page 3-13 Page 14 Page 15
Chapter 3 Chapter 4 Chapter 5
Objectives of Project Research Methodology Production Process Raw Material and Their Attributes Steps Of Alcohol Cycle Formation of culture Fermentation process Distillation
Page 16-21
Page 22 Page 23 Page 24-30 Page 30-38 Page 39-41 Page 42 Page 43
Chapter 6 Chapter 7 Chapter 8
Finding and analysis Conclusion Observation & recommendations Limitations Bibliography
Chapter 9 Chapter 10
Page 44 Page 45
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LIST OF TABLES/FIGURES/IMAGE/FLOW CHART
Molasses Figure 5.1 Figure 5.2 Yeast
Figure 5.3 Figure 5.4 Figure 5.5 Figure 5.6 Figure 5.7 Figure 5.8 Table 5.9 Table 5.10 Figure 5.11 Figure 5.12 Figure 5.13 Table 5.14 Figure 5.15 Table 5.16
Yeast Life Cycle pH Scale With pH Value Flow Diagram of Alcohol Cycle PETRIDISHES AUTOCLAVE Flow Chart of fermentation Technical Aspect For Fermentation Time Duration For Fermentation Process Fermentation Vat Cooling Coil Fermentation Tank Line Diagram Of Distillation Capacity of plants Flow chart of distillation Specification of Rectified Spirit
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CHAPTER-1
EXECUTIVE SYNOPSIS
The project Entitled as “Waste related to the process and to having the knowledge of the ethanol making” at INDIA GLYCOL LTD.” comprises of the production process and the waste from it at different products manufactured in the unit of INDIA GLYCOL LTD. The project shows the full process of country liquor and India made foreign liquor with molasses . The process goes as through certain stages which include the development of culture (yeast), Its multiplication in the prefermenter,the fermentation process and the distillation process with the other auxiliary additives. Then these raw martial are used along the series of continuous process in line to
extrude the desired shape as per the specification of the product. INDIA GLYCOL LTD. industries manufactures alcohol in different forms for different other industries and depending upon the market requirement which use these products to manufacture other products. The report also detects the flaws in the process as obsolete technology used to produce power and steam through boiler , as well as flaws related to the production lines a very deep analysis is done and the solution for the problems is also provided at the end of the report.
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CHAPTER-2
Alcohol Industry In India
Indian Spirits Sector - Overview Indian Liquor Industry with estimated market value of INR 340 bn is growing at 12-15% over the last two years. The industry is estimated to have sold 115 mn cases of IMFL last year. The sector is expected to maintain its CAGR of ~15% while the premium segment Wine and Vodkas expected to grow at a higher rate. With consolidation and foreign acquisitions gaining steam the sector is about to witness next phase with realization rising in line with that of their foreigncounterparts.There are 325 distilleries in India, with an installed capacity of about 3.58 billion liters of liquor. However, production rate is about 40% of total licensed capacity as total requirement of liquor stands at 1.3 billion liters. Major National Players: United spirits with about 60 % of market share in IMFL is the undisputed leader. Radica Khaitanwho entered the IMFL space some 8 years back has already cornered 12 % market share and gaining. Other players include Mohan Meakin (9%), Jagatjit (8.5%), etc. International players: The major international players are Pernod Richard, Remy Cointreau, and Diageo (Diageo hastied up with Radico for entering Indian markets in brown spirits)Investment RationaleInherent Potential, Deregulation, western cultural influence and high entry barriers has helpedthe industry in notching up higher sales growth. Alcohol sale is driven by the high GDP growthand more people entering the drinking club with newly obtained prosperity or from up tradingfrom the existing brand. Inherent Potential: Since liberalization, the economy has been growing at steady pace with per capita income rising from INR 23,222 in 2005 to INR 6,012 in 1991.Shift from country liquor to IMFL is expected with rising per capita income and limiting the saleof country liquor by states due to hygiene factor.Industry has one of the lowest per capita consumption of both Liquor and Beer and also since the
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INTRODUCTION ABOUT INDIA GLYCOL LTD
COMPANY PROFILE
India Glycols is a leading company that manufactures green technology based bulk, specialty and performance chemicals and natural gums, spirits, industrial gases, sugar and nutraceuticals. The company was established as a single mono-ethylene glycol plant in 1983. Since then, IGL has brought together cutting-edge technology, innovation and an unflagging commitment to quality, to manufacture a wide range of products that have found global demand. IGL?s state-ofthe-art, integrated facilities manufacture chemicals including glycols, ethoxylates, glycol ethers and acetates, and various performance chemicals. Its product range spans the chemicals, spirits, herbal and other phytochemical extracts and guar gum, industrial gases and realty sectors, and finds application across an increasing number of industries. These products are manufactured in compliance with stringent global standards of plant operations, quality and safety. The company?s facilities have been approved and certified by international agencies including Det Norske Veritas (DNV). The operations at all plants are closely monitored through distributed control systems (DCS), which facilitate a high degree of control over the quality of products.
The company has installed distillery effluent evaporators at Gorakhpur and the concentrated effluent is burnt in specially designed boilers; the calorific value of the concentrated, effluent generates super-heated steam which is. utilised in the turbo generator with capacity of 12.5 MW for power generation. In FY 2007-08 the company acquired controlling stake in the Shakumbari Sugar & Allied Industries (SSAIL) that is engaged in business of manufacturing sugar. SSAIL?s manufacturing plant is located in Uttar Pradesh with a crushing capacity of 3200 tones per day (TCD) along with a modern distillery of 40 kl per day (KLPD), producing high quality rectified spirit, ethanol
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and country liquor and an internal bagasse-fired co-generation plant of 3 MW catering to the captive power needs of the sugar and distillery units.
COMPANY HISTORY
1983- India Glycols Ltd was incorporated at New Delhi on 19thNovembe as a public limited company as u.p.glycols limited obtained the Certificate of Commencement of Business on 3rd February 1984.Thecompanywaspromoted by Vam Organic Chemicals Ltd. The company manufactures m ono-ethyleneglycol (MEG) , diethylene glycol (DEG) and triethylene glycol (TEG). - The company entered into a technical know-how agreement with `ScientificDesign Company Inc., USA (SD) for the supply of process know-how only for the conversion of ethanol into MEG as the promoter VAM agreed to advise freeof cost on the conversion process of molasses into ethanol.- The company also entered into an agreement with Toyo Engineering India Ltd.,for implementing the project within guaranteed cost and time limit. 1986- The name of the Company was changed to `India Glycols Limited „Effective from 4th September. 1988- 70 shares subscribed for by the signatories to the Memorandum of 1995- The company had tied up with Sanyo Chemical Industrial SurfactantsCovering major industries like textiles, toiletries, pharmaceuticals,agrochemicals, paper, lubricants etc.- The Company also proposed to set up facilities for chlorosulphation to produce other specialty chemicals to maintain better quality standards. 2003 -The Board of Directors at their meeting held on December 4, 2003 have approved the merger of wholly owned subsidiary company CDS InternationalLtd with the company. The Board of Directors at their meeting held on December 4, 2003 has approvedthe merger of wholly owned subsidiary company CDS International Ltd with thecompany. On Novembers a public limited company as `U.P. Glycols Limited „and obtained the Certificate of Commencement of Business on 3rd February,1984. The company was promoted by Vam Organi Chemicals Ltd.
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IGL BUSINESSES
IGL?s flagship chemicals division started out with a path-breaking green approach to manufacturing ethylene oxide and derivatives. Using the molasses-ethyl alcohol-ethylene 'green route', the company is the only one of its kind in the world. With the emphasis now increasingly shifting to green manufacturing, the chemical division is well poised to meet the industry?s need for environmentally responsible products and production techniques. Keeping in mind the critical dependence on agricultural feedstock, the company has taken up several initiatives including backward integration into sugar manufacturing to ensure seamless raw material availability. Other complementary initiatives include co-opting the cane growing community to ensure cane availability while providing adequate returns to the farmer. Apart from chemicals, India Glycols has a significant presence in the natural active pharmaceuticals and nutraceuticals space with Ennature Biopharma; a well-established natural gum division manufacturing guar gum and a variety of derivatives; a spirits division that manufactures country and Indian-made foreign liquor adhering to the highest quality standards; and Shakumbari Sugar – a well-established player in the Indian sugar industry. The company is the Leading manufacturers of Glycols, Ethoxylates, Performance Chemicals, Glycol Ethers & Acetates, Guar Gum and Potable Alcohol. The company has more than 1,000 customers in various such as Textile, Agrochemical, Oil & Gas, Personal Care, Pharmaceuticals, Brake Fluids, Detergent, Emulsion Polymerisation & paints etc. India Glycols (IGL) was promoted by Vam Organics to manufacture 20,000 tpa of monoethylene glycol (MEG) at Kashipur, UP.
Future Plans
India Glycols will focus on various areas in future such as developing cost-effective emulsifier for crop protection chemicals; development of eco-friendly surfactants to replace alkylphenol ethoxylates; development of green demulsifier for crude oil emulsion and setting up an application development laboratory equipped with all sophisticated instruments for various industries.
Exports
IGL has traditionally looked to leverage the export potential of its products. The company has therefore initiated the process of aligning to emerging global trends and has established facilities and operations that are in compliance with global good manufacturing practices.
Customer Focus
The company strives to achieve excellence through proactively addressing customer needs and requirements. Integral to this approach is the identification and development of customised products backed by research and development support.
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MAJOR PRODUCTS UNDER INDIA GLYCOL LTD.
Agrochemicals
India Glycols works closely with clients in the agrochemical industry in order to understand their requirements, and create products that meet their specific needs. The company offers a wide range of chemicals that find use in three product categories – insecticides, fungicides and herbicides.
Pharmaceuticals
IGL?s products find application primarily in the manufacture of ointments, tablets and syrups. The company has taken every measure to ensure that its manufacturing facilities adhere to strict quality and hygiene standards, and its products meet Indian and global purity standards.
Healthcare and food processing
Guar gum is used extensively in the healthcare and food products industry, and manufacturers are required to adhere to strict quality and purity standards. IGL has invested in the latest technology to ensure that its guar gum products are manufactured with minimal human intervention, thus ensuring a hygienically produced, high purity product. The company?s gum products have been approved under the US Federal Register as „Generally Recommended as Safe? category for food, feed and pharmaceutical applications.
Automotive
India Glycols manufactures two products for the automotive industry – brake fluid and antifreeze coolant. The company is one of India?s leading manufacturers of brake fluid, which it supplies to all the major Indian oil companies.
Textiles
India Glycols Limited caters for the range of chemicals required for both dry and wet processing of fibres and fabrics. Being the largest manufacturer of ethoxylates, IGL?s strength has been in providing customised products for batch as well as continuous processes. Besides, we are committed to the concept of “grey to green” transformation by providing green chemical alternatives as textile auxillaries. IGL?s focus is always to provide environment-friendly products meeting the international safety norms of GOTS, REACH, IKEA, OEKO-TEX, etc.
Paints and emulsion polymerisation
India Glycols offers a comprehensive range of products for the paints and emulsion polymerisation industry. The company?s strength lies in its ethylene oxide-based (EO) 11
emulsifiers and anti-settling agents. IGL?s captive feedstock of EO ensures that customers get the benefit of consistent quality and reliable supply.
Innovation
Innovation has always played a pivotal role in IGL's success story of multifold business growth and ever-growing customer base. The innovation team at IGL, a dedicated group of researchers, is continuously engaged in adding new, value-added products to our product range. At IGL, we take utmost care to ensure that our products are environment-friendly and comply to all national and international safety norms. The R&D division, since its inception in 1994, is dedicated to developing as well as acquiring new, advanced technologies for the quick growth and sustenance of business. The results have been the outcome of many successful collaborations with international experts from academia and various industries. India Glycols has a focused R&D section within its distillery to introduce unique, improvised processes and techniques to achieve high fermentation efficiencies. With the help of pilot fomenters, our team constantly conducts research on fermentation processes with different raw materials and simulates the same on plant scale so as to improve yields. The research team is also working on the 'smart distillery concept' capable of producing alcohol from different raw materials, ie, molasses, grains and sugarcane.
Innovation strategy
The Innovation Strategy of IGL, structured in line with the vision and mission statement of the organization, is to drive business through market-led innovations in product, process and application technologies, thereby establishing ourselves as a “solution provider”. The salient features of the strategy are: 1-The R&D function focuses on developments, scaling-up of processes, quality and cost reduction 2-Major projects are customer-driven, using product / application expertise 3-Innovation integrates the customer interface with all other functions 4-Value creation through differentiated product attributes and cost optimisation 5- Networking with external institutions to help in knowledge updation and capability building. The R&D function focuses on profitable growth and value creation for IGL's stakeholders.
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SWOT ANALYSIS
Strength
IGL is uniquely positioned as a petrochemical manufacturer through the organic route, and is probably the largest player in the world in its segment. Though the gross block of the company is Rs9.7bn, its replacement cost is estimated to be ~Rs32bn. This along with technological knowhow, would act as a strong barrier for entry, thereby offering competitive safety for the company.The Gorakhpur unit is fully integrated one, thereby ensuring operationalsmoothness. Higher realizations with stability in outlook and prices. Improving product range (180 at present) would also enhance realisations and consequently better margins. IGL has the ability to switch its feedstocks, between molasses, ethanoland sugarcane. Thus, it can procure molasses and other raw material at the start of a season(Oct-Nov) and rationalize its raw material costs. Its storage facility also enablesit to manage inventories on a higher scale.
Weakness
IGL?s margins could face pressure if MEG prices continue to fall vis-a-vis hikes in prices of molasses and ethanol. While IGL is integrating backwards to reduce the price volatility in its raw materials, the same cannot be eliminatedand hence would continue to dog the operations of the company. Newer capacity expansion being undertaken in the M. East (Saudi Arabia & Iran) hasthe potential to lower the landed cost of imported MEG in India and to impactrealisations. Currently, POY/PSF industry accounts for ~70% of MEGconsumption in India and ~35% of IGL?s revenues. This imparts high sensitivityto an industry and any slowdown in that sector has the potential to impact IGL?searnings.
Opportunities
IGL has flexibility in using ethanol or molasses as its feedstock for MEG/EO manufacturing, which can help optimise its raw material cost. By setting up co-generation plants, IGL will be able to lower its power costs (12%of net sales in FY08) to 8% of net sales in FY10. Expansions in the polyester industry (Indo Rama, JBF, Reliance and Garden Mills) will ensure offtake of IGL?s incremental capacity. IGL is diversifying its revenue stream through venturing into Nutraceuticals, CO2 and Real Estate, which are expected toaccount for ~10% of revenues by FY10.
Threats
MEG capacity expansion in M. East may dampen IGL?s offtake.Additional capacitiesmay impac t global prices which will impose margin pressure. Also, any changes in custom duties on MEG (7.5%) and swing in Rs/USD rates have the potential to dampen realisations and 13
margins. Currentlythe Reliance group, which is the largest domestic manufacturer of MEG,consu mes majority of its production in-house. Any sharp scale up in its merchant sales can upset the business prospects of IGL. After Shakumbari expansion,there would be another factor influencing the costing structure of IGL namely sugarcane. We have drawn our estimates on cane prices of Rs 125/qntl. Thus,any unfavourable change in the pricing or availability of cane can substantially impair the earnings of the company . IGL is undertaking capex of Rs4.9bn over the next 2 years. There is also a shutdown of 25-35 days envisaged at its MEGfacility. Any derailment or delay of the same could impact its earningssubstantially. Export s constitute ~14% of its revenues and any adversemovement in exchange rate can depress margins
Path to excellence:Integrity – honesty in every action Commitment – On the foundation of integrity, doing whatever it takes to deliver, as promised. Passion – Missionary zeal arising out of an emotional engagement with work. Seamlessness – Thinking and working together across functional silos, hierarchy levels, businesses and geographies. Speed - Responding to stakeholders with a sense of urgency and remaining one step ahead.
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Awards
1991 ? ? Award National Safety Award for meritorious performance in industrial safety, in achieving longest accident-free period National Safety Award for outstanding performance in industrial safety as runner up in achieving lowest average frequency rate from Organisation Ministry of Labour, Government of India.
1992 ? Award Award of Merit for operating 27,55,364 employee hours without occupational injury or illness from Organisation National Safety Council, USA
1997 ? 1998 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK Award for Best Project / Entrepreneur in the biomethanation sector.
1999 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK
2000 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK
2001 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK
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2002 ? ? Award Safety Award in recognition and commendation of services rendered to the cause of safety National Safety Award for outstanding performance in industrial safety, in achieving longest accident-free period.
Perfect Record Award for operating 7,208,784 employee hours without occupational injury or illness award from Organisations British Safety Council, UK,Ministry of Labour, Government of India , National Safety Council, USA 2004 ? Award Best Performing Power Plant from International Safety Award in recognition of proven track record of maintaining excellent safety standards. British Safety Council, UK
2005 ? Award International Safety Award in recognition and commendation of services rendered to the cause of safety. From Organisation British Safety Council, UK
2008 ? ? Award Best Quality ENA Award in recognition of quality ENA production. Best Enhanced Performance for enhanced performance in exports.
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CERTIFICATION FOR INDIA GLYCOL LTD.
IGL is having a different certification of ISO for its Liquid carbon dioxide application in Kashipur and Gorakhpur units and for its Natural Gums Division (NGD). India Glycols has two beverage-grade liquid CO2 plants of 80MTPD capacity each, at Kashipur and Gorakhpur units. The salient features of the liquid CO2 plants are as follows: The state-of-the-art liquid CO2 plants and technology has been obtained from Wittemann Inc, USA, on a turnkey basis. The company?s plants process CO2 without using any chemicals for purification. The raw CO2 is purified using washing, scrubbing and absorption methods, and a specially designed NOx removal system. The purity level of liquid CO2 is 99.99+ per cent (beverage grade), and the plants have stringent dual testing procedures: one uses gas chromatographs and the other employs the latest online analyser obtained from PAC Inc, USA. A complete online analysis of the product is done for impurities like total hydrocarbons, total aromatic hydrocarbons, total sulphur, oxygen, nitrogen and moisture. The liquid CO2 plants are approved for ISO 9001-2000 and ISO 22000/HACCP certification. Both plants have a liquid CO2 storage capacity of 220MT each. India Glycols Limited owns a large fleet of mobile tankers of various capacities for liquid CO2 to ensure timely deliveries as per our customers' requirements. The company has a huge storage capacity of basic raw material, i.e., molasses for use in its distillery, thus ensuring round-theclock availability of liquid CO2. Applications of liquid carbon dioxide ? ? ? ? ? ? ? Carbonation of beer and soft drinks for superior quality and a fresh, tingling taste. Grinding of spices to preserve the aroma and for increased production rates. Packaging of foodstuffs in a controlled atmosphere for superior quality and fresh taste. Quick-freezing in tunnels and cabinets for fresh taste; reduction in loss of weight; and increased production rate. Preservation of meat during the mincing process. Transportation of chilled food with fairly low investment. As dry ice for the pharmaceuticals and food industry.
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In the Manufacturing industry ? ? ? CO2 welding (MIG / MAG) to provide an inert atmosphere. Hardening of cores and moulds in foundries for reduced production time and better surface properties and accuracy. Use in fire extinguishers - a critical safety feature in any manufacturing unit.
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CHAPTER-3 OBJECTIVE OF PROJECT
The objective of this project is to study about the manufacturing process of alcohol in INDIAN GLYCOL LTD:? ? ? ? To study the overall manufacturing process of alcohol To know about the production process of the fermentation and distillation unit. To work over the waste management. To recommend feasible solutions to the problems.
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CHAPTER-4 RESEARCH METHODOLOGY
a) Research design : The research is based on exploration of production process as well as description of production process, so the type of research designs used are: ? Exploratory Research. ? Descriptive Research. b) Data collection: Data is collected about the various specification about the different process line from both primary sources as well as secondary sources ? Primary sources: through direct interaction from supervisors, operators working on the production line and knowing the process more deeply . ? Secondary sources: data collected from Industry guide as well as different websites, books etc.
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CHAPTER-5 PRODUCTION PROCESS
RAW MATERIAL USED IN ALCOHAL PRODUCTION
MOLASSES Molasses is the residue from the manufacturing of sugar . These materials if available are excellent sources of alcohol. They contain 50-55%of sugar and a ton should yield between 70-80 gallons of alcohol. Most molasses is naturally alkaline and acid is needed to add to obtain the proper pH value. Molasses? is applied to the final effluent obtained in the preparation of sugar by repeated crystallization. The amount of molasses obtained and its quality (composition) provide information about the nature of the beets (local conditions of growth and effects of the weather) and the processing in the sugar factory, such as the efficiency of the juice clarification, the method of crystallization during boiling, and the separation of the sugar crystals from the lowgrade massecuite. In white sugar factories the yield of molasses is in the neighbourhood of 4% on beets, corresponding to up to 25% on sugar. With an average sugar content in the beets of 1618% only 13 to 14% of the sugar will be recovered as a commercial product. As an average, 2.22.6% sugar on beets will go into the molasses when raw sugar is produced. The yield of molasses is affected by various factors and differs from batch to batch. The daily storage loss in Western Europe is estimated at 0.062% sugar on stored beets or 0.1% sugar decrease in the white sugar yield. Molasses is a by-product of sugar production that is brown or black in color. In sugar production, the juice is removed from the sugar cane and then boiled. This is then spun to remove the sugar crystals from the mixture, and the remaining product is molasses. Although molasses is a popular ingredient in baking its unique properties means that it also has many other non-culinary uses. The objective of the sugar industry is to produce molasses whose purity is as low as possible. Commercial molasses ordinarily has 48 % sugar is present. CLASSIFICATION OF MOLASSES 1- First Grade Molasses- It contains more than 50% TRS. 2- Second Grade Molasses- It contains 40%-50% TRS. 3- Third Grade Molasses- It conations 40% TRS.
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Uses of Molasses
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Molasses is commonly used with yeast and water in the fermentation process of making rum. It is also used in creating some other alcoholic drinks such as stout and dark ales. Some tobacco companies add it to their product for smoking through a certain type of pipe popular in the Middle Eastern countries. Some anglers use molasses as a groundbait (also called chum or berley). This is designed to attract fish to the area that an angler is fishing. In some parts of the world it is used to produce ethanol (ethyl alcohol) for use as an alternative fuel source. It can also be mixed with water and used to remove rust. It is used in some horticultural settings to promote microbe activity in the soil. Molasses is also added to some cattle feed to add essentials vitamins and minerals.
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USE OF MOLASSES IN LIQUOR INDUSTRIES When molasses is to be fermented to alcohol, the sugar content should be high. Raffinose, which amounts to 0.5 to 2% in beet molasses, is broken down into fructose and melibiose by yeasts which contain the enzyme saccharine. Melibiose in turn is broken down by some yeasts (e.g. bottom yeasts) into glucose and galactose. Raffinose is broken down completely by the bottom yeasts; top yeasts ferment only one-third of the raffinose. The alcohol and yeast industry, using beet and cane molasses, is concerned with the suitability for alcohol fermentation or for the production of yeast. There are two type of molasses which are used in alcohol making are free and levy molasses. Free molasses is used for the production of rectified sprit and levy form is used for the making of country liquor.
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5.1 MOLASSES
YEAST Yeasts are single-celled fungi. As fungi, they are related to the other fungi that people are more familiar with. These include edible mushrooms available at the supermarket, common baker?s yeast used to leaven bread, molds that ripen blue cheese and the molds that produce antibiotics for medical and veterinary use. Many consider edible yeast and fungi to be as natural as fruits and vegetables.
5.2 YEAST The typical yeast cell is approximately equal in size to a human red blood cell and is spherical to ellipsoidal in shape. Because of its small size, it takes about 30 billion yeast cells to make up to one gram of compressed baker?s yeast. Yeast reproduce vegetatively by budding, a process during which a new bud grows from the side of the existing cell wall. This bud eventually breaks away from the mother cell to form a separate daughter cell. Each yeast cell, on average, undergoes this budding process 12 to 15 times before it is no longer capable of reproducing. During commercial production, yeast is grown under carefully controlled conditions on a sugar
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containing media typically composed of beet and cane molasses. Under ideal growth conditions a yeast cell reproduces every two to three hours. Yeast is the essential ingredient in many bakery products. It is responsible for leavening the dough and imparting a delicious yeast fermentation flavor to the product. It is used in rather small amounts in most bakery products, but having good yeast and using the yeast properly often makes the difference between success and something less than success in a bakery operation.
5.3 Yeast Life Cycle The yeast cell's life cycle: 1. Budding 2. Conjugation 3. Spore Nutrition and growth Yeasts are chemoorganotrophs, as they use organic compounds as a source of energy and do not require sunlight to grow. Carbon is obtained mostly from hexose sugars, such as glucose andfructose, or disaccharides such as sucrose and maltose. Some species can metabolize pentose sugars like ribose, alcohols, and organic acids. Yeast species either require oxygen for aerobic cellular respiration (obligate aerobes) or are anaerobic, but also have aerobic methods of energy production (facultative anaerobes). Unlike bacteria, there are no known yeast species that grow only anaerobically (obligate anaerobes). Yeasts grow best in a neutral or slightly acidic pH environment. Yeasts vary in what temperature range they grow best. For example, Leucosporidium frigidum grows at -2 to 20 °C (28 to 68 °F), Saccharomyces telluris at 5 to 35 °C (41 to 95 °F), and Candida slooffi at 28 to 45 °C (82 to 113 °F). The cells can survive freezing under certain conditions, with viability decreasing over time.
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In general, yeasts are grown in the laboratory on solid growth media or in liquid broths. Common media used for the cultivation of yeasts include potato dextrose agar (PDA) or potato dextrose broth, Wallerstein Laboratories nutrient (WLN) agar, yeast peptone dextrose agar (YPD), and yeast mould agar or broth (YM). Home brewers who cultivate yeast frequently use dried malt extract(DME) and agar as a solid growth medium. The antibiotic cycloheximide is sometimes added to yeast growth media to inhibit the growth of Saccharomyces yeasts and select for wild/indigenous yeast species. This will change the yeast process. The appearance of a white, thready yeast, commonly known as kahm yeast, is often a byproduct of the lactofermentation (or pickling) of certain vegetables, usually the result of exposure to air. Although harmless, it can give pickled vegetables a bad flavor and must be removed regularly during fermentation.
Uses
Alcoholic beverages Alcoholic beverages are defined as beverages that contain ethanol (C2H5OH). This ethanol is almost always produced by fermentation – the metabolism of carbohydrates by certain species of yeast under anaerobic or low-oxygen conditions. Beverages such as mead, wine, beer, or distilled spirits all use yeast at some stage of their production. A distilled beverage is a beverage containing ethanol that has been purified by distillation. Carbohydrate-containing plant material is fermented by yeast, producing a dilute solution of ethanol in the process. Spirits such as whiskeyand rum are prepared by distilling these dilute solutions of ethanol. Components other than ethanol are collected in the condensate, including water, esters, and other alcohols, which (in addition to that provided by the oak it is aged in) account for the flavour of the beverage.
Industrial ethanol production
The ability of yeast to convert sugar into ethanol has been harnessed by the biotechnology industry to produce ethanol fuel. The process starts by milling a feedstock, such as sugar cane, field corn, or other cereal grains, and then adding dilute sulfuric acid, or fungal alpha amylase enzymes, to break down the starches into complex sugars. A glucoamylase is then added to break the complex sugars down into simple sugars. After this, yeasts are added to convert the simple sugars to ethanol, which is then distilled off to obtain ethanol up to 96% in concentration. Saccharomyces yeasts have been genetically engineered to ferment xylose, one of the major fermentable sugars present in cellulosic biomasses, such as agriculture residues, paper wastes, and wood chips. Such a development means ethanol can be efficiently produced from more inexpensive feedstocks, making cellulosic ethanol fuel a more competitively priced alternative to gasoline fuels.
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SULPHURIC ACID H2SO4 Sulphuric acid (alternative spelling sulphuric acid) is a highly corrosive strong mineral acid with the molecular formula H2so4. It is a colorless to slightly yellow viscous liquid which is soluble in water at all concentrations. Sometimes, it may be dark brown as dyed during industrial production process in order to alert people's awareness to its hazards. Sulphuric acid is used in the process because the maintain the pH value because the pH value of alcohol is 4 - 3 and the molasses which is added is of basic nature that is alkaline so we add the sulphuric acid to make it acidic .
5.4 pH Scale with range
UREA (NH2CONH2): Urea works as the catalyst for the good fermentation by providing the need of required nitrogen. Which is help full in the growth of the yeast. ANTIBIOTIC: These are used to prevent the growth of other bacteria?s during the process.
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ALCOHOL PRODUCTION PROCESS:
The four steps in the Alcohol Cycle-
Formation of culture
Pre fermentation
Fermentation
Distillation 5.5 Flow diagram
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FORMATION OF CULTURE
Yeast is called as a culture in the industries. The initial stage of formation of culture is done into the lab. In laboratory pure culture is raised from single yeast cell. Pour plate method is used for propagation of yeast. In this method six test tube containing 9 ml. of sterilized distilled water is taken. Then 1 ml. of yeast culture is added in the first test tube. This 1ml. of yeast is mixed well into the first test tube then it is transferred into the 2nd test tube for more dilution. This process of transferring is done till 6th test tube or when there is a sufficient dilution of the culture is done. The 250ml. of flask is taken in which we mix. Glucose (10 gm), yeast extracted (3 gm), peptone (3 gm) and maintain the pH around 4.5-4.8. The formed mixture is put into the autoclave for around 15-20 minutes at the pressure of 15 psi. After cooling it is transferred to petridishes. A solid media is formed in the petridishes. Then the solid media and the sample of 6th test test tube is mixed into the specific condition. In the course of 48 hrs. very tiny white or yellowish colonies of yeast are found.
5.6 PETRIDISHES
5.7 AUTOCLAVE
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FREMANTATION
Fermentation is a bio-chemical reaction where the substrate is converted into desired product with the help of micro-organism which may be yeast, Mould or bacteria and the enzyme present in the Micro-organism actually acts in the reaction. REACTION :
Fermentation is a biological process in which a chemical substrate is transformed into a different end product by the action of microbiological cells. During fermentation sugar is converted into alcohol in the presence of yeast. During this process Co2 and heat is generated . Heat is removed by the circulating chilled water in the jackets of the fermenter to maintain the temperature. There are various intermediates steps during the alcoholic fermentation.Side reaction can take place between the intermediates product or a different pathway can be followed by the action of microorganisms other than yeast. Because we have other chemicals besides glucose in our substrate which are added to increase the growth of the culture . Yeast can produce different end products than ethanol for example pectin and hemi cellulose can be fermented to methanol and certain amino acids can be converted to higher alcohol. In order to obtain pure ethanol these by products have to be removed in the subsequent distillation step. During distillation the by products are separated by their difference in volatility.
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FLOW DIAGRAM OF FERMENTATION PROCESS
CV1
CV2
AEROBIC PROCESS
CV3
PF 1
PF2
ANEROBC PROCESS
F1
F2
F3
F4
CV-CULTURE VESSEL ONE, PF- PREFERMENTER, F- FERMENTER 5.8 Flow Chart 30
5.9 Table for Technical Aspect For Fermentation
DURATION OF FERMENTATION
24 hours 0 28-34 C
TEMPERATURE DURING FERMENTATION
% ALCOHOL AFTER COMPLETION
8-9%
SETTING GARVITY OF YEAST VESSELS
1.045
SETTING pH OF YEAST VESSELS
4.5-4.9
Fermentation process is carried out into two steps 1- AEROBIC PROCESS 2- ANAEROBIC PROCESS
AEROBIC PROCESS: The fermentation process which includes fresh is referred as an aerobic fermentation. The presence of air is most important for the growth of yeast and they reproduce and increase the density and thereby the alcohol is produced in a conductive manner. Aerobic fermentation is a type of misnomer and without aerobic condition, fermentation will never occur. Main characteristics of aerobic fermentation are needed for adequate aeration of process. The quantity of air that is needed per hour is almost 60 times the quantity of fermentation medium volume. The adequate supply clean air is more essential for aerobic fermentation of bioreactor and is usually sparged inside the fermentation medium. Aerobic fermentation has a mechanism for complete mixing and stirring of fermentation medium and biological cells.
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ANAEROBIC PROCESS: A (part of a) process that occurs in the absence of free oxygen is termed as the anaerobic process. Composting without oxygen results in fermentation. This causes organic compounds to break down by the action of living anaerobic organisms. This stage comes after the aerobic process. In anaerobic process the conversion of sugar into ethyl alcohol and Co2 takes place. At this stage yeast does not get any oxygen so further propagations of yeast biomass reduces and the max. amount of sugar is converted into alcohol. The flow diagram previously shows the process of fermentation with its different stages. From CV to PF the process is aerobic and after that the process is anaerobic.
5.10 TABLE FOR TIME DURATION FOR EACH PROCESS
CV1
CV2
11-12 Hrs.
CV2
CV3
7-8 Hrs.
CV3
PF
7-8 Hrs.
PF
F
6-7 Hrs.
F
WASH
16-17 Hrs.
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TEMPERATURE CONTROL.
Since there is some heat generated during fermentation, care must be taken to ensure that the temperature does not rise too high and kill the yeast. In fermenters the size of those for on-farm plants, the heat loss through the metal fermenter walls is sufficient to keep the temperature from rising too high when the outside air is cooler than the fermenter. Active cooling must be provided during the periods when the temperature differential cannot remove the heat that is generated. The maximum heat generation and heat loss must be estimated for the particular fermenter to assure that water cooling provisions are adequate.
Figure 5.11 Fermentation Vat Cooling Coil
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SPECIFICATIONS OF THE FERMENTATION TANK
The configuration of the fermentation tank has very little influence on system performance. In general, the proportions of the tank should not be extreme. Commonly, tanks are upright cylinders with the height somewhat greater than the diameter. The bottom may be flat (but sloped for drainage) or conical. The construction materials may be carbon steel (commonplace), stainless steel, copper, wood, fiberglass, reinforced plastic, or concrete coated on the inside with sprayed-on vinyl. Usually, the tanks are covered to permit collection of the C02 evolved during fermentation so that the ethanol which evaporates with it can be recovered.
These tanks come equipped with: · Cooling jacket · Oval manway · Conical bottom · Bottom drain · Racking port · Temperature port · Sample port · Ladder holder · AISI 304 stainless with 316 stainless lid · Lid lifting mechanism (tanks 1500 liters and larger) · Support legs
Figure 5.12 Fermentation Tank
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Fermentation process in CV1 At the initial stage the container which is around 400 ltr. Is cleaned with water and steaming is done in order to make the environment of the container free from error. After the application of this process dry steam is circulated for 1hrs. to make the surface of the container moisture free so that wort(molasses + water) which is added can be free from the moisture and the specific gravity can be maintained. Wort is added into the container with the setup specific gravity of 1.055 and other nutrients are added with it to make the reaction worth full. The additives which are added are uria , Zinc, MgSo4 , H2SO4. The process is carried out at the temperature of 121.5•c and at the pressure of 1kg for 45 minute and then pressure is opened. Then the hot wort is cooled to tem. 31-32 •c.now a culture pitch is added to a setup gravity of around 1.050.We will Find a fall in gravity which we will allow to be of around 0.015 when we find this much fall of the gravity of the liquid then we stops the process for CV1 and the liquid is transferred to the CV2. Fermentation process in CV2 and CV3 The setup gravity and the process which is carried in the previous CV1 process is repeated into CV2 and CV3 only the amount of doping is changed means they depend upon the amount of concentration of the solution which we want. Fermentation process in PF section This is the final stage of the growth of culture because this is the final stage of the aerobic process which means the flow of oxygen for the growth of yeast. In this uria, H2SO4, zing, Rcide and antibody is added the only change from the previous process is that only yeastext is not added which work as the nutrients this process is carried out for around 6-7 hrs. and after that when we find the fall in gravity of 0.015 we transfer the liquid into the fermentation process which is the last process of the fermentation in this process the value of TRS(total reduce suger) Is around 6-7 % which will increase in the final process to around 15-16%. Final Fermentation in section F After the transferring the wort from prefermentation section to fermentation section we put the flow of air for around 2 Hrs. for the final growth of the culture and to settled down the wort. The specific gravity setup gravity is around 1.107-1.108 and the final specific gravity should be around 1.052-1.053 and the amount of TRS should lie between 15-16%.Since the process is anaerobic so after the supply of air at the initial stage we stop the supply and we don?t allow the more air supply because in this stage no further development of culture takes place because they don?t find any media to growth and under this condition they react with wort and produce the ethanol with some amount of Co2 and heat. The total time period for this process is 16-17 Hrs.
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DISTILLATION
Distillation is a separation process for a mixture of liquids or oils. It relies on differences in the boiling points of the component liquids to be separated. The mixture to be separated is added to a Distilling Pot where it is heated to the boiling point. Lower boiling components will preferentially vaporize first. This vapor passes into a Distilling Head and then into a Condensor. Within the Condensor the vapor is cooled and it liquifies. The resulting liquid is then collected in a Receiving Flask. Initially, low boiling components are collected in the Receiving Flask. As the distillation proceeds, these components are depleted from the Distilling Pot and higher boiling components begin to distil over. Switching out the Receiving Flask at the appropriate point allows for the separation of the component liquids of the mixture.
DISTILLATION PRINCIPLES Separation of components from a liquid mixture via distillation depends on the differences in boiling points of the individual components. Also, depending on the concentrations of the components present, the liquid mixture will have different boiling point characteristics. Therefore, distillation processes depends on the vapour pressure characteristics of liquid mixtures. Vapour Pressure and Boiling The vapour pressure of a liquid at a particular temperature is the equilibrium pressure exerted by molecules leaving and entering the liquid surface. Here are some important points regarding vapour pressure: ? ? ? ? ? energy input raises vapour pressure vapour pressure is related to boiling a liquid is said to „boil? when its vapour pressure equals the surrounding pressure the ease with which a liquid boils depends on its volatility liquids with high vapour pressures (volatile liquids) will boil at lower temperatures ? the vapour pressure and hence the boiling point of a liquid mixture depends on the relative amounts of the components in the mixture
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5.13 Line Diagram of Distillation Proces
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FACTORS AFFECTING DISTILLATION COLUMN OPERATION The performance of a distillation column is determined by many factors, for example: ? feed conditions
? ?
state of feed composition of feed
? internal liquid and fluid flow conditions and weather conditions
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DISTILLATION PROCESS
Rectified sprit (Used as industrial alcohol)
Extra neutral alcohol
Indian made foreign liquor
country liquor
Distillation process is carried out to make two types of product 1- Rectified Sprit 2- Extra neutral alcohol Rectified Sprit : A rectified spirit, rectified alcohol, or neutral spirit is highly concentrated ethanol which has been purified by means of repeated distillation, a process that is called rectification. It typically contains 95% alcohol by volume (ABV). Rectified spirits are used in mixed drinks, in the production of liqueurs, for medicinal purposes, and as a household solvent. Extra neutral alcohol : A Extra neutral alcohol is colourless and has a neutral smell and taste.It is generally distilled from sugarcane molasses. It is used as a base for manufacturing Indian made foreign liquor and the country liquor. The ENA plant is based on the principles of multi pressure-cascading techniques and the process control is done by Digital Distributed Control System.
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5.14 Capacities of different plants:
Location Total licensed capacity (per annum)
KASHIPUR
803 lac.BL
GORAKHPUR
1000 lac.BL
SAHARANPUR
1000 lac. BL
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PROCESS OF DISTILLATION
5.15 Flow chart
WASH IN
36-37 •c
CONDENSATION
64.5•c PRE HEAT EXCHANGER
70-74•c PUMP
STEAM (FLOW IS 109611KG/Hrs)
STEAM
CONTAINER T-7
CONDENSATION
C1
CH3OH
C3
CONDENSATION
T9
Waste (spent wash) RECIVER
(Send to develop more condense alcohol)
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Wash in is the final product of the fermentation process which work as the input of the distillation process. The wash is input at the tem. Of 36-37 deg.c to the condenser where its temperature is raised by heating it through the hot air to 64-65 deg.c from where it is transferred to the pre heat exchanger (A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact.) to raise its temperature to 70-74 deg.c and this heated wash is carried to the C1 block. Steam is taken as one more input in this block with the flow rate of 109611KG/Hrs and waste is removed from it in the form of spent wash which work as the fuel for the power plant. The initial feed is done into the feed plate which is in the analyzer column which contain 23 tunnel type plate. As the name suggest analyzer means the separation of more volatile vapors from the less volatile and leaving behind the less volatile on to the bottom of the coloum. The waste is carried out from the bottom of the container because the waste which is carried out are the less volatile and are not helpful in the formation of the high concentrated alcohol. When the steam is provided to the wash and due to having the difference in the volatility the vapour starts forming at the different heat range and the alcohol with high concentration is having more volatility than the other input material which is used so by heating it we can extract the high concentration alcohol easily. The wash is heated to the tem. Range of 63-67 deg.c is then admitted to condenser for more heating because ethanol is more volatile and there are two factors which determine the vapor pressure of ethanol (because what makes ethanol volatile is that it was a high vapor pressure). What makes the vapor pressure of ethanol quite high is that it is a small molecule with a low molecular weight. In fact, if you look at other molecules with similar size and weight, many of them are gases at room temperature. The molecular weight of ethanol (C2H5OH) is approximately 46 grams/mole. Carbon dioxide (CO2) has a molecular weight of 44 grams/mole, but it is a gas. Butane, C4H6 has a molecular weight of 54 g/mol and is a gas. Chlorine (Cl2) is a gas with molecular weight of 71 g/mol! So you might predict that ethanol should be a gas at room temperature from this. However, ethanol is a liquid. The reason it is a liquid is because it can hydrogen bond. The alcohol group, -OH, in the molecule has both a hydrogen bonded to an oxygen atom, which is allows for hydrogen bonding. Hydrogen bonding is a very strong intermolecular force, and this is what makes ethanol a liquid (and water too, which has a molecular weight of only 18 g/mol -- water is not volatile because it has two -OH groups, and so can hydrogen bond much better than ethanol can). So ethanol is volatile because it is a small and light molecule, but it is not as volatile as you might otherwise expect due to hydrogen bonding.
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After the condensation where there is a rise in temperature of the vapors to make the concentration more volatile is send to the container T-7 and from there it is transfer to C3 .
In C3 again steam is provided and some by product is taken off like CH3OH and waste is also removed from the bottom of the container .C3 contain two outlet valve one is to the reciver in which the solution is send after the final chemistry and one is for further processing to make the concentration of ethanol nor condense and the process takes place in such a way that the vapour is again send to the condenser where the temperature is increased and through T-9 it comes to the C-3 and then go to the reciver.
5.16 Specification of Rectified Spirit (Analytical): Sr. 1 2 3 5 6 8 9 Parameters Strength pH Ethanol Content Sp. Gravity @ 15º C Miscibility with water Aldehyde Content Ester Content Unit ----%v/v ----Gms / 100ml Gms / 100ml IS Standard Value 67.0 4.5 – 6 95.26 0.8171 Miscible 0.006 0.02
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CHAPTER-6 FINDINGS AND ANALYSIS FOR PROCESS
CRITERIA OF PRODUCTION AND OPERATION MANAGEMENT SYSTEM PERFORMANCE There are basically three criteria under which any organization perform production and operation management system 1- Effectiveness 2- Customer satisfaction 3- Efficiency Whether the organisation is in the public sector or in the private sector or it?s a manufacturing or service unit, the productive or a optimal utilization of resources is always a desirable objective . Effectiveness has more dimensions to it. It involve more optimality in the fulfillment of multiple objective with the possible resources. This is not difficult to imagine because modern production and operation management have to serve the so called target customer. Effectiveness has to be again viewed in terms of the short and long term horizons because what you seem now like an effective solution may not be all that effective in the future. The effectiveness of operation system may depend not only upon a multiobjective satisfaction but also on its flexibility through which it can show more adaptability towards the future change program . Indian Glycol operation and production management system also works under this guide line of effectiveness, customer satisfaction and efficiency. The market is changing and the company can stand over in market by having a good control over it production because their product they reach to their customers. The system should be flexible because they should be ready towards the change.
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PRODUCTION AND OPERATION SYSTEM There are four type of production and operation system 1234Job shop Batch type Mass production Continuous flow type
Indian Glycol ltd do the continuous flow type production system because there is only two type of product in which they deal (country liquor and Indian made foreign). They produce the large amount of liquor (45 lakhs ltr.) with having a very less variety this also so that they are having a very less flexibility on to their operation system.
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FINDINGS AND ANALYSIS ON WASTE
During the total production cycle that is the conversion of raw material into the final product large verities of waste is generated. Since they incurred a huge amount of company investment and if they could be recovered or if they can work as the alternative recourse for some other process then they are going to increase the company revenue or reduces the investment in the process. So it?s become a important task for the operation people to manage waste and India Glycol Ltd is working effectively over it . Some waste which are utilized by the Indian Glycol Ltd. 1- Waste from the distillation process that is spent wash is having a some amount of alcohol contained into it which is flammable and is being used into the boiler to produce steem.
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CHAPTER-7 CONCLUSION
The production process in the INDIA GLYCOL LTD. though cannot be changed much as it is done through machines and the process is related with each other and if we need any change we have to suffer from heavy losses by stopping the whole process . But the other things such as input material (molasses), machine handling, cost cutting, efficiency, work load etc. can be improvised. Inventory management can be done through JIT method instead of keeping extra molasses container near press on the shop floor. It follows 5S method to improve efficiency and quality of the product. Cutting down costs include recycling of waste, use of waste material if possible, avoiding damages to machine parts. Workload is lowered by the rotation policy like transferring men from operation to another if they are free. This helps to build up good work environment, improves overall efficiency and developing the multitasking for the employes. But the only thing to be done is need of more automation in the semi finished goods ,raw material handling and finished material comes out of machine. This will avoid manual labor and accidents and will help to increase the overall efficiency.
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CHAPTER-8
OBSERVATIONS AND RECOMMENDATIONS
?
Yeast is one of the important raw material into the process of fermentation and it?s required a huge type to grow and develop which is used for generation of alcohol and once the process is completed the yeast is waste and send for draining which incurred a loss to the raw material Suggestion- Yeast should be recovered by the process of recycling.
?
Specific gravity plays a important role in the generation of good alcohol and the process which is used to check the fall in gravity is manual and having a possibility of human error with it which may cause a huge loss to the organisation. Suggestion- If possible the process should be automated.
?
Steam generation is a huge, bulky and expensive process because it required a huge setup for it and the steam which is used into the process of heating the fermentation tank and then they are realized into the environment are just a waste to the organization. Suggestion: This steam should be recovered by the steam recovery plant such as Use of Low-Grade Waste Steam to Power Absorption Chillers and by the Use of Vapor Recompression to Recover Low-Pressure Waste Steam.
?
To control over the use of steam generated by the power plant they can go to the solar distillation system in which heating of the process can be done by the solar system.
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CHAPTER-9 LIMITATIONS
The major constraints that limit the project are as follows: ? Photography was strictly prohibited inside the plant area, so pictorial representation of press and line is not possible. ? The managerial staff was very strict in disclosing the data about the demand as well as the customers. ? The data collected is approximate and not accurate.
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BIBLIOGRAPHY
? Principles of Fermentation Technology, Second Edition by P F STANBURY and S. Hall ? Fermentation Microbiology And Biotechnology by Mansi El-Mansi, Charles F. A. Bryce ? THERMAL ENGINEERING BY R.S. KHURMI ? www.indiaglycols.com ? http://www.wikipedia.org/
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doc_641800458.docx
Managing waste and process study
MANAGING WASTE AND UNDERSTANDING THE PROCESS OF ETHANOL MAKING IN INDIA GLYCOL LTD.
Summer Internship Project Report Submitted towards Partial fulfillment of Post Graduate Diploma in Management (Approved by AICTE, Govt. of India) Academic Session 2011-2013
Under the Guidance of: Industry Guide Mr. Praveen Srivastava SR. Manager (Production) Mr. Anoop kumar Srivastava DY. Manager (Production and Microbiology) INDIA GLYCOL LTD. Faculty Guide Dr. Shailendra Dube Professor Operations management IMS, Ghaziabad Submitted By: Shivam Dubey Roll No: BM-011203
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PREFACE
The project entitled as “MANAGING WASTE AND UNDERSTANDING THE PROCESS OF ETHANOL MAKING IN INDIA GLYCOL LTD.” is basically a study about the production process of ethanol making ,fermentation and waste management in INDIA GLYCOL LTD. Gorakhpur U.P. The major aspects of the process are been covered and a study on the loopholes in the process is done to detect the process and provide the alternative route for the use of waste , in continuation to that the solution to those problems are also been provided. The major problem faced during the on goings of the project is related to data unavailability and the technical unawareness about the machines employed in the production process apart from these drawbacks there was a constraint of lack of support from the employees and the workers who were consulted for the technical specifications. In a manufacturing company, production process is very important as it affects the efficiency through which the company can manufacture with minimum defects and wastes. Thus it is necessary to understand each parts and steps in the process of a manufacturing machine for an employee, so that he can handle the machine properly and bring about possible innovative changes which can bring down the cost. Understanding about the production process helps to cut down cost to provide the customer product at minimum price. It is necessary for maintaining the quality of the products. A good process maintains the standard necessary to be in competition. Thus it is the most important part to be understood in a company.
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ACKNOWLEDGEMENTS
I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to Mr. Praveen Srivastava and Mr. Anoop Srivastava for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards my parents & member of INDIA GLYCOL LTD. for their kind co-operation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to Mr.Sanjeev khanna (Head HRD) and to industry persons for giving me such a motivation ,attention and time for the full fill ment of my project. My thanks and appreciations also go to my colleague in developing the project and people who have willingly helped me out with their abilities.
Shivam Dubey IMS Ghaziabad
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TABLE OF CONTENTS
Chapter 1 Chapter 2
Executive summary Alcohol industries in INDIA Introduction about company
Page 1 Page 2 Page 3-13 Page 14 Page 15
Chapter 3 Chapter 4 Chapter 5
Objectives of Project Research Methodology Production Process Raw Material and Their Attributes Steps Of Alcohol Cycle Formation of culture Fermentation process Distillation
Page 16-21
Page 22 Page 23 Page 24-30 Page 30-38 Page 39-41 Page 42 Page 43
Chapter 6 Chapter 7 Chapter 8
Finding and analysis Conclusion Observation & recommendations Limitations Bibliography
Chapter 9 Chapter 10
Page 44 Page 45
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LIST OF TABLES/FIGURES/IMAGE/FLOW CHART
Molasses Figure 5.1 Figure 5.2 Yeast
Figure 5.3 Figure 5.4 Figure 5.5 Figure 5.6 Figure 5.7 Figure 5.8 Table 5.9 Table 5.10 Figure 5.11 Figure 5.12 Figure 5.13 Table 5.14 Figure 5.15 Table 5.16
Yeast Life Cycle pH Scale With pH Value Flow Diagram of Alcohol Cycle PETRIDISHES AUTOCLAVE Flow Chart of fermentation Technical Aspect For Fermentation Time Duration For Fermentation Process Fermentation Vat Cooling Coil Fermentation Tank Line Diagram Of Distillation Capacity of plants Flow chart of distillation Specification of Rectified Spirit
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CHAPTER-1
EXECUTIVE SYNOPSIS
The project Entitled as “Waste related to the process and to having the knowledge of the ethanol making” at INDIA GLYCOL LTD.” comprises of the production process and the waste from it at different products manufactured in the unit of INDIA GLYCOL LTD. The project shows the full process of country liquor and India made foreign liquor with molasses . The process goes as through certain stages which include the development of culture (yeast), Its multiplication in the prefermenter,the fermentation process and the distillation process with the other auxiliary additives. Then these raw martial are used along the series of continuous process in line to
extrude the desired shape as per the specification of the product. INDIA GLYCOL LTD. industries manufactures alcohol in different forms for different other industries and depending upon the market requirement which use these products to manufacture other products. The report also detects the flaws in the process as obsolete technology used to produce power and steam through boiler , as well as flaws related to the production lines a very deep analysis is done and the solution for the problems is also provided at the end of the report.
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CHAPTER-2
Alcohol Industry In India
Indian Spirits Sector - Overview Indian Liquor Industry with estimated market value of INR 340 bn is growing at 12-15% over the last two years. The industry is estimated to have sold 115 mn cases of IMFL last year. The sector is expected to maintain its CAGR of ~15% while the premium segment Wine and Vodkas expected to grow at a higher rate. With consolidation and foreign acquisitions gaining steam the sector is about to witness next phase with realization rising in line with that of their foreigncounterparts.There are 325 distilleries in India, with an installed capacity of about 3.58 billion liters of liquor. However, production rate is about 40% of total licensed capacity as total requirement of liquor stands at 1.3 billion liters. Major National Players: United spirits with about 60 % of market share in IMFL is the undisputed leader. Radica Khaitanwho entered the IMFL space some 8 years back has already cornered 12 % market share and gaining. Other players include Mohan Meakin (9%), Jagatjit (8.5%), etc. International players: The major international players are Pernod Richard, Remy Cointreau, and Diageo (Diageo hastied up with Radico for entering Indian markets in brown spirits)Investment RationaleInherent Potential, Deregulation, western cultural influence and high entry barriers has helpedthe industry in notching up higher sales growth. Alcohol sale is driven by the high GDP growthand more people entering the drinking club with newly obtained prosperity or from up tradingfrom the existing brand. Inherent Potential: Since liberalization, the economy has been growing at steady pace with per capita income rising from INR 23,222 in 2005 to INR 6,012 in 1991.Shift from country liquor to IMFL is expected with rising per capita income and limiting the saleof country liquor by states due to hygiene factor.Industry has one of the lowest per capita consumption of both Liquor and Beer and also since the
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INTRODUCTION ABOUT INDIA GLYCOL LTD
COMPANY PROFILE
India Glycols is a leading company that manufactures green technology based bulk, specialty and performance chemicals and natural gums, spirits, industrial gases, sugar and nutraceuticals. The company was established as a single mono-ethylene glycol plant in 1983. Since then, IGL has brought together cutting-edge technology, innovation and an unflagging commitment to quality, to manufacture a wide range of products that have found global demand. IGL?s state-ofthe-art, integrated facilities manufacture chemicals including glycols, ethoxylates, glycol ethers and acetates, and various performance chemicals. Its product range spans the chemicals, spirits, herbal and other phytochemical extracts and guar gum, industrial gases and realty sectors, and finds application across an increasing number of industries. These products are manufactured in compliance with stringent global standards of plant operations, quality and safety. The company?s facilities have been approved and certified by international agencies including Det Norske Veritas (DNV). The operations at all plants are closely monitored through distributed control systems (DCS), which facilitate a high degree of control over the quality of products.
The company has installed distillery effluent evaporators at Gorakhpur and the concentrated effluent is burnt in specially designed boilers; the calorific value of the concentrated, effluent generates super-heated steam which is. utilised in the turbo generator with capacity of 12.5 MW for power generation. In FY 2007-08 the company acquired controlling stake in the Shakumbari Sugar & Allied Industries (SSAIL) that is engaged in business of manufacturing sugar. SSAIL?s manufacturing plant is located in Uttar Pradesh with a crushing capacity of 3200 tones per day (TCD) along with a modern distillery of 40 kl per day (KLPD), producing high quality rectified spirit, ethanol
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and country liquor and an internal bagasse-fired co-generation plant of 3 MW catering to the captive power needs of the sugar and distillery units.
COMPANY HISTORY
1983- India Glycols Ltd was incorporated at New Delhi on 19thNovembe as a public limited company as u.p.glycols limited obtained the Certificate of Commencement of Business on 3rd February 1984.Thecompanywaspromoted by Vam Organic Chemicals Ltd. The company manufactures m ono-ethyleneglycol (MEG) , diethylene glycol (DEG) and triethylene glycol (TEG). - The company entered into a technical know-how agreement with `ScientificDesign Company Inc., USA (SD) for the supply of process know-how only for the conversion of ethanol into MEG as the promoter VAM agreed to advise freeof cost on the conversion process of molasses into ethanol.- The company also entered into an agreement with Toyo Engineering India Ltd.,for implementing the project within guaranteed cost and time limit. 1986- The name of the Company was changed to `India Glycols Limited „Effective from 4th September. 1988- 70 shares subscribed for by the signatories to the Memorandum of 1995- The company had tied up with Sanyo Chemical Industrial SurfactantsCovering major industries like textiles, toiletries, pharmaceuticals,agrochemicals, paper, lubricants etc.- The Company also proposed to set up facilities for chlorosulphation to produce other specialty chemicals to maintain better quality standards. 2003 -The Board of Directors at their meeting held on December 4, 2003 have approved the merger of wholly owned subsidiary company CDS InternationalLtd with the company. The Board of Directors at their meeting held on December 4, 2003 has approvedthe merger of wholly owned subsidiary company CDS International Ltd with thecompany. On Novembers a public limited company as `U.P. Glycols Limited „and obtained the Certificate of Commencement of Business on 3rd February,1984. The company was promoted by Vam Organi Chemicals Ltd.
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IGL BUSINESSES
IGL?s flagship chemicals division started out with a path-breaking green approach to manufacturing ethylene oxide and derivatives. Using the molasses-ethyl alcohol-ethylene 'green route', the company is the only one of its kind in the world. With the emphasis now increasingly shifting to green manufacturing, the chemical division is well poised to meet the industry?s need for environmentally responsible products and production techniques. Keeping in mind the critical dependence on agricultural feedstock, the company has taken up several initiatives including backward integration into sugar manufacturing to ensure seamless raw material availability. Other complementary initiatives include co-opting the cane growing community to ensure cane availability while providing adequate returns to the farmer. Apart from chemicals, India Glycols has a significant presence in the natural active pharmaceuticals and nutraceuticals space with Ennature Biopharma; a well-established natural gum division manufacturing guar gum and a variety of derivatives; a spirits division that manufactures country and Indian-made foreign liquor adhering to the highest quality standards; and Shakumbari Sugar – a well-established player in the Indian sugar industry. The company is the Leading manufacturers of Glycols, Ethoxylates, Performance Chemicals, Glycol Ethers & Acetates, Guar Gum and Potable Alcohol. The company has more than 1,000 customers in various such as Textile, Agrochemical, Oil & Gas, Personal Care, Pharmaceuticals, Brake Fluids, Detergent, Emulsion Polymerisation & paints etc. India Glycols (IGL) was promoted by Vam Organics to manufacture 20,000 tpa of monoethylene glycol (MEG) at Kashipur, UP.
Future Plans
India Glycols will focus on various areas in future such as developing cost-effective emulsifier for crop protection chemicals; development of eco-friendly surfactants to replace alkylphenol ethoxylates; development of green demulsifier for crude oil emulsion and setting up an application development laboratory equipped with all sophisticated instruments for various industries.
Exports
IGL has traditionally looked to leverage the export potential of its products. The company has therefore initiated the process of aligning to emerging global trends and has established facilities and operations that are in compliance with global good manufacturing practices.
Customer Focus
The company strives to achieve excellence through proactively addressing customer needs and requirements. Integral to this approach is the identification and development of customised products backed by research and development support.
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MAJOR PRODUCTS UNDER INDIA GLYCOL LTD.
Agrochemicals
India Glycols works closely with clients in the agrochemical industry in order to understand their requirements, and create products that meet their specific needs. The company offers a wide range of chemicals that find use in three product categories – insecticides, fungicides and herbicides.
Pharmaceuticals
IGL?s products find application primarily in the manufacture of ointments, tablets and syrups. The company has taken every measure to ensure that its manufacturing facilities adhere to strict quality and hygiene standards, and its products meet Indian and global purity standards.
Healthcare and food processing
Guar gum is used extensively in the healthcare and food products industry, and manufacturers are required to adhere to strict quality and purity standards. IGL has invested in the latest technology to ensure that its guar gum products are manufactured with minimal human intervention, thus ensuring a hygienically produced, high purity product. The company?s gum products have been approved under the US Federal Register as „Generally Recommended as Safe? category for food, feed and pharmaceutical applications.
Automotive
India Glycols manufactures two products for the automotive industry – brake fluid and antifreeze coolant. The company is one of India?s leading manufacturers of brake fluid, which it supplies to all the major Indian oil companies.
Textiles
India Glycols Limited caters for the range of chemicals required for both dry and wet processing of fibres and fabrics. Being the largest manufacturer of ethoxylates, IGL?s strength has been in providing customised products for batch as well as continuous processes. Besides, we are committed to the concept of “grey to green” transformation by providing green chemical alternatives as textile auxillaries. IGL?s focus is always to provide environment-friendly products meeting the international safety norms of GOTS, REACH, IKEA, OEKO-TEX, etc.
Paints and emulsion polymerisation
India Glycols offers a comprehensive range of products for the paints and emulsion polymerisation industry. The company?s strength lies in its ethylene oxide-based (EO) 11
emulsifiers and anti-settling agents. IGL?s captive feedstock of EO ensures that customers get the benefit of consistent quality and reliable supply.
Innovation
Innovation has always played a pivotal role in IGL's success story of multifold business growth and ever-growing customer base. The innovation team at IGL, a dedicated group of researchers, is continuously engaged in adding new, value-added products to our product range. At IGL, we take utmost care to ensure that our products are environment-friendly and comply to all national and international safety norms. The R&D division, since its inception in 1994, is dedicated to developing as well as acquiring new, advanced technologies for the quick growth and sustenance of business. The results have been the outcome of many successful collaborations with international experts from academia and various industries. India Glycols has a focused R&D section within its distillery to introduce unique, improvised processes and techniques to achieve high fermentation efficiencies. With the help of pilot fomenters, our team constantly conducts research on fermentation processes with different raw materials and simulates the same on plant scale so as to improve yields. The research team is also working on the 'smart distillery concept' capable of producing alcohol from different raw materials, ie, molasses, grains and sugarcane.
Innovation strategy
The Innovation Strategy of IGL, structured in line with the vision and mission statement of the organization, is to drive business through market-led innovations in product, process and application technologies, thereby establishing ourselves as a “solution provider”. The salient features of the strategy are: 1-The R&D function focuses on developments, scaling-up of processes, quality and cost reduction 2-Major projects are customer-driven, using product / application expertise 3-Innovation integrates the customer interface with all other functions 4-Value creation through differentiated product attributes and cost optimisation 5- Networking with external institutions to help in knowledge updation and capability building. The R&D function focuses on profitable growth and value creation for IGL's stakeholders.
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SWOT ANALYSIS
Strength
IGL is uniquely positioned as a petrochemical manufacturer through the organic route, and is probably the largest player in the world in its segment. Though the gross block of the company is Rs9.7bn, its replacement cost is estimated to be ~Rs32bn. This along with technological knowhow, would act as a strong barrier for entry, thereby offering competitive safety for the company.The Gorakhpur unit is fully integrated one, thereby ensuring operationalsmoothness. Higher realizations with stability in outlook and prices. Improving product range (180 at present) would also enhance realisations and consequently better margins. IGL has the ability to switch its feedstocks, between molasses, ethanoland sugarcane. Thus, it can procure molasses and other raw material at the start of a season(Oct-Nov) and rationalize its raw material costs. Its storage facility also enablesit to manage inventories on a higher scale.
Weakness
IGL?s margins could face pressure if MEG prices continue to fall vis-a-vis hikes in prices of molasses and ethanol. While IGL is integrating backwards to reduce the price volatility in its raw materials, the same cannot be eliminatedand hence would continue to dog the operations of the company. Newer capacity expansion being undertaken in the M. East (Saudi Arabia & Iran) hasthe potential to lower the landed cost of imported MEG in India and to impactrealisations. Currently, POY/PSF industry accounts for ~70% of MEGconsumption in India and ~35% of IGL?s revenues. This imparts high sensitivityto an industry and any slowdown in that sector has the potential to impact IGL?searnings.
Opportunities
IGL has flexibility in using ethanol or molasses as its feedstock for MEG/EO manufacturing, which can help optimise its raw material cost. By setting up co-generation plants, IGL will be able to lower its power costs (12%of net sales in FY08) to 8% of net sales in FY10. Expansions in the polyester industry (Indo Rama, JBF, Reliance and Garden Mills) will ensure offtake of IGL?s incremental capacity. IGL is diversifying its revenue stream through venturing into Nutraceuticals, CO2 and Real Estate, which are expected toaccount for ~10% of revenues by FY10.
Threats
MEG capacity expansion in M. East may dampen IGL?s offtake.Additional capacitiesmay impac t global prices which will impose margin pressure. Also, any changes in custom duties on MEG (7.5%) and swing in Rs/USD rates have the potential to dampen realisations and 13
margins. Currentlythe Reliance group, which is the largest domestic manufacturer of MEG,consu mes majority of its production in-house. Any sharp scale up in its merchant sales can upset the business prospects of IGL. After Shakumbari expansion,there would be another factor influencing the costing structure of IGL namely sugarcane. We have drawn our estimates on cane prices of Rs 125/qntl. Thus,any unfavourable change in the pricing or availability of cane can substantially impair the earnings of the company . IGL is undertaking capex of Rs4.9bn over the next 2 years. There is also a shutdown of 25-35 days envisaged at its MEGfacility. Any derailment or delay of the same could impact its earningssubstantially. Export s constitute ~14% of its revenues and any adversemovement in exchange rate can depress margins
Path to excellence:Integrity – honesty in every action Commitment – On the foundation of integrity, doing whatever it takes to deliver, as promised. Passion – Missionary zeal arising out of an emotional engagement with work. Seamlessness – Thinking and working together across functional silos, hierarchy levels, businesses and geographies. Speed - Responding to stakeholders with a sense of urgency and remaining one step ahead.
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Awards
1991 ? ? Award National Safety Award for meritorious performance in industrial safety, in achieving longest accident-free period National Safety Award for outstanding performance in industrial safety as runner up in achieving lowest average frequency rate from Organisation Ministry of Labour, Government of India.
1992 ? Award Award of Merit for operating 27,55,364 employee hours without occupational injury or illness from Organisation National Safety Council, USA
1997 ? 1998 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK Award for Best Project / Entrepreneur in the biomethanation sector.
1999 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK
2000 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK
2001 ? Award Safety Award in recognition and commendation of services rendered to the cause of safety from Organisation British Safety Council, UK
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2002 ? ? Award Safety Award in recognition and commendation of services rendered to the cause of safety National Safety Award for outstanding performance in industrial safety, in achieving longest accident-free period.
Perfect Record Award for operating 7,208,784 employee hours without occupational injury or illness award from Organisations British Safety Council, UK,Ministry of Labour, Government of India , National Safety Council, USA 2004 ? Award Best Performing Power Plant from International Safety Award in recognition of proven track record of maintaining excellent safety standards. British Safety Council, UK
2005 ? Award International Safety Award in recognition and commendation of services rendered to the cause of safety. From Organisation British Safety Council, UK
2008 ? ? Award Best Quality ENA Award in recognition of quality ENA production. Best Enhanced Performance for enhanced performance in exports.
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CERTIFICATION FOR INDIA GLYCOL LTD.
IGL is having a different certification of ISO for its Liquid carbon dioxide application in Kashipur and Gorakhpur units and for its Natural Gums Division (NGD). India Glycols has two beverage-grade liquid CO2 plants of 80MTPD capacity each, at Kashipur and Gorakhpur units. The salient features of the liquid CO2 plants are as follows: The state-of-the-art liquid CO2 plants and technology has been obtained from Wittemann Inc, USA, on a turnkey basis. The company?s plants process CO2 without using any chemicals for purification. The raw CO2 is purified using washing, scrubbing and absorption methods, and a specially designed NOx removal system. The purity level of liquid CO2 is 99.99+ per cent (beverage grade), and the plants have stringent dual testing procedures: one uses gas chromatographs and the other employs the latest online analyser obtained from PAC Inc, USA. A complete online analysis of the product is done for impurities like total hydrocarbons, total aromatic hydrocarbons, total sulphur, oxygen, nitrogen and moisture. The liquid CO2 plants are approved for ISO 9001-2000 and ISO 22000/HACCP certification. Both plants have a liquid CO2 storage capacity of 220MT each. India Glycols Limited owns a large fleet of mobile tankers of various capacities for liquid CO2 to ensure timely deliveries as per our customers' requirements. The company has a huge storage capacity of basic raw material, i.e., molasses for use in its distillery, thus ensuring round-theclock availability of liquid CO2. Applications of liquid carbon dioxide ? ? ? ? ? ? ? Carbonation of beer and soft drinks for superior quality and a fresh, tingling taste. Grinding of spices to preserve the aroma and for increased production rates. Packaging of foodstuffs in a controlled atmosphere for superior quality and fresh taste. Quick-freezing in tunnels and cabinets for fresh taste; reduction in loss of weight; and increased production rate. Preservation of meat during the mincing process. Transportation of chilled food with fairly low investment. As dry ice for the pharmaceuticals and food industry.
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In the Manufacturing industry ? ? ? CO2 welding (MIG / MAG) to provide an inert atmosphere. Hardening of cores and moulds in foundries for reduced production time and better surface properties and accuracy. Use in fire extinguishers - a critical safety feature in any manufacturing unit.
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CHAPTER-3 OBJECTIVE OF PROJECT
The objective of this project is to study about the manufacturing process of alcohol in INDIAN GLYCOL LTD:? ? ? ? To study the overall manufacturing process of alcohol To know about the production process of the fermentation and distillation unit. To work over the waste management. To recommend feasible solutions to the problems.
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CHAPTER-4 RESEARCH METHODOLOGY
a) Research design : The research is based on exploration of production process as well as description of production process, so the type of research designs used are: ? Exploratory Research. ? Descriptive Research. b) Data collection: Data is collected about the various specification about the different process line from both primary sources as well as secondary sources ? Primary sources: through direct interaction from supervisors, operators working on the production line and knowing the process more deeply . ? Secondary sources: data collected from Industry guide as well as different websites, books etc.
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CHAPTER-5 PRODUCTION PROCESS
RAW MATERIAL USED IN ALCOHAL PRODUCTION
MOLASSES Molasses is the residue from the manufacturing of sugar . These materials if available are excellent sources of alcohol. They contain 50-55%of sugar and a ton should yield between 70-80 gallons of alcohol. Most molasses is naturally alkaline and acid is needed to add to obtain the proper pH value. Molasses? is applied to the final effluent obtained in the preparation of sugar by repeated crystallization. The amount of molasses obtained and its quality (composition) provide information about the nature of the beets (local conditions of growth and effects of the weather) and the processing in the sugar factory, such as the efficiency of the juice clarification, the method of crystallization during boiling, and the separation of the sugar crystals from the lowgrade massecuite. In white sugar factories the yield of molasses is in the neighbourhood of 4% on beets, corresponding to up to 25% on sugar. With an average sugar content in the beets of 1618% only 13 to 14% of the sugar will be recovered as a commercial product. As an average, 2.22.6% sugar on beets will go into the molasses when raw sugar is produced. The yield of molasses is affected by various factors and differs from batch to batch. The daily storage loss in Western Europe is estimated at 0.062% sugar on stored beets or 0.1% sugar decrease in the white sugar yield. Molasses is a by-product of sugar production that is brown or black in color. In sugar production, the juice is removed from the sugar cane and then boiled. This is then spun to remove the sugar crystals from the mixture, and the remaining product is molasses. Although molasses is a popular ingredient in baking its unique properties means that it also has many other non-culinary uses. The objective of the sugar industry is to produce molasses whose purity is as low as possible. Commercial molasses ordinarily has 48 % sugar is present. CLASSIFICATION OF MOLASSES 1- First Grade Molasses- It contains more than 50% TRS. 2- Second Grade Molasses- It contains 40%-50% TRS. 3- Third Grade Molasses- It conations 40% TRS.
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Uses of Molasses
?
Molasses is commonly used with yeast and water in the fermentation process of making rum. It is also used in creating some other alcoholic drinks such as stout and dark ales. Some tobacco companies add it to their product for smoking through a certain type of pipe popular in the Middle Eastern countries. Some anglers use molasses as a groundbait (also called chum or berley). This is designed to attract fish to the area that an angler is fishing. In some parts of the world it is used to produce ethanol (ethyl alcohol) for use as an alternative fuel source. It can also be mixed with water and used to remove rust. It is used in some horticultural settings to promote microbe activity in the soil. Molasses is also added to some cattle feed to add essentials vitamins and minerals.
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? ? ?
USE OF MOLASSES IN LIQUOR INDUSTRIES When molasses is to be fermented to alcohol, the sugar content should be high. Raffinose, which amounts to 0.5 to 2% in beet molasses, is broken down into fructose and melibiose by yeasts which contain the enzyme saccharine. Melibiose in turn is broken down by some yeasts (e.g. bottom yeasts) into glucose and galactose. Raffinose is broken down completely by the bottom yeasts; top yeasts ferment only one-third of the raffinose. The alcohol and yeast industry, using beet and cane molasses, is concerned with the suitability for alcohol fermentation or for the production of yeast. There are two type of molasses which are used in alcohol making are free and levy molasses. Free molasses is used for the production of rectified sprit and levy form is used for the making of country liquor.
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5.1 MOLASSES
YEAST Yeasts are single-celled fungi. As fungi, they are related to the other fungi that people are more familiar with. These include edible mushrooms available at the supermarket, common baker?s yeast used to leaven bread, molds that ripen blue cheese and the molds that produce antibiotics for medical and veterinary use. Many consider edible yeast and fungi to be as natural as fruits and vegetables.
5.2 YEAST The typical yeast cell is approximately equal in size to a human red blood cell and is spherical to ellipsoidal in shape. Because of its small size, it takes about 30 billion yeast cells to make up to one gram of compressed baker?s yeast. Yeast reproduce vegetatively by budding, a process during which a new bud grows from the side of the existing cell wall. This bud eventually breaks away from the mother cell to form a separate daughter cell. Each yeast cell, on average, undergoes this budding process 12 to 15 times before it is no longer capable of reproducing. During commercial production, yeast is grown under carefully controlled conditions on a sugar
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containing media typically composed of beet and cane molasses. Under ideal growth conditions a yeast cell reproduces every two to three hours. Yeast is the essential ingredient in many bakery products. It is responsible for leavening the dough and imparting a delicious yeast fermentation flavor to the product. It is used in rather small amounts in most bakery products, but having good yeast and using the yeast properly often makes the difference between success and something less than success in a bakery operation.
5.3 Yeast Life Cycle The yeast cell's life cycle: 1. Budding 2. Conjugation 3. Spore Nutrition and growth Yeasts are chemoorganotrophs, as they use organic compounds as a source of energy and do not require sunlight to grow. Carbon is obtained mostly from hexose sugars, such as glucose andfructose, or disaccharides such as sucrose and maltose. Some species can metabolize pentose sugars like ribose, alcohols, and organic acids. Yeast species either require oxygen for aerobic cellular respiration (obligate aerobes) or are anaerobic, but also have aerobic methods of energy production (facultative anaerobes). Unlike bacteria, there are no known yeast species that grow only anaerobically (obligate anaerobes). Yeasts grow best in a neutral or slightly acidic pH environment. Yeasts vary in what temperature range they grow best. For example, Leucosporidium frigidum grows at -2 to 20 °C (28 to 68 °F), Saccharomyces telluris at 5 to 35 °C (41 to 95 °F), and Candida slooffi at 28 to 45 °C (82 to 113 °F). The cells can survive freezing under certain conditions, with viability decreasing over time.
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In general, yeasts are grown in the laboratory on solid growth media or in liquid broths. Common media used for the cultivation of yeasts include potato dextrose agar (PDA) or potato dextrose broth, Wallerstein Laboratories nutrient (WLN) agar, yeast peptone dextrose agar (YPD), and yeast mould agar or broth (YM). Home brewers who cultivate yeast frequently use dried malt extract(DME) and agar as a solid growth medium. The antibiotic cycloheximide is sometimes added to yeast growth media to inhibit the growth of Saccharomyces yeasts and select for wild/indigenous yeast species. This will change the yeast process. The appearance of a white, thready yeast, commonly known as kahm yeast, is often a byproduct of the lactofermentation (or pickling) of certain vegetables, usually the result of exposure to air. Although harmless, it can give pickled vegetables a bad flavor and must be removed regularly during fermentation.
Uses
Alcoholic beverages Alcoholic beverages are defined as beverages that contain ethanol (C2H5OH). This ethanol is almost always produced by fermentation – the metabolism of carbohydrates by certain species of yeast under anaerobic or low-oxygen conditions. Beverages such as mead, wine, beer, or distilled spirits all use yeast at some stage of their production. A distilled beverage is a beverage containing ethanol that has been purified by distillation. Carbohydrate-containing plant material is fermented by yeast, producing a dilute solution of ethanol in the process. Spirits such as whiskeyand rum are prepared by distilling these dilute solutions of ethanol. Components other than ethanol are collected in the condensate, including water, esters, and other alcohols, which (in addition to that provided by the oak it is aged in) account for the flavour of the beverage.
Industrial ethanol production
The ability of yeast to convert sugar into ethanol has been harnessed by the biotechnology industry to produce ethanol fuel. The process starts by milling a feedstock, such as sugar cane, field corn, or other cereal grains, and then adding dilute sulfuric acid, or fungal alpha amylase enzymes, to break down the starches into complex sugars. A glucoamylase is then added to break the complex sugars down into simple sugars. After this, yeasts are added to convert the simple sugars to ethanol, which is then distilled off to obtain ethanol up to 96% in concentration. Saccharomyces yeasts have been genetically engineered to ferment xylose, one of the major fermentable sugars present in cellulosic biomasses, such as agriculture residues, paper wastes, and wood chips. Such a development means ethanol can be efficiently produced from more inexpensive feedstocks, making cellulosic ethanol fuel a more competitively priced alternative to gasoline fuels.
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SULPHURIC ACID H2SO4 Sulphuric acid (alternative spelling sulphuric acid) is a highly corrosive strong mineral acid with the molecular formula H2so4. It is a colorless to slightly yellow viscous liquid which is soluble in water at all concentrations. Sometimes, it may be dark brown as dyed during industrial production process in order to alert people's awareness to its hazards. Sulphuric acid is used in the process because the maintain the pH value because the pH value of alcohol is 4 - 3 and the molasses which is added is of basic nature that is alkaline so we add the sulphuric acid to make it acidic .
5.4 pH Scale with range
UREA (NH2CONH2): Urea works as the catalyst for the good fermentation by providing the need of required nitrogen. Which is help full in the growth of the yeast. ANTIBIOTIC: These are used to prevent the growth of other bacteria?s during the process.
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ALCOHOL PRODUCTION PROCESS:
The four steps in the Alcohol Cycle-
Formation of culture
Pre fermentation
Fermentation
Distillation 5.5 Flow diagram
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FORMATION OF CULTURE
Yeast is called as a culture in the industries. The initial stage of formation of culture is done into the lab. In laboratory pure culture is raised from single yeast cell. Pour plate method is used for propagation of yeast. In this method six test tube containing 9 ml. of sterilized distilled water is taken. Then 1 ml. of yeast culture is added in the first test tube. This 1ml. of yeast is mixed well into the first test tube then it is transferred into the 2nd test tube for more dilution. This process of transferring is done till 6th test tube or when there is a sufficient dilution of the culture is done. The 250ml. of flask is taken in which we mix. Glucose (10 gm), yeast extracted (3 gm), peptone (3 gm) and maintain the pH around 4.5-4.8. The formed mixture is put into the autoclave for around 15-20 minutes at the pressure of 15 psi. After cooling it is transferred to petridishes. A solid media is formed in the petridishes. Then the solid media and the sample of 6th test test tube is mixed into the specific condition. In the course of 48 hrs. very tiny white or yellowish colonies of yeast are found.
5.6 PETRIDISHES
5.7 AUTOCLAVE
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FREMANTATION
Fermentation is a bio-chemical reaction where the substrate is converted into desired product with the help of micro-organism which may be yeast, Mould or bacteria and the enzyme present in the Micro-organism actually acts in the reaction. REACTION :
Fermentation is a biological process in which a chemical substrate is transformed into a different end product by the action of microbiological cells. During fermentation sugar is converted into alcohol in the presence of yeast. During this process Co2 and heat is generated . Heat is removed by the circulating chilled water in the jackets of the fermenter to maintain the temperature. There are various intermediates steps during the alcoholic fermentation.Side reaction can take place between the intermediates product or a different pathway can be followed by the action of microorganisms other than yeast. Because we have other chemicals besides glucose in our substrate which are added to increase the growth of the culture . Yeast can produce different end products than ethanol for example pectin and hemi cellulose can be fermented to methanol and certain amino acids can be converted to higher alcohol. In order to obtain pure ethanol these by products have to be removed in the subsequent distillation step. During distillation the by products are separated by their difference in volatility.
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FLOW DIAGRAM OF FERMENTATION PROCESS
CV1
CV2
AEROBIC PROCESS
CV3
PF 1
PF2
ANEROBC PROCESS
F1
F2
F3
F4
CV-CULTURE VESSEL ONE, PF- PREFERMENTER, F- FERMENTER 5.8 Flow Chart 30
5.9 Table for Technical Aspect For Fermentation
DURATION OF FERMENTATION
24 hours 0 28-34 C
TEMPERATURE DURING FERMENTATION
% ALCOHOL AFTER COMPLETION
8-9%
SETTING GARVITY OF YEAST VESSELS
1.045
SETTING pH OF YEAST VESSELS
4.5-4.9
Fermentation process is carried out into two steps 1- AEROBIC PROCESS 2- ANAEROBIC PROCESS
AEROBIC PROCESS: The fermentation process which includes fresh is referred as an aerobic fermentation. The presence of air is most important for the growth of yeast and they reproduce and increase the density and thereby the alcohol is produced in a conductive manner. Aerobic fermentation is a type of misnomer and without aerobic condition, fermentation will never occur. Main characteristics of aerobic fermentation are needed for adequate aeration of process. The quantity of air that is needed per hour is almost 60 times the quantity of fermentation medium volume. The adequate supply clean air is more essential for aerobic fermentation of bioreactor and is usually sparged inside the fermentation medium. Aerobic fermentation has a mechanism for complete mixing and stirring of fermentation medium and biological cells.
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ANAEROBIC PROCESS: A (part of a) process that occurs in the absence of free oxygen is termed as the anaerobic process. Composting without oxygen results in fermentation. This causes organic compounds to break down by the action of living anaerobic organisms. This stage comes after the aerobic process. In anaerobic process the conversion of sugar into ethyl alcohol and Co2 takes place. At this stage yeast does not get any oxygen so further propagations of yeast biomass reduces and the max. amount of sugar is converted into alcohol. The flow diagram previously shows the process of fermentation with its different stages. From CV to PF the process is aerobic and after that the process is anaerobic.
5.10 TABLE FOR TIME DURATION FOR EACH PROCESS
CV1
CV2
11-12 Hrs.
CV2
CV3
7-8 Hrs.
CV3
PF
7-8 Hrs.
PF
F
6-7 Hrs.
F
WASH
16-17 Hrs.
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TEMPERATURE CONTROL.
Since there is some heat generated during fermentation, care must be taken to ensure that the temperature does not rise too high and kill the yeast. In fermenters the size of those for on-farm plants, the heat loss through the metal fermenter walls is sufficient to keep the temperature from rising too high when the outside air is cooler than the fermenter. Active cooling must be provided during the periods when the temperature differential cannot remove the heat that is generated. The maximum heat generation and heat loss must be estimated for the particular fermenter to assure that water cooling provisions are adequate.
Figure 5.11 Fermentation Vat Cooling Coil
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SPECIFICATIONS OF THE FERMENTATION TANK
The configuration of the fermentation tank has very little influence on system performance. In general, the proportions of the tank should not be extreme. Commonly, tanks are upright cylinders with the height somewhat greater than the diameter. The bottom may be flat (but sloped for drainage) or conical. The construction materials may be carbon steel (commonplace), stainless steel, copper, wood, fiberglass, reinforced plastic, or concrete coated on the inside with sprayed-on vinyl. Usually, the tanks are covered to permit collection of the C02 evolved during fermentation so that the ethanol which evaporates with it can be recovered.
These tanks come equipped with: · Cooling jacket · Oval manway · Conical bottom · Bottom drain · Racking port · Temperature port · Sample port · Ladder holder · AISI 304 stainless with 316 stainless lid · Lid lifting mechanism (tanks 1500 liters and larger) · Support legs
Figure 5.12 Fermentation Tank
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Fermentation process in CV1 At the initial stage the container which is around 400 ltr. Is cleaned with water and steaming is done in order to make the environment of the container free from error. After the application of this process dry steam is circulated for 1hrs. to make the surface of the container moisture free so that wort(molasses + water) which is added can be free from the moisture and the specific gravity can be maintained. Wort is added into the container with the setup specific gravity of 1.055 and other nutrients are added with it to make the reaction worth full. The additives which are added are uria , Zinc, MgSo4 , H2SO4. The process is carried out at the temperature of 121.5•c and at the pressure of 1kg for 45 minute and then pressure is opened. Then the hot wort is cooled to tem. 31-32 •c.now a culture pitch is added to a setup gravity of around 1.050.We will Find a fall in gravity which we will allow to be of around 0.015 when we find this much fall of the gravity of the liquid then we stops the process for CV1 and the liquid is transferred to the CV2. Fermentation process in CV2 and CV3 The setup gravity and the process which is carried in the previous CV1 process is repeated into CV2 and CV3 only the amount of doping is changed means they depend upon the amount of concentration of the solution which we want. Fermentation process in PF section This is the final stage of the growth of culture because this is the final stage of the aerobic process which means the flow of oxygen for the growth of yeast. In this uria, H2SO4, zing, Rcide and antibody is added the only change from the previous process is that only yeastext is not added which work as the nutrients this process is carried out for around 6-7 hrs. and after that when we find the fall in gravity of 0.015 we transfer the liquid into the fermentation process which is the last process of the fermentation in this process the value of TRS(total reduce suger) Is around 6-7 % which will increase in the final process to around 15-16%. Final Fermentation in section F After the transferring the wort from prefermentation section to fermentation section we put the flow of air for around 2 Hrs. for the final growth of the culture and to settled down the wort. The specific gravity setup gravity is around 1.107-1.108 and the final specific gravity should be around 1.052-1.053 and the amount of TRS should lie between 15-16%.Since the process is anaerobic so after the supply of air at the initial stage we stop the supply and we don?t allow the more air supply because in this stage no further development of culture takes place because they don?t find any media to growth and under this condition they react with wort and produce the ethanol with some amount of Co2 and heat. The total time period for this process is 16-17 Hrs.
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DISTILLATION
Distillation is a separation process for a mixture of liquids or oils. It relies on differences in the boiling points of the component liquids to be separated. The mixture to be separated is added to a Distilling Pot where it is heated to the boiling point. Lower boiling components will preferentially vaporize first. This vapor passes into a Distilling Head and then into a Condensor. Within the Condensor the vapor is cooled and it liquifies. The resulting liquid is then collected in a Receiving Flask. Initially, low boiling components are collected in the Receiving Flask. As the distillation proceeds, these components are depleted from the Distilling Pot and higher boiling components begin to distil over. Switching out the Receiving Flask at the appropriate point allows for the separation of the component liquids of the mixture.
DISTILLATION PRINCIPLES Separation of components from a liquid mixture via distillation depends on the differences in boiling points of the individual components. Also, depending on the concentrations of the components present, the liquid mixture will have different boiling point characteristics. Therefore, distillation processes depends on the vapour pressure characteristics of liquid mixtures. Vapour Pressure and Boiling The vapour pressure of a liquid at a particular temperature is the equilibrium pressure exerted by molecules leaving and entering the liquid surface. Here are some important points regarding vapour pressure: ? ? ? ? ? energy input raises vapour pressure vapour pressure is related to boiling a liquid is said to „boil? when its vapour pressure equals the surrounding pressure the ease with which a liquid boils depends on its volatility liquids with high vapour pressures (volatile liquids) will boil at lower temperatures ? the vapour pressure and hence the boiling point of a liquid mixture depends on the relative amounts of the components in the mixture
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5.13 Line Diagram of Distillation Proces
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FACTORS AFFECTING DISTILLATION COLUMN OPERATION The performance of a distillation column is determined by many factors, for example: ? feed conditions
? ?
state of feed composition of feed
? internal liquid and fluid flow conditions and weather conditions
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DISTILLATION PROCESS
Rectified sprit (Used as industrial alcohol)
Extra neutral alcohol
Indian made foreign liquor
country liquor
Distillation process is carried out to make two types of product 1- Rectified Sprit 2- Extra neutral alcohol Rectified Sprit : A rectified spirit, rectified alcohol, or neutral spirit is highly concentrated ethanol which has been purified by means of repeated distillation, a process that is called rectification. It typically contains 95% alcohol by volume (ABV). Rectified spirits are used in mixed drinks, in the production of liqueurs, for medicinal purposes, and as a household solvent. Extra neutral alcohol : A Extra neutral alcohol is colourless and has a neutral smell and taste.It is generally distilled from sugarcane molasses. It is used as a base for manufacturing Indian made foreign liquor and the country liquor. The ENA plant is based on the principles of multi pressure-cascading techniques and the process control is done by Digital Distributed Control System.
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5.14 Capacities of different plants:
Location Total licensed capacity (per annum)
KASHIPUR
803 lac.BL
GORAKHPUR
1000 lac.BL
SAHARANPUR
1000 lac. BL
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PROCESS OF DISTILLATION
5.15 Flow chart
WASH IN
36-37 •c
CONDENSATION
64.5•c PRE HEAT EXCHANGER
70-74•c PUMP
STEAM (FLOW IS 109611KG/Hrs)
STEAM
CONTAINER T-7
CONDENSATION
C1
CH3OH
C3
CONDENSATION
T9
Waste (spent wash) RECIVER
(Send to develop more condense alcohol)
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Wash in is the final product of the fermentation process which work as the input of the distillation process. The wash is input at the tem. Of 36-37 deg.c to the condenser where its temperature is raised by heating it through the hot air to 64-65 deg.c from where it is transferred to the pre heat exchanger (A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact.) to raise its temperature to 70-74 deg.c and this heated wash is carried to the C1 block. Steam is taken as one more input in this block with the flow rate of 109611KG/Hrs and waste is removed from it in the form of spent wash which work as the fuel for the power plant. The initial feed is done into the feed plate which is in the analyzer column which contain 23 tunnel type plate. As the name suggest analyzer means the separation of more volatile vapors from the less volatile and leaving behind the less volatile on to the bottom of the coloum. The waste is carried out from the bottom of the container because the waste which is carried out are the less volatile and are not helpful in the formation of the high concentrated alcohol. When the steam is provided to the wash and due to having the difference in the volatility the vapour starts forming at the different heat range and the alcohol with high concentration is having more volatility than the other input material which is used so by heating it we can extract the high concentration alcohol easily. The wash is heated to the tem. Range of 63-67 deg.c is then admitted to condenser for more heating because ethanol is more volatile and there are two factors which determine the vapor pressure of ethanol (because what makes ethanol volatile is that it was a high vapor pressure). What makes the vapor pressure of ethanol quite high is that it is a small molecule with a low molecular weight. In fact, if you look at other molecules with similar size and weight, many of them are gases at room temperature. The molecular weight of ethanol (C2H5OH) is approximately 46 grams/mole. Carbon dioxide (CO2) has a molecular weight of 44 grams/mole, but it is a gas. Butane, C4H6 has a molecular weight of 54 g/mol and is a gas. Chlorine (Cl2) is a gas with molecular weight of 71 g/mol! So you might predict that ethanol should be a gas at room temperature from this. However, ethanol is a liquid. The reason it is a liquid is because it can hydrogen bond. The alcohol group, -OH, in the molecule has both a hydrogen bonded to an oxygen atom, which is allows for hydrogen bonding. Hydrogen bonding is a very strong intermolecular force, and this is what makes ethanol a liquid (and water too, which has a molecular weight of only 18 g/mol -- water is not volatile because it has two -OH groups, and so can hydrogen bond much better than ethanol can). So ethanol is volatile because it is a small and light molecule, but it is not as volatile as you might otherwise expect due to hydrogen bonding.
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After the condensation where there is a rise in temperature of the vapors to make the concentration more volatile is send to the container T-7 and from there it is transfer to C3 .
In C3 again steam is provided and some by product is taken off like CH3OH and waste is also removed from the bottom of the container .C3 contain two outlet valve one is to the reciver in which the solution is send after the final chemistry and one is for further processing to make the concentration of ethanol nor condense and the process takes place in such a way that the vapour is again send to the condenser where the temperature is increased and through T-9 it comes to the C-3 and then go to the reciver.
5.16 Specification of Rectified Spirit (Analytical): Sr. 1 2 3 5 6 8 9 Parameters Strength pH Ethanol Content Sp. Gravity @ 15º C Miscibility with water Aldehyde Content Ester Content Unit ----%v/v ----Gms / 100ml Gms / 100ml IS Standard Value 67.0 4.5 – 6 95.26 0.8171 Miscible 0.006 0.02
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CHAPTER-6 FINDINGS AND ANALYSIS FOR PROCESS
CRITERIA OF PRODUCTION AND OPERATION MANAGEMENT SYSTEM PERFORMANCE There are basically three criteria under which any organization perform production and operation management system 1- Effectiveness 2- Customer satisfaction 3- Efficiency Whether the organisation is in the public sector or in the private sector or it?s a manufacturing or service unit, the productive or a optimal utilization of resources is always a desirable objective . Effectiveness has more dimensions to it. It involve more optimality in the fulfillment of multiple objective with the possible resources. This is not difficult to imagine because modern production and operation management have to serve the so called target customer. Effectiveness has to be again viewed in terms of the short and long term horizons because what you seem now like an effective solution may not be all that effective in the future. The effectiveness of operation system may depend not only upon a multiobjective satisfaction but also on its flexibility through which it can show more adaptability towards the future change program . Indian Glycol operation and production management system also works under this guide line of effectiveness, customer satisfaction and efficiency. The market is changing and the company can stand over in market by having a good control over it production because their product they reach to their customers. The system should be flexible because they should be ready towards the change.
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PRODUCTION AND OPERATION SYSTEM There are four type of production and operation system 1234Job shop Batch type Mass production Continuous flow type
Indian Glycol ltd do the continuous flow type production system because there is only two type of product in which they deal (country liquor and Indian made foreign). They produce the large amount of liquor (45 lakhs ltr.) with having a very less variety this also so that they are having a very less flexibility on to their operation system.
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FINDINGS AND ANALYSIS ON WASTE
During the total production cycle that is the conversion of raw material into the final product large verities of waste is generated. Since they incurred a huge amount of company investment and if they could be recovered or if they can work as the alternative recourse for some other process then they are going to increase the company revenue or reduces the investment in the process. So it?s become a important task for the operation people to manage waste and India Glycol Ltd is working effectively over it . Some waste which are utilized by the Indian Glycol Ltd. 1- Waste from the distillation process that is spent wash is having a some amount of alcohol contained into it which is flammable and is being used into the boiler to produce steem.
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CHAPTER-7 CONCLUSION
The production process in the INDIA GLYCOL LTD. though cannot be changed much as it is done through machines and the process is related with each other and if we need any change we have to suffer from heavy losses by stopping the whole process . But the other things such as input material (molasses), machine handling, cost cutting, efficiency, work load etc. can be improvised. Inventory management can be done through JIT method instead of keeping extra molasses container near press on the shop floor. It follows 5S method to improve efficiency and quality of the product. Cutting down costs include recycling of waste, use of waste material if possible, avoiding damages to machine parts. Workload is lowered by the rotation policy like transferring men from operation to another if they are free. This helps to build up good work environment, improves overall efficiency and developing the multitasking for the employes. But the only thing to be done is need of more automation in the semi finished goods ,raw material handling and finished material comes out of machine. This will avoid manual labor and accidents and will help to increase the overall efficiency.
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CHAPTER-8
OBSERVATIONS AND RECOMMENDATIONS
?
Yeast is one of the important raw material into the process of fermentation and it?s required a huge type to grow and develop which is used for generation of alcohol and once the process is completed the yeast is waste and send for draining which incurred a loss to the raw material Suggestion- Yeast should be recovered by the process of recycling.
?
Specific gravity plays a important role in the generation of good alcohol and the process which is used to check the fall in gravity is manual and having a possibility of human error with it which may cause a huge loss to the organisation. Suggestion- If possible the process should be automated.
?
Steam generation is a huge, bulky and expensive process because it required a huge setup for it and the steam which is used into the process of heating the fermentation tank and then they are realized into the environment are just a waste to the organization. Suggestion: This steam should be recovered by the steam recovery plant such as Use of Low-Grade Waste Steam to Power Absorption Chillers and by the Use of Vapor Recompression to Recover Low-Pressure Waste Steam.
?
To control over the use of steam generated by the power plant they can go to the solar distillation system in which heating of the process can be done by the solar system.
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CHAPTER-9 LIMITATIONS
The major constraints that limit the project are as follows: ? Photography was strictly prohibited inside the plant area, so pictorial representation of press and line is not possible. ? The managerial staff was very strict in disclosing the data about the demand as well as the customers. ? The data collected is approximate and not accurate.
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BIBLIOGRAPHY
? Principles of Fermentation Technology, Second Edition by P F STANBURY and S. Hall ? Fermentation Microbiology And Biotechnology by Mansi El-Mansi, Charles F. A. Bryce ? THERMAL ENGINEERING BY R.S. KHURMI ? www.indiaglycols.com ? http://www.wikipedia.org/
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