Abstract

Intenship report at Noon Sugar Mills is concentrated in production of ethanol. The

objective of this report is to knowing the production proses of ethanol at Noon Sugar
Mills, India. The author himself jumps into the plant to the research about making ethyl
alcohol or ethanol, Ethanol is produced both as a petrochemical, through the hydration
of ethylene and, via biological processes, by fermenting sugars with yeast. Which
process is more economical depends on prevailing prices of petroleum and grain feed
stocks. Noon Sugar Mills Ltd. produce ethanol from molasses which is obtained from
the side product from white sugar production. The thick liquid left behind from the
production of white sugar is known as MOLASSES, which used as the basic raw
material for the production of Alcohol. Molasses still contains sugar contents up to 50%.
The production consist of four main process, dilution section, pre-fermentation section,
fermentation section and distillationsection.

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Preface
I am thankful to Almighty Allah who has blessed us with the courage, strength and
wisdom so that we have been able to complete this internship report, with the help HE has
bestowed upon us.
Internship is one of the requirements to obtained a degree in Department of Chemical
Engineering, Faculty of Engineering.The internship in this report is concentrated in Production
of ethanol at Noon Sugar Mills.
During the preparation and implementation of internship, we have got a lot of help and
guidance from the various parties. Therefore, we do not forget to thank those who have assisted
in the preparation and implementation of internship.
Thus internship is structured, may be useful for various parties, especially for the
development of science in Chemical Engineering, Faculty of Engineering. The author realizes
that this report there are still many shortcomings. Therefore, criticism and suggestions may help
to enhance this report.

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Table of Contents
Abstract.......................................................................................................................... i
Preface.......................................................................................................................... ii
Table of Contents........................................................................................................ 1
Chapter I..................................................................................................................... 1
1.1.

Background.................................................................................................... 1

1.2.

History Industry............................................................................................. 2

1.3.

Objectives...................................................................................................... 3

1.4.

Problems........................................................................................................ 3

Chapter II.................................................................................................................... 4
Chapter III................................................................................................................... 5
3.1.

Raw Material Specification............................................................................. 5

3.1.

Description of the Processes..........................................................................6

3.2.

Location......................................................................................................... 9

Chapter IV.................................................................................................................. 9
Conclusion............................................................................................................... 9
Bibliography............................................................................................................. 10

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Chapter I
Preliminary
1.1.

Background
Sugar is a broad term applied to a large number of carbohydrates present in many
plants and characterized by a more or less sweet taste. The primary sugar, glucose is a
product of photosynthesis and occurs in all green plants. In most plants, sugar occurs as a
mixture that cannot readily be separated into components. In the sap of some plants, the
sugar mixtures are condensed into syrup. Juices of sugarcane (Saccharum
officinarum)and Sugar beet (Beta Vulgaris) are rich in pure sucrose. These two sugar
crops are the main sources of commercial sucrose.
The Sugarcane is a thick, tall, perennial grass that flourishes in tropical and
subtropical regions. Sugar synthesized in the leaves is used as a source of energy for
growth and is sent to the stalks for storage. It is the sweet sap in the stalks that is the
source of sugar as we know it. The reed accumulates sugar to about 15 percent of its
weight. Sugarcane yields about 2,600,000 tons of sugar per year.
The Sugar beet is a beet root variety with the highest sugar content, for which it is
specifically cultivated. About 3,700,000 tons of sugar is manufactured from sugar beet.
Sugar is not only used as a constituent in industrial and homemade food, but also
as raw

material in fermentation to produce ethyl alcohol, butyl alcohol, glycerin and

citric acid. Sugar is also an ingredient in transparent soaps and can be converted to esters
which yield tough, insoluble and infusible resins.
Following are the Processing Steps while making Sugar
Cane is first washed to remove mud and debris.
After washing, Cane is chopped and shredded by crushers.
Juice is extracted from cane either by pressing the cane through series of mills or
by diffusion i.e. leaching.
Juice is then clarified to remove floating impurities.
Clarified juice is then heated in pan evaporator for concentration and it is
concentrated up to 65-68 BRIX.
A mixture of syrup and Crystals is obtained which is known as MASSECUITE.
This Mixture is then centrifuged and crystals are separated.
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The thick liquid left behind is known as MOLASSES, which is the basic raw
material for the production of Alcohol. Molasses may be used for the production of
power alcohol and Molasses is also used for feed stock. Bagasse is also a by-product
of the industry. Bagasse is used as a source of energy fuel in sugar industry for sugar
processing and also used for making medium density fiber board (MDFB).

1.2.

History Industry
NOON SUGAR MILLS LTD. is the Company was incorporated in 1964 as a
public company listed on all the Stock Exchanges of Pakistan for setting up of a plant for
manufacture of white sugar, in the province of Punjab. The plant went into production in
1966 with a daily crushing capacity of 1,500 MT of sugar cane, which has since been
raised to 4,000 MT per day in 2002. Further extension to 9,000 TCD has become
operative in 2006-2007 crushing season.
An Alcohol Distillery of French origin was added during 1986 with a production
capacity of 50,000 litres/day in 2002. Another facility with an option to provide either
30,000 LPD Industrial of fuel Grade Ethanol was added in 2002. A new Fuel Ethanol
plant of 100,000 LPD, based on Molecular Sieve technology has been added in 2005.
The Distillery is ISO 9001 certified since 1998. which upgraded to ISO-9001-2000.
An Effluent Treatment Plant employing the Canadian technology of ABV BioGas reactors has been installed since 1997, to use its bio-degradable waste water as a
renewable source of energy to replace 70% of fuel oil / natural gas, for generation of
process steam. This has also enabled the Company to fulfill its obligation towards
reducing the environmental pollution. The Company has a gratifying record of average
payout in the last 10 years is 27.5%.

1.3.

Objectives
1) To know the engineering aspects of ethanol process in Noon Sugar Mills industry.
2) To know the circumstances and operating conditions fermentation, distillation and
diluted in Noon Sugar Mills industry.
3) Obtain work experience in companies engaged in the technique of making ethanol.

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1.4. Problems
1. How the operating conditions and process of making ethanol in Noon Sugar Mills
industry?
2. What is the process of fermentation, distillation and dilution?
3. How the overall of the processes and units in Noon Sugar Mills industry?

Chapter II
Ethanol, also commonly called alcohol, ethyl alcohol, and drinking alcohol, is the principal
type of alcohol found in alcoholic beverages, produced by the fermentation of sugars by yeasts.
It is a neurotoxic, psychoactive drug, and one of the oldest recreational drugs. It can cause
alcohol intoxication when consumed in sufficient quantity.
Ethanol is a volatile, flammable, colorless liquid with a slight chemical odor. It is used as an
antiseptic, a solvent, a fuel, and due to its low freezing point, the active fluid in many alcohol
thermometers. The molecule is a simple one, being an ethyl group linked to a hydroxyl group. Its
structural formula, CH3CH2OH, is often abbreviated as C2H5OH, C2H6O or EtOH. Ethanol is
produced both as a petrochemical, through the hydration of ethylene and, via biological
processes, by fermenting sugars with yeast. Which process is more economical depends on
prevailing prices of petroleum and grain feed stocks.

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Fermentation is the process of culturing yeast under favorable thermal conditions to produce
alcohol. This process is carried out at around 3540 C (95104 F). Toxicity of ethanol to yeast
limits the ethanol concentration obtainable by brewing; higher concentrations, therefore, are
obtained by fortification or distillation. The most ethanol-tolerant yeast strains can survive up to
approximately 18% ethanol by volume.
Ethanol fermentation, also called alcoholic fermentation, is a biological process which
converts sugars such as glucose, fructose, and sucrose into cellular energy, producing ethanol
and carbon dioxide as a side-effect. Because yeasts perform this conversion in the absence of
oxygen, alcoholic fermentation is considered an anaerobic process. Ethanol fermentation has
many uses, including the production of alcoholic beverages, the production of ethanol fuel, and
bread baking.

Chapter III
3.1. Raw Material Specification
The basic raw material required for the production of ethyl alcohol or ethanol includes:

Water
There are three main sources to supply water in the distillery.

Canal Water (Hardness 70-100ppm)

Soils Tube Well Saline Water (Hardness 400-600ppm)
Molasses
The waste mother liquor of the sugar industry from which the sugar could not be
extracted by crystallization is known as molasses. It still contains sugar contents up to
50%.

Average%

Compounds

20
35
07
09
04

Water
Sucrose
Dextrose (glucose)
Fructose
Other Carbohydrates

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12
4.5
05
0.4

Ash
Nitrogenous Compounds
Non Nitrogenous Compounds
Wax, Pigments, Vitamins

Specific gravity of molasses =1.43

PH =6
The yield of molasses per ton of cane is usually approximately 2.7% but it can be
affected by the quality of sugarcane.

Sulfuric Acid

Yeast
The yeast used in cultural tanks is Saccharomyces cerevisiae contains 150-300 million
cells per cm3
Nutrients (Urea, Phosphoric acid)
Air

3.1.

Description of the Processes

Sections of Distillery
Distillery plant operation is mainly divided into following sections.

Utility Section
Dilution Section
Pre-Fermentation Section
Fermentation Section
Distillation Section

A. Utility Section
The section where supply arrangements and storage of raw material is controlled
is known as utility section of the plant.
There are following circuits involved in the utilities section.
Process Water Circuit
Process water has much importance in distillery. The water used in processing i.e. in
dilution of molasses and for washing purpose, is called Process Water. Process water is
also used in cooling circuit.
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 Cooling Water Circuit

The water used for cooling purpose or to control the temperature of the exothermic
reaction is known as cooling water.
Instrument Air Circuit
The air used to control the instruments i.e. flow meters, level controllers etc. on the plant
is known as Instrument Air.
Process Air Circuit
The air used in the process for mixing and to provide the oxygen for growth of
microorganisms is called process air
Chilling Unit
It is a unit where we cool the water up to required temperature (10-13 oC), So that the
exothermic reaction in the Bub Vat is controlled, and to continue the reaction in the tank.
B. Dilution Section
In dilution Section, molasses and water are mixed in the ratio of 1:3. The main
purpose of the dilution is to get the brix which is much lower than the actual brix of
molasses. The main cause of dilution is to get the better yield of production. Pure
molasses have very high brix.
Following are the chemicals which are required for making the dilution of required
properties.

Molasses
Process Water
H2SO4
Process Air
Antifoaming Agent

C. Pre-Fermentation Section
Pre-fermentation is a process in which Inoculum or bacteria are prepared for
alcoholic fermentation. Inoculation or microorganisms are prepared by using certain
chemicals (Urea, Yeast, NaF, and H3PO4) which provide environment to cells for their
best growth.
Bub Vats are feed from dilution tank R-312 A/B. The brix of feed given to Bub
Vats is 25-29% which is further reduced to 15% by the addition process water.
Nutrients such as urea, H3PO4, NaF are added to Bub Vats for better growth of
microorganisms. Brix of Bub Vats is controlled at 6-7%. If controlled brix is low than
6%, yeast cells will die. Another thing which is also very important for preEthanol Production at Noon Sugar Mills Ltd.

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fermentation is the circulation of Bub Vats. There are basically two purposes of
circulation.
Better mixing of Biomass.
To control temperature of Bub vats.
Mixing of biomass is done to circulate microorganisms. If circulation is not done,
then cells will settle down at the bottom and will reduce the fermentation efficiency.
Circulation with heat exchanger is done to control the temperature of Bub Vats by
exchanging heat with cooling water. If cooling is not done properly, the temperature of
the Bub Vats increases, the anti-cells like wild yeast etc. formed which results increase
in acidity.
D. Fermentation Section
Fermentation is a bio-chemical reaction in which organic compound is converted to
alcohol in the presence of enzymes. The enzymes are microorganisms, which acts as a biocatalyst.
The action of enzymes is greatly affected by the following factors.
The temperature at which microorganism alive.
The pH of the substrate.
Growth of unwanted wild yeast, bacteria or germs in culture tank.
To get a maximum chemical yield, it is frequently advisable to suppress additional increase
in microorganisms.
Chemical used during fermentation
Yeast

The yeast used in cultural tanks is Saccharomyces cerevisiae contains 150-300 million
cells per cm3

Sodium Fluoride

It is used as a germicide in the culture tanks in which yeast is cultured. These culture
tanks are Bub Vats. NaF is used because wild yeast and some other germs are harmful
for yeast

Urea

Urea is also added in cultural tanks i.e. Bub Vats. Microorganisms use nitrogen as feed
so it is used as micro-nutrients.

Calgon (Sodium hexa Meta Phosphate)

By the use of Calgon, all muddy type material settles down at the bottom of the
fermenter.

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E. Distillation Section
A process in which a liquid or vapor mixture of two or more substances is separated into
its component fractions of desired purity, by the application and removal of heat is known as
Distillation.
The product from the fermentation section the distillated twice, in distillery I and II.
Distillery-I was imported from France and made by the company M/S SPEICHUM. It has the
capacity of making 50,000 Liters/Day. It consists of three distillation columns.
Vacuum Column
D-510
Low Boiling Column D-530
Rectification Column D-540
The plant of distillery-II was imported from Brazil. By the use of this plant, we can prepare or
distill the Absolute Alcohol which can be used as a fuel for internal combustion engines when
mixed with petrol or gasoline. Its production is 30,000 Liters/Day. There are three columns in
distillery-II also, but two out of them are in operation.
Boiling Column(A)
Rectification Column(B)

D-510
D-540

Boiling column is operating under pressure of 1.6bar thats why this distillation is also known as
pressure distillation and rectification column is producing rectified spirit. Rectified spirit is taken
from top two plates of the column and stored in daily receiver storage tank. The ethanol
concentration is 96%.

3.2.

Location

Noon Sugar Mills Ltd. is located in Bhalwal, District Sargodha. It was established in
1966. After the production of sugar from sugarcane, Molasses is produced as a by-product. For
the conversion of sugar present in the Molasses into Industrial Alcohol, Noon Sugar Distillery
was established in 1985 and started commercial production of Ethanol from Molasses.

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Chapter IV
Conclusion
Noon Sugar Mills Ltd. is a factory located in Bhalwal, District Sargodha, Pakistan which
produce white sugar, with molasses as side product, which used as ethanol raw material. The
process of ethanol production is consist of four main processes, dilution section, prefermentation section, fermentation section, and distillation section.

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Bibliography
Shahid, Muhammad. NOON SUGAR MILLS LIMITED BHALWAL. July 21, 2012
https://www.scribd.com/doc/100730609/Chemical-Engineering-Internship-Report-at-NoonSugar-Mills-Ltd-Distillery (accessed May 26, 2016)
Ethanol. https://en.wikipedia.org/wiki/Ethanol (accessed May 26, 2016)
Noon Mills Sugar Ltd. http://www.noonsugar.com/ (accessed May 26, 2016)

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