Quality Manual: I. Functional Objective

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I. Functional Objective:

To produce quality alcohol product as per customer requirements within optimum fermentation
and distillation efficiencies.

II. Operational Objectives:

A. MOLASSES TREATMENT

1. To remove the impurities present in molasses and pasteurize the wort to reduce the presence
of bacteria.
2. To produce wort of 26-280Bx with 32-380C temperature.
3. Accommodate up to 20% Spent Wash recycle.

B. FERMENTATION
a) Culture Propagation

1. Accurate wort blending and nutrient dosing to achieve lesser residence time of yeast culture.
2. To obtain viable yeast culture for fermentation to ensure efficient conversion of sugar to alcohol.

b) Fermentation Proper

1. Maintain optimum fermentation condition of 7º end Brix, pH 4.5 and 32 º Celsius to achieve
maximum fermentation efficiency.
2. Maintain a minimum of 8.5% alcohol in fermented wash.
3. To achieve a minimum yield of 280 liters of alcohol per metric ton of molasses and minimum
efficiency of 86%.
4. To produce fermented wash at a volume required by distillation section.

B. DISTILLATION

1. To ensure maximum recovery of alcohol in fermented wash through efficient distillation.


2. To achieve minimum distillation efficiency of 96%.
3. To achieve the desired capacity of 160,000 liters of alcohol R.S per day of production.
4. To produce desired alcohol quality as Rectified Spirit (R.S.) of 94.5% minimum purity.
5. To limit 0.5% alcohol on spent wash and spent lees ensuring effective column operation.
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C. DEHYDRATION

1. To produce anhydrous alcohol of 99.5% minimum purity.


2. To achieve the desired capacity of 150,000 liters of anhydrous alcohol per day of production.
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III.SIPOC Diagram

SUPPLIER INPUT PROCESS OUTPUT CUSTOMER


PRP Production Pasteurized Fermentation
Target Wort

SPG Steam &


Power MOLASSES
TREATMENT
WTP Process
Water

Molasses
MCD

Spent Wash
Distillation
(recycle)
MTP Pasteurized Fermented Distillation
Wort Wash

WTP Process
Water FERMENTATION

SPG Steam &


Power
QA
yeast culture
Fermentation Fermented Rectified Anhydrous Section
wash Spirit

WTP Softened Spent Wash Biogas Section &


water DISTILLATION MTP

SPG Steam &


Power
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Steam
condensate SPG

Distillation Rectified Anhydrous MCD


Spirit Alcohol
DEHYDRATION
Steam Steam & Power
condensate Generation
SPG Steam &
Power Production PRP
Target
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IV. Process Description:

MOLASSES TREATMENT

Molasses treatment is very important to remove impurities and bacteria that arrive with
molasses. The treatment consist of molasses dilution to 42 0Brix and heating up to 800C. it consist of
1 unit dynamic decanter and 2 units static decanter. After this the wort need cooling between 32-
380C, and then pass to another mixer for brix adjustment before heading to the fermenters.

FERMENTATION

Culture Propagation

The fermentation process employs a special yeast culture, which can withstand
variations in the molasses quality, temperature and other shock loads. Yeast Culture prepared
by the QAD is dropped to a Culture Vessel with prepared wort of 10 - 12º Brix, 4.4 - 4.6 pH and
a temperature of 32 - 34º C. The Culture Vessel is then fed with Urea and DAP for nourishment.
This process will continue until the yeast culture reaches 180,000 L. Continuously transferring
from Culture Vessel 2 to Pre-Fermenter Tank.

Fermentation Proper
Fed Batch Fermentation plant consists of five fermenter tanks with plate heat
exchangers for cooling. Temperature in the fermenters is maintained to an optimum level as
required for efficient reaction with the help of Plate Heat Exchanger and recirculation pumping
system. This recirculation also helps in proper mixing of fermented wash. The retention time
for the reaction is about 24 to 36 hours. After completion of reaction the fermented wash is
delivered to Continuous Stabilization Tank (CST). In CST, solids are settled down. The
supernatant goes to Buffer Tank (BT) and sludge from the bottom goes to Biogas Section.
The fermented mash collected in the Buffer Tank is feed to Distillation section.

DISTILLATION AND DEHYDRATION

Rectified Spirit (RS)


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The fermented mash is preheated using a beer heater at the top of the Primary column
and followed by a plate heat exchanger and finally delivered to the top of Primary column. The
mash runs down the Primary column from tray to tray, while vapor goes up in the column
contacting the mash at each tray. As a result of this contact and boiling, alcohol and other
impurities along with some water are stripped in the form of vapors and remaining mash in the
form of vinasse (effluent) is disposed off from the bottom of the Primary column for Biogas
section. When the vapors of alcohol and other volatile compounds reach the top, they are
separated out from the top of Primary column and taken to Pre-Rectifier column where they
are condensed in beer heater and other Primary condensers. The heat is supplied by the Final
Rectifier vapors from the Reboilers provided at the bottom of the Primary column. Two
reboilers are provided at the bottom of the Primary column to facilitate the heat transfer from
Primary column to Pre Rectifier column. The vapors from Pre Rectifier column top condensed
in the above condensers are collected and then sent as reflux liquid. The RS drawn from this
column and is fed to RS cooler and sent to RS Storage tank and ready to feed to the
DEHYDRATION SECTION.

Anhydrous Alcohol

The preheated feed enters the Recovery Column. The Recovery Column is pressurized &
its purpose is to vaporize the ethanol feed & to process the recycle liquid coming from the Mol
Sieve Regeneration system. The column contains sieve trays. Since the ethanol feed has already
been rectified & only needs to be vaporize, it can be fed at or near the top of the Regeneration
column. There is a feed location at tray 45. Energy is provided to the column via the Reboiler
using steam under flow control. The steam condensate flows under level control through the
feed Preheater to steam condensate return system. Anhydrous ethanol vapor is fed under flow
control to the Mol. Sieve Unit. It is first superheated in the Mol. Sieve Super heater, against
steam. This is to prevent condensation of liquids onto the molecular sieve bed, which would
decrease their adsorption efficiency. The superheated ethanol vapors are directed to the Mol
Sieve Units for dehydration. The vapor passes up through one bed of molecular sieve beads at a
pressure. Incoming water is adsorbed on the molecular sieve bed. Anhydrous ethanol vapor
exits the Mol Sieve Units. The Mol Sieve Units are cycled so that one is regenerating while the
other is adsorbing water from the vapor stream. The regeneration is accomplished by doing two
things. First, a vacuum is applied to the bed undergoing regeneration. Second, a portion of the
anhydrous ethanol vapor stream is directed down through the bed. This combination causes
water to desorbs from the molecular sieve beads & transfer into the ethanol vapor stream. The
mixture of ethanol & water is condensed in the Weak Alcohol Condenser against cooling water.
Any uncondensed vapor leaving the vent of the Weak Alcohol Condenser enters the Weak
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Alcohol Tank, where it is contacted with cooled regenerant liquid. The liquid regenerant stream
collects in the Weak Alcohol Tank. The regenerant liquid is circulated through the Weak Alcohol
Recirculation Cooler for cooling against cooling water & sprayed into the Weak Alcohol Tank.
The portion of the regenerant liquid is pumped out of the circulation loop under level control by
the Weak Alcohol Recirculation Pump & fed to Recovery Column. Another portion of the
regenerant liquid flows to the Mol Sieve Vacuum pump. The Mol Sieve Vacuum Pump provides
the vacuum source for the system. It is used to pump down the system during start-up & to
remove non-condensable during steady state operation. The seal liquid & non-condensable
leaving the Vacuum Pump is separated in the Vacuum drum. This liquid is returned to the Weak
Alcohol Tank under level control of the Vacuum Drum. Anhydrous ethanol vapor from the Mol
Sieve Units passes through the pressure control valve into the Mol Sieve Condenser, where it is
condensed against cooling water. The anhydrous ethanol product flows by gravity through the
Product cooler, to product storage.

V. Departments/Sections Concerned

1. Quality Assurance Department


2. Steam and Power Generation Section
3. Materials Control Department
4. Production Planning
5. Water Treatment Section
6. Biogas Section
7. Molasses Treatment Section
8. Fermentation Section
9. Distillation and Dehydration Section

VI. References/List of Procedures

KBK Operating Manual


GlobalTech Operating Manual????????

Prepared By: Reviewed By: Approved By:

Lubert Joseph T. Campo Hernie C. Alpas Noli G. Segovia


Process Team Leader Head – Production Department Factory Operations Manager

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