Sugar 2

BAHIR DAR INSTITUTE OF TECHNOLOGY
FACULITY OF CHEMICAL AND FOOD ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING (stream of sugar)
INTERNSHIP REPORT
Prepared by; ID NO.
1. Mekete Yitayew---------------0501822
2. Gashaye Zeru------------------0501187
HOST COMPANY- WONJI /SHOA SUGAR FACTORY
The duration of internship is for 45 days
Date-21/05/2016
Bahir Dar institute of technology Page i

Gashaye and mekete’s internship report
Declaration
This report is done by Mekete and Gashaye .We are 4th year chemical engineering students
have undertake our internship experience in WONJI/SHOA sugar factory under the guidance
of Mr.Amenu(company advisor)and Mr.Gemechu Kassaye(academic advisor).
We certify that our report is written based on guide line given by industry-company linkage of
the institute.
Mr.Gemechu
Name of advisor signature
Mekete Yitayew
Signature
Gashaye Zeru
Signature
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Bahir Dar institute of technology
Acknowledgement
Next to God we would like to express our heartfeel gratitude to our academic Advisor
MR.Gemechu Kassaye for his great help in the case of moral support and give advice for us
how can we do our report and lead to perfection.
Our great thanks also for MR.Amenu for his unreserved help in the case of showing
willingness to accept the training and support that everything we need for the training program
including moral and material support, description all about the plants.
In addition to this, we need to thanks to our company Advisor;
MR.Ahmed, MR.Esayas, MR.Mosisa and other operators and factory workers for their great
help to grasp Good knowledge during our internship.
We would like to thank all the societies WONJI for their cooperation and love every one as
their relatives.
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Executive summary
Now a day, WONJI/SHOA sugar factory is grown to be the first oldest sugar factory in
Ethiopia. This factory uses canes as a raw material for the production of commercial sugar
using milling, clarification, evaporation and pan housing plant and other related equipment’s
like cooling tower, heat exchanger, rotary filter, pumps, Fans and other unit operation in
different sections.
The factory comprises four inter connected plants;-milling, evaporation, clarification, pan
house and RO and power generation plant. Each section in the company has its own purpose;
some of them are;-a milling plant which is used to separate the mixed juice from the bagasse,
clarification which is used to the removing of impurities, Non Sugar and coloring matters from
the mixed juice , evaporation which is used to the removing of water by vaporization from the
solution of non-volatile substances. The other is water treatment which is used to prepare hard
water to soft water by removing ions and minerals.
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List of figure page
1. Figure 1 company structure …………………………………………5

2. Fig. 2 Auxiliary cane carrier/ACC/ …………………………………8
3. Fig.3 arrangement of mill ……………………………….………10
4. Fig.4 scale with load cell ……………………………………..…..12

5. Fig.5: Flow Diagram of Juice Clarification and Filtration process .................................14
6. Fig.6. The Dorr Clarifier ………………………………………..…19
7. Figure 7: Operation of Rotary Vacuum Filter ..………….……21
8. Figure 8:vapor cell followed by quadruple effect evaporator
With vapor bleeding……………………………………………………….24
9. Figure 9:body parts of evaporator……………………………………………25
10. Figure 10:process of crystallization in vacuum pan…………………….....25
11. Figure 11:molasses dilutor………………………………………………….27
12. Figure 12: reverse osmosis………………………………………………..36
13. Figure 13: water treatment plant…………………………………………..38
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Table of Contents
CHAPTER ONE ..................................................................................................................... 1

1. Background History of WSSF ....................................................................................................... 1
1.1. WSSF Overall Organization and Work Flow Chart .............................................................. 3
CHAPETER TWO.................................................................................................................. 5
2. How we get in to the company....................................................................................................... 5
2.1. Cane handling ............................................................................................................................. 6
2.2. Cane preparation ......................................................................................................................... 7
2.3. Milling plant................................................................................................................................ 8
2.4. Imbibitions water ........................................................................................................................ 9
2.5. Clarification .............................................................................................................................. 10
2.6. Evaporation ............................................................................................................................... 21
2. 7. Pan boiling plant ...................................................................................................................... 25
2.8. Quality control .......................................................................................................................... 30
2.9. BOILER AND WATER TREATMENT .................................................................................. 33
CHAPTER THREE ...................................................................Error! Bookmark not defined.
3. The overall benefits.......................................................................... Error! Bookmark not defined.
3.1. Improving practical skills.......................................................................................................... 40
3.2. Knowledge gain from internship............................................................................................... 41
3.3. Communication skills ............................................................................................................... 41
3.4. Team Playing ............................................................................................................................ 41
3.5. Leadership skills ....................................................................................................................... 42
3.6. Work ethics ............................................................................................................................... 42
3.7 Entrepreneurship skill ................................................................................................................ 43
3.8. Conclusion ................................................................................................................................ 43
3.9. Recommendation ...................................................................................................................... 44
Reference ....................................................................................Error! Bookmark not defined.
Appendix ................................................................................................................................ 47
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CHAPTER ONE
1. Background History of WSSF
The factory is found in Oromia Regional State near Adama Town at 108 km far from Addis
Ababa. Constructed in 1954 it is the oldest and the pioneer in the history of Ethiopian sugar
industry and Shoa sugar factory constructed in 1962 was the second oldest and both have
stopped production since July,2012 and July, 2013 respectively. The two factories constructed
by Holland Company known as H.V.A had a capacity of producing 75000 tons of sugar per a
year. The sugarcane plantation land of these two sectaries was 7,000 hectares out of which
1,000 had been planted by out grower.
In a bid to replace these two oldest factories with a new and another one, an expansion project
had been carried out both in the cane cultivation field and the factory since three years back.
The factory plant expansion project has come into completion July 2013. Accordingly, the
newly and highly automated Wonji/Shoa Sugar Factory will initially have capacity of crushing
6,250 tons of cane per a day and producing 174,946 tons of sugar per annum which further
expansion will reach up to 12,500TCD maximizing its production to 22, 0000 tons of sugar per
a year. The new plant will initially have a capacity of producing 10,000 mete cube ethanol per
annum that with further expansion will reach 12,800 meter cube. By the end of the GTP period
the factory would be able to contribute 32 megawatt electric powers to the regional grid in
additional to satisfying its own demand. In agricultural expansion project is currently being
carried out around the area known as Wakie Tiyo, Welenchiti and North Dodotas areas. The
factories, with the help of the agricultural expansion project, eill have 16,000 hectares of
sugarcane plantation field. And the entire factory’s sugarcane field cultivated with the
agricultural expansion project is owned by out grower farmers of the surrounding area.
Vision
To be the leading company in sugar industry and make more customers.
Mission
Bahir Dar institute of technology Page 1

Wonji/Shoa as an agro industry striving to increase stake holders’ satisfaction through
core business activity including Expanding and optimizing sugar cane plantation of own and
out growth cane to meet own requirement and creating income for the out growers, sufficient
employment opportunities in plantation. Producing and marketing sugar and downstream
products. Participating in the renewable energy sector through the integration of the national
portfolio of cost efficient bio fuel and bio energy assets.
Value
Team work bring individual and organization growth
Objectives
 Continually increase the production of sugar so as to attain a production capacity of 1.5

million tons by the year 2015/16.
 Establishing co-generation facilities and ethanol plant by year 2015/146.
 Increasing land productivity of existing cane area to 16,000 quintal/hectare by the year
2015/16.
 Continually decrease production cost.
Main Production of the company
 To produce the commercial sugars 6000 ton per day

 To produce the molasses
 To produce 32 Mw electrical power
Main Customers of Company
Main customer of commercial sugars
 Moha soft drink factory

 Coca cola soft drink factory
 Café, restaurants and hotels
 Rural and urban people of Ethiopia
 Export to other country
Main customer of final molasses
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 Balezaf alcohol and liquor factory
 Rural and urban people of Ethiopia
1.1. WSSF Overall Organization and Work Flow Chart

Man power
The company is organized with a combined workforce of more than 3000 employees. The
company is coordinated by Sugar Corporation. The manager is a mechanical engineer by
profession. The company has chemical engineers, mechanical engineers, electrical engineers,
chemists, finance manager, accountants, and marketing personnel, electrical technologist,
senior mechanics, welder, and the number of workers running the factory. In addition to its
highly skilled and experienced man power, the factory is well equipped with the latest
technology equipment’s machineries and other facilities that are necessary to successfully
expand and maintain the factory by the in house work force.
Overall management related tasks
 Formulate and ensures the implementation of quality policy.

 Provides necessary resources to maintain and improve the system.
 Appropriate internal communication process.
 Ensures if customer interests are handled appropriately
Purchasing and supplies, finance and administration related task
 Control over major supplier selection and purchasing.

 Monitor and review supplier performance.
 Define qualification of personnel and ensure recruitment of suitable qualified staff.
 Staff are properly treated, apprised of their performance and counseled.
 Ensures customers are credit worthy.
 Process and production planning.
 Control and monitor process
 Define workmanship standards.
 Preservation and packing of finished goods.
 Technical evaluation of raw materials for production line before purchasing.
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 Preparation of product specification.
Maintenance related tasks
 Maintenance of production equipment’s and machineries.

 Control over engineering activities.
 Maintain and ensure calibration of inspection, measuring and testing equipment’s.
 Manage and control over all utilities supporting the production realization process.
Administration
Define qualification of personal and ensures recruitment of suitable qualified staff at the time
required.
 General administration
 Provide induction training to new recruits
Finance
 Ensures customers are credit worthy.

 Ensures all sales are invoiced properly.
 Ensures all transactions are accurately recorded in the accounting records.
 Ensures audit and other statutory and regulatory compliance issues are handled
correctly, efficiently and promptly.
 Conducts timely financial analysis leading to informed and analyzed decision.
Quality control
 Incoming inspection
 In process inspection
 Final inspection of final products
Stores
 Make sure non-conforming products handling process is function well

 Make goods inward inspection before receiving
 Ensure final product, raw material, spare part and auxiliary materials are store
 Safety and securely under appropriate condition until required
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Marketing
 Study current and future market and propose appropriate actions

 Maximizes sales through use of various marketing structure
 Measures customer
 Satisfaction regularly and take prompt action
Organization workflow
Figure 1 company structure
CHAPETER TWO
2. How we get in to the company
Our faculty plays a great role to join in to the sugar research and training center in wonji shoa
sugar factory by giving enough attitudes to schedule given to us and starting from the guards.
They treated us in a good manner and helped us to contact with human resource officer. They
also a good person for us, on the factory side, everything was smooth. We also meet the
manager of the research and training center, MR.Amenu. He gave us plenty of Advices how
handle our tasks and how to communicate and learn from the operators and other members of
the company. Then he lead us to the shift engineers in each plants and they gave us a brief
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description of every section in the factory(milling, evaporator, clarification, boiler and RO
plant) then he told to the operator that we are student and to answer our question. The shift
Engineer, ready to answer all the question when we went to ask him.
Harvesting
The sugar cane weather it is matured or not must first identify by either observing or checking
by any means.
The indicator of maturity of cane
 its brix measurement

 the breakage at the nodes
 yellowish color of the whole plants
 metallic sound when traping by finger nail
 by the bulk density of the cane
If the cane fulfills the above indicators, it burned by fire at the field. The burned sugar cane is
cut either mechanically or manually.
2.1. Cane handling
Cane loading
It is carried out by mechanical method. The loaders are loading the cane on the carts to
transporte in to factory.
Cane weighing bridge
It is a load cell of computerized mechanism used to measure the tare weight of the carts and the
gross weight of carts with the cane. The net weight of the cane which is delivered to the factory
is determined by subtracting the tare weight from the gross weight.
The importances of knowing the weight of the cane delivered in to the factory are;
 to know amount of cane used per day

 For stastical information like Varity of cane, cutting number etc.
 for farmer and driver payment
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 to know accurately the performance of the factory
 to calculate the yield of sugar per year
 for chemical control of the factory
Cane yard
It is used as temporary cane storage place. During day time cane transport is carried out, but
not night. But sugar factory operates continuously so that cane must store at day time for night
time and emergency processing.
Cane unloading
The cane which comes in to factory unloading by unloader on to feeder table by means of fixed
over head travelling crane or are self discharging. But in Wonji/Shoa over head travelling crane
is used and feed in to feeder table.
The feeder tables feed the cane into Auxiliary Cane Carrier (ACC) through leveler and
delivered to MCC (main cane carrier).MCC conveys the cane from ACC in to BCC.
Fig. 2 Auxiliary cane carrier/ACC/
2.2. Cane preparation

It is the process of reducing the cane fed to the mill in to small pieces suitable for the
subsequent extraction process.
 The objectives of cane preparation are:

• To reduce the size of the pieces of cane to a size suitable for handing in the
extraction process
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• To rupture as many of the sugar bearing cells in the cane as possible to facilitate the
extraction of sugar
• To produce the cane that has the right characteristic for milling and diffusion
Cane Knives
It is used to break the rind of cane to facilitate disintegration of cell and extraction of
juice.According to Wonji/Shoa sugar factory there two sets of knives; first set and second set
of knives.
The speed of rotation of knives varies from 500 to 750 rpm .Power absorbed by a first set of
knives is of the order of 7.5 to 12 KW/TFH. For the 2nd set of knives, power absorbed is about
15 to 25 KW/TFH.First set of knife has smaller in size than second set of knife.
Fibrizor
It is the last cane preparatory powerful equipment which is used to improve the preparation and
disintegration of the cane. i.e. Rapture cell tissue. It is placed between cane knives and first
mill. The speed of fibrizor is generally of the order of 800 to 1200 rpm.The power absorbed
mostly between 35 to 40 kw/tfh.
Cane equalizer
Is used to even out the distribution of the cane and level the layer of cane when leveling knives
fairly low.
Magnetic separator
It is placed over belt transporting the prepared cane from fibrizer to the mill. Its application is
to attract metallic/ferric materials that come with prepared cane. Increasing order of speeds are;
feeder table, auxiliary cane carrier, main cane carrier and belt cane conveyor to prevent
chocking.
2.3. Milling plant

In Wonji/Shoa sugar factory there are five successive mills. As the prepared cane enters in to
the first mill, the juice extracts from it which is called primary juice and enters to first juice
tank. The unextracted juice containing bagasse enters to the second mill; again the juice
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separated and enters in to second mill juice tank which is called secondary juice. The juices
from first and second mill juice tank enter into rotary screener; where the left bagasse is
separated from juice. Then the juice is passed through screens and goes in to evaporation unit.
The bagasse left over the screen is mixing with first mill bagasse. in order to get maximum
amount of juice, imbibition water is added between 4th and 5th mills.The imbibition water is
used to extract the last juice from the last bagasse(final bagasse).The final bagasse goes to
boiler plant through under ground belt conveyor for steam generation. The juice in last mill
juice tank is mixed into 3rd mill bagasse and extracts from 4th mill.From 4th mill juice tank, the
juice mixed into 2nd mill bagasse and extracts from 3rd mill. After this the juice from 3rd mill
juice tank mixed into 1st mill bagasse.The speed and the gap of rollers varies from mill to mill.
It decreases as transport from 1st mill to 5th mill. i.e.1stmill>2ndmill>3rdmill>4thmill>5thmill
Fig.3 arrangement of mill
2.4. Imbibitions water

The imbibitions water is used to extract the last juice from the last bagasse (final
bagasse).Imbibition water are two types; cold and hot water.
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Imbibitions water is added between 4th and 5th mills. In WSSF mostly added hot water (around
70oc is good) exceptionally cold water is used when flowrate of hot is less and as a result it is
not enough.
There are three types of imbibitions. these are;
1. Simple Imbibition
Where water only added on each mills.
2. Double Imbibition
Where water is applied to the bagasse from the next to last two mills and combined thin juice
from the last two mills is returned to the earlier mills.
3. Compound Imbibition
Where water is added on 4th outlet bagasse which feed in to 5th mill.
2.5. Clarification
The juice coming from the extraction plant has to be purified in the clarification process. This
requires that the juice be boiled an
Juice weighing
Mixed juice is normally weighed or measured by juice weighing tank/hopper/.The volume of
the juice is converted to weight by multiplying it by its specific gravity. Imbibition water is
also weighed or measured. When it is measured, its volume is also converted to weight
multiplying by its specific gravity. Weighing of bagasse is very inconvenient. Hence the
weight of bagasse is calculated from general mass balance.
Cane + Imbibition Water = Mixed Juice + Bagasse
Bagasse = Cane + Imbibition Water - Mixed juice.
Thus, mixed juice weighing is one of the steps in chemical control rather than part of the
process itself. The basis of process control is an accurate determination of the weight of mixed
juice enter
The purpose of mixed juice weighing

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 To determine the weight of bagasse supplied to boiler plant.
 To determine the milling plant extraction.
 To determine the boiling house recovery.
Method of juice weighing
There are different methods of juice weighing practices in sugar industries.

1. The Maxwell - Boulogne
One of the best known and first used juice scales was the Maxwell-Boulogne scale in which a
fixed counter weight on a lever arm was made to balance a juice tank.
2. Servo - Balans
This scale was designed and manufactured in Holland. Its design is based on a beam
scale using the servo principle to move the poise along the beam to balance the load,
through a complicated system of levers .A very important aspect of the design is that
the weight hopper (juice holding tank) is weighed twice; when full and again when
empty.
3. Scale with Load Cells
Today most juice weighing scales have been converted or designed to operate with load cells.
These have replaced all mechanical parts associated with the original Servo-Balans weighing
mechanism and valve-operating cams. In Wonji/shoa sugar factory such system is used.
Fig.4 scale with load cell
Juice pre-heating
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Juice heating is excited in a number of vessels called juice heaters or pre-heaters. Measured
mixed juice is heated to a temperature of 75 °C. The main purpose of such heating is:-
 Certain organic constituents like proteins are coagulated.

 Destroys micro-organisms and enzymes preventing loss of sucrose by
microbiological activity.
 Accelerates the reaction rate between the juice acids and the lime which
will be subsequently added.
Heating mixed juice at its acidic pH (5.4) accelerates inversion. Therefore heating is carried
out as rapidly as possible and the juice is treated with lime.
2. The sulphited mixed juice is heated to about 5 °C above boiling point. Therefore the
pressure in the juice will be above atmospheric pressure and it is let to flash out its air bubbles
that would retard settling of impurities in the clarifier. When the juice is exposed to
atmospheric pressure in a flash tank, it loses its excess heat and drops to compatible
temperature to atmospheric pressure.
3. The clear juice from the clarifier is heated to 110 - 115 °C before it flows to evaporators
such heating of the clear juice would bring the immediate starting of boiling in the 1 st
vessel as the result evaporation capacity is raised.
Figure.5
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Measured mixed juice is heated to a temperature of 75 °C and directed to liming and
sulphuring.
Clarification process
The purpose of clarification process is to remove the maximum possible impurities from the juice as
early as possible in the process. The pH of juice extracted from fresh cane is about 5.5 and can be as
low as 4.0 if the cane is deteriorated or has reached the mill several days after harvest.
The objectives of clarification are:
a) To separate soluble and insoluble matter that can precipitate.

b) To reduce color and turbidity of the juice
c) To produce clear juice of correct pH (7.0)
d) To kill or inactivate microorganisms in the juice by heat treatment.
Essential conditions to obtain good clarification are:
 Constant juice flow.

 Constant quality and concentration of additives (lime, flocculant...)
 Constanttemperature
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Fig.5: Flow Diagram of Juice Clarification and Filtration Process for the Production of
Plantation White Sugar
Liming
Liming neutralizes the acidity of the juice and also reacts with phosphoric acid in the juice to
produce a precipitate. Lime used in raw sugar factories is hydrated lime (Ca (OH)2) or quick
lime(CaO).
Lime and Its Behavior in Juice Clarification
The solubility of Ca (OH) 2 in water is very low (0.2 % at 25 °C). The solubility of lime is
greatly increased in a sucrose solution. The solubility of lime is also increased by some non
sugar substances present in the juice. The solubility of Ca (OH)2 decreases with the increase in
temperature.
The completeness of the chemical reactions is influenced by the following factors:
 PH of the solution
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 The concentration of the reagents
 The temperature of the solution
 Solubility of the precipitate in the solution of sucrose and non sucrose juice
Liming Processes
There are at least three types of liming processes;
(a) Cold Liming

(b) Intermediate Liming
(c) Hot Liming
(a) Cold Liming
Mixed juice is limed to pH between 8.0 and 8.6 and is then heated to 3 0C above boiling point
and sent to flash tank and clarifier. Cold liming is not common because high pH and low
temperature are good conditions for growth of the bacteria.
(b) Intermediate Liming
Mixed juice is heated to 70 0C, limed to a pH between 8.0 and 8.6 and heated to 3 0C above
boiling point and sent to flash tank and clarifier.This process is good for enzymatic action on
starch (juice kept at 70 0C for 10 minutes allows enzymes in juice to reduce starch content to
an acceptable level).
(c) Hot Liming
Mixed juice, heated to 3 0C above boiling, is sent to the flash tank and limed to a pH between
8.0 and 8.6 before going to the clarifier. Hot liming produces greater mud volumes than
intermediate liming.
2.5.1. Methods of Juice Clarification
Depending on the type of final product to be produced, there are different methods of juice
clarification.
1. Defecation Process
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It is a process carried out by heating and liming of mixed juice. The treatment causes formation
of heavy precipitate of complex composition.
2.Sulfitation Process
In the sulfitation system clarification is done by heat, lime and sulphurdioxide gas. The mixed
juice is heated to 75 °C. The excess of lime is neutralized by SO2 gas.
Advantages of Sulphitation;
 Rapid settling of juice

 Fast boiling of massecuites
 Marked improvement of sugar color
 Better elimination of phosphates and waxes during clarification.
Disadvantages of Sulphitation
 Heavier deposited of scale in heaters

 Higher ash content of sugar
 Great expense cost for sulphure and its generation equipments.
The types of sulphitation system is used in Ethiopian Sugar Industries are;
1. Preliming (Alkaline Sulphitation) – Wonji/Shoa Experience
The mixing of lime and juice is done with the help of a power driven agitating device.The
excess of lime is neutralized by sulphure dioxide in the sulphitation tank.
2. Simultaneous Sulphitation (Neutral Sulphitation) - Metahara Experience
In the simultaneous sulphitation system the lime remains in contact with the juice for a very
short period of time. The raw juice is heated to 75 oC and directed to the sulphitation vessel
where lime milk and SO2 are admitted. The advantage of the system is that the time in which
reducing sugars exposed to higher alkalinity is negligible and reaction of lime with reducing
sugar is very limited.
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3. Shock Liming Modification (Finchaa Experience)
The mixed juice heated to 75 oC is first pre-limed to pH 7.2 - 7.5. After a very short period of time, the
same juice is subjected to 2nd liming (shock liming) where its pH is raised to 9.2 - 9.5 and gassed with
SO2 simultaneously in a suitably designed sulphiator tank. After gas treatment
Sulpherdioxide (SO2) Gas Generation
In sugar factories which apply the sulphitation process, the SO2 gas is usually generated by
burning sulphure in special designed furnaces.
S + O2 SO2 + Heat (70 KCal/32 gms)
The sulphure has to be melted first. The melting point is 119 oC. The reaction of sulphur
burning is exothermic. The gas produced would then contain unburned sulphure vapor in
addition to the sulphure dioxide gas and other gases from air. This sulphure vapor is undesired
because of:-
a. Waste of sulphure - (Economical Loss)

b. It condenses (sublimate) in the pipe and values blocking them.
In order to avoid formation of sulphure vapor, the excess of heat librated during combustion
has to be removed by cooling the sulphure stoves.
Carbonation Process
The main clarifying agents in the carbonation process are lime and CO2 gas. The process
consists basically of precipitating calcium carbonate.
Ca (OH)2 + CO2 CaCO3(s) + H2O
The precipitate (Calcium Carbonate) adsorbs coloring matter and gums. It is easily filterable.
some times PO4 are added to on mixed juice if there is shortage of PO4.
The advantages of phosphate adding are:-
 Greater colloid elimination

 Fewer lime salts in clarified juice ~ More rapid settling
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 Faster mud filtration
 Better working conditions of low grade massecuites
The disadvantages of phosphate addition;
 The precipitate tricalcium phosphate is difficult to filter.
 Increased mud volume

 Higher lime consumption
 Extra cost
However, the advantages are more than of set the extra cost. The liming and the sulphitation of
juice is going to 2nd heater and heated to 102-105oc.
The Flash Tank
When the juice is subjected to atmospheric pressure in the flash tank, it will flash (auto
evaporation) and its temperature will go down to 100 0C. the juice is going to the clarifier will
be constantly at 100 0C.it allow the evacuation of air and gas bubbles to avoid building of
pressure in the flash tank. Velocity of steam in the vent must not be too high to avoid
entrainment of juice droplets.
Dorr Clarifier
It is a large vessel which consists of four supper imposed compartments with feed chamber at
the top and each forming a complete clarifier independent of the other. It is provided with a
central hollow shaft, rotating very slowly and movers the scrapers at approximately 12
revolutions per hour which slowly brush the bottom of the compartments, i.e. tray.
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Fig. 6: The Dorr Clarifier
The Flocculent
The flocculent is a polymer of high molecular weight, which is added to lime juice before entry
into the clarifier to enhance the production of large flocs in the mud. Mud with large flocs will
settle more rapidly. The dosage of flocculant in limed juice depends on cane quality and
climatic conditions. In practice, if a dosage of more than 4 ppm on cane.
Preparation of Flocculent Solution
Flocculants are costly and their efficiency will depend on the care with which they are utilized.
The following precautions must be taken:
(a) Flocculants must be stored in well-closed packing to avoid formation of lumps.

(b) The addition of flocculants to water when preparing a solution must be done at a
slow and uniform rate to avoid formation of lumps.
(c) Water used for preparation of solution should be of good quality and at a
temperature of less than 50 0C. It is advisable to use cooled condensate.
(d) The agitators for the mixing should run at low speed.
(e) The concentration of the stock solution should not exceed 0.2 %.
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2.5.2. Muddy Juice Filtration
The objectives of mud filtration are:-
 Separate the solid impurities from the muddy juice.

 Recover as much as possible the sucrose present in the juice.
The filtered juice is known as filtrate while the filtered muds are known as filter–cake.
The Rotary Vacuum Filter
The filter is made up of a hollow drum rotating about a horizontal axis. It has 3 zones.
(i) A “low ‘’ vacuum of between 12 - 25 Cm mercury.
(ii) A “high” vacuum of between 43 - 50 Cm mercury.
(iii) A section under atmospheric pressure.
Operation
Bagacillo is added from the cyclone above it. The mixer is fitted with an agitator with lateral
arms, which mix the muds and bagacillo to the correct consistency.
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Figure 7: Operation of Rotary Vacuum Filter
 As the filter rotates in a counter-clockwise direction, low vacuum is applied to the

filtering section (from point “0” to point “1” on the diagram), which pick up the feed,
and cake formation takes place on the surface of the screens. The first filtrate is very
dirty due to suspended solids and is directed to the “cloudy filtrate” receiver. As the
drum continues its rotation, the cake thickens, and wash water from sprays is applied.
(“1” to “2”; “2” to “3”). The arc of rotation from “2” to “3” is the area of cake washing,
where hot water is applied. The water displaces the filtrate through the cake and the
filtrate is directed to the “clear filtrate” receiver. From point “3” to point “4”, the cake
is made to dry by draining water and filtrate through it. At point “4”, the vacuum is cut
off and the filtering sections come into contact with the atmosphere. The cake detaches
itself from the screen surface and falls off when it meets a rubber scraper, which directs
it to a conveyor belt. When a section passes point “0”, vacuum is again applied and a
new cycle is started.
2.6. Evaporation
Evaporation is equipment used to remove water to concentrate the sucrose solution to the brix
of 65-70o brix.
Types of evaporator
Based on the concept of steam economy, there are 3 types of evaporator arrangement. These
are;
1, single effect evaporator
 The required capacity is so small

 Steam is cheap
 The vapor is so contaminated that it cannot be reused
2, single effect with vapor recompression
21
They are the simplest means of reducing energy requirement of evaporator in
compressing the vapor from single evaporator so that the vapor can be also heating
medium in the same evaporator.
3, multiple effect evaporators
It is use for economizing on energy consumption. They can be double, triple, quadruple,
quintuple, sextuple etc. as the no- increase, the energy (steam) saving is increasing, but the rate
of evaporation (which is minimum when the number of effect is greater than five and
maximum when the no- of effects is 3) decrease. The rate of evaporation falls with the no-
effect because of the driving force, log-mean temperature difference is decreasing. An
arrangement of 4 vessels in series known as quadruple effect evaporator where as quintuple
effect evaporator consists of five vessel in series. In WSSF it uses five effect evaporator
vessels.
2.6.1. Multiple effect evaporators
Semi kestner type evaporators
1.1st effect evaporator
Receive the clarified juice at a brix of 15o and at a temperature range of 115-120oc. the heating
media is exhaust steam. The exit vapor has a temperature of 112-125oc and used as a heating
medium of 1st effect evaporator. The steam exit from the vapor cell is used for boiling of low
grade sugar and 2nd heaters.
2. 2nd effect evaporator
It is heated by exhaust steam (112-115oc). One part of the exit steam is used for 1st heater and
partly used for boiling of high grade sugar.
Robert type evaporators
3. 3rd effect evaporator
Generates a vapor at 100-1010c is heated by vapor which comes from 1st effect. The vapor so
furnished is divided between 3rd effect evaporator and primary juice heater.
22
4. 4th effect evaporator
Is heated by the vapor which comes from 2nd effect vapor generated at about 900c are totally
supplied to the calandria of 4th effect.
4. 5th Effect Evaporator
 Is the last effect, which delivers syrup with temperature of 60o
23
Fig.8: Vapor Cell Followed by Quadruple Effect Evaporators with Vapor Bleeding
Accessories of Evaporators
An evaporator has two main body parts. These are;
 The heating calandria, and

 The vapor body
24
Fig.9: Body Parts of Evaporators
2. 7. Pan boiling plant

After evaporation, the concentration of syrup has to be carried further in order to obtain sugar
in crystal form. To achieve this, massecuites have to be evaporated to a Brix content of
between 92 % and 96 %. The process of forming crystals by evaporation and concentration in
known as pan boiling.
Syrup Sulphitation
Syrup sulphitor is used for sulphitation of syrup.SO2 used for bleaching purpose. After
sulphitation dark brown syrup is converted to light, pink and color like honey.
Crystallization
Fig.10: Process of Crystallization in Vacuum Pan
A massecuite is a mixture of crystals and mother liquor. The boiling of massecuite can only be
carried out in specially designed “evaporators” called vacuum pans.
25
Boiling of Syrup
Boiling of Syrup Accomplished by:-
1. Crystallization
2. Purification Process
Crystallization in pans consists of two simultaneous processes:
1. Further concentration of syrup (Evaporation)
2. Crystal formation and growth.
In order to takes place crystallization process it must be reach in super saturated solution.
Super saturation sugar solution may be classified in to three super saturation zones. These are;
1. Meta stable zone
This is above saturation line and in which existing sugar crystals will grow but new ones
cannot be formed.
2. Intermediate zone
Where new crystals may be formed but only in the presence of other super crystals.
3. Labile zone
Where crystals are formed spontaneously.
As the nature of material to be handled in pans and evaporators is quite different, the design
aspect is also to be changed accordingly. Such as:
1. Diameter of tubes is bigger in pans than evaporators
2. Length of tubes is shorter in pans. For better circulation in pan mechanical

circulators are also provided especially for low grade pans.
In the process of crystallization, the solution has to be boiled at lowest possible temperature
(under vacuum) in order to:-
1. Avoid sucrose destruction by heat
26
2. Formation of color to be minimize
3. To use low pressure steam
4. High heat transfer/latent (110 °C and 0.6 Kg/Cm2) heat or improves the heat
transfer by maintaining sufficient temperature difference between the steam/vapor and boiling
Liquid.
2.7.1 Vacuum pan

Is equipment in which crystallization and boiling takes place based on the no. of boiling
system. The number And the capacity of the pan depends on the amount of material they
handle/the crushing rate of the factory./
Molasses diluter/molasses condition tank/
They are used to supply conditioned molasses to the pans. These tanks are fitted with steam
cells, hot water lines and thermometer for measuring temperature. The contents of the tanks are
well mixed by stirrer/air jet mixer/to prevent local hot spot.
Fig.11.molasse dilutor
Massecuite (Strike) Receivers:
They are commonly called crystallizers although crystallization is not expected in these units
due short retention time of massecuite in them and no proper cooling facility
Massecuite Pumps: - They are special designed pumps to handle high viscosity material and
used to transfer massecuite from strike receivers to
 Centrifugal machines for “A” (High Grade) massecuite and
27
 To cooling crystallizers for low grade massecuite, especially final massecuite
 Massecuite pumps are mostly rotary or gear type positive displacement pumps.
2.7.2.Cooling Crystallizers or Continuous Crystallizer
These types of crystallizers are designed for low grade massecuites. They give more consistent
molasses exhaustibility.
The capacity of these crystallizers is designed to give enough retention (cooling) time of
massecuites inside them.
Advantages of vertical crystallizer
 Lower cost because of absence of stage

 Higher heating surface to volume ratio
2.7.3. Centrifugation
The process of separation of sugar crystals from the molasses in massecuite is carried
out in machine is called centrifugal.
There are two types of centrifugals. These are batch and continuous centrifugal.
The batch centrifugal produces sugar intermittently and used to cure “A”and”B”sugar
when the latter made to export.
The continuous centrifugal produce sugar continually and used
curing”B”and”C”massecutes especially when the former produce “B”sugar that is
reprocessed.
28
A centrifugal machine essentially consists of;
(a) Revolving basket with drive arrangement
(b) Monitor casing.
In a batch centrifugal machine the basket is a cylindrical drum with perforations,
Supported on a heavy vertical shaft with drive arrangement at the top.
2.7.4. Drying of sugar

In order for sugar to be properly handled and successfully stored, it has to be dried to a safe
moisture level. Raw sugar, depending in its polarization, is surrounded by a film of molasses,
which contains Non-sugars and reducing sugars .if the sugar is not dried sufficiently, growth of
micro-organisms could develop, which would causes deterioration and loss in storage.
The level of drying is determined by the required polarization to satisfy its market values, both
international and local.
The Safety Factor (S.F)
( % H 2O )
The Safety Factor ( S .F ) 
( 100  Pol % )
A Value of 0.25 or Less is Re quired
The Dilution Indicator
( 100  % H 2 O)
The Dilution Indicator ( D.I ) 
( 100  Pol %  % H 2O )
A Value of 0.33 or Less is Considered Satisfactory.
29
Bahir dar institute of technology
Dilution Indicator ( D.I )  33 .3  Safety Zone
Dilution Indicator ( D.I ) 33 .3  50  Doubtful Zone
Dilution Indicator ( D.I )  50  Zone of Deterioration
Raw sugar of 98.50 Pol is generally dried to between 0.2 – 0.5 % moisture. Refined sugar is
dried to between 0.02 – 0.03 % moisture.
Sugar Dryers
There are several types of dryers, namely.
Horizontal: Cascade and Roto - Louvre Dryers
Vertical: Comessa Dryer
Fluidized Bed Dryers: Used for Refined or V.H.P. Sugars
2.7.4.1. Fluidized bed dryer

The fluidized bed dryer consists of a vertical cylinder separated into two compartments, upper
and lower, by a perforated plate containing gas distribution nozzles.
Part of the lower compartment (wind box) receives hot air for drying, which is produced by a
steam heat exchanger mounted in the main fluidizing air duct. The other section of the wind box
receives cold air.
Sugar from centrifugal is fed into the upper compartment expansion chamber) at the desired feed
rate and forms a bed about 300 mm deep non the perforated plate, where the hot air passing
through the plate fluids the sugar while drying it. The nozzles in the perforated plate are specially
designed to distribute air evenly through the sugar and keep it uniformly fluidized. The discharge
rate is controlled by means of a vibrating feed. The desired sugar then packaged by automatic
machine then to store.
2.8. Quality control

Brix Determination (Brix % Cane)
30
 Brix % Cane (Bc) = be (4 – 0.0125 F )
Where;be-brix extraction and F-pol

factor
Pol Determination (Pol % Cane)
PC  Pe (4  0.0125 F )
Purity of Cane (Pty
Pe PCane
Purity of Cane   100 OR   100
be BCane
Determination of Dry Substance (Moisture) % Cane
The method is used to determine moisture content of prepared cane, which is accepted by ICUMSA.
m2  m3
Moisture % Cane   100

m2  m1 Where; m1 is Weight Empty Container,
m2 is Weight Empty Container Plus the Sample and m is Weight Empty Container Plus Dried Sample
Determination of Preparation Index (PI)
The method is based on the determination of preparation index of cane by measuring the extent
of cell rupture which is accepted by ICUMSA
B1
Pr eparation Index   100
B2
Bagasse Analysis
Determination of Pol Percent Bagasse (Through Moisture in Bagasse)
Pol % Bagasse = Pol Reading (2.6 + 0.0026 M)
M is Moisture % Bagasse
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Filter Cake Analysis
Determination of Pol (Sucrose) in Filter Cake
 Pol % Filter Cake = Polarization Reading in 200 mm Pol Tube.
Determination of Moisture in Filter Cake
m2  m3
Moisture % Filter Cake   100
m2  m1

Where; m1 is Mass of Dry Basin
m2 is Mass of Basin plus Wet Filter Cake
m3 is Mass of Basin plus Dry Filter Cake
Determination of Brix in Juices
 Brix % Juice = Refractometer Reading
Determination of Brix in Syrup (Dilution 1:3 m/m)
 Brix of Syrup = Refractometer Reading  3
Determination of Brix in "A", "B" Massecuites, Magma and Other Running
(Dilution 1:5 m/m)
 Brix % Massecuites (Sample) = Refractometer Reading  5
Determination of Brix in Final Molasses (Dilution 1:10 m/m)
 Brix % Molasses = Refracometer Reading  10
Determination of Pol in Factory Products
 % Pol = Pol Reading  Pol Factor
Determination of Pol in "A", "B" Massecuites, Magma and Other Running
 Pol % Massecuites = Pol Reading  Pol Factor
Determination of Pol in Last Massecuites and Final Molasses
Pol % Molasses/Massecuites = Pol Reading  Pol Factor  10
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2.9. BOILER AND WATER TREATMENT
2.9.1. Water treatment

Water treatment is the process of purifying waste water from suspended solids, dissolved solids,
minerals and micro organisms. In Wonji/shoa sugar factory the source of water is Awash River;
which is 1.5km far from factory. This water source is transported to factory by pumping with two
centrifugal pumps through large tube.
In Wonji/Shoa sugar factory there are two types of waste water treatment systems. These are
External treatment and internal treatment systems. First let us discuss External waste water
treatment in Wonji/Shoa sugar factory.
2.9.1.1. External waste water treatment

Is the treatment of water before goes to boiling systems from raw water to get deminerilized
water for the steam and electricity generation. In external treatment the raw water is treated with
chemical reagents in steel tanks to eliminate the salts in solution. Sometimes chemical treatment
is accompanied by ion exchange treatment for removing undesirable components from water.
From here mainly there are five processes. Let us discuss each process one by one.
1. Decantation
Is the process in which separation of solid from liquid using gravity and density
difference to remove suspended solids. A particle accelerate vertically down ward until
the drag force, Fd equals the driving force,Fnet.
Fnet=gravitational force-buoyant force
The tanks in which decantation takes place are under ground rectangular tanks. From
where the raw water enters directly into these three series of tanks. Then the raw water
leaves the mud and transports to the 2nd and third tank consecutively by over flow from
the tanks. The tanks in which decantation takes place are 4m height underground tanks.
After this the water divides in to two, injection water and treatment needed water.
The injection water is taken into over head pipes by pumping it with centrifugal pumps.
After decantation the treatment water leads to clarification process (HRSCC) through
large tube.
2. Clarification process
33
Is the process in which high solid contact takes place with addition of chemicals. This is
both chemical and physical treatment methods are takes place. The unit operation in
which clarification takes place are two circular tanks called, High Rate Solid Contact
Clarifier (HRSCC).
The main objective of clarification is to minimize suspended solids and turbidity.
I.e. Suspended solid decrease from 150-250 to 50 and Turbidity 100-200 NTU to 25-50
NTU.
There are different types of zones in HRSCC according to amount of suspended solids
and impurities in it.
1, center zone; from this zone discrete particle is settled.
2, Flocculent zone ; flocculent particles are settled. floc formation is taking place.
3, clear zone(hindered zone); used to settle contacting particles as a zone or blanket
maintaining the same relative position with respect to each other.
Clear liquid is formed.
The flow rate of water in to HRSCC is 250m^3/hr.
As the water enters to HRSCC of center zone the impeller rotates and disturb the impure
water; thus suspended solids collected with scraper so that sludge removes in to bottom
part of HRSCC.Relativly pure water overflows from center zone to flocculation zone
then to clear zone.
In order to get high quality treated water with short period of time we use chemicals; like
Aluminum sulphate to coagulation and polymer for flocculation of suspended solids in
water. In addition we use sodium hypochlorite as disinfectant for destroy algae, insect
and bacteria.
During mixation into water the amounts of chemicals required are;
 Alum(Al2(SO4)3)-20 ppm
 NaOCl-2 ppm
 Polymer-0.5 ppm
Let us discuss the 3rd process the so called filtration process.
3. Filtration process
34
Is the removal of solid particles from a fluid by passing a fluid through a filtering
medium, or septum on which solids are deposited. The treatment most industrial
filters are pressure filters, vacuum filters or centrifugal separators.
From clarifying water; filteratation mainly takes place into two filters. These are;
Multi Grade Filter (MGF) and Ultra Filter (UF)
3.1. MULTI GRADE FILTER (MGF)
Multi grade filter is a depth filter that makes use of coarse and fine media mixed
together in a fixed proportion. It can works on the principles of retention and
removal of physical impurities in a graded manner through voids of the filtering
media. The physical impurities of raw water that means suspended solid, dirty and
all visible are removed up to 50 micron. By using different sand size zone.
Multi grade filter is also called sand filter; because the water flows through filter
medium of different sand size zone by pressure differential across the medium.
The working method is by physical means.
The main objective of MGF is to remove suspended solids and to decrease
turbidity of water that left from high rate solid contact clarification
unit/HRSCC/.To do so there are two types of MGF;
3.2. ULTRA FILTRATION
Before the water reaches ultra filtration unit/UF/enters to basket filter used as
guard that filters undesired size particles not to pass a membrane filter/UF/.If such
particles pass it closes the membrane pore. The flow rate of feed water is mostly
(44-45)m^3/hr and the product/filtered water/flow rate is 40m^3/hr. at the same
time the left water is removed at flow of 4m^3/hr.It is a tangential flow pressure
driven filtration process that separates particles on the basis of the molecular size
.The media for UF process is semi-permeable membrane.
The main objective of this treatment of water is to:
 Removal of colloidal materials like nonreactive silica, iron and Al
 Removal of high molecular weight
 Removal of virtually all particulate matter , suspended solids ,bacteria and
viruses
Generally fine particles removed by ultra filtration process.
35
4. Reverse osmosis
Before the water flows into horizontal arranged tubes that has a membrane sheet in it, it enters
another filter in order to minimize the risk of membrane sheets. Here undesired size impurity for
reverse osmosis removes. The movement of molecules from high concentration to low
concentration through semi-permeable membrane is reverse osmosis. The main objective of
reverse osmosis is to remove dissolved impurities from water by high pressure for further
treatment process. The pressure applied by high pressure pump to force feed water through thin
semi-permeable membrane is from 45 to 60 bar; thus pure water passes through it. The majority
of dissolved salts and all organic material, bacteria, and suspended solids are retained by the
membrane and are discharged from the system with the brine.
Fig.12.reverse osmosis
Degasser tower
Is a large tank that is used to remove CO2 for prevention of carbon monoxide
formation.
5. Ion exchange process
This is the last process for external treatment of water. From decantation up to this process
almost all impurities are removed. So that the water that feed to ion exchange must be clean,
colorless and odorless; low in amount of heavy metals and organics and free of suspended solids,
36
oil and free chlorine. The nature of pre treatment depends on the impurities present in water and
can involve oxidation, coagulation, flocculation, clarification, disinfection and filtration. The
main objective from here is to remove ionic compounds like sulphate ion and chloride ions.
There are three processes in ion exchange process, includes; softening, dealkalization and
demineralization. Based on this the process of ion exchange is used to;
 Soften source of hard water

 Dealkalize water with high alkanity
 Demineralize water completely
2.9.1.2. Internal treatment of water
Is the treatment of water in boiler by introducing chemicals and precipitated salts are
removed in blow down. The object of blowing down a boiler is to maintain the
concentration of dissolved and suspended solids within the specified limits to avoid
priming and carryover. In order to generate steam and electricity the water must be
internally treated as desired water to prevent scaling and corrosion which decreases
efficiency of boiler. There are different problems occur if water is not treated well;
includes carry over, hardness, scale formation, corrosion, PH etc. Some of the problems
in boiler can be solved as;
 For Ph: - To increase the ph water caustic soda flakes and tri-sodium phosphate are
used in solution form.
 For hardness:- To minimize the hardness sodium hexamet phosphate is used
 For phosphate:-To maintain the phosphate level sodium Hexameta phosphate or
sodium phosphate is used.
 For dissolved oxygen: 1) to minimize the dissolved oxygen level
hydrazine or sodium sulphite are used.
2) By increasing the feed water temp 100 to 1100c D.O. level can minimized.
 Caustic Alkalinity :- To maintained the caustic alkalinity caustic soda flakes

and tri sodium phosphate are used in solution form
37
The flow of DM water/deminerilized water/and condensate water after

external treatment enters into DM tank and condensate tank respectively. Then
enters in to hot well through tubes the over flow water returns back through
back tubes. The hot water leads into deaerator where air like O2 removes
through two stands by deaerators.For targeted objective the water enters in to
boiler; where steam generation takes place and used for many processes as
evaporator unit. Thus also produce electricity from generator when the turbine
rotates.
Figure 13.water treatment plant
2.9.2. Steam and Power Generation

2.9.2.1. Steam Generation
Steam is generated in boiler plant. Steam boiler is heart of a sugar factory. It generates 32
MW power from burning of bagasse.
Boiler means any closed vessel having water holding capacity of 22.75 L and pressure 3.5
Kg/Cm2 and above be used for steam generation under pressure, having installed mountings.
Types of Boilers
There are many types of boilers but basically they fall under two categories:
38
 Fire Tube Boiler

 Water Tube Boiler
Fire Tube Boiler
Fire Tube or "Fire in tube" Boilers: - Long steel tubes through which the hot gasses from a
furnace pass and around which the water to be converted in to steam.
Fire tube boilers have a lower initial cost, are more fuel efficient and easy to operate, but they are
limited due to lower capacity of 25 TPH and Pressures @ 17.5 Kg/Cm2.
Example - Locomotive Boiler
- Cochran Boiler
- Cornish Boiler
Water Tube Boiler
The water passing through the tubes and the hot gasses passing outside the tubes, These boilers
can be of single or multiple drum type and can be built to any steam capacity and pressure, have
higher efficiency than fire tube boilers.
39
CHAPTER THREE
3. The overall benefits
The aim of internship practice is to improve the understanding of technology students
in practical and general professional ethics for the development of our country in science
and technology. During practicing this program we have gotten some skills from the
community and the work which is exciting in the company because of practicing on are
the following.
3.1. Improving practical skills

We were grasping different practical skills in our internship days. The performance of
workers of the factory was shown practically by different sections and workers of the
factory at the spots of the machines by demonstration method in addition they share their
advantage and disadvantage experiences, exchanging ideas and standardized production
systems.
 To improve production qualities
 The effect of turbidity on sugar production
 How to check the pH variation.
 How to reduce total suspended solids
 How to control the color of the product sugar
 How to avoid solubility and hygroscope of sugar
 The purpose sulphitation and liming
40
 The maximization of sugar production and reduction of final molasses purity etc.
3.2. Knowledge gain from internship

In Wonji/ Shoa sugar factory there are so many people work together; we have asked questions
in order to get information. In this factory we made a group to observe the plants and solve some
problems, for this reason we improve our knowledge and understanding skills.We match the
theoretical part that we know with practical aspects. We have also observed the working
principle of each unit operations and manage ourselves for the future; what our job seems like.
3.3. Communication skills

Communication skill is very important for us to get full information about our needs. We
communicate with workers in the factory to develop our Knowledge.
When persons work on the process by uncomfortable condition we ask them and work together
in order to get the information about that process.
When we communicate them they exchange and give ideas for us. Factory workers are not
always use words to communicate rather they also use signs when the place is far and impossible
to listen with each other.
3.4. Team Playing

In WSSF different workers work at different team, such as; Management team, sales team,
project team and so on. For the proper function of a team each member must be committed to
mission, vision, Behavior, work style and goal. Team playing skills are very important for their
good well-being. General skill such as; Good communication, Good concentration, Fast decision
making, Self-confidence are required for each team. A company with suitably functioning devote
to a special task will always have a graph going up words, with different workers working as
different processes. Such as: cane preparation, mill juice extraction, juice sulphitation and liming
juice, juice evaporation, juice crystallization, centrifugal separation, sugar drying and cooling,
grading and weighing, sewing and packaging. The team members must believe in one another
and must be ready to work hand with hand in both adverse (unfavorable) and favorable
situations. In general, this internship program has given towards a common purpose a lot in
making student work different kinds of plan in group. This helps to share different kinds of
knowledge from different perspectives.
41
3.5. Leadership skills

We have seen the great leader in WSSF. In daily activities he always control and manage all of
the workers. Such as: processer, Mechanics, Electricians, Laboratorial, Power house controller
and water treatment examiner. This person is often a well principles individual who is focused on
a common goal. From this we have to develop a deep understanding of what is valuable to us. It
is also essential for us to understand ethics. The most top managerial position in the factory is
managing director but, in this company there is practice the above things and any suggestion can
transfer from top to bottom in addition to bottom to top. In our internship activity we have gotten
leader ship skill. Such as:
 How communicate with worker on working issue.

 How to initiate the workers.
 Employ professional worker.
 Give know how for worker about the production quality with related profit.
 How control the level of quality of raw materials.
 How give service for person.
Generally, leadership plays a key role not only in the work place (company) but also as a citizen
it has a great impart in country wise.
3.6. Work ethics

Any people should have ethics not only in the work place but also in the social life. Because of
it indicates that a good personality. In our understanding work ethics is a set of values on hard
work and diligence it also believe in normal benefit of work and its ability to enhance. However,
in this company some people loss their ethics. It may be due to personal case or the company
leadership system. Generally, work ethical employee is a key to productivity. This is to near for a
factory to be productive; all of the employees have to be disciplined and ethical in their working
environment. Generally work ethics have broad definition. Including:-
 Punctual (on time)

 Accountable and responsible etc.
 Respecting other worker.
 Keep the property of the company.
42
 Finding the development of company.

Many employers indicated that a strong work ethics ranks at the top of the Least along
with proficiency in chosen professions. Instruction to develop during work ethics Arrive
the work position on time, Put a positive spin on negative comments, Developing a
strong work ethics, Honor your commitments, Strip to do the job right the first time,
Respect what others contribute to the work environment, Got to extra time whenever
necessary to ensure that your verbal and written interaction switch others are productive.
3.7 Entrepreneurship skill

Many employers indicated that a strong work ethics ranks at the top of the Least along
with proficiency in chosen professions. Instruction to develop during work ethics Arrive
the work position on time ,Put a positive spin on negative comments ,Developing a strong
work ethics ,Honor your commitments ,Strip to do the job right the first time, Respect
what others contribute to the work environment ,Got to extra time whenever necessary to
ensure that your verbal and written interaction switch others are productive
All employees can be considered as work ethical if he/ she is, Punctual (on time), Not absent
(except during special cases), Committed for his or her work, Accountable or responsible.
In this internship program we learned small business startup skills where we should be
empowered with knowledge and skills to become effective entrepreneur. The state of being an
entrepreneurship can be realized when one engages in profitable risks and creates something of
value. It is defined by their habit of innovating and redefines market trends and limits.
3.8. Conclusion
Wonji/Shoa sugar factory is the oldest sugar factory in Ethiopia built by a Dutch company, with
a crushing capacity of 1450 TCD. The company is the leading sugar factory in using many
varieties of sugar canes having different qualities. (For instance; NCO-334, N-14, B52-298 . . .
etc.). At present, even though, the factory uses high quality canes, statistic records show that,
there is a great loss when compared with other sugar factories in Ethiopia. Regardless of the use
of the best quality canes which are up to the world standards, the factory suffers from a great
loss. As techno students we consider this a burning issue. As a result, we intended to discuss and
figure out, causes, preventions and cost analysis of loss through bagasse, filter cake, final
43
molasses and inversion, as well as dust sugar product development as a contribution through the
process for enhancing the factory’s profit.
3.9. Recommendation
 The clarified juice has much amount of impurity as we observe from samples at pan in
mirror and at discharge of batch centrifugal. But if DSM screen installed after Dorr
clarifier for more clarification of clarified juice this problem can be solved.
 There are many instruments from clarification that do not functional and are corroded
like; 3rd heater. This is economical loss by itself. So it is better to clean and use carefully.
 There is lost of cane in different areas; from plantation area up to cane
preparation/harvesting area, road falling, cane yard, under feeder
tables,mcc,acc/.Conservation of cane must be done as much as possible by close holes
 To get more clear juice as a suplementer use dry and wet cleaning methods
 As we understand there are material selection problems during installation. Because most
of the time there is breakage of internal fork conveyor between mills, some tubes lost
sugar content juice, under feeder tables supportive of fork conveyor breaks, for SO2
preparation selected material must be done based on property of it.so, During
maintenance material selection must be takes place to reduce future loss.
 In pan house we observe so many problems like; overflow of B1massecuite from vertical
monocrystallizer,overflow of melt from melter tank, leakage of valves and pumps/around
mengler pump there was much loss of sugar, molasses loss around it’s tanks like;A-
mol,B1 -mol,B2- mol,C-mol(final molasses),B1 sugar lost by over flowing from
mengler.Such problem leads to loss much amount of sugar and molasses. As a solution
operators must be control their Unit operation/must be controlled inlet and outlet
valves/to prevent overflows, Correct measures must done for prevent leakage of
pumps/parts of pump must observed, efficiency of pump must ensured/
 in RO plant there is loss of water due to leakage around pumps,Ro,basket filter. So, there
must be done corrective measurement. In addition water flows from MGF, ultra filtration
etc .especially in drainage form remove to environment is clarified and relatively much
qualified than raw water so that it is better to design another collection tank and recycled
by adding with clarified water. Since it is our resource and pass processes.
44
 Arround boiler plant there is loss of ash and bagasse.So that to prevent such loss install
glass or paper board production factory by continuously process of sugar factory.
45
References
1. Different data books from the factory.
2. Hand Book of Cane sugar engineering e-hugot 3rd edition. 1986
3. Principles of Sugar Technology Pieter Honig Vol. 1,2,3 – 1963 5. RA Sail, MF
Chaudary, ST Abbas, MI Latif, AG Khan. J. Zhejiang Univ. Sci., 2006, 7(12), 974- 980
4. SN Pandey, BD Nautiyal, CP Sharma. J. Environ. Biol., 2008, 29(2), 267-270. 7. SK
Chatterjee, I Bhattacharjee, G Chandra. India Environ. Monitor Assess. 2010, 161(1-4),
177-189.
46
Appendix
C-cane crushed
47
F-filter cake
ICUMSA-international commission for uniform methods of sugar analysis
I-intake sucrose amount
M-final molasses
Pty-purity
Qt-quintals
Rpm-revolution per minute
S-syrup amount
TCD-ton of cane crushed per day
WSSF-Wonji/ Shoa sugar factory
48

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BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULITY OF CHEMICAL AND FOOD ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING (stream of sugar)

Prepared by; ID NO.

HOST COMPANY- WONJI /SHOA SUGAR FACTORY

The duration of internship is for 45 days

Bahir Dar institute of technology Page i

Name of advisor signature

In addition to this, we need to thanks to our company Advisor;

List of figure page

1. Figure 1 company structure …………………………………………5

4. Fig.4 scale with load cell ……………………………………..…..12

12. Figure 12: reverse osmosis………………………………………………..36

13. Figure 13: water treatment plant…………………………………………..38

CHAPTER ONE ..................................................................................................................... 1

To be the leading company in sugar industry and make more customers.

Bahir Dar institute of technology Page 1

Team work bring individual and organization growth

 Continually increase the production of sugar so as to attain a production capacity of 1.5

Main Production of the company

 To produce the commercial sugars 6000 ton per day

Main Customers of Company

Main customer of commercial sugars

 Moha soft drink factory

Main customer of final molasses

1.1. WSSF Overall Organization and Work Flow Chart

Overall management related tasks

 Formulate and ensures the implementation of quality policy.

Purchasing and supplies, finance and administration related task

 Control over major supplier selection and purchasing.

Maintenance related tasks

 Maintenance of production equipment’s and machineries.

 Ensures customers are credit worthy.

 Make sure non-conforming products handling process is function well

 Study current and future market and propose appropriate actions

Figure 1 company structure

The indicator of maturity of cane

 its brix measurement

2.1. Cane handling

Cane weighing bridge

 to know amount of cane used per day

Fig. 2 Auxiliary cane carrier/ACC/

2.2. Cane preparation

 The objectives of cane preparation are:

2.3. Milling plant

Fig.3 arrangement of mill

2.4. Imbibitions water

There are three types of imbibitions. these are;

Where water only added on each mills.

Cane + Imbibition Water = Mixed Juice + Bagasse

Bagasse = Cane + Imbibition Water - Mixed juice.

The purpose of mixed juice weighing

Method of juice weighing

There are different methods of juice weighing practices in sugar industries.

3. Scale with Load Cells

Fig.4 scale with load cell

 Certain organic constituents like proteins are coagulated.

The objectives of clarification are:

a) To separate soluble and insoluble matter that can precipitate.

Essential conditions to obtain good clarification are: