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University of San Carlos

Cebu City, Philippines

ON-THE-JOB TRAINING REPORT

A terminal report submitted to the

Department of Chemical Engineering

In partial fulfillment of the requirementsfor the course ChE !"

by

YNNO C. IGUT

#une $, %&"'

0

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I( Basic OJT Information

Host Company : San Carlos )ioenergy Inc(

San Carlos Eco*one,

)rgy( Punao and Palampas

San Carlos City, +egros ccidental

Officia Contact P!rson :Elvira Despi-Catalan

#. Coordinator

/&!0 !"% ''!1

OJT P!rio" :April %2, %&"' 3 4ay %%, %&"'

Tota OJT Ho#rs :%'

Ar!a of Assi$nm!nt : -4ill and )oiling 5ouse Department

-Distillery Department

-6uality Control and Assurance Department

-Environmental 4anagement Department

%ir!ct p!r'isor : Efren A( 7romea #r(

4ill and )oiling 5ouse Department

egromea8scbiph(com

/&!0 %"! ""1'

/9$!0 1%! %$' 22$"

)ienvenido .anaman

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mailto:egromea@scbiph.commailto:egromea@scbiph.com

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Distillery Department

btanaman8scbiph(com

/9$!0 1"2 '! :"&"

#ocelyn S( Sorrilla

6uality Control and Assurance Department

;sorrilla8scbiph(com

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#aymar #(

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sales agreement =ith Petron Corporation, the countrys leading oil company and

gasoline retailer, for the supply of bioethanol( In addition to that, the company

also produces semi refined liquid sugar =hich is sold to sugar centrals in +egros

ccidental( .he company also produces po=er /electricity0, and contributes to the

+egros ccidental po=er grid using the bagasse of the sugarcane etracted from

the milling department( n a daily basis, SC)I processes a maimum of ",'&&

tons of sugarcane to produce "%',&&& liters of )ioethanol and generate a rated

capacity of around 2(4 =here at least %( 4h is to be supplied to the po=er

grid( .he production of both alternative and rene=able energy is governed by

separate contracts, apart from those eecuted =ith other government agencies

under the Eecutive )ranch(

SC)I uses sugarcane as their ra= material during the first fe= years of

operation( +egros ccidental, being the sugarcane capital of the Philippines, is

strategically the best location to put up this plant( Situated at the San Carlos Agro-

Industrial Economic >one on the Eastern coast of +egros ccidental, SC)I ta?es

advantage of both favorable =eather patterns and the best quality and yield in

sugarcane to supply the countrys fuel and energy demands, in compliance =ith

the mandates of the )iofuels Act of %&&$, other=ise ?no=n as

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money by selling semi refined liquid sugar to sugar centrals around +egros

ccidental(

4a;ority of the shares of the company is o=ned by the

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the different parameters of the process for all of =hich are carefully monitored in

the control room(

.he supervisor also sho=ed us the material balance for the multiple effect

evaporator /@igure ""0(

%isti!ry %!partm!nt

@ermentation Section Process @lo= @amiliari*ation

o Equipment, machineries G instrumentation

.he process as =ell as the different equipment in the fermentation

section =as discussed by the supervisor( .he different equipment

involved in the fermentation section are the culture vessels /@igure

"%0, pre-fermenters /@igure "!0, fermenters /@igure "0, yeastseparators and the buffer tan?( All of the =or?ing parameters

/temperature, p5, etc(0 are monitored in the control room since the

process is also automated( .he supervisor allo=ed me to have

hands on eperience in the monitoring of parameters(

o Heast propagation, cell count, etc(

Every morning /:&& A(4(0, =e are tas?ed to get samples from the

t=o fermenters( .he samples are then analy*ed under the

microscope to chec? yeast activities and also for contaminants

inside the fermenter( .he cell count of =hich is done by the 6CFA

department and our tas? is to go there and get the results( Every 1 A(4(, =e are tas?ed to get the culture broth /inoculum0

prepared by the microbiologist in the 6CFA department( .he

contents of =hich is then poured in the culture vessel "( .he

nutrient source for the yeast is also manually prepared using urea,

biocide and magnesium sulfate( During a specific time, =e are tas?ed to prepare the culture vessels(

.he preparation involves sterili*ation of the tan?s using steam

=hich can be monitored in the control room( It also involves the

preparation of the culture broth, molasses solution =ith sugar

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content of J"% bri( .he )ri of the molasses solution =as

measured using digital refractometer(

o 4aterials involved in the fermentation process, its uses

.he different materials involved in the fermentation process =as

eplained by the supervisor( .he supervisor discussed to us the

yeast used for fermentation, Saccharomyces pombe, and its

advantages and disadvantages over Saccharomyces cerevisiae( .he

nature and the source of molasses, the nutrient source and the

defoamer /.ur?ey red oil0 =as also sho=n and its uses =ere

discussed(

A manual for the fermentation section =as also handed so as to

study the different materials involved in the fermentation process

and its corresponding uses(

o Stoichiometry and 4aterial )alance

.he supervisor handed as a manual so as to study the material and

energy balance along the fermentation section(

o Process Control and 4onitoring, .roubleshooting

.he process is monitored in the control room using computers(

.he control room displays the =or?ing parameters of eachequipment and displays any change in the trend of the conditions(

.he pumps also can be automatically controlled /on or off0 in the

control room( .he supervisor allo=ed us to manage the control

room but =e are up to monitoring the operating conditions only

/chec?ing for deviations in temperature, p5, pressure, etc(0 because

the pumping system is a critical part of the process(

Distillation and Dehydration Sectiono Process @lo= @amiliari*ation /Equipment, machineries G instrumentation0

.he distillation process and the different equipment used =as

eplained by supervisor( .he process from the buffer tan? of the

fermentation section to the distillation columns /primary column,

dealdehyde column, rectification column, recovery column( @igure

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"'0 until the molecular sieve =as discussed by the supervisor( A

process flo= diagram =as also printed to have a full grasp of the

process(

.he =hole process =as also toured together =ith the supervisor(

ther equipment present such as the plate heat echangers /@igure

"$0 and the cooling to=ers /@igure "20 =ere also toured and the

uses of such =ere eplained(

o 4aterial and Energy )alance

A manual =as handed by the supervisor for us to study the mass

and energy balances across the distillation process(

o Process Control, 4onitoring and .roubleshooting

.he =or?ing conditions of the process =ere monitored in the

control room /@igure ":0( .he supervisor also let us manage the

monitoring of the parameters(

)#aity Contro an" Ass#ranc! %!partm!nt

eighing 5ouse

o A =eighing bridge /@igure %"0 is used to measure the =eight of the

sugarcanes being delivered to SC)I( .he =eighing bridge is also used to

measure the incoming molasses and other materials /bagasse, salt, coconut

shells, etc(0( e are tas?ed to =eigh these materials and also placing the

results in the computer system(

Cane Acceptance and Analysis

o .he cane acceptance part involves the use of the machine called corer

/@igure %%0 in =hich it is used to obtain sugarcane samples from the

delivery truc?s(

o .he cane analysis part involves the analysis of the absolute ;uice, the ;uice

etracted from pressing the sugarcane samples using hydraulic press( .he

analysis uses an apparatus called Saccharomat, a digital polarimeter to

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measure the apparent purity and bri of the sample( 4oisture content is

also analy*ed in this part(

4ill and )oiling 5ouse Section

o .he 4ill and )oiling house lab involves the analysis of the sugar solution

samples from the 4ill and )oiling house department( .he analysis

includes measurement of the sugar concentration /)ri0, the apparent

purity, p5 and turbidity(

)oiler Section

o .he boiler section involves the analysis of the boiler house =aste=ater and

also the =ater used to generate steam( .he analysis involves the

measurement of the silica content of the =ater and the chemical oygen

demand /CD0(

Incoming Process 4aterials Sectiono .he IP4 section involves the analysis of the molasses /sugar content, p5,

etc0( Analysis of the sugar content =as mainly done by .otal Sugar as

Inverts analysis( .he unfermentable sugar concentration =as also analy*ed

using the Unfermentable

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.he process of anaerobic digestion =as eplained by the

supervisor and operators( .he supervisor toured us to anaerobic

digestion plant and eplained to us the different equipment used

such as AD tan? /@igure %0, the lamella clarifier /@igure %'0, the

degasser and the biogas storage tan?s( .he input and output

materials and ho= they =ere disposed =ere also discussed( .he

)iogas plant flo= =as also eplained by the supervisor and

operators(

o Anaerobic Digestion Control and 4onitoring

.he p5 of the incoming spent =ash to the AD tan?, the solution

inside the AD tan? and the overflo= =ere analy*ed every hour(

.his part of the training also involves the analysis of the Chemical

ygen Demand /CD0 of the incoming spent =ash and also the

eit =ash from the AD tan? and the .otal Kolatile @atty Acids /.-

K@A0 content and al?alinity of the =ash inside the AD tan?(

o Environmental 4anagement Practices

.he manager eplained to us the =aste=ater treatment flo=

diagram( e also toured the compost area /@igure !"0 =here the

materials for composting are the mud press from the boiling house,

ash and distillery spent =ash( e also toured the offsite lagoons used for the untreated spent

=ash and the lagoon for the =aste=ater from the boiler house

/@igure !%0(

IK( +arrative of earning Acquired .hrough the #. Eperience

Mill and Boiler House Department

@irst, I =as eposed in the milling department =here I spent : hours( .he

milling department involves several processes( @irst is the crusher part =here the

sugarcanes are reduced in si*e by the action of cutters( .he crushed sugarcanes

are then passed to a leveler =hich uniformly feeds the crushed sugarcanes to the

etractor( .he etractors are termed as for? crushers /@igure '0( .hese for?

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crushers first etract ;uice from the sugarcane =ithout any additives( .he

etracted ;uice from this part is called the absolute ;uice and is stored in the ;uice

tan?( .he bagasse /leftover fibers of sugarcanes0 from the first etraction are

passed to the net set of for? crushers /second stage0 in =hich they are mied

=ith =ater so as to dissolve the remaining sugars( .he principle of solid liquid

etraction can be applied in this part( .he bagasse after the second stage is passed

again to another set of for? crushers /third stage0 =here pure =ater is further

added to increase the concentration gradient and etract more sugar from the

bagasse( @inally it is passed on to the fourth stage /@igure $0 =here the eiting

bagasse is no= fed to the boiler house so that it can be used as fuel for po=er

generation( It is really evident in the plant, that they ma?e the most out of their

ra= material(

.he 4illing department also includes the boiling house( .he boiling house

also involves several processes( @irst, the etracted ;uice from the different stages

of etraction are placed in a heater for clarification purposes( .hen the heated

;uice is passed on to the liming tan? =here Calcium ide /Ca0 is added also for

clarification purposes and so as to regulate the p5 of the solution( .he optimum

p5 should be around $(:-2(%( .hen the solution is further heated to "&&oC and is

placed on an isothermal clarifier tan?( At "&&oC, the ;uice from the solution is

separated from the heavy solid particles also termed as mud( .he ;uice from the

clarifier is termed as clear ;uice =ith sugar concentration of approimately "'

bri( )ri is a measure of the sugar content of the solution( .he clarified ;uice is

no= passed to the multiple effect evaporators =ith ' effects /@igure 20( n the

other hand, the settled mud is passed through a rotary drum filter /@igure 10 in

=hich the filtrate is also fed to the evaporators( Using the concepts learned from

the academe, the filtrate has the same concentration as the clarified ;uice for theyare in equilibrium( .his part of the process caught my interest for =e have studied

theories and design parameters for rotary drum filters in ChE %', Introduction to

Particle .echnology and design for multiple effect evaporators in ChE %, 5eat

and 4ass .ransfer Processes( .he type of evaporators used is a vertical tube

evaporator( It =as not hard understanding the flo= of process at this part because

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of the fact that this =as discussed in my ChE % class( .he aim of the evaporator

is to reach a syrup concentration of $' bri by removing =ater from the clarified

;uice( A bri spindle is used at the 'theffect to measure the bri of the overflo=(

e also got the chance to loo? at the theoretical material and energybalances prepared by the Design Engineer himself /@igure ""0( .he concept of

conservation is truly the governing principle for such design( It =as not a simple

in and out process but there are many recycle streams placed to conserve energy( I

tried also to connect the diagram in the actual setting but it =as definitely hard

especially because the piping systems are too hard to follo=(

Distillery Department

.he net department that I have been into is the distillery department

=here I spent 22 hours( At first, I =as introduced to the supervisor and the

operators of the section( .he distillery department involves the fermentation and

the distillation section =here each section is manned by a single operator and

guided by the supervisor( I =as very ecited since =e have been designing

theoretical fermenters in ChE%!, Engineering of 5omogenous Chemical

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and preparing the nutrient mi( After the retention time, it is epected that the

yeasts consumed the nutrients inside, have gro=n and multiplied so that they

should no= be transferred to CK-% for further multiplication and gro=th and then

to the CK-!( Each of the vessels before the gro=th and multiplication period must

be sterili*ed using steam( I have tried operating the sterili*ation part of the CK-!

and CK-% and monitoring these operation through the computers in the control

room( It is actually good that each vessels are no= automated for any changes in

the operating conditions /e(g( temperature, miture level, etc(0 can be closely

analy*ed( .he operators are very critical in the =or?ing conditions of the process(

Any deviations from the normal =or?ing conditions are immediately attended to(

After the sterili*ation, the culture media is prepared by filling the tan? =ith

diluted molasses /J"%-"$ bri0( Concentrated molasses is fed to the tan?s /J:'

bri0 =hich is simultaneously added =ith =ater to obtain the desired

concentration( I have also tried preparing the molasses solution in the culture

vessels and sadly, the process is trial and error( ater is fed =ith the molasses and

then measuring its bri in a specified volume( e have suggested to ma?e mass

balance around the culture vessels so as to ?no= the theoretical amount of =ater

and molasses needed and they said that they =ill ta?e it into consideration(

.he yeasts from the CK-! are then transferred to t=o pre-fermenters /P@s0

=or?ing in parallel( .hen after the specified retention time, the contents from P@"

and P@% /@igure "0 are transferred to the @ermenter "( .here are actually t=o

fermenters coined as @" and @% /@igure "'0 both having a capacity of ",%'& m !

/",%'&,&&& 0( .he method of introducing the solution in @% is by cascading

motion, meaning the solution in @" =ill enter a pipe connecting @" and @% once

the contents in @" reaches a certain level( A syrup tan? =as constructed initially

for storage of syrup but since the ra= material for fermentation is no= molasses,the syrup tan? is converted into another fermenter namely @!( .he solution from

@" and @% =ill also cascade to @!( All fermenters have a retention time of

approimately !$-: hours( .he solution from these fermenters is then transferred

to the buffer tan? and is passed to the yeast separators and then to the storage tan?

for distillation(

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.he distillation process for me is one the processes that I loo? for=ard to

seeing in the actual scale( .he distillation process in SC)I is continuous(

5onestly, I epected that the stripping and rectification part is connected in a

single column yet in SC)I, it is separated( In the academe also =e are used to

designing distillation columns =ith %& stages at maimum yet the number of

stages in the stripping section alone is 2%( .he distillation process also ?ept true in

its schematic diagram in the sense the condensers are located at the top and the

reboilers at the bottom ecept for the reflu tan? =hich is located at the bottom( It

=as interesting eploring the distillation columns and tracing the entry and eit of

materials involved in the process( .he actual setting is really harder but the

principles governing the process is still the Kapor-iquid equilibria of ethanol and

=ater miture( .his =as also emphasi*ed in the eplanation of our supervisor( .he

distillation section has columns in order namely the primary column,

dealdehyde column, the rectification column and the recovery column /@igure

"0( ne smart thing in the distillation section for me is that the process ends in a

molecular sieve =hich uses ceramic *eolites =ith pores small enough to trap

=ater moisture and recover J11(:B of absolute ethanol( I have also seen the

material and energy balances around the column and =hat ama*ed me is the

actual conservation of energy specifically the heat energy( @or eample, the heat

from the vapor output of another column is used to heat the incoming solution in

the reboiler( .his in return condenses the vapor product( .he true sense of

conservation and economics is observed in the distillery(

Quality Control and Assurance Department

I spent '$ hours in the 6uality Control department( .he quality control

department is divided into 2 parts namely the =eighing house, the cane

acceptance and analysis section, the mill and boiling house section, the boiler

section, incoming process materials section and the fermentation and distillation

section( I have been in all 2 sections and have =or?ed for : hours each section(

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Doing the =or? of an analyst is definitely not li?e my analytical chemistry

laboratory( .he pace is very fast and every movement must be precise especially

because =e are dealing =ith eplicit amounts and there is no second trial( Every

hour =e get ne= samples to analy*e( Some of the samples li?e the molasses ta?es

an hour to analy*e and during that hour there are samples coming in( hat I have

learned from the 6C department is the art of multitas?ing( @or eample, I am

doing an analysis on the alcohol content of the sample( .he titration is automated

and =ill ta?e several minutes that is =hy the total cell count /.CC0 in the

fermenters can be done =hile =aiting for the results( .his s?ill I ?no= =ill help

me in the future to do my tas?s =ell(

It =as truly a very ?no=ledgeable eperience especially because the

analysts eplained to me the theory behind the analysis and taught me proper

laboratory techniques li?e the proper handling of pipets and proper titration etc(

.he analysts also taught me to use advanced chemistry apparatus li?e the

Saccharomat, a digital polarimeter used for measuring the apparent purity of the

syrup sample and the spectrophotometer =hich is used for measuring turbidity

and silica content /ppm0( I also had the chance to =or? =ith several heavy

machineries li?e the corer machine =hich is used to get sugarcane samples, the

hydraulic press =hich is used to etract absolute ;uice from the sugarcane samples

and the =eighing bridge =hich is used to =eigh the contents of the sugarcane

truc?s(

ne of the most nerve-=rec?ing part in my eperience in the 6C

department is the part =here I get to do advanced analysis =ithout any

demonstration and ;ust reading theories behind the analysis and the actual

eperimental procedure( Personally I =ould say that it all boils do=n to trust( I

believe that I have been diligent enough to not miss out on the important points in

the analysis that I have performed to the point =here they gave me tas?s in =hich

they thin? I can do =ithout their supervision( I managed to do .otal Sugar as

Inverts /.SI0 analysis =ithout any eperience in titrating a sample =hile ?eeping

it in contact =ith a heating surface(

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.he eperience =as also ama*ing because the manager treated us li?e

regular analysts( She reprimands us =henever =e missed out on important points

during the analysis =hich in a =ay is very helpful so that =e =ill never ma?e the

same mista?es again( +ot all analysts in the 6CF6A department are Chemistry

ma;ors but they are very critical on their analysis(

Environmental Management Department

I spent 1" hours in the Environmental 4anagement Department /E4D0(

As they say, the most critical and important part of every plant is not the

production but the =aste disposal( 5aving molasses as their ra= material, the

plant is producing thrice the amount of =aste because the plant =as originally

designed for syrup( .he plant is equipped =ith an Anaerobic Digester System

/@igure %0 =hich can accommodate only %&&,&&& Fday of spent =ash /=aste

from the distillery section0 but during the usage of molasses, the =aste rose up to

'&&,&&& Fday( )ecause of this, the E4D accommodated & hectares of land so

that they can store the untreated spent =ash and do natural decomposition of

organic matter( .he problem no= is the foul smell it brings =hich at abnormal

=eather conditions covers the =hole city( .he main lesson I obtained from theE4D is trying to balance =aste production =ith the desired product production( It

is not al=ays good hearing that the production has increased for it could also

mean that the =aste production also has increased( @urthermore, I ?no= this

learning =ill help me soon in my future endeavors as a Chemical Engineer

especially if ILm in charge in the design part(

.he E4D supervisors and operators toured us to the Anaerobic Digester

and =e even climbed the tan? to see the different safety devices installed at thetop( .here are pressure brea?ers and vacuum brea?ers present at the top( All these

safety devices are used to monitor the biogas production( .he AD tan? is used to

convert the organic matters present in the spent =ash to methane biogas =hich is

also further utili*ed as additional source of fuel in the boiler house(

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.he 4anager discussed to us the design for the Anaerobic Digester tan?

/@igure %'0( .he design as I quote from him is the first and last because it is not

the usual AD design( Instead of a single room tan?, the inside is divided into five

compartments( .he AD ho=ever does not function the =ay it should have as it

=as originally designed( Some modifications =ere done so that the AD can

function li?e an Upflo= Anaerobic Digester .an? /UAS)0( .his goes to sho= that

equipment designs can change from time to time depending on the significance

and efficiency of operation(

During a specific time, =e get samples from the AD tan? to analy*e its

volatile fatty acids /K@A0 content, chemical oygen demand /CD0 and

al?alinity( .hese factors are important for the flo= rate of =aste into the AD is not

constant and =ill depend on these factors( @or eample, if the K@A content is

high, the flo=rate should be decreased for the acidogens =ill produce more acids

that the methanogens cannot accommodate( .his can also lead to a decrease in p5

=hich the methanogens are sensitive to(

I have also learned in E4D the importance of team=or? in accomplishing

tas?s( .he manager itself is very hands on in the actual operation(

K(

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astly, I believe that my training from the University of San Carlos has been

an enormous help in understanding the different processes in SC)I( .he things

going on in the different equipment and analysis are not that hard to understand

because of the theories learned in the academe(

KI( Annees

17

Figure 1. Safety shoes, hard hat and ocial practicum I.D.issued by the San Carlos Bioenergy Inc.

4ill and )oiling 5ouse Department

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18

Figure 3. Belt coneyor of the !ill and Boiling "ouse

Department

Figure #. Serice Bus of SCBI.

Figure $. For% crushers for &uice e'tractionFigure (. Belt coneyor in the !illDepartment )Closer loo%*

Figure +. Bagasse in the nal stage ofe'traction. -hese are then deliered to theboiler house as fuel.

Figure 1. !ill and Boiling house control roomFigure /. 0otary Drum Filter Figure . 2aporator indo.Figure 4. !ultiple e5ect eaporators )$ e5ects*

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19

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1

2

3

1 2

@ermentation Section

20

Figure 11. -heoretical !ass Balance along the multiple e5ect eaporators.

Distillery Department

Figure 1#. Culture essels 1, # and

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1 2

Distillation Section

21

Figure 13. 6re7fermenters 1 and #.

Figure 1#. 6late heat e'changers for cooling of thesolutions in the distillation section.

Figure 1(. Fermenters 1 and #.

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22

Figure 1$. Continuous distillation columns.

Figure 1+. 6late "eat 2'changers

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23

Figure 1. Distillery section control room.

Figure 14. Cooling toers for the Fermentationsection )-op* and for the Distillation section)B8--8!*

Figure #. 6umps and other accessories.

Figure 1/. Bioethanol storage tan%s.

6CF6A Department

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24

Figure #1. 9eighing house and theeigh bridge.

Figure ##. Corer machine used in theCane :cceptance part.

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25

Figure #3. ;uality control and analysis laboratory eamella Clarier.

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26

Figure #+. Sand Filters. -hese are used to clarify theasteater from the boiler house.

Figure #. Biogas storage tan%. -he Biogasproduced in the :.D. is stored here and is furthertransferred to the boiler house as additional fuel.

Figure #4. Cartridge lters. Claries furtherthe treated asteater from the sand lters.

Figure #/. SCBI=s 0eerse 8smosis )08*. ?sed to clarifyspent ash from the distillery but the operation asstopped since the maintenance cost is ery e'pensie.

Figure 3. ?ltraltration unit. -he nalstage after the reerse osmosis system.

-he treated ater that comes out form thise

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Figure 31. Compost area of the 2nironmental !anagementDepartment.