Internship Report

Uzair Malik

Internship Report
FATIMA SUGAR MILL,KOT ADDU
[A practical effort to investigate the industrial life and its
difference from curricular life.]

Internship Report

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Internship Report

Abstract
Industry is a place where an internee deals with an assortment of Chemical techniques which
are engaged in various houses such as , Mill House, Boiling House, Process House etc.. After
working as an internee here, now I am utterly competent to manage and work in such houses
and give suggestions for the advancement of their performances in future. Practically I have
gained a lot of acquaintance about machines and practical verve too. Before I was only
proverbial with the names and functioning of machines but here I have seen their true
working and practical execution excessively.

Signature

G M (P&C)

Department of Chemical
Fatima Sugar Mill, Kot Addu

DEDICATION

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It is my pleasure to dedicate my internship report to my beloved parents, who are the most
valuable asset in my live and without their prayers and pure love I was unable to complete
not only this internship but also my whole life achievements.

ACKNOWLEDGEMENT

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First of all we present our gratitude to the almighty ALLAH, the Merciful, and the Most
Beneficent, who is the Supreme Authority, Lord of the World, guides in darkness and helps in
difficulties. All respect to the Holy prophet Muhammad (peace be upon him), who enable us
to recognize our creator and the golden principles of Islam.
I would like to acknowledge the knowledgeable guidance of my internship advisor
Ch.Muhmmad Hussain GM (P&C), Sajid kaleem PM , and all the Senior and Assistant
Engineers who led me throughout my internship and provided me every possible mentoring
and guidance to understand the theme of internship. Their guidance during the completion of
the report cannot be valued in words. I owe a sense of utmost gratitude to the management of
Fatima Sugar Mill, who gave me all the valuable support and opportunities to complete Fourweek internship program and compile this report.
Their cooperation and supervision is also acknowledged from core of my heart.

Internee,
Uzair Malik

Company Bio data:

The company was incorporated as a Public United Company In 1988 and certificate of
commencement of business was granted in 1989.

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The project was financed by ICP-Led consortium consisting of NBF ABL, MCB, UBL and
HBL. Initially the sponsors of the company injected a capital of Rs. 128.459 million and
subsequently it was enhanced to Rs. 720.478 million at different intervals.

Mills basic plant & machinery was acquired and installed by The Heavy Mechanical
Complex, Taxila (A State Engineering Company), however, other vital equipments such as
turbines, gearboxes etc. were imported from Germany and United Kingdom. The plant was
started with initial crushing capacity of 4,000 M.Tons per day and it was subsequently
enhanced in four phases. Currently the plant is working at the crushing capacity of 9,500 M.
Tons per day.
The company is recognized in the local and international market as a fine quality producer of
white refined sugar & molasses and also holds a substantial share in the local market. The
company is also engaged in the export of white refined sugar and molasses and is
contributing to the national economy in the form of foreign exchange.
In pursuance to its quality consciousness, the company has been accredited ISO-9001
certification by SGS & Ukas Quality Management and GMP-13 certification by Skal
International, Member of Control Union World Grop. The company has very clear goals and
objectives and is striving to achieve competitive advantage by adopting latest technology &
innovations, consistent training of its technical staff in the field of sugar industry and through
appropriate strategies

Chemical Department
Chemical engineering is the branch of engineering that deals with the application of physical
science (e.g., chemistry and physics), and life sciences (e.g., biology, microbiology and
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biochemistry) with mathematics and economics, to the process of converting raw materials or
chemicals into more useful or valuable forms. In addition to producing useful materials,
modern chemical engineering is also concerned with pioneering valuable new materials and
techniques such as nanotechnology, fuel cells and biomedical engineering.
Requirements:
Chemical engineering largely involves the design, improvement and maintenance of
processes involving chemical or biological transformations for large-scale manufacture.
Chemical engineers ensure the processes are operated safely, sustainably and economically.
Chemical engineers in this branch are usually employed under the title of process engineer. A
related term with a wider definition is chemical technology. A person employed in this field is
called a chemical engineer
Functions:
The main function of this department is to test the quality of sugar, with the help of this
department sugarcane is crushed in to white refined sugar. The main goal of this department is
to maintain a quality standard.
This department plays his role during whole the process because different types of chemicals
are mixed in sugarcane juice for making the juice in to liquid shape. This department checks
the quality during the whole crushing process. This department also plays a imperative role in
the production of sugar in the mill because the back bone of sugar industry is chemical
department a cane can never be directly converted into sugar without making its several
reaction with several chemicals now which chemicals should be used and which should not be
only a chemical engineer knows it better amongst other for e.g. If there is a wrong reaction then
cane will not be converted into sugar beside it ,it will be converted into something different
which is not admirable because it will cause a great loss to industry which is not good for not
even country not even for any industry.
Chemical department is working under very experienced person who has vast knowledge
about chemical. All the chemists are very experienced and professional.

Different Sections of Plant:

Actually FSML is a quite big plant and it cant produce a enormous amount of sugar if its
work is not divided so here is the first step for this by isolating the consignment of this mill
into different houses.
There are 4 houses in which the complete load of the mill is divided:
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Mill House
Boiling House
Process House
Power House
Now I will tell you practically about these houses that what I have experienced in these quite
a few houses and what I have gained after working here for one month and what are the
defects which according to me should be detached from here to perk up the competence and
production of Mill.
On the following page all the tasks assigned to me by the Head of my Department are
described briefly and further report is assembled according to that given schedule.

Cane Yard
Cane is unloaded in cane yard.
Capacity of cane yard is 6000 ton.
Firstly we weigh the cane and loaded in the cranes.
Through conveyors cane travel towards the mill house.
Firstly it is levelled through the leveler.
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Then it is passed through the cutters.

Cutting and Shredding

Here are three cutters.

1. cutter cum leveler.
2. two different capacity where it is cut into many pieces with specific angles according to
our own will.
3. then it is passed through shredder where pieces of cane converted into its cells.
Then it is entered into the MILL HOUSE

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Mill House
Mill House:
Main purpose of the mill house is to extract the maximum juice from cells of cane.
For this purpose we pass these cane through rolling mills.
There are six mills in mill house.
Cane fibers passed through these mills in such manner as shown in the figure.

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When these fibers enter in first mill then (70 to 75)% juice is extracted and then
These fibers enter into second mill and so on..
Hot water is showered on it when it passes from second mill, similarly when it is passed from
third,fourth and fifth mill.
This water is known as imbibation water.
Juice is collected in mixed juice tank and bagass from sixth mill goes to the boilers through
elevator, as a solid fuel in boilers.
Juice is pumped through pumps from mixed juice tank to rotary screen for screening purpose.
After rotary screen it is collected in a tank from where it is pumped towards the heaters for
heating purpose.

Note
( A typical mixed juice from extraction will contain perhaps 15% sugar and the residual fibre,
called bagasse, will contain 1 to 2% sugar, about 50% moisture and some of the sand and grit
from the field as "ash". A typical cane might contain 12 to 14% fibre which, at 50% moisture
content gives about 25 to 30 tons of bagasse per 100 tons of cane or 10 tons of sugar.)

Juice and baggasse is the final product of mill house. Juice is sent to the process house for
the preparation of sugar and baggasse is sent to boiler house through conveyers which is used
as a fuel in boilers.

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Steam Generation

Boilers
In simple words boiler is the type of heat exchanger.
Boiler is a close vessel in which water or other fluid is heated.
There are many types of boilers such as

Fire tube boiler

Water tube boiler
FBC Boiler
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AFBC Boiler
PFBC Boiler
Waste heat Boiler

Atmospheric Circulating Fluidized Bed Combustion Boilers

Here we use water tube boiler for the generation of steam having pressure 22 kg/cm 2 and
temperature is 2800C.
There are four boilers. Three of 60 ton and one is of 20 ton. Flow rate of baggasse is
400ton/h.
Water Tube Boiler
In water tube boiler, boiler feed water flows through the tubes and enters the boiler drum. The
circulated water is heated by the combustion gases and converted into steam at the vapor
space in the drum. These boilers are selected when the steam demand as well as steam
pressure requirements are high as in the case of process cum power boiler / power boilers.

The features of water tube boilers are:

Forced, induced and balanced draft provisions help to improve combustion efficiency.
Less tolerance for water quality calls for water treatment plant.
Higher thermal efficiency levels are possible

Major Parts of boilers

1. Furnace
2. Economizer
3. Super Heater
4. Steam Drum.

1. Furnace

Bagass through elevator forward into the furnace with flow rate of 400ton/h.
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In the inner surface of the furnace tubes are present in which water is circulated.
Bagas is burn in the furnace which produce heat and water convert into steam.

2. Economizer
In boilers, economizers are heat exchange devices that heat fluids, usually water, up to but
not normally beyond the boiling point of that fluid. Economizers are so named because they
can make use of the enthalpy in fluid streams that are hot, but not hot enough to be used in a
boiler, thereby recovering more useful enthalpy and improving the boiler's efficiency. They
are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler
to preheat the cold water used to fill it.

3. Super Heater
The steam which comes in the second portion of steam drum is dry steam. But we need super
saturated steam for use in the mill for different purposes. So this is done in super heater.
There are bent tubes in this portion. Dry steam is there in these tubes and is heated to a temp.
of 350-3800C. Now it is superheated steam.

4. Steam Drum
There are three portion of steam drum,
1. water portion
2. dry steam portion
3. super heated steam portion.
Water comes from supply in the water portion it forwards into header and is heated in water
tubes and convert into steam and rises up ward.
It changes into dry steam and is collected in the dry steam portion.
From dry steam chamber it is sent to the super heater and superheated steam finally comes
into superheated portion. It is then distributed to different places to perform its function
through lines.

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Boiling House

Juice Section
Primary Heating
Juice is entered into the heaters, firstly in which, known as primary heaters.
To increase the economy we also pass it through the vapor heater from there is comes into the
primary heaters as pre-heated.
There are four primary heaters through which juice is passed and heat up to
65 -800 C then it goes to the defecation tanks.

Lime slacker
In lime slacker we add Cao according to crushing rate.
We add lime less than one percent of crushing rate.
In this mill crushing rate is 9000 ton per day so we add Cao 4.1 ton per hour in it.
After preparing Cao we dozze it into reaction tank.

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Defecation Process
There are three defecation tanks for defecation process.
Heated juice come into defecation tank and we treated it with cao here.
Main purpose of these tanks is to control the PH of juice.
When it comes its pH used to 5.5 to 6.5, after treatment its pH will be 7.2 to 8.0.
After treatment in defecation tank juice come to the secondary heaters.

Secondary heaters
There are three secondary heaters.
Used to increase the temperature of juice.
Here temperature raised up to 95 to 1050C.
If juice is not heated up to required level then it will not properly clear in the
Clarifiers.
Through pumps juice forward towards the clarifiers for cleaning purpose.
Juice is divided in three different clarifiers of different capacities.
Clarifiers

Before clarifiers juice come into flash tank from where non condensable gases is removed.
Then we add the solution of poly electrolyte also known as Talosep with the help of dozing
tank.
By adding this chemical dissolved impurities is settled down in the bottom of each
compartment from where through diaphragm pump it is collected in mud storage tank.
From mud storage tank it comes into the mud mixer from there we mix baggacillo. Then we
drag it into vacuum filters. Here are five vacuum filters which extract further juice from mud

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by creating vacuum through vacuum pump. Hot water having 80C to 85C temperature also
showered.
There are three portions of vacuum filter
1. High vacuum
2. Low vacuum
3. No vacuum
In high vacuum portion juice is extracted and through tubes it comes toward the header.
Header is connected with a plate known as Teflon plate which is further connected with pipes
through their juice forward towards the defecation tank and the mud which is sticked with the
surface of vacuum filter is separated through scraper and with the help of conveyors its is
discharged from the mill at certain height in the trucks or etc..
The clear juice from the clarifiers forwards towards the rotary screen.
Here the pH of clear juice is 6.5-7.2. and temperature is 85-950C.
Here are two rotary screens which filters the juice and this clear juice forward towards the
clear juice tank and then towards the pre-heater for further heating so that evaporation
process carried out easily.
In pre-heater its temperature increases up to 105 to 1100C.
After pre-heater juice forwards to the evaporators.
The clear juice has probably only 15% sugar content but saturated sugar liquor, required
before crystallization can occur, is close to 80% sugar content. Evaporation in a steam heated
multiple effect evaporator is the best way of approaching the saturated condition because low
pressure water vapors can be produced for heating duties elsewhere in the factory.

Evaporators
Types Of Evaporators
Basically six types of evaporators are used according to requirement.
1. Falling Film Evaporators.
2. Rising Film Evaporators.
3. Forced Circulation Evaporators.
4. Plate Evaporators.
5. Compact Evaporators.
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6. Thermal and Mechanical vapor Recompression.

Typical Applications of Evaporators

1. Product Concentration.
2. Dryer feed pre concentration
3. Volume Reduction.
4. Water or Solvent Recovery
5. Crystallization
Here are two basic types of evaporators used for process.
Three evaporators are falling film evaporators and five are Robert type evaporators.
FFEs have 6000m2,5000 m2.4300 m2meter square heating surface area and
Robert type evaporators have 4000 , 2000. 1800, 1200 , 1000 meter square heating surface
area.
juice from pre-heater enters into the FFEs.
Through distributers juice is spread into evaporators tube by making film on the surface of
the tubes. Steam is injected on both side of the evaporators at the 75% of clandria so that
properly heating can done.
Through steam evaporation takes place and juice become dense.
There are two buckets in the bottom which receive the juice.
1st bucket receive directly and 2nd receive the over flow of 1st. juice from 2nd bucket again send
towards the tube side and juice from 1 st bucket send towards the 2nd evaporator for further
concentration and so on.
In shell side vapors goes toward the 2nd evaporator as a 1st effect vapor for heating purpose.
Before forwarding towards 2nd evaporators it passes through the demister from where juice is
separated from vapors and non condensable gases removed through pipes.
While in rising film evaporators juice is pumped from bottoms to the tube and steam is
injected on both sides of calendria in the center of tubes a spherical pipe is present through
over flow of tubes forwards towards the next evaporator and so on.
After passing through these evaporators juice convert into syrup and is collected in syrup
receiving bottle.
In last evaporators juice boils also due to vacuum which is created by condensors.

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Pan Section
There are two types of pan are using for sugar making process.
1. Continuous Pans
2. Batch Pans

Batch Pan
In batch pans we prepare grain for process in continuous pans.
We develop crystals of sugar and feed the crystals in continuous pans to develop the crystals
immediately in continuous pans.

A Batch Pan
In A batch pan crystals are prepared through syrup , mother liquor or A-heavy and seed
through seed crystallizer.
After preparing grain for A-continuous pan it is dozed in A-continuous pan.

A-continuous pan
Syrup from receiving bottle fed into A-conti pan and grain from A-batch fed into the A-conti.
Due to these grains , crystals in continuous pan develop in short time and we can get
maximum crystals.
Here boiling also done due to vacuum which is created by condensers.

A massecuite boiling
1. Injection water temperature should be 25c to 30c.
2. Boiling should be efficient
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3. Brix range should be from 92 to 97

4. Seed quantity should be sufficient
After boiling in A-continuous pan massecuite is drawn into U-crystallizer.
In U-crystallizer there are mixing arms in it and the main purpose is that properly mixing of
grains and syrup so that maximum crystals can be developed.
After U-crystallizer messecuite forwards towards the pug mill after pug mill it forward
towards the raw continuous centrifugal.
Continuous centrifuge
1. Nickel screen should be in good condition
2. Water temperature should be 80 to 85 c
3. Raw liquor Brix should be 60 to 62
4. Raw liquor temperature should be 85 to 88 c
5. centrifuge has 1600 rpm

In centrifugal crystals and A-heavy is separated.

Mainly A-heavy sent to the B-continuous pan. It is also sent towards the A-batch and seed
crystallizer to prepare seed.
The crystals from centrifugal sent to the re-melter here it convert into the magma.
From magma mingler it forward to the liquor heater for heating purpose.
B massecuite boiling
1. Vacuum should be from 23in Hg to 26 in HG
2. In B pan brix should be 96-99
3. Seed quantity should be sufficient
The liquor from raw centrifugal is separated and forward to the B-continuous pan for further
curing.
In B-batch pan we prepare feed by using seed.
Here also boiling done under vacuum and through steam.
After boiling, the massecuite forward towards the vertical crystallizer by passing through the
U-crystallizer.
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cold water tubes are passed in the vertical crystallizers where through cooling process
crystals are developed.

Pug mill
Pug mill divided the flow.
It works just like a station.
It provides massecuite in the centrifugal

Centrifugal
In centrifuges crystal of B-sugar and molasses separated.
Molasses forward toward the C- continuous pan and B-sugar used in A- continuous pan.

C-Batch pan
In c-batch we prepare c grain which is used in c-continuous pan.
Then here c-massecuite is prepared.
C massecuite boiling
1. Vaccume of c pan should be 23 in Hg to 27 in Hg
2. Seed quantity should be sufficient
3.In C massecuite brix should be from 99 t0 103
After boiling it cools down in u crystallizer then it passes through 4 to 5 vertical crystallizer
where through cold water its further cooling is done and crystals developed.to develop further
crystals it passes through pug mill and finally it is spun in the centrifuges for separation of
molasses and crystals.
Crystals known as c- sugar and forward towards the foreworker and then centrifuges by
centrifugals here we obtain final molasses from which we can not extract further sucrose and
crystals forward to the after worker for further curing. The sugar we get after curing feed into
seed crystallizer

Talo Clarifier Section

1. Raw sugar temperature should be 80-90c
2. Chemical dozzing according to need
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3. Clear liquor pH should be 7.2 to 7.3

Heating is done because in next step we have to treat it with different chemicals such as
phosphoric acid , talo float , talo flake etc.
From centrifugals the color or crystals is brown thats why it is also known as brown sugar.
But after treatment its color change into white.
After chemical dozing liquor forward to the liquor evaporators from there concentration of
liquor increases.
After evaporation process liquor is stored in liquor storage tank.
From liquor storage tank liquor is forward to the refine batch pan.

Refine Pan
1.Vacuum of refine pan should be 26 in Hg
2. Seed should be in appropriate quantity
3. Vapor pressure of pan should be 0.2 to 0.5 kg/cm2
4. Brix should be from 91 to 92
Here we also grow maximum crystals in limited time and send it to the refine centrifugal.
We separate mother liquor and crystals in it.
The Mother liquor is known as Run Off.
Run Off again send to the refine batch for growing the crystals of next stage batches.
Run Off send to the refine batch four time then it is called rejected run off and is send to the
storage tanks from where it is used for A or B grain as per house requirement.

Refine centrifugals
1. Temperature of washing steam should be 150 to 160 0C and pressure should be 4 bar
2. All the nozzles should be clean
The crystals from centrifugal are wet and also known as wet sugar and send to the hopper

Hopper
A storage container used to dispense granular materials through the use of gravity, sometimes
assisted by mechanical agitation
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From hopper it forward through elevators to the dryers.

Dryer
In dryers hot dry air of radiator having near about 2 kg pressure and 150c is injected for
drying purpose.
Temperature of dry sugar is 35-450C and pH is 6 6.8
Now again through elevators sugar forward to the sugar grader.

Sugar grader
Grader divided the sugar in to two grades.
1. Required size
2. Under size
The under size sugar is used for making the seed.

Bagging
The required size after weighing process forward for bagging
When all the process of sugar is conceded and sugar in its original outward appearance
reaches to its ultimate juncture which is storing it in bags ,At that stage we uses a machine
which automatically sets the amount of sugar to be stored in bags .The valve opens just for a
moment and a lot of sugar goes into bags then it slows down and small amount of sugar goes
into bag until it reaches its mandatory credence which is on average 50kg here. The bags
which are attached with the machines are attached manually with the help of labour , its not
automatic.

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