See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/310951112

Internship Report of Etihad Sugar Mills Limted, Karamabad, RYK

Technical Report · July 2014

DOI: 10.13140/RG.2.2.17450.21448

CITATIONS READS
0 3,408

1 author:

Muhammad Usman Habib

University of Engineering and Technology, Lahore
1 PUBLICATION   0 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Internship Report of Etihad Sugar Mills Limted, Karamabad, RYK View project

All content following this page was uploaded by Muhammad Usman Habib on 27 November 2016.

The user has requested enhancement of the downloaded file.

 Internship Report
Muhammad Usman Habib (11053123-052)

Internship
at
Etihad Sugar Mills Limited.

National Highway (N-5), Karamabad,

District Rahim Yar Khan

Submitted by: Supervised by:

Muhammad Usman Habib Muhammad Nadeem (Chief Chemist)
Roll # 11053123-052 M. Zulfiqar (Deputy Chief Chemist)
University of Gujrat, Gujrat. Engr. Zia-ul-Haq (Shift Chemist)

From 4th July 2014 To 17th July 2014

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

Dedication

I dedicate this effort to my Parents, Teachers &

Learned Chemists of ESML

Who guide

&

Encourage me during the

Preparation of this report

And I want to say

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

ACKNOWLEDGEMENT

All the thanks and praises for Allah who given guidance and wisdom to
mankind and enabled me to complete this task. I am very thankful to all my
Supervisors i.e. Mr. Muhammad Nadeem (Chief Chemist), Muhammad
Zulfiqar (Deputy Chief Chemist), Engr. Zia-ul-Haq (Shift Chemist), Engr.
Muhammad Shahzad and Muhammad Nazir, who helped me a lot to produce
this report.

I am thankful to my department who accepted my request to do internship in

Etihad Sugar Mills Limited, Rahim Yar Khan. I am also grateful to all
employees of the Etihad Sugar Mills Limited who guided me during the
course of internship. The behavior of all the department supervisors is kind
enough to me because they gave a lot of time to guide me the mechanism
of Chemical Department in which I worked.

I am also thankful to the Management of Etihad Sugar Mills Limited,

Karamabad, Rahim Yar Khan, who gave me all the valuable support and
opportunities to complete Internship program and compile this report.

Muhammad Usman Habib

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

Introduction to Sugar and Sugar Industry:

The word sugar originates from the Sanskrit word sharkara which means sugar. It may
also be traced through all the Aryan languages, as schaker in Persian, sukkar in Arabic,
sincer in Assyrian, zucchero in Italian, sucre in French, zucher in German, saccharum in
Latin and ozucarin Spanish etc stand as Testimony for its origin from sharkara.

Sugar is a major form of carbohydrates and is found probably in all green plants. It occurs
in significant amounts in most fruits and vegetables. There are three main simple sugars
Sucrose, Fructose and Glucose. Sucrose is in fact a combination of fructose and glucose
and the body quickly breaks down into these separate substances.

All energy stored in food is derived originally from the sun and it is made by green plant
life. The sun's energy acts upon the green chemical "chlorophyll" in the leaves of plants
to produce sugars and starches from the carbon-dioxide in the atmosphere and the water
from the roots by a process known as Photosynthesis. These carbohydrates (starches
and sugar) acts as a plants food and energy supply. The energy need of human body is
largely dependent on the carbohydrates that are derived from plants.

The sugar is one of the essential commodities of the life which plays very important role
in the dietary of human beings as it quickly raises the level of glucose in the blood.

The sugar can be produced by many of the sources, but two are the main sources for
production of sugar in Pakistan i.e. Sugarcane and Sugar Beet. The other sources are
Maple, Palm, Coconut and Apple, but these sources are costly and their production is in
negligible quantities. But, the main crop which is being used for production of Sugar all
over the world is Sugarcane.

In a nut shell, the process for sugarcane refining is carried out in following steps
 Pressing of sugarcane to extract the juice.
 Boiling the juice until it begins to thicken and sugar begins to crystallize.
 Spinning the crystals in a centrifuge to remove the syrup, producing raw sugar.
 Refining the raw sugar by washing and filtering to remove remaining non-sugar
ingredients and color.
 Crystallizing, drying and packaging the refined sugar.

For the sugar industry, capacity utilization is conceptually different from that applicable to
industries in general. It depends on three crucial factors the actual number of ton of
sugarcane crushed in a day, the recovery rate which generally depends on the quality of
the cane and actual length of the crushing season.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

In Pakistan, the sugar industry possesses the organized and unorganized players. The
unorganized players mainly produce Gur and Shakkar, the less refined forms of sugar
and the organized players are Sugar Mills owners.

In the world, the Brazil is a country that is largest producer of sugarcane as well as
Refined Sugar.

Main Competitors:

According to Pakistan Sugar Mills Association (PSMA), there are 78 Sugar Mills in
Pakistan (39 in Punjab, 32 in Sindh and 7 in NWFP). Although, 78 out of these 77 are the
competitors for Etihad Sugar Mills Limited, but the most competition is lying in following
nearest sugar mills:-

1. JDW Sugar Mills Limited, Sadiqabad

2. JDW Sugar Mills Limited (Unit-II), Sadiqabad
3. RYK Mills Limited, Liaqatpur
4. Hamza Sugar Mills Limited, Khanpur
5. Ghotki Sugar Mills Limited, Ghotki
6. SGM Sugar Mills Limited, Ghotki
7. Ashraf Sugar Mills Limited, Bahawalpur

Introduction to Organization:
Etihad Sugar Mills Limited, Karamabad, Rahim Yar Khan was established on 1 st June,
2006 as a Private Limited Company and is listed at Lahore Stock Exchange of Pakistan.
The company is engaged in the manufacturing and sale of sugar. The company’s site is
situated at Mouza Karamabad Abad, Tehsil & District Rahim Yar Khan. Its head office is
situated at Lahore. The mills covered total 100 Acres out of which 74 acres is for Mills
plant, yard and offices, rest of the 26 acres are for colony, quarters, grounds, hostels and
Masjid.

Organization’s Products:
The company’s main product is White Refined Sugar, however it has also following by
products:-

1. Bagasse
2. Molasses
3. Press Mud

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

Organization’s Processing Departments:

There are four main departments/houses in this Sugar mill but our main concern with
Chemical department / Boiling House.
1. Mill House
2. Boiler House
3. Power House
4. Boiling House

Chemical Department:
DGM (Production) is head of the department and he is responsible for all boiling /
chemical procedures apply on the sugarcane juice. The chemical department is totally
responsible for production of sugar from juice. They apply methods, heat and some
chemicals to transform the sugar from sugarcane. The complete process of production of
sugar is as under:-

Processing of sugar cane for manufacturing of

white sugar in ETIHAD SUGAR MILLS:-

MILL HOUSE:

CANE TIPPERS:
Loaded cane trolleys are tilted by hydraulic jacks into feeding tables. Feeding
tables are 4 in Nos. and these tables transfer cane into carrier # 01. Length of
the feeding table is 15.5m.

CANE CUTTERS: (03 Nos.)

CANE CUTTER # 01

Motor 1000KW, Knives 40 Nos. It is driven by electric motor. It performs the

duty of cane chopping and leveling. Its clearance is about 2 Ft.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

CANE CUTTER # 02

Motor 850KW, Knives 40 Nos. It cuts the cane into small pieces, its clearance
is about 10”

CANE CUTTER # 03

Motor 1000KW, Knives 80 Nos. It completely cuts the cane into small pieces at
minimum clearance of 2”.

SHREDDER:
Steam Turbine 3000KW, Swinging Hammers 88 Nos. It shreds the cane and
raptures all the sugar cane cells to open position. Total No. of disc’s in this, is
23.

MILLS TENDEM: (06 Nos.)

Mills tendem consists of 06 Mills driven by steam turbines having power 850KW
each. Shredded cane is passed through series of 06 mills for extraction of juice.
Imbibition water is sprayed on last mills for maximum extraction of juice. This
extracted mixed juice is filtered through rotary screens. Here, the pH of the juice
is 5.6. Screened juice is sent to Boiling House for processing and bagasse from
last mills is sent to boilers as fuel.

BOILER HOUSE:

BOILERS: (04 NOS.)

Main object of boiler is to produce steam at pressure 23Kg/cm2 and temperature
of 350ºC. Bagasse is fed to boilers, furnaces where it is burnt and produces
steam. Surplus bagasse is sent to bagasse yard, which is sold out. In case of
shortage of bagasse, furnace oil is burnt as standby fuel.

03, Boilers (Capacity 80ton/hour)

01, Boiler (Capacity 40ton/hour)

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

POWER HOUSE:

STEAM TURBINE GENERATORS: (03 Nos.)

Steam Turbine Generators 03 Nos., Steam produced by boilers is used for the
operation of steam turbine generators. 16MW power is used for the operation
of all electric motors installed in Mills.

02, Steam Turbine Generators (Capacity 5MW)

01, Steam Turbine Generators (Capacity 6MW)

BOILING HOUSE:

JUICE HEATERS:
1. Condensate & Primary Juice Heaters: (04 Nos.) (H.S. 350m2 each)

Screened juice is passed through juice heaters in series and temperature is

raised up to 65ºC by using steam / vapors. There are 3 Primary juice heaters
and 1 condensate heater.

2. Defecations Tanks: (02 Nos.)

Here milk of lime (M.O.L.) is added in heated juice and after some retention
time, juice is passed through secondary juice heaters. Here, the pH of the
juice will increase to 7.2.

3. Secondary Juice Heaters: (05 Nos.)

Limed mixed juice is passed through secondary juice heaters and

temperature is raised up to 105ºC for further treatment in juice clarifiers.

03, Secondary Juice Heaters, (H.S. 350m2 each)

02, Secondary Juice Heaters, (H.S. 400m2 each)

4. Juice Clarifier (03 Nos.) (Capacity 170m3 each)

After secondary heating poly electrolyte is used before entering of juice in

clarifiers it stays there for 1 to 1:30 hours to complete the reaction between
M.O.L. and impurities of the juice. The impurities settle down in the clarifier.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

Settling is speedy by addition of poly electrolyte. The clear juice from clarifier
is decanted and passed through rotary screens. This filtered juice is sent to
series of evaporators. Settled impurities (Muddy Juice) is taken out from the
bottom of the clarifiers and is sent to vacuum filters for filtration.

VACUUM FILTERS: (04 Nos.)

Muddy juice taken from clarifiers is mixed with Bagacillo in Mud Mixer and sent
to the troughs of vacuum filters. Vacuum filter drum rotates and mud climbs over
the drum. Hot water is sprayed by Nozzles on the drum. Remaining juice and
washing water is sucked through tubes by vacuum. Sucked filtered juice is
returned to defecation tank and mud is sent out by scrapping the mud from
drums of vacuum filters. It is manure for cane growers. Filtering Area of these,
are 58m2.

EVAPORATORS: (09 Nos.)

Decanted juice from juice clarifier called clear juice is taken into series of
evaporators. It is boiled with help of exhaust steam (obtained from turbines of
mills and power house). The thick juice obtained from evaporators called syrup
is fed to pans. The brix of this thick syrup is about 65-67%.

02, Evaporators, Capacity 5000m2, No. of tubes 14000

02, Evaporators, Capacity 3000m2, No. of tubes 10200

01, Evaporators, Capacity 2500m2, No. of tubes 8500

02, Evaporators, Capacity 1100m2, No. of tubes 3600

01, Evaporators, Capacity 4000m2, No. of tubes 10000

01, Evaporators, Capacity 1800m2, No. of tubes 6800

While three more Falling film evaporators are in under construction, after them,
the brix of syrup would increase up to 70%.

03, Evaporators, Capacity 5000m2, No. of tubes 10000

CONDENSERS: (18 Nos.)

Vapors from Evaporators and Vacuum pans are send to Condensers where
these vapors are converted into Water and then this water is further send to

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

Injection tanks. Total no. of condensers are 18 but management proposed one
more condenser to install in the site.

COOLING TOWERS: (14 Nos.)

There are 14 cooling towers that are used to low down the temperature of water
which is in the injection tank. There is a fan for each cooling tower, 1450 rpm
and motor that rotates it has power of 45KW.

VACUUM PANS: (FOR A, B & C MASSECUITES)

05, Batch Pan, Capacity 70Ton each, H.S. 380m2
03, Continues Pan, Capacity 68m3 each, H.S. 700m2
02, Continues Pan, Capacity 102m3 each, H.S. 948m2

The syrup is fed into pans where it is again boiled to produce mixture of crystals
and molasses called Massecuite. There are 05 pans for A Massecuite, 03 pans
for B Massecuite and 02 pans for C Massecuite. Massecuite which is prepared
in the A-Pans, is dropped into relative crystallizers. Similarly B and C
Massecuite which are prepared in relative pans, are dropped into relative
crystallizers.

MASSECUITE CRYSTALLIZERS: (17 Nos.)

Prepared massecuite from pans is sent into crystallizers for further
crystallization by motion of massecuite by scrolls driven by gear and motor. The
massecuite is transferred to centrifugal station by massecuites pumps. There
are 10 crystallizers for 10 vacuum pans. 07 vertical crystallizers are also placed
to cool down the Massecuite B and C before sending to centrifugal section.

CENTRIFUGES K-1100: (29 Nos.)

Massecuite is passed through Centrifuges which separates crystals of sugar
and molasses. First separate molasses, “A” Heavy is again boiled in B-Pans for
B-Massecuite. B-Massecuite is again passed through Centrifuges for separation
of sugar crystals and molasses. This obtained molasses called B-Heavy is again
boiled in C-Pans for C-Massecuite. C-Massecuite is again passed through
Centrifuges for separation of sugar crystals and final molasses. This final
molasses is sent out in molasses ponds for sale as a raw material for distilleries
and sugar crystals separated from B & C Massecuite are used as seed in pans
and sugar crystals obtained from A-Massecuite are taken into sugar remelter.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

13, Centrifuges for A-Heavy

07, Centrifuges for B-Heavy

03, Centrifuges for C-Heavy (Double Cure)

06, Centrifuges for C-Heavy

SUGAR REMELTER: (Capacity 30ton/hour.)

Here sugar is remelted by using hot water and steam with 02 Nos. stirrers. This
remelt is called raw liquor. This raw liquor is sent to Talo station.

TALO CLARIFIER:
Raw liquor before taking into clarifier is treated with phosphoric acid, color quest,
lime sucrate and Talo float. These chemicals are used to remove remaining
impurities in sugar. In Talo clarifier with some retention time these impurities
float up in clarifier and clear liquor is taken out from bottom side. Floated
impurities called scum is removed from clarifier by scraper driven by gear and
motor. The clear (fine) liquor is sent to pan station. The removed serum is sent
back to defecation tank.

REFINE PANS: (06 Nos.) (Capacity 70 ton each)

Fine liquor is taken into pan. It is boiled for some time to get required brix for
crystallization. Very small fine crystals seed (obtained from the sugar grader not
bagable) is fed into it. Required crystal size is obtained by further boiling called
the refine massecuite. Prepared massecuite is dropped into crystallizers. From
which it is pumped to refine Centrifuges for separation of crystals and molasses.

REFINE CENTRIFUGES TSK (05 Nos.)

Refine Centrifuges are automatic batch type Centrifuges which separates fine
sugar crystals and molasses. This molasses is reused for making more refine
massecuites. Fine crystals (Sugar) is dropped into hopper which shift it to sugar
dryers.

SUGAR DRYER: (03 Nos.)

While sugar passes through these dryers, remaining moisture is removed by
blowing hot air through them. Hot air is passed by fans called blowers fitted for
this purpose.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

SUGAR ELEVATORS: (03 Nos.)

Elevators lift the dried sugar through buckets at some height and feed to sugar
grader for its size wise separation.

SUGAR GRADERS: (04 Nos.)

Here, sugar travels over graders moving to and fro. At sugar grader frames of
screens of different mesh are fitted. Through which fine, very small crystals
(seed) and extra-large size crystals are separated and sugar crystals of required
size drop into sugar bins.

SUGAR BINS (03 Nos.)

Sugar bins are used for holding bag able sugar.

AUTOMATIC WEIGHING MACHINE (02 Nos.)

Automatic weighing machines are installed under sugar bins, machine drops sugar after
50Kgs accurate weight into poly propylene bag attached under it manually. The weight of
these bags is re-checked by electronic weighing scales kept under. After that the bags
sewing is done by sewing machines (02 Nos.) fitted over wooden conveyors. These
sewed bags are sent to sugar go down where it is stacked up to the height of 50 layers
by sugar stacker.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.
 Internship Report
Muhammad Usman Habib (11053123-052)

Future Prospects of the Organization:

Etihad Sugar Mills Limited focuses on the future growth of sugar mills in sugar industry,
which they are planning to start corporate farming at about 1000 acres initially.

Vision:
To be the lead in sugar industry by building the company’s image through quality
improvement, competitive prices and meeting social obligations.

Mission:
1. To endeavor to be the market leader by offer high quality sugar to our valuable
customers at competitive prices.

2. To continue improving operating performance and profitability thereby ensuring

growth for the company.

University of Gujrat.
Chemical Engineering Department, Hafiz Hayat Campus, Gujrat.

View publication stats