Sugar and Fermentation Industry: Chemical Technology

Noida Institute of Engineering and Technology, Greater
Noida
Sugar and Fermentation Industry
Unit: 2
Chemical Technology
Dr. Mansi Singh
Noida Institute of Engineering
and Technology, Greater Noida
B Tech 6th Semester Department of Chemical
Engineering
Dr. Mansi Singh KCH603 CT Unit 2

1
08/26/2020
Content
• Course Objective • Old Question Papers

• Course Outcome • Expected Questions for University Exam
• CO-PO and PSO Mapping • Topic Objective
• Topic-wise Objective and Outcomes • References
• Prerequisite and Recap
• Sugar
• Fermentation products such as Alcohol,
Acetic acid, Citric acid and antibiotics
• Faculty Video Links, Youtube & NPTEL
Video Links and Online Courses Details
• Daily Quiz
• Weekly Assignment
• MCQ s
08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 2

Course Objective
1. To introduce about Chemical Process Technology with reference to Indian

resources
2. To study about industries, trade and export potential, small scale industries and
rural development.
3. To understand the preparation of process flow diagrams.
4. To study about instruments with the help of their diagrams used in CPT.
5. To analyze various process symbols used in Chemical industries.
Dr. Mansi Singh KCH603 CT Unit 2

08/26/2020 3
Course Outcome
Student will able to:

1. Analyze how the industries lying emphasis on process flow sheet.
2. Evaluate the process conditions used in different plants.
3. Studied the end use of products generate..
4. Understand the design aspects in Chemical Industries.
5. Analyze the material required in different industries.

CO-PO and PSO Mapping
Course Program Outcomes (POs) PSOs

outcome 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
1 3 3 3 2 3 2 2 1 1 1 1 1 3 3 2
2 3 3 3 2 3 2 2 1 1 1 1 1 3 3 3
3 3 3 3 2 3 2 2 1 1 1 1 1 3 2 1
4 3 3 3 2 3 2 2 1 1 1 1 1 3 3 2
5 3 3 3 2 3 1 1 1 1 1 1 1 3 2 3
Average
3- Highly related; 2- Moderately related; 1-Slightly related

Topic-wise Objective and Outcomes
UNIT TOPIC OBJECTIVE OUTCOMES
Sugar To provide students Student will able to describe

an insight of sugar sugar production processes
industries. and by-products
2 Fermentation To provide students Student will able to describe

products an insight of the importance of different
fermentation fermentation products.
industries.

Prerequisite and Recap
UNIT TOPIC PREREQUISITE RECAP
Sugar
Basic knowledge of Different types of

2 organic chemistry carbohydrates
Fermentation
products

Sugar
• Sugar is an important source of carbohydrate

• It is a vital ingredient in most of daily consumption articles. For ex. Cold
• drink, juice, tea, biscuits, sweets, and bakery items etc.
• India is the largest sugar consumer and second largest producer in the
• world according to foreign agricultural service.
• Indian sugar industry has total turn over of Rs. 500 billion per annum and
contributes almost Rs. 22.5 billion to the central and state exchequer as
taxes and excise duty every according to Ministry of Food & Govt. of
India.
• In India according to ISMA 622 sugar industries are established.
• Sugar industry covers around about 7.5% of total rural population and
provides employment about 5 lakh people in rural and semi-rural areas.

Sugar
Sources of sugar
• Glucose fruits, veg & honey
• Maltose barley
• Sucrose sugar cane, sugar beet & fruits
• Lactose milk
• Fructose fruits & honey
• Sugar from sugar cane:
 Sugar cane composition: Water =70%, Fibrous material =10-16%, Sucrose = 9.5-
16%, Gummy material =0.5-2%

Sugar
Sugar from sugarcane

Sugar
Manufacturing process
• Harvesting of cane
• Transport & handling
• Cutting & shredding
• Extraction of juice
• Filtration
• Evaporation
• Crystallization
• Centrifugation
• Drying and packing
• Refining of brown sugar

Sugar
Cutting & shredding

• Cutters are mechanical equipment which is used to cut the canes into desired size.
• In the cutter equipment consist no. of cutting blades to cut the cane.
• Cutter machine is operated by electric motor shaft pulley & belt arrangement.
• Shredder is used to remove leaves and undesired solid particles from cane.
Cutter machine Shredder

Sugar
Extraction of juice
• raw cane juice obtain by extraction operation. when
sugar cane cells are braked sweet
• liquid substance came out that is known as cane
juice.
• cane crusher are used to carry on extraction. these
are in 5 to 7 nos.
• it is operated by electric motor. it consist 3 friction
roller in each crusher.
1. main roller or driver : feed & discharge roller are
driven by main roll.
2. feed roller : canes are suck or pull by feed roller.
3. discharge roller : it discharge bagasse and juice.
• these roller are attach each other in triangle shape.
cane crusher

Sugar
• Filtration process is the separation of suspended & colloidal particles from raw
juice.
• Clarification: in clarification process sludge, mud, suspended & colloidal particles
are removes by some chemical compounds.
 raw cane juice are filled in clarifier (conical shape vessel), where phosphoric acid,
lime & sulphur dioxide are mixed with the help of agitator.
 when these chemicals are mixed, suspended and colloidal particles are collect in
flock and resulting settled down.
 neat and clean juice comes out from the upper section of clarifier, sludge and mud
are collect in bottom and drainage to rotary filter.
 calcium phosphate : as flocculent
 lime & SO2 : acts as bleaching agent
 CO2 : acts as acidifying agent

Sugar
Vaccum rotary press mud filter:

• Clarified mud from the clarifier further filtered in rotary filter.
• In rotary filter consist a rotary drum & vacuum atmosphere in its
• center.
• Mud & sludge are stick on the periphery of rotating drum by the
• action of suction. Solid cake removes from the drum by doctor
blade.
Rotary filter
Clarifier

Sugar
Evaporation
• Evaporation process deals heat and mass transfer operation both.
• Evaporators are used in process industry to concentrate liquids.
• The operation is performed normally by use of low pressure, dry & saturated steam.
• The evaporator consist a heat exchanger in inner section .
• In the evaporator feed interred at upper section and concentrated thick liquor exit at
• bottom section.
• Steam used to evaporate juice: 1 liter steam to evaporate 4 liter juice.
• Steam temperature 113-130 degree Celsius at 1st pan and 55 degree Celsius at last
pan .
• Each subsequent vessel with decreasing pressure.
• Last pan being under almost a total vacuum.
• Here used 3 to 5 number evaporator known as multiple effect evaporator.

Sugar
MULTIPPLE EFECT EVAPORATOR :

Sugar
Crystallization
• In the field of engineering crystallization process considered as mass transfer
operation.
• Purest form of substance is obtained.
• The object of the process is usually the recovery of the solute (crystals) from the
solvent.
Process consist 3 major events:

1. Clustering , 2. Nucleation, & 3. growth Crystallizer

Sugar
Centrifugation
• Centrifugation process is based on centrifugal force.
• To remove the sugar crystals from the molasses, high-speed (1,800-2,000 rpm)
rotating spin applied to the massecuite, resulting by the action of centrifugal force
sugar crystals and mother liquor being separate.
Centrifuge

Sugar
Drying & packing

• Drying is very essential mass transfer operation in processing sugar cane into sugar.
• The moisture content in sugar after leaving centrifuge which varies b/w 0.5 to 2. %
needed to reduced about 0.05% for safe storage.
• Screening: here sugar crystals are separate by a screen in the form of over, under &
desired size.
• Packing: packing is final process of sugar where screened crystals will be packed
in different size of bags.

Sugar
Refining of brown sugar

• The relatively pure brown coloured liquor from the filtration stage ,”raw liquor” is
then subjected to decolourisation by contact with bone-char.
• The bone-char consist of activated carbon on a calcium phosphate skeleton.
• It has a high surface area and the unique ability to absorb colour and inorganic ash
impurities from the sugar.
• The melted and liquid liquor is stored in a long vertical and cylindrical vessel about
36hrs.
• The vessel is already packed with bone-char, where bone-char & liquor comes in
intimate contact, resulting impurities and colour are absorbed by bone-char.
• The decolorized ‘fine liquor’ is ready for the final refining & recovery step, which
is achieved by crystallization in vacuum pans.

Sugar
By products of sugar
• Bagasse : it is a solid fibrous material contains more cellulose.
1. Used in Pulp & paper industry, and also cattle feed.
2. Boiler fuel to produce steam & power.
3.Mixture of powder bagasse and tar coal is used to seal building roof to become water
proof.
• Black strap molasses :
1. Raw material for fermentation industry.
2. Molasses is used in bakery, sweets, chocolates & biscuits industry.
3. It is Used to produce denatured power alcohol (spirit) & potable alcohol.
4. Molasses is also used to produce industrial and automobile fuel.
• Filter cake : filter cake is used as fertilizer. It contains full of sulphur, phosphorus,
calcium and nitrogen.

Sugar
SUGAR MAP
SUGAR PORODUCING AREAS IN WORLD MAJOR SUGAR

INDIA CONSUMER NATIONS
• UP =44%, MH =14%, TN =10%, 1. India, 2. European union, 3. China, 4.
• Karnataka=9%, AP =6%, Gujrat = 4%, Brazil,
5. United states.
• Bihar =3%, Haryana =3%, Punjab
MAOR SUGAR EXPORTING
=3%,
NATIONS
• other =5% . 1. Brazil
MAJOR SUGAR PPLAYERS IN 2. Thailand
INDIA: 3. Australia
1. Bajaj Hindustan, Lakhimpur-khiri. 4. Mexico
2. Shree Renuka sugars, Haldia W.B. 5. Guatemala
3. Dhampur sugar mills, Moradabad. 6. India
7. European union
4. Balrampur chini mills, Balrampur.
8. Cuba
5. Sarawasti sugar mills, Saharanpur 9. South Africa
road,Yamuna nagar. 10.United Arab

Fermentation and fermentation products
Fermentation
• Fermentation is the process of growing microorganisms in a nutrient media by
maintaining physico- chemical conditions and thereby converting feed into a
desired end product
• Fermentation technology is the use of organisms to produce food, pharmaceuticals
and alcoholic beverages on a large scale industrial basis.
• The basic principle involved in the industrial fermentation technology is that
organisms are grown under suitable conditions, by providing raw materials meeting
all the necessary requirements such as carbon, nitrogen, salts, trace elements and
vitamins.
• The end products formed as a result of their metabolism during their life span are
released into the media, which are extracted for use by human being and that have a
high commercial value.
• Examples in India of typical fermentation industries presently economic are Ethyl
Alcohol and Penicillin.

Ethanol from molasses

• India is the second largest producers of the world to convert molasses into alcohol
• Ethanol has become one of the important products as alternative feedstock for large
number of organic chemicals and fuel.
• It can be prepared by fermentation of molasses
• Typical reaction as follows

Ethanol from molasses

Molasses handling
It involves
• Weighing of the molasses
• pumping of molasses to the molasses tank from which the measured quantity of
molasses is transferred to the fermenter
• Preparation of yeast inoculam,
• propagation of yeast
• Yeast (Saccharomyces cerevisiae)) material is prepared in water cooled yeast
vessels by inoculating molasses with yeast
• Then transferred to aerated yeast activation vessel to allow time for yeast cell
multiplication

Fermentation
• Conversion of sugar into ethanol and by products
• After fermentation alcohol content 8-10 %
• Fermentation exothermic process – heat will be generated
• Rising temperature reduces alcohol productivity
• Nutrients added intermittently depending upon requirement
• Sulphuric acid and anti foaming agent added to control pH and excess air
• After fermentation dil. Liquor is preheated and pumped the beer still where the
alcohol 50-60percent

Distillation of dilute alcohol for removal of impurities

• Aldehydes and other impurities is distilled off.
• Then it is move to the aldehyde column were its recovered
• Residue at the bottom of the beer column known as slops or tillage are discharged
and treated for the recovery of energy
• Concentration of the dilute alcohol to rectified spirit and absolute alcohol
• Diluted alcohol is concentrated to 95-96percent alcohol in the rectifying column

• Many fermentation processes are in direct competition with strictly chemical

synthesis.
• Alcohol, acetone, butyl alcohol and acetic acid produced by fermentation have
largely been superseded by their synthetic counterparts.
• Almost all the major antibiotics are obtained from fermentation processes.

1. Vineger
• Vinegar is used today mainly in the food industry as;
(a) a food condiment, sprinkled on certain foods such as fish at the table;
(b) for pickling and preserving meats and vegetables; vinegar is particularly useful in
this respect as it can reduce the pH of food below that which even sporeformers
may not survive;
(c) It is an important component of sauces especially renowned French sauces many of
which contain vinegar; Vinegar is a product resulting from the conversion of
alcohol to acetic acid by acetic acid bacteria, Acetobacter.

2. Citric Acid
• Uses in the food industry
(i) Citric acid is the major food acidulant used in the manufacture of jellies, jams,
sweets, and soft drinks.
(ii) It is used for artificial flavoring in various foods including soft drinks.
(iii) Sodium citrate is employed in processed cheese manufacture.
• For a long time the production of citric acid has been based on the use of molasses
and various strains of Aspergillus niger

3. Pharmaceutical products:
• The pharmaceutical industry has long employed fermentation (bio-synthesis) to
manufacture some of its most important medicaments.
• Fermentation is presented for antibiotics, biologicals, vitamins and hormones.
• Antibiotic drugs extracted from microorganism growth under commercial
fermentation conditions are sufficiently complex in molecular structure.
• Typical of the drugs produced under different processing conditions are : Penicillin,
streptomycin and erythromycin.
• Antibiotics are chemical substances produced by certain types of microorganisms
which will inhibit the growth and even destroy body-harmful microorganisms.

Penicillin Manufacture

Medium for penicillin

1. The Penicillium chrysogenum usually contain its carbon source which is found in
corn steep liquor and glucose.
2. A medium of corn steep liquor and glucose are added to the fermenter. Medium
also consists of salts such as MgSO4, K3PO4 and sodium nitrates. They provide the
essential ions required for the fungus metabolic activity.
Heat sterilization
3. Medium is sterilized at high heat and high pressure, usually through a holding tube
or sterilized together with the fermenter.
4. The pressurized steam is used and the medium is heated to 121°C at 30 psi or twice
the atm. pressure
Note: High temp. short time conditions are used to minimise degradation of certain
components of the media.

Fermentation
• It is done in a fed-batch mode as glucose must not be added in high amounts at the
beginning of growth (which will result in low yield of penicillin production as
excessive glucose inhibit penicillin production).
• The fermentation conditions for the Penicillium mold, usually requires
temperatures at 20-24°C while pH conditions are kept at 6.5
• The pressure in the bioreactor is much higher than the atmospheric pressure
(1.02atm). This is to prevent contamination from occurring as it prevents external
contaminants from entering.
• It is necessary to mix the culture evenly
throughout the culture medium.
Fungal cells are able to handle
rotation speed of around 200 rpm.
Fermentors

Seed Culture
• The seed culture is developed first in the lab by the addition of Penicillium
chrysogenum spores into a liquid medium. When it has grown to the acceptable
amount, it is inoculated into the fermenter.
• The medium is constantly aerated and agitated. Carbon and nitrogen are added
sparingly alongside precursor molecules for penicillin fed-batch style. Typical
parameters such as pH, temperature, stirrer speed and dissolved oxygen
concentration, are observed.
• After about 40 hours, penicillin begins to be secreted by the fungus.
• After about 7 days, growth is completed, the pH rises to 8.0 or above and penicillin
production ceases.

Removal of biomass
• Filtration is carried out as bioseparation is required to remove the biomass from the
culture (removing the fungus and other impurities away from the medium, which
contains the penicillin).
• A Rotary vacuum filter is commonly employed for filtration as it is able to run in
continuous mode in any large scale operations.
• After filtration, phosphoric acid, a non-oxidising agent, is introduced, to decrease
pH from 8.0 to 6.5 so as to prevent loss of activity of penicillin.

Addition of solvent
• Organic solvents such as amyl acetate / butyl acetate are added to dissolve the
penicillin present in the filtrate.
• At this point, penicillin is present in the solution and any other solids will be
considered as waste (can be used as fertilizers and animal feed).

Extraction
• A series of extraction processes are carried upon the dissolved penicillin, to obtain
a better purity of the penicillin product.
• The acetate solution is first mixed with a phosphate buffer, followed by a
chloroform solution, and mixed again with a phosphate buffer and finally in an
ether solution.
• Penicillin is present in high concentration in the ether solution and it will be mixed
with a solution of sodium bicarbonate to obtain the penicillin-sodium salt, which
allow penicillin to be stored in a stable powder form at rtp. The penicillin-sodium
salt is obtained from the liquid material by basket centrifugation, in which solids
are easily removed.

Fluid bed drying

• Drying is necessary to remove any remaining moisture present in the powdered
penicillin salt.
• In fluid bed drying, hot gas is pumped from the base of the chamber containing the
powdered salt inside a vacuum chamber.
• Moisture is removed this way, and this result in a much drier form of penicillin.
Storage
• Penicillin is stored in containers and kept in a dried environment. The White
Penicillin-Sodium salt
• The resulting penicillin (called Penicillin G) can be chemically and enzymatically
modified to make a variety of penicillins with slightly different properties.
• These can be semi-synthetic penicillins, such as; Penicillin V, Penicillin O,
ampicillin and amoxycillin.

Faculty Video Links, Youtube & NPTEL Video Links and
Online Courses Details
• https://nptel.ac.in/content/storage2/courses/102103015/module1/lec1/4.html
• https://www.youtube.com/watch?v=2Admn5dmMqo
• https://nptel.ac.in/content/storage2/courses/102105058/Assignment-We
ek%207.pdf

Daily Quiz
1. What are by-products of sugar industry?

2. What is the problem in storage of sugar cane?
3. What is fermentation?
4. Give few examples of fermentation products
5. Explain the production of ethyl alcohol.

Weekly Assignment
1. Explain the different properties of Acetic Acid, Citric Acid and Glucose?
2. Explain the process for the production of Glucose?
3. Describe the process for the production of Acetic Acid and Citric Acid?
4. Explain the end use of Acetic Acid, Citric acid and Glucose?
5. Define major engineering problems from Acetic Acid, Citric Acid and Glucose
production?
6. How penicillin is manufactured ?

MCQ s
1. Yeast is used in the production of

a) ethyl alcohol
b) acetic acid
c) cheese
d) curd
2. Ethanol is produced by
a) continuous fermentation
b) batch fermentation
c) both (1) and (2)
d) none of these
3. To maintain aseptic conditions during fermentation which of the following is
needed?
e) Sterilization of fermentor
f) Sterilization of air supply
g) Aeration and agitation
h) All of these
MCQ s
4. Which of the following is not a product of fermentation?

a) Lactate
b) Oxygen
c) Carbon dioxide
d) Ethanol
5. Which is not fruit or vegetable based fermented product
e) Wine
f) Beer
g) Vinegar
h) Sauerkraut
6. After the fermentation is over, ethanol is recovered by
i) centrifugation
j) distillation
k) filtration
l) cell disintegration

Old Question Papers

Old Question Papers

Old Question Papers

Expected Questions for University Exam
1. Explain the production of ethyl alcohol by fermentation

2. Draw the flow sheet of sugar production and explain.
3. Explain the manufacturing of citric acid.
4. How penicillin is manufactured.
5. Explain the different properties of Acetic Acid, Citric Acid and Glucose?
6. Explain the process for the production of Glucose?
7. Describe the process for the production of Acetic Acid and Citric Acid?
8. Explain the end use of Acetic Acid, Citric acid and Glucose?
9. Define major engineering problems from Acetic Acid, Citric Acid and Glucose
production?

Topic Objective
At the end of this presentation student should have learned that
•How sugar is manufactured from sugarcane and what are the byproducts of
sugar industry?
•What are different fermentation products and how they are manufactured?
•How fermentation is related largely to food industry?

References
Ref. Books:
1. Dryden, C. E. “Outlines of Chemical Technology” (Edited and Revised by
M. Gopala Rao and M. Sittig) East West Press. Pvt. Ltd, New Delhi, 3rd
Edition (1997).
2. Austin G. T. Shreve’s Chemical Process Industries”, 5th Edition, McGraw
Hill (1984).
3. O P Gupta, "Chemical Process Technology", Khanna Publishing House.


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Noida Institute of Engineering and Technology, Greater

Sugar and Fermentation Industry

Dr. Mansi Singh KCH603 CT Unit 2

• Course Objective • Old Question Papers

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 2

1. To introduce about Chemical Process Technology with reference to Indian

Dr. Mansi Singh KCH603 CT Unit 2

Student will able to:

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 4

Course Program Outcomes (POs) PSOs

3- Highly related; 2- Moderately related; 1-Slightly related

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 5

UNIT TOPIC OBJECTIVE OUTCOMES

Sugar To provide students Student will able to describe

2 Fermentation To provide students Student will able to describe

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 6

UNIT TOPIC PREREQUISITE RECAP

Basic knowledge of Different types of

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 7

• Sugar is an important source of carbohydrate

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 8

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 9

Sugar from sugarcane

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 10

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 11

Cutting & shredding

Cutter machine Shredder

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 12

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 13

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 14

Vaccum rotary press mud filter:

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 15

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 16

MULTIPPLE EFECT EVAPORATOR :

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 17

Process consist 3 major events:

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 18

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 19

Drying & packing

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 20

Refining of brown sugar

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 21

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 22

SUGAR PORODUCING AREAS IN WORLD MAJOR SUGAR

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 23

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 24

Ethanol from molasses

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 25

Ethanol from molasses

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 26

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 27

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 28

Distillation of dilute alcohol for removal of impurities

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 29

• Many fermentation processes are in direct competition with strictly chemical

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 30

08/26/2020 Dr. Mansi Singh KCH603 CT Unit 2 31