Cleaner Production Assessment in Mekanissa Alcohol and Liquor Factory
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Date
2019-12
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Addis Ababa University
Abstract
Mekanissa Alcohol and Liquor Factory is a branch of National Alcohol and Liquor Factory
which uses molasses or technical alcohol as raw material to produce ethanol. The production
process consists of five major sections i.e. molasses treatment, fermentation, distillery, liquor
and utilities. Raw material and energy utilization efficiencies of all sections are evaluated based
on cleaner production manual. Where, cleaner production options were assessed, filtered and
evaluated for all sections.
In the fiscal year, factory produced alcohol was71.37% of the designed capacity. Overall
efficiency of the alcohol production was 81.64%; of which the efficiency of fermentation and
distillery were 72% and 97.2% respectively. And it is low compared to expected performance at
fermentation and distillation; which is 94.6% and 99% respectively. Average residual sugar in
fermentation was 2,252 kg per day. The total absolute alcohol loss per day from the fermentation
and distillation were 946.76 and 535.79 liters respectively. Molasses, technical alcohol, and
water consumptions per liter of produced alcohol were found to be 4.23 kg, 1.131liters and
15.13liters respectively. Thermal energy and electric energy consumptions per liter of alcohol
were found to be 14,635.552 kJ and 1,575.50kJ respectively which are higher than factory
standards.
Boiler combustion efficiency and thermal efficiency were 82.66% and 71.75% respectively. All
boiler energy losses are evaluated; of which, energy loss due to dry flue gas is the maximum one
which is 15.69%. There are two heat integrations proposed in this study to conserve energy; one
is in molasses treatment section and the other is between boiler and distillery sections. Recovery
of heat from dark and white stillages, CO2 recovery, waste water recycling and heat lost
recoveries; are proposed to improve resource utilization and reducing environmental pollution.
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Keywords
Cleaner production, fermentation, energy, molasses