COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP REPORT

ALMEDA TEXTILE PLC.

PREPARED BY GROUPMEMBERIDNo

1. ABRHALEY GEBREYOHANNES ……………… 0064/06

2. GEBREMARIAM TEKLEMIKAEL ……………. 0573/06
3. YODIT YBRAH ……………………………… 1648/06

DURATION DATE: 21/06/08 -21/10/08 E.C

SUBMITED DATE:
ACKNOWLEDGEMENT

First of all we would like to thank God that he gives our full of health to finish this internship
program. Then, we would like to thank our family because they are my back bone in all our life.
And as the same time we would like to thank our friends.

Next, we would like to thank to our academic advisorBrhane Tsegay that he advice and
recommend us by coming to the company and by any other different ways.

Also, we would like to thank to the supervisor of the company that he gives us lot information
and we want give respect to ALTEX workers.
CHAPTER ONE
GENERAL HISTORY OF ALMEDA TEXTILE PLC.

1.1 INTRODUCTION

Almeda Textile PLC is a non-governmental entity invested by EFFORT (Endowment Fund for
Rehabilitation of Tigray) which is the total investment of 94.22 million USA Dollar& sixty
Percent of total investment of ALTEX goes to all the brand new.

Almeda Textile PLC located at the historic town of Adwa, 5Kms far away from Soloda
Mountain and 17kms away from Aksum airport.
1.2 BACK GROUND OF THE COMPANY

ALMEDA Textile Share Company is a private company which established in 1996 G.C.
accordance with the commercial code of Ethiopia with a share capital of 180,000,000 Birr. This
company is one of companies of the EFORT group with an objective to enhance the investment
opportunities, it is the biggest Textile
Manufacturing company in the country. It has 100 million Birr sales volume. That is 70% Sales
volume in local market and 30% sales volume in global market. ALMEDA is enjoying complete
new production lines imported Switzerland, Italy, Germany and Japan that take up a total
investment of 94 million Dollar.
1.3 VISION OF THE COMPANY
Develop Almeda reference for Ethiopian Textile as and garmenting industry and create the
conditioned that Almeda can become leader in the Ethiopian market in terms of export and local
market sale.
CORE VALUES:
 Customer satisfaction
 Reliability
 Commitment
 Good governance
1.4 MISSION OF THE COMPANY

 To make profit by competing in the global market

 To generate foreign exchange by increasing export
 To create employment opportunities to the community
 To have sustainable production capacity and contribute in the development of the foreign
and the country.
1.5 OBJECTIVE OF THE COMPANY
The company is established to accomplish the following business objectives
 To produce threads yarns and all kinds of cloths from cotton, polyester and cotton and
Polyester mix at any ratio.
 To produce clothing materials for personnel and house hold uses.
 To engage in agricultural activities where becomes necessary for the realization of its
Business.
 To engage generally in any other trade necessary or conducive to the achievement of its
Business
1.6 RAW MATERIYAL AND INPUTS OF THE COMPANY

 Lint cotton
 Polyester
 Dyestuffs of different type
 LPG ( Liquid Petroleum Gas)
 Furnace oil
  Chemicals & Auxiliaries

1.7MAIN PRODUCT OF THE COMPANY

The main products of the company are:

 Trousers
 Jeans
 T-shirts
 Shirt
 Bed sheet
 Uniform
 Military/police
 Over all
 Bed sheet14
 Yarn
 Gwen
 Gray fabric and dyed fabric
 Bed cover…..
1.8 MAIN CUSTOMERS OF THE COMPANY

Customers are the consumers of one company’s product and these also play an important role in
increasing the potential of the company’s production capacity by balancing the demand and
supply of the company. Almeda have an enough potential customers locally and globally these
are:
1.8.1Global customers (experts)
Name of the customer country
QC supply USA

Bern apparel USA

Edwards USA

Tsi USA
 Kopper man Germany

Vitcon PLC Sudan

Chamorro USA

Bigga Italy

Pinakle USA

1.8.2Local customers

 Guna
 Tigray police, Amhara police
 National defiance
 Federal police
 Somali police
 Oromia, Afar, Southern nation nationalities and peoples ,Gambela, Harrer and
Benshanguelgumz regional states police15
 Eagle foam
 Finch a sugar…

1.9 TECHNOLOGY AND MACHINERY OF THE COMPANY Machinery in the textile

technology in mills, the design capacity is capable to produce a variety of product & very
flexible in changing to any type of textile yarn, fabric & made up in 100% cotton & manmade
fibers of blends of any ratio .That has designed to process carded, combed. waxed& twisted
yarn in both ring & open end spinning system up to NE60&30 count respectively.

1.9.1 Spinning Machine

The term spinning is used to refer to spin which means that the raw material specifically
cotton is converted to yarn. Through different process and operation, the cotton changed its form
to yarn. This is the main function of spinning department. To do this different techniques are
employed.
Before any kinds of operation begin the cotton is arranged in the label and tested to meet its
specification. And this is done by expert`s that has been graduated from different higher
institutes. Most of them are graduated by industrial engineering stream. The main functions of
these experts are the following;

Checking the raw cotton using different instrument before they receive from the supplier

Checking and mixing different kinds of cotton according to their specification

1.9.2 Weaving Machine

Weaving is the interlacing of two sets of yarns, i.e. warp and weft yarns at right angle to each
other. This mechanism converts yarn to fabric by using the following three motions.

 Primary motion
  Secondary motion
 Ancillary motions.

Figure 4:- Sample figure in weaving department

Tocomplex design of fabric. The designed production Capacity of this department is 28,000
meters of fabric. The product types that can be produced in the department are;

Different types of plain fabric (sheeting,

1.9.3 Wet Processing Machine
1.9.3.1 Singing and Desizing
Singingis the process of removing protruding fibers by the means of burning. Before the fabric is
singeined it must be brushed in order to stand the fibers perpendicularly with the fabric. Brushes
remove external fluffs from the fabric and erect protruding fibers on the fabric making them
suitable to singeing. The fabric is singeined by using flame and the flame is formed from liquor
petroleum gas (LPG) with the addition of compressed air. Flame is adjusted in both sides of the
fabric to remove or burn protrudes fibers. Note that the flame must have normal color that

1.9.3.2 Parameters of desizing

A.Temprature:- Is fundamental thing that accelerate chemical reaction. So padding temperature
of this process is about 80 degree centigrade.

B. Machine speed:- This is arranged according to the heaviness of fabric; because the
interaction time between the solution and fabric is crucial thing in such a way that materials
having more weight needs slow speed so as the chemical will penetrate easily. Therefore, the
speed ranges from 60 up to 90 meter per minute.

C. Pick up: - This is the measurement of chemical solution take up by the fabric and it is mainly
controlled by squeezing pressure after padding the fabric. Most of time pick up will be adjusted
to 80%.

is sky blue.

D.PH of chemical solution:- PH of desizing chemical should be in the optimum level otherwise
chemicals in different PH possess different reactions even though they are the same.

E. Batching time: this is very important factor for reaction of chemicals and starch. Batching
time of desizing process ranges from 4 up to 8 hours.

1.9.3.3. Scouring and Bleaching

This process is carried out to remove the natural impurities present in the cotton such as oils,
fats, waxes, mineral matter and dirt. This makes the fabric more absorbent so that it can absorb
the chemicals in subsequent process. This carried out without bringing any physical or chemical
change in the fabric structure. Scouring is the preparatory process for bleaching which makes the
fabric more absorbent to the bleaching chemicals. Problems due to the presence of oils, fats and
waxes.

These are higher fatty acids with very high molecular weight. They are hydrophobic in nature
and affect the absorption of the fabric. They form a thin firm on the surface of the fiber and make
it difficult for the penetrations of the chemical. The removal of this firm is a must for bleaching,
dyeing and printing. The process of scouring thus helps in the removal of these main natural
impurities along with other impurities.
 Changes which takes place during scouring
 The saponifiable oils and fats are converted in to soaps.
 The UN saponifiable fats and oils are removed in the form of emulsion.
 Proteins are hydrolysis in to soluble product.
 The pectin is converted in to soluble salts.
 Mineral matter gets dissolved.
 Dirt particles are removed and held in soluble form.
 Simple amino acids are hydrolyzed in to ammonia.

Saponification

It is the conversion of a higher a glyceride of the fatty accede in to soap by the action of an alkali
(I .e NaOH).

HEAT

Vegetable oil +NaOH Glycerin (insoluble in water) +fatty acid

(Soluble in water)

Fatty acid+ NaOH Soap /sodium salt (soluble in water)

Emulsification: - unsaponifiable oils and waxes cannot be removed by saponification. Waxes are
also highly hydrophobic and they are ester of fatty alcohols and fatty acid. They can be removed
from the fiber by converting them into emulsion.
Emulsion is a fairly stable mixture of two liquids which normally do not react with each other.
The soap which formed due to saponification is act as the emulsifying agent different process
carrying – out scouring

1. Lime soda process 3. Treatment with soda-ash and soap

2. Caustic-soda boil technique 4. Enzymatic scouring (bio-scouring)

In KTSCO, there is caustic –soda boil technique scouring process. Caustic-soda boils technique
The goods are impregnated with the alkali liquor containing caustic-soda, detergent, wetting
agent and emulsifying agent.the liquor is heated at boil for about 6-10hr.Then the scouring liquor
is drained-out and the good are washed with hot water and cold water.

Table 1 recipe of caustic soda boil technique

RECIPES OR CHEMICALS Amount

NaOH 1-1.5%

Na2SiO3 1%

SOAP 1%

Wetting agent (surfactant) 1%

PH 10-11

Time 6-10hr

2.3.3.4. Bleaching
Bleachingis carried-out to remove the natural coloring matter from the fabric to make the fabric
perfectly white. Bleaching is a must when the fabric taken to dyeing with lighter shade. It is also
a must when a perfectly white fabric is required. Bleaching agent is a chemical which
decomposes the coloring matter to remove it with subsequent washing. The bleaching agent can
be oxidative (removal of electron) or reductive (addition of electron). Oxidative bleaching agents
are preferred because of the reductive agents are unstable under atmospheric condition. The
action of bleaching is enhanced by addition of certain chemicals known as optical brightening
agent which improves the brightness of the fabric. In KTSC there is bleaching with hydrogen
peroxide.
Bleaching with hydrogen peroxide is the universal bleaching agent because it can be used for
many kinds of fiber including wool, synthetic fiber, silk and etc apart from agent. Hydrogen
peroxide is stable under acidic condition but decompose under alkaline condition. The beaching
takes place only by the addition of an alkali and increase the temperature. It liberates hydroxyl
ion in an aqueous medium (in the presence of water). The hydroxyl ion is he active bleaching
species (active agent) which carries –out the bleaching action. The decomposition of hydrogen
peroxide leads to a liberation of oxygen.

There are two types of bleaching in KTSC these are half and full bleach.
Half bleach: - is used to when the fabric required normal white color.
H2O2:- used for remove the natural color of the cotton.
Wetting agent: - used to increase wet ability of fabric.
Stabilizer: - used for stabilize bleaching solution.
Full bleach: - is used to when we required perfectly white fabric.

Figure 1.bleaching machine

Table 2Recipes chemicals for half and full bleach

chemicals for bleaching chemicals sizes

H2O2 9-11L
NaOH 3L
Stabilizer 3L
Wetting agent 2-2.2kg (for wet fabric)
Optical brightening agent 3L
PH 11
 Temperature 90oc
Scouring: - is the process of removal of waxes, oils, grease, crushed seed cottons
etc. by alkali treatment at high temperature.
A. Bleaching: - is the process of whitening of fabric by removing other color from it.
Oxidizing agent like hydrogen per oxide is responsible for the process.

Bleaching of fabrics may be:

1. Normal bleaching (half bleach):- is bleaching by H2O2 this is mostly used for dyeing or
printing.
2. Optical brightening bleaching (full bleach):- the fabric is bleached by H2O2 and optical
brightening agents.

In both scour and bleaching acetic acid is added at the end to neutralize NaOH if the fabric does
not need mercerization. The chemicals that are added in both scouring and bleaching are H2O2,
NaOH, Stabilizer, Wetting agent (soap), optical brightening (optional), acetic acid and steam.

1.9.3.4.Parameters of combined scouring and bleaching

A. Pick up: - the machine does not squeeze after impregnation of chemical solution then the
fabric picks about 120% on the weight of fabric because it moves freely.
B. Temperature: - temperature to scour and bleach of fabric should be 95 degree centigrade
for steamer and for the washing purpose is not less than 90 degree centigrade.
C. PH: - ph of scouring and bleaching process ranges from 9.5 up to 11 because at this
temperature active oxygen works properly. Speed of machine: - it is indicated in the
above indirectly but normally the speed of the machine is 60 meter per minute.
D. Steaming time:- is the time in which the fabric stays for chemical reaction. Fabric should
stay 25 minute in the steamer otherwise below this temperature no sufficient bleaching
and above this there will be deterioration of fabric.
1.9.4. Mercerization: - is a preparation process which is only applicable to cellulose fibers
cotton in particular.

Merceration has the following objectives:

 To increase lustrity
 To make more stronger
 To create greater capacity to accept dye.
 To make fabric soft handle and more extensible.

1.9.4.1.Parameters of mercerization

A. Temperature: - temperature of the impregnation caustic bath is at room

temperature but washing temperature is 90 degree centigrade
B. Speed of machine: - is 40 meter per minute.
1.9.5. Washing machine
Washing machine is used to remove caustic after mercerization and unfixed dyes of dyed
fabrics.
The washing may be: -
A. Reduction washing: - just by adding acetic acid or sodium hydrosulfite we are
going to decrease shade variation.
To remove immature fibers and create shine.
B. Normal washing: - by adding hard water, detergent and sequestering (chelating)
agent.
1.9.5.1 Parameters of washing
1. Temperature: - not less than 90 degree centigrade
2. Speed: - 35 up to 40 meter per minute
3. Squeezing pressure: - if the pressure is high it removes more water from
the fabric.
1.9.6 Drying machine
 The main function of this machine is to remove water from fabrics. Drying mechanism
can be by steam or circulating hot air in drying equipment.
Process parameters are s peed and temperature.
1.9.7 Printing
Printing is another type of coloration has been described as dying as localized, pattern
design.
Printing of textile materials of different types these are:
 Screen printing
 Roller printing
 Heat transfer printing

Among the above screen printing is most widely used and now a day's applicable in Almeda. The
screen is prepared according the design needed for the purpose.

The essential ingredients for printing paste are:

Thickener: is used for thickening of paste or to increase viscosity of paste.

Binder or Fixer: to fix the pigment with fabric.

Urea: used for uniform solubilizing.

Two by gum: to make it the fabric shine for specific color.

Anti-foaming agent: to prevent foam.

Fixing agent (cross linker): to increase fixation and to increase rubbing, washing and cleaning
fastness. The above eight chemicals are called paste in combination an d their color is white.
Pigments are found always in the form of liquid and they are very viscous.

1.9. 8Stenter machine;

This machine works two things; physical and chemical finish.

Some of chemical finish are:

I. Soft finish: - making the fabric good soft handle.

II. Resin finish: - the fabric will become stiff and hard.
III. Anti-microbial finish: - the will have resistance to external microorganisms.
IV. Repellent finish: - having the tendency of water impermeable.
V. Ammonia: to make the fabric flexible
VI. Flame retardant finish: - fabrics finished with this process will not burn easily.

Some of physical finish are:

1. Drying: - removing water from the fabric.

2. Widening: - adjusting width of the fabric from 155 cm to 160 cm.
3. Tint finish: - padding or dyeing the ground of the fabric after printing.
In addition to this stenter can perform heat setting to mean that changing the poly ester molecule
from crystalline to amorphous structure in order to increase dye up take.

Mechanical finish:

Some of mechanical finishes are:-

1.10 Calendaring: - shining effect of fabric to have silky appearance by pressing the fabric
between metal and textile rollers at high pressure.

Raising: - to raise fibers from the fabric so as to have furry feeling for human being.

1.11 Sanforizing: - one of the mechanical finish to give fabric softness and permanent shrinkage.
Sanforizing mainly used for cotton fabrics because they have tendency to shrink after washing.
Generally mechanical finish is mechanism of giving aesthetic appearance to the fabric
mechanically.

1.12 Dyeing

Dyeing is the process of coloring textile materials by immersing them in an aqueous solution of
dye liquor. Normally the dye liquor consists of dye, water and auxiliary to improve the
effectiveness of dyeing heat is usually applied to the dye liquor

Dyeing is performed in different methods:

a) Exhaust dyeing or batch dyeing: in this company this process most of time is used for
dyeing of knit fabrics.But in some cases it is also used for woven fabrics. For this method we use
different machines; like jigger, sclavos or high temperature dyeing machines etc. Despite of less
production, jiggers are not used regularly. Jiggers are not only used for dyeing but also for
desizing, scouring, bleaching or wet chemical finishing. Knit dyeing by sclavos this high
temperature and high speed is used for knitted fabrics.

b) Semi continuous dyeing: semi refers to us the whole reaction is not inside the machine. Th e
machines for semi continuous are of different types among these one is "cold pad batch".

Advantage of using this machine

  Reduce energy consumption
 The process is not complex
 better leveling of dye stuff
 Dark shades are achieved easily.

Process parameters for cold pad batch

a. PH: this is about 11

b. Dyeing temperature: padding as well as batching time is room temperature.
c. Speed of machine: this differs according the heaviness of fabric for example Canvas
fabric run at maximum of 25 meter per minute and light fabrics run at speed of 50 meter
per minute.
d. Batching time: Is different for different type of dyes most of the time it is 12 hours but in
some cases when we dye by turquoise or special dye the time will be extended to 24
hours.
e. Pick up: Average value pick up of dye stuff and chemicals by fabric is 70%. Dye stuff
and alkali solutions must be prepared in separate bathes but mixed during process. The
reason if we mixed them together there will be hydrolysis of dyes so the dye stuff
becomes less functional.

c) Continuous dyeing: is the process of dyeing and Fixation at the same time. Among these
machines one is thermo sol machine. In this machine most of the time we process cotton, poly
ester and blend of poly ester and cotton fabrics by: Pad- dry- chemical pad in cold pad batch for
cotton. Pad- dry- fix (thermo sol) for cotton, poly ester and blend of these.

Parameters of pad- dry- fix (thermosol):

1. Padding temperature: Room temperature is the padding time.

2. Drying: the fabric is dried in two stages; one removing 70% of the water by infrared the
second is drying the fabric inside drying chamber at 140 degree centigrade.
3. Fixation time: this is the dwelling time inside the fixation chamber to react the dye with
fiber.

Fabrics can dyed in two ways for blend of poly ester and cotton:
One bath dyeing: dyes for cotton and for polyester are mixed together and the fabric is padded
in this solution; and recipe for one bath dyeing are:

Two bath dyeing method: Poly esters fibers are dyed first in thermo sol machine then washed to
remove unfixed disperse dyes and cotton part is dyed in cold pad batch machine. Mostly this is
used for dark shades that cannot be achieved by one bath method.

1.13 Knitting,Knitting department has the capacity to produce single jersey, popcorn; lap PK
& Rib in addition to the Flat machines can produce cuff & collar of different design and sizes .

1.14 Knit Dying

The process is capable to produce dyed and belched knit products. Its product mix is 100%
Cotton, PC in different properties, Different chemical treated products, Enzyme washed, Milking
treated and antimicrobial treated products are the main output of the process.

1.15 Garmenting
Garment is currently producing different types of wearing apparels for the local & international
market. The company has very flexible and brand new state-of-the art technology in its design
and pattern making, make up, finishing, embellishment and quality control units.

1.16. Wastewater treatment of ALTEX

WWT is a liquid waste that means water supply of the community after it has been used in
variety of application on a neat processing. Purpose of WWT is to reduce the concentration of
pollutants that affected the environment and living things. There are so money water treatment
methods which are listed below.

1. Physical WWT: separation of solids from wastewater.

2. Chemical WWT: Depending on the PH, Chlorides and values; it breaks down in to small
particles to be suitable for treatment.

3. Biological WWT: it follows the algae bacteria and parasitic which are growths in the tank that
collects the water and to perform WWT convection by the compressor pump lines.

In KTSC it is used only physical & biological methods, it is the only option using this method
because chemical treatment is expensive. Steps in process of WWT describes below.

1. Primary treatment: It is the entering of WT which comes from different sections such as toilet,
shower, and sizing. It has a money metal integrated wire that is to filter the water from large
suspended solids to small suspended arranged in a step. The first step is used to filter the very
large things or dust, next

2. Sand filtration : It is the second step which has a horizontal level to select the very small dusts
from waste water. Also it has fine different integrated wires. It is the removal of degradable
organic matter in the suspended through biological conversion in to biomass. The biomass
subsequently removes by sedimentation. Screening: It is the first WWT system. It uses
physical barrier and it removes coarse large solids such as plastics, woods sticks, and clothes.
a. To protect pumps and other mechanical equipment from damage.
b. To protects closing valves and other accessories in the WWT.
C. To remove all the process none reliabilities chemical and effectiveness.
Grit chamber: It is used to inert or grit in the waste water. It includes heavy material with
specific greatly greater than organic solids.
3. Equalization tank : It is the third step that has eight tanks connected with one big tank. Each
tank has its Owen metal pipe which has air pressure in the, inserting under the water level to
circulate the water to protect from sedimentation due to its odor.It is used to decolorized,
odorless and neutralized the water by using water PH amount is seven. It includes: flow
equalization, organic equalization and nutrient balancing.

Objective of equalization tank:

Equalization of flows to minimize surge.

Equalization organic loads to dampen.

Neutralization of PH variation to bring it to the lunge. .

 There is a bacteria treatment and decomposition of organic materials but organic materials are
not treating because there is no chemical treatment is takes place. Sludge measurement,
temperature, PH, chemical demand measurement process is takes place

4. Final sedimentation tank

It has two tanks which all water treatment fulfill means the color ,odor, PH value and terdigidity
less than 5mg/l then it enters to the river after Cleaned. In this Step process measurement is taken
by selective bakery which is used for the purpose the sludge amount is 650ml/s sediments in the
bakery.in this value the water is enough clean and after the cleaned water enters to the river the
remainder sludge at the center of the tank is goes to the next step falling tank because excess
bacteria is there.

Figure 2 wastewater treatment of ALTEX

1.17 FACED ENGES

we have faced so many problems in the internship program some of the difficulties are.
 Site language- when we joined in to the project the name of woven processing material
made confusion.
 Work flow- since our site is too vast one worker (employee) can work in many or more
than one works. This make us confused to separate the workers to communicate with us
or to help us by their profession.
 Experience of the employee-while asking a question they lose a confidence, since they
are not experienced. They have not able to communicate freely with us.
1.18 MEASURES TO SOLVE CHALLENGES
 : The measures I used to solve the problems are the follows
 To solve the challenges regarding to site language I decide to create a good relationship
with the daily workers of the department.
 To know the work task of each employee I decided to arrange a program that meets with
the employee, they are volunteer to accept the program then the problem is solved.
 The challenges regarding to experience as explained above I have good friend ship with
all the workers or employees, so it helps to build a confidence and to communicate freely,
at that time I got a good experience form the employee and from the skilled person.

CHAPTER TWO

OVER ALL COMPANY STRUCTURE

2.1 MANAGEMENT STRUCTURE OF THE COMPANY

 GENERAL MANAGER: guides, controls and give commands for its branch and
control overall activity in the company.
 LEGAL ADVISOR: it is for consulting or advising if there is a related issues around
laws and rules.
 INTERNAL AUDITOR: audit the financial and product of the company.

 PRODUCTION AND THECNICAL DGM: works as behalf of manager for

technical and production sector.
 COMMERCIAL DGM: control all the activity of financial and supply of the
company.
 ENGINEERING DEPARTMENT: works on modification of materials, spare parts,
repairing of rooms like civil and repairing of motors etc.
 TECHNIQUE and department: it is a research and development on techniques in the
factory.
 FINANCE DEPARTMENT: control and study payment and custom clearance and
cost analysis.
 MARKETING DEPARTMENT: control sales, study cost or price of product and
promotion of product.
 SUPPLY DEPARTMENT: purchasing of materials depend of department demand
and distribute accordingly.
 BRANCH OFFICE: works on financial supply and HR activities.

 HUMAN RESOURCE DEVELOPMENT: promotions, annual leaves control

discipline of community in the company.
 G/SERVICE DEPARTMENT: giving BUS service, clean lines of the company,
gardening and guarding.
 ATC: coach and train the new operators and gives refreshment course for old operators,
shift leaders, supervisors and invite other company operators and trains and entrain
them.SYSTEM11
 SYSTEM DEVELOPMENT: works on QMS (quality management system), make
ready for certification or works to be certified, and responsible for anew facilities for the
company development.

2.2 MATERIAL AND ENERGY BALANCE ON SELECTED EPUIPMENTS
MATERIAL BALANCE
Material balance of sizing
Mass out=mass inlet
 A given yarn is warping on 8 beams with:-
Warp count 20X, weft count 20
Total No of ends 400
Warp density 60 X, weft density 48
Width = 63
Total weight of yarn = 1500kg39
Total length yarn = 12100m
Is to be sized after sizing the total weight of the yarn is increased by 8% and the total length is by
one percent.
Balance on weight
No of cones = No of end
No of beams
No of cones = 4000 ends = 500 cones
8 beams
Since the total weight of the output yarn is increased by 8% therefore.
T .wt of output = 1500kg +8% x 1500kg
T.Wt of output= 1620kg
- The T. w .t increased after sizing is by 1620kg - 1500kg= 120kg
Balance on length
Since, the total length of the material will be increased 1% after sizing. Therefore, the total
length of output yarn is
T. Length output = 12100 +1% x 12100m
T. length output = 12100 + 121T. Length output =12221m.Then the T. w.t increased after sizing
is by 12221m- 12100m = 121m

2.3The work task we have been executing

During the internship period, we have been executing a number of works in different areas such
as processing, which are relevant to our field. The following are the major areas that we have
been executing:

 Design of chemical in laboratory

  Controlling chemical parameters of sizing. Desizing, mercerizing and washing machines.

We work in detail on checking chemical parameters and their effect on different processing
areas.

In addition to the above activities, we also have been satisfying on the project of printing
machine.

2.4. Over all plant efficiency analysis

It is obvious that most Almedafactory institutions are more profitable, because and liquors are
the needs of many persons.in almedatextile factory is also satisfactory, because of the following
reasons;
 The workers of the company are too clever.
 It dominates and owns too much consumer

2.5ENVIROMENTAL IMPACT ANALYSIS

Environmental impacts start at the farm level, when toxic chemicals are used to support growth
of cotton (fertilizers, insecticides, fungicides). In the case of synthetics (which represent more
than 60 % of fiber production), the most important resource is oil. Thus, production of synthetic
fibers leads to exploitation fossil fuels, directly for production processes in the textile industry
and indirectly for processes involved in extracting and refining the oil Resource use, high waste
volumes, water use, and toxic .Textile industry is extremely energy-, water- and chemical-
intensive mainly due to wet processing. Regardless the type of fabrics and their final destination,
most of them go through wet processing, which consists of cleaning, bleaching, dyeing, and
finishing in an aqueous environment. Wet processing puts enormous pressure on the
environment, as it requires great amounts of water and large volumes of toxic substances. It
involves treatment with chemical baths, often requires washing, rinsing and dying.
Environmental issues within the textile industry are very heterogeneous and depend
on the type of fibers used for production – natural (cotton, wool, flax, silk) versus
manmade/synthetic (polyester, polyamide, rayon, acetate, acrylic) and the type of CSR Activities
and Impacts of the Textile Sector 11 production process (wet versus dry).
For this reason, it is very difficult, if not impossible, to apply a single life cycle assessment to
highlight the environmental pressure resulting from the whole production process within this
sector).
This is due to a circular relationship that exists in the area of resource use: industry uses the
available resources and in turn produces goods and services to society, consequently sustainings
their resource base through waste minimization, and efficiency is a rational firm decision.
The textile industry still faces challenges in dealing with sustainable development issues from
the point of view of natural resource usage such as oil for synthetic garment manufacturing, and
soil for growing cotton, due to increasing world consumption of these resources and thus
intensifying scarcity. Noted sustainable development challenges for this industry also include
social issues within the industry supply chain, in terms of lab our and working conditions.
Despite industry’s efforts to portray their overseas factories as contributing to sustainable
development through their Codes of Conduct in host countries, the industry remains in high
NGO scrutiny.

CHAPTER THREE
THE OVER BENEFITS ALL THAT GAINED FROM THE COMPANY

3.1 IMPROVING PRACTICAL SKILL

 Problem solving approaches and procedure in solving practical problems like weaving
operation.
 Practices how to calculate the order analysis in the department by taking practical sample.
 The other main importance this internship program is helps to know technologies about
spinning, weaving, finishing, knitting and garmenting of Almeda textile private limited
company (plc.)
 Practically how to adapt the overall survival in the company.

3.2 UPGRADING THEORETICAL KNOWLADGE

 Seeing practically and get more information through observation.
  Ask the maintenance operators and other responsible person to the different machines in
different department.
 By relate with theories, calculations, machine type differences, working principles,
efficiencies, and property of the machines.
 And by using manuals and other materials from the company.

3.3 INTERPERSONAL COMMUNICATION SKILL

In the internship program, I have got a chance to communicate with each department
manager, maintenance heads and operators, production heads shift leaders, training centers
and peoples around marketing, finance, supply that responsible for their own authority.

During interpersonal communication we also develop our verbal and nonverbal symbols:-

Verbal: during communicating, that the way of or the speaking must be clear and light words to
make easy for understand.

Non-verbal: when communicate with someone, the act, sign and symbols must be regular.
Example: Eye contacts, gesture, space, touch…

3.4 TEAM PLAYING SKILL

 Our cooperation between us, confidence in the group members, respect seniority and
before taking actions our individual opinions are comes in to one great idea (by sharing
ideas), even to get permissions some facilities from the hosting company ALTEX, all we
have responsibility to ask.
 We also try to solve some problems in group, we spent most of our times together with
pleasure
 Treat each other; even invite some lunch, tea… just to maintain working relationships.
 Encourage team members to share ideas

3.5 LEADERSHIP SKILL

Generally, from the working condition in company the following effect is observed of leader in
doing task.

 How to organize workers and allocate for different tasks and duty.
 How solving when problem faced and handling the employers.
 How to negotiate when the workers fight to each other
  How to indicated workers to be increase production capacity.
 Organizing group members.

3.6 UNDERSTANDING WORK ETHICS

In ALTEX there are job disciplines for operator to increase or develop a good team sprite and
friendly relationship among themselves and machine safety. For example: eating, smoking inside
the production area is prohibited. As we have stayed, I have got practical work/job disciplines
that used to me after graduation like;

Punctuality: it has its own benefits

The company will be more productive

Employee will be motivated morally and financially

Bosses will have more confidence to the employee

Employee will improve industrial culture

Method of quality control

Principle of 3M’s (manpower, material, machinery)

Glove: to protect touching of chemicals and other hazardous material.

Mask: used for covering of mouth and nose; and protect dust and tiny –particles from entering.

Safety rules during machine operation: for example before operate the machine pay proper
attention to the people around the machine, wear properly (don’t wear scarf, high heal shoe, tied
the long hair properly).

3.7 ENTERPRENEURESHIP SKILL

As a chemical engineer and entrepreneur, knowing the condition of factory on how it is going
on, departmental sections and types of available technologies used in the factory helps to identify
required in the current market level. In addition at the time of internship I know the steps and
mechanisms they used in the factory based on:
 The problem solving to understand the problem of the plant
 Job creator with my colleges
  The ability to work both as part of a team and independently
 Able to research effectively (available markets, supplier, customers and the competition)
 Able to plan coordinate and organize effectively
Self-motivated and disciplined

CHAPTER FOUR

Biogas production from wastewater treatment sludge

4.1. Introduction and back grand

Biogas, is a renewable energy, can be produced from a variety of organic raw materials and
utilized for various energy services such as heat, combined heat and power or as a vehicle fuel.
Biogas can be produced by anaerobic digestion or fermentation of biodegradable materials such
as biomass, manure, sewage, municipal waste, green waste, plants material and energy.
Emphasis is laid on sludge from municipal wastewater treatment plants in this paper. As we
know, large amounts of waste activated sludge, containing organic and mineral components, are
produced by municipal and industrial wastewater treatment plants. Most relevant is municipal
solid waste. Sludge handling represents a bottleneck in wastewater treatment plants, due to
environmental, economic, social and legal factors. If handled properly, sludge can be a valuable
resource for renewable energy production and a source of nutrients for agriculture. The
characteristics of sludge vary widely from relatively fresh fecal materials generated in bucket
latrines to sludge which has undergone bacterial decomposition. The treatment required is
therefore dependent on the characteristics of the sludge.The contribution of renewable sources is
almost negligible that this would lead to an energy crisis in the future and increase in the
pollution. Environment pollution is one of the most important consequences faced by human
beings in day to day life. The climate change due to dumping of waste materials to the
environment and global demand for the fossil fuels is the big hassle to humans. Biotechnology
approaches are the most sustainable, environmental friendly and cost effective way of converting
the waste material in to biogas.
4.2. Problem statement and its justification
Throughout the internship period we found some problems related with our knowledge of
Chemical engineering, especially in area of using energy since almeda textile industry
consumed high amount of electric power which is costly for steam boiler, electric boiler, oil
boiler and other machine.so our project tray to solve the problem using biogas as the source of
energy.

In the wastewater treatment plant there is much amount of sludge removed as waste and which is
highly polluted the environment and ceases series dieses in the community. so we prefer to find
solution by doing our project on this problem.
The sludge which remove is highly polluted the environments
4.3 Objective
4.3.1 General Objective
 Minimizing of cost in the company

4.3.2 Specific objective

 Reduce greenhouse gas emission and global warming

 The process is environmental friendly
 Reduce deposal waste and environmental pollution
 Give an energy supply for the company

4.4. Significant of project

This project used mainly for the company to supply energy in order to minimize the cost to pay
for electric power.This project also used for us to improve theoretical as well as practical
knowledge’s. The project also helps us for the researchers to do such kinds of project. Moreover,
the project used to treat waste product to remove many problem which are list in the above.
4.5. Scope and limitation
This project was carried out to provide energy by using biogas and treat sewage. The
performance status of wastewater treating sludge was identified us by research. Aspects look
into were hydraulic digester design in a historic context, anaerobic treatment process, packing
and filtration media, design concepts, engineering design, detail engineering and isometric
Drawings for illustration purposes. Field construction and other subsequent
Activities such as wetland design and cost for the treatment of effluent are beyond the scope of
the current study.
4.6. LITERATURE REVIEW

4.6.1 Research and development of biogas technology

Biogas plant has been described to consist of a mixing chamber, an airtight digester with an
agitator, a pond for the slurry and a gas-holder. The feedstock, which is mainly dung and poultry
droppings is mixed with water in the mixing chamber and emptied into the digester where it is
metabolized by micro-organisms. Biogas and digested substrate are the main output products.
The latter is stored in a standard manure storage tank known as a gas storage tank. Biogas
consists of approximately 60:40 mixture of methane (CH4) and carbon dioxide (CO2) with
calorific value of 23 MJ/m3, and can be used to fuel internal combustion engines to generate
electricity. It can also serve as cooking and heating.

4.6.1. Renewable energy source

The current global energy supply is highly dependent on fossil sources (crude oil, lignite,
Hard coal, natural gas). These are fossilized remains of dead plants and animals,which have
been exposed to heat and pressure in the Earth's crust over hundreds of millions of years. For
This reason, fossil fuels are non-renewable resources which reserves are being depleted
much.Faster than new ones are being formed. The World’s economies are dependent today of
crude oil. There is some disagreement among. Scientists on how long this fossil resource will last
but according to researchers the peak oil.Production has already occurred or it is expected to
occur within the next period of time.
4.6.2. Reduced greenhouse gas emissions and mitigation of global warming

Utilization of fossil fuels such as lignite, hard coal, crude oil and natural gas converts carbon,
Stored for millions of years in the Earth’s crust, and releases it as carbon dioxide (CO2 ) in to
the atmosphere. An increase of the current CO2 concentration in the atmosphere causes global
Warming as carbon dioxide is a greenhouse gas. The combustion of biogas also Releases CO2,
However, the main difference, when compared to fossil fuels, is that the carbon in biogas was
recently up taken from the atmosphere, by photosynthetic activity of the plants.

The carbon cycle of biogas is thus closed within a very short time (between one and several
years Biogas production by AD reduces also emissions of methane (CH4) and nitrous oxide
(N2O) from storage and utilization of untreated animal manure as fertilizer. Potential of
methane is higher than of carbon dioxide by 23 fold and of nitrous oxide by 296 Fold. When
biogas displaces fossil fuels from energy production and transport, a reduction of Emissions of
CO2, CH4and N2O will occur, contributing to mitigate global warming.

4.6.3. Waste reduction

One of the main advantages of biogas production is the ability to transform waste material In to
a valuable resource, by using it as substrate. Many countries are facing Enormous problems
associated with overproduction of organic wastes from industry, agriculture and households.
Biogas production is an excellent way to comply with recycling of the digested substrate as
fertilizer. AD can also contribute to reducing the volume of waste and of costs for waste
disposal.

4.6.4.The nature of textile sludge

Main sources of wastewater generated by the textile wet-processing industry originate from the
washing (scouring) and bleaching of natural fibers and from the dyeing and finishing steps.
Given the great variety of fibers, dyes, process aids and finishing products in use these processes
generate wastewaters of great chemical complexity and diversity which are not adequately
treated in conventional WWTP. The chemical composition of textile mill effluents is also
changing rapidly as a result of shifting consumers preferences. Most significant is the current
popularity of cotton fabrics and bright colors leading to greater usage of reactive dyes. An even
more important cause of shifting wastewater composition are the new and tighter restrictions on
discharged effluents and consumer goods.

4.6.5 Sludge from municipal wastewater treatment sludge

Sludge generated from municipal wastewater treatment plants are mainly primary sludge and
activated sludge. The end-product after handling the two types of sludge through anaerobic or
anerobic digestion is digested sludge.values of gas production from primary sludge and activated
sludge , it is inconclusive to provide the methane content of the gas production .
1. Primary sludge
Primary is also called raw sludge which comes from the bottom of the primary clarifier. Primary
sludge is easily biodegradable since it consists of more easily digestible carbohydrates and
fats, compared to activated sludge which consists of complex carbohydrates, proteins and
long chain hydrocarbons. So biogas is more produced.
2. Activated sludge
Activated sludge is also called excess sludge or waste activated sludge which comes from the
secondary treatment. It‘s a result of overproduction of microorganisms in the activated
sludge process. The content of activated sludge was just mentioned above. Activated sludge
is more difficult to digest than primary sludge.
3. Digested sludge

After anaerobic digestion of primary and activated sludge the residual product is digested sludge.
The digested sludge is reduced in mass, less odorous, safer in the aspect of pathogens and more
easily dewatered than the primary and activated sludge.

4.6.6. Parameters for biogas production

1. Temperature
Anaerobic digestion can take place at any temperature between 4oC and 60oC. There appear to
be two main temperature ranges within this wider range corresponding to two different sets of
bacteria, usually called the mesophylls, those which operate be stat 20-4oC, and the thermopiles,
which prefer to live at temperatures between 40oCand 60oC. Digestion can also occur in the
psychrophilic range, 4-20oC, but is much slower. The rate of gas production increases with
increased temperature but there is a distinct break in the rise around 40oC, as this favors neither
the hemophilic or the Thermophile. A small capacity digester can be used if supplementary heat
is supplied to maintain a constant temperature of 35oC, if it is to be loaded with one type of
material (for example pig manure) and if it has some form of agitation to keep slurry gently
stirred. Methane bacteria can tolerate a minimum temperature of about 4oC but function best in
higher temperature ranges up to 60oC.

The range most commonly used in municipal sewage treatment plants is 33- 38oCThermophilic
temperatures of 55-58oC have been investigated for anaerobic digestion but high heating
requirements and unstable operation have restricted practical application of this technology. The
methane forming bacteria are very sensitive to thermal changes and for optimum operation the
temperature should be controlled within a narrow range of the selected operating temperature.
2. Retention Times

The length of time that volatile solids remain in an anaerobic digester is an important factor in
the digestion process. The solids retention time (SRT) represents the average time
microorganisms spend in the system. Minimum solids retention times foranaerobic digestion
systems are in the range of 2-6 days, depending on the temperature .In completely mixed
anaerobic digesters where no recycling occurs, theSRT is equal to the hydraulic retention time
(HRT). Hydraulic retention times usually vary from 10 to 30 days depending on the temperature.
If solid retention time is too short the microbes are “washed out” of the digester and digestion
process fails, while along retention time requires a large digester.
3. Loading Rate

The loading rate is also related to the residence time of slurry, that is, how many daysit stays in
the digester. Undigested slurry is heavier so it goes to the bottom. As itdigests it raises to the top
and to the overflow part. If the loading rate is correct the digestion is sweet, the pH of the content
is maintained at 8 to 8.5 and the gas is good quality to maintain uniform gas production and to
minimize the possibility of upsetting the balance between the two bacteria processes in the
digester, the loading rate should be maintained as uniformly as possible. This is especially
important when one considers the effects of age and management practices on liquid manure
quantity and characteristics. When loading rate is too high it inhibits gas production, but it may
be possible to gradually increase the loading rate once the microbial population is properly
established.

4.7 METHODOLOGY
This portion focuses on which methods are employed to collect data, organized and analysis
data during the internship program in Almeda Textile plc. So that different techniques are used
which are relevant and important for the study.

1. Data collection:

The following methods are employed to gather information in preparing this paper:

 Primary source:
 interviewing the concerned body
 observing in the working time
 Secondary source:
 Referring coloration handouts

4.7.1 Anaerobic digestion method

Anaerobic digestion is a process in which microorganisms break down biodegradable materials

from sewage sludge in the absence of oxygen to manage waste and to release energy. Typically
during a digestion process, about 30-60% of the input solid is converted to biogas, the rest of the
sludge is then dewatered, potentially converted to fertilizer, and disposed to landfill. Anaerobic
digestion is one of the oldest and most widely used methods for sewage sludge treatments. It
benefits in reduction of solids and the destruction of pathogens. Another advantage of this
process is its availability at all scales, from small to large waste water treatment facilities.
Process of anaerobic Digestion

The digestion process comprises of four steps: hydrolysis, acid genesis, acetogenesis, and
methanogens. All four steps occur simultaneously within in a digester. The microorganisms
involved with each phase are metabolically dependent upon each other for survival. . Hydrolysis
The hydrolysis phase consists of breaking down complex particulate matter into lower molecular
weight compounds using hydrolytic enzymes such as proteases, cellulose, and lipases. The large
compounds, for examples proteins, carbohydrates, and lipids, are hydrolyzed into smaller units
such as amino acids, sugars and fatty acids. These small units will be taken in by microbial cells.

4.7.1.1 Acid genesis

Acid genesis is known as the beginning of fermentation. It continues breaking down the small
units from hydrolysis phase into more simple ones. The facultative and obligate bacteria used in
this phase break down amino acids, sugars resulted from hydrolysis into acetic acid and volatile
fatty acids, for instance propionic and butyric acid. Those bacteria also break down fatty acids
existing in the digester into hydrogen, carbon dioxide and more of volatile fatty acids. The
simple molecules including acetic acid, hydrogen and carbon dioxide can be taken by the
bacteria in the last phase -methanol genesis. The volatile fatty acids are more complex and need
to undergo another phase called acetone genesis. The role of facultative bacteria is essential for
the whole digestion process. They can metabolize through the oxidative pathway, and thus
remove any dissolved oxygen within the mixture. Oxygen is toxic to some microorganisms,
especially the methanol genesis.

4.7.1.2 Acetogenesis

During acetogenesis, volatile fatty acids which are formed during the acid genesis phase react
with water in the presence of acetogenic bacteria. The products of these reactions are acetate,
hydrogen and carbon dioxide. These products are also formed during the acid genesis phase, but
the complete acid break down is only achieved during acetogenesis. The reactions below show
how propionic acid and butyric acid react with water as examples of volatile fatty acids getting
broken down to form methane.

Breakdown of propionic acid:

Step 1: Acetogenesis

CH3CH2COOH + 2H2O = CH3COOH + CO2 + 3H2

Step 2: Methanogens

CH3COOH = CO2 + CH4

The first step occurs during acetogenesis while the second step is seen in methanogens. These two steps
occur simultaneously. The products of acetogenesis are converted to biogas at the same rate at which they
are produced

4.7.1.3. Methanogens

Methanogens is the last stage of digestion. Methanogen microorganisms break down the end
products of acetogenesis which are acetate, carbon dioxide and hydrogen to form biogas,
predominantly made up of methane and carbon dioxide. About 70% of methanogens use
acetoclastic pathway to form methane; while the other 30% use carbon dioxide reduction.

4.8. RESULT and Discussion

• biogas enhance energy security by diversifying energy sources & utilizing local
resources
• It brings independence of the industries by reducing dependency on the consumption
of fossil fuel
• It brings several environmental benefits, mainly in terms of GHG reduction.
It would reduce the equivalent fossil fuel import bill of the government & there by
improve the balance of payment position.
• It brings additional economic and income generation activity into rural areas
• It Reduce problem of biogas waste management
It would diversify the rural economy, which generally rely entirely on food crops, byintroducing
energy plantations it creates possible additional revenues for the agricultural and forestry
sectors.

4.8.1 Experimental method

Two sets of experiments were performed, the first set was performed in a 4L vessel, and
the second set was performed in 10L plastic bottles both to mimic batch bioreactors.
Details of these two sets of experiments are discussed below:

Set 1: The first part of the experiments was carried out in 4L plastic bottles filled by 3 L sludge.
The purpose of this part is to study the effect of sludge concentration and retention time on
biogas production. Conditions at which maximum biogas production obtained were tested by this
experiment. The bottles were hooked with a hollow pipe sealed with rubber tube which can be
closed to prevent gas escape from the bottles. . The withdrawn gas sample was then sent to the
gas analyzer. The initial weight of the bottles and their weight aftersampling were recorded.
Knowing the difference in the weight and the concentration of CH4 gas enables calculating it

mass. .

Figure 3. Bach reactor containing activated sludge and bottle contain biogas
The experiment was done at room temperature and atmospheric pressure and also the sludge was
stayed for one month. During this time we recorded data to determine the mass of biogas
released from plastic reactor to the bottle and the data was recorded in five day interval.Then
amount of produced biogas was measured by gas detector instrument. The result of this
experiment shows when the retention time increase the mass of biogas also increase.theresult
express in the following graph.

Sampling is needed, a syringe is inserted through the rubber tube which is then opened allowing
the gas to flow into

The second experiment was done similar to the first but there is a difference in amount of
activated sludge and volume of reactor. We used 10L plastic filled by 8L activated
sludge. The main objective was to determine the amount sludge effect on biogas
production. The result shows that when the amount of sludge increase the production of
biogas also increase.

4.8.2 Detail design of biogas reactor

8.1. Anaerobic baffled reactor (ABR)

An Anaerobic Baffled Reactor (ABR) is an improved septic tank because of the series of
baffles under which the waste water is forced to flow. The increased contact time with the
active biomass (sludge) results in improved treatment. The anaerobic baffled reactor (ABR)
is made up of a series of up flow and down flow baffles, where the baffles are used to direct
the flow of wastewater in an up flow mode through a series of sludge blanket reactors. This
configuration provides a more intimate contact between anaerobic biomass and wastewater
which improves treatment performance. It could be used as primary treatment as well,
especially where toilet effluents are diluted with flush water. Separation of the solids
retention times (SRT) from the hydraulic retention times (HRT) is the key to the successful
operation of an ABR. Due to this fact, a baffled reactor is considered as the best alternative in
aerobic treatment and/or primary Settlement. The majority of settle able solids are removed
in the sedimentation chamber at the beginning of the ABR, which typically represents 50 %
of the total volume. The up flow chambers provide additional removal and digestion of
organic matter: BOD may be reduced by up to 90 %, which is far superior to that of a
conventional septic tank. Critical design parameters include a hydraulic retention time (HRT)
between 48 to 72 hours, up-flow velocity of the wastewater less than 0.6 m/h and the Number
of up-flow chambers (2 to 3). The treatment efficiency achievable is 70-95% BOD removal,
which makes the effluent quality moderate but usually superior to that of a Conventional
septic tank. This technology is easily adaptable and can be applied at the household level or
for a small neighborhood. An ABR can be designed for a single house or a group of houses
that are using a considerable amount of water for clothes washing, showering, and toilet
Flushing. It is mostly appropriate for industry waste water treatment use and supply of
wastewater are relatively constant.

This technology is also appropriate for areas where land may be limited since the tank
installed Underground and requires a small area. It should not be installed where there is a
high Ground water table as infiltration will affect the treatment efficiency and contaminate
the Ground water although the removal of pathogens is not high, the ABR is contained so
users do not come in contact with any of the wastewater or disease causing Pathogens.
Effluent and sludge must be handled with care as they contain high levels of Pathogenic
organisms. To prevent the release of potentially harmful gases, the tank should be Vented.
ABR tanks should be checked to ensure that they are watertight and the levels of the Scum
and sludge should be monitored to ensure that the tank is functioning well. Because of the
delicate ecology, care should be taken not to discharge harsh chemicals into the ABR. the
sludge should be removed annually using a vacuum truck to ensure proper functioning of the
ABR. This picture shows that biogas production from wastewater sludge and simple
engineering drawing indicating by the numbers. The number express from the sludge first
enter the reactor up to the biogas storage tank.
 Figure 4 Engineering drawing of biogas production ABR
1—Inlet; 2—Inlet pipe; 3—Fermentation chamber; 4—Gas chamber; 5—Movable plug;
6—Biogas guide; 7—Outlet pipe; 8—Hydraulic chamber ; 9—Overflow pipe.10—Storage
tank.

Raw wastewater

Primary
treatment
Aerobic west water Treated waste
water
Treatment
operation

eration

Solids Solid

Solids to disposal
An aerobic
sludge digestion

Biogas
destruction CO2,CH4,H2O
devise

Flow chart:5. Diagram of Biogas Recovery from wastewater treatment sludge

4.9. MATERIAL AND ENERGY BALANCE
The heating value of any fuel is the energy released per unit mass or per unit volume of the fuel when
the fuel is completely burned. The term calorific value is synonymous to the heating value. Typical units
for expressing calorific or heating value are MJ/kg in SI units or Btu/lb in English units. The heating value
of a fuel depends on the assumption made on the condition of water molecules in the final combustion
products.

The higher heating value (HHV) refers to a condition in which the water is condensed out of the
combustion products. Because of this condensation all of the heating value of the fuel including
sensible heat and latent heat are accounted for.

The lower heating value (LHV), on the other hand refers to the condition in which water in the
final combustion products remains as vapor (or steam); i.e. the steam is not condensed into
liquid water and thus the heat is not accounted for.

The term net heating value (NHV) refers to LHV. The term gross heating value (GHV) refers
to HHV.

The high heating value can be estimated from the composition of the fuel (Gaur and
Reed 1995),
HHV=0.35Xc+1.18XH+0.10XS-0.02XN-0.10XO-0.02XASH (Eq. 1)

HHV=0.35Xc+1.18XH+0.10XS-0.02XN-0.10XO-0.02XASH (Eq. 1)

1. Estimation of HHV of saw dust

Composition of elements

M (%) Ash (%) C (%) H (%) O (%) N (%) S (%)

0.35 o.65 51.6 6.26 41.4 0.00 0.00

Equation 1 is used to calculate high heating value

HHV=0.35Xc+1.18XH+0.10XS-0.02XN-0.10XO-0.02XASH

Substituting from compositions listed in the table above for saw dust

HHV= 0.35(51.64 )+ 1.18(6.26 ) +0.10(0.00 ) -0.02(0.00 )- 0.10( 41.45 ) -0.02(0.65 )

 =21.3 MJ/kg

2. Estimation of LHV of saw dust

Equation 2 is used to calculate low heating value

LHV= HHV(1-M)-2.447M
Substituting for HHV and moisture content,

LHV= (21.3 MJ/kg)(1-0.35)-2.447(0.35)

= 12.99 MJ/kg

HHV of furnace oil = 45.69 MJ/kg LHV of furnace oil=37.86 MJ/kg

V=30 L/hr

m=density x V

=0.97kg/Lx30L/hr

=29.1kg/hr of furnace oil

Energy supplied by combustion of fuel = mass of fuel consumed X heating value

=37.86MJ/hrX 29.1kg/h

= 1101.7 MJ/hrby furnace oil

1101.7 MJ/hr =12.99 MJ/hr X M

m=841kg/hr

Thus 29.1kg/hr of furnace oil can be substituted by84kg/hr to generate 1101.7 MJ/hr of energy.

4.10 ENVIRONMENTAL IMPACTS

Any organization has a legal and moral obligation to safeguard the health and welfare of its
employees and the general public. Safety is also good business; the good management practices
needed to ensure safe operation will also ensure efficient operation. The term “loss prevention”
is an insurance term, the loss being the financial loss caused by an accident. This loss will not
only be the cost of replacing damaged plant and third party claims, but also the loss of earnings
from lost production and lost sales opportunity.
All manufacturing processes are to some extent hazardous, but in chemical processes there are
additional, special, hazards associated with the chemicals used and the process conditions. The
worker must be aware of these hazards, and ensure, through the application of sound engineering
practice, that the risks are reduced to acceptable levels.

4.11 Conclusion and Recommendations

4.11.1. Conclusion

During our internship period, we have got relevant professional and practical
experiences, entrepreneurial skills and creative thinking etc, which are very important for
us after graduation. In our internship period, we have seen practical works in our
company. In this practical work period, we have got important knowledge about fabric
making process and we have seen the real work of Chemical Engineer in practical world.
And also we have got full information about the historical development of Almeda
Textile, services of organizational structure of and its duty.
In this internship program companies also can become familiar with the candidates at
an early stage of their studies through internship. Hence, it can reduce risks, when
employing graduates, as it is already familiar with the performance and the profile of the
candidates

4.11.2. Recommendations
Almeda textile giving a good service for the society in making yarn and finished fabrics.
This service is helpful in socio-economic activities of the country. We recommend that
Altexie use only single de sizing, scouring and bleaching operation. These process take
more time, more space, extra cost of chemical, generation of more effluent, more amount
of water, more amount of thermal energy, etc. so in order to solve such problem the
company use combined operation. Such as combined de sizing and scouring, combining
scouring and bleaching operation to reduce time, space, and initial cost, produce more
production and to reduce chemical cost. In addition to this, the company uses one side
 singeing .So the singed fabric is difficult for subsequent process especially for printing
and light dyeing. One side singeing creates uneven singeing or incomplete singeing.
We recommend if the use biogas instead of steam boiler it became more profitable.

Abbreviation and Acronyms

 ALTEX-almeda textile
 PLC- private limited company
 ETB- Ethiopian birr
 EFFORT- Endowment Fund For the Re-habilitation Of Tigray
 DGM-Deputy General Manager
 ATC-Almeda training center
 R & D- Research and Development
 HR- Human Resource
 ABR-Anaerobic baffle reactor
 HBR-Hydraulic retention time
 SRT-Solid retention time
 BOD-Biological oxygen demand
 WWT-Waste water treatment

Reference

1.Quality control manual of ALTEX

2. Laboratory manual of ALTEX

3. Biogas text book
4 Spinning manual
5 Wet processing manual

6library
7and from other operators