Professional Documents
Culture Documents
BAHIR-DAR UNIVERSITY
BAHIR-DAR INSTITUTE OF TECHNOLOGY
FACULTY OF CHEMICAL AND FOOD ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
Internship final report: (FEB 16 – JUNE 16, 2017)
Internship hosting company: MOHA Soft drinks industry (Nifas silk plant)
ACKNOWLEDGEMENT
First of all we would like to thank the almighty God for helping us on the correct way. we would
like appreciate and respect to the institution for providing these precious opportunities that
enable me familiar with practical skill. Special thanks for our advisors Mr. Tadele N. and Mr.
Natnael G. and the company supervisor w/ro wudie Tibebu for her encouragement, guidance and
the fact that she has provided me with all the supporting materials, facilities and her advice to
complete my project successfully. And also special thanks for Ato Yewlsew belay, all quality
control chemists, carbon dioxide production plant laboratory chemists and technics. Finally I
would like express my gratitude to all MOHA soft drink operators, advisors to help the
internship experience (especially Addis (technics supervisor)).
EXECUTIVE SUMMARY
This report and the project work consists the brief history and profile of our hosting company
including the main raw material used to produce its main products. And also the main customers
that use its main products and supplier, consequently its organizational structure and detail work
flow of beverages production activities in each section and the overall systems of the
organization the report also describes the current practice and activities that take place in the
production Department and other main supportive departments. The factors constrained their
activities was also identified. Following this I tried to describe the analysis made to solve those
problems by using different techniques and recommendation during internship I was able to
understand the company competitive strength and dedications of both the management and
employees in every fate of organization operations. In addition to the overall benefit that I gained
during the internship and the significance of the project these are in terms of improving and
upgrading the practical skill, theoretical knowledge ,team playing skills leadership skills, work
ethics, entrepreneurship skills and interpersonal communication skills
Contents
ACKNOWLEDGEMENT ............................................................................................................................ 2
EXECUTIVE SUMMARY .......................................................................................................................... 3
LIST OF FIGURE......................................................................................................................................... 7
LIST OF TABLE .......................................................................................................................................... 9
ACRONYMS .............................................................................................................................................. 10
CHAPTER ONE: INTRODUCTION ......................................................................................................... 11
1.1 Back ground of the MOHA soft drink industry in Ethiopia.............................................................. 11
1. 2 Objective of the company ................................................................................................................ 12
1.3 Mission and Vision of the company ................................................................................................. 12
1.4 Main product s of the company......................................................................................................... 13
1.5 The main customer of the company .................................................................................................. 13
1.6 Organizational structure .................................................................................................................... 14
CHATER TWO: THE OVERALL INTERNSHIP EXPERIENCE ........................................................... 16
2.1 How we get into the company........................................................................................................... 16
2.2 Production process description of the company................................................................................ 17
2.2.1 Raw materials of carbonated soft drinks .................................................................................... 18
2.2.2 Water treatment .......................................................................................................................... 18
2.2.3 Boiler room ................................................................................................................................ 25
2.2.3 Bottle and case washer room ..................................................................................................... 25
2.2.4 Carbon dioxide production plant................................................................................................ 32
............................................................................................................................................................ 33
2.2.5 Syrup room................................................................................................................................. 37
2.2.6 Filling room ............................................................................................................................... 42
2.2.7 Quality control section ............................................................................................................... 44
2.2.8 Cooling compressor section ....................................................................................................... 50
CHAPTER THREE: OVERALL INTERNSHIP BENEFITS ................................................................... 52
3.1.1 Improving Interpersonal Communication Skills ........................................................................ 52
3.1.2 Improving Team playing skills .................................................................................................. 52
3.1.3 Improving work ethics ............................................................................................................... 52
3.1.4 Upgrading of Theoretical Knowledge ........................................................................................ 53
LIST OF FIGURE
LIST OF TABLE
ACRONYMS
PI=Pepsi international
S.C=share company
CO2=carbon dioxide
CH4 =methane
O2=oxygen
H2O=water
N2=nitrogen
CO=carbon monoxide
CaCO3= limestone
H2SO2=sulfuric acid
CaSO4=gypsum
C2H4=ethylene
C2H4O=ethylene oxide
M reading=methyl purple
P reading=phenophtaline
MOHA Soft Drinks Industry S.C. has adhered to Pepsi Cola International Standards and Good
Manufacturing Practices (GMP).
MOHA holds 52% of the market share in soft drinks industry in the country. With an expansion
and replacement of obsolete machinery, production capacity of the plants has increased
substantially. MOHA, in addition to the initial purchase price of the Soft Drinks factory, has
invested Birr 8 Million for the expansion of new projects, Birr 153 million for refurbishment and
replacement of existing plants and Birr 241 million for marketing, infrastructure, excluding
advertisement and sponsorship expenses. Also, a significant growth over the years of production,
sales, and profitability due to reorganization of operations has been achieved. Productivity has
improved tremendously with major cost savings and has insured a regular supply of high quality
products. It has also succeeded in reaching new market areas across the country.
The drink Pepsi was firstly introduced as “brad’s drink” in United States. Who made it at his
drug store where the drink was sold, It was renamed to Pepsi cola in 1898, named after the
digestive enzyme pepsin and kola nuts used in the recipe.
In 1903, Bradham moved the bottling of Pepsi cola from his drug store to a rented ware house.
That year Bradham sold 7989 gallons of syrup. The next year Pepsi was sold in six-ounce
bottles, and sales increased. In addition to selling the drink at drugstore counters; Bradham
bottled Pepsi for sale on store shelves .At this time bottling was a new innovation in food
packaging However, due to major increases in the price of sugar, Braham began to lose money
on Pepsi and in 1923 he filed for bankruptcy. The Craven Holding Company of craven country,
North Carolina, purchased the company’s assets. In 1931 Charles G.Guth of the Loft Company
in New York City purchased Pepsi-Cola from the holding company. Guth had difficulty getting
the business going again, but he increased sales by selling larger bottles at an unchanged price.
By 1933 Pepsi Cola was sold by 313 franchised U.S. dealers bottled in the united states, Cuba,
and England and Sold in 83 countries. The consumption of soft drinks in their various forms has
taken place for many centuries in order to meet the body’s fundamental requirement for
hydration. The most obvious source of hydration is water, but in earlier times the consumption of
water was very hazardous as it was frequently contaminated by micro-organisms .Outbreaks of
cholera, dysentery and (other waterborne illnesses were common in many European cities prior
to the twentieth century.
The companies state that its first responsibility and primary focus is to both satisfy and delight
the community of end users whom it exist to serves, to fulfill needs and wants and to improve
their quality of life. It says that knowing the path to the end users lies through the retail and
wholesale trades and its priority that to listen and respond to the
MOHA’s vision is to make each of the Pepsi products to be a drink of first choice amount
consumers and obtainable throughout the Ethiopian market. The company intends to create
superior value for its shareholders, its customers and employees. raw material and suppliers of
the company
MOHA operates with attend office located at A.A led by a chief executive office (C.E.O)
appointed by the chairman of the ward. The C.E.O is empowered to direct, plan, coordinate,
organize, control and administer the overall operation of the company. Hire and file personal
directly or through this delegated management team. Represent the company in all fields of the
company activities. To approve annual budget and justify to the board chairman or MIDROC–
Ethiopia, keep and maintain the proper booking of the company accounts. Hierarchically the
C.E. chairman of the board currently O is accountable to the activities of the company reporting
to C.E.O are grouped in to the following functions
1. Finance division
2. Human resource division
3. Marketing division
4. Technical division
5. Procurement &stores /supplies division
6. Quality control &production division
7. Audit division
8. MIS service
9. Legal service
10. Plants at different location
11. Regional office
Concentrate - receipt and handling must be properly managed ensure good quality
beverage.
Carbon dioxide - imparts a pungent slightly acidic taste to the finished product as well as
crating greater eye appeal.CO2 to extent used as preservatives
The water treatment selection is depends on the source of water. The raw water supplies are
contaminated by different pollutants when the water affected by pollutant the water may have
Bad odor
Taste
Smell
But in our plant (Nifas silk Pepsi cola plant) the source of water supply is the ground water
source which is usually free from of natural organic matter but can be high in minerals, alkalinity
compounds such as Ca+ & Mg2+ it is also free from external pollution, but it is not pure water,
there is growth of microorganisms & minerals unless it can’t be treated. To treat this water
MOHA soft drink (Nefas silk) uses coagulation system.
Coagulation
In beverage industry, coagulation water treatment technology also known as convectional lime
treatment systems (CLTS). This mechanism can also use to meet different conditions therefore
they remain a valuable treatment used in different manners to meet our treatment needs.
I. Lime: - lime is used for alkalinity reduction. It is also used to increase the pH of the
water. The total alkalinity of the treated water should be below 50 ppm. Lime reduces
alkalinity by converting carbon dioxide to bicarbonate alkalinity, and bicarbonate
alkalinity to the insoluble forms calcium carbonate and magnesium hydroxide, which
precipitate out of the water.
II. Calcium chloride: - reacts with the lime to reduce the water alkalinity. Sodium alkalinity
is present when the total alkalinity is greater than the hardness of the water. Calcium
chloride which forms calcium carbonate from the sodium bicarbonate as the calcium
bicarbonate is formed. In some cases, water contains sodium alkalinity.If sodium
alkalinity is present, it will be necessary to add small amounts of calcium chloride to get
the treated water total alkalinity below the maximum limit of 50 ppm.
Reaction
Na2CO3+CaCl2−−−−−−−−−→ CaCO3 + 2NaCl
Aluminum
Sulphate Calcium Chloride
Raw
water
Intermediate
Lime
Coagulation Tank Sand Filter Tank
Chlorine
Carbon Purifier
UV Polisher
Coagulation is a chemically water treatment process by doing smaller particles in to heavier that
is they can quickly settle out. In this tank mixing is take place that is as we can see the above
flow diagram the water and the four chemicals (lime, aluminum sulphate, calcium chloride and
chlorine) mixed together. There are three parts the 1st one is the mixing process takes place, the
2nd part is some chemicals settled out, and it looks like slightly pure. The final part will be more
purified than the second part of the tank. Finally the treated water goes to the sand filter.
Sand filter
The treated water that comes from coagulation tank enters in to the sand filter.in this tank there is
small sand that is used to settle the lime. This used to remove the unwanted chemicals except
chlorine from water.in the sand filter we can checked the lime dosage in the treated water, by
using the formula : A= 2P-M
Where
M -is will tell us if all bicarbonate was removed whether we have free lime present.
When A is positive, that is 2P is >M this implies that free lime is present in the treated
water.
When A is negative, that is M is> P this implies that bicarbonate is present in the treated
water.
For proper lime treatment A value should be in between 2 and 7.
− Then titrate by using 0.02NH2SO4 until the color can be changed into pink into colorless
end point.
− Then the numbers that can be used for titration is record” P” reading.
− After record the number then add 3 droplet of M- solution (methyl purple).
− The color can be changed in to greens
− Continue titration by using 0.02NH2SO4 until the color can be changed green into purple
end point.
− Then record total 0.02NH2SO4 usage M” reading.
Example
P=10, 2*10=20
M= 22
-2 this implies that under treated with lime. This is corrected by addition of lime.
Intermediate tank
Carbon purifier
The treated water that comes from the intermediate tank is entered in to the carbon purifier. This
is used to remove chlorine by using activated carbon that present in the water. The presence of
chlorine can be changed the color and test of the final product (Pepsi, Miranda ,7up Miranda
apple, Miranda orange and Miranda tonic). The chlorine dosage in the carbon purifier must be in
between 6and8.
If the color can be hanged the water has chlorine, therefore the treated water can be corrected by
removed chlorine before enter in to the polisher. Because if the water that has chorine is passed
in to the process can be changed the color and test of the products.
5micro Polisher
This is used to remove suspended activated carbon that comes from the carbon purifier and other
unwanted particle that may be passed through the carbon purifier.
Appearance Clear
Taste None
Odor None
Fluoride 1.0ppm
Chlorine None
The other water treatment done is softening the hard water for softener the row water used comes
from municipal. The equipment used for softening purpose
Sodium chloride mixing tank: - It uses to dissolve the salt that used to clean the softener 1 & 2
Softener 1 and 2:-These two softener equipment’s used to change the hardness of water to soft
one by using zeolites in it here chemicals like calcium and magnesium. Remove by ion
exchange. The purpose of softening is to remove scale formation
The softening water used for bottle washing and steam generation.
The bottle washer clean and sanitize returnable bottles that have been brought back from the
trade. Returnable bottles are rinsed to remove beverage residues, straws and any liquids or
suspended material. High strength of caustic, caustic based detergent, or caustic with other
additives, at elevated temperatures are used to clean and sanitize the bottle. The bottle washer
takes dirty bottles from the trade and subjects them to:
Water to deliver a clean and sanitary bottle to the conveyer ensure route to the filler. For glass
bottle extending soak time can allow a slight reduction in the basic requirements. Washed bottles
that exist the washer should be checked for caustic carry over at start up and during operation.
Checking for caustic carryover should be performed at start up and twice per shift, testing a
complex row of pockets at the bottle discharge station of the bottle washer and during production
every two hours 3 additional bottles should be spot checked. Generally the washer section is the
major part of the company.in this section the process become started by selecting the most defect
bottles by using manual inspection.then transfer in to the washer machin by using bottle
conveyor.the soap can be added in to the conveyor in order in to reduce friction between the
conveyor and the bottles.then the bottle is interd in to the washer machine.
Depalletization
Case washer
Uncasing
Washing compartment 1
Washing compartment 2
Washing compartment 3
Inspection
Case Washing: is a process of cleaning the case that can be used again for casing the finished
product. The case washer is a cleaning machine that cleans cases separately from bottles. There
are two partitioned spaces where cases are to be treated. They are treated with by warm caustic
soda and also by cold water by applying high pressure spray jet. The desirable amount of heat is
controlled by heat regulator that heat is transferred by convection system from the steam coming
from the boiler. The water that used to clean both the bottle and case is coming from the water
treatment room from softener.
Hot caustic soak condition:- as a minimum 2.0% caustic, 65oc temprature, and 6.0
minutes contact time.
Pre-final rinse:-approved rinse agent must be used, and result in the following pre-rinse
conditions:
− PH of 7.5 +/-0.5
− Free EDTA of 5ppm (minimum)
Pre-final rinse:- approved rinse agent dosing must be inerlocked with pre-final rinse
recirculation.
Pre-final rinse recirculation is set to continue when the washer stops.
Final rinse:- treated or portable water must be used.
Inspection:- post-wash inspection by human and/or EBI as pre pepsico requarments.
Temperature 65oc
Concentration 2.25(+/-0.25)%
Temperature 75oc
Purposes of rinse
N: B there is a high risk of thermal shock if the cooling temperature differential is >28oc.
Bottles inspection
Inspection removes with dirt or foreign materials, and verifies efficiency of washing process.
In MOHA soft drink there are two types of inspection. These are:-
1. Manual inspection:-in this section the bottles can be checked by human by using light,
there a lot of shifts because one shift can be worked only for 15 minutes.
2. Electronic based inspection (EBI):- in this part the equipment can be worked by capturing
photo. The operator can be worked for one hour.
1. Finish
2. Neck
3. Shoulder
4. Sidewall
5. Bottom
Storage tank
Purging
Boiler
used as a closed vessel in which water or other liquid is heated; steam or vapor is generated, by
applying heat.in the case of carbon dioxide production plant they are generate carbon dioxide by
using air and diesel oil. Diesel oils are organic compounds they are hydrogen, oxygen and carbon
sometimes sulfur.in the boiler there are two reactions, this are complete combustion and
incomplete combustion. Complete combustion is produced by sufficient amount of oxygen and
the amount of oxygen can be in the range of 3-5%. In the case of incomplete combustion the
amount of oxygen is less than one. If there is incomplete combustion they can be produce very
dangerous gases (H2S, CO, SO2, HCN, NOx).
Soda scrubber
Scrubber system are a diverse group of air pollution control device of alkaline material usually
hydrated lime soda ash, or sodium bicarbonate in to the gas stream to react with acid gases.
The flue gas that comes from the boiler is enters in to the soda scrubber.in the scrubber there is
ceramics used to the reaction media and Na2CO3 in order to remove H2S, SO2.
Absorber
The absorber is exothermic because it is open system .it is release heat. On absorber is forced
and counter current In absorber the MEA and co2 mixed to use is double heat exchanger cool
dawn to 40oc using cooling water. In absorber the temperature 35oc -40oc when the
temperature is cold MEA can capture the co2 when the temperature is hot MEA can fled the
co2 so the MEA can capture the co2 in absorber. The flue gas enters the absorber bottom .The
lean lye (MEA-lye without CO2) is led to the absorber through a distributor in the top. The
distributor ensures that the lean lye is evenly distributed throughout the entire surface of the
absorber To increase the contact between the lean lye and the flue gas is the upper section of
the absorber filled with plastic tower packing The lean lye trickles through the tower from
above entering the tower packing, while the flue gas containing CO2 flows from the bottom
to the top. At this counter flow the CO2 contained in the flue gas will be absorbed by the
relatively cold lean lye. The Lye pumped out of the absorber contains now the CO2 from the
flue gas and is called Rich Lye. The Rich Lye pump is pumping the lye to the stripper
through the lye cooler. The absorber is fitted with a demister in the top, to avoid MEA
droplets to escape with the gas going to free air. The white smoke coming from the absorber
outlet is mainly water vapour, nitrogen and oxygen .The rich MEA goes to heat exchanger
and the T 96oc
Stripper
The Rich Lye containing CO2 is preheated in the lye cooler before entering the stripper. In order
to release the CO2 from the lye solution must the solution be heated to its boiling point.in striper
we use steam to Increase the TO rich MEA from 96oc-110oc and not to let reaction occur The
heat input is coming from the burner, and in the boiler a mix of steam and CO2-gas will be
generated and flow through the stripper. The Rich Lye from the absorber (MEA-lye with CO2) is
led to the stripper, where it enters through a distributor in the top. The distributor ensures that the
Rich Lye is evenly distributed throughout the entire surface of the stripper. To increase the
contact between the Rich Lye and the steam from the boiler is the upper section of the stripper
filled with ceramic tower packing. The Rich Lye trickles through the tower from above entering
the tower packing, while the mixture of steam and CO2 flows from the bottom to the top. At this
counter flow the CO2 contained in the Rich Lye was released efficiently. The mix of steam and
CO2 flows from the top of the stripper to the gas cooler.
Gas cooler
The steam and CO2 developed in the boiler and stripper must be separated before entering the
purification and liquefaction unit. For this purpose is the gas cooler installed. Using cooling
water is the steam condensed, and the CO2 is cooled down to approx. 40˚C. The condensed
water is send back to the lye tank through. The cooled CO2 gas will flow from the top of the
water separator to the liquefaction unit. The water separator is equipped with a demister which is
preventing water droplets to escape with the gas.
This is the most important part of the carbon dioxide production plant. PPM solution is used as
an oxidizing agent. It oxidizes other gases except co2 and it removes all organic materials and
impurities. It increases contact and surface area.
Compressor
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume.an air compressor is a specific type of gas compressor.in the case of carbon dioxide
production plant, in order to pressurize the CO2 and transport in to the hydrator.
Dehydrator
Dehydrator is used for removes water or moisture from the carbon dioxide. Although water has
been removed from the CO2 gas in intermediate and after cooler, it still contains some water.
To remove the remaining water the gas is led through a dehydrator. The dehydrator system
consists of two vessels filled with molecular sieve. The molecular sieve has the capability to
absorb water.
Carbon filter
Carbon filtering is the method of filtering that uses a bed of activated carbon to remove
contaminants and impurities, using chemical adsorption. Each granule of carbon provides a large
surface area/pore structure, allowing contaminants the maximum possible exposure to the active
sites within the filter media. Carbon filter can be used to remove, Odor, Test, Smell.
Condenser
A condenser is advice used to condense a substance from its gaseous to its liquid state, by
cooling it.in that case ammonia used as a coolant, and the gas form of carbon dioxide are
changed in to liquid.
Simple syrup is prepared from nutritive or non-nutritive sweeteners and treated water. Nutritive
sweetener includes cane sugar, beet sugar, liquid sucrose, medium sugar. Nonnutritive
sweeteners are artificial sweeteners such as aspartame. First the treated water adds in to the
dissolving tank. The dissolving tank is jacketed vessel and the water was boiled up to 800c.Then
the sugar will be fed to the screw conveyer. The screw conveyer can reduce the size of the sugar
and the conveyer the sugar enters the dissolving tank. When the sugar enter to the dissolving
tank the temperature of water is decreasing in to 240c-300c.Then we wait the temperature is
800c.To rise the temperature to 800c and agitate. Activated carbon added to the dissolving tank
and kept in the tank around 30-40 minute to trap and it remove the organic matter. The sugar and
the treated water mixture from the jacketed vessel were filled in the sugar filter and half in the
filter aid mixer. In filter aid mixer we add diatoms earth .and it circulated with in the sugar filter
and filter aid. During this circulation filter aid will make cake inside the sugar filter the filter aids
by activated carbon and diatoms earth
b Granulate
Water Celatom
sugar
Heat
Sugar Polisher exchanger
dissolving
Filter
Activated tank
paper
carbon
Nutritive sweeteners include cane sugar, high fructose corn syrup, liquid sucrose and
medium invert sugar, all meeting Pepsi cola sweetener specifications.
Non-nutritive sweeteners are artificial sweetener such as aspartame.
Concentrate components can be solids emulsions, and extracts, and liquid components.
Treated water is always fully treated water meeting all Pepsi cola water specifications.
CIP METHOD
c) Rinse by 38OC -OC water for 10-15 minutes then checking for the absence of
chemicals.
2. The five steps
a) First rinse by 50OC- 60OC water for 10-15 minutes
b) Cleaning by 50OC -60OC using caustic soda for 20 minutes and the concentration of this
soda should be in between 0.5%-2%.
c) Rinse by 38OC -OC water for 10-15 minutes then checking for the absence of chemicals
d) Sanitize either by hot water at 80OC for 15 minutes or chlorine at 100ppm concentration
for 20 minutes
Rinse by water for 10-15 minutes then checking the absence of chemicals.
Filling
Filler is a machine which is used to fill the bottle with the drink that has been prepared in the
Para mix. It is connected with the Para mix and the crowner cork. In nifas silk pepsi company
there are two fillers one of the filler (the new one) has a better capacity than the older filler and
the maximum filling capacity of this machine is 24000. This machine has bowl pressure, bowl
level, bowl liter, capacity, mode filler, bottle counter and temperature and controlled by PLC
system. These all things have their own purpose. The various filling processes are selected at the
operator panel. First the drink is stored in the bowl and above this drink car bon dioxide gas will
be placed and then when the empty bottle is transported by the in feed conveyer through the in
feed worm gear which pushes the bottles in sequenced manner. Then the bottles are pressed
against the filling valve by a lifting element called piston. The piston will perceive the existence
of the bottles during the lifting process. If the bottle is present the processes is started and the
bottle is filled. The corresponding filling valve remains closed if the bottle is missing. The
machine works by lubrication system automatically .there are also 60 filling valves called vents
and expanding tubes where these tubes have small holes that are used to transport the gas as well
as the drinks respectively. In this section the co2 should be filled first in the bottles in order to
balance the temperature and pressure as well. When the fluid (drink) poured in to the bottle the
gas occupying the remaining space of the bottle goes up to the returned gas media through the
vent tube.
Full bottle inspection: filled bottles are also inspected manually and by EBI. First they are
inspected by EBI for any defect i.e. if the crowns are not placed at the right place or if the bottles
are perfectly filled. Manual inspection is done by people who check if the bottle is of the right
fill height. Products should not be under filled or over filled.
1. GMP
2. HACCP
3. QAS
4. EMS
1. GMS :- is a good safety system which lay out, control and evaluate the implementation
of the following program:-
− Training program
− Personal hygiene program
− Company visits health checks
− Food handling practice
− Pest control
− Cleaning and sanitation
− Handling breakable
− Process equipment machinery layout
− Structure and fabrication
2. HACCP:- it is a safety management system with the following program
− Food safety policy
− HACCP team description
− Prerequisite programs description
− Product description
− List of ingredients and indirect raw materials
− Process description
− Process flow diagrams
− Factory flow diagram lay out
− Hazard analysis
The overall processes in the company can be checked in this section. According to the
laboratory test whether the processes continue or not can be decided in this section. One of
the main goal of the quality control is to present the consumer with a product that is NOT
consistently with in standards, but that has a long shelf life .the primary purpose of quality
control and plant testing program is
A Specification
5 Corresponding A4/1.13-(0.35*A4)
conductivity
7 Moisture 0/04%
For conductivity
NOTE: all the final result can be inserted in to our computer and we can get the result.
Given
Sample=102
Unit=50
Required
Solution
S=M*J/T
J: sample
T: unit
S=71.22*102/50=145.288
This implies that the amount of distilled water add in to the sample. Then stir gently until
completely dissolved. Then divide the sample in to two equal portions by using vacuumed
filtration apparatus that is microspores. Finally read the absorbance of the sample by using
spectrophotometer first blank the instrument with distilled water.
Given
Sample=50
Unit=28
Solution
S=M*J/T
J: sample
T: unit
S=71.22*50/28=127.178
This number implies that the amount of distilled water added. Then read the conductivity of the
sample.
NOTE: by using the same procedure we can calculate the amount of absorbance and conductivity
of the finished simple syrup.
AB=0.384
BA=0.196
BB=0.518
CSB=50.6
CSA=80.2
Where;
N: B finally all the result that can be calculated above must be inserted our computer we can
know color, turbidity, and ash content of the sample.
M-alkalinity test
Total hardness
Finally all the result that can be get from the above four result can be inserted in to the computer.
Then the results that get the computer tell as how much lime, aluminums sulphate, calcium
chloride and chlorine added in to the coagulation tank.
Ammonia
cylinder
Compressor
Oil separator
Condenser
CHAPTER FOURE:
Conclusion
The plant produces six products with well-organized and a good quality standards & distributed
to the consumer with a short time due to the number of the consumers that accept the product and
the products are checked by the executive organizational office members on unknown days. So
the plant should produce an acceptable, standard, and legal products to satisfy the consumer’s
needs.Internships are the reflection of the real world work environments. Our experience as an
intern at MOHA soft drinks is full of exciting memories as it is the preview of the coming
chapter of our life. We had acquired new knowledge, developed essential skills, experienced the
practical work settings, met experts in our field and made new friends in four months which is a
great accomplishment for an undergraduate student like us. Beside the practical knowledge and
skills we built up during the internship, we had developed proper work ethics and essential
qualities every engineer shall have. Some of the most important qualities we developed are
industriousness, team work, communication skill and accountability. In conclusion, during our
stay at MOHA soft drinks we have achieved most of the goals we set up at the beginning of the
internship.
Recommendation
From the time of internship duration in NIFAS SILK beverage plant there are some
limitations/short coming that are challenges the workers, affect environment and obstacles for
the operators. Some of these are:-
Since the condition is very warm and noisy, which is difficult for the workers in order to
3perform their activities, the air ventilator should be necessary especially in co2
production plant some measures have to be taken to reduce the noise.
Enough operator instructions and manuals should be present in the worker and there
should be have full structural flow diagram of the unite operations /operators for each
section to perform appropriate activities.
Most of the operators are done their activities in habitual actions so educated chemical
engineers should be necessary for the safety and security of the machines and
equipment’s especially for co2 plant.
The manual inspection becomes replaced by machine is more appropriate for the
company.
The drainage of the waste water from the compartment may contain caustic soda;
therefore further water treatment mechanism can be important.
If the source of the ground water is insufficient, added more ground water.
CHAPTER FIVE
PROECT WORK
5.1 Introduction
Absorber is process equipment used to remove one or more gaseous components. From gaseous
mixture by using suitable type solvent mostly present in less quantity.
Absorption: in absorption column or tower, a gas fed from the bottom of an absorption tower.
The tower is packed with packing to increase contact time and efficiency. Based on absorbent
(chemical reaction between the solute and the solvent) there are two types of absorption
processes: physical and chemical absorption. Physical absorption occur when there is no
significant chemical reaction between the absorbent and the solute. Chemical absorptions are
processes for absorbing CO2 and H2S with aqueous solution of mono ethanol amine (MEA), di
ethanol amine (DEA). It depends on whether there is any chemical reaction between the solute
(CO2) and the solvent (MEA). In the case of MOHA soft drink they chemical absorption method.
In the absorption of carbon dioxide by caustic soda, the carbon dioxide reacts directly with the
caustic soda and the process of mass transfer is thus made much more complicated. Again, when
carbon dioxide is absorbed in an ethanolamine solution (MEA), there is direct Chemical reaction
between the amine (MEA) and the gas (carbon dioxide gas).In the case considered, the chemical
reaction is irreversible and of the type in which a Solute gas A (CO2) absorbed from a mixture by
a substance B (MEA) in the liquid phase, which combines with according to the equation
A + B → AB
As the gas approaches the liquid interface, it dissolves and reacts at once with B. The new
product AB, thus formed, diffuses towards the main body of the liquid.
5.3 Objective
This project works increasing carbon dioxide production by choosing best solvents and doing
cost estimation between the solvents, up to theoretical evaluation of efficiency increment due to
change of solvent type.
Limitation
When we doing this project there are many difficulties, these are
Lack of related work in quality control room.
Lack of chemical such as potassium carbonate in the company
The absence of absorber in laboratory scale, in MOHA soft drinks.
The nature of carbon dioxide (CO2 )
Ter V. el al (2011), they were studied about amine based solvent for carbon dioxide absorption
“from molecular structure to process”. The aim of the study was the development of improved,
energy efficient amine based solvents in targeted, through experimental work and by further
understanding of the role of molecular structure on the solvent absorption properties for amine
based solvent in carbon dioxide absorption process and focuses on the development of an energy
efficient solvent for a carbon dioxide post-combustion absorption process, by evaluating the
absorption properties of amine based solvents with different molecular structure. to achieve this
goal: (1) knowledge on structure-activity relationships for amine based absorbents for CO2
absorption is developed both by experimental work and molecular calculation; (2) focuses on
understanding the reaction mechanism between an amine and CO2 and on the identification of
the solvent properties influencing their performance for CO2 absorption.
(3) solvent with carbon dioxide, was studied using quantum mechanical calculations; (4) in the
solvent screening experiment various solvent molecular structural aspects were tested on their
influences on carbon dioxide absorption capacity; (5) for the more promising identified in
number 4 subsequent solvent screening experiments were performed at low carbon dioxide
partial pressure to determine their carbon dioxide absorption and regeneration capacity under
more realistic conditions. From this work the potential solvents 1,6-hexamethyl-diamine
(HMDA) and 1,6-hexamethyl-diamine,N,N’-dimethyl (HMDA,N,N’) were selected for further
investigation; (6) the carbon dioxide solubility for the selected solvent candidate 1,6-hexamethyl-
MONOJIT K. et al (2012), they were studied about CO2 capture/separate technologies. The aim
of the study was examine the current status of various methods and technologies used for CO2
capture and separation from thermal power plant flue gas. The result shows that absorption is
matured technology for post combustion capture but solvent loses corrosion and high cost of
separation the main issues for this process.
absorber height
solvent temperature and
pressure
In his work, he investigated that the absorber height on the energy consumption in re boiler, the
diameter of the column was kept constant and the absorber height was varied .As he stated with
increasing in the absorber height, the attained rich loading increased and hence, the re boiler duty
decreased.
As the temperature of absorption decrease the driving force for absorption increases.
However, the rate of the reaction and diffusivity decrease as temperature is decreased.
Simulations were run at solvent temperature of 20, 30and 40oc and the re boiler duty for
these runs did not differ significantly. Hence, the temperature of the solvent does not have a
significant effect on the performance of the system because the solvent has a low specific
heat and it takes up the heat of absorption quickly.
5.7 Methodology
Material and chemicals
Material
Table 5.1 laboratory test equipment’s that can be used the production process
No Equipment Function
1 Beakers Used for testing the presence of odor, oil and grease after
carbon purifier and carbon dioxide storage tank, used to test
water hardness.
2 Fyrite Used to measure the amount of oxygen in the boiler, and the
proportionate amount of carbon dioxide in the boiler and
released from absorber.
3 DT tester To test the presence of NOX, H2S, HCN, CO, HOCO, SO2,
5 Zahm and Nagel Used to test the purity of carbon dioxide gas in both after
purity tester carbon and storage tank.
7 Burette Used for titration (MEA, soda, and hard water) purpose
Chemical
No Chemicals Function
2 Soda ( Na2CO3) For separating carbon dioxide from other flue gas
3 0.1N Hydrochloric acid (Hcl) Used for titrating MEA and soda (neutralizing purpose)
Firstly we take 250 ml of MEA by using 250 ml of measuring cylinder. Then by using pipette
instrument we can take one ml of MEA and transfer to 250 Erlenmeyer flask (beaker).then after
we add three drop let of methyl orange in one ml of MEA solution. Finally we titrate the above
solution by using 0.1NHcl solution drop by drop until the color changed from orange into light
red and record the normality of MEA.
We begin with filling mea solution into 250 ml measuring cylinder.by using refrigerator reduce
the temperature of the solution until the temperature can be 20 up to 24 oc.then we immerse bume
to the MEA solution. Finally we measured the density of MEA.
We start by taking CO2 fyrite (containing red fluid) and adjust the CO2 fyrite to zero mark by
passing the top tester. Then we insert the tip of the absorber fyrite tester sucker into the top of the
absorber. Right then we Sequeez and release the plastic sucker of the CO2 18 times to absorb the
sample gas. Then we take off the sucker. Then invert the sample gas into fyrite until fluid drain
into the bottom the fyrite. And hold fyrite at 45o angle momentarily to allow fluid droplets drain
to the bottom fyrite. Finally fyrite held upright to permit fluid in column to sterilize a few second
and read % CO2 scale at point corresponding to top of the fluid column.
To make cost analysis on MEA solution we use the efficiency of CO2 plant and amount of CO2
enter in to storage tank per day, from data and to know % amount CO2 released per day we
measure release CO2 Amount 4 times per day for consecutive 6 day, and takes the average.
Finally we get the amount of CO2 by using the following formula:-
The solvent to be used in the absorber is a very important design consideration. Traditionally,
monoethanolamine was chosen to absorb the carbon dioxide from the feed. However for many
crucial and convincing reasons most new plants are designed to use potassium carbonate.
First of all, potassium carbonate is a more efficient absorbent of carbon dioxide than either
monoethanolamine. This means that for a given amount of solvent potassium carbonate can
absorb more carbon dioxide than MEA.
If less solvent is needed, then piping systems and absorber volume can be smaller. In addition,
the cost of solvent is less because less is needed and potassium carbonate is cheaper than
traditional solvent (MEA).
Secondly the use of potassium carbonate over the other solvent eliminates the need for a heat
exchanger between the absorber and stripper. In potassium carbonate system the stripper runs
cooler than the absorber this is not true for the MEA, because MEA required the heating of the
bottoms stream from the absorber before it reaches the stripper. But the potassium carbonate
system requires no such heating. The elimination of this heating exchanger increases the
profitability of our plant because heat exchangers are both coasty to purchase and maintain.
Thirdly, potassium carbonate increase the safety of carbon dioxide removal system MEA absorbs
not only carbon dioxide but also small amount of hydrogen as well. This hydrogen is then
continuous throughout the stripper and the top stream with the carbon dioxide. Beside,
decreasing the purity of product carbon dioxide stream, this hydrogen possesses a safety threat.
Flashing of hydrogen can cause fires or explosions if proper precautions are not taken. Using
potassium carbonate reduces the risk of such accidents.
Finally, the most convincing argument for the use of potassium carbonate as a solvent is that this
is the present industry standard ,in plant (MOHA) must convert over to potassium carbonate as
our solvent of choice, Because potassium carbonate is significantly better than MEA.
In order to remove carbon dioxide from the freedom stream two main vessels are needed, the
absorber and stripper. Inside the absorber chemical reaction will occur in which CO2 is
chemically absorbed onto the solvent and this compounds, along with water, will flow out of the
bottom of absorber. That stream will then go through a flash chamber to lower temperature and
pressure of liquid (and to separate out some co2) before proceeding onto the stripper where the
CO2 will separate out from the solvent.
DT test
(NOX,so2,HC
MEA % of CO2 Soda Water O2
N,FORMAL
hardness(
Date (Mono ethyl amine) (carbon dioxide) DEHYDE)
ppm)
From the above table we can observe that as MEA normality increase the amount of CO2
released from absorber decrease and this is advisable according to environmental point of view.
However as MEA normality (concentration) increase the cost required also increase. Also the
released amount of gas that released from absorber is high.
Given
Required
Solution
By using formula, A=
=44.73kg
co2
3
2.5
1.5
co2
0.5
0
1.9 1.95 1.97 2 2.1 2.25
Normality of MEA
Pressure 3.5-20kpas
CO2 Absorption
rate
1lb=0.453kg,
1kg=1.523$
=1.523$*22
=33.506 birr/kg
1kg=0.946$
=0.946$*22
=20.812 birr/kg
January 651.5
February 67.9
March 228.6
April 40
May 177
Total 1165 kg
Conclusion
Generally carbon dioxide production plant can be produce 2400kg per day. During the
production there are many side effects, these are the concentration of MEA (mono ethanol
amine), temperature, surface area.as we see the relation between MEA and carbon dioxide, as the
concentration of MEA increase the amount of carbon dioxide released from the absorber increase
vise verse, and these also precede increase surface area. As the temperature of absorption
decrease the driving force for absorption increases. As the solution we can conclude that in the
place of MEA solvents replace the new solvent, which is potassium carbonate. Because
potassium carbonate is more efficient than MEA by cost, the working temperature is lower than
MEA.
Recommendation
As much as possible replace the oldest solvent (MEA) by new solvent (potassium carbonate).
Do further analysis and laboratory test on potassium carbonate.
Use more concentrated MEA solution.
Increasing height and size of absorber in order to increase CO2 absorption capacity and
also changing.
Knowing the life time of the ceramics in the absorber tower.
Reference
1. Anusha kothandaraman (2006)
2. Coulson volume 2 and 6
3. James T. et al, “Carbon dioxide absorption and desorption in packed column”.
4. J. Tim C. et al, “properties of concentrated aqueous potassium carbonate/ piperazine
for CO2 capture”,
5. Jason U. et al, -"design of CO2 absorption in an ammonia plant",
6. Monoji K. et al “CO2 capture/separate technologies”. (2012).
7. Pepsi international quality manual, analytical method (1999).
8. PepsiCo beverages international quality manual, manufacturing processes (2002).
9. Ter V. el al “Amine based solvent for carbon dioxide absorption “from molecular
structure to process”. (2011).