MEKELLE UNIVERSITY

Ethiopian Institute of Technology - Mekelle (Eit-M)

DEPARTMENT OF CHEMICAL ENGINEERING

PROJECT TITLE: Enhancing Efficiency of Absorption Unit for Carbon

Dioxide Capture to Reduce Emissions.

HOSTING COMPANY- MOHA Soft Drink Industry SC, Mekelle plant

GROUP MEMBERS ID NUMBER

1. Edul Hailu EITM/UR157951/11

2. Winta Brhane EITM/UR158652/11
3. Tsegay fisseha EITM/TUR158652/11

Advisor: Ins. Kiros Fisseha (Msc)

OCTOBER 23, 2024
Mekelle, Ethiopia

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Acknowledgement

We would like to begin by expressing our sincere gratitude to God for His constant guidance and
support throughout our journey.
We extend our heartfelt appreciation to our advisor, Ins. Kiros Fesseha, whose invaluable
insights and encouragement have greatly contributed to the success of this project.
Our deepest thanks go to our supervisor, Mr. Grmay Brhane, for his comprehensive support
during our internship, ensuring that we gained a thorough understanding of the industry's
workings. We also wish to acknowledge Mr. Tebeje Argae for granting us the opportunity to
engage with various departments, enhancing our practical experience.
Finally, we are immensely grateful to our family and friends for their unwavering moral support,
which has been crucial in helping us complete this report.

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Abstract
This report outlines a four-month internship at MOHA Soft Drinks Industry, specifically at the
Mekelle plant, which boasts a capital investment of 108,654,000 birr and a production capacity
of 36,000 bottles per hour. The intern ship's primary focus was on optimizing CO2 production
within the absorption column, addressing the concerning 15-20% CO2 release into the
environment. The project aimed to improve production efficiency by regulating input variables
and increasing the concentration of Monoethanolamine (MEA). This initiative aligns with
MOHA's mission to become Ethiopia's leading soft drink manufacturer by enhancing operational
responsiveness and sustainability.

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List of figures
Figure 1.1 Structure of MOHA soft drinks factory S.C Mekelle plant 2
Figure 1.2 Main products of MOHA soft drinks factory 4
Figure 2.1 Water treatment process 7
Figure 2.2 Aerator 8
Figure 2.3 Sand filter 9
Figure 2.4 Reverse Osmosis 10
Figure 2.5 General process flow diagram of syrup preparation batching process 15
Figure 2.6 Flow diagram of CO2 production 17
Figure 2.7 Boiler 18
Figure 2.8 Soda ash tanker 18
Figure 2.9 Absorption tower 19
Figure 2.10 After water scrubber 20
Figure 2.11 CO2 compressor 20
Figure 2.12 Freon liquid condenser 21
Figure 2.13 CO2 storage 22
Figure 2.14 Overall flow diagram of the production room 23
Figure 2.15 Crate washer machine 24
Figure 2.16 Bottle washer machine 25
Figure 2.17 Empty bottle inspection machine 28
Figure 2.18 Mixer machine 29
Figure 2.19 Filler machine 30
Figure 2.20 Size Equipment 39
Figure 3.1 Solvent vs amount of CO2 absorbed per 150ml 47
Figure 3.2 Flow sheet for CO2 capture from flue gasses using amine based system 50
Figure 3.3 Absorption process counter currently 55

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List of tables
Table 3-1 Properties of carbon dioxide 48
Table 3-2 Effect of pressure and volumetric flow rate on CO2 recovery 54
Table 5-1 Appendix A for table 3.2 68

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Symbols and Abbreviations

✔ A.C- Activated carbon
✔ CCS-Carbon Dioxide Capture and Storage
✔ CCP- Critical Control Point
✔ CIP-Clean In Place
✔ EBI- Empty Bottle Inspection
✔ FBI- Full Bottle Inspection
✔ nfg in–Input of flue gas molar flow rate
✔ ni CO2- input of molar flow rate CO2
✔ HEX – Heat exchanger
✔ mA.C-Mass of Activated Carbon
✔ MAG-Metal Active Gas
✔ MEA - MonoEthanolAmine
✔ MIG-Metal Inert Gas
✔ MOHA - Mohammed Hussein Al-Amoudi
✔ MOs- Micro Organisms
✔ nCO2 cc– Molar flow rate of concentrated carbon dioxide
✔ ntg– Molar flow rate of treated gas
✔ PCCC-Post –Combustion Carbon Dioxide Capture
✔ PepsiCo – Pepsi Cola
✔ ppm-Parts Per million
✔ RO- Reverse Osmosis
✔ RPB-Rotating Packed Bed
✔ S.C – Sharing Company
✔ U.V-Ultra violet
✔ H-Height
✔ Ab-Area of base

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Table of contents
Acknowledgment ii
Abstract iii
List of figures iv
List of tables v
Symbols and Abbreviations vi
Table of contents vii
CHAPTER ONE 1
1 INTRODUCTION 1
1.1 Background of the Company 1
1.2 Objective 2
1.3 Mission 2
1.4 Vision 3
1.5 End Products and service of the Company 4
1.6 The Main Customers or End Users of the Hosting Company 5
CHAPTER TWO 6
2 PROCESS TECHNOLOGY OF THE FACTORY 6
2.1 Process description 6
2.1.1 Water treatment plant 6
2.1.2 Syrup preparation section 14
2.1.3 Carbon dioxide Production Room 15
2.1.4 Process description of the production room 23
2.1.5 Filling Room 27
2.1.6 Boiler Plant and Air Compressor 32
2.1.7 Sanitation 32
2.1.8 WasteWater Treatment 33
2.2 Mass and Energy Balance of Main Unit Operations 36
2.2.1 Material Balance for Sugar Dissolving Tank (Sugar Preparation) 36
2.2.2 Energy balance 37
2.3 Main Equipment Sizing of Carbon Dioxide Storage 39
2.4 Environmental Considerations of the plant 41
2.4.1 Occupational Safety and Health Protection 41

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2.4.2 Quality — the Key to Performance (Quality Control) 41
CHAPTER THREE 43
3 CASE STUDY: optimize the Efficiency of Carbon Dioxide Capture in Absorption Units 43
3.1 Short Summary 43
3.2 Introduction 43
3.3 Problem Statement 45
3.4 Objective 45
3.4.1 General Objective 45
3.4.2 Specific Objectives 45
3.5 Scope of the project 45
3.6 Literature review 46
3.6.1 Gas Absorption 46
3.6.1.1 Physical absorption 46
3.6.1.2 Chemical absorption 46
3.6.2 Properties of Carbon Dioxide 47
3.6.3 Applications of CO2 48
3.6.4 Washing Liquid MEA (MonoEthanolAmine) 49
3.6.5 Temperature 51
3.6.6 The Packed Column 51
3.7 Methodology 53
3.8 Material balance 54
3.9 Result and discussion 56
3.9.1 Results 56
3.9.2 Discussion 56
3.10 Conclusion and Recommendation 59
3.10.1 Conclusion 59
3.10.2 Recommendation 60
CHAPTER FOUR 61
4 OVERALL BENEFIT GAINED FROM THE INTERNSHIP 61
4.1 In terms of improving theoretical knowledge 61
4.2 In terms of improving practical skill 61
4.3 In terms of improving industrial problem solving capability 62
4.4 In terms of improving team playing skill 62

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4.5 In terms of improving leadership skill 63
4.6 In terms of understanding about work ethics 63
4.7 In terms of entrepreneurship skill 64
4.8 In terms of improving interpersonal communication skill 64
CHAPTER FIVE 65
5 OVER ALL CONCLUSION AND RECOMMENDATION 65.
5.1 Conclusion 65
5.2 Recommendation 66
References 66
Appendix 68

CHAPTER ONE

1 INTRODUCTION
In Ethiopia, MOHA operates over seven manufacturing plants dedicated to soft drinks. The sugar
content in carbonated and soft beverages can vary significantly, depending on whether the
product is intended for immediate consumption or supplied as a concentrate, commonly known
as "syrup." A typical formulation for these beverages includes not only sugar but also flavoring
or concentrated fruit juices, acidity regulators, preservatives, stabilizers, antioxidants, and
coloring agents. For "diet" and other "sugar-free" options, traditional sugar is replaced with
artificial sweeteners such as aspartame. The production of carbonated soft drinks is one of the
most energy-intensive processes within the food industry. It requires substantial energy inputs
for refrigeration, mixing, purification, and heating during the carbonation and bottling or canning
stages [10].

1.1 Background of the Company

MOHA Soft Drinks Industry is a private company owned by Mohamed Hussein Al Amoudi.
Located in Mekelle, Tigray Region, approximately 760 km from Addis Ababa, the plant was
established in 2005 E.C. with an initial capital of 108,654,000 birr. After a gradual development
process, the company officially commenced regular operations on February 15, 2007, equipped
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with a filler machine capable of producing 36,000 bottles per hour. The total initial investment
for the company, including a CO2 gas plant, amounted to 80 million USD.
MOHA Soft Drinks Industry produces five flavors of soft drinks: 7 Up, Miranda Orange,
Miranda Apple, Miranda Tonic, and Pepsi. Today, it stands as one of the leading producers of
carbonated soft drinks in Ethiopia. The machinery used in production has been imported from
various countries and installed by Union Engineering Company, which provided design and
technical support.
The company operates a glass bottle production line that generates approximately 36,000 bottles
daily. With an annual turnover reaching 556 million birr, MOHA Soft Drinks Industry has
experienced an average annual sales growth rate of 12%[9].

Figure 1.1 Structure of MOHA soft drinks factory S.C Mekelle plant

1.2 Objective

The company is committed to produce and supply high quality and safe products that satisfy the
needs of customers.
✔ Creating values to customers and to be owners by making their products the first
choice of the customers.
✔ To carry on beverage manufacturing, processing and bottling.
✔ To manufacture, sell and distribute carbon dioxide.

1.3 Mission

The mission of the company is to be the best soft drinks industry in the country. The company
believes it will continuously improve the production capacity in which customers, employees,

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partners and the communities served will be satisfied by the products. These will be
accomplished through the development of employees, an emphasis on cost, efficiency, market
expansion and profitability. The company will expand marketing areas to both protect and
improve positions by placing emphasis on innovation and technological improvement to always
keep a head of the competition.

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1.4 Vision

MOHA soft drinks have bright future opportunities and

plans to be: -
✔ The best Pepsi cola bottler in the world.
✔ The best in sales volume growth and in return on capital employed.
✔ To make each of its products to be a drink of first choice among the consumers and
obtainable throughout the Ethiopian market.

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1.5 End Products and service of the Company
MOHA soft drinks company is one of the soft drinks beverage companies in Ethiopia that
produce six different brand beverages these are:
✔ Mirinda orange (orange flavor)
✔ 7 up
✔ Pepsi cola (cola flavor)
✔ Mirinda tonic
✔ Mirinda Apple
✔ Kool water gas

Figure 1.2 Main products of MOHA soft drinks factory

These all products are 300ml (0.3L) and the filler machine fills 36,000 bottles per hour. In
addition to these, the plant also produces carbon dioxide gas for the beverage purpose. According
to the efficiency of producing carbon dioxide, the plant could sell it for home consumption and
supply it to consumers who need it for food preservation purposes. To produce the above
mentioned products, MOHA soft drinks industry S.C got a franchised license from international
Pepsi Cola company. This company controls the quality and safety of the products in the market.

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1.6 The Main Customers or End Users of the Hosting Company

The consumer is the individual who drinks the product. The customer is either the direct retail
outlet or an independent wholesale distributor to independent retailers or multiple
retailer/supermarket chains, whose individual stores are either served directly or via a
distribution center. Generally, the products are brought to;
✔ Supermarkets
✔ Restaurants
✔ Institutions
✔ Product distributing stores
✔ Hotels

CHAPTER TWO

2 PROCESS TECHNOLOGY OF THE FACTORY

2.1 Process description

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During our intern-ship at MOHA Soft Drinks Industry, which began on June 29, 2024, we were
assigned to specific departments while also being given the opportunity to observe various
operations across the facility. This exposure allowed us to gain insights into multiple sections,
particularly focusing on production and quality control. Our primary areas of engagement
included the steam boiler section, where we learned about the generation of steam; the air
compressor section; the water treatment section; and the flue gas boiler section, which is
essential for producing and preparing pure CO2 gas. Throughout our intern-ship, we received
guidance from our supervisors and collaborated closely with the company’s operators, enabling
us to understand the step-by-step work activities involved. As a result of this hands-on
experience, we have developed a comprehensive understanding of the operational processes,
production methods, water treatment techniques, and the underlying principles and functions that
drive the company's activities.

2.1.1 Water treatment plant

Water treatment is any process that makes water more acceptable for a specific end use, the end
use may be drinking, industrial and water supply. Water treatment removes contaminants or
reduces their concentration so that the water becomes fit for its desired end use. Here the
company uses its main source from ground water. This water contains some unwanted impurities
like; suspended solids, micro organisms, heavy metals and dissolved ions. So water treatment is
used to remove these unneeded impurities and some unnecessary materials. The water from the
ground is pumped into the raw water tank and passes through different unit processes for final
treatment.

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Ground water Concrete tank

Sand filter
Raw water storage

Activated carbon filter tank Back washing

Service water
Cartridge filter polisher (10)
micro size
Softener tank

U.V (1) dies infection Chiller

Soft water
Cartridge filter polisher (5) micro size

Reverse osmosis
Boiler room

Product water tanker

Carbon filter tanker two

Carbon filter tanker three

Ultra violet U.V (2)

Treated water

Figure 2.1 Water treatment process

A) Bore-hole: The source of the raw water is groundwater of Aynalem and it’s found five
kilo-meters more far apart from the industry. The raw water comes into the industry
through tubes by the help of pumps. The source of water is used for the overall Production

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process. For preparation of syrup, for bottle washing and crate washing, for chiller and
boiler, etc. The ground water source is usually free from natural organic matter but can be
high in minerals, alkalinity compounds such as Ca & Mg, it is also free from external
pollution, but it’s not pure water because there is growth of microorganisms and minerals
that will be treated in the plant.
B) Raw Water Reservoir: It is a tank made from concrete used to receive the pumped water
from the bore-hole and store before transferring to a sand tank. The reason required to store the
water in concrete tanks is to have a consistent supply of water and moreover the water used to be
treated with chlorine (0.01 – 0.03 ppm) to reduce the amount of microorganisms. The concrete
tank is able to store 300,000-liter water and the tank is separated into two tanks for the reason of
standby during cleaning and when there is risk of leakage. In addition, there is a circulation line
inside the tank for the purpose of well mixing chlorine and refreshments of the raw water.
C) Aeration: Aeration with compressed air with or without ozone is used to oxidize ferrous ions
to ferric oxide or hydroxide which separate from the solution to remove carbon dioxide from
water, hydrogen supplied, and volatile organic substances i.e. iron.

Figure 2.2 Aerator

D) Sand Filter: Is equipment that is used to remove suspended solid and float-able material
from the water. In other words, it serves as a physical treatment of the raw water. There are three
partitions inside the sand filter tanker. At the upper part of the tank there are sands which are also
called gravels and they are relatively larger in size. On the medium part of the tank there are also
sands which are lesser in size than gravels and also they cover a few heights above the gravel.
Finally, the bottom of the tank is filled with fine sand filters followed by anthracite at top up that

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enhances filtration of foreign matter or suspended particles coming with raw water which may
occur during storage at concrete tanks.

Figure 2.3 Sand filter

E) Intermediate Tank: There are two raw water storage tanks used to receive and store the raw
water that passed through sand filter tanks. Each storage tank receives from their proportional
sand filter. Then chlorine will be added in these tanks for disinfection of microorganisms and the
water will be stored for about two hours. The amount of chlorine added must be five percent of
the size of the tank or 5 ml/l.
Then from this tank the water will be transferred in to four different parts such as;
✔ Into activated carbon filter
✔ Into softener
✔ Into service water
✔ Backwash water

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F) Activated Carbon Filter Tank (A.C): Is one of the three types of carbon filter tanks and it
has activated carbon in it that is mainly used to DEchlorinate the raw water which had a chlorine
added at the raw water storage tank. Uses for the chemical filtration such as flavor, chlorine,
color etc.

G) Cartridge Filter (Polisher, 10µ): It is used to filter the DE chlorinated water by using a 10
micro sized polishing filter bag. This bag prevents particles whose sizes are greater than one
micro. Then after passing through this bag, the water will be available for the next treatment,
which is ultraviolet.
H) Ultraviolet Light (Uv-1): UV light intensity meters are available which indicate the
penetration of UV light through the glass sleeve and the water. Low intensity means the UV dose
is too low to provide adequate disinfection. This meter will indicate when cleaning or lamp
replacement is needed.
I) Cartridge Filter (5 Micro Sized Polisher): This cartridge filter is the same application with
the first one. But the mesh sizes of them are different. Also it is very small particles than the ten
(10) micro polishers.
J) Reverse Osmosis (RO): It is a material used to treat the water by using high pressure to
remove almost all contaminants. In this step, high pressure is applied on the water to pass
through the reverse osmosis membrane and the filtrate will be collected in the product tank.
Reverse osmosis is a Nano system process applied by changing the pressure from low to high in
order to remove suspended particles including MOs and mid to large sized organic molecules.

Figure 2.4 Reverse Osmosis

K) Product Water Tank: It is a tank used to store the water after being treated in reverse
osmosis. In this tank, chlorine will be added for the removal of remaining Mos. After

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chlorinating, the water will be distributed into two carbon filter tanks, which are carbon filter two
and three.
L) Carbon Filter Tank: Two and three the working principle of these tanks is similar to that of
tank one, which is DE chlorinating the water that is chlorinated in product water tanks by using
the activated carbon in it. Generally, these activated carbon (2&3) addressees the following
activities: -
✔ Reduction in inorganic including metals well in execs of 90%
✔ Removal of mid to large size organic molecules
✔ Removals of physical discrepancies (turbidity, colloidal matter, odor, color).
After DEchlorinating is performed, the water will be transferred to a one micro size
cartridge filter now almost all microorganisms are dead or removed.
M) Ultra Violet (Uv-2): It is the final treatment for the product water. Used for destroying any
present microorganisms. It’s known as the critical control point (CCP) for the quality of the
water. After passing through UV, now the water can be used for production purposes, such as
syrup preparation and filling room.
N) Softener Tank: Soft water is the water used for non-product uses mainly for heat exchange
and rinsing purposes. The water is softened by ion exchange (zeolite- exchanger) method by
adding sodium chloride to remove magnesium and calcium from the water. There are two tanks
for softener resin which have similar size and application. But at a time, only one of them will
work while the other one will be regenerated using a brine tank that contains sodium chloride.
Generally, its application is to change the hard water into a soft one. Its mechanism is to remove
chemicals like calcium and magnesium which could increase the hardness of the water and plus
to this, those minerals could have an itching effect on boiler and bottle washer machines by
forming scales on the machines body. Therefore, removing the minerals made the water soft and
safe. Clean in place (CIP),

Backwash and Regeneration

It has six steps:

I. RO CIP => it is required when the pressure in the membrane gets 12-14 bars.
✔ 1st Step: - Circulate the membrane using anthracite at PH>10 and then flush with water

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✔ 2nd Step: - Circulate the membrane with citric acid at PH 2-3 and then flush with water
✔ 3rd Step: - Circulate the membrane with anti-scalant or fumados in order to prevent scale
formation and then flush with product water.
II. Carbon Filter Tanks:
The procedure for the carbon filter tanks is given below:
✔ Lowering for 4 min at Back washes for 4 min
✔ Filling up 2 min
✔ First filtrate for 30 up to 45 min.
III. Sand filters tanker:
It has the following process of sand filter tanker:
✔ Backwash (6 step)
✔ Lowering for 4 min.
✔ Backwash air for 4 min.
✔ Backwash air plus water for 4 min
✔ Back wash for 5 min.
✔ Filling up 2 min.
IV. Softener Tank
The Regeneration Step has three basic steps. These are: -
✔ Sodium chloride injection for 2160 sec.
✔ Displacement for 3600 sec.
✔ Final rinse with 0.2m3 water.
V. Dosing Tank
It is the process of adding different chemicals in the dosing tank. Some of the chemicals are:
✔ Caustic dosing tank
✔ Anti- scalant dosing tank, and chlorine dosing tank.
VI. Brine Tank: is a tank used to prepare sodium chloride that is needed for regeneration of the
softener tank. It takes about 300 kg of sodium chloride for a single regeneration process.

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2.1.2 Syrup preparation section

A. Sugar dissolution
Sugar is used in the soft drinks industry to have the proper taste of the soft drink of the products.
In this plant the sugar dissolves at a high level of temperature. And the sugar comes from local
area wengi sugar factory and also from South Africa products most of the time MOHA soft
drinks industry uses the South Africa sugar.
B. Syrup preparation
In this room, most chemists control the proportion of the solution and time control due to
different materials having different properties. Such as Miranda and Pepsi syrup time intervals
relative to water. Miranda syrup can be used immediately but Pepsi syrup must wait one day or
24 hours. The soft drink powder concentrate is mixed with water to make a thick solution called
syrup. It contains 20% soft drink powder and 80% water.
Five steps of syrup preparation
I. Pre-Batch Inspection:
Pre-batch is important in order to check the following things:
✔ Ensure tank cleanliness
✔ Check treated water quality
✔ Check strainers
✔ Check salts dissolution tank
✔ Confirm absence of sugar for diets
II. Staging
Ensure the correct amount of concentrate ingredients for the number of units to be batched,
inspect concentrate containers for breakage. Ensure concentrate rate is within shelf-life record
plant information and concentrate data on batch control record.
III. Batch
Ensure simple syrup contains the correct quantity of sugars. (If Brix is on target, but the volume
is high or low, then the finished syrup will not be on target.) By knowing the Brix value (and
associated density volume is in the tank, the sugar weight can be calculated:

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Mass=density/volume Follow Beverage Document instructions. Match final volume target.
Thoroughly rinse all concentrate containers.
IV. Analytical Verification
Check the Brix of the finished syrup. Prepare control drinks using the fresh finished syrup. If
necessary, prepare control drinks using the aged finished syrup.
V. Syrup Use: -Age, if necessary
Generally, the process of syrup preparation is shown in the figure 2.5

Pre-batch inspection

Staging

Batching

Analytical verification

Syrup use

Figure 2.5 General process flow diagram of syrup preparation batching process

2.1.3 Carbon dioxide Production Room

Carbon dioxide is the most useful element in soft drinks factories. This is used to produce clean
CO2 production for keeping the soft drinks for a long period of time (keep the durability of soft
drink)and the company supply for marketing (selling to other companies like MESSEBO, Dessie
MOHA plant).The production capacity of CO2 is 160 kg/hr.

In addition, the company uses as a raw material for the production of carbon dioxide fuel
(diesel), air, mono ethyl-amine (MEA) and water. The purity of CO2 produced is 99.99%.

Benefits of carbon dioxide in soft drinks industries;

✔ as a preservative
✔ Provide mouth good feel and

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✔ Sparkle to drink, as an input for the mixer [blender], for carbonation of the drink and
pressurizing the bottle.
Chemicals used to produce carbon dioxide are;
✔ Fuel oil
✔ Monoethanolamine (MEA), activated carbon and sodium carbonate (NaCO3)
The main properties that make CO2 useful for beverage carbonation and storage are;
✔ CO2 is less reactive
✔ Denser than air which makes it preferable for pressurizing CO 2 has good odor and
Diesel

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C
FUEL OIL BURNER SODA
ABSORBER
TANKER SCRUBBR

WATER HEAT NOX FLUSH

STRIPPER
SEPARATOR EXCHANGER

AFTER DEYHEDRATOR
COMPRESSOR
WATER
SCRUBBER

STORAGE REFRIGERATOR
COMPRESSOR AND CARBON FILTER
EVAPORATOR CO2 CONDENSOR

Figure 2.6 Flow diagram of CO2 production

In MOHA soft drinks factory carbon dioxide is produced through burning of fuel such as diesel
oil. In order to produce pure desired CO 2 in the CO2 production section it passes some steps after
fuel burning in the boiler as follows. Flue gasses leave from the boiler after fuels are burning
through the burner.
A) Fuel Oil Tanker: It is a tanker that used to store the basic source for the production of carbon
dioxide, which is fuel oil. The fuel oil is burned in order to give CO2 gas.
B) Burner: The fuel oil will be brought into the burner and the burner will be generating CO 2 by
combustion of fuel oil. In this case the source of O 2 is from the environment. There are also by-
products such as soot, SO2, CO, SO3 etc. The reaction at burner is a composition reaction.
In the reaction of oil gas with oxygen (O2) to produce carbon dioxide (CO2), water (H2O), heat,
and flue gasses, it is essential to maintain an oxygen level of 2% to 3%. Insufficient oxygen can
lead to a reduction in carbon dioxide production and an increase in nitrogen monoxide (NO)
emissions.

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Figure 2.7 Boiler

C) Soda Scrubber:The fuel gas from the burner contains some Sulphur oxides (SO 2 and SO3)
that are formed due to Sulphur content in the fuel oil. Sulphur and Sulphur oxide components are
very harmful to the CO2 plant. They cause corrosion on the plant and if entering the MEA system
they will degrade the solution. Therefore, it must be removed before it passes to further process.
So it showers with soda ash solution by circulating in the system by means of soda scrubber
pump and the heat is removed in the soda cooling using cooling water. Therefore, a chemical
called sodium carbonate will be added in the soda scrubber in order to remove the Sulphur.

Figure 2.8 Soda ash tanker

D) Absorber: Absorption is a gas-liquid mass transfer operation in which a component is
transferred from the gas phase to the liquid. And the rate of absorption is determined by the rate
of molecular diffusion that largely controls this interphase mass transfer. The component which
is being absorbed is called solute and in which it is absorbed is called solvent. So CO 2 in the
absorber is fitted with a demister at the top, to avoid MEA droplets and to escape from the gas
going to free air. The white smoke coming from the absorber outlet is mainly water vapor,
nitrogen, and O2. The CO2 content out of the absorber is one of the most important values to
know when troubleshooting the generating unit. MEA+ CO2→MEA-CO2+heat.

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Figure 2.9 Absorption tower

E) NOx Flash: The MEA that has absorbed CO2 in the absorber (referred to as rich MEA) is
pumped from the bottom of the absorber through the rich/lean MEA heat exchanger, where it is
preheated before entering the NOx flash column. In the NOx flash column, NO, N2, and O2 are
separated and released.
F) Stripper: The rich lye containing CO 2 is preheated in the lye cooler before entering the
stripper. In order to release CO 2 from the lye solution, must the solution be heated to its boiling
point The steam and CO2 is separated from the MEA and gasses to the gas cooler from the top of
the stripper and MEA is circulated in the boiler. MEA-CO2 +heat→MEA+CO2
G) Heat Exchanger: It is also called a gas cooler. During stripper the mechanism used to
separate CO2 and MEA was heat. Then this heat must be decreased before further processing and
it is done by using a heat exchanger. After the heat exchanger, CO 2 will be cooled. Water
Separator When CO2 passes through the heat exchanger it will be cooled and it may absorb the
moisture. Therefore, this water separator separates the moisture from CO2 if any.
H) After Water Scrubber: It is a chemical called potassium per manganese. And it has two
major applications. The first one is it removes moisture present after the water separator. The
second application is that it mainly extracts a substance called ammonia.

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Figure 2.10 After water scrubber

I)Compressor:The compression of the CO2 gas is done by two double acting two stage oil free
reciprocating compressors. The CO2 gas is pressurized to 16 bar. Between the two stage
compressors the CO2 gas is cooled in an intermediate cooler and after the second stage the CO 2
gas is cooled in an after cooler. Both coolers are cooled by cooling water.

Figure 2.11 CO2 compressor

J) Dehydrator:This dehydrator is used to remove the moisture contents in the CO 2 gas. Since it
is a process to remove the remaining water which consists of two vessels filled with molecular
sieves one in operation the other in regeneration/standby. And the two dehydrators are working
by 8 hrs. That means if the one is working for 8 hrs the second one is rest and the reverse one.
K) Carbon Filter: A non-regenerative activated carbon filter is installed downstream the
dehydrator. The activated carbon filter will primarily remove any H 2S, but also act as a guard
against smelling substances such as aromatic hydrocarbons, oxygenates chlorinated components
like Vinyl chloride. In addition, this uses a layer of carbon packing to increase the purity of the
carbon dioxide to about 99.99%. Carbon filters remove bad smell, taste, colors and odors as well
as other trace gasses.

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L) Refrigerator Compressor & CO2 Condenser
The CO2 gas from the filter unit is going to the CO2 condenser, it is a heat exchanger where CO2
is on one side and refrigerant is on the other side. This is a Freon condenser which is a Freon
liquid used to cool CO2 gas. Carbon dioxide gas needs to be liquefied before storing and sending
to the end users.

Figure 2.12 Freon liquid condenser

M) Storage
The tank is typically insulated with at least 10 cm of insulation, which is usually covered with a
pre-painted aluminum jacket. This setup is ideal for storing liquid CO2 before it is evaporated
back into gas form. The normal storage pressure is around 16 bars, and the temperature is
maintained at approximately -18°C.

Figure 2.13 CO2 storage

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N) Evaporator
The liquid CO2 will be transferred to an evaporator, where it will be heated until it transforms
into gas. Once it has changed into gas, the CO2 will be directed to the filler room, where it will
be mixed with syrup and water to create the final product.

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2.1.4 Process description of the production room

Figure 2.14 Overall flow diagram of the production room

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A) DE Palletize
Manually disassemble the crates and separate the bottle sets onto the conveyor..
B) DE Packer
The machine separates the bottle and the crate, then the bottle is going to the bottle washer and
the crate is also going to the crate washer.
C) Case (Crate) Washer Machine
Crate washer is a machine used to wash the crates which are dirty and come from the users or
customers. Its operating mode is either manual or automatically. This machine washes a
maximum of 3900 crates per hour and water is supplied by water pumping motors. Here crates
are washed by caustic soda as a soap.

Figure 2.15 Crate washer machine

D) Bottle Washing; The bottle washer takes dirty bottles returned from the trade. And
“Returnable” bottles are cleaned and sanitized to remove beverage residues, straws, and any
liquids and all organic matter on the returnable bottles to fill the final beverage.

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Pre-inspection and detection of contaminants for bottles prior to washing;
✔ Bottles are checked for contaminants prior to bottle washing.
The bottles are pre-inspected for non-existence of caps, presence of liquid residues and the
appropriateness of the color (clear or green).
✔ The bottles are then checked for contaminants and if found contaminated are automatically
rejected.
The critical areas of inspection are:
✔ Locking ring area
✔ Sidewalls
✔ Bottoms (for evidence of dirt, foreign objects, or liquid) Bottles are inspected with the
following goals:
✔ Dirty bottles: Bottles should be returned to the in-feed of the washer for re-cleaning.
✔ Unclean able bottles: Unclean able bottles (paint, concrete, welding drops, etc.) should be
destroyed. They should never be reintroduced into the washer.
✔ Heavily scuffed bottles: Heavily scuffed bottles rejected at the inspection station should be
destroyed.
✔ Damaged glass: Bottles rejected at the inspection station for damage or any physical
abnormality should be destroyed. Even minor damage at the locking ring area, or at the screw
thread of roll-ons, can present both a safety hazard and a potential quality problem from CO 2
loss.

Figure 2.16 Bottle washer machine

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1. Prewashing Zone
Prewashing zone is the washing process before it washes with caustic which is washed at room
temperature. This process is mostly to remove large physical matter.
2. Detergent Zone
The zone uses caustic as a deterrent to wash the bottles. Detergent zone has two sub steps to
wash the bottles.
First soak:
✔ First fitter rooting soak
✔ Its suggested temperature is 70oC
✔ Its suggested concentration 1.7%
✔ Its immersion time 5 min and 30 sec
Second soak:
✔ Second filter rotating soak
✔ Its suggested temperature is 75oC
✔ Its suggested concentration is 1.5%
✔ It's immersion time 2 min and 45 sec
Hot Water -this zone is used to decrease the temperature of bottles due to exchange of
temperature.
✔ The temperature of the bottle should not be greater than 60oC
✔ The concentration become to 0% (it may not be exactly 0 %)
✔ The immersion time become 1 min and 16sec
3. Rinse Zone

✔ This rinse zone has three rinsing steps: -

1) First rinse
2) Second rinse
3) Third rinse (final rinse)
✔ Rinsing process is used to pull water in order to rinse the bottles in three stages. Then the
bottle temperature becomes at least 28oC finally when discharged. And in order to
remove caustic concentration 3rd rinsing occurs.

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✔ 1stRinse: -In this step the concentration of caustic soda is made to be zero and the
temperature is lowered up to 200c.
✔ 2ndRinse: - It is similar to the first rinse but the slight difference in temperature and contact
time.
✔ 3rdRinse: - This is the 3rd step in which microorganisms will be destroyed.

2.1.5 Filling Room

It is one of the production sections whose purpose is to verify that containers are consistently
filled to the correct level as established by correct volume or weight for the brand and package
type. There are 6 main machines to do the entire job under the filling room. These machines are
listed as follows: -
1. Empty Bottle inspection (EBI)
2. Mixer Machine
3. Filler Machine
4. crowning
5. Full Bottle Inspection (FBI)
6. Date code

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1.Empty Bottle Inspection (EBI)

Figure 2.17 Empty bottle inspection machine

This machine is used to inspect the empty bottle that comes from the bottle washer. It has about
8 parameters to inspect the coming of each bottle.
✔ Bottle neck: By using a manual system detects the bottle neck, whether it is cracked
(broken) or not.
✔ Base: It checks the bottle's base or bottom part. If it is too thick or too thin
✔ Inside wall: It checks whether the inside wall is cracked.
✔ Caustic: detecting whether there is any caustic in the bottle that comes from the bottle
washer.
✔ Residual liquid: checking whether a residual liquid is present in the bottle.
✔ Too tall: detecting the length of the bottle, it checks the bottle whether it is too tall.
✔ Too short: Similar to the upper one, detects the height whether the bottle is too short.
Mixing the mix processor prepares the beverage for filling. For Pepsi-Cola, 7-Up and
carbonated flavors the mix processor combines the finished syrup, treated water and
carbon dioxide in the correct proportions (and ratios) and transfers the blended final
beverage to the filler. In addition to the proportioning function, mix processing will
usually incorporate de-aeration, mixing, carbonating and cooling. The key elements of
the mix processor:

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1. DE aeration: is called removing dissolved oxygen based on a vacuum system. The major
function of reducing air is to be greater product stability in filling and less foaming, less product
oxidation and less risk of contamination and achieving maximum filling speed.
2. Proportioning: refers to the finished syrup, CO2 and water are being proportioned correctly.
3. Carbonation: addition of carbon dioxide as the beverage is chilled, it absorbs carbonation.
Carbonation is the step of adding carbon dioxide to a drink. Non-carbonated drinks do not
include the carbonization step.
4. Cooling: Most beverage operations use cooling to 2°C for cold filling. The use of the cold
filling process minimizes foaming at the filler, allows the systems to run at lower carbonating
pressures, and can give a faster rated speed.
2. Mixer machine

Figure 2.18 Mixer machine

Mixer machine is a machine which is used to mix three different things. These are:
✔ Carbon dioxide (CO2)
✔ Syrup
✔ Water

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3. Filler Machine

Figure 2.19 Filler machine

It is a machine used to fill the product into empty bottles. The machine that sucks the bottles and
fills the product is called a bowl. This machine has 6 sequences from receiving the empty bottles
to filling the product. These sequences are stated as follows:
✔ Evacuation: - When coming to fill the bottles may hold strange gasses for the product.
Therefore, this step used to remove those gasses.
✔ Flushing: - Then the bottles will be flushed with CO2.
✔ Pressurization: - This step is used to remove the CO 2 that was applied for flushing. It is
carried out after the container is sealed to the sealing valve. Removing the CO 2 is
required to prevent contact between product and CO 2, unless otherwise it may result in
exceeding the CO2 amount in the product.
✔ Filling: - Is a step of which the product is filled into the bottles.
✔ Correction: - If the fill height becomes greater than the range then it will be corrected or
sacked. This is done under the correction step.
✔ Snifting: - used to balance the pressure between the container and the surrounding.

4. Crowning
Bottles are transferred from the filler to the crowner by the in feed conveyor. At that point, a
guide rail transfers bottles from the in feed conveyor to the in feed star wheel. Simultaneously, a
crown is fed into the crowner reset. The crowning head assembly then places and crimps the
crown on top of the bottle. The function of the crowner is to mechanically apply and seal crowns
to bottles. This procedure uses a crimping technique that applies pressure to the top and sides of
the crown. This pressure causes the crown to adapt to the neck of the bottle.

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5.Full bottle inspection (FBI): Bottle inspection system for the beverage industry inspects filled
bottles at high production line speeds for proper fill level 300ml (it detects whether the bottle
filled in proper quantity of soft drink or not), cap position (missing, incorrect, skewed and under
or over torque cap) and tamper band integrity; defective bottles are automatically rejected.
Like an EBI machine, this machine also inspects the status of a full bottle. There are parameters
used to check the full bottle. The basic parameters are the following:
1. Under fill: This parameter checks the fill height of the product, and if the height of the
product in the bottle is found to be under its standard height the bottle will be discarded from the
process.
2. Uncrowned: If the cork does not fit correctly, it will be checked and removed from the
process line.
3. Empty Bottle: When a bottle cracked in the bowl, it would jump some number of bottles
without filling. During this moment the FBI will remove those empty bottles with the help of a
sensor.
6.Date code
Used to print information such as, expiration date, company name and time on the surface of the
pet filled with the soft drinks. To perform this activity, it uses different materials and
mechanisms. The sensor is very important in this system of date coder machines. If this
information is not printed on the surface of the pet filled with soft drinks the soft drink is out of
use by the customer. The purpose of this is not only for the company, but also the usersor the
customers of the company should read the date of production and the expiration date of the soft
drinks to get the expected benefit and to keep their health in good condition.

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2.1.6 Boiler Plant and Air Compressor

Boiler plant produces softened and hot water at 80°C for the bottle washer, crate washer, syrup
room plant and water treatment plant. In this plant they use diesel oil to heat the soft water to
form steam. Raw materials and materials of boilers have stainless steel, aluminum spring,
distilled water, steam hose and water hose etc. Air compressor produces pure air for the boiler,
burner and other processes. It is also an interesting plant for the company.

2.1.7 Sanitation

Each and every week the machines will take place sanitation with water and a specialty
detergent. This helps the machines to be clean and lets them perform their job with ease in the
boiler room. This room is one of the company’s essential units. It mainly produces steam for
syrup room, bottle washer & crate washer. The main parameters used to produce steam are: -
Furnace (Heavy oil), soft water. The reason behind choosing a furnace over fuel (Light oil) is
that it is cheaper than fuel. A detailed description for the boiler room process. After preparing all
the required parameters that are producing steam, the first thing that will be done is to bring the
furnace from the furnace tank to modify the furnace storage tank.

On the other hand, an equal mixture of product water and soft water is also boiled in the water
tank with steam before getting into the boiler. Water is boiled before getting into the boiler,
because to maintain the temperature of the water and the temperature of the boiler. Otherwise it
will take us too much time until it boils and changes into steam. And if we add cool water into
the boiler, it could also decrease the temperature in the boiler. Next step will be boiling the
water until 180oC, where the water changes into steam. The furnace which is used as a base to
boil the water is burned by using gas in the boiler. During boiling, the water and the flame will
have no direct contact. There is a thick plate between them used as a heat exchanger in order to
boil the water. When the temperature reaches 180 oC, the water will completely change into
steam and this steam is automatically transferred into the distributor tank. A Distributor tank is a
tank used to receive the steam from the boiler and distribute it to the syrup room (in order to boil
the sugar), bottle washer and crate washer. After completing its task, the steam will return back

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to the boiler room and stored into the condenser tank in order to change it into liquid. When the
steam changes into liquid, it will transfer into the water tank so that any steam will not be low,
instead it will circulate for the next batch.

2.1.8 WasteWater Treatment

To neutralize the waste water that comes from different areas of the plant by adding chemicals.
The plant uses the water and different chemicals for washing purposes in different areas for
different purposes and runs to the waste water stages. This wastewater must be treated before
being discharged into the environment because it is dangerous for humans, animals and plants.
Source of wastewater
✔ Bottle washer room
✔ Water treatment room
✔ Syrup room
✔ The filling area
✔ Production room
But the waste water coming from other areas is considered as there are no dangerous chemicals
so join with the final treated wastewater. The raw wastewater should not contain any oxidants
other than chlorine, greases, or other water immiscible. The neutralized system is used to
neutralize the incoming waste water to a PH range of 6.0 to 8.0. There is a double stage system
provide, in the first stage the inlet waste water is mixed and equalized. Since the waste water
treatment system has two stages. The coming wastewater contains a physical presence of floating
and deposited materials which are removed by a screening method. The two stages have the
same principles, but may different in the amount of dosing chemicals depending of the PH of the
water reading in PH meter. This waste water is measured by sensor either acidic or basic then
dosing the chemical to neutralize. But most of the time the inlet wastewater is basic because of
the caustic soda, then add the acid. The mixing of the waste water is performed by a circulation
pump placed at the outlet of the waste water stage; this pump activates itself when a wastewater
flow is detected at the outlet of the stage using the flow meter installed.

Depending on the PH of the waste water which enters stage 2 caustic, or acidic is dosed using a
dosing valve. In addition, a fine tuning of the PH occurs via the use of the dosing pump
arrangement based on the outlet of PH measured. The potassium per manganese is added to the

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waste water to avoid the smell/odors of the waste water. There are circulating pumps inside the
waste water to mix the addition of chemicals like ppm and dosing acid or caustic because the
water is stable there is creation of the smell and no equal distribution of the added chemicals and
the waste water is not neutralized.

Waste water treatment is a process to convert waste water which is by neutralizing the waste
water i.e. dosing acid (H2SO4) to the waste or base. Treatment means removal of impurities from
water being treated and is expected to avoid or minimize environmental degradation or health
problems. After neutralizing the waste adjusts the PH valuebetween 6.5 -7.8 then opens the
draining valve to the plant area [9].
MOHA soft drink industry uses one of the latest mechanisms for waste water treatment and it
has three stages;
A. Physical treatment
B. Chemical treatment
C. Biological treatment
A. Physical Treatment
The physical treatment is used for removing suspended solid particles. Some equipment and
steps are used in this way.
✔ Pump pit - these two pipes are used to pump the waste water to the defender and it
recycles back these pumps to remove small objectives.
✔ Metal sieve - it captures the suspended particles (Large particles).
✔ Primary filtration - filters the large particles by using mesh with wide holes.
✔ Secondary filtration – filters the remaining solid particles passed through the primary by
using very narrow mesh’s to become free from the solid waste particle’s.
B. Chemical Treatment
✔ This is used in the neutralization tanker by measuring the PH.
✔ Chemicals like sulfuric acid (H2SO4) and sodium hydroxide (NaOH) are used to balance the
PH level.
✔ If the PH is acidic (below 6) it needs dosing of base, if the PH is base (above 8) it needs
dosing of acid.
✔ Anti-foam chemical used for removing the foam from the tanker

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C. Biological Treatment
It uses biological methods for aerobic and anaerobic methods.
✔ Anaerobic is used in the absence of oxygen.
✔ Aerobic requires free oxygen for growth so in presence of oxygen by using the blower
mixer it helps for destroying microorganisms and stopping bad smell.

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2.2 Mass and Energy Balance of Main Unit Operations

2.2.1 Material Balance for Sugar Dissolving Tank (Sugar Preparation)

mA.C=2.5kg

Water=1500L

sugar=2570 kg mout=?

mFP=7.71kg
Input = Output
msugar + mwater +m AC +mFP=mout

ρ Water=1000 kg/m3
1m3=1000L
mwater =ρV

mwater =1000 Kg/m3 × 1500 L ×10− 3 m3 / L

mwater =1500 Kg

2570Kg+ 1500Kg+ 7.71Kg+ 2.5Kg = 4080.21Kg¿ mout

Sugar Balance
2570 Kg/4080.21Kg = 0.63%

Water Balance
1500Kg/4080.21Kg = 0.36%
Carbon Balance
2.5Kg/4080.21Kg = 6.1×10 −4 %
mFP Balance:
7.71Kg/4080.21Kg = 0.0019

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2.2.2 Energy balance

According to the first law of thermodynamics, energy can neither be created nor destroyed but
can be changed from one form to another form.The first law of thermodynamics for an open
system at steady state has this form.
Accumulation = Input - Output + Generation - Consumption.
Input =Output.
ΔH+ ΔKE+ Δ PE =Q-WS
Where Q=Heat
ΔH=Change in enthalpy
ΔKE = change in kinetic energy
Δ PE = change in potential energy
WS = shaft work
Energy balance on the boiler

Assumptions
✔ There is no change in length (Δ PE = 0)
✔ No moving part (WS = 0)
✔ There is no movement (ΔKE = 0)
Therefore, the equation will be reduced to,
Q = ΔH
Min = 3500 Mout = 3430 kg
Tin = 25 Tout = 200oC

Then from the above simplified equation Q = ΔH

Where h = enthalpy
H=εmℎ – εmℎ

M = mass flow rate

Hfg = enthalpy at saturated water
1 atm ≈ l bar
Then 8 bar = 0.8 M pas

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Then enthalpy at 8 bar = 2950 kJ/kg = 665 kcal/kg. And also at temperature of 60°c saturated
water enthalpy will be
hfg = 2345.4 kJ/kg =80 kcal/kg
Then Q = ΔH = Σ mh − Σ mhfg = m Σ (h – hfg)
kg
Q=ΔH = 3500
( 2950− 23454 ) ℎr
KJ
Q = ΔH = 42322 but 1 KJ = 1000 J, 1hr = 3600sec
ℎr
KJ 1 ℎr
Then Q = ΔH = 42322 * = 18.4 KW
ℎr 3600 sec
Therefore, Q = ΔH = 18.4 KW

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2.3 Main Equipment Sizing of Carbon Dioxide Storage

V=?

Figure 2.20 Size Equipment

To find the storage of volume of the tanker to design is as we know to find the volume
ρ =M/V
Where the ρ = density of carbon dioxide in kg/m3
M= mass of carbon dioxide in kg/hr.
V =volume of carbon dioxide m3/hr.
In the company the carbon dioxide mass was manufactured in per hour

1hr = 160 kg/hr.

The density of carbon dioxide also ρ co 2=50.32kg/m3
Now we calculate the amount of volume that stored in the tank in per hour by cross each other
ρ =M/V
V= M/ ρ
V=160 kg/hr⁄50.32kg/m3
V=3.17 m3/hr.
Now our carbon dioxide tank stored 3.17 m3/hr.
V=Ab*H

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2
πD
Where Ab= for cylindrical…………….....................................................Ab=Area of the
4
base
Where H=L……………………………………………………………………...Height=length
V=Ab ×L
V= π D2 /4 ×L………..The volume was calculated in the above V=3.17m 3/hr. then we required
the diameter and π is …………………we take ………3.14 and also we take the assumptions
Assume L/D=2……………...most of the ratios seems like, by cross each other; L=2D
V= π D2 /4 ×L
3.17m3/hr=3.14×D2/4×2D
3.17m3/hr=2×3.14×D3/4………………………………by cross each other we find the Diameter
D3 =4×3.17/2×3.14
D3=12.68/6.28
D3= 2.019
(D3)1/3= (2.019)1/3
D= (2.019)0.333
D=1.26 m…………………………………………………. the length we substitute now
L=2D
L=2×1.26m
L=2.52m
The Area of the base also
Ab=¿ π D 2 /4
Ab=3.14 × (1.26)2/4
Ab=4.985/4
Ab=1.24m2

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2.4 Environmental Considerations of the plant

Even though environmental protection at MOHA is an ongoing process of continuous

optimization of the environmental management and a comprehensive approach involving
communication, research and development of new products, operation of the plants and facilities,
there are some problems like bad smell around waste treatment department and release of CO 2 to
the environment, which pollutes the environment and affects the workers and the people who
leaves around there.
2.4.1 Occupational Safety and Health Protection
MOHA aims to minimize all risks and hazards at all workplaces in order to protect the health and
well-being of the Employees, contractors, and visitors etc.

2.4.2 Quality — the Key to Performance (Quality Control)

What is quality? Quality can be simply defined as a level of excellence. Excellence can be
described as having great merit. Merit, in turn, can mean having a feature of quality deserving of
praise. Quality determines the performance of a beverage in the market- place. A quality
beverage is one that meets the standards of performance expected by both the manufacturer and
the consumer. To perform well, the beverage must meet the following basic quality standards:
✔ The beverage must have the sensory properties that satisfy the consumer’s expectations.
✔ It must present no health hazard to the public, in general, and to the consumer, in
particular.
✔ The beverage must retain its initially produced quality for the prescribed shelf life in the
marketplace.
✔ The product must meet the description offered on its label and in media advertising.
✔ The full range of a company’s beverage products must reflect a positive image of the
company.
✔ The cost of the beverage to the purchaser must be reasonable.
✔ Quality control is done measuring certain parameters and comparing to the set value or
set point. Quality control is made in, Wastewater treatment plant, Water treatment plant,
Carbon dioxide plant, Simple syrup, final syrup and final full bottle.

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✔ The quality of the wastewater can be identified by measuring different parameters like,
Sludge volume index, Biological oxygen demand, Chemical oxygen demand, Total
dissolved solids and Phosphorus content.
✔ Beverage quality can be analyzed by measuring the parameters like Microbial content,
Carbon dioxide content, Degree brix and Beverage Bottle pressure. There are also other
quality measurements for Incoming bottles, Thickness or stretch of the plastic bottles,
Incoming sugar quality and Carbon dioxide quality.

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CHAPTER THREE

3 CASE STUDY: Optimize the Efficiency of Carbon Dioxide

Capture in Absorption Units to Reduce Emissions.
3.1 Short Summary

The objective of this project is to enhance CO₂ production by optimizing the input variables of
the absorption column and increasing the concentration of Monoethanolamine (MEA) solvent.
Currently, the absorber at the MOHA soft drinks industry is limited to producing 160 kg/hr of
CO₂, while the flue gas input flow rate significantly exceeds this capacity, leading to excess
CO₂ emissions and increased raw material costs. To address this inefficiency, we propose
optimizing the operational parameters by reducing both the inlet pressure and the volumetric
flow rate of the flue gas. Our studies indicate that CO₂ recovery improves as the inlet pressure
and flow rate decrease. Tests were conducted at pressures ranging from 9 atm to 8.6 atm, with
corresponding flow rates decreasing from 1613.3 L/min to 1477 L/min. This optimization is
expected to increase CO₂ recovery from 82.5% to 93%, while minimizing raw material
consumption. Although temperature does affect the absorption process, its impact is less
significant compared to pressure and flow rate. Therefore, we will maintain a constant
temperature of 40°C during our observations. Additionally, many CO₂ capture studies
emphasize the importance of minimizing energy consumption during chemical absorption. A key
challenge in this regard is the thermal energy required for regenerating chemical solvents. To
optimize CO₂ concentration, we will utilize MEA in a counterflow system to absorb CO₂ from
flue gasses produced by diesel combustion. This project aims to improve CO₂ recovery
efficiency while promoting sustainable practices within the industry by reducing environmental
impact and operational costs.

3.2 Introduction

The advancement of carbon dioxide capture and storage (CCS) technologies is essential for
increasing carbon dioxide concentration in industrial plants. Currently, chemical absorption
processes are the preferred method for post-combustion carbon dioxide capture (PCCC).

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However, a significant challenge arises from the large volumes of exhaust gas produced by fossil
fuel power plants entering the PCCC process. Conventional absorption systems, such as packed
bed columns, face considerable mass transfer limitations at the gas-liquid interfacial area.
To enhance mass transfer between gas and liquid phases, the rotating packed bed (RPB)
technology was introduced by Ramshaw and Mallinson in 1981. In a rotating packed bed, the
dynamics of liquid and gas flow differ significantly from traditional systems. While gravity
drives downward liquid flow and upward gas flow in packed beds, the centrifugal force in an
RPB creates outward liquid flow and inward gas flow. The high rotational speed of the RPB
disperses the liquid into fine droplets, thereby increasing the gas-liquid interfacial area and
enhancing the mass transfer rate.
Numerous studies have explored the feasibility of CO2 capture using RPBs with various amine
solutions. However, most of these investigations utilized fresh amine solutions. In real-world
absorption processes, the lean solvent input is not devoid of CO2. For a 30 wt%
Monoethanolamine (MEA) process, lean and rich loading levels should ideally range from 0.35
to 0.49 to minimize energy expenditure during solvent regeneration.
The purpose of this study is to evaluate the performance of 30 wt% MEA solutions at various
loading levels in a rotating packed bed system. This research aims to optimize CO2 capture
efficiency while addressing the practical constraints associated with solvent use in industrial
applications. [3].

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3.3 Problem Statement

The current CO2 recovery process at the absorption unit is operating below optimal efficiency,
resulting in sub-par recovery rates and increased operational costs. This inefficiency not only
affects the overall productivity of the facility but also contributes to higher greenhouse gas
emissions, undermining sustainability goals. Identifying the key factors influencing CO2
absorption rates, including solvent selection, temperature, pressure, and flow dynamics, is crucial
for enhancing the performance of the unit. The objective is to optimize the CO2 recovery process
to achieve a minimum of 93% recovery efficiency while reducing energy consumption and
operational costs by at least 15%. This optimization will support environmental compliance,
improve economic viability, and contribute to the facility’s commitment to reducing its carbon
footprint..

3.4 Objective

3.4.1 General Objective

✔ To optimize the Efficiency of Carbon Dioxide Capture in Absorption Unit.

3.4.2 Specific Objectives

✔ To evaluate the impact of operational parameters.

✔ To propose optimization parameters.
✔ conduct energy and material balance assessments.

3.5 Scope of the project

The project will be conducted at the MOHA Soft Drink Industry, focusing on optimizing and
purifying carbon dioxide obtained from the absorption unit. The primary objective is to enhance
the quality and efficiency of carbon dioxide for commercial purposes. The outcomes of this
study will provide significant benefits to Mohammed Hussien Al-Amoidi (MOHA) Soft Drink,
contributing to improved product quality and operational efficiency.

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3.6 Literature review

3.6.1 Gas Absorption

A key aspect in an absorption system, also known as scrubbing, is the contact between gas and
liquid phase. Gas absorption is a unit operation where one or more components in a gas mixture
are dissolved in a liquid (solvent). The absorption may either be a purely physical phenomenon
or involve a chemical reaction, such as the reaction between CO 2 and mono ethanol amine
(MEA). Also, Gas absorption is a mass transfer operation in which one or more species (solute)
is removed from a gaseous stream by dissolving in a liquid (solvent). The insoluble
component(s) presenting in the gas stream not absorbed is called the carrier gas. Two methods of
operation in gas absorption exist, those are countercurrent and concurrent operations. In co-
current absorption, there is no minimum liquid-to-gas ratio and it is less efficient than counter-
current operation. The advantage of concurrent operation is the lack of flooding limitation, and
high gas flow rate can be used which reduces their required column diameter. For counter-
current operation, the gas which leaves the column or tower via the top enters from below while
the liquid flows in through the top and exits via the bottom in an opposite direction.
Absorption occurs in two reaction processes which classified as,

3.6.1.1 Physical absorption

In this type of process, the component being absorbed is more soluble in the liquid absorbent
than other components of the gas stream, but does not react chemically with the absorbent. The
equilibrium concentration of the ascorbate in the liquid phase is strongly dependent on the partial
pressure of the gas phase [2].

3.6.1.2 Chemical absorption

Absorption with chemical reaction involves the reaction in the liquid phase to vehemently
remove a solute from a mixture of gas. It has the capacity to increase the absorption coefficient
of the liquid-film compared to an ordinary physical absorption. Reaction in the liquid phase
greatly increases the driving force for mass transfer since there is reduction in the equilibrium
partial pressure of the solute over the solution. A good instance is the absorption of NH 3 from a
gas stream with the use of a dilute acidic solution. Also is the removal of CO 2 from solutions as

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well as other acid gasses. An effective comparison of chemical reactions was given by McCabe
et al (2005) in the absorption of NH3 in dilute HCl in gas concentration (ln 0.02 / 6) and the
absorption of NH3 in water which gives 5.7 and 12 respectively for the same change in
concentration. Also, an experiment carried out by Bubulka, Kelly, Schruende & Wallace (2008)
at the Rose- Hulman Institute of Technology Indiana shows that chemical solvent MEA amongst
other solvents used, absorbed carbon dioxide at the highest rate, collecting 1.4849 grams of
carbon dioxide. The highest physical solvent used was Methanol which absorbed 1.021 grams of
carbon dioxide. The result is shown in the graph [2].

Figure 3.1 Solvent vs amount of CO2 absorbed per 150ml

3.6.2 Properties of Carbon Dioxide

Carbon dioxide (CO2) is composed of two oxygen atoms covalently bonded to a single carbon
atom. It is a trace gas with a concentration of 0.039% by volume in atmospheric air. In the
seventeenth century, Jan Baptist Van Helmont observed that during burning of charcoal in the
closed vessel, the mass of the resulting ash was much less than that of the original charcoal. [4].

3.6.2.1 Physical and Chemical Properties of Carbon Dioxide

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Table 3-1 Properties of carbon dioxide
Physical properties Chemical properties

Freezing point = -78OC kJ

Its latent heat vaporization = 571.08
kg
kg Its vapor pressure = 58.5 bar
Liquid CO2 density = 50.32
m3

Inert or non-flammable Its boiling point = -78OC sublimes

Its taste is neutral Its melting point = -57OC pressurized

Nontoxic and heavier than air kg

Density = 1.98 ,1.67×of air
m3

3.6.3 Applications of CO2

Gas Plants produce Carbon dioxide mainly into two forms - Liquid and Solid. Solid CO 2 is also
known as "dry ice" and is used as refrigerants in the food industry and for small shipments. CO 2
is widely utilized during the storage and shipping of ice cream and other frozen foods. Some of
the CO2 applications are listed below;

Fire Extinguishers: CO2 blocks oxygen contact with those flammable materials so as to
extinguish the fire.
Beverage: This gas is used to fill in soft drinks as a gas form.
Plants: Plants require CO2 to execute photosynthesis, and greenhouses can promote plant growth
with additional CO2.
PH Control: CO2 can be the best alternative for sulfuric acid which is used in water treatment
facilities to control alkalinity.
Medicine: In medicine, up to 5% CO 2 is added to pure oxygen. This helps in provoking
breathing and to stabilize the O2/CO2 balance in blood.

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Welding: CO2 gas is used in the MIG/MAG metal inert gas & metal active gas and can be either
used in 100% form known as a shielding gas for MAG welding or in a combination of CO 2 and
Argon mixtures known as MIG welding [5].

3.6.4 Washing Liquid MEA (MonoEthanolAmine)

The liquid phase employed in the gas absorption process is commonly referred to as the washing
liquid or solvent. In choosing the washing liquid, ‘‘preference is given to solvents with high
solubility for the target solute and high selectivity, low volatility, low cost, low corrosive
tendencies, high stability, low viscosity, low tendency to foam, and low flammability. Liquid
interaction with the gas phase can either be physical or chemical. Weak bonding forces between
the fluid molecules are responsible for withholding the gasses in physically absorbing solvent,
whereas in the chemical absorption either a reversible or an irreversible reaction consumes the
gasses for the formation of a chemical complex. In either case, a change in the conditions of state
can result in the release of the absorbed gas by the washing liquid.
Chemically absorbing sol-vents are known to have higher solubility compared to their
counterpart as a result of the reaction taking place when the phases adequately contact each
other. As the solutes disappear in the liquid phase, a chance is created for more solutes to be
dissolved. A continuous scrubbing system is used to separate CO 2 from a gaseous stream. The
system consists of two main elements, an absorber, where CO 2 is absorbed into a sorbent and a
regenerator (or stripper), where CO2 is released (in concentrated form) and the original sorbent is
recovered. Chemical absorption systems tend to be more efficient than the other systems as the
process is accompanied by a chemical reaction that enhances the overall mass transfer from gas
phase to liquid phase. In a power plant application cooled flue gasses flow vertically upwards
through the absorber counter current to the absorbent (MEA in a water solution, with some
additives). The MEA reacts chemically with the CO2 in the flue gasses to form a weakly bonded
compound (carbonate) the scrubbed gasses are then washed and vented to the atmosphere. The
CO2-rich solution leaves the absorber and passes through a heat exchanger, then further heated in
a re boiler using low-pressure steam. The weakly bonded compound formed during absorption is
broken down by the application of heat, regenerating the sorbent, and producing a concentrated
CO2 stream. The hot CO2-lean sorbent is then returned to the heat exchanger, where it is cooled,
then sent back to the absorber. Some fresh MEA is added to make up for losses incurred in the

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process. The CO2 product is separated from the sorbent in a flash separator, and then taken to the
drying and compression unit. It is compressed to very high pressures (about 2000 psig) so that it
is liquefied and easily transported to long distances to the designated storage or disposal facility
[11].

Figure 3.2 Flow sheet for CO2 capture from flue gasses using amine based system

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3.6.5 Temperature

As the temperature of absorption decreases, the driving force for absorption increases. However,
the rate of the reaction and diffusivity decrease as temperature is decreased. An analysis was
performed to see the effect of temperature on the performance of the system. Simulations were
run at solvent temperatures of 20, 30 and 40°C. 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. This is mainly because the solvent has a low specific heat and it takes
up the heat of absorption quickly. This causes the temperature of the solvent to rise upon reaction
with CO2 and negates the effect of having lower solvent temperature. The absorber tends to
exhibit a temperature bulge at the top of the column. There is a significant amount of reaction at
the top of the column when the lean liquid enters. Due to the highly exothermic nature of the
reaction, a lot of heat is released. The liquid takes up this heat and since the liquid has low
specific heat, its temperature rises. This causes the bulge at the top of the column. As the liquid
proceeds down the column, it exchanges heat with the gas and hence gets cooled.

3.6.6 The Packed Column

The packed column/tower is a device employed in the chemical industry for a number of mass
transfer operations. Common operations carried out with the packed column include distillation,
gas absorption and desorption, and leaching. From an external view, the packed column is no
more than a cylindrical tower equipped with two openings at the top and bottom to allow for
liquid and gas streams entry and exit. These streams are arranged counter currently with the
liquid flows inlet and outlet situated at the top and bottom respectively. The con-verse is true for
the gas flow. An internal reconnoiter from top to down reveals some additional internal features
such as liquid distributor, section(s) of pickings supported above and below with a support plate,
liquid collectors, and liquid re-distributors.

Advantages of Packed Column

✔ Usually used for corrosive liquids because it is cheaper than plate columns.
✔ It is important for toxic or flammable liquids to be kept as small as possible for safety
reasons.
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✔ Packed columns are more suitable for handling foaming systems.
✔ The pressure drop can be lower for packing than plates and considered for vacuum
columns.
✔ Packing should always be used for small diameter columns, say less than 0.6m [8].

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3.7 Methodology

In order to achieve the objectives, different techniques were implemented, data was collected and
compiled from different observations that were made while working in the plant. 15-20% of CO2
is released to the environment. This released CO2 with the treated gas is due to higher flow of
input variables (molar flow rate and volumetric flow rate). The input variables are taken from the
pressure gauge sensor and volumetric flow rate reader for row one. Whereas, the remaining data
are inserted manually. Then, using the help of excel and ideal gas law principle the CO2
production can be optimized and calculated. By observing the percentage of CO2 recovery
during different input variables, the CO2 production can be optimized with the best option.
Applying ideal gas law and excel software help to know the phenomena and best option of the
process.

Assumptions

Steady state reaction: accumulation=generation=0

The reaction obeys ideal gas law

PV=nRT………………………...ideal gas law

Molar flow rate in = Molar flow rate out…………………. material balance

3.7.1 materials and methods

Materials

Sensors:

• Pressure gauge sensors for measuring pressure in the plant.

• Volumetric flow rate meters for assessing the flow rates of gasses.

Data Management Tools:

• Microsoft Excel for data organization, analysis, and calculations.

Methods

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In order to achieve the objectives, different techniques were implemented data was collected and
compiled from different observation that were made while working in the plant

1. Data Collection

To effectively analyze CO2 production and optimize recovery, a comprehensive data collection
approach was implemented. The following steps were taken:

• Observation in the Plant: Operators were engaged to provide firsthand information regarding
operational processes. This involved direct observation of the plant's functioning and discussions
with operators to gather insights about CO2 release and related variables.

• Sensor Data Acquisition: Data on input variables, specifically molar flow rate and volumetric
flow rate, were obtained using pressure gauge sensors and volumetric flow rate meters. This data
was crucial for understanding the relationship between these variables and CO2 emissions.

• Manual Data Entry: For parameters not captured by sensors, operators manually entered
relevant data into a structured format. This included operational conditions and other variables
that could influence CO2 production.

• Online Research: Additional information was sourced from reputable online resources to
supplement the data collected from the plant. This included academic articles, industry reports,
and best practices related to gas recovery and emissions.

2. Data Compilation

The collected data was compiled into a centralized database for ease of analysis. This involved:

• Organizing Data: Data was categorized based on input variables, operational conditions, and
corresponding CO2 emissions. Excel was utilized for its capability to handle large datasets and
perform calculations.

3. Application of Ideal Gas Law

The ideal gas law was employed to facilitate calculations related to CO2 production. The law is
expressed as:

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PV = nRT

Where: • P = Pressure (in atm) • V = Volume (in liters)

• n = Number of moles of gas

• R = Ideal gas constant (0.08205 L·atm/(K·mol))

• T = Temperature (in Kelvin)

Using the collected data, the following steps were undertaken:

• Calculating Molar Flow Rate: The molar flow rate was calculated using the ideal gas law,
factoring in the measured pressure, volume, and temperature conditions.

• Estimating CO2 Production: By applying the ideal gas law, CO2 production under various
input conditions was estimated. This involved manipulating the equation to isolate variables of
interest.

4. Analysis of CO2 Recovery

With the calculated values in hand, a detailed analysis was conducted:

• Percentage of CO2 Recovery: The percentage recovery of CO2 was analyzed under different
operational conditions. This involved comparing the amount of CO2 produced against potential
emissions based on input flow rates.

• Optimization Identification: By examining the relationships between input variables and CO2
recovery percentages, optimal conditions for maximizing CO2 production were identified.

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Pi(a Vi(L/ R(L·atm T i( Pi*Vi R*Ti nfgin(mo ni ncc ntg(mol ncc/ni
tm) min) / K) le/ CO2(m CO2 e/ CO2
(K·mol)) minute ole/min (mo minute
) ute) le/m )
inut
e)
9 1613. 0.08205 313 14519 25.693 565.10 73.463 60.6 491.63 0.82
3 .15 .7 96 17 23 1 85 5039
8.9 1550 0.08205 313 13795 25.693 536.89 69.796 60.6 467.10 0.86
.15 96 67 57 1 01 8381
8.8 1525 0.08205 313 13420 25.693 522.30 67.899 60.6 454.40 0.89
.15 96 18 23 1 26 2646
8.7 1500 0.08205 313 13050 25.693 507.90 66.027 60.6 441.87 0.91
.15 96 15 2 1 43 7955
8.6 1497 0.08205 313 12874 25.693 501.05 65.137 60.6 435.92 0.93
.15 .2 96 94 73 1 17 049
Table 3-2 Effect of pressure and volumetric flow rate on CO2 recovery

3.8 Material balance

Material balance is the calculation of input raw materials needed to meet some product and
determining the amount of raw materials consumed and products produced. The basic law
behind material balance is in a chemical reaction “ substance (mass) is neither created nor
destroyed but can be changed from one form to another form”. There is a physicochemical
difference between raw materials and products but the total mass of input is exactly equal to the
total mass of the product.

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ntotal gas emit 1200 mol/min=nsolvent in

nslution out

501.1mol/min=nfg gas in

Figure STYLEREF 1 \s 3. SEQ Figure \*

n∈¿ n out … … … … … . .(1)
160 kg / ℎr
nCO2 cc= =3.64kmol / ℎr
44 kg/kmol
1 ℎr
=3.64kmol / ℎr * *1000mol /kmol
60 min
=60.61mol /min
nCO2cc is 93% of total nCO2 in.
nCO 2 cc
Then, nCO2 in= =65.1mol /min
0.93
And the total input carbon dioxide into the absorber is 13% of the total flue gas into the absorber.
65.1 mol/min
nfg= =501.1mol /min
0.13
nsolution=nCO2cc + nsolvent
=60.61mol /min+ 1200mol /min
=1260.61mol /min
nCO2 emit=nCO2 in-nCO2 cc
=65.1mol/min-60.61mol /min
=4.49mol /min
ntotal gas emit=nfg-nCO2 cc

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= 501.1mol/min-60.61mol/min
=440.49mol/min

3.9 Result and discussion

3.9.1 Results

Optimization is an increasing efficiency of recovering the product with a constant input or

producing a fixed product by minimizing the raw materials. Thus, decreasing the flue gas feed
rate from 1613.3L/min to 1497L/min and keeping the product the same, the CO 2 released to the
environment decreases from 17.5% to 7%. Due to minimizing the flue gas feed rate about 20.15
birr/min is saved; and CO2 recovery increases from 82.5% to 93%. The concentration of mono
ethanol amine must be increased to enhance capturing of CO 2 in the absorber. Increasing MEA
concentration from 30%wt to 40%wt the thermal energy requirements decrease with 5%-8%.

Pressure 9 atm 8.9 atm 8.8 atm 8.7 atm 8.6 atm
Gas flow rate 1613.3L/min 1550L/min 1525L/min 1500L/min 1497L/min

Efficiency 82%% 86% 89% 91% 93%

3.9.2 Discussion

Effect of MEA Weight %

The thermal energy requirement was found to decrease substantially with increasing MEA
concentration. It seems attractive to use higher MEA concentrations. However, increasing the
MEA concentration is expected to have corrosive effects. It is therefore required to use better
corrosion inhibitors in order to realize the energy saving potential of higher MEA concentrations
Moreover, at high MEA concentration, it is expected to have a higher MEA content in the vent
gas, but a good washing section can overcome this problem and keep the MEA content in the
vent gas as low as possible. The wash section used in the process flow sheets always resulted in a
MEA-content lower than 1 ppm upon an increase of the MEA concentration from 30 to 40 wt.
%, the thermal energy requirement decreased by 5-8 %. Furthermore, the cooling water and
solvent consumption decreased with increasing MEA concentration.
Effect of Temperature

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As absorption temperature decreases, the driving force for CO2 absorption increases, but both
reaction rate and diffusivity decline. Simulations at 20, 30, and 40°C showed that reboiler duty
remained largely unchanged, indicating minimal impact of solvent temperature on performance
due to its low specific heat. In the absorber, a temperature bulge forms at the top from significant
reactions, raising the liquid's temperature. As it flows down, it cools by exchanging heat with the
gas. Thus, while lower temperatures enhance absorption potential, the system's heat dynamics
mitigate their overall effect on performance.

Effect of pressure

The data indicates a clear trend where decreasing pressure enhances CO2 capture efficiency in
the absorption unit. At 9 atm, the efficiency is 82%, but it increases progressively to 93% at 8.6
atm. This trend suggests that lower pressures facilitate better interaction between the absorbent
and CO2, likely due to reduced gas density and increased molecular mobility, allowing for more
effective absorption. This phenomenon can be attributed to the principles of gas solubility and
Henry's law, which state that gas solubility in a liquid increases as pressure decreases. As
pressure drops, the driving force for CO2 to dissolve into the absorbent becomes more favorable,
leading to higher capture rates. In practical applications, optimizing pressure settings could
significantly enhance the performance of CO2 capture systems, making them more efficient and
potentially more cost-effective. This insight emphasizes the importance of operational
parameters in designing effective carbon capture technologies.

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Effect of flue gas feed rate

The data indicates a clear trend between gas flow rate and CO2 capture efficiency. As the flow
rate decreases from 1613.3 L/min to 1497 L/min, the capture efficiency increases from 82% to
93%. This suggests that lower flow rates allow for longer contact times between the flue gas and
the absorbent, enhancing absorption effectiveness. The initial drop in efficiency at higher flow
rates may be attributed to insufficient interaction time, leading to incomplete CO2 absorption.
Conversely, as the flow rate decreases, the system allows for better mass transfer and saturation
of the absorbent, resulting in improved capture rates. These findings highlight the importance of
optimizing gas flow rates in CO2 capture systems to achieve maximum efficiency. Balancing
operational conditions is crucial for enhancing overall performance while ensuring economic
viability.

3.10 Conclusion and Recommendation

3.10.1 Conclusion

In conclusion, our calculations indicate that CO2 recovery efficiency has improved from 82.5%
to 93%. To further optimize this recovery, we recommend reducing the flue gas content in the
feed and maximizing the concentration of Monoethanolamine (MEA) to enhance CO2
absorption. Our results demonstrate that a CO2 recovery rate of 93% is achievable; however,
some CO2 is still released into the atmosphere along with the flue gasses. As the concentration
of the gas increases, so does the amount of carbon dioxide captured. Therefore, optimizing CO2
recovery involves increasing MEA concentration while minimizing flue gas feed into the
absorber. It is important to note that while achieving a CO2 recovery rate above 93% can
compromise the purity of the captured carbon dioxide, further increases in MEA concentration
are necessary to effectively absorb the solute. However, higher MEA concentrations can lead to
increased corrosion of the absorber materials. To ensure the safe and effective performance of
the system while producing pure carbon dioxide, careful consideration must be given to the
materials used in construction..

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3.10.2 Recommendation

✔ Implementing Membrane Separation Technology, This method offers a compact and energy-
efficient solution by selectively separating CO₂ from other gasses, resulting in lower
operational costs and improved purity levels.
✔ It has been observed that the use of expired Monoethylamine and sodium carbonate
(Na₂CO₃) is negatively affecting CO₂ production. The expiration date for these materials
was in 2023. Discontinue Use of Expired Monoethylamine and Sodium Carbonate
✔ MEA has a long history of commercial CO 2 optimization with various feeds including flue
gasses. Uninhibited MEA is generally limited by corrosion problems, then to improve this
problem by using MEA step wisely.
✔ Use higher pressure absorption processes at recovery of CO 2; for these processes, the driving
force for CO2 absorption and the cyclic loading between absorption and desorption will be
insufficient for economical CO2 recovery.

✔ some amount of carbon dioxide is released to the atmosphere, this must be optimized and
increased efficiency by studying and evaluating the parameters that affect the absorption
efficiency to improve the profit.

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CHAPTER FOUR

4 OVERALL BENEFIT GAINED FROM THE INTERNSHIP

Intern-ship program is a method of letting the students assume themselves as potentially
responsible workmen for a particular work by assigning them to actively participating in
production control as well as maintenance in industrial companies. This internship program is a
very essential program because the student develops their skill practically and shares different
ideas with their community. It also gives us the way to decide our future job and company. The
benefits that we gained are listed below.

4.1 In terms of improving theoretical knowledge

This intern-ship programme enhanced both our theoretical knowledge and practical skills. The tasks we
undertook were closely aligned with many of the courses we studied in the classroom, particularly in
areas such as mechanical unit operations, process dynamics and control, and mechanical design. Prior to
the intern-ship, we had focused on these subjects in our classes. During the intern-ship, we were able to
apply and expand upon this theoretical knowledge through the following benefits gained from the
company:

✔ Production and formation of soft drinks, CO2

✔ Kind of raw material to form soft drinks
✔ Designing machines used to process
✔ How to recycle and treat waste materials. The intern-ship takes a great role in terms of
upgrading our theoretical knowledge. It helps us to gain more theoretical knowledge related
to the real world.

4.2 In terms of improving practical skill

The various courses we took focused primarily on the theoretical aspects of engineering. While
some instructors attempted to bridge the gap between theory and practice by using visual aids in
their lectures or taking us on company visits, these efforts often fell short of providing a clear
understanding of real-world engineering. However, this internship program allowed us to
connect the theoretical knowledge we had gained in class with practical applications. Over the

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four-month duration of the intern-ship, we were responsible for tasks such as maintaining filler
machines and managing engage/disengage systems.

✔ Engaging and disengaging of the conveyor system.

✔ Adjusting and controlling un packer and packer machine
✔ Controlling steam production electrical work flow up board
✔ Controlling CO2 production electrical work flow up board
✔ Troubleshooting and maintenance of the production system
✔ Adjusting and controlling the filler and capping machine controlling board

4.3 In terms of improving industrial problem solving capability

Here some of the industrial should solve:
✔ Used to grades our levels of accuracy were showings of willingness & Interests to accept we
have positioned.
✔ Used to judge ourselves how we properly obeyed and followed the rules & regulations and
as well as the work ethics of the organization.
✔ The other is considering how we are correctly effective & efficient in relating those
problems observed in the industry to our knowledge.

4.4 In terms of improving team playing skill

When different individuals come together to work for common goals of the company for
increasing productivity, the most important point is just reaching an agreement on different
points on the work to be done at a time. A person with good team playing skill will upgrade to:
✔ Help and cooperate with others.
✔ Share ideas with colleagues openly and willingly.
✔ Give a comment to the team.
✔ Demonstrate reliability.
✔ Treat others in a respectful and supportive manner.
✔ Increase the ability of active participants.
✔ Become a problem solver on time.

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4.5 In terms of improving leadership skill
Our current roles offer limited opportunities for us to take on leadership responsibilities, which has
restricted our ability to fully develop our leadership skills during our time at the company. However, by
observing the company leader in action, we have gained valuable insights into providing relevant and
effective solutions to various challenges. We recognize that the decision-making process is a crucial
aspect of leadership. To enhance our leadership skills, we propose the following initiatives:
✔ To organize, prepare, and arrange all required materials.
✔ To become more reasons because in action.
✔ To gain a deeper understanding of myself and enhance my self-worth.
✔ To become accurate and more skillful in my judgment.
✔ To give technical support.
✔ To increase my work status.
In addition, this leadership skill needs:
✔ Taking care of your parts.
✔ Good communication skills.
✔ Team cooperating skill.
✔ Decision making skill.
✔ Having good work ethics Better accurate and instantaneous decision making.

4.6 In terms of understanding about work ethics

Related issues: Work ethics includes both how one feels about their job, career or vocation and
how one does his /her job or responsibilities. It demonstrates many things about who and how a
person is. It also involves such characteristics as honesty and accountability. Essentially, it
breaks down to what does or would do in a particular situation.
✔ In our period of internship, we understand work ethics, one of ethics is punctuality. To be
punctual is the duty of every worker that they could achieve their task with the time given.
Some of work ethics are listed as follows:
✔ Reliability
✔ Punctuality
✔ Office disciplines
✔ Honesty
✔ Co-operation

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4.7 In terms of entrepreneurship skill

Entrepreneurship skills are making certain individuals able to create a new set of ideas that may
help in the construction stream not only in the production process. But also any form of activity
that has a certain land product to it. During the entrepreneurship period, we were not able to
come-up with a whole new set of ideas that we implemented into action. There are different
types of entrepreneur skills including personal traits and management skills.

The basic entrepreneurial skills listed below

✔ Self-confidence and self-motivation Communication skills
✔ Personal relationships and sales
✔ Listening skills, morals and ethics
✔ Risk taking and time management.

4.8 In terms of improving interpersonal communication skill

Interpersonal communication is a field of study that explores the dynamics between participants
who rely on one another and share a common history. This form of communication can take
place in one-on-one conversations or involve interactions among multiple individuals within a
society. It helps us understand the reasons behind people's behaviors and communication styles,
allowing them to construct and negotiate their social realities. While interpersonal
communication can be examined as a distinct area of study, it also occurs within broader
contexts such as groups and organizations. In our company, diverse individuals come together,
each with unique educational backgrounds, economic situations, cultural influences, and life
experiences. Given our goal of achieving high-quality work, it is essential that we cultivate
strong communication skills.

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CHAPTER FIVE
5 OVER ALL CONCLUSION AND RECOMMENDATION
5.1 Conclusion

In conclusion, this internship at the MOHA Soft Drink Company taught us a lot about how the
company works, from starting out to making drinks. The Mekelle Pepsi Cola plant is focused on
making safe, legal, and high-quality beverages that meet what customers want. All employees
share the responsibility of ensuring product safety and quality, and they are committed to
following food safety standards and improving their work.

During our time at the plant, we participated in many hands-on activities that went beyond what
we learned in school. This experience helped us understand how to work in a professional setting
and taught us to take our responsibilities seriously. It also improved our education by giving us
practical skills and introducing us to the real world of work.

We realized there is a big difference between what we learn in class and what we do in practice.
This internship helped us connect the two, making us more knowledgeable and skilled. Before
the internship, we sometimes took lab activities lightly, but now we understand the importance of
doing them carefully. This experience has prepared us to approach all tasks at the company with
attention and dedication.

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5.2 Recommendation

Here are the revised recommendations for the company in the specified areas:

1. Wastewater Treatment Practices:

The company currently uses only preliminary physical methods for wastewater treatment, such
as screening and homogenization, discharging it without meeting necessary treatment standards.
This poses risks to surface water, groundwater, and soil. We recommend implementing a
comprehensive wastewater treatment system that complies with environmental regulations to
ensure safe disposal and minimize impact.
2. Raw Material Management:

The recent sugar shortage has led to halted operations and economic challenges. To address
this, we suggest establishing a proactive procurement strategy to ensure the timely availability of
essential raw materials.

3. Spare Parts Availability:

Insufficient spare parts can cause production delays. We recommend maintaining an inventory
management system to track spare parts and facilitate timely procurement, supporting
uninterrupted operations.

4. Computer-Based Management Systems:

To improve operational efficiency, we suggest implementing a computer-based management

control system. This will enhance oversight of workforce activities and streamline processes
across the company.

5. Integration of Theory and Practice:

There is a gap in connecting practical knowledge with theoretical concepts among operators.
We recommend developing training programs that emphasize this integration, helping employees
better understand production processes.

By addressing these areas, MOHA Soft Drink Company can improve operational efficiency,
ensure environmental compliance, and enhance employee knowledge and safety.

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References
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[3] Austria, G.Carbon dioxide Absorption in Aqueous ethanol amine solutions, chemical
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[4] Dr.N.K Patel.Module:2 Carbon Dioxide.
[5] http://www.buzwairgases.com
[6] Koonaphapdeelert, S., Wu, Z. and Li, K. 2009. Carbon dioxide stripping in ceramic hollow
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[8] Li, J. and Chen, B. 2005. Review of CO2 absorption using chemical solvents in hollow fiber
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[9] PepsiCo, (2005). Quality manual PepsiCo international Analytical methods Vol-2 700
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[11].Strelzoff, S. 1980. Choosing the optimum CO2-removal system. Separation Tech-nology 2:
Gas/Liquid/Solid Systems. New York: McGraw Hill Publication Company.

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Appendix
Table 5-1 Appendix A for table 3.2
P Pressure measured in atm
V Volumetric flow rate measured in L/min
N Molar flow rate measured in mol/min
R Universal gas constant measured in L.atm/mol.k
T=Tav Temperature measured in kelvin

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