DOB-DEPARTMENT OF MECHANICAL ENGINEERING

ODA BULTUM UNIVERSITY

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

HOSTING COMPANY: DASHEN BREWERY SHARE COMPANY

DURATION OF INTERNSHIP REPORT: MARCH 01/07/2015 To JUN
30/10/2015
PREPARED BY:
NAME ID NO
1. DEGSEW MESAFNT 0127/12

INTERNSHIP ADVISOR:MR.ADANE

SUBMISSION DATE:9 /2/2016 E.C

CHIRO, ETHIOPIA

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DECLARATION OF THE INTERNSHIP

I declare that this report is my original work and all sources and materials used for the purpose
have been properly acknowledged. And I would like to assure with my signature.

Name Signature Date

1. ____________ ____________ ______________

APPROVAL
The undersigned certify that the above candidates have fulfilled the condition of the project
Paper in full fulfilment for semester project in Mechanical Department.

1.Dept. Head Signature Date

--------------- ------------------- --------------------

2.Advisor/Supervisor Signature Date

---------------------- ----------------------- --------------------

3.Examiner Signature Date

---------------------- ---------------------- --------------------

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ACKNOWLEDGEMENT
First and foremost I would like to express my great gratitude to GOD for his blessing and
helping throughout my entire life.
Secondly, I would like to forward my special Thanks to supervisor Mr.Selomon B.
who provides me a practical knowledge about operation of all Mechanical machines in work area
and automated control system in the industry packaging room.And I would like to express the
deepest gratitude for my advisor Mr. Adane who advises me to do this internship report by
attending my progress friendly. Finally I am also great full for all who helped me directly and
indirectly.

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EXECUTIVE SUMMARY
This report contains the internship report that has performed in Dashen beer Share Company
from march 01/07/2015 to June 30/10/2015. It includes the background internship hosting
company, its main services and customers, as well as its overall objectives, organization and
work flow of each section, overall internship experience including work tasks, it enables me to
get practical knowledge, improve my practical skill, upgrading my theoretical knowledge,
improving team playing skills, improving leadership skills and understanding about work ethics
related issue also developed social and communication skills, how to communicate with
different class of employees (how to communicate with an engineer, operator and technicians
also developed our work with ethics like punctuality, working with others (teamwork). After all
this; topic have also included conclusions and recommendation for improvement of works in the
company. Generally, I gained a lot from the experience and intend to use it in the future.

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List of abbreviations
AC Alternative Current
AD ANAEROBIC DIGESTION
CCD CONTINUES CAMERA DETECTION
CHP COMBINED HEAT POWER
CPU CENTRAL PROCESSING UNIT
DBSC DASHEN BREWERY SHARE COMPANY
DC DIRECT CURRENT
DOL DIRECT ON LINE
EBI EMPTY BOTTLE INSPECTOR
EEP ETHIOPIA ELECTRIC POWER
EEPA ETHIOPIA ELECTRIC POWER AUTHORITY
EMS ENVIRONMENT MANAGEMENT SYSTEM

FBI FULL BOTTLE INSPECTOR

H HYDROGEN
HC HYDROCHLORIC ACID
I/O INPUT OUTPUT
ISO INTERNATIONAL SYSTEM ORGANIZATION
KV KILO VOLT
LED LIGHT EMITTED DIODE
MW MEGA WATT
NC NORMALLY CLOSED
NO NORMALLY OPEN
PLC PROGRAMMING LOGIC CONTROLLER
QMS QUALITY MANAGEMENT SYSTEM
RTD RESISTANCE TEMPERATURE DETECTOR
S.C SHARE COMPANY
TBM TIME BASED MAINTENANCE
VFA VOLATILE FATTY ACID

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Table of Contents
DECLARATION OF THE INTERNSHIP ............................................................................................................... I
APPROVAL ...................................................................................................................................................... I
ACKNOWLEDGEMENT ................................................................................................................................... II
EXECUTIVE SUMMARY ................................................................................................................................. III
List of abbreviations ..................................................................................................................................... IV
list of figures................................................................................................................................................ VII
list of tables ................................................................................................................................................. VII
CHAPTER ONE ............................................................................................................................................... 1
1. INTRODUCTION ..................................................................................................................................... 1
1.1 Brief History ...................................................................................................................................... 1
1.2 Vision, Mission and Objective of the Company Vision ................................................................. 2
1.3 General benefits of Biogas .................................................................................................................. 2
1.4 Dashen Main Products and Service of Brewery S.C ...................................................................... 3
1.5 End users (customers) of Dashen brewery .......................................................................................... 3
1.6 Over all Organizational Structure and Work Flow ............................................................................. 4
1.7 Work flow of the main sections .......................................................................................................... 5
CHAPTER TWO .............................................................................................................................................. 6
2. INTERNSHIP OVERALL EXPERIENCE ........................................................................................... 6
2.1 The Section of the Company I Have Been Working........................................................................... 6
2.1.2 Utility Section ............................................................................................................................ 15
2.2:Work Piece or Work Task ................................................................................................................ 19
2.3:Procedures and Methods, .................................................................................................................. 19
2.4:Challenges......................................................................................................................................... 19
2.5:Measures ........................................................................................................................................... 19
CHAPTER-THREE .......................................................................................................................................... 20
3.1:THE OVERALL BENEFIT GAINED FROM THE INTERNSHIP ................................................ 20
3.1.1:Personal ethics ........................................................................................................................... 22

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3.1.2:Professional ethics ..................................................................................................................... 22

CHAPTER FOUR ........................................................................................................................................... 23
CONCLUSIONS AND RECOMMENDATIONS .................................................................................. 23
4.1:Conclusions....................................................................................................................................... 23
4.2:Recommendations ............................................................................................................................. 23
CHAPTER FIVE ............................................................................................................................................. 25
PROJECT TTLE: BIOGAS PRODUCTION FROM WASTE MATERIAL ..................................... 25
ABSTRACT.................................................................................................................................................... 25
5.1 Background of the Project ................................................................................................................ 26
5.1.1:Introduction ................................................................................................................................ 26
5.2:Statement of the Problem .................................................................................................................. 26
5.3:Objective of the project..................................................................................................................... 26
5.3.1:General objectives ...................................................................................................................... 26
5.3.2:Specific objective ....................................................................................................................... 26
5.4: Literature review .............................................................................................................................. 27
5.5:Methodology ..................................................................................................................................... 29
5.5.1:Methodology flow chart ............................................................................................................. 29
5.6: Scope of the project ......................................................................................................................... 29
5.7:System Design Biogas Production and System Analysis ................................................................. 30
................................................................................................................................................................ 30
5.8: Processes of biogas production ........................................................................................................ 34
5.9:Conclusion and Recommendations ................................................................................................... 43
5.9.1:Conclusions ................................................................................................................................ 43
5.9.2:Recommendations ...................................................................................................................... 44
References .................................................................................................................................................. 45

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list of figures
FIGURE 1:LOCATION OF DASHEN BREWERY .....................................................................................................2
FIGURE 2:ORGANIZATION STRUCTURE OF DASHEN BREWERY SHARE COMPANY ................................4
FIGURE 3:BLOCK DIAGRAM OF PRODUCTION PROCESSES ............................................................................5
FIGURE 4:OVERALL FLOWS OF THE PRODUCT IN THE PACKAGING ROOM ..............................................6
FIGURE 5:DEPELLETIZER MACHINE .....................................................................................................................7
FIGURE 6:UN CASER MACHINE..............................................................................................................................7
FIGURE 7:CRATE WASHER MACHINE ..................................................................................................................8
FIGURE 8:BOTTLE WASHER MACHINE ................................................................................................................9
FIGURE 9:CLEANED BOTTLE INSPECTORS .......................................................................................................10
FIGURE 10:FILLER WITH CROWNER ...................................................................................................................11
FIGURE 11: PASTURALIZER ..................................................................................................................................12
FIGURE 12: LABELER ..............................................................................................................................................13
FIGURE 13:EMPTY BOTTLE INSPECTOR ............................................................................................................14
FIGURE 14:CASER ....................................................................................................................................................15
FIGURE 15:ELECTRICAL POWER DISTRIBUTION BLOCK DIAGRAM OF THE COMPANY .......................16
FIGURE 16:METHODOLOGY FLOW CHART .......................................................................................................29
FIGURE 17:SYSTEM DESIGN BIOGAS PRODUCTION .......................................................................................30
FIGURE 18:ANAEROBIC DIGESTION PROCESS .................................................................................................35
FIGURE 19:MAIN COMPONENTS AND GENERAL PROCESS FLOW OF BIOGAS PRODUCTION ..............40

list of tables
TABLE 1:DIFFERENCE BETWEEN MAIN PRODUCTS .........................................................................................3
TABLE 2:TEMPERATURE DURING BOTTLE WASHING .....................................................................................9
TABLE 3:THERMAL STAGE AND TYPICAL RETENTION TIMES ....................................................................37

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CHAPTER ONE

1. INTRODUCTION
GENERAL BACKGROUND OF DASHEN BREWERY S.C
1.1 Brief History
The origin of the name of Dashen brewery factory is taken from the famous mountain ras
dashen, which is located 100km from the brewery factory, Ethiopia’s highest mountain. Dashen
brewery factory is located in Gondar town. It is situated on the area of 85,000 square meters with
building area of 12,000sqm. DBS.C is established in September 2000 GC, with an initial capital
of over 340 million birr’s. (1) The brewery has 509 employees, of which 403 permanent and 106
contracts. It is owned by Amhara regional state rehabilitation development organization. Dashen
brewery utilizes state of the art technology and highly qualified experts that enables it to compete
on the export market with the leading international beer producing and marketing companies.
Dashen brewery S.C is the first brewery certified with ISO 14001, 2004 EMS (Environmental
management system) and ISO 9001, 2008 QMS (Quality management system). This enables the
company to focus on customer satisfaction measurement, formulate policy and objective by
taking in to account regulatory requirement and information on activities with significant
environmental impact. Before expansion Dashen brewery, it had annual production capacity of
300,000 Hecto liter, but after the expanding its production capability its annual production is
enhanced by three-fold, 769,000 Hecto liter. Dashen brewery S.C participates in different social
activities such as in building public schools and health centers, funding sport activities,
supporting art and environmental conservation and creating job opportunities.

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Figure 1:location of dashen brewery

1.2 Vision, Mission and Objective of the Company Vision

 To be the best brewer in Ethiopia in terms of quality products, customer service and the
employer of choice.
 The purpose of the company is in order to improve delighting consumers, enriching
communities and enhancing Ethiopian progress.
Mission
 It is an endowment (gift) fund established to contribute for the development of Amhara
region by producing and selling costumer proffered or contribute quality beer at
competitive price and generate responsibility.
 To be best Ethiopian beer lead drinks company with sustained revenue growth and
consistently improving returns on invested capital.
 Employees of the brewery have a fair commitment ownership feeling or especially the
technical team their commitment is increasing.
Generally employees in production quality maintenance department are highly committed energetic
with fair a composing
Objective of the company
 To support the socio-economical development of the Amhara Region in particular and
the overall development wellbeing of the country in general.
 Dashen brewery has customer focused orientation.
 Dashen brewery has prevalence of accountability.
 Dashen brewery has well trained and committed work force.
 It gives value for the eco-environment friendly manner.
 Economic use of resources.
1.3 General benefits of Biogas
 Renewable energy sources
 Reduced greenhouse gas emissions and mitigation of global warming

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 For cooking and heating.

 .As an illuminatant for domestic and street lighting.
 For running tube well and water pump.

1.4 Dashen Main Products and Service of Brewery S.C

 Dashen beer
 Draft beer and
 Cellar

Basic properties Bottled beer Bottled beer Draft Cellar

Pasteurization Temp 25℃-66for1 hour 73℃for30minute No pasteurization
Expiration date About one year About one month About 24 hours
Product container Bottle Short cylinder Short cylinder
Alcoholic content 4.8 % 4.8 % 5.5 %
Table 1:difference between main products

1.5 End users (customers) of Dashen brewery

The end users/customers are every person aged above 18 years old. There is no any limit or
boundary in order to be a customer for Dashen beer. The products are distributed across the
country in four regions and three warehouses. The regions are:
 Region 1: covers Amhara, Benishangul and afar region.
 Region 2: this covers the whole Tigray region.
 Region 3: covers central and western part of Ethiopia.
 Region 4: east and south parts of Ethiopia
There are three warehouses: thus are
 Gondar, Woldia and Addis Ababa.
Dashen brewery exports its products to the following foreign countries
 California and Chicago in America, Australia, Israel, Southern Sudan.

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1.6 Over all Organizational Structure and Work Flow

The new organizational structure of Dashen Brewery Company looks as shown below in block
Diagram.
Board director

General Manager

International audit service

Planning service

Legal service

H.R Technical
Financial department Supply
administratio departmen
department
n department t

DGM Maintenance
marketing

Sales and distribution Production

Quality
Customer’s service and promotion
department
division
Market research and development
division

Region 1 Region 2 Region 3 Region4

Figure 2:Organization structure of Dashen brewery Share Company

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1.7 Work flow of the main sections

Figure 3:Block diagram of production processes

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CHAPTER TWO

2. INTERNSHIP OVERALL EXPERIENCE

2.1 The Section of the Company I Have Been Working
I have been doing my internship program in Dashen brewery factory. The section I have been
working Dashen brewery factory comprises or includes three sections:
➢ Packaging
➢ Utility
➢ Maintenance
Packaging Section Machineries
The machines used in the bottling section to fill bottles by beer and to send it to the customers
are: de-palletizer, UN caser, Crate Washer, Bottle washer, Visual inspection screen, Empty bottle
inspector (EBI), Filler, Pasteurizer, Labeler, Full bottle inspector, Ink jet printer, Caser and
palletizer (2). The overall process in the production room is as shown below.

De-palletizer Crate washer

machine Uncaser machine
machine

Bottlewasher
machine
Emptybottle Glideliner
inspector (EBI) machine
machine Pasteurizer
machine
Filler machine Crowner machine

Full bottle inspection (FBI) Printer machine Labeler machine

Caser machine
Palletizer machine

Figure 4:Overall flows of the product in the packaging room

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DE palletizer: -Crates with empty bottles are collected from the customers and arranged on
pallets (60 crates on one pallet). The fork lifter (car) lifts the pallet and puts it on the roller
conveyor. Then the conveyor moves the pallet and crates towards the de palletizer robot, which
separates the crates from the pallet. The pallet moves to the palletizer and the crates moves to the
uncaser through the chain conveyors. The machine is shown in the figure 4 below.

Figure 5:depelletizer machine

Uncaser: - It is used to separate empty bottles from the crate. Empty bottles are lifted from the
crate by a gripper head and put it on the chain conveyor. The gripper head has packaging bells
which are operating pneumatically (use air). In this factory, uncaser robot has 6 (six) gripper
heads, each head has 24 packing bells which can hold up 24 empty bottles at the same time

Figure 6:Un caser machine

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Crate washer: - The bottle crates must be easily conveyed from the depalletizer, via the un
packer & packer, to the palletize. Because the crates can become dirty during transport and in
stores, after emptying they pass through a crate washer & turner & are stacked in a crate store
until used after filling. Here the type of conveyor used for bottle crate transport is roller conveyor
which is driven by roller chain or belt drive which can be brought into operation by pressure
rollers.

Figure 7:Crate washer machine

Bottle Washer: - This machine is used to wash the dirty bottles by using hot water, caustic one,
caustic two and fresh water. Afterwards the labels and all dirty things removed by vacuum
pumps. In bottle washer 11 electrical drives are available from those 7 motors work
synchronously by using electrical encoders that used for synchronization to move the bottle
holder chain with the same speed and frequency. The other two motors big 11.5 KW motors
used to adjust two caustic levels. The last two drives used in fed and discharge the 40 bottles
with a pulse. Dashen brewery performance of bottle washing machine conveyed up to 63 bottle
carriers, and which can be hold up 40 bottles in each row of bottle carrier at the same time (3).

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Pre-warming, presoak 35 to 40 0c
Second soak 55 to 60 0c
Caustic bath 75 to 85 0c
Intermediate rinsing 45 to 50 0c
Table 2:Temperature during bottle washing

Figure 8:Bottle washer machine

Empty Bottle Inspect (EBI): - It is used to inspect the empty bottles before it goes to filler and
cause unwanted production step. And Faulty bottles are rejected by a pusher installed at the in-
fed. The following parameters are to be checked.
 Optical (or Mechanical) gap detection-
 Optical detection of too high /short bottles
 Contour detection
 Foreign bottle detection
 Glass color detection.
 Base inspection
 Neck finish inspection

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Figure 9:cleaned bottle inspectors

Detection systems operate with very high-speed CCD cameras with integrated analogue – digital
converters very rapid picture capture taking about 1/25000 second. Inspections of bottles
comprise:
 External, interior side wall inspection, Bottom inspection, Bottle mouth inspection,
Residual liquid detection by high frequency radiation.
Beer filling: - In this machine there are 3 proximity sensors. The first one checks the presence of
bottles that is ready to pressurizing one. The second proximity sensor is located on before beer
filling that checks broken bottles and the 3rd one check to refuse the entry of broken bottles. In
addition to this there are also in feed monitor and encoder. The in-feed monitors are photo cells
that control the position of bottles at the in-feed part and the encoder is used to control the
movement of the bowl. This is a mechanical filling machine; in order to fill bottles (3).

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Figure 10:filler with crowner

Principle of bottle filling: Bottle filling machines are always built as rotating machines with up
to 120 filling bulbs. The bottles are delivered on a conveyor belt, separated to a predetermined
spacing by in feed worm, and positioned on a lifting platform under the filling elements by a star
wheel loading device
Pasteurizer machine: - Pasteurizer means of killing micro-organisms in an aqueous solution by
heating. The basic aim of pasteurization is for the shelf life of beer.

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Figure 11: pasturalizer

Labeler Machine: - It is an important machine which is found in bottling section that contains
label marker. Every bottle is provided with at two levels body and neck labels. The labelers are

used to differentiate the factory products among others. This machine works with different
sensors and encoders to control the overall functionality of labelling process. There are two
proximity sensors, two photocells, counter, encoder and different derive motors. The first
proximity sensor that is located at the in-feed part checks the gap and positions of bottles, the
second one check the presence of crown and the two photocells used to check body and neck
label of a bottle. The labeler has maximum labelling capacity of 48,000 bottles per hour.

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Figure 12: labeler

Video jet Printer: - It is a video jet printer type which helps to print production date on the bottles.
This machine has an interrupted power supply to operate the machine fast.
Full bottle inspection (FBI): -. It inspects the under fill, overfill, Neck label and Body label.
Full bottle inspector is located next to video jet which contains sensors, these sensors are used to
inspect: -
➢ Neck label, Body label, Missed label, proper closing of crown cork, under fill, over fill.
FBI is used to inspect the following parameters of the filled bottles after labeling.
 Identify crowned & UN crowned bottle
 Identifies under and over filled bottle
 Identifies whether the two label papers on the neck & base have the stamp (brand) of
the factory attached to the filled bottle or not
 Identifies production bottle or not

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Figure 13:Empty bottle inspector

Caser Machine: -This machine is used to load filled bottles on the crates. There are different
electrical devices that are integrated for the operations of this machine which are intended to
specific task. These are mechanical switch, sensors, photoelectric cell, encoders and proximity
switches. The proximity switch used to check whether the filled bottles are fully placed on the
conveyor or not and the other sensor makes sure that six crates are ready to accept the filled
bottles, if the crate is less than six the caser will stop. The other sensors check whether the filled
bottles are arranged exactly to fit with the holes of the machine. There is also another sensor
which used to check other unwanted materials are present in the washed cask. If there are
unwanted materials the machine will stop.

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Figure 14:Caser

Palletizer machine: - It is a robotic operation that picks up the full crates and arranges them on a
pallet that makes suitable for lifting. It is the reverse operation of de-palletizer.

2.1.2 Utility Section

We can say utility room is the back bone of Dashen beer production because it is the source of:
Steam from boiler plant, Process and service water from water treatment plant, Compressed air
and carbon dioxide from carbon dioxide recovery plant, Cooled glycol from ammonia cooling
plant. Those listed products have significant impact on production that is why we say utility
room is the back bone of Dashen beer production.

Electric Power Distribution in Dashen Brewery; the company power supply is 15 kV gained
directly from high transmission power lines of EEP substation. This high voltage is transmitted
to the two parallel connected three-phase transformers by copper cable. The two transformers
share the 15kV load, their working principle is based on the principle of parallel connection of
transformer. The transformers primary winding is star connection and the secondary winding is
delta connection. These transformers step down the supply 15 kV voltage in to the required
voltage which is 380V, each of the transformers have switch gear and also have Change over
switch which uses to isolate the transformer when maintenance is required. When there is power
fluctuation there is reserved diesel A.C generator which generates about 1.8MW and couples to

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the transformers by bus coupler. The AC emergency generator is standby and it’s on/off
controlled by timers as the diagram shown below. Bus-bar: When number of lines operating at
the same voltage levels needs to be connected electrically, bus-bars are used. Bus-bars are
conductors made of copper or aluminum, with very low impedance and high current carrying
capacity. Different types of bus-bar arrangements (7). Single bus-bar arrangement: It consists of
single bus-bar. Both incoming and outgoing lines are connected to the single bus-bar. The
advantages of this arrangement are low maintenance, low initial cost and simple operation.
Necessary conditions to operate transformers in parallel are:
 The line to line terminal voltage must be the same
 Phase sequence must be the same
 The transformers should have the same polarity, etc.
Some of the main advantages of operating transformers in parallel are:
 To handle large load
 Maintenance without power disruption
 To increase reliability
 To increase efficiency

Figure 15:Electrical power distribution block diagram of the company

Drive motors: There are many electrical motors that are used for different purpose. Motors
mostly used in the company that is, induction motors, synchronous motor and servo motors

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Synchronous motor: Those motors are doubly exited fed type and have direct current in their
field windings and ac armature windings. This motor is mainly used at washer machine for the
purpose of driving bottle chain holders.
Induction motor: It is a type of electric motor that converts electrical energy in to mechanical
energy in which alternating current from a power source is fed through a primary winding and
induces a current in a secondary winding, with the parts arranged so that the resulting magnetic
field causes a movable rotor to rotate with respect to a fixed stator. Induction motor also called
rotating transformer. It is mainly used for the purpose of driving the conveyor chain, filler, labeler
and EBI.
Servo motor: Servo motor is an electrical device which can push or rotate an object with great
precision. If you want to rotate and object at some distance then use servomotor.
This motors is supplied by both ac and dc sources. In dashen brewery It is mainly used at the
robotic machine (caser and UN caser, and DE pelletizer and pelletizer) to control the position of
grippers.

Motor Starting Methods: They are different way of motor starting in order to motor winding
from damage.
i. Star-delta starting methods: Star delta starting is motor stating mechanism that
minimize the large amount of starting current
Machine use star-delta starting dashen company in production section:
 Bottle washer, Crate washer, Filler and crown, Pasteurization and Labeler.
ii. Direct online starting: DOL starter applies the full line voltage to the motor terminal. It
sometime used to start small Water pump and conveyor belts. In case of asynchronies motor,
such as three phase squirrel cage Motor, the motor will draw a high starting current until it
has run up
to its full speed.
iii. Auto-transformer starting method: This method use when given power source not
enough to start the motor we connect another source in order to start the motor .This
starting rarely use in dashen company since they have enough power source in order to
start the motor.

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iv. Reverse-Forward starting method:

This method we connect two contactors in two side of the motor. The motor is run based
on which contactor is energized. This types of starting method is use in order to move
object horizontally, vertically, up and down
Machine use this types of starting Dashen Company in production section:
a) Caser and uncaser
depelletizer and pelletizer

Maintenance section
The maintenance section of the company has the following objectives: -
 To minimize the loss of production time and profit because of malfunction of the
machines.
 To avoid catastrophic damage of properties and loss of human life.
 To preserve the companies‟ investment by providing a good care of machine to prolong
the safety and life of machine and workman.
 To reduce the down time of the production. The following types of maintenance
activities are carried out by this section:
 Preventive Maintenance: It is a daily maintenance (cleaning, inspection, oiling and
retightening)
 Periodic Maintenance (Time based maintenance - TBM): Time based maintenance
consists of periodically inspecting, servicing and cleaning equipment and replacing parts
to prevent sudden failure and process problems.
 Predictive Maintenance: This is a method in which the service life of important part is
predicted based on inspection or diagnosis, in order to use the parts to the limit of their
service life.
 Corrective maintenance: It is carried out when the Equipment’s fails below the acceptable
condition while in operation.

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2.2:Work Piece or Work Task

I Have Been Executing I perform several tasks in the company, both in packaging and utility
room. Labeler machine, filler machine, bottle washer machine, And I have done different work
tasks by my self,and together with company employee and with students from different
universities.
 Replaced and adjust damaged brush
 Replaced stack and damaged centering bell
 Roller replaced all bottle guide wear strip
 Replaced labeler feed screw and adjusted

2.3:Procedures and Methods,

I Have Been Using While Performing My Tasks
The company has its own routine to perform the maintenance activity. However, in order to
improve my problem-solving skills, I used the following procedures while performing tasks.
 Reading maintenance history of the machine
 Reading the Manual
 Discussing with colleagues
 Reading the blueprint of the machine
 Assisting the Disassembly of the machine
 Inspecting the machine component
 Cleaning the machine component

2.4:Challenges
I have been facing while performing My work tasks
During my task work there were different challenges. Some of these are:
 The company government system and excess number of students in the group
 Less willingness of worker to show something what we want to ask and over work of
the manager in each department

2.5:Measures
I have been taken in order to overcome the challenges

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I took so many measures in order to overcome the challenges which we face during performing
our daily task:
 Asking students that are well informed about the machine during their intern time.
 Asking and working together with the worker,
 Reading different book and sated data to know the operation of the machine.
 Communicating with students that is from different university which have different idea
 In order to overcome the challenge, we follow the following measures and finally we
develop trust and a good relationship with workers and management staffs.
 By working hardly beyond the specified working time

CHAPTER-THREE
3.1:THE OVERALL BENEFIT GAINED FROM THE INTERNSHIP
Internship is one method of making opportunity for undergraduate students potentially valuable
and explores general career avenues as well as specific companies. Such arrangement can provide
me with valuable work experience and an opportunity to line up job before graduation, in addition
to securing good work experience. Internship programs are also potentially valuable to company.
Unfortunately, some companies continue to regard interns as a little more than free source of
labor to catch up on filling and other tedious office work.
Upgrading Theoretical Knowledge
Because I was in the company which is technologically developed, I improved the theoretical
knowledge. The practical skill makes us ready to realize, understand and grasp theoretical
knowledge. This is due to visible and practically done activities are unforgettable in nature.
In terms of improving My practical Skills
In the company gain, practical experience of applying my engineering judgment and working
successfully with others .Generally, I can offer the following practical skills from my internship
season;
a. Creativity and an innovative approach to solving problems
b. The ability to analyze and interpret complex data

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c. Critical thinking and the ability to evaluate design, plans and projects
d. Effective assessment and management risk, resources and time
e. Interpersonal sensitivity, persuasiveness and the ability to work as a part of team
f. Clear written and oral communication skills
g. Awareness of ethical issues and the wider impact of our work
Improving Industrial Problem-solving Capability
I get the benefit in industrial problem-solving capability in the company. To solve the industrial
problem, I must understand theoretical principle and follow the instruction manual. If I can’t
understand instructional manual in order to solve industrial problem, it is better to ask
professional person.
In terms of improving our team playing skills
Teamwork is also a very important interpersonal skill to have in workplace. All the company
workers collaborate with each other and share ideas with them to come to a common goal. This
skill was developed easily and rapidly. It begins when we were in campus. Some assignments
given were done in groups. This helps us to handle different characters of the persons we worked
with. The reason behind this is our work tasks did not allow communicating with colleagues only,
but also co-operated us with the persons we worked with. Even each work task was done and
completed as a team. In the work that we have been engaged, we have to communicate and work
with the Engineers, mechanics and the operator moreover we communicate with all the office
organizational structure directly or indirectly. We understand that for the proper functioning of a
team, each member should have fast decision-making skill, self-confidence and good
communication skill. We also deeply understand that listening, cooperating with people in my
workplace, communicating our thoughts and feelings and it also means we can come to solutions
on problems and also increase productivity of the company.
In terms of improving My leadership skills
Leadership is a process of leading the careers of the company What I gain from internship
regarding improving leadership is that to inspire workers into higher levels of teamwork. There
is a certain thing must be known to do that. These are;
 Know our-selves and seek self-improvement

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 Be technically proficient
 Make sound and timely decision
 Know peoples and look out for their well-being
 Develop a sense of responsibility in workers
 Ensure the tasks were understand, supervise and accomplished
Finally, what we grasp is becoming a leadership is not an easy task because it takes a conscious
commitment and consistent effort to develop one's leadership skill. But on the positive side,
anyone who is willing to make the effort can become a good leader.

In terms of understanding about work ethics related issues

In today's complex world, ethical conduct of workers is very important for developing healthy
working environment and increasing productivity. There are two common types of ethics. These
are;

3.1.1:Personal ethics
These principles of personal ethics are values that are expected to be possessed by all individuals
in their life, such as Concern for the well-being of others, Honest, Fairness, and Compliant to the
law, refusing to take un-fair advantages and Punctuality.

3.1.2:Professional ethics
Professional ethics refer to the standards or a set of moral principles for regulating behaviors of
a certain defined profession. These are Punctuality, Office disciplines, Reliability, Honesty,
Cooperation, Transparency and openness, Accountability, Integrity.
In terms of Entrepreneurship skills
Successful completion of this internship provides me with the opportunity to establish my own
business or gain employment in a supervisory or management role. Participating in an internship
allows me to gain a better perspective of postgraduate employment by applying the principles
and theories I have developed in classroom and internship program. This practical application
creates an easier transition for me from the classroom to the working world. While participating
in this internship I realize that creativity and problem solving is one of the starting points of
entrepreneurs.

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CHAPTER FOUR

CONCLUSIONS AND RECOMMENDATIONS

4.1:Conclusions
The internship semester makes the new curriculum so good to give real practical skills and make
the students familiar to the outside world. Even though there was a gap between the things which
I know in the class with the outside environment, I got practical work experiences and benefits
at Dashen Brewery S.C. Some of the benefits the internship offered to us include;
 Allow me to both make and develop professional contacts, for my future job search.
 Assist me in developing greater understanding of my own strength and weakness,
 The Company’s organization and work flow
 Upgrade my theoretical knowledge into practical skill
 Knowing and understanding of the working environment
 Work ethics and contact way with the company workers and other people
 Leadership skill h) Knowing the local construction terms
 Knowing Working standards
 Team playing skills
During the internship, I also develop and enhance employability skills. Because this time, I feel
like I am part of the organization and feel more to increase my productivity hence, gain a greater
sense of responsibility and personal direction. It assists me in moving toward my career goals by
combining what I had learned from school, practical and supervised work experience; it thus
explained the necessity of every student to undergo this process.

4.2:Recommendations
During my four months of internship experience period, I have seen some positive and negative
sides about the internship hosting company. The internship program holds benefits to the field
supervisor and hosting company by providing motivated workers at no or relatively small cost to
an organization and furnishing the opportunity to train possible future employees for the
organization. Participating in internship program allows the field supervisor and organization to
maintain a working relationship with the university in which I am enrolled. In several cases,

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special projects can be accomplished more inexpensively by using student expertise. Therefore,
we suggest that, the company should: - host more intern students in the future for the common
good of the student and its company. The other thing that I recommended the company is that to
change its poor advertisement in media about their works. Although the company has its own
website, it is not sufficient to advertise all the works of the company. So, I think the company
should give more attention to organize commercials and prepare posters that will attract owners
towards the company. The company should full fill the safety material for the students or it should
inform the university to do so. The loss of steam at the wort kettle should be recycled to the next
process. The company should have established a project design, development and expansion
board that able to modify activities and create new ideas and strategies to improve customer
satisfaction based on current needs. In addition, if this board is established, the interns will work
with them and because they have fresh mind and high motivation, they will contribute a lot to be
not only the company competent with brewing factories in Ethiopia but also in the world.

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CHAPTER FIVE

PROJECT TTLE: BIOGAS PRODUCTION FROM WASTE MATERIAL

ABSTRACT

This project is done to produce a renewable energy from the waste material in Dashen brewery
to reduce the problems justified below. It consists of brief description about biogas and how to
produce the gas from waste material. In the literature review of this project, I described the whole
processes of biogas production and the necessary parts such as inlet pit, outlet pit, pipe line
connections and the fixed dome digester. It also compares the biogas with natural gas and
describes the main differences (8) .In the methodology part I described the different data
collecting techniques such as observation, questioner and interviews. This amount of energy can
be used for different applications such as boilers, automobiles and generators.

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5.1 Background of the Project

5.1.1:Introduction
This project supports the initiative of making our company sustainable and environmentally
friendly. It consists on creating a Biogas system for Dashen Beer Company that would be both
eco-friendly and environmentally-friendly. To do so, I had to use Biotechnological, Engineering
and Management concepts that I studied in my months passed at Dashen Beer Company. Indeed,
creating a biogas system for Dashen Beer Company could significantly decrease the electricity
bills and will help manage the wastes. Also, the results of this project could be used in our
colleague’s work that is about Composting and Cogeneration. I described the whole processes of
biogas production and the necessary parts such as inlet pit, outlet pit, pipe line connections and
the fixed dome digester. It also compares the biogas with natural gas and describes the main
differences.

5.2:Statement of the Problem

In Dashen Brewery Company, there are a lot of motors and machines that needs much amount
of electrical energy and power. This energy consumption leads the company to spend much
amount of money or bill. In addition to this, the boiling furnace need fuel for combustion to
generate heat, this fuel is cost and economically affects the company. Dashen Brewery has no
alternative energy production and only use energy from the main supply (EELPA) and generators
but the factory must develop alternative energy for its demand.

5.3:Objective of the project

5.3.1:General objectives
The objective of this project is biogas production from waste material in Dashen brewery.

5.3.2:Specific objective
 To produce methane gas
 To replace the fuel consumption with methane gas
 To reduce the amount of money that will paid for electricity
 To design bio gas production and system analysis
 To design and analysis methane gas production
 To study detailed process of biogas roductio from waste material at dashen brewery

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5.4: Literature review

(Wikipedia, 2005 and Maekawa, 1999) Biogas typically refers to methane rich gas produced
from fermentation of organic matter under anaerobic environment). Methane (CH4) from
biomass is more famous for its greenhouse effect as it naturally arises from forest fires, swa-
psand other wetlands as well as landfills, rice paddies and ruminant animal's guts. Biogas has
not become adominant energy source yet, however its production is an effective way for waste
management treatment that is gradually evolving into an environmentally sound and
economically sustainable solution especially in rural areas) (9).

(Rahmouni et al., 2002; Heteu and Martin, 2003) After digestion, biogas goes to the gas
handling system while the effluent is stored for future use as high quality soil amendment. The
biogas handling system starts with purification, because anaerobic digestion generates methane
(40 to 70%), carbon dioxide (CO2, 30 to 50%), water vapor, hydrogen sulfide (H2S) and traces
of ammonia. Water vapor must be removed for two reasons: first to prevent freezing and water
accumulation in the installation especially during cold weather, and second to prevent corrosion
of high pressure storage containers. Frost proof condensation traps are present in almost all
biogas treatment plants because of their simplicity and cheap Prices; they are sometimes
coupled with other means to remove water. H2S must be removed because of its own toxicity
(10).

(Shannon, 1997 and Andrews and Quick, 1984) Currently, biogas can be used as a heating fuel
(household and industrial applications) as well as in electrical power generation and co-
generation of electricity and hot water. Most of these applications require large central gas
storage facilities and/or stationary generators. Large scale production schemes cangain higher
economical profits if biogas was used as avehicle fuel In betterwords, farm set biogas production
plant would be more economically sound when biogas is also used as vehicle engine fuel source
and in particular tractors (11).
(Prakash et al., 1999) who tried to find a "simple approach for estimating the limiting
equivalence ratio for the apparent bulk flame spread limit for a methane fuelled dual-fuel engine".

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His argument was that knock occurs at higher ranges often outside the common operation of the
engine or with high turbo charging, so people should tackle the low load conditions first. In
another simulation, presence of methane in combustion chamber was found able to not only slow
the flame propagation, but also delay the inception of ignition further complicating lower loading
conditions.
CristinaRodriguez, A.Alaswad, K.Y.Benyounis, A.G.Olabi in 2003, was work on production
of biogas from grass. The feed stock quality in influence by grass composition of the harvesting
time, the chopping size is important factor. In anaerobic digestion the grass shall be suitable in
order to micro-organisms and converted a large surface area before feeding the digester and thus
increase the degradation process. The grass maturity increases the percentage of cell wall
component (lignin and cellulose etc) and also increases the percentage of cell contents (sugar
proteins etc). Pretreatment method of grass is increase degradation process and accelerated the
biogas production. Many pre-treatment methods are following to pre-treating the grass like
physical, mechanical, ultrasound, microwave, thermal, chemical, biological etc. In this pre-
treatment process is to increase the surface area of the grass. Production of biogas is depending
on the grass specie and its components. Anaerobic digestion process is different for grass specie
and its type. To increase the production of methane, crop and grass substrates content low lignin.
These components are high degradable and cell components (12).
Biogas is a gas fuel mixture produced by the natural fermentation of the biomass in the absence
of oxygen. It is an odorless and colorless gas that burns with a blue flame similar to that of liquid
petroleum gas. Using the resulting biogas as a fuel in the brewery boilers or in a combined heat
and power (CHP) plant can generate a positive energy balance. Whether it is better to burn the
biogas directly in the boiler or to set up a separate CHP plant has to be evaluated economically
for each project, and will depend on local conditions, scale of operation and so on. Oil or gas fuel
can partly be replaced by biogas, resulting in operational cost saving and the resulting reduction
in fossil fuel use makes the brewery more sustainable. CHP plants produce both electrical and
thermal energy, which attract subsidies that make it economically feasible in spite of the initial
investment cost (13).

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5.5:Methodology
To collect all the necessary information and data about the waste in Dashen, I used the following
methods:
Observation:
 In Dashen brewery, I have seen that much amount of waste is released. But nothing is done
to recycle and use the waste.
 The waste in the tank has a bad smell due to the malfunction of the waste storage due to
careless treatment.
Questioner:
 I asked and made an interview to the waste treatment plant operator
 I also asked the manager about the waste treatment plant

5.5.1:Methodology flow chart

Problem Literature State the

Observations
identification review problem

System design
Conclusion and System
recommendation analysis

Figure 16:Methodology flow chart

5.6: Scope of the project
This project contains introduction, background, objectives, literature review, methodology,
design, discussions, analysis and also the conclusion and the future recommendations.

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5.7:System Design Biogas Production and System Analysis

Storage tank Mixer

Waste
material malt
Hydrolysis
wastage

Liquids Bio stabilization Bio gasification

Separator
Effluent

Biogas
Bio gas out storage

Figure 17:System Design biogas production

Size of the digester (Volume) In order to calculate the volume of the digester,I need two
parameters which are the daily feedstock (in liter) and the retention time (RT). As mentioned
previously, the organic matter used is coming from malt waste.
𝑙
𝑉𝐷 = 𝑠𝑑( ) ∗ 𝑅𝑇(𝑑𝑎𝑦)
𝑑𝑎𝑦
Where:

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𝑉𝐷= Volume of the digester in liter

𝑆𝑑 = daily feedstock in liter per day
𝑅𝑇 =Retention time in days
The daily feedstock corresponds to the quantity of organic matter produced per day and is equal
to:
Sd = biomass + water
The biomass corresponding to the total solid waste and the water have a 1:1 ratio, therefore:

Sd = Malt waste + beer waste + water

kg kg
Sd = (5700 + 12 ( )) ∗ 1
day day
l
= (5712 )
day
l
= 5712 ( )
day
The retention time (RT) refers to the time that the organic matter passes inside the digester.
It can vary depending on the climate of the region studied and, on the digester, used. The digester
that I will be using in my study is a fixed dome digester and has a retention time of 1 month on
average.
Then the final digester volume is equal to:
𝑙
𝑉𝑑 = 5712( ) ∗ 30𝑑𝑎𝑦
𝑑𝑎𝑦
= 171360 litter
= 171.36 m3
≈ 171m3

The volume of the digester that I want to build is 171 𝑚3.

Dimensions: According to the calculations above, the size corresponding to the quantity of
biomass produced in Dashen Company is 171𝑚3. To facilitate the construction, I will be using
the same dimensions as a 171𝑚3 fixed dome digester.

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i. Calculation of energy production per year: It can be calculated by using the calorific value
(CV) of methane. « The amount of energy produced by the complete combustion of a
material or fuel is measured in units of energy per amount of material » ("calorific value -
Wiktionary", 2017).The caloric value of methane is 9.94 kWh/m3 and in this caloric value
of methane, the volume of methane is given as 10743.191m3.
Etot = CVCH4 ∗ VCH4
9.94kWh
= ∗ 10743.191 m3
m3
= 106787.32 kWh

ii. Calculation of the energy saved in one year: I will consider 5% of energy loss to make sure
that the engine is overfed rather than underfed.
Esaved = 0.95 ∗ Etot
= 0.95 ∗ 106787.32 kWh
= 101447.954 kWh
iii. Calculation of the energy supplied by the biogas in one hour
Esaved
Et(1h) =
24 ∗ 365
= 101447.954 ∗ 365 ∗ 24
= 11.58 ≈ 12kW
iv. Calculation of the energy supplied by the biogas in one month
Et(1month) = 12 kW ∗ 24 ∗ 30
= 8640 kW
Fixed dome Plant: Fixed dome digesters are the most ancient, therefore the most known and the
most used type of digester plants in the world. The popularity of the fixed dome digester is due
to the fact that the raw materials used for the construction are very easy to find. The fixed dome
digester is constructed underground and its surface over the ground level resembles a dome. It is
composed of a mixing tank constructed above the ground level, inlet and outlet chambers and an
overflow tank. Inside of the dome, there is a fixed gas holder which holds the produced biogas
wanted (14).

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How does it work?

 The organic matter is mixed with water into the mixing tank to create slurry and then
introduced through the fixed dome digester through the inlet chamber. The digester is
not completely filled, but only partially filled with slurry.
 The slurry will stay into the digester for two months to help the decomposition of OM
by the anaerobic bacteria. The anaerobic decomposition also called fermentation lead
to the formation of biogas which starts to accumulate inside the dome. The more biogas
aggregate inside the dome, the more used slurry is pushed inside the outlet chamber and
then into the overflow tank.
 The matter collected in the overflow tank is called digestive and can be used for
plantations. When biogas is needed, the gas valve placed at the top of the dome opens.

Advantages
The advantages of the fixed dome digester are that it is a cheap technology that involves low
budget for the initial investment and the construction. It also has a long lifespan that can go over
20 years. Its main strength is the easy construction and the availability of the material used. It
also has the advantage of creating jobs for it needs skilled workers (14).
Drawbacks
The disadvantages that can be disconcerting for the production of biogas are as followed: The
construction needs skilled bricklayers and high skilled technicians to make sure that the
construction is well insulated and that the gas does not leak. The structure should be very well
insulated to avoid gas escaping from the plant. Moreover, the fact that the construction is
underground can limit the access to the digester in case of damage and finally, the gas can be
confronted to pressure fluctuations.
Conversion to electricity
Once the biogas has been produced and collected, it can be used as efficiently as possible. Biogas
can be used for three main purposes: thermal energy, electricity and Biodiesel. In my case, I
would like to use it for electricity and heat. Regardless of the use of the biogas, it is virtually
impossible to use it as it is produced. The only valuable gas is the methane while the other
components are useless, or harmful. One or more purification steps are therefore necessary to be

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able to use biogas as electricity or heating resource. The purification consists of removing
unwanted substances and pollutants (ammonia, sulfur elements, minerals, etc.) and increasing its
methane content (by removing CO2 and other gaseous compounds) to produce a gas comparable
to natural gas. The bio methane thus obtained constitutes cleaned and enriched biogas with a
calorific value equivalent to natural gas. There are many ways to convert biogas into electricity.
The most used heat engines for biogas conversion into electricity are gas turbines and combustion
engines. However, combustion engines are more interesting than gas engines because they are
less expensive and more efficient. In order to transform my biogas into usable electricity and
heat, I can use a biogas burner that has the ability to minimize the quantity of dangerous
substances such as hydrogen sulfide and CO2 in biogas and use the biome thane essentially for
electricity and heating.

5.8: Processes of biogas production

AD is a microbiological process of decomposition of organic matter in absence of oxygen. The
main products of this process are biogas and digestate. Biogas is a combustible gas, consisting
primarily of methane and carbon dioxide. Digestate is the decomposed substrate, resulted from
the production of biogas. During AD, very little heat is generated in contrast to aerobic
decomposition (in presence of oxygen), like it is the case of composting. The energy, which is
chemically bounded in the substrate, remains mainly in the produced biogas, in form of methane.
The process of biogas formation is a result of linked process steps, in which the initial material
is continuously broken down into smaller units. Specific groups of micro-organisms are involved
in each individual step. These organisms successively decompose the products of the previous
steps. Highlights the four main process steps: hydrolysis, acidogenesis, acetogenesis, and
methanogenesis (15).

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Carbohydrates
Sugars
Carbons acids
Alcohols
Acid acetic Methane
Fats Fatty-acid carbon carbon
dioxide dioxide
Hydrogen
carbon dioxide hydrogen
Protein Amino-acid ammonia

Hydrolysis acidogenesis acetogenesis methanogenesis

Figure 18:Anaerobic Digestion process

The formation of the biogas is essentially due to the activity of several microbes. The chemical
process of the biogas formation required 4 steps involved consecutively:

Hydrolysis: It is theoretically the first step of AD, during which the complex organic matter
(polymers) is decomposed into smaller units (mono- and oligomers). During hydrolysis,
polymers like carbohydrates, lipids, nucleic acids and proteins are converted into glucose,
glycerol, purines and pyridines (16).
Hydrolysis: microorganisms secreting enzymes that breaks down the organic matter, such as
carbohydrates, lipids, glucose and pyridines. Hydrolytic microorganisms excrete hydrolytic
enzymes, converting biopolymers into simpler and soluble compounds as it is shown below

Fatty acid, glycerol

Lipids Lipase

Polysaccharide Monosacharide
Cellulose, Cello bias, Amylase

Protein Amino acids

Protease

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A variety of microorganisms is involved in hydrolysis, which is carried out by exoenzymes,

produced by those microorganisms which decompose the undissolved particulate material.
The products resulted from hydrolysis are further decomposed by the microorganisms involved
and used for their own metabolic processes.
Acidogenesis: During acidogenesis, the products of hydrolysis are converted by acidogenic
(fermentative) bacteria into methanogenic substrates. Simple sugars, amino acids and fatty acids
are degraded into acetate, carbon dioxide and hydrogen (70%) as well as into volatile fatty acids
(VFA) and alcohols (30%).
Acetogenesis: Products from acidogenesis, which cannot be directly converted to methane by
methanogenic bacteria, are converted into methanogenic substrates during acetogenesis. VFA
and alcohols are oxidized into methanogenic substrates like acetate, hydrogen and carbon
dioxide. VFA, with carbon chains longer than two units and alcohols, with carbon chains longer
than one unit, are oxidized into acetate and hydrogen. The production of hydrogen increases the
hydrogen partial pressure. This can be regarded as a „waste product “of acetogenesis and inhibits
the metabolism of the acetogenic bacteria. During methanogenesis, hydrogen is converted into
methane. Acetogenesis and methanogenesis usually run parallel, as symbiosis of two groups of
organisms.

Methanogenesis: The production of methane and carbon dioxide from intermediate products is
carried out methanogenic bacteria. 70% of the formed methane originates from acetate, while the
remaining 30% is produced from conversion of hydrogen (H) and carbon dioxide (CO2),
according to the following equations.

Acetic acid Methane+ carbon dioxide

Methanogenic bacteria

Hydrogen +carbon dioxide

Methane +water
Methanogenic bacteria

Methanogenesis is a critical step in the entire anaerobic digestion process, as it is the slowest
biochemical reaction of the process. Methanogenesis is severely influenced by operation

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conditions. Composition of feedstock, feeding rate, temperature, and pH are examples of factors
influencing the methanogenesis process. Digester overloading, temperature changes or large
entry of oxygen can result in termination of methane production.

Anaerobic Digester Parameters: The efficiency of AD is influenced by some critical parameters;

thus, it is crucial that appropriate conditions for anaerobic microorganisms are provided. The
growth and activity of anaerobic microorganisms is significantly influenced by conditions such
as exclusion of oxygen, constant temperature, pH-value, Nutrient supply, stirring intensity as
well as presence and number of inhibitors (e.g. ammonia). The methane bacteria are fastidious
anaerobes, so that the presence of oxygen into the digestion process must be strictly avoided (17).
Temperature: The AD process can take place at different temperatures, divided into three
temperature ranges: psychrophilic (below 25oC), mesophilic (25oC – 45oC), and thermophilic
(45oC – 70oC). There is a direct relation between the process temperatures.
Thermal stage Process temperature Minimum retention time

Psychrophilic <25’0c 70 to 80

Mesophilic 25 to 45’0c 30 to 40

Thermophilic 45 to 75’0c 15 to 20
Table 3:Thermal stage and typical retention times
Many modern biogas plants operate at thermophilic process temperatures as the thermophilic
process provides many advantages, compared to mesophilic and psychrophilic processes:
 Effective destruction of pathogens
 Higher grow rate of methanogen bacteria at higher temperature
 Reduced retention time, making the process faster and more efficient
 Improved digestibility and availability of substrates
 Better degradation of solid substrates and better substrate utilization
 Better possibility for separating liquid and solid fractions
The thermophilic process has also some disadvantages:
 larger degree of imbalance
 Larger energy demand due to high temperature

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 Higher risk of ammonia inhibition

Volatile Fatty Acids (VFA): The stability of the AD process is reflected by the concentration of
intermediate products like the VFA. The VFA are intermediate compounds (acetate, propionate,
butyrate, lactate), produced during acidogenesis, with a carbon chain of up to six atoms. In most
cases, AD process instability will lead to accumulation of VFA inside the digester, which can
lead furthermore to a drop of pH value. However, the accumulation of VFA will not always be
expressed by a drop of pH value, due to the buffer capacity of the digester, through the biomass
types contained in it. Animal manure e.g. has a surplus of alkalinity, which means that the VFA
accumulation should exceed a certain level, before this can be detected due to significant decrease
of pH value. At such point, the VFA concentration in the digester would be so high, that the AD
process will be already severely inhibited. Practical experience shows that two different digesters
can behave totally different in respect to the same VFA concentration, so that one and the same
concentration of VFA can be optimal for one digester, but inhibitory for the other one. One of
the possible explanations can be the fact that the composition of microorganism populations
varies from digester to digester. For this reason, and like in the case of pH, the VFA concentration
cannot be recommended as a stand-alone process monitoring parameter.
Ammonia: Ammonia (NH3) is an important compound, with a significant function for the AD
process. NH3 is an important nutrient, serving as a precursor to foodstuffs and fertilizers and is
normally encountered as a gas, with the characteristic pungent smell. Proteins are the main source
of ammonia for the AD process. Too high ammonia concentration inside the digester, especially
free ammonia (the unionized form of ammonia), is considered to be responsible for process
inhibition. This is common to AD of animal slurries, due to their high ammonia concentration,
originating from urine. For its inhibitory effect, ammonia concentration should be kept below 80
mg/l. Methanogenic bacteria are especially sensitive to ammonia inhibition. The concentration
of free ammonia is direct proportional to temperature, so there is an increased risk of ammonia
inhibition of AD processes operated at thermophilic temperatures, compared to mesophilic ones.
Macro- and Micronutrients (Trace Elements) And Toxic Compounds: Microelements (trace
elements) like iron, nickel, cobalt, selenium, molybdenum or tungsten are equally important for
the growth and survival of the AD microorganisms as the macronutrients carbon, nitrogen,
phosphor, and Sulphur. The optimal ratio of the macronutrients carbon, nitrogen, phosphor, and

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Sulphur is considered. Insufficient provision of nutrients and trace elements, as well as too high
digestibility of the substrate can cause inhibition and disturbances in the AD process. Another
factor, influencing the activity of anaerobic microorganisms, is the presence of toxic compounds.
They can be brought into the AD system together with the feedstock or are generated during the
process. The application of threshold values for toxic compounds is difficult, on one hand
because these kinds of materials are often bound by chemical processes and on the other hand
because of the capacity of anaerobic microorganisms to adapt, within some limits, to
environmental conditions, herewith to the presence of toxic compounds.
Comparison between the biogas and the natural gas: The biogas produced by the natural
fermentation of the organic waste using a biogas system could be considered as the best
alternative to the heavily dependency on the classical use of biomass (combustion). The biogas
has approximately similar characteristics as the natural gas used to satisfy the daily needs if the
local society in terms of cooking and heating. (18)
Biogas plant components: A biogas plant is a complex installation, consisting of a variety of
elements. The layout of such a plant depends to a large extent on the types and amounts of
feedstock supplied. As there are many different feedstock types suitable for digestion in biogas
plants, there are, correspondingly, various techniques for treating these feedstock types and
different digester constructions and systems of operation. Furthermore, depending on the type,
size and operational conditions of each biogas plant, various technologies for conditioning,
storage and utilization of biogas are possible to implement. As for storage and utilization of
digestate, this is primarily oriented towards its utilization as fertilizer and the necessary
environmental protection measures related to it (19)

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Figure 19:Main components and general process flow of biogas production

Safety of biogas plants: Construction and operation of a biogas plant is related to a number of
important safety issues, potential risks and hazards for humans, animals and the environment.
Taking proper precautions and safety measures have the aim of avoiding any risks and hazardous
situations, and contribute to ensuring a safe operation of the plant. Fulfilment of important safety
issues and stipulating clear preventive and damage control measures is a condition for obtaining
the building permits.
 Explosion prevention
 Fire prevention
 Mechanical dangers
 Sound statically construction
 Electrical safety
 Lightning protection
 Thermal safety
 Noise emissions protection
 Asphyxiation, poisoning prevention
 Hygienic and veterinary safety

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 Avoidance of air polluting emissions

 Prevention of ground and surface water leakages
 Avoidance of pollutants release during waste disposal
 Flooding safety
Description of biogas plant: Biogas is mostly methane gas, and when methane burns it produce
a clean heat Source without harmful by products. The best way to understand what biogas plant
is, is to know what happens in a biogas plant, which we will explain. Organic material arrives at
the biogas plant: Those are also anaerobic digestion facilities. The organic materials are the
‘input’ or feed for the biogas plant (20).
 Digester: Digester is the most important part in the biogas system. This digester is a physical
structure where chemical and microbial reactions take place and it has several names such as
anaerobic reactor. Its main function is to provide and ensure all the conditions required for
the production of the biogas using the biomass in terms of the temperature, the air and the
water needed.
 Slurry mixing tan: This is a tank in which the dung is mixed with water and fed to the digester
through the inlet pit. In my case there is no a dung to be mixed and since the raw material is
in liquid form, the waste water directly enters to the digester.
 Outlet tan: An outlet tank is usually provided in a fixed dome type of plant from where slurry
indirectly taken to the field.
 Pipeline connection: We have to use a sophisticated and modern pipeline connection
associated with the bio digester in order to achieve a high efficiency. As we know the biogas
contains water vapor. This water vapor passes through the pipe some of it condenses and
transforms into liquid (water) form and this liquid will create an obstacle for the gas flow. In
order to overcome this problem, I should install a water trap to make the water able to escape.
This water trap should be attached to the biogas pipes at any low point where the water could
be easily collected. In terms of the structure the water trap is composed of T-joint linking a
tube down from the main tube into a container of water. Generally, this container is plastic
water storage. In terms of the mechanism the gas produced is prevented from escaping due
to the pressure of the water.

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Mechanism of biogas production: Concerning the mechanism used in the production of the
biogas with perfect installation:
 First, the biomass is introduced to the digester via pumping the liquid matter.
 The substrate is heated and stirred for a day with a minimum temperature of 37°C in
order to provide all the necessary conditions for the microbial activity required in the
biogas production.
 The biogas produced during the fermentation phase is accumulated above the substrate.
It is kept in the gas storage tank at low pressure.
 After a retention period which varies depending on the type of digester used, the biomass
is transformed intro digestate which is a gooey mixture of brown color that could be
used by the farmers as fertilizer (21)
 The biogas is formed and then forwarded to the water scrubber to remove Co2 and other
impurities.
 Then the water scrubbed biogas transferred to a balloon to trap the remaining moisture
in order to produce the bio-methane that could be used for producing electricity and for
heating.

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5.9:Conclusion and Recommendations

5.9.1:Conclusions
The main purpose behind this project is to apply the concepts learnt during my internship into
real life examples. This project supports the initiative of making our company sustainable and
environmentally friendly. It consists on creating a Biogas system for Dashen Beer Company that
would be both eco-friendly and environmentally-friendly. To do so, I had to use
Biotechnological, Engineering and Management concepts that I studied in my months passed at
Dashen Beer Company. Indeed, creating a biogas system for Dashen Beer Company could
significantly decrease the electricity bills and will help manage the wastes. Also, the results of
this project could be used in my colleague’s work that is about Composting and Cogeneration.
To implement this project, I did a literature review to understand very well the situation in Dashen
Company and how biogas is used around the world then I did a comparative analysis of the
different biogas technologies so I could base my design on one of them and last but not least, I
adapted my project to the case of Dashen Beer Company with specific measures and innovations.
Even though this project was very interesting, I have to admit that I faced some challenges. For
example, I had difficulties in finding the exact amount of waste produced in Dashen Beer
Company. Fortunately, this project taught me a lot not only academically but also socially (22).
To conclude, we can say that a biogas system could encourage Dashen Company and community
to take care of the environment and evolve step by step in the domain of sustainable development.

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5.9.2:Recommendations
Dashen Beer Company is a very modern beer industry that is constantly evolving. It keeps
bringing new changes to facilitate. In recent years, the company has been going green, trying to
use renewable energies in order to be in line with the new expectations. From this point of view,
I believe that bringing a biogas system to the company could not only protect the environment
but also reduce the costs of electricity. The biogas that will be produced will generate up to 8640
kW per month which can be very interesting. However, Dashen Beer Company is still not at the
forefront of modernity since I do not sort my waste (23). Indeed, waste management could bring
a lot of help to the production of biogas and would significantly change the amount of electricity
produced. The type of waste that I am using in my project is malt waste and beer waste. The
waste produced is important because I have many bi products. However, bringing more waste
could make my project even more profitable. I could organize an awareness day about the
benefits of sustainable development.

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References

1. Dashen brewery Bulletin .

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4. Wolfgang Kunze, “technology brewing and malting “2nd editions, September 1999
GC.
5. W.Bolton, "Programmable logic contoller", 5th edition ed. .
6. W. BOLTON “Programmable Logic Controllers”, 5TH Edition, .
7. Books and manuals of dashen brewery that are found in dashen in each department
offic
8. Organic waste types for biogas production. (2017). Biogas-renewable-energy.info. [.
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10. Rahmouni et al., 2002; Heteu and Martin, 2003.
11. Shannon, 1997 and Andrews and Quick, 1984.
12. CristinaRodriguez,A.Alaswad, K.Y.Benyounis, A.G.Olabi in 2003.
13. Design and Fabrication of a modified portable Biogas pdf. .
14. Fixed dome digester - Appropedia: The sustainability wiki. (2017. .
15. Hansen KH, Angelidaki I, Ahring BK (1998) Anaerobic digestion. .
16. Biogas from waste | Biogas CHP | Biogas cogeneration. (2017). .
17. Hejnfelt A, Angelidaki I (2009) Anaerobic digestion of slaughterhouse by-products.
.
18. Organic waste types for biogas production. (2017). .
19. Gustavsson J, Svenson BH, Karlsson A (2011) The feasibility of Biogas. .
20. Organic waste types for biogas production. (2017). .
21. Hansen KH, Angelidaki I, Ahring BK (1998) Anaerobic digestion. .
22. Hejnfelt A, Angelidaki I (2009) Anaerobic digestion of slaughterhouse by-products.
23. Biogas from waste | Biogas CHP | Biogas cogeneration. (2017). .
24. Dashen Magazine .
25. Kunze. International 2nd edition. By Dr. Trevor Warn right. London, 1999. .

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