HAWASSA UNIVERSITY

INSTITUTEOF TECHNOLOGY

Faculty Of Manufacturing
School Of Mechanical Engineering
Presented by- Natnael seid
ID-Tech/1699/07
September-2012
 BACKGROUND OF THE COMPANY

 BGI Ethiopia is an international brew company that operates in many countries.

 It is the first private owned brewery in Ethiopia, which was established in 1998
(GC).
 The factory situated in Northern Ethiopia, Kombolcha Town. More than
15,000,000 USD have invested in 1997 to erect this new modern company in the
heart of the Wollo region
 MAIN PRODUCT AND SURVICE
. The factory produces three brands beer: Bati, Castle and St. George bottled
beers. Now castle and St. George ,raya ,zebidar panash beers are produce.

Generally, the company play important role in:

supporting and promoting social activities,
committing with socio-economic problems of the country,
Training the workers to upgrade them a high level of competence and all the workers
show great commitment and devotion to keep the brewery and its product popular.
4 Overall organizational structure and work flow
Head Office
Addis Ababa

Technical Administration Sales &Marketing Finance

Department Department Section Department

Administration
Salesmen
Office
Maintenance Bottling Fabrication Accounting Finished
Dep’t Dep’t Dep’t Promoters Section Goods Store
Medical
General Service Empty
Kegging Brew Sales and car
Workshop Section House Drivers Store

Security
Electric Filtration Guards Full
Bottling
Section Stores
Section

Utility Quality
Control  .

Spare Parts
Store Raw Materials
Store

Garage
 Utility Section
• Under this section
 water treatment plant
 Boiler plant
Air compressor plant
Co2 compressor
 and Refrigeration plant are found. 

i. Water treatment plant

 From raw water tanker the water is pumped to sand filter
tank to be filtered mechanically. Water passes layer of
sand and store in to filtered water tanker.
 Filtered water is pumped to chlorinated water
tank, for microbiological treatment and another
part water is used for bottle washing and
pasteurizer in bottling.
 Chlorinated water passes through the carbon filter
tank to remove the chlorine and then the water
will be used for brewing.

ii. Boiler plant

• Boiler is used to produce steam for utilization of:
cleaning bottles
 sterilization of beer
 cleaning beer line
for boiling or heating of malt in brew house.
Types 1.fire tube
2.water tube
iii. Air compressor plant

Compressed air is used in the factory

for
 cleaning in workshop,
 blowing of car tire,
cleaning dust of the machine,
cleaning of floor and
use for pneumatic system of
De crater and crater machine.
iv. CO2 Compressor plant
 Foam trappers: - Solid matters are washing
with water and removed in the foam trap.
 The scrubbers: - Is to remove water-soluble
impurities from the CO2.
 The Balloon:- Is used to store CO2, evens out
the variation in CO2 flow rate and controls the
stopping and starting of the compressor.
 The Drier: - Dries Co2 not to have very
saturated humidity.
 Deodorizer: - Remove non water-soluble
impurities and it contains an activated carbon
bed through which CO2 passes.
 Liquefaction: - The pure, dried and
compressed CO2 gas is turned in to liquid CO2
by cooling it down by glycol to below
 v. Refrigeration plant
  In this plant, ammonia is firstly
cool by water, which its
temperature is down to 2 with the
help of air fan in water cooling
tower.
 Then this called ammonia is used
to cool glycol to the desire
temperature aboutand stored in an
insulated tank.
 Executed task
In four-month internship duration, I have carried the following tasks :-
 increase the steam production capacity
 maintenance check up of boiler
 maintenance co2 piston type compressor
 pumps
 changing of bearing
Challenges on work
Each position has its own assigned person for each task you don’t get the chance to
work. But afterward when the operator knows you and begin to communicate well
with him, he let the work to operate yourself.
There was also communication problem with operators and technicians. Most of
the operators run the machine by long time experience
The other challenge is to joining and considering yourself as one of the company
member. At the beginning everything is guest to accept but gradually it becomes so
simple.
 Some manuals are not written in common language this makes a little challenge to
get information about a specific machine.
 Benefits of the internship
 Improving practical skill
 Upgrading theoretical knowledge 
 Improving interpersonal communication skill
 Improving team playing skill
 Improving leadership skill
 Work ethics
 Entrepreneurship skill
 Conclusion
The internship program helps me
 It enables me to gain practical first-hand knowledge, key skills and
appropriate working attitude through hand-on experience.
 It helps me to gain greater understanding of mechanical engineering
including the techniques and skills of professionals.
 I have seen for myself the kinds of personalities, temperaments,
diplomacy, community relations, behaviors, and other normative
modes of conduct.
 PART TWO

INTERNSHIP PROJECT
Project title:- Economizer that uses
exhaust biogas as flue gas
 Introduction
 The efficiency of industrial boiler is increase by using economizer and air pre
heater .
 An economizer is a mechanical device which is used as a heat exchanger by
pre heating fluid to increase boiler steam production capacity and to reduce
energy consumption
 This action increases the boiler feed water temperature there by reduce the
time required to convert the boiler feed water into steam as well as decrease
energy used for steam production
 In the company bio gas is continuously burned and released to the
environment with out any usage.
 Using this wasted energy for economizer is one way of conserve the heat
energy which is going out for extracting the heat and transfer it to a boiler
feed water .
 Problem statement
 BGI company used some percent of steam generated from
boiler to increase the water temperature. this decreases the
steam generated from boiler.
 The exhaust biogas pollutes the environment.
 The boiler takes more time for steam production.
 Energy is wasted for burning of biogas

The purpose of this project is to encounter this problems.

 Objective

General objective
 The general objective of this project is to use the exhaust biogas as a flue gas
for economizer to increase the temperature of the feed water in order to
increase boiler production capacity.
Specific objective
 To minimize air pollution
 To increase the temperature of boiler feed water.
 To increase boiler production capacity.
 To minimize production time.
 To decrease energy consumption.
Scope of the project
 The scope of the project is simple design of economizer and simple solid
work model
 Methodology
 Measuring the wasted energy as burned biogas
 Using this energy as input energy for economizer for designing

Select suitable heat exchanger

identify heat balance

Flow design part design

Shell design Bundle design

Simple
Tube design
solid work
Working principle

Exhaust Economizer condensat Boiler

biogas T° water e water receives
burns =55°c tanker well heated
T°=65°c water
Raw water
T=30℃

The temperature Steam

of used steam used Steam
decrease for d/t produced
&change to tasks
water T°=75°c
 Economizer design criterion
The exhaust bio gas and the water must not be mixed
It must be easy to construct
Heat exchange must be through conduction
The design must maintain out put economizer T°=55.3°c & above.
Due to this reasons shell & tube heat exchanger is preferable.
Shell and tube heat exchanger
Benefits of the project
Using energy from burned biogas for economizer
 The temperature of water entering to condensate
water tanker is increased by 25℃ and also the water
leaving the condensate water tanker is increased
nearly by 13℃
 the time needed for 5000kg of steam production is
reduced from one hour to 0.73 hour (43 minute)
 Steam produced in one hour is increased by 1850
kg /hr
 Conclusion
 From this project we can conclude that by using the exhaust
biogas in the company the temperature of the feed water
increased by 25°c.
 In some companies to increase this temperature use steam
generated from the boiler ,but this has draw back on production
& production time .to overcome this problem ,use bio gas for
economizer is very crucial.
Due to increase in T
 Can decrease production time
 Can increase production capacity
 Can avoid air pollution
 Increase efficiency of the boiler
Recommendation
 To maximize and increase the products of the company it is
better designing economizer that use exhaust bio gas as flue gas
Any one interested can use this project as background research
as well as extending for thesis project .
Thank you ǃ