MEKELLE UNIVERSITY

ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE

Department of Chemical Engineering

Project Title: Production of Activated Carbon from Corncob

Hosting company: Moha Soft Drinks Industry Share Company

Prepared By: ID No
Mulu Belay Eitm/ur96440/08
Weldegebrial Nigus Eitm/ur96335/08
Yirga Abadi Eitm/ur96439/08

MEKELLE ETHIOPIA

DATE 03/11/2011
Acknowledgments
It is our radiant sentiment to place on record our best regards, deepest sense of gratitude to our
advisor Mr. Alemework MSc. in chemical engineering next to GOD as well as our principal
factory supervisor Mr. Kifle Abebe who gave us the golden opportunity to do this wonderful
project on the topic of activated carbon production. in spite of being his extraordinary busy with
his duties, took time out to hear, guide and keep us on the correct path and allowing us to carry
out our project at their esteemed organization and extending during the training. We are also
grateful for Mr. Mebrahtom for his willingness to help us in giving more information regarding
of all the process of the company and the completion of our project.

Secondly we would also like to thank our parents and friends who helped us a lot in finalizing
this project within the limited time frame.

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Abstract
The aim of this paper was to express and present the four-month internship report and project. It
contains two parts; the first part was about internship report and the second part about internship
project. Moha soft drink industry Mekelle plant was the 8 th plant of Moha companies with a
building capital of 108,654,000 birr. The efficiency of Moha soft drink Industry was 36000
bottles per hour and the objectives of the company was to manufacture, to distribute, bottled soft
drinks and concentrates. The company’s mission was to be the best soft drink industry in the
country. It will continuously improve its responsiveness to the needs and choice of its customers,
employees, partners in which it serves. Moha soft drinks Industry produces 7 up, Miranda
orange, Miranda apple, Miranda tonic, Pepsi, CO2 and the company have four main sections such
as water treatment section, CO2 production section, Syrup preparation section, Steam generation
(steam boiler) section, Soft drink production section. Generally, the company has its own
production process technologies and quality controls mechanisms.

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List of Figures
figure1. 1: Main Products................................................................................................................3

figure1. 2: carbon filter...................................................................................................................9

figure1. 3: Ro Diagram..................................................................................................................10

figure1. 4: CO2 Production............................................................................................................12

figure1. 5: UN Packer Machine.....................................................................................................14

figure1. 6: Crate washer machine..................................................................................................15

figure1. 7: Bottle washer machine.................................................................................................15

figure1. 8: Bottle washer washing cycle........................................................................................16

figure1. 9: Empty bottle inspection...............................................................................................17

figure1. 10: Mixer Machine...........................................................................................................18

figure1. 11: Filler machine............................................................................................................19

figure1. 12: Filler bottle inspection machine................................................................................19

figure1. 13: Date coder machine....................................................................................................20

figure1. 14: Packer Machine..........................................................................................................21

figure1. 15: Boiler..........................................................................................................................21

figure1. 16: Steam Distribution.....................................................................................................23

figure2. 1: Moha soft drinks process diagram…………………………….…………………….29

figure3.1:Corncob production …………...………………………………………………………50

figure3. 2: profile of raw corncob and Vicoma.............................................................................52

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List of tables
Table1. 1: The raw materials usage and supplier of the company...................................................4
Table1. 2: Classification of manpower............................................................................................6

Table 3. 1: Raw materials and equipment’s for preparation of AC……………………………...48

Table 3. 2: Proximate analysis of the raw corncobs and its ashes................................................51
Table 3. 3: Elemental composition produced corncob activated carbons (AC)............................51

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Abbreviations
AC Activated Carbon
ADM Account Development Representative
BET Brunauer-Emmett-Teller
C Compressor
CC Corn Cob
CCP Critical Control Limit
CEO Chief Executive Officer
CIPS Clean In Place System
CL Critical Limit
CO Concentrate
CO2, PR Carbon Di Oxide Production
CP Caps
CM Chemical Additives
E Evaporator
EBI Empty Bottle Inspection
FBI Full Bottle Inspection
GAC Granular Activated Carbon
HACCP Hazards Analysis Critical Control Point
M Misking
MEA Mono Ethanol Di Amine
MOHA Mohammed Hussein Almoudi
PA Powdered Activated Carbon
R, tray Returnable trays
S.C Share Company
W Washer
WS Water Softener

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SYMBOLS
Ca Calcium
Co Carbon mono oxide
Co2 Carbon dioxide
D Diameter
H Height
Na2Co3 Sodium carbonates (soda ash)
NaOH Sodium hydro oxide

H2so4 Sulphuric acid

Hf Enthalpy of feed water

Hs Enthalpy of super-heated water
L Length
M Mass
Mg magnesium
N2 Nitrogen
Nh3 Ammonia
No Nitrogen mono oxide
O2 Oxygen
Qlb Heat loss
QR Enthalpy loss due to radiation
QS Heat gained by steam
QSA Sensible heat on ash

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 Table of contents
Content Page No.

Acknowledgments............................................................................................................................i
Abstract............................................................................................................................................ii
List of Figures................................................................................................................................iii
List of tables...................................................................................................................................iv
Abbreviations...................................................................................................................................v
SYMBOLS.....................................................................................................................................vi
1 Introduction and Background of the Company........................................................................1
1.1 History of Pepsi Company................................................................................................1
1.1.1 Plant Background of Moha Mekelle..........................................................................1
1.2 The Objective of the Company.........................................................................................2
1.2.1 Mission of the Company............................................................................................2
1.2.2 Vision of the Company..............................................................................................2
1.3 The Main Products of the Company.................................................................................3
1.3.1 The Main Supplier or Service of the Company.........................................................3
1.3.2 Main Services of Moha..............................................................................................4
1.4 The Company End Users or Customers............................................................................5
1.5 The Overall Organization Structure and Work Flow of the Company.............................5
1.5.1 Working Hours of the Moha Company.....................................................................6
1.5.2 Classification of Man Power States in Moha Company............................................6
1.6 The Main Sections of the Company..................................................................................7
1.6.1 Water Treatment Section...........................................................................................7
1.6.2 Syrup Preparation Section.......................................................................................10
1.6.3 Carbon dioxide Production Room...........................................................................11
1.6.4 Soft Drink Production Section.................................................................................13
1.6.5 Wastewater Treatment.............................................................................................23
1.6.5.1 Physical Methods.............................................................................................24
1.6.5.2 Chemical Treatment.........................................................................................24
2 Process Technology of the Company.....................................................................................27
2.1 Moha Soft Drink Process Technologies..........................................................................29

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 2.2 Material and Energy Balance of Main Unit....................................................................31
2.2.1 Material Balance......................................................................................................31
2.2.2 Energy Balance on Boiler........................................................................................32
2.3 Main Equipment Sizing of the Company........................................................................33
2.4 Environmental Consideration of the Plant......................................................................34
2.4.1 Haccp Plan...............................................................................................................34
2.4.2 Negative Impact of the Company............................................................................36
3 Production of Activated Carbon from Corncob.....................................................................37
3.1 Short Summary...............................................................................................................37
3.2 Introduction.....................................................................................................................38
3.3 Statement of the Problem................................................................................................38
3.4 Objectives........................................................................................................................39
3.4.1 General Objective....................................................................................................39
3.4.2 Specific Objectives..................................................................................................39
3.5 Scope of the Project........................................................................................................39
3.6 Literature Review............................................................................................................40
3.6.1 Chemical Activation................................................................................................42
3.6.1.1 Chemical modification using acids and bases..................................................43
3.6.1.2 Chemical modification by oxidation treatment................................................43
3.6.1.3 Chemical modification by sulfurization...........................................................44
3.6.1.4 Surface impregnation.......................................................................................44
3.6.1.5 Corncob............................................................................................................44
3.6.2 Physical Activation..................................................................................................45
3.6.3 Classification of Activated Carbons........................................................................45
3.6.4 Applications of Activated Carbon...........................................................................46
3.6.4.2 Environmental field..........................................................................................46
3.6.4.3 Metal finishing field.........................................................................................47
3.6.4.4 Alcohol and Soft Drink Purification................................................................47
3.7 Materials and Methods....................................................................................................48
3.7.1 Methods.......................................................................................................................48
3.8 Results and Discussion....................................................................................................51
3.8.1 Precursor Characterization.......................................................................................51

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 3.9 Process Equipment Sizing...............................................................................................54
3.9.1 Cost Analysis...........................................................................................................54
3.10 Conclusion and Recommendation for the Project...........................................................55
3.10.1 Conclusion...................................................................................................................55
3.10.2 Recommendations.......................................................................................................56
4 Over all Benefit from the Internship......................................................................................57
4.1 In Terms of Improving Theoretical Knowledge.............................................................57
4.2 In Terms of Improving Practical Skill............................................................................57
4.3 In Terms of Improving Industrial Problem Solving Capacity........................................58
4.4 In Terms of Improving Team Playing Skill....................................................................58
4.5 In Terms of Improving Leadership Skill.........................................................................59
4.6 In Terms of Understanding About Work Ethics Related Issues.....................................59
4.7 In Terms of Entrepreneurship Skill.................................................................................59
4.8 In Terms of Improving Interpersonal Communication Skill..........................................60
5 Conclusion and Recommendations........................................................................................60
5.1 Conclusion......................................................................................................................60
5.2 Recommendations..............................................................................................................61
References......................................................................................................................................62
Appendices....................................................................................................................................64

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 1 Introduction and Background of theCompany
1.1 History of Pepsi Company

Pepsi cola traces its origins to 1898 when Caleb Brad ham, a pharmacist in New Bern, North
caroling, created a curative drink called Pepsi cola – Pepsi cola later referred to simply as Pepsi
was a mixture of carbonated water, cane sugar, syrup and an extract from tropical Kola nuts. To
sell this product, Brad ham formed the Pepsi Cola Company in 1903.Pepsi plant in Ethiopia was
begun in factories like Dessie 1952, Tekle Haimanot 1961, and Nifas Silk 1966, Gondar 1986
etc. Moha soft drinks, owned by Sheikh Mohammed Al-Almoudi founded in May 15/ 1996 with
acquisition of those four Pepsi plants.

1.1.1 Plant Background of Moha Mekelle

Moha soft drinks industry Mekelle plant is the 8 th plant of Moha companies (of Dessie, Tekle
Haimanot, Nifas Silk, Gondar, Alem Gene, Jigjiga and Hawassa plant). Pepsi cola industry is a
private company which owned by Mohamed Hussein Al Almoudi.

The location of the plant is in Tigray region Mekelle city 780kmfar from Addis Ababa and it was
established on2005E.C with capital of 108,654,000 birr. In addition, through gradual process
February 07, 2007 was graduated and starts its regular process with the efficiency of 36000
bottles per hour. The initial cost of the company is 80,000,000 birr including CO 2 gas plant.
Pepsi cola industry producing five flavors of soft drinks these are (7up, Mirinda orange, Mirinda
apple, Mirinda tonic, Pepsi). The company is now one of the leading producers of carbonated
soft drinks in Ethiopia. The machines are coming from different abroad countries and planted by
union engineering company designers and technical. There is one line that is glasses bottle line,
it produces about 36,000 bottles per hour and the annual turnover of the company have reached
to birr 556 million and sales stands at an average annual growth rate of 12%.

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Markets

Moha holds 52% of the market share in soft drinks industry in the country. With an expansion
and replacement of obsolete machinery, production capacity of the plants has increased
substantially. Moha, in addition to the initial purchase price of the Soft Drinks factory, has
invested Birr 8 Million for the expansion of new projects, Birr 153 million for replacement of
existing plants and birr 241 million for marketing, infrastructure, excluding advertisement and
sponsorship expenses. In addition, a significant growth over the years of production, sales, and
profitability due to reorganization of operations has been achieved. Productivity has improved
tremendously with major cost savings and has insured a regular supply of high quality products.
It has also succeeded in reaching new market areas across the country.

1.2 The Objective of the Company

Moha soft drink industry is as stipulated in the memorandum association, its business
purposes(objectives) are to manufacture, sell, buy, bottle, distribute and otherwise deal in no-
alcoholic, mineral and a clean waters and ingredients.

1.2.1 Mission of the Company

The company’s mission is to be the best soft drink industry in the country. It will continuously
improve its responsiveness to the needs and concerns of its customers, employees, partners, and
the communities in which it serves. The company will expand its marketing areas to both protect
and improve its positions by placing emphasis on innovation, concerned on production quality,
producing based on its own specification and technological improvement to keep always a head
of the competition.

1.2.2 Vision of the Company

Moha soft drink factory vision is to be the best Pepsi cola bottler in the world and to make each
of its products to be drink of first choice among consumers and obtainable throughout the
market. It intends to create superior value for its shareholders, its customers, and its employees

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1.3 The Main Products of the Company

Moha Soft Drink Company is one of the soft drink beverage companies in Ethiopia that produce
seven different brand beverages.

These are:

• Mirinda orange (orange flavor)

• 7 up

• Pepsi cola (cola flavor)

• Mirinda tonic

• Mirinda Apple

• Cool water gas

• CO2 gas

figure1. 1:Main Products

These all products are 300ml (0.3L) and 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
for consumers who need it for food preservation purpose. To produce the above-mentioned
products, Moha Soft Drinks Industry SC got a franchised license from international Pepsi Cola
Company. This company controls the quality and safety of the products in the market.

1.3.1 The Main Supplier or Service of the Company

• Domestic (Ethiopia) sugar factory

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 • Domestic(Ethiopia) caustic soda plan

• Pepsi- cola international

• Domestic(Ethiopia) crate factory

• Domestic(Ethiopia) cork factory

Table1. 1: The raw materials usage and supplier of the company

Raw materials Supplier of the company Unit
Sugar Local market(Ethiopia) At
Water Local market( borehole Aynalem, Mekelle, Tigray, Lt
Ethiopia)
CO2 gas Itself(Moha Mekelle plant) Kg
Sand Local market( Ethiopia) Unit
Pepsi concentrate Pepsi cola international Unit
Caustic soda Local market(Ethiopia) Kg
7up concentrate Pepsi cola international Unit
M-orang concentrate Pepsi cola international Unit
M-apple concentrate Pepsi cola international Unit
M-tonic concentrate Pepsi cola international Unit
M-Ananas concentrate Pepsi cola international Unit
DIVOLE Hal dag Kg
DIVO AI Hal dag Kg
Oil(furnace and diesel ) America Lt
Crown cork Ethiopian crown cork factory

1.3.2 Main Services of Moha

 Transport service
 Cafeteria service
 Available of workers shoes, clothes, gloves and masks

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1.4 The Company End Users or Customers

The end users or customers of the company are the whole Ethiopians people. Some of the end
users are as listed below
• Mekelle
• Shire
• South part of Tigray
• South east part of Tigray
• West part of Tigray
• East part of Tigray and central part of Tigray
• Amara (Sokota& kobo)
• Dessie
• Afar (zone two)

1.5 The Overall Organization Structure and Work Flow of the Company

The overall organization of Moha soft drink industry is that there is one head office (chief
executive office in Addis Ababa, which controls the whole other branches. The C.E.O is
empowered to direct, plan, coordinate, organize, control and administer the overall operation of
the company. Hire and file personal directly or through this delegated management team. In each
factory, the plant general manager has a great role to coordinate the work.

There are also different departments to make the workflow easy and fast. In Moha soft drink
industry, under the plant general manager there are Executive secretary, Vehicle maintenance
supervisor and various departments such as department of sales, production, technical,
administrative, procurement and store supply, quality control and food safety. Additionally, each
department has their own sub-department. In sales department market unit manager, fleet
supervisor, up country sale supervisor, warehouse supervisor, sales promotion supervisor, and
branch manager are located. For furthermore, the market unit manager has its own sub divisions
such as shift supervisor, territory development manager (TDM), account development
representative (ADR) and customer representative (CR). In addition, under the technical
department mechanical supervisor and electrical supervisor are founding. In finance department
general account supervisor and cost and budget supervisor. In administrative department
personnel, general service supervisor and medical service and safety supervisor are located. In

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procurement and store supply, department procurement and store supply supervisor was list.
Quality control and food safety department includes quality control supervisor is found. The
working flow of each section of the company is caring out in organized system. Therefore, the
workflow is going in such away. Generally, the overall organizational structure of the company
that we tried to express above is looks like as below in diagram.

1.5.1 Working Hours of the Moha Company

The company is designing to operate a normal working hour, which shall not be exceeding 8 hours a
day, or 48 hours a week. The company works with two shifts from Monday up to Saturday, which is
from 2:30 up to 6:30 in the morning and from 8:30 up to 12:30 pm in the afternoon operates in extra
shift from 12:30 up to 2:30 in the evening. It is difficult to mention the actual output of the factory per-
day. However, theoretically it believed that the plant processes at a full production capacity about
36,000 bottles per hour. This production rate is analyzing by taking no consideration of the mechanical
and operational dawn time during the working hours. However, in consideration of the mechanical and
operational dawn time the output of the factory has believed between25000-30000 of bottles per hour.

1.5.2 Classification of Man Power States in Moha Company

Table1. 2:Classification of manpower
Employees Male Female Total
Permanent 147 81 228
Contract 11 1 12
Piece rate 50 - 50
Total 208 82 290

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1.6 The Main Sections of the Company
From the beginning of the internship day (march22/2019) all we apply on Moha soft drink
industry worked and grouped according to our department even if we invited to see all
departments for few days through our supervisors. Due to this reason, we have been working on
production and quality focus section especially in steam boiler section-to produce hot water
(steam) and flue gas boiler sections. To produce pure CO 2gas in the company during our
duration, we have seen and understood almost all work activities step by step with the help of our
supervisor and the company’s operators. From what we have seen and study before, now we can
understand the operating, production method, water treatment method, waste water treatment
process, working principal and functions.These sections include:

 water treatment section

 Syrup preparation section

 CO2 production section

 Soft drink production section

 waste water treatment section

1.6.1 Water Treatment Section

The objective or principle of water treatment process are to remove the different impurities in the
raw water, to render the water safe and clean and to ensure the treated water quality meets the
standards of water to produce the soft drink. Moha soft drink company uses ground water, the
raw water comes from a small residential area known as Aynalem and stored in reservoir,
consequently a chemical is added (dosed) in order to treat biological elements goes through the
coming raw water. As we move from the surface, the first zone encountered is the “unsaturated
zone” (also referred to as the “vadose zone”). In this area, the geologic media (dirt, clay, sand,
etc.) contains a mixture of water and void spaces with air--hence, the terms “unsaturated” or
“variably saturated.” Continuing downward, we reach the “capillary fringe,” which is generally
considered the beginning of the “saturated zone,” but is sometimes considered a distinct entity.
This interface between unsaturated and saturated zones is not completely understood, and is the
subject of much study with regard to movement of certain contaminants within it. The “saturated
zone” is the area where air is at a minimum, and water is at a maximum. The geologic media

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were saturated with water. Dissolved oxygen in the saturated zone is extremely rare; many deep
ground water formations exist under anaerobic or hypoxic conditions. It is within the saturated
zone where actual ground water supplies are founding, and where most production wells are
placed. Throughout the saturated zone, many strata of varying permeability will be found. For
this reason, we need different water treatment technics; Steps on water treatment.

• Aeration
• Sand water treatment
• Intermediate tank
• Activated carbon filter
• Polisher
• Uv1 (ultra-violent )
• Ro membrane (reverse osmosis)
• Activated carbon filter 2
• Polisher
• UV 2
• Softener

A. Physical Treatment (Screening)

Physical treatment is used to treat materials such as sands, flocks, and other grids travelling with
raw water by using a technique of washing sand filter such as; lowering, back wash water. This
water goes in to intermediate tank and stay there; this physically treated water will be
distinguished in to three parts;
• water softener
• Service water
• Product water

B. Carbon Filtration Treatment (Chemical)

The filtration system is used to remove rest turbidity, dissolved organic components and chlorine
from the water. Chlorinated water is diverted via pumps to the activated carbon filter plant.
There is one carbon filter in operation; with a capacity of 25m³/h and controlled fully
automatically. The backwash steps will be carried out in semi-automatic. An inlet and outlet
pressure transmitter ensures that the filter is not over pressurized and provides an automatic

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alarm should this be the case. The filters are backwashed as required to remove the filter cake
produced and any broken carbon particles. During backwash, there can be only two filters in
operation. Backwash is carried out using filtered, chlorinated product water from the buffer tank.
In this process, water is pumped into the filter from the vessel bottom. The water exits the top of
the filter and is passed to drain. This process loosens and removes the filter cake that has been
accumulated on the top layers of carbon. In addition, the backwash step chlorinates the outlet
piping of the filter in order to ensure destruction of microbiology.

figure1. 2: carbon filter

C. UV Treatment

It is used to treat biological wastes in water purification, which are passed through the previous
treatment method. And this method is used to clarify the dead microorganisms which are forced
from the carbon filtration system.

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D. Reverse Osmosis

Ro has been used for the production of demineralized water for over 30 years. In reverse osmosis
water is transported across a membrane under high pressure, leaving a product that consists
mainly of water and a concentrate containing most other components such as minerals and
unwanted residues. Many contaminants including iron, manganese, ammonium, traces of
pesticides and medicines, organic micro pollutants, and radioactive particles can be removed
with reverse osmosis alone. The reverse osmosis system consists essentially of a membrane
component. The reverse osmosis membrane retains salts, whereas the water permeates through
the membrane. To produce the differences in salt concentration across the membrane a pressure
difference is necessary in order to overcome the osmotic pressure. This pressure difference is
achieved by using a high-pressure pump to pass the raw water to the membrane

figure1. 3: Ro Diagram

1.6.2 Syrup Preparation Section

A. Sugar Dissolvation

Sugar used in soft drink industry to have the proper test of the soft drink the products. In this
plant the sugar dissolves at high level of temperature and the sugar comes from local Wangi
sugar factory and also from South Africa product, but most of time Moha soft drinks industry
uses the South Africa sugar.

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 B. Syrup preparation

In this room, most chemist control the proportion of the solution and time control due to different
material has different property, Such as Miranda and Pepsi syrup time interval relatively to
water. Miranda syrup can use immediately, but Pepsi syrup must wait one day or 24 hours. The
soft drink powder concentrates are mixed with water to make a thick solution called Syrup. That
contains 20% soft drink powder and 80% water.

1.6.3 Carbon dioxide Production Room

Carbon dioxide is the most useful element in soft drink factory. This is used to produce clean
CO2 production for keeping the soft drink for 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 160kg/h.

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 figure1. 4: CO2 Production
In order to produce pure desired CO2in the CO2 production section it passes some steps after fuel
burning in the boiler as follows:
Flue gases leave from boiler after fuels are burning through burner.
A. Flue Gas Scrubber Tower: Clean the flue gas by soda ash that comes from flue boiler
through chimney. Then the cleaned flue gas inters into absorber.
B. Absorber Tower: Is the tower in which CO2 isolates from other unwanted gases by
MEAsolution. The unwanted gases leave from the absorber in to environment as shown above
figure. But only CO2 (the desired gas in the company) is captured by MEA solution and then it
goes to stripper tower.
C. Stripper Tower: Is the tower in which the reach MEA (contain more CO 2) that comes
from absorber tower is separate by steam. At this stage we already gate only pure CO 2 and we
can use it in many company or plants but in the Moha plant there is one process in addition to
these processes since their product is for food purpose they give more protection (keep more
safety the products of that processes).

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NOx Flush Tower: Separated CO2 from stripper tower may not pure 100%. There may some
remaining MEA solution with CO 2. So in order to gate the purest CO 2it must inter in to NOx
flush tower in which CO2is separate from the remaining impurities, i.e. the gas content is going
in to the drier processes and water separator unit. The liquid one is goes in to the stripper tower
and the remaining separated MEA solution is goes in to the absorber tower and MEA tanker.
Then after the only pure CO2 in the form of gases inter to its condenser in which CO 2in gas form
is changed in to liquid phase through Freon by body contact. Finally, the CO2liquid stored in the
storage for a certain period as liquid and we can use it for the production process. There is
returning valve assembling with storage tanker. If there is whether condition change that helps to
transport the gas form to the condenser for again cooling process.

1.6.4 Soft Drink Production Section

In this section, the preparation of soft drink takes place in the production sector we have seen and
understood all the production flow of the organization systematically with the help of our
supervisor and operators. The Steps to prepare the final product passes the following series of
machines and areas, which are:
 UnpackerandPacker machine
 Create washer machine
 Bottle washer machine
 Empty bottle inspection machine
 Mixer machine
 Filler and crowner machine
 Full bottle inspection machine
 Date coder machine

A. Un Packer Machine

This machine is used to pick up the bottles from the craters and put into the bottle conveyor.
Firstly, empty bottles are unload from forklift truck to de palletize zone.The palletize bottles de
palletize and put to conveyor using workers manually and convey to unpacker machine. The
unpacker machine is fully automatic machine with the speed of 40,000 bottles per hour. And it
helps to remove the bottle from the crate by pneumatic (air) system.This machine has six sensors

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which help the machine for proper timing and gripping the bottle, also order the next creates and
stop it.
The unpacker machine have components such as pusher which press the four create and stop it,
blocker which help to block the four crate to stay in a fixed and in a right position and gripper to
hold the 96 bottles and put it on the conveyor. After that the empty bottles it can pick four crates
of bottle at once. The empty bottles are passing on to the bottle washer and the empty crate
passing to the create washer.

figure1. 5: UN Packer Machine

B. Crate Washer Machine

This machine use to wash the crate with warm water and high-pressure spray from different
direction. The crate washer is used to wash the empty crate as its name indicates by receiving
from the de-crater by means of the conveyor belt. At the de-crater, the empty glass and the empty
crate are separated by the de-crater and move in different direction to reach their washing station
(washer machine). The washing station for the empty crate is crate washer. The crate washer
cleans the dirty materials from both the inside and outside of the crate. Lastly, the cleaned crate
is transferring to the re-crater (packer machine) where the filled glass with the soft drink is
returned it.

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 figure1. 6: Crate washer machine

C. Bottle Washer Machine

Bottle washer machine is the most important machine which is used to disinfect and wash dirty
bottles. The bottles are introduced to bottle washer by introducer and pusher. Bottle washer
machine can wash 40,000 bottles per hour in four stages. The bottles are washed internally and
externally.

figure1. 7: Bottle washer machine

This machine has its own washing cycle and consists of four distinct phases.
1. Pre-wash

The pre-soaking stage takes place in one or two stages; after leaving the presoaking area, the
bottles are over turned and emptied, the dripping waterfalls onto a collection pan and is filtered
before returning into the presoaking area itself. The presoaking area is maintained at a constant

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temperature and continuously renewed by hot water coming partly from the first rinsing area and
partly from the detergent sprayer’s tank without any additional energy consumption. An internal
sprayer and an external shower perform a double step heat recovery process to increase bottles
and carrier’s temperature before immersion in the main detergent tank.

2. Washing
The washing stage takes place in the main detergent bath where also two label extraction stations
are located. The time of immersion and the temperature can be set according to the specific
characteristics of the bottles being cleaned.
3. Caustic spraying
After the soaking in the hot caustic solution the bottles are turned upside down until they’re
completely emptied. A final washing stage is then performed by a set of sprayers directing a jet
of detergent solution inside the bottle.
4. Rinsing
The rinsing stage is divided into four gradually decreasing temperature zones. The first three
ones perform rinsing with internal and external sprays of re-circulated water supplied by
Centrifugal pumps while the final one with just internal sprays of fresh water. After completion
of the rinsing cycle, the rinsing water is conveyed to the presoaking station. Bottles are then
properly emptied before being discharged.

figure1. 8: Bottle washer washing cycle

1-Bottle in feed conveyor 12-1st rinse spray
2-Bottle accumulation 13-2nd rinse spray
3-Bottle loading 14-3rd rinse spray
4-Residuale liquid collector plate 15-Fresh water spray

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5-1st prewashing stage at 30℃ 16-Fresh water in feed
6-2nd prewashing stage at 45℃ 17- Bottle discharge system
7-Heat recovery sprayer at 65℃ 18-Bottle discharge conveyor
8-Heat recovery washer at 70℃ 19-prewash filter
9-Prewash collector plate 20-Bage filter
10-Detergent soak 21-1st level extraction pump
11-Causting spray 22-2nd level extraction pump

After completing this washing cycle some additives are added to the final stage of rinsing i.e.
Divot help to control the water hardness, Divot Le help to control the pH level, Divot Bright help
to remove un erased date prints and chlorine help to kill micro-organisms.

Visual Inspection: - The washed bottles might have dirty, cracks or broken so such
defects will be identified and removed during visual inspection by human.

D).Empty Bottle Inspection Machine (EBI)

The washed bottles might have dirty, cracks or broken so such defects will be identified and
removed during visual inspection.

figure1. 9: Empty bottle inspection

E. Mixer Machine

The star blend plus evolution blender is a system for the preparation of drinks in which the
correct quantity of basic ingredients (water, syrup and CO2) is measured and dosed in a
continuous electronically controlled process which leads to very high product quality (high
precision Brix and CO2 Volume values) in all operating conditions (steady−state and during
transitory phases).

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 figure1. 10:Mixer Machine
Generally, mixer machine mixes three different things. These are:
 Carbon dioxide (CO2)
 Syrup
 Water
Mixing ratio of syrup to water Pepsi cola, 7up, Mirinda tonic and Mirinda orange, Mirinda
Amanas was 1:5; but Mirinda apple is 1:4. Amount of CO2 by the volume: Pepsi is 3.5, 7up is
3.7, Miranda orange is 2.1, Miranda apple is 3.0, Miranda tonic is 4.0 and Miranda Ananas is
2.4.

F. Filler Machine

Is a machine that used to fill the washed bottles with soft drink that coming from mixer tanker.
Filling process: First the bottle is connected to the vacuum chamber where the air inside the
bottle is sucked then CO2 at a certain pressure is filled with soft drink, finally bottle discharge to
which crowning after filling sterile water jet is installed before the crowner who continuous
sprays a thin stream of sterile hot water drowns out. This cause the soft drink to foam and
oxygen is removed by foam before closing the bottle with crown cork. The average filling speed
of the filler is about 36,000 bottles per hour.

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 figure1. 11: Filler machine

G. Crowner/Capper Machine

After the individual bottle are filling and conveyed to the capper/closure machine. The bottles
transferred by a star-wheel conveyor to a crowner that applies the cap or crown to the bottle. In
the crowner, the bottles supported on a rotating table and as the crowner rotates, the crown
applied and crimped to the bottle.

H. 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-torqued cap) and
tamper band integrity; defective bottles are automatically rejected.

figure1. 12: Filler bottle inspection machine

I. Visual Inspection
There may be the bottles which are not well crowed and well filled that are not rejected by the
FBI machine. So these bottles are pickup/reject by the workers.

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J. Date Coder Machine

Date coder uses to print information’s such as; expire date, company name (tells where the soft
drink produce) and time on the surface of the pet filled with the soft drinks. To perform this
activity, it uses different materials and mechanism. The sensor is very important in this system of
date coder machine. The sensor senses the movement of the pet filled with the soft drinks and
sends the message to the Plc. which is connected to it.

figure1. 13: Date coder machine

K. Packer Machine

It is used to pack the washed crates coming from the crate washer with labeled bottles these
passed through date coder machine from filler machine. The function of this machine is the
inverse of that of the de-crater means there-crater is used to takes the glass filled with the soft
drink from the conveyor belt and puts in the washed crate. As the de-crater the photo electric
sensors plays the great role in this machine. The sensors are very sensitive to the movement of
the glass filled with the soft drink and empty crate. The sensor sends the message to the plc.
Then by receiving the message from plc orders the re-crater to takes the glass filled with the soft
drink under this machine and puts in the empty crate that is used to handle and for guarding of
the glass with the soft drinks during transportation.

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 figure1. 14: Packer Machine

L. Boiler Section (Steam Boiler)

Boiler section is used to produce boil the water & changed into steam to use for any process for
heating at the plant. Boiler is a closed vessel in which water is using to heat a fluid, generate a
steam, superheat, perform any combination under pressure, or vacuum by direct application of
heat.

figure1. 15: Boiler

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A. Steam Plant

This plant is used for the production of steam or boils water by using water as raw material.
Water comes from water section and stored in water storage tanks. There is water level sensor
attached to the unboiled water storage tanks in order to detect /sense the level water in the tanks.
The boiler (fire tube boiler type) of the company can use diesel oil or furnace oil, but the
company still now uses diesel oil. Production of steam starts by burning diesel oil, air in the
burner using spark ignition. The soft water is initially pre heated in the economizer to 85°C by
the excess steam before it enters to the boiler.

B. Components of Boiler

• Load controller with in electrical valves: regulates the furnace temperature

• Servo-motor: used to spray oil to the boiler which comes from oil tank

• Ignition: positive and negative electrode tips rub together to form spark to ignite the
Boiler

• Photocell: has aflame sensor to turn off the spark after igniting the burner

• Safety valves: keep the boiler from high pressure

• Slight glass: used to observe the flame inside the boiler

• Blow: used to remove dirty steam and dirty water.

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 figure1. 16: Steam Distribution

C. Fuel Consumption of Boiler

The boiler in the company is the pillar (backbone of the company-have multi-purpose as listed
above). In the company, the boiler running hour is for production, for syrup, for CIP process and
other cleaning purpose and the average running hour per month 300, 25, 78 and 4 respectively

The Steam is used in

 Bottle washer

 Crate washer

 Syrup preparation room to dissolve the sugar and syrup

 CIP (clean in place) system

1.6.5 Wastewater Treatment

In Moha soft drink S.c there were three wastewater treatment methods first physical treatment;
the waste from all plants of the company was blended in one line and piped in to concrete tanker
but there was metallic sheet filter that separates large and solid maters from the waste. Second
biological treatments; there were continuous stirring for removing microorganisms growing on
the side of the tanker and there was aeration to remove anaerobic microorganisms engulfed by

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the aerobic microorganisms. Third chemical treatments; there were two automatically dosing
hydrochloric acid and sodium hydroxide tanks for adjusting the PH value of the waste drained.
Moha drains wastewater of PH. 5.5 to 8.5.

Source of Waste Water Treatment

• From bottle washer and create washer

• From Water treatment plant

• From Syrup preparation room

• From weakly and daily cleaning etc.

1.6.5.1 Physical Methods

Include processes where no gross chemical or biological changes are carried out and strictly
physical phenomena are used to improve or treat the wastewater. Examples would be coarse
screening to remove larger entrained objects and sedimentation or clarification. In the process of
sedimentation, physical phenomena relating to the settling of solids by gravity are allowed to
operate. The physical treatment is used for removing of suspended solid particles. Some
equipment’s and steps are used in this like.

2) Pump pit - this two pipes are used to pump the waste water to the defender and it recycle
back this pumps remove small objectives.

3) Mesh with wide holes.

4) 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.

1.6.5.2 Chemical Treatment

Consists using some chemical reaction or reactions to improve the water quality. Probably the
most commonly used chemical process is chlorination. Chlorine, a strong oxidizing chemical, is
used to kill bacteria and to slow down the rate of decomposition of the wastewater. A chemical
process commonly used in many industrial wastewater treatment operations is neutralization.
Neutralization consists of the addition of acid or base to adjust pH levels back to neutrality.
Since lime is a base it is sometimes used in the neutralization of acid wastes.

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 • This is used in the neutralization tanker by measuring our PH difference our PH must be
between “6.5-8”.

• Chemicals like sulfuric acid (H2SO4) and sodium hydroxide (NaOH) are used to balance
the PH level.

• If our PH is acid (below 6.5) it needs dosing of base, if our PH is base (above 8) it need
dosing of acid.

We have two methods:

1. Primary Treatment
2. Secondary Treatment
 Primary Treatment
In this treatment, most of the settle able solids are separated or removed from the wastewater by
the physical process of sedimentation. When certain chemicals are used with primary
sedimentation tanks; some of the colloidal solids are also removed. Biological activity of the
wastewater in primary treatment is of negligible importance. The purpose of primary treatment
is to reduce the velocity of the wastewater sufficiently to permit solids to settle and floatable
material to surface.

The results obtained by primary treatment, together with anaerobic sludge digestion as described
later, are such that they can be compared with the zone of degradation in stream self-purification.
The use of chlorine with primary treatment is discussed under the section on Preliminary
Treatment.

 Secondary Treatment
Secondary treatment depends primarily upon aerobic organisms which biochemically decompose
the organic solids to inorganic or stable organic solids. It is comparable to the zone of recovery
in the self-purification of a stream.

Chlorination

This is a method of treatment which has been employed for many purposes in all stages in
wastewater treatment, and even prior to preliminary treatment. It involves the application of
chlorine to the wastewater for the following purposes:

1. Disinfection or destruction of pathogenic organisms

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2. Prevention of wastewater decomposition

Odor control and Protection of plant structures

3. Reduction or delay of biochemical oxygen demand (BOD)

While chlorination has been commonly used over the years, especially for disinfection, other
methods to achieve disinfection as well as to achieve similar treatment ends are also used.

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2 Process Technology of the Company
Soft drink bottling or manufacturing involves five major processes. Each with its own safety
issues that must be evaluated and controlled,

1; treating water

2; compounding ingredients

3; carbonating product

4; filling product

5; packaging

The figure below includes the 5 process issues of the company. But it is not the flow diagram of
the entire company. It only describes a view of the processes technologies of the sections. It
includes water treatment, syrup mixing section, carbon dioxide production section, washing,
production section, packaging and transporting facilities.

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 The diagram below describes the basic bottling operation of Moha soft drink industry.

Warehouse Rout
truck

Raw material
Valve coderwarmer loose packer
Depalletizersingle filler rinser filler washer

ww

R, Trays W
CP

C02 PR
Ev C

Boiler
Raw water

W S CIP
S

C M

CO

Mixing tank
Filter
HFCS

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Descriptions:
To palletize
To tanks filler and carobs cooler

Carobs cooler system

To rinser and washer
CIPS CIP system
M Misk.ing
HFCS high fructose corn syrup
CO concentrate
Co2 PR CO2 Production
WS water softener
CM chemical additives
CPcaps
R, tray returnable trays
W Washer
E Evaporator
C compressor
figure2. 1:Moha soft drinks process diagram

2.1 Moha Soft Drink Process Technologies

As a soft drink producer, one of the challenges face is preventing contamination in the process
and ultimately in the product. Undetected microorganisms can not only ruin the taste of
beverages, but cause illness as well. Soft drinks include all drinks made from water or mineral
water, sugar, aromas, and essences, and usually contain carbon dioxide. Other beverage products
such as flavored water, sports and energy drinks, and ice tears use a similar manufacturing
process. Because of their PH level, high sugar level, low preservative content and production
processes, these types of drinks are extremely susceptible to yeast and mold development.
Microbial management is critical in order to prevent contamination.

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Soft Drink Processing Steps:

• Sugar Syrup Clarification

The mixture of sugar, flavorings, essences, and water is called syrup. Syrup clarification will
retain particles and crystals from your syrup.
• Water Microbial Stabilization
Water accounts for the largest portion of your beverage and needs to be safe. The pre filtration
phase plays a key role in your process protecting the final filter, ensuring the long life and good
economics of your filter train, and reducing the initial bio burden. Final filtration removes
microorganisms such as bacteria, mold, yeast, and protozoa to achieve the required contaminant
free water quality.
• Carbonation
Carbonation is the step of adding carbon dioxide to a drink. The CO2 that you inject into your
beverage must be free of particles and microorganisms. Non-carbonated drinks do not include
the carbonization step.
• Bottle Blower and Bottle Washer
The air used in the bottle blower to turn the pre-forms into the final bottle must be free of
contaminants. Its filtration ensures a bottle with low bio burden is produced. Bottle blowing can
be done in any beverage process using bottles. Just as the air used in the bottle blower must be
free of contaminants, the water used to rinse the bottles must also be free of contaminants; its
filtration ensures good quality of the bottles prior to filling. A safe and reliable container is
essential to maintain the quality and shelf life of your drink.
• Bottle Filler
Gas filtration can also be used during the filling process of carbonated drinks. In order for the
filling to be possible, the filler bowl must be pressurized and the gas used must be
microbiologically stable.
• Date coder
After filling the bottles, the date coder can printed
Expiration date
Company name
Production time on the surface of the filled bottle with the soft drinks

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 • Packaging

Packaging is the final process used to put final products (filled bottles) in to the washed crates.

There is a sensor which tells whether 96 bottles are came or not. If 96 bottles come

To the machine, the machine lifts up these bottles up and puts in to the four crates.

If not, it waits the bottles until to be 96. Finally, those loaded crates are convoyed to storage.

2.2 Material and Energy Balance of Main Unit

2.2.1 Material Balance
Mirinda production on mixer

Assumptions:

• The operation is at steady state

• No generation

• Accumulation is zero

• At room temperature 1kg is equal to 1L in the mixer machine

• In put=out put

Given:
Density of water=1000kg/m3
Density of syrup=1.2399kg/m3
Volume of required water=184L (0.184m3)

Water = 184kg Syrup = 1200kg

Mixer
Machine

TOTAL MIXED LIQUID=??

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Over all material balance:
Water + Syrup = total liquid
Total liquid = 184Kg + 1200Kg =1384Kg.
Total liquid =1384Kg =1384L=1384000ml.

Finally, this amount (1384000ml) of mixed liquid will be transfer to the filler section. However,
some amount of the liquid part will expect to loss 24 bottles (7200ml) per day so, the exact value
which going to the filler house is 1,376,800ml.

2.2.2 Energy Balance on Boiler

Energy takes many forms, such as heat, kinetic energy, chemical energy, potential energy but
because of inter-conversions it is not always easy to isolate separate constituents of energy
balances. Energy balance is the sum total of any form of energy generated, stored, lost and
absorbed by a system. The basic law of energy balance is “energy cannot be created nor
destroyed it can be converted from one form to other form”. In this project report energy balance
calculation will be done for boiler.

The total energy generated from the fuel in the boiler is used for generating steam. The energy
from the fuel can be lost due to radiation (QR) heat lost through stack gas (Qst) Loss from boiler
surfaces (Qlb), sensible heat in ash (Qsa). Generally, the summation of the heat generated by the
fuel is;

Q =∑Qloss + QSteam 73.8%heat in steam

12.7%dry flue gas loss
8.1%heat loss due to H2 in flue
100% 1.7% heat loss due to moisture in fuel
Fuel 0.3% heat loss due to moisture in air
2.4 heat loss due to unburned residual
1% Heat loss due to radiation

Qloss =QR + Qlb+ Qsa + Qst

Since these heat values are not known accurately we can generally calculate the heat gained by
the steam in the boiler

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Qs = m (Hs –Hf)
Where
Hs= Enthalpy of superheated steam (kJ/kg)
Hf = Enthalpy of feed water (kJ/kg)
m = amount of water

An input of 4000Kg of water in a temperature of50 0C produces steam with temp of 135 0C at a
pressure of 11Mp and the enthalpies are Hs = 10000 and Hf =2000. Therefore, we can calculate
the heat of steam

Qs = 4000 (10000 – 2000)

Qs = 24, 000MJ

Therefore, the total heat carried by the steam is 24, 000MJ

2.3 Main Equipment Sizing of the Company

Liquid CO2 Storage Tank Equipment Sizing

CO2 produced=160Kg/h
Density of liquid CO2=50.32Kg/m3
Material of construction, carbon steel
Shape of tank horizontal cylinder with two cone ends
Now, Find volume of liquid CO2 storage.
Volume of CO2 storage=mass of CO2/density of CO2
Volumes==3.17965m3/hr.
V=3.17965m3/hr.*24hr
V=76.3116057m3/day
Average time to be store for seven day
V=76.311607m3/d*7day
V=534.18124m3
The tank was 90%full
V=534.18124/0.9=593.5347m3

Finished syrup storage tank

Mass of syrup to be stored =1200kg/day (mass=density*volume)

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Density of syrup=1.2399kg/m3
Material of construction, carbon steel
Shape of tank vertical cylindrical
Now volume of storage tank=mass of syrup/density of syrup
V=1200kg/1.2399kg/m3
V=967.82m3/day
Average time to be store is one day
V=967.82m3/day*1day=967.82m3
The tank is 90%full=967.82/0.9

V=1075.356m3

2.4 Environmental Consideration of the Plant

Moha soft drink industry gives a great emphasis for the quality of food safety and environmental
protections. But it has its own disadvantages on the environment. The company takes the
following action to control the food safety and environmental protections.

2.4.1 Haccp Plan

HACCP (Hazard Analysis and Critical Control Points) is a preventive food safety program
designed to control food safety hazards as food flows through a food service operation from
purchasing to serving. Haccp have seven principles, which encompass a systematic approach to
the identification, prevention, and control of food safety hazards include:

1. Conduct a Hazard Analysis: a hazard is defined as a biological, chemical or physical agent that
is reasonably likely to occur, and will cause illness or injury in the absence of its control.

2. Determine Critical Control Points: a critical control points defined as a point, step, or
procedure in a food process at which control can be applied, and, as a result, a food safety hazard
can be prevented, eliminated, or reduced to acceptable levels. Critical control points are locations
in a process at which some aspect of control can be applied to control food safety hazards that
have been determined reasonably likely to occur.

3. Establish Critical Limits: Critical limits (CL) are the parameters that indicate whether the
control measure at the CCP is in or out of control. A critical limit is a maximum or minimum

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value to which a biological, chemical, or physical parameter must be controlled at a CCP to
prevent, eliminate, or reduce to an acceptable level the occurrence of a food safety hazard.

4. Establish Monitoring Procedures: Monitoring is a planned sequence of observations or

measurements to assess whether a CCP is under control and to produce an accurate record for
future use in verification, Every CCP that is in the Haccp plan must be monitored to ensure that
the critical limits are consistently met and that the process is producing safe product.

5. Establish Corrective Actions: The specific corrective actions depend upon the process used
and type of food produced.

The corrective actions consist of:

• Identifying and eliminating the cause of the deviation,
• Ensuring that the CCP is under control after the corrective action is taken,
• Ensuring that measures are established to prevent recurrence, and
• Ensuring that no product affected by the deviation is shipped.
6. Establish Recordkeeping and Documentation Procedures: Records are written evidence
documenting the operation of the Haccp system. All measurements taken at a CCP, and any
corrective actions taken, should be documented and kept on file. These records can be used to
trace the production history of a finished product. If any questions arise about the product, a
review of records may be the only way to determine whether the product was produced in a safe
manner according to the Haccp plan. The Haccp records should:
• Contain the date and time of the activity reflected on the record.
• Contain the signature or initials of the employee making the entry.
7. Establish Verification Procedures: Haccp systems must be systematically verified. Verification
ensures that the Haccp plan is being implemented as written. Verification confirms the accurate
monitoring of the critical control points. The verification procedures demonstrate that the Haccp
system is adequately controlling food safety hazards. After initial validation the system must be
verified periodically. Periodic verification involves the use of methods, procedures, or tests in
addition to those used for monitoring, to determine whether the Haccp system is in compliance
with the Haccp plan, or whether the Haccp plan needs modification and revalidation to achieve
its food safety objective. Establishments must also be able to provide supporting documentation
for verification procedures and frequencies specified the Haccp plan.

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8. Wastewater: the waste water of Moha soft drink industry has no effect in environment,
because it has a waste water treatment process and it can be used to plants and other agricultural
activities.

2.4.2 Negative Impact of the Company

Moha soft drink uses fuels for the production of CO 2 and steam boiler. Therefore, this fuel
contains different dangerous gases such as, NO 2, NO, CO, CO2.then those gases can be removed
to atmosphere during the production process. This can cause for different problems such as:
health problem (cancer, bronquite), acidic rain, global warming, and air pollution.

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INTERNSHIP PROJECT

3 Production of Activated Carbon from Corncob

3.1 Short Summary

In this project work the raw materials required for the preparation of activated carbon were
procured from locally available source called corn cob to reduce the cost of activated carbon
which imports from abroad (Denmark). A tubular pyrolyzer was fabricated for the purpose of
carbonization. Activated carbon was prepared from dry corn cobs using chemical activation
followed by carbonization in a high temperature tubular pyrolyzer in an inert atmosphere .
The corn cob products were impregnated with potassium hydroxide (KOH). The chemically
treated corn cob was then proceeding to the activation process at various activation temperatures
under the use of CO2 as an oxidizing agent.
The experiment was conducted in order to know the effect of different levels of different factors.
The factors were concentration of activating agent, pyrolysis temperature and activation
temperature. Having conducted the optimization experiments of the stated parameters we finally
found our optimized parameter’s result was activated carbon. Then after we produced activated
carbon from corn cob, which is commercially important to Moha soft drinks industry.

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 3.2 Introduction

Activated carbon is an excellent adsorbent and thus is used to purify, decolorize, deodorize,

Detoxicate, filter or remove the salts and mineral contents. They are used as catalyst or catalyst
supports. The adsorbent properties of activated carbon are essentially attributed to their large
surface area, a high degree of surface reactivity, universal adsorption effect and favorable pore
size. These unique characteristics are dependent on the type of raw material employed and
method of activation. Basically, there are two methods of activations; Physical and chemical
activations. Activated carbon can be made from many substances containing high carbon content
such as coconut shells, walnut shells, coal, wood, bagasse etc. In the present work corn cobs
were used to prepare activated carbon. Corn Cobs is suitable for preparing micro porous
activated carbon due to its excellent natural structure and low ash content. Preparation of
Activated carbon was done by Carbonization followed by activation.

Moha soft drink industry uses activated carbon for different purpose such as water treatment,
CO2 production, and syrup preparation. This can be imported from abroad country.

Our project investigates the production of activated carbon, which is environmentally friendly
adsorbent which known as corn cob. The goal of the project is to detail a mass balance on the
production of activated carbon and compare the effects of chemical reagents and process
variables on this production process.

3.3 Statement of the Problem

Moha soft drinks industry uses activated carbon for different purposes like, water treatment,
carbon dioxide production and for syrup preparation. But this activated carbon is an expensive
product that the company uses to buy from abroad (Denmark). Moha soft drink uses 7455 Kg per
year by purchased 89.67 birr for one kilogram. So this reduces the profit of Moha soft drink
industry due to the money of the foreign currency exchanges. Therefore, this project was
intended to solve the problem by producing activated carbon using the locally available raw
material corn cob.

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3.4 Objectives

3.4.1 General Objective

The aim of this project was to produce activated carbon from locallyavailable agricultural by
product corn cob through chemical activation.

3.4.2 Specific Objectives

The Specific objectives of this project work were:

 To characterize the byproduct corn cob (moisture, ash and carbon content).

 To determine the effect of activating temperature on the production of activated carbon

 To determine the effect of concentration of activating agent (KOH) on the quality of

activated carbon.
 Study the effect of the initial metal ion concentration for maximum removal of metal
ions, using adsorbents.

3.5 Scope of the Project

In this project, corn cob was used as raw material in preparation of activated carbon using
chemical activation method. The adsorbent corn cob Seeds chosen for the present study is
available plenty in all regions of Ethiopia.

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3.6 Literature Review

Activated carbon has been proven to be an effective adsorbent for the removal of a variety of
pollutants, such as heavy metals and dyes from aqueous solutions. It is extensively used for
adsorption, due to its high surface area (ranges from 500 to 1500 m2/g), well-developed internal
micro porosity, and wide spectrum of surface functional groups. However, research on the
surface modification of activated carbon is significant, due to the lack of a functional group in
activated carbon, and to improve affinity towards certain contaminants, to facilitate their removal
from water. It is essential to understand the factors that influence the adsorption of activated
carbon prior to their modification, in order to tailor their specific physical and chemical
properties, and enhance their affinity for the metals and dye species present in waste water.
These properties include the specific surface area, pore-size distribution, pore volume, and the
presence of different types of surface functional groups.

The recent years, there is a growing research interest in the production of activated carbons and
surface modified activated carbons from renewable and cheaper precursors which are mainly
industrial, and plant materials and agricultural by-products, especially used in applications
concerning wastewater treatment. The use of Activated Carbon (AC) has a long history dating
back to ancient times.

The Egyptians used charcoal for reduction of ores in the manufacture of bronze and for
medicinal applications as early as 3750 BC (Inglezakis and Poulopoulos).

On the other hand, the Hindu documents dating from 450 BC show the use of sand and charcoal
filters for the purification of drinking water. Activated carbon in form of char is also reported in
keeping drinking water fresh in recent studies of the wrecks of Phoenician trading ships
(University of Kentucky). In the time of Hippocrates (ca. 460 - 370 BC) and Pliny the Elder (AD
23 - 79) wood chairs were employed for medicinal purposes. During the time of Columbus (15 th
century) sailors put drinking water in wooden barrels that were blackened in the insides with fire
to keep the water fresh.

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The specific adsorptive properties of charcoal were first observed by Scheele in 1773 in the
treatment of gases. However, it was Lowitz in 1786 that provided the first systematic account of
the adsorptive power of charcoal in the liquid phase. The charcoal was used for decolorizing raw
sugar syrups in sugar refining industry. The use of activated carbon in form of charcoal for
decolorization in sugar refineries was later patented in England in 1812 (Inglezakis and
Poulopoulos). It was later realized that bone char had an even higher decolorizing ability, hence
a switch took place from wood charcoal to bone char in the sugar industry in 1817.

Later in Agricultural Waste as Raw Materials for the Production of Activated Carbon the
nineteenth century, systematic studies were carried out on the manufacture and regeneration of
bone chars by Schatten in Germany and the application of charcoal air filters for removing
vapors and gases in London sewers by Stannous(University of Kentucky).

Activated carbon was first produced on an industrial scale at the beginning of the twentieth
century, and major developments then took place in Europe. The Swedish chemist von Ostreijko
obtained two patents, in 1900 and 1901, covering the basic concepts of chemical and physical
activation of carbon with metal chlorides and carbon dioxide and steam, respectively. In 1909, a
plant named ‘Chemische Werke’ was built to manufacture, for the first time on a commercial
scale, the powdered activated carbon Eponits and Norits (Dabrowski). There were similar
developments in the United States at the same time. The first activated carbon was produced
from black ash, a waste product of soda production, for decolorizing liquids (Hassler). The first
commercial production of activated carbon in the United States took place in 1913.

At present, activated carbon finds wide application in many areas. It is used especially in
environmental pollution control as well as in industry for various liquid and gas phase
adsorptions. Among liquid phase applications, one can list food processing, preparation of
alcoholic beverages, decolorization of oils and fats, product purification in sugar refining,
purification of chemicals (acids, amines, glycerin, glycol, etc.), enzyme purification,
decaffeination of coffee, gold recovery, refining of liquid fuels, purification in electroplating
operations, purification in the clothing, textile, personal care, cosmetics, and pharmaceutical
industries, applications in the chemical and petrochemical industries. Gas phase applications
include; recovery of organic solvents, removal of Sulphur-containing toxic components from

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exhaust gases, biogas purification, and use in gas masks, among others. Activated carbon is also
used in medical and veterinary applications, soil improvement, removal of pesticide residues,
and nuclear and vacuum technology.

Agricultural waste and by-products can be used for the production of AC with a high adsorption
capacity, considerable mechanical strength, and low ash content.

A literature survey reveals a huge amount of information on the potential of agricultural wastes
as raw materials for the production of commercial activated carbon. Various types of agricultural
wastes and by-products have been studied depending on their local availability. So Chemical
Department at the University of Mekelle has stayed for about 4 months explored ways of
developing activated carbons from local agricultural wastes corn cob.

Literature shows a 43.5% carbon content in corncob feedstock, which makes it a promising
precursor for the production of nonporous carbon. The corncobs also contain 48.4% oxygen,
7.9% Hydrogen, and 0.21% Nitrogen. If it is assumed that half the oxygen leaves as water and
the other half as carbon dioxide, a theoretical yield of 43.5% should be obtainable from pyrolysis
of the corn cobs. Activated carbon is produced from corn cob mainly by two methods those are
physical and chemical activations. This literature is in terms of cost effectiveness and its
activation methods. The chemical activation was selected for this project work.

In the literature survey all process conditions and technological alternative are surveyed to
develop the project.

3.6.1 Chemical Activation

In chemical activation the precursor is impregnated with a given chemical agent and pyrolyzed
thereafter. As a result of the pyrolysis process, a much richer carbon content material with a
much more ordered structure is produced, and once the chemical agent is removed after the heat
treatment, the porosity is highly developed. Chemical activation offers several advantages since
it is carried out in a single step, combining carbonization and activation, performed at lower
temperatures and therefore resulting in the development of better porous structure. Several
activating agents have been reported for the chemical activation process. However, the

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commonly used ones are phosphoric acid, zinc chloride, potassium hydroxide, potassium
carbonate and ammonium chloride. For instance, phosphoric acid was used for the preparation of
activated carbons from peanut hulls, corn cobs,Almond shells and pecan shells. The activation
conditions were variable in terms of temperature and activation time.

In particular, corn cob that was activated with KOH at 500 - 800oC for 1 h, did not generally
give AC with good internal surface areas.

Potassium carbonate was also used in the activation process of corn cob at 500 - 800oC for 1 h.
However, the surface areas of the resulting ACs were generally less than those reported for KOH
activated carbons.

Chemical modification of the surface of activated carbon is possible through reaction with an
acid and base. Based on this fact, the method is further classified into two major categories, such
as, acidic surface modification and basic surface modification.

3.6.1.1 Chemical modification using acids and bases

Acid treatment of activated carbon is one of the important methods used for surface
modification. The preferred acids used for the purpose are sulfuric acid and nitric acid.
Treatment with an acid or base removes the mineral elements and enhances the acidic property
and hydrophilicity of the surface. Adsorption of Cr (VI) onto surface modified coconut-based
activated carbon using nitric acid and sodium hydroxide was studied.

Nitric acid / sulfuric acid treated activated carbon shows increased adsorption over its original
activated carbon. That the increase in the adsorption capacity of activated carbon for the removal
of copper and nickel metal ions were due to the surface modification using sodium hydroxide
treatment.

3.6.1.2 Chemical modification by oxidation treatment

Oxidation treatment increases the concentration of acidic oxygen groups on the surface of
activated carbon, thereby increasing the polarity and decreasing the pH to the point of zero
charge. The adsorption of heavy metal ions on to the oxidized activated carbon surface was,

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therefore, enhanced by electrostatic interactions between the negatively charged activated carbon
surface and the positively charged metal species in solution. Moreover, acidic oxygen groups can
behave as ion exchange centers, retain metallic species, release protons into aqueous solutions
and give rise to the formation of metal ligand surface severe oxidation conditions might even
lead to complete destruction of the carbon texture. The studies generally report that ozonation
drastically increases the number and type of acidic oxygen-containing surface groups.

3.6.1.3 Chemical modification by sulfurization

The process of sulfurization may be carried out in a single or successive stage in the
atmosphere, using various sulfurizing agents such as sulfur, sulfur dioxide, carbon di sulfide, and
hydrogen sulfide and disodium sulfide. By maintaining the sulfurizing agent in contact with
activated carbon for a particular time at room temperature or higher temperature, sulfur surface
complexes are produced. The surface sulfur deposits or weakly retained sulfur on activated
carbon is removed by washing. The surface modification of activated carbon using sulfurization
by various methods and the resultant adsorbent has been tested for a large numbers of metal ions
such as Hg(II), Cd(II), Pb(II), Cu(II), Zn(II), and Cr(VI)), in aqueous solutions. These heavy
metal ions usually have a high affinity for sulfur, demonstrated by their natural occurrence as
metal sulfide. This has a strong environmental impact due to its numerous industrial applications
and high toxicity. Thus, the sulfurization treatment of activated carbon has an important
beneficial effect on metal species adsorption. The activated carbon prepared by sulfurization
method has a marked influence on the heavy metal adsorption process.

3.6.1.4 Surface impregnation

Surface impregnation is another important method of chemical modification. Recent research

works report that the impregnation of activated carbon with transition metals, which show
enhanced adsorption capacity towards heavy metal adsorption from aqueous solutions.The
surface impregnation method may be successfully carried out with commercial activated carbon
using microwave heating. The surface impregnated activated carbon using iron has been
successfully used for the removal of arsenic from aqueous solution.

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 3.6.1.5 Corncob

Corncob can be obtained as a cost free agricultural waste in large quantities. It has been utilized
to prepare activated carbon, which is useful in heavy metal ion removal. Khan and Wahab
demonstrated the adsorption of copper ions by concentrated sulfuric acid treated corncobs. It was
reported that the treating of corncobs with sulfuric acid and heating at 150 oC, shows marked
enhancement in adsorption towards copper metal ions. Murugesan studied the effective removal
of Cr (VI) ions from aqueous solution using Sulphuric acid treated corncob. The study of the
oxidation of corncobs by citric acid and nitric acid was carried out by Leyva Ramos. It was also
reported that the adsorption capacities of citric acid and nitric acid oxidized corncobs was higher
than those of unmodified corncobs. In this project work we produced an efficient adsorbent
matter corn cob.

3.6.2 Physical Activation

The physical methods are typically thermal processes conducted at temperatures below 700 oC
using oxidizing gases like air, CO 2 and steam of H2O as second step after pyrolysis. This process
is used to create a porous structure that increases the adsorption capacity of AC materials. The
porous AC is produced when the oxidant converts carbon materials to form CO and CO 2 opening
pores in AC materials.

Physical activation method involves carbonization of the raw material at elevated temperature
(500–900 °C) in an inert atmosphere, followed by activation at high temperature (800–1000°C)
in a CO2 or steam atmosphere.

A. Carbonization; is the process for the conversion of an organic substance into carbon or a
carbon containing residue through pyrolysis or destructive distillation.

B. Activation; is a carefully controlled oxidation process to develop a porous carbon structure.

Here the production of activated carbon from corn using physical activation is as follows.

3.6.3 Classification of Activated Carbons

Activated carobs are classified according to its particle sizes and shape in to powder, granular.
A. Powdered activated carbon (PAC)

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The size of powder activated carbon is less than 100µm in size with an average diameter
between 15 and 25 µm. Thus, they present a large internal surface with a small diffusion
distance. PAC is made up of crushed or ground carbon particles, 95–100% of which will pass
through a designated mesh sieve or sieve. Powdered activated carbons are mainly used in liquid
phase adsorption and flue gas treatment. In wastewater treatment, the most common used of
powdered activated carbon is in the secondary treatment called powdered activated carbon
treatment process.

B. Granular activated carbon (GAC)

Granular activated carbon has a relatively larger particle size compared to powdered activated
carbon and consequently, presents a smaller external surface. Diffusion of the adsorbate is thus
an important factor. These carbons are therefore preferred for all adsorption of gases and vapors
as their rate of diffusion are faster. Granulated carbons are used for water treatment,
deodorization and separation of components of flow system.

3.6.4 Applications of Activated Carbon

Activated carbon is used in gas purification, gold purification, metal extraction, water
purification, medicine, sewage treatment, air filters in gas masks and respirators, filters in
compressed air and many other applications. Some of the applications include.

• Water Purification

• Environmental field

• Metal finishing field

• Alcohol and Soft Drink Purification

3.6.4.1 Water Purification

Activated carbon water filters have been used in home water purification systems primarily to
remove taste and odor. Taste and odor, although undesirable, are generally not considered
unhealthy. In recent years, however, activated carbon filters have been used to remove some of
the contaminants that have been discovered in water supplies. Activated carbon is most effective
at removing organic compounds such as volatile organic compounds, pesticides and benzene. It
can also remove some metals, chlorine and radon.

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 3.6.4.2 Environmental field

Here, activated carbon adsorption has numerous applications in removing pollutants from air or
water streams both in the field and in industrial processes such as spill cleanup, groundwater
remediation, drinking water filtration, air purification, volatile organic compounds capture from
painting, dry cleaning, gasoline dispensing operations, and other processes.

3.6.4.3 Metal finishing field

This is one major industrial application of activated carbon in the metal finishing field. It is very
widely employed for purification of electroplating solutions. For example, it is a main
purification technique for removing organic impurities from bright nickel plating solutions. A
variety of organic chemicals are added to plating solutions for improving their deposit qualities
and for enhancing properties like brightness, smoothness, ductility, etc. Due to passage of direct
current and electrolytic reactions of anodic oxidation and cathode reduction, organic additives
generate unwanted break down products in solution.

3.6.4.4 Alcohol and Soft Drink Purification

Activated carbon filters can be used to remove organic impurities from alcohols (vodka and
whiskey) that affect color, taste, and odor increasing its purity. Some other common uses
included corn and cane sugar refining, dry cleaning recovery processes, fat and oil removal,
catalyst support, battery electrodes and super-capacitors.

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 3.7 Materials and Methods

Table 3. 1:Raw materials and equipment’s for preparation of AC

Raw materials Chemical used Equipment used

Corncob 25ZnCl2 Muffle furnace

50ml KOH Electrical dry oven

25ml KOH Stop watch

40ml methyl orange Thermocouple

Nitrogen cylinder

Contactor etc.

The following steps were carried out for the preparation of activated carbon from corncobs.

3.7.1 Methods

1.Procurement of raw material: The corn cobs were collected from a nearby local vendors
shop and canteens from environment and washing of the collected corncobs.

2. Drying: The corn cobs were spread under the sunlight to remove the moisture content and it
was allowed for 1 day to dry and kept in oven for 2 hours for complete removal of moisture.

3. Crushing &size determination: The corn cobs were crushed into small pieces for a particular
size range of less than 1 mm. Crushing was done by using hammer followed by mixer. Sieve
analysis was done with the cleaned, dried and powdered sample. The apparatus was set
according to the mesh number and then the samples were placed in a shaker for about 30
minutes.

4.Treatment with zinc chloride: The reduced product of desired size was treated with zinc
chloride for chemical activation. The concentration of zinc chloride used was 50%. The corn cob
sample was treated with zinc chloride solution and it was mixed for about half an hour in a
mechanical shaker. The sample was filtered and dried.

5.Fabrication of reactor: materials and equipment’s used:

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 • Mullite tube of 1 meter length

• Nichrome wire of 2 cm in diameter

• Ceramic cement

• Ceramic wool blanket

• Rubber cork

• Thermocouple

• Ceramic beads

• DTC

• Bubbler

• Nitrogen cylinder

• Contactor (on off controller)

• Aluminum box

Mullite was marked and divides in to different regions. The center was marked as heating zone
where the ample were kept

The length of heating zone 4 rounds of wires was done to provide even distribution of heating for
the sample kept. Ceramic cement was applied around the winding of wires so that it does not
move and touch each other. It was allowed to dry for 1 hour. Ceramic wool blanket was wrapped
up around the heating zone. A tubular pyrolyzer with electrical connection was stipulated.

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 3.7.2 Chemical Activation Method

Carbonization: Material having appreciable carbon content is pyrolyzed at temperature ranging

between 550–750°C, in the absence of oxygen (usually in inert atmosphere with gases like argon
or nitrogen).

Activation/Oxidation: in this process raw material or carbonized material is exposed to oxidizing

atmospheres (carbon monoxide, oxygen, or steam) at temperatures above 250°C, usually in the
temperature range of 600–800°C. : Before carbonization, the raw material can be impregnated
with certain chemicals. The chemical needs to be typically an acid, strong base, or a salt
(phosphoric acid, potassium hydroxide, sodium hydroxide, zinc chloride, respectively). After
impregnation, the raw material needs to be carbonized at lower temperatures (450–900°C). It is
believed that the carbonization / activation step proceeds simultaneously with the chemical
activation. Chemical activation is preferred over physical activation owing to the lower
temperatures and shorter time needed for activating material.

Finally: 7 kg of corn cob was cut into fragments manually and inserted to electrical dry oven for
moisture removal then balancing and drying constant mass of 3.251 kg was found. leaving
1.94kg for ash determination the 1kg dry corn cob was inserted to muffle furnace for carbonation
at carbonation temperatures of 550 and 750 degrees centigrade for a time of two hours both then
it was soaked in to 50%KOH and 25%KOH solution separately at activating temperature of 600
and 800 degrees centigrade at same activating time of one hour and washed using soft water to
remove impurities. finally, 1g activated carbon was inserted in to test solution (methyl orange)
for 10 minutes in suction filter and the mass of the activated carbon was weighted after uptake
the increase in mass of activated carbon show its adsorbing capacity.

a) Carbonization of corncobs b) tableting of corncobs

figure3. 1: Corncob production

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 3.8 Results and Discussion
3.8.1 Precursor Characterization
Table 3.2 and table 3.3present the proximate and elemental compositional analysis of the raw
corncobs (CC) and their ashes.Carbon content of a precursor is one of the most important indices
for choosing a precursor for activated carbon production (Shaw and Avery, 1993).And as can be
seen from the Table3.2, the local variety of corncobs was found to have high potentials for
activated carbon production due to its high carbohydrate (87.27%) and low ash (2.87%) content.
However, table 3.3, the inorganic elemental analysis of the precursors showed metallic oxides
(K, Na and Al) that are stable and have no tendency for changing the adsorption process from
physical to chemical at room temperature.

Table 3.2: Proximate analysis of the raw corncobs and its ashes

Sample ID Proximate analysis, %Wt.

Carbohydrate protein ash Moisture

CC 87.27 2.69 5.685 5.025

Table 3. 3:Elemental composition produced corncob activated carbons (AC)

sample Elemental analysis

SIO2 K Na Al LIO

CC 2.41 1.33 1.04 0.50 94.82

CCA 28.76 28.17 6.23 1.57 23.98

Figure 3.2 shows the profile of the raw corncobs between 0 - 1000 0C temperature ranges. It can
be seen from the figure that there was an initial weight loss at temperatures below 200 0C, which
could be from evaporation of the moisture originally contained in the precursor. Weight loss
occurring above this temperature is considered to be due to vaporization of volatile organic
compounds (as reported by Kim et al., 2001). The major portion of the volatile matter of the

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organic precursors was volatized temperature range of 270-400 0C. That was the basis for
carbonizing at 3000C in order to trap more organic volatiles and subsequent KOH activation.

Weight of precursor, %
120
100
80
Vicoma
60
Corn cob
40
20
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 T0C
figure3. 2: profile of raw corncob and Vicoma
The sources of the tables are found from the average analysis using a Thermo Scientific Model
ICE 3500 Atomic Absorption Spectrometer (AAS) equipped with hollow cathode lamp. And
B.H. Diya’uddeen, I.A. Mohammed, A.S. Ahmed, and B.Y. Jibril, “Production of Activated
Carbon from Corncobs and its Utilization in Crude Oil Spillage Clean Up”. Agricultural
Engineering International: the CIGR Ejournal. Manuscript EE 08 004. Vol.X. April, 2008
contain tables.

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Characterization of the prepared activated carbon was done various analyses such as iodine
number, methylene blue test, ash content BET test, adsorption test. There were three samples
what we were preparing activated carbon from corn cob. Sample 1, sample 2. And sample 3.
Sample 1 was prepared at 8000c and sample 2 and sample 3 was prepared at 6500c.

1. Yield: Sample 1 had yield of 13.03 %, whereas the yield of Sample 2 and Sample 3 was
25.07% and 26.5% respectively. Even though the yield of Sample 1 was low, the adsorbent
properties of Sample 1 were greater, and can be inferred from the following results.

2. Iodine number: Sample 1 had an iodine number of 950 mg/g, which was the closest to the
iodine number of the commercially available activated carbon which is 1050 mg/g. Sample 2 and
Sample 3 which had iodine numbers of 837 and 880 mg/g respectively.

3. Ash content: Sample 1 had an ash content of 2.2% whereas Sample 2 and Sample 3 had ash
content of 2.7% and 2.5 % respectively. Ash content of the commercially available activated
carbon is less than 1%. Any raw material whose is content is less than 7% is considered to be
good for the manufacture of Activated Carbon

4. Methylene blue test: Sample 1 had a decolorizing power of 150, as compared to 225 of the
commercially available activated carbon. Sample 2 and Sample 3 had decolorizing power of 125
and 139 respectively.

5. Adsorption test: The procedure carried out indicated that the prepared activated carbon is a
moderate adsorbate.

6. BET (Brunauer-Emmett-Teller): surface area analysis: ASAP2020 (accelerated surface

area and porosimetry) analyzer was used for this test.

The surface area of the prepared activated Carbon was found to be 750m2/g for sample 1
whereas the commercially available activated carbon has a surface area of 900-1020 m2/g.
Sample 2 and Sample 3 had surface area of 646m2/g and 680m2/g respectively.

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3.9 Process Equipment Sizing
Product activated carbon Storage Tank consists of:

Mass of AC to be stored =2500kg/day

Density of AC=2.2kg/m3

Material of construction, carbon steel

Shape of tank vertical cylindrical

Now volume of product tank=mass of AC/density of AC

V=2500kg/day/2.2kg/m3

V=1136.36m3/day

Average time to be store is three days

V=1136.35m3/day*3day=3409.09

If the tank was 95% full=3409.09/0.95

V=3588.52m3

3.9.1 Cost Analysis

Costs were developed assuming a 14 percent yield corncob-based activated carbon assume in
moha factory 320 days per year of production and two shiftsfor 24 hours a day purchases 89.67
birr per kg of activated carbon. Production of 7455 kg/year of activated carbon requires a capital
investment accounts 668,489.85 birr per year. Considering the electric energy consumption high
quality, high surface area, and granular activated carbons made from physical activation of
corncob sells for 78.30 birr/kg and less, depending on their particular use. If the corncob-based
activated carbons are used effectively in a particular niche market, they could sell for 78.00 to
82.00 birr/kg. In this case, the difference in product manufacturing cost and product sales cost
could be sufficient to realize a profit for the manufacturer. So the locally produced agricultural bi
product corncob is profitable than activated carbon which comes from aboard.

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3.10 Conclusion and Recommendation for the Project
3.10.1Conclusion
Activatedcarbon from corn cobs were produced at various conditions and successfully employed
in the removal of minerals from water surface.Activated carbon is prepared by different methods
both physical and chemical activation as well as combination of both physical and chemical
activation. The drawback of physical activation is that the yields are relatively poor while also
required higher temperature for the activation process. A number of literatures are available for
the chemical activation process using the different chemical activating agent. Chemical
activation gives higher yields of carbon as well as larger pore size in the carbon is created.
Mesopores is normally desired in treatment of effluents. As the activated carbon produced is
highly dependent on the raw materials used as well as the activation procedure, this project try to
optimize parameters for the activation process.It can be concluded that the optimum activation
temperature was 7000c and the temperature has no definite effect on both the apparent and solid
densities of the corn cob activated carbons.

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 3.10.2Recommendations

In this project work corncob was selected as raw material to prepare activated carbon due to its
low content of ash and excellent natural structure. The overall study shows that the waste corn
cob can be a promising material for the preparation of activated carbon with large adsorption
ability. But waste corn cobs are expensive and cannot be done at a profit with the current
circumstances.so using elements such as bagasse, coconut shells, walnut shells,coal and so on
were also possible to prepare activated carbon.

 It is recommended that the future work involving the comparative economic analysis on the
use of activated corn cob with commercial spillage adsorbents should be carried out.
 Testing on the other crop residues and analysis of the volatile organic compounds should
be studied.

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4 Over all Benefit from the Internship
Internship program is a method of letting the students to assume themselves as potentially
responsible workman for a particular work by assigning them to actively participating in
production control as well as maintenance in industrial company.

This internship program is very essential program because the students develop their skill
practically and share different idea with their community. It also gives us the way to decide their
future job and company. The benefits that we gained are listed below.

4.1 In Terms of Improving Theoretical Knowledge

This internship program provided us building our intellectual knowledge and practical skills. The
works we did mostly related to most courses that we have taken in the class room, especially
mechanical unit operation, process dynamics and control, chemical design etc. during class time,
before the internship, we mainly discussed those subjects. During internship time, theoretical
benefits that we have gained from the company are;

• Production and formation of soft drinks, CO2

• Kind of raw material to form soft drinks.

• How to design the machines used to process?

• How to recycle and treatment waste materials

The internship takes a great roll in terms of up grading theoretical knowledge. It helps us to gain
more theoretical knowledge related to the real world.

4.2 In Terms of Improving Practical Skill

The several courses that we were taken in the class dealt with the theoretical side of engineering.
Some lectures took the initiative and try to illustrate the practical part of this field by displaying
graphic images in their lecture. That was more or less illustrative or even took us to the company
to show what the actual engineering looks like. Generally, this internship program helps to
matching theoretical that we had taken before with in actual work/practical and we responsible to
handle the following piece of works in the company during fourth month duration. Filler
machine maintenance engaged and disengages system.

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 • 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

• Trouble shooting 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 Capacity

We use to judge our self how we properly obeyed, followed the rules & regulations, and as well
as the work ethics of the organization.

The other is considering how we correctly effective & efficient in relating those problems
observed in the industry to my knowledge’s.

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 co-operate with others

• Share ideas with colleagues to openly and willingly

• Give comment the team

• Demonstrate reliability

• Treat others in respectful and supportive manner

• Increase the ability of active participant

• Become a problem solver on time

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 4.5 In Terms of Improving Leadership Skill

There is no much place of responsibility given to us to lead any task, so that we have not got full
benefit from leadership skills during our start at the company. But from the observation of the
leader of the company leading the workers, we understood from the internship to give relevant
and important solutions to the problems. In terms of improving leadership skills, we offered the
following:

 To plan, prepare and schedule all necessary materials

 To become more reasons because in action
 To know my selves and to make self-important
 To become accurate and more skill on my judgment
 To give technical sup
 To increase my work status

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 whom 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 particular situation.

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 processbut also any form of activity
that has certain land product to it. During 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

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 • Listening skills, morals and ethics

• Risk taking and time management.

4.8 In Terms of Improving Interpersonal Communication Skill

Inter-personal communication is communication scholar in which numerous ways, always

describing participants who are dependent upon one another and have the shared history. It can
involve one on one conversations or individuals interacting with many people within a society.

Since the aim of the company is to accomplish the work in good way, we need to have good
communicative skills. During our internship, we have improved my communication skill by
communicating starting from daily labor to project manager learning different type of production
terms.

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 5 Conclusion and Recommendations
5.1 Conclusion

Moha soft drink industry Mekelle plant is legally producing a safe and quality beverage products
(Mirinda orange, Mirinda apple, Mirinda tonic, 7-up & Pepsi Cola) and services that continue to
satisfy the growing needs and requirements of the customers. Product safety and quality is the
responsibility of everyone in the plant and they are totally committed to meet food safety and
product quality requirements and continue to improve at all levels and within all function of the
plant to ensure production of safe products and customer satisfaction. The plant produces five
products with well-organized and a good quality standard. Products are distributed to the
consumer within short period of time after production due to the high demand and extensive
customer base. As part of its quality control, products are checked by the executive
organizational office members randomly at an unspecified time. The company also works for an
extended time to increase its production volume and meet product demand. Generally, the
internship program was very necessary and important to apply the theoretical knowledge to the
practical skills and to develop communication, team spirit and managerial skill.

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 5.2 Recommendations
It is recommended to Moha soft drink Industry that according to observation during stays of four
months on Moha soft drinks industry;

It is observed that there is a problem in waste water plant. Part of the sensors reading like PH
sensor does not match the operation of the plant and the sensors are in failure due to lack of
maintenance and well trained chemical engineer.

Wasting pure water that is drained from the reverse osmosis through the concentrate flush to the
wastewater treatment plant, that water was purified water which passes through all the treatment
processes operations of water treatment. This can be used as washing such goods.

 It was observed;
 Some amount of carbon dioxide is released to the atmosphere; this must be optimized and
increased efficiently by using modified absorber and scrubbers to improve the profit of
the company and to prevent environmental impacts.
 In most under developed countries particularly in this country Ethiopia industrial wastes
are not considered as useful. Even if industrial wastes are wastes, they are friendly used
for the production of valuable products (fertilizer, ceramic and biogas). So it is better to
use and recycle rather than discharge of the wastes.

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References
1. Ahmedna, M., M.M. .Johns, S.J. Clark, W.E. Marshall, and M.M. Rao. 1997. Potential of
agricultural by-product based activated carbon for use in raw sugar decolorization. Journal of
Science, Food and Agriculture, 75: 117-124.
2. Ahmedna, M., Marshall, W.E., Rao, R.M., 2000(a). Production of granular activated carbons
from select agricultural by-products and evaluation of their physical, chemical, and
adsorption properties. Bio resource Technol. 71, 113-123.
3. B.H. Diya’uddeen, I.A. Mohammed, A.S. Ahmed, and B.Y. Jibril, April, (2008) “Production
of activated Carbon from Corncobs and its Utilization in Crude Oil Spillage Clean Up”.
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Appendices

Definition of terms

Activation_ is a carefully controlled oxidation process to develop a porous carbon structure.

Carbonization_ is the process for the conversion of an organic substance into carbon or a carbon
containing residue through pyrolysis.

Concentrate - the basic raw material of Pepsi cola called as beverage base-imported from Pepsi
international.

Degree brix - measure of the amount of solid in final or simple syrup

Final syrup – mixture of water, sugar, and beverage base.

Pyrolysis _chemical change brought about by the action heat.

Simple Syrup– mixture of water and sugar.

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