The internship program that I’m currently taking is the best opportunity to uncover the industry world

which has involved many chemical engineering applications. Normally, the program was assigned by the
university for about 4 months starting from October but the company wasn’t organized. Consequently,
we haven’t done anything in the whole month. One reason was, they were going to do an international
audit with peoples that the international Pepsi company has sent. and the other reason was the revision
of schedules irregularly just because they have accepted too many students. but, as soon as the month
ended, we started the program regularly for two days in a week. Even if, that’s not enough I am trying
my best to know and explore better. In some cases, I was able to observe and understand some of the
unit operations and process in the industry but not been able to explore what actually Is going on the
process. So, I googled and searched different sources to add an understanding about the activities
additional to the lectures given to me during the weekly sessions. I’m going to provide the activities I
have observed and understood as follows:

Thursday, Nov 21,2019- DAY 1: Waste water treatment plant: In this plant, the different wastes
collected from different streams (water treatment room, syrup room, utilities such as boiler, chiller, co2
plant, production area such as crate washer, sanitation, packer unpacker, and cafeteria) and areas are
treated physically, chemically and Biologically to make the waste useable by the society, the industry
itself and other beings. it’s a bioreactor type which involves culturing of bacteria to make the waste
safer. The waste water treatment plant has manly got three classifications:

1. Primary treatment 2. Secondary treatment 3. tertiary treatment

The primary treatment which consists of the temporarily holding tank that holds the sewage in a basin
where heavy solids can settle to the bottom and lighter one’s float. The settled and floating bodies are
removed and the liquid only will be discharged for the secondary treatment. Basic functions of the
primary treatment:

1.removal of solid waste- where bees, flies and coaches are removed.

2.pre-equalization- the waste water has a pH of (8-14) due to the chemicals used in sanitation and crate
and bottle wash by NaOH and other chemicals. So, it has to decrease up to 11 by using a strong Sulfuric
acid (98% conc.).

The secondary treatment is designed to substantially degrade the biological content of the waste water
through an aerobic biological process.in this stage a motor is used to avoid two problems:

1.avoid high flow coming from primary treatment

2.avoid scale which will clog the pipes and cause corrosion and the waste being brought to series of
operational reactors and separators that involve chemical and biological activities. The waste water then
collected and separated in the plate separator -1 and treated with the chemical poly electrolyte(a
chemical used to flocculate the waste) and passed to the bio- reactor-1 to be treated with the cultured
bacteria’s leaving in an ECO BIO BLOCKS to feed up on the bacteria’s found in the waste water then
passed to bioreactor-2 for the same but better purification purpose goes to plate separator-2 with poly
aluminum chloride added to it. The tertiary treatment is use full in raising the quality of the water to
domestic and industrial standards or to specific requirements set by EPA and PEPSI Co int. by adding a
hypochlorite and decreasing the PH to 7.

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Thursday,28 November, 2019-DAY 2: Carbon-dioxide production plant: The fuel oil gets filtered and
changed to gaseous form after burning it at(100-160°C) then proceed to flue gas scrubber and get mixed
with soda-ash to lose sulfur in any form. The gaseous product will proceed to exhauster fan to be
pushed towards the absorber and the absorber by using MEA (mono ethanolamine) absorbs the CO2
and the remaining gases like So2, S, N, C O are removed. The MEA carrying the CO2 will be separated in
the stripper and cooled using a gas cooler and passes through the water separator to lose some
moisture and pass to the PPM (potassium per manganate) scrubber for further purification.

Because the gas has lost its speed due to the long distance it has came it will be pressurized and
energized by a compressor and cooled because it may get heat passing through all this and it will
proceed to Dominik hunter to let the gas pass and to don’t let the impurities before going into the
dehydrators to remove moistures.

Finally, the last purification is done using an activated carbon to stabilize most physical properties then
condensation and refrigeration process takes place using FREON gas to cool the CO2 gas up to -30°C and
store it.

Friday, 6 December, 2019- DAY 3: Filler Room: in this room three major operations will take place. EBI
(empty bottle inspection, mixing and filling). And additional operations like date coding are there.

EBI- a unit operation aided by programmable logic control which inspects bottles with different
problems inspecting: base of the bottle, impurity, neck finish and others.

Mixing: the syrup from the syrup room, the water from water treatment room and co2 from co2 room
will be mixed in the carbonation tank. The co2 being cooled for better solubility. Regulators are used
here for proportioning the ratio of the water and syrup as well as regulating the amount of co2 used for
each respective product.

Filling: the liquid comes with 84 valves and the co2 valve to rinse the bottle using high pressure co2 and
fill the bottle using a spreader. The co2 comes inside the spreader and the liquid comes outside of the
spreader to avoid foaming. Then crowning machine covers the bottle with cork.

The check mat differentiates the uncrowned, the underfilled and the overfilled bottles and finally the
video jet machine prints the date, time and company’s production code.

About the company:

The company has a lot of amazing technologies, better working environment and compound, and very
careful of sanitation and hygiene. This awarded it the much acceptance from the society as well as the
international Pepsi company. my communication with the operators has been great and will be. They
are contributing much knowledge.

Specifically, on the internship program the company is a little bit unorganized and not participating me
on some duties. The company didn’t sufficiently integrate me with its staff. That made my program
biased but I am still working on it for a better understanding. The schedule is also another problem for
me. I am assigned for Wednesday and Thursday for about 4 hours and that is a very short period of time
for exploring each operation.