Brewery Engineering Report: Analysis of Plant Systems and Processes

This report provides an overview of the engineering aspects of a brewery, addressing various systems and processes. It begins by examining the use of compressed air in fermentation and other applications, followed by a discussion of the refrigeration system's safety features. The report then delves into the purpose and operation of cooling towers, as well as the different stages of the water treatment plant, including aerobic and anaerobic processes, and the application of the DAF clarifier system. The report also describes the expansion loops in the piping system, the safety features of the oxygen pressure vessel, and the analysis of flue gas exiting the boilers, including its temperature and oxygen levels. Further, it mentions the last heat transfer surface of the boilers, the number of operators required, real-time monitoring tools, and the maintenance crew's operations. Finally, it covers the production and collection of carbon dioxide gas, providing a comprehensive understanding of the brewery's engineering infrastructure.

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1) a) Compressed air is used in fermentation.
b) Used for filling and capping.
2) Power failure warning.
3) A cooling tower rejects heat away to the atmosphere through the cooling of a water
stream to a lower temperature.
Mechanical draft towers use rotating fans to force the air into circulation, thus producing
a cooling effect. Counterflow towers are designed in a way that uses water that enters
from the top while air is introduced at the bottom and exits at the top.
4) Aerobic water treatment is a process that utilizes microorganisms to converts organic
matter in the wastewater into carbon dioxide and new biomass in the presence of oxygen.
The role of aerobic bacteria is to break down the organic matter in the waste in the
wastewater. The anaerobic process is an energy efficient process in which
microorganisms transform organic matter in the wastewater into biogas in the absence of
oxygen.
5) a) Cleaning.
b) Product production.
6) The Dissolve air floatation (DAF) is a water treatment process that clarifies wastewater
by removing solids which are suspended in the wastewater. The extraction of solids is
achieved by dissolving air in wastewater under relatively high pressure and releasing
them at low pressure (atmospheric pressure) in a floatation tank. The released air creates
buoyancy with the suspended particles causing them to float. The accumulated solid
waste ate the floating tower are skimmed by a skimmer to remove the sludge and directed
towards the hopper which discharge. The settled solids at the bottom are then
concentrated and discharged away by an automatic controlled pneumatic drain valve.
7) The expansion loops within the interconnected pipes across the various process provides
enough flexibility to prevent intense thermal expansions and contraction from causing
unwanted excessive stress within the piping systems. They are fitted at different intervals
and at the different decree of loop depending on the pressure supported by the pipes and
the distance between the points the fluids enter the pipes and the ejection point.
8)
a) Pressure regulator gauge and valves.
b) Chain.
9) The exit temperature of the flue gas is at about 40 degrees Celsius and above. The
existing flue gas contains small quantities of oxygen which was not exhausted during
combustion in the boiler. The high temperatures of the existing flue gas decrease the
internal temperature of the boiler and also the higher percentage of the oxygen gas in the
flue gas exiting reduces the temperatures of the boiler as there is incomplete combustion.
The last heat transfer surface of the boiler is the steel shell.

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10) a) 4
b) Flow charts and computerized gadgets.
c) Cleaning and lubricating moving parts.
11) Carbon dioxide is produced by reacting hydrochloric acid with carbonate, calcium
carbonate in an enclosed glass beaker and collected over water as shown in the diagram
below.

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Reference.
JWC Environmental, a Sulzer Brand, 2850 S. Redhill Ave, Suite 125, Santa Clara USA
https://www.jwce.com/knowledge-center/what-is-a-daf/
Quora,
https://www.quora.com/How-is-carbon-dioxide-prepared-and-collected-in-a-laboratory