This document describes the manufacturing process for producing carbon dioxide (CO2) at a plant. The process involves burning natural gas to produce a flue gas containing CO2, which is then captured and purified in multiple steps. Key steps include scrubbing to remove water-soluble impurities, absorption to remove acidic impurities using MEA and soda ash solutions, stripping the CO2 from the solution, cooling, purification using potassium permanganate, activated carbon and other filters, compression to high pressure, drying, carbon filtration, liquefaction, storage, and vaporization before transfer to filling lines. The process is designed to produce very high purity CO2 meeting stringent specifications.

1. CO2 Plant
(Manufacturing
Process & Quality
Control)
Learn Practical experiences

2. Carbon di oxide is an odorless, colorless and
tasteless gas at normal temperature.
Its an acidic gas, compound of carbon &
Oxygen.
Heavier than air and ten times more dissolve
in water.
Air content 0.03% carbon di oxide
O=C=O

3.  3rd largest ingredient
 Increase mouth feeling and make effervescence
appearance of beverage i.e contribute to sensory
 Acts against microorganism
 Maintain acidity & package integrity of beverage
Syrup & water clearing. Syrup transfer from beverage
tank to filler bowl & beverage filling
Why we need carbon di oxide?

4. Rank Parameter Specification
A Purity,%CO2 99.9% minimum
B Water or Dew Point 20 ppm maximum, -55°C or lower
B Nitrogen 120 ppm maximum
B Carbon Monoxide 10 ppm maximum
B Oxygen 30 ppm maximum
A Nitric Oxide (NO) 2.5 maximum
A Nitrogen Di Oxide(NO2) 2.5 maximum
A Phosphine 0.3 maximum
B Total Hydrocarbons 50 ppm maximum
B Non- Volatile Organic
residue
5 ppm maximum
B Nonvolatile Residue 10 ppm maximum
B Ammonia 2.5 maximum
CO₂ quality as per Pepsi Co requirement

5. Rank Parameter Specification
A Aromatic Hydrocarbon 20 ppb maximum
A Hydrogen Cyanide None Detected
A Vinyl Chloride None Detected
A Ethylene Oxide None Detected
A Acetaldehyde 0.2 maximum
A
Other Volatile Oxygenates
1 ppm maximum
A Total Sulfur 0.1 ppm
A Sulfur Dioxide 1 ppm maximum
A
Characteristics
Colorless, Tasteless, no off -
odors
CO₂ quality as per Pepsi Co requirement

7. Natural gas burns with air to form flue gas. Flue gas temp 366 °C where CO2
flue gas 10.5 -12%, O2 flue gas 1-2.5% and CO max. 50 ppm .
Reactivator pressure max. 20 psi

8. SCRUBBER
Flue gas enters to scrubber tower through upward flow facing downward
stream of soft water. Bulk amount of water soluble impurities removed at
this stage. Soft water drain temperature should be below 60 degree celsius
and soft water pH should be below 8 to decrease CO2 loss.

9. ABSORBER
CO2 flue gas enters absorber tower from scrubber tower. Absorber tank
contains MEA 8-10 % and soda ash 3-4% which absorb acidic impurities.
Absorber 1 temp- 55 °C
absorber 2 temp- 40 °C

10. HEAT EXCHANGER
Strong MEA solution of 50 °C pass through heat exchanger to rise up
temperature up to 102°C prior to enter stripper tower

11. STRIPPER TOWER
At stripper tower CO2 separated from MEA, left weak MEA solution at reactivaor
tank. Stripper temp 125°C and pressure 20psi

12. SOLUTION COOLER
Weak MEA solution of high temperature pass through solution cooler 1 to
decrease its temperature up to 55° C & solution cooler 2 upto 40°C

13. GAS COOLER
Hot CO2 gas leaving from stripper cooled by gas cooler. Outlet from
stripper 125°C & out from gas cooler 40°C

14. PURIFIER UNIT
Potassium permanganate is bulk removal of NO, MEA, NH3, CH3CHO, C2H5OH,SO2,NO2, H2S.
Activated Carbon adsorb aromatics & witt fill media is trace removal of NO, MEA, NH3,
CH3CHO, C2H5OH,SO2,NO2, H2S.

15. COMPRESSOR
Compressor compress CO2 gas at 3 stages. Suction press 7 psi, 1st stage
compression pressure 69.5 psi, 2nd stage pressure 345 psi & 3rd stage pressure
1000 psi. This high pressure hot gas then enter to drier.

16. DRYER UNIT
Dryer composed of molecular sieves remove moisture and others
impurities, dew point should be -57°C

17. CARBON FILTER
Before liquification CO2 pass through 4 stages carbon filter to remove
very trace amount of aromatics

18. LIQUEFIER
Liquefier converts high pressure CO2 gas to CO2 liquid. Temp -30°C

19. STORAGE TANK
Liquid CO2 stored at storage tank at 20 bar pressure with
re-liquefaction

20. VAPORIZER
Vaporizer converts CO2 liquid to CO2 vapor prior to transfer to filling line

21. PARKER 5 STAGES FILTRATION
CO2 finally filtered through this filtration system to remove very trace
amount of impurities.