200kg/h Fully Automatic CO2 Recovery System
- Introduction to the CO2 Recovery System
Our company is a domestic supplier specializing in gas purification and separation equipment. Building upon the absorption of advanced technologies from international companies, we have continuously innovated and independently developed a high-purity CO2 recovery system (working principle diagram attached). The CO2 recovery system consists of units for defoaming, water washing, gas holder storage, compression, freeze drying, adsorption drying, refrigeration, storage tank, and vaporization. It is used to recover carbon dioxide generated during the fermentation process and purify it for reuse.
From Brew to Bubble: Harnessing CO₂ in the Modern Brewery—Process Summary:
The CO2-rich fermentation gas from the brewery’s fermentation tanks serves as the gas source for this system. The incoming gas first enters a defoamer to capture and remove any entrained foam from the source. Subsequently, the gas enters a scrubbing tower, where the vast majority of organic impurities and odors are removed through water washing. Our scrubbing tower utilizes advanced packing and special spray heads, delivering excellent washing efficiency. The gas holder acts as a buffer for the gas processing equipment.
The scrubbed gas then enters the compression system. The compression system of this unit is a dedicated CO2 compressor set configured for three-stage compression. The gas pressure is increased to 1.5-1.8 MPa within this system. The freeze dryer serves as the primary drying equipment, performing low-temperature dehumidification, with a gas outlet temperature of 2~4°C. Installing the freeze dryer enhances the efficiency of the subsequent dryer.
The gas, after freeze drying, enters an activated carbon adsorber for further removal of organic impurities and odors. It then proceeds to the dryer for deep drying. After this treatment, the atmospheric pressure dew point of the gas can reach below -60°C. The dryer is PLC-controlled.
The CO2 liquefaction system of this unit comprises a CO2 evaporative condenser and a Freon R22 refrigeration unit. The deeply dried CO2 gas is liquefied at low temperature (-18°C) within the CO2 evaporative condenser. Gaseous impurities—such as N2 and O2—are expelled as non-condensable gases during the CO2 liquefaction and purification process, thereby enhancing the purity of the carbon dioxide. The liquefied CO2 is stored in a low-temperature CO2 storage tank. The tank can be insulated cost-effectively with polyurethane. The storage tank system includes subsystems for automatic and safety venting, level indication, etc., ensuring high reliability.
For the production plant, the purpose of recovering CO2 is its application. Therefore, we recommend using our company’s automated water-bath type CO2 vaporizer. This system represents a reliable and stable thermal control and pressure reduction control system. The selected vaporization capacity is greater than the CO2 recovery capacity to meet the user’s demands for concentrated, high-volume CO2 usage. If intended for external sale, a filling unit needs to be added.
As breweries enhance their quality control levels and strengthen measures against beer oxygen pickup, the purity requirements for carbon dioxide are becoming increasingly stringent. Your company can configure a CO2 purification system (optional add-on) according to demand to obtain a purer liquid CO2 product.
The control system for this unit includes display instruments for monitored parameters and key operational parameters. The compressor set and refrigeration unit have independent control and fault shutdown systems.
II. Technical Performance and Parameters of the CO2 Recovery System
Equipment Operating Environment and Conditions:
Gas Source Purity: ≥97%
Gas Source Pressure: 0.003~0.005 MPa
Gas Source Temperature: Max 30°C
Main Design Specifications of the Unit:
(1) CO2 Gas Recovery Capacity: 200 Kg/h
(2) Liquid Storage Tank
* Pressure: 1.5-2.0 MPa
* Storage Temperature: -20°C
* Storage Capacity: 20 m³
(3) CO2 Liquid Purity: 99.95%-99.99%
(4) CO2 Dew Point Temperature after Vaporization: -60°C
(5) Cooling Water Inlet Temperature: ≤20°C
(6) Electrical Power
* Power Supply: 3P-380V-50Hz
* Control Voltage: 220V/24V
* Total Installed Capacity: ≈60 KW
(7) Scrubbing Water
* Scrubbing Water Inlet Temperature: Max 30°C
* Scrubbing Water Inlet Pressure: 0.2 MPa
* Scrubbing Water Quality: Tap water, but chloride content must not exceed 0.1 ppm
* Scrubbing Water Consumption: 1 m³/h
(8) Cooling Water
* Cooling Water Inlet Temperature: <20°C
* Cooling Water Inlet Pressure: 0.3 MPa
* Cooling Water Quality: Industrial circulating water
III. CO2 Recovery System Configuration Plan
Primary Purification System: Defoamer, Scrubbing Tower, Circulation Water Pump, Gas Holder, Water Seal, Piping, Valves, Instruments
1-1 Defoamer: For removing foam carried by the CO2 feedstock gas. Foam in the feedstock gas is removed by atmospheric water sprayed from the top of the defoamer. The water is then discharged to the drain via a bottom drain device. The water spray condition can be observed through a sight glass installed on the defoamer.
Includes: Internal spray system, automatic drain device, sight glass, level switches (2), pneumatic butterfly valves (2) Φ76.2.
Technical Parameters: Capacity: 200kg/h CO2; Vessel Diameter: 400mm; Height: 2000mm; Material: SS304.
1-2 Scrubbing Tower: Feedstock gas enters from the bottom, passes through the packing layer, and contacts scrubbing water counter-currently to remove alcohol and suspended particles. The scrubbed water is recycled in the defoamer.
Scope of Supply: Scrubbing tower, demister, water distributor, packing, built-in water seal, sight glass, high-level alarm device, automatic water inlet valve, water piping, solenoid valve, drain valve, circulation water pump (Southern brand) with related valves and pressure gauge.
Technical Parameters: Capacity: 200kg/h CO2; Diameter: 300mm; Height: 3000mm; Material: SS304.
High-Efficiency Scrubbing Tower Features: Uses high-efficiency packing, significantly improving washing efficiency and effectively removing organic impurities (H₂S, dimethyl sulfide, ethanol, etc.). Removal rate of organic impurities exceeds 99%. High automation level, reliable operation of the primary purification system.
1-3 Gas Holder: Provides buffering between the CO2 feedstock gas and the compressor. The compressor load is controlled by the fullness of the gas holder, so its volume determines the compressor’s start/stop frequency. Made from biaxial coated high-strength membrane material for long service life. Includes low-level alarm structure.
Scope of Supply: Gas holder, support frame for suspension, compressor load control components and cables, sensors, weight, signal cables, etc., for compressor load control, interface flanges.
Technical Parameters: Volume: 20 m³; Dimensions: Diameter 2000mm, Length 6400mm; Material: Food-grade rubber.
Compression System: One Compressor Unit
The CO2 compressor is a two-stage oil-free compressor mounted on a skid. Compressor load is controlled based on the gas holder’s fullness.
Scope of Supply: One oil-free lubricated compressor, safety valves, high/low-pressure safety switches, mating flanges and valves, high exhaust temperature switch, pressure gauges, temperature gauges, intake filter assembly, cooler assembly, safety valve assembly.
Technical Parameters: Manufacturer: Liu Er Kong; Model: ZWET-1.8/20 (1 unit); Suction Pressure: 0.05 MPa (gauge); Discharge Pressure: 2.00 MPa (gauge).
Compression System Features: Equipped with valves for automatic compressor drainage, eliminating manual operation. High automation. High-pressure indication and protection. Control cabinet has operation indication, fault indication, motor overload protection.
Purification System: Freeze Dryer, Adsorber, Dryer, Piping, Valves, Instruments (PLC Controlled)
3-1 Freeze Dryer: Capacity: 3 m³/min. Cools the CO2 gas from the compressor (25°C—60°C) to 2°C—6°C, simultaneously removing moisture before it enters the adsorption dryer towers.
Features: a. Improves CO2 gas purity by cooling and draining water. b. Prevents ice blockage in downstream CO2 condensation and storage systems. c. Fully automatic, unmanned operation.
3-2 Adsorption Dryer (Built-in Pressureless Heating Regeneration, Fast Regeneration, Low Gas Consumption): Dual-tower adsorption dryer. Each tower contains activated carbon and molecular sieve. Dual-tower structure automatically switches periodically, with one tower working while the other regenerates. Two adsorption dryer towers mounted on a skid, with built-in flow distributors and anti-impact layers. The activated carbon removes remaining alcohol and odors. The 3A molecular sieve is used for food-grade CO2 gas drying. Each tower’s operation cycle is approximately 12-24 hours (adjustable). Regeneration gas comes from non-condensable gases in the CO2 condenser and vent gases from the top of the storage tank.
Scope of Supply: Two skid-mounted adsorption dryer towers with built-in flow distributors and anti-impact layers, adsorbent, desiccant, pneumatic ball valves (8) ￠25.4, temperature sensors (3), pressure gauges (2), electric heaters (2), flow regulating ball valve (1) ￠25.4, gas filter (outlet) for removing dust.
Technical Parameters: Capacity: 200kg/h CO2; Vessel Diameter: 273mm; Vessel Height: 2200mm; Material: SUS304; Adsorbent: CH-18# Granular Activated Carbon Ф4-6mm; Desiccant: 3A Molecular Sieve.
Purification System Features and Configuration: Uses pneumatic ball valves, high automation. Adsorber + Dryer controlled by PLC. a. Offers both automatic and manual electrical control operation modes. b. Utilizes pneumatic valves and SIEMENS S7 Smart programmable controller. c. Prevents operational errors, e.g., ice blockage caused by incomplete dryer regeneration.
Condensation & Liquefaction System: Refrigeration Unit, CO2 Evaporative Condenser, Piping, Valves, Instruments
4-1 Refrigeration Unit (1 set): Refrigeration Compressor Type: Semi-hermetic piston compressor. Includes a skid-mounted refrigeration system for liquefying gaseous CO2. Refrigerant: R22.
Scope of Supply: Oil filter, pressure control and distribution system, inlet filter, built-in motor, pressure gauges, solenoid valves for automatic operation, pressure and temperature sensors.
Technical Parameters: Manufacturer: Bitzer; Processing Capacity: 200kg/h; Refrigeration Unit Model: 4GE-23-40P; Expansion Valve Model: TGEX-11TR 38KW; Condensing Temperature: -18°C to -25°C.
4-2 CO2 Condenser: Horizontal shell-and-tube heat exchanger, installed with a 5-degree tilt to improve separation of non-condensable gases.
Scope of Supply: Pressure transmitter, automatic venting device for non-condensable gases, safety valve (1), solenoid valve (1), Danfoss expansion valve, shut-off valves, sight glass, etc.
Technical Parameters: Capacity: 200kg/h; Condensing Area: 13 m²; CO2 Temperature: -25°C; CO2 Pressure: 1.9 MPa; Material: 304.
Liquefaction System Features: 1. CO2 system pressure maintained at 1.5-1.8 MPa, effectively reducing O2 solubility in liquid CO2. This ensures both liquid CO2 purity and carbon dioxide yield. 2. CO2 evaporative condenser is tilted 5 degrees, equipped with a timed automatic venting device. High-point venting effectively discharges non-condensable gases like O2 and N2.
Liquid Storage: 15 m³ CO2 Vertical Vacuum Liquid Storage Tank, Piping, Valves, Instruments
5-1 CO2 Liquid Storage Tank Volume: 15 m³.
Features: Level indication, overpressure automatic venting system.
Working Pressure: 2.0 MPa; Vessel Diameter: 2400mm; Material: 16MNDR; Installation Form: Vertical; Insulation Form: Double-layer vacuum.
High-Efficiency Vaporizer System
The main working principle of this product utilizes the thermal energy from the cooling circulating water of the brewery’s power equipment as the medium to vaporize liquid carbon dioxide. The circulating water absorbs energy released by the power equipment, raising its temperature. Typically, other devices are needed to cool the water back to a temperature suitable for cooling the power equipment, consuming additional energy, especially in summer. Using our water-bath vaporizer consumes thermal energy from the circulating water during CO2 vaporization, lowering the water temperature by 4-10°C. This achieves the goal of vaporizing liquid CO2 while allowing the circulating water to directly cool the power equipment without other treatment, saving energy for both vaporization and cooling, significantly improving economic. When no circulating water is available, the system automatically or manually switches to steam piping as the heat source for vaporization.
Scope of Supply: Vaporizer vessel (SUS304), inlet welded ball valve (￠25.4/1), inlet pneumatic ball valve (￠25.4/1), outlet welded ball valve after vaporization (￠25.4/1), safety valve (DN20), pressure gauges (2), self-operated pressure reducing valve (1).
Technical Parameters: Vaporization Capacity: Max 250 kg/h CO2; Inlet/Outlet Pipe Size: ￠25.4; Inlet Pressure: 1.6-2.0 MPa; Outlet Pressure: 0.7-0.9 MPa; Outlet Temperature: 5-15°C (adjustable).
CO2 Purification System (Customer Optional, Priced Separately)
Purification Unit Features: Reliable performance, stable quality – represents the most advanced CO2 purification unit domestically. System pressure controlled below 1.5~1.8 MPa, achieving CO2 product purity ≥99.99%. This unit allows the CO2 recovery system to recover from a feedstock gas of 99% purity and guarantee a product purity of 99.99%, with nitrogen and oxygen content at very low levels.
Liquid CO2 from the CO2 condenser is pumped into the top of the purification column via a liquid pump and flows through the packing bed into the reboiler. Inside the reboiler, gas is generated due to heat exchange between CO2 gas from the dryer and liquid CO2 in the reboiler. Within the packing bed, gas and liquid CO2 flow counter-currently, completing the purification process. At the bottom of the reboiler, high-purity liquid is pumped into the CO2 storage tank via a liquid pump.
Processing Capacity: 200 kg/hour; Purity: 99.99%
Components: Purification Column (1 unit, 304 stainless steel, with imported 304 packing); Reboiler (1 unit, 304 stainless steel, with built-in heat exchanger); Canned Motor Pump (1 unit, Dalian); Capacitive Level Gauge (1 unit, E+H).
Filling Unit (Customer Optional, Priced Separately)
The filling unit is determined based on the brewery’s needs, filling liquid CO2 from the low-temperature storage tank into CO2 cylinders using a filling pump. Primarily used for filling small keg cylinders or for external sales.
Equipment Includes: Filling pump, safety valve, pressure gauge, pneumatic ball valve, metal hose, and proximity switch.
Control System: Compressor Control Cabinet (1), CO2 Control Cabinet (1)
The electrical system includes the following components:
Control Section: The control cabinet is equipped with a Siemens PLC and terminal blocks for I/O signals to/from the motor control center for the CO2 equipment. The control panel features an operator panel, allowing the operator to monitor the CO2 equipment’s operation status at any time.
Examples of controllable/monitorable options on the OP interface:
Control: Valve operation, alarm acknowledgment and reset.
Monitoring: Equipment status, alarm status, CO2 operating hours, adsorption dryer tower operating time and status, process temperatures and pressures.
If the indoor ambient temperature exceeds 35°C, the electrical cabinet should be placed in an air-conditioned room.
Control Voltage: 24 VDC. Coil voltage for motor starters is 220 VAC.
The control cabinet contains the main switch, motor starting devices, connections for I/O signals, cables, etc.
- CO2 Recovery System Equipment List
| No. | Equipment Name | Unit | Qty | Model / 50KG | Technical Performance Indicators | Manufacturer | Remarks |
| 一 | Custom Equipment | ||||||
| 1 | Defoamer | Unit | 1 | Φ400×2000mm | Stainless Steel | Runqiang | |
| 2 | Scrubber (with built-in water seal) | Unit | 1 | Φ300×3000mm | Stainless Steel | Runqiang | |
| 3 | Adsorption Dryer Tower | Unit | 2 | Φ273×2200mm | Stainless Steel | Subcontract | |
| 4 | Heater | Unit | 2 | 3.6KW | Stainless Steel | Jiangdu | |
| 5 | Liquefier (Condenser) | Unit | 1 | 13 m² | 304 Stainless | Subcontract | |
| 6 | Double-layer Vacuum Vertical Liquid Storage Tank | Unit | 1 | 15 m³ | 16Mn Steel | Subcontract | |
| 7 | Gas Holder | Unit | 1 | Φ273*6400, 20m³ | Food-grade Rubber | Jiangdu | |
| 8 | Vaporizer | Set | 1 | 200 Kg/h | 304 Stainless | Runqiang | |
| 9 | Skid Frame | Set | 1 | Carbon Steel | Runqiang | ||
| 二 | Standard Equipment | ||||||
| 1 | Compressor Set | Unit | 1 | ZWET-1.8/20 | Displacement: 1.8 m³/min, Power: 30 KW | Liu Er Kong | |
| 2 | Piston Refrigeration Unit | Unit | 1 | 4GE-23-40P (incl. expansion valve, low-temp valves) | R22 | Bitzer | |
| 3 | Water-cooling Unit | Unit | 1 | Bitzer | |||
| 4 | Circulation Water Pump | Unit | 1 | Q=5 m³/h, H=20m | Stainless Steel | Southern | |
| 5 | Freeze Dryer | Unit | 1 | 3 m³/min | Suzhou | ||
| 三 | Electrical Control & Instruments | ||||||
| Electrical Control Cabinet / Instrument Cabinet | Set | 1 | PLC, Color Touch Screen, Electrical Components | S7-200 Smart, 1000 Screen | Siemens, Siemens, Chint | ||
| 四 | Valves / Pipe Fittings / Pipes | Set | 1 | SUS304 | Pneumatic Ball Valves | Zhejiang | |
| 五 | Process Packing | Set | 1 | Activated Carbon, Molecular Sieve, Scrubbing Tower Packing | CH-18# Granular, 3A Spherical, SS Material | Shanghai, Shanghai Xin’ao, Jiangsu Wuxi | |
| 六 | Installation & Commissioning | ||||||
| 七 | Insulation | Set | 1 | Cold Insulation: Polyurethane Foam; Hot Insulation: Rock Wool |
Contact Tiantai if there are any interests please:
Email: grainbrew@cnbrewery.com
Phone: 0086 186 7882 2391
Sharon
Tiantai Brewtech