Exercise 3 Plant Design EVIDENTE

MAPÚA UNIVERSITY
SCHOOL OF CHEMICAL, BIOLOGICAL,

AND MATERIAL ENGINEERING AND SCIENCES
Design of Process and Equipment of Bioethanol Purification of

Calaca Batangas Biofuel Plant
By:
Evidente, Ralph Carlo T.
An Individual Report Submitted in Partial Fulfillment of the

Requirements for the Degree of Bachelor of Science in
Chemical Engineering
Dr. Alvin R. Caparanga
December 2017
TABLE OF CONTENTS
Chapter 1: Process Description .............................................................................. 1

Chapter 2: Process Flow Diagram.......................................................................... 3
Chapter 3: Material Balance................................................................................... 5
Energy Balance ............................................................................................ 21
Chapter 4: Equipment Sizing ............................................................................... 33
Chapter 5: Equipment Specification .................................................................... 62
Chapter 6: Hazard and Operability Study .......................................................... 68
Chapter 7: Piping and Instrumentation Diagram .............................................. 76
Chapter 8: Waste Minimization, Prevention, and Treatment Plan .................. 78
CHAPTER 1
Process
Description
Process Description
This section separates the fermentation broth into water, anhydrous ethanol and solids.
Distillation and molecular sieve adsorption are used to recover ethanol from the raw fermentation
liquid and produce 80% wt. ethanol. Distillation is accomplished in two columns. The first column,
which can be seen in DT-301, is called Water Remover Column. It removes the dissolved CO2,
most of the water, and the dissolved solids. The overhead stream from this column is fed to Vent
Scrubber along with the vent vapors from (containing mostly CO2, ethanol vapor, and oxygen),
with a CO2 recovery of 99.8%. At the bottom part is to recover nearly all the ethanol from its vapor
form. The effluent is fed back to DT-301.
New in the Process & Justification
The material will then be sent to the beer column, a distillation column (DT-301) with 32
stages operating at 48% efficiency that removes CO2 and a small amount of ethanol into the vapor
overhead, recovers roughly 98% of ethanol into the vapor side-draw (sent to the rectification
column), and recovers roughly 90% of the water plus all residual algal components and other solids
into the bottoms (stillage) stream. The feed to the beer column is preheated in an economizer heat
exchanger by cross-exchange with the bottoms stream fed to the lipid extraction section. The
products from the bottom will be also possibly used as a by-product and will be sold to nearby
energy plants.
CHAPTER 2
Process Flow
Diagram
NOTES:
CO2 recycle to
Water
[43] ponds 01. DT – Distillation Column
Toperating = 25
Poperating = 101.325 kPa
02. FD – Flash Drum
Tin =25 [42] 03. GT – Gas Tank
Tout = 12 04. HX – Heat Exchanger
[38] Toperating = 12 05. M – Mixing Tank
Vapors from FD-201 [40] Poperating = 2200 kPa 06.P – Pump
GT-301 VS-301 Water Feed Temperature: 26
[41] 07. VS – Vent Scrubber
HX-301
[50]
Pin = 101.325 kPa

Pout = 400 kPa
[45]
[44]
P-301
Toperating = 25 Poperating = 193.531 kPa
Poperating = 101.325 kPa Poverhead = 188.5 kPa
HX-302 Pbottom = 212.783 kPa
[49]
[47] [48] Tray Efficiency: 0.48
DT-301
M-301
[46]
Tin =25 [51]
P-302
[39] Tout = 80
Pin = 101.325 kPa
Liquids from FD-201 Pout = 111.458 kPa [52]
HX-303 Calaca,
Batangas
Biofuel
Tin =27 Plant
To water
Tout = 20 recycle pool
Process Flow Diagram
Drawing No. D-G01-205

Sheet 1 of 1 Rev. No. 0
CHAPTER 3
Material Balance
NOTES:
01.HX – Heat Exchanger

02.GT – Gas Tank
Calaca,
Batangas
Biofuel
Plant
Material Balance of Area 300

NOTES:

CO 2 recycle to
Water
ponds
02.P – Pump
[43]
03.VS – Vent Scrubber
[42]
[40] VS-301
[41]
HX-301
[44]
[45]
P-301
Calaca,
Batangas
Biofuel
Plant

NOTES:

02.DT – Distillation Tower
Calaca,
Batangas
Biofuel
Plant

Assumptions, Heuristics, References, & Detailed Calculations
Table 1. Basic Components for bioethanol production
Name Chemical formula Use in the process
Acetate C2H4O2 Acetate groups present in the
hemicellulose polymer
Acetic acid C2H4O2 Coming from acetate hydrolysis and
fermentation by-product
Carbon dioxide CO2 Fermentation product
Cellobiose C12H22O11 Coming from cellulose hydrolysis and
saccharification
Cellulose C5H10O5 Feedstock
Corn steep liquor Unknown Bacteria feed nitrogen source
Diammonium (NH4)2HPO4
Bacteria feed nitrogen source
phosphate (DAP)
Enzyme CH1.57N0.29O0.31S0.007 Saccharification enzyme
Ethanol C2H6O Desired product
Furfural C5H4O2 Hemicellulose hydrolysis by-product
Glucose C6H12O6 Coming from cellulose hydrolysis and
saccharification
Glycerol C3H8O3 Fermentation by-product
Hemicellulose C5H8O4 Feedstock
Lactic acid C3H6O3 Fermentation by-product
Lignin C10H13.9O1.3 Feedstock
Oxygen O2 Fermentation product
Succinic acid C4H6O4 Fermentation by-product
Sulfuric acid H2SO4 Acid catalyst
Water H2O Product moisture, washing and reaction
product
Xylitol C5H12O5 Fermentation by-product
Xylose C5H10O5 Coming from hydrolysis and
saccharification
Z. mobilis CH1.8O0.5N0.2 Fermentation bacteria
9
Gas Tank (GT-301)
Mass Balance Equation:

[Vapors in Stream 38] + [Vapors in Stream 50] = [Vapors in Stream 40] = [Vapors in Stream 41]
✓ Solving for the components of Stream 50 based on the available heuristic from the
Process Simulation:
Produced Bioethanol: 495,322.868 kg/day
Vapor Distillate Flowrate Used: 11,784 kg/day
11784 𝑥
=
495322.68 258,688.52
𝒙 = Total mass of Stream 50 = 6154.340635 kg/day
Reference for heuristic: Bioethanol Production. Process modeling and simulation with ProSimPlus.
(March 2009). Retrieved November 10, 2017, from http://www.bioethanol.prosim.net/index.html
Heuristics Used at Stream 50: 60% CO2, 20% H2O, 20% O2 (Source: Fasahati & Liu, 2012)
✓ Applicable for all lignocellulosic feedstocks
Components Composition Total Amount

(kg/day)
CO2 60% 3692.604381
H2O 20% 1230.868127
O2 20% 1230.868127
Total 100% 6154.340635
10
✓ Previous calculation from Flash Drum (on Area 200)
Stream 38
Components mol flow (kmol/d) mass flow (kg/d)
Water 17730.97778 319157.6

Ethanol 2786.084684 111635.07
CO2 791.2801636 34824.24
O2 553.42375 17709.56
Total 21861.76638 483326.47
✓ Component Balance: [38] + [50] = [40] = [41]
Stream 40 and 41
Components mol frx mol flow (kmol/d) mass flow (kg/d)

Water 0.820547 17,789.48 320,388.47
EtOH 0.111774 2423.267127 111,635.07
CO2 0.040377 875.3828268 38,516.84
O2 0.027301 591.8883791 18,940.43
Total 1 21,680.01 470,559.38
11
VS-301 (Vent Scrubber)
✓ Solving for the components of Stream 42 based on the available heuristic from the
Process Simulation:
Produced Bioethanol: 495,322.868 kg/day
Water Inlet Used: 864,000 kg/day
864,000 𝑥
=
495322.868 258,688.52
[42] = 𝒙 = 474,167.529 kg/day
Reference for heuristic: Bioethanol Production. Process modeling and simulation with ProSimPlus.
(March 2009). Retrieved November 10, 2017, from http://www.bioethanol.prosim.net/index.html
✓ Stream 41 from the Gas Tank:
Stream 41
Components mol frxn mol flow (kmol/d) mass flow (kg/d)
Water 0.820547 17,789.48 320,388.47
EtOH 0.111774 2423.267127 111,635.07
CO2 0.040377 875.3828268 38,516.84
O2 0.027301 591.8883791 18,940.43
Total 1 21,680.01 470,559.38
Note from the table: Amount of CO2 in Steam 41 = 38,516.84438 kg/day

Assumption: 99.8% recovery of CO2 (Source: Fasahati & Liu, 2012)
12
[43] = Amount of CO2 in Stream 43 = 0.998(38,516.84438) = 38,439.81069 kg/day
✓ Mole Balance Equations:
[41] + [42] = [43] + [44]

[44] = [45]
Stream 45
Components mol fraction mol flow (kmol/d) mass flow (kg/d)
Water 0.935994 44,117.49 794,556.00
EtOH 0.051412 2423.267127 111,635.07
CO2 3.71E-05 1.750763636 77.0336
O2 0.012557 591.8883791 18,940.43
Total 1 47,134.40 925,208.53
13
M-301 (Mixer)
✓ From previous calculation, components of Stream 45 and Stream 39 (liquids coming

from flash drum) are the following:
Stream 45
Components mol fraction mol flow (mol/d) mass flow (kg/d)
Water 0.935994 44,117.49 794,556.00

EtOH 0.051412 2423.267127 111,635.07
CO2 3.71E-05 1.750763636 77.0336

O2 0.012557 591.8883791 18,940.43
Total 1 47,134.40 925,208.53
Stream 39
Components mol fraction mol flow mass flow
Water 0.204625 4432.744444 79789.4
Acetic Acid 0.004581 99.2397169 5959.345
Ethanol 0.30 6500.864263 260481.83
H2SO4 0.00 0.007072119 0.693626361
Glycerol 0.20 4402.846129 405458.1
Succinic Acid 0.10 2206.759251 260596.2
Lactic Acid 0.000636 13.78526762 813.8822

Xylitol 0.070777 1533.21825 138112.3
CSL 2.16E-10 4.67677E-06 8.42566E-05
14
Z. mobilis 7.33E-11 1.58869E-06 3.91237E-05
Glucose 0.067235 1456.495799 262169.2438
Cellubiose 0.000673 14.58171261 4991.269189
Xylose 0.044515 964.3099583 144771.854
Furfural 0.001748 37.86758066 3638.695826
Lignin 1.03E-10 2.23E-06 1.30E-03
Total 1 21662.71945 1566782.815
✓ Mass Balance Equations

Use OMB and Component Balance
[39] + [45] = [46]
[46] = [47] = [48]
Water and Ethanol Balance, respectively:
Amount of Water in Stream 46 = 79789.4 + 794,556.00 = 874, 345.4

Amount of Ethanol in Stream 46 = 260,481. 83 + 111,635.07 = 372,116.90
15
The remaining amounts of other components in the stream 46 will be the amounts of
components in the stream 39.
Stream 46, 47 and 48
Components mol fraction mol flow(kmol/d) mass flow (kg/d)
Water 0.001279767 48,547.77 874,345.40
EtOH 0.000212932 8077.55709 372,116.90
H2SO4 1.86428E-10 0.007072119 0.69
Glucose 3.83614E-05 1455.235959 262,169.34
Xylose 2.54202E-05 964.3099587 144,771.85

Lignin 2.25762E-14 8.56426E-07 0.001296285
Furfural 0.998226472 37867580.66 3,638,695,826
Cellobiose 3.84388E-07 14.58171264 4991.2692
Z.mobilis 4.19244E-12 0.00015904 0.003912372
CSL 2.48088E-15 9.4112E-08 8.42566E-05
Glycerol 0.000116058 4402.654896 405,458.10
Succinic Acid 5.81723E-05 2206.759251 260,596.20
Acetic Acid 2.61606E-06 99.2397169 5959.345
lactic acid 2.38174E-07 9.035104352 813.8822
Xylitol 2.39289E-05 907.7377588 138,112.30

CO2 4.61518E-08 1.750763636 77.0336
O2 1.56028E-05 591.8883791 18,940.43
Total 1 37,934,859.20 3,641,184,178.75
16
DT-301 (Water-Remover Column)
✓ Mass Balance Equations

Use component balance
[48] =[49] + [50] + [51]

[51] = [52]
Solving for stream 51
[51] = [48] – [49] – [50]
✓ The figure above shows the amount of the components of Stream 50 which is calculated
based on the heuristics. Detailed calculation of this can be seen on page 10.
✓ Previous calculations of Stream 48 and 49 are the following:
Stream 49

Water 0.80934333 21535.27 387634.81
CO2 0.00001942 0.52 22.74

EtOH 0.18760519 4991.86 299964.97
H2SO4 0.00000027 0.01 0.69
Lignin 0.00000000 0.00 0.00

Furfural 0.00142315 37.87 3638.70
Z. mobilis 0.00000000 0.00 0.00

O2 0.00002647 0.00 0.00
CSL 0.00000000 0.00 0.00
17
Glycerol 0.00000005 0.00 0.12
Succinic Acid 0.00000001 0.00 0.04
Acetic Acid 0.00160813 42.79 2569.51
lactic acid 0.00000046 0.01 1.09
Total 1 26,608.32 693,832.69
Stream 48
Components mol fraction mol flow(kmol/d) mass flow (kg/d)
Water 0.001279767 48,547.77 874,345.40
EtOH 0.000212932 8077.55709 372,116.90
H2SO4 1.86428E-10 0.007072119 0.69
Glucose 3.83614E-05 1455.235959 262,169.34
Xylose 2.54202E-05 964.3099587 144,771.85
Lignin 2.25762E-14 8.56426E-07 0.001296285
Furfural 0.998226472 37867580.66 3,638,695,826
Cellobiose 3.84388E-07 14.58171264 4991.2692
Z.mobilis 4.19244E-12 0.00015904 0.003912372
CSL 2.48088E-15 9.4112E-08 8.42566E-05
Glycerol 0.000116058 4402.654896 405,458.10
Succinic Acid 5.81723E-05 2206.759251 260,596.20
Acetic Acid 2.61606E-06 99.2397169 5959.345
lactic acid 2.38174E-07 9.035104352 813.8822
Xylitol 2.39289E-05 907.7377588 138,112.30
CO2 4.61518E-08 1.750763636 77.0336
O2 1.56028E-05 591.8883791 18,940.43
Total 1 37,934,859.20 3,641,184,178.75
18
• Water Balance:
[Water]51 = [Water]48 -[Water]49 - [Water]50
[Water]51= 874,345.40 - 387634.81 – 1230.868127 = 485,479.71
• EtOH Balance:
[EtOH]51 = [EtOH]48 -[EtOH]49 - [EtOH]50
[EtOH]51= 372,116.90- 299964.97– 0 = 72,151.93
Stream 51 and 52
Water 0.713959 26,956.12 485,479.71
EtOH 0.041482 1566.204871 72,151.93
Glucose 0.038543 1455.235959 262,169.34

Xylose 0.025541 964.3099587 144,771.85
Cellobiose 0.000386 14.58171264 4991.2692

Glycerol 0.116609 4402.653551 405,457.98
Succinic Acid 0.058448 2206.758889 260,596.16

Acetic Acid 0.001495 56.45020103 3,389.83
lactic acid 0.000239 9.022973468 812.79
Xylitol 0.003297 124.4851791 138,112.30

O2 0.015677 591.888125 18,940.42
Total 1 37,755.82 1,796,873.58
19
References for Assumptions and Heuristics:
Salih, F. M. (2011). Microalgae Tolerance to High Concentrations of Carbon Dioxide: A

Review. Journal of Environmental Protection, 02(05), 648-654.
doi:10.4236/jep.2011.25074
Fasahati, P., & Liu, J. J. (2012). Process simulation of bioethanol production from brown
algae. IFAC Proceedings Volumes, 45(15), 597-602. doi:10.3182/20120710-4-sg-
2026.00055
Bioethanol Production: Process modeling and simulation with ProSimPlus. (March 2009).
Retrieved November 10, 2017, from http://www.bioethanol.prosim.net/index.html
20
CHAPTER 3
Energy Balance
ENERGY BALANCE
Assumption/s:
• 5% heat losses
• Constant heat capacities (Cp ) for all components
• Heat capacities (Cp ) are taken from the following references:
✓ Perry’s Chemical Engineering Handbook, 7th edition
✓ NIST Chemistry WebBook, SRD 69
✓ https://cameochemicals.noaa.gov/
Evaluation of the Outlet temperatures of Heat Exchangers
Equipment: HX-301
✓ Amount of Coolant = 21.95 𝑘𝑔/𝑠
𝒌𝒈 𝒌𝒈 𝑱
𝒎̇𝒊 , 𝒎̇𝒊 , Cpi , 𝑿𝒊 ∙ 𝑪𝒑𝒊
Components 𝒅 𝒔 MW 𝒏𝒊 , 𝒎𝒐𝒍 𝑿𝒊 𝒌𝒈−𝑲
Water 320,388.47 3.7082 18.00 0.206011 0.820493 4200 3446.072
EtOH 111,635.07 1.292073 46.00 0.028089 0.11187 1899.935 212.5457
CO2 38,516.84 0.445797 44.00 0.010132 0.040352 923.7971 37.27737
O2 18,940.43 0.219218 32.00 0.006851 0.027284 933.3519 25.46572
Cp,ave 3721.361
The heat load is obtained from:
𝑞̇ = 𝑚̇𝐶𝑃,ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 )
𝑘𝑔 𝐽
𝑞̇ = ( 5.665288 ) (3721.361 ) (25 − 12)℃
𝑠 𝑘𝑔 − ℃
𝑞̇ = 274.0736 𝑘𝑊
, while the outlet temperature is given by:
𝑞̇
𝑇𝐶,𝑜𝑢𝑡 = 𝑇𝐶,𝑖𝑛 +
(𝑚̇𝐶𝑃 )𝐶
22
274.0736
𝑇𝐶,𝑜𝑢𝑡 = 20 ℃ +
(21.95)(4.2)
𝑻𝑪,𝒐𝒖𝒕 = 𝟐𝟐. 𝟗𝟕 ℃
Equipment: HX-302
✓ Amount of Hot Water = 0.25 𝑘𝑔/𝑠
Components 𝒎̇𝒊 , 𝒎̇𝒊 , MW 𝒏𝒊 , 𝒎𝒐𝒍 𝑿𝒊 Cpi , 𝒌𝒈−𝑲 𝑿𝒊 ∙ 𝑪𝒑𝒊
𝒅 𝒔
Water 874,345.40 10.11974 18 0.562208 0.001279 4200 5.372972
EtOH 372,116.90 4.306909 46 0.093628 0.000213 1899.935 0.404776
H2SO4 0.69 8.03E-06 98.07 8.19E-08 1.86E-10 975.8669 1.82E-07
Glucose 262,169.34 3.034367 180 0.016858 3.84E-05 1213.366 0.046543
Xylose 144,771.85 1.6756 150 0.011171 2.54E-05 2019.117 0.051323
Lignin 0.001296285 1.5E-08 154.7 9.7E-11 2.21E-13 1100 2.43E-10
Furfural 3,639 0.042115 96 0.000439 9.98E-07 7825.506 0.007812
Cellobiose 4991.2692 0.057769 342 0.000169 3.84E-07 2599.211 0.000999
Z.mobilis 0.003912372 4.53E-08 24.6 1.84E-09 4.19E-12 1213.366 5.08E-09
CSL 8.42566E-05 9.75E-10 18 5.42E-11 1.23E-13 4200 5.18E-10
Glycerol 405,458.10 4.692802 92 0.051009 0.000116 2489.853 0.288993
Succinic Acid 260,596.20 3.01616 118 0.025561 5.82E-05 78.89274 0.004589
Acetic Acid 5959.345 0.068974 60 0.00115 2.62E-06 1277.871 0.003343
lactic acid 813.8822 0.00942 90 0.000105 2.38E-07 2369.728 0.000564
Xylitol 138,112.30 1.598522 152 0.010517 2.39E-05 2807.304 0.067179
CO2 77.0336 0.000892 44 2.03E-05 4.61E-08 923.7971 4.26E-05
O2 18,940.43 0.219218 32 0.006851 1.56E-05 933.3519 0.014549
Cp,ave 6.26368
𝑞̇ = 𝑚̇𝐶𝑃,𝑐 (𝑇𝐶,𝑜𝑢𝑡 − 𝑇𝐶,𝑖𝑛 )
23
𝑘𝑔 𝐽
𝑞̇ = ( 28.84249 ) (6.26368 ) (80 − 25)℃
𝑠 𝑘𝑔 − ℃
𝑞̇ = 9.936 𝑘𝑊
𝑞̇
𝑇𝐻,𝑜𝑢𝑡 = 𝑇𝐻,𝑖𝑛 −
(𝑚̇𝐶𝑃 )𝐻
9.936
𝑇𝐻,𝑜𝑢𝑡 = 110 −
(0.25)(4.2)
𝑻𝑯,𝒐𝒖𝒕 = 𝟏𝟎𝟎. 𝟓𝟑𝟕 ℃
Equipment: HX-303
✓ Amount of Coolant = 21.95 𝑘𝑔/𝑠
Components 𝒎̇𝒊 , 𝒎̇𝒊 , MW 𝒏𝒊 , 𝒎𝒐𝒍 𝑿𝒊 Cpi , 𝒌𝒈−𝑲 𝑿𝒊 ∙ 𝑪𝒑𝒊
𝒅 𝒔
Water 485,479.71 5.618978 18 0.312165 0.00071 4200 2.983339
EtOH 72,151.93 0.835092 46 0.018154 4.13E-05 1899.935 0.078484
Glucose 262,169.34 3.034367 180 0.016858 3.84E-05 1213.366 0.046543
Xylose 144,771.85 1.6756 150 0.011171 2.54E-05 2019.117 0.051323
Cellobiose 4991.2692 0.057769 342 0.000169 3.84E-07 2599.211 0.000999
Glycerol 405,457.98 4.692801 92 0.051009 0.000116 2489.853 0.288992
Succinic Acid 260,596.16 3.016159 118 0.025561 5.82E-05 78.89274 0.004589
Acetic Acid 3,389.83 0.039234 60 0.000654 1.49E-06 1277.871 0.001901
lactic acid 812.79 0.009407 90 0.000105 2.38E-07 2369.728 0.000564
Xylitol 138,112.30 1.598522 152 0.010517 2.39E-05 2807.304 0.067179
O2 18,940.42 0.219218 32 0.006851 1.56E-05 933.3519 0.014549
3.538463
Cp,ave
𝑞̇ = 𝑚̇𝐶𝑃,ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 )
24
𝑘𝑔 𝐽
𝑞̇ = ( 20.79715 ) (3.358463 ) (27 − 20)℃
𝑠 𝑘𝑔 − ℃
𝑞̇ = 488.253 𝑘𝑊
𝑞̇
𝑇𝐶,𝑜𝑢𝑡 = 𝑇𝐶,𝑖𝑛 +
(𝑚̇𝐶𝑃 )𝐶
488.253
𝑇𝐶,𝑜𝑢𝑡 = 20 ℃ +
(21.95)(4.2)
𝑻𝑪,𝒐𝒖𝒕 = 𝟐𝟓. 𝟐𝟗𝟔 ℃
Formulas based on the assumptions:
∆𝐻𝑖 = 𝑚̇𝑖 𝐶𝑝𝑖 ∆𝑇
∆𝐻 = ∑ ∆𝐻𝑖
𝑖=1
𝑄𝑣𝑒𝑠𝑠𝑒𝑙 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛 − 𝑄𝑙𝑜𝑠𝑠
Table 1. Energy Balance at Gas Tank (GT-301)
Components GT-301
ṁ, kg/d Cp, J/kg-K Tin,℃ Tout,℃ ΔH, J/d ΔH, kJ/s
Water 320,388.47 4200 37 25 -1.6E+10 -186.893
EtOH 111,635.07 1899.935 37 25 -2.5E+09 -29.4582
H2SO4 0 975.8669 37 25 0 0
Glucose 0 1213.366 37 25 0 0
Xylose 0 2019.117 37 25 0 0
Lignin 0 133515.7 37 25 0 0
Furfural 0 7825.506 37 25 0 0
Cellobiose 0 2599.211 37 25 0 0
Z.mobilis 0 1213.366 37 25 0 0
CSL 0 4200 37 25 0 0
Glycerol 0 2489.853 37 25 0 0
Succinic Acid 0 78.89274 37 25 0 0
Acetic Acid 0 1277.871 37 25 0 0
lactic acid 0 2369.728 37 25 0 0
Xylitol 0 2807.304 37 25 0 0
CO2 38,516.84 923.7971 37 25 -4.3E+08 -4.94191
25
O2 18,940.43 933.3519 37 25 -2.1E+08 -2.45529
Total -1.9E+10 -223.749
Table 2. Energy Balance at Heat Exchanger (HX-301)
HX-301
Components ṁ, kg/d Cp, J/kg-K Tin,℃ Tout,℃ ΔH, J/d ΔH, kJ/s
Water 320,388.47 4200 25 12 -1.7E+10 -202.468
EtOH 111,635.07 1899.935 25 12 -2.8E+09 -31.9131
H2SO4 0 975.8669 25 12 0 0
Glucose 0 1213.366 25 12 0 0
Xylose 0 2019.117 25 12 0 0
Lignin 0 133515.7 25 12 0 0
Furfural 0 7825.506 25 12 0 0
Cellobiose 0 2599.211 25 12 0 0
Z.mobilis 0 1213.366 25 12 0 0
CSL 0 4200 25 12 0 0
Glycerol 0 2489.853 25 12 0 0
Succinic 0 78.89274 25 12 0 0
Acid
Acetic Acid 0 1277.871 25 12 0 0
Lactic acid 0 2369.728 25 12 0 0
Xylitol 0 2807.304 25 12 0 0
CO2 38,516.84 923.7971 25 12 -4.6E+08 -5.35373
O2 18,940.43 933.3519 25 12 -2.3E+08 -2.6599
Total -2.1E+10 -242.394
Table 3. Energy Balance at Mixing Tank (M-301)
M-301
Water 874,345.40 4200 12 25 47739258840 552.5377
EtOH 372,116.90 1899.935 12 25 9190972420 106.377
H2SO4 0.69 975.8669 12 25 8753.526488 0.000101
Glucose 262,169.24 1213.366 12 25 4135393796 47.86335
Xylose 144,771.85 2019.117 12 25 3800046503 43.98202
Lignin 0 133515.7 12 25 0 0
Furfural 3,638.70 7825.506 12 25 370170675.1 4.284383
Cellobiose 4,991.27 2599.211 12 25 168653744.7 1.952011
Z. mobilis 0 1213.366 12 25 0 0
CSL 0 4200 12 25 0 0
Glycerol 405,458.10 2489.853 12 25 13123902480 151.897
26
Succinic Acid 260,596.20 78.89274 12 25 267268925.2 3.09339
Acetic Acid 0 1277.871 12 25 0 0
Lactic acid 813.88 2369.728 12 25 25072762.53 0.290194
Xylitol 138,112.30 2807.304 12 25 5040401341 58.33798
CO2 77.03 923.7971 12 25 925081.1297 0.010707
O2 18,940.43 933.3519 12 25 229815132.5 2.659897
Total 84091890455 973.2858
Components HX-302
ṁ, kg/d Cp, J/kg-K Tin,℃ Tout,℃ ΔH, J/d ΔH, kJ/s
Water 874,345.40 4200 25 80 2.01974E+11 2337.66
EtOH 372,116.90 1899.935 25 80 38884883317 450.0565
H2SO4 0.69 975.8669 25 80 37034.15052 0.000429
Glucose 262,169.24 1213.366 25 80 17495896828 202.4988
Xylose 144,771.85 2019.117 25 80 16077119819 186.0778
Lignin 0 133515.7 25 80 0 0
Furfural 3,638.70 7825.506 25 80 1566106702 18.12623
Cellobiose 4,991.27 2599.211 25 80 713535073.7 8.258508
Z.mobilis 0 1213.366 25 80 0 0
CSL 0 4200 25 80 0 0
Glycerol 405,458.10 2489.853 25 80 55524202801 642.6412
Succinic Acid 260,596.20 78.89274 25 80 1130753145 13.08742
Acetic Acid 0 1277.871 25 80 0 0
lactic acid 813.88 2369.728 25 80 106077072.2 1.227744
Xylitol 138,112.30 2807.304 25 80 21324774903 246.8145
CO2 77.03 923.7971 25 80 3913804.78 0.045299
O2 18,940.43 933.3519 25 80 972294791.3 11.25341
Total 3.55773E+11 4117.747
Table 5. Energy Balance at Water-Remover Column (DT-301)
DT-301
Water 874,345.40 4200 80 27 -1.94629E+11 -2252.65
EtOH 372,116.90 1899.935 80 27 -37470887560 -433.691
H2SO4 0.69 975.8669 80 27 -35875.01299 -0.00042
Glucose 262,169.34 1213.366 80 27 -16859689080 -195.135
Xylose 144,771.85 2019.117 80 27 -15492497719 -179.311
27
Lignin 0.001296285 133515.7 80 27 -9172.947739 -0.00011
Furfural 3,639 7825.506 80 27 -1509155636 -17.4671
Cellobiose 4991.2692 2599.211 80 27 -687588233.5 -7.9582
Z.mobilis 0.003912372 1213.366 80 27 -251.5983801 -2.9E-06
CSL 8.42566E-05 4200 80 27 -18.75551916 -2.2E-07
Glycerol 405,458.10 2489.853 80 27 -53505140881 -619.272
Succinic Acid 260,596.20 78.89274 80 27 -1089634849 -12.6115
Acetic Acid 5959.345 1277.871 80 27 -403609376.1 -4.6714
lactic acid 813.8822 2369.728 80 27 -102220000.5 -1.1831
Xylitol 138,112.30 2807.304 80 27 -20549328543 -237.839
CO2 77.0336 923.7971 80 27 -3771660.866 -0.04365
O2 18,940.43 933.3519 80 27 -936938524.6 -10.8442
Total -3.4324E+11 -3972.68
HX-303
Water 485,479.71 4200 27 20 -14273103597 -165.198
EtOH 72,151.93 1899.935 27 20 -959587727.1 -11.1063
H2SO4 - 975.8669 27 20 - -
Glucose 262,169.34 1213.366 27 20 -2226751388 -25.7726
Xylose 144,771.85 2019.117 27 20 -2046178944 -23.6826
Lignin - 133515.7 27 20 - -
Furfural - 7825.506 27 20 - -
Cellobiose 4991.2692 2599.211 27 20 -90813540.28 -1.05108
Z.mobilis - 1213.366 27 20 - -
CSL - 4200 27 20 - -
Glycerol 405,457.98 2489.853 27 20 -7066714561 -81.7907
Succinic Acid 260,596.16 78.89274 27 20 -143914013 -1.66567
Acetic Acid 3,389.83 1277.871 27 20 -30322387.48 -0.35095
lactic acid 812.79 2369.728 27 20 -13482628.14 -0.15605
Xylitol 138,112.30 2807.304 27 20 -2714062260 -31.4128
CO2 - 923.7971 27 20 - -
O2 18,940.42 933.3519 27 20 -123746544.5 -1.43225
Total -29688677591 -652.2098
28
Pump (P-301)
• Assumption/s:
✓ Incompressible flow of fluid
✓ Transfer of ethanol solution from vent scrubber for mixing with other liquids from
flash drum
✓ Constant pressure operations
✓ Negligible heat transfer to surroundings
✓ The solution flows into pump by gravity and is transferred 3.5 m to the centerline
of mixing tank (M-301)
✓ 10 m friction head (f )
✓ Constant pipe diameter
Mechanical Energy Balance

∆𝑃 ∆𝑢2 𝑔
+ + ∆𝑧 + 𝐹 = 𝑊
𝜌 2𝑔𝐶 𝑔𝐶
𝑔
∆𝑧 + 𝐹 = 𝑊
𝑔𝐶
Potential Energy
𝑔 𝑚
∆𝑧 = (9.8 2 ) (3.5 𝑚)
𝑔𝐶 𝑠
𝑔 𝑚2
∆𝑧 = 34.3 2
𝑔𝐶 𝑠
Friction
𝐹 = 𝑓𝑔
𝑚
𝐹 = (10𝑚) (9.8 )
𝑠2
𝑚2
𝐹 = 98
𝑠2
𝑚2 𝑚2
𝑊 = 34.3 + 98
𝑠2 𝑠2
2
𝑚
𝑊 = 132.3 2
𝑠
Power Requirement
✓ Basis: 1 hr operation
✓ Set up time = 2 hrs
𝑃 = ṁ𝑊
29
1 𝑚2
𝑃 = (38,550.35542 𝑘𝑔 ∙ ) (132.3 2 )
2ℎ 𝑠
𝑘𝑔 1ℎ 𝑚2
𝑃 = (19,275.17771 ) ( ) (132.3 2 )
ℎ 3600 𝑠 𝑠
𝑃 = 708.36278 𝑊
𝑷 = 𝟎. 𝟕𝟎𝟖𝟒 𝒌𝑾
30
Pump (P-302)
• Assumption/s:
✓ Incompressible flow of fluid
✓ Transfer of ethanol solution from mixing tank for heating
✓ Constant pressure operations
✓ Negligible heat transfer to surroundings
✓ The solution flows into pump by gravity and is transferred 3.5 m to the centerline
of heat exchanger (HX-302)
✓ 10 m friction head (f )
✓ Constant pipe diameter
Mechanical Energy Balance

∆𝑃 ∆𝑢2 𝑔
+ + ∆𝑧 + 𝐹 = 𝑊
𝜌 2𝑔𝐶 𝑔𝐶
𝑔
∆𝑧 + 𝐹 = 𝑊
𝑔𝐶
Potential Energy
𝑔 𝑚
∆𝑧 = (9.8 2 ) (3.5 𝑚)
𝑔𝐶 𝑠
𝑔 𝑚2
∆𝑧 = 34.3 2
𝑔𝐶 𝑠
Friction
𝐹 = 𝑓𝑔
𝑚
𝐹 = (10𝑚) (9.8 )
𝑠2
𝑚2
𝐹 = 98 2
𝑠
𝑚2 𝑚2
𝑊 = 34.3 2 + 98 2
𝑠 𝑠
𝑚2
𝑊 = 132.3 2
𝑠
Power Requirement
✓ Basis: 1 hr operation
✓ Set up time = 2 hrs
𝑃 = ṁ𝑊
1 𝑚2
𝑃 = (103,832.9771 𝑘𝑔 ∙ ) (132.3 2 )
2ℎ 𝑠
31
𝑘𝑔 1ℎ 𝑚2
𝑃 = (19,275.17771 ) ( ) (132.3 2 )
ℎ 3600 𝑠 𝑠
𝑃 = 1907.930954 𝑊
𝑷 = 𝟏. 𝟗𝟎𝟖 𝒌𝑾
32
CHAPTER 4
Equipment Sizing
Pump (P-301)
• Heuristics for Rotary Pumps:
✓ Rotary slurry pumps with an efficiency ranging from 50-80%
✓ Rubber lining is used for corrosive or abrasive slurries with pH below 2.5
✓ For pumping fluids with viscosities less than 0.1 Pa-s
✓ Capacity range for centrifugal pumps is 0.5 – 20,000 m3/hr
Components ṁ, kg/d ṁ , kg/h ṁ, kg/s 𝝆 , kg/m3 𝑿𝒊 𝝆 * 𝑿𝒊

Water 794556.00 33106.5 9.196250 1000 0.858785855 858.785855
Ethanol 111635.07 4651.5 1.292073 789 0.120659361 95.200236
CO2 77.03 3.2 0.000892 1.98 8.32608E-05 0.000165
O2 18940.43 789.2 0.219218 1.429 0.020471523 0.029254
Total 925208.53 38550.4 10.708432 1 954.015509
To solve for the volumetric flow rate, Q:

𝑘𝑔
ṁ 38,550.4 ⁄ℎ 𝒎𝟑
𝑄= = = 𝟒𝟎. 𝟒𝟎𝟖𝟓𝟒𝟕
𝜌 𝑘𝑔 𝒉
954.016 ⁄𝑚3
To solve for the discharge head, H:

𝑃𝑜𝑢𝑡
𝐻=
ṁ𝑔
𝐽
708.36 𝑠
𝐻=
𝑘𝑔 𝑚
𝑠 (9.8 𝑠 2 )
10.708432
𝑯 = 𝟔. 𝟕𝟓 𝒎
To solve for the input power:
✓ Assuming 50% efficiency
𝑃𝑜𝑢𝑡
𝜀=
𝑃𝑖𝑛
𝐽
708.36 𝑠
𝑃𝑖𝑛 =
0.50
𝑷𝒊𝒏 = 𝟏𝟒𝟏𝟔. 𝟕𝟐 𝑾
34
Summary of Pump Specification (Basis: 1 hour operation)
Design Temperature 𝟓𝟓 ℃
Design Pressure 𝟏𝟏𝟏. 𝟒𝟓𝟕𝟓 𝒌𝑷𝒂
Capacity 𝟒𝟎. 𝟒𝟎𝟖𝟓𝟒𝟕 𝒎𝟑
Pressure Head 𝟔. 𝟕𝟓 𝒎
Input Power 𝟏, 𝟒𝟏𝟔. 𝟕𝟐 𝑾
Output Power 𝟕𝟎𝟖. 𝟑𝟔 𝑾
Pump type 𝑪𝒆𝒏𝒕𝒓𝒊𝒇𝒖𝒈𝒂𝒍 𝑺𝒍𝒖𝒓𝒓𝒚 𝑷𝒖𝒎𝒑
Efficiency 50%
35
Pump (P-302)
• Heuristics for Rotary Pumps:
✓ Rotary slurry pumps with an efficiency ranging from 50-80%
✓ Rubber lining is used for corrosive or abrasive slurries with pH below 2.5
✓ For pumping fluids with viscosities less than 0.1 Pa-s
✓ Capacity range for centrifugal pumps is 0.5 – 20,000 m3/hr

Water 874345.40 36431.06 10.119738 1000 0.350862 350.8621184
EtOH 372,116.90 15504.87 4.306909 789 0.149325 117.8175129
H2SO4 0.69 0.03 0.000008 1840 2.78E-07 0.00051215
Glucose 262169.34 10923.72 3.034367 1540 0.105205 162.0153193
Xylose 144771.85 6032.16 1.675600 1520 0.058095 88.30416283
Lignin 0.001296 0.00 0.000000 1260 5.2E-10 6.55427E-07
Furfural 3639 151.61 0.042115 1160 0.00146 1.693780759
Cellobiose 4991.27 207.97 0.057769 500 0.002003 1.001461946
Glycerol 405458.10 16894.09 4.692802 1260 0.162704 205.0076084
Succinic Acid 260596.20 10858.18 3.016160 1560 0.104573 163.1346179
Acetic Acid 5959.35 248.31 0.068974 1050 0.002391 2.510968593
Lactic acid 813.88 33.91 0.009420 1210 0.000327 0.395184929
Xylitol 138112.30 5754.68 1.598522 1520 0.055422 84.24214156
CO2 77.03 3.21 0.000892 1.98 3.09E-05 6.12067E-05
O2 18940.43 789.18 0.219218 1.429 0.007601 0.010861142
Total 2491991.44 103832.98 28.842494 1 1176.996313

𝑘𝑔
ṁ 103,832.98 ⁄ℎ 𝒎𝟑
𝑄= = = 𝟖𝟖. 𝟐𝟏𝟖𝟔𝟑𝟓
𝜌 𝑘𝑔 𝒉
1,176.996 ⁄𝑚3
To solve for the discharge head, H:
36
𝑃𝑜𝑢𝑡
𝐻=
ṁ𝑔
𝐽
1907.93 𝑠
𝐻=
𝑘𝑔 𝑚
𝑠 (9.8 𝑠 2 )
28.842494
𝑯 = 𝟔. 𝟕𝟓 𝒎
To solve for the input power:
✓ Assuming 50% efficiency
𝑃𝑜𝑢𝑡
𝜀=
𝑃𝑖𝑛
𝐽
1907.93 𝑠
𝑃𝑖𝑛 =
0.50
𝑷𝒊𝒏 = 𝟑, 𝟖𝟏𝟓. 𝟖𝟔 𝑾
Summary of Pump Specification (Basis: 1 hour operation)

Design Pressure 𝟏𝟏𝟏. 𝟒𝟓𝟕𝟓 𝒌𝑷𝒂
Capacity 𝟖𝟖. 𝟐𝟏𝟖𝟔𝟑𝟓 𝒎𝟑
Pressure Head 𝟔. 𝟕𝟓 𝒎
Input Power 𝟑, 𝟖𝟏𝟓. 𝟖𝟔 𝑾
Output Power 𝟏𝟗𝟎𝟕. 𝟗𝟑 𝑾
Pump type 𝑪𝒆𝒏𝒕𝒓𝒊𝒇𝒖𝒈𝒂𝒍 𝑺𝒍𝒖𝒓𝒓𝒚 𝑷𝒖𝒎𝒑
Efficiency 50%
37
HEAT EXCHANGER (HX-301)
Heuristics for shell-and-tube heat exchanger

• Counter-current flow with tube-side for the outlet and shell-side for residual biomass
water
• Use overall heat transfer coefficient 425 W/k. m2 (light organic to light organic) for
estimation purposes.
• Standard outside diameter (OD) and length (L) are 0.0254 m and 4.9 m respectively, for
shell-and-tube heat exchanger.
• The design pressure is 10% above the operating pressure.
• 8.9 mm corrosion allowance
Energy Balance Temperature condition 𝑇𝑖𝑛 𝑇𝑜𝑢𝑡

Hot side (Residual biomass and water) 25 ℃ 22 ℃
Cold side (outlet from HX-201) 20 ℃ 22.97 ℃
Design Pressure
𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 101.325 𝑘𝑃𝑎
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 (1 + 0.1)
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 111.4575 𝑘𝑃𝑎
Heat Transfer area

Q
𝐴=
𝑈∆𝑇𝑙𝑚
∆𝑇𝑖𝑛 − ∆𝑇𝑜𝑢𝑡 (25 − 22.97) − (12 − 20)

∆𝑇𝑙𝑚 = = = 2.0149 𝐾
∆𝑇 25 − 22.97
ln ∆𝑇 𝑖𝑛 ln( 12 − 20 )
𝑜𝑢𝑡
From energy balance at HX-201, 𝑄 = 242.394 𝑘𝐽/𝑠
38
𝑘𝐽 1000 𝐽
242.394 𝑠 ×
1 𝑘𝐽
𝐴= 𝑤 = 283.0518 𝑚2
(425 2 ) × 1.0149 𝐾
𝑚 −𝐾
Tube length, Diameter, and Number of Tubes
𝐴
𝑛(Number of tubes) =
𝜋𝐷𝐿
(𝐴𝑠𝑠𝑢𝑚𝑒 𝑛𝑒𝑔𝑙𝑖𝑔𝑖𝑏𝑙𝑒 𝑝𝑖𝑝𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑠𝑖𝑛𝑐𝑒 𝑃𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒 ≈ 𝑃𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒)
283.0518 𝑚2
𝑛 = = 723.9 ≈ 700
𝜋(0.0254 𝑚)(4.9 𝑚)
Shell Diameter, Number of Passes and Pitch
(B𝑎𝑠𝑒𝑑 𝑓𝑟𝑜𝑚 T𝑎𝑏𝑙𝑒 14−9 𝑃𝑙𝑎𝑛𝑡 𝐷𝑒𝑠𝑖𝑔𝑛 𝑎𝑛𝑑 𝐸𝑐𝑜𝑛𝑜𝑚𝑖𝑐𝑠 𝑓𝑜𝑟 𝐶𝐻𝐸 𝑏𝑦 𝑇𝑖𝑚𝑚𝑒𝑟ℎ𝑎𝑢𝑠)
and by interpolation,
𝐷𝑠ℎ𝑒𝑙𝑙 = 0.940 𝑚
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 1 𝑝𝑎𝑠𝑠
𝑃𝑖𝑡𝑐ℎ = 0.0317𝑚 𝑡𝑟𝑖𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐ℎ
Wall thickness
𝑃𝑟𝑖
t= + 𝐶𝑐
SEj − 0.6𝑃
𝐼𝐷𝑠ℎ𝑒𝑙𝑙
𝑟𝑖 = = 0.47 𝑚
2
By interpolation, from Table 12-10 of high-alloy steel from cladding and corrosion
resistance stainless 204 (SA-240)
𝑆 = 104,022.85 𝑘𝑃𝑎 (high-alloy steel)
39
𝐸𝑗 = 1.0 (Fully radiographed double-welded butt joints)
𝐶𝑐 = 0.0089 𝑚
(111.457.5 − 101,325)𝑘𝑃𝑎 × 0.47 𝑚

t= + 0.0089 𝑚
(104,022.85 kPa × 1.0) − 0.6(111.457.5 − 101,325)𝑘𝑃𝑎
𝑡 = 0.0575 𝑚 (57.5 𝑚𝑚)
40

water

Design Pressure
Heat Transfer area

Q
𝐴=
𝑈∆𝑇𝑇𝑙𝑚
∆𝑇𝑖𝑛 − ∆𝑇𝑜𝑢𝑡 (25 − 100.537) − (80 − 110)

∆𝑇𝑙𝑚 = = = −49.313 𝐾
∆𝑇 25 − 100.537
ln ∆𝑇 𝑖𝑛 ln( 80 − 110 )
𝑜𝑢𝑡
41
𝑘𝐽 1000 𝐽
−246.8145 𝑠 ×
1 𝑘𝐽
𝐴= 𝑤 = 11.777 𝑚2
(425 2 ) × (−49.313) 𝐾
𝑚 −𝐾

𝐴
𝜋𝐷𝐿
11.777 𝑚2
𝑛 = = 30.12 ≈ 30
𝜋(0.0254 𝑚)(4.9 𝑚)
(𝑏𝑎𝑠𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒 14−9 𝑃𝑙𝑎𝑛𝑡 𝐷𝑒𝑠𝑖𝑔𝑛 𝑎𝑛𝑑 𝐸𝑐𝑜𝑛𝑜𝑚𝑖𝑐𝑠 𝑓𝑜𝑟 𝐶𝐻𝐸 𝑏𝑦 𝑇𝑖𝑚𝑚𝑒𝑟ℎ𝑎𝑢𝑠)
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑓𝑜𝑢𝑟 𝑃𝑎𝑠𝑠𝑒𝑠
𝑃𝑖𝑡𝑐ℎ = 0.0317𝑚 𝑠𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ
Wall thickness
𝑃𝑟𝑖
t= + 𝐶𝑐
SEj − 0.6𝑃
𝑟𝑖 = = 0.1329 𝑚
2
By interpolation, from table 12-10 of high-alloy steel from cladding and corrosion
𝐶𝑐 = 0.0089 𝑚
42
(111.4575 − 101.325)𝑘𝑃𝑎 × 0.1329 𝑚
t= + 0.0089 𝑚
(104,022.85 kPa × 1.0) − 0.6(111.4575 − 101.325)𝑘𝑃𝑎
𝑡 = 0.02265 𝑚 (22.65 𝑚𝑚)
43

water

Design Pressure
Heat Transfer area

Q
𝐴=
𝑈∆𝑇𝑙𝑚
∆𝑇𝑖𝑛 − ∆𝑇𝑜𝑢𝑡 (27 − 25.3) − (30 − 20)

∆𝑇𝑙𝑚 = = = 2.8914 𝐾
∆𝑇 27 − 25.3
ln ∆𝑇 𝑖𝑛 ln( 30 − 20 )
𝑜𝑢𝑡
44
𝑘𝐽 1000 𝐽
652.2098 𝑠 ×
1 𝑘𝐽
𝐴= 𝑤 = 530.75 𝑚2
(425 2 ) × (2.8914) 𝐾
𝑚 −𝐾

𝐴
𝜋𝐷𝐿
530.75 𝑚2
𝑛 = = 1357.41 ≈ 1357
𝜋(0.0254 𝑚)(4.9 𝑚)
(𝑏𝑎𝑠𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒 14−9 𝑃𝑙𝑎𝑛𝑡 𝐷𝑒𝑠𝑖𝑔𝑛 𝑎𝑛𝑑 𝐸𝑐𝑜𝑛𝑜𝑚𝑖𝑐𝑠 𝑓𝑜𝑟 𝐶𝐻𝐸 𝑏𝑦 𝑇𝑖𝑚𝑚𝑒𝑟ℎ𝑎𝑢𝑠)
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑜𝑛𝑒 𝑃𝑎𝑠𝑠
𝑃𝑖𝑡𝑐ℎ = 0.0317 𝑚 𝑡𝑟𝑎𝑖𝑛𝑔𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐ℎ
Wall thickness
𝑃𝑟𝑖
t= + 𝐶𝑐
SEj − 0.6𝑃
𝑟𝑖 = = 0.47 𝑚
2
By interpolation, from table 12-10 of high-alloy steel from cladding and corrosion
𝐶𝑐 = 0.0089 𝑚
45
(111.4575 − 101.325)𝑘𝑃𝑎 × 0.47 𝑚
t= + 0.0089 𝑚
(104,022.85 kPa × 1.0) − 0.6(111.4575 − 101.325)𝑘𝑃𝑎
𝑡 = 0.0575 𝑚 (57.5 𝑚𝑚)
46
Mixing Tank (M-301)
• Heuristics for Mixing Tank
✓ Design temperature is set 25℃ above the operating temperature.
✓ Design pressure is 10% above the operating pressure
✓ Height-to-diameter tank ratio of 1
✓ 70 % fill capacity
✓ 9 mm corrosion allowance for corrosive streams
✓ Residence time equal to 25 minutes
Design temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 25
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 30 + 25
𝑻𝒅𝒆𝒔𝒊𝒈𝒏 = 𝟓𝟓 ℃
Design pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 )
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
𝑷𝒅𝒆𝒔𝒊𝒈𝒏 = 𝟏𝟏𝟏. 𝟒𝟓𝟖 𝒌𝑷𝒂
47
Water 874345.40 36431.06 10.119738 1000 0.350862 350.8621184
EtOH 372,116.90 15504.87 4.306909 789 0.149325 117.8175129
H2SO4 0.69 0.03 0.000008 1840 2.78E-07 0.00051215
Glucose 262169.34 10923.72 3.034367 1540 0.105205 162.0153193
Xylose 144771.85 6032.16 1.675600 1520 0.058095 88.30416283
Lignin 0.001296 0.00 0.000000 1260 5.2E-10 6.55427E-07
Furfural 3639 151.61 0.042115 1160 0.00146 1.693780759
Cellobiose 4991.27 207.97 0.057769 500 0.002003 1.001461946
Glycerol 405458.10 16894.09 4.692802 1260 0.162704 205.0076084
Succinic Acid 260596.20 10858.18 3.016160 1560 0.104573 163.1346179
Acetic Acid 5959.35 248.31 0.068974 1050 0.002391 2.510968593
Lactic acid 813.88 33.91 0.009420 1210 0.000327 0.395184929
Xylitol 138112.30 5754.68 1.598522 1520 0.055422 84.24214156
CO2 77.03 3.21 0.000892 1.98 3.09E-05 6.12067E-05
O2 18940.43 789.18 0.219218 1.429 0.007601 0.010861142
Total 2491991.44 103832.98 28.842494 1 1176.996313
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1176.996
𝑚3

kg
ṁ 103832.98 ⁄ℎ 𝑚3
𝑄= = = 88.2186
𝜌 𝑘𝑔⁄ ℎ
1176.996 𝑚3
For 70% filling capacity:
88.2186 𝑚3
𝑉𝑑𝑒𝑠𝑖𝑔𝑛 =
0.70
𝑚3
𝑉𝑑𝑒𝑠𝑖𝑔𝑛 = 126.0266
ℎ
𝑚3 1ℎ
𝑉𝑑𝑒𝑠𝑖𝑔𝑛 = 126.0266 𝑥 (25 min) 𝑥 ( )
ℎ 60 𝑚𝑖𝑛
𝑽𝒅𝒆𝒔𝒊𝒈𝒏 = 𝟓𝟐. 𝟓𝟏 𝒎𝟑
48
𝑑 2
𝑉 = 𝜋 ( ) (𝑑) = 52.51 𝑚3
2
Solving for the diameter & height:
𝒅 = 𝒉 = 𝟒. 𝟎𝟓𝟖𝟕 𝒎
Thickness of tank
• Using the equation for vessels at atmospheric pressure:
𝑃𝑟𝑖
𝑡= + 𝐶𝐶
𝑆𝐸𝑗 − 0.6𝑃
Based on Table 12-10 of Timmerhaus, et al. (2004). Plant Design and Economics for Chemical
Engineers:
Parameters Assumption Values
Corrosion Allowance (m) Corrosive streams Cc = 0.0089 m
Maximum Allowable Stainless steel type 316 S = 73,100 kPa
Stress, kPa (SA-240)
Efficiency of Joints Fully radiographed double- Ej = 1.0
welded butt joint
4.0587 𝑚
(111.458 𝑘𝑃𝑎) ( )
𝑡= 2 + 0.0089 𝑚
(73,100 𝑘𝑃𝑎 )(1.0) − 0.6(111.458 𝑘𝑃𝑎)
𝒕 = 𝟎. 𝟎𝟏𝟏𝟗𝟗 𝒎 = 𝟏𝟏. 𝟗𝟗 𝒎𝒎
Outside Diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
4.0587 𝑚 11.99
𝐷𝑜 = 2( + )
2 1000
𝑫𝒐 = 𝟒. 𝟎𝟖𝟐𝟕 𝒎
External Volume
𝜋𝐷𝑂 2 ℎ
𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 =
4
𝜋(4.0827 𝑚)2 (4.0587 𝑚)
4
𝑽𝒆𝒙𝒕𝒆𝒓𝒏𝒂𝒍 = 𝟓𝟑. 𝟏𝟑𝟑𝟗 𝒎𝟑
Volume of Steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙
49
𝑉𝑠𝑡𝑒𝑒𝑙 = (53.1339 − 52.51)𝑚3
𝑽𝒔𝒕𝒆𝒆𝒍 = 𝟎. 𝟔𝟐𝟑𝟗 𝒎𝟑
Mass of Steel
𝑚𝑠𝑡𝑒𝑒𝑙 = 𝑉𝑠𝑡𝑒𝑒𝑙 𝑥 𝜌𝑠𝑡𝑒𝑒𝑙
𝑘𝑔
𝑚𝑠𝑡𝑒𝑒𝑙 = 0.6239 𝑚3 𝑥 7830
𝑚3
𝒎𝒔𝒕𝒆𝒆𝒍 = 𝟒𝟖𝟖𝟓. 𝟐𝟏 kg
Impeller
Heuristics considered:
✓ The impeller diameter is 90% of the tank diameter
✓ Height-to-diameter impeller ratio is 1
✓ Clearance is 5% of tank diameter
✓ Width-to-diameter impeller ratio is 0.1
✓ The solution should be mixed at 1 m/s
✓ Joint efficiency is 1.0
✓ Agitation of liquid-liquid mixture requires approximately 1 kW/m3
Dimensions of Impeller
𝐷𝑖 = 0.90 𝑥 𝑑
𝐷𝑖 = 0.90 𝑥 4.0587
𝑫𝒊 = 𝟑. 𝟔𝟓𝟐𝟖 𝒎
𝑯𝒊 = 𝟑. 𝟔𝟓𝟐𝟖 𝒎
At 5% clearance
𝐶 = 0.05 𝑥 𝑑
𝐶 = 0.05 𝑥 4.0587
𝑪 = 𝟎. 𝟐𝟎𝟐𝟗 𝒎
𝑊𝑖
0.1 =
𝐷𝑖
𝑊𝑖
0.1 =
3.6528
𝑾𝒊 = 𝟎. 𝟑𝟔𝟓𝟑 𝒎
50
Impeller Rotational Speed
𝑚 1 1 𝑟𝑒𝑣 60 𝑠
𝑁𝑠 = 1.0 [ ]( )( )
𝑠 1(3.6528 𝑚) 2𝜋 𝑟𝑎𝑑 1 𝑚𝑖𝑛
𝑵𝒔 = 𝟐. 𝟔𝟏𝟒𝟐 𝒓𝒑𝒎
Power Requirement
1 ℎ𝑟 𝑘𝑔 𝑚3 1 𝑘𝑊
𝑃 = 25 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 ( ) (103832.98 )( )( 3 )
60 𝑚𝑖𝑛 ℎ 1176.996 𝑘𝑔 𝑚
𝑃 = 36.7578 𝑘𝑊
P = 36757.8 W
Summary of Mixer Specification
Design Pressure 𝟏𝟏𝟏. 𝟒𝟓𝟖 𝒌𝑷𝒂
Tank Volume 𝟓𝟐. 𝟓𝟏 𝒎𝟑
Tank Diameter 𝟒. 𝟎𝟓𝟖𝟕 𝒎
Tank Height 𝟒. 𝟎𝟓𝟖𝟕 𝒎
Thickness 𝟏𝟏. 𝟗𝟗 𝒎𝒎
Mass of Steel 𝟒𝟖𝟖𝟓. 𝟐𝟏 kg
Material of Construction Stainless steel type 316
Impeller Diameter 𝟑. 𝟔𝟓𝟐𝟖 𝒎
Impeller Clearance 𝟎. 𝟐𝟎𝟐𝟗 𝒎
Impeller Width 𝟎. 𝟑𝟔𝟓𝟑 𝒎
Operating Speed 𝟐. 𝟔𝟏𝟒𝟐 𝒓𝒑𝒎
Power Requirement 36757.8 W
Residence time 25 min
51
Gas Tank (GT-301)
• Heuristics for Gas Tank
✓ Design temperature is set 25 ℃ above the operating temperature.
✓ Design pressure is 10% above the operating pressure
✓ 3.81 mm corrosion allowance for non-corrosive streams
✓ Optimum diameter-length ratio of 1
✓ Porous powder insulation with 0.013m thickness
✓ Minimum wall thickness of 9.7 mm for rigidity for pressure vessels of 1.52 m in
diameter
✓ Design capacities of storage tanks should be 1.5 times the capacity
✓ Storage capacity of 30 days often is specified for raw materials and products
Design temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 25
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 100 + 25
𝑻𝒅𝒆𝒔𝒊𝒈𝒏 = 𝟏𝟐𝟓 ℃
Design pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 )
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
𝑷𝒅𝒆𝒔𝒊𝒈𝒏 = 𝟏𝟏𝟏. 𝟒𝟓𝟖 𝒌𝑷𝒂

Water 320,388.47 13349.5 3.708200 1000 0.654547556 654.547556
Ethanol 111,635.07 4651.5 1.292073 789 0.228068328 179.945911
CO2 38,516.84 1604.9 0.445797 1.98 0.078689182 0.155805
O2 18,940.43 789.2 0.219218 1.429 0.038694935 0.055295
Total 489480.81 20395.0 5.665287 1 834.704566
52
kg
ṁ 489480.81 ⁄𝑑 𝑚3
𝑄= = = 586.41
𝜌 𝑘𝑔⁄ 𝑑
834.70457 𝑚3
Volume of the tank:
𝑉
(ℎ𝑜𝑙𝑑𝑢𝑝 𝑡𝑖𝑚𝑒) =
𝑉̇
𝑚3
𝑉 = (1.5)(30 𝑑)(586.41 )
𝑑
𝑽𝒅𝒆𝒔𝒊𝒈𝒏 = 𝟐𝟔𝟑𝟖𝟖. 𝟓𝟒 𝒎𝟑
Solving for the diameter & length:

𝑑 2
𝑉 = 𝜋 ( ) (𝐿)
2
𝑑 2
𝑉 = 𝜋 ( ) (𝑑)
2
3
𝑑 2
26388.54 𝑚 = 𝜋 ( ) (𝑑)
2
𝒅 = 𝟑𝟐. 𝟐𝟔𝟖𝟐 𝒎
𝐿= 𝑑
𝑳 = 𝟑𝟐. 𝟐𝟔𝟖𝟐 𝒎
Thickness of tank
𝑃𝑟𝑖
𝑡= + 𝐶𝐶
Engineers:
Corrosion Allowance (m) Non-corrosive streams Cc = 0.00381 m
Maximum Allowable High-tensile steel S = 137,900 kPa
Stress, kPa
welded butt joint
32.2682 𝑚
(111.458 𝑘𝑃𝑎) ( )
𝑡= 2 + 0.00381 𝑚
(137,900 𝑘𝑃𝑎 )(1.0) − 0.6(111.458 𝑘𝑃𝑎)
𝒕 = 𝟎. 𝟎𝟏𝟔𝟖𝟔 𝒎 = 𝟏𝟔. 𝟖𝟔 𝒎𝒎
53
Summary of Storage Tank for Gas Specification
Design Temperature 𝟏𝟐𝟓 ℃
Design Pressure 𝟏𝟏𝟏. 𝟒𝟓𝟖 𝒌𝑷𝒂
Tank Volume 𝟐𝟔𝟑𝟖𝟖. 𝟓𝟒 𝒎𝟑
Tank Diameter 𝟑𝟐, 𝟐𝟔𝟖𝟐 𝒎
Tank Height 𝟑𝟐. 𝟐𝟔𝟖𝟐 𝒎
Thickness 𝟏𝟔. 𝟖𝟔 𝒎𝒎
Material of Construction High-tensile steel
Residence time 30 days
54
Absorption Tower (VS-301)
• Heuristics for Packed Absorption Tower
✓ Design temperature is set 30℃ above the operating temperature.
✓ Design pressure is 10% over maximum operating pressure or 70 to 175 kPa
greater whichever is higher
✓ 9 mm corrosion allowance
✓ Minimum wall thickness of 9.7 mm for rigidity for pressure vessels over 1.52 m
in diameter
✓ Tray spacing of 0.6 m
✓ Absorption tray efficiency of 20%
✓ 0.75 kPa pressure drop per tray
✓ Additional 1 m at the top and 2 m at the bottom for towers of 1m in diameter
✓ Limit tower height to 50 m for structure stability
Design temperature
𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 35℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 30℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 65℃
Design pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 1.1𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔
Number of Stages
𝑃𝑖𝑠𝑎𝑡
𝐾𝑖 =
𝑃
, where 𝑃𝑖𝑠𝑎𝑡 obtained using Thermosolver (Antoine Equation)
Component Pi
Carbon dioxide 211.42 kPa
211.42 𝑘𝑃𝑎
𝐾𝑖 =
212.8841 𝑘𝑃𝑎
𝐾𝑖 = 0.9931
55
𝐿
𝐴𝑖 =
𝐾𝑖 𝑉
From material balance:

𝑘𝑚𝑜𝑙
𝐿 = 19756
ℎ
𝑘𝑚𝑜𝑙
𝑉 = 20395
ℎ
𝑘𝑚𝑜𝑙
19756
𝐴𝑖 = ℎ
𝑘𝑚𝑜𝑙
0.9931 (20395 )
ℎ
𝐴𝑖 = 0.9754
𝐴𝑁+1
𝑖 − 𝐴𝑖
𝑁+1 = 𝑠𝑜𝑙𝑢𝑡𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑
𝐴𝑖 − 1
N Absorbed fraction
1 0.5
2 0.658
3 0.741
4 0.79
5 0.82
6 0.85
7 1.0
𝑵 = 𝟕 𝒔𝒕𝒂𝒈𝒆𝒔
Diameter
𝑘𝑔 𝑘𝑔
𝜌𝐿 = 1040 3
; 𝜌𝑉 = 32.381393 3
𝑚 𝑚
𝑘𝑚𝑜𝑙 𝑘𝑔
𝐿 𝜌𝑉 0.5 19756 32.381393 3
( ) = ℎ ( 𝑚 )0.50
𝑉 𝜌𝐿 𝑘𝑚𝑜𝑙 𝑘𝑔
20395 1040 3
ℎ 𝑚
𝐿 𝜌𝑉 0.5
( ) = 0.17
𝑉 𝜌𝐿
(based from Figure 15-5, Plant Design and Economics for CHE by Timmerhaus)
56
𝐶𝑠𝑏 = 0.08
𝑚𝑁
𝜎𝐶𝑂2 = 194.1092988
𝑚
𝜎 0.2 𝜌𝐿 − 𝜌𝑉 0.5
𝑉𝑛𝑓 = 𝐶𝑠𝑏 ( ) ( )
20 𝜌𝐿
194.1092988 0.2 1040 − 32.381393 0.5

𝑉𝑛𝑓 = 0.08 ( ) ( )
20 1040
𝑚
𝑉𝑛𝑓 = 0.124
𝑠
𝑚̇𝑉′
𝐴𝑛 =
𝑉𝑛
𝑉𝑛 = 0.70𝑉𝑛𝑓
𝑚
𝑉𝑛 = 0.7 𝑥 0.124
𝑠
𝑚
𝑉𝑛 = 0.0868
𝑠
𝑚3
𝑚𝑉′ = 0.006787 (𝑓𝑟𝑜𝑚 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑏𝑎𝑙𝑎𝑛𝑐𝑒)
𝑠
𝑚3
0.006787 𝑠
𝐴𝑛 = 𝑚
0.0868 𝑠
𝐴𝑛 = 0.078 𝑚2
𝐴𝐶 = 𝐴𝑛 + 𝐴𝑑
(Downcomers occupy 15% of cross-sectional area)
0.078 𝑚2
𝐴𝐶 =
0.85
𝐴𝐶 = 0.092 𝑚2
57
4𝐴𝐶 0.5
𝐷=
𝜋
4(0.092 𝑚2 )0.50
𝐷=
𝜋
𝑫 = 𝟎. 𝟑𝟖𝟔 𝒎
Height
𝐻𝐶 = (𝑁𝑎𝑐𝑡 − 1)𝐻𝑆 + ∆𝐻
𝑁
𝑁𝑎𝑐𝑡 =
𝜇
7 𝑠𝑡𝑎𝑔𝑒𝑠
𝑁𝑎𝑐𝑡 =
0.20
𝑵𝒂𝒄𝒕 = 𝟑𝟓 𝒔𝒕𝒂𝒈𝒆𝒔
𝐻𝐶 = (35 − 1)(0.6 𝑚) + (1(0.386 𝑚) + 2(0.386𝑚))

𝑯𝑪 = 𝟐𝟏. 𝟓𝟓𝟖 𝒎
Wall thickness
Thickness of tank
𝑃𝑟𝑖
𝑡= + 𝐶𝐶
Engineers:
Corrosion Allowance (m) Corrosive streams Cc = 0.0089 m
Maximum Allowable High-alloy steel S = 128,900 kPa
Stress, kPa
welded butt joint
0.386 𝑚
(212.8841 𝑘𝑃𝑎) ( )
𝑡= 2 + 0.0089 𝑚
(128,900 𝑘𝑃𝑎 )(1.0) − 0.6(212.8841 𝑘𝑃𝑎)
𝒕 = 𝟎. 𝟎𝟎𝟗𝟐𝟏𝟗 𝒎 = 𝟗. 𝟐𝟏𝟗 𝒎𝒎
58
Outside Diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
0.386 𝑚 9.219
𝐷𝑜 = 2( + )
2 1000
𝑫𝒐 = 𝟎. 𝟒𝟎𝟒𝟒 𝒎
External Volume
𝜋𝐷𝑂 2 ℎ
4
𝜋(0.4044 𝑚)2 (21.558 𝑚)
4
𝑽𝒆𝒙𝒕𝒆𝒓𝒏𝒂𝒍 = 𝟐. 𝟕𝟔𝟗 𝒎𝟑
Volume of Steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙
𝑉𝑠𝑡𝑒𝑒𝑙 = (2.769 − 1.98)𝑚3
𝑽𝒔𝒕𝒆𝒆𝒍 = 𝟎. 𝟕𝟖𝟗 𝒎𝟑
Mass of Steel
𝑚𝑠𝑡𝑒𝑒𝑙 = 𝑉𝑠𝑡𝑒𝑒𝑙 𝑥 𝜌𝑠𝑡𝑒𝑒𝑙
𝑘𝑔
𝑚𝑠𝑡𝑒𝑒𝑙 = 0.789𝑚3 𝑥 7830
𝑚3
𝒎𝒔𝒕𝒆𝒆𝒍 = 𝟒𝟖𝟖𝟓. 𝟐𝟏 kg
59
DISTILLATION TOWER (DT-301)
• The design pressure is 10% above the operating pressure

• The design temperature is set 30 degrees above the operating temperature
• Continuous distillation
• Plates
𝑘𝑚𝑜𝑙
Feed 374.42 𝑧𝑓 0.363
𝑑𝑎𝑦
𝑘𝑚𝑜𝑙
Distillate 124.48 𝑥𝐷 1.0
𝑑𝑎𝑦
𝑘𝑚𝑜𝑙
Bottom 239.95 𝑥𝐵 0.033
𝑑𝑎𝑦
Operating Design
Temperature (˚C) 210 240
Pressure (kPa) 101.325 111.458
Determination of Relative volatility:

𝑃𝐶𝑂2
𝛼=
𝑃𝑤𝑎𝑡𝑒𝑟
3.37 𝑚𝑚𝐻𝑔
𝛼=
1 𝑚𝑚𝐻𝑔
𝛼 = 3.37
Number of stages:
0.9999 1 − .033
ln (1 − 0.9999 . 033 )
𝑁𝑚 =
ln(3.37)
𝑁𝑚 = 10
𝑁 = 𝑁𝑚 (2), S. Walas. (1990). Heuristics in Chemical Engineering
𝑁 = 20
Reflux Ratio:
• Assuming the production would increase
𝐹𝑑𝑒𝑠𝑖𝑔𝑛 = 1.5(374.42)
𝑘𝑚𝑜𝑙
𝐹𝑑𝑒𝑠𝑖𝑔𝑛 = 561.63
𝑑𝑎𝑦
60
𝐷𝑑𝑒𝑠𝑖𝑔𝑛 = 1.5(124.48)
𝑘𝑚𝑜𝑙
𝐷𝑑𝑒𝑠𝑖𝑔𝑛 = 186.72
𝑑𝑎𝑦
1 𝐹
𝑅𝑚 = ( )
𝛼−1 𝐷
1 561.63
𝑅𝑚 = ( )
3.37 − 1 186.72
𝑅𝑚 = 1.26
𝑅 = 1.2(𝑅𝑚 ), S. Walas. (1990). Heuristics in Chemical Engineering
𝑅 = 1.2(1.26)
𝑅 = 1.5
Tower Diameter:
𝑆 = 0.5(𝐷)0.3 , C. M. Lek, G. P. Rangaiah, K. Hidajat, (2004). Revisiting Some Rules of Thumb
0.6𝑚 = 0.5(𝐷)0.3
𝐷 = 1.836 𝑚
Tower Height:
Trays Basing = 0.6 m
Distance above and below the top and bottom tray = 2 m
𝑁𝑡𝑟𝑎𝑦𝑠 = 20 − 1
𝑁𝑡𝑟𝑎𝑦𝑠 = 19
𝐻 = (19)(0.6𝑚) + 2
𝐻 = 13.4 𝑚
6. Design the column internals: plates, distributors, packing supports.
7. Mechanical design: vessel and internal fittings.
61
Chapter 5
Equipment
Specification
Pump
Identification: Item number: P-301
Number Required: 1
Operation: 24 hours per day
Materials Handled: Water, Ethanol, CO2, O2
Conditions: Design Temperature: 55 °C
Design Pressure: 111.4575 kPa
Design Data: Mass Flow Rate: 38, 550.4 kg/hr
Residence Time: 1 hr
Capacity 40.4085 m3
Pressure Head 6.75 m
Input Power 1,416.72 W
Output Power 708.36 W
Pump Type Centrifugal Slurry Pump
Efficiency 50%
Material of Construction Stainless Steel (Type 304)
Equipment Drawing
Pump
Identification: Item number: P-302
Number Required: 1
Materials Handled: Water, EtOH, H2SO4, Glucose, Cellobiose, Xylose,
Furfural, Cellulose, Hemicellulose, Lignin, Glycerol,
Succinic Acid, Acetic Acid, Lactic Acid, Xylito, CO2, O2
Conditions: Design Temperature: 55 °C
Design Data: Mass Flow Rate: 103, 832.98 kg/hr
Residence Time: 1 hr
Capacity 88.2186 m3
Pressure Head 6.75 m
Input Power 3,815.86 W
Output Power 1,907.93 W
Pump Type Centrifugal Slurry Pump
Efficiency 50%
Equipment Drawing
63
Mixing Tank
Identification: Item number: M-301
Number Required: 1
Materials Handled: Water, EtOH, H2SO4, Glucose, Cellobiose, Xylose,
Furfural, Cellulose, Hemicellulose, Lignin, Glycerol,
Succinic Acid, Acetic Acid, Lactic Acid, Xylito, CO2, O2
Conditions: Design Temperature: 55 ℃
Design Data: Mass Flow Rate: 103,832.98 kg/h
Power Requirement: 36,737.8 W
Impeller Diameter 3.6528 m
Impeller Clearance 0.2029 m
Impeller Width 0.3653 m
Operating Speed 2.6142 rpm
Residence Time 25 min
Dimensions: Tank Volume 52.51 m3
Tank Diameter 4.0587 m
Tank Height 4.0587 m
Thickness 11.99 mm
Mass of Steel: 4, 885.21 kg
Equipment Drawing
64
Gas Tank
Identification: Item number: GT-301
Number Required: 1
Materials Handled: Water, EtOH, H2SO, CO2, O2
Design Data: Mass Flow Rate: 20,395 kg/h
Residence Time 30 d
Tank Height 32.2682 m
Thickness 16.86 mm
Equipment Drawing
65
Vent Scrubber
Identification: Item number: VS-301
Number Required: 1
Materials Handled: Water, EtOH, H2SO, CO2, O2
Residence Time 1 hr
Tank Height 21.56 m
Thickness 9.219 mm
Number of Stages 35
Material of Construction High-alloy steel (SA-240)
Equipment Drawing
66
Distillation Tower
Identification: Item number: DT-301
Number Required: 1
Materials Handled: Water, Light-organics, EtOH, H2SO, CO2, O2
Residence Time 1 hr
Heating Reboiler
Dimensions: Reflux Ratio 1.5
Number of Stages 20
Tower Diameter 1.836 m
Tower Height 13.4 m
Tray Distance 60 cm
Equipment Drawing
67
Chapter 6
Hazard and
Operability Study
Heat Exchanger
Equipment Deviations Possible Cause of Consequence of the Additional Process Notes and Questions
Reference from Deviation deviation implications of Indications
and Operating this consequence
operating conditions
conditions
HX-301 Flow
More Pipe blockage Temperature of process Eventual leakage High temperature
fluid remains constant alarm
Less Failure of cooling Temperature of process Pump starvation Low temperature
water valve fluid remains constant alarm
No Damaged or closed Contamination of Equipment
valve process fluid damage
Temperature
More Damaged control Excessive load of the Increased amount TIC-301 Check for repair
valve corresponding materials of by-products maintenance and
Outlets blocked irregularities
Less Damaged control Insufficient load of Reduced output TIC-301
valve corresponding materials
HX-302 Flow
Temperature
69
conditions
HX-303 Flow
Temperature
70
Pumps
conditions
P-301 Flow
More Increased capacity Equipment damage Eventual leakage Check for repairs,
maintenance, and
irregularities.
Less Control valve failure Less output Pump starvation
No Damaged or closed Disrupted production Equipment
control valve rate, pump cavitation Damage
Pressure
More Pump overheats Explosion/malfunction Equipment PI-301 Check for repairs,
due to impeller of pump. damage and maintenance, and
thermal expansion. leakage. irregularities.
Less Pump cavitation Pump damaged Equipment PI-301
damage
No Damaged Pump or impeller Equipment PI-301
damage damage
P-302 Flow
More Increased capacity Equipment damage Eventual leakage Check for repairs,
maintenance, and
irregularities.
Less Control valve failure Less output Pump starvation
No Damaged or closed Disrupted production Equipment
control valve rate, pump cavitation Damage
Pressure
More Pump overheats Explosion/malfunction Equipment PI-302 Check for repairs,
due to impeller of pump. damage and maintenance, and
thermal expansion. leakage. irregularities.
71
Less Pump cavitation Pump damaged Equipment PI-302
damage
No Damaged Pump or impeller Equipment PI-302

damage damage
Mixing Tank
conditions
M-301 Flow
More Damaged or closed Excessive load of the Increased amount FIC-301 Check for repairs,
control valve. corresponding materials of by-product maintenance, and
irregularities.
Less Blockage on M-201 Insufficient load of Reduced output.
corresponding
materials.
72
Vent Scrubber
conditions
VS-301 Flow and Level
High • Pump seal fails Slow leak only expected LIC-302 Regular inspections
• Solenoid valve to from pump and maintenance.
the scrubber sump
fails to open Scrubber sumps fills Sump high level alarm
and then overflows via
the emergency pH meter will detect a
overflows drop in pH
The emergency
overflow is sized for
all make-up water
supply flow operating
together at maximum
rates.
Low • Pipeline rupture Loss of production LIC-302 Consider repair the

• Wrong closure Fire pipeline and always
malfunction of any No fluid to downstream check and maintain a
downstream process good condition for
valve/upstream valves
valve
Pressure
High • Malfunction of any Increase the vent PIA-302 Install pressure control
downstream valve scrubber pressure
• External fire
73
GAS TANK
conditions
GT-301 Level
More • Failure of control Flooding inside the tank Risk of tank LIC-301 Install backward
valve either from explosion overflow alarm with
GV- 306 or DV- auto shutdown.
301
• Blockage in GV-
301
Less • Failure control Disrupted production LIC-301 Check the temperature
valve rate of inlet stream to FDb
• Problem in to prevent this.
temperature of the
stream inlet in flash Install a low lever
drum (FDb) alarm
Pressure
More • Failure of control Tank will rupture or PIA-301 Install pressure relieve
Valve burst valve and install high
• Too high level of pressure alarm.
gas
Temperature
High • Temperature of Thermal stress on tank TIA-301 Check the
inlet is hotter than Temperature limits of
normal the tank
Install temperature
control
74
Low • Low tank pressure There might be a TIA-301
• Temperature of changing of forms of
inlet colder than the gas (vapor to liquid)
normal
Distillation Column
conditions
DT-301 Pressure
Less Desired pressure is not Decreased in vapor Decrease in PIA-301 Regular monitoring of
met. density condenser pressure
temperature
More Pressure is higher than Increase in latent heat Difficulty in PIA-301
normal of vaporization separation
Level
Less Feed pipes may be Lesser yield of distilled Reduced output LIC-303 Repair and
damaged water maintenance of feed
pipes
More Control system fails Distilled water will The equipment LIC-303 Repair and
overflow may be damaged maintenance of the
controller
75
Chapter 7
Piping and
Instrumentation
Diagram
NOTES:
TIC
FV 302 301
01. DT – Distillation Column
LT
302
02. FD – Flash Drum
LIC
03. GT – Gas Tank
LT TT
301 301 301 CO 2 recycle to
LIC [43] ponds
TIA PIA
302
V 301 04. HX – Heat Exchanger
301 301
05. M – Mixing Tank
06. P – Pump
07. VS – Vent Scrubber
PIA
Vapors from FD-201 [40] [41] Valves and Instruments
VS-301 302
FV-301 [38] GT-301
PI FV-303 [42] 01. FV – Flow Valve
[50] HX-301
301
V 302
02. V – Valve
FV-304 Water 03. FT – Flow Transmitter
V 304
[44] 04. FIC – Flow Indicator and
Controller
P-301 05. LT – Level Transmitter
FV-306
FT
301
FIC
301
PIA
303
06. LIC – Level Indicator and
TIC
[45] 302 Controller
07. PI – Pressure Indicator
PI
302
HX-302
TT
302
08. TT – Temperature Transmitter
FV-305 [49] 09. TIC – Temp Indicatior and
[48] To DT-302
[46]
DT-301 Controller
M-301
V 305
10. TIA – Temp Indicator and Alarm
[47]
P-302
V 303
[51]
[39]
FV-307
LIC LT HX-303
Liquids from FD-201 303 303
TT TIC
[52] 303
303
Calaca,
To water
recycle pool Batangas
Biofuel
Plant
Piping and Instrumentation

Diagram
Drawing No. D-G01-205 Rev. No. 0

Sheet 1 of 1
Chapter 8
Waste
Minimization,
Prevention, and
Treatment Plan
`
Waste Minimization
As a sustainable process, it is being proposed that the recovered carbon dioxide from VS-301 should be
recycled back to the process, by either direct feeding into cultivation pond (CP-101) or by allowing a
pretreatment process before it is recycled back to the process, considering that it should not compromise
the quality of the bioethanol product being produced and the raw microalgae itself.
Treatment Design
To address the large wastewater production of the plant coming from DT-301 aside from the screening and
clarifiers, it is suggested that the plant should incorporate a wastewater treatment plant using bioreactors.
Wastewater treatment technology is a technique used to aid treatment on wastewater through different
levels of processes such as: (1) the primary, which includes settling and other physical treatments; (2)
secondary, which includes the biological type of treatment and; (3) tertiary, which constitutes the
disinfection process. In some cases, tertiary treatment is followed by filtration process and sludge handling.
As mentioned, the wastewater is characterized to have different organic compounds such as the unreacted
triglycerides, salts, free glycerol and methanol. One effective process to address these is to incorporate a
biological process in the wastewater treatment plant. There are different types of wastewater treatment
process. Such of the more advanced technologies include the sequencing batch reactor and membrane
biological reactor.
Environmental Considerations
Water Quality
Water quality can be affected by the resource input and management used in cultivation of algae,
weather events and integrity of infrastructure and processing spent and waste water. Eutrophication of
water, contamination of ground water and salinization of water sources are the concerns on releasing culture
waters on natural environment. Leakage of culture fluid to groundwater or surface water could occur if the
integrity of the system is compromised, if flooding occurs, or if spills occur during transfers of fluid during
process stages or waste removal, but most of these events could be avoided with proper management.
Released waters could be more saline than receiving waters, particularly if water from saline aquifers is
used for algae cultivation. Such point-source discharge will be regulated by the Philippine Clean Water Act
of 2004 (R.A. 9275) and Laguna Lake Development Authority (R.A. 4850) especially that the water quality
and general condition of Laguna de Bay is being closely monitored.
Land-Use Change
80
Environmental effects, such as net Greenhouse Gas (GHG) emissions, changes in biodiversity, and
changes in ecosystem services such as food production are all associated with land- use changes. In addition,
there is growing concern about the spatial and temporal scales of some types of conversions, such as
deforestation and urbanization. A substantial land area for power lines and roads, facilities and large-scale
deployment of algal biodiesels and bioethanol is required for a commercial-scale production thus
conversion of lands from other of its existing uses will occur.
TABLE 1.1 A Summary of the Committee’s Judgment on the Likelihood of Land (or Water Surface)
Conversion to Algae Cultivation Ponds and Facilities, Based on Value for Other Land (or Surface Water)
Uses. (Source: Sustainable development of Algal biofuels in the United states, 2012).
Land Type Possible or Likely Unlikely
Productive agricultural land X
Marginally or unproductive agricultural land X
Desert X
Brownfields X
High-value coastal land X
Low-value coastal land X
Forest land X
Rangeland, low-density grazing land X
Parks and conservation land X
Wetlands X
Residential land X
81
Industrial parks X
Urban land other than brownfields X
Former catfish pond lands X
Offshore X
NOTE: Low-value land is assumed to be used to cultivate algae for biofuels.
Greenhouse-Gas (GHG) Emissions

GHG emissions are an important factor to consider during the whole production process. It is highly
dependent on the production methods and the type of feedstock used. And three main assumptions in
calculating the carbon intensity of biodiesels are:
• Greenhouse Gas Emissions from growing the feedstock
• Greenhouse Gas Emission from transporting the feedstock
• Greenhouse Gas Emission from processing the feedstock into biodiesel
For algae bioethanol production, the total greenhouse gas emission strongly depends on the initial
concentration and on the energy system used to concentrate the ethanol according to Dexin Luo et al (2010)
in their article. Biofuel produced from perennial feedstocks such as switchgrass and miscan thus can have
very low greenhouse gas emissions because a significant portion of the biomass is used to generate process
heat and electricity, with extra electricity produced and exported to the grid. The main assumption in
calculating the Carbon dioxide intensity in algae bioethanol production are:
• Greenhouse Gas Emission from Process Electricity Consumption
• Greenhouse Gas Emission Onsite Process Heat Consumption
• Net Energy and Greenhouse Gas Emissions from On-Site Combined Heat and Power
The other factors that are not sometimes considered but can be very significant are:
• Greenhouse Gas Emissions from the change in land use of the area where the diesel feedstock is
grown
• Greenhouse Gas Emissions from transportation of the biodiesel from the factory to its point of use
• The amount of Carbon Dioxide produced at the tail pipe.
The potential to mitigate GHG emissions is one of the motivations to develop biodiesels. The basis
of mitigation is that carbon emissions from combusting a biodiesel are cancelled by the corresponding
capture in photosynthesis. This said, the net GHG emissions of producing biodiesels and coproducts are not
82
zero because of carbon and other GHGs emitted in processing. In addition, ethanol purification process is
a major energy consumption and a significant contributor to the carbon footprint. With the lead scenario
based on a natural-gas-fueled combined heat and power system to provide process electricity and extra heat
conservative assumptions around the ethanol separation process, the net life cycle energy consumption,
excluding photosynthesis decreases and the net life cycle greenhouse gas emissions also decreases. In
comparison to gasoline, it gives a reduction in the carbon footprint for this ethanol fuel on an energy
equivalent basis. The gas emissions from algae bioethanol can be further reduced via employment of higher
efficiency heat exchangers in ethanol purification and/or with use of solar thermal for some of the process
heat.
Air Quality
The air quality impacts of algal biodiesel and bioethanol production will depend on system design.
Different air quality issues arise in conjunction with the different steps of the algal supply chain. The wide
range of potential organisms for producing algal biodiesels and bioethanol with the wide range of final fuel
products result in a broad range of possible air emissions. The air emissions will be regulated under the
Philippine Clean Air Act (R.A. 9275).
Species Invasiveness and Aquatic Biodiversity
Species invasiveness is a concern unique to biodiesels produced from algae and vascular plants.
Biodiversity is affected by changing land use or altering landscapes to produce algal biofuel (diesel and
ethanol) feedstocks.
A common cause is the releases of improved nongenetically engineered or genetically engineered
strains of algae from biodiesel and bioethanol production cultures to natural environments, especially from
open ponds. Releases may occur during the feedstock production stage or possibly during the harvesting or
drying stages and it will probably occur most often through aerosolization, although leakages from ponds
or weather-related spillage (for example, high tides and heavy storms) also are possible. Also, introducing
non-native algae to a new environment can have a huge effect.
Table 1.2. Comparison of Typical Tailpipe Emissions from Biodiesels to Conventional Gasoline or Diesel
(Source: Sustainable Development of Algal Biodiesels in the United States, 2012).
BIOETHANOL (E10) BIOETHANOL (E85) BIODIESEL (B20 and FISHER-TROPSCH

B100)
83
16% reduction in CO 15% reduction in 10% (B20) and 50% NOX reductions due to
ozone-forming volatile (B100) reductions in the higher cetane
organic compounds CO emissions number and even
further reductions with
the addition of catalyst.
Reductions in 40% reduction in CO 15% (B20) and 70% ( Little or no particulate
particulates emissions B100) reduction in emissions due to low
particulate emissions sulfur and aromatic
content.
No significant 20% reductions in 10% (B20) and 40% Expected reduction in
reductions in NOx particulate emissions (B100) reduction in hydrocarbon and CO
emissions total hydrocarbon emissions
emission
Higher acetaldehyde 10% reductions in NOX 20% (B20) and 100%
emissions emissions (B100) reductions in
sulfate emissions
80% reductions in 2% (B20) and 9%
sulfate emissions (B100) reductions in
NOX emissions
Lower reactivity of No change in methane
hydrocarbon emissions emissions
Higher ethanol
acetaldehyde emissions
Notes:
E10, a fuel mixture of 10% anhydrous ethanol and 90% gasoline sometimes called gasohol, can be used
in the internal combustion engines of most modern automobiles and light-duty vehicles without need for
any modification on the engine or fuel system. It is a new grade of automotive fuel at German filling
stations since 2011. E stands for ethanol and 10 for the ethanol content in the fuel. Bioethanol in E10
substitutes fossil fuel and therefore it makes an important contribution towards reducing
CO2 emissions in the transport sector. It reduces greenhouse gas emissions by more than 70%
compared to fossil fuels and its production is based on renewable agricultural raw materials grown
sustainably in Europe.
84
E85, a mixture of 85% ethanol and 15% gasoline, is generally the highest ethanol fuel mixture found in
the United States and several European countries. This mixture has an octane rating of 94-97 which is
significantly lower than pure ethanol, but still higher than normal gasoline (87-93 octane, depending on
country). E85 Commodore emitted somewhere between 5.5% and 26% less CO2 than the E10 car.
B20 Biodiesel is a blend of 20%biodiesel and 80% petroleum diesel
B100 biodiesel is the pure form of the fuel.
Waste Products
Sludge, from solid waste from algal biodiesel and bioethanol manufacturing processes, are most
likely to be generated from an anaerobic digester and fermentation (only for bioethanol) from which the
volatile organic acids have been converted to methane and CO2 and the biogas was produced, respectively.
The methane is useful as a diesel supplement for the process, as for biogas, it is usefull to produce heat and
electricity which can improve the overall energy balance. To convert dissolved solids to sludge, anaerobic
digestion in many cases is followed by aerobic digestion.
Recycling raw materials and minimizing of waste can enhance the sustainability of a production
process. If the oil-extracted biomass is recycled or made into coproducts, a source of waste would be
reduced or eliminated. Anaerobic digestion is another method of waste disposal and can generate electricity
as a coproduct. For the disposal of waste biomass, blow down of solids from production and recycling
ponds, and saltwater, companies are considering landfilling waste, underground injection, and diverting
processed water to sewage systems. Solid wastes are to be eliminated in compliance with the Philippine
Ecological Solid Waste Management Act (R.A. 9003).
Pathogens and Toxins

Many algal species have food grade status and are used as feed in aquaculture. Algal toxin-
producing strains are not likely to be used in algal biofuel production however some species regarded as
benign may in produce toxins previously unknown; examples of these include newly discovered euglenoid
toxins and free radical toxins. In addition, contaminating toxin-producing algae and cyanobacteria could
potentially colonize production systems.
Human toxins that are produced by cyanobacteria have been found in freshwater, marine, and estuarine
organisms and include cytotoxins, hepatotoxins, dermatotoxins, and neurotoxins among others. Ecotoxicity
from algal toxins is observed in fish, shellfish, or invertebrate herbivores. Toxins can affect viability,
growth, and fecundity of many organisms.
85
Monitoring algal composition is critical to maintain the desired characteristics for processing
biomass to fuels and ensuring that the coproducts from lipid-extracted algae are safe for use and minimizing
downstream effects of water-soluble toxins. Minimizing sources of human and animal pathogens in algal
culture could include:
• A high level of treatment or sterilization of wastewater.
• Using agricultural grade fertilizers
• Use of high-pH brines to reduce survival of pathogen competitors of cyanobacteria.
Mosquito-Borne Diseases
Poorly managed open ponds can provide habitats for mosquito larvae. Photobioreactors and
raceways would not represent mosquito habitat unless there is substantial leakage of culture fluid, and
puddles are formed. Standing waters, which can vary from large lakes to small puddles or filled buckets,
can be used by mosquitoes to opportunistically lay their eggs. The full area of algae cultivation ponds would
not be optimal habitat because of the required stirring and agitation for adequate mixing of nutrients and
light exposure. However, any relatively still edges of open ponds and outlying puddles or open-water
storage vessels would be suitable for the growth of mosquito larvae. Algae is a constitute food for mosquito
larvae, the high nutrient.
Safety Considerations
The biofuel (diesel and ethanol) plant is committed in managing health, safety and environmental
(HSE) matters as an integral part of the business. Compliance with the federal laws, regulations and
environmental standards will be strictly monitored to meet the HSE quality standards. The plant will
continue to seek the improvement of HSE management to try to minimize or prevent the predicted impacts
to health and the environment.
Wastewater Treatment
There are three major processes by which the wastewater treatment undergoes, namely: primary,
secondary, and tertiary.
In the primary treatment, large solid materials are removed such that the flow through the
equipment would not be obstructed. Moreover, it also prevents the damage and clogging in the downstream
equipment and to the river bank. The first sludge is then produced from the batch separator as the influent
86
passes through it. The primary clarifier, which receives the rest of the treated influent, further reduces the
suspended solid present in the water.
The secondary treatment consists of the following equipment: sequencing batch reactor,
equalization tank, aerator and sedimentation tank. For the sequencing batch reactor, oxygen is bubbled to
enable the production of activated sludge such that organic matter is reduced. This is measured by the
biochemical oxygen demand (BOD) and chemical oxygen demand (COD). This is then passed through the
equalization tank, and then streamed into the aerator. The aerator incorporates air to the wastewater to allow
aerobic bio-degradation of the pollutant components, which is an essential part of most biological
wastewater treatment systems. Biological treatment utilizes microorganisms, which naturally occurs in
wastewater, to allow degradation of contaminants; in contrast, chemical treatment employs chemicals to
react and stabilize contaminants in the wastewater stream. The resulting sludge is then passed through the
drying beds. Lastly, the sedimentation tank is used for removal of the suspended solids in the wastewater.
In the tertiary treatment, cloth media filtration is employed to maximize the removal of solid over
a wide range of particles size, which also ensures the removal of debris that can possibly damage the
membrane reactor. The influent is then treated with chlorine to allow disinfection. In wastewater treatment,
chlorine is a known disinfectant since it allows destruction of target organisms through oxidation of cellular
material. In addition, it is safe and provides ease in handling and storage. Disinfection with chlorine reduces
mutagenic and carcinogenic compounds. After disinfection of the influent, the treated water is ready for
disposal.
87
`
NOTES:
Wastes from from

Wastewater DT-301
(Bottoms)
D-601 and D-602 LEGEND:
INFLUENT
Primary
Screening TREATED INFLUENT
Clarifier
Equalization Sedimentation Membrane
Aerator
Tank Tank Bioreactor
SLUDGE
Sequencing
Chlorine
Batch Batch
Activated
Separator Reactor EFFLUENT
Sludge
NOTES:
Cloth Media
Drying Beds Disinfection
Filtration Wastewater from DT-301
Sludge Sludge • Water

• Ethanol
• Soluble sugars
• CO2
• O2
Dried Sludge Treated
Water
Calaca,
Batangas
Biofuel
Plant
WASTEWATER TREATMENT
FACILITY
`

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MAPÚA UNIVERSITY

SCHOOL OF CHEMICAL, BIOLOGICAL,

Design of Process and Equipment of Bioethanol Purification of

An Individual Report Submitted in Partial Fulfillment of the

Dr. Alvin R. Caparanga

Chapter 1: Process Description .............................................................................. 1

form. The effluent is fed back to DT-301.

New in the Process & Justification

Pin = 101.325 kPa

Process Flow Diagram

Drawing No. D-G01-205

01.HX – Heat Exchanger

Material Balance of Area 300

Drawing No. D-G01-205

01.HX – Heat Exchanger

Material Balance of Area 300

Drawing No. D-G01-205

01.HX – Heat Exchanger

Material Balance of Area 300

Drawing No. D-G01-205

Mass Balance Equation:

𝒙 = Total mass of Stream 50 = 6154.340635 kg/day

Components Composition Total Amount

CO2 60% 3692.604381

H2O 20% 1230.868127

Total 100% 6154.340635

Components mol flow (kmol/d) mass flow (kg/d)

Water 17730.97778 319157.6

CO2 791.2801636 34824.24

Total 21861.76638 483326.47

✓ Component Balance: [38] + [50] = [40] = [41]

Components mol frx mol flow (kmol/d) mass flow (kg/d)

EtOH 0.111774 2423.267127 111,635.07

CO2 0.040377 875.3828268 38,516.84

O2 0.027301 591.8883791 18,940.43

Total 1 21,680.01 470,559.38

[42] = 𝒙 = 474,167.529 kg/day

✓ Stream 41 from the Gas Tank:

Components mol frxn mol flow (kmol/d) mass flow (kg/d)

Water 0.820547 17,789.48 320,388.47

EtOH 0.111774 2423.267127 111,635.07

CO2 0.040377 875.3828268 38,516.84

O2 0.027301 591.8883791 18,940.43

Total 1 21,680.01 470,559.38

Note from the table: Amount of CO2 in Steam 41 = 38,516.84438 kg/day

✓ Mole Balance Equations:

[41] + [42] = [43] + [44]

Components mol fraction mol flow (kmol/d) mass flow (kg/d)

Water 0.935994 44,117.49 794,556.00

EtOH 0.051412 2423.267127 111,635.07

CO2 3.71E-05 1.750763636 77.0336

O2 0.012557 591.8883791 18,940.43

Total 1 47,134.40 925,208.53

✓ From previous calculation, components of Stream 45 and Stream 39 (liquids coming

Water 0.935994 44,117.49 794,556.00

CO2 3.71E-05 1.750763636 77.0336

Total 1 47,134.40 925,208.53

Components mol fraction mol flow mass flow

Water 0.204625 4432.744444 79789.4

Acetic Acid 0.004581 99.2397169 5959.345

Ethanol 0.30 6500.864263 260481.83

H2SO4 0.00 0.007072119 0.693626361

Glycerol 0.20 4402.846129 405458.1

Succinic Acid 0.10 2206.759251 260596.2