K4 - Report PDF

PRODUCTION OF METHANOL AND BIOFLOCCULANT FROM POME
KK4
MONETISATION OF POME INTO RENEWABLE GAS AND GREEN

CHEMICALS
FACULTY OF ENGINEERING AND BUILT ENVIRONMENT

UNIVERSITI KEBANGSAAN MALAYSIA
BANGI
2020
DECLARATION
We hereby declare that the work in this final year design project is our own except for
the quotations and summaries which have been duly acknowledged.
18 June 2020 CHEAH CHING WEI

A157594
RAVINKUMAR A/L MANIMARAN

A158192
SITI BARAKAH BINTI MOHD KHAIRI

A158482
SIVAPRIYA A/P NADARAJU

A158432
AFIQ SYAZWAN BIN MOHD HAIZOLLIZAM

A158912
NUREDAHTUL FAEZAN BINTI MOHAMMAD

YUSOP
A159291
ACKNOWLEDGEMENT
Praise to Allah, the most gracious the most merciful. Thank you for giving us strength
and spirit to us to complete this project. We will never complete this challenging Final
Year Design Project if we did not receive some help from these people.
First and foremost, we would like to express our highest appreciation to our
beloved supervisor, Prof Dr Ir Siti Kartom Kamarudin, Assoc. Prof Dr Masli Irwan
Rosli, and our industrial mentor, Miss Hemavathi Silvamany for their concern and
guidance in this project. Special thanks to our lecturers Ir Dr Syuhaida Harun, Dr
Rosiah Rohani, Prof Ir Dr Abdul Wahab, Dr Darman Nordin, Prof Ir Dr Sobri Tarrif, ,
Dr Teow Yeit Haan, Dr Ir Nor Yuliana Yuhana and Assoc Prof Dr Shahbudin Masdar
@ Mastar for guiding and giving us knowledge complete this project. Without the
encouragement and patience, we believe that we would hardly finish our tasks before
the due date. Also, we would like to express our highest gratitude to our parents for
giving us all the moral support when we really need one. Thank you very much and
may god bless your help,
Lastly, we would like to thank all our coursemates, seniors, and those who are
involved in helping our in this project directly and indirectly. Without all of the help
it is impossible for us to complete this project. Your kindness and cooperation is
highly appreciated. Just words alone cannot illustrate how much we thank you all.
MONETISATION OF POME INTO RENEWABLE GAS AND GREEN CHEMICALS
ABSTRACT
The proposed design project is to build a processing plant that produces methanol and
bioflocculant from the palm oil mill effluent (POME). This purpose of this study is to
minimize the waste from palm oil mill and at the same time converting is to valuable
materials. This study aims to produce bioflocculant at 2000 tonnes /year. In the first
phase, the study began with feasibility study of the product based on several factors
such as supply and demand, product price and production process of the product.
After that, it is followed by a rough draft of the methanol and bioflocculant production
processes. From the draft, several factors that need to be considered such as type of
reactors, type of separation units, plant location and utility have been collected and
evaluated in order to select the most efficient unit process for treating POME and
produce desired product. The location chosen for the operation is Lahad Datu, Sabah.
This process is started by lowering the POME temperature to 30oC. Later, POME will
be treated through anaerobic digester which is UASB reactor to produce biogas that
will be then used to produce methanol. Caustic scrubbing will be performed to
separate H2S gas from the biogas mixture. After that, the treated biogas will be
processed to produce methanol and 99.9% purity of methanol can be produced after
purification process. The liquid obtained after the anaerobic process in the UASB
reactor will be used to produce bioflocculant in the MBBR reactor with the presence
of B.marisflavi type bacteria. Furthermore, the initial economic study to estimate
gross profit was carried out taking into account the sale price of the product with the
total price of raw materials as well as the capital expenditure of process unit
purchases. The results shows that gross profit earned was RM 378 million. Second
phase study of this project is to perform mass and energy balance by manual
calculation and simulations software. Heat integration analysis in processing plants is
carried out and as much as 75% of the energy can be recovered. Moreover, process
control analysis (P&ID) was conducted to control the process and to optimize product
production while maintaining high product quality. Waste treatment system is also
designed to minimize waste produced and ensuring that the waste released is in
compliance with established standards. Safety analyzes such as HAZOP and HIRARC
are also carried out to ensure that the process plant is safe and in compliance with the
regulations set by safety agencies such as OSHA 1994. Economic analysis of this
study was also conducted to determine the rate of return on investment, payback
period and net present value. The analysis shows that the rate of return is 0.4, the
payback period is 2.3 years and the net present value is RM 85.6 million. Detailed
calculations of the design of each process unit are also carried out individually to
ensure the loading and specification of each process unit to ensure plant safety.
ABSTRAK
Kajian projek reka bentuk yang dijalankan adalah untuk pembinaan sebuah kilang
yang menghasilkan metanol dan pengumpal-bio daripada efluen kilang minyak kelapa
sawit(POME). Kajian ini dijalankan adalah bagi meminimakan sisa buangan daripada
minyak kelapa sawit dan pada masa yang sama menggunakan sisa tersebut untuk
menghasilkan suatu bahan yang boleh menjana pendapatan. Kajian ini menyasarkan
penghasilan pengumpal-bio sebanyak 2000 tan/tahun .Pada fasa pertama, kajian
dimulakan dengan menilai kebolehpasaran produk berdasarkan beberapa faktor seperti
permintaan semasa dan bekalan, harga dan cara penghasilan produk tersebut. Selepas
itu, draf kasar bagi proses penghasilan metanol dan pengumpal-bio dijalankan. Dari
draf tersebut, faktor yang diambil kira seperti jenis reaktor, jenis unit pemisahan,
pelan lokasi dan utiliti telah dikumpul dan dinilai untuk memilih proses yang paling
efisien dalam proses merawat POME dan penghasilan produk. Lokasi yang dipilih
untuk menjalankan operasi adalah Lahad Datu, Sabah. Proses ini dimulakan dengan
menurunkan suhu POME kepada 30oC. Kemudian, POME akan dirawat melalui
proses pencernaan anerobik di dalam reaktor UASB untuk menghasilkan biogas yang
akan digunakan untuk menghasilkan metanol. Pembersihan kaustik akan dijalankan
bagi memisahkan gas H2S dari campuran biogas. Selepas itu, biogas yang telah
dirawat akan diproses untuk menghasilkan metanol dan 99.9% metanol dapat
dihasilkan selepas proses penulenan. Cecair yang diperoleh selepas proses anerobik
dalam reaktor UASB akan digunakan untuk menghasilkan pengumpal-bio di dalam
reaktor MBBR dengan kehadiran bakteria jenis B.marisflavi. Selain itu, kajian awal
ekonomi untuk menganggar untung kasar dijalankan dengan mengambil kira harga
jualan produk dengan jumlah harga bahan mentah serta perbelanjaan modal pembelian
unit proses. Hasil kajian menunjukkan untung kasar yang diperolehi adalah sebanyak
RM 378 juta. Fasa kedua kajian adalah dengan membuat pengiraan imbangan jisim
dan imbangan tenaga secara manual dan simulasi telah dijalankan. Analisis
penyepaduan tenaga dalam loji proses dijalankan dan sebanyak 75% tenaga dapat
dipulihkan. Seterusnya, kajian analisis kawalan proses (P&ID) telah dijalankan bagi
mengawal proses dan bagi mengoptimumkan penghasilan produk di samping
menghasilkan produk yang bermutu. Sistem rawatan sisa buangan loji juga
dikenalpasti dengan meminimakan bahan buangan dan memastikan sisa buangan yang
dilepaskan adalah menepati piawaian yang telah ditetapkan. Analisis keselamatan
seperti HAZOP dan HIRARC juga dijalankan untuk memastikan loji proses adalah
selamat dan menepati undang-undang yang telah ditetapkan oleh agensi keselamatan
seperti OSHA 1994. Analisis ekonomi bagi kajian ini juga dijalankan bagi mengetahui
kadar pulangan pelaburan, tempoh bayaran pulangan pelaburan dan nilai semasa
bersih. Hasil analisis menunjukkan kadar pulangan adalah 0.4, tempoh bayaran
pulangan adalah 2.3 tahun dan nilai semasa bersih adalah RM 85.6 juta. Pengiraan
terperinci reka bentuk setiap unit proses juga dijalankan secara individu bagi
memastikan muatan dan spesifikasi setiap unit proses untuk menjamin keselamatan
loji.
EXECUTIVE SUMMARY
In this design project, a sustainability palm oil mill effluent (POME) treatment
pathway in palm oil mill industry has been designed. Besides treating POME in an
effective way, our designed plant is able to produce green chemicals such as
polysaccharide bioflocculant, methanol and other by-products. The produced
polysaccharide can widely be used in flocculating algae. This nontoxic and
biodegradable flocculant have high potential to be commercialized. The methanol
produced can act as a basic building block in the production of other chemicals such
as plastics, solvent, fuel and paints. Two by products are produced which is the sludge
oil and sludge. The sludge oil can be sold to other industries to produce chemicals like
perfume or biodiesel. The sludge has high organic content which can serve as an
organic fertilizer to the oil palm plantation itself.
The annual production of main product which is the bioflocculant is 2000

tonnes. This production is only about 0.15% of the shortage of supply and demand in
the year of 2025. The quantity of POME received plays and important role in the
production of products as it is the main raw material. Since our designed plant are
focusing on monetization of POME, the annual production is sufficient for the
sustainability of the plant. In addition, the production of methanol is 800 tonnes per
year. This only covers a small portion of the supply and demand in the year 2025
which is 0.001% due to the same reason as above.
This plant is designed into two main parts which are the biochemical and
chemical plant. The POME treatment and bioflocculant production will be done in the
biochemical plant while the methanol production will take place in the chemical plant.
First and foremost, the most important raw material need in our plant is POME. This
hot POME is received from Felda Global Ventures (FGV) Mercu Puspita Palm Oil
Mill will be stored and cooled down in the cooling pond. Once the POME is at 37°C,
it will undergo anaerobic process in up flow anaerobic sludge blanket (UASB) reactor
to produce biogas. This biogas will serve as the raw material in the chemical plant.
The anaerobically digested POME will then be sent to moving bed bioreactor
(MBBR) for aerobic process to take place. The anaerobic process will produce the
bioflocculant. The bioflocculant will undergo a downstream process to reduce the
moisture content to 10%. The POME then will enter the wastewater treatment to be
treated until it meets the Standard B limit before been discharged.
The biogas consists of methane and carbon dioxide will undergo scrubbing
process to remove the trace amount of hydrogen sulphide before been supplied to the
chemical plant. Next, the biogas will undergo methane steam reforming process
followed by methanol forming process. Both of this process occurs in two different
packed bed reactors. The methanol will undergo a purification process to produce
99.9% purity methanol.
Mass and energy balance are conducted for the whole plant using manual and
simulation calculations. Two simulation software have been used which is the
Superpro Designer® in calculation of the biochemical plant while iCON in calculation
of the chemical plant. The manual calculation and simulation calculation have been
compared for both mass and energy balance. The error percentage obtained is about
9.4%. Besides, heat integration has been done in our designed plant by using the pinch
analysis steps in order to reuse the heat energy and minimize the total energy wastage.
The total heat energy recovery from heat integration is 75%.
Control system have been designed for each equipment that involve in the
production plant. Degree of freedom analysis have been done to determine the number
of parameters that should be controlled in the equipment. The control strategies have
been stated for each equipment. Basically, the chemical plant requires more control
system compared to the biochemical plant because chemical process is highly specific
in terms of the reaction and separation process. Piping system and suitable pipe size
have been determined for each stream. A piping and instrumentation diagram (P&ID)
have been drawn for the production plant.
A detailed design for all the equipment involves in the production plant have
been done. This is to ensure a proper manufacture and construction of all the
equipment. Mechanical design for six major equipment has been done which is the
UASB reactor (T-101, T-102 and T-103), MBBR (T-105), cooler (CO-101), methanol
forming reactor (R-102), phase separator (S-102) and distillation column (C-101).
This mechanical design will show the maximum allowable working pressure
(MAWP), the wall thickness and suitable support for that particular equipment. For
the equipment involves in biochemical process, mostly the equipment are made up of
carbon steel and concrete while for chemical process, the equipment are mostly made
up of carbon steel.
Waste treatment plant includes sequencing batch reactor, MBBR, clarifier,

phytoremediation pond, incinerator and gas stack. The biochemical oxygen demand
(BOD) and chemical oxygen demand (COD) value of the discharged wastewater is
8mg/L and 17.1 mg/L respectively. Both values is below the standard B discharge
limit, so it is safe to discharge to the river. Hydrogen sulphide gas is scrubbed using
sodium hydroxide and processed to produce biosulphur as by-product. The unreacted
gas is incinerated in incinerator to generate energy and hazardous composition which
is carbon monoxide is converted into carbon dioxide using platinum catalytic
converter.
Economic evaluation for this production is carried out in order to identify the
profit for the whole process. The sales price for the bioflocculant is RM 90 per kg
with the design life 25 years. Our production is expected to not make profit for the
first two years because construction is still ongoing and by the third year, half of the
processing plant will be operated. Minimum acceptable rate of return (MARR) is 0.3
because the process is producing new product and high risk. As the economic analysis
been conducted, the return of investment (ROI) is 0.4 and the value is generally higher
that MARR. It is acceptable as it could offer higher return of investment compared to
the expected rate. Besides, payback period (PBP) is 2.3 years and it is lower than
PBPreference which is 2.5 years. It could attract investors as it offers early payback
period. Moreover, the net present value (NPV) and net discounted flow rate of return
(DCFRR) is RM 85.6 million and 0.544 respectively. This process could give positive
net present value and it shows that our production is feasible and could make profit
from it.
For plant safety, all the potential hazards of all chemicals and microbe
involving in the production are identified by referring to the material safety data sheet
(MSDS). All the chemical hazards, toxic and flammable materials in this production
are identified in which the most flammable material in our plant is methane.
Flammable gas detector will be placed in our plant to detect any leakage of methane.
Legislative requirements which are applicable to bioflocculant and methanol
production plant are identified as well. Hazard identification, risk assessment and risk
control (HIRARC) study is conducted throughout the plant to evaluate all possible
hazards and their related risks. Hazard system is done based on each equipment to
identify the sources, receptors, how it is transmitted and the barrier.
Hazard and operability (HAZOP) study is conducted on every equipment to

identify all possible hazards beforehand. Different study nodes are identified for each
equipment, with different parameters and guide words. A revised P&ID is produced
after HAZOP study by taking appropriate actions, such as installing alarms and flow
controller to prevent any hazard to take place.
LIST OF CONTENT
Page
DECLARATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
ABSTRAK v
EXECUTIVE SUMMARY vi
LIST OF CONTENT x
LIST OF TABLES xvii
CHAPTER I INTRODUCTION
1.1 Background 1
1.2 Source of raw material 2
1.3 Product usage 3
1.4 By-products 5
1.4.1 Biomass 5
1.4.2 Ethanol 5
1.4.3 Methane 6
1.4.4 Carbon dioxide 7
1.4.5 Carbon Monoxide 7
CHAPTER II ECONOMY ISSUES

2.1 Introduction 8
2.2 Global Market analysis 8
2.2.1 Bioflocculant Market 8
2.2.2 Methanol market 9
2.3 Supply and demand 10
2.3.1 Supply and Demand of Bioflocculant 10
2.3.2 Supply and demand of methanol 11
2.4 Plant capacity 11
2.4.1 Plant capacity of bioflocculant 11
2.4.2 Plant capacity of methanol 11
2.5 Future marketing potential 12
CHAPTER III PRODUCTION DESIGN CONCEPT
3.1 Process design level 1 13
3.1.1 Reaction 13
3.1.2 Stoichiometry 13
3.1.3 Reaction Conditions 14
3.1.4 Reaction conversion 14
3.1.5 Selectivity 19
3.1.6 Catalyst 20
3.1.7 Design constraints 21
3.2.1 Input-output structure 21
3.2.2 Design capacity 22
3.2.3 Mass balance 22
3.2.4 Economic potential analysis for level 2 24
3.3.1 Number of reactors 25
3.3.2 Reactor selection 25
3.3.3 Reactor heat effect 25
3.3.4 Reactor sizing 28
3.3.5 Compressor design and costing 29
3.3.6 Reactor costing 31
3.3.7 Economical potential Analysis of Level 3 34
3.4.1 Distillation column 35
3.4.2 Centrifuge 36
3.4.3 Settlement tank 36
3.4.4 Dryer 37
3.4.5 Phase separator 38
3.4.6 Scrubber 38
3.4.7 Economic potential analysis for level 4 40
3.5 Production process of methanol and bioflocculant 41
3.5.1 Process flow diagram 41
3.5.2 Process description 41
3.5.3 Growth curve 42
3.5.4 Monod Equation 43
3.6 Overall mass balance 47
3.6.1 Overall mass balance by manual calculation 47
3.6.2 Overall mass balance by iCON ® and SuperPro ® 47
3.6.3 Comparison of mass balance by manual calculation
and iCON ® / SuperPro ® software 50
3.7 Overall energy balance 50
CHAPTER IV HEAT INTEGRATION
4.1 Introduction 53
4.2 Pinch analysis 53
4.2.1 Data extraction 53
4.2.2 Interval Temperature 54
4.2.3 Heat Cascade 55
4.2.4 Heat Exchanger Network 56
4.2.5 Total Heat Recovery 57
CHAPTER V PROCESS CONTROL AND PIPING

5.1 Introduction 58
5.2 Process control analysis 58
5.2.1 Control strategies on unit operations 59
5.2.2 Type of intrumentations 59
5.3 Control configuration for unit operation 60
5.3.1 Control configuration on reactors 61
5.3.2 Control configuration on phase separator 63
5.3.3 Control configuration on distillation column 65
5.3.4 Control configuration on scrubber 68
5.3.5 Control configuration on dryer 70
5.3.6 Control configuration on UASB reactors 72
5.3.7 Control configuration on aerated tank 74
5.3.8 Control configuration on gas holder 75
5.4 Valves 77
5.5 Piping system 77
CHAPTER VI DETAILED DESIGN

6.1 Cooling pond (Cp-101) Designed by: Ravinkumar A/L
Manimaran (A158192) 85
6.1.1 Heat transfer in cooling pond 85
6.1.2 Area of Cooling Pond 87
6.1.3 Dimension of Cooling Pond 87
6.1.4 Construction Material of Cooling Pond 88
6.1.5 Schematic Diagram of Cooling Pond 88
6.2 Upflow anaerobic sludge blanket, UASB (T-101, T-102 &
T-103) Designed by: Ravinkumar A/L Manimaran
(A158192) 89
6.2.1 Introduction 89
6.2.2 Dimension of UASB 90
6.2.3 Volumetric Hydraulic Load 90
6.2.4 Organic Loading Rate 90
6.2.5 Sludge Loading Rate 91
6.2.6 Uflow Velocity of POME in UASB 91
6.2.7 UASB Reactor Efficiency 92
6.2.8 Sludge Production 93
6.2.9 Gas Separation System 93
6.3 Settling Tank ( T-104) Designed by: Ravinkumar A/L
Manimaran (A158192) 94
6.3.2 Settling Velocity of Sludge Particle 94
6.3.3 Area of Settling Tank 95
6.3.4 Dimension of Settling Tank 95
6.3.5 Construction Material for Settlement Tank 96
6.4 Moving bed biofilm reactor, MBBR (T-105) Design By:
Siti Barakah Binti Mohd Khairi (A158482) 96
6.5 Mixer (M-101) Design by: Afiq Syazwan Bin Mohd
Haizollizam(A158912) 97
6.5.1 Design Dimension 97
6.5.2 Design of Impeller 98
6.5.3 Summary of Calculation 99
6.6 Dessicant dryer (dd-101) Design by: Cheah Ching Wei
(A157594) 100
6.7 Rotary dryer (d-101) Design by: Cheah Ching Wei
(A157594) 100
6.8 Belt Press (BP-101) Design by: Cheah Ching Wei
(A157594) 100
6.9 Kettle reboiler (H-101) Design by: Cheah Ching Wei
(A157594) 101
6.10 Gas Holder (GH-101) Design by: Siti Barakah Binti
Mohd Khairi (A158482) 101
6.10.2 Material selection 101
6.10.3 Design specification 101
6.10.4 Wall thickness of gas holder GH-101 102
6.10.5 Summary of detailed design parameter of gas
holder 103
6.11 Gas scrubber (Sr-101) Design by: Siti Barakah Binti
Mohd Khairi (A158482) 103
6.11.2 Material selection 103
6.11.3 Design specification 103
6.11.4 Wall thickness of gas scrubber (SR-101) 104
6.11.5 Summary of detailed design parameters of gas
scrubber 105
6.12 Heater (H-102) Design by: Nuredahtul Faezan Binti
Mohammad Yusop(A159291) 105
6.13 Syngas packed bed reactor (R-101) Design by:Afiq
Syazan Bin Mohd Haizollizam (A158912) 106
6.13.1 Rate law 107
6.13.2 Design dimension 109
6.13.3 Design of bed 110
6.13.4 Summary of calculation 111
6.14 Cooler (CO-101) Design by: Nuredahtul Faezan binti
Mohammad Yusop (A159291) 111
6.15 Phase separator (S-101) Designed by: Cheah Ching Wei
(A157594) 112
6.16 Phase separator (S-102) Designed by: Cheah Ching Wei
(A157594) 113
6.17 Distillation column (C-101) Design By: Siva Priya A/P
Nadaraju (A158432) 113
6.17.1 Summary of Design Specification 114
6.18 Reflux drum (Rd-101) Design by: Siva Priya A/P
Nadaraju (A158432) 115
6.18.1 Summary of design specification 115
CHAPTER VII WASTE MANAGEMENT

7.1 Introduction 116
7.1.1 Environment Acts and Regulations in Malaysia 116
7.2 Waste generation 117
7.2.1 Gaseous waste 117
7.2.2 Liquid waste 118
7.3 Waste characteristics 118
7.3.1 Waste characteristics of each type of waste 118
7.3.2 BOD and COD calculation 119
7.3.3 Conclusion 121
7.4 Waste management 122
7.4.1 Waste management summary 128
7.5 WWTP process flow diagram 129
CHAPTER VIII ECONOMIC ANALYSIS

8.1.1 Design life 131
8.1.2 Scrap value 131
8.1.3 Plant capacity estimation 131
8.2 Estimation of total capital investment, (Ctc) 131
8.2.1 Fixed investment capital (CFC) 132
8.2.2 Working capital (CWC) and land capital (CL) 134
8.3 Estimation of total product cost (TPC) 135
8.3.1 Manufacturing Costs (COM) 135
8.3.2 General expenses (GE) 142
8.3.3 Total product cost, TPC 143
8.4 Depreciation 143
8.5 Breakeven analysis and capacity 144
8.6 Process profitability analysis 145
8.6.1 Methods that do not consider the time value of
money 145
8.6.2 Methods that consider the time value of money 148
8.6.3 Results of profitability analysis 149
CHAPTER IX HAZARD IDENTIFICATION AND ANALYSIS

9.2 Legislative requirement 153
9.2.1 Environment Quality Act 1974 154
9.2.2 Occupational Safety and Health Act 1994 155
9.2.3 Factory and Machinery 1967 155
9.3 Hazard identification 156
9.3.1 Identification of chemical hazard 156
9.3.2 Identification of hazardous toxic materials 157
9.3.3 Identification of hazardous flammable materials 157
9.4 Hazard identification, risk assesstment and risk control
(Hirarc) 158
9.5 Concept of hazard system 170
9.6 HAZOP Study 173
9.6.1 Hazop for Equipment in Chemical Process 173
CHAPTER X PLANT LOCATION AND LAYOUT

10.2 Suggestion of plant location 206
10.3 Selection of plant location 208
10.4 Plant layout 209
10.5 Site layout 209
CHAPTER XI MECHANICAL DESIGN

11.1 Mechanical design for Upflow Anaerobic Sludge Blanket,
uasb (T-101, T-102 & T-103) Design by: Ravinkumar
A/L Manimaran (A158192) 210
11.2 Mechanical design for Moving Bed Biofilm Reactor (T-
105) Design by: Siti Barakah Binti Mohd Khairi
(A158482) 211
11.3 Mechanical design for Packed Bed Reactor (R-102)
Design by: Afiq Syazwan Bin Mohd Haizollizam
(A158912) 212
11.4 Mechanical design for Cooler (C-101) Design by:
Nuredahtul Faezan Binti Mohammad Yusop (A159291) 213
11.5 Mechanical design for Phase Separator (S-102) Designed
by:Cheah Ching Wei (A157594) 214
11.6 Mechanical design for Distillation Column (C-101)
Designed by: Sivapriya A/P Nadaraju (A158432) 215
CONCLUSION 217
REFERENCE 219
LIST OF TABLES
No Table Page
Table 1.1 Chemical and physical properties of methanol and

bioflocculant 2
Table 1.2 Properties of POME 3
Table 1.3 Physical and Chemical properties of Ethanol 6
Table 1.4 Physical and chemical properties of methane 6
Table 1.5 Physical and chemical properties of carbon dioxide 7
Table 1.6 Physical and chemical properties of carbon dioxide 7
Table 3.1 Condition for chemical reactions 14
Table 3.2 Condition for biochemical reactions 14
Table 3.3 Data of concentration for conversion in syngas reaction 15
Table 3.4 Data of concentration for conversion in methanol reaction 18
Table 3.5 Properties of catalyst used in the production of methanol 20
Table 3.6 Raw materials 24
Table 3.7 Adiabatic temperature for all four reactors 27
Table 3.8 Syngas synthesis reactor sizing 28
Table 3.9 Methanol synthesis reactor sizing 29
Table 3.10 Annual cost for compressor, C-101 30
Table 3.13 Fm value 32
Table 3.14 Fp value 32
Table 3.15 Annual cost for UASB reactor 32
Table 3.16 Annual cost for aerated tank 33
Table 3.17 Cost of R-101 34

Table 3.18 Cost of R-102 34
Table 3.19 Data for potential economy of process design level 3 34
Table 3.20 Annual cost for distillation column 36
Table 3.21 Annual cost of centrifuges 36
Table 3.22 Annual cost for settlement tank 37
Table 3.23 Annual cost for dryer 37
Table 3.24 Annual cost for phase separator 38
Table 3.25 Annual cost for scrubber 39
Table 3.26 Fep 4 40
Table 3.27 Substrate and biomass concentration 45
Table 3.28 calculations to plot graph of 1/ against 1/S is plotted. 45
Table 3.29 Input material flowrate 47
Table 3.30 Output material flowrate 47
Table 3.31 Comparison of mass balance by manual calculation and

software 50
Table 3.32 Standard Enthalphy Formation, ΔHof production of

bioflocculant 51
Table 3.33 Specific heat capacity production of bio-flocculant 51
Table 3.34 Standard Enthalphies formation, ΔHof production of methanol 52
Table 3.35 Specific heat capacity production of methanol 52
Table 3.36 Comparison of heat balance calculation 52
Table 4.1 Process Data for Each Utility Unit 53
Table 4.2 Interval Temperature for ΔTmin = 10℃ 54
Table 4.3 Heat capacities at Interval Temperature 54
Table 4.4 Heat Cascade 55
Table 4.5 Summary from heat cascade 56
Table 4.6 Total energy recovery 57

Table 5.1 Types of intrumentation applied on the unit process with its
objectives 60
Table 5.2 letter code for instrumentation symbol 60
Table 5.3 Criteria for R-101 61
Table 5.4 Control strategies for R-101 62
Table 5.5 Criteria for R-102 63
Table 5.6 Control strategies for R-102 63
Table 5.7 Criteria for S-101, S-102 64
Table 5.8 Control strategies on S-101, S-102 64
Table 5.9 Criteria for C-101 66
Table 5.10 Criteria for reflux drum 67
Table 5.11 Control strategies on C-101 67
Table 5.12 Criteria for SR-101 69
Table 5.13 Control configurations of SR-101 70
Table 5.14 Criteria for D-101 71
Table 5.15 Control configuration for D-101 72
Table 5.16 Criteria for T-101, T-102, T-103 73
Table 5.17 Control configurations for T-101, T-102, T-103 73
Table 5.18 Criteria for T-105 75
Table 5.19 Control configuration of T-105 75
Table 5.20 Criteria for GH-101 76
Table 5.21 Control configuration for GH-101 76
Table 5.22 Pipe sizing for liquid streams 81
Table 5.23 Pipe sizing for vapour stream 82
Table 5.24 Pipe sizing for mixture stream 84
Table 6.1 Information of POME required to design cooling pond 85
Table 6.2 General information of UASB 89

Table 6.3 Characteristics of sludge 94
Table 6.4 Summary of MBBR reactor 96
Table 6.5 The inlet and outlet stream for each component for M-101 97
Table 6.6 Results for design of mixer M-101 99
Table 6.7 Specification of desiccant dryer model DD-101 100
Table 6.8 Calculation summary and dimension of kettle reboiler 100
Table 6.9 Specification of belt press model PC-7 100
Table 6.10 Process parameter and dimension of kettle reboiler 101
Table 6.11 Design parameters gas holder, GH-101 102
Table 6.12 Design pressure for each part of gas holder SR-101 102
Table 6.13 Thickness of gas holder, GH-101 102
Table 6.14 Summary of gas holder, GH-101 103
Table 6.15 Design parameters gas scrubber, SR-101 104
Table 6.16 Design pressure for each part of gas scrubber, SR-101 104
Table 6.17 Thickness of scrubber, SR-101 104
Table 6.18 Summary of scrubber design 105
Table 6.19 Design specification of H-102 105
Table 6.20 The inlet and outlet stream for each component for R-101 107
Table 6.21 Design dimension of R-101 110
Table 6.22 Results for design of packed bed reactor R-101 111
Table 6.23 Design specification of CO-101 112
Table 6.24 Calculation summary 113
Table 6.25 Calculation summary 113
Table 6.26 Distillation column C-101 design summary 114
Table 6.27 Reflux drum RD-101 design summary 115
Table 7.1 Standard A and Standard B of Industrial Effluent Discharge

Limit. 117
Table 7.2 Characteristics of gaseous waste 118
Table 7.3 Characteristics of wastewater 119
Table 7.4 Characteristics of lean NaOH solution 119
Table 7.5 Summary of the COD and BOD value of each wastewater
stream. 120
Table 7.6 BOD and COD concentration after equalization tank 121
Table 7.7 Mass flow rates for inlet and outlet of NaOH regeneration in
R-101 127
Table 7.8 Summary of BOD and COD after each process 128
Table 8.1 Cost for Purchased-Equipment and Installation 132
Table 8.2 Direct costs 133
Table 8.3 Indirect costs 134
Table 8.4 Total capital investment 135
Table 8.5 Raw materials price 136
Table 8.6 Total labour per shift 137
Table 8.7 Cost of labour per year 137
Table 8.8 Direct manufacturing cost 139
Table 8.9 Fixed manufacturing cost 141
Table 8.10 General expenses cost 143
Table 8.11 Susggested values for risk and minimum acceptable return on
investment 146
Table 8.12 Summarizes some information of our project investment. 147
Table 8.13 Profitability analysis 149
Table 8.14 Profitability analysis for NPV 150
Table 8.15 Protability analysis for NPV = 0 151
Table 9.1 Chemical hazards identification 156
Table 9.2 Hazardous toxic materials identification 157
Table 9.3 Hazardous flammable materials identification 157

Table 9.4 Description of likelihood 158
Table 9.5 Description of severity 159
Table 9.6 Risk matrix 159
Table 9.7 Explanation on risk matrix 159
Table 9.8 HIRARC study of plantwide 160
Table 9.9 HIRARC study of chemical reaction 161
Table 9.10 HIRARC study of Bioflocculant production 167
Table 9.11 Concept of Hazard System based on equipment 170
Table 9.12 Concept Hazard System 171
Table 9.13 HAZOP study on R-101 at node 1 174
Table 9.27 HAZOP study on S-101 at node 1 190

Table 9.32 HAZOP study on C-101 at node 1 196
Table 10.1 Comparison among four site locations 206
Table 10.2 Mark analysis for each factor 207
Table 10.3 Scoring for each location selected 208
Table 10.4 Minimum distances between units of various hazard category 209
Table 11.1 Summary for mechanical design of UASB 210
Table 11.2 Summary of MBBR reactor 211
Table 11.3 Summary for design condition of reactor R-102 212
Table 11.4 Summary for design condition of Cooler CO-101 213
Table 11.5 Operating conditions dimension for phase separator S-102 214
Table 11.6 Summary of calculations for phase separator, S-102 214
Table 11.7 Dimension for the steel welding neck flanges(in mm) 215
Table 11.8 Summary for design condition of distillation column C-101 215
LIST OF FIGURES
No. Figure Page
Figure 1.1 Structural formula of Methanol 1
Figure 1.2 Mechanism of bioflocculant BM-8 4
Figure 1.3 Efficiency of bioflocculant BM-8 compared to other agents 5
Figure 1.4 Structural formula of Ethanol 6
Figure 2.1 Global flocculants market share by end-user (%) 9
Figure 2.2 Global methanol market volume, by end use, 2014-2024

(kilotones) 9
Figure 2.3 Graph of supply and demand of bioflocculant from year 2016
to 2030 10
Figure 2.4 Graph of supply and demand of methanol from year 2016 to
2030 11
Figure 3.1 Syngas reaction conversion 16
Figure 3.2 Methanol reaction conversion 18
Figure 3.3 Selectivity graph for Syngas synthesis reactor 19
Figure 3.4 Selectivity graph for Methanol synthesis reactor 20
Figure 3.5 Input-output structure 22
Figure 3.6 Economic potential curve for level 2 24
Figure 3.7 Graph of adiabatic temperature against conversion 27
Figure 3.8 Potential economy curve for process design level 3 35
Figure 3.9 Potential economy curve for process level 4 40
Figure 3.10 Growth curve of B. marisflavi 43
Figure 3.11 Graph of 1/ against 1/S is plotted. 46
Figure 3.12 iCON for Syngas synthesis reactor 48
Figure 3.13 iCON for Methanol synthesis reactor 48
Figure 3.14 SuperPro for UASB 49

Figure 3.15 SuperPro for MBBR 49
Figure 4.1 Relationship between Tint with Hot/Cold Stream 55
Figure 4.2 Grid heat exchanger network 56
Figure 4.3 Network design below the pinch 57
Figure 4.4 Network design above the pinch 57
Figure 5.1 R-101 61
Figure 5.2 R-102 62
Figure 5.3 S-101, S-102 64
Figure 5.4 C-101 65
Figure 5.5 SR-101 68
Figure 5.6 D-101 71
Figure 5.7 T-101, T-102, T-103 72
Figure 5.8 T-105 74
Figure 5.9 GH-101 76
Figure 5.10 Schematic diagram of (a) butterfly valve and (b) diaphragm
valve 77
Figure 6.1 Cooling pond 89
Figure 6.2 Diagram for mixer M-101 97
Figure 6.3 Diagram for syngas packed bed reactor 107
Figure 6.4 Diagram of Cooler(CO-106) 111
Figure 6.5 Distillation column C-101 114
Figure 6.6 Reflux Drum (RD-101) 115
Figure 7.1 Waste generation in the process 116
Figure 8.1 Graph breakeven 144
Figure 9.1 HAZOP study on R-101 nodes 173
Figure 9.2 HAZOP study on R-102 nodes 181
Figure 9.3 HAZOP study on S-101 nodes 189

Figure 9.4 C-101 195
Figure 10.1 Exact plant location 209
Figure 11.1 Circular bioeconomy 218

CHAPTER I
INTRODUCTION
1.1 BACKGROUND
Thera two main product that produced for our plant which is methanol and
bioflocculant. Methanol is an alcohol with simplest of long series of organic
compound. This compound consist one methyl bond with a functional group which is
hydroxy group (OH) and chemical formula CH3OH, or emperical formula CH4O.
Methanol also widely known as methyl alcohol. This compound is volatile, colourless,
toxic, highly flammable, poisonous liquid and distinctive odour that similar to ethanol.
Figure 1.1 below shows the structural formula of methanol.
Figure 1.1 Structural formula of Methanol
Next, flocculant is function as agent which also known as flocking agent for
stimulate aggregation of colloids, cells and suspended solids which are commonly
used for waste water treatment, drinking water production and fermentation process. It
can be classified into three groups which is inorganic flocculants, organic synthetic
flocculants also known as bio-flocculant and naturally occurring flocculants. Bio-
flocculant can be produced from plant parts or biomass. This flocculant also can be
derived from microbe, either from single culture or mixed culture of two different
2
microorganism. Table 1.1 below shows the chemical and physical properties for both
products.
Table 1.1 Chemical and physical properties of methanol and bioflocculant
Properties Methanol Polysaccharide-Bioflocculant

Composition - 79.08% carbohydrate
15.4% proteins
Molecular Formula CH3OH (C6H10O5)n
Molecular Weight 32.042 5.13 x 105
(g/mol)
Boiling point (oC) 64.7 250 (pyloysis)
Melting point (oC) -259 128.7
3
Density (kg/m ) 792 1070
pH 7 (70% aqueous solution of 7
methanol)
Source: Ncbi 2018
1.2 SOURCE OF RAW MATERIAL
Malaysia is one of the main Palm Oil supplier in the world. The production of palm
oil in Malaysia is rapidly growth where the palm oil planted area is growth from 193
000 hectares in 1970 to 5.74 million hectares in 2016 (Ain et al. 2018). Palm Oil Mill
Effluent (POME) can be obtained from palm oil production because POME is by-
product for this production. There are also product other than POME are being
produced from palm oil processing which is palm kernel (OPK), crude palm oil, palm
oil fronds (OPF) and empty fruit bunches. POME is the most expensive and difficult
waste to manage due to high content of suspended solids and large volume tonnes
generated at a time. This is because the POME shoulde be treated well by aerobic,
anaerobic/facultative process before it discharged into landfills and river to prevent
occurence of water pollution. The raw POME that been received from mill is usually
has temperature 70-80oC with initial pH of 4.5-6.5. It presence as thick brownish
colour liquid with unpleasent odor. The composition of POME are mainly water, oil,
suspended solid, dissolved solid and sand. Table 1.2 below shows the properties of
POME.
3
Table 1.2 Properties of POME
Parameters Average Value Current Standard Discharge

Concentration Raw limit
POME (DOE,1982)
COD mg/L 51000 100

BOD3 mg/L 25000 100
Temperature (°C) 85 45
TSS mg/L 18000 400
Oil & Grease mg/L 4000-6000 50
Ammoniacal Nitrogen mg/L 35 NA
Total Nitrogen mg/L 750 200

pH 9.0 5.0-9.0
Source: (Madaki et al. n.d.)
1.3 PRODUCT USAGE
Methanol are mainly used organic synthesis, as a fuel, solvent, and antifreeze. It also
represents one of the most important chemical raw material for more than hundred
consumer that we used in our daily life such as plastics, building material, CDs and
DVDs and variety of pharmaceutical and health product. Indeed, the primary use of
methanol is in the chemical industry, as either a feedstock, solvent or cosolvent. This
alcohol is a key component in the production of renewable biodiesel fuels and has
potential to use as clean-burning fuel which can be blended directly into gasoline or
used as a fuel additive to reduce emissions. Other advantages of this clean-burning
fuel are it can reduce the greenhouse gas emission by 25% to 35% compared to
traditional gasoline, reducing urban zone and emission are also less reactive. Next,
methanol also contributes in wastewater treatment plant which is it function to
eliminate harmful nitrates.
The products that will be produced in the plant are biogas, fertilizer, sludge oil
and polysaccharide bioflocculant. The biogas will be produced from the anaerobic
process in which it will be captured and used as energy in the plant. The sludge
produced in the plant can be used as fertilizer as it has rich source of nutrient. Two
product that will be commercialised are the sludge oil and bioflocculant. The sludge
4
oil has potential as feedstock in production of many different chemicals such as

biodiesel.
Next, the main product in our plant is polysaccharide bioflocculant. The type
of bioflocculant is BM-8 as it is produced from Bacillus marisflavi. This bioflocculant
BM-8 is made up of 75% polysaccharide and 24% protein (Bukhari et al. 2018). It has
the potential in harvesting microalgae. The mechanism for the flocculation of
bioflocculant BM-8 is as shown in Figure 1.3.
Bioflocculant
BM-8
Patching
Algae cells
Figure 1.2 Mechanism of bioflocculant BM-8
Source: Bukhari et al. 2018
Algae have negative surface charge while the bioflocculant BM-8 is positively
charged. The charge among the algae will be neutralized upon addition of
bioflocculant. The algae will come together and form a large particle which will settle
easily. Graph in Figure 1.4 shows the efficiency of bioflocculant BM-8 in flocculating
algae compared to other commercialized agents which Polyaluminium Coagulant –
High purity (PAC-HP), Polyaluminium Coagulant – Sulphate (PAC-S),
Polyaluminium Coagulant – calcium (PAC-V) and Polyaluminium Coagulant –
Industrial class (PAC-IV).
5
Recovery (%)
Concentration (mg/L)
Figure 1.3 Efficiency of bioflocculant BM-8 compared to other agents
Source: Bukhari et al. 2018
Based on the graph, bioflocculant BM-8 able to recover 60% of algae by using
100mg/L while for other flocculating agents, it requires more than 500mg/L to recover
60% of algae. These results show that the bioflocculant produced is highly efficient
and able to be commercialized.
1.4 BY-PRODUCTS
1.4.1 Biomass
Biomass are been produced by agriculture industry and it is carbon based and is
composed of a mixture of organic containing hydrogen, usually including atoms of
oxygen, nitrogen and also small quantities of other atoms, including alkali, alkaline
earth and heavy metals. POME that we used as raw material also contains large
amount of biomass. The main component inside biomass is cellulose (40-60%),
hemicellulose (20-40%) and lignin (10-24%). In this plant, biomass is been utilized as
fertilizer for plant.
1.4.2 Ethanol
Ethanol is similar like methanol which is organic compound that have same functional
group (OH) but different in number of carbons. It has chemical formula C2H6O and
6
figure 1.2 below shows the structure of ethanol. The physical and chemical properties
of this alcohol are been shown in table 1.3.
Figure 1.4 Structural formula of Ethanol
Table 1.3 Physical and Chemical properties of Ethanol
Properties Values
Molecular Formula C2H5OH

Molecular Weight (g/mol) 46.07
Boiling point (oC) 78

Melting point (oC) -114.1
Density (kg/m3) 785.5
pH 7.33
Source: PubChem 2016
1.4.3 Methane
Methane is been produced in synthesis of methanol. It is an organic compound which

is the simplest hydrocarbon with chemical formula CH4. Methane is a colorless,
odorless and highly flammable gas. It is main component in natural gas that can be
used to generate electricity. The physical and chemical properties of methane are been
shown in table 1.4.
Table 1.4 Physical and chemical properties of methane
Properties Value
Molecular Formula CH4

Boiling point (oC) 144
Melting point (oC) −182.5

pH 7
7
1.4.4 Carbon dioxide
Carbon dioxide also the main component inside natural gas beside methane. There are
also small amount of carbon dioxide inside air which is 0.04%. This gas is been
produced by all aerobic organisms includes human and animal when they they
metabolize carbohydrates and lipids to produce energy by respiration. The physical
and chemical properties of carbon dioxide are been shown in table 1.5.
Table 1.5 Physical and chemical properties of carbon dioxide
Properties Value
Molecular Formula CO2

Boiling point (oC) -78.46
Melting point (oC) −56.5
pH 5
1.4.5 Carbon Monoxide
Carbon monoxide is an odorless, colorless and tasteless flammable gas that can give
harm to us because it uses hemoglobin as an oxygen carrier. It can be found in fumes
produced from combustion of fuel in car or motorcycle. This gas also can be produced
indoors and will poison human and animal who breathe it. The physical and chemical
properties of carbon monoxide are been shown in table 1.6.
Table 1.6 Physical and chemical properties of carbon dioxide
Properties Value
Molecular Formula CO
Boiling point (oC) -191.5
Melting point (oC) −205
pH 6

CHAPTER II
ECONOMY ISSUES
2.1 INTRODUCTION
Flocculating agents are generally divided into 3 types which are inorganic flocculants,
organic synthetic flocculants and naturally occurring flocculants where bioflocculants
are naturally occurring flocculants. Bioflocculants used highly in biotechnologies due
to their outstanding flocculation properties, biodegradability, eco-friendly and free of
secondary pollution risk (Aljuboori et al. 2014). Methanol is a simple alcohol with the
formula of CH3OH and it is used as fuel for combustion to generate heat and/or
electrical energy, fuel for vehicles and as solvent and feedstock for the generation of
other chemicals (Leonie 2017). Methanol is commercially produced from synthesis
gas by using the low pressure technology.
2.2 GLOBAL MARKET ANALYSIS
2.2.1 Bioflocculant Market
Flocculants are widely used in water treatment plants as well as in water purifiers. The
process of water treatment includes grates, sedimentation, granular filtration,
coagulation, flocculation, and disinfection. Flocculants also find applications in the
food and beverages industry for the treatment of wastewater. Further, in the mining
industry, these are used for the removal of red muds from minerals during the
treatment process. Increasing demand for specific formulations in emerging
economies tends to create ample opportunity for the growth of the industry (OMR
Global 2019).
9
Figure 2.1 Global flocculants market share by end-user (%)
Source: OMR Global
Asia-Pacific is expected to have a prominent share in the global market owing

to increasing demand from expanding chemical industries. Rising industrial output
with rapid economic growth tends to drive the demand for flocculants in various
industries such as power generation, oil and gas and food and beverages. In
developing countries such as India and China, the availability of cost-effective labor is
attracting most multinational companies to invest and established plant unit.
2.2.2 Methanol market
The global methanol market was estimated at USD 21.4 billion in 2016 and is
expected to witness significant growth on account of the rising demand for
petrochemical derived products such as olefins, adhesives, detergents, solvents,
plastics, lubricants and fibers. It is extensively utilized in the automotive industry. It
can be mixed with gasoline and utilized in the core combustion engines of
automobiles.
Figure 2.2 Global methanol market volume, by end use, 2014-2024 (kilotones)
Source: Hexa Research

10
Asia-Pacific region is probable to be the fastest growing market in terms of volume,

growing at a CAGR of 8.6% and the trend is expected to continue over the forecast
period. However, the growth of industrialization and globalization in the developing
nations such as China and India, there is a high demand and availability of methanol
derivatives, for instance, formaldehyde, biodiesel, DME in industries related to
automotive, construction, furniture and textile which is anticipated to boost the
market.
2.3 SUPPLY AND DEMAND
2.3.1 Supply and Demand of Bioflocculant
Bioflocculant is expected to grow and increase at a compound annual growth rate

(CAGR) of 9.23% from 2019 to 2023 globally (MarketWatch 2019). The trend of the
graph shows the demand of bioflocculant increases gradually from year 2016 until
2030.
Figure 2.3 Graph of supply and demand of bioflocculant from year 2016 to 2030
Source: MarketWatch 2019

11
2.3.2 Supply and demand of methanol
Methanol is expected to grow increasingly at a compound annual growth rate (CAGR)

of 9.8% from 2019 to 2026 globally (Market Share 2019). The graph curve shows the
demand of methanol increases gradually from year 2016 until 2026.
Figure 2.4 Graph of supply and demand of methanol from year 2016 to 2030
Source: MarketWatch 2019
2.4 PLANT CAPACITY
2.4.1 Plant capacity of bioflocculant
Bioflocculant demand (2025) = 4416.33 kilotonnes
Bioflocculant supply (2025) = 3215.93 kilotonnes
Bioflocculant deficiency (2025) = 1200.4 kilotonnes
Bioflocculant production rate = 352.3 kg/hr
2.4.2 Plant capacity of methanol
Methanol demand (2025) = 283047.93 kilotonnes

12
Methanol supply (2025) = 190424.31 kilotonnes
Methanol deficiency (2025) = 92623.6 kilotonnes
Methanol production rate = 150.34 kg/hr
2.5 FUTURE MARKETING POTENTIAL
Bioflocculants are used in the wastewater treatment field for removing suspended
solids and metal ions, at which colloids come out of suspension in the form of floc or
flakes (Zaki et al. 2014). Bioflocculant can also be used for treating dye wastewater.
Methanol is used in everyday products, such as plastics, paints, cosmetics and fuels.
It is also an energy resource used in the marine, automotive, and electricity sectors,
and an emerging renewable energy resource. It is possible that, in the not-to-distant
future, most liquid-consuming transportation vehicles that are cars, trucks, trains, and
planes may use methanol as their energy source (Luyben 2010).
CHAPTER III
PRODUCTION DESIGN CONCEPT
3.1 PROCESS DESIGN LEVEL 1
3.1.1 Reaction
In this process design, both chemical and biochemical reaction is involved in the
production of product. For chemical reaction, it involves in the syngas synthesis and
methanol synthesis. Next, for biochemical reaction, it involves anaerobic and aerobic
process. Anaerobic process is involved in the production of biogas while aerobic
process is involved in the production of bioflocculant.
3.1.2 Stoichiometry
The stoichiometry for chemical equation are as below:
i. Syngas synthesis
CH4 + H2O CO + 3H2 …(3.1)

CO + H2O CO2 + H2 …(3.2)
CH4 + 2H2O CO2 + 4H2 …(3.3)
ii. Methanol synthesis
CO2 + H2 CO + H2O …(3.4)

CO2 + 3H2 CH3OH + H2O …(3.5)
The stoichiometry for biochemical reactions are as below:

14
i. Anaerobic Process
C6H12O6 3CH4 + 3CO2 …(3.6)
ii. Aerobic Process
C6H12O6 + 0.021O2 + 0.005NH3N 0.036CH1.77O0.46N0.29 + 0.99C6H10O5 +

0.024CO2 + 1.026H2O…(3.7)
3.1.3 Reaction Conditions
All this reaction condition must be met in for a complete reaction to product enough
product. The reaction condition for both chemical and biochemical reaction are as
shown below:
i. Chemical reaction
Table 3.1 Condition for chemical reactions
Parameter Syngas Synthesis Methanol Synthesis

Pressure (bar) 25 50
Catalyst NiO/α-Al2O3 Cu/ZnO/Al2O3
ii. Biochemical reaction
Table 3.2 Condition for biochemical reactions
Parameter Anaerobic Process Aerobic Process

Pressure (bar) 1.0 - 3.0 1.0 - 3.0
pH 6.5 - 7.8 7.0
Microbe Methanogens B. marisflavi
3.1.4 Reaction conversion
i. Syngas synthesis
The rate law for each of the following equation are as below:
R1 = k1/P2.5H2 (PCH4PH2O – P3H2PCO/K1)(1/Ω2) …(3.8)

R2 = k3/PH2 (PCOPH2O – PH2PCO2/K11)(1/Ω2) …(3.9)
15
R3 = k2/P3.5H2 (PCH4P2H2O – P4H2Pco/K111)(1/Ω2) …(3.10)
The materials balance for each of the components are as below:
d(NCH4) / d(x) = -NCH4 …(3.11)

d(NCO2) / d(x) = (R2+R3)/(-rm/NCH4) …(3.12)
d(NCO) / d(x) = (R1-R2)/(-rm/NCH4) …(3.13)
d(NH2) / d(x) = (3*R1+R2+4*R3)/(-rm/NCH4) …(3.14)
d(NH2O) / d(x) = (-R1-R2-2*R3)/(-rm/NCH4) …(3.15)
The partial pressure equation for each of the components are as below:
PCH4 = NCH4/(NCH4 + NCO2 + NH2O + NH2 + NCO) …(3.16)

PCO2 = NCO2/(NCH4 + NCO2 + NH2O + NH2 + NCO) …(3.17)
PH2O = NH2O/(NCH4 + NCO2 + NH2O + NH2 + NCO) …(3.18)
PH2 = NH2/(NCH4 + NCO2 + NH2O + NH2 + NCO) …(3.19)
PCO = NCO/(NCH4 + NCO2 + NH2O + NH2 + NCO) …(3.20)
Ω = 1 + KCOPCO + KH2PH2 + KCH4PCH4 + KH2OPH2O/PH2 …(3.21)
The reaction constant for each of the equation are as below:
K1 = exp (-26830/Ts + 30.114) …(3.17)

K11 = exp (4400/Ts – 4.036) ) …(3.18)
K111 = K1 K11 …(3.19)
Equation (3.8) to (3.19) are solved using Polymath® software by inserting some of the
constant values below. A graph of concentration of reactant/product against
conversion is plotted to determine the conversion from X=0.1 to X =1.0. The results
and graphs are as shown in Table 3.3 and Figure 3.1 respectively.
Table 3.3 Data of concentration for conversion in syngas reaction
x NCH4 NCO2 NCO NH2 NH2O

0.0 13.88 9.76 0.01 0.01 13.88
0.1 12.52813 9.758695 1.363172 4.064293 12.52944
0.2 11.29067 9.743083 2.616246 7.761069 11.30759
0.3 10.25717 9.693857 3.698975 10.81235 10.32331
0.4 9.24402 9.576192 4.829789 13.73413 9.427828
0.5 8.397859 9.391255 5.860886 16.08768 8.766604
0.6 7.568363 9.105353 6.976284 18.29026 8.223011
0.7 6.875586 8.775685 7.99873 20.03893 7.859901
0.8 6.196452 8.373811 9.079737 21.67446 7.582641
0.9 6.196452 8.373811 9.079737 21.67446 7.582641
16
1 6.196452 8.373811 9.079737 21.67446 7.582641
Figure 3.1 Syngas reaction conversion
Constant used:
R = 8.205745*10^-5 m3 atm K-1 mol-1

k1 = 5.19*10^9
k2 = 9.90*10^3
k3 = 1.32*10^10
Ts = 973.15 K
NCH4 = 23.91kmol/hr
NCO2 = 15.81kmol/hr
NH2O = 7.663462 kmol/hr
NH2 = 0.01 kmol/hr
NCO = 0.01 kmol/hr
KCO = 23.6
KH2 =-0.05641
KCH4 =0.4356
KH2O =0.6412
K1 = exp (-26830/Ts + 30.114)
K11 = exp (4400/Ts – 4.036)
K111 = K1 K11
17
ii. Methanol synthesis
The rate law for each of the following equation are as below:
R1= KM*((PCO2*PH2)-(1/KpM)*(PM*PH2O/(PH2^2)))
/(1+Ka*(PH2O/PH2)+Kb*sqrt(PH2)+Kc*PH2O) …(3.20)
R2 = KR*(PCO2-(1/KpR)*(PCO*PH2O/PH2))
/(1+Ka*(PH2O/PH2)+Kb*sqrt(PH2)+Kc*PH2O) …(3.21)
The materials balance for each of the components are as below:
d(NCO2) / d(x)= -NCO2 …(3.22)

d(NH2) / d(x) = (-3*R1-R2)/(-rm/NCO2) …(3.23)
d(NM) / d(x) = (R1)/(-rm/NCO2) …(3.24)
d(NH2O) / d(x) = (R1+ R2)/(-rm/NCO2) …(3.25)
d(NCO) / d(x) = (R2)/(-rm/NCO2) …(3.26)
The partial pressure equation for each of the components are as below:
PCO = NCO/(NCO + NCO2 + NH2O + NH2 + NM) …(3.27)

PCO2 = NCO2/(NCO + NCO2 + NH2O + NH2 + NM) …(3.28)
PH2O = NH2O/(NCO + NCO2 + NH2O + NH2 + NM) …(3.29)
PH2 = NH2/(NCO + NCO2 + NH2O + NH2 + NM) …(3.30)
PM =NM/(NCO + NCO2 + NH2O + NH2 + NM) …(3.31)
The reaction constant for each of the equation are as below:
Ka = 3453.38 …(3.32)
Kb = 0.499*exp(17197/(R*T)) …(3.33)
Kc = (6.62*10^11)*exp(124119/(R*T)) …(3.34)
KM = (1.07)*exp(36696/(R*T)) …(3.35)
KR = (1.22*10^10)*exp(-94765/(R*T)) …(3.36)
KpM = exp((7059.73/T)-47.415) …(3.37)
KpR = exp((-4773.26/T)-4.672) …(3.38)
Equation (3.20) to (3.38) are solved using Polymath® software by inserting some of
the constant values below. A graph of concentration of reactant/product against
conversion is plotted to determine the conversion from X=0.1 to X =1.0. The graph
and results are as shown in Table 3.4 and Figure 3.2 respectively.
18
Table 3.4 Data of concentration for conversion in methanol reaction
x NCO2 NH2 NM NH2O NCO

0.0 10.20775 25.58135 0.01 7.598396 13.61595
0.1 9.196728 22.54828 1.021022 8.609418 13.61595
0.2 8.354896 20.02279 1.862854 9.45125 13.61595
0.3 7.529644 17.54703 2.688106 10.2765 13.61595
0.4 6.84041 15.47933 3.37734 10.96574 13.61595
0.5 6.164751 13.45235 4.052999 11.6414 13.61595
0.6 5.600454 11.75946 4.617296 12.20569 13.61595
0.7 5.047271 10.09991 5.170479 12.75887 13.61595
0.8 4.585264 8.713892 5.632486 13.22088 13.61595
0.9 4.585264 8.713892 5.632486 13.22088 13.61595
1.0 4.585264 8.713892 5.632486 13.22088 13.61595
Figure 3.2 Methanol reaction conversion
Constant used:
R = 8.314 m3 atm K-1 mol-1

T=523.15 K
NM(0) = 0.01 kmol/hr
NCO2(0) = 10.20775 kmol/hr
NH2O(0) = 7.598396 kmol/hr
NH2(0) =25.58135 kmol/hr
NCO(0) =13.61595 kmol/hr
19
3.1.5 Selectivity
The selectivity of a product is defined as the ratio of concentration of product to

concentration of limiting reactant converted. The mathematical equation of selectivity
is as below:
By using the equation of selectivity, the selectivity graph is obtained from

Polymath® software. The graph of selectivity is shown in Figure 3.3 and 3.4 for
syngas synthesis reactor and methanol synthesis reactor respectively.
Figure 3.3 Selectivity graph for Syngas synthesis reactor
Where
SCO = Selectivity of carbon monoxide
SCO2 = Selectivity of carbon dioxide
SH2 = Selectivity of hydrogen

20
Figure 3.4 Selectivity graph for Methanol synthesis reactor
Where
SM = Selectivity of Methanol
3.1.6 Catalyst
Catalyst is a substance that is used to increase the rate of reaction without undergoing
any change to itself. Catalyst is only used in the production of methanol. Both
chemical reaction, syngas synthesis and methanol synthesis require different type of
catalyst. In syngas synthesis reaction, the required catalyst is nickel doped alumina
(NiO/α-Al2O3). This catalyst is suitable in steam reforming to produce syngas. Next,
in methanol synthesis reaction, the catalyst used is aluminium oxide coated with
copper and zinc which is also known as Cu/ZnO/Al2O3. The function of copper and
zinc is to promote and increase the methanol formation while aluminium oxide is for
methanol dehydration. Table 3.5 below shows the properties of the catalyst used.
Table 3.5 Properties of catalyst used in the production of methanol
Type of Catalyst
Properties Nickel doped alumina Aluminium oxide coated with
copper and zinc
Chemical Formula NiO/α-Al2O3 Cu/ZnO/Al2O3
Physical State Solid Solid
Melting Point (°C) 1955 2072
21
3.1.7 Design constraints
In designing the process for production of bioflocculant and methanol, there are a few
major constraints faced. First and foremost, there is no commercialized technology in
the production of methanol or bioflocculant by utilizing POME as the raw materials.
The design is very new as it is based from lab scaled studies. To add on, the
equipment used such as MBBR is a new type of technology that requires more studies
on the type of carries used etc. Secondly, is to cater a high flowrate of POME inlet
from the nearby palm oil mill. The received POME will be stored in a large cooling
pond before been pumped to anaerobic digestion tank. Next, it involves some
flammable chemicals such as methane and methanol. These chemicals will be placed
further from the buildings and any possible ignition sources. Besides that, the syngas
synthesis and methanol synthesis occur at a very high temperature and pressure. For
syngas synthesis, the temperature and pressure required is 700°C and 25 bar while for
methanol synthesis, the temperature and pressure required is 250°C and 50 bar. These
two reactors will be isolated from other process equipment which releases heat. Proper
safety features and maintenance will be designed for these reactors.
3.2.1 Input-output structure
The input for designed plant are POME, ethanol, water and a microbe which is B.
marisflavi. The POME will undergo anaerobic process to produce biogas which will
be fed to the chemical reaction to produce methanol. The remaining POME will
undergo aerobic process to produce bioflocculant. The effluent will be wastewater that
will be treated further before been discharger. The sludge oi is obtained by skimming
the POME before the anaerobic process. Figure below shows the input-out model
structure for this plant.
22
Figure 3.5 Input-output structure
3.2.2 Design capacity
The production rate of bioflocculant is 369.5 kg/h and the production rate of methanol
is 150.4kg/h. The plant operates for 355 days in a year which is equivalent for 8520
hours. Plant can produce about 3.1 thousand tonnes of bioflocculant and 1.3 thousand
tonnes of methanol annually. This plant capacity is decided based on the economic
analysis of bioflocculant and methanol
3.2.3 Mass balance
i. Biochemical Mass Balance
For UASB (Assume r1 is rate of reaction for (3.6))
Nout = Nin + αr1V
r1 = 0.000803 mol L-1h-1
The obtained biogas is about 28m3 per ton POME. This biogas consists of 51%
of methane and 49% of carbon dioxide. It will be sent to the chemical plant. The
remaining glucose is 374.4 kg/hr
For MBBR (Assume r2 is rate of reaction for (3.7))
Nout = Nin + αr2V

23
r2 = 0.000685 mol L-1h-1
Thus, 329.2 kg/hr of bioflocculant is produce from aerobic process in the

MBBR. The remaining glucose is 36.7kg/hr.
ii. Chemical Mass Balance
Syngas synthesis reaction (Assume r1, r2 and r3 are for rate of reaction (3.1), (3.2) and
(3.3) respectively)
Nout = Nin + αr1 + αr2 + αr3
The obtained value for r1, r2 and r3 for conversion, X= 0.8 are as below:
r1 = 27250000 kmol/hr
r2 = -17550000 kmol/hr
r3 = 17.37895 kmol/hr
Methanol synthesis reaction (Assume r4 and r5 are for rate of reaction (3.4) and (3.5)
respectively)
Nout = Nin + αr4 + αr5
The obtained value for r4 and r5 for conversion, X= 0.8 are as below:
r4 = -0.000005516 kmol/hr
r5 = 3.938x 10-18 kmol/hr
Therefore, the methanol produced is 5.63kmol/hr which is equals to 180.38kg/hr

24
3.2.4 Economic potential analysis for level 2
Economic potential analysis for level 2 is done to determine the gross profit of the
production plant. Table 3.6 below shows a summary of the raw material involved in
the production of bioflocculant and methanol while figure 3.6 shows the economic
potential curve for level 2. The formula used in level 2 calculation is:
fPE2 = Cost of Main Product + Cost of Byproduct – Cost of Raw Material
Based on the curve, the conversion is selected at 0.8. This is because after 0.8
conversion, the profit becomes constant.
Table 3.6 Raw materials
Raw Materials Price (RM/year)

Ethanol 6.15 Million
Nutrient 6.63 Million
Water 4.31 Million
Total 17.1 Million
Figure 3.6 Economic potential curve for level 2

25
Process design for level 3 includes the cost for all reactors and compressors that been
used for the whole process. Details for reactor system are considered. Design
variables such as reactor sizing, compressor requirement, heat management and
excess reactacts are considered.
3.3.1 Number of reactors
First, the POME will undergo anaerobic reaction which occurs in the upflow
anaerobic sludge blanket (UASB) reactor to produce biogas. Three UASB reactor is
available to cater a high volume of POME inlet. The biogas consist of methane and
carbon dioxide will be the raw material for methanol production while the remaining
POME will undergo aerobic reaction which occurs in the moving bed bioreactor
(MBBR).
In the chemical plant, syngas synthesis takes place in the syngas reactor while
the methanol synthesis occurs in the methanol reactor. Overall, the total number of
reactors are six where four from the biochemical plant and two from chemical plant.
3.3.2 Reactor selection
UASB shows a great production for biogas of 28m3 with only 10 days retention time
and 96% COD removal (Fang et al. 2011). For aerobic reactor, MBBR is used to
produce bioflocculant at the same time it has a high COD removal which is 90% in
two and a half days (Vijayaraghavan et al. 2007).
For syngas and methanol synthesis, it is suitable to use packed bed reactor.
This is because the reaction involves gaseous reactant and catalysed by solid catalyst.
3.3.3 Reactor heat effect
Reaction that takes place in the reactor can absorb or release heat. This will affect the
temperature and have deviation from set temperature. In order to maintain the
26
specified temperature, the reactor must be jacketed which have flow of hot or cold
water. Heat effect and adiabatic temperature is calculated to determine it is adiabatic
or isothermal. The calculation formula for adiabatic temperature by assuming the
average specific heat can be used is as shown below:
For chemical reaction (syngas and methanol synthesis):
For anaerobic process:
For aerobic process:
Where
ΔH°rx = Heat of reaction at reference temperature
Cpi = Specific heat of each product i which includes reactant and impurities
Ta = Adiabatic temperature of reactor/tank
Tm = Inlet temperature of reactor/tank

27
X = Conversion
θ = ratio of reactant i to limiting reactant
Spreadsheet is used to solve the adiabatic temperature for all the four types of
reactors which is UASB, MBBR, syngas reactor and methanol reactor. The data is
tabulated in Table 3.7 and the graph is shown in figure 3.7.
Table 3.7 Adiabatic temperature for all four reactors
Ta (°C)
Conversion UASB MBBR Syngas Reactor Methanol
Reactor
0.1 304.42 303.57 699.98 250.03
0.2 305.24 303.93 699.97 250.05
0.3 305.82 304.25 699.95 250.08
0.4 306.25 304.52 699.94 250.12
0.5 306.58 304.78 699.92 250.15
0.6 306.84 305.00 699.91 250.18
0.7 307.06 305.21 699.89 250.22
0.8 307.39 305.39 699.88 250.26
0.9 307.46 305.56 699.86 250.31
1.0 307.52 305.71 699.85 250.35
Figure 3.7 Graph of adiabatic temperature against conversion

28
In the biochemical reactors (UASB and MBBR), the adiabatic temperature

increases with conversion showing that this is an exothermic reaction. The difference
in temperature between inlet and outlet for UASB is 3°C which for MBBR is 2°C.
Since the difference in temperature is low, both reactors can be operated as adiabatic
reactor.
In the chemical reactors, the syngas synthesis reactor shows a small decrease
in temperature showing it is an endothermic reaction. The temperature difference
between inlet and outlet is only 0.13°C. For methanol synthesis reactor, the
temperature increases showing it is an exothermic reaction. The temperature
difference between inlet and outlet is only 0.32°C. Thus, both of these reactors can be
operated as adiabatic reactors because it shows small difference in temperature.
3.3.4 Reactor sizing
Reactor sizing involves the calculation of the size of each reactor based on the
conversion.
For syngas synthesis packed bed reactor, the sizing table is as shown below.
The optimum sizing is taken at conversion of 0.8.
Table 3.8 Syngas synthesis reactor sizing
X SCO2 SH2 r1 r2 r3 v
0.1 4.53 3 1.36 -0.006 0.004 0.059
0.2 2.32 2.94 2.60 -0.014 -0.003 0.062
0.3 1.53 2.84 3.66 -0.038 -0.028 0.067
0.4 1.02 2.7 4.73 -0.097 -0.087 0.071
0.5 0.714 2.59 5.67 -0.189 -0.018 0.074
0.6 0.493 2.52 6.64 -0.332 -0.322 0.081
0.7 0.357 2.48 7.50 -0.497 -0.487 0.086
0.8 0.255 2.46 8.38 -0.681 -0.688 0.091
0.9 0.188 2.44 9.14 -0.891 -0.881 0.098
1 0.138 2.44 9.86 -1.080 -1.070 0.104
For methanol synthesis packed bed reactor, the sizing table is as shown below.
The optimum sizing is taken at conversion of 0.8 as well.
29
Table 3.9 Methanol synthesis reactor sizing
X SCO2 SH2 r1 r2 v
0.1 4.53 3 1.02 0.632 0.083
0.2 2.32 2.94 1.86 0.070 0.142
0.3 1.53 2.84 2.69 0.480 0.130
0.4 1.02 2.7 3.38 0.939 0.127
0.5 0.714 2.59 4.05 1.390 0.126
0.6 0.493 2.52 4.62 1.766 0.129
0.7 0.357 2.48 5.17 2.135 0.132
0.8 0.255 2.46 5.63 2.443 0.136
0.9 0.188 2.44 6.09 2.745 0.140
1.0 0.138 2.44 6.46 2.996 0.145
3.3.5 Compressor design and costing
Cost of compressors are been calculated C-101, C-102, C-103
Power, W to compress recycle gas RGf from P1 to P2 using compressor:
Where , Z = Compressibility coefficient
R= Gas constant
T1= Temperature inlet
RG = flowrate of recycle stream
n = polytropic index (=1.6 – 1.8)
Outlet temperature :
30
Where , T2 = Temperature outlet
T1 = Temperature inlet
P2 = Pressure outlet
P1 = Pressure inlet
n = polytropic index
Annual cost of the compressor, Kpt can be calculated by using following

equation:
Where, IMSK = Present Marshall and Swift index
IMSD = Past Marshall and Swift index
W= Power
 = Compressor efficiency
Fd = Design factor (=1.5)
Cp = Cost power (RM/kWj)
Annual cost that have been calculated for all compressors are as follows :
Table 3.10 Annual cost for compressor, C-101
Criteria Value
Inlet pressure (bar) 1
Outlet pressure (bar) 3
Power (kW) 23.5
Installation cost, Kpk (RM) 3,933.22
Annual cost, Kpt (RM) 81,933.22
Conversion, Power, W (kW) Installation cost, Kpk Annual cost, Kpt

31
X (RM) (RM)
0.1 494.1542513 50666.85986 1713413.152
0.2 529.7445463 53640.30456 1836592.456
0.3 562.3230277 56330.69661 1949337.288
0.4 589.53184 58556.17063 2043492.067
0.5 616.2048095 60719.93225 2135786.627
0.6 638.4815702 62514.15563 2212864.998
0.7 660.3194891 64262.12527 2288421.325
0.8 678.5581908 65714.03418 2351522.177
0.85 696.4376367 67130.54002 2413377.836
0.9 711.3700067 68308.5491 2465036.131
1 725.141259 69391.01739 2512676.245
Conversion, Power, W (kW) Installation cost, Kpk Annual cost, Kpt

X (RM) (RM)
0.1 42.32616326 6754.232557 147565.0655
0.2 41.07863135 6590.552157 143227.4944
0.3 40.03987408 6453.580417 139615.5887
0.4 39.02156795 6318.683129 136074.587
0.5 38.17110701 6205.534707 133117.079
0.6 37.3373905 6094.172715 130217.6532
0.7 36.64108432 6000.821796 127795.9866
0.8 35.95849327 5908.999156 125421.916
0.85 35.38841311 5832.070995 123439.0812
0.9 34.82955799 5756.440756 121495.2167
1 34.36419769 5693.296485 119876.4994
3.3.6 Reactor costing
a. UASB reactor
Annual cost of a reactor, Krt can be calculated by using the following equation :
Where, Imsk= Present Marshall and Swift Index
Imsd = Past Marshall and Swift Index
D= Diameter of the reactor

32
LR= Length of the reactor
FM= Design material factor
Fp= Pressure factor
Fi= Installation factor
Design material’s factor, Fm and pressure factor, Fp is as shown in Table 3.13 and
Table 3.14.
Table 3.13 Fm value
Construction material Fm
Carbon steel 1.00
Stainless steel (chromium-molibdenum) 2.15
Stainless steel 3.75
(Source: Wan Ramli Wan Daud 2002)
Table 3.14 Fp value
Pressure (bar) Fp
1.6 1.00
6.8 1.05
13.6 1.15
20.4 1.20
27.2 1.35
34.0 1.45
40.8 1.60
47.6 1.80
54.4 1.90
61.2 2.30
68.0 2.50
(Source: Wan Ramli Wan Daud 2002)
The values for IMSD is taken based on 2009 index which is 1487.2. Design material
factor, Fm , pressure factor, Fp and installation factor, FI are at 3.75, 1.00 and 1.5
respectively. Design material is taken based on the stainless steel value. The value of
pressure factor is taken based on operating pressure at 1 bar. All the value for
installation factor is the standard values for installation in Malaysia. The annual cost
for all three UASB reactor are based on the characteristics below:
Table 3.15 Annual cost for UASB reactor

33
Criteria Value
Conversion 0.8
Working volume (m3) 538.16
Total volume (m3) 645.78
Number of reactors 3
Diameter (m) 8.18
Krt(RM) for each reactor 7,799,413.21
Total Krt (RM) 23,398,239.64
b. Aerated tank
Annual cost of a reactor, Krt can be calculated by using the following equation :
Where , IMSK = Present Marshall and Swift index
IMSD = Past Marshall and Swift index
V= Volume of the reactor
The calculated annual cost for aerated tank is shown below:
Table 3.16 Annual cost for aerated tank
Criteria Value
Conversion 0.8
Krt (RM) for reactor 2,753,003.00
c. Packed bed reactor
The values for IMSD is taken based on 2009 index which is 1487.2. Design material
factor, Fm , pressure factor, Fp and installation factor, FI are at 3.75, 1.00 and 1.5
respectively. Design material is taken based on the stainless steel value. The value of
pressure factor is taken based on operating pressure at 1 bar. All the value for
installation factor is the standard values for installation in Malaysia. The annual cost
for two packed bed reactors are based on the characteristics below:
Annual cost of a reactor, Krt can be calculated by using the following equation:
34
Table 3.17 Cost of R-101
Criteria Value
Diameter 0.35
Krt (RM) for reactor 34,292.51
Table 3.18 Cost of R-102
Criteria Value
Diameter 0.39
Krt (RM) for reactor 47,905.98
3.3.7 Economical potential Analysis of Level 3
The economic potential for level 3 is given by:
Hence, the economic potential for level 3 is shown in Table 3.19 and Figure 3.8.
Table 3.19 Data for potential economy of process design level 3
X Fep2 Compressors Aerated tank UASB reactor R-101 R-102 Fep3

0.1 386969438 1918279.55 2753003 7799413.21 25153.14 36410.83 374437178.08
0.2 388345979.7 2031024.38 2753003 7799413.21 35238.79 37521.24 375689778.92
0.3 389695412.9 2125179.16 2753003 7799413.21 33333.94 39358.67 376945124.79
0.4 390822430.3 2217473.72 2753003 7799413.21 32881.78 40672.58 377978985.83
0.5 391927251.9 2294552.09 2753003 7799413.21 32703.19 41704.41 379005875.84
0.6 392849976.8 2370108.42 2753003 7799413.21 33177.99 44147.69 379850126.29
0.7 393754528.4 2433209.27 2753003 7799413.21 33581.68 46124.46 380689196.62
0.8 394509990.9 2495064.93 2753003 7799413.21 34292.51 47905.58 381380311.48
0.9 395250575.1 2546723.23 2753003 7799413.21 34910.71 50001.67 382066523.13
35
1 395867140.3 2594363.34 2753003 7799413.21 35723.20 51970.75 382632666.62
Figure 3.8 Potential economy curve for process design level 3
Process design level 4 involving all separation units that been used throughout the
process. Separation process is a process to separate two or more mixture to obtain
high purity of product. Separation unit is very important in any process that involve
removing impurities, recycling reactant or the further purification of desired product.
The separation units that been used in this process are distillation column, centrifuge,
settlement tank, dryer, phase separator and scrubber.
3.4.1 Distillation column
Cost for distillation column can be calculated by using following equation:
Installation cost:
Annual cost:
36
The conditions and calculated cost for distillation column are shown in Table 3.20
Table 3.20 Annual cost for distillation column
Criteria Value
Diameter (m) 0.4572
Length (m) 10.69
Area of condenser (m2) 6.297408
Area of reboiler (m2) 7.021412
Km (RM) 3,211,068.85
Kmt (RM) 1,070,356.28
3.4.2 Centrifuge
Annual cost for centrifuge can be calculated by using following equation:
The condition and calculated cost for both two centrifuges are shown in Table 3.21
Table 3.21 Annual cost of centrifuges
Criteria Value
Diameter (m) 3.1
Height (m) 5.1
Number of centrifuges 2
Volumetric flowrate (L/hr) 33.87
Krt for each centrifuge (RM) 1370.97
Total Krt of centrifuges (RM) 2741.95
3.4.3 Settlement tank
Annual cost for settlement tank can be calculated by using following equation:
37
The condition and calculated cost for both two settlement tank are shown in Table
3.22
Table 3.22 Annual cost for settlement tank
Criteria Value
Volume (m3) 282.53
Diameter (m) 9.25
Height (m) 4.203
Number of settlement tank 2
Krt for each settlement tank (RM) 2,164,732.89
Total Krt of settlement tank (RM) 4,329,465.78
3.4.4 Dryer
Annual cost for dryer can be calculated by using following equation:
The condition and calculated value for dryer as shown in Table 3.23
Table 3.23 Annual cost for dryer
Criteria Value
Area (m2) 0.9628
Tfeed,in (oC) 30
Tproduct,out (oC) 90
Tsteam,in (oC) 350
Tsteam,out (oC) 122.54
Krt for dryer (RM) 12,148.60
38
3.4.5 Phase separator
Cost for phase separator can be calculated by using following equation:
Installation cost:
Annual cost:
The conditions and calculated cost for phase separator are shown in Table 3.24
Table 3.24 Annual cost for phase separator
Criteria Value
Diameter (m) 0.821
Height (m) 4.520
Km for phase separator (RM) 5,086,414.13
Kmt for phase separator (RM) 1,695,471.37
3.4.6 Scrubber
Cost for scrubber can be calculated by using following equation:
Where, Ce = cost correlation based on year 2010 (RM)
a = constant = 17 400
b = constant = 79
39
S = shell mass (kg)
n = 0.85
To calculate the shell mass of the gas scrubber, equation below is used:
Where Dc = vessel diameter, m
Lc = vessel length, m
tw = wall thickness, m
 = metal density, kg/m3
To calculate the annual cost of the gas scrubber, equation below is used:
Where IMSd = Marshall and Swift index based on year 2010 = 1487.2
The condition and calculated cost for scrubber as shown in Table 3.25
Table 3.25 Annual cost for scrubber
Criteria Value
Shell mass 125.26
Length (m) 1.55
Diameter (m) 0.52
Ce 22 194.82
Krk for scrubber (RM) 893,180.20
Krt for scrubber (RM) 297,726.49
40
3.4.7 Economic potential analysis for level 4
Economic potential can be calculated based on the formula:
Total cost for all separation units = RM 7,407,910.47
Table 3.26 Fep 4
Conversion, X Fep3 (RM) Total cost for all separation units (RM) Fep4 (RM)
0.1 374,437,178.08 7,407,910.47 371,274,025.90
0.2 375,689,778.92 7,407,910.47 372,526,626.80
0.3 376,945,124.79 7,407,910.47 373,781,972.60
0.4 377,978,985.83 7,407,910.47 374,815,833.70
0.5 379,005,875.84 7,407,910.47 375,842,723.70
0.6 379,850,126.29 7,407,910.47 376,686,974.10
0.7 380,689,196.62 7,407,910.47 377,526,044.50
0.8 381,380,311.48 7,407,910.47 378,217,159.30
0.9 382,066,523.13 7,407,910.47 378,903,371.00
1 382,632,666.62 7,407,910.47 379,469,514.50
Figure 3.9 Potential economy curve for process level 4

41
3.5 PRODUCTION PROCESS OF METHANOL AND BIOFLOCCULANT
3.5.1 Process flow diagram
The process flow diagram for production of bioflocculant and methanol is attached in
Appendix.
3.5.2 Process description
The process involved biochemical and chemical reaction. Biochemical reaction begin
from the raw material POME till producing biogas and bioflocculant. Chemical
reaction begin from utilizing the biogas produced from biochemical reaction to form
methanol.
Biochemical process will take place first in the production plant. Firstly, the
main raw material which is the palm oil mill effluent (POME) will be received from
nearby mill and been stored in the cooling pond. It is left about 8 to 12 hours for
cooling process. Then, the sludge oil will be skimmed from the top of the cooling
pond. The POME will be pumped into the UASB. In UASB, anaerobic process takes
place where the methanogens in the POME will produce methane and carbon dioxide
which is known as biogas. This biogas will be used as raw material is chemical
process. The hydraulic retention time (HRT) in the UASB is 10 days (Fang et al.
2011). The POME will then be sent to a settlement tank to separate the solid biomass
from water. After that, POME will be pumped to MBBR. In MBBR, aerobic process
takes place to produce bioflocculant. MBBR is a type of aerated tank which uses
specific carrier that contains microbe (Smitha et al. 2017). The microbe used for
aerobic process is B. marisflavi which is a type of microbe isolated from POME itself.
The HRT in MBBR is 2.5 days (Nurul-Adela et al. 2016). After aerobic process, the
remaining wastewater will be centrifuged to remove all the solid biomass. All the
solid biomass will be dewatered using a screw press to form a cake. This biomass
cake can be used as fertilizer. The wastewater from centrifuge will be pumped to the
mixer. The wastewater contains bioflocculant will be mixed with ethanol (Nurul-
Adela et al. 2016). This process will make the bioflocculant to solidify. Then, the
42
bioflocculant will be separated from wastewater. Bioflocculant will be dried and sent
for packing while the wastewater will be pumped to the wastewater treatment system.
The biogas with CO2 and CH4 composition of 50%v/v and 50%v/v will be produced
with trace amount of H2S of 1000ppm. After the scrubbing process, the H2S
concentration will be reduced until 30ppm. Then, it will be mix with another stream
which containing steam and it will be compressed to 32 bar and heated until 700⁰C
before flowed into the methane steam reforming reactor. In the packed bed reactor,
which contain NiO/α-Al2O3 catalyst, Methane and steam will be converted into syngas
at 80% conversion (Abd Nasir et al. 2019). Then, it will flow through another phase
separator. The liquid stream will be sent to the waste water treatment while the vapor
stream will be cooled, mix with recycle stream and compressed to 250 ⁰C and 50bar
before flowed into the methanol forming reactor which is a packed bed reactor with
Cu/ZnO/Al2O3 as the catalyst (Lücking n.d.). After the reaction, the unsaturated vapor
will be separated in the phase separator and the liquid stream will be sent to the
distillation column. 40% of the vapor stream will be recycled and the rest will be
purged as the fuel for the furnace. The distillation column is operated at 1 bar, top
temperature at 68⁰C and bottom temperature at 103⁰C to separate methanol from
water- methanol mixture. The top product is methanol at purity of 99% and bottom
product is methanol-water mixture and will be sent to waste water treatment
3.5.3 Growth curve
The growth curve of Bacillus marisflavi in the POME is as shown in figure 6.1. The
lag phase takes about 2 hours where the bacteria will adapt to the new environment
and get ready to grow. The second phase is at the log phase where the bacteria
multiply at the highest rate due to abundant of nutrient. The log phase occurs for 16
hours. Next, it will undergo stationary phase. In this phase the bacteria will have equal
growth and dead rate due to completion of nutrients and increase in waste products.
Finally, the bacteria will enter the dead phase where the bacteria are no longer active.
Based on this figure, the duration of cultivation of bacteria in the seed fermenter will
be 16 hours. This is because the bacteria will undergo stationary phase followed by
43
dead phase after 16 hours. These bacteria will be introduced to main fermenter with
aerobic condition for production of bioflocculant.
Figure 3.10 Growth curve of B. marisflavi
Source: Nuradela et al. 2016
3.5.4 Monod Equation
Monod equation is a mathematical representation of the growth of microorganisms

such as bacteria. The Monod equation is as stated below:
Where :
is the specific growth rate of microorganisms
is the maximum specific growth rate of the microorganisms
S is the concentration of the limiting substrate for growth
Ks is the half velocity constant

44
Table below shows the information of the growth of B. marisflavi in the present of
glucose as the limiting substrate based on the source Nuradela et al. 2016.
45
Table 3.27 Substrate and biomass concentration
Time (hr) S (g/L) X (g/L)

0.0 9.00 0.40
3.0 8.58 1.08
6.2 7.50 3.00
12.0 1.83 7.16
21.6 1.92 8.08
35.5 1.66 8.25
47.5 1.66 8.50
Source: Nuradela et al. 2016
To obtain the value of and Ks the Monod equation is rearranged as shown

below.
Based on the information on the growth of B. marisflavi as in table 3.28 and the
rearranged Monod equation, a graph of 1/ against 1/S is plotted.
Table 3.28 calculations to plot graph of 1/ against 1/S is plotted.
Time (hr) S (g/L) X (g/L) 1/S 1/X dX dt dX/dt (1/X)*(dX/dt) 1/V V

0.0 9.00 0.40 0.11 2.50
3.0 8.58 1.08 0.12 0.93 0.68 2.88 0.24 0.22 4.57 0.22
6.2 7.50 3.00 0.13 0.33 1.92 3.36 0.57 0.19 5.25 0.19
12.0 1.83 7.16 0.55 0.14 4.16 5.76 0.72 0.10 9.91 0.10
21.6 1.92 8.08 0.52 0.12 0.92 9.60 0.10 0.01 84.31 0.01
35.5 1.66 8.25 0.60 0.12 0.17 13.92 0.01 0.001 675.52 0.001
47.5 1.66 8.50 0.60 0.12 0.25 12.00 0.02 0.002 408.00 0.002
46
Figure 3.11 Graph of 1/ against 1/S is plotted.
Based on the graph,
The y intercept = 1.9873
1/ μmax = 1.9873
μmax = 0.5032 hr-1
The gradient = 526.2
Ks / μmax = 526.2
Ks = 264.78 g/L
Thus, the value of μmax is 0.5032 hr-1 and the value of Ks is 264.78 g/L
47
3.6 OVERALL MASS BALANCE
3.6.1 Overall mass balance by manual calculation
The overall mass balance is calculated using the formulas and with the aid of
Microsoft Excel. The optimum conversion is taken from the data obtain using
Polymath® software which is at 80%.
Table 3.29 Input material flowrate
Input Materials Flowrate (kg/hr)

Water 200.8
NaOH 24.2
Nutrient 45
Ethanol 78.5
POME 36000
Air 2000
Total 38348.5
Table 3.30 Output material flowrate
Output Materials Flowrate (kg/hr)

Fuel 494.2
Methanol 150.4
Water 262.2
Wastewater 35958.9
Lean NaOH 24.2
Sludge Oil 216.0
Bioflocculant 369.5
Fertilizer 867.0
Total 38342.4
Therefore, the total Mass flowrate in = total mass flowrate out
3.6.2 Overall mass balance by iCON ® and SuperPro ®
i. iCON ®
For Syngas synthesis reactor

48
Figure 3.12 iCON for Syngas synthesis reactor
For methanol synthesis reactor
Figure 3.13 iCON for Methanol synthesis reactor
ii. Superpro®
For UASB
49
Figure 3.14 SuperPro for UASB
For MBBR
Figure 3.15 SuperPro for MBBR

50
3.6.3 Comparison of mass balance by manual calculation and iCON ® / SuperPro ®

software
Table 3.31 Comparison of mass balance by manual calculation and software
Unit Software Error Percentage (%)

Syngas synthesis reactor iCON ® 29.8
Methanol synthesis reactor iCON ® 4.4
UASB SuperPro ® 1.2
MBBR SuperPro ® 2.2
3.7 OVERALL ENERGY BALANCE
Energy balance is the arithmetic balancing of energy inputs versus outputs for a
system. It is used to determine the heat released or absorbed during the reaction. The
reaction is exothermic if the heat is released and is endothermic if heat is absorbed. To
compute energy balance for the production of methanol and bio-flocculant, the
required data such as standard enthalphies of formation and coefficient of molar heat
capacity of components are tabulated in Table 3.32, Table 3.33, Table 3.34 and Table
3.35. The comparison between manual and iCON calculations are tabulated in Table
3.36.
Assumption:
1. There are no kinetic energy, potential energy and work done by the system.
2. The system is steady-flow diagram
The molar enthalpy change of a component is given by:
…3.1
51
2
…3.2
Where, Cp = the molar heat capacity of the component
T1 = reference temperature
T2 = inlet or outlet temperature
List of formula used:
Input enthalphy, …3.2

Output enthalphy, …3.3
Total input enthalphy, … 3.4
Total output enthalphy, … 3.5
Heat of energy for reactor, Q = Ho – Hi + rΔHrxn …3.6
Heat of reaction, ΔHrxn = ∑Hproduct – ∑Hreactant … 3.7
Heat involved, Q = Ho – Hi … 3.8
Table 3.32 Standard Enthalphy Formation, ΔHof production of bioflocculant
Component ∆Hof (kJ/mol)

Suspended solid -1273.3
Sludge oil -892
Water -285.8
Methane -74.85
Carbon dioxide -393.5
Biomass -91
Bioflocculant -963
Oxygen 94.383
Ammonium nitrate -365.22
Table 3.33 Specific heat capacity production of bio-flocculant
Component Cp (kJ/kgK)
Glucose, C6H12O6 181.83
Palmitic Acid, C16H32O2 472.00
Water, H2O 29.60
Methane, CH4 58.06
52
Carbon dioxide, CO2 2.79

Biomass, CH1.77O0.48N0.29 26.83
Table 3.34 Standard Enthalphies formation, ΔHof production of methanol
Component ∆Hof (kJ/mol)

Methane -74.85
Carbon monoxide -110.53
Carbon dioxide -393.5
Water -285.8
Hydrogen 0
Methanol -238.7
Table 3.35 Specific heat capacity production of methanol
Component Cp (kJ/kgK)
Methane 4.438
Carbon monoxide 1.174
Carbon dioxide 1.22
Water 4.187
Hydrogen 14.9
Methanol 4.785
Table 3.36 Comparison of heat balance calculation
Unit Qmanual (kW) Qsoftware (kW) Error (%)

R-101 -107 -74.01 30.83
R-102 78.377 81.06 3.42
UASB (Anaerobic) -21181.5 -1500.2 29.18
MBBR (Aerobic) -1103.5 -1103.5 9.36
CHAPTER IV
HEAT INTEGRATION
4.1 INTRODUCTION
Heat integration is a great technique to minimize energy consumption and maximize

heat recovery in desigining a process. One of the most widely applied methods for
heat exchanger networks that emerged was a set of techniques called pinch
technology. Pinch point usually occurs between the hot stream and cold stream
curves. Problem Table Method is used since it will generate more accurate value
compare to temperature-enthalphy diagram.
4.2 PINCH ANALYSIS
4.2.1 Data extraction
There are 8 utilities involved for the pinch analysis which are the cooler and heater. A
total of 5 hot streams and 3 cold streams involved. Table 4.1 shows the process data
for each utility unit.
Table 4.1 Process Data for Each Utility Unit
No Utility Unit Type Ts (℃) Tt (℃) CP (kW/℃) Q (kW)

1 CO-101 Hot 700 350 0.068333 23.92
2 CO-102 Hot 350 150 0.055654 11.13
3 CO-103 Hot 250 50 0.196896 39.38
4 CO-104 Hot 68 30 0.015519 0.59
5 CO-105 Hot 90 30 0.015917 0.96
6 H-101 Cold 30 160 0.225934 -29.37
7 H-102 Cold 350 700 0.041640 -14.57
8 H-103 Cold 76.9 250 0.011244 -1.95
54
4.2.2 Interval Temperature
In problem table method, the actual stream temperature Tact is converted into interval
temperature Tint using equations (4.1) and (4.2) as shown.
Hot stream : Tint = Tact – (1/2) ΔTmin ...(4.1)

Cold Stream : Tint = Tact + (1/2) ΔTmin ...(4.2)
Where ΔTmin = 10℃
ΔHi = (ΣCpc – ΣCpH)iΔTi … (4.3)
After Tact converted into Tint, the heat balance for the streams are carried out using
equation (4.3) and is tabulated in Table 4.2. After that, the value of QHmin, Qcmin and
Tpinch is dtermined.
Table 4.2 Interval Temperature for ΔTmin = 10℃
No Utility Type Source Target Source Target

unit Temperature Temeprature interval interval
Ts (℃) Tt (℃) temperature, temperature,
ts(℃) ts (℃)
1 CO-101 Hot 700 350 695 345
2 CO-102 Hot 350 150 345 145
3 CO-103 Hot 250 50 245 45
4 CO-104 Hot 68 30 63 25
5 CO-105 Hot 90 30 85 25
6 H-101 Cold 30 160 35 165
7 H-102 Cold 350 700 355 705
8 H-103 Cold 76.9 250 81.9 255
Table 4.3 Heat capacities at Interval Temperature
Tint (℃) Interval, i ΔTint (℃) Cpi ΔHi = Excess/Deficient

CpiΔTint heat
705
695 1 10 0.04164 0.4164 Deficit
355 2 340 -0.02669 -9.0763 Excess
345 3 10 -0.06833 -0.6833 Excess
255 4 90 -0.05565 -5.0088 Excess
245 5 10 -0.04441 -0.4441 Excess
165 6 80 -0.24131 -19.3044 Excess
145 7 20 0.040282 0.8056 Deficit
85 8 60 0.040282 2.3169 Deficit
81.9 9 3.1 0.024364 0.0755 Deficit
63 10 18.9 0.013121 0.2480 Deficit
45 11 18 0.013121 0.2362 Deficit
35 12 10 -0.03144 -0.3144 Excess
55
25 13 10 -0.01522 -0.1552 Excess
Tint Interval Cpi

(℃)
705
1
695 1 0.04164
355 2 -0.02669
345 3 2 7 -0.06833
255 4 -0.05565
245 5 3 -0.04441
165 6 -0.24131
145 7 0.040282
85 8 5 0.040282
81.9 9 0.024364
63 10 4 8 0.013121
45 11 0.013121
35 12 6 -0.03144
25 13 -0.01522
0.0683 0.0557 0.1969 0.0155 0.0159 0.2259 0.0416 0.0112
Figure 4.1 Relationship between Tint with Hot/Cold Stream
4.2.3 Heat Cascade
The temperature interval where heat is equal to zero is the pinch point and the pinch
temperature could be determined. The minimum required heat for hot utility process,
QHmin is the heat introduced to the top when pinch point established. While the heat at
the bottom is minimum required heat for cold utility process, QCmin. The infromation
from the heat cascade and graph composite curve is concluded in Table 4.4.
Table 4.4 Heat Cascade
Iteration No of interval ΔHi First Iteration Second Iteration

Temperature
(℃)
705 0.0000 0.41
695 1 0.4164 -0.4164 0
355 2 -9.0763 8.6599 9.10
345 3 -0.6833 9.3432 9.80
255 4 -5.0088 14.3520 14.80
245 5 -0.4441 14.7961 15.20
165 6 -19.3044 34.1006 34.50
145 7 0.8056 33.2949 33.70
85 8 2.3169 30.8780 31.30
81.9 9 0.0755 30.8025 31.20
63 10 0.2480 30.5545 31.00
45 11 0.2362 30.3183 30.70
35 12 -0.3144 30.6327 31.00
25 13 -0.1552 30.7879 31.20
56
The summary obtained from heat cascade above is listed in table 4.5 below.
Table 4.5 Summary from heat cascade
Summary from heat integration result

Minimum required heat for hot utilities process, Qhmin 0.41 kW
Minimum required heat for cold utilities process, Qcmin 31.20 kW
ΔT min 10 ℃
Pinch temperature (interval) 695 ℃
Pinch temperature hot stream 700 ℃
Pinch temperature cold stream 690 ℃
4.2.4 Heat Exchanger Network
Figure 4.2 show heat exchanger network represented as grid.
700 CP
1 700 700 350 0.068334917
2 350 350 150 0.055653533
3 250 250 50 0.1968957
4 68 68 30 0.015519139
5 90 90 30 0.0159174
6 160 160 30 0.225933833
7 700 690 350 0.04164
8 250 250 76.9 0.01124375
690
Figure 4.2 Grid heat exchanger network
Network design only are performed when the representation grid is divided into
below pinch and above pinch. There are some conditions that need to be obeyed when
performing heat exchange. For above pinch, the heat capacity of hot stream must
lower or equal to cold stream (CPH ≤ CPC) and only hot utilities allowed. For below
pinch, the heat capacity of hot stream must greater or equal to cold stream (CP H ≥
CPC) with only utility allowed. Figure 4.3 for below pinch and figure 4.4 above pinch.
57
700℃
1 700℃ 350℃
C 23.9kW
9.76kW
2 350℃ 150℃
C 11.1kW
3 250℃ 111kW 50℃ 39.4kW
4 68℃ C
30℃ 0.6kW
0.6kW
5 90℃ C
30℃ 1.0kW
1.0kW
160℃ 30℃ 6 29.4kW
690℃ 29.4kW 350℃ 7 14.2kW
250℃ 23.9kW 76.9℃ 8 1.9kW
1.9k
690℃
Figure 4.3 Network design below the pinch
700℃
0.4kW 700℃ 690℃ 7

H
0.4kW 690℃
Figure 4.4 Network design above the pinch
4.2.5 Total Heat Recovery
The total energy recovery is the energy saved after heat exchanger network is
performed using pinch analysis.
Percentage recovery (%)
Table 4.6 Total energy recovery
Energy Requirement (kW) Total Energy Recovery (%)

Before After
122 30 75%
58
CHAPTER V
PROCESS CONTROL AND PIPING
5.1 INTRODUCTION
Piping and instumentation diagram (PID) is a drawing that shows the details of piping
and instrumentation equipments in the plant including valves, fittings and their
arrangement. It is differ from process flow diagram (PFD) that only shows the
arrangement of the major equipments and their pipes interconnection. In this section,
basic instrumentation and control system for bioflocculant production plant are
introduced.
These instruments normally involve in the control system for main processing
units in the plant. They may be incorporated in automatic control loops or a manual
operating of the proces operation. Intruments will monitor the critical process
variables and will be fitted with automatic alarms to alert the operators regarding
critical hazardous situations and make adjustment to control the parameter. This is
very crucial especially for a chemical plant to ensure safe operations.
5.2 PROCESS CONTROL ANALYSIS
One of the steps during process design of a chemical plant in constructing control
systems. In this step, a chemical engineer will select the control a equipment to
control by find their control objectives, manipulated variables, controlled parameter as
well as the control configuration connecting manipulation and measurements. Any
variation of the process variables from the desired value may affect the product
quality. The objective of the implementing control system is to ensure the safety of the
plant and to achieve a stable production rate as well as desired product quality. To
59
ensure the plant is safe, process variables involved must be kept in within the knows
safe operating condition range. Any dangerous situation must be able to be detected as
soon as possible and automatic shutdown systems should be implemented.
5.2.1 Control strategies on unit operations
There will be one or more control objectives on each unit operation to ensure the
smooth productuion and safe operation. The primary objectives when specifying
instrumentation and control schemes are listed as follow (Sinnot 2009)
i. Safe plant operation – To ensure the process variables within knows

safe operating limits, detect any dangerous situations as they develop
and to provide alarms and automatic shutdown systems, besides
providng interlocks and alarms to prevent dangerous operating
procedures.
ii. To achieve the designed production rate
iii. To maintait the product quality at specified standards
iv. To operate ar efficient low cost and commensurate with the other
objectives
v. To maintain the steady operation with minimal operator intervention
5.2.2 Type of intrumentations
The controller used in unit operation can be either feed-forward control or feedback
control, depending on the control objectives. The controller functions normally by a
basis where any disturbace affects the controlled variable and the variable deviates
from set point, the controller changes its output in such a way as to return the
controlled variable to set point. Table below shows the types of instrumentation
applied on the unit process with its objectives.
60
Table 5.1 Types of intrumentation applied on the unit process with its objectives
Intrumentations Objectives
Flow
- Flow controller (FL) - Indicates and control the flow rate in the pipeline
- Flow transmitter - Detect and send signals of deviations in the flow to
controller
Level
- Level controller (LC) - Control the level of liquid in the unit operation by
- Level tranmitter (LT) regulating the input or output of liquid flow rate
- Element to detect deviation of level in unit operation
Pressure
- Pressure controller (PC) - Indicate and control pressure of the pipeline or
- Pressure transmitter (PT) pressure vessel
- Detect and send signals of the pressure deviations to
controller
Temperature
- Temperature controller (TC) - Control the temperature of the main stream by
- Temperature transmitter regulating the flow rate of the utility line
(TT) - Element to detect the deviation in temperature
Composition
- Composition controller (AC) - Control the material composition of a stream
- Composition transmtter (AT) - Detect the changes of stream material composition
The type of instrument is indicated on a circle representing the instrument

controller by a letter code. The first letter indicates the property to be measured while
the second and subsequent letters indicate its fuction. The letter code for
instrumentation symbol is shown in the Table 5.2
Table 5.2 letter code for instrumentation symbol
Measured First Indicating Controller Transmitter Final

variable letter only Recording Indicating Blind control
element
Flowrate F FI FRC FIC FC FT FV
Level L LI LRC LIC LC LT LV
Pressure P PI PRC PIC PC PT PV
Temperature T TI TRC TIC TC TT TV
Composition A AI ARC AIC AC AT AV
Source: Sinnot 2012
5.3 CONTROL CONFIGURATION FOR UNIT OPERATION
Every unit operation in this plant is controlled by several objectives. Instrumentations

implemented are of basic requirements to ensure a safe and smooth production
process while detailed instrumentations will be implemented after the HAZOP studies.
61
5.3.1 Control configuration on reactors
Packed bed reactors of R-101 is used for producing syngas while R-102 is used to
produce methanol gas. Information below shows the mathemathical model for two
types of packed bed reactors which is R-101 and R-102
Figure 5.1 R-101
Total mass balance
Total energy balance
Table 5.3 Criteria for R-101
Criteria Value
Number of variables 6
Number of equations 2
Disturbances 2
Degree of freedom 2
Controller needed 2
62
Table 5.4 Control strategies for R-101
Parameter Control Objective Controlled Manipulated Control action Type of

variable variable valve
Pressure To avoid the Pressure inside Outlet stream Transmitter Butterfly
reactor from phase separator flow rate from send signal to valve – to
overpressure and (Set point : the reactor control valve. control
explode 25bar ) Reduce valve vapor flow
opening when
the pressure
inside reactor
higher than the
set point
Temperature To avoid the Outlet Flowrate of hot Transmitter Butterfly
reactor from temperature of stream/cooling send the signal valve – to
overheating reactor (set medium to control control
point 700℃) valve. vapor flow
Increase valve
opening when
temperature
higher than set
point.
PIC
23
TT
22
PT
23
TIC
22
C.w in
C.w out
Figure 5.2 R-102
Total mass balance

63
Table 5.5 Criteria for R-102
Criteria Value
Disturbances 2
Degree of freedom 2
Controller needed 2
Table 5.6 Control strategies for R-102
Parameter Control Controlled Manipulated Control Type of

Objective variable variable action valve
Pressure To avoid the Pressure Outlet stream Transmitter Butterfly
reactor from inside phase flow rate from send signal to valve – to
overpressure separator (Set the reactor control valve. control
and explode point : 50bar) Reduce valve vapor flow
opening when
the pressure
inside reactor
higher than the
set point
Temperature To avoid the Temperature Flowrate of hot Transmitter Butterfly
reactor from inside reactor stream/cooling send the signal valve –
overheating at 250℃ medium to control good
valve. control
Increase valve
opening when
temperature
higher than set
point.
5.3.2 Control configuration on phase separator
Phase separator S-101 is to separate syngas and water while S-102 is used to separate
methanol and unreacted syngas. Informations below shows the mathemathical model
for phase separator
64
Figure 5.3 S-101, S-102
Total mass balance
Volume
Table 5.7 Criteria for S-101, S-102
Criteria Value
Disturbances 1
Degree of freedom 2
Controller needed 2
Table 5.8 Control strategies on S-101, S-102

Pressure To avoid Pressure Outlet stream Transmitter Butterfly
overpressure inside phase flow rate 63 send signal to valve – to
and explode separator (Set control valve. control
point : 25bar) Increase valve vapor flow
opening when
the pressure
inside higher
than the set
point
Level To avoid Level of fluid Flowrate of Transmitter Diaphragm
spillage of in phase bottom product send the signal valve –
containment separator to control good
valve. control
Increase valve
65
opening when
the level is
over the
maximum
allowable
volume.
5.3.3 Control configuration on distillation column
Distillation coulm C-101 is used to separate methanol and water to get 99.9% purity
of methanol as the top product. Informations below shows mathemathical model for
distillation column
Figure 5.4 C-101
Total mass balance

66
Accumulation of total energy = accumulation of total enthalpy
Since
Simplify the liquid and enthalpy properties
Assuming area of distillation column is constant and
Ideal gas law
Equilibrium of vapor composition for each stage
Table 5.9 Criteria for C-101
Criteria Value
Disturbances 2
Degree of freedom 4
Controller needed 4
Reflux drum mathematical model

67
Total mass balance
Reflux ratio
Table 5.10 Criteria for reflux drum
Criteria Value
Disturbances 1
Degree of freedom 1
Controller needed 1
Overall control needed 5
Table 5.11 Control strategies on C-101
Parameter Control Controlled Manipulated Control action Type of valve

Objective variable variable
Pressure To avoid over Pressure inside Inlet flow rate Open the valve Diaphragm
pressure and distillation of coolant into when pressure valve –
explode within column at 1.5 partial inside higher because good
set point 1.5bar bar condenser at than the set flow control
stream 69 point to get
optimum
pressure.
The valve is
close when the
pressure below
than set point
Temperature To avoid Temperature Flowrate of Open valve Diaphragm
overheating inside cooling water when the valve –
within set point distillation temperature because good
103℃ column at higher then set flow control
103℃ point.
Close the valve
when the
temperature
lower than set
point
Level of To avoid Level of fluid Flow rate of Increase valve Globe valve –
distillation spillage of in distillation bottom product opening when because good
column containment column at stream 68 the level is flow control
over the
68
maximum
allowable
volume.
Close the valve
when level is
not over
maximum
allowable
volume.
Level of reflux To prevent Reflux drum Output flow Open valve Globe valve –
drum overflow in level rate of the when the level because good
drum distillate is over the flow control
product maximum
allowable
value.
Close the valve
when the level
not over
maximum
allowable
value.
Composition To maintain Purity of Flow rate of Open the valve Globe valve –
the purity of Methanol is liquid reflux when not get because good
the final (99.9%) back to set purity of flow control
product distillation methanol to
column regulate flow
rate of liquid
reflux and
close the valve
when the
purity
achieved.
5.3.4 Control configuration on scrubber
Scrubber SR-101 is used to scrub H2S gas from the biogas before further process.
Informations below shows mathemathical model for scrubber
Figure 5.5 SR-101

69
Total mass balance
Equation of state (Ideal gas law)
PV = nRT
Volume
Table 5.12 Criteria for SR-101
Criteria Value
70
Disturbances 3
Degree of freedom 3
Controller needed 3
Table 5.13 Control configurations of SR-101

Flow To control the Flow rate of Flow rate of Transmitter Diaphragm
flow rate of NaOH NaOH/ Water send signal to valve–
NaOH/water 1.2kg/hr and control valve. good
enter the water 23kg/hr Reduce valve control
scrubber opening when
flow rate of
scrubbing
agent higher
then set point
To control the Flow rate of Flow rate of Transmitter Butterfly
flow rate of methane, producer gas send signal to valve –
methane that water and fed to scrubber control valve. control
will enter the carbon Reduce valve vapor flow
reactor dioxide. opening when
flow rate of
scrubbing
agent higher
then set point
Level To avoid Level of fluid Outlet liquid Transmitter Diaphragm
spillage of in scrubber flow rate send the signal valve –
containment to control good
valve. control
Increase valve
opening when
the level is
over the
maximum
allowable
volume.
5.3.5 Control configuration on dryer
Dryer D-101 is used to dry desired product which is bioflocculant before being
transferred to storage tank. Informations below shows mathemathical model for dryer
71
FC
13
FT
13
Figure 5.6 D-101
Total mass balance
(𝛿𝑣/𝛿𝑡) = 𝜌1𝐹1 − 𝜌2𝐹2
𝜌𝐶𝑝𝑉 𝛿𝛿𝑡 𝐶𝐴 = 𝜌𝐶𝑝𝐹1(𝑇2 − 𝑇1) + 𝑄
Volume
𝑉 = 𝑏𝑎𝑠𝑒 𝑥 𝑤𝑖𝑑𝑡ℎ 𝑥 ℎ𝑒𝑖𝑔ℎ𝑡
Energy balance on cooling water
Table 5.14 Criteria for D-101
Criteria Value
72
Disturbances 2
Degree of freedom 1
Controller needed 1
Table 5.15 Control configuration for D-101
Parameter Control Control Manipulated Control action Type of valve

objective Variable variable
Flow To control Flow rate of Flow rate of Transmitter send Diaphragm
the flow air NaOH/ Water signal to control valve –good
rate of air 1516.7kg/hr valve. control valve
Reduce valve
opening when flow
rate of scrubbing
agent higher then
set point
5.3.6 Control configuration on UASB reactors
Three UASB reactors T-101, T-102 and T-103 are being arranged in parallel to
produce biogas from palm oil mill effluent. Information below shows the
mathemathical model for UASB reactors
Figure 5.7 T-101, T-102, T-103
Total mass balance

73
Win = Wout
Height
Table 5.16 Criteria for T-101, T-102, T-103
Criteria Value
Disturbances 2
Degree of freedom 3
Controller needed 3
The temperature is not controlled since the present of cooling pond before the UASB
Table 5.17 Control configurations for T-101, T-102, T-103

Flow To control the Flow rate of Flow rate of Transmitter Diaphragm
flow rate of water 11333.3 water and send signal to valve–
water and kg/hr and suspended control valve. good
suspended suspended solid Reduce valve control
solid solid is opening when
600kg/hr flow rate of
suspended
solid and
water higher
then set point
pH To control the pH is control Flowrate of pH sensor Diaphragm
pH in the in the range of sodium measures the valve–
UASB 7-8 hydroxide pH value, and good
pH transmitter control
send signal pH
controller, a
valve to adjust
74
inlet flows of
sodium
hydroxide
5.3.7 Control configuration on aerated tank
Aerated tank T-105 is used to sparge the liquid from settlement tank. Informations
below shows mathemathical model for aerated tank
Figure 5.8 T-105
Total mass balance
Win = Wout
Height
75
Table 5.18 Criteria for T-105
Criteria Value
Disturbances 2
Degree of freedom 4
Controller needed 3
Table 5.19 Control configuration of T-105
Type of Objective Control Manipulated Control Type of

controller Variable variable action valve
Temperature To maintain Temperature of Flow of inlet TT will detect Diaphragm
controller the aerated tank hot water flow the changes valve
temperature to the jacketed inside the T-
inside the vessel 105, send the
aerated tank at signal to TC
37°C and valve will
adjust the inlet
flow of
cooling water
pH controller To maintain pH of the cell Flow of NaOH pH sensor Diaphragm
the pH at 5.5 inside the into the measures the valve
which is the aerated tank aerated tank pH value, and
optimum pH pHT send
condition for signal pH
our microbes controller, a
valve to adjust
inlet flows of
NaOH
Level To maintain The level of The outlet The LT will Diaphragm
controller the level of liquid mixture flow of liquid detect and valve
foam and in the aerated mixture send signal to
liquid mixture tank LC, valve will
inside the adjust outlet
aerated tank flow of liquid
mixture
5.3.8 Control configuration on gas holder
Gas holder GH-101 is used as storage tank for the gas being scrubbed from H2S gas.
Informations below shows the mathemathical model for gas holder
76
Figure 5.9 GH-101
Total mass balance
Volume
Table 5.20 Criteria for GH-101
Criteria Value
Disturbances 3
Degree of freedom 1
Controller needed 1
Table 5.21 Control configuration for GH-101
Parameter Control Controlled Manipulated Control Types of

objective variable variable action valve
Pressure To avouid the Pressure gas Outlet stream Transmitter Butterfly
gas holder holder (Set flow rate from send signal to valve – to
from point : 1 bar) the gas holder control valve. control vapor
overpressure Increase valve flow
and explode opening when
the pressure
inside reactor
77
higher that the

set point
5.4 VALVES
There are several valves used for different purposes in methanol and bioflocculant
production plant:
i. Pressure relief valve, to reduce pressure in an equipment in case of emergency.
Generally, the types of valves used in chemical plant are gate valve, plug
valve, ball valve, globe valve, diaphragm valve and butterfly valve. We choose
butterfly valve and diaphragm in production of bioflocculant and methanol.
Diaphragm valve is usually used to handle stream containing solid or hazards while
butterfly valve to handle vapour. Schematic diagram of butterfly valve and diaphragm
are shown in figure 5.10 (a) and (b).
a) Butterfly Valve b) Diaphragm Valve
Figure 5.10 Schematic diagram of (a) butterfly valve and (b) diaphragm valve
5.5 PIPING SYSTEM
Piping system is one of the important parts of chemical process industry. Pipes are
used to convey solids or fluids from one place to another. Industrial piping can be
manufactured from various types of materials, such as fiberglass, steel, aluminium,
plastics and so on. Basically, piping system involves pipes, flanges, gaskets, fittings,
valves, bolting and pipe support. Beside selecting the right piping material, pipe
diameter is an important aspect in desigining the piping system. To get the optimum
78
and safe plant operations, the suitable pipe diameter for every single stream needs to
be determined. Diameter of pipes is identified by its nominal size with optimum
diameter calculation. As for our plant using stainless steel of pipe because it has good
resistance towards corrosion and ease fabrication. All the piping used are stainless
steel Schedule 40. The sizing of pipe is determined based on ASME/ANSI B36.19
Stainless Steel Pipe. In production plant, there are two phases of flows (liquid, vapor
and mixture).
a. Liquid flow
Stainless steel optimum diameter can be ustimate by using the economic pipe
diameter as show in equation below (sinnot 2006).
Stainless steel: Di, optimum = 0.465m0.51ρ-0.36 ...(5.1)
Where: Di, optimum is inside optimum diameter, m is flowrate (kg/s) and ρ is

density (kg/m3).
b. Vapor flow
For long pipe, the gas velocity can approach the sonic velocity (Crowl & Louver
2002). The velocity of sound is determined using the thermodynamic reaktionship.
(1/2)
Assuming the gas in ideal state and is equivalent to,
(1//2)
…(5.4)
79
Where = 1.32 for tri-atomic gas, gc = 32.174 ft.Ibm/s2.Ibf, Rg = 1545 ft.Ibf/Ibmol.oR,
T is temperature in Rankine and M is molecular mass in Ibmol.
Qm = ρUA ...(5.5)
Where Qm is gas flowrate (kg/s), ρ is density of fluid (kg/m3), U is sonic velocity

(m/s), A is cross sectional area of pipe (m2).
Thus, diameter of pipe can be determined by equation (5.6).
…(5.6)
Using equation given, the diameter of pipe for vapour stream can be
determined. The diameter is then compared with the standards based on ANSI/ASME
B36.10M:1995 Wrought Steel Pipe Seamless and Welded to determine the nominal
pipe dimension. Table 5.11 shows the results obtained. While table 5.12 shows the
specification of nominal pipe in vapour flow.
c. Mixture Flow
Lines transporting gas and liquid in two-phase flow should be sized primarily on the
basis of flow velocity. Flow velocity should be kept at least below fluid erosional
velocity. The velocity above which erosion may occur can be determined by the
following empirical equation (5.7):
80
Where Ve is fluid erosional velocity (ft/s) , C is emprical constant (100 for

continous service), ρm is gas/liquid mixture density at operating pressure and
temperature (Ibm/ft3)
Once Ve is known, the minimum cross-sectional area required to avoid fluid

erosion may be determined fro the following derived equation (5.8).
...(5.8)
Where A is minimum pipe cross sectional area required (ft2), G is mixture

flow rate (Ibm/s), Z is gas compressibility factor, R is gas/liquid (m3 gas/m3liquid), T
is operating temperature (oR) and P is operating pressure (psia).
Table 5.22, table 5.23 and table 5.24 show the pipe sizing for liquid stream,
vapour streams and mixed stream respectively.
Table 5.22 Pipe sizing for liquid streams
Stream G(kg/h) G(kg/s) Density(kg/m^3) Doptimum(m) Doptimum(in) Dnominal(in) Dout(in) t(in) Din(in)
1 36016 10.00444 997 0.17895187 7.04535301 8.00 8.625 0.32 7.891
2 36016 10.00444 997 0.17895187 7.04535301 8.00 8.625 0.32 7.891
3 216 0.06 997 0.013167246 0.518395804 0.75 1.05 0.11 0.824
4 35800 9.944444 997 0.178403714 7.02377205 8.00 8.63 0.32 7.891
5 11933.3 3.314806 997 0.101875894 4.010864126 5.00 5.56 0.28 6.065
6 11933.3 3.314806 997 0.101875894 4.010864126 5.00 5.56 0.28 6.065
7 11933.3 3.314806 997 0.101875894 4.010864126 5.00 5.56 0.28 6.065
8 11933.3 3.314806 997 0.101875894 4.010864126 5.00 5.56 0.28 6.065
9 11933.3 3.314806 997 0.101875894 4.010864126 5.00 5.56 0.28 6.065
10 11933.3 3.314806 997 0.101875894 4.010864126 5.00 5.56 0.28 6.065
22 33946.4 9.429556 997 0.173631432 6.835886831 8.00 8.63 0.32 7.891
23 33946.4 9.429556 997 0.173631432 6.835886831 8.00 8.63 0.32 7.891
24 45 0.0125 997 0.00591646 0.23293162 0.38 0.68 0.10 0.493
29 33879.9 9.411083 997 0.173457878 6.829053986 8.00 8.63 0.32 7.891
30 33879.9 9.411083 997 0.173457878 6.829053986 8.00 8.63 0.32 7.891
34 513.2 0.142556 997 0.020472446 0.806002252 1.00 1.32 0.13 1.049
35 33850.3 9.402861 997 0.173380573 6.826010486 8.00 8.63 0.32 7.891
36 33850.3 9.402861 997 0.173380573 6.826010486 8.00 8.63 0.32 7.891
37 363.9 0.101083 997 0.017180049 0.676380243 0.38 0.68 0.10 0.493
38 34214.3 9.503972 997 0.174328925 6.863347226 8.00 8.63 0.32 7.891
39 33522.6 9.311833 997 0.172522511 6.792228525 8.00 8.63 0.32 7.891
45 24.2 0.006722 2130 0.003280824 0.129166384 0.25 0.54 0.09 0.364
46 24.2 0.006722 2130 0.003280824 0.129166384 0.25 0.54 0.09 0.364
55 0.7 0.000194 921.9979 0.000728033 0.02866273 0.25 0.54 0.088 0.364
66 494.2 0.137278 877.6736 0.021025402 0.827772181 1.00 1.32 0.133 1.049
82
67 260.5 0.072361 925.4513 0.014880875 0.585861525 1.00 1.32 0.133 1.049

68 260.5 0.072361 925.45 0.014880875 0.585861525 1.00 1.32 0.133 1.049
68a 262.2 0.072833 925.45 0.014930323 0.587808291 1.00 1.32 0.133 1.049
70 150.4 0.041778 745.25 0.012156862 0.478616872 1.00 1.32 0.133 1.049
71 150.4 0.041778 746.25 0.012150995 0.478385882 1.00 1.32 0.133 1.049
Table 5.23 Pipe sizing for vapour stream
Density Din Dnominal

Stream T(®C) T(®R) M(lb/mol) (kg/m3) G(kg/s) A(ft/s) A(m2) (m) Din(inch) (inch) Dout(inch) t(inch) Din(inch)
11 37 558.27 0.0396 997 3.913E-10 30414.33 6.5068E-09 9.1E-05 0.003583 0.125 0.405 0.068 0.269
13 37 558.27 0.0396 997 3.913E-10 30414.33 6.5068E-09 9.1E-05 0.003583 0.125 0.405 0.068 0.269
15 37 558.27 0.0396 997 3.913E-10 30414.33 6.5068E-09 9.1E-05 0.003583 0.125 0.405 0.068 0.269
19 37 558.27 0.0396 997 1.567E-09 30414.33 1.3023E-08 0.00013 0.005069 0.125 0.405 0.068 0.269
20 30 545.67 0.0396 997 3.591E-09 30069.15 1.9824E-08 0.00016 0.006254 0.125 0.405 0.068 0.269
26 30 545.67 0.0396 997 3.378E-08 30069.15 6.0799E-08 0.00028 0.010953 0.125 0.405 0.068 0.269
26a 30 545.67 0.0396 997 3.378E-08 30069.15 6.0799E-08 0.00028 0.010953 0.125 0.405 0.068 0.269
28 30 545.67 0.0396 997 1.972E-09 30069.15 1.4692E-08 0.00014 0.005384 0.125 0.405 0.068 0.269
41 30 545.67 0.0396 997 1.943E-08 30069.15 4.6107E-08 0.00024 0.009538 0.125 0.405 0.068 0.269
41a 90 653.67 0.0396 997 1.775E-08 32910.57 4.2126E-08 0.00023 0.009117 0.125 0.405 0.068 0.269
43 90 653.67 0.0396 997 2.506E-08 32910.57 5.0053E-08 0.00025 0.009938 0.125 0.405 0.068 0.269
44 30 545.67 60.698 1.0946 0.000128 768.036 0.0007069 0.03 1.181064 1.25 1.66 0.14 1.38
47 30 545.67 60.698 1.0947 0.000128 768.036 0.00070684 0.03 1.18101 1.25 1.66 0.14 1.38
48 30 545.67 60.698 1.0947 0.000128 768.036 0.00070684 0.03 1.18101 1.25 1.66 0.14 1.38
49 30 545.67 39.644 995.6174 1.683E-08 950.3423 2.4157E-07 0.00055 0.021833 0.125 0.405 0.068 0.269
50 160 779.67 39.644 0.6003 2.335E-05 1135.979 0.00033517 0.02066 0.813259 1 1.315 0.133 1.049
51 75 626.67 52.91 0.8306 0.0002814 881.5649 0.00112288 0.03781 1.488536 1.5 1.9 0.145 1.61
51a 350 1121.67 52.91 9.2829 1.882E-05 1179.417 7.5101E-05 0.00978 0.384961 0.5 0.84 0.109 0.622
83
52 700 1751.67 32.978 8.3857 1.316E-05 1866.886 5.2522E-05 0.00818 0.321932 0.38 0.675 0.091 0.493
53 700 1751.67 32.978 8.3857 1.316E-05 1866.886 5.2522E-05 0.00818 0.321932 0.38 0.675 0.091 0.493
53a 492 1377.27 32.978 3.7689 3.303E-05 1655.393 0.00013179 0.01295 0.509962 0.75 1.05 0.113 0.824
56 350 1121.67 32.978 0.3039 0.0004539 1493.909 0.00181112 0.04802 1.890456 2 2.375 0.154 2.067
57 450 1301.67 32.978 7.477 1.713E-05 1609.319 6.8333E-05 0.00933 0.367204 0.38 0.675 0.091 0.493
58 350 1121.67 38.786 37.516 0.0001092 1377.523 8.3246E-05 0.01029 0.405298 0.5 0.84 0.109 0.622
59 150 761.67 38.786 11.0433 2.758E-05 1135.141 8.4957E-05 0.0104 0.409443 0.5 0.84 0.109 0.622
60 250 941.67 38.786 20.2639 1.352E-05 1262.163 4.164E-05 0.00728 0.286647 0.375 0.675 0.091 0.493
61 250 941.67 47.146 19.7099 1.532E-05 1144.803 4.7199E-05 0.00775 0.305183 0.375 0.675 0.091 0.493
61a 260 959.67 46.464 23.5829 4.787E-06 1164.143 2.3919E-05 0.00552 0.217253 0.25 0.54 0.088 0.364
63 50 581.67 46.464 23.5829 6.149E-06 906.3246 3.0723E-05 0.00625 0.246222 0.25 0.54 0.088 0.364
64 50 581.67 46.464 23.5829 8.424E-07 906.3246 1.1372E-05 0.0038 0.149798 0.25 0.54 0.088 0.364
65 30 545.67 46.464 23.5829 2.519E-06 877.8301 1.998E-05 0.00504 0.198558 0.25 0.54 0.088 0.364
69 68 614.07 70.444 745.2456 1.008E-08 756.294 2.4221E-07 0.00056 0.021862 0.125 0.405 0.068 0.269
84
Table 5.24 Pipe sizing for mixture stream
Density T Dnominal
Stream P(psia) (ibm/ft3) G(lbm/s) (℃) T(®R) R Z ve(ft/s) A(ft2) D(inch) (inch) Dout(inch) t(inch) Din(inch)
12 14.504 62.24 7.19197478 37 558.27 1.3155 0.0007 12.6755 9.377682 11.9692 12 12.75 0.406 11.94
14 14.504 62.24 7.19197478 37 558.27 1.3155 0.0007 12.6755 9.377682 11.9692 12 12.75 0.406 11.94
16 14.504 62.24 7.19197478 37 558.27 1.3155 0.0007 12.6755 9.377682 11.9692 12 12.75 0.406 11.94
17 14.504 62.24 14.3839496 37 558.27 1.3155 0.0007 12.6755 9.377682 11.9692 12 12.75 0.406 11.94
18 14.504 62.24 21.5759856 37 558.27 1.3155 0.0007 12.6755 9.377682 11.9692 12 12.75 0.406 11.94
21 14.504 62.24 0.78729588 30 545.67 1.3155 0.0007 12.6755 9.377057 11.96881 12 12.75 0.406 11.94
25 14.504 62.24 0 37 558.27 1.3155 0.0007 12.6755 9.377682 11.9692 12 12.75 0.406 11.94
27 14.504 62.24 0.03974448 30 545.67 1.3155 0.0007 12.6755 9.377057 11.96881 12 12.75 0.406 11.94
31 14.504 62.24 0.01812691 30 545.67 1.3155 0.0007 12.6755 9.377057 11.96881 12 12.75 0.406 11.94
32 14.504 62.24 0.01812691 30 545.67 1.3155 0.0007 12.6755 9.377057 11.96881 12 12.75 0.406 11.94
43a 15.9544 62.24 1.10359824 30 545.67 1.3155 0.0007 12.6755 9.379763 11.97053 12 12.75 0.406 11.94
54 43.512 0.02 0.55293205 350 1121.67 0.03697 1 707.1068 9.470082 12.02803 14 14 0.437 13.13
62 435.12 2.35 0.71576806 50 581.67 0.0438 0.6362 65.23281 14.43778 14.85141 16 16 0.5 15
CHAPTER VI
DETAILED DESIGN
6.1 COOLING POND (CP-101)

Designed by: Ravinkumar A/L Manimaran (A158192)
The main function of cooling pond in our plant is to reduce the temperature of POME
obtained directly from the palm oil mill. POME will be received from the mill at a
temperature of 85°C (Zainal et al. 2017). This temperature is not suitable for
anaerobic process because the microbe that involves is mesophilic which work best in
the temperature range of 35°C to 40°C (Choong et al. 2017). A cooling pond is chosen
rather than tank because it is low in construction and operation cost. It is also easy to
operate and maintain in which skilled workers are not required. This cooling pond
also serves as a storage of POME. The general information of POME required for the
design of cooling pond is as below. The calculations can be referred in appendix A1.
Table 6.1 Information of POME required to design cooling pond
Information Value
Inlet flowrate of POME (kg/h), F 36000
Inlet temperature of POME, T in (K) 358.15
Outlet temperature of POME, T out (K) 308.15
Heat capacity of water, Cp (kJ/kg.K) 4.2
Convective heat transfer coefficient, h (W/m2.K) 369
Emissivity of water, ε 0.96
Stefan constant, σ (W/m2.K) 5.670 × 10-8
Source: Zainal et al. 2017
6.1.1 Heat transfer in cooling pond
The design of cooling pond is based on the energy balance on the cooling pond.
Assumption made to calculate the heat transfer at the surface of cooling pond is heat is
86
transferred through convection and radiation only. The overall heat formula is shown
as below
Heat Transferred (Q) = Heat Transferred by + Heat Transferred by

Convection (Q convection) Radiation (Q radiation)
a. Heat Transferred (Q)
Heat is transferred from the cooling pond to the atmosphere. This is because the
temperature in the cooling pond is higher compared to the atmosphere. The formula
for the heat transferred in the cooling pond is as below.
Q = mCpΔT where, m = Inlet POME flowrate (kg/hr)
Cp = Specific heat capacity (kJ/kg.K)
ΔT = Difference in temperature (K)
= (36000)(4.2)(358.15-308.15)
= 7560000 kJ/hr
Thus, the rate of heat transfer from the cooling pond to atmosphere is 7560000 kJ/hr
b. Heat Transferred by Convection (Q convection)
Heat by convection means heat is transferred from one place to another thorough the
fluid. In this case, heat is transferred from the cooling pond to the atmosphere through
the air as the fluid. The calculation of heat transferred by convection in the cooling
pond is as below.
Q convection = hAΔT where, h = Convective heat transfer coefficient (W/m2.K)

A = Surface area of the pond (m2)
= (369)(A)(358.15-308.15)
87
= 18450 A kJ/hr
c. Heat Transferred by Radiation (Q radiation)
Heat transferred by radiation involves the when the high energy electron emits energy
to fall back to low energy level. The water molecule on the surface of the pond may
emit energy to release heat. The calculation of heat transferred by radiation in the
cooling pond is as below.
Q radiation = ε σ A (Tin4 – Tsurrounding4) where, ε = Emissivity of water

σ = Stefan Constant
(W/m2.K) A = Surface area
of the pond (m2)
= (0.96)(5.670× 10-8)A(358.154-308.154)
= 404.8 A kJ/hr
6.1.2 Area of Cooling Pond
The area of cooling pond is calculated by using the energy balance equation in the
cooling pond
Q = Qconvection + Qradiation
7560000 = 18450A + 404.8A
A = 400 m2
Thus, the surface area of the pond is 400 m2.
6.1.3 Dimension of Cooling Pond
The retention time in the cooling pond is about one day as the temperature must be
reduced from 85°C to 37°C (Rahman 2017). The supply of POME will be 16 hours
since it’s the working hours in the palm oil mill per day. The volume calculation of
the pond is as below by taking 20% of safety factor for volume:
V = Q pome × HRT × S.F

88
= 36 m3/hr × 16 hr × 1.2
= 691.2m3
Length, width and depth of pond is as below:
Area of pond = Length × Width
Assume the length and width are the same
400 = L2
L = 20 m
The length and the width of the cooling pond is 20m × 20m
Volume of pond = Depth × Area
691.2 = H × 400
H = 1.73 m
Therefore, dimension of the pond is 20m × 20m × 1.73m
6.1.4 Construction Material of Cooling Pond
The construction of cooling pond is relatively easy because just have to dig a large
area of hole. The hole must be covered with liner which have some important function
for ponding system. High density polyethylene (HDPE) pond liner will be used to
cover the surface of the ground. The function of this pond line is to prevent
contaminant from POME entering the ground. It also helps to prevent the water loss to
the ground. This is the most economical way for constructing a cooling pond with an
easy operation and maintenance.
6.1.5 Schematic Diagram of Cooling Pond
The diagram below shows the schematic diagram of the cooling pond. The dimension,
20 shown
liner, inlet and outlet piping system are also m in the diagram.
Inlet Outlet
1.73 m
HDPE
l
i
n
e
r
89
Figure 6.1 Cooling pond
Source: Tilley et al 2014
6.2 UPFLOW ANAEROBIC SLUDGE BLANKET, UASB (T-101, T-102 & T-103)
6.2.1 Introduction
Upflow anaerobic sludge blanket (UASB) reactor is a column type tank reactor that
will be used in anaerobic process. It is widely used in industrial wastewater treatment
in chemical and sewage industries (Lier et al. 2015). The detailed design of UASB
requires some information. The hydraulic retention time (HRT) for UASB in treating
POME is about 10 days for an efficient production of biogas and chemical oxygen
demand (COD) removal (Ohimain et al. 2017). The volume required to contain
POME for 10 days is 5760 m3. To cater a large volume of POME, three identical
UASB is used. Each UASB with a volume of 2304 m3 with 20% extra as safety factor.
The calculation for UASB are done according to the formula by Bal et al. 2010.The
calculations can be referred in appendix A1.
Table 6.2 General information of UASB
Information Value
Inlet (m3/h) 36
Inlet (m3/day) 576
HRT (days) 10
HRT (hours) 240
3
Volume (m ) 5760
Number of Tanks 3
3
Volume of one tank (m ) 1920
Safety Factor (%) 20
Volume after extra (%) 2304
90
6.2.2 Dimension of UASB
Since the designed UASB is a column type tank reactor, the ratio of H: D used is 3:1
(Clapp et al. 2018). The height and diameter are calculated using the volume formula
by assuming the UASB is a tall cylindrical tank.
H = 29.77 m
6.2.3 Volumetric Hydraulic Load
The volumetric hydraulic load (VHL) is the volume of wastewater supplied daily into
the UASB per unit volume of the UASB.
where Q = inlet volumetric flowrate of the UASB (m3/day)
V = volume of UASB (m3)
Thus, the volumetric hydraulic loading rate of the POME into the UASB is 0.25 per
day
6.2.4 Organic Loading Rate
The volumetric organic load (Lv) is defined as the amount of organic matter supplied
daily to the UASB per unit volume of UASB. The influent substrate concentration
(So) is 51 kg COD/m3 (Zainal et al. 2017). The calculation for Lv is shown below.
.day
91
Thus, the organic loading rate of the organic material into the UASB is 12.75 kg/m 3
per day.
6.2.5 Sludge Loading Rate
The sludge loading rate (Ls) referred to the amount of organic matter that is supplied
to the UASB per unit of biomass in the UASB. The total volatile solid in POME (M)
is 34 kgVS/m3 (Zainal et al. 2017). The calculation for Ls is shown below.
.day
Thus, the sludge loading rate into the UASB is 864 kg COD/kg VS per day.
6.2.6 Uflow Velocity of POME in UASB
Upflow velocity (ν) of the POME is calculated from the relation between the inlet
flowrate and the cross sectional area of the UASB. The calculation of ν is as shown
below.
where Q = inlet volumetric flowrate of the UASB (m3/hr)
A = cross sectional area of UASB (m3)
= 0.4652 m/hr
Thus, the velocity if POME pumped into the UASB is about 0.4652 m/hr.
92
6.2.7 UASB Reactor Efficiency
a. Chemical Oxygen Demand (COD)
where Ceff = COD at the effluent (kg COD/m3)
So = COD at inffluent (kg COD/m3)
Ex = Removal efficiency (%)
The COD at the influent is 51 kg COD/m3 (Zainal et al. 2017) while the removal
efficiency of UASB is 96.5% for the HRT of 10 days (Ohimain et al. 2017).
Thus, the COD outlet of the UASB is .
b. Biochemical Oxygen Demand (BOD)
It can be assumed that the BOD is about 50% of the COD for POME (Chong et al.
2018). The BOD for effluent from POME is 892.5 mg COD/L.
c. Total Suspended Solid (TSS)
TSS = 102(Ex)t-0.24 (Bal et al. 2010) where, t = HRT(hours)
Ex = COD removal
efficiency TSS = 102(96.5)(240)-0.24
= 2641.66 mg/L
Thus, the TSS outlet of the UASB is .

93
6.2.8 Sludge Production
The amount of sludge produced is highly related to the COD of the POME inlet. The
production of solid sludge can be calculated by using the equation below.
Ps = Y × COD where, Ps = production of solids in UASB (kg TSS/day)
Y = yield of solid production (kg TSS/kg COD)
The yield of solid can be assumed at 0.2 kgTSS/day since POME is high in COD
The density of sludge produced is 1060 kg/m3
Ps = (0.2) (51) = 10.2 kg TSS/day
Volumetric sludge production = 0.007 m3/day
Thus, the amount of sludge produced in the UASB is 10.2 kg/day.
6.2.9 Gas Separation System
The gas hood will be located at the top of the UASB. The main function of the gas
hood is to collect the biogas. The area of gas hood interface is calculated from the
equation below.
where, Kg = biogas release rate (m3gas/m2.hr)
Qg = expected biogas production (m3/hour)
Ai = area of gas hood interface (m2)
Assume Kg = 5.0 m3gas/m2.hr (Bal et al. 2010)
2
94
Thus, the area and diameter of the gas hood is 21.3 m2 and 5.2 m respectively.
6.3 SETTLING TANK ( T-104)

6.3.1 Introduction
Settling tank is a low cost technology that is widely used in a wastewater treatment
plant to remove solid from wastewater. Sufficient time have to be allowed for the
settling of solid to take place (Rozema 2015). Settling tank is located right after the
UASB in our plant. The main function of this settlement tank is to remove the sludge
from the anaerobically treated POME. The HRT in the settling tank is about 10 hours
to allow the sludge to settle down efficiently. The characteristics of the sludge are as
shown in table below. The calculation can be referred in appendix A1.
Table 6.3 Characteristics of sludge
Characteristics Value Source

Diameter (μm) 100 Wang et al. 2018
Density (g/ml) 1.02 Jones et al. 2010
Specific gravity 1.02 Jones et al. 2010
6.3.2 Settling Velocity of Sludge Particle
Settling velocity is the speed of the particle to settle down in the settling tank. The
settling velocity of the sludge particle have to be calculated as shown below by
referring formulas from Rozema 2015.
Vp = 0.00135 × d2 × (SG – 1) where, Vp = Settling velocity (inches/min)

d = Diameter of particle (μm)
SG = Specific gravity of the particle
Vp = 0.00135 × (100)2 × (1.02 – 1)
= 0.27 inches/min
Thus, the settling velocity of the sludge particle in the settling tank is 0.27 inches/min.
95
6.3.3 Area of Settling Tank
The area of the settling tank can be calculated by using the settling velocity of sludge
particle and inlet volumetric flowrate of anaerobically treated POME. The calculation
is as shown below by referring the formula from Rozema 2015.
where, A = Area of settling tank (ft2)

Q = Volumetric flow rate (gallon/min)
Vp = Settling velocity (inches/min)
A = 87.48 m2
Thus, the area of the settling tank is 87.48 m2.
6.3.4 Dimension of Settling Tank
The settling tank that will be used in our plant is an open cylindrical shape.
A = πr2
The diameter of the settling tank is 10.55 m.
The volume of settling tank is calculated by using the flowrate into the settling tank
and 20% as the safety factor for volume.
V = Q (m3/hr) × HRT (hr) × Safety factor
= 36 m3/hr × 10 hr × 1.2
= 432 m3
The height of the settling tank is calculated by using the volume and area.
V = AH
96
= 4.94 m
Thus, the diameter and height of the settling tank is 10.55 m and 4.94 m respectively.
6.3.5 Construction Material for Settlement Tank
Since settlement tank is a simple technology which can be constructed by using

concrete. Concrete is cheap if compared to steel plates such as carbon steel or stainless
steel. The anaerobically treated POME might be more acidic. The concreted wall
exposed to POME can be coated with epoxy to prevent any corrosion.
6.4 MOVING BED BIOFILM REACTOR, MBBR (T-105)

Design By: Siti Barakah Binti Mohd Khairi (A158482)
Table 6.4 below shows the overall calculation that related to the measurement for
MBBR reactor construction. The calculation can be referred in appendix A2.
Table 6.4 Summary of MBBR reactor
Design condition Unit Value

Operating temperature ˚C 30
Operating pressure/Design pressure bar 1
Material of construction - Concrete, Grade M30
Vessel length m 14.5
Vessel width m 9.79
Vessel height, H m 6.9
Overall minimum thickness of vessel, toverall m 0.125
Nuimber of manifold - 3
Length of manifold m 7.69
Length of grid m 2.804
Number of laterals per manifold - 48
Diameter of carrier mm 12
Height of carrier mm 9
Air flowrate in orifice m3/hr 1.7
Velocity of air in manifold m/s 4.8
97
6.5 MIXER (M-101)

Design by: Afiq Syazwan Bin Mohd Haizollizam(A158912)
The mixer M-101 are located right after centrifuge CF-101 which is the biomass is
been removed from the wastewater. The function of the mixer is to mix the
wastewater that contains bioflocculant with ethanol. This process will make the
bioflocculant to solidify and occurs at 30oC and 3 bar. The calculations can be referred
in appendix part A3.
Figure 6.2 Diagram for mixer M-101
Table 6.5 The inlet and outlet stream for each component for M-101
Substance Stream 36, Stream Stream 38, Density, kg/m3

kg/h 37a, kg/h kg/h
Water 33484.4 53.2 33500.8 1000
Suspended 36.7 0.0 36.7 1500
solids
Bioflocculant 329.2 0.0 329.2 1050
Ethanol 0.0 310.7 310.7 785.5
Total 33850.3 363.9 34177.4
6.5.1 Design Dimension
Total volume flow in= 34.23 m3/h

98
Hence,
By applying 20% safety factor to prevent overflow,
H/D ratio = 2
Calculate the height and diameter using this formula
D = Di = 5.94 m
H = 2 (5.94) = 11.88m
6.5.2 Design of Impeller
Impeller width, Wi
Diameter impeller, Di
99
Height of impeller from vessel floor, C
Length of impeller width, Li
Diameter of impeller base, Dd
Thickness of disc, x
6.5.3 Summary of Calculation
Table 6.6 shows the summary of the calculation for design of Mixer M-101.
Table 6.6 Results for design of mixer M-101
Parameter Results
Operating pressure 3 bar
Operating temperature 30 °C
Volume of mixer 328.6 m3
Height of mixer, H 11.88 m
Diameter of mixer, D 5.94 m
Impeller width, Wi 0.40 m
Diameter of impeller, Di 1.98 m
Height of impeller above vessel floor, C 1.98 m
Length of impeller, Li 0.50 m
Diameter of impeller base, Dd 1.32 m
Thickness of disc, x 0.08 m
100
6.6 DESSICANT DRYER (DD-101)

Design by: Cheah Ching Wei (A157594)
This unit reduces the dryer service fluid humidity. Table 6.7 shows the design
summary. The calculations can be referred in appendix part A4.
Table 6.7 Specification of desiccant dryer model DD-101
Specification Value Unit

Flow rate capacity at 1.7 bar 3.9 m3/hr
Vessel height 35 cm
Vessel Diameter 9 cm
Desiccant mass 23 kg
6.7 ROTARY DRYER (D-101)

The bioflocculant is dried in rotary dryer. Table 6.8 shows the design summary. The
calculations can be referred in appendix part A4.
Table 6.8 Calculation summary and dimension of kettle reboiler
Physical properties/ Dimension Value Unit

Rotating shell diameter 2.3 m
Minimum shell length 32 m
Volumetric heat transfer coefficient, U 150 W/m3∙°C
6.8 BELT PRESS (BP-101)

Belt press is used in sludge dewatering . Table 6.9 shows the design summary. The
Table 6.9 Specification of belt press model PC-7

Flow rate capacity 0.5 - 4 m3/hr
Effective belt width 600 mm
Effective area 3.3 m2
Installed power 0.5 hp
Dimension (LxWxH) 2x 1.37x 1.65 m
101
6.9 KETTLE REBOILER (H-101)

Kettle reboiler (H-101) is used to generate steam at 2 bar and 120.21°C for the syngas
reforming reaction. Table 6.10 shows the process parameter and dimension of kettle
reboiler. The calculations can be referred in appendix part A4.
Table 6.10 Process parameter and dimension of kettle reboiler

Water flowrate 250.8 kg/hr
Shell diameter 1.01 m
Minimum shell length 4.8 m
Tube bundle diameter 0.51 m
6.10 GAS HOLDER (GH-101)

Design by: Siti Barakah Binti Mohd Khairi (A158482)
6.10.1 Introduction
Gas holder, GH-101 act as holding tank for the gas such as methane and cabon
dioxide before distribute it to reactor for further process. HRT for the gases in gas
holder is 24 hours
6.10.2 Material selection
Type of material for conctructing gas holder is stainless steel 304. This material have
higher melting point compares to other type of stainless steel and could store biogas. It
is also not cause harmful to the people either during production or use (R.C Bourg,
2012)
6.10.3 Design specification
GH-101 will be contstructed in cylindrical shape with flat head for top and bottom of
the shell. Below are the design parameters for the gas holder. The calculations can be
referred in appendix part A2.
102
Table 6.11 Design parameters gas holder, GH-101
Parameter Unit SI
Operating pressure, PO 1.01 kPa
Operating temperature, T 30oC
Diameter vessel, Di 8.75 m
Radius, R 4.38 m
Height of vessel, Hs 13.12 m
Layout Vertical
Operating pressure of gas holder is higher than atmospheric pressure and resulting it
to have internal pressure. Design pressure of each part of the vessel is being calculated
by using PD = PO + 0.433h where h is the height of each part of the column. Safety
factor of 10% is taken.
Table 6.12 Design pressure for each part of gas holder SR-101
Type of part PD (bar) PJ (bar)

Cylindrical shell 2.32 2.55
As there is no corrosive material pass through SR-101, corossion allowance that could
be consider is 2mm(0.0785 in).
6.10.4 Wall thickness of gas holder GH-101
The wall thickness, t for each part of the pressure vessel has to be calculated in order
to get the minimum wall thickness, tmin under internal pressure.
Table 6.13 Thickness of gas holder, GH-101
Part Formula tcalc(mm) tmin(mm) tmin+CA(mm)

Cylindrical shell 7.98 7.98 9.98
(circumferential
stress)
(longitudinal
stress)
Based on the nominal thickness in the market, the thickness of the vessel is 10mm and
it is slightly higher that calculated minimum thickness of the vessel.
103
6.10.5 Summary of detailed design parameter of gas holder
Table 6.14 Summary of gas holder, GH-101
Parameter Value
Inside Diameter, Di 8.75 m

Height Of Vessel, Hv 13.12 m
Height Of Shell, Hs 13.12 m
Thickness of gas holder, t 10 mm
Design pressure, Pd 2.32 bar
Type Of Head Flat head
Type Of Shell Cylindrical
Material Of Vessel Stainless Steel Grade 304
6.11 GAS SCRUBBER (SR-101)

6.11.1 Introduction
Gas scrubber is used to separate hydrogen sulphide from biogas. It is located after
UASB reactor where the biogas been produced. Sodium hydroxide is act as solvent to
be reacted with hydrogen sulphide and will be out as bottom product as lean sodium
hydroxide.
Stainless steel SA-240 is chosen as it provide good corrosion resistance towards acids
with good weldability. It also could provide good area reduction rate at low
temperature. It is also good to resist intergranular corrosion.
SR-101 will be constructed in cylindrical shape for the middle with ellipsoidal shape
for head and bottom of the shell. Below are the design parameters of scrubber. The
104
Table 6.15 Design parameters gas scrubber, SR-101
Parameter Unit SI
Operating pressure, PO 202 kPa
Radius, R 0.74 m
Layout Vertical
Operating pressure of scrubber is higher than atmospheric pressure and resulting it to

have internal pressure. Design pressure of each part of the vessel is being calculated
by using PD = PO + 0.433h where h is the height of each part of the column. Safety
factor of 10% is taken.
Table 6.16 Design pressure for each part of gas scrubber, SR-101

Top head ellipsoidal 2.06 2.26
Bottom head ellipsoidal 2.47 2.72
As there is no corrosive material pass through SR-101, corossion allowance that could
be consider is 2mm(0.0785 in).
6.11.4 Wall thickness of gas scrubber (SR-101)
The wall thickness, t for each part of the pressure vessel has to be calculated in order
to get the minimum wall thickness, tmin under internal pressure.
Table 6.17 Thickness of scrubber, SR-101

Top ellipsoidal 1.23 1.48 3.48
head
(circumferential
stress)
Bottom ellipsoidal 1.48 1.48 3.48
head
105
Based on stainless steel gauge thickness, gauge number 10 has been chosen as it have
the closest nominal thickness to the minimum thickness from the calculation. The
nominal thickness is 3.571mm which is slightly higher than minimum thickness.
6.11.5 Summary of detailed design parameters of gas scrubber
Table 6.18 Summary of scrubber design
Parameter Value

Top Head Height, He 0.37 m
Thickness of scrubber, t 3.157 mm
Type Of Head Ellipsoidal
6.12 HEATER (H-102)

Design by: Nuredahtul Faezan Binti Mohammad Yusop(A159291)
6.12.1 Introduction
In our plant we used heater to increase the temperature before it goes into the reactor.
The temperature need to increase from 690℃ to 700℃ by using steam as service
fluid. The calculations can be referred in appendix part A5.
Table 6.19 Design specification of H-102
Parameter Value
Total flowrate process fluid (kg/hr) 902.9
Temperature Shell Inside (℃) 690
Temperature Shell Outside (℃) 700
Temperature Tube Inside (℃) 750
Temperature Tube Outside (℃) 700
Assumption Overall heat transfer coefficient, Uo 30
(W/m2 ◦C)
Tube Side
Triangular pitch
Outer diameter, do (mm) 20
106
Inner diameter, di (mm) 16

Length of tube, L (m) 1.78
Area of one tube, At (m2) 0.11
Number of tubes 82
Number of tube passes 2
Linear fluid velocity, ut (m/s) 1.47
Heat transfer coefficient, hi (W/m2 ◦C) 46.25
Pressure drop, ∆Pt (kPa) 0.07
Shell Side
Pull through floated head type
Number of shell passes 1
Bundle diameter, Db (mm) 276.55
Shell diameter, Ds (mm) 364.55
Baffle cut (%) 25
Baffle spacing, IB (mm) 72.91
Tube pitch, Pt (mm) 25
Equivalent diameter, de (mm) 14.2
Shell side Mass velocity, Gt (kg/sm2) 56.02
Heat transfer coefficient, hs (W/ m2 ◦C) 7681.71
Pressure drop, ∆Ps (kPa) 14.78
Overall heat transfer coefficient, Uo (W/m2 ◦C) 36.16
6.13 SYNGAS PACKED BED REACTOR (R-101)

Design by:Afiq Syazan Bin Mohd Haizollizam (A158912)
Packed bed reactors are commonly used in chemical reactions whereas it is filled with
solid catalyst particles that most often used to catalyst gas reactions. The syngas
reactor is located right after the gas holder (GH-101) where biogas are been stored
after hydrogen sulphide scrubbed away from it. The methane and steam will be
converted into syngas at 80% conversion in this reactor (R-101). The catalyst used for
this reaction is NiO/α-Al2O3. The calculations can be referred in appendix part A3.
107
Figure 6.3 Diagram for syngas packed bed reactor
Table 6.20 The inlet and outlet stream for each component for R-101
Substance Inlet (Stream 52), Outlet (Stream Density, kg/m3

kg/h 53), kg/h
Methanol 0.0 0.0 792
Water 250.8 136.8 1000
Methane 222.6 99.2 0.656
Carbon 0.0 253.8 1.14
Monoxide
Hydrogen 0.0 43.8 0.0899
Carbon Dioxide 429.5 369.3 1.98
Total 902.9 902.9
6.13.1 Rate law
Reaction:
CH4 + H2O → CO + 3H2 (1)

CO + H2O → CO2 + H2 (2)
CH4 + 2H2O → CO2 + 4H2 (3)
108
Differential mole balance for packed bed reactor,
The rate law for the reaction is a first order reactor, therefore,
Stoichiometry,
= =
where y =
For isothermal operation,
=
109
By combining rate law and stoichiometry,
6.13.2 Design dimension
Volume for reaction;
Where, is the total CH4 flowrate, 13.88 mol/h
X is the conversion
is a density of catalyst, 1870 kg/m3
is the voidage, 0.4 for sphere solid catalyst
is the rate constant
For 80% conversion (X=0.8),
r1 = 8.38, r2 = -0.681, r3 = -0.688
= 0.0917 m3
110
By applying 10% safety factor;
Diameter of tank calculated using;
By taking ratio height shell to diameter 1:4 where Hvessel = 4D while taking ratio 1:2
for diameter to height head for both bottom and top, D = 2Hhead. Hence, the height for
packed bed reactor is 1.05 m with 0.0875 m head height for both bottom and top.
Table 6.21 Design dimension of R-101
Condition Values
Operating pressure, Po 25 bar (362.6psi)
Temperature, T 973.15K (700oC)
Length Shell 1.05 m
Length Vessel 1.225 m
Diameter 0.35 m
6.13.3 Design of bed
By using catalyst solid sphere shape with diameter particle of 2mm.
Taking the diameter of bed, Dbed = Di = 0.35 m.
For the Bed Height, Hbed =

111
= = 0.735 m
Density catalyst, ρc = 1870 kg/m3

e(voidage) = 0.3
Volume of catalyst required = 0.15 m3
Weight of catalyst = ρcV(1 - e) = 141.372 kg

= 1386.86 N
6.13.4 Summary of calculation
Table 6.22 shows the summary of the calculation for design of packed bed reactor R-
101.
Table 6.22 Results for design of packed bed reactor R-101
Parameter Results
Height of reactor, H 1.225 m
Diameter of reactor, D 0.35 m
Volume for reaction 0.108 m3
Height of bed, Hbed 0.735 m
Diameter of bed, Dbed 0.35 m
Weight of catalyst 141.372 kg
6.14 COOLER (CO-101)

Design by: Nuredahtul Faezan binti Mohammad Yusop (A159291)
53a 54
Figure 6.4 Diagram of Cooler(CO-106)

112
Cooler is used to decrease temperature from 492℃ to 350℃ for production of

methanol. The type of heat exchanger used is shell and tube heat exchanger and
Kern’s method is applied. Table below shows the summary design specification of
cooler (CO-101). The calculations can be referred in appendix part A5.
Table 6.23 Design specification of CO-101
Parameter Value
(W/m2 ◦C)
Tube Side
Square pitch
Number of tubes 58
Shell Side
Pull-through floated head type
Baffle cut (%) 25
6.15 PHASE SEPARATOR (S-101)

Designed by: Cheah Ching Wei (A157594)
This unit operates at 350 oC and 3 bar. Table 6.4 shows the calculation summary. The
113
Table 6.24 Calculation summary

Vapor fraction 0.9987 -
Vessel diameter, Dv 0.71 m
Total shell height, hT 1.97 m
Total volume, VT 1.1 m3
6.16 PHASE SEPARATOR (S-102)

Designed by: Cheah Ching Wei (A157594)
This unit operates at 50 oC and 30 bar. Table 6.25 shows the calculation summary.
The calculations can be referred in appendix part A4.

Vapor fraction 0.6387 -
Vessel diameter, Dv 0.86 m
Total shell height, hT 2.37 m
Ratio of hT/Dv 2.77 -
Total volume, VT 1.37 m3
6.17 DISTILLATION COLUMN (C-101)

Design By: Siva Priya A/P Nadaraju (A158432)
In C-101, the feed contains methanol and water. The function of C-101 is to separate
methanol from water to increase the purity of final product. Methanol is identified as
the light key component (LK) while water as the heavy key (HK) component since
methanol has lower boiling point compared to water.
114
Figure 6.5 Distillation column C-101
6.17.1 Summary of Design Specification
The design of distillation column C-101 is summarized in table below: The

Table 6.26 Distillation column C-101 design summary
Parameter Value / Type

Feed temperature, °C 50
Feed pressure, bar 28
Type of tray Sieve tray
Material of construction Carbon steel SA516 Grade 70
No. of stages 15
Inner Diameter, m 1.538
Height, m 7.69
Feed location 13th
115
6.18 REFLUX DRUM (RD-101)

Design by: Siva Priya A/P Nadaraju (A158432)
Figure 6.6 Reflux Drum (RD-101)
6.18.1 Summary of design specification
The design of reflux drum RD-101 is summarized in table below: The calculations can
be referred in appendix part A6.
Table 6.27 Reflux drum RD-101 design summary

Feed pressure, bar 1.5
Reflux ratio 1.188
Diameter, m 2.329
Length, m 6.986
116
CHAPTER VII
WASTE MANAGEMENT
7.1 INTRODUCTION
In this methanol and bioflocculant production plant, there are a few types of waste
generated including gaseous waste and liquid waste. The waste can only be discharged
after being treated to reduce the impacts towards environment and public health.
Figure 1 shows the waste generation in the process.
Waste
NaOH solution fuel gas contains

Stream 65
carbon monoxide
H2S scrubbing Steam reforming Methanol Synthesis Methanol
Methanol, water Stream 68a
Biogas
Lean NaOH solution
Stream 46
contain NaHS
Ethanol, water, air Stream 43a
POME Anaerobic digestion Bioflocculant Synthesis Bioflocculant dehydration Bioflocculant
Liquid discharge
Sludge dewatering Stream 34
from belt press
Fertilisers
Figure 7.1 Waste generation in the process
7.1.1 Environment Acts and Regulations in Malaysia
In Malaysia, waste generated from industrial activity need to comply to a few

environment acts and regulations. The regulations are listed as below:
1. Environmental Quality (Industrial Effluent) Regulations 2009
2. Environmental Quality (Clean Air) Regulations (Amendment) 2014

117
3. Environmental Quality (Scheduled Wastes) Regulations 2005
In the Environmental Quality (Industrial Effluent) Regulations 2009, it is

stated that the water discharged from the industry need to abide the standard A and B.
The waste generated in this chemical plant have a higher COD and BOD than the
standard and treatment is needed to reduce the BOD and COD level to abide to the
regulations. In this chemical, standard B is applied due to the location of the effluent
discharge is at the downstream. Standard A and Standard B of Industrial Effluent
Discharge Limit are shown in table 7.1:
Table 7.1 Standard A and Standard B of Industrial Effluent Discharge Limit.
Parameter Standard A Standard B

pH 6.0- 9.0 5.5 – 9.0
Temperature 40˚C 40˚C
COD 120 mg/L 200 mg/L
BOD5 at 20˚C 20 mg/L 50 mg/L
Suspended Solid 50 mg/L 100 mg/L
Formaldehyde 10 mg/L 20 mg/L
Barium 1.0 mg/L 2.0 mg/L
Fluoride 2.0 mg/L 5.0 mg/L
Phenol 0.001 mg/L 1.0 mg/L
Free Chloride 1.0 mg/L 2.0 mg/L
Sulfide 0.50 mg/L 0.50 mg/L
Oil and grease 1.0 mg/L 10 mg/L
Ammonia and nitrogen 10 mg/L 20 mg/L
Source: DOE Malaysia 2009
7.2 WASTE GENERATION
Gaseous waste and liquid waste is generated during the process of the chemical plant.
The content and of the waste produced is identified.
7.2.1 Gaseous waste
a. Fuel gas containing carbon monoxide
Carbon monoxide is present in vapor stream 65 which contain methane carbon

dioxide , water, methanol and hydrogen
118
b. Vapor containing ethanol and water
Gaseous waste produced contains air, ethanol and water from bioflocculant
dehydration in the main process
7.2.2 Liquid waste
a. Wastewater
Wastewater produced from the process included treated POME and methanol.
b. Lean NaOH solution
Lean NaOH solution contains NaHS produced from the hydrogen sulfide scrubber.
7.3 WASTE CHARACTERISTICS
The characteristics of the waste produced is identified and quantified. This is

important for the waste treatment process selection.
7.3.1 Waste characteristics of each type of waste
a. Gaseous waste
The gaseous waste generated have the characteristics in table 7.2:
Table 7.2 Characteristics of gaseous waste
Composition Stream 43a Stream 65

Air (kg/h) 1517 0
Ethanol (kg/h) 249 0
Water (kg/h) 36.8 1.5
Methane (kg/h) 0 99.5
Carbon dioxide (kg/h) 0 123.7
Carbon monoxide (kg/h) 0 254.5
Hydrogen (kg/h) 0 9.8
Methanol (kg/h) 0 5.2
Ethanol concentration (mg/L) 137950 0
Total flowrate (kg/h) 1802 494.2
119
b. Wastewater
The ethanol and water in the gaseous waste stream will be stripped off from the vapor
phase and the stream 43a characteristics considered because the wastewater together
with other waste stream after equalization tank in waste treatment process. The
characteristics of wastewater is shown in table 7.3:
Table 7.3 Characteristics of wastewater
Total Concentration of
Ethanol Methanol Suspended Sludge Water
Stream flowrate waste
(kg/h) (kg/h) solid(kg/h) (kg/h) (kg/h)
(kg/h) (mg/L)
34 0 0 - 43 513 556 77310
39 62 0 36 0 33461 33559 2944
43a 249 0 0 0 37 286 137950
68a 0 25 0 0 237 262 94181
c. Lean NaOH solution
Lean NaOH solution is the used caustic solution after H2S scrubbing process. NaHS
produced from the process is the waste generated. The characteristics of the waste
produced is shown in table 7.4:
Table 7.4 Characteristics of lean NaOH solution
Stream NaHS (kg/h) NaOH (kg/h) Water (kg/h) Total flowrate (kg/h)
46 1.92 0.13 29 31
7.3.2 BOD and COD calculation
Chemical Oxygen Demand (COD) and biochemical oxygen demand (BOD) is an

important parameter to be considered for industrial effluent in order to comply to rules
and regulations. The effluent of the treatment plant will need to comply to standard B
of Environmental Quality (Industrial Effluent) Regulations 2009.
a. Chemical oxygen demand (COD)
Chemical Oxygen Demand (COD) is the oxygen needed for the chemical oxidation of
the organics and oxidizable inorganics contained in wastewater. COD for the
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wastewater is calculated based on the concentration of waste in the wastewater.

Calculation of COD:
C = concentration of the component, mg/L

np = number of moles of the component
mp = molecular weight of the component
nO2 = number of moles of oxygen
MO2 = molecular weight of oxygen
b. Biological oxygen demand (BOD)
Biochemical oxygen demand (BOD) is the oxygen needed by the microbe in the
wastewater to break down organic material. The concentration of BOD in the brewery
wastewater is 0.6- 0.7 of COD for all types of contaminants (Brito et al. 2007). For
this BOD estimation, 0.7 of COD is used in calculating BOD.
Oxidation reaction:
Methanol : 2CH3OH + 3O2 → 2CO2 + 4H2O
Ethanol : CH3OH + 3O2 → 2CO2 + 3H2O
Suspended solid : C6H12O6 + 6O2 → 6CO2 + 6H2O
Table 7.5 Summary of the COD and BOD value of each wastewater stream.
STREAM CONTENT COD BOD COD

PHASE
NO. IN THE CONCENTRATION CONCENTRATION AMOUNT
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STREAM IN EACH STREAM IN EACH STREAM IN EACH

(MG/L ) (MG/L ) STREAM
(MG)
68a Methanol L 141271.06 98889.74 3.69E+07
Ethanol,
43a V 1264597 885219
Water, Air 3.61E+08
Treated POME
39 containing L 2894 2026 9.71E+07
Ethanol
Liquid
34 discharge from L+S - - -
belt press
After the equalization tank, all the wastewater is mixed and treated using
activated sludge process. Due to different amount of flow in inlet stream, the COD
concentration is obtained by using formula: COD concentration = total COD amount/
total flowrate. The COD and BOD of wastewater after mixing in equalization tank is
shown in table 7.6.
Table 7.6 BOD and COD concentration after equalization tank
Phase COD concentration (mg/l ) BOD concentration (mg/l ) COD Amount (mg)
L 14279 9995 4.95E+08
Mass balance of COD at equalization tank:
∑COD amount in stream 68a,43a, 39, 34= ∑COD amount in outlet stream
(3.69x107 + 3.61x108 + 9.71x107)mg = 4.95x108 mg, Balanced
7.3.3 Conclusion
From the calculation done, the COD concentration calculated is 14279 mg/L and the
BOD concentration is 9995 mg/L. Standard B is abided for the wastewater discharge
limit as the discharge point is at the downstream of a river. COD and BOD of the
waste stream exceeds the discharge limit of Standard B effluent according to the
Environment Quality Act 1974, which is 200mg/L and 50mg/L respectively.
Therefore, treatment is needed before the waste is discharged.
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7.4 WASTE MANAGEMENT
Waste minimization and waste reduction strategy is carried out by regenerate the
scrubber solution and reduce the waste content in the industrial effluent.
The fuel gas in stream 65 is incinerated and the carbon monoxide is converted
to carbon dioxide using platinum catalyst in the catalytic converter. The vapor from
all the pressure relief valve in main production process will also be incinerated in this
incinerator.
The gaseous waste in stream 43a contains only ethanol, water and air. The
gaseous waste is sent to the equalization tank to separate the ethanol and water out of
the vapor mixture by scrubbing it using wastewater and aerate the wastewater. Ethanol
and water in the vapor mixture will retain in the liquid phase and the concentration of
the oxygen of the outlet gas will be lowered due to the aeration of the wastewater
before undergoing activated sludge process.
Wastewater is treated by using activated sludge treatment and

phytoremediation process to reduce the BOD and COD of the wastewater. NaHS
solution is treated using microbial fermentation to regenerate the NaOH solution.
a. Incineration
Before releasing to the atmosphere, the fuel gas will be combusted using an
incinerator to reduce hazardous gas emission and generate energy from the gas. The
reactions involved in the combustion process are as follows:
CH4 + 2O2 → CO2 + 2H2O

CH3OH + 3/2 O2 → CO2 + 2H2O
In the incinerator, catalytic converter is used to convert carbon monoxide

which is a hazardous greenhouse gas in the flue gas into carbon dioxide which is a
non-hazardous lesser impact greenhouse gas using platinum catalyst. Small amount of
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platinum crystal is needed for this reaction and the catalyst is self-regenerative with
the presence of oxygen gas. The reaction involved in the catalyst converter is:
Carbon monoxide oxidation:
2CO + O2 → 2CO2
ii. Gas Stack
The flue gas that have been incinerated will have only trace amount of carbon
monoxide and it will be removed through gas stack so that the concentration at ground
level will safe.
Detail for gas stack design:
Wind speed, u = 1.8 m/s

Stack velocity, vs = 3 m/s
Pressure, P = 100 kPa
Air temperature, Ta (K) = 305
Stack temperature, Ts (K) = 423
Height, Hs = 30 m
Diameter, d =1m
Plume rise, ∆h =
= 1.94 m
Effective stack height, H = 31.94 m
Hence, the final stack height will be 31.94m which is approximately 32m.
With a stack at 31.94 m, we can ensure that the concentration of hazardous material at
ground level is safe.
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b. Activated sludge treatment
An activated sludge process is a treatment process which make use of microorganisms

to degrade organics and remove nutrients from wastewater to produce a high-quality
effluent. Ethanol and methanol are expected to improve the cell growth in the
wastewater. Before the wastewater is fed into the activated sludge tank, it is aerated
with the gaseous waste which contain oxygen and scrub the ethanol from the gaseous
waste in equalization tank before the gaseous waste is vented. After the activated
sludge process, the slurry is sent to the clarifier tank and sludge produced is settled
down in the settling tank. The sludge produced is composted to produce fertilizers
(Fumi et al. 1995). Ethanol and methanol is expected to improve the cell growth in the
waste water (Al-dawery 2013; Caballero et al. 2011).
. An activated sludge process is a treatment process which make use of

microorganisms to degrade organics and remove nutrients from wastewater to produce
a high-quality effluent. Ethanol and methanol are expected to improve the cell growth
in the wastewater. Before the wastewater is fed into the activated sludge tank, it is
aerated with the gaseous waste which contain oxygen and scrub the ethanol from the
gaseous waste in equalization tank before the gaseous waste is vented. After the
activated sludge process, the slurry is sent to the clarifier tank and sludge produced is
settled down in the settling tank. The sludge produced is composted to produce
fertilizers (Fumi et al. 1995). Ethanol and methanol is expected to improve the cell
growth in the waste water (Al-dawery 2013; Caballero et al. 2011).
Design parameter from reference (Caballero et al. 2011; PATWARDHAN 2017):
The COD and BOD removal efficiency : 98%.
Hydraulic retention time in each tank, Ʈ : 2 hours.
Working volume of each tank is calculated as below.
Flowrate, F : 34.6 m3/hr

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Volume require for each tank = F x Ʈ
Volume require for each tank : 69.32m³
Volume of each tank is considered with 10% addition to prevent overflow due to
wastewater flowrate surge, V= 69.32 x (1+10%) =76.257 m³
Diameter : 3.2 m
Height : 9.6 m
Tank actual volume : 77.2 m3
Number of tanks :3
Total retention time : 6 hours
Sludge retention time : 7 days
Sludge recycle flowrate : 0.4 m³/hr
Kg BOD/kg MLSS : 0.16
c. Phytoremediation
Phytoremediation utilizes the rhizosphere to capture the impurities of water to reduce

the BOD and COD of the wastewater in order to comply with the effluent discharge
limit. It is a bioremediation process that degrade, transfer and stabilize contaminants
in the soil and groundwater. The plant that is used in this waste treatment plant is
vetiver grass (Chrysopogon zizanioides) (Darajeh et al. 2014). The vetiver grass will
be harvested and composted to produce fertilizers if the plant has overgrown or die.
This is only possible because the remediated wastewater does not contain heavy
metal. The research shows efficiency of 94% and 96% when treating wastewater with
initial BOD and COD concentration of 52 mg/L and 102mg/L. However, the research
also shows that the plant can reduce 281mg/L COD concentration and 217 mg/L BOD
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concentration when treating wastewater with initial BOD and COD concentration of
350 mg/L and 721 mg/L. The wastewater in this waste treatment plant is 199.9 mg/L
and 285.6 mg/L after aerobic digestion. Thus, phytoremediation is applicable to this
wastewater treatment plant..
Design details (Darajeh et al. 2014):
COD removal efficiency : 94%.
BOD removal efficiency : 96%.
Calculation of pond volume needed is as below.
Flowrate, F : 34.6 m3/hr
Hydraulic retention time in pond, ƮP : 14 days
Minimum ponding volume = F x ƮP = 7764.31 m3
Volume of pond is considered with 10% addition to prevent overflow due to

wastewater flowrate surge, V= 7764.31 x (1+ 9%) = 8400 m³
Height : 2m
Number of ponds needed :2
Width of pond : 30m
Length of each pond : 70m
d. NaHS regeneration by microbe

Biological process is used to treat the NaHS solution and regenerate the caustic
solution. The microbe utilized in the process is thiobacillus spp. which is immobilized
on the carrier and it would oxidize the NaHS produced from the scrubbing process
into NaOH with a retention time of 4 hours and temperature of 30 ֯C(T. de Boerstraat
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2011; Visser et al. 1997). The reaction is carried out with existence of nutrient
medium containing 4mg/l NH4Cl, 1mg/l MgSO4.7H2O and 2 g/l KH2PO4 with
aeration. The fermentation broth is flowed to the next settling tank and the elemental
sulfur will be settle down in the tank. The elemental sulfur will be centrifuged and it
can be used as the addictive in the fertilizers. The liquid from the centrifuge will be
flowed back to the bioreactor. The regenerated caustic solution in settling tank will be
pumped back to the H2S scrubber.
The tank size is 250m3 and able to accommodate the fermentation broth for 8
hours retention time for higher conversion if there is any fluctuation in NaOH purity.
The pH is controlled by administration of NaOH into the bioreactor.
Main Reaction (O’Brien et al. 2007):
NaHS + 0.5 O2 → NaOH + S
Side Reaction:
2 NaHS + 4 O2 → Na2SO4+H2SO4
2 NaOH + H2SO4 → Na2SO4+2H2O
Process parameter (Janssen et al. 2000; O’Brien et al. 2007):
Operating Temperature : 30°C
Operating pressure : 1 bar
NaHS conversion : 100%
NaOH regeneration selectivity : 98%
Sulphate ion generation selectivity : 2%
Table 7.7 Mass flow rates for inlet and outlet of NaOH regeneration in R-101
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Component Mass Flow Rate Inlet Mass Flow Rate Outlet

kg/hr kmol/hr kg/hr kmol/hr
Sodium hydroxide NaOH 0.205 0.005 1.832 0.046
Sodium hydrosulfide NaHS 2.373 0.042 0 0
Water H2O 29.263 1.626 29.270 1.626
Oxygen O2 2.712 0.085 1.993 0.062
Sulphur S 0 0 1.329 0.042
Sodium sulphate Na2SO4 0 0 0.120 0.001
Total 34.55 1.76 34.55 1.78
7.4.1 Waste management summary
The fuel gas containing carbon monoxide is incinerated in incinerator before it is

released to the environment. Carbon monoxide is converted to carbon dioxide using
platinum catalyst before the flue gas from incineration is released to the surrounding.
The gaseous waste containing ethanol is scrubbed, and the purified air is vented out of
the system. The BOD and COD of Wastewater will be reduced to 8mg/l and 17.1mg/l
after the activated sludge and phytoremediation. The new COD and BOD value is
under the discharge limit of standard B in Emission Standard for Industrial Effluent
2009. The wastewater will be discharged to the environment after the waste treatment
process. The sludge in the pond will be cleaned from the pond every three months and
mix with the sludge produced in the main process to be belt pressed and marketed as
fertilizers.
Table 7.8 Summary of BOD and COD after each process
Efficiency of COD Efficiency of BOD

COD, mg/L BOD, mg/L
removal, % removal
Before process - 14279 - 9995
After activated sludge 98 286 98 200
After phytoremediation 94 17.1 96 8
The NaOH is regenerated from NaHS through the biological treatment and
recycle to the main process. Solid sulfur, also known as bio-sulfur or elemental sulfur
produced from the process can be used in fertilizer formulation, composting and
production of sulfuric acid (Järvensivu 2015).
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7.5 WWTP PROCESS FLOW DIAGRAM
Please refer to Appendix E.

130
CHAPTER VIII
ECONOMIC ANALYSIS
8.1 INTRODUCTION
Economic analysis for designing a plant is very important in order to determine

whether the process is profitable or not. Besides, it can also show how many years is
needed to get a return in investment. Hence, in order to fulfill the criteria for economy
analysis, it is necessary to calculate the payback period, return on investment, net
present value and discounted rate of return
Besides constructing the plant and start the operation, a large amount of money
need to be invested for :
 Purchase and install machinery and equipment
 Purchase or rent land and prepare site
 Obtain utility services like electricity, water and wireless
 Construct building for administrative office, production facilities,

utilities, warehouse, control rooms, laboratories, maintenance
workshops, canteen and etc.
 Expenses to start plant operation after being constructed before

obtaining revenue from sales such as buying raw materials, transport
the raw materials, materials to support the production and etc.
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8.1.1 Design life
Production of bioflocculant was designedto operate for 25 years from year 2022 to
2047. Constuction of the plant would takes up about 3 years which is from year 2020
to 2022. Several factors such as changing in demand of bioflocculant, new technology
discovery, process changes and eqiupment changing were considered when designing
the operating life of the plant.
8.1.2 Scrap value
Scrap value is the net amout of money obtain from sales of used properties that is no
longer useful for the production plant, over and above any changes involved in
removal and sale. Scrap value is estimated to be 15% of fixed assests at the end of the
design life.
8.1.3 Plant capacity estimation
During the first operating year, ptoduction rate of bioflocculant is 50%, followed by
90% during the secong year and 100% for upcoming years. The reason is rhat during
start-up of the plant, the labirs, workers and staff are newly to operate effectively apart
from giving sufficient time for the company to test maket value of the product. After
having steady market and enough skilled labors, the plant will operate at full capacity.
8.2 ESTIMATION OF TOTAL CAPITAL INVESTMENT, (CTC)
A large amount of money is needed to prepare for start-up and construction industrial
plant. The money is used for purchase and installed all the needed equipment, building
and others. Capital investment includes land capital, fixed capital and working capital.
Where, = Fixed Capital Investment

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= Working Capital
= Land Capital
8.2.1 Fixed investment capital (CFC)
Fixed capital represents the total cost of the plant ready to start operate. This cost not
only include cost for construction but also includes the cost of design, contractor
involved and other engineering. The cost paid for construction are basically includes
all of equipment in plant and their installation, construction supervision, all
instrumentation, piping and control devices, auxiliary facilities and building such as
administrative office and control tower. Purchase cost for each equipment are been
done using CAPCOST and also compared the price with online shopping sites such as
alibaba and made-in-china. The comparison are been made to know the current price
for that equpiment and price might be change due to differences material and
thickness used for variety functions of equipment such as heavy duty pump are used
for early stage process that consist of POME that contains high amount of suspended
solids. The installation cost are been calculated by multiple the purchase cost with
installation factor. The factor for each equipment are been determined based on table
in lecture note according to type of equipment as example 20-60% for centrifugal
separtor and 30-60% for compressor.
a. Direct cost
Table 8.1 Cost for Purchased-Equipment and Installation
Equipment Unit Purchased Cost Installation Installation Cost

(RM Million) Factor (Fraction) (RM Million)
Processing Plant
a) Reactor 2 8.4 0.50 4.2

b) UASB 3 4.98 0.50 2.49
c) Aerobic 1 1.35 0.50 0.68
tank
d) Seed 1 0.098 0.50 0.049
Fermenter
e) Separator 1 0.21 0.40 0.084
f) Scrubber 1 0.21 0.40 0.084
g) Mixer 1 0.13 0.30 0.039
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h) Column 1 0.42 0.80 0.336

i) Compressor 4 0.43 0.50 0.215
j) Screwpress 1 0.63 0.40 0.252
k) Centrifuge 2 1.1 0.50 0.55
l) Pump 7 0.064 0.40 0.025
m) Heater 2 0.17 0.50 0.085
n) Cooler 6 8.16 0.50 4.08
o) Heat 3 0.63 0.50 0.315
Exchanger
p) Air Blower 1 0.012 0.50 0.006
q) Cooling 1 0.019 0.40 0.008
Pond
r) Gas Holder 1 0.336 0.45 0.151
s) Water Tank 1 0.013 0.45 0.006
t) Storage 7 0.294 0.45 0.132
Tank
Waste Treatment Plant
u) Fermenter 1 0.098 0.50 0.049
v) Phytorem 1 0.133 0.40 0.053
w) Pump 4 0.035 0.40 0.014
x) Settlement 1 0.045 0.50 0.023
Tank
y) Centrifuge 1 0.55 0.50 0.275
z) Blower 1 0.012 0.50 0.006
aa) Total 28.525 14.207
Table 8.2 Direct costs
Direct Costs % Equipment Cost Cost (RM Million)
Purchased-equipment - 28.525
Purchased-equipment - 14.20
installation
Purchased equipment 100 28.525
delivery
Instrumentation and 26.0 7.417
controls (installed)
Piping (Installed) 31 8.843
Electrical system 10 2.853
(Installed)
Building (including 29 8.272
services)
Yard improvement 12 3.423
Service facilities 55 15.689
(installed)
Total 86.146
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b. Indirect costs
Indirect costs are mainly consisting of non-manufacturing fixed capital investment

that includes all the construction overhead such as engineering and supervision,
construction expenses, legal expenses contingencies and contractor fees. This cost is
estimated based on purchase equipment cost by multiple it with percantage of
equipment cost. This percentage are been determine based on range of fixed-capital
investment (FCI) on table indirect cost. Each indirect cost have different percentage
and this percentage mostly affected by the size of the plant and etc.
Table 8.3 Indirect costs
Indirect Cost % Equipment Cost Cost (RM Million)
Engineering and 32 9.128

supervision
Construction expenses 34 9.699
Legal expenses 4 1.141
Contractor's fees 19 5.420
Contingencies 37 10.554
Total 35.941
Therefore, the fixed capital investment for our plant is RM 116.501 million.
8.2.2 Working capital (CWC) and land capital (CL)
Working capital is the additional investment that needed for start the plant up. It must
over and above the fixed capital, operate it to the point when the income is achieved.
It includes the cost of start-up, initial catalyst charges, raw materials, and intermediate
process, finished product inventories and fund to cover outstanding accounts from
135
customers. Most of the working capital are being withstand and recovered at the end
of the project. Therefore, the working capital cost are being estimated based on the
total capital investment.
We need a large area of land for our plant because our plant is combination of
biological and chemical pathway. The area for future expansion of our plant also must
be considered in determine the area for the plant location. Our plant required about 20
acres land to build the plant. The land cost in FGV Mercu Puspita Mill area is RM 33,
000 per acre. So, the land capital cost is RM 825, 000. Table 8.4 shows the total
capital investment for our plant.
Table 8.4 Total capital investment
Aspect % Total Capital Investment Cost (RM Million)

Fixed Capital Investment - 116.501
Working Capital 20 200.47
Land Capital - 26.90
Total Capital Investment 792.00
8.3 ESTIMATION OF TOTAL PRODUCT COST (TPC)
The total product cost are the sum of two component which comprises the general
expenses in the plant and the manufacturing cost. The simplify equation of total
product cost are as shown below:
Total Product Cost = Cost of Manufacturing + General Expenses
8.3.1 Manufacturing Costs (COM)
Manufacturing cost are the main cost that is required in the production and processing
the main products of the plant which is the methanol and bioflocculant. This
manufacturing cost can be subcategorized into three different categories which is
Direct Manufacturing Cost, Fixed Manufacturing Cost and Plant Overhead Cost.
The simplified equation for manufacturing cost is as shown below which the sum of
all three categories of manufacturing is cost.
136
Manufacturing Cost = Direct Manufacturing Cost + Fixed Manufacturing Cost +
Plant Overhead Cost
a. Direct manufacturing cost
Direct manufacturing cost are the expenses that directly involved in the production of
products. It will be directly proportional to the rate of production of product or the
plant capacity. There are some cost are taken into consideration when calculating the
direct manufacturing cost:
i. Raw material
Raw material are the most important component in the direct manufacturing cost. A
constant and proper supply of raw material is required for a good production process
in the plant. In the production of methanol and bioflocculant, the raw materials needed
are water, sodium hydroxide, nutrient medium, ethanol and POME. The estimation of
required raw materials and the cost of raw materials are shown in table below:
Table 8.5 Raw materials price
Raw Materials Mass Flowrate Mass Flowrate Price per unit Price (RM) in
(kg/h) (kg/year) (RM/kg) million
Water 250.8 2167000 0.005 0.011
Sodium 1.2 10370 10.30 0.11
Hydroxide
Nutrient Medium 45 388800 44.1 1.715
Ethanol 78.5 678250 6.30 4.270
POME 36000 311000000 No charge No charge
Total 6.106
ii. Operating labour
Labour are the workers involve in the production plant. Labourers can be divided into
two categories which is skilled labour and unskilled labour. The wages for the labour
is different depends on the type of labourers, industries and locations which is set by
the Labour Department of the Ministry of Human Resource. Ulrich method have been
137
used to estimate the labour requirement in the production plant. The first table shows
the number of operator required for each equipment. The second table shows the
calculation for cost of labour per year.
Table 8.6 Total labour per shift
Equipment Type Number of Operators per shift Operators per

equipment per equipment shift
Anaerobic Tank 3 0.50 1.50
Aerobic Tank 1 0.50 0.50
Seed Fermenter 1 0.50 0.50
Dryer 1 0.30 0.30
Syngas reactor 1 0.50 0.50
Methanol reactor 1 0.50 0.50
Distillation column 1 0.35 0.35
Compressor 5 0.15 0.75
Heat exchangers 9 0.10 0.90
Waste Treatment Plant 1 2.00 2.00
Waste Water Treatment Plants 1 2.00 2.00
Vessels 7 0.00 0.00
Total laborers per shift 9.8
Table 8.7 Cost of labour per year
Conditions Value/Units
Operation per hour 24
Operation hour in one year 24 x 355 = 8520
Shift per day 3
Hour per shift 24/3 = 8
Number of shift per year 8520/8 = 1065
Shift per operator per year 254
Operator required per shift 4.2
Number of operator per shift 9.8
Total operating labor 41
Cost of one labor (RM/month) 2000
Cost of one labor (RM/year) 24000
Cost of total operating labor (RM million / year) 1.0
Based on the calculation using Ulrich method, the total operating labour cost is
RM 1.0 million each year
iii. Utilities
Steam, compressed air, electricity and cooling water are some types of utilities. It is
highly depended on the source of supply, location of plant and the amount needed. As
a rough approximation, utility costs for ordinary chemical processes amount to 10% to
138
20% of the total product cost. For utilities in our plant, it cost RM 23.7 million per
year
iv. Supervision and clerical labour
For manufacturing operation, certain amount of direct supervisory and clerical

assistance is required. This type of labour is required based on certain criteria which is
operating labour, process complexity and the product quality. This cost of supervision
is approximately 8% of fixed capital investment. For supervision and clerical labour in
our plant, it cost RM 9.3 million per year.
v. Maintenance and repairs
Maintenance are required in order to prevent misfunction of any process equipment

which may lead to any incident. It is also important for a continuous production
process in the plant. The cost of maintenance and repairs may range from 2% to 20%
of the equipment cost. The charges for plant building maintenance is about 3% to 4%
of the building cost. For maintenance and repair in our plant, it cost RM 5.7 million
per year.
vi. Operating supplies
Operating supplies are the consumable items such as charts, lubricants, test chemicals,
custodial supplies and similar supplies which cannot be considered as raw materials or
maintenance and repairs. The cost for theses types of supplies is about 15% of total
cost for maintenance and repairs. For operating supplies, it cost RM 0.9 million per
year.
vii. Laboratory expenses
Laboratory expenses involves the test for control of operations, product quality
control and improvement of the current product. This laboratory charges are generally
calculated by estimating the employee hours involved and multiplying this by the
139
appropriate rate. This cost may be taken as 10% to 20% of the operating labour. For
laboratory expenses in our plant, it cost RM 0.2 million per year.
viii. Catalyst and solvent
Cost for catalyst and solvents are important and should be estimated based on catalyst
requirement and price for the process. Catalyst is required in the reactor for syngas
production and methanol production. The cost of catalyst is estimated about 10% of
the cost of raw materials. For catalyst and solvent, the cost is 0.6 million because the
catalyst only required in small amount for chemical reaction.
ix. Patents and royalty
Patents are the payment done due to usage of process that is developed by other
company or person. Patents covers many products and manufacturing processes. To
use patents owned by others, it is necessary to pay for the patent rights or a royalty
based on the amount of material produced. Even when the company involved in the
operation obtained the original patent, a certain amount of the total expense involved
in the development and procurement of the patent rights should be borne by the plant
as an operating expense. The patents and royalty cost is estimated at 0 to 6% of the
total product cost. The cost for patents and royalty is about RM 7.1 million. This
patents covers the patented methanol production process.
x. Summary
The summary of direct manufacturing cost for each of the component are as stated
below:
Table 8.8 Direct manufacturing cost
No. Direct Manufacturing Cost Cost (RM, million)

1 Raw Materials 17.1
2 Operating Labour 1.0
3 Utilities 23.7
4 Supervision and Clerical Labour 9.3
5 Maintenance and Repair 5.7
6 Operating Supplies 0.9
7 Laboratory Expenses 0.2
8 Catalyst and Solvent 0.6
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9 Patents and Royalty 7.1

Total 65.6
b. Fixed manufacturing
Fixed charge which is also known as fixed costs are the costs that change in little or
not at all with the amount of production in the plant. This shows that fixed charge is
not affected by the quantity of methanol and bioflocculant produced in the plant.
Fixed charges includes depreciation, local property taxes, insurance and loan interest.
i. Financing
Financing cost is the interest payable for the capital cost obtained by borrowing from
financial institutions such as the bank. Interest is considered to be the compensation to
be paid for the use of borrowed money. A fixed rate of interest is established at the
time the capital is borrowed. Therefore interest is definite cost if it is necessary to
borrow the capital used to make the investment for the plant. Annual interest rates
usually amount to 5% to 10% of the total value of borrowed capital. The total
financing cost is RM 21 million.
ii. Local taxes
The magnitude of local property taxes depends on the particular locality of the plant
and the regional laws. Annual property taxes for plants in percentages of fixed capital
investment are in the range of 2% to 4% in highly populated areas while 1% to 2% in
less populated area. This production plant will be established in Lahad Datu, Sabah,
Malaysia. It can be considered that this is a less populated area. So the local taxes is
estimated at 2%. The total taxes for our plant is about RM 2.3 million.
iii. Property insurance
Property insurance rates depends on the types of process being carried out in the
manufacturing plant. It also highly related to the extent of available protection
facilities. The premium rates amount to about 1% of the fixed capital investment per
year. The total property insurance for our plant is about RM 1.2 million.
141
iv. Summary
The summary of fixed manufacturing cost for each of the component are as stated
below:
Table 8.9 Fixed manufacturing cost
No. Fixed Manufacturing Cost Cost (RM, million)

1 Financing 21.0
2 Local Taxes 2.3
3 Property Insurance 1.2
Total 24.5
c. Plant overhead cost
Plant overheads costs are expenditures required for routine general plant service
whereby non-manufacturing machinery, equipment and buildings are required to
provide such services. The fixed charges and direct costs for these items are part of
the plant overhead costs. Plant overhead costs for a process plant is about 50% to 70%
percent of the total expenses for operating labour, supervision and maintenance.
Plant overhead cost = 0.6 x (Operating Labour Cost + Supervision and Clerical
Labour
Cost + Maintenance and Repair Cost)
= 0.6 x ( RM 1.0 million + RM 9.3 million + RM 5.7 million)
= RM 9.6 million
d. Total cost of manufacturing
The total cost of manufacturing is the sum of direct manufacturing cost, fixed costs
and plant overheads cost. The calculation of total cost of manufacturing methanol and
bioflocculant are as shown below.
Total manufacturing cost = Direct Manufacturing Cost + Fixed Cost + Plant Overhead
Cost
142
= RM 54.6 million + RM 24.5 million + RM 9.6 million
= RM 88.7 million
8.3.2 General expenses (GE)
General expenses are the cost that is related to the management and administrative
level which is not directly involved to the manufacturing process. The general
expenses can be categorized into administrative expenses, distribution and marketing,
and research and development expenses. The simplified equation for general expenses
are as below:
General expenses = Administrative expenses + Distribution and marketing expenses

+ Research and development expenses
a. Administrative expenses
Administrative expenses are directly connected with executive and admin activities
that include among salaries and wages for administrators, secretaries, accountants,
computer support staff, engineering and legal personnel. Besides that, administrative
expenses also comprises the cost for office supplies, equipment, administrative
buildings and other related items and activities. Administrative cost can be estimated
at 15% to 25% of the operating labour cost.
b. Distribution and marketing costs
No manufacturing operation can be considered a success until the products have been
sold or put to some profitable uses. Distribution and marketing cost includes salaries,
wages, supplies and other expenses for sales office. Besides that, it also includes
travelling expenses, shipping expenses, cost of containers and advertising expenses.
Distribution and marketing costs vary widely for different types of plants depending
on the produced product, other product sold by the company, plant location and
company policies. For a process plant, the distribution and market cost are about 2%
to 20% of the total product cost
143
c. Research and development cost
Research and development cost are the expenses that required for study on improving
the current operation process and quality of product. This expenses includes salaries
of all personnel, equipment for research, costs of materials and consultants fees. These
cost amount to about 2% to 5% of the total product cost.
d. Summary
The of general expenses cost for each of the component are as stated below:
Table 8.10 General expenses cost
No. General Expenses Cost (RM, million)

1 Administrative Expenses 0.15
2 Distribution and Marketing Cost 23.70
3 Research and Development Cost 5.9
Total 29.8
8.3.3 Total product cost, TPC
Total Product Cost = Cost of Manufacturing + General Expenses
= RM 88.7 million + RM 29.8 million
= RM 118.5 million
8.4 DEPRECIATION
Depreciation is a measure of the decrease in the value of an asset iver time. Physical
facilitties, including costs such as design and engineering, shipping and fiels erection
of the plant deprecible. Land in not depreciable, but improvements to the land, suach
as grading and adding utility services are depriciable. Some companies use
deprecation as a means to set aside a fund to replace a plant when it is no longer
operable. There are five methods in determining the depreciation value :
i. Straight-line method
144
ii. Declining balance method
iii. Double declining balance method
iv. Sum of years digits methos
v. Sinking fund method
The calculation method for depreciation value for this plant is straight-line
method. In this method, the property value is assumed to decrease linearly with time
over the service life. Annual depreciation charge is shown below ;
Where,
CFC = Fixed capital investment
S = Salvage or scrap value of the plant or equipment at the end of its service life
N = service life of the plant or equipment
AD for the plant is RM 4,660,048.00
8.5 BREAKEVEN ANALYSIS AND CAPACITY
The total income and total expenditure in the design plant at full capacity is
considered to determine the breakeven point which is at 2.3 years as shown in Figure
8.1
Figure 8.1 Graph breakeven

145
8.6 PROCESS PROFITABILITY ANALYSIS
Process profitability analysis involves evaluation of profitability in the operation

according to the breakeven capacity or economical capacity. There are two types of
profitability analysis for a manufacturing project:
 Methods that do not consider time value of money
 Methods that consider the time value of money
8.6.1 Methods that do not consider the time value of money
a. Return on Investment (ROI)
Return on investment (ROI) method to determine ratio of the profit to investment.

Although any of several measures of profit and investment can be used, common are
not profit and total capital investment. This can be expressed as,
146
Where :
ROI = annual return on investment (fraction or percentage per year)
Npj = net profit fot the year j
CTC = total capital investment
Net profit usually is not constact from year to year for a project. Total
investment also changes if additional investments are made during project operation.
Therefore, the ROI for a project is determined as an average during the life of project
is given by :
Where :
Np.j = net profit for the year j
N = evaluation period (normally the life of the project)
-b = the year the first investment made in the project based on year 1 as the
start of operation of the project
Cj = amount of investment made for the year j
ROI that has been determined is then compared with a rate of return value
known as the Minimum Acceptable Rate of Return (MARR) that is given by the
symbol mar . the value of mar depends in the type of process and the level of risk for
the project. The value of mar can be taken from the following table :
Table 8.11 Susggested values for risk and minimum acceptable return on investment
Investment description Level of risk Minimum acceptable return, mar (after

income taxes), percent per year
Basis : safe corporate investment Safe 4-8
147
opportunies or cost of capital

New capacity with established Low 8-16
corporate market position
New product entering into Medium 24-32
established market, or new product
technology
New product of process in a new High 24-32
application
Everything new, high R&D and Very high 32-48+
marketing effort
b. Payback period
The profitability measure of payback period, or payout period is the length of time
necessary for the total return to equal to the capital investment. The initial fixed
capital investment and the annual cash flow are usually in this calculation by using the
following equation :
Table 8.12 Summarizes some information of our project investment.
Information Value Unit

Fixed capital investment 116,501,200.00 RM
Working capital 178,550,000.00 RM
Total capital investment 295,876,200.00 RM
Full capacity 3,148,140.00 kg/yr
Total product cost a full capacity 118,480,816.00 RM/yr
Fixed charges (including general expenses) 29,770,204.00 RM/yr
Direct manufacturing cost at full capacity 88,710,612.00 RM/yr
Design life 25 Yr
Scrap value at end of design life 0 RM
Annual depreciation charges 4,660,048.00 RM/yr
Taxation rate 0.25
Minimum acceptable rate of return (MARR) 0.30
148
Main product sales price (bioflocculant) 90 RM/kg
8.6.2 Methods that consider the time value of money
a. Net present value, NPV
The net present value, NPV is the total of the present worth oa all cash flows minus
the present worth of all capital investments, as defined by
Where
NPV = net present value
Aj = cash flow in year j
fdi,j = selected present worth factor for the cash flows with interest rate,i in
yearj
recj = return earning cash
dj = depreciation charge in year j
Cj = total capital investment in year j
b. Discounted cash flow rate of return, DCFRR
The discounted cash flow rate of return, DCFRR is the return obtained from an
investment in which all investments and cash flows are discounted. It is determines by
setting the NPV equal to zero and sloving for the discount rate that satisfies the
resulting relation. Thus ,
149
The DCFRR is only of concern when the project rates favourably compared to
the value of mar used in calculating the net present value. Clearly if the NPV that is
calculated equals zero, then the mar used is the DCFRR. However, if the NPV is
greater than zero, then the DCFRR must be calculated from equation above. For the
project to be favourable, the discounted cash flow rate of return must be greater than
the mar used. By using Microsoft Excel defined function “Goal-Seek”, our DCFRR
value can be computed as 27%. Since the value of i for a project is greater than marr,
then the project is said to be attractive. Following table summarizes our calculation of
DCFRR for our plant.
8.6.3 Results of profitability analysis
Table 8.13 Profitability analysis
Method Values Conclusion

Return of investment, 0.41 The value is generally
ROI higher than marr
Payback period, PBP 2.23 The value is generally
lower than PBPref
Net present value, NPV RM85.6 The value is positive
Net discounted flow rate 0.544 The value is higher that
of return, DCFRR marr
Table 8.14 Profitability analysis for NPV
Discounted Cumulative
Income Depreciation Taxable Tax Discount cash flow or discounted
Production Expenditure (revenue) Gross charges income payable Net profit Cash flow factor at I present value cash flow
Year rate (RM) (RM) profit (RM) (RM) (RM) (RM) (RM) (RM) = MARR (RM) (RM)
0 0 34950360 0 0 0 - 0 -34950360 -34950360 1 -34950360 -34950360
1 0 69900720 0 0 0 - 0 -69900720 -69900720 0.77 -53769784.6 -88720144.6
2 0.5 20047000 102314550 82267550 4660048 77607502 19401875.5 62865674.5 67525722.5 0.59 39956048.8 -48764095.8
3 0.9 109609754.8 184166190 74556435.2 4660048 69896387.2 17474096.8 57082338.4 61742386.4 0.46 28103043.4 -20661052.4
4 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.35 24661697.1 4000644.7
5 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.27 18970536.2 22971180.9
6 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.21 14592720.2 37563901.1
7 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.16 11225169.4 48789070.4
8 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.12 8634745.7 57423816.1
9 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.09 6642112.0 64065928.1
10 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.07 5109317.0 69175245.1
11 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.06 3930243.8 73105488.9
12 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.04 3023264.5 76128753.4
13 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.03 2325588.1 78454341.4
14 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.03 1788913.9 80243255.3
15 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.02 1376087.6 81619342.9
16 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.02 1058528.9 82677871.8
17 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 814253.0 83492124.9
18 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 626348.5 84118473.3
19 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 481806.5 84600279.9
151
20 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 370620.4 84970900.3
21 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 285092.6 85255992.9
22 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 219302.0 85475294.9
23 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 168693.9 85643988.7
24 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 129764.5 85773753.2
25 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 99818.8 85873572.1
26 0 -88710612 0 -88710612 -88710612 -88710612 0.00 -96704.9 85776867.2
Table 8.15 Protability analysis for NPV = 0
Discount Discounted Cumulative

Income Depreciation Taxable Tax factor at cash flow or discounted
Production Expenditure (revenue) Gross charges income payable Net profit Cash flow I= present value cash flow
Year rate (RM) (RM) profit (RM) (RM) (RM) (RM) (RM) (RM) MARR (RM) (RM)
0 0 34950360 - 0 - - - -34950360 (34,950,360) 1.00 -34950360 -34950360
1 0 69900720 - - - - - -69900720 (69,900,720) 0.65 - 45264039 -80214399
2 0.5 20047000 102314550 82267550 4660048 77607502 19401876 62865675 67525723 0.42 28314738 -51899661
3 0.9 109609755 184166190 74556435.2 4660048 69896387 17474097 57082338 61742386 0.27 16764800 -35134861
4 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.18 12384628 -22750233
5 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.11 8019636 -14730597
6 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.07 5193095 -9537502
7 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.05 3362776 -6174726
8 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.03 2177557 -3997168
9 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.02 1410072 - 2587096
10 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 913089 -1674008
11 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 591268 -1082740
12 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.01 382874 - 699865
13 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 247929 -451936
14 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 160546 -291390
152
15 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 103961 -187429
16 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 67320 -120109
17 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 43593 -76516
18 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 28228 -48288
19 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 18279 -30009
20 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 11837 -18172
21 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 7665 -10507
22 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 4963 -5544
23 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 3214 -2330
24 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 2081 -249
25 1 118480816 204629100 86148284 4660048 81488236 20372059 65776225 70436273 0.00 1348 1099
26 0 -88710612 - -88710612 -88710612 (88710612) 0.00 -1099 0
CHAPTER IX
HAZARD IDENTIFICATION AND ANALYSIS
9.1 INTRODUCTION
It is important to identify the hazards and reduce the risk before an accident can occur.
Hazard has the potential to cause harm or damage to people, property and also the
environment, while risk is a measure of human injury, environmental damage or
economic loss in terms of both the incident likelihood and severity or magnitude of
the loss or injury. Industrial risk must be managed appropriately by identifying
hazard, assessing risk, controlling risk and communicating risk.
9.2 LEGISLATIVE REQUIREMENT
Possible hazard associated with the operation processing plant has to abide by the
standards in the national law. The standards issued by the government are to ensure
the safety of people, property and environment. Any activity around the production
plant needs to obey and obtain permission from Department of Environment (DOE)
and the Department of Occupational Safety and Health (DOSH). The related acts
which must be followed by our production plant are:
i) Environment Quality Act 1974

ii) Occupational Safety and Health Act 1994
iii) Factory and Machinery Act 1967
154
9.2.1 Environment Quality Act 1974
An act relating to the prevention, abatement, control of pollution and enhancement of

the environment and the purposes connected therewith. Industrial activities are
required to obtain approvals from the Director General of Environment Quality for
Environmental Impact Assessment (EIA) reports, site suitability evaluation, written
permission to construct, written approval for installation of incinerator, fuel burning
equipment and chimney and license to use and occupy prescribed premises.
EIA is required to carry out to ensure the safety of the public is safeguarded,
the environment is protected and sustainability criteria is considered. The objective of
EIA guideline is to establish and integrate procedures for carrying out risk analysis of
new major hazardous industrial installations, storage and transportation facilities. For
our plant, waste generated from our plant such as wastewater containing ethanol,
methanol and treated pome and lean sodium hydroxide will have proper treatment
method before being discharged according to the standard.
Environmental Quality (Clean Air) Regulation 2014 applied in any industrial

plant, fuel burning equipment, process or premises that discharges or is capable of
discharging air pollutants into the open air and premises that is used for any industrial
or trade purposes. This act sets maximum permissible emission values for various air
pollutants from particular trade, industry or process. For our production, carbon
monoxide is released and it is within the range of the emission standards which
1000mg/m3.
Environmental Quality (Industrial Effluent) Regulation 2009 states the

acceptable conditions for the discharge of industrial effluent for parameter of COD.
Industrial effluent treatment system must be supervised by a competent person
certified by the Director General. This regulation also states that an authorized officer
may carry out an in-situ or ex-situ analysis of industrial effluent using any instruments
approved by the Director General.
155
9.2.2 Occupational Safety and Health Act 1994
According to the act, it shall be the duty of every employer and self-employed person
to ensure, the safety, health and welfare at work of all his employees and it shall be
the duty of every employer and every self-employed person to conduct his
undertaking in such manner as to ensure, not being his employees, who may be
affected thereby are not thereby exposed to risks to their safety or health. This
regulations is enforced by the Department of Safety and Health (DOSH).
Control of Industrial Major Accident Hazards (CIMAH) 1996 states every

manufacturer who undertakes an industrial activity shall as soon as he becomes aware
of an imminent danger which may affect the safety of persons or the environment,
take immediate action to rectify the situation and establish and maintain a good
management system for controlling any major accident. The threshold quantity of
oxygen is 500 tonnes and for hydrogen is 10 tonnes. Since our plant processes
hazardous substance less than the threshold quantity, then our production plant is a
Non-Major Hazard Installation (NMHI).
Under Safety Health Regulation 1997, any chemical and allied industry with
more than 100 employees is required to employ Safety and Health Officer (SHO).
Employer is to establish Safety and Health Committee if there are 40 and more
persons employed and it is directed by the director general of Department of
Occupational Safety and Health (DOSH). Safety and health committee are required to
review measure taken to ensure and safety and health at workplace, investigate
matters at workplace which is considered not safe or risky to health and that has been
brought to the attention of the employer, and is to attempt to resolve the matters.
9.2.3 Factory and Machinery 1967
It is an act to provide for the control of factories with respect to matters relating to
safety, health and welfare of persons therein, the registration and inspection of
machinery and for matters connected therewith. Regulation 5 states that no person
shall manufacture or cause to be manufactured any steam boiler or unfired pressure
vessel without the permission in writing of the Chief Inspector. Regulation 10 explain
156
that every steam boiler must have the essential fittings that are safety valves, water
gauges, steam pressure gauge, low water alarm, inspector’s test attachment,
nameplate, manhole door and others.
Factories and Machinery (Building Operations and Works of Engineering

Construction) (Safety) Regulations 1986 apply to building operations and works of
engineering construction. Regulation 4 states that it is the duty of every contractor and
employer, who undertakes any operation or works to which these regulations apply to
comply with such of the requirements as affect him or any person employed by him.
The regulation states that during the construction being done, a designated person
shall supervise the concrete work, how the cleaning, repairing and maintenance are
done, the scaffolds construction and others.
9.3 HAZARD IDENTIFICATION
Hazards can be categorized into five types that are chemical hazard, health hazard,
mechanical hazard, thermodynamic hazard, electric and electromagnetic hazard. There
are several components in our plant that can be included in hazard system which are
methane, carbon dioxide, ethanol, carbon monoxide, methanol and sodium hydroxide.
9.3.1 Identification of chemical hazard
The chemicals involved in the production of bioflocculant and methanol are methane,
carbon dioxide, ethanol, carbon monoxide, methanol and sodium hydroxide.
Table 9.1 Chemical hazards identification
Chemical Acidity Alkalinity Explosiveness Flammability Toxicity Corrosiveness
Methane No No Yes (May Yes (Extremely No No

explode if flammable)
heated)
Carbon Yes No Yes (May No No No
dioxide explode if
heated)
Ethanol No No Yes (Gas/vapour Yes (Highly Yes Yes
explosive with flammable)
air within
explosion limits)
Carbon No No Yes (May Yes (Extremely Yes No
monoxide explode if flammable)
157
heated)
Methanol No No Yes (May form Yes (Highly Yes Yes
explosive flammable)
vapour-air
mixture)
Sodium No Yes Yes (Heat No Yes Yes
hydroxide release resulting
in fire or
explosion risk)
9.3.2 Identification of hazardous toxic materials
The chemicals involved are classified based on its toxicity and are tabulated in Table
9.2. The Permissible Allowable Limit (PEL), Threshold Limit Value (TLV),
Immediate Dangerous to Life and Health values (IDLH) and Emergency Response
Plan Guidelines (ERPG) are stated.
Table 9.2 Hazardous toxic materials identification
Chemical PEL-OSHA TLV-OSHA IDLH ERPG1 ERPG2 ERPG3

(ppm) (ppm) (ppm) (ppm) (ppm) (ppm)
Ethanol TWA: 1000 TWA: 1000 3300 1800 3300 N/A

Carbon TWA: 50 TWA: 25 1200 200 350 500
monoxide
Methanol TWA: 200 TWA: 200 N/A 200 1000 5000

STEL: 250
Sodium N/A N/A N/A N/A N/A N/A

hydroxide
9.3.3 Identification of hazardous flammable materials
The specified chemicals are categorized based on their flammability stating its flash
points, Lower Flammable Limit (LFL), Upper Flammable Limit (UFL) and Auto
Ignition Temperature (AIT) which is tabulated in Table 9.3.
Table 9.3 Hazardous flammable materials identification
Chemical Description Flash point (oC) LFL (v/v %) UFL (v/v %) AIT (oC)
Methane Avoid impact against -187.8 NA NA 537.2

158
container
Ethanol Highly flammable 25 3.3 19 368.8
Carbon Extremely flammable NA 12.5 74.0 605
monoxide gas
Methanol Burns with clean, 12.2 6.72 36.5 385
clear flame, being
almost invisible in
daylight
Note that:
 Flash point: the lowest temperature at which it can vaporize to form an

ignitable mixture in air
 LFL: the lower end of the concentration for which air/vapour mixtures can
ignite
 UFL: the upper end of the concentration for which air/vapour mixtures can
ignite
 AIT: Auto Ignition Temperature: the lowest temperature at which a
fuel/oxidant mixture will spontaneously ignite
9.4 HAZARD IDENTIFICATION, RISK ASSESSTMENT AND RISK CONTROL

(HIRARC)
HIRARC is the short form of Hazard Identification, Risk Assessment and Risk
Control. The objective is to provide a systematic method to evaluate hazards and their
related risks. HIRARC is one of the general duties as prescribed under the
Occupational Safety Health Act 1994 (Act 154) for employers to provide a safe
workplace to employees and people associated with the chemical plant. This provide
an objective approach of an identified hazard and also a method to mitigate the risk
based on table 9.4 and table 9.5. The reaction consideration is based on table 9.6.
Table 9.7 shows the risk matrix to decide whether the risk is either low, medium or
high.
Table 9.4 Description of likelihood
Likelihood Example Rating

The most likely result of the hazard/ event being
Most likely 5
realized
Possible Has a good chance of occurring and is not unusual 4
Conceivable Might be occur at sometimes in the future 3
Remote Has not been known to occur after many years 2
Inconceivable Is practically impossible and has never occurred 1
159
Table 9.5 Description of severity
Severity Example Rating

Numerous fatalities, irrecoverable property damage
Catastrophic 5
and productivity
Approximately one single fatality major property
Fatal 4
damage if hazard is realized
Serious Non-fatal injury, permanent disability 3
Minor Disabling but not permanent injury 2
Negligible Minor abrasions, bruises, cuts, first aid type injury 1
Table 9.6 Risk matrix
Severity (S)
Likelihood (L)
1 2 3 4 5
5 5 10 15 20 25
4 4 8 12 16 20
3 3 6 9 12 15
2 2 4 6 8 10
1 1 2 3 4 5
Table 9.7 Explanation on risk matrix
Risk Description Action

A HIGH risk requires immediate action to control the
15-
hazard as detailed in the hierarchy of control.
2 HIGH
Actions taken must be documented on the risk
5
assessment form including date for completion.
A MEDIUM risk requires a planned approach to controlling
the hazard and applies temporary measure if
5-12 MEDIUM required. Actions taken mut be documented on the
risk assessment form which includes the date for
completion.
A risk identified as LOW may be considered as acceptable
and further reduction may not be necessary.
1-4 LOW However, if the risk can be resolved quickly and
efficiently, control measures should be implemented
and recorded.
HIRARC is conducted throughout the plant. Following are the HIRARC for
each process and general works involved that supports to the process of methanol
production. In our plant, HIRARC will be managed on these aspects which includes
plant wide, storage, compressor and chemical reaction.
Table 9.8 HIRARC study of plantwide
Process unit: General work Location Plantwide

Hazard Identification, Risk Assessment, Risk Control (HIRARC) Date: 23/3/2020 Prepared by KK4
Review date: Approved by
Hazard Identification Risk Assessment Risk Control
Hazard
Mechanical hazards, Electrical Risk
hazards, Thermal (
Likelihood
hazards, Noise, Existing Control Measures L
Severity
Chemical (What action has been x
Substances, Dust, taken to reduce the S Additional control
No. Main process Work Activity Ergonomics Effect? effect?) ) measures
1 General Regular Slippery floor Physical Injury PPE - Safety boots -
Maintenance maintenance Buddy System 2 2 4
and Work instruction
Cleaning Pro Falling from height Physical injury, PPE - Safety harness -
cess may lead to death Buddy System 2 4 8
Work instruction
Inhalation of toxic gases Asphyxiation PPE- protective mask -
(suffocation, may Medical clinic 1 4 4
lead to death) Work instruction
Cuts injury involving Physical Injury PPE - Safety boots -
machinery Buddy system 2 2 4
Work instruction
Cleaning of tank Slippery floor Physical Injury PPE - Safety boots -
Buddy system 2 2 4
Work instruction
Falling from height Physical injury, PPE - Safety harness
may lead to death Buddy System 2 4 8 -
Work instruction
161
Inhalation of toxic gases Asphyxiation PPE- protective mask -

(suffocation, may Medical clinic 1 4 4
lead to death) Work instruction
-
Work after Rotational shift
1 2 2
Overtime normal working Medical clinic
2 Work hours Psychological stress Physical injury Toolbox meeting
Working at Rotational shift
hot area/ con Maintanance Fainting, Limit exposure time at hot 2 2 4 Installation of cooling
3 ditions work/cleaning Heat Stress Dehydration condition equipments nearby
Table 9.9 HIRARC study of chemical reaction
Process unit: Overall Methanol Production Location Chemical reaction

Hazard Identification, Risk Assessment, Risk Control (HIRARC)
Date: 23/3/2020 Prepared by KK4
Hazard
Likelihood
Severity
Mechanical hazards, Electrical
hazards, Thermal hazards, Noise, Existing Control Measures
Work Chemical Substances, Dust, (What action has been taken to Risk Additional control
No. Main process Activity Ergonomics Effect? reduce the effect?) (LxS) measures
1 R-101 Reaction in Overpressure inside reactor Explosion Work instruction 3 5 15 Ensure no ignition
Reactor tank Emergency Response Plan (ERP) source nearby
High pressure alarm Regular maintenance
Pumping of Pipe leakage May cause PPE - Gloves, Safety boots, face 2 2 4 Regular maintenance
POME into bacterial infection mask
reactor of liquid effluent Leakage detector system
Pumping of Pipe leakage and release of gas Explosion Work instruction 3 5 15 Ensure no ignition
gas product out with ignition source Emergency Response Plan (ERP) source nearby
162
of reactor Leakage detector system Regular maintenance

Pipe leakage and release of toxic Asphyxiation Emergency Response Plan (ERP) 3 4 12 Ensure no ignition
gas (suffocation, may Leakage detector system source nearby
lead to death) Regular maintenance
2 SR-101 Work instruction Ensure no ignition
Removal of
Scrubber Leakage of scrubber inlet pipe H2S poisoning Emergency Response Plan (ERP) 3 5 15 source nearby
H2S
process Leakage detector system Regular maintenance
Work instruction Ensure no ignition
Malfunction of microbe removal H2S poisoning Emergency Response Plan (ERP) 3 5 15 source nearby
Leakage detector system Regular maintenance
Pumping of
PPE - Safety boots
sodium Leakage of water inlet pipe which
Physical Injury Buddy system 2 2 4 Regular maintenance
hydroxide to causes slippery floor
Work instruction
scrubber inlet
Pumping of
lean sodium Work instruction Ensure no ignition
Pipe leakage and release of gas
hydroxide Explosion Emergency Response Plan (ERP) 3 5 15 source nearby
with ignition source
product out of Leakage detector system Regular maintenance
scrubber
3 T-101 Storage Overpressure inside tank Explosion Work instruction 3 5 15 Ensure no ignition
Gas storage Emergency Response Plan (ERP) source nearby
Tank rupture Leakage of gas Emergency Response Plan (ERP) 3 4 12 Ensure no ignition
High pressure alarm source nearby
Regular maintenance
Pumping of Pipe leakage May cause PPE - Gloves, Safety boots, face 2 2 4 Regular maintenance
gas into tank bacterial infection mask
of liquid effluent Leakage detector system
163
gas out of with ignition source Emergency Response Plan (ERP) source nearby
tank Leakage detector system Regular maintenance
S-101 Separation High level in separator Overflow Work instruction 2 3 6 Ensure no ignition
4 Separation of process Emergency Response Plan (ERP) source nearby
liquid and High level alarm Regular maintenance
vapour Pumping of Pipe leakage and release of Explosion Work instruction 3 5 15 Ensure no ignition
mixture into mixture with ignition source Emergency Response Plan (ERP) source nearby
separator Leakage detector system Regular maintenance
vapour out of with ignition source Emergency Response Plan (ERP) source nearby
Pumping of Pipe leakage and release of liquid Explosion Work instruction 3 5 15 Ensure no ignition
liquid out of with ignition source Emergency Response Plan (ERP) source nearby
S-102 Separation high level in separator Overflow Work instruction 2 3 6 Ensure no ignition
5 Separation of process Emergency Response Plan (ERP) source nearby
liquid and High level alarm Regular maintenance
vapour Pumping of Pipe leakage and release of Explosion Work instruction 3 5 15 Ensure no ignition
mixture into mixture with ignition source Emergency Response Plan (ERP) source nearby
vapour out of with ignition source Emergency Response Plan (ERP) source nearby
164

Pumping of Pipe leakage and release of liquid Explosion Work instruction 3 5 15 Ensure no ignition
liquid out of with ignition source Emergency Response Plan (ERP) source nearby
6 R-102 Pumping into Valve malfunction No or less High flow alarm
Methanol reactor inlet reactant flows Low flow alarm
production into reactor Bypass pipelines 2 3 6
Automatic shutdown system Scheduled inspection
Emergency Response Plan (ERP) and maintenance
Overflow of Scheduled inspection
2 3 6
reactor and maintenance
Pipe leakage No or less
reactant flows 2 3 6 Scheduled inspection
into reactor and maintenance
Exposed to ignition source Explosion Scheduled inspection
and maintenance
3 5 15
Keep away from
ignition source
Pumping into Valve malfunction overflow of Scheduled inspection
2 3 6
reactor inlet reactor and maintenance
Excess reactant
flows out of 2 3 6 Scheduled inspection
reactor and maintenance
Pipe leakage No or less
reactant flows 2 3 6 Scheduled inspection
into reactor and maintenance
and maintenance
3 5 15
Keep away from
ignition source
Methanol Reactor overpressure Reactor ruptures High pressure alarm Scheduled inspection
3 5 15
reaction in Low pressure alarm and maintenance
165
reactor Automatic shutdown system

Emergency Response Plan (ERP)
Release of
hazardous 3 5 15 Scheduled inspection
gaseous and maintenance
High operating temperature Reactor Temperature controller
overheating High temperature alarm
Low temperature alarm 3 5 15
Reactor ruptures Scheduled inspection
3 5 15
and maintenance
Heat stress PPE - heat protective gloves Shield surfaces where
Safety distance marking 2 2 4 close contact with hot
equipment
Exposed to ignition source Explosion Emergency Response Plan (ERP) Scheduled inspection
and maintenance
3 5 15
Keep away from
ignition source
7 D-101 Pumping into Valve malfunction No or less High flow alarm
Distillation distillation mixture flow Low flow alarm
Column 1 column inlet Bypass pipelines 3 4 12
3 4 12
mixture and maintenance
Pipe leakage No or less Scheduled inspection
3 4 12
mixture flow and maintenance
and maintenance
3 5 15
Keep away from
ignition source
Pumping out Valve malfunction No or less 3 4 12 Scheduled inspection
166
from mixture flow and maintenance

distillation
column
3 4 12
Pipe leakage No or less Scheduled inspection
3 4 12
mixture flow and maintenance
and maintenance
3 5 15
Keep away from
ignition source
Distillation Accumulation of mixture at the Column ruptures High level alarm
process trays Low level alarm 2 5 10 Scheduled inspection
Automatic shutdown system and maintenance
Column overflow Scheduled inspection
2 5 10
and maintenance
High operating temperature Column Temperature controller
overheating High temperature alarm
3 5 15
Low temperature alarm Scheduled inspection
Column ruptures Scheduled inspection
3 5 15
and maintenance
Exposed to ignition source Explosion Emergency Response Plan (ERP) Scheduled inspection
and maintenance
3 5 15
Keep away from
ignition source
Reflux drum malfunctioning Undesired Ratio control system
product High level alarm
3 3 9
Low level alarm Scheduled inspection
3 4 12
Cooler and heater malfunction Undesired Temperature controller 3 3 9 Scheduled inspection
167
product High temperature alarm and maintenance

Low temperature alarm
Automatic shutdown system
Overheating of Scheduled inspection
3 4 12
pipe and maintenance
Table 9.10 HIRARC study of Bioflocculant production
Overall Bioflocculant
Process unit:
Hazard Identification, Risk Assessment, Risk Control (HIRARC) Production Location Biological reaction
Date: 23/3/2020 Prepared by KK4
Hazard
Likelihood
Severity
Mechanical hazards, Electrical
hazards, Thermal hazards, Noise, Existing Control Measures
Work Chemical Substances, Dust, (What action has been taken to Risk Additional control
No. Main process Activity Ergonomics Effect? reduce the effect?) (LxS) measures
1 Cooling Draining of Drain leakage which causes Physical Injury PPE - Gloves, Safety boots, face
Pond C-101 POME into slippery floor mask 3 3 9 Regular maintenance
cooling pond Leakage detector system
Storage of Overflow Physical Injury PPE - Gloves, Safety boots, face Regular maintenance
POME mask 2 2 4
2 UASB T-101 Pumping of May cause PPE - Gloves, Safety boots, face
POME into Pipe leakage bacterial infection mask 2 2 4 Regular maintenance
UASB of liquid effluent Leakage detector system
Reaction in
Overpressure in tank Explosion Emergency Response Plan (ERP) 3 5 15 source nearby
tank
3 Settlement Separation of High level in tank Overflow Work instruction 2 2 4 Ensure no ignition
168
tank T-104 solid biomass Emergency Response Plan (ERP) source nearby
from water High level alarm Regular maintenance
Pumping of May cause PPE - Gloves, Safety boots, face
POME into Pipe leakage bacterial infection mask 2 2 4 Regular maintenance
tank of liquid effluent Leakage detector system
4 T-105 Pumping of May cause PPE - Gloves, Safety boots, face
MBBR POME into Pipe leakage bacterial infection mask 2 2 4 Regular maintenance
MBBR of liquid effluent Leakage detector system

Reaction in
Overpressure in tank Explosion Emergency Response Plan (ERP) 3 5 15 source nearby
tank
Reaction May cause Work instruction

Microbe contamination 2 3 6 Regular cleaning
using microbe infection Leakage detector system
5 Centrifuge May cause

Separation of
CF-101 bacterial infection PPE - Gloves, Safety boots, face
liquid and Pipe leakage 2 2 4 Regular maintenance
of liquid effluent mask
solid
Physical injury
Pumping of
PPE - Gloves, Safety boots, face
wastewater
Pipe leakage Physical injury mask 2 2 4 Regular maintenance
out of
Leakage detector system
centrifuge
6 Mixer M- May cause
101 bacterial infection
Mixing Pipe leakage mask 2 2 4 Regular maintenance
of liquid effluent
Leakage detector system
Physical injury
7 Dryer D-101 Regular maintenance
Drying of Work instruction
Overheating Explosion 2 3 6 Ensure no ignition
bioflocculant Emergency Response Plan (ERP)
source nearby
169
8 Conveyor Transportatio
CV-102 PPE - Gloves, Safety boots, face
n of Operator’s mistake Physical injury 2 2 4 Regular maintenance
mask
bioflocculant

Machine problem Physical injury 2 2 4 Regular maintenance
mask
9.5 CONCEPT OF HAZARD SYSTEM
Hazard is defined as an inherent physical or chemical characteristics that has the

potential for causing harm to people, environment or property. Concept of hazard
system consists of four basic components which are hazard source, receptors,
transmission path and barrier.
Table 9.11 Concept of Hazard System based on equipment
Bil Sources Receptors Transmission path Barrier

1 Gas holder that containing Workers, nearby Dispersion in air Physical barrier,
methane and carbon residents, school maintenance and
dioxide childred, commercial emergency
area response
2 Scrubber that containing Workers, nearby Dispersion in air Physical barrier,
hydrogen sulphide at 400 residents, school maintenance and
ppm childred, commercial emergency
area response
3 Packed bed reactor, R-101 Workers, nearby Thermal radiation Physical barrier,
that containing syngas at residents, school maintenance and
temperature 700oC childred, commercial emergency
area response
4 Packed bed reactor, R-102 Workers, nearby Dispersion in air Physical barrier,
that containing mix of residents, school maintenance and
gases, operating at childred, commercial emergency
pressure 50 bar area response
5 Distillation column to Workers, nearby Dispersion in air Physical barrier,
separate water and residents, school maintenance and
methanol childred, commercial emergency
area response
Table 9.12 Concept Hazard System
Hazard Source Hazard Category Description Transmission Path Receptor Barrier

Methane Health, Chemical -Extremely flammable. Thermal radiation -Operators on duty. -Wall of storage tank.
-May cause respiratory transmission. -Residents nearby. -Personal protective
difficulty, headache and equipment for operators.
nausea. -Regular maintenance
check for every pipeline.
Carbon dioxide Health -May displace oxygen Thermal radiation -Operators on duty. -Wall of storage tank.
and cause suffocation. transmission. -Residents nearby. -Personal protective
-May explode if heated. equipment for operators.
-Regular maintenance
Sodium hydroxide Health, Chemical -Strongly irritating and Thermal radiation -Operators on duty. -Wall of storage tank.
corrosive. transmission. -Residents nearby. -Personal protective
-May cause severe burns equipment for operators.
and permanent damage to -Regular maintenance
any tissue in contact. check for every pipeline.
Carbon monoxide Health -Toxic if inhaled. Thermal radiation -Operators on duty. -Wall of storage tank.
-May cause damage to transmission. -Residents nearby. -Personal protective
organs. equipment for operators.
-May explode if heated. -Regular maintenance
Ethanol Health -May form explosive Thermal radiation -Operators on duty. -Wall of storage tank.
mixtures with air. transmission. -Residents nearby. -Personal protective
-Highly flammable. equipment for operators.
172
Methanol Health -Over-exposure may Thermal radiation -Operators on duty. -Wall of storage tank.
result to death. transmission. -Residents nearby. -Personal protective
-Hazardous in case of equipment for operators.
skin contact, eye contact, -Regular maintenance
ingestion or inhalation. check for every pipeline.
Boiler Thermodynamic -Low water level and Thermal radiation -Operators on duty. -Wall of storage tank.
excessive pressure may transmission. -Residents nearby. -Personal protective
lead to explosion. equipment for operators.
Pressure vessel Thermodynamic -May cause explosion Thermal radiation -Operators on duty. -Wall of storage tank.
-May cause permanent transmission. -Residents nearby. -Personal protective
injuries on affected equipment for operators.
people -Regular maintenance
Microbe (Bacillus Biological -May be contaminated When in direct contact -Operators on duty. -Personal protective
marisflavi) -May be toxic to human with the contaminated -Residents nearby. equipment for operators.
health microbe
9.6 HAZOP STUDY
The HAZOP (Hazards and Operability) study is a formal procedure to identify hazards in chemical process facility. The procedure is effective
in identifying hazards and is well accepted by the chemical industry. HAZOP studies are conducted on all equipments that are involved in the
production of biofolocculant and methanol. HAZOP studies are divided into two parts which is chemical and biological process. The HAZOP
studies for major equipments are shown below and the others are shown in Appendix B.
9.6.1 Hazop for Equipment in Chemical Process
Hazop for the most hazardous equipments are stated in this chapter. Other equipments are stated in the appendix B.
a. R-101
Figure 9.1 HAZOP study on R-101 nodes

174
Table 9.13 HAZOP study on R-101 at node 1
HAZARD AND OPERABILITY STUDY REPORT

Project Title: PRODUCTION OF METHANOL AND BIO-FLOCCULANT FROM PALM OIL MILL EFFLUENT (POME)
Project Number: 1 Date: 23 March 2020
Drawing Number: R-101 Person in charge: Mr Afiq Syazwan
Line Number: 52 Study Team: KK4
Item: node 1 Parameter: Flow
GUIDE DEVIATION CAUSE CONSEQUENCES SAFEGUARDS ACTION
WORD
No No flow enters the  Inlet pipe ruptured  No reaction occurs None  Scheduled maintenance
reactor.  Inlet pipe blocked  Energy wastage and inspection.
 Install by-pass
Low Low flow entering  Inlet pipe partially  Low production rate None  Scheduled maintenance
the reactor. blocked  Energy wastage and inspection.
 Incomplete reaction  Install by-pass
High High flow entering  Malfunction or  Pressure build-up in None  Scheduled maintenance
the reactor. overflow from reactor and inspection.
previous unit process  Unreacted raw material
carried over to next unit
operation
175

Line Number: - Study Team: KK4
Item: node 2 Parameter: Temperature
WORD
Low Low temperature  Valve cooled water  Low production rate  None  Scheduled maintenance and
inside reactor. failed opened  Incomplete reaction inspection.
High High temperature  Valve cooled water  Vessel or pipeline  Temperatu  Scheduled maintenance and
inside reactor. failed closed rupture re inspection.
controller  Install high temperature
alarm
176

Item: node 2 Parameter: Pressure
WORD
Less Less pressure inside  Compressor before  Low production rate  None  Scheduled maintenance and
reactor enter reactor failed  Incomplete reaction inspection.
to operate  Install low pressure alarm
High High pressure  Outlet flow too low  Vessel or pipeline  Pressure  Scheduled maintenance and
inside reactor. rupture relief valve inspection.
 Pressure  Install high pressure alarm
 Explosion controller  Install gas detectors
177

Item: node 2 Parameter: Level
WORD
Low Low level inside  Low flow into  No reaction occur  None  Scheduled maintenance and
reactor. reactor inspection.
High High level inside  High flow into  Overflow inside  Temperature  Scheduled maintenance and
reactor. reactor reactor controller inspection.
 Install high temperature
alarm
178

WORD
No No flow out of  Outlet pipe ruptured  No production occurs None  Scheduled
reactor.  Outlet pipe blocked  Pressure build-up in maintenance and
 Valve failed closed reactor inspection.
 Install by-pass
Low Low flow out of  Outlet pipe partially  Low production rate None  Scheduled
reactor. blocked  Pressure build-up in maintenance and
reactor inspection.
 Install by-pass
High High flow entering  Valve failed opened  Unreacted raw material None  Scheduled
the reactor. carried over to next maintenance and
unit operation inspection.
179

WORD
No No inlet flow of  Block of inlet pipe  No cooling water flow into Temperature  Install flow indicator
cooling water  Inlet pipe rupture the jacket of tank controller  Install bypass
 Valve failed closed  Temperature in reactor  Scheduled maintenance and
increases inspection
 Affects reaction of biogas
inside reactor
Low Low inlet flow of  Inlet pipe partially blocked  Low flowrate of cooling Temperature  Install flow meter
cooling water  Inlet pipe leak water flow into the jacket of controller  Scheduled maintenance and
 Valve partially closed tank inspection
 Temperature in reactor
increases
High No inlet flow of  Valve failed opened  Continuous flow of cooling Temperature  Install flow meter
cooling water water into the jacket of tank controller  Scheduled maintenance and
 Temperature in reactor inspection
becomes low
 Insufficient energy supply
for reaction inside reactor
180

WORD
No No outlet flow of  Block of outlet pipe  No water flows out of the None  Install flow indicator
cooling water  Outlet pipe rupture jacket  Install bypass
 Accumulation of water in  Scheduled maintenance and
the jacket inspection
 High pressure in reactor
jacket
 Rupture of reactor
Low Low outlet flowrate  Outlet pipe partially blocked  Low flowrate of water out None  Install flow meter
of cooling water  Outlet pipe leak of the tank  Scheduled maintenance and
inspection
High High outlet flowrate  High inlet flowrate  Continuous flow out of None  Install flow meter
of cooling water water  Scheduled maintenance and
inspection
181
b. R-102
Figure 9.2 HAZOP study on R-102 nodes

182

WORD
No No flow enters the  Inlet pipe ruptured  No reaction occurs None  Scheduled
reactor.  Inlet pipe blocked  Energy wastage maintenance and
inspection.
 Install by-pass
Low Low flow entering  Inlet pipe partially blocked  Low production rate None  Scheduled
the reactor.  Energy wastage maintenance and
 Incomplete reaction inspection.
 Install by-pass
High High flow entering  Malfunction or overflow  Pressure build-up in None  Scheduled
the reactor. from previous unit process reactor maintenance and
 Unreacted raw inspection.
material carried over
to next unit
operation
183

WORD
Low Low pressure inside  Low flow of raw material  Low production  None  Scheduled maintenance and
reactor. into reactor rate inspection.
 Outlet flow too high  Energy wastage
 Compressor before enter  Incomplete
reactor failed to operate reaction  Install low pressure alarm
High High pressure  Outlet flow too low  Vessel or pipeline  None  Scheduled maintenance and
inside reactor. rupture inspection.
 Release of  Install high pressure alarm
flammable biogas
gas cloud
184

WORD
Low Low temperature  Valve cooled water  Low production rate  None  Scheduled maintenance and
inside reactor. failed opened  Incomplete reaction inspection.
High High temperature  Valve cooled water  Vessel or pipeline  Temperature  Scheduled maintenance and
inside reactor. failed closed rupture controller inspection.
alarm
185

WORD
Low Low level inside  Low flow into  No reaction occur  None  Scheduled maintenance and
reactor. reactor inspection.
High High level inside  High flow into  Overflow inside  Temperature  Scheduled maintenance and
reactor. reactor reactor controller inspection.
alarm
186

WORD
No No flow out of  Outlet pipe ruptured  No production None  Scheduled
reactor.  Outlet pipe blocked occurs maintenance and
 Valve failed closed  Pressure build-up in inspection.
reactor  Install by-pass
Low Low flow out of  Outlet pipe partially blocked  Low production rate None  Scheduled
reactor.  Pressure build-up in maintenance and
reactor inspection.
 Install by-pass
High High flow entering  Valve failed opened  Unreacted raw None  Scheduled
the reactor. material carried over maintenance and
to next unit inspection.
operation
187

WORD
No No inlet flow of  Block of inlet pipe  No cooling water Temperature  Install flow indicator
cooling water  Inlet pipe rupture flow into the jacket controller  Install bypass
 Valve failed closed of tank  Scheduled
 Temperature in maintenance and
reactor increases inspection
 Affects reaction of
syngas inside
reactor
Low Low inlet flow of  Inlet pipe partially blocked  Low flowrate of Temperature  Install flow meter
cooling water  Inlet pipe leak cooling water flow controller  Scheduled
 Valve partially closed into the jacket of maintenance and
tank inspection
 Temperature in
reactor increases
High No inlet flow of  Valve failed opened  Continuous flow of Temperature  Install flow meter
cooling water cooling water into controller  Scheduled
the jacket of tank maintenance and
 Temperature in inspection
reactor becomes low
 Insufficient energy
supply for reaction
inside reactor
188

WORD
Low Low temperature of  Low set temperature in water  Temperature in reactor Temperature  Install temperature indicator
cooling water cooling system becomes low controller  Scheduled maintenance and
 Insufficient energy inspection
supply for reaction inside
reactor
High High temperature of  High set temperature in water  Temperature of reactor Temperature  Install temperature indicator
cooling water cooling system increases controller  Scheduled maintenance and
 Water cooling system spoilt  Affects reaction of inspection
syngas inside reactor
189
c. S-101
Figure 9.3 HAZOP study on S-101 nodes

190
Table 9.27 HAZOP study on S-101 at node 1

Drawing Number: S-101 Person in charge: Mr Afiq Syazwan
WORD
No No flow enters the  Inlet pipe ruptured  No separation occurs None  Scheduled
separator  Inlet pipe blocked maintenance and
inspection.
 Install by-pass
Low Low flow entering  Inlet pipe partially blocked  Separator may run None  Scheduled
the separator. dry maintenance and
 Separation efficiency inspection.
decrease  Install by-pass
High High flow entering  Malfunction or overflow  Pressure build-up in None  Scheduled
the separator. from previous unit process separator maintenance and
 Overflow of inspection.
separator
191

WORD
Low Low pressure inside  Low flow of raw material  Release of  None  Scheduled maintenance and
separator. into separator flammable gas inspection.
 Outlet flow of gas too high   Install gas detectoes
 Rupture at column
High High pressure  Outlet flow of gas too low  Vessel or  Pressure  Scheduled maintenance and
inside separator.  Malfunction of pressure pipeline rupture controller inspection.
relief valve  Release of  Pressure  Install gas detectors
flammable relief valve  Install high pressure alarm
biogas gas
cloud
192

WORD
Low Low level of  Low flow of raw material  Spillage of None  Scheduled maintenance and
containment inside into separator hazardous inspection.
separator.  Outlet flow of liquid too substances  Close outlet valve to allow
high raw material build-up in
 Rupture at column  separator
 Install low pressure alarm
High High level of  Outlet flow of liquid too low  Overflow inside Level controller  Scheduled maintenance and
containment inside  High flow of raw material column inspection.
separator. into separator  Install high pressure alarm
193

WORD
No No flow out the  Outlet pipe ruptured  Pressure build-up in None  Scheduled
separator  Outlet pipe blocked separator maintenance and
 Valve failed closed  Spillage of hazardous inspection.
material  Install by-pass
Low Low flow out the  Outlet pipe partially blocked  Spillage of hazardous None  Scheduled
separator. material maintenance and
inspection.
 Install by-pass
High High flow out the  Malfunction or overflow  Separation efficiency None  Scheduled
separator. from previous unit process decrease maintenance and
 Low level in inspection.
separator
194

WORD
No No flow out the  Outlet pipe ruptured  Pressure build-up in None  Scheduled
separator  Outlet pipe blocked separator maintenance and
 Valve failed closed  Release of flammable inspection.
gas  Install by-pass
Low Low flow out the  Outlet pipe partially blocked  Release of flammable None  Scheduled
separator. gas maintenance and
 Pressure build-up in inspection.
separator  Install by-pass
High High flow out the  Malfunction or overflow  Separation efficiency None  Scheduled
separator. from previous unit process decrease maintenance and
inspection.
195
d. C-101
Figure 9.4 C-101

196
Table 9.32 HAZOP study on C-101 at node 1

Project title : PRODUCTION OF BIOFLOCCULANT AND METHANOL FROM PALM OIL MILL EFFLUENT (POME)
Project number : 1 Date : 23 March 2020
Drawing number : C-101 Person in charge : Ms Sivapriya
Line number : 66 Study team : KK4
Item : Node 1 Parameter : Flow
GUIDE DEVIATIONS CAUSES CONSEQUENCES SAFEGUARDS ACTION REQUIRED
WORDS
Less Less feed flow into  Partial clogging of  Separation efficiency decrease None  Scheduled inspection and
distillation column pipe  Level decreased in distillation maintenance at pipe and
 Pipe leakage column valve
 Valve failed close  Install low level alarm
No No feed flow into  Pipe broken or  No separation occurs None  Scheduled inspection and
distillation column plugged maintenance at pipe and
 Valve failed close valve
 Install low level alarm
High More feed flow into  Valve failed open  Overflow and spillage of  Level controller of  Scheduled inspection and
distillation column containment column maintenance at level
controller
 Install high level alarm

197

WORDS
Less Less flow of outlet top  Partial clogging of  Over containment in reflux drum None  Scheduled inspection and
product pipe  Rupture of reflux drum maintenance at pipe
 Pipe leakage
No No flow of outlet top  Pipe broken  Over containment in reflux drum None  Scheduled inspection and
product  Full clogging of pipe  Rupture of reflux drum maintenance at pipe
198

WORDS
Less Less flow of outlet bottom  Partial clogging of  Overflow in distillation column None  Scheduled inspection and
product pipe  Spillage of containment maintenance at pipe
 Pipe leakage  Install high level alarm
No No flow of outlet bottom  Pipe broken  Overflow in distillation column None  Scheduled inspection and
product  Full clogging of pipe  Spillage of containment maintenance at pipe
 Install high level alarm
High More flow of outlet bottom  Valve failed open  Separation efficiency decrease None  Scheduled inspection and
product  Pipe might rupture maintenance at pipe and
 Low level in distillation column valve
 Install low level alarm

199

Line number : - Study team : KK4
Item : Node 4 Parameter : Level
WORDS
Less Low level of containment  Feed flow rate is too  Separation efficiency decrease None  Scheduled inspection and
in distillation column low  Distillation column may run dry maintenance at pipe and
 Outlet flow rate is too column
high  Install low level alarm
 Leakage of column
High High level of containment  Feed flow rate is too  Overflow in distillation column  Level controller  Scheduled inspection and
in distillation column high  Spillage of containment maintenance at pipe
 Outlet flow rate is too
low  Install high level alarm
200

Item : Node 4 Parameter : Pressure
WORDS
Less Low pressure in the  Reboiler not working  Backflow of product  Pressure controller  Scheduled inspection and
column well  Leakage of containment maintenance at column
 Leakage of column  Install low level alarm
 Outlet flow rate is too  Install low pressure alarm
high
High High pressure in the  Condenser not  Rupture of column  Pressure controller  Scheduled inspection and
column working well  Leakage of containment maintenance at column
 Outlet flow rate is too
low  Install high pressure alarm
201

Item : Node 4 Parameter : Temperature
WORDS
Less Low temperature in the  Reboiler not working  Separation efficiency decreases  Temperature  Scheduled inspection and
column well controller maintenance at column
 Install low temperature alarm
High High temperature in the  Condenser not  Overheat or damage of column  Temperature  Scheduled inspection and
column working well  Specification of product is not met controller maintenance at column

alarm
202

Item : Node 5 Parameter : Level
WORDS
Less Low level in reflux drum  Input flow rate too  Reflux drum may run dry  Level controller at  Scheduled inspection and
low reflux drum maintenance at reflux drum
 Output flow rate too
high
 Leakage of column
High High level in reflux drum  Input flow too high  Overflow in reflux drum  Level controller at  Scheduled inspection and
 Output flow rate too  Spillage of containment reflux drum maintenance at reflux drum
low
203

WORDS
Less Low temperature in  Controller failure  Very low temperature fluid leads None  Scheduled inspection and
condenser to off-spec product maintenance at condenser
High High temperature in  Condenser  Produces off-spec product  Flow controller at  Scheduled inspection and
condenser malfunction  Failed to convert gas to water condenser maintenance at condenser
 Water failed to flow
alarm
204

WORDS
Less Low temperature in  Low flow of steam  Produces off-spec product None  Scheduled inspection and
reboiler through reboiler maintenance at reboiler
High High temperature in  High flow of steam  Produces off-spec product None  Scheduled inspection and
reboiler through reboiler maintenance at reboiler

alarm
CHAPTER X
PLANT LOCATION AND LAYOUT
10.1 INTRODUCTION
Plant location play an important roles on the profability of a project. It also has effect
to on scope for fututre expansion. There are several major factor that must be
considered in selection for suitable plant location. Among the major factors are listed
below:-
i. Raw material supply
The availability and price of the product will often determine the plant
location. This is because it will give huge impact mainly in cost when there are
no supply of raw material nearby the plant site. Plants producing huge amount
of chemical are usually located close to the source of the major raw material
ii. Transportation facilities
The transport of materials and products to and from the plant will be very
important factor in selection of plant location. It will be very convenient when
the site selected is close to at least two major forms of transport: road, airport,
sea port and rail.
206
iii. Public utilities and infrastructure
Chemical processes invariably require infrastructure and utilities such as

electric power and large amount of for cooling and for general use. Therefore,
the plant should be located near the water source of suitable quality.
iv. Land area
As we all know, huge area of land is needed for plant construction. Area for
future expansion of plant also need to considered for this factor . Next,
reasonable land price are necessary for saving cost.
v. Availability of labouur
Plant with huge production capacity need a high amount of workforce. The
plant location play important role when the site locate at easy to access are or
near the residental area.
10.2 SUGGESTION OF PLANT LOCATION
They are four places that been research and considered to be our plant location. These
four locations will be compared to each other based on raw material supply, land
availability and land prices, transport facilities, labour availability and utilities. The
list of the comparison for the four location are shown in Table 10.1 and for each
location are being evaluate and rate based on marks for each factor. These are being
shown at Table 10.2
Table 10.1 Comparison among four site locations
Location / site Lahad Datu, Morib, Muar, Johor Manjung,

location Sabah Selangor Perak
requirements
Map
Price RM 33, 000 per RM 250,000 per RM 150,000 per RM 500,000 per
acre acre acre acre
207
Mill Nearby (Raw FGV Mercu Seri Morib Palm Muar Palm Oil Pantai Remis
material source) Puspita Mill Oil Sdn Bhd Mill Bhd Palm Oil Mill
Infrastructure Available Available Available Available

Port/ Harbour Lahad Datu Port Port Klang (56 Muar Port (18 Hutan Melintang
(96 km) km) km) port (110 km)
Facilities Available in 8 Available in 11 Available in 10 Available in 5
km radius km radius km radius km radius
Utilities Electric supply Electric supply Electric supply Electric supply
from SESB from TNB from TNB from TNB
electric electric electric electric
substation, water substation, water substation, water substation, water
supply from supply from supply from supply from
Lahad Datu SYABAS Ranhill SAJ Sdn Lembaga Air
Water Supply (Syarikat Bhd (Syarikat Perak (LAP)
Bekalan Air Air Johor)
Selangor Sdn
Bhd)
Transportation Lahad Datu KLIA (41km) Senai Sultan Azlan
Airport (96km) International Shah Airport
Airport (141 km) (240 km)
Labour Residents of Residents of Residents of Residents of
FELDA Sahabat Kampung Bukit Bakri and Changkat
and fresh Kanchung and fresh graduates Keruing and
graduates fresh graduates fresh graduates
Nearby river and Lumerau river Titip river Gersik river Raja Hitam river
standard apply Standard B Standard B Standard B Standard A
Table 10.2 Mark analysis for each factor
Factor Marks (8-10) Marks (4-7) Marks (0-3)

Land area Large area for future Small area for future Does have much space
expansion site expansion site for future expansion
Land prices Low price Moderate price High price
Raw material Distance between Distance between Distance between
supply supplier and plant below supplier and plant below supplier and plant higher
than 20 km than 50 km than 50 km
Transport facilities Have good federal road Have intermediate Poor federal road and
and highway federal road and highway
Near to port highway
Slightly far to port
Utilities High electric supply High electric supply High electric supply with
with low cost with medium cost high cost
Public facilities More public facilities Slightly more public Less public facilities
provided utilities provided provided
Labor availability High amount of labor Slightly high amount of Low amount of labor
available labor available available
Residential Near with site area Slightly far with site area Far with site area
distance
Mark must be given for all four locations selected for each factor based on the
mark analysis. Based on the comparison of total score for all four locations, location
208
with highest mark are the finalize location for our plant. Table 10.3 shows the scoring
for each location selected based on the mark analysis listed in Table 10.2
Table 10.3 Scoring for each location selected
Factor Lahad Datu, Morib, Selangor Muar, Johor Manjung,

Sabah Perak
Land area 10 7 8 5
Availability
Land prices 10 5 7 3
Raw material 7 7 7 7
supply
Transport facilities
a) Port facilities 6 8 10 6
b) Airport facilities 6 9 5 3
c) Roadway 6 7 6 7
Utilities
a) Water supply 8 8 7 9
b) Power supply 10 10 10 10
Public facilities 10 9 9 10
Residential 9 8 8 9
distance
Labor availability 8 6 6 7
Total 90 84 83 76
Rank 1st 2nd 3rd 4th
10.3 SELECTION OF PLANT LOCATION
Based on the marks evalution, Lahad Datu, Sabah has the higesht score and the first
ranking among the suggested locations. It is chosen as our finalized plant location due
to following the reason:-
i. Reliable raw material and water supply
ii. Public facilities at 8 km from plant location
iii. Huge area of plant availability with lowest price
iv. Located 96 km from Lahad Datu Port
About 20 acres of land is purchased and the cost of the land is approximately
RM 26.9 million whereas the price of land at that area is RM 33, 000 per acre. Our
209
plant located near the FGV Mercu Puspa Mill. Figure 10.1 shows the exact land that
we choose for our plant site location.
Figure 10.1 Exact plant location
10.4 PLANT LAYOUT
In order to reduce the effect of controllable and uncontrollable factors that will
contribute to losses, layout arrangement and spacing is important. One of
uncontrollable factor that we considered is the wind direction. The wind direction at
our plant site location is northwest. Based on our plant layout, we placed our main
gate, administration building, car park, office, workshop and warehouse at upwind.
While, we placed all the tank farm and equipments that may spill flammable liquid at
the downwind to reduce the loss potential from an explosion or fire.
The spacing required between the various blocks based upon the relative hazard of
each process. By evaluating the process hazards and then we classifying them in high
hazard (HH), intermediate hazard (IH) and moderate hazard (MH) groups
Table 10.4 Minimum distances between units of various hazard category
Distance (in m) MH IH HH
MH 15 30 60
IH 30 60
HH 60
10.5 SITE LAYOUT
Please refer to Appendix G.

210
CHAPTER XI
MECHANICAL DESIGN
11.1 MECHANICAL DESIGN FOR UPFLOW ANAEROBIC SLUDGE BLANKET,

UASB (T-101, T-102 & T-103)
Design by: Ravinkumar A/L Manimaran (A158192)
By considering the internal pressure for UASB, the mechanical calculation for the
Table 11.1. The calculations can be referred in appendix part C1.
Table 11.1 Summary for mechanical design of UASB

Operating pressure/Design pressure psi 43.51
Material of construction - Carbon steel SA516 Grade 70
Vessel internal diameter, Di m 9.924
Vessel external diameter, Do m 9.964
Shell height
2:1 ellipsoidal head (top), he m 2.48
Cylindrical, hc m 21.34
Conical head (bottom), L m 5.95
Overall minimum thickness of vessel, toverall mm 35.8
Corrosion allowance, CA mm 4
MAWP of vessel psi 52.93
Longitudinal stress, σL N/mm2 18.61
Circumferential stress, σh N/mm2 37.22
Direct stress, σw N/mm2 2.82
Bending stress, σb N/mm2 0.0024
Torsional shear stresses, τ N/mm2 0
211
Stress analysis N/mm2 (σmax) < S

(37.22 < 117.9)
Elastic stability N/mm2 (∑σ)compressive < σc

(2.823 < 80.27)
Support The deisgned UASB does not have

support since it will be directly bolted to
the base ring on the ground
Area of one bolt, Ab mm2 1412.5

Actual width required, Lb mm 32.26
Base ring thickness, tb mm 54.77
Type of flanged joint - Welded flanged joint
Blind flange
11.2 MECHANICAL DESIGN FOR MOVING BED BIOFILM REACTOR (T-105)

Table below shows the overall calculation that related to the measurement for MBBR
reactor construction. The calculations can be referred in appendix part C2.

Vessel width m 9.79
Corrosion allowance, CA m 0.002
Bending stress, σb N/mm2 ±0.013
212
(2.9 < 30)

Type of pipe support - Pipe shoe clamp

Resultant stresses, σs (compressive) N/mm2 σs(compressive) ˂
0.125E(ts/Ds) sin θs
0.015< 355.06
2
Area of one bolt, Ab mm 176.95
Distance from the edge of the skirt to the outer edge of m 0.076
the ring, Lr
Actual width required, Lb m 0.905
Base ring thickness, tb m 0.103
Type of flanged joint - Slip on flange joint
11.3 MECHANICAL DESIGN FOR PACKED BED REACTOR (R-102)

Design by: Afiq Syazwan Bin Mohd Haizollizam (A158912)
By considering the internal pressure of the vessel, reactor R-102, the conditions that
are needed for the design have been calculated through series of formulae stated. The
conditions for the design our distillation column have been summarized and tabulated
as followed in Table 11.3. The calculations can be referred in appendix part C3.
Table 11.3 Summary for design condition of reactor R-102

Material of construction - Stainless steel SA240 Grade 304
Shell height
a) 2:1 ellipsoidal head (top), he m 0.0915
b) Cylindrical, hc m 1.1
c) 2:1 ellipsoidal head (bottom), he m 0.0915
Bed Diameter, Dbed m 0.366
Bed Height, Hbed m 0.770
213

(88.973< 122)
(0.280 < 567.01)

Type of vessel support - Straight skirt support
Skirt thickness, ts m 0.015
Resultant stresses, σs (tensile) N/mm2 σs(tensile) ˂ fs J sin θs
0.417 < 97.533
Resultant stresses, σs (compressive) N/mm2 σs(compressive) ˂ 0.125E(ts/Ds)
sin θs
0.561 < 1024.59

Area of one bolt, Ab mm2 58
Type of flanged joint - Welded-neck flanged
11.4 MECHANICAL DESIGN FOR COOLER (C-101)

Design by: Nuredahtul Faezan Binti Mohammad Yusop (A159291)
By considering the internal pressure of the vessel, Cooler CO-101, the conditions that
conditions for the design our cooler have been summarized and tabulated as followed
in Table 11.4. The calculations can be referred in appendix part C4.
Table 11.4 Summary for design condition of Cooler CO-101

Shell Diameter, Ds m 0.35
Inner Radius of Cylindrical shell, R m 0.18
Length of shell, L m 1.78
Bending stress, σb N/mm2 0
(10.24 < 138)
214

(21.235< 226.36)
Type of vessel support - Saddle Support

11.5 MECHANICAL DESIGN FOR PHASE SEPARATOR (S-102)

Designed by:Cheah Ching Wei (A157594)
Phase separator (S-102) is a vertical vessel used to purify methanol through phase
separation. The type of shell is cylindrical while the type of head is ellipsoidal head
with ratio 2:1.Table 11.5 summarizes the operating conditions and dimension of S-
102. The calculations can be referred in appendix part C5.
Table 11.5 Operating conditions dimension for phase separator S-102
Parameter Values unit

Operating Pressure, Po 30 bar
Operating Temperature, To 50 ºC
Vessel diameter, D 0.856 m
Shell height, HS 2.372 m
Top/ bottom head height, ho 0.21 m
Since the operating pressure is greater than the atmospheric pressure, the vessel is
designed based on the internal pressure. Construction material is stainless steel type
304 with corrosion allowance of 2 mm and maximum allowable stress of 19290 psi.
Table 11.6 Summary of calculations for phase separator, S-102
Properties Value unit

Corrosion Allowance 2 mm mm
Joint Efficiency, E 0.85 -
Vessel external diameter 0.888 m
Minimum thickness 14 mm
Ellipsoidal head/bottom height 0.22 m
Shell height 2.37 m
MAWP vessel 36.56 bar
Longitudinal stress 40.12 N/mm2
Circumferential stress 80.24 N/mm2
Direct stress 0.253 N/mm2
Bending stress ± 0.34 N/mm2
Type of support Straight skirt -
Skirt support thickness 8 mm
Height of skirt 1.25 m
No of bolts for base ring 8 -
215
Table 11.7 Dimension for the steel welding neck flanges(in mm)
Stream Nominal d1 D B T d4 f d2 k d3
Pipe Size
62 (in) 406 438 711 60 158.75 533 2 35 629 533
63 (out) 14 16 95 14 52 35 2 16 67 38
63 (out) 33 41 155 21 68.33 73 2 22 114 70
11.6 MECHANICAL DESIGN FOR DISTILLATION COLUMN (C-101)

Designed by: Sivapriya A/P Nadaraju (A158432)
By considering the internal pressure of the vessel, distillation column C-101, the
conditions that are needed for the design have been calculated through series of
formulae stated. The conditions for the design of distillation column have been
summarized and tabulated as followed in Table 11.8. The calculations can be referred
in appendix part C6.
Table 11.8 Summary for design condition of distillation column C-101

Shell height
(133.583 < 138)

Elastic stability N/mm 2
(∑σ)compressive < σc
(1.603 < 228.72)

1.0217 < 138
216

1.7068 < 731.47

Distance from the edge of the skirt to the outer edge m 0.076
of the ring, Lr
217
CONCLUSION
A sustainable plant has been designed by monetizing the POME to produce

renewable gas and green chemicals. The plant will have a multi role in the palm oil
industry since it is able to treat the POME efficiently with short HRT and lower
footprint besides producing sludge fertilizer that can be used in the oil palm
plantation. The production of bioflocculant and methanol generates an income which
is able to sustain the plant. The produced bioflocculant have high potential in
flocculating algae and the methanol can be used as a building block to produce other
chemical such as fuel, acid and solvents.
In this plant, the plant capacity for the production of bioflocculant is 2000
tonnes annually while for methanol is 800 tonnes annually. The sales price for the
bioflocculant is RM 90 per kg with the design life 25 years. Besides, payback period
(PBP) is 2.3 years and it is lower than PBPreference which is 2.5 years. It could attract
investors as it offers early payback period.
Our plant will be located at Lahad Datu, Sabah. The selection is based on the
suitability of land for transport, availability of raw materials, manpower, infrastructure
and etc. Our plant will be located near the FGV Mercu Puspita palm oil mill. We
obtain our main raw material, which is the POME from this palm oil mill. About 36
m3/hour of POME will be supplied to our plant. The detailed plant layout has been
drawn in order to have a structured plant which is high in safety.
The received POME will undergo anaerobic process to produce biogas. This
biogas will be used in the production of methanol by methane reforming and methanol
forming reactor. The remaining POME will undergo aerobic process to produce
bioflocculant. Now the POME is already low in COD and BOD content. It will enter
the waste treatment plant before been discharged to the nearby river. The discharge
limit in that area is Standard B. Green technologies are used in treating the POME to
produce biogas and bioflocculant such as UASB, MBBR and phytoremediation.
Each equipment in this plant is designed in detail based on the process

specification. The designs are done to ensure the equipment operate efficiently for its
218
role in this plant. Mechanical design have been done to some of the major equipment
such as the UASB reactor (T-101, T-102 and T-103), MBBR (T-105), cooler (CO-
101), methanol forming reactor (R-102), phase separator (S-102) and distillation
column (C-101). This major equipment is either a pressure vessel or most crucial
equipment in this plant.
Lastly, the safety of the whole plant has been analyzed by using a few studies
such as HIRARC and HAZOP studies. The chemical and biohazard have been
determine such as flammability of biogas and methanol. HAZOP studies have been
done for each equipment in order to obtain suggestion to improve the safety of the
plant. Some of the improvement from HAZOP studies are to add pressure relief valve
in pressurized vessel and flammable gas detector in the plant.
In a nutshell, the designed plant is highly based on the sustainability concept

which focus on the environment, economic and social impacts. The environment is
ensured clean since the POME is treated and the biogas is captured. This highly
supporting the Sustainable Development Goals (SDGs) which is SDG 13: Climate
action since the biogas is one of the causes of global warming. Besides, this designed
plant is able to generate income based on the produced bioflocculant and methanol.
For social responsibilities, a circular bioeconomy can be developed with the oil palm
plantation, palm oil mill and our plant. The chart below shows the circular
bioeconomy.
Figure 11.1 Circular bioeconomy

219
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treatments. Journal of Oil Palm Research 29(4): 528–540.
223
APPENDIX A
DETAILED DESIGN
CHAPTER I
DETAILED DESIGN OF COOLING POND
1.1 INTRODUCTION
The main function of cooling pond in our plant is to reduce the temperature of POME
obtained directly from the palm oil mill. POME will be received from the mill at a
temperature of 85°C (Zainal et al. 2017). This temperature is not suitable for anaerobic
process because the microbe that involves is mesophilic which work best in the
temperature range of 35°C to 40°C (Choong et al. 2017). A cooling pond is chosen
rather than tank because it is low in construction and operation cost. It is also easy to
operate and maintain in which skilled workers are not required. This cooling pond also
serves as a storage of POME. The general information of POME required for the design
of cooling pond is as below
Table 1.1 Information of POME required to design cooling pond

Information Value
Inlet flowrate of POME (kg/h), F 36000
Inlet temperature of POME, Tin (K) 358.15
Outlet temperature of POME, Tout (K) 308.15
Heat capacity of water, Cp (kJ/kg.K) 4.2
Convective heat transfer coefficient, h (W/m2.K) 369
Emissivity of water, ε 0.96
Stefan constant, σ (W/m2.K) 5.670 × 10-8
Source: Zainal et al. 2017

2
1.2 HEAT TRANSFER IN COOLING POND
The design of cooling pond is based on the energy balance on the cooling pond.
Assumption made to calculate the heat transfer at the surface of cooling pond is heat is
transferred through convection and radiation only. The overall heat formula is shown
as below
Heat Transferred (Q) = Heat Transferred by + Heat Transferred by

Convection (Q convection) Radiation (Q radiation)
1.2.1 Heat Transferred (Q)
Heat is transferred from the cooling pond to the atmosphere. This is because the
temperature in the cooling pond is higher compared to the atmosphere. The formula for
the heat transferred in the cooling pond is as below.
Q = mCpΔT where, m = Inlet POME flowrate (kg/hr)
Cp = Specific heat capacity (kJ/kg.K)
= (36000)(4.2)(358.15-308.15)
= 7560000 kJ/hr
Thus, the rate of heat transfer from the cooling pond to atmosphere is 7560000 kJ/hr
1.2.2 Heat Transferred by Convection (Q convection)
Heat by convection means heat is transferred from one place to another thorough the
fluid. In this case, heat is transferred from the cooling pond to the atmosphere through
3
the air as the fluid. The calculation of heat transferred by convection in the cooling pond
is as below.
Q convection = hAΔT where, h = Convective heat transfer coefficient (W/m2.K)

= (369)(A)(358.15-308.15)
= 18450 A kJ/hr
1.2.3 Heat Transferred by Radiation (Q radiation)
Heat transferred by radiation involves the when the high energy electron emits energy
to fall back to low energy level. The water molecule on the surface of the pond may
emit energy to release heat. The calculation of heat transferred by radiation in the
cooling pond is as below.
Q radiation = ε σ A (Tin4 – Tsurrounding4) where, ε = Emissivity of water

σ = Stefan Constant (W/m2.K)
= (0.96)(5.670× 10-8)A(358.154-308.154)
= 404.8 A kJ/hr
1.3 AREA OF COOLING POND
The area of cooling pond is calculated by using the energy balance equation in the
cooling pond
Q = Qconvection + Qradiation
7560000 = 18450A + 404.8A
A = 400 m2
4
Thus, the surface area of the pond is 400 m2.
1.4 DIMENSION OF COOLING POND
The retention time in the cooling pond is about one day as the temperature must be
reduced from 85°C to 37°C (Rahman 2017). The supply of POME will be 16 hours
since it’s the working hours in the palm oil mill per day. The volume calculation of the
pond is as below by taking 20% of safety factor for volume:
V = Q pome × HRT × S.F
= 36 m3/hr × 16 hr × 1.2
= 691.2m3
Length, width and depth of pond is as below:
Area of pond = Length × Width
Assume the length and width are the same
400 = L2
L = 20 m
The length and the width of the cooling pond is 20m × 20m
Volume of pond = Depth × Area
691.2 = H × 400
H = 1.73 m
Therefore, dimension of the pond is 20m × 20m × 1.73m

5
1.5 CONSTRUCTIOIN MATERIAL OF COOLING POND
The construction of cooling pond is relatively easy because just have to dig a large area
of hole. The hole must be covered with liner which have some important function for
ponding system. High density polyethylene (HDPE) pond liner will be used to cover
the surface of the ground. The function of this pond line is to prevent contaminant from
POME entering the ground. It also helps to prevent the water loss to the ground. This
is the most economical way for constructing a cooling pond with an easy operation and
maintenance.
1.6 SCHEMATIC DIAGRAM OF COOLING POND
The diagram below shows the schematic diagram of the cooling pond. The dimension,
liner, inlet and outlet piping system are also shown in the diagram.
20 m
Inlet Outlet
1.73 m
HDPE
liner
Figure 1.1 Cooling pond
Source: Tilley et al 2014

6
CHAPTER II
DETAILED DESIGN OF UPFLOW ANAEROBIC SLUDGE BLANKET
2.1 INTRODUCTION
Upflow anaerobic sludge blanket (UASB) reactor is a column type tank reactor that will
be used in anaerobic process. It is widely used in industrial wastewater treatment in
chemical and sewage industries (Lier et al. 2015). The detailed design of UASB
demand (COD) removal (Ohimain et al. 2017). The volume required to contain POME
for 10 days is 5760 m3. To cater a large volume of POME, three identical UASB is
used. Each UASB with a volume of 2304 m3 with 20% extra as safety factor. The
calculation for UASB are done according to the formula by Bal et al. 2010.
Information Value
3
Inlet (m /h) 36
3
Inlet (m /day) 576
HRT (days) 10
HRT (hours) 240
3
Volume (m ) 5760
Number of Tanks 3
3
7
2.2 DIMENSION OF UASB
Since the designed UASB is a column type tank reactor, the ratio of H:D used is 3:1
2
D 2 D 2
V = Hπr = Hπ( ) = (3D)π( )
2 2
3 4V 3 4(2304)
D=√ =√ = 9.924 m
3π 3π
H = 29.77 m
2.3 VOLUMETRIC HYDRAULIC LOAD
Q
VHL = where Q = inlet volumetric flowrate of the UASB (m3/day)
V
576 m3 /day
VHL = = 0.25 m3 / m3 .day
2304 m3
day
2.4 ORGANIC LOADING RATE
daily to the UASB per unit volume of UASB. The influent substrate concentration (So)
is 51 kg COD/m3 (Zainal et al. 2017). The calculation for Lv is shown below.
8
Q×So (576 m3 /day)(51 kg COD/m3)

Lv = =
V 2304 m3
Lv = 12.75 kg COD/m3.day
Thus, the organic loading rate of the organic material into the UASB is 12.75 kg/m3 per
day.
2.5 SLUDGE LOADING RATE
The sludge loading rate (Ls) referred to the amount of organic matter that is supplied to
the UASB per unit of biomass in the UASB. The total volatile solid in POME (M) is 34
kgVS/m3 (Zainal et al. 2017). The calculation for Ls is shown below.

Ls = =
M 34 kgVS/m3
Ls = 864 kg COD/kg VS.day
2.6 UPFLOW VELOCITY OF POME IN UASB
below.
Q
ν= where Q = inlet volumetric flowrate of the UASB (m3/hr)
A
36
ν= 9.924 2
= 0.4652 m/hr
(π)( )
2
9
2.7 UASB REACTOR EFFICIENCY
2.7.1 Chemical Oxygen Demand (COD)
ExSo
Ceff = So - where Ceff = COD at the effluent (kg COD/m3)
100
(96.5)(51)
Ceff = 51 - = 1.785 kg COD/m3 = 1785 mg COD/L
100
Thus, the COD outlet of the UASB is 1785 mg COD/L.
2.7.2 Biochemical Oxygen Demand (BOD)
2.7.3 Total Suspended Solid (TSS)
Ex = COD removal efficiency

TSS = 102(96.5)(240)-0.24
= 2641.66 mg/L
Thus, the TSS outlet of the UASB is 2461.66 mg COD/L.

10
2.8 SLUDGE PRODUCTION
Ps = (0.2) (51) = 10.2 kg TSS/day
2.9 GAS SEPARATION SYSTEM
The gas hood will be located at the top of the UASB. The main function of the gas hood
is to collect the biogas. The area of gas hood interface is calculated from the equation
below.
Qg
Kg = where, Kg = biogas release rate (m3gas/m2.hr)
Ai
106.522
5 = Ai
11
106.522
Ai = = 21.304 m2
5
𝐷 2
Ai = π ( 2 )
A 21.304
D= 2√ π = 2√ = 5.2 m
π
12
CHAPTER III
DETAILED DESIGN OF SETTLING TANK
3.1 INTRODUCTION
Settling tank is a low cost technology that is widely used in a wastewater treatment
plant to remove solid from wastewater. Sufficient time have to be allowed for the
settling of solid to take place (Rozema 2015). Settling tank is located right after the
UASB in our plant. The main function of this settlement tank is to remove the sludge
from the anaerobically treated POME. The HRT in the settling tank is about 10 hours
to allow the sludge to settle down efficiently. The characteristics of the sludge are as
shown in table below.
Table 3.1 Characteristics of sludge

Characteristics Value Source
Diameter (μm) 100 Wang et al. 2018
Density (g/ml) 1.02 Jones et al. 2010
Specific gravity 1.02 Jones et al. 2010
3.2 SETTLING VELOCITY OF SLUDGE PARTICLE
Settling velocity is the speed of the particle to settle down in the settling tank. The
settling velocity of the sludge particle have to be calculated as shown below by referring
formulas from Rozema 2015.
Vp = 0.00135 × d2 × (SG – 1) where, Vp = Settling velocity (inches/min)

d = Diameter of particle (μm)
SG = Specific gravity of the particle
13
Vp = 0.00135 × (100)2 × (1.02 – 1)
= 0.27 inches/min
Thus, the settling velocity of the sludge particle in the settling tank is 0.27 inches/min.
3.3 AREA OF SETTLING TANK
The area of the settling tank can be calculated by using the settling velocity of sludge
particle and inlet volumetric flowrate of anaerobically treated POME. The calculation
is as shown below by referring the formula from Rozema 2015.
Q
A = 1.604 × V where, A = Area of settling tank (ft2)
p
Q = Volumetric flow rate (gallon/min)

Vp = Settling velocity (inches/min)
m3 264.17 gal 1 hr
Q = 36 × 3 × =158.508 gal/min
hr 1m 60 mins
158.508
A = 1.604 × =941.65 ft2
0.27
A = 87.48 m2
Thus, the area of the settling tank is 87.48 m2.
3.4 DIMENSION OF SETTLING TANK
The settling tank that will be used in our plant is an open cylindrical shape.
A = πr2
A 87.48
r = √ =√ = 5.276 m
π π
14
The diameter of the settling tank is 10.55 m.
The volume of settling tank is calculated by using the flowrate into the settling tank and
20% as the safety factor for volume.
V = Q (m3/hr) × HRT (hr) × Safety factor
= 36 m3/hr × 10 hr × 1.2
= 432 m3
The height of the settling tank is calculated by using the volume and area.
V = AH
V 432 m3
H = =
A 87.48 m2
= 4.94 m
Thus, the diameter and height of the settling tank is 10.55 m and 4.94 m respectively.
3.5 CONSTRUCTION MATERIAL FOR SETTLEMENT TANK
Since settlement tank is a simple technology which can be constructed by using

concrete. Concrete is cheap if compared to steel plates such as carbon steel or stainless
steel. The anaerobically treated POME might be more acidic. The concreted wall
exposed to POME can be coated with epoxy to prevent any corrosion.
MBBR REACTOR
1.1 INTRODUCTION
MBBR reactor is an open tank for aeration process in order to produce bioflocculant by
using specialised bacteria which is Bacillus marisflavi. Moving bed biofilm reactor
(MBBR) is an advanced wastewater treatment technology that gives high treatment
efficiency with low operating and maintenance cost and robust operation procedure. The
effectivity of removing up to 90% of chemical oxygen demand and 95% of biological
oxygen demand with nutrients from effluent stream had been proven when there is
sufficient retention time (Jenkins and Sanders 2012). Moreover, the process is based on bio
carriers that will attract the biomass and grow them on the surface (Ødegaard et al. 2000).
Other specialty is that the bio carriers can be used up to 10 years and can be operated
continuously without the need for backwashing, and low head-loss. ((Rusten et al. 1998).
The biofilms that grows on the surface of the bio carriers would suspended throughout the
entire volume of the reactor (Qiqi et al. 2012). Furthermore, MBBR reactor is better than
other aerated reactors such as membrane bioreactor (MBR), activated sludge process (ASP)
and sequencing batch bioreactor (SBBR) in terms of operating cost, efficiency of suspended
solids removal and installation space required. MBBR reactor takes up small space as it can
maximizes surface area through the carriers.
Figure 11.1 Schematic showing the principles of MBBR reactor
Figure 11.2 MBBR carrier
1.2 VESSEL DESIGN FOR MBBR REACTOR, T-105
Vessel design for MBBR reactor are separated into few parts according into its design
specification. Every value and assumptions that have been made are comes with evidence.
MBBR reactor is operating at 1.01 bar with temperature 30oC. The material that will be
used to construct MBBR reactor is poured reinforced concrete grade M30. Concrete been
choose as the construction material because this reactor need to hold up a huge volume of
sludge with 24 hours HRT. The volume of the tank is 979m3 while considering the safety
factor. Concrete is the best material to be choosen as it could hold high volume of sludge
and can winstand a good amount of tensile stress. Mix ratio for cement to sand to aggregate
for this concerete is 1:0.75:1.5. The compressive strength of M30 concrete is 4350psi.
The mechanical design of MBBR reactor is subjected under ASME internal pressure
procedure and EUROCODE 2 for concrete materials. MBBR reactor is lie under internal
pressure because its absolute pressure is higher than atmospheric pressure. MBBR reactor
in an open tank and rectangular in shape. It consist of air diffuser at the bottom of the tank
and MBBR carrier that will be poured before the process start. This tank is embedded on
the floor.
Table 11.1 Operating condition of T-105
Criteria Value
Operating pressure, Po 1 bar
Joint efficiency, E 1 ( full radiography)
Corrosion allowance, CA 2 mm
Length, L 14.5 m
Width, W 9.79 m
Height, h 6.9 m
1.2.3 Design pressure
Design pressure is calculated by considering the hydrostatic pressure. Design pressure is

calculated using following equation ;
𝑃𝐷 = 𝑃𝑜 + 0.433ℎ
PD = Design pressure, psi
Po = Operating pressure, psi
h = Height, ft
PD = 25.01 psi
1.2.4 Diffuser design
Diffuser design for an aerobic system is considering few aspects such as length of manifold,
number of laterals, size of diffuser hole and etc. Calculation for diffuser design is shown
below.
Known parameters and their values ;
Design air flowrate (Qair,total) = 3672 m3/hr
Min design air flow rate/orifice (Qorifice, min) = 1.6 m3/hr
Max design air flow rate/orifice (Qorifice, max) = 1.75 m3/hr
Reactor length (Lreactor,length) = 14.5 m
Reactor width (Lreactor,width) = 9.79 m
Initial estimates of key design parameter values ;
Manifold length (Lmanifold) = 7961 mm
Grid spacing (Lgrid spacing) = 1820 mm

Grid width (Wgrid) = 2804 mm
Diffuser spacing (Ldiffuser spacing) = 300 mm
Wall spacing (Lwall, length) = 1219 mm
Wall spacing (Lwall,width) = 914 mm
Manifold diameter (Dmanifold) = 366 mm
Orifice spacing (Lorifice spacing) = 38 mm
𝑄𝑎𝑖𝑟,𝑡𝑜𝑡𝑎𝑙
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑖𝑓𝑖𝑐𝑒 = = 8000 𝑜𝑟𝑖𝑓𝑖𝑐𝑒
𝑄𝑜𝑟𝑖𝑓𝑖𝑐𝑒,𝑚𝑎𝑥
𝐿𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠 𝑝𝑒𝑟 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑 = + 1 = 27(𝑖𝑛𝑡𝑒𝑔𝑒𝑟)
𝐿𝑑𝑖𝑓𝑓𝑢𝑠𝑒𝑟 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
Ldiffuser spacing is typically starts at the largest interval. After considering the size for
the oxygen inlet to the manifold, the Lmanifold is reduced and the total number of laterals for
manifold for this process is 24 laterals. Lorifice spacing is generally taking at the minimum
spacing which is 38mm.
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠 𝑝𝑒𝑟 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑 = 24 × 2 = 48 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠
𝐿𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑙𝑒𝑛𝑔𝑡ℎ − 𝐿𝑤𝑎𝑙𝑙 𝑠𝑝𝑎𝑐𝑖𝑛𝑔,𝑙𝑒𝑛𝑔𝑡ℎ

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑, 𝑙𝑒𝑛𝑔𝑡ℎ = = 2.89
𝑊𝑔𝑟𝑖𝑑 + 𝐿𝑔𝑟𝑖𝑑 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
= 3 (𝑖𝑛𝑡𝑒𝑔𝑒𝑟)
𝐿𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑤𝑖𝑑𝑡ℎ − 𝐿𝑤𝑎𝑙𝑙 𝑠𝑝𝑎𝑐𝑖𝑛𝑔,𝑙𝑒𝑛𝑔𝑡ℎ

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑, 𝑤𝑖𝑑𝑡ℎ = = 1.12
= 1(𝑖𝑛𝑡𝑒𝑔𝑒𝑟)
𝑊𝑔𝑟𝑖𝑑 − 𝐿𝑒𝑛𝑑 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑖𝑓𝑖𝑐𝑒 𝑝𝑒𝑟 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠 = = 30
𝐿𝑜𝑟𝑖𝑓𝑖𝑐𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑖𝑓𝑖𝑐𝑒𝑠 = 30 × 24 × 3 × 1 = 2160
3672
𝑎𝑖𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑝𝑒𝑟 𝑜𝑟𝑖𝑓𝑖𝑐𝑒, 𝑄′𝑜𝑟𝑖𝑓𝑖𝑐𝑒 = = 1.7 𝑚3 /ℎ𝑟
2160
Q’orifice is 1.7 m3/hr which is higher than Qorifice, min and lower than Qorifice,maz. The
value is acceptable as it is in the range for the air flowrate per orifice.
1.75 − 1.7
𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 = × 100 = 2.85%
1.75
Calculated perecentage error is 2.85% and it is lower than 5%. The value is
acceptable.
𝑄𝑎𝑖𝑟 𝑓𝑙𝑜𝑤
𝑎𝑖𝑟 𝑓𝑙𝑜𝑤 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
𝐴𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑 × 𝑁𝑔𝑟𝑖𝑑,𝑤𝑖𝑑𝑡ℎ × 𝑁𝑔𝑟𝑖𝑑,𝑙𝑎𝑡𝑒𝑟𝑎𝑙
3672
= = 17309.1 𝑚/ℎ𝑟
22 0.3 2
( 7)×( 2 ) ×3×1
17309.1
𝑎𝑖𝑟 𝑓𝑙𝑜𝑤 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = 4.8 𝑚/𝑠
3600
1.2.5 MBBR carrier design
MBBR carrier is to provide a surface where biofilm can grow. Type of material for MBBR
carrier is high density poly ethylene (HDPE) material. This material been choose because
it have almost same density as water and it could been process easily in MBBR reactor.
Type of biocarrier is PE01 that have 4 room with diameter and height are 12 mm and 9 mm
respectively. By the rule of thumb, 60% of reactor is media and 40% is water. This MBBR
carrier can be used up to 10 years and could have high biofilm load,
1.2.6 Minimum wall thickness
Thickness for concrete wall is been verified based on three criteria. First, wheather the wall
is exterior or interior. In this case, the wal for MBBR reactor is fall to interior wall as is
play less inposrtant role in insulating the reactor from heat and cold. Second, what are the
wall is made of. It is either strong or weak materials. Strong materials need thinner wall
and vice versa. Lastly, the climate. As our production is in Malaysia that have tropical
climates, thinner walls is preferable. Value of thickness for the wall is based on nominal
thickness of concrete wall. Table below show the minimum thickness for few types of
concrete wall.
Table 11.2 Thickness of the wall (G. Peter,1998)
Material Exterior wall Interior wall

Rammed earth 37.5-45cm 37.5-45cm
Adobe brick 30cm 30cm
Poured concrete(not reinforced) 12.5-20cm 12.5-20cm
Poured concrete (reinforced) 12.5cm 12.5cm
Stone 30-37.5cm 25cm
Based on the table above, the minimum thickness for the concrete wall of MBBR
reactor is 12.5 cm.
1.2.7 Pipe support
Type of pipe support for manifold pipe is pipe shoe clamp. It is choosen as it can stop pipes
from rubbing against dissimilar metals. It means that they are able to prevent
electrochemical transfer and galvanic corrosion. It also keep insualtion from grinding
against objects or rupturing. In the same way, they should minimize the movement and
wear that comes with heat transfer.
1.2.8 Combined loading
Combined loading must be designed to winstand the worst combination of loading without
failure. A trial thickness is assumed based on the calculated and resultant stress from all
loads determined to ensure that the maximum allowable stress intensity is not exceeded at
any point.
a. Primary stress
Primary stresses are due to following sources :
i. Longitudinal (σL) and circumferential stresses (σH) due to pressure
P = 0.1 N/mm2
Di = 14500 mm
t = 125 mm
𝑃𝐷𝑖
σL = = 1.8125 𝑁/𝑚𝑚2
4𝑡
𝑃𝐷𝑖
σh = = 3.625 𝑁/𝑚𝑚2
2𝑡
ii. Direct stress (σw)
𝑊
σw =
𝜋 (𝐷𝑖 + 𝑡)𝑡
Where ;
W = Wv + WI ;
𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡
Cv = 1.02 m
Dm = 14.7 m
Hv = 6.9 m
Hence, Wv = 19072 N
Direct stress, σw = 0.0016 N/mm2
iii. Bending stress (σb)
𝑀 𝐷
σb = ± 𝐼 ( 2𝑖 + 𝑡)
𝑣
M = total bending moment
Iv = second moment of area of the vessel about the plane of bending
𝑊𝑥 2
𝑀=
2
x = Hv = 6.9 m
Deff = 14.9 m
Pw = 1280 N/m2
W = 19072 N/m
M = 454008.96 Nmm
π
Iv = 64 (Do 4 − D1 4 ) = 2.49 x 1014 mm4
Hence, bending stress, σb = 0.013 N/mm2

iv. Torsional shear stress (τ)
The torsional shear stresses can be neglected in preliminary vessel design because these loads will
normally be small, where, τ = 0
b. Principal stresses, σ1 and σ2
1
σ1 = 2 [σh + σz + √(σh − σz )2 + 4τ2 ]
1
σ2 = 2 [σh + σz − √(σh − σz )2 + 4τ2 ]
Total longitudinal stresses for upwind, σz

σz (upwind) = σL + σW + σb
σz (upwind) = 1.82 N/mm2
Total longitudinal stresses for downwind, σz

σz (downwind) = σL + σW − σb
σz (downwind) = 1.79 N/mm2
Principal stresses for upwind,
1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 3.65 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 1.82 N/mm2 = σz (upwind)
Principal stresses for downwind,

1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 3.625 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 1.79 N/mm2 = σz (downwind)
c. Maximum allowable stress intensity (∆σMAX)
Assume τ = 0, σ3 = 0.5
For upwind condition,
σ1 – σ3 = 2.9 N/mm2
For downwind condition,

σ2 – σ3 = 1.09 N/mm2
Hence, the maximum allowable stress intensity, (∆σmax) = 2.9 N/mm2. According to
EUROCODE 2, maximum allowable stress at temperature 303 oF is S = 30 N/mm2 . Since,
(∆σmax) = 2.9 N/mm2 ˂ S = 30 N/mm2, therefore, the design is safe to use.
d. Elasticity stability
E  t 
Critical buckling stress,  c   

31 v2  R
 p


Modulus of elasticity, E of concrete M30 is 5.47 N/mm2.
σc = 355.06 N/mm2
(∑ 𝜎) = 0.015 𝑁/𝑚𝑚2
𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒
Since the value of (∑ 𝜎)𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ˂ σc, therefore, the design is safe to use.
From the analysis of combined loading, the material we chose has fulfilled both
requirements of maximum stress intensity and elastic stability:
Δσmax  S and (∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ) < 𝜎𝑐

Therefore, the design is safe.
1.2.9 Base ring and anchor bolt design
The anchor bolts are assumed to share the overtuning load equallt and the bolt area
required :
1 4Ms
Ab = [ − W]
Nb fb Db
With, Ab = area of one bolt at the root of the thread, mm2
Nb = number of bolts
fb = maximum allowable bolt stress, N/mm2
Ms = bending moment at the base, Nm
W = weight of the vessel, N
Db = bolt circle diameter, m
Assumptions that being made for the calculations are as follows :

 bolt circle diameter, Db = 14.5 m
 circumference of bolt circle = 48.5 m
 maximum allowable bolt stress, fb = 30 N/mm2
 take number of bolts = 20 bolts
Bolt spacing = 2278.57 mm. Bolt spacing > 600 mm, therefore the bolt spacing is
acceptable.
The area of one bolt at the root of the thread, Ab.

The bending moment at the base, Ms = 454009 Nm
The weight of the vessel, W = 19072 N
1 4Ms
Ab = [ − W]
Nb fb Db
1 4(90410.92 )
Ab = [ − 6502.24 ]
8 × 125 1.574
Ab = 176.95 mm2
Total compressive load on the base ring per unit length, Fb

4Ms W
Fb = [ 2
+ ]
πDs πDs
Fb =3166.81 Nm−1
Taking the bearing pressure as 3.5 N/mm2, the minimum width of the base ring, Lb
Fb 1
Lb = × 3
fc 10
Lb = 0.9 mm
The required thickness for thickness base ring is found by treating the ring as cantilever
beam:
3𝑓𝑐′
𝑡𝑏 = 𝐿𝑟 √
𝑓𝑟
With, tb = base ring thickness, mm

Lr = the distance from the edge of the skirt to the outer edge of the ring, mm
f’c = actual bearing pressure, N/mm2
fr = allowable design stress in the ring of material, fr = 140 N/mm2
Take Lr = 76 mm,
Actual width required = Lr + ts + 50 mm
= 171 mm
𝐹𝑏
𝑓𝑐′ = = 18.52 N/mm2
171
3𝑓 ′
Base ring thickness, tb = 𝐿𝑟 √ 𝑓 𝑐
𝑟
= 103.4 mm
1.2.10 Flanged joint
Flanged joints are used for connecting pipes to the vessels. Type of flanged joints that been
used for this reactor is slip on flanges. It is preferred because of it is the cheapest compared
to other type of flanges, easy adjustment and it is generally used for pipe work. This flanges
joint is located at the inlet and outlet stream. Type B flanges is for inlet and outlet of liquid
and type A flanges is for the gas stream inlet at the bottom of the tank.
Table 11.3 Flanges measurements
Type BC(mm) R(mm) H(mm) T(mm) T1(mm) T2(mm) B(mm) OD(mm) ID(mm)
A 298.45 269.75 246.13 44.45 26.29 42.93 22.35 342.9 221.49
B 431.80 381.00 365.25 55.62 30.27 54.10 25.4 482.6 327.15
1.3 SUMMARY
reactor construction

Vessel width m 9.79
(2.9 < 30)


0.015< 355.06
the ring, Lr
SCRUBBER
1.4 DETAIL DESIGN GAS SCRUBBER SR-101
1.4.1 Introduction
Gas scrubber is used to separate hydrogen sulphide from biogas. It is located after UASB
reactor where the biogas been produced. Sodium hydroxide is act as solvent to be reacted
with hydrogen sulphide and will be out as bottom product as lean sodium hydroxide. At the
top product of gas scrubber, methane and carbon dioxide will be produce and being
transferred to the next equipment to further the process
Random tower packing column is selected as they are not limited to reduction of
pressure drop throughout the column (Gurbilek 2013). It also could have high capacity
compared to trays column that have same efficiency. Type of liquid distributors used is
gravitational type such as orifice distributor as it promote better contact compared to spray
nozzles (Barbour et al. 1995).
Stainless steel SA-240 is chosen as it provide good corrosion resistance towards acids with
good weldability. It also could provide good area reduction rate at low temperature. It is
also good to resist intergranular corrosion (International Stainless Steel Forum 2012).
SR-101 will be constructed in cylindrical shape for the middle with ellipsoidal shape for
head and bottom of the shell. Below are the design parameters of scrubber.
Table 1.1 Design parameters gas scrubber, SR-101

Parameter Unit SI
Operating pressure, PO 202 kPa
Radius, R 0.74 m
Layout Vertical
Operating pressure of scrubber is higher than atmospheric pressure and resulting it to have
internal pressure. Design pressure of each part of the vessel is being calculated by using PD
= PO + 0.433h where h is the height of each part of the column. Safety factor of 10% is
taken.
PJ = 1.1Po
Pgage = Po - Patm
Pgage = 0.2 bar
Ellipsoidal height, he
𝐷𝑖 1.49
he = = = 0.037 m
4 4
For the cylindrical shell height, Hc
Hc = H - 2he = 4.99 – (2 × 0.37) = 4.29 m
Tangent to tangent height , L
ℎ
L = ℎ𝑐 + 2 ( 3𝑒 ) = 4.49 m
Table1.2 Design pressure for each part of gas scrubber, SR-101

Top head ellipsoidal 2.06 2.26
Bottom head ellipsoidal 2.47 2.72
As there is no corrosive material pass through SR-101, corossion allowance that could be
consider is 2mm(0.0785 in).
1.4.4 Wall thickness of gas scrubber SR-101
The wall thickness, t for each part of the pressure vessel has to be calculated in order to get
the minimum wall thickness, tmin under internal pressure.
Table 1.3 Thickness of scrubber, SR-101

Top ellipsoidal 𝑃𝐷 1.23 1.48 3.48
𝑡=
head 2𝑆𝐸 − 0.2𝑃
Cylindrical shell 𝑃𝑅 1.46 1.48 3.48
𝑡=
(circumferential 𝑆𝐸 − 0.6𝑃
stress)
Bottom ellipsoidal 𝑃𝐷 1.48 1.48 3.48
𝑡=
head 𝑆𝐸 − 0.2𝑃
Based on stainless steel gauge thickness, gauge number 10 has been chosen as it have the
closest nominal thickness to the minimum thickness from the calculation. The nominal
thickness is 3.571mm which is slightly higher than minimum thickness.
1.4.5 Maximum Allowable Working Pressure
The maximum allowable working pressure for each of vessel part, MAWPp is the maximum
internal pressure including the static head pressure. However, any metal thickness
considered as corrosion allowance must be excluded from the calculation.
Table 1.4 MAWP of scrubber, SR-101
Part Formula MAWPpart(ba MAWPpart+CA(ba MAWP(bar MAWPvessel(ba

r) r) ) r)
Top 𝑃 2.897 2.90 2.86 2.45
ellipsoidal 2𝑆𝐸𝑡
=
head 𝐷 + 0.2𝑡
Cylindrica 𝑃 2.894 2.90 2.48 2.45
l shell 2𝑆𝐸𝑡
=
𝑅 + 0.6𝑡
Bottom 𝑃 2.897 2.90 2.45 2.45
ellipsoidal 2𝑆𝐸𝑡
=
head 𝐷 + 0.2𝑡
The smallest value of MAWPpart is been chosen to become MAWPvessel. Thus,

MAWPvessel is 2.45bar
1.4.6 Summary of detailed design parameters of gas scrubber
Table 1.5 Summary of scrubber design

Parameter Value

Top Head Height, He 0.37 m
Thickness of scrubber, t 3.157 mm
MAWPvessel 2.45 bar
Type Of Head Ellipsoidal
GAS HOLDER
1.5 DETAIL DESIGN GAS HOLDER GH-101
1.5.1 Introduction
Gas holder, GH-101 act as holding tank for the gas such as methane and cabon dioxide
before distribute it to reactor for further process. HRT for the gases in gas holder is 24
hours. Gas holder is located before the chemical stream process for methanol because to
ensure that the biogas is stored and have enough amount of biogas to be operated to produce
methanol. The gas holder containing biogas that already free from hydrogen sulphide that
make it less toxic and less corrosive gas. Volume of gas holder by considering safety factor
is 7904 m3.
Type of material for conctructing gas holder is stainless steel 304. This material have higher
melting point compares to other type of stainless steel and could store biogas. It is also not
cause harmful to the people either during production or use (R.C Bourg, 2012)
GH-101 will be contstructed in cylindrical shape with flat head for top and bottom of the
shell. Below are the design parameters for the gas holder.
Table 2.1 Design parameters gas holder, GH-101

Parameter Unit SI
Operating pressure, PO 1.01 kPa
Radius, R 4.38 m
Layout Vertical
Operating pressure of gas holder is higher than atmospheric pressure and resulting it to
have internal pressure. Design pressure of each part of the vessel is being calculated by
using PD = PO + 0.433h where h is the height of each part of the column. Safety factor of
10% is taken.
PJ = 1.1Po
Pgage = Po - Patm
Pgage = 0.2 bar
Table 2.2 Design pressure for each part of gas holder SR-101
As there is no corrosive material pass through SR-101, corossion allowance that could be
consider is 2mm(0.0785 in).
1.5.4 Wall thickness of gas holder GH-101
The wall thickness, t for each part of the pressure vessel has to be calculated in order to get
the minimum wall thickness, tmin under internal pressure.
Table 2.3 Thickness of gas holder, GH-101

𝑡=
(circumferential 𝑆𝐸 − 0.6𝑃
stress)
𝑡=
(longitudinal 𝑆𝐸 + 0.4𝑃
stress)
Based on the nominal thickness in the market, the thickness of the vessel is 10mm and it is
slightly higher that calculated minimum thickness of the vessel.
The maximum allowable working pressure for each of vessel part, MAWPpart is the
maximum internal pressure including the static head pressure. However, any metal
thickness considered as corrosion allowance must be excluded from the calculation.
Table 2.4 MAWP of gas holder, GH-101
Part Formula MAWPpart MAWPpart+CA(bar) MAWP(bar) MAWPvessel(bar)

(bar)
Cylindrical 𝑃 3.79 1.07 2.72 2.72
shell 𝑆𝐸𝑡
=
(circumference) 𝑅 + 0.6𝑡
Cylindrical 𝑃 7.61 1.07 6.54 2.72
shell 2𝑆𝐸𝑡
=
(longitudinal) 𝑅 − 0.4𝑡
The smallest value of MAWPpart is been chosen to become MAWPvessel. Thus, MAWPvessel
is 2.72bar
1.5.6 Summary of detailed design parameters of gas holder
Table 2.5 Summary of gas holder, GH-101

Parameter Value

Thickness of gas holder, t 10 mm
MAWPvessel 2.72 bar
Type Of Head Flat head
1.1 DETAILED DESIGN OF SYNGAS PACKED BED REACTOR R-101
Packed bed reactors are commonly used in chemical reactions whereas it is filled with solid
catalyst particles that most often used to catalyse gas reactions. The syngas reactor is located
right after the gas holder (GH-101) where biogas are been stored after hydrogen sulphide
scrubbed away from it. The methane and steam will be converted into syngas at 80%
conversion in this reactor (R-101). The catalyst used for this reaction is NiO/α-Al2O3
Figure 1.1 Diagram for syngas packed bed reactor
Substance Inlet (Stream 52), Outlet (Stream 53), Density, kg/m3

kg/h kg/h
Methanol 0.0 0.0 792
Water 250.8 136.8 1000
Methane 222.6 99.2 0.656
Carbon Monoxide 0.0 253.8 1.14
Hydrogen 0.0 43.8 0.0899
Total 902.9 902.9
1.1.1 RATE LAW
Reaction:
CH4 + H2O → CO + 3H2 (1)

CO + H2O → CO2 + H2 (2)
CH4 + 2H2O → CO2 + 4H2 (3)

𝑑𝑋
𝐹𝑎𝑜 𝑑𝑊 = −𝑟𝑎 ′
−𝑟𝑎 ′ = 𝑘𝑃𝑎
= 𝑘𝑅𝑇𝐶𝑎
Stoichiometry,
𝑃
𝑣 = 𝑣𝑒 (1 + 𝜀𝑋) ( 𝑃𝑜 )
𝐹𝑎
𝐶𝑎 = 𝑣
𝐶𝑎𝑜 (1−𝑋) 𝑃𝑜 𝐶𝑎𝑜 (1−𝑋)
= ( 𝑃 )= 𝑦
1+𝜀𝑋 1+𝜀𝑋
𝑃𝑜
where y = 𝑃

𝑑𝑦 𝛼
= − 2𝑦 (1 + 𝜀𝑋)
𝑑𝑊

𝐶𝑎𝑜 (1−𝑋) 𝑃𝑜
−𝑟𝑎 ′ = 𝑘𝑅𝑇𝑜 (𝑃)
1+𝜀𝑋
1.1.2 DESIGN DIMENSION

𝐹𝑜 𝑋
𝑉=
ρc (1 − e)(−r)
Where, 𝐹𝑜 is the total CH4 flowrate, 13.88 mol/h

X is the conversion
ρ𝑐 is a density of catalyst, 1870 kg/m3
𝑒 is the voidage, 0.4 for sphere solid catalyst
𝑟 is the rate constant
r1 = 8.38, r2 = -0.681, r3 = -0.688
(13.88)(0.8)
𝑉=
1870(1 − 0.4)(8.38 + (−0.681) + (−0.688))
= 0.0917 m3
𝑉 = 1.1 𝑥 0.0917 = 0.108 𝑚3
1
𝑉 = [𝜋(𝐷2 )(3𝐷)]
4
By taking ratio height shell to diameter 1:4 where Hvessel = 4D while taking ratio 1:2 for
diameter to height head for both bottom and top, D = 2Hhead. Hence, the height for packed
bed reactor is 1.05 m with 0.0875 m head height for both bottom and top.
Condition Values
Length Shell 1.05 m
Diameter 0.35 m
1.1.3 DESIGN OF BED
For the Bed Height, Hbed = 0.6 × 𝑉𝑒𝑠𝑠𝑒𝑙 ℎ𝑒𝑖𝑔ℎ𝑡, 𝐻
= 0.6 × 1.225 = 0.735 m

e(voidage) = 0.3
Weight of catalyst = ρcV(1 - e) = 1870 × 0.108 × (1 − 0.3) = 141.372 kg

= 1386.86 N
1.1.4 PRESSURE DROP
Pressure drop for packed bed reactor are calculated using Ergun equation as below;
∆𝑃 𝑉(1 − 𝜀)2 𝜌𝑓 𝑉 2 (1 − 𝜀)
= 150 2 2 + 1.75
𝐿 ∅𝑠 𝐷𝑝 𝜀 3 ∅𝑠 𝐷𝑝 𝜀 3
Where, 𝐿 is the bed length, 0.735 m

𝐷𝑝 is the catalyst particle diameter, 2 mm
V is the superficial gas velocity, 0.311 m/s
𝜀 is the bed porosity, 0.38 is been take
𝜌𝑓 is gas density, 8.3857 kg/m3
𝜇𝑓 is the gas viscosity, 0.0393 cP
Using formula above the pressure drop of R-101, ∆𝑃 = 0.083 𝑏𝑎𝑟
1.1.5 SUMMARY OF CALCULATION
Table 1.3 shows the summary of the calculation for design of packed bed reactor R-101.
Table1.3 Results for design of packed bed reactor R-101
Parameter Results
Pressure drop, ∆𝑃 0.083 bar
1.2 ETAILED DESIGN OF METHANOL PACKED BED REACTOR R-102
The methanol forming reactor is located right after the compressor (K-104) where the mixture
of recycle gas and syngas produced from R-101 are compressed to 250oC and 50 bar. The
methanol are been forming inside this reactor using the feed from syngas. The catalyst used for
this reaction is Cu/ZnO/Al2O3 and it is endothermic reaction so there are no temperature
changes inside this reactor
Stream 61
60
R-102
60
Stream 60
Figure 1.2 Diagram for methanol packed bed reactor
60
Substance Inlet (Stream 60), Outlet (Stream 61), Density, kg/m3
kg/h kg/h
149.0 149.0 0.656
Methane
Methanol 1.2 181.4 792
Water 136.4 237.7 997
Carbon Monoxide 381.4 381.4 1.14
Hydrogen 51.6 17.6 0.0899
Total 1168.80 1168.85
1.2.1 RATE LAW
Reaction:
CO2 + H2 → CO + H2O (1)

CO2 + 3H2 → CH3OH + H2O (2)

𝑑𝑋
𝐹𝑎𝑜 𝑑𝑊 = −𝑟𝑎 ′
−𝑟𝑎 ′ = 𝑘𝑃𝑎
= 𝑘𝑅𝑇𝐶𝑎
Stoichiometry,
𝑃
𝑣 = 𝑣𝑒 (1 + 𝜀𝑋) ( 𝑃𝑜 )
𝐹𝑎
𝐶𝑎 = 𝑣
𝐶𝑎𝑜 (1−𝑋) 𝑃𝑜 𝐶𝑎𝑜 (1−𝑋)
= ( 𝑃 )= 𝑦
1+𝜀𝑋 1+𝜀𝑋
𝑃𝑜
where y = 𝑃

𝑑𝑦 𝛼
= − 2𝑦 (1 + 𝜀𝑋)
𝑑𝑊

𝐶𝑎𝑜 (1−𝑋) 𝑃𝑜
−𝑟𝑎 ′ = 𝑘𝑅𝑇𝑜 (𝑃)
1+𝜀𝑋
𝐹𝑜 𝑋
𝑉=
ρc (1 − e)(−r)
Where, 𝐹𝑜 is the total CH4 flowrate, 20.58 mol/h

X is the conversion
𝑒 is the voidage, 0.285 for sphere solid catalyst
𝑟 is the rate constant

r1 = 5.63, r2 = 2.443,
(20.58)(0.8)
𝑉=
1190(1 − 0.285)(8.38 + (5.63) + (2.443))
= 0.136 m3
𝑉 = 1.1 𝑥 0.0917 = 0.150 𝑚3
1
𝑉 = [𝜋(𝐷2 )(3𝐷)]
4
By taking ratio height shell to diameter 1:4 where Hvessel = 4D while taking ratio 1:2 for
diameter to height head for both bottom and top, D = 2Hhead. Hence, the height for packed
bed reactor is 1.10 m with 0.0915 m head height for both bottom and top.
Condition Values
Operating pressure, Po 50 bar (725.2 psi)
Length Shell 1.10 m
Diameter 0.366 m
1.2.3 DESIGN OF BED

= 0.6 × 1.283 = 0.7698 m

e(voidage) = 0.285

= 1252.03 N
1.2.4 PRESSURE DROP
Pressure drop for packed bed reactor are calculated using Ergun equation as below;
∆𝑃 𝑉(1 − 𝜀)2 𝜌𝑓 𝑉 2 (1 − 𝜀)
= 150 2 2 + 1.75
𝐿 ∅𝑠 𝐷𝑝 𝜀 3 ∅𝑠 𝐷𝑝 𝜀 3
Where, 𝐿 is the bed length, 0.7698 m

𝐷𝑝 is the catalyst particle diameter, 2 mm
V is the superficial gas velocity, 0.152 m/s
𝜀 is the bed porosity, 0.38 is been take
𝜌𝑓 is gas density, 20.264 kg/m3
𝜇𝑓 is the gas viscosity, 0.0393 cP
Using formula above the pressure drop of R-102, ∆𝑃 = 0.0479 𝑏𝑎𝑟
Table 1.3 shows the summary of the calculation for design of packed bed reactor R-102.
Table1.6 Results for design of packed bed reactor R-102
Parameter Results
Pressure drop, ∆𝑃 0.0479 bar
1.3 DETAILED DESIGN OF MIXER M-101
The mixer M-101 are located right after centrifuge CF-101 which is the biomass is been
removed from the wastewater. The function of the mixer is to mix the wastewater that contains
bioflocculant with ethanol. This process will make the bioflocculant to solidify and occurs at
30oC and 3 bar.
Stream 37a
Stream 36
Stream 38
Figure 1.3 Diagram for mixer M-101
Table 1.7 The inlet and outlet stream for each component for M-101
Substance Stream 36, Stream 37a, Stream 38, Density, kg/m3

kg/h kg/h kg/h
Water 33484.4 53.2 33500.8 1000
Suspended 36.7 0.0 36.7 1500
solids
Bioflocculant 329.2 0.0 329.2 1050
Ethanol 0.0 310.7 310.7 785.5
Total 33850.3 363.9 34177.4
Total volume flow in= 34.23 m3/h
Hence, 𝑉 = 34.23 × 8 ℎ𝑜𝑢𝑟𝑠 = 273.83 𝑚3
By applying 20% safety factor to prevent overflow, 𝑉 = 1.2 × 273.83 = 328. 6 𝑚3
H/D ratio = 2
Calculate the height and diameter using this formula
𝜋𝐷2 𝐻 𝜋𝐷2 (2𝐷)

𝑉= =
4 4
D = Di = 5.94 m
H = 2 (5.94) = 11.88m
1.3.2 DESIGN OF IMPELLER
1 1
Impeller width, Wi 𝑊𝑖 = 𝐷= (5.94) = 0.40 𝑚
5 5
1 1
Diameter impeller, Di 𝐷𝑖 = 𝐷= (5.94) = 1.98 𝑚
3 3
1 1
Height of impeller from vessel floor, C 𝐶= 𝐷= (5.94) = 1.98 𝑚
3 3
1 1
Length of impeller width, Li 𝐿𝑖 = 𝐷= (5.94) = 0.50 𝑚
4 4
2 2
Diameter of impeller base, Dd 𝐷𝑑 = 𝐷= (5.94) = 1.32 𝑚
3 3
Thickness of disc, x 𝑋 = 0.039𝐷 = 0.039(5.94) = 0.08 𝑚

Table 1.3 shows the summary of the calculation for design of mixer M-101.
Table 1.8 Results for design of M-101
Parameter Results
Volume of mixer 328.6 m3
Height of mixer, H 11.88 m
Diameter of mixer, D 5.94 m
Impeller width, Wi 0.40 m
Diameter of impeller, Di 1.98 m
Height of impeller above vessel floor, C 1.98 m
Length of impeller, Li 0.50 m
Diameter of impeller base, Dd 1.32 m
Thickness of disc, x 0.08 m
1
CHAPTER I
DETAILED DESIGN OF KETTLE REBOILER(H-101)
(Designed by Cheah Ching Wei A157594)
Kettle reboiler (H-101) is used in steam generation for the syngas reforming reaction. In
this reboiler, steam will be generated from water at 2 bar.
Figure 1.1 Kettle reboiler (H-101)
Design Calculation
Physical properties of the process fluid (water) at 2 bar are shown in Table 1.1.
Table 1.1 Physical properties of the water at 2 bar

Physical properties Value
Water flowrate (kg/hr) 250.8
Boling point, TB(°C) 120.21
Latent heat, Hl(kJ/kg) 2201.6
2
Mean specific heat of liquid water, Cpw(kJ/kg ∙°C) 2.12

Critical pressure, PC (bar) 220.5
Sensible heat (maximum) = (120.21-0)2.12 = 201.85 kJ/kg
Total heat load = (201.85 + 2201.6) x (250.8/3600) = 167.44 kW
Assume heat loss is 5%, maximum heat load (duty) = 1.05 x 167.44 = 175.81 kW
Assume U equal to 1000 W/m2 ∙°C and both shell and tube sides are isothermal
(Sinnott 2005), steam is available at 3 bar and steam saturation temperature is 133.6°C.
Mean temperature difference, ΔTm = 133.6- 120.21 = 13.39°C
Heat transfer area required = (175.81*103)/ (1000*13.39) = 13.13 m2
U-tube with internal diameter of 25 mm and outer diameter(OD) of 30 mm is

selected. Nominal length of one U-tube is 4.8m.
Number of U- tube needed = 10.942/ [4.8π ∙ (30x10-3)] =29.024 tubes
Using square pitch diagram, pitch = 1.5 x 30mm (OD) = 45mm.
Minimum bend radius is taken as 45mm and proposed layout gives 30 U-tubes, tube
outer limit diameter is 510 mm.
Heat flux based on estimated area: q = 175.81/13.13 = 13.39 kW/m2
Boiling coefficient,
3 3 3
Hnb = 0.104 (220.6)0.69(13.39 x103)0.7[1.8 (220.6)0.17 + 4 (220.6)1.2 +10 (220.6)10]
3
=2965.7 W/m2∙°C
Steam condensing coefficient and steam fouling coefficient is 8000 W/m2∙°C and
5000 W/m2∙°C. Water fouling coefficient is 6000 W/m2∙°C and tube material is carbon
steel, kW = 55 W/m∙°C (Sinnott 2005).
30
1 1 1 30x10−3 ln
= + + 25 + 30 ( 1 + 1 )
𝑈𝑂 2965.7 6000 2 ∗ 55 25 5000 8000
UO = 1078.7 W/m2∙°C
The deviation from the original estimate of 1000 W/m2∙°C. is only 5.6% , the design
is acceptable.
Take liquid level as 600mm from base, free board = 1010- 600 = 410mm
410 mm
600 mm
510mm
Figure 1.2 Sketching of kettle rebiler side view
From the sketch in Figure 1.2, width at liquid level =970mm
Shell diameter = bundle diameter x2 = 1010 mm
Shell minimum length = 4800mm.

4
DETAILED DESIGN OF PHASE SEPARATOR (S-102)
(Designed by Cheah Ching Wei, A157594)
Phase separator (S-102) in the process is to separate liquid from the gaseous mixture
containing methane, carbon dioxide, carbon monoxide, hydrogen, before the further
separation of the methanol from the waste water in distillation column (C-101). The inlet
of the phase separator consists of methane, carbon dioxide, carbon monoxide, hydrogen,
water and methanol. At the end of the separation, water and methanol will be leave as
bottom product while methane, carbon dioxide, carbon monoxide, hydrogen, and some
amount of water and methanol will leave as top product. The inlet temperature and pressure
of the stream are 50 oC and 30 bar. Figure 1.3 shows the phase separator to be designed and
the flow rate of each component at the inlet and outlet after flash calculation . In order to
know the vapor fraction of the phase separator, isothermal flash calculation is being done
first. F63CH4 = 149 kg/h
F63CD = 201.8 kg/h
F63CM = 381.4 kg/h
F63H = 17.6 kg/h
F62CH4 = 149 kg/h F62W = 1.8 kg/h
F62CD = 201.8 kg/h F62M = 6.4 kg/h
F62CM= 381.4 kg/h
F62H = 17.6 kg/h
F62W = 237.7 kg/h
F62M= 181.4 kg/h
F66W = 235.9 kg/h
F66M = 175 kg/h
Figure 1.3 Phase separator S-102
First step is to determine the saturated pressure of each component,

Ln(P(mmHg)) = A - B / ( T (°K) - C )
Where A, B, C, = Antoinne coefficient (mmHg)

T = Inlet temperature (°K)
5
Then by using Roult’s law, find the K-value for each compenent,
Ki = Psat/P
Where Psat = Saturated pressure (kPa)

P = Inlet pressure (kPa)
Make an initial guess for the vapor fraction, V which is ranging from 0 to 1 and
iterative procedure is repeated until total moles of vapor with its mole fraction, y is 1. Table
1.2 shows the Vguess and the ∑y obtained. ∑y is 1 when vapor fraction is at 0.64. After
obtaining the V and y value, x can be calculated. Table 1.3 shows the summary of the
calculation.
zi K i
∑ yi = ∑ =1
1 + V(K i − 1)
i i
xi = yi/Ki
Where z = mole fraction of inlet component

V = vapor fraction
yi = moles of vapor with its mole fraction
xi = total moles of liquid with its liquid fraction
Table1.2 Iteration made
Vguess ∑y
0.83 1.1
0.72 1.07
0.64 1
Table1.3 Summary of isothermal flash calculation

Component zi Ki yi xi
Methane 0.169 10.608 0.2514 0.0237
Carbon dioxide 0.084 19.300 0.1272 0.0066
Carbon monoxide 0.247 13.969 0.3721 0.0266
Hydrogen 0.158 22.346 0.2416 0.0108
Water 0.240 0.0040 0.0027 0.6594
6
Methanol 0.102 0.0190 0.0051 0.2728
Vessel Diameter
Physical properties of the liquid and vapor in the vessel were determined and shown in
table In order to start calculating the diameter and height of the phase separator, some of
the physical properties of the streams need to be determined first.Table 1.4 shows the
physical properties needed to calculate the diameter and height of vessel.
Table 1.4 Physical properties required

Liquid density, ρL 875.4 kg/m3
Vapor density, ρv 19.9 kg/m3
Top flow rate 410.11 kg/h
Bottom flow rate 577.79 kg/h
Souders-Brown equation is used to calculate the vertical terminal vapor velocity. K

correction factor is needed for operation at different operating pressure, K correction factor
is 0.825 at 30 bar. For separator K value for separator about 3 m with mist eliminator
(Dooley et al. 2004),
K = 0.107m/s x 𝐾𝑓𝑎𝑐𝑡𝑜𝑟 = 0.088 m/s
Terminal velocity,
ut = K[(ρL - ρv)/ ρv]1/2
Where ρL = Liquid density (kg/m3)
ρv = Vapour density (kg/m3)

7
ut = 0.58 m/s
As the separation design at k value already includes an exit mist eliminator, a design
factor of 100% is apply. Thus, ut = ud = 0.58 m/s
Vapor volumetric flow rate, vv = 577.79/(19.9 x 3600) = 0.008 m3/s
For vertical separator with demister, us = ut
Minimum vessel diameter, Dv = (4vv/πud)1/2 = 0.13 m
Dv calculated is too small, iteration have been made and vessel diameter is 0.86m.
Vessel Height
Figure 1.4 shows the schematic diagram of phase separator. The height of the separator will
be calculated by section as shown in the diagram.
h7
h6
D
h5
h4
h3
h2
h1
Figure1.4 Phase separator schematic diagram

8
For height from low liquid level (LLL) to bottom tangent line, h1,
Operating pressure = 30 bar < 70 bar, hence h1 will be set at 0.15m.
Assume a minimum of 25 minutes hold up .
Liquid volumetric flow rate,
vL = 410.11/(875.36 x 3600) = 0.00013 m3/s
Volume held in the vessel,
V = 0.00013 x 25 x 60 = 0.195 m3
Liquid depth required,
hL = Volume held up/vessel cross-sectinal area = 0.388 m
The surge time is assumed at 5 minutes, for the surge volume,
Surge volume = 0.0013 ×5×60 = 0.039 m3
For surge height or height from normal liquid level (NLL) to HLL, hn
Surge height, hn = surge volume/vessel cross-sectional area

9
hn = 0.078 m
For height from LLL to HLL,
h2 = hL + hn =0.466 m
For height from HLL to the inlet nozzle, if h3 calculated is less than 0.3, then h3 is 0.3m.
h3 = 0.3 Dv = 0.24 m < 0.3 m, thus h3 = 0.3m
For inlet nozzle diameter, if h4 calculated is less than 0.4064m, then set h4 at
0.4064m.
𝑣𝐿
λ=𝑣 = 0.001
𝐿 +𝑣𝑉
4Qm √ρm 0.5

dn = ( )
60π
Where vm = vL + vv (m3/s),
ρm = ρL λ + ρV (1 − λ) (kg/m3)
h4 = dn = 0.2068 m< 0.4064 m, Thus, h4 = 0.4064 m
For disengagement height, if h5 calculated less than 0.6 m, set h5 at 0.6 m.

10
h5 = 0.45Dv = 0.36 m < 0.6m, thus h5 = 0.6 m
For height/thickness of mist eliminator, it is set at 0.15 m.
h6 = 0.15 m
For height from mist eliminator to the top tangent line, if h7 calculated is less than
0.3 m, set h7 at 0.3 m.
h7 = 0.15Dv = 0.12 m < 0.3 m, thus h7 = 0.3m
Height of separator,
hT = h1 + h2 + h3 + h4 + h5 + h6 + h7
hT = 2.37 m
For phase separator, the hT/Dv ratio is usually between 1 to 3.
hT/Dv = 2.77 (Acceptable)
Total volume of the separator,

11
VT = π(Dv/2)2hT = 1.367 m3
Table 1.5 shows the summary of the results obtained from manual calculation of the
phase separator S-102.

Parameter Result
Dv 0.86 m
h1 0.15 m
h2 0.47 m
h3 0.30 m
h4 0.41 m
h5 0.60 m
h6 0.15 m
h7 0.30 m
hT 2.37 m
hT/Dv 2.77
VT 1.37 m3
12
containing methane, carbon dioxide, carbon monoxide, hydrogen, water and methanol
before the material stream flow into the compressor. This is to reduce the risk of compressor
failure due to liquid in the compressor. This separator serve as a knock out drum before the
gas compression. The inlet of the phase separator consists of methane, carbon dioxide,
carbon monoxide, hydrogen and water. At the end of the separation, small amount of water
will leave as bottom product while methane, carbon dioxide, carbon monoxide, hydrogen,
and water will leave as top product. The inlet temperature and pressure of the stream are
350 oC and 3 bar. Figure 1.5shows the phase separator to be designed and the flow rate of
each component at the inlet and outlet after flash calculation . In order to know the vapor
fraction of the phase separator, isothermal flash calculation is being done first.
F63CH4 = 99.2 kg/h

F63CD = 369.3 kg/h
F63CM = 253.8 kg/h
F54CH4 = 99.2 kg/h F63H = 43.8 kg/h
F54CD = 369.3 kg/h F62W = 136.1 kg/h
F54CM= 253.8 kg/h
F54H = 43.8 kg/h
F54W = 136.8 kg/h
F55W = 0.7 kg/h

Ln(P(mmHg)) = A - B / ( T (°K) - C )

13
Ki = Psat/P

calculation.
zi K i
∑ yi = ∑ =1
1 + V(K i − 1)
i i
xi = yi/Ki

V = vapor fraction
Table 1.6 Iteration made
Vguess ∑y
0.9987 1
Table 1.7 Summary of isothermal flash calculation

Methane 0.117 326.708 0.1169 0.0004
Carbon dioxide 0.158 631.620 0.1587 0.0003
Carbon monoxide 0.171 425.888 0.1713 0.0004
Hydrogen 0.410 673.419 0.4108 0.0006
Water 0.143 0.143 0.1423 0.9984
14
Vessel Diameter

Liquid density, ρL 985 kg/m3

is 0.96 at 3 bar. For separator K value for separator with mist eliminator(Dooley et al.
2004),
K = 0.107m/s x 𝐾𝑓𝑎𝑐𝑡𝑜𝑟 = 0.103 m/s
Terminal velocity,
ut = K[(ρL - ρv)/ ρv]1/2
ut = 3.243 m/s
15
Dv calculated is too small, iteration have been made and vessel diameter is 0.71 m
Vessel Height
h7
h6
D
h5
h4
h3
h2
h1
Figure 1.6 Phase separator schematic diagram

16
vL = 0.7/(985 x 3600) = 1.97 x10-8 m3/s
V = 1.97 x10-8 x 25 x 60 = 2.96 x10-5 m3
hL = Volume held up/vessel cross-sectinal area = 7.48x10-5 m
Surge volume = 1.97 x10-8 ×5×60 = 5.92x10-6 m3
For surge height or height, hn from normal liquid level (NLL) to HLL, hn
hn = surge volume/vessel cross-sectional area
hn = 1.4958 x10-5 m
h2 = hL + hn = 8.97 x10-5 m < 0.3m, thus set to 0.3m

17
For height from HLL to the inlet nozzle, if h3 calculated is less than 0.3, then set h3 at 0.3m.
h3 = 0.3 Dv = 0.213 m < 0.3 m, thus h3 = 0.3m
For inlet nozzle diameter, if h4 calculated is less than 0.4064m, then h4 is 0.4064m.
𝑣𝐿
λ=𝑣 = 0.001
𝐿 +𝑣𝑉
4Qm √ρm 0.5

dn = ( )
60π
ρm = ρL λ + ρV (1 − λ) (kg/m3)
h4 = dn = 0.087 m< 0.168 m, Thus, h4 = 0.168 m
h5 = 0.45Dv = 0.3195 m < 0.6 m, thus h5 = 0.6 m
h6 = 0.15 m
18
0.3 m, set h7 at 0.3 m.
h7 = 0.15Dv = 0.1065 m < 0.3 m, thus h7 = 0.3m
hT = h1 + h2 + h3 + h4 + h5 + h6 + h7 = 1.968 m
VT = π(Dv/2)2hT = 1.1 m3
Summary of Calculation
Table 1.9 shows the summary of the results obtained from manual calculation of the phase
separator S-2.
Table1.9 Calculation summary

Parameter Result
Dv 0.71 m
h1 0.15 m
h2 0.30 m
h3 0.30 m
h4 0.17 m
h5 0.60 m
h6 0.15 m
h7 0.30 m
hT 1.97 m
hT/Dv 2.77
VT 1.1 m3
19
DETAILED DESIGN OF DESICCANT DRYER (DD-101)
A desiccant air dryer uses special drying agent beads (silica gel) to absorb water vapor
from an air stream. Silica gel is regenerative so that the drying agent doesn’t need replacing
in order to provide vapor-free compressed air consistently. Figure 1.7 shows the schamatic
diagram of belt press.
F33 W = 1516.7 kg/h
F32 air = 1516.7 kg/h
Figure 1.7 Belt press, BP-101
Design Detail
In desiccant dryer, the air intake from the atmosphere is first dehumidified before used as
to dry bioflocculant in rotary dryer. The flowrate of the sludge is 1516.7 kg/h which is
equivalent to 1.517m3/hr. Based on the details provided, desiccant dryer model D-2 from
Van Air Systems can be adapted in this process and the specification is shown in table 1.10.
.
Table 1.10 Specification of desiccant dryer model D-2

Flow rate capacity at 1.7 bar 3.9 Nm3/hr
Height 35 cm
Width 9 cm
Desiccant mass 23 kg
Empty vessel weight 2 kg
Max working pressure 13.8 barg
Source: Van Air System 2012

20
DETAILED DESIGN OF ROTARY DRYER(D-101)
The bioflocculant is is being dried from 49% initial moisture to 10% final moisture in rotary
dryer. Hot air enters at 135°C with a humidity of 0.015.The exit gas temperature is 90°C
with a humidity of 0.097. The exit solid has a temperature of 80°C while bioflocculant
enter the dryer at 30°C. The diagram of rotary dryer is shown in figure.
F41a air = 1516.7 kg/h

F41a air = 1516.7 kg/h
F41a W = 36.8 kg/h
F41a E = 248.6 kg/h
GS = 1516.7kg/hr
Y1
F42 W = 40.3 kg/h
F40 W = 77.1 kg/h F42 BF = 329.2 kg/h
F40 E =248.6 kg/h
F42 BF = 248.6 kg/h
Figure 1.8 Rotary Dryer, D-101
Design calculation
Enthalpy change equation:
H’S1 = [cPS + CPW∙X1] (TS1 – Tref)
H’S2 = [cPS + CPW∙X2] (TS2 – Tref)
H’G1 = [cPair + CPV∙Y1] (TG1 – Tref) + Y1∙ λ
H’G2 = [cPair + CPV∙Y2] (TG2 – Tref) + Y2∙ λ

21
The equation above is the enthalpy equation in the rotary dryer and the parameter
of the drying process is shown in table 1.11 (Mujumdar & Hall 2006; Sinnott 2005). Figure
1.9 shows the solid and gas temperature profiles in a counter-current rotary dryer.
Table 1.11 Parameter of rotary dryer

Parameter Symbol Value Unit
Reference temperature Tref 0 °C
Heat capacity of solid cPS 0.85 kJ/kg∙°C
Heat capacity of liquid CPW 2.87 kJ/kg∙°C
Temperature of solid inlet TS1 30 °C
Temperature of solid outlet TS2 80 °C
Heat capacity of dry air cPai 1.005 kJ/kg∙°C
Heat capacity of liquid vapour CPV 1.88 kJ/kg∙°C
Temperature of air leaving dryer TG1 90 °C
Temperature of air entering dryer TG2 135 °C
Latent heat of liquid evaporated λ 2256 kJ/kg
Mass flowrate of gas phase Gs 1516.7 kg/hr
Enthalpy of vapour leaving dryer H’G1 327.1 kJ/hr
Enthalpy of vapour entering dryer H’G2 193.32 kJ/hr
Mass flowrate of solid phase Ls 329.2 kg/hr
Enthalpy of bioflocculant entering dryer H’S1 91.92 kJ/hr
Enthalpy of bioflocculant leaving dryer H’S2 92.09 kJ/hr
Moisture content in inlet bioflocculant X1 0.4973 -
Moisture content in outlet bioflocculant X2 0.1091 -
Moisture content in inlet air Y2 0.015 -
Moisture content in outlet air Y1 0.0976 -
Figure 1.9 Solid and gas temperature profiles in a counter-current rotary dryer.
22
a. Calculation of the shell diameter
Calculation of diameter of the shell need to be performed to obtain the rotating shell
diameter.
Humid volume, VH = [(1/28.97) + (Y/18.02)] x 22.4 x [(Tg + 273)/273]
Humid volume of the inlet gas (135°C, Y2 = 0.015), VH2 = 0.15 m3/kg dry air
Humid volume of the exit gas (90°C, Y1 = 0.098), VH1 = 0.062 m3/kg dry air
The maximum volumetric gas flow rate, Gs x VH2 = 4.79 m3/s
Total volume needed maximum volumetric flowrate with 10% more volume for
minor process upset. Total volume is 5.03 m3. Take the maximum superficial air velocity
to be 1.2 m/s (this is 20% less than the maximum allowable velocity since part of the dryer
is filled with the moving solid, and the entire cross-section is not available for gas flow).
Volume = (πd2/4) x (1.2) = 3.686
Diameter, d = 2.3m.
b. Calculation of the number of heat transfer units
The dryer is considered to consist of three zones as shown in Figure 1.9. The temperature
and humidity or moisture content of the streams can be obtained by material and energy
balance.
23
i. Zone III
Only heating of the solid occurs in this zone; there is little water left for vaporization. At
the boundary between zones III and II, the solid is at TSB (= TSA) = 41°C
Enthalpy of the solid at the inlet to zone III,
H’SB = [0.85 + (2.867) x 0.00301] x (41 – 0) = 1.2 kJ/kg dry solid
Humid heat of the gas entering zone III, CHB = [1.005 + (1.88) x (0.015)] = 1.033
kJ/kg.∙K (this remains constant in zone III, since the humidity does not change in this
section).
Heat balance: LS (H’S2 – H’SB) = GS (cHB)III (TG2 - TGB)
329 x (92.09 – 1.2) = 1517 x 1.033 x (135 – TGB)
TGB = 133°C
Adiabatic saturation temperature of air entering zone II (133°C and humidity of

0.015) is 41.3°C. This is close to the guess value of 41°C and TSA = TSB = 41°C is not
changed.
At the boundary B, ∆TB = 133 – 41 = 92°C, at end 2, ∆T2 = 135 – 100 = 35°C
Log mean temperatur in zone III (∆T)m = (92 – 35)/[ln(92 – 35)] = 14.14°C
Number of heat transfer units, (NtG)III = (T2 – TGB)/(∆T)m = (135 – 35)/14 = 0.126
24
ii. Zone II
In order to calculate (NtG)II, we need the value of TGA. This can be obtained by heat
balance.
H’GB = [1.005 + 1.88 x Y] x (133 – 0) + 2256 x YB
= 38.6 kJ/kg. (since YB = 0.015)
H’SA = [0.85 + CPS x X1] x (TSA – 0)
= [0.85 + 4.187 x 0.25] x (41 – 0)
= 104.22 kJ/kg dry solid
Enthalpy balance: LS x (H’SB – H’SA) = GS x (H’GB – H’GA)
329 x (1.2 – 104.22) = 1517 x (38.6 – H’GA)
H’GA = 175.6 kJ/kg
TGA = 102.00°C
Temperature differences at section A, (∆T)A = 102 – 41 = 61°C; (∆T)B = 92.22°C
(∆T)m = (92 – 61)/[ln(92/61)] = 75.54
133 – 102
Number of heat transfer units, (NtG)II = (TGB - TGA)/(∆T)m = = 0.41
75.54
25
Before calculating (NtG)I, let us check the validity of the assumed value of the exit
gas temperature, TG1 = 90°C, by making an energy balance over zone I.
GS (H’G2 – H’G1) = LS (H’S2 - H’S1)
1517 (173.32 – H’G1) = 329 (92.09 – 91.92)
H’G1 = 173
TG1 = 86°C
iii. Zone I
In zone I, (∆T)I = 86 – 80 = 6°C; (∆T)A = 61°C; (∆T)m = (6 – 61)/[ln(6/61)] = 23.7
Number of heat transfer units, (NtG)I = (TGA – TG1)/(∆T)m = 2.53
Total number of heat transfer units NtG = 3.07
c. Length of a transfer unit
The gas mass flow rate, G’ = (16707/3600)/[(π/4) x 22] = 1.477 kg/m2 s
Volumetric heat transfer coefficient, U = 150W/m3 K
Humid heat at the ends: CH2 = 1.005 + 1.88 x 0.015 = 1.033
CH1 = 1.005 + 1.88 x 0.04306 = 1.188
Average humid heat, CH = 1.058 kJ/kg K = 1058 J/kg.K

26
Length of a heat transfer unit, LT = G’CH/Ua = (1.4771 x 1058)/150 = LT =10.42 m
Length of the dryer, L = (NtG) x (LT) = 3.07 x 10.42 = 31.99 m, round off to 32m.
Thus , the length of dryer is 32m and the diameter of the dryer is 2.3m
27
BELT PRESS (BP-101)
Belt press also known as belt press filteris an industrial machine, used for solid/liquid
separation processes, particularly the dewatering of sludges in the chemical industry.in this
proess water is separated from the sludge before the sludge can be dicharged as fertilisers.
F32 W = 513.3 kg/h

F32 S = 798.1 kg/h F33 W = 144.4 kg/h
F33 S = 758.2 kg/h
F34 W = 368.9 kg/h

F34 S = 39.9 kg/h
Figure 1.10 Belt press, BP-101
Design Detail
In belt press, the slurry sludge is dewatered to produce fertilizers. The flowrate of the sludge
is 1311.5 kg/h which is equivalent to 1.311 m3/hr. Based on the details provided by FRC
System International, belt press model PC-7 from FRC can be adapted in this process. The
specification of belt press model PC-7 is shown in table 1.12.
Table 1.12 Specification of bel press model PC-7

Flow rate capacity 0.5 - 4 m3/hr
Effective belt width 600 mm
Effective area 3.3 m2
Weight of the unit 700 kg
Installed power 0.5 hp
Dimension (LxWxH) 2x 1.37x 1.65 m
Source: FRC System International 2018

CHAPTER 1
DETAILED PROCESS DESIGN
1.1 DETAILED DESIGN OF COOLER, C-101
(Designed by: Nuredahtul Faezan binti Mohammad Yusop, A159291)
Total flowrate that enter the cooler, CO-101 is 902.9 kg/h which are water, Methane, Carbon
Dioxide, Carbon Monoxide and Hydrogen.
53a 54
Figure 1.1 Diagram of Cooler C-101
Table 1.1 Physical properties of cooling water and process fluid
Physical Properties Steam Process Fluid

(Tube) (Shell)
Density (kg/m3) 20.09 3.70
Specific heat capacity (kJ/kg ◦C) 1.98 2.19
Viscosity (mNs/m2) 1.9E-05 2.86E-05
Thermal conductivity (W/m ◦C) 0.04082 0.070
Inlet flow rate (kg/hr) 707.76 902.9
Inlet temperature (◦C) 150 492
Outlet temperature (◦C) 350 350
Dimension of Cooler
T1 =T492°C o
1 = 150 C
TT 2=
2 = 350°C
130o
C
T2 = 350°C
t2 = 121oC
o
t1t=
1=110 C
150°C
Figure 1.2 Temperature profile of cooler CO-101
Head load, Q = m Cp ΔT = (902.9/3600) (2.1914) (492-350)

= 78.05 kW
𝑄 78.05
Mass flow rate of steam, ṁ = 𝐶 = (1.984)(350−150) = 0.197 kg/s
𝑝 ∆𝑇
(𝑇1 −𝑡2 )−(𝑇2 −𝑡1 ) (492−350)−(350−150)

Tlm = (𝑇 −𝑡 ) = (492−350) = 169.35 ᵒC
𝑙𝑛 1 2 𝑙𝑛
(𝑇2 −𝑡1 ) (350−150)
𝑇 −𝑇 492−350 𝑡 −𝑡 350−150
R = 𝑡1−𝑡2 = 350−150 = 0.71 S = 𝑇2 −𝑡1 = 492−150 = 0.58
2 1 1 1
By choosing 2 pass shell which gives,
Ft = 0.7
Tm = Ft Tlm = (0.7) (169.35) = 118.54ᵒC
From Figure 12.1, assuming U = 100 W/ m2 ᵒC (Towler & Sinnot 2013)
𝑄 78.055𝑥103
Provisional area, A = 𝑈𝑇 = (100)(118.54) = 6.58 m2
𝑚
Choose internal diameter of 16 mm, outer diameter of 20 mm and length of 1.78 m as well as
carbon steel as the material.
Area of one tube = 𝜋𝑑𝐿 = 𝜋(20 𝑥10−3 )(1.78) = 0.11 m2
𝑃𝑟𝑜𝑣𝑖𝑠𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 6.58

Number of tube, Nt = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒 = 0.11 ≈ 58 tubes
Tube
150+350
Mean Temperature = = 250 ℃
2
Tube cross sectional area = 𝜋𝑟 2=π (16)2/4 = 201.1 mm2

58
Tube per pass = = 29
2
Total flow area, A = Number of tube per pass x Tube cross sectional area
= (29)(201.1x10^-6) = 0.005832 m2
𝑚 0.197
Tube velocity, ut = 𝜌𝐴 = (20.09)(0.005832) = 1.68 m/s
𝜌𝑢𝑑𝑒
Re = = 2.84E+04
𝜇
𝐶𝑝 𝜇
Pr = = 0.9235
𝑘𝑓
L/di = 111.25
According to figure 12.23 of Towler & Sinnot 2013,
jh = 0.0038;
Heat transfer coefficient, hi = 268.21W/m2 ᵒC
Shell
Use square pitch,

Tube pitch, pt = 1.25do =1.25 (20) = 25 mm
With K1 = 0.156, n1 = 2.291 from Table 12.4 of Towler & Sinnot 2013
1 1
𝑁 58
Bundle diameter, Db = 𝑑𝑜 (𝐾𝑡 )𝑛1 = (20)(0.156)2.291 = 264.82 mm
1
Use a pull-through floated head type,

According to Figure 12.10 of Towler & Sinnot 2013, bundle diametrical clearance = 89
mm
Shell diameter, Ds = Db + bundle diametrical clearance = 264.82+ 89 = 353.82 mm
𝐷𝑠 642.58
Baffle spacing, lb = = = 128.52 mm
5 5
1.1
Equivalent diameter, de = (𝑝𝑡 2 − 0.917𝑑𝑜 2 )= 14.2 mm
𝑑𝑜
(𝑝𝑡 −𝑑𝑜 )𝐷𝑠 𝑙𝑏
Area of cross flow, As = = 0.005007 m2
𝑝𝑡
𝑀
Shell velocity, us = 𝐴𝑠 = 50.087 kg/sm2
𝜌𝑢𝑑𝑒
Re = = 24911.15
𝜇
𝐶𝑝 𝜇
Pr = = 0.8980
𝑘𝑓
Choose 25 per cent baffle cut, from Figure 12.29 of Towler & Sinnot 2013,
jh = 0.0038
ℎ𝑖 𝑑𝑒 1
= 𝑗ℎ 𝑅𝑒𝑃𝑟 3
𝑘𝑓
Heat transfer coefficient, hs = 448.0938 W/m2 ᵒC
Overall Coefficient
Thermal conductivity of carbon steel = 50 W/m. ᵒC

Taking fouling coefficient from Table 12.2 where, hod = 5000 W/m2.ᵒC and hid = 5000
W/m2.ᵒC
𝑑
1 1 1 𝑑𝑜 ln( 𝑜 ) 𝑑 1 𝑑 1
𝑑𝑖 𝑜 𝑜
= + + + +
𝑈𝑜 ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑤 𝑑𝑖 ℎ𝑖 𝑑𝑖 ℎ𝑖𝑑
Uo = 135.38 W/m2. ᵒC
The different between overall coefficient and initial assumed value is 26.13% which is in
between 0 to 30%, thus it is acceptable.
Pressure Drop (Tube)
According to Figure 12.24, jf = 0.0038 (Towler & Sinnot, 2013)

𝐿 𝜌𝑢𝑡 2
Pressure drop, ΔP = 𝑁𝑝 [8𝑗𝑓 (𝑑 ) + 2.5]
𝑖 2
= 333.0669 N/m2
= 0.04831 psi
Pressure Drop (Shell)

𝐷 𝐿 𝜌𝑢2
Pressure drop, ΔP = 8𝑗𝑓 ( 𝑑𝑆 )(𝑙 )
𝑒 𝐵 2
= 76568.97 N/m2
= 11.1054 psi
Since the pressure drop for shell and tube is low thus the design for cooler (CO-101) is
satisfied.
Summary of Design
Parameter Value
Tube Side
Square pitch
Number of tubes 58
Shell Side
Baffle cut (%) 25
1.2 DETAILED DESIGN OF HEAT EXCHANGER, HE-103
(Designed by: Nuredahtul Faezan binti Mohammad Yusop, A159291)
Total flowrate that enter the Heat Exchanger, HE-103 is 1168.9 kg/h which are water, Methane,
Carbon Dioxide, Carbon Monoxide and Hydrogen.
61b
41d 41e
61
Figure 1.3 Diagram of Heat Exchanger (HE-103)
Table 1.3 Physical properties of cooling water and process fluid
Physical Properties Steam Process Fluid

(Tube) (Shell)
Density (kg/m3) 1.22 297.76
Specific heat capacity (kJ/kg ◦C) 0.72 2.7937
Viscosity (mNs/m2) 2.0E-05 6.24E-05
Thermal conductivity (W/m ◦C) 0.00237 0.1887
Inlet flow rate (kg/hr) 11338.56 1168.9
Inlet temperature (◦C) 30 250
Outlet temperature (◦C) 90 100
Dimension of Heat Exchanger
T1 =T250°C o
1 = 150 C
TT 2=
2 = 100°C
130o
C
T2 = 90°C
t2 = 121oC
o
t1t=
1=110 C
30°C
Figure 1.4 Temperature profile of heat exchanger HE-

103
Head load, Q = m Cp ΔT = (1168.9/3600) (2.7937) (250-100)
= 136.07 kW
𝑄 136.07
Mass flow rate of steam, ṁ = 𝐶 = (0.72)(90−30) = 3.1497 kg/s
𝑝 ∆𝑇
(𝑇1 −𝑡2 )−(𝑇2 −𝑡1 ) (250−90)−(100−30)

Tlm = (𝑇 −𝑡 ) = (250−90) = 108.87 ᵒC
𝑙𝑛 1 2 𝑙𝑛
(𝑇2 −𝑡1 ) (100−30)
𝑇 −𝑇 250−100 𝑡 −𝑡 90−30
R = 𝑡1−𝑡2 = = 2.5 S = 𝑇2 −𝑡1 = 250−30 = 0.2727
2 1 90−30 1 1
By choosing 2 pass shell which gives,
Ft = 0.85
Tm = Ft Tlm = (0.85) (108.87℃) = 92.54ᵒC
From Figure 12.1, assuming U = 50 W/ m2 ᵒC (Towler & Sinnot 2013)
𝑄 136.07𝑥103
Provisional area, A = 𝑈𝑇 = = 29.41 m2
𝑚 (50)(92.54)
Choose internal diameter of 16 mm, outer diameter of 20 mm and length of 1.78 m as well as
carbon steel as the material.
Area of one tube = 𝜋𝑑𝐿 = 𝜋(20 𝑥10−3 )(1.78) = 0.11 m2
𝑃𝑟𝑜𝑣𝑖𝑠𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 29.41

Number of tube, Nt = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒 = ≈ 262 tubes
0.11
Tube
90+30
Mean Temperature = = 60 ℃
2
Tube cross sectional area = 𝜋𝑟 2=π (16)2/4 = 201.1 mm2

262
Tube per pass = = 131
2
Total flow area, A = Number of tube per pass x Tube cross sectional area
= (131) (201.1x10^-6) = 0.026343 m2
𝑚 3.1497
Tube velocity, ut = 𝜌𝐴 = (1.222)(0.026343) = 97.84 m/s
𝜌𝑢𝑑𝑒 1.22(97.84)(16𝑥10−3 )
Re = = =9.57E+04
𝜇 2𝑥105
𝐶𝑝 𝜇 (0.72𝑥103 )(2𝑥10−5 )
Pr = = = 6.0741
𝑘𝑓 0.00237
L/di = 111.25
According to figure 12.23 of Towler & Sinnot 2013,
jh = 0.00283
Heat transfer coefficient, hi = 72.74w/m2 ᵒC
Shell
Use triangular pitch,

Tube pitch, pt = 1.25do =1.25 (20) = 25 mm
With K1 = 0.249, n1 = 2.207 from Table 12.4 of Towler & Sinnot 2013
1 1
𝑁 262
Bundle diameter, Db = 𝑑𝑜 (𝐾𝑡 )𝑛1 = (20)(0.249)2.207 = 468.12 mm
1
Use a pull-through floated head type,

According to Figure 12.10 of Towler & Sinnot 2013, bundle diametrical clearance = 90
mm
Shell diameter, Ds = Db + bundle diametrical clearance = 468.11+ 90 = 558.12 mm
𝐷𝑠 558.12
Baffle spacing, lb = = = 111.6237 mm
5 5
1.1
Equivalent diameter, de = (𝑝𝑡 2 − 0.917𝑑𝑜 2 )= 14.2 mm
𝑑𝑜
(𝑝𝑡 −𝑑𝑜 )𝐷𝑠 𝑙𝑏
Area of cross flow, As = = 0.01246 m2
𝑝𝑡
𝑀
Shell velocity, Gs = 𝐴𝑠 = 26.06 (kg/s)m2
𝐺𝑠𝑑𝑒 26.06(16𝑥10−3 )
Re = = =5930
𝜇 6.24𝑥105
𝐶𝑝 𝜇 (2.7937𝑥103 )(6.24𝑥10−5 )
Pr = = =0.9235
𝑘𝑓 0.1887
Choose 25 per cent baffle cut, from Figure 12.29 of Towler & Sinnot 2013,
jh = 0.0038
ℎ𝑖 𝑑𝑒 1
= 𝑗ℎ 𝑅𝑒𝑃𝑟 3
𝑘𝑓
Heat transfer coefficient, hs = 614.18 W/m2 ᵒC
Overall Coefficient
Thermal conductivity of carbon steel = 50 W/m. ᵒC

Taking fouling coefficient from Table 12.2 where, hod = 5000 W/m2.ᵒC and hid = 5000
W/m2.ᵒC
𝑑
1 1 1 𝑑𝑜 ln( 𝑜 ) 𝑑 1 𝑑 1
𝑑𝑖 𝑜 𝑜
= + + + +
𝑈𝑜 ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑤 𝑑𝑖 ℎ𝑖 𝑑𝑖 ℎ𝑖𝑑
Uo = 51.795 W/m2. ᵒC
The different between overall coefficient and initial assumed value is 3.47% which is in
between 0 to 30%; thus it is acceptable.
Pressure Drop (Tube)

𝐿 𝜌𝑢𝑡 2
Pressure drop, ΔP = 𝑁𝑝 [8𝑗𝑓 (𝑑 ) + 2.5]
𝑖 2
= 58400.14 N/m2
= 8.4680 psi
Pressure Drop (Shell)

𝐷 𝐿 𝜌𝑢2
Pressure drop, ΔP = 8𝑗𝑓 ( 𝑑𝑆 )(𝑙 )
𝑒 𝐵 2
= 314.45 N/m2
= 0.046 psi
Since the pressure drop for shell and tube is low thus the design for Heat Exchanger (HE-
103) is satisfied.
Summary of Design
Table 1.4 Design specification of HE-103
Parameter Value
Tube Side
Triangular pitch
Number of tubes 262
Shell Side
Baffle cut (%) 25
1.3 DETAILED DESIGN OF OTHER EQUIPMENT
Calculation of the other Heat Exchanger are the same by using formula as Cooler CO-101 and
Heat Exchanger H-103. Summarize detail design are shown in table below for Cooler CO-102,
Cooler CO-103, Cooler CO-104, Cooler CO-105, Cooler CO-106, Heater H-101 and Heat
Exchanger HE-101.
Parameter Value
(W/m2 ◦C)
Tube Side
Triangular pitch
Number of tubes 178
Shell Side
Baffle cut (%) 25
Parameter Value
(W/m2 ◦C)
Tube Side
Triangular pitch
Number of tubes 30
Shell Side
Split ring floated head type
Baffle cut (%) 25
Parameter Value
(W/m2 ◦C)
Tube Side
Triangular pitch
Number of tubes 2
Shell Side
Baffle cut (%) 25
Parameter Value
(W/m2 ◦C)
Tube Side
Triangular pitch
Number of tubes 5
Shell Side
Baffle cut (%) 25
Table 1.9 Design specification of H-102
Parameter Value
(W/m2 ◦C)
Tube Side
Triangular pitch
Number of tubes 82
Shell Side
Baffle cut (%) 25
Table 1.10 Design specification of HE-102
Parameter Value
(W/m2 ◦C)
Tube Side
Triangular pitch
Number of tubes 326
Shell Side
Baffle cut (%) 25
CHAPTER I
DETAILED DESIGN OF DISTILLATION COLUMN (C-101)
1.1 INTRODUCTION
Distillation column is a unit operation used to separate components which have different
volatility by using boiling point as a reference. In C-101, the feed contains methanol
and water. The function of C-101 is to separate methanol from water to increase the
purity of final product. Methanol is identified as the light key component (LK) while
water as the heavy key (HK) component since methanol has lower boiling point
compared to water. Figure 1.1 shows distillation column C-101 with its operating
condition tabulated in Table 1.1. Table 1.2 shows the flow rate of each stream
connecting to the column.
69 CO-104 Distillate
RD-101 70
66 P-107
Feed
Bottom
67 68
C-101
H-102
Figure 1.1 Distillation Column C-101

2
Table 1.1 Operating condition of distillation column C-101

Parameter Temperature (°C) Pressure (bar)
Feed 50 28
Distillate 75 1.5
Condensate 80 1.5
1.2 MASS BALANCE OF DISTILLATION COLUMN
The material balance of C-101 is obtained and tabulated in Table 1.2.
Table 1.2 Flow rate of distillation column C-101

Component Feed flow rate (kg/h) Distillate flow rate Bottom flow rate (kg/h)
(kg/h)
Water 235.9 0.1 235.9
Methanol 175.0 150.3 24.6
TOTAL 410.9 150.4 260.5
1.3 TYPE OF TRAY
The type of tray that has been used in this distillation column is sieve tray column
because sieve tray column has good efficiency due to its minimum back mixing. Besides
that, the cost for sieve tray is relatively low.
1.4 MATERIAL OF CONSTRUCTION
The pressure vessel design codes and standards include lists of acceptable materials, in
accordance with the appropriate material standards. Since flash tank deals with
relatively clean fluids which is free of corrosive and erosive components, hence a
carbon steel SA-516 is selected as construction material.
3
1.5 MCCABE THIELE METHOD
Mc-Cabe-Thiele method is used to design the distillation column.
Assumptions:
 Constant molar overflow

 There is no any chemical reaction
 There are no any mass generation, mass accumulation and mass generation
1.6 CALCULATION OF AMOUNT OF DISTILLATE AND BOTTOM PRODUCT
Assumptions:
 At steady state there are no any material losses, material accumulation and
material generation.
 There is no any chemical reaction inside the column
Overall material balance:
F=D+W
18.85 = D + W
Material balance:
Fx = Dx + Wx
18.85(0.29) = D(0.9919) + W(0.0442)
Solving above two equations:
D = 8.054 kmol/hr
W = 10.796 kmol/hr
4
1.7 EQUILIBRIUM DATA OF METHANOL AND WATER MIXTURE
Table 1.3 Methanol water equilibrium data
Liquid Vapour T(◦C)
0 0 100
0.1 0.42 87.7
0.2 0.58 81.7
0.3 0.66 78
0.4 0.73 75.3
0.5 0.78 73.1
0.6 0.82 71.2
0.7 0.87 69.3
0.8 0.91 67.6
0.9 0.96 66
1 1 64.5
Temperature composition diagram of methanol/water

100
95
90
Temperature (˚C)
85
80
Vapour
75
Liquid
70
65
60
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Methanol composition
Figure 1.2 Temperature composition diagram of methanol/water

5
1.8 CALCULATION OF MINIMUM REFLUX RATIO
1.8.1 Drawing q Line
Feed is at saturated liquid condition; therefore according to q line equation q value

should be 1. Therefore,
q=1
1.9 CALCULATION OF OPERATING REFLUX RATIO
For many systems the optimum selection of the design reflux ratio will lie between 1.2
to 1.5 times the minimum reflux ratios. Assume operating reflux ratio is 1.25 of
minimum reflux ratio.
𝑅𝑚𝑖𝑛
= 0.4872
𝑅𝑚𝑖𝑛 + 1
𝑅𝑚𝑖𝑛 = 0.95
R = 1.25 × 𝑅𝑚𝑖𝑛
R = 1.25 × 0.95
R = 1.1875
1.10 CALCULATION OF ACTUAL NUMBER OF STAGES REQUIRED

𝑅
Slope of top operating line = 𝑅+1
1.1875
= 1.1875+1
= 0.5429
Therefore TOL equation:
y = 0.5429x + 0.45
6
Vapour-Liquid Equilibrium Curve
Molar fraction of methanol in vapour
Molar fraction of methanol in liquid
Figure 1.3 Vapour liquid equilibrium curve
According to Figure 1.3, the vapour- liquid equilibrium curve counts number of
theoretical plates.
Total number of stages = 15
There are total condenser and partial reboiler. Total condenser does not act as
equilibrium stage, but partial reboiler acts as equilibrium stage. So, reboiler stage need
to reduce from total theoretical stages.
Number of theoretical stages required = 15 – 1
= 14
1.11 CALCULATION OF LIQUID AND VAPOUR AMOUNTS IN BOTH SECTIONS

1.11.1 Rectifying Section
𝐿𝑜
𝑅= 𝐷
1.1875 = 𝐿𝑜 /8.054
𝐿𝑜 = 9.564 𝑘𝑚𝑜𝑙/ℎ𝑟
According to constant molar overflow:
Ln = Lo = 9.564 kmol/hr
7
Material balance:
Vn = Lo + D
Vn = 9.564 + 8.054
Vn = 17.618 kmol/hr
1.11.2 Stripping Section
According to given data, feed is at saturated liquid condition therefore all feeding
liquids join with stripping section liquid.
Lm = F + Ln
Lm = 18.85 + 9.564
Lm = 28.414 kmol/hr
Vm = Vn
Vm = 17.618 kmol/hr
Table 1.4 Density of mixture
Temperature (◦C) Density of liquid mixture (kg/m3) Density of vapour mixture (kg/m3)
77 892.15 1.45
65 761.12 1.11
100 953.12 0.74
1.11.3 Rectifying Section Densities
Rectifying section is operating in between 65˚C -77˚C. Therefore at the average

temperature, density values can be calculated.
Liquid density of rectifying section, ρL = (761.12 + 892.15)/2
ρL = 826.6 kg/m3
Vapour density of rectifying section, ρV = (1.11 + 1.45)/2
ρV = 1.28 kg/m3
8
1.11.4 Stripping Section Densities
Stripping section is operating in between 77˚C - 100˚C. Therefore at the average

Similarly;
Liquid density of rectifying section, ρL’ = (892.15 + 953.12)/2
ρL’ = 922.64 kg/m3
Vapour density of rectifying section, ρV’ = (1.45 + 0.74)/2
ρV’ = 1.095 kg/m3
1.11.5 Diameter Of Rectifying Section
𝐿 𝜌𝑉
𝐹𝐿𝑉 = √
𝑉 𝜌𝐿
9.564 1.28
𝐹𝐿𝑉 = √
17.618 826.6
𝐹𝐿𝑉 = 0.0214
Assume tray spacing = 0.45m
According to flooding velocity, sieve plates graph,
K1 = 0.084
The flooding velocity can be estimated from the correlation given by Fair.
𝜌𝐿 − 𝜌𝑉
𝑈𝑓 = 𝐾1 √
𝜌𝑉
826.6 − 1.28
𝑈𝑓 = 0.084√
1.28
𝑈𝑓 = 2.13 𝑚/𝑠
Assume 80% flooding condition; Ua = 0.8Uf
Ua = 0.8 × 2.13
Ua = 1.71 m/s
9
Average molecular weight of the mixture assuming 50% methanol
= 32 × 0.5 + 18 × 0.5
= 25 kg/kmol
Vn = 17.618 × 25/(1 × 3600)
Vn = 0.122 m3/s
𝑉𝑛
= 𝑈𝑎
𝐴𝑛
0.122
𝐴𝑛 =
1.71
𝐴𝑛 = 0.0717𝑚2
An = Ac – Ad
Assume Ad = 12% of Ac
An = Ac – 0.12Ac
An = 0.88Ac
0.0717 = 0.88 × Ac
Ac = 1.85 m2
𝜋𝐷𝑐2
𝐴𝑐 =
4
𝜋𝐷𝑐2
1.85 =
4
Dc = 1.534 m
Therefore, column diameter of rectifying section is 1.534m.
1.11.6 Diameter Of Stripping Section
This is similar to rectifying section:
28.414 1.095
𝐹𝐿𝑉 = √
17.618 922.6
10
𝐹𝐿𝑉 = 0.0556
Assume tray spacing = 0.45 m
K1 = 0.08
922.64 − 1.095
𝑈𝑓 = 0.08√
1.095
𝑈𝑓 = 2.32 𝑚/𝑠
Assume 80% flooding condition;
Ua = 0.8 × 2.32
Ua = 1.86 m/s
There is no vapour amount changes in stripping section compared to rectifying section.

Therefore,
Vm = 0.122 m3/s
𝑉𝑛
= 𝑈𝑎
𝐴𝑛
0.122
𝐴𝑛 =
1.86
𝐴𝑛 = 0.0659 𝑚2
Therefore according to above derived equations:
An = 0.88Ac
Ac = 1.75 m2
Dc = 1.49 m
Therefore stripping section column diameter is 1.49m.
1.12 CALCULATION OF HOLE DIAMETER AND AREA
Hole size less than 6.5 mm. Entrainment may be greater with larger hole sizes. (Page
No. 568 Coulson & Richardson 6th volume 4th edition).
Therefore hole diameter is considered as 6mm.

11
1.12.1 Number Of Holes In A Tray At Rectifying Section
For a plate, there is one downcomer on the plate and top downcomer also affected to
bottom plate. Therefore, two downcomer areas need to be reduced from the active area.
Aa = Ac – 2Ad
Aa = Ac – (0.12 × 2Ac)
Substituting to above equation,
Aa = 0.0619 m2
Assume holes area is 10% of active area
Ah = 0.1Aa
Total holes area in a tray, Ah = 0.1 × 0.0619
= 0.00619 m2
0.0062
Area of a hole =π× 4
= 2.83 × 10-5 m2
0.00619
Number of hole in a plate = 2.83 × 10−5
= 219
1.12.2 Number Of Holes In A Tray At Stripping Section
All equations are similar to rectifying section calculation:
Aa = 0.0569 m2
Ah = 0.1Aa
Ah = 0.00569 m2
0.00569
= 201
12
1.13 FLOW PATTERN OF RECTIFYING SECTION

9.564 𝑘𝑚𝑜𝑙 25𝑘𝑔 826.6𝑘𝑔
Liquid flow rate of rectifying section = ( 3600 × 𝑘𝑚𝑜𝑙)/( )
𝑠 𝑚3
= 8.035 × 10-5 kg/s
1.14 FLOW PATTERN OF STRIPPING SECTION

28.414 𝑘𝑚𝑜𝑙 25𝑘𝑔 922.6𝑘𝑔
Liquid flow rate of stripping section = ( 3600 × 𝑘𝑚𝑜𝑙)/( )
𝑠 𝑚3
= 2.14 × 10-4 kg/s
1.15 COLUMN EFFICIENCY CALCULATION
“Van Winkle’s correlation” is used to calculate to efficiency of column.
Maximum and minimum temperatures of inside the column are respectively 100˚C and
65˚C. Assume liquid temperature is average temperature of column. Assume properties
of liquid mixture equal to water properties.
100+65
Average temperature of column = 2
= 82.5˚C
Surface tension of liquid at 82.5˚C is calculated according to their molar basis of feed.
σL = 0.0513 N/m
For Uv, maximum Ua value from both sections is taken.
Uv = Ua
Uv = 1.86 m/s
μL = 4.862 × 10-4 Ns/m2
Since there are both vapour and liquid densities, the average density is taken.
ρV = 1.19 kg/m3
ρL = 874.62 kg/m3
DLK = 5 × 10-9 m2/s
Weir height, hw = 45mm
Fractional area calculation:

13
𝑎𝑟𝑒𝑎 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠
FA = Fractional Area = 𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑙𝑢𝑚𝑛 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
0.005691
FA = 0.625
FA = 0.00911
Surface tension number calculation:

𝜎𝐿
𝐷𝑔 =
𝜇𝐿 × 𝑈𝑣
0.0513
𝐷𝑔 =
0.0004862 × 1.86
Dg = 56.83
Liquid Schmidt number calculation:

𝜇𝐿
𝑆𝑐 =
𝜌𝐿 × 𝐷𝐿𝐾
0.0004862
𝑆𝑐 =
874.62 × 5 × 10−9
Sc = 111
Reynolds number calculation:
ℎ𝑤 × 𝑈𝑣 × 𝜌𝑣
𝑅𝑒 =
𝜇𝐿 × 𝐹𝐴
0.045 × 1.86 × 1.19

𝑅𝑒 =
0.0004862 × 0.00911
Re = 22457.24
Therefore,
𝐸𝑚𝑣 = 0.07𝐷𝑔0.14 𝑆𝑐 0.25 𝑅𝑒 0.08
Emv = 0.07 × 56.830.14 × 1110.25 × 22457.240.08
Emv = 0.89 = 89%
Efficiency of column = 89%

14
Number of theoretical stages required = 14
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠

𝐸𝑚𝑣 =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠
14
0.89 =
Number of actual stages = 15.7
Therefore, number of actual stages required = 16
1.17 CALCULATION OF HEIGHT OF THE COLUMN
Assume thickness of a plate is 5mm.
Total thickness of trays = 0.005 × 16
= 0.08 m
Height of column, Hc = (Nact – 1)Hs +∆H + plate thickness
= (16 – 1) × 0.45 + 1 + 0.08
= 7.69 m
Therefore, height of column is 7.69m.
1.18 CALCULATION OF FEED TRAY LOCATION
Assume plate numbers are counted from top to bottom.
According to vapour-liquid equilibrium curve, feed tray location can be found.
Feed composition of methanol is 0.29. This value is at 11th plate (theoretical) of the
column. To calculate the actual feed tray location, the value need to be divided with
column efficiency.
11
Therefore feed tray location = 0.89
= 12.33
= 13th plate
15
1.19 SUMMARY OF DESIGN SPECIFICATION
The design of distillation column C-101 is summarized in table below:

No. of stages 15
Height, m 7.69
Feed location 13th
CHAPTER II
DETAILED DESIGN OF REFLUX DRUM (RD-101)
2.1 INTRODUCTION
A reflux drum is to hold the condensed vapour from the top of the column so that liquid
which is known as reflux can be recycled back to the column. Methanol which is in
vapour phase moves up the column, and as it exits the top of the column, it is cooled by
a condenser. The condensed liquid which is methanol is stored in the reflux drum RD-
101. Some of this liquid is recycled back to the top of the column and this is called
the reflux. The methanol that is removed from the system is known as
the distillate or top product of the distillation column. Figure 2.1 shows reflux drum
RD-101 with its operating conditions tabulated in Table 2.1.
69
CO-104
RD-101
70
Figure 2.1 Reflux Drum RD-101
Table 2.1 Operating condition of reflux drum RD-101

Inlet 75 1.5
Outlet 68 1.2
17
2.2 MASS BALANCE OF REFLUX DRUM
The material balance of RD-101 is obtained and tabulated in Table 2.2.
Table 2.2 Flow rate of reflux drum RD-101

Component Inlet flow rate (kg/h) Outlet flow rate (kg/h)
Water 0.1 0.1
Methanol 150.3 150.3
2.3 DESIGN CALCULATION
Assumptions:
 Hold-up time for reflux drum is 5 minutes

 Length to diameter ratio is 3
 Reflux drum is half full
 The reflux drum is horizontal
The reflux ratio calculated using McCabe-Thiele method is 1.1875.
Product flow rate = 150.4 kg/hr
Reflux flow rate = Reflux ratio × Product flow rate
= 1.1875 × 150.4
= 178.6 kg/hr
Hold-up liquid in drum = Hold-up time × Reflux flow rate

5
= 60 × 178.6
= 14.88 m3
Volume of drum = 14.88 × 2
= 29.77 m3
3 4𝑉
Diameter of drum =√
3𝜋
3 4 29.77
= √3 𝜋
18
= 2.33 m
Length of drum = Diameter × Length:Diameter
= 2.33 × 3
= 6.99 m
The design of reflux drum RD-101 is summarized in table below:
Table 2.3 Reflux drum RD-101 design summary

Feed pressure, bar 1.5
Reflux ratio 1.188
Diameter, m 2.329
Length, m 6.986
224
APPENDIX C
MECHANICAL DESIGN
I) UPFLOW ANAEROBIC BLANKET SLUDGE REACTOR (UASB)
II) MOVING BED BIOFILM REACTOR (MBBR)
III) PACKED BED REACTOR
IV) HEAT EXCHANGER (COOLER)
V) PHASE SEPARATOR
VI) DISTILLATION COLUMN

CHAPTER I
DETAILED DESIGN OF UPFLOW ANAEROBIC SLUDGE BLANKET
1.1 GENERAL INFORMATION ON UPFLOW ANAEROBIC SLUDGE

BLANKET
Upflow anaerobic sludge blanket (UASB) reactor is a column type tank reactor that will
be used in anaerobic process. It is widely used in industrial wastewater treatment in
chemical and sewage industries (Lier et al. 2015). The detailed design of UASB
demand (COD) removal (Ohimain et al. 2017). The volume required to contain POME
for 10 days is 5760 m3. To cater a large volume of POME, three identical UASB is
used. Each UASB with a volume of 2304 m3 with 20% extra as safety factor. The
calculation for UASB are done according to the formula by Bal et al. 2010
Information Value
Inlet (m3/h) 36
3
Inlet (m /day) 576
HRT (days) 10
HRT (hours) 240
3
Volume (m ) 5760
Number of Tanks 3
3
2
1.2 DIMENSION OF UASB
Since the designed UASB is a column type tank reactor, the ratio of H:D used is 3:1
D 2
2
D 2
V = Hπr = Hπ( ) = (3D)π( )
2 2
3 4V 3 4(2304)
D=√ =√ = 9.924 m
3π 3π
H = 29.77 m
1.3 VOLUMETRIC HYDRAULIC LOAD
Q
VHL = where Q = inlet volumetric flowrate of the UASB (m3/day)
V
576 m3 /day
VHL = = 0.25 m3 / m3 .day
2304 m3
day
1.4 ORGANIC LOADING RATE
daily to the UASB per unit volume of UASB. The influent substrate concentration (So)
is 51 kg COD/m3 (Zainal et al. 2017). The calculation for Lv is shown below.

Lv = =
V 2304 m3
3
Lv = 12.75 kg COD/m3.day
Thus, the organic loading rate of the organic material into the UASB is 12.75 kg/m3 per
day.
1.5 SLUDGE LOADING RATE
The sludge loading rate (Ls) referred to the amount of organic matter that is supplied to
the UASB per unit of biomass in the UASB. The total volatile solid in POME (M) is 34
kgVS/m3 (Zainal et al. 2017). The calculation for Ls is shown below.

Ls = =
M 34 kgVS/m3
Lv = 864 kg COD/kg VS.day
1.6 UPFLOW VELOCITY
below.
Q
ν= where Q = inlet volumetric flowrate of the UASB (m3/hr)
A
36
ν= 9.924 2
= 0.4652 m/hr
(π)( 2 )
4
1.7 UASB REACTOR EFFICIENCY
1.7.1 Chemical Oxygen Demand (COD)
ExSo
Ceff = So - where Ceff = COD at the effluent (kg COD/m3)
100
(96.5)(51)
Ceff = 51 - = 1.785 kg COD/m3 = 1785 mg COD/L
100
Thus, the COD outlet of the UASB is 1785 mg COD/L.
1.7.2 Biochemical Oxygen Demand (BOD)
1.7.3 Total Suspended Solid (TSS)
Ex = COD removal
efficiency TSS = 102(96.5)(240)-0.24
= 2641.66 mg/L
Thus, the TSS outlet of the UASB is 2461.66 mg COD/L.

5
1.8 SLUDGE PRODUCTION
Ps = (0.2) (51) = 10.2 kg TSS/day
1.9 GAS SEPARATION SYSTEM
The gas hood will be located at the top of the UASB. The main function of the gas hood
is to collect the biogas. The area of gas hood interface is calculated from the equation
below.
Qg
Kg = where, Kg = biogas release rate (m3gas/m2.hr)
Ai
106.522
5= Ai
106.522
Ai = = 21.304 m2
5
𝐷 2
Ai = π ( 2 )
6
A 21.304
D= 2√ π = 2√ = 5.2 m
π
7
CHAPTER II
MECHANICAL DESIGN OF UPFLOW ANAEROBIC SLUDGE BLANKET
2.1 INTRODUCTION
A pressure vessel any closed vessel with diameter more than 150 mm that can withstand
at the pressure difference more than one bar, which is to be designed to fulfill the
process requirements. Consequently, pressure vessels are be designed to withstand
either internal or external pressure.
2.2 THICKNESS OF UASB AND THE MAXIMUM ALLOWABLE WORKING

PRESSURE (MAWP)
Anaerobic process in our plant occurs in the UASB. The POME from cooling pond will
enter the UASB in which the retention time 10 days. The anaerobic process produces
biogas which will be collected and stored in the gas holder. Three identical UASB (T-
101, T-102 and T-103) will be used to cater large volume of POME. The capacity of
each UASB is 2304 m3.
2.2.1 Material Selection
The operating temperature in UASB is about 37oC while the POME will be pumped
into the UASB at 3 bar. So the design pressure is 3 bar. POME have a pH of 4 which is
acidic but it does not poses corrosive effect towards the tank (Bukhari et al. 2018).
Carbon steel SA-516 grade 70 is selected as the construction material since it has a
lower price than other materials and is available in a wide range of standard forms and
sizes (Sinnott et al. 2013). Iron is the main composition of this material. Carbon steel
8
SA-516 grade 70 have a minimum tensile strength of 70000 psi and maximum thickness
of 205 mm. The maximum allowable stress for carbon steel SA-516 at 37 oC is 17100
psi.
2.2.2 Design Specifications
The mechanical design of UASB is done based on American Society of Mechanical

Engineers (ASME) internal pressure procedure. This is because the operating pressure
or the pressure in side the vessel is assumed to be higher than the atmospheric pressure,
which is higher than 14.7 psi. Figure 2.1 below shows the shape of the commercialized
UASB. Cylindrical shell is chosen to construct a tall column type bioreactor. The
ellipsoidal heads are chosen because it is more economical and domed to reduce
mechanical stresses. The bottom part is conical so that the sludge cleaning work
becomes easy during maintenance.
Figure 2.1 UASB
The UASB is designed with a vertical vessel with 3:1 ellipsoidal head at the top
and the bottom. This UASB is designed under internal pressure, 43.51 psi (3 bar). The
construction material is carbon steel SA-516 grade 70, with corrosion allowance of 4
mm. The design and operating condition for UASB is shown in Table 2.1.
9
Table 2.1 Design and operating Condition in UASB

Condition Values
Operating pressure, Po (bar) 3
Temperature, T (oC) 37
Joint efficiency, E 1.0 (full radiography)
Corrosion allowance, CA (mm) 4
Length 29.77 m
Diameter 9.92 m
2.2.3 Height of each parts
For top part, the ratio of the ellipsoidal head is H:D = 2:1
D
=2
2h
9.92
he =
4
= 2.48 m
For the bottom part, the apex angle for the conical bottom is 40o.
D 9.92
L = tan2 α = tan240
= 5.95 m
For cylindrical shell height,
hc = H − ℎ𝑒 − 𝐿
= 29.77 m – 2.48 m – 5.95 m
= 21.34 m
The height for the ellipsoidal head, cylindrical shell and conical head is tabulated in
Table 2.2.
10
Table 2.2 Dimension of UASB

Dimension Value (m) Value (in) Value (ft)
Vessel Height, H 29.77 1172.05 97.67
Vessel Inside Diameter, Di 9.92 390.55 32.55
Shell Height, Hs 21.34 840.16 70.01
Top head height, he 2.48 97.64 8.13
Bottom head height, L 5.95 234.25 19.52
2.2.4 Design Pressure
Since the operating pressure of UASB is 3 bar which is greater than atmospheric
pressure (Pa > Patm), the UASB were designed as internal pressure. Firstly, the design
pressure for each part of the vessel is calculated by using equation:
PD =PO +0.433h
Where, h = height of each part from top shell
Po = operating pressure
PD = design pressure
h = height (ft)
Hence,
i. Ellipsoidal top head
PD = 43.51 + 0.433 (8.13) = 47.04 psi
ii. Cylindrical shell
PD = 43.51 + 0.433 (8.13 + 70.01) = 77.35 psi
iii. Conical bottom head
PD = 43.51 + 0.433 (8.13 + 70.01 + 19.52) = 85.61 psi
A safety factor about 10% is added to design pressure for safety purpose. The new
design pressure is Pj = 1.10PD and the data is tabulated in the Table 2.3.
11
Table 2.3 New Design Pressure for UASB
Part PD (psi) Pj (psi)

Ellipsoidal Top Head 47.04 51.74
Cylindrical Shell 77.35 85.08
Conicacl Bottom Head 85.61 94.39
2.2.5 Minimum Wall Thickness
The wall thickness formulas for each part of the vessel are from ASME Code UG-32
(d) and UG-27 (c). The maximum allowable stress value, S is from ASME Code given
in Subpart 1 of Section II, Part D.
For top ellipsoidal head:
PD (51.742)(390.72)
Thickness, t = = =0.5912 in
2SE-0.2P 2(17100)(1)-(0.2)(51.741)
For cylindrical shell:

i. Circumferential Stress
PR (85.08)(390.72/2)
Thickness, t= = (17100)(1)-(0.6)(85.08) = 0.9749 in
SE-0.6P
ii. Longitudinal Stress

PR (85.08)(390.72/2)
Thickness, t = = = 0.4855 in
2SE+0.4P (2)(17100)(1)+(0.4)(85.08)
For bottom conical head:
PD (94.39)(390.72)
Thickness, t = = = 1.409 in
2cos α(SE+0.2P) 2cos(40)((17100)(1))-(0.2)(94.39)
Thus, the overall thickness, toverall is determined, which is the highest value of minimum
thickness calculated for each part.
toverall = 1.409 in
= 35.80 mm
After considering the corrosion allowance of 4 mm,

12
t = 35.80+ 4 = 39.80 mm
The closest tnominal of type SA-516 Grade 70 is 40 mm.
tmin = tnominal – CA
= 40 mm – 4 mm
= 36 mm (1.417 in)
The maximum allowable working pressure (MAWP) for a pressure vessel is determined
by calculating every part using internal pressure procedure. The formula of internal
design pressure for each part of the vessel can be found in ASME Code UG-32 part (D)
and UG-27 part (c). By using tmin from the calculation above, the MAWPvessel is
calculated.
For the top ellipsoidal head:
2SEt 2(17100)(1)(1.417 )
MAWPellipsoidal = = = 123.94 psi
D+0.2t 390.72+0.2(1.417 )
Pressure at top = MAWPellipsoidal - PH = 123.94 – 0.433(8.14) = 120.42 psi
For the cylindrical shell:
Circumferential
SEt (17100)(1)(1.417 )
MAWPc = = = 123.49 psi
R+0.6t (195.36)+0.6(1.417 )
Pressure at top = MAWPc - PH = 123.49 – 0.433(78.14) = 89.66 psi
Longitudinal
2SEt 2(17100)(1)(1.417 )
MAWPL = = = 248.78 psi
R-0.4t (195.36)-0.4(1.417 )
Pressure at top = MAWPL - PH = 248.78 – 0.433(78.14) = 214.95 psi

13
For the bottom head conical:
2SEtcosα 2(17100)(1)(1.417 )cos40

MAWPconical = = = 95.22 psi
D-0.8tcosα 390.72-0.8(1.417 )cos40
Pressure at top = MAWPconical - PH = 95.22 – 0.433(97.68) = 52.93 psi
The value of MAWPpart and pressure at top is obtained and tabulated as shown below.
Table 2.4 MAWPpart and pressure at top of UASB
Part of the vessel MAWPpart (psi) Pressure at top, (psi)

Top ellipsoidal head 123.94 120.42
Circumferential 123.49 89.66
Cylindrical shell
Longitudinal 248.78 214.95
Bottom ellipsoidal head 95.22 52.93
The smallest value of pressure at top will be taken as the MAWPvessel as it shows the
maximum allowable pressure at the weakest point on the vessel.
Thus, MAWPvessel = 52.93 psi which is higher than the operating pressure. The design
is acceptable.
2.3 COMBINED LOADING
Besides pressure, a pressure vessel subjected to other loads that can be categorized into
major and subsidiary loads. Hence, it must be designed to withstand the worst
combination of loading without failure. There are the sources of combined loading
which are internal and external pressure, weight loads, wind loads, earthquake (seismic
load), and eccentric loads (Sinnott et al. 2013). All of these are related to primary
stresses and summarized into principal stresses in the end of calculation
2.3.1 Primary Stresses
Primary stresses are due to longitudinal and circumferential stresses, direct stress,
bending stress and torsional shear stress.
14
a. Longitudinal (σL) and circumferential (σh) stresses
PDi
σL =
4t
0.3 (9924)
= = 18.61 N/mm2
4(40)
PDi
σh =
2t
0.3 (9924)
= = 37.22 N/mm2
2(40)
b. Direct stress (σw)
W
σw = where, W = Wv + WI
π (Di+t)t
Wv =240Cv Dm (Hv +0.8Dm )t
Cv = 1.15
Dm = Di + t = 9.924 + 0.04 = 9.964 m
Hv = 24.15 m
t = 40 mm
Hence, Wv = 240(1.15)(9.964)(224.15 +0.8 (9.964))(40)
= 3532708.1 N
W
Direct stress, σw =
π (Di+t)t
3532708.1
=
π (9924+40)40
15
= 2.82 N/mm2 (compressive stress)
c. Bending stresses, σb
M D
σb = ± ( i +t)
I 2 v
M = total bending moment;
Wx2
M=
2
x = Hv = 24.14 m
Deff (including insulation) = Do = Di +2t = 9.964 m
Pw = 1280 N/m2
W = Pw Deff =(1280)(9.964) = 12753.92 N/m
(12753.92)(24.14)2
M= = 3716107.12 Nm = 3.716 x 106 Nmm
2
π π
Iv = (Do 4 - D1 4 ) = (99644 -99244 ) = 7.72 x 1012 mm4
64 64
M Di
Hence, Bending stresses, σb = ± ( 2 +t)
Iv
3.716 x 106 9924

=± 12 ( +40)
7.72×10 2
= ± 0.0024 N/mm2
d. Torsional shear stresses, τ
The torsional shear stresses resulting from torque caused by loads offset from the vessel
axis. These loads will normally be small and can be neglected in preliminary vessel
design.
16
2.3.2 Principal Stresses, σ1 AND σ2
1
σ1 = 2 [σh +σz +√(σh - σz )2 +4τ2 ]
1
σ2 = 2 [σh +σz -√(σh - σz )2 +4τ2 ]
σz (upwind) = 18.61 + 2.82 + 0.0024

= 21.43 N/mm2
σz (downwind) = σL + σW - σb
σz (downwind) = 18.61 + 2.82 - 0.0024

= 21.42 N/mm2
Table 2.5 Primary stresses

Primary stresses Value (N/mm2)
Longitudinal stress, σL 18.61
Circumferential stress, σh 37.22
Direct stress, σw 2.82
Bending stress, σb ± 0.0024
Torsional shear stresses, τ
0
Total longitudinal stress, σz (upwind)
21.43
Total longitudinal stress, σz (downwind)
21.42
1
σ1 = 2 [σh +σz +√(σh - σz )2 +4τ2 ]
1
= 2 [37.22+21.43+√(37.22- 21.43)2 +4(0)2 ]
17
= 37.22 N/mm2
1
σ2 = 2 [σh +σz -√(σh - σz )2 +4τ2 ]
1
= 2 [37.22+21.43-√(37.22- 21.43)2 +4(0)2 ]
= 21.43 N/mm2
1
σ1 = 2 [σh +σz +√(σh - σz )2 +4τ2 ]
1
= 2 [37.22+21.42+√(37.22- 21.42)2 +4(0)2 ]
= 37.22 N/mm2
1
σ2 = [σh +σz -√(σh - σz )2 +4τ2 ]
2
1
= 2 [37.22+21.42-√(37.22- 21.420)2 +4(0)2 ]
= 21.43 N/mm2
2.3.3 Maximum Allowable Stress Intensity (∆σMAX)
Assume σ3 = 0 due to thin walled vessel
σ1 – σ3 = 37.22 – 0
= 37.22 N/mm2

18
σ2 – σ3 = 21.43 – 0
= 21.43 N/mm2
Hence, the maximum allowable stress intensity, (∆σmax) = 37.22 N/mm2
According to ASME Code, maximum allowable stress at temperature 310 K,
S = 117.9 N/mm2
Since, (∆σmax) = 37.22 N/mm2 ˂ S = 117.9 N/mm2, the designed UASB is safe to
operate.
2.3.4 Elastic Stability
E  t 
Critical buckling stress,  c =  
(
3 1− v2 ) R
 p


For steel at ambient temperature, E = 200000 N/mm2 with a safety factor of 12, the
σc = 2 x 104 (t / D0) = 2 x 104 (40 / 9964) = 80.27 N/mm2
(∑ 𝜎)𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 = σb + σw = 0.0024 + 2.82 = 2.8224 N/mm2
Since the value of (∑ 𝜎)𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ˂ σc, the critical value of buckling is not exceeded.
The design of UASB is safe to operate.
(Δσ)max  S and (∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ) < 𝜎𝑐 Therefore, the design is safe.
2.4 VESSEL SUPPORT ANALYSIS
The vessel support must be designed to withstand the weight of the vessel, contents and
any superimposed loads such as wind loads. Support will impose localized loads on the
vessel wall and the design must be checked to ensure resulting stress concentrations are
19
below the maximum allowable design stress. It is also important to allow the ease of
access to the vessel and the fittings for inspection and maintenance (Sinnott et al. 2013).
The UASB does not have any vessel support because the it is directly attached
to the concrete base below. The height of the tank is about 29 m in which supports are
not suitable. The UASB can be bolt to the base on the ground.
2.5 BASE RING AND ANCHOR BOLT DESIGN
The loads carried by the vessel will be transmitted to the foundation slab base ring. The
moment produced by wind and other lateral loads will tend to overturn the pressure
vessel. This will be opposed by the couple set up by the weight of the vessel and the
tensile load of the anchor bolts (Sinnott et al. 2013).
The anchor bolts are assumed to share the overturning load equally and the bolt area
required:
1 4Ms
Ab = [ ]−W
Nb fb Db
Assumptions:
• bolt circle diameter, Db = 10.16 m
• circumference of bolt circle = 31.92 m
• maximum allowable bolt stress, fb = 125 N/mm2
• take number of bolts as 20
20
31.92×1000
Bolt spacing = = 1596 mm
20
Therefore, the bolt spacing is acceptable as it follows the guidelines which is the bolt
spacing must be more than 600mm.
The area of one bolt at the root of the thread, Ab,
The bending moment at the base, Ms = 3719005.17 Nmm
The weight of the vessel, W = 3532708.1 N
1 4Ms
Ab = [ ] -W
Nb fb Db
1 4 (3719005.17 )
Ab = [ ] - 3532708.1
20×125 10160
Ab = 1412.5 mm2
Use M45 bolts with a root area of 353 mm2 is suitable to be used to bolt the UASB
onto the concrete base (Sinnott et al. 2013).
4Ms W
Fb = [ + ]
πD2s πDs
4(3719) 3532708.1
Fb = [ 2+ ]
π x 9.964 π×9.964
Fb = 112900 Nm-1
Fb 1
Lb = ×
fc 103
112900
Lb =
3.5x 103
Lb = 32.26 mm
21
beam:
3𝑓𝑐′
𝑓𝑟
Lr = the distance from the edge of the vessel to the outer edge of the ring, mm
Take Lr = 200 mm,
3𝑓 ′
𝑟
3(3.5)
= 200√ 140
= 54.77 mm
2.6 FLANGED JOINT
Flanged joints are used for connecting pipes and instruments to vessels, for manhole
cover, and for removable vessel heads when ease of access is required. It also used on
the vessel body when it is required to divide the vessel into sections for transport and
maintenance. It can reduce high-stress concentration at the base of the flange by
transferring stress to the adjoining pipe. First, the welding-neck flange is the best flange
for UASB because the liquid flow is high in suspended solid and sludge may cause high
shear and vibration load. Welding-neck flange have high strength and high resistance
to dishing, it is manufactured with a long-tapered hub. The welding-neck flange
diagram is shown in Figure 2.2.
22
Figure 2.2 Diagram of Weld Neck Flange (ASME B16.5)
Next, blind flanges are also used in the UASB. The main function of blind flange
is to seal any end of the piping system. The propose of blind flange in UASB is to cover
the manhole, cleaning or drainage hole and unused inlet or outlet pipe. Figure below
shows the diagram of blind flange.
Figure 2.3 Diagram of Blind Flange (ASME B16.5)

23
2.7 SUMMARY OF MECHANICAL DESIGN OF UASB
By considering the internal pressure for UASB, the mechanical calculation for the Table
2.6.
Table 2.6 Summary for mechanical design of UASB

Shell height
2:1 ellipsoidal head (top), he m 2.48
Cylindrical, hc m 21.34
Conical head (bottom), L m 5.95
Overall minimum thickness of vessel, toverall mm 35.8
Corrosion allowance, CA mm 4
MAWP of vessel psi 52.93
Bending stress, σb N/mm2 0.0024
(37.22 < 117.9)

(2.823 < 80.27)

Actual width required, Lb mm 32.26
Base ring thickness, tb mm 54.77
Blind flange
TOP VIEW OF UASB TOP VIEW OF EFFLUENT OVERFLOW BOX V-NOTCH WEIR OF EFFLUENT
CROSS SECTIONAL VIEW OF UASB
A A B B OVERFLOW BOX
A Stream 11 A
e
Hol
Man
FACULTY OF ENGINEERING AND

BUILT ENVIRONMENT
DEPARTMENT OF CHEMICAL
ENGINEERING AND PROCESS
Stream 12
Stream 12
PRODUCTION OF BIOFLOCCULANT
AND METHANOL FROM POME
B B
MECHANICAL DESIGN OF UPFLOW
ANAEROBIC SLUDGE BLANKET
(UASB)
SUPERVISOR
1) PROF. IR DR. SITI KARTOM
KAMARUDIN
2) PROF. MADYA DR. MASLI
INLET OF CIRCULAR PUMP TOP VIEW OF INLET DISTRIBUTION PIPE IRWAN ROSLI
CROSS SECTIONAL VIEW
SYSTEM 3) HEMAVATHI SILVAMANY
OF BLIND FLANGE
D D
C GROUP
KK 4
GROUP MEMBERS
RAVINKUMAR MANIMARAN A158192
CHEAH CHING WEI A157594
SITI BARAKAH A158482
NUREDAHTUL FAEZAN A159291
12B AFIQ SHAZWAN A158912
SIVA PRIYA A158432
DRAWN BY
RAVINKUMAR MANIMARAN
DATE
23th MARCH 2020
TYPE 05 BLIND FLANGE (EN 1092-1 TYPE 05)
DIMENSION (mm)
DRAWING NOT TO SCALE
UNIT DIMENSION IN MILLIMETER
NO. NOMINAL SIZE A B C D (mm)
CROSS SECTIONAL VIEW OF WELD 12A 800 920 975 44 30
NECK FLANGE 12B 800 920 975 44 30 DESIGN SPECIFICATIONS
Stream 8A
MAN HOLE 1200 1340 1405 60 20
Design Temperature : 37°C
MAN HOLE 1200 1340 1405 60 20 Operating Pressure : 300 kPa
Design Pressure : 365 kPa
Design Thickness : 35.8 mm
12A Corrosion Allowance : 4 mm
Inside Diameter : 9924 mm
Vessel Height : 29770 mm
CLASS 150 WELD NECK FLANGE
C
DIMENSION (mm) Height of cylindrical shell : 21335 mm
NO. NOMINAL SIZE A B C D E F G H I J Height of ellipsoidal head : 2480 mm
Height of conical bottom : 5955 mm
8 150.0 279.4 25.4 215.9 192.0 168.4 154.1 88.9 241.3 12.7 50.8
D D
Stream 8B 8A 300.0 482.6 31.7 381.0 365.3 323.9 304.8 114.3 431.8 16.5 66.0 Material Used : Carbon Steel
Man Hole
8B 300.0 482.6 31.7 381.0 365.3 323.9 304.8 114.3 431.8 16.5 66.0 (SA-516)
Stream 8 11 15.0 88.9 11.2 35.1 30.2 21.3 15.8 47.8 60.5 7.4 29.2
12 150.0 279.4 25.4 215.9 192.0 168.4 154.1 88.9 241.3 12.7 50.8
MBBR REACTOR
1.1 INTRODUCTION
MBBR reactor is an open tank for aeration process in order to produce bioflocculant by
using specialised bacteria which is Bacillus marisflavi. Moving bed biofilm reactor
(MBBR) is an advanced wastewater treatment technology that gives high treatment
efficiency with low operating and maintenance cost and robust operation procedure. The
effectivity of removing up to 90% of chemical oxygen demand and 95% of biological
oxygen demand with nutrients from effluent stream had been proven when there is
sufficient retention time (Jenkins and Sanders 2012). Moreover, the process is based on bio
carriers that will attract the biomass and grow them on the surface (Ødegaard et al. 2000).
Other specialty is that the bio carriers can be used up to 10 years and can be operated
continuously without the need for backwashing, and low head-loss. ((Rusten et al. 1998).
The biofilms that grows on the surface of the bio carriers would suspended throughout the
entire volume of the reactor (Qiqi et al. 2012). Furthermore, MBBR reactor is better than
other aerated reactors such as membrane bioreactor (MBR), activated sludge process (ASP)
and sequencing batch bioreactor (SBBR) in terms of operating cost, efficiency of suspended
solids removal and installation space required. MBBR reactor takes up small space as it can
maximizes surface area through the carriers.
Figure 11.1 Schematic showing the principles of MBBR reactor
Figure 11.2 MBBR carrier
1.2 VESSEL DESIGN FOR MBBR REACTOR, T-105
Vessel design for MBBR reactor are separated into few parts according into its design
specification. Every value and assumptions that have been made are comes with evidence.
MBBR reactor is operating at 1.01 bar with temperature 30oC. The material that will be
used to construct MBBR reactor is poured reinforced concrete grade M30. Concrete been
choose as the construction material because this reactor need to hold up a huge volume of
sludge with 24 hours HRT. The volume of the tank is 979m3 while considering the safety
factor. Concrete is the best material to be choosen as it could hold high volume of sludge
and can winstand a good amount of tensile stress. Mix ratio for cement to sand to aggregate
for this concerete is 1:0.75:1.5. The compressive strength of M30 concrete is 4350psi.
The mechanical design of MBBR reactor is subjected under ASME internal pressure
procedure and EUROCODE 2 for concrete materials. MBBR reactor is lie under internal
pressure because its absolute pressure is higher than atmospheric pressure. MBBR reactor
in an open tank and rectangular in shape. It consist of air diffuser at the bottom of the tank
and MBBR carrier that will be poured before the process start. This tank is embedded on
the floor.
Table 11.1 Operating condition of T-105
Criteria Value
Operating pressure, Po 1 bar
Joint efficiency, E 1 ( full radiography)
Length, L 14.5 m
Width, W 9.79 m
Height, h 6.9 m
1.2.3 Design pressure
Design pressure is calculated by considering the hydrostatic pressure. Design pressure is

calculated using following equation ;
𝑃𝐷 = 𝑃𝑜 + 0.433ℎ
PD = Design pressure, psi
Po = Operating pressure, psi
h = Height, ft
PD = 25.01 psi
1.2.4 Diffuser design
Diffuser design for an aerobic system is considering few aspects such as length of manifold,
number of laterals, size of diffuser hole and etc. Calculation for diffuser design is shown
below.
Known parameters and their values ;
Design air flowrate (Qair,total) = 3672 m3/hr
Min design air flow rate/orifice (Qorifice, min) = 1.6 m3/hr
Max design air flow rate/orifice (Qorifice, max) = 1.75 m3/hr
Reactor length (Lreactor,length) = 14.5 m
Reactor width (Lreactor,width) = 9.79 m
Initial estimates of key design parameter values ;
Manifold length (Lmanifold) = 7961 mm
Grid spacing (Lgrid spacing) = 1820 mm

Grid width (Wgrid) = 2804 mm
Diffuser spacing (Ldiffuser spacing) = 300 mm
Wall spacing (Lwall, length) = 1219 mm
Wall spacing (Lwall,width) = 914 mm
Manifold diameter (Dmanifold) = 366 mm
Orifice spacing (Lorifice spacing) = 38 mm
𝑄𝑎𝑖𝑟,𝑡𝑜𝑡𝑎𝑙
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑖𝑓𝑖𝑐𝑒 = = 8000 𝑜𝑟𝑖𝑓𝑖𝑐𝑒
𝑄𝑜𝑟𝑖𝑓𝑖𝑐𝑒,𝑚𝑎𝑥
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠 𝑝𝑒𝑟 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑 = + 1 = 27(𝑖𝑛𝑡𝑒𝑔𝑒𝑟)
𝐿𝑑𝑖𝑓𝑓𝑢𝑠𝑒𝑟 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
Ldiffuser spacing is typically starts at the largest interval. After considering the size for
the oxygen inlet to the manifold, the Lmanifold is reduced and the total number of laterals for
manifold for this process is 24 laterals. Lorifice spacing is generally taking at the minimum
spacing which is 38mm.
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠 𝑝𝑒𝑟 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑 = 24 × 2 = 48 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠
𝐿𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑙𝑒𝑛𝑔𝑡ℎ − 𝐿𝑤𝑎𝑙𝑙 𝑠𝑝𝑎𝑐𝑖𝑛𝑔,𝑙𝑒𝑛𝑔𝑡ℎ

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑, 𝑙𝑒𝑛𝑔𝑡ℎ = = 2.89
𝑊𝑔𝑟𝑖𝑑 + 𝐿𝑔𝑟𝑖𝑑 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
= 3 (𝑖𝑛𝑡𝑒𝑔𝑒𝑟)
𝐿𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑤𝑖𝑑𝑡ℎ − 𝐿𝑤𝑎𝑙𝑙 𝑠𝑝𝑎𝑐𝑖𝑛𝑔,𝑙𝑒𝑛𝑔𝑡ℎ

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑, 𝑤𝑖𝑑𝑡ℎ = = 1.12
= 1(𝑖𝑛𝑡𝑒𝑔𝑒𝑟)
𝑊𝑔𝑟𝑖𝑑 − 𝐿𝑒𝑛𝑑 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑖𝑓𝑖𝑐𝑒 𝑝𝑒𝑟 𝑙𝑎𝑡𝑒𝑟𝑎𝑙𝑠 = = 30
𝐿𝑜𝑟𝑖𝑓𝑖𝑐𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑖𝑓𝑖𝑐𝑒𝑠 = 30 × 24 × 3 × 1 = 2160
3672
𝑎𝑖𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑝𝑒𝑟 𝑜𝑟𝑖𝑓𝑖𝑐𝑒, 𝑄′𝑜𝑟𝑖𝑓𝑖𝑐𝑒 = = 1.7 𝑚3 /ℎ𝑟
2160
Q’orifice is 1.7 m3/hr which is higher than Qorifice, min and lower than Qorifice,maz. The
value is acceptable as it is in the range for the air flowrate per orifice.
1.75 − 1.7
𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 = × 100 = 2.85%
1.75
Calculated perecentage error is 2.85% and it is lower than 5%. The value is
acceptable.
𝑄𝑎𝑖𝑟 𝑓𝑙𝑜𝑤
𝑎𝑖𝑟 𝑓𝑙𝑜𝑤 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
𝐴𝑚𝑎𝑛𝑖𝑓𝑜𝑙𝑑 × 𝑁𝑔𝑟𝑖𝑑,𝑤𝑖𝑑𝑡ℎ × 𝑁𝑔𝑟𝑖𝑑,𝑙𝑎𝑡𝑒𝑟𝑎𝑙
3672
= = 17309.1 𝑚/ℎ𝑟
22 0.3 2
( 7)×( 2 ) ×3×1
17309.1
𝑎𝑖𝑟 𝑓𝑙𝑜𝑤 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = 4.8 𝑚/𝑠
3600
1.2.5 MBBR carrier design
MBBR carrier is to provide a surface where biofilm can grow. Type of material for MBBR
carrier is high density poly ethylene (HDPE) material. This material been choose because
it have almost same density as water and it could been process easily in MBBR reactor.
Type of biocarrier is PE01 that have 4 room with diameter and height are 12 mm and 9 mm
respectively. By the rule of thumb, 60% of reactor is media and 40% is water. This MBBR
carrier can be used up to 10 years and could have high biofilm load,
1.2.6 Minimum wall thickness
Thickness for concrete wall is been verified based on three criteria. First, wheather the wall
is exterior or interior. In this case, the wal for MBBR reactor is fall to interior wall as is
play less inposrtant role in insulating the reactor from heat and cold. Second, what are the
wall is made of. It is either strong or weak materials. Strong materials need thinner wall
and vice versa. Lastly, the climate. As our production is in Malaysia that have tropical
climates, thinner walls is preferable. Value of thickness for the wall is based on nominal
thickness of concrete wall. Table below show the minimum thickness for few types of
concrete wall.
Table 11.2 Thickness of the wall (G. Peter,1998)
Material Exterior wall Interior wall

Rammed earth 37.5-45cm 37.5-45cm
Adobe brick 30cm 30cm
Poured concrete(not reinforced) 12.5-20cm 12.5-20cm
Poured concrete (reinforced) 12.5cm 12.5cm
Stone 30-37.5cm 25cm
Based on the table above, the minimum thickness for the concrete wall of MBBR
reactor is 12.5 cm.
1.2.7 Pipe support
Type of pipe support for manifold pipe is pipe shoe clamp. It is choosen as it can stop pipes
from rubbing against dissimilar metals. It means that they are able to prevent
electrochemical transfer and galvanic corrosion. It also keep insualtion from grinding
against objects or rupturing. In the same way, they should minimize the movement and
wear that comes with heat transfer.
1.2.8 Combined loading
Combined loading must be designed to winstand the worst combination of loading without
failure. A trial thickness is assumed based on the calculated and resultant stress from all
loads determined to ensure that the maximum allowable stress intensity is not exceeded at
any point.
a. Primary stress
Primary stresses are due to following sources :
i. Longitudinal (σL) and circumferential stresses (σH) due to pressure
P = 0.1 N/mm2
Di = 14500 mm
t = 125 mm
𝑃𝐷𝑖
σL = = 1.8125 𝑁/𝑚𝑚2
4𝑡
𝑃𝐷𝑖
σh = = 3.625 𝑁/𝑚𝑚2
2𝑡
ii. Direct stress (σw)
𝑊
σw =
𝜋 (𝐷𝑖 + 𝑡)𝑡
Where ;
W = Wv + WI ;
𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡
Cv = 1.02 m
Dm = 14.7 m
Hv = 6.9 m
Hence, Wv = 19072 N
Direct stress, σw = 0.0016 N/mm2
iii. Bending stress (σb)
𝑀 𝐷
σb = ± 𝐼 ( 2𝑖 + 𝑡)
𝑣
M = total bending moment
𝑊𝑥 2
𝑀=
2
x = Hv = 6.9 m
Deff = 14.9 m
Pw = 1280 N/m2
W = 19072 N/m
M = 454008.96 Nmm
π
Iv = 64 (Do 4 − D1 4 ) = 2.49 x 1014 mm4
Hence, bending stress, σb = 0.013 N/mm2

iv. Torsional shear stress (τ)
The torsional shear stresses can be neglected in preliminary vessel design because these loads will
normally be small, where, τ = 0
b. Principal stresses, σ1 and σ2
1
σ1 = 2 [σh + σz + √(σh − σz )2 + 4τ2 ]
1
σ2 = 2 [σh + σz − √(σh − σz )2 + 4τ2 ]

σz (upwind) = 1.82 N/mm2

σz (downwind) = 1.79 N/mm2
1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 3.65 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 1.82 N/mm2 = σz (upwind)

1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
= 3.625 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
Assume τ = 0, σ3 = 0.5
σ1 – σ3 = 2.9 N/mm2

σ2 – σ3 = 1.09 N/mm2
Hence, the maximum allowable stress intensity, (∆σmax) = 2.9 N/mm2. According to
EUROCODE 2, maximum allowable stress at temperature 303 oF is S = 30 N/mm2 . Since,
(∆σmax) = 2.9 N/mm2 ˂ S = 30 N/mm2, therefore, the design is safe to use.
d. Elasticity stability
E  t 

31 v2  R
 p


Modulus of elasticity, E of concrete M30 is 5.47 N/mm2.
σc = 355.06 N/mm2
(∑ 𝜎) = 0.015 𝑁/𝑚𝑚2
𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒
Δσmax  S and (∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ) < 𝜎𝑐

Therefore, the design is safe.
1.2.9 Base ring and anchor bolt design
The anchor bolts are assumed to share the overtuning load equallt and the bolt area
required :
1 4Ms
Ab = [ − W]
Nb fb Db
Assumptions that being made for the calculations are as follows :

 bolt circle diameter, Db = 14.5 m
 circumference of bolt circle = 48.5 m
 maximum allowable bolt stress, fb = 30 N/mm2
 take number of bolts = 20 bolts
Bolt spacing = 2278.57 mm. Bolt spacing > 600 mm, therefore the bolt spacing is
acceptable.
The area of one bolt at the root of the thread, Ab.

The bending moment at the base, Ms = 454009 Nm
The weight of the vessel, W = 19072 N
1 4Ms
Ab = [ − W]
Nb fb Db
1 4(90410.92 )
Ab = [ − 6502.24 ]
8 × 125 1.574
Ab = 176.95 mm2

4Ms W
Fb = [ 2
+ ]
πDs πDs
Fb =3166.81 Nm−1
Fb 1
Lb = × 3
fc 10
Lb = 0.9 mm
beam:
3𝑓𝑐′
𝑓𝑟

Take Lr = 76 mm,
= 171 mm
𝐹𝑏
𝑓𝑐′ = = 18.52 N/mm2
171
3𝑓 ′
𝑟
= 103.4 mm
1.2.10 Flanged joint
Flanged joints are used for connecting pipes to the vessels. Type of flanged joints that been
used for this reactor is slip on flanges. It is preferred because of it is the cheapest compared
to other type of flanges, easy adjustment and it is generally used for pipe work. This flanges
joint is located at the inlet and outlet stream. Type B flanges is for inlet and outlet of liquid
and type A flanges is for the gas stream inlet at the bottom of the tank.
Table 11.3 Flanges measurements
Type BC(mm) R(mm) H(mm) T(mm) T1(mm) T2(mm) B(mm) OD(mm) ID(mm)
A 298.45 269.75 246.13 44.45 26.29 42.93 22.35 342.9 221.49
B 431.80 381.00 365.25 55.62 30.27 54.10 25.4 482.6 327.15
1.3 SUMMARY
reactor construction

Vessel width m 9.79
(2.9 < 30)


0.015< 355.06
the ring, Lr
125
16
A 6900 A
9
12
MBBR CARRIER
FACULTY OF ENGINEERING AND BUILT ENVIRONMENT
C CHEMICAL ENGINEERING PROGRAMME
PROJECT TITLE :
1219
B B 14500 B PRODUCTION OF METHANOL AND BIOFLOCCULANT
FROM POME
SIDE VIEW OF MBBR REACTOR 4 38
DRAWING TITLE :
Mechanical Drawing of MBBR Reactor (T-105)
DIFFUSER GROUP KK4
914
2804 25
GROUP MEMBERS :
25 Ravinkumar A/L Manimaran (A158192)
Cheah Ching Wei (A157594)
Siti Barakah Mohd Khairi (A158482)
Sivarpriya A/P Nadaraju (A158432)
365 Afiq Syazwan Mohd Haizollizam (A158912)
Nuredahtul Faezan Mohammad Yusop (A159291)
SUPERVISORS :
Prof IR DR Siti Kartom Kamarudin
300 Prof Madya DR Masli Irwan Rosli
7961 9827
DRAWN BY:
C Siti Barakah Mohd Khairi (A158482)
B 152
300
DETAILS C (pipe shoe clamp) DESIGN SPECIFICATIONS :
Wall Thickness : 125 mm

Design pressure : 1.05 bar
Design temperature : 30°C
Material : Poured reinforced concrete
Grade : M 30
Compressive strength : 4350 psi
366
1820
1219 FLANGES Shell type : Rectangular
ID
14500 H
TOP VIEW OF MBBR REACTOR T2 TEST AND STANDARD :
BC ASME Code Section UG-20
OD T1 ASME Code Section UG-21
ASME Code Section UG-31
ASME Code Section UG-44
EUROCODE 2 Reinforced Concrete Design
EUROCODE 2 Part 1
DRAWING NO:
G-4/MD/T-105/2
DATE:
24th March 2020
24
CHAPTER I
1.1 VESSEL DESIGN FOR METHANOL PACKED BED REACTOR R-102
1.1.1 MATERIAL SELECTION
The operating temperature and pressure are 250oC and 50 bar respectively. Syngas that
consists of carbon monoxide, carbon dioxide, methane and hydrogen which some of
this component are corrosive gas while methanol that been formed are flammable and
extremely corrosive. This chemical needs special construction material to construct the
pressure vessel. Stainless steel SA-240 grade 304 is selected as the construction material
since its excellent resistance to corrosion and is available in a wide range of standard
forms and sizes. This grade is an austenitic chromium alloy which contains 18%
chromium and 8% nickel has the tensile strength (80 ksi) and yield strength (30 ksi).
1.1.2 DESIGN SPECIFICATION
The mechanical design of Packed Bed Reactor R-102 is subjected to ASME internal
pressure procedure. This is because the absolute pressure of the vessel is higher than the
atmospheric pressure, which is higher than 15 psi. Figure 6.2 below shows the shape of
the vessel and its dimension. Cylindrical body is chosen because this is the common
shape of reactor shell. The ellipsoidal heads are chosen for both bottom and top because
it is more economical, suitable for high pressure and domed to reduce mechanical
stresses.
25
Figure 1.1 Dimension of Packed Bed Reactor R-102
The reactor is designed with a vertical vessel with 2:1 ellipsoidal head at the top and the
bottom. The construction material is stainless steel SA-240 grade 304, with corrosion
allowance of 2 mm. The operating condition for reactor R-102 is shown in Table 6.3.
Table 1.1 Operating Condition in Reactor R-102
Condition Values
Joint efficiency, E 0.8 (single welded)
Length 1.283 m
Diameter 0.366 m
26
Table 1.2 The inlet stream for each component
Substance Mass flow rate, kg/h Density, kg/m3

Methanol 1.2 792
Water 136.4 1000
Methane 149.0 0.656
Carbon Monoxide 381.4 1.14
Hydrogen 51.6 0.0899
Carbon Dioxide 449.2 1.98
Total 1168.80
For ellipsoidal height, the ratio of the ellipsoidal head is 2:1

𝐷𝑖
ℎ𝑒 =
4
0.366
= 4
= 0.0.915 m

hc = H − 2he
= 1.283 – 2(0.0915)
= 1.1 m
Table 1.3 Dimension of Reactor R-102

Vessel Height, H 1.283 50.514 4.210
Shell Height, Hs 1.1 43.31 3.61
Top head height, ho 0.092 0.300 3.603
Bottom head height, ho 0.092 0.300 3.603
1.1.3 DESIGN OF BED
Take diameter of bed, Dbed = Di = 0.366 m.
= 0.6 × 1.283 = 0.770 m

27
Catalyst used= Cu/ZnO/Al2O

e(voidage) = 0.285

= 1252.026 N
1.1.4 DESIGN PRESSURE
Since the operating pressure of the reactor (50 bar) is greater than atmospheric pressure
(Pa > Patm), the reactor is designed under internal pressure. Firstly, the design pressure
for each part of the vessel is calculated by using equation:
PD = PO + 0.433h
Where h= height of each part from top shell
Po= operating pressure
h = height (ft)
Hence,
i. Ellipsoidal 2:1 top head, PD = 725.2 + 0.433 (0.300) = 725.33 psi
ii. Cylindrical shell, PD = 725.2 + 0.433 (3.609 + 0.300) = 726.89 psi
iii. Ellipsoidal 2:1 bottom head, PD = 725.2 + 0.433 (3.609 +0.300+ 0.300)
= 727.02 psi
design pressure is Pj = 1.10PD and the data is tabulated in the Table 6.4 below.
28
Table 1.4 New Design Pressure for R-102

Ellipsoidal 2:1 top head 725.33 797.86
Ellipsoidal 2:1 bottom head 727.02 799.72
1.1.5 MINIMUM WALL THICKNESS
The wall thickness formulas for each part of the column are from ASME Code UG-32
PD (797.86)(14.41)
Thickness, t = = =0.410 in
2SE−0.2P 2(17694.60)(0.8)−(0.2)(797.86)
PR (799.58)(14.41/2)
Thickness, t = SE−0.6P = (17694.60)(0.8)−(0.6)(799.58) =0.420 in
For bottom ellipsoidal head:
PD (799.72)(14.41)
Thickness, t = 2SE−0.2P = 2(17694.60)(0.8)−(0.2)(799.72) =0.410 in
thickness calculated for each part
toverall = 0.420 in = 10.70 mm

29
After considering the corrosion allowance of 2mm,
t = 10.70 + 2 = 12.70 mm
The closest tnominal of type SA-240 Grade 304 is13.0 mm.
= 13.0 mm – 2 mm
= 11 mm (0.430 in)
1.1.6 MAXIMUM ALLOWABLE WORKING PRESSURE
The maximum allowable working pressure for any type pressure vessel, MAWP is
determined by calculating every part under internal pressure. The formula of internal
design pressure for each part of the reactor can be found in ASME Code UG-32 part (D)
and UG-27 part (c). By using tmin from the calculation above, the MAWPvessel is
calculated.

2SEt 2(17694.60)(0.8)(0.43)
Internal pressure = D+0.2t = = 845.81 psi
14.41+0.2(0.43)
Static head PH = 0.433 (0.300) = 0.130 psi

MAWPvessel = internal pressure – static head = 845.68 psi
For the bottom head ellipsoidal:

2SEt 2(17694.60)(0.8)(0.43)
14.41+0.2(0.43)
Static head, PH = 0.433 (3.609+ 0.300+ 0.300) = 1.82 psi

30
∴ MAWPvessel = internal pressure – static head = 843.98 psi

SEt (17694.60)(0.8)(0.43)
Internal pressure = R+0.6t = 14.41 = 821.27 psi
( )+0.6(0.43)
2
Static head PH = 0.433 (3.609 +0.300) = 1.69 psi

MAWPvessel= internal pressure – static head = 819.58 psi
The value of internal pressure and MAWPvessel is obtained and the result is shown.
Table 1.5 Internal pressure and MAWPvessel for each part of the reactor R-102
Part of the column MAWPpart (psi) Static head, PH(psi) MAWPvessel (psi)
Top ellipsoidal head 845.81 0.13 845.68
Cylindrical Shell 821.27 1.69 819.58
Bottom ellipsoidal head 845.81 1.82 843.98
By choosing the smallest value, the MAWPvessel is 819.58 psi (56.51 bar)
1.1.7 COMBINED LOADING
Pressure vessel subjected to other loads (major and subsidiary load) in addition to
pressure. Hence, it must be designed to withstand the worst combination of loading
without failure. There are the sources of combined loading which are internal and
external pressure, weight loads, wind loads, earthquake (seismic load), and eccentric
loads (Sinnott 2005). All of these are related to primary stresses and summarized into
principal stresses in the end of calculation.
a. PRIMARY STRESSES
Primary stresses are due to following sources:
(i) Longitudinal (  L ) and circumferential stresses (  H ) due to pressure

(ii) Direct stress (  W )
31
(iii)Bending stresses (  b )
(iv) Torsional shear stresses (  )
Design pressure take as 10% above operating P as safety factors

P0 = 725.2 psi = 4.997 N/mm2
PD = (1.10) (725.2)
= 797.72 psi = 5.497 N/mm2
i) Longitudinal (  L ) and circumferential (  h ) stresses
𝑃𝐷𝑖
σL = 4𝑡
5.497 (366)
= 4(11)
= 45.865 N/mm2
𝑃𝐷𝑖
σh = 2𝑡
5.497 (366)
=
2(11)
= 91.730 N/mm2
ii) Direct stress, σw

𝑊
σw = where, W = Wv + WI
𝜋 (𝐷𝑖+𝑡)𝑡
𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡
Cv = 1.08
Dm = Di + t = 0.366 + 0.011 = 0.377 m
Hv = 2 2
hc + he = 1.1+ 3 (0.092) = 1.161 m
3
t = 11 mm
Hence, Wv = 240(1.08)(0.377)(1.161 + 0.8 (0.377))(0.011)

= 1.5722 N
𝑊
Direct stress, σw = 𝜋 (𝐷𝑖+𝑡)𝑡
1.5722
= 𝜋 (366+11)11
32
iii) Bending stresses, σb

𝑀 𝐷
σb = ± 𝐼 ( 2𝑖 + 𝑡)
𝑣

𝑊𝑥 2
𝑀=
2
x = 𝐻𝑣 = 1.161 m
𝐷𝑒𝑓𝑓 (including insulation) = 𝐷𝑜 = 𝐷𝑖 + 2t = 0.388 m
Pw = 1280 N/m2
W = 𝑃𝑤 𝐷𝑒𝑓𝑓 = (1280)(0.388) = 496.64 N/m
496.64 x 1.1612
M= =334.716 Nm =3.347 x 105 Nmm
2
π π
Iv = (Do 4 − Di 4 ) = (0.3884 − 0.3664 ) = 0.0002317 m4
64 64
= 2.317 × 108 mm4
𝑀 𝐷
Hence, Bending stresses, σb = ± 𝐼 ( 2𝑖 + 𝑡)
𝑣
3.347x 105 366

= ± 2.317×108 ( + 11)
2
= ± 0.280 N/mm2
iv) Torsional shear stresses, τ

The torsional shear stresses can be neglected in preliminary vessel design
because these loads will normally be small, where, τ = 0.
b. PRINCIPAL STRESSES, σ1 AND σ2
1
σ1 = 2 [σh + σz + √(σh − σz )2 + 4τ2 ]
33
1
σ2 = 2 [σh + σz − √(σh − σz )2 + 4τ2 ]

σz (upwind) = 45.865 + (−0.0001173) + 0.2803
= 46.145 N/mm2

σz (downwind) = 45.865 + (−0.0001173) − 0.2803
= 45.585 N/mm2
Table 1.6 Primary stresses for R-102

Torsional shear stresses, τ 0
Total longitudinal stress, σz (upwind) 46.145
Total longitudinal stress, σz (downwind) 45.585

1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [91.730 + 46.145 + √(91.730 − 46.145)2 + 4(0)2 ]
= 91.730 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [91.730 + 46.145 − √(91.730 − 46.145)2 + 4(0)2 ]
= 46.145 N/mm2 = σz (upwind)

34

1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [91.730 + 45.585 + √(91.730 − 45.585)2 + 4(0)2 ]
= 91.730 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [91.730 + 45.585 − √(91.730 − 45.585)2 + 4(0)2 ]
c. MAXIMUM ALLOWABLE STRESS INTENSITY (∆σMAX)
Assume τ = 0, σ3 = 0.5 (5.514) = 2.757

σ1 – σ3 = 91.730 – 2.757
= 88.973 N/mm2

σ2 – σ3 = 45.585 – 2.757
= 42.828 N/mm2

According to ASME Code, maximum allowable stress at temperature 250 oC,
S = 122 N/mm2
Since, (∆σmax) = 88.973 N/mm2 ˂ S = 122 N/mm2, therefore, the design is safe to use.
d. Elastic Stability
E  t 

3 1 v2  R
 p


35
σc = 2 x 104 (t / D0) = 2 x 104 (11 / 0.388) = 567.01 N/mm2
Δσ max  S and (∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ) < 𝜎𝑐 Therefore, the design is safe.
1.1.8 VESSEL SUPPORT ANALYSIS
The vessels support must be designed to withstand the weight of the vessel including
weight of material are packed inside and contents and any superimposed loads such as
wind loads. Support will impose localized loads on the vessel wall, and the design must
be checked to ensure resulting stress concentrations are below the maximum allowable
design stress. It is also important to allow the ease of access to the vessel and the fittings
for inspection and maintenance (Sinnott 2005).
a. THICKNESS OF SUPPORT
The skirt support had been chosen as the support for distillation column. Since the
height of distillation column, H = 1.283 m with the internal diameter, Di = 0.366 m, the
skirt support is suitable for the use of tall vessel which subject to wind loading.
The resultant stresses in the skirt,

σs (tensile) = σbs – σws ; σs (compressive) = σbs + σws
4𝑀
Bending stress in the skirt, σbs = 𝜋(𝐷 +𝑡 𝑠)𝑡
𝑠 𝑠 𝑠 𝐷𝑠
𝑊
Dead weight stress in the skirt, σws = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
Assume skirt support height, hs = 0.5 m, skirt thickness, ts = 11 mm

36
Total height, x = H + hs = 1.283 + 0.5 = 1.783 m

Ds = Di = 366 mm
W = 496.64 N/m (from 6.3.6.a(iii))
Maximum dead weight load on the skirt will occur when the vessel is full of water.
𝜋
Approximate weight = (4 × 0.3662 ) × 1.283 × 1000 × 9.81
= 1324.182 N
Weight of vessel = 1.5722 N
Weight of catalyst = 1252.026 N
Total weight, W = 1324.182 + 1.5722 + 1252.026 = 2577.78 N
= 2.578 kN
For the bending stress in the skirt,  bs
𝑊𝑥 2
Maximum bending moment, Ms = 2
(2577.78)(1.6619)2
= 2
= 685.095 Nm
Hence,
4(685.095 × 1000 )
Bending stress in the skirt,  bs = 𝜋(366+11)(366)(11)
= 0.417 N/mm2
𝑊
Dead weight stress in the skirt, σws (hydraulic test) = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
1.5722
=
𝜋(366+11)11
= 0.000088 N/mm2
𝑊
Dead weight stress in the skirt, σws (operating) = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
2577.78
= 𝜋(366+11)11
= 0.144 N/mm2
Therefore, resultant stresses
Maximum σs (tensile) = σbs – σws = 0.417 – 0.000088 = 0.4169 N/mm2
σs (compressive) = σbs + σws = 0.417 + 0.144 = 0.561 N/mm2
37
The skirt thickness under the worst combination of wind and dead weight loading
should not exceed the following design criteria.
σs (tensile) ˂ fs J sinθs
σs (compressive) ˂ 0.125E (ts/Ds) sinθs
Assumptions:
 maximum allowable stress for skirt material at Tamb = 20°C, fs = 138 N/mm2
 weld joint factor, J = 0.8
 base angle, θs = 90°
 Yong’s modulus, E = 200000 N/mm2
Therefore,
fs J sinθs = 122(0.8) sin (90°)
= 97.533 N/mm2
0.125E (ts/Ds) sinθs = 0.125(200000)(11/366)sin(90°)

= 1024.59 N/mm2
σs (tensile) = 0.4169N/mm2 ˂ fs J sin θs = 97.533 N/mm2

σs (compressive) = 0.561 N/mm2 ˂ 0.125E (ts/Ds) sin θs = 1024.59 N/mm2
Since both criteria are satisfied, thus, the assumed value of skirt thickness, ts = 0.011 m
is acceptable. With corrosion allowance of 4 mm, the design skirt thickness, ts = 0.015
m.
b. BASE RING AND ANCHOR BOLT DESIGN
The loads carried by the skirt will be transmitted to the foundation slab by the skirt base
ring. The moment produced by wind and other lateral loads will tend to overturn the
pressure vessel. This will be opposed by the couple set up by the weight of the vessel
and the tensile load of the anchor bolts (Sinnott 2005).
38
required:
1 4Ms
Ab = [ − W]
Nb fb Db

Assumptions:
 bolt circle diameter, Db = 1.550 m = 1550 mm
 circumference of bolt circle = 1550 π mm = 4869.469 mm
 maximum allowable bolt stress, fb = 100 N/mm2
 take number of bolts as 8
𝜋×1.550×1000
Bolt spacing = = 608.68 mm
8
Bolt spacing > 600 mm, therefore the bolt spacing is satisfactory.

The bending moment at the base, Ms = 685.095 Nm
1 4Ms
Ab = [ − W]
Nb fb Db
1 4(685.095 )
Ab = [ − 1.5722 ]
8 × 100 1.550
Ab = 41.080 mm2
Use M10 bolts with nominal stress area = 58.0 mm2

39
4Ms W
Fb = [ + ]
πD2s πDs
4(685.095) 1.5722
Fb = [ + ]
π x 0.3662 π × 0.366
Fb = 6513.133 Nm−1
Fb 1
Lb = × 3
fc 10
6513.133
Lb =
3.5x 103
Lb = 1.861 mm
1.1.9 FLANGED JOINT
cover, and for removable vessel heads when ease of access is required for maintenance
or inspection. It also used on the vessel body when it is required to divide the vessel
into sections for transport and maintenance. It can reduce high-stress concentration at
the base of the flange by transferring stress to the adjoining pipe. Welding-neck flange
is the best-designed butt weld available because of its inherent structural value and ease
of assembly. Welding-neck flange have high strength and high resistance to dishing, it
is manufactured with a long-tapered hub. The tapered hub is created by the gradual
increase in metal thickness from the weld join to the flange facing. The welding-neck
flange diagram is shown in Figure 6.3.2
40
Figure 6.3.2 Diagram of Weld Neck Flange ASME B16.5
Table 1.7 Size of flanges used for fitting on each pipe on R-102
Stream NPS D B H OD f L K N
No (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
60 10 90 16 35 40 2 14 60 28
61 10 90 16 35 40 2 14 60 28
1.1.10 SUMMARY FOR DESIGN
By considering the internal pressure of the vessel, reactor R-102, the conditions that are
needed for the design have been calculated through series of formulae stated. The
conditions for the design our distillation column have been summarized and tabulated
as followed in Table 6.3.8.
Table 1.8 Summary for design condition of reactor R-102

Material of construction - Stainless steel SA240 Grade 304
Shell height
Bed Diameter, Dbed m 0.366
41
Bed Height, Hbed m 0.770

(88.973< 122)
(0.280 < 567.01)

0.417 < 97.533
Resultant stresses, σs (compressive) N/mm2 σs(compressive) ˂ 0.125E(ts/Ds)
sin θs
0.561 < 1024.59

Area of one bolt, Ab mm2 58
Type of flanged joint - Welded-neck flanged
REFERENCE
Afandizadeh, S. & Foumeny, E. A. 2001. Design of packed bed reactors: Guides to

catalyst shape, size, and loading selection. Applied Thermal Engineering 21(6):
669–682. doi:10.1016/S1359-4311(00)00072-7
Ankita, I. K., Devika, G., Lakshmi Priya, K., Remya, R. & Jayamohan, J. 2016.
Applications of Geosynthetics in Embankments- A Review. International
Advanced Research Journal in Science, Engineering and Technology (IARJSET)
5(1): 31–41. doi:10.17148/IARJSET
ASME. 2013. 2013 ASME Boiler & Pressure Vessel Code 2013. ASME Boiler &
Pressure Vessel Code 802.
PRODUCED BY AN AUTODESK STUDENT VERSION
SIDE VIEW CROSS CROSS SECTIONAL

TOP VIEW OF REACTOR
SECTION OF REACTOR VIEW OF REACTOR
S61
Outlet R8.60
Ø392.0
91.5
Faculty of Engineering & Built Environment
R1.2573
13
Chemical Engineering Programme
Project Title:
PRODUCTION OF METHANOL AND

BIOFLOCCULANT FROM POME

Drawing Title:
TOP AND SIDE VIEW TOP AND SIDE OF Mechanical Design of Packed Bed Reactor
1281.6 769.8 (R-102)
OF SKIRT SUPPORT WELDING NECK FLANGE
Prepared By:
KK 4
1712.9
Group Members:
1.) Ravinkumar A/L Manimaran (A158192)
10 2.) Siti Barakah binti Mohd Khairi
(A158482)
366 3.) Sivapriya A/P Nadaraju (A158432)
N 4.) Afiq Syazwan bin Mohd Haizollizam (A158912)
5.) Cheah Ching Wei (A157594)
500 S60 15 L 6.) Nuredahtul Faezan binti Mohammad Yusop
H (A159291)
S60
Inlet B
500 Scale:
15 OD Drawing Not to Scale
f
K
D
Dimensions:
All Dimensions in mm
Drawn By:
Afiq Syazwan bin Mohd Haizollizam(A158912)
ANCHOR BOLT DESIGN Submission Date:
6th March 2020
DIMENSION (MM)
Design Specifications:
BOLT SIZE ROOT AREA D H F C - Design temperature (°C): 250
M10 58.5 10 6.63 17 18.48 - Design pressure (bar): 50
- MAWP Vessel (bar): 56.51
WELDING NECK FLANGES - Thickness vessel (mm): 13.0
- SA-204 Type 304 Stainless Steel
DIMENSION (MM)
- Straight skirt with ASME SA-516 Grade 70 Carbon
NO. NOMINAL PIPES SIZES (MM) D B OD L K N f Steel
S60 10 90 16 40 14 60 28 2 - Flanged joint with welding-neck flange class 150
S61 10 90 16 40 14 60 28 2 for all pipes
PRODUCED BY AN AUTODESK STUDENT VERSION - Bolt size M10
2
CHAPTER I
PRESSURE VESSEL DESIGN
1.1 INTRODUCTION
During designing pressure vessel, design factor such as construction material and join
efficiency, corrosion allowance and design pressure are considered. The selection of
construction material depends on the ease of fabrication, suitability and construction
cost. For mechanical design of heat exchanger CO-101, carbon steel SA-516 is used as
the construction material. This is because material used has lower melting point due to
high carbon content inside the steel. Not only that, this material also are ductile and
elastic. In addition, the corrosion allowance (CA) which is 4 mm is added as additional
method to deal corrosive material as as high temperature and pressure condition. Table
1.1 shows the operating condition in Cooler CO-101.
Table 1.1 Operating Condition in Cooler CO-101
Condition Values
SI unit English unit
Operating pressure, Po 700 kpa 101.526 (psi)
o
Temperature, T 421 C 789.8 F
Design Stress, S 20000 psi
Corrosion allowance, CA 4 mm 0.1575 in
Length 1.78 m 70.08 in
Shell Diameter, Ds 0.35 m 13.78 in
Inner radius of cylindrical shell, R 0.18 m 7.087 in
3
1.1.1 DESIGN PRESSURE
Since the operating pressure of the cooler (7 bar) is greater than atmospheric pressure
(Pa > Patm), the distillation column is designed under internal pressure. Firstly, the design
pressure for each part of the vessel is calculated by using equation:
PD = PO + 0.433h
h = height (ft)
Hence,
PD = 101.526 + 0.433 (13.78 in x 0.0833) = 102.23 psi
Hence,
Pj = 1.10 (102.23) = 112.23 psi
1.1.2 MINIMUM WALL THICKNESS
For top hemispherical head (High pressure vessel) :

PD (112.23)(7.0866)
Thickness, 𝑡1 = 2SE−0.2P = 2(20000)(1)−(0.2)(112.23) =0.0199 in

PR (112.23)(0.18)
Thickness, 𝑡2 = SE−0.6P = (20000)(1)−(0.6)(112.23) =0.0399 in
4

PR (112.23)(0.18)
Thickness, 𝑡3 = 2SE+0.4P = 2(20000)(1)−(0.4)(112.23) =0.0199 in
To account for the corrosion that might happen in the vessel, corrosion allowance is
added to each of the thickness obtained. Since the operating pressure of the vessel is
high, we choose the maximum corrosion alloance, CA = 4 mm (0.1575in)
t1 = 0.0199 + 0.1575 t2 = 0.0399 + 0.1575 T3 = 0.0199 + 0.1575
= 0.1774 in = 0.1974 in = 0.1774 in
= 4.505 mm = 5.013 mm = 4.503 mm
After going through the process of overall thickness uniformity, the overall wall
thickness can be calculated as below:
toverall = 0.1974 in = 5.013 mm
After considering the corrosion allowance of 4mm (0.1575 in).
tcalc = tuser – CA
= 0.1974 in – 0.1575 in
= 0.0399 in (2.35 mm)
toverall = 0.1974 in (5.013 mm)
The closest tnominal of type SA-516 Grade 70 is 0.25in (6.35mm) to toverall.

= 0.25 in – 0.1575 in
= 0.0925 in (2.35mm)
1.1.3 ALLOWABLE WORKING PRESSURE
design pressure for each part of the column can be found in ASME Code UG-32 part
(D) and UG-27 part (c). By using tmin from the calculation above, the MAWPvessel is
calculated.
For the hemispherical head:

2SEt 2(20000)(1)(0.0925)
0.18+0.2(0.0925)
Static head PH = 0.433 (13.78x0.0833) = 0.497 psi

5

Circumferential
SEt (20000)(1)(0.0925)
Internal pressure = R+0.6t = = 258.58 psi
(0.18)+0.6(0.0925)

Longitudinal
2SEt 2(20000)(1)(0.0925)
Internal pressure = R−0.4t = = 524.96 psi
(0.18)+0.4(0.0925)

Table 1.2 Internal pressure and MAWPvessel for each part of the distillation column C-101
Hemispherical head 520.86 0.50 520.36
Cylindrical shell
Circumferential 259.08 0.50 258.58
Longitudinal 524.96 0.50 524.47
By choosing the smallest value, the MAWPvessel is 258.58 psi.
1.1.4 COMBINED LOADING
6
6.2.6.1 PRIMARY STRESSES

(a) Longitudinal (  L ) and circumferential stresses (  H ) due to pressure
(b) Direct stress (  W )
(c) Bending stresses (  b )
(d) Torsional shear stresses (  )

P0 = 458.75 psi = 3.164 N/mm2
PD = 112.23 psi
= 0.7738 N/mm2
Ds = 0.35 m = 350mm
t = 6.35mm
a. Longitudinal (  L ) and circumferential (  h ) stresses
𝑃𝐷𝑖
σL = 4𝑡
0.7738 (0.35𝑥1000)
= 4(6.35)
= 10.663 N/mm2
𝑃𝐷𝑖
σh = 2𝑡
0.7738 (0.35𝑥1000)
= 2(6.35)
= 21.325 N/mm2
b. Direct stress, σw
𝑾
𝛔𝐰 = 𝝅 (𝑫𝒊+𝒕)𝒕
where, W = Wv + WI
𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡
Cv = 1.08
Height between tangent lines, Ht = 0.35 m
Mean diameter of vessel, Dm = 7.167 m
7
Minimum wall thickness, tmin = 6.35 mm

Number of tubes, Nt = 58
Tube length, L = 1.78 m
Inner tube diameter, di = 0.016 m
Outer tube diameter, do = 0.02 m
Density of material (Alloy 230), ρm = 7750 kg/m3
Gravitational acceleration, g = 9.81 m/s2
Number of baffles,t = 25
Shell Area, As = 0.005 m2
Hence,
Weight of shell, Wv = 1.08π(7750)(0.3564)(9.81)(0.35 +
0.8 (0.3564))(6.35x10−3 )
= 370.75 N
π(7750)(0.022 − 0.0162 )(1.78)(58)(9.81)

Weight of tube, Wt =
4
= 887.83 N
100 − Baffle cut

Weight of internal fitting, Wf = (No. of baffles)t𝐴𝑠 ( ) 𝜌𝑚
100
100 − 25
= 25(0.001)(0.005)(( ) (7750)(9.81)
100
= 7.1376 N
𝜋(7750)(0.0162 )(1.78)(58)(9.81)
Weight of tube side fluid flow =
4
= 1578.4 N
Weight of shell side fluid flow = 7750(0.005)(0.35)(9.81)
Hence,
Total weight = 370.75 + 887.83 + 7.1376 + 1578.4 + 133.23
8
= 2977.3 N = 2.9773 kN
𝑊
2977.3
= 𝜋 (350+6.35)6.35
c. Bending stresses, σb
Since the heat exchanger is in horizontal position and not considered tall, there is assued
to be no wind loads and hence the bending stress, σb = 0.
d. Torsional shear stresses, τ
Torsional shear stresses, τ results from torque caused by loads offset from the vessel
axis. These loads will normally be small and can be neglected in preliminary vessel
designs
e. Principal stresses, σ1 and σ2
1
σ1 = 2 [σh + σz + √(σh − σz )2 + 4τ2 ]
1
σ2 = 2 [σh + σz − √(σh − σz )2 + 4τ2 ]
σ3 = 0.5p
Since torsional shear stress can be neglected and σ3 negligible for thin walled vessels,
the formulas above hence become:
σ1 = σh (Circumferential stress)
σ2 = σz (Longitudinal stress)
Since the bending stress, σb can be neglected for horizontal and short vessels, there will
only be one value of σz .
σz = σL + σW + σb
σz = 10.663 + 0.4188 + 0
= 11.081 N/mm2
9
Therefore,
σ1 − σ2 = 𝜎ℎ − 𝜎𝑧
= 21.325 − 11.081
= 10.244 N/𝑚𝑚2
The maximum allowable stress intensity, ∆𝜎𝑚𝑎𝑥 = 10.244 𝑁/𝑚𝑚2 . The maximum
allowable stress of Carbon steel is 20000 psi which is equivalent to 137.895 N/mm2.
Therefore, the design is partially accepted since∆𝜎𝑚𝑎𝑥 < 𝑆𝑑𝑒𝑠𝑖𝑔𝑛 .

Total longitudinal stress, σz 11.081
f. Elastic Stability
Under conditions where the resultant axial stress σz due to the combined loading is
compressive, the vessel may fail by elastic instability (buckling). Local buckling will
normally occur at a stress lower than that required to buckle the complete vessel. For a
curved plate subjected to and axial compressive load, the critical buckling stress, σc is:
E  t 

31 v2  R
 p


For steel at ambient temperature, E = 200000 N/mm2, the poisson’s ratio is 0.339 and
taking safety factor of 12.
𝐷𝑜
Radius of curvature, 𝑅𝑝 =
2
10
0.35 + (2x0.0381)
= = 0.23𝑚
2
1 159068 0.0064
𝜎𝑐 = 𝑥 ( )
12 √3(1 − 0.3392 ) 0.23
= 226.36 𝑁/𝑚𝑚2
Maximum compressive stress, (∑ 𝜎)𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 = 𝜎1 − 𝜎3 = 21.325 𝑁/𝑚𝑚2 and is

well below the critical buckling stress, σc. Therefore (∑ 𝜎)𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ˂ σc. Since both
the analyses are satisifed, the design is considerd safe and can be accepted.
1.1.5 VESSEL SUPPORT ANALYSIS
The vessels support must be designed to withstand the weight of the vessel and contents
and any superimposed loads such as wind loads. Horizontal vessel are installed on two
saddle supports as shown in figure 1.1. A vessel supported on two saddles can be known
as simple beam. The location in which the limit at the supports and at the mid is equal
in magnitude would be at an equally uniform charge and the distribution of the
longitudinal axial bending moment.
Figure 1.1 Horizontal Cylindrical Vessel on Saddle Supports
Source: Sinnot 2009
The total weight loads that have to be withstand by the saddle support is 2977.3 N with
a vessel diameter of 0.35 m. From Chemical Engineering Design (Sinnot 2009), the
11
dimension of the standard saddle support should be designed according to the following
conditions in table 1.4 where figure 1.2 illustrates the dimensions of the conditions.
Figure 1.2 Standard Steel Saddles
Source: Sinnot 2009
Table 1.4 Standard Dimensions for Saddle Supports with Vessel Diameter 0.4m
V Y C E J G t1 t2
Bolt Diameter (mm) Bolt Holes (mm)
(m) (m) (m) (m) (m) (m) (mm) (mm)
0.32 0.1 0.37 0.16 0.127 0.063 5 4 13.33 16.67
1.1.6 Flanged Joint
transferring stress to the adjoining pipe. Welding-neck flange is the best-designed butt
weld available because of its inherent structural value and ease of assembly. Welding-
neck flange have high strength and high resistance to dishing, it is manufactured with a
long-tapered hub. The tapered hub is created by the gradual increase in metal thickness
from the weld join to the flange facing. The welding-neck flange diagram is shown in
Figure 6.3.
12
Figure 6.2 Diagram of Weld Neck Flange ASME B16.5
Table 1.5 Size of flanges used for fitting on each pipe on CO-101
Pipe A B C D H J K P Diameter
Size (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) of bolt
holes
3.5 228.6 139.7 30.16 90.12 101.6 133.35 80.96 184.15 22.23
2 165.1 92.08 22.23 52.5 60.33 84.14 69.85 127 19.05
1.1.7 SUMMARY FOR DESIGN
By considering the internal pressure of the vessel, Cooler CO-101, the conditions that
conditions for the design our cooler have been summarized and tabulated as followed
in Table 6.8.
Table 1.6 Summary for design condition of Cooler CO-101

Shell Diameter, Ds m 0.35
Inner Radius of Cylindrical shell, R m 0.18
Length of shell, L m 1.78
13

Bending stress, σb N/mm2 0
(10.24 < 138)

(21.235< 226.36)
Type of vessel support - Saddle Support
25
a a
350 350
Faculty Of Engineering And Built

Environmnent
175 (FKAB)
TOP VIEW OF HEAT EXCHANGER 6.35
DEPARTMENT OF CHEMICAL
a
CROSS SECTIONAL VIEW OF ENGINEERING & PROCESS (JKKP)
2130 TUBE BUNDLES Project Title:
1780 Production Of Methanol and Bio Flocculant From
TUBE SIDE INLET Stream 53a
70.76 Palm Oil Mill Effluent (POME)
25% baffle cut Drawing Title:

Alphabet DESCRIPTION Mechanical Design of Cooler (CO-101)
20 A 350 SADDLE Supervisor:

B
SUPPORT 1. Prof. Ir Dr. Siti Kartom Kamarudin
2. Prof Madya Dr Masli Irwan
C BAFFLE 3. Hemavathi Silvamany (Sime Darby)
D HEMISPHERICAL Group Members:
B D
TUBE SIDE OUTLET
Stream 54 C HEAD 1. Ravinkumar A/L Manimaran
a
2. Afiq Syazwan Bin Mohd Haizollizam
SIDE VIEW OF HEAT EXCHANGER
3. Nuredahtul Faezan Binti Mohammad
Yusop
4. Siti Barakah Binti Mohd Khairi
J J 5. Sivapriya A/P Nadaraju

H H
D D Drawn by:
K Nuredahtul Faezan Binti Mohammad Yusop
C K (A159291)
B C
P B Design Specification:
A P
A
TUBE SIDE FLUID FLANGE Wall Thickness : 6.35 mm
SHELL SIDE FLUID FLANGE
Corrosion Allowance : 4 mm
120°
Design Pressure : 7 bar
t1
Design Temperature : 421 deg C
V
Material Vessel : SA-516
Shell Type : Cylindrical
SADDLE SUPPORT Top Head Type : Hemispherical
VESSEL DIAMETER MAX WEIGHT(kN) V Y C E J G t2 t1 BOLT DIAMETER
t1 0.4 23 1/2 320 1000 370 160 127 63 4 5 13
G J J
t2 Y E E
WELDING NECK FLANGE
CONNECTION NOMINAL SIZE (in) A B C D H J K
No of Bolt Holes
(NBH)
Diameter of Bolt
Holes (DBH)
P Approx. Weight (ib) AW DRAWING NOT TO SCALE
C T1 2 165.1 92.1 22.2 52.5 60.3 84.1 69.9 8 19.1 127.0 9
UNITS DIMENSION IN MILLIMETER
SADDLE SUPPORT AND VIEW FROM A
T2 2 165.1 92.1 22.2 52.5 60.3 84.1 69.9 8 19.1 127.0 9
(MM)
Stream 53a 3 1/2 228.6 139.7 30.2 90.1 101.6 133.4 81.0 8 22.2 184.0 18
Stream 54 3 1/2 228.6 139.7 30.2 90.1 101.6 133.4 81.0 8 22.2 184.0 18
Date : 14th March 2020
1
CHAPTER I
containing methane, carbon dioxide, carbon monoxide, hydrogen, before the further
separation of the methanol from the waste water in distillation column (C-101). The inlet
of the phase separator consists of methane, carbon dioxide, carbon monoxide, hydrogen,
water and methanol. At the end of the separation, water and methanol will be leave as
bottom product while methane, carbon dioxide, carbon monoxide, hydrogen, and some
amount of water and methanol will leave as top product. The inlet temperature and pressure
of the stream are 50 oC and 30 bar. Figure 1.1 shows the phase separator to be designed and
the flow rate of each component at the inlet and outlet after flash calculation . In order to
know the vapor fraction of the phase separator, isothermal flash calculation is being done
first. F63CH4 = 149 kg/h
F63CD = 201.8 kg/h
F63CM = 381.4 kg/h
F63H = 17.6 kg/h
F62CH4 = 149 kg/h F62W = 1.8 kg/h
F62CD = 201.8 kg/h F62M = 6.4 kg/h
F62CM= 381.4 kg/h
F62H = 17.6 kg/h
F62W = 237.7 kg/h
F62M= 181.4 kg/h
F66W = 235.9 kg/h
F66M = 175 kg/h

2

Ln(P(mmHg)) = A - B / ( T (°K) - C )

Ki = Psat/P

calculation.
zi K i
∑ yi = ∑ =1
1 + V(K i − 1)
i i
xi = yi/Ki

V = vapor fraction
Table 1.1 Iteration made
Vguess ∑y
0.83 1.1
0.72 1.07
0.64 1
3
Table 1.2 Summary of isothermal flash calculation

Methane 0.169 10.608 0.2514 0.0237
Carbon dioxide 0.084 19.300 0.1272 0.0066
Carbon monoxide 0.247 13.969 0.3721 0.0266
Hydrogen 0.158 22.346 0.2416 0.0108
Water 0.240 0.0040 0.0027 0.6594
Methanol 0.102 0.0190 0.0051 0.2728
Vessel Diameter

Liquid density, ρL 875.4 kg/m3

is 0.825 at 30 bar. For separator K value for separator about 3 m with mist eliminator
(Dooley et al. 2004),
K = 0.107m/s x 𝐾𝑓𝑎𝑐𝑡𝑜𝑟 = 0.088 m/s
Terminal velocity,
ut = K[(ρL - ρv)/ ρv]1/2

4
ut = 0.58 m/s
Dv calculated is too small, iteration have been made and vessel diameter is 0.86m.
Vessel Height
h7
h6
D
h5
h4
h3
h2
h1
Figure1.2 Phase separator schematic diagram

5
vL = 410.11/(875.36 x 3600) = 0.00013 m3/s
V = 0.00013 x 25 x 60 = 0.195 m3
hL = Volume held up/vessel cross-sectinal area = 0.388 m
Surge volume = 0.0013 ×5×60 = 0.039 m3
For surge height or height from normal liquid level (NLL) to HLL, hn
Surge height, hn = surge volume/vessel cross-sectional area
hn = 0.078 m
6
h2 = hL + hn =0.466 m
For height from HLL to the inlet nozzle, if h3 calculated is less than 0.3, then h3 is 0.3m.
h3 = 0.3 Dv = 0.24 m < 0.3 m, thus h3 = 0.3m
For inlet nozzle diameter, if h4 calculated is less than 0.4064m, then set h4 at 0.4064m.
𝑣𝐿
λ=𝑣 = 0.001
𝐿 +𝑣𝑉
4Qm √ρm 0.5

dn = ( )
60π
ρm = ρL λ + ρV (1 − λ) (kg/m3)
h4 = dn = 0.2068 m< 0.4064 m, Thus, h4 = 0.4064 m
h5 = 0.45Dv = 0.36 m < 0.6m, thus h5 = 0.6 m
h6 = 0.15 m
7
0.3 m, set h7 at 0.3 m.
h7 = 0.15Dv = 0.12 m < 0.3 m, thus h7 = 0.3m
hT = h1 + h2 + h3 + h4 + h5 + h6 + h7
hT = 2.37 m
VT = π(Dv/2)2hT = 1.367 m3
Table 1.4 shows the summary of the results obtained from manual calculation of the
phase separator S-102.
8

Parameter Result
Dv 0.86 m
h1 0.15 m
h2 0.47 m
h3 0.30 m
h4 0.41 m
h5 0.60 m
h6 0.15 m
h7 0.30 m
hT 2.37 m
hT/Dv 2.77
VT 1.37 m3
9
CHAPTER II
2.1 MECHANICAL DESIGN OF PHASE SEPARATOR (S-102)
Phase separator (S-102) is used to carry out the phase separation to purify methanol. Since
the operating pressure for this reaction is greater than the atmospheric pressure, the phase
separator is designed based on the internal pressure. Table 2.1 summarizes the operating
conditions and dimension of S-102.
Table 2.1 Operating conditions dimension for phase separator S-102

Parameter Values
Operating Pressure, Po 30 bar
Operating Temperature, To 50ºC
Vessel diameter, D 0.856
Shell height, HS 2.372
2.1.1 Types of Shell and Head
Types of head and shell are assumed based on the operating conditions and process in order
to design the mechanical drawing for phase separator S-102. A vertical cylinder is chosen
as the shell whereas ellipsoidal type head is chosen for both top and bottom head of phase
separator . The selection parts for mechanical design for S-102 are listed in Table 2.2.
Table 2.2 Selection of Parts and type for Mechanical Design

Parts Type
Top Head Ellipsoidal 2:1
Shell Cylindrical
Bottom Head Ellipsoidal 2:1
10
The shape of ellipsoidal head is defined by the ratio of the major and minor axis. This will
have a depth of head which is quarter of the vessel’s internal diameter, D as shown in Figure
2.1. Ellipsoidal head is chosen compared to spherical and torispherical head because
ellipsoidal can withstand high pressure better compare to others.
Figure 2.1 Ellipsoidal head of ratio 2:1
2.1.2 Sizing of Vessel
a. Sizing of top and bottom head height, HH
For ellipsoidal heads,

Di
ho =
4
= 0.214 m
For total vessel height, H,

Hs = H + 2ho
= 2.8 m
Table 2.3 Summary of dimension of the vessel

Dimension Value (SI Unit)
Vessel Height, H 2.80 m
Vessel Internal Diameter, Di 0.86 m
Vessel Internal Radius, Ri 0.43 m
Shell Height, Ho 2.37 m
Top Head Height, ho 0.21 m
Bottom Head Height, ho 0.21 m
11
2.1.3 Design Factors
Before proceeding with detailed mechanical drawing for this process equipment, there are
some design factors that need be considered and justified first.
a. Design Pressure
Design pressure is being calculated by adding hydrostatic pressure to the operating pressure
of the vessel.
PD = Po + 0.433h
Where PD = Design pressure for vessel
Po = Vessel operating pressure (gage value)
h = Height of each part from top shell
Therefore,
Ellipsoidal 2:1 top head: PD = 435+ 0.433(0.702 ft) = 478.96 psi
Cylindrical shell: PD = 438 + 0.433(8.486 ft) = 482.67 psi
Ellipsoidal 2:1 bottom head: PD = 435 + 0.433(9.189 ft) = 483.00 psi
Safety factor about 10 % is considered to the design pressure, PD to prevent vessel failure
during minor process upsets. The new design pressure added with safety factor will be PJ
= 1.10PD and shown in Table 2.4.
12
Table 2.4 Design pressure for each part of phase separator, S-102
Parts of phase separator PD (psi) PF (psi)
b. Design temperature
The design temperature of vessel, T is taken as the maximum operating temperature of the
phase separator which is 50 ºC.
c. Materials of construction
Stainless Steels Type 304 is used as our material to construct this phase separator because
these steels exhibit excellent corrosion resistance to a wide range of atmospheric, chemical,
textile, petroleum and food industry exposures. Since the vessel operate at a considerably
pressure and acidic condition(vapor mixture consist of carbon dioxide which is acidic),
stainless steel type 304 is suitable as the material of construction for the vessel.
d. Maximum allowable stress
The maximum allowable stress for Austenitic Stainless Steels Type 316 the at temperature
50ºC is 𝑆 = 19290 𝑝𝑠𝑖.
e. Joint efficiency
A double–welded butt joint with partial degree of radiography is used where the joint
efficiency is 0.85 (ASME code, Table UW-12 Section VIII Part D, 2010).
13
f. Corrosion allowance
A minimum corrosion allowance of 2 mm will be used since the reactants and the product
produce is not highly corrosive substance.
g. Design Loads
The vessel is generally subjected to major and subsidiary loads. Proper care must be taken
to determine the combination of possible loads which gives the worst situation and design
for that loading conditions. Summary of all design specifications is listed in Table 2.5
below
Table 2.5 Design factor specification of phase separator, S-102

Specifications Values
Layout Vertical
Design Temperature 50ºC
Material of Construction Austenitic Stainless Steel Type 304
Max Allowable Stress 19290 psi
Corrosion Allowance 2 mm
Joint Efficiency, E 0.85
h. Minimum Wall Thickness (tmin)
According to UG16, the vessel is classified as thin-walled vessels since value of t/D is
0.007, significantly smaller than 1.10. In this case, all calculations are performed upon each
parts of vessel on determining thickest tmin which is then is used to determine the maximum
allowable working pressure of vessel, MAWPvessel.
14
i. Cylindrical Shell
Circumferential Stress
Referring to ASME Code Part UG.27(c) (1), thickness for circumferential cylinder is
PR
t=
SE − 0.6 P
(482.67)(16.86)
𝑡=
(19290)(0.85) − 0.6(482.67)
𝑡 = 0.502 𝑖𝑛
= 12.83 mm
Longitudinal Stress
Referring to ASME Code Part UG.27(c) (2), thickness for longitudinal cylinder is
PR
t=
2 SE + 0.4 P
(482.67)(16.86)
𝑡=
(2)(19290)(0.85) + 0.4(482.67)
𝑡 = 0.505 𝑖𝑛
= 12.833 mm
15
ii. Ellipsoidal Head
Top Head
Referring to ASME Code Part UG.32 (d) (1), thickness for top cover of vessel is
PD
t=
2 SE − 0.2 P
(478.96)(16.86)
𝑡=
(2)(19290)(0.85) − 0.2(478.96)
𝑡 = 0.494 𝑖𝑛
= 12.55 mm
Bottom Head
Referring to ASME Code Part UG.32 (d) (1), thickness for bottom cover of vessel is
PD
t=
2 SE − 0.2 P
(483)(16.86)
𝑡=
(2)(19290)(0.85) − 0.2(483)
𝑡 = 0.4981 𝑖𝑛
= 12.65 mm
16
Summary of design pressure and thicknesses calculated from each part is tabulated in Table
2.6
Table 2.6 Design pressure and wall thickness of the vessel

Part Design pressure (psi) Wall thickness Wall thickness (mm)
(in)
Top Cover 435.417391 0.4939 12.5459
Bottom Cover 439.091854 0.4981 12.6521
The minimum thickness for whole vessel is chosen from the highest value of thickness
calculated for each part. Therefore, the calculated minimum thickness of vessel is 12.83
mm since this is the largest value.
By considering corrosion allowance, CA of 2 mm
tuser = tcalc + CA
= 12.83 + 2 mm
= 14.83 mm
The thickness obtained is then compared with the nominal thickness available for austenitic
stainless steel SA-316. The nearest value of nominal thickness is chosen as tnominal which is
16 mm. Minimum thickness for vessel is calculated by subtracting back the corrosion
allowance from the nominal thickness.
tmin = tnominal –CA
= 14 mm
Therefore, after uniformity the minimum thickness for the vessel is 14 mm.
17
2.1.4 Maximum Allowable Working Pressure for Vessel (MAWPvessel)
MAWPpart for each part of phase separator, S-102 are calculated by using minimum
thickness, tmin = 14 mm as in previous part.
a. Cylindrical Shell
Referring to ASME Code Part UG.27(c) (1), pressure for circumferential cylinder is
SEt
P=
R + 0.6t
(19290)(0.85)(0.55)
𝑃=
(16.86) + 0.6(0.55)
𝑃 = 1051.45 𝑝𝑠𝑖
b. Ellipsoidal 2:1 Top and Bottom Head
Referring to ASME Code Part UG.32 (d) (1), pressure for both ellipsoidal top and bottom
head is
2 SEt
P=
D + 0.2t
2(19290)(0.85)(0.55)
𝑃=
(1.1) + 0.2(0.55)
𝑃 = 534.29 𝑝𝑠𝑖
18
Table 2.7 Summary of MAWPvessel calculation

Part MAWPpart Static Head, ρgh MAWPvessel
(psig) (psig) (psig)
Cylindrical 1058.2376 3.6745 1054.5631
Ellipsoidal Head 534.2913 0.3042 533.9871
Ellipsoidal Bottom 534.2913 3.9786 530.3127
By taking the lowest MAWPvessel as the MAWP for the vessel, the maximum allowable
pressure of the vessel is 530.31 psi.
2.1.5 Combined Loading
As discussed previously, pressure vessels are subjected to other loads as well other than
pressure such as major and subsidiary loads. Therefore, combined loading analysis is
performed to the vessel so that it can withstand any worst combination of loadings without
failure. However, the main objective of this analysis is to make sure that the pressure vessel
is safely designed by analyzing the primary stresses and elastic stability.
For a cylindrical shell, primary stresses are required to achieve a static equilibrium
which includes longitudinal and circumferential stresses due to internal or external
pressure, direct stress, bending stress and torsional shear stress.
2.1.6 Weight of Vessel Calculation
The weight of vessel is calculated by referring Chemical Engineering Design Fourth

Edition.
a. Weight of Vessel, Wv
Wv = 240 Cv Dm (Hv + 0.8Dm) t
Cv = 1.08
19
Minimum wall thickness, tmin = 14 mm
Mean diameter of vessel, Dm = Di + t
= 0.87 m
Height between tangent lines of the cylindrical section, Hv
Hv = 2.37 m
Therefore, weight of vessel is
Wv = 11.1 kN
2.1.7 Stress Analysis
Vessel thickness, tmin = 14 mm
Internal Diameter, Di = 856 mm
Design Pressure, PD = 435.11 psi = 3 N/mm2
a. Primary Stresses
i. Longitudinal Stress, σL
PDi
L =
4t
20
(3)(856)
𝜎𝐿 =
4(16)
𝜎𝐿 = 40.11 𝑁/𝑚𝑚2
ii. Circumferential Stress, σh
PDi
h =
2t
(3)(856)
𝜎ℎ =
2(16)
𝜎ℎ = 80.24 𝑁/𝑚𝑚2
b. Direct Stress
WV
w =
 ( Di + t )t
11109
𝜎𝑤 =
𝜋(872)16
𝜎𝑤 = 0.253 𝑁/𝑚𝑚2
 w is a compressive stress and the value will be -0.253 N/mm2 since the points are above
the support.
21
c. Bending Stress
M x Di
b =  ( + t)
IV 2
Where Mx = total bending moment
On performing bending stress, values as below are calculated first.
Outer diameter including insulation,
Do = Di + 2(t)
= 0.888 m
1. The second moment of area of the vessel, IV

IV = ( Do 4 − Di 4 )
64
𝜋
𝐼𝑉 = (8884 − 8564 )
64
𝐼𝑉 = 4.17𝑥109
22
2. Effective diameter of column, Deff
Deff = Do
= 0.888 m
3. The load per unit length, w

w = PwDeff ; Where : Pw = Wind Pressure = 1280 N/m2
= (1280)( 0.888)
w = 1137.25 N/m
4. Total bending moment, Mx
wx 2
Mx =
2
w= the load per unit length
x = distance measured from the free end
x = hv = 2.37 m
(1137.25)(2.37)2
𝑀𝑥 =
2
𝑀𝑥 = 3200.46 𝑁. 𝑚
Therefore, value of bending stress is
M x Di
b =  ( + t)
IV 2
23
3200.46 856.47
𝜎𝑏 = ± ( + 16)
4.17𝑥109 2
𝜎𝑏 = 0.34 𝑁/𝑚𝑚2
d. Torsional Shear Stress
The torsional shear stresses can be neglected in preliminary design because these loads will
normally be small, τ = 0.
e. Total Longitudinal Stresses for Upwind and Downwind
By using values that obtained from longitudinal stresses, direct stress and bending stress,
principal stresses are determined by performing calculation below.
i. Total longitudinal stresses, σz
σz (upwind) = σ L + σw + σb
= 40.71 N/mm2
σz (downwind) = σL + σw - σb)
= 40.03 N/mm2
ii. Principal Stresses
Since torsional shear stress is negligible, therefore σ1 = 80.24 N/mm2 ,σ2 = 40.03 N/mm2
and σ3 =1.5 N/mm2.
24
f. Maximum Allowable Stress Intensity, (Δσ)max
The maximum intensity of stress allowed will depend on the theory of failure adopted in
the design method. The maximum shear-stress theory is normally used for pressure vessel
design. The vessel wall thickness must be enough to ensure the maximum stress intensity
does not exceed the design stress for the material of construction.
(Δσ) max = σ 1 - σ3
= 78.74 N/mm2
For austenitic stainless steel, SA-304 maximum allowable stress is 11700 psi, (ASME code
Subpart 1 Stress Table 1A).
Sdesign = 19290 psi
= 132.9 N/mm2
Value of (Δσ)max must be smaller than Sdesign in order for the material to be safely used for
construction.
Comparing both values,
78.74 N/mm2 < 132.9 N/mm2
(Δσmax) < Sdesign
Therefore, the material and design is safe to be used.

25
g. Elastic Stability
Under conditions where the resultant axial stress σz due to the combined loading is
compressive, the vessel may fail by elastic instability (buckling). Local buckling will
normally occurs at a stress lower than that required to buckle the complete vessel.
Therefore, the mechanical design must be checked to ensure that the maximum value of
resultant axial stress does not beyond the critical value at which the buckling occur.
i. Critical buckling, σc
It is calculated for a curved plate subjected to an axial compressive load.
E t
c = ( )
3(1 − v 2 ) Rp
Considering steels at ambient temperature, E= 200,000N/mm2 and with a safety factor of

12,
t
 c = 2 x104
Do
16
𝜎𝑐 = 2𝑥104
888.47
𝜎𝑐 = 360.17 𝑁/𝑚𝑚2
ii. Compressive Stress, σcompressive
∑σcompressive = σ b + σw
= 0.087 N/mm2
26
Comparing both values, 0.087 N/mm2 < 360.17 N/mm2
σcompressive < σc
From comparison above, it is found that the maximum allowable compressive stress is well
above the critical buckling stress. Thus, the design is safe and the buckling process does
not occur. Material chosen is suitable for design purpose.
Table 1.8 Combined Loading

Stress Value (N/mm2)
Longitudinal Stress σL 40.12
Circumferential Stress, σH 80.24
Direct Stress, σw 0.253
Bending Stress, σb 0.341
Total Longitudinal Stress, σz (upwind) 40.71
Total Longitudinal Stress, σz (downwind) 40.03
Table 1.9 Principal Stress Analysis

Stress Value (N/mm2)
σ1 80.24
σ2 40.03
σ3 1.50
Max allowable stress intensity, (∆σ)max 78.74
Buckling stress, σc 360.17
2.1.8 Vessel Support
The support chosen must be able to carry weight of the vessel, contents and any
superimposed loads, for example wind loads. Moreover, the design must be checked to
ensure the resulting stress concentrations are below the maximum allowable design stress
and the vessels as well as fittings are able for inspection and maintenance.
a. Straight Skirt Support
Phase separator S-102 is assumed arranged vertically. Straight skirt support is being chosen
for this phase separator since it is usually used for vertical vessels as they do not impose
concentrate loads on the vessel shell.
27
Skirt supports consists of a cylindrical shell welded to the base of the vessel. A
flange at the bottom of the skirt transmits load to the foundations. Secondly, the design
must consist a reinforced opening. Skirt thickness is a core in supports design. The skirt
thickness must be sufficient to withstand the dead-weight loads and bending moments
imposed on it by the vessel and it will not be under the vessel pressure.
b. Skirt Thickness Design
The resultant stresses in the skirt are:
σs (tensile) = σbs – σws
σs (compressive) = σbs + σws
where:
4M s
 bs =
 ( Ds + ts )ts Ds
W
 ws =
 ( Ds + ts )ts
- Assume the skirt height to be 1.25 m
- Distance measured from free end/ total height, x:
X = height of column + height of skirt
= 4.05
- Shell Diameter, Ds = Di = 0.856 m

28
- Weight of vessel, Wv = 11.1 kN
- Load per unit length, w = 1137.25 N/m
- Bending moment at the base of skirt, Ms:
wx 2
Ms =
2
= 7.46 kN/mm2
4M s
Bending stress in the skirt,  bs =
 ( Ds + ts )ts Ds
𝜎𝑏𝑠 = 2.17 𝑁/𝑚𝑚2
W
Dead weight stress in the skirt,  ws =
 ( Ds + ts )ts
𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡𝑖𝑛𝑔) = 1.508 𝑁/𝑚𝑚2
𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) = 0.683 𝑁/𝑚𝑚2
Therefore, the resultant stresses,
σs (tensile) = σbs – σws(testing)
= 0.666 N/ mm2
σs (compressive) = σbs + σws(operating) = 2.857 N/ mm2

29
The skirt thickness under any worst combination of wind and dead weight loading should
follow the below design criteria:
σs (tensile) < fs J sin θs and σs (compressive) < 0.125E (ts / Ds) sin θs
Assumptions made in the calculation:
1) Weld joint factor, J = 0.85
2) Base angle, θs = 90°
3) Max allowable design stress, fs = 135 N/mm2
4) Young’s modulus, E = 200 000 N/mm2
σs (tensile) < fs J sin θs
0.666 N/mm2 < 114.75 N/mm2
σs (compressive) < 0.125E (ts / Ds) sin θs
2.857 N/mm2 < 174.97 N/mm2
Therefore, the first and the second criterion is satisfied.
From the calculations and justifications, it is shown that the skirt thickness fulfill both
conditions. Since both the criteria are satisfied, assumptions for the value of skirt thickness,
t = 16 mm is acceptable.
30
c. Base Ring and Anchor Belt Design
The loads carried by the skirt will be transmitted to the foundation slab by skirt base ring.
The moment produced by wind and other lateral loads will tend to overturn the pressure
vessel and this will be opposed by the couple set up by the weight of vessel and tensile load
of the anchor bolts. For this phase separator S-102, double plate with gusset is chosen in
order to make the vessel more stable and strongly built as shown in Figure 11.2
Figure 11.2 Single plate with gusset
Source: Sinnott & R.K 2005
The anchor bolts are assumed to share the overturning load equally, and the bolt area
required is given by:
1 4M s
Ab = [ −W ]
N b fb Db
Where,
Ab = Area of one bolt at the root of thread (mm2)
Nb = Number of bolts
31
Fb = Maximum allowable bolt stress (N/mm2)
Ms = Bending moment at the base
W = Weight of vessel (N)
Db = Approximate pitch circle diameter (m)
Assumptions made:
1) Db = 1.6 m
2) Circumference of bolt circle = 5026.55 mm
3) Max allowable bolt stress, fb = 125 N/mm2
Choosing the minimum number of bolts, Nb = 8
Weight of vessel, Wv = 11109 N
1 4M s
Ab = [ −W ]
N b fb Db
𝐴𝑏 = 7.54 𝑚𝑚2
Nominal bolt area chosen: 353 mm2 , Diameter of bolt = 24 mm

32
The base ring must be sufficiently wide to distribute the load to the foundation. The total
compressive load on the base ring per unit length,
 4M s W 
Fb =  + 
  DS  DS 
2
𝐹𝑏 = 17.08 𝑘𝑁/𝑚
Theoretically, the minimum width of base ring, Lb
Fb 1
Lb = 
f c 1000
With maximum allowable bearing pressure within range 3.5 N/mm2 – 7.0 N/mm2
Assume fc = 3.5 N/mm2 (assume worst case scenario)
𝐿𝑏 = 4.88 𝑚𝑚 (theoretical)
The skirt width too low, assume actual Lb as 134 mm.
Base ring thickness,
3 fc
tb = Lr
fr
Where
Lr = distance from the edge of the skirt to the outer edge of the ring (mm)
f’c = actual bearing pressure (N/mm)

33
3 fc
tb = Lr
fr
3(3.5)
𝑡𝑏 = 76√
0.127
𝑡𝑏 = 3.97 𝑚𝑚
Thus, the required minimum thickness for the base ring is 3.79 mm. It is concluded
that the designed straight skirt support is suitable for phase separator S-102 because the
calculated bolt root area is 7 mm2 which is much lower than the M24 bolt root area.
Minimum number of bolt is used which is 8.
2.1.9 Flange Joints
The flanges chosen to be used for the design of this vessel are welding neck flanges joints.
a. Flange Design Calculation
The optimum size of the stainless steel pipe can be determined using the below equation.
Doptimum = 0.465 m0.43 ρ -0.31
Where, m = mass flowrate, kgs-1
ρ = density, kgm-3
34
Figure 12.6.5 Dimensions of weld flange joint, Class 150 steel Pipe
Source: Global Supply Line 2019
Table 1.10 Dimension for the steel welding neck flanges

Stream Nominal d1 D B T d4 f d2 k d3
Pipe Size
(mm)
62 (in) 406 438 711 60 158.75 533 2 35 629 533
63 (out) 14 16 95 14 52 35 2 16 67 38
63 (out) 33 41 155 21 68.33 73 2 22 114 70
Source: Sinnott & R.K 2005
2.1.10 Summary of Calculation
Table 1.11 Summary of calculations for phase separator, S-102

Properties Value
Operating temperature (ºC) 50
Operating pressure (bar) 20
Material of construction Stainless Steel Type-304
Vessel internal diameter (m) 0.856
Vessel external diameter (m) 0.888
Minimum thickness (mm) 14
Vessel height (m) 2.8
Ellipsoidal head/bottom height (m) 0.22
Shell height (m) 2.37
MAWP vessel (bar) 36.56
Longitudinal stress (N/mm2) 40.12
Circumferential stress (N/mm2) 80.24
Direct stress(N/mm2) 0.253
Bending stress (N/mm2) ±0.34
Type of support Straight skirt
Skirt support thickness (mm) 8
Height of skirt (m) 1.25
No of bolts for base ring 8
Area of one bolt (mm2) 353
TOP VIEW OF PHASE

SEPARATOR
CROSS SECTIONAL VIEW OF CROSS SECTIONAL VIEW OF
PHASE SEPARATOR PHASE SEPARATOR
FACULTY OF ENGINEERING AND BUILT

S63 ENVIRONMENT
JABATAN KEJURUTERAAN KIMIA
A A 100
A A B B DAN PROSES
C 100 10 C
PROJECT TITLE:
5° PRODUCTION OF METHANOL AND
300 BIOFLOCCULANT FROM POME
B B 430
430 16

R100 90°
250 700 DRAWING TITLE:

150 MECHANICAL DESIGN OF Phase Separator
(S-102)
SUPERVISOR:
1) PROF. IR DR. SITI KARTOM KAMARUDIN
600
2) PROF. MADYA DR. MASLI IRWAN ROSLI
INDUSTRIAL SUPERVISOR:
1) HEMAVATHI SILVAMANY
C C
PREPARED BY:
CROSS-SECTIONAL SINGLE PLATE
AREA OF MANHOLE CROSS SECTIONAL OF KK 4
WELDING NECK FLANGE WITH GUSSET
406
GROUP MEMBERS:
1) RAVINKUMAR
2) CHEAH CHING WEI
S62 100
300
3) NUREDAHTUL FAEZAN
4) SITI BARAKAH
152 5) AFIQ SYAZWAN
R914 6) SIVA PRIYA
SCALE:
914 DRAWING NOT TO SCALE
485
140 DIMENSION:
ALL DIMENSIONS IN MM
103.9 d3
DRAWN BY:
150
CHEAH CHING WEI (A157594)
d1 24 SUBMISSION DATE:
23/03/2020
T DESIGN SPECIFICATIONS:
S66 1250
d2 Phase Separator (S-102)
76
B
Top head height (mm) : 214
f
Shell height (mm) : 2372
Bottom head height (mm) : 214
134
d4 Design temperature (°C) : 50
6 Design pressure (kPa) : 3000
k
8 Design thickness (mm) : 16
D
Corrosion allowance(mm) :2
WELDING NECK FLANGES
Ellipsoidal heads and cylindrical shell with
DIMENSION (MM) ASME UNS 30400 / SA-240 Type 304 Stainless Steel
NO NOMINAL PIPES SIZES (MM) d1 D B T d4 f d2 k d3
S62 406 438 711 60 158.75 533 2 35 629 533 Straight skirt with ASME SA-516 Grade70
S63 14 16 95 14 52 35 2 16 67 38 Carbon Steel
S66 33 41 155.45 21 68.33 73 2 22 114 70
Bolt size M24 with BS 4190:1967

CHAPTER I
DETAILED DESIGN OF DISTILLATION COLUMN (C-101)
1.1 INTRODUCTION
Distillation column is a unit operation used to separate components which have different
volatility by using boiling point as a reference. In C-101, the feed contains methanol
and water. The function of C-101 is to separate methanol from water to increase the
purity of final product. Methanol is identified as the light key component (LK) while
water as the heavy key (HK) component since methanol has lower boiling point
compared to water. Figure 1.1 shows distillation column C-101 with its operating
condition tabulated in Table 1.1. Table 1.2 shows the flow rate of each stream
connecting to the column.
69 CO-104 Distillate
RD-101 70
66 P-107
Feed
Bottom
67 68
C-101
H-102
Figure 1.1 Distillation Column C-101

2
Table 1.1 Operating condition of distillation column C-101

Feed 50 28
Distillate 75 1.5
Condensate 80 1.5
1.2 MASS BALANCE OF DISTILLATION COLUMN
The material balance of C-101 is obtained and tabulated in Table 1.2.
Table 1.2 Flow rate of distillation column C-101

Component Feed flow rate (kg/h) Distillate flow rate Bottom flow rate (kg/h)
(kg/h)
Water 235.9 0.1 235.9
Methanol 175.0 150.3 24.6
TOTAL 410.9 150.4 260.5
1.3 TYPE OF TRAY
The type of tray that has been used in this distillation column is sieve tray column
because sieve tray column has good efficiency due to its minimum back mixing. Besides
that, the cost for sieve tray is relatively low.
1.4 MATERIAL OF CONSTRUCTION
The pressure vessel design codes and standards include lists of acceptable materials, in
accordance with the appropriate material standards. Since flash tank deals with
relatively clean fluids which is free of corrosive and erosive components, hence a
carbon steel SA-516 is selected as construction material.
3
1.5 MCCABE THIELE METHOD
Mc-Cabe-Thiele method is used to design the distillation column.
Assumptions:
 Constant molar overflow

 There is no any chemical reaction
 There are no any mass generation, mass accumulation and mass generation
1.6 CALCULATION OF AMOUNT OF DISTILLATE AND BOTTOM PRODUCT
Assumptions:
 At steady state there are no any material losses, material accumulation and
material generation.
 There is no any chemical reaction inside the column
Overall material balance:
F=D+W
18.85 = D + W
Material balance:
Fx = Dx + Wx
18.85(0.29) = D(0.9919) + W(0.0442)
Solving above two equations:
D = 8.054 kmol/hr
W = 10.796 kmol/hr
4
1.7 EQUILIBRIUM DATA OF METHANOL AND WATER MIXTURE
Table 1.3 Methanol water equilibrium data
Liquid Vapour T(◦C)
0 0 100
0.1 0.42 87.7
0.2 0.58 81.7
0.3 0.66 78
0.4 0.73 75.3
0.5 0.78 73.1
0.6 0.82 71.2
0.7 0.87 69.3
0.8 0.91 67.6
0.9 0.96 66
1 1 64.5
Temperature composition diagram of methanol/water

100
95
90
Temperature (˚C)
85
80
Vapour
75
Liquid
70
65
60
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Methanol composition
Figure 1.2 Temperature composition diagram of methanol/water

5
1.8 CALCULATION OF MINIMUM REFLUX RATIO
1.8.1 Drawing q Line
Feed is at saturated liquid condition; therefore according to q line equation q value

should be 1. Therefore,
q=1
1.9 CALCULATION OF OPERATING REFLUX RATIO
For many systems the optimum selection of the design reflux ratio will lie between 1.2
to 1.5 times the minimum reflux ratios. Assume operating reflux ratio is 1.25 of
minimum reflux ratio.
𝑅𝑚𝑖𝑛
= 0.4872
𝑅𝑚𝑖𝑛 + 1
𝑅𝑚𝑖𝑛 = 0.95
R = 1.25 × 𝑅𝑚𝑖𝑛
R = 1.25 × 0.95
R = 1.1875

𝑅
Slope of top operating line = 𝑅+1
1.1875
= 1.1875+1
= 0.5429
Therefore TOL equation:
y = 0.5429x + 0.45
6
Vapour-Liquid Equilibrium Curve
Molar fraction of methanol in vapour
Molar fraction of methanol in liquid
Figure 1.3 Vapour liquid equilibrium curve
According to Figure 1.3, the vapour- liquid equilibrium curve counts number of
theoretical plates.
Total number of stages = 15
There are total condenser and partial reboiler. Total condenser does not act as
equilibrium stage, but partial reboiler acts as equilibrium stage. So, reboiler stage need
to reduce from total theoretical stages.
Number of theoretical stages required = 15 – 1
= 14
1.11 CALCULATION OF LIQUID AND VAPOUR AMOUNTS IN BOTH SECTIONS

1.11.1 Rectifying Section
𝐿𝑜
𝑅= 𝐷
1.1875 = 𝐿𝑜 /8.054
𝐿𝑜 = 9.564 𝑘𝑚𝑜𝑙/ℎ𝑟
According to constant molar overflow:
Ln = Lo = 9.564 kmol/hr
7
Material balance:
Vn = Lo + D
Vn = 9.564 + 8.054
Vn = 17.618 kmol/hr
1.11.2 Stripping Section
According to given data, feed is at saturated liquid condition therefore all feeding
liquids join with stripping section liquid.
Lm = F + Ln
Lm = 18.85 + 9.564
Lm = 28.414 kmol/hr
Vm = Vn
Vm = 17.618 kmol/hr
Table 1.4 Density of mixture
Temperature (◦C) Density of liquid mixture (kg/m3) Density of vapour mixture (kg/m3)
77 892.15 1.45
65 761.12 1.11
100 953.12 0.74
1.11.3 Rectifying Section Densities
Rectifying section is operating in between 65˚C -77˚C. Therefore at the average

Liquid density of rectifying section, ρL = (761.12 + 892.15)/2
ρL = 826.6 kg/m3
Vapour density of rectifying section, ρV = (1.11 + 1.45)/2
ρV = 1.28 kg/m3
8
1.11.4 Stripping Section Densities
Stripping section is operating in between 77˚C - 100˚C. Therefore at the average

Similarly;
Liquid density of rectifying section, ρL’ = (892.15 + 953.12)/2
ρL’ = 922.64 kg/m3
Vapour density of rectifying section, ρV’ = (1.45 + 0.74)/2
ρV’ = 1.095 kg/m3
1.11.5 Diameter Of Rectifying Section
𝐿 𝜌𝑉
𝐹𝐿𝑉 = √
𝑉 𝜌𝐿
9.564 1.28
𝐹𝐿𝑉 = √
17.618 826.6
𝐹𝐿𝑉 = 0.0214
Assume tray spacing = 0.45m
K1 = 0.084
The flooding velocity can be estimated from the correlation given by Fair.
𝜌𝐿 − 𝜌𝑉
𝑈𝑓 = 𝐾1 √
𝜌𝑉
826.6 − 1.28
𝑈𝑓 = 0.084√
1.28
𝑈𝑓 = 2.13 𝑚/𝑠
Assume 80% flooding condition; Ua = 0.8Uf
Ua = 0.8 × 2.13
Ua = 1.71 m/s
9
Average molecular weight of the mixture assuming 50% methanol
= 32 × 0.5 + 18 × 0.5
= 25 kg/kmol
Vn = 17.618 × 25/(1 × 3600)
Vn = 0.122 m3/s
𝑉𝑛
= 𝑈𝑎
𝐴𝑛
0.122
𝐴𝑛 =
1.71
𝐴𝑛 = 0.0717𝑚2
An = Ac – Ad
Assume Ad = 12% of Ac
An = Ac – 0.12Ac
An = 0.88Ac
0.0717 = 0.88 × Ac
Ac = 1.85 m2
𝜋𝐷𝑐2
𝐴𝑐 =
4
𝜋𝐷𝑐2
1.85 =
4
Dc = 1.534 m
Therefore, column diameter of rectifying section is 1.534m.
1.11.6 Diameter Of Stripping Section
This is similar to rectifying section:
28.414 1.095
𝐹𝐿𝑉 = √
17.618 922.6
10
𝐹𝐿𝑉 = 0.0556
Assume tray spacing = 0.45 m
K1 = 0.08
922.64 − 1.095
𝑈𝑓 = 0.08√
1.095
𝑈𝑓 = 2.32 𝑚/𝑠
Assume 80% flooding condition;
Ua = 0.8 × 2.32
Ua = 1.86 m/s
There is no vapour amount changes in stripping section compared to rectifying section.

Therefore,
Vm = 0.122 m3/s
𝑉𝑛
= 𝑈𝑎
𝐴𝑛
0.122
𝐴𝑛 =
1.86
𝐴𝑛 = 0.0659 𝑚2
Therefore according to above derived equations:
An = 0.88Ac
Ac = 1.75 m2
Dc = 1.49 m
Therefore stripping section column diameter is 1.49m.
1.12 CALCULATION OF HOLE DIAMETER AND AREA
Hole size less than 6.5 mm. Entrainment may be greater with larger hole sizes. (Page
No. 568 Coulson & Richardson 6th volume 4th edition).
Therefore hole diameter is considered as 6mm.

11
1.12.1 Number Of Holes In A Tray At Rectifying Section
For a plate, there is one downcomer on the plate and top downcomer also affected to
bottom plate. Therefore, two downcomer areas need to be reduced from the active area.
Aa = Ac – 2Ad
Aa = Ac – (0.12 × 2Ac)
Substituting to above equation,
Aa = 0.0619 m2
Ah = 0.1Aa
Total holes area in a tray, Ah = 0.1 × 0.0619
= 0.00619 m2
0.0062
Area of a hole =π× 4
= 2.83 × 10-5 m2
0.00619
= 219
1.12.2 Number Of Holes In A Tray At Stripping Section
All equations are similar to rectifying section calculation:
Aa = 0.0569 m2
Ah = 0.1Aa
Ah = 0.00569 m2
0.00569
= 201
12
1.13 FLOW PATTERN OF RECTIFYING SECTION

9.564 𝑘𝑚𝑜𝑙 25𝑘𝑔 826.6𝑘𝑔
Liquid flow rate of rectifying section = ( 3600 × 𝑘𝑚𝑜𝑙)/( )
𝑠 𝑚3
= 8.035 × 10-5 kg/s
1.14 FLOW PATTERN OF STRIPPING SECTION

28.414 𝑘𝑚𝑜𝑙 25𝑘𝑔 922.6𝑘𝑔
Liquid flow rate of stripping section = ( 3600 × 𝑘𝑚𝑜𝑙)/( )
𝑠 𝑚3
= 2.14 × 10-4 kg/s
1.15 COLUMN EFFICIENCY CALCULATION
“Van Winkle’s correlation” is used to calculate to efficiency of column.
Maximum and minimum temperatures of inside the column are respectively 100˚C and
65˚C. Assume liquid temperature is average temperature of column. Assume properties
of liquid mixture equal to water properties.
100+65
Average temperature of column = 2
= 82.5˚C
Surface tension of liquid at 82.5˚C is calculated according to their molar basis of feed.
σL = 0.0513 N/m
For Uv, maximum Ua value from both sections is taken.
Uv = Ua
Uv = 1.86 m/s
μL = 4.862 × 10-4 Ns/m2
Since there are both vapour and liquid densities, the average density is taken.
ρV = 1.19 kg/m3
ρL = 874.62 kg/m3
DLK = 5 × 10-9 m2/s
Weir height, hw = 45mm
Fractional area calculation:

13
𝑎𝑟𝑒𝑎 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠
FA = Fractional Area = 𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑙𝑢𝑚𝑛 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
0.005691
FA = 0.625
FA = 0.00911
Surface tension number calculation:

𝜎𝐿
𝐷𝑔 =
𝜇𝐿 × 𝑈𝑣
0.0513
𝐷𝑔 =
0.0004862 × 1.86
Dg = 56.83
Liquid Schmidt number calculation:

𝜇𝐿
𝑆𝑐 =
𝜌𝐿 × 𝐷𝐿𝐾
0.0004862
𝑆𝑐 =
874.62 × 5 × 10−9
Sc = 111
Reynolds number calculation:
ℎ𝑤 × 𝑈𝑣 × 𝜌𝑣
𝑅𝑒 =
𝜇𝐿 × 𝐹𝐴
0.045 × 1.86 × 1.19

𝑅𝑒 =
0.0004862 × 0.00911
Re = 22457.24
Therefore,
𝐸𝑚𝑣 = 0.07𝐷𝑔0.14 𝑆𝑐 0.25 𝑅𝑒 0.08
Emv = 0.07 × 56.830.14 × 1110.25 × 22457.240.08
Emv = 0.89 = 89%
Efficiency of column = 89%

14
Number of theoretical stages required = 14
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠

𝐸𝑚𝑣 =
14
0.89 =
Number of actual stages = 15.7
Therefore, number of actual stages required = 16
1.17 CALCULATION OF HEIGHT OF THE COLUMN
Assume thickness of a plate is 5mm.
Total thickness of trays = 0.005 × 16
= 0.08 m
Height of column, Hc = (Nact – 1)Hs +∆H + plate thickness
= (16 – 1) × 0.45 + 1 + 0.08
= 7.69 m
Therefore, height of column is 7.69m.
1.18 CALCULATION OF FEED TRAY LOCATION
Assume plate numbers are counted from top to bottom.
According to vapour-liquid equilibrium curve, feed tray location can be found.
Feed composition of methanol is 0.29. This value is at 11th plate (theoretical) of the
column. To calculate the actual feed tray location, the value need to be divided with
column efficiency.
11
Therefore feed tray location = 0.89
= 12.33
= 13th plate
15
The design of distillation column C-101 is summarized in table below:

No. of stages 15
Height, m 7.69
Feed location 13th
CHAPTER II
MECHANICAL DESIGN OF DISTILLATION COLUMN
2.1 INTRODUCTION
A pressure vessel is a closed container designed to hold gases or liquids at a pressure

substantially different from the ambient pressure. Consequently, pressure vessels are
containers for the containment of pressure, either internal or external. Therefore, the
mechanical designs of six pressure vessels are shown in this chapter. The designs are
subject to internal procedures only.
2.2 VESSEL DESIGN FOR DISTILLATION COLUMN C-101

2.2.1 Material Selection
The operating temperature and pressure are 50oC and 28 bar respectively. Methanol is
a flammable gas. This chemical needs special construction material to construct the
pressure vessel. Carbon steel SA-516 grade 70 is selected as the construction material
since it has a lower price than other materials and is available in a wide range of standard
forms and sizes (Towler & Sinnot 2013). Iron is the main composition of this material.
Carbon steel SA-516 grade 70 has the highest tensile strength (70-90 ksi) and yield
strength (38 ksi) among the other grades.
2.2.2 Design Specification
The mechanical design of distillation column C-101 is subjected to ASME internal

pressure procedure. This is because the absolute pressure of the vessel is higher than the
atmospheric pressure, which is higher than 15 psi. Figure 11.1 below shows the shape
of the vessel and its dimension. Cylindrical body is chosen because this is the common
shape of distillation column body. The ellipsoidal heads are chosen because it is more
economical, suitable for high pressure and domed to reduce mechanical stresses.
17
Di
Figure 2.1 Dimension of Distillation Column C-101
The distillation column is designed with a vertical vessel with 2:1 ellipsoidal head at
the top and the bottom. This column is designed under internal pressure, 406.1 psi (28
bar). The construction material is carbon steel SA-516 grade 70, with corrosion
allowance of 2 mm. The operating condition for distillation column C-101 is shown in
Table 2.1.
Table 2.1 Operating Condition in Distillation Column C-101

Condition Values
Operating pressure, Po 28 bar (406.1 psi)
Length 7.69 m
Diameter 1.538 m
18
Table 2.2 The inlet stream for each component
Substance Mass flow rate, kg/h Density, kg/m3

Methanol 175.0 792
Water 235.9 1000
Total 410.9
For ellipsoidal height, the ratio of the ellipsoidal head is 2:1

𝐷𝑖
ℎ𝑒 =
4
1.538
= 4
= 0.375 m

hc = H − 2he
= 7.69 – 2(0.375)
= 6.9 m
Table 2.3 Dimension of Distillation Column C-101

Vessel Height, H 7.69 302.756 25.230
Shell Height, Hs 6.9 271.654 22.638
Top head height, ho 0.375 14.764 1.230
Bottom head height, ho 0.375 14.764 1.230
2.2.3 Design Pressure
Since the operating pressure of the distillation column (28 bar) is greater than
atmospheric pressure (Pa > Patm), the distillation column is designed under internal
pressure. Firstly, the design pressure for each part of the vessel is calculated by using
equation:
PD = PO + 0.433h
19

h = height (ft)
Hence,
i. Ellipsoidal 2:1 top head, PD = 406.1 + 0.433 (1.312) = 406.68 psi
ii. Cylindrical shell, PD = 406.1 + 0.433 (22.638 + 1.312) = 451.02 psi
iii. Ellipsoidal 2:1 bottom head, PD = 406.1 + 0.433 (22.638 +1.312+ 1.312)
= 452.05 psi
Table 2.4 New Design Pressure for C-101

2.2.4 Minimum Wall Thickness
PD (447.35)(60.534)
Thickness, t = 2SE−0.2P = 2(20015.2)(1)−(0.2)(447.35) =0.6780 in

PR (458.13)(60.534/2)
Thickness, t = SE−0.6P = (20015.2)(1)−(0.6)(458.13) =0.7024 in

PR (458.13)(60.534/2)
Thickness, t = 2SE+0.4P = 2(20015.2)(1)−(0.4)(458.13) =0.3448 in
20
For bottom ellipsoidal head:

PD (458.75)(60.534)
Thickness, t = 2SE−0.2P = 2(20015.2)(1)−(0.2)(458.75) =0.6953 in
thickness calculated for each part.
toverall = 0.7024 in = 17.874 mm
After considering the corrosion allowance of 2mm,

t = 17.874 + 2 = 19.874 mm
The closest tnominal of type SA-516 Grade 70 is 20.0 mm.

= 20.0 mm – 2 mm
= 18 mm (0.7074 in)
design pressure for each part of the column can be found in ASME Code UG-32 part
(D) and UG-27 part (c). By using tmin from the calculation above, the MAWPvessel is
calculated.

2SEt 2(20015.2)(1)(0.7074)
60.534+0.2(0.7074)
Static head PH = 0.433 (1.312) = 0.568 psi

For the bottom head ellipsoidal:

2SEt 2(20015.2)(1)(0.7074)
60.534+0.2(0.7074)
Static head, PH = 0.433 (22.638 +1.312+ 1.312) = 10.938 psi

∴ MAWPvessel = internal pressure – static head = 458.75 psi
21

Circumferential
SEt (20015.2)(1)(0.7074)
Internal pressure = R+0.6t = 60.534 = 461.31 psi
( )+0.6(0.7074)
2

Longitudinal
2SEt 2(20015.2)(1)(0.7074)
Internal pressure = R−0.4t = 60.534 = 944.39 psi
( )+0.4(0.7074)
2

Table 2.5 Internal pressure and MAWPvessel for each part of the distillation column C-101
Top ellipsoidal head 466.69 0.568 466.12
Cylindrical shell
Longitudinal 944.39 10.37 934.03
Bottom ellipsoidal head 466.69 10.938 458.75
By choosing the smallest value, the MAWPvessel is 458.75 psi.
2.2.6 Combined Loading
22
a. Primary stresses

(a) Longitudinal (  L ) and circumferential stresses (  H ) due to pressure
(b) Direct stress (  W )
(c) Bending stresses (  b )
(d) Torsional shear stresses (  )

P0 = 458.75 psi = 3.164 N/mm2
PD = (1.10) (458.75)
= 504.625 psi = 3.48 N/mm2
a) Longitudinal (  L ) and circumferential (  h ) stresses
𝑃𝐷𝑖
σL = 4𝑡
3.164 (1538)
= 4(18)
= 67.583 N/mm2
𝑃𝐷𝑖
σh = 2𝑡
3.164 (1538)
= 2(18)
= 135.165 N/mm2
b) Direct stress, σw
𝑊
σw = (𝐷𝑖+𝑡)𝑡
where, W = Wv + WI
𝜋
𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡
Cv = 1.15
Dm = Di + t = 1.538 + 0.018 = 1.556 m
Hv = 2 2
hc + h = 6.9+ 3 (0.375) = 7.167 m
3 e
t = 18 mm
23
Hence, Wv = 240(1.15)(1.556)(7.167 + 0.8 (1.556))(18)

= 6502.24 N
𝑊
6502.24
= 𝜋 (1556+18)18
c) Bending stresses, σb
𝑀 𝐷
σb = ± 𝐼 ( 2𝑖 + 𝑡)
𝑣

𝑊𝑥 2
𝑀=
2
x = 𝐻𝑣 = 7.167 m
𝐷𝑒𝑓𝑓 (including insulation) = 𝐷𝑜 = 𝐷𝑖 + 2t = 1.574 m
Pw = 1280 N/m2
W = 𝑃𝑤 𝐷𝑒𝑓𝑓 = (1280)(1.574) = 2014.72 N/m
2014.72 x 7.1672
M= =51739.13 Nm =5.174 x 107 Nmm
2
π π
Iv = 64 (Do 4 − D1 4 ) = (1.5744 − 1.5384 ) = 0.000266 m4
64
= 2.66 × 1010 mm4
𝑀 𝐷
Hence, Bending stresses, σb = ± 𝐼 ( 2𝑖 + 𝑡)
𝑣
5.174 x 107 1538

=± ( + 18)
2.66×1010 2
= ± 1.529 N/mm2
d) Torsional shear stresses, τ

The torsional shear stresses can be neglected in preliminary vessel design because
these loads will normally be small, where, τ = 0.
24
b. Principal stresses, σ1 AND σ2
1
σ1 = 2 [σh + σz + √(σh − σz )2 + 4τ2 ]
1
σ2 = 2 [σh + σz − √(σh − σz )2 + 4τ2 ]

σz (upwind) = 67.583 + (−0.0739) + 1.529
= 69.038 N/mm2

σz (downwind) = 67.583 + (−0.0739) − 1.529
= 65.980 N/mm2

Total longitudinal stress, σz (upwind) 69.038
Total longitudinal stress, σz (downwind) 65.980

1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [135.165 + 69.038 + √(135.165 − 69.038)2 + 4(0)2 ]
= 135.165 N/mm2 = σh
1
σ2 = 2 [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [135.165 + 69.038 − √(135.165 − 69.038)2 + 4(0)2 ]
25
= 69.038 N/mm2 = σz (upwind)

1
σ1 = 2 [𝜎ℎ + 𝜎𝑧 + √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
1
= 2 [135.165 + 65.980 + √(135.165 − 65.980)2 + 4(0)2 ]
= 135.165 N/mm2 = σh
1
σ2 = [𝜎ℎ + 𝜎𝑧 − √(𝜎ℎ − 𝜎𝑧 )2 + 4𝜏 2 ]
2
1
= 2 [135.165 + 65.980 − √(135.165 − 65.980)2 + 4(0)2 ]
Assume τ = 0, σ3 = 0.5 (3.164) = 1.582

σ1 – σ3 = 135.165 – 1.582
= 133.583 N/mm2

σ2 – σ3 = 69.038 – 1.582
= 67.456 N/mm2

According to ASME Code, maximum allowable stress at temperature 374 oF,
S = 138 N/mm2
Since, (∆σmax) = 133.583 N/mm2 ˂ S = 138 N/mm2, therefore, the design is safe to use.
d. Elastic Stability
E  t 

31 v2  R
 p


σc = 2 x 104 (t / D0) = 2 x 104 (18 / 1.574) = 228.717 N/mm2
26

Δσmax  S and (∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 ) < 𝜎𝑐 Therefore, the design is safe.
2.2.7 Vessel Support Analysis
The vessels support must be designed to withstand the weight of the vessel and contents
and any superimposed loads such as wind loads. Support will impose localized loads on
the vessel wall, and the design must be checked to ensure resulting stress concentrations
are below the maximum allowable design stress. It is also important to allow the ease
of access to the vessel and the fittings for inspection and maintenance (Sinnott 2005).
a. Thickness of support
The skirt support had been chosen as the support for distillation column. Since the
height of distillation column, H = 7.69 m with the internal diameter, Di = 1.538 m, the
skirt support is suitable for the use of tall columns which subject to wind loading. One
of the most important factors is they do not impose concentrated loads on the vessel
shell (Sinnott 2005).
The resultant stresses in the skirt,
σs (tensile) = σbs – σws ; σs (compressive) = σbs + σws
4𝑀
Bending stress in the skirt, σbs = 𝜋(𝐷 +𝑡 𝑠)𝑡
𝑠 𝑠 𝑠 𝐷𝑠
𝑊
Dead weight stress in the skirt, σws = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
Assume skirt support height, hs = 2.3 m, skirt thickness, ts = 45 mm

Total height, x = H + hs = 7.69 + 2.3 = 9.47 m
Ds = Di = 1538 mm
W = 2014.72 N/m (from 6.2.6.1(c))
27
Maximum dead weight load on the skirt will occur when the vessel is full of water.
𝜋
Approximate weight = (4 × 1.5382 × 10) × 1000 × 9.81
= 140333.7998 N
Weight of vessel = 6502.24 N
Total weight, W = 140333.7998 + 6502.24 = 146836.04 N
For the bending stress in the skirt,  bs
𝑊𝑥 2
Maximum bending moment, Ms = 2
(2014.72 )(9.474)2
= 2
= 90410.92 Nm
Hence,
4(90410.92 × 1000 )
Bending stress in the skirt,  bs = 𝜋(1538+45)(45)(1538)
= 1.0507 N/mm2
𝑊
Dead weight stress in the skirt, σws (hydraulic test) = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
6502.239
= 𝜋(1538+45)45
= 0.0291 N/mm2
𝑊
Dead weight stress in the skirt, σws (operating) = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
146836.04
= 𝜋(1538+45)45
= 0.6561 N/mm2
Therefore, resultant stresses
Maximum σs (tensile) = σbs – σws = 1.0507 – 0.0291 = 1.0217 N/mm2
σs (compressive) = σbs + σws = 1.0507 + 0.6561 = 1.7068 N/mm2
The skirt thickness under the worst combination of wind and dead weight loading
should not exceed the following design criteria.
σs (tensile) ˂ fs J sinθs
σs (compressive) ˂ 0.125E (ts/Ds) sinθs
28
Assumptions:
 maximum allowable stress for skirt material at Tamb = 20°C, fs = 138 N/mm2
 weld joint factor, J = 1.0
 base angle, θs = 90°
 Yong’s modulus, E = 200000 N/mm2
Therefore,
fs J sinθs = 138(1.0) sin (90°)
= 138 N/mm2
0.125E (ts/Ds) sinθs = 0.125(200000)(45/1538)sin(90°)

= 731.47 N/mm2
σs (tensile) = 1.0217 N/mm2 ˂ fs J sin θs = 138 N/mm2

σs (compressive) = 1.7068 N/mm2 ˂ 0.125E (ts/Ds) sin θs = 731.47 N/mm2
Since both criteria are satisfied, thus, the assumed value of skirt thickness, ts = 0.045 m
is acceptable. With corrosion allowance of 2 mm, the design skirt thickness, t s = 0.047
m.
b. Base ring and anchor bolt design
The loads carried by the skirt will be transmitted to the foundation slab by the skirt base
ring. The moment produced by wind and other lateral loads will tend to overturn the
pressure vessel. This will be opposed by the couple set up by the weight of the vessel
and the tensile load of the anchor bolts (Sinnott 2005).
required:
1 4Ms
Ab = [ − W]
Nb fb Db

29
Assumptions:
 bolt circle diameter, Db = 1.574 m = 1574 mm
 circumference of bolt circle = 1574 π mm = 4944.87 mm
 maximum allowable bolt stress, fb = 125 N/mm2
 take number of bolts as 8
𝜋×1.574×1000
Bolt spacing = = 618.11 mm
8
Bolt spacing > 600 mm, therefore the bolt spacing is satisfactory.

The bending moment at the base, Ms = 90410.92 Nm
1 4Ms
Ab = [ − W]
Nb fb Db
1 4(90410.92 )
Ab = [ − 6502.24 ]
8 × 125 1.574
Ab = 223.26 mm2
Use M24 bolts (BS4190:1967) root area = 353 mm2 (Towler & Sinnott 2013)

4Ms W
Fb = [ 2
+ ]
πDs πDs
4(90410.92) 6502.24
Fb = [ + ]
π x 1.5742 π × 1.574
Fb =47779.48 Nm−1
30
Fb 1
Lb = × 3
fc 10
47779.48
Lb =
3.5x 103
Lb = 13.651 mm
beam:
3𝑓𝑐′
𝑓𝑟

Take Lr = 76 mm,
= 76 + 45 + 50 mm
= 171 mm
𝐹𝑏 47.7795
𝑓𝑐′ = = = 0.2794 N/mm2
171 171
3𝑓 ′
𝑟
3(0.2794)
= 76√ 140
= 5.881 mm
31
c. Flanged Joint
transferring stress to the adjoining pipe. Welding-neck flange is the best-designed butt
weld available because of its inherent structural value and ease of assembly. Welding-
neck flange have high strength and high resistance to dishing, it is manufactured with a
long-tapered hub. The tapered hub is created by the gradual increase in metal thickness
from the weld join to the flange facing. The welding-neck flange diagram is shown in
Figure 1.2.
Figure 2.2 Diagram of Weld Neck Flange ASME B16.5
Table 2.7 Size of flanges used for fitting on each pipe on C101
D B1 t T1 X t2 t1 A h K G f
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
584.20 336.55 53.85 142.75 425.45 71.12 17.78 355.60 31.75 514.35 412.75 1.60
95.25 15.75 14.22 52.32 38.10 30.48 7.62 21.34 15.75 66.55 35.05 1.60
444 254.51 47.75 117.35 320.55 55.68 13.92 273.05 28.45 387.35 323.85 1.60
584.20 336.55 53.85 142.75 425.45 71.12 17.78 355.60 31.75 514.35 412.75 1.60
584.20 336.55 53.85 142.75 425.45 71.12 17.78 355.60 31.75 514.35 412.75 1.60
32
2.2.8 Summary For Design
By considering the internal pressure of the vessel, distillation column C-101, the
conditions that are needed for the design have been calculated through series of
formulae stated. The conditions for the design our distillation column have been
summarized and tabulated as followed in Table 2.8.
Table 2.8 Summary for design condition of distillation column C-101

Shell height
(133.583 < 138)

Elastic stability N/mm 2
(∑σ)compressive < σc
(1.603 < 228.72)

1.0217 < 138
1.7068 < 731.47

2
Area of one bolt, Ab mm 223.26
the ring, Lr
33
2.2.9 Nameplate for Distillation Column C-101
KK4 Bioflocculant and Methanol Company
450.95 80
80 450.95
DC 001
2020
Figure 2.3 Nameplate for Distillation Column C-101

1500
S69 Top view of distillation column
Cross sectional view of skirt
375
Manhole 1 S69a
1200
Faculty of Engineering & Built

360
Environment
1000
78
Department of Chemical Engineering
Project Title:
Production of Methanol and
1500 Skirt support Bioflocculant from POME

18
Top view of sieve plate Group KK4
6
B1
Supervisors:
1. Prof. Ir. Dr. Siti Kartom Kamarudin
7690
2. Prof. Madya Dr. Masli Irwan Rosli

3. Ms. Hemavathi Silvamany
Group members:
2300
45
1. Cheah Ching Wei
2. Ravinkumar Manimaran
S66 3. Nuredahtul Faezan
4. Siti Barakah
1000 5. Sivapriya Nadaraju
6. Afiq Syazwan
Welding neck flange B2
Mechanical Drawing of Distillation
Column (C-101)
Manhole 2 S67a Detail drawing of B1 Detail drawing of B2 Drawn by:

Sivapriya Nadaraju (A158432)
Submission date:
S67 23rd March 2020
X
Drawing not to scale
A
Unit: Millimeter
t2
t1
T1
B1
h Diameter: 1500 mm
Height: 7690 mm
G t
Operating pressure: 2800 kPa
K f Operating temperature: 50 °C
D
Material type: Carbon steel SA516
Welding-neck flange dimension (mm) Grade 70
Stream Component D B1 t T1 X t2 t1 A h K G f Height of ellipsoidal head: 375 mm
66 Methanol + Water 584.20 336.55 53.85 142.75 425.45 71.12 17.78 355.60 31.75 514.35 412.75 1.60 Height of cylindrical shell: 6900 mm
67 Water 95.25 15.75 14.22 52.32 38.10 30.48 7.62 21.34 15.75 66.55 35.05 1.60 Minimum wall of thickness: 18 mm
69 Methanol 444.50 254.51 47.75 117.35 320.55 55.68 13.92 273.05 28.45 387.35 323.85 1.60
Skirt thickness: 45 mm
Corrosion allowance: 2 mm
67a Methanol + Water 584.20 336.55 53.85 142.75 425.45 71.12 17.78 355.60 31.75 514.35 412.75 1.60
Design pressure: 3109.19 kPa
69a Methanol + Water 584.20 336.55 53.85 142.75 425.45 71.12 17.78 355.60 31.75 514.35 412.75 1.60
MAWP vessel: 3162.97 kPa
226
APPENDIX D
PFD BEFORE HEAT INTEGRATION

HE-101 Kettle Reboiler K-101 Compressor R-101 Reactor CO-101 Cooler CO-102 Cooler CO-103 Cooler CO-104 Cooler
P-101 Pump
T-101 UASB SR-101 Scrubber HE-102 Heat Exchanger S-101 Phase Separator K-104 Compressor S-102 Phase Separator RD-101 Reflux Drum
CP-101 Cooling Pond
T-102 UASB SF-101 Seed Fermenter K-102 Compressor K-103 Compressor R-102 Reactor C-101 Distillation Column CO-105 Cooler
P-102 Pump
T-103 UASB T-104 Settlement Tank H-101 Heater P-106 Pump P-107 Pump P-108 Pump H-102 Heater
P-103 Pump
B-101 Blower P-105 Pump GH-101 Gas Holder CF-101 Centrifuge M-101 Mixer CF-102 Centrifuge CO-106 Cooler
P-104 Pump
F-101 Air Filter T-106 Buffer Tank T-105 MBBR HE-103 Heat Exchanger BP-101 Belt Press CV-101 Conveyor D-101 Rotary Dryer
CV-102 Conveyor
FACULTY OF ENGINEERING
53 64 65
54
56 AND BUILT ENVIRONMENT
57 58 63
FUEL
59 61 62
CO-101 CHEMICAL ENGINEERING
51a K-103
S-101
PROGRAMME
49 50 R-101 CO-102 K-104 CO-103
51
K-102 HE-102
51b H-101 52 66
HE-101 60 S-102
48
WATER 55
45 TITTLE
PRODUCTION OF METHANOL AND
20 44 R-102 BIOFLOCCULANT FROM POME
47 69 CO-104
SODIUM
HYDROXIDE
24
K-101 RD-101 PROCESS FLOW DIAGRAM (PFD)
70 71
AFTER HEAT INTEGRATION
NUTRIENT 3
GH-101 CO-105
SR-101 P-108 METHANOL SUPERVISOR
11 KAMARUDIN
ETHANOL
24f 2) PROF. MADYA DR. MASLI
12 IRWAN ROSLI
19
2
B.marisflavi INDUSTRIAL SUPERVISOR
Vent air
67 68 68a 1) HEMAVATHI SILVAMANY
1 T-101 C-101
37
CP-101 H-102
WATER
8 13 46
GROUP
POME P-101 5 SF-101
KK4
LEAN SODIUM
25 HYDROXIDE
P-102 14
4
25a GROUP MEMBERS:
24b
39 SLUDGE OIL
1) RAVINKUMAR
T-102
9 17
27a WASTEWATER
2) CHEAH CHING WEI
15
6
T-106 CF-102 3) NUREDAHTUL FAEZAN
23 35 43a
30 WASTEWATER
16 T-105 29 36 CO-106 4) SITI BARAKAH
P-103
40 43 5) AFIQ SYAZWAN
22 P-106
10
18 CF-101 38 6) SIVA PRIYA
T-103 M-101
P-107 42
7 CV-102
P-105
31 D-101 RAW MATERIAL
28
24c
24d 24e T-104 BIOFLOCCULANT
P-104 33
32
24a
PRODUCT
CV-101
SODIUM 21 34 FERTILIZER
HYDROXIDE 27 41 41a
26 26a BP-101
WASTEWATER
DATE : 23th MARCH 2020
F-101 HE-103
B-101
AIR
Stream 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24a 24b 24c 24d 24e 24f 25 26 26a 27 27a 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41a 42 43 43a
Temperature (°C) 80 80 37 37 37 37 37 37 37 37 37 37 37 37 37 37 37 37 37 30 30 30 30 30 30 30 37 37 37 37 37 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 90 80 90 30
Pressure (bar) 1 1.5 1 1 1 1 1 3 3 3 1 1 1 1 1 1 1 1 1 1 1 3 1.5 1 1 1 1 1 1 1 1 1 1.5 1.5 1.5 1 3 1 1 1 1 1 3 1 1.5 1 1 1.4 1.3 1 1.2 1
Phase L L L L L L L L L L G S+L G S+L G S+L S+L S+L G G S+L L L L L L S+L S+L S+L S+L S+L G G G G G L L S S+L S L L L L L L S G G S V G+L
Hydrogen Sulphide (ppm) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1600.0 0.0 1600.0 0.0 1600.0 0.0 0.0 0.0 1600.0 1600.0 0.0 0.0 0.0 - - - - - - - 0.0 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
B.marisflavi (kg/hr) - - - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Water (kg/hr) 34000.0 34000.0 0.0 34000.0 11333.3 11333.3 11333.3 11333.3 11333.3 11333.3 0.0 11333.3 0.0 11333.3 0.0 11333.3 22666.7 34000.0 0.0 0.0 510.0 33490.0 33490.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 33487.8 33487.8 3.3 513.3 144.4 368.9 33484.4 33484.4 53.2 33537.8 33460.8 77.1 0.0 0.0 40.3 36.8 36.8
Suspended Solid (kg/hr) 1800.0 1800.0 0.0 1800.0 600.0 600.0 600.0 600.0 600.0 600.0 0.0 124.8 0.0 124.8 0.0 124.8 249.6 374.4 0.0 0.0 3.7 370.7 370.7 - - - - - - - - 0.0 0.0 0.0 - 0.0 36.7 36.7 0.0 0.0 4.1 0.0 36.7 36.7 0.0 36.7 36.7 0.0 0.0 0.0 0.0 0.0 0.0
Sludge Oil (kg/hr) 216.0 216.0 216.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Methane (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 73.3 0.0 73.3 0.0 73.3 0.0 0.0 0.0 146.7 222.6 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Carbon Dioxide (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 143.2 0.0 143.2 0.0 143.2 0.0 0.0 0.0 286.3 429.5 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Biomass (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 285.9 0.0 285.9 0.0 285.9 571.8 857.7 0.0 0.0 771.9 85.8 85.8 - - - - - - - - 0.0 0.0 0.0 - 0.0 26.2 26.2 26.2 798.1 758.2 39.9 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Nutrient medium (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Bioflocculant (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 329.2 329.2 0.0 0.0 0.0 0.0 329.2 329.2 0.0 329.2 0.0 329.2 0.0 0.0 329.2 0.0 0.0
Ethanol (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 - - - - - - - - 0.0 0.0 0.0 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 310.7 310.7 62.1 248.6 0.0 0.0 0.0 248.6 248.6
Air (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 - - - - - - - - 5268.7 5268.7 5188.7 80.0 3672.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1516.7 1516.7 0.0 1516.7 1516.7
Total (kg/hr) 36016.0 36016.0 216.0 35800.0 11933.3 11933.3 11933.3 11933.3 11933.3 11933.3 216.5 11744.0 216.5 11744.0 216.5 11744.0 23488.0 35232.1 433.0 652.1 1285.6 33946.4 33946.4 - - - - - - - 0.0 5268.7 5268.7 5188.7 80.0 3672.0 33879.9 33879.9 29.6 1311.5 906.7 408.8 33850.3 33850.3 363.9 34214.3 33559.6 654.8 1516.7 1516.7 369.5 1802.1 1802.1
Stream no 44 45 46 47 48 49 50 51 51a 51b 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 68a 69 70 71
Temperature(℃) 30 30 30 30 30 30 160 75 350 690 700 700 350 350 350 450 350 150 250 250 50 50 50 30 50 103 103 103 68 68 30
Pressure (bar) 3 1 1 2 1 1 1.2 1 28 26 25 18 3 3 3 30 30 20 50 45 30 25 24 10 23 1.5 1.5 1.5 1.5 1.5 1
Phase G L L G G V V V V V V V V+L L V V V V V V V+L V V V L L L L G L L
Water (kg/hr) 0.0 23.0 23.0 0.0 0.0 250.8 250.8 250.8 250.8 250.8 250.8 136.8 136.8 0.7 136.1 136.1 136.4 136.4 136.4 237.7 237.7 1.8 0.3 1.5 235.9 235.9 235.9 236.6 0.1 0.1 0.1
Methane (kg/hr) 222.6 0.0 0.0 222.6 222.6 0.0 0.0 222.6 222.6 222.6 222.6 99.2 99.2 0.0 99.2 99.2 149.0 149.0 149.0 149.0 149.0 149.0 49.6 99.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Carbon Dioxide 429.5 0.0 0.0 429.5 429.5 0.0 0.0 429.5 429.5 429.5 429.5 369.3 369.3 0.0 369.3 369.3 449.3 449.3 449.3 201.8 201.8 201.8 80.8 123.7 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Carbon Monoxide (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 253.8 253.8 0.0 253.8 253.8 381.4 381.4 381.4 381.4 381.4 381.4 127.1 254.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Hydrogen (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 43.8 43.8 0.0 43.8 43.8 51.6 51.6 51.6 17.6 17.6 17.6 7.8 9.8 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Methanol (kg/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1.2 1.2 1.2 181.4 181.4 6.4 1.2 5.2 175.0 24.6 24.6 24.6 150.3 150.3 150.3
Sodium Hydroxide (kg/hr) 0.0 1.2 1.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1.0 0.0 0.0 0.0
Total (kg/hr) 652.1 24.2 24.2 652.1 652.1 250.8 250.8 902.9 902.9 902.9 902.9 902.9 902.9 0.7 902.2 902.2 1168.8 1168.8 1168.8 1168.8 1168.8 757.9 266.7 494.2 410.9 260.5 260.5 262.2 150.4 150.4 150.4
227
APPENDDIX E
WASTE WATER TREATMENT PLANT

B-101 Blower T-101 Equalization Tank T-103 Aeration Tank T-106 Settling Tank PP-101 Phytoremediation Pond
B-102 Blower P-101 Pump T-104 Aeration Tank P-103 Pump P-105 Pump
T-102 Aeration Tank P-102 Pump P-104 Pump
R-101 Moving Bed Bioreactor T-105 Settling Tank CF-101 Decanter Centrifuge
LIQUID DISCHARGE 7 AND BUILT ENVIRONMENT
FROM SCREW PRESS SPENT AIR
19 23
2
9
TREATED POME CHEMICAL ENGINEERING
3 13 PP-101 TREATED WATER
8 16 18
PROGRAMME
T-102 T-103 T-104 T-106
METHANOL,WATER T-101 P-101 22 P-103 24
20
4 6
12 15 17 20a
TITTLE
SLUDGE WASTE TREATMENT PLANT
21
B-101
ETHANOL, WATER,AIR FOR PRODUCTION OF
10 11 14
5 METHANOL AND
B-102
AIR 28
32
SPENT AIR
31
P-104
SUPERVISOR
25 SODIUM HYDROXIDE
35 SOLUTION 1) PROF. IR DR. SITI KARTOM
29
KAMARUDIN
LEAN SODIUM 30
HYDROXIDE
R-101 34
P-105
IRWAN ROSLI
T-105 33
26
P-102 INDUSTRIAL SUPERVISOR
CF-101 1) HEMAVATHI SILVAMANY
27 36
NUTRIENT SOLID
MEDIUM SULPHUR
GROUP MEMBERS:
Stream 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20a 21 22 23 24
COD concentration (mg/L) - 2893.9 141271.1 1264598.6 - 1264598.6 - 14278.8 14278.8 - - - 3434.0 - - 999.2 - 285.6 285.6 285.6 - - - 17.1 - 1) RAVINKUMAR MANIMARAN
BOD concentration (mg/L) - 2025.7 98889.7 885219.0 - 885219.0 - 9995.1 9995.1 - - - 2403.8 - - 699.5 - 199.9 199.9 199.9 - - - 8.0 -
2) CHEAH CHING WEI
Stream 25 26 27 28 29 30 31 32 33 34 35 36 3) NUREDAHTUL FAEZAN

Temperature(°C) 30 30 30 30 30 30 30 30 30 30 30 30
Pressure(bar) 1 1 1 1 1 2 1 2 1 1 2 1
4) SITI BARAKAH
Phase L V L V L+S L+S L L L+S L S S 5) AFIQ SYAZWAN
Flowrate(kg/hr)
NaOH 0.21 0.00 - 0.00 1.83 1.83 1.78 1.78 0.05 0.05 0.05 0.00 6) SIVA PRIYA
NaHS 2.37 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Water 29.26 0.00 - 0.00 29.27 29.27 28.37 28.37 0.90 0.90 0.90 0.00
Air 0.00 9.40 - 8.68 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
S 0.00 0.00 - 0.00 1.33 1.33 0.00 0.00 1.33 0.00 0.00 1.33
DATE : 15 JUN 2020
Na2SO4 0.00 0.00 - 0.00 0.12 0.12 0.00 0.00 0.09 0.00 0.00 0.09
228
APPENDIX F
I) P&ID BIO BEFORE HAZOP
II) P&ID CHEMICAL BEFORE HAZOP

P-101 Pump T-101 UASB SF-101 Seed Fermenter
CP-101 Cooling Pond T-102 UASB T-104 Settling Tank P-106 Pump P-107 Pump CO-106 Cooler
P-102 Pump T-103 UASB P-105 Pump T-105 MBBR CF-101 Centrifuge M-101 Mixer CF-102 Centrifuge D-101 Rotary Dryer
P-103 Pump B-101 Blower T-106 Buffer Tank HE-102 Heat Excahnger BP-101 Belt Press CV-101 Conveyor CV-102 Conveyor
P-104 Pump F-101 Filter
ETHANOL 24f
AND BUILT ENVIRONMENT
B.marisflavi 24
CHEMICAL ENGINEERING
PROGRAMME
NUTRIENT
3
SLUDGE OIL
FT
30
2
FC 20 TITTLE
30 PRODUCTION OF METHANOL AND
pHT (P&ID 1)
29 TT BIOGAS
1 TIC 28 Vent Air
28
CP-101 pHC
29 C.w out
P-101 11
POME C.w in
SF-101 SUPERVISOR
4a 1) PROF. IR DR. SITI KARTOM
KAMARUDIN
12
pHC pHT IRWAN ROSLI
04 04 24b
T-101 37
INDUSTRIAL SUPERVISOR
4 19
27a 25 1) HEMAVATHI SILVAMANY
Mainten ance
FIC FT discharge point
01 01 24d
5 25a
36
13
8
P-102
GROUP KK 4
FT
4b 10 TT M-101
14 TIC 11 LT LC
11 12 12 38
39 GROUP MEMBERS:
pHC pHT C.w in P-107
05 05 C.w out
FC T-105
T-102 10
WASTEWATER 1) RAVINKUMAR
T-106
9 FIC FT 43a
CF-102
6
02 02
Maintenance
17 2) CHEAH CHING WEI
discharge point
29 WASTE
30 35
P-103 VAPOUR
40 CO-106 4) SITI BARAKAH
P-106 43 5) AFIQ SYAZWAN

15 22 23
18 CF-101 6) SIVA PRIYA
42
4c P-105
16
24e 31 D-101 RAW MATERIAL
T-104 CV-102 BIOFLOCCULANT
pHC pHT
06 06
FC
T-103 13
10 FIC FT 28
PRODUCT
03 03
7 Maintenance
discharge point
21 32 33 FT
P-104
13 INTERMEDIATE
PRODUCT
24c CV-101
FERTILIZER
34
BP-101
24a DATE : 23rd MARCH 2020

WASTEWATER
To CO-103
SODIUM
HYDROXIDE 27 41
26 41a
26a
B-101 HE-102
AIR
F-101 From R-101
H-101 Kettle Reboiler GH-101 Gas Holder HE-101 Heat Exchanger HE-102 Heat Exchanger R-102 Reactor S-102 Phase Separator CO-104 Cooler
K-101 Compressor K-102 Compressor R-101 Reactor CO-102 Cooler CO-103 Cooler C-101 Distillation Column RD-101 Reflux Drum
Sr-101 Scrubber K-103 Compressor CO-101 Cooler S-101 Phase separator K-104 Compressor P-108 Pump CO-105 Cooler
P-109 Pump H-101 Heater H-102 Reboiler
PIC
19
To flare
PT
TT 19
18
61 CHEMICAL ENGINEERING
TIC
18 FFC PROGRAMME
25a 65
C.w in C.w out FT2 FT1
25a 25a
R-101 PIC
64 To flare 25 FUEL
53 63 TITTLE
52
PIC
23 PRODUCTION OF METHANOL AND
62 PT
58 59 To 25 BIOFLOCCULANT FROM POME
51 51a 51b H-101 TT flare
22
K-104 PT
CO-103
CO-102 23
K-102 HE-101 P&ID 2
TIC
22 LT S-102
24
TIC TT C.w in SUPERVISOR

14a 14a CO-101 C.w out 66
53a 1) PROF. IR DR. SITI KARTOM
R-102 LIC
50 60
24 KAMARUDIN
49 H-101 2) PROF. MADYA DR. MASLI
IRWAN ROSLI
WATER P-109 INDUSTRIAL SUPERVISOR

57 1) HEMAVATHI SILVAMANY
54
FC FT
14 14
45
PT PIC
GROUP
48 To flare 20 20 PIC
SODIUM 28 KK4
HYDROXIDE 56
PT
PC To flare 28 To flare GROUP MEMBERS:
17 K-103 69 CO-104 LT
PT
LT To flare 29
17
21
LIC
44 47 S-101 RD-101
70
29
71
1) RAVINKUMAR
LC
21 2) CHEAH CHING WEI
Sampling point
BIOGAS K-101 P-108 CO-105
METHANOL 3) NUREDAHTUL FAEZAN
LT AT AIC
16 30 30
FC SR-101 GH-101 4) SITI BARAKAH

15
5) AFIQ SYAZWAN
LC LT
FT 16 55 27
15 LIC
27
6) SIVA PRIYA
TT 67 68 68a
26
C-101
RAW MATERIAL
H-102
WATER
TIC
61a 26
PRODUCT
INTERMEDIATE
PRODUCT
From B-101 To D-101
46 LEAN SODIUM
HYDROXIDE
HE-102
DATE: 23rd MARCH 2020

229
APPENDIX G
PLANT LAYOUT
s
E
W
Weighing station
Surau Toilet
Guard Post
Sabah Electricity Wind
Direction
Parking Area Sdn Bhd (SESB)
Guard Post Cafeteria

Main Road
CHEMICAL ENGINEERING
PROGRAMME
TITLE:
PRODUCTION OF
BIOFLOCCULANT AND
Administration Office Laboratory Future Expansion
Parking area
METHANOL FROM POME
PLANT LOCATION:
MERCU PUSPITA MILL,
LAHAD DATU SABAH.
Assembly Area
Assembly area Engine Room Water Tank
Warehouse SUPERVISOR
Maintenance & Workshop
Emergency Response KAMARUDIN
Store Toilet Control Room 2) PROF. MADYA DR. MASLI
Team
IRWAN ROSLI
Loading Bay
Sludge Oil Fertilizer
INDUSTRIAL SUPERVISOR
Tank Tank
1) HEMAVATHI SILVAMANY
Ethan
ol
Nutrie BioFloccul Methanol
Tank
CF-101 D-101 nt Tank ant Tank Tank
GROUP MEMBERS:
M-101
1) RAVINKUMAR MANIMARAN
CF-102 2) CHEAH CHING WEI

SF-
T-103 BP-101
101
NaOH
SR-101 C-101
Waste water treatment plant Tank
4) SITI BARAKAH
T-102 T-105 T-106 5) AFIQ SYAZWAN

S-101 S-102
6) SIVA PRIYA
Cooling Pond
T-101 T-104 GH-101

R-101 R-102
17 June 2020

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PRODUCTION OF METHANOL AND BIOFLOCCULANT FROM POME

MONETISATION OF POME INTO RENEWABLE GAS AND GREEN

FACULTY OF ENGINEERING AND BUILT ENVIRONMENT

18 June 2020 CHEAH CHING WEI

RAVINKUMAR A/L MANIMARAN

SITI BARAKAH BINTI MOHD KHAIRI

SIVAPRIYA A/P NADARAJU

AFIQ SYAZWAN BIN MOHD HAIZOLLIZAM

NUREDAHTUL FAEZAN BINTI MOHAMMAD

The annual production of main product which is the bioflocculant is 2000

Waste treatment plant includes sequencing batch reactor, MBBR, clarifier,

Hazard and operability (HAZOP) study is conducted on every equipment to

CHAPTER II ECONOMY ISSUES

CHAPTER V PROCESS CONTROL AND PIPING

CHAPTER VI DETAILED DESIGN

CHAPTER VII WASTE MANAGEMENT

CHAPTER VIII ECONOMIC ANALYSIS

CHAPTER IX HAZARD IDENTIFICATION AND ANALYSIS

CHAPTER X PLANT LOCATION AND LAYOUT

CHAPTER XI MECHANICAL DESIGN

Table 1.1 Chemical and physical properties of methanol and

Table 1.2 Properties of POME 3

Table 1.3 Physical and Chemical properties of Ethanol 6

Table 1.4 Physical and chemical properties of methane 6

Table 1.5 Physical and chemical properties of carbon dioxide 7

Table 1.6 Physical and chemical properties of carbon dioxide 7

Table 3.1 Condition for chemical reactions 14

Table 3.2 Condition for biochemical reactions 14

Table 3.3 Data of concentration for conversion in syngas reaction 15

Table 3.4 Data of concentration for conversion in methanol reaction 18

Table 3.5 Properties of catalyst used in the production of methanol 20

Table 3.6 Raw materials 24

Table 3.7 Adiabatic temperature for all four reactors 27

Table 3.8 Syngas synthesis reactor sizing 28

Table 3.9 Methanol synthesis reactor sizing 29

Table 3.10 Annual cost for compressor, C-101 30

Table 3.11 Annual cost for compressor, C-102 30

Table 3.12 Annual cost for compressor, C-103 31

Table 3.13 Fm value 32

Table 3.14 Fp value 32

Table 3.15 Annual cost for UASB reactor 32

Table 3.16 Annual cost for aerated tank 33

Table 3.17 Cost of R-101 34

Table 3.19 Data for potential economy of process design level 3 34

Table 3.20 Annual cost for distillation column 36

Table 3.21 Annual cost of centrifuges 36

Table 3.22 Annual cost for settlement tank 37

Table 3.23 Annual cost for dryer 37

Table 3.24 Annual cost for phase separator 38

Table 3.25 Annual cost for scrubber 39

Table 3.26 Fep 4 40

Table 3.27 Substrate and biomass concentration 45

Table 3.28 calculations to plot graph of 1/ against 1/S is plotted. 45

Table 3.29 Input material flowrate 47

Table 3.30 Output material flowrate 47

Table 3.31 Comparison of mass balance by manual calculation and

Table 3.32 Standard Enthalphy Formation, ΔHof production of

Table 3.33 Specific heat capacity production of bio-flocculant 51

Table 3.34 Standard Enthalphies formation, ΔHof production of methanol 52

Table 3.35 Specific heat capacity production of methanol 52

Table 3.36 Comparison of heat balance calculation 52

Table 4.1 Process Data for Each Utility Unit 53

Table 4.2 Interval Temperature for ΔTmin = 10℃ 54