MAPÚA UNIVERSITY

School of Chemical, Biological, Materials Engineering and Sciences

PANGASINAN POLYLACTIC ACID PLANT

Submitted by:

Asuncion, Jose Daniel G.

A Process and Equipment Design Report Submitted in Partial

Fulfillment of the Requirements for the Degrees of Bachelor of
Science in Chemical Engineering and Bachelor of Science in
Biological Engineering

Dr. Rhoda B. Leron

October 2018
Abstract

This plant focuses on the manufacturing of polylactic acid pellets. Polylactic acid is an

eco-friendly and biodegradable thermoplastic produced from renewable sources (mostly crops)

such as corn, sugar beets, wheat and other starch-rich products. Using statistical data such as

the supply and demand as well as the projected value, the plant’s projected market share is 1%.

In an hourly basis, the estimated capacity of the plant is 160kg of plastic. The polylactic acid

plant manufactured by Pangasinan PLA Producers (Triple P) is located in Binalonan,

Pangasinan. The said location was considered due to the abundance of raw material that is

needed in the production process which is corn. In terms of environmental concerns,

sustainable development concept and economical reason, bioplastics are now being used in the

industry, e.g. PLA, which can be an alternative for PET. From the data and projection, the

demand of PLA increases while the supply remains constant. The assumption is based on the

price the market has set. As there is currently no producers of polylactic lactic acid within the

country, the company took the initiative to be the first and aim to lessen the gap between the

supply and demand for polylactic acid. Moreover, Philippines can be less dependent on the

imports of polylactic acid once the country has started putting up polylactic acid producing

plants.

The raw material used for the polylactic acid in this plant is milled-corn, a main product

of agriculture in Pangasinan. The main concern for waste in the plant is wastewater since all

processes, especially fermentation process, generate an abundant amount of wastewater. The

production of polylactic acid involves 3 major process namely: Pre-treatment, Fermentation,

and Polymerization.
PROCESS FLOW
DIAGRAM
 1% H2SO4 Cooling Water
solution (in)
[2] 99.75% Water
0.25% Sulfuric Acid [9]
100%
furfural
ST-101
(Wet Milled [1] [1]
M-101 HE-101
[6]
NOTES:
Corn Feed) Wastewater
Furfural
47.1% Dextrose CB-101 47.1% Dextrose Treatment Facility
28% Xylose 28% Xylose Storage Tank
17.8% Lignin 17.8% Lignin ST-102
7.1% Water 7.1% Water
Cooling Water
[10]
100% [5]
01. ST – Storage Tank
(out)
furfural 3.21% Dextrose
9.42% Dextrose
Cooling Water 1.98% Xylose

02. CB – Conveyor
[16] 4.68% Lignin
5.6% Xylose (in)
9.42% Dextrose 3.56% Lignin 90.13% Water
10.08% Dextrose

03. M – Mixer
5.6% Xylose 81.22% Water 10.08% Dextrose [13] 5.85% Xylose
3.56% Lignin [3] 0.2% Sulfuric Acid 5.85% Xylose 10.08% Dextrose 3.49% Lignin
81.22% Water 3.49% Lignin 5.85% Xylose 80.58% Water

04. P – Pump
0.2% Sulfuric 80.58% Water 3.49% Lignin
Acid [4] 80.58% Water F-101
R-101
PU-101 [11] [12] [15]
19.96% Dextrose [17]
P-101
[8]
[7]
HE-102
P-102
11.41% Xylose
8.52% Lignin Ethanol 05. R – Reactor
06. HE – Heat Exchanger
60.11% Water
Cooling Water
[14] (out)
CB-102

Ethanol Storage NaOH

07. F – Filter
19.96% Dextrose
08. HT – Holding Tank
Cooling Water Tank 11.41% Xylose
Water (in) Condensing Steam ST-103 8.52% Lignin [17] [18]
[23] 60.11% Water
100% Ethanol 100% Ethanol [26]
100% Ethanol M-102
HE-103
[22] [25] [27] [19]
0.48% Ethanol
3.19% Sodium Hydroxide
Cooling Water 96.33% Water
[24]
7.28% Dextrose (out)
4.16% Xylose [20]
3.10% Lignin
54.89% Water
29.48% Ethanol
7.28% Dextrose 1.09% Sodium Hydroxide Cellulose
4.16% Xylose 8.16% Dextrose enzyme, water
4.67% Xylose Cooling Water 8.16% Dextrose
3.10% Lignin 16.17% Dextrose
3.48% Lignin (in) 4.67% Xylose
54.89% Water [31] 9.10% Xylose [36]
83.69% Water 3.48% Lignin
29.48% Ethanol 1.78% Lignin
83.69% Water
1.09% Sodium Hydroxide HE-104 72.95% Water
R-102 [30] [33] [35] [35] R-103
F-102 16.17% Dextrose
[21] CB-103 9.10% Xylose
[28] [29] 1.78% Lignin
2.69% Dextrose 72.95% Water
P-103 1.58% Xylose
Cooling Water
Condensing Steam Water [32] [34] 4.66% Lignin
8.93% Dextrose (out)
91.16% Water
5.03% Xylose
0.98% Lignin [37]
85.06% Water
F-103
[38]
[42]
[40] [41] Wastewater
8.93% Dextrose 17.69% Dextrose
5.03% Xylose
0.98% Lignin [39]
17.69% Dextrose
9.81% Xylose
HT-101
17.69% Dextrose
9.81% Xylose P-105
9.81% Xylose
72.51% Water
To P-201 Treatment
Facility
Pangasinan
72.51% Water 72.51% Water
P-104
85.06% Water
2.84% Dextrose
1.70% Xylose
Polylactic
1.32% Lignin
94.14% Water
Acid Plant

CB-104

Solid waste management

Process Flow Diagram
[39]
facility
2.84% Dextrose
1.70% Xylose
1.32% Lignin
94.14% Water
(Pre-treatment Section)

Drawing No. D-G03-11819

Sheet 1 of 3 Rev. No.
 ST-201
Biomass ST-203
Butanol
NOTES:
ST-202
Ammonia
100% Biomass ST-203
[44] Butanol
100% Butanol [53]

17.69% Dextrose
9.80% Xylose
72.51% Water
M-201 [46]
100% Ammonia
Cooling Water
(in)
01. M – Mixer
02. BR – Bioreactor
From P-105 33.98% Ammonium
[43] [56]
A/B 59.89% Biomass Lactate 42.33% Butyl Lactate
33.98% Ammonium ER-201 [59]
13.63% Ammonium 35.82% Xylose 32.71% Xylose HE-201

03. P – Pump
59.89% Biomass Lactate Lactate 24.96% Water
CF-201 30.19% Water
25.93% Biomass 13.63% Ammonium 14.37% Xylose 35.82% Xylose [52] [55] 100% Butanol
13.10% Dextrose BR-201 Lactate 12.19% Water 30.19% Water

[45]
7.26% Xylose
53.71% Water
14.37% Xylose
12.19% Water
[48]
[49] [51]

[57] [58]
04. CF – Centrifuge
P-201
96.76% Biomass
1.1% Dextrose
P-202 Cooling Water
(out) 05. ER – Esterification Reactor
06. HE – Heat Exchanger
[50] 40.92% Butanol [54] EX-201
1.16% Xylose 59.08% Lactic Acid
0.978% Water 42.33% Butyl Lactate
32.71% Xylose
[47] 100% CO2
24.96% Water

75% Butanol
07. EX – Extractor
Wastewater
Treatment
Wastewater
Treatment
[60] 25% Xylose
08. HR – Hydrolysis Reactor
Facility Facility
Wastewater
Treatment Wastewater [61]
62.91% Butyl Lactate
09. EC - Evaporator
Facility Treatment 37.09% Water
Facility

Cooling Water
[76]
(in)

HE-202
100% Water
[78] [75]
P-203
62.91% Butyl Lactate
To Water [77] 100% Steam 37.09% Water
Storage Tank [62]
Cooling Water
100% Steam 100% Steam
(out)
[70] [66]

95% Lactic Acid 56.94% Lactic Acid

5% Water 43.06% Water
95% Lactic Acid
5% Water To Water
To PPR-301 [80] EC-203 EC-202 To Water EC-201 [64] HR-201
Storage Tank
[71] Storage Tank
100% Water [67] [65]

[79] 100% Water

[74] [63]
100% Butanol Pangasinan
Steam (in)
P-206
100% Water
75.72% Lactic Acid [69]
Polylactic
24.78% Water
To Water
Storage [73]
64.5% Lactic Acid
35.5% Water
Butanol
Storage Tank
Acid Plant
Tank

P-204
[68]

P-205 64.5% Lactic Acid

Process Flow Diagram
[72] 35.5% Water
75.72% Lactic Acid
24.78% Water
(Fermentation Section)

Drawing No. D-G03-11819

Sheet 2 of 3 Rev. No.
 NOTES:

Wastewater 100% Water

28.43% Water Treatment

01. PPR – Prepolymer Reactor

[90]
71.57% Lactic Acid Facility

02. P – Pump
1.71% Water
98.29% Lactide

[87] DC-301
19% Water

03. LR – Lactide Reactor

81% Prepolymer
2.45% Water Zinc Diiminate
[82]
PPR-301 97.55% Lactide Catalyst [94]
PR-301
[89] 1.71% Water

04. DC – Distillation Column

5% Water P-303
98.29% Lactide [92]
95% Lactic Acid
From P-206 [81] [91] [95]
Tin Octonoate

05. PR – Polymer Reactor

Catalyst
P-302 [101]
LR-301 0.66% Water
[85] 99.34% Lactide 1.71% Water

06. DV – Devolatilizer
25.79% Lactide
72.5% PLA [93]

Catalyst

07. HE – Heat Exchanger

[86] Storage
2.45% Water
97.55% Lactide
2.87% Water [88] P-305
[83]

08. C – Crystallizer
97.13% Prepolymer
P-304

09. CB – Conveyor
2.87% Water
97.13% Prepolymer
Cooling Water(in)

[98]
[84]

10. D – Dryer
0.66% Water
Catalyst HE-305
99.34% Lactide
Storage [100] [97]

P-301
[99]
Cooling Water(out)
DV-301
1.71% Water
25.79% Lactide
72.5% PLA
11. CF – Centrifugal Fan
[96]
12. DH – Dehumidifier
D-301
[105]
2.09% Water 2.09% Water 2.09% Water 0.025% Water 0.025% Water
97.91% PLA 97.91% PLA 97.91% PLA 99.975% PLA 99.975% PLA
Polylactic Acid
[102] C-301 [103] CB-301 [104] [106] CB-302 [107]
Packaging

[111]

[110]

CF-301
Air

[108] [109]

DH-301 Water

Pangasinan
Polylactic
Acid Plant

Process Flow Diagram

(Polymerization Section)

Drawing No. D-G03-11819

Sheet 3 of 3
Rev. No.
Process Flow Description

The production of polylactic acid comprises of three different sections namely, (1) Pretreatment

Section, (2) Fermentation Section, and (3) Polymerization Section

Pre-treatment Section

The purchased milled corn stocked inside the storage tank (ST-101) with water will be

transported to the mixer (M-101) by means of using a conveyor belt (CB-101). Addition of

sulfuric acid as a catalyst is necessary in M-101 in preparation for the acid hydrolysis process

in the first reactor (R-101). Furfural, a by-product obtained from the acid hydrolysis process

from R-101, is condensed in a heat exchanger prior to being moved in a storage tank (ST-102).

The said by-product can be sold off in the market for extra profit. The acquired solids in slurry

from the filtration tank (F-101) will be transported to the second mixer (M-102) where it will

be mixed with ethanol and NaOH. Thereafter, the mixture will be pumped towards the second

reactor (R-102) for the delignification process where ethanol can be recovered and purged into

its corresponding storage tank (ST-103). After the filtration in F-102, the solids in the slurry

will undergo through the last stage of treatment which is the enzymatic hydrolysis inside the

third reactor (R-103). The enzymatic hydrolysis incorporates the use of a cellulase enzyme as

catalyst. From R-103, the mixture will undergo filtration once again in F-103. The resulting

liquor from F-103 is rich in dextrose and will be stored in a holding tank (HT-101) before being

transferred onto the fermentation section.

Fermentation Section

Production of lactic acid

From section 1, xylose, dextrose, and water will enter the mixer, and from a different

stream the biomass will enter the mixer. The mixture will be divided equally and pumped to

five fermentation tanks where each fraction will be mixed with inoculum and ammonia. The

fermentation will 12 hours for the biomass to complete the digestion of the substrates in the

mixture. Following the completion of the fermentation, the broth will be placed in holding

tanks to proceed to the succeeding process.

Purification

After fermentation, the broth will be subjected to several processes such as

centrifugation to remove biomass from the broth. The broth will undergo esterification on a

reactor to convert ammonium lactate to butyl lactate by reacting butanol in the mixture. To

remove remaining xylose in the mixture, the solution is passed through an extraction column,

where butanol is utilized for extraction. The remaining solution containing water and butyl

lactate is subjected to hydrolysis to convert butyl lactate to lactic acid, undergoing specific

operating condition and using a catalyst (Amberlyst 15). The lactic acid solution from the

reactor will be concentrated using evaporators, and will then proceed to polymerization.

Polymerization Section

From the Evaporator of the fermentation process, lactic acid is pumped into the pre-

polymer reactor(PPR-301) to produce the lactic acid prepolymer with composition of 97.1%

prepolymer and the latter for water. Used unreacted stream will be sent to the wastewater
treatment plant. Lactic acid prepolymer is, then, pumped into the lactide reactor(LR-301) for

the cyclization of low molecular weight Lactic acid, forming lactide. The product contains

97.5% lactide and 2.45% water. A Tin Octanoate catalyst was used to further boost the process.

Lactide is then pumped into the Distillation Column(DC-301) to further remove the water

content and to purify the entering lactide. A recycle stream was also introduced in the

distillation column which came from the devolatilizer equipment(DV-301). Mass flow rate for

water is low, so it can be sent to the wastewater treatment plant. Purified Lactide is then pumped

into the Polymerization reactor(PR-301) to produce the polylactic acid. Tin Octoate was also

used as a catalyst to make the reaction faster. Polylactic acid and some purified lactide is, then,

pumped into the devolatilizer(DV-301) to extract the polylactic acid. Unreacted lactide is

pumped back into the distillation column. Polylactic acid, then, undergoes crystallization from

the crystallizer(C-301), transported next to the dryer(D-301) for drying. After the crystallized

polylactic acid has dried, it is sent to the packaging area for finishing and packaging.
MATERIAL
BALANCES
 Pangasinan
Polylactic
Acid Plant

Process Flow Diagram

(Fermentation Section)

Drawing No. D-G03-11819

Rev. No.
Sheet 1 of 1
 Pangasinan
Polylactic
Acid Plant

Material Balance

Drawing No. D-G03-11819

Sheet 1 of 1 Rev. No.
 PIPING AND
INSTRUMENTATION
DESIGN
 NOTES:
Valves
01. LCV – Level Control Valve
ST-201
02. FCV – Flow Control Valve
Biomass ST-203
Butanol 03. TV – Temperature Valve
ST-202
Ammonia
04. GV-Gate Valve
[44]
TIT I/P ST-203 05. RV- Relief Valve
[53]
202 Butanol
TY TIC TT
PIT 201 201 201
TIT 202
M-201 201
[46]
HS
LT
From P-105 [43]
PIT LIC
203
202 [56] Cooling Water
A/B
LT
201
201

PIA
LIC LT
PIA
202
203
ER-201 TV-201

HE-201
(in)
Instruments
201
202 202 CF-201 [59]
[52] [55]
HS
LC 201
BR-201
201
LCV-101

[45] [48]
LCV-202
[49] [51]

FCV-202
LCV-203

[57] [58]
LIC
LT
204
06. F - Flow
204
FCV-201

P-201
FT
202
FIC
202
P-202 Cooling Water
(out)
07. L - Level
EX-201
FT
201
FIC
201
[50] [54]

LCV-204 08. P - Pressure

[47]
09. T – Temperature
10. X – Composition
Wastewater Wastewater
t.
[60]
Treatment Treatment
Facility Facility [61]
Wastewater
Treatment Wastewater
FT
203
11. A -Alarm
12. H – High
Facility Treatment
FIC
Facility FCV-203
203

TY
I/P

TIC TT
13. I – Indicator
202 202 202

PIA
203
14. T -Transmitter
Cooling Water
(in)
TV-202
[76]
HE-202
15. C- Controller
16. LAH- Lvel
[78] [75]
P-203
TIT
PIT
PIT 203
To Water [77] PIT 205
204
Storage Tank 206 TIT
TIT FIC FT PIT
Cooling Water TIT 205
204 204 204 203
(out) 206
HS
[70] [66]
203 LT LIC
FIC FT 205 205
207 207
To Water
Storage Tank
Pangasinan
To P-301 [80] EC-203 [71] EC-202 To Water EC-201 [64] HR-201 [62]

LCV-207
PIA
206 Storage Tank FCV-204 LCV-205 Polylactic
[67] [65]

[79]
FIC FT
Acid Plant
[74] [63]
FIC 205 205
FT
206 206
Steam (in)
P-206 [69]

To Water LCV-205 Butanol

Storage [73] PIA Storage Tank
Tank 204
LCV-206

PIA
205 Piping and Instrumentation
P-204
Diagram
[68]

P-205
[72]

Drawing No. D-G03-11819

Sheet 1 of 1 Rev. No.
HAZARD AND
OPERABILITY
STUDY
Equipment Deviations from What event could Consequence of the Additional implication of this Process indications Notes and questions
Reference and operating cause this Deviation on item of consequence
Operating conditions deviation? equipment under
Conditions consideration
Mixer Level

M-201 Less LCV-106 is Wrong ratio of Less supply in the fermentation LCV-106 Regular maintenance
damaged components in solution. tank checkups

Empty mixer Maintenance and repair of

LCV-106 is closed Damage the mixer instrument

Mechanical strain in the Over supply in the fermentation

More Excessive loading equipment. tank LCV-106

Mechanical strain in the Over supply in the fermentation

Damage in LCV- equipment tank LCV-106
106
Mechanical strain in the Over supply in the fermentation
Damage in LCV- equipment tank LCV-106
106
Mechanical strain in the No supply in the fermentation
LCV-101 is closed equipment tank
LCV-101

Bioreactor Pressure
BR-101
More PIT-201 is Potential Rupture in the Potential Explosion PIT-201 Monitor flow
Damaged reactor
Damage on reactor
FCV-201 is closed Strain on the reactor None
Damage on reactor
FIC-201 fails
Strain on the reactor Damage on reactor FIC-201

FT-201 fails Potential Fire

Strain on the reactor FT-201
 Temperature TIT-201 is
More damaged Thermal strain on the TIT-201
tank
TIT-201 fails
Less Inefficient process TIT-201
Pump Flow
P-201 Less FCV-201 is closed Pump cavities Damage to pump None Monitor flow

Lines plugged
Pump cavities Damage to pump None
LCV-202 is closed
Deadhead pump Damage to pump None
FIC-202 fails
Deadhead pump Damage to pump FIC-202

FIC-202 fails
More Upset in the reactor Damage to reactor. FIC-202

Damage to reactor.
FIC-202 fails FIC-202
to open LCV-203 Upset in the reactor
Damage to pump
Pressure
Less LCV-202 closed
Deadhead pump Damage to pump FIC-202

PIA-201 fails Damage to pump

Deadhead pump PIA-201
FIC-202 fails
More to open LCV-203 Upset in the reactor Damage to pump FIC-202

FIC-202 fails Damage to pump

Upset in the reactor FIC-202
PIA-201 fails
Deadhead pump Damage to pump PIA-201

Temperature LCV-202 closed Damage to pump

More Deadhead pump FIC-202
 FIC-202 fails to Deadhead pump FIC-202
close LCV-202

Pump Flow
P-202 Less LCV-202 closed Pump cavities Damage to pump None
Check for repairs,
Lines plugged Pump cavities Damage to pump None maintenance and
irregularities.
LCV-202 closed Deadhead pump Damage to pump None

LIC-202 fails Deadhead pump Damage to pump LIC-202

More LIC-203 fails Upset in the reactor Damage to reactor. FLC-203

Damage to reactor.
LIC-203 fails Upset in the reactor LIC-203
to open LCV-203

Damage to pump

Pressure LCV-203 closed Deadhead pump FIC-203

Less

Damage to pump

More PIA-307 fails Deadhead pump Damage to pump PIA-307

FIC-203 fails Upset in the reactor FIC-203

to open LCV-203 Damage to pump

FIC-203 fails Upset in the reactor Damage to pump FIC-203

PIA-307 fails Deadhead pump PIA-307

Damage to pump

Temperature LCV-203 closed Deadhead pump Damage to pump FIC-203

 More
FIC-203 fails to Deadhead pump FIC-203
close LCV-203

Pump Flow
P-101 Less LCV-101 closed Pump cavities Damage to pump None
Always monitor PI-101,
Lines plugged Pump cavities Damage to pump None pump replacement and
cavitation reliever.
LCV-203 closed Deadhead pump Damage to pump None

FIC-203 fails Deadhead pump Damage to pump FIC-203

More FIC-203 fails Upset in the reactor FIC-203

FIC-203 fails Upset in the reactor Damage to reactor. FIC-203

to open LCV-203

Pressure Damage to reactor.

Less LCV-203 closed Deadhead pump FIC-203

Damage to pump

PIA-307 fails Deadhead pump PIA-207

More Damage to pump

FIC-203 fails Upset in the reactor FIC-203

to open LCV-203 Damage to pump

FIC-203 fails Upset in the reactor Damage to pump FIC-203

PIA-307 fails Deadhead pump PIA-207

Temperature Damage to pump
More
LCV-203 closed Deadhead pump Damage to pump FIC-203
 FIC-203 fails to Deadhead pump FIC-203
close LCV-203

Esterification Level
Reactor Less LCV-203 is closed Upset the reactor Damage to reactor LIC-201
ER-201 Damage to reactor Check pipes and supply
LIC-203 Fails Upset the reactor LIC-201 stream
Damage to reactor

LIC-203 fails to Upset the reactor Damage to reactor LIC-201

open LCV-201
Damage to reactor
Pipe Blockage Upset the reactor None
Damage to reactor Repair pipeline system

LT-201 fails Upset the reactor Damage to reactor LT-201

Damage to reactor Instruct operators on

More LCV- 201 is Overflow FIC-201 procedures
closed None

LT-201 fails Overflow None FIC-201 Instruct operators on

procedures

Pipe Blockage Upset the reactor Possible explosion None

Pressure Possible explosion

Less LCV-201 fails Inefficient process LIC-201
Possible explosion
PIT-201 fails Inefficient process PIT-201

Possible explosion
More LCV-201 is closed Strain on the reactor FIC-201

FIC-201 fails Strain on the reactor None FIC-201

FIC-201 fails to Strain on the reactor Damage on reactor FIC-201

open LCV-201
 Potential Explosion
PIT-201 fails Strain on the reactor PIT-201

Temperature
Less TIT-201 fails Inefficient Process TIT-201

More TIT-201 fails Thermal stress on the TIT-201

reactor

HS-202 fails Thermal stress on the HS-202

reactor

Heat Exchanger Flow

HE-201
Less Failure of cooling Temperature of process Pump starvation Low temperature alarm
water valve fluid remains constant

Temperature of process High temperature alarm

More Pipe blockage fluid remains constant Eventual leakage

Temperature
Insufficient load of Check for repairs,
corresponding materials maintenance and
Less Leakage on HR- Reduced output TIC-201 irregularities
201
Excessive load of
corresponding materials Check for repairs,
maintenance and
More TV-201 closing Excessive output lead to spoilage TIC-201 irregularities
failure. Outlets
blocked.
 EQUIPMENT
SPECIFICATION
 MIXER
IDENTIFICATION
EQUIPMENT CODE M-201
FUNCTION Mixing of Xylose, dextrose, water, and biomass.
MATERIAL HANDLED Xylose, dextrose, water, and biomass
EQUIPMENT DESIGN
CAPACITY 40.52 m3
LENGTH 3.44 m
THICKNESS 10 mm
TEMPERATURE OPERATING DESIGN
24oC 55oC
PRESSURE OPERATING DESIGN
101.325 Kpa 111.45 Kpa
MATERIAL OF CONSTRUCTION Carbon Steel
CORROSION ALLOWANCE 9 mm
IMPELLER DIAMETER 0.8 m
IMPELLER SPEED 0.76 m/s
POWER REQUIREMENT 1.62 KW
EQUIPMENT FIGURE
 FERMENTATION TANK
IDENTIFICATION
EQUIPMENT CODE BR-201
FUNCTION Supply operating condition for fermentation
NO. OF EQUIPMENT 5
MATERIAL HANDLED Xylose, Biomass, dextrose, water, inoculum, ammonia
EQUIPMENT DESIGN
CAPACITY 11 m3
LENGTH 3.44 m
THICKNESS 0.01 m
TEMPERATURE OPERATING DESIGN
o
37 C 67oC
PRESSURE OPERATING DESIGN
101.325 Kpa 111.45 Kpa
MATERIAL OF CONSTRUCTION Carbon steel
CORROSION ALLOWANCE 9 mm
IMPELLER DIAMETER 0.8 m
IMPELLER SPEED 0.308 m/s
POWER REQUIREMENT 1.62 KW
EQUIPMENT FIGURE
 PUMP
IDENTIFICATION
EQUIPMENT CODE P-201
FUNCTION Transfer fluid from fermentation tank to centrifuge
NO. OF EQUIPMENT 1
MATERIAL HANDLED Xylose, ammonium lactate, water, biomass
EQUIPMENT DESIGN
CAPACITY
TEMPERATURE OPERATING DESIGN
37oC 67oC
SHAFT WORK 105.84 J/Kg
POWER INPUT 99.83 KW
EQUIPMENT FIGURE
 CENTRIFUGE
IDENTIFICATION
EQUIPMENT CODE CF-201
FUNCTION Remove biomass
NO. OF EQUIPMENT 1
MATERIAL HANDLED Biomass, xylose, ammonium lactate, water
EQUIPMENT DESIGN
TEMPERATURE OPERATING DESIGN
o
37 C 67oC
PRESSURE OPERATING DESIGN
100 Kpa 110Kpa
CAPACITY 0.36 m
CORROSION ALLOWANCE 9 mm
MATERIAL OF CONSTRUCTION Stainless steel 316 (SA-240)
EQUIPMENT FIGURE
 PUMP
IDENTIFICATION
EQUIPMENT CODE P-202
FUNCTION Transfer liquid from centrifuge to reactor
NO. OF EQUIPMENT 1
MATERIAL HANDLED Xylose, ammonium lactate, water
EQUIPMENT DESIGN
CAPACITY 0.53 m3
TEMPERATURE OPERATING DESIGN
37oC 67oC
SHAFT WORK 105.84 J/Kg
POWER INPUT 38.04 KW
EQUIPMENT FIGURE
 ESTERIFICATION REACTOR
IDENTIFICATION
EQUIPMENT CODE ER-201
FUNCTION Provide operating conditions for esterification
NO. OF EQUIPMENT 1
MATERIAL HANDLED Butanol, water, Xylose, ammonium lactate, butyl lactate,
ammonium hydroxide
EQUIPMENT DESIGN
CAPACITY 2.11 m3
LENGTH 1.75 m
THICKNESS 0.00918 m
MASS 2035.8 Kg
TEMPERATURE OPERATING DESIGN
80oC 110oC
PRESSURE OPERATING DESIGN
26.66 Kpa 29.33 Kpa
MATERIAL OF CONSTRUCTION High-alloy stainless steel 304 (SA-240)
CORROSION ALLOWANCE 9 mm
EQUIPMENT FIGURE
 HEAT EXCHANGER
IDENTIFICATION
EQUIPMENT CODE HE-201
FUNCTION Cool liquid
NO. OF EQUIPMENT 1
MATERIAL HANDLED Xylose, Water, Butyl lactate
EQUIPMENT DESIGN
HEAT TRANSFER AREA 2.17 m2
FLOW RATE 708.58 kg/hr
TEMPERATURE INNER TUBE OUTER TUBE
INLET: 80OC INLET: 15 OC
O
OUTLET: 37 C OUTLET: 23 OC
MATERIAL OF CONSTRUCTION Carbon steel
LENGTH 4.9 m
DIAMETER 0.019 m
EQUIPMENT FIGURE
 EXTRACTION COLUMN
IDENTIFICATION
EQUIPMENT CODE EX-201
FUNCTION Remove Xylose
NO. OF EQUIPMENT 1
MATERIAL HANDLED Butanol, water, xylose, butyl lactate
EQUIPMENT DESIGN
CAPACITY 1.093 m3
LENGTH 2.49 m
THICKNESS 9.53 mm
TEMPERATURE OPERATING DESIGN
O
37 C 67 OC
PRESSURE OPERATING DESIGN
150 Kpa 325 Kpa
MATERIAL OF CONSTRUCTION Stainless steel type 316
CORROSION ALLOWANCE 9 mm
EQUIPMENT FIGURE
 WASTE
MINIMIZATION,
PREVENTION, AND
TREATMENT
PLAN
Environmental Assessment and Waste Management Plan

In line with the plant location, it is also important to consider the environmental

impact of the plant to nearby communities and the environment. For this plant, potential of

pollution will be wastewater and solid waste generation.

Air Emission

Main emissions from the plant will come from the fermentation area and the dryer

from the polymerization plant, which consist of CO2 and VOC. Other minor sources will

come from filters or storages. Due to possible dangers surrounding these emissions, the plant

insures that the requirement for air quality standards are met under RA 8749: Clean Air Act

of the Philippines. Installation of Vacuum vents and gas absorbers/wet walls maybe required

as the concentration of these emissions continue to rise during the plant operation.

Water Quality

Generation of wastewater accumulates during construction and operation phase. For

operation plants, most wastewater generation comes from the Fermentation section of the

plant, next to the Pre-treatment and polymerization process. These wastewaters will be

intoxicated since these waters contain TSS, and other solutions and compounds that maybe

harmful to the environment. In line with the said problem, each process will be monitored,

meeting the minimum accumulation of harmful components to the environment and the

required quality of discharge streams regulated by RA 9275: Philippine Clean Water Act of

2004. These streams are assumed to be connected to the Wastewater treatment plant, so no

amount of the wastewater will be discharged without treatment.

Land Quality: Soil and Geology

During construction phase will affect the land quality of the proposed site. For

construction phase, dust settling will be the major concern as this will also pose a threat to

human health. The plant’s source of water will come from underground. Digging will be

required for the installation of pipes and wells and it might affect the soil quality within the

area, as well as the reduction in plant diversity. Water Sprinkler will be used for the dust

settling and the installation will be double/triple-checked to prevent leakage when on

operational phase. 6-months maintenance will be implemented to ensure the quality of pipes.

Noise Pollution

Possible noise accumulation will come from the construction of the plant. Once the

plant has been constructed, the plant will follow the guidelines posted by DENR concerning

noise pollution.

Waste Disposal

Accumulation of solid waste disposal will only come from filter during pre-treatment.

As the solid waste generation is minimal, no hazardous components are found. Proper

segregation, recycling will be implemented and disposal to the landfill will be shipped after

inspection of the waste. Any other waste from offices and other facilities will also be

included during operational phase.

Human Toxicity

The major concern will be during the construction phase of the plant for the plant

operators and workers, no concerns for those nearby the site since the place is isolated from
the residential area. During operational phase, possible areas would be from the wastewater

treatment plant or from the handling of waste. Both may contain hazardous compounds which

were found during the collection but will be at minimum. No critical process poses a threat to

the employees.

Flora and Fauna

The site contains only grasslands. Most of the land will be retained. No significant

concerns has been identified for the impacts of the proposed plant site.
APPENDICES
 Material

Balance

Calculation
 MIXER

Components IN IN OUT

[45] [46] [47]

Dextrose 440.03 - 440.03

𝑪𝟔 𝑯𝟏𝟐 𝑶𝟔

Xylose 243.95 - 243.95

𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

Water 1804.07 - 1804.07

𝑯𝟐 𝑶

Biomass - 34.5 34.5

TOTAL 2488.06 870.82 3358.88

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = 𝑀𝑎𝑠𝑠 𝐼𝑁

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑖𝑛 [45] + ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 [46]

∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [45] = 𝑀𝑎𝑠𝑠 𝐶6 𝐻12 𝑂6 + 𝑀𝑎𝑠𝑠 𝐶5 𝐻10 𝑂5 + 𝑀𝑎𝑠𝑠 𝐻2 𝑂

 ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [45] = 440.03 𝐾𝑔 + 243.95 𝐾𝑔 + 1804.08 𝐾𝑔

∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [45] = 𝟐𝟒𝟖𝟖. 𝟎𝟔 𝑲𝒈

∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [46] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠

∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [46] = 𝟖𝟕𝟎. 𝟖𝟐 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = 𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [47]

𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [47] = 2488.06 𝐾𝑔 + 870.82 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [47] = 𝟑𝟑𝟓𝟖. 𝟖𝟖 𝑲𝒈

FERMENTATION

Components IN IN OUT OUT

[4] [5] [7] [8]

 Dextrose 440.03 - - -

𝑪𝟔 𝑯𝟏𝟐 𝑶𝟔

Xylose 243.95 - - 243.95

𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

Water 1804.07 - - 205.61

𝑯𝟐 𝑶

Biomass 870.82 - - 1016.91

Ammonia - 90.55 - -

𝑵𝑯𝟑

Ammonium Lactate - - - 231.39

𝑵𝑯𝟒 𝑪𝟑 𝑯𝟓 𝑶𝟑

CO2 - - 84.65 -

TOTAL 3358.88 90.55 84.65 1697.87

Assumptions:

 100 % conversion of Dextrose.

 All carbon Dioxide are released.

 All Inoculum are consumed.

 All Ammonia are consumed.

 No fermentation of Xylose involved.

Overall Reaction:
1.13 𝐶6 𝐻12 𝑂6 + 0.93 𝑂2 + 1.46 𝑁𝐻3 + 𝑁𝐻4 𝑂𝐻

→ 2.92 𝐶𝐻1.75 𝑂0.15 𝑁0.15 + 0.89 𝐶𝑂2 + 4.45 𝐻2 𝑂 + 𝑁𝐻4 𝐶3 𝐻5 𝑂3

𝑁𝐻4 𝐶3 𝐻5 𝑂3 / H2O = 0.2247

𝑁𝐻4 𝐶3 𝐻5 𝑂3/ CO2 = 1.1236

𝑁𝐻4 𝐶3 𝐻5 𝑂3/Biomass = 0.3425

𝑁𝐻4 𝐶3 𝐻5 𝑂3/ 𝑁𝐻4 𝑂𝐻 = 0.6849

𝑁𝐻4 𝐶3 𝐻5 𝑂3/ NH3 = 0.6849

𝑁𝐻4 𝐶3 𝐻5 𝑂3/ O2 = 1.0753

𝑁𝐻4 𝐶3 𝐻5 𝑂3 / 𝐶6 𝐻12 𝑂6 = 0.8849

Molecular Weight:

𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 107. 06 Kg / Kmol

𝐶𝑂2 = 44.01 Kg / Kmol

Biomass = 23.15 Kg / Kmol

𝑁𝐻4 𝑂𝐻= 35.04 Kg / Kmol

𝑁𝐻3 = 17.03 Kg / Kmol

𝑂2 = 31.998 Kg / Kmol
 𝐶6 𝐻12 𝑂6 = 180.156 Kg / Kmol

𝐻2 𝑂 = 18.01 Kg / Kmol

𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶6 𝐻12 𝑂6 𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = ×
𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶6 𝐻12 𝑂6 𝐶6 𝐻12 𝑂6 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

440.03 𝐾𝑔 0.8849
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = ×
𝐾𝑔 1
180. 156
𝐾𝑚𝑜𝑙

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 𝟐. 𝟏𝟔 𝑲𝒎𝒐𝒍𝒆𝒔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 × 𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 × 107.06
𝐾𝑚𝑜𝑙

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 𝟐𝟑𝟏. 𝟑𝟗 𝑲𝒈

 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡

1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
0.3425

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝟔. 𝟑 𝑲𝒎𝒐𝒍𝒆𝒔

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝐹𝑜𝑟𝑚𝑒𝑑 𝐵𝑖𝑜𝑚𝑎𝑠𝑠

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 37.61 𝐾𝑚𝑜𝑙𝑒𝑠 + 6.3 𝐾𝑚𝑜𝑙𝑒𝑠

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝟒𝟑. 𝟗𝟏𝑲𝒎𝒐𝒍𝒆𝒔

𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠

𝐾𝑔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 43. 91 𝑘𝑚𝑜𝑙𝑒𝑠 × 23.15
𝐾𝑚𝑜𝑙𝑒𝑠

𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝟏𝟎𝟏𝟔. 𝟗𝟏 𝑲𝒈 𝒐𝒇 𝑩𝒊𝒐𝒎𝒂𝒔𝒔

 𝐻2 𝑂 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡

1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
0.2247

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝟗. 𝟔𝟏 𝑲𝒎𝒐𝒍𝒆𝒔

𝑁𝐻3 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡

1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
0.6849

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝟑. 𝟏𝟓 𝑲𝒎𝒐𝒍𝒆𝒔

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 𝑀𝑜𝑙𝑒𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑜𝑙𝑒 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠

 𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 + 3.15 𝐾𝑚𝑜𝑙𝑒𝑠

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝟓. 𝟑𝟏 𝑲𝒎𝒐𝒍𝒆𝒔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 × 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3 = 5.31 𝐾𝑚𝑜𝑙𝑒𝑠 × 17.03
𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑵𝑯𝟑 = 𝟗𝟎. 𝟓𝟓 𝑲𝒈

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 − 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 9. 61 𝐾𝑚𝑜𝑙𝑒𝑠 − 2.16 𝐾𝑚𝑜𝑙𝑒𝑠

𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝟕. 𝟒𝟓 𝑲𝒎𝒐𝒍𝒆𝒔

𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 × 𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂

𝐾𝑔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 7.45 × 18.01
𝐾𝑚𝑜𝑙𝑒𝑠

𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝟏𝟑𝟒. 𝟏𝟕 𝑲𝒈

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 1804. 07 𝐾𝑔 + 134.17 𝐾𝑔

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝟏𝟗𝟑𝟖. 𝟑𝟖 𝑲𝒈

𝐶𝑂2 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
1.1236

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 = 𝟏. 𝟗𝟐 𝑲𝒎𝒐𝒍𝒆𝒔

 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 × 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2 = 1.92 𝐾𝑚𝑜𝑙𝑒𝑠 × 44.01
𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2 = 𝟖𝟒. 𝟔𝟓 𝑲𝒈

𝑂2 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒 𝑜𝑓 𝑂2 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓𝑂2 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
1.0753

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑂2 = 𝟐 𝑲𝒎𝒐𝒍𝒆𝒔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑂2 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2 = 2 𝐾𝑚𝑜𝑙𝑒𝑠 + 32
𝐾𝑚𝑜𝑙𝑒
 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2 = 𝟔𝟒 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47]

= 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶6 𝐻12 𝑂6 + 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47] = 440.03 𝐾𝑔 + 243.95 𝐾𝑔 + 1804.07 𝐾𝑔 + 870.82 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47] =3358.88 Kg

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [48] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [48] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [48] = 𝟗𝟎. 𝟓𝟓 𝑲𝒈

 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [50] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [50] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [50] = 𝟖𝟒. 𝟔𝟓 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49]

= 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49] = 243.95 𝐾𝑔 + 1938.38 𝐾𝑔 + 1016.91 𝐾𝑔 + 231.39 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49] = 𝟑𝟒𝟑𝟎. 𝟔𝟓 𝑲𝒈

CENTRIFUGE
 Components IN OUT OUT

[50] [52] [53]

Water 1938.38 96.91 1841.46

𝑯𝟐 𝑶

Biomass 1016.91 1016.91 -

Ammonium Lactate 231.39 11.56 219.82

𝑵𝑯𝟒 𝑪𝟑 𝑯𝟓 𝑶𝟑

Xylose 243.95 12.19 231.75

𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

TOTAL 3430.65 1137.59 2293.05

Assumptions:

 All Biomass is removed.

 Assume 5% losses

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = 𝑀𝑎𝑠𝑠𝑠 𝐼𝑁

𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 𝑀𝑎𝑠𝑠 𝑡𝑟𝑒𝑎𝑚 [52] + 𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50]

𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50] = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝐼𝑁

𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑎𝑠𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 + 𝑀𝑎𝑠𝑠 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50] = 2423.95 𝐾𝑔 + 1938.38 𝐾𝑔 + 1016.91 𝐾𝑔 + 231.39 𝐾𝑔

 𝑀𝑎𝑠𝑠 𝑠𝑡𝑒𝑒𝑎𝑚 [50] = 𝟑𝟒𝟑𝟎. 𝟔𝟓 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑜𝑓 𝑠𝑡𝑟𝑒𝑎𝑚 [52]

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑎𝑠𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 + 𝑀𝑎𝑠𝑠 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = 12.19 Kg + 96.91 Kg + 1016.91 Kg+ 11.56 Kg

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = 𝟏𝟏𝟑𝟕. 𝟓𝟗 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑜𝑓 𝑠𝑡𝑟𝑒𝑎𝑚 [53]

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 + 𝑀𝑎𝑠𝑠 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 231.75 𝐾𝑔 + 1841.46 𝐾𝑔 + 219.82 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 𝟐𝟐𝟗𝟑. 𝟎𝟓 𝑲𝒈

 ESTERIFICATION

Components IN IN OUT OUT

[54] [55] [56] [57]

Water 1841.46 - - 1822.97

𝑯𝟐 𝑶

Xylose 231.75 - - 231.75

𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

Ammonium 219.82 - - -

Lactate

𝑵𝑯𝟒 𝑪𝟑 𝑯𝟓 𝑶𝟑

Butyl Lactate - - - 299.98

𝑪𝟕 𝑯𝟏𝟒 𝑶𝟑

Butanol - 249.15 49.83 -

𝑪𝟒 𝑯𝟏𝟎 𝑶

Ammonium - - 71.94 -

Hydroxide

𝑵𝑯𝟒 𝑶𝑯

TOTAL 2293.05 249.15 121.77 2354.72

Assumptions:

 All Ammonium Lactate is converted to Butyl Lactate

 Excess Butanol is fed to the reactor

 Water and Xylose are inert

Reaction:

𝐶3 𝐻9 𝑂3 𝑁 + 𝐶4 𝐻10 𝑂 → 𝐶7 𝐻14 𝑂3 + 𝐻2 𝑂 + 𝑁𝐻3

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 =
𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁

1 𝐾𝑚𝑜𝑙𝑒
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 = 299.98 𝐾𝑔 ×
107.06 𝐾𝑔

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 = 2.02 𝐾𝑚𝑜𝑙𝑒s

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 × 146.1
𝐾𝑚𝑜𝑙𝑒𝑠
 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 𝟐𝟗𝟗. 𝟗𝟖 𝑲𝒈

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝐶4 𝐻10 𝑂 𝐼𝑁 − 𝑀𝑜𝑙𝑒𝑠 𝐶4 𝐻10 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑏𝑢𝑡𝑎𝑛𝑜𝑙 𝑛𝑒𝑒𝑑𝑒𝑑 ∗ 1.2

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐼𝑁 =
𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑢𝑡𝑎𝑛𝑜𝑙

𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 = 249.15 𝐾𝑔 ×
74.1 𝐾𝑔

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐼𝑁 = 3.36 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 3.36 𝐾𝑚𝑜𝑙𝑒𝑠 × 0.2

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 0.2 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 0.67 𝐾𝑚𝑜𝑙𝑒𝑠 × 74.1
𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝟒𝟗. 𝟖𝟑 𝑲𝒈

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 × 𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑁𝐻4 𝑂𝐻

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 × 35.04
𝐾𝑚𝑜𝑙𝑒𝑠
 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 𝟕𝟏. 𝟗𝟒 𝑲𝒈

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 − 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂

𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 1841.46 𝐾𝑔 ×
18.01 𝐾𝑔

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 102. 24 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 ×
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻

1𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 ×
2 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 1.01 𝐾𝑚𝑜𝑙𝑒𝑠

 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 102.24 𝐾𝑚𝑜𝑙𝑒𝑠 − 1.01 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑂𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 101. 22 𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂

𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 101.22 𝐾𝑚𝑜𝑙𝑒𝑠 × 18.01
𝐾𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝟏𝟖𝟐𝟐. 𝟗𝟕 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = 231.75 𝐾𝑔 + 1841.46 𝐾𝑔 + 219.82 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = 𝟐𝟐𝟗𝟑. 𝟎𝟓 𝑲𝒈

 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [55] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [55] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [55] = 𝟐𝟒𝟗. 𝟏𝟓 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = 49.83 𝐾𝑔 + 71.94 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = 𝟏𝟐𝟏. 𝟕𝟕 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 231.75 𝐾𝑔 + 1822.97 𝐾𝑔 + 299.98 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝟐𝟑𝟓𝟒. 𝟕𝟐 𝑲𝒈

Extraction Column

Components IN IN OUT OUT

[57] [58] [59] [60]

Water 1822.97 - - 1822.97

𝑯𝟐 𝑶

Xylose 231.75 - 231.75 -

𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓

Butyl Lactate 299.98 - - 299.98

𝑪𝟕 𝑯𝟏𝟒 𝑶𝟑

Butanol - 695.27 695.27 -

𝑪𝟒 𝑯𝟏𝟎 𝑶

TOTAL 2354.72 695.27 927.02 2122.96

Assumptions:

 No Butyl lactate is lost in the operation

 Excess Butanol is fed.

 All Xylose in the mixture are removed

𝑀𝑎𝑠𝑠 𝐼𝑁 = 𝑀𝑎𝑠𝑠 𝑂𝑈𝑇

 𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝐶5 𝐻10 𝑂5 + 𝑀𝑎𝑠𝑠 𝐶7 𝐻14 𝑂3

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 231.75 𝐾𝑔 + 1822.97 𝐾𝑔 + 299.98 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝟐𝟑𝟓𝟒. 𝟕𝟐 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [58] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [58] = 𝟔𝟗𝟓. 𝟐𝟕 𝑲𝒈

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = 231.75 𝐾𝑔 + 695.27 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = 𝟗𝟐𝟕. 𝟎𝟐 𝑲𝒈

 𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = 1822.97 𝐾𝑔 + 299.98 𝐾𝑔

𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = 𝟐𝟏𝟐𝟐. 𝟗𝟔 𝑲𝒈

ENERGY
BALANCE
 INPUT

m, Cp, mCp, KJ/hr-K

Kg/hr KJ / Kg-K
Dextrose 440.03 1.21 532.44
Ammonia 90.55 2.2 199.21
Water 1804.07 4.19 7559.09
Biomass 870.82 1.29 1123.36
xylose 243.95 1.67 407.40
Oxygen 64.32 0.92 59.17
Total 9880.68
Fermentation

 The process is at steady-state.

 There is no heat transfer in the surroundings.

 The operating condition is 37 degrees Celsius.

 The feed temperature is 25 degrees Celsius.

 The product temperature 37 degrees Celsius.

 The energy is conserved inside the fermenter.

 𝑚𝐻𝐼𝑁 = 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 )

∑ 𝑚 𝐶𝑝,𝐼𝑁 = 440.03 (1.21) + 90.55(2.2) + 1804.07 (4.19) + 870(1.29) + 243.95(1.67)

+ 64.32(0.92)

𝑲𝑱
∑ 𝑚 𝐶𝑝,𝐼𝑁 = 𝟗𝟖𝟖𝟎. 𝟔𝟖
𝒉𝒓 − 𝑲

OUTPUT
m, Kg/hr Cp, KJ / Kg-K mCp
ammonium lactate 231.39 1.61 372.55
Water 205.61 4.19 861.51
Biomass 1016.91 1.29 1311.82
xylose 243.95 1.67 407.40
CO2 64.32 0.84 54.03
Total 3007.31
𝑚𝐻𝑂𝑈𝑇 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇1 − 𝑇𝑟𝑒𝑓 )

∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 231.39 (1.61) + 205.61 (4.19) + 1016.91 (1.29) + 243.95(1.67) + 64.32(0.84)

𝑲𝑱
∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 𝟑𝟎𝟎𝟕. 𝟑𝟏
𝒉𝒓 − 𝑲
 REACTANTS
components Molar Mass Moles nHf mHf
Kg/Kmol Kmol KJ/mol KJ/Kg
Dextrose 90.08 1 -1262 -14009.76
Ammonium Hydroxide 35.04 2 -336.7 -19218.03
Total -33227.80

PRODUCTS
components Molar Mass Moles nHf mHf
Kg/Kmol Kmol KJ/mol KJ/Kg
ALA 107.06 2 -688.28 -12857.83
water 18.02 2 -285.8 -31720.31
Total -44578.14

𝐻𝑅𝑋𝑁 = ∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

1000 1000
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = [−688.28 × × 2] + [−285.8 × × 2]
107.06 18.02
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 44578.14
𝐾𝑔
1000 1000
∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡𝑠 = [−1262 × × 1] + [−336.7 × × 2]
90.08 18.02
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 33227.80
𝐾𝑔
𝐾𝐽 𝐾𝐽
𝐻𝑅𝑋𝑁 = −44578.14 − (−33227.80 )
𝐾𝑔 𝐾𝑔
𝐾𝐽
𝐻𝑅𝑋𝑁 = −11350.34
𝐾𝑔
𝐾𝑔 𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = 231.39 (= −11350.34 )
ℎ𝑟 𝐾𝑔
𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = −2626429.9
ℎ𝑟
 𝑄 = 𝑚𝐻𝑂𝑈𝑇 − 𝑚𝐻𝐼𝑁 + 𝑚𝐻𝑂𝑈𝑇
𝑄 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇2 − 𝑇𝑟𝑒𝑓 ) − 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 ) + 𝑚𝐻𝑂𝑈𝑇
𝐾𝐽 𝐾𝐽 𝐾𝐽
𝑄 = 3007.31 (25 − 25)𝐾 − 9880.68 (37 − 25)𝐾 + (−2626429.9 )
ℎ𝑟 − 𝐾 ℎ𝑟 − 𝐾 ℎ𝑟
𝐾𝐽
𝑄 = −2744998
ℎ𝑟

P-201

Assumptions:

 Negligible heat transfer to surroundings

 Constant pipe diameter

 Constant pressure operations

 Water goes into pump by gravity transferred 0.8m to CF-201

 10 m Friction head

Mechanical Energy Balance

∆𝑃 ∆𝑢2 𝑔
+ + ∆𝑧 ( ) + 𝐹 = 𝑊
𝜌 2𝑔𝑐 𝑔𝑐

𝑔
𝑊 = ∆𝑧 ( )+𝐹
𝑔𝑐

𝑔 𝑚 𝑚2
∆𝑧 ( ) = (0.8𝑚) (9.8 2 ) = 7.84 2
𝑔𝑐 𝑠 𝑠

𝐹 = 𝑓𝑔
 𝑚 𝑚2
𝐹 = (10𝑚)𝑥 (9.8 ) = 98
𝑠2 𝑠2

𝑚2 𝑚2 𝑚2
𝑊 = 98 + 7.84 = 105.84
𝑠2 𝑠2 𝑠2

Power requirement:

𝑃 = 𝑚̇𝑊

𝑚2
𝑃 = (1697.87 𝑘𝑔)(105.84 )
𝑠2

𝑃 = 179702.56 𝐽/ℎ𝑟

Esterification

 The process is at steady-state.

 There is no heat transfer to the surrounding.

 The operating temperature is 80 degrees Celsius.

 The entering feed is 37 degrees Celsius.

 The energy is conserved inside the reactor.

INPUT
Components m, Cp, mCp,
kg/hr KJ / Kg-K
KJ/hr-K
Ammonium 219.82 1.61 353.92
Lactate
water 195.32 4.19 818.43
xylose 231.75 1.67 387.03
butanol 249.15 2.49 620.40
Total 2179.79

𝑚𝐻𝐼𝑁 = 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 )

∑ 𝑚 𝐶𝑝,𝐼𝑁 = 219.82(1.61) + 195.32 (4.19) + 231.75 (1.67) + 249.15(2.49)

 𝑲𝑱
∑ 𝑚 𝐶𝑝,𝐼𝑁 = 𝟐𝟏𝟕𝟗. 𝟕𝟗
𝒉𝒓 − 𝑲

OUTPUT
Components m, Cp, mCp,
kg/hr KJ / Kg K
KJ/ hr-K
Butyl Lactate 299.98 1.97 590.98
water 176.83 4.19 740.96
xylose 231.75 1.67 387.03
butanol 49.83 2.49 124.08
ammonium 6.219 1.61 10.01
OH
Total 1853.06

𝑚𝐻𝑂𝑈𝑇 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇1 − 𝑇𝑟𝑒𝑓 )

∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 299.98 (1.97) + 176.82(4.19) + 231.75 (1.67) + 49.83 (2.49) + 6.21(1.61)

𝑲𝑱
∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 𝟏𝟖𝟓𝟑. 𝟎𝟔
𝒉𝒓 − 𝑲

REACTANTS
Components Molar Mass Moles nHf mHf
Kg/Kmol Kmol KJ/mol KJ/Kg
Ammonium Lactate 107.06 1 -688.28 -6428.91
Butanol 74.1 1 -274.43 -3703.5
Total -10132.42

PRODUCTS
components Molar Mass Moles nHf mHf
Kg/Kmol Kmol KJ/mol KJ/Kg
BLA 146.1 1 -401.78 -2750.03
water 18.02 1 -285.8 -15860.15
ammonia 17.03 1 -45.9 -2695.24
Total -21305.433
 𝐻𝑅𝑋𝑁 = ∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

1000 1000 1000

∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = [−401.78 × × 1] + [−285.8 × × 1] + [−45.9 × × 1]
146.1 18.02 17.03
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 21305.43
𝐾𝑔
1000 1000
∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡𝑠 = [−688.28 × × 1] + [−274.43 × × 1]
107.06 74.1
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 10132.42
𝐾𝑔
𝐾𝐽 𝐾𝐽
𝐻𝑅𝑋𝑁 = −21305.43 − (−10132.42 )
𝐾𝑔 𝐾𝑔
𝐾𝐽
𝐻𝑅𝑋𝑁 = −11173
𝐾𝑔
𝐾𝑔 𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = 299.98 (−11173 )
ℎ𝑟 𝐾𝑔
𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = −3351764
ℎ𝑟
𝑄 = 𝑚𝐻𝑂𝑈𝑇 − 𝑚𝐻𝐼𝑁 + 𝑚𝐻𝑂𝑈𝑇
𝑄 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇2 − 𝑇𝑟𝑒𝑓 ) − 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 ) + 𝑚𝐻𝑂𝑈𝑇
𝐾𝐽 𝐾𝐽 𝐾𝐽
𝑄 = 1853.06 (80 − 25)𝐾 − 2179.79 (37 − 25)𝐾 + (−3351764 )
ℎ𝑟 − 𝐾 ℎ𝑟 − 𝐾 ℎ𝑟
𝐾𝐽
𝑄 = −328206.01
ℎ𝑟

HE-201

Assumptions:

 Constant heat capacities

 Negligible heat loss to the surroundings

  𝑄𝑔𝑎𝑖𝑛 = 𝑄𝑙𝑜𝑠𝑠

(80 − 15) − (37 − 23)

∆𝑇𝑙𝑚 =
80 − 15
ln (37 − 23)

∆𝑇𝑙𝑚 = 33.22 𝐾

𝑄 = 𝑚𝐶𝑝Δ𝑇

𝑘𝐽
𝑄 = (708.58𝑘𝑔) (2.43 ) (80 − 37)𝐾
𝑘𝑔 ∙ 𝐾

𝑄 = 74039. 52 𝑘𝐽

Mass of water used:

𝑄 = 𝑚𝐶𝑝Δ𝑇

𝑘𝐽
−74039.52 = (𝑚) (4.18 ) (15 − 23)𝐾
𝑘𝑔 ∙ 𝐾

𝑚 = 2214.1 𝑘
P-202

Assumptions:

 Negligible heat transfer to surroundings

 Constant pipe diameter

 Constant pressure operations

 Water goes into pump by gravity transferred 0.8m to CF-201

 10 m Friction head

Mechanical Energy Balance

∆𝑃 ∆𝑢2 𝑔
+ + ∆𝑧 ( ) + 𝐹 = 𝑊
𝜌 2𝑔𝑐 𝑔𝑐

𝑔
𝑊 = ∆𝑧 ( )+𝐹
𝑔𝑐
 𝑔 𝑚 𝑚2
∆𝑧 ( ) = (0.8𝑚) (9.8 2 ) = 7.84 2
𝑔𝑐 𝑠 𝑠

𝐹 = 𝑓𝑔

𝑚 𝑚2
𝐹 = (10𝑚)𝑥 (9.8 ) = 98
𝑠2 𝑠2

𝑚2 𝑚2 𝑚2
𝑊 = 98 + 7.84 = 105.84
𝑠2 𝑠2 𝑠2

Power requirement:

𝑃 = 𝑚̇𝑊

𝑚2
𝑃 = (646.91 𝑘𝑔)(105.84 2 )
𝑠

𝑃 = 68468.95 𝐽/ℎ𝑟
Equipment

Sizing

Calculation

Mixer (M-201)
Heuristics:

 Optimum length-to-diameter ratio is 3

 Corrosion allowance is 9 mm.
 Design temperature is 30 degrees Celsius above operating temperature.
 Design pressure is 10% above operating pressure.
 10% freeboard.
 The mixer diameter is three times the turbine impeller diameter and impeller level above
bottom.
 Mild agitation with an impeller at superficial velocities of 0.03 m/s to 0.06 m/s.

COMPONENT MASS FLOW RATE DENSITY KG/M3

DEXTROSE 440.03 1540
XYLOSE 243.95 1520
WATER 1804.07 1000
BIOMASS 870.82 574.713
TOTAL 3348.87 4634.7

Operating Temperature = 25 oC = 298 K

Design Temperature = 298 K + 30 K

Design Temperature = 328 K

Operating Pressure = 101.325 Kpa

Design Pressure = 101.325 Kpa (1.1)

Design Pressure = 111.45 Kpa

 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.1205 (1540) + 0.0735 (1520) + 0.5435 (1000) + 0.2623 ( 574.7)

𝐾𝑔
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 991.72
𝑚3

𝐾𝑔 𝑑𝑎𝑦 12 ℎ𝑟
𝑚 3348.87 ℎ𝑟 (1 𝑐𝑦𝑐𝑙𝑒)( 𝑑𝑎𝑦 )
𝑉𝑓𝑒𝑒𝑑 = =
𝜌 𝐾𝑔
991.72 3
𝑚

𝑉𝑓𝑒𝑒𝑑 = 40.52 𝑚3

Volume of the reactor

𝑉 = 𝑉𝑓𝑒𝑒𝑑 (1.1)

𝑉 = 40.52 (1.1)

𝑉 = 44.57 𝑚3

Inside Diameter ,

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

3𝜋 3
𝑉= 𝐷
4 𝑖
 3𝜋 3
44.57 𝑚3 = 𝐷
4 𝑖

𝐷𝐼 = 2.67 𝑚

Length,

𝐿 = 3𝐷𝐼

𝐿 = 3 (2.67)

𝐿 = 7.98 𝑚

PARAMETER
CORROSION Corrosive Streams 𝐶𝑐 = 0.009 𝑚
ALLOWANCE (M)
MAXIMUM Carbon Steel 𝑆 = 94500 𝐾𝑝𝑎
ALLOWANCE
STRESS (KPA)
EFFICIENCY OF Fully Radiographed 𝐸𝑗 = 0.85
JOINTS double-welded butt
joint

𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆𝐸𝑗 − 0.6𝑃

7.98
111.45 𝐾𝑝𝑎( 2 )
𝑡= + 0.009𝑚
94500 𝐾𝑝𝑎(0.85) − 0.6(111.45 𝐾𝑝𝑎)
 𝑡 = 0.0145 𝑚

𝐷𝑜 = 2 (𝑟𝑖 − 𝑡)

7.98
𝐷𝑜 = 2 ( − 0.0145)
2

𝐷𝑜 = 8 𝑚

External Volume

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

𝜋
𝑉= 2.672 (8)
4

𝑉 = 44.84 𝑚3

Volume Steel

𝑉𝑆𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙

𝑉𝑆𝑡𝑒𝑒𝑙 = 44.84 𝑚3 − 44.57 𝑚3

 𝑉𝑆𝑡𝑒𝑒𝑙 = 0.27 𝑚3

Mass of Mixer

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 𝑉𝑠𝑡𝑒𝑒𝑙 × 𝜌𝑠𝑡𝑒𝑒𝑙

𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.27 𝑚3 × 7830
𝑚3

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 2114.1 𝐾𝑔

Diameter Impeller
𝐷𝐼
𝐷𝑇𝐼 =
3

2.66
𝐷𝑇𝐼 =
3

𝐷𝑇𝐼 = 0.88 𝑚

Impeller level above bottom

𝐷𝐼
𝐻𝐼 =
3

2.66
𝐻𝐼 =
3

𝐻𝐼 = 0.88 𝑚
Impeller blade width

𝐷𝐼
𝑊𝐼 =
15

2.66
𝑊𝐼 =
15

𝑊𝐼 = 0.177 𝑚

For Homogenizing mixture

𝑚
𝑁 = 0.038
𝑠

Wall baffles (thickness)

𝐷𝑖
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 =
10

2.66
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 =
10

𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 = 0.266 𝑚

Speed of Impeller

For Homogenizing mixture

𝑚
𝑁 = 0.038
𝑠
Reynolds Number

2
𝐷𝑇𝐼 𝑛𝜌
𝑅𝑒 =
𝜇

1
(0.88)2 ((0.308)(
0.88 ))(991.72)
( 2 )
𝑅𝑒 =
8.9 × 10−4

𝑅𝑒 = 604035.48

5
𝑃 = 𝐾𝑡 𝑛3 𝐷𝑇𝐼 𝜌

1 3
𝑃 = (5.75)((0.038)( ) (0.88)2 (991.72)
0.88
( 2 )

𝑃 = 15.5 𝑘𝑊

Fermentation tank (BR-201)

Heuristics considered:

 Design temperature is set 30 degrees Celsius above the operating temperature.

 Volume of industrial scale bioreactor ranges from 0.5m3 to 2.5m3

 70% fill capacity; 30% free space.

 The equipment is cylindrical.

 Height-to-diameter ratio is 1

 Based on literature residence time is about 12 hours.

 Design pressure is 10% above the operating pressure.

 Mild agitation with an impeller at superficial velocities of 0.03 m/s to 0.06 m/s

Operating conditions:

Operating Temperature = 37 oC = 310 K

Design Temperature = 310 K + 30 K

Design Temperature = 340 K

Operating Pressure = 101.325 Kpa

 Design Pressure = 101.325 Kpa (1.1)

Design Pressure = 111.45 Kpa

COMPONENT MASS FLOW RATE DENSITY KG/M3

DEXTROSE 440.03 1540
XYLOSE 243.95 1520
WATER 1804.07 1000
BIOMASS 870.82 574.713
TOTAL 3348.87 4634.7

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.1205 (1540) + 0.0735 (1520) + 0.5435 (1000) + 0.2623 ( 574.7)

𝐾𝑔
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 991.72
𝑚3

Volume of the feed

𝐾𝑔 𝑑𝑎𝑦 12 ℎ𝑟
𝑚 3348.87 ℎ𝑟 (1 𝑐𝑦𝑐𝑙𝑒)( 𝑑𝑎𝑦 )
𝑉𝑓𝑒𝑒𝑑 = =
𝜌 𝐾𝑔
991.72 3
𝑚
 𝑉𝑓𝑒𝑒𝑑 = 40.52 𝑚3

Volume of the reactor

𝑉 = 𝑉𝑓𝑒𝑒𝑑 (1.3)

𝑉 = 40.52 (1.3)

𝑉 = 52.67

Number of Fermenter per cycle

- Usual Volume of Industrial Scale bioreactor: 11 m3

Number of fermenter per cycle = V/VUSUAL

Number of fermenter per cycle = 52.67 / 11

Number of fermenter per cycle= 4.78 = 5 Fermenters per cycle

Inside Diameter

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

𝜋 3
𝑉= 𝐷
4 𝑖
 𝜋 3
11 𝑚3 = 𝐷
4 𝑖

𝐷𝐼 = 2.41 𝑚

Internal Volume

- Assume 70% fill capacity

𝑉
𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 =
0.7

11
𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 =
0.7

𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 15. 71 𝑚3

Length

𝜋 2
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 𝐷 𝐿
4 𝑖

𝜋
15.71 = (2.41)2 𝐿
4

𝐿 = 3.44 𝑚
Thickness

PARAMETER
CORROSION Corrosive Streams 𝐶𝑐 = 0.009 𝑚
ALLOWANCE (M)
MAXIMUM Carbon Steel 𝑆 = 94500 𝐾𝑝𝑎
ALLOWANCE
STRESS (KPA)
EFFICIENCY OF Fully Radiographed 𝐸𝑗 = 1
JOINTS double-welded butt
joint

Design equation for cylindrical shells:

𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆𝐸𝑗 − 0.6𝑃

2.41
111.45 𝐾𝑝𝑎( 2 )
𝑡= + 0.009𝑚
94500 𝐾𝑝𝑎(1) − 0.6(111.45 𝐾𝑝𝑎)

𝑡 = 0.01 𝑚

𝐷𝑜 = 2 (𝑟𝑖 − 𝑡)
 2.41
𝐷𝑜 = 2 ( − 0.01)
2

𝐷𝑜 = 2.43 𝑚

External Volume

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

𝜋
𝑉= 2.432 (3.44)
4

𝑉 = 15.95 𝑚3

Volume Steel

𝑉𝑆𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙

𝑉𝑆𝑡𝑒𝑒𝑙 = 15.95 𝑚3 − 15. 71 𝑚3

𝑉𝑆𝑡𝑒𝑒𝑙 = 0.24 𝑚3

Mass of Fermentation tank

 𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 𝑉𝑠𝑡𝑒𝑒𝑙 × 𝜌𝑠𝑡𝑒𝑒𝑙

𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.24 𝑚3 × 7830
𝑚3

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 1879.2 𝐾𝑔

Diameter of Impeller

𝐷𝑖
𝐷𝑇𝐼 =
3

2.41
𝐷𝑇𝐼 =
3

𝐷𝑇𝐼 = 0.8033 𝑚

Impeller level above bottom

𝐷𝑖
𝐻𝐼 =
3

2.41
𝐻𝐼 =
3
 𝐻𝐼 = 0.8033 𝑚

Impeller blade width

𝐷𝑖
𝑊𝐼 =
15

2.41
𝑊𝐼 =
3

𝑊𝐼 = 0.8033 𝑚

Speed of Impeller

For Homogenizing mixture

𝑚
𝑁 = 0.038
𝑠

Wall baffles (thickness)

𝐷𝑖
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 =
10

2.41
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 =
10

𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 = 0.241 𝑚
Reynolds Number

2
𝐷𝑇𝐼 𝑛𝜌
𝑅𝑒 =
𝜇

1
(0.8024)2 ((0.308)(
0.8024 ))(991.72)
( 2 )
𝑅𝑒 =
8.9 × 10−4

𝑅𝑒 = 552006.75

5
𝑃 = 𝐾𝑡 𝑛3 𝐷𝑇𝐼 𝜌

1
𝑃 = (5.75)((0.038)( )3 (0.8033)2 (991.72)
0.8024
( 2 )

𝑃 = 1.62 𝑘𝑊
 Pump (P-201)
Heuristics:

 Centrifugal pump with 50% efficiency

COMPONENT MASS FLOW RATE (KG/HR) DENSITY (KG/M3)

XYLOSE 243.95 1520
WATER 205.61 997
BIOMASS 1016.91 574.713
AMMONIUM 231.40 1054
LACTATE
TOTAL 1697.87

Volumetric Flow Rate

𝑚̇
𝑉̇ =
𝜌
̇ 𝑘𝑔
1697.87
𝑉̇ = ℎ𝑟
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
(0.14) (1520 3 ) + (0.12) (997 3 ) + (0.60) (574.713 3 ) + (0.14) (1054 3 )
𝑚 𝑚 𝑚 𝑚
𝑚3
= 2.06
ℎ𝑟
Head
𝑃
𝐻=
𝑚𝑔
𝐽
𝑃 = 179702.56
ℎ𝑟
𝐽
179702.56
𝐻= ℎ𝑟
̇ 𝑘𝑔 𝑚
(1697.87 ℎ𝑟 ) (9.8 2 )
𝑠

𝐻 = 10.8 𝑚
For Centrifugal Pump
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
49.92 𝑊
𝑃𝑖𝑛 =
0.5
𝑃𝑖𝑛 = 99.83 𝑊
 Centrifuge (CF-201)

Heuristics considered:

 Design temperature is set 30 degrees Celsius above the operating temperature.

 Design Pressure is 10% higher than operating pressure

 Optical length -to-diameter ratio is 1

 10% freeboard

COMPONENT MASS FLOW RATE DENSITY KG/M3

DEXTROSE 243.95 1540
XYLOSE 205.61 1520
WATER 1016.91 1000
BIOMASS 239.31 574.713
TOTAL 1705.78 4634.7

Operating conditions:

Operating Temperature = 37 oC = 310 K

 Design Temperature = 310 K + 30 K

Design Temperature = 340 K

Operating Pressure = 100 Kpa

Design Pressure = 100 Kpa (1.1)

Design Pressure = 110 Kpa

𝑚𝑎𝑠𝑠
𝑉=
𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦

1705.78 𝐾𝑔
𝑉=
𝐾𝑔
4634.7 3
𝑚

𝑉 = 0.36 𝑚3

Volume internal (10% Freeboard)

𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 1.1 𝑉

𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 1.1 (0.36)

𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 0.4 𝑚3

Inside Diameter and Length

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
 𝜋 2
𝑉= 𝐷 𝐷
4 𝑖 𝑖

𝜋 2
0.4 = 𝐷 𝐷
4 𝑖 𝑖

𝐷𝑖 = 0.8 𝑚

𝐿 = 0.8 𝑚

Thickness

PARAMETER
CORROSION Corrosive Streams 𝐶𝑐 = 0.009 𝑚
ALLOWANCE (M)
MAXIMUM Stainless 316 steel 𝑆 = 119086.09 𝐾𝑝𝑎
ALLOWANCE (SA-240)
STRESS (KPA)
EFFICIENCY OF Fully Radiographed 𝐸𝑗 = 1
JOINTS double-welded butt
joint

𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆𝐸𝑗 − 0.6𝑃

0.8
110 𝐾𝑝𝑎( 2 )
𝑡= + 0.009𝑚
119086.09 𝐾𝑝𝑎(1) − 0.6(110 𝐾𝑝𝑎)

𝑡 = 0.00937 𝑚

Outside Diameter
 𝐷𝑜 = 2 (𝑟𝑖 + 𝑡)

0.8
𝐷𝑜 = 2 (( ) + 0.00937)
2

𝐷𝑜 = 0.8187 𝑚

External Volume

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

𝜋
𝑉= (0.8187)2 (0.8)
4

𝑉 = 0.42 𝑚3

Volume of steel

𝑉𝑆𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙

𝑉𝑆𝑡𝑒𝑒𝑙 = 0.42 𝑚3 − 0.4𝑚3

𝑉𝑆𝑡𝑒𝑒𝑙 = 0.02 𝑚3

Mass of steel

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 𝑉𝑠𝑡𝑒𝑒𝑙 × 𝜌𝑠𝑡𝑒𝑒𝑙

 𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.02 𝑚3 × 7883
𝑚3

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 157.66 𝑘𝑔

Pump (P-202)
Heuristics:

 Centrifugal pump with 50% efficiency

COMPONENT MASS FLOW RATE (KG/HR) DENSITY (KG/M3)

WATER 195.33 997
AMMONIUM 219.83 1054
LACTATE
XYLOSE 231.76 1520
TOTAL 646.91

Volumetric Flow Rate

𝑚̇
𝑉̇ =
𝜌
̇ 𝑘𝑔
646.91 𝑚3
𝑉̇ = ℎ𝑟 = 0.53
𝑘𝑔 𝑘𝑔 𝑘𝑔 ℎ𝑟
(0.36) (1520 3 ) + (0.30) (997 3 ) + (0.34) (1054 3 )
𝑚 𝑚 𝑚

Head
𝑃
𝐻=
𝑚𝑔
𝐽
𝑃 = 68468.95
ℎ𝑟
𝐽
68468.95
𝐻= ℎ𝑟
𝑘𝑔 𝑚
(646.91 ) (9.8 2 )
ℎ𝑟 𝑠
𝐻 = 10.8 𝑚
For Centrifugal Pump
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
 19.02𝑊
𝑃𝑖𝑛 =
0.5
𝑃𝑖𝑛 = 38.04 𝑊

Heat Exchanger (HE-201)

Heuristics:

 The flow is counter current with feed at the tube side and water at the shell side
𝑊
 Heat transfer coefficient water to liquid: 285 2
𝑚 ∙𝐾
 Outer diameter is 0.019m and the length is 4.9m
Temperature Conditions

INLET OUTLET
TEMPERATURE (℃) TEMPERATURE (℃)
COLD SIDE 15 23
HOT SIDE 80 37

Heat Transfer Area

𝑄
𝐴=
𝑈𝐹∆𝑇
(80 − 15) − (37 − 23)
∆𝑇𝑙𝑚 =
80 − 15
ln ( )
37 − 23
∆𝑇𝑙𝑚 = 33.22 𝐾
𝑄 = 𝑚𝐶𝑝Δ𝑇
𝑘𝐽
𝑄 = (708.58𝑘𝑔) (2.43 ) (80 − 37)𝐾
𝑘𝑔 ∙ 𝐾
𝑄 = 74039. 52 𝑘𝐽 = 20.56653 𝑘𝑊
20566.53 𝑊
𝐴=
𝑊
(285 2 )(33.22 𝐾)
𝑚 ∙𝐾
𝐴 = 2.17 𝑚2
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
2.17 𝑚2
𝑛=
𝜋(0.019)(4.9)
 𝑛 = 7.42 𝑡𝑢𝑏𝑒𝑠 ~ 7 𝑡𝑢𝑏𝑒𝑠

By interpolation from table 14-9 (Timmerhaus),

𝐷𝑖,𝑠ℎ𝑒𝑙𝑙 = 0.203 𝑚

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑜𝑛𝑒 𝑝𝑎𝑠𝑠

0.0254 𝑚, 𝑡𝑟𝑖𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐ℎ

Esterification Reactor (ER-201)

Heuristics considered:

 Design temperature is set 30 degrees Celsius above the operating temperature.

 Volume of industrial scale bioreactor ranges from 0.5m3 to 2.5m3

 70% fill capacity; 30% free space.

 The equipment is cylindrical.

 Height-to-diameter ratio is 1

 Based on literature residence time is about 12 hours.

 Design pressure is 10% above the operating pressure.

Operating conditions:

Operating Temperature = 80 oC = 353 K

Design Temperature = 353 K + 30 K

 Design Temperature = 383 K

Operating Pressure = 26.66 Kpa

Design Pressure = 26.66 Kpa (1.1)

Design Pressure = 29.33 Kpa

COMPONENT MASS FLOW RATE DENSITY KG/M3

XYLOSE 231.75 1520
WATER 195.32 1000
AMMONIUM LACTATE 219.82 1054
BUTANOL 249.15 810
TOTAL 896.04 4384

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.2586 (1520) + 0.2179 (1000) + 0.2453 (1054) + 0.2780 ( 810)

𝐾𝑔
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 1094.9
𝑚3

3 /𝑅𝑇
𝐾 = 2.2602 (𝑇 0.3498 )(𝑒 −9.91 𝑥10 )

𝐽
𝑅 = 8.314 𝑚𝑜𝑙 𝐾 𝑇 = 80𝑜 𝐶 +273 = 353 K
 3 /(8.314)353
𝑘 = 2.2602 (3530.3498 )(𝑒 −9.91 𝑥10 )

𝑘 = 0.601 𝑚𝑖𝑛−1

𝑘 = 865.44 𝑑𝑎𝑦 −1

𝐹𝐴
𝑣𝑜 =
𝐶𝐴

25.55
𝐶𝐴 =
𝑣𝑜
𝐾𝑚𝑜𝑙𝑒 𝐾𝑔 1
𝑣𝑜 = (25.55 ) (90.73 )( )
ℎ𝑟 𝑘𝑚𝑜𝑙 1094. 𝐾𝑔
𝑚3

𝑚3
𝑣𝑜 = 2.11
ℎ𝑟

𝐾𝑚𝑜𝑙𝑒
25.55
𝐶𝐴 = ℎ𝑟
𝑚3
2.11
ℎ𝑟

𝐶𝐴 = 12.1 𝑘𝑚𝑜𝑙/𝑚3

30.87
𝑉𝐶𝑆𝑇𝑅 =
(0.601)(12.1)

𝑉𝐶𝑆𝑇𝑅 = 4.24 𝑚3

4.24 𝑚3
𝑅𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒 = 𝜏 =
𝑚3
2.11
ℎ𝑟
 𝜏 = 2ℎ𝑟𝑠 = 120 𝑚𝑖𝑛𝑠

Diameter and Length

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

𝜋 2
𝑉= 𝐷 𝐷
4 𝑖 𝑖

𝜋 2
4.24 = 𝐷 𝐷
4 𝑖 𝑖

𝐷𝑖 = 1.75 𝑚

𝐿 = 1.75 𝑚

Thickness of tank

- Using the equation for vessels at atmosphere pressure:

𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆𝐸𝑗 − 0.6𝑃

PARAMETER
CORROSION Corrosive Streams 𝐶𝑐 = 0.009 𝑚
ALLOWANCE (M)
MAXIMUM High-alloy steel 𝑆 = 111666.67 𝐾𝑝𝑎
ALLOWANCE Stainless 304
STRESS (KPA) (SA-240)
EFFICIENCY OF Fully Radiographed 𝐸𝑗 = 1
JOINTS double-welded butt
joint
 1.75
23.33 ( 2 )
𝑡= + 0.009
23.33 (1) − 0.6(23.33)

𝑡 = 0.00918 𝑚

Outside Diameter

𝐷𝑜 = 2 (𝑟𝑖 + 𝑡)

1.75
𝐷𝑜 = 2 (( ) + 0.00918)
2

𝐷𝑜 = 1.76𝑚

External Volume

𝜋 2
𝑉= 𝐷 𝐿
4 𝑖

𝜋
𝑉= (1.76)2 (1.75)
4

𝑉 = 4.25 𝑚3

Volume of steel

𝑉𝑆𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙

𝑉𝑆𝑡𝑒𝑒𝑙 = 4.5 𝑚3 − 4.24𝑚3

 𝑉𝑆𝑡𝑒𝑒𝑙 = 0.26 𝑚3

Mass of steel

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 𝑉𝑠𝑡𝑒𝑒𝑙 × 𝜌𝑠𝑡𝑒𝑒𝑙

𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.26 𝑚3 × 7830
𝑚3

𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 2035. 8 𝐾𝑔

Heat Exchanger (HE-201)

Heuristics:

 The flow is counter current with feed at the tube side and water at the shell side
𝑊
 Heat transfer coefficient water to liquid: 285 2
𝑚 ∙𝐾
 Outer diameter is 0.019m and the length is 4.9m
Temperature Conditions

INLET OUTLET
TEMPERATURE (℃) TEMPERATURE (℃)
COLD SIDE 15 23
HOT SIDE 80 37

Heat Transfer Area

𝑄
𝐴=
𝑈𝐹∆𝑇
(80 − 15) − (37 − 23)
∆𝑇𝑙𝑚 =
80 − 15
ln (37 − 23)

∆𝑇𝑙𝑚 = 33.22 𝐾
𝑄 = 𝑚𝐶𝑝Δ𝑇
𝑘𝐽
𝑄 = (708.58𝑘𝑔) (2.43 ) (80 − 37)𝐾
𝑘𝑔 ∙ 𝐾
 𝑄 = 74039. 52 𝑘𝐽 = 20.56653 𝑘𝑊
20566.53 𝑊
𝐴=
𝑊
(285 2 )(33.22 𝐾)
𝑚 ∙𝐾
𝐴 = 2.17 𝑚2
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
2.17 𝑚2
𝑛=
𝜋(0.019)(4.9)
𝑛 = 7.42 𝑡𝑢𝑏𝑒𝑠 ~ 7 𝑡𝑢𝑏𝑒𝑠

By interpolation from table 14-9 (Timmerhaus),

𝐷𝑖,𝑠ℎ𝑒𝑙𝑙 = 0.203 𝑚

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑜𝑛𝑒 𝑝𝑎𝑠𝑠

0.0254 𝑚, 𝑡𝑟𝑖𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐

Extractor (EX-201)
Heuristics:

 The design temperature is 30℃ higher than the operating temperature

 The design pressure is 10% over than the maximum operating pressure or 70 to 175 kPa
higher whichever is greater
 100% extraction stage efficiency
 Height-to-diameter tank ratio of 3
 80% fill capacity
 9mm corrosion allowance
 Actual velocity is 85% of flooding velocity
Assumptions:

 Single stage extraction column

 Slope of equilibrium line is 1

Design Temperature
𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 37℃

𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 30℃

𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 37℃ + 30℃

 𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 67℃

Design Pressure
𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 150 𝑘𝑃𝑎

𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 175 𝑘𝑃𝑎

𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 150 𝑘𝑃𝑎 + 175 𝑘𝑃𝑎

𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 325 𝑘𝑃𝑎

COMPONENT MASS FLOW RATE (KG/HR) DENSITY (KG/M3)

XYLOSE 231.76 - 1520
WATER 176.84 176.84 997
BUTYL LACTATE 299.99 299.99 980
TOTAL 708.58 476.83

Mixture Density
For inlet streams:
𝑀𝐷 = (0.33)(1520) + (0.25)(997) + (0.42)(980)
𝑘𝑔
𝑀𝐷 = 1162.45
𝑚3
For outlet streams:
𝑀𝐷 = (0.37)(997) + (0.63)(980)
𝑘𝑔
𝑀𝐷 = 986.29
𝑚3
Volume
𝑀𝑎𝑠𝑠 𝑇𝑜𝑡𝑎𝑙
𝑉=
𝑀𝑖𝑥𝑡𝑢𝑟𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦
708.58 476.83
𝑉= +
1162.45 986.29
𝑉 = 1.093𝑚3
Dimension
For 80% filling capacity:
1.093 𝑑
𝑉= = 1.36625 = 𝜋( )2 (3𝑑)
0.8 2
𝑑 = 0.83 𝑚
ℎ = 2.49 𝑚
Wall thickness
 𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆𝐸𝑗 − 0.6𝑃

𝑆 = 137,900 (𝑆𝑡𝑎𝑖𝑛𝑙𝑒𝑠𝑠 𝑠𝑡𝑒𝑒𝑙 𝑡𝑦𝑝𝑒 316)

𝐸𝑗 = 1.0 (𝐹𝑢𝑙𝑙𝑦 𝑟𝑎𝑑𝑖𝑜𝑔𝑟𝑎𝑝ℎ𝑒𝑑 𝑑𝑜𝑢𝑏𝑙𝑒 − 𝑤𝑒𝑙𝑑𝑒𝑑 𝑏𝑢𝑡𝑡 𝑗𝑜𝑖𝑛𝑡𝑠)
0.83
(325 − 150)𝑘𝑃𝑎( )𝑚
𝑡= 2 + 0.009 𝑚
(137900)(1) − 0.6(325 − 150)𝑘𝑃𝑎
1000𝑚𝑚
𝑡 = 9.53𝑥10−3 𝑚 ( )
1𝑚
𝑡 = 9.53 𝑚𝑚