Appendix 3264

St-4931 Conceptual Process Design Production of Chitin and Chitosan from Shrimp Shells
Appendices Table of Content

Number Title
A Base of Design A-1

A.1 Basic Assumptions A-2
A.2 Kinetics A-3
A.2.a Demineralization (Lactic acid) A-3
A.2.b Enzymatic Deproteinization A-5
A.2.c Chemical Demineralization (Hydrochloric acid) A-6
A.2.d Chemical Deproteinization A-7
A.2.e Chemical Deacetylation A-8
A.3 Shrimp Shell Compositions A-9
B Thermodynamics B-1
C Process Structure, Description, and Balances C-1
C.1 Process Flow Scheme Diagram C-2
C.2 Utilities Summary C-7
C.3 Process Stream Summary C-10
D Equipment Design D-1
D.1 Integration by Process Simulation D-2
D.2 Lactic Acid Fermentation (R101 a/b) D-11
D.2.a Stoichiometry D-12
D.2.b Mass Balance of Fermentation D-13
D.2.c Reaction Condition Optimization D-14
D.2.d Fermentation Simulation D-15
D.2.e Dimensioning of Fermentor D-18
D.2.f Cooling Requirement D-19
D.2.g Microfilter Design D-19
D.2.h Superpro Designer Simulation D-19
D.3 Reactor Simulation (R301 a/b, R302, R401) D-22
D.3.a Mean Conversion and Total Reactor volume for CSTRs in N series D-23
D.3.b Residence Time Distribution D-23
D.3.c Impeller D-25
D.4 Rotary Drum Filter (S301, S302, S401) D-27
D.4.a Sample Calculation (S301) D-28
D.4.b Comparison to Aspen Plus Simulation D-32
D.5 Shrimp Shell Crusher (A201) and Chitosan Grinder (A401) D-33
D.5.a A201 Shrimp Shell Crusher Design D-34
D.5.a.a Energy Utilization for Size Reduction D-34
D.5.a.b Equipment Design D-34
D.5.b A401 Chitosan Grinder D-37
D.5.b.a Vessel Design D-38
D.6 Evaporators and Heat Exchangers D-39
D.6.a C201 Ethanol Evaporator D-40
D.6.a.a Design of the Vessel D-40
CPD 3264
I
Appendices Table of Content (cont'd)

Number Title
D.6.b Heat Integration and Heat Exchanger D-48
D.6.b.a Design Heat Exchanger for Sterilization D-48
D.6.b.b Design Heat Exchanger for Ethanol Evaporation System D-50
D.7 Extractor, Dryer, Buffer and Mixing Tanks D-57
D.7.a Benzoic Acid Extractor (S201) D-58
D.7.a.a Number of Stages D-58
D.7.a.b Equipment Design D-60
D.7.a.b.a Mass Transfer in Leaching Operations D-60
D.7.b Product Dryer D-64
D.7.c Buffer Tanks (T101 and T102) D-66
D.7.d Mixing Tanks (V301 and V401) D-67
D.8 Pump and Line Calculation D-69
D.9 Equipment Data Summary Sheets and Specification Sheets D-81
E Waste Streams E-1
F Economics F-1
CPD 3264
II
Appendix A.1 Basic Assumptions
Table A.1.1 Summary of Basis Assumptions

Shrimp shell composition
Degree of deacetylation (Initially) 25 % w/w
Ratio of bonded water to free water 50 %
Benzoic acid extractor
Benzoic acid recovery 99 %
Ethanol/water loss 5%
Lactic acid fermentation
Innoculum concentration 5 % w/w
Water 85 %
Lactobacillus sp. 15 %
Glucose concentration 15 % w/w
Utilization of glucose 99.9 % w/w
Glucose - lactate (Yield) 0.871 Cmol/Cmol
Glucose - growth (Yield) 0.123 Cmol/Cmol
Chitin Demineralization and Deproteinization
Demineralization 90 % w/w
Deproteinization Occasionally
Ratio of <24> to <3> 2 w/w
Chitin purification
Demineralization 95 % w/w
Ratio of HCl solution to solid 5 w/w
Molar concentration of HCl 0.5 N
Chitin deacetylation
Degree of deacetylation 90 % w/w
Deproteinization in deacetylation Occasionally
Ratio of NaOH over solids 10 w/w
Concentration of NaOH 45 % w/w
Drum filters (Filter 1, Filter2)
Chitin and solid loss 1 % w/w
Liquid fraction 20 % w/w
Drum filters (Filter 3)
Chitin and solid loss 1 % w/w
Liquid fraction 20 % w/w
Washing extraction water to cake 3 w/w
Product Dryer
Bounded Water Dried Out 90 % w/w
Free Water Dried Out 100 % w/w
CPD 3264
A-2
Appendix A.2 Kinetics
A.2.a Demineralization (Lactic acid)
Demineralization from shrimp shell takes place by fermentation with lactic acid. This is
described as equation A.2.1.
CaCO3 ( s )  2CH 3 HCOHCOOH ( aq )

(A.2.1)
 Ca (CH 3 HCOHCOO  ) 2 ( aq )  CO2 ( g )  H 2 O (aq )
Configuration of ‘in-situ’ lactic acid production and demineralization with fed-batch reactor is
shown in Figure A.2.2.1. [1]
Figure A.2.1 Reactor Configuration of in-situ fermentation
In this experiment, lactic acid was produced from whey lactose in a batch-fed fermentation
process, using immobilized cells of Lactobacillus. Fermentation was carried out and
demineralization of chitinous material took place simultaneously. This fermentation process had
been studied to produce low-cost lactic acid ‘in-situ’ and to investigate its direct use for the
demineralization of crayfish chitinous fraction. In this figure MF cell represents micro-filtration
cell, 0.2 μm, and CF is chitinious fraction. First, lactic acid solution flows to fermentation circuit
(a), until a lactic acid concentration of 20 g/l is reached. At this stage demineralization is not
carried out. Second, when it reaches 20 g/l, lactic acid solution is fed through fermentation
circuit (b), and demineralization takes place. Results from this experiment are shown in Figure
A.2.2.
CPD 3264
A-3
1 80
0.9
70
0.8
[kg-mineral/kg-mineral initial]
60
0.7
Lactic Acid [kg/m^3]

Mineral Fraction
50
0.6
0.5 40
0.4
30
0.3
20
0.2
10
0.1
0 0
0 10 20 30 40 50
time (hours)
Figure A.2.2 Lactic acid Production and Demineralization
Trend curves are described as follows for lactic acid production and demineralization,
respectively.
Lactic acid production
L  0.0013t  0.0914t  0.1035t  0.1801
3 2
(A.2.2)
Demineralization
M  0.0012t - 0.0862t - 0.5483t  100.94
3
(A.2.3)2
In which L represents lactic acid concentration [kg/m3], M is mineral fraction based on initial
mineral mass in chitinous material. [kg-mineral/kg-mineral initial], and t is reaction time [hour].
Reaction rate of demineralization is calculated by differentiation of equation A.2.2 and is
describes as equation A.2.4.
dM
 0.0036t 2 - 0.1724t  0.5483 (A.2.4)
dt
Demineralization depends on concentration of lactic acid and fraction of minerals in the reactor.
Therefore we can describe the reaction rate generally as follows.
dM
  kd  L  M
 
(A.2.5)
dt
Where kd is rate constant,  is degree of polynomial of lactic acid, and  is that of mineral.
As we mentioned before, we also assume that three periods (different three stages) exist for
demineralization of chitinous material. kd, , and  is calculated by iteration for three stages
using equation A.2.2, A.2.3, A.2.4, A.2.5. Solved values are listed below.
CPD 3264
A-4
Table A.2.1 In situ Lactic acid Production and Demineralization

k[1/hr]  
First stage 0.9763 0.3100 0.0337
(t:0-6 h, L:0-3 kg/m3 M:1-0.97)
Second stage 0.7232 0.4567 0.5840
(t:6-40 h, L:3-68 kg/m3 M:0.97-0.20)
Third stage 45.37 - 1.744
(t:40-50 h, L:68-71 kg/m3 M:0.20-0.09)
k is converted from [1/hr] to [1/s] and the kinetics of three stages are listed below.
First stage
dM
 2.71  104  L0.3100  M 0.0337 (A.2.6)
dt
Second stage
dM
 1.27  104  L0.4567  M 0.5840 (A.2.7)
dt
Third stage
dM
 0.0126  M
1.744
(A.2.8)
dt
The third stage is assumed to be the function of mineral fraction only, because the high
concentration of lactic acid is assumed to be not rate limiting in this stage.
A.2.b Enzymatic Deproteinization

Deproteinization takes place during the fermentation by aid of proteases. Protein hydrolysis is
generally described generally as follows.
(Protein) n (aq)+(n-1)H 2 O(l)  n  Protein (l) (A.2.9)
Experimental results of deproteinization through fermentation of shrimp shells with lactic acid,
are shown in Fig A.2.3
Trend of P fraction profile can be described as equation A.2.10. (Dash line in Figure A.2.3) This
equation is estimated through Michaelis-Menten equation.
0.1  0.24t
P (A.2.10)
0.1  1.24t
In which P is the fraction of protein based on mass in the chitinous material initially. The
reaction rate is expressed in equation A.2.11.
dP 0.1
 (A.2.11)
(0.1  1.24t )
2
dt
It is assumed that this reaction can be written as A.2.12, which is depending on protein fraction.
dP
  ke  P

(A.2.12)
dt
CPD 3264
A-5
0.9
0.8
[kg-protein/kg-protein initial]
0.7
Protein Fraction
0.6
0.5
0.4
0.3
0.2
0.1
0
0 10 20 30 40 50
time [hours]
Figure A.2.3 Enzymatic Deproteinization
In which k is rate constant,  is degree of polynomial of protein fraction. ke and  is calculated as

25.20 [1/hr] and 4.291 respectively. ke is converted to second base, and it is 0.0070 [1/s]
dP
 0.0070  P 4.291 (A.2.13)
dt
A.2.c Chemical Demineralization (Hydrochloric acid)

Shrimp shells contain 34 % of minerals (dry basis), and it consists of mainly calcium carbonate.
Demineralization from shrimp shell is accomplished by extraction of calcium carbonate with
dilute hydrochloric acid to form calcium chloride. It is described as equation. Pseudo first-order
reaction kinetics is observed [2]. The rate of reaction can be described as:
CaCO3 ( s)  2 HCl (aq)  CaCl2 (aq)  CO2 ( g )  H 2O(l ) (A.2.14)

dM
  ka M (A.2.15)
dt
Where M represents mineral fraction [kg-mineral/kg-mineral initial], which calcium is dominant,

t is treatment time and ka [1/s] is the rate constant. Mineral fraction bases on amount of the
mineral that is bounded to chitin initially. ka is expressed by Arrhenius equation with amount of
hydrochloric acid, HCl, which reacts with the mineral to form soluble solid. HCl also controls
the pH of the reactor. The reaction rate is assumed to be proportional to the amount of hydrogen
chloride, A.
E

k a  Ak a 0  e RT
. (A.2.16)
In which A represents amount of HCl [N·l-solution/kg-solid] that is calculated by multiplying

solution to solid ratio [l-solution/kg-solid] and concentration of HCl [N] (N=mol/kg-solvent). ka0
is the Arrhenius rate constant, E is the activation energy, R is gas constant, and T is reaction
temperature.
CPD 3264
A-6
Activation energy and the rate constant are calculated using experimental data, which is listed in
Table A.2.2. [3] They are calculated through Arrhenius plot. (lnka against 1/T) However some
experimental data shows negative activation energy, hence we calculate the average value
without these values. The experiments with lower solution to solid ratio (5.4) show negative
activation energies. It might involve another kinetic step, such as absorption or desorption. In
our process, 5 is taken as the solid-solution ratio for the chitin purification process (chemical
demineralization). However, our solid-solution ratio is wet basis, while the experiments had done
and based on dry basis (without H2O-bound). Therefore, if the wet basis solid-solution ratio is
converted to dry basis, our solid-solution ration becomes approximately 10 in dry basis.
Additionally, low concentration of hydrogen chloride, 0.5 N, is adopted for the chitin purification.
Therefore we extracted the kinetics data from the experiment with 12.6 solid-solution ratio, and
0.56 N of hydrogen chloride.
Table A.2.2 Demineralization condition

Solution to solid ratio Concentration Temperature Rate constant ka Ea[J/mol]
[ml/g] HCl [N] T [K] ka[10 -3/min]
5.4 0.56 85.8 0.203

5.4 0.56 44.2 0.403 -15597.52971
5.4 1.64 85.8 2.86
5.4 1.64 44.2 6.17 -17488.77106
12.6 0.56 84 3.37
12.6 0.56 40 1.92 11878.45675
9 1.1 100 15
9 1.1 65 4.55 35725.63101
Activation energy, E, is calculated as 11.88 kJ/mol and Arrhenius rate constant ka0 is 3.3110-4
kg-solid/(s·N·l-solution).
Therefore the rate expression is described as follows,
23800
dM 
 3.31  10
-4
 A M e RT
(A.2.17)
dt
A.2.d Chemical Deproteinization (Sodium hydroxide)

Sodium hydroxide solution is used to remove protein from shrimp shell. Deproteinization from
shrimp shell appears to have two-stage first-order reaction kinetics. The change in reaction rates
occurs when the protein concentration becomes low. The protein concentration above 7% is taken
as the first stage and below 7 % is taken as the second stage. The rate of reaction is described as
follows,
dP
  kb P (A.2.18)
dt
Where P represents fraction of protein based on mass in the chitinous material initially. Rate
constant kb is expressed by Arrhenius equation with amount of sodium hydroxide, NaOH, which
acts as a catalyst and controls the pH of the reaction.
E

kb  Bkb 0 e RT
. (A.2.19)
CPD 3264
A-7
In which B represents amount of NaOH [N·ml-solution/g-solid] that is calculated by multiplying

solvent to solid ratio and concentration of NaOH, and ka0 is the Arrhenius rate constant.
Experimental results are shown in Table A.2.3, where kb1 represents rate constant for high protein
contents (7 %), kb2 represents rate constant for low protein contents (<7 %). Experimental results
are shown in the table below. [4]
Table A.2.3 Deproteinization Experiment

Solution to solid ratio Concentration Total amount B Temperature Rate constant kb1 Rate constant kb2
[ml/g] HCl [N] HCl [Nml/g] T [K] kb[10^-2/min] kb[10^-4/min]
17 0.91 15.47 84 1.68 3.97
17 0.91 15.47 40 0.314 13.5
8 2.09 16.72 84 9.42 8.66
8 2.09 16.72 40 1.39 2.68
12.5 1.5 18.75 99 8.79 4.17
12.5 1.5 18.75 62 3.76 6.42
17 2.09 35.53 84 5.7 6.07
17 2.09 35.53 40 0.712 10.8
Activation energy, E, and Arrhenius rate constant of the first stage, kb10, (higher protein
concentration) are calculated as 35.88 kJ/mol and 37.71 g/(s·N·ml·g) respectively. Those for
second stage (low concentration) are calculated as 24.76 kJ/mol and 3.62810-3 kg-solid/(s·N·l-
solution), respectively.
First Stage
35800
dP 
 37.7  B  P  e RT
(A.2.20)
dt
Second Stage
24760
dP 
 3.63  10
-3
 BPe RT
(A.2.21)
dt
A.2.e Chemical Deacetylation

Chitosan is produced by deacetylation of chitin. The deacetylation of chitin also behaves as a
pseudo first order reaction. Chitin is treated with hot, concentrated solution of NaOH and
chitosan is produced as an insoluble precipitate. Therefore the reaction rate is described as the
function of D, which is degree of deacetylation in the system.
dD
 kc (1  D ) (A.2.22)
dt
kc is expressed by Arrhenius equation with amount of sodium hydroxide, NaOH.
E

k c  B  kc 0  e RT
(A.2.23)
kc0 is the Arrhenius rate constant. Experimental results are shown in Table A.2.4. [5] 50 % NaOH
solution, (1:10 w/w) is used for the experiment.
CPD 3264
A-8
Table A.2.4 Deacetylation Experiment

Temperature time Deacetylation Degree Rate constant
T [C] [min] kc
60 90 68 0.012923898
60 180 76 0.004863715
75 15 55 0.100271826
80 15 64 0.08539559
85 15 73 0.066216785
115 30 82 0.019592889
115 20min 2times 87
115 20min 3times 95
Activation energy, E, is calculated as 71.7 kJ/mol. B· kc 0 is calculated as 4.10 106 [1/s].

71700
dD 
6
 4.10  10  (1  D )  e RT
(A.2.24)
dt
Appendix A.3 Shrimp Shell Compositions
Table A.3.1 Shrimp Shell Compositions

Component [6] [7] [8] [9] [10] Average
Mineral 36 32 40 28 - 34.0
Protein 41 50 35 40 35 40.2
Chitin 20 18 25 23 18 20.8
Lipid related 3 - - - - 3.0
Other carbohydrate - - - - - 2.0
Note: First two sources [6] and [7] have been normalized.
Reference:
[1] J.Bautista, M.Jover, Process Biochemistry, 37, 2001, pp229-234

[2] Chang,k.L. Tsai,G., Journal of Agriculutral and Food Chemistry, 45, 1997, pp.1900-1904
[5] I Kolodziejska, A Wojtasz-Pajak, Bulletin of The Sea Fisheries Institute, 2 (150), 2000, 15-24
[6] Gilberg, A. Stenberg, E. Process Biochemistry, 36, 2001, p.809 – 812
[7] Legarreta, I.G. Zakaria, Z., Hall, G.M., Lactic Acid Fermentation of Prawn Waste; Comparison of
Commercial and Isolated Starter Culture, EUCHIS I, Drest, 1995
[8] No, H.K.,Hur, E.Y., Journal of Agricultural and Food Chemistry, 46, 1998, p. 3844 - 3846
[9] Ferrer, J., Paez, G., Biosource Technology, 57, 1996, p.55 – 60
[10] Cosio, et.al Journal of Food Science, 47, 1981, p. 901-905
CPD 3264
A-9
St-4931 Conceptual Process Design Production of Chitin and Chitosan
from Shrimp Shells
Table B.1 Comparison of heat of formation (at 25 ºC)

Heat of formation Heat of formation Heat of solid formation Heat of solution
kJ/mol (Literture) kJ/mol (ASPEN) kJ/mol (ASPEN) kJ/mol (ASPEN)
Acetic acid -412.2 -432.8 -486.1
Ammonium sulfate -1174.3 -1181.0
Benzoic acid -228.5 -294.1
Calcium chloride -877.1 -471.5 -795.8
Calcium carbonate -1220.0 -329.4
Calcium lactate - -1294.0
Chitin - -973.2
Chitosan - -953.3
Carbon dioxide -393.5 -393.5 -413.8
Ethanol -163.3 -235.0 -288.3
Glucose -1264.0 -1140.5
Hydrochloric acid -167.2 -92.3 -167.2
Lactic acid -621.1 -599.6
Lipids (Stearic acid) -947.2 (s) -764.0
Nitrogen 0.0 0.0
Oxygen 0.0 0.0 -11.7
Protein(Leucine) -648.9 -494.2
Sodium chloride -411.1(s) -181.4 -411.3
Sodium hydroxide -469.6 -197.8 -425.8
Sulfuric acid -735.1 -735.2 -909.3
Water -286.4 -241.8 -292.9
CPD 3264
B-1
St-4931 Conceptual Process Design Production of Chitin and Chitosan
from Shrimp Shells
Table B.2 Comparision of boiling point and heat capasity (at 25 ºC)
Heat capacity Heat capacity

J/mol·K (Literature) J/mol·K (ASPEN)
Acetic acid 129 62
Ammonium sulfate 187 195
Benzoic acid 217 201
Calcium chloride 72.9 59
Calcium carbonate 111 109
Calcium lactate - 210
Chitin - 130
Chitosan - -
Carbon dioxide 38 37
Ethanol 107 128
Glucose - 370
Hydrochloric acid 98 29
Lactic acid 192
Lipids (Stearic acid) 502 610
Nitrogen 29 29
Oxygen 29 29
Protein (Leucine) 191 180
Sodium chloride 51 36
Sodium hydroxide 87 -53
Sulfuric acid 83.7 85
Water 76 70
CPD 3264
B-2
1
25 1
1
45
101
40
6.3 40
Innoculum 1 4.2 3.9
43.2
6.3
112a
115a
25 25 43.2
105 43.2 Gas
102 103 104 FC 106a
E101 P103
Glucose P101 4.4 3.8 6.1
5.1 4.1
0.9 pHC TC
43.3 43.3
25 PC 40 40
25 110 6.1 I
108 109 114a 116a
107 FC LC RC
43.3
E102 P104 1.2
S101a
N-source P102 111a PI
40
113a 4.1
R101a P105a 40
116b
1
5
40
112b 40
6.3 LC
115b
43.2
FC 106b T101
6.1
5.1
43.3 FC pHC TC
I PC 40
111b
114b
LC RC
1.2
PI S101b
40 1.1
113b
25
R101b P105b 117
4.3
25
118 FC
P106
3
Designers Process Flow Scheme - Improved Solution

PROCESS EQUIPMENT LIST
A.A.Khan Project : Production of Chitin and Chitosan from Shrimp Shells
E101 Glucose sterilizer P103 R101A-B feed pump P106 R301 feed pump Plant Unit : U1000 – Lactic Acid Fermentation Section
E102 N-source sterilizer P104 R101A-B feed pump R101 a/b Lactic acid fermentor H. Shibata
Proj. ID Number : CPD 3264
P101 E101 feed pump P105a S104A feed pump S101 a/b Biomass recycle microfilter M.T.A.P. Kresnowati Completion Date : 21 December 2001
P102 E102 feed pump P105b S104B feed pump T 101 Lactic acid buffer tank S.L.Tai Stream number Temp. (K) Pressure (Bara)
CPD3264
C-3
25
1.9
2
201 32.3
Shrimp shells X201

203
1
1.1 MI FC
25
25 202
214
1
X202 1
P202 25.7
3.4
25.7
Ethanol A201 204
25 205
4 S201 3
215
P201
25.7
3.3
206
72.2 1 1 1
207 87.2 87.2 FC 35

211 212 213
E202 LC
E201 RC
PC
2.6 E203 1.1
TC T201
77 32.3 FC
208 216
1.3
87.2
P203
LC
210
Benzoic acid
P204
1.1
C201
87.2
209
PROCESS EQUIPMENT LIST Designers Process Flow Scheme - Improved Solution

A201 Shrimp shell crusher P201 C201 feed pump S201 Benzoic acid extractor Project Production of Chitin and Chitosan from Shrimp Shells
A.A.Khan :
C201 Ethanol evaporator P202 V201 feed pump T 201 Ethanol buffer tank Plant Unit : U2000 – Shrimp Shells Pretreatment Section
H. Shibata
E201 Feed C201 preheater P203 S201 feed pump X201 conveyer Proj. ID Number : CPD 3264
M.T.A.P. Kresnowati Completion Date : 21 December 2001
E202 Ethanol heat exchanger P204 C201 Bottom pump X202 conveyer
E203 T op 201 condenser S.L.Tai Stream number Temp. (K) Pressure (Bara)
CPD3264
C-4
3
LC 4.3
FC
T101 25
118 Gas
1
1 RC
pHI TC
25
1 301 4.2
FC
25 25
R301a
204 303
2 X301
PI
1.1 pHI TC 1.0

1.1
1.7
Fermentation
25
25 25
302 S301 25
305
broth
307 304
R301b 1
P301 PC
HCl 25 FI P303
306
2.2 RC FC
25 FC
308
X302
1
P302
LI
39.9 3.5
1 4
311 39.9
39.9
313
pHI 316
V301 2.3 1
PI
1.0
25 39.9
25
310 312
309
P305 S302
P304 R302
TC 1.1
39.9
314
PC 1.7
FI
39.9
315
PROCESS EQUIPMENT LIST

P306
Waste water
P301 S301 feed pump R302 Chitin purification reactor
P302 HCl feed pump S301 Fermentation broth drum filter Designers Process Flow Scheme - Improved Solution
P303 S301 filtrate pump S302 Chitin drum filter Project Production of Chitin and Chitosan from Shrimp Shells
A.A.Khan :
P304 R302 feed pump V301 HCl Chitin mixer Plant Unit : U3000 – Enzymatic deproteinization and
H. Shibata demineralization + chitin purification
P305 S302 feed pump X301 conveyer Proj. ID Number : CPD 3264
P306 S302 filtrate pump X302 conveyer
R301 a/b Enzymatic deproteinisation demineralisation reactor S.L.Tai Stream number Temp. (K) Pressure (Bara)
CPD3264
C-5
25
1
FC
1
40
4
411
1 415
Water FI
27
water
414
1 PI
25 X402
314 S401 TC 1
PC
3 X401 40
FC
5.8
D401 416 1
RC
3.9 35
1.1 40
FC 410
25 417
25
402
401 PC
1
LI FI Chitosan
P401 A401
NaOH 1.1 4.6 6.6 27
28.0 43.8 412 1.8

V401 28.0 E403
404 409 27
403 P404
413
P402
E401 Waste water
(NaOH rich)
3.3
108
405
E402
pHI TC 2.3
3.0
121 7.4
121
407 121
406
408
P403
R401
PROCESS EQUIPMENT LIST Designers Process Flow Scheme - Improved Solution

A401 Chitosan grinder P401 V401 feed pump S401 Chitosan drum filter Project : Production of Chitin and Chitosan from Shrimp Shells
A.A.Khan
D401 Product dryer P402 R401 feed pump V401 NaoH chitin mixer Plant Unit : U4000 – Chitin deacetylation
H. Shibata
E401 R401 heat exchanger P403 S401 feed pump X401 conveyer Proj. ID Number : CPD 3264
E402 Feed R401 preheater P404 S401 filtrate pump X402 conveyer
E403 Product R401 cooler R401 Deacethylation reactor S.L.Tai Stream number Temp. (K) Pressure (Bara)
CPD3264
C-6
SUMMARY OF UTILITIES
EQUIPMENT UTILITIES
Heating Cooling Power REMARKS
Nr. Name Load Consumption (kg/h) Load Consumption (kg/h) Actual Consumption (t/h, kWh/h)
Steam Hot Cooling Air Chilled Load Steam (t/h) Electr.
kW LP MP HP Oil kW Water Water kW HP MP kWh/h
A201 Crusher grinder 0.27 0.27
A401 Chitosan crusher 0.04 0.04
C201 Ethanol Flash destillation 14.1 23
D401 Dryer 70.8 118 6.83 6.83
E101 Glucose sterilizer 36.8 66
E102 N-source sterilizer 12.3 22
E201 Feed C201 preheater 0.3 1
E203 Top C201 condenser 12.3 2095
E402 Feed R401 preheater 25.4 42
E403 Product R401 cooler 15.0 2554
P101 E101 feed 0.17 0.17
P102 E102 feed 0.06 0.06
P103 R101A-B feed 0.12 0.12
P104 R101A-B feed 0.04 0.04
P105A S104A feed 0.19 0.19
P105B S104B feed 0.19 0.19
P106 R301 feed 0.17 0.17
P201 C201 feed 0.01 0.01
P202 V201 feed 0.00 0.00
P203 S201 feed 0.00 0.00
P204 C201 Bottom 0.00 0.00
P301 S301 feed 0.34 0.34
P302 HCl feed 0.06 0.06
P303 S301 filtrate 0.06 0.06
P304 R302 feed 0.02 0.02
P305 S302 feed 0.18 0.18
P306 S302 filtrate 0.04 0.04
P401 V401 feed 0.04 0.04
P402 R401 feed 0.44 0.44
P403 S401 feed 0.66 0.66
P404 S401 filtrate 0.05 0.05
R101a Lactic acid fermentor 38.5 3288 8.45 8.45
R101b Lactic acid fermentor 38.5 3288 8.45 8.45
Sub Total 159.6 184.0 87.7 104.2 11225.1 26.9 26.9
Project ID Number : CPD3264

Completion Date : Dec-01
SUMMARY OF UTILITIES
EQUIPMENT UTILITIES
Heating Cooling Power REMARKS
Nr. Name Load Consumption (kg/h) Load Consumption (kg/h) Actual Consumption (t/h, kWh/h)
Steam Hot Cooling Air Chilled Load Steam (t/h) Electr.
kW LP MP HP Oil kW Water Water kW HP MP kWh/h
R301 Enzymatic deprotreinisation demineralisation 113.7 9708 0.11 0.11
R302 Chitin purification 0.0 0.00 0.00
R401 Deacetylation 0.0 15.4 658 0.01 0.01
S101A Biomass recycle microfilter 5.55 5.55
S101B Biomass recycle microfilter 5.55 5.55
S201 Benzoic acid extractor n.a
S301 Fermentation broth drum filter 0.14 0.14
S302 Chitin drum filter 0.09 0.09
S401 Chitosan drum filter 0.19 0.19
T101 Lactic acid buffer tank 38.8 3313
T201 Ethanol buffer tank n.a
V301 HCl chitin mixer 0.00 0.00
V401 NaOH chitin mixer 0.00 0.00
X201 conveyer n.a
X202 conveyer n.a
X301 conveyer n.a
X302 conveyer n.a
X401 conveyer n.a
X402 conveyer n.a
subtotal 0.0 167.9 658.0 13020.9 11.6 11.6
TOTAL 159.6 184.0 87.7 272.1 11883.1 13020.9 38.5 38.5

Completion Date : Dec-01
STREAM Nr. : 101 102 103 104

Name : Innoculum Glucose feed Cold in E101 Hot Out E101
COMP MW tonnes/day kmol/day tonnes/day kmol/day tonnes/day kmol/day tonnes/day kmol/day
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 - - - - - - - -
Benzoic Acid 122,12 - - - - - - - -
Calcium carbonate 100,09 - - - - - - - -
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - - - - - - -
Chitosan 161,16 - - - - - - - -
Ethanol 46,07 - - - - - - - -
Glucose 180,16 - - 8,777 0,049 8,777 0,049 8,777 0,049
Hydrocloric Acid 36,46 - - - - - - - -
Lactic Acid 90,08 - - - - - - - -
Lipid 284,48 - - - - - - - -
Lactobacillus sp. 24,60 - - - - - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - - -
Sodium Cloride 58,44 - - - - - - - -
Sodium Hydroxide 40,00 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - - -
Water 18,02 - - 39,221 2,177 39,221 2,177 39,221 2,177
Total - - 47,997 2,225 47,997 2,225 47,997 2,225

Enthalpy kW - (7.936,832) (7.936,832) (7.900.058)
Phase liquid liquid liquid liquid
Press. Bara 1,00 0,97 4,24 3,93
Temp oC 25,00 25,00 25,00 43,20
STREAM Nr. : 105 106a/b 107 108

Name : Hot Press. Out E101 Glucose In R101a/b N-source feed Cold in E102
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 - - - - 0,526 0,004 0,526 0,004
Benzoic Acid 122,12 - - - - - - - -
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - - - - - - -
Chitosan 161,16 - - - - - - - -
Ethanol 46,07 - - - - - - - -
Glucose 180,16 8,777 0,049 4,388 0,024 - - - -
Lactic Acid 90,08 - - - - - - - -
Lipid 284,48 - - - - - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - - -
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - - -
Water 18,02 39,221 2,177 19,610 1,088 13,074 0,726 13,074 0,726
Total 47,997 2,225 23,999 1,113 13,599 0,729 13,599 0,729

Enthalpy kW (7.900.058) (3.950.029) (2.400,875) (2.400,875)
Press. Bara 6,26 6,26 0,87 4,37
Temp oC 43,20 43,20 25,00 25,00

Completion Date : 21 Dec 2001
CPD3264
C-11
STREAM Nr. : 109 110 111a/b 112a/b

Name : Hot Out E102 Hot Press. Out E102 N-source in R101a/b Gas out R101a/b
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 0,526 0,004 0,526 0,004 0,263 0,002 - -
Benzoic Acid 122,12 - - - - - - - -
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - 0,039 0,001
Chitin 203,19 - - - - - - - -
Chitosan 161,16 - - - - - - - -
Ethanol 46,07 - - - - - - - -
Glucose 180,16 - - - - - - - -
Lactic Acid 90,08 - - - - - - - -
Lipid 284,48 - - - - - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - - -
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - - -
Water 18,02 13,074 0,726 13,074 0,726 6,537 0,363 - -
Total 13,599 0,729 13,599 0,729 6,800 0,365 0,039 0,001

Enthalpy kW (2.388.596) (2.388.596) (1.194.298) (4,072)
Phase liquid liquid liquid gas
Press. Bara 3,80 6,12 6,12 1,00
Temp oC 43,33 43,33 43,33 40,00
STREAM Nr. : 113a/b 114a/b 115a/b 116a/b

Name : Out R101a/b In S101a/b Biomass recycle Permeate S101a/b
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 0,035 0,000 0,035 0,000 0,009 0,000 0,026 0,000
Benzoic Acid 122,12 - - - - - - - -
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - - - - - - -
Chitosan 161,16 - - - - - - - -
Ethanol 46,07 - - - - - - - -
Glucose 180,16 0,004 0,000 0,004 0,000 0,001 0,000 0,003 0,000
Lactic Acid 90,08 5,094 0,057 5,094 0,057 1,274 0,014 3,821 0,042
Lipid 284,48 - - - - - - - -
Lactobacillus sp. 24,60 2,203 0,090 2,203 0,090 1,763 0,072 0,441 0,018
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - - -
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 0,234 0,002 0,234 0,002 0,059 0,001 0,176 0,002
Water 18,02 35,056 1,945 35,056 1,945 8,764 0,486 26,292 1,459
Total 42,628 2,094 42,628 2,094 11,869 0,573 30,759 1,521

Enthalpy kW (6.979,117) (6.979,117) (1.800,416) (5.178,699)
Press. Bara 1,15 5,14 5,00 4,14
Temp oC 40,00 40,00 40,00 40,00

CPD3264
C-12
STREAM Nr. : 117 118 201 202

Name : Lactic acid Lactic acid in R301 Shrimp shells feed Crushed shrimp shells
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 0,053 0,000 0,053 0,000 - - - -
Benzoic Acid 122,12 - - - - 0,300 0,002 0,300 0,002
Calcium Cloride 110,99 - - - - 3,978 0,036 3,978 0,036
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - - - 1,825 0,009 1,825 0,009
Chitosan 161,16 - - - - 0,608 0,004 0,608 0,004
Ethanol 46,07 - - - - - - - -
Glucose 180,16 0,007 0,000 0,007 0,000 0,234 0,001 0,234 0,001
Lactic Acid 90,08 7,642 0,085 7,642 0,085 - - - -
Lipid 284,48 - - - - 0,351 0,001 0,351 0,001
Lactobacillus sp. 24,60 0,881 0,036 0,881 0,036 - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - 4,703 0,038 4,703 0,038
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 0,351 0,004 0,351 0,004 - - - -
Water 18,02 52,584 2,918 52,584 2,918 18,000 0,999 18,000 0,999
Total 61,518 3,043 61,518 3,043 30,000 1,091 30,000 1,091

Enthalpy kW (10.396,186) (10.396,186) (3.885,959) (3.885,959)
Phase liquid liquid solid solid
Press. Bara 1,15 4,31 1,00 1,00
Temp oC 25,00 25,00 25,00 25,00
STREAM Nr. : 203 204 205 206

Name : Ethanol in S201 Out S201 Solvent out S201 Cold in E202
Acetic Acid 60,05 - - - - - - - -
Benzoic Acid 122,12 0,000 0,000 0,003 0,000 0,297 0,002 0,297 0,002
Calcium Cloride 110,99 - - 3,978 0,036 - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - 1,825 0,009 - - - -
Chitosan 161,16 - - 0,608 0,004 - - - -
Ethanol 46,07 1,021 0,022 0,051 0,001 0,970 0,021 0,970 0,021
Glucose 180,16 - - 0,234 0,001 - - - -
Lactic Acid 90,08 - - - - - - - -
Lipid 284,48 - - 0,351 0,001 - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - 4,703 0,038 - - - -
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - - -
Water 18,02 0,333 0,018 18,005 0,999 0,327 0,018 0,327 0,018
Total 1,354 0,041 29,759 1,090 1,595 0,042 1,595 0,042

Enthalpy kW (131,970) (3.878,760) (138,175) (138,175)
Press. Bara 1,90 1,02 1,02 4,00
Temp oC 32,32 25,71 25,71 25,71

CPD3264
C-13
STREAM Nr. : 207 208 209 210

Name : Hot out E202 Hot out E208 Bottom C201 Benzoic acid slurry
Acetic Acid 60,05 - - - - - - - -
Benzoic Acid 122,12 0,297 0,002 0,297 0,002 0,297 0,002 0,297 0,002
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - - - - - - -
Chitosan 161,16 - - - - - - - -
Ethanol 46,07 0,970 0,021 0,970 0,021 0,196 0,004 0,196 0,004
Glucose 180,16 - - - - - - - -
Lactic Acid 90,08 - - - - - - - -
Lipid 284,48 - - - - - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - - -
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - - -
Water 18,02 0,327 0,018 0,327 0,018 0,105 0,006 0,105 0,006
Total 1,595 0,042 1,595 0,042 0,598 0,012 0,598 0,012

Enthalpy kW (135,054) (134,733) (41,497) (41,497)
Press. Bara 3,30 2,60 1,10 1,31
Temp oC 72,22 77,00 87,22 87,22
STREAM Nr. : 211 212 213 214

Name : Top C201 Cold out E202 Cold out E203 Fresh Ethanol
Acetic Acid 60,05 - - - - - - - -
Benzoic Acid 122,12 0,000 0,000 0,000 0,000 0,000 0,000 - -
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - - -
Carbon dioxyde 44,01 - - - - - - - -
Chitin 203,19 - - - - - - - -
Chitosan 161,16 - - - - - - - -
Ethanol 46,07 0,774 0,017 0,774 0,017 0,774 0,017 0,247 0,005
Glucose 180,16 - - - - - - - -
Lactic Acid 90,08 - - - - - - - -
Lipid 284,48 - - - - - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - - -
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - - -
Water 18,02 0,223 0,012 0,223 0,012 0,223 0,012 0,110 0,006
Total 0,997 0,029 0,997 0,029 0,997 0,029 0,357 0,011

Enthalpy kW (79,146) (82,267) (94,532) (37,436)
Phase liquid liquid/vapour liquid liquid
Press. Bara 1,00 1,00 1,00 1,13
Temp oC 87,22 87,22 35,00 25,00

CPD3264
C-14
STREAM Nr. : 215 216 301 302

Name : Fresh Ethanol in T201 Mixed Ethanol Gas out R301 Out R301
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 - - - - - - 0,053 0,000
Benzoic Acid 122,12 - - 0,000 0,000 - - 0,003 0,000
Calcium carbonate 100,09 - - - - - - 0,400 0,004
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - - - 7,801 0,036
Carbon dioxyde 44,01 - - - - 1,511 0,034 0,062 0,001
Chitin 203,19 - - - - - - 1,825 0,009
Chitosan 161,16 - - - - - - 0,608 0,004
Ethanol 46,07 0,247 0,005 1,021 0,022 - - 0,051 0,001
Glucose 180,16 - - - - - - 0,241 0,001
Lactic Acid 90,08 - - - - - - 1,201 0,013
Lipid 284,48 - - - - - - 0,351 0,001
Lactobacillus sp. 24,60 - - - - - - 0,881 0,036
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - - - 4,703 0,038
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - - - 0,351 0,004
Water 18,02 0,110 0,006 0,333 0,018 - - 71,234 3,953
Total 0,357 0,011 1,354 0,041 1,511 0,034 89,766 4,102

Enthalpy kW (37,436) (131,970) (156,394) (14.232,212)
Phase liquid liquid gas liquid
Press. Bara 3,37 1,07 1,00 1,02
Temp oC 25,00 32,32 25,00 25,00
STREAM Nr. : 303 304 305 306

Name : In S301 Fermentation broth Fermentation broth Cake out S301
Acetic Acid 60,05 - - - - - - - -
Benzoic Acid 122,12 0,003 0,000 0,003 0,000 0,003 0,000 0,000 0,000
Calcium carbonate 100,09 0,400 0,004 0,004 0,000 0,004 0,000 0,396 0,004
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 7,801 0,036 7,591 0,035 7,591 0,035 0,211 0,001
Carbon dioxyde 44,01 0,062 0,001 0,060 0,001 0,060 0,001 0,002 0,000
Chitin 203,19 1,825 0,009 0,018 0,000 0,018 0,000 1,807 0,009
Chitosan 161,16 0,608 0,004 0,006 0,000 0,006 0,000 0,602 0,004
Ethanol 46,07 0,051 0,001 0,050 0,001 0,050 0,001 0,001 0,000
Glucose 180,16 0,241 0,001 0,139 0,001 0,139 0,001 0,102 0,001
Lactic Acid 90,08 1,201 0,013 1,169 0,013 1,169 0,013 0,032 0,000
Lipid 284,48 0,351 0,001 0,342 0,001 0,342 0,001 0,009 0,000
Lactobacillus sp. 24,60 0,881 0,036 0,881 0,036 0,881 0,036 - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 4,703 0,038 2,625 0,021 2,625 0,021 2,078 0,017
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 0,351 0,004 0,342 0,003 0,342 0,003 0,009 0,000
Water 18,02 71,234 3,953 65,634 3,642 65,634 3,642 5,600 0,311
Total 89,766 4,102 78,915 3,756 78,915 3,756 10,852 0,346

Enthalpy kW (14.232,212) (12.911,449) (12.911,449) (1.320,757)
Phase liquid liquid liquid solid
Press. Bara 4,20 1,08 1,63 1,00
Temp oC 25,00 25,00 25,00 25,00

CPD3264
C-15
STREAM Nr. : 307 308 309 310

Name : Fresh HCl HCl in V301 Mixed Chitin HCl In R302
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 - - - - 0,001 0,000 0,001 0,000
Benzoic Acid 122,12 - - - - 0,000 0,000 0,000 0,000
Calcium carbonate 100,09 - - - - 0,396 0,004 0,396 0,004
Calcium Cloride 110,99 - - - - - - - -
Calcium Lactate 218,22 - - - - 0,211 0,001 0,211 0,001
Carbon dioxyde 44,01 - - - - 0,002 0,000 0,002 0,000
Chitin 203,19 - - - - 1,807 0,009 1,807 0,009
Chitosan 161,16 - - - - 0,602 0,004 0,602 0,004
Ethanol 46,07 - - - - 0,001 0,000 0,001 0,000
Glucose 180,16 - - - - 0,102 0,001 0,102 0,001
Hydrocloric Acid 36,46 0,820 0,022 0,820 0,022 0,820 0,022 0,820 0,022
Lactic Acid 90,08 - - - - 0,032 0,000 0,032 0,000
Lipid 284,48 - - - - 0,009 0,000 0,009 0,000
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - - - 2,078 0,017 2,078 0,017
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - - - 0,009 0,000 0,009 0,000
Water 18,02 44,210 2,453 44,210 2,453 49,810 2,764 49,810 2,764
Total 45,030 2,476 45,030 2,476 55,882 2,822 55,882 2,822

Enthalpy kW (8.140,755) (8.140,755) (9.461,512) (9.461,512)
Press. Bara 1,06 2,17 1,02 1,26
Temp oC 25,00 25,00 25,00 25,00
STREAM Nr. : 311 312 313 314

Name : Gas out R302 Out R302 In S302 Filtrate S302
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 - - 0,001 0,000 0,001 0,000 0,001 0,000
Benzoic Acid 122,12 - - 0,000 0,000 0,000 0,000 0,000 0,000
Calcium carbonate 100,09 - - 0,020 0,000 0,020 0,000 0,000 0,000
Calcium Cloride 110,99 - - 0,417 0,004 0,417 0,004 0,399 0,004
Calcium Lactate 218,22 - - 0,211 0,001 0,211 0,001 0,202 0,001
Carbon dioxyde 44,01 0,122 0,003 0,045 0,001 0,045 0,001 0,043 0,001
Chitin 203,19 - - 1,807 0,009 1,807 0,009 0,018 0,000
Chitosan 161,16 - - 0,602 0,004 0,602 0,004 0,006 0,000
Ethanol 46,07 - - 0,001 0,000 0,001 0,000 0,001 0,000
Glucose 180,16 - - 0,102 0,001 0,102 0,001 0,009 0,000
Hydrocloric Acid 36,46 - - 0,546 0,015 0,546 0,015 0,523 0,014
Lactic Acid 90,08 - - 0,032 0,000 0,032 0,000 0,031 0,000
Lipid 284,48 - - 0,009 0,000 0,009 0,000 0,009 0,000
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - 2,078 0,017 2,078 0,017 0,089 0,001
Sodium Cloride 58,44 - - - - - - - -
Sulphuric Acid 98,07 - - 0,009 0,000 0,009 0,000 0,009 0,000
Water 18,02 - - 49,877 2,768 49,877 2,768 44,373 2,462
Total 0,122 0,003 55,759 2,819 55,759 2,819 45,715 2,484

Enthalpy kW (12,635) (9.449,507) (9.449,507) (8.189,107)
Phase gas liquid liquid liquid
Press. Bara 0,97 0,97 3,52 1,05
Temp oC 39,88 39,88 39,88 39,88

CPD3264
C-16
STREAM Nr. : 315 316 401 402

Name : Waste water Cake out S302 Fresh NaOH NaOH in V401
Acetic Acid 60,05 - - - - - - - -
Ammonium sulphate 132,16 0,001 0,000 0,000 0,000 - - - -
Benzoic Acid 122,12 0,000 0,000 0,000 0,000 - - - -
Calcium carbonate 100,09 0,000 0,000 0,020 0,000 - - - -
Calcium Cloride 110,99 0,399 0,004 0,017 0,000 - - - -
Calcium Lactate 218,22 0,202 0,001 0,009 0,000 - - - -
Carbon dioxyde 44,01 0,043 0,001 0,002 0,000 - - - -
Chitin 203,19 0,018 0,000 1,789 0,009 - - - -
Chitosan 161,16 0,006 0,000 0,596 0,004 - - - -
Ethanol 46,07 0,001 0,000 0,000 0,000 - - - -
Glucose 180,16 0,009 0,000 0,093 0,001 - - - -
Hydrocloric Acid 36,46 0,523 0,014 0,023 0,001 - - - -
Lactic Acid 90,08 0,031 0,000 0,001 0,000 - - - -
Lipid 284,48 0,009 0,000 0,000 0,000 - - - -
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 0,089 0,001 1,989 0,016 - - - -
Sodium Cloride 58,44 - - - - - - - -
Sodium Hydroxide 40,00 - - - - 30,290 0,757 30,290 0,757
Sulphuric Acid 98,07 0,009 0,000 0,000 0,000 - - - -
Water 18,02 44,373 2,462 5,505 0,305 37,020 2,054 37,020 2,054
Total 45,715 2,484 10,044 0,336 67,310 2,812 67,310 2,812

Enthalpy kW (8.189,107) (1.260,400) (9.255,097) (9.255,097)
Phase liquid solid liquid liquid
Press. Bara 1,68 1,00 1,08 3,90
Temp oC 39,88 39,88 25,00 25,00
STREAM Nr. : 403 404 405 406

Name : Mixed chitin NaOH Cold in E401 Hot out E401 Hot out E402
Acetic Acid 60,05 - - - - - - - -
Benzoic Acid 122,12 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Calcium Cloride 110,99 0,017 0,000 0,017 0,000 0,017 0,000 0,017 0,000
Calcium Lactate 218,22 0,009 0,000 0,009 0,000 0,009 0,000 0,009 0,000
Carbon dioxyde 44,01 0,002 0,000 0,002 0,000 0,002 0,000 0,002 0,000
Chitin 203,19 1,789 0,009 1,789 0,009 1,789 0,009 1,789 0,009
Chitosan 161,16 0,596 0,004 0,596 0,004 0,596 0,004 0,596 0,004
Ethanol 46,07 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Glucose 180,16 0,093 0,001 0,093 0,001 0,093 0,001 0,093 0,001
Lactic Acid 90,08 0,001 0,000 0,001 0,000 0,001 0,000 0,001 0,000
Lipid 284,48 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 1,989 0,016 1,989 0,016 1,989 0,016 1,989 0,016
Sodium Cloride 58,44 - - - - - - - -
Sodium Hydroxide 40,00 30,290 0,757 30,290 0,757 30,290 0,757 30,290 0,757
Sulphuric Acid 98,07 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Water 18,02 42,525 2,360 42,525 2,360 42,525 2,360 42,525 2,360
Total 77,354 3,147 77,354 3,147 77,354 3,147 77,354 3,147

Enthalpy kW (10.515,497) (10.515,497) (10.383,721) (10.358,366)
Press. Bara 1,06 4,58 3,78 2,98
Temp oC 28,04 28,04 106,00 121,00

CPD3264
C-17
STREAM Nr. : 407 408 409 410

Name : Out R401 Hot in E401 Cold in E403 Cold out E403
Acetic Acid 60,05 0,464 0,008 0,464 0,000 0,464 0,008 0,464 0,008
Benzoic Acid 122,12 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Calcium Cloride 110,99 0,017 0,000 0,017 0,000 0,017 0,000 0,017 0,000
Calcium Lactate 218,22 0,009 0,000 0,009 0,000 0,009 0,000 0,009 0,000
Carbon dioxyde 44,01 0,002 0,000 0,002 0,000 0,002 0,000 0,002 0,000
Chitin 203,19 0,220 0,000 0,220 0,001 0,220 0,001 0,220 0,001
Chitosan 161,16 1,840 0,000 1,840 0,011 1,840 0,011 1,840 0,011
Ethanol 46,07 0,000 0,000 0,000 - 0,000 0,000 0,000 0,000
Glucose 180,16 0,093 0,000 0,093 0,000 0,093 0,001 0,093 0,001
Lactic Acid 90,08 0,001 0,000 0,001 0,000 0,001 0,000 0,001 0,000
Lipid 284,48 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 1,989 0,016 1,989 0,000 1,989 0,016 1,989 0,016
Sodium Cloride 58,44 0,037 0,001 0,037 0,000 0,037 0,001 0,037 0,001
Sodium Hydroxide 40,00 30,265 0,757 30,265 0,000 30,265 0,757 30,265 0,757
Sulphuric Acid 98,07 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Water 18,02 42,397 2,782 42,397 0,009 42,397 2,353 42,397 2,353
-
Total 77,354 3,563 77,354 0,023 77,354 3,147 77,354 3,147
Enthalpy kW (10.373,775) (10.373,775) (10.505,551) (10.520,502)
Press. Bara 2,29 7,38 6,58 5,78
Temp oC 121,00 121,00 43,76 35,00
STREAM Nr. : 411 412 413 414

Name : Fresh water in S401 Filtrate S401 Waste water Cake out S401
Acetic Acid 60,05 - - 0,464 0,008 0,464 0,008 0,000 0,000
Ammonium sulphate 132,16 - - 0,000 0,000 0,000 0,000 0,000 0,000
Benzoic Acid 122,12 - - 0,000 0,000 0,000 0,000 0,000 0,000
Calcium carbonate 100,09 - - 0,000 0,000 0,000 0,000 0,019 0,000
Calcium Cloride 110,99 - - 0,017 0,000 0,017 0,000 0,000 0,000
Calcium Lactate 218,22 - - 0,009 0,000 0,009 0,000 0,000 0,000
Carbon dioxyde 44,01 - - 0,002 0,000 0,002 0,000 0,000 0,000
Chitin 203,19 - - 0,002 0,000 0,002 0,000 0,218 0,001
Chitosan 161,16 - - 0,018 0,000 0,018 0,000 1,822 0,011
Ethanol 46,07 - - 0,000 0,000 0,000 0,000 0,000 0,000
Glucose 180,16 - - 0,049 0,000 0,049 0,000 0,044 0,000
Hydrocloric Acid 36,46 - - 0,000 0,000 0,000 0,000 0,000 0,000
Lactic Acid 90,08 - - 0,001 0,000 0,001 0,000 0,000 0,000
Lipid 284,48 - - 0,000 0,000 0,000 0,000 0,000 0,000
Nitrogen 14,01 - - - - - - - -
Oxygen 32,00 - - - - - - - -
Protein 123,54 - - 1,945 0,016 1,945 0,016 0,044 0,000
Sodium Cloride 58,44 - - 0,037 0,001 0,037 0,001 0,000 0,000
Sodium Hydroxide 40,00 - - 30,261 0,757 30,261 0,757 0,004 0,000
Sulphuric Acid 98,07 - - 0,000 0,000 0,000 0,000 0,000 0,000
Water 18,02 10,380 0,576 50,129 2,782 50,129 2,782 2,648 0,147
Total 10,380 0,576 82,935 3,563 82,935 3,563 4,800 0,160

Enthalpy kW (1.905,148) (11.784,998) (11.784,998) (640,651)
Phase liquid liquid liquid solid
Press. Bara 1,00 1,03 1,79 1,00
Temp oC 25,00 27,03 27,03 27,03

CPD3264
C-18
STREAM Nr. : 415 416 417

Name : Wet gas Dry chitosan Dry product
COMP MW tonnes/day kmol/day tonnes/day kmol/day tonnes/day kmol/day
Acetic Acid 60,05 - - 0,000 0,000 0,000 0,000
Ammonium sulphate 132,16 - - 0,000 0,000 0,000 0,000
Benzoic Acid 122,12 - - 0,000 0,000 0,000 0,000
Calcium carbonate 100,09 - - 0,019 0,000 0,019 0,000
Calcium Cloride 110,99 - - 0,000 0,000 0,000 0,000
Calcium Lactate 218,22 - - 0,000 0,000 0,000 0,000
Carbon dioxyde 44,01 - - 0,000 0,000 0,000 0,000
Chitin 203,19 - - 0,218 0,001 0,218 0,001
Chitosan 161,16 - - 1,822 0,011 1,822 0,011
Ethanol 46,07 0,000 0,000 - - - -
Glucose 180,16 - - 0,044 0,000 0,044 0,000
Hydrocloric Acid 36,46 - - 0,000 0,000 0,000 0,000
Lactic Acid 90,08 - - 0,000 0,000 0,000 0,000
Lipid 284,48 - - 0,000 0,000 0,000 0,000
Lactobacillus sp. 24,60 - - - - - -
Nitrogen 14,01 - - - - - -
Oxygen 32,00 - - - - - -
Protein 123,54 - - 0,044 0,000 0,044 0,000
Sodium Cloride 58,44 - - 0,000 0,000 0,000 0,000
Sodium Hydroxide 40,00 - - 0,004 0,000 0,004 0,000
Sulphuric Acid 98,07 - - 0,000 0,000 0,000 0,000
Water 18,02 2,476 0,137 0,171 0,009 0,171 0,009
Total 2,476 0,137 2,323 0,023 2,323 0,023

Enthalpy kW (383,918) (185,951) (185,951)
Phase gas solid solid
Press. Bara 1,00 1,00 1,00
Temp oC 40,00 40,00 40,00
CPD3264
C-19
Table D.1.1 ASPEN Feed Summary
1 13 21 22 24 FERMOUT GAS
CRUSHER MIXER MIXTANK WASHTANK MIXTANK2 ENZDMDP1 DRYER
LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID VAPOR

Mass Flow tonne/day
ACETACID 0 0 0 0 0 0 0
AMMONSUL 0 0 0 0 0 0.05 0
BENZACID 0.30 0 0 0 0 0 0
CACL2 0 0 0 0 0 0 0
CACO3 3.98 0 0 0 0 0 0
CA-LACT 0 0 0 0 0 0 0
CHITIN 1.83 0 0 0 0 0 0
CHITOSAN 0.61 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0
ETHANOL 0 0.25 0 0 0 0 0
GLUCO(L) 0 0 0 0 0 6.59E-03 0
GLUCO(S) 0.23 0 0 0 0 0 0
H20BOND 9.00 0 0 0 0 0 0
H2OFREE 9.00 0.11000016 44.21 10.38 37.02 52.63 3.81E-02
HCL 0 0 0.82 0 0 0 0
H2SO4 0 0 0 0 0 0.35 0
LACTACID 0 0 0 0 0 7.65 0
NACL 0 0 0 0 0 0 0
NAOH 0 0 0 0 30.29 0 0
N2 0 0 0 0 0 0 2.34
O2 0 0 0 0 0 0 0.64
PROTE(L) 0 0 0 0 0 0 0
PROTE(S) 4.70 0 0 0 0 0 0
STEAR-01 0.35 0 0 0 0 0 0
Total Flow tonne/day 30.0 0.4 45.0 10.4 67.3 60.7 3.0
Temperature C 25.0 25.0 25.0 25.0 25.0 25.0 25.0
Pressure atm 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Table D.1.2 ASPEN Model Design Specifications
Design Specification Value Manipulated Limits

Variable
Mass flow rate of 0.004616 kg/s Reactor volume of 0.01 m3 – 1000 m3
CaCO3 in 4E-F (Tol 0.00002) EnzDMDP5
CaCO3 in 6E-F (Tol 0.000001) ChemDM5
Protein (S) in 8A (Tol 0.0005) ChemDA1
Chitosan in 8E-F (Tol 0.0001) ChemDA5
CPD 3264
D-4
Design Notes: The conversions of each reactor were controlled by the volume of reactors.
Design specification value is calculated by the feed and the conversion. Tolerances are set as
0.05 % of the specification values.
Table D.1.3 ASPEN simulated results for Enzymatic deproteinization and
demineralization (R301)
Reactions Reactor volume Residence time Heat duty
[m3] [s] [Watt]
EnzDMDP1 EnzDM, EnzDP 2.85 2865 -46068
Total 14.21 14296 -115785
Table D.1.4 ASPEN simulated results for Chitin purification (R302)

Reactions Reactor volume Residence time Temperature
3
[m ] [s] [K]
CHEMDM1 ChemDM 0.31 485 305.0
Total 1.55 2404
Table D.1.5 ASPEN simulated results for Chitin deacetylation (R401)

Reactions Reactor volume Residence time Heat duty
[m3] [s] [Watt]
CHEMDA1 ChemDA, ChemDP1, Neutral 0.18 163 -4277
CHEMDA2 ChemDA, ChemDP2 0.55 493 -5122
Total 2.34 2100 -15411
CPD 3264
D-5
Table D.1.6 ASPEN simulation design specification for ‘SEP’
Benzoic acid Drum filter 1 Drum filter 2 Drum filter 3 Drum filter 3 Purge 1 Purge 2 DRYER
extractor (step 1) (step 2)
Acetic acid 0 0.027 0.041928 0.01306 0.01 0 0 0
Ammonium sulfate 0 0.027 0.041928 0.01306 0.01 0 0 0
Benzoic acid 0.99 0.027 0.041928 0.01306 1 0 0 0
Calcium chloride 0 0.027 0.041928 0.01306 0.01 0 0 0
Calcium carbonate 0 0.99 0.99 0.99 1 0 0 0
Calcium lactate 0 0.027 0.041928 0.01306 0.01 0 0 0
Chitin 0 0.99 0.99 0.99 1 0 0 0
Chitosan 0 0.99 0.99 0.99 1 0 0 0
CO2 0 0.027 0.041928 0.01306 0.01 0.9605 0.732 0
Ethanol 0.95 0.027 0.041928 0.01306 0.01 0 0 1
Glucose(L) 0 0.027 0.041928 0.01306 0.01 0 0 0
Glucose(S) 0 0.4355 0.9128 0.4783 1 0 0 0
H2O-Bound 0 0.4355 0.9128 0.4783 1 0 0 0.9
H2O-Free 0.03508 0.027 0.041928 0.01306 0.086 0 0 1
HCL 0 0.027 0.041928 0.01306 0.01 0 0 0
Sulfuric acid 0 0.027 0.041928 0.01306 0.01 0 0 0
Lactic acid 0 0.027 0.041928 0.01306 0.01 0 0 0
Lipids 0 0.027 0.041928 0.01306 0.01 0 0 0
Sodium chloride 0 0.027 0.041928 0.01306 0.01 0 0 0
Sodium hydroxide 0 0.027 0.041928 0.01306 0.01 0 0 0
Nitrogen 0 0 0 0 0 1 1 1
Oxygen 0 0 0 0 0 1 1 1
Protein(L) 0 0.027 0.041928 0.01306 0.01 0 0 0
Protein(S) 0 0.99 0.99 0.99 1 0 0 0
Table D.1.7 ASPEN ‘HEATER’ design specifications

Temperature [ºC] Pressure [atm] Heat duty
E201 77 1 ---
E202-3 35 1 ---
P402 --- 2.5 0
E402 121 2.5 ---
E403 35 2.2 ---
EDryer1 37 0.05 ---
EDryer2 37 0.05 ---
CPD 3264
D-6
Table D.1.8 ASPEN Simulation Stream Summary a

1 2 3 4A 4B 4C 4D 4E-F 4LIQIOD 4VAPOR 5 5MIX 6A 6B
CRUSHER EXTRACT ENZDMDP1 ENZDMDP2 ENZDMDP3 ENZDMDP4ENZDMDP5 PURGE1 FILTER1 MIXTANK CHEMDM1 CHEMDM2 CHEMDM3
CRUSHER EXTRACT ENZDMDP1 ENZDMDP2 ENZDMDP3ENZDMDP4 ENZDMDP5 PURGE1 PURGE1 FILTER1 MIXTANK CHEMDM1 CHEMDM2
LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID VAPOR LIQUID LIQUID LIQUID LIQUID
Mass Flow tonne/day
ACETACID 0 0 0 0 0 0 0 0 0 0 0 0 0 0
AMMONSUL 0 0 0 0.05 0.05 0.05 0.05 0.05 0.05 0 1.43E-03 1.43E-03 1.43E-03 1.43E-03
BENZACID 0.30 0.30 3.00E-03 3.00E-03 3.00E-03 3.00E-03 3.00E-03 3.00E-03 3.00E-03 0 8.11E-05 8.11E-05 8.11E-05 8.11E-05
CACL2 0 0 0 0 0 0 0 0 0 0 0 0 0.19 0.30
CACO3 3.98 3.98 3.98 2.57 1.65 1.05 0.65 0.40 0.40 0 0.39 0.39 0.22 0.12
CA-LACT 0 0 0 3.08 5.08 6.39 7.25 7.80 7.80 0 0.21 0.21 0.21 0.21
CHITIN 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 0 1.81 1.81 1.81 1.81
CHITOSAN 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0.61 0 0.60 0.60 0.60 0.60
CO2 0 0 0 0.62 1.02 1.29 1.46 1.57 0.06 1.51 0.00 0.00 0.08 0.12
ETHANOL 0 0 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0 0.00 0.00 0.00 0.00
GLUCO(L) 0 0 0 6.60E-03 6.60E-03 6.61E-03 6.62E-03 6.62E-03 6.62E-03 0 1.79E-04 1.79E-04 1.79E-04 1.79E-04
GLUCO(S) 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0 0.10 0.10 0.10 0.10
H20BOND 9.00 9.00 9.00 9.00 9.00 9.00 9.00 9.00 9.00 0 3.92 3.92 3.92 3.92
H2OFREE 9.00 9.00 9.01 61.89 62.05 62.16 62.23 62.28 62.28 0 1.68 45.89 45.92 45.94
HCL 0 0 0 0 0 0 0 0 0 0 0.00 0.82 0.70 0.62
H2SO4 0 0 0 0.35 0.35 0.35 0.35 0.35 0.35 0 9.49E-03 9.49E-03 9.49E-03 9.49E-03
LACTACID 0 0 0 5.11 3.46 2.37 1.67 1.21 1.21 0 3.26E-02 3.26E-02 3.26E-02 3.26E-02
NACL 0 0 0 0 0 0 0 0 0 0 0 0 0 0
NAOH 0 0 0 0 0 0 0 0 0 0 0 0 0 0
N2 0 0 0 0 0 0 0 0 0 0 0 0 0 0
O2 0 0 0 0 0 0 0 0 0 0 0 0 0 0
PROTE(L) 0 0 0 1.35 1.95 2.29 2.52 2.68 2.68 0 0.07 0.07 0.07 0.07
PROTE(S) 4.70 4.70 4.70 3.35 2.76 2.41 2.19 2.03 2.03 0 2.01 2.01 2.01 2.01
STEAR-01 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0 0.01 0.01 0.01 0.01
Total Flow kmol/day 1.1 1.1 1.1 4.1 4.1 4.1 4.1 4.1 4.1 0.0 0.3 2.8 2.8 2.8
Total Flow tonne/day 30.0 30.0 29.8 90.4 90.4 90.4 90.4 90.4 88.9 1.5 10.9 55.9 55.9 55.9
Total Flow m3/day 26.4 26.4 26.2 85.9 85.9 85.8 85.8 85.8 84.5 840.3 8.9 54.3 55.2 55.7
Temperature C 25.0 25.0 25.7 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 31.9 35.8
Pressure atm 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Enthalpy J/kg -1.12E+07 -1.12E+07 -1.13E+07 -1.37E+07 -1.37E+07 -1.37E+07 -1.37E+07 -1.37E+07 -1.38E+07 -8.94E+06 -1.05E+07 -1.46E+07 -1.46E+07 -1.46E+07
Enthalpy Watt -3.89E+06 -3.89E+06 -3.88E+06 -1.43E+07 -1.43E+07 -1.43E+07 -1.44E+07 -1.44E+07 -1.42E+07 -1.56E+05 -1.32E+06 -9.46E+06 -9.46E+06 -9.46E+06
Density kg/m3 1136.1 1136.1 1134.1 1052.3 1053.3 1053.9 1054.4 1054.6 1052.1 1.8 1215.2 1029.2 1012.1 1002.4
Average MW 27.5 27.5 27.3 22.1 22.1 22.1 22.1 22.1 21.9 44.0 31.4 19.8 19.8 19.8
CPD 3264
D-7
Table D.1.8 continued

6C 6D 6E-F 6LIQUID 6VAPOR 7 7MIX 7MIXHP 7MIXHPHT 8A 8B 8C 8D
CHEMDM4 CHEMDM5 PURGE2 FILTER2 MIXTANK2 P402 E401 CHEMDA1 CHEMDA2 CHEMDA3 CHEMDA4 CHEMDA5
CHEMDM3 CHEMDM4 CHEMDM5 PURGE2 PURGE2 FILTER2 MIXTANK2 P402 E401 CHEMDA1 CHEMDA2 CHEMDA3 CHEMDA4
LIQUID LIQUID LIQUID LIQUID VAPOR LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID
Mass Flow tonne/day
ACETACID 0 0 0 0 0 0 0 0 0 0.00 0.09 0.26 0.36
AMMONSUL 1.43E-03 1.43E-03 1.43E-03 1.43E-03 0 0 6.00E-05 6.00E-05 6.00E-05 6.00E-05 6.00E-05 6.00E-05 6.00E-05
BENZACID 8.11E-05 8.11E-05 8.11E-05 8.11E-05 0 0 3.40E-06 3.40E-06 3.40E-06 3.40E-06 3.40E-06 3.40E-06 3.40E-06
CACL2 0.36 0.40 0.42 0.42 0 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
CACO3 0.07 0.04 0.02 0.02 0 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
CA-LACT 0.21 0.21 0.21 0.21 0 8.83E-03 8.83E-03 8.83E-03 8.83E-03 8.83E-03 8.83E-03 8.83E-03 8.83E-03
CHITIN 1.81 1.81 1.81 1.81 0 1.79 1.79 1.79 1.79 1.48 0.91 0.56 0.35
CHITOSAN 0.60 0.60 0.60 0.60 0 0.60 0.60 0.60 0.60 0.84 1.29 1.57 1.74
CO2 0.15 0.16 0.17 0.04 0.12 1.87E-03 1.87E-03 1.87E-03 1.87E-03 1.87E-03 1.87E-03 1.87E-03 1.87E-03
ETHANOL 0.00 0.00 0.00 0.00 0 5.78E-05 5.78E-05 5.78E-05 5.78E-05 5.78E-05 5.78E-05 5.78E-05 5.78E-05
GLUCO(L) 1.79E-04 1.79E-04 1.79E-04 1.79E-04 0 7.50E-06 7.50E-06 7.50E-06 7.50E-06 7.50E-06 7.50E-06 7.50E-06 7.50E-06
GLUCO(S) 0.10 0.10 0.10 0.10 0 0.09 0.09 0.09 0.09 0.09 0.09 0.09 0.09
H20BOND 3.92 3.92 3.92 3.92 0 3.58 3.58 3.58 3.58 3.58 3.58 3.58 3.58
H2OFREE 45.95 45.96 45.96 45.96 0 1.93 38.95 38.95 38.95 38.93 38.88 38.85 38.83
HCL 0.58 0.56 0.55 0.55 0 0.02 0.02 0.02 0.02 2.50E-03 9.75E-05 9.75E-05 9.75E-05
H2SO4 9.49E-03 9.49E-03 9.49E-03 9.49E-03 0 3.98E-04 3.98E-04 3.98E-04 3.98E-04 3.98E-04 3.98E-04 3.98E-04 3.98E-04
LACTACID 3.26E-02 3.26E-02 3.26E-02 3.26E-02 0 1.37E-03 1.37E-03 1.37E-03 1.37E-03 1.37E-03 1.37E-03 1.37E-03 1.37E-03
NACL 0 0 0 0 0 0 0 0 0 0.03 0.04 0.04 0.04
NAOH 0 0 0 0 0 0 30.29 30.29 30.29 30.27 30.27 30.27 30.27
N2 0 0 0 0 0 0 0 0 0 0 0 0 0
O2 0 0 0 0 0 0 0 0 0 0 0 0 0
PROTE(L) 0.07 0.07 0.07 0.07 0 3.03E-03 3.03E-03 3.03E-03 3.03E-03 1.90E+00 1.92E+00 1.93E+00 1.94E+00
PROTE(S) 2.01 2.01 2.01 2.01 0 1.99 1.99 1.99 1.99 0.09 0.07 0.06 0.05
STEAR-01 0.01 0.01 0.01 0.01 0 3.97E-04 3.97E-04 3.97E-04 3.97E-04 3.97E-04 3.97E-04 3.97E-04 3.97E-04
Total Flow kmol/day 2.8 2.8 2.8 2.8 0.0 0.3 3.1 3.1 3.1 3.1 3.1 3.1 3.1
Total Flow tonne/day 55.9 55.9 55.9 55.8 0.1 10.0 77.4 77.4 77.4 77.4 77.4 77.4 77.4
Total Flow m3/day 56.0 56.2 56.3 56.2 71.2 8.6 93.5 93.4 96.2 96.2 96.4 96.4 96.5
Temperature C 38.0 39.2 39.9 39.9 39.9 39.9 28.0 25.0 121.0 121.0 121.0 121.0 121.0
Pressure atm 1.0 1.0 1.0 1.0 1.0 1.0 1.0 2.5 2.5 2.3 2.3 2.3 2.3
Enthalpy J/kg -1.46E+07 -1.46E+07 -1.46E+07 -1.46E+07 -8.93E+06 -1.08E+07 -1.17E+07 -1.18E+07 -1.16E+07 -1.16E+07 -1.16E+07 -1.16E+07 -1.16E+07
Enthalpy Watt -9.46E+06 -9.46E+06 -9.46E+06 -9.45E+06 -1.26E+04 -1.26E+06 -1.05E+07 -1.05E+07 -1.04E+07 -1.04E+07 -1.04E+07 -1.04E+07 -1.04E+07
Density kg/m3 997.1 994.1 992.5 992.2 1.7 1169.3 827.4 828.1 804.3 803.9 802.9 802.2 801.8
Average MW 19.8 19.8 19.8 19.8 44.0 30.0 24.6 24.6 24.6 24.6 24.6 24.6 24.6
CPD 3264
D-8

8E-F 8HPLT 8LPLT 9 10 11 12 12PRE 13 14 15 16 16HOT 16HT
E403 VALVE FILTER3 WASHTANK FILTER4 DRYER EDRYER2 MIXER EXTRACT E201 MIXER E202-3 FLASH
CHEMDA5 E403 VALVE FILTER3 WASHTANK FILTER4 EDRYER2 DRYER MIXER EXTRACT E202-3 FLASH E201
LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID VAPOR LIQUID
Mass Flow tonne/day
ACETACID 0.46 0.46 0.46 6.05E-03 6.05E-03 6.05E-05 6.05E-05 6.05E-05 0 0 0 0 0 0
AMMONSUL 6.00E-05 6.00E-05 6.00E-05 7.83E-07 7.83E-07 7.83E-09 7.83E-09 7.83E-09 0 0 0 0 0 0
BENZACID 3.40E-06 3.40E-06 3.40E-06 4.44E-08 4.44E-08 4.44E-08 4.44E-08 4.44E-08 0 4.90E-04 0.30 4.90E-04 4.90E-04 0.30
CACL2 0.02 0.02 0.02 2.28E-04 2.28E-04 2.28E-06 2.28E-06 2.28E-06 0 0 0 0 0 0
CACO3 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0 0 0 0 0 0
CA-LACT 8.83E-03 8.83E-03 8.83E-03 1.15E-04 1.15E-04 1.15E-06 1.15E-06 1.15E-06 0 0 0 0 0 0
CHITIN 0.22 0.22 0.22 0.22 0.22 0.22 0.22 0.22 0 0 0 0 0 0
CHITOSAN 1.84 1.84 1.84 1.82 1.82 1.82 1.82 1.82 0 0 0 0 0 0
CO2 1.87E-03 1.87E-03 1.87E-03 2.45E-05 2.45E-05 2.45E-07 2.45E-07 2.45E-07 0 0 0 0 0 0
ETHANOL 5.78E-05 5.78E-05 5.78E-05 7.55E-07 7.55E-07 7.55E-09 0 0 0.25 1.02 0.97 0.77 0.77 0.97
GLUCO(L) 7.50E-06 7.50E-06 7.50E-06 9.79E-08 9.79E-08 9.79E-10 9.79E-10 9.79E-10 0 0 0 0 0 0
GLUCO(S) 0.09 0.09 0.09 0.04 0.04 0.04 0.04 0.04 0 0 0 0 0 0
H20BOND 3.58 3.58 3.58 1.71 1.71 1.71 0.17 0.17 0 0 0 0 0 0
H2OFREE 38.82 38.82 38.82 0.51 10.89 0.94 0.00 0.00 0.11000016 0.33 0.33 0.22 0.22 0.33
HCL 9.75E-05 9.75E-05 9.75E-05 1.27E-06 1.27E-06 1.27E-08 1.27E-08 1.27E-08 0 0 0 0 0 0
H2SO4 3.98E-04 3.98E-04 3.98E-04 5.20E-06 5.20E-06 5.20E-08 5.20E-08 5.20E-08 0 0 0 0 0 0
LACTACID 1.37E-03 1.37E-03 1.37E-03 1.78E-05 1.78E-05 1.78E-07 1.78E-07 1.78E-07 0 0 0 0 0 0
NACL 0.04 0.04 0.04 4.78E-04 4.78E-04 4.78E-06 4.78E-06 4.78E-06 0 0 0 0 0 0
NAOH 30.27 30.27 30.27 0.40 0.40 0.00 0.00 0.00 0 0 0 0 0 0
N2 0 0 0 0 0 0 0 0 0 0 0 0 0 0
O2 0 0 0 0 0 0 0 0 0 0 0 0 0 0
PROTE(L) 1.95E+00 1.95E+00 1.95E+00 2.54E-02 2.54E-02 2.54E-04 2.54E-04 2.54E-04 0 0 0 0 0 0
PROTE(S) 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0 0 0 0 0 0
STEAR-01 3.97E-04 3.97E-04 3.97E-04 5.19E-06 5.19E-06 5.19E-08 5.19E-08 5.19E-08 0 0 0 0 0 0
Total Flow kmol/day 3.1 3.1 3.1 0.1 0.7 0.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Total Flow tonne/day 77.4 77.4 77.4 4.8 15.2 4.8 2.3 2.3 0.4 1.4 1.6 1.0 1.0 1.6
3
Total Flow m /day 96.5 94.0 94.0 3.7 14.2 3.6 0.9 0.9 0.4 1.7 1.8 1.2 862.4 2.0
Temperature C 121.0 35.0 35.0 35.0 27.0 27.0 37.0 -1.4 25.0 32.3 25.7 35.0 87.2 77.0
Pressure atm 2.3 2.2 1.0 1.0 1.0 1.0 0.1 0.1 1.0 1.0 1.0 1.0 1.0 1.0
Enthalpy J/kg -1.16E+07 -1.18E+07 -1.18E+07 -1.07E+07 -1.42E+07 -1.15E+07 -6.92E+06 -6.96E+06 -9.06E+06 -8.42E+06 -7.49E+06 -8.19E+06 -6.86E+06 -7.30E+06
Enthalpy Watt -1.04E+07 -1.05E+07 -1.05E+07 -5.95E+05 -2.50E+06 -6.41E+05 -1.86E+05 -1.87E+05 -3.74E+04 -1.32E+05 -1.38E+05 -9.45E+04 -7.91E+04 -1.35E+05
Density kg/m3 801.6 822.9 822.9 1287.6 1072.0 1329.4 2646.7 2729.8 837.3 815.8 874.7 808.0 1.2 816.9
Average MW 24.6 24.6 24.6 32.7 21.0 30.0 102.1 102.1 31.1 33.3 38.3 34.2 34.2 38.3
CPD 3264
D-9

17 20 21 22 23 24 25 26 27 27PRE FERMOUT GAS
MIXTANK WASHTANK MIXTANK2 EDRYER1 ENZDMDP1 DRYER
FLASH FILTER1 FILTER2 FILTER4 FILTER3 EDRYER1 DRYER
LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID LIQUID VAPOR MIXED LIQUID VAPOR
Mass Flow tonne/day
ACETACID 0 0 0 0 0 0 5.99E-03 0.46 0 0 0 0
AMMONSUL 0 0.05 0 0 1.37E-03 0 7.7553E-07 5.9199E-05 0 0 0.05 0
BENZACID 0.30 2.92E-03 0 0 7.77E-05 0 0 3.3573E-06 0 0 0 0
CACL2 0 0 0 0 0.40 0 2.25E-04 1.72E-02 0 0 0 0
CACO3 0 3.99E-03 0 0 1.98E-04 0 0 1.96E-04 0 0 0 0
CA-LACT 0 7.59 0 0 0.20 0 1.14E-04 8.72E-03 0 0 0 0
CHITIN 0 0.02 0 0 0.02 0 0 2.20E-03 0 0 0 0
CHITOSAN 0 6.08E-03 0 0 6.02E-03 0 0 1.84E-02 0 0 0 0
CO2 0 0.06 0 0 0.04 0 2.42E-05 1.85E-03 0 0 0 0
ETHANOL 0.20 0.05 0 0 1.32E-03 0 7.47E-07 5.70E-05 7.55E-09 7.55E-09 0 0
GLUCO(L) 0 6.44E-03 0 0 1.71E-04 0 9.69E-08 7.40E-06 0 0 6.59E-03 0
GLUCO(S) 0 0.13 0 0 0.01 0 0 0.05 0 0 0 0
H20BOND 0 5.08 0 0 0.34 0 0 1.87 1.54 1.54 0 0
H2OFREE 0.10 60.60 44.21 10.38 44.03 37.02 9.95 38.31 0.97 0.97 52.63 3.81E-02
HCL 0 0 0.82 0 0.52 0 1.26E-06 9.63E-05 0 0 0 0
H2SO4 0 0.34 0 0 9.09E-03 0 5.14E-06 3.93E-04 0 0 0.35 0
LACTACID 0 1.17 0 0 0.03 0 1.77E-05 1.35E-03 0 0 7.65 0
NACL 0 0 0 0 0 0 4.73E-04 0.04 0 0 0 0
NAOH 0 0 0 0 0 30.29 0.39 29.87 0 0 0 0
N2 0 0 0 0 0 0 0 0 2.34 2.34 0 2.34
O2 0 0 0 0 0 0 0 0 0.64 0.64 0 0.64
PROTE(L) 0 2.60 0 0 0.07 0 0.03 1.92 0 0 0 0
PROTE(S) 0 0.02 0 0 0.02 0 0 4.42E-04 0 0 0 0
STEAR-01 0 0.34 0 0 9.08E-03 0 5.1375E-06 3.92E-04 0 0 0 0
Total Flow kmol/day 0.0 3.7 2.5 0.6 2.5 2.8 0.6 3.0 0.2 0.2 3.0 0.1
Total Flow tonne/day 0.6 78.1 45.0 10.4 45.7 67.3 10.4 72.6 5.5 5.5 60.7 3.0
3
Total Flow m /day 0.7 75.5 45.2 10.4 47.5 85.8 10.5 90.4 123839.8 51867.6 59.8 2589.4
Temperature C 87.2 25.0 25.0 25.0 39.9 25.0 27.0 35.0 37.0 -1.4 25.0 25.0
Pressure atm 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.1 0.1 1.0 1.0
Enthalpy J/kg -6.00E+06 -1.43E+07 -1.56E+07 -1.59E+07 -1.55E+07 -1.19E+07 -1.55E+07 -1.18E+07 -6.12E+06 -7.21E+06 -1.48E+07 -1.69E+05
Enthalpy Watt -4.15E+04 -1.29E+07 -8.14E+06 -1.91E+06 -8.19E+06 -9.26E+06 -1.86E+06 -9.93E+06 -3.90E+05 -4.59E+05 -1.04E+07 -5.92E+03
3
Density kg/m 918.6 1034.0 995.9 993.5 962.8 784.7 987.9 802.4 0.0 0.1 1015.2 1.2
Average MW 47.8 21.0 18.2 18.0 18.4 23.9 18.4 24.2 22.6 22.6 20.2 28.6
CPD 3264
D-10
10
22
9
16 FERMOUT
4VAPOR
13
MIXER E202-3
FILTER1
3 4A 4B 4C 4D 4E-F
4LIQIOD 20
CRUSHER PURGE1
15 ENZDMDP1 ENZDMDP2 ENZDMDP4 ENZDMDP5
16HOT ENZDMDP3
EXTRACT
5 6VAPOR
FLASH PURGE2 FILTER2

21 5MIX 6A 6B 6C 6D 6E-F
17 MIXTANK 6LIQUID 23
E201
CHEMDM1 CHEMDM2 CHEMDM3 CHEMDM4 CHEMDM5
24
7
7MIXHPHT 7MIXHP
7MIX
E401
P402 MIXTANK2
FILTER3 27PRE 27
FILTER4 EDRYER1
8A 8B 8C 8D 8E-F 8HPLT 8LPLT 11 12PRE 12
E403
CHEMDA3 VALVE
CHEMDA1 CHEMDA4 WASHTANK EDRYER2
CHEMDA2 CHEMDA5 DRYER
26 GAS
25
Figure D.1.1 ASPEN simulation flow scheme
CPD 3264
D-3
D.2.a Stoichiometry
In the lactic acid fermentation substrate is converted to biomass (Lactic acid bacteria), product
(lactic acid), and for energy for maintenance. Lactic acid fermentation is anaerobe and considered
to be growth related product. Further, substrate conversion to biomass is called anabolic reaction
and substrate conversion to lactic acid is called catabolic reaction.
In this calculation we consider all the substrate to be glucose while the N-source used is
(NH4)2SO4. Calculation is based on C-mol substrate, product, and biomass.
Calculation for pH = 7 and T = 25C
Catabolic reaction
Glucose + H2O  lactate + H+ + HCO3- (D.2.1)
Glucose = CH2O
Lactate = CH5/3O –1/3
CH2O + a H2O  b CH5/3O –1/3 + c H+ + d HCO3- (D.2.2)
Balance:
C : 1–b–d=0
H : 2 + 2a – 5/3 b – c – d = 0
O : 1 + a – b – 3d = 0
Charge : -b(-1/3) –c(+1) –d(-1) = 1/3 b – c + d = 0
Complete reactions :
CH2O  CH5/3O –1/3 + 1/3 H+

Gcat = Glactate - Gglucose = 125.952 – 158.976 = - 33.024 kJ/C-mol glucose (D.2.3)
(All the values used were taken form reference 1)
Overall Reaction
Glucose + N-source + H2O  biomass + lactate + H+ + HCO3- + Greaction (D.2.4)
a CH2O + b NH4+ + c H2O  CH1.8O0.5N0.2 + d CH5/3O –1/3 + e H+ + f HCO3- + 1/YGXm (D.2.5)
1/YGXm = 200 + 18 (6 - C)1.8 + exp(( (3.8-)2)0.16 ) (3.6+0.4C) ) (D.2.6)

C-source = glucose  C = 6,  = 4
 YGXm = 236.051 kJ/C-mol X
(All formulas and values used were taken from reference 1)
CPD 3264
D-12
a CH2O + b NH4+ + c H2O  CH1.8O0.5N0.2 + d CH5/3O –1/3 + e H+ + f HCO3- + 1/YGXm (D.2.5)
balance :
C : a–1–d–f =0
H : 2a + 4b + 2c – 1.8 – 5/3d – e – f = 0
O : a + c – 0.5 – d – 3f = 0
N : b – 0.2 = 0
Charge : b(+1) – d(-1/3) – e(+1) – f(-1) = 0
G : a Gglucose - Gx – d Glactate - Greaction = 0
(Gx = Gibbs free energy of biomass formation, kJ/mol)
complete overall reaction :
7.447 CH2O + 0.2 NH4+  CH1.8O0.5N0.2 + 6.397 CH5/3O –1/3 + 2.382 H+ + 0.05 HCO3- + 0.4 H2O
+ 236.051 kJ/C-mol X (D.2.7)
D.2.b Mass Balance of Fermentation
Fermentation will be done continuously in a chemostat (CSTR), equipped with Temperature

controller (for constant temperature operation) and pH controller (for constant pH operation).
L
Dilution factor : D  (D.2.8)
V
1
Substrate specific rate : qS    mS (D.2.9)
YSXm
 S   
Product specific rate: qP    X    S mS (D.2.10)
  PYSX  P  P
m
Biomass recycle ratio = 1 - 
Substrate balance :
 rSV  L (CS 0  CS )  0  D(CS 0  CS )
  Cx  (D.2.11)
rS  qS Cx  qS
Biomass balance :
rxV  L  Cx  0  L
    D (D.2.12)
rx   Cx  V
Product balance :
rPV  L CP  0  Cx
 CP  q p (D.2.13)
rP  qP Cx  D
in chemostat, Cs is only determined by the microbes itself,

CS  KS  KS D
   max  CS   (D.2.14)
K S  CS  max    max   D
CPD 3264
D-13
simplifying equations D.2.11, D.2.12, D.2.13 and D.2.14, we can write the three state variables
(CS,CX, and CP) in terms of D.
 KS D
CS  ( D.2.15)
 max   D
D(CS 0  CS )
Cx  ( D.2.16)
qS
CX
C P  qP ( D.2.17)
D
D.2.c Reaction Condition Optimization
Optimization was done to operating pH and temperature.

pH and T dependent variables :
 Gcat,
K (pH new)
G cat (pH new) = G cat (pH = 7) + RT ln (D.2.18)
K (pH=7)
 Greact
K (pH new)
G react (pH new) = G react (pH = 7) + RT ln (D.2.19)
K (pH=7)
 maintenance
m Gibbs  69000  1 1  
mS = ; m Gibbs  4.5 exp -  -  (D.2.20)
G cat  8.314  Tnew 298  
 specific growth
3  -G cat   4.5  69000  1 1  
 max = exp -  -  (D.2.21)
G Gibbs  8.314  Tnew 298  
but as this process is a substrate level phosphorylation process, the calculation will under estimate
max. Therefore max from reference will be taken as standard, max = 0.4 /hour at pH = 6 and T =
30C [2].
The decision will be based on product efficiency, safety, and economic.

qP
Product efficiency is defined as =  
qS  q P
CPD 3264
D-14
Table D.2.1 : Reaction condition selection

pH 7 6 6 6 6 5.5 5.5 5.5 5 5 5
T 298 303 308 313 318 308 313 318 308 313 318
G
cat -33.024 -27.223 -27.128 -27.032 -26.936 -24.180 -24.036 -23.892 -21.231 -21.040 -20.849
G
reaction 236.051 250.729 250.987 251.245 251.503 259.187 259.600 260.014 267.940 268.529 269.121
m
Gibbs 4.500 7.125 11.115 17.094 25.936 11.115 17.094 25.936 11.115 17.094 25.936
mS 0.136 0.262 0.410 0.632 0.963 0.460 0.711 1.086 0.524 0.812 1.244
Ysx m 0.134 0.127 0.127 0.126 0.126 0.123 0.123 0.122 0.119 0.119 0.118
Ysp m 0.859 0.867 0.867 0.867 0.867 0.871 0.871 0.872 0.875 0.875 0.876
 0.342 0.400 0.621 0.949 1.432 0.517 0.788 1.184 0.419 0.635 0.949
qS 2.681 3.418 5.311 8.136 12.296 4.672 7.138 10.759 4.049 6.166 9.262
qP 2.322 2.998 4.660 7.140 10.793 4.129 6.311 9.516 3.609 5.499 8.266
 0.464 0.467 0.467 0.467 0.467 0.469 0.469 0.469 0.471 0.471 0.472
Fermentation will be done at pH = 5.5 and T = 40C.
Reaction stoichiometry after optimization :

8.160 CH2O + 0.2 NH4+  (D.2.22)
CH1.8O0.5N0.2 + 7.110 CH5/3O –1/3 + 2.620 H++ 0.050 HCO3- + 0.4 H2O + 259.6 kJ/C-mol X
or
1.36 C6H12O6 + 0.1 (NH4)SO4       (D.2.23)
CH1.8O0.5N0.2 + 2.370 C3H6O3 + 0.1 H2SO4 + 0.05 CO2 + 0.45 H2O
D.2.d Fermentation simulation
Fermentation simulation is done on Matlab.
Limitation :
Max glucose concentration in water 52 C-mol/L (=1562 g/L)
Max lactose concentration in water 40 C-mol/L (=1200 g/L)
Table D.2.2: Simulation results based on trials of different dilution factor rate.
D /h 0.1200 0.2000 0.3040 0.4000 0.6000 0.7040
Cp C-mol/L 4.9007 4.8171 4.7554 4.7162 4.6311 4.5004
Cs C-mol/L 0.0047 0.0088 0.0163 0.0268 0.0830 0.2179
Cx C-mol/L 0.3758 0.4515 0.5031 0.5304 0.5581 0.5540
CPD 3264
D-15
Fig D.2.1 Graph of Cs/Cp against Dilution factor
D is chosen to be 0.60 /hour, quite safe Dcrit = max = 0.788/hour

D ± 20% = 0.48 - 0.72 / hour
Fig D.2.2 Graph of Cp against Dilution factor with different recycle ratios
CPD 3264
D-16
Matlab M-File
n=100;
beta=0;
C0 = 5.3; % 5% glucose in feed in Cmol/L
Ks=0.026;
mumax=0.4;
ms=0.262;
gamS=4;
gamP=4;
gamX=4.2;
Ysxm=0.1267;
Yspm=0.8669;
F=gamS/gamP/Ysxm - gamX/gamP;
E=gamS/gamP;
for i=1:n
D(i)=0.4/n*i;
Cs(i)=beta*Ks*D(i)./(mumax-beta*D(i));
Cx(i)=D(i).*(C0-Cs(i))./(1/Ysxm*beta*D(i)+ms);
Cp(i)=F*beta*Cx(i)+E*ms.*Cx(i)./D(i);
end
It was decided to take 80% biomass recycle.
Cp = 4.9007 Cmol/L = 147.0210 g/L

Cx = 1.8791 Cmol/L = 46.2259 g/L
Cs = 0.0047 Cmol/L = 0.1410 g/L
Substrate utilization = 99.91 %
CPD 3264
D-17
D.2.e Dimensioning of Fermentor

Innoculum
N2 out 2
4
1
Cooling water in
Cooling water out
5
3
N2 in
Fig D.2.3 Fermentor layout
Amount of lactic acid required for demineralization process = 6.14 ton/day = 8.528 kC-mol/hour
Excess lactic acid availability 20%  10.660 kC-mol/hour
From the mass balance

Fermentor volume = Q in D
(D.2.24)
% working volume  number of fermentor
Volume of (each) the fermentor should be 3.410 m3.
(assumption : Working volume = 75% and Total number of fermentor ‘online’ = 2, cleaning
every 40 days)
Dimensioning
H = 1.5 D
D2 1.5 D 3
V= p H= p
4 4
4V
Þ D= 3
1.5p
D = 1.425 m
H = 2.138 m
Operating times
shut down 1.67hours
Cleaning 10hours
Sterilization 2hours
start up 1.67hours
Total 15.33hours
 1days
operation day/fermentor 39days

number of fermentor 2
cleaning every 40days
number of fermentor 'on' 2
CPD 3264
D-18
D.2.f Cooling requirement
Heat balance =  H in   H out  H reaction (D.2.25)

(enthalpy values were taken from aspen simulation, assuming biomass as solid protein)
From the heat balance, cooling requirement : 77 kWatt
Media used : cooling water (20C-30C)
Q
Cooling water required = =6576 kg/h
Cpcoolingwater  T
D.2.g Microfilter design
Assumption :
Concentration factor (retentate / feed) = 4
Rejection of biomass = 80%
From Superpro Designer simulator, we get total area required is 55.62 m2 (per fermentor)
Using membrane filter (microfiltration), type : hollow fiber membrane with specification :
Fiber diameter 1.5 mm
Length 1 m
Number of fiber per tubes 3000
Total area available pertubes 14.13 m2
Tubes dimension, diameter 0.1 m, length 1 m
Number of tubes required per fermentor = 4
Total number of tubes required = 4 x (2 + 1) = 12

One set for each fermentor + one set for spare.
D.2.h Superpro Designer Simulation
Below is the output from a superpro designer simulation. A stoichiometry reactor is used based
on equation D.2.23. Input data based on amount of lactic acid required. The diagram represents
both R101 and R102.
T : 40.71 °C
Flow rate : 4.915 m3/h
Power requirement for fermentor = 16.9 kW (specific power 0.3 kW/m3)
For microfilter : 25.8 kW (specific power 0.2 kW/m2)
CPD 3264
D-19
Table D.2.3: Stream S-106 (Superpro Designer) vs 116A+116B Product stream

Component Stream S-106 Stream 116A+116B Stream S-106
Mass flow kg/hr Mass flow kg/hr Concentration kg/m3
Amm. Sulfate 2.11 2.21 0.08
Biomass 36.72 36.72 1.43
Carb. Dioxide 3.28 3.28 0.13
Glucose 0.32 0.27 0.01
Lactic acid 318.41 318.40 12.40
Sulfuric Acid 14.63 14.63 0.57
Water 2191.37 2191.02 85.37
S-104 S-105 S-102
S-103 P-3 / MX-101

Mixing
S-106
P-1 / V-101 S-101
Stoich. Fermentation
P-2 / MF-101
Microfiltration
Fig D.2.4 Superpro Designer Flowsheet for R101/R102 Fermentor
From Table D.2.3, it can be seen that the calculated results give similar results as that simulated
in Superpro Designer. Hence, the calculated results are acceptable. Heat duties obtained from
Superpro designer are used for the energy balances.
List of symbols :
C = amount of carbon atom per molecule of the substrate

CS0 = initial substrate concentration (C-mol/m3)
CS = final substrate concentration (C-mol/ m3)
CX = final biomass concentration (C-mol/ m3)
CP = final product concentration (C-mol/ m3)
Cp = specific heat (kJ/kg°C)
D = dilution factor
D = fermentor diameter (m)
H = fermentor height (m)
K = reaction equilibrium constant
KS = specific affinity coefficient on substrate (Cmol/m3)
mGibbs = maintenance coefficient on Gibbs free energy (kJ/C-mol biomass/h)
mS = maintenance coefficient on substrate (C-mol substrate/C-mol biomass/h)
Q = heat (kJ/h)
qS = substrate specific rate
qP = product specific rate
T,Tnew = reaction temperature, K
CPD 3264
D-20
R = gas constant = 8.314 J/L mol K

rS = rate of substrate consumption (C-mol/h)
rX = rate of biomass production (C-mol/h)
rP = rate of product formation (C-mol/h)
YGXm = Biomass yield on Gibbs free energy
YSXm = yield of biomass on substrate (C-mol biomass/C-mol substrate)
V = fermentor volume (m3)
 = %biomass not recycled

Gcat = Gibbs free energy for catabolic reaction, kJ/mol
Glactate = Gibbs free energy of lactate formation, kJ/mol
Gglucos = Gibbs free energy of glucose formation, kJ/mol
Greact = Gibbs free energy for reaction, kJ/mol
L = flow rate out from fermentor (m3/h)
 = specific growth rate of biomass (/h)
max = maximal specific growth rate of biomass (/h)
,  S = degree of reduction of substrate
P = degree of reduction of product
Reference:
[1] Heijnen, J.J. Bioenergetic of Microbial Growth in Flickinger, M.C. Drew, S.W. Encyclopedia of
Bioprocess Technology : Fermentation, Biocatalyst, and Bioseparation. 1999 : 267 - 291
[2] C. Akerberg, et.al. Applied Microbiology and Biotechnology. 1998. 49 : 682 – 690
CPD 3264
D-21
D.3.a Mean conversion and total reactor volume for CSTRs in N series
Mean conversion for first order reaction with CSTRs in N series is theoretically described as
equation D.3.1.
N
Cout  1 
  (D.3.1)
Cin  1  kti 
When the conversion is set at certain value, required working volume for each number of CSTRs
in series can be calculated.
1
0.9
Reactor Volume (Based on 1 CSTR)[-]
0.8
0.7
0.6
0.5
0.4
ASPEN simulation
0.3
0.2
Theoretical
0.1
0
0 2 4 6 8 10 12 14 16 18 20
Number of CSTRs
Figure D.3.1 Reactor volume and number of CSTRs
For reference, ASPEN plus simulation results are also shown in Figure D.3.1. It is observed that
following number of CSTRs in series increases, total reactor working volume decreases.
D.3.b Residence Time Distribution
Residence time distribution of CSTRs in series can be described as follows.

( N 1)
1 t 1  t 
E (t )       exp   (D.3.2)
ti  ti  ( N  1)!  ti 
N and ti is described as follows by t and  , which are mean residence time and mean
deviation.
t
ti  (D.3.3)
N
2
t
N (D.3.4)
2
CPD 3264
D-23
Mean Residence
Time
Fig D.3.2 Residence time distribution
t
 tCt (D.3.5)
 Ct
 2

 (t  t ) Ct
2
(D.3.6)
 Ct
Residence time distributions of CSTRs in series are drawn as Figure 8.2.3. In Figure 8.2.3 ,
mean residence times are normalized. It shows that with increasing number of CSTRs in series,
the residence time distributions become uniform and less distributed.
The cumulative residence time, F (t) is described as equation D.3.7. This function is the volume
fraction of material in the outlet stream, which has been in the system for times less than t is equal
to F(t).
t
F (t )   E (t )dt (D.3.7)
0
Cumulative residence time, F(t), equals 0.10 shows that 10 % of the feed have left between time
0 and t (younger than t). When the number of CSTRs increases, ‘t’ for F(t)=0.10 increases. This
tendency can be seen in Figure D.3.3. As it is mentioned in Chapter 8.2.2, if tA (time required to
meet specification) is set as mean residence time of the reactor, 90 % of the particles should stay
longer than tB (time required for 10 % less conversion) to have conversion in the range of
10 % deviated from the specification. From the Table 8.2.1, 0.7 is taken for the design criteria of
‘t’ for F(t)=0.10.
From the figure D.3.3, we can conclude 16 CSTRs in series are needed to meet the specifications.
Therefore 15 baffles are installed for each reactor.
CPD 3264
D-24
0.9
0.8
(time / mean residence time) [-]
0.7
Normalized Residence time
0.6
0.5
F(t)=0.10
0.4
16 CSTRs
0.3
0.2
0.1
0
0 5 10 15 20
Numbers of CSTRs [-]
Figure D.3.3 Cumulative residence time (=0.10) and numbers of CSTRs
D.3.c Impeller
The mixing patterns in a CSTR are quite complex and play a key role in contacting the reactants.
To achieve high stage efficiency for reaction, it is necessary to provide fairly vigorous agitation.
From empirical correlations, which are listed below, it is possible to estimate the agitation power,
P [W].
N Po  N 3  Di   M
5
P (D.3.8)
gc
Di  N   M
2
N Re  (D.3.9)
M
In which, N Po represents a power number of rotating [-], N Re is an impeller Reynolds number [-],
N is the rate of impeller rotation [1/s], Di is the impeller diameter,  M is the density of liquid
[kg/m3],  M is viscosity of liquid [kg/m2], and g c is universal constant [m/s2].
Di is set to be one-third of the reactor diameter, D, and the parameters of the mixture are taken
for that of water,  M , and  M , because water is the dominant component in each reactor.
Calculated results are shown in Table D.3.1. N Re is calculated through equation D.3.9 and N Po
is interpreted from power correlations for turbine impellers. Correlation of N Re and N Po is
shown in Figure D.3.4.
CPD 3264
D-25
Please refer to Table D.3.1 for impeller duty of agitation.
Table D.3.1 Impeller duty

Enzymatic Chemical DM Chemical DA
D(Diamter of reactor) 0.91 0.43 0.50
Height 1.37 0.65 0.75
Di (D of Impller) [m] 0.30 0.14 0.17
N[rps] 0.3 0.3 0.3
Temperature [C] 25 25-40 121
viscosity(kg/ms) 0.00100 0.00063 0.00028
Density [kg/m3] 995 995 995
Nre [-] 27413 9688 29393
Np0 [-] 5.7 5.2 5.8
P [W] 0.3932 0.0085 0.0200
P total [W] 18.9 0.406 0.962
Figure D.3.4 Impeller Reynolds number and impeller power
List of Symbol :
Cout = outlet concentration N Po = power number of rotating

Cin = concentration of feed
k = rate constant N Re = impeller Reynolds number
ti = time N = rate of impeller rotation [1/s]
t = mean residence time Di = impeller diameter
ti = residence time of each reactor M = liquiddensity [kg/m3]
 = mean deviation M = liquid viscosity [kg/m2]
E = fraction flow
N = number of CSTR gc = universal constant [m/s2]
F = cumulative residence time
CPD 3264
D-26
CPD 3264
D-23
D.4 S301, S302 & S401 Filter
Below are the specifications for each filter.
Table D.4.1: Rotary Vacuum Drum filter specifications

Filter S301 Filter S302 Filter S401
Rotation speed, rpm 0.25 0.25 0.2
Percentage area submerged 37.5 37.5 37.5
Pressure drop, -P N/m2 4104 4 104 4  104
Time per rotation, s 240 240 300
Liquid fraction with cake, % 20 20 20
Voidage of cake, % 40 40 40
Zoning, %
Filtering 37.5 37.5 37.5
Washing - - 31.25
Dewatering 62.5 62.5 31.25
Zoning time, s
Filtering 90 90 112.5
Washing - - 93.75
Dewatering 150 150 93.75
Solid recovery percentage, % 99 99 99
Incoming flow specifications
Mass of solids, tonnes/day 9.01 8.45 3.93
Mass of liquids, tonnes/day 79.92 47.30 73.43
Mass Fraction 0.11 0.18 0.05
Solid density, kg/m3 1135 1149 1110
Liquid density, kg/m3 1050 970 990
Liquid viscosity, Ns/m2 110-3 110-3 110-3
Particle size, m 5  10-4 1  10-4 5  10-5
Assumptions made:
1. Incompressible cake
2. The resistance to flow of a given volume of cake is not appreciably affected either by the
pressure difference across the cake or by the rate of deposition of material
3. Constant filtrate rate
4. Recovery of solids is 99 %
5. Porosity of cake is 40 % and liquid fraction is 20 %.
6. Values of filtrate and cake volumetric flow rate are taken from ASPEN PLUS.
7. Solids and liquid densities are taken from ASPEN PLUS simulation.
D.4.a Sample calculation (S301)
Mass of solids 9.01 1000 m3

1. Volumetric flow rate of solids in =   7.94
Density 1135 day
Mass of liquids 79.92  1000 m3
2. Volumetric flow rate of liquids in =   76.11
Density 1050 day
3. Assuming incompressible solids, and the particles are of spherical shape the specific
resistance is calculated
5(1  e) 2 S 2
r (D.4.1)
e3
CPD 3264
D-28
e = 0.4
Area of particle  Dp 2
  0.0052
S=  
Volume of particle 1/ 6 D p 3 1/ 6    0.0053
S = 12000 m-1
5(1  0.4) 2 120002
r=  4.05  109 m 2
0.43
4. The volume of cake per day is:
Vol of cake = 8.93 m3
5. Volume of filtrate per day:
Vol of filtrate = 75.52 m3
6. Area of filtrate required for a day:
t r 
For a filtration at constant rate  2 V (D.4.2)
V A (P )
t = 1 day
V = 75.52 m3
-P = 40 000 N/m2
 = 1  10-3 Ns/m2
Volume of cake 8.93
 =   0.12
Volume of filtrate 75.52
therefore the area for filtration needed per day
r  4.05  109  1 103  0.12

A= V2  75.522  261m 2
(P )t (40000)  1
7. Drum specifications
With 0.25 rpm, it takes 4 minutes to complete one round. 37.5 % of the wheel is
submerged in the feed suspension. Hence to calculate the drum filter area:
1440
Number of rotations per day =  360 rotations
4
261
Area of drum required per rotation =  0.73 m 2
360
0.73
Total drum area =  1.94 m 2
0.375
Drum dimensions, with L = 2D
Area = 2D2
CPD 3264
D-29
Area 1.94
D =   0.6 m (D.4.3)
2 2
L = 2  D = 1.2 m
8. Cake thickness
V 0.12  75.52
Cake thickness, l =   0.034m (D.4.4)
A 261
9. Pump requirement
Pumps are needed to create vacuum in the filter and also needed to pump the filtrate.
Drum
Filter
L+S
S
Vacuum
pump
Vacuum
receiver
Filtrate
L
pump
Fig D.4.1 Pumping device
A simple calculation for the pump duty is calculated below. The pumps are assumed to be
centrifugal.
P  Q p
Power  (D.4.5)
Pump efficiency
Efficiency of the pump is assumed as 50 %. [1]
Filtrate pump
Flowrate through pump = 75.52 m3/day

40000  75.52
Power =  6  106 J / day
0.5
= 0.07 kW
Vacuum pump
CPD 3264
D-30
To create the required vacuum pressure, some air is taken in from the atmosphere.
Ratio of air to filtrate = 1

Flowrate through pump = 75.52 m3/day
40000  75.52
Power =  6  106 J / day
0.5
= 0.07 kW
Below is the summary for the three main filters on the plant.
Table D.4.2: Summary of Drum filters

Specifications S301 S302 S401
Specific resistance, r, m-2 4.05109 1.01  1011 4.05  1011
Specific surface, S, m-1 12000 60000 120000
Vol of cake, m3/day 8.93 8.59 3.61
Vol of filtrate, m3/day 75.52 47.48 100.93
Vol of washing water, m3/day - - 10.5
Volume of cake deposited by unit 0.12 0.18 0.04
volume of filtrate, v
Area of filtrate per day, A, m2 261 1020 1920
Rotations per day 360 360 288
Surface area of filtrate,m2 0.73 2.82 6.67
Total area of drum, m2 1.94 7.53 17.80
Filter diameter, D, m 0.6 1.1 1.7
Filter length, L, m 1.2 2.2 3.4
Cake thickness, l, m 0.034 0.008 0.002
Filtrate pump, kW 0.070 0.044 0.093
Vacuum pump, kW 0.070 0.044 0.093
A simplified diagram of the drum filter can be seen on Fig. D.4.2:
CPD 3264
D-31
S301 & S302 S401

Air inlet for Washing Dewatering
filtrate zone zone
Dewatering zone discharge Air inlet
for filtrate
discharge
Cake Cake
Discharge Discharge
scraper scraper
Filtrate
Filtrate discharge
discharge
Figure D.4.2 : Drum filter with respective zones
D.4.b Comparison to Aspen Plus simulation
A simulation to determine the filter size is also carried out in Aspen Plus as a double check. The
same parameters and assumptions are used. Below are the results of the simulation.
Table D.4.3 Aspen Simulation check

S301 S301 Aspen S302 S302 Aspen S401 S401 Aspen
Diameter, m 0.6 0.6 1.1 1.0 1.7 1.65
Length, m 1.2 1.20 2.2 2.0 3.4 3.3
The results are reasonably similar. The calculated results are acceptable.
List of Symbol :
r = specific resistance, m-2  = viscosity of filtrate
S = Specific surface of particles, m-1  = volume of cake deposited by unit volume of
e = voidage, void fraction filtrate
t = time of filtration, day L = length of filter
V = Volume of filtrate D = diameter of filter
A = Area of filtration Qp = Flowrate through the pump, m3/day
-P = Pressure drop across the filter
Reference:
1 Sinnott “Coulson & Richardson Vol 6”, 2nd Edition p 478
CPD 3264
D-32
D.5.a A201 Shrimp Shell Crusher Design
The shrimp shells are initially crushed in order to reach a larger surface area and uniformed
particle size that will eventually determine the size and quality of the product. It is assumed that
the shrimp shells have an average length of 3 cm, for which the shells will be crushed to
approximately 1 mm (16 mesh) in size.
D.5.a.a Energy Utilization for size reduction
It is impossible to estimate accurately the amount of energy required in order to effect a size
reduction of a given material, but a number of empirical laws have been put forward. For our feed
size range, Bond Law is implemented. This law is usually used for feed particle sizes that range
from 5  10-2 m to 1  10-6 m [1].
 1 1 
Bond dictates: E  100 Ei    (D.5.1)
 x x1 
 2
where E is the energy consumption, kWh/ton

Ei is the Bond work index, kWh/ton
x1 is the feed particle size, mm
x2 is the product particle size, mm
From Perry’s Chemical Engineering Handbook Table 20-4, p. 20-14, Ei is estimated to be 13.81
kWh/ton for an average for any material. x1 and x2 are 30 mm and 1 mm respectively. Therefore
E, the energy requirement is calculated as;
 1 1 
E  100 Ei   
 x x1 
 2 
 1 1 
E  100  13.81  
 1 30 
E  1128.9 kWh / ton
Since the flowrates of solids is 20.7 tonnes/day, the energy requirement in kWh;
20.7
E  1128.9   973.6 kWh
24
D.5.a.b Equipment design
Before the size of the mill is determined, the residence time distribution is estimated. The mean
residence time is estimated at 22 min[2]. This value is based on the example given in Perry’s
Chemical Engineering Handbook.
tonnes 1
1. Amount of feed in the vessel = 30   22 min  0.458 tonnes
day 24  60
2. Density of the feed = 1165 kg/m3
1000
3. Volume of feed in the vessel = 0.458   0.39 m3
1165
CPD 3264
D-34
4. Assume that the vessel is divided into 3 parts where each part consists of different ball
sizes. The ball size is determined by the size of the feed. It is assumed that the degree of
reduction for each section is in the order of 3. Hence, the feed size in Zone 1,2 and 3 are
30 mm, 10 mm and 3 mm respectively. The ball is estimated from literature [3]. The
formula obtain is:
Ball size  19.931 Feed size 
0.469
(D.5.2)
5. The proportions of the feed in each zone is also estimated. It is assumed that the feed is
85 % in zone 1, 10 % and 5 % in zone 2 and 3 respectively. Hence the residence time for
each zone is :
85
Residense time zone 1 =  22 min = 18.7 min
100
10
100
5
100
6. The ratio of materials to be crushed over the volume of balls is inversely proportional to
the size of the balls. The larger the balls the less is required for each unit of feed. Again
from literature [3], the ratio of balls to material is estimated and the volume of balls is
determined.
Table D.5.2 : Ball size and volume

Ball size Vol Ball: Vol Feed Vol of Balls, m3
Zone 1 98 35 11.75
Zone 2 59 150 6
Zone 3 35 200 4
Total volume of balls = 21.75 m3
7. Percentage of balls in the vessel = 50 %

21.75
8. Total volume of vessel =  43.5 m3
0.5
9. The volume of the cylinder and cone is then estimated by assuming that all balls in zone
1 and half the balls in zone 2 are resident in the cylinder while the other half of ball in
zone 2 and the balls in zone 3 are resident in the conical section.
Vol of balls (zone 1) 1 Vol of balls (zone 2)

Volume of cylinder =  (D.5.3)
Percentage of balls in vessel 2 Percentage of balls in vessel
11.75 1 6
Volume of cylinder =   30 m3
0.5 2 0.5
Volume of conical section = Volume of vessel - Volume of cylinder
Volume of conical section = 43.5 - 30 = 13.5 m3
10. Design of cylindrical section
Ratio of Height to Diameter = 1
CPD 3264
D-35
Vol of cylinder  4 30  4
Diameter of cylinder =   3.4m
 
Height of cylinder = 3.4 m
42.3 42.3
Critical rotation speed is defined as =   23 rpm
D 3.4
Normal percentage from critical speed = 65 %
Rotational speed of cylindrical = 0.65  23 = 15 rpm
11. Design of conical section
Diameter of base of cone,D1 = Diameter of cylinder = 3.4 m

Diameter of top of cone D2 = 0.5 Diameter of base of cone
Volume of conical section, Vcon =

1 1
 D12 H1   D2 2  H1  H 2  (D.5.4)
12 12
1  D3 
 H1  D12  D2 2  2  (D.5.5)
12  D1 
Vcon  12
 D23 
   D12  D2 2   h2
 D1 
h1
Height of H1 =
13.5  12
 5.4m
 1.73 
   3.42  1.7 2   D2
 3.4 
D1
D 1.7
Height of H2 = 2 H1  5.4  2.7m
D1 3.4
Height of conical section, H1 – H2 = 5.4 – 2.7 = 2.7 m
Total length of vessel = 2.7 + 3.4 = 6.1 m
Final design of the vessel can be seen on Fig D.5.1.
CPD 3264
D-36
3.4 m 2.7 m
3.4 m 15 rpm 1.7 m
6.1 m
Fig D.5.1 A201 Shrimp Crusher dimensions
D.5.b A401 Chitosan Grinder
Basically the same procedure for selection and calculation methods are used for the A201
shrimp shell crusher design. Bond’s Law is again implemented for energy utilization
calculations.
 1 1 
E  100 Ei    (D.5.6)
 x x1 
 2
where Ei = 13.81 kWh/ton

x1 = 0.1 mm
x2 = 0.05 mm
E = 1810 kWh/ton
Amount of solids to be crushed = 1.78 ton/day = 0.0742 ton/hr
E = 1810  0.0742 = 134.8 kWh
CPD 3264
D-37
D.5.b.a Vessel design
1. Solids from dryer = 2.32 ton/day
2. With 70 % solids from the dryer that needs to be crushed and 10 % of the crushed
solids needs to be recrushed.
Solids needed to be crushed = 2.32  0.7  2.32  0.7  0.1  1.79ton / day
Density of feed = 600 kg/m3
1790
Volume of solids =  2.98m3 / day
600
3. With the residence time of 10 minutes,
2.98
Solids in the vessel =  10  0.021m3
24  60
4. Ratio of solids to ball volume = 250
Volume of balls in vessel = 0.021  250 = 5.2 m3
5. With the assumptions that the vessel is 50 % filled with balls;
Volume of vessel = 5.2/0.5 = 10.4 m3
6. Vessel dimensions
The ratio of diameter to height is unity
4V 4  10.4
Diameter, D = 3  3  2.4m
 
Height, H = D = 2.4 m
42.3 42.3
Critical rotation speed is defined as =   27.5 rpm
D 2.4
Normal percentage from critical speed = 65 %
Rotational speed of cylindrical = 0.65  28 = 18 rpm
List of symbol :
E = energy consumption, kWh/ton x2 = product particle size, mm
Ei = Bond work index, kWh/ton D = diameter, m
x1 = feed particle size, mm H = height, m
Reference:
[1]M. Rhodes, Introduction to Particle Technology, 2000, p. 248

[2] Robert H. Perry, “Perry’s Chemical Engineers’ Handbook, 7th ed., 1998, Chapter 20
[3] Synott R.K., Coulson and Richardson Chemical Engineering , 1999, Vol. 2, p. 83
CPD 3264
D-38
D.6.a C201 Ethanol evaporator
D.6.a.a Design of the vessel
The vessel consists of two parts, the vessel for evaporation and the heat exchanger to boil off the
solvent. Operating conditions are 87 C at 1 atm.
Vessel for evaporation
Solvent recovery vapour:

997.3 kg/day
Feed: 1595 kg/day
Liquid slurry: 597.7 kg/day
Fig. D.6.1 : Mass balance over evaporator
The column diameter is based on the velocity of the vapour. Based on Souders and Brown
equation, Lowenstein (1961), the maximum allowable superficial vapour velocity, umax[1]:
u  (0.171l 2  0.27l  0.047) (    )   (D.6.1)

max L v v
where, l = vapour space, m

L = liquid phase density, kg/m3
v = vapour phase density, kg/m3
Assuming that l = 0.5 m, and with L = 918 kg/m3 and v = 1.16;
umax  (0.171  0.52  0.27  0.5  0.047) (918  1.16)  918  1.4m / s
The minimum column diameter can be calculated as:
4Vw 4(997.3 / 86400)

Dc    0.1m (D.6.2)
v umax  1.16 1.4
where, Vw = vapour flowrate, kg/s
This diameter is physically to small for a vessel. Hence, 10 % of the vapour velocity is taken.
u = 1.4  0.1 = 0.14 m/s
CPD 3264
D-40
Therefore the column diameter is:
4Vw 4(997.3 / 86400)

Dc    0.3m (D.6.3)
v u  1.16  0.14
Taking the height of column as 2Dc, H = 0.6 m.
Liquid height is then calculated as: H – l = 0.6 – 0.5 = 0.1 m
Heat Exchanger Unit

Feed in Feed out
T1 = 77 C T2 = 87 C
Steam out Steam in

t2 = 133.5 C T1 = 190 C
Fig D.6.2: Heat Exchange diagram
The heat exchange is in countercurrent flow. Feed enters the vessel at 77 C and leaves as vapour
and slurry at 87 C. Steam used is low pressure steam at 3 bara. Description of the steam
properties are listed on Table D.6.1. Steam is superheated at 190 C.
Table D.6.1: Steam properties[2]

Low pressure 3 bar
Temperature of evaporation 133.5 C
Density of saturated liquid 931.97 kg/m3
Density of evaporate 1.66 kg/m3
Density of vapour 1.65 kg/m3
Enthalpy of saturated liquid 561.4 kJ/kg
Enthalpy of evaporate 2163.3 kJ/kg
Enthalpy of saturated vapour 2724.7 kJ/kg
Specific heat capacity, Cp 2.135 kJ/kg C
Viscosity of steam[3] 1.3  10-5 Ns/m2
a. The duty of the evaporator is obtained from ASPEN PLUS simulation. Heat duty is
14090 W.
b. The flow rate of steam required is calculated from;
Q = MCpT + Mhev (D.6.4)
where, Q = duty, kJ/s

M = Mass flowrate of steam, kg/s
Cp = Specific heat capacity, kJ/kg C
T = Temperature difference of steam in and out, C
hev = Enthalpy of evaporate, kJ/kg
CPD 3264
D-41
Q 14.09
therefore, M =   6.2  103 kg / s
C p T  hev 2.135  (190  133.5)  2163.3
Mass flowrate of steam 6.2  103 m3

Volumetric flow rate of steam =   3.7  103
Density of steam 1.65 s
c. Heat exchanger design
Following the design procedure in Coulson and Richardson Vol 6 for heat
exchangers, an iterative calculation is carried out. Steam is introduced in the tube side
while the shell side is filled with the benzoic acid/solvent mixture.
1. Estimate the inner tube diameter, di of 12 mm with 2 mm wall thickness.

Outside diameter, do is therefore 16 mm.
 di 2
2. Tube inner cross sectional area, Across =  1.13  104 m 2
4
3. Guess for U, the overall heat transfer coefficient as 500 W/m2 C (for steam-
organic solvent system)
4. Calculate the amount of tubes required.
Q  UATm (D.6.5)
where, Q = Heat exchanger duty, W or J/s

U = Overall heat transfer coefficient, W/m2 C
A = Area required for heat transfer, m2
Tm = log mean temperature difference
Calculate Tm
Tm = FtTlm (D.6.6)
(T1  t2 )  (T2  t1 ) (77  133.5)  (87  190)

Tlm =   77.43C (D.6.7)
(T1  t2 ) (77  133.5)
ln ln
(T2  t1 ) (87  190)
The heat exchanger is only a 1 tube pass to 1 shell pass. Hence, a correction
factor, Ft is not required. Ft = 1.0
Tm = 1  77.43 = 77.43 C
Q 14090
Area required, A =   0.364 m2
U Tm 500  77.43
With number of passes as 1, and the length of tubes, L as 1.0 m the amount of
area provided by 1 tube:
Area provided by one tube =  d o L  (no. of passes) =   0.016 1.0  1=0.05m 2
CPD 3264
D-42
0.364
Number of tubes required, Nt =  7.3  8 tubes
0.05
Area provided by tubes = 8  0.05 = 0.40 m2
Volumetric flowrate of steam 3.7  103 m

Tube velocity, ut =  4
 4.1
A cross  no. of tubes 1.13  10  8 s
5. Shell inside diameter
Bundle diameter, Db  d o ( N t / K1 )1/ n 1

(D.6.8)
where fore 1 pass tube exchanger with square pitch, K1 = 0.215, n1 = 2.207
Db = 0.02(8/0.215)1/2.207 = 82 mm
Take a distance of 5 mm shell from bundle diameter, inner shell diameter, Ds =

92 mm.
6. Tube side pressure drop
Tube side pressure drop is defined as:
  L   
m
 u 2
Pt  N p 8 j f     2.5 t (D.6.9)
  di   w   2
where, Pt = tube side pressure drop, N/m2 (Pa)

Np = number of tube side passes
ut = tube side velocity, m/s
L = length of one tube, m
 = viscosity of tube side material, Ns/m2
w = viscosity at the tube side wall due to temperature difference, Ns/m2
jf = Friction factor
The viscosity difference can be ignored. The friction factor can be determined from
Reynolds’ Number and from the chart provided in [4];
 ut di 466.8  4.1  0.012

Retube =   45600 (D.6.10)
 5.1  104
where density,  and viscosity,  are averaged from saturated steam and
saturated liquid steam.
 = (1.65 + 9.32)/2 = 466.8 kg/m3 and

 = (1.3  10-5 + 1  10-3)/2 = 5.1  10-4 Ns/m2
jf = 3.5  10-3
CPD 3264
D-43
  1.0   m  466.8  4.12 N

Pt  1 8  3.5  103   1  2.5   19200 2
  0.012   2 m
Normally, maximum pressure drop for operating conditions at 3 bara is 0.4 

system gauge pressure. Hence, maximum pressure drop is 0.8 bara. From the
results obtained, tube side pressure drop is within specifications (0.2 bara).
7. Shell side pressure drop
Employing Kern’s Method;
0.14
 D   L  u 2   
Ps  8 j f  s    s   (D.6.11)
 d e   lB  2   w 
where, Ps = Shell side pressure drop, N/m2

us = shell side linear velocity, m/s
 = viscosity of shell side material, Ns/m2
w = viscosity at the shell side wall due to temperature difference, Ns/m2
lB = baffle spacing
Procedure:
a. Calculate area for cross-flow, As for the hypothetical row of tubes at the shell
equator, given by:
( pt  d o ) Ds lB
As  (D.6.12)
pt
where, pt = tube pitch = 1.25  do = 0.02 m
taking Ds/lB =4, lB = 0.092/4 = 0.023 m
As = 4.2  10-4 m2
b. Calculate the shell side mass velocity, Gs and the linear velocity, us:
WS
Gs = , (D.6.13)
AS
where Ws = fluid flowrate on the shell side, kg/s = 1.88  10-2 kg/s
Gs = 1.88  10-2/4.2  10-4 = 44.14 kg/m2s

us = Gs/ = 44.14/875 = 5  10-2 m/s (D.6.14)
Density of flow taken from ASPEN PLUS.
CPD 3264
D-44
c. Calculate the shell side equivalent diameter, de for a square pitch

arrangement.
A square pitch is chosen for its ease for cleaning.
 p 2   d o2   0.022  0.022  
4 t  4 
de       1.58  102 m
4 4
(D.6.15)
 do 0.02
d. Shell side Reshell, is given by:
GS d e 44.14  1.58  102

Reshell =   700 (D.6.16)
 1  103
friction factor from Reshell based on [5] = 0.095

(Baffle cutting of 15 %)
e. Shell side pressure drop
Ignoring temperature effects on viscosity change;
 0.092  1  875  0.05

2
1  215 N / m2
0.14
Ps  8  0.095  2  
 1.58  10  0.023  2
Shell side pressure drop is insignificant.
8. Check guessed U
Finally, U which was guessed in the beginning needs to be assessed if the value
is reasonable.
Overall heat transfer coefficient based on the outside area of a tube is:
d 
d o ln  o 
1
 
1 1
  di   d o 1  d o 1 (D.6.17)
U o ho h od 2k w di hid d i hi
where UO = the overall coefficient based on the outside area of a tube, W/m2 C
ho = outside fluid film coefficient, W/m2 C
hi = inside fluid film coefficient, W/m2 C
hod = outside dirt coefficient (fouling factor), W/m2 C
hid = inside dirt coefficient, W/m2 C
kw = thermal conductivity of the tube wall material, W/m C
di = tube inside diameter, m
do = tube outside diameter, m
From Coulson and Richardson, Vol 6, Chapter 12, the following are given:
hod = 5000 W/m2 C (organic liquids)
CPD 3264
D-45
hid = 10000 W/m2 C (Steam oil free)

kw = 45 (steel)
Calculation of hi and ho:
Tube side film coefficient:
0.14
0.33
jh tube Retube Prtube k f tube   
hi    (D.6.18)
di  w 
where, jh-tube = heat transfer factor

Retube = Reynolds number in tube
Prtube = Prandtl number in tube
kf-tube = fluid thermal conductivity in tube, W/m C
jh-tube is based on Retube. Retube = 45600, according to [6] jh-tube = 3.5 10-3
From [7], kf-tube = 0.6 W/m C
C  2130  5  104
Pr = P   1.8 (D.6.19)
k f tube 0.6
Ignoring temperature dependence on viscosity change,
3.5  103  45600  1.80.33 W

h i  9697.6 2 (D.6.20)
0.012 mC
Shell side film coefficient:
0.14
0.33
jh  shell Re shell Prshell k f  shell   
ho    (D.6.21)
di  w 
where, jh-tube = heat transfer factor

Retube = Reynolds number in tube
kf-tube = fluid thermal conductivity in tube, W/m C
jh-shell is based on Reshell. Reshell = 700, according to [8] jh-shell = 0.022

From [7], kf-shell = 0.3 W/m C, taking the properties of water,
C  4200  1  103
Pr = P   14 (D.6.22)
k f  shell 0.3
Ignoring temperature dependence on viscosity change,
0.022  700  140.33 W

h o  696 2
0.012 mC
CPD 3264
D-46
d 
d o ln  o 
From:
1 1
 
1
  di   do 1  do 1
U o ho h od 2k w di hid di hi
 0.016 
0.016ln  
1

1

1
  0.012   0.016 1  0.016 1
U o 696 5000 2  45 0.012 10000 0.012 9697.6
Uo = 510.5 W/m2 C
The guessed or estimated U of 500 W/m2 C is acceptable.

0.3 m
Solvent recovery
vapour
0.6 m
Steam in
Benzoic acid
1.0 m slurry
Feed in
Steam out
0.1 m 0.4 m
Fig D.6.3: Forced-circulation evaporator with dimensions
CPD 3264
D-47
D.6.b Heat Integration and Heat Exchanger
D.6.b.a Design Heat exchanger for Sterilization
Table D.6.2 Composition of Stream <103> and <107>

STREAM Nr. : 103 107
COMP tonnes/day tonnes/day
Ammonium sulphate - 0.526
Glucose 8.777 -
Water 39.221 13.074
Total 47.997 13.599
Input Sterilization process Output

25°C 140°C, 3 bar, 2’min 40°C
Figure D.6.4 Outline of sterilization process
Sample calculation : Sterilization of glucose feed stream
Table D.6.3 Enthalphy profile of stream <103>

T P H
[°C] [kPa] [Watt]
25 101.3 -7936832
25 261.8 -7936832
40 261.8 -7907064
40 101.3 -7907064
90 261.8 -7801572
125 261.8 -7720736
140 261.8 -7683962
Output temperature is not necessary to be 25°C as the fermentation will be conducted at 40°C.
Setting T approach = 15°C, stream composite were plot as figure D.6.5.
160
145
130
115
cold
100
T©
hot
85
70
55
40
25
10
0 100000 200000 300000 400000 500000 600000 700000 800000 900000 1000000
H (kJ/h)
Figure D.6.5 Stream Composite of stream 103 - 104
CPD 3264
D-48
From figure D.6.5 we see that it is only possible to preheat the feed stream until 120°C. After that
steam heating until 140° is required. And it is only possible to cool down the output until 43°C.
No further cooling will be conducted to cool down the stream until 40°C, to minimize number of
heat exchanger. But, higher cooling duty in the fermentor will be required, instead. Final
sterilization system design configuration is presented in figure D.6.6.
140oC
43°C
Steam,
Holding :
2 min
HE 1 HE 2
25oC 120°C 140oC
Figure D.6.6 Sterilization system design
For further heating,

Steam requirement =
Q = Hcold 140°C – Hhot 120°C = 132387 kJ/h
steam = 2013 kJ/kg (medium pressure steam, 10 bar at 180°C)
Q
msteam = = 66 kg/h (D.6.23)
l steam
steam = heat of condenstation of steam
msteam = mass flow of steam
Q = heat duty
Dimensioning plate heat exchanger
Calculation were based on Number of Transfer Unit approaches [9].
ti - to UA
Number of Tansfer Unit (NTU) =  = = (D.6.24)
D tm mCp
ti = input temperature of fluid
to = ouput temperature of fluid
tm = mean logaritmic temperature difference = tLMTD x correction factor (F)
U = overall heat transfer coefficient
A = heat transfer area
m = mass flow rate of fluid
Cp = specific heat of fluid
As the correction factor were determined from NTU and type of pass system used, iterative
calculation method will be required here.
CPD 3264
D-49
HE 1
Cold Stream Hot stream
Tin (°C) 25 140
Tout (°C) 125 43.2
Q (kJ/h) 777946.3
216.1
mCp (kJ/h°C) 7915.9
First assumption F = 1  NTU = 6.868

For NTU = 6.868 and 4/4 pass system : F = 0.88 (table in [7])
Therefore NTU = 6.648
Since glucose % in stream is realtively small, we assumed the system to be water - water system
and U for water-water system were used in this calculation. U was set to be 6550 W/m2°C
(usually between 5700 – 7400 W/m2°C [7]).
From equation X.1.1 we got area needed = 2.31 m2.

Using plate with area = 0.1 m2, number of plate needed will be 48.
HE 2
Cold Stream Hot stream
Tin (°C) 125 180
Tout (°C) 140 180
Q (kJ/h) 132387.0
36.8
mCp (kJ/h°C) 7915.9
First assumption F = 1  NTU = 0.318

For small NTU, F = 1
Therefore NTU = 0.318
Since glucose % in stream is realtively small, we assumed the system to be steam - water system
and U for steam-water system were used in this calculation. U was set to be 6550 W/m2°C
(usually between 5700 – 7400 W/m2°C [7]).
From equation X.1.1 we got area needed = 0.12 m2.

Using plate with area = 0.1 m2, number of plate needed will be 4.
D.6.b.b Design Heat Exchanger Network for Ethanol Evaporation System
Table D.6.4 Enthalpy profile for stream <206> and <211>

Stream H T m Cp average mCp
no. [Kwatt] [C] [ton/day] [kJ/kgC] [kJ/hC]
Cold <206> -138.2 25.71 1.595 3.636 241.61
<208> -134.7 77.00 1.595
Hot <208> -79.1* 87.22 0.997 1,157 48,088
-92.5* 87.22 0.997 3.366 139.88
<211> -94.5 35.00 0.997
* condensation process
CPD 3264
D-50
T approach = 15C
100
90
80
70
T(oC) 60 hot
50 cold
40
30
20
10
0
0 10000 20000 30000 40000 50000 60000
H (kJ/h)
Figure D.6.7 Grand Composite for Heat Exchanger Network

in Ethanol Evaporation System
From figure D.6.7, it was shown that most of the heat available in stream <211> is from its
condensation process. Maximum temperature of feed (preheated) can be achieved is 72.22C.
And further condensation for stream <211> is still required. Table D.6.5 shows detailed
calculation of heat duty for each heat exchanger.
Table D.6.5 Detailed calculation for Heat Exchanger Duty

HE 1 Tin Tout Q check
H1 87.22 87.22
C1 72.22 25.71 11236
total heat available in H1 55392kJ/h

total heat required to heat C1 (until T out) 11236kJ/h
additional cooling duty required 44156kJ/h 12.27kWatt

additional heating duty required 1156kJ/h 0.32kWatt
Since heat duty for each heat exchanger is quite low, type of heat exchanger used is double pipe
heat exchanger.
Dimensioning heat exchanger.

LP steam
0.32 kW
72.2oC 25oC
77oC
E201
87.2oC 87.2oC
E202 35oC
12.27 kW
E203
Cooling water
Figure D.6.8 Heat Exchanger Network Design for Ethanol Evaporation System
CPD 3264
D-51
Q  m  Cp  T  U  A  TLMTD  F (D.6.25)
Q = heat duty
M =mass flow
Cp=specific heat
T=delta temperature
TLMTD =logaritmic mean temperature different
U=overall heat transfer coefficient
A=heat exchanger area
F=correction factor
for double pipe heat exchanger, F = 1
Table D.6.6 Dimensioning E201

Tin [C] Tout [C]
Hot (LP steam) 133.5 133.5
Cold 72.22 77
Heat duty (Q) [kJ/h] 1155.7 (from table D.6.8)
Heat duty (Q) [kW] 0.32 (from table D.6.8)
TLMTD [C] 58.86
As ethanol is an organic solvent, than we can take the overall heat transfer coefficient for steam
vs organic solvent system, which is usually range between 500 – 1000 W/m2C [10]. For this case
the U used is 750 W/m2C. Therefore the area required will be,
Q 0.32  1000
A   0.727  10-2 m 2
U  TLMTD  F 750  58.86
The hotter stream will be placed inside.

Hot (top C201) 87.22 87.22
Cold (feed) 25 72.22
Heat duty (Q) [kJ/h] 11236 (from table D.6.8)
TLMTD [C] 33.19
As ethanol is an organic solvent, than we can take the overall heat transfer coefficient for organic
solvent vs organic solvent system, which is usually range between 100 – 300 W/m2C [10]. For
this case the U used is 200 W/m2C. Therefore the area required will be,
Q 3.12  1000
A   0.470 m 2
U  TLMTD  F 200  33.19
CPD 3264
D-52

Hot (top C201) 87.22 35
Cold (feed) 20 25
TLMTD [C] 33.19
As ethanol is an organic solvent, than we can take the overall heat transfer coefficient for organic
solvent vs water system, which is usually range between 250 – 750 W/m2C [10]. For this case
the U used is 500 W/m2C. Therefore the area required will be,
Q 12.27 1000
A   0.739 m 2
U  TLMTD  F 500  33.19
D.6.b.c Design Heat Exchanger Network for Chitin Deacetylation System
Table D.6.9 Enthalpy profile for stream <404> and <408>

Stream H T m Cp average mCp
no. [Kwatt] [C] [ton/day] [kJ/kgC] [kJ/hC]
Cold <404> -10515.5 28.04 77.354 1.888 6085.18
<406> -10358.4 121.00 77.354
Hot <408> -10373.8 121.00 77.354 1.906 6142.06
<410> -10520.5 35.00 77.354
T approach = 15C
140
120
100
80
T (oC)
hot
cold
60
40
20
0
0 100000 200000 300000 400000 500000 600000 700000
H (kJ/h)
Figure D.6.9 Grand Composite for Heat Exchanger Network in Chitin Deacetylation
System
Detailed calculation for heat exchanger duty is presented in Table D.6.10.
CPD 3264
D-53
Table D.6.10 Detailed calculation for Heat Exchanger Duty

HE 2 Tin Tout Q check
H2 121.00 43.76 474394kJ/h
C2 106.00 28.04 474394kJ/h
total heat available in H2 528217kJ/h 146.73kWatt

total heat required to heat C2 (until T out) 474394kJ/h 131.78kWatt
additional cooling duty required 53823kJ/h 14.95kWatt

additional heating duty required 91278kJ/h 25.35kWatt
for shell and tube heat exchanger, correction factor is calculated from Z, , and graphs in
reference [7].
Tcold
Z D.6.26
Thot
Tcold
 D.6.27
Thot in  Tcold in

Hot (R401 output) 121 43.8
Cold (R401 feed) 28.04 106
TLMTD [C] 15.4
Z 0.9907
 0.8386
F 0.9 4/8
0.8 3/6
From reference [10] we approximate the overall heat transfer coefficient to be 1750 W/m2C.
Since the correction factor is not much different from 3/6 and 4/8, we chosed 3 pass in shells and
6 pass in tubes shell and tube heat exchanger system. Therefore the area required will be,
Q 131.8  1000
A   6.128 m 2
U  TLMTD  F 1750  15.4  0.8
The hotter stream will be placed in tubes.
CPD 3264
D-54

Hot (LP steam) 133.5 133.5
Cold 106 121
Heat duty (Q) [kJ/h] 91278 (from table D.6.10)
TLMTD [C] 19
Z 0
 0.545
F 1 1/2
1 2/4
Therefore the area required will be,
Q 25.36  1000
A   1.066 m 2
U  TLMTD  F 1250  19  1

Hot (R401 output) 43.8 35
Cold (R401 feed) 20 25
TLMTD [C] 15.9
Z 0.352
 0.370
F 0.96 1/2
0.96 2/4
Therefore the area required will be,
Q 14.9  1000
A   1.398 m 2
U  TLMTD  F 700  15.9  0.96
CPD 3264
D-55
List of Symbols :
A = Area required for heat transfer, m2 Ps = Shell side pressure drop, N/m2
Across = Tube inner cross sectional area Pt = tube side pressure drop, N/m2 (Pa)
Cp = Specific heat capacity, kJ/kg C Q = heat duty
di = tube inside diameter, m Retube = Reynolds number in tube
do = tube outside diameter, m
do = Outside diameter ti = input temperature of fluid
Db = bundle diameter to = ouput temperature of fluid
F=correction factor T=delta temperature
hev = Enthalpy of evaporate, kJ/kg T = Temperature difference of steam in and
ho = outside fluid film coefficient, W/m2 C out, C
hi = inside fluid film coefficient, W/m2 C TLMTD =logaritmic mean temperature different
hod = outside dirt coefficient (fouling factor), tm = mean logaritmic temperature difference =
W/m2 C
tLMTD x correction factor (F)
hid = inside dirt coefficient, W/m2 C
us = shell side linear velocity, m/s
ut = tube side velocity, m/s
jh-tube = heat transfer factor
u = vapour velocity
kf-tube = fluid thermal conductivity in tube, W/m
umax = max. allowable superficial vapour velocity
C
U = Overall heat transfer coefficient, W/m2 C
kw = thermal conductivity of the tube wall
UO = the overall coefficient based on the outside
material, W/m C
area of a tube, W/m2 C
l = vapour space, m
Vw = vapour flowrate, kg/s
lB = baffle spacing
Ws = fluid flowrate on the shell side, kg/s
m = mass flow rate of fluid
 = viscosity of tube side material, Ns/m2
msteam = mass flow of steam
M =mass flow w = viscosity at the tube side wall due to
M = Mass flowrate of steam, kg/s temperature difference, Ns/m2
Nt = Number of tubes required steam = heat of condenstation of steam
Np = number of tube side passes L = liquid phase density, kg/m3
pt = tube pitch v = vapour phase density, kg/m3
Reference:
[1] Coulson and Richardson, “Chemical Engineering Vol 6”, 2nd Edition, p 499
[2] www.connel.com/cgi-bin/steam1.pl
[3] pump.net/otherdata/viscsteamwater.htm
[4] Coulson and Richardson, “Chemical Engineering Vol 6”, 3rd Edition, p 667
[7] Perry’s Chemical Engineering Handbook, 7th Edition
[9] Campbell, J.M. gas Conditioning and Processing Vol. 2. 1998 p:141-142
[10]Coulson and Richardson, “Chemical Engineering Vol 6”, 3rd Edition p:566-569
CPD 3264
D-56
D.7.a Benzoic acid Extractor (S201)
D.7.a.a Number of stages
In countercurrent washing, if the amount of solvent removed with the insoluble solid in the
underflow is constant, and independent of the concentration of the solution in the tank, then the
amount of solvent leaving each tank in the underflow will be the same, and therefore the amount
of solvent in the overflow will also be the same. Hence the ratio of the solvent discharged in the
overflow to that in the underflow is constant and is taken as R, where:
Amount of solvent discharged in the overflow

R (D.7.1)
Amount of solvent discharged in the underflow
If perfect mixing occurs in each of the tanks and solute is not preferentially adsorbed on the
surface of the solid, the concentration of the solution in the overflow will be the same as that in
the underflow. If it is assumed that all the solute has been brought into solution in the agitators,
then:
Amount of solute discharged in the overflow

R (D.7.2)
Amount of solute discharged in the underflow
Amount of solution discharged in the overflow

R (D.7.3)
Amount of solution discharged in the underflow
L1 L2 Lh+1 Ln+1
w1 w2 Lh wh+1 wn+1
Ln
wh wn
Solvent for
washing
S0 S1 Sh-1 Sh Sn-1 Sn
W0 W1 Wh-1 Wh Wn-1 Wn
Washing tank 1 Washing tank 2 Washing tank 3
Fig D.7.1: Series of tanks arranged for countercurrent washing
Let L1,…., Lh,…., Ln be the amounts of solute in the overflows from washing tank 1 to n,
respectively.
Let w1,…., wh,…., wn be the corresponding quantities of solution.
An amount of wn+1 of wash liquid, fed to the nth tank, contains an amount Ln+1 of solute.
CPD 3264
D-58
Let S1,…., Sh,…. Sn and W1,…., Wh,…., Wn be the amounts of solute and solution in the
underflows from the tanks.
Let S0 and W0 be the amounts of solute and solution with the solids which are fed to the system
for washing.
Taking a solute balance on tank h:
S h 1  S h  Lh  Lh 1 (D.7.4)
Taking a balance of solution:
Wh 1  Wh  wh  wh 1 (D.7.5)
Lh wh
Also: R   (D.7.6)
S h Wh
Taking a balance on solute for each of the tank in turn:
Tank n:
S n 1 S n  Ln  Ln 1  RS n  Ln 1  RS n  Ln 1 (D.7.7)
Tank n-1
S n  2  S n 1  Ln 1  Ln  RS n 1  RS n  R 2 S n  RLn 1 (D.7.8)
Tank 2
S1  S2  L2  L3  RS2  RS3  R n 1 Sn  R n  2 Ln 1 (D.7.9)
Tank 1
S0  S1  L1  L2  RS1  RS 2  R n S n  R n 1 Ln 1 (D.7.10)
Adding over the whole system:

S0  Sn  ( R  R 2  ....  R n ) Sn  (1  R  ...  R n 1 ) Ln 1 (D.7.11)
R n 1  1 Rn 1
and rearranging gives : S0  Sn  Ln 1 and ( R  1) S0  ( R n 1  1) S n  ( R n  1) Ln 1 (D.7.12)
R 1 R 1
Assume the liquid fed to the washing system is pure solvent or the amount of solute is
insignificant, Ln+1 will be equal to zero and:
Sn R 1
 n 1 (D.7.13)
So R  1
In this equation, (Sn/S0), f represents the fraction of the solute fed to the washing system which
remains associated with the washed solids. The minimum number of washing tanks,n required is
given by:
CPD 3264
D-59
R 1
f  (D.7.14)
R n 1  1
 1
log 1  ( R  1) 
n  f
1 (D.7.15)
log R
Hence from the system according to mass balances:
Overflow discharge
Solvent for washing
EtOH : 1.26 t/d
EtOH : 1.33 t/d
Benzoic acid : 0.285
Washing tank
Solid Feed Underflow discharge
Solids : 20.7 t/d Benzoic acid : 0.015 t/d
H2O : 9 t/d Solids : 20.7 t/d
Benzoic acid : 0.3 t/d EtOH : 0.005 t/d

H2O : 9.02 t/d
Fig D.7.2: Leaching system
Amount of solvent discharged in the overflow

R
Amount of solvent discharged in the underflow
Calculating R:
0.297
R  119
0.003
S n 0.003
Calculating f : f    0.01
So 0.3
 1  1 
log 1  ( R  1)  log 1  (119  1) 
Therefore the minimum number of stages : n   f
1   0.01 
1
log R log119
n 1
Therefore the extraction can be carried out in one washing tank.
D.7.a.b Equipment design
In order to design the equipment, the residence time and the flowrates are measured.
D.7.a.b.a Mass Transfer in Leaching Operations
Mass transfer rates are difficult to assess because it is impossible to define the shape of the
particles through which transfer must take place. It is possible, however, to obtain an approximate
indication of the rate of transfer from the particles to the bulk of the liquid. Using the concept of a
thin film as providing the resistance to transfer, the equation for mass transfer may be written as:
CPD 3264
D-60
dM k ' A(cs  c)
 (D.7.16)
dt b
where A is the area of the solid-liquid interface

b is the effective thickness of the liquid film surrounding the particles
c is the concentration of the solute in the bulk of the solution at time t
cs is the concentration of the saturated solution in contact with the particles
M is the mass of solute transferred in time t
k’ is the diffusion coefficient (this is approximately equal to the liquid phase diffusivity)
Expanding the equation for a constant total volume of solution V, dM = V dc
dc k ' A(cs  c)

dt Vb
dc t k'A
co cs  c  to Vb dt
c
cs  co k ' A
ln  t (D.6.17)
cs  c Vb
To determine the residence time of solvent needed for the removal of benzoic acid, first the
residence time of solids is assumed to be 1min.
0.3 tonnes / day 1min

1. Amount of benzoic acid in tank =  2.1 104 tonnes
60  24
30 tonnes / day  1min
2. Amount of feed in tank =  0.021tonnes
24  60
3. Density of solids = 1165 kg/m3
0.021tonnes  1000 kg / tonnes
4. Volume of feed in tank =  0.018m3
1165 kg / m3
5. Ratio of feed to solvent = 1 v/v
6. Volume of solvent in tank = 0.018 m3
0.021 830 kg / m3
7. Amount of solvent in tank =  0.0148 tonnes
1000 kg / tonnes
8. Percentage of benzoic acid removal = 99 %
9. Concentration of benzoic acid in tank to be removed =
Amount of Benzoic acid
 Percentage removed
Amount of solvent
2.1 10-4 kg  solute
=  0.99  0.014
0.0148 kg  solvent
kg  solute
 0.0133  830  11.5 3
m  solvent
10. Concentration of benzoic acid in tank at steady state
To calculate the concentration of benzoic acid at steady state in the tank, the following
equation is taken:
1.33  1000 m3
Flow rate of solvent =  1.6
830 day
Amount of benzoic acid to be removed in a day = 0.3  0.99 = 0.297 t/d
CPD 3264
D-61
Concentration of benzoic acid at steady state in tank =

0.297  1000 kg  benzoic acid
 185.3
1.6 m3  solvent
cs  co k ' A
11. From ln  t , the time required for the mass transfer can be calculated.
cs  c Vb
A, the area of the solid-liquid interface is calculated by estimating the particle size of
benzoic acid to be D = 1 mm.
Volume of benzoic acid solids = 0.3 m3/day

Volume of benzoic acid in tank at 1 min residence time = 2.1  10-4 m3
4 D3
Volume of one benzoic acid particle =  = 5.24  10-10 m3
3 8
2.1 10 4
Number of benzoic particles in the tank =  398000
5.24  1010
D2
Area of one benzoic acid particle = 4  3.14  106 m 2
4
Total area of benzoic acid particles , A = 3.14  10-6  398000 = 1.25 m2
cs = 299.7 kg-benzoic acid/m3-solvent

co = 177.86 kg-benzoic acid/m3-solvent
c = 177.86 + 9.5 kg-benzoic acid/m3-solvent
k’ = 1.21  10-9 m2/s
b = 1  10-6 m
V = 0.017 m3 (Volume of solvent)
Therefore the required time for mass transfer =

6
 299.7  185.3  0.017 1 10
t  ln   9
 1.5s
 299.7  185.3  11.5  1.25 1.2110
Hence, the residence time of 1 minute is sufficient for the removal of benzoic acid as the mass
transfer is only 1.1 seconds, which is not rate limiting.
12. Residence time of solvent
Vi
Residence time,  i  where Vi = Volume in m3 and Fi = Flowrate m3/s
Fi
 i Vi Fj
Therefore  , where i = solvent phase, and j = Solid phase (D.7.18)
 j Fi V j
Since j = 1 minute and Vi = Vj;
CPD 3264
D-62
Fj 30  1000 1.33  1000

i   
Fi 1165 830
25.75
  16.1min
1.6
13. Design of the tank
The tank is design to enable the separation of liquid from solids. This can be
accomplished by using a rotary blade that scoops the solids from the liquid and by means
of a scraper, deposited out of the tank. Figure D.7.3 shows the leaching equipment.
Solids feed
Solvent feed
Extract
Solids flow
Liquid flow
Spend solids
Figure D.7.3: Leaching equipment
1. Tank volume
Total volume of solids + solvent in tank = 0.018 + 0.018 = 0.036 m3

Assume working volume of 40 % = 0.036/0.4 = 0.09 m3
If the tank is cubical, and the width x, length y, and depth z, are in ratio of 1:1:1,
Volume  xyz  x 3 (D.7.19)

0.09  x 3
x  0.5 m, y  0.5 m, z  0.5 m
CPD 3264
D-63
2. Radius of the impeller
Assume that the bowl is hemi-spherical, i.e. half the size of a spherical.
1 4
   r 3  0.036 m3
Volume of bowl = 2 3
r  0.25m
3. Speed of rotation
Since the residence time for the solids is 1 minute, and the shape of the bowl is hemi-
spherical, the speed of rotation should be 0.5 rpm. This would allow sufficient time for
contact between the solids that needs to be extracted against the solvent.
D.7.b Product dryer (D401)
Calculation :
feed
steam
out
Vapour
out
steam
in
product
Figure D.7.4 Product dryer schematics
Mass balance :
Amount of water evaporated = mwater  xwfeed m feed  xwproduct m product (D.7.20)

mwater  103.18 kg/h
where m = mass flow rate in kg/h

x = mass fraction of water in respective part
Energy balance :
H in   H out  Q  0 (D.7.21)
setting the reference temperature to be 25C, then we come into
mbounded water   Cpwater   40  25   H evaporation
40
   Cpwater   32.89  25  H evaporation
32.98
 (D.7.22)
Hevaporation at 5 kPa (32.89°C) = 2423.84 kJ/kg
Hevaporation at 40°C = 2406.90 kJ/kg
CPD 3264
D-64
 Q = 254808 kJ/h
where, Q = heat duty, kg/hr

m = mass flow rate inkg/h
Cpwater = specific heat capacity, kJ/kg C
Hevaporation = Enthaply heat of evaporation at respective temperature
amount of steam required :

Q
Q    msteam  H condensation  msteam  (D.7.23)
  H condensation
for low pressure steam (3 bar, 133.54C) Hcondenstaion = 2163.27 kJ/kg
 msteam = 117.8 kg/h = 43.58 m3/h (v = 0.37 m3/kg)
where  = heat tranfer efficiency

Hcondensation = enthalpy heat of condensation, kJ/kg
msteam = mass flow rate of steam, kg/hr
Dimensioning
Typical evaporation rate (revap) =50 kg H2O/h m3

Amount of water evaporate (mwater ) = 103.18 kg/h
Working volume = 60%
mwater
Total volume required = = 3.44 m3 (D.7.24)
revap  60%
Check :
tot flowin + tot flowout
Average flow rate of material = = 1471.83 m3/h
2
Veff dryer
Residence time = = 0.002 h  reasonable value
average flow rate of material
Assumption : H = 4 D
D2 V
V  H   D3 D 3 (D.7.25)
4 
D = 1.03 m
H = 4.12 m
V(check) = 3.44 m3
Total area available = A =  DH =13.35 m2

Effective area = Aeff = 60% A = 8.01 m2
Max. Effective area + paddle and center heating= Aeff2 = 68% A = 9.08 m2
Check :
Area required for heat transfer :
Q  U  Aheat transfer  T (D.7.26)
heat transfer coefficient = U = 347.5 kJ/h m C 2
Taverage = 99.74 C
Aheat transfer = 7.35 m2
CPD 3264
D-65
 sufficient area is available for heat transfer.
Power consumption :
Power required is function of size of dryer, density of material and dryer capacity. It can be
approximated with equation D.7.27
P  L  D  0.2 (D.7.27)
while P in HP, L and D in feet
P = 9.16 HP = 6832.7 Watt
notes : water-vapor equilibrium and steam data were taken from ( 1).
D.7.c Buffer tanks (T101 and T102)
T101: Lactic acid buffer tank
The lactic acid buffer tank capacity is based on the storage of lactic acid for 1 day. Therefore the
amount of lactic acid required for enzymatic deproteinization and demineralization is 60.64
tonnes/day (Stream 118). The density of the fluid is 1015.24 kg/m3.
60.64 1000 m3
Volumetric flowrate =  1.63
1015.24 day
Effective volume, Veffective = 1.63  1 day = 1.63 m3
Taking the effective volume as 75 % of the vessel volume,
Vessel volume = 1.63/0.75 = 2.17 m3
Take H = 2D , where H = height of vessel and D = diameter of vessel
D = 1.1 m, H = 2.2 m
4Veffective
The liquid height is then calculated as  1.72m .
D 2
T201:Ethanol buffer tank
The same procedure carried out for T101 is done. The basis of storage for 1 day is assumed.
Volumetric flowrate = 60 m3/day
Effective volume, Veffective = 30 m3
Taking the effective volume as 80 % of the vessel volume,
CPD 3264
D-66
Vessel volume = 37.5 m3

D = 2.9 m, H = 5.8 m and liquid height is 4.54 m.
D.7.d Mixing tanks (V301 and V401)
V301: HCl chitin mixer
This mixer is provided to ensure a heterogeneous mixture when solids and liquid enters the
reactor.
Total flow stream 303 + 305 = 54.15 m3/day
Taking a residence time of 5 minutes, Veffective = 0.188 m3
Take the effective volume as 75 % of the vessel volume,
With H = 2D,
D = 0.55 m, H = 1.1 m
V401: NaOH chitin mixer
This mixer serves the same function as for V301.

Total flow stream 401 + 310 = 94.37 m3/day
Taking a residence time of 5 minutes, Veffective = 0.328 m3
Take the effective volume as 75 % of the vessel volume,
With H = 2D,
D = 0.65 m, H = 1.3 m
Impeller calculations for V301 and V401:
For calculation details refer to Appendix D.3,
Table D.7.1: Impeller speed and power requirements.

Specification V301 V401 Units
m, mean density 1032.1 819.7 kg/m3
m, mean viscosity 0.001 0.001 kg/ms
Di, diameter of impeller 0.18 0.22 m
N, Rotational speed 0.5 0.5 rps
NRe, Reynolds number 17340 19240 -
NPo, Power number 5.5 5.8 -
gc, dimensional constant 1 1 -
P, Power 0.146 0.284 W
List of symbols :
A = area of the solid-liquid interface

b = effective thickness of the liquid film surrounding the particles
Cpwater = specific heat capacity, kJ/kg C
c = concentration of the solute in the bulk of the solution at time t
cs = concentration of the saturated solution in contact with the particles
f = fraction of the solute fed to the washing system which remains associated with the washed solids
CPD 3264
D-67
Hcondensation = enthalpy heat of condensation, kJ/kg

Hevaporation = Enthaply heat of evaporation at respective temperature
k’ = diffusion coefficient (this is approximately equal to the liquid phase diffusivity)
L = amount of solute overflow
M = mass of solute transferred in time t
m = mass flow rate in kg/h
msteam = mass flow rate of steam, kg/hr
n = minimum number of washing tanks
Q = heat duty, kg/hr
S = amount of solute
W= amount of solution
x = mass fraction of water in respective part
 = heat tranfer efficiency
Reference :
[1] Smith, J.M. Van Ness,H.C. Introduction to chemical engineering thermodynamics, 1996
CPD 3264
D-68
Sample calculation for P305
CO2 311
12 m 315
S302
0.5 m
2.5 m
0.43 m
1.2 m
Filter 2 Filter Cake
R302 316
0.7 m 313 2.5 m 0.5 m
312 Waste
0.5 m 314
P305 Water
P306
Figure D.8.1 Piping diagram for P305
Given:
Pumping fluid = HCl-Water-Chitin
Mass flow rate , G = 0.64 kg/s
Temperature, T = 313 K
Pipe material = Stainless Steel
Solution:
Density,  = 992 kg/cum
Viscosity,  = 1 × 10-3 N s /m 2
Volumetric flow rate Q, = 6.50 × 10-4 m3 / s
Economic Pipe Diameter Calculation:

For Commercial SS pipe,
d , optimum  260 G 0.52  -0.37
d , optimum  260 0.640.52 992-0.37 (D.8.1)
d , optimum  16.1 mm
Taking Nominal Pipe Diameter = ¾ inch = 19.05 mm

Using Schedule 40S pipe
Inside pipe diameter = 0.824 inch = 20. 93 mm
 d2   20.932
Cross-sectional area =   344 mm 2
4 4
= 3.44  10 m
-4 2
Pressure Drop Calculation:

flow rate 6.5  10-4
Fluid Velocity , u    1.89 m / s
Area 3.44  10-4
CPD 3264
D-70
4G 4  0.64
Reynold’s number, Re  
 d   1  10-3  20.93  10-3
 39, 260 (Turbulent Flow)
Using Genereaux’s formula for friction loss,

P  4.13  1010 G1.84  0.16  1d 4.84 (D.8.2)
3 0.16 1 4.84
 4.13  10 (0.64)  (1 10 ) (992) (20.93)
10 1.84
 2.49 kPa / m
Take the higher value, and design 20 % more pressure drop above the average
P  2.5  1.22 kPa / m
P  3.5 kPa / m
The loss through the bends and block valves can be included in line pressure-loss calculation as an
equivalent length of pipe. All the bends will be taken as 90 elbows of standard radius, equivalent
length= 30d, and the valves as plug values, fully open, equivalent length = 18 d. Line to pump suction:
Length  0.70 m
Bends, 2  30  20.93  10-3  1.26 m
Valves, 1  18  20.93  10-3  0.38 m
 2.33 m
u 2
Entry losses = 
2
992(1.6  1.2) ^ 2
At maximum design velocity   1.77 kPa
2
Control Valve pressure drop, allow normal 140 kPa

( 1.22 ) maximum 200 kPa
Heat exchanger, allow normal 70 kPa
Orifice, allow normal 15 kPa
Line from pump discharge

Length  2.20 m
Bends, 3  30  20.93  10-3  1.88 m
Valves, 1  18  20.93  10-3  0.38 m
 4.46 m
The line pressure-drop calculation is given in table D.8.1. The calculation for the discharge side is the
same as for suction side.
CPD 3264
D-71
Table D.8.1 Pump and line Calculation form
Pump and line Calculation Sheet

Fluid HCl-Water-Chitin DISCHARGE CALCULATION
Temperature ºC 40 Line size mm 20.93
Density kg/cum 992 Flow Norm Max Units
Viscosity mNs/spqm 1 u2 Velocity 1.89 2.27 m/s
Normal flow kg/s 6.45E-01 f2 Friction loss 2.5 3.5 kPa
Design Max flow kg/s 7.74E01 L2 Line length 4.46 4.46 m
f2L2 Line loss 11.1 15.5 kPa
SUCTION CALCULATION Orifice 15 21.6 kPa
Line Size mm 20.93 Control valve 140 202 kPa
Flow Norm Max Units Equipment - - kPa
u1 Velocity 1.89 2.27 m/s (a) Heat ex. - - kPa
f1 Friction loss 2.5 3.5 kPa/m (b) - - kPa
L1 Line length 2.33 - M (c) - - kPa
f1L1 Line loss 5.82 8.14 kPa (6) Dynamic loss 166.1 238.7 kPa
2
u1 /2 Entrance 1.77 2.55 kPa
z1
Strainer - - kPa Static Head 1.2 1.2 m
gz2
(1) Sub-total 7.89 10.7 kPa 11.7 11.7 kPa
Equip.press 101.3 101.3 kPa
(max)
z1 Static Head 0.7 0.7 m Contigency - - kPa
gz1 6.81 6.81 kPa (7) Sub-total 113 113 kPa
Equip. press 101.3 101.3 kPa (7)+(6) Discharge press 279 352 kPa
(2) Sub.total 108 108 kPa Suction press 101 97.4 kPa
(8) Diff. Press 179 254 KPa
(2)-(1) (3) Suction press 100.5 97.4 kPa
(4) VAP.PRESS 3.24 3.24 kPa (8)/ g 18.3 26.1 m
(3)-(4) (5) NPSH 97.3 94.2 kPa Valve/(6) Control valve
(5)/ g 10.0 9.68 m % Dyn. loss 84%
CPD 3264
D-72
Table D.8.2 Line Specification of all Streams
Nominal Pipe Inside

Stream Schedule Reynold’s
Diameter Diameter in / Flow
Number Number. Number
in / mm mm
101 1/2 / 9.52 40S 0.62 / 15.80 Intermittent flow
102 3/4 / 19.05 40S 0.82 / 20.93 33,795 Turbulent
103 3/4 / 19.05 40S 0.82 / 20.93 33,795 Turbulent
104 3/4 / 19.05 40S 0.82 / 20.93 33,795 Turbulent
105 3/4 / 19.05 40S 0.82 / 20.93 33,795 Turbulent
106a 1/2 / 9.52 40S 0.62 / 15.80 22,400 Turbulent
106b 1/2 / 9.52 40S 0.62 / 15.80 22,400 Turbulent
107 1/4 / 6.35 40S 0.41 / 10.41 19,200 Turbulent
108 1/4 / 6.35 40S 0.41 / 10.41 19,200 Turbulent
109 1/4 / 6.35 40S 0.41 / 10.41 19,244 Turbulent
110 1/4 / 6.35 40S 0.41 / 10.41 19,244 Turbulent
111a 1/4 / 6.35 40S 0.41 / 10.41 9622 Turbulent
111b 1/4 / 6.35 40S 0.41 / 10.41 9622 Turbulent
112a 1/8 / 3.17 80S 0.21 / 5.46 6646 Turbulent
112b 1/8 / 3.17 80S 0.21 / 5.46 6646 Turbulent
113a 3/4 / 19.05 40S 0.82 / 20.93 30,014 Turbulent
113b 3/4 / 19.05 40S 0.82 / 20.93 30,014 Turbulent
114a 3/4 / 19.05 40S 0.82 / 20.93 30,014 Turbulent
114b 3/4 / 19.05 40S 0.82 / 20.93 30,014 Turbulent
115a 1/4 / 6.35 40S 0.41 / 10.41 16,795 Turbulent
115b 1/4 / 6.35 40S 0.41 / 10.41 16,795 Turbulent
116a 1/2 / 9.52 40S 0.62 / 15.80 28,700 Turbulent
116b 1/2 / 9.52 40S 0.62 / 15.80 28,700 Turbulent
117 3/4 / 19.05 40S 0.82 / 20.93 43,300 Turbulent
118 3/4 / 19.05 40S 0.82 / 20.93 43,300 Turbulent
201 Conveyer
202 Conveyer
203 1/8 / 3.17 80S 0.21 / 5.46 4,237 Turbulent
204 Conveyer
205 1/8 / 3.17 80S 0.21 / 5.46 5,816 Turbulent
206 1/8 / 3.17 80S 0.21 / 5.46 5,816 Turbulent
207 1/8 / 3.17 80S 0.21 / 5.46 5,816 Turbulent
208 1/8 / 3.17 80S 0.21 / 5.46 5,816 Turbulent
209 1/8 / 3.17 80S 0.21 / 5.46 1466 Laminar
210 1/8 / 3.17 80S 0.21 / 5.46 1466 Laminar
211 1 / 25.40 5S 1.18 / 30.01 40,687 Turbulent
212 1/8 / 3.17 80S 0.21 / 5.46 3,203 Turbulent
213 1/8 / 3.17 80S 0.21 / 5.46 3,203 Turbulent
214 1/8 / 3.17 80S 0.21 / 5.46 1,035 Laminar
215 1/8 / 3.17 80S 0.21 / 5.46 1,035 Laminar
216 1/8 / 3.17 80S 0.21 / 5.46 4,237 Turbulent
301 1 / 25.40 5S 1.18 / 30.01 46,243 Turbulent
302 1 / 25.40 5S 1.18 / 30.01 43,518 Turbulent
303 1 / 25.40 5S 1.18 / 30.01 43,518 Turbulent
304 1 / 25.40 5S 1.18 / 30.01 38,205 Turbulent
305 1 / 25.40 5S 1.18 / 30.01 38,205 Turbulent
306 Conveyer
307 3/4 / 19.05 40S 0.82 / 20.93 31,705 Turbulent
308 3/4 / 19.05 40S 0.82 / 20.93 31,705 Turbulent
309 3/4 / 19.05 40S 0.82 / 20.93 41,175 Turbulent
CPD 3264
D-73

Stream Nominal Pipe
Schedule Inside Reynold’s
Number Diameter mm Flow
Number Diameter mm Number
310 3/4 / 19.05 40S 0.82 / 20.93 41,175 Turbulent
311 3/4 / 19.05 40S 0.82 / 20.93 10812 Turbulent
312 3/4 / 19.05 40S 0.82 / 20.93 39,260 Turbulent
313 3/4 / 19.05 40S 0.82 / 20.93 39,260 Turbulent
314 3/4 / 19.05 40S 0.82 / 20.93 32,187 Turbulent
315 3/4 / 19.05 40S 0.82 / 20.93 32,187 Turbulent
316 Conveyer
401 1 / 25.40 40S 1.05 / 26.65 37,200 Turbulent
402 1 / 25.40 40S 1.05 / 26.65 37,200 Turbulent
403 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
404 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
405 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
406 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
407 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
408 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
409 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
410 1 / 25.40 40S 1.05 / 26.65 42,800 Turbulent
411 1/4 / 6.35 40S 0.41 / 10.41 14,688 Turbulent
412 1 / 25.40 40S 1.05 / 26.65 459,00 Turbulent
413 1 / 25.40 40S 1.05 / 26.65 459,00 Turbulent
414 Conveyer
415 6 / 152.4 40S 6.06 / 154.05 18,500 Turbulent
416 Conveyer
List of symbols :
d = pipe diameter, mm
G = mass flow rate, kg/s
Q = volumetric flow rate, m2/s
Re = Reynold’s number
u = fluid velocity, m/s
P = pressure drop kPa/m
 = density, kg/cum
 =viscosity, Ns/m2
CPD 3264
D-74
CRUSHERS AND GRINDERS – SUMMARY
EQUIPMENT NR. : A201 A401

NAME : Shrimp Shell Chitosan
Crusher Grinder
Hardinage mill Ball mill
Pressure [atm] : 1.0 1.0
Temp. [oC] : 25.0 25.0
Volume [m3] : 43.2 10.4
Diameter [m] : 3.4/1.7 (1) 2.4
L or H [m] : 6.1 2.4
Capacity [kg/day] : 20,700 1,789
Duty [kWh] : 973.6 134.8
Internals
- Ball sizes [mm] : 98/59/35 (2) 12
- Rotation [rpm] : 15 18
- Particle size [mm]:
Feed : 30 0.1
Product : 1 0.05
- Res. time [min] : 22 10
Number
- Series : 1 1
- Parallel : - -
Materials of Lining: Rubber Lining: Rubber
Construction (3) : Vessel: CS Vessel: CS
Balls : Steel Balls : Steel
Other : Appendix D.5 Appendix D.5
Remarks:
(1) Hardinage mill consist of a cylindrical and conical section
(2) Three different ball sizes are used in the hardinage mill
(3) CS = Carbon Steel
Designers : A.A. Khan H. Shibata Project ID-Number : CPD3264

S.L.Tai M.T.A.P Kresnowati Date : December 21st 2001
CPD 3264
D-82
FILTERS – SUMMARY
EQUIPMENT NR. : S301 S302 S401 S101 a/b

NAME : Filter 1 Filter 2 Filter 3 Microfilter
Drum Drum Drum Microfilter
Pressure [atm] : 1.0/0.6 1.0/0.6 1.0/0.6 1.0
Temp. [oC] : 25.0 40.0 27.0 40.0
Area [m2] : 1.94 7.53 17.80 55.62
Diameter [m] : 0.6 1.1 1.7 0.1 (1)
L or H [m] : 1.2 2.2 3.4 1.0
Capacity [kg/day] : 88,930 55,750 77,360 11,869
Internals
- Rotation [rpm] : 0.25 0.25 0.2 n.a.
- Particle size [mm]: 0.5 0.1 0.05 n.a.
- Cake thick. [mm]: 34 8 2 n.a.
Duty [kW]
- Filtrate pump 0.07 0.044 0.093 n.a.
- Vacuum pump (2) 0.07 0.044 0.093 n.a.
Number
- Series : 1 1 1 -
- Parallel : - - - 3 (3)
Materials of Filter: Filter: Filter: Filter:
Construction (4) : Polypropylene Polypropylene Polypropylene Hollow fibers
Vessel: SS304 Vessel: SS316 Vessel: CS Vessel: SS304
Other : Appendix D.4 Appendix D.4 Appendix D.4 Appendix D.2
Remarks:
(1) 0.1 m is for one tube. Each microfilter consist of 4 tubes. Each tube has 3000 fibers.
(2) Assuming air to filtrate ratio of one
(3) One installed spare included
(4) SS = stainless steel

CPD 3264
D-83
VESSELS & REACTOR – SUMMARY
EQUIPMENT NR. : R101 a/b T101 T201 S201 D401

NAME : Lactic acid Lactic acid Ethanol Benzoic acid Product
Fermentor buffer tank buffer tank extractor dryer
CSTR Tank Tank Tank Rotary
Pressure [atm] : 1.0 1.0 1.0 1.0 0.05
Temp. [oC] : 40.0 25.0 32.0 25.0 40
Volume [m3] : 3.41 (1) 37.5 (5) 2.17 (6) 0.13 (2) 3.44
Diameter [m] : 1.43 2.9 1.1 0.5 1.03
L or H [m] : 2.14 5.8 2.2 0.5/0.5 (3) 4.12
Internals
- Impeller sp. [rpm] : n.a. n.a. n.a. 0.5 n.a.
- Catalyst
Type : n.a. n.a. n.a. n.a. n.a.
Shape : n.a. n.a. n.a. n.a. n.a.
Duty [kW]
- Impeller 8.45 n.a. n.a. n.a. n.a.
- Cooling water 38.0 38.79 n.a. n.a. n.a.
- Steam n.a. n.a. n.a. n.a. 70.8 (4)
Number
- Series : - 1 1 1 1
- Parallel : 2 - - - -
Materials of Vessel: Vessel: Vessel: CS Vessel: SS304 Vessel:
Construction (7) : SS304 SS304 SS304
Other : Appendix Appendix Appendix D.7 Appendix D.7 Appendix
D.2 D.7 D.7
Remarks:
(1) R101/102 : effective volume = 2.56 m3 for residence time of 1.67 hours
(2) S201 : effective volume = 0.036 m3 for residence time of 16.1 min (liquid) and 1 min (solids)
(3) S201 : Structure of container is cubical.
(4) D401 : Steam at 3 bara
(5) T101 : effective volume = 30 m3 with liquid height of 4.54 m
(6) T201 : effective volume = 1.63 m3 with liquid height of 1.72 m
(7) CS = Carbon steel, SS = Stainless steel

CPD 3264
D-84
VESSELS & REACTOR – SUMMARY
EQUIPMENT NR. : V301 V401 R301a/R301b R302 R401

NAME : HCl chitin NaOH Chitin Chitin Deacetylation
mixer chitin deproteinization purification
mixer demineralization
CSTR CSTR PFR (3) PFR (3) PFR (3)
Pressure [atm] : 1.0 1.0 1.0 1.0 2.3
Temp. [oC] : 25.0 25.0 25.0 25/40 121.0
Volume [m3] : 0.25 (1) 0.87 (2) 7.1 (4) 1.55 (5) 2.3 (6)
Diameter [m] : 0.55 0.65 0.91 0.43 0.50
L or H [m] : 1.1 1.3 10.9 10.4 12.0
Internals
- Impeller sp. [rpm] : 30 30 18 18 18
- Catalyst
Type : n.a. n.a. n.a. HCl NaOH
Shape : n.a. n.a. n.a. n.a. n.a.
Duty [kW]
- Impeller 1.5  10-4 2.8  10-4 0.019 4.1  10-4 9.6  10-4
- Cooling water n.a. n.a. 113.7 (7) n.a. 15.4
- Steam n.a. n.a. n.a. n.a. n.a.
Number
- Series : 1 1 2 1 1
- Parallel : - - - - -
Materials of Vessel: Vessel: CS Vessel: SS304 Vessel: Vessel:
Construction (8) : SS316 SS316 SS304
Other : Appendix Appendix Appendix D.3 Appendix Appendix D.3
D.7 D.7 D.3
Remarks:
(1) V301 : effective volume = 0.188 m3 for residence time of 5 mins
(2) V401 : effective volume = 0.655 m3 for residence time of 5 mins
(3) PFR installed with baffles and stirrers
(4) R301 : effective volume = 6 m3 for residence time of 1 hours 41 mins
(5) R302 : effective volume = 1.32 m3 for residence time of 34 mins
(6) R401 : effective volume = 1.96 m3 for residence time of 29 mins
(7) Chilled water (5-15 C) used instead of cooling water.
(8) SS = Stainless steel; CS = Carbon steel

CPD 3264
D-85
HEAT EXCHANGERS & EVAPORATOR – SUMMARY
EQUIPMENT NR. : C201

NAME : Ethanol
Evaporator
Forced
Evaporator
Substance
- Tubes : L.P. Steam
- Shell : Benzoic acid +
Solvent
Duty [kW] : 14.1
Heat Exchange
area [m2] : 0.37
Number
- Series : 1
- Parallel : -
Pressure [bara]
- Tubes : 3.0
- Shell : 1.0
Temperature
In / Out [oC]
- Tubes : 190.0/133.5
- Shell : 77.0/87.0
Special Materials of Tubes : SS304
Construction (1) : Shell : SS304
Other : Appendix D.6
Remarks:
(1) CS = Carbon Steel; SS = Stainless steel

CPD 3264
D-86
EQUIPMENT NR. : E101A/B E102A/B

NAME : Glucose N-source
Sterilizer Sterilizer
Plate Plate
Substance
- Side A : Glucose (NH4)2SO4
- Side B : MP Steam MP Steam
Duty [kW] : 252.87 75.74
Heat Exchange
area [m2] : 2.43 0.73
Number
- Series : 1 1
- Parallel : - -
Pressure [bara]
- Side A : 7.5 7.5
- Side B : 10.0 10.0
Temperature
In / Out [oC]
- Side A : 25.0 / 43.2 25.0 / 43.2
- Side B : 180.0 / 180.0 180.0 / 180.0
Special Materials of Tubes : SS Tubes : SS

Construction (1) : Shell : SS Shell : SS
Other : Appendix D.6 Appendix D.6
Remarks:

CPD 3264
D-87
EQUIPMENT NR. : E201 E202 E203

NAME : Feed C201 Ethanol heat Top C201
Preheater exchanger condenser
Double pipe Double pipe Double pipe
Substance
- Inner Tubes : L.P. Steam Ethanol Ethanol
- Outer Tubes : Ethanol Ethanol Cooling water
Duty [kW] : 0.32 3.12 12.27
Heat Exchange
area [m2] : 0.0073 0.47 0.74
Number
- Series : 1 1 1
- Parallel : - - -
Pressure [bara]
- Inner Tubes : 3.0 1.0 1.0
- Outer Tubes : 3.2 4.0 1.0
Temperature
In / Out [oC]
- Inner Tubes : 133.5/133.5 87.2 /87.2 87.2 / 35.0
- Outer Tubes : 72.2/ 77.0 25.0 / 77.2 20.0 / 25.0
Special Materials of InnerTubes: CS InnerTubes: CS InnerTubes: CS
Construction (1) : Outer Tubes: CS Outer Tubes: CS Outer Tubes: CS
Other : Appendix D.6 Appendix D.6 Appendix D.6
Remarks:

CPD 3264
D-88
EQUIPMENT NR. : E401 E402 E403

NAME : R401 heat Feed R401 Product R401
exchanger preheater cooler
Shell and tube Shell and tube Shell and tube
Substance
- Tubes : NaOH/Chitosan L.P. Steam NaOH/Chitosan
- Shell : NaOH/Chitin NaOH/Chitin Cooling water
Duty [kW] : 131.78 25.35 14.95
Heat Exchange
area [m2] : 5.48 1.01 1.40
Number
- Series : 1 1 1
- Parallel : - - -
Pressure [bara]
- Tubes : 7.6 3.0 6.9
- Shell : 4.0 3.3 1.0
Temperature
In / Out [oC]
- Tubes : 121.0/ 43.8 133.5/133.5 43.8/ 25.0
- Shell : 28.04 / 106.0 106.0/121.0 20.0 / 25.0
Special Materials of InnerTubes: CS InnerTubes: CS InnerTubes: CS
Construction (1) : Outer Tubes: CS Outer Tubes: CS Outer Tubes: CS
Other : Appendix D.6 Appendix D.6 Appendix D.6
Remarks:

CPD 3264
D-89
PUMPS, BLOWERS & COMPRESSORS – SUMMARY
EQUIPMENT NR. : P-102 A/B P-103 A/B P-104A A/B P-104B A/B P-105 A/B
NAME : R101 Feed R101 Feed S101 Feed S101 Feed R301 Feed
Pump Pump Pump Pump Pump
Type : Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm
Number : 2 2 2 2 2
Medium Glucose / Ammonium Lactic acid / Lactic acid / Lactic acid
transferred : Water Sulphate/ Water Water
Water
Capacity
[kg/s] :
[m3/s] : 4.79  10-4 1.60  10-4 4.26  10-4 4.26  10-4 4.79  10-4
3
Density [kg/m ] : 803 912 1160 1160 1110
Pressure [bara]
Suct. / Disch. : 1.05 / 7.49 0.87/7.72 1.15/5.80 1.15/5.80 1.09/4.31
Temperature
In / Out [oC] : 25.0 25.0/25.0 39.9/39.9 39.9/39.9 25.0/25.0
Power [kW]
- Theor. : 3.08  10-1 1.09  10-1 1.67  10-1 1.67  10-1 1.54  10-1
- Actual : 4.41  10-1 1.56  10-1 2.37  10-1 2.37  10-1 2.20  10-1
Number
- Theor. :
- Actual : 2 (1) 2 (1) 2 (1) 2 (1) 2 (1)
Special Materials of
Construction : MS casing MS casing MS casing MS casing MS casing
Other (2) : Single Single Single Single Single
mechanical mechanical mechanical mechanical mechanical
seals seals seals seals seals
Remarks:
(1) One installed spare included.
(2) Appendix D.8

CPD 3264
D-90
EQUIPMENT NR. : P-201 A/B P-202 A/B P-203 A/B P-204 A/B P-301 A/B
NAME : C201 Feed V201 Feed S201 Feed C201 Bottom S301 Feed
Pump Pump Pump Discharge Pump
Pump
Number : 2 2 2 2 2
Medium Ethanol / Ethanol / Benzoic acid / Chitin /
transferred : Water Ethanol Water Water Water
Capacity
[kg/s] :
[m3/s] : 2.19  10-5 4.93  10-6 1.09  10-5 7.53  10-6 9.78  10-4
3
Density [kg/m ] : 846 837 816 919 1050
Pressure [bara]
Suct. / Disch. : 1.02 / 4.0 1.09/3.37 1.07/1.90 1.10/1.31 1.02/4.2
Temperature
In / Out [oC] : 51.4 25.0/25.0 32.3/32.3 87.2/87.2 25.0/25.0
Power [kW]
- Theor. : 6.52  10-3 1.12  10-3 1.60  10-3 1.60  10-4 3.1  10-1
- Actual : 7.25  10-3 1.25  10-3 1.77  10-3 1.78  10-4 3.44  10-1
Number
- Theor. :
- Actual : 2 (1) 2 (1) 2 (1) 2 (1) 2 (1)
Remarks:
(2) Appendix D.8

CPD 3264
D-91
EQUIPMENT NR. : P-302 A/B P-303 A/B P-304 A/B P-305 A/B P-306 A/B
NAME : V301 Feed S301 Filtrate R302 Feed S302 Feed S302 Filtrate
Pump Pump Pump Pump Pump
Number : 2 2 2 2 2
Medium Protein
transferred : HCl hydrolysate HCl / Chitin HCl / Chitin HCl / Water
Capacity
[kg/s] :
5.23  10-4 8.73  10-4 6.28  10-4 6.50  10-4 5.50  10-4
3
[m /s] :
3
Density [kg/m ] : 996 1000 1000 992 963
Pressure [bara]
Suct. / Disch. : 1.06/2.17 1.08/1.68 1.02/2.27 0.97/3.52 1.05/1.68
Temperature
In / Out [oC] : 25.0/25.0 25.0/25.0 25.0/25.0 39.9/39.9 25.0/25.0
Power [kW]
- Theor. : 5.80  10-2 5.25  10-2 7.81  10-2 1.65  10-1 3.43  10-2
- Actual : 6.06  10-2 5.82  10-2 8.67  10-2 1.84  10-1 3.81  10-2
Number
- Theor. :
- Actual : 2 (1) 2 (1) 2 (1) 2 (1) 2 (1)
Remarks:
(2) Appendix D.8

CPD 3264
D-92
EQUIPMENT NR. : P-401 A/B P-402 A/B P-403 A/B P-404 A/B
NAME : R401 Feed V401 Filtrate S401 Feed S401 Filtrate
Pump Pump Pump Pump
Type : Diaphragm Diaphragm Diaphragm Diaphragm
Number : 2 2 2 2
Medium NaOH / NaOH / NaOH
transferred : Chitin NaOH Chitosan
Capacity
[kg/s] :
1.11  10-3 1.22  10-4 1.12  10-3 6.50  10-4
3
[m /s] :
3
Density [kg/m ] : 531 785 802 895
Pressure [bara]
Suct. / Disch. : 1.06/4.58 1.08/4.00 2.29/7.63 1.03/1.79
Temperature
In / Out [oC] : 121.0/121.0 25.0/25.0 121.0/121.0 31.0/31.0
Power [kW]
- Theor. : 1.18  10-1 3.56  10-2 5.96  10-1 4.43  10-2
- Actual : 4.35  10-1 3.95  10-2 6.62  10-1 4.92  10-2
Number
- Theor. :
- Actual : 2 (1) 2 (1) 2 (1) 2 (1)
Construction : MS casing MS casing MS casing MS casing
Other (2) : Single Single Single Single
mechanical mechanical mechanical mechanical
seals seals seals seals
Remarks:
(2) Appendix D.8

CPD 3264
D-93
GRINDING – SPECIFICATION SHEET
EQUIPMENT NUMBER : A201 In Series : 1

NAME : Shrimp Shell Crusher In Parallel : none
General Data
Service : - Crush / Grind / Pulverize
Type : - Mill / Cutter / Dicer / Crusher (1)
Position : - Horizontal
- Vertical
Internals : - Ball / Pebble / Rod / Cone
- Size [mm] : 98/59/35 (2)
Energy consumption [kWh] : 973.6
Vessel Diameter (ID) [m] : 6.1 (3)
Vessel Height [m] : 3.4 (4)
Vessel Tot. Volume [m3] : 43.2 (5)
Residence time [min] : 22.0 (6)
Rotational speed [rpm] : 15.0
Vessel Material : CS (7)
Lining Material : Rubber
Lining Material : Steel
Process Conditions
Stream Data Feed Product
Temperature [oC] : 25.0 : 25.0

Pressure [atm] : 1.0 : 1.0
Particle size [mm] : 30.0 : 1.0
Mass Flow [kg/s] : 0.24 : 0.24
Remarks:
(1) Mill is of Hardinage type consisting of 3 zones with 3 different internal ball sizes.
(2) Zone 1 = 98 mm, Zone 2 = 59 mm, Zone 3 = 35 mm
(3) Cylindrical section = 3.4 m, conical section = 2.7 m
(4) Cylindrical section = 3.4 m. conical section = 1.7 m
(5) Internal ball volume = 21.6 m3, where 11.75 m3 for 98 mm balls, 6 m3 for 59 mm balls and 4 m3
for 35 mm balls
(6) Zone 1 = 18.7 mins, Zone 2 = 2.2 mins and Zone 3 = 1.1 min.
Appendix D.5 for calculation details

CPD 3264
D-94
GRINDING – SPECIFICATION SHEET
EQUIPMENT NUMBER : A401 In Series : 1

NAME : Chitosan Grinder In Parallel : none
General Data
Service : - Crush/ Grind / Pulverize
Type : - Mill / Cutter / Dicer / Crusher
- Vertical
Internals : - Ball / Pebble / Rod / Cone
- Size [mm] : 12.0
Energy consumption [kWh] : 134.8
Vessel Diameter (ID) [m] : 2.4
Vessel Height [m] : 2.4
Vessel Tot. Volume [m3] : 10.4
Residence time [min] : 10.0
Lining Material : Rubber
Lining Material : Steel
Process Conditions
Stream Data Feed Product
Temperature [oC] : 25.0 : 25.0

Pressure [atm] : 1.0 : 1.0
Particle size [mm] : 0.1 : 0.05
Mass Flow [kg/s] : 0.021 : 0.021
Remarks:

CPD 3264
D-95
FILTER – SPECIFICATION SHEET
EQUIPMENT NUMBER : S301 In Series : 1

NAME : Filter 1 In Parallel : none
General Data
Service : - Buffer / Storage / Separation / Reaction
Type : - Rotating Vacuum Drum
- Vertical

Vessel Length [m] : 1.2
Filter Total Area [m2] : 1.94
Vessel Material : SS316 (1)
Filter Material : Polypropylene
Zoning : Filter / Wash / Dewater (2)
Vacuum pump [kW] : 0.07
Process Conditions
Stream Data Feed Solids Filtrate
Temperature [oC] : 25.0 : 25.0 : 25.0

Pressure [atm] : 1.0 : 1.0 : 0.6
3
Density [kg/m ] : 1052 : 1135 : 1050
Mass Flow [kg/s] : 1.040 : 0.126 : 0.914
Particle size [m] : 5  10-4 : 5  10-4 : n.a.
Composition mol% wt% mol% wt% mol% wt%

Calcium Carbonate 0.10 0.45 1.14 3.65 0.00 0.01
Calcium Lactate 0.87 8.69 0.28 1.94 0.93 9.62
Chitin/Chitosan 0.31 2.71 3.65 22.20 0.00 0.03
Lactic acid 0.33 1.34 0.10 0.30 0.35 1.48
Protein 0.93 5.24 4.86 19.15 0.57 3.33
Water 96.37 79.35 89.75 51.60 96.98 83.17
Others (Ammonium sulphate, CO2, ethanol, 1.09 2.22 0.22 1.16 1.17 2.36
lipids, glucose/carbohydrates, biomass, H2SO4)
Remarks:
(1) SS = Stainless steel
(2) Filter = 37.5 %, Dewater = 62.5 %

CPD 3264
D-96

General Data
- Vertical

Process Conditions
Temperature [oC] : 39.88 : 39.88 : 39.88

Pressure [atm] : 1.0 : 1.0 : 0.6
3
Density [kg/m ] : 992 : 1149 : 970
Mass Flow [kg/s] : 0.645 : 0.116 : 0.529

Calcium Chloride 0.14 0.75 0.05 0.17 0.14 0.87
Chitin/Chitosan 0.00 4.32 3.72 23.75 0.00 0.05
Hydrochloric acid 0.58 0.98 0.19 0.23 0.58 1.14
Protein 0.03 3.73 4.80 19.8 0.03 0.20
Water 99.14 89.45 91.0 54.8 99.14 97.06
Others (Calcium carbonate, Calcium lactate, CO2, 0.11 0.77 0.24 1.25 0.11 0.68
lactic acid, lipids, glucose/carbohydrates,
biomass, H2SO4)
Remarks:
(2) Filter = 37.5 %, Dewater = 62.5 %

CPD 3264
D-97

General Data
- Vertical

Process Conditions
Temperature [oC] : 27.0 : 27.0 : 27.0

Pressure [atm] : 1.0 : 1.0 : 0.6
3
Density [kg/m ] : 995 : 1110 : 990
Mass Flow [kg/s] : 1.015 : 0.056 : 0.959

Acetic acid 0.21 0.53 0.00 0.00 0.22 0.56
Chitin/Chitosan 0.33 2.35 7.73 42.51 0.00 0.02
Protein 0.43 2.27 0.22 0.92 0.44 2.34
Sodium Hydroxide 20.32 34.50 0.06 0.08 21.23 36.49
Water 78.66 60.16 91.71 55.16 78.07 60.44
Others (Calcium Carbonate, Calcium lactate, 0.05 0.19 0.28 1.33 0.04 0.15
CaCl2, glucose/carbohydrates, NaCl)
Remarks:
(2) Filter = 37.5 %, Wash = 31.25 %, Dewater = 31.25 %

CPD 3264
D-98
VESSEL – SPECIFICATION SHEET

NAME : Benzoic acid extractor In Parallel : none
General Data
Type : - Kennedy Extractor
- Vertical
Internals : - Demister / Plate / Coil / Rotary blade (1)
Heating/Cooling medium : - none / Open / Closed / External Hxgr /________
- Type : n.a.
- Quantity [kg/s] : n.a.
- Press./Temp.’s [bara/oC] : n.a.
Vessel Width [m] : 0.5
Vessel Tot. Volume [m3] : 0.125 (2)
Other :
Process Conditions
Stream Data Feed Extract Spend solids
Solvent flow
Temperature [oC] : 25.7 : 25.7 : 25.7

Pressure [atm] : 1.0 : 1.0 : 1.0
Density [kg/m3] : 1136 : 875 :1135
Mass Flow [kg/s] : 0.363 : 0.018 : 0.344

Benzoic acid 0.2 1.0 5.8 18.7 0.0 0.0
Ethanol 2.0 3.3 50.5 60.8 0.1 0.2
Shrimp shells 8.2 37.2 0.0 0.0 8.5 39.3
Water 89.6 58.5 43.7 20.5 91.4 60.5
Remarks:
(1) Rotary blade with 0.25 m radius at 0.5 rpm.
(2) Vessel is cubical. Effective volume of 0.036 m3.

CPD 3264
D-99
EQUIPMENT NUMBER : R101 a/b In Series : none

NAME : Lactic acid fermentor In Parallel : 2
General Data
Type : - CSTR
- Vertical
Internals : - Demister / Plate / Coil / _________
- Type : Cooling water
- Quantity [kg/s] : 0.90
- Press./Temp.’s [bara/oC] : 1 bara/20-30 C
Other :
Process Conditions
Stream Data Feed Top Bottom
Temperature [oC] : 43.2 : 40.0 : 40.0

Pressure [bara] : 1.0 : 1.0 : 1.0
Density [kg/m3] : 1128 : 1.96 :1115
Mass Flow [kg/s] : 0.494 : 4.51  10-4 : 0.493

Ammonium Sulphate 0.10 0.64 - - 0.01 0.08
Carbon dioxide - - 100 100 - -
Glucose 1.19 10.29 - - 0.00 0.01
Lactic acid 0.69 2.98 - - 2.70 11.95
Lactobacillus sp. 3.49 4.13 - - 4.28 5.17
Sulphuric acid 0.03 0.14 - - 0.11 0.55
Water 94.50 81.82 - - 92.89 82.24
Remarks:

CPD 3264
D-100
EQUIPMENT NUMBER : R301a/R301b In Series : 2

NAME : Chitin deproteinization and In Parallel : none
demineralization
General Data
Type : - PFR with baffles and stirrers
- Vertical
- Type : Chilled water
- Press./Temp.’s [bara/oC] : 1.0 bara /5-15 C
Vessel Material : SS304
Other :
Process Conditions
Temperature [oC] : 25.2 : 25.0 : 25.0

Pressure [bara] : 1.0 : 1.0 : 1.0
Density [kg/m3] : 1075 : 1.8 : 1052
Mass Flow [kg/s] : 1.056 : 0.017 : 1.039

Calcium Carbonate 0.96 4.36 - - 0.10 0.45
Calcium lactate - - - - 0.87 8.69
CO2 - - 100 100 0.03 0.07
Chitin/Chitosan 0.31 2.67 - - 0.31 2.72
Lactic acid 2.05 8.37 - - 0.33 1.34
Protein 0.92 5.15 - - 0.93 5.24
Water 94.71 77.34 - - 96.37 79.35
Others (Ammonium sulphate, lipids, glucose, 1.05 2.11 - - 1.06 2.14
ethanol, H2SO4, Biomass)
Remarks:

CPD 3264
D-101
EQUIPMENT NUMBER : R302 In Series : 1

NAME : Chitin Purification In Parallel : none
General Data
- Vertical
- Type : n.a.
- Quantity [kg/s] : n.a.
- Press./Temp.’s [bara/oC] : n.a.
Other :
Process Conditions
Temperature [oC] : 25.0 : 39.9 : 39.9

Pressure [bara] : 1.0 : 1.0 : 1.0
Density [kg/m3] : 1029 : 1.71 : 992
Mass Flow [kg/s] : 0.647 : 0.002 : 0.645

Calcium carbonate 0.14 0.71 - - 0.00 0.04
CO2 - - 100 100 0.04 0.08
Chitin/Chitosan 0.45 4.31 - - 0.00 4.32
HCl 0.80 1.47 - - 0.58 0.98
Protein 0.60 3.72 - - 0.03 3.73
Water 97.94 89.13 - - 99.14 89.45
Others (CaCl2, Ca lactate, Glucose, lactic acid, 0.07 0.66 - - 0.21 1.40
lipids, H2SO4)
Remarks:

CPD 3264
D-102
EQUIPMENT NUMBER : R401 In Series : 1

NAME : Deacetylation In Parallel : none
General Data
- Vertical
- Type : Cooling water
- Press./Temp.’s [bara/oC] : 1 bara/ 20-30 C
Other :
Process Conditions
Temperature [oC] : 121.0 : - : 121.0

Pressure [atm] : 2.3 : - : 2.3
Density [kg/m3] : 804 : - : 802
Mass Flow [kg/s] : 0.895 : - : 0.895

Acetic acid - - - - 0.22 0.60
Chitin/Chitosan 0.40 3.08 - - 0.00 2.66
Protein 0.51 2.57 - - 0.44 2.57
NaOH 24.06 39.16 - - 21.23 39.13
H2O 74.98 54.97 - - 78.07 54.81
Others (CaCO3, Ca lactate, CaCl2, glucose, HCl, 0.05 0.22 - - 0.04 0.83
NaCl)
Remarks:

CPD 3264
D-103
HEAT EXCHANGER – SPECIFICATION SHEET
EQUIPMENT NUMBER : C201 In Series : 1

NAME : Ethanol evaporator In Parallel : none
General Data
Service : - Heat Exchanger - Vaporizer
- Cooler - Reboiler
- Condenser (Air cooled)
Type : - Fixed Tube Sheets - Plate Heat Exchanger
- Floating Head - Finned Tubes
- Hair Pin - Thermosyphon
- Double Tube - Forced Evaporator
- Vertical
Capacity [kW] : 14.09 (Calc.)
Heat Exchange Area [m2] : 0.37 (Calc.)
Overall Heat Transfer Coefficient [W/m  C] :
2o
500 (Approx.)
Log. Mean Temperature Diff. (LMTD) [oC] : 77.44
Passes Tube Side : 1 (1)
Passes Shell Side : n.a. (2)
Correction Factor LMTD (min. 0.75) : 1.0
o
Corrected LMTD [ C] : 77.44
Process Conditions
Shell Side Tube Side
Medium : Ethanol/Benzoic acid LP Steam
Mass Stream [kg/s] : 1.88  10-2 6.17  10-3
Mass Stream to
- Evaporize [kg/s] : 1.15  10-2 n.a.
- Condense [kg/s] :
Average Specific Heat [kJ/kgoC] : 4.2 2.13
Heat of Evap. / Condensation [kJ/kg] : - 2163.3
Temperature IN [oC] : 77.0 190
Temperature OUT [oC] : 87.0 133.5
Pressure [bara] : Atm. 3.0
Material (3) : CS CS
Remarks:
(1) 8 tubes, 12 mm ID, 16 mm OD. 20 mm square pitch. Length = 1 m. 0.19 bar pressure drop
(2) 92 mm ID, 15 % baffle cut. 0.002 bar pressure drop
(3) CS = carbon steel

CPD 3264
D-104
EQUIPMENT NUMBER : E101A/B In Series : 1

NAME : Glucose Sterilizer In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
6550/5700 (1) (Approx.)
Log. Mean Temperature Diff. (LMTD) [oC] : 16.55/47.1 (2)
No. of plates : 52 (3)
Stream pass type : 4/4
Correction Factor LMTD (min. 0.75) : 0.88/1
o
Corrected LMTD [ C] : 14.56/47.1
Process Conditions
Side A Side B
Medium : Glucose MP Steam
Mass Stream [kg/s] : 0.556 0.0183
Mass Stream to
- Evaporize [kg/s] :
- Condense [kg/s] : 0.0183
Average Specific Heat [kJ/kgoC] : 3.95 n.a.
Heat of Evap. / Condensation [kJ/kg] : n.a. 2013
Temperature IN [oC] : 25.0 180.0
Pressure [bara] : 7.5 10.0
Material (4) : SS SS
Remarks:
(1) 6550 for heat exchanger between glucose feed and glucose product and 5700 between glucose and
M.P steam.
(2) 16.55 for heat exchanger between glucose feed and glucose product and 47.1 between glucose and
M.P steam.
(3) Number of plates are 48 or feed-product exchanger while 4 for glucose and M.P steam.

CPD 3264
D-105
EQUIPMENT NUMBER : E102A/B In Series : 1

NAME : N-Source Sterilizer In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
6550 /5700 (1) (Approx.)
Log. Mean Temperature Diff. (LMTD) [oC] : 16.55/47.1 (2)
No. of plates : 19 (3)
Stream pass type : 4/4
o
Process Conditions
Side A Side B
Medium : (NH4)2SO4 MP Steam
Mass Stream [kg/s] : 0.157 6.1  10-3
Mass Stream to
- Condense [kg/s] : n.a. 6.1  10-3
Average Specific Heat [kJ/kgoC] : 4.18 n.a.
Heat of Evap. / Condensation [kJ/kg] : n.a. 2013
Material (4) : SS SS
Remarks:
(5) 6550 for heat exchanger between (NH4)2SO4 feed and (NH4)2SO4 product and 5700 between
(NH4)2SO4 and M.P steam.
(6) 16.55 for heat exchanger between (NH4)2SO4 feed and (NH4)2SO4 product and 47.1 between
(NH4)2SO4 and M.P steam.
(7) Number of plates are 16 or feed-product exchanger while 3 for (NH4)2SO4 and M.P steam.

CPD 3264
D-106
EQUIPMENT NUMBER : E201 In Series : 1

NAME : Feed C201 Preheater In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
750 (Approx.)
Inner Tube Side : 1
Outer Tube Side : 1
Correction Factor LMTD (min. 0.75) : 1
o
Process Conditions
Inner Side Outer Side
Medium : LP Steam Ethanol
Mass Stream [kg/s] : 1.47  10-4 0.018
Mass Stream to
- Condense [kg/s] : 1.47  10-4 n.a.
Average Specific Heat [kJ/kgoC] : - 3.73
Heat of Evap. / Condensation [kJ/kg] : 2163.3 -
Remarks:

CPD 3264
D-107

NAME : Ethanol heat exchanger In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
200 (Approx.)
Inner Tube Side : 1
Outer Tube Side : 1
o
Process Conditions
Medium : Ethanol Ethanol
Mass Stream [kg/s] : 0.012 0.018
Mass Stream to
- Condense [kg/s] : 0.012 n.a.
Remarks:

CPD 3264
D-108

NAME : Top C201Condenser In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
500 (Approx.)
Inner Tube Side : 1
Outer Tube Side : 1
o
Process Conditions
Medium : Ethanol Cooling water
Mass Stream to
- Condense [kg/s] :
Heat of Evap. / Condensation [kJ/kg] : - -
Remarks:

CPD 3264
D-109

NAME : R401 heat exchanger In Parallel : none
General Data
- Cooler - Reboiler
- Double Tube - Fixed Shell and tube
- Vertical
2o
1750 (Approx.)
No of Passes Tube Side : 3
No of Passes Shell Side : 6
o
Process Conditions
Tube Side Shell Side
Medium : NaOH/Chitosan NaOH/Chitin
Mass Stream to
- Condense [kg/s] :
Remarks:

CPD 3264
D-110

NAME : Feed R401 preheater In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
1250 (Approx.)
o
Process Conditions
Medium : LP Steam NaOH/Chitin
Mass Stream to
- Condense [kg/s] : 0.012
Remarks:

CPD 3264
D-111

NAME : Product R401 cooler In Parallel : none
General Data
- Cooler - Reboiler
- Vertical
2o
700 (Approx.)
o
Process Conditions
Medium : NaOH/Chitosan Cooling water
Mass Stream to
- Condense [kg/s] :
Remarks:

CPD 3264
D-112
DIAPHRAGM PUMP – SPECIFICATION SHEET
EQUIPMENT NUMBER : P-101 A/B Operating : 1

NAME : E101 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Operating Conditions & Physical Data
Pumped liquid : Glucose-Water
Temperature (T) [oC] : 25.0
Density () [kg/m3] : 803.0
Viscosity () [Ns/m2] : 0.001
Vapour Pressure (pv) [bara] : 0.0324 at Temperature [oC] : 25.0
Power
Capacity (v) 3
[m /s] : 4.79e-04
Suction Pressure (ps) [bara] : 9.70e-01
Discharge Pressure (pd) [bara] : 4.24
Theoretical Power [kW] : 1.57e-01 { = v( pd - ps)102 }
Pump Efficiency [-] : 0.9
Power at Shaft [kW] : 1.74e-01
Construction Details (1)
RPM : 1725 Nominal diameter
Drive : Electrical Suction Nozzle [mm] : 38.1
Type electrical motor : Standard Discharge Nozzle [mm] : 38.1
Tension [V] : 110/220 Cooled Bearings : Yes / No
Rotational direction : Clock / Cooled Stuffing Box : Yes / No
Counter Cl. Smothering Gland : Yes / No
Foundation Plate : Combined / If yes
two parts - Seal Liquid : Yes / No
Flexible Coupling : Yes - Splash Rings : Yes / No
Pressure Gauge Suction : No - Packing Type :
Pressure Gauge Discharge : Yes - Mechanical Seal : Yes / No
Min. Overpressure above - N.P.S.H. [m] : 9.38
pv/pm [bar] : 0.1 { = pmg }
Construction Materials (2)
Pump House : MS Wear Rings :
Pump Rotor : HT Steel Shaft Box :
Shaft : HT Steel
Special provisions : none
Operating Pressure [bara] : 4.24 Test Pressure [bara] :
Remarks:
(1) Single mechanical and fluid seal required. Further details to be specified by Rotating Equipment
specialist.
(2) MS = Mild Steel; HT Steel = High Tensile Steel

CPD 3264
D-113

NAME : E102 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Ammonium Sulphate-Water
Density () [kg/m3] : 912.0
Power
Capacity (v) 3
[m /s] : 1.60e-04
Suction Pressure (ps) [bara] : 8.68e-01
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-114

NAME : R101A-B Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Glucose-Water
Density () [kg/m3] : 803.0
Power
Capacity (v) 3
[m /s] : 4.79e-04
Suction Pressure (ps) [bara] : 3.93
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-115

NAME : R101A-B Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Ammonium Sulphate-Water
Density () [kg/m3] : 912.0
Power
Capacity (v) 3
[m /s] : 1.60e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-116
EQUIPMENT NUMBER : P-105A A/B Operating : 1

NAME : S101A Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Lactic Acid-Water
Density () [kg/m3] : 1160.0
Power
Capacity (v) 3
[m /s] : 4.26e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-117
EQUIPMENT NUMBER : P-105B A/B Operating : 1

NAME : S101B Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Lactic Acid-Water
Density () [kg/m3] : 1160.0
Power
Capacity (v) 3
[m /s] : 4.26e-04
Type electrical motor : Discharge Nozzle [mm] : 38.1
Tension [V] : Cooled Bearings : Yes / No
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-118

NAME : R301 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Lactic Acid
Density () [kg/m3] : 1110.0
Power
Capacity (v) 3
[m /s] : 4.79e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-119

NAME : C201 feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Ethanol-Water
Density () [kg/m3] : 846
Viscosity () [Ns/m2] : 0.00074
Power
Capacity (v) 3
[m /s] : 2.19e-5
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-120

NAME : V201 feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Ethanol
Density () [kg/m3] : 837
Viscosity () [Ns/m2] : 0.00093
Power
Capacity (v) 3
[m /s] : 4.93e-6
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-121

NAME : S201 feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Ethanol-Water
Density () [kg/m3] : 816.0
Viscosity () [Ns/m2] : 0.00093
Power
Capacity (v) 3
[m /s] : 1.092e-5
Type electrical motor : Standard Discharge Nozzle […] : 12.7
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-122

NAME : C201 bottom discharge Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Benzoic Acid-Water
Density () [kg/m3] : 919.0
Viscosity () [Ns/m2] : 0.0011
Power
Capacity (v) 3
[m /s] : 7.53e-6
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.
Designers : A.A.Khan Project ID-Number : CPD3264

H. Shibata Date : December 21st 2001
M.T.A.P. Kresnowati
S.L.Tai
CPD 3264
D-123

NAME : S301 feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Chitin-Water
Density () [kg/m3] : 1050.0
Power
Capacity (v) 3
[m /s] : 9.78e-4
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-124

NAME : V301 feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : HCl
Density () [kg/m3] : 996.0
Power
Capacity (v) 3
[m /s] : 5.23e-4
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-125

NAME : S301 filtrate Pump Installed Spare : 1
Service : Discharge Pump
Type : Diaphragm
Number : 2
Pumped liquid : Protein hydrolysate, Asthaxanthin etc.
Density () [kg/m3] : 1000.0
Power
Capacity (v) 3
[m /s] : 8.73e-4
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-126

NAME : R302 feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : HCl-Chitin
Density () [kg/m3] : 1000.0
Power
Capacity (v) 3
[m /s] : 6.28e-4
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-127

NAME : S302 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : HCl-Chitin
Density () [kg/m3] : 992.0
Power
Capacity (v) 3
[m /s] : 6.50e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-128

NAME : S302 Filtrate Pump Installed Spare : 1
Type : Diaphragm
Number : 2
Pumped liquid : HCl rich waste water
Density () [kg/m3] : 963.0
Power
Capacity (v) 3
[m /s] : 5.50e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-129

NAME : V401 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : NaOH
Density () [kg/m3] : 785.0
Power
Capacity (v) 3
[m /s] : 1.22e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-130

NAME : R401 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : NaOH-Chitin
Density () [kg/m3] : 531.0
Power
Capacity (v) 3
[m /s] : 1.11e-03
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-131

NAME : S401 Feed Pump Installed Spare : 1
Service : Feed Pump
Type : Diaphragm
Number : 2
Pumped liquid : Chitosan-NaOH
Density () [kg/m3] : 802.0
Power
Capacity (v) 3
[m /s] : 1.12e-03
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-132

NAME : S401 Filtrate discharge Pump Installed Spare : 1
Type : Diaphragm
Number : 2
Pumped liquid : NaOH rich waste water
Density () [kg/m3] : 895.0
Power
Capacity (v) 3
[m /s] : 5.84e-04
pv/pm [bar] : 0.1 { = pmg }
Shaft : HT Steel
Remarks:
specialist.

CPD 3264
D-133
1. Stream CO2
Exit velocity
Volumetric flow rate of CO2 = 0.011 m3/s

 D2
Cross-sectional area of stack = = 0.785 m2
4
Exit velocity of gas from stack = 0.011/0.785 = 0.014 m/s
2. Stream 210 (Benzoic acid)
Amount of benzoic acid in stream = 300 kg/day

Amount of solvent = 300 kg/day (50 % ethanol, 50 % H2O)
From the solubility data on Table 4.4.1, solvent of 50 % ethanol has a solubility of benzoic
acid of about 200 kg/ton-solvent.
Hence, 300 kg of solvent dissolves 60 kg of benzoic acid. Hence, 240 kg/day of benzoic acid
are in solids.
3. Stream 305 (HCl)
Acidity of the stream:
Amount of solution = 45.2 tonnes/day = 45.2 m3/day (density = 1000 kg/m3)

Amount of HCl = 520 kg/day
Concentration of H2SO4 =
Amount of HCl (kg/day) 520

  0.32kmol / m3
Molecular weight (kg/kmol)  Amount of solution (m /day) 36.5  45.2
3
pH = - log [H+] = - log [0.32] = 0.50
4. Stream 413 (NaOH)
Alkalinity of the stream:
Stream 304 and Stream 309 are added together. In stream 304, the main acidic component is
H2SO4 while in stream 309, HCl. Therefore neutralization that takes place, ignoring the weak
acids which are in small quantities.
a. HCl (aq) + NaOH (aq)  NaCl (aq) + H2O (l)

b. H2SO4 (aq) + 2 NaOH (aq)  Na2SO4 (aq) + H2O (l)
Amount of HCl = 0.32 kmol/m3  45.2 m3/day solution = 14.5 kmols/day

Amount of H2SO4 = 0.05 kmol/m3  74.6 m3/day solution = 3.73 kmols/day
CPD 3264
E-2
Amount of NaOH required = 14.5 + 23.73 = 21.92 kmols
Amount of NaOH available = 30.26 tonnes/day

Amount of solution = 50 m3
Amount of NaOH (kg/day) 30260

  756.5kmol / day
Molecular weight (kg/kmol) 40
Amount of NaOH remaining after neutralization = 756.5 – 21.92 = 734.6 kmols/day
After addition, the total solution volume is the sum of the solution in each stream = 45.2 + 74.6 +
50 = 170 m3/day
Concentration of NaOH =
Amount of HCl (kmol/day) 734.6
3
  4.3kmol / m3
Amount of solution (m /day) 170
pOH = -log [OH-] = - log [4.3] = -0.6

pH = 14 + 0.6 > 14.
The pH range is from 0 to 14. Hence, the pH of the stream is 14.
CPD 3264
E-3
Total Capital Investment = 9.51 million €
Year 1 = 4.76 million € (Design + Construction)

Year 2 = 4.76 million € (Construction + Working Capital)
Table F. 1 Summary of Data for the Cash Flow Diagram

End Year Capital Costs Net Annual Cumulative Disc. Cash Cumulative
No. Annual Cumulative Cash Flow Cash Flow flow at 13% DCF at 13%
(NFW) (NPW)
€ million € million € million € million € million € million
0 0
1 4,76E+00 4,76E+00 -4,76E+00 -4,76E+00 -4,21E+00 -4,21E+00
2 4,76E+00 9,51E+00 -4,76E+00 -9,51E+00 -3,72E+00 -7,93E+00
3 3,40E+02 3,30E+02 2,35E+02 2,28E+02
4 3,40E+02 6,70E+02 2,08E+02 4,36E+02
5 3,40E+02 1,01E+03 1,84E+02 6,20E+02
6 3,40E+02 1,35E+03 1,63E+02 7,84E+02
7 3,40E+02 1,69E+03 1,44E+02 9,28E+02
8 3,40E+02 2,03E+03 1,28E+02 1,06E+03
9 3,40E+02 2,37E+03 1,13E+02 1,17E+03
10 3,40E+02 2,71E+03 1,00E+02 1,27E+03
11 3,40E+02 3,05E+03 8,86E+01 1,36E+03
12 3,40E+02 3,39E+03 7,84E+01 1,44E+03
13 3,40E+02 3,73E+03 6,94E+01 1,51E+03
14 3,40E+02 4,07E+03 6,14E+01 1,57E+03
15 3,40E+02 4,41E+03 5,43E+01 1,62E+03
16 3,40E+02 4,75E+03 4,81E+01 1,67E+03
17 3,40E+02 5,09E+03 4,25E+01 1,71E+03
Figure F.1 Project Cash Flow Diagram
6000
5000
Cumulative cash flow, million €
4000
NFW
3000 NPW at 15 %
NPW at 100 %
2000 NPW at 500 %
NPW at 751 %
1000
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
-1000
Time, years
CPD 3264
F-2
Table F.1 continued

End
Year Cumulative Cumulative Cumulative Cumulative Cumulative Cumulative Cumulative
No. DCF at 100% DCF at300% DCF at 500% DCF at 700% DCF at 750% DCF at 751% DCF at 752%
(NPW) (NPW) (NPW) (NPW) (NPW) (NPW) (NPW)
0 Eu million Eu million Eu million Eu million Eu million Eu million Eu million
1
2
3 -2,38E+00 -1,19E+00 -7,93E-01 -5,95E-01 -5,60E-01 -5,59E-01 -5,58E-01
4 -3,57E+00 -1,49E+00 -9,25E-01 -6,69E-01 -6,25E-01 -6,25E-01 -6,24E-01
5 3,89E+01 3,82E+00 6,48E-01 -5,23E-03 -7,21E-02 -7,33E-02 -7,44E-02
6 6,01E+01 5,15E+00 9,10E-01 7,77E-02 -7,04E-03 -8,48E-03 -9,92E-03
7 7,08E+01 5,48E+00 9,54E-01 8,81E-02 6,16E-04 -8,70E-04 -2,35E-03
8 7,61E+01 5,56E+00 9,61E-01 8,94E-02 1,52E-03 2,46E-05 -1,46E-03
9 7,87E+01 5,59E+00 9,63E-01 8,95E-02 1,62E-03 1,30E-04 -1,35E-03
10 8,00E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,42E-04 -1,34E-03
11 8,07E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,43E-04 -1,34E-03
12 8,10E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
13 8,12E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
14 8,13E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
15 8,13E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
16 8,14E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
17 8,14E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
8,14E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
8,14E+01 5,59E+00 9,63E-01 8,96E-02 1,64E-03 1,44E-04 -1,34E-03
CPD 3264
F-3

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St-4931 Conceptual Process Design Production of Chitin and Chitosan from Shrimp Shells

Appendices Table of Content

A Base of Design A-1

Appendices Table of Content (cont'd)

Appendix A.1 Basic Assumptions

Table A.1.1 Summary of Basis Assumptions

Appendix A.2 Kinetics

A.2.a Demineralization (Lactic acid)

CaCO3 ( s )  2CH 3 HCOHCOOH ( aq )

Figure A.2.1 Reactor Configuration of in-situ fermentation

Lactic Acid [kg/m^3]

Table A.2.1 In situ Lactic acid Production and Demineralization

A.2.b Enzymatic Deproteinization

Figure A.2.3 Enzymatic Deproteinization

In which k is rate constant,  is degree of polynomial of protein fraction. ke and  is calculated as

A.2.c Chemical Demineralization (Hydrochloric acid)

CaCO3 ( s)  2 HCl (aq)  CaCl2 (aq)  CO2 ( g )  H 2O(l ) (A.2.14)

Where M represents mineral fraction [kg-mineral/kg-mineral initial], which calcium is dominant,

In which A represents amount of HCl [N·l-solution/kg-solid] that is calculated by multiplying

Table A.2.2 Demineralization condition

5.4 0.56 85.8 0.203

A.2.d Chemical Deproteinization (Sodium hydroxide)

In which B represents amount of NaOH [N·ml-solution/g-solid] that is calculated by multiplying

Table A.2.3 Deproteinization Experiment

A.2.e Chemical Deacetylation

Table A.2.4 Deacetylation Experiment

Activation energy, E, is calculated as 71.7 kJ/mol. B· kc 0 is calculated as 4.10 106 [1/s].

Appendix A.3 Shrimp Shell Compositions

Table A.3.1 Shrimp Shell Compositions

[1] J.Bautista, M.Jover, Process Biochemistry, 37, 2001, pp229-234

Table B.1 Comparison of heat of formation (at 25 ºC)

Heat capacity Heat capacity

Designers Process Flow Scheme - Improved Solution

Shrimp shells X201

207 87.2 87.2 FC 35

PROCESS EQUIPMENT LIST Designers Process Flow Scheme - Improved Solution

1.1 pHI TC 1.0

PROCESS EQUIPMENT LIST

28.0 43.8 412 1.8

PROCESS EQUIPMENT LIST Designers Process Flow Scheme - Improved Solution

Project ID Number : CPD3264

Project ID Number : CPD3264

STREAM Nr. : 101 102 103 104

Total - - 47,997 2,225 47,997 2,225 47,997 2,225

STREAM Nr. : 105 106a/b 107 108

Total 47,997 2,225 23,999 1,113 13,599 0,729 13,599 0,729

Project ID Number : CPD3264

STREAM Nr. : 109 110 111a/b 112a/b

Total 13,599 0,729 13,599 0,729 6,800 0,365 0,039 0,001

STREAM Nr. : 113a/b 114a/b 115a/b 116a/b

Total 42,628 2,094 42,628 2,094 11,869 0,573 30,759 1,521

Project ID Number : CPD3264

STREAM Nr. : 117 118 201 202

Total 61,518 3,043 61,518 3,043 30,000 1,091 30,000 1,091

STREAM Nr. : 203 204 205 206

Total 1,354 0,041 29,759 1,090 1,595 0,042 1,595 0,042

Project ID Number : CPD3264

STREAM Nr. : 207 208 209 210

Total 1,595 0,042 1,595 0,042 0,598 0,012 0,598 0,012